Power Plant, Utility PU-821/T (NSN 6115-01-547-6713) (EIC YVC) PU-822A/T (NSN 6115-01-547-6738) (EIC YVB)
Uploaded by
Billy MorrisonPower Plant, Utility PU-821/T (NSN 6115-01-547-6713) (EIC YVC) PU-822A/T (NSN 6115-01-547-6738) (EIC YVB)
Uploaded by
Billy Morrison*TM 11-6115-742-13&P
TECHNICAL MANUAL
OPERATOR AND FIELD MAINTENANCE MANUAL
INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST
FOR
POWER PLANT, UTILITY
PU-821/T (NSN 6115-01-547-6713) (EIC YVC)
PU-822A/T (NSN 6115-01-547-6738) (EIC YVB)
*TM 11-6115-742-13&P dated 30 May 2012, including all changes, supersedes TM 11-6115-742-13&P dated 15 October 2008
DISTRIBUTION STATEMENT D. Distribution authorized to the Department of Defense and U.S. DOD contractors only, for official use or for
administrative and operational purposes. This determination was made on 5 August 2011. Other requests for this document will be referred
to Commander, U.S. Army Communications-Electronics Life Cycle Management Command (CECOM LCMC), 6001 Combat Drive, ATTN:
AMSEL-LCL-ECM, Aberdeen Proving Ground, MD 21005-1846.
WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et.
seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et. seq. Violations of these export laws are subject to
severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.
DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of the document.
HEADQUARTERS, DEPARTMENT OF THE ARMY
30 May 2012
TM 11-6115-742-13&P
5
SAFETY STEPS TO FOLLOW IF SOMEONE IS
VICTIM OF ELECTRICAL SHOCK.
1 SEND FOR HELP AS SOON AS POSSIBLE.
2 DO NOT TRY TO PULL OR GRAB INDIVIDUAL.
3 IF POSSIBLE, TURN OFF ELECTRICAL POWER.
4
IF YOU CANNOT TURN OFF ELECTRICAL POWER, PULL, PUSH, OR
LIFT PERSON TO SAFETY USING A DRY WOODEN POLE, A DRY
ROPE, OR SOME OTHER INSULATING MATERIAL.
5
AFTER INJURED PERSON IS FREE OF CONTACT WITH SOURCE OF
ELECTRICAL SHOCK, MOVE PERSON A SHORT DISTANCE AWAY.
IMMEDIATELY START ARTIFICIAL RESUSCITATION.
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TM 11-6115-742-13&P
WARNING
HIGH VOLTAGE
is used in operation of this equipment.
DEATH ON CONTACT
may result if personnel fail to observe safety precautions.
Never work on electronic equipment unless there is another person nearby who is familiar with operation and
hazards of the equipment and who is competent in administering first aid. When operators aid the technician, the
technician must warn operators about dangerous areas.
When possible, shut off power supply to equipment before beginning work on equipment. Take particular care to
ground every capacitor that could potentially store a dangerous electrical charge. Turn off power when working
inside equipment. Always ground every part of equipment before touching it.
Be careful not to contact high-voltage connections or 115 VAC input connections when installing or operating
equipment.
Whenever the nature of operation permits, keep one hand away from equipment to reduce hazard of current
flowing through the body.
WARNING: Do not be misled by the term “low voltage.” Under adverse conditions, potentials as low as 50 volts
may cause death.
For Artificial Respiration, refer to FM 4-25.11.
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TM 11-6115-742-13&P
ELECTRICAL HAZARD
Under adverse conditions, voltage used in this equipment can cause death or serious injury. Observe the
following safety precautions:
GROUND THE EQUIPMENT Before connecting primary power cables, connect grounding cable from
ground lug on power control box to earth ground. Do not remove
grounding cable until signal cables and primary power cables have been
disconnected and Genset has been shut down.
AVOID THE POWER INPUT Be careful not to contact 208/115 VAC connections when installing or
servicing equipment.
DO NOT SERVICE ALONE Never work on equipment unless there is another person nearby who is
familiar with operation and hazards of equipment and who can
administer first aid.
USE ONLY ONE HAND Whenever possible, use only one hand to service equipment. Keep
other hand away to reduce hazard of current flowing through vital organs
of the body.
WARNING
BURN HAZARD
Equipment and Genset may be hot to touch. Allow unit to cool before handling or use gloves when handling.
Serious injury or death from burns or scalding could result from contact with high-pressure steam and/or liquid.
Failure to observe this warning can result in serious injury.
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TM 11-6115-742-13&P
WARNING
HIGH VOLTAGE
RF energy is present near the antenna during transmission. Touching the antenna during transmission may
result in death or serious injury. Maintain at least 30 inches between vehicular antennas and personnel during
transmissions.
WARNING
Death or serious injuries can result:
• When antenna tip caps are not installed on antennas.
• When an antenna is not tied down, it could hit a fixed object such as an overhead bridge, tree limb,
etc. Antenna could break, and flying antenna parts might strike nearby personnel.
WARNING
HEAVY EQUIPMENT
Improperly lifting or carrying heavy equipment can result in serious injury or death. Refer to the following weight
limits as guidelines:
One-Person Two-Person Two-Person Max.
Handling Function Max. Lift Max. Lift Lift (Male Only)
Lift object from floor and place it on surface not 37 lb. 74 lb. 112 lb.
greater than 5 feet above floor.
Lift object from floor and place it on surface not 44 lb. 88 lb. 174 lb.
greater than 3 feet above floor.
Carry object 33 feet or less. 42 lb. 84 lb. 164 lb.
WARNING
The ECU for the TMSS-MED weighs 1150 lbs. Use only a mechanical lift to move equipment. Do not attempt to
lift, carry, or move the ECU without a mechanical lift. Failure to observe this warning can result in serious injury or
death to personnel.
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TM 11-6115-742-13&P
WARNING
SERIOUS INJURY OR DEATH CAN RESULT IF THE FOLLOWING ARE NOT
CAREFULLY OBSERVED WHEN INSTALLING AND USING THE ANTENNAS USED
WITH YOUR RADIO SETS.
1. ARE THERE ANY POWER LINES IN YOUR
AREA OF OPERATION?
2. HOW HIGH ARE THESE POWER LINES?
3. HOW TALL ARE POLES OR TOWERS
CARRYING POWER LINES?
MOBILE OPERATION WITH WHIP ANTENNAS
DO NOT STOP YOUR VEHICLE UNDER POWER LINES
• If possible, try to maintain mobile communications with your antenna(s) tied down.
• Make sure an antenna tip cap is securely taped on end of each whip antenna.
• Do not lean against or touch a whip antenna while transmitter is on.
• During cross-country operation, do not allow anyone to stick an arm, leg, or weapon over sides of vehicle.
Serious or fatal accident can occur if your antenna accidentally touches a power line, and a leg, arm, or
weapon contacts a damp bush or a ground.
• If you are not sure that an antenna or your vehicle will clear a power line, stop before you get close to the
power line. Carefully tie down antenna or remove antenna sections to make sure that you can drive
safely under power line.
• Do not climb on top of vehicle or shelter during radio transmissions.
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TM 11-6115-742-13&P
FIXED OPERATION WITH LONG-RANGE ANTENNAS
WARNING
NEVER RAISE LONG-RANGE ANTENNAS DIRECTLY UNDER POWER LINES
If you raise long-range antennas near power lines, power line poles, towers, or buildings with overhead power line
connections, never put the antenna closer than two times the antenna height to the base of the power line, pole,
tower, or buildings.
NEVER RAISE ANY LONG-RANGE ANTENNA WITHOUT A FULL TEAM
Before raising a long-range antenna, inspect all of the parts making up the antenna kit. Do not raise the antenna
if any parts are missing or damaged.
Do as much of the assembly work as possible on the ground.
When raising the antenna, allow only team personnel in the area.
Make sure that the area you use for the anchors is firm. If the ground is marshy or sandy, get specific instructions
from your crew chief or supervisor on how to reinforce the anchors.
When selecting locations for anchors, avoid traveled areas and roads. If you cannot avoid these areas, get
specific instructions from your supervisor as to what clearance your guy wires must have over the traveled areas
and road.
Clearly mark all guy wires and ropes with the warning flags or signs supplied by your unit. In an emergency, use
strips of white cloth as warning streamers.
If you suspect that power lines have made accidental contact with your antenna, stop operations, rope off the
antenna area, and notify your superiors.
If weather in your area can cause ice to form on your long-range antenna and its guy wires and ropes, add extra
guys to support the system. Rope off the area and post it with warning signs like “BEWARE OF FALLING ICE.”
Do not try to raise any antenna during an electrical storm.
Closely monitor your anchors and guys. Check them daily and immediately before and after bad weather.
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TM 11-6115-742-13&P
ESD
CLASS 1
GENERAL HANDLING PROCEDURES FOR ESD ITEMS
• USE WRIST GROUND STRAPS OR • PERIODICALLY CHECK CONTINUITY
MANUAL GROUNDING PROCEDURES. AND RESISTANCE OF GROUNDING
SYSTEM.
• KEEP ESD ITEMS IN PROTECTIVE • USE ONLY METALIZED SOLDER
COVERING WHEN NOT IN USE. SUCKERS.
• GROUND ALL ELECTRICAL TOOLS • HANDLE ESD ITEMS IN PROTECTED
AND TEST EQUIPMENT. AREAS ONLY.
MANUAL GROUNDING PROCEDURES
• MAKE CERTAIN EQUIPMENT IS • TOUCH PACKAGE OR
POWERED DOWN. REPLACEMENT ESD ITEM TO
GROUND BEFORE OPENING.
• TOUCH GROUND PRIOR TO • TOUCH GROUND PRIOR TO
REMOVING ESD ITEMS. INSERTING REPLACEMENT ESD
ITEMS.
ESD PROTECTIVE PACKAGING AND LABELING
• COVER ANTISTATIC MATERIAL WITH AN OUTER WRAP OF EITHER TYPE 1
ALUMINIZED MATERIAL OR CONDUCTIVE PLASTIC FILM OR HYBRID LAMINATED
BAGS HAVING AN INTERIOR OF ANTISTATIC MATERIAL WITH AN OUTER METALIZED
LAYER.
• LABEL WITH SENSITIVE ELECTRONIC SYMBOL AND CAUTION NOTE.
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TM 11-6115-742-13&P
WARNING
Lithium-Sulfur Dioxide Non-Rechargeable Batteries
Lithium-Sulfur Dioxide (LiSO2) batteries have been designed to provide a safe, high-capacity power source in a
relatively small lightweight package. However, if misused or abused, these batteries can be dangerous.
LiSO2 batteries contain liquefied sulfur dioxide (corrosive causes burns to the skin), acetonitrile (mildly toxic), and
lithium metal (extremely reactive and flammable). All LiSO2 batteries have multiple safety features to contain
these hazards.
Store LiSO2 batteries at temperatures below 130ºF. Segregate different battery chemistries from each other.
Keep batteries in original packaging until ready for use. Examine packages/batteries for bulging, cracking, or any
signs of leakage before putting batteries into equipment. Use only appropriate batteries for each particular item.
When replacing batteries in equipment containing more than one LiSO2 battery, replace all LiSO2 batteries at the
same time. Replace with batteries from same contract number and date code only.
Never charge a LiSO2 battery.
Never short-circuit terminals.
Remove batteries from equipment if it is not to be used within 30 days.
Depleted batteries should be turned in to designated personnel for disposal processing (CDD activation) and
disposal in accordance with local regulations or through Defense Reutilization and Marketing Office.
In event of a venting, clear area until pungent odor of sulfur dioxide is cleared. Handle leaking batteries with
rubber or plastic gloves. Get immediate medical attention for any skin or respiratory irritation.
Refer to TB 43-0134, Battery Disposition and Disposal, for additional information.
DO NOT mix primary and rechargeable batteries in equipment, such as BA-5590/U and the BB-390A/U batteries.
2
When using LiSO batteries, immediately power down equipment and replace with new batteries upon low power
indication.
WARNING
Compressed air is dangerous and can cause serious bodily harm. Protective means or methods should be
observed to prevent a chip or particle (of any size) from being blown into eyes or skin of operator or other
personnel. Do not use compressed air for cleaning purposes unless you can reduce it to less than 30 pounds per
square inch gauge (30 psig) and then only with effective chip guarding and personnel protective equipment
(industrial safety glasses and full face shield).
WARNING
Trichlorotrifluoroethane, trichloroethane, and similar chemical solvents threaten public health and the environment
by destroying ozone in earth’s upper atmosphere. Use only nonhazardous cleaning material such as a clean
cloth, water, and mild detergent.
h
TM 11-6115-742-13&P
WARNING
Grounding TMSS-MED equipment is essential to prevent serious electrical shock or even death. Most favorable
TMSS-MED grounding is achieved when TMSS-MED trailer is directly connected via proper sized grounding wire
to ground rod assembly. Refer to “Earth Grounding and Bonding Pamphlet”, CECOM TR-98-6, Oct 1998 for more
detailed information on grounding equipment.
WARNING
To avoid possible electrical shock, ensure that grounding cables from ground lugs are connected to GROUND on
frame of TMSS prior to power up. Do not remove grounding cable while powered up.
WARNING
To avoid possible electrical shock, do not remove grounding cable until signal cables and primary power cables
have been disconnected.
WARNING
Eye protection and gloves are required for deploying and removing TMSS-MED grounding. Notify service level
maintenance of any mushroomed stake heads. Visually inspect all cable before handling. Use gloves when
handling cable.
WARNING
If a circuit breaker does not stay in ON position when closed, DO NOT attempt to close it repeatedly. That could
create an overload situation hazardous to personnel and equipment. Investigate and identify cause of problem.
Correct situation before attempting to close breaker again.
WARNING
To avoid electrical shock and damage to equipment, be certain POWER ON/OFF circuit breaker is set to OFF
and power cable is disconnected at power source before disconnecting signal cables.
WARNING
Fiber-optic cables can be degraded or damaged by dust, dirt, oils, and misalignment.
Use care to insert and remove connectors straight in and out without angling.
Keep cable connectors capped when not connected.
Do not connect dusty, dirty, or oily connectors.
Do not coil or knot cables tightly.
Never look into end of a fiber-optic cable or connector. Infrared (IR) signals can cause eye damage. Failure to
observe this warning can cause damage to equipment or personal injury.
Heat or cold stress can occur under extreme temperature conditions. Follow TB MED 507, FM 21-10, and TB
MED 508 for proper preventive measures.
WARNING
Hearing protection is required when within 8 feet of the Genset operating position.
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TM 11-6115-742-13&P
WARNING
Items that may shatter (i.e., meters, displays, or any other type of glass or plastic) should be visually inspected
prior to use to prevent potential injury from broken edges. Failure to observe this warning can result in serious
injury.
WARNING
Voltage sources, in addition to being an electrical shock hazard, may also potentially produce serious burns.
Care should be exercised when using hand tools around exposed power connectors, never letting the tool bridge
two terminals. Failure to observe this warning can result in serious injury.
WARNING
High voltage and amperage present at electrical connections. Ensure that all switches and circuit breakers have
been de-energized prior to performing any troubleshooting procedures.
WARNING
Critical fasteners used to secure equipment should be installed and periodically inspected for retention. Missing
fasteners should be noted and replaced. Loose fasteners should be tightened. Failure to observe this warning
can result in serious injury.
WARNING
Special caution must be taken during troubleshooting since protective covers and safety devices may be removed
or disabled to gain access and make tests.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer, ensure wheels are chocked. Injury
to personnel could result from trailer suddenly rolling or tipping.
WARNING
If ECU has been in operation, components may be extremely cold or extremely hot. To prevent serious injury to
personnel, allow sufficient time for components to warm up/cool down before troubleshooting.
WARNING
If Genset has been in operation, components may be extremely hot. To prevent serious injury to personnel, allow
the Genset to cool down before performing procedures.
WARNING
Diesel fuel is flammable. Do not fill fuel tank with engine running, while smoking, or when near an open flame.
Never overfill tank or spill fuel. If fuel is spilled, clean it up immediately. Failure to comply may result in serious
injury or death.
WARNING
BE AWARE: Nuclear, Biological, Chemical (NBC) protective masks will not protect from carbon monoxide
poisoning.
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TM 11-6115-742-13&P
WARNING
AC voltage (120 VAC), DC voltage (+28 VDC), and current sufficient to cause serious injury or death are present
at the PDP. Before starting this task, ensure all power is de-energized and disconnected from shelter. Failure to
comply with this warning could result in electrical shock or death to the individual.
WARNING
AC voltage (208 VAC, 3Ø), (28 VAC), and DC voltage (+28 VDC), and current sufficient to cause serious injury or
death are present. Before starting this task, ensure all power is de-energized and disconnected from shelter.
Failure to comply with this warning could result in electrical shock or death to the individual.
WARNING
REFRIGERANT UNDER PRESSURE
WARNING
Death or severe injury may result if you fail to observe safety precautions. Never use a heating torch on any part
of the system that contains refrigerant. Do not let liquid refrigerant touch you, and do not inhale refrigerant gas
WARNING
Death or severe damage may result if personnel fail to observe safety precautions. Use great care to avoid
contact with liquid refrigerant or refrigerant gas being discharged under pressure. Sudden and irreversible tissue
damage can result from freezing. Wear thermal protective gloves and a face protector or goggles in any situation
where skin/eye contact is possible. Prevent contact of refrigerant gas with flame or hot surfaces. Heat causes
the refrigerant to break down and form carbonyl chloride (phosgene), a highly toxic and corrosive gas.
WARNING
Brazing alloys and flux contain materials that are hazardous to health. Avoid breathing vapors or fumes from
brazing operations. Perform operations only in well ventilated areas. Wash hands with soap and water after
handling brazing alloys and flux. Wear gloves and protective goggles or face shield to protect against burns.
WARNING
Special caution must be taken during troubleshooting since protective covers and safety devices may be removed
or disabled to gain access and make tests.
WARNING
Never use a heating torch on any part that contains refrigerant. Heat may cause the refrigerant to decompose and
release irritating, toxic, and corrosive gases. All refrigerant must be removed and recovered from the system and
the entire system must be purged with dry nitrogen before beginning any brazing operation.
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TM 11-6115-742-13&P
WARNING
Sudden and irreversible tissue damage can result from freezing. Wear gloves and a face protector or safety
glasses in any situation where skin or eye contact with refrigerant is possible.
WARNING
Heat may cause the refrigerant to decompose and release irritating, toxic, and corrosive gases. Prevent contact
of refrigerant with flame or hot surfaces.
WARNING
Never introduce high discharge pressure into a refrigerant cylinder. This can cause the cylinder to rupture and
injure personnel.
WARNING
Never introduce liquid refrigerant into the suction shut off valve. This can cause damage to the compressor.
WARNING
The system must be evacuated before charging. Moisture and air in the system will prevent the refrigeration unit
from operating properly.
WARNING
If a circuit breaker does not stay in ON position when energized, DO NOT attempt to energize repeatedly. That
could create an overload situation hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
WARNING
If Genset has been in operation, fluids and components may be extremely hot. To prevent serious injury to
personnel, allow the Genset to cool down before performing procedures.
WARNING
Never attempt to perform maintenance when Genset in an operational status. To prevent serious injury to
personnel or damage to equipment, DO NOT enter enclosure with Genset operating.
WARNING
The Genset for the TMSS-MED weighs 1350 lbs (612.35 kg). Use only a mechanical lift to move equipment. Do
not attempt to lift, carry, or move the Genset without a mechanical lift. Failure to observe this warning can result
in serious injury or death to personnel.
WARNING
Dry cleaning solvent MIL-PRF-680 is toxic and flammable. Always wear protective goggles and gloves, and use
only in a well-ventilated area. Avoid contact with skin, eyes, and clothes and DO NOT breath vapors. DO NOT
use near open flame or excessive heat.
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TM 11-6115-742-13&P
WARNING
Removing metal parts could be dangerous to personnel. Always wear eye protection when replacing wheel
studs. Failure to follow this warning may result in injury to personnel.
WARNING
The cotter pin prevents the spindle nut from coming loose. Failure to install the cotter pin properly will cause the
spindle nut to back off of the spindle causing loss of wheel assembly.
WARNING
Never replace only one brakeshoe. Combinations of old and new brakeshoes will cause uneven braking.
Accidents causing serious injury or death to personnel or damage to equipment may result.
WARNING
DO NOT allow grease to contact brakeshoe linings. Wipe excess lubricant from the brakeshoe linings to prevent
grease soaking into the materials. Brakeshoe linings can absorb grease and oil, causing early glazing of linings
and very poor breaking action. Failure to follow this warning may cause brakes to malfunction, resulting in injury
or death to personnel or damage to equipment.
WARNING
When the following step is being performed, the trailer is in a very unstable position. This procedure should be
performed in a timely manner and the trailer should not be left unattended. Failure to observe this warning can
result in serious injury or death to personnel or damage to the TMSS-MED trailer and/or its contents.
WARNING
When performing maintenance on brake system, ensure that wheels are securely chocked. Failure to follow this
warning may cause trailer to roll, resulting in serious injury or death to personnel or damage to equipment.
WARNING
Trailer may move during process. DO NOT lie under trailer while moving vehicle. Severe injury may result to
personnel.
WARNING
Use caution when removing hydraulic push rod assembly due to spring tension.
WARNING
Dry cleaning solvent, P-D-680, is toxic and flammable. Always wear protective goggles and gloves and use
solvent only in a well-ventilated area. Avoid contact with skin, eyes, and clothes, and DO NOT breathe vapors.
DO NOT use near open flame or excessive heat. The solvent’s flash point is 100°F to 138°F (38°C to 59°C). If
you become dizzy while using cleaning solvent, immediately get fresh air and medical help. If solvent contacts
eyes, immediately wash your eyes and get medical aid.
WARNING
Empty fuel tank weighs 33 pounds and may require two persons to safely remove to avoid injury to personnel.
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TM 11-6115-742-13&P
WARNING
DO NOT handle brakeshoes, drum/hubs, or other brake components unless area has been properly cleaned.
There may be asbestos dust on these components which can be dangerous if touched or inhaled. Wear an
approved filter mask and gloves.
WARNING
NEVER use compressed air or a dry brush to clean brake components. Injury may result.
WARNING
Hot coolant is under pressure. Opening the radiator while the coolant is hot can result in possible burns and
damage to equipment.
WARNING
High voltage and amperage present at electrical connections. Do not enter ECU with power applied. To prevent
serious injury to personnel or damage to equipment, DO NOT enter enclosure with ECU operating.
WARNING
In event of a venting, clear area until pungent odor of Sulfur Dioxide is cleared. Handle leaking batteries with
rubber or plastic gloves. Get immediate medical attention for any skin or respiratory irritation.
WARNING
Ensure that TMSS-MED is level and ground is stable (not soggy or soft). Trailer could sink into soft or unstable
ground. Injury to personnel, or damage to TMSS-MED trailer and/or its components could result from trailer
suddenly rolling or tipping.
WARNING
Observe all lifting and weight restrictions. Failure to observe this warning can result in serious injury or death to
personnel or damage to the TMSS-MED trailer and/or its contents.
WARNING
Tire and wheel assembly weigh in excess of 110 lbs. Removal and replacement require a two person lift to avoid
injury to personnel.
WARNING
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry before working around TMSS-MED.
Jewelry can catch on equipment and cause injury, or may short across electrical circuit and cause severe burns
or electrical shock.
WARNING
Wear eye protection and gloves when hammering stakes and ground rod sections. Failure to observe this
warning may result in injury to the eye or exposed skin from flying metal fragments.
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TM 11-6115-742-13&P
WARNING
Cut end of air intake is extremely sharp. Exercise care to prevent injury.
WARNING
If heater has been operating exhaust may be extremely hot. Allow time to cool before removing.
WARNING
Cylinders are pressurized containers. The pressure in the cylinder can exceed 2000 psi. A nitrogen pressure
regulator should be used at all times when nitrogen is used for leak check or purge operations. Nitrogen is an
inert gas. However, it also presents danger as a suffocant and, therefore, must be discharged in a ventilated
location.
o/p blank
TM 11-6115-742-13&P
LIST OF EFFECTIVE PAGES/WORK PACKAGES
NOTE: This manual dated 30 May 2012 supersedes TM 11-6115-742-13&P dated 15 October 2008
Zero in the “Change No.” column indicates an original page or work package.
Date of issue for the original manual is:
Original: 30 May 2012
TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 112 AND TOTAL
NUMBER OF WORK PACKAGES IS 168, CONSISTING OF THE FOLLOWING:
Page/WP No. Change No. Page/WP No. Change No.
Front Cover 0 Chp 5 title page 0
Blank 0 Blank 0
Warning summary (16 pgs) 0 WP 0027 (4 pgs) 0
i – xxx 0 WP 0028 (26 pgs) 0
Chp 1 title page 0 WP 0029 (32 pgs) 0
Blank 0 WP 0030 (30 pgs) 0
WP 0001 (6 pgs) 0 WP 0031 (6 pgs) 0
WP 0002 (10 pgs) 0 WP 0032 (4 pgs) 0
WP 0003 (22 pgs) 0 WP 0033 (4 pgs) 0
Chp 2 title page 0 WP 0034 (2 pgs) 0
Blank 0 Chp 6 title page 0
WP 0004 (12 pgs) 0 Blank 0
WP 0005 (46 pgs) 0 WP 0035 (2 pgs) 0
WP 0006 (12 pgs) 0 WP 0036 (4 pgs) 0
WP 0007 (2 pgs) 0 WP 0037 (4 pgs) 0
WP 0008 (12 pgs) 0 WP 0038 (2 pgs) 0
WP 0009 (4 pgs) 0 WP 0039 (14 pgs) 0
Chp 3 title page 0 WP 0040 (6 pgs) 0
Blank 0 WP 0041 (30 pgs) 0
WP 0010 (2 pgs) 0 WP 0042 (6 pgs) 0
WP 0011 (8 pgs) 0 WP 0043 (4 pgs) 0
WP 0012 (4 pgs) 0 WP 0044 (4 pgs) 0
WP 0013 (4 pgs) 0 WP 0045 (4 pgs) 0
WP 0014 (4 pgs) 0 WP 0046 (4 pgs) 0
WP 0015 (4 pgs) 0 WP 0047 (6 pgs) 0
WP 0016 (2 pgs) 0 WP 0048 (16 pgs) 0
Chp 4 title page 0 WP 0049 (6 pgs) 0
Blank 0 WP 0050 (4 pgs) 0
WP 0017 (2 pgs) 0 WP 0051 (4 pgs) 0
WP 0018 (4 pgs) 0 WP 0052 (10 pgs) 0
WP 0019 (12 pgs) 0 WP 0053 (4 pgs) 0
WP 0020 (4 pgs) 0 WP 0054 (6 pgs) 0
WP 0021 (8 pgs) 0 WP 0055 (4 pgs) 0
WP 0022 (6 pgs) 0 WP 0056 (4 pgs) 0
WP 0023 (6 pgs) 0 WP 0057 (6 pgs) 0
WP 0024 (6 pgs) 0 WP 0058 (6 pgs) 0
WP 0025 (6 pgs) 0 WP 0059 (8 pgs) 0
WP 0026 (8 pgs) 0 WP 0060 (4 pgs) 0
A
TM 11-6115-742-13&P
LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued
Page/WP No. Change No. Page/WP No. Change No.
WP 0061 (6 pgs) 0 WP 0105 (4 pgs) 0
WP 0062 (6 pgs) 0 WP 0106 (4 pgs) 0
WP 0063 (6 pgs) 0 WP 0107 (6 pgs) 0
WP 0064 (20 pgs) 0 WP 0108 (4 pgs) 0
WP 0065 (8 pgs) 0 WP 0109 (6 pgs) 0
WP 0066 (4 pgs) 0 WP 0110 (6 pgs) 0
WP 0067 (6 pgs) 0 WP 0111 (4 pgs) 0
WP 0068 (4 pgs) 0 WP 0112 (4 pgs) 0
WP 0069 (8 pgs) 0 WP 0113 (8 pgs) 0
WP 0070 (12 pgs) 0 WP 0114 (4 pgs) 0
WP 0071 (6 pgs) 0 Chp 8 title page 0
WP 0072 (6 pgs) 0 Blank 0
WP 0073 (4 pgs) 0 WP 0115 (2 pgs) 0
WP 0074 (24 pgs) 0 WP 0116 (4 pgs) 0
WP 0075 (4 pgs) 0 WP 0117 (4 pgs) 0
WP 0076 (4 pgs) 0 WP 0118 (2 pgs) 0
WP 0077 (4 pgs) 0 WP 0119 (6 pgs) 0
WP 0078 (4 pgs) 0 WP 0120 (4 pgs) 0
WP 0079 (6 pgs) 0 WP 0121 (6 pgs) 0
WP 0080 (4 pgs) 0 WP 0122 (10 pgs) 0
WP 0081 (10 pgs) 0 WP 0123 (4 pgs) 0
WP 0082 (4 pgs) 0 WP 0124 (8 pgs) 0
WP 0083 (4 pgs) 0 WP 0125 (6 pgs) 0
WP 0084 (8 pgs) 0 WP 0126 (18 pgs) 0
WP 0085 (14 pgs) 0 WP 0127 (10 pgs) 0
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TM 11-6115-742-13&P
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 30 May 2012
TECHNICAL MANUAL
OPERATOR AND FIELD MAINTENANCE MANUAL
INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST
FOR
POWER PLANT, UTILITY
PU-821/T (NSN 6115-01-547-6713) (EIC YVC)
PU-822A/T (NSN 6115-01-547-6738) (EIC YVB)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes, or if you know of a way to improve
the procedures, please let us know. We’d prefer that you submit your recommended changes
electronically, either by e-mail ([email protected]) or online
(http://edm.apg.army.mil/pubs/2028.html). Alternatively, you may mail or fax your letter, DA Form
2028 (Recommended Changes to Publications and Blank Forms), located in the back of this
manual, directly to: Commander, U.S. Army Communications-Electronics Command, 6001
Combat Drive, ATTN: AMSEL-LCL-ECM, Aberdeen Proving Ground, MD 21005-1846. The fax
number is 443-861-551, DSN 848-5521.
In any case, we will send you a reply.
*TM 11-6115-742-13&P dated 30 May 2012, including all changes, supersedes TM 11-6115-742-13&P dated 15 October 2008
DISTRIBUTION STATEMENT D. Distribution authorized to the Department of Defense and U.S. DOD
contractors only, for official use or for administrative and operational purposes. This determination was made on
5 August 2011. Other requests for this document will be referred to Commander, U.S. Army Communications-
Electronics Life Cycle Management Command (CECOM LCMC), 6001 Combat Drive, ATTN: AMSEL-LCL-ECM,
Aberdeen Proving Ground, MD 21005-1846.
WARNING- This document contains technical data whose export is restricted by the Arms Export Control Act
(Title 22, U.S.C., Sec 2751, et. seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App.
2401 et. seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance
with provisions of DoD Directive 5230.25.
DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of the
document.
i
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TABLE OF CONTENTS
Page No.
WP Sequence No.
How to Use This Manual
Chapter 1 – General Information, Equipment Description, and Theory of Operation for TMSS-MED
General Information ..................................................................................................................WP 0001
Figure 1. TMSS-MED System Configuration ...................................................................WP 0001-1
Table 1. Nomenclature Cross-Reference List ..................................................................WP 0001-3
Table 2. Abbreviation/Acronym List .................................................................................WP 0001-4
Equipment Description and Data ..............................................................................................WP 0002
Figure 1. TMSS-MED Configuration ................................................................................WP 0002-1
Figure 2. TMSS-MED Shelter Components .....................................................................WP 0002-2
Figure 3. TMSS-MED Trailer Major Components ............................................................WP 0002-3
Figure 4. TMSS-MED Genset ..........................................................................................WP 0002-4
Figure 5. TMSS-MED ECU ..............................................................................................WP 0002-5
Figure 6. TMSS-MED Cargo Bay .....................................................................................WP 0002-5
Figure 7. TMSS-MED Chassis .........................................................................................WP 0002-6
Figure 8. TMSS-MED PDU ..............................................................................................WP 0002-6
Figure 9. TMSS-MED Tent Lighting Set...........................................................................WP 0002-7
Theory of Operation ..................................................................................................................WP 0003
Figure 1. Genset Fault System ........................................................................................WP 0003-3
Figure 2. Fuel System ......................................................................................................WP 0003-5
Figure 3. Engine Heater Flow Diagram ............................................................................WP 0003-6
Figure 4. Engine Coolant System. ...................................................................................WP 0003-7
Figure 5. Engine Lubrication System ...............................................................................WP 0003-8
Figure 6. Output Supply System ......................................................................................WP 0003-10
Figure 7. Barrier Panel Component Location ...................................................................WP 0003-11
Figure 8. Governor Control System... ..............................................................................WP 0003-12
Figure 9. Battery Charging System ..................................................................................WP 0003-13
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Theory of Operation – Continued ............................................................................................WP 0003
Figure 10. ECU (Version 1) Control Panel Component Location ....................................WP 0003-15
Figure 11. Power Distribution/Fault System (Version 1). .................................................WP 0003-16
Figure 12. ECU (Version 2) Control Panel Component Location ....................................WP 0003-17
Figure 13. Power Distribution/Fault System (Version 2) ..................................................WP 0003-18
Chapter 2 – Operator Instructions
Description and Use of Operator Controls, Indicators, and Connectors ................................. WP 0004
Figure 1. Genset Control Panel (Top Panel) – Controls, Indicators, and Connectors ....WP 0004-1
Table 1. Genset Control Panel (Top Panel) – Controls, Indicators, and Connectors ......WP 0004-1
Figure 2. Genset Control Panel (Bottom Panel) – Controls, Indicators,
and Connectors ..................................................................................................WP 0004-3
Table 2. Genset Control Panel (Bottom Panel) – Controls,
Indicators, and Connectors ................................................................................WP 0004-3
Figure 3. Genset Power Distribution Panel – Controls, Indicators,
and Connectors ..................................................................................................WP 0004-4
Table 3. Genset Power Distribution Panel – Controls, Indicators, and Connectors ........WP 0004-4
Figure 4. Fuel Control Panel – Controls, Indicators, and Connectors .............................WP 0004-5
Table 4. Fuel Control Panel – Controls, Indicators, and Connectors...............................WP 0004-5
Figure 5. Fuel Gauge – Controls, Indicators, and Connectors ........................................WP 0004-6
Table 5. Fuel Gauge – Controls, Indicators, and Connectors ..........................................WP 0004-6
Figure 6. ECU Control Panel – Controls, Indicators, and Connectors .............................WP 0004-7
Table 6. ECU Control Panel – Controls, Indicators, and Connectors ..............................WP 0004-7
Figure 7. PDU Control Panel – Controls, Indicators, and Connectors .............................WP 0004-9
Table 7. PDU Control Panel – Controls, Indicators, and Connectors ..............................WP 0004-9
Figure 8. Power Distribution Panel - Controls, Indicators, and Connectors
(Updated Version) ..............................................................................................WP 0004-11
Table 8. Power Distribution Panel - Controls, Indicators, and Connectors
(Updated Version) ..............................................................................................WP 0004-11
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Operation Under Usual Conditions ..........................................................................................WP 0005
Figure 1. TMSS-MED System Deployment Footprint ......................................................WP 0005-1
Figure 2. Shelter Site Dimensions....................................................................................WP 0005-2
Figure 3. Correct Trailer Operating Positions ..................................................................WP 0005-3
Figure 4. Wheel/Skid Plate Assembly Mounting Positions ..............................................WP 0005-4
Figure 5. Wheel Chocks ...................................................................................................WP 0005-5
Figure 6. Remove the Crossbar .......................................................................................WP 0005-7
Figure 7. Remove and Position Shelter End Caps ..........................................................WP 0005-8
Figure 8. Lower Shelter Transport Bag to Ground ...........................................................WP 0005-9
Figure 9. Expand and Lift Shelter.....................................................................................WP 0005-10
Figure 10. Red Flag Locations .........................................................................................WP 0005-11
Figure 11. Shelter Resting on Four Push Poles...............................................................WP 0005-11
Figure 12. Position of Additional Red Flagged Keepers ..................................................WP 0005-12
Figure 13. Position End Caps Next to Center Section .....................................................WP 0005-13
Figure 14. Secure End Cap Frame to Center Section Frame ..........................................WP 0005-13
Figure 15. Secure End Cap Covers to Center Section Covers ........................................WP 0005-14
Figure 16. Shelter in Erected Position..............................................................................WP 0005-15
Figure 17. Shelter Lift Locations ......................................................................................WP 0005-16
Figure 18. Attach Floor to Shelter ....................................................................................WP 0005-17
Figure 19. Shelter Installation Complete ..........................................................................WP 0005-18
Figure 20. Connect Ducts to Shelter ................................................................................WP 0005-19
Figure 21. Typical Shelter Lighting Arrangement.............................................................WP 0005-20
Figure 22. Location of PDU with Respect to Trailer and Shelter .....................................WP 0005-22
Figure 23. Location of Fuel Control Panel .......................................................................WP 0005-24
Figure 24. Aux Fuel Lines to External Fuel Supply ..........................................................WP 0005-25
Figure 25. Tie Back Doorways .........................................................................................WP 0005-31
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Operation Under Usual Conditions – Continued .....................................................................WP 0005
Figure 26. Grip Shelter by Hubs.......................................................................................WP 0005-32
Figure 27. Secure First Cinch Strap .................................................................................WP 0005-34
Figure 28. Roll Up Shelter with Floor ...............................................................................WP 0005-34
Figure 29. Ready for Assisted Lift of Shelter ...................................................................WP 0005-35
Figure 30. Lift Transport Bag ...........................................................................................WP 0005-35
Figure 31. Push Transport Bag onto Trailer .....................................................................WP 0005-36
Figure 32. Trailer Leveled and Secured ...........................................................................WP 0005-37
Figure 33. Attach Trailer to Tow Vehicle ..........................................................................WP 0005-38
Figure 34. Secure Tongue Jack Assembly ......................................................................WP 0005-40
Figure 35. Trailer Safety Brake Lockout...........................................................................WP 0005-41
Figure 36. Trailer Properly Chocked and Positioned on Transport Trailer Deck .............WP 0005-44
Table 1. Weight of TMSS-MED Trailer.............................................................................WP 0005-45
Figure 37. CG Tag Location on TMSS-MED Trailer ........................................................WP 0005-45
Figure 38. CG of TMSS-MED Trailer ...............................................................................WP 0005-46
Operation Under Unusual Conditions ......................................................................................WP 0006
Emergency Shutdown Procedures ..........................................................................................WP 0007
Stowage and Decal/Data Plate Guide .....................................................................................WP 0008
Figure 1. Location of Identification and Data Plates on Trailer Rear ...............................WP 0008-1
Table 1. Identification and Data Plates on Trailer Rear ...................................................WP 0008-1
Figure 2. Location of Identification and Data Plates on Trailer Curbside.........................WP 0008-2
Table 2. Identification and Data Plates on Trailer Curbside ............................................WP 0008-2
Figure 3. Location of Identification and Data Plates on Trailer Front...............................WP 0008-3
Table 3. Identification and Data Plates on Trailer Front...................................................WP 0008-3
Figure 4. Location of Identification and Data Plates on Trailer Roadside ........................WP 0008-4
Table 4. Identification and Data Plates on Trailer Roadside ............................................WP 0008-4
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Stowage and Decal/Data Plate Guide – Continued.................................................................WP 0008
Figure 5. Location of Identification and Data Plates on ECU Front .................................WP 0008-5
Table 5. Identification and Data Plates on ECU Front .....................................................WP 0008-5
Figure 6. Location of Identification and Data Plates on ECU Curbside and Rear ...........WP 0008-6
Table 6. Identification and Data Plates on ECU Curbside and Rear ...............................WP 0008-6
Figure 7. Location of Identification and Data Plates on Genset Front .............................WP 0008-7
Table 7. Identification and Data Plates on Genset Front .................................................WP 0008-7
Figure 8. Location of Identification and Data Plates on Genset Curbside .......................WP 0008-8
Table 8. Identification and Data Plates on Genset Curbside ...........................................WP 0008-8
Figure 9. Location of Identification and Data Plates on Genset Rear ..............................WP 0008-9
Table 9. Identification and Data Plates on Genset Rear ..................................................WP 0008-9
Figure 10. Location of Identification and Data Plates on Genset Control
Panel and Circuit Breaker Panel.....................................................................WP 0008-10
Table 10. Identification and Data Plates on Genset Control Panel and
Circuit Breaker Panel .......................................................................................WP 0008-10
Figure 11. Location of Identification and Data Plates on Genset Control
Panel Access Door ...........................................................................................WP 0008-11
Table 11. Identification and Data Plates on Genset Control Panel
Access Door .....................................................................................................WP 0008-12
On-Vehicle Equipment Loading Plan .......................................................................................WP 0009
Figure 1. TMSS-MED Shelter Loading Plan ....................................................................WP 0009-1
Table 1. TMSS-MED Shelter Loading Plan .....................................................................WP 0009-1
Figure 2. TMSS-MED Trailer Loading Plan .....................................................................WP 0009-2
Table 2. TMSS-MED Trailer Loading Plan .......................................................................WP 0009-3
Chapter 3 – Crew Troubleshooting Procedures
Crew Troubleshooting Index ....................................................................................................WP 0010
Table 1. Crew Troubleshooting Index ..............................................................................WP 0010-1
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Genset (Engine) Troubleshooting Procedures ........................................................................WP 0011
Table 1. Crew Troubleshooting – Genset (Engine)..........................................................WP 0011-2
Table 2. Engine Heater (Hydronic) Fault Codes ..............................................................WP 0011-7
Genset (Electrical) Troubleshooting Procedures .....................................................................WP 0012
Table 1. Crew Troubleshooting – Genset (Electrical) ......................................................WP 0012-2
ECU Troubleshooting Procedures ...........................................................................................WP 0013
Table 1. Crew Troubleshooting – ECU ............................................................................WP 0013-2
Table 2. ECU Hydronic Heater Fault Codes ....................................................................WP 0013-4
Trailer Troubleshooting Procedures ........................................................................................WP 0014
Table 1. Crew Troubleshooting – Trailer ..........................................................................WP 0014-2
Shelter (Mechanical) Troubleshooting Procedures .................................................................WP 0015
Table 1. Crew Troubleshooting – Shelter (Mechanical) ...................................................WP 0015-2
Shelter (Electrical) Troubleshooting Procedures .....................................................................WP 0016
Table 1. Crew Troubleshooting – Shelter (Mechanical) ...................................................WP 0016-2
Chapter 4 – Crew Maintenance Instructions
Service Upon Receipt ..............................................................................................................WP 0017
PMCS Introduction ...................................................................................................................WP 0018
PMCS ......................................................................................................................................WP 0019
Table 1. Crew Preventive Maintenance Checks and Services ........................................WP 0019-1
Table 2. Crew Functional Checks and Services ..............................................................WP 0019-12
Genset – Bulbs and Covers Crew Maintenance......................................................................WP 0020
Figure 1. Control Panel Indicator and PDP Lights Removal/Replacement......................WP 0020-4
Crew Maintenance – Fluids .....................................................................................................WP 0021
Table 1. Engine Oil Recommendations............................................................................WP 0021-3
Figure 1. Oil Fill Tube and Dip Stick on Engine Location.................................................WP 0021-3
Figure 2. Location of Radiator and Radiator Overflow Bottle ..........................................WP 0021-5
Figure 3. Master Brake Cylinder Service .........................................................................WP 0021-7
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
ECU Control Panel Crew Maintenance ...................................................................................WP 0022
Figure 1. ECU Control Panel Lens Indicator and Mode Select Switch
Knob Removal/Replacement............................................................................WP 0022-3
Figure 2. ECU Heater (Hydronic) Coolant Reservoir .......................................................WP 0022-5
Crew Maintenance – Electrical ................................................................................................WP 0023
Table 1. Normal Meter Reading for Battery .....................................................................WP 0023-3
Figure 1. Location of Connectors and Meters for 24 VDC Battery
Charging ...........................................................................................................WP 0023-4
Crew Maintenance – Shelter Cover Maintenance ...................................................................WP 0024
Figure 1. Repair of Shelter Cover ....................................................................................WP 0024-3
Figure 2. Shelter Cover(s) Removal/Replace ..................................................................WP 0024-6
Crew Maintenance – Shelter Strut Maintenance .....................................................................WP 0025
Figure 1. Repair of Shelter Strut ......................................................................................WP 0025-3
Figure 2. Shelter Struts Removal/Replacement ...............................................................WP 0025-6
Crew Maintenance – Shelter Repair Using Field Repair Kit ....................................................WP 0026
Figure 1. Shelter Keepers Removal/Replacement...........................................................WP 0026-3
Figure 2. Shelter Main Hub(s) Removal/Replacement ....................................................WP 0026-5
Figure 3. Main Staking Bracket Removal/Replacement ..................................................WP 0026-7
Chapter 5 – Maintainer Troubleshooting Procedures
Maintainer Troubleshooting Index .............................................................................................WP 0027
Table 1. Maintainer Troubleshooting Index ......................................................................WP 0027-1
Genset (Electrical) Troubleshooting Procedures .......................................................................WP 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) ..............................................WP 0028-2
Figure 1. 12V Constant Voltage Test Hookup .................................................................WP 0028-26
Genset (Engine) Troubleshooting Procedures ..........................................................................WP 0029
Table 1. Maintainer Troubleshooting – Genset (Engine) .................................................WP 0029-2
Figure 1. Solenoids ..........................................................................................................WP 0029-7
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Genset (Engine) Troubleshooting Procedures – Continued ......................................................WP 0029
Table 2. Engine Selector Switch (ESS) Function.............................................................WP 0029-8
Figure 2. Flywheel Location in Speed Sensor Port ..........................................................WP 0029-14
Figure 3. Genset Fault System ........................................................................................WP 0029-16
ECU (Electrical)/Hydronic Heater Troubleshooting Procedures ................................................WP 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater .......................WP 0030-2
Table 2. ECU Hydronic Heater Fault Codes ....................................................................WP 0030-19
Figure 1. Circuit Breaker Location for TMSS-MED ECU (Version 1) ...............................WP 0030-20
Figure 2. Circuit Breaker Location for TMSS-MED ECU (Version 2) ...............................WP 0030-20
Figure 3. Hydronic (Auxiliary) Heater Circuit ....................................................................WP 0030-21
Table 3. Mode Select (Version 1) Switch Test .................................................................WP 0030-22
Table 4. Mode Select (Version 2) Switch Test .................................................................WP 0030-22
Table 5. Heater Contactor Measurements .......................................................................WP 0030-26
Table 6. CMSP/EMSP Voltage Inputs..............................................................................WP 0030-28
Table 7. CMSP/EMSP Voltage Outputs ...........................................................................WP 0030-28
Table 8. CMSP/EMSP 28 VAC Outputs...........................................................................WP 0030-29
ECU (Heating & Cooling)/Hydronic Heater Troubleshooting Procedures .................................WP 0031
Table 1. Maintainer Troubleshooting – ECU (Heating & Cooling) ...................................WP 0031-2
Trailer (Electrical) Troubleshooting Procedures ........................................................................WP 0032
Table 1. Maintainer Troubleshooting – Trailer (Electrical) ...............................................WP 0032-2
Trailer (Mechanical) Troubleshooting Procedures .....................................................................WP 0033
Table 1. Maintainer Troubleshooting – Trailer (Mechanical)............................................WP 0033-2
Shelter (Electrical) Troubleshooting Procedures .......................................................................WP 0034
Table 1. Maintainer Troubleshooting – Shelter (Electrical). .............................................WP 0034-2
Chapter 6 – Maintainer Maintenance Instructions - Genset
Service Upon Receipt ................................................................................................................WP 0035
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Genset PMCS Introduction ........................................................................................................WP 0036
PMCS (Genset) ..........................................................................................................................WP 0037
Table 1. Maintainer Preventive Maintenance Checks and Services - Genset .................WP 0037-1
Genset Maintenance Index ........................................................................................................WP 0038
Genset - Access Panel ..............................................................................................................WP 0039
Figure 1. Side Access Panels Removal/Replacement.....................................................WP 0039-3
Figure 2. Power Distribution Panel Access Panel Removal/Replacement ......................WP 0039-5
Figure 3. Control Panel Access Panel Removal/Replacement ........................................WP 0039-7
Figure 4. Top Access Panel Removal/Replacement .......................................................WP 0039-9
Figure 5. Genset Access Door Latches Removal/Replacement ......................................WP 0039-11
Figure 6. Access Cover Removal/Replacement ..............................................................WP 0039-13
Genset Control Panel Bulbs, Covers And Fuse.........................................................................WP 0040
Figure 1. Control Panel Latch Removal/Replacement .....................................................WP 0040-3
Figure 2. Fuse Removal/Replacement.............................................................................WP 0040-5
Genset Battery, Battery Fuse, Support Bracket, and Warmer...................................................WP 0041
Figure 1. Battery Fuse Removal/Replacement (Version 1) .............................................WP 0041-4
Figure 2. Battery Fuse (Version 2 and 3) and Associated Cables
Removal/Replacement .....................................................................................WP 0041-7
Figure 3. Battery, Retainer, Mounting Bracket Removal/Replacement (Version 1) ........WP 0041-12
Figure 4. Battery, Retainer, Mounting Bracket Removal/Replacement (Version 2). .......WP 0041-18
Figure 5. Battery, Retainer, Mounting Bracket Removal/Replacement (Version 3) ........WP 0041-24
Figure 6. Battery Warmer Removal/Replacement (Version 1) ........................................WP 0041-27
Figure 7. Battery Warmer Removal/Replacement (Version 2 and 3) ..............................WP 0041-30
Genset Oil and Oil Filter.............................................................................................................WP 0042
Table 1. Engine Oil Recommendations............................................................................WP 0042-4
Figure 1. Oil and Filter Removal/Replacement ................................................................WP 0042-5
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Genset Air Filter .........................................................................................................................WP 0043
Figure 1. Air Intake Filter Removal/Replacement ............................................................WP 0043-3
Genset Fuel Filter ......................................................................................................................WP 0044
Figure 1. Fuel Filter Removal/Replacement ....................................................................WP 0044-4
Genset Fuel Tank ......................................................................................................................WP 0045
Figure 1. Genset Fuel Tank Drain Location .....................................................................WP 0045-3
Genset Low Oil Pressure Cut-Off Switch...................................................................................WP 0046
Figure 1. Low Oil Pressure Cut-Off Switch Removal/Replacement.................................WP 0046-4
Genset Electric Fuel Pump ........................................................................................................WP 0047
Figure 1. Electric Fuel Pump Removal/Replacement ......................................................WP 0047-4
Genset Fuel Injection System ....................................................................................................WP 0048
Figure 1. Oil Dipstick Mount .............................................................................................WP 0048-3
Figure 2. Fuel Injector Removal/Replacement.................................................................WP 0048-5
Figure 3. Fuel Injector Pump Removal/Replacement ......................................................WP 0048-9
Figure 4. Fuel Injection System Lines Removal/Replacement ........................................WP 0048-15
Genset Glow Plug and Glow Plug Connector ............................................................................WP 0049
Figure 1. Glow Plug/Connector Strip Removal/Replacement ..........................................WP 0049-5
Genset Oil Pressure Switch .......................................................................................................WP 0050
Figure 1. Oil Pressure Switch Removal/Replacement .....................................................WP 0050-4
Genset Oil Pressure Sending Unit .............................................................................................WP 0051
Figure 1. Oil Pressure Sending Unit Removal/Replacement ...........................................WP 0051-4
Genset Solenoid ........................................................................................................................WP 0052
Table 1. Electronic Connections for Genset Solenoids....................................................WP 0052-3
Figure 1. K2 or K3 Solenoid Removal/Replacement .......................................................WP 0052-4
Figure 2. K4 Solenoid and Circuit Breaker Removal/Replacement .................................WP 0052-7
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Genset Starter ............................................................................................................................WP 0053
Figure 1. Starter Removal/Replacement ..........................................................................WP 0053-4
Genset Diesel Speed Sensor.....................................................................................................WP 0054
Figure 1. Diesel Speed Sensor Removal/Replacement...................................................WP 0054-5
Genset Coolant Temperature Sensor ........................................................................................WP 0055
Figure 1. Coolant Temperature Sensor Removal/Replacement ......................................WP 0055-4
Genset Coolant Temperature Switch .........................................................................................WP 0056
Figure 1. Coolant Temperature Switch Removal/Replacement .......................................WP 0056-4
Genset Thermostat ....................................................................................................................WP 0057
Figure 1. Thermostat Removal/Replacement ..................................................................WP 0057-5
Genset Engine Coolant ..............................................................................................................WP 0058
Table 1. Radiator Coolant to Water Ratios ......................................................................WP 0058-4
Figure 1. Engine Coolant Removal/Replacement ............................................................WP 0058-4
Figure 2. Engine Coolant Reservoir Bottle Removal/Replacement .................................WP 0058-6
Genset Radiator .........................................................................................................................WP 0059
Figure 1. Radiator, Hoses, and Clamps Removal/Replacement .....................................WP 0059-7
Genset Alternator .......................................................................................................................WP 0060
Figure 1. Alternator Removal/Replacement .....................................................................WP 0060-4
Genset Fan Belt .........................................................................................................................WP 0061
Figure 1. Fan Belt Adjustment, Removal/Replacement ...................................................WP 0061-5
Genset Fan ................................................................................................................................WP 0062
Figure 1. Fan Removal/Replacement ..............................................................................WP 0062-5
Genset Water Pump ..................................................................................................................WP 0063
Figure 1. Water Pump Removal/Replacement ................................................................WP 0063-5
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Genset Engine Heater (Hydronic) ..............................................................................................WP 0064
Figure 1. Engine Heater (Hydronic) Removal/Replacement ............................................WP 0064-5
Figure 2. Engine Heater (Hydronic) Fuel Pump and Fuel Filter
Removal/Replacement .....................................................................................WP 0064-10
Figure 3. Engine Heater (Hydronic) Hose Removal/Replacement ..................................WP 0064-18
Figure 4. Engine Heater (Hydronic) Hose Fuse Removal/Replacement .........................WP 0064-20
Genset Exhaust System ............................................................................................................WP 0065
Figure 1. Exhaust Flex Pipe, Elbow and Muffler Removal/Replacement ........................WP 0065-7
Genset Exhaust Manifold ...........................................................................................................WP 0066
Figure 1. Exhaust Manifold and Gasket Removal/Replacement .....................................WP 0066-4
Torque Specifications ................................................................................................................WP 0067
Figure 1. Bolt Diameter and Thread Pitch ........................................................................WP 0067-1
Table 1. Component Torque Specifications .....................................................................WP 0067-2
Table 2. Flanged Head Bolt Torque Specifications..........................................................WP 0067-3
Table 3. Standard Bolt Torque Specifications ..................................................................WP 0067-3
Table 4. Newton-Meters to Kilogram-Meters ...................................................................WP 0067-4
Table 5. Kilogram-Meters to Foot Pounds .......................................................................WP 0067-4
Table 6. Newton-Meters to Foot Pounds .........................................................................WP 0067-5
Genset – Control Panel AC Meters ...........................................................................................WP 0068
Table 1. Meter Connections .............................................................................................WP 0068-3
Figure 1. Meter Removal/Replacement ...........................................................................WP 0068-4
Genset Control Panel – Gauges and Meters .............................................................................WP 0069
Table 1. Meter/Gauge Connections .................................................................................WP 0069-5
Figure 1. Meter/Gauge Removal/Replacement ...............................................................WP 0069-6
Table 2. Hour Meter Connections ....................................................................................WP 0069-8
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Genset Control Panel – Switches and Potentiometer ...............................................................WP 0070
Figure 1. Potentiometer Removal/Replacement ..............................................................WP 0070-4
Table 1. Genset Control Panel - Rotary Switch Connections ..........................................WP 0070-7
Figure 2. Rotary Switch Removal/Replacement ..............................................................WP 0070-8
Table 2. Genset Control Panel - Toggle Switch Connections ..........................................WP 0070-11
Figure 3. Toggle Switch Removal/Replacement ..............................................................WP 0070-12
Genset Control Panel Lights ......................................................................................................WP 0071
Figure 1. Light Assemblies Removal/Replacement .........................................................WP 0071-3
Table 1. Indicator Light(s) Connections ...........................................................................WP 0071-5
Genset Control Panel – Switches ..............................................................................................WP 0072
Figure 1. Battery Switch Removal/Replacement .............................................................WP 0072-4
Genset – Control Panel..............................................................................................................WP 0073
Figure 1. Control Panel Component Identification ...........................................................WP 0073-4
Table 1. Component Identification ...................................................................................WP 0073-4
Genset – Power Distribution Panel Connectors ........................................................................WP 0074
Table 1. Genset Power Distribution Panel – Light Connections (Old Version) ................WP 0074-3
Figure 1. Power Distribution Panel Lights (Old Version) Removal/Replacement ............WP 0074-4
Table 2. Genset Power Distribution Panel – Light Connections (New Version) ..............WP 0074-6
Figure 2. Power Distribution Panel Lights (New Version) Removal/Replacement ..........WP 0074-7
Table 3. J1 and J4 Connections .......................................................................................WP 0074-10
Figure 3. Connector (J1 and J4) Removal/Replacement .................................................WP 0074-11
Table 4. J2 and J3 Connections .......................................................................................WP 0074-14
Figure 4. Connector (J2 and J3) Removal/Replacement .................................................WP 0074-15
Table 5. J5 Connections ..................................................................................................WP 0074-18
Figure 5. Connector (J5) Removal/Replacement.............................................................WP 0074-19
Table 6. J6 Connections ..................................................................................................WP 0074-21
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Genset – Power Distribution Panel Connectors – Continued. ...................................................WP 0074
Figure 6. Connector (J6) Removal/Replacement.............................................................WP 0074-22
Figure 7. Connector Pin Identification ..............................................................................WP 0074-23
Genset Barrier Panel – Current Transformer.............................................................................WP 0075
Table 1. Genset Barrier Panel – Current Transformer Connections................................WP 0075-3
Figure 1. Current Transformer Removal/Replacement ....................................................WP 0075-4
Genset Barrier Panel – Transducer ...........................................................................................WP 0076
Table 1. Genset Barrier Panel – Transducer Connections ..............................................WP 0076-3
Figure 1. Transducer Removal/Replacement ..................................................................WP 0076-4
Genset Barrier Panel – Relays ..................................................................................................WP 0077
Figure 1. Relay Removal/Replacement ...........................................................................WP 0077-3
Genset Barrier Panel – Time Delay ...........................................................................................WP 0078
Figure 1. Time Delay Removal/Replacement ..................................................................WP 0078-3
