TECHNICAL MANUAL OPERATOR, ORGANIZATIONAL, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)

Transcription

1 TECHNICAL MANUAL OPERATOR, ORGANIZATIONAL, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) TRAILER, SUPPORT UNIT (57958) NSN FOR AN/TSQ-1 38 DISTRIBUTION RESTRICTION: Distribution authorized to U.S. Government agencies only, to protect technical or operational information from automatic dissemination. Other requests for this document will be referred to: Commander, U.S. Army CECOM Intelligence Material Management Center, ATTN: SELIM-TE, Vint Hill Farms Station, Warrenton, Virginia DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of content or reconstruction of the document. This publication is not available through AG Publications. Requisition through U.S. Army CECOM Intelligence Materiel Management Center, Vint Hill Farms Station, Warrenton, VA HEADQUARTERS, DEPARTMENT OF THE ARMY 1 NOVEMBER 1993

2 WARNING Personnel must be clear from under the trailer during set-up or take-down rations. WARNING Generator output switch must be off and generator not operating while handling power cable and connecting power cable to the using equipment. WARNING Fuel leaks must be repaired before any operation of the trailer or generator. WARNING When filling the fuel tanks, maintain metal-to-metal contact between fuel tank filler neck and fuel nozzle to prevent sparks from static electricity. There should be no smoking or open flame within 50 feet of the fueling operation. WARNING Flammable material. Drain fuel into approved container (see page x). WARNING To avoid injury, protect face when opening drain valve. WARNING Generator must be shut down before performing any maintenance on the critical system. WARNING No smoking or open flames allowed within 50 feet during fuel system maintenance. WARNING Do not position head beneath drain valve area. WARNING The fumes of trichlorotrifluorethane cleaning fluid are toxic. Avoid breathing vapors for long periods. Use only in a well ventilated area. Do use near heat or open flame. Death or serious injury may result.

3 WARNING WARNING HIGH VOLTAGE IS USED IN THE OPERATION OF THIS EQUIPMENT DEATH ON CONTACT MAY RESULT IF PERSONNEL FALL TO OBSERVE SAFETY PRECAUTIONS NEVER WORK ON ELECTRONIC EQUIPMENT UNLESS THERE IS ANOTHER PERSON NEARBY WHO IS FAMILIAR, WITH THE OPERATION AND HAZARDS OF THE EQUIPMENT AND WHO IS COMPETENT IN ADMINISTERING FIRST AID. WHEN THE TECHNICIAN IS AIDED BY OPERATORS HE MUST WARN THEM ABOUT DANGEROUS AREAS. WHENEVER POSSIBLE THE POWER SUPPLY TO THE EQUIPMENT MUST BE SHUT OFF BEFORE BEGINNING WORK ON THE EQUIPMENT. TAKE PARTICULAR CARE TO GROUND EVERY CAPACITOR LIKELY TO HOLD A DANGEROUS POTENTIAL WHEN WORKING INSIDE THE EQUIPMENT. AFTER THE POWER HAS BEEN TURNED OFF ALWAYS GROUND EVERY PART BEFORE TOUCHING IT. BE CAREFUL NOT TO CONTACT HIGH VOLTAGE CONNECTIONS OF 115 VOLT AC INPUT CONNECTIONS WHEN INSTALLING OR OPERATING THIS EQUIPMENT. WHENEVER THE NATURE OF THE OPERATION PERMITS. KEEP ONE HAND AWAY FROM THE EQUIPMENT TO REDUCE THE HAZARD OF CURRENT FLOWING THROUGH VITAL ORGANS OF THE BODY. WARNING DO NOT BE MISLED BY THE TERM "LOW VOLTAGE'. POTENTIALS AS LOW AS 50 VOLTS MAY CAUSE DEATH UNDER ADVERSE CONDITIONS a

4 5 SAFETY STEPS TO FOLLOW IF SOMEONE IS 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 ELECTRICAL POWER, PULL, PUSH, OR LIFT THE PERSON TO SAFETY USING A DRY WOODEN POLE OR A DRY ROPE OR SOME OTHER INSULATING MATERIAL SEND FOR HELP AS SOON AS POSSIBLE AFTER THE INJURED PERSON IS FREE OF CONTACT WITH THE SOURCE OF ELECTRICAL SHOCK, MOVE THE PERSON A SHORT DISTANCE AWAY AND IMMEDIATELY START ARTIFICIAL RESUSCITATION IF VICTIM IS NOT BREATHING FOR ARTIFICIAL RESPIRATION REFER TO FM b

5 Technical Manual No &P HEADQUARTERS DEPARTMENT OF THE ARMY Washington, D.C. 1 November 1993 OPERATOR, ORGANIZATIONAL, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) FOR TRAILER, SUPPORT UNIT, (57958) NSN 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 the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form located in the back of this manual direct to: Commander, U.S. Army CECOM Intelligence Materiel Management Center, ATTN: SELIM-TE, Vint Hill Farms Station, Warrenton, VA A reply will be furnished to you. TABLE OF CONTENTS Paragraph Page CHAPTER 1. INTRODUCTION 1-1 Section I. General 1-1 Scope Maintenance forms and records Destruction of Army materiel to prevent enemy use Administrative storage Calibration Reporting of errors Reporting equipment improvement recommendations (EIRs) i

