M116A2 Military Trailer Manual Number TM 5 6115 632 14

8/7/2019 M116A2 Military Trailer Manual Number TM 5 6115 632 14

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TM 5-6115-632-14&P

TECHNICAL MANUAL

O P E R A T O R ' S , U N I T , I N T E R M E D I A T E D I R E C T S U P P O R T

A N D I N T ER M ED I A T E GEN ER A L SU PPOR T M A I N T EN A N C E

MANUAL ( INCLUDING REPAIR PARTS AND

SPEC I A L T OOL S L I ST S)

P O W E R U N I T

PU-753/M (NSN 6115-00-033-1389)

M E P - 0 0 3 A

M 1 1 6 A 2

10 KW 60 HZ GENERATOR SET

2-WHEEL, 2-T IRE, MODIFIED

T R A I L E R

This manual supersedes Chapter 14 of TM 5-6115-594-14&P dated 25 September 1984.

Approved for public release. Distribution is unlimited.

H E A D Q U A R T E R S , D E P A R T M E N T O F T H E A R M Y

1 7 J U N E 1 9 8 8


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TM 5-6115-632-14&PC4

CHANGE HEADQUARTERSDEPARTMENT OF THE ARMY

NO. 4 WASHINGTON, D.C., 30 September 1996

Operators, Unit, Intermediate Direct Support andIntermediate General Support Maintenance Manual

(Including Repair Parts and Special Tools Lists)

POWER UNIT, PU-753/M(NSN 6115-00-033-1389)

MEP-003A 10 KW 60 HZ GENERATOR SETM116A2 2-WHEEL, 2-TIRE, MODIFIED TRAILER

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited

TM 5-6115-632-14&P, 17 June 1988, is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in themargin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pagesi and ii i and ii1-1 and 1-2 1-1 and 1-2D-7 and D-8 D-7 and D-8D-11 through D-16 D-11 through D-16D-19 through D-22 D-19 through D-22

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

DENNIS J. REIMER

General, United States ArmyOfficial: Chief of Staff

JOEL B. HUDSONAdministrative Assistant to the

Secretary of the Army02496

DISTRIBUTION:To be distributed in accordance with DA Form 12-25-E, block no. 3867, requirements for TM 5-6115-632-14&P.


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TM 5-6115-632-14&P

C3

CHANGE HEADQUARTERS

DEPARTMENT OF THE ARMY

NO. 3 WAS HINGTON, D. C . , 17 S ep tem ber 1991

Operators, Unit, Intermediate Direct Support

and In te rm edia te Genera l S uppor t Ma in tenance

Manual (Including Repair Parts and Special Tools Lists)

POWER UNIT

P U - 7 5 3 / M ( N S N 6 1 1 5 - 0 0 - 0 3 3 - 1 3 8 9 )

M E P - 0 0 3 A 1 0 K W 6 0 H Z G E N E R A T O R S E T

M l 1 6 A 2 2 W H E E L , 2 - T I R E , M O D I F I E D T R A I L E R

Approved for public release; distribution is unlimited

TM 5611563214&P, 17 June 1988, is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar inthe margin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages

35 and 3-6 35 and 3-6

3-11 and 312 3-11 and 3-12

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

GORDON R. SULLIVANGeneral, United States Army

Chief of Staff

Official:

PATRICIA P. HICKERSON

Brigadier General, United States Army

The Adjutant General

DISTRIBUTION:

To be distributed in accordance with DA Form 1225.E, (qty rqr block no. 3867)


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S A F E T Y S T E P S T O F O L L O W I F S O M E O N E I S T H E

V I C T I M O F E L E C T R I C A L S H O C K

D O N O T T R Y T O P U L L O R G R A B T H E I N D I V I D U A L

I F P O S S I B L E , T U R N O F F T H E E L E C T R I C A L P O W E R

I F Y O U C A N N O T T U R N O F F T H E E L E C T R I C A L

P O W E R , P U L L , P U S H , O R L I F T T H E P E R S O N T O

S A F E T Y U S I N G A W O O D E N P O L E O R A R O P E O R

S O M E O T H E R I N S U L A T I N G M A T E R I A L

S E N D F O R H E L P A S S O O N A S P O S S I B L E

A F T E R T H E I N J U R E D P E R S O N I S F R E E O F

C O N T A C T W I T H T H E S O U R C E O F E L E C T R I C A L

S H O C K , M O V E T H E P E R S O N A S H O R T D I S T A N C E

A W A Y A N D I M M E D I A T E L Y S T A R T A R T I F I C I A L

R E S U S C I T A T I O N


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ARMY TM 5-6115-632-14&PAIR FORCE TO-35C2-3-491-1

WARNING

All specific cautions and warnings contained in this manual shall be strictlyadhered to. Otherwise, severe injury, death and/or damage to the equipmentmay result.

HIGH VOLTAGE

is produced when this power unit is in operation.

DEATH

or severe burns may result if personnel fail to observe safety precautions. Donot operate this power unit until the ground terminal stud has been connectedto a suitable ground. Disconnect the battery ground cable on the generator setbefore removing and installing components on the engine or in the electricalcontrol panel system. Remove all rings, watches, and other jewelry whenperforming maintenance on this equipment. Loose fitting clothing should besecured to prevent it catching in moving parts. Do not attempt to service orotherwise make any adjustments, connections or reconnections of wires or

cables until generator set is shut down and completely de-energized.DANGEROUS GASES

Batteries generate explosive gas during charging: therefore, utilize extremecaution. Do not smoke, or use open flame in the vicinity of the generator setwhen servicing batteries.

Exhaust discharge contains noxious and deadly fumes. Do not operate powerunit generator set in enclosed areas unless exhaust discharge is properlyvented to the outside.

To avoid sparking between filler nozzle and fuel tank, always maintain metal tometal contact between filler nozzle and fuel tank when filling generator set fueltank.

Do not smoke or use open flame in the vicinity of the generator set whilefueling.

LIQUIDS UNDER HIGH PRESSURE

are generated as a result of operation of the power unit generator set. Do notexpose any part of the body to a high pressure leak in the fuel injection system.

NOISE

Operating noise level of the generator set can cause hearing damage. Earprotectors, as recommended by the medical or safety officer, must be wornwhen working near this power unit.


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ARMY TM 5-6115-632-14&P

AIR FORCE TO-35C2-3-491-1

WARNING

Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes andprolonged exposure of skin to cleaning solvent. Wash exposed skin thor-oughly. Dry cleaning solvent (P-D-680) used to clean parts is potentially dan-gerous to personnel and property. Do not use near open flame or excessiveheat. Flash point of solvent is 100F. to 138F. (38C. to 59 C.).


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*TM 5-6115-632-14&P

TECHNICAL MANUAL HEADQUARTERSDEPARTMENT OF THE ARMY

NO. 5-6115-632-14&P WASHINGTON, D.C., 17 June 1988

Operators, Unit, Intermediate Direct Support andIntermediate General Support Maintenance Manual

(Including Repair Parts and Special Tools Lists)

POWER UNIT, PU-753/M(NSN 6115-00-033-1389)

MEP-003A 10 KW 60 HZ GENERATOR SETM116A2 2-WHEEL, 2-TIRE, MODIFIED TRAILER

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes, or if you know of a way to improve theseprocedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes toPublications and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to:Commander, US Army Aviation and Troop Command, ATTN: AMSAT-I-MP, 4300 Goodfellow Blvd., St.Louis, MO 63120-1798. You may also submit your recommended changes by E-mail directly to. A reply will be furnished directly to you. Instructions for

sending an electronic 2028 may be found at the back of this manual immediately preceding the hard copy2028.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited

TABLE OF CONTENTSPAGE

CHAPTER 1 INTRODUCTIONSection I General ..................................................................................................................................... 1-1Section II Description and Data ................................................................................................................ 1-2

CHAPTER 2 OPERATING INSTRUCTIONSSection I Operating Procedures............................................................................................................... 2-1Section II Operation of Auxiliary Equipment ............................................................................................. 2-1

Section III Operation Under Unusual Conditions....................................................................................... 2-2CHAPTER 3 OPERATOR/CREW MAINTENANCE INSTRUCTIONSSection I Consumable Operating and Maintenance Supplies ................................................................. 3-1Section II Lubrication Instructions............................................................................................................. 3-1Section III Preventive Maintenance Checks and Services (PMCS)........................................................... 3-1Section IV Troubleshooting........................................................................................................................ 3-17Section V Operator/Crew Maintenance..................................................................................................... 3-17

*This manual supersedes Chapter 14 of TM 5-6115-594-14&P dated 25 September 1984.

