18352 TM 9 6115 653 14 And P POWER UNIT PU 732/M (NSN 00 260 3082) MEP 113A 15 KW 400 HZ GENERATOR SET M200 2 WHEEL, 4 TIRE, MODIFIED TRAILER

User Manual: TM-9-6115-653-14-and-P POWER UNIT PU-732/M (NSN 6115-00-260-3082) MEP-113A 15 KW 400 HZ GENERATOR SET M200 2-WHEEL, 4-TIRE, MODIFIED TRAILER Military Generators == MEP 113A

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*TM 9-6115-653-14&P

TECHNICAL MANUAL

OPERATOR, UNIT, DIRECT AND GENERAL SUPPORT
MAINTENANCE MANUAL
(INCLUDING REPAIR PARTS AND
SPECIAL TOOLS LISTS)

POWER UNIT
PU-732/M (NSN 6115-00-260-3082)
MEP-113A 15 KW 400 HZ GENERATOR SET
M200A1 2-WHEEL, 4-TIRE, MODIFIED
TRAILER

Approved for public release; distribution is unlimited.

* This manual supersedes Chapter 4 of TM 5-6115-594-14&P dated 25 September 1984.

HEADQUARTERS, DEPARTMENT OF THE ARMY
15 FEBRUARY 1990

TM 9-6115-653-14&P
C2
CHANGE
NO

HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, DC, 5 August 1991

Operator, Unit, Direct and General Support Maintenance Manual
(Including Repair Parts and Special Tools Lists)

POWER UNIT, PU-732/M, (NSN 6115-00-260-3082)
MEP-113A, 15 KW, 400 HZ,
GENERATOR SET
M200A1 2-WHEEL, 4-TIRE, MODIFIED TRAILER

Approved for public release, distribution is unlimited
TM 9-6115-653-14&P, 15 February 1990, 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

B-1 and B-2

B-1 and B--2

2. Retain this sheet in front of manual for reference purposes.
By Order of the Secretary of the Army:
GORDON R SULLIVAN
General, United States Army
Chief of Staff
Official:
PATRICIA P. HIICKERSON
Brigadier General, United States Army
The Adjutant General

DISTRIBUTION:
To be distributed In accordance with DA Form 12-25E, (qty rqr block no 0931)

TM 9-6115--653-14&P
C1
CHANGE

HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D C 5 DECEMBER 1990

NO 1

Operator, Unit, Direct and General Support Maintenance Manual
(Including Repair Parts and Special Tools Lists)

POWER UNIT, PU-732/M, NSN 6115-00-260-3082)
MEP-113A, 15 kW, 400 HZ, GENERATOR SET
M200A1, 2-WHEEL, 4-TIRE, MODIFIED TRAILER

Approved for public release, distribution is unlimited
TM 9-6115-653-14&P, 15 February 1990 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

D-11 and D-12
D-17 and D-18
D-25 and D-26

2. Retain this sheet In front of manual for reference purposes
By Order of the Secretary of the Army
CARL E VUONO
General, United Stares Army
Chief of Staff
Official:
THOMAS F SIKORA
Brigadier General, United States Army
The Adjutant General

DISTRIBUTION:
To be distributed In accordance with DA Form 12-25E, (qty rqr block no 0931)

TM 9-6115--653-14&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 DRY WOODEN POLE OR A DRY
ROPE OR SOME OTHER INSULATING MATERIAL
SEND FOR HELP AS SOON AS POSSIBLE

AFTER THE INJURED PERSON IS FREE OF
CONTACT WITH THE SOURCE OF ELECTRICAL
SHOCK, MOVE THE PERSON A SHORT DISTANCE
AWAY AND IMMEDIATELY START ARTIFICIAL
RESUSCITATION

TM 9-61 15-653-14&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 unit Is in operation
DEATH
or severe burns may result If personnel fail to observe safety precautions. Do not operate this power unit until the ground
terminal stud has been connected to a suitable ground. Disconnect the battery ground cable on the generator set 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 equiprnent. Loose fitting clothing should be secured to prevent it
catching moving parts. Do not attempt to service or otherwise make any adjustments, connections or reconnections of
wires or cables until generator set is shut down and completely de-energized
DANGEROUS GASES
Batteries generate explosive gas during charging therefore, utilize 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 unit generator set 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 tank.
Do not smoke or use open flame in the vicinity of the power unit while refueling generator set.
LIQUIDS UNDER HIGCH PRESSURE
are generated as a result of operation of the power unit generator set. 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 set can cause hearing damage. Ear protectors, as recommended by the medical
or safety officer, must be worn when working near this power unit.
WARNING
Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes and prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly. Dry cleaning solvent (PD-680) used to clean parts is potentially dangerous to
personnel and property. Do not use near open flame or excessive heat Flash point of solvent Is 100°F to 138°F (38°C to
59°C).

*TM 9-6115-653-14&P

TECHNICAL MANUAL

HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 15 February 1990

NO 9-6115-653-14&P

Operator, Unit, Direct and General Support Maintenance Manual
(Including Repair Parts and Special Tools Lists)
for
POWER UNIT, PU-732/M
(NSN 6115-00-260-3082)
MEP-113A 15 KW 400 HZ GENERATOR SET
M200A1 2-WHEEL, 4-TIRE, MODIFIED TRAILER
Approved for public release; distribution is unlimited.
TABLE OF CONTENTS
Page
CHAPTER 1.
Section I.
Section II.
CHAPTER 2.
Section I.
Section II.
Section III.
CHAPTER 3.
Section I.
Section II.
Section III.
Section IV.
Section V.
CHAPTER 4.

INTRODUCTION
General............................................................................................................................................. 1-1
Description and Data......................................................................................................................... 1-2
OPERATING INSTRUCTIONS
Operating Procedures ....................................................................................................................... 2-1
Operation of Auxiliary Equipment...................................................................................................... 2-2
Operation Under Unusual Conditions ................................................................................................ 2-2
OPERATOR/CREW MAINTENANCE INSTRUCTIONS
Consumable Operating and Maintenance Supplies ........................................................................... 3-1
Lubrication Instructions ..................................................................................................................... 3-1
Preventive Maintenance Checks and Services (PMCS) .................................................................... 3-1
Troubleshooting .............................................................................................................................. 3-20
Operator/Crew Maintenance ........................................................................................................... 3-20
UNIT MAINTENANCE

Section I.
Section II.
Section III.

Service Upon Receipt of Equipment ................................................................................................. 4-1
Movement to a New Worksite ........................................................................................................... 4-6
Repair Parts, Special Tools, Special Test, Measurement and
Diagnostic Equipment (TMDE)....................................................................................................... 4-7
Section IV. Lubrication Instructions ..................................................................................................................... 4-7
Section V.
Preventive Maintenance Checks and Services.................................................................................. 4-8
Section VI. Troubleshooting .............................................................................................................................. 4-12
Section VII. Radio Interference Suppression ...................................................................................................... 4-12
Section VIII. Maintenance of Power Unit Trailer .................................................................................................. 4-13

*This manual supersedes Chapter 4 of TM 5-6115-594-14&P dated 25 September 1984.

TM 9-6115-653-14&P

Page
CHAPTER 5.

DIRECT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS

Section I. Introduction .......................................................................................................................................... 5-1
Section II. Maintenance of Power Unit Trailer ....................................................................................................... 5-1
Section II. Generator Set ...................................................................................................................................... 5-2
CHAPTER 6.

TEST AND INSPECTION AFTER REPAIR

Section I. General Requirements ......................................................................................................................... 6-1
Section II. Inspection ............................................................................................................................................ 6-1
Section III. Operational Tests................................................................................................................................. 6-1
APPENDIX A. REFERENCES ....................................................................................................................................A-1
APPENDIX B. COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS......................................................B-1
APPENDIX C. MAINTENANCE ALLOCATION CHART...............................................................................................C-1
APPENDIX D. UNIT, DIRECT AND GENERAL SUPPORT AND DEPOT
MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST.........................................................D-1

TM 9-6115-653-14&P

LIST OF ILLUSTRATIONS
Figure
1-1
1-2
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
5-1
5-2
5-3
5-4
D-1
D-2
D-3
D-4
D-5
D-6
D-7
D-8

Title

Page

Power Unit, Curbside Front, Three-Quarter View .................................................................................
Power Unit, Roadside Rear, Three-Quarter View.................................................................................
Power Unit Packed for Shipment .........................................................................................................
Unpacking Power Unit .........................................................................................................................
Installing Power Unit............................................................................................................................
External Fuel Line Connection.............................................................................................................
Fuel Can Bracket Replacement ...........................................................................................................
Accessory Box Replacement ...............................................................................................................
Fire Extinguisher Bracket Replacement...............................................................................................
Front Step Replacement......................................................................................................................
Rear Step and Bracket Replacement...................................................................................................
Fender Replacement ...........................................................................................................................
Personnel Platform Replacement ........................................................................................................
Accessory Box Repair .........................................................................................................................
Power Unit Markings ...........................................................................................................................
Detaching Generator Set From Trailer.................................................................................................
Lifting Generator Set ...........................................................................................................................
Generator Set......................................................................................................................................
Trailer Body.........................................................................................................................................
Accessory Box.....................................................................................................................................
Front Steps..........................................................................................................................................
Rear Steps ..........................................................................................................................................
Fenders...............................................................................................................................................
Personnel Platform..............................................................................................................................
Handbrakes .........................................................................................................................................

1-3
1-3
4-1
4-2
4-4
4-6
4-13
4-14
4-15
4-17
4-19
4-21
4-23
5-1
5-2
5-3
5-4
D-8
D-10
D-14
D-16
D-18
D-20
D-22
D-24

LIST OF TABLES
Number
3-1
3-2
4-1

Title

Page

Consumable Operating and Maintenance Supplies..............................................................................
Operator/Crew Preventive Maintenance Checks and Services (PMCS)...............................................
Unit Preventive Maintenance Checks and Services (PMCS) ...............................................................

iii/(iv blank)

3-1
3-4
4-9

TM 9-6115-653-14&P
CHAPTER 1
INTRODUCTION
Section I. GENERAL
1-1. Scope. This manual is for your use in operating and maintaining the Power Unit, PU-732/M The PU-732/M is a
mobile power unit used to supply power to any system or equipment requiring up to 15 KW of 400 Hz input operating
power In addition to operating Instructions and operator, unit, and direct and general support maintenance procedures,
this manual contains a Repair Parts and Special Tools List for the power unit.
1-2. Maintenance Forms and Records. Maintenance forms and records used by Army personnel are prescribed by
DA Pam 738-750.
1-3. 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 on a DA Form 2028 directly to Commander, US Army
Troop Support Command, ATTN AMSTR-MCTS, 4300 Goodfellow Boulevard, St Louis, MO, 63120-1798.
1-4. 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 Troop Support Command, ATTN:
AMSTR-QX, 4300 Goodfellow Boulevard, St. Louis, MO, 63120-1798.
1-5. Levels of Maintenance Accomplishment. Army users shall refer to the Maintenance Allocation Chart (MAC) for
tasks and levels of maintenance to be performed.
1-6. Destruction of Army Materiel. Destruction of Army materiel to prevent enemy use shall be in accordance with
TM 750-244-3.
1-7. Administrative Storage.
a. Placement of equipment in administrative storage should be for short periods of time when a shortage of
maintenance effort exists Items should be In mission readiness within 24 hours or within the time factors as determined
by the directing authority. During the storage period appropriate maintenance records will be kept.
b. Before placing equipment In administrative storage, current maintenance services and equipment serviceable
criteria (ESC) evaluations should be completed, shortcomings and deficiencies should be corrected, and all modification
work orders (MWO's) should be applied .
c. Storage site selection. Inside storage is preferred for Items selected for administrative storage If inside storage
Is not available, trucks, vans, conex containers and other containers may be used.
1-8. Preparation for Shipment and Storage. Refer to TB 740-97-2.