6 TABLE OF CONTENTS - continued Paragraph Page II. Description and data 1-1 Purpose and use Description Differences between models System application Tabulated data CHAPTER 2. SERVICE UPON RECEIPT AND INSTALLATION 2-1 Section I. Systems planning 2-1 Power limitations II. Site and shelter requirements 2-1 Siting Shelter requirements III. Service upon receipt of materiel 2-1 Unpacking Checking unpacked equipment IV. Installation instructions 2-2 Tools, test equipment and materials required for installation Assembly of equipment Installation instructions Special installations V. Preliminary adjustment of equipment 2-2 Adjustments Installation and circuit lineup CHAPTER 3. OPERATING INSTRUCTIONS 3-1 Section I. Controls and instruments 3-1 Damage from improper settings Operator/crew controls II. Operation under usual conditions 3-1 Preliminary starting procedures Initial adjustments Operating procedure III. Operation under unusual conditions 3-4 Special instructions IV. Preparation for movement 3-5 Moving procedures Pre-hookup inspection CHAPTER 4. OPERATOR/CREW MAINTENANCE INSTRUCTIONS 4-1 Section I. Tools and equipment 4-1 Maintenance items II. Lubrication instructions 4-1 Trailer, support unit lubrication ii

7 TABLE OF CONTENTS - continued Paragraph Page III. Preventive maintenance checks and services (PMCS) 4-1 General Special instructions Preventive maintenance checks and services procedures IV. Troubleshooting 4-7 General V. Operator/crew maintenance of trailer, support unit 4-8 Maintenance restrictions CHAPTER 5. ORGANIZATIONAL MAINTENANCE INSTRUCTIONS 5-1 Section I. Tools and equipment 5-1 General II. Repainting and refinishing instructions 5-1 Painting instructions Stenciling instructions III. Lubrication instructions 5-1 Cleaning Lubrication points IV. Preventive maintenance checks and services (PMCS) 5-4 General V. Troubleshooting 5-6 Scope VI. Maintenance of Trailer, Support Unit 5-6 General MEP-114A generator set Remove/replace tie-down straps Replace cable assembly, W Remove/replace storage box (left and right) Test cable assembly, W Test power cable assembly Repair storage box (left and right) Replace generator power cable assembly Remove/replace cable reel CHAPTER 6. FUNCTIONING OF EQUIPMENT 6-1 Section I. Fuel system 6-1 Generator fuel sources II. Generator power cable and bracket 6-1 Power hookup CHAPTER 7. DIRECT SUPPORT MAINTENANCE INSTRUCTIONS 7-1 Section I. General 7-1 General instructions Tools and equipment iii

8 TABLE OF CONTENTS - continued Paragraph Page II. Preventive maintenance checks and services (PMCS) 7-1 Instructions III. Troubleshooting 7-2 General IV. Maintenance of trailer, support unit 7-2 General Remove/replace fuel tank Clean/replace check valve Replace fuel filter Replace fuel system hoses Remove/replace generator Remove/replace fire extinguisher bracket Remove/replace liquid container bracket Remove/replace ladder assembly V. Direct Support testing procedures 7-10 General CHAPTER 8. GENERAL SUPPORT MAINTENANCE INSTRUCTIONS 9-1 CHAPTER 9. MATERIEL USED IN CONJUNCTION WITH MAJOR ITEM 9-1 APPENDIX A. REFERENCES A-1 B. COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS B-1 C. ADDITIONAL AUTHORIZATION LIST C-1 D. MAINTENANCE ALLOCATION CHART FOR TRAILER, SUPPORT UNIT D-1 E. REPAIR PARTS AND SPECIAL TOOLS LIST E-1 F. EXPENDABLE SUPPLIES AND MATERIALS LIST F-1 INDEX Index-1 iv

9 LIST OF ILLUSTRATIONS Figure Page 1-1. Support Unit Fuel System (Trailer--Underside View) Stenciling Information Leveling Jack Air Assembly Lubrication Points (2 sheets) Fuel Filter Tie-Down Straps Power Cable and Bracket Fuel Tank Fuel Tank Outlet Assembly Fuel Filter Assembly Generator Set Removal (Three-Quarter Front View) Liquid Container Bracket Assembly B-1. End Item Components... B-3 B-2. Basic Issue Items... B-4 E-1. Trailer, Support Unit (3 Sheets)... E-8 E-2. Ladder Assembly... E-14 E-3. Fuel Tank Assembly... E-16 E-4. Fuel System (Trailer--Underside View)... E-18 E-5. Bracket Assembly, Power... E-20 E-6. Reel, Cable Assembly... E-22 E-7. Storage Box Assembly... E-24 E-8. Special Tools.... E-26 v

10 LIST OF TABLES Number Title Page 1-1. Items Comprising an Operable Equipment Preparation for Movement Checklist Operator/Crew PMCS for Movement Operations Operator/Crew PMCS During On-Site Operations Troubleshooting (Operator/Crew) Lubrication Specifications Organizational Preventive Maintenance Checks and Services Troubleshooting (Organizational) Direct Support Preventive Maintenance Checks and Services Troubleshooting (Direct Support) vi

11 SAFETY SUMMARY The following are precautions that are not related to any specific procedures and therefore do not appear elsewhere in this publication. These are precautions that personnel must understand and apply during operation and maintenance. Three major hazard areas have been identified with this unit. 1. High Power KEEP AWAY FROM LIVE CIRCUITS Operating personnel must at all times observe all safety regulations and all high voltage warnings in this technical manual. To avoid casualties, always shut down the generator before you perform any maintenance on the electrical system. DO NOT SERVICE OR ADJUST ALONE Under no circumstances should any person attempt to operate or service the generator or electrical system except in the presence of someone who is capable of rendering aid. RESUSCITATION Personnel working with or near high voltages should be familiar with modern methods of resuscitation. Such information may be obtained from the Bureau of Medicine and Surgery. The following warning appears in the text of this manual, and is repeated here for emphasis. WARNING Generator must be shut down before performing any maintenance on the electrical system. 2. Flammable Material REFUEL WITH EXTREME CARE Operating personnel must at all times observe all safety regulations and all fuel handling warnings in this technical manual. Be sure to maintain metal-to-metal contact between fuel tank filler neck and fuel nozzle to prevent sparks from static electricity. DO NOT REFUEL ALONE Under no circumstances should any person attempt to refuel except in the presence of someone who is capable of rendering aid. vii

