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TECHNICAL MANUAL
O P E R A T O R ' S , U N I T , I N T E R M E D I A T E D I R E C T S U P P O R T
A N D I N T ER M ED I A T E GEN ER A L SU PPOR T M A I N T EN A N C E
MANUAL ( INCLUDING REPAIR PARTS AND
SPEC I A L T OOL S L I ST S)
P O W E R U N I T
PU-753/M (NSN 6115-00-033-1389)
M E P - 0 0 3 A
M 1 1 6 A 2
10 KW 60 HZ GENERATOR SET
2-WHEEL, 2-T IRE, MODIFIED
T R A I L E R
This manual supersedes Chapter 14 of TM 5-6115-594-14&P dated 25 September 1984.
Approved for public release. Distribution is unlimited.
H E A D Q U A R T E R S , D E P A R T M E N T O F T H E A R M Y
1 7 J U N E 1 9 8 8
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TM 5-6115-632-14&PC4
CHANGE HEADQUARTERSDEPARTMENT OF THE ARMY
NO. 4 WASHINGTON, D.C., 30 September 1996
Operators, Unit, Intermediate Direct Support andIntermediate General Support Maintenance Manual
(Including Repair Parts and Special Tools Lists)
POWER UNIT, PU-753/M(NSN 6115-00-033-1389)
MEP-003A 10 KW 60 HZ GENERATOR SETM116A2 2-WHEEL, 2-TIRE, MODIFIED TRAILER
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited
TM 5-6115-632-14&P, 17 June 1988, is changed as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in themargin. An illustration change is indicated by a miniature pointing hand.
Remove pages Insert pagesi and ii i and ii1-1 and 1-2 1-1 and 1-2D-7 and D-8 D-7 and D-8D-11 through D-16 D-11 through D-16D-19 through D-22 D-19 through D-22
2. Retain this sheet in front of manual for reference purposes.
By Order of the Secretary of the Army:
DENNIS J. REIMER
General, United States ArmyOfficial: Chief of Staff
JOEL B. HUDSONAdministrative Assistant to the
Secretary of the Army02496
DISTRIBUTION:To be distributed in accordance with DA Form 12-25-E, block no. 3867, requirements for TM 5-6115-632-14&P.
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C3
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 3 WAS HINGTON, D. C . , 17 S ep tem ber 1991
Operators, Unit, Intermediate Direct Support
and In te rm edia te Genera l S uppor t Ma in tenance
Manual (Including Repair Parts and Special Tools Lists)
POWER UNIT
P U - 7 5 3 / M ( N S N 6 1 1 5 - 0 0 - 0 3 3 - 1 3 8 9 )
M E P - 0 0 3 A 1 0 K W 6 0 H Z G E N E R A T O R S E T
M l 1 6 A 2 2 W H E E L , 2 - T I R E , M O D I F I E D T R A I L E R
Approved for public release; distribution is unlimited
TM 5611563214&P, 17 June 1988, is changed as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar inthe margin. An illustration change is indicated by a miniature pointing hand.
Remove pages Insert pages
35 and 3-6 35 and 3-6
3-11 and 312 3-11 and 3-12
2. Retain this sheet in front of manual for reference purposes.
By Order of the Secretary of the Army:
GORDON R. SULLIVANGeneral, United States Army
Chief of Staff
Official:
PATRICIA P. HICKERSON
Brigadier General, United States Army
The Adjutant General
DISTRIBUTION:
To be distributed in accordance with DA Form 1225.E, (qty rqr block no. 3867)
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S A F E T Y S T E P S T O F O L L O W I F S O M E O N E I S T H E
V I C T I M O F E L E C T R I C A L S H O C K
D O N O T T R Y T O P U L L O R G R A B T H E I N D I V I D U A L
I F P O S S I B L E , T U R N O F F T H E E L E C T R I C A L P O W E R
I F Y O U C A N N O T T U R N O F F T H E E L E C T R I C A L
P O W E R , P U L L , P U S H , O R L I F T T H E P E R S O N T O
S A F E T Y U S I N G A W O O D E N P O L E O R A R O P E O R
S O M E O T H E R I N S U L A T I N G M A T E R I A L
S E N D F O R H E L P A S S O O N A S P O S S I B L E
A F T E R T H E I N J U R E D P E R S O N I S F R E E O F
C O N T A C T W I T H T H E S O U R C E O F E L E C T R I C A L
S H O C K , M O V E T H E P E R S O N A S H O R T D I S T A N C E
A W A Y A N D I M M E D I A T E L Y S T A R T A R T I F I C I A L
R E S U S C I T A T I O N
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ARMY TM 5-6115-632-14&P
AIR FORCE TO-35C2-3-491-1
WARNING
Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes andprolonged exposure of skin to cleaning solvent. Wash exposed skin thor-oughly. Dry cleaning solvent (P-D-680) used to clean parts is potentially dan-gerous to personnel and property. Do not use near open flame or excessiveheat. Flash point of solvent is 100F. to 138F. (38C. to 59 C.).
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*TM 5-6115-632-14&P
TECHNICAL MANUAL HEADQUARTERSDEPARTMENT OF THE ARMY
NO. 5-6115-632-14&P WASHINGTON, D.C., 17 June 1988
Operators, Unit, Intermediate Direct Support andIntermediate General Support Maintenance Manual
(Including Repair Parts and Special Tools Lists)
POWER UNIT, PU-753/M(NSN 6115-00-033-1389)
MEP-003A 10 KW 60 HZ GENERATOR SETM116A2 2-WHEEL, 2-TIRE, MODIFIED TRAILER
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes, or if you know of a way to improve theseprocedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes toPublications and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to:Commander, US Army Aviation and Troop Command, ATTN: AMSAT-I-MP, 4300 Goodfellow Blvd., St.Louis, MO 63120-1798. You may also submit your recommended changes by E-mail directly to. A reply will be furnished directly to you. Instructions for
sending an electronic 2028 may be found at the back of this manual immediately preceding the hard copy2028.
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited
TABLE OF CONTENTSPAGE
CHAPTER 1 INTRODUCTIONSection I General ..................................................................................................................................... 1-1Section II Description and Data ................................................................................................................ 1-2
CHAPTER 2 OPERATING INSTRUCTIONSSection I Operating Procedures............................................................................................................... 2-1Section II Operation of Auxiliary Equipment ............................................................................................. 2-1
Section III Operation Under Unusual Conditions....................................................................................... 2-2CHAPTER 3 OPERATOR/CREW MAINTENANCE INSTRUCTIONSSection I Consumable Operating and Maintenance Supplies ................................................................. 3-1Section II Lubrication Instructions............................................................................................................. 3-1Section III Preventive Maintenance Checks and Services (PMCS)........................................................... 3-1Section IV Troubleshooting........................................................................................................................ 3-17Section V Operator/Crew Maintenance..................................................................................................... 3-17
*This manual supersedes Chapter 14 of TM 5-6115-594-14&P dated 25 September 1984.
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CHAPTER 4 UNIT MAINTENANCESection I Service Upon Receipt of Equipment......................................................................................... 4-1Section II Movement to a New Worksite................................................................................................... 4-6Section III Repair Parts, Special Tools, Special Test,
Measurement and Diagnostic Equipment (TMDE)................................................................ 4-7Section IV Lubrication Instructions............................................................................................................. 4-7Section V Preventive Maintenance Checks and Services ........................................................................ 4-8Section VI Troubleshooting........................................................................................................................ 4-13
Section VII Radio Interference Suppression ............................................................................................... 4-13Section VIII Maintenance of Power Plant Trailer.......................................................................................... 4-13
CHAPTER 5 INTERMEDIATE (FIELD), (DIRECT SUPPORT AND GENERAL SUPPORT)MAINTENANCE INSTRUCTIONS
Section I Introduction............................................................................................................................... 5-1Section II Maintenance of Power Plant Trailer.......................................................................................... 5-1Section III Generator Set ........................................................................................................................... 5-7
CHAPTER 6 TEST AND INSPECTION AFTER REPAIRSection I General Requirements.............................................................................................................. 6-1Section II Inspection.................................................................................................................................. 6-1Section III Operational Tests ..................................................................................................................... 6-1
APPENDIX A REFERENCES ......................................................................................................................... A-1APPENDIX B COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS ........................................ B-1
APPENDIX C MAINTENANCE ALLOCATION CHART .................................................................................. C-1APPENDIX D UNIT, INTERMEDIATE (FIELD) (DIRECT SUPPORT AND GENERAL
SUPPORT) AND DEPOT MAINTENANCE REPAIR PARTSAND SPECIAL TOOLS LIST ................................................................................................. D-1
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CHAPTER 1INTRODUCTION
Section I. GENERAL
1-1. Scope. This manual is for your use in operating and maintaining the Power Unit, PU-753/M. The PU-753/M is mobile power unit used to supply power to any system or equipment requiring up to 10 kW of 60 Hz input operating powerIn addition to operating instructions and operator, unit, and intermediate direct support and general support maintenanceprocedures, this manual contains a Repair Parts and Special Tools List for the power unit.