1-1

TM 9-6115-653-14&P
Section II. DESCRIPTION AND DATA
1-9.
Description. Power Unit PU-732/M (figures 1 1 and 1-2) is made up of one Precise Power Generator Set, DOD
Model MEP-1 13A, mounted on a modified M1200A1 trailer. The generator set is a liquid-cooled diesel engine-driven
unit with a load capacity of 15 KW at 400 Hz The trailer is a two-wheeled unit with dual tires mounted The trailer has a 21/2-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.
1-10. Tabulated Data. The tabulated data provides operator and unit level personnel with the dimensions and weights
for Power Unit, PU-732/M. These specifications are computed from the combined dimensions and weights of the
generator set and trailer as modified for use with the power unit. Specifications of the Individual components can be
found in their respective technical publications. For additional Information concerning Generator Set DOD Model MEP-1
13A, refer to TM 5-6115-464-12 and -34. For additional information on the M200A1 trailer, refer to TM 9-2330-20514&P. The tabulated data also Includes the location and content of all data plates unique to the power unit.
a. Identification and Instruction Plates.
(1) Identification plate.
(a) Location This plate is located on the front roadside frame between the trailer body and the lunette.
(b) Content.
US
POWER UNIT
PU 732/M
KW 15
HERTZ 400
NSN 6115-00-260-3082
(2) Instruction plate.
(a) Location. This plate is located near the ground stud on the front, roadside corner of the trailer body.
(b) Content.
GROUND TERMINAL

1-2

TM 9-6115-653-14&P

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

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

1-3

TM 9-6115-653-14&P

b. Tabulated Data for Power Unit
Overall Length
Overall Width
Overall Height
Net Weight (empty)
Net Weight (filled)
Shipping Weight
Cubage

166 3/8 inches (423 6 centimeters)
95 1/2 inches (242 6 centimeters)
84 inches (213 4 centimeters)
1179.3 (kilograms)
1250.5 (kilograms)
1341.27 (kilograms)
788 cubic feet (22 3 cubic meters)

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

1-4

TM 9-6115-653-14&P
CHAPTER 2
OPERATING INSTRUCTIONS
Section I. OPERATING PROCEDURES
2-1. Power Unit Operating Procedures. The typical mission for any mobile power generating equipment can be
described In three steps or phases. In the first phase, the power unit Is towed to the worksite and installed by unit level
technicians (paragraph 4-2). In the second phase of the mission, the operator starts the generator set, runs it to power a
system or equipment, and eventually shuts it down. In the final phase, the power unit is dismantled, packed up and
either moved to a new worksite or returned to standby status (paragraph 4-3). This final phase is also accomplished by
unit level technicians.
a. Generator Set Operating Procedures.
WARNING
Do not operate power unit generator set until properly grounded (paragraph 4-2, b ) Serious
injury or death by electrocution can result from operating an ungrounded generator set.
Operating noise level of generator set can cause hearing damage. Ear protectors, as
recommended by medical or safety officer, must be worn when working near power unit.
CAUTION
To avoid damage to equipment, make certain of voltage, frequency, and phase
requirements of load connected to power unit.
NOTE
Before starting generator set, do your Before PMCS as described In table 3-2.
Detailed procedures for prestarting, starting, operating, and shutting down the power unit generator set is found in TM 56115-464-12 and on the Operating Instruction data plate found on the equipment. Refer to the data plate, located inside
the right hand control panel door, to start and run the generator set Monitor and adjust power output as required during
operation At the end of the mission, shut down generator set in accordance with operating instructions on the data plate.
b. Trailer Operating Procedures. Refer to TM 9-2330-205-14&P for specific operating procedures for the M200A1
trailer.
Section II. OPERATION OF AUXILIARY EQUIPMENT
2-2. Operation of Auxiliary Equipment. There is no auxiliary equipment supplied with the power unit.

2-1

TM 9-6115-653-14&P
Section III. OPERATION UNDER UNUSUAL CONDITIONS
2-3. Operation Under Unusual Conditions. When operating the power unit 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 5-6115-464-12 for special procedures when operating the generator set under unusual conditions.
b. Refer to TM 9-2330-205-14&P for special procedures when operating the trailer under unusual conditions.

2-2

TM 9-6115-653-14&P
CHAPTER 3
OPERATOR/CREW MAINTENANCE INSTRUCTIONS
Section I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES
3-1. Consumable Supplies. Consumable supplies used In the maintenance and operation of the power unit are listed
In Table 3-1.
Table 3-1. Consumable Operating and Maintenance Supplies
(1)

(2)

Component
application

National
stock number

(3)

Description

(4)
Qty
req. for
initial
operation

(5)
Qty
req. 8 hrs.
operation

General
Cleaning

6850-00-664-5685

Solvent, Drycleaning, PD-680

1 quart

As required

Personnel
Platform

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)

Note
s

Section II. LUBRICATION INSTRUCTIONS
3-2. General. Detailed Instructions for the lubrication of the major components of the power unit are contained In the
applicable Lubrication Orders (LO's). Refer to DA Pam 25-30 to ensure the latest editions of the LO's are used.
3-3. Generator Lubrication. Refer to TM 5-6115-464-12 for generator set Lubrication Order.
3-4. Trailer Lubrication. There are no operator/crew lubrication requirements for the power unit trailer.
Section III. 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

TM 9-6115-653-14&P
b

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

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

Do (W) PMCS weekly.

Do (M) PMCS monthly.

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 fall 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 Iist 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
c
done

Interval. This column shows when each check is to be done.
Item to be Inspected. This column identifies the general area or specific part where the check or service is to be

d. Procedures. This column lists the checks or services to be done and explains how to do them.
e. Equipment is Not Ready/Available If. This column Iists conditions that rnake 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.

3-2

TM 9-6115-653-14&P
a. Routine Inspections. Use the following Information to help identify potential problems before and during checks
and services.
WARNING
Drycleaning solvent PD-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 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 PD-680, get fresh air immediately
and get medical aid. If PD-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 PD-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 III

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

3-3

TM 9-6115-653-14&P

CAUTION
Equipment operation is allowable with minor leakage (Class I or 11) 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 III leaks should be reported to your supervisor or unit maintenance.
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.
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS).
B BEFORE

D DURING

A AFTER

W WEEKLY

ITEM TO BE INSPECTED
INTERVAL

ITEM
NO.
B

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 leveling jacks. Injury to personnel could result from trailer
suddenly rolling or tipping.
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, or If you are operating the equipment
for the first time.

3-4

M MONTHLY

EQUIPMENT IS NOT
READY/AVAILABLE IF:

TM 9-6115-653-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) (cont)
B BEFORE

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED

EQUIPMENT IS NOT
READY/AVAILABLE IF:

GENERATOR SET EXTERIOR
a Check on, around, and beneath generator set
for fuel or oil and coolant leaks
leak is detected.

A Class III coolant or lubrication oil leak or any class fuel.

b Check that generator set ground is properly
Installed and grounding connections are
tight.

Not properly grounded

c Manually open and close radiator louvers to
check for proper operation.
2

FUEL GAGE
Check fuel gage (1) for sufficient fuel for
continuous operation.

3-5

TM 9-6115-653-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) (cont)
B BEFORE

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

•

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED
M

COOLANT LEVEL
Check coolant level (2) Proper level is two inches
below the overflow pipe Add coolant as required.

•

EQUIPMENT IS NOT
READY/AVAILABLE IF:

If coolant is below proper coolant level

HYDRAULIC FLUID LEVEL
Check level of fluid In hydraulic sump (3).

3-6

If hydraulic fluid is below the full mark.

TM 9-6115-653-14&P

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

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED
M

ENGINE OIL LEVEL
Check oil filler dipstick (4) for proper oil level
Add oil as required

EQUIPMENT IS NOT
READY/AVAILABLE IF:

If engine oil is at or below
ADD mark

ACCESSORIES
Check that the following accessories are
not missing
a Sledge hammer
b Fire extinguisher

Fire extinguisher is missing

c Slide hammer
d Ground rods

Ground rods are missing

e Fuel Drum Adapter
7

BRACKETS
Check fire extinguisher and fuel can mounting
brackets for loose hardware and broken fittings

3-7

TM 9-6115-653-14&P

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

D DURING

A AFTER

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED

W WEEKLY

M MONTHLY

EQUIPMENT IS NOT
READY/AVAILABLE IF:

TIRES
a Check for cuts, foreign objects, or unusual tread
wear Remove any stones from between the
treads

One tire is flat, missing, or
unserviceable

b Check that tire pressure is 35 psi (241 22 kPa)
when tires are cool
9

WHEELS
Check for wheel damage and loose or missing
stud nuts (5)

LUNETTE
Check lunette (6) for Insecure mounting and
obvious damage

One wheel is damaged
One stud nut is loose or
missing

Lunette Is loose or bent

INTERVEHICULAR CABLE
Check cable (7) and connector for cuts and breaks

3-8

Intervehicular cable is
broken or missing

TM 9-6115-653-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) (cont)
B BEFORE

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

D
*

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED
M
SAFETY CHAINS
Check safety chains (8) for insecure mounting
and obvious damage

EQUIPMENT IS NOT
READY/AVAILABLE IF:

Safety chains are missing or
unsecured

AIR HOSES, FITTINGS AND BRAKE AIR
CHAMBER
Check air hoses (9) , fittings (10) and brake air
chamber (1 i) for signs of damage or leaks

3-9

Damage or leaks are
detected

TM 9-6115-653-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) (cont).
B BEFORE

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

D
*

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED
M
HYDRAULIC HOSES, FITTINGS AND MASTER
CYLINDER
Check brake system hoses (12) and fittings (13)
and master cylinder (14), and check under vehicle
for signs of brake fluid leaks

EQUIPMENT IS NOT
READY/AVAILABLE IF:

A class III brake fluid leak is
detected.

LANDING LEG
Check condition of landing leg (15)

3-10

There is indication that leg
might collapse

TM 9-6115-653-14&P

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

B BEFORE

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED
M

LEVELING JACK
Check condition of leveling jack (16)

EQUIPMENT IS NOT
READY/AVAILABLE IF:

There Is Indication that a jack
might collapse

LIGHTS
a With Intervehicular cable connected to towing
vehicle, operate vehicle light switch through
all settings and check lights (17)

Taillights fall to operate
properly

NOTE
An assistant is required while checking brake
lights
b Step on brake pedal and check brake
lights (17)

3-11

Brake lights fall to operate
properly

TM 9-6115-653-14&P

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

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED
M

LIGHTS (cont)

BRAKE SYSTEM
Test brake system by hooking trailer to towing
vehicle and applying brakes

EQUIPMENT IS NOT
READY/AVAILABLE IF:

Service brakes fall 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

GENERATOR SET GAGES AND INSTRUMENTS
a Check that air cleaner condition Indicator (18)
does not Indicate a clogged air cleaner Pressto-test

Light remains on during
operation

b Check that battery charging ammeter (1 9) is
In green area during normal operation

Battery indicator not In
green area

3-12

TM 9-6115-653-14&P
Table 3-2 Operator/Crew Preventive Maintenance Checks and Services (PMCS) (cont)
B BEFORE

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

•

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED

EQUIPMENT IS NOT
READY/AVAILABLE IF:

GENERATOR SET GAGES AND INSTRUMENTS
(cont)

4885-014
c.

Check that frequency meter (20) Indicates
400 Hz (red Iine) when generator Is operating
under load

Check that kilowatt meter (21) reading does
not exceed 100%

Correct frequency cannot be
maintained

4885-015

Check that A C ammeter (22) reading does not
exceed 100% of rated current or more than 5%
load difference between phases

3-13

No Indication when load
is applied

TM 9-6115-653-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) (cont)
B BEFORE

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

•

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED

EQUIPMENT IS NOT
READY/AVAILABLE IF:

GENERATOR SET GAGES AND INSTRUMENTS

(cont)
f.