12 SAFETY SUMMARY continued RESUSCITATION Personnel working with volatile or explosive fuel should be familiar with modern methods of resuscitation and burn first aid. Such information may be obtained from the Bureau of Medicine and Surgery. The following warnings appear in the text of this technical manual, and are here repeated for emphasis. WARNING The fumes of trichlorotrifluorethane cleaning fluid are toxic. Avoid breathing vapors for long periods. Use only in a well ventilated area. Do not use near heat or open flame. Death or serious injury may result. WARNING No smoking or open flames allowed within 50 feet of the unit during fuel system maintenance or refueling operations. DO NOT DRAIN FUEL ONTO GROUND WARNING Flammable material. Drain into approve container. Fuel removed from fuel tanks must be placed only into fuel cans or into fuel tanks of vehicles/equipment which use the same type of fuel. 3. High Pressure Air Maintenance personnel must at all times observe all safety regulations pertaining to accidental release of high pressure air. To avoid casualties when performing maintenance on any part of the air system, always open draincock on air reservoir and bleed air from system. The following warning appears in the text of this technical manual, and is repeated here for emphasis. WARNING Accidental or intentional release of high pressure (up to 105 psi) air could cause severe injury to eyes and skin of personnel. viii

13 SAFETY SUMMARY - continued WARNING TRICHLOROTRIFLUOROETHANE, TRICHLOROETHANE and similar chemical solvents will no longer be used for ordinary cleaning of equipment. These substances threaten public health and the environment by destroying ozone in the earth's upper atmosphere. Suitable non-hazardous cleaning materials will be used instead, such as a clean cloth, water and mild detergent or an approved substitute solvent, such as isopropyl alcohol. ix

14 TRAILER, SUPPORT UNIT (TSU) 1-0

15 CHAPTER 1 INTRODUCTION Section I. GENERAL 1-1. Scope. This technical manual contains the operating instructions for operator, organizational, direct support, and general support maintenance for the trailer, support unit Maintenance Forms and Records. Department of the Army forms and procedures used for equipment maintenance will be those prescribed by TM (TAMMS) Destruction of Army Materiel to Prevent Enemy Use. See TM covering the destruction of Army materiel to prevent enemy use Administrative Storage. For test procedures, forms and records, and inspections required during administrative storage of this equipment, refer to TM , Administrative Storage of Equipment Calibration. The trailer, support unit requires no calibration. Refer to TM for calibration requirements for the MEP-114A generator set Reporting of Errors. The reporting of errors, omissions, and recommendations for improving this publication by the individual user is encouraged. Reports should be submitted on DA Form 2028 (Recommended Changes to Publications) and forwarded directly to the Commander, U.S. Army Electronics Materiel Readiness Activity, Vint Hill Farms Station, Warrenton, Virginia 22186, Attn: SELEM-ME-E Reporting Equipment Improvement Recommendations (EIRs). EIRs will be submitted on SF 368, Quality Deficiency Report, in accordance with TM (TAMMS). EIRs should be mailed directly to the Commander, U.S. Army Electronics Materiel Readiness Activity, Vint Hill Farms Station, Warrenton, Virginia 22186, Attn: SELEM-ME-F. A reply will be furnished directly to you. Section II. DESCRIPTION AND DATA 1-8. Purpose and Use. The trailer, support unit (Fig. 1-1) is used to provide 115/208-Vac, 400-Hz, 3-phase power in support of field mission equipment Description. The trailer, support unit consists of a MEP-114A 30 kw diesel generator set, an XM ton flatbed trailer and the following miscellaneous equipment items: The generator fuel system, storage boxes, fire extinguishers, folding stairs, cable reel, ladder, and various tie downs. a. Fuel System. The fuel system (Fig. 1-2) includes two fuel tanks, fuel lines, control valves, fittings, and a fuel filter system. The fuel system is connected to the generator set at the fuel selector valve on the generator. Each fuel tank has a capacity of 113 gallons of diesel fuel. When full, the system provides fuel for 72 hours of continuous operation of the generator. b. Power cable. A 50-foot power cable which connects the generator to the using equipment is stored on a reel on the forward deck of the trailer (Fig. 1-1). Power is transferred to the external power cable via the generator power cable bracket (Fig. 1-1) mounted near the generator set on the trailer deck. 1-1

16 Figure 1-1. Support Unit 1-2

17 Figure 1-2. Fuel System (Trailer--Underside View) 1-3

18 c. Storage Box. A storage box is mounted at the rear of the trailer on each side (Fig. 1-1). Each box is equipped with a tray and tiedown straps. d. Fire Extinguisher. A GFE fire extinguisher is located on the left rear corner of the trailer (Fig. 1-1). e. Ladder Assembly. A ladder assembly is mounted on the left side of the trailer for access to the generator set (Fig. 1-1). A vehicular boarding ladder is strapped to the rear of the trailer. f. Cable Reels. Cable reels are mounted on left and right rear storage boxes Differences Between Models. All models of the trailer unit are identical System Application. The trailer, support unit provides 30 kw of 115/208 Vac, 400-Hz, 3-phase power to using equipment Tabulated Data. c. Specifications. The following specifications pertain to the trailer, support unit, less the generator set (refer to TM ). For the XM-1034, refer to TM &P. Model Designation: Overall Length: Deck Height: Overall Width: Weight, Maximum Cross-Country Towed Load: Total Weight With Fuel: EIC MOD 238 inches 36 inches, laden 96 inches 15,760 pounds 12,890 pounds a. Items Comprising an Operable Equipment. See Table 1-1. b. Stenciled Information. Stenciled information on the trailer, support unit is shown in Fig Maximum Towing Speed Highway: Unimproved Road: 50 mph 25 mph 1-4