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CHAPTER 4 UNIT MAINTENANCESection I Service Upon Receipt of Equipment......................................................................................... 4-1Section II Movement to a New Worksite................................................................................................... 4-6Section III Repair Parts, Special Tools, Special Test,

Measurement and Diagnostic Equipment (TMDE)................................................................ 4-7Section IV Lubrication Instructions............................................................................................................. 4-7Section V Preventive Maintenance Checks and Services ........................................................................ 4-8Section VI Troubleshooting........................................................................................................................ 4-13

Section VII Radio Interference Suppression ............................................................................................... 4-13Section VIII Maintenance of Power Plant Trailer.......................................................................................... 4-13

CHAPTER 5 INTERMEDIATE (FIELD), (DIRECT SUPPORT AND GENERAL SUPPORT)MAINTENANCE INSTRUCTIONS

Section I Introduction............................................................................................................................... 5-1Section II Maintenance of Power Plant Trailer.......................................................................................... 5-1Section III Generator Set ........................................................................................................................... 5-7

CHAPTER 6 TEST AND INSPECTION AFTER REPAIRSection I General Requirements.............................................................................................................. 6-1Section II Inspection.................................................................................................................................. 6-1Section III Operational Tests ..................................................................................................................... 6-1

APPENDIX A REFERENCES ......................................................................................................................... A-1APPENDIX B COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS ........................................ B-1

APPENDIX C MAINTENANCE ALLOCATION CHART .................................................................................. C-1APPENDIX D UNIT, INTERMEDIATE (FIELD) (DIRECT SUPPORT AND GENERAL

SUPPORT) AND DEPOT MAINTENANCE REPAIR PARTSAND SPECIAL TOOLS LIST ................................................................................................. D-1

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LIST OF ILLUSTRATIONS

Figure

1-1

1-2

3-1

3-23-3

3-44-14-24-34-4

4-54-64-7

5-15-25 35 4

5 55-6B-1

B-2D-1D-2

D-3

D-4

D-5

Number

3-13-2

4-1

Title

Power Unit, Roadside Fron t, Three-Quarter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Unit, Curbside Rear, Three-Quarter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fitted Cover Installed on Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fitted Cover Rolled Up for Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tarpaulin Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bow Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Uncrating Generator Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unpacking Fitted Cover, Bows and Tarpaulin Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External Fuel Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Can Bracket Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessory Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fire Extinguisher Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leg Prop Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fender and Bed Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Accessory Box Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Unit Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Detaching Generator Set from Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lifting Generator Set .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Components of End item. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic Issue items .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trailer Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Accessory Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Leg Prop Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

1-21-3

3-183-193-203-204-14-24-44-6

4-14

4-154-15

5-25-4

5-65-7

5-85-9B-2

B-3D-10D-12D-14D-18D-20

LIST OF TABLES

Title Page

Consumable Operating and Maintenance Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Operator/Crew Preventive MaintenanceChecks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Unit Preventive Ma intenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

iii/(iv blank)


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CHAPTER 1INTRODUCTION

Section I. GENERAL

1-1. Scope. This manual is for your use in operating and maintaining the Power Unit, PU-753/M. The PU-753/M is mobile power unit used to supply power to any system or equipment requiring up to 10 kW of 60 Hz input operating powerIn addition to operating instructions and operator, unit, and intermediate direct support and general support maintenanceprocedures, this manual contains a Repair Parts and Special Tools List for the power unit.

1-2. Limited Applicability. Some portions of this publication are not applicable to both services. These portions arprefixed to indicate the service to which they pertain: (A) for Army, and (F) for Air Force. Portions not prefixed arapplicable to both services.

1-3. Maintenance Forms and Records.

a. (A) Maintenance forms and records used by Army personnel are prescribed by DA Pam 738-750.

b. (F) Maintenance forms and records used by Air Force personnel are prescribed in AFM66-1 and the applicable 0020 Series Technical Orders.

1-4. Reporting of Errors. Reporting of errors and omissions and recommendations for improvement of thispublication by the individual user is encouraged. Reports should be submitted as follows:

a. (A) Army DA Form 2028 directly to: Commander, US Army Aviation and Troop Command, ATTN: U AMSAT-MT, 4300 Goodfellow Boulevard, St. Louis, MO 63120-1798.

b. (F) Air Force AFTO Form 22 directly to: Commander, Sacramento Air Logistics Center, ATTN: SM-ALCMMEDTA, McClellan Air Force Base, CA, 95652-5609, in accordance with TO-00-5-1.

1-5. Reporting Equipment Improvement Recommendations (EIR). El Rs will be prepared using SF 368, U ProducQuality Deficiency Report. Instructions for preparing EIRs are provided in DA PAM 738-750, The Army MaintenancManagement System. EIRs should be mailed directly to: Commander, US Army Aviation and Troop Support CommandATTN: AMSAT-I-MDO, 4300 Goodfellow Boulevard, St. Louis, MO 63120-1798.

1-6. Levels of Maintenance Accomplishment.

a. (A) Army users shall refer to the Maintenance Allocation Chart (MAC) for tasks and levels of maintenance to beperformed.

b. (F) Air Force users shall accomplish maintenance at the user level consistent with their capability in accordancewith policies established in AFM 66-1.

1-7. Destruction of Army Materlel. Destruction of Army materiel to prevent enemy use shall be in accordance with TM750-244-3.

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1-8. Administrative Storage.

a. Army equipment placed in administrative storage will have preventive maintenance performedin accordance with the PMCS tables before storage. When equipment is removed from stor-age, PMCS will be performed to ensure operational readiness.

b. (F) For administrative storage procedures for Air Force equipment, refer to TO 35-1-4, Pro-cessing and Inspection of Aerospace Ground Equipment for Storage and Shipment.

1-9. Preparation for Shipment and Storage.

a. (A) Army Refer to TB 740-97-2.

b. (F) Air Force Refer to TO 35-1-4 for component of end item generator sets and TO 38-1-5for installed engine.

Section Il. DESCRIPTION AND DATA

1-10. Description. Power Unit PU-753/M is made up of one Tactical Utility Generator Set, DOD ModelMEP-003A, mounted on a modified M116A2 trailer. The generator set is an air-cooled, dieselengine-driven unit with a load capacity of 10 KW at 60 Hz. The trailer is a two-wheeled unit with a 3/4-

ton carrying capacity. The modifications to the basic trailer provide stowage for the accessories andall equipment necessary for mobile operation as well as providing a work platform for the operator andmaintenance personnel. Figures 1-1 and 1-2 illustrate the power unit with the fitted cover removed toshow the generator set.

1-2

Figure 1-1. Power Unit, Roadside Front, Three-Quarter View.


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Figure 1-2. Power Unit, Curbside Rear, Three-Quarter View.

1-11. Tabulated Data. The tabulated data provides operator and unit level personnel with thedimensions and weights for Power Unit, PU-753/M. These specifications are computed from the com-bined dimensions and weights of the generator set and trailer as modified for use with the power unit.Specifications of the individual components can be found in their respective technical publications.For additional information concerning Generator Set, DOD Model MEP-003A, refer toTM5-6115-585-12 and -34. For additional information on the M116A2 trailer, refer to TM 9-2330-202-14&P.The tabulated data also includes the location and content of all data plates unique to the power unit.

a. Identification and Instruction Plates.

(1) Identification plate.

(a) Location. This plate is located on the front curbside frame between the trailer body andthe drawbar ring.

