Bil7252.tmp TM 5 6115 633 14 And P POWER PLANT AN/MJQ 18 (NSN 00 033 1398) MEP 003A 1 60 HZ GENERATOR SETS M103A3 2 WHEEL 1/2 TON MODIFIED TRAILER
User Manual: TM-5-6115-633-14-and-P POWER PLANT AN/MJQ-18 (NSN 6115-00-033-1398) MEP-003A 1 60 HZ GENERATOR SETS M103A3 2-WHEEL 1 1/2 TON MODIFIED TRAILER Military Generators == MEP 003A
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TM5-6115-633-14&P
TECHNICAL MANUAL
OPERATOR, UNIT, INTERMEDIATE DIRECT SUPPORT
AND GENERAL SUPPORT MAINTENANCE MANUAL
(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LISTS)
POWER
AN/MJQ-18
(2)
(NSN
PLANT
6115-00-033-1398)
MEP-003A
10
KW
GENERATOR
M103A3
2-WHEEL,
MODIFIED
This
manuals
supersedes
Chapter
15
of
TM
60
HZ
SETS
1
1/2
TON
TRAILER
5-6115-594-14&P
dated
25
September
HEADQUARTERS, DEPARTMENT OF THE ARMY
13
JUNE
1988
1984.
TM 5-6115-633-14&P
C3
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C, 4 September 1996
NO. 3
Operator, Unit, Intermediate Direct Support and
General Support Maintenance Manual
(Including Repair Parts and Special Tools Lists)
POWER PLANT
AN/MJQ-18 (NSN 6115-00-033-1398)
(2) MEP-003A 10 KW 60 HZ
GENERATOR SETS
M103A3 2-WHEEL, 1 1/2 TON
MODIFIED TRAILER
DISTRIBUTION STATEMENT A Approved for public release, distribution is unlimited
TM 5-6115-633-14&P, 13 June 1988, is changed as follows
1.
2.
Remove and insert pages as Indicated below. New or changed text material Is indicated by a vertical bar in the
margin An Illustration change is indicated by a miniature pointing hand
Remove pages
Insert pages
i and ii
1-1 and 1-2
D- 17 through D-20
i and ii
1-1 and 1-2
D-17 through D-20
Retain this sheet In front of manual for reference purposes
By Order of the Secretary of the Army:
DENNIS J REIMER
General, United States Army
Chief of Staff
Official:
JOEL B HUDSON
Administrative Assistant to the
Secretary of the Army
02145
DISTRIBUTION
To be distributed In accordance with DA Form 12-25-E, block no 3868, requirements for TM 5-6115-633-14&P
TM 5-6115–633-14&P
C2
CHANGE
NO.
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D. C., 11 June 1991
2
Operator, Unit, Intermediate Direct Support and
General Support Maintenance Manual
(Including Repair Parts and Special Tools Lists)
POWER PLANT AN/MJQ–18
NSN 6115–00-033-1398
(2) MEP-003A, 10 kW, 60 HZ
GENERATOR SETS
M103A3, 2–WHEEL, 1 1/2 TON
MODIFIED TRAILER
Approved for public release; distribution is unlimited
TM 5-6115–633–14&P, 13 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 the margin. An illustration change is indicated by a miniature pointing hand.
Remove pages
Insert pages
iii and iv
1–1 through 1–4
3–7 and 3–8
3–19 through 3–22
4–1 through 4–6
4–15 and 4–16
C-3 and C–4
iii and iv
1–1 through 1–4
3–7 and 3–8
3–19 through 3–22
4–1 through 4–6
4–15 and 4–16
C-3 and C-4
2. Retain this sheet in front of manual for reference purposes.
By Order of the Secretary of the Army:
CARL E. VUONO
General, 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 12–25E, (qty rqr block no. 3868).
TM5-6115-633-14&P
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 WOODEN POLE OR A 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
a
ARMY TM 5-6115-633-14&P
WARNING
All specific cautions and warnings contained in this manual shall be strictly adhered to. Otherwise, severe injury, death and/or damage to the equipment
may result.
HIGH VOLTAGE
is produced when this power plant is in operation.
DEATH
or severe burns may result if personnel fail to observe safety precautions. Do
not operate this power plant until the ground terminal stud has been connected
to a suitable ground. Disconnect the battery ground cables on the generator
sets before removing and installing components on the engine or in the
electrical control panel system. Remove all rings, watches, and other jewelry
when performing maintenance on this equipment. Loose fitting clothing should
be secured to prevent it catching in moving parts. Do not attempt to service or
otherwise make any adjustments, connections or reconnection of wires or
cables until generator sets are shut down and completely de-energized.
DANGEROUS GASES
Batteries generate explosive gas during charging: therefore, utilize extreme
caution. Do not smoke, or use open flame in the vicinity of the generator set
when servicing batteries.
Exhaust discharge contains noxious and deadly fumes. Do not operate power
plant generator sets in enclosed areas unless exhaust discharge is properly
vented to the outside.
To avoid sparking between filler nozzle and fuel tank, always maintain metal to
metal contact between filler nozzle and fuel tank when filling generator set fuel
tanks.
Do not smoke or use open flame in the vicinity of the power plant while fueling
generator sets.
LIQUIDS UNDER HIGH PRESSURE
are generated as a result of operation of the power plant generator sets. Do
not expose any part of the body to a high pressure leak in the fuel injection
system.
NOISE
Operating noise level of the generator sets can cause hearing damage. Ear
protectors, as recommended by the medical or safety officer, must be worn
when working near this power plant.
b
ARMY TM 5-6115-633-14&P
WARNING
Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning solvent. Wash exposed skin thoroughly. Dry cleaning solvent (P-D-680) used to clean parts is potentially
dangerous to personnel and property. Do not smoke or use near open flame or
excessive heat. Flash point of solvent is 100°F. to 138°F.(38°C. to 59°C.).
c/(d Blank)
*ARMY TM 5-6115-633-14&P
TECHNICAL MANUAL
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D C, 13 June 1988
NO 5-6115-633-14&P
Operator, Unit, Intermediate Direct Support and
General Support Maintenance Manual
(Including Repair Parts and Special Tools Lists)
POWER PLANT
AN/MJQ-18 (NSN 6115-00-033-1398)
(2) MEP-003A 10 KW 60 HZ
GENERATOR SETS
M103A3 2-WHEEL, 1 1/2 TON
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 these
procedures, please let us know Mali your letter or DA Form 2028 (Recommended Changes to
Publications 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 copy
2028.
DISTRIBUTION STATEMENT A Approved for public release, distribution is unlimited
TABLE OF CONTENTS
PAGE
CHAPTER
1
INTRODUCTION
Section I
General ........................................................................................................................................
1-1
Section II
Description and Data ...................................................................................................................
1-2
CHAPTER
2
OPERATING INSTRUCTIONS
Section I
Operating Procedures
.......................................................................................
2-1
Section II
Operation of Auxiliary Equipment ................................................................................................
2-2
Section III
Operation Under Unusual Conditions ..........................................................................................
2-2
CHAPTER
3
. .
OPERATOR/CREW MAINTENANCE INSTRUCTIONS
Section I
Consumable Operating and Maintenance Supplies ....................................................................
3-1
Section II
Lubrication Instructions................................................................................................................
3-1
Section III
Preventive Maintenance Checks and Services (PMCS)..............................................................
3-1
Section IV
Troubleshooting ...........................................................................................................................
3-18
Section V
Operator/Crew Maintenance Instructions ....................................................................................
3-18
*This manual supersedes Chapter 15 of TM 5-6115-594-14&P dated 25 September 1984.
Change 3 i
ARMY TM 5-6115-633-14&P
Page
CHAPTER 5.
Section l.
Section Il.
Section Ill.
Section IV.
CHAPTER 6.
INTERMEDIATE (FIELD) DIRECT SUPPORT AND GENERAL
SUPPORT MAINTENANCE INSTRUCTIONS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
Maintenance of Power Plant Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance of Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-9
5-11
TEST AND INSPECTION AFTER REPAIR
General Requirements . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
Section lll.
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPENDIX A.
REFERENCES . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1
APPENDIX B.
COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS . . . . . . . . . . . . . . . . . . . . . . . .
B-1
APPENDIX C.
MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
.
APPENDIX D.
UNIT, INTERMEDIATE (FIELD) (DIRECT SUPPORT AND GENERAL
GENERAL SUPPORT) AND DEPOT MAINTENANCE REPAIR PARTS
AND SPECIAL TOOLS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section l.
Section Il.
ii
6-1
D-1
ARMY
LIST
Figure
OF
Title
TM
5–6115-633-14&P
ILLUSTRATIONS
Page
1–1
Power Plant, Roadside Front, Three–Quarter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
1–2
Power Plant, Curbside Rear, Three–Quarter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3
3–1
Fitted Cover Installed on Power Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–19
3-2
Fitted Cover Rolled Up for Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–20
3–3
Bow Assembly Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
4-1
Unpacking Power Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4–2
Installing Power Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4–3
External Fuel Line Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–6
4-4
DELETED
4–5
Accessory Box Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–16
4–6
Fire Extinguisher Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–17
4–7
Four–Wire Switch Box Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–18
4-8
Five–Wire Switch Box Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–19
4–9
Switch Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–20
4–10
Load Terminal and Terminal Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–21
4-11
Indicator Light and Wire Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–23
4-12
Switch to Load Terminal Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–24
4–13
Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–25
4–14
Ground Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–27
4–15
Taillight Cable Assembly and Electrical Lead Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–29
5-1
Leg Prop Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–2
5–2
Leg Prop Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–3
5–3
Fender and Bed Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5-4
Accessory Box Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5–5
Power Plant Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5-8
5–6
Detaching Generator Set from Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-7
Lifting Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–10
5-8
Switch Box Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–12
B- 1
Components of End Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B–2
B–2
Basic lssue ltems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B–3
D–1
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–10
D–2
Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–12
D–3
Five–Wire Power Cable... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–14
D-4
Four–Wire Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–16
D–5
Five–Wire Switch Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–18
D-6
Four–Wire Distribution Box... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–22
D–7
Distribution Box Electrical Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–26
D-8
Trailer Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–28
D–9
Accessory Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–34
D-10
Data Plates and Reflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–36
D–11
Leg Prop Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–38
D–12
Taillight Cable Assembly and Electrical Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-40
Change 2
i i i
ARMY TM 5-6115-633-14&P
LIST OF TABLES
Number
3-1
3-2
4-1
4-2
iv
Title
Page
Consumable Operating and Maintenance Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operator/Crew Preventive Maintenance
Checks and Services (PMCS). . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Unit Preventive Maintenance Checks and Services (PMCS) . .. . . . . . . . . . . . . . . . . . . . . 4-9
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
ARMY TM 5-6115-633-14&P
CHAPTER 1
INTRODUCTION
SECTION I. GENERAL
1-1.
Scope. This manual Is for your use in operating and maintaining the Power Plant, AN/MJQ-18 The AN/MJQ- 18 is
a mobile power plant used to supply power to any system or equipment requiring up to 10 kW of 60 Hz input operating
power In addition to operating Instructions and operator, unit, and Intermediate direct support and general support
maintenance procedures, this manual contains a Repair Parts and Special Tools List for the power plant.
1-2.
Limited Applicability. Some portions of this publication are not applicable to both services These portions are
prefixed to Indicate the service to which they pertain (A) for Army, and (F) for Air Force Portions not prefixed are applicable
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 00-20 Series Technical Orders
1-4.
Reporting of Errors. Reporting of errors and omissions and recommendations for Improvement of this
publication 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 AMSAT-IMT, 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). EIR’s will be prepared using SF 368, Product
Quality Deficiency Report Instructions for preparing EIR’s are provided In DA PAM 738-750, The Army Maintenance
Management System EIR’s should be mailed directly to Commander, US Army Aviation and Troop Support Command,
ATTN AMSAT-I-MDO, 4300 Goodfellow Boulevard, St Louis, MO 63120-1798.
1-6.
Levels of Maintenance Accomplishment.
a.
(A) Army users shall refer to the Maintenance Allocation Chart (MAC) for tasks and levels of maintenance to
be performed
b.
(F) Air Force users shall accomplish maintenance at the user level consistent with their capability in
accordance with polices established in AFM 66-1
1-7.
Destruction of Army Materiel. Destruction of Army materiel to prevent enemy use shall be In accordance with
TM 750-244-3.
Change 3 1-1
ARMY TM 5-6115-633-14&P
Administrative Storage.
1-8.
a.
Army equipment placed in administrative storage will have preventive maintenance performed in
accordance with the PMCS tables before storage. When equipment is removed from storage, PMCS will
be performed to ensure operational readiness.
b.
(F) For administrative storage procedures for Air Force equipment, refer to TO 35-1-4, Processing and
Inspection of Aerospace Ground Equipment for Storage and Shipment.
1–9.
Preparation for Shipment and Storage.
a.
(A) Army - Referto TB 740-97-2.
b.
(F) Air Force - Refer to TO 35-14 for component of end item generator sets and TO 38-1-5 for installed
engine.
Section Il. DESCRIPTION AND DATA
1-10.
Description. Power Plant AN1MJQ-18 is made up of two Tactical Utility Generator Sets, DOD Model
MEP–003A, mounted on a single modified M103A3 trailer. These generator sets are air-cooled, diesel
engine-driven units, each with a load capacity of 10 KW at 60 Hz. The trailer is a two– wheeled unit with a 1–1/2–ton
carrying capacity. The modifications to the basic trailer provide stowage for the accessories and all equipment
necessary for mobile operation as well as providing a work platform for the operator and maintenance personnel.
Output from the power plant is applied to the system or equipment being powered through a switch box. The
AN/MJQ–18 is supplied with either a 4–wire or a 5–wire configuration switch box. Figures 1–1 and 1–2 illustrate the
power plant with the fitted cover removed to show the generator sets.
Figure 1-1
1 - 2
Change 2
ARMY TM 5-6115-633-14&P
Figure 1-2
Figure 1–2. Power Plant, Curbside Rear Three–Quarter View.
Tabulated Data. The tabulated data provides operator and unit level personnel with the dimensions and
1-11.
weights for Power Plant, AN/MJQ-18. These specifications are computed from the combined dimensions and
weights of the generator sets and trailer as modified for use with the power plant. Specifications of the individual
components can be found in their respective technical publications. For additional information concerning
Generator Set, DOD Model MEP–003A, refer to TM 5–6115-585–12 and –34. For additional information on the
M103A3 trailer, refer to TM 9–2330–213–14&P. The tabulated data also includes the location and content of all
data plates unique to the power plant.
a. Identification and Instruction Plates.
(1) Identification plate.
(a) Location. This plate is located on the front roadside frame between the trailer body and
the drawbar ring.
(b) Content.
us
POWER PLANT, ELECTRIC
AN/MJQ-18
KW10
HERTZ 60
NSN 6115-00-033-1398
Change 2
1 - 3
ARMY TM 5-6115-633-14&P
(2) Identification plate.
(a) Location. This plate is located next to the ground stud on the rear, roadside corner of the
trailer bed.
(b) Content.
GROUND TERMINAL
(3) Wiring diagram information plate.
(a) Location. This plate is mounted inside the switch box.
(b) Content (see figure 4-7 or 4-8).
(4) Warning plate.
(a) Location. This plate is located on the switch box terminal board cover.
(b) Content.
DANGER
HIGH VOLTAGE
NOTE
The following two data plates are found only on the 5-wire configuration switch box.
(5) Information plate.
(a) Location. This plate is located on the outboard side of the switch box next to ground
terminal E2.
(b) Content.
AC GROUND
(6) Information plate.
(a) Location. This plate is located next to ground terminal E1 on the rear of the switch box.
(b) Content.
EQUIPMENT
(FRAME)
GROUND
1-4
ARMY TM 5-6115-633-14&P
b. Tabulated Data for Power Plant.
Overall Length
Overall Width
Overall Height
Net Weight (empty)
Net Weight (filled)
Shipping Weight
Cubage
171.5 inches (435.6 centimeters)
83 inches (210.8 centimeters)
95 inches (241.3 centimeters)
5150 pounds (2340.9 kilograms)
5320 pounds (2418.1 kilograms)
5700 pounds (2590.9 kilograms)
799 cubic feet (22.69 cubic meters)
1.12.
Differences Between Models. There are no differences between models, serial numbers, or
serial number groups applicable to this equipment.
1-5/(1-6 blank)
ARMY TM 5-6115-633-14&P
CHAPTER 2
OPERATING INSTRUCTIONS
Section l. OPERATING PROCEDURES
2-1. Operating Procedures. Before the power plant generators are started and operated, the power
plant is towed to a worksite and installed. Installation instructions are provided in paragraph 4-2.
Instructions for dismantling the power plant for movement are given in paragraph 4-3.
a. Generator Set Operating Procedures. Detailed prestarting, startup, operating and shutdown
procedures for the generator sets can be found on the Operating Instructions data plate located on the
right hand side of each generator set control cubicle, and in the generator set technical manual, TM
5-6115-585-12.
WARNING
Do not operate power plant until it is properly grounded (paragraph 4-2, b).
Serious injury or death by electrocution can result from operating an
ungrounded generator set.
Operating noise level of the generator sets can cause hearing damage. Ear
protectors, as recommended by medical or safety officer, must be worn when
working near power plant.
CAUTION
To avoid damage to equipment, make certain of voltage, frequency, and
phase requirements of load connected to generator sets.
NOTE
Make sure generator set circuit breakers and switch box rotary switch are in
OFF position before proceeding.
Before starting generator set, do your Before PMCS as described in table 3-2.
b. Switch Box Operating Procedures.
(1) Single generator set operation. Use the switch box to operate only one generator set as
follows:
(a) Make sure power and ground cables are connected to generator set and switch box.
(b) Turn generator set on and bring it up to rated speed, voltage and frequency. (Refer to
TM 5-6115-585-12.)
(c) Close generator set circuit breaker (move to ON position).
(d) Turn rotary switch on switch box to GEN 1 or GEN 2 position, as applicable.
(e) To stop operation, move rotary switch and generator set circuit breaker to OFF position.
Turn generator set off. (Refer to TM 5-6115-585-12.)
2-1
ARMY TM 5-6115-633-14&P
(2) Dual generator set operation. Use the switch box to alternately operate both generator sets
as follows:
(a) Make sure power and ground cables are connected to switch box and both generator
sets.
(b) Select first generator set to be used and bring it into operation in accordance with
paragraph 2-1, b (1), steps (b) through (d).
(c) Turn second generator set on and bring it up to rated speed, voltage and frequency.
(Refer to TM 5-6115-585-12.) Close circuit breaker (move to ON position).
(d) Move switch box rotary switch to GEN position corresponding to second generator set.
(e) Open circuit breaker on first generator set (move to OFF position) and turn generator set
off. (Refer to TM 5-6115-585-12.)
(f) To stop operation, move rotary switch to OFF position and open circuit breaker on
generator set still running. Turn generator set off. (Refer to TM 5-6115-585-12.)
c. Trailer Operating Procedures. Refer to TM 9-2330-213-14&P for specific operating
procedures for the M103A3 trailer.
Section Il. OPERATION OF AUXILIARY EQUIPMENT
2-2. Operation of Auxiliary Equipment. There is no auxiliary equipment supplied with the power plant.
Section Ill. OPERATION UNDER UNUSUAL CONDITIONS
2-3. Operation Under Unusual Conditions. When operating the power plant under unusual conditions
such as extremes in temperature or difficult terrain, there are steps that must be taken to protect the
equipment.
a. Refer to TM 5-6115-585-12 for special procedures when operating the generator sets under
unusual conditions.
b. Refer to TM 9-2330-213-14&P for special procedures when operating the trailer under unusual
conditions.
2-2
ARMY TM 5-6115-633-14&P
CHAPTER 3
OPERATOR/CREW MAINTENANCE INSTRUCTIONS
Section l. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES
3-1.
Consumable Supplies. Consumable supplies used in the maintenance and operation of the
power plant are listed in Table 3-1.
Table 3-1. Consumable Operating and Maintenance Supplies.
(2)
(1)
Component
application
(4)
(3)
National
stock
number
Description
Qty
required
for initial
operation
(5)
Qty
required
8 hours
operation
General
Cleaning
6850-00-664-5685
Solvent, Drycleaning,
P-D-680
1 quart
As required
Leg Prop
Assembly
9150-00-190-0904
Grease, Automotive and
Artillery, GAA
1 pound
As required
Leg Prop
Assembly
9150-00-186-6681
Oil, Lubricating,
OE/HDO-30
1 quart
As required
9150-00-402-4478
Oil, Lubricating, OEA
1 quart
As required
(6)
Notes
Section Il. LUBRICATION INSTRUCTIONS
3-2. General. Detailed instructions for the lubrication of the major components of the power plant are
contained in the applicable Lubrication Orders (LO’s). Refer to DA Pam 310-1 to ensure that the latest
editions of the LO’s 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 plant
trailer. However, the operator shall assist unit maintenance.
Section Ill. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
NOTE
The PMCS chart in this section contains all necessary Operator/Crew
preventive maintenance checks and services for this equipment.
3-5. General. The preventive maintenance checks and services listed in Table 3-2 are grouped
according to stages of equipment operation or time intervals. Using the following as a guide, do the
checks and services at the intervals shown.
a. Before you operate, perform your before (B) PMCS. Observe all CAUTIONS and WARNINGS.
3-1
ARMY TM 5-6115-633-14&P
b. While you operate, perform your during (D) PMCS. Observe all CAUTIONS and WARNINGS.
c. After you operate, be sure to perform your after (A) PMCS.
d. Do (W) PMCS weekly.
e. Do (M) PMCS monthly.
f. If equipment fails to operate, refer to Section IV Troubleshooting. If the problem cannot be
corrected, see paragraph 3-8, Reporting Deficiencies.