19 Table 1-1. Items Comprising an Operable Equipment Part Height Depth Width Weight NSN Item Number Qty (in) (in) (in) (lb) Generator Set, 30 kw MEP-114A ,000 ac Fuel Tank, Front C Fuel Tank, Rear C / / Storage Box Assembly Ladder Assembly /2 7-1/4 19-3/4 20 Bracket Assembly, / Power Connector Cable Reel / Cable, Power Stored on Cable Reel Fire Extinguisher O-E /4 8-1/8 5-1/4 17-1/2 Cable Reel Ladder Assy C Cable Assy Stored on Cable Reel Cable Assy Stored on Cable Reel 1-5

20 STENCILED DATA A - GROUND RODS STORAGE B - AIR DUCTS STORAGE C - FLAMMABLE NO SMOKING WITHIN 50 FEET D - VEHICLE BOARDING LADDER STORAGE HOOK STYLE LADDER STORAGE E - CAPACITY 113 GALLONS F - WARNING NOISE AREA MAY CAUSE HEARING LOSS USE EAR PROTECTION G - NO SMOKING WITHIN 50 FEET Figure 1-3. Stenciling Information 1-6

21 CHAPTER 2 TM &P SERVICE UPON RECEIPT AND INSTALLATION Section I. SYSTEMS PLANNING 2-1. Power Limitations. The 50-foot power cable limits the distance from the using equipment the trailer, support unit must be parked. The MEP-114A generator set provides 3 phase, 400 hertz alternating current at 30 kw for up to 72 hours of continuous operation without refueling. The generator set can be used to power any equipment requiring 400 hertz input. Section II. SITE AND SHELTER REQUIREMENTS 2-2. Siting. The trailer, support unit can be positioned as needed with practically no limitations. The selected site should be fairly level and make maximum use of natural protective barriers while allowing enough space on all sides for service and maintenance. The soil of the site should be firm and well drained. In areas where the soil will not support the generator trailer, use planks or other suitable material as dunnage. The selected site must provide for access to the unit by towing and fueling vehicles Shelter Requirements. The trailer, support unit requires no sheltering during movement or operation. However, during periods in which the unit will be positioned in one place for prolonged periods of time, considerations should be given to sheltering the unit from extended exposure to extremes of sunlight, humidity, blowing sand, etc., which can be detrimental to the tires, paint, metallic and electrical portions of the trailer, generator set, and miscellaneous equipment. a. For operator/crew and organizational maintenance, no shelter provisions are required. b. Maintenance of the trailer, support unit will require a work space of approximately 24 feet by 30 feet. Section III. SERVICE UPON RECEIPT OF MATERIEL 2-4. Unpacking. Use tow vehicle to position the trailer in the desired position. a. Banding and Tiedowns. Remove all banding and movement tiedown straps from the equipment. b. Protective Coverings. Remove all tarpaulins, plastic sheeting, etc., used as protective covering for the equipment during movement. c. MEP-114A Generator. Refer to TM and accomplish all receiving actions pertaining to the generator set. d. XM-1034 Trailer. Refer to TM &P Checking Unpacked Equipment. a. Damage Inspection. Inspect the equipment for damage incurred during shipment. (Refer to Fig. 1-1 for location of components.) If the equipment has been damaged, report the damage on SF 364. b. Discrepancies. Check the equipment against the component listing in Appendix B, Section II and the packing slip to determine if the shipment is complete. Report all discrepancies in accordance with TM (TAMMS). The equipment should be placed in service even though a minor assembly or part that does not affect proper functioning is missing. 2-1

22 c. Modifications. Check to see whether the equipment has been modified. (Equipment that has been modified will have the Modification Work Order (MWO) number on the drawbar, near the identification plate.) Check to see whether all currently applicable MWO's have been accomplished. (Current MWO's applicable to the equipment are listed in DA PAM ) Section IV. INSTALLATION INSTRUCTIONS 2-6. Tools, Test Equipment and Materials Required for Installation. The trailer, support unit requires no.tools, test equipment or material for installation. After the procedures in paragraphs 2-4 and 2-5 have been performed, the generator set can be prepared for operation. Refer to TM for data on the MEP-114A generator set Assembly of Equipment. The trailer, support unit as received requires no assembly to prepare it for operation Installation Instructions. The trailer, support unit requires no installation. a. Interconnections. The trailer, support unit and generator set are interconnected as received and require no on-site interconnections to be made. b. Installation of Plug-In Items. No plug-in items are provided as part of the unit Special Installations. The trailer, support unit requires no special installations. Section V. PRELIMINARY ADJUSTMENT OF EQUIPMENT Adjustments. Refer to TM &P for trailer adjustments. Refer to TM for preliminary adjustments of the MEP-114A generator set that must be accomplished prior to initiating operation Installation and Circuit Lineup. a. External Connections. Unreel power cable from cable reel to connect the generator output to the using equipment. In laying cable between trailer, support unit and using equipment, allow sufficient slack for terrain or other obstructions so that the cable is not a hazard to pedestrian or vehicular traffic. Bury or support cable as necessary to produce a safe interconnection path. WARNING Generator output switch must be off and generator not operating while handling power cable and connecting power cable to the using equipment. Insert cable plugs into receptacles on trailer and using equipment and securely tighten both couplers. b. Switch Settings, Patch Panel Connections, and internal Control Settings. Not applicable to trailer unit. Refer to TM for data pertaining to the MEP-114A generator set. c. Circuit Lineup. Not applicable to the trailer, support unit. 2-2