1-2. Limited Applicability. Some portions of this publication are not applicable to both services. These portions arprefixed to indicate the service to which they pertain: (A) for Army, and (F) for Air Force. Portions not prefixed arapplicable to both services.
1-3. Maintenance Forms and Records.
a. (A) Maintenance forms and records used by Army personnel are prescribed by DA Pam 738-750.
b. (F) Maintenance forms and records used by Air Force personnel are prescribed in AFM66-1 and the applicable 0020 Series Technical Orders.
1-4. Reporting of Errors. Reporting of errors and omissions and recommendations for improvement of thispublication by the individual user is encouraged. Reports should be submitted as follows:
a. (A) Army DA Form 2028 directly to: Commander, US Army Aviation and Troop Command, ATTN: U AMSAT-MT, 4300 Goodfellow Boulevard, St. Louis, MO 63120-1798.
b. (F) Air Force AFTO Form 22 directly to: Commander, Sacramento Air Logistics Center, ATTN: SM-ALCMMEDTA, McClellan Air Force Base, CA, 95652-5609, in accordance with TO-00-5-1.
1-5. Reporting Equipment Improvement Recommendations (EIR). El Rs will be prepared using SF 368, U ProducQuality Deficiency Report. Instructions for preparing EIRs are provided in DA PAM 738-750, The Army MaintenancManagement System. EIRs should be mailed directly to: Commander, US Army Aviation and Troop Support CommandATTN: AMSAT-I-MDO, 4300 Goodfellow Boulevard, St. Louis, MO 63120-1798.
1-6. Levels of Maintenance Accomplishment.
a. (A) Army users shall refer to the Maintenance Allocation Chart (MAC) for tasks and levels of maintenance to beperformed.
b. (F) Air Force users shall accomplish maintenance at the user level consistent with their capability in accordancewith policies established in AFM 66-1.
1-7. Destruction of Army Materlel. Destruction of Army materiel to prevent enemy use shall be in accordance with TM750-244-3.
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1-8. Administrative Storage.
a. Army equipment placed in administrative storage will have preventive maintenance performedin accordance with the PMCS tables before storage. When equipment is removed from stor-age, PMCS will be performed to ensure operational readiness.
b. (F) For administrative storage procedures for Air Force equipment, refer to TO 35-1-4, Pro-cessing and Inspection of Aerospace Ground Equipment for Storage and Shipment.
1-9. Preparation for Shipment and Storage.
a. (A) Army Refer to TB 740-97-2.
b. (F) Air Force Refer to TO 35-1-4 for component of end item generator sets and TO 38-1-5for installed engine.
Section Il. DESCRIPTION AND DATA
1-10. Description. Power Unit PU-753/M is made up of one Tactical Utility Generator Set, DOD ModelMEP-003A, mounted on a modified M116A2 trailer. The generator set is an air-cooled, dieselengine-driven unit with a load capacity of 10 KW at 60 Hz. The trailer is a two-wheeled unit with a 3/4-
ton carrying capacity. The modifications to the basic trailer provide stowage for the accessories andall equipment necessary for mobile operation as well as providing a work platform for the operator andmaintenance personnel. Figures 1-1 and 1-2 illustrate the power unit with the fitted cover removed toshow the generator set.
1-2
Figure 1-1. Power Unit, Roadside Front, Three-Quarter View.
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(2) Instruction plate
(a) Location. This plate is located near the ground stud on the rear, curbside corner of the trailerbody.
(b) Content.
GROUND TERMINAL
b. Tabulated Data for Power Unit.
Overall Length 142 inches (360.8 centimeters)Overall Width 73.5 inches (186.7 centimeters)Overall Height 74.75 inches (189.8 centimeters)Net Weight (empty) 2890 pounds (1310 kilograms)Net Weight (Filled) 3040 pounds (1378.7 kilograms)Shipping Weight 3060 pounds (1387.7 kilograms)Cubage 412.23 cubic feet (11.63 cubic meters)
1-12. Differences Between Models. There are no differences between models, serial numbers, or serial numbergroups applicable to this equipment.
* u .S .GOVERNMENT PR INT I NGOFFICE: 1991- 554-030/40101
1-4 Change 2 PIN: 064390-00
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CHAPTER 2
OPERATING INSTRUCTIONS
Section I. OPERATING PROCEDURES
2.1. Operating Procedures. The typical mission for any mobile power generating equipment can bedescribed in three steps or phases. In the first phase, the power unit is towed to the worksite and in-
stalled by unit level technicians (paragraph 4-2). In the second phase of the mission, the operatorstarts the generator set, runs it to power a system or equipment, and eventually shuts it down. In thefinal phase, the power unit is dismantled, packed up and either moved to a new work site or returned tostandby status (paragraph 4-3). This final phase is also accomplished by unit level technicians.
WARNING
Do not operate generator set until it is properly grounded (paragraph 4-2, b.)Serious injury or death by electrocution can result from operating an un-grounded generator set.
Operating noise level of generator can cause hearing damage. Ear
protectors, as recommended by medical or safety officer, must be worn whenworking near power unit.
CAUTION
To avoid damage to equipment, make certain of voltage, frequency, andphase requirements of load connected to generator set.
NOTE
Before starting generator set, do your Before PMCS as described in table 3-2.
In order to perform the operators task during the mission, refer to the data plate located on the right-
hand side of the generator set control cubicle. Follow the operating instructions on the data plate tostart and run the generator set. Monitor and adjust generator set power output as required duringoperation. At the end of the mission, shut down the generator set in accordance with the operatinginstructions on the data plate. For a copy of the information on the data plate, as well as more detailedoperating procedures for the generator set, refer to TM 5-6115-585-12. For trailer operatingprocedures, refer to TM 9-2330-202-14&P.
Section Il. OPERATION OF AUXILIARY EQUIPMENT
2-2. Operation of Auxiliary Equipment. There is no auxiliary equipment supplied with the power unit.
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CHAPTER 3
OPERATOR/CREW MAINTENANCE INSTRUCTIONS
Section I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES
3-1. Consumable Supplies. Consumable supplies used in the maintenance and operation of thepower unit are listed in Table 3-1.
Table 3-1. Consumable Operating and Maintenance Supplies.
(1) (2) (3) (4) (5) (6)
Qty QtyNational required required
Component stock for initial 8 hoursapplication number Description operation operation Notes
General 6850-00-664-5685 Solvent, Drycleaning, 1 quart As requiredCleaning P-D-680
Leg Prop 9150-00-190-0904 Grease, Automotive and 1 pound As required
Assembly Artillery, GAA
Leg Prop 9150-00-186-6681 Oil, Lubricating, 1 quart As requiredAssembly OE/HDO-30
9150-00-402-4478 Oil, Lubricating, OEA 1 quart As required
Section Il. LUBRICATION INSTRUCTIONS
3-2. General. Detailed instructions for the lubrication of the major components of the power unit arecontained in the applicable Lubrication Orders (LOs). Refer to DA Pam 310-1 to ensure the latesteditions of the LOs are used.
3.3. Generator Lubrication. Refer to TM 5-6115-585-12 for generator set Lubrication Order.
3-4. Trailer Lubrication. There are no operator/crew lubrication requirements for the power unittrailer. However, the operator shall assist unit maintenance.
Section Ill. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
NOTE
The PMCS chart in this section contains all necessary Operator/Crewpreventive maintenance checks and services for this equipment.
3.5. General. The preventive maintenance checks and services listed in Table 3-2 are groupedaccording to stages of equipment operation or time intervals. Using the following as a guide, do thechecks and services at the intervals shown.