3-6. Purpose of PMCS Table. The purpose of the PMCS table is to provide a systematic method of
inspecting and servicing the equipment. In this way, small defects can be detected early before they
become a major problem causing the equipment to fail to complete its mission. The PMCS table is
arranged with the individual PMCS procedures listed in sequence under assigned intervals. The most
logical time (before, during, or after operation) to perform each procedure determines the interval to
which it is assigned. Make a habit of doing the checks and services in the same order each time and
anything wrong will be seen quickly. See paragraph 3-7 for an explanation of the columns in
table 3-2.
3-7. Explanation of Columns. The following is a list of the PMCS table column headings with a
description of the information found in each column.
a. Item No. This column shows the sequence in which the checks and services are to be
performed, and is used to identify the equipment area on the Equipment Inspection and Maintenance
Worksheet, DA Form 2404.
b. Interval. This column shows when each check is to be done.
c. Item to be Inspected/Procedures. This column identifies the general area or specific part
where the check or service is to be done, lists the checks or services to be done and explains how to do
them.
d. Equipment is Not Ready/Available If. This column lists conditions that make the equipment
unavailable for use because it is unable to perform its mission or because it would represent a safety
hazard. Do not accept or operate equipment with a condition in the “Equipment is Not Ready/Available
If” column.
3-8. Reporting Deficiencies. If you discover any problem with the equipment during PMCS or while
operating it that you are unable to correct, it must be reported. Refer to DA Pam 738-750 and report
the deficiency using the proper forms.
3-9. Special Instructions. Preventive maintenance is not limited to performing the checks and
services listed in the PMCS table. Covering unused receptacles, stowing unused equipment and other
routine procedures such as equipment inventory, cleaning components, and touch-up painting are
not listed in the PMCS table. These are things you should do any time you see they need to be done. If
a routine check is listed in the PMCS table it is because other operators have reported problems with
this 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 before
and during checks and services.
3-2
ARMY TM 5-6115-633-14&P
WARNING
Drycleaning solvent P-D-680 is both toxic and flammable. Wear safety goggles
and gloves and use in a well-ventilated area. Avoid prolonged breathing of
vapors and avoid skin contact. Do not smoke or use near open flame or
excessive heat. Flash point of solvent is 100°F to 138°F (38°C to 59°C). If you
become dizzy while 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.
(1) 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 clean
rubber or plastic parts and material.
(2) Bolts, nuts, and screws. Check them all to make sure they’re not loose, missing, bent, or
broken. Don’t try to check them all with a tool, but look for chipped paint, bare metal, or
rust around bolt heads. If you find one loose, tighten it or report it to unit maintenance.
(3) 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.
(4) Electrical wires, connectors, terminals and receptacles. Look for cracked or broken
insulation, bare wires, and loose or broken connectors. Tighten loose connectors and
make sure the wires are in good condition. Examine terminals and receptacles for
serviceability.
(5) Hoses and fluid lines. Look for wear, damage, and leaks. Make sure clamps and fittings
are tight. Wet spots and stains around a fitting or connector can mean a leak. If a leak
comes from a loose connector, tighten it. If something is broken or worn out, report it to
unit maintenance.
b. Leakage Definitions. It is necessary for you to know how fluid leakage affects the status of your
equipment. The following are definitions of the types/classes of leakage you need to know to be able
to determine the status of your equipment. Learn and be familiar with them. When in doubt, NOTIFY
YOUR SUPERVISOR!
Leakage Definitions:
Class I
Seepage of fluid (as indicated by wetness or discoloration) not great
enough to form drops.
Class II
Leakage of fluid great enough to form drops but not enough to cause
drops to drip from item being checked/inspected.
Class Ill
Leakage of fluid great enough to form drops that fall from the item
being checked/inspected.
3-3
ARMY TM 5-6115-633-14&P
CAUTION
Equipment operation is allowable with minor leakage (Class I or ll) of any fluid
except fuel. Of course, consideration must be given to the fluid capacity in the
item being checked/inspected. When in doubt, notify your supervisor.
When operating with Class I or II leaks, continue to check fluid level more often
than 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 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.
Within designated interval, these checks are to be performed in the order
listed.
B - Before
D - During
Interval
Item
no.
A - After
W - Weekly
Item to be inspected.
Procedure: check for and
have repaired, filled, or
adjusted as needed
WARNING
Before performing any maintenance that requires climbing on or
under trailer, set trailer
handbrakes, chock wheels, and
lower rear leg prop. Injury to
personnel could result from trailer
suddenly rolling or tipping.
3-4
M - Monthly
Equipment is not
ready/available if:
ARMY TM 5-6115-633-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) – CONT.
D – During
B - Before
Interval
Item
no.
A – After
W – Weekly
Item to be inspected.
Procedure: check for and
have repaired, filled, or
adjusted as needed
M – Monthly
Equipment is not
ready/available if:
NOTE
Perform weekly as well as before
PMCS if:
You are the assigned operator but
have not operated the equipment
since the last weekly inspection.
You are operating the equipment
for the first time.
Generator set checks and services in this table are described as
performed on a single generator
set. These procedures must be
performed on each of the two
generator sets that make up the
AN/MJQ-18.
1
2
GENERATOR SET EXTERIOR
a. Check on, around, and beneath the
generator set (1) for fuel or oil
leaks.
A Class Ill lubrication
oil or any class fuel
leak is detected.
b. Check that generator set (1)
grounds are properly installed,
and grounding connections are
tight.
Not properly
grounded.
FUEL GAGE
Check fuel gage (2) for sufficient fuel for
continuous operation.
3-5
ARMY TM 5-6115-633-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) – CONT.
D – During
B - Before
Interval
Item
no.
A – After
W – Weekly
Item to be inspected.
Procedure: check for and
have repaired, filled, or
adjusted as needed
2
FUEL GAGE – CONT
3
ENGINE OIL LEVEL
Check oil filler dipstick (3) for proper
oil level. Add oil as required.
4
AIR CLEANER INDICATOR
Check indicator (4) for a restricted air
cleaner. If red warning indicator becomes
visible, notify unit maintenance for
cleaning or replacement.
3-6
M – Monthly
Equipment is not
ready/available if:
ARMY TM 5-6115-633-14&P
Table 3–2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) – CONT.
B – Before
D –During
A – After
W – Weekly
M – Monthly
3-7
ARMY TM 5-6115–633-14&P
Table 3–2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) – CONT.
B – Before
3-8
Change 2
D –During
A – After
W – Weekly
M – Monthly
ARMY TM 5-6115-633-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) – CONT.
D – During
B - Before
Interval
Item
no.
10
B
D A
W M
A – After
W - Weekly
Item to be inspected.
Procedure: check for and
have repaired, filled, or
adjusted as needed
Intervehicular cable
is broken or missing.
SAFETY CHAINS
Check safety chains (10) for insecure
mounting and obvious damage.
12
Equipment is not
ready/available if:
INTERVEHICULAR CABLE
Check cable (9) and connector for cuts
and breaks.
11
M – Monthly
Safety chains are
missing or
unsecured.
BOW ASSEMBLIES
Inspect four long bow assemblies (11) and
two short bow assemblies (12).
13
FITTED COVER
a. Check fitted cover (13) for missing and
defective tiedown straps and snap
fasteners (14).
b. Check for missing and defective
ropes (15).
c. Check for missing and defective straps
and buckles (16).
d. Check for ripped seams and tears.
3-9
ARMY TM 5-6115-633-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) – CONT.
B - Before
D – During
A – After
W – Weekly
Item to be inspected.
Procedure: check for and
have repaired, filled, or
adjusted as needed
Interval
Item
no.
13
FITTED COVER - CONT
14
LIGHTS
a. With intervehicular cable connected to
towing vehicle, operate vehicle light
switch through all settings and check
lights.
NOTE
An assistant is required while
checking brake lights.
b. Step on brake pedal and check brake
lights (17).
3-10
M - Monthly
Equipment is not
ready/available if:
ARMY TM 5-6115-633-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) – CONT.
B - Before
D – During
Interval
Item
no.
15
A – After
W – Weekly
Item to be inspected.
Procedure: check for and
have repaired, filled, or
adjusted as needed
Equipment is not
ready/available if:
AIR HOSES, FITTINGS AND BRAKE AIR
CHAMBER
Check air hoses (18), fittings (19)
and brake air chamber (20) for signs
of damage or leaks.
16
M – Monthly
Damage or leaks
are detected.
HYDRAULIC HOSES, FITTINGS AND MASTER
CYLINDER
Check brake system hoses (21) and
fittings (22) and master cylinder
(23), and check under vehicle for
signs of brake fluid leaks.
A class Ill brake fluid
leak is detected.
3-11
ARMY TM 5-6115-633-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) - CONT.
B - Before
D – During
Interval
Item
no.
17
A – After
W – Weekly
Item to be inspected.
Procedure: check for and
have repaired, filled, or
adjusted as needed
Support leg assembly
is seized.
REAR LEG PROP ASSEMBLY
Inspect leg prop assembly (25) for
broken or missing parts.
3-12
Equipment is not
ready/available if:
SUPPORT LEG ASSEMBLY
With trailer connected to towing vehicle, check support leg assembly (24)
for ease of operation.
18
M – Monthly
Leg prop assembly is
unserviceable.
ARMY TM 5-6115-633-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) - CONT.
D – During
B - Before
Item
no.
●
W – Weekly
Item to be inspected.
Procedure: check for and
have repaired, filled, or
adjusted as needed
Interval
19
A - After
●
Equipment is not
ready/available if:
BRAKE SYSTEM
Test brake system by hooking trailer
to towing vehicle and applying brakes.
20
M – Monthly
Service brakes fail to
operate.
TRAILER OPERATION
a. Be alert for any unusual noises while
towing trailer. Stop and investigate
any unusual noises.
b. Ensure that trailer is tracking/following
correctly behind towing vehicle with no
side pull.
21
●
GENERATOR SET GAGES AND INSTRUMENTS
a.
Check that battery indicator (26)
is in yellow area while batteries
are charging and in green area when
batteries are fully charged.
b.
Check that frequency meter (27)
indicates 60 Hz (red line) when
generator is operating under load.
Battery indicator not
in correct area.
Correct frequency
cannot be obtained
and maintained.
3-13
ARMY TM 5-6115-633-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) - CONT.
D – During
B - Before
W – Weekly
Item to be inspected.
Procedure: check for and
have repaired, filled, or
adjusted as needed
Interval
Item
no.
21
A - After
M - Monthly
Equipment is not
ready/available if:
GENERATOR SET GAGES AND
INSTRUMENTS – CONT
c. Check that current meter (28) reading
does not exceed 100% or more than 5%
load difference between phases.
3-14
d.
Check that voltmeter (29) indicates
desired output voltage as determined by load connections and ampsvolts transfer switch.
Desired voltage cannot be obtained and
maintained.
e.
Check engine oil pressure gage (30)
for 20 to 45 psig indication.
Oil pressure drops
below 20 psig.
ARMY TM 5-6115-633-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services(PMCS) - CONT.
A – After
D– During
B – Before
W – Weekly
Item to be inspected.
Procedure: check for and
have repaired, filled, or
adjusted as needed
Interval
Item
no.
M – Monthly
Equipment is not
ready/available if:
GENERATOR SET GAGES AND
INSTRUMENTS – CONT
21
FUEL TANK
22
I
a.
Fill fuel tank (31).
NOTE
Fuel system temperature must be
above freezing when draining
water and sediment.
b.
Open drain (32) and drain water and
sediment from fuel tank. Allow to drain
until fuel runs clean.
3-15
ARMY TM 5-6115-633-.14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) – CONT.
D - During
B - Before
Interval
Item
no.
A - After
W - Weekly
Item to be inspected.
Procedure: check for and
have repaired, filled, or
adjusted as needed
22
FUEL TANK – CONT
23
FUEL STRAINER AND FILTERS
M - Monthly
Equipment is not
ready/available if:
Drain water and sediment from strainer
(33), primary (34) and secondary (35)
filters. Allow to drain until fuel runs clean.
24
HANDBRAKES
With trailer hooked to towing vehicle,
set handbrakes (36). Move traiIer
slightly to see if handbrakes hold
wheels.
3-16
Handbrakes cannot be
adjusted.
ARMY TM 5-6115-633-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services(PMCS) - CONT.
B - Before
D– During
Interval
Item
no.
A – After
W – Weekly
Item to be inspected.
Procedure: check for and
have repaired, filled, or
adjusted as needed
24
HANDBRAKES – CONT
25
BRAKE DRUMS AND HUBS
M - Monthly
Equipment is not
ready/available if:
WARNING
A defect in the operation of the
brakes or hub can cause these
parts to get hot enough to cause
serious burns. Use extreme caution when attempting to detect
heat in this area.
Feel for overheating to detect dragging or binding.
26
Brakes or hub are
dragging or binding.
REFLECTORS
Check for damaged or missing reflectors.
27
BATTERIES
Check battery (37) electrolyte level. Level
should be about 3/4 inch above top of
plates. Add water if level is low. Use
clean water (distilled water if available).
3-17
ARMY TM 5-6115-633-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services(PMCS) - CONT.
D - During
B - Before
Interval
Item
no.
A – After
W - Weekly
Item to be inspected.
Procedure: check for and
have repaired, filled, or
adjusted as needed
27
BATTERIES - CONT
28
FIRE EXTINGUISHER
M - Monthly
Equipment is not
ready/available if:
Inspect and weigh fire extinguishers.
(See paragraph 3-12.)
29
TRAILER FRAME
Inspect entire chassis frame for
damage, cracks, and broken welds.
Frame is obviously
broken or cracked.
Section IV. TROUBLESHOOTING
3-10. Power Unit Troubleshooting. There are no troubleshooting procedures authorized at operator
level for the power plant end item. Troubleshooting procedures for the individual generator sets and
trailer are contained in their respective technical manuals referenced below.
a. Generator Set Troubleshooting. Refer to TM 5-6115-585-12 for troubleshooting procedures.
b. Trailer Troubleshooting. Refer to TM 9-2330-213-14&P for troubleshooting procedures.
Section V. OPERATOR/CREW MAINTENANCE
Enclosure Maintenance. Maintenance of the enclosure at operator level is limited to
3-11.
replacement of the fitted cover and/or the bows.
a. Fitted Cover Replacement. (See figures 3-1 and 3-2.)
3-18
ARMY TM 5-6115-633-14&P
(1) Removal.
(a)
Untie 25 ropes (1, figure 3-1) fastening fitted cover to trailer body (2).
(b)
Unfasten six straps and buckles (3) securing rear curtain (4). Roll up curtain, and
secure with three rollup straps (5) provided.
(c)
Unfasten six straps and buckles (3) securing front curtain (6). Roll up curtain, and
secure with three rollup straps (5) provided.
(d)
Roll up each side (7) of fitted cover, in turn, and secure each side with six rollup straps
(5) provided.
(e)
Working under fitted cover (1, figure 3-2), unfasten 12 straps (2) securing fitted
cover to bow assemblies (3). Remove fitted cover.
(2) Installation.
NOTE
Front curtain is provided with three tie-down ropes. Rear curtain only has two
ropes.
(a) Position fitted cover (1, figure 3-2) on top of bows (3) making certain front of fitted
cover is at front of trailer.
Figure 3-1. Fitted Cover Installed on Power Plant.
3-19
ARMY TM 5-6115-633-14&P
Figure 3–2. Fitted Cover Rolled Up for Removal.
(b) Secure fitted cover (1, figure 3-2) to bow assembly (3) with 12 straps (2) provided.
(c) Unfasten rollup straps (5, figure 3-1) securing sides of fitted cover and lower both sides (7).
(d) Unfasten rollup straps (5) securing front and rear curtains (4, 6) and lower both curtains.
(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 25 ropes (1) provided.
b. B o w A s s e mbly Repla cement. (See figure 3–3.)
(1) R e m o v a l .
(a) Remove fitted cover (paragraph 3-11, a.(t)).
(b) Remove two quick release pins (1) securing each bow assembly (2) in pockets (3) on trailer body(4). Lift
each bow out of pocket and off trailer body.
3 - 2 0
Change
2
ARMY TM 5-6115-633-14&P
Figure 3–3. Bow Assembly Replacement.
(2) Installation.
(a) Lift each bow (2) onto trailer, aline ends with pockets (3) in trailer body (4) and drop bow in place. Secure
each bow assembly with two quick release pins (1) provided.
(b) Install fitted cover on trailer (paragraph 3-11, a.(2)).
3-12. Fire Extinguisher Maintenance. The AN/MJQ-18 Power Plant is equipped with two 2–3/4 lb HaIon fire
extinguishers. Maintenance is limited to weighing the fire extinguishers monthly to insure that they are sufficiently
charged. Fully charged, each fire extinguisher (with head and horn attached) weighs 5 lb. Send the unit to
specialized activity for recharging if it weighs 4 lb, 12 oz or less.
Change 2
3-21
ARMY TM 5-6115-633-14&P
WARNING
Monobromotrifluoroethane liquid or gas (Halon 1301) can cause death or
serious injury if personnel fail to observe safety precautions. Inhalation of
monobromotrifluoroethane 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 HaIon 1301 (including the spray in the immediate vicinity of the discharge) may freeze the skin on contact. In the event of frostbite, warm the
affected area quickly to body temperature. Immerse hands in warm water or
place hands in armpits. Get medical attention promptly.
CAUTION
Do not attempt to verify readiness of fire extinguisher by partially discharging
unit. Any discharge of contents will require refilling.
3-22
ARMY TM 5-6115-633-14&P
CHAPTER
UNIT
4
MAINTENANCE
Section l. SERVICE UPON RECEIPT OF EQUIPMENT
4-1. Inspecting and Servicing Equipment. The power plant shall be unpacked, inspected, and
serviced as described in the following paragraphs. Unpacked equipment must be checked against the
Equipment Packing List to ensure completeness. Discrepancies must be reported in accordance with
the instructions given in DA Pam 738-750.
a. Unpacking Power Plant. (See figure 4-1.) The generator sets are packed in place on the
trailer body. Before beginning the unpacking procedure, locate, remove, and save the two
Depreservation Guides.
WARNING
Steel strapping used in packaging of power plant has sharp edges. Care
should be taken when cutting and handling strapping to avoid injury to
personnel.
(1)
Remove lag screws securing plywood boxes over generator sets and lift boxes off generator
sets. Remove wooden wedges and fiberboard pads positioned around base of generator
sets.
(2)
Remove barrier material and corrugated paper surrounding generator sets.
NOTE
Inspection and servicing of equipment will be easier to perform before fitted
cover is put in place on power plant.
(3)
Pry off end of plywood fitted cover box (strapped to one generator set box). Take out fitted
cover. Remove plastic protective film and set fitted cover aside.
(4)
Remove ground wires and clamps taped to one generator set.
(5)
Take tape or covers off ends of power cables.
(6)
Remove two boxed fire extinguishers taped to generator sets. Unpack fire extinguishers and
secure one in each fender-mounted bracket.
(7)
Take plywood box off switch box.
(8)
Remove strapping, framing and fiberboard edge protectors securing bows and remove
bows from trailer.
(9)
Remove oil drain taped to generator set and install in place. (Refer to
TM 5-6115-585-12.)
(10)
Remove package of technical publications from accessory box and save.
(11)
Unpack and inventory accessories in accessory box.
4 - 1
ARMY TM 5-6115-633-14&P
Figure 4–1. Unpacking Power Plant.
4 - 2 Change 2
ARMY TM 5-6115-633-14&P
(12) Connect power cables to each generator set load terminal board as follows and in
accordance with identification on cables, wires and generator set terminals:
(a) White wire to load terminal L0;
(b) Black wire to load terminal L1;
(c) Red wire to load terminal L2;
(d) Blue wire to load terminal L3.
(e) Green wire to generator set ground terminal (5-wire switch box only).
(13) Refer to DA Form 2258, Depreservation Guide for Vehicles and Equipment, packed with
power plant and follow instructions given for putting power plant in service.
(14) Stow all authorized accessories in accessory box.
(15) Install bows on power plant (paragraph 3-11, b.(2)).
(16) Install fitted cover on power plant (paragraph 3-11, a.(2)).
b. Inspection and Servicing of Generator Set. Refer to Service Upon Receipt of Materiel in
TM 5-6115-585-12 for initial inspection and servicing procedures.
c. Inspection and Servicing of Trailer. Refer to Service Upon Receipt of Materiel in TM 9-2330213-14&P for initial inspection and servicing procedures.
4-2. Installation. (See figure 4-2.) Installation of the power plant at a worksite involves positioning
the trailer and grounding the power plant.
a. Positioning Power Plant. Position the power plant on the worksite as follows:
(1) Select an area as level as possible to install power plant 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 turning
inner 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 extinguishers and fuel cans from power plant when generator sets
are in operation. This will insure that, in the event of fire, extra fuel will not be
involved and the extinguishers will remain accessible.
(5) Locate fuel cans and fire extinguishers on ground away from power plant.
4-3
ARMY TM 5-6115-633-14&P
Figure 4–2. Installing Power Plant.
WARNING
Do not operate generator sets until power plant is properly grounded
(paragraph 4-2, b.). Serious injury or death by electrocution can result
from operating an ungrounded power plant.
CAUTION
To avoid damage to equipment, make certain of voltage, frequency, and
phase requirements of load being connected to generator sets.