23 CHAPTER 3 OPERATING INSTRUCTIONS Section I. CONTROLS AND INSTRUMENTS 3-1. Damage From Improper Settings. a. For damage that may be incurred from improper settings of the controls relative to movement of the trailer, refer to TM &P. b. For damage due to improper setting of generator controls, refer to TM Operator/Crew Controls. (Refer to Fig. 1-1 for location of controls.) a. Generator Set. For generator controls, refer to TM b. XM For trailer controls, refer to TM &P. Section II. OPERATION UNDER USUAL CONDITIONS 3-3. Preliminary Starting Procedures. a. Set Both Parking Brakes. (See TM &P.) Block wheels, front and back. b. Lower the four leveling jacks by pulling out the lock pins and manually lowering them to the vertical position. Reinsert the lock pins to lock the jacks in the vertical position (refer to Fig. 3-1). c. Close air valve on tow vehicle and open draincock on trailer s air reservoir (Fig. 3-2). Disconnect the Service and Emergency air hoses from the tow vehicle. Connect the hoses to the dummy couplings on the underside of the drawbar. d. Disconnect the intervehicular power cable from the tow vehicle and stow receptacle in the clip on the drawbar. e. Unhook safety chains from tow vehicle. f. Remove latch pin and open pintle. g. Lower each of the two front jack pads to the surface using the hand cranks. h. Using the two front leveling jacks, raise the trailer sufficiently to release the lunette from the pintle on the tow vehicle. Move tow vehicle clear of the trailer. i. Using the two front leveling jacks, lower trailer enough to allow rear leveling jacks to be lowered to vertical position. j. Lower rear leveling jacks by pulling out lock pins and manually lowering jacks to the vertical position. k. Insert lock pins to lock jacks in place. l. Visually check that trailer is level. If not, use hand cranks to adjust jack pads. m. Refer to MIL-G-28554A for processing of the fuel system and the fuel tanks. n. Refer to TM for processing of the MEP-114A generator set. o. Refer to TM for grounding requirements for the MEP-114A generator set. Ground rod sections are stored in the storage boxes on either side of the trailer, support unit. The grounding cable for the generator set is stowed on the power cable bracket assembly. Connect grounding cable from generator to the ground rod, using the cable connector. p. Prior to fueling the unit, perform the following checks. 3-1

24 Figure 3-1. Leveling Jack 3-2

25 Figure 3-2. Air Assembly 3-3

26 WARNING Fuel leaks must be repaired before any operation of the trailer or generator. (1) Inspect fuel tanks for leaks and tightness of filler cap. (2) Inspect fuel lines for condition and verify that they are connected to the generator. (3) Verify that fuel shutoff valve is in the open position. NOTE Shutoff valve will be open except for fuel line repairs or in the event of a fuel line leak. q. To fill fuel tanks: (1) Remove filler cap. WARNING When filling the fuel tanks, maintain metal-to-metal contact between tank filler neck and fuel nozzle to prevent sparks from static electricity. There shall be no smoking or open flames within 50 feet of the fueling operation. (2) Insert nozzle and fill tank with appropriate amount of fuel. (3) Install fuel tank filler cap. (4) Repeat above steps 1, 2, and 3 for second fuel tank Initial Adjustments. Not applicable to trailer. Refer to TM for prestarting procedures for the generator set Operating Procedure. Refer to TM for generator set starting procedures, normal operating checks (oil pressure, temperature, voltage, etc.) and shutdown procedure. Section III. OPERATION UNDER UNUSUAL CONDITIONS 3-6. Special Instructions. In addition to the operating procedures described for usual conditions, special instructions for operating and servicing the trailer, support unit under unusual conditions are contained or referenced herein. In addition to normal preventive maintenance service, special care in cleaning and lubrication must be observed where extremes of temperature, humidity, and terrain conditions are present or anticipated. Proper cleaning, lubrication, and storage and handling of fuels and lubricants not only ensure proper operation and functioning, but also guard against excessive wear of the working parts and deterioration of the materials. a. Extreme Cold Weather Conditions. Extensive preparation of material scheduled for operation in extreme cold weather is necessary. Generally, extreme cold weather causes lubricants to thicken or congeal, cracks insulation, causes electrical short circuits and various construction materials to become hard, brittle, and easily damaged or broken. CAUTION It is imperative that the approved practices and precautions be followed. TM contains information which is specifically applicable to this trailer unit as well as to other vehicles. 3-4

27 b. Extreme Hot Weather Conditions. Do not park the trailer, support unit in the sun for long Periods of time as the heat and sunlight will lead to deterioration of painted surfaces. If possible, park the trailer, support unit under cover to protect it from sun, sand, and dust. Cover inactive trailer with tarpaulins if no other suitable shelter is available. Metallic parts inactive for long periods in hot, humid weather, are subject to rapid rusting and accumulation of fungi growth. Frequently inspect, clean, and lubricate to prevent excessive deterioration. c. Operation under extremely sandy conditions necessitates frequent inspection, cleaning, and lubrication of the chassis working parts. d. When moving the trailer, support unit over rough or rocky ground, care must be exercised by the tow vehicle driver to minimize the shock. Correct tire pressure must be maintained to preclude damage. Refer to TM &P. e. After operation in unusual conditions, remove ice, snow, mud, etc., from trailer, support unit and from hoses, tubes, and electrical connections. f. Operation Under Emergency Conditions. (1) Fuel tank leaking: Stop generator, close fuel shut-off valve under leaking fuel tank, and drain fuel into approved fuel container(s). (See page x.) Utilize other fuel tank until leaking tank can be replaced as described in paragraph 7-6. (2) Leaking fuel line: Stop generator, close fuel shut-off valve feeding leaking fuel line. Utilize other fuel tank and lines until leaking fuel line can be replaced. (3) Clogged fuel line: (a) Switch: to other fuel tank and resume operation. (b) Close fuel shut-off valve feeding clogged fuel line. (c) Disconnect fuel line at fuel shut-off valve. (d) With small container in hand to prevent spillage, open fuel shutoff valve to determine if fuel is flowing through the bottom tank plate fittings and shut-off valve. (See Fig. 7-2.) (e) If there is no fuel flow, close valve, drain fuel tank, and replace or unclog fittings as required. (See page x.) (f) If fuel flow occurs, close valve, disconnect fuel line at inlet side of check valve (see Fig. 1-2). (g) Using prime mover air hose, blow air through the fuel line from the check valve end to the shut-off valve end of the fuel line. (h) Ensure that fuel filter is free of sediment, particulates, and water, and that inlet and outlet ports are clear. (i) Disconnect fuel line at fuel filter outlet and at generator (see page x). Blow air through fuel line from generator end to fuel filter end. (j) Reconnect all fuel lines, reprime the system, and resume operation. Section IV. PREPARATION FOR MOVEMENT 3-7. Moving Procedures. The following procedures should be followed when preparing the trailer, support unit for movement. a. Power down the generator set and prepare it for movement as directed in TM