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a.
b.
c.
d.
e.
f.
Before you operate, perform your before (B) PMCS. Observe all CAUTIONS and WARNINGS.
While you operate, perform your during (D) PMCS. Observe all CAUTIONS and WARNINGS.
After you operate, be sure to perform your after (A) PMCS.
Do (W) PMCS weekly.
Do (M) PMCS monthly.
If equipment fails to operate, refer to Section IV Troubleshooting. If the problem cannot becorrected, see paragraph 3-8, Reporting Deficiencies.
3-6. Purpose of PMCS Table. The purpose of the PMCS table is to provide a systematic method ofinspecting and servicing the equipment. In this way, small defects can be detected early before theybecome a major problem causing the equipment to fail to complete its mission. The PMCS table isarranged with the individual PMCS procedures listed in sequence under assigned intervals. The mostlogical time (before, during, or after operation) to perform each procedure determines the interval towhich it is assigned. Make a habit of doing the checks and services in the same order each time andanything wrong will be seen quickly. See paragraph 3-7 for an explanation of the columns intable 3-2.
3.7. Explanation of Columns. The following is a list of the PMCS table column headings with adescription of the information found in each column.
a. Item No. This column shows the sequence in which the checks and services are to beperformed, and is used to identify the equipment area on the Equipment Inspection and MaintenanceWorksheet, DA Form 2404.
b. IntervalThis column shows when each check is to be done.
c. Item to be Inspected/Procedures. This column identifies the general area or specific partwhere the check or service is to be done, lists the checks or services to be done and explains how to dothem.
d. Equipment is Not Ready/Available If This column lists conditions that make the equipmentunavailable for use because it is unable to perform its mission or because it would represent a safetyhazard. Do not accept or operate equipment with a condition in the Equipment is Not Ready/AvailableIf column.
3.8. Reporting Deficiencies. If you discover any problem with the equipment during PMCS or whileoperating it that you are unable to correct, it must be reported. Refer to DA Pam 738-750 and reportthe deficiency using the proper forms.
3-9. Special Instructions. Preventive maintenance is not limited to performing the checks andservices listed in the PMCS table. Covering unused receptacles, stowing unused equipment and otherroutine procedures such as equipment inventory, cleaning components, and touch-up painting arenot listed in the PMCS table. These are things you should do any time you see they need to be done. Ifa routine check is listed in the PMCS table it is because other operators have reported problems withthis item. Take along tools and cleaning cloths needed to perform the required checks and services.Use the information in the following paragraphs to help you identify problems at any time.
a. Routine Inspections. Use the following information to help identify potential problems beforeand during checks and services.
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WARNING
(1)
(2)
(3)
(4)
(5)
Drycleaning solvent P-D-680 is both toxic and flammable. Wear safety gogglesand gloves and use in a well-ventilated area. Avoid prolonged breathing ofvapors and avoid skin contact. Do not use near open flame or excessive heat.Flash point of solvent is 100F to 138F (38C to 59C). If you become dizzywhile using P-D-680, get fresh air immediately and get medical aid. If P-D-680 contacts eyes, flush with water and get medical aid immediately.
Keep it clean. Dirt, grease, and oil get in the way and may cover up a serious problem.Use drycleaning solvent P-D-680, to clean metal surfaces. Use soap and water to cleanrubber or plastic parts and material.
Bolts, nuts, and screws. Check them all to make sure theyre not loose, missing, bent, orbroken. Dont try to check them all with a tool, but look for chipped paint, bare metal, orrust around bolt heads. If you find 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 weld is found, report it to higher level of maintenance.
Electrical wires, connectors, terminals and receptacles. Look for cracked or broken
insulation, bare wires, and loose or broken connectors. Tighten loose connectors andmake sure the wires are in good condition. Examine terminals and receptacles forserviceability.
Hoses and fluid lines. Look for wear, damage, and leaks. Make sure clamps and fittingsare tight. Wet spots and stains around a fitting or connector can mean a leak. If a leakcomes from a loose connector, tighten it. If something is broken or worn out, report it tounit maintenance.
b. Leakage Definitions. It is necessary for you to know how fluid leakage affects the status of yourequipment. The following are definitions of the types/classes of leakage you need to know to be ableto determine the status of your equipment. Learn and be familiar with them. When in doubt, NOTIFYYOUR SUPERVISOR!
Leakage Definitions:
Class I Seepage of fluid (as indicated by wetness or discoloration) not greatenough to form drops.
Class II Leakage of fluid great enough to form drops but not enough to causedrops to drip from item being checked/inspected.
Class Ill Leakage of fluid great enough to form drops that fall from the itembeing checked/inspected.
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CAUTION
Equipment operation is allowable with minor leakage (Class I or II) of any fluidexcept fuel. Of course, consideration must be given to the fluid capacity in theitem being checked/inspected. When in doubt, notify your supervisor.
When operating with Class I or II leaks, continue to check fluid level more oftenthan required in the PMCS. Parts without fluid will stop working and/or cause
equipment damage.
Class Ill leaks should be reported to your supervisor or unit maintenance.
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS)
NOTE
If the equipment must be kept in continuous operation, check and service onlythose items that can be checked and serviced without disturbing operation.Make the complete checks and services when the equipment can be shutdown.
Within designated interval, these checks are to be performed in the orderlisted.
B Before D During A After W Weekly M Monthly
Itemno. B
Interval
D A W M
Item to be inspected.Procedure: check for andhave repaired, filled, or
adjusted as needed
WARNING
Before performing any mainte-nance that requires climbing on orunder trailer, set trailer hand-brakes, chock wheels, and lowerrear leg prop. Injury to personnelcould result from trailer suddenlyrolling or tipping.
NOTE
Perform weekly as welI as beforePMCS if you are the assigned op-erator but have not operated theequipment since the last weeklyinspection.
Equipment is notready/avaiIable if:
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Table 32. Operator/Crew Preventive Maintenance Checks and Services (PMCS) - Cont.
Item
No.
1
2
B
Interval
D A W
Item to be Inspected.
Procedure: check for andhave repaired, filled, oradjusted as needed
NOTE
Perform weekly as well as before PMCS if
you are operating the equipment for the first
time.
GENERATOR SET EXTERIOR
NOTE
Slight fuel leak (Class I or II leaks) by the
control unit shaft is normal and is necessary
to lubricate shaft. Any other fuel leak or
fuel leakage around the control unit shaft is
a Class III leak and makes the equipment
not ready/available.
a. Check on, around, and beneath the
generator set (1) for fuel or oil leaks.
b. Check that generator set (1) grounds are
properly installed, and grounding
connections are tight.
FUEL GAGE
Check fuel gage (2) for sufficient fuel for
continuous operation.
b Before D During A After W Weeklv M Monthly
M
Change 3 3-5
Equipment is Not Ready/
Available If
A Class III lubrication oil or
any class fuel leak is detected.
Not properly grounded.
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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) - CONT.
B - Before D - During A After W Weekly M - Monthly
Itemno.
3
4
3-6
Item to be inspected.Procedure: check for and
have repaired, filled, oradjusted as needed
ENGINE OIL LEVEL
Check oil filler dipstick (3) for properoil level. Add oil as required.
AIR CLEANER INDICATOR
Check indicator (4) for a restricted air
cleaner. If red warning indicator becomesvisible, notify unit maintenance for clean-ing or replacement.
Equipment is notready/available if:
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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) CONT.
B Before
Itemno.
5
6
7
8
D During A After W Weekly
q
q
q
q
Interval
Item to be inspected.Procedure: check for and
have repaired, filled, or
adjusted as needed
ACCESSORIES
Check that the following accessories arenot missing.
a. Sledge hammer
b. Fire extinguisher
c. Driver/puller
d. Ground rods.
BRACKETS
Check fire extinguisher and fuel canmounting brackets for loose hardwareand broken fittings.
TIRES
a. Check tires (5) for cuts, foreign
objects, or unusual tread wear.Remove any stones from between thetreads.
b. Check that tire pressure is 35 psi(241.22 kPa) when tires are cool.
WHEELS
Check for damage and for missing orloose stud nuts (6).
M Monthly
Equipment is not
ready/avaiIable if:
Fire extinguisher ismissing.