(6) Refer to data plate on load terminal board cover and toTM 5-6115-585-12. Connect power plant to
system or equipment to be powered.
b. Grounding. Check that generator sets are grounded to GROUND TERMINAL stud on trailer body. Using
ground wire supplied, connect power plant to a suitable ground as described below. 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. 6 AWG may be used.
4 - 4
Change
2
ARMY TM 5-6115-633-14&P
(1) Underground water system. Ground power plant to one of the accessible pipes in an
underground water system. Make certain underground pipe is made of metal and there is
no insulation, such as a water meter, between ground wire and earth.
(2) Ground rod. Drive ground rod a minimum of eight feet into earth. A ground rod must have a
minimum diameter of 5/8-inch, if solid, or 3/4-inch if pipe.
NOTE
It may be necessary to saturate the area around ground rod with water if soil
conditions are dry.
(3) Ground plate. Ground power plant to a metal plate buried four feet deep. Ground plate
should cover a minimum area of nine square feet.
c. External Fuel Line Connection. (See figure 4-3.) The power plant generator sets can be
fueled from an external source such as a five-gallon fuel can or 55 gallon drum. This eliminates the
need for frequent refilling of each generator’s fuel tank during long intervals of operation.
(1)
Remove fuel can adapter and fuel pickup tube from storage locations on generator set and
assemble by threading pickup tube into adapter.
(2)
Thread one end of auxiliary fuel line onto fuel can adapter fitting and tighten.
(3)
Connect free end of auxiliary fuel line to AUXILIARY FUEL CONNECTION. This connection is
located immediately below control cubicle on right-hand side of generator set.
(4)
Insert fuel can adapter in external fuel source and secure by pressing down on lever.
(5)
Set MASTER SWITCH on control panel to PRIME AND RUN AUX FUEL position.
NOTE
When generator set is run on auxiliary fuel, as described above, fuel is first
pumped into generator set fuel tank by auxiliary fuel pump. Fuel is then fed to
generator set engine from fuel tank.
4-5
ARMY TM 5-6115-633-14&P
Figure 4–3. External Fuel Line Connection.
Section Il. MOVEMENT TO A NEW WORKSITE
4-3
Dismantling for Movement. Because the power plant is designed to be mobile, a minimum amount of
effort is required to relocate to a new worksite. Procedures are as follows:
4-6
a.
Disconnect power plant from system or equipment being powered.
b.
Disconnect ground cable from source of ground and from power plant GROUND TERMINAL stud. Roll
up cable and store in accessory box.
c.
Using slide hammer, remove ground rod. Disassemble, clean, and stow ground rod in accessory box.
d.
Disconnect power plant from external fuel sources, if applicable.
e.
Stow any remaining authorized equipment in accessory box.
f.
Secure fire extinguishers and fuel cans in their respective mounting brackets.
g.
Lower and secure fitted cover in place on power plant.
h.
Remove locking pin from leg prop assembly on rear of trailer. Swing leg prop back and up into traveling
position and secure with pin.
Change 2
ARMY TM 5-6115-633-14&P
i. Attach power plant to towing vehicle. (Refer to TM 9-2330-213-14&P.)
4-4. Reinstallation After Movement. After movement to a new worksite, install power plant in
accordance with paragraph 4-2.
Section Ill. REPAIR PARTS, SPECIAL TOOLS, SPECIAL TEST, MEASUREMENT AND
DIAGNOSTIC EQUIPMENT (TMDE)
4-5. Tools and Equipment. There are no special tools or equipment required to maintain the
AN/MJQ-18 power plant.
4-6. Maintenance Repair Parts. Repair parts and equipment for maintenance of this power plant are
listed 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 maior components of the power pIant are
contained in the applicable Lubrication Orders (LO’s). Refer to DA Pam 310-1 to ensure that the latest
editions of the L.O.’S are used. This section contains lubrication instructions that are not included in
the Lubrication Orders.
4-8.
Generator Lubrication. Refer to TM 5-6115-585-12.
4.9.
Trailer Assembly Lubrication.
a. Trailer Lubrication. Refer to TM 9-2330-213-14&P for trailer Lubrication Order.
b. Leg Prop Assembly Lubrication. The rear leg prop assembly is a modification to the standard
M103A3 trailer and, as such, does not appear in the associated LO. Semiannually lubricate leg prop
assembly as follows:
WARNING
Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning solvent. Wash exposed skin thoroughly. Dry cleaning solvent (P-D-680) used to clean parts is potentially
dangerous to personnel and property. Do not use near open flame or
excessive heat. Flash point of solvent is 100°F. to 138°F. (38°C. to 59°C.).
(1) Clean hydraulic lubrication fitting and area around lubrication points with P-D-680 or
equivalent.
(2) Inject sufficient GAA grease into hydraulic fitting to lubricate screw theads inside leg prop
assembly.
NOTE
Refer to Lubrication Order in TM 9-2330-213-14&P for lubricating oils
specified for use within different anticipated temperature ranges.
(3) Apply OE lubricating oil to both ends of leg prop assembly pivot shaft.
4-7
ARMY TM 5-6115-633-14&P
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
NOTE
The PMCS chart in this section contains all necessary unit preventive
maintenance checks and services for this equipment.
4-10. General. The trailer assembly and generator sets must be inspected and serviced systematically to
insure that the power plant is ready for operation at all times. Inspection will allow defects to be
discovered and corrected before they result in serious damage or failure, Table 4-1 contains a tabulated
list 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 the
generator sets are scheduled weekly or on a per-hours-of-operation basis. The running time meter on
the control panel is used to determine the generator set operating time. Using the following as a guide,
do the checks and services at the intervals shown. Observe all CAUTlONS and WARNINGS.
a.
For PMCS performed on an operating time basis, perform your hourly (H) PMCS as close as
possible to the time intervals indicated.
NOTE
For units in continuous operation, perform PMCS before starting
operation if continuous operation will extend service interval past that
which is shown.
b.
Perform your weekly (W) PMCS every week or 40 hours of generator set operating time.
c.
Perform your monthly (M) PMCS every month or 100 hours of generator set operating time.
d.
Do your semiannual (S) PMCS once every six months or 500 hours of generator set operating time.
e.
Do your annual (A) PMCS once every year or 1000 hours of generator set operating time.
f.
If you discover a problem with the equipment, refer to Section VI, Troubleshooting. If you cannot
correct the problem, refer to paragraph 4-12, Reporting Deficiencies.
4-11. Explanation of Columns. The following is a list of the PMCS table column headings with a
description of the information found in each column.
a.
Item No. This column shows the sequence in which to do the checks and services, and is used to
identify the equipment area on the Equipment Inspection and Maintenance Worksheet, DA
Form 2404.
b
Interval.. This column shows when each check is to be done.
c.
Item to be Inspected. This column identifies the general area or specific part where the check or
service is to be done.
d. Procedures. This column lists the checks or service you have to do and explains how to do them.
4-12. Reporting Deficiencies. If you discover any problem with the equipment during PMCS that you are
unable to correct, it must be reported, Refer to DA Pam 738-750 and report the deficiency using
the proper forms.
4-8
Change 1
ARMY TM 5-6115-633-14&P
Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS). – CONT.
H – Hours of operation
(As indicated)
W – Weekly
(40 hours)
M - Monthlv
(100 hours)
S – Semiannually
(500 hours)
A – Annually
(1000 hours)
Interval
Item
no.
Item to be
Inspected
Procedures
WARNING
Before performing any maintenance
that requires climbing on or under
trailer, set trailer handbrakes, chock
wheels, and lower rear leg prop.
Injury to personnel could result from
trailer suddenly rolling or tipping.
NOTE
Generator set checks and services in
this table are described as performed
on a single generator set. These
procedures must be performed on
each of the two generator sets that
that make up the AN/MJQ-18.
1
Generator Set
Inspect generator set for fuel and oil
leaks, loose or missing components and
hardware, and unusual wear or
deterioration. Clean generator set.
NOTE
Fuel system must be above freezing
temperature when draining water and
sediment from strainer, filters,
and tank.
2
Fuel Strainer and
Filters
Open drains on fuel strainer, and primary
and secondary filters. Drain water and
sediment (para 3-20, TM 5-6115-585-12).
Allow to drain until fuel runs clean.
3
Fuel Tank
Open drain on fuel tank and drain water
and sediment (para 3-13, TM 5-6115584-12). Allow to drain until fuels runs
clean,
Change 1 4 - 9
ARMY TM 5-6115-633-14&P
Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS). – CONT.
4
Fuel Pumps
Clean or replace, as necessary, fuel
strainer in bottom of fuel pump.
5
100
Lubricating Oil
and Filter
Change lubricating oil and filter every
100 hours of operation (LO 5-6115585-12).
6
300
Fuel Strainer
Clean fuel strainer every 300 hours of
operation (para 4-10. TM 5-6115-585-12).
7
500
Primary Fuel
Filter
Service primary filter every 500 hours of
operation (para 4-20, TM 5-6115-585-12).
8
1000
Secondary Fuel
Filter
Service secondary filter every 1000 hours
(para 4-20, TM 5-6115-585-12).
9
300
Batteries
Perform a hydrometer test on batteries
every 300 hours, or quarterly. Refer to
para 4-25c, TM 5-6115-585-12 for test
procedures.
10
500
Crankcase Breather
Inspect breather tube every 500 hours.
Clean as necessary (para 4-45,
TM 5-6115-585-12).
11
100
Dust Caps on Air
Cleaner
Clean out dust caps on air cleaner assembly
every 100 operating hours (more
frequently under unusual conditions).
12
1000
Air Cleaner
Clean every 1000 operating hours or as
conditions dictate. Replace air cleaner
every 2000 operating hours.
13
Taillights
Replace any broken or cracked lenses
or defective buIbs.
14
Intervehicular
Cable
Check for cuts, breaks, frayed wires, or
damaged plug.
15
Drawbar Ring
Check security of mounting. Inspect ring
for excessive wear.
4-10
Change 1
ARMY TM 5-6115-633-14&P
Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS). - CONT.
H – Hours of operation
(As indicated)
W - Weekly
(40 hours)
M – Monthlv
(100 hours)
S – Semiannually
(500 hours)
A – Annually
(1000 hours)
Interval
Item to be
Inspected
Item
no.
Procedures
16
Safety Chains
Inspect for broken links or missing chain(s).
17
Reflectors
Replace any cracked, broken, or missing
refIectors.
18
Data Plates and
Markings
Make sure data plates are legible and
secure. Replace illegible data plates.
19
Support Leg
Assembly
Inspect brackets and leg for bent or
broken parts.
20
Rear Leg Prop
Assembly
Inspect bracket and leg prop for bent or
broken parts.
21
Suspension
Assemblies
a. Inspect shackles, bearings, pins, leaf
springs and spring eyes for damage or
broken parts.
b. Inspect mounting brackets for cracks
or loose or missing hardware.
c. Inspect shock absorbers for damage or
leaks.
22
Axle
a. Check for damaged axle tube.
b. Check for loose or missing U-bolts or
nuts.
23
Wheels and Tires
a. Check serviceability of tires as
indicated in TM 9-2610-200-24.
b. Tighten wheel stud nuts.
C h a n g e
4-11
ARMY TM 5-6115-633-14&P
Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS). – CONT.
H – Hours of operation
(As indicated)
W -- Weekly
(40 hours)
M – Monthly
(100 hours)
S – Semiannually
(500 hours)
A – Annually
(1OOO hours)
Interval
Item
no.
H
Item to be
Inspected
W
M
S
24
Procedures
A
Brakes
a. Inspect brake linings for wear. Replace
if brake shoe lining is less than 1/8inch (3.2 mm) thick.
b. Inspect brake adjusting screw, retaining
screw, retaining pins, springs,
and clips for corrosion and wear.
c. Inspect hydraulic wheel cylinders for
leaks.
d. Inspect master cylinder for leaks or low
fluid level. Fill to within 1/2 inch
from top,
e, Adjust brakes (page 4-52,
TM 9-2330-213-14&P).
25
Wheel Bearings
Clean and repack (page 4-105,
TM 9-2330-213-14&P).
26
Hydraulic Brake
Tubes and Hoses
Inspect for dents, cracks, loose
connections and leaks.
27
Trailer – Road
Test
Perform road test paying special attention
to items that were repaired or adjusted.
Section VI. TROUBLESHOOTING
4-13. Troubleshooting. Troubleshooting procedures for components unique to the power plant end
item are given in paragraph 4-14. Troubleshooting information for the individual generator sets and trailer
are contained in their respective technical manuals referenced below.
a. Generator Set Troubleshooting. Refer to TM 5-6115-585-12 for troubleshooting procedures
applicable to the generator set.
b. Trailer Troubleshooting. Refer to TM 9-2330-213-14&P for troubleshooting procedures
applicable to the trailer.
4-12
C h a n g e
1
PIN:
064445-001
ARMY TM 5-6115-633-14&P
4-14.
Power Plant Troubleshooting. Table 4-2 contains troubleshooting information for locating and
correcting operating troubles which may develop in components unique to the power pIant end item.
Each malfunction is followed by a list of tests or inspections which will help determine probable cause
and corrective actions to take. Perform the tests/inspections and corrective actions in the order
listed. This manual cannot list all malfunctions that may occur, nor all tests or inspections and
corrective actions. If a malfunction is not listed or cannot be corrected by listed corrective actions,
notify your supervisor.
Table 4-2. Troubleshooting.
Malfunction
Test or inspection
Corrective action
1. POWER IS ABSENT AT SWITCH BOX LOAD TERMINAL(S) WHEN ONE GENERATOR SET IS
OPERATING.
Step 1.
Check that generator set circuit breaker is set to ON position.
If circuit breaker is in OFF position, set to ON position.
Step 2.
Check for power output at generator set load terminals.
If power is absent at generator set load terminals, troubleshoot
generator set. (Refer to TM 5-6115-585-12).
Step 3.
Inspect power cable connections inside switch box for looseness or broken wire
terminals.
Tighten loose connections. If any wire terminals are broken, replace
cable (paragraph 4-25, d.) or refer to higher level of maintenance for
repair.
Step 4.
Perform continuity check on associated generator set power cable
(paragraph 4-23, a.).
If cable is defective, replace cable (paragraph 4-25, d.) or refer to
higher level of maintenance for repair.
Step 5.
Perform continuity check on rotary switch (paragraph 4-23, c.).
If switch is defective, notify higher level of maintenance.
2. POWER IS ABSENT AT ONE OR MORE SWITCH BOX LOAD TERMINALS WHEN EITHER GENERATOR
SET IS OPERATING.
Step 1.
Check wire associated with non-functioning load terminal(s) for looseness or
broken terminals inside switch box.
Tighten loose connection(s). If any terminals are broken, replace wire
(paragraph 4-25, c.).
4-13
ARMY TM 5-6115-633-14&P
Table 4-2. Troubleshooting – CONT.
Malfunction
Test or inspection
Corrective action
2. POWER IS ABSENT AT ONE OR MORE SWITCH BOX LOAD TERMINALS WHEN EITHER GENERATOR
SET IS OPERATING – CONT.
Step 2.
Perform continuity check on wire from switch to non-functioning load terminal(s)
(paragraph 4-23, b.(2)).
Replace defective wire(s) (paragraph 4-25, c.).
Step 3.
Perform continuity check on switch (paragraph 4-23, c.).
If switch is defective, notify higher level of maintenance.
3. ONE OR BOTH INDICATOR LIGHTS FAIL TO LIGHT WHEN ASSOCIATED GENERATOR SET IS
OPERATING AND ROTARY SWITCH IS SET TO “ON“ POSITION FOR THAT GENERATOR.
Step 1.
Check if bulb is defective.
If bulb is defective, replace.
Step 2.
Check wires inside switch box associated with non-functioning light for looseness
or broken wire terminals.
Tighten loose connections. If any terminals are broken, replace wire(s)
(paragraph 4-25, c.) or refer to higher level of maintenance for repair.
Step 3.
Perform continuity check on wires associated with non-functioning indicator
(paragraph 4-23, b.(3) or (4), as applicable).
If wires are defective, replace indicator light and wire assembly
(paragraph 4-25, b.).
Step 4.
Perform continuity check on indicator housing (paragraph 4-23, b.(3) or (4),
as applicable).
If housing is defective, replace indicator light and wire assembly
(paragraph 4-25, b.).
Section VIl. RADIO INTERFERENCE SUPPRESSION
4-15.
General Methods Used to Attain Proper Suppression. Essentially, suppression is attained by
providing a low resistance path to ground for stray currents. The methods used include shielding ignition and high-frequency wires, grounding the frame with bonding straps, and using filtering systems.
4-14
ARMY TM 5–6115-633-14&P
4-16. Radio Interference Suppression Components. All component parts of the power plant end item, whose
primary or secondary function is radio interference suppression, are on the generator sets. Refer to TM
5–6115-585-12 for location of radio interference suppression components.
Section Vlll. MAINTENANCE OF POWER PLANT TRAILER
4-17. General. This section of the manual contains unit level maintenance procedures for components of the
M103A3 trailer added when the trailer is used as part of the AN/MJQ-18 power plant. These components are not
covered in the overall trailer maintenance manual. For all other unit maintenance procedures on the trailer, refer to
TM 9–2330–213-14&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 to personnel could result from trailer suddenly rolling or tipping.
PARAGRAPH 4-18 AND FIGURE 4-4 HAVE BEEN DELETED.
Change
4-15
ARMY TM 5-6115-633-14&P
figure 4-5.
4-19.
figure 4-5.
4-20.
4
-
1
figure 4-6.
6
ARMY TM 5-6115-633-14&P
Figure 4-6. Fire Extinguisher Bracket Replacement.
b. Installation.
(1) Position fire extinguisher bracket (4) on fender (5).
(2) Insert four screws (1) with four washers (2) down through bracket (4) and through
fender (5).
(3) Install one nut (3) on each screw (1). Tighten hardware to secure bracket (4).
4-21.
Leg Prop Assembly Servicing. Servicing of the leg prop assembly is limited to semiannual
lubrication (paragraph 4-9, b.).
Section IX. MAINTENANCE OF ELECTRICAL SYSTEM
4-22.
General. This section contains maintenance information on electrical components unique to
the power plant end item. For all other electrical system maintenance, refer to the applicable
generator set and trailer manuals as follows:
a. Generator Set Maintenance. For generator set maintenance procedures, refer to TM 5-6115585-12.
b. Trailer Maintenance. For trailer maintenance procedures, refer to TM 9-2330-213-14&P.
4-23.
Switch Box Testing. To isolate the source of an electrical system problem, perform continuity
tests on the components of the switch box as described below. Refer to the schematic diagram inside
the switch box (shown in figure 4-7 or 4-8, as applicable) to locate and identify the test points
indicated in these procedures.
4-17
ARMY TM 5-6115-633-14&P
Figure 4-7. Four- Wire Switch Box Schematic Diagram.
a. Power Cable Assembly Test.
4-18
(1)
Set multimeter for continuity testing.
(2)
Set switch box rotary switch to GEN 1 position and locate power cable assembly associated
with that switch position.
(3)
Test white wire by touching one probe of multimeter to load terminal L0 on generator set
and touching other probe to load terminal L0 on switch box. Multimeter must indicate
continuity between these points.
(4)
Repeat step (3) for black wire (between L1 on generator set and A1 on switch), red wire
(between L2 on generator set and A2 on switch) and blue wire (between L3 on generator
set and A3 on switch).
(5)
On power plants supplied with the 5-wire configuration switch box (figure 4-8), the green
(ground) wire must also be tested. Disconnect wire from frame ground stud under generator set control panel. Test for continuity between free end of wire and ground stud E1 on
switch box.
(6)
If multimeter does not indicate continuity exists on each wire in the cable, replace power
cable assembly (paragraph 4-25, d.).
(7)
To test power cable assembly associated with GEN 2 switch position, perform steps (2)
through (6) substituting switch terminals B1, B2 and B3 for terminals A1, A2 and A3, as
test points. Generator set load terminal designations and wire color-coding is identical for
both power cables.
ARMY TM 5-6115-633-14&P
Figure 4-8. Five- Wire Switch Box Schematic Diagram.
b. Switch Box Internal Wiring Test.
(1)
Set multimeter for continuity testing.
(2)
Test wires between switch terminals and load terminals by touching probes to each of the
following pairs of test points: L1 on switch to L1 load terminal, L2 to L2, and L3 to L3. If
multimeter does not indicate continuity between each pair of test points replace associated
wire (paragraph 4-25, c.).
(3)
Test wires and socket associated with GEN 1 indicator light by testing for continuity between
switch terminal A2 and socket XDS1, and switch terminal A3 and socket XDS1. If multimeter
does not indicate continuity exists on both of these wires, replace light and wire assembly
(paragraph 4-25, b.).
(4)
Test wires and socket associated with GEN 2 indicator light by testing for continuity between
switch terminal B2 and XDS2 socket, and switch terminal B3 and XDS2 socket. If multimeter
does not indicate continuity exists on both of these wires, replace light and wire assembly
(paragraph 4-25, b.).
(5)
On 5-wire switch box only, test ground wire by touching one probe to switch box load terminal L0 and touch remaining probe to AC GROUND terminal E2 on switch box. If multimeter does not indicate continuity, replace associated wire (paragraph 4-25, e.).
4-19
ARMY TM 5-6115-633-14&P
c. Switch Test.
(1) Set multimeter for continuity testing.
(2) Set switch lever to GEN 1 position.
(3) Touch one probe to switch terminal A1 and remaining probe to switch terminal L1. Repeat
test between terminals A2 and L2, and terminals A3 and L3. If multimeter does not indicate
continuity exists between each pair of terminals, switch is defective. Notify higher level of
maintenance.
