OPERATOR’S, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT...

* A R M Y T M 5 - 6 1 1 5 - 6 3 0 - 1 4 & P

TECHNICAL MANUAL

OPERATOR’S , UN IT , D IRECT SUPPORT ANDG E N E R A L S U P P O R T M A I N T E N A N C E M A N U A L

( INCLUDING REPAIR PARTS ANDSPECIAL TOOLS L IST )

P O W E R U N I T

P U - 7 5 1 / M ( N S N 6 1 1 5 - 0 0 - 0 3 3 - 1 3 7 3 )M E P - 0 0 2 A 5 K W 6 0 H Z G E N E R A T O R S E T

M 1 1 6 A 1 2 - W H E E L , 2 - T I R E ,MODIFIED TRAILER

*This manual supersedes Chapter 12 of TM 5-6115-594-14&P dated 25 September 1984.

Approved for public release; distribution is unlimited

HEADQUARTERS, DEPARTMENT OF THE

5 OCTOBER 1989

A R M Y

TM 5-6115-630-14&PC3

CHANGE HEADQUARTERSDEPARTMENT OF THE ARMY

NO. 3 WASHINGTON, D.C, 31 July 1996

Operator’s, Unit, Direct Support andGeneral Support Maintenance Manual

(Including Repair Parts and Special Tools List)

POWER UNITPU-751/M (NSN 6115-00-033-1373)

MEP-002A 5 KW 60 HZ GENERATOR SETM116A1 2-WHEEL, 2-TIRE,

MODIFIED TRAILER

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

TM 5-6115-630-14&P, 5 October 1989, 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 pages

D-19 and D-20 D-19 and D-20

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

By Order of the Secretary of the Army:

DENNIS J. REIMERGeneral, United States Army

Official: Chief of Staff

JOEL B. HUDSONAdministrative Assistant to the

Secretary of the Army01999

DISTRIBUTION:To be distributed in accordance with DA Form 12-25-E, block no. 4421, requirements for TM 5-6115-630-14&P.

MILTON H. HAMILTON

T M 5 – 6 1 1 5 – 6 3 0 - 1 4 & P

C 2

C H A N G E H E A D Q U A R T E R S

DEPARTMENT OF THE ARMY

N O . 2 WASHINGTON, D.C., 3 APRIL 1992

Operator ’s , Un i t , D i rec t Suppor t and

G e n e r a l S u p p o r t M a i n t e n a n c e M a n u a l

( Inc lud ing Repai r Par ts and Spec ia l Too ls L is t )

P O W E R U N I T ,

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

M E P – 0 0 2 A , 5 K W , 6 0 H Z G E N E R A T O R S E T

M116A1 2–WHEEL, 2–TIRE,

M O D I F I E D T R A I L E R

Approved for public release; distribution is unlimited

TM 5–6115-630-14&P, dated 5 October 1989, is changed as follows:

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

Remove pages Insert pages

3–11 and 3–12 3–11 and 3–12

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


GORDON R. SULLIVAN

Official: General, United States ArmyChief of Staff

MILTON H. HAMILTONAdministrative Assistant to the

Secretary of the Army00905

DISTRIBUTION:To be distributed in accordance with DA Form 12-25E, (qty rqr block no. 4421)

TM 5-6115-630-14&P

SAFETY STEPS TO FOLLOW IF SOMEONEIS THE VICTIM OF ELECTRICAL SHOCK

DO NOT TRY TO PULL OR GRAB THE INDIVIDUAL

IF POSSIBLE, TURN OFF THE ELECTRICAL POWER

IF YOU CANNOT TURN OFF THE ELECTRICALPOWER, PULL, PUSH, OR LIFT THE PERSON TOSAFETY USING A DRY WOODEN POLE OR A DRYROPE OR SOME OTHER INSULATING MATERIAL

SEND FOR HELP AS SOON AS POSSIBLE

AFTER THE INJURED PERSON IS FREE OFCONTACT WITH THE SOURCE OF ELECTRICALSHOCK, MOVE THE PERSON A SHORT DISTANCEAWAY AND IMMEDIATELY START ARTIFICIALRESUSCITATION

a

TM 5-6115-630-14&P

WARNING

b

All specific cautions and warnings contained in this manual shall be strictly adhered to.Otherwise, severe injury, death and/or damage to the equipment may 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. Do not operate thispower unit until the ground terminal stud has been connected to a suitable ground. Disconnectthe battery ground cable on the generator set before removing and installing components on theengine or in the electrical control panel system. Remove all rings, watches, and other jewelrywhen performing maintenance on this equipment. Loose fitting clothing should be secured toprevent it catching moving parts. Do not attempt to service or otherwise make any adjustments,connections or reconnection of wires or cables until generator set is shut down and completelyde-energized.

DANGEROUS GASES

Batteries generate explosive gas during charging: therefore, utilize extreme caution. Do notsmoke, or use open flame in the vicinity of the generator set when servicing batteries.

Exhaust discharge contains noxious and deadly fumes. Do not operate power generator set inenclosed areas unless exhaust discharge is properly vented to the outside.

To avoid sparking between filler nozzle and fuel tank, always maintain metal to metal contactbetween filler nozzle and fuel tank when filling generator set fuel tank.

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

LIQUIDS UNDER HIGH PRESSURE

are generated as a result of operation of the power unit generator set. Do not expose any part ofthe body to a high pressure leak in the fuel injection system.

NOISE

Operating noise level of the generator set can cause hearing damage. Ear protectors, asrecommended by the medical or safety officer, must be worn when working near this power unit.

WARNING

Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes and prolonged exposureof skin to cleaning solvent. Wash exposed skin thoroughly. Dry cleaning solvent (P-D-680) usedto clean pads is potentially dangerous to personnel and properly. Do not use near open flame orexcessive heat. Flash point of solvent is 100°F to 138°F (38°C to 59°C).

*TM 5-6115-630-14&P

TECHNICAL MANUAL HEADQUARTERSDEPARTMENT OF THE ARMY

NO. 5-6115-630-14&P WASHINGTON, D.C., 5 October 1989

Operator’s, Unit, Direct Support andGeneral Support Maintenance Manual

(Including Repair Parts and Special Tools List)

POWER UNITPU-751/M (NSN 6115-00-033-1373)

MEP-002A 5 KW 60 HZ GENERATOR SETM116A1 2-WHEEL, 2-TIRE,

MODIFIED TRAILER

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

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes, or if you know of a way to improvethese procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changesto Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual directlyto: Commander, US Army Aviation and Troop Command, ATTN: AMSAT-I-MP, 4300 GoodfellowBlvd., St. Louis, MO 63120-1798. You may also submit your recommended changes by E-maildirectly to <mpmt%/[email protected]>. A reply will be furnished directly to you.Instructions for sending an electronic 2028 may be found at the back of this manual immediatelypreceding the hard copy 2028.

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 ......................................................................................... 2-1Section III Operation Under Unusual Conditions ................................................................................... 2-2

CHAPTER 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 Instructions ........................................................................... 3-17

*This manual supersedes Chapter 12 of TM 5-6115-594-14&P dated 25 September 1984.

Change 4 i

TM 5-6115-630-14&P

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

CHAPTER 5 DIRECT SUPPORT AND GENERAL SUPPORTMAINTENANCE INSTRUCTIONS

Section I Introduction ........................................................................................................................... 5-1Section II Maintenance of Power Unit Trailer ....................................................................................... 5-1Section III Generator Set ....................................................................................................................... 5-8

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-1

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

APPENDIX C MAINTENANCE ALLOCATION CHART ..............................................................................C-1

APPENDIX D UNIT, DIRECT SUPPORT AND GENERALSUPPORT AND DEPOT MAINTENANCE REPAIR PARTSAND SPECIAL TOOLS LIST ...........................................................................................D-1

ii Change 4

TM 5-6115-630-14&P

LIST OF ILLUSTRATIONS

F i g u r eTitle Page

1-11-23-13-23-33-44-14-24-34-44-54-64-75-15-25-35-45-55-6

D-1D-2D-3D-4D-5

Number

3-1

Power Unit, Roadside Front, Three-Quarter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Power Unit, Curbside Rear, Three-Quarter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-3Fitted Cover installed on Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-18Fitted Cover Rolled Up for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-19Tarpaulin Support Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-20Bow Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-20Uncrating Generator Set...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-1Unpacking Fitted Cover, Bows and Tarpaulin Support . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4-2Installing Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-4External Fuel Line Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-6Fuel Can Bracket Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-13Accessory Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-14Fire Extinguisher Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-15Leg Prop Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-2Fender and Bed Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-4Accessory Box Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-7Power Unit Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-7Detaching Generator Set fromTraiier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-8Lifting Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-9Components of End ltem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..B-2Basic lssue ltems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..B-3Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..D-8Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..D-10Trailer Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..D-12Accessory Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..D-16Leg Prop Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..D-18

LIST OF TABLES

Title Page

Consumable Operating and Maintenance Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-13-24-1

Operator/Crew Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . ...3-4Unit Preventive Maintenance Checks and Services(PMCS) . . . . . . . . . . . . . . . . . . . . . ...4-9

iii/(iv blank)s

TM 5-6115-63-14&P

CHAPTER 1

INTRODUCTION

Section I. GENERAL

1-1. Scope. This manual is for your use in operating and maintaining the Power Unit, PU-751/M. The PU-751/M is amobile power unit used to supply power to any system or equipment requiring up to 5 kW of 60 Hz input operating power.In 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. Maintenance Forms and Records. Maintenance forms and records used by Army personnel are prescribed byDA Pam 738-750.

1-3. Reporting of Errors. Reporting of errors and omissions and recommendations for improvement of thispublication by the individual user is encouraged. Submit DA Form 2028 directly to: Commander, US Army Aviation andTroop Command, ATTN: AMSAT-I-MT, 4300 Goodfellow Boulevard, St. Louis, MO 63120-1798.

1-4. Reporting Equipment Improvement Recommendations (EIR). EIR’s will be prepared using SF 368, ProductQuality Deficiency Report. Instructions for preparing EIR’s are provided in DA PAM 738-750, The Army MaintenanceManagement System. EIR’s should be mailed directly to: Commander, US Army Aviation and Troop Support Command,ATTN: AMSAT-I-MDO, 4300 Goodfellow Boulevard, St. Louis, MO 63120-1798.

1-5. Levels of Maintenance Accomplishment. Army users shall refer to the Maintenance Allocation Chart (MAC) fortasks and levels of maintenance to be performed.

1-6. Destruction of Army Materiel. Destruction of Army materiel to prevent enemy use shall be in accordance withTM 750-244-3.

1-7. Administrative Storage.

a. Placement of equipment in administrative storage should be for short periods of time when a shortage ofmaintenance efforts exists. Items should be in mission readiness within 24 hours or within the time factors as determinedby the directing authority. During the storage period appropriate maintenance records will be kept.

b. Before placing equipment in administrative storage, current maintenance services and equipment serviceablecriteria (ESC) evaluations should be completed, shortcomings and deficiencies should be corrected, and all modificationwork orders (MWO’s) should be applied.

c. Storage site selection. Inside storage is preferred for items selected for administrative storage. If insidestorage is not available, trucks vans, conex containers and other containers may be used.

1-8. Preparation for Shipment and Storage. Refer to TB 740-97-2.

Change 4 1-1

Figure 1-1.