Ground rods aremissing.
One tire is flat,
missing, orunserviceable.
One or more wheel isdamaged. One ormore stud nuts areloose or missing.
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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) - CONT.
B - Before
Itemno.
8
9
10
11
3-8
D During A After W Weekly
Item to be inspected.Procedure: check for andhave repaired, filled, or
adjusted as needed
WHEELS CONT
DRAWBAR RING
Check drawbar ring (7) for insecuremounting and obvious damage.
INTERVEHICULAR CABLE
Check cable (8) and connector for cutsand breaks.
SAFETY CHAINS
Check safety chains (9) for insecuremounting and obvious damage.
M Monthly
Equipment is notready/available if:
Ring is loose or bent.
Intervehicular cableis broken or missing.
Safety chains aremissing orunsecured.
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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) CONT.
B Before
Itemno.
11
12
13
D During A After W Weekly
q
q
q
Interval
D A w M
Item to be inspected.Procedure: check for andhave repaired, filled, or
adjusted as needed
SAFETY CHAINS CONT
BOW ASSEMBLIES AND TARPAULIN SUPPORT
Inspect for damaged bow assemblies (10) ortarpaulin support (11).
FITTED COVER
a.
b.
c.
d.
Check fitted cover (12) for missing anddefective tiedown straps and snapfasteners (13).
Check for missing and defectiveropes (14).
Check for missing and defective strapsand buckles (15).
Check for ripped seams and tears.
M Monthly
Equipment is notready/available if:
3-9
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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) - CONT.
B - Before D - During A - After W - Weekly M - Monthly
Itemno.
18
19
20
Interval
Item to be inspected.Procedure: check for and
have repaired, filled, oradjusted as needed
BRAKE SYSTEM
Test brake system by hooking trailerto towing vehicle and applying brakes.
TRAILER OPERATION
a.
b.
Be alert for any unusual noises whiletowing trailer. Stop and investigate
any unusual noises.
Ensure that trailer is tracking/followingcorrectly behind towing vehicle with noside pull.
GENERATOR SET GAGES AND INSTRUMENTS
a.
b.
Check that battery indicator (19)is in yellow area while batteriesare charging and in green area whenbatteries are fully charged.
Check that frequency meter (20)
indicates 60 Hz (red line) whengenerator is operating under load.
c. Check that current meter (21) readingdoes not exceed 100% or more than 5%load difference between phases.
3-12 Change 3
*U. S. Go v e rnm e n t P r i n t i n g Off i ce : 1991 - 554 - 030 / 4 0132
Equipment is notready/available if:
Service brakes fail tooperate.
Battery indicator not ingreen or yellow area.
Correct frequency
cannot bemaintained.
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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) CONT.
B Before D During A After W Weekly M Monthly
Item
no.
20
Interval
Item to be inspected.Procedure: check for and
have repaired, filled, or
adjusted as needed
GENERATOR SET GAGES ANDINSTRUMENTS CONT
d. Check that voltmeter (22) indicatesdesired output voltage as deter-mined by load connections and amps-volts switch.
e. Check engine oil pressure gage (23)for 25 psig indication.
Equipment is not
ready/avaiIable if:
Desired voltage can-
not be obtained andmaintained.
Oil pressure dropsbelow 15 psig.
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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) - CONT.
B - Before D During A After W - Weekly M Monthly
Itemno.
21
22
3-14
Interval
Item to be inspected.Procedure: check for and
have repaired, filled, oradjusted as needed
FUEL TANK
a. Fill tank (24) upon completion ofoperation.
NOTE
Fuel system temperature must beabove freezing when draining
water and sediment.b. Open drain (25) and drain water and
sediment from fuel tank. Allow to drainuntil fuel runs clean.
FUEL STRAINER AND FILTERS
Drain water and sediment from strainer(26), primary (27) and secondary (28)
filters. Allow to drain until fuel runs clean.
Equipment is notready/available if:
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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) CONT.
B Before D During A After W Weekly M Monthly
Itemno.
22
23
Interval
Item to be inspected.Procedure: check for and
have repaired, filled, oradjusted as needed
FUEL STRAINER AND FILTERS CONT
HANDBRAKES
With trailer hooked to towing vehicle, sethandbrakes (29). Move trailer slightly tosee if handbrakes hold wheels.
Equipment is notready/available if:
3-15
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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) CONT.
B Before D During A After w - Weekly M Monthly
Item
no.
24
25
26
IntervalItem to be inspected.
Procedure: check for andhave repaired, filled, or
adjusted as needed
BRAKE DRUMS AND HUBS
WARNING
A defect in the operation of thebrakes or hub can cause theseparts to get hot enough to causeserious burns. Use extreme cau-
tion when attempting to detectheat in this area.
Feel for overheating to detect drag-ging or binding.
REFLECTORS
Check for damaged or missing reflectors,
BATTERIES
Check battery (30) electrolyte level. Level
should be about 3/4 inch above top ofplates. Add water if level is low. Use
clean water (distilled water if available).
Equipment is notready/available if:
Brakes or hub aredragging or binding.
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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) CONT.
B Before D During A After W Weekly M Monthly
Itemno.
28
Interval
Item to be inspected.Procedure: check for and
have repaired, filled, oradjusted as needed
FIRE EXTINGUISHER
Inspect and weigh fire extinguisher.(See paragraph 3-12.)
TRAILER FRAME
Inspect entire chassis frame fordamage, cracks, and broken welds.
Section IV. TROUBLESHOOTING
3-10. Power Unit Troubleshooting. There are no troubleshooting procedures authorized at operatorlevel for the power unit end item. Troubleshooting procedures for the individual generator set andtrailer are contained in their respective technical manuals referenced below.
a. Generator Set Troub/eshooting. Refer to TM 5-6115-585-12 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 replace-ment of the fitted cover and/or the bows.
a. Fitted Cover Replacement. (See figures 3-1 and 3-2.)
(1) removal.
Equipment is notready/available if:
Frame is obviouslybroken or cracked.
(a)
(b)
(c)
(d)
(e)
Untie 27 ropes (1, figure 3-1) fastening fitted cover to trailer body (2).
Unfasten six straps and buckles (3) securing rear curtain (4). Roll up curtain, andsecure with three rollup straps (5) provided.
Unfasten six straps and buckles (3) securing front curtain (6). Roll up curtain, and
secure with three rollup straps (5) provided.Roll up each side (7) of fitted cover, in turn, and secure each side with four rollup straps(5) provided.
Working under fitted cover (1, figure 3-2), unfasten eight straps (2) securing fittedcover to bow assemblies (3). Remove fitted cover.
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(2) Installation.
NOTE
Front curtain is provided with three tie-down ropes. Rear curtain only has tworopes.
(a) Position fitted cover (1, figure 3-2) on top of bows (3) making certain front of fittedcover is at front of trailer.
(b) Secure fitted cover (1) to bow assembly (3) with eight straps (2) provided.
(c) Unfasten rollup straps (5, figure 3-1) securing sides of fitted cover and lower bothsides (7).
(d) Unfasten rollup straps (5) securing front and rear curtains (4,6) and lower bothcurtains.
(e) Secure front and rear curtains (4, 6) to sides (7) with six straps and buckles (3)provided on each curtain.
(f) Secure fitted cover to trailer body (2) with 27 ropes (1) provided.
Figure 3-1. Fitted Cover Installed on Power Unit.
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Figure 3-2. Fitted Cover Rolled Up for Removal.
b. Tarpaulin Support and Bow Assembly Replacement. (See figures 3-3 and 3-4.)
(1) Removal.
(a) Remove fitted cover (paragraph 3-11, a.(l)).
(b) Remove one screw (1, figure 3-3), one flat washer (2), one Iockwasher (3) and onewing nut (4) securing tarpaulin support (5) to each of four bow assemblies (6) andremove tarpaulin support.
(c) Remove two quick release pins (1, figure 3-4) securing each bow assembly (2) inpocket (3) on trailer body (4). Lift each bow out of pocket and off trailer body.
(2) Installation.
(a) Lift each bow (2, figure 3-4) onto trailer, aline bow ends with pockets (3) in trailer body(4) and drop bow in place. Secure each bow assembly with two quick release pins (1)provided.