(4) Set switch lever to GEN 2 position and repeat step (3) above, substituting terminals B1, B2
and B3 for A1, A2 and A3.
4-24. Switch Box Replacement. (See figure 4-9.)
a. Removal.
(1) Detach power cables (1) from load terminals on generator sets (2). (Refer to TM 5-6115585-12.)
(2) Working underneath roadside fender (3), remove four screws (4), four flat washers (5)
and four Iockwashers (6) securing switch box (7) to fender.
(3) Lift switch box (7) off fender.
Figure 4-9. Switch Box Replacement.
4-20
ARMY TM 5-6115-633-14&P
b. Installation.
(1) Position switch box (7) on fender (3).
(2) Working underneath fender (3) insert four screws (4), four flat washers (5) and four lockwashers (6) through fender and into switch box (7) and tighten.
(3) Connect power cables (1) to load terminals on generator sets (2). (Refer to TM 5-6115585-12.)
4-25.
Switch Box Repair.
WARNING
Make sure generator set circuit breakers are in OFF position before performing
any repairs on switch box. Failure to observe this precaution may result in
injury or death by electrocution.
a. Load Terminal and Terminal Board Replacement. (See figure 4-10.) There are four load
terminals on the switch box terminal board. This procedure is typical for all four. When reconnecting
wires, refer to the schematic inside the switch box (figure 4-7 or 4-8, as applicable) and to the
identification bands on the wires.
Figure 4-10. Load Terminal and Terminal Board Replacement.
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ARMY TM 5-6115-633-14&P
(1) R e m o v a l
(a)
Remove 16 screws (1), 16 Iockwashers (2) and 16 flat washers (3) securing cover(4)
to switch box (5) and take cover off switch box.
NOTE
When disconnecting more than one wire, make sure wires are tagged to
identify the load terminal to which they attach before disconnecting wires.
(b)
Working inside switch box (5), remove nut (6) and flat washer (7) from terminal (8).
Detach wire(s) (9) by sliding terminal lug(s) off stud.
(c)
Remove flat washer (10), nut (11) and internal tooth Iockwasher (12) and pull terminal
(8) off terminal board (13).
(d)
Remove six screws (14), six flat washers (15) and six nuts (16) and take terminal board
(13) and gasket (17) off switch box (5).
(2) Installation.
(a) Position gasket (17) and terminal board (13) on switch box (5) and fasten with six
screws (14), six flat washers (15) and six nuts (16).
(b) Insert terminal (8) through terminal board (13) and into switch box (5).
(c) Install internal tooth Iockwasher (12) and nut(11) on terminal stud (8) and tighten
against inside of terminal board (13).
NOTE
Observe identification tags when installing internal wires.
(d) Slide flat washer (10) and terminal lug(s) of wire(s) (9) onto stud (8).
(e) Install flat washer (7) and nut (6) on terminal (8) and tighten against wire terminal lug.
(f) Position cover (4) on switch box (5) and secure with 16 screws (1), 16 Iockwashers (2)
and 16 flat washers (3).
b. Indicator Light and Wire Assembly Repair and Replacement. (See figure 4-11.) There are two
indicator light and wire assemblies in the switch box. This procedure is typical for both. When
attaching wires, refer to the schematic inside the switch box (figure 4-7 or 4-8, as applicable). The
indicator light and wire assembly is repaired by replacing defective terminals or soldering broken
wires. Soldering shall be done in accordance with TB SIG 222.
(1) Removal.
(a) Remove 16 screws (1), 16 Iockwashers (2) and 16 flat washers (3) securing cover (4)
to switch box (5) and take cover off switch box.
(b) Remove screw (6), nut (7) and star washer (8) attaching each indicator light wire
terminal (9) to its respective switch terminal (10). Take power cable wire (11) and
indicator light wire (12) off switch terminal.
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ARMY TM 5-6115-633-14&P
Figure 4-11. Indicator Light and Wire Assembly Replacement.
(c) Unscrew nut (13) and internal tooth Iockwasher (14) securing indicator light housing
(15) to cover (4) and slide nut and Iockwasher off wires (12).
(d) Pull terminal (9) off each wire (12).
(3) Pull out light and wires through cover (4).
(2) Installation.
(a)
Pull terminal (9) off each indicator light wire (12).
(b)
Feed wires (12) through hole in cover (4) and fit light housing (15) in hole.
(c)
Slide nut (13) and Iockwasher (14) over both wires (12), thread onto housing (15) on
inside of cover (4) and tighten.
(d)
Crimp one temrinal (9) onto each wire (12).
(e)
Position terminal (9) of each indicator light wire (12) against underside of switch terminal (10). Position terminal of power cable wire(11) against terminal of indicator light
wire. Insert screw (6) up through wire terminals and switch terminal. Install star washer
(8) and nut (7) on screw and tighten against switch terminal.
4-23
ARMY TM 5-6115-633-14&P
(f) Position cover (4) on switch box (5) and secure with 16 screws (1), 16 Iockwashers (2)
and 16 flat washers (3).
c. Switch to Load Terminal Wire Replacement. (See figure 4-12.) There are three wires
connecting the switch to the load terminals. When attaching wires, refer to the schematic inside the
switch box (figure 4-7 or 4-8, as applicable) and to the identification bands on the wires.
Figure 4-12. Switch to Load Terminal Wire Replacement.
(1) Removal.
(a) Remove 16 screws (1), 16 Iockwashers (2), and 16 flat washers (3) securing cover (4)
to switch box (5) and take cover off switch box
(b) Remove nut (6)and flat washer (7) from load terminal stud (8) inside switch box (5).
Slide wire terminal (9) off stud.
NOTE
When removing more than one wire, tag switch terminals for identification.
(c) Remove screw (10), nut (11) and star washer (12) securing wire terminal (13) to
switch terminal (14). Take wire off switch.
4-24
ARMY TM 5-6115-633-14&P
(2) Installation.
NOTE
Observe identification tags on switch terminals when installing wires.
(a)
Position wire terminal (9) against underside of switch terminal (13). Insert screw (10)
up through wire terminal and switch terminal. Install star washer (12) and nut (11) on
screw and tighten against switch terminal.
(b)
Slide terminal (9) at free end of wire onto load terminal stud (8) and secure with flat
washer (7) and nut (6).
(c)
Position cover (4) on switch box (5) and secure with 16 screws (1), 16 Iockwashers (2)
and 16 flat washers (3).
d. Power Cable Replacement. (See figure 4-13.) There are two power cables on the power
plant - one for each generator set. This procedure is typical for both. When attaching wires, refer to
the schematic inside the switch box (figure 4-7 or 4-8, as applicable) and to the identification bands
on each of the five wires that make up each cable.
(1) Removal.
(a) Disconnect power cable from load terminals on generator set. (Refer to
TM 5-6115-585-12.)
Figure 4-13. Power Cable Replacement.
4-25
ARMY TM 5-6115-633-14&P
(b)
Remove 16 screws (1), 16 Iockwashers (2) and 16 flat washers (3) securing cover (4)
to switch box (5) and take cover off switch box.
NOTE
Tag switch terminals for identification when removing wires. If identification
bands on wires are illegible, tag wires.
(c)
Remove screw (6), nut (7) and star washer (8) attaching each of three wires (9)
(black, red and blue) to its respective switch terminal (10). Take off wires.
(d)
Remove nut (11) and flat washer (12) from load terminal L0 (13) inside switch box
(5). Take off white wire (14) associated with power cable being removed.
(e)
On 5-wire switch box only, repeat step (d) for ground terminal E1 and green wire (15).
(f)
Loosen power cable clamping nut (16) on outside of switch box (5) and pull cable
through cable clamp and out of box.
(2) Installation.
(a)
Feed cable through cable clamping nut (16) and through hole into switch box (5).
(b)
Tighten clamping nut (16) on outside of switch box (5) to prevent cable from moving.
(c)
Slide terminal of white wire (14) onto load terminal L0 (13) and secure with flat washer
(12) and nut (11).
(d)
On 5-wire switch box only, repeat step (c) for ground terminal E1 and green wire (15).
NOTE
Observe identification tags when installing wires.
(e)
Position each of three wires (9) (black, red and blue) against underside of its
respective switch terminal (10). Insert screw (6) up through wire terminal and switch
terminal. Install star washer (8) and nut (7) on screw and tighten against switch
terminal. Where an indicator light wire is also mounted to the switch terminal, the
indicator light wire shall be positioned against the underside of the switch terminal and
the power cable wire shall be positioned against the indicator light wire.
(f)
Position cover (4) on switch box (5) and secure with 16 screws (1), 6 Iockwashers (2)
and 16 flat washers (3).
(g)
Connect power cable to load terminals on generator set. (Refer to TM 5-6115-585-12.)
e. Ground Wire Replacement (5-Wire Switch Box). (See figure 4-14.) In the 5-wire switch box
only, a wire connects load terminal L0 to AC GROUND terminal E2 located on the side of the switch box
below the terminal board.
(1) R e m o v a l
(a) Remove 16 screws (1), 16 Iockwashers (2) and 16 flat washers (3) securing cover (4)
to switch box (5) and take cover off switch box.
4-26
ARMY TM 5-6115-633-14&P
Figure 4-14. Ground Wire Replacement.
(b) Remove nut (6) and flat washer (7) from load terminal L0 (8) inside switch box (5).
(c) Slide power cable ground (white) wire terminals (9) and switch box ground wire terminal
(10) off load terminal L0 (8).
(d) Remove nut (11) and flat washer (12) from AC GROUND terminal E2 (13) inside switch
box (5). Side ground wire terminal (14) off terminal E2.
(2) Installation.
(a) Install switch box ground wire terminal (14) on AC GROUND terminal E2 (13) and secure
with flat washer (12) and nut (11).
(b) Install other switch box ground wire terminal (10) on load terminal L0 (8). Install power
cable ground (white) wire terminals (9) on terminal L0 and secure both wires with flat
washer (7) and nut (6).
(c) Position cover (4) on switch box (5) and secure with 16 screws (1), 16 Iockwashers (2)
and 16 flat washers (3).
4-27
ARMY TM 5-6115-633-14&P
4-26. Taillight Cable Assembly and Electrical Lead Repair and Replacement. One taillight cable
assembly and one electrical lead connect each taillight to the trailer wiring harness. The taillight cable
assembly and electrical lead are replaced by unplugging four connectors at each end. Repair is
accomplished by replacing defective connectors. To manufacture a replacement cable assembly and
electrical lead, install new connectors on suitable lengths of insulated wire using the procedure
described for repair.
a. Male Connector Replacement. (See figure 4-15.)
(1) Slide shell (1) back on wire lead (2).
(2) Remove washer (3).
(3) Slide shell (1) off over contact (4).
(4) Cut oiff contact (4).
NOTE
Be careful not to strip too much insulation from wire. Connector contact must
be crimped onto insulation to hold securely.
(5) Strip insulation off wire lead (2) equal to depth of new contact (4).
(6) Slide shell (1) and washer (3) of new connector onto wire lead (2).
(7) Slide contact (4) onto stripped wire and solder in accordance with TB SIG 222.
(8) Crimp contact onto wire.
(9) Slide shell (1) forward over washer (3) and contact (4).
b. Female Connector Replacment. (See figure 4-15.)
(1)
Slide shell (5) and sleeve (6) back on wire lead (7).
(2)
Cut off contact (8).
(3)
Slide shell (5) and sleeve (6) off wire lead (7).
NOTE
Be careful not to strip too much insulation from wire. Connector contact must
be crimped onto insulation to hold securely.
4-28
(4)
Strip insulation off wire lead (7) equal to depth of new contact (8).
(5)
Slide shell (5) and sleeve (6), onto wire lead (7).
(6)
Slide contact (8) onto stripped wire and solder in accordance with TB SIG 222.
ARMY TM 5-6115-633-14&P
Figure 4-15. Taillight Cable Assembly and Electrical Lead Repair.
(7) Crimp contact onto wire.
(8) Slide shell (5) and sleeve (6) forward over contact (8).
4-29/(4-30 blank)
ARMY TM 5-6115-633-14&P
CHAPTER
AND
5
INTERMEDIATE (FIELD) DIRECT SUPPORT
GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
Section I. INTRODUCTION
5-1. General.
This chapter contains Intermediate Direct Support and General Support level
maintenance procedures for components of the AN/MJQ-18 Power Plant which are not part of the
basic generator sets or trailer. For all other intermediate direct and general support maintenance
procedures on the trailer, refer to TM 9-2330-213-14&P. For intermediate direct and general support
maintenance procedures on the generator set, refer to TM 5-6115-585-34.
WARNING
Before performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes, chock wheels and lower rear leg prop. Injury to
personnel could result from trailer suddenly rolling or tipping.
Section
Il.
MAINTENANCE
OF
POWER
PLANT
TRAILER
5-2. Leg Prop Assembly Maintenance. Maintenance of the leg prop assembly at the Intermediate
Direct Support and General Support level consists of repairing or replacing the assembly as required.
a. Leg Prop Assembly Replacement.
(See figure 5-1.)
(1) R e m o v a l .
(a) While supporting leg prop assembly, pull out angled bar (1) and lower leg from traveling
position.
(b) Line up boss (2) on upper leg (3) with holes in bracket (4) and insert angled bar (1) to
lock leg in support position.
(c) Remove either one of two cotter pins (5) from leg prop assembly pivot shaft (6).
(d) While steadying leg prop assembly, remove shaft (6) with remaining cotter pin (5) in
place.
WARNING
When angled bar is removed in step (e), leg prop assembly will fall from
bracket if not supported. To prevent injury to personnel or damage to
equipment, do not permit leg assembly to drop.
(e) Lift leg assembly slightly to take weight off angled bar (1) and remove bar.
(f) L o w e r l e g a s s e m b l y f r o m b r a c k e t ( 4 ) .
(g) Remove three screws (7), three flat washers (8) and three nuts (9), and remove
bracket (4) from trailer frame (10).
5
-
1
ARMY TM 5-6115-633-14&P
Figure 5-1. Leg Prop Assembly Replacement.
(2) Installation.
(a)
Position bracket (4) on trailer frame (10) and install three screws (7), three flat
washers (8), and three nuts (9). Tighten hardware to secure bracket.
(b)
Lift leg assembly into bracket (4) and secure by inserting angled bar(1) through
holes in bracket and boss (2) on upper leg (3).
(c)
Position leg assembly to line up boss (2) on top of leg with pivot holes in bracket
(4). Insert pivot shaft (6).
(d)
Insert cotter pin (5) in pivot shaft (6) and bend cotter pin legs in opposite directions.
(e)
Pull out angled bar (1) to unlock leg prop assembly.
(f)
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. (See figure 5-2.) Repair of the leg prop assembly is limited to
welding and repainting. However, partial disassembly is possible to facilitate repair. If required,
repaint in accordance with MIL-T-704, Type F, color Green No. 383 of MIL-C-46168.
5-2
ARMY TM 5-6115-633-14&P
(1) Disassembly.
(a) Remove leg prop assembly from trailer (paragraph 5-2, a.(1)).
(b) Clamp leg prop assembly in vise with spring pin (1) facing up.
(c) Using suitable drift, drive spring pin (1) out of upper leg (2) and remove leg base (3).
(2) Assembly.
(a) Clamp upper leg (2) in vise with spring pin hole facing up.
(b) Insert leg base (3) into upper leg (2) and turn leg base until hole in screw lines up with
hole in upper leg.
(c) Install spring pin (1) to secure leg base (3) to upper leg (2).
(d) Install leg prop assembly on trailer (paragraph 5-2, a. (2)).
Figure 5-2. Leg Prop Disassembly.
5-3. Trailer Bed and Fenders Repair and Replacement. (See figure 5-3.) The body of the modified
trailer 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)).
5-3
ARMY TM 5-6115-633-14&P
Figure 5-3. Fender and Bed Replacement.
5-4
ARMY TM 5-6115-633-14&P
(2) Remove bow assemblies (paragraph 3-11, b.(1)).
(3) Remove accessory box (paragraph 4-19, a.).
(4) Remove switch box (paragraph 4-24, a.).
(5) Remove both generator sets (paragraph 5-7, a.).
(6) Working under trailer, unplug four connectors (1) joining trailer main wiring harness (2)
to roadside composite light cable assembly (3), and four connectors (4) joining cable
assembly to composite light (5).
(7) Repeat step (6) for curbside composite light cable assembly.
(8) Remove two screws (6) and two Iockwashers (7) securing each composite light (5) to its
bracket (8) and remove both composite lights.
(9) Remove eight screws (9), 16 flat washers (10) and eight nuts(11) securing each
generator mounting rail (12) to trailer body (13) and remove both rails.
(10) Remove cotter pin (14), nut (15) and flat washer (16) from each of two trailer lifting rings
(17) and remove lifting rings.
NOTE
The two trailer body support brackets located at the front of the trailer are
secured with only two screws and two flat washers each.
(11) Working under trailer, remove 16 screws (18),28 flat washers (19) and 12 nuts (20)
securing trailer body support brackets (21) to trailer frame (22).
NOTE
There are 18 short screws and four long screws securing trailer body to trailer
frame. Since corner screws must extend through trailer frame rails, corner
mounting locations require longer screws (step (13)).
(12) Remove 18 screws (23), 36 flat washers (24) and 18 nuts (25) securing trailer body (13)
to trailer frame (22).
(13) Remove four long screws (26), eight flat washers (27) and four nuts (28) securing trailer
body (13) to trailer frame (22) at corner mounting locations.
WARNING
When lifting trailer body, use lifting equipment with a minimum lifting capacity
of 2000 lb. Do not stand under trailer body while it is being lifted. Failure to
observe these precautions can cause injury to personnel or damage to
equipment.
(14) Using lifting equipment with a minimum lifting capacity of 2000 lb. lift trailer body (13) off
trailer frame (22).
5-5
ARMY TM 5-6115-633-14&P
b. Repair. Repair of the trailer bed and fenders is limited to replacement of footmans loops and
straightening welding, and repainting the bed and fender weldment. If required, repaint in
accordance with MIL-T-704, Type F or G, as applicable, color Green, No. 383 of MIL-C-46168.
There is one footmans loop mounted to the top of each fender. Replace footmans loop as follows:
(1) Remove two screws (29), two flat washers (30) and two self-locking nuts (31) securing
footmans loop (32) to fender and take off footmans loop.
(2) Position new footmans loop (32) on fender and secure with two screws (29), two
flat washers (30) and two self-locking nuts (31).
c. Installation.
WARNING
When lifting trailer body, use lifting equipment with a minimum lifting capacity
of 2000 lb. Do not stand under trailer body while it is being lifted. Failure to
observe these precautions can cause injury to personnel or damage to
equipment.
(1)
Using lifting equipment with a minimum lifting capacity of 2000 lb. lift trailer body (13) onto
trailer frame (22) and aline mounting holes.
NOTE
There are 18 short screws and four long screws, securing trailer body to trailer
frame. Since corner screws must extend through trailer chassis rails, corner
mounting locations require longer screws (step (2)).
5-6
(2)
Working on top of trailer body, insert four long screws (26) with one flat washer (27) each
through trailer body (13) and trailer frame (22) rails at corner mounting locations.
(3)
Insert 18 screws (23) with one flat washer (24) each through trailer body (13) and rails of
trailer frame (22).
(4)
Working under trailer, install one flat washer (24 and 27) and one nut (25 and 28) on
each of 22 screws installed in steps (2) and (3). Tighten hardware to secure trailer body
(13) to trailer frame (22).
(5)
Install and tighten two screws (18) and two flat washers (19) securing each of two front
trailer body support brackets (21) to trailer frame (22).
(6)
Install and tighten 12 screws (18), 24 flat washers (19) and 12 nuts (20) securing
remaining trailer body support brackets (21) to trailer frame (22).
(7)
Insert one lifting ring (17) into each of two mounting holes in trailer body (13) and secure
with one flat washer (16) and one nut (15). Install one cotter pin (14) in each nut and
spread cotter pin ends.
(8)
Position two generator set mounting rails (12) on trailer body (13). Insert eight screws (9)
with eight flat washers (10) through each mounting rail and through trailer bed and
frame (22).
ARMY TM 5-6115-633-14&P
(9)
Working under trailer, install one flat washer (10) and one nut (11) on each of 16 mounting
rail screws (9) and tighten.
(10)
Position one composite light (5) on each rear mounting bracket (8) and secure each light
with two screws (6) and two Iockwashers (7).
(11)
Working under trailer, connect one composite light cable assembly (3) to each composite
light (5) by plugging four cable assembly connectors into four composite light connectors
(4). Plug four connectors at opposite end of each cable assembly into four connectors (1)
on trailer main wiring harness (2).
(12)
Install both generator sets (paragraph 5-7, b.).
(13)
Install switch box (paragraph 4-24, b.).
(14)
Install accessory box (paragraph 4-19, b.).
(15)
Install six bows (paragraph 3-11, b(2)).
(16)
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. Accessory Box Repair. (See figure 5-4.) The accessory box is repaired by replacing the hasp,
the catches and the footmans loops, as required. The box itself maybe straightened, welded, and
repainted. If required, repaint in accordance with MIL-T-704, Type F, color Green, No. 383 of MILC-46168.
a. Catch and Hasp Replacement.
(1) Grind off or drill out solid rivets (1) securing catch or hasp (2) to accessory box (3).
(2) Position new catch or hasp (2) on accessory box and secure with solid rivets (1).
(3) Touch up with paint as required.
b. Footmans Loop Replacement.