28 WARNING Generator output switch must be off and generator not operating while handling power cables. b. Disconnect power cable from trailer and using equipment, rewind cable onto cable reel and secure cable reel with lock pin. The cable reel winch can be operated by using one of the leveling jack hand cranks. c. Disconnect grounding cable from the ground rod. Coil cables and stow in storage box. d. Disconnect generator ground cable from ground rod and secure on hooks on side of power cable bracket assembly Prehookup Inspection. Perform the sequential steps as listed in Table 3-1. Note: Refer to Figures 1-1 through 1-3 for location of items. Table 3-1. Preparation for Movement Checklist Sequence Item Inspect For 1 Generator Set a. All switches and controls in shutdown position as shown in TM b. Loose hardware c. Access doors closed and latched. 2 Fuel System a. Leaks, damaged lines, loose couplings or loose filler caps. b. Fuel shutoff valves in open position. 3 Cable Reel a. Power cable connector secured in the bracket on trailer deck and tiedown strap is tight. b. Cable reel lock pin in locked position. c. Dust cap on power cable receptacle in position and tight. 4 Ladder Assembly a. Ladder properly stored and the two latches properly secured. 5 Storage Boxes a. General condition of boxes, hinges and latching mechanism. b. Ground rods, air ducting, and other items are properly secured by tiedown straps. c. Doors closed and latched. 6 Fire Extinguisher a. General condition and that it is locked in position. b. Seal not broken. 7 Ladder a. Hook ladder properly secured by two tiedown straps. b. Condition of tiedown straps. 8 Cable Reels (to a. Serviceability include cable assemblies 3-6

29 CHAPTER 4 TM &P OPERATOR/CREW MAINTENANCE INSTRUCTIONS Section I. TOOLS AND EQUIPMENT 4-1. Maintenance Items. The tools and equipment issued with or authorized for use by the operator for maintenance of the trailer, support unit are listed in the Maintenance Allocation Charts, Appendix D of this manual. Section II. LUBRICATION INSTRUCTIONS 4-2. Trailer, Support Unit Lubrication. Refer to the organizational maintenance instructions in Chapter 5 for lubrication to be accomplished. Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 4-3. General. The purpose of PMCS is to detect first signs of electrical and mechanical failures of assemblies in the materiel, and to ensure that appropriate corrective action is taken before expensive and time consuming repairs or replacements are required. The PMCS system is based on frequent inspections and services accomplished by the equipment operator. Those repair services requiring higher level assistance are included in Organizational Maintenance Instructions (Chapter 5) and Direct Support Maintenance Instructions (Chapter 7). Refer to Tables 4-1 and 4-2 for operator/crew PMCS on the trailer, support unit. Refer to TM for operator/crew PMCS on the MEP-114A generator set and to TM &P for the Flatbed Trailer. a. Before You Operate. Always keep in mind the CAUTIONS and WARNINGS. Perform your Before (B) PMCS. b. While You Operate. Always keep in mind the CAUTIONS and WARNINGS. Perform your During (D) PMCS. c. After You Operate. Be sure to perform your After (A) PMCS. d. If the Equipment Fails to Operate. Troubleshoot with proper equipment. Report any deficiencies using the proper forms. See TM Special Instructions. The principal criteria for determining the frequency of PMCS is hours of operation. If this is not practical for the trailer, support unit, the daily/monthly intervals will be used for operator PMCS actions. Operation under adverse conditions may require preventive maintenance services to be performed more frequently. NOTE If the equipment must be kept in continuous operation, check and service only those items that can be checked and serviced without disturbing operation. Make the complete checks and services when the equipment can be shut down Preventive Maintenance Checks and Services Procedures. The following general procedures apply to PMCS and to all inspections and are just as important as the specific procedures. a. Inspections. To check that items are in good condition, correctly assembled or stowed, secure, not 4-1

30 excessively worn, not leaking, and adequately lubricated apply to most items in the PMCS. Any or all of these checks that are pertinent to any item (including supporting, attaching, or connecting members) will be performed automatically, as general procedures, in addition to any specific procedures given. (1) Inspection for good condition is usually visual inspection to determine if the unit is safe and serviceable; not bent, twisted, chafed, burned, broken, cracked, bare, frayed, dented, collapsed, torn, cut, or deteriorated. (2) Inspection of a unit to see if it is correctly assembled or stowed, is usually a visual inspection to see if the unit is in its normal position on the vehicle, and if all its parts are present and in their correct relative positions. (3) Inspection of a unit to see if it is secure is usually a visual and physical inspection for tightness of the unit. This inspection will include all brackets, lockwashers, locknuts, locking wires, cotter pins, and tiedown straps as well as any connecting hoses, tubes, or wires. b. Operator's Daily PMCS. The daily PMCS is a systematic inspection of the trailer, support unit each day it is operated so that defects may be discovered and corrected before they result in serious damage or failure. (1) Before Operation Service. This is a brief service to ascertain that the materiel is ready for operation; it is mainly a check to determine if conditions affecting the materiel's readiness have changed since the last After Operation service. (2) During Operation Service. This service consists of detecting unsatisfactory performance, or other indications of malfunction of any part of the unit. (3) After Operation Service. This service consists of investigating any deficiencies noted during operation and repeating part of the Before Operation Service. It is the basic daily service for tactical materiel and consists of correcting any operating deficiencies. (4) Daily Service. This consists of a visual and physical inspection of the entire trailer, support unit to ensure that all items are in a safe and serviceable condition. See Table 4-2. c. Specific Procedures For Operators. Table 4-1 gives the specific procedures to be performed on the trailer, support unit during movement operations. The symbol in the interval column means that the procedure opposite it should be performed in the sequence indicated during that part of the daily service where the number appears (before, during or after operation). The procedures given in Table 4-2 are to be performed on a daily basis while the trailer, support unit is parked. 4-2