Genset Barrier Panel – Voltage Regulator ................................................................................WP 0079
Table 1. Voltage Regulator Connections .........................................................................WP 0079-3
Figure 1. Voltage Regulator Removal/Replacement........................................................WP 0079-4
Figure 2. Voltage Regulator Connections and Potentiometer Identification ....................WP 0079-6
Genset Barrier Panel – Speed Sensor ......................................................................................WP 0080
Table 1. Speed Sensor Connections ...............................................................................WP 0080-3
Figure 1. Speed Sensor Removal/Replacement..............................................................WP 0080-4
Genset Barrier Panel – Precision Governor ..............................................................................WP 0081
Table 1. Precision Governor Connections .......................................................................WP 0081-3
Figure 1. Precision Governor Removal/Replacement......................................................WP 0081-4
Figure 2. Potentiometer Location and Identification.........................................................WP 0081-5
Genset Barrier Panel – Circuit Breaker .....................................................................................WP 0082
Table 1. Battery Charger Connections .............................................................................WP 0082-3
Figure 1. Circuit Breaker Removal/Replacement.............................................................WP 0082-4
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Genset Barrier Panel – Battery Charger ....................................................................................WP 0083
Table 1. Battery Charger Connections .............................................................................WP 0083-3
Figure 1. Battery Charger Removal/Replacement ...........................................................WP 0083-4
Genset Fuel Panel .....................................................................................................................WP 0084
Figure 1. Fuel Selector Switch Connections ....................................................................WP 0084-3
Figure 2. Fuel Selector Switch Removal/Replacement....................................................WP 0084-4
Figure 3. Auxiliary Fuel Port Removal/Replacement .......................................................WP 0084-7
Genset Fuel System ..................................................................................................................WP 0085
Figure 1. Genset Fuel Gauge Removal/Replacement .....................................................WP 0085-4
Figure 2. Genset Fuel Tank Removal/Replacement ........................................................WP 0085-9
Figure 3. Genset Fuel Line Heater Removal/Replacement .............................................WP 0085-14
Genset Removal/Replacement ..................................................................................................WP 0086
Figure 1. Genset Removal/Replacement .........................................................................WP 0086-6
Figure 2. Preparation for Engine/Generator Removal/Replacement ...............................WP 0086-8
Table 1. Generator to Barrier Panel Wiring Connections.................................................WP 0086-10
Figure 3. Electrical and Hydronic Heater Connections for Engine/Generator
Removal/Replacement .....................................................................................WP 0086-11
Figure 4. Oil and Fuel Preparation for Engine/Generator Removal/Replacement ..........WP 0086-13
Figure 5. Radiator and Exhaust Manifold Connections Removal/Replacement ..............WP 0086-15
Figure 6. Engine (hydronic) Heater and Battery Warming Plate Connections
Removal/Replacement .....................................................................................WP 0086-17
Figure 7. EGA Removal/Replacement .............................................................................WP 0086-19
Table 2. Fuel line Heater Connections .............................................................................WP 0086-22
Table 3. Generator to Barrier Panel Connections ............................................................WP 0086-24
Figure 8. Separating Engine Generator Assembly ..........................................................WP 0086-28
Chapter 7 – Maintainer Maintenance Instructions - ECU
Service Upon Receipt - ECU .....................................................................................................WP 0087
PMCS Introduction – ECU .........................................................................................................WP 0088
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
PMCS (ECU) ..............................................................................................................................WP 0089
Table 1. Maintainer Preventive Maintenance Checks and Services – ECU ....................WP 0089-1
ECU Maintenance Index ............................................................................................................WP 0090
ECU Access Panel.....................................................................................................................WP 0091
Figure 1. ECU Access Panel Latch Removal/Replacement ............................................WP 0091-3
ECU Condenser Coil and Grill ...................................................................................................WP 0092
Figure 1. Condenser Grill Removal/Replacement ...........................................................WP 0092-3
Figure 2. Condenser Coil Cleaning ..................................................................................WP 0092-5
ECU Duct Cover, Sliding Door, Evaporator Panel, Damper ......................................................WP 0093
Figure 1. ECU Duct Cover Removal/Replacement ..........................................................WP 0093-3
Figure 2. ECU Sliding Door Removal/Replacement ........................................................WP 0093-5
Figure 3. ECU Evaporator Panel Assembly Removal/Replacement ...............................WP 0093-7
Figure 4. ECU Damper Assembly Removal/Replacement ..............................................WP 0093-9
ECU Hydronic Heater ................................................................................................................WP 0094
Figure 1. Hydronic Heater Removal/Replacement ..........................................................WP 0094-4
Figure 2. Hydronic Heater Fuel Pump and Fuel Filter Removal/Replacement ................WP 0094-8
Figure 3. Hydronic Heater Hose Removal/Replacement .................................................WP 0094-11
Figure 4. Hydronic Heater Fuse Removal/Replacement .................................................WP 0094-13
ECU Cut-Off Switches ...............................................................................................................WP 0095
Figure 1. High Temperature Cut-off Switch Removal/Replacement ................................WP 0095-3
Figure 2. High Pressure Cut-Off Switch Removal/Replacement .....................................WP 0095-6
Figure 3. Low Pressure Cut-Off Switch Removal/Replacement ......................................WP 0095-9
ECU – Evaporator Fan Motor ....................................................................................................WP 0096
Table 1. Evaporator Motor Electrical Connections...........................................................WP 0096-3
Figure 1. Evaporator Motor Removal/Replacement.........................................................WP 0096-4
Figure 2. Evaporator Blower Fan Removal/Replacement................................................WP 0096-7
xvii
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
ECU – Condenser Fan Motor ....................................................................................................WP 0097
Table 1. Condenser Fan Motor Electrical Connections ...................................................WP 0097-3
Figure 1. Condenser Fan Removal/Replacement............................................................WP 0097-4
ECU Evaporator Motor Belt .......................................................................................................WP 0098
Figure 1. ECU Evaporator Motor Belt Adjustment ...........................................................WP 0098-3
Figure 2. ECU Evaporator Motor Belt Removal/Replacement .........................................WP 0098-6
ECU – Compressor and Vibration Dampers ..............................................................................WP 0099
Table 1. Compressor Connections...................................................................................WP 0099-4
Figure 1. Compressor Removal/Replacement .................................................................WP 0099-5
ECU – Valves .............................................................................................................................WP 0100
Figure 1. TEV Removal/Replacement..............................................................................WP 0100-4
Figure 2. Quench Valve Removal/Replacement ..............................................................WP 0100-9
Figure 3. Hot Gas By-Pass Valve Removal/Replacement ...............................................WP 0100-12
Figure 4. High Pressure Relief Valve Removal/Replacement .........................................WP 0100-16
Figure 5. Solenoid Valve Removal/Replacement ............................................................WP 0100-19
ECU Air Filter .............................................................................................................................WP 0101
Figure 1. ECU Air Filter Locations....................................................................................WP 0101-3
ECU – Filter/Drier .......................................................................................................................WP 0102
Figure 1. Filter/Drier Removal/Replacement ....................................................................WP 0102-4
ECU Control Panel Door ............................................................................................................WP 0103
Figure 1. ECU Control Panel Faceplate Fluids and components
Removal/Replacement .....................................................................................WP 0103-7
Figure 2. ECU Thermostat Removal/Replacement..........................................................WP 0103-10
ECU Control Panel – Circuit Breakers .......................................................................................WP 0104
Table 1. Circuit Breaker Connections/Wire ID Numbers..................................................WP 0104-3
Figure 1. Circuit Breaker Removal/Replacement (Version 1) ..........................................WP 0104-4
Figure 2. Circuit Breaker Removal/Replacement (Version 2) ..........................................WP 0104-5
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
ECU Control Panel – Contactors ...............................................................................................WP 0105
Figure 1. Contactor Removal/Replacement .....................................................................WP 0105-3
ECU Control Panel – Relays......................................................................................................WP 0106
Figure 1. Relay Removal/Replacement ...........................................................................WP 0106-3
ECU Control Panel – Transformer and Bridge Rectifier ............................................................WP 0107
Figure 1. Transformer Removal/Replacement .................................................................WP 0107-3
Figure 2. Bridge Rectifier Removal/Replacement ............................................................WP 0107-5
ECU Control Panel – Starter Protectors ....................................................................................WP 0108
Figure 1. CMSP/EMSP Removal/Replacement ...............................................................WP 0108-3
ECU Removal/Replacement ......................................................................................................WP 0109
Figure 1. ECU Removal/Replacement .............................................................................WP 0109-6
ECU – Purging and Brazing .......................................................................................................WP 0110
ECU – Leak Testing ...................................................................................................................WP 0111
ECU – System Evacuation.........................................................................................................WP 0112
Figure 1. Evacuation Set-up (Shop Method) ....................................................................WP 0112-3
Figure 2. Evacuation Set-up (Field Method) ....................................................................WP 0112-3
ECU – System Charging and Recovery ....................................................................................WP 0112
Figure 1. Refrigerant Recovery Layout ............................................................................WP 0113-3
Figure 2. System Charging (Using Electronic Refrigerant Scale) ....................................WP 0113-5
Figure 3. System Charging (Using Standard Scale) ........................................................WP 0113-6
ECU – Subcool Setting ..............................................................................................................WP 0114
Table 1. R407c Conversion Table....................................................................................WP 0114-4
Chapter 8 – Maintainer Maintenance Instructions – Trailer & Shelter
Service Upon Receipt – Trailer & Shelter ..................................................................................WP 0115
PMCS Introduction – Trailer & Shelter .......................................................................................WP 0116
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
PMCS (ECU) ..............................................................................................................................WP 0117
Table 1. Maintainer Preventive Maintenance Checks and
Services – Trailer & Shelter ...............................................................................WP 0117-1
Trailer & Shelter Maintenance Index .........................................................................................WP 0118
Trailer Level, Safety Chain, and Tongue Jack ...........................................................................WP 0119
Figure 1. Trailer Level Removal/Replacement .................................................................WP 0119-2
Figure 2. Safety Chain Removal/Replacement ................................................................WP 0119-3
Figure 3. Tongue Jack Assembly Removal/Replacement ...............................................WP 0119-5
Trailer Lift Sling ..........................................................................................................................WP 0120
Figure 1. Lift Sling Removal/Replacement .......................................................................WP 0120-3
Trailer Stabilizer Leg and Cargo Net .........................................................................................WP 0121
Figure 1. Stabilizer Leg Removal/Replacement...............................................................WP 0121-4
Figure 2. Cargo Net Removal/Replacement ....................................................................WP 0121-6
Trailer Basic ...............................................................................................................................WP 0122
Figure 1. Reflector Removal/Replacement ......................................................................WP 0122-3
Figure 2. Ground Stud Removal/Replacement ................................................................WP 0122-5
Figure 3. Lanyard Assembly Removal/Replacement .......................................................WP 0122-7
Figure 4. Fire Extinguisher Bracket Removal/Replacement ............................................WP 0122-9
Trailer Cargo Restraint Cage .....................................................................................................WP 0123
Figure 1. Cargo Restraint Cage Removal/Replacement..................................................WP 0123-4
Trailer Vehicle Stop Light ...........................................................................................................WP 0124
Figure 1. Vehicle Stop Light, Lamp (Incandescent) and Blackout Light
Removal/Replacement .....................................................................................WP 0124-3
Figure 2. Vehicle Stop Light (Incandescent) Removal/Replacement ..............................WP 0124-5
Figure 3. Vehicle Stop Light (LED) Removal/Replacement .............................................WP 0124-8
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Trailer Inter-Vehicular Cable ......................................................................................................WP 0125
Figure 1. Inter-Vehicular Cable Removal/Replacement...................................................WP 0125-5
Table 1. Cable Assembly/Stop Light (LED) Connections ................................................WP 0125-6
Figure 2. Inter-Vehicular Cable Connectors (Incandescent) ............................................WP 0125-6
Table 2. Cable Assembly/Stop Light (Incandescent) Connections ..................................WP 0125-6
Trailer Brakes (Wheel Assembly) ..............................................................................................WP 0126
Figure 1. Brake Hub/Drum Removal/Replacement..........................................................WP 0126-5
Figure 2. Wheel Cylinder, Brakeshoe, and Backing Plate Removal/Clean
and Inspect/Replacement.................................................................................WP 0126-8
Figure 3. Brake Adjustment ..............................................................................................WP 0126-17
Trailer Brakes .............................................................................................................................WP 0127
Figure 1. Master Cylinder Removal/Replacement ...........................................................WP 0127-3
Figure 2. Brake Line Removal/Replacement ...................................................................WP 0127-7
Figure 3. Bleed Brake System .........................................................................................WP 0127-9
Trailer Brakes (Brake Actuator and Hand Brakes) ....................................................................WP 0128
Figure 1. Brake Actuator Mounting Brackets Removal/Replacement..............................WP 0128-4
Figure 2. Tow Pintle and Breakaway Lever Removal/Replacement ................................WP 0128-5
Figure 3. Brake Actuator Shock Absorber and Hydraulic Push Rod
Removal/Replacement .....................................................................................WP 0128-6
Figure 4. Brake Actuator Assembly (New Version) Removal/Replacement ....................WP 0128-8
Figure 5. Brake Actuator Assembly Removal/Replacement ............................................WP 0128-10
Figure 6. Hand Brake Removal/Replacement .................................................................WP 0128-13
Figure 7. Hand Brake and Sheath Removal/Replacement ..............................................WP 0128-16
Trailer Tire and Wheel Assembly ...............................................................................................WP 0129
Figure 1. Wheel Assembly Removal/Replacement..........................................................WP 0129-5
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Shelter Lighting ..........................................................................................................................WP 0130
Figure 1. Fluorescent Lamp in Lighting Fixture Removal/Replacement ..........................WP 0130-3
Figure 2. Fuse in Lighting Fixture Removal/Replacement ...............................................WP 0130-5
Chapter 9 – Parts Information for TMSS-MED
Introduction ................................................................................................................................WP 0131
Table 1. SMR Code Explanation ....................................................................................WP 0131-1
GROUP 00 Power Plant, Utility, A1-38283D-001 (PU-821/T),
A1-38283D-002 (PU-822A/T) ..............................................................................WP 0132
Figure 1. Power Plant, Utility, A1-38283D-001 (PU-821/T),
A1-38283D-002 (PU-822A/T) ...........................................................................WP 0132-2
GROUP 01 Tent, Modular, General Purpose System, TMSS100G/TMSS100T ......................WP 0133
Figure 2. Tent, Modular, General Purpose System,
TMSS100G/TMSS100T ...................................................................................WP 0133-1
GROUP 0101 Air Conditioner, T256250G/T256250T ..............................................................WP 0134
Figure 3. Air Conditioner, T256250G/T256250T..............................................................WP 0134-2
GROUP 010101 Air Conditioner Enclosure, T250250G/T250250T .........................................WP 0135
Figure 4. Air Conditioner Enclosure, T250250G/T250250T.............................................WP 0135-2
GROUP 01010101 Panel, Evaporator Assembly, TG423-0451-1G/TG423-0451-1T ..............WP 0136
Figure 5. Panel, Evaporator Assembly, TG423-0451-1G/TG423-0451-1T .....................WP 0136-2
GROUP 01010102 Control , Enclosure, Air Conditioner, 088T103 ..........................................WP 0137
Figure 6. Control , Enclosure, Air Conditioner, 088T103 .................................................WP 0137-2
GROUP 01010103 Blower Assembly, 054T102 .......................................................................WP 0138
Figure 7. Blower Assembly, 054T102 ..............................................................................WP 0138-1
GROUP 0102 Generator, Diesel Engine, T282271G/T282271T..............................................WP 0139
Figure 8. Generator, Diesel Engine, T282271G/T282271T .............................................WP 0139-2
GROUP 010201 Battery Assembly, T235064 ..........................................................................WP 0140
Figure 9. Battery Assembly, T235064 ..............................................................................WP 0140-2
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
GROUP 010202 Engine Assembly, T245264...........................................................................WP 0141
Figure 10. Engine Assembly, T245264 ............................................................................WP 0141-1
GROUP 01020201 Cooling System Installation, TG440-0001 .................................................WP 0142
Figure 11. Cooling System Installation, TG440-0001 ......................................................WP 0142-2
GROUP 01020202 Air Intake Assembly, X-14210-057-0.........................................................WP 0143
Figure 12. Air Intake Assembly, X-14210-057-0 ..............................................................WP 0143-2
GROUP 010203 Radiator Installation, TG421-9000 ................................................................WP 0144
Figure 13. Radiator Installation, TG421-9000 ..................................................................WP 0144-2
GROUP 010204 Exhaust Assembly, T235005 .........................................................................WP 0145
Figure 14. Exhaust Assembly, T235005 ..........................................................................WP 0145-2
GROUP 010205 Control Panel Assembly, T225453 ................................................................WP 0146
Figure 15. Control Panel Assembly, T225453 .................................................................WP 0146-1
GROUP 010206 Power Distribution Panel Assembly, TG421-9007 ........................................WP 0147
Figure 16. Power Distribution Panel Assembly, TG421-9007 .........................................WP 0147-1
GROUP 010207 Barrier Panel Assembly, T225250-5 .............................................................WP 0148
Figure 17. Barrier Panel Assembly, T225250-5 ...............................................................WP 0148-2
GROUP 0103 Chassis, Trailer Assembly, T215125G/T215125T ............................................WP 0149
Figure 18. Chassis, Trailer Assembly, T215125G/T215125T ..........................................WP 0149-1
GROUP 010301 Stop Light, Vehicular, 12375837-BK-SP .......................................................WP 0150
Figure 19. Stop Light, Vehicular, 12375837-BK-SP.........................................................WP 0150-2
GROUP 010302 Tongue Jack Assembly, 190754 ...................................................................WP 0151
Figure 20. Tongue Jack Assembly, 190754 .....................................................................WP 0151-2
GROUP 010303 Brake Installation, T6421-9006G/T6421-9006T ............................................WP 0152
Figure 21. Brake Installation, T6421-9006G/T6421-9006T .............................................WP 0152-1
GROUP 01030301 Actuator Assembly, TG404-0819G/TG404-0819T ....................................WP 0153
Figure 22. Actuator Assembly, TG404-0819G/TG404-0819T .........................................WP 0153-2
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
GROUP 0104 Tent, MXA2000G/MXA2020T ............................................................................WP 0154
Figure 23. Tent, MXA2000G/MXA2020T .........................................................................WP 0154-2
GROUP 010401 Tent, End Cap, MXA2020G/MXA2020T........................................................WP 0155
Figure 24. Tent, End Cap, MXA2020G/MXA2020T .........................................................WP 0155-2
GROUP 010402 Tent, Roof and Sides, MXA2035G/MXA2035T .............................................WP 0156
Figure 25. Tent, Roof and Sides, MXA2035G/MXA2035T ..............................................WP 0156-2
GROUP 0106 Light Set, Tent, H300070...................................................................................WP 0157
Figure 26. Light Set, Tent, H300070 ................................................................................WP 0157-2
GROUP 010601 Wiring Kit, Electrical, T2-95205 .....................................................................WP 0158
Figure 27. Wiring Kit, Electrical, T2-95205 ......................................................................WP 0158-2
National Stock Number Index ....................................................................................................WP 0159
Part Number Index .....................................................................................................................WP 0160
Chapter 10 – Destruction of Equipment to Prevent Enemy Use for TMSS-MED
General Information ...................................................................................................................WP 0161
Destruction Procedures .............................................................................................................WP 0162
Chapter 11 – Supporting Information for TMSS-MED
References .................................................................................................................................WP 0163
MAC Introduction .......................................................................................................................WP 0164
Maintenance Allocation Chart (MAC) ........................................................................................WP 0165
Table 1. MAC for TMSS Medium .....................................................................................WP 0165-1
Table 2. Tools and Test Equipment for TMSS Medium ...................................................WP 0165-5
Table 3. Remarks for TMSS Medium ...............................................................................WP 0165-6
Components of End Item (COEI) and Basic Issue Items (BII) List ............................................WP 0166
Table 1. Components of End Item List .............................................................................WP 0166-2
Table 2. Basic Issue Items ..............................................................................................WP 0166-9
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TABLE OF CONTENTS – Continued
Page No.
WP Sequence No.
Additional Authorization List (AAL) ............................................................................................WP 0167
Table 1. Additional Authorization List ...............................................................................WP 0167-1
Expendable and Durable Items List ...........................................................................................WP 0168
Table 1. Expendable and Durable Items List ...................................................................WP 0168-1
Table 2. Shelter Repair Kit Items .....................................................................................WP 0168-5
Index
Foldout Figures
FO-1. Schematic – ECU (V1) ...........................................................................................FP-1
FO-2. Schematic – Wiring Diagram – ECU (V1) ..............................................................FP-3
FO-3. Schematic – Schematic – ECU (V2) ......................................................................FP-5
FO-4. Schematic – Wiring Diagram – ECU (V2) ..............................................................FP-7
FO-5. Schematic – ECU Refrigerant ................................................................................FP-9
FO-6. Schematic – Genset Control Panel ........................................................................FP-11
FO-7. Schematic – Genset Power Distribution Panel ......................................................FP-13
FO-8. Schematic – Genset Barrier Panel Sh 1 of 5 .........................................................FP-15
Schematic – Genset Barrier Panel Sh 2 of 5 ........................................................FP-17
Schematic – Genset Barrier Panel Sh 3 of 5 ........................................................FP-19
Schematic – Genset Barrier Panel Sh 4 of 5 ........................................................FP-21
Schematic – Genset Barrier Pane Sh 5 of 5 .........................................................FP-23
FO-9. Schematic – Genset Wiring Harness .....................................................................FP-25
FO-10. Wire List – Genset Sh 1 of 2 ................................................................................FP-27
Wire List – Genset Sh 2 of 2 ................................................................................FP-29
FO-11. Genset Connectors Sh 1 of 2...............................................................................FP-31
Genset Connectors Sh 2 of 2 .............................................................................FP-33
xxv
TM 11-6115-742-13&P
Foldout Figures – Continued
FO-12. Schematic – Hydronic Heater ..............................................................................FP-35
FO-13. Wiring Diagram – Inter-Vehicular cable (LED).....................................................FP-37
FO-14. Schematic – Wiring Diagram – Inter-Vehicular cable (Incandescent) ................FP-39
FO-15. Schematic –Genset Power Distribution Panel – New Version (with EMI) ..........FP-41
FO-16. Schematic –Genset Power Distribution Panel – New Version (without EMI) .....FP-43
Back Cover
xxvi
TM 11-6115-742-13&P
HOW TO USE THIS MANUAL
PURPOSE AND SCOPE
This technical manual provides Operator and Service level maintenance information for Utility Power Plant PU-
821/T and PU-822A/T. To simplify the discussions, the Utility Power Plant PU-821/T and PU-822A/T will be
referred to throughout this manual as the Medium Trailer Mounted Support System (TMSS-MED) used in support
of the Command Post Platform (CPP). The information includes equipment description and theory of operation,
Operator instructions, troubleshooting procedures, maintenance and testing procedures, and supporting data
including Repair Parts and Special Tools List for identifying and ordering repair parts.
ARRANGEMENT, IDENTIFICATION AND LOCATION OF FRONT MATTER, REAR MATTER, CHAPTERS,
AND WORK PACKAGES
This manual is composed of front matter, chapters containing Work Packages (WPs), and rear matter. These
areas are described in greater detail in the following paragraphs.
Front Matter
The front matter includes such items as the Warning Summary, List of Effective Pages/WPs, Table of Contents,
and How to Use This Manual.
Chapters and Work Packages
The WPs contain information pertinent to the performance of specific tasks. Each WP is maintained as a
separate entity. The WPs are grouped into chapters based on overall content. WPs are arranged in numerical
sequence regardless of chapter division. The chapter divisions and the WPs contained within the chapters are
listed in the Table of Contents. The contents of each chapter are outlined briefly in the following paragraphs.
Chapter 1 - General Information, Equipment Descriptions, and Theory of Operation. This chapter provides
general and descriptive information concerning the equipment. Theory of Operation appropriate to the
maintenance level covered is also provided.
Chapter 2 - Crew Instructions. This chapter provides a description and location of the controls, indicators, and
connectors on each piece of equipment used in the TMSS-MED. It also contains a description and location of the
decals and data plates for each piece of equipment and operation under usual and unusual conditions.
Chapter 3 - Crew Troubleshooting Procedures. This chapter provides operational checkout and troubleshooting
procedures appropriate to the maintenance level covered.
Chapter 4 - Crew Maintenance Instructions. This chapter provides information on performing preventive
maintenance actions. Included are instructions concerning service upon receipt of equipment, inspection,
preventive maintenance checks and services, and repair actions.
Chapter 5 – Maintainer Troubleshooting Procedures.. This chapter provides troubleshooting/fault isolation
procedures appropriate to the maintenance level covered
Chapter 6 – Maintainer Maintenance Instructions. This chapter provides information and instructions on
performing maintenance repair appropriate to the maintenance level covered.
Chapter 7 Maintainer Maintenance Instructions- ECU. This chapter provides information and instructions on
performing maintenance repair appropriate to the maintenance level covered.
Chapter 8 Maintainer Maintenance Instructions- Trailer and Shelter. This chapter provides information and
instructions on performing maintenance repair appropriate to the maintenance level covered.
xxvii
TM 11-6115-742-13&P
Chapters and Work Packages – Continued
Chapter 9. – Parts Information. This chapter provides information on the Repair Parts and Special Tools List
(RPSTL). This chapter also contains the national stock number list and part number list. The RPSTL is used to
support the maintenance actions in Chapters 4, 6 and 8.
Chapter 10 – Destruction of Equipment to Prevent Enemy Use. This chapter provides information on how to
damage the TMSS-MED to prevent usage by the enemy.
Chapter 11 - Supporting Information. Included are a list of reference material, the Maintenance Allocation Chart
(MAC) which identifies maintenance actions and their maintenance levels, Components of End Item (COEI) list,
Basic Issue Items (BII) list, Additional Authorization List (AAL), and Expendable and Durable Items list.
Rear Matter
The rear matter includes an alphabetical index, foldouts, and copies of DA Form 2028 for recommending
improvements to the manual.
Identifying Work Packages
Each WP is identified by a four-digit number. These first digits are assigned sequentially. A new WP that is
inserted between two WPs shall use a point numbering scheme to create a new number that logically fits between
the two existing WP numbers. Point numbers shall start with “1” and continue in numerical sequence as needed.
WPs are revised due to equipment configuration differences, support equipment differences, or other similar
situations. For example:
WP 0035 might cover installation of a handle on a basic unit.
WP 0035.1 might cover installation of the same handle on a differently configured unit,
or
installation of an alternate handle in place on the original handle, requiring a different procedure,
or
installation of the handle using an alternate technique or different tools,
or
installation of the handle using alternate fasteners.
Locating Work Packages
There are two ways to locate a WP when the number is not known, using the Table of Contents in the manual's
front matter and using the Index in the manual's rear matter.
xxviii
TM 11-6115-742-13&P
Locating a Work Package in the Table of Contents
First determine the category of the WP subject and then find the appropriate chapter in the Table of Contents.
Scan the WP titles in that chapter until the WP subject matter is found. Follow the leader line to find the WP
number.
TABLE OF CONTENTS
WP Sequence No.
Page No.
WARNING SUMMARY
HOW TO USE THIS MANUAL
Chapter 1 - General Information, Equipment Description and Theory of Operation
General Information ......................................................................................................... WP 0001
Figure 1. TMSS-MED System Configuration .............................................0001-1
Table 1. Nomenclature Cross-Reference List ..........................................0001-3
Table 2. Abbreviations / Acronyms...........................................................0001-4
Equipment Data and Description ..................................................................................... WP 0002
Figure 1. TMSS-MED Configuration . ........................................................0002-1
Figure 2. TMSS-MED Shelter Components . ............................................0002-2
Figure 3. TMSS-MED Trailer Major Components......................................0002-3
Locating a Work Package in the Index
Look up the subject matter alphabetically in the Index. The index lists the applicable WP number and the page
number within the WP on which the subject matter starts.
INDEX
Subject WP Sequence No. - Page No.
A
Access Panels and Latches (Genset)
Removal/Replacement ......................................................................................0039-2
Repair Parts 0135,
0139
Actuator brake
Removal/Replacement ......................................................................................0128-7
Repair Parts .......................................................................................................0153
Additional Authorization List (AAL) ......................................................................0167
Additional Authorization List ..............................................................................0167-1
Explanation of Columns in the AAL ...................................................................0167-1
WORK PACKAGE CONTENT AND PRESENTATION
The content and the presentation techniques used in the WPs vary according to the material covered.
xxix
TM 11-6115-742-13&P
Common Features
In all cases, the WP title is placed at the top of the page immediately below the manual and WP number and is
set off by horizontal lines as shown below.
TM 11-6115-742-13&P 0002
GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
TMSS-MED
EQUIPMENT DESCRIPTION AND DATA
On the second and subsequent pages of the WP, the manual and WP number are repeated.
The page number is placed at the bottom of the page and consists of the WP number and a sequential number
denoting the page within the WP as shown below.
0002-1
Paragraphs are not numbered.
Primary paragraphs are denoted by headings set in BOLD UPPER CASE (CAPITAL) type.
Secondary and lower-level paragraphs are denoted by headings set in Bold Title Case. These paragraphs
always relate to and are subordinate to the most recent primary paragraph heading.
Common Features - Continued
Figures and Tables are numbered sequentially within each WP starting with numeral 1. References to Figures,
Tables, and Items are in title case (such as Figure 1).
Descriptive Narrative
For WPs consisting primarily of descriptive narrative (e.g., equipment data, theory of operation, etc.), text begins
immediately below the WP title and number.
xxx
TM 11-6115-742-13&P
Procedures
The example below is for WPs consisting primarily of procedures such as maintenance tasks, operating
instructions, etc. The initial setup section provides information on tools, material/parts, personnel required, and
equipment condition. Procedural steps are numbered.
TM 11-6115-742-13&P 0092
CONDENSER GRILL REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit One
(WP 0165, Item 1)
References
Materials/Parts WP 0005
Spray bottle (WP 0168, Item 54)
Sealing compound Equipment Condition
(WP 0168, Item 49) ECU shut down
WARNING
If ECU has been in operation, components may be extremely cold or extremely
hot. To prevent serious injury to personnel, allow sufficient time for components
to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure, (WP 0005).
2. Remove and retain eight screws (Figure 2, Item 2) and eight washers (Figure 2, Item 1) that secure ECU
condenser grill (Figure 2, Item 3).
3. Remove and retain condenser grill (Figure 2, Item 3).
In most cases, figures relating to the procedural step are also provided. When the figure is indexed (as in
maintenance procedures), procedural steps include the figure number and item number inside parentheses.
Supporting Information
The Supporting Information WPs contain instructions detailing the content and presentation techniques used in
the WPs.
xxxi/xxxii blank
TM 11-6115-742-13&P
CHAPTER 1
GENERAL INFORMATION, EQUIPMENT DESCRIPTION,
AND THEORY OF OPERATION
FOR
TMSS-MED
TM 11-6115-742-13&P 0001
GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
TMSS-MED
GENERAL INFORMATION
SCOPE
This Operator and Field Maintenance Manual Including Repair Parts and Special Tools List (RPSTL) provides
instructions and procedures for setup, operation, teardown, maintenance, and repair of the Utility Power Plant
P/U-821/T and PU-822A/T. To simplify the discussions, the Utility Power Plant P/U-821/T and PU-822A/T will be
referred to throughout this manual as Trailer Mounted Support System-Medium (TMSS-MED). The two major
components of the TMSS-MED system are a soft-walled shelter and a trailer support system. Typical
configuration for the TMSS-MED is shown in (Figure 1).
TMSS Shelter
The TMSS-MED shelter is a soft-walled shelter that can be rapidly deployed in the field by a minimum of four
people. The shelter does not require any special equipment for either erecting or striking. The TMSS-MED
shelter and system components are carried as cargo on the TMSS-MED trailer.
TMSS Trailer
The TMSS-MED trailer consists of one 18 kW, 120/208 Volt, 3-Phase, 60 Hz, diesel powered generator and one
60,000 BTU/hour Environmental Control Unit (ECU) mounted on a trailer chassis. A vehicle capable of pulling
4,200 lbs. is required to tow the TMSS-MED trailer.
Figure 1. TMSS-MED System Configuration.
0001-1
TM 11-6115-742-13&P 0001
MAINTENANCE FORMS, RECORDS, AND REPORTS
Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as
applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual, DA PAM 738-
751, Functional Users Manual for the Army Maintenance Management Systems – Aviation (TAMMS-A); or AR
700-138, Army Logistics Readiness and Sustainability.
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)
If the TMSS-MED needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell
us what you don’t like about your equipment. Let us know why you don’t like the design or performance. If you
have internet access, the easiest and fastest way to report problems or suggestions is to follow the instructions
and links below
If you have a user's account you can submit the PQDR for ALL CECOM (B16) Warranty, EIR and PQDRs
(including those B16 Aviation related) through the Navy’s Web Product Quality Deficiency Reporting (PQDR) site,
https://www.pdrep.csd.disa.mil/pdrep_files/report_tools/pqdr.htm. If you do not, either go to EZ PDR,
https://pdrep.csd.disa.mil/pdrep/ezdr.do, and input your PQDR there or establish a new account. New accounts
can be established at https://www.pdrep.csd.disa.mil/pdrep_files/accessforms/useraccess.htm and selecting the
“User Access Request” link on the left side of the web page.
Use the PQDR for Warranties, EIRs and PQDRs. There is a block on the PQDR that can be clicked if it is a
Warranty. The originator can still put in the description that they want this investigated as an EIR and then enter
what the issue is.
You may also submit your SF 368 (Product Quality Deficiency Report) via email (usarmy.apg.cecom.mbx.lrc-leo-
[email protected]), facsimile (443-861-6356) or regular mail (call 443-861-6310 or 443-861-6311
or 443-861-6312) for the current mailing address).
We will send you a reply.
CORROSION PREVENTION AND CONTROL (CPC)
Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any
corrosion problems with this item be reported so that the problem can be corrected and improvements can be
made to prevent the problem in future items. Corrosion specifically occurs with metals. It is an electrochemical
process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or
salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as
tarnishing, pitting, fogging, surface residue, and/or cracking. Plastics, composites, and rubbers can also degrade.
Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV)
processes. The most common exposures are excessive heat or light. Damage from these processes will appear
as cracking, softening, swelling, and/or breaking. SF Form 368, Product Quality Deficiency Report should be
submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS)
User’s Manual.
OZONE DEPLETING SUBSTANCES (ODS)
The use of Class 1 ODS for new acquisitions has been curtailed by Section 326 of the National Defense
Authorization Act of Fiscal Year 1993 (Public Law 102, 484) and related Army Policy.
DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE
Destruction of Army electronics materiel to prevent enemy use shall be in accordance with TM 750-244-2.
Procedures to destroy this equipment to prevent enemy use are located in (Chapter 10, WP 0161 and WP 0162)
of this manual. Additional information can be found in TM 750-244-2, Procedures for Destruction of Electronic
Material to Prevent Enemy Use.
0001-2
TM 11-6115-742-13&P 0001
PREPARATION FOR STORAGE OR SHIPMENT
Administrative storage of equipment issued to and used by Army activities will have Preventive Maintenance
Checks and Services (PMCS) performed before storing. When removing the equipment from administrative
storage, the PMCS checks should be performed to assure operational readiness.
WARRANTY INFORMATION
TMSS-MED system is warranted for one year. Contact the Regional Support Center (RSC) representative for
further information on warranted items. Report all defects to supervisor, who will take appropriate action.
NOMENCLATURE CROSS-REFERENCE LIST
Common names and/or abbreviations are used in this manual to make a procedure easier to read. The
Nomenclature Cross-Reference List (Table 1) matches the official nomenclatures with the common names.
Table 1. Nomenclature Cross-Reference List.
OFFICIAL NOMENCLATURE COMMON NAME
Air Conditioner Environmental Control Unit, ECU
Air Duct Hose Supply/Return Duct
Antifreeze Coolant
Cable Assembly, Special Purpose Inter-Vehicular Cable Assembly
Cinch Belt Cinch Straps
Engine Generator Genset
Heavy-High Mobility Multi-Purpose Wheeled Vehicle H-HMMWV
Heating, Ventilating, and Air Conditioning HVAC
Power Distribution Unit PDU
Power Plant, Utility TMSS-MED
Stake Rebar/Red Stake
Tent Component Kit Field Repair Kit
Tent, Roof and Sides Shelter
0001-3
TM 11-6115-742-13&P 0001
LIST OF ABBREVIATIONS/ACRONYMS
The Abbreviation/Acronym List (Table 2) is an alphabetical list of abbreviations/acronyms used throughout this
manual.
Table 2. Abbreviation/Acronym List.
ABBREVIATION/ACRONYM NAME
AC Alternating Current
AHSS Aux Heat Selector Switch
BII Basic Issue Items
BR Bridge rectifier
BTU British Thermal Unit
CAGEC Commercial and Government Entity Code
CB Circuit Breaker
CC Condenser Coils
CCR Contactor, Compressor
CCS Command Center System
CF Condenser Fan
CHT Contactor, Heater
CHT HIGH Contactor, Heater High
CHT LOW Contactor, Heater Low
CMP Compressor
CMSP Condenser Motor Starter Protector
COEI Components of End Item
CP Command Post
CPC Corrosion Prevention and Control
CPCS Command Post Communication System
CPP Command Post Platform
CR Motor Compressor
D Depot
DMR Depot Mobilization Requirements
DS Direct Support
ECU Environmental Control Unit
EIR Equipment Improvement Recommendations
EMSP Evaporator Motor Starter Protector
ESC Equipment Serviceability Criteria
FGC Functional Group Code
F/D Filter/Dryer
FM Field Manual
FO Foldouts
FU Fuse
GB Ground Bar
GS General Support
HCP Hardness Critical Procedures
HDBK Handbook
HGBV Hot Gas Bypass Valve
HM Hour Meter
HMMWV High Mobility Multi-Purpose Wheeled Vehicle
HPC High Pressure Cutout
HPRV High Pressure Relief Valve
HTC High Temperature Cutout
HTR1 Heater, Electric 18 KW, 208 VAC
HTR2 Heater, Electric 9 KW, 208 VAC
HVAC Heating, Ventilating and Air Conditioning
I/O Input/Output
LED Light Emitting Diode
0001-4
TM 11-6115-742-13&P 0001
Table 2. Abbreviation/Acronym List – Continued.
ABBREVIATION/ACRONYM NAME
LPC Low Pressure Cutout
MAC Maintenance Allocation Chart
MC Motor, Condenser Fan
ME Motor, Evaporator Fan
MOS Military Occupational Specialties
MSS Mode Select Switch
MWO Modification Work Order
NBC Nuclear, Biological, and Chemical
NSN National Stock Number
ODS Ozone Depleting Substances
OPL Out-of-Phase Light
P/N Part Number
PDB Power Distribution Block
PDP Power Distribution Panel
PMCS Preventive Maintenance Checks and Services
POL Power On Light
PQDR Product Quality Deficiency Report
PSI Pounds per Square Inch
PSR Phase Sending Relay
QA Quality Assurance
QV Quench Valve
RPSTL Repair Parts and Special Tools List
S1 Switch, Low Pressure
S2 Switch, High Pressure
S3 Switch, High Temp Stage Close
S4 Switch, Low Temp Stage Close
SDR Supply Discrepancy Report
SG Sight Glass
SMR Source, Maintenance and Recoverability
SOP Standard Operating Procedure
SV Solenoid Valve
SV1 Solenoid Valve (Liquid)
TAMMS The Army Maintenance Management System
TB Troubleshooting
TD Time Delay, Relay
TDR Transportation Discrepancy Report
TEV/D Thermal Expansion Valve and Distributor
TMDE Test, Measurement, and Diagnostic Equipment
TMSS Trailer Mounted Support System
TMSS-MED Trailer Mounted Support System - Medium
TX1 Control Transformer
U/I Unit of Issue
UPS Uninterruptible Power Supply
VAC Voltage, Alternating Current
VI Vibration Isolators
WD50 Auxiliary Heater
WP Work Package
QUALITY OF MATERIAL
Material used for replacement, repair, or modification must meet the requirements of this Operator and Field
Maintenance Manual. If quality of material requirements is not stated in this Operator and Field Maintenance
Manual, the material must meet the requirements of the drawings, standards, specifications, or approved
engineering change proposals applicable to the subject equipment.
0001-5
TM 11-6115-742-13&P 0001
SAFETY, CARE, AND HANDLING
To prevent personal injury and damage to equipment, obey the following general rules and precautions:
1. Become familiar with the warnings and cautions listed in the front of this manual.
a. Warnings – Present circumstances or procedures that, if not strictly adhered to, may cause injury or
death.
b. Cautions – Present circumstances that can cause damage to equipment or loss of the mission.
2. Recognize that improperly lifting or carrying heavy equipment can result in serious injury. Follow number of
lifter guidelines/requirements in safety marking (labels or stencils) and caution statements in technical
documentation.
3. Ensure all power is turned off before starting any removal task. Power should be removed before connecting
or disconnecting cables due to shorting hazards.
4. Recognize that equipment (Genset or ECU) may be hot. Allow equipment to cool down before performing
any maintenance procedures.
5. Do not touch connector terminals with any tool, bare hands, or dirty cloth. Tools damage the connector. Dirt
or sweat causes corrosion.
6. Before touching any electrical components, discharge static electricity by touching a metal chassis or cabinet
before handling component. A static discharge to an electrical component can destroy internal circuits.
7. Know where emergency equipment is located. Read instructions on the fire extinguisher label.
8. Ensure hands are clean before working on equipment.
NUCLEAR HARDNESS
All Hardness Critical Procedures (HCP) in this manual are marked with the acronym “HCP” as follows:
1. When the entire task, including all paragraphs and procedures, is considered hardness-critical, only the task
title is marked by the acronym “HCP” before the title.
2. When only certain processes and steps within the work package are hardness-critical, only the applicable
process and steps are marked by the acronym “HCP” between each applicable step number and the text.
PARTS INFORMATION FOR REPAIR PARTS, SPECIAL TOOLS, TMDE AND SUPPORT EQUIPMENT
Repair parts are listed and illustrated in parts information work packages (WP 0131 through WP 0160) of
(Chapter 9) in this TM. Maintenance Allocation Chart (MAC) is in (WP 0165).
END OF WORK PACKAGE
0001-6
TM 11-6115-742-13&P 0002
GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
TMSS-MED
EQUIPMENT DESCRIPTION AND DATA
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES
The TMSS-MED (Figure 1) is comprised of a trailer and soft-walled shelter. The trailer consists of an
Environmental Control Unit (ECU), Genset, and cargo bay (transports the shelter and accessories). The ECU
provides heating and cooling to the shelter. The Genset is designed primarily to power the ECU and secondarily
to power shelter lighting and utility outlets for operating AC electric devices. The shelter can be quickly erected in
the field providing an open interior command center, including lighting, heating/cooling, and mobile power
generation/distribution in support of many different configurations of Standard Integrated Command Post Systems
(SICPS) Platforms.
The TMSS-MED is designed for mobility and can be towed by a vehicle capable of pulling 4,200 lbs. The TMSS-
MED is transportable by vehicle, air, rail, or sea and can be loaded by crane and transported by aircraft.
Figure 1. TMSS-MED Configuration.
0002-1
TM 11-6115-742-13&P 0002
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
TMSS-MED Shelter
The TMSS-MED shelter (Figure 2) is composed of a frame with two pre-attached covers and end-caps. The
frame consists of an arrangement of various sized struts connected as pairs and articulated at the hubs. The
hubs enable the struts to move freely and allow for quick erect and strike. The interior and exterior cover fabric is
fire retardant, mildew resistant, and water repellent. The covers are also abrasion and UV resistant. The exterior
fabric enhances blackout in the visual and near infrared spectrum. Covers are pre-attached to the frame at the
hubs (via keepers) so that there is approximately one foot of dead air space between the covers and acts as
natural insulation. The covers are removable in the event of damage or change of mission. All TMSS-MED
shelters feature screen windows, conditioned air supply and return duct ports, wind lines, and ground staking
eyes.
(Exterior
Cover Removed
End Cap for clarity)
Interior Cover
Hub
Frame
Exterior Cover
ECU Duct Port
End Cap
Power Input
Keeper
(Typical)
ECU Duct
Port
Wind
Lines
(Typical)
Door (Typical)
Stakes
(Typical)
Figure 2. TMSS-MED Shelter Components.
0002-2
TM 11-6115-742-13&P 0002
TMSS-MED Trailer
The TMSS-MED trailer (Figure 3) consists of one 18 kW, 120/208 VAC, 3-Phase, 60 Hz, diesel engine Genset
and one 60,000 BTU/hour ECU mounted on a trailer chassis. The TMSS-MED Shelter and accessories are
added as cargo. A vehicle capable of pulling 4,200 lbs. can tow the trailer. The on-board Genset meets the noise
requirements for Tactically Quiet Generators.
Genset Cargo
Access
Panel
(Typical)
ECU
ECU
Control Genset
Panel Control
Panels
Circuit
Breakers
Power
Distribution
Panel
Trailer
D Fire Extinguisher
Inter-vehicular
Cable Assembly
Figure 3. TMSS-MED Trailer Major Components.
0002-3
TM 11-6115-742-13&P 0002
TMSS-MED Genset
The 18 kW Genset (Figure 4) consists of a four cylinder, liquid-cooled, 1,800 RPM, diesel engine coupled to a
single bearing, four-pole generator. The engine’s fuel is supplied from an in-chassis fuel tank. The Genset is
intended primarily to provide electric power to the ECU which in turn provides conditioned air (hot or cold) to the
shelter. The Genset can provide three main levels of output power:
1. The ECU draws near-maximum electric power from the Genset (approximately 18kW) when operating in high
heat mode. In this mode, there is only enough remaining electric power from the Genset for shelter lighting
(no BFA computers or peripheral equipment).
2. The ECU draws approximately 9kW of electric power (about one half max power) from the Genset when
operating in low heat or Air Conditioning (AC) mode. In either of these modes, there is approximately 9kW
electric power available from the Genset for shelter lighting and BFA computers and peripheral equipment.
3. The ECU draws no power from the Genset when it is not operating and the maximum 18kW of electric power
is available for secondary use.
NOTE
The Genset should not be operating when there is no electric load on it.
The Genset is housed in a weatherproof, acoustically insulated, aluminum enclosure. The enclosure contains the
Genset Control Panel, Power Distribution Panel, Circuit Breaker Panel, and Fuel Control Panel. Two 12 VDC,
non-spillable, maintenance-free batteries are use to operate the Genset.
Fuel
Control
Panel
Figure 4. TMSS-MED Genset.
0002-4
TM 11-6115-742-13&P 0002
TMSS-MED ECU
The ECU (Figure 5) provides 60,000 BTU/hour (5 tons) of cooling at 131°F (ambient air temperature) or 18 kW of
electrical heating. The ECU is designed to provide heating or cooling of the enclosed space created by deployed
shelters over an ambient temperature range of -50°F to 131°F. The TMSS-MED ECU has an additional fuel-fired
coolant heater that adds up to 17,000 BTU of heat capability for cold weather environments.
There are two different versions of the ECU. All specifications are the same except for the MODE SELECT
switch on the ECU Control Panel and the circuit breaker layout behind the control panel (see Figure 1 and
Figure 2, WP 0030). On version 1, the MODE SELECT switch has four settings (HEAT, OFF, FAN and COOL)
and uses maximum power (18 kW) provided by the Genset and has very little power available for other operations
such as laptops or communications equipment. On version 2, the MODE SELECT switch has five settings (HEAT
HIGH 18 kW, HEAT LOW 9 kW, OFF, FAN, and COOL). When utilizing the HEAT LOW 9 kW setting, the Genset
has 9kW of power available for other operations such as laptops or communications equipment.
Ducts
Damper
Assembly
Figure 5. TMSS-MED ECU.
TMSS-MED Cargo Bay
The cargo bay (Figure 6) provides 76 cubic feet of storage space for carrying the TMSS-MED shelter and its
accessories. The TMSS-MED shelter and contents are held in place during transit by a webbed cargo net.
Cargo
Net
Figure 6. TMSS-MED Cargo Bay.
0002-5
TM 11-6115-742-13&P 0002
TMSS-MED Chassis
The TMSS-MED trailer chassis (Figure 7) provides a sturdy mobile platform for the ECU and Genset to be
mounted, operated, and transported on. The cargo bay provides ample area for storage and transportation of the
shelter, PDU, lighting, and air ducts. There is one storage compartment for tools and auxiliary equipment. An
adjustable tongue jack is provided to raise and lower the tow ring (lunette) to pintle height and to level the trailer.
Figure 7. TMSS-MED Chassis.
TMSS-MED Power Distribution Unit (PDU)
The PDU (Figure 8) takes 208 VAC, 3Ø, 60 Hz, from the Genset and provides both 208 VAC, 3Ø, 60 Hz, and 120
VAC output. The outputs are circuit breaker protected and may be monitored by the voltmeter present on the
PDU.
Figure 8. TMSS-MED PDU.
0002-6
TM 11-6115-742-13&P 0002
TMSS-MED Tent Lighting Set
TMSS-MED tent lighting set (Figure 9) contains 120 VAC florescent lighting and a wiring kit (not shown). The
lighting provides ample task lighting for use in the TMSS-MED. The wiring kit provides the cabling and circuit
protection (surge protector) required for interconnectivity of the lighting.
Figure 9. TMSS-MED Tent Lighting Set.
DIFFERENCES BETWEEN MODELS
There are two TMSS-MED systems:
• Power Plant, Utility, PU-821/T, GREEN, NSN 6115-01-547-6713, is a green trailer and green shelter.
• Power Plant, Utility, PU-822A/T, TAN, NSN 6115-01-547-6738, is a tan trailer and tan shelter.
The Model differences have no effect on operation or maintenance functions. The Model/Series information for
the TMSS-MED trailer is found on the trailer data plate which is located on the roadside of the trailer on the trailer
tongue.
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EQUIPMENT DATA
Shelter Specifications
NOTE
Height listed below is for external dimension.
Specifications:
Dimensions (with-out end-caps) .......................... 200" L x 228" W x 216" H
(5.08 m L x 5.79 m W x 5.48 m H)
Dimensions (with end-caps) ................................ 328" L x 228" W x 216" H
(8.33 m L x 5.79 m W x 5.48 m H)
Doors/Boots ......................................................... 2 side doors (one per shelter side)
4 door blanks (two per end cap) for booting vehicle to shelter
Insulation Factor .................................................. R-3
2 2
Foot Print ............................................................ 442 ft (41.06 m )
Total Weight ......................................................... 633 lb (287.12 kg)
Packaging ............................................................ 3 cargo bags
Trailer Specifications
Specifications:
Dimensions ............................................................ 191" L x 85" W x 77.5" H
(4.85 m L x 2.16 m W x 1.97 m H)
Wheel Track .......................................................... 72" (1.83 m)
Ground Clearance
Unloaded ........................................................... 18" (0.46 m)
Loaded (Combat Load) ..................................... 16" (0.41 m)
Tow Ring (Lunette) Nominal Height ...................... 28" (0.71 m)
Weights: (Maximum)
Tare ................................................................... 3,500 lb (1,588 kg)
Gross................................................................. 4,200 lb (1905 kg)
Tongue (loaded with cargo) .............................. 420 lb (190.5 kg)
Cargo Area ............................................................ 41" D x 81" W x 45.5" H
(1.04 m D x 2.06 m W x 1.16 m H)
3 3
Cargo Area Capacity ............................................. 76 ft (2.4 m )
Noise Level (at 3 feet from the control panel)
with the ECU Off ............................................... 68.2 dBA
with the ECU On ............................................... 75.9 dBA
Electrical System ................................................... 24 VDC
Brakes
Primary .............................................................. Hydraulic surge brake with automatic breakaway actuator
Secondary ......................................................... Two independent, lever-operated mechanical parking
brakes
Axle........................................................................ Single
Suspension ............................................................ Torflex suspension rated at 6,000 lbs
Tires
Size ................................................................... Two 37 x 12.50 x 16.5 LT
Load Rating ....................................................... D, bias ply
Type .................................................................. Goodyear R/T II, run-flat
Inflation.............................................................. 20 psi (highway)/17 psi (off road)
Fuel Tank .............................................................. 16-gallon capacity, baffled
Maximum Speed when Towing Vehicles .............. 55 MPH
0002-8
TM 11-6115-742-13&P 0002
Genset Specifications
Specifications:
Dimensions ........................................................... 84" L x 34" W x 45.5" H
(2.13 m L x .86 m W x 1.15 m H)
Weight .................................................................. 1350 lbs. (612.35 kg)
Engine .................................................................. Four-cylinder, liquid-cooled, direct injection, 1800 RPM,
diesel
Ambient Temp
Minimum........................................................... -50ºF (-46ºC)
Maximum.......................................................... 140ºF (+60ºC)
Fuel
Type ................................................................. Diesel, JP8
Consumption .................................................... 1¼ gal/hr @ full load
Battery Capacity ................................................... 24 VDC
Lubricating Oil ...................................................... Capacity 8.6 qt. (8.13 liter)
Coolant ................................................................. Capacity 3.1 gal. (11.73 liter)
Generator ............................................................. Four-pole, single bearing generator rated for 18 kW at 125ºF
providing 120/208 VAC, 60 Hz, 3Ø power
Power Distribution Panel
120 VAC, 20 A, 1 phase receptacle ................. 2 ea
208 VAC, 60 A, 3 phase .................................. 2 ea
120 VAC, 4 A, battery charger receptacle ....... 1 ea
24 VDC NATO/slave receptacle ...................... 1 ea
ECU Specifications
Specifications:
Dimensions ........................................................... 64.9" L x 33.8" W x 38.3" H
(1.6 m L x 0.86 m W x 0.97 m H)
Weight .................................................................. 520 lbs. (235.86 kg)
Voltage / Phase / Hertz ........................................ 208 VAC / 3Ø / 60 Hz
24 VDC NATO/slave receptacle ........................... 1 ea
Minimum Power Factor ........................................ 0.90
Maximum Power Draw ......................................... 18 kW
Cooling output ...................................................... 60,000 BTU/hr at 125ºF
Heating output ...................................................... 60,000 BTU/hr electric heat
17,000 BTU fuel-fired auxiliary heater
Minimum Cooling Capacity................................... 60,000 BTU/Hr
Ducts .................................................................... 16" (.41 m) dia (supply and return)
Rated Ambient Temperature ................................ 125ºF (51.66ºC)
Ambient Temperature (Cooling)
Maximum.......................................................... 131ºF (55.0ºC)
Minimum........................................................... 40ºF (4.44ºC)
Ambient Temperature (Heating) Minimum ........... -50ºF (-45.55ºC)
Air Flow................................................................. 2400 CFM
Minimum Fresh Air Supply ................................... 280 SCFM
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PDU Specifications
Specifications:
Dimensions .......................................................... 16" L x 19" W x 19*.5" H
(0.41 m L x 0.48 m W x 0.49 m H)
Weight .................................................................. 30 lbs (13.6 kg)
Input Power .......................................................... 120/208 VAC, 3Ø, 60 Hz, 60A
Input Connector ................................................... 120/208 VAC, 3Ø, 5 wire, 60A, Male
Output Connections
120/208 VAC, 3 phase 5 wire, 60 A, Female ... 1 ea
Straight blade flange outlet 120 volt ................. 6 ea
Circuit Breakers
20 A GFI, single pole ........................................ 5 ea
30 A GFI, single pole ........................................ 1 ea
Voltmeter (0-150 VAC) ........................................ 1 ea
END OF WORK PACKAGE
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GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
TMSS-MED
THEORY OF OPERATION
TMSS MED Shelter
The TMSS-MED shelter consists of a frame with two pre-attached covers. The frame is made up of various sized
strut pairs and articulating hubs that enable the struts to move freely for quick erect and strike. Both the interior
and exterior covers are made with specially coated polyester fabrics, are fire retardant, mildew resistant, and
water repellent. The covers incorporate abrasion resistant and UV resistant fabrics. The exterior fabric finish
enhances blackout in the visual and near infrared spectrum. Both covers are pre-attached to the frame at the hub
points in such a way that there is approximately one foot of dead air space between the covers serving as natural
insulation. These covers are easily removable in the event of damage or change of mission.
The floor is made from a heavy-duty polyester material which provides a barrier against insects and vermin,
abrasions, and ground moisture. All TMSS-MED shelters feature screen windows, conditioned air (fresh, hot, and
cold) supply and return duct ports, wind lines, and ground stake eyes.
TMSS MED Generator Set
The 18 kW Generator Set consists of a four cylinder, liquid-cooled, 1800 RPM, Diesel engine coupled to a single
bearing, four-pole generator. The engine’s fuel is supplied from the in-chassis fuel tank. The Genset is housed in
a weatherproof, acoustically insulated, aluminum enclosure. The enclosure also contains the Genset Control
Panel, Power Distribution Panel, and two 12 VDC, non-spillable, maintenance-free batteries suitable for 24 VDC
engine starting. The Genset is intended primarily to power the ECU and secondarily to power shelter lighting and
utility outlets for operating AC electric devices.
TMSS MED ECU
The ECU, which operates off of 208 VAC, 3 Ø, 60 Hz, provides 60,000 BTU/hour (5 tons) of cooled air or 60,000
BTU/hr of hot air to the TMSS-MED Shelter. The ECU has an auxiliary fuel-fired heater that provides an
additional 17,000 BTU/hr hot air output for cold weather climates. Heat output can be regulated manually or by
auto returned air flow and temperature. A selector switch determines the mode of operation. Airflow is directed to
and returned from the shelter by way of insulated air ducts. The ECU is housed in a weatherproof, aluminum
enclosure that may be removed from the trailer and operated independent of the TMSS-MED trailer (requires an
external power source).
TMSS MED Trailer
The SICPS/TMSS Med trailer chassis consists of a six-inch structural steel frame with four tie-down rings and an
aluminum upper structure. The TMSS chassis is equipped with a hydraulic surge brake system, two hand-
operated parking brakes, two HMMWV standard tires, and a 16-gallon, in-chassis baffled fuel tank, fitted with a
four-inch diameter filler and a fuel level indicator. Two 24 VDC tail light assemblies are wired to a 12-pin plug for
connecting to the towing vehicle receptacle. An adjustable tongue jack is provided to raise and lower the tow ring
(lunette) to pintle height and to level the trailer. A storage post for attaching the dolly wheel/skid plate assembly
during towing is provided adjacent to the jack. There is one storage compartment for tools and auxiliary
equipment.
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TM 11-6115-742-13&P 0003
GENSET
NOTE
Refer to (Figures FO-6 to FO-11) for schematics of the Genset and its associated
electronic components.