(1) Remove two screws (4), 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 secure with two screws (4) two
washers (5), and two self-locking nuts (6).
5-6. Marking. (See figure 5-5.) The power plant four-digit registration number, preceded by the
prefix “VC” and the words “U.S. ARMY, ” is marked in three places on the trailer. Marking is done in
accordance with MIL-STD-642. On the fender, over each wheel, “T.P.50 PSI” is marked in 1.00±
.12 inch high characters in accordance with MIL-STD-130. On the switch box, “GEN 1”, “GEN 2“ and
‘OFF” are marked on the cover at their respective switch lever positions. On the 5-wire switch box
only, “E1” and “E2” are marked next to their respective ground terminal studs. Figure 5-5 shows the
approximate location of markings on the power plant. If required, touch-up painting of the base color
shall be done in accordance with MIL-T-704, Type F, color Green, No. 383 of MIL-C-46168.
5-7
ARMY TM 5-6115-633-14&P
Figure 5-4. Accessory Box Repair.
Figure 5-5. Power Plant Markings.
5-8
ARMY TM 5-6115-633-14&P
Section Ill. GENERATOR SET
5-7. Generator Set Replacement. (See figures 5-6 and 5-7.) Power Plant AN/MJQ-18 has two
generator sets. Replacement procedures are identical for both.
a. Removal.
(1) Remove fitted cover (paragraph 3-11, a.(1)).
(2) Remove six bow assemblies (paragraph 3-11, b.(1)).
(3) Disconnect all power cables and ground wires (1, figure 5-6) from generator set (2).
NOTE
The beveled washers (6) may have been welded in place.
(4) Remove four screws (3), four Iockwashers (4), four flat washers (5) and four beveled
washers (6), securing generator set (2), to mounting rails (7) on trailer bed (8).
(5) Remove engine oil drain hose (9) from grommet in trailer bed (8).
(6) Disconnect external fuel line (10) if connected.
Figure 5-6. Detaching Generator Set from Trailer.
5-9
ARMY TM 5-6115-633-14&P
Figure 5-7. Lifting Generator Set.
WARNING
When lifting generator set, use lifting equipment with a minimum lifting capacity 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 to
equipment.
(7) Attach lifting equipment with a minimum lifting capacity of 1500 lb (1, figure 5-7) to lifting
eye (2) on top of generator set (3) and remove generator set from trailer.
b. Installation.
WARNING
When lifting generator set, use lifting equipment with a minimum lifting capacity 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 to
equipment.
(1) Attach lifting equipment with a minimum lifting capacity of 1500 lb (1, figure 5-7) to lifting
eye (2) on top of generator set (3) and lift generator.
(2) Lower generator set (2, figure 5-6) onto mounting rails (5) on trailer bed (6) and aline
mounting holes.
5-10
ARMY TM 5-6115-633-14&P
(3)
Insert four screws (3), four Iockwashers (4), four flat washers (5) and four beveled
washers (6) down through generator set skid into nuts welded to underside of mounting
rails (7).
(4)
Position beveled washers (6) so that screw heads are parallel to tops of washers. While
holding beveled washers in position, tighten hardware to secure generator set (2) to
trailer (8).
(5)
Insert engine oil drain hose (9) through grommet in trailer bed (8).
(6)
Install six bow assemblies (paragraph 3-11, b.(2)).
(7)
Install fitted cover (paragraph 3-11, a.(2)).
Section IV. MAINTENANCE OF ELECTRICAL SYSTEM
5-6. Switch Box Repair. (See figure 5-8.) Repairs to the switch box require disconnecting wires.
When reconnecting wires, refer to the schematic inside the switch box (figure 4-7 or 4-8, as
applicable).
WARNING
Make sure generator set circuit breakers are in OFF position before performing
any repairs on switch box. Failure to observe this precaution may result in
injury or death by electrocution.
a. Switch Replacement.
NOTE
Replacement switch will have unmarked terminals and will have to be
compared with original switch.
(1) Removal.
(a)
Remove 16 screws (1), 16 Iockwashers (2) and 16 flat washers (3) securing cover (4)
to switch box (5) and take cover, with switch (6) attached, off switch box.
NOTE
Make sure identification bands on wires are legible before disconnecting wires
from switch. Tag switch terminals and all unmarked wires.
(b)
Disconnect all wires from switch (6) by removing one screw (7), one nut (8) and one
star washer (9) from each switch terminal.
(c)
Remove screw (10) and Iockwasher(11) securing knob (12) to switch (6) and take off
knob.
(d)
Remove four screws (13), four nuts (14), eight flat washers (15) and preformed
packing (16) securing switch (6) to cover(4) and take switch off cover.
5-11
ARMY TM 5-6115-633-14&P
Figure 5-8. Switch Box Switch Replacement.
5 - 1 2
ARMY TM 5-6115-633-14&P
(2) Installation.
(a) Position switch (6) on inside of cover (4). Insert four screws (13) with one flat washer
(14) and one preformed packing (15) each through cover and switch standoffs.
NOTE
Install nut (14) so that flat side mates with washer (15).
(b) Install one flat washer (15) and one nut (14) on end of each screw (13) and tighten.
(c) Position knob (12) on switch (6) and install screw (10) and Iockwasher (11).
NOTE
Observe identification bands on wires when reconnecting wires,
(d) Connect indicator light wires to switch (paragraph 4-25, b.(2)).
(e) Connect power cables to switch (paragraph 4-25, d.(2)).
(f) Connect load terminal wires to switch (paragraph 4-25, c.(2)).
(g) Position cover (4) on switch box (5) and secure with 16 screws (1), 16 lockwashers
(2) and 16 flat washers (3).
b. Power Cable and Wiring Repair. The switch box wiring is repaired by tightening or replacing
loose or damaged terminals. The power cables are repaired by replacing damaged terminals. The
repair parts and special tools list in this manual lists part numbers for the terminals. The replacement
terminals are soldered onto the wires in accordance with procedures given in TB SIG 222 (TO 31-364) and TM 55-1500-323-25 (TO 1-1A-14).
5-13/(5-14 blank)
ARMY TM 5-6115-633-14&P
CHAPTER 6
TEST AND INSPECTION AFTER REPAIR
Section I. GENERAL REQUIREMENTS
6 - 4 . G e n e r a l R e q u i r e m e n t s . The activity performing the repair is responsible for the performance of
all applicable tests and inspections specified in the technical manuals referenced below. Activities
performing maintenance on any component of the power plant must perform those tests and
inspections required by the applicable component or system repair instruction.
Section ll. INSPECTION
6-2. Generator Set Inspections. Refer to TM 5-6115-585-12 and -34 for inspections required
following repair of the generator set.
6-3. Trailer Inspections. Refer to TM 9-2330-213-14&P for inspections required following repair of
the trailer.
Section lll. OPERATIONAL TESTS
6-4. Generator Set Operational Tests. Refer to TM 5-6115-585-12 and -34 for operational tests
required to verify satisfactory performance of the generator set.
6-5. Trailer Operational Tests. Refer to TM 9-2330-213-14&P for operational tests required to verify
satisfactory performance of the trailer.
6-1(6-2 blank)
ARMY TM 5-6115-633-14&P
APPENDIX
A
REFERENCES
A - 1 . S c o p e . This appendix lists all pamphlets, forms, technical manuals, specifications and
miscellaneous publications referenced in this manual.
A-2. Forms and Records.
A i r F o r c e M a i n t e n a n c e M a n a g e m e n t P r o g r a m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AFM 66-1
Technical Order System Publication Improvement Report
a n d R e p l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AFTO Form 22
R e c o m m e n d e d C h a n g e s t o P u b l i c a t i o n s a n d B l a n k F o r m s . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028
DA Form 2258
Depreservation Guide for Vehicles and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DA Form 2404
Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M a i n t e n a n c e R e q u e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2407
C o n s o l i d a t e d I n d e x o f A r m y P u b l i c a t i o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 310-1
The Army Maintenance Management System (TAMMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DA PAM 738-750
Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SF 388
A-3. Military Specifications.
Chemical Agent Resistant Aliphatic Polyurethane Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-C-46168
Identification Marking of U.S. Military Property . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI L-STD-130
MIL-STD-642
Identification Marking of Combat and Tactical Transport . . . . . . . . . . . . . . . . . . . .
Treatment and Painting of Materiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-T-704
A-4.
Technical
Manuals.
Fabric Repairing, Tents, Canvas, Webbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 10-16
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, 12/240
and 120/208 V (DOD Model MEP-003A) Utility Class 400 HZ
(6115-00-465-1027) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 5-6115-585-12
Organizational, Direct Support and General Support Maintenance
Repair Parts and Special Tools List (Including Depot
Maintenance 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 and
120/208 V (DOD Model MEP-003A) Utility Class, 60 HZ
(NSN 6115-00-465-1030) and (Model MEP-112A), Utility Class,
400 Hz (6115-00-485-1027) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM 5-6115-585-24P
Intermediate (Field) (Direct and General Support) and Depot
Level Maintenance Manual for Generator Set, Diesel Engine
Driven, 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, 400 HZ
(6115-00-465-1027) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 5-6115-585-34
Installation Practices for Aircraft Electric and Electronic
W i r i n g [ T O 1 - 1 A - 1 4 ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 55-1500-323-25
A-1
ARMY TM 5-6115-633-14&P
Procedures for Destruction of Equipment to Prevent
Enemy Use (Mobility Equipment Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-244-3
Operator’s, Organizational, Direct Support and General Support
Maintenance Manual (Including Repair Parts and Special Tools
List) for Chassis Trailer: 1-1/2-Ton, 2-Wheel, M103A1
(NSN
2330-00-835-8620),
(2330-00-141-8052),
(2330-00-141-8051),
M103A2
(2330-00-049-8050),
M103A3
M103A3C (2330-00-542-2181), M103A4,
M103A4C (233-00-542-2182); Trailer,
Cargo; M104 (2330-00-754-0509), M104A1 (2330-00-835-8630),
M105A1
(2330-00-835-8631),
M105A2
(2330-00-141-8050)
M105A2C (2330-00-542-5689); Trailer Tank, Water, 400 Gallon,
M107A1 (2330-00-835-8633) M107A2 (2330-00-141-8049),
M107A2C (2330-00-542-5688) and Trailer, Van, Shop, Folding
Sides, M448 (2330-00-631-5692) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2330-213-14&P
Organizational, Direct Support, and General Support Care
Maintenance and Repair of Pneumatic Tires and Inner
..
9-2610-200-24
T u b e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM
Air Force Technical Order System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TO-00-5-1
Painting and Marking of USAF Aerospace Ground Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TO 35-1-3
Processing and Inspection of Aerospace Ground Equipment
for Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TO 35-1-4
Processing and Inspection of Non-Mounted, Non-Aircraft
Gasoline and Diesel Engines for Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TO 38-1-5
A-5. Technical Bulletins.
Solder and Soldering [TO 31-3-64] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB SIG 222
Preservation of USAMECOM Mechanical Equipment for
Shipment and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 740-97-2
A-2
ARMY TM 5-6115-633-14&P
APPENDIX
COMPONENTS
OF
END
ITEM
AND
B
BASIC
ISSUE
ITEMS
LISTS
Section I. INTRODUCTION
B - 1 . S c o p e . This appendix lists components of end item and basic issue items for the power plant to
help you inventory items required for safe and efficient operation.
B - 2 . G e n e r a l . The Components of End Item and Basic Issue Items Lists are divided into the following
sections:
a. Section II. Components of End Item. This listing is for informational purposes only, and is not
authority to requisition replacements. These items are part of the end item, but are removed and separately packaged for transportation or shipment. As part of the end item, these items must be with the
end item whenever it is issued or transferred between property accounts. Illustrations are furnished to
assist you in identifying the items.
b. Section III. Basic Issue Items. These are the minimum essential items required to place the
power plant in operation, to operate it, and to perform emergency repairs. Although shipped separately packaged, Bll must be with the power plant during operation and whenever it is transferred
between property accounts. The illustrations will assist you with hard-to-identify items. This manual is
your authority to request/requisition replacement Bll, based on TOE/MTOE authorization of the end
item.
B - 3 . E x p l a n a t i o n o f C o l u m n s . The following provides an explanation of columns found in the tabular
listings:
a. Column (1), Illustration Number (Illus No.). This column indicates the number assigned to
the item.
b. Column (2), National Stock Number. Indicates the National stock number assigned to the
item.
c. Column (3), Description. Indicates the federal item name and, if required, a minimum
description to identify and locate the item. The last line for each item indicates the FSCM (in
parentheses) followed by the part number.
If item needed differed for different models of this equipment, the model would be shown under the
“Usable On Code” heading in this column. The Usable On Code is not applicable for this equipment.
d. Column (4), Unit of Measure (UIM). Indicates the measure used in performing the actual
operational/maintenance
function.
This
measure
is
expressed
by
a
two-character
alphabetical
abbreviation (eg, ea, in, pr).
e. Column (5), Quantity Required (Qty Req’d). Indicates the quantity of the item authorized to be
used with/on the equipment.
B-1
ARMY TM 5-6115-633-14&P
Section Il. COMPONENTS OF END ITEM
(1)
Illus
no.
1
(2)
National
stock number
5120-00-243-2957
(3)
Description
FSCM and part number
Hammer, Hand, Engineers 8 lb.
(4)
(5)
U/M
Qty’d
req’d
Usable
on code
EA
1
EA
2
Hammer, Slide (97403) 13226 E7741
EA
1
Switch Box (97403) 13226 E5859-1
EA
1
Switch BOX (97403) %220 E4462
EA
1
Cable Assembly (97403) 13226 E5888-1
and
Cable Assembly (97403) 13226 E5888-2
EA
1
EA
1
Cable Assembly ~7403) 13212 E3584-4
and
EA
1
Cable Assembly (97403) 13212 E3585-4
EA
1
(3.6 kg) (81348) GGG-H-86
2
5975-00-878-3791
Rod, Ground, Driven, Sectional,
9 ft (2.7 m) (81349) Ml L-R-l 1461
3
4
5
B-2
5120-01-013-1676
ARMY TM 5-6115-633-14&P
Section Ill. BASIC ISSUE ITEMS
(1)
(2)
Illus
no.
1
National
stock number
(3)
Description
FSCM and part number
Extinguisher, Fire, Hand,
2-3/4 lb. (1 .25 kg) (81 349)
Usable
on code
(4)
(5)
UIM
Qty’d
req’d
EA
2
EA
1
M IL-E-52031
2
Manual, Technical,
TM 5-61 15-633-14&P
B-3/(B-4 blank)
ARMY TM 5-6115-633-14&P
APPENDIX
MAINTENANCE
C
ALLOCATION
CHART
Section I. INTRODUCTION
C-1.
General.
a. This section provides a general explanation of all maintenance and repair functions authorized
at various maintenance levels.
b. S e c t i o n I I d e s i g n a t e s o v e r a l l r e s p o n s i b i l i t y f o r t h e p e r f o r m a n c e o f m a i n t e n a n c e f u n c t i o n s o n
the identified end item or component. The implementation of the maintenance functions upon the end
item or component will be consistent with the assigned maintenance functions.
c. Section Ill lists the tools and test equipment required for each maintenance function as
referenced from Section Il.
d. S e c t i o n I V c o n t a i n s s u p p l e m e n t a l i n s t r u c t i o n s , e x p l a n a t o r y n o t e s a n d / o r i l l u s t r a t i o n s r e q u i r e d
for
a
particular
maintenance
function.
C-2. Explanation of Columns in Section Il.
a. Group Number. Column 1. The assembly group is a numerical group assigned to each assembly in a top down breakdown sequence. The applicable assembly groups are listed on the MAC in
disassembly sequence beginning with the first assembly removed in a top down disassembly
sequence.
b. Assembly Group. Column 2. This column contains a brief description of the components of
each assembly group.
c . M a i n t e n a n c e F u n c t i o n s . C o l u m n 3 . This column lists the various maintenance functions (A
through K) and indicates the lowest maintenance category authorized to perform these functions. The
symbol designations for the various maintenance categories are as follows:
C
- Operator or crew
O - Unit maintenance
F – Intermediate direct support maintenance
H - Intermediate general support maintenance
D
–
Depot
maintenance
The maintenance functions are defined as follows:
A – Inspect. To determine serviceability of an item by comparing its physical, mechanical, and
electrical characteristics with established standards.
B - Test. To verify serviceability and to detect electrical or mechanical failure by use of test
equipment.
C – Service. To clean, to preserve, to charge, and to add fuel, lubricants, cooling agents, and
air. If it is desired that elements, such as painting and lubricating, be defined separately, they may be
so listed.
C-1
ARMY TM 5-6115-633-14&P
D - Adjust. To rectify to the extent necessary to bring into proper operating range.
E - Aline. To adjust specified variable elements of an item to bring to optimum performance.
F - Calibrate. To determine the corrections to be made in the readings of instruments or test
equipment used in precise measurement. Consists of the comparison of two instruments, one of
which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy
of the instrument being compared with the certified standard.
G – Install. To set up for use in an operational environment such as an emplacement, site, or
vehicle.
H - Replace. To replace unserviceable items with serviceable like items.
I - Repair. Those maintenance operations necessary to restore an item to serviceable condition
through correction of material damage or a specific failure. Repair may be accomplished at each
category of maintenance.
J - Overhaul. Normally, the highest degree of maintenance performed by the Army in order to
minimize time work in process is consistent with quality and economy of operation. It consists of that
maintenance necessary to restore an item to completely serviceable condition as prescribed by maintenance standard in technical publications for each item of equipment. Overhaul normally does not
return an item to like new, zero mileage, or zero hour condition.
K - Rebuild. The highest degree of material maintenance. It consists of restoring equipment as
nearly as possible to new conditions in accordance with original manufacturing standards. Rebuild is
performed only w hen required by operational considerations or other paramount factors and then only
at the depot maintenance category. Rebuild reduces to zero the hours or miles the equipment, or
component thereof, has been in use.
d. Symbols. The uppercase letter placed in the appropriate column indicates the lowest level at
which that particular maintenance function is to be performed.
e. Tools and Equipment. Column 4. This column is provided for referencing by code, the special
tools and test equipment, (Section III ) required to perform the maintenance functions (Section II).
f. Remarks. Column 5. This column is provided for referencing by code, the remarks (Section
IV) pertinent to the maintenance functions.
C-3. Explanation of Columns in Section Ill. Section Ill, Tools, Test, and Support Equipment
Requirements is not applicable.
C-4. Explanation of Columns in Section IV. Section IV, Remarks, is not applicable.
C-2
ARMY TM 5-6115-633-14&P
Section Il. MAINTENANCE ALLOCATION CHART
ENCLOSURE
Fitted
C
0.5
C
Cover
0.1
C
0.1
C
Bows
0.1
GENERATOR
SET
F
3.0
C
0.2
See TM 56115-58512, -34 for
generator
set maintenance.
ELECTRICAL SYSTEM
Cables
Switch
BOX
O
O
0.1
0.2
C
O
0.1
0.5
Switch
O
0.5
O
0.5
F
1.0
O
0.5
Load Terminals
Wiring
O
0.2
O
O
0.2
0.5
Light and Wire
O
Assembly
0.2
O
1.0
O
0.4
C-3
ARMY TM 5-6115-633-14&P
TRAILER
C
O
ASSEMBLY
0.5
1.0
Fire
C
O
Extinguisher
Bracket
0.1
0.5
F
F
4.0
4.0
O
F
0.5
2.0
Bed/Fenders
Accessory
Box
Reflectors
C
O
and Data
Plates
0.1
0.5
Leg Prop
C
F
F
Assembly
0.1
0.5
0.7
Taillight
C
O
O
O
Cable
Assembly
0.1
0.3
1.0
0.5
TM 92330–
213–14
&P for
trailer
assembly
mainte–
nance.
C-4
*U.S.
Change 2
GOVERNMENT
PRINTING
OFFICE:
1991-
554-030/40096
064445-002
ARMY TM 5-6115-633-14&P
APPENDIX D
UNIT, INTERMEDIATE, (FIELD) (DIRECT SUPPORT AND
GENERAL SUPPORT) AND DEPOT MAINTENANCE REPAIR PARTS
AND SPECIAL TOOLS LIST)
Section I. INTRODUCTION
D - 1 . S c o p e . This joint Army and Air Force manual lists repair parts and special tools required for the
performance of unit, intermediate (field), (direct and general support) and depot maintenance of the
power plant. The following paragraphs are keyed to applicable users. All users should read paragraph
4, Special Information, prior to using this manual.
D - 2 . G e n e r a l . Repair Parts and Special Tools List is divided into the following sections:
a . ( A L L ) R e p a i r P a r t s - Section II. A list of repair parts authorized for the performance of maintenance at the unit, intermediate (field) (direct support and generaI support) and depot level in figure
and item number sequence.
b. (ALL) Special Tools, Test and Support Equipment – Section III. A list of special tools, test and
support equipment authorized for the performance of maintenance at the unit intermediate (field),
(direct support and general support) and depot level.
c. National Stock Number and Reference Number Index – Section IV. A list of National stock
numbers in numerical sequence, followed by a list of reference numbers appearing in all the listings,
in alphanumeric sequence, cross-referenced to the illustration figure number and item number.
d. Reference Designator Index – Section V. T h e r e f e r e n c e D e s i g n a t o r C o l u m n i n c l u d e s a l l
assigned reference designators arranged first in alphabetical order, second in numeric order.
Opposite each symbol is listed the figure and item number of the part in Section II and the reference
number.