TM 5-6115-630-14&P

Section Il. DESCRIPTION AND DATA

1-9. Description. Power Unit PU-751/M is made up of one Tactical Utility Generator Set, DOD ModelMEP-002A, mounted on a modified M116A1 trailer. The generator set is an air-cooled diesel engine-driven unitwith a load capacity of 5 KW at 60 Hz. The trailer is a two-wheeled unit with a 3/4-ton carrying capacity. Themodifications to the basic trailer provide stowage for the accessories and all equipment necessary for mobileoperation as well as providing a work platform for the operator and maintenance personnel. Figures 1-1 and 1-2illustrate the power unit with the fitted cover removed to show the generator set.

TM 5-6115-630-14&P

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

1-10. Tabulated Data. The tabulated data provides operator and unit level personnel with the dimensionsand weights for Power Unit, PU-751/M. These specifications are computed from the combined dimensions andweights of the generator set and trailer as modified for use with the power unit. Specifications of the individualcomponents can be found in their respective technical publications. For additional information concerningGenerator Set, DOD Model MEP-002A, refer to TM5-6115-584-12 and -34. For additional information on theM116A1 trailer, refer to TM 9-2330-202-14&P. The tabulated data also includes the location and content of alldata 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 and the drawbarring.

(b) Content.

USPOWER UNITPU 751/MKW 5HERTZ 60NSN 6115-00-033-1373

Change 1 1-3

TM 5-6115-630-14&P

(2) Instruction plate.

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

(b) Content.

GROUND TERMINAL

b. Tabulated Data for Power Unit.

Overall Length 142 inches (360.7 centimeters)Overall Width 73 inches (185.4 centimeters)Overall Height 79 inches (200.6 centimeters)Net Weight (empty) 2200 pounds (998.8 kilograms)Net Weight (filled) 2390 pounds (1084 kilograms)Shipping Weight 2520 pounds (1144 kilograms)Cubage 413 cubic feet (11.56 cubic meters)

1-11. Differences Between Models. There are no differences between models, serial numbers, or serialnumber groups applicable to this equipment.

1-4

TM 5-6115-630-14&P

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 installed by unitlevel technicians (paragraph 4-2). In the second phase of the mission, the operator starts the generator set, runsit to power a system or equipment, and eventually shuts it down. In the final phase, the power unit is dismantled,packed up and either moved to a new work site or returned to standby status (paragraph 4-3). This final phase isalso accomplished by unit level technicians.

WARNING

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

Operating noise level of generator can cause hearing damage. Ear protectors, asrecommended by medical or safety officer, must be worn when working near power unit.

CAUTION

To avoid damage to equipment, make certain of voltage, frequency, and phaserequirements 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 operator’s tasks during the mission, refer to the data plate located on the right-hand side ofthe generator set control cubicle. Follow the operating instructions on the data plate to start and run the generatorset. Monitor and adjust generator set power output as required during operation. At the end of the mission, shutdown the generator set in accordance with the operating instructions on the data plate. For a copy of theinformation on the data plate, as well as more detailed operating procedures for the generator set, refer to TM5-6115-584-12. For trailer operating procedures, 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

TM 5-6115-630-14&P

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 the equipment.

a. Refer to TM 5-6115-584-12 for special procedures when operating the generator set under unusualconditions.

b. Refer to TM 9-2330-202-14&P for special procedures when operating the trailer under unusual conditions.

2-2

TM 5-6115-630-14&P

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 the powerunit are listed in Table 3-1.

Table 3-1. Consumable Operating and Maintenance Supplies.

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

required requiredComponent National for initial 8 hoursapplication stock number Description operation operation Notes

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

Leg Prop 9150-00-190-0904 Grease, Automotive and Artillery, GAA 1 pound As requiredAssembly

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

Leg Prop 9150-00-402-4478 Oil, Lubricating, OEA 1 quart As requiredAssembly

Section Il. LUBRICATION INSTRUCTIONS

3-2. General. Detailed instructions for the lubrication of the major components of the power unit are containedin the applicable Lubrication Orders (LO’s). Refer to DA Pam 25-30 to ensure the latest editions of the LO’s areused.

3-3. Generator Lubrication. Refer to TM 5-6115-584-12 for generator set Lubrication Order.

3-4. Trailer Lubrication. There are no operator/crew lubrication requirements for the power unit trailer.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/Crew preventivemaintenance checks and services for this equipment.

3-1

TM 5-6115-630-14&P

3-5. General. The preventive maintenance checks and services listed in Table 3-2 are grouped according tostages of equipment operation or time intervals. Using the following as a guide, do the checks and services at theintervals shown.

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 be corrected, seeparagraph 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 they become amajor problem causing the equipment to fail to complete its mission. The PMCS table is arranged with theindividual PMCS procedures listed in sequence under assigned intervals. The most logical time (before, during, orafter operation) to perform each procedure determines the interval to which it is assigned. Make a habit of doingthe checks and services in the same order each time and anything wrong will be seen quickly. See paragraph 3-7for an explanation of the columns in table 3-2.

3-7. Explanation of Columns. The following is a list of the PMCS table column headings with a descriptionof the information found in each column.

a. Item No. This column shows the sequence in which the checks and services are to be performed, and isused to identify the equipment area on the Equipment Inspection and Maintenance Worksheet, DA Form 2404.

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

c. Item to be Inspected/Procedures. This column identifies the general area or specific part where the checkis or service is to be done, lists the checks or services to be done and explains how to do them.

d. Equipment is Not Ready/Available If. This column lists conditions that make the equipment unavailable foruse because it is unable to perform its mission or because it would represent a safety hazard. Do not accept oroperate equipment with a condition in the “Equipment is Not Ready/Available If” 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 report thedeficiency using the proper forms.

3-9. Special Instructions. Preventive maintenance is not limited to performing the checks and serviceslisted in the PMCS table. Covering unused receptacles, stowing unused equipment and other routine proceduressuch as equipment inventory, cleaning components, and touch-up painting are not listed in the PMCS table.These are things you should do any time you see they need to be done. If a routine check is listed in the PMCStable it is because other operators have reported problems with this item. Take along tools and cleaning cloths

3-2

TM 5-6115-630-14&P

needed to perform the required checks and services. Use the information in the following paragraphs to help youidentify problems at any time.

a. Use the following information to help identify potential problems before and duringRoutine Inspections.checks and services.

WARNING

(1)

(2)

(3)

(4)

(5)

Drycleaning solvent PD-680 is both toxic and flammable. Wear safety goggles andgloves and use in a well-ventilated area. Avoid prolonged breathing of vapors and avoidskin contact. Do not use near open flame or excessive heat. Flash point of solvent is100°F to 138°F (38°C to 59°C). If you become dizzy while using PD-680, get fresh airimmediately and get medical aid. If PD-680 contacts eyes, flush with water and getmedical aid immediately.

Keep it clean. Dirt, grease, and oil get in the way and may cover up a serious problem. Use drycleaningsolvent PD-680, to clean metal surfaces. Use soap and water to clean rubber or plastic parts andmaterial.

Bolts, nuts, and screws. Check them all to make sure they’re not loose, missing, bent, or broken. Don’ttry to check them all with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If youfind one loose, tighten it or report it to unit maintenance.

Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. If a broken weldis found, report it to higher level of maintenance.

Electrical wires connectors, terminals and receptacles. Look for cracked or broken insulation, barewires, and loose or broken connectors. Tighten loose connectors and make sure the wires are in goodcondition. Examine terminals and receptacles for serviceability.

Hoses and fluid lines. Look for wear, damage, and leaks. Make sure clamps and fittings are tight. Wetspots and stains around a fitting or connector can mean a leak. If a leak comes from a loose connector,tighten it. If something is broken or worn out, report it to unit maintenance.

It is necessary for you to know how fluid leakage affects the status of your equipment.The following are definitions of the types/classes of leakage you need to know to be able to determine the status

b. Leakage Def in i t i ons .

of your equipment. Learn and be familiar with them. When in doubt, NOTIFY YOUR SUPERVISOR!

Leakage Definitions:

Class I Seepage of fluid (as indicated by wetness or discoloration) not greatenough to form drops.

Class II

Class Ill

Leakage of fluid great enough to form drops but not enough to causedrops to drip from item being checked/inspected.

Leakage of fluid great enough to form drops that fall from the item beingchecked/inspected.

3-3

TM 5-6115-630-14&P

Itemno.

CAUTION

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

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

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 only thoseitems that can be checked and serviced without disturbing operation. Make the completechecks and services when the equipment can be shut down.

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

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

B - Before

Interval

D - During A – After W - Weekly

Item to be inspected.Procedure: check for and have repaired,

filled, or adjusted as needed

WARNING

Before performing any maintenance thatrequires climbing on or under trailer, settrailer handbrakes, chock wheels, and lowerrear leg prop. Injury to personnel couldresult from trailer suddenly rolling or tipping.

NOTE

Perform weekly as well as before PMCS ifyou are the assigned operator but have notoperated the equipment since the last weeklyinspection.

M - Monthly

Equipment is notready/available if:

3-4

TM 5-6115-630-14&P

Itemno.

1

2

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

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

●

●

Interval Item to be inspected.Procedure: check for and have repaired,


NOTE

Perform weekly as well as before PMCS ifyou are operating the equipment for the firsttime.

GENERATOR SET EXTERIOR

a. Check on, around, and beneath the generatorset (1) for fuel or oil leaks.

b. Check that generator set (1) grounds areproperly installed and groundingconnections are tight.

FUEL GAGE

Check fuel gage (2) for sufficient fuel forcontinuous operation.


A Class Ill lubrication oil orany class fuel leak isdetected.

Not properly grounded.

3-5

TM 5-6115-630-14&P

Itemno.

3

4


B - Before D – During A – After W – Weekly

B

●

●

Interval

D

●

A

●

W M



ENGINE OIL LEVEL

Check oil filler dipstick (3) for proper oil level. Addoil as required.

4874 -004

AIR CLEANER INDICATOR

Check indicator (4) for a restricted air cleaner.If red warning indicator becomes visible, notifyunit maintenance for cleaning or replacement.

4874 -005

M – Monthly


3-6

TM 5-6115-630-14&P

Itemno.

5

6

7

8


B – Before D – During A – After W - Weekly

B

●

●

●

●

Interval

D A W M



ACCESSORIES

Check that the following accessories are notmissing.

a. Sledge hammer

b. Fire extinguisher

c. Slide hammer

d. Ground rods.

e. Fuel drum adapter

BRACKETS

Check fire extinguisher and fuel can mountingbrackets for loose hardware or broken fittings.

TIRES

a.

b.

Check tires (5) for cuts, foreign objects, orunusual tread wear. Remove any stones frombetween the treads.

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

WHEELS

Check for damage and for missing or loose studnuts (6).

M – Monthly


Fire extinguisher is missing.

Ground rods are missing.

One tire is flat, missing, orunserviceable.

One or more wheels aredamaged. One or morestud nuts are loose ormissing.

3-7

TM 5-6115-630-14&P

Itemno.

8

9

10

11


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

B

●

●

●

●

Interval

D A W M



WHEELS (cont)

4874-006

DRAWBAR RING

Check drawbar ring (7) for insecure mounting andobvious damage.

INTERVEHICULAR CABLE

Check cable (8) and connector for cuts and breaks.

SAFETY CHAINS

Check safety chains (9) for insecure mounting andobvious damage.