Check that A C voltmeter (23) Indicates desired
output voltage as determined by load connections and amps-volts selector switch

Desired voltage cannot be
obtained and maintained

4885-016

Check engine oil pressure gage (24) for
20 to 55 psig indication

Oil pressure drops below
20 psig

Check coolant temperature gage (25) for
170°to 200°F (76 70 to 93 30C) Indication

Temperature exceeds 200°F
(93 3°C)

4885-017

3-14

TM 9-6115-653-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) (cont).
B BEFORED DURINGA AFTER

W WEEKLY

M MONTHLY
ITEM TO BE INSPECTED

ITEM
NO.

INTERVAL
B

•

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED

GENERATOR SET GAGES AND INSTRUMENTS
(cont)
i

Check that all lights on FAULT INDICATOR
panel (26) are out during operation Check
bulb operation with TEST or RESET switch on
panel

4885-018
21

EQUIPMENT IS NOT
READY/AVAILABLE IF:

•

FUEL TANK
a.

Fill set tank upon completion of operation
NOTE
Fuel system temperature must be above
freezing when draining water and sediment

Open drain (27) and drain water and sediment
from fuel tank Into a suitable container Allow
to drain until fuel runs clean

3-15

Fault light will not go out
when switch Is set to TEST
or RESET position, then
released All bulbs should
be lit when switch is in TEST
or RESET position

TM 9-6115-653-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) (cont)
B BEFORE

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

•

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED
M

FUEL TANK (cont)

4885-019

•

DAY TANK
NOTE
Fuel system temperature must be above
freezing when draining water and sediment
Open drain (28) and drain -water and sediment from
day tank into a suitable container Allow to drain
until fuel runs clean

3-16

EQUIPMENT IS NOT
READY/AVAILABLE IF:

TM 9-6115-653-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) (cont)
B BEFORE

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

A
•

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED
M
DAY TANK (cont)

4885-049

•

FUEL STRAINER AND FILTERS
Drain water and sediment from strainer (29),
primary (30) and secondary (31) filters into a
suitable container Allow to drain until fuel runs
clean

3-17

EQUIPMENT IS NOT
READY/AVAILABLE IF:

TM 9-6115-653-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) (cont).
B BEFORE

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

A
•

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED

EQUIPMENT IS NOT
READY/AVAILABLE IF:

M
BATTLE SHORT INDICATOR LIGHT
Push In on lens housing Light (32) should
Illuminate If not, replace bulb

•

CIRCUIT BREAKER INDICATOR LIGHT
Push in on lens housing Light (33) should
Illuminate If not, replace bulb

4885-021
26

•

BRAKE DRUMS AND HUBS
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 drums and hubs for overheating

•

AIR RESERVOIR
Open draincock (34) to drain moisture from air
reservoir (35) and close when finished

3-18

Brakes or hub are dragging
or binding

TM 9-6115-653-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) (cont)
B BEFORE

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

•

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED

EQUIPMENT IS NOT
READY/AVAILABLE IF:

AIR RESERVOIR (cont)

4885-022
28

•

HANDBRAKES
With trailer hooked to towing vehicle, set handbrakes (36) Move trailer slightly to see If handbrakes hold wheels Adjust as required

4885-023

3-19

Handbrakes cannot
be adjusted

TM 9-6115-653-14&P
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (PMCS) (cont)
B BEFORE

D DURING

A AFTER

W WEEKLY

M MONTHLY

ITEM TO BE INSPECTED
ITEM
NO.

INTERVAL
B

PROCEDURE: CHECK FOR AND HAVE REPAIRED,
FILLED, OR ADJUSTED AS NEEDED

EQUIPMENT IS NOT
READY/AVAILABLE IF:

•

REFLECTORS
Check for damaged or missing reflectors

•

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)

4885-024

•

FIRE EXTINGUISHER
a
inspect seal for damage Inspect gage to see
If extinguisher needs recharging
b.

•

inspect and weigh fire extinguisher
(See paragraph 3-11 )

TRAILER FRAME
Inspect entire chassis frame for damage, cracks,
and broken welds

3-20

Frame is obviously broken
or cracked

TM 9-6115-653-14&P
Section IV. TROUBLESHOOTING
3-10.
Power Unit Troubleshooting. There are no troubleshooting procedures authorized at operator level for the
power unit end item . Troubleshooting procedures for the generator set and trailer are contained In their respective
technical manuals referenced below.
a. Generator Set Troubleshooting Refer to TM 5-6115-464-12 for troubleshooting procedures applicable to the
generator set.
b.

Trailer Troubleshooting Refer to TM 9-2330-205-1 4&P for troubleshooting procedures applicable to the trailer.
Section V. OPERATOR/CREW MAINTENANCE

3-11.
Fire Extinguisher Maintenance. The PU-732/M Power Unit is equipped with a 5 lb CO2 fire extinguisher.
Maintenance is limited to weighing the fire extinguisher monthly to insure that it is sufficiently charged. Fully charged,
the fire extinguisher weighs 13 lb. Send the unit to specialized activity for recharging if it weighs 12.5 lb or less.
CAUTION
Do not attempt to verify readiness of a fire extinguisher by partially discharging unit. Any
discharge of contents will require refilling.

3-21/(3-22 blank)

TM 9-6115-653-14&P
CHAPTER 4
UNIT MANTENANCE
Section I. SERVICE UPON RECEIPT OF EQUIPMENT
4-1 Inspecting and Servicing Equipment. The power unit is unpacked, inspected, and serviced as described in the
following paragraphs. Unpacked equipment must be checked against the Equipment Packing List to insure
completeness. Discrepancies must be reported in accordance with instructions In DA Pam 738-750
a. Unpacking Power Unit (See figures 4-1 and 4-2 ) The generator set is packed in place on the trailer frame
Before beginning the unpacking procedure, locate, remove, and save the waterproof envelopes marked Depreservatlon
Guide

4885-025

Figure 4-1. Power Unit Packed for Shipment.

4-1

4885-026

Figure 4-2. Unpacking Power Unit.

4-2

TM 9-6115-653-14&P

WARNING
The steel banding used in packaging of power unit has sharp edges. Care should be taken
when cutting and handling banding to avoid injury to personnel.
(1) Remove steel banding around plywood box covering generator set.
(2) Remove lag screws securing plywood box cover over generator set and lift cover off generator.
(3) Remove wooden wedges and spacers from around generator set base.
(4) Remove and save package of technical manuals secured to barrier material covering generator.
(5) Remove four sets of attaching hardware and drop plywood cover from beneath generator set.
(6) Remove barrier material and fiberboard caps from generator set.
(7) Remove packaged fire extinguisher from within generator set enclosure Unpack and secure fire
extinguisher in bracket on front roadside step.
(8) Remove steel banding around accessory box, unpack and Inventory contents.
(9) Refer to DA Form 2258, Depreservation Guide for Vehicles and Equipment, packed with power unit and
follow instructions given for putting unit into service.
(10) Stow technical manuals in box on inside of generator set enclosure rear curbside door.
(11) Stow all authorized accessories in the accessory box.
b. Inspection and Servicing of Generator Set. Refer to Service Upon Receipt of Materiel In TM 5-6115-464-12 for
initial inspection and servicing procedures.
c. Inspection and Servicing of Trailer. Refer to Service Upon Receipt of Materiel In TM 9-2330-205-14&P for
initial inspection and servicing procedures
4-2 Installation. (See figure 4-3 ) Installation of the power unit at a worksite involves positioning the trailer and
grounding the power unit.
a.

Positioning Power Unit. Position the power unit on the worksite as follows:
(1) Select an area as level as possible to install power unit and position trailer.
(2) Set trailer handbrakes and lower landing leg.
(3) Chock both sets of wheels.
(4) Lower both rear leveling jacks, secure leveling jacks with lockpins, and extend lower tubes by stepping on
hinged pads

4-3

TM 9-6115-653-14&P

Figure 4-3. Installing Power Unit.

WARNING
Remove fire extinguishers and fuel cans from power unit when generator set is in operation
This will insure that in the event of fire, extra fuel will not be involved and extinguisher will
remain accessible.
(5) Locate fuel cans and fire extinguisher on ground away from power unit.
WARNING
Do not operate generator set until power unit is properly grounded (paragraph 4-2, b) Serious
injury or death by electrocution can result from operating an ungrounded power unit.
CAUTION
To avoid damage to equipment, make certain of voltage, frequency, and phase
requirements of load being connected to generator set

4-4

TM 9-6115-653-14&P
(6) Connect power unit to system or equipment to be powered Refer to TM 5-6115-464-12 and generator
set load terminal board data plate.
(7) Remove two platform anchor quick-release pins and lower personnel platform.
(8) Close all doors on generator set enclosure except control panel doors and the two doors immediately
below the control panel.
b. Grounding. Check that generator set is grounded to GROUND TERMINAL stud on trailer frame. Using
ground wire supplied with power unit, connect power unit GROUND TERMINAL to a suitable ground as described
below. The following sources of good ground are listed in order of preference.
NOTE
As a substitute for the supplied ground wire, any copper wire of a least No. 6 AWG may be
used.
(1) Underground water system. Ground power unit 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 the 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 unit 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 4-4 ) The power unit generator set 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 the generator's
fuel tank during long Intervals of operation.
(1) Remove fuel can adapter and fuel pickup tube from storage locations on power unit 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
next to the fuel filler above the trailer roadside fender.
(4) Insert fuel can adapter in external fuel source and secure by pressing down on lever.
(5) Set FUEL SELECTOR VALVE beneath fuel filler to AUXILIARY position.

4-5

TM 9-6115-653-14&P

Figure 4-4. External Fuel Line Connection.

Section II. MOVEMENT TO A NEW WORKSITE
4-3 Dismantling for Movement. Because the power unit is designed to be mobile, a minimum amount of effort is
required to relocate to a new worksite Procedures are as follows:
a. Disconnect power unit from system or equipment being powered.
b. Disconnect ground cable from source of ground and from power unit GROUND TERMINAL. 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 unit from external fuel source, if applicable.
e. Stow any remaining authorized equipment in accessory box.
f. Secure fire extinguisher and fuel cans in their respective mounting brackets.
g. Close all doors on the generator set enclosure.
h. Swing personnel platform Into traveling position and secure with two platform anchor quick-release pins.

4-6

TM 9-6115-653-14&P

WARNING
Use care when releasing spring-loaded lower tube of leveling jacks. The lower tube will
return to retracted position with considerable force and can cause injury.
i.

Retract lower tubes of leveling jacks. Swing leveling jacks up into traveling position and secure with lockpins.

Remove wheel chocks.

Attach power unit to towing vehicle. Refer to TM 9-2330-205-14&P.

Release trailer handbrakes.

4-4 Reinstallation After Movement.
paragraph 4-2.

After movement to a new worksite, install power unit in accordance with

Section III. 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 PU-732/M power unit.
4-6 Maintenance Repair Parts. Repair parts and equipment for maintenance of this power unit 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 major components of the power unit are contained in the
applicable Lubrication Orders (LO’s). Refer to DA Pam 25-30 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 5-6115-464-12 for generator set Lubrication Order.
4-9 Trailer Assembly Lubrication.
a.

Trailer Lubrication. Refer to TM 9-2330-205-14&P for trailer Lubrication Order.

b
Personnel Platform Lubrication .The personnel platform is a modification to the standard M200A1 trailer and, as
such, does not appear in the associated L O Lubricate the personnel platform semiannually as follows:

4-7

TM 9-6115-653-14&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
(PD-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).
(1) Using PD-680, or equivalent, clean area to be lubricated.
(2) Apply OE lubricating oil to personnel platform pivot points and to platform anchor quick-release pins.

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 set must be inspected and serviced systematically to insure that
the power unit 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 or annually. Unit PMCS on the generator set is scheduled monthly or on a per-hours-of-operation basis.
The running time meter on the control panel is used to determine the operating time of the generator set. Using the
following as a guide, do the checks and services at the intervals shown. Observe all CAUTIONS and WARNINGS.
a.
time

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

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

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

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

e. 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.