D - 3 . E x p l a n a t i o n o f c o l u m n s . The following provides an explanation of columns in the tabular lists in
Sections II and Ill.
a. (ALL) Illustrations, (Column 1). This column is divided as follows:
(1) F i g u r e N u m b e r . Indicates the figure number of the illustration on which the item is shown.
(2) I t e m N u m b e r . Indicates the number used to identify the item on the illustration.
b. (ALL) Source, Maintenance, and Recoverability Codes (SMR), (Column 2).
(1) U n i f o r m S o u r c e C o d e s a p p l i c a b l e t o a l l M i l i t a r y S e r v i c e s .
D-1
ARMY TM 5-6115-633-14&P
G E N E R A L : Source Codes are assigned to support items to indicate the manner of acquiring support
items for maintenance, repair, or overhaul of end items. Source codes are entered in the first and
second positions of the Uniform SMR Code format as follows:
Definition
Code
PA
PB
Item procured and stocked for anticipated or known usage.
Item procured and stocked for insurance purposes because
essentiality dictates that a minimum quantity be available
in the supply systems.
PC
Item procured and stocked and which otherwise would be coded
PA except that it is deteriorative in nature.
PD
Support item, excluding support equipment, procured for initial
issue or outfitting and stocked only for subsequent or
additional initial issues or outfittings. Not subject to automatic replenishment.
PE
Support equipment procured and stocked for initial issue or
outfittings to specified maintenance repair activities.
PF
Support equipment which will not be stocked but which will be
centrally procured on demand.
PG
Item procured and stocked to provide for sustained support for
the life of the equipment. It is applied to an item peculiar to the
equipment which because of probable discontinuance or shutdown
of production facilities would prove uneconomical to reproduce at
a later time.
KD
An item of depot overhaul/repair kit and not purchased separately. Depot kit defined as a kit that provides items required
at the time of overhaul or repair.
KF
An item of maintenance kit and not purchased separately.
Maintenance kit defined as a kit that provides an item that can
be replaced at unit or intermediate levels of maintenance.
KB
Item included in both a depot overhaul/repair kit and a
maintenance
kit.
MO
Item to be manufactured or fabricated at unit level.
MF
Item to be manufactured or fabricated at intermediate
maintenance
levels.
A i r F o r c e - Intermediate
Army
D
-
2
(*)
- General Support (*)
ARMY TM 5-6115-633-14&P
Definition
Code
MD
Item to be manufactured or fabricated at depot maintenance level.
AO
Item to be assembled at unit level.
AF
Item to be assembled at intermediate maintenance levels.
Air Force – Intermediate (*)
Army – Direct Support (*)
AH
Item to be assembled at intermediate maintenance levels.
Air Force – Intermediate (*)
Army – General Support (*)
AD
Item to be assembled at depot maintenance level.
XA
Item is not procured or stocked because the requirements for the
item will result in the replacement of the next higher assembly.
XB
x c
Item is not procured or stocked. If not available through salvage,
requisition.
Installation
drawings,
diagram,
instruction
sheet,
field
service
drawing, that is identified by manufacturer’s part number.
XD
A support item that is not stocked. When required, item will be
procured through normal supply channels.
(*)NOTE
For USAF and the USA Safeguard Program, only Code “F” will be used to
denote intermediate maintenance. On joint programs, use of either code F or
H by the jointing service will denote intermediate maintenance to USAF and
USA Safeguard Program.
(2) Uniform Maintenance Codes applicable to all Military Services: G E N E R A L : M a i n t e n a n c e
Codes are assigned to indicate the levels of maintenance authorized to USE and REPAIR support
items. The Maintenance Codes are in the third and fourth position of the Uniform SMR Code Format.
(a) Use (Third Position): The Maintenance Code entered in the third position indicates the
lowest level maintenance level authorized to remove, replace, and use the support item. The
Maintenance Code entered in the third position indicates one of the following levels of maintenance.
Code
o
Application/Explanation
Support item is removed, replaced, used at the unit level of
maintenance.
D-3
ARMY TM 5-6115-633-14&P
Code
F
Application/Explanation
Support item is removed, replaced, used at the following intermediate
levels:
USAF - Intermediate (*)
U S A - Direct Support (*)
H
Support item is removed, replaced, used at the following intermediate
levels:
USAF - Intermediate (*)
USA - General Support (*)
Definition
Code
D
Support items that are removed, replaced, used at Depot only:
U S A F – Depot, Mobile Depot and Specialized Repair Activity.
USA – Depot, Mobile Depot and Specialized Repair Activity.
(b) Repair (Fourth Position): The maintenance code entered in the fourth position indicates
whether the item is to be repaired and identifies the lowest maintenance level with the capability to
perform complete repair (i.e., all authorized maintenance functions).
o
The lowest maintenance level capable of complete repair of the support
item is the unit level.
F
The lowest maintenance level capable of complete repair of the support
item is the following intermediate level:
USAF – Intermediate (*)
USA - General Support (*)
H
The lowest maintenance level capable of complete repair of the support
item is the following intermediate level:
USAF – Intermediate (*)
USA - General Support (*)
(*) NOTE
For USAF programs and the USA Safeguard Program, Code F will be used to
denote intermediate maintenance. On joint programs, use of either Code F or
H by the joining Service will denote intermediate maintenance to USAF and the
USA Safeguard Program.
Code
D
Definition
The lowest maintenance level capable of complete repair of the support
item is the depot level.
USAF – Depot, Mobile Depot, and Specialized Repair Activity.
USA – Depot, Mobile Depot, and Specialized Repair Activity.
D-4
ARMY TM 5-6115-633-14&P
Application/Explanation
Code
L
Repair restricted to designated Specialized Repair Activity.
Z
Nonreparable. No repair is authorized.
B
No repair is authorized. The item may be reconditioned by adjusting,
lubricating, etc., at the user level. No parts or special tools are
procured for the maintenance of this item.
(3) Uniform Recoverability Codes applicable to all Military Services: G E N E R A L :
Recoverability Codes are assigned to support items to indicate the disposition action on unserviceable
items. The recoverability code is entered in the fifth position of the uniform SMR Code Format as
follows:
Recoverability
Definition
Codes
Nonreparable item. When unserviceable, condemn and dispose at
Z
the level indicated in column 3.
Reparable item. When uneconomically reparable, condemn and
O
dispose at unit level.
Reparable item. When uneconomically reparable, condemn and
F
dispose at the following intermediate levels:
U S A F - Intermediate (*)
U S A - Direct Support (*)
Reparable item. When uneconomically reparable, condemn and
H
dispose at the following levels:
USAF – Intermediate (*)
USA – General Support (*)
(*) NOTE
For USAF programs and the USA Safeguard Program, Code F will be used to
denote intermediate maintenance. On joint programs, use of either Code F or
H by the joining Service will denote intermediate level of USAF and the USA
Safeguard
Program.
Recoverability
Definition
Codes
D
Reparable item. When beyond lower level repair capability,
return to depot. Condemnation and disposal not authorized
below depot level.
L
Reparable item. Repair, condemnation and disposal not
authorized
below
depot/Specialized
Repair
Activity
level.
D-5
ARMY TM 5-6115-633-14&P
Recoverability
Definition
Codes
Item requires special handling or condemnation procedure
A
because of specific reasons (i.e., precious metal content,
high-dollar value, critical material or hazardous material).
Refer to appropriate manuals/directives for specific
instructions.
c. (ALL) National Stock Number (Column 4). Indicates the National Stock Number assigned to
the item and will be used for requisitioning purposes.
d. (ALL) Description (Column 5). Indicates the Federal item name and any additional descriptions of the item required. The abbreviation “w/e” when used as part of the nomenclature, indicates
that the National Stock Number includes all armament, equipment, accessories and repair parts
issued with the item. A part number or other reference number is followed by the applicable five digit
Federal Supply Code for manufacturer in parentheses. If two reference numbers and Federal Supply
Codes for manufacturer are listed, the first listing refers to the Department of Defense Drawing
Number, the second listing refers to the actual part manufacturer. Items that are included in kits and
sets are listed below the name of the kit or set with the quantity of each item in the kit or set indicated in
the quantity incorporated in unit column.
e. (ALL) Unit of Measure (U/M) (Column 6). Indicates the standard of the basic quantity of the
listed item as used in performing the actual maintenance function. This measure is expressed by a
two-character alphabetical abbreviation (e.g., ea, in, pr, etc.). When the unit of measure differs
from the unit of issue, the lowest unit of issue that will satisfy the required units of measure will be
requisitioned.
f. (ALL) Quantity Incorporated in Unit (Column 7). Indicates the quantity of the item used in the
assembly group. A “V” appearing in this column in lieu of a quantity indicates that a definite quantity
cannot be indicated (e.g., shims, spacers, etc.).
D-4. Special Information.
a. (ALL) Identification of Usable On Codes for this Manual is not applicable.
b. Army unit maintenance personnel will extract the items which they require from Section ll, 3rd
or 4th position of column 2 of the intermediate direct and general support RPSTL. Parts which are
manufactured or assembled at a higher level than that authorized to install the part are indicated by the
use of higher level code in the source column.
c. Stockage Information.
(1) Air Force stockage information is contained in Initial Supply Support Lists issued separately
from this publication by Sacramento Air Logistics Center in accordance with AFM 67-1,
part 1, chapter 12.
D-6
ARMY TM 5-6115-633-14&P
(2) Army stockage is demand based in accordance with AR 710-2. Repair parts listed in this
publication represent those authorized for use at indicated maintenance levels and will be
requisitioned on an as-required basis until stockage is justified in accordance with
AR 710-2.
d. In the parts list, some items are indented to show that they are a component of the item under
which they are indented.
D-5. How to Locate Repair Parts.
a. (ALL) When National Stock Number or reference number is unknown:
(1)
Using the table of contents, determine the functional group; i.e., batteries and related
parts, exhaust and breather pipes, within which the repair part belongs. This is necessary
since illustrations are prepared for functional groups.
(2)
(3)
Find the illustration covering the functional group to which the repair part belongs.
Identify the repair part on the illustration and note the illustration figure and item number of
the repair part.
(4)
Using the Repair Parts Listing, find the figure and item number noted on the illustration.
b. (ALL) When national stock number or reference number is known:
(1) Using the Index of National Stock Numbers and Reference Numbers, find the pertinent
national stock number or reference number. This index is in ascending NSN sequence
followed by a list of reference numbers in alphanumeric sequence, cross-referenced to
the illustration figure number and item number.
(2) After finding the figure and item number, locate the figure and item number in the repair
parts list.
D-6. (F) Use of the Reference Designator Index Section. This Section (Section V) is used when the
reference designator is known or identified by other technical manuals supporting this equipment. The
reference number is given in this section. If description or location is desired, note the figure and item
number. Turn to Section II to the noted figure and item number. The location of the part and
description is given in this listing.
D-7.
Abbreviations.
Abbreviations
Explanation
Not
Applicable
D-8. Federal Supply Codes for Manufacturers.
Manufacturer
C o d e
Not
Applicable
D-7
ARMY TM 5-6115-633-14&P
D-9. Recommendation for Maintenance Publication Improvements. Report of errors, omissions, and
recommendations for improving this publication by the individual user is encouraged. Reports should
be submitted as follows:
a. Air Force AFTO Form 22 in accordance with T.O. 00-5-1, directly to: Commander,
Sacramento Air Logistics Center, ATTN: SM-ALC-MMEDTA, McClellan AFB, CA 95652-5609.
b. Army DA Form 2028, directly to: Commander, US Army Troop Support Command, ATTN:
AMSTR-MCTS, 4300 Goodfellow Boulevard, St. Louis, MO 63120-1798.
D-8/(D-9 blank)
ARMY TM 5-6115-633-14&P
Figure D-1. Enclosure.
D - 1 0
SECTION II
ARMY TM5-6115-633-14&P
(1)
ILLUSTRATION
A
B
FIG
ITEM
NO.
NO.
(2)
SMR CODE
(6)
(7)
(8)
U/M
QTY
INC
IN
UNIT
USMC
QTY
PER
EQUIP
D-1
1
PAOFF
FITTED COVER
13226E7740 97403
EA
1
D-1
2
D-1
3
PAOZZ
ROPE, SISAL
T-R-605B 81349
EA
25
PAOZZ
GROMMET, METALLIC
MIL-G-16491D 81349
EA
25
D-1
4
PAOZZ
5340-00-078-7029
CLIP, END STRAP
MS51926-3 96906
EA
24
D-1
5
PAOZZ
D-1
6
5340-00-057-6956
BUCKLE, SPRING ACTION
MS51929-2 96906
EA
12
CHAPE ASSEMBLY
13214E1392 97403
EA
12
D-1
7
D-1
8
RING, DEE
MS51925-1
EA
16
EA
26
A
ARMY
(3)
USMC
B
AIR
FORCE
C
D
A
NAVY
USMC
SSI
(4)
B
REPL
FACTOR
NATIONAL
STOCK
NUMBER
(5)
DESCRIPTION
USABLE
ON
CODE
REF NUMBER
& MFR CODE
GROUP 01 - ENCLOSURE
PAOZZ
6115-01-206-1271
5365-01-031-9674
96906
HOOK, SNAP
MIL-S-43770/1SWZE3
81349
D-1
9
PAOZZ
2540-00-924-8478
BOW, VEHICULAR, TOP
13212E3597-1 97403
EA
4
D-1
10
PAOZZ
2540-00-926-1003
BOW, VEHICULAR TOP
13212E3597-2 97403
EA
2
D-11
ARMY TM 5-6115-633-14&P
Figure D-2. Generator Set.
D-12
SECTION II
ARMY TM5-6115-633-14&P
(1)
ILLUSTRATION
A
B
FIG
ITEM
NO.
NO.
(2)
SMR CODE
D-2
1
PAOFH
D-2
2
D-2
3
A
ARMY
(3)
B
AIR
FORCE
C
D
A
NAVY
USMC
SSI
(4)
B
REPL
FACTOR
NATIONAL
STOCK
NUMBER
(5)
DESCRIPTION
USABLE
ON
CODE
REF NUMBER
& MFR CODE
(6)
(7)
(8)
U/M
QTY
INC
IN
UNIT
USMC
QTY
PER
EQUIP
GROUP 02 - GENERATOR SET
D-2
4
D-2
5
PAOZZ
PAOZZ
6115-00-465-1030
GENERATOR SET, DIESEL
MEP-003A 30554
EA
2
5305-00-719-5235
SCREW, CAP, HEX
MS90727-114 96906
EA
8
5310-00-584-5272
LOCKWASHER
MS35338-48
EA
8
WASHER, FLAT
PN NOT AVAILABLE
EA
8
WASHER, BEVELED
13206E4482-2 97403
EA
8
5310-01-150-5922
D-13
96906
ARMY TM 5-6115-633-14&P
Figure D-3. Five-Wire Power Cable.
D - 1 4
SECTION II
ARMY TM5-6115-633-14&P
(1)
ILLUSTRATION
A
B
FIG
ITEM
NO.
NO.
(2)
SMR CODE
(6)
(7)
(8)
U/M
QTY
INC
IN
UNIT
USMC
QTY
PER
EQUIP
D-3
1
PAOFF
CABLE ASSY, POWER (FIVE-WIRE)
(GEN 1)
13226E5888-1 97403
EA
1
D-3
2
PAOFF
CABLE ASSY, POWER (FIVE-WIRE)
(GEN 2)
13226E5888-2 97403
EA
1
D-3
3
PAFZZ
CABLE
CO-04-HDF- 81349
(4/1-4/8R) 1620
FT
AR
D-3
4
PAOZZ
BAND, IDENTIFICATION
MIL-P-15024/8 81349
TYPE K2
EA
26
D-3
5
PAOZZ
5940-00-115-5007
TERMINAL, LUG
MS25036-130 96906
EA
8
D-3
6
PAOZZ
5940-00-113-9833
TERMINAL, LUG
MS25036-131 96906
EA
2
D-3
7
PAOZZ
SLEEVING, INSULATION
MS23053/5-107-5 81349
EA
AR
D-3
8
PAOZZ
WIRE, SIZE 6 AWG
QQW343C06 B1B 81348
EA
4
D-3
9
PAOZZ
SLEEVING, INSULATION
MS23053/5-109-5 81349
EA
AR
A
ARMY
(3)
B
AIR
FORCE
C
D
A
NAVY
USMC
SSI
(4)
B
REPL
FACTOR
NATIONAL
STOCK
NUMBER
(5)
DESCRIPTION
REF NUMBER
& MFR CODE
USABLE
ON
CODE
GROUP 03 - ELECTRICAL SYSTEM
0301 - POWER CABLES
6150-01-B76-1221
D-15
ARMY TM 5-6115-633-14&P
Figure D-4. Four- Wire Power Cable.
D-16
SECTION II
(1)
ILLUSTRATION
A
B
FIG
ITEM
NO.
NO.
ARMY TM5-6115-633-14&P
(2)
SMR CODE
A
ARMY
(3)
B
AIR
FORCE
C
D
A
NAVY
USMC
SSI
(4)
B
REPL
FACTOR
NATIONAL
STOCK
NUMBER
(5)
DESCRIPTION
USABLE
ON
CODE
REF NUMBER
& MFR CODE
(6)
(7)
(8)
U/M
QTY
INC
IN
UNIT
USMC
QTY
PER
EQUIP
0301 - POWER CABLES
D-4
1
CABLE ASSY, POWER (FOUR-WIRE)
(GEN 1)
13212E3584-4 97403
EA
1
D-4
2
CABLE ASSY, POWER (FOUR-WIRE)
(GEN 2)
13212E3585-4 97403
EA
1
D-4
3
CABLE
CO-04HDE (4/2)
1480
FT
AR
PAFZZ
81349
D-4
4
PAOZZ
TUBING, INSULATION (2.000 ID X
0.045 NOM WALL)
MIL-I-23053/5 81349
CLASS 1
EA
1
D-4
5
PAOZZ
TUBING, INSULATION (0.500 ID X
0.025 NOM WALL)
MIL-I-23053/5 81349
CLASS 1
EA
8
D-4
6
PAOZZ
5490-00-113-8191
TERMINAL, LUG
MS25036-127 96906
EA
3
D-4
7
PAOZZ
5490-00-113-9831
TERMINAL, LUG
MS25036-128 96906
EA
1
D-17
ARMY TM 5-6115-633-14&P
Figure D-5. Five Wire Switch Box.