Ring is loose or bent.

Intervehicular cable isbroken or missing.

Safety chains are missing orunsecured.

3-8

TM 5-6115-630-14&P

Itermno.

11

12

13


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

B

●

●

Interval

D A w

●

M



SAFETY CHAINS (cont)

4874-007

BOW ASSEMBLIES AND TARPAULIN SUPPORT

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

FITTED COVER

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

b. Check for missing and defective ropes (14).

c. Check for missing and defective straps andbuckles (15).

d. Check for ripped seams and tears.


3-9

TM 5-6115-630-14&P

Itemno.

13

14


B - Before D – During A – After W - Weekly

B

●

Interval

D A W M



FITTED COVER (cont)

4874 -008

LIGHTS

a.

b.

With intervehicular cable connected to towingvehicle, operate vehicle light switch throughall settings and check lights.

NOTE

An assistant is required while checking brakelights.

Step on brake pedal of towing vehicle and checkbrake lights (16).

M – Monthly


Lights do not functionproperly.

3-10

TM 5-6115-630-14&P

Itemno.

15

16

17


B – Before D – During A – After W – Weekly

B

●

Interval

D

●

●

●

A W M



HYDRAULIC HOSES AND TUBES

Check brake system hoses and tubes, and checkunder vehicle for signs of brake fluid leaks.

SUPPORT LEG ASSEMBLY

With trailer connected to towing vehicle, checksupport leg assembly (17) for ease of operation.

4874-010

REAR LEG PROP ASSEMBLY

Inspect leg prop assembly (18) for broken ormissing parts

M – Monthly


Any brakedetected.

fIuid leaks are

Support leg assembly isseized.

Leg prop assembly isunserviceable.

3-11

TM 5-6115-630-14&P

Itemno.

18

19

20


B - Before

B

Interval

D

●

●

●

A

3-12 Change 2

W M

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



BRAKE SYSTEM

Test brake system by hooking trailer to towingvehicle and applying brakes.

TRAILER OPERATION

a.

b.

Be alert for any unusual noises while towingtrailer. Stop and investigate any unusual noises.

Ensure that trailer is tracking/following correctlybehind towing vehicle with no side pull.

GENERATOR SET GAGES AND INSTRUMENTS

a.

b.

Check that battery indicator (19) is in yellowarea while batteries are charging and in greenarea when batteries are fully charged.

Check that frequency meter (20) indicates60 Hz (red line) when generator is operatingunder load.

c. Check that ammeter (21) reading does notexceed 100% or more than 5% load differencebetween phases.


Service brakes fail tooperate.

Indicating in the red.

TM 5-6115-630-14&P

Itemno.

20


B – Before D – During A – After W – Weekly

B

Interval

D A w M



GENERATOR SET GAGES ANDINSTRUMENTS (cont)

d.

e.

Check that voltmeter (22) indicates desiredoutput voltage as determined by load connec-tions and amps-volts transfer switch.

4874-013

Check engine oil pressure gage (23) for 25 psiindication.

M – Monthly


Desired voltage cannot beobtained and maintained.

Oil pressure drops below15 psi.

3-13

TM 5-6115-630-14&P

Itemno.

21

22


B - Before

B

Interval

D A

●

●

w M

D – During A – After W – Weekly



FUEL TANK

a.

b.

Fill tank (24) upon completion of operation.

NOTE

Fuel system temperature must be abovefreezing when draining water and sediment.

Open drain (25) and drain water and sedimentfrom fuel tank into a suitable container. Allowto drain until fuel runs clean.

FUEL STRAINER AND FILTERS

Drain water and sediment from strainer (26),primary (27) and secondary (28) filters. Allow todrain until fuel runs clean.

M - Monthly


3-14

TM 5-6115-630-14&P

Itemno.

22

23

Table3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) (cont).

B - Before D - During A – After W – Weekly

B

Interval

D A

●

W M



FUEL STRAINERS AND FILTERS (cont)

4874-016

HANDBRAKES

With trailer hooked to towing vehicle, set hand-brakes (29). Move trailer slightly to see if hand-brakes hold wheels.

4874-017

M - Monthly


3-15

TM 5-6116-630-14&P

Itemno.

24

25

26

Table3-2. Operator/Crew Preventive Maintenance Checks and Sevices (PMCS) (cont).

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

B

Interval

D A W M



* BRAKE DRUMS AND HUBS

WARNING

A defect in the operation of the brakes or hubcan cause these parts to get hot enough tocause serious burns. Use extreme cautionwhen attempting to detect heat in this area.

Feel for overheating to detect dragging or binding.

REFLECTORS

Check for damaged or missing reflectors.

BATTERIES

Check battery (30) electrolyte level. Level shouldbe about 3/4 inch above top of plates. Add waterif level is low. Use clean water (distilled water ifavailable).


Brakes or hub are draggingor binding.

3-16 Change 1

TM 5-6115-630-14&P


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

Interval Item to be inspected.Item Procedure: check for and have repaired, Equipment is notno. B D A W M filled, or adjusted as needed ready/available if:

27 ● FIRE EXTINGUISHER

Inspect and weight fire extinguisher.(See paragraph 3-12.)

28 ● TRAILER FRAME

Inspect entire chassis frame for damage, cracks, Frame is obviously brokenand broken welds. broken or cracked.

Section IV. TROUBLESHOOTING

3-10. Power Unit Troubleshooting. There are no troubleshooting procedures authorized at operator levelfor the power unit end item. Troubleshooting procedures for the individual generator set and trailer are containedin their respective technical manuals referenced below.

a. Generator Set Troub leshooting. Refer to TM 5-6115-584-12 for troubleshooting procedures.

b. Trailer Troubleshooting. Refer to TM 9-2330-202-14&P for troubleshooting procedures.

Section V. OPERATOR/CREW MAINTENANCE

3-11. Enclosure Maintenance. Maintenance of the enclosure at operator level is limited to replacement ofthe fitted cover and/or the bows.

a. Fitted Cover Replacement . (See figures 3-1 and 3-2.)

(1) Rermoval.

(a) Untie 27 ropes (1, figure 3-1) fastening fitted cover to trailer body (2).

Roll up curtain, and secure with three

Roll up curtain, and secure with three

(b) Unfasten six straps and buckles (3) securing rear curtain (4).rollup straps (5) provided.

(c) Unfasten six straps and buckles (3) securing front curtain (6).rollup straps (5) provided.

(d) Roll up each side (7) of fitted cover, in turn, and secure each side with four rollup straps (5) provided.

3-17

TM 5-6115-630-14&P

3-18

(e) Working under fitted cover (1, figure 3-2), unfasten eight straps (2) securing fitted cover to bowassemblies (3). Remove fitted cover.

(2) Installation.

(a)

(b)

(c)

(d)

(e)

(f)

Front curtain

NOTE

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

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

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

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

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

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

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

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

TM 5-6115-630-14&P

4874-020

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

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

(1) Removal.

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

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

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

(2) Installation.

(a)

(b)

(c)

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

Position tarpaulin support (5, figure 3-3) on bows (6) and secure tarpaulin support to each bow withone screw (1), two flat washers (2), one Iockwasher (3) and one wing nut (4).

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

3-19

TM 5-6115-630-14&P

Figure 3-3. Tarpaulin Support Replacement.

F i g u r e 3 - 4 . B o w R e p l a c e m e n t .

3-20 Change 1

TM 5-6115-630-14&P

3-12. Fire Extinguisher Maintenance. The PU-751/M Power Unit is equipped with a 5 lb Halon fire extinguisher.Maintenance is limited to weighing the fire extinguisher monthly to insure that it is sufficiently charged. Fully charged, thefire extinguisher (with head and horn attached) weighs 5 lb. Send the unit to specialized activity for recharging if it weighs4 lb 12 oz or less.

WARNING

Monobromotrifluoroethane liquid or gas (Halon 1301) can cause death or serious Injury ifpersonnel fall to observe safety precautions. Inhalation of monobromotrifluoroethane gas atconcentrations of 5% to 6% for more than 4 or 5 minutes may result In serious cardiac or centralnervous 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 the affected areaquickly to body temperature. Immerse hands in warm water or place hands in armpits. Getmedical attention promptly.

CAUTION

Do not attempt to verify readiness of fire extinguisher by partially discharging unit. Any dischargeof contents will require refilling.

Change 4 3-21/(3-22 blank)

TM5-6115-630-14&P

CHAPTER 4

UNIT MAINTENANCE

Section I. SERVICE UPON RECEIPT OF EQUIPMENT

4-1. lnspecting and Servicing Equipment. The power unit is unpacked, inspected, and serviced asdescribed in the following paragraphs. Unpacked equipment must be checked against the Components of EndItem and Basic Issue Items Lists to ensure completeness. Discrepancies must be reported in accordance withinstructions in DA Pam 738-750.

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

Figure 4-1. Uncrating Generator Set.

WARNING

Steel banding used in packaging of power unit has sharp edges. Care should be takenwhen cutting and handling banding to avoid injury to personnel.

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

4-1

TM 5-6115-630-14&P

(2)

(3)

(4)

(5)

(6)

(7)

(8)

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

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 fire extinguisher inbracket 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 fitted cover is put inplace on power unit.

4-2 Change 1

(10)

(11)

(12)

(13)

(14)

(15)

TM 5-6115-630-14&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 with power unit andfollow 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)).

c .

b. Inspection and Servicing of Generator Set . Refer to Servicing Upon Receipt of Material in TM 5-6115-584-12 for initial inspection and servicing procedures.

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

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

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

(1)

(2)

Select an area as level as possible to install power unit and position trailer.

Set trailer handbrakes and lower trailer support leg.

(3)

(4)

Chock both wheels and lower rear leg prop assembly. Adjust leg prop assembly by turning inner leguntil leg base makes firm contact with ground

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 involved andextinguisher will remain accessible.

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

WARNING

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

4-3

TM 5-6115-630-14&P

Figure 4-3. Installing Power Unit.

CAUTION

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

(6) Refer to data plate on load terminal board cover and to TM 5-6115-584-12. Connect power unit tosystem or equipment to be powered.

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

NOTE

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

4-4

(1)

(2)

(3)

TM 5-6115-630-14&P

Underground water system. Ground power unit to one of the accessible pipes in an underground watersystem. Make certain underground pipe is made of metal and there is no insulation, such as a watermeter, between ground wire and earth.

Ground rod. Drive ground rod a minimum of eight feet into earth. A ground rod must have a minimumdiameter of 5/8-inch, if solid, or 3/4-inch if pipe.

NOTE

It may be necessary to saturate the area around ground rod with water if soil conditionsare dry.

Ground plate. Ground power unit to a metal plate buried four feet deep. Ground plate should cover aminimum area of nine square feet.

c. External Fuel L ine Connection. (See figure 4-4.) The power unit generator set can be fueled from anexternal source such as a five-gallon fuel can or 55 gallon drum. This eliminates the need for frequent refilling ofthe generator’s fuel tank during long intervals of operation.

(1)

(2)

(3)

(4)

(5)

Remove fuel can adapter and fuel pickup tube from storage locations on generator set and assemble bythreading pickup tube into adapter.

Thread one end of auxiliary fuel line onto fuel can adapter fitting and tighten.

Connect free end of auxiliary fuel line to AUXILIARY FUEL CONNECTION. This connection is locatedimmediately below control cubicle on right-hand side of generator set.