Fault System
The fault system (Figure 1) protects the generator set against potential faults described below and provides an
indication of any incurred fault. The following summary of the fault system will assist in understanding the
operation of the generator set. Additional details relating to specific protection devices are provided in the
descriptions of the respective systems. The fault system consists of the following:
• Three malfunction indicators
• High temperature switch and relay (K4)
• Over speed switch and relay (K5)
• Low oil pressure switch and relay (K6)
• Governor control relay (K7) with time delay circuit
• BATTLE SHORT switch
Activation of the over temperature switch, over speed switch, or low oil pressure switch will cause it’s respective
relay to energize. Each relay has a normally closed and normally open contact. The normally closed contact of
the relay opens disconnecting the 24 VDC supply to the governor controller and the fuel pump resulting in
generator shutdown. The normally open contact closes illuminating the relay’s fault indicator lamp which is
located on the control panel.
High Temperature switch (HTS) - activates when the engine coolant leaving the engine exceeds 220 °F.
Over Speed Switch (SS) – activates when the engine speed exceeds 1900 rpm (approximately 64 Hz).
Low Oil Pressure Switch (LOPS) – activates when engine oil pressure drops below 20 psi.
The governor bypass relay (K7) has a four second Time Delay Relay (TDR) in its circuit. The time delay causes
the (K7) relay to bypass the high temperature relay (K4) and low oil pressure relay (K6) until the engine starts.
The (K7) relay also disconnects the alternator trigger until the four second delay completes.
To reset an activated fault indicator lamp the ENGINE selector switch needs to be set to OFF then the system can
be restarted to verify the malfunction has been corrected.
The BATTLE SHORT Switch can be activated before the generator set is started to bypass the fault protection
circuits and provide 24 VDC to the governor control module and fuel pump regardless of the malfunction.
0003-2
TM 11-6115-742-13&P 0003
Fault System – Continued
Battle Short
Switch
TDR Alternator
4s
GC Bypass GC Bypass
Relay Relay
(1/4) K7 (1/4) K7
Governor
Control (GC)
Engine High Temp Low Oil
Shutdown Engine Speed Pressure
Selector
Switch (HTS) Switch (SS) Switch (LOPS)
Switch
Fuel Pump
Engine Low Oil
High Temp
Over Speed Pressure
Relay (K4)
Relay (K5) Relay (K6)
Control Panel Malfunction Indicators
Figure 1. Genset Fault System.
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TM 11-6115-742-13&P 0003
Fuel System
NOTE
Refer to (Figure FO-12) a schematic of the Engine (hydronic) Heater.
The Fuel System is comprised of the engine fuel subsystem which provides fuel to the engine and a heater fuel
subsystem for the engines hydronic heater. An auxiliary fuel source, such as a 55 gallon drum of diesel, can be
used to supplement the fuel tank. The Fuel System (Figure 2) is comprised of the following components:
• Standard float type fuel gauge
• Fuel tank with source and return lines
• Auxiliary fuel line with return line
• In-line fuel heater
• Engine and hydronic heater fuel filters
• Two fuel pumps
• Four injector pumps
• Four fuel injectors
• Hydronic engine heater
With the ENGINE Selector Switch (SW3) set to START or RUN the fuel transfer pump is powered and draws fuel
from the fuel tank. After fuel reaches the injector pumps it is pressurized and forced into the fuel injectors. The
fuel is then sprayed by the injectors into the engine combustion chamber where it’s mixed with air and ignited.
The fuel that is not burned by the engine is returned to the fuel tank by an excess fuel return line. With the engine
running, the electrical governor controller adjusts the mechanical governor to maintain a steady metered flow of
fuel to the injection pumps. The EMERGENCY STOP button (SW7), located on the generator set circuit breaker
panel, can immediately shutdown the engine by causing the mechanical governor to halt fuel flow at the fuel
injector pump.
The in-line fuel heater is used for cold temperature operation. The FUEL LINE HEATER Switch (SW8), located
on the control panel, when actuated, ensures that the diesel fuel does not jell and clog the fuel filters. The in-line
fuel heater is a separate, battery-powered heater that is wrapped around the fuel lines to heat the fuel before it
reaches the engine and hydronic heater.
When the ENGINE HEATER Switch (SW6) is actuated, the hydronic heater fuel pump draws fuel from the fuel
tank. The fuel is converted to heat, raising the engine coolant above freezing in low temperature environments.
The four switches SW3, SW6, SW7, and SW8 provide the 24 VDC control logic and power needed to operate the
engine heater, fuel line heater, fuel pumps, and fuel injector pumps.
0003-4
TM 11-6115-742-13&P 0003
Fuel System – Continued
AUX
Fuel Source
Fuel
Gauge Fuel Tank
Fuel RTN
To ECU
In-line
Hydronic
Fuel Heater
Heater
24 VDC
Fuel Heater
Solenoid
Fuel Fuel
Filter Filter
Fuel RTN
Fuel Line
Heater Switch Fuel RTN
SW8
Fuel Pump Fuel Pump
24 VDC 24 VDC
Fuel Injector Mechanical
Hydronic
Pumps Governor
Heater
Engine
Actuator
Fuel
Injectors 24 VDC
24 VDC
(4X)
Electrical
Governor
Control
Engine Engine
Selector Heater
Switch SW6
SW3 Emergency
Stop
SW7
Figure 2. Fuel System.
0003-5
TM 11-6115-742-13&P 0003
Engine Heater System
NOTE
Refer to (Figure FO-12) a schematic of the Engine (hydronic) Heater.
The engine heater (Figure 3, Item 1) is a diesel fueled internal combustion heater that heats the cooling system
fluid and circulates this fluid through the battery heater tray (Figure 3, Item 2), through the water pump housing
(Figure 3, Item 3) and into the engine block (Figure 3, Item 4). The heated fluid exits at the rear of the engine
block (Figure 3, Item 4) into a mechanically operated thermostat shutoff housing (Figure 3, Item 5) before
returning to the engine heater (Figure 3, Item 1).
The thermostat shutoff (Figure 3, Item 5) operates in an opposite fashion as the engine coolant temperature
thermostat. A common engine coolant thermostat is spring loaded and is in the closed position until the engine
reaches a certain temperature at which time the spring opens and allows the coolant to flow from the water pump
(Figure 3, Item 3) to the engine block (Figure 3, Item 4). The engine heater thermostat is spring loaded and is
normally in the open position so that coolant can flow when the engine is cold. Once the engine coolant
temperature rises to a preset temperature, the spring closes and prevents any more fluid from circulating through
the engine heater circuit.
The engine block (hydronic) heater has its own built in fault system. A flashing light indicates a fault. Refer to
(Table 2 of WP 0011) for indicator fault code.
1
2
Legend
1 – Engine Heater
2 – Battery Heater Tray 4
3 5
3 – Water Pump Housing
4 – Engine Block
5 – Thermostat Shut-Off (mechanical)
= Flow
Figure 3. Engine Heater Flow Diagram.
The Fuel Line Heater is a separate, battery-powered heater that is wrapped around the fuel lines to heat the fuel
before it reaches the engine.
0003-6
TM 11-6115-742-13&P 0003
Engine Cooling System
The Engine Cooling System (Figure 4) consists of the following components:
• Radiator • Control panel COOLANT TEMP meter • Cooling jackets (part of engine)
• Thermostat • Water pump • Coolant high temperature switch
• Temperature sender • Belt driven radiator fan • Cutoff valve
The water pump forces the coolant through passages (cooling jackets) in the engine block and cylinder head
where the coolant absorbs heat from the engine. When the engine reaches normal operating temperature, the
thermostat opens and the heated coolant flows through the upper radiator hose assembly to the radiator. The
cooling fan circulates air through the radiator where the coolant temperature is reduced. A coolant high
temperature switch in conjunction with the fault system provides automatic fault shutdown in the event the coolant
temperature exceeds 180 +/- 3°F (82 +/- 2°C). The COOLANT TEMP meter indicates the engine coolant
temperature, from 100°F to 240°F (38°C to 115°C). When the engine is cold, coolant is also routed through a
cutoff valve to the heater. The coolant passes from the heater to the battery mounting plate and back into the
engine block. The cutoff valve is set to close when the coolant temperature exceeds 100°F (38°C).
Cooling Air
Radiator
Radiator
Cooling Battery
Fan Mounting
Plate
Coolant
Temperature
Meter
Water Engine
Pump (Hydronic)
Heater
Coolant
Temperature
Sender
Engine
Cooling Cutoff Valve
Jackets
Coolant High
Temperature
Switch
Thermostat
Fault
System
Figure 4. Engine Coolant System.
0003-7
TM 11-6115-742-13&P 0003
Engine Lubrication System
The Engine Lubrication System (Figure 5) consists of an oil sump, dipstick, oil pump, pressure relief valve, oil
pressure sender, OIL PRESSURE meter, low oil pressure switch, and filter. The oil sump is a reservoir for engine
lubricating oil. The dipstick indicates oil level in the sump. The oil level can only be checked when the engine is
not running. The pump draws oil from the sump through a strainer removing large impurities. A pressure relief
valve monitors oil pressure and shunts oil back into the sump to help relieve pressures in excess of 63.81 psi
(440 kPa). The oil then passes through a spin-on type filter where small impurities are removed. From the filter,
oil is distributed to the engine’s internal moving parts and returns to the oil sump. The oil pressure sender located
in the engine crankcase senses oil pressure. The oil pressure is displayed on the OIL PRESSURE Meter. The
low oil pressure switch, also located in the engine crankcase, functions with the generator set fault system. The
engine is automatically shut off if the oil pressure drops below 20 psi (138 kPa).
Engine Oil
Sump
Oil Pump
Pressure
Relief Valve
(440 kPa)
Oil
Pressure
Meter
Oil Filter
Oil Pressure
Sender
Engine
Moving
Parts
Low Oil
Pressure
Switch
Fault
System
Figure 5. Engine Lubrication System.
0003-8
TM 11-6115-742-13&P 0003
Power Generation/Supply System
The Power Generation/Supply System (Figure 6) consists of the following components:
• AC generator
• AC generator junction box
• Generator circuit breaker CB5 GEN
• Fuse bank
• VOLTAGE/AMMETER switch for monitoring individual phases
• Ammeter, voltmeter, frequency meter, and watts meter
• Load distribution terminal blocks
• Load output circuit breakers
• Power distribution connectors
Power (208 VAC, 3Ø, 60 Hz, 60 A) created by the AC generator is routed through a junction box to the main load
disconnect circuit breaker CB5 GEN. The switched 3 phase power from CB5 GEN is then routed to voltage
blocks L1 (black), L2 (red), and L3 (blue). The generators un-switched neutral and ground lines are routed
directly from the junction box to their respective terminal blocks. The terminal blocks act as a load distribution
point. Power is then distributed through circuit breakers CB1 J1, CB2 J2, CB3 J3, and CB4 J4 to interface load
connectors J1, J2, J3, and J4.
The CB5 GEN circuit breaker enables or interrupts the power to the load terminal blocks. The power is monitored
at the load side of the circuit breaker. Power from phase legs L1, L2, and L3 is passed through fuses F1, F2, and
F3 to the VOLT/AMP switch SW1. The SW1 switch transfers individual phases for monitoring on control panel
meters A-C AMPERES, HERTZ, and A-C VOLTS. Current transformers are used to sense the power flow
through the load side of CB5 GEN. The current transformers are used by a watts transducer which computes
power usage and displays it on the A-C KILOWATTS meter.
The AC generator voltage output is sensed by the voltage regulator circuit. The voltage regulator maintains the
generator output voltage by providing a DC control signal to the field terminals of the exciter. The AC generator
frequency is controlled by the governor control system, sensed by the frequency transducer and is read on the
HERTZ frequency meter. The circuit breakers in the circuit breaker panel disconnect the load whenever an
overload or short circuit exists. The critical operating parameters of the engine are monitored by the fault system
which shuts down the engine when a fault occurs and stops power generation.
0003-9
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Power Generation System - Continued
Fault
System
Governor
Control
AC
Generator
Voltage
Regulator
AC AC AC
HERTZ KWATTS
AMPS VOLTS
AC Generator Meter Meter
Meter Meter
Junction Box
Watts
Generator VOLT/AMP Tranducer
Circuit Breaker Switch
CB5 GEN
Fuse Bank
F1, F2, F3
Current
Transformers
Load Distribution Terminal Blocks
3Ø 1 Ø, L1 1 Ø, L2 3 Ø L1, L2, L3
L1, L2, L3
Circuit Circuit Circuit Circuit
Breaker Breaker Breaker Breaker
CB1 J1 CB2 J2 CB3 J3 CB4 J4
ECU Light/Utility Light/Utility Utility
J1 Connector J2 Connector J3 Connector J4 Connector
Figure 6. Output Supply System.
0003-10
TM 11-6115-742-13&P 0003
Barrier Panel
The barrier panel (Figure 7) is located behind the control panel and power distribution panel on the Genset. It
contains the electronic components used to control, regulate, and distribute the power generated by the Genset.
The barrier panel components consist of:
• Watt Transducer • Speed Sensor • Battery Charger
• Fuses • Precision Governor • Current Transformers
• Relays (K4-K7) • Circuit Breakers (CB1 through CB5) • Terminal Blocks
• Voltage Regulator
WATT MAIN OVERTEMP ENGINE MAIN
TRANSDUCER RELAY RELAY OVERSPEED RELAY
FUSES K7 TIMER K4 RELAY K6
K5
VOLTAGE PRECISION
REGULATOR GOVERNOR
SPEED CB1
SENSOR CB2
CB3
CB4
CB5
Ø (RED)
TERMINAL
BLOCK
Ø (BLACK)
TERMINAL
BLOCK
BATTERY
CHARGER
GROUND (GREEN) CURRENT NEUTRAL (WHITE)
TERMINAL BLOCK TRANSFORMERS TERMINAL BLOCK
Ø (BLUE)
TERMINAL BLOCK
Figure 7. Barrier Panel Component Location.
0003-11
TM 11-6115-742-13&P 0003
Governor Control System
The Governor Control System (Figure 8) consists of an electronic precision governor controller, electronic speed
switch, a speed sensor, electronic actuator control unit, mechanical governor, and emergency stop switch. The
speed sensor is a magnetic pickup coil. It registers the speed of the engine, which is typically 1800 rpm, as the
flywheel teeth pass within the field of the pickup coil. The speed sensor signal is monitored by an engine speed
switch. The signal is also used by the governor controller in a feedback control loop to regulate engine speed.
The governor controller regulates speed with a control signal applied to the actuator control unit. The electro-
mechanical actuator adjusts the control linkage to the injection fuel pump system in response to the governor
control signal. The EMERGENCY STOP switch, located on the control panel, shuts down the generator by
disconnecting the governor control signal to the actuator control unit, eliminating fuel to the injector pumps.
Voltage Regulation System
The voltage regulator senses 208 VAC between phase legs L1 to L3 of the generator. The control panel
VOLTAGE ADJUST potentiometer provides a means to adjust the generator field current, which is 70 amps
typically, to maintain the desired 208 VAC output voltage for different loads.
Magnetic
Pickup
Governor Speed
Controller Switch
Fault
System
EMERGENCY
STOP Switch
Actuator
Control
Unit
Mechanical
Control
Linkage
Fuel Injection
System
Figure 8. Governor Control System.
0003-12
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Battery Charging System
The battery charging system (Figure 9) consists of the following:
• Circuit breaker CB2 J2 • Two 12 VDC batteries
• Indicator lamps J2 and J5 • External battery charger input connector J5
• Fuse F8 • NATO/Slave connector J6
• Battery charger • Genset alternator
• BATTERY CHARGER AMPS meter • Battery Switch
For normal charging conditions the Genset alternator provides a DC charge to the battery. The battery charge is
also supplemented by a built-in battery charger when CB2 J2 is actuated. The battery chargers current can be
monitored on Genset control panel meter BATTERY CHARGE AMPS. The battery can also be charged through
the battery charger with the Genset shut down. An external 120 VAC input can be applied to J5 INPUT connector
to provide power, thereby preventing battery freeze-up in cold climates. The battery charge can be monitored at
control panel meter BATTERY CHARGE AMPS for this condition. For an emergency situation external power can
be applied directly to the battery through the NATO/Slave connector J6. The BATTERY SWITCH should be OFF
when connecting or disconnecting the input to J6 and ON when charging the battery.
Circuit
Breaker
CB2 J2
1Ø, L1
J2 & J5
Light/Utility J5 Input
Indicator
J2 Connector Connector
Lamps
1Ø, External
Source
Fuse F8
J6 Connector Battery
24 VDC Charger
NATO/Slave
DC Output
Battery
Battery Charger
Meter Alternator
Switch
Battery
Figure 9. Battery Charging System.
0003-13
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ENVIRONMENTAL CONTROL UNIT
Power Distribution/Fault System
The Power Distribution/Fault System (Figure 10 for Version 1 or Figure 12 for Version 2) distributes power and
protects the ECU against potential faults. The following summary of the system and its components will assist in
understanding the operation of the ECU in cooling or heating mode. The summary also provides a description of
any fault indicators.
The system consists of the following:
• 24 Volt power supply
• Phase sensing relay
• Two motor starter protectors
• Time delay relay
• Heater and compressor contactors
• High temperature cutout
• High and low pressure cutout switches
Refer to (Figure 10 for Version 1 or Figure 12 for Version 2) to locate the system components.
A 24 volt power supply consisting of 208/24 volt step down transformer (TX1) provides a 24 VAC control voltage
to the protective relays and fault sensors. The 24 VAC is also converted to 24 VDC by a bridge rectifier (BR) to
supply power to the auxiliary heater.
The Phase Sensing Relay (PSR) detects an out of phase condition when incoming power wires are connected in
the wrong order. During an out of phase condition, the normally open relay contact remains open removing the
24 VAC control voltage to the contactors and motor starter protectors, disabling the ECU. The normally closed
relay remains closed applying 24 VAC to the Out of Phase Indicator (OPL), turning it red.
The Condenser Motor Starter Protector (CMSP) and Evaporator Motor Starter Protector (EMSP) enable the fan
motors to draw large turn-on surge current without tripping a circuit breaker. A Time Delay Relay (TDR) turns on
the compressor starter 15 seconds before power is applied to the compressor.
The Compressor Contactor (CCR) and Heater Contactor (CHT) apply line voltages to the compressor and heater
units. During normal operation the 24 VAC control voltage actuates the contactors. When a fault occurs, large
current flows to the motor through the overload heater elements in the contactor. The elements heat up and
cause the normally-closed contacts to spring open. This will de-energize the contactor relay and shut off power to
the motor. After the contactor heater cools down, it can be reset manually to re-apply power to the motor.
The High Temperature Cutout (HTC) switch is a protective thermostat located in the evaporator enclosure. The
HTC acts as a safety to cut off power to the heater coils and blower motor if the temperature in the enclosure
exceeds 190 °F. Two causes for excessive temperatures is blockage of airflow through the evaporator enclosure
or a fan failure.
The High Pressure Cutout (HPC), located at the discharge side of the compressor protects the high pressure side
of the refrigerant system. The HPC switch shuts down the compressor by removing the 24 VAC control signal
from the compressor contactor when the pressure exceeds the preset value of the switch. The HPC has a
manual reset button.
The Low Pressure Cutout (LPC) is located on the suction side of the compressor. The LPC switch shuts down
the compressor by removing the 24 VAC control signal from the compressor contactor when the pressure falls
below the preset value of the switch.
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TM 11-6115-742-13&P 0003
CIRCUIT
CONTROL BREAKERS
TRANSFORMER PHASE SENSING TIME DELAY
RELAY RELAY
TX1 CB1 CB2 CB3 PSR TD
BRIDGE POWER
BR TB PDB-2 PDB-1
RECTIFIER DISTRIBUTION
BLOCK
S3S4
THERMOSTAT
EMSP EMSP CCR CHT GB
TERMINAL
BLOCK
GROUND BAR
CONDENSOR EVAPORATOR COMPRESSOR HEATER
MOTOR STARTER MOTOR STARTER CONTACTOR CONTACTOR
PROTECTOR PROTECTOR
Figure 10. ECU (Version 1) Control Panel Component Location.
0003-15
TM 11-6115-742-13&P 0003
Genset
3Ø
Evaporator Condenser
Motor Starter Motor Starter CB3 CB2
Protector Protector
Time High Low
Evaporator Condenser 24V Power
Delay Pressure Pressure
Fan Motor Fan Motor Supply
Relay Cutout Cutout
24 VAC 24 VDC
Phase
Heater Compressor Sensing CB1
Contactor Contactor Auxiliary
Relay Heater
18 kW
Electric Compressor
Heater Motor
Out-Of
Phase
Light
High Mode
Temperature Temp Selector
Controller Cutout Switch
Figure 11. Power Distribution/Fault System (Version 1).
0003-16
TM 11-6115-742-13&P 0003
CIRCUIT
BREAKERS
CONTROL
TRANSFORMER
TX1 CB1 CB2 CB3 CB4 CB5
PHASE SENSING
RELAY
TIME DELAY
RELAY
BRIDGE BR TB PSR TD PDB-1
RECTIFIER POWER
S3S4
DISTRIBUTION
BLOCK
THERMOSTAT
CHT CHT
EMSP EMSP CCR LOW HIGH GB
TERMINAL
BLOCK
GROUND BAR
CONDENSOR EVAPORATOR COMPRESSOR HEATER HEATER
MOTOR STARTER MOTOR STARTER CONTACTOR CONTACTOR CONTACTOR
PROTECTOR PROTECTOR (LOW) (HIGH)
Figure 12. ECU (Version 2) Control Panel Component Location.
0003-17
TM 11-6115-742-13&P 0003
Genset
3Ø
Evaporator Condenser
Motor Starter Motor Starter CB2 CB3 CB4 CB5
Protector Protector
24V Power Compressor Heater Heater
Evaporator Condenser Contactor Contactor
Fan Motor Supply Contactor
Fan Motor (Low) (High)
24 VAC 24 VDC
9 kW 9 kW
CB1 Auxiliary Compressor Electric Electric
Heater Motor Heater Heater
Time
Delay
Relay
Mode Phase Low High
Selector Sensing Pressure Pressure
Switch Relay Cutout Cutout
High Out-Of
Temp Phase
Cutout Light
Temperature
Controller
Figure 13. Power Distribution/Fault System (Version 2).
0003-18
TM 11-6115-742-13&P 0003
Heating System
NOTE
Refer to (Figures FO-1 and FO-2) for electrical schematic and wiring diagrams of
the ECU (Version 1). Refer to (Figures FO-3 and FO-4) for electrical schematic
and wiring diagrams of the ECU (Version 2).
The Heating System consists of the following:
ECU (Version 1)
• Temperature Control • Evaporator blower fan
• CB3 power to 18 kW heater coil and • Baffle
compressor motor
• Heater contactor
ECU (Version 2)
• Temperature Control • Heater contactor, low
• CB3 power to compressor motor • Heater contactor, high
• CB4 power to 9 kW heater coil, low (V2) • Evaporator blower fan
• CB5 power to 9 kW heater coil, high (V2) • Baffle
The temperature control is set by the operator and senses the air temperature in the return duct. It applies a
24 VAC control line to the appropriate contactor for heating or cooling to maintain the operator setting.
For the Version 1 (V1) ECU, CB3 supplies power to both the 18 kW heater coil and compressor motor. The
Heater Contactor (CHT) switches the line power to the coil when demanded by the 24 VAC control line.
For the Version 2 (V2) ECU, CB3 supplies power to the compressor motor. CB4 and CB5 supply power to the
9 kW low heat and 9kW high heat coils respectively. Heater Contactor (CHT) Low switches line power to the low
heat coil and CHT High switches power to the high heat coil. When the Mode Select Switch (MSS) is set to High
Heat both coils are switched on to supply 18 kW heat.
The evaporator blower fan is a one speed blower. It forces warmed air through the duct work during the heat
mode and cooled air when in cool mode. The baffle is located on the intake duct. Since the blower is a one
speed fan the baffle is used to regulate air flow across the heater coils. Closing the baffle will cause greater heat
transfer from the coils and increases heat output.
Auxiliary Heater System
The Auxiliary Heating System consists of the following:
• Hydronic heater • Mode select switch
• Hydronic heater radiator • Built-in self test
• Auxiliary heater switch
The auxiliary heater is a hydronic heater located in the condenser enclosure. It provides additional heat for
extreme cold weather. The heater burns diesel fuel supplied by the generator fuel tank to warm a hot water
radiator. It operates in either manual or automatic mode according to the AUXILIARY HEATER select switch.
The Mode Select Switch (MSS) determines how the heater operates in conjunction with the main heating and
cooling systems. With the MSS switch set to HEAT (V1) or HEAT LOW/HIGH (V2) the auxiliary heater can be
used to provide additional heat to the TMSS-MED shelter. With the MSS switch set to OFF the heater can be
used to thaw out the evaporator motor in extreme cold weather operation. The auxiliary heater is disabled when
the MSS switch is set to COOL.
The auxiliary heater has built-in circuits to continually monitor operation. In the event of an operational failure a
flash code is generated and displayed on the AUXILIARY HEAT switch. Refer to (Table 2, WP 0030) for a list of
the fault indications.
0003-19
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Cooling System (Refrigeration)
NOTE
Refer to (Figure FO-5) for a refrigeration schematic of the ECU.
The components of cooling system and their interaction are described below. Use refrigeration schematic (FO-5)
to identify components and trace fluid flow. The refrigeration components of the cooling system consist of the
following:
• Compressor • Filter/Dryer • Solenoid valve
• Vibration isolators • High pressure relief valve • Thermal expansion valve and distributor
• Condenser fan • Service port (Hi & Lo) • Evaporator fan
• Condenser coils • Sight glass • Evaporator coils
• Quench valve • Hot gas-bypass valve
The Compressor (CMP) compresses refrigerant in the closed system. The pressure differential across the low
pressure suction side and high pressure discharge side causes circulation. The Vibration Isolators (VI) decrease
stress on the copper refrigerant lines created by transmission of compressor induced vibration. The input and
output lines are also protected by high pressure and low pressure cutoff switches which shut down the
compressor in the event of a pressure fault.
The Condenser Fan (CF) draws cool ambient air into the condenser enclosure. The air is then passed through
and warmed by the Condenser Coils (CC). The fan then forces the warm air to exit through the coils. The
condensation process converts the high pressure gas into a high pressure liquid.
The liquid refrigerant from the condenser passes through a Filter/Dryer (F/D) which removes any water vapor or
debris. The F/D stops contaminants from clogging the Thermal Expansion Valve and Distributor (TEV/D). The
TEV/D allows fluid to enter the evaporator at a controlled pressure. It meters the flow of high pressure liquid
refrigerant, so the evaporator coils can maintain the correct amount of refrigerant required for the superheat
process. The TEV/D valve is regulated by a sensing bulb that is attached to the output of the evaporator (suction
side). The sensing bulb must maintain good thermal contact with the suction line for accurate operation. The
bulb is also insulated to provide more accurate feedback.
A High Pressure Relief Valve (HPRV) is located downstream of the F/D before the high pressure service port.
The HPRV acts as a safety to vent fluid from the system, releasing pressure before the bursting point of the
copper tubing is reached. Since the copper utilized in the refrigeration system has a 600 lb bursting pressure
rating the HPRV valve is set to open at 550 psig.
The Sight Glass (SG) provides a window into the liquid flow where service personnel can observe fluid condition.
Bubbles occurring in the SG are one indication of an ECU failure.
The Solenoid Valve (SV) is opened and closed by the temperature controller allowing fluid to enter the
evaporator. It is part of a feedback loop between the temperature controller and the temperature sensor located
in the duct leading to the TMSS-MED shelter.
The evaporator fan, more appropriately called supply fan, operates in both cool and warm modes. For cool mode,
warm shelter air is cooled by the evaporator coils and blown back into the shelter by the fan. For warm mode,
cool shelter is warmed by the heater elements and forced back into the shelter. The evaporator coils are
constructed of copper tubing with series of soft aluminum fins attached to increase heat transfer. As refrigerant
passes through the coils, it absorbs heat from the surrounding air thereby cooling it. Another result of the transfer
process is lower refrigerant pressure with a return to the gaseous state. A low pressure service port is located on
the suction side of the evaporator coils between the evaporator and compressor.
0003-20
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Cooling System (Refrigeration) – Continued
The Hot Gas Bypass Valve (HGBV) is a pressure actuated mechanical valve. It keeps the pressure from
dropping to low, on the suction side, and requiring long compression cycles to bring the pressure back up, on the
discharge side. The valve is regulated by an equalization line that is attached to the low pressure line. A drop in
pressure within the low pressure line, below 55 psig, causes the valve to open. The valve then allows hot
compressed gas, from the discharge line of the compressor, to bypass the condensing and evaporator coils and
return to the low pressure line directly.
The Quench Valve (QV) is controlled by both a temperature sensing bulb and pressure equalization line. When
the valve is opened, cool refrigerant from condenser is allowed to mix with the hot bypass gas. The sensing bulb
opens the valve when the superheat value of 20°F is reached. The equalization line then regulates how far to
open the valve to maintain the superheat value.
TRAILER
Hydraulic Brake System
The hydraulic brakes are controlled by a surge actuator system. The rolling momentum of the trailer forces the
surge actuator to compress during braking. The actuator applies pressure to the hydraulic cylinder synchronizing
the towing vehicle and trailer brakes. The actuator also applies the brakes if the trailer breaks away from the
towing vehicle.
The Hydraulic Brake System consists of the following:
• Hydraulic brake actuator assembly
• Hydraulic brake tube assemblies
• Brake hose assembly
• Wheel brake components
The major components of the hydraulic brake system and their functions are as follows:
Lunette Ring - attaches to the towing vehicle pintle hook. The lunette ring controls the master cylinder assembly.
When the towing vehicle goes forward, the lunette ring is pulled and the brakes are released. When the towing
vehicle slows down, the weight of the trailer pushes the lunette ring into the towing vehicle and the brakes are
applied.
Master Cylinder Assembly – changes mechanical motion of the lunette ring and breakaway lever into hydraulic
pressure. It has a built in shock absorber to prevent jerky lunette ring movement. The damper also slows the rate
of the hydraulic pressure increase when the towing vehicle backs up, thus allowing the trailer to be slowly backed
up for short distances on level terrain.
Breakaway Chain – attaches to towing vehicle. It will pull the breakaway lever up if the trailer and the towing
vehicle uncouple.
Breakaway Lever – controls the master cylinder. When the lever is up, the brakes are applied. When it is down,
the lunette controls the master cylinder.
Leaf Spring – holds the breakaway lever up. The breakaway lever must be reset any time it has been pulled up.
Hydraulic Brake Tubes and Hoses – transfer hydraulic pressure from the master cylinder assembly to the wheel
cylinder.
Wheel Cylinder – changes hydraulic pressure into mechanical motion. When the wheel cylinder is pressurized, it
pushes the brake shoes against the brake drum.
END OF WORK PACKAGE
0003-21/22 blank
TM 11-6115-742-13&P
CHAPTER 2
OPERATOR INSTRUCTIONS
FOR
TMSS-MED
TM 11-6115-742-13&P 0004
OPERATOR INSTRUCTIONS
TMSS-MED
DESCRIPTION AND USE OF OPERATOR CONTROLS, INDICATORS, AND CONNECTORS
GENERAL
This work package contains illustrations and tables that describe the location and function of each control,
indicator, and connector used for operation of TMSS-MED Trailer. Each major panel is shown in detail in
(Figures 1 through 7) and their functions described in associated tables.
GENSET CONTROL PANEL (TOP PANEL)
1 2 3 4 5 6 7 8 3 9 10 1
40 60
80 58 60 62 10 20 2 10 0 150 200 2
20 5 5 50 50
10 65 30 30
0 0 50 0 0 0
11
12
00000
13
21
20 19 18 17 16 15 14
Figure 1. Genset Control Panel (Top Panel) – Controls, Indicators, and Connectors.
Table 1. Genset Control Panel (Top Panel) – Controls, Indicators, and Connectors.
CONTROLS, INDICATORS, AND
ITEM FUNCTION
CONNECTORS
1 Panel Latch Enables access to electrical enclosure behind Control Panel
FOR AUTHORIZED TECHNICIANS ONLY.
2 A-C AMPERES meter Indicates current drawn (Amps) from Genset.
3 Panel lights Two panel lights illuminate Genset Control Panel.
4 DC VOLTS meter Indicates 16-36 VDC voltage from battery system.
5 HERTZ meter Indicates operating frequency (Hz) generated by Genset.
6 COOLANT TEMP meter Indicates engine coolant temperature.
0004-1
TM 11-6115-742-13&P 0004
Table 1. Genset Control Panel (Top Panel) – Controls, Indicators, and Connectors – Continued.
CONTROLS, INDICATORS, AND
ITEM FUNCTION
CONNECTORS
7 A-C KILOWATTS meter Indicates power draw on Genset.
8 HOURMETER Total Hours Accumulated - Indicates total operating hours of
engine.
9 OIL PRESSURE meter Indicates engine oil pressure in pounds per square inch (psi).
10 A-C VOLTS meter Indicates operating voltage (V) generated by Genset.
11 BATTERY CHARGER AMPS meter Indicates rate of charging current to battery system from
Genset.
12 FUEL LINE HEATER switch Pre-heats engine fuel for operation in cold weather climates
where ambient temperatures are below 0°F (-17.77°C).
13 ENGINE HEATER switch Starts auxiliary engine block heater within Genset for cold
weather starting down to -50ºF (-45.55°C).
ENGINE HEATER flashes - A engine heater (hydronic) fault is
present. For indicator functions see (Table 2 in WP 0012).
14 VOLTAGE ADJUST potentiometer Enables manual adjustment of Genset output voltage.
15 ENGINE selector switch Four-position switch controls engine operation.
PREHEAT - allows cold engine glow plugs to warm up before
attempting to start engine.
OFF - Shuts down engine.
RUN – Allows engine to run once glow plugs have warmed up.
START – Energizes engine once glow plugs have warmed up.
16 LOW OIL PRESSURE light Illuminates red if engine shuts down on low oil pressure.
17 OVERSPEED light Illuminates red if engine shuts down from an over-speed
condition.
18 HIGH COOLANT TEMP light Illuminates red if engine shuts down from high coolant
temperature.
19 PANEL LIGHT switch Turns on panel lights. Turns off lights when released.
20 VOLT/AMP select switch Four-position switch selects any two legs of Genset output for
AC Ammeter and Voltmeter readings.
OFF – Disconnects A-C AMPERES and A-C VOLTS meters
from circuit.
L1/L2 – Allows the A-C AMPERES and A-C VOLTS meters to
indicate current and voltage present between legs L1 and L2.
L2/L3 – Allows the A-C AMPERES and A-C VOLTS meters to
indicate current and voltage present between legs L2 and L3.
L3/L1 – Allows the A-C AMPERES and A-C VOLTS meters to
indicate current and voltage present between legs L1 and L3.
21 BATTLE SHORT switch Overrides system shutdown protection devices to keep Genset
operating.
0004-2
TM 11-6115-742-13&P 0004
GENSET CONTROL PANEL (BOTTOM PANEL)
NOTE
The door covering the circuit breakers has been removed for clarity.
1 2 3 4 5
EMERGENCY
CB1 CB2 CB3 CB4 CB5
OFF ON EMERGENCY
SHUTDOWN
PRE SS I N TO E NG AGE
TURN CLOCKWI SE TO RES ET
J1 J2 J3 J4 GEN
BATTERY SWITCH
STOP
7 6
Figure 2. Genset Control Panel (Bottom Panel) – Controls, Indicators, and Connectors.
Table 2. Genset Control Panel (Bottom Panel) – Controls, Indicators, and Connectors.
CONTROLS, INDICATORS, AND
ITEM FUNCTION
CONNECTORS
1 CB1 J1 circuit breaker 3-Pole 60A protects ECU from over-power conditions.
2 CB2 J2 circuit breaker 1-Pole 20A protects 120 VAC outlet J2 at Power Distribution
Panel.
3 CB3 J3 circuit breaker 1-Pole 20A protects 120 VAC outlet J3 at Power Distribution
Panel.
4 CB4 J4 circuit breaker 3-Pole 30A protects additional load from over-power conditions.
5 CB5 GEN circuit breaker 3-Pole 90A protects loads connected to Genset from over-
power.
6 EMERGENCY STOP button. Push button immediately shuts down Genset.
7 BATTERY SWITCH OFF – ON switch disconnects battery power to control panel.
0004-3
TM 11-6115-742-13&P 0004
GENSET POWER DISTRIBUTION PANEL
NOTE
The old version of the Power Distribution Panel is covered in (Figure 3 and
Table 3. For updated version, refer to (Figure 8 and Table 8).
1 2 1 3 1 4 1 5
J1 J4
120/208 VOLTS J2 J3 120/208 VOLTS
120 VOLTS 120 VOLTS 30 AMPERES
60 AMPERES 20 AMPERES
20 AMPERES
J5 J6
120 VOLTS 24 VOLTS
INPUT
DC
7 6
Figure 3. Power Distribution Panel – Controls, Indicators, and Connectors.
Table 3. Power Distribution Panel – Controls, Indicators, and Connectors.
CONTROLS, INDICATORS, AND
ITEM FUNCTION
CONNECTORS
1 Amber indicator lamps (Blackout) Push-to-test indicates power is present at the
respective receptacle.
2 J1 120/208 VOLTS 60 AMPERES Provides generator power for ECU.
receptacle
3 J2 120 VOLTS 20 AMPERES Provides AC power for shelter lighting and utility outlets.
receptacle
4 J3 120 VOLTS 20 AMPERES Provides AC power for shelter lighting and utility outlets.
receptacle
5 J4 120/208 VOLTS 30 AMPERES Provides AC power outlet for general use.
receptacle
6 J6 24 VOLTS DC receptacle NATO/Slave receptacle accepts 24 VDC power for emergency
starting from an external source or provides 24 VDC power to an
external requirement.
7 J5 120 VOLTS INPUT receptacle Allows battery charging from a 120 VAC external source. The
five foot battery charger cable connects to this receptacle.
0004-4
TM 11-6115-742-13&P 0004
FUEL CONTROL PANEL
1 2 3 4
TRAILER
AUXILIARY
OFF AUX
AUX ILIARY
FUEL SUPPLY FUEL RETURN
FUEL SUPPLY
Figure 4. Fuel Control Panel – Controls, Indicators, and Connectors.
Table 4. Fuel Control Panel – Controls, Indicators, and Connectors.
CONTROLS, INDICATORS, AND
ITEM FUNCTION
CONNECTORS
1 AUXILIARY FUEL SUPPLY Quick connect/disconnect fitting and bulb primer to deliver fuel
connector from external source.
2 AUXILIARY FUEL RETURN Quick connect/disconnect fitting to maintain static air pressure
connector within fuel system and external fuel source.
3 FUEL SUPPLY switch Three position switch which closes fuel supply or selects fuel
supply source.
OFF position if fuel system is being serviced or if engine is not
going to be run for an extended period of time.
TRAILER position if engine is to run from trailer fuel tank.
AUX position if engine is to run from an auxiliary fuel supply.
4 Filler cap Covers pipe for putting fuel into fuel tank.
0004-5
TM 11-6115-742-13&P 0004
FUEL GAUGE
1/2
1/4 3/4
E F
Figure 5. Fuel Gauge – Controls, Indicators, and Connectors.
Table 5. Fuel Gauge – Controls, Indicators, and Connectors.
CONTROLS, INDICATORS, AND
ITEM FUNCTION
CONNECTORS
1 Fuel Gauge Gives indication of fuel present in Genset fuel tank.
0004-6
TM 11-6115-742-13&P 0004
ECU CONTROL PANEL
1 2 3
OUT OF
POWER ON PHASE
ENM
HOURS 1/10
TEMPERATURE
MODE SELECT
HEAT HIGH
AUXILIARY HEAT 18KW
OFF
MANUAL AUTO HEAT LOW
9KW
OFF
FAN
COOL
6 5 4
Figure 6. ECU Control Panel – Controls, Indicators, and Connectors.
Table 6. ECU Control Panel – Controls, Indicators, and Connectors.
CONTROLS, INDICATORS, AND
ITEM FUNCTION
CONNECTORS
1 Hour-meter Indicates total number of run-time hours on ECU.
2 POWER ON indicator light Illuminates green when power is present in the unit.
3 OUT OF PHASE indicator light Illuminates red when power source (i.e. Genset, shore power) is
incorrectly phased.
4 MODE SELECT switch Five-position switch selects mode of operation.
HEAT HIGH/18KW - Provides heated air to be circulated through
the ducts. Draws near maximum electrical power from the
Genset.
HEAT LOW/9KW - Provides heated air to be circulated through
the ducts. Draws approximately one-half maximum electrical
power from the Genset.
OFF - De-energizes the ECU.
FAN - Provides fresh air only through the ducts.
COOL - Provides conditioned air to be circulated through the
ducts. The ECU draws approximately one-half maximum
electrical power from the Genset.
0004-7
TM 11-6115-742-13&P 0004
Table 6. ECU Control Panel – Controls, Indicators, and Connectors – Continued.
CONTROLS, INDICATORS, AND
ITEM FUNCTION
CONNECTORS
4 MODE SELECT switch Certain models have a four-position switch (HEAT-OFF-FAN-
(cont.) COOL) that selects mode of operation. Their functions are:
Four-position switch selects mode of operation.
HEAT – Selects heat mode of ECU utilizing 18 KW of power from
the Genset.
OFF – De-energizes the ECU.
FAN – Provides fresh air only through the ducts.
COOL – Provides conditioned air to be circulated through the
ducts. The ECU draws 18 KW of power in this mode.
5 AUXILIARY HEAT indicator/switch Three position switch which selects mode of operation.
light
MANUAL – Continuous heat to shelter.
OFF – No heat to shelter.
AUTO – Thermostatically controlled heat to shelter.
AUXILIARY HEAT flashes - A hydronic heater fault is present.
See indicator functions (Table 2 in WP 0011 or WP 0030).
6 TEMPERATURE dial Allows operator to manually regulate shelter interior temperature.
0004-8
TM 11-6115-742-13&P 0004
PDU CONTROL PANEL
2 3
V OLTME TE R
AC
VOLTS
O
L1 L2
L3
5
16 P DU-F EE D THRUPO WER DI ST RI BUTIO N BOX
6
CB1 CB2 CB3 CB4 CB5 CB6
15 P1 P2 P3 P4 P5 P6
14 13 12 11 10 9 8
Figure 7. PDU Control Panel – Controls, Indicators, and Connectors.
Table 7. PDU Control Panel – Controls, Indicators, and Connectors.
CONTROLS, INDICATORS,
ITEM FUNCTION
AND CONNECTORS
1 AC VOLTS meter Indicates operating voltage of selected phase (L1, L2, L3).
2 J1 INPUT POWER 120/208 VAC Provides connection for input of 208 VAC into PDU.
3 PHASE connector
3 J2 OUTPUT POWER 120/208 Provides connection for output of 208 VAC.
VAC 3 PHASE
4 VOLTMETER select switch Voltmeter selector switch selects phase (L1, L2, L3) to be
measured by AC VOLTS meter.
5 P3 120 VOLTS 30 AMPERES Provides connection for output of 120 VAC when CB1 is energized.
connector
0004-9
TM 11-6115-742-13&P 0004
Table 7. PDU Control Panel – Controls, Indicators, and Connectors – Continued.
CONTROLS, INDICATORS,
ITEM FUNCTION
AND CONNECTORS
6 P4 120 VOLTS 20 AMPERES Provides connection for output of 120 VAC when CB4 is energized.
connector
7 CB6/P6 circuit breaker Single pole 20A GFI circuit breaker for output load protection of P6.
8 CB5/P5 circuit breaker Single pole 20A GFI circuit breaker for output load protection of P5.
9 CB4/P4 circuit breaker Single pole 20A GFI circuit breaker for output load protection of P4.
10 P6 120 VOLTS 20 AMPERES Provides connection for output of 120 VAC when CB6 is energized.
connector
11 P5 120 VOLTS 20 AMPERES Provides connection for output of 120 VAC when CB5 is energized.
connector
12 CB3/P3 circuit breaker Single pole 30A GFI circuit breaker for output load protection of P3.
13 CB2/P2 circuit breaker Single pole 20A GFI circuit breaker for output load protection of P2.
14 CB1/P1 circuit breaker Single pole 20A GFI circuit breaker for output load protection of P1.
15 P2 120 VOLTS 20 AMPERES Provides connection for output of 120 VAC when CB2 is energized.
connector
16 P1 120 VOLTS 20 AMPERES Provides connection for output of 120 VAC when CB1 is energized.
connector
17 Indicator light Each connector has a light which illuminates when power is present
(not shown) at connector.
0004-10
TM 11-6115-742-13&P 0004
GENSET POWER DISTRIBUTION PANEL – (UPDATED VERSION)
1 2 1 3 1 4 1 5
J1 J4
J2 J3 120/208 VOLTS
120/208 VOLTS
120 VOLTS 120 VOLTS 30 AMPERES
90 AMPERES
20AMPERES 20AMPERES
J5 J6
120 VOLTS
INPUT 24 VOLTS DC
7 6
Figure 8. Power Distribution Panel - Controls, Indicators, and Connectors (Updated Version).
Table 8. Power Distribution Panel - Controls, Indicators, and Connectors (Updated Version).
CONTROLS, INDICATORS, AND
ITEM FUNCTION
CONNECTORS
1 Amber indicator lamps with (Blackout) Swivel-to-test indicates power is present at respective
blackout covers receptacle.
2 J1 120/208 VOLTS 90 AMPERES Connects generator to ECU.
receptacle
3 J2 120 VOLTS, 20 AMPERES Provides AC power for shelter lighting and utility outlets.
receptacle
4 J3 120 VOLTS, 20 AMPERES Provides AC power for shelter lighting and utility outlets.
receptacle
5 J4 120/208 VOLTS, 30 AMPERES Provides AC power for general use.
receptacle
6 J6 24 VOLTS DC receptacle NATO/Slave receptacle accepts 24 VDC power for emergency
starting from an external source or provides 24 VDC power to an
external requirement.
7 J5 120 VOLTS INPUT receptacle Allows battery charging from a 120 VAC external source. The
five foot battery charger cable connects to this receptacle.
END OF WORK PACKAGE
0004-11/12 blank
TM 11-6115-742-13&P 0005
OPERATOR INSTRUCTIONS
TMSS-MED
OPERATION UNDER USUAL CONDITIONS
INITIAL SETUP:
Tools and Special Tools References
Field repair kit WP 0004, WP 0006, WP 0009,
WP 0010, WP 0011, WP 0019,
Personnel Required WP 0030
Four to six
GENERAL
The following WP covers site selection, setup, and initial power-up procedures of the TMSS-MED shelter and
trailer system. The manual also covers power-down, teardown, and storing of the system.
SECURITY MEASURES FOR ELECTRONIC DATA
Follow the security measures described in AR 25-2, Information Assurance, to control access to classified
electronic data. For the TMSS-MED system, follow the procedures described in the current version of the User
Security Manual/Standard Operating Procedure (USM/SOP).
SITE REQUIREMENTS
To ensure minimal problems and good operation of the TMSS-MED system, ensure area is:
• Dry
• Level with minimum clearing of 39 feet (11.88 meter) x 39 feet (11.88 meter) for deployment and
operation of trailer, shelter, and any associated equipment (Figure 1).
• Free of hazards (e.g., trees, buildings, or other structures), that would cause physical interference with
the system and any associated equipment.
• Free of any obstructions that would interfere with the air intakes and exhausts of the ECU and Genset.
39 ft.
(11.88 m)
39 ft. (11.88 m)
Figure 1. TMSS-MED System Deployment Footprint.
0005-1
TM 11-6115-742-13&P 0005
ASSEMBLY AND PREPARATION FOR USE
Perform all set-up and PMCS procedures (WP 0019) before operating the trailer.
Review all tow vehicle operating instructions before coupling or uncoupling the trailer.
Review On-Vehicle Equipment Loading Plan (WP 0009) and become familiar with equipment location.
PREPARING SHELTER SITE
Verify that there is enough space to erect the shelter. The footprint of the shelter requires a clear space
measuring 32 feet from end-to-end and 23 feet from side-to-side. This space must be free from all obstructions
and should generally be level all around. (Figure 2) shows a diagram of the area required to site the shelter.
23 feet
Sid e - to - Side
32 feet
E n d - to - E nd
Figure 2. Shelter Site Dimensions.
0005-2
TM 11-6115-742-13&P 0005
TRAILER SETUP
Securing Trailer for Operation
WARNING
The TMSS-MED trailer must be level to prevent equipment damage.
Genset exhaust fumes must be directed away from the shelter, the trailer, and
personnel.
1. After positioning trailer in an operational position, engage two handbrakes (Figure 3, Item 1).
2. Lower two rear stabilizer legs (Figure 3, Item 2). Place rear stabilizer pads as close to ground as possible.
CORRECT INCORRECT
INCORRECT 1
1
1
2
2 2
Figure 3. Correct Trailer Operating Positions.
NOTE
A combined wheel/skid plate assembly is provided with the trailer to maintain the
trailer in a level operating position when the tow vehicle disconnects from the
trailer. The wheel/skid plate assembly must be secured to the tongue jack before
disconnecting the tow vehicle.
Use the skid plate to stabilize the trailer in most operating environments. Use the
wheel when necessary to move short distances when the trailer needs to be
repositioned without a tow vehicle.
If terrain around the trailer is soft, uneven, or generally unfavorable, do not use
the wheel.
3. Remove two assembly pins (Figure 4, Items 3 and 4) holding wheel/skid plate assembly (Figure 4, Item 6) to
storage post (Figure 4, Item 8).
4. Raise tongue jack post (Figure 4, Item 5) by rotating tongue jack hand crank (Figure 4, Item 7).
5. Position wheel/skid plate assembly so that either skid plate (INSET A) or wheel (INSET B) are facing the
ground below the tongue jack post (Figure 4, Item 5). If wheel/skid plate assembly does not clear the ground,
continue turning the tongue jack hand crank to raise the trailer.
0005-3
TM 11-6115-742-13&P 0005
Securing Trailer for Operation – Continued
6. Lift wheel/skid plate assembly up into tongue jack extension until wheel/skid plate clears ground and insert
upper assembly pin (Figure 4, Item 4) in extension pin hole.
7. Insert lower assembly pin (Figure 4, Item 3) to secure wheel/skid plate assembly to tongue jack extension.
8. Rotate tongue jack hand crank to lower tongue jack post until trailer is supported by wheel or skid plate.
9. Extend two rear stabilizer legs (Figure 4, Item 2).
10. Check that bubble level on trailer indicates that trailer is level.
END OF TASK
7 8
6 5
6 (REF)
6 (REF)
4
Figure 4. Wheel/Skid Plate Assembly Mounting Positions.
0005-4
TM 11-6115-742-13&P 0005
Chock Wheels
NOTE
Wheel chocks are not provided with equipment.
1. If trailer is parked on level ground and neither side of trailer needs to be raised, place one chock block
(Figure 5, Item 1) in front of one tire and place another chock block (Figure 5, Item 2) in back of the other tire.
2. If trailer is parked on level ground and one side of trailer needs to be raised, place chock blocks (Figure 5,
Item 3) in front and back of tire remaining on the ground.
3. If trailer is parked on an incline with tongue of trailer facing uphill, place chock blocks (Figure 5, Item 5) in
back of both tires.
4. If trailer is parked on an incline with tongue of trailer facing downhill, place chock blocks (Figure 5, Item 4) in
front of both tires.
END OF TASK
2
1 3
5 4
5
4
Figure 5. Wheel Chocks.
Uncouple Trailer from Towing Vehicle
WARNING
If trailer is loaded, rear stabilizer legs must be deployed prior to opening pintle
hook. Failure to follow this warning may result in injury to personnel or damage
to equipment.
1. Ensure two handbrakes (Figure 4, Item 1) are engaged.
2. Disconnect trailer inter-vehicular cable, safety breakaway cable, and safety chains from the towing vehicle.
3. Open towing vehicle pintle hitch by removing safety pin and lifting locking latch.
0005-5
TM 11-6115-742-13&P 0005
Uncouple Trailer from Towing Vehicle – Continued
WARNING
The trailer tongue is heavy – up to 420 lb (190.5 kg) loaded tongue weight. Use
front crank to raise and lower trailer tongue. If tongue jack is inoperative, remove
load from trailer and use four or more persons to lift trailer tongue. Failure to
follow this warning may result in serious personnel injury or equipment damage.
4. Rotate trailer tongue jack hand crank (Figure 4, Item 7) to raise trailer tongue so that lunette ring is clear of
pintle hook.
CAUTION
When operating hand crank, do not force tongue jack extension beyond normal
operating range or permanent damage may occur.
5. Close towing vehicle pintle hitch and reinsert safety pin.
6. Move tow vehicle away from trailer.
END OF TASK
Install Ground Rod Assembly
The trailer is equipped with three-section grounding rod with drive stud and three bronze couplings. One 25 foot
# 6 AWG ground wire is provided for grounding trailer to ground rod assembly.
WARNING
Improper or no equipment grounding can result in serious electrical shock or
death. Refer to “Earth Grounding and Bonding Pamphlet”, CECOM TR-98-6, Oct
1998 for more detailed information on grounding equipment.
Wear eye protection and gloves when hammering stakes and ground rod
sections. Failure to observe this warning may result in injury to the eye or
exposed skin from flying metal fragments.
1. Remove grounding rods from trailer bed (located on trailer bed between ECU and Genset).
2. Remove sledge hammer from stake set transport bag (WP 0009, Figure 1, Item 4).
NOTE
Refer to TM 11-5820-1118-13&P for appropriate grounding.
The best position for the grounding rod assembly is by the front roadside of the
trailer where the bubble level is located.
In rocky areas where the grounding rod cannot be driven into the ground, dig a
six inch trench and lay the grounding rod on its side.
In very dry conditions, keep the ground wet where the grounding rod is located.
3. Attach threaded collar to first section of grounding rod. Using sledge hammer, drive first section of grounding
rod into earth until top of rod is just above surface of hole. Use threaded collar to attach and drive in the two
remaining grounding rods.
4. Connect ground wire to grounding rod assembly with threaded to collar and bolt.
0005-6
TM 11-6115-742-13&P 0005
Install Ground Rod Assembly – Continued
5. Connect ground wire to trailer ground stud (GROUND CONNECTION), located on roadside under ECU.
Secure using washer and wing nut.
END OF TASK
SHELTER SETUP
Off-loading Shelter
WARNING
Tent weights 633 lb (287.12 kg). This procedure requires four personnel and a
team leader (spotter) to off-load the shelter package from the trailer cargo bay.
Excessive strain on individual personnel could lead to bodily injury.
1. Remove stake set transport bag (WP 0009, On-Vehicle Equipment Loading Plan, Figure 2, Item 4) from the
cargo bay and place in a common location out of the immediate shelter setup area.
2. Unbuckle six cargo net clasps (Figure 6, Item 1) and drop cargo net to the ground.
3. Loosen six cargo bay tarp tie down straps, remove cargo bay tarp and place out of immediate work area.
4. Remove four retaining pins (Figure 6, Item 2) securing the cargo bay crossbar (Figure 6, Item 3). Remove the
cargo bay crossbar (Figure 6, Item 3) and place away from immediate work area.
2 3
1
Figure 6. Remove the Crossbar.
5. Remove the electrical wiring kit transport bag (WP 0009, On-Vehicle Equipment Loading Plan, Figure 2,
Item 3) from the cargo bay and place in a common location out of the immediate shelter setup area.
0005-7
TM 11-6115-742-13&P 0005
Off-loading Shelter – Continued
NOTE
Each transport bag containing an end cap is a two-person lift.
6. Remove two shelter end caps in transport bags (WP 0009, On-Vehicle Load Plan, Figure 2, Item 6 & 7) from
cargo bay.
7. Place shelter end cap bags approximately 10 feet apart on either side of the center point where shelter will be
raised (for a total of 20 feet between each shelter end cap bag) as shown in (Figure 7).
Pl a c e E nd Ca ps
Approxi mat ely
20' apart
Figure 7. Remove and Position Shelter End Caps.
8. Position four team members around cargo bay end of trailer. Pull the shelter transport bag one half turn
towards rear of trailer and then pull shelter transport bag to cargo bay edge.
WARNING
Tent weights 633 lb (287.12 kg). This procedure requires four personnel and a
team leader (spotter) to off-load the shelter package from the trailer cargo bay.
Excessive strain on individual personnel could lead to bodily injury.
9. Grasp cargo net with one hand and guide shelter transport bag into cargo net (cradled in the cargo net) with
other hand. Use cargo net to aid in lowering shelter transport bag as shown in (Figure 8).
0005-8
TM 11-6115-742-13&P 0005
Offloading Shelter – Continued
Figure 8. Lower Shelter Transport Bag to Ground.
10. Pull shelter transport bag across ground to center of intended setup site.
END OF TASK
Unpack Shelter
1. Stand shelter transport bag upright and remove shelter repair kit, push poles, and cinched shelter.
2. Unbuckle two outer cinch straps from cinched shelter and place in transport bag to prevent loss.
3. Unwrap floor from shelter bundle and remove floor from immediate area.
4. Stand shelter up so that exterior side (green or tan) is facing up and interior side (white) is facing down.
5. Orient shelter so that long side of shelter is facing end cap bags. Proper alignment will reduce the possibility
of having to reposition shelter later.
6. Remove shelter cinch straps and place in transport bag to prevent loss.
END OF TASK
Expand and Lift Shelter
1. Position four personnel around shelter perimeter (Figure 9).
2. Locate outermost exterior lifting hubs (hubs with the coated steel wire loops).
CAUTION
When lifting hubs, lift from underneath where hub is connected to strut. Do not
lift the shelter by the struts only. Do not lift by coated steel wire loops. The
outermost exterior lifting hubs and the top of the struts are the only places from
which shelter should be lifted.
0005-9
TM 11-6115-742-13&P 0005
Expand and Lift Shelter – Continued
3. Check that wind lines are not snagged on any hubs.
4. With both hands, grasp lifting hubs. On the Team Leader’s command, lift shelter off ground, take two short
steps backward, and put shelter down.
5. If any resistance is felt by any team member, immediately yell “STOP”, identify restriction, and correct it
(WP 0010, Crew Troubleshooting Index).
6. Continue to lift, step back, and expand shelter as shown in (Figure 9) until the shelter is at maximum spread
(at maximum spread, the shelter will resist any further expansion).
Figure 9. Expand and Lift Shelter.
NOTE
Lifting the shelter is performed in two stages: Lift to waist height and lift to full
height.
7. Distribute four push poles to the crew.
8. Look under shelter cover and locate the four red flags (Figure 10, Item 1) on the interior cover (two red flags
per side). There is one keeper associated with each red flag.