D-18 Change 4
ARMY TM 5-6115-633-14&P
SECTION II
(1)
(2)
(3)
(4)
ILLUSSMR CODE
USMC
TRATION
a
b
a
b
c
d
a
b
NATIONAL
FIG ITEM
AIR
REPL
STOCK
NO. NO. ARMY FORCE NAVY USMC SSI FACTOR NUMBER
(5)
DESCRIPTION
REF NUMBER
& MFR CODE
(6)
(7)
(8)
QTY USMC
USABLE
INC QTY
ON
IN
PER
CODE U/M UNIT EQUIP
0302 - Switch Box
D-5
D-5
D-5
1
2
PBOFF
XBOFF
3
D-5
D-5
4
5
XBOZZ
D-5
6
PAOZZ
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
7
8
9
10
PAFZZ
PAOZZ
PAOZZ
PAOZZ
5940-01-B76-1201
5330-00-178-9319
5305-00-968-1727
5310-00-809-4058
5310-00-088-1251
11
12
13
14
PAOZZ
PAOZZ
PAOZZ
PAOZZ
D-5
6115-01-B76-1197
15
5310-00-042-4229
5310-00-006-8286
5310-00-004-9129
5310-0-187-2413
XBFZZ
D-5
D-5
16
17
PAOZZ
5305-00-989-7435
D-5
18
PAOZZ
5310-00-045-3296
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
19
20
PAOZZ
PAFZZ
20A PAFZZ
21
5310-00-014-5850
5930-00-829-3238
5355-01-162-3704
PAFZZ
21A PAFZZ
22
23
24
25
26
27
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAOZZ
5330-00-579-7916
5305-00-963-7467
5310-00-809-5998
5310-00-225-6993
5330-00-618-5361
5305-01-135-7528
BOX, SWITCH (FIVE-WIRE)
13226E5859-l
.BOX
13226E5B61
..NUT, BLIND RIVET
MS27130-S99
..FASTENER, PANEL
.PLATE, INFORMATION
13212E3587
.BOARD TERMINAL
13211E4775
.GASKET
13212E3583
.SCREW, MACHNE
MS35206- 23
.WASHER, FLAT
MS27183-10
.NUT, SELF-LOCKING
MS51922-1
.POST, TERMINAL
MS39347-4
.LOCKWASHER, INTERNAL TOOTH
MS35333-113
.NUT, PLAIN, HEX
MS16203-41
.WASHER, FLAT
AN961-6168
.WASHER, FLAT
AN961-616T
.COVER
13212E3579
.WASHER, FLAT
.SCREW MACHINE
MS35207-264
.LOCKWASHER
MS3533-3
.WASHER, FLAT
MS271342
.SWITCH, ROTARY
MIL-S-15291/12
.KNOB
07000-1
.LOCKWASHER
02015-4
.SCREW
02016-28
.PACKING, PREFORMED
MS28775-115
.SCREW, CAP, SOCKET HEAD
MS16997-149
.WASHER, FLAT
kMS27183-18
.NUT, SELF-LOCKING
MS51922-33
.PACKING, PREFORMED
MS28775-015
.SCREW, MACHINE
MS35215-95
EA
1
EA
1
EA
16
EA
EA
2
1
EA
1
EA
1
EA
6
EA
6
EA
6
EA
5
EA
4
EA
10
EA
11
EA
11
EA
1
EA
EA
2
16
EA
16
EA
16
EA
1
EA
1
EA
1
EA
1
EA
1
EA
4
EA
8
EA
4
EA
4
EA
9
97403
97403
A
96906
97403
97403
97403
96906
96906
96906
96o06
96906
96906
81352
88044
97403
96906
96906
96906
81349
82121
82121
82121
96906
96906
96906
96906
96906
96906
Change 4 D-19
ARMY TM 5-6115-633-14&P
SECTION II
(1)
(2)
(3)
(4)
ILLUSSMR CODE
USMC
TRATION
a
b
a
b
c
d
a
b
NATIONAL
FIG ITEM
AIR
REPL
STOCK
NO. NO. ARMY FORCE NAVY USMC SSI FACTOR NUMBER
(5)
DESCRIPTION
REF NUMBER
& MFR CODE
(6)
(7)
(8)
QTY USMC
USABLE
INC QTY
ON
IN
PER
CODE U/M UNIT EQUIP
0302 - Switch Box - CONT
D-5
D-5
28
29
D-5
30
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
D-5
31
32
33
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOOO
33A PAOOO
33B PAOZZ
33C PAOZZ
33D PAOZZ
33E MOOZZ
33F PAOZZ
33G PAOZZ
34
PAOOO
34A PAOOO
348 PAOZZ
34C PAOZZ
34D PAOZZ
34E PAOZZ
34F PAOZZ
34G PAOZZ
35
36
37
38
39
40
41
42
XBFZZ
MDOZZ
PAOZZ
MDOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
.WASHER, STAR
5310-00-411-0687 .NUT, PLAIN, HEX
MS35650-3385T
.TUBE STUFFING
13218E5149-10
5310-01-166-6154 .WASHER
13218E5139- 5
5301-00-164-2351 .GASKET
13218E5140-5
6120-00-253-0688 .LIGHT AND WIRE ASSY
13212E3581-2
6210-00-900-9423 ..LIGHT INDICATOR
13214E1391
6210-01-230 1851 ...HOUSING
181-88309-553
...LAMP
GSB(OR)
6210-00-941-6690 ...LENS
181-0937-003
..WIRE
M5086/1-18
..INSULATION TUBING
M23053/5-106
5940-00-113-8184 ..TERMINAL
MS25036-150
6120-00-406-1398 .LIGHT AND WIRE ASSY
13212E3581-1
6210-00-900-9423 ..LIGHT, INDICATOR
13214E1391
6210-01-230-1851 ...HOUSING
181-8836-09-553
...LAMP
G96(GR)
6210-00-941-6690 ...LENS
181-0937-003
..WIRE
M5086/1-18
..INSULATION TUBING
M230535-106
..TERMINAL LUG
MS25036-105
.PLATE, WARNING
13216E7603
.PLATE, INFORMATION
13226E5889-1
5320-00-721-5239 .RIVET
MS16535-153
.PLATE, INFORMATION
13226E5889-2
5310-01-078-5998 .NUT, PLAIN, WING
MS35425-75
5310-00-184-8971 .LOCKWASHER
MS35338-103
5310-00-187-2413 .WASHER, FLAT
AN961-616T
5310-00-584-7995 .NUT, PLAIN, HEX
MS16203-27
EA
EA
9
9
EA
2
EA
2
EA
2
EA
1
EA
1
EA
1
EA
1
EA
1
EA
2
EA
2
EA
2
EA
1
EA
1
EA
1
EA
1
EA
1
EA
2
EA
2
EA
2
EA
1
EA
1
EA
8
EA
1
EA
1
EA
2
EA
3
EA
1
96906
97403
97403
97403
97403
97403
72619
73070
72619
96908
81349
96906
97403
97403
72619
73070
72619
96906
96906
96906
97403
97403
96906
97403
96906
96906
81352
96908
D-20 Change 4
ARMY TM 5-6115-633-14&P
SECTION II
(1)
(2)
(3)
(4)
ILLUSSMR CODE
USMC
TRATION
a
b
a
b
c
d
a
b
NATIONAL
FIG ITEM
AIR
REPL
STOCK
NO. NO. ARMY FORCE NAVY USMC SSI FACTOR NUMBER
(5)
DESCRIPTION
REF NUMBER
& MFR CODE
(6)
(7)
(8)
QTY USMC
USABLE
INC QTY
ON
IN
PER
CODE U/M UNIT EQUIP
0302 -Switch Box - CONT
D-5
D-5
43
44
PAOZZ
PAOZZ
D-5
D-5
45
46
PAOZZ
D-5
47
PAOZZ
D-5
48
5307-00-227-1741 .STUD
13214E1223
5310-01-026-5824 .NUT, PLAIN, HEX
MS16203-39
.WASHER, STAR
5305-00-269-3211 .CREW, CAP, HEX
MS90725-60
5310-00-637-9541 .LOCKWASHER
MS35338-46
.WASHER, FLAT
EA
1
EA
2
EA
EA
2
4
EA
4
EA
4
97403
96906
96906
96906
Change 4 D-21
ARMY TM 5-6115-633-14&P
Figure D-6. Four-Wire Distribution Box.
D-22
SECTION II
(1)
ILLUSTRATION
A
B
FIG
ITEM
NO.
NO.
ARMY TM5-6115-633-14&P
(2)
SMR CODE
A
ARMY
(3)
B
AIR
FORCE
C
D
A
NAVY
USMC
SSI
(4)
B
REPL
FACTOR
NATIONAL
STOCK
NUMBER
(5)
DESCRIPTION
(6)
(7)
(8)
U/M
QTY
INC
IN
UNIT
USMC
QTY
PER
EQUIP
BOX, DISTRIBUTION (FOUR-WIRE)
13220E4462 97403
EA
1
BOX
13220E4466
USABLE
ON
CODE
REF NUMBER
& MFR CODE
0302 - DISTRIBUTION BOX
D-6
1
D-6
2
EA
1
D-6
3
PAOZZ
NUT, BLIND RIVET
MS27130-S57 96906
EA
4
D-6
4
PAOZZ
NUT, BLIND RIVET
MS27130-S99 96906
EA
16
D-6
5
PAOZZ
FASTENER, PANEL
MIL-F-5591C 81349
TYPE 3A
EA
2
D-6
6
PAOZZ
RIVET
MS20426A4-6
EA
4
PLATE, INFORMATION
13212E3587 97403
EA
1
5320-00-117-6963
97403
96906
D-6
7
XBOZZ
D-6
8
PAOZZ
5940-01-B76-1201
BOARD, TERMINAL
13211E4775 97403
EA
1
D-6
9
PAFZZ
5330-01-178-9319
GASKET
13212E3583
EA
1
97403
D-6
10
PAOZZ
5305-00-988-1727
SCREW, MACHINE
MS35206-283 96906
EA
6
D-6
11
PAOZZ
5310-00-809-4058
WASHER, FLAT
MS27183-10 96906
EA
6
D-6
12
PAOZZ
5310-00-088-1251
NUT, SELF-LOCKING
MS51922-1 96906
EA
6
D-6
13
POST, TERMINAL
MS39347-4 96906
EA
4
D-6
14
PAOZZ
5310-00-042-4229
LOCKWASHER, INTERNAL TOOTH
MS35333-113 96906
EA
5
D-6
15
PAOZZ
5310-00-006-8286
NUT, PLAIN, HEX
MS16203-41 96906
EA
8
D-6
16
PAOZZ
5310-01-004-9129
WASHER, FLAT
AN961-616S 81352
EA
11
PAOZZ
5310-00-187-2413
WASHER, FLAT
AN961-616T 81342
EA
11
COVER
13212E3579
D-6
D-6
17
XBFZZ
EA
1
D-6
18
PAOZZ
5305-00-989-7435
SCREW, MACHINE
MS35207-264 96906
EA
16
D-6
19
PAOZZ
5310-00-045-3296
LOCKWASHER
MS35338-43
EA
16
D-6
20
PAOZZ
5310-00-014-5850
WASHER, FLAT
MS27183-42 96906
EA
16
D-23
97403
96906
SECTION II
ARMY TM5-6115-633-14&P
(1)
ILLUSTRATION
A
B
FIG
ITEM
NO.
NO.
(2)
SMR CODE
(6)
(7)
(8)
U/M
QTY
INC
IN
UNIT
USMC
QTY
PER
EQUIP
D-6
21
PAFZZ
SWITCH, ROTARY
13205E5024 97403
EA
1
D-6
22
PAFZZ
D-6
23
PAFZZ
5330-00-579-7916
PACKING, PREFORMED
MS28775-115 96906
EA
1
5305-00-983-7467
SCREW, CAP, SOCKET HEAD
MS16997-149 96906
EA
4
D-6
24
PAFZZ
5310-00-809-5998
WASHER, FLAT
MS27183-18 96906
EA
8
D-6
D-6
25
PAFZZ
5310-00-225-6993
NUT, SELF-LOCKING
MS51922-33 96906
EA
4
26
PAFZZ
5330-00-618-5361
PACKING, PREFORMED
MS28775-015 96906
EA
4
D-6
27
PAOZZ
5305-01-135-7258
SCREW, MACHINE
MS35215-95 96906
EA
9
D-6
28
PAOZZ
5310-00-913-9776
LOCKWASHER
MS35335-91
EA
9
NUT, PLAIN, HEX
MS35650-3385T 96906
EA
9
TUBE, STUFFING
13218E5149-9 97403
EA
2
WASHER
13218E5139-5
EA
2
97403
97403
A
ARMY
(3)
B
AIR
FORCE
C
D
A
NAVY
USMC
SSI
(4)
B
REPL
FACTOR
NATIONAL
STOCK
NUMBER
(5)
DESCRIPTION
USABLE
ON
CODE
REF NUMBER
& MFR CODE
0302 - DISTRIBUTION BOX - CONT.
D-6
29
D-6
30
D-6
31
PAOZZ
5310-00-411-0687
PAOZZ
5310-01-166-6154
96906
D-6
32
PAOZZ
5330-01-164-2351
GASKET
13218E5140-5
EA
2
D-6
33
PAOOO
6210-00-253-0688
LIGHT AND WIRE ASSY
13212E3581-2 97403
EA
1
D-6
34
PAOOO
6210-00-406-1398
LIGHT AND WIRE ASSY
13212E3581-1 97403
EA
1
D-6
35
PAFZZ
TERMINAL, LUG
MS25036-105 96906
EA
4
D-6
36
XBFZZ
PLATE, WARNING
13216E7603 97403
EA
1
D-6
37
PAOZZ
5305-00-269-3211
SCREW, CAP, HEX
MS90725-60 96906
EA
4
D-6
38
PAOZZ
5310-00-637-9541
LOCKWASHER
MS35338-46
EA
4
D-24/(D-25 BLANK)
96906
ARMY TM 5-6115-633-14&P
Figure D-7. Distribution Box Electrical Leads.
D
-
2
6
SECTION II
ARMY TM5-6115-633-14&P
(1)
ILLUSTRATION
A
B
FIG
ITEM
NO.
NO.
(2)
SMR CODE
(6)
(7)
(8)
U/M
QTY
INC
IN
UNIT
USMC
QTY
PER
EQUIP
D-7
1
MFFFF
LEAD, ELECTRICAL (W3)
13212E3586-1 97403
EA
1
D-7
2
MFFFF
LEAD, ELECTRICAL (W4)
13212E3586-2 97403
EA
1
D-7
D-7
3
MFFFF
LEAD, ELECTRICAL (W5)
13212E3586-3 97403
EA
1
4
MFFFF
LEAD, ELECTRICAL (W6)
(USED ON SWITCH BOX)
PN 13226E5859-1 ONLY)
13212E3586-4 97403
EA
1
D-7
5
PAOZZ
WIRE
M5086/2-2
FT
AR
A
ARMY
(3)
B
AIR
FORCE
C
D
A
NAVY
USMC
SSI
(4)
B
REPL
FACTOR
NATIONAL
STOCK
NUMBER
(5)
DESCRIPTION
USABLE
ON
CODE
REF NUMBER
& MFR CODE
0302- DISTRIBUTION BOX
ELECTRICAL LEADS
6150-01-152-8315
81349
D-7
6
PAOZZ
5940-00-113-8191
TERMINAL, LUG
MS25036-127 96906
CL 1 SZ 2
EA
3
D-7
7
PAFZZ
5940-00-113-9831
TERMINAL, LUG
MS25036-128 96906
CL 1 SZ 2
EA
5
D-7
8
PAFZZ
TUBING, SHRINKABLE
MS23053/5-108-5 81349
EA
AR
D-27/(D-28 BLANK)
ARMY TM 5-6115-633-14&P
Figure D-8. Trailer Body (Sheet 1 of 2).
D-29
ARMY TM 5-6115-633-14&P
Figure D-8. Trailer Body (Sheet 2 of 2).
D - 3 0
SECTION II
ARMY TM5-6115-633-14&P
(1)
ILLUSTRATION
A
B
FIG
ITEM
NO.
NO.
(2)
SMR CODE
(6)
(7)
(8)
U/M
QTY
INC
IN
UNIT
USMC
QTY
PER
EQUIP
D-8
1
PAOZZ
5340-00-229-0340
LOOP, STRAP FASTENER
MS51939-3 96906
EA
4
D-8
2
PAOZZ
D-8
3
PAOZZ
5305-00-088-8332
SCREW, MACHINE
MS35190-272 96906
EA
8
5310-00-809-8546
WASHER, FLAT
MS27183-8 96906
EA
9
D-8
4
PAOZZ
LOCK NUT
PN NOT AVAILABLE
EA
9
D-8
D-8
5
XBFZZ
RAIL, MOUNTING, CURBSIDE
13220E4457-2 97403
EA
1
6
XBFFF
RAIL, MOUNTING, ROADSIDE
13220E4458-2 97403
EA
1
D-8
7
XDOZZ
5305-00-782-9495
SCREW, CAP, HEX
MS90725-111 96906
EA
16
D-8
8
PAFZZ
5310-00-809-5998
WASHER, FLAT
MS27183-18 96906
EA
32
D-8
9
PAOZZ
5310-00-225-6993
NUT, SELF-LOCKING
MS51922-33 96906
EA
16
D-8
10
XBOZZ
4210-00-223-4857
BRACKET, FIRE EXTINGUISHER
13214E1235 97403
EA
2
D-8
11
PAOZZ
5305-00-068-0502
SCREW, CAP, HEX
MS90725-6 96906
EA
8
D-8
12
PAOZZ
5310-00-809-4058
WASHER, FLAT
MS27183-10 96906
EA
8
D-8
13
PAOZZ
5310-00-088-1251
NUT, SELF-LOCKING
MS51922-1 96906
EA
8
D-8
14
PAOZZ
5340-00-930-1754
CLAMP, LOOP
MS21334-2 96906
EA
2
D-8
15
PAOZZ
5305-00-984-6202
SCREW, MACHINE
MS35206-264 96906
EA
1
D-8
16
CLAMP, CABLE
PN NOT AVAILABLE
EA
2
D-8
17
PAOZZ
WIRE, NO. 6 AWG
QQ-W-343C06B1B 81348
FT
AR
D-8
18
PAOZZ
SLEEVING, INSULATION
M23053/5-109-0 81349
EA
AR
D-8
19
PAOZZ
STRAP, TIEDOWN
MS3367-1-1 96906
TY 1 CL 1
EA
AR
D-8
20
PAOZZ
4730-00-809-9703
ELBOW, PIPE TO HOSE
MS24519-9 96906
EA
2
D-8
21
PAOZZ
4730-00-908-3194
CLAMP, HOSE
MS35842-11 96906
EA
2
A
ARMY
(3)
B
AIR
FORCE
C
D
A
NAVY
USMC
SSI
(4)
B
REPL
FACTOR
NATIONAL
STOCK
NUMBER
(5)
DESCRIPTION
REF NUMBER
& MFR CODE
USABLE
ON
CODE
04 TRAILER
5970-00-914-3118
D-31
SECTION II
(1)
ILLUSTRATION
A
B
FIG
ITEM
NO.
NO.
ARMY TM5-6115-633-14&P
(2)
SMR CODE
A
ARMY
(3)
B
AIR
FORCE
C
D
A
NAVY
USMC
SSI
(4)
B
REPL
FACTOR
NATIONAL
STOCK
NUMBER
(5)
DESCRIPTION
(6)
(7)
(8)
U/M
QTY
INC
IN
UNIT
USMC
QTY
PER
EQUIP
HOSE, RUBBER
MIL-H-6000 81349
EA
2
USABLE
ON
CODE
REF NUMBER
& MFR CODE
04 TRAILER - CONT.
D-8
22
D-8
23
PAOZZ
5325-00-903-5909
GROMMET
MS35489-112
EA
2
D-8
24
PAOZZ
5310-00-543-4717
NUT, PLAIN WING
MS35425-28 96906
EA
1
D-8
25
PAOZZ
5310-01-004-9129
WASHER, FLAT
AN961-616S 81352
EA
4
PAOZZ
5310-00-187-2413
WASHER, FLAT
AN961-616T 88044
EA
4
D-8
26
PAOZZ
5310-01-026-5824
NUT, PLAIN, HEX
MS16203-39 96906
EA
3
D-8
27
PAOZZ
5307-00-227-1741
STUD
13214E1223
D-8
28
PAOZZ
D-8
29
PAOZZ
D-8
30
XBFHD
D-8
31
PAOZZ
5805-01-186-7145
D-8
32
PAOZZ
D-8
33
PAOZZ
D-8
34
XAFFF
D-8
35
PAOZZ
D-8
36
PAOZZ
D-8
37
PBFZZ
D-8
38
PAFZZ
D-8
39
PAOZZ
D-8
40
D-8
41
96906
EA
1
WASHER, STAR
PN NOT AVAILABLE
EA
2
TERMINAL, LUG
MS20659-110 96906
TY 1 CL 1
EA
6
TRAILER ASSY
13226E5858 97403
EA
1
SCREW, CAP, HEX
13218E0021-41 97403
EA
4
5310-00-823-8803
WASHER, FLAT
MS27183-21 96906
EA
44
5310-00-269-4040
NUT, SELF-LOCKING
MS51922-49 96906
EA
22
FLATBED, TRAILER
13226E5857 97403
EA
1
5340-01-126-3826
PIN, QUICK-RELEASE
MS17990C613 96906
EA
12
4010-01-B75-1772
CHAIN, WELDLESS
13218E0025-4 97403
EA
12
CLIP, SPRING TENSION
M24066/2-128
EA
8
5320-00-637-6068
RIVET, SOLID
MS20427-4C5 96906
EA
16
5305-00-724-5911
SCREW, CAP, HEX
MS90725-163 96906
EA
18
PAOZZ
5305-00-269-3211
SCREW, CAP, HEX
MS90725-60 96906
EA
16
PAOZZ
5310-00-080-6004
WASHER, FLAT
MS27183-14 96906
EA
28
5940-00-115-4992
D-32
97403
SECTION II
ARMY TM5-6115-633-14&P
(1)
ILLUSTRATION
A
B
FIG
ITEM
NO.
NO.
(2)
SMR CODE
D-8
42
PAOZZ
D-8
43
PAOZZ
D-8
44
PAOZZ
A
ARMY
(3)
B
AIR
FORCE
C
D
A
NAVY
USMC
SSI
(4)
B
REPL
FACTOR
NATIONAL
STOCK
NUMBER
(5)
DESCRIPTION
(6)
(7)
(8)
U/M
QTY
INC
IN
UNIT
USMC
QTY
PER
EQUIP
NUT, SELF-LOCKING
MS51922-17 96906
EA
12
RING, LIFTING
13226E7730-6 97403
EA
2
WASHER
MS35338-51
EA
2
USABLE
ON
CODE
REF NUMBER
& MFR CODE
04 TRAILER - CONT.
5310-00-087-4652
5310-00-584-7888
96906
D-8
45
PAOZZ
5310-00-832-9719
NUT, SELF-LOCKING
MS51922-61 96906
EA
2
D-8
46
PAFZZ
5365-01-B75-1770
SHIM
13212E3590-2
D-8
47
D-8
48
D-8
49
D-8
D-8
EA
AR
PIN, COTTER
PN NOT AVAILABLE
EA
2
CHASSIS, TRAILER
13226E7734 97403
EA
1
SCREW, DRIVE
PN NOT AVAILABLE
EA
2
50
WASHER, FLAT
PN NOT AVAILABLE
EA
2
51
NUT, SELF-LOCKING
PN NOT AVAILABLE
EA
2
XBFHH
D-33
97403
ARMY TM 5-6115-633-14&P
Figure D-9. Accessory Box.
D - 3 4
SECTION II
ARMY TM5-6115-633-14&P
(1)
ILLUSTRATION
A
B
FIG
ITEM
NO.
NO.