3-19
(b) Position tarpaulin support (5, figure 3-3) on bows (6) and secure tarpaulin support toeach bow with one screw (1), one flat washer (2), one Iockwasher (3) and one wingnut (4).
(c) Install fitted cover on trailer (paragraph 3-11, a.(2)).
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Figure 3-3
Figure 3-4
TM 5-6115-632-14&P
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3-12. Fire Extinguisher Maintenance.
WARNING
Monobromotrifluoroethane liquid or gas (Halon 1301) can cause death orserious injury if personnel fail to observe safety precautions. Inhalation ofmonobromotrifluoroethane gas at concentrations of 5% to 6% for more than 4
or 5 minutes may result in serious cardiac or central nervous system effects.Liquid Halon 1301 (including the spray in the immediate vicinity of thedischarge) may freeze the skin on contact. In the event of frostbite, warm theaffected area quickly to body temperature. Immerse hands in warm water orplace hands in armpits. Get medical attention promptly.
CAUTION
Do not attempt to verify readiness of fire extinguisher byunit. Any discharge of contents will require refilling.
partially discharging
The PU-753/M Power Unit is equipped with a 2-3/4 lb Halon fire extinguisher. Maintenance is limited to
weighing the fire extinguisher monthly to insure that it is sufficiently charged. Fully charged, the fireextinguisher (with head and horn attached) weighs 5 lb. Send the unit to specialized activity for rechargingif it weighs 4 lb, 12 oz or less.
3-21/(3-22 blank
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CHAPTER 4
UNIT MAINTENANCE
Section I. SERVICE UPON RECEIPT OF EQUIPMENT
4-1. Inspecting and Servicing Equipment. The power unit is unpacked, inspected, and serviced as
described in the following paragraphs. Unpacked equipment must be checked against the EquipmentPacking List to ensure completeness. Discrepancies must be reported in accordance with instructionsin DA Pam 738-750.
a. Unpacking Power Unit. (See figures 4-1 and 4-2.) The generator set is packed in place on thetrailer body. Before beginning the unpacking procedure, locate, remove, and save the waterproofenvelopes marked Depreservation Guide.
Figure 4-1. Uncrating Generator Set.
WARNING
Steel banding used in packaging of power unit has sharp edges. Care should
be taken when cutting and handling banding to avoid injury to personnel.
(1) Remove lag screws securing plywood box cover over generator set and lift cover offgenerator. Remove wooden wedges positioned around base of generator.
4-1
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(10)
(11)
(12)
(13)
(14)
(15)
TM 5-6115-632-14&P
Remove protective film from fitted cover and set fitted cover aside.
Remove strapping and wood blocking securing bows and tarpaulin support from trailer.
Refer to DA Form 2258, Depreservation Guide for Vehicles and Equipment, packed withpower unit and follow instructions given for putting unit in service.
Stow all authorized accessories in the accessory box.
Install bows and tarpaulin support on power unit (paragraph 3-11, b (2)).
Install fitted cover on power unit (paragraph 3-11, a (2)).
b. Inspection and Servicing of Generator Set. Refer to Servicing Upon Receipt of Material inTM 5-6115-585-12 for initial inspection and servicing procedures.
c. Inspection and Servicing of Trailer. Refer to Servicing Upon Receipt of Material in TM 9-2330-202-14&P for initial inspection and servicing procedures.
4-2. Installation. (See figure 4-3.) Installation of the power unit at a worksite involves positioning thetrailer and grounding the power unit.
a. Positioning Power Unit. Position the power unit on the worksite as follows:
(1) Select on area as level as possible to install power unit and position trailer.
(2) Set trailer handbrakes and lower trailer support leg.
(3) Chock both wheels and lower rear leg prop assembly. Adjust leg prop assembly by turninginner leg until leg base makes firm contact with ground.
(4) Lift and secure fitted cover in raised position away from generator set exhaust.
WARNING
Remove fire extinguisher and fuel cans from power unit when generator set is inoperation. This will insure that, in the event of fire, extra fuel will not be involvedand extinguisher will remain accessible.
(5) Locate fuel cans and fire extinguisher on ground away from power unit.
WARNING
4-3
Do not operate generator set until power unit is properly grounded (paragraph4-2, b.). Serious injury or death by electrocution can result from operating anungrounded power unit.
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Figure 4-3. Installing Power Unit.
CAUTION
To avoid damage to equipment, make certain of voltage, frequency, andphase requirements of load being connected to generator set.
(6) Refer to data plate on load terminal board cover and to TM5-6115-585-12. Connect powerunit to system or equipment to be powered.
b. Grounding. Check that generator set is grounded to GROUND TERMINAL stud on trailer body.Using ground wire supplied with power unit, connect power unit to a suitable ground as describedbelow. The following sources of a good ground are listed in order of preference.
NOTE
As a substitute for the supplied ground wire, any copper wire of at least No. 6AWG maybe used.
4-4
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(1)
(2)
(3)
TM 5-6115-632-14&P
Underground water system. Ground power unit to one of the accessible pipes in anunderground water system. Make certain underground pipe is made of metal and there isno insulation, such as a water meter, between ground wire and earth.
Ground rod. Drive ground rod a minimum of eight feet into earth. A ground rod must have aminimum diameter of 5/8-inch, if solid, or 3/4-inch if pipe.
NOTE
It maybe necessary to saturate the area around ground rod with water if soilconditions are dry.
Ground plate. Ground power unit to a metal plate buried four feet deep. Ground plateshould cover a minimum area of nine square feet.
c. Extemal Fuel Line Connection. (See figure 4-4.) The power unit generator set can be fueledfrom an external source such as a five-gallon fuel can or 55 gallon drum. This eliminates the need forfrequent refilling of the generators 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 andassemble by threading 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 islocated immediately 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 firstpumped into generator set fuel tank by auxiliary fuel pump. Fuel is then fed togenerator set engine from fuel tank.
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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 minimumamount of effort is required to relocate to a new worksite. Procedures are as follows:
a.
b.
c.
d.
e.
f.
9.
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 up cable and store in accessory box.
Using slide hammer, remove ground rod. Disassemble, clean, and stow ground rod inaccessory 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.
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h. Remove locking pin from leg prop assembly on rear of trailer. Swing leg prop back and upinto traveling position and secure with pin.
i. Attach power unit to towing vehicle. (Refer to TM 9-2330-202-14&P.)
j. Release trailer handbrakes.
4-4. Reinstallation After Movement. After movement to a new worksite, install power unit inaccordance with paragraph 4-2.
Section Ill. REPAIR PARTS, SPECIAL TOOLS, SPECIAL TEST, MEASUREMENT ANDDIAGNOSTIC EQUIPMENT (TMDE)
4-5. Tools and Equipment. There are no special tools or equipment required to maintain thePU-753/M power unit.
4-6. Maintenance Repair Parts. Repair parts and equipment for maintenance of this power unit arelisted and illustrated in the repair parts and special tools list in Appendix D of this manual.
Section IV. LUBRICATION INSTRUCTIONS
4-7. General. Detailed instructions for the lubrication of the major components of the power unit arecontained in the applicable Lubrication Orders (LOs). Refer to DA Pam 310-1 to ensure that the latesteditions of the L.O.S are used. This section contains lubrication instructions that are not included inthe Lubrication Orders.
4-8. Generator Lubrication. Refer to TM 5-6115-585-12 for generator set Lubrication Order.
4.9. Trailer Assembly Lubrication.
a. Trai/er Lubrication. Refer to TM 9-2330-202-14&P for trailer Lubrication Order.
b. Leg Prop Assembly Lubrication. The rear leg prop assembly is a modification to the standard
M116A2 trailer and, as such, does not appear in the associated L.O. Semiannually lubricate leg propassembly as follows:
WARNING
Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes andprolonged exposure of skin to cleaning solvent. Wash exposed skin tho-roughly. Dry cleaning solvent (P-D-680) used to clean parts is potentiallydangerous to personnel and property. Do not use near open flame orexcessive heat. Flash point of solvent is 100F. to 138F. (38C. to 59C.).
(1) Clean hydraulic lubrication fitting and area around lubrication points with P-D-680 orequivalent.
(2) Inject sufficient GAA grease into hydraulic fitting to lubricate screw threads inside leg propassembly.
4-7
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NOTE
Refer to Lubrication Order in TM 9-2330-202-14&P for lubricating oils specifiedanticipated temperature ranges.