9. Each crew member place one hand on flagged keeper and hold push pole in other hand.
CAUTION
Never lift on a keeper that does not have a red flag. Failure to heed this caution
could result in damage to the shelter.
10. On command, simultaneously lift shelter with one hand and place their respective push poles against keeper
with the red flag.
11. As quickly as possible, lift until push poles will fit vertically between ground and keeper.
0005-10
TM 11-6115-742-13&P 0005
Expand and Lift Shelter – Continued
Figure 10. Red Flag Locations.
12. Slowly lower shelter until four push poles (Figure 11, Item 1) are supporting entire shelter as shown in
(Figure 11).
Figure 11. Shelter Resting on Four Push Poles.
WARNING
Two crew members are required to always hold the shelter when it is resting on
the four push poles because it is not totally stable. The team leader must always
monitor this operation and should immediately stop progress if there is any
sideways motion of the shelter. Personal injury and damage to the shelter could
result.
13. Identify additional four red flagged lifting keepers (Figure 12, Item 1) located approximately four feet inside
shelter from outer flagged keepers.
0005-11
TM 11-6115-742-13&P 0005
Expand and Lift Shelter – Continued
1 1
Figure 12. Position of Additional Red Flagged Keepers.
14. Instruct two diagonally opposed crew members to remove push poles and move inwards to red flagged lifting
keepers and place push poles in a vertical position to support shelter. Remaining two crew members hold
and steady shelter at this time.
15. Instruct remaining two crew members to advance push poles to inner red flagged lifting keepers. Initial two
crew members hold and steady shelter at this time. The center section of the shelter is now at waist height
resting on push poles.
END OF TASK
Attach End Caps
Before the shelter is raised to full height, the two end caps are attached to the center section as follows:
1. Remove both end caps from transport bags.
2. Remove cargo straps from end caps and stow in transport bags.
3. Expand end caps in same manner as shown in (Figure 9).
4. Orient each end cap so that red hubs are pointed towards mounting pins on center section frame.
5. Unroll two cover sides of each end cap.
6. Ensure end cap doors are unzipped.
7. Align both end caps (Figure 13, Item 1) to two open ends of the center section (Figure 13, Item 2).
0005-12
TM 11-6115-742-13&P 0005
Attach End Caps – Continued
2
1
1
Figure 13. Position End Caps Next to Center Section.
8. Secure one end cap frame (Figure 14, Item 1) to one end of center section frame (Figure 14, Item 4) by lifting
end cap and placing red end cap hubs (Figure 14, Item 2) onto pin protruding from the white colored hubs
(Figure 14, Item 3) on the center section frame.
9. Insert pin (Figure 14, Item 5) to secure red hubs to white hubs.
3 4
2
2 5
1
3
3
2
Figure 14. Secure End Cap Frame to Center Section Frame.
10. Locate black tabs sewn into centers of both ends of center section exterior cover (Figure 15, Item 2) and the
center of both ends of end cap exterior cover (Figure 15, Item 1).
11. Beginning at black tab on end cap, join end cap exterior hook-and-loop seam to black tab on center section
exterior hook-and-loop flap, working from center outwards to edge of upper end cap frame.
NOTE
If the hook-and-loop seam is fastened beyond the grommets, the shelter will not
lift properly and internal struts could break.
12. Locate red tabs sewn into centers of both ends of center section interior cover and center of both ends of end
cap interior cover.
13. Beginning at red tab on end cap, connect the hook-and-loop seam to the flap, working from the red tab
outward to the grommet sewn in each side of center section hook-and-loop flap.
0005-13
TM 11-6115-742-13&P 0005
Attach End Caps – Continued
2
1
1
Figure 15. Secure End Cap Covers to Center Section Covers.
14. Attach hook-and-loop seam on end cap exterior cover down to grommet.
15. Ensure that all hook-and-loop seams are smooth in order to prevent leaks.
16. If not already opened, unzip the doors on end caps to allow access for push poles.
17. Repeat above steps for opposite end cap.
END OF TASK
Raise Shelter to Full Height
CAUTION
If setting up during high winds, position additional personnel along the windward
side to hold wind lines while shelter is being raised.
Never lift on keepers that do not have red flags. Damage to frame could result.
Prior to final lift, all personnel should check that doors are not caught on any
hubs or between struts. A snagged cover will prevent shelter from lifting to full
height.
1. Lift each end cap off ground slightly and move in towards center section about one foot.
2. Return to push poles and grasp bottom of push pole to lift shelter to full height.
CAUTION
If any resistance is felt, stop immediately to prevent possible damage to the
shelter.
3. On command, lift shelter until side walls come to a vertical position and shelter is self supporting.
4. Inspect hubs with staking plates attached at shelter bottom and make sure hubs are in a vertical position. If
necessary, place foot against bottom hub and push into position.
5. Finish securing both end caps to center section by attaching hook-and-loop seam from grommet down to
ground.
0005-14
TM 11-6115-742-13&P 0005
Raise Shelter to Full Height – Continued
6. The shelter should now be fully erect as shown in (Figure 16).
Figure 16. Shelter in Erected Position.
7. If shelter is in desired location, return push poles to shelter transport bag and proceed to “Install Floor"
procedure. If shelter requires repositioning, perform the following paragraph, then proceed to “Install Floor”
procedure.
END OF TASK
Reposition Shelter
The following two methods are used to reposition the shelter.
NOTE
Four people and a Team Leader (spotter) are required for either of these
procedures.
Method 1 - Push Poles:
1. Place push poles against interior keepers with red flags (Figure 12, Item 1) and lift shelter off ground.
2. Move shelter so that it is positioned correctly.
3. Stop immediately if bottom of any wall drags on ground.
4. Return push poles to the transport bag.
Method 2 – Arms and hands:
1. For small adjustments, position personnel in doorways so that they are aligned with long wall.
2. Place one hand on exterior lifting hub (Figure 17, Item 1) and other hand on corresponding interior hub inside
the doorway (Figure 17, Item 2).
0005-15
TM 11-6115-742-13&P 0005
Reposition Shelter – Continued
3. All four personnel should lift wall in unison and move shelter into correct position.
NOTE
Make sure that end or side walls do not angle inward beyond a vertical position.
1
2
Figure 17. Shelter Lift Locations.
END OF TASK
Install Floor
1. Prepare to install shelter floor by ensuring that all inner flaps are pulled in and are laying flat with hook-and-
loop fastener strip facing up.
2. Identify which shelter side door will be used as primary door.
3. Verify shelter center section staking plates are level (parallel) with ground. Place foot on staking plate and
push down to level.
NOTE
When raising shelter in windy conditions, place additional stakes through staking
plates on secondary door side of shelter.
4. Drive one stake through staking plate on each corner of center section on primary door side of shelter.
5. Place floor inside shelter by primary door and unfold floor.
6. Center door flap on floor to shelter side door.
0005-16
TM 11-6115-742-13&P 0005
Install Floor – Continued
7. Check fit of floor with respect to shelter.
8. Using two personnel start attaching floor to shelter center section on either side of door and work in opposite
directions as shown in (Figure 18).
9. Complete joining floor to one side of shelter.
10. Pull floor tight towards inside of secondary door to remove any slack or bumps.
11. Join opposite section of floor to shelter to complete floor installation.
WARNING
Wear eye protection and gloves when hammering stakes and ground rod
sections. Failure to observe this warning may result in injury to the eye or
exposed skin from flying metal fragments.
12. Drive one stake through each staking plate in corners of secondary side of shelter.
Figure 18. Attach Floor to Shelter.
END OF TASK
Secure Shelter
WARNING
All wind lines and ground stakes must be utilized, especially during inclement
weather conditions. During adverse weather conditions, periodically check the
wind lines and stakes. Failure to adequately secure shelter could result in
personal injury and/or damage to shelter.
Wear eye protection and gloves when hammering stakes and ground rod
sections. Failure to observe this warning may result in injury to the eye or
exposed skin from flying metal fragments.
0005-17
TM 11-6115-742-13&P 0005
Secure Shelter – Continued
1. Drive stakes through remaining staking plates (Figure 19, Item 3) along both sides of shelter center section
and into ground (Figure 19, Item 1) approximately four to five feet from shelter perimeter. Center stakes
between the shelter wind line loops.
2. Fully unravel all wind lines (Figure 19, Items 2 and 4) and secure to ground stakes (Figure 19, Item 1).
Secure multiple wind lines to each ground stake (Figure 19 for example).
3. Use cam-lock tensioner on wind lines to tighten each wind line.
Figure 19. Shelter Installation Complete.
END OF TASK
Connect ECU Ducts to Shelter and Trailer
1. Remove two port caps (Figure 20, Items 1 and 2) from ECU.
2. Loosen belt securing ECU duct transport bags and shelter light set transport bags to trailer deck between
ECU and Genset. Refer to (WP 0009) On-Vehicle Equipment Loading Plan for locations.
3. Remove two ECU duct transport bags from storage area and remove ducts from transport bags.
4. Return transport bags to trailer deck.
0005-18
TM 11-6115-742-13&P 0005
Connect ECU Ducts to Shelter and Trailer – Continued
5. Position belted end of each duct toward ECU ports.
6. Loosen belts on each duct.
NOTE
The input duct has a fine filter screen just inside duct opposite belted end.
Screen end of duct goes inside shelter.
7. Attach air return duct (Figure 20, Item 3) to lower ECU port (Figure 20, Item 2) and tighten belt to secure in
place.
8. Attach air supply duct (Figure 20, Item 4) to upper ECU port (Figure 20, Item 1) and tighten belt to secure in
place.
9. To cool shelter, pull air supply duct (Figure 20, Item 4) through shelter supply port (Figure 20, Item 6). Pull air
return duct (Figure 20, Item 3) through shelter return port (Figure 20, Item 5). Ensure there is approximately
two feet of air supply duct (Figure 20, Item 4) and one foot of air return duct (Figure 20, Item 3) pulled into
shelter at each port.
10. To heat shelters, pull air supply duct through lower shelter return port (Figure 20, Item 5). Pull air return duct
(Figure 20, Item 3) through upper shelter supply port (Figure 20, Item 6). Ensure that there is approximately
two feet of air supply duct and one foot of air return duct pulled into shelter at each port.
11. Secure ducts to shelter ports by tightening belts on shelter ports.
1 2
6
5
4
3
Figure 20. Connect Ducts to Shelter.
END OF TASK
0005-19
TM 11-6115-742-13&P 0005
CONNECTING CABLES AND EQUIPMENT
Install Power Cables from Genset to Shelter
The electrical wiring kit includes two 30 foot power cables to bring power from the Genset (through the J2 and J3
connectors on the Power Distribution Panel) to the shelter lights and/or other accessory items that may be used in
the shelter. Refer to Description and Use of Operator Controls, Indicators, and Connectors (WP 0004), if
necessary.
1. Remove power cables from electrical wiring kit transport bag.
2. Unscrew connector weather cover on power cable by turning cover counterclockwise to release and lift.
3. Using the guide slot, align power cable connector with J2 or J3 receptacle on Power Distribution Panel
(Figure 21, Item 1) and twist clockwise to lock into place.
4. Run power cable(s) through cable sleeve (Figure 21, Item 2) located in shelter interior and exterior covers
next to ECU ducts.
NOTE
The shelter floor has a cable runner built into it for use when cable is being run to
opposite side of shelter.
5. Route cables through shelter so that cables do not interfere with movement of personnel through shelter.
J1 J4
120/208 VOLTS
90 AMPERES
J2
120 VOLTS
20AMPERES
J3
120 VOLTS
20AMPERES
120/208 VOLTS
30 AMPERES 3
J5 J6
120 VOLTS
INPUT 24 VOLTS DC
Figure 21. Typical Shelter Lighting Arrangement.
END OF TASK
0005-20
TM 11-6115-742-13&P 0005
Install Shelter Lighting
The TMSS-MED system includes two fluorescent light sets (one set consists of two lighting fixtures) for lighting
the interior of the shelter. The fluorescent lighting fixtures are intended to be daisy-chained together so that one
power cable can be used for lighting the shelter.
NOTE
Each shelter lighting fixture comes with two strap-mounted clip connectors (one
on each side) to provide flexibility in mounting.
1. Arrange four shelter lighting fixtures on shelter floor (Figure 21, Item 3).
2. Starting with lighting fixture closest to power cable from Genset, connect male connector of first lighting fixture
to female connector of power cable.
3. Connect female connector of same lighting fixture to male connector of second lighting fixture.
4. Connect remaining lighting fixtures to each other working in a circular motion around the shelter.
NOTE
Use two looped keepers located on third level of shelter interior. The outer
keepers are located behind hook-and-loop strip connecting end caps to center
shelter section. To access keepers, separate hook-and-loop strip in-line with 3rd
row of keepers.
5. Lift first lighting fixture and connect clip to the outer looped keeper (Figure 21, Item 4) closest to power input
cable.
6. Slide strap locks up or down the strap to level lighting fixture at desired height.
7. Lift second lighting fixture and stretch power cord from first lighting fixture to second lighting fixture.
8. Connect second lighting fixture clip connectors to looped keepers at far end of shelter.
9. Repeat procedure above for the remaining two lighting fixtures.
10. Run mounting straps through loops and hook back to lighting fixture so that light faces the wall.
END OF TASK
Install Power Distribution Unit (PDU)
The TMSS-MED system includes one Power Distribution Unit (PDU) to route electric power from either the
Genset or a remote power source. PDUs provide a method of distributing power to branch circuits, utility
extension cords, and lighting fixtures in the shelter. The PDU utilizes standard military 60 A power cable
connectors.
NOTE
When operating in HEAT mode, the ECU will draw approximately 18 kW of
power. This only leaves spare power to run the lights or small additional items.
When operating in COOL mode the ECU will draw approximately 10 kW of power
for lights and additional electric devices.
0005-21
TM 11-6115-742-13&P 0005
Install Power Distribution Unit (PDU) – Continued
1. Position PDU (Figure 22, Item 1) in close proximity between trailer (Figure 22, Item 4) and shelter (Figure 22,
Item 2).
1
4
2
3
Figure 22. Location of PDU with Respect to Trailer and Shelter.
2. Connect 25 foot, 60 A power cable (Figure 22, Item 3) to J4 (30 A) connector on Power Distribution Panel.
3. Connect 25 foot, 60 A power cable (Figure 22, Item 3) to input connector J1 on PDU.
END OF TASK
0005-22
TM 11-6115-742-13&P 0005
Connect Equipment to PDU
NOTE
The PDU connectors are standard single phase, grounded 3-prong connectors.
The PDU has one 30 A connector and five 20 A connectors.
Two circuit breakers, on the PDU, draw power from each phase of the Genset
output. For proper load leveling, power draw should be distributed between each
phase evenly. Failure to level the power draw can result in the Genset circuit
breakers identifying an overload when there is not one present.
1. Lift hinged weather shield to one of four PDU output connectors, and connect male end of power cord into
PDU connector.
2. Allow weather shield to lower back into place.
3. Run attached power cords through cable sleeve located in shelter exterior and interior covers next to ECU
ducts.
4. Connect cables to the intended equipment.
END OF TASK
GENERATOR FUELING
Fueling Genset from Fuel Control Panel
Check the fuel level in the trailer fuel tank by viewing the mechanical fuel level indicator (Figure 23, Item 3)
located behind a hinged access door between the ECU and the Generator.
WARNING
Diesel fuel is flammable. Do not fill fuel tank with engine running, while smoking,
or when near an open flame. Never overfill tank or spill fuel. If fuel is spilled,
clean it up immediately. Failure to comply may result in serious injury or death.
Add fuel as follows, if needed:
1. Check fuel level by opening fuel sight door (Figure 23, Item 3).
2. Remove fuel cap (Figure 23, Item 1) located on Fuel Control Panel (Figure 23, Item 2). A plastic funnel is
provided and found in storage compartment.
3. Fill fuel tank with fuel.
4. Re-install fuel cap on filler mouth.
5. Recheck fuel level.
0005-23
TM 11-6115-742-13&P 0005
Fueling Genset from Fuel Control Panel – Continued
TRAILER
OFF AUX
AUXILIARY AUXILIARY
FUEL SUPPLY FUEL RETURN
FUEL SUPPLY
2
1 2
3
13
Figure 23. Location of Fuel Control Panel.
END OF TASK
Fueling Genset from Auxiliary Fuel Source
TMSS-MED trailer comes with one auxiliary fuel return line (Figure 24, Item 1) and one auxiliary fuel supply line
(Figure 24, Item 3). The auxiliary fuel supply line has a bulb primer (Figure 24, Item 4) to start fuel moving from
the external source.
1. Insert end of auxiliary fuel supply line (Figure 24, Item 3) closest to bulb into auxiliary fuel source (Figure 24,
Item 2). Connect opposite end to AUXILIARY FUEL SUPPLY connector (Figure 24, Item 6).
2. Insert end of auxiliary fuel return line (Figure 24, Item 1) into auxiliary fuel source (Figure 24, Item 2).
Connect opposite end to AUXILIARY FUEL RETURN connector (Figure 24, Item 5).
3. Turn FUEL SUPPLY switch to AUX position.
4. Prime bulb (Figure 24, Item 4) on auxiliary fuel supply line (Figure 24, Item 3) until resistance is felt. Check
for any leaks.
0005-24
TM 11-6115-742-13&P 0005
Fueling Genset from Auxiliary Fuel Source – Continued
TRAILER
OFF AUX
FUEL SUPPLY
6
5
4 3 2
Figure 24. Aux Fuel Lines to External Fuel Supply.
END OF TASK
SYSTEM POWER-UP PROCEDURES
WARNING
There should be a 3-ft. stand-off when Genset is in operational status. Failure to
comply may result in hearing loss.
Genset Start Procedure
1. Place BATTERY SWITCH on Circuit Breaker Panel to ON position.
NOTE
If engine is cold, (i.e., has not been operated within the last 2 to 3 hours),
continue with Step 2.
If engine is warm, proceed to Step 3.
If operating in Arctic conditions, (i.e., ambient temperatures are 0°F or below),
refer to Operation Under Unusual Conditions (WP 0006).
2. Place ENGINE selector switch on Genset Control Panel to PREHEAT position for approx 10 to 20 seconds.
3. Turn and hold ENGINE selector switch in the START position until engine starts. After engine starts, release
ENGINE selector switch and it will spring-return to the RUN position.
0005-25
TM 11-6115-742-13&P 0005
Genset Start Procedure – Continued
4. Immediately after starting the engine:
• Check lubrication oil pressure at OIL PRESSURE gauge on Genset Control Panel. The minimum oil
pressure is 20 psi (normal oil pressure is 20 to 55 psi). If oil pressure does not rise promptly to over
20 psi, stop engine by turning ENGINE selector switch to OFF and contact service maintenance.
• Check to see if leaks are evident, both inside and under enclosure. If leaks are present, turn engine off
and call service maintenance.
5. Turn VOLT/AMP select switch from OFF to L1-L2 position. Read VOLTS meter. It should read 208 VAC. If
not, fine-tune voltage to 208 VAC using VOLTAGE ADJUST potentiometer on Genset Control panel. With
voltage set, verify that HERTZ frequency meter is reading between 60-61 Hz.
6. Turn VOLT/AMP select switch to L2-L3 position and check that AC VOLTS meter and HERTZ frequency
meter readings are the same as for L1-L2. Do the same for L3/L1 position. If Genset does not deliver
desired voltage and frequency or if there is a marked difference among the three legs, do not operate Genset.
Contact service maintenance.
7. Move circuit breaker CB5 (GEN) on Circuit Breaker Panel to ON position. Power is now available from
generator.
END OF TASK
Applying Power from Genset
1. To make power available at the J2 and J3 receptacles turn ON circuit breakers CB2 and CB3. When power is
available at a receptacle, the indicator light above that receptacle will illuminate.
WARNING
Verify that circuit breaker CB1 is off before connecting ECU power cord to Power
Distribution Panel. Serious injury or death could occur.
2. Connect power cable from ECU to receptacle J1 on Power Distribution Panel. Power is made available to
ECU through receptacle J1 which in turn is protected by circuit breaker CB1.
3. Periodically check all meter readings on Genset Control Panel.
END OF TASK
ECU Start Procedure
NOTE
Ensure airflow to and from the ECU is unobstructed. This includes the fan on top
and louvers on the sides.
1. Ensure ECU power cable is connected to power source.
2. If using Genset power, turn CB1 on Circuit Breaker Panel to ON position. If using shore power, apply shore
power.
0005-26
TM 11-6115-742-13&P 0005
ECU Start Procedure – Continued
CAUTION
Do not run ECU with red OUT OF PHASE light on. Damage to motor can result.
3. Ensure green POWER ON indicator light on ECU Control Panel is lit.
4. Verify that red OUT OF PHASE indicator light on ECU Control Panel is not lit. If lit, conduct Out of Phase
troubleshooting procedures (WP 0011 and WP 0030).
CAUTION
Do not set thermostat below 50 degrees in cool mode and not above 90 degrees
in heat mode. Setting thermostat outside this range can cause the ECU to
malfunction.
Do not adjust the thermostat frequently. Select a temperature and leave it.
Frequent adjustment can cause premature failure of the thermostat.
5. Set TEMPERATURE dial to the desired temperature required to maintain a comfortable interior shelter
temperature.
NOTE
Keep all shelter doors and windows, exterior and interior, closed as much as
possible to maintain dead air space between the exterior and interior covers.
Use camouflage netting or other shading means to reduce solar energy absorbed
by the shelter.
6. Turn ECU MODE SELECT switch to appropriate position. Modes of operation are:
– OFF, no ECU operation.
– FAN, circulating fan only operation.
– COOL, provides cool air and fan operation, utilizes 10 kW of Genset power during cooling operations.
– HEAT LOW 9 kW, utilizes 9 kW of Genset power during heating operations. The remaining power may
be used to power ancillary devices.
– HEAT HIGH 18 kW, utilizes 18 kW of Genset power during heating operations. The minimal remaining
power may be used to power only a few ancillary devices.
END OF TASK
PDU Start Procedure
1. Turn CB4 on Genset Circuit Breaker Panel to the ON position.
2. Twist two locks on PDU cover, and raise cover to gain access to circuit breaker panel.
3. Set applicable circuit breakers on PDU to ON position. Yellow power lights located above each connector will
illuminate to indicate connector is active (hot).
4. On PDU, turn VOLTMETER select switch to L1, L2, and L3 positions, each time checking reading on A-C
VOLTS meter on PDU. Verify that distribution is balanced.
5. Close PDU cover and secure 2 locks.
END OF TASK
0005-27
TM 11-6115-742-13&P 0005
Checking PDU Power Draw
1. On Genset Control Panel, turn the VOLT/AMP select switch to the L1/L2 position.
2. Note amperage draw shown on A-C AMPERES meter on Genset Control Panel.
3. Switch VOLT/AMP select switch to L2/L3 and L3/L1 positions and note amperage draw on A-C AMPERES
meter on Genset Control Panel.
4. Compare Amperage draw on each leg. Adjust equipment to even out power draw across all legs.
END OF TASK
SYSTEM POWER-DOWN
PDU Shut-Down Procedure
CAUTION
Prior to shutting down PDU, ensure all ancillary equipment being powered by
PDU has been properly shut down in accordance with shut down procedures for
each individual piece. Equipment may become damaged or critical data may be
lost if proper procedures have not been followed.
Prior to powering down PDU, ensure all tasks inside of the shelter have been
performed. Internal lighting will be lost if powered by the PDU.
1. Shut down all equipment being powered by the PDU.
2. Set all circuit breakers on PDU to the OFF position. Yellow power lights located above each active connector
will go out indicating power no longer present at connector.
3. Set CB4 on Genset Circuit Breaker Panel to OFF position.
END OF TASK
ECU Shut-Down Procedure
1. Turn ECU MODE SELECT switch on the ECU Control Panel to OFF position.
2. Turn CB1 on Genset Circuit Breaker Panel to OFF position. If using shore power, turn OFF.
3. Disconnect ECU power cable from power source (J1 on Power Distribution Panel or shore power).
4. Stow ECU power cable on trailer bed between ECU enclosure and Genset enclosure.
END OF TASK
Genset Shut-Down Procedure
1. Verify that ECU and PDU have been shut down.
2. Set all circuit breakers on Circuit Breaker Panel to OFF position. There should be no load on generator.
3. On Genset Control Panel, turn VOLT/AMP select switch to OFF position.
0005-28
TM 11-6115-742-13&P 0005
Genset Shut-Down Procedure – Continued
CAUTION
Verify that all circuit breakers on Genset Circuit Breaker Panel are in the OFF
position prior to stopping the engine.
4. On Genset Control Panel, turn ENGINE select switch OFF position.
5. On Genset Circuit Breaker Panel, turn BATTERY SWITCH to OFF position.
END OF TASK
DISCONNECTING CABLES AND EQUIPMENT
Disconnect Equipment from PDU
1. If Genset has not been completely shut down, ensure that appropriate circuit breaker on PDU has been set to
OFF.
2. Disconnect all cables attached to P1 through P6 of PDU.
3. Properly gather all power cables and store with appropriate pieces of equipment or in proper storage location
on TMSS-MED trailer.
4. Set PDU outside of shelter in preparation for loading onto trailer.
END OF TASK
Disconnecting Input Power to PDU
CAUTION
Prior to disconnecting cables, ensure PDU is shut down and that all ancillary
equipment being powered by PDU has been properly shut down in accordance
with shut down procedures for each individual piece. Equipment may become
damaged or critical data may be lost if proper procedures have not been
followed.
1. If Genset has not been completely shut down, ensure that CB4 on Genset Circuit Breaker Panel has been set
to OFF position.
2. Disconnect the 25 foot, 60 A power cable from J1 of the PDU and from J4 (30 A) connector on the Power
Distribution Panel. Roll up 25 foot, 60 A power cable and prepare for storage.
3. Set outside of shelter in preparation for loading onto trailer.
END OF TASK
Removal of Shelter Lighting
1. If Genset has not been completely shut down, ensure that appropriate circuit breaker has been set to OFF
position.
2. Disconnect power cables that run from lighting fixture to lighting fixture and to power source.
0005-29
TM 11-6115-742-13&P 0005
Removal of Shelter Lighting – Continued
3. Loosen mounting straps and disconnect clips from keepers. Lower lighting fixtures one at a time. Repeat
until all four lighting fixtures have been removed.
4. Store power cables and lighting fixtures in appropriate transport bag.
5. Set transport bag outside of shelter in preparation for loading onto trailer.
END OF TASK
Disconnect Power Cables from Genset to Shelter
1. If Genset has not been completely shut down, ensure that appropriate circuit breakers (CB2 and CB3) on
Genset Circuit Breaker Panel are in the OFF position.
2. Remove power cables routed through shelter and cable sleeve located in shelter interior and exterior covers
next to ECU ducts.
3. Disconnect power cable connector from J2 or J3 receptacle on Power Distribution Panel.
4. Install connector weather cover onto power cable by turning cover clockwise to tighten.
5. Roll up power cable(s) and store power cables in appropriate transport bag.
6. Set transport bags outside of shelter in preparation for loading onto trailer.
END OF TASK
Disconnect Grounding Rod Assembly
1. Remove wing nut and washer from trailer ground stud (GROUND CONNECTION) (located on roadside under
ECU) and disconnect ground wire. Replace washer and wing nut onto trailer ground stud (GROUND
CONNECTION).
2. Disconnect ground wire from grounding rod assembly. Coil up ground wire and set aside.
3. Loosen and remove grounding rod from earth ground. If necessary, disassemble grounding rod one section
at a time by loosening and removing bronze couplings.
4. Disconnect threaded collar from first section of grounding rod.
5. Return ground wire, threaded collar and bronze couplings to storage.
6. Secure grounding rod sections to trailer bed (between ECU and Genset enclosures).
END OF TASK
SHELTER TEAR DOWN
Disconnect ECU Ducts from Shelter and Trailer
1. Loosen belts on each duct at ECU end.
2. Remove supply air duct from upper ECU port.
0005-30
TM 11-6115-742-13&P 0005
Disconnect ECU Ducts from Shelter and Trailer – Continued
3. Remove return air duct from lower ECU port.
4. Install two port caps on ECU ports and tighten belts.
5. Loosen belts on shelter supply and return ports to allow for removal of ducts.
6. Remove air ducts from supply and return ports of shelter.
7. Compress air ducts and return to transport bags.
8. Set transport bags outside of shelter in preparation for loading onto trailer.
END OF TASK
Floor Removal
1. Remove stakes securing staking plates in corners of secondary side of shelter.
2. Disconnect floor from shelter by starting on secondary side of shelter and detaching the hook-and-loop strip
on floor from the hook-and-loop seam on shelter working in opposite directions to complete one side.
3. Detach the hook-and-loop strip on floor from the hook-and-loop seam on both end cap covers and faceplates.
4. Complete all remaining hook-and-loop strips on floor from the hook-and-loop seams on shelter.
5. Fold floor ends in and remove floor from shelter.
6. Fold floor into quarters lengthwise and remove floor from immediate work area.
END OF TASK
Shelter Preparation
1. Tie back two side doorways in the open position (Figure 25).
2. Close all interior and exterior windows.
3. Start at ground level and unfasten interior hook-and-loop connector strips on both sides of end caps.
4. Start at ground level and unfasten exterior hook-and-loop connector strips on both sides of end caps up to
frame.
Figure 25. Tie Back Doorways.
0005-31
TM 11-6115-742-13&P 0005
Shelter Preparation – Continued
WARNING
Do not enter the shelter once the wind lines and ground stakes are removed.
The shelter could collapse and cause serious injury.
5. Remove all wind lines and ground stakes and pack in transport bag.
END OF TASK
Lowering Shelter
1. Lift bottom of each end cap and pull backwards about one foot and place on ground to allow to collapse
correctly.
2. Position four personnel in a square pattern around shelter perimeter. Proper position is indicated by four
ground flaps marked with “TO STRIKE, LIFT HERE”.
3. Locate lifting hub under shelter exterior cover above ground flap.
WARNING
Grip shelter at hubs - never grip the struts (Figure 26). As struts fold in, hands
and fingers can become pinched between struts.
4. At command of the team leader, lift shelter approximately six inches off ground and step backwards in one
unified movement. The center of shelter will come down to ground level.
5. Complete detaching end cap hook-and-loop seams on both sides.
Figure 26. Grip Shelter by Hubs.
END OF TASK
0005-32
TM 11-6115-742-13&P 0005
SYSTEM PACKING AND LOADING
Packing End Caps
NOTE
Ensure that the end caps doors are unzipped.
1. Remove pin holding red hub to white hub and lift end cap clear of center of shelter.
2. Replace pin into pin stud.
3. Starting with exterior side, roll end cap door towards frame.
4. Flip end cap over so that the white side is up.
5. Roll interior end cap towards frame and secure to center hub with hook-and-loop strap.
6. Compress end cap by lifting upwards at hubs and walking towards each other.
7. Place one cinch strap around top of end cap and tighten.
8. Place second cinch strap around bottom of end cap and tighten.
9. Pull transport bag over upright end cap. Flip end cap bag over and close transport bag with drawstring.
10. Repeat same procedure for second end cap.
11. Place both bagged end caps out of immediate work area but near trailer.
END OF TASK
Packing Main Shelter
1. Position all hands under exterior cover on upper portion of strut.
2. Have all personnel lift upward in one motion and walk towards center of main shelter section.
3. Move inwards until main section is approximately 4/5 of way compressed.
4. Inspect compressed shelter section to make sure no wind lines are caught in any struts.
5. Compress shelter the rest of the way.
6. Retrieve four cinch straps from transport bag.
7. Place one cinch belt around top of compressed shelter and tighten. See (Figure 27).
8. Invert compressed shelter so that white side is facing up.
9. Push cover in between struts so that all interior looped keepers are exposed.
10. Push against shelter from all directions to compress further.
11. Cinch second strap around compressed shelter and tighten.
12. Invert shelter so exterior side (green or tan) is facing up.
0005-33
TM 11-6115-742-13&P 0005
Packing Main Shelter – Continued
13. Check and retighten cinch straps around compressed shelter as necessary.
Figure 27. Secure First Cinch Strap.
14. Place shelter floor on a suitable flat surface.
15. Place buckle end of cinch strap under floor, about five inches in.
16. Lay shelter on one side and position at one end of folded floor.
17. Retighten cinch strap (on shelter) as necessary.
18. Roll shelter up into floor as shown in (Figure 28).
Figure 28. Roll Up Shelter with Floor.
19. Compress shelter as it is rolled up.
20. Secure cinch straps around floor and shelter.
21. Stand white side of shelter upright.
22. Remove push poles and repair kit from transport bag.
23. Place Transport Bag over shelter.
24. Push shelter over with the instruction panel (exterior section of transport bag) down.
25. Replace push poles and repair kit in transport bag.
26. Pull rope to close end of transport bag and secure bag with a knot.
27. Fasten two belts on the transport bag. The shelter is now secure and ready for loading onto trailer.
END OF TASK
0005-34
TM 11-6115-742-13&P 0005
Load Shelter onto Trailer
WARNING
Tent weighs 633 lbs (287.12 kg). This procedure requires four personnel to
safely lift the shelter onto the trailer. Personnel injury may result from lifting
excessive weight.
1. Unhook cargo net from trailer and remove superstructure cross bar.
2. Arrange cargo net to lay flat on ground, as shown in (Figure 29).
3. Roll shelter over onto cargo net.
Figure 29. Ready for Assisted Lift of Shelter.
4. Have all personnel grasp cargo net with both hands and on team leaders command, lift transport bag by lifting
up on cargo net, as shown in (Figure 30).
Figure 30. Lift Transport Bag.
5. Set bottom of transport bag on rear edge of the trailer’s cargo bay and roll transport bag one-half turn onto
trailer’s cargo bay, as shown in (Figure 31).
0005-35
TM 11-6115-742-13&P 0005
Load Shelter onto Trailer – Continued
WARNING
Tent weighs 633 lbs (287.12 kg). This procedure requires four personnel to
safely lift the shelter onto the trailer. Personnel injury may result from lifting
excessive weight.
6. Push transport bag to front of cargo deck.
Figure 31. Push Transport Bag onto Trailer.
7. Place two end cap transport bags on top of main shelter transport bag.
8. Place remaining shelter components in respective positions on trailer, as shown in On-Vehicle Equipment
Loading Plan (WP 0009).
9. Secure trailer crossbar to trailer using four retaining pins.
10. Secure cargo net to trailer crossbar with four cargo net clasps.
CAUTION
Leave the tarps off if trailer system is to be transported backwards on a train or
truck.
11. Place tarp over trailer and secure to trailer with tie down straps.
END OF TASK
PREPARATION FOR MOVEMENT
There are two ways to transport the trailer: Shipping pertains to moving the trailer by truck, aircraft, railroad, or
sea. Towing means that the trailer will be attached to a vehicle capable of pulling 4,200 lbs., both on and off road.
Refer to Towing Instructions. The following paragraphs describe both methods.
0005-36
TM 11-6115-742-13&P 0005
Coupling the Trailer to a Tow Vehicle
WARNING
Power to the Genset batteries MUST BE turned off prior to moving the trailer.
Failure to follow this warning may result in serious equipment damage and
personnel injury.
1. Verify that all circuit breakers and switches are in the OFF position.
2. Verify that power to the batteries is off by ensuring the BATTERY SWITCH on the Circuit breaker Panel is in
the OFF position.
WARNING
Ensure that towing vehicle and trailer are on level ground before coupling.
Failure to follow this warning may result in serious personnel injury or equipment
damage.
3. Apply both handbrakes (Figure 32, Item 1).
WARNING
Ensure weight of trailer is on tongue jack post (Figure 32, Item 3) before raising
rear stabilizer legs. Failure to follow this warning may cause trailer to tip,
resulting in serious injury to personnel or damage to equipment.
4. Fully retract and secure both rear stabilizer legs (Figure 32, Item 2).
5
2
4
3
Figure 32. Trailer Leveled and Secured.
5. Rotate tongue jack hand crank (Figure 32, Item 6) to raise trailer tongue (Figure 32, Item 4) until lunette ring
(Figure 32, Item 5) is higher than towing vehicle pintle hook (Figure 33, Item 8).
0005-37
TM 11-6115-742-13&P 0005
Coupling the Trailer to a Tow Vehicle – Continued
WARNING
When operating the tongue jack hand crank do not force the tongue jack beyond
the normal operating range, or permanent damage may occur.
The trailer drawbar is heavy – up to 420 lbs (190.5 kg) loaded tongue weight. If
the tongue jack is inoperative, remove load from trailer or use four or more
persons to lift the drawbar. Failure to follow this warning may result in serious
personnel injury or equipment damage.
6. Remove safety pin (Figure 33, Item 9) from pintle hitch (Figure 33, Item 2). Open pintle hitch (Figure 33,
Item 2) by pulling up on locking latch (Figure 33, Item 1).
1 2
3 5
6
4
8
3
9 7
Figure 33. Attach Trailer to Tow Vehicle.
7. Back up towing vehicle in front of lunette ring (Figure 33, Item 4).
8. Adjust height of lunette ring (Figure 33, Item 4) by rotating tongue jack hand crank (Figure 32, Item 6).
9. Place lunette ring on towing vehicle pintle hook and close pintle hitch. Check that locking latch is locked by
pulling up on pintle hitch. The pintle hitch should not come up.
10. Re-insert safety pin (Figure 33, Item 9) into pintle hitch (Figure 33, Item 2).
11. Cross two trailer safety chains under trailer tongue and hook to towing vehicle eyebolts. If safety chains are
too long, they can be twisted to be shortened. It is recommended that wire be used across hook openings to
prevent accidental unhooking.
0005-38
TM 11-6115-742-13&P 0005
Coupling the Trailer to a Tow Vehicle – Continued
CAUTION
Safety chains must be attached on opposite sides of the trailer tongue or frame
and crossed under the tongue when passed forward to the towing vehicle so as
to cradle the tongue in the event of a breakaway. Slack should only be sufficient
to permit full turns.
Failure to provide enough slack can result in twisting the trailer tongue.
12. Attach safety breakaway cable (Figure 33, Item 6) to towing vehicle. Ensure there is enough slack in the
cable to allow trailer to make full turns.
CAUTION
Ensure that breakaway lever is fully released. If the breakaway lever is not fully
released, the brakes will drag, heat up, and burn out.
13. Ensure breakaway lever (Figure 33, Item 5) is pushed all the way back toward trailer and that breakaway
lever is not engaged in leaf spring (Figure 33, Item 7).
14. Rotate tongue jack hand crank (Figure 34, Item 1) to raise wheel/skid plate assembly (Figure 34, Item 3) off
the ground.
15. Remove two assembly pins (Figure 34, Item 4) holding wheel/skid plate assembly to tongue jack extension
(Figure 34, Item 2).
16. Release extension pin (Figure 34, Item 5) and push tongue jack extension all the way up into tongue jack
(Figure 34, Item 7). Secure tongue jack extension by reinserting pin in tongue jack.
17. Continue to rotate tongue jack crank to fully raise tongue jack.
18. Place wheel/skid plate assembly onto storage post (Figure 34, Item 6) with skid plate facing rear of the trailer.
19. Secure wheel/skid plate assembly to storage post by inserting two assembly pins.
20. Connect electrical plug on the inter-vehicular cable to receptacle of towing vehicle.
21. Check all towing vehicle and trailer lights for proper operation.
22. Release trailer handbrakes.
0005-39
TM 11-6115-742-13&P 0005
Coupling the Trailer to a Tow Vehicle – Continued
7
6 1
5
4
Figure 34. Secure Tongue Jack Assembly.
END OF TASK
0005-40
TM 11-6115-742-13&P 0005
Off-Road Driving Conditions
The TMSS-MED trailer is equipped with a safety brake actuator device that is intended to keep the safety brakes
from engaging when the vehicle is operating off-road.
CAUTION
During extreme off road transport, tire pressure should be reduced to 17 psi.
Failure to observe this warning could result in equipment damage.
NOTE
This procedure is to be used for all off-road operation of the TMSS-MED Trailer.
1. Ensure trailer lunette ring (Figure 35, Item 1) is level with towing vehicle.
2. Ensure safety chains (Figure 35, Item 4) are properly attached to towing vehicle.
3. Ensure safety breakaway cable (Figure 35, Item 2) is properly attached to towing vehicle.
4. Ensure rear stabilizer legs are properly stowed.
5. Ensure that trailer light cable is securely attached to the towing vehicle.
6. Ensure trailer tongue jack assembly (not shown) is properly stowed (failure to properly stow tongue jack
assembly will result in damage to trailer tongue jack).
7. Ensure trailer handbrakes are disengaged.
8. Ensure all trailer cargo is secured.
9. Insert safety brake actuator lockout rod (Figure 35, Item 3) into the safety brake actuator lockout bore
(Figure 35, Item 5), thus bypassing the trailer actuated braking system. (If trailer actuator is not pinned out,
trailer actuated brakes may engage during extreme assents and descents, causing damage to the trailer
tongue.)
ACTUATOR
LOCKOUT
Figure 35. Trailer Safety Brake Lockout.
END OF TASK
0005-41
TM 11-6115-742-13&P 0005
Towing Instructions
NOTE
Refer to FM 21-305 for further information on proper towing practices.
Driving.
CAUTION
Sudden stops may cause drawbar to bend or buckle and may cause damage to
hydraulic brake actuator assembly.
1. When the trailer is coupled, always start and stop the towed load slowly and gradually. Do this whether or not
the trailer is loaded.
2. When driving a vehicle towing a trailer with a hydraulic brake actuator assembly, sudden and fast deceleration
will cause the trailer hydraulic brakes to be applied.
3. Never exceed the maximum speed of 55 mph (88.5 km/h) highway or 20 mph (32.2 km/h) cross-country.
4. When driving the towing vehicle and trailer, the overall length of the unit must be kept in mind when turning
and passing other vehicles. Because the unit is hinged in the middle, turning and backing are also affected.
Heavier payloads will increase stopping distance and decrease off-road maneuverability.
END OF TASK
Turning.
CAUTION
Tight turns may cause damage to hydraulic brake actuator assembly.
1. When turning corners, allow for the fact that the trailer wheels may turn inside the turning radius of the towing
vehicle.
2. To make a right turn at an intersection, drive the towing vehicle partway into the intersection, then cut sharply
to the right. This will allow for the turning radius of the trailer to keep its wheels off the curb.
END OF TASK
Backing.
CAUTION
Always back the towing vehicle slowly and gradually.
1. Whenever possible, use an assistant driver or another person to act as a ground guide.
2. Adjust all towing vehicle rearview mirrors before backing.
3. When backing, the rear of the trailer will move in the opposite direction in which the towing vehicle is turned.
When the towing vehicle is turned to the right, the rear of the trailer will go left. When the towing vehicle is
turned and backing in a straight line is required, turn the towing vehicle in the direction the trailer is moving.
This will slowly bring the towing vehicle and trailer into a straight line.
END OF TASK
0005-42
TM 11-6115-742-13&P 0005
Towing Instructions – Continued
Stopping.
CAUTION
Sudden stops may cause drawbar to bend or buckle and may cause damage to
hydraulic brake actuator assembly.
Always stop the towing vehicle by applying brakes gradually and smoothly. Do this whether or not the trailer is
loaded.
END OF TASK
Parking.
When the towing vehicle and the trailer are to be left unattended, set the trailer handbrakes, set the towing vehicle
parking brakes, turn off the engine, and set wheel chocks.
END OF TASK
Preparation for Shipping
1. Chock (Figure 36, Item 2) wheels once the trailer is positioned upon the transport vehicle.
2. Use skid plate (not wheel) to support tongue jack (Figure 36, Item 4) during shipping. The skid plate resting
on the deck surface will support the tongue jack. The trailer tongue jack must be fully retracted.
3. Apply two handbrakes (Figure 36, Item 1).
CAUTION
Avoid hitting the retracted tongue jack when loading and unloading the trailer or
damage will occur to the tongue jack.
4. Secure trailer to transport deck using the two tie-down rings (Figure 36, Item 3).
5. When traveling, the axle/suspension allows the trailer to move in an up and down motion. If extra tarpaulins
are used to cover the trailer, they should be tied only to the trailer and not to the transport deck.
0005-43
TM 11-6115-742-13&P 0005
Towing Instructions – Continued
34 2
43
Figure 36. Trailer Properly Chocked and Positioned on Transport Trailer Deck.
END OF TASK
0005-44
TM 11-6115-742-13&P 0005
WEIGHT AND CENTER OF GRAVITY
The weight and Center of Gravity (CG) has been calculated using the fully loaded TMSS-MED trailer. This
information is useful when moving the unit with a lifting device (crane, tow truck, etc.). It gives the operator an
idea of how to adjust slings for balancing the unit and for placement onto transportation equipment.
NOTE
CG is based on TMSS-MED trailer being packed in accordance with On-Vehicle
Equipment Loading Plan (WP 0009).
CG may vary slightly due to equipment movement during transport.
Refer to (Figure 37 and Table 1) for information on weights, CG, and overall
measurements of shelter for lifting, loading, and transport of shelter.
Table 1. Weight of TMSS-MED Trailer.
ITEM GROSS WEIGHT (LB)
TMSS-MED Trailer (less payload) 3,500 lb (1,588 kg)
Cargo 700 lb (1.737 kg)
Total gross weight (trailer and cargo) 4,200 lb (1905 kg)
Tongue (with cargo) 420 lb (191 kg)
Figure 37. CG Tag Location on TMSS-MED Trailer.
0005-45
TM 11-6115-742-13&P 0005
WEIGHT AND CENTER OF GRAVITY – Continued
NOTE
Positive CG measurements for (Figure 38) begin from the curbside corner of the
TMSS-MED trailer.
X - Begins at trailer pintle ring of the TMSS-MED trailer and moves toward the
trailer center.
Y - Begins at widest part of the TMSS-MED trailer and moves toward the trailer
center.
Z - Begins at lowest part of the TMSS-MED trailer and moves toward the trailer
center.
(2.18 M)
85.94 IN
(Y) (1.09 M) (OVER ALL)
42.97 IN
CG
(1.99 M)
78.48 IN
(OVER ALL)
(Z)
(1.01 M)
39.8 IN
CG
(X)
(3.20 M)
126.20 IN
CL (4.94 M) CG
194.49 IN
(OVER ALL)
Figure 38. CG of TMSS-MED Trailer.
END OF TASK
END OF WORK PACKAGE
0005-46
TM 11-6115-742-13&P 0006
OPERATOR INSTRUCTIONS
TMSS-MED
OPERATION UNDER UNUSUAL CONDITIONS
INITIAL SETUP:
Personnel Required References
Two WP 0005, WP 0011, WP 0019, WP 0030,
WP 0042, WP 0058, WP 0089, WP 0094,
WP 0101, WP 0109, WP 0111
GENERAL
This work package covers operating the TMSS-MED system in arctic, tropical, and desert climates. This work
package also describes off road towing of the trailer.
SECURITY MEASURES FOR ELECTRONIC DATA
Follow the security measures described in AR 25-2, Information Assurance, to control access to classified
electronic data. For the TMSS-MED system, follow the procedures described in the current version of the User
Security Manual/Standard Operating Procedure (SOP).
UNUSUAL ENVIRONMENT/WEATHER
Arctic Climates
NOTE
Refer to Engine Oil Recommendations (WP 0042, Table 1) for proper Genset oil
viscosity in arctic climates.
Refer to Radiator Coolant to Water Ratios (WP 0058, Table 1) for proper Genset
engine antifreeze to water ratios for arctic climates.
Sub zero temperatures and climatic conditions associated with cold weather affect the efficient operation of the
equipment. Keep equipment as dry as possible. After the equipment has been exposed to the cold and is moved
into a warm environment, moisture will collect on the trailer. Dry the external surfaces whenever possible. Follow
the instructions and precautions below for operation under such adverse conditions.
Starting the Genset in Arctic Conditions
The Genset is equipped with an engine heater for warming the engine and a fuel heater to warm up the fuel prior
to starting the engine in arctic climates.
CAUTION
The engine and fuel line heaters are not required when outside temperatures are
above 0°F (-17.77°C).
1. Move Genset Control Panel FUEL LINE HEATER switch to the up position.
2. Move Genset Control Panel ENGINE HEATER switch to the up position.
3. Allow fuel line and engine heaters to operate for approximately 20 minutes before starting engine.
4. Refer to Genset Start Procedure (WP 0005).
END OF TASK
0006-1
TM 11-6115-742-13&P 0006
Stopping the Genset in Artic Conditions
1. Move Genset Control Panel FUEL LINE HEATER switch to the down position.
2. Move Genset Control Panel ENGINE HEATER switch to the down position.
3. Refer to Genset Shut Down Procedure (WP 0005).
END OF TASK
Heating the Shelter in Arctic Climates
1. Primary Method. The ECU has electric heating strips that electrically heat the incoming air as it passes over
the strips.
a. Verify that the Air Supply and Return ducts are secured to their respective ports on the shelter as
described in Connect ECU Ducts to Shelter and Trailer (WP 0005).
b. Adjust the Damper on the ECU Return port to reduce the speed of the air flowing into and through the
Return Port. The Damper has four positions:
Open: Position for normal air cooling operation.
1/3: Position for heating air in mildly cold conditions (minimal heat needed).
2/3: Position for heating air in cold conditions (nominal heat needed).
Closed: Position for heating air in extreme cold conditions.
c. Secure the Supply and Return ducts to their respective ECU ports as described in Connect ECU Ducts to
Shelter and Trailer (WP 0005).
d. Turn the ECU Mode Select knob to HEAT HIGH 18 KW or HEAT LOW 9 KW mode according to the
current temperature inside the shelter.
2. Secondary Method. The ECU has an internal auxiliary fuel-fired heater for adding extra heat to the air to the
shelter through the Supply duct. The auxiliary heater draws its fuel from the Genset fuel tank.
NOTE
The auxiliary heater can be used to heat the shelter without using the electric
(primary) heat.
a. Turn AUXILIARY HEAT Select knob to MANUAL to provide continuous heat.
b. Turn AUXILIARY HEAT Select knob to AUTOMATIC to provide thermostat controlled heat to shelter.
END OF TASK
Operation in Tropical Climates
NOTE
Leaving the trailer inactive for long periods during rainy or humid conditions can
cause rapid rust. Fungus may develop in the cargo box as well as in shelter
component storage bags. Frequent inspections, cleaning, and lubrication are
necessary to maintain operational readiness of trailer and shelter.
Refer to Engine Oil Recommendations (WP 0042, Table 1) for proper Genset oil
viscosity in tropical climates.
Refer to Radiator Coolant to Water Ratios (WP 0058, Table 1) for proper Genset
engine antifreeze to water ratios for tropical climates.
0006-2
TM 11-6115-742-13&P 0006
Operation in Tropical Climates - Continued
High relative humidity causes condensation to form on the control panels whenever the temperature of the unit is
lower than the surrounding air. To minimize this condition, provide as much ventilation as possible. Dry the unit
control panel surfaces. Operate the ECU with the baffle in the open position.
If engine overheating occurs:
1. Turn off ECU to remove all electrical load on Genset, allowing engine to idle.
2. Observe coolant temperature gauge for steady cooling.
CAUTION
Stop engine if coolant temperature gauge suddenly increases beyond
approximately 230°F (110°C). Failure to comply will result in damage to engine.
3. If engine coolant temperature continues to increase or does not lower, stop engine. Perform troubleshooting
procedures in (Chapter 3).
END OF TASK
Desert Climates
NOTE
Refer to Engine Oil Recommendations (WP 0042, Table 1) for proper Genset oil
viscosity in desert climates.
Refer to Radiator Coolant to Water Ratios (WP 0058, Table 1) for proper Genset
engine antifreeze to water ratios for desert climates.
Operating the Genset and ECU in dusty or sandy areas requires frequent servicing of air filters and cooling system
fluids.
1. Frequently check air intake louvers. If air intake louvers become clogged and inoperable, stop engine and
refer to (WP 0101) for emergency air cleaner servicing.
2. If engine overheating occurs:
a. Turn off all electric loads on Genset and allow engine to idle.
b. Observe engine coolant temperature gauge for steady cooling.
CAUTION
Stop engine if coolant temperature gauge suddenly increases beyond
approximately 230°F (110°C). Failure to comply will result in damage to engine.
c. If coolant temperature continues to increase or does not lower, stop engine. Perform applicable
troubleshooting procedures in (Chapter 3 or Chapter 5).
Trailers completing operation in dusty, sandy areas must be lubricated and serviced by service maintenance as
soon as possible.
END OF TASK
0006-3
TM 11-6115-742-13&P 0006
Extreme Heat
NOTE
Refer to Engine Oil Recommendations (WP 0042, Table 1) for proper Genset oil
viscosity in extreme heat.
Refer to Radiator Coolant to Water Ratios (WP 0058, Table 1) for proper Genset
engine antifreeze to water ratios for extreme heat.
Extreme heat exists when ambient temperatures reach 95°F (35°C) or more. The effect of extreme heat on
Genset is a decrease in engine efficiency.
Before Operation, perform the following:
1. Perform before operation checks and services.
2. Check for foreign objects in front of radiator and clean as required.
3. Frequently check coolant temperature gauge and oil pressure gauge. Engine is overheating if one or more of
the following conditions exist:
a. Engine coolant temperature is more than approximately 230°F (110°C) as indicated by temperature
gauge.
b. Engine oil pressure drops below approximately 15 psi (103 kPa) with engine under a load.
END OF TASK
0006-4
TM 11-6115-742-13&P 0006
OPERATING ECU AS STAND – ALONE UNIT
The ECU may be removed from the trailer and operated as a stand alone unit. The ECU requires 208 VAC, 3 Ø
60 Hz and can draw up to 18 kW of power when operating in the HEAT HIGH/18 KW mode. Before hooking the
ECU up to any alternate power source, ensure that sufficient power is present and that other pieces of equipment
are not utilizing the power.
1. Remove ECU from trailer as described in ECU Removal/Replacement (WP 0109) and place on supports
(i.e., 8” high minimum treated lumber).
2. Connect supply and return ducts to ECU as described in Connect ECU Ducts between the Shelter and the
Trailer (WP 0005).
3. If hydronic heater is to be used, remove access panel and attach fuel line to fuel filter and run under ECU to
fuel source. If necessary, refer to (WP 0094) of this TM.
WARNING
Prior to performing the following step, ensure that power source is properly shut
down. Do not connect ECU to an active connection. Failure to observe this
warning can result in serious injury or death to personnel.
CAUTION
Prior to performing the following step, ensure that output connector on power
source and connector on ECU power cable mate up properly. Damage to
equipment could occur if improper electrical connections are made.
4. Connect ECU power cable to power source.
5. Start power source in accordance with procedures in appropriate TM(s).
NOTE
Prior to performing the following step, ensure that all PMCS (WP 0019 and
WP 0089) have been performed on the ECU.
Prior to performing the following step, ensure that all lines (i.e., drip lines, fuel
lines, ducts) are not kinked, damaged, or obstructed.
6. Start ECU in accordance with ECU Start Procedure (WP 0005).
7. Ensure the green POWER ON indicator light on ECU Control Panel is lit.
CAUTION
Do not run ECU with red OUT OF PHASE light on. Damage to motor can result.
8. Verify that red OUT OF PHASE light on ECU Control Panel is not on. If OUT OF PHASE light is lit, conduct
out of phasing troubleshooting procedures (WP 0011 and WP 0030).
CAUTION
Do not set thermostat below 50 degrees in cool mode and not above 90 degrees
in heat mode. Setting thermostat outside this range can cause the ECU to
malfunction.
0006-5
TM 11-6115-742-13&P 0006
OPERATING ECU AS STAND-ALONE UNIT – Continued
CAUTION
Do not adjust thermostat frequently. Select a temperature and leave it.
Frequent adjustment can cause premature failure of thermostat.
Temperature difference between ambient and interior shelter temperature is a
function of many variables.
9. Set ECU TEMPERATURE control to desired temperature required to maintain a comfortable interior shelter
temperature.
NOTE
Keep all shelter doors and windows, exterior and interior, closed as much as
possible to maintain dead air space between exterior and interior covers.
In very hot and sunny conditions, open interior and exterior windows for
convection to reduce heat.
Use camouflage netting or other shading means to reduce solar energy
absorbed by shelter.
The auxiliary heater is not used under normal operating conditions.
10. Turn ECU MODE SELECT switch to appropriate position. Modes of operation are:
– OFF, no ECU operation.
– FAN, circulating fan only operation.
– COOL, provides cool air and fan operation.
– HEAT LOW 9 KW, utilizes 9 kW of Genset power during heating operations. The remaining power may
be used to power ancillary devices.
– HEAT HIGH 18 KW, utilizes 18 kW of Genset power during heating operations. The minimal remaining
power may be used to power only a few ancillary devices.
END OF TASK
0006-6
TM 11-6115-742-13&P 0006
INTERIM CHEMICAL, BIOLOGICAL, RADIOLOGICAL, AND NUCLEAR (CBRN) DECONTAMINATION
PROCEDURES
CBRN
Contaminants are CBRN agents that have been formulated to kill or to incapacitate human beings.
General Guidance
NOTE
TMSS-MED items rendered inoperable due to contamination do not need to be
decontaminated and are to be discarded.
The TMSS-MED is mission-critical. The system is compatible for use by Soldiers in Mission Oriented Protective
Posture (MOPP) 4. Operators, using onboard equipment, must be able to conduct immediate decontamination
within 15 minutes, operational decontamination using onboard or crew-served equipment within six hours, and
thorough decontamination when mission allows reconstitution.
Probable CBRN Situation(s)
Use and storage Techniques, Tactics, and Procedures (TTP) dictate that access to the TMSS-MED is limited to
necessary maintenance and critical functions. This limits the exposure risk of components inside the TMSS-MED
to CBRN as the TMSS-MED provides a degree of protection. Under normal conditions with the access restricted,
the TMSS-MED acts as a self-contained, sealed system only exposed to external contamination. Radiation
contamination is unlikely to every system and subsystem. With all critical operational systems protected by the
TMSS-MED from contamination and thereby avoiding most risks associated with decontamination and ensuring at
least one decontamination-survivable workstation, the TMSS-MED operational capability as a critical system may
be degraded but is not destroyed by an CBRN event.
Immediate Decontamination (Equipment Only)
Per FM 3-11.5 referenced in (WP 0111), operator spray-down/wipe-down should be done within 15 minutes.
Operators use the M100 Absorbent Decontamination System (ADS) or the onboard M11/M13 decontamination
apparatus to decontaminate surfaces that they must touch or contact to operate the equipment. Radiological
contamination in the form of dust particles may be wiped, scraped, or brushed off.
Implementation. Decontamination of every surface that must be touched to operate the TMSS-MED is handled
in accordance with FM 3-11.5. The same procedures and actions are used for each item of equipment.