(b) Content.

usPOWER UNIT

PU 753/MKW 10HERTZ 60NSN 6115-00-033-1389

1-3


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(2) Instruction plate

(a) Location. This plate is located near the ground stud on the rear, curbside corner of the trailerbody.

(b) Content.

GROUND TERMINAL

b. Tabulated Data for Power Unit.

Overall Length 142 inches (360.8 centimeters)Overall Width 73.5 inches (186.7 centimeters)Overall Height 74.75 inches (189.8 centimeters)Net Weight (empty) 2890 pounds (1310 kilograms)Net Weight (Filled) 3040 pounds (1378.7 kilograms)Shipping Weight 3060 pounds (1387.7 kilograms)Cubage 412.23 cubic feet (11.63 cubic meters)

1-12. Differences Between Models. There are no differences between models, serial numbers, or serial numbergroups applicable to this equipment.

* u .S .GOVERNMENT PR INT I NGOFFICE: 1991- 554-030/40101

1-4 Change 2 PIN: 064390-00


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CHAPTER 2

OPERATING INSTRUCTIONS

Section I. OPERATING PROCEDURES

2.1. Operating Procedures. The typical mission for any mobile power generating equipment can bedescribed in three steps or phases. In the first phase, the power unit is towed to the worksite and in-

stalled by unit level technicians (paragraph 4-2). In the second phase of the mission, the operatorstarts the generator set, runs it to power a system or equipment, and eventually shuts it down. In thefinal phase, the power unit is dismantled, packed up and either moved to a new work site or returned tostandby status (paragraph 4-3). This final phase is also accomplished by unit level technicians.

WARNING

Do not operate generator set until it is properly grounded (paragraph 4-2, b.)Serious injury or death by electrocution can result from operating an un-grounded generator set.

Operating noise level of generator can cause hearing damage. Ear

protectors, as recommended by medical or safety officer, must be worn whenworking near power unit.

CAUTION

To avoid damage to equipment, make certain of voltage, frequency, andphase requirements of load connected to generator set.

NOTE

Before starting generator set, do your Before PMCS as described in table 3-2.

In order to perform the operators task during the mission, refer to the data plate located on the right-

hand side of the generator set control cubicle. Follow the operating instructions on the data plate tostart and run the generator set. Monitor and adjust generator set power output as required duringoperation. At the end of the mission, shut down the generator set in accordance with the operatinginstructions on the data plate. For a copy of the information on the data plate, as well as more detailedoperating procedures for the generator set, refer to TM 5-6115-585-12. For trailer operatingprocedures, refer to TM 9-2330-202-14&P.

Section Il. OPERATION OF AUXILIARY EQUIPMENT

2-2. Operation of Auxiliary Equipment. There is no auxiliary equipment supplied with the power unit.

2-1
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Section Ill. OPERATION UNDER UNUSUAL CONDITIONS

2-3. Operation Under Unusual Conditions. When operating the power unit under unusual conditionssuch as extremes in temperature or difficult terrain, there are steps that must be taken to protect theequipment.

a.

b.

2-2

Refer to TM 5-6115-585-12 for special procedures when operating the generator set underunusual conditions.

Refer to TM 9-2330-202-14&P for special procedures when operating the trailer under unusualconditions.
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CHAPTER 3

OPERATOR/CREW MAINTENANCE INSTRUCTIONS

Section I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES

3-1. Consumable Supplies. Consumable supplies used in the maintenance and operation of thepower unit are listed in Table 3-1.

Table 3-1. Consumable Operating and Maintenance Supplies.

(1) (2) (3) (4) (5) (6)

Qty QtyNational required required

Component stock for initial 8 hoursapplication number Description operation operation Notes

General 6850-00-664-5685 Solvent, Drycleaning, 1 quart As requiredCleaning P-D-680

Leg Prop 9150-00-190-0904 Grease, Automotive and 1 pound As required

Assembly Artillery, GAA

Leg Prop 9150-00-186-6681 Oil, Lubricating, 1 quart As requiredAssembly OE/HDO-30

9150-00-402-4478 Oil, Lubricating, OEA 1 quart As required

Section Il. LUBRICATION INSTRUCTIONS

3-2. General. Detailed instructions for the lubrication of the major components of the power unit arecontained in the applicable Lubrication Orders (LOs). Refer to DA Pam 310-1 to ensure the latesteditions of the LOs are used.

3.3. Generator Lubrication. Refer to TM 5-6115-585-12 for generator set Lubrication Order.

3-4. Trailer Lubrication. There are no operator/crew lubrication requirements for the power unittrailer. However, the operator shall assist unit maintenance.

Section Ill. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

NOTE

The PMCS chart in this section contains all necessary Operator/Crewpreventive maintenance checks and services for this equipment.

3.5. General. The preventive maintenance checks and services listed in Table 3-2 are groupedaccording to stages of equipment operation or time intervals. Using the following as a guide, do thechecks and services at the intervals shown.

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a.

b.

c.

d.

e.

f.

Before you operate, perform your before (B) PMCS. Observe all CAUTIONS and WARNINGS.

While you operate, perform your during (D) PMCS. Observe all CAUTIONS and WARNINGS.

After you operate, be sure to perform your after (A) PMCS.

Do (W) PMCS weekly.

Do (M) PMCS monthly.

If equipment fails to operate, refer to Section IV Troubleshooting. If the problem cannot becorrected, see paragraph 3-8, Reporting Deficiencies.

3-6. Purpose of PMCS Table. The purpose of the PMCS table is to provide a systematic method ofinspecting and servicing the equipment. In this way, small defects can be detected early before theybecome a major problem causing the equipment to fail to complete its mission. The PMCS table isarranged with the individual PMCS procedures listed in sequence under assigned intervals. The mostlogical time (before, during, or after operation) to perform each procedure determines the interval towhich it is assigned. Make a habit of doing the checks and services in the same order each time andanything wrong will be seen quickly. See paragraph 3-7 for an explanation of the columns intable 3-2.

3.7. Explanation of Columns. The following is a list of the PMCS table column headings with adescription of the information found in each column.

a. Item No. This column shows the sequence in which the checks and services are to beperformed, and is used to identify the equipment area on the Equipment Inspection and MaintenanceWorksheet, DA Form 2404.

b. IntervalThis column shows when each check is to be done.

c. Item to be Inspected/Procedures. This column identifies the general area or specific partwhere the check or service is to be done, lists the checks or services to be done and explains how to dothem.

d. Equipment is Not Ready/Available If This column lists conditions that make the equipmentunavailable for use because it is unable to perform its mission or because it would represent a safetyhazard. Do not accept or operate equipment with a condition in the Equipment is Not Ready/AvailableIf column.

3.8. Reporting Deficiencies. If you discover any problem with the equipment during PMCS or whileoperating it that you are unable to correct, it must be reported. Refer to DA Pam 738-750 and reportthe deficiency using the proper forms.

3-9. Special Instructions. Preventive maintenance is not limited to performing the checks andservices listed in the PMCS table. Covering unused receptacles, stowing unused equipment and otherroutine procedures such as equipment inventory, cleaning components, and touch-up painting arenot listed in the PMCS table. These are things you should do any time you see they need to be done. Ifa routine check is listed in the PMCS table it is because other operators have reported problems withthis item. Take along tools and cleaning cloths needed to perform the required checks and services.Use the information in the following paragraphs to help you identify problems at any time.

a. Routine Inspections. Use the following information to help identify potential problems beforeand during checks and services.

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CAUTION

Equipment operation is allowable with minor leakage (Class I or II) of any fluidexcept fuel. Of course, consideration must be given to the fluid capacity in theitem being checked/inspected. When in doubt, notify your supervisor.

When operating with Class I or II leaks, continue to check fluid level more oftenthan required in the PMCS. Parts without fluid will stop working and/or cause

equipment damage.

Class Ill leaks should be reported to your supervisor or unit maintenance.

Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS)

NOTE

If the equipment must be kept in continuous operation, check and service onlythose items that can be checked and serviced without disturbing operation.Make the complete checks and services when the equipment can be shutdown.

Within designated interval, these checks are to be performed in the orderlisted.