Insert fuel can adapter in external fuel source and secure by pressing down on lever.

Set MASTER SWITCH on control panel to PRIME AND RUN AUX FUEL POSITION.

NOTE

When generator set is run on auxiliary fuel, as described above, fuel is first pumped intogenerator set fuel tank by auxiliary fuel pump. Fuel is then fed to generator set enginefrom fuel tank.

4-5

TM 5-6115-630-14&P

Figure 4-4. External Fuel Line Connection.

Section Il. MOVEMENT TO A NEW WORKSITE

4-3. Dismantling for Movement. Because the power unit is designed to be mobile, a minimum amount ofeffort is required to relocate to a new worksite. Procedures are as follows:

a.

b.

c.

d.

e.

f.

g.

4-6

Disconnect power unit from system or equipment being powered.

Disconnect ground cable from source of ground and from power unit GROUND TERMINAL stud. Roll upcable and store in accessory box.

Using slide hammer, remove ground rod. Disassemble, clean, and stow ground rod in accessory box.

Disconnect power unit from external fuel source, if applicable.

Stow any remaining authorized equipment in accessory box.

Secure fire extinguisher and fuel cans in their respective mounting brackets.

Lower and secure fitted cover in place on power unit.

TM 5-6115-630-14&P

h.

j .

Remove locking pin from leg prop assembly on rear of trailer. Swing leg prop back and up into travelingposition and secure with pin.

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

Release trailer handbrakes.

4-4. Reinstallation After Movement. After movement to a new worksite, install power unit in accordancewith 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 the PU-751/Mpower unit.

4-6. Maintenance Repair Parts. Repair parts and equipment for maintenance of this power unit are listedand 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 are containedin the applicable Lubrication Orders (LO’s). Refer to DA Pam 25-30 to ensure that the latest editions of the L.O.’Sare used. This section contains lubrication instructions that are not included in the Lubrication Orders.

4-8.

4-9.

a.

b.

General Lubrication. Refer to TM 5-6115-584-12 for generator set Lubrication Order.

Trailer Assembly Lubrication.

Trailer Assembly Lubrication. Refer to TM 9-2330-202-14&P for trailer Lubrication Order.

Leg Prop Assembly Lubrication. The rear leg prop assembly is a modification to the standard M116A1trailer and, as such, does not appear in the associated LO. Semiannually lubricate leg prop assembly as follows:

WARNING

Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes and prolongedexposure of skin to cleaning solvent. Wash exposed skin thoroughly. Dry cleaningsolvent (PD-680) used to clean parts is potentially dangerous to personnel and property.Do not use near open flame or excessive heat. Flash point of solvent is 100°F to 138°F(38°C to 59°C).

Clean hydraulic lubrication fitting and area around lubrication points with PD-680 or equivalent.

Inject sufficient GAA grease into hydraulic fitting to lubricate screw threads inside leg prop assembly

( 1 )

(2)

4-7

TM 5-6115-630-14&P

NOTE

Refer to Lubrication Order in TM 9-2330-202-14&P for lubricating oils specified for usewith different anticipated temperature ranges.

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

Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

NOTE

The PMCS chart in this section contains all necessary unit preventive maintenancechecks and services for this equipment.

4-10. General. The trailer assembly and generator set must be inspected and serviced systematically to insurethat the power unit is ready for operation at all times. Inspection will allow defects to be discovered and correctedbefore they result in serious damage or failure. Table 4-1 contains a tabulated list of preventive maintenancechecks and services to be performed by unit maintenance personnel. All of the unit PMCS on the trailer isscheduled to be performed semiannually. Unit PMCS on the generator set is scheduled weekly or on aper-hours-of-operation basis. The running time meter on the control panel is used to determine the generator setoperating time. Using the following as a guide, do the checks and services at the intervals shown. Observe allCAUTIONS 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 as possible to thetime intervals indicated.

NOTE

For units in continuous operation, perform PMCS before starting operation if continuousoperation will extend service interval past that 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 operating time.

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

If you discover a problem with the equipment, refer to Section Vl, Troubleshooting. If you cannot correct theproblem, 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 used to identifythe equipment area on the Equipment Inspection and Maintenance Worksheet, DA Form 2404.

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

4-8

TM 5-6115-630-14&P

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

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

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

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

H - Hours of operation M - Monthly(As indicated) (100 hours)

S – Semiannually A – Annually(500 hours) (1000 hours)

Itemno.

1

2

3

4

H

Interval

M

●

●

●

S

●

A Item to be inspected

Generator Set

Fuel Strainer and Filters

Fuel Tank

Fuel Pumps

Procedures

WARNING

Before performing any maintenance thatrequires climbing on or under trailer, settrailer handbrakes, chock wheels, and lowerrear leg prop. Injury to personnel couldresult from trailer suddenly rolling or tipping.

Inspect generator set for fuel and oil leaks, looseor missing components and hardware, andunusual wear or deterioration. Clean generatorset.

NOTE

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

Open drains on fuel strainer, and primary andsecondary filters. Drain water and sediment intoa suitable container (table 3-2, TM 5-6115-584-12). Allow to drain until fuel runs clean.

Open drain on fuel tank and drain water andsediment into a suitable container (table 3-2,TM 5-6115-584-12). Allow to drain until fuel runsclean.

Clean or replace, as necessary, fuel strainerin bottom of fuel pump (table 4-1,TM 5-6115-584-12).

4-9

TM 5-6115-630-14&P

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

Itemno.

5

6

7

8

9

10

11

12

13

14

15

16

17

4-10

H - Hours of operation M – Monthly(As indicated) (100 hours)

Interval

H

100

300

500

1000

300

500

100

1000

M S

●

●

●

●

●

A Item to be inspected

Lubricating Oil and Filter

Fuel Strainer

Primary Fuel Filter

Secondary Fuel Filter

Batteries

Crankcase Breather

Dust Caps on Air Cleaner

Air Cleaner

Taillights

Intervehicular Cable

Drawbar Ring

Safety Chains

Reflectors

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

Procedures

Change lubricating oil and filter every 100 hours ofoperation (LO. 5-6115-584-12).

Clean fuel strainer every 300 hours of operation(para 3-20, TM 5-6115-584-12).

Service primary filter every 500 hours of operation(table 4-1, TM 5-6115-584-12).

Service secondary filter every 1000 hours (table4-1, TM 5-6115-584-12).

Perform a hydrometer test on batteries every 300hours, or quarterly. Refer to para 4-25,TM 5-6115-584-12 for test procedures.

Inspect breather tube every 500 hours. Clean asnecessary (para 4-45, TM 5-6115-584-12).

Clean out dust caps on air cleaner assembly every100 operating hours (more frequently underunusual conditions).

Clean every 1000 operating hours or as conditionsdictate. Replace air cleaner every 2000 operatinghours.

Replace any broken or cracked lenses or defectivebulbs (page 4-52, TM 9-2330-202-14&P).

Check for cuts, breaks, frayed wires, or damagedplug.

Check security of mounting. Inspect ring forexcessive wear.

Inspect for broken links or missing chain(s).

Replace any cracked, broken, or missingreflectors (page 4-232, TM 9-2330-202-14&P).

TM 5-6115-630-14&P


Itemno.

18

19

20

21

22

23

24


S – Semiannually A – Annually(500 hours) (1000 hours)

Interval

H M s

●

●

●

●

●

●

●

●

●

A

●

Item to be inspected

Data Plates and Markings

Support Leg Assembly

Rear Leg Prop Assembly

Suspension Assemblies

Axle

Wheels and Tires

Brakes

Procedures

Make sure data plates are legible and secure.Replace illegible data plates (page 4-236,TM 9-2330-202-14&P).

Inspect brackets and leg for bent or broken parts.

Inspect bracket and leg prop for bent or brokenparts.

a.

b.

c.

a.

b.

a.

b.

a.

b.

c.

d.

Inspect shackles, bearings, pins, leaf springsand spring eyes for damage or broken parts.

Inspect mounting brackets for cracks or looseor missing hardware.

Inspect shock absorbers for damage or leaks.

Check for damaged axle tube.

Check for loose or missing U-bolts or nuts.

Check serviceability of tires as indicated inTM 9-2610-200-24.

Tighten wheel stud nuts.

Inspect brake linings for wear. Replace ifbrake 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 corrosionand wear.

Inspect hydraulic wheel cylinders for leaks.

Adjust brake (page 4-154,TM 9-2330-202-14&P).

4-11

TM 5-6115-630-14&P



S - Semiannually A – Annually(500 hours) (1000 hours)

IntervalItemno. H M s A Item to be inspected Procedures

25 ● Wheel Bearings Clean and repack. (page 4-180,TM 9-2330-202-14&P).

26 ● Trailer – Road Test Perform road test paying special attention to itemsthat were repaired or adjusted, in accordance withTM 9-2330-202-14&P).

Section VI. TROUBLESHOOTING

4-13. Power Unit Troubleshooting. There are no troubleshooting procedures authorized at unit level forthe power unit end item. Troubleshooting procedures for the individual generator set and trailer are contained intheir respective technical manuals referenced below.

a. Generator Set Troubleshooting. Refer to TM 5-6115-584-12 for troubleshooting procedures applicable tothe generator set.

b. Trailer Troubleshooting. Refer to TM 9-2330-202-14&P for troubleshooting procedures applicable to thetrailer.

Section VIl. RADIO INTERFERENCE SUPPRESSION

4-14. General Methods Used to Attain Proper Suppression. Essentially, suppression is attainedby providing a low resistance path to ground for stray currents. The methods used include shielding ignition andhigh-frequency wires, grounding the frame with bonding straps, and using filtering systems.

4-15. Radio Interference Suppression Components. All component parts on the power unit enditem, whose primary or secondary function is radio interference suppression, are on the generator set. Refer toTM 5-6115-584-12 for location of radio interference suppression components.

Section Vlll. MAINTENANCE OF POWER UNIT TRAILER

4-12

4-16. General. This section of the manual contains unit level maintenance procedures for components of theM116A1 trailer added when the trailer is used as part of the PU-751/M power unit. These components are notcovered in the overall trailer maintenance manual. For all other unit maintenance procedures on the trailer, referto TM 9-2330-202-14&P.

TM 5-6115-630-14&P

WARNING

Before performing any maintenance that requires climbing on or under trailer, set trailerhandbrakes, chock both wheels, and lower rear leg prop. Injury to personnel could resultfrom trailer suddenly rolling or tipping.

4-17. Fuel Can Bracket Replacement. (See figure 4-5.) There are four fuel can brackets supplied withthe PU-751/M. Two brackets are mounted on top of each fender. Replacement procedures described below aretypical for all four.

a. Removal.

(1) Remove four screws (1, figure 4-5), four self-locking nuts (2) and four Iockwashers (3) securing bracket(4) to fender (5).

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

Figure 4-5. Fuel Can Bracket Replacement.

4-13

TM 5-6115-630-14&P

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 self-locking nut (2) on 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 bedforward of the generator set.

a. Removal.

(1)

(2)

Remove four screws (1, figure 4-6), four flat washers (2), and four nuts (3) securing accessory box (4) totrailer bed (5).

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

b.

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

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

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

Installation.

secure accessory box (4).

Figure 4-6. Accessory Box Replacement.