(3) Apply OE lubricating oil to both ends of leg prop assembly pivot shaft.
for use within different
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
NOTE
The PMCS chart in this section contains all necessary unit preventivemaintenance chdcks and services for this equipment.
4-10. General. The trailer assembly and generator set must be inspected and serviced systematically toinsure that the power unit is ready for operation at all times. Inspection will allow defects to bediscovered and corrected before they result in serious damage or failure. Table 4-1 contains a tabulatedlist of preventive maintenance checks and services to be performed by unit maintenance personnel.All of the unit PMCS on the trailer is scheduled to be performed semiannually. Unit PMCS on thegenerator set is scheduled weekly or on a per-hours-of-operation basis. The running time meter on thecontrol panel is used to determine the qenerator set operatinq time. Using the followinq as a guide, dothe checks and services at the intervals shown. Observe all CAUTIONS and WARNINGS.
a.
b .
c.
d.
e.
f
4-11.
For PMCS performed on an operating time basis, perform your hourly (H) PMCS as close aspossible to the time intervals indicated.
NOTE
For units in continuous operation, perform PMCS before startingoperation if continuous operation will extend service interval pastthat which is shown.
Perform your weekly (W) PMCS every week or 40 hours of generator set operating time.
Perform your monthly (M) PMCS every month or 100 hours of generator set operating time.
Do your semiannual (S) PMCS once every six months or 500 hours of generator set operating
Do your annual (A) PMCS once every year or 1000 hours of generator set operating time.
time.
If you discover a problem with the equipment, refer to Section Vl, Troubleshooting. If you cannotcorrect the problem, refer to paragraph 4-12, Reporting Deficiencies.
Explanation of Columns. The following is a list of the PMCS table column headings with adescription of the information found in each column.
a. Item No. This column shows the sequence in which to do the checks and services, and is usedto identify the equipment area on the Equipment Inspection and Maintenance Worksheet, DA Form2404.
b. Interval. This column shows when each check is to be done.
c. Item to be Inspected. This column identifies the general area or specific part where the checkor service is to be done.
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Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS). CONT.
H Hours of operation W Weekly M Monthly(As indicated)
S Semiannually(40 hours)
A Annually
(100 hours) (500 hours) (1000 hours)
Item
no.S
5
6
7
8
9
10
11
12
13
14
15
Interval
H
100
300
500
1000
300
500
100
1000
w M
q
q
q
A
Item to beInspected
Lubricating Oil
and Filter
Fuel Strainer
Primary FuelFilter
Secondary FuelFilter
Batteries
Crankcase Breather
Dust Caps on Air
Cleaner
Air Cleaner
Taillights
IntervehicularCable
Drawbar Ring
Procedures
Change lubricating oil and filter every 100
hours of operation (L.0. 5-6115-585-12).
Clean fuel strainer every 300 hours of
operation (para 4-20, TM 5-6115-585-12).
Service primary filter every 500 hours ofoperation (para 4-20, TM 5-6115-585-12).
Service secondary filter every 1000 hours
(para 4-20, TM 5-6115-585-12).
Perform a hydrometer test on batteries
every 300 hours, or quarterly. Refer topara 4-25c, TM 5-6115-585-12 for testprocedures.
Inspect breather tube every 500 hours.
Clean as necessary (para 4-45,
TM 5-6115-585-12).
Clean out dust caps on air cleaner assemblyevery 100 operating hours (more frequently
under ususual conditions).
Clean every 1000 operating hours or as
conditions dictate. Replace air cleaner
every 2000 operating hours.
Replace any broken or cracked lensesor defective bulbs (page 4-52,
TM 9-2330-202-14&P).
Check for cuts, breaks, frayed wires, ordamaged plug.
Check security of mounting. Inspect ring
for excessive wear.
4-10 Change 1
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Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS). CONT.
H - Hours of operation W -- Weekly M Monthly S Semiannually A Annually(As indicated) (40 hours) (100 hours) (500 hours) (1000 hours)
Itemno.
16
17
18
19
20
21
22
23
H
Interval
W M S
q
q
q
q
q
q
q
q
A
Item to beInspected
Safety Chains
Reflectors
Data Plates and
Markings
Support Leg
Assembly
Rear Leg Prop
Suspension
Assemblies
Axle
Wheels and Tires
Procedures
Inspect for broken links or missing chain(s).
Replace any cracked, broken, or missing
reflectors (page 4-232, TM 9-2330-202-
14&P).
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
broken parts.
a. Inspect shackles, bearings, pins, leaf
springs and spring eyes for damage or
b.
c.
a.
b.
a.
b.
broken parts.
Inspect mounting brackets for cracks
or loose or 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
in TM 9-2610-200-24.
Tighten wheel stud nuts.
Change 1 4-11
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Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS). CONT.
Item
no.
24
25
26
27
28
H
Interval
W M S
q
q
q
q
A
q
Item to be
Inspected
Brakes
Wheel Bearings
Hydraulic Brake
Actuator
Hydraulic Brake
Tubes and Hoses
Trailer Road
Test
Procedures
H - Hours of operation W Weekly M Monthly(As indicated)
S - Semiannually A Annually(40 hours) (100 hours) (500 hours) (1000 hours)
4-12 Change 1
a.
b.
c.
d.
Inspect brake linings for wear. Replace
if brake shoe lining is less than l/8-
inch (3.2 mm) thick (page 4-140,
TM 9-2330-202-14&P).
Inspect brake adjusting screw, retaining
screw, retaining pins, springs, and
clips for corrosion and wear.
Inspect hydraulic wheel cylinders for
leaks.
Adjust brake (page 4-154,
TM 9-2330-202-14&P).
Clean and repack. (page 4-180),
TM 9-2330-202-14&P).
a. Check security of brake actuator
mounting.
b. Service brake actuator (page 4-156,
TM 9-2330-202-14&P).
Inspect for dents, cracks, loose connections
and leaks.
Perform road test paying special attention
to items that were repaired or adjusted,
in accordance with TM 9-2330-202-14.
PIN: 064390-
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Section VI. TROUBLESHOOTING
4-13. Power Unit Troubleshooting. There are no troubleshooting procedures authorized at unit levelfor the power unit end item. Troubleshooting procedures for the individual generator set and trailerare contained in their respective technical manuals referenced below.
a. Generator Set Troubleshootinq. Refer to TM 5-6115-585-12 for troubleshooting proceduresapplicable to the generator set.
b. Trailer Troubleshooting. Refer to TM 9-2330-202-14&P for troubleshooting proceduresapplicable to the trailer.
Section VII. RADIO INTERFERENCE SUPPRESSION
4-14. General Methods Used to Attain Proper Suppression. Essentially, suppression is attained byproviding a low resistance path to ground for stray currents. The methods used include shieldingignition and high-frequency wires, grounding the frame with bonding straps, and using filteringsystems.
4-15. Radio Interference Suppression Components. All component parts on the power unit end item,
whose primary or secondary function is radio interference suppression, are on the generator set.Refer to TM 5-6115-585-12 for location of radio interference suppression components.
Section VIII. MAINTENANCE OF POWER UNIT TRAILER
4-16. General. This section of the manual contains unit level maintenance procedures forcomponents of the MII6A2 trailer added when the trailer is used as part of the PU-753/M power unit.These components are not covered in the overall trailer maintenance manual. For all other unitmaintenance procedures on the trailer, refer to TM 9-2330-202-14&P.
WARNING
Before performing any maintenance that requires climbing on or under trailer,set trailer handbrakes, chock both wheels, and lower rear leg prop. Injury topersonnel could result from trailer suddenly rolling or tipping.
4-17. Fuel Can Bracket Replacement. (See figure 4-5.) There are four fuel can brackets suppliedwith the PU-753/M. Two brackets are mounted on top of each fender. Replacement proceduresdescribed below are typical for all four.
a. Removal.
(1) Remove four screws (1, figure 4-5), four nuts (2) and four flat washers (3) securingbracket (4) to fender (5).
(2) Remove bracket (4) from fender (5).
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Figure 4-5. Fuel Can Bracket Replacement.
b. Installation.
(1) Position fuel can bracket (4) on fender (5).
(2) Insert four screws (1) down through bracket (4) and through fender (5).