B Before D During A After W Weekly M Monthly

Itemno. B

Interval

D A W M

Item to be inspected.Procedure: check for andhave repaired, filled, or

adjusted as needed

WARNING

Before performing any mainte-nance that requires climbing on orunder trailer, set trailer hand-brakes, chock wheels, and lowerrear leg prop. Injury to personnelcould result from trailer suddenlyrolling or tipping.

NOTE

Perform weekly as welI as beforePMCS if you are the assigned op-erator but have not operated theequipment since the last weeklyinspection.

Equipment is notready/avaiIable if:

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Table 32. Operator/Crew Preventive Maintenance Checks and Services (PMCS) - Cont.

Item

No.

1

2

B

Interval

D A W

Item to be Inspected.

Procedure: check for andhave repaired, filled, oradjusted as needed

NOTE

Perform weekly as well as before PMCS if

you are operating the equipment for the first

time.

GENERATOR SET EXTERIOR

NOTE

Slight fuel leak (Class I or II leaks) by the

control unit shaft is normal and is necessary

to lubricate shaft. Any other fuel leak or

fuel leakage around the control unit shaft is

a Class III leak and makes the equipment

not ready/available.

a. Check on, around, and beneath the

generator set (1) for fuel or oil leaks.

b. Check that generator set (1) grounds are

properly installed, and grounding

connections are tight.

FUEL GAGE

Check fuel gage (2) for sufficient fuel for

continuous operation.

b Before D During A After W Weeklv M Monthly

M

Change 3 3-5

Equipment is Not Ready/

Available If

A Class III lubrication oil or

any class fuel leak is detected.

Not properly grounded.


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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) - CONT.

B - Before D - During A After W Weekly M - Monthly

Itemno.

3

4

3-6

Item to be inspected.Procedure: check for and

have repaired, filled, oradjusted as needed

ENGINE OIL LEVEL

Check oil filler dipstick (3) for properoil level. Add oil as required.

AIR CLEANER INDICATOR

Check indicator (4) for a restricted air

cleaner. If red warning indicator becomesvisible, notify unit maintenance for clean-ing or replacement.

Equipment is notready/available if:


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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) CONT.

B Before

Itemno.

5

6

7

8

D During A After W Weekly

q

q

q

q

Interval


have repaired, filled, or

adjusted as needed

ACCESSORIES

Check that the following accessories arenot missing.

a. Sledge hammer

b. Fire extinguisher

c. Driver/puller

d. Ground rods.

BRACKETS

Check fire extinguisher and fuel canmounting brackets for loose hardwareand broken fittings.

TIRES

a. Check tires (5) for cuts, foreign

objects, or unusual tread wear.Remove any stones from between thetreads.

b. Check that tire pressure is 35 psi(241.22 kPa) when tires are cool.

WHEELS

Check for damage and for missing orloose stud nuts (6).

M Monthly

Equipment is not

ready/avaiIable if:

Fire extinguisher ismissing.

Ground rods aremissing.

One tire is flat,

missing, orunserviceable.

One or more wheel isdamaged. One ormore stud nuts areloose or missing.

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B - Before

Itemno.

8

9

10

11

3-8



adjusted as needed

WHEELS CONT

DRAWBAR RING

Check drawbar ring (7) for insecuremounting and obvious damage.

INTERVEHICULAR CABLE

Check cable (8) and connector for cutsand breaks.

SAFETY CHAINS

Check safety chains (9) for insecuremounting and obvious damage.

M Monthly


Ring is loose or bent.

Intervehicular cableis broken or missing.

Safety chains aremissing orunsecured.


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B Before

Itemno.

11

12

13


q

q

q

Interval

D A w M


adjusted as needed

SAFETY CHAINS CONT

BOW ASSEMBLIES AND TARPAULIN SUPPORT

Inspect for damaged bow assemblies (10) ortarpaulin support (11).

FITTED COVER

a.

b.

c.

d.

Check fitted cover (12) for missing anddefective tiedown straps and snapfasteners (13).

Check for missing and defectiveropes (14).

Check for missing and defective strapsand buckles (15).

Check for ripped seams and tears.

M Monthly


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B - Before D During A After W Weekly M Monthly

Itemno.

13

14

B

Interval

D

q

A w M



FITTED COVER CONT

LIGHTS

a. With intervehicular cable connected totowing vehicle, operate vehicle lightswitch through all settings and checklights.

NOTE

An assistant is required whilechecking brake lights.

b. Step on brake pedal and check brakelights (16).


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B - Before D - During A - After W - Weekiy M - Monthly

Itemno. B D A W M

15

16

17

Interval

Item to be inspected.

Procedure: check for andhave repaired, filled, or

adjusted as needed

HYDRAULIC HOSES AND TUBES

Check brake system hoses and tubes,and check under vehicle for signs ofbrake fluid leaks.

SUPPORT LEG ASSEMBLY

With trailer connected to towing vehi-

cle, check support leg assembly (17)for ease of operation.

REAR LEG PROP ASSEMBLY

inspect leg prop assembiy (18) forbroken or missing parts.


Any brake fluid leaksare detected.

Support leg assembly

is seized.

Leg prop assembly isunserviceable.

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B - Before D - During A - After W - Weekly M - Monthly

Itemno.

18

19

20

Interval



BRAKE SYSTEM

Test brake system by hooking trailerto towing vehicle and applying brakes.

TRAILER OPERATION

a.

b.

Be alert for any unusual noises whiletowing trailer. Stop and investigate

any unusual noises.

Ensure that trailer is tracking/followingcorrectly behind towing vehicle with noside pull.

GENERATOR SET GAGES AND INSTRUMENTS

a.

b.

Check that battery indicator (19)is in yellow area while batteriesare charging and in green area whenbatteries are fully charged.

Check that frequency meter (20)

indicates 60 Hz (red line) whengenerator is operating under load.

c. Check that current meter (21) readingdoes not exceed 100% or more than 5%load difference between phases.

3-12 Change 3

*U. S. Go v e rnm e n t P r i n t i n g Off i ce : 1991 - 554 - 030 / 4 0132


Service brakes fail tooperate.

Battery indicator not ingreen or yellow area.

Correct frequency

cannot bemaintained.


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Item

no.

20

Interval


have repaired, filled, or

adjusted as needed

GENERATOR SET GAGES ANDINSTRUMENTS CONT

d. Check that voltmeter (22) indicatesdesired output voltage as deter-mined by load connections and amps-volts switch.

e. Check engine oil pressure gage (23)for 25 psig indication.

Equipment is not

ready/avaiIable if:

Desired voltage can-

not be obtained andmaintained.

Oil pressure dropsbelow 15 psig.

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B - Before D During A After W - Weekly M Monthly

Itemno.

21

22

3-14

Interval



FUEL TANK

a. Fill tank (24) upon completion ofoperation.

NOTE

Fuel system temperature must beabove freezing when draining

water and sediment.b. Open drain (25) and drain water and

sediment from fuel tank. Allow to drainuntil fuel runs clean.

FUEL STRAINER AND FILTERS

Drain water and sediment from strainer(26), primary (27) and secondary (28)

filters. Allow to drain until fuel runs clean.



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Itemno.

22

23

Interval



FUEL STRAINER AND FILTERS CONT

HANDBRAKES

With trailer hooked to towing vehicle, sethandbrakes (29). Move trailer slightly tosee if handbrakes hold wheels.


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B Before D During A After w - Weekly M Monthly

Item

no.

24

25

26

IntervalItem to be inspected.

Procedure: check for andhave repaired, filled, or

adjusted as needed

BRAKE DRUMS AND HUBS

WARNING

A defect in the operation of thebrakes or hub can cause theseparts to get hot enough to causeserious burns. Use extreme cau-

tion when attempting to detectheat in this area.

Feel for overheating to detect drag-ging or binding.

REFLECTORS

Check for damaged or missing reflectors,

BATTERIES

Check battery (30) electrolyte level. Level

should be about 3/4 inch above top ofplates. Add water if level is low. Use

clean water (distilled water if available).


Brakes or hub aredragging or binding.