4-8

TM 9-6115-653-14&P

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.
c.
done.
d.

Interval. This column shows when each check is to be done.
Item to be Inspected. This column identifies the general area or specific part where the check or service is to be

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
Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS).
H - Hours of operation
(As indicated

M - Monthly
(100 hours)

S - Semiannually
(500 hours)

A - Annually
1,000 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 leveling jacks Injury to personnel
could result from trailer suddenly rolling or
tipping
1

•

Generator Set Exterior

•

Fuel Strainer and Filters

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
Open drains on fuel strainer, and primary and
secondary fuel filters Drain water and sediment
into a suitable container Allow to drain until fuel
runs clean

•

Fuel Tanks

Open drains on main fuel tank and day tank Drain
water and sediment Into a suitable container
Allow to drain until fuel runs clean

4-9

TM 9-6115-653-14&P
Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS) (cont).
H - Hours of operation
(As indicated)

M - Monthly
(100 hours)

S - Semiannually
(500 hours)

A - Annually
1,000 hours)

INTERVAL
ITEM
NO.

•

ITEM TO BE INSPECTED

PROCEDURES

Fuel Pumps

Clean or replace, as necessary, fuel strainer In bottom of fuel
pump

•

Batteries

Perform a hydrometer test on batteries every 100 hours Refer
to TM 5-6115-464-12 for test procedures

•

V-Belts

Inspect for worn, frayed, oil soaked, or cracked belts Check
adjustment Proper adjustment for fan belt is a deflection of 1/2
inch with application of 12-14 lb pressure midway between
alternator and water pump pulley

•

Fuel Filters

Replace filter elements every 100 hours of operation

300

Fuel Strainer

Clean fuel strainer every 300 hours of operation

300

Lubricating Oil and Filter

Change lubricating oil and filter every 300 hours of operation or
six months

•

Hydraulic Sump

Drain and refill (Refer to LO)

•

Hydraulic Filter

Replace filter (Refer to LO)

•

Hydraulic Actuator Screen

Clean filter (Refer to LO)

300

Breather and
Breather Tube

Inspect for damage Clean breather and
tube at oil change interval

Air Cleaner

Clean air cleaner element whenever necessary as Indicated by
air filter condition indicator light

•

Taillights

Replace any broken or cracked lenses or defective bulbs

•

Intervehicular

Check for cuts, breaks, frayed wires, or damaged Cable plug

4-10

TM 9-6115-653-14&P

Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS) (cont)
H - Hours of operation
(As indicated

M - Monthly
(100 hours)

S - Semiannually
(500 hours)

A - Annually
1,000 hours)

INTERVAL
ITEM
NO.

ITEM TO BE INSPECTED

PROCEDURES

•

Lunette

Check security of mounting Inspect ring for excessive wear

•

Safety Chains

Inspect for broken links or missing chain(s)

•

Reflectors

Replace any cracked, broken, or missing reflectors

•

Data Plates and Markings

Make sure data plates are legible and securely mounted
Replace illegible data plates

•

Landing Leg

Inspect landing leg and brace for bent or broken parts

•

Leveling Jacks

Inspect leveling lacks for bent or broken parts

•

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

•

Axle

a.
b.

Check for damaged axle tube
Check for loose or missing U-bolts or nuts

•

Wheels and Tires

Check serviceability of tires as Indicated In
TM 9-2610-200-24
Tighten wheel stud nuts to 450 to 500 ft-lb
(611 to 678 Nom)

•

Brakes

a.
b.
c.
d.

4-11

Inspect brake linings for wear Replace If brake shoe
lining is less than 1/8-inch (3 2 mm) thick
Inspect brake adjusting screw, retaining screw, retaining
pins, springs, and clips for corrosion and wear
Inspect hydraulic wheel cylinders for leaks
Adjust brakes

TM 9-6115-653-14&P
Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS) (cont)
H - Hours of operation
(As indicated

M - Monthly
(100 hours)

S - Semiannually
(500 hours)

A - Annually
1,000 hours)

INTERVAL
ITEM
NO.

ITEM TO BE INSPECTED

PROCEDURES

Wheel Bearings

Clean and repack wheel bearings

Hydraulic Brake Hoses and

Inspect for dents, cracks, loose connections and Fittings leaks

Air Hoses and Fittings

Inspect for dents, cracks, loose connections and leaks

Brake Master Cylinder

Check fluid level Fill to 1/2 Inch from top

Trailer - Road Test

Perform road test paying special attention to items that were
repaired or adjusted, In accordance with TM 9-2330-205-14&P

Section VI. TROUBLESHOOTING
4-13 Power Unit Troubleshooting. There are no troubleshooting procedures authorized at unit level for
the power unit end item . Troubleshooting procedures for the individual generator set and trailer are
contained in their respective technical manuals referenced below:
a. Generator Set Troubleshooting. Refer to TM 5-6115-464-12 for troubleshooting procedures applicable
to the generator set.
b. Trailer Troubleshooting. Refer to TM 9-2330-205-14&P for troubleshooting procedures applicable to
the trailer.
Section VII. RADIO INTERFERENCE SUPPRESSION
4-14 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.
4-15 Radio Interference Suppression Components. All component parts on the power unit end item,
whose primary or secondary function is radio interference suppression, are on the generator set. Refer to
TM 5-6115-464-12 for location of radio interference suppression components

4-12

TM 9-6115-653-14&P
Section VIII. MAINTENANCE OF POWER UNIT TRAILER
4-16 General. This section of the manual contains unit level maintenance procedures for components of the M200A1
trailer added when the trailer is used as part of the PU-732/M power unit. These components are not covered in the
overall trailer maintenance manual. For all other unit maintenance procedures on the trailer, refer to TM 9-2330-20514&P. When power unit has been painted in camouflage, replacement parts must be painted to match authorized
patterns and colors as specified in TB 43-0147. Application of camouflage paint shall be done in accordance with MIL-C53072.
WARNING
Before performing any maintenance that requires climbing on or under trailer, set trailer
handbrakes, chock both wheels, and lower rear leveling jacks. Injury to personnel could
result from trailer suddenly rolling or tipping.
4-17. Fuel Can Bracket Replacement. (See figure 4-5.) There are two fuel can brackets supplied with the PU-732/M.
The brackets are mounted on top of the curbside front step. Replacement procedures described below are the same for
both.

4885-029

Figure 4-5. Fuel Can Bracket Replacement
a.

Removal.
(1) Remove four screws (1, figure 4-5), four self-locking nuts (2) and four flat washers (3) securing bracket (4)
to step (5).
(2) Remove bracket (4) from step (5).

4-13

TM 9-6115-653-14&P

Installation.
(1) Position fuel can bracket (4) on step (5).
(2) Insert four screws (1) down through bracket (4) and through step (5).
(3) Install one washer (3) and one self-locking nut (2) on each screw (1). Tighten hardware to secure bracket
(4).

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

Figure 4-6. Accessory Box Replacement.
4885-030

Removal.
(1) Remove three screws (1, figure 4-6), three flat washers (2) and three nuts (3) securing accessory box (4)
to trailer frame (5).
(2) Slide accessory box (4) forward and off front step (6).

Installation.
(1) Position accessory box (4) on front trailer step (6) with narrow end between handbrake lever (7) and trailer
frame (5).

4-14

TM 9-6115-653-14&P
(2) Slide accessory box (4) so that top of box contacts lip of trailer frame (5).
(3) Insert three screws (1) down through trailer frame (5) into accessory box (4).
(4) Install one nut (3) and one washer (2) on each screw (1) and tighten.
4-19 Fire Extinguisher Bracket Replacement. (See figure 4-7 ). The fire extinguisher supplied with the power unit is
carried in a bracket mounted on the front roadside step.

Figure 4-7. Fire Extinguisher Bracket Replacement.
4885-031

Removal.
(1) Remove four screws (1, figure 4-7), four flat washers (2), and four nuts (3) securing bracket (4) to step (5).
(2) Remove bracket (4) from step (5).

Installation.
(1) Position fire extinguisher bracket (4) on step (5).
(2) Insert four screws (1) down through bracket (4) and through step (5).
(3) Install one flat washer (2) and one nut (3) on each screw (1). Tighten hardware to secure bracket (4).

4-15

TM 9-6115-653-14&P
4-20 Front Step Replacement. (See figure 4-8 ) The roadside and curbside front steps are symmetrical, and
replacement procedures are the same except where noted in the steps below.
a.

Removal.
NOTE
When removing roadside front step, omit steps (1) and (2).
(1) Remove fuel can brackets (paragraph 4-17, a).
(2) Remove accessory box (paragraph 4-18, a).
(3) Remove cotter pin (1, figure 4-8) and clevis pin (2) securing handbrake cable (3) to handbrake lever
mechanism (4).
(4) Remove two screws (5), two flat washers (6) and two nuts (7) securing handbrake (8) to trailer frame (9).
(5) Remove two screws (10), two flat washers (11) and two nuts (12) securing handbrake cable bracket (13) to
front step (14).
NOTE
There are two screws, flat washers, and nuts securing handbrake bracket to front step. It
only necessary to remove one set of attaching hardware to remove front step from trailer
frame.
(6) Remove screw (15), flat washer (16), lockwasher (17) and nut (18) directly beneath pivot point of
handbrake lever (4).
(7) Remove seven screws (19) 14 flat washers (20) and seven nuts (21) securing front step (14) to front
edge of fender (22).
(8) Remove four screws (23, 24 and 25), eight flat washers (26) and four nuts (27) securing front step (14) to
edge of trailer frame (9).
(9) Remove three screws (28), three flat washers (29) and three nuts (30) securing front step (14) to trailer
cross brace channels (31) and remove front step (14) and spacers (32) and (33).

Installation.
NOTE
Three different length screws are used to mount the front step. Screws with index numbers
(5), (10), (18) and (23) in figure 4-8 are one inch long. Screw with index number (24) is 1-1/4
inch long. Screws with index numbers (15), (22) and (27) are 1-3/4 inch long. Observe
lengths and locations when installing hardware.

4-16

TM 9-6115-653-14&P

Figure 4-8. Front Step Replacement.

4-17

TM 9-6115-653-14&P

(1) Position front step (14) and spacers (32) and (33) on cross brace channels (31 ) and trailer frame (9) insert
cloves on handbrake cable (3) through hole in front step (14)
(2) Insert four screws (23, 24 and 25) with flat washers (26) through front step (14) and trailer frame (9)
(3) Insert three screws (28) with flat washers (29) through front step (14) and trailer cross brace channels (31 )
(4) Working under step, install one nut (30) on each screw (28) securing front step (14) to cross brace
channels (31 ) and install one flat washer (26) and one nut (27) on each screw (23, 24 and 25) securing
step to trailer frame (9) Tighten seven sets of hardware
(5) Secure front step (14) to fender (22) with seven screws (19), 14 flat washers (20) and seven nuts (21)
(6) insert screw (15) with flat washer (16) through handbrake bracket (8) front step (14) and cross brace
channel (31 ) Install lockwasher (17) and nut (18) on screw from underneath and tighten
(7) Insert two screws (5) with flat washers (6) through handbrake bracket (8) and trailer frame (9) Install one
nut (7) on each screw and Tighten
(8) Insert two screws (10) through front step (14) and handbrake cable bracket (13) Install one flat washer (11)
and one nut (12) on each screw and tighten
(9) Position cloves on handbrake cable (3) on handbrake lever mechanism (4) Insert clevis pin (2) and secure
with cotter pin (1 )
NOTE
When installing roadside front step, omit steps (10) and (11)
(10) Install accessory box (paragraph 4-18, b)
(11) install fuel can brackets (paragraph 4-17, b)
4-21. Rear Step and Bracket Replacement. (See figure 4-9 ) The roadside and curbside rear steps are
symmetrical, and replacement procedures are the same for both
a.