31 Table 4-1. Operator/Crew PMCS for Movement Operations TM &P Note: Refer to TM for PMCS of Generator Set MEP-114A. Refer to TM &P for PMCS for Flatbed Trailer. B = Before Operation D = During Operation A = After Operation Item Interval Item to be Movement Operations Procedures Actions Following Procedure No. B D A Inspected 1 Fuel System WARNING Fuel leaks must be repaired before any operation of the trailer, support unit. a. Visually check all tubing and a. If Indications suggest a fuel connections for any sign of a leak, notify organizational fuel leak. maintenance. WARNING Flammable material. Drain fuel Into an approved container. b. Open drain valve on fuel filter b. Close drain valve when fluid (Fig. 1-2 for location) and stops draining. drain water from filter. 2 Entire Trailer, a. Visually check all equipment a. Notify organizational mainte- Support Unit Installed on trailer deck for nance of any damage discovered. any sign of damage since last inspection. 4-3

32 Table 4-1. Operator/Crew PMCS for Movement Operations - Continued Item Interval Item to be Movement Operations Procedures Actions Following Procedure No. B D A Inspected 2 Entire Trailer, b. Visually check storage box and b. Notify organizational malnte- Support Unit tool box door gaskets and nance of any damage discovered. (continued) latching mechanisms for damage. c. Check all tiedown straps for c. If straps are loose, rebuckle damage and tightness. and tighten. If straps are damaged, notify organizational maintenance. d. Physically inspect cable reel, d. Notify organizational malntestorage boxes,. stair assembly, nance if any of the items feel fire extinguisher, power cable loose. bracket assembly, generator mounting bolts, and CBR components (if Installed) for signs of looseness in mounting. 3 Entire Trailer, a. Be alert for any unusual noise a. Investigate and correct, or re- Support Unit or Improper operation of the port to organizational malnteunit. nance, any suspected faults or troubles. 4 Fuel System WARNING Flammable material. Drain fuel into an approved container. 4-4

33 Table 4-1. Operator/Crew PMCS for Movement Operations - Continued B = Before Operation D = During Operation A = After Operation Item Interval Item to be Movement Operations Procedures Actions Following Procedure No. B D A Inspected 4 Fuel System a. Open drain valve on fuel filter a. Close drain valve when fluid (continued) (Fig. 1-2) and drain any con- stops draining. densation collected during movement. WARNING Fuel leaks must be repaired before any operation of the trailer, support unit. b. Visually check fuel tanks, b. If a leak Is suspected, notify tubing, and connections for organizational maintenance. signs of leaks. 5 Entire Trailer, a. Check generator set and all a. Notify organizational mainte- Support Unit other Items mounted on the nance of any damage or loosetrailer deck for signs of ness detected. damage or looseness In mounting. 4-5

34 Table 4-2. Operator/Crew PMCS During On-Site Operations Note: Refer to TM for PMCS of Generator Set. Refer to TM &P for PMCS for Flatbed Trailer. D = Daily W = Weekly M = Monthly Item Interval Item to be Movement Operations Procedures Actions Following Procedure No. B D A Inspected 1 Fuel System a. On a daily basis, visually check a. If any sign of a fuel leak is the entire fuel system for any detected, Immediately cease sign of leaks. operation and notify organizational maintenance of defect. 2 Grounding system a. Check that generator, power a. Notify organizational mainteconnector panel, and grounding nance of any looseness or cable are tight and undamaged. damage to grounding system cables and connections. 3 Entire Trailer, a. Visually check trailer, stor- a. Advise organizational mainte- Support Unit age boxes, cable reel assembly, nance. fuel tanks, and generator for cleanliness, scratches, and damage. 4 Ladder Assembly a. Check ladder assembly to see a. Advise organizational maintethat the cylindrical fastener nance. assemblies are securely attached. 5 Entire Trailer, a. Remove all foreign matter from a. None. Support Unit trailer, support unit. 4-6

35 Section IV. TROUBLESHOOTING 4-6. General. This section contains troubleshooting information and tests to be used by the operator/crew for locating and correcting malfunctions in the trailer, support unit. Trouble shooting is a systematic isolation of defective components by means of an analysis of trouble symptoms, testing to determine the defective component, and applying the remedies. Each malfunction listed in the troubleshooting table (Table 4-3) is followed by a list of probable causes of the trouble and corrective action necessary to remedy the malfunction. This technical manual does not cover all malfunctions that may occur during operation. If a specific malfunction is not covered, proceed to isolate the system in which the malfunction occurs and then locate the defective component. Table 4-3. Troubleshooting (Operator/Crew) Malfunction Probable Cause Corrective Action 1. Fuel leaks. a. Fuel line cracked or a. Stop generator. Close punctured. fuel shutoff valve. Notify organizational maintenance. b. Fuel tank cracked or b. Stop generator. Close punctured. fuel shutoff valve. Notify organizational maintenance. 2. Generator Not a. Fuel tank(s) empty. a. Check and fill fuel Getting Fuel tank(s). b. Fuel filter clogged. b. Stop generator, open filter air vent valve, and filter drain valve. Check for water, sludge, and particulates. c. Fuel line(s) clogged. c. Notify organizational maintenance. d. Shutoff valve on one or d. Open valve to full open. both fuel tanks not fully closed. 4-7