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(2) Installation.

NOTE

Front curtain is provided with three tie-down ropes. Rear curtain only has tworopes.

(a) Position fitted cover (1, figure 3-2) on top of bows (3) making certain front of fittedcover is at front of trailer.

(b) Secure fitted cover (1) to bow assembly (3) with eight straps (2) provided.

(c) Unfasten rollup straps (5, figure 3-1) securing sides of fitted cover and lower bothsides (7).

(d) Unfasten rollup straps (5) securing front and rear curtains (4,6) and lower bothcurtains.

(e) Secure front and rear curtains (4, 6) to sides (7) with six straps and buckles (3)provided on each curtain.

(f) Secure fitted cover to trailer body (2) with 27 ropes (1) provided.

Figure 3-1. Fitted Cover Installed on Power Unit.


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Figure 3-2. Fitted Cover Rolled Up for Removal.

b. Tarpaulin Support and Bow Assembly Replacement. (See figures 3-3 and 3-4.)

(1) Removal.

(a) Remove fitted cover (paragraph 3-11, a.(l)).

(b) Remove one screw (1, figure 3-3), one flat washer (2), one Iockwasher (3) and onewing nut (4) securing tarpaulin support (5) to each of four bow assemblies (6) andremove tarpaulin support.

(c) Remove two quick release pins (1, figure 3-4) securing each bow assembly (2) inpocket (3) on trailer body (4). Lift each bow out of pocket and off trailer body.

(2) Installation.

(a) Lift each bow (2, figure 3-4) onto trailer, aline bow ends with pockets (3) in trailer body(4) and drop bow in place. Secure each bow assembly with two quick release pins (1)provided.

3-19

(b) Position tarpaulin support (5, figure 3-3) on bows (6) and secure tarpaulin support toeach bow with one screw (1), one flat washer (2), one Iockwasher (3) and one wingnut (4).

(c) Install fitted cover on trailer (paragraph 3-11, a.(2)).


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3-12. Fire Extinguisher Maintenance.

WARNING

Monobromotrifluoroethane liquid or gas (Halon 1301) can cause death orserious injury if personnel fail to observe safety precautions. Inhalation ofmonobromotrifluoroethane gas at concentrations of 5% to 6% for more than 4

or 5 minutes may result in serious cardiac or central nervous system effects.Liquid Halon 1301 (including the spray in the immediate vicinity of thedischarge) may freeze the skin on contact. In the event of frostbite, warm theaffected area quickly to body temperature. Immerse hands in warm water orplace hands in armpits. Get medical attention promptly.

CAUTION

Do not attempt to verify readiness of fire extinguisher byunit. Any discharge of contents will require refilling.

partially discharging

The PU-753/M Power Unit is equipped with a 2-3/4 lb Halon fire extinguisher. Maintenance is limited to

weighing the fire extinguisher monthly to insure that it is sufficiently charged. Fully charged, the fireextinguisher (with head and horn attached) weighs 5 lb. Send the unit to specialized activity for rechargingif it weighs 4 lb, 12 oz or less.

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CHAPTER 4

UNIT MAINTENANCE

Section I. SERVICE UPON RECEIPT OF EQUIPMENT

4-1. Inspecting and Servicing Equipment. The power unit is unpacked, inspected, and serviced as

described in the following paragraphs. Unpacked equipment must be checked against the EquipmentPacking List to ensure completeness. Discrepancies must be reported in accordance with instructionsin DA Pam 738-750.

a. Unpacking Power Unit. (See figures 4-1 and 4-2.) The generator set is packed in place on thetrailer body. Before beginning the unpacking procedure, locate, remove, and save the waterproofenvelopes marked Depreservation Guide.

Figure 4-1. Uncrating Generator Set.

WARNING

Steel banding used in packaging of power unit has sharp edges. Care should

be taken when cutting and handling banding to avoid injury to personnel.

(1) Remove lag screws securing plywood box cover over generator set and lift cover offgenerator. Remove wooden wedges positioned around base of generator.

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(2)

(3)

(4)

(5)

(6)

(7)

(8)

Remove and save package of technical manuals secured to barrier material coveringgenerator.

Remove barrier material surrounding inner container.

Remove inner, half-slotted container from around generator set.

Remove coiled ground cable from within base of generator set.

Remove packaged fire extinguisher taped to generator set. Unpack and secure fireextinguisher in bracket on roadside fender.

Unpack and inventory contents of accessory box.

Install ground wire between generator set ground stud and power unit ground terminal.

Figure 4-2. Unpacking Fitted Cover, Bows and Tarpaulin Support.

(9) Remove box containing fitted cover.

NOTE

Inspection and servicing of equipment will be easier to perform before fittedcover is put in place on power unit.

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(10)

(11)

(12)

(13)

(14)

(15)

TM 5-6115-632-14&P

Remove protective film from fitted cover and set fitted cover aside.

Remove strapping and wood blocking securing bows and tarpaulin support from trailer.

Refer to DA Form 2258, Depreservation Guide for Vehicles and Equipment, packed withpower unit and follow instructions given for putting unit in service.

Stow all authorized accessories in the accessory box.

Install bows and tarpaulin support on power unit (paragraph 3-11, b (2)).

Install fitted cover on power unit (paragraph 3-11, a (2)).

b. Inspection and Servicing of Generator Set. Refer to Servicing Upon Receipt of Material inTM 5-6115-585-12 for initial inspection and servicing procedures.

c. Inspection and Servicing of Trailer. Refer to Servicing Upon Receipt of Material in TM 9-2330-202-14&P for initial inspection and servicing procedures.

4-2. Installation. (See figure 4-3.) Installation of the power unit at a worksite involves positioning thetrailer and grounding the power unit.

a. Positioning Power Unit. Position the power unit on the worksite as follows:

(1) Select on area as level as possible to install power unit and position trailer.

(2) Set trailer handbrakes and lower trailer support leg.

(3) Chock both wheels and lower rear leg prop assembly. Adjust leg prop assembly by turninginner leg until leg base makes firm contact with ground.

(4) Lift and secure fitted cover in raised position away from generator set exhaust.

WARNING

Remove fire extinguisher and fuel cans from power unit when generator set is inoperation. This will insure that, in the event of fire, extra fuel will not be involvedand extinguisher will remain accessible.

(5) Locate fuel cans and fire extinguisher on ground away from power unit.

WARNING

4-3

Do not operate generator set until power unit is properly grounded (paragraph4-2, b.). Serious injury or death by electrocution can result from operating anungrounded power unit.
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Figure 4-3. Installing Power Unit.

CAUTION

To avoid damage to equipment, make certain of voltage, frequency, andphase requirements of load being connected to generator set.

(6) Refer to data plate on load terminal board cover and to TM5-6115-585-12. Connect powerunit to system or equipment to be powered.

b. Grounding. Check that generator set is grounded to GROUND TERMINAL stud on trailer body.Using ground wire supplied with power unit, connect power unit to a suitable ground as describedbelow. The following sources of a good ground are listed in order of preference.

NOTE

As a substitute for the supplied ground wire, any copper wire of at least No. 6AWG maybe used.

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h. Remove locking pin from leg prop assembly on rear of trailer. Swing leg prop back and upinto traveling position and secure with pin.

i. Attach power unit to towing vehicle. (Refer to TM 9-2330-202-14&P.)

j. Release trailer handbrakes.

4-4. Reinstallation After Movement. After movement to a new worksite, install power unit inaccordance with paragraph 4-2.

Section Ill. REPAIR PARTS, SPECIAL TOOLS, SPECIAL TEST, MEASUREMENT ANDDIAGNOSTIC EQUIPMENT (TMDE)

4-5. Tools and Equipment. There are no special tools or equipment required to maintain thePU-753/M power unit.

4-6. Maintenance Repair Parts. Repair parts and equipment for maintenance of this power unit arelisted and illustrated in the repair parts and special tools list in Appendix D of this manual.