4-14 Change 1

TM 5-6115-630-14&P

4-19. Fire Extinguisher Bracket Replacement. (See figure 4-7.) The fire extinguisher supplied withthe 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 self-locking nuts (2), and four flat washers (3) securing bracket(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).

(3) Install one flat washer (3) and one self-locking nut (2) on each screw (1). Tighten hardware to securebracket (4).

4-20. Leg Prop Assembly Servicing. Servicing of the leg prop assembly is limited to semiannuallubrication (paragraph 4-9, b.).

Change 1 4-15/(4-16 blank)

TM 5-6115-630-14&P

CHAPTER 5

DIRECT SUPPORT AND GENERAL SUPPORTMAINTENANCE INSTRUCTIONS

Section I. INTRODUCTION

5-1. General. This chapter contains Direct Support and General Support level maintenance procedures forcomponents of the M116A1 trailer added when the trailer is used as part of the PU-751/M power unit. Thesecomponents are not covered in the overall trailer maintenance manual. For all other direct and general supportmaintenance procedures on the trailer, refer to TM 9-2330-202-14&P. For direct and general supportmaintenance procedures on the generator set, refer to TM 5-6115-584-34.

WARNING

Before performing any maintenance that requires climbing on or under trailer, set trailerhandbrakes, chock wheels and lower rear leg prop. Injury to personnel could result fromtrailer suddenly rolling or tipping.

Section Il. MAINTENANCE OF POWER UNIT TRAILER

5-2. Leg Prop Assembly Maintenance. Maintenance of the leg prop assembly at the Intermediate DirectSupport and General Support level consists of repairing or replacing the assembly as required.

a. Leg Prop Assembly Replacement. (See figure 5-1.)

(1) Removal.

(a) While supporting leg prop assembly, pull out angled bar (1, figure 5-1) and lower leg from travelingposition.

(b) Line up boss (2) on upper leg (3) with holes in bracket (4) and insert angled bar(1) to lock leg insupport position.

(c) Remove either one of two cotter pins (5) from leg prop assembly pivot shaft (6).

(d) While steadying leg prop assembly, remove shaft (6) with remaining cotter pin (5) in place.

WARNING

When angled bar is removed in step (e), leg prop assembly will fall from bracket if notsupported. To prevent injury to personnel or damage to equipment, do not permit legassembly to drop.

(e) Lift leg assembly slightly to take weight off angled bar (1) and remove bar.

(f) Lower leg assembly from bracket (4).

5-1

TM 5-6115-630-14&P

(g) Remove three screw (7), three flat washers (8), three Iockwashers (9), and three nuts (10) andremove bracket (4) from trailer frame (11).

Figure 5-1. Leg Prop Assembly Replacement.

(2) Installation.

(a)

(b)

(c)

(d)

(e)

(f)

5-2

Position bracket (4) on trailer frame (11) and install three screws (7), three flat washers (8), threeIockwashers (9) and three nuts (10). Tighten hardware to secure bracket.

Lift leg prop assembly into bracket (4) and secure by inserting angled bar(1) through holes in bracketand boss (2) on upper leg (3).

Position leg prop assembly to line up boss (2) on top of leg with pivot holes in bracket (4). Insert pivotshaft (6).

Insert cotter pin (5) in pivot shaft (6) and bend cotter pin legs in opposite directions.

Pull out angled bar (1) to unlock leg prop assembly.

Swing leg prop assembly up into traveling position and secure by inserting angled bar (1)holes in bracket (4) and boss (2) on upper leg (3).

through

TM 5-6115-630-14&P

b. Leg Prop Assembly Repair. Repair of the leg prop assembly is limited to welding and repainting. However,partial disassembly is possible to facilitate repair. If required, repaint in accordance with MIL-T-704 andMIL-C-46168.

(1) Disassembly.

(a)

(b)

(c)

Remove leg prop assembly from trailer (paragraph 5-2, a.(1)).

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

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

(2) Assembly.

(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 in upper 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)

(2)

(3)

(4)

(5)

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

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

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

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

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

(6)

chassis (5).

NOTE

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

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

NOTE

Removal of the trailer body requires the removal and disassembly of both handbrakelever assemblies. The handbrake lever assemblies are symmetrical and this procedure istypical for both.

5-3

TM 5-6115-630-14&P

Figure 5-2. Fender and Bed Replacement.

5-4

(7)

(8)

(9)

(10)

(11)

Remove two screws (9), two spacersassembly (12) from trailer chassis (5).

TM 5-6115-630-14&P

10), and two nuts (11) and remove roadside handbrake lever

Remove cotter pin (13), washer (14), shaft (15), and pulley (16) from handbrake lever assembly (12).

Working under trailer, pull handbrake cable clevis (17) back through holes in front two braces on trailerbody.

Repeat steps (7) through (9) to remove and disassemble curbside handbrake lever assembly.

WARNING

When lifting trailer body, use lifting equipment with a minimum lifting capacity of 500 lb.Do not stand under trailer body while it is being lifted. Failure to observe theseprecautions can cause injury to personnel or damage to equipment.

Using suitable lifting equipment with a minimum lifting capacity of 500 lb, lift trailer body (4) off of trailerchassis (5).

b. Repair. Repair of the trailer bed and fenders is limited to replacement of strap fastener loops andstraightening, welding, and repainting the bed and fender weldment. If required, repaint in accordance withMIL-T-704 and MIL-C-46168. There is one strap fastener loop mounted to the top of each fender. Replace asfollows:

(1) Remove two screws (18), two flat washers (19) and two self-locking nuts (20) securing strap fastenerloop (21) to fender and take off strap fastener loop.

(2) Position new strap fastener loop (21) on fender and secure with two screws (18), two flat washers (19)and two self-locking nuts (20).

c. Installation.

(1)

(2)

(3)

(4)

(5)

WARNING

When lifting trailer body, use lifting equipment with a minimum lifting capacity of 500 lb.Do not stand under trailer body while it is being lifted. Failure to observe theseprecautions can cause injury to personnel or damage to equipment.

Using suitable lifting equipment with a minimum lifting capacity of 500 lb, lift trailer body (4) onto trailerchassis (5) and aline mounting holes.

Insert 10 screws (1) with flat washers (2) through trailer bed and through trailer chassis frame rails.

Working under trailer, install one nut (3) on each screw (1).

Insert 16 screws (6) with 16 flat washers (7) through trailer body braces into trailer chassis.

Working under trailer, install one nut (8) on each screw (6). Tighten hardware to secure trailer body totrailer chassis.

5-5

TM 5-6115-630-14&P

(6)

(7)

(8)

(9)

(10)

(11)

(12)

(13)

(14)

(15)

Feed roadside handbrake cable clevis (17) forward through holes in front two braces on trailer body.

Wrap handbrake cable around pulley (16), position pulley in handbrake lever assembly (12) and insertshaft (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 topscrew goes through spacer (22) and bottom screw goes through handbrake cable clevis.

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

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

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 fitted cover shall be made in accordance with FM 10-16, FabricRepairing.

5-5. Accessory Box Repair. (See figure 5-3.) The accessory box is repaired by replacing the hasp, thecatches and the footmans loops, as required. The box itself may be straightened, welded, and repainted. Ifrequired, repaint in accordance with MIL-T-704 and 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 accessory box (3).

(2) Position new catch or hasp (2) on

(3) Touch up with paint as required.

b. Strap Fastener Loop Replacement.

accessory box and secure with solid rivets (1).

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

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

5-6

TM 5–6115-630-14&P

Figure 5–3. Accessory Box Repair.

5-6. Marking. (See figure 5-4.) The power unit four-digit registration number, preceded by the prefix "VC" andthe words “U.S. ARMY,” is marked in three places on the trailer. Marking is done in accordance 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 withMlL–STD-130. Figure 5-4 shows the approximate location of markings on the power unit. If required, touch–uppainting of the base color is done in accordance with MIL-T-704 and MIL-C-46168.

Figure 5-4. Power Unit Markings.

Change 1 5-7

TM 5-6115-630-14&P

Section Ill. GENERATOR SET

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

a. Removal.

(1)

(2)

(3)

(4)

(5)

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

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

Disconnect ground wire (1, figure 5-5) from generator set (2) to GROUND TERMINAL stud (3) on trailerbed (4).

NOTE

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

Remove four cap screws (5), eight flat washers (6), and four nuts (7) securing generator set (2), totrailer (4).

Remove engine oil drain hose (8) from grommet in trailer bed.

Figure 5-5. Detaching Generator Set from Trailer.

5-8 Change 1

TM 56-6115-630-14&P

(6)

b.

WARNING

When lifting generator set, use lifting equipment with a minimum lifting capacity of 1500lb. Do not stand under generator while it is being lifted. Failure to observe theseprecautions can cause injury to personnel or damage to equipment.

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

Installation.

WARNING

When lifting generator set, use lifting equipment with a minimum lifting capacity of 1500lb. Do not stand under generator while it is being lifted. Failure to observe theseprecautions can cause injury to personnel or damage to equipment.

(1)

(2)

Figure 5-6. Lifting Generator Set.

Attach Iifting equipment with a minimum lifting capacity of 1500 lb (1, figure 5-6) to lifting eye (2) on topof generator set (3) and lift generator.

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

Change 1 5-9

TM5-6115-630-14&P

(3)

(4)

(5)

(6)

(7)

5-10

Insert four cap screws (5) with flat washers (6) down through generator set skid and trailer bed (4).

Working under trailer, install one flat washer (6) and one nut (7) on each bolt (5). Tighten hardware.

Insert engine oil drain hose (8) through grommet in trailer bed.

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

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

TM 5-6115-630-14&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 of allapplicable tests and inspections specified in the technical manuals referenced below. Activities performingmaintenance on any component of the power unit must perform those tests and inspections required by theapplicable component or system repair instruction.

Section Il. INSPECTION

6-2. Generator Set Inspections. Refer to TM 5-6115-584-12 and -34 for inspections required followingrepair of the generator set.

6-3. Trailer Inspections.trailer.

Refer to TM 9-2330-202-14&P for inspections required following repair of the

Section Ill. OPERATIONAL TESTS

6-4. Generator Set Operational Tests. Refer to TM 5-6115-584-12 and -34 for operational tests requiredto verify satisfactory performance of the generator set.

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

6-1/(6-2 blank)

TM 5-6115-630-14&P

APPENDIX A

REFERENCES

A-1. Scope. This appendix lists all pamphlets, forms, technical manuals, specifications and miscellaneouspublications referenced in this manual.

A-2. Forms and Records.

Recommended Changes to Publications and Blank Forms . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028Depreservation Guide for Vehicles and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2258Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2404Maintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . DA Form 2407Consolidated lndex of Army Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 25-30The Army Maintenance Management System (TAMMS) . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 738-750Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF368

A-3. Military Specifications.

Chemical Agent Resistant Aliphatic Polyurethane Coating . . . . . . . . . . . . . . . . . . . . . . . . MIL-C-46168Identification Marking of U.S. Military Property . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-130Identification Marking of Combat and Tactical Transport . . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-642Treatment and Painting of Materiel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-T-704

A-4. Technical Manuals.