36 NOTE Refer to TM for operator/crew troubleshooting information pertaining to the generator set, and TM &P for Flatbed Trailer. Any malfunction that is beyond the scope of operator/crew shall be referred to organizational maintenance. Section V. OPERATOR/CREW MAINTENANCE OF TRAILER, SUPPORT UNIT Maintenance Restrictions. Operator/crew maintenance of the trailer, support unit is restricted to performing PMCS (Tables 4-1 and 4-2) and troubleshooting (Table 4-3). 4-8

37 CHAPTER 5 ORGANIZATIONAL MAINTENANCE INSTRUCTIONS Section I. TOOLS AND EQUIPMENT 5-1. General. The tools and equipment issued or authorized for use by organizational maintenance for the trailer, support unit are listed in Maintenance Allocation Charts, Appendix D of this manual. a. Tools. (1) Tool kit, General Mechanics: Automotive. b. Test Equipment. Multimeter AN/USM-223. c. Materials. Materials required in support of organizational maintenance are: (1) MIL-L-3150 Oil, Lubricating. (2) Sandpaper Medium and Fine Grit. (3) Paint brushes. (4) Paint thinner. (5) MIL-P Primer. (6) MIL-C Paint, forest green. NOTE Refer to TM for materials required for organizational maintenance of the generator, and TM &P for the Flatbed Trailer. Section II. REPAINTING AND REFINISHING INSTRUCTIONS 5-3. Stenciling Instructions. Marking (stenciling) of the trailer, support unit will be performed by organizational maintenance personnel. a. (Refer to Figure 1-3.) Clean area to be stenciled to remove all dirt, grease, etc. Sand and repaint, if required. b. Stencil with MIL-P black paint. Section III. LUBRICATION INSTRUCTIONS 5-4. Cleaning. Before lubricating the equipment, carefully wipe all lubrication points to remove any foreign matter Lubrication Points. For lubrication under usual conditions, refer to Table 5-1 and Figure 5-1 for lubrication points and type of lubricant to be used. a. The lubrication period is semiannual except for unusual operating conditions. b. For lubrication in weather below 0 'F, refer to TM for instructions. c. After fording, remove foreign matter from lubrication points and lubricate. d. Refer to TM for information pertaining to lubrication points and lubricants to be used for the MEP-114A generator set. e. Refer to TM &P for information pertaining to lubrication points and lubricants to be used for the Flatbed Trailer Painting Instructions. a. General instructions are included in TM , Painting Instructions for Field Use. b. Spot painting will be performed under the control of organizational maintenance personnel. Clean area to be painted to bare metal. Prime area with MIL- P After primer is dry, apply MIL-C forest green paint. 5-1

38 Figure 5-1. Lubrication Points (Sheet 1 of 2) 5-2

39 Points (Sheet 2 of 2) 5-3

40 Table 5-1. Lubrication Specifications POINT ASSEMBLY PART LUBRICANT A Storage Boxes Hinge MIL-L-3150 oil B Storage Boxes Latch MIL-L-3150 oil C Ladder Assembly Pivot Point (2) MIL-L-3150 oil D Ladder Assembly Latches (2) MIL-L-3150 oil E Cable Reel Shaft MIL-L-3150 oil F Cable Reel Lock Pin MIL-L-3150 oil Section IV. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 5-6. General. a. Table 5-2 lists the organizational PMCS for the trailer, support unit. b. For Flatbed Trailer organizational PMCS, refer to TM &P. c. The PMCS system is based on regularly scheduled inspections and services designed to detect early signs of electrical or mechanical failures of assemblies in the materiel, and to ensure that appropriate corrective actions are taken before expensive and time consuming repairs or replacements are required. d. Those repair services requiring higher level assistance are included in Direct Support Maintenance Instructions (Chapter 7). Table 5-2. Organizational Preventive Maintenance Checks and Services Note: Refer to TM for PMCS of generator set. Refer to TM &P for PMCS for Flatbed Trailer. Item To Be Inspected Procedure Interval References GENERATOR 1. Perform PMCS prescribed in manual Per TM TM SET for MEP-114A generator set. 2. Check tightness of screws, lock- 6 Months Figure 7-4 washers and nuts holding generator to trailer deck. 5-4

41 TABLE 5-2. Organizational Preventive Maintenance Checks and Services Continued TM &P Item to be Procedure Interval References Inspected GENERATOR 3. Check generator power cable 6 months TM SET (Cont.) connections per TM. 4. Check tightness of hardware on 6 months Figure E-5 power cable mounting bracket. FUEL 1. Check tightness of all screws, 6 months Figure 7-1. SYSTEM lockwashers, and nuts holding fuel tanks to trailer deck. 2. Check tightness of all fuel 6 months Figure 7-3 line fittings. CABLE 1. Check tightness of mounting 6 months Figure E-6 REEL hardware. 2. Examine assembly for signs of 6 months Figure E-6 damage. POWER 1. Inspect condition of power 6 months Figure E-5 CABLE cable assembly. ASSEMBLY 2. Check connector mounting 6 months Figure E-5 hardware for tightness. 3. Check power cable assembly 6 months TM for proper connection. CABLE Check condition of cable assembly. 6 months Figure E-1 ASSEMBLY W1 STORAGE Check condition of storage 6 months Figure E-7 BOXES LEFT boxes. AND RIGHT 2. Check storage boxes mounting 6 months Figure E-7 hardware for tightness. 3. Check storage boxes' door 6 months Figure E-7 latches for proper operation. 4. Check footman loop mounting 6 months Figure E-7 hardware for tightness. 5. Check condition of straps. 6 months Figure E-7 5-5