Section IV. LUBRICATION INSTRUCTIONS

4-7. General. Detailed instructions for the lubrication of the major components of the power unit arecontained in the applicable Lubrication Orders (LOs). Refer to DA Pam 310-1 to ensure that the latesteditions of the L.O.S are used. This section contains lubrication instructions that are not included inthe Lubrication Orders.

4-8. Generator Lubrication. Refer to TM 5-6115-585-12 for generator set Lubrication Order.

4.9. Trailer Assembly Lubrication.

a. Trai/er Lubrication. Refer to TM 9-2330-202-14&P for trailer Lubrication Order.

b. Leg Prop Assembly Lubrication. The rear leg prop assembly is a modification to the standard

M116A2 trailer and, as such, does not appear in the associated L.O. Semiannually lubricate leg propassembly as follows:

WARNING

Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes andprolonged exposure of skin to cleaning solvent. Wash exposed skin tho-roughly. Dry cleaning solvent (P-D-680) used to clean parts is potentiallydangerous to personnel and property. Do not use near open flame orexcessive heat. Flash point of solvent is 100F. to 138F. (38C. to 59C.).

(1) Clean hydraulic lubrication fitting and area around lubrication points with P-D-680 orequivalent.

(2) Inject sufficient GAA grease into hydraulic fitting to lubricate screw threads inside leg propassembly.

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NOTE

Refer to Lubrication Order in TM 9-2330-202-14&P for lubricating oils specifiedanticipated temperature ranges.

(3) Apply OE lubricating oil to both ends of leg prop assembly pivot shaft.

for use within different

Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

NOTE

The PMCS chart in this section contains all necessary unit preventivemaintenance chdcks and services for this equipment.

4-10. General. The trailer assembly and generator set must be inspected and serviced systematically toinsure that the power unit is ready for operation at all times. Inspection will allow defects to bediscovered and corrected before they result in serious damage or failure. Table 4-1 contains a tabulatedlist of preventive maintenance checks and services to be performed by unit maintenance personnel.All of the unit PMCS on the trailer is scheduled to be performed semiannually. Unit PMCS on thegenerator set is scheduled weekly or on a per-hours-of-operation basis. The running time meter on thecontrol panel is used to determine the qenerator set operatinq time. Using the followinq as a guide, dothe checks and services at the intervals shown. Observe all CAUTIONS and WARNINGS.

a.

b .

c.

d.

e.

f

4-11.

For PMCS performed on an operating time basis, perform your hourly (H) PMCS as close aspossible to the time intervals indicated.

NOTE

For units in continuous operation, perform PMCS before startingoperation if continuous operation will extend service interval pastthat which is shown.

Perform your weekly (W) PMCS every week or 40 hours of generator set operating time.

Perform your monthly (M) PMCS every month or 100 hours of generator set operating time.

Do your semiannual (S) PMCS once every six months or 500 hours of generator set operating

Do your annual (A) PMCS once every year or 1000 hours of generator set operating time.

time.

If you discover a problem with the equipment, refer to Section Vl, Troubleshooting. If you cannotcorrect the problem, refer to paragraph 4-12, Reporting Deficiencies.

Explanation of Columns. The following is a list of the PMCS table column headings with adescription of the information found in each column.

a. Item No. This column shows the sequence in which to do the checks and services, and is usedto identify the equipment area on the Equipment Inspection and Maintenance Worksheet, DA Form2404.

b. Interval. This column shows when each check is to be done.

c. Item to be Inspected. This column identifies the general area or specific part where the checkor service is to be done.

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d. Procedures. This column lists the checks or service you have to do and explains how to dothem.

4-12. Reporting Deficiencies. If you discover any problem with the equipment during PMCS that youare unable to correct, it must be reported. Refer to DA Pam 738-750 and report the deficiency usingthe proper forms.

Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS).

Itemno.

1

2

3

4

Interval

q

q

q

Item to beInspected

Generator Set

Fuel Strainer andFilters

Fuel Tank

Fuel Pumps

Procedures

WARNING

Before performing any maintenancethat requires climbing on or undertrailer, set trailer handbrakes, chockwheels, and lower rear leg prop.injury to personnel could resultfrom trailer suddenly rolling ortipping.

Inspect generator set for fuel and oilleaks, loose or missing components andhardware, and unusual wear or deterio-ration. Clean generator set.

NOTE

Fuel system must be above freezingtemperature when draining water andsediment from strainer, filters,and tank.

Open drains on fuel strainer, andprimary and secondary filters. Drainwater and sediment (para 3-20,TM 5-6115-585-12). Allow to drain

until fuel runs clean.Open drain on fuel tank and drain waterand sediment (para 3-13, TM 5-6115-585-12). Allow to drain until fuelruns clean.

Clean or replace, as necessary, fuelstrainer in bottom of fuel pump.

Change 1 4-9
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Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS). CONT.

H Hours of operation W Weekly M Monthly(As indicated)

S Semiannually(40 hours)

A Annually

(100 hours) (500 hours) (1000 hours)

Item

no.S

5

6

7

8

9

10

11

12

13

14

15

Interval

H

100

300

500

1000

300

500

100

1000

w M

q

q

q

A

Item to beInspected

Lubricating Oil

and Filter

Fuel Strainer

Primary FuelFilter

Secondary FuelFilter

Batteries

Crankcase Breather

Dust Caps on Air

Cleaner

Air Cleaner

Taillights

IntervehicularCable

Drawbar Ring

Procedures

Change lubricating oil and filter every 100

hours of operation (L.0. 5-6115-585-12).

Clean fuel strainer every 300 hours of

operation (para 4-20, TM 5-6115-585-12).

Service primary filter every 500 hours ofoperation (para 4-20, TM 5-6115-585-12).

Service secondary filter every 1000 hours

(para 4-20, TM 5-6115-585-12).

Perform a hydrometer test on batteries

every 300 hours, or quarterly. Refer topara 4-25c, TM 5-6115-585-12 for testprocedures.

Inspect breather tube every 500 hours.

Clean as necessary (para 4-45,

TM 5-6115-585-12).

Clean out dust caps on air cleaner assemblyevery 100 operating hours (more frequently

under ususual conditions).

Clean every 1000 operating hours or as

conditions dictate. Replace air cleaner

every 2000 operating hours.

Replace any broken or cracked lensesor defective bulbs (page 4-52,

TM 9-2330-202-14&P).

Check for cuts, breaks, frayed wires, ordamaged plug.

Check security of mounting. Inspect ring

for excessive wear.

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Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS). CONT.

Item

no.

24

25

26

27

28

H

Interval

W M S

q

q

q

q

A

q

Item to be

Inspected

Brakes

Wheel Bearings

Hydraulic Brake

Actuator

Hydraulic Brake

Tubes and Hoses

Trailer Road

Test

Procedures

H - Hours of operation W Weekly M Monthly(As indicated)

S - Semiannually A Annually(40 hours) (100 hours) (500 hours) (1000 hours)

4-12 Change 1

a.

b.

c.

d.

Inspect brake linings for wear. Replace

if brake shoe lining is less than l/8-

inch (3.2 mm) thick (page 4-140,

TM 9-2330-202-14&P).

Inspect brake adjusting screw, retaining

screw, retaining pins, springs, and

clips for corrosion and wear.

Inspect hydraulic wheel cylinders for

leaks.

Adjust brake (page 4-154,

TM 9-2330-202-14&P).

Clean and repack. (page 4-180),

TM 9-2330-202-14&P).

a. Check security of brake actuator

mounting.

b. Service brake actuator (page 4-156,

TM 9-2330-202-14&P).

Inspect for dents, cracks, loose connections

and leaks.

Perform road test paying special attention

to items that were repaired or adjusted,

in accordance with TM 9-2330-202-14.

PIN: 064390-


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Figure 4-5. Fuel Can Bracket Replacement.

b. Installation.

(1) Position fuel can bracket (4) on fender (5).

(2) Insert four screws (1) down through bracket (4) and through fender (5).

(3) Install one washer (3) and one nut (2) onto each screw (1). Tighten hardware to securebracket (4).

4-18. Accessory Box Replacement. (See figure 4-6.) The accessory box is mounted to the trailer

bed forward of the generator set.

a. Removal.