(3) Install one washer (3) and one nut (2) onto each screw (1). Tighten hardware to securebracket (4).
4-18. Accessory Box Replacement. (See figure 4-6.) The accessory box is mounted to the trailer
bed forward of the generator set.
a. Removal.
(1) Remove four screws (1, figure 4-6), four flat washers (2), and four nuts (3) securingaccessory box (4) to traiIer bed (5).
(2) Lift accessory box (4) off trailer (5).
b. Installation.
(1) Position accessory box (4) on trailer bed (5).
(2) Insert four screws (1) through accessory box mounting brackets and trailer bed (5).
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Figure 4-6. Accessory Box Replacement.
(3) Working under trailer, install one flat washer (2) and one nut (3) on each screw (1).Tighten hardware to secure accessory box (4).
4-19. Fire Extinguisher Bracket Replacement. (See figure 4-7.) The fire extinguisher supplied with
the power unit is carried in a bracket mounted on the rear of the trailer roadside fender.
a. Removal.
(1) Remove four screws (1, figure 4-7), four nuts (2), and four flat washers (3) securingbracket (4) to fender(5).
(2) Remove bracket (4) from fender (5).
b. Installation.
(1) Position fire extinguisher bracket (4) on fender (5).
Figure 4-7. Fire Extinguisher Bracket Replacement.
(2) Insert four screws (1) down through bracket (4) and through fender (5).
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(3) Install one flat washer (3) and one 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.).
4-16
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Figure 5-1. Leg Prop Assembly Replacement.
(2) Installation.
(a)
(b)
(c)
(d)
(e)
(f)
Position bracket (4) on trailer frame (11) and install three screws (7), three flatwashers (8), three lockwashers (9) and three nuts (10). Tighten hardware to securebracket.
Lift leg prop assembly into bracket (4) and secure by inserting angled bar (1) through
holes in bracket and 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 pivot shaft (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) through holes in bracket (4) and boss (2) on upper leg (3).
b. Leg Prop Assembly Repair. Repair of the leg prop assembly is limited to welding and repaint-ing. However, partial disassembly is possible to facilitate repair. If required, repaint in accordance
with MIL-T-704, Type F, color Green No. 383 of MIL-C-46168.
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(1) Disassembly.
TM 5-6115-632-14&P
(a) Remove leg prop assembly from trailer (paragraph 5-2, a.(l)).
(b) Clamp leg prop assembly in vise with spring pin facing up.
(c) Using suitable drift, drive spring pin out of upper leg and remove leg base.
(2) Assemb/y.
(a) Clamp upper leg in vise with spring pin hole facing up.
(b) Insert leg base into upper leg and turn leg base until hole in screw lines up with hole inupper leg.
(c) Install spring pin to secure leg base to upper leg.
(d) Install leg prop assembly on trailer (paragraph 5-2, a. (2)).
5-3. Trailer Bed and Fenders Repair and Replacement. (See figure 5-2.) The body of the modifiedtrailer consists of a single weldment that includes both fenders and the bed of the trailer.
a. Removal.
(1) Remove fitted cover (paragraph 3-11, a.(1)).
(2) Remove tarpaulin support and four bow assemblies (paragraph 3-11, b.(1)).
(3) Remove accessory box (paragraph 4-18, a.).
(4) Remove generator set (paragraph 5-7, a.).
(5) Remove 10 screws (1, figure 5-2), 20 flat washers (2), and 10 nuts (3) securing trailerbody (4) to trailer chassis (5).
NOTE
Observe position of screws securing rear braces on trailer body to trailerchassis.
(6) Remove 16 screws (6), 32 flat washers (7) and 16 nuts (8) securing trailer body (4) totrailer chassis (5).
NOTE
Removal of the trailer body requires the removal and disassembly of bothhandbrake lever assemblies. The handbrake lever assemblies are symmetrical
and this procedure is typical for both.
5-
(7) Remove two screws (9), two spacers (10), and two nuts (11) and remove roadside hand-brake lever assembly (12) from trailer chassis (5).
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Figure 5-2. Fender and Bed Replacement.
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(8) Remove cotter pin (13), washer (14), shaft (15), and pulley (16) from handbrake leverassembly (12).
(9) Working under trailer, pull handbrake cable clevis (17) back through the holes in the fronttwo braces on the trailer body.
(10) Repeat steps (7) through (9) to remove and disassemble curbside handbrake leverassembly.
WARNING
When lifting trailer body, use lifting equipment with a minimum lifting capacityof 500 lb. Do not stand under trailer body while it is being lifted. Failure toobserve these precautions can cause injury to personnel or damage toequipment.
(11) Using suitable lifting equipment with a minimum lifting capacity of 500 lb, lift trailer body
(4) off of trailer chassis (5).
b. Repair. Repair of the trailer bed and fenders is limited to straightening, welding, and
repainting. If required, repaint in accordance with MIL-T-704, Type F, color Green, NO. 383 of MIL-C-46168.
c.
(1)
(2)
(3)
(4)
(5)
Installation.
WARNING
(6)
(7)
When lifting trailer body, use lifting equipment with a minimum lifting capacityof 500 lb. Do not stand under trailer body while it is being lifted. Failure toobserve these precautions can cause injury to personnel or damage toequipment.
Using suitable lifting equipment with a mimimum lifting capacity of 500 lb, lift trailer body
(4) onto trailer chassis (5) and aline mounting holes.Insert 10 screws (1) with flat washers (2) through trailer bed and through trailer chassisframe rails.
Working under trailer, install one flat washer (2) and one nut (3) on each screw (1).
Insert 16 screws (6) with 16 flat washers (7) through trailer body braces into trailerchassis.
Working under trailer, install one flat washer (7) and one nut (8) on each screw (6).Tighten hardware to secure trailer body to trailer chassis.
Feed roadside handbrake cable clevis (17) forward through holes in front two braces ontrailer body.
Wrap handbrake cable around pulley (16), position pulley in handbrake lever assembly(12) and insert shaft (15).
5-5
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TM5-6115-632-14&P
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Install washer (14) and cotter pin (13) to secure shaft (15).
Assemble handbrake lever assembly (12) using two screws (9) and two spacers (10).Make certain top screw (9) goes through spacer (18) and bottom screw (9) goes throughhandbrake cable clevis.
Position assembled handbrake lever assembly (12) on trailer chassis (5) and install twonuts (11). Tighten hardware.
Repeat steps (6) through (10) to assemble and install curbside handbrake leverassembly.
Install generator set (paragraph 5-7, b.).
Install accessory box (paragraph 4-18, b.).
Install tarpaulin support and four bow assemblies (paragraph 3-11, b.(2)).
Install fitted cover (paragraph 3-11, a.(2)).
5-4. Fitted Cover Repair. Repairs to the fitted cover shall be made in accordance with FM 10-16,
Fabric Repairing.
5-5. AccessoryBox Repair. (See figure 5-3.) The accessory box is repaired by replacing the hasp,the catches and the footmans loops, as required. The box itself may be straightened, welded, andrepainted. If required, repaint in accordance with MIL-T-704, Type F, color Green, No. 383 of MIL-C-46168.
a, Catch and Hasp Replacement.
(1) Grind off or drill out solid rivets (1, figure 5-3) securing catch or hasp (2) to accessorybox (3).
(2) Position new catch or hasp (2) on accessory box and secure with solid rivets (1).
(3) Touch up with paint as required.
Figure 5-3. Accessory Box Repair,
5-6
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b. Footmans Loop Replacement.
TM 5-6115-632-14&P
(1) Remove two screws (4, figure 5-3), two flat washers (5), and two self-locking nuts (6)securing footmans loop (7) to accessory box lid.
(2) Position new footmans loop (7) on accessory box (3) and install with two screws (4) twowashers (5), and two self-locking nuts (6).
5-6. Marking. (See figure 5-4.) The power unit four-digit registration number, preceded by theprefix VC and the words U.S. ARMY, is marked in three places on the trailer. Marking is done inaccordance with MIL-STD-642. On the fender, over each wheel, T.P. 35 PSI is marked in 1.00 .12 inch high characters in accordance with MIL-STD-130. Figure 5-4 shows the approximate loca-tion of markings on the power unit. If required, touch-up painting of the base color is done inaccordance with MIL-T-704, Type F, color Green, No. 383 of MIL-C-46168.