Likely Results. Systems incapable of withstanding decontamination are replaced. The TMSS-MED operational
capabilities and ease of maintenance become degraded but not destroyed since the vital operational components
are shielded inside the facility from most of the effects of the CBRN event. The remaining contaminated systems
continue with the decontamination process.
Operational Decontamination
NOTE
Normally the vital operational components would be shielded inside the
TMSS-MED from most of the effects of the CBRN event. In the event that a
component vital to the operational integrity of the TMSS-MED is contaminated but
unlikely to survive the operational decontamination wash-down and contamination
does not either hinder the operational ability of the system or pose a significant risk
to the operators, operational decontamination should be delayed until such time as
a replacement component is available.
0006-7
TM 11-6115-742-13&P 0006
Operational Decontamination – Continued
Per FM 3-5, equipment wash-down should be performed within six hours of being contaminated when the mission
does not permit a thorough decontamination. This process removes gross contamination and limits its spread.
Implementation. Every contaminated surface is washed down. The same procedures and actions are used for
each item of equipment.
Likely Results. Under operational decontamination procedures, every contaminated system that was adequately
and immediately decontaminated survives operational decontamination.
Thorough Decontamination
NOTE
In the event that a system vital to the operational integrity of TMSS-MED is
contaminated but unlikely to survive the Detailed Equipment Decontamination
(DED) and contamination does not either hinder the operational ability of the
system or pose a significant risk to the operators, operational decontamination
should be delayed until such time as a replacement system is available.
Per FM 3-11.5, DED restores items so that they can be used without MOPP gear. Normally, DED is conducted
as part of a reconstitution or during breaks in combat operations. This operation requires support from a chemical
decontamination unit.
Implementation. The chemical decontamination unit conducts a DED when the tactical situation permits. The
same procedures and actions are used for each item of equipment.
Likely Results. Under thorough decontamination procedures, every system that was adequately and
operationally decontaminated survives thorough decontamination.
RADIOACTIVE DECONTAMINATION PROCEDURES
NOTE
The following is only a brief guideline. Complete information may be found in
DA PAM 700-48.
Obtain assistance from medical personnel if decontamination of eyes, ears, nose,
or mouth is necessary.
Commanders must appoint a Radiation Safety Officer (RSO)/Radiation Protection Officer (RPO)/Radiation
Protection Staff Officer (RPSO)/Radiation Control Officer (RCO) at the appropriate unit level. Personnel handling
Radiologically Contaminated Equipment (RCE) incur a risk of exposure to and contamination from radioactive
materials. Proper radiation safety oversight is essential to minimize personnel exposure potential and to ensure
proper follow-up after the incident is over. In addition to the precautions outlined in DA PAM 700-48, personnel
handling RCE ensure trained personnel conduct radiation safety monitoring. Such monitoring includes, as a
minimum, surveys of personnel and equipment used and bioassays to document any exposure to the RCE
handler.
0006-8
TM 11-6115-742-13&P 0006
General Decontamination Procedure
The specific decontamination methods and procedures selected for use in particular circumstances depend on the
type, extent, and location of the contamination. However, the general approach to decontamination outlined below
applies to most situations.
1. Always perform decontamination under the direction of radiation safety personnel.
2. Access to contaminated areas must be controlled.
3. Provide protection, including appropriate clothing, for workers.
4. Evaluate what is to be decontaminated.
5. Obtain necessary equipment and materials.
6. Survey all items to be released to an unrestricted area.
7. Begin with the mildest decontamination method and progress to harsher, more abrasive, or caustic methods as
required.
8. Work from the outside of the contaminated area to the inside.
9. Isolate all clean areas from contaminated areas. Cover clean areas adjacent to those being decontaminated
with taped down paper, plastic, or other disposable material to prevent recontamination.
10. Minimize the generation of contaminated liquids and airborne radioactivity during the work. Collect and treat as
contaminated waste all liquids generated and materials used during decontamination operations.
11. Survey items between major steps in the decontamination process.
12. Continue decontamination until contamination levels are reduced to appropriate levels as per DA PAM 700-48.
13. Document the completion of decontamination, including the name of the individual performing the final survey,
the date, and the survey results. Utilize DA Forms 7399-R, 7400, and 7401. These forms are available on the
Army Electronic Library CD-ROM and the USAPA website.
END OF TASK
Personnel Decontamination
Before external decontamination of an individual is begun, the following steps should be taken to help establish
priorities for decontamination and follow-up effort.
1. Observe any physical effects on the contaminated person (i.e., bleeding, irregular breathing, burns, or shock).
2. Assess the extent of any injuries. Medical treatment of injuries takes priority over decontamination.
3. Determine the extent and magnitude of contamination using personnel survey techniques.
4. Document survey results on DA Form 7399.
5. Remove contaminated clothing, place it in a plastic bag, and hold it for further disposition.
6. Obtain assistance from medical personnel if decontamination of eyes, ears, nose, or mouth is necessary.
7. Personnel should be decontaminated as quickly as possible using the least drastic means necessary.
0006-9
TM 11-6115-742-13&P 0006
Personnel Decontamination - Continued
8. Decontamination methods should begin with mild methods, which should be continued as long as they are
effective, and progress to harsher methods only as required.
9. Extreme care should be taken to prevent the spread of contamination to any skin or body opening.
10. All liquids generated and materials used during decontamination should be collected and treated as
contaminated waste.
11. Personnel performing the decontamination should take all necessary precautions to protect themselves.
12. Cool or lukewarm water should be used for all washing and rinsing. Hot water causes the skin pores to open,
driving contamination deeper into the skin. Cold water closes the pores, trapping contamination in the skin.
END OF TASK
Specific Personnel Decontamination Methods
NOTE
In all cases of personnel contamination, the RPO must be consulted. If ingestion
or inhalation of radioactive material is suspected, bioassays should be performed.
1. Thorough washing with nonabrasive soap and lukewarm water is the best general method of decontaminating
the hands and other parts of the body. If the contaminant is localized, it is often more practical to mask off the
affected area and cleanse with swabs rather than risk the danger of spreading the contaminant by general
washing. Organic solvents must be avoided as decontaminating agents because they may increase the
probability of the radioactive materials penetrating through the pores of the skin. Special attention must be given
to the areas between the fingers and around the nails. The outer edges of the hands are easily contaminated
and must not be neglected in the washing.
2. After repeated washings, the skin may tend to chap. To avoid this, apply lanolin or hand cream and then
continue to wash. If repeated washing with soap and water is unsuccessful in the personnel decontamination,
the individual should be referred to the local medical officer for application of the more drastic chemical
decontamination.
3. In the event several individuals have become contaminated or the contamination on an individual is not localized
to a small portion of the body, the following decontamination procedure is recommended.
a. Place individual in a lukewarm shower.
b. Using a mild soap, individual should cover entire body with lather.
c. While still covered with lather, individual should step out of shower.
d. Sprinkle a heavy coat of mild soap flakes all over lathered individual (purpose of lather is to cause soap
flakes to adhere to person).
e. Using hands, the contaminated individual rubs the soap flakes on the body into a paste.
NOTE
It is necessary for the contaminated individual to rub body surfaces with their hands
while rinsing in order to remove soap paste. Soap paste remains on those areas
that have not been thoroughly washed. Although a soft cloth may be used, a brush
may not. Particular attention should be given to hairy portions of the body.
0006-10
TM 11-6115-742-13&P 0006
Specific Personnel Decontamination Methods - Continued
f. The contaminated individual returns to shower and rinses soap off the body by starting at the top and
working downward.
g. When the individual has rinsed to the point that the individual no longer feels slimy and while still under
shower, the individual should be examined by an assistant for traces of soap. The presence of soap
indicates which areas of the body have not been decontaminated.
h. After removing all traces of soap, the individual should leave the shower and dry the body.
i. After drying off, the individual must be monitored. If still contaminated, repeat above procedures. In the
event residual contamination is localized, repeat decontamination procedures to those areas still showing
contamination.
END OF TASK
Equipment and Material Decontamination
NOTE
Contaminated soil around accident and water runoff should be scraped up and
containerized for removal as radioactive waste.
Materials that cannot be easily or cost-effectively decontaminated should be evaluated for possible disposal as
radioactive waste. Porous items (e.g., wood, paper, cloth), intricately designed equipment, and items of low
replacement cost tend to fall in this category. If decontamination of equipment and/or materials is required, many
cleaning, abrasive, chemical, and electrochemical methods are available. Listed here are a few of the simpler and
least costly methods. These methods should be repeated until surveys indicate the need for harsher methods.
Under no circumstances is dry sweeping of radioactive contamination allowed. Appropriate Personal Protection
Equipment (PPE) must be worn.
• Place masking, adhesive, friction, or duct tape over the contaminated area; remove. When removed,
discard as radioactive waste.
• Use vacuum-cleaning techniques with a conventional wet or dry vacuum cleaner modified to include a High-
Efficiency Particulate Air (HEPA) filter on the exhaust. Dispose of bag or collection container as radioactive
waste. Respiratory protection must be used. If a HEPA filter is not available, do not vacuum.
• Wipe or wet mop using a decontaminating agent or detergents and hot water.
END OF TASK
JAMMING AND ELECTRONIC COUNTERMEASURES (ECM) PROCEDURE
The TMSS-MED system is not subject to jamming.
END OF WORK PACKAGE
0006-11/12 blank
TM 11-6115-742-13&P 0007
OPERATOR INSTRUCTIONS
TMSS-MED
EMERGENCY SHUTDOWN PROCEDURES
INITIAL SETUP:
Personnel Required Equipment Condition
One Equipment ON
References
WP 0004
GENERAL
This work package contains procedures for the emergency shutdown of the various pieces of equipment of the
TMSS-MED. Refer to Description and Use of Operator Controls, Indicators, and Connectors (WP 0004) for more
information about the location and function of controls, indicators, and connectors.
EMERGENCY SHUTDOWN PROCEDURES
Emergency Genset Operation
A Battle Short Switch on the Genset Control Panel is used when the Genset must remain running regardless of
operating conditions. The BATTLE SHORT switch overrides any automatic system shutdown protection devices
(such as low oil pressure, high water temperature) to keep the Genset operating.
1. Lift up the BATTLE SHORT switch cover on the Genset Control Panel.
2. Move the BATTLE SHORT switch to UP position.
To disengage the Battle Short Override, close the BATTLE SHORT switch cover by pressing down. Closing the
switch cover will turn off the BATTLE SHORT switch.
Emergency Power Down of Genset
1. Press the EMERGENCY STOP button on the Circuit Breaker Panel to immediately terminate all power from
the Genset.
2. After shutdown, set all circuit breakers on the Circuit Breaker Panel and ECU control panel to the OFF
position.
Emergency Power Down of ECU
1. If the ECU is running on power from the Genset, press EMERGENCY STOP on the Genset Circuit Breaker
Panel to immediately stop all power to the ECU.
2. If the ECU is running on an external power source (i.e., shore power), set MODE SELECT switch on the ECU
Control Panel to OFF to stop the unit.
END OF WORK PACKAGE
0007-1/2 blank
TM 11-6115-742-13&P 0008
OPERATOR INSTRUCTIONS
TMSS-MED
STOWAGE AND DECAL/DATA PLATE GUIDE
TRAILER
1
1
LABEL 2
LABEL 1
LIFT
Figure 1. Location of Identification and Data Plates on Trailer Rear.
Table 1. Identification and Data Plates on Trailer Rear.
LABEL DESCRIPTION
1 Stencil – Identifies location of proper Lift point on trailer.
2 Instruction plate – Black with white text. Informs user of procedure required to unload shelter from
trailer bed.
0008-1
TM 11-6115-742-13&P 0008
6 5 4 3
LABEL 1
LABEL 3
LIFT
LABEL 2
ACTUATOR
LOCK OUT
LABEL 4
LABEL 5 LABEL 6
DOLLY WHEEL/SKID PLATE
ASSEMBLY TIE DOWN TP - 20
MUST BE STORED
ON POST
WHEN TOWING
Figure 2. Location of Identification and Data Plates on Trailer Curbside.
Table 2. Identification and Data Plates on Trailer Curbside.
LABEL DESCRIPTION
1 Stencil – Identifies location of proper Lift point on trailer.
2 Instruction plate – Black with white text. Informs user of Actuator Lock Out.
3 Shipping instruction plate - Black with white text. Provides overall dimensions and Center of Gravity
data required for lifting and shipping.
4 Instruction plate – Black with white text. Informs user of proper location/storage of dolly wheel/skid
plate during transport of trailer.
5 Stencil – Identifies location of proper Tie Down point on trailer.
6 Instruction plate – Black with white text. Informs user of tire pressures required.
0008-2
TM 11-6115-742-13&P 0008
3
2
Figure 3. Location of Identification and Data Plates on Trailer Front.
Table 3. Identification and Data Plates on Trailer Front.
LABEL DESCRIPTION
1 Caution plate - Red with white text. Warns user of importance of trailer being level before operating
system.
2 Vehicle Identification Plate – Black with white text. Provides VIN, Model number, weight, and other
pertinent data about the trailer of the TMSS-MED.
3 CARC stenciling – Reminds personnel of presence of CARC paint.
0008-3
TM 11-6115-742-13&P 0008
8
7 3
6 5 4
Figure 4. Location of Identification and Data Plates on Trailer Roadside.
Table 4. Identification and Data Plates on Trailer Roadside.
LABEL DESCRIPTION
1 Instruction plate – Black with white text. Informs user of Actuator Lock Out.
2 Instruction plate – Black with white text. Informs user of system ground connection location on
trailer.
3 Instruction plate – Black with white text. Informs user of tire pressures required.
4 Stencil – Identifies location of proper Tie Down point on trailer.
5 Amendment Plate - Black with white text. Provides information regarding modifications to system.
6 Vehicle Identification Plate – Black w/white text. Provides VIN, Model number, weight, and other
pertinent data about the TMSS-MED.
7 Stencil – Identifies location of proper Lift point on trailer.
8 Instruction plate – Red with white text. Informs user of Actuator Lock Out.
0008-4
TM 11-6115-742-13&P 0008
ECU
LABEL 1 4 3 2 LABEL 3
LABEL 2
SUC TION
DO NOT REMOVE COVERS LIQU ID
LOW PRE SSUR E
DURING OPERATION HIGH PRESSU RE
LABEL 4
ECU
STARTAND STOPPROCEDURES: ENVIROMENTAL CONTROLUNIT (ECU)
START PROCEDURE
1. MODE SE LEC T SW I TCH MU ST BE IN “OFF” POSI TION .
2. CH EC K CI RC UI T BR EA KER I N MAS TER C ONTR OL PA NE L
MUS T BE I N “ON ” POSI TION TO B RI NG P OW ER IN TO TH E E CU .
3. SELE CT OP ER ATI NG MODE .
FA N: VEN TI LATION ON LY
COLL: C OOLI NG MODE (THE RM OS TAT C ONTR OLLE D)
HE AT: H EATIN G MOD E (TH ER MOSTAT CON TROLLED )
THE RM OS TAT I S P RE SET AT 70F. TO AD JU ST TH ER MOSTAT TU R N T EMPE RATU RE
DI AL TO DE SI RE D TE MPE RATU RE A ND LEAVE AT SETTI NG IT I S RE COMME ND ED TH AT
THE TH ER MOSTAT N OT B E AD JU STE D FRE QU EN TLY.
STOPPROCEDURE
1. TUR N MODE S ELEC T SW I TCH TO “OFF” POS ITI ON
2. IN SID E MAS TER C ONTR OL PA NE LTU RN E CU C IR C UI T BR EA KER TO “OFF” POS ITION
Figure 5. Location of Identification and Data Plates on ECU Front.
Table 5. Identification and Data Plates on ECU Front.
LABEL DESCRIPTION
1 Warning plate - Red with white text. Warns user not to remove access cover during operation of
ECU.
2 Instruction plate – Red with white text. Informs user of high pressure connection on ECU.
3 Instruction plate – Red with white text. Informs user of low pressure connection on ECU.
4 Instruction plate – Black with white text. Instructs user on operational procedures for the ECU.
0008-5
TM 11-6115-742-13&P 0008
2
1
CURBSIDE REAR VIEW
LABEL 1
DO NOT PRESSURE WASH LABEL 2
DO NOT REMOVE COVERS
DURING OPERATION
Figure 6. Location of Identification and Data Plates on ECU Curbside and Rear.
Table 6. Identification and Data Plates on ECU Curbside and Rear.
LABEL DESCRIPTION
1 Instruction plate – Black with white text. Informs user not to pressure wash ECU fins.
2 Warning plate – Red with white text. Warns user not to remove access cover during operation of
ECU.
0008-6
TM 11-6115-742-13&P 0008
GENSET
1 2 3
5 4
LABEL 1 LABEL 2
WARNING: DO NOT REMOVE CAUTION: WHILE PERFORMING
DURING OPERATION MAINTENANCE WITH ENGINE RUNNING,
WEAR APPROVED HEARING PROTECTION
LABEL 3
LABEL 4 LABEL 5
DO NOT STEAM CLEAN
LUBE OIL COOLANT
INSIDE ENCLOSURE DRAIN DRAIN
Figure 7. Location of Identification and Data Plates on Genset Front.
Table 7. Identification and Data Plates on Genset Front.
LABEL DESCRIPTION
1 Warning plate - Red with white text. Warns user not to remove access cover during operation of
Genset.
2 Caution plate – Black with white text. Reminds user to wear appropriate protection equipment
when Genset is operational.
3 Instruction plate – Black with white text. Informs user not to steam clean engine.
4 Instruction plate – Black with white text. Informs user of Genset lube oil drain plug.
5 Instruction plate – Black with white text. Informs user of location of Genset coolant drain plug.
0008-7
TM 11-6115-742-13&P 0008
1 LABEL 1
DIESEL FUEL
RECOMMENDED
JP8 MAY BE USED
JP4/JP5 AND KEROSENE
ARE NOT TO BE USED
Figure 8. Location of Identification and Data Plates on Genset Curbside.
Table 8. Identification and Data Plates on Genset Curbside.
LABEL DESCRIPTION
1 Instruction plate – Black with white text. Informs user of fuel used by Genset.
0008-8
TM 11-6115-742-13&P 0008
1 2 3
LABEL 1 LABEL 3
WARNING: DO NOT REMOVE DO NOT STEAM CLEAN
DURING OPERATION INSIDE ENCLOSURE
LABEL 2
CAUTION: WHILE PERFORMING
CAUTION: WHILE
MAINTENANCE PERFORMING
WITH ENGINE RUNNING
MAINTENANCE
WEAR APPROVEDWITH ENGINE
HEARING RUNNING,
PROTECTION
WEAR APPROVEDHEARING PROTECTION
Figure 9. Location of Identification and Data Plates on Genset Rear.
Table 9. Identification and Data Plates on Genset Rear.
LABEL DESCRIPTION
1 Warning plate - Red with white text. Warns user not to remove access cover during operation of
Genset.
2 Caution plate – Black with white text. Reminds user to wear appropriate protection equipment when
Genset is operational.
3 Instruction plate – Black with white text. Informs user not to steam clean engine.
0008-9
TM 11-6115-742-13&P 0008
LABEL 1
DANGER
HIGH VOLTAGE A-C H ERT Z A -C A-C
AM PERES KIL OWATTS VO LTS
BEHIND PANEL
1
DANGER
DANG ER B ATTERY HIG H VOLTAG E
HI GH VOLTAG E COO LANT OI L CHA RGER BEHIND PANEL
D C VOLTS TEM P HOU RMETER PR ESSU RE
BEHIND PANEL AM PS
1 FU E L LI N E H EA TE R 2
FLI P SWIT CH U PT O EN GA GE
FLI P SWI TC H DO WN TO TU RN O FF
C A UT I ON
D O NO T OP ER ATE HE ATER
WHE N OU TSI DE T EM PER ATU RE
I SA BO VE 0 DE GR EES FA HR EN HEI T
A U TO M AT I C V O L TA G E
VOLT/AM P PANEL L IGHT
HIGH
ENGINE AD J U S T I N C R E A SE
COOLANT LOWOIL
TEMP OVERSPEED PRESSURE
B AT TL E S HO R T E N GI N E H E AT ER
FLI PS WIT CH U PT O EN GA GE
R AI SE C OV ER
FLI P SWI TCH U P TO EN GA GE FLI P SWI TCH DO WN TO TU RN O FF
C LO SE C OV ER TO R ES ET
NO OPERATOR-L EVEL
MAINTAINABLE F UNCTIONS
BEHIND THI SPANEL
LABEL 4 LABEL 2
4
NO OPERATOR-LEVEL CAUTION
MAINTAINABLE FUNCTIONS DO NOT OPERATE HEATER
WHEN OUTSIDE TEMPE RATURE
BEHIND THIS PANEL IS ABOVE 0 DE GREE S FAHRE NHEIT
LABEL 3
EMERGENCY CB1 CB2 CB3 CB4 CB5
OFF ON EMERGENCY
SHUTDOWN SHUTDOWN
PRESS IN TO ENGAG E
PRESS INTOENGAGE TURNCLOCKWISE
J1 J2 J3 J4 GEN
BATTERYSWITCH
O TO RESET
TURN CLOCKWISE
TO RESET
Figure 10. Location of Identification and Data Plates on Genset Control Panel and Circuit Breaker Panel.
Table 10. Identification and Data Plates on Genset Control Panel and Circuit Breaker Panel.
LABEL DESCRIPTION
1 Warning plate – Red with white text. Informs user of presence of high voltage.
2 Warning plate – Red with white text. Informs user that heater should not be operated when
temperature is above 0° F (-17.77°C).
3 Instruction plate – Red with white text. Instructs user on emergency shut down of Genset.
4 Warning plate – Red with white text. Informs user that no crew maintenance present behind control
panel.
0008-10
TM 11-6115-742-13&P 0008
1 2 3 4
T MS S
OPE RATING PR OCE DUR E - FUE LFIRED CO OLAN TH EATER DA I L
Y: C H EC K F UE LS U PP L
, C O O LA NT L EV EL S. CH E CK FO RA N Y LE AK S. CH E CK BATT ER .Y
Y OPE RATING PRO CE DUR E - BATTERY SW ITCH
A FTE R F I RS T 50 H O UR S : C HA N GE O L LE R . C HE C K TE N SI O N O N B ELT DR I VE S . C HE C K
I AN D OI LF I T
SWI TC H: WHE NT HE S WIT CH I S TU RN ED “ O N” T HE O PE RATI ON N I DI CATO R ( TOG G LE) C O O LAN T LE V ELS . TH E B A
T TE RY S WI CT H MU S TB E TU R N ED TO TH E ‘ ON ’ PO S I TI O N TO O P ER ATE T HE GE N SE .T
LI GH TS U P
. S HO RT L
YT HE RE AFT ER , TH E HE T
AE R BE G IN S OP ER A
T IO NA ND D EL IV ER S E VE RY 50 H O U RS : CH E CK T EN S IO N ON BE L T DRV I ES , C H EC K C O O LA NTA N D O I LLE V ELS .
HE TA ED C OO LA NT TO TH E EN GI NE . E VE RY 12 5 HO U R S: CL EA NA I R FI LTE R. IF O P ER ATI N G I N H O T CL IM ATE , C H AN G EA I R FI L
T ER . CH E CK
START UP PR O CE DU RE F UE LF ILTE R . U ST-HP
TH E CO O LAN TC IR C ULATI NG PU MP , C ER AMI C IG N T
I O RA ND C O MB US TI ON AI R FAN S ATR T E VE RY 25 0 HO U R S: CH A NG E O I L. CH E CK T EN S IO N O F B ELT DR I VE S. A DJU S T IF TO O LO O SE . C LE AN
OP ER A
T IO NA ND AF TER AP PR OX IM ATELY6 0S EC ON D S CO M BUS TI O N START S A ( UD IB LE) . A I R FI T
L E R. RE M O VE / CL EA N F UE LI N JEC TO R NO Z ZLE S . R EMO V E/ CL EA N S PAR K
AF TER TH E C OO LA NT TEM P HA S RE AC HE D THE S ET PO I NT O F1 70 DE GR EE ST HE H EATE R A R RE S TO R O N E XH A US .TU S E DI E SE LF U ELT O C LE AN . SAT R TA N D S TO P P R O C E D U R E S : G E N S ET A N D E C U
WIL LA UTO MA T IC ALLYAD JUS TI TS H EAT OU TP UT TOA LOW ER O PE RATI NG R AN G E. E VE RY 50 0 HO U R S: SA M EA S 25 0 HO U R P R OC E DU R E. A LS O, CH A NG E F U ELAN D AI R F L I TE R .
IF TH E TEM P ER A T UR E OF TH E CO O LAN T CO NT N I UE ST O RI SE AN D CLI M B O VER 174 DE GR EE S F E VE RY 1, 00 0 HO U R S: RE P EAT 500 H O U R PR O C ED U RE . ALS O CH E CK AL LE XT ER N AL FI TT IN G S . S TA RT PR O C E D U R E
T TH E HE T
A A ER O UT LET, T HE H EATER WILL CY CLE O FF . E VE RY 2, 00 0 HO U R S: DE C AR B ON I ZE E N G N I E I FP ER F OR M I N G P OO R L. DR A N
Y I AN D C LE A N FU E LTAN K. 1. C H EC K O I L, CO O LA N TAN D B ATTE R. Y
WHE N TH ET EM PE RATU RE FAL LS BE LOW 14 9D EG R EES F TH E HE A T ER WI LL RE ST A RTA ND C H EC K I NJ EC TO R S- C LE AN O R C HA N GE AS RE Q U IR E D. CH A NG E F ILTE R SA ND 2. C H EC K P O WE R S EL EC TI O N S WI TC H : M U ST B E I N “ O FF ” P OS I TI O N.
RE PE A
T THE HEATI N G CY CLE . D R IV E B ELTS . 3. T UR N AMM E TE R/ V O T LM E TE R S WI TC H FR O M “ O FF ” TO AN Y LE G P O S T I O
I N.
4. T UR N E N G IN E S T A RT S WI TC H C O U NT ER C LO C KW IS E TO PR EH E A . HO L D FO R T EN
T
SWI TC HI NG OF F I M PO R T
A NT:DEI SE L EN G N I E B U RN SA P PR O XI M ATE YL O N E PI N T O F OI L EV ER Y EI G H TH O U RS OF S E CO N D S ( LO NG E R I F WE ATH ER IS CO L D) .
M AN UAL L Y: WH EN H EATI NG I S N O LO NG ER R EQ U IR ED , SWI TC H TH E HE T
A ER O FF 5. T UR N E N G IN E S WI TC H C LO C KW IS E TO STAR T PO S IT I ON . RE LE AS E WH E N E NG I N E
BY M EA NS O FT HE TO G GLE S WI TCH . C O N TI NU O U S O PE R AT IO N A
T F UL LL OA D . O I LLE V EL MUS T BE CH E CK ED EV E RY E IG H T HO U R SA ND
TH E IN DI CATO R LI GH TT UR NS O FF, C O MB US TI ON S
I E XTI NG U S
I HE D FO LLO WED B YAN R E FI LLE DA S R E QU I R ED . O TH E RW SI E, SE R O I U S D AM A G E C O UL D R ES U L T TO E N GI N E. S TAR TS .
AF TER R UN CY CLE O FA PPR O XI MATE L Y 90 SE CO ND S. 6. T UR N P O WE R S WI TC H F RO M “ O FF” TO “ G E N” PO S IT I ON .
TH E O I LF I LLI S L OC ATE D O N R O C KE R H EA D O F T HE EN G IN E . TH I S FI LL CA N B E U S ED TO A DD O IL 7. T UR N G E G ER ATO R C IR C U IT B RE A KE RS T O “ O N” PO S I TI O N. T U RN ON O TH ER C IR C UI T
WH I LE TH E E N G N I E I S R UN N I NG. B R EA KE R S TH ATAR E N EE D ED .
S TO P P R O C E D U R E
F UE LC O N SU MP TI O N: 1. 25 G PH @ 100 % LO AD . F UE LTAN K H O LD S 1 6 GA LL ON S . F IL LE VE RY 12 1. T U RN EC U AN DA LL EL EC T RI C AL DE V IC ES “ OF F” .
H O U RS TO P RE VE N T FU EL STAR VATO
I N AN D E N G IN E S H UT DO W N. 2. T UR N AL LC IR C UI T B RE AK E RS T O “ O FF ” P OS I TI O N.
3. T UR N P O WE R S EL EC T SW IT C H TO “ O FF ” P O SI T O I N.
I M P OR T
ANT : TH E RE SH O UL D B E N O LO A D O N T HE G EN ER ATO R . D O N O TS H UT
E N G IN E O FF WI TH ALO A D O N T HE GE N ER ATO R.
4. T UR N E N G IN E S WI TC H TO “ OF F” PO S T I I ON .
E C U S TA R TA N D S TO P P R O C E D U R E S
1. T UR N E C U C IR C U IT B RE A KE RS T O “ O N” .
2. G O TOA C CE S S PAN EL O N F RO WAR D SI D E O F EC U F O R O PE R A T I NG N
I S TR U CT IO N S .
F O R MA XI M UM O P ER T A I NG PE R FO R MAN C E O F TH E G EN E RATO R SE T
A N D TO VA O ID WE T STAC K IN G
, US EA MIN I M U MLO A D O F 1 0kw A
TA LLT I M ES .
( se e WAT TME TE R on I N ST RU M E NT PA NE L)
T OMA N I TAI NA M N
I I M UM O F 10 kw. U SE T H E H V
A C U N ITA SA LO A D.
I F C LI M A
T E C O NT R OL I S N OT N E ED ED IN TH E S HE L T ER . R E M OV E TH E AI R D U CT S
F RO M TH E S HE L T ER A ND CO N TI N U E O PE RAT NI G T HE HVA C U NI T .
LABEL 1
LABEL 3
OPERATING PROCEDURE - FUEL FIRED COOLANT HEATER TMSS
SWITCH : WHEN THE SWITCH IS TUR NED “ON ” THE OPERATION INDICATOR (TO GGL E)
OPERATING PROCEDURE - BATTERY SWITCH
LIGHT S UP. SHORTLY THER EAF TER, T HE HEATER BEGINS O PERAT IO N AND DELIVERS
HEATED COO LANT T O T HE ENG INE. THE BATTERY SWITCH MUST BETURNED TO THE ‘ON’POSITION TO OP ERATETHE GENSET.
STARTU P PROCEDURE
THE COO LANT CIRC ULATING PUMP, CERAMIC IGNITOR AND CO MBUSTION AIR FAN START
OPERATION AND AF TER APPRO XIMATELY 60 SECO NDS CO MBU STIO N STARTS (AUD IBLE).
AFT ER THE COO LANT TEMP HAS REACHED T HE SET POINT OF 170 DEG REES T HE H EAT ER
WILL AUTOMAT ICALLYADJUST IT S HEAT OUT PUTT O A LOW ER O PERATING RANGE.
IF T HE TEMPERATURE OF T HE CO OLANT CO NTINUES TO RISEAND CLIMB OVER 174 DEGREES F
L ABEL 4
AT T HE HEAT ER O UTL ET,T HE HEAT ER W ILL CYCLE OF F.
WHEN THE TEMPERATURE FALLS BEL OW 14 9 DEG REES F THE HEATER WILL RESTART AND
REPEAT TH E HEATING CYCLE.
UST-HP
SWITCH ING O FF
MANUALLY: W HEN HEAT ING IS NO LONG ER REQU IRED, SW IT CH T HE HEAT ER O FF
STA RTAND STOP PROCE DURES: GEN SET AND ECU
BY MEANS OF THE TOG GLE SWITCH. START PROCEDURE
THE IND ICAT OR LIG HT TURNS OF F, CO MBUST IO N IS EXTINGU ISHED FOL LOW ED BY AN 1. CHECK OIL, COOLANT AND BATTERY.
AFT ER RUN CYCLE O F APPROXIMAT ELY 90 SECONDS. 2. CHECK P OWER S ELECTION SW ITCH: MUST BE IN “OFF” P OSITION.
3. TURN AMMETER/VOLTMETE R SWITCH FROM “OFF” TO ANY LEG POSITION.
4. TURN ENGINE START SWITCH COUNTE RCLOCKWISE TO P REHEAT. HOLD FOR TEN
SECONDS (LONGER IF WEATHER IS COLD).
5. TURN ENGINE SWITCH CLOCK WISE TO START POSITION. RELEASE WHEN ENGINE
STARTS.
6. TURN POWER SWITCH FROM “OFF” TO “GEN” POSITION.
7. TURN GENE RATOR CIRCUIT BREAKERS TO “ON” POSITION. TURN ON OTHER CIRCUIT
BRE AKERS THAT ARE NE EDED.
LABEL 2 STOP PROCEDURE
1. TURN ECUANDA LL ELECTRICA LDEVICES “OFF”.
TMSS-MED 2. TURN ALLCIRCUIT BREAKERS TO “OFF” POSITION.
3. TURN POWER SELECT SWITCH TO “OFF” POSITION.
DAILY: CHECK FUEL SUPPLY, COOLANT LEVELS. CHE CK FORA NY LEAKS. CHECK BATTERY. IMPORTANT: THERE SHOULD BE NO LOAD ON THE GENERATOR. DO NOT SHUT
AFTER FIRST 50 HOURS: CHANGE OILAND OIL FILTER. CHECKTENSION ON BELT DRIVES. CHECK ENGINE OFF WITHA LOAD ON THE GENERATOR.
COOLANT LEVELS. 4. TURN ENGINE SWITCH TO “OFF” P OSITION.
EVERY50 HOURS: CHECK TENSION ON BELT DRIVES, CHECK COOLANTAND OIL LE VELS.
EVERY125 HOURS: CLEAN AIR FILTER. IF OPERATING IN HOT CLIMATE, CHANGE AIR FILTER. CHECK ECU START AND STOP PROCEDURE S
FUEL FILTER. 1. TURN ECU CIRCUIT BREAKE RS TO “ON”.
EVERY250 HOURS: CHANGE OIL. CHECK TENSION OF BELT DRIVES. ADJUS T IF TOO LOOSE. CLEAN 2. GO TOACCESS PANE LON FROWARD SIDE OF ECU FOR OPERATING INSTRUCTIONS.
A IR FILTER. REMOVE/CLEAN FUEL INJECTOR NOZZLES. REMOVE/CLEAN SPARK
A RRESTOR ON EX HAUST. USE DIESEL FUEL TO CLEAN.
EVERY500 HOURS: SAMEA S 250 HOUR PROCEDURE. ALSO, CHANGE FUELAND AIR FILTER.
EVERY1,000 HOURS: REPEAT 500 HOUR P ROCEDURE.ALSO CHECKALL EXTERNALFITTINGS.
EVERY2,000 HOURS: DECARBONIZE ENGINE IFPERFORMING POORLY. DRAINAND CLEAN FUELTANK.
CHECK INJECTORS-CLEAN OR CHANGE AS REQUIRED. CHANGE FILTERSAND
DRIVE BE LTS. LABEL 5
IMPORTANT: DIESEL ENGINE BURNSAPPROXIMATELY ONE PINT OF OIL EVERYE IGHT HOURS OF
CONTINUOUS OPERATION AT FULL LOAD. OILLEVE LMUST BE CHE CKE D EVERY EIGHT HOURSAND
REFILLEDAS REQUIRED. OTHERW ISE, S ERIOUS DAMAGE COULD RE SULT TO ENGINE. FOR MAXIMUM OPERATING PERFORMANCE OF THE GENERATOR SET
AND TO AVOID WET STACKING, USE AMINIMUM LOA D OF 10kwATALLTIMES.
THE OIL FILL IS LOCATED ON ROCKER HEAD OF THE ENGINE. THIS FILL CAN BE USED TO ADD OIL (s ee WATTMETER on INSTRUMENT PANEL)
WHILE THE ENGINE IS RUNNING.
TO MAINTAIN A MINIMUM OF 10kw. USE THE HVAC UNITAS ALOAD.
FUELCONSUMPTION: 1.25 GPH @ 100% LOAD. FUELTANK HOLDS 16 GALLONS. FILL EVERY 12 IF CLIMATE CONTROL IS NOT NEEDED IN THE S HELTER. REMOVE THE AIR DUCTS
HOURSTO PREVENT FUEL STARVATIONAND ENGINE SHUTDOWN. FROMTHE SHELTE RAND CONTINUE OPERATING THE HVA C UNIT.
Figure 11. Location of Identification and Data Plates on Genset Control Panel Access Door.
0008-11
TM 11-6115-742-13&P 0008
Table 11. Identification and Data Plates on Genset Control Panel Access Door.
LABEL DESCRIPTION
1 Instruction plate – Black with white text. Informs user of Operating Procedures for Fuel Fired Coolant
Heater.
2 Instruction plate – Black with white text. Informs user of scheduled PMCS.
3 Instruction plate – Black with white text. Informs user of required setting of BATTERY SWITCH for
Genset operation.
4 Instruction plate – Black with white text. Informs user of start and stop procedures for Genset and
ECU.
5 Instruction plate – Black with white text. Informs user of load requirements on Genset to prevent wet
stacking.
END OF WORK PACKAGE
0008-12
TM 11-6115-742-13&P 0009
OPERATOR INSTRUCTIONS
TMSS-MED
ON-VEHICLE EQUIPMENT LOADING PLAN
SCOPE
The following illustrations and tables assist in identifying all on-vehicle equipment when the TMSS-MED system is
ready to deploy.
1
2
5
6
6
Figure 1. TMSS-MED Shelter Loading Plan.
Table 1. TMSS-MED Shelter Loading Plan.
ITEM NO. ITEM NAME QUANTITY
1 Main shelter 1
2 Shelter floor 1
3 Cinch straps 2
4 Push poles 4
5 Shelter transport bag 1
6 Shelter end caps 2
0009-1
TM 11-6115-742-13&P 0009
ROADSIDE CURBSIDE
1
10
7 2
3
6
Figure 2. TMSS-MED Trailer Loading Plan.
0009-2
TM 11-6115-742-13&P 0009
Table 2. TMSS-MED Trailer Loading Plan.
ITEM NO. ITEM NAME QUANTITY
1 ECU Ducts (1-supply, 1-return) (in cargo bags) 2
2 Shelter (in cargo bag) 1
3 Electrical Wiring kit (in cargo bag) 1
4 Stake set (in cargo bag) 1
5 Storage compartment which holds:
Shelter repair kit 1
Funnel 1
Auxiliary fuel lines 1
Technical Manual TM 11-6115-742-13&P 1
250 hour push pack 1
6 End cap (in cargo bag) 1
7 End cap (in cargo bag) 1
8 Shelter light set (in cargo bag) 2
9 Dry chemical fire extinguisher 1
10 Ground Rod Assembly (not shown) 1
END OF WORK PACKAGE
0009-3/4 blank
TM 11-6115-742-13&P
CHAPTER 3
CREW TROUBLESHOOTING PROCEDURES
FOR
TMSS-MED
TM 11-6115-742-13&P 0010
CREW TROUBLESHOOTING PROCEDURES
TMSS-MED
CREW TROUBLESHOOTING INDEX
GENERAL
This WP contains a troubleshooting index of conditions/indications that may develop during maintenance or
operation. Maintenance is limited to those failures that may be repaired at the crew level. The troubleshooting
index identifies the condition/indication, which is followed by a column that identifies the work package and
page(s) where crew level troubleshooting procedure(s) may be found (in the form of an inspection), followed by
simple corrective actions which may be done by the crew. These inspections and corrective actions should be
performed in the order listed. The index is provided to assist in the quick location of a problem. The manual
cannot list all conditions/indications that may occur. If a condition/indication is encountered that is not listed or
that cannot be corrected by the corrective actions provided, notify the supervisor.
TROUBLESHOOTING INDEX
The troubleshooting index assists the operator after a fault occurs. When a fault occurs, carefully inspect the
equipment for fault indications to determine the best condition/indication to follow. The most important step in
troubleshooting is recognizing the conditions/indications and combination of conditions/indications. Use the
corrective action for a given condition/indication in the order of appearance. If the first repair attempt is
unsuccessful, proceed to the next recommended corrective action to resolve the problem. If a fault is
encountered that is not listed or that cannot be corrected by the corrective actions provided, notify the supervisor.
Except for the equipment in the Crew Troubleshooting Index (Table 1), refer to appropriate technical manual(s) for
any remoted equipment. (Table 1) is provided as a tool to maintain equipment in good operating condition and
ready for its primary mission.
Table 1. Crew Troubleshooting Index.
ITEM CONDITION/INDICATION WP
GENSET (Engine)
1 Coolant leaking ...................................................................................................... 0011-2
2 Fuel leaking ........................................................................................................... 0011-2
3 Oil leaking .............................................................................................................. 0011-2
4 Battery acid leaking ............................................................................................... 0011-3
5 Engine does not crank ........................................................................................... 0011-3
6 Engine turns over slowly ........................................................................................ 0011-3
7 Engine cranks but does not start ........................................................................... 0011-3
8 Engine cranks but does not start (ambient temperature below 32°F (0°C)) ......... 0011-3
9 Engine stops (no warning lights) ........................................................................... 0011-4
10 Engine stops (HIGH COOLENT TEMP warning light on) ................................... 0011-4
11 Engine stops (LOW OIL PRESSURE warning light on) ...................................... 0011-4
12 Engine stops (OVERSPEED warning light on).................................................... 0011-5
13 Excessive carbon deposits appear on exhaust outlet ......................................... 0011-5
14 Engine emits excessive smoke ............................................................................. 0011-5
15 DC VOLT meter reads below 28 VDC while Genset is running ............................ 0011-5
16 Engine temperature remains below 120°F (48.88°C) ........................................... 0011-5
17 AC KILOWATTS meter reads 0 with Genset under load ...................................... 0011-5
18 Engine temperature above 220°F (104.4°C), engine still running ......................... 0011-5
19 Engine oil pressure reading below 20 psi, engine still running ............................. 0011-6
20 Engine heater (Hydronic) will not start (no fault code) .......................................... 0011-6
21 Engine heater (Hydronic) (fault code F01 or F02) ................................................. 0011-6
0010-1
TM 11-6115-742-13&P 0010
Table 1. Crew Troubleshooting Index – Continued.
ITEM CONDITION/INDICATION WP
GENSET (Engine) - Continued
22 Engine heater (Hydronic) (fault code F03) ............................................................ 0011-6
23 Engine heater (Hydronic) (fault code F04, F05, F06, F07, F08, F09, F010) ........ 0011-6
GENSET (Electrical)
1 Generator produces no voltage ............................................................................. 0012-2
2 Generator produces low voltage (under no load condition)................................... 0012-2
3 Generator produces low voltage (under load condition)........................................ 0012-2
4 Generator produces high voltage (under no load condition) ................................. 0012-2
5 Generator produces high voltage (under load condition) ...................................... 0012-2
6 Generator voltage fluctuates/wanders ................................................................... 0012-3
7 Generator frequency out of tolerance ................................................................... 0012-3
8 Generator builds voltage from start-up then goes to low voltage .......................... 0012-3
ECU
1 ECU will not run on Genset power ........................................................................ 0013-2
2 ECU will not run on shore power ........................................................................... 0013-2
3 Voltage out of phase (red light on ECU control panel light) .................................. 0013-2
4 Conditioned air too cold (in Heat mode) ................................................................ 0013-2
5 Conditioned air too warm (in Cool mode) .............................................................. 0013-2
6 Evaporator or condenser fan does not operate ..................................................... 0013-3
7 Coolant leaking ...................................................................................................... 0013-3
8 Fuel leaking ........................................................................................................... 0013-3
9 Hydronic heater will not start (no fault code) ......................................................... 0013-3
10 Hydronic heater (fault code F01 or F02)................................................................ 0013-3
11 Hydronic heater (fault code F03, F04, F05, F06, F07, F08, F09, F010) ............... 0013-3
TRAILER
1 Hand brake does not engage ................................................................................ 0014-2
2 Trailer lights do not work ....................................................................................... 0014-2
3 Trailer does not track straight when towed ............................................................ 0014-2
4 Tire will not hold air pressure ................................................................................. 0014-2
5 Tongue jack assembly will not raise/lower ............................................................ 0014-2
6 Stabilizer leg will not raise/lower............................................................................ 0014-3
SHELTER (Mechanical)
1 Shelter/end cap will not spread while on ground ................................................... 0015-2
2 Shelter/end cap will not erect ................................................................................ 0015-2
3 Shelter/end cap will not stay erected ..................................................................... 0015-2
4 Shelter/end cap or shelter door leaks .................................................................... 0015-2
5 Keepers coming out while erected ........................................................................ 0015-2
6 Shelter/end cap has unusual shape when erected ............................................... 0015-3
7 Shelter/end cap binds when coming down ............................................................ 0015-3
8 Shelter/end cap will not collapse completely when on ground .............................. 0015-3
9 Shelter or end cap shakes excessively ................................................................. 0015-3
SHELTER (Electrical)
1 Shelter lighting does not come on ......................................................................... 0016-2
2 No power from PDU............................................................................................... 0016-2
3 Power indicator lights inoperable........................................................................... 0016-2
END OF WORK PACKAGE
0010-2
TM 11-6115-742-13&P 0011
CREW TROUBLESHOOTING PROCEDURES
TMSS-MED
GENSET (ENGINE) TROUBLESHOOTING PROCEDURES
INITIAL SETUP:
Personnel Required References
Two WP 0005, WP 0006, WP 0022, WP 0023
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by crew-level qualified
personnel. This work package provides a systematic approach to locating and correcting malfunctions of the
TMSS-MED. Each section is arranged according to the condition/indication of a problem. The corrective action
items have been arranged in order of complexity, with simpler actions listed first. The manual cannot identify all
malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be corrected by the
corrective actions provided, contact your supervisor.
WARNING
Special caution must be taken during troubleshooting since protective covers and
safety devices may be removed or disabled to gain access and make tests.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand brakes are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0011-1
TM 11-6115-742-13&P 0011
Table 1. Crew Troubleshooting – Genset (Engine).
ITEM CONDITION/INDICATION CORRECTIVE ACTION
WARNING
If Genset has been in operation, components (i.e.,
engine, radiator) may be extremely hot. To prevent
serious injury to personnel, allow sufficient time for
cool down before proceeding with checks.
1 Coolant leaking Inspect overflow bottle and hose for damage or leaking.
Inspect radiator for damage or leaking.
Inspect coolant hoses for proper connections, damage, or
leaking.
Check coolant drain valves are turned off and drain plug
is secure.
Contact Maintainer Maintenance.
2 Fuel leaking WARNING
All fuels generate explosive fumes and gases.
Utilize extreme caution. Do not smoke or use open
flame when in the vicinity of fuels and associated
tanks, lines. Death or severe burns to the operator
or damage to the equipment may result.
Inspect fuel tank for damage or leaking.
Inspect fuel lines for damage or leaking.
Inspect fuel pump for damage or leaking.
Inspect fuel filter for damage or leaking.
Check fuel drain valve is turned off and drain plug is
secure.
Contact Maintainer Maintenance.
3 Oil leaking Inspect oil filter for damage or leaking.
Inspect oil pan for damage or leaking.
Inspect oil lines and drain valves.
Contact Maintainer Maintenance.
0011-2
TM 11-6115-742-13&P 0011
Table 1. Crew Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
4 Battery acid leaking WARNING
Batteries generate explosive gas during charging.
Utilize extreme caution. Do not smoke or use open
flame in the vicinity of the battery. Death or severe
burns may result.
Battery acid can be dangerous, do not touch. Death
or severe burns may result.
Inspect battery for cracks or other breaks.
Contact Maintainer Maintenance.
5 Engine does not crank Check BATTERY SWITCH is set to ON.
Check batteries for loose connections.
Check for loose ground connection on engine.
Check solenoid(s) and starter for loose connections.
Check for low voltage. If below 24 VDC, attach generator
NATO slave receptacle to vehicle and attempt to start
engine (WP 0005).
Contact Maintainer Maintenance.
6 Engine turns over slowly Attach generator NATO slave receptacle to vehicle or
trailer and attempt to start engine (WP 0005). If engine
still starts slowly, contact Maintainer Maintenance.
7 Engine cranks but does not start Check if EMERGENCY STOP button pushed in. Reset.
Check for fuel supply valve set to proper operating mode
(WP 0005). Reset.
Check actuator and diesel speed sensor connections.
Check for fuel.
Check fuel level in fuel tank. Add fuel and restart engine
(WP 0005).
Contact Maintainer Maintenance.
8 Engine cranks but does not start (ambient Check if EMERGENCY STOP button pushed in. Reset.
temperature below 32°F (0°C))
Check for fuel supply valve is set to proper operating
mode (WP 0005). Reset.
0011-3
TM 11-6115-742-13&P 0011
Table 1. Crew Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
8 Set ENGINE switch to PREHEAT for approximately 30
(cont.) seconds. Restart.
Check fuel level in fuel tank. Add fuel and restart engine
(WP 0005).
Set ENGINE HEATER (hydronic) and FUEL LINE
HEATER switches to on (UP) (WP 0006).
Contact Maintainer Maintenance.
9 Engine stops (no warning lights) Check if EMERGENCY STOP button pushed in. Reset.
No fuel. Refill fuel tank, Set CB1 – CB5 OFF and remove
load. Turn ENGINE switch to OFF then to START to
restart engine (WP 0005).
Contact Maintainer Maintenance.
10 Engine stops (HIGH COOLANT TEMP WARNING
warning light on)
If coolant is not visible in radiator, let the engine
cool down then restart engine and add coolant
while the engine is running.
Engine overheating due to lack of coolant. Refill radiator
to 1" and overflow bottle to proper level of 1/3 to 1/2 full
(WP 0022).
Turn ENGINE switch to OFF then to START to restart
engine and check warning light (WP 0005).
Re-circulated exhaust gas or engine air. Reposition
trailer for better circulation. Turn ENGINE switch to OFF
then to START to restart engine and check warning light
(WP 0005).
Obstructed air inlets or exhausts. Clear air inlets and
exhausts. Turn ENGINE switch to OFF then to START to
restart engine and check warning light (WP 0005).
Overloaded engine. Reduce load on engine. Turn
ENGINE switch to OFF then to START to restart engine
and check warning light (WP 0005).
Contact Maintainer Maintenance.
11 Engine stops (LOW OIL PRESSURE Engine shutdown due to low oil pressure. Check and
warning light on) refill engine oil (WP 0022). Turn ENGINE switch to
START to restart engine. Check warning light
(WP 0005).
Contact Maintainer Maintenance.
0011-4
TM 11-6115-742-13&P 0011
Table 1. Crew Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
12 Engine stops (OVERSPEED warning light Check for fuel. Refill fuel tank. Turn ENGINE switch to
on) OFF then to START to restart engine (WP 0005).
Contact Maintainer Maintenance.
13 Excessive carbon deposits appear on WARNING
exhaust outlet
If Genset has been in operation, exhaust system (pipes,
muffler, spark arrestor) may be extremely hot. To
prevent serious injury to personnel, allow sufficient time
for cool down before proceeding.
Engine operating without sufficient load. Perform the
following:
• Add additional load to the engine by turning on the
ECU and operating at minimum 50% load for 4 hours.
Obstructed exhaust system. Perform the following:
• Check that exhaust pipe outlet is not clogged or
blocked.
• Check that an exhaust pipe is not broken.
• Check rain cap for proper function.
Obstructed air inlet system. Perform the following:
• Check that air filter inlet is not blocked.
• Check that air filter is not clogged.
Contaminated fuel. Contact Maintainer Maintenance.
Contact Maintainer Maintenance.
14 Engine emits excessive smoke Ensure FUEL SUPPLY switch is placed fully in proper
position.
Contact Maintainer Maintenance.
15 DC VOLT Meter reads below 28 VDC Contact Maintainer Maintenance.
while Genset is running
16 Engine temperature remains below 120°F Contact Maintainer Maintenance.
(48.88°C)
17 AC KILOWATTS meter reads 0 with Contact Maintainer Maintenance.
Genset under load
18 Engine temperature above 220°F on NOTE
COOLANT TEMP gauge (104.4°C),
engine still running At high ambient temperatures the COOLANT
TEMP gauge temp can read 230° F (110°C)
normally.
0011-5
TM 11-6115-742-13&P 0011
Table 1. Crew Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
18 Engine temperature above 220°F on Shut down system (WP 0005). Contact Maintainer
(cont.) COOLANT TEMP gauge (104.4°C), Maintenance.
engine still running
19 Engine oil pressure below 20 psi, engine NOTE
still running
At high ambient temperatures the OIL PRESSURE
gauge temp can read 15 psi normally.
Shut down system (WP 0005). Contact Maintainer
Maintenance.
NOTE
When ENGINE HEATER switch (on Genset
control panel) flashes, there is a problem with the
engine heater (hydronic). See Engine Heater
(Hydronic) Fault Codes (Table 2) for fault codes.
20 Engine heater (hydronic) will not start (no Check batteries are connected.
fault code)
Check battery switch is turned to on.
Check battery voltage is above 20 VDC. If low, recharge
batteries (WP 0023) or slave off vehicle.
Contact Maintainer Maintenance.
21 Engine heater (hydronic) (fault code F01 Turn ENGINE HEATER switch on Genset control panel
or F02) off for 2 minutes.
Check Genset fuel level, fuel Genset if necessary
(WP 0005).
Contact Maintainer Maintenance.
22 Engine heater (hydronic) (fault code F03) Turn ENGINE HEATER switch on Genset control panel
off for 2 minutes.
Check battery voltage on DC VOLTS meter. If low,
recharge batteries (WP 0023) or slave off vehicle. If
voltage within 22 to 28 VDC, contact Maintainer
Maintenance.
Turn ENGINE HEATER switch on Genset control panel
ON.
Contact Maintainer Maintenance.
23 Engine heater (hydronic) (fault code F04, Contact Maintainer Maintenance.
F05, F06, F07, F08, F09, F010)
0011-6
TM 11-6115-742-13&P 0011
NOTE
When ENGINE HEATER switch (on Genset control panel) flashes, there is a
problem with the Engine heater (Hydronic). The number of flashes indicates a
specific fault code (i.e., one flash is F01, two flashes is F02).
There is a sequence of slow and fast flashes. Count the slow flashes.
Table 2. Engine Heater (Hydronic) Fault Codes.
FAULT
DESCRIPTION POSSIBLE CAUSE
CODE
F01 No Start-up • Fuel Supply
• Restricted Air Flow Through Intake or Exhaust
F02 Flame Extinguished • Fuel Supply
• Restricted Air Flow Through Intake or Exhaust
F03 Under/Over voltage • Vehicle Charging System
F04 Premature Flame Detection • Heater faulty
F05 Circulating Pump Interruption or Short Circuit • Open or Shorted Wiring
• Defective Pump
F06 Temperature Sensor Interruption or Short • Heater faulty
Circuit
F07 Metering Pump (Fuel pump) Interruption or • Open or Shorted Wiring
Short Circuit
F08 Combustion Fan Motor Interruption, Short • Heater faulty
Circuit, or Incorrect fan Speed
F09 Pencil Type Glow Plug/Flame Detector • Heater faulty
Interruption or Short Circuit
F10 Overheating Condition • Coolant Flow Restriction
• Circulation Pump
END OF WORK PACKAGE
0011-7/8 blank
TM 11-6115-742-13&P 0012
CREW TROUBLESHOOTING PROCEDURES
TMSS-MED
GENSET (ELECTRICAL) TROUBLESHOOTING PROCEDURES
INITIAL SETUP:
Personnel Required References
Two WP 0005
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by crew-level qualified
personnel. This work package provides a systematic approach to locating and correcting malfunctions of the
TMSS-MED. Each section is arranged according to the condition/indication of a problem. The corrective action
items have been arranged in order of complexity, with simpler actions listed first. The manual cannot identify all
malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be corrected by the
corrective actions provided, contact your supervisor.
WARNING
Special caution must be taken during troubleshooting since protective covers and
safety devices may be removed or disabled to gain access and make tests.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand brakes are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0012-1
TM 11-6115-742-13&P 0012
Table 1. Crew Troubleshooting – Genset (Electrical).
ITEM CONDITION/INDICATION CORRECTIVE ACTION
WARNING
If Genset has been in operation, components may be
extremely hot. To prevent serious injury to
personnel, allow sufficient time for cool down before
proceeding with checks.
1 Generator produces no voltage Check that VOLT/AMP selector switch is properly set.
Check that CB5 on circuit breaker panel is not tripped.
Reset if needed and recheck voltage.
Contact Maintainer Maintenance.
2 Generator produces low voltage (under Check that voltage is within 5 VAC of norm (208 VAC) on
no load condition) A-C VOLT gauge.
Adjust voltage using VOLTAGE ADJUST potentiometer on
Genset Control Panel.
If voltage is more than ±5 VAC from norm, contact
Maintainer Maintenance.
3 Generator produces low voltage (under Check that voltage is within 5 VAC of norm (208 VAC) on
load condition) A-C VOLT gauge.
Adjust voltage using VOLTAGE ADJUST potentiometer on
Genset Control Panel.
If voltage is more than ±5 VAC from norm, contact
Maintainer Maintenance.
4 Generator produces high voltage (under Check that voltage is within ±5 VAC of norm (208 VAC) on
no load condition) A-C VOLT gauge.
Adjust voltage using VOLTAGE ADJUST potentiometer on
Genset Control Panel.
If voltage is more than ±5 VAC from norm, contact
Maintainer Maintenance.
5 Generator produces high voltage (under Check that voltage is within ±5 VAC of norm (208 VAC) on
load condition) A-C VOLT gauge.
Adjust voltage using VOLTAGE ADJUST potentiometer on
Genset Control Panel.
If voltage is more than ±5 VAC from norm, contact
Maintainer Maintenance.
0012-2
TM 11-6115-742-13&P 0012
Table 1. Crew Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
6 Generator voltage fluctuates/wanders Contact Maintainer Maintenance.
7 Generator frequency out of tolerance Verify that sufficient fuel is present.
Verify that there are no sudden or frequent load changes.
Turn on equipment one at a time while monitoring
HERTZ meter (WP 0005). If meter begins to drop, do not
add any more draw to the system.
Ensure that air filter is clean and is not clogged.
Contact Maintainer Maintenance.
8 Generator builds voltage from start-up Contact Maintainer Maintenance.
then goes to low voltage
END OF WORK PACKAGE
0012-3/4 blank
TM 11-6115-742-13&P 0013
CREW TROUBLESHOOTING PROCEDURES
TMSS-MED
ECU TROUBLESHOOTING PROCEDURES
INITIAL SETUP:
Personnel Required References
Two WP 0005
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by crew-level qualified
personnel. This work package provides a systematic approach to locating and correcting malfunctions of the
TMSS-MED. Each section is arranged according to the condition/indication of a problem. The corrective action
items have been arranged in order of complexity, with simpler actions listed first. The manual cannot identify all
malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be corrected by the
corrective actions provided, contact your supervisor.