Fabric Repairing, Tents, Canvas, Webbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM10-16Operator and Organizational Maintenance Manual for Generator Set,

Diesel Engine Driven, Tactical Skid Mounted, 5KW, 1 Phase, 2 Wire;1 Phase, 3 Wire and 3 Phase, 4 Wire; 120, 120/240 and 120/208V(DOD Model MEP-002A) Utility Class 60HZ(6115-00-465-1044) . . . . . . . . . . . . . . . . . TM5-6115-584-12

Organizational, Intermediate (Field) Direct and General Support and Depot LevelMaintenance Repair Parts and Special Tools List: Generator Set, DieselEngine Driven, Tactical Skid Mounted, 5 KW, 1 Phase, 2 Wire; 1 Phase, 3 Wire;3 Phase, 4 Wire, 120, 120/240 and 120/208 V (DOD Model MEP-002A)Utility Class, 60 HZ (NSN 6115-00-465-1044) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM5-6115-584-24P

Intermediate (Field) (Direct and General Support) and Depot Level MaintenanceManual for Generator Set, Diesel Engine Driven, Tactical Skid Mounted, 5 KW,1 Phase, 2 Wire; 1 Phase, 3 Wire; 3 Phase, 4 Wire, 120, 120/240 and 120/208 V(DOD Model MEP-002A), Utility Class, 60 HZ (NSN 6115-00-465-1044) . . . . . . . . . . . TM 5-6115-584-34

Procedures for Destruction of Equipment to Prevent Enemy Use(Mobility Equipment Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 750-244-3

Operator’s, Organizational, Direct Support and General Support MaintenanceManual Including Repair Parts and Special Tools List for Trailer, Cargo: 3/4-Ton,2-Wheel, M101 (NSN 2330-00-738-9509), M101A1 (2330-00-898-6779),M101A2 (2330-01-101-4697) and Chassis, Trailer: 3/4-Ton, 2-Wheel, M116(2330-00-542-5987), M116A1 (2330-00-898-6780) and M116A2(2330-01-101-8434) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM9-2330-202-14&P

A-1

TM 5-6115-630-14&P

Organizational, Direct Support, and General Support Care Maintenanceand Repair of Pneumatic Tires and Inner Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2610-200-24

A-5. Technical Bulletins.

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

A-2

TM 5-6115-630-14&P

APPENDIX B

COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS


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

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

a. Section Il. Components o f End Item. This listing is for informational purposes only, and is not authority torequisition replacements. These items are part of the end item, but are removed and separately packaged fortransportation or shipment. As part of the end item, these items must be with the end item whenever it is issuedor transferred between property accounts. Illustrations are furnished to assist you in identifying the items.

b. Section III. Basic Issue Items.These are the minimum essetial items required to place the power unit inoperation, to operate it, and to perform emergency repairs. Although shipped separately packaged, Bll must bewith the power unit during operation and whenever it is transferred between property accounts. The illustrationswill assist you with hard-to-identify items. This manual is your authority to request/requisition Bll, based onTOE/MTOE authorization of the end item.

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

a. Column (1). Illustration Number (Illus No.). This column indicates the number assigned to the item.

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

c. Column (3). Description. Indicates the federal item name and, if required, a minimum description to identifyand locate the item. The last line for each item indicates the FSCM (in parentheses) followed by the part number.If item needed differed for different models of this equipment, the model would be shown under the “Usable onCode” heading in this column. The Usable on Code is not applicable for this equipment.

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

e. Column (5). Quantitv Reauired (Qty Req’d). Indicates the quantity of the item authorized to be used with/onthe equipment.

B-1

TM 5-6115-630-14&P

Section Il. COMPONENTS OF END ITEM

(1) (2) (3) (4) (5)Illus National Description Usable Qtyno. stock number FSCM and part number on code U/M req’d

1 5120-00-243-2957 Hammer, Hand, Engineers 8 lb. ea 1(3.6 kg) (81348) GGG-H-86

2 5975-00-878-3791 Rod, Ground, Driven, Sectional ea 29 ft (2.7 m) (81349) MlL-R-11461

3 5120-01-013-1676 Hammer, Slide (97403) 13226E7741 ea 1

B - 2

TM 5-6115-630-14&P

Section III. BASIC ISSUE ITEMS

4874-036-2

(1) (2) (3) (4) (5)Illus National Description Usable Qtyno. stock number FSCM and part number on code U/M req’d

1 4210-00-270-4512 Extinguisher, Fire, 5 lbs ea 1(2.03 kg) O-E-910

2 Manual, Technical TM 5-6115-630-14&P ea 1

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T M 5 - 6 1 1 5 - 6 3 0 - 1 4 & P

A P P E N D I X C

MAINTENANCE ALLOCATION CHART


C - 1 . G e n e r a l .

a. This section provides a general explanation of all maintenance and repair functions authorized at variousmaintenance levels.

b. Section II designates overall responsibility for the performance of maintenance functions on the identifiedend item or component. The implementation of the maintenance functions upon the end item or component willbe consistent with the assigned maintenance functions.

c. Section Ill lists the tools and test equipment required for each maintenance function as referenced fromSection Il.

d. Section IV contains supplemental instructions, explanatory notes and/or illustrations required for a particularmaintenance function.

C-2. Explanation of Columns in Section II.

a. Group Number. Column 1. The assembly group is a numerical group assigned to each assembly in a topdown breakdown sequence. The applicable assembly groups are listed on the MAC in disassembly sequencebeginning with the first assembly removed in a top down disassembly sequence.

b. Assembly Group. Column 2. This column contains a brief description of the components of each assemblygroup.

c. Maintenance Functions. Column 3. This column lists the various maintenance functions (A through K) andindicates the lowest maintenance category authorized to perform these functions. The symbol designations forthe various maintenance categories are as follows:

C – Operator or crewO – Unit maintenanceF - Direct support maintenanceH – General support maintenanceD – Depot maintenance

The maintenance functions are defined as follows:

A - Inspect. To determine serviceability of an item by comparing its physical, mechanical, and electricalcharacteristics with established standards.

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

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C – Service. To clean, to preserve, to charge, and to add fuel, lubricants, cooling agents, and air. If it isdesired that elements, such as painting and lubricating, be defined separately, they maybe so listed.

D - Adjust. To rectify to the extent necessary to bring into proper operating range.

E - Align. To adjust specified variable elements of an item to bring to optimum performance.

F – Calibrate. To determine the corrections to be made in the readings of instruments or test equipment usedin precise measurement. Consists of the comparison of two instruments, one of which is a certified standard ofknown accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared with thecertified standard.

G - Install. To setup for use in an operational environment such as emplacement, site, or vehicle.

H - Replace. To replace unserviceable items with serviceable like items.

I - Repair. Those maintenance operations necessary to restore an item to serviceable condition throughcorrection of material damage to a specific failure. Repair may be accomplished at each category ofmaintenance.

J - Overhaul. Normally, the highest degree of maintenance performed by the Army in order to minimize timework in process is consistent with quality and economy of operation. It consists of that maintenance necessary torestore an item to completely serviceable condition as prescribed by maintenance standard in technicalpublications for each item of equipment. Overhaul normally does not return an item to like new, zero mileage, orzero hour condition.

K - Rebuild. The highest degree of material maintenance. It consists of restoring equipment as nearly aspossible to new conditions in accordance with original manufacturing standards. Rebuild is performed only whenrequired by operational considerations or other paramount factors and then only at the depot maintenancecategory. Rebuild reduces to zero the hours or miles of the equipment, or component thereof, has been in use.

d. Symbols. The uppercase letter placed in the appropriate column indicates the lowest level at which thatparticular maintenance function is to be performed.

e. Tools and Equipment. Column 4. This column is provided for referencing by code, the special tools andtest equipment, (Section Ill) required to perform the maintenance functions (Section II).

f. Remarks. Column 5. This column is provided for referencing by code, the remarks (Section IV) pertinent tothe maintenance functions.

C-3. Explanation of Columns in Section III. Section III, Tools, Test, and Support EquipmentRequirements is not applicable.

C-4. Explanation of Columns in Section IV. Section IV, Remarks, is not applicable.

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Section II. MAINTENANCE ALLOCATION CHART

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APPENDIX D

UNIT, DIRECT SUPPORT AND GENERAL SUPPORT ANDDEPOT MAINTENANCE REPAIR PARTS

AND SPECIAL TOOLS LIST


D-1. Scope. This Army manual lists repair parts and special tools required for the performance of unit, directand general support and depot maintenance of the power unit. The following paragraphs are keyed to applicableusers. All users should read paragraph D-4, Special Information, prior to using this manual.

D-2. General. The Repair Parts and Special Tools List is divided into the following sections:

a. Repair Parts - Section II. A list of repair parts authorized for the performance of maintenance at the unit,intermediate (field) (direct and general support) and depot level in figure and item number sequence.

b. Special Tools. Test and Support Equipment - Section III. A list of special tools, test and support equipmentauthorized for the performance of maintenance at the unit, direct and general support and depot level.

c. National Stock Number and Reference Number Index - Section IV. A list of National stock numbers innumerical sequence, followed by a list of reference numbers appearing in all the listings, in alphanumericsequence, cross-referenced to the illustration figure number and item number.

d. Reference Designator Index - Section V. The reference Designator Column includes all assigned referencedesignators arranged first in alphabetical order, second in numerical order. Opposite each symbol is listed thefigure and item number of the part in Section II and the reference number.

D-3. Explanation Of Columns. The following provides an explanation of columns in the tabular lists inSections II and Ill.

a. IIIusfrations. (Column 1). This column is divided as follows:

(1) Figure number. Indicates the figure

(2) Itern number. Indicates the number

number of the illustration on which the item is shown.

used to identify the item on the illustration.

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b. Source. Maintenance. and Recoverabilitv Codes (SMR), (CoIumn 2).

(1) Uniform source codes applicable to all militaty services.

GENERAL: Source Codes are assigned to support items to indicate the manner of acquiring support items formaintenance, repair, or overhaul of end items. Source codes are entered in the first and second positions of theUniform SMR Code format as follows:

Code Definition

PA Item procured and stocked for anticipated or known usage.

D-2

PB Item procured and stocked for insurance purposes because essentiallydictates that a minimum quantity be available in the supply systems.

PC Item procured and stocked and which otherwise would be coded PAexcept that it is deteriorative in nature.

PD Support item, excluding support equipment, procured for initial issue oroutfitting and stocked only for subsequent or additional initial issues oroutfittings. Not subject to automatic replenishment.

PE

PF

PG

KD

KF

KB

MO

Support equipment procured and stocked for initial issue or outfittings tospecified maintenance repair activities.

Support equipment which will not be stocked but which will be centrallyprocured on demand.

Item procured and stocked to provide for sustained support for the lifeof the equipment. It is applied to an item peculiar to the equipment whichbecause of probable discontinuance or shutdown of production facilitieswould prove uneconomical to reproduce at a later time.

An item of depot overhaul/repair kit and not purchased separately. Depotkit defined as a kit that provides items required at the time of overhaul orrepair.

An item of maintenance kit and not purchased separately. Maintenancekit defined as a kit that provides an item that can be replaced at unit ordirect support/general support levels of maintenance.

Item included in both a depot overhaul/repair kit and a maintenance kit.

Item to be manufactured or fabricated at unit level.

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Code

MF

MD

AO

Definition

Item to be manufactured or fabricated at general support maintenance

Item to be manufactured or fabricated at depot maintenance level.

Item to be assembled at unit level.

levels.

AF Item to be assembled at direct support maintenance levels.

AH Item to be assembled at general supporl maintenance levels.