(2)
SMR CODE
(6)
(7)
(8)
U/M
QTY
INC
IN
UNIT
USMC
QTY
PER
EQUIP
D-9
1
PBOOO
6115-01-230-0677
BOX, ACCESSORY
13226E7737 97403
EA
1
D-9
2
PAOZZ
D-9
3
PAOZZ
5340-00-234-8422
HASP, HINGED
MS27969-4 96906
EA
1
5320-01-168-3097
RIVET, SOLID
MS9460-102 96906
EA
8
D-9
4
PAOZZ
5340-00-975-2126
CATCH, CLAMPING AND STRIKE
MS18015-1 96906
EA
2
D-9
D-9
5
PAOZZ
5320-00-753-3830
RIVET, SOLID
MS20613-4P5 96906
EA
8
6
PAOZZ
5305-00-957-7086
SCREW, MACHINE
MS24693-S273 96906
EA
4
D-9
7
PAOZZ
5310-00-059-9263
NUT, SELF-LOCKING
MS21046C3 96906
EA
4
D-9
8
PAOZZ
5310-00-014-5850
WASHER, FLAT
MS27183-42 96906
EA
4
D-9
9
PAOZZ
5340-00-229-0340
LOOP, STRAP FASTENER
MS51939-3 96906
EA
2
D-9
10
PAOZZ
5306-00-225-8496
SCREW, CAP, HEX
MS90725-31 96906
EA
4
D-9
11
PAOZZ
5310-00-407-9566
LOCKWASHER
MS35338-45
EA
8
EA
4
A
ARMY
(3)
B
AIR
FORCE
C
D
A
NAVY
USMC
SSI
(4)
B
REPL
FACTOR
NATIONAL
STOCK
NUMBER
(5)
DESCRIPTION
USABLE
ON
CODE
REF NUMBER
& MFR CODE
0401 - ACCESSORY BOX
D-9
12
PAOZZ
5310-00-880-7744
D-35
96906
NUT, PLAIN, HEX
MS51967-5 96906
ARMY TM 5-6115-633-14&P
Figure D-10. Data Plates and Reflectors.
D-36
SECTION II
ARMY TM5-6115-633-14&P
(1)
ILLUSTRATION
A
B
FIG
ITEM
NO.
NO.
(2)
SMR CODE
(6)
(7)
(8)
U/M
QTY
INC
IN
UNIT
USMC
QTY
PER
EQUIP
D-10
1
PAOZZ
9905-00-205-2795
REFLECTOR, RED
MS35387-1 96906
EA
4
D-10
2
PAOZZ
9905-00-202-3639
REFLECTOR, AMBER
MS35387-2 96906
EA
2
D-10
3
D-10
4
PAOZZ
5305-00-068-0500
SCREW, CAP, HEX
MS90725-3 96906
EA
12
PAOZZ
5310-00-809-4058
WASHER, FLAT
MS27183-10 96906
EA
12
D-10
D-10
5
PAOZZ
5310-00-088-1251
NUT, SELF-LOCKING
MS51922-1 96906
EA
12
6
XBOZZ
PLATE, IDENTIFICATION
13220E4463-2 97403
EA
1
D-10
7
PAOZZ
RIVET
PN NOT AVAILABLE
EA
4
D-10
8
PAOZZ
PLATE, IDENTIFICATION
13205E4918 97403
EA
1
A
ARMY
(3)
B
AIR
FORCE
C
D
A
NAVY
USMC
SSI
(4)
B
REPL
FACTOR
NATIONAL
STOCK
NUMBER
(5)
DESCRIPTION
REF NUMBER
& MFR CODE
USABLE
ON
CODE
0402 - DATA PLATES AND
REFLECTORS
9905-01-085-7703
D-37
ARMY TM 5-6115-633-14&P
Figure D-11. Leg Prop Assembly.
D-38
SECTION II
(1)
ILLUSTRATION
A
B
FIG
ITEM
NO.
NO.
ARMY TM5-6115-633-14&P
(2)
SMR CODE
A
ARMY
B
AIR
FORCE
(3)
USMC
C
NAVY
D
USMC
A
SSI
(4)
B
NATIONAL
REPL
STOCK
FACTOR NUMBER
(5)
DESCRIPTION
REF NUMBER
& MFR CODE
USABLE
ON
CODE
(6)
(7)
(8)
U/M
QTY
INC
IN
UNIT
USMC
QTY
PER
EQUIP
0403 LEG PROP
D-11
1
XBFFZ
2950-00-420-8929
LEG PROP ASSEMBLY
13214E1206 97403
EA
1
D-11
2
PAOZZ
5315-00-839-5822
PIN, COTTER
MS24665-353 96906
EA
2
D-11
3
XBOZZ
5315-01-162-0143
SHAFT
13214E1209 97403
EA
1
D-11
4
XBOZZ
6115-01-220-1548
BRACKET
13214E1207 97403
EA
1
D-11
5
XBOZZ
2590-00-453-8977
LEG, UPPER
13214E1208 97403
EA
1
D-11
6
PAOZZ
4730-00-172-0049
FITTING, LUBRICATION
MS15006-1 96906
EA
1
D-11
7
XBOZZ
5315-00-838-4584
PIN, SPRING
MS16562-66 96906
EA
1
D-11
8
XBOZZ
5315-01-158-2144
SCREW
13214E1210
EA
1
D-11
9
PAOZZ
5310-01-149-0869
NUT
13214E1211 97403
EA
1
D-11
10
XBOZZ
2590-01-167-8596
BASE, LEG
13214E1212 97403
EA
1
D-11
11
PAOZZ
5305-00-269-3213
SCREW, CAP, HEX
MS90725-62 96906
EA
3
D-11
12
PAOZZ
5310-00-080-6004
WASHER, FLAT
MS27183-14 96906
EA
6
D-11
13
PAOZZ
5310-00-087-4652
NUT, SELF-LOCKING
MS51922-17
EA
3
D-39
ARMY TM 5-6115-633-14&P
Figure D-12. Taillight Cable Assembly and Electrical Lead.
D-40
ARMY TM 5-6115-633-14&P
SECTION II
(1)
(2)
(3)
(4)
ILLUSSMR CODE
USMC
TRATION
a
b
a
b
c
d
a
b
NATIONAL
FIG ITEM
AIR
REPL
STOCK
NO. NO. ARMY FORCE NAVY USMC SSI FACTOR NUMBER
(5)
DESCRIPTION
(6)
(7)
(8)
QTY USMC
USABLE
INC QTY
ON
IN
PER
CODE U/M UNIT EQUIP
REF NUMBER
& MFR CODE
0404 - Taillight Cable Assemblies and Electrical Lead
D-12
D-12
D-12
D-12
D-12
D-12
D-12
D-12
D-12
D-12
D-12
1
2
3
4
5
6
7
8
9
10
11
PBOFF
6150-01-166-9112 CABLE ASSY ROADSIDE
13216E7479-1
6150-01-166-9111 .CABLE ASSY, CURBSIDE
13216E7479-2
5935-00-167-7775 .CONNECTOR, PLUG
MS2714- 1
9905-01-B75-1051 .BAND, MARKER
M434361-66
.CABLE
M 13486/7-1
TYPE I CL B
5935-00-462-6603 .CONNECTOR, PLUG
M827142-2
6150-01-166-9135 .LEAD, ELECTRICAL
13216E7476
5935-00-167-7775 .CONNECTOR, PLUG
MS27144-1
STYLE 1
9905-01-B75-1051 .BAND, MARKER
MA3436/1-6
6145-00-152-6499 .CABLE
M13486/1-5
TYPE I CL A
5935-00-462-6603 .CONNECTOR PLUG
US27142-2
MOOFF
PAOZZ
PAOZZ
MFFZZ
PAOZZ
MOOFF
PAOZZ
PAOZZ
PAOZZ
PAOZZ
Section III
EA
1
EA
1
EA
6
EA
20
EA
2
EA
6
EA
2
EA
2
EA
4
EA
2
EA
2
97403
97403
96906
81349
81349
96906
97403
9690M
81349
81349
96906
SPECIAL TOOLS, TEST AND SUPPORT EQUIPMENT
Not Applicable
Change 4 D-41/(D-42 blank)
ARMY TM 5-6115-633-14&P
Section IV. NATIONAL STOCK NUMBER AND REFERENCE NUMBER INDEX
NSN
2540-00-924-8478
2540-00-926-1003
2590-00-420-8929
2590-00-453-8977
2590-01-167-8596
4010-00-875-1772
4210-00-223-4857
4730-00-172-0049
4730-00-809 9703
4730-00-908-3194
5305-00-068-0500
5305-00-068-0502
5305-00-088-8332
5305-00-269-3211
5305-00-269-3213
5305-00-719-5235
5305-00-724-5911
5305-00-782-9495
5305-00-957-7086
5305-00-983-7467
5305-00-984-6202
5305-00-988-1727
5305-00-989-7435
5305-01-135-7258
5306-00-225-8496
5307-00-227-1741
5310-00-006-8288
5310-00-014-5850
5310-00-442-4229
5310-00-045-3296
5310-00-059-9263
5310-00-080-6004
5310-00-087-4652
5310-00-088-1251
5310-00-184-8971
5310-00-187-2413
5310-00-225-6993
NSN
5310-00-269-4040
5310-00-407-9566
Figure
No.
D-1
D-1
D-11
D-11
D-11
D-8
D-8
D-11
D-8
D-8
D-10
D-8
D-8
D-5
D-6
D-11
D-2
D-8
D-8
D-9
D-5
D-6
D-8
D-5
D-6
D-5
D-6
D-5
D-6
D-9
D-5
D-8
D-5
D-6
D-5
D-6
D-9
D-6
D-5
D-6
D-9
D-8
D-11
D-8
D-11
D-5
D-6
D-8
D-10
D-5
D-5
D-5
D-8
D-8
D-5
D-6
D-8
Figure
No
D-8
D-9
Item
No.
9
10
1
5
10
36
10
6
20
21
3
11
2
46
37
11
2
39
7
6
23
23
15
8
10
17
18
27
27
10
43
27
13
15
19
20
8
14
18
19
7
41
12
42
12
10
12
13
5
40
14
41
16
25
25
25
9
Item
No.
33
11
5310-00-411-0687
5310-00-543-4717
5310-00-584-5272
5310-00-584-7888
5310-00-584-7995
5310-00-637-9541
5310-00-809-4058
5310-00-809-5998
5310-00-809-8546
5310-00-823-8803
5310-00-832-9719
5310-00-880-774
5310-00-913-9776
5310-01-004-9129
5310-01-026-5824
5310-01-078-5996
5310-01-149-0869
5310-01-150-5922
5310 01-166-6154
5315-00-838-4584
5315-00-839-5822
5315-01-158-2144
5315-01-162-0143
5320-00-117-6963
5320-00-637-6068
5320-00-721-5239
5320-00-753-3830
5320-01-168-3097
5325-00-903-5909
5330-00-579-7916
5330-00-618-5361
5330-01-164-2351
5330-01-178-9319
5340-00-057-6958
5340-00-078-7029
5340-00-229-0340
5340-00-234-8422
5340-00-930-1754
5340-00-975-2126
D-5
D-6
D-8
D-2
D-8
D-5
D-5
D-6
D-5
D-6
D-8
D-10
D-5
D-6
D-8
D-8
D-8
D-8
D-9
D-6
D-5
D-6
D-8
D-5
D-8
D-5
D-11
D-2
D-5
D-6
D-11
D-11
D-11
D-11
D-6
D-8
D-5
D-9
D-9
D-8
D-5
D-6
D-5
D-6
D-5
D-6
D-5
D-6
D-1
D-1
D-8
D-9
D-9
D-8
D-9
29
29
24
3
44
42
47
38
9
11
12
4
24
24
8
3
32
45
12
28
14
16
25
44
26
39
7
5
31
31
7
2
8
3
6
38
37
5
3
23
22
22
26
26
32
32
7
9
5
4
1
9
2
14
4
Change 4 D-43
ARMY TM 5-6115-633-14&P
Section IV. NATIONAL STOCK NUMBER AND REFERENCE NUMBER INDEX
NSN
5340-01-126-3826
5365-01-B75-1770
5365-01-031-9674
5490-00-113-8191
5490-00-113-9831
5805-01-186-7145
5935-00-167-7775
5935-00-462-6603
5940-00-113-8184
5940-00-113-8191
5940-00-113-9831
5940-00-113-9833
5940-00-115-4992
5940-00-115-5007
5940-00-B76-1201
5970-00-914-3118
6115-00-465-1030
6115-01-B76-1197
6115-01-206-1271
6115-01-220-1548
6115-01-230-0677
Figure
No.
Item
No.
D-8
D-8
D-1
D-4
D-4
D-8
D-12
D-12
D-12
D-12
D-5
D-7
D-7
D-3
D-8
D-3
D-5
D-6
D-8
D-2
D-5
D-1
D-11
D-9
35
46
7
6
7
31
3
8
6
11
33G
6
7
6
29
5
6
8
18
1
2
1
4
1
Figure
No.
Item
No.
D-44 Change 4
NSN
6120-00-253-0688
6120-00-406-1398
6145-00-153-6499
6150-01-B76-1221
6150-01-152-8315
6150-01-166-9111
6150-01-166-9112
6150-01-166-9135
6210-00-253-0688
6210-00-406-1398
6210-00-900-9423
6210-00-941-6690
6210-01-230-1851
9905-00-202-3639
9905-00-205-2795
9905-01-B75-1051
9905-01-085-7703
D-5
D-5
D-12
D-3
D-7
D-12
D-12
D-12
D-5
D-6
D-5
D-6
D-5
D-5
D-5
D-5
D-5
D-5
D-10
D-10
D-12
D-12
D-10
33
34
10
2
1
2
1
7
33
33
34
34
33A
34A
33D
34D
33B
34B
2
1
4
9
8
ARMY TM 5-6115-633-14&P
Section IV. NATIONAL STOCK NUMBER AND REFERENCE - CONT
Number
Reference
Number
FSCM
AN961-616S
81352
AN961-616S
AN961-616T
81352
81352
88044
CO-04HDF-(4/1-4/8R)1620
CO-04H E (42)1480
G9B(GR)
81349
81349
73070
MEP-003A
MIL-G-16491D
MIL-H-6000
MIL-I-230535 CLASS 1
30554
81349
81349
81349
MIL-P-15024/8 TYPE K2
MIL-S-15291/12
MIL-S-3770/1 -SWZE3
MS15006-1
MS16203-27
MS16203-39
81349
MS16203-41
96S06
MS16535-153
MS16562-66
MS16997-149
96006
96906
98906
MS17990C613
MS18015-1
MS20426A4-6
MS20427-4C5
MS20613-4P5
MS20659-110 TY1 CL1
MS21046
MS21334-2
MS24519-9
MS24665-353
MS24693-S273
MS25036-105
96906
96906
96906
96906
98906
96906
96906
96906
96906
96906
96906
96906
MS25036-127
MS25036-127 CL1-5Z2
MS25036-128
MS25036-129CL1-5Z2
MS25036-130
MS25036-131
MS25036-150
MS27130-S57
MS27130-S99
MS27142-2
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
MS27144-1
MS27144-1 STYLE 1
MS27183-8
MS27183-10
96906
96906
96906
96906
Reference
81349
96906
96906
96906
Fig.
No.
Item
No.
D-5
D-6
D-8
D-5
D-6
D-5
D-8
D-3
D-4
D-5
D-5
D-2
D-1
D-7
D-4
D-4
D-3
D-5
D-1
D-11
D-5
D-5
D-8
D-5
D-6
D-5
D-11
D-5
D-6
D-8
D-9
D-6
D-8
D-9
D-8
D -9
D-8
D-8
D-11
D-9
D-6
D-5
D-4
D-7
D-4
D-7
D-3
D-3
D-5
D-6
D-5
D-12
D-12
D-12
D-12
D-8
D-5
14
16
25
41
16
14
25
3
3
33C
34C
1
3
22
4
5
4
20
8
6
42
44
26
13
15
37
7
23
23
35
4
6
38
5
29
7
14
20
2
6
35
34G
6
6
7
7
5
6
33G
3
3
6
11
3
8
3
9
Fig.
Item
FSCM
MS27183-14
96906
MS27183-18
96906
MS27183-21
MS27183-42
96906
96906
MS27969-4
MS28775-015
96906
96906
MS28775-115
96906
MS3367-1 TY1 CL1
MS35190-272
MS35206-264
MS35206283
96906
96906
96906
96906
MS35207-264
96906
MS35215-95
96906
MS35333-113
MS35335-91
MS35338-43
96906
96906
96906
MS35338-45
MS35338-46
96906
96906
MS35338-48
MS35338-51
MS35338-103
MS35387-1
MS35387-2
MS35425-28
MS35425-75
MS35489-112
MS35650-3385T
96906
96906
96906
96906
96906
96906
96906
96906
96906
MS35842-11
MS39347-4
MS39347-4
MS51922-1
96906
96906
96906
96906
MS51922-17
96906
MS51922-33
96906
MS51922-49
MS51922-61
96906
96906
No.
No.
D-6
D-8
D-10
D-8
D-11
D-5
D-6
D-8
D-8
D-5
D-6
D-9
D-9
D-5
D-6
D-5
D-6
D-8
D-8
D-8
D-5
D-6
D-5
D-6
D-5
D-6
D-6
D-6
D-5
D-6
D-9
D-5
D-6
D-2
D-8
D-5
D-10
D-10
D-8
D-5
D-8
D-5
D-6
D-8
D-5
D-6
D-5
D-6
D-8
D-10
D-8
D-11
D-5
D-6
D-8
D-8
D-8
11
12
4
41
12
24
24
8
32
19
20
8
2
26
26
22
22
19
2
15
8
10
17
18
27
27
14
28
18
19
11
47
38
3
44
40
1
2
24
39
23
29
29
21
11
13
10
12
13
5
42
12
25
25
9
33
45
Change 4 D-45
ARMY TM 5-6115-633-14&P
Section IV. NATIONAL STOCK NUMBER AND REFERENCE - CONT
Reference
Number
FSCM
MS51925-1
MS51926-3
MS51929-2
MS51939-3
96906
96906
96906
96906
MS51967-5
MS90725-3
MS90725-6
MS90725-31
MS90725-60
96906
96906
96906
96906
96906
MS90725-62
MS90725-111
MS90725 114
MS9460-102
M13486/1-5 TYPE 1, CLA
M13486/7-1 TYPE 1, CLB
M23053/5-106
96906
96906
96906
96906
81349
81349
96906
M23053/5-107-5
M23053/5-108-5
M23053/5-1 09-0
M23053/5-109-5
M24066/2-128
M43436/1-6
81349
81349
81349
81349
M5086/1-18
81349
91349
96906
M5086/2-2
QQW343C06B1B
QQ-W-343C06B1B
T-R-6053
13205E4918
13205E5024
13206E4482-2
13211E4775
81349
81348
81348
81349
97403
97403
97403
97403
13212E3579
97403
13212E3581-1
97403
13212E3581-2
97403
13212E3583
97403
13212E3584-4
13212E3585-4
13212E3586-1
13212E3586-2
13212E3586-3
13212E3586-4
13212E587
97403
97403
97403
97403
97403
97403
97403
Fig.
No.
Item
No.
D-1
D-1
D-1
D-8
D-9
D-9
D-10
D-8
D-9
D-5
D6
D-11
D-8
D-2
D-9
D-12
D-12
D-5
D-5
D-3
D-7
D-8
D-3
D-8
D-12
D-12
D-5
D-5
D-7
D-3
D-8
D-1
D-10
D-6
D-2
D-5
D-6
D-5
D-6
D-5
D-6
D-5
D-6
D-5
D-6
D-4
D-4
D-7
D-7
D-7
D-7
D-5
7
4
5
1
9
12
3
11
10
46
37
11
7
2
3
10
5
33F
34F
7
8
18
9
37
9
4
33E
34E
5
8
17
2
8
21
5
6
8
15
17
34
34
33
33
7
9
1
2
1
2
3
4
5
Reference
Number
FSCM
13212E3590-2
13212E3597-1
13212E3597-2
13214E1206
13214E1207
13214E1208
13214E1209
13214E1210
13214E1211
13214E1212
13214E1223
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
13214E1235
13214E1391
97403
97403
13214E1392
13216E7476
13216E7479-1
13216E7479-2
13216E7603
97403
97403
97403
97403
97403
13218E0021-41
13218E0025-4
13218E5139-5
97403
97403
97403
13218E5140-5
97403
13218E5149-9
13218E5149-10
13220E4457-2
13220E4458-2
13220E4462
13220E4463-2
13220E4486
13226E5857
13226E5858
13226E5859-1
13226E5861
13226E5888-1
13226E5888-2
13226E5889-1
13226E5889-2
13226E7734
13226E7737
13226E7740
13226E-7730-6
181-0937-003
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
72619
181-8836-09-553
72619
Fig.
No.
Item
No.
D-6
D-8
D-1
D-1
D-11
D-11
D-11
D-11
D-11
D-11
D-11
D-5
D-8
D-8
D-5
D-5
D-1
D-12
D-12
D-12
D-5
D-6
D-8
D-8
D-5
D-6
D-5
D-6
D-6
D-5
D-8
D-8
D-6
D-10
D-6
D-8
D-8
D-5
D-5
D-3
D-3
D-5
D-5
D-8
D-9
D-1
D-8
D-5
D-5
D-5
D-5
7
46
9
10
1
4
5
3
8
9
10
43
27
10
33A
34A
6
7
1
2
35
36
31
36
31
31
32
32
30
30
5
6
1
6
2
34
30
1
2
1
2
36
38
48
1
1
43
33D
34D
33C
34C
Section V. REFERENCE DESIGNATOR INDEX
Not Applicable
*U.S. GOVERNMENT PRINTING OFFICE : 1997 - 554-024/60125
D-46 Change 4
TM 5-6115-633-14&P
By Order of the Secretary of the Army:
CARL E. VUONO
General, United States Army
Chief of Staff
Official:
R. L. DILWORTH
Brigadier General, United States Army
The Adjutant General
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25A, Operator, Unit,
Intermediate Direct Support and General Support Maintenance Manual requirements for Generator Sets, Gas/Diesel Engine, Trailer Mounted (PU
Series)
*U.S. GOVERNMENT PRINTING OFFICE: 1988 554-169/87031
PIN: 064445-000
Source Exif Data:
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