(1) Remove four screws (1, figure 4-6), four flat washers (2), and four nuts (3) securingaccessory box (4) to traiIer bed (5).

(2) Lift accessory box (4) off trailer (5).

b. Installation.

(1) Position accessory box (4) on trailer bed (5).

(2) Insert four screws (1) through accessory box mounting brackets and trailer bed (5).

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Figure 4-6. Accessory Box Replacement.

(3) Working under trailer, install one flat washer (2) and one nut (3) on each screw (1).Tighten hardware to secure accessory box (4).

4-19. Fire Extinguisher Bracket Replacement. (See figure 4-7.) The fire extinguisher supplied with

the power unit is carried in a bracket mounted on the rear of the trailer roadside fender.

a. Removal.

(1) Remove four screws (1, figure 4-7), four nuts (2), and four flat washers (3) securingbracket (4) to fender(5).

(2) Remove bracket (4) from fender (5).

b. Installation.

(1) Position fire extinguisher bracket (4) on fender (5).

Figure 4-7. Fire Extinguisher Bracket Replacement.

(2) Insert four screws (1) down through bracket (4) and through fender (5).

4-15


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(1) Disassembly.

TM 5-6115-632-14&P

(a) Remove leg prop assembly from trailer (paragraph 5-2, a.(l)).

(b) Clamp leg prop assembly in vise with spring pin facing up.

(c) Using suitable drift, drive spring pin out of upper leg and remove leg base.

(2) Assemb/y.

(a) Clamp upper leg in vise with spring pin hole facing up.

(b) Insert leg base into upper leg and turn leg base until hole in screw lines up with hole inupper leg.

(c) Install spring pin to secure leg base to upper leg.

(d) Install leg prop assembly on trailer (paragraph 5-2, a. (2)).

5-3. Trailer Bed and Fenders Repair and Replacement. (See figure 5-2.) The body of the modifiedtrailer consists of a single weldment that includes both fenders and the bed of the trailer.

a. Removal.

(1) Remove fitted cover (paragraph 3-11, a.(1)).

(2) Remove tarpaulin support and four bow assemblies (paragraph 3-11, b.(1)).

(3) Remove accessory box (paragraph 4-18, a.).

(4) Remove generator set (paragraph 5-7, a.).

(5) Remove 10 screws (1, figure 5-2), 20 flat washers (2), and 10 nuts (3) securing trailerbody (4) to trailer chassis (5).

NOTE

Observe position of screws securing rear braces on trailer body to trailerchassis.

(6) Remove 16 screws (6), 32 flat washers (7) and 16 nuts (8) securing trailer body (4) totrailer chassis (5).

NOTE

Removal of the trailer body requires the removal and disassembly of bothhandbrake lever assemblies. The handbrake lever assemblies are symmetrical

and this procedure is typical for both.

5-

(7) Remove two screws (9), two spacers (10), and two nuts (11) and remove roadside hand-brake lever assembly (12) from trailer chassis (5).


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(8)

(9)

(10)

(11)

(12)

(13)

(14)

(15)

Install washer (14) and cotter pin (13) to secure shaft (15).

Assemble handbrake lever assembly (12) using two screws (9) and two spacers (10).Make certain top screw (9) goes through spacer (18) and bottom screw (9) goes throughhandbrake cable clevis.

Position assembled handbrake lever assembly (12) on trailer chassis (5) and install twonuts (11). Tighten hardware.

Repeat steps (6) through (10) to assemble and install curbside handbrake leverassembly.

Install generator set (paragraph 5-7, b.).

Install accessory box (paragraph 4-18, b.).

Install tarpaulin support and four bow assemblies (paragraph 3-11, b.(2)).

Install fitted cover (paragraph 3-11, a.(2)).

5-4. Fitted Cover Repair. Repairs to the fitted cover shall be made in accordance with FM 10-16,

Fabric Repairing.

5-5. AccessoryBox Repair. (See figure 5-3.) The accessory box is repaired by replacing the hasp,the catches and the footmans loops, as required. The box itself may be straightened, welded, andrepainted. If required, repaint in accordance with MIL-T-704, Type F, color Green, No. 383 of MIL-C-46168.

a, Catch and Hasp Replacement.

(1) Grind off or drill out solid rivets (1, figure 5-3) securing catch or hasp (2) to accessorybox (3).

(2) Position new catch or hasp (2) on accessory box and secure with solid rivets (1).

(3) Touch up with paint as required.

Figure 5-3. Accessory Box Repair,

5-6


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b. Footmans Loop Replacement.

TM 5-6115-632-14&P

(1) Remove two screws (4, figure 5-3), two flat washers (5), and two self-locking nuts (6)securing footmans loop (7) to accessory box lid.

(2) Position new footmans loop (7) on accessory box (3) and install with two screws (4) twowashers (5), and two self-locking nuts (6).

5-6. Marking. (See figure 5-4.) The power unit four-digit registration number, preceded by theprefix VC and the words U.S. ARMY, is marked in three places on the trailer. Marking is done inaccordance with MIL-STD-642. On the fender, over each wheel, T.P. 35 PSI is marked in 1.00 .12 inch high characters in accordance with MIL-STD-130. Figure 5-4 shows the approximate loca-tion of markings on the power unit. If required, touch-up painting of the base color is done inaccordance with MIL-T-704, Type F, color Green, No. 383 of MIL-C-46168.

T.P. 35 PSI

Figure 5-4. Power Unit Markings.

Section Ill. GENERATOR SET

5-7. Generator Set Replacement. (See figures 5-5 and 5-6.)

a. Removal.

(1) Remove fitted cover (paragraph 3-11, a.(1)).

(2) Remove tarpaulin support and four bow assemblies (paragraph 3-11, b.(1)).

5-


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TM 5-6115-632-14&P

(3) Disconnect ground wire (1, figure 5-5) from generator set (2) to GROUND TERMINALstud (3) on trailer bed (4).

NOTE

The beveled washers (6) may have been welded in place.

(4) Remove four bolts (5), four beveled washers (6), four flat washers (7), four Iockwashers(8) and four nuts (9) securing generator set (2), to trailer (4).

(5) Remove engine oil drain hose (10) from grommet in trailer bed.

Figure 5-5. Detaching Generator Set from Trailer.

WARNING

When lifting generator set, use lifting equipment with a minimum lifting capa-city of 1500 lb. Do not stand under generator while it is being lifted. Failure to

observe these precautions can cause injury to personnel or damage toequipment.

(6) Attach lifting equipment with a minimum lifting capacity of 1500 lb (1, figure 5-6) to liftingeye (2) on top of generator set (3) and remove generator set from trailer.

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TM 5-6115-632-14&P

b. Installation.

WARNING

When lifting generator set, use lifting equipment with a minimum lifting capa-city of 1500 lb. Do not stand under generator while it is being lifted. Failure to

observe these precautions can cause injury to personnel or damage toequipment.

(1) Attach lifting equipment

Figure 5-6. Lifting Generator Set.

with a minimum lifting capacity of 1500 lb (1, figure 5-6) to liftingeye (2) on top of generator set (3) and lift generator.

(2) Lower generator set (2, figure 5-5) onto trailer bed (4) and aline mounting holes.

(3) Insert four bolts (5) with beveled washers (6) down through generator set skid and trailerbed (4).

(4) Working under trailer, install one flat washer (7), one Iockwasher (8) and one nut (9) oneach bolt (5).

(5) Position beveled washers (6) so that bolt heads are parallel to top of washers. While hold-ing beveled washers in position, tighten hardware to secure generator set (2) to

trailer (4).

5-


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TM 5-6115-632-14&P

CHAPTER 6

TEST AND INSPECTION AFTER REPAIR

Section I. GENERAL REQUIREMENTS

6-1. General Requirements. The activity performing the repair is responsible for the performance ofall applicable tests and inspections specified in the technical manuals referenced below. Activities

performing maintenance on any component of the power unit must perform those tests and inspectionsrequired by the applicable component or system repair instruction.