AD Item to be assembled at depot maintenance level.

XA Item is not procured or stocked because the requirements for the item willresult in the replacement of the next higher assembly.

XB Item is not procured or stocked. If not available through salvage, requisition.

XC Installation drawings, diagram, instruction sheet, field service drawing, that isidentified by manufacturers part number.

XD A support item that is not stocked. When required, item will be procured throughnormal supply channels.

(2) Uniform maintenance codes applicable to all military services: GENERAL: Maintenance Codes areassigned to indicate the levels of maintenance authorized to USE and REPAIR support items. The MaintenanceCodes are in the third and fourth position of the Uniform SMR Code Format.

(a) Use (third position): The Maintenance Code entered in the third position indicates the lowest levelmaintenance level authorized to remove, replace, and use the support item. The Maintenance Code entered inthe third position indicates one of the following levels of maintenance.

Code Application/Explanation

O Support item is removed, replaced, used at the unit level of maintenance

F Support item is removed, replaced, used at direct support level.

H Support item is removed, replaced, used at the general support level.

Code Definition

Support items that are removed, replaced, used at Depot only: Depot, MobileDepot and Specialized Repair Activity.

(b) Repair (fourth position): The maintenance code entered in the fourth position indicates whether theitem is to be repaired and identifies the lowest maintenance level with the capability to perform complete repair(i.e., all authorized maintenance functions).

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Code

O

F

H

Code

D

Code

L

Z

B

Application/Explanation

The lowest maintenance level capable of complete repair of the support item isthe unit level.

The lowest maintenance level capable of complete repair of the support item isdirect support.

The lowest maintenance level capable of complete repair of the suppot item isgeneral support.

Definition

The lowest maintenance level capable of complete repair of the support item isthe depot level: Depot, Mobile Depot, and Specialized Repair Activity.

Application/Explanation

Repair restricted to designated Specialized Repair Activity.

Nonreparable. No repair is authorized.

No repair is authorized. The item may be reconditioned by adjusting, lubricating,etc., at the user level. No parts or special tools are procured for the maintenanceof this item.

(3) Uniform recoverability codes applicable to all military services: GENERAL: Recoverability Codes areassigned to support items to indicate the disposition action on unserviceable items. The recoverability code isentered in the fifth position of the uniform SMR Code Format as follows:

RecoverabilityCodes Definition

Z Nonreparable item. When unserviceable, condemn and dispose at the levelindicated in column 3.

O Reparable item. When uneconomically reparable, condemn and dispose atunit level.

F Reparable item. When uneconomically reparable, condemn and dispose atdirect support.

H Reparable item. When uneconomically reparable, condemn and dispose atgeneral support level.

D-4

RecoverabilityCodes

D

L

A

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Definition

Reparable item. When beyond lower level repair capability, return todepot. Condemnation and disposal not authorized below depot level.

Reparable item. Repair, condemnation and disposal not authorized belowdepot/Specialized Repair Activity level.

Item requires special handling or condemnation procedure because ofspecific reasons (i.e., precious metal content, high-dollar value, criticalmaterial or hazardous material). Refer to appropriate manuals/directivesfor specific instructions.

c. National Stock N u m b e r ( Column 4). Indicates the National Stock Number assigned to the item and will beused for requisitioning purposes.

d. Description (Column 5). Indicates the Federal item name and any additional descriptions of the itemrequired. The abbreviation “w/e” when used as a part of the nomenclature, indicates that the National StockNumber includes all armament, equipment, accessories and repair parts issued with the item. A part number orother reference number is followed by the applicable five digit Federal Supply Code for Manufacturer inparentheses. If two reference numbers and Federal Supply Codes for Manufacturer are listed, the first listingrefers to the Department of Defense Drawing Number, the second listing refers to the actual part manufacturer.Items that are included in kits and sets are listed below the name of the kit or set with the quantity of each item inthe kit or set indicated in the quantity incorporated in unit column.

e. Unit of Measure (U/M) (Column 6). Indicates the standard of the basic quantity of the listed item as used inperforming the actual maintenance function. This measure is expressed by a two-character alphabeticalabbreviation (e.g., ea, in, pr. etc.). When the unit of measure differs from the unit issue, the lowest unit of issuethat will satisfy the required units of measure will be requisitioned.

f. Quantity Incomorated in Unit (Column 7). Indicates the quantity of the item used in the assembly group. A“V” appearing in this column in lieu of a quantity indicates that a definite quantity cannot be indicated (e.g., shims,spacers, etc.).

D-4. Special Information.

a. Identification of Usable On Codes for this Manual is not applicable.

b. Army unit maintenance personnel will extract the items which they require from Section II, 3rd or 4thposition of column 2 of the intermediate direct and general support RPSTL. Parts which are manufactured orassembled at a higher level than that authorized to install the part are indicated by the use of higher level code inthe source column.

c. Stockage Information. Army stockage is demand based in accordance with AR 710-2. Repair pads listedin this publication represent those authorized for use at indicated maintenance levels and will be requisitioned onan as-required basis until stockage is justified in accordance with AR 710-2.

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d. In the parts list, some items are indented to show that they are a component of the item under which they areindented.

D-5. How to Locate Repair Parts.

a. When NationaI Stock Number or Reference Number is Unknown:

(1) Using the table of contents, determine the functional group; i.e., batteries and related parts, exhaust andbreather pipes, within which the repair part belongs. This is necessary since illustrations are prepared forfunctional groups.

(2) Find the illustration covering the functional group to which the repair part belongs.

(3) Identify the repair part on the illustration and note the illustration figure and item number of the repairpart.

(4) Using the Repair Part Listing, find the figure and item number on the illustration.

b. When National Stock Number or Reference Number is known:

(1) Using the Index of National Stock Numbers and Reference Numbers, find the pertinent national stocknumber or reference number. This index is in ascending NSN sequence followed by a list of referencenumbers in alphanumeric sequence, cross-referenced to the illustration figure number and item number.

(2) After finding the figure and item number, locate the figure and item number in the repair parts list.

D-6. Abbreviations.

Not Applicable

D-7. Federal Supply Codes for Manufacturers.

Not Applicable

D-8. Recommendation for Maintenance Publication Improvements. Report of errors, omissions, andrecommendations for improving this publication by the individual user is encouraged. Reports should be submitted sfollows: Army DA Form 2028, directly to: Commander, US Army Aviation and Troop Command, ATTN: AMSAT-I-MT,4300 Goodfellow Boulevard, St. Louis, MO 63120-1798.

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D-8

Figure D-1. Enclosure.

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(1) (2) (3) (4) (5) (6) (7)ILLUS- SMR CODE USMC DESCRIPTION

TRATION QTY USMCa b a b c e a b NATIONAL USABLE INC QTY

FIG ITEM AIR REPL STOCK REF NUMBER ON IN PERNO. NO. ARMY FORCE NAVY USMC SSI FACTOR NUMBER & MFR CODE CODE U/M UNIT EQUIP

Group 01 - ENCLOSURE

D-1 1 PAOFF 2540-00-926-0993 FITTED COVER EA 113214E1219 97403

D-1 2 PAOZZ .ROPE, SISAL EA 27T-R-605B 81394

D-1 3 PAFZZ 5325-01-875-3182 .GROMMET METALLIC EA 27MIL-G-16491 81349

D-1 4 PAFZZ 5340-00-078-7029 .CLIP, END STRAP EA 20MS51926-3 96906

D-1 5 PAFZZ 5340-00-057-6956 .BUCKLE, SPRING ACTION EA 8MS51929-2 96906

D- 1 6 MFFFF .CHAPE ASSEMBLY EA 1213214E1392 97403

D-1 7 PAFZZ 5340-00-057-6956 .BUCKLE, SPRING ACTION EA 12MS51929-9 96906

D-1 8 PAFZZ 5365-01-031-9674 .RING, DEE EA 14MS51925-1 97403

D-1 9 XBFZZ .HOOK, TEE EA 2213226E0953

D-1 10 XBOZZ 2510-01-198-2885 SUPPORT TARPAULIN EA 113221E4799 97403

D-1 11 PAOZZ 5305-00-984-6215 SCREW, MACHINE EA 4MS35206-268 96906

D-1 12 PAOZZ 5310-00-014-5859 WASHER, FLAT EA 8MS27183-42 96906

D-1 13 PAOZZ 5310-00-933-8121 LOCKWASHER EA 4MS35338-139 96906

D-1 14 PAOZZ 5310-00-515-9267 NUT, PLAIN, WING EA 4MS35425-37 96906

D-1 15 PAOZZ 2540-00-926-0994 BOW, VEHICULAR, TOP EA 413214E1218 97403

Change 4 D-9

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Figure D-2. Generator Set:

D-10 Change 1

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Group 02 - GENERATOR

D-2 1 PDFHZ 6115-00-465-1044 GENERATOR SET DIESEL EA 1MEP-002A 30554

D-2 2 PAOZZ 5305-00-719-5235 SCREW, CAP, HEX EA 4MS90727-114 96906


D-2 4 PAOZZ 5310-00-067-9507 NUT, SELF-LOCKING EA 4MS51922-37 96906

Change 4 D-11

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Figure D-3. Trailer Body.

D - 1 2

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Group 04 - TRAILER04--Body

D-3 1 XBOZZ BRACKET ASSEMBLY, LIQUID EA 4CONTAINERMS53052-1 96906




D-3 5 PAOZZ 4210-00-223-4857 BRACKET ASSEMBLY, FIRE EA 1EXTINGUISHER13214E1235 97403

D-3 6 PAOZZ 5305-00-068-0502 SCREW, CAR HEX EA 4MS90725-6 96906



D-3 9 PAOZZ 9905-00-205-2795 REFLECTOR EA 4MS35387-1 96906

D-3 10 PAOZZ 9905-00-202-3639 REFLECTOR EA 2MS35387-2 96906

D-3 11 PAOZZ 5305-00-068-0500 SCREW, CAP HEX EA 12MS90725-3 96906

D-3 12 MDFZZ 9906-01-085-7703 PLATE, IDENTIFICATION EA 113205E4918 97403

D-3 13 MDFZZ PLATE, IDENTIFICATION EA 113216E7604-43 97403

D-3 14 PAOZZ 5305-00-253-5614 SCREW, DRIVE EA 4MS21318-20 96906

D-3 15 PAOZZ 5340-00-229-0340 LOOP, STRAP FASTENER EA 2MS51939-3 96906

D-3 16 PAOZZ 5303-00-957-7086 SCREW, MACHINE EA 4MS24893-S273 96906


D-3 18 PAOZZ 5310-00-877-5797 NUT, SELF-LOCKING EA 2MS21044N3 96906

D-3 19 PAOZZ CLAMP LOOP EA 2MS21333-68 96906

D-3 20 PAOZZ 5305-0-989-7435 SCREW, MACHINE EA 2MS35207-264 96906

D-3 21 PAOZZ 5307-00-227-1741 STUD EA 113214E1223 97403

Change 4 D-13

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04 - Body (cont)

D-3 22 PAOZZ 5310-01-026-5824 NUT, PLAIN EA 3MS16203-39 96906

D-3 23 PAOZZ 5310-00-913-9776 LOCKWASHER EA 2MS35335-91 95905

D-3 24 PAOZZ 5310-00-187-2413 WASHER, FLAT EA 4AN961-616T 88044

D-3 25 PAOZZ 5310-00-543-4717 NUT, PLAIN, WING EA 1MS35425-28 96906

D-3 26 PAOZZ 4730-00-908-3194 CLAMP, HOSE EA 1MS353842-11 96906

D-3 27 MOOOO 4720-01-260-2572 HOSE, RUBBER EA 1MIL-H-6000 81349

D-3 28 PAOZZ 5325-00-903-5909 GROMMET EA 1MS35489-112 96906

D-3 29 PAOZZ 4730-00-809-9703 ELBOW EA 1MS24519-9 96906

D-3 30 XAFFF BODY, TRAILER (FENDERS AND EA 1BED)13221E7326 97403

D-3 31 PAOZZ 5340-00-087-5269 .PIN, QUICK RELEASE EA 8MS17990-C613 96906

D-3 32 PAOZZ 4010-00-188-9011 .CHAIN, WELDLESS EA 8RR-C-271 81348

D-3 33 MOOOO .WIRE, GROUND EA 213221E7329 97403

D-3 34 PAOZZ 6145-00-578-6594 .WIRE, ELECTRICAL FT 5M5086/2-6-9 81349

D-3 35 PAOZZ 5940-00-115-4992 .TERMINAL LUG EA 1MS20659-110 96906




D-14(D-15 blank) Change 4

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F i g u r e D - 4 . A c c e s s o r y B o x .