Removal
(1)

Remove two screws (1, figure 4-9), two fiat washers (2) and two nuts (3) securing rear step bracket (4)
and platform anchor (5) to trailer frame (6) under taillight (7)

(2) Remove two screws (8), four flat washers (9) and two nuts (10) securing rear step (11) to trailer frame (6)
(3) Remove five screws (12), ten flat washers (13) and five nuts (14) securing rear step (11) to tender (15)
Remove rear step from trailer

4-18

TM 9-6115-653-14&P

Figure 4-9. Rear Step and Bracket Replacement
NOTE
If rear step bracket (4) must be straightened or replaced, do step 4 Remove
and retain reflector for installation on new or repaired rear step bracket
(4) Remove three screws (16), three flat washers (17), and three nuts (18) Separate rear
step bracket (4) from step (11)

4-19

TM 9-6115-653-14&P

Installation
(1) If rear step bracket (4) and step (11) were separated during removal, alone bracket and step and install
three screws (16), three flat washers (17), three nuts (18) and tighten
(2) Position rear step (11 ) on trailer frame (6)
(3) Secure rear step (11 ) to trailer frame (6) with two screws (8), four flat washers (9) and two nuts (10)
(4) Secure rear step (11 ) to fender (15) with five screws (12), ten flat washers (13) and five nuts (14)

4-22

(5)

Alone two mounting holes in rear step bracket (4) with holes in trailer frame (6) under taillight (7) and
insert two screws (1 )

(6)

Slide S-hook at chain end of platform anchor (5) onto threaded end of lower screw (1 ) inside trailer
frame (6).

(7)

Install one flat washer (2) and one nut (3) on each screw (1 ) and tighten

Fender Replacement. (See figure 4-10 ) The fenders on the trailer are symmetrical, and replacement
procedures are the same for both.
a.

Removal
(1) Remove five screws (1, figure 4-10), ten flat washers (2) and five nuts (3) securing fender (4) to trailer
frame (5).
WARNING
There are five sets of hardware securing fender to rear step and seven sets of hardware
securing fender to front step This hardware should be removed in sequence from trailer
frame outward In this way, last two screws on front and rear lower fender edge will support
fender until you are out from underneath
(2) Remove six screws (6), 12 flat washers (7) and six nuts (8) securing fender (4) to front step (9).
(3) Remove four screws (10), eight flat washers (11 ) and four nuts (12) securing fender (4) to rear step (13).
WARNING
Support fender while removing remaining two screws When screws are removed, tender will
drop
(4) Remove one screw (6), two flat washers (7) and one nut (8) securing fender (4) to front step (9)
(5) Remove one screw (10), two flat washers (11) and one nut (12) securing fender (4) to rear step (13)
(6) Remove fender (4)

4-20

TM 9-6115-653-14&P

Figure 4-10. Fender Replacement

4-21

TM 9-6115-653-14&P

Installation
(1) Position fender (4) on trailer
(2) Insert one screw (10) with flat washer (11) through lower outside edge of fender (4) Into rear step (13), and
Insert one screw (6) with flat washer (7) through lower outside edge of fender (4) into front step (9)
(3) Install one washer (11) and one nut (12) on screw (10), and one washer (7) and one nut (8) on screw (6)
Tighten hardware
(4) Insert five screws (1 ) with flat washers (2) down through fender (4) into trailer frame (5)
(5) Working under fender, Install one flat washer (2) and one nut (3) on each screw (1 ) and tighten
(6) Insert six screws (6) with flat washers (7) through fender (4) Into front step (9) install one washer (7) and
one nut (8) on each screw (6) and tighten
(7) Insert four screws (10) with flat washers (11) through fender (4) into rear step (13) install one washer (11)
and one nut (12) on each screw (10) and tighten

4-23.

Personnel Platform Replacement. (See figure 4-11 ) This platform is mounted on the rear of the trailer to
facilitate access to generator set controls and indicators
Removal
(1) Remove two screws (1, figure 4-11), four flat washers (2) and two self-locking nuts (3) securing platform
(4) to mounting brackets (5)
WARNING
Support platform while removing anchors When anchors are removed, platform will drop
(2) Remove two platform anchors (6) by pushing In on button on head of pin while pulling pin out of mounting
hole.
NOTE
Mounting brackets are fastened with self-locking nuts Removal may damage locking
capability when reinstalled Do not remove mounting brackets unless they are damaged
(3) Remove three screws (7) three flat washers (8) and three self-locking nuts (9) from each mounting bracket
(5) and take mounting brackets off of trailer frame (10)

4-22

TM 9-6115-653-14&P

Figure 4-11. Personnel Platform Replacement.
b. Installation
NOTE
If mounting brackets have not been removed, omit step (1 )
(1) Position each mounting bracket (8) on trailer frame (10) Insert three screws (7) through
frame into each
bracket Install one washer (8) and one self-locking nut (9) on each
screw and tighten
(2) Holding platform (4) in vertical position, position platform on mounting brackets (5) so
that holes in
platform line up with holes in brackets and Install platform anchors
(6) in upper mounting hole on each side
of platform
(3) Secure platform (4) to brackets (5) with two screws (1), four flat washers (2) and two selflocking nuts (3)

4-23(4-24 blank)

TM 9-6115-653-14&P

CHAPTER 5
DIRECT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
Section I. INTRODUCTION
5-1 General. This chapter contains direct and general support level maintenance procedures for components of the
M200A1 trailer added when the trailer is used as part of the PU-732/M power unit These components are not covered in
the overall trailer maintenance manual For all other direct and general support maintenance procedures on the trailer,
refer to TM 9-2330-205-14&P For direct and general support maintenance procedures on the generator set, refer to
TM 5-6115-464-34
WARNING
Before performing any maintenance that requires climbing on or under trailer, set trailer
handbrakes, chock wheels and lower rear leveling Jacks Injury to personnel could result from
trailer suddenly roiling or tipping
Section II. MAINTENANCE OF POWER UNIT TRAILER
5-2 Step and Fender Repair. Repair of the front and rear steps and the fenders is limited to straightening,
welding
and repainting If required, repaint in accordance with MIL-T-704, Type F. Color Green, No 383 of MIL-C-46168 If power
unit is painted in camouflage, refer to paragraph 5-4, Marking
5-3 Accessory Box Repair. (See figure 5-1 ) The accessory box is repaired by replacing the latch and strike
assemblies The box itself may be straightened, welded and repainted If required, repaint in accordance with MiL-T-704,
Type F. Color Green, No 383 of MIL-C-46168 If power unit is painted in camouflage, refer to paragraph 5-4, Marking
Replace latch and strike assemblies as follows
a.

Grind off or drill out solid rivets (1, figure 5-1 ) securing latch and strike assembly (2) to accessory box (3)

Position new latch and strike assembly (2) on accessory box (3) and secure with solid rivets (1)

Touch up with paint as required

4885 036

Figure 5-1. Accessory Box Repair.

5-1

TM 9-6115-653-14&P

5-4.Marking. (See figure 5-2 ) The power unit four-digit registration number, preceded by the prefix
"VB" and the words "U S ARMY", is marked in three places on power unit trailer Marking is done in
accordance with MlL-STD-642 On the fender, over each wheel, "T P 35 PSI" is marked in 1 00 + 12
inch high characters in accordance with MIL-STD-130 figure 5-2 shows the approximate location of
markings on power unit If required, touch-up ' of the base color shall be done in accordance with
MIL-T-704 Type F. Color Green, No 383 of MIL-C-46168 When power unit has been previously
painted in camouflage, any touch-up painting following repairs must match authorized patterns and
colors as specified in TB 43-0147 Application of camouflage paint shall be done in accordance with
MIL-C-53072

Figure 5-2. Power Unit Markings.
Section III. GENERATOR SET
5-5 Generator Set Replacement. (See figures S-3 and 5-4)
a. Removal
(1) Disconnect ground wire (1, figure 5-3) from generator set (2) to GROUND TERMINAL
stud (3) on trailer

5-2

TM 9-6115-653-14&P

NOTE
Two center mounting screws on each side can be reached through cutouts in
trailer frame under each fender The beveled washers (5) may have been
welded in place

Figure 5-3. Detaching Generator Set from Trailer.
(2) Remove eight screws (4), eight beveled washers (5), eight flat washers (6) and eight
nuts (7) securing
generator set (2) to trailer.
WARNING
When lifting generator set, use lifting equipment with a minimum lifting
capacity of 3500 lb. Do not stand under generator while it is being lifted Do
not permit generator set to swing Failure to observe these precautions can
cause Injury to personnel or damage to equipment.
(3) Attach lifting equipment with a minimum letting capacity of 3500 lb (1, figure 5-4) to both
lifting eyes (2) on
top edges of generator set (3) Insert a rope (4) through each of four
tiedown rings (5) on generator set.
(4) With one person at each rope to steady and guide generator set (3), lift generator set off
of trailer.
5-3

TM 9-6115-631-14&P

Figure 5-4. Lifting Generator Set
b. Installation
WARNING
When letting generator set, use lifting equipment with a minimum lifting
capacity of 3500 lb Do not stand under generator Do not permit generator set
so swing Failure to observe these precautions can cause Injury to personnel
or damage to equipment
(1) Attach lifting equipment with a minimum lifting capacity of 3500 lb (1, figure 5-4) to lifting
eyes (2) on top
edges of generator set (3) Insert a rope (4) through each of four tiedown
rings (5) on generator set.
(2) With one person at each rope to steady and guide generator set (3), lift generator set
and carefully lower it
onto trailer
NOTE
Two center mounting screws on each side can be reached through cutouts in
trailer frame under each fender
(3) Insert eight screws (4, figure 5-3) with beveled washers (5) down through generator set
skids into trailer
(4) Working under trailer Install one flat washer (6) and one nut (7) on each screw (4)
(5) Position beveled washers (5) so that screw heads are parallel to tops of washers While
holding beveled
washers in position, tighten hardware
(6) Connect generator set ground wire (1) to trailer GROUND TERMINAL stud (3)
5-4

TM 9-6115-653-14&P

CHAPTER 6
TEST AND INSPECTION AFTER REPAIR
Section I. GENERAL REQUIREMENTS
6-1 General Requirements. The activity performing the repair s 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 unit must perform those tests and
Inspections required by the applicable component or system repair Instruction
Section II. INSPECTION
6-2 Generator Set inspections. Refer to TM 5-6115-464-12 and -34 for Inspections required
following repair of the generator set
6-3 Trailer Inspections. Refer to TM 9-2330-205-14&P for Inspections required following repair of
the trailer
Section III OPERATIONAL TESTS
6-4 Generator Set Operational Tests. Refer to TM 5-6115-464-12 and -34 for operational tests
required to verify satisfactory performance of the generator set
6-5 Trailer Operational Tests. Refer to TM 9-2330-205-14&P for operational tests required to
verify satisfactory performance of the trailer

6-1/(6-2 blank)

TM 9-6115-653-14&P
APPENDIX A
REFERENCES
A-1. Scope. This appendix lists all pamphlets, forms, technical manuals, specifications and
miscellaneous publications referenced in this manual
A-2

Forms and Records.

Supply Policy Below the Wholesale Level ........................................................
Recommended Changes to Publications and Blank Forms ..............................
Depreservation Guide for Vehicles and Equipment ..........................................
Equipment Inspection and Maintenance Worksheet.........................................
Maintenance Request. ......................................................................................
Consolidated Index of Army Publications..........................................................
The Army Maintenance Management System (TAMMS) ..................................
Product Quality Deficiency Report ....................................................................
A-3.

AR 710-2
DA Form 2028
DA Form 2258
DA Form 2404
DA Form 2407
DA PAM 25-30
DA PAM 738-750
SF 368

Military Specifications.

Chemical Agent Resistant Aliphatic Polyurethane Coating...............................

MIL-C-46168

Chemical Agent Resistant Coating (CARC) System Application Procedure and
Q/C Inspection ..................................................................................................
Identification Marking of U S Military Property ..................................................
Identification Marking of Combat and Tactical Transport..................................
Treatment and Painting of Materiel ...................................................................
A-4.