WARNING
Special caution must be taken during troubleshooting since protective covers and
safety devices may be removed or disabled to gain access and make tests.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand brakes are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0013-1
TM 11-6115-742-13&P 0013
Table 1. Crew Troubleshooting – ECU.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
1 ECU will not run on Genset power Ensure POWER ON light on ECU is lit indicating power
available to ECU.
Ensure power cable from Genset to ECU is properly
connected and no apparent damage is present.
Ensure Genset is running.
Ensure CB1 and CB5 on Genset Circuit Breaker Panel
are energized and have not tripped or need reset.
Contact Maintainer Maintenance.
2 ECU will not run on shore power NOTE
If red light is lit, do not attempt to use shore
power.
Ensure POWER ON light on ECU is lit indicating power
available to ECU.
Disconnect shore power. Connect to Genset and operate
ECU (WP 0005).
3 Voltage out of phase Contact Maintainer Maintenance.
(red light on ECU control panel light)
4 Conditioned air too cold Ensure temperature dial on ECU control panel is set to
(in Heat mode) proper temperature.
Ensure MODE SELECT switch on ECU control panel is
set to proper selection (WP 0005).
Check for open or missing access panels on unit.
If using hydronic heater, ensure AUXILIARY HEAT switch
on ECU control panel is NOT flashing.
Ensure ducts are attached properly and that no cuts, slits,
or other damage is present allowing air to escape.
Contact Maintainer Maintenance.
5 Conditioned air too warm Ensure temperature dial on ECU control panel is set to
(in Cool mode) proper temperature.
Ensure MODE SELECT switch on ECU control panel is
set to proper selection (WP 0005).
Check for open or missing access panels on unit.
0013-2
TM 11-6115-742-13&P 0013
Table 1. Crew Troubleshooting – ECU – Continued.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
5 Conditioned air too warm Check that evaporator coils are not iced over. If
(cont.) (in Cool mode) necessary, shut down ECU (WP 0005) and allow any ice
to melt.
Check that condenser coils are not clogged or blocked.
Ensure air filters are not clogged.
Contact Maintainer Maintenance.
6 Evaporator or condenser fan does not Ensure belt is properly tensioned and not loose, and that
operate no damage is present.
Contact Maintainer Maintenance.
7 Coolant leaking Contact Maintainer Maintenance.
8 Fuel leaking Contact Maintainer Maintenance.
NOTE
Fault code is determined by the number of times
the AUXILIARY HEAT switch flashes (i.e. one
flash is F01, two flashes is F02, etc.). See ECU
Hydronic Heater Fault Codes (Table 2) for fault
codes.
9 Hydronic heater will not start (no fault Ensure POWER ON light on ECU is lit indicating power
code) available to ECU.
Ensure AUXILIARY HEAT switch is set to AUTO or
MANUAL and that switch is illuminated.
Contact Maintainer Maintenance.
10 Hydronic heater (fault code F01 or F02) Set AUXILIARY HEAT switch (hydronic heater) on ECU
Control Panel to OFF. Wait 2 minutes.
Check Genset fuel level. If necessary, refuel (WP 0005).
Attempt to re-start hydronic heater (turn AUXILIARY
HEAT switch to MANUAL or AUTO).
If unit fails to start after 3 attempts, contact Maintainer
Maintenance.
11 Hydronic heater (fault code F03, F04, Contact Maintainer Maintenance.
F05, F06, F07, F08, F09, F010)
0013-3
TM 11-6115-742-13&P 0013
NOTE
When AUXILIARY HEAT switch (on ECU control panel) flashes, there is a
problem with the hydronic heater. The number of flashes indicates a specific
fault code (i.e., one flash is F01, two flashes is F02).
There is a sequence of slow and fast flashes. Count the slow flashes.
Table 2. ECU Hydronic Heater Fault Codes.
FAULT
DESCRIPTION POSSIBLE CAUSE
CODE
F01 No Start-up • Fuel Supply
• Restricted Air Flow Through Intake or Exhaust
F02 Flame Extinguished • Fuel Supply
• Restricted Air Flow Through Intake or Exhaust
F03 Under/Over voltage • Vehicle Charging System
F04 Premature Flame Detection • Heater faulty
F05 Circulating Pump Interruption or Short Circuit • Open or Shorted Wiring
• Defective Pump
F06 Temperature Sensor Interruption or Short • Heater faulty
Circuit
F07 Metering Pump (Fuel pump) Interruption or • Open or Shorted Wiring
Short Circuit
F08 Combustion Fan Motor Interruption, Short • Heater faulty
Circuit or Incorrect fan Speed
F09 Pencil Type Glow Plug/Flame Detector • Heater faulty
Interruption or Short Circuit
F10 Overheating Condition • Coolant Flow Restriction
• Circulation Pump
END OF WORK PACKAGE
0013-4
TM 11-6115-742-13&P 0014
CREW TROUBLESHOOTING PROCEDURES
TMSS-MED
TRAILER TROUBLESHOOTING PROCEDURES
INITIAL SETUP:
Personnel Required References
Two WP 0005
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by crew-level qualified
personnel. This work package provides a systematic approach to locating and correcting malfunctions of the
TMSS-MED. Each section is arranged according to the condition/indication of a problem. The corrective action
items have been arranged in order of complexity, with simpler actions listed first. The manual cannot identify all
malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be corrected by the
corrective actions provided, contact your supervisor.
WARNING
Special caution must be taken during troubleshooting since protective covers and
safety devices may be removed or disabled to gain access and make tests.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand brakes are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
If Genset has been in operation, components may be extremely hot. To prevent
serious injury to personnel, allow the Genset to cool down before performing
procedures.
0014-1
TM 11-6115-742-13&P 0014
Table 1. Crew Troubleshooting – Trailer.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
1 Hand brake does not engage Inspect brake cable(s) for damage.
Adjust hand brake.
Contact Maintainer Maintenance.
2 Trailer lights do not work Verify that vehicle lights are on.
Inspect inter-vehicular cable for bent pins, corrosion,
or other visible damage.
Check and tighten connections. Test lights.
Contact Maintainer Maintenance.
3 Trailer does not track straight when towed Improper tire pressure. Ensure both tires are
properly inflated for use (20 psi - highway;
17 psi - off road).
Check hand brakes are not over tightened.
Contact Maintainer Maintenance.
4 Tire will not hold air pressure Inspect tire for visible damage (cuts, holes, slices,
etc.) or excessive wear.
Contact Maintainer Maintenance.
5 Tongue jack assembly will not raise/lower Ensure no dirt, rocks, sand, or other debris are
present.
Ensure tongue jack assembly is not at full extension
or retraction (WP 0005). If so, perform the following:
1. Connect trailer to vehicle.
2. Move tongue jack assembly to center position.
3. Adjust skid plate/dolly wheel assembly so that
it is within 2 to 3 inches of the ground.
4. Lift trailer off of vehicle using tongue jack
assembly.
Inspect crank for damage or corrosion.
Inspect leg for bowing, bending, kinking, or other
physical deformities that may stop tongue jack
assembly from raising/lowering.
Contact Maintainer Maintenance.
0014-2
TM 11-6115-742-13&P 0014
Table 1. Crew Troubleshooting – Trailer – Continued.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
6 Stabilizer leg will not raise/lower Ensure stabilizer leg is not at full extension. If so,
perform the following:
1. Raise stabilizer leg to fully raised position.
2. Adjust jack foot so that it is within 2 to 3 inches
of the ground.
3. Lift trailer off of vehicle using tongue jack
assembly.
Ensure no dirt, rocks, sand, or debris is present.
Inspect for corrosion.
Inspect leg for bowing, bending, kinking, or other
physical deformities that may stop leg from
raising/lowering.
Contact Maintainer Maintenance.
END OF WORK PACKAGE
0014-3/4 blank
TM 11-6115-742-13&P 0015
CREW TROUBLESHOOTING PROCEDURES
TMSS-MED
SHELTER (MECHANICAL) TROUBLESHOOTING PROCEDURES
INITIAL SETUP:
Personnel Required References
Two WP 0005, WP 0025, WP 0026, WP 0155,
WP 0166
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by crew-level qualified
personnel. This work package provides a systematic approach to locating and correcting malfunctions of the
TMSS-MED. Each section is arranged according to the condition/indication of a problem. The corrective action
items have been arranged in order of complexity, with simpler actions listed first. The manual cannot identify all
malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be corrected by the
corrective actions provided, contact your supervisor.
WARNING
Special caution must be taken during troubleshooting since protective covers and
safety devices may be removed or disabled to gain access and make tests.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0015-1
TM 11-6115-742-13&P 0015
Table 1. Crew Troubleshooting – Shelter (Mechanical).
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
1 Shelter/end cap will not spread Shelter/end cap fabric is binding. Check all fabric and release from
while on ground binding point.
Bottom hubs are catching on Check sides of shelter/end cap are
ground obstruction. not binding on ground. Clear
ground area as necessary.
Broken hub. Replace hub (WP 0026).
Broken strut pair. Replace strut pair (WP 0025).
Strut pair pulled out of hub. Open hub and inspect hub for
damage. Repair strut/hub
(WP 0025, WP 0026).
2 Shelter/end cap will not erect Shelter/end cap fabric is binding. Check all fabric and release from
binding point.
Bottom hubs are catching on Check sides of shelter/end cap are
ground obstruction. not binding on ground. Clear
ground area as necessary.
Hub broken. Replace hub (WP 0026).
Broken strut pair. Replace strut pair (WP 0025).
Strut pair pulled out of hub. Open hub and inspect hub for
damage. Repair strut/hub
(WP 0025, WP 0026).
3 Shelter/end cap will not stay Shelter/end cap was not lifted to Refer to (WP 0005) and review
erected fully erect position. procedures.
Shelter/end caps not properly Check shelter/end cap is properly
staked. staked.
4 Shelter/end cap or shelter door Velcro seams loose. Check all Velcro seams to ensure
leaks that they are properly secured IAW
setup procedures.
Fabric torn. Repair tear in fabric using field
repair kit (WP 0166). If tear is
greater then 10", replace
shelter/end cap or shelter door
(WP 0155).
5 Keepers coming out while Keepers are not tight. Tighten keeper using keeper tool
erected from field repair kit.
Inspect hub assembly. If hub is
unserviceable, replace (WP 0026).
0015-2
TM 11-6115-742-13&P 0015
Table 1. Crew Troubleshooting – Shelter (Mechanical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
5 Keepers coming out while Keepers are not tight (cont.) Retighten all keepers before
(cont.) erected (cont.) erecting shelter.
Periodically check keepers during
extended operation.
If keeper will not tighten due to
damaged hub, contact Maintainer
Maintenance.
6 Shelter/end cap has unusual Hub broken. Replace hub (WP 0026).
shape when erected
Broken strut pair. Replace strut pair (WP 0025).
7 Shelter/end cap binds when Seams still attached. Check that Velcro seams are
coming down properly separated (WP 0005).
Doors impeding process. Check that doors are open.
Wind line or stake still attached. Check that all ground stakes/ wind
lines have been removed.
Hub broken. Replace hub (WP 0026).
Broken strut pair. Replace strut pair (WP 0025).
Strut pair pulled out of hub. Open hub and inspect hub for
damage. Repair strut/hub
(WP 0025, WP 0026).
8 Shelter/end cap will not collapse Obstacle present. Check that there are no
completely when on ground obstructions present.
Hub broken. Replace hub (WP 0026).
Broken strut pair. Replace strut pair (WP 0025).
Strut pair pulled out of hub. Open hub and inspect hub for
damage. Repair strut/hub
(WP 0025, WP 0026).
9 Shelter or end cap shakes Wind lines not installed Check that wind lines are properly
excessively properly/loose. installed and properly tightened.
Shelter/end cap not secure/not Check that shelter or end cap has
properly staked. been staked down in accordance
with set-up procedures (WP 0005).
END OF WORK PACKAGE
0015-3/4 blank
TM 11-6115-742-13&P 0016
CREW TROUBLESHOOTING PROCEDURES
TMSS-MED
SHELTER (ELECTRICAL) TROUBLESHOOTING PROCEDURES
INITIAL SETUP:
Personnel Required References
One WP 0005
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by crew-level qualified
personnel. This work package provides a systematic approach to locating and correcting malfunctions of the
TMSS-MED. Each section is arranged according to the condition/indication of a problem. The corrective action
items have been arranged in order of complexity, with simpler actions listed first. The manual cannot identify all
malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be corrected by the
corrective actions provided, contact your supervisor.
WARNING
Special caution must be taken during troubleshooting since protective covers and
safety devices may be removed or disabled to gain access and make tests.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0016-1
TM 11-6115-742-13&P 0016
Table 1. Crew Troubleshooting – Shelter Lighting.
ITEM CONDITION/INDICATION CORRECTIVE ACTION
1 Shelter lighting does not come on Check that the shelter lighting switch is turned on.
Check that the shelter lighting is plugged in (WP 0005).
Check that power to the shelter lighting is turned on.
Contact Maintainer Maintenance.
2 No power from PDU Check that Genset is operating properly and has not shut
down.
Check other legs of PDU for voltage. Rotate
VOLTMETER switch between L1, L2 and L3 and observe
AC VOLTS meter on PDU.
Check that PDU is properly connected (WP 0005)
(Genset and PDU).
Check that all necessary circuit breakers are on (Genset
and PDU).
Verify that no one circuit has been overloaded. If
necessary re-distribute load.
Contact Maintainer Maintenance.
3 Power indicator lights inoperable Check that Genset is operating properly and has not shut
down.
Check other legs of PDU for voltage. Rotate
VOLTMETER switch between L1, L2 and L3 and observe
AC VOLTS meter on PDU.
Check that no circuit breakers have tripped (Genset and
PDU). Reset if necessary.
Contact Maintainer Maintenance.
END OF WORK PACKAGE
0016-2
TM 11-6115-742-13&P
CHAPTER 4
CREW MAINTENANCE INSTRUCTIONS
FOR
TMSS-MED
TM 11-6115-742-13&P 0017
CREW MAINTENANCE INSTRUCTIONS
TMSS-MED
SERVICE UPON RECEIPT
INITIAL SETUP:
Personnel Required References
Two WP 0005, WP 0019
GENERAL
The following procedures are required to be performed by the crew in order to prepare the shelter and its contents
for use.
SITING
To ensure minimal problems with set-up of TMSS-MED and good operation of equipment being used inside
TMSS-MED, ensure area is:
• Dry.
• Level with adequate room for trailer, shelter, system grounding, and all other associated equipment.
• Free of items (trees, buildings, or other structures) that would impede set-up of TMSS-MED or cause
physical interference for trailer, shelter, system grounding, and all other associated equipment.
• Free of items (e.g., towers, power lines, radar, trees, buildings) that would cause interference with
electronic equipment being used inside of shelter.
SHELTER REQUIREMENTS
The TMSS-MED shelter requires a footprint of 23 feet (7.01 meters) by 32 feet (9.75 meters). In addition, the
TMSS-MED trailer requires a foot print of 16 feet (4.85 meters) by 7 feet (2.16 meters) for set-up and installation.
SERVICE UPON RECEIPT OF MATERIEL
Inspect each system component for damage incurred during shipment. If any damage is visible, notify supervisor.
Report the damage on DD Form 361, Transportation Discrepancy Report. Check the equipment against the
packing slip to see if the shipment is complete. Report all discrepancies in accordance with applicable service
instructions.
Once all covers are removed, inspect the trailer, shelter, and each piece of equipment. Inspect all connectors,
cables, and loose pieces of equipment located in the trailer cargo box. Refer to Crew PMCS (WP 0019) before
placing the equipment into service.
INSTALLATION INSTRUCTIONS
The TMSS-MED requires some assembly depending upon the mode of operation. To setup the TMSS-MED in a
fixed position, refer to Operation Under Usual Conditions (WP 0005) for setup and installation procedures.
PRELIMINARY SERVICING OF EQUIPMENT
Perform all Crew PMCS for the TMSS-MED as listed in Crew PMCS (WP 0019).
PRELIMINARY CHECKS AND ADJUSTMENT OF EQUIPMENT
There are no preliminary checks and adjustment of this equipment. Before placing the TMSS-MED into service,
ensure all Crew PMCS (WP 0019) has been performed.
END OF WORK PACKAGE
0017-1/2 blank
TM 11-6115-742-13&P 0018
CREW MAINTENANCE INSTRUCTIONS
TMSS-MED
PMCS INTRODUCTION
GENERAL
This work package provides data necessary to keep the TMSS-MED operational ready. PMCS are performed to
keep the TMSS-MED in operational condition. The checks are used to find, correct, and report problems.
Maintenance personnel are required to perform the tasks as indicated in Crew PMCS (WP 0019, Table 1). PMCS
are performed by the crew each time the equipment is operated. Prior to performing any maintenance that
requires climbing on or under TMSS-MED, ensure cage bolts are not inserted and wheels are chocked. Injury to
personnel could result from TMSS-MED suddenly rolling or tipping.
Before you begin operating the TMSS-MED and/or its equipment, perform Before PMCS.
Once a week perform Weekly PMCS. If TMSS-MED has not been operated in a week, perform Before PMCS.
Perform Monthly PMCS once a month. If TMSS-MED has not been operated in a month, perform After PMCS at
the same time.
If you are operating the TMSS-MED for the first time, perform Weekly and Monthly PMCS the first time you do
your Before PMCS.
If you find something wrong when performing PMCS, fix it if you can. Otherwise, notify Maintainer Maintenance.
WARNINGS AND CAUTIONS
Special attention should be paid to the WARNINGS and CAUTIONS appearing in the crew PMCS table. A
WARNING means someone could be injured. A CAUTION means equipment could be damaged.
LEAKAGE DEFINITION
It is necessary for you to know how fluid leakage affects the status of the trailer. The following are definitions of
the classes of leakage you need to know to be able to determine the status of the trailer. Learn these leakage
definitions. When in doubt, contact Maintainer Maintenance.
CAUTION
Crews must report Class III leaks to Maintainer Level Maintenance. Failure to
comply may result in damage to equipment.
NOTE
The following note applies to non-flammable liquids only. Any leakage of
flammable liquid is unacceptable.
Equipment operation is allowable with minor leakages (Class I or II).
Consideration must be given to fluid capacity of the item or system being
checked. When Crew is in doubt, notify next level maintenance.
When operating with Class I or II leaks, continue to check fluid levels as required
in your PMCS.
0018-1
TM 11-6115-742-13&P 0018
LEAKAGE DEFINTION – Continued
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.
CLASS III – Leakage of fluid great enough to form drops that fall from the item being checked.
INSPECTION
Look for signs of a problem or trouble. Senses help here. You can feel, smell, hear, or see many problems. Be
alert when on the TMSS-MED.
Inspect to see if items are in good condition. Are they correctly assembled, stowed, and secured, or excessively
worn, leaking, corroded, or improperly lubricated? Correct any problems found or notify the next level of
maintenance.
There are some common items to check all over the TMSS-MED. These include the following:
1. Bolts, clamps, nuts, and screws: Continuously check for looseness. Look for chipped paint, rust, or corrosion
around bolt and screw heads and nuts. Tighten them when you find them loose. If tools are not available,
Crews must notify Maintainer Level Maintenance.
2. Welds: Many items on the TMSS-MED are welded. To check these welds, look for chipped paint, rust
corrosion, or gaps. When these conditions exist, Crews must notify Maintainer Level Maintenance.
3. Electrical wires, connectors, and harnesses: Tighten loose connectors. Look for cracked or broken insulation,
bare wires, and broken connectors. If any are found, Crews must notify Maintainer Level Maintenance.
4. Hoses and fluid lines: Look for wear, damage, and leaks, and make sure clamps and fittings are tight. Wet
spots mean a leak. A stain by a fitting or connector can also mean a leak. When you find a leak, Crews must
notify Maintainer Level Maintenance.
5. Fan belts: Look for wear and damage, make sure belts are not cracked, frayed, or excessively worn. When
these conditions exist, Crew must notify Maintainer Level Maintenance.
LUBRICATION SERVICE INTERVALS - NORMAL CONDITIONS
General
For safer, more trouble-free operations, make sure that your TMSS-MED is serviced when it needs it. Proper
lubrication and service intervals, which are the responsibility of the Crew level maintenance, are found in this WP.
Adherence
Intervals (on-condition or hard time) and the related man-hour times are based on normal operation. The man-
hour time specified is the time needed to do all the services prescribed for a particular interval. On-condition (OC)
oil sample intervals shall be applied. Change the hard time interval if lubricants are contaminated or if operating
the equipment under adverse operating conditions, including longer-than-usual operating hours. The calendar
interval may be extended during periods of low activity. If extended, adequate preservation precautions must be
taken. Hard time intervals must be applied during the warranty period.
0018-2
TM 11-6115-742-13&P 0018
WARNING
Cleaning solvents may be toxic and flammable. Wear protective goggles and
gloves; use only in well-ventilated area; avoid contact with skin, eyes, and clothes,
and do not breath vapors. Keep away from heat or flame. Never smoke when
using cleaning solvent. Failure to comply may result in serious injury or death to
personnel.
If personnel become dizzy while using cleaning solvents, immediately get fresh air
and medical help. If cleaning solvent contacts skin or clothes, flush with cold
water. If cleaning solvent contacts eyes, immediately flush eyes with water and
get medical attention. Failure to comply may result in serious injury or death to
personnel.
Cleaning Fittings Before Lubrication
Clean parts with cleaning solvent. Dry before lubricating.
Lubrication After Fording
If a fording operation occurs, lubricate all fittings below fording depth and check submerged gear boxes for
presence of water.
Lubrication After High Pressure Washing
After a thorough washing, lubricate all grease fittings and oil can points outside and underneath trailer.
Corrosion Control
Refer to General Information (WP 0001), Corrosion Prevention and Control (CPC), for appropriate corrosion
control procedures.
Hard Time Lubrication Intervals
For equipment under manufacturer’s warranty, hard time lubrication intervals shall be followed. Intervals shall be
shortened if lubricants are known to be contaminated or if operation is under adverse conditions (e.g. longer than
usual operating hours, extended idling periods, extreme dust).
EXPLANATION OF TABLE ENTRIES
Item Number - Numbers in this column are for reference. When completing DA Form 2404/DA Form 5988E
(Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indicating a
fault. Item numbers appear in the order in which the checks/services are performed for the interval listed.
Interval – This column indicates when a procedure must be performed (e.g., Before, During, After, Monthly).
Item to Be Checked or Serviced – This column indicates the item that is to be checked or serviced.
Procedure – This column describes the procedure that must be followed to ensure the equipment is capable of
performing its intended mission.
Equipment Not Ready/Available If – This column lists conditions that make the TMSS-MED not fully mission-
capable. If possible, fix the problem using the troubleshooting procedures and/or maintenance procedures in the
manual. If this is not possible, write up the items not fixed on DA Form 2404/DA Form 5988E for Crew
maintenance. For further information on how to use this form, see DA PAM 750-8.
0018-3
TM 11-6115-742-13&P 0018
EXPLANATION OF TABLE ENTRIES - Continued
Other Entries – Be sure to observe and annotate all special circumstances that appear/occur.
NOTE
If the equipment must be kept in continuous operation, only perform those
procedures that will not disturb operation. Complete checks and services when
the equipment is shut down.
END OF WORK PACKAGE
0018-4
TM 11-6115-742-13&P 0019
CREW MAINTENANCE INSTRUCTIONS
TMSS-MED
PMCS
INITIAL SETUP:
Tools and Special Tools Personnel Required
Field repair kit Two
Materials/Parts References
Oil (WP 0165, Items 35 and 36) WP 0020, WP 0022, WP 0024
Coolant (WP 0165, Item 2) WP 0025, WP 0026, WP 0166
Brake Fluid (WP 0165, Item 6)
Table 1. Crew Preventive Maintenance Checks and Services.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
EVIRONMENTAL
CONTROL UNIT
(ECU)
1 Before ECU Enclosure 1. Inspect access panels for Cannot secure access
damage. Check that all latches and panels.
hinges are operational.
2. Inspect filters. Check that filters Filters excessively dirty.
are clean and free of excessive dirt,
grease, and grime.
3. Inspect supply and return ducts. Supply ducts ripped, torn,
Check that no damage or corrosion or otherwise damaged
is present. Check that screens are beyond repair. Screens
free of debris. are obstructed.
4. Inspect fan blades and protective Fan blades/cage bent,
cage. Check that no damage or impeding operation.
corrosion is present.
5. Inspect evaporator fan bearings. Bearings damaged,
Check that no damage or corrosion noisy, or corroded.
is present.
6. Inspect condenser and Coils damaged, leaking.
evaporator coils. Check that no
damage, leaks, or corrosion present.
7. Inspect interior base for water
build-up.
8. Check for missing, damaged,
corroded, or loose hardware.
0019-1
TM 11-6115-742-13&P 0019
Table 1. Crew Preventive Maintenance Checks and Services – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
1 Before ECU Enclosure 9. Inspect condenser grill. Check that Condenser grill is
(cont.) grill is not clogged or damaged and is excessively dirty,
clean and free of excessive dirt, clogged, or damaged.
grease, and grime.
10. Inspect interior for fluid. If fluid is Class III coolant or
present, inspect further for loose lubrication leak present.
connections or damaged hoses. Any fuel leak present.
Damaged hoses or loose
connections present.
2 Before End Panel, 1. Inspect sliding door. Check that
Evaporator knob is operational and is not
Assembly damaged, corroded, or loose.
2. Inspect damper plate and damper
rod. Check that items are operational
and not damaged, corroded, or loose.
3. Inspect duct covers. Check that
no rips, tears, or other damage is
present.
4. Check for missing, damaged,
corroded, or loose hardware.
3 Before Control 1. Inspect panel. Check that all Cannot secure access
Enclosure, ECU latches and hinges are operational. panels.
2. Check all components Components missing or
(i.e., switches, knobs, meter, lens, damaged.
thermostat) for damage.
3. Check for missing, damaged,
corroded, or loose hardware.
4 Before Blower Assembly 1. Check all components (i.e., blower, Components missing or
evaporator motor) for damage. damaged.
2. Inspect belt. Check for proper Broken or loose belt.
tension, damage, or excessive wear.
3. Check for missing, damaged,
corroded, or loose hardware.
5 Before Heater (Hydronic) 1. Check coolant levels in reservoir. Cannot replenish
Add coolant if necessary (WP 0020). coolant.
0019-2
TM 11-6115-742-13&P 0019
Table 1. Crew Preventive Maintenance Checks and Services – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
GENSET
6 Before Generator, 1. Inspect access panels for damage. Cannot secure access
Diesel Engine Check that all latches and hinges are panels.
operational.
2. Check that air intake and exhaust
louvers are free and clear of debris.
3. Inspect electronic components Components missing or
(i.e., switches, circuit breakers, damaged and renders
meters, lights) on control panel(s) for the unit not mission
damage. Check that all components capable.
are operational (no loose items, burnt
out bulbs, etc.).
4. Inspect ground stud/cable. Check Ground stud/cable
that no damage or corrosion is damaged, corroded, or
present. frayed.
5. Inspect fuel control panel. Check Components missing or
lines, fuel cap, and selector switch for damaged.
damaged, corroded, or missing parts.
6. Inspect fuel lines for leaks at Any fuel leaks.
external and internal connections.
7. Check fuel gauge. Verify that
sufficient fuel is present for operation.
8. Check that frequency on HERTZ HERTZ meter not within
gauge is between 58 Hz to 62 Hz. specified range.
9. Check for missing, damaged,
corroded, or loose hardware.
7 Before Battery 1. Inspect battery. Check that no Cracked/damaged
Assembly damage or other obvious deterioration battery.
is present to battery.
2. Inspect battery cables. Check that Cables fraying, improper
connections are secure, no fraying, connections, or battery
corrosion, or other visible damage is corrosion is present.
present.
3. Check for missing, damaged,
corroded, or loose hardware.
0019-3
TM 11-6115-742-13&P 0019
Table 1. Crew Preventive Maintenance Checks and Services – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
8 Before Engine 1. Inspect engine for missing, loose, Any condition that
Assembly or damaged parts. Check for wear or renders the unit not
deterioration. mission capable.
2. Inspect all cables and hoses for Engine leaks present.
leaks, cracks, swelling, or other Damaged hoses, cables,
obvious deterioration. Check that all or other parts.
clamps are properly secured.
3. Check fluid levels. Verify that Low fluid, discolored
fluids (i.e., oils, coolants) are at their fluids.
proper levels, no discoloration or
indication of burning/overheating is
present. If necessary, add oil or
coolant. See (WP 0022) for proper
instructions and specifications.
4. Check for fuel, oil, and coolant Any fuel leaks present.
leaks. Any Class III oil or
coolant leaks present.
5. Check hydronic heater for leaks. Any fuel leaks present.
Any Class III oil or
coolant leaks present.
6. Check for missing, damaged,
corroded, or loose hardware.
9 Before Cooling System, 1. Inspect fan blades/pulley for Fan blades or pulley bent
Engine obvious damage. or damaged.
2. Inspect all belts for proper tension, Broken or loose belts.
damage, or excessive wear.
3. Inspect water pump for cracks, Water pump inoperative,
leaks, or other damage. damaged, or leaking.
4. Check for missing, damaged,
corroded, or loose hardware.
10 Before Air Intake 1. Inspect air filter. Air filter clogged or
Assembly missing.
2. Check for missing, damaged, Hardware missing.
corroded, or loose hardware.
11 Before Radiator 1. Inspect radiator for dents, holes, or Radiator assembly
Assembly leaks. damaged/leaking.
2. Inspect hoses for cracks, swelling, Hoses cracked, swollen,
or other obvious deterioration. damaged, or leaking.
0019-4
TM 11-6115-742-13&P 0019
Table 1. Crew Preventive Maintenance Checks and Services – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
11 Before Radiator 3. Inspect overflow bottle for cracks, Class III leaks.
(cont.) Assembly leaks, or other obvious deterioration.
4. Inspect hose clamps. Verify that Clamps loose or
clamps are secure and that no damaged.
damage or other obvious deterioration
is present.
WARNING
Ensure radiator is fully cooled.
Hot coolant could erupt into
crew’s face and cause severe
injury.
5. Check coolant level. Verify that
fluid in overflow bottle is 1/3 to 1/2 full
and no discoloration or indication of
burning/overheating is present. If
necessary, add coolant to reservoir.
See (WP 0022) for proper instructions
and specifications.
6. Check for missing, damaged,
corroded, or loose hardware.
12 Before Exhaust 1. Inspect muffler and exhaust pipes Muffler/exhaust pipes
Assembly for dents, holes, or leaks. damaged/leaking.
2. Inspect clamps. Check that Clamps loose or
clamps are secure and that no damaged.
damage or other obvious deterioration
is present.
3. Check for missing, damaged,
corroded, or loose hardware.
TRAILER
13 Before Chassis, Trailer 1. Inspect all exterior surfaces.
Assembly Ensure that they are free and clear of
loose debris.
2. Inspect parking brakes. Ensure Parking brakes will not
that both parking breaks are engaged. engage.
3. Inspect wheel chocks. Ensure that
they are present and in proper
location.
0019-5
TM 11-6115-742-13&P 0019
Table 1. Crew Preventive Maintenance Checks and Services – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
13 Before Chassis, Trailer 4. Inspect wheels and tires for Wheels/tires damaged,
(cont.) Assembly damage, foreign objects, loose or extreme wear, lug nuts
missing lug nuts, or unusual tread missing/not properly
wear. Remove any stones from tightened. Tires are
between the treads. unserviceable.
5. Check tires for correct pressure: Tires will not hold air.
Highway: 20 psi
Off Road: 17 psi
6. Inspect lift rings for insecure
mounting, damaged, corroded, or
loose hardware.
7. Check that the following Ground rods/fire
accessories are not missing: extinguisher missing.
a. Sledge Hammer (in cabinet)
b. Ground Rods
c. Fire Extinguisher
8. Inspect inter-vehicular cable to Inter-vehicle
ensure it is in good condition, the cable/connector
cable/connector is complete and damaged or corroded.
secured in its mounting clip, and cable
is not damaged/corroded.
9. Inspect lunette ring for insecure Lunette ring loose,
mounting, damaged, corroded, or corroded, or missing.
loose hardware.
10. Inspect safety chains for insecure Safety chains loose,
mounting, damaged, corroded, or damaged, corroded, or
loose hardware. missing.
11. Inspect brake systems hoses and Brake system hoses
fittings. Check under vehicle for signs leaking, damaged, or
of brake fluid leaks. If necessary, add missing.
brake fluid as described in (WP 0022).
12. Inspect all mounting brackets for
broken fittings, damaged, corroded, or
loose hardware.
13. Inspect ground stud/cable. Ground stud/cable loose,
Check that the ground is properly corroded, fraying, or
installed, connections are tight, and missing.
that no damage, fraying, or corrosion
is present.
0019-6
TM 11-6115-742-13&P 0019
Table 1. Crew Preventive Maintenance Checks and Services – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
13 Before Chassis, Trailer 14. Check for missing, damaged,
(cont.) Assembly corroded, or loose hardware.
14 Before Stop Light, 1. Inspect for missing or damaged
Vehicular lens lights or loose hardware.
2. Inspect electrical cables for Cables damaged, frayed,
damage or fraying. or inoperative.
15 Before Tongue Jack 1. Inspect condition of skid plate/dolly Skid plate/dolly wheel
Assembly wheel assembly for proper mounting tongue jack missing,
to landing post or tongue jack. inoperative, or shows
signs of structural
damage.
2. Inspect crank handle for proper Crank handle damaged,
operation. Check that no corrosion is missing, or inoperative.
present on mechanism.
3. Check for missing, damaged,
corroded, or loose hardware.
SHELTER
16 Before Shelter 1. Inspect all keepers for physical Exterior keepers missing.
damage. Keepers should be snug
and not easily turned. Replace if
necessary using field repair kit
(WP 0026).
2. Inspect shelter floor for punctures,
tears, separated seams, or other
visible damage.
3. Inspect all visible hubs and hub
extensions for breaks, cracks, or
displacement.
4. Inspect all wind lines for cuts,
fraying, or other visible damage.
5. Inspect all stakes and stake plates
for physical damage.
6. Inspect cinch belts for cuts,
fraying, or other visible damage.
7. Inspect all visible struts for breaks, Shelter will not stay
cracks, or other visible damage. erected.
Repair if necessary using field repair
kit (WP 0025).
0019-7
TM 11-6115-742-13&P 0019
Table 1. Crew Preventive Maintenance Checks and Services – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
17 Before Shelter, End Cap 1. Inspect end cap covers (interior
and exterior) for punctures, tears,
separated seams, or other visible
damage. Repair, if necessary, using
field repair kit (WP 0024).
2. Inspect doors (interior and exterior)
for punctures, tears, separated
seams, or other visible damage.
Repair if necessary using field repair
kit (WP 0024).
3. Inspect all visible struts for breaks, End cap will not stay
cracks, or other visible damage. erected.
Repair if necessary using field repair
kit (WP 0025).
4. Inspect all visible hubs and hub
extensions for breaks, cracks, or
displacement.
5. Inspect cinch belts for cuts,
fraying, or other visible damage.
18 Before Shelter, Roof, 1. Inspect covers (interior and
and Sides exterior) for punctures, tears,
separated seams, or other visible
damage. Repair if necessary using
field repair kit (WP 0024).
2. Inspect all visible struts for breaks, Shelter will not stay
cracks, or other visible damage. erected.
Repair if necessary using field repair
kit (WP 0025).
3. Inspect riser struts for breaks,
cracks, or other visible damage.
POWER
DISTRIBUTION
UNIT (PDU)
19 Before PDU 1. Inspect overall unit for damage.
2. Inspect all circuit breakers. Verify
that all are operational and no
damage is present.
3. Inspect all outlets. Verify that no
visible damage is present.
0019-8
TM 11-6115-742-13&P 0019
Table 1. Crew Preventive Maintenance Checks and Services – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
19 Before PDU 4. Check that connectors are secure,
(cont.) no fraying, corrosion, or other visible
damage is present.
5. Check for missing, damaged,
corroded, or loose hardware.
LIGHT SET,
SHELTER
20 Before Light Set 1. Inspect overall unit for damage.
2. Inspect lamps. Verify that no
visible damage is present.
3. Inspect electrical connection.
Ensure that connection is secure, no
corrosion or other visible damage is
present.
4. Check for missing, damaged,
corroded, or loose hardware.
21 Before Wiring Kit, 1. Inspect electrical cables. Ensure
Electrical that no fraying or other visible
damage is present.
2. Inspect electrical connectors.
Ensure that connection is secure, no
corrosion or other visible damage is
present.
3. Check for missing, damaged,
corroded, or loose hardware.
ECU
NOTE
The following items are located on the
ECU control panel located behind the
access door.
22 During Power indicator Verify that POWER ON light is No power to ECU.
light illuminated.
(POWER ON)
Phase indicator Verify that OUT OF PHASE light is OUT OF PHASE light
light (OUT OF NOT illuminated. illuminated.
PHASE)
0019-9
TM 11-6115-742-13&P 0019
Table 1. Crew Preventive Maintenance Checks and Services – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
22 During Hour meter Verify that hour meter is
(cont.) (HOURS 1/10) operational.
Auxiliary heat switch Verify that AUXILIARY HEAT
(AUXILIARY HEAT) switch light is NOT flashing.
GENSET
NOTE
The following items are located
on the Genset control panel
located on the curbside of the
Genset.
23 During AC Ammeter Verify that AC ammeter does NOT
(A-C AMPERES) exceed 60 amps.
Frequency meter Verify that frequency meter reads Frequency cannot be
(HERTZ) 60 Hz ±2% (1.2 Hz). adjusted within
tolerance.
Wattmeter Verify that wattmeter does NOT
(A-C KILOWATTS) exceed 18 kW.
AC Voltmeter Verify that AC voltmeter reads AC voltage cannot be
(A-C VOLTS) 208 VAC. adjusted to 208 VAC.
DC Voltmeter Verify that DC voltmeter reads
(D-C VOLTS) between 26 VDC – 31 VDC.
Green area on meter is 24 VDC to
31 VDC.
Temperature Gauge Verify that temperature gauge Temperature gauge
(COOLANT TEMP) reads between 170°F – 200°F exceeds 200°F
(76.66°C-93.33°C). (93.33°C).
Hour meter Verify that hour meter is Hour meter is non-
(HOURMETER) operational. operational.
Oil Pressure Gauge Verify that oil pressure gauge Oil pressure gauge falls
(OIL PRESSURE) reads 20 to 55 psi. below 20 psi.
Battery Charger Verify that battery charger Non-operational.
Ammeter ammeter reads:
(BATTERY Normal – 0 amps.
CHARGER AMPS) If battery is being charged via the
120 VAC battery charger, ammeter
should read: 0 to 5 amps.
0019-10
TM 11-6115-742-13&P 0019
Table 1. Crew Preventive Maintenance Checks and Services – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
23 During Ammeter – Rotate switch (L1-L2, L2-L3, L3-
(cont.) Voltmeter selector L1). Each time review readings on
switch AC voltmeter (A-C VOLTS) and AC
(VOLT/AMP) ammeter (A-C AMPERES). If
necessary adjust VOLTAGE
ADJUST potentiometer.
Panel light switch Rotate switch to illuminate panel
(PANEL LIGHT) lights. Switch should return to
normal position upon release.
High Coolant Push light to test for operational HIGH COOLANT TEMP
Temperature status. light is on and remains
indicator light illuminated. Indicates
(HIGH COOLANT that temperature is over
TEMP) 200°F. Engine must be
shut down.
Over Speed Push light to test for operational OVERSPEED indicator
indicator light status. light is on and remains
(OVERSPEED) illuminated. Engine must
be shut down.
Low oil-pressure Push light to test for operational LOW OIL PRESSURE
indicator light status. indicator is on and
(LOW OIL remains illuminated.
PRESSURE) Engine must be shut
down.
Voltage adjust Rotate potentiometer A-C VOLTS meter
potentiometer clockwise/counter-clockwise. AC fluctuates.
(VOLTAGE voltmeter (A-C VOLTS) should Change phases on
ADJUST) fluctuate with adjustment. VOLT/AMP switch and
verify that potentiometer
is bad.
Indicator lamps
NOTE
The following items are located
on the Genset Power
Distribution Panel located on the
curbside of the Genset.
The following applies to the
indicator lights for connectors J1
through J5 (AC voltage) of
Genset power distribution panel.
J6 (+28 VDC) does not have a
indicator light.
0019-11
TM 11-6115-742-13&P 0019
Table 1. Crew Preventive Maintenance Checks and Services – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
23 Indicator lamps Push light to test for operational Indicator light does not
(cont.) status on old version PDP only. illuminate during test.
Swivel black out cover to check Contact Maintainer
operational status. On new Maintenance if lamp not
version PDP only. illuminated.
PDU
24 During Voltmeter select Rotate switch. Each time review
switch readings on voltmeter on PDU.
TRAILER
25 After Fuel tank If the Genset will be non- Old fuel, sludge, and/or
operational for more than 120 water in fuel tank.
days, run Genset until ½ - inch of
fuel is left in tank and drain tank.
26 After Trailer/ECU/Genset Perform visual inspection of trailer, Class III leaks found.
Genset, ECU for fuel, oil, coolant,
and other leaks.
CAUTION
The items listed in the following table need to be performed when the Genset is
in an operational status with no load on Genset.
Table 2. Crew Functional Checks and Services.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
1 Weekly Engine selector Rotate switch through each setting Any function on the
switch (ENGINE) verifying that switch is fully ENGINE switch does not
functional. operate properly.
2 Weekly Battle short switch Flip up red cover and engage Genset shuts down.
(BATTLE SHORT) BATTLE SHORT switch. Place BATTLE SHORT switch
Genset in an operational status. bad.
Attempt to power down generator.
3 Weekly Emergency shut Place Genset in an operational Genset DOES NOT shut
down switch status. Attempt to power down down. EMERGENCY
(EMERGENCY) generator with emergency shut- switch bad.
down switch.
END OF WORK PACKAGE
0019-12
TM 11-6115-742-13&P 0020
CREW MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET – BULBS AND COVERS
CONTROL PANEL / POWER DISTRIBUTION PANEL INDICATOR LIGHTS REMOVAL/REPLACEMENT
INITIAL SETUP:
Materials/Parts References
Lamp, incandescent WP 0005, WP 0074
Lamp, LED, red
Equipment Condition
Personnel Required Genset shut down
One BATTERY SWITCH - OFF
GENERAL
This work package provides information on the removal/replacement of subassemblies for the Genset. They
consist of:
• Control Panel indicator lights removal/replacement.
• Power Distribution Panel push to test indicator lights removal/replacement (on old version PDPs only).
NOTE
The removal/replacement of the Power Distribution Panel push to test indicator
lights are for the old version only. For new version, refer to Maintainer
Maintenance (WP 0071).
If necessary, refer to Controls, Indicators, and Connectors of the Genset (WP 0004).
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand brakes are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0020-1
TM 11-6115-742-13&P 0020
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
In event of a venting, clear area until pungent odor of Sulfur Dioxide is cleared.
Handle leaking batteries with rubber or plastic gloves. Get immediate medical
attention for any skin or respiratory irritation.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
PANEL LIGHTS
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF. Refer to
Genset Shut Down Procedure (WP 0005).
2. Undo access panel latches and open.
3. Remove and retain panel light (Figure 1, Item 2).
4. Remove and properly discard incandescent bulb (Figure 1, Item 1).
END OF TASK
REPLACEMENT
1. Align incandescent bulb (Figure 1, Item 1), insert and rotate until seated.
2. Insert panel light (Figure 1, Item 2) and tighten.
3. Start Genset in accordance with Genset Start Procedure (WP 0005) and test light to ensure proper operation.
4. Close access panel.
END OF TASK
0020-2
TM 11-6115-742-13&P 0020
MALFUNTION/WARNING LIGHTS
NOTE
The following procedure for the Power Distribution Panel lights is only applicable
to the old version push to test lights (Figure 1, Items 5 and 6).
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Undo access panel latches and open.
3. Remove and retain indicator light (Figure 1, Items 3 or 6).
4. Remove and discard LED (Figure 1, Items 4 or 5).
END OF TASK
REPLACEMENT
1. Align LED (Figure 1, Items 4 or 5), insert and rotate until seated.
2. Insert indicator light (Figure 1, Items 3 or 6) and tighten.
3. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM and test light to ensure proper
operation.
4. Close access panel.
0020-3
TM 11-6115-742-13&P 0020
1
2
4 3
5
6
Figure 1. Control Panel and Power Distribution Panel Indicator Lights Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0020-4
TM 11-6115-742-13&P 0021
CREW MAINTENANCE INSTRUCTIONS
TMSS-MED
SERVICE- FLUIDS
INITIAL SETUP:
Tools and Special Tools References
Funnel WP 0005
Materials/Parts Equipment Condition
Oil (WP 0168, Items 35 or 36) Trailer parked, brakes engaged and wheels
Cloth, cleaning (WP 0168, Item 14) chocked
Rubber gloves (WP 0168, Item 24) Genset Control Panel - ENGINE switch
Safety glasses set to OFF
Antifreeze (WP 0168, Item 2)
DOT 3 brake fluid (WP 0168, Item 6) Genset Control Panel - BATTERY SWITCH
Personnel Required set to OFF
One
GENERAL
This work package provides information needed by the Crew when performing the following maintenance
procedures on the TMSS-MED trailer and shelter.
• Add oil to engine – Service
• Add coolant to engine radiator – Service
• Add brake fluid to master cylinder – Service
WARNING
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never allowing the tool to bridge two
terminals. Failure to observe this warning can result in serious injury.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing any service or maintenance.
CARBON MONOXIDE (EXHAUST GAS) CAN KILL YOU
Carbon monoxide does not have color or smell, but it can kill you. Breathing
carbon monoxide produces symptoms of headache, dizziness, loss of muscular
control, a sleepy feeling, and coma. Brain damage or death can result from
heavy exposure. Carbon monoxide occurs in the exhaust fumes of fuel-burning
heaters and internal combustion engines. When there is no air movement,
carbon monoxide can become dangerously concentrated. Precautions must be
followed to ensure crew safety when the ECU, Genset, or any other vehicle is
operated near the shelter.
0021-1
TM 11-6115-742-13&P 0021
Batteries generate explosive gas during charging. Utilize extreme caution. Do
not smoke or use open flame in the vicinity of the battery. Death or severe burns
may result.
Battery acid can be dangerous. Do not touch. Death or severe burns may result.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
ADD OIL TO ENGINE SERVICE
WARNING
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing the following service.
NOTE
To ensure proper engine oil level, check daily, especially before and after
operation. Engine oil should be between the two marks on the dipstick. Engine
oil should not smell burnt and should be of the proper color and consistency.
1. Verify that Genset has been shut down, engine is cool, and that BATTERY switch is set to OFF (WP 0005,
Genset Stop Procedure).
2. Remove and retain rear Genset access panel (Figure 1, Item 1).
3. Check oil level with the dipstick (Figure 1, Item 2). If oil level is low, proceed to next step. If oil level is correct
insert dipstick (Figure 1, Item 2) and go to step 10.
4. Remove and retain oil filler cap (Figure 1, Item 3).
NOTE
Make sure that oil being added is the proper weight and viscosity for your
environment (see Table 1). Use funnel supplied with trailer to avoid spillage.
5. Add oil to engine at filler cap (Figure 1, Item 3) and re-check the oil level.
6. Insert dipstick and install oil filler cap (Figure 1, Item 3).
7. Start Genset in accordance with Genset Start Procedure (WP 0005) and allow engine to run for a few minutes
to circulate oil through engine.
8. Shut down Genset in accordance with Genset Stop Procedure (WP 0005) and allow a few minutes for the oil
to settle.
0021-2
TM 11-6115-742-13&P 0021
SERVICE – Continued
9. Check oil level with the dipstick (Figure 1, Item 2). If oil level is still low, repeat steps 4 through 7. If dipstick
(Figure 1, Item 2) indicates proper oil level, re-insert the dipstick (Figure 1, Item 2) and verify that oil filler cap
(Figure 1, Item 3) is secure.
10. Wipe off any oil that has spilled. Install and latch rear access panel (Figure 1, Item 1).
11. Start Genset in accordance with Genset Start Procedure (WP 0005).
NOTE
Refer to Expendable and Durable Items (WP 0168) for NSN and other
information on oil listed in table below.
Table 1. Engine Oil Recommendations.
Ambient Mono- Multi-
Temperature grade Grade
Below 5°F (–15°C) 5W 5W/20
Between 5°F (–15°C) and 50°F (10°C) 10W 10W/30
Between 40°F (5°C) and 85°F (30°C) 20W 10W/30 or 15W/40
Above 85°F (30°C) 30W 15W/40 or 20W/40
Figure 1. Oil Fill Tube and Dip Stick on Engine Location.
END OF TASK
0021-3
TM 11-6115-742-13&P 0021
ADD COOLANT TO ENGINE RADIATOR - SERVICE
WARNING
If Genset has been in operation, the radiator and its contents may be extremely
hot and coolant may spew out of radiator when cap is removed. To prevent
serious injury to personnel, allow the Genset to cool down before performing the
following step.
NOTE
Level of coolant in coolant bottle should be checked daily especially before and
after operation. Coolant bottle should be 1/3 to 1/2 full. Coolant should also be
inspected for proper color and consistency.
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Stop Procedure).
2. Remove and retain Genset access panel (Figure 2, Item 4).
NOTE
When performing the following step, if the coolant does not have the proper color
or consistency then the coolant should be drained and replaced. Contact Service
maintenance.
3. Check fluid level in radiator overflow bottle (Figure 2, Item 3). Fluid level in overflow bottle should be 1/3 to
1/2 full when the engine is cool.
4. If necessary, remove cap and add coolant to achieve the proper level (1/3 to 1/2 full) in radiator overflow
bottle (Figure 2, Item 3).
5. Remove and retain access cap (Figure 2, Item 2) located on the top of the Genset enclosure.
6. Remove and retain radiator cap (Figure 2, Item 1) and observe coolant level. Coolant should be one inch
below the overflow level.
0021-4
TM 11-6115-742-13&P 0021
SERVICE – Continued
NOTE
When performing the following step, use funnel provided with the trailer.
7. If required, add coolant through the access cap (Figure 2, Item 2) until proper level is obtained.
8. Install and tighten radiator cap (Figure 2, Item 1) and access cap (Figure 2, Item 2).
9. Start Genset in accordance with Genset Start Procedure (WP 0005) and allow engine to run for a few minutes
to circulate coolant through engine.
10. Shut down the Genset in accordance with Genset Stop Procedure (WP 0005) and allow radiator to cool.
Check coolant level in radiator overflow bottle (Figure 2, Item 3). Radiator overflow bottle (Figure 2,
Item 3) should be 1/3 to 1/2 full when the engine is cool. If necessary, repeat steps 3 through 7.
11. Install and latch rear access panel (Figure 2, Item 4).
12. Start Genset in accordance with Genset Start Procedure (WP 0005).
14
32
23
4
1
Figure 2. Location of Radiator and Radiator Overflow Bottle.
END OF TASK
0021-5
TM 11-6115-742-13&P 0021
MASTER BRAKE CYLINDER SERVICE
CAUTION
When performing the following service, DO NOT mix brake fluid types.
NOTE
When master cylinder reservoir cap is removed use caution to keep debris from
getting onto cap and into reservoir.
1. Remove and retain master cylinder reservoir cap (Figure 3, Item 1).
NOTE
When performing the following service, if fluid is contaminated, discolored,
viscosity is incorrect, or if master cylinder reservoir is completely dry, contact
next level of maintenance.
2. Inspect fluid level in master cylinder reservoir (Figure 3, Item 2). Fluid level should be approximately 3/4”
from the neck of the master cylinder reservoir (Figure 3, Item 2).
3. If necessary, add brake fluid to master cylinder reservoir (Figure 3, Item 2).
NOTE
If cap does not turn smoothly remove and check threads. Forcing cap can result
in damage to cap or master cylinder.
4. Replace master cylinder reservoir cap (Figure 3, Item 1) (cap should turn 1/4 turn clockwise to tighten).
0021-6
TM 11-6115-742-13&P 0021
Figure 3. Master Brake Cylinder Service.
END OF TASK
END OF WORK PACKAGE
0021-7/8 blank
TM 11-6115-742-13&P 0022
CREW MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU CONTROL PANEL ASSEMBLY
ECU CONTROL PANEL ASSEMBLY
INITIAL SETUP:
Materials/Parts References
Lens, indicator, green WP 0005
Lens, indicator, red
Coolant Equipment Condition
Personnel Required ECU shut down
One
GENERAL
This work package provides information on the removal and replacement of components on the ECU control
panel. They consist of:
• Control panel indicator POWER ON lens removal/replacement.
• Control panel indicator OUT OF PHASE lens removal/replacement.
• Check/refill ECU heater (hydronic) coolant reservoir.
If necessary, refer to Description and Use of Operator Controls, Indicators, and Connectors (WP 0004) for the
controls, indicators, and connectors of the ECU.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
NOTE
Removal of the access panels during operations will prevent the ECU from
properly conditioning the air.
0022-1
TM 11-6115-742-13&P 0022
CONTROL PANEL INDICATOR LENS REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
2. Open ECU Control Enclosure (Figure 1, Item 1).
3. Turn indicator lens (Figure 1, Items 2 and 3) counter clockwise and remove.
END OF TASK
REPLACEMENT
1. Align indicator lens (Figure 1, Items 2 and 3) with socket.
2. Insert, apply moderate pressure, and turn clockwise until secure.
3. Close ECU Control Enclosure (Figure 1, Item 1).
4. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005).
0022-2
TM 11-6115-742-13&P 0022
Figure 1. ECU Control Panel Lens Indicator and Mode Select Switch Knob
Removal/Replacement.
END OF TASK
0022-3
TM 11-6115-742-13&P 0022
ECU HEATER (HYDRONIC) COOLANT RESERVOIR
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
CHECK/REFILL COOLANT
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
2. Unlatch and remove forward access panel from ECU.
3. Turn radiator cap (Figure 2, Item 1) of ECU heater (hydronic) reservoir (Figure 2, Item 2) counterclockwise to
open.
4. Check and fill reservoir (Figure 2, Item 2) as needed.
CAUTION
Do not overfill reservoir. Space must be allowed for the expansion of the heated
coolant or overheating will result.
END OF TASK
ECU HEATER (HYDRONIC) REPLACEMENT
1. Install radiator cap (Figure 2, Item 1) to reservoir (Figure 2, Item 2) and turn clockwise to tighten.
2. Attach forward access panel to ECU.
3. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005).
0022-4
TM 11-6115-742-13&P 0022
2
Figure 2. ECU Heater (Hydronic) Coolant Reservoir.
END OF TASK
END OF WORK PACKAGE
0022-5/6 blank
TM 11-6115-742-13&P 0023
CREW MAINTENANCE INSTRUCTIONS
TMSS-MED
TRAILER AND SHELTER ELECTRICAL SERVICE
CHARGE BATTERIES – SERVICE
INITIAL SETUP:
Materials/Parts Equipment Condition
NATO Cable Trailer parked, brakes engaged and wheels
chocked
Personnel Required Genset Control Panel - ENGINE switch set to
One OFF
Genset Control Panel - BATTERY SWITCH
References set to OFF
WP 0005
GENERAL
This work package provides information needed by the Crew when performing the following maintenance
procedures on the TMSS-MED trailer and shelter.
• Charge batteries - Service
• Trailer lights/Inter-vehicular cable - Test
WARNING
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never allowing the tool to bridge two
terminals. Failure to observe this warning can result in serious injury.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing any service or maintenance.
CARBON MONOXIDE (EXHAUST GAS) CAN KILL YOU
Carbon monoxide does not have color or smell, but it can kill you. Breathing
carbon monoxide produces symptoms of headache, dizziness, loss of muscular
control, a sleepy feeling, and coma. Brain damage or death can result from
heavy exposure. Carbon monoxide occurs in the exhaust fumes of fuel-burning
heaters and internal combustion engines. When there is no air movement,
carbon monoxide can become dangerously concentrated. Precautions must be
followed to ensure crew safety when the ECU, Genset, or any other vehicle is
operated near the shelter.
Batteries generate explosive gas during charging. Utilize extreme caution. Do
not smoke or use open flame in the vicinity of the battery. Death or severe burns
may result.
Battery acid can be dangerous. Do not touch. Death or severe burns may result.
0023-1
TM 11-6115-742-13&P 0023
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
CHARGE BATTERIES SERVICE
WARNING
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never allowing the tool to bridge two
terminals. Failure to observe this warning can result in serious injury.
NOTE
Prior to performing the following steps, inspect the batteries and cables for any
visible damage. Verify that fluid level(s) are correct. If necessary, contact Unit
maintenance to check fusible link between batteries.
Battery Charging (using alternator on Genset engine)
1. Start Genset in accordance with Genset Start Procedure (WP 0005) and allow alternator to charge battery.
2. Observe DC VOLTS meter (Figure 1, Item 1) and BATTERY CHARGER AMPS meter (Figure 1, Item 2) on
Genset control panel (Figure 1, Item 3). See (Table 1) for normal meter indications.
3. If battery does not charge, contact Service maintenance.
END OF TASK
Battery Charging (using 24 VDC)
NOTE
The batteries should be charged once every 6 months.
1. Connect appropriate NATO cable to 24 VOLTS DC (J6) (Figure 1, Item 5) of Genset Power Distribution Panel
(Figure 1, Item 7) and to 28 VDC power source.
2. Verify that DC source is properly energized.
3. Check the indicator lamp and charge the batteries for eight hours.
4. Set ENGINE switch (Figure 1, Item 4) on the Generator Power Distribution Panel to the RUN position.
0023-2
TM 11-6115-742-13&P 0023
Battery Charging (using 24 VDC) - Continued
5. Observe DC VOLTS meter (Figure 1, Item 1) on Genset control panel (Figure 1, Item 3). See (Table 1) for
normal meter indications. If battery does not charge (DC VOLTS meter should read between 24 to 28 VDC)
after eight hours, continue charging for an additional four hours.
6. If battery does not charge after a total of 12 hours, contact Service maintenance.
END OF TASK
Battery Charging (using single phase 120 VAC)
NOTE
The batteries should be charged once every 6 months.
1. Connect battery charger cable (provided with the trailer) to 120 VOLT INPUT (J5) (Figure 1, Item 6) on the
Genset Power Distribution Panel and to 120 VAC power source.
2. Verify that AC source is properly energized.
3. Check the indicator lamp and charge the batteries for eight hours.
4. Set ENGINE switch (Figure 1, Item 4) on the Generator Power Distribution Panel to the RUN position.
5. Observe DC VOLTS meter (Figure 1, Item 1) on Genset control panel (Figure 1, Item 3). See (Table 1) for
normal meter indications. If DC VOLTS meter does not read between 24 to 28 VDC after eight hours,
continue charging for an additional four hours.