D - 1 6

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04 - Accessory Box

D-4 1 XDOFF 6115-01-230-0677 BOX, ACCESSORY EA 113226E7737 97403

D-4 2 PAOZZ 5340-00-229-0340 .LOOP, STRAP FASTENER EA 2MS51939-3 96906

D-4 3 PAOZZ 5305-00-957-7086 .SCREW, MACHINE EA 4MS24693-S273 96906

D-4 4 PAOZZ 5310-00-014-5850 .WASHER, FLAT EA 4MS27183-42 96906

D-4 5 PAOZZ 5310-00-059-9263 .NUT, SELF-LOCKING EA 4MS21046C3 96906

D-4 6 PAOZZ 5340-00-234-8422 .HASP, HINGED EA 1MS27969-4 96906

D-4 7 PAOZZ 5310-01-18-3097 .RIVET, SOLID EA 8MS9460-102 96906

D-4 8 PAOZZ 5340-00-975-2126 .CATCH, CLAMPING AND STRIKE EA 2MS18015-1 96906

D-4 9 PAOZZ 5320-00-753-3830 .RIVET, SOLID EA 8MS20613-4P5 96906

D-4 10 PAOZZ 5306-00-225-8496 BOLT, MACHINE EA 4MS90725-31 96906

D-4 11 PAOZZ 5310-00-407-9566 LOCKWASHER EA 4MS353385 96906

D-4 12 PAOZZ 5310-00-880-7744 NUT, PLAIN, HEX EA 4MS51967-5 96906

D-4 13 MFFFF STRAP ASSEMBLY EA 213220E5288-2 97403

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Figure D-5. Leg Assembly.

D - 1 8

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04 - Frame

D-5 1 XBFFF 2950-00-420-8929 LEG PROP ASSEMBLY EA 113214E1206 97403

D-5 2 PAOZZ 5315-00-839-5822 .PIN, COTTER EA 2MS2465-353 96906

D-5 3 XBOFF 5315-01-162-0143 .SHAFT EA 113214E1209 97403

D-5 4 XBOFF 6115-01-220-1548 .BRACKET EA 113214E1207 97403

D-5 5 XBOFF 2590-00-453-8977 .LEG, UPPER EA 113214E1208-1 97403

D-5 6 PAOZZ 4730-00-172-0049 .FITTING, LUBRICATION EA 1MS15006-1 96906

D-5 7 PAOZZ 5315-00-838-4584 .PIN, SPRING EA 1MS16562-66 96906

D-5 8 XBOFF 5315-01-158-2144 .SCREW EA 113214E1210 97403

D-5 9 XBOZZ 5310-01-149-0869 .NUT EA 113214E1211 97403

D-5 10 XBOZZ 2590-01-167-8596 .BASE, LEG EA 113214E1212-1 97403




Change 4 D-19

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SECTION III. SPECIAL TOOLS, TEST AND SUPPORT EQUIPMENT

NOT APPLICABLE

SECTION IV. NATIONAL STOCK NUMBER AND REFERENCE NUMBER INDEX

FIGURE ITEM FIGURE ITEMNSN NO. NO. NSN NO. NO.

2510-01-198-2885 D-1 10 5310-00-187-2413 D-3 242540-00-926-0993 D-1 1 5310-00-407-9566 D-4 112540-00-926-0994 D-1 15 5310-00-515-9267 D-1 142590-00-420-8929 D-5 1 5310-00-543-4717 D-3 252590-00-453-8977 D-5 5 5310-00-806-4058 D-3 72590-00-167-8596 D-5 10 5310-00-809-5998 D-2 34010-00-188-9011 D-3 32 5310-00-877-5797 D-3 184210-00-223-4857 D-3 5 5310-00-880-7744 D-4 124720-01-260-2572 D-3 27 5310-00-913-9776 D-3 234730-00-172-0049 D-5 6 5310-00-933-8121 D-1 134730-00-809-9703 D-3 29 5310-01-149-0869 D-5 94730-00-908-3194 D-3 26 5310-01-026-5824 D-3 225305-00-068-0500 D-3 11 5315-00-838-4584 D-5 75305-00-068-0502 D-3 6 5315-00-839-5822 D-5 25305-00-253-5614 D-3 14 5315-01-158-2144 D-5 85305-00-269-3211 D-3 36 5315-01-162-0143 D-5 35305-00-269-3213 D-3 2 5320-00-753-3830 D-4 95305-00-269-3213 D-5 11 5320-01-168-3097 D-4 75305-00-719-5235 D-2 2 5325-00-903-5909 D-3 285305-00-957-7086 D-3 16 5325-01-875-3182 D-1 35305-00-957-7086 D-4 3 5340-00-057-6956 D-1 55305-00-984-6215 D-1 11 5340-00-057-6956 D-1 75305-00-989-7435 D-3 20 5340-00-078-7029 D-1 45306-00-225-8496 D-4 10 5340-00-087-5269 D-3 315307-00-227-1741 D-3 21 5340-00-229-0340 D-3 155310-00-014-5850 D-1 12 5340-00-229-0340 D-4 25310-00-014-5850 D-3 17 5340-00-234-8422 D-4 65310-00-014-5850 D-4 4 5340-00-975-2126 D-4 85310-00-059-9263 D-4 5 5365-01-031-9674 D-1 85310-00-067-9507 D-2 4 5940-00-115-4992 D-3 355310-00-080-6004 D-3 3 6115-00-465-1044 D-2 15310-00-080-6004 D-3 37 6115-01-220-1548 D-5 45310-00-080-6004 D-5 12 6115-01-230-0677 D-4 15310-00-087-4652 D-3 4 6145-00-578-6594 D-3 345310-00-087-4652 D-3 38 9905-00-202-3639 D-3 105310-00-087-4652 D-5 13 9905-00-205-2795 D-3 95310-00-088-1251 D-3 8 9905-01-085-7703 D-3 12

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SECTION IV. NATIONAL STOCK NUMBER AND REFERENCE NUMBER INDEX (CONT)

REFERENCE FIG. ITEM REFERENCE FIG. ITEMNUMBER FSCM NO. NO. NUMBER FSCM NO. NO.

AN961-616T 88044 D-3 24 MS51922-17 96906 D-5 13MEP-002A 30554 D-2 1 MS51922-37 96906 D-2 4MIL-G-16491 81349 D-1 3 MS51925-1 96906 D-1 8MIL-H-6000 81349 D-3 27 MS51926-3 96906 D-1 4MS15006-1 96906 D-5 6 MS51929-2 96906 D-1 5MS16203-39 96906 D-3 22 MS51929-2 96906 D-1 7MS16562-66 96906 D-5 7 MS51939-3 96906 D-3 15MS17990-C613 96906 D-3 31 MS51939-3 96906 D-4 2MS18015-1 96906 D-4 8 MS51967-5 96906 D-4 12MS20613-4P5 96906 D-4 9 MS53052-1 96906 D-3 1MS20659-110 96906 D-3 35 MS90725-3 96906 D-3 11MS21044N3 96906 D-3 18 MS90725-31 96906 D-4 10MS21046C3 96906 D-4 5 MS90725-6 96906 D-3 6MS21318-20 96906 D-3 14 MS90725-60 96906 D-3 36MS21333-68 96906 D-3 19 MS90725-62 96906 D-3 2MS24519-9 96906 D-3 29 MS90725-62 96906 D-5 11MS24665-353 96906 D-5 2 MS90727-114 96906 D-2 2MS24693-S273 96906 D-3 16 MS9460-102 96906 D-4 7MS24693-S273 96906 D-4 3 M5086/2-6-9 81349 D-3 34MS27183-10 96906 D-3 7 RR-C-271 81348 D-3 32MS27183-14 96906 D-3 3 T-R-605B 81348 D-1 2MS27183-14 96906 D-3 37 13205E4918 97403 D-3 12MS27183-14 96906 D-5 12 13214E1206 97403 D-5 1MS27183-18 96906 D-2 3 13214E1207 97403 D-5 4MS27183-42 96906 D-1 12 13214E1208 97403 D-5 5MS27183-42 96906 D-3 17 13214E1209 97403 D-5 3MS27183-42 96906 D-4 4 13214E1210 97403 D-5 8MS27969-4 96906 D-4 6 13214E1211 97403 D-5 9MS35206-268 96906 D-1 11 13214E1212 97403 D-5 10MS35207-264 96906 D-3 20 13214E1218 97403 D-1 15MS35335-91 96906 D-3 23 13214E1219 97403 D-1 1MS35338-45 96906 D-4 11 13214E1223 97403 D-3 21MS35338-139 96906 D-1 13 13214E1235 97403 D-3 5MS35387-1 96906 D-3 9 13214E1392 97403 D-1 6MS35387-2 96906 D-3 10 13216E7604-43 97403 D-3 13MS35425-28 96906 D-3 25 13220E5888-2 97403 D-4 13MS35425-37 96906 D-1 14 13221E4799 97403 D-1 10MS35489-112 96906 D-3 28 13221E7325 074-3 D-3 30MS35842-11 96906 D-3 26 13221E7329 97403 D-3 33MS51922-1 96906 D-3 8 13266E0953 97403 D-1 9MS51922-17 96906 D-3 4 13226E7737 97403 D-4 1MS51922-17 96906 D-3 38

D-21

TM 5-6115-630-14&P

Section V. REFERENCE DESIGNATOR INDEX

Not Applicable

D-22


Official:

WILLIAM J. MEEHAN, II

TM 5-6115-630-14&P

CARL E. VUONOGeneral, United States Army

Chief of Staff

Brigadier General, United States ArmyThe Adjutant General

DISTRIBUTION:To be distributed in accordance with DA Form 12-25A, Operator, Unit, and Direct

Support and General Support Maintenance Requirements for Generator Set, DieselEngine Driven, Trailer Mounted.

* U.S. GOVERNMENT PRINTING OFFICE: 1996-406-421/62197

P I N : 0 6 6 8 0 9 - 0 0 0

OPERATOR’S, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT...

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