MIL-C-53072
MIL-STD-130
MIL-STD-642
MIL-T-704

Technical Manuals.

Operator and Organizational Maintenance Manual Generator Set,
Diesel Engine Driven, Tactical Skid Mounted, 15 KW, 3 Phase,
4 Wire, 1201208 and 240/41 6V (DOD Model MEP-004A) Utility
Class, 50/60 Hz (NSN 6115-00-118-1241), (Model MEP-103A),
Precise Class, 50/60 Hz (6115-00-118-1245), (Model MEP-113A),
Precise Class, 400 Hz (6115-00-118-1244) ................................................
Organizational, Intermediate (Field) (Direct Support and General
Support and Depot Maintenance Repair Parts and Special Tools
List) Generator Set, Diesel Engine Driven, Tactical Skid Mounted,
15 KW, 3 Phase, 4 Wire, 120/208 and 240/416 V (DOD Models
MEP-004A) Utility Class, 50/60 HZ (NSN 6115-00-118-1241),
(Model MEP-103A3, Precise Class, 50/60 HZ (6115-00-118-1245),
(Model MEP-113A), Precise Class, 400 Hz (6115-00-118-1244) ................

A-1

TM 5-6115-464-1 2

TM 5-6115-464-24P

TM 9 61115-653-148&P
Intermediate (Field) Direct and General Support and Depot Level
Maintenance Manual, Generator Set, Diesel Engine Driven,
Tactical Skid Mtd, 15 KW, 3 Phase, ~ Wire, 120/208 and
240/416 Volts DOD Model MEP-004A, Utility Class, 50160 HZ
(NSN 6115-00-118-1241), Model MEP-103A, Precise Class,
50/60 HZ (61 15-00-1 18-1245), Model MEP-1 13A, Precise
Class, 400 1 IZ (6115-00-118-1244)............................................................
Procedures for Destruction of Equipment to Prevent Enemy Use
(Mobility Equipment Command)...................................................................
Operator's, Organizational, Direct Support and General Support Maintenance
Manual Including Repair Parts and Special Tools List for Chassis, Trailer,
Generator, 2-1/2 Ton, 2-Wheel M200A1 (NSN 2330 00-331-2307) ............
14&P
Organizational, Direct Support, and General Support Care Maintenance
and Repair of Pneumatic Tires and Inner Tubes .........................................
A-5.

TM 5-6115-464-34
TM 750-244-3

9-2330-205-

TM 9-2610-200-24

Technical Bulletins

Color, Marking and Camouflage Patterns Used on Military Equipment Managed
by USATROSCOM.......................................................................................
TB 43-0147
Preservation of USAMECOM Mechanical Equipment for
Shipment and Storage .................................................................................
TB 740-97-2

A-2

TM 9-6115-653-14&P
APPENDIX B
Section I. INTRODUCTION
B-1 SCOPE This appendix lists components of end item and basic issue items for the power unit to
help you
inventory items required for sate and efficient operation
B-2 General 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 pad 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 unit in operation, to operate it, and to perform emergency repairs Although shipped separately
packaged, Bll must be with the power unit 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 Bll, based on TOE/MTOE authorization of the end item
B-3 Explanation Of Columns.
tabular
listings

The following provides an explanation of columns found in the

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, it 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 (U/M) Indicates the measure used in performing the actual
operational
maintenance function This measure is expressed by a two-character alphabetical abbreviation (eg,
ea. in pr).
e. Column (5). Quantity Required (Qty Req’d) Indicates the quantity of the item authorized to
be used with/on the equipment
B-1

TM 9-6115-653-14&P
Section II. COMPONENTS OF END ITEM

(1)

(2)

ILLUS
NO.

NATIONAL
STOCK NUMBER

(3)
DESCRIPTION
USABLE
ON CODE

FSCM AND PART NUMBER

(4)

(5)

U/M

QTY
REQ’D

5120-00-243-2957

Hammer, Hand, Engineers 10 lb.
(3 6 kg) (81348) GGG-H-86

5975-00-878-3791

Rod, Ground, Driven, Sectional
9 ft (2.7 m) (81349) MIL-R-11461

5120-01-013-1676

Hammer, Slide (97403) 13226E7741

7240-00-177-6154

Spout, Can, Flexible (81349)
MIL-S-1285

2910-00-066-1235

Adapter Assy, Fuel Drum (97403)
13214E7541

GOVERNMENT PRINTING Of OFFICE 1991 - 554-030/40098

067311-002

Change 2

B-2

TM 9-6115-653-14&P
Section III. BASIC ISSUE ITEMS

TM
SECTION II. COMPONENTS OF ITEM LIST
(1)

(2)

ILLUS
NO.

NATIONAL
STOCK NUMBER

4210-00-270-4512

(3)
DESCRIPTION
FSCM AND PART NUMBER

USABLE
ON CODE

(4)

(5)

U/M

QTY
REQ’D

Extinguisher, fire, Hand, 5 lb
(2 3 kg) (81348) O-E-910

Manual, Technical
TM 5-6115-653-14&P

B-3/(B-4 blank)

TM 9-6115-653-14&P
APPENDIX C
MAINTENANCE 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. Section II designates overall responsibility for the performance of maintenance functions on 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 III lists the tools and test equipment required for each maintenance function as referenced from
Section II
d. Section IV contains supplemental Instructions, explanatory notes and/or Illustrations required for a particular
maintenance function
C-2 Explanation of Columns in Section II
a. Group Number Column 1 The assembly group is a numerical group assigned to each assembly in a 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. Maintenance Functions Column 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 venous
maintenance categories are as follows
C - Operator or crew
O - Unit maintenance
F - Direct support maintenance
H - 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 serviceably and to detect electrical or mechanical failure by use of test equipment

C-1

TM 9-6115-653-14&P
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
D - Adjust To rectify to the extent necessary to bring Into proper operating range
E - Alone 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 ceded 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 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 to 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 when required by operational considerations or other paramount factors and then
only at the depot maintenance category Rebuild reduces to zero the hours or miles of the equipment,
or component thereof, has been in use
d. Symbols The uppercase letter placed in the appropriate column indicates the lowest level at
which 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 III. Tools, Test, and Support Equipment Requirements is
not applicable
C-4 Explanation of Columns in Section IV. Remarks, is not applicable.

C-2

TM 9-6115-653-14&P
Section II. MAINTENANCE ALLOCATION CHART

(1)

(2)
A

Group
No.

Assembly
group

GENERATOR SET

ACCESSORIES

B
I
n
s
p
e
c
t

T
e
s
t

C
0. 2

(3)
Maintenance functions
C
D
E
F
G
H
C
a
S
R
l
I
e
A
e
i
n
A
r
d
p
b
s
l
v
j
l
r
t
i
i
u
a
a
a
g
c
s
c
t
l
n
e
t
e
e
l

C
2 .0

(4)
I

R
e
p
a
i
r

O
v
e
r
h
a
u
l

F
3. 0

Sledge Hammer

C
0.1

Fire Extinguisher

C
0.1

Slide Hammer

C
0.1

Ground Rods

C
0.1

TRAILER ASSEMBLY

C O
0.5 1.0

0.5

2.0

Fuel Can/Fire
Extinguisher Brackets

C
0.1

O
0.5

Steps/Platforms

C
0.1

O
1.0

F
2.0

O
1.0

F
2.0

Fenders

C
0.1

O
0.5

Data Plates

O
0.2

Leveling Jacks

C
0.1

Lighting

C O
0.1 0.3

Handbrake

C
0.1

O
0.2

K
R
e
b
u
i
l
d

Tools and
equipment

Remarks

See TM 56115-464-12,-34
for generator set
maintenance

C
0.5

Accessory Box

Reflectors

(5)

O
1.0

O
05

F
0.5

C-3/(C-4blank)

See TM 9
2330-205-14&P
for trailer
maintenance

`TM 9-6115-653-14&P
APPENDIX D
UNIT, DIRECT, GENERAL SUPPORT AND DEPOT MAINTENANCE
REPAIR PARTS AND SPECIAL TOOLS LIST
Section I. INTRODUCTION
D-1 Scope. This manual lists repair parts and special tools required for the performance of unit,
direct and
general support and depot maintenance of the power unit
D-2 General. The Repair Parts and Special Tools List is divided into the following sections
a. Repair Parts - Section II. A list of repair parts authorized for the performance of maintenance
at the unit, direct and general support and depot level in figure and item number sequence
b. Special Tools. Test and Support Equipment - Section III. A list of special tools, test and
support equipment authorized for the performance of maintenance at the unit, direct and general
support and depot level
c. National Stock Number and Reference Number Index - Section IV. A list of National stock
numbers 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. The reference Designator Column includes all
assigned reference designators arranged first in alphabetical order, second in numerical order
Opposite each symbol is listed the figure and item number of the part in Section II and the reference
number
D-3 Explanation of Columns. The following provides an explanation of columns in the tabular lists
in Sections II and III
a. Illustrations (Column 1). This column is divided as follows
(1) figure number Indicates the figure number of the Illustration on which the Item Is shown
(2) Item number Indicates the number used to Identify the item on the illustration

D-1

TM 9-6115-653-14&P

b. Source, Maintenance, and Recoverability Codes (SMR), (Column 2)
(1) Source codes
GENERAL 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
Code
PA

Definition
Item procured and stocked for anticipated or known usage

PB
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
specified

Support equipment procured and stocked for Initial Issue or outfittings to
maintenance repair activities

PF
procured on

Support equipment which will not be stocked but which will be centrally
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
kit defined as a
overhaul or repair

An item of depot overhaul/repair kit and not purchased separately Depot
kit that provides Items required at the time of

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 DS/GS levels of maintenance
KB

Item Included in both a depot overhaul/repair kit and a maintenance kit

Item to be manufactured or fabricated at unit level
D-2

TM 9-6115-653-14&P
Code

Definition

Item to be manufactured or fabricated at general support maintenance

Item to be manufactured or fabricated at depot maintenance level

Item to be assembled at unit level

Item to be assembled at direct support maintenance levels

Item to be assembled at general support maintenance levels

Item to be assembled at depot maintenance level

levels

XA
result In the

Item is not procured or stocked because the requirements for the item will
replacement of the next higher assembly

XB
Item is not procured or stocked If not available through salvage,
requisition XC
Installation drawing, diagram, instruction
sheet, field service drawing, that is identified by
manufacturer's part number
XD
through normal

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

(2) Maintenance codes: GENERAL Maintenance 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
Application/Explanation
O
Support item is removed, replaced, used at the unit level of maintenance
F
Support item is removed, replaced, used at direct support level
H
Support item is removed, replaced, used general support level
Code
Definition
D
Support items that are removed, replaced, used at depot only 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)

D-3

TM 9-6115-653-14&1P
Code

Application/Explanation

O
Item is the unit

The lowest maintenance level capable of complete repair of the support
level

F
item is direct

The lowest maintenance level capable of complete repair of the support
support level

H
item is general

The lowest maintenance level capable of complete repair of the support
support level

Code

Definition

D
The lowest maintenance level capable of complete repair of the support
item is the
depot level Depot, Mobile Depot, and
Specialized Repair Activity
Code

Application/Explanation

Repair restricted to designated Specialized Repair Activity

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) Recoverability codes GENERAL 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
Codes

Definition

Z
level indicated in

Nonreparable Item When unserviceable, condemn and dispose at the
column 3

O
at unit level

Reparable item When uneconomically reparable, condemn and dispose

F
at direct support

Reparable item When uneconomically reparable, condemn and dispose
level

H
at general

Reparable hem When uneconomically reparable, condemn and dispose
support level
D-4

TM 9-6115-653-14&P
Recoverability
Codes

Definition

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

Reparable item Repair, condemnation and disposal not authorized below
depot/Specialized Repair Activity level

Item requires special handling or condemnation procedure 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. National Stock Number (Column 4). Indicates the National Stock Number assigned to the Item and will be used
for requisitioning purposes
d. Description (Column 5). Indicates the Federal Item name and any additional descriptions of the Item required
The abbreviation "w/e" when used as a 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. 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 9,
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.
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.