T.P. 35 PSI
Figure 5-4. Power Unit Markings.
Section Ill. GENERATOR SET
5-7. Generator Set Replacement. (See figures 5-5 and 5-6.)
a. Removal.
(1) Remove fitted cover (paragraph 3-11, a.(1)).
(2) Remove tarpaulin support and four bow assemblies (paragraph 3-11, b.(1)).
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(3) Disconnect ground wire (1, figure 5-5) from generator set (2) to GROUND TERMINALstud (3) on trailer bed (4).
NOTE
The beveled washers (6) may have been welded in place.
(4) Remove four bolts (5), four beveled washers (6), four flat washers (7), four Iockwashers(8) and four nuts (9) securing generator set (2), to trailer (4).
(5) Remove engine oil drain hose (10) from grommet in trailer bed.
Figure 5-5. Detaching Generator Set from Trailer.
WARNING
When lifting generator set, use lifting equipment with a minimum lifting capa-city of 1500 lb. Do not stand under generator while it is being lifted. Failure to
observe these precautions can cause injury to personnel or damage toequipment.
(6) Attach lifting equipment with a minimum lifting capacity of 1500 lb (1, figure 5-6) to liftingeye (2) on top of generator set (3) and remove generator set from trailer.
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b. Installation.
WARNING
When lifting generator set, use lifting equipment with a minimum lifting capa-city of 1500 lb. Do not stand under generator while it is being lifted. Failure to
observe these precautions can cause injury to personnel or damage toequipment.
(1) Attach lifting equipment
Figure 5-6. Lifting Generator Set.
with a minimum lifting capacity of 1500 lb (1, figure 5-6) to liftingeye (2) on top of generator set (3) and lift generator.
(2) Lower generator set (2, figure 5-5) onto trailer bed (4) and aline mounting holes.
(3) Insert four bolts (5) with beveled washers (6) down through generator set skid and trailerbed (4).
(4) Working under trailer, install one flat washer (7), one Iockwasher (8) and one nut (9) oneach bolt (5).
(5) Position beveled washers (6) so that bolt heads are parallel to top of washers. While hold-ing beveled washers in position, tighten hardware to secure generator set (2) to
trailer (4).
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TM 5-6115-632-14&P
CHAPTER 6
TEST AND INSPECTION AFTER REPAIR
Section I. GENERAL REQUIREMENTS
6-1. General Requirements. The activity performing the repair is responsible for the performance ofall applicable tests and inspections specified in the technical manuals referenced below. Activities
performing maintenance on any component of the power unit must perform those tests and inspectionsrequired by the applicable component or system repair instruction.
Section Il. INSPECTION
6-2. Generator Set Inspections. Refer to TM 5-6115-585-12 and -34 for inspections requiredfollowing repair of the generator set.
6-3. Trailer Inspections. Refer to TM 9-2330-202-14&P for inspections required following repair ofthe trailer.
Section Ill. OPERATIONAL
6-4. Generator Set Operational Tests. Refer to TM 5-6115-585-12required to verify satisfactory performance of the generator set.
TESTS
and -34 for operational tests
6-5. Trailer Operational Tests. Refer to TM 9-2330-202-14&P for operational tests required to verifysatisfactory performance of the trailer.
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ARMY TM 5-6115-632-14&PAIR FORCE TO-35C2-3-491-1
APPENDIX A
REFERENCES
A1. Scope. This appendix lists all pamphlets, forms, technical manuals, specifications andmiscellaneous publications referenced in this manual.
A-2. Forms and Records.
Air Force Maintenance Management Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Technical Order System Publication Improvement Report
and Reply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Recommended Changes to Publications and Blank Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Depreservation Guide for Vehicles and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Consolidated Index of Army Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .The Army Maintenance Management System (TAMMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Quality Deficiency Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-3. Military Specifications.
Chemical Agent Resistant Aliphatic Polyurethane Coating. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Identification Marking of U.S. Military Property. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Identification Marking of Combat and Tactical Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Treatment and Painting of Materiel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4. Technical Manuals.
Fabric Repairing, Tents, Canvas, Webbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operator and Organizational Maintenance Manual for Generator
Set, Diesel Engine Driven, Tactical Skid Mounted, 10 KW,1 Phase, 2 Wire; 1 Phase, 3 Wire and 3 Phase, 4 Wire; 120, 12/240and 120/208 V (DOD Model MEP-003A) Utility Class 400 HZ
(6115-00-465-1027) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Organizational, Direct Support and General Support Maintenance
Repair Parts and Special Tools List (Including DepotMaintenance Repair Parts and Special Tools) for Generator Sets,Diesel Engine Driven, Tactical Skid Mounted, 10 KW, 1 Phase,2 Wire; 1 Phase, 3 Wire; 3 Phase, 4 Wire, 120, 120/240 and120/208 V (DOD Model MEP-003A) Utility Class, 60 HZ(NSN 6115-00-465-1030) and (Model MEP-112A), Utility Class,400 Hz (6115-00-465-1O27) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate (Field) (Direct and General Support) and DepotLevel Maintenance Manual for Generator Set, Diesel EngineDriven, Tactical Skid Mounted, 10 KW, 1 Phase, 2 Wire;1 Phase, 3 Wire; 3 Phase, 4 Wire, 120, 120/240 and
120/208 V (DOD Model MEP-003A), Utility Class, 60 HZ(NSN 6115-00-465-1030) and (Model MEP-112A), Utility Class,400HZ (6115-00-465-1027) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedures for Destruction of Equipment to PreventEnemy Use (Mobility Equipment Command). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AFM-66-1
AFTO Form 22DA Form 2028
DA Form 2258DA Form 2404DA Form 2407DA PAM 310-1
DA PAM 738-750
SF 368
MIL-C-46168
MlL-STD-130MlL-STD-642MIL-T-704
FM 10-16
TM 5-6115-585-12
TM 5-6115-585-24P
TM 5-6115-585-34
TM 750-244-3
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Operators, Organizational, Direct Support and General SupportMaintenance Manual Including Repair Parts and Special ToolsList for Trailer, Cargo: 3/4-Ton, 2-Wheel, M101(NSN 2330-00-738-9509), M101AI (2330-00-898-6779),M101A2 (2330-01-101-4697) and Chassis, Trailer 3/4-Ton, 2-Wheel, M1 16 (2330-00-542-5987), M116A1 (2330-00-898-6780)and M116A2(2330-01-101-8434). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2330-202-14&P
Organizational, Direct Support, and General Support CareMaintenance and Repair of Pneumatic Tires and InnerTubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... TM 9-2610-200-24
Air Force Technical Order System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TO-00-5-1Painting and Marking of USAF Aerospace Ground Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . TO 35-1-3
Processing and Inspection of Aerospace Ground Equipmentfor Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TO 35-1-4
Processing and Inspection of Non-Mounted, Non-AircraftGasoline and Diesel Engines for Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TO 38-1-5
Lubrication Order, Generator Set,Diesel Engine Driven, TacticalSkid Mounted, 10KW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L 05-6115-585-12
A-5. Technical Bulletins.
Preservation of USAMECOM Mechanical Equipment forShipment and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 740-97-2
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APPENDIX B
COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS
Section I INTRODUCTION
B-1. Scope. This appendix lists components of end item and basic issue items for the power unit to:help you inventory items required for safe and efficient operation.
B-2. General. The Components of End Item and Basic Issue Items Lists are divided into the followingsections.
a. Section II. Components of End Item. This listing is for informational purposes only, and is notauthority to requisition replacements. These items are part of the end item, but are removed and sep-arately packaged for transportation or shipment. As part of the end item, these items must be with theend item whenever it is issued or transferred between property accounts. Illustrations are furnished toassist you in identifying the items.
b. Section III. Basic Issue Items. These are the minimum essential items required to place thepower unit in operation, to operate it, and to perform emergency repairs. Although shipped sepa-rately packaged, Bll must be with the power unit during operation and whenever it is transferred be-
tween property accounts. The illustrations will assist you with hard-to-identify items. This manual isyour authority to request/requisition replacement Bll, based on TOE/MTOE authorization of the enditem.
B-3. Explanation of Columns. The following provides an explanation of columns found in the tabularlistings:
a. Column (1), Illustration Number (IIIus No.). This coIumn indicates the number assigned to