6. If battery does not charge after a total of 12 hours, contact Service maintenance.
END OF TASK
Table 1. Normal Meter Reading for Battery.
Meter Normal Indication Notes
Green area on meter is 24 VDC to
DC VOLTS Indicator in green area meter
31 VDC
If battery is being charged via the
BATTERY CHARGER AMPS 0 amps 120 VAC battery charger, the
ammeter should read: 0 to 5 amps
0023-3
TM 11-6115-742-13&P 0023
2
1
7 6 5
Figure 1. Location of Connectors and Meters for 24 VDC Battery Charging.
0023-4
TM 11-6115-742-13&P 0023
TRAILER LIGHTS/INTER-VEHICULAR CABLE - TEST
1. Connect inter-vehicular cable assembly to tow vehicle.
2. While driver pushes down on brake pedal, observe that trailer brake lights activate.
3. While driver activates turn signals and hazard lights, observe that turn signal and hazard light on trailer
activate.
4. While driver activates black-out drive lights, observe that trailer blackout lights activate.
5. If any of the above steps fail, contact Service maintenance.
END OF TASK
END OF WORK PACKAGE
0023-5/6 blank
TM 11-6115-742-13&P 0024
CREW MAINTENANCE INSTRUCTIONS
TMSS-MED
SHELTER COVER ASSEMBLY
SHELTER - COVER REPAIR (USING FIELD REPAIR KIT)
INITIAL SETUP:
Tools and Special Tools Equipment Condition
Field repair kit Shelter is unpacked and spread out
Materials/Parts
Cover
Personnel Required
One to four
GENERAL
This work package provides information needed by the Crew when performing the following maintenance
procedures on the TMSS-MED shelter.
• Shelter – Cover repair (using field repair kit)
• Shelter – Cover removal/replacement
WARNING
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never allowing the tool to bridge two
terminals. Failure to observe this warning can result in serious injury.
If Genset has been in operation, components may be extremely hot. To prevent
serious injury to personnel, allow the Genset to cool down before performing any
service or maintenance.
CARBON MONOXIDE (EXHAUST GAS) CAN KILL YOU
Carbon monoxide does not have color or smell, but it can kill you. Breathing
carbon monoxide produces symptoms of headache, dizziness, loss of muscular
control, a sleepy feeling, and coma. Brain damage or death can result from
heavy exposure. Carbon monoxide occurs in the exhaust fumes of fuel-burning
heaters and internal combustion engines. When there is no air movement,
carbon monoxide can become dangerously concentrated. Precautions must be
followed to ensure crew safety when the ECU, Genset, or any other vehicle is
operated near the shelter.
Batteries generate explosive gas during charging. Utilize extreme caution. Do
not smoke or use open flame in the vicinity of the battery. Death or severe burns
may result.
Battery acid can be dangerous. Do not touch. Death or severe burns may result.
0024-1
TM 11-6115-742-13&P 0024
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
NOTE
The field repair kit is supplied with the shelter.
Field repair kit is intended to repair a hole or tear in a shelter cover 10" in size or
less.
The following procedure can be used to repair the main shelter section, end
caps, and doors.
REPAIR
1. Examine the damaged area of the interior and exterior covers (Figure 1, Item 1).
2. If necessary, remove only those keepers necessary to peel back the exterior or interior cover (Figure 1,
Item 1) to reach the hole or tear (Figure 1, Item 2).
NOTE
When performing the following steps:
• Allow approximately 1/4" extra on all sides.
• If patching a small hole or tear, cut the patch into a circle.
• If the tear or hole is too large, cut the patch into an oval shape.
3. Choose matching color self adhering patch material (Figure 1, Item 3) from the repair kit. Using scissors, cut
enough self adhering patch material (Figure 1, Item 3) to cover the hole or tear.
4. Peel backing off of self adhering patch material (Figure 1, Item 3) and align with hole or tear (Figure 1,
Item 2).
5. Press self adhering patch material (Figure 1, Item 3) firmly over hole or tear (Figure 1, Item 2), smoothing
away any air bubbles. Patch will be secured immediately.
6. If necessary, replace cover and tighten all keepers as described in this WP.
0024-2
TM 11-6115-742-13&P 0024
Figure 1. Repair of Shelter Cover.
END OF TASK
0024-3
TM 11-6115-742-13&P 0024
NOTE
The following procedures apply to main shelter and end caps.
SHELTER COVER REMOVAL
1. If necessary, strike the shelter (Figure 2, Item 2) (see WP 0005) and separate end caps (Figure 2, Item 1)
from the main section.
2. Spread shelter (Figure 2, Item 2) out to full extension so that cover being replaced is face up.
CAUTION
When performing the following step, do not step on struts. Struts could become
damaged or break due to weight.
NOTE
When performing the following step, inspect all keepers for damage (stripped
threads, broken or frayed loop, remember to keep track of which keepers went
into which holes. Looped keepers must be returned to proper location(s).
3. Using spanner wrench, remove and retain all keepers (Figure 2, Item 4).
4. Roll cover (Figure 2, Item 3) off of frame (Figure 2, Item 5).
NOTE
If removing both interior and exterior covers, continue with steps 5 and 6.
5. Compress the frame (Figure 2, Item 5).
6. Flip the shelter (Figure 2, Item 2) over. Repeat steps 2 through 4.
END OF TASK
0024-4
TM 11-6115-742-13&P 0024
SHELTER COVER REPLACEMENT
CAUTION
Do not step on struts. Struts could become damaged or break due to weight.
1. Spread the frame (Figure 2, Item 5) out completely.
2. Using door sections for alignment, spread cover (Figure 2, Item 3) over frame (Figure 2, Item 5).
CAUTION
NEVER use a thread-locking additive on the keepers. This will damage the
threads and prevent the keeper from being removed at a later time for repairs.
NOTE
Place the keepers back into their original positions to ensure the proper
placement of the looped keepers.
Keepers will screw in easily. If keeper will not screw in by hand, check to make
sure the keeper is straight, and check the threads in the hub (Figure 2, Item 6) to
ensure they are not damaged. If damaged, replace with a new hub.
3. Install keeper (Figure 2, Item 4) through cover (Figure 2, Item 3) located at center of bottom sides. (Identified
by the stake plates attached to the hubs).
4. Roll cover (Figure 2, Item 3) (from sides) into center of frame (Figure 2, Item 5). (Cover should now be in a
double roll, attached at each end to the appropriate stake plated hub).
5. Working from already attached hubs (Figure 2, Item 6), attach keepers (Figure 2, Item 4) in line with two
previously attached hubs (Figure 2, Item 6) (This should result in the center of the cover attached to the
frame).
6. Unroll cover (Figure 2, Item 3) over until next set of hubs (Figure 2, Item 6) are present. Align holes with
frame (Figure 2, Item 5).
7. Install keepers (Figure 2, Item 4) and attach to hubs (Figure 2, Item 6).
8. Repeat until all keepers (Figure 2, Item 4) are installed being mindful of proper locations of looped keepers
(Figure 2, Item 4).
9. Compress the shelter (Figure 2, Item 2) 4/5th of the way.
10. Using spanner wrench, tighten all keepers (Figure 2, Item 4).
0024-5
TM 11-6115-742-13&P 0024
3
4
5
6
Figure 2. Shelter Cover(s) Removal/Replace.
END OF TASK
END OF WORK PACKAGE
0024-6
TM 11-6115-742-13&P 0025
CREW MAINTENANCE INSTRUCTIONS
TMSS-MED
SHELTER STRUT
INITIAL SETUP:
Tools and Special Tools Personnel Required
Field repair kit One to four
Materials/Parts Equipment Condition
Duct tape (WP 0168, Items 17 or 18) Shelter is unpacked and spread out
Strut
GENERAL
This work package provides information needed by the Crew when performing the following maintenance
procedures on the TMSS-MED shelter.
• Shelter - strut repair (using field repair kit)
• Shelter - strut removal/replacement
WARNING
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never allowing the tool to bridge two
terminals. Failure to observe this warning can result in serious injury.
If Genset has been in operation, components may be extremely hot. To prevent
serious injury to personnel, allow the Genset to cool down before performing any
service or maintenance.
CARBON MONOXIDE (EXHAUST GAS) CAN KILL YOU
Carbon monoxide does not have color or smell, but it can kill you. Breathing
carbon monoxide produces symptoms of headache, dizziness, loss of muscular
control, a sleepy feeling, and coma. Brain damage or death can result from
heavy exposure. Carbon monoxide occurs in the exhaust fumes of fuel-burning
heaters and internal combustion engines. When there is no air movement,
carbon monoxide can become dangerously concentrated. Precautions must be
followed to ensure crew safety when the ECU, Genset, or any other vehicle is
operated near the shelter.
Batteries generate explosive gas during charging. Utilize extreme caution. Do
not smoke or use open flame in the vicinity of the battery. Death or severe burns
may result.
Battery acid can be dangerous. Do not touch. Death or severe burns may result.
NOTE
The following procedure can be used to repair struts for both the main shelter
section and end caps.
0025-1
TM 11-6115-742-13&P 0025
If fractured strut(s) is found during shelter inspection, remove only the exterior
cover required to gain access to damaged strut.
SHELTER STRUT REPAIR (USING FIELD REPAIR KIT)
1. If necessary, remove keepers as described in this WP.
2. Peel back exterior cover to gain access to damaged strut (Figure 1, Item 1).
3. Using hack saw (provided with field repair kit) trim off 1/2" from each end of damaged strut (Figure 1, Item 1).
NOTE
The field repair kit is supplied with the shelter.
4. Retrieve repair sleeve (Figure 1, Item 2) from field repair kit.
5. Slide the repair sleeve (Figure 1, Item 2) over damaged strut (Figure 1, Item 1), keeping damaged strut
(Figure 1, Item 1) centered in repair sleeve (Figure 1, Item 2).
NOTE
Tape one end ONLY of the repair sleeve (Figure 1, Item 2) with the duct tape
(Figure 1, Item 3). This will allow broken strut (Figure 1, Item 1) to telescope
within the repair sleeve (Figure 1, Item 2) and maintain its critical length.
6. Wrap tape around end of broken strut (Figure 1, Item 1) that is closest to the center hinge (Figure 1, Item 4).
This will ensure repair sleeve (Figure 1, Item 2) does not slide into and bind the hinge.
7. Replace shelter cover.
8. Tighten all keepers as described in this WP.
0025-2
TM 11-6115-742-13&P 0025
3
4
Figure 1. Repair of Shelter Strut.
END OF TASK
0025-3
TM 11-6115-742-13&P 0025
NOTE
The following procedures apply to main shelter and end caps.
This repair procedure can be accomplished in all weather conditions.
SHELTER STRUT REMOVAL
1. If necessary, strike the shelter (Figure 2, Item 2) (see WP 0005) and separate end caps (Figure 2, Item 1).
2. Identify broken strut(s) (Figure 2, Item 4) and associated hub(s) (Figure 2, Item 7).
3. Contract frame until tension on strut(s) are reduced.
NOTE
If damaged strut(s) (Figure 2, Item 4) are located on interior of shelter, remove as
much cover as is necessary to access strut(s) (Figure 2, Item 4).
Work on one strut pair at a time to prevent confusion.
4. Using spanner wrench, remove keepers (Figure 2, Item 5) holding cover (Figure 2, Item 3) to the affected
hubs (Figure 2, Item 7).
5. Remove and retain eight screws (Figure 2, Item 6) from hub (Figure 2, Item 7) that secure broken strut
(Figure 2, Item 4).
NOTE
When performing the following step, be observant of strut positions in hub.
6. Remove and retain top of hub (Figure 2, Item 7).
7. Remove damaged strut (Figure 2, Item 4) from the hub (Figure 2, Item 7).
NOTE
Before removing damaged strut, match new strut to old strut to ensure
replacement strut is correct type.
8. Remove damaged strut(s) (Figure 2, Item 4) one at a time, being observant of color on ends.
END OF TASK
0025-4
TM 11-6115-742-13&P 0025
REPLACEMENT
CAUTION
Placing the strut in backwards can prevent the shelter from erecting or cause
other struts to break.
NOTE
Place new strut alongside old strut and verify the strut being replaced is correct
type and color.
1. Position strut (Figure 2, Item 4) and install into hub (Figure 2, Item 7).
2. Insert end hinge rod of strut (Figure 2, Item 4) into hub (Figure 2, Item 7) base.
NOTE
If multiple struts are in hub, ensure that all struts are securely seated.
3. Install top of hub (Figure 2, Item 7) and secure with eight screws (Figure 2, Item 6).
4. If necessary, repeat procedure beginning with step 4 of removal procedure until all damaged struts are
replaced.
5. If necessary, install cover as described in this WP.
6. Verify proper assembly, erect shelter (as described in WP 0005).
0025-5
TM 11-6115-742-13&P 0025
2 3 4
1 1
5
3 (Ref)
7A 7
4 (Ref)
7B
Figure 2. Shelter Struts Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0025-6
TM 11-6115-742-13&P 0026
CREW MAINTENANCE INSTRUCTIONS
TMSS-MED
SHELTER KEEPER REPAIR
SHELTER KEEPER- REMOVAL/REPLACEMENT (USING FIELD REPAIR KIT)
INITIAL SETUP:
Tools and Special Tools Personnel Required
Field repair kit One
Materials/Parts Equipment Condition
Keeper Shelter is unpacked and spread out
Hub
GENERAL
This work package provides information needed by the Crew when performing the following maintenance
procedures on the TMSS-MED trailer and shelter.
• Keeper - removal/replacement (using field repair kit)
• Main hub - removal/replacement
• Main Staking Bracket - removal/replacement
WARNING
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never allowing the tool to bridge two
terminals. Failure to observe this warning can result in serious injury.
If Genset has been in operation, components may be extremely hot. To prevent
serious injury to personnel, allow the Genset to cool down before performing any
service or maintenance.
CARBON MONOXIDE (EXHAUST GAS) CAN KILL YOU
Carbon monoxide does not have color or smell, but it can kill you. Breathing
carbon monoxide produces symptoms of headache, dizziness, loss of muscular
control, a sleepy feeling, and coma. Brain damage or death can result from
heavy exposure. Carbon monoxide occurs in the exhaust fumes of fuel-burning
heaters and internal combustion engines. When there is no air movement,
carbon monoxide can become dangerously concentrated. Precautions must be
followed to ensure crew safety when the ECU, Genset, or any other vehicle is
operated near the shelter.
Batteries generate explosive gas during charging. Utilize extreme caution. Do
not smoke or use open flame in the vicinity of the battery. Death or severe burns
may result.
Battery acid can be dangerous do not touch. Death or severe burns may result.
0026-1
TM 11-6115-742-13&P 0026
NOTE
The following procedure can be used to replace keepers on both the main shelter
section and end caps.
KEEPER REMOVAL
1. Identify damaged keeper (Figure 1, Items 1 or 2).
NOTE
The field repair kit is supplied with the shelter.
2. Using spanner wrench, (provided in the field repair kit) loosen keeper (Figure 1, Items 1 and 2) and remove
from hub (Figure 1, Item 4).
END OF TASK
REPLACEMENT
1. Retrieve a replacement keeper (Figure 1, Items 1 and 2) from the field repair kit. Inspect to ensure O-ring is
present around base and that O-ring is not damaged.
CAUTION
NEVER use thread-locking additive on keepers. This will damage the threads
and prevent the keeper from being removed.
NOTE
Inspect threads of hub (Figure 1, Item 4) and keeper (Figure 1, Items 1 and 2) to
ensure they are not damaged. If damaged, contact Service maintenance to
replace hub. Keeper should screw in easily. If keeper (Figure 1, Items 1 and 2)
will not screw in by hand, check to make sure that keeper (Figure 1, Items 1
and 2) is straight and that cross-threading did not occur.
When performing the following step, ensure all sewn seams of shelter are
aligned. Fabric reinforced circles around keepers should not be twisted.
2. Screw new keeper (Figure 1, Items 1 and 2) through shelter (Figure 1, Item 3) into the hub (Figure 1, Item 4)
by hand until snug.
0026-2
TM 11-6115-742-13&P 0026
CAUTION
When performing the following step, do not over tighten. This could damage the
threads and prevent the keeper from being removed.
3. Use the spanner wrench, tighten one-quarter turn past hand tight.
Figure 1. Shelter Keepers Removal/Replacement.
END OF TASK
0026-3
TM 11-6115-742-13&P 0026
NOTE
The following procedures apply to main shelter and end caps.
HUB REMOVAL
1. If necessary, strike the shelter (Figure 2, Item 2) (see WP 0005) and separate end caps (Figure 2, Item 1)
from the main section.
2. Spread shelter (Figure 2, Item 2) out to full extension.
CAUTION
When performing the following step, do not step on struts. Struts could become
damaged or break due to weight.
NOTE
When performing the following step, inspect all keepers for damage (stripped
threads, broken or frayed loop). Remember to keep track of which keepers went
into which holes. Looped keepers must be returned to proper location(s).
3. Using spanner wrench, remove and retain keepers (Figure 2, Item 5) from damaged area.
4. Remove cover off of damaged area.
5. Identify broken main hub(s) (Figure 2, Item 4) and associated strut(s) (Figure 2, Item 3).
6. Remove and retain eight screws (Figure 2, Item 6) from damaged main hub (Figure 2, Item 7). Remove hub
top (Figure 2, Item 7A).
7. Annotate location(s) of struts (Figure 2, Item 3) inside of lower main hub (Figure 2, Item 7B).
END OF TASK
0026-4
TM 11-6115-742-13&P 0026
REPLACEMENT
1. Remove struts (Figure 2, Item 3) from base of main hub (Figure 2, Item 7B) one at a time and place into base
of new main hub (Figure 2, Item 7B).
2. Place main hub top (Figure 2, Item 7A) onto bottom half of main hub (Figure 2, Item 7B) and secure using
eight screws (Figure 2, Item 6).
3. Repeat steps until all broken/damaged main hubs (Figure 2, Item 7) are replaced.
4. Re-assemble shelter (Figure 2, Item 2) and install all removed keepers (Figure 2, Item 5).
5. Verify proper assembly, erect shelter (as described in WP 0005).
3 4
2
1 1
5 ( Ty pical)
7A
7
3 (Ref)
7B
Figure 2. Shelter Main Hub(s) Removal/Replacement.
END OF TASK
0026-5
TM 11-6115-742-13&P 0026
MAIN STAKING BRACKET REMOVAL
1. If necessary, strike the shelter (Figure 2, Item 2) (see WP 0005) and remove shelter cover (see procedure in
this WP).
2. Identify broken/damaged main staking bracket (Figure 3, Item 3).
3. Remove and retain keeper (Figure 3, Item 4) securing shelter to main staking bracket (Figure 3, Item 3).
4. Remove and retain eight screws (Figure 3, Item 1) securing main staking bracket (Figure 3, Item 3) to hub
(Figure 3, Item 2).
NOTE
When performing the following step, do not allow the hub to separate.
5. Disassemble main staking bracket (Figure 3, Item 3) from hub (Figure 3, Item 2).
6. Properly dispose of damaged piece(s).
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following step inspect all pieces to ensure completeness
and serviceability.
1. Assemble main staking bracket (Figure 3, Item 3) and hub (Figure 3, Item 2). Secure using eight screws
(Figure 3, Item 1).
2. Inspect keeper (Figure 3, Item 4) for completeness and serviceability, replace if necessary.
CAUTION
NEVER use a thread-locking additive on the keepers. This will damage the
threads and prevent the keeper from being removed at a later time for repairs.
3. Install assembly to appropriate place on shelter. Secure using keeper (Figure 3, Item 4).
0026-6
TM 11-6115-742-13&P 0026
REPLACEMENT – Continued
4. If necessary, install cover as described in this WP.
5. Verify proper assembly, erect shelter (as described in WP 0005).
NOTE
Shelter removed for clarity.
Figure 3. Main Staking Bracket Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0026-7/8 blank
TM 11-6115-742-13&P
CHAPTER 5
MAINTAINER TROUBLESHOOTING PROCEDURES
FOR
TMSS-MED
TM 11-6115-742-13&P 0027
MAINTAINER TROUBLESHOOTING PROCEDURES
TMSS-MED
MAINTAINER TROUBLESHOOTING INDEX
GENERAL
This WP contains a troubleshooting index of conditions/indications that may develop during maintenance or
operation. Maintenance is limited to those failures that may be repaired at the Maintainer level. The
troubleshooting index identifies the condition/indication, which is followed by a column that identifies the work
package and page(s) where Maintainer level troubleshooting procedure(s) may be found (in the form of an
inspection), followed by simple corrective actions which may be done by the Maintainer level. These inspections
and corrective actions should be performed in the order listed. The index is provided to assist in the quick
location of a problem. The manual cannot list all conditions/indications that may occur. If a condition/indication is
encountered that is not listed or that cannot be corrected by the corrective actions provided, notify the supervisor.
TROUBLESHOOTING INDEX
The troubleshooting index assists the operator after a fault occurs. When a fault occurs, carefully inspect the
equipment for fault indications to determine the best condition/indication to follow. The most important step in
troubleshooting is recognizing the conditions/indications and combination of conditions/indications. Use the
corrective action for a given condition/indication in the order of appearance. If the first repair attempt is
unsuccessful, proceed to the next recommended corrective action to resolve the problem. If a fault is
encountered that is not listed or that cannot be corrected by the corrective actions provided, notify the supervisor.
Table 1. Maintainer Troubleshooting Index.
ITEM CONDITION/INDICATION WP
GENSET (Electrical)
1 Generator produces no voltage .................................................................. 0028-2
2 Generator produces no voltage (for one phase leg) ................................... 0028-2
3 Generator produces no voltage (all phases bad)........................................ 0028-2
4 Generator produces low voltage (under no load condition) ........................ 0028-4
5 Generator produces high voltage (under no load condition) ...................... 0028-6
6 Generator produces high voltage (under load condition) ........................... 0028-6
7 Generator produces low/high voltage (under load condition) ..................... 0028-6
8 Generator voltage fluctuates/wanders ........................................................ 0028-8
9 Generator frequency out of tolerance ......................................................... 0028-9
10 Generator builds voltage from start-up then goes to low voltage ............... 0028-10
11 No reading present on AC meter (A-C AMPERE, HERTZ, A-C
KILOWATTS A-C-VOLTS) (M1 – M4) ....................................................... 0028-10
12 No reading present on DC VOLTS meter (M5)........................................... 0028-11
13 HOURMETER (M7) not operating .............................................................. 0028-11
14 No reading present on BATTERY CHARGER AMPS meter (M9).............. 0028-11
15 No reading present on COOLANT TEMP gauge (M6) ............................... 0028-12
16 No reading present on OIL: PRESSURE gauge (M8) ................................ 0028-12
17 BATTLE SHORT switch (SW5) suspect bad .............................................. 0028-12
18 PANEL LIGHT switch (SW2) suspect bad .................................................. 0028-13
19 VOLT/AMP switch (SW1) suspect bad ....................................................... 0028-13
20 ENGINE switch (SW3) suspect bad ........................................................... 0028-14
21 ENGINE HEATER switch (SW6) suspect bad ............................................ 0028-15
22 FUEL LINE HEATER switch (SW8) suspect bad .......................................
0027-1
TM 11-6115-742-13&P 0027
Table 1. Maintainer Troubleshooting Index – Continued.
ITEM CONDITION/INDICATION WP
GENSET (Electrical) – Continued
23 HIGH COOLANT TEMP(L3), OVERSPEED(L4) , or LOW OIL
PRESSURE (L5) suspect bad ................................................................... 0028-16
24 Control panel light(s) (L1 – L2) suspect bad ............................................... 0028-16
25 VOLTAGE ADJUST potentiometer (R1) suspect bad ................................ 0028-16
26 BATTERY SWITCH (SW9) suspect bad .................................................... 0028-17
27 EMERGENCY STOP (SW7) suspect bad .................................................. 0028-17
28 Circuit Breaker (CB1 – CB5) suspect bad .................................................. 0028-18
29 Power distribution panel light(s) (L6 – L10) suspect bad ............................ 0028-18
30 Relay (K4, K5, or K6) suspect bad ............................................................. 0028-19
31 Relay (K7) suspect bad............................................................................... 0028-19
32 Time delay (TDM) suspect bad ................................................................... 0028-20
33 Watt transducer (XDR) suspect bad ........................................................... 0028-20
34 Current transformer (CT) suspect bad ........................................................ 0028-21
35 Voltage regulator (VR) suspect bad ............................................................ 0028-21
36 Speed sensor (SS) suspect bad ................................................................. 0028-22
37 Governor controller (GC) suspect bad ........................................................ 0028-23
38 Battery charger (BC) suspect bad .............................................................. 0028-24
39 Voltage regulator or generator suspect bad ............................................... 0028-24
GENSET (Engine)
1 Coolant leaking ........................................................................................... 0029-2
2 Fuel leaking ................................................................................................. 0029-3
3 Oil leaking ................................................................................................... 0029-4
4 Battery acid leaking ..................................................................................... 0029-5
5 Engine does not crank ................................................................................ 0029-5
6 Engine turns over slowly ............................................................................. 0029-8
7 Engine cranks but does not start ................................................................ 0029-9
8 Engine stops (no warning lights) ................................................................. 0029-16
9 Engine stops (HIGH COOLANT TEMP light on)......................................... 0029-18
10 Engine stops (LOW OIL PRESSURE light on) ........................................... 0029-21
11 Engine stops (OVERSPEED light on) ......................................................... 0029-22
12 Engine emits white smoke from exhaust .................................................... 0029-23
13 Engine emits blue smoke from exhaust ...................................................... 0029-23
14 Engine emits heavy black smoke from exhaust.......................................... 0029-24
15 Excessive carbon deposits on exhaust outlet ............................................. 0029-24
16 Engine temperature remains below 120°F (48.88°C) ................................. 0029-24
17 AC KILOWATTS meter reads 0 with Genset under load ............................ 0029-25
18 DC VOLT meter reads below 28 VDC while Genset is running ................. 0029-25
19 Engine temperature above 220°F (104.4°C), engine still running .............. 0029-27
20 Engine oil pressure below 20 psi, engine still running ................................ 0029-27
21 Engine heater (hydronic) will not start (no fault code) ................................ 0029-28
22 Engine heater (hydronic) (fault code F01 or F02) ....................................... 0029-29
23 Engine heater (hydronic) (fault code F03) .................................................. 0029-30
24 Engine heater (hydronic) (fault code F04, F05, F06, F08, F09) ................. 0029-30
25 Engine heater (hydronic) (fault code F07) .................................................. 0029-30
26 Engine heater (hydronic) (fault code F010) ................................................ 0029-30
0027-2
TM 11-6115-742-13&P 0027
Table 1. Maintainer Troubleshooting Index – Continued.
ITEM CONDITION/INDICATION WP
ECU (Electrical)/Hydronic Heater
1 ECU will not run on GENSET power .......................................................... 0030-2
2 ECU will not run on shore power ................................................................ 0030-3
3 ECU won’t run in any mode ........................................................................ 0030-3
4 ECU won’t run in cool mode ....................................................................... 0030-5
5 ECU won’t run in HEAT mode. (V1) ........................................................... 0030-5
6 ECU won’t run in HEAT HIGH (or HEAT LOW) mode (V2) ........................ 0030-6
7 Evaporator fan does not operate 0030-8
8 Condenser fan does not operate ................................................................ 0030-9
9 Compressor won’t run ................................................................................. 0030-10
10 Pressure switch fault ................................................................................... 0030-12
11 Hydronic heater will not start (no fault code) .............................................. 0030-13
12 Hydronic heater (fault code F01 or F02) ..................................................... 0030-15
13 Hydronic heater (fault code F03) ................................................................ 0030-15
14 Hydronic heater (fault code F07) ................................................................ 0030-15
15 Hydronic heater (fault code F04, F05, F06, F08, F09, F010) ..................... 0030-17
16 Coolant leaking from hydronic heater/hoses .............................................. 0030-17
17 Fuel leaking from hydronic heater .............................................................. 0030-17
ECU (Electrical Tests)
1 Mode select switch - Test ........................................................................... 0030-22
2 Thermostat - Test ........................................................................................ 0030-23
3 Circuit breakers - Test................................................................................. 0030-24
4 Compressor contactor - Test ...................................................................... 0030-25
5 Heater contactor - Test ............................................................................... 0030-26
6 Transformer- Test ....................................................................................... 0030-27
7 Bridge rectifier - Test................................................................................... 0030-27
8 CMSP/EMSP - Test .................................................................................... 0030-28
ECU (Heating & Cooling)/Hydronic Heater
1 Conditioned air too warm (in Cool mode) ................................................... 0031-2
2 Conditioned air too cold (in Heat mode) ..................................................... 0031-4
3 Blower does not operate ............................................................................. 0031-5
4 Discharge pressure too high ....................................................................... 0031-5
5 Discharge pressure too low ........................................................................ 0031-5
6 Suction pressure too high ........................................................................... 0031-5
7 Suction pressure too low............................................................................. 0031-5
8 Compressor fails to start ............................................................................. 0031-5
9 Compressor "short cycles" .......................................................................... 0031-5
10 Compressor noisy ....................................................................................... 0031-5
11 Compressor starts normally but shuts down due to overload ..................... 0031-6
12 Compressor excessively noisy.................................................................... 0031-6
13 Conditioned air too cold (in Heat mode) ..................................................... 0031-6
0027-3
TM 11-6115-742-13&P 0027
Table 1. Maintainer Troubleshooting Index – Continued.
ITEM CONDITION/INDICATION WP
TRAILER (Electrical)
1 Tail light intermittent .................................................................................... 0032-2
2 Tail light does not work ............................................................................... 0032-3
TRAILER (Mechanical)
1 Hand brake does not engage...................................................................... 0033-2
2 Hand brake does not disengage ................................................................. 0033-2
3 Brake fluid present under trailer .................................................................. 0033-2
4 Brake actuator does not engage ................................................................. 0033-2
5 Hydraulic brakes exhibit failure ................................................................... 0033-2
6 Trailer does not track straight when towed or leans to side ....................... 0033-3
7 Tire(s) will not hold air pressure .................................................................. 0033-3
8 Tongue jack assembly will not raise/lower .................................................. 0033-3
9 Trailer stabilizer leg does not raise/lower ................................................... 0033-3
10 Excessive motion of lunette ........................................................................ 0033-3
SHELTER (Electrical)
1 Shelter lighting does not come on .............................................................. 0034-2
2 No power from PDU .................................................................................... 0034-2
3 Power indicator lights inoperable ................................................................ 0034-2
END OF WORK PACKAGE
0027-4
TM 11-6115-742-13&P 0028
MAINTAINER TROUBLESHOOTING PROCEDURES
TMSS-MED
GENSET (ELECTRICAL)
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit WP 0005, WP 0013, WP 0029,
(WP 0165, Item 1) WP 0040, WP 0041, WP 0044,
Multimeter (WP 0165, Item 2) WP 0068 through WP 0086
Personnel Required
Two
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by maintainer-level
qualified personnel. This work package provides a systematic approach to locating and correcting malfunctions of
the TMSS-MED. Each section is arranged according to the condition/indication of a problem. The corrective
action items have been arranged in order of complexity, with simpler actions listed first. The manual cannot
identity all malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be
corrected by the corrective actions provided, contact your supervisor.
WARNING
Special caution must be taken during troubleshooting since protective covers and
safety devices may be removed or disabled to gain access and make tests.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand brakes are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0028-1
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical).
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
1 Generator produces no voltage Fuse blown Set BATTERY SWITCH to ON.
Set ENGINE switch to RUN.
Open Genset control panel
(WP 0040) and observe fuse
LEDs. If LED is illuminated, fuse is
bad, replace (WP 0040).
Wiring Verify that Crew troubleshooting
tasks (WP 0013) have been
completed.
Contact next level of maintenance.
2 Generator produces no voltage VOLT/AMP switch or volt Set BATTERY SWITCH to ON.
(for one phase leg) meter
Set CB5 to OFF.
Set ENGINE switch to OFF.
Open up generator junction box
and attach DMM across the bad
phase (L1, L2, or L3) to neutral
(L0), on the source side.
Start engine.
If DMM voltage is not 120 VAC
+/- 10% then replace generator
(WP 0086).
If within tolerance, use DMM to
measure 120 VAC +/- 10% across
source side (terminal 1, 5, or 7) of
VOLT/AMP switch (SW1) and L0
(neutral terminal block).
If within tolerance, isolate failure to
either SW1 or volt meter M4.
Replace faulty component.
If not within tolerance, fuse or path
to generator is open.
3 Generator produces no voltage Voltage regulator Set BATTERY SWITCH to ON.
(all phases bad)
Set CB5 to OFF.
0028-2
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
3 Generator produces no voltage Voltage regulator Set ENGINE switch to OFF.
(cont.) (all phases bad)
Remove two voltage regulator
mounting screws to access the
underside. Verify the regulator
fuse is not blown. Replace fuse if
defective (WP 0079).
Locate the F+ and F- field
terminals and power input
terminals (L3 at terminal 3 and L1
at terminal 4) on regulator. Verify
continuity of the field terminal wires
and power input wires to generator.
Disconnect wires from voltage
adjust terminals (6 and 7) of
regulator.
Verify VOLTAGE ADJUST
potentiometer on Control Panel
sweeps 1000 +/- 10% ohms across
the wires. Replace potentiometer if
bad (WP 0070).
Reconnect the wires to terminals 6
and 7.
Proceed to residual field loss
malfunction.
NOTE
Residual magnetism in the field coils of the generator may have become too weak to
initiate electrical generation. The weak magnetic flux cannot overcome wire
resistance to start self generating current flow. Loss of the residual can be due to
long periods of disuse, vibration during shipping, or extreme high temperature
condition.
The exciter field coils can be re-magnetized by applying DC voltage potential across
them. This method of restoring residual magnetism is referred to as "flashing the
generator".
Residual field loss Flash the generator field terminals
to restore residual magnetism.
0028-3
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
3 Generator produces no voltage Voltage regulator
(cont.) (all phases bad)
CAUTION
To ensure that the voltage regulator is not damaged by the flash potential (raw
battery voltage), disconnect the field wires at the voltage regulator.
Remove generator field terminal
wires #237 and #238 from F+ and
F- on regulator.
Connect two hookup wires to the
battery positive (+) and negative (-)
terminals.
Connect battery (+) to wire #237
field F+ and battery (-) to wire #238
field F-.
After 3 to 5 seconds, remove the
battery negative (-) from the F-
wire. An inductive arc should
result if no arc occurs, repeat the
process.
Residual field loss Disconnect the hookup wires from
the battery and reconnect the field
wires to the voltage regulator.
Perform voltage regulator
adjustment (WP 0079). If
adjustment fails isolate to voltage
regulator or generator. Proceed to
Step 39.
4 Generator produces low voltage Fuse blown Set BATTERY SWITCH to ON.
(under no load condition)
Set ENGINE switch to RUN.
Open Genset control panel and
observe fuse LEDs.
If LED is illuminated, fuse is bad,
replace (WP 0040).
0028-4
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
4 Generator produces low voltage Output out of adjustment Verify that Crew troubleshooting
(cont.) (under no load condition) tasks (WP 0013) have been
completed.
Contact next level of maintenance.
Under-speed operation Verify HERTZ meter shows a
reading of 60 HZ +/- 10%.
If out of tolerance perform governor
control adjustment (WP 0081).
Voltmeter Set BATTERY SWITCH to ON.
Start engine.
Set VOLT/AMP switch to L1.
Use a DMM to measure 120 VAC
+/- 10% across the L1 (black) and
L0 (neutral) terminal blocks.
If the voltage is not within tolerance
proceed to the voltage regulator
malfunction.
If the voltage is within tolerance
replace the voltmeter (WP 0068) or
VOLT/AMP switch (SW1)
(WP 0070).
Voltage regulator Set BATTERY SWITCH to ON.
Set CB5 to OFF.
Set ENGINE switch to OFF.
Remove two voltage regulator
mounting screws to access the
underside. Verify the regulator
fuse is not blown. Replace fuse if
defective (WP 0079).
Disconnect wires from voltage
adjust terminals (6 and 7) of
regulator and verify VOLTAGE
ADJUST potentiometer on Control
Panel sweeps 1000 +/- 10% ohms
across the wires. Replace
potentiometer (WP 0070) if bad.
0028-5
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
4 Generator produces low voltage Voltage regulator Reconnect the wires to terminals 6
(cont.) (under no load condition) and 7.
Perform voltage regulator
adjustment (WP 0079). If
adjustment fails isolate to voltage
regulator or generator. Proceed to
Step 39.
5 Generator produces high voltage Fuse blown Set BATTERY SWITCH to ON.
(under no load condition)
Set ENGINE switch to RUN.
Open Genset control panel and
observe fuse LEDs. If LED is
illuminated, fuse is bad, replace
(WP 0040).
Output out of adjustment Verify that Crew troubleshooting
tasks (WP 0013) have been
completed.
Contact next level of maintenance.
6 Generator produces high voltage Fuse blown Set BATTERY SWITCH to ON.
(under load condition)
Set ENGINE switch to RUN.
pen Genset control panel and
observe fuse LEDs. If LED is
illuminated, fuse is bad, replace
(WP 0040).
Output out of adjustment Verify that Crew troubleshooting
tasks (WP 0013) have been
completed.
Contact next level of maintenance.
7 Generator produces low/high Excessive load Verify A-C Killowatts meter reads
voltage (under load condition) below the maximum of 18 kW
output power. If greater than 18
kW reduce the load.
Unbalanced load Use the VOLT/AMP switch to
monitor the voltage and current on
each phase of the generator.
0028-6
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
7 Generator produces low/high Unbalanced load If current draw on one phase varies
(cont.) voltage (under load condition) greatly from the others, swap loads
to different connectors to balance
load.
Voltage meter Set BATTERY SWITCH to ON.
Start engine.
Set VOLT/AMP switch to L1.
Use a DMM to measure 120 VAC
+/- 10% across the L1 (black) and
L0 (neutral) terminal blocks.
If the voltage is not within tolerance
proceed to the voltage regulator
malfunction.
If the voltage is within tolerance
replace the voltmeter (WP0068).
Voltage regulator Set BATTERY SWITCH to ON.
Set CB5 to OFF.
Set ENGINE switch to OFF.
Remove two voltage regulator
mounting screws to access the
underside. Verify the regulator
fuse is not blown. Replace fuse if
defective (WP 0079).
Disconnect wires from voltage
adjust terminals (6 and 7) of
regulator and verify VOLTAGE
ADJUST potentiometer on Control
Panel sweeps 1000 +/- 10% ohms
across the wires. Replace
potentiometer if bad (WP 0070).
Reconnect the wires to terminals 6
and 7.
Perform voltage regulator
adjustment (WP 0079). If
adjustment fails isolate to voltage
regulator or generator. Proceed to
Step 39.
0028-7
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
8 Generator voltage Fuse blown Set BATTERY SWITCH to ON.
fluctuates/wanders
Set ENGINE switch to RUN.
Open Genset control panel and
observe fuse LEDs. If LED is
illuminated, fuse is bad, replace
(WP 0040).
Diesel Engine not operating Verify that Crew troubleshooting
properly tasks (WP 0013) have been
completed.
Contact next level of maintenance.
Voltage regulator Set BATTERY SWITCH to ON.
Set CB5 to OFF.
Set ENGINE switch to OFF.
Remove two voltage regulator
mounting screws to access the
underside. Verify the regulator
fuse is not blown. Replace fuse if
defective (WP 0079).
Disconnect wires from voltage
adjust terminals (6 and 7) of
regulator and verify VOLTAGE
ADJUST potentiometer on Control
Panel sweeps 1000 +/- 10% ohms
across the wires. Replace
potentiometer if sweep isn’t smooth
or has dead spots (WP 0070).
If wires shielded, verify ground
continuity of shield.
Reconnect the wires to terminals 6
and 7.
Perform voltage regulator
adjustment (WP 0079). If
adjustment fails replace voltage
regulator (WP 0079).
0028-8
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
8 Generator voltage Frequency wandering Start engine.
(cont.) fluctuates/wanders
Set CB5 and CB1 to ON.
Operate ECU in heat or cool mode.
Verify HERTZ meter frequency is
stable. If frequency
fluctuates/wanders perform
governor adjustment (WP 0081),
troubleshoot governor (WP 0029) if
adjustment doesn’t correct
problem.
9 Generator frequency out of Fuse blown Set BATTERY SWITCH to ON.
tolerance
Set ENGINE switch to RUN.
Open Genset control panel and
observe fuse LEDs. If LED is
illuminated, fuse is bad, replace
(WP 0040).
Generator load unbalanced Verify that Crew troubleshooting
across all three phases tasks (WP 0013) have been
completed.
Using VOLT/AMP selector switch,
check amperage draw across each
phase.
If draw is not balanced throughout
each phase, transfer draw from
one phase to another. Primarily
done by changing the plug used on
the PDU, Leg 1 is CB1 and CB4,
Leg 2 is CB2 and CB5, Leg 3 is
CB3 and CB6.
Contaminated fuel/fuel filter Remove fuel filter (WP 0044).
Inspect fuel and filter.
If contamination is suspected,
replace fuel filter, drain, and refill
fuel tank (WP 0044).
Restart engine (WP 0005). If
condition persists, contact next
level of maintenance.
0028-9
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
9 Generator frequency out of Governor failure Perform governor adjustment
(cont.) tolerance (WP 0081).
Troubleshoot governor (WP 0029)
if adjustment doesn’t bring
frequency within tolerance.
10 Generator builds voltage from Fuse blown Set BATTERY SWITCH to ON.
start-up then goes to low voltage
Set ENGINE switch to RUN.
Open Genset control panel and
observe fuse LEDs. If LED is
illuminated, fuse is bad, replace
(WP 0040).
Verify that Crew troubleshooting
tasks (WP 0013) have been
completed.
Contact next level of maintenance.
Voltage regulator Perform regulator adjustment
(WP 0079).
Replace regulator (WP 0079) if
adjustment doesn’t correct
problem.
11 No reading present on AC meter Bad/incorrect connection Disconnect terminals from meter.
(A-C AMPERE, HERTZ, A-C
KILOWATTS A-C-VOLTS)
(M1 – M4)
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2 and CM2
are properly connected and no
wires are loose.
Bad meter Test meter as described in
(WP 0069). If appropriate reading
present on DMM, replace DC
VOLTS meter (WP 0069).
If appropriate reading not present
on DMM. Continue
troubleshooting circuit.
0028-10
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
12 No reading present on DC Bad/incorrect connection Disconnect terminals from meter.
VOLTS meter (M5)
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Bad meter Test DC VOLTS meter as
described in (WP 0069). If
appropriate input on DMM, replace
DC VOLTS meter (WP 0069).
If input not present, continue
troubleshooting circuit.
13 HOURMETER (M7) not operating Bad/incorrect connection Disconnect terminals from meter.
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2 and CM2
are properly connected and no
wires are loose.
Bad meter Test HOURMETER as described in
(WP 0069). If appropriate input on
DMM, replace HOURMETER
(WP 0069).
If input not present, continue
troubleshooting circuit.
14 No reading present on BATTERY Bad/incorrect connection Disconnect terminals from meter.
CHARGER AMPS meter (M9)
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2 and CM2
are properly connected and no
wires are loose.
Bad meter Test BATTERY CHARGER AMPS
meter as described in WP 0106. If
appropriate reading on DMM,
replace BATTERY CHARGER
AMPS meter (WP 0069).
If input not present, continue
troubleshooting circuit.
0028-11
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
15 No reading present on COOLANT Bad/incorrect connection Disconnect terminals from gauge.
TEMP gauge (M6)
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2 and CM2
are properly connected and no
wires are loose.
Bad gauge Test COOLANT TEMP gauge as
described in (WP 0069). If
appropriate reading on DMM,
replace COOLANT TEMP gauge
(WP 0069).
If input not present, continue
troubleshooting circuit.
16 No reading present on OIL: Bad/incorrect connection Disconnect terminals from gauge.
PRESSURE gauge (M8)
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2 and CM2
are properly connected and no
wires are loose.
Bad gauge Test OIL PRESSURE gauge as
described in (WP 0069). If
appropriate reading present on
DMM, replace OIL PRESSURE
gauge (WP 0069).
If appropriate reading not present
on DMM. Continue
troubleshooting circuit.
17 BATTLE SHORT switch (SW5) Bad/incorrect connection Disconnect terminals from switch.
suspect bad
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2 and CM2
are properly connected and no
wires are loose.
0028-12
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
17 BATTLE SHORT switch (SW5) Bad switch Disconnect terminals from switch.
(cont.) suspect bad Set DMM to read ohms. Connect
meter leads to terminals on
BATTLE SHORT switch and toggle
switch. DMM should read open
with switch off and short with
switch on. IF these conditions are
not met, BATTLE SHORT switch
bad, replace (WP 0070).
18 PANEL LIGHT switch (SW2) Bad/incorrect connection Disconnect terminals from switch.
suspect bad
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2 and CM2
are properly connected and no
wires are loose.
Jumper missing off of Check ENGINE switch for jumpers:
ENGINE switch
FROM TO
(terminal #) (terminal #)
3 7
7 11
Bad PANEL LIGHT switch Disconnect terminals from PANEL
LIGHT switch. Set DMM to read
ohms. Connect meter leads to
read from terminals #1 to #2 on
PANEL LIGHT switch and toggle
switch. DMM should read open
with switch off and short with
switch on. IF these conditions are
not met, PANEL LIGHT switch bad,
replace (WP 0070).
19 VOLT/AMP switch (SW1) suspect Bad/incorrect connection Disconnect terminals from switch.
bad
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2 and CM2
are properly connected and no
wires are loose.
0028-13
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
19 VOLT/AMP switch (SW1) suspect Bad/incorrect connection Check switch for jumpers:
(cont.) bad
FROM TO
(terminal #) (terminal #)
2 6
4 8
10 14
12 16
11 19
13 17
Bad switch Check for 120 VAC input at across
the source side (terminal 1, 5, or 7)
of VOLT/AMP switch (SW1) and L0
(neutral) terminal blocks.
If 120 VAC (±10%) present at all
three inputs of VOLT/AMP switch
(SW1) switch is bad. Replace
(WP 0070).
If 120 VAC (±10%) not present for
any phase. Continue
troubleshooting circuit.
20 ENGINE switch (SW3) suspect Jumper missing off of Check switch for jumpers:
bad ENGINE switch
FROM TO
(terminal #) (terminal #)
3 7
7 11
Bad/incorrect connection Disconnect terminals from switch.
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2 and CM2
are properly connected and no
wires are loose.
Bad switch Replace (WP 0070).
0028-14
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
21 ENGINE HEATER switch (SW6) Bad/incorrect connection Disconnect terminals from switch.
suspect bad
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2 and CM2
are properly connected and no
wires are loose.
Fuses at Engine heater blown Check and replace fuses at engine
heater.
Bad switch Disconnect terminals from switch.
Set DMM to read ohms.
Connect meter leads to read from
terminals #1 to #4 and #2 to #3 on
ENGINE HEATER switch (SW6).
Toggle switch. DMM should read
open with switch off and short with
switch on. IF these conditions are
not met, ENGINE HEATER switch
(SW6) bad, replace (WP 0070).
22 FUEL LINE HEATER switch Jumper missing off of FUEL Check switch for jumpers:
(SW8) suspect bad LINE HEATER switch
FROM TO
(terminal #) (terminal #)
3 4
Bad/incorrect connection Disconnect terminals from switch.
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2 and CM2
are properly connected and no
wires are loose.
Bad switch Disconnect terminals from switch.
Set DMM to read ohms. Connect
meter leads to read from terminals
#1 to #4 and #2 to #3 on FUEL
LINE HEATER switch (SW8).
Toggle switch. DMM should read
open with switch off and short with
switch on. IF these conditions are
not met, FUEL LINE HEATER
switch (SW8) bad, replace
(WP 0070).
0028-15
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
23 HIGH COOLANT TEMP(L3), Bad/incorrect connection Disconnect terminals from light.
OVERSPEED(L4) , or LOW OIL
PRESSURE (L5) suspect bad
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2 and CM2
are properly connected and no
wires are loose. Also check
connections at meters (M6 and
M8).
If all lights are not working check
common connection at ENGINE
switch (SW3).
Bad socket Disconnect terminals from bad light
and from one "good "light. Re-
connect terminals from bad light to
"good" light. If light operates,
socket bad replace (WP 0071).
24 Control panel light(s) (L1 – L2) Bad/incorrect connection Disconnect terminals from light.
suspect bad
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
If both lights are not working check
common connection at PANEL
LIGHTS switch (SW2).
Bad socket Swap terminals from bad light and
from "good "light. If light operates,
socket bad replace (WP 0071).
If one or both lights still do not
work, troubleshoot PANEL LIGHTS
switch (SW2).
25 VOLTAGE ADJUST Jumper missing off of Inspect potentiometer for jumper
potentiometer (R1) suspect bad potentiometer between wiper (center terminal)
and max (right terminal).
If jumper is damaged, missing or
not making good connection
repair/replace (WP 0070).
0028-16
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
25 VOLTAGE ADJUST Bad/incorrect connection Inspect terminals of potentiometer
(cont.) potentiometer (R1) suspect bad for good solder connections. If
solder joints are damaged, missing
or not making good connection
repair/replace (WP 0070).
Disconnect terminals from wiring
harness. Inspect terminal lugs for
good connection or corrosion.
Clean/replace terminal.
Potentiometer bad Disconnect terminals from
potentiometer. Set DMM to read
ohms. Connect meter leads to
maximum and minimum terminals
on potentiometer. Fully rotate
shaft on potentiometer. Meter
should sweep smoothly from 0Ω to
1,000Ω. If DMM shows any
irregularities (i.e., suddenly drops
to 0 Ω or is erratic in operation)
replace potentiometer (WP 0070).
26 BATTERY SWITCH (SW9) Bad/incorrect connection Disconnect fuse from battery
suspect bad (WP 0041). Remove panel
(WP 0072).
Disconnect terminals from switch.
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Bad switch Disconnect terminals from switch.
Set DMM to read ohms. Connect
meter leads to terminals on
BATTERY SWITCH (SW9).
Toggle switch. DMM should read
open with switch off and short with
switch on. IF these conditions are
not met, BATTERY SWITCH
(SW9) bad, replace (WP 0072).
27 EMERGENCY STOP (SW7) Bad/incorrect connection Disconnect fuse from battery
suspect bad (WP 0041). Remove panel
(WP 0072).
0028-17
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
27 EMERGENCY STOP (SW7) Bad switch Disconnect terminals from switch.
(cont.) suspect bad
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Disconnect terminals from switch.
Set DMM to read ohms. Connect
meter leads to terminals on
EMERGENCY STOP (SW7).
Pull switch in and out. DMM
should read open with switch in
and short with switch out. If these
conditions are not met,
EMERGENCY STOP (SW7) bad,
replace (WP 0072).
28 Circuit Breaker (CB1 – CB5) Bad/incorrect connection Disconnect fuse from battery
suspect bad (WP 0041). Remove panel
(WP 0072).
Disconnect terminals from suspect
CB.
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Bad circuit breaker (CB1 – Disconnect all terminals from
CB5) suspect CB. Set DMM to read
ohms. Connect meter leads to
terminals of suspect CB. Toggle
CB. DMM should read open with
CB off and short with CB on. If
these conditions are not met, CB
bad, replace (WP 0082).
29 Power distribution panel light(s) Bad/incorrect connection Ensure connectors CF3/CM3 and
(L6 – L10) suspect bad CF4/CM4 are properly connected
and no wires are loose.
Disconnect terminals from light.
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
If multiple lights are not working
check common connections.
(wire #s 117 and 149).
0028-18
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
29 Power distribution panel light(s) Bad socket Swap terminals from bad light and
(cont.) (L6 – L10) suspect bad from "good "light. If light operates,
socket bad replace (WP 0074).
If one or more lights still do not
work, troubleshoot wiring to pin #2
of light(s).
30 Relay (K4, K5, or K6) suspect Bad/incorrect connection Remove relay from socket.
bad
Inspect relay and socket for good
connection or corrosion. Clean
terminals.
Inspect individual wires going into
socket for good connection, visible
damage and/or corrosion. Re-seat
wires as necessary.
Ensure connectors CF2/CM2 are
properly connected and no wires
are loose.
Bad relay Relays K4, K5 and K6 are
interchangeable. Swap known
good relay for suspect relay. If
problem moves with relay. Bad
relay, replace (WP 0077).
If problem does not move with
relay, bad socket on barrier panel.
Contact next level of maintenance.
31 Relay (K7) suspect bad Bad/incorrect connection Remove K7 relay from socket.
Inspect relay and socket for good
connection or corrosion. Clean
terminals.
Inspect individual wires going into
socket for good connection, visible
damage and/or corrosion. Re-seat
wires as necessary.
Ensure connectors CF2/CM2 are
properly connected and no wires
are loose.
Bad relay If problem does not get resolved,
K7 relay is bad replace (WP 0077).
0028-19
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
32 Time delay (TDM) suspect bad Fuse F2 bad Check F2 ensure LED is not
illuminated. If Illuminated, replace
fuse (WP 0040).
Bad/incorrect connection Disconnect terminals from time
delay.
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2/CM2 are
properly connected and no wires are
loose.
K7 relay bad Check K7 relay as described in this
WP.
Time delay bad, replace
(WP 0078).
33 Watt transducer (XDR) suspect Fuse bad Check fuses F1 and F3 ensure
bad LED is not illuminated. If
Illuminated, replace fuse
(WP 0040).
Bad/incorrect connection Disconnect terminals from time
delay.
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2/CM2 are
properly connected and no wires
are loose.
Bad Input Measure AC input to Watt
Transducer:
AC DMM
FROM TO
INPUT Reading
L1 2 11 120 VAC
L3 8 11 120 VAC
0028-20
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
33 Watt transducer (XDR) suspect Bad current transformer Shut down Genset (WP 0005).
(cont.) bad
Disconnect fuse from battery
(WP 0041). Remove panel
(WP 0072).
Set DMM to read ohms. Measure
resistance across CTs. If DMM
reads open, CT bad, replace
(WP 0075).
Bad watt transducer, replace.
34 Current transformer (CT) suspect Bad/incorrect connection Disconnect terminals from suspect
bad current transformer.
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2/CM2 are
properly connected and no wires are
loose.
Bad current transformer Set DMM to read ohms. Measure
resistance across CTs. If DMM
reads open, CT bad, replace
(WP 0075).
Bad watt transducer Troubleshoot watt transducer as
described in this WP.
35 Voltage regulator (VR) suspect Fuse bad Check F1 and F7 ensure LED is
bad not illuminated. If Illuminated,
replace fuse (WP 0040).
Bad/incorrect connection Disconnect terminals from Voltage
regulator.
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connectors CF2/CM2 are
properly connected and no wires are
loose.
0028-21
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
35 Voltage regulator (VR) suspect Voltage regulator out of Refer to (WP 0079) for the following
(cont.) bad adjustment adjustment procedures:
• Voltage Output
• Stability
• V/Hz Roll-Off Freq
Poor voltage regulation Replace voltage regulator
(WP 0079).
36 Speed sensor (SS) suspect bad Bad/incorrect connection Disconnect terminals from speed
sensor.
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connections to TB1 are
properly connected and no wires
are loose.
Ensure connectors CM1, CM2,
CM3, and CM4 are properly
connected and no wires are loose.
Speed sensor bad Set DMM to read ohms. Measure
resistance across pins. 8 and 9 of
speed sensor. DMM should read 0
Ω. Measure resistance across
pins. 12 and 13 of speed sensor.
DMM should read 0 Ω. If any
resistance present, replace speed
sensor (WP 0080).
No power to speed sensor Energize system (WP 0005).
Set DMM to read VDC. Measure
across pins 1 and 2 of speed
sensor for 28 VDC. If 28 VDC not
present troubleshoot power source.
Set DMM to read VAC. Measure
across pins 3 and 4 of speed
sensor. If DMM does not read >1.0
VAC rms, replace speed sensor
(WP 0080).
0028-22
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
37 Governor controller (GC) suspect NOTE
bad
Refer to (WP 0081) for brief
description of potentiometers and
their functionality.
Bad/incorrect connection Disconnect terminals from
governor controller.
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
Ensure connections to TB1 are
properly connected and no wires
are loose.
Ensure connectors CM1, CM2,
CM3, and CM4 are properly
connected and no wires are loose.
No power to governor Energize system (WP 0005).
controller.
Set DMM to read VDC.
Measure across pins 1 and 2 of
governor controller for 12-15 VDC.
If voltage not present troubleshoot
power source.
No speed signal to governor With the engine running, check for
the following:
FROM TO DMM
(pin #) (pin #) Reading
2 3 5-30 VDC
2 4 5-30 VDC
If governor does not meet
requirements, replace as described
in (WP 0081).
Governor not tuned or Perform adjustments for:
adjusted for engine/ • Gain (P2)
application • Integral Adjust (P3)
• Speed (Freq.) (P4)
• Derivative (P6)
as described in (WP 0118).
Governor will not adjust. If governor will not adjust, replace
as described in (WP 0081).
0028-23
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
38 Battery charger (BC) suspect bad Bad/incorrect connection Disconnect terminals from speed
sensor.
Inspect terminal lugs for good
connection or corrosion.
Clean/replace terminal.
No 120 VAC to battery Energize system (WP 0005).
charger
Set DMM to read VAC. Measure
across pins L and N of battery
charger for 120 VAC.
If 120 VAC not present, check in-
line fuse to battery charger. If fuse
bad replace, if fuse is good,
troubleshoot power source.
No DC voltage from battery Set DMM to read VDC. Measure
charger across pins + and - of battery
charger for 24 VDC.
If 24 VDC battery charger bad,
replace (WP 0083).
39 Voltage regulator or generator Generator physical damage. Remove generator covers and
suspect bad perform visual inspection: burnt
windings, loose connections,
broken wires, frayed insulation,
cracked brackets, missing
hardware, etc.
Check for foreign objects which
may have been drawn into the
generator. Verify that the
generator’s air gaps (main rotor
and exciter) are free from
obstructions.
Generator insulation Inspect generator for heavy buildup
breakdown. of contamination (dirt, oil, moisture
etc.) on the windings. Clean and
dry windings.
Voltage regulator faulty. Perform the following test to isolate
failure to voltage regulator or
generator.
0028-24
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
39 Voltage regulator or generator
(cont.) suspect bad.
CAUTION
To ensure that the voltage regulator is not damaged by applied battery
voltage, in step 2 below, disconnect the field wires at the generator
junction box and isolate them from contact with any moving or electrical
conducting surface.