Identification of Usable On Codes for this manual is not applicable

b. Army unit maintenance personnel will extract the items which they require from Section II, 3rd or 4th position of
column 2 of the 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 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-5

TM 9-6115-653-14&P
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.

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) Find the illustration covering the functional group to which the repair part belongs
(3) Identify the repair part on the Illustration and note the illustration figure and Item number of the repair part
(4) Using the Repair Parts Listing, find the figure and Item number noted on the illustration

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 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 pad and description is given in this listing
D-7 Abbreviations
Abbreviations

Explanation
Not Applicable

D-8 Federal Supply Codes for Manufacturers.
Code

Manufacturer
Not Applicable

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
directly to Commander, US Army Troop Support Command, ATTN AMSTR-MCTS, 4300 Goodfellow Boulevard,
St. Louis, MO 63120-1798.

D-6

Figure D-1. Generator Set.

(D-7 blank)/D-8

TM 9-6115-653-14&P
(1)
ILLUSTRATION
(a)
FIG
NO.

(b)
ITEM
NO.

(2)
SMR CODE
a

b
c
AIR
ARMY FORCE NAVY

(3)
USMC
d

USMC

SSI

b
REPL
FACTOR

(4)
NATIONAL
STOCK
NUMBER

(5)
DESCRIPTION
REF NUMBER
& MFR CODE

USABLE
ON
CODE

(6)

(7)

(8)

U/M

QTY
INC
IN
UNIT

USMC
QTY
PER
EQUIP

Group 01- GENERATOR
D-1

D-1

6115 00 118 1244

PAFZZ

5305 00 J24 7222

5310 01 185 0586

531001 8238803

5310 00 269 4040

D-9

GENERATOR SET, DIESEL
MEP 113A

97403

SCREW, CAP, HEX
MS90728 164

96906

WASHER, REVELED
13206E4482 3

97403

WASHER,FLAT
MS27183 21

96906

NUT, SELF-LOCKING
MS51922 49

96906

TM 9-6115-653-14&P

Figure D-2. Trailer Body
D-10

TM 9-6115-653-14&P
(2)
SMR CODE

(1)
ILLUSTRATION
(a)
FIG
NO.

(b)
ITEM
NO.

b
c
AIR
ARMY FORCE NAVY

(3)
USMC
d

USMC

SSI

b
REPL
FACTOR

(4)
NATIONAL
STOCK
NUMBER

(5)
DESCRIPTION
REF NUMBER
& MFR CODE

USABLE
ON
CODE

(6)

(7)

(8)

U/M

QTY
INC
IN
UNIT

USMC
QTY
PER
EQUIP

Group 03 - Trailer
03 - Body
D-2

PAOZZ

2590-00-473-6331

BRACKET ASSEMBLY, LIQUID
CONTAINER MS53052-1 96906

D-2

XBOZZ

5305-00-269-3210

SCREW, CAP, HEX
MS90725 62

96906

WASHER, FLAT
MS27183-14

96906

NUT, SELF-LOCKING
MS51922-17

96906

BRACKET, FIRE EXTINGUISHER
13214E1235

97403

SCREW, MACHINE
MS35206 311

96906

BRACKET ASSEMBLY
13214E1214

97403

SCREW, CAP, HEX
MS90725 6

96906

WASHER, FLAT
MS27183-10

96906

NUT, SELF-LOCKING
MS51922-1

96906

CLIP, SPRING
13214E1213-1

97403

NUT, PLAIN, WING
MS35435-28

96906

NUT, PLAIN, HEX
MS16203-27

96906

WASHER, FLAT
AN961 - 616S

81352

WASHER, FLAT
AN961-616T

81352

NUT, PLAIN, HEX
MS16203 39

96906

LOCKWASHER
MS35333-110

96906

STUD
13214E1223

97403

PLATE, IDENTIFICATION
13205E4918

97403

PLATE, IDENTIFICATION
13216E7604-39

97403

SCREW, DRIVE
MS21318-21

96906

D-2

PAOZZ

5310-00 080-6004

PAOZZ

5310-00-087-4652

PAOZZ

4210-00-223-4857

PAOZZ

5305-00-984-5691

PAOZZ

5340-00-999-6277

PAOZZ

5305-00 068-0502

PAOZZ

5310-00-809-4058

PAOZZ

5130-00-088-1251
'

D-2

14A

PAOZZ

MDFZZ

5304-00-914-2578

5310 00-543-4717

5310-00-584-7995

5310-00 004-9129

5310-00-187-2413

5310-00-026-5824

5310-00 022 8847

5307-00-227-1741

9905-01-085-7703

MDFZZ

PAOZZ

5305-00-253-5616

Change 1

D-11

TM 9-6115-653-14&P

(2)
SMR CODE

(1)
ILLUSTRATION
(a)
FIG
NO.

(b)
ITEM
NO.

b
c
AIR
ARMY FORCE NAVY

(3)
USMC
d

USMC

SSI

b
REPL
FACTOR

(4)
NATIONAL
STOCK
NUMBER

(5)
DESCRIPTION
REF NUMBER
& MFR CODE

USABLE
ON
CODE

(6)

(7)

(8)

U/M

QTY
INC
IN
UNIT

USMC
QTY
PER
EQUIP

Group 03 - TRAILER
03 Body (cont)
D-2

D-2

PAOZZ

4730-00-908-3193

5325-00-290-1960

MHOZZ

PAOZZ

5940-00-115-4992

8145-00-395-8799

D-12

CLAMP, HOSE
MS35842-12

96803

GROMMET
MS35489 -7

96906

HOSE
ZZ-H-426

81348

TERMINAL LUG
MS20659-110

96906

WIRE, NO. 6AWG
ZZ-W-343

81348

TM 9-6115-653-14&P

Figure D-3. Accessory Box.

D-14

TM 9-6115-653-14&P

(2)
SMR CODE

(1)
ILLUSTRATION
(a)
FIG
NO.

(b)
ITEM
NO.

b
c
AIR
ARMY FORCE NAVY

(3)
USMC
d

USMC

SSI

b
REPL
FACTOR

(4)

(5)
DESCRIPTION

NATIONAL
STOCK
NUMBER

REF NUMBER
& MFR CODE

USABLE
ON
CODE

(6)

(7)

(8)

U/M

QTY
INC
IN
UNIT

USMC
QTY
PER
EQUIP

03 - Accessory Box
D-3

D-3

XBFFF

PAFZZ

PAOZZ

2450-00-903-3503

5340-00-975-2126

5320-00-753-3830

5306-00-225-8498

5310-00-087-7493

5310-00-985-3806

ACCESSORY BOX
13214E1256
CATCH, CLAMPING AND STRIKE
ASSEMBLY
MS18015-1

96906

RIVET
MS20613-4P5

96906

SCREW,CAP,HEX
MS90725-33

96906

WASHER,FLAT
MS27183-13

96906

NUT, SELF LOCKING
MS51922-9

96906

D-15

97403

TM 9-6115-653-14&P

Figure D-4. Front Steps.

D-16

TM 9-6115-653-14&P

(2)
SMR CODE

(1)
ILLUSTRATION
(a)
FIG
NO.

(b)
ITEM
NO.

b
c
AIR
ARMY FORCE NAVY

(3)
USMC
d

USMC

SSI

b
REPL
FACTOR

(4)
NATIONAL
STOCK
NUMBER

(5)
DESCRIPTION
REF NUMBER
& MFR CODE

USABLE
ON
CODE

(6)

(7)

(8)

U/M

QTY
INC
IN
UNIT

USMC
QTY
PER
EQUIP

03 - FRONT STEPS
D-4

D-4

XBOFF

PAOZZ

XDFZZ

2330-01-150-9864

2510-00-196-682

5306 00-225-499

5310-00 081-4219

5310-00-984-3806

5305-00-225-9081

5306 00-225-8503

5365-00-944-2692

D-4 9 XBFZZ

D-4

XBFZZ

5365-00-945-5998

XBFZZ

Change 1

STEP,FRONT,CURBSIDE
13214E1461

97403

STEP, FRONT, ROADSIDE
13214E1462

97403

SCREW,CAP,HEX
MS90725-4

96906

WASHER, FLAT
MS27183-12

96906

NUT, SELF-LOCKING
MS51922-9

96906

SCREW, CAP, HEX
MS90725 36

96906

SCREW, CAP, HEX
MS90725 39

96906

SPACER
13214E1267-1

97403

CHANNEL
13214E1268

97403

SPACER
13214E1267-2

97403

CHANNEL
13214E1463

94703

D-17

TM 9-6115-653-14&P

Figure D-5. Rear Steps.

D-18

TM 9-6115-653-14&P

(2)
SMR CODE

(1)
ILLUSTRATION
(a)
FIG
NO.

(b)
ITEM
NO.

b
c
AIR
ARMY FORCE NAVY

(3)
USMC
d

USMC

SSI

b
REPL
FACTOR

(4)

(5)
DESCRIPTION

NATIONAL
STOCK
NUMBER

REF NUMBER
& MFR CODE

USABLE
ON
CODE

(6)

(7)

(8)

U/M

QTY
INC
IN
UNIT

USMC
QTY
PER
EQUIP

03 - Rear Steps
D-5

D-5

XBOFF

PAOZZ

XBOFF

PAOZZ

5340-01-875-8820

5305-00-269-3213

5310-00-080-6004

5310-00-087-4652

2510-01-N73-0729

2510-01-N73-0794

5306-00-225-8499

5310-00-081-4219

5310-00-984-3806

D-19

BRACKET, STEP, REAR
13214E1309-1

97403

SCREW, CAP, HEX
MS90725-62

96906

WASHER, FLAT
MS27183-14

96906

NUT, SELF-LOCKING
MS51922-17

96906

STEP, REAR, ROADSIDE
13214E1261

97403

STEP, REAR, CURBSIDE
13214E1259

97403

SCREW, CAP,HEX
MS90725-34

96906

WASHER, FLAT
MS27183-12

96906

NUT, SELF-LOCKING
MS51922-9

96906

TM 9-6115-653-14&P

Figure D-6. Fenders.

D-20

TM 9-6115-653-14&P

(2)
SMR CODE

(1)
ILLUSTRATION
(a)
FIG
NO.

(b)
ITEM
NO.

b
c
AIR
ARMY FORCE NAVY

(3)
USMC
d

USMC

SSI

b
REPL
FACTOR

(4)

(5)
DESCRIPTION

NATIONAL
STOCK
NUMBER

REF NUMBER
& MFR CODE

USABLE
ON
CODE

(6)

(7)

(8)

U/M

QTY
INC
IN
UNIT

USMC
QTY
PER
EQUIP

Group 03 - Fenders
D-6

D-6

XBOFF

PAOZZ

2510-01-213-3242

2510-01-195-4273

5306-00-225-8500

5310-00-081-4219

5310-00-984-3806

D-21

FENDER, ROADSIDE
13214E1264

97403

FENDER, CURBSIDE
13214E1263

97403

SCREW, CAP, HEX
MS90725-35

96506

WASHER,FLAT
MS27183-12

96906

NUT, SELF-LOCKING
MS51922-9

96906

TM 9-6115-653-14&P

Figure D-7. Personnel Platform.
D-22

TM 9-6115-653-14&P

(2)
SMR CODE

(1)
ILLUSTRATION
(a)
FIG
NO.