Section Il. INSPECTION

6-2. Generator Set Inspections. Refer to TM 5-6115-585-12 and -34 for inspections requiredfollowing repair of the generator set.

6-3. Trailer Inspections. Refer to TM 9-2330-202-14&P for inspections required following repair ofthe trailer.

Section Ill. OPERATIONAL

6-4. Generator Set Operational Tests. Refer to TM 5-6115-585-12required to verify satisfactory performance of the generator set.

TESTS

and -34 for operational tests

6-5. Trailer Operational Tests. Refer to TM 9-2330-202-14&P for operational tests required to verifysatisfactory performance of the trailer.

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TM 5-6115-632-14&P

Operators, Organizational, Direct Support and General SupportMaintenance Manual Including Repair Parts and Special ToolsList for Trailer, Cargo: 3/4-Ton, 2-Wheel, M101(NSN 2330-00-738-9509), M101AI (2330-00-898-6779),M101A2 (2330-01-101-4697) and Chassis, Trailer 3/4-Ton, 2-Wheel, M1 16 (2330-00-542-5987), M116A1 (2330-00-898-6780)and M116A2(2330-01-101-8434). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2330-202-14&P

Organizational, Direct Support, and General Support CareMaintenance and Repair of Pneumatic Tires and InnerTubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... TM 9-2610-200-24

Air Force Technical Order System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TO-00-5-1Painting and Marking of USAF Aerospace Ground Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . TO 35-1-3

Processing and Inspection of Aerospace Ground Equipmentfor Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TO 35-1-4

Processing and Inspection of Non-Mounted, Non-AircraftGasoline and Diesel Engines for Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TO 38-1-5

Lubrication Order, Generator Set,Diesel Engine Driven, TacticalSkid Mounted, 10KW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L 05-6115-585-12

A-5. Technical Bulletins.

Preservation of USAMECOM Mechanical Equipment forShipment and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 740-97-2

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ARMY TM 5-6115-632-14&PAIR FORCE TO-35C2-3-491-1

APPENDIX B

COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS

Section I INTRODUCTION

B-1. Scope. This appendix lists components of end item and basic issue items for the power unit to:help you inventory items required for safe and efficient operation.

B-2. General. The Components of End Item and Basic Issue Items Lists are divided into the followingsections.

a. Section II. Components of End Item. This listing is for informational purposes only, and is notauthority to requisition replacements. These items are part of the end item, but are removed and sep-arately packaged for transportation or shipment. As part of the end item, these items must be with theend item whenever it is issued or transferred between property accounts. Illustrations are furnished toassist you in identifying the items.

b. Section III. Basic Issue Items. These are the minimum essential items required to place thepower unit in operation, to operate it, and to perform emergency repairs. Although shipped sepa-rately packaged, Bll must be with the power unit during operation and whenever it is transferred be-

tween property accounts. The illustrations will assist you with hard-to-identify items. This manual isyour authority to request/requisition replacement Bll, based on TOE/MTOE authorization of the enditem.

B-3. Explanation of Columns. The following provides an explanation of columns found in the tabularlistings:

a. Column (1), Illustration Number (IIIus No.). This coIumn indicates the number assigned tothe item.

b. Column (2), National Stock Number. Indicates the National stock number assigned to theitem.

c. Column (3), Description. Indicates the federal item name and, if required, a minimum des-cription to identify and locate the item. The last line for each item indicates the FSCM (in paren-theses) followed by the part number. If item needed differed for different models of this equipment,the model would be shown under the Usable on Code heading in this column. The Usable On Code isnot applicable for this equipment.

d. Column (4), Unit of Measure (U/M). Indicates the measure used in performing the actualoperational/maintenance function. This measure is expressed by a two-character alphabeticalabbreviation (eg, ea, in, pr).

e. Column (5), Quantity Required (Qty Reqd). Indicates the quantity of the item authorized to beused with/on the equipment.

B-1


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Section Il. COMPONENTS OF END ITEM

(1)

Illusno.

1

2

3

Figure B-1. Components of End Item

(2)

National

stock number

5120-00-243-2957

5975-00-878-3791

5120-01-013-1676

(3)Description Usable

FSCM and part number on code

Hammer, Hand, Engineers 8 lb.(3.6kg) (81348) GGG-H-86

Rod, Ground, Driven, Sectional

9 ft (2.7 m) (81349) MlL-R-1 1461

Hammer, Slide (97403) 13226E7741

(4)

U/M

EA

EA

EA

(5)Qtydreqd

1

2

1

B-2


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TM 5-6115-632-14&P

Section III. BASIC ISSUE ITEMS

Figure B-2. Basic Issue Items

(1) (2) (3)

Illus National Description Usableno. stock number FSCM and part number on code

1 4210-00-555-8837 Extinguisher, Fire, Hand,2-3/4 lb. (1.25kg)MIL-E-52031

2 Manual, TechnicalTM 5-6115-623-14&P/TO-35C2-3-491-1

(4) (5)Qtyd

U/M reqd

EA 1

EA 1

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APPENDIX C

MAINTENANCE ALLOCATION

Section I. INTRODUCTION

C-1. General.

CHART

a. This section provides a general explanation of all maintenance and repair functions authorizedat various maintenance levels.

b. Section II designates overall responsibility for the performance of maintenance functions onthe identified end item or component. The implementation of the maintenance functions upon the enditem or component will be consistent with the assigned maintenance functions.

c. Section Ill lists the tools and test equipment required for each maintenance function as refer-enced from Section Il.

d. Section IV contains supplemental instructions, explanatory notes and/or illustrations requiredfor a particular maintenance functions.

C-2. Explanation of Columns in Section Il.

a. Group Number. Column 1. The assembly group is a numerical group assigned to each assem-bly in a top down breakdown sequence. The applicable assembly groups are listed on the MAC indisassembly sequence beginning with the first assembly removed in a top down disassemblysequence.

b. Assembly Group. Column 2. This column contains a brief description of the components ofeach assembly group.

c. Maintenance Functions. Column 3. This column lists the various maintenance functions (Athrough K) and indicates the lowest maintenance category authorized to perform these functions. Thesymbol designations for the various maintenance categories are as follows:

C O F H D

Operator or crewUnit maintenanceIntermediate direct support maintenanceIntermediate general support maintenanceDepot maintenance

The maintenance functions are defined as follows:

A Inspect. To determine serviceability of an item by comparing its physical, mechanical, andelectrical characteristics with established standards.

B Test. To verify serviceability and to detect electrical or mechanical failure by use of testequipment.

C Service. To clean, to preserve, to charge, and to add fuel, lubricants, cooling agents, andair. If it is desired that elements, such as painting and lubricating, be defined separately, they may beso listed.

C-1


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Section Il. MAINTENANCE ALLOCATION CHART

(1)

Group

no.

01

02

03

04

(2)

Assembly

group

ENCLOSURE

Fitted Cover

Bows

GENERATOR SET

ACCESSORIES

Sledge Hammer

Fire

Extinguisher

Slide Hammer

Ground Rods

TRAILER ASSEMBLY

Accessory Box

Fuel Can/Fire

Extinguisher

Brackets

Bed/Fenders

c

0.1

c

0.1

c

0.2

c

0.1

c

0.1

c

0.1

c

0.1

c

0.5

c

0.1

o1.0

c2.0

c

0.5

(3)

Maintenance functions

c

0.5

c

0.1

F

3.0

c

0.1

c

0.1

c

0.1

c

0.1

0

0.5

0

0.5

F

4.0

F

1.0

F

2.0

F

4.0

(4)

Tools and

equipment

(5)

Remarks

See TM 5-

6115-585-

-12, -34 for

generator

set mainte-

nance.

See TM 9-

2330-202-

14&P for

trailer

mainte-

nance.

C-3


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(1) (2) (3) (4) (5)

Maintenance functions

A B C D E F G H I J K

Group Assembly Tools and Remarks

no. group equipment

Reflectors c 0

0.1 0.5

Data Plates o

0.2

M116A2 Military Trailer Manual Number TM 5 6115 632 14

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Transcript of M116A2 Military Trailer Manual Number TM 5 6115 632 14