(b)
ITEM
NO.

b
c
AIR
ARMY FORCE NAVY

(3)
USMC
d

USMC

SSI

b
REPL
FACTOR

(4)
NATIONAL
STOCK
NUMBER

(5)
DESCRIPTION
REF NUMBER
& MFR CODE

USABLE
ON
CODE

(6)

(7)

(8)

U/M

QTY
INC
IN
UNIT

USMC
QTY
PER
EQUIP

03 - Personnel Platform
D-7

D-7

PAOZZ

XBOFF

PAOZZ

XBOFF

PAOZZ

5340-01-156-6142

2510-00-926-3517

5305-00-939-9204

5310-00-809-8533

5310-00-067-6356

5340-00-097-7676

5340-00-999-6441

5305-00-042-6417

5310-00-809-5998

5310-00-225-6993

D-23

ANCHOR, PLATFORM
13214E1303

97403

PLATFORM, PERSONNEL
13214E1298

97403

SCREW, CAP, HEX
MS90725-187

96906

WASHER, FLAT
MS27183-23

96906

NUT, SELF LOCKING
MS51922-57

96906

BRACKET, LEFT
13214E1299

97403

BRACKET, RIGHT
13214E1300

97403

SCREW, CAP, HEX
MS90725-113

96906

WASHER, FLAT
MS27153-18

96906

NUT, SELF-LOCKING
MS51922-33

96906

TM 9-6115-653-14&P

Figure D-8. Handbrakes

D-24

TM 9-6115-653-14&P

(2)
SMR CODE

(1)
ILLUSTRATION
(a)
FIG
NO.

(b)
ITEM
NO.

b
c
AIR
ARMY FORCE NAVY

(3)
USMC
d

USMC

SSI

b
REPL
FACTOR

(4)
NATIONAL
STOCK
NUMBER

(5)
DESCRIPTION
REF NUMBER
& MFR CODE

USABLE
ON
CODE

(6)

(7)

(8)

U/M

QTY
INC
IN
UNIT

USMC
QTY
PER
EQUIP

03 - Handbrakes
D-8

D-8

XBFZZ

6115-01-876-2084

PAFZZ

PAOZZ

5306-00-225-8499

PAOZZ

XBFZZ

5310-00-081-4219

5310-00-984-3806

5340-01-226-5766

5365-00-989-3304

Change 1

STRAP, BRAKE CABLE
13214E1271

97403

BRACKET, BRAKE CABLE
13214E1270

97403

SCREW, CAP, HEX
MS90725-34

96906

SCREW, CAP, HEX
MS90725-39

96906

WASHER, FLAT
MS27183-12

96906

NUT, SELF-LOCKING
MS51922-9

96906

BRACKET, BRAKE
13214E1269

97403

SPACER
13214E1272

97403

D-25

TM 9-6115-653-14&P
Section III. SPECIAL TOOLS, TEST, AND SUPPORT EQUIPMENT
Not Applicable

Section iV. NATIONAL STOCK NUMBER AND REFERENCE NUMBER INDEX

NSN
2330-01-150-9864
2450-00-903-3503
2510-00-926-3517
2510-01-N73-0729
2510-01-N73-0794
2510-01-195-4273
2510-01-196-4682
2510-01-213-3242
2590-00-473-6331
4210-00-223-4857
4730-00-908-3193
5304-00-914-2578
5305-00-042-6417
5305-00-068-0502
5305-00-225-9081
5305-00-253-5616
5305-00-269-3210
5305-00-269-3213
5305-00-724-7222
5305-00-939-9204
5305-00-984-5691
5306-00-225-8398
5306-00-225-8499

5306-00-225-8500
5306-00-225-8503
5307-00-227-1741
5310-00-004-9129
5310-00-022-8847
5310-00-026-5824
5310-00-067-6356
5310-00-080-6004
5310-00-081-4219

FIGURE
NO.
D-4
D-3
D-7
D-5
D-5
D-6
D-4
D-6
D-2
D-2
D-2
D-2
D-7
D-2
D-4
D-2
D-2
D-5
D-1
D-7
D-2
D-3
D-4
D-5
D-8
D-6
D-4
D-2
D-2
D-2
D-2
D-7
D-2
D-5
D-4
D-5
D-6

ITEM
NO.
1
1
2
5
6
2
2
1
1
5
21
11
8
8
6
20
2
2
2
3
6
4
3
7
3
3
7
17
14
16
15
5
3
3
4
8
4

NSN
5310-00-087-4652
5310-00-087-7493
5310-00-088-1251
5310-00-187-2413
5310-00-225-6993
5310-00-269-4040
5310-00-543-4717
5310-00-584-7995
5310-00-809-4058
5310-00-809-5998
5310-00-809-8533
5310-00-984-3806

5310-00-985-3806
5310-01-185-0586
5310-01-823-8803
5320-00-753-3830
5325-00-290-1960
5340-00-087-7676
5340-00-975-2126
5340-00-999-6277
5340-00-999-6441
5340-01-875-8820
5340-01-156-6142
5340-01-226-5766
5365-00-944-2692
5365-00-945-5998
5365-00-989-3304
5940-00-115-4992
6115-00-118-1244
6115-01-876-2084
6145-00-395-8799
9905-01-085-7703

FIGURE
NO.
D-8
D-2
D-5
D-3
D-2
D-2
D-7
D-1
D-2
D-2
D-2
D-7
D-7
D-4
D-5
D-6
D-8
D-3
D-1
D-1
D-3
D-2
D-7
D-3
D-2
D-7
D-5
D-7
D-8
D-4
D-4
D-8
D-2
D-1
D-8
D-2
D-2

ITEM
NO.
5
4
4
5
10
14
10
5
12
13
9
9
4
5
9
5
6
6
3
4
3
22
6
2
7
7
1
1
7
8
10
8
24
1
1
25
18

*U.S. GOVERNMENT PRINTING OFFICE 1991 554-123/20096

PIN: 0-67311-001

Change 1

D-26

TM 9-6115-653-14&P

Section IV. NATIONAL STOCK STOCK NUMBER AND REFERENCE NUMBER INDEX (cont)
Reference
Number
AN961-616S
AN961-616T
MS16203-27
MS16203-39
MS18015-1
MS20613-4P5
MS20659-110
MS21318-21
MS27183-10
MS27183-12

MS27183-13
MS27183-14
MS27183-18
MS27183-21
MS27183-23
MS35206-311
MS35333-110
hAS35435-28
MS35489-27
MS35842-12
MS51922-1
MS51922-17
MS51922-33
MS51922-49
MS51922-57
MS51922-9

MS53052-1
MS90725-113
MS90728-164
MS90725-187
MS90725-33

FSCM
81352
81352
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
969O6
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906

Fig.
No.
D-2
D-2
D-2
D-2
D-3
D-3
D-2
D-2
D-2
D-4
D-5
D-6
D-8
D-3
D-2
D-5
D-7
D-1
D-7
D-2
D-2
D-2
D-2
D-2
D-2
D-2
D-5
D-7
D-1
D-7
D-3
D-4
D-5
D-6
D-8
D-2
D-7
D-1
D-7
D-3

Item
No.
14
14
13
15
2
3
24
20
9
4
8
4
5
5
3
3
9
4
4
6
16
12
22
21
10
4
4
10
5
5
6
5
9
5
6
1
8
2
3
4

Reference
Number
MS90725-34

MS90725-35
MS90725-36
MS90725-39
MS90725-6
MS90725-62
QQ-W-343
ZZ-H-428
13205E4918
13206E4482-3
13214E1213-1
13214E1214
13214E1223
13214E1235
13214E1256
13214E1259
13214E1261
13214E1263
13214E1264
13214E1267-1
13214E1267-2
13214E1268
13214E1269
13214E1270
13214E1271
13214E1272
13214E1298
13214E1299
13214E1300
13214E1303
13214E1309-1
13214E1461
13214E1462
13214E1463
13216E7604-39

D-27

FSCM
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
81348
81348
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403

Fig.
No.
D-4
D-5
D-8
D-6
D-4
D-4
D-8
D-2
D-2
D-5
D-2
D-2
D-2
D-1
D-2
D-2
D-2
D-2
D-3
D-5
D-5
D-6
D-6
D-4
D-4
D-4
D-8
D-8
D-8
D-8
D-7
D-7
D-7
D-7
D-5
D-4
D-4
D-4
D-2

Item
No.
3
7
3
3
6
7
4
8
2
2
25
23
18
3
11
7
17
5
1
6
5
2
1
8
10
9
7
2
1
8
2
6
7
1
1
1
2
11
19

TM 9-6115-653-14&P
Section V. REFERENCE DESIGNATOR INDEX
Not Applicable

D-28

TM 9-6115-653-14&P

By Order of the Secretary of the Army:

CARL E. VUONO
General, United States Army
Chief of Staff
Official:

WILLIAM J. MEEHAN, II
Brigadier General, United States Army
The Adjutant General

DISTRIBUTION:
To be distributed in accordance with DA Form 12-25A, Operator, Unit, Direct Support and
General Support Maintenance Requirements for Generator Set, Diesel Engine Driven, Trailer
Mounted.

*U.S. GOVERNMENT PRINTING OFFICE 1990 754-029/20047

The Metric System and Equivalents
Linear Measure

Liquid Measure
1 centiliter = 10 milliters = .34 fl. ounce
1 deciliter = 10 centiliters = 3.38 fl. ounces
1 liter = 10 deciliters = 33.81 fl. ounces
1 dekaliter = 10 liters = 2.64 gallons
1 hectoliter = 10 dekaliters = 26.42 gallons
1 kiloliter = 10 hectoliters = 264.18 gallons

1 centimeter = 10 millimeters = .39 inch
1 decimeter = 10 centimeters = 3.94 inches
1 meter = 10 decimeters = 39.37 inches
1 dekameter = 10 meters = 32.8 feet
1 hectometer = 10 dekameters = 328.08 feet
1 kilometer = 10 hectometers = 3,280.8 feet

Square Measure
Weights
1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47

1 centigram = 10 milligrams = .15 grain
1 decigram = 10 centigrams = 1.54 grains
1 gram = 10 decigram = .035 ounce
1 decagram = 10 grams = .35 ounce
acres
1 hectogram = 10 decagrams = 3.52 ounces
1 kilogram = 10 hectograms = 2.2 pounds
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons

1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu.
inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet

Approximate Conversion Factors
To change
inches
feet
yards
miles
square inches
square feet
square yards
square miles
acres
cubic feet
cubic yards
fluid ounces
pints
quarts
gallons
ounces
pounds
short tons
pound-feet
pound-inches

Multiply by

centimeters
2.540
meters
.305
meters
.914
kilometers
1.609
square centimeters 6.451
square meters
.093
square meters
.836
square kilometers
2.590
square hectometers .405
cubic meters
.028
cubic meters
.765
milliliters
29,573
liters
.473
liters
.946
liters
3.785
grams
28.349
kilograms
.454
metric tons
.907
Newton-meters
1.356
Newton-meters
.11296

To change
ounce-inches
centimeters
meters
meters
kilometers
square centimeters
square meters
square meters
square kilometers
square hectometers
cubic meters
cubic meters
milliliters
liters
liters
liters
grams
kilograms
metric tons

To
Newton-meters
inches
feet
yards
miles
square inches
square feet
square yards
square miles
acres
cubic feet
cubic yards
fluid ounces
pints
quarts
gallons
ounces
pounds
short tons

Temperature (Exact)
°F

Fahrenheit
temperature

5/9 (after
subtracting 32)

Celsius
°C
temperature

Multiply by
.007062
.394
3.280
1.094
.621
.155
10.764
1.196
.386
2.471
35.315
1.308
.034
2.113
1.057
.264
.035
2.205
1.102

PIN: 067311-000

Source Exif Data:

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Create Date                     : 1997:05:13 07:56:36Z
Keywords                        : LOGSA
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Format                          : application/pdf
Title                           : 18352.doc
Creator                         : LOGSA
Description                     : 
Page Mode                       : UseOutlines
Page Count                      : 101

EXIF Metadata provided by EXIF.tools

18352 TM 9 6115 653 14 And P POWER UNIT PU 732/M (NSN 00 260 3082) MEP 113A 15 KW 400 HZ GENERATOR SET M200 2 WHEEL, 4 TIRE, MODIFIED TRAILER

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