1. Shutdown the Genset (WP 0005).
2. Remove generator junction box cover. Disconnect red F (+) and black F (-) generator field wires
at the spade lug connectors. Isolate voltage regulator side of field terminal wires to ensure
contact cannot occur with any electrical conducting or rotating surfaces.
3. Connect the multimeter terminals across two generator phase legs (L1 to L2, L1 to L3, or L2 to
L3) for line-to-line voltage measurement in step 6 below.
NOTE
In step 4, use only one 12 Volt battery from the 24 Volt series connected
battery. Refer to figure 1 for hookup. The voltage regulator feedback
circuit will be replaced by a constant battery voltage applied to the
generator field terminals.
4. Use hookup wire to run jumper connections from the genset battery positive (+) to the red F (+)
field wire and negative (-) to the black F (-) generator field wire at the junction box.
5. Start up the genset (WP 0005). Leave CB5 in the OFF position to ensure no load is applied to
the generator.
6. Use the multimeter to verify the three line-to-line voltage outputs are within (175 to 240 VAC).
7. If the voltage outputs are correct, replace the voltage regulator. If any voltage measurement
fails, replace the generator.
0028-25
TM 11-6115-742-13&P 0028
Table 1. Maintainer Troubleshooting – Genset (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
AUTOMATIC
VOLTAGE REGULATOR RED JUMPER WIRE
(BARRIER PANEL)
* NOTE: ISOLATE REGULATOR LEADS * BLACK JUMPER WIRE
FROM SURFACE CONTACT
_ +
12 V 12 V
_
+
RED BLACK 24 VDC BATTERY
T1 T3
F (+) F (-)
T4 T6
T7 T9 L0
T10 L3
T12 GENSET
POWER
T11 T5 L2 DISTRIBUTION
SYSTEM
L1
CB5
T8 T2 GENERATOR
JUNCTION BOX
GENERATOR OUTPUT STAGE
_
MULTIMETER
+
Figure 1. 12V Constant Voltage Test Hookup.
END OF WORK PACKAGE
0028-26
TM 11-6115-742-13&P 0029
MAINTAINER TROUBLESHOOTING PROCEDURES
TMSS-MED
GENSET (ENGINE)
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit WP 0040 through WP 0065,
(WP 0162, Item 1) WP 0068 through WP 0070,
Multimeter (WP 0162, Item 2) WP 0072, WP 0080, WP 0081,
WP 0083 through WP 0086
Personnel Required
Two
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by maintainer-level
qualified personnel. This work package provides a systematic approach to locating and correcting malfunctions of
the TMSS-MED. Each section is arranged according to the condition/indication of a problem. The corrective
action items have been arranged in order of complexity, with simpler actions listed first. The manual cannot
identity all malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be
corrected by the corrective actions provided, contact your supervisor.
WARNING
Special caution must be taken during troubleshooting since protective covers and
safety devices may be removed or disabled to gain access and make tests.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand brakes are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0029-1
TM 11-6115-742-13&P 0029
Table 1. Maintainer Troubleshooting – Genset (Engine).
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
1 Coolant leaking Over flow bottle leaking Inspect bottle/coolant hoses for
damage/leaks. Replace hoses,
bottle (WP 0059) and replenish
coolant (WP 0058) as
necessary.
Coolant hoses leaking Inspect radiator and coolant
hoses for damage or loose
clamps. Replace if necessary
(WP 0059).
Inspect coolant lines/hoses of
battery warmer and engine
heater (hydronic) for damage or
loose clamps. If clamps are
loose, tighten. If damage is
present or leaks persist, contact
next level of maintenance.
If replacing coolant hose does
not correct the leak replace the
higher level assembly.
Battery warming tray Inspect battery warming tray
and fittings for leaks. Tighten
fittings or replace battery
warming tray (WP 0041).
Engine coolant temperature Inspect sensor for leaking. If
sensing leaking leaking around sensor, remove
sensor, apply sealant to threads
and install sensor (WP 0055).
Engine thermostatic switch Inspect switch for leaking. If
leaking leaking around switch, remove
switch, apply sealant to threads
and install switch (WP 0056).
Radiator leaking Inspect radiator for damage/
leaks. If damage or leaks are
found, replace radiator
(WP 0059).
Thermostat housing leaking Inspect thermostat housing and
seal for leaks. If leaks are
found, remove housing, replace
thermostat seal and install
housing (WP 0057).
0029-2
TM 11-6115-742-13&P 0029
Table 1. Maintainer Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
1 Coolant leaking Water pump leaking Inspect water pump and seal for
(cont.) leaks. If water pump is leaking,
remove water pump, install new
seal, remount water pump, and
test. If water pump is leaking
from front bearing housing or
drain port, replace water pump
and seal (WP 0063).
Coolant drain valve will not Inspect coolant drain for
lock/leaking leaking/functionality. If drain
valve is not functioning or is
leaking, contact next level
maintenance.
Replace radiator (WP 0059).
Engine heater (hydronic) has Inspect engine heater
internal leak (hydronic). If any leaks are
found from the pump or the
body of the heater, replace
engine heater (hydronic)
(WP 0064).
Engine head gasket leaking Contact next level of
maintenance.
2 Fuel leaking Fuel filter leaking Inspect filter for signs of leaking.
If leaks are found, replace filter
(WP 0044).
Fuel lines leaking Inspect fuel lines for leaking,
damage, or loose clamps. If
clamps are loose, tighten.
If damage is present or leaks
persist, replace fuel lines
(WP 0084).
Fuel tank leaking Drain all fuel (WP 0045).
Operate generator on alternate
fuel source.
Replace fuel tank (WP 0085).
Fuel tank drain valve will not Inspect fuel drain valve for
lock/leaking damage or signs of leaking. If
any leaking is found, drain all
fuel, operate generator on
alternate fuel source.
Replace fuel tank (WP 0085).
0029-3
TM 11-6115-742-13&P 0029
Table 1. Maintainer Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
2 Fuel leaking Fuel selector switch leaking Inspect fuel selector switch for
(cont.) leaking, damaged, or loose
clamps. If clamps are loose,
tighten.
If damage is found or leaks
persist, replace fuel selector
switch (WP 0084).
Fuel injectors/injector pumps Inspect for loose or damaged
leaking fittings or leaks.
Replace leaking fuel injector/
injector pump (WP 0048).
Fuel pump leaking Inspect fuel pump for leaks.
Replace fuel pump (WP 0047).
3 Oil leaking Oil filter leaking Inspect filter for signs of leaking.
If leaks are found, replace filter
(WP 0042).
Oil pressure sending unit leaking Inspect sending unit for leaking
around mounting hardware. If
leaks are present, remove
sending unit and hardware, coat
threads with sealant and install
(WP 0051).
Oil pressure switch leaking Inspect switch for leaking
around mounting hardware. If
leaks are present, remove
switch and hardware, coat
thread with sealant and install
(WP 0050).
Oil drain valve will not Inspect oil drain valve for
lock/leaking leaking or damage.
If any leaks or damage found,
replace drain valve (WP 0042).
Oil drain lines leaking Inspect oil drain lines for
leaking, damage, or loose
clamps. If clamps loose,
tighten.
If damage is found or leaks
persist, replace damaged oil
drain line (WP 0042).
0029-4
TM 11-6115-742-13&P 0029
Table 1. Maintainer Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
3 Oil leaking Valve cover/oil pan leaking Inspect valve cover and oil pan
(cont.) for loose bolts. Inspect seals.
If seals are damaged, replace
engine (WP 0086).
Main engine seals leaking Inspect front and rear of engine
for signs of leaking. Oil leaking
from generator indicates a bad
rear main seal.
If leaks are found, replace
engine (WP 0086).
4 Battery acid leaking Battery Replace battery (WP 0041).
5 Engine does not crank Fuse blown Set BATTERY SWITCH to ON.
Set ENGINE switch to RUN.
Open Genset control panel
(WP 0040) and observe fuse
LEDs. If LED is illuminated,
fuse is bad, replace (WP 0040).
Fuse repeatedly blows Set ENGINE switch to OFF.
Set BATTERY SWITCH to OFF.
Use continuity measurements
on faulty fuse line to isolated
component failure.
If short to ground, remove
components one at a time until
ground short is located.
If not short to ground, replace
faulty fuse and repeat continuity
measurement for adjacent
power line shorts.
If fault not isolated, perform
continuity measurements on
ENGINE switch and BATTERY
SWITCH.
0029-5
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
5 Engines does not crank Low/bad battery Set BATTERY SWITCH to OFF.
(cont.)
Using DMM, measure across
battery terminals.
If DMM reads:
0 VDC – Replace battery fuse
(WP 0041).
< 18 VDC - Replace batteries
(WP 0041).
18 to 24 VDC – Recharge
batteries (WP 0023).
> 28 VDC - Replace batteries
(WP 0041).
If battery was not replaced,
replace battery (WP 0041).
Set BATTERY SWITCH to ON.
Remove NATO/Slave cable
from J6 if connected.
Remove external charging cable
from J5 if connected.
Set CB2 and CB5 to OFF.
Crank engine. If engine does
not start continue to next
possible malfunction. If engine
runs, set CB2 and CB5 to ON,
verify battery charge meter
reads 0 or more amps. If less
than 0 amps, proceed to
step 16.
Connections Check electrical connections for
damaged wires, loose
connections, or corrosion. If
necessary, tighten, clean, or re-
connect.
Starter system (Starter solenoid Using DMM, measure voltage at
(K2) located on front of engine, terminal (1) on K2 solenoid for
top solenoid) 24 to 28 VDC (see Figure 1). If
24 to 28 VDC not present,
check connections from starter
to K2 solenoid.
0029-6
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
5 Engines does not crank Starter system (Starter solenoid Using DMM, check for continuity
(cont.) (K2) located on front of engine, between terminal (2) on K2
top solenoid) solenoid and engine ground
(see Figure 1). If no or
restricted continuity, check
wiring between solenoid and
ground for connections.
Hold ENGINE switch to START.
Using a DMM, measure voltage
at terminal (3) on K2 solenoid
(see Figure 1). If voltage is not
between 24 to 28 VDC, contact
next level of maintenance.
Using a DMM, measure voltage
at terminal (4) on K2 solenoid
(see Figure 1). If voltage is not
between 24 to 28 VDC, replace
solenoid (WP 0052).
If voltage is between 24 to
28VDC, replace starter
(WP 0053).
4 SOLENOID 1 4 SOLENOID 1
(K2 or K3) (K4)
Power out Power In Power In Power out
2 3 2 3
Ground Trigger Ground Trigger
Figure 1. Solenoids.
Verify Engine Selector Switch
(ESS).
Set ENGINE switch to STOP.
Using a DMM, measure battery
voltage (24 to 28 VDC), across
ESS terminal 1 and engine
block ground lug (EBGL).
0029-7
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
5 Engines does not crank Starter system (Starter solenoid If voltage out of tolerance is
(cont.) (K2) located on front of engine, trace voltage back to battery.
top solenoid)
If voltage within tolerance, set
ENGINE switch to START. Use
DMM to measure between 24 to
28 VDC across ESS terminal 4
and engine block ground lug
(EBGL).
If voltage out of tolerance,
replace switch (WP 0070).
If voltage within tolerance, set
ENGINE switch to STOP, and
trace continuity from switch
terminal 4 to starter solenoid
trigger terminal K2S-3.
Table 2. Engine Selector Switch Function.
Terminal Function
1 Battery (+), battle short switch
2 Alternator trigger
3 No connection
4 Starter solenoid K2 trigger
5 No connection
6 Volts DC, coolant temp, and oil pressure meter
7 No connection
8 Fuel pump, governor controller, HTS, LOPS, K7, K4
9 Fault lights
10 No connection
11 Battery charger
12 Glow plug solenoid K3S-3 trigger.
6 Engine turns over slowly Low/bad batteries Set BATTERY SWITCH to OFF.
Attach generator NATO slave
receptacle to vehicle or trailer
and attempt to start.
0029-8
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
6 Engine turns over slowly Low/bad batteries If engine turns over normally,
(cont.) test batteries by measuring
across battery terminals using
DMM.
If measurement is:
< 24 VDC – Recharge
batteries (WP 0023).
24 to 28 VDC - Replace
batteries (WP 0041).
If engine does not turn over
normally, check slave vehicle for
proper voltage and connections.
If engine still does not turn over
normally, replace starter
(WP 0053).
Contact next level of
maintenance.
7 Engine cranks but does not start EMERGENCY STOP button Verify that EMERGENCY STOP
button is not pushed in by
twisting clockwise 1/8 turn.
Fuse blown Set BATTERY SWITCH to ON.
Set ENGINE switch to RUN.
Open Genset control panel
(WP 0040) and observe fuse
LEDs. If LED is illuminated, fuse
is bad, replace (WP 0040).
Connections Check electrical connections for
damaged wires, loose
connections, corrosion on
connectors. If necessary tighten,
clean, or reconnect.
Interrupted fuel flow Inspect fuel lines for damage or
leaks. Tighten lines if
necessary, and restart system
(WP 0005).
Inspect fuel filter for debris or
contamination. If necessary,
replace filter, replace fuel in fuel
tank, and restart engine.
0029-9
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
7 Engine cranks but does not start Interrupted fuel flow Check fuel pump operation as
(cont.) follows:
1. Turn ENGINE switch to RUN.
2. Listen & feel for fuel pump
operation.
3. If not operating, remove
electrical connection.
4. Turn ENGINE switch to RUN.
5. Using a DMM, measure for
24 to 28 VDC at terminals. If
voltage is not present,
contact next level of
maintenance.
6. If voltage is present,
reconnect terminals to fuel
pump and loosen fuel return
line.
7. Turn ENGINE switch to RUN
and observe fuel flow out of
fuel line. If no fuel flow,
replace fuel pump
(WP 0047).
NOTE
If pump operates but ambient
temperature is below 0°F (-
17.77 °C) proceed to fuel line
icing troubleshooting (see
below).
8. If no operation is detected,
use a DMM to measure
ground continuity to fuel
pump.
9. If no operation is detected
and fuel pump ground is
good, use DMM to measure
between 24 to 28 VDC from
wire #29 to EBGL.
10. If voltage within tolerance,
replace fuel pump
(WP 0047).
0029-10
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
7 Engine cranks but does not start Interrupted fuel flow 11. If voltage out of tolerance,
(cont.) proceed to electrical control
malfunction (see below).
Check fuel line connections as
follows:
1. Remove fuel return line from
fuel injector rail. Set ENGINE
switch to RUN. Observe fuel
discharge.
2. If fuel observed, check for
clogged fuel injectors. If
injectors clean, check
governor and engine actuator
operation (see below).
3. If no fuel is observed,
disconnect fuel line from fuel
injector pump rail. Observe
fuel discharge.
Frozen fuel line If fuel is observed, clear
obstruction from injector pump
rail.
If no fuel present, check for
frozen or clogged fuel line.
Inspect fuel filter for frozen/jelled
fuel. Replace filter if frozen.
Set FUEL LINE HEATER
switch to ON.
Use DMM to measure between
24 to 28 VDC across the fuel line
heater terminals.
If within tolerance, set ENGINE
HEATER switch to ON and thaw
frozen fuel lines. Restart engine
when engine block warm.
Use DMM to verify ground
continuity at heater solenoid
ground K4S-2.
0029-11
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
7 Engine cranks but does not start Frozen fuel line Use DMM to measure between
(cont.) 24 to 28 VDC across trigger
(K4S-3) and EBGL terminal
(K4S-2). If out of tolerance,
replace solenoid K4 (WP 0052)
or heater switch SW8
(WP 0070).
If within tolerance, use DMM to
measure between 24 to 28 VDC
across power –in (K4S-1) and
EBGL terminal (K4S-2).
If within tolerance, replace
solenoid K4 (WP 0052) or fuel
line heater (WP 0084).
If out of tolerance, replace
solenoid K4, fuel line heater, or
heater circuit breaker CB
(WP 0052).
Glow plug solenoid bad Turn BATTERY SWITCH to
(Glow plug solenoid (K3) ON.
located near starter)
Using DMM, measure input
terminal (1) on K3 solenoid for
24 to 28 VDC (see Figure 1). If
24 to 28 VDC not present, check
electrical connections. If
necessary tighten, clean, or re-
connect.
Using DMM, check ground
connection terminal (2) on K3
solenoid for continuity to
engine ground (see Figure 1).
If continuity is not present,
check electrical connections. If
necessary tighten, clean, or
reconnect.
Hold ENGINE switch to
PREHEAT.
Using DMM, measure trigger
terminal (3) on K3 solenoid for
24 to 28 VDC (see Figure 1).
0029-12
TM 11-6115-742-13&P 0029
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
7 Engine cranks but does not start Glow plug solenoid bad If voltage is not present, check
(cont.) (Glow plug solenoid (K3) electrical connections from start
located near starter) switch. Contact next level of
maintenance.
Check terminal (4) on K3
solenoid for 24 to 28 VDC (see
Figure 1). If no voltage present,
replace solenoid.
Test for 24 to 28 VDC at glow
plug connector strip. If no
voltage is present, contact next
level maintenance.
Turn BATTERY SWITCH to
OFF.
Check electrical connections to
connecting strip and glow plugs
for damaged wire, loose
connections, and corrosion on
connectors. If necessary tighten,
clean, or re-connect.
Disconnect connector strip.
Remove individual glow
plug(s). Using DMM, test glow
plug resistance. If resistance
is not between 3Ω and 4Ω,
replace glow plugs (WP 0049).
Use DMM to verify ground
continuity to glow plug solenoid
terminal K3S-2.
Hold ENGINE switch to
PREHEAT.
Using DMM, measure between
24 to 28 VDC across trigger
(K3S-3) and EBGL terminal
(K3S-2).
If voltage not within tolerance,
check for voltage across ESS
switch terminal 12 and EBGL. .
Isolate fault to switch or
solenoid.
0029-13
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
7 Engine cranks but does not start Diesel speed sensor Disconnect terminals of diesel
(cont.) malfunction speed sensor.
Loosen lock-nut on diesel speed
sensor, and remove diesel
speed sensor (WP 0054).
Inspect diesel speed sensor port
and verify that flywheel tooth is
centered in speed sensor port
(Figure 2).
Flywheel
Gear Center
Figure 2. Flywheel Location in Speed Sensor Port
Insert diesel speed sensor and
gently tighten by hand until
diesel speed sensor makes
contact with fly wheel (resistance
is felt) then back off 1/8 to 1/4
turn and tighten lock nut.
Turn BATTERY SWITCH to ON.
Crank engine, test for 2.5 VAC
to 5.0 VAC at terminals. If no
voltage, replace diesel speed
sensor (WP 0054).
If less that 2.5 VAC:
Hold diesel speed sensor to
prevent movement and loosen
lock nut.
Turn diesel speed sensor
Counter-Clock wise 1/16 to 1/8
turn and tighten lock-nut.
Crank engine, test for 2.5 VAC
to 5.0 VAC at terminals.
Contact next level of
maintenance.
0029-14
TM 11-6115-742-13&P 0029
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
7 Engine cranks but does not start Governor, engine actuator, or If voltage at solenoid trigger
(cont.) speed sensor K3S-3 is within tolerance isolate
to solenoid or glow plug.
Replace faulty component.
Check engine actuator for
loose or missing connections.
If no physical damage evident
verify governor linkage can
move freely by hand.
Hold ENGINE switch to
START.
Use hand to move linkage, so
as to control speed manually.
Perform governor control
adjustment (WP 0081).
If governor cannot be adjusted,
set ENGINE switch to OFF.
Use a DMM to verify continuity
between EMERGENCY STOP
switch and governor control
terminal 5. If no continuity, with
stop released. Replace switch
(WP 0072).
Set ENGINE switch to RUN.
Use a DMM to measure for 24
to 28 VDC between governor
control terminals 1 and 2.
If not within tolerance proceed
to electrical control malfunction
(see below).
If within tolerance, start engine
by controlling linkage manually.
Use a DMM to measure greater
than 2.0 VDC across governor
controller speed sensor terminal
3 and ground terminal 2.
If voltage greater than 2.0 VDC
isolate to actuator or governor
controller. Replace faulty
component.
0029-15
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
7 Engine cranks but does not start Electrical control malfunction If voltage not within tolerance
(cont.) isolate to speed sensor or
governor controller. Replace
faulty component.
Set ENGINE switch to RUN.
Activate BATTLE SHORT switch to
bypass fault system relays,
(Figure 1).
Use a DMM to measure for 24 to
28 VDC between governor control
terminals 1 and 2.
If within tolerance, isolate to stuck
open relay (K4, K5, K6) or switch
(ESS).
If not within tolerance, use
process of elimination to isolate
node to shorted governor
controller, fuel pump, or relay.
Battle
Short
Governor
Controller
Engine Fault System Relays
Select
Switch
K4 K5 K6
Fuel
Pump
+ Hour
24 VDC Meter
Battery K7
Figure 3. Genset Fault System.
8 Engine stops (no warning lights) EMERGENCY STOP button Reset EMERGENCY STOP switch
engaged by twisting clockwise 1/8 turn.
Fuse blown Set BATTERY SWITCH to ON.
Set ENGINE switch to RUN.
0029-16
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
8 Engine stops (no warning lights) Fuse blown Open Genset control panel and
(cont.) observe fuse LEDs. If LED is
illuminated, fuse is bad, replace
(WP 0040).
Interrupted fuel flow Inspect fuel lines for damage or
leaks.
Inspect fuel filter for debris or
contamination. If necessary,
replace filter (WP 0044), replace
fuel in fuel tank, and restart engine.
Check fuel pump operation as
follows:
1. Turn ENGINE switch to RUN.
2. Listen & feel for fuel pump
operation.
3. If not operating, remove
electrical connection.
4. Turn ENGINE switch to RUN.
5. Using a DMM, measure for 24
to 28 VDC at terminals. If
voltage is not present, contact
next level of maintenance.
6. If voltage is present, reconnect
terminals to fuel pump and
loosen fuel return line.
7. Turn ENGINE switch to RUN
and observe fuel flow out of fuel
line. If no fuel flow, replace fuel
pump (WP 0047).
Proceed to trouble shoot
interrupted fuel flow malfunction,
(Item 7) above.
Connections (on diesel speed Check electrical connections for
sensor or actuator) damaged wires, loose connections,
corrosion on connectors. If
necessary tighten, clean, or re-
connect.
0029-17
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
8 Engine stops (no warning lights) Diesel speed sensor Disconnect terminals of diesel
(cont.) malfunctioning speed sensor.
Loosen lock-nut on diesel speed
sensor, and remove diesel speed
sensor (WP 0054).
Inspect diesel speed sensor port
and verify that flywheel tooth is
centered in speed sensor port
(Figure 2).
Crank engine, test for 2.5 VAC to
5.0 VAC at terminals. If no
voltage, replace diesel speed
sensor (WP 0054).
If less that 2.5 VAC:
Hold diesel speed sensor to
prevent movement and loosen
lock nut.
Turn diesel speed sensor
Counter-Clock wise 1/16 to 1/8
turn and tighten lock-nut.
Crank engine, test for 2.5 VAC to
5.0 VAC at terminals.
Proceed to trouble shoot governor,
engine actuator, or speed sensor
malfunction, (Item 7) above.
9 Engine stops (HIGH COOLANT Engine overheating Check engine temperature gauge.
TEMP light on) If gauge reads above 220˚F,
coolant system problem is
indicated. If temperature gauge
reads below 220˚F, replace engine
coolant temperature sensor
(WP 0056).
Allow engine to cool.
Check engine oil for signs of water
contamination. If any
contamination is found, discontinue
use of engine and contact next
level of maintenance.
Inspect coolant level. If level is
low, replenish fluid.
0029-18
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
9 Engine stops (HIGH COOLANT Inspect coolant system for signs of
(cont.) TEMP light on) leaking. If any leaks found,
conduct coolant leaking
troubleshooting procedures.
Inspect radiator for signs of
leaking. If any leaks found,
replace radiator (WP 0059).
Inspect radiator cooling fins for
damage or blocked with debris. If
fins are crushed, use a comb to
straighten them. If dirty, allow to
cool then clean with low pressure
water.
Inspect engine cooling fan and
belt for damage. If damaged,
replace (WP 0062 and
WP 0061).
Check if re-circulated exhaust
gas or engine air is occurring by
clearing obstructions from
louvers and repositioning trailer
for better circulation.
Check for clogged air inlet or
exhaust outlet. Clear debris if
blocked.
Verify generator A-C Kilowatts
meter doesn’t exceed 18 kW.
Decrease generator load if
overloaded.
Verify generator load is
balanced for all three phase
legs.
If unbalanced, turn off all
peripheral equipment and
restart generator. Monitor each
phase leg on A-C Amperes
meter as equipment is turned
on. Isolate failure to load or
genset.
0029-19
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
9 Engine stops (HIGH COOLANT If engine oil is contaminated with
(cont.) TEMP light on) coolant or other internal mechanical
engine component failure is evident
from Service troubleshooting
replace engine (WP 0086).
Remove cover from generator and
disconnect generator from engine
(WP 0086). Rotate generator
manually to ensure free rotation.
Replace generator if damage
evident (bearings binding, shaft
bent).
Engine thermostatic switch NOTE
Before replacing thermostat or
water pump, ensure thermostatic
switch is operating properly.
If no signs of leaking are apparent,
replace thermostat (WP 0057).
Restart engine. If engine overheats
again, replace water pump
(WP 0063).
If condition persists, contact next
level of maintenance.
Allow engine to cool.
Disconnect wiring from thermostatic
switch and tape ends so they touch.
Test for continuity across switch
terminals. If switch is open, replace
switch (WP 0056).
Start engine.
If HIGH COOLANT TEMP light
illuminates and system shuts down,
contact next level of maintenance.
Continue to test for continuity across
switch. If switch opens prior to
engine reaching normal operating
temperature, replace switch
(WP 0056).
0029-20
TM 11-6115-742-13&P 0029
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
9 Engine stops (HIGH COOLANT Engine thermostatic switch Engine must be cool before
(cont.) TEMP light on) proceeding.
Set ENGINE switch to OFF.
Bypass thermostatic switch as in
Service Troubleshooting.
Swap overheat relay K4 with over
speed relay K5.
Start engine, if engine shuts down
for over speed fault replace relay. If
engine still shuts down for overheat
fault, replace governor control relay
K7 or time delay relay TDM.
10 Engine stops (LOW OIL Engine oil pressure low Check engine oil level. Add oil, if
PRESSURE light on) necessary (WP 0022).
If any leaks found, conduct oil
leaking troubleshooting procedures.
Start engine and monitor oil
pressure. If oil pressure does not
rise, LOW OIL PRESSURE light
illuminates, and engine shuts down,
notify next level of maintenance.
If oil pressure raises above 20 psi,
and engine shuts down,
troubleshoot oil pressure switch.
NOTE
Operating an engine with low oil
pressure can lead to serious
damage. If the oil sending unit is
functioning properly and the
troubleshooting procedure below
does not correct the failure
replace the engine.
Set ENGINE switch to OFF.
Bypass low oil pressure switch as in
Service Troubleshooting, Oil
Pressure Switch.
Swap low oil pressure relay K6 with
over speed relay K5.
0029-21
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
10 Engine stops (LOW OIL Engine oil pressure low Start engine, if engine shuts down
(cont.) PRESSURE light on) for over speed fault replace relay.
If engine still shuts down for low oil
pressure fault, replace governor
control relay K7 or time delay relay
TDM.
Oil pressure switch Disconnect wiring from pressure
switch and tape off so wires cannot
touch
Test switch terminal for continuity.
If switch is closed, replace switch
(WP 0050).
Start engine. If switch closes once
the pressure reads above 20 psi
and remains closed, the switch is
good.
If the switch opens after the engine
has achieved 20 psi, or does not
close at all, replace switch
(WP 0050).
Low Oil pressure cut-off Disconnect wiring from low oil
switch pressure switch and tape off so
wires cannot touch.
Test switch terminals for continuity.
If switch is closed, replace switch
(WP 0046).
Start engine. If pressure reads
below 20 psi and switch opens, the
switch is good.
If switches test good, notify next
level of maintenance.
11 Engine stops (OVERSPEED light Contaminated fuel/fuel filter Remove fuel filter, inspect fuel for
on) signs of MOGAS. If any MOGAS
contamination is suspected,
replace the fuel filter, drain, and
refill fuel tank with clean fuel
(WP 0044).
If condition continues, contact next
level of maintenance.
0029-22
TM 11-6115-742-13&P 0029
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
11 Engine stops (OVERSPEED light Speed switch or over speed Start engine and monitor HERTZ
(cont.) on) relay meter. Overspeed frequency
switch is set to trip at 64 Hz. If
engine shutdown occurs at 64 Hz
perform governor adjustment
(WP 0081).
Set ENGINE switch to OFF.
Swap over speed relay K5 with
high temperature relay K4.
Start engine, if engine shuts down
for high temperature fault replace
relay.
Set ENGINE switch to OFF then
RUN to clear faults.
Verify inputs to speed switch. Use
DMM to measure between 24 to 28
VDC across switch terminal 1
(power) and terminal 2 (ground).
Use DMM to measure ground
continuity from EBGL to terminal 2
(ground). Measure an open
between terminals 11 and 12.
Replace speed switch (WP 0080).
12 Engine emits white smoke from Contaminated fuel/fuel filter Remove fuel filter, check for dirt,
exhaust obstructions, or contaminated fuel.
Replace filter (WP 0044) and/or
fuel.
Check fuel quality, replace fuel if
inferior quality.
Check engine oil for proper level.
If level is overfull, drain off excess
oil and restart engine.
Replace engine (WP 0086).
13 Engine emits blue smoke from Engine oil level over full Check engine oil for proper level.
exhaust If level is overfull, drain off excess
oil and restart engine.
If engine oil level is correct, or blue
smoke persists, check for coolant
in oil.
Replace engine (WP 0086).
0029-23
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
14 Engine emits heavy black smoke Clogged air filter Remove air filter, inspect for
from exhaust excessive dirt or moisture. If
unserviceable, replace air filter
(WP 0043).
Remove fuel filter, check for dirt,
obstructions, or contaminated
fuel. Replace filter, and/or fuel
(WP 0044).
Contact next level of
maintenance.
Fuel injection system defective Check fuel injectors for dirt and
clogging (WP 0048). Clean or
replace fuel injectors, if problem
not corrected replace engine
(WP 0086).
15 Excessive carbon deposits on Blocked or obstructed Remove muffler exhaust pipe
exhaust outlet muffler/exhaust pipe and check for dirt or other
obstructions. Clean or replace
muffler (WP 0065).
Exhaust pipe damaged or Remove exhaust pipe and
excessively corroded inspect. If damaged or
excessively corroded, replace
(WP 0065).
Contaminated fuel/fuel filter Remove fuel filter, check for dirt,
obstructions, or contaminated
fuel. Replace filter, and/or fuel
(WP 0044).
Adjust governor controller
(WP 0081). If adjustment
doesn’t correct the problem
replace engine (WP 0086).
Contact next level of
maintenance.
16 Engine temperature remains Fuse blown Set BATTERY SWITCH to ON.
below 120°F (48.88°C)
Set ENGINE switch to RUN.
Open Genset control panel and
observe fuse LEDs. If LED is
illuminated, fuse is bad, replace
(WP 0040).
0029-24
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
16 Engine temperature remains Coolant temperature sensor Replace coolant temperature
(cont.) below 120°F (48.88°C) inoperable sensor (WP 0055).
Thermostat stuck open Replace thermostat (WP 0057)
and monitor COOLANT TEMP
gauge on control panel.
COOLANT TEMP gauge Replace COOLANT TEMP
inoperative gauge (WP 0069).
17 AC KILOWATTS meter reads 0 Fuse blown Set BATTERY SWITCH to ON.
with Genset under load
Set ENGINE switch to RUN.
AC KILOWATTS meter bad or Open Genset control panel and
out of calibration. observe fuse LEDs. If LED is
illuminated, fuse is bad, replace
(WP 0040).
Replace AC KILOWATTS meter
(WP 0068).
18 DC VOLT meter reads below 28 Fuse blown Set BATTERY SWITCH to ON.
VDC while Genset is running
Set ENGINE switch to RUN.
Open Genset control panel and
observe fuse LEDs. If LED is
illuminated, fuse is bad, replace
(WP 0040).
Fan belt out of adjustment Perform fan belt adjustment or if
excessively worn or damaged necessary, replace (WP 0061).
Alternator output out of Set BATTERY SWITCH to ON.
tolerance Start engine. Verify alternator is
operational.
Using DMM, measure output
terminal lug mounted on the
alternator. If alternator output is
below 27 VDC or above 32 VDC,
replace alternator (WP 0060).
Verify battery charger is
operational.
Shut down engine and set CB2
to OFF.
0029-25
TM 11-6115-742-13&P 0029
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
18 DC VOLT meter reads below 28 Alternator output out of Use DMM to measure ground
(cont.) VDC while Genset is running tolerance continuity between battery
negative terminal and battery
charger GND terminal.
Connect battery charger cable to
J5 and use an external source to
run the battery charger.
Use DMM to measure 120 VAC
+/- 10% between battery charger
L and N terminals. Replace
battery charger (WP 0083) if out
of tolerance.
Use DMM to measure between
24 and 28 VDC across pins +
and – of battery charger.
Replace battery charger
(WP 0083) if out of tolerance.
If within tolerance, and DC VOLT
meter reads out of tolerance
replace DC VOLT meter
(WP 0068).
If within tolerance verify battery
charger is operational when
generator provides AC power.
Disconnect battery charger cable
from J5.
Start genset and allow it to reach
normal operating condition.
Set BATTERY SWITCH to ON
and disconnect any cable at J6.
Disconnect any load connected
to light/utility connector J2 and
set circuit breaker CB2 to ON.
Use a DMM to measure between
24 to 28 VDC across pins + and
– of battery charger. If within
tolerance switch load removed
from J2 (phase 1) to J3
(phase 2).
If out of tolerance replace battery
charger (WP 0083).
0029-26
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
NOTE
At high ambient temperatures the COOLANT TEMP gauge
temp can read 230° F (110°C) normally.
19 Engine temperature above 220°F Set BATTERY SWITCH to ON.
(104.4°C), engine still running
Set ENGINE switch to RUN.
Fuse blown Open Genset control panel and
observe fuse LEDs. If LED is
illuminated, fuse is bad, replace
(WP 0040).
Faulty component Replace thermostatic switch
(WP 0056). Start engine.
If engine shuts down/overheats,
conduct troubleshooting
procedure for engine shuts down
(HIGH COOLANT TEMP light
on).
20 Engine oil pressure below 20 psi,
engine still running NOTE
At high ambient temperatures the OIL PRESSURE gauge
temp can read 15 psi normally.
If engine does not shut down,
replace temperature sensor
(WP 0055).
Contact next level of
maintenance.
Set BATTERY SWITCH to ON.
Set ENGINE switch to RUN.
Fuse blown Open Genset control panel and
observe fuse LEDs. If LED is
illuminated, fuse is bad, replace
(WP 0040).
Check engine oil level. If
necessary, add oil (WP 0042).
0029-27
TM 11-6115-742-13&P 0029
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
20 Engine oil pressure below 20 psi, Faulty component Start engine and observe OIL
(cont.) engine still running PRESSURE gauge. If oil
pressure does not come up to
proper level
(20 psi), replace pressure switch
(WP 0050).
Start engine and observe OIL
PRESSURE gauge. If oil
pressure does not come up to
proper level
(20 psi),replace oil pressure
sending unit (WP 0051).
Replace oil pressure gauge
(WP 0069).
If oil pressure does not reach
normal operating level replace
engine (WP 0086).
NOTE
The fault code is determined by the number of times the
AUXILIARY HEAT switch flashes (i.e. one flash is F01,
two flashes is F02, etc.).
Internal Safety Cut Off Switch Reset Procedure:
1. Set ENGINE HEATER switch to OFF.
2. Set ENGINE switch to OFF.
3. Set BATTERY SWITCH to OFF.
4. Set BATTERY SWITCH to ON.
5. Set FUEL LINE HEATER switch to ON.
21 Engine heater (hydronic) will not Power or control line Inspect all electrical connections
start (no fault code) interrupted. and wire for damage and
connectivity.
Ensure BATTERY and ENGINE
HEATER switches are set to ON.
Test for 24 to 28 VDC between
heater terminal A-5 (wire # GN)
and terminal F-1 (wire # RD4).
If not within tolerance, ensure
BATTERY and ENGINE
HEATER switches are set to ON.
Use DMM to verify ground
continuity from EBGL to heater
terminals X2-2(wire #409) and
X1-5 (wire # GN).
0029-28
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
21 Engine heater (hydronic) will not Power or control line Test for between 24 to 28 VDC at
(cont.) start (no fault code) interrupted. heater terminal X2-1 (wire #RD4)
and X1-2 (wire #YL). Use wire
#409 as ground reference.
If not within tolerance isolate to
engine heater or ENGINE
HEATER switch SW6. Replace
faulty component.
Contact next level of maintenance.
Fuse blown Remove cover from engine heater
(hydronic) fuse block. Remove
fuses and inspect. Replace if
necessary (WP 0064).
Contact next level of maintenance.
Fuse blown repeatedly Inspect electrical connections for
shorted wires at input terminals.
Replace heater (WP 0064).
22 Engine heater (hydronic) (fault Fuel source interrupted Verify fuel level. Add fuel, if
code F01 or F02) necessary.
Inspect fuel line for damage or
loose connections. If loose, tighten
and restart.
If damaged, replace fuel lines
(WP 0085).
Fuel filter clogged Remove and inspect fuel filter for
debris (WP 0044). If filter is
clogged, replace filter (WP 0044).
Fuel pump inoperable Perform Internal Safety Cut Off
Switch Reset Procedure.
Turn on engine heater (hydronic),
listen for fuel pump operation. If
pump does not operate after 15
seconds.
0029-29
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
22 Engine heater (hydronic) (fault Fuel pump inoperable Disconnect cable at fuel pump, and
(cont.) code F01 or F02) test for 24 to 28 VDC. If voltage is
between 24 and 28 VDC, replace
fuel pump. If no voltage is present,
check fuse, replace if necessary
(WP 0064). If voltage is still not
present, replace engine heater
(hydronic) (WP 0064).
Contact next level of maintenance.
23 Engine heater (hydronic) (fault Battery voltage not within Check battery voltage. If less than
code F03) acceptable limits 24 VDC, recharge batteries
(WP 0023) or attach slave vehicle.
Perform Internal Safety Cut Off
Switch Reset Procedure.
Check battery voltage.
If greater than 32 VDC,
troubleshoot batteries.
If battery voltage is 20 to 30 VDC,
replace engine heater (hydronic)
(WP 0064).
24 Engine heater (hydronic) (fault Replace engine heater (hydronic)
code F04, F05, F06, F08, F09) (WP 0064).
25 Engine heater (hydronic) (fault Fuel pump wiring damaged Repair damaged wiring.
code F07)
Fuel pump inoperable Perform Internal Safety Cut Off
Switch Reset Procedure.
Turn on engine heater (hydronic),
listen for fuel pump operation. If
pump does not operate after 15
seconds, disconnect cable at fuel
pump, and test for 24 to 28 VDC.
If voltage is between 24 and 28
VDC, replace fuel pump
(WP 0064).
Replace heater (WP 0064).
26 Engine heater (hydronic) (fault Flow restriction Inspect coolant line for damage,
code F010) loose connections or restriction
(i.e., clogging, bends, kinks).
0029-30
TM 11-6115-742-13&P 0029
Table 1. Field Troubleshooting – Genset (Engine) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
26 Engine heater (hydronic) (fault Flow restriction If loose, tighten and restart.
(cont.) code F010) If bent or kinked, undo and restart.
If damaged, contact next level of
maintenance.
Inspect coolant line for damage or
restriction (i.e., clogging, bends,
kinks).
If damaged/restricted, replace
coolant line (WP 0064).
Circulation pump bad. Replace engine heater (hydronic)
(WP 0064).
Use DMM to measure between 24
to 28 VDC across heater terminal
X1-1 (wire # BK) and X1-5
(wire # GN).
If within tolerance replace heater
(WP 0064).
If not within tolerance isolate to
heater or heater switch SW6.
Replace faulty component.
0029-31
TM 11-6115-742-13&P 0029
NOTE
When ENGINE HEATER switch (on Genset control panel) flashes, there is a
problem with the Engine heater (Hydronic). The number of flashes indicates a
specific fault code (i.e., one flash is F01, two flashes is F02).
There is a sequence of slow and fast flashes. Count the slow flashes.
Table 3. Engine Heater (Hydronic) Fault Codes.
FAULT
DESCRIPTION POSSIBLE CAUSE
CODE
F01 No Start-up • Fuel Supply
• Restricted Air Flow Through Intake or Exhaust
F02 Flame Extinguished • Fuel Supply
• Restricted Air Flow Through Intake or Exhaust
F03 Under/Over voltage • Vehicle Charging System.
F04 Premature Flame Detection • Heater faulty
F05 Circulating Pump Interruption or Short Circuit • Open or Shorted Wiring
• Defective Pump
F06 Temperature Sensor Interruption or Short • Heater faulty
Circuit
F07 Metering Pump (Fuel pump) Interruption or • Open or Shorted Wiring
Short Circuit
F08 Combustion Fan Motor Interruption, Short • Heater faulty
Circuit or Incorrect fan Speed
F09 Pencil Type Glow Plug/Flame Detector • Heater faulty
Interruption or Short Circuit
F10 Overheating Condition • Coolant Flow Restriction
• Circulation Pump
END WORK PACKAGE
0029-32
TM 11-6115-742-13&P 0030
MAINTAINER TROUBLESHOOTING PROCEDURES
TMSS-MED
ECU (ELECTRICAL)/HYDRONIC HEATER
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit (WP 0165, Item 1) WP 0003, WP 0005, WP 0031,
Multimeter (WP 0165, Item 2) WP 0064, WP 0085, WP 0092,
WP 0095 thru WP 0099,
Personnel Required WP 103 thru 108, WP 0113
Two
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by maintainer-level
qualified personnel. This work package provides a systematic approach to locating and correcting malfunctions of
the TMSS-MED. Each section is arranged according to the condition/indication of a problem. The corrective
action items have been arranged in order of complexity, with simpler actions listed first. The manual cannot
identify all malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be
corrected by the corrective actions provided, contact your supervisor.
WARNING
Special caution must be taken during troubleshooting since protective covers and
safety devices may be removed or disabled to gain access and make tests.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand brakes are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0030-1
TM 11-6115-742-13&P 0030
NOTE
There are two different circuit designs for the ECU control panel. Refer to
(WP 0003) for a brief explanation of the differences.
Refer to (Figures FO-1 and FO-2) for schematic and wiring diagram of Version 1
of the ECU.
Refer to (Figures FO-3 and FO-4) for schematic and wiring diagram of Version 2
of the ECU.
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
1 ECU will not run on GENSET ECU circuit breaker tripped Disconnect power source from
power ECU.
Open ECU control panel.
Inspect circuit breaker(s)
(Figures 1 or 2). If tripped, reset
and test system.
If circuit breaker(s) (Figures 2
or 3) trip again, contact next level
of maintenance.
Power interrupted at source Verify that:
Green POWER light not lit or • Proper connections are made
dim (WP 0005).
• Genset power operational.
• Circuit breaker(s) (Figures 1
or 2) do not need reset.
• Proper voltage present.
Voltage out of phase Operate ECU on shore power to
POWER OUT OF PHASE ensure ECU is operating properly.
light lit
Disconnect power cable from
Genset and reconnect.
High pressure switch out Locate high pressure out switch
inside of ECU (near rear
condenser chamber) and depress
red RESET switch. If high
pressure switch out trips within
30 minutes, contact next level of
maintenance.
Contact next level of maintenance.
0030-2
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
2 ECU will not run on shore power Condenser coil dirty Inspect condenser coil for dirt and
debris. If dirty, clean (WP 0092).
ECU circuit breaker tripped Disconnect power source from
ECU.
Open ECU control panel.
Inspect circuit breaker(s)
(Figures 1 or 2). If tripped, reset
and test system.
If circuit breaker(s) (Figures 1
or 2) trip again, contact next level
of maintenance.
Power out of phase Indicates incorrect wiring
Red POWER OUT OF connection.
PHASE light lit
Turn off shore power.
Disconnect pig tail from power
source.
Change order of connections and
reconnect.
Turn on shore power.
If POWER OUT OF PHASE light is
lit, change order of connections
again.
If problem persists, contact next
level of maintenance.
Internal fault in system Contact next level of maintenance.
3 ECU won’t run in any mode CB keeps tripping Use schematic to identify load
connected to circuit breaker.
Proceed to
CONDITION/INDICATION below
for isolation routine.
Phase Sense Relay (PSR) or Actuate CB1 and CB2.
TX1 bad
0030-3
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
3 ECU won’t run in any mode Phase Sense Relay (PSR) or If CB2 trips, shutdown power at the
(cont.) TX1 bad source and disconnect ECU power
cable at connector J1 of Genset
control panel. Use continuity
measurements to isolate short to
PSR or TX1. Replace PSR
(WP 0106) or TX1 (WP 0107).
If CB1 trips, shutdown power at the
source and disconnect the ECU
power cable at connector J1 of the
Genset control panel. Use process
of elimination to isolate short to
EMSP or HM. Replace EMSP
(WP 0108) or HM (WP 0103).
If POWER OUT-OF-PHASE light lit
replace PSR (WP 0106).
POWER ON LIGHT (POL) Use multimeter to measure
bad between 22 to 26 VAC across
transformer terminals X1 and X2.
If not within tolerance, use process
of elimination to isolate failure to
bridge rectifier BR, transformer
TX1, fuel pump FP, or auxiliary
heater. Replace bridge rectifier BR
(WP 0107), transformer TX1
(WP 0107), fuel pump FP or
auxiliary heater (WP 0094).
Use multimeter to measure
between 22 to 26 VAC across
POL, wire #34B and #33D.
Replace POL (WP 0103) if within
tolerance.
Replace CB1 (WP 0104) if not
within tolerance.
MSS switch, PSR, or Ensure CB1 and CB2 are actuated.
evaporator fan bad
Set MSS switch to FAN.
If evaporator fan does not start,
use multimeter to measure
between 22 to 26 VAC across fan
hot (terminal A1) (wire # 37C) and
fan neutral (terminal A2) (wire #
33G).
0030-4
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
3 ECU won’t run in any mode MSS switch, PSR, or If within tolerance, proceed to Item
(cont.) evaporator fan bad 5 CONDITION/INDICATION to
isolate evaporator fan failure.
Use multimeter to measure
between 22 to 26 VAC across MSS
source (wire # 36A) and fan neutral
(wire #33G). If within tolerance
replace MSS switch (WP 0103).
If not within tolerance replace PSR
(WP 0106).
4 ECU won’t run in cool mode MSS switch Ensure CB1, CB2, and CB3 are
actuated.
Set MSS switch to COOL.
Adjust thermostat to lowest setting.
If evaporator fan is not operating
proceed to Item 5
CONDITION/INDICATION for
isolation routine.
If condenser fan is not operating
proceed to Item 6
CONDITION/INDICATION for
isolation routine.
If compressor is not operating
proceed to Item 7
CONDITION/INDICATION for
isolation routine.
Proceed to (WP 0031) to
troubleshoot ECU cooling function.
5 ECU won’t run in HEAT mode. Thermostat, High Ensure CB1, CB2, and CB3 are
(V1) Temperature Cutout (HTC), actuated.
or MSS bad
Set MSS switch to HEAT.
Adjust thermostat to highest
setting.
If evaporator fan is not operating
proceed to Item 5
CONDITION/INDICATION for
isolation routine.
0030-5
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
5 ECU won’t run in HEAT mode. Thermostat, High Use multimeter to measure
(cont.) (V1) Temperature Cutout (HTC), between 22 to 26 VAC at
or MSS bad thermostat output wire #40 and
neutral terminal board contact
(TB-2).
If within tolerance proceed to
troubleshoot heater coil/contactor
below.
Use multimeter to measure
between 22 to 26 VAC at terminal
board contact TB-4 and neutral
terminal board contact (TB-2).
If within tolerance, replace
thermostat and sensor (WP 0103).
If not within tolerance, use
multimeter to measure between 22
to 26 VAC at terminal board
contact TB-3 and neutral terminal
board contact (TB-2).
If within tolerance, replace HTC
switch (WP 0095).
If not within tolerance replace MSS
switch (WP 0103).
Heater coil/contactor bad Use multimeter to measure 190 to
230 VAC at terminals T1 to T2 and
T3 to T2 on contactor CHT.
If both measurements are within
tolerance, refer problem to next
level of maintenance.
If either measurement is out of
tolerance, replace CHT (WP 0105).
Contact next level of maintenance.
6 ECU won’t run in HEAT HIGH (or Thermostat, High Ensure CB1, CB2, CB4, and CB5
HEAT LOW) mode (V2) Temperature Cutout (HTC), are actuated.
or MSS bad
Set MSS switch to HEAT HIGH (or
HEAT LOW).
Adjust thermostat to highest
setting.
0030-6
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
6 ECU won’t run in HEAT HIGH (or Thermostat, High If evaporator fan is not operating
(cont.) HEAT LOW) mode (V2) Temperature Cutout (HTC), proceed to Item 5
or MSS bad CONDITION/INDICATION for
isolation routine.
Use multimeter to measure
between 22 to 26 VAC across
thermostat output (wire #40A) and
terminal board contact TB-2.
If within tolerance proceed to
troubleshoot heater coil/contactor
below.
Use multimeter to measure
between 22 to 26 VAC across
terminal contacts TB-4 and TB-2.
If within tolerance, replace
thermostat and sensor (WP 0103).
If not within tolerance, use
multimeter to measure between 22
to 26 VAC across terminal contacts
TB-3 and TB-2.
If within tolerance, replace HTC
switch (WP 0095).
If not within tolerance replace MSS
switch (WP 0104).
HIGH HEAT heater For HEAT HIGH mode, use
coil/contactor bad multimeter to measure between
190 to 230 VAC at terminals T1 to
T2 and T3 to T2 on contactor CHT
HIGH.
If both measurements are within
tolerance refer to next level of
maintenance.
If either measurement is out of
tolerance, replace CHT HIGH
(WP 0105).
Contact next level of maintenance.
0030-7
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
6 ECU won’t run in HEAT HIGH (or LOW HEAT heater For LOW HEAT mode, use
(cont.) HEAT LOW) mode (V2) coil/contactor bad multimeter to measure 190 to 230
VAC at terminals T1 to T2 and T3
to T2 on contactor CHT LOW.
If both measurements are within
tolerance refer to next level of
maintenance.
If either measurement is out of
tolerance, replace CHT LOW
(WP 0105).
Contact next level of maintenance.
7 Evaporator fan does not operate Damaged/loose fan belt Inspect evaporator fan belt.
If too loose/tight adjust.
If damaged, replace (WP 0098).
ECU circuit breaker tripped Disconnect power source from
ECU.
Open ECU control panel.
Inspect circuit breaker(s)
(Figures 1 or 2). If tripped, reset
and test system.
If circuit breaker(s) (Figures 1
or 2) trip again, contact next level
of maintenance.
Contact next level of maintenance.
Evaporator Motor Starter Ensure CB1 and CB2 are actuated
Protector EMSP tripped and MSS switch is set to FAN.
Use multimeter to measure
between 22 to 26 VAC across
EMSP terminal A1 (wire #37C) and
terminal A2 (wire 33G). If not
within tolerance, shutdown power
and use continuity measurements
to verify wiring from MSS to EMSP.
Replace faulty component.
NOTE
Allow EMSP to cool down before
attempting to reset.
Manually reset EMSP if tripped.
0030-8
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
7 Evaporator fan does not operate Power interrupted at source. If resetting starter protector does
(cont.) not correct failure use multimeter to
measure between 190 to 230 VAC
at terminals T1 to T2 and T3 to T2
on the EMSP.
If both measurements are within
tolerance replace evaporator fan
motor (WP 0096).
If either measurement is out of
tolerance, replace EMSP
(WP 0108) or evaporator fan motor
(WP 0096).
8 Condenser fan does not operate Damaged/loose fan belt Inspect evaporator fan belt.
If too loose/tight adjust.
If damaged, replace (WP 0098).
ECU circuit breaker tripped Disconnect power source from
ECU.
Open ECU control panel.
Inspect circuit breaker(s)
(Figures 1 or 2). If tripped, reset
and test system.
If circuit breaker(s) (Figures 1
or 2) trip again, contact next level
of maintenance.
Contact next level of maintenance.
MSS switch bad Ensure CB1, CB2, and CB3 are
actuated.
Ensure MSS switch is set to COOL
and thermostat is set to lowest
setting.
Use multimeter to measure
between 22 to 26 VAC across MSS
wire #41A and neutral terminal
board contact TB-2. If not within
tolerance replace MSS switch
(WP 0104).
0030-9
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
8 Condenser fan does not operate MSS switch bad If within tolerance, use multimeter
(cont.) to measure between 22 to 26 VAC
across CMSP wire #41D and
neutral terminal board contact
TB-2.
Condenser Motor Starter If not within tolerance shutdown
Protector CMSP tripped ECU and use continuity
measurements to verify path
between MSS and CMSP.
Replace faulty component.
NOTE
Allow CMSP to cool down before
attempting to reset.
Manually reset CMSP if tripped.
Power interrupted at source If resetting starter protector does
not correct failure use multimeter to
measure between 190 to 230 VAC
at terminals T1 to T2 and T3 to T2
on the CMSP.
If both measurements are within
tolerance replace condenser fan
motor (WP 0097).
If either measurement is out of
tolerance, replace CMSP
(WP 0108) or condenser fan motor
(WP 0097).
9 Compressor won’t run Power interrupted at source Ensure CB1, CB2, and CB3 are
actuated.
Ensure MSS switch is set to COOL
and thermostat is set to lowest
setting.
Use multimeter to measure
between 190 to 230 VAC at
terminals T1 to T2 and T3 to T2 on
compressor.
If both measurements are within
tolerance, proceed to POSSIBLE
MALFUNCTION Compressor/TDR
bad for isolation routine.
0030-10
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
9 Compressor won’t run Power interrupted at source Use multimeter to measure
(cont.) between 190 to 230 VAC at
terminals T1 to T2 and T3 to T2 on
Power Distribution Block 2 (PDB2).
If either measurement is not within
tolerance, shutdown ECU and use
continuity measurements to isolate
to CB3, compressor, CCR, or CHT.
Compressor contactor (CCR)
tripped NOTE
Allow CCR to cool down before
attempting to reset.
Manually reset CCR if tripped.
If resetting CCR does not correct
problem replace contactor
(WP 0105) or compressor
(WP 0099).
Compressor/Time Delay Use multimeter to measure
Relay (TDR) bad between 22 to 26 VAC across
terminal board contacts TB-7 and
TB-2. If not within tolerance
proceed to CONDITION/
INDICATION step 8 below and
verify pressure switches.
Use multimeter to measure
between 22 to 26 VAC at CCR wire
#45 and negative lead to neutral
terminal TB2. If not within
tolerance replace TDR.
Set MSS switch to OFF.
Attach multimeter probe positive
lead to wire #45 at compressor and
negative lead to neutral terminal
TB2.
Monitor multimeter to verify 15
second turn-on time delay for the
next step.
Set MSS switch to COOL.
0030-11
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
9 Compressor won’t run Compressor/Time Delay If multimeter reading becomes 22
(cont.) Relay (TDR) bad to 26 VAC after approximately 15
seconds, replace compressor
(WP 0099).
If 15 second time delay doesn’t
occur after MSS set to COOL
replace TDR (WP 0106).
10 Pressure switch fault High Pressure Cutout (HPC) NOTE
or Low Pressure Cutout
(LPC) Switch. Perform pressure test
(WP 0113) before completing
the next action.
Ensure CB1, CB2, and CB3 are
actuated.
Ensure MSS switch is set to COOL
and thermostat is adjusted to
lowest setting.
Use multimeter to measure
between 22 to 26 VAC at TB6. If
within tolerance replace HPC
(WP 0095).
If not within tolerance replace LPC
(WP 0095).
0030-12
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
NOTE
The fault code is determined by the number of times the
AUXILIARY HEAT switch flashes (i.e. one flash is F01, two
flashes is F02, etc.). Refer to (Table 2) for fault codes.
If power is cut off from hydronic heater for any reason, the
hydronic heater internal safety cut off switch must be reset
as follows:
Hydronic Heater Reset Procedure
1. Power down ECU.
2. Disconnect power source (i.e., Genset, shore power) from
ECU for 20 seconds.
3. Reconnect power source.
Due to length of fuel line to ECU, always make two attempts
when restarting.
11 Hydronic heater will not start Circuit breaker tripped Disconnect power source from
(no fault code) ECU.
Open ECU control panel.
Inspect circuit breaker(s)
(Figures 1 or 2). If tripped, reset
and test system.
If circuit breaker(s) (Figures 1
or 2) trip again, contact next level
of maintenance.
Bad hydronic heater fuses Replace 15 A fuse and/or 5 A fuse
inside hydronic heater wiring
harness (WP 0094).
Power interrupted at source Set CB1 and CB2 to ON.
Ensure MSS switch set to OFF.
Use multimeter to measure
between 22 to 26 VDC across
battery positive terminal X2-1 of
and negative terminal X2-2 of
heater, (Figure 3).
If within tolerance, proceed to
POSSIBLE MALFUNCTION
control circuit bad for isolation
routine.
0030-13
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
11 Hydronic heater will not start Power interrupted at source Use multimeter to measure
(cont.) (no fault code) between 22 to 26 VDC across
bridge rectifier positive terminal
(wire # 17) and negative terminal
(wire #57).
If within tolerance, replace fuse F2
or hydronic heater (WP 0094).
If not within tolerance, replace
bridge rectifier BR (WP 0092) or
hydronic heater (WP 0094).
Control circuit bad Set Auxiliary Heat Switch (AHSS)
to MAN.
Use multimeter to measure
between 22 to 26 VDC across ON
SIGNAL terminal (X1-1) and
battery negative terminal (X2-2).
If within tolerance, replace hydronic
heater (WP 0094) or AHSS switch
(WP 0103).
Use multimeter to measure
between 22 to 26 VDC across
CMSP wire # 51 and battery
negative terminal # X2-2.
If within tolerance, isolate to AHSS
switch or EMSP (V2 only).
Replace faulty component.
If not within tolerance, isolate
failure to fuse F1, starter protector
CMSP, or hydronic heater.
Replace faulty component.
Heat contactor CHT (V1) or If hydronic heater works in MAN
CHT LOW (V2) faulty mode but not in AUTO mode
isolate to AHSS switch or contactor
CHT (V1) or CHT LOW (V2).
Replace faulty component.
0030-14
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
12 Hydronic heater (fault code F01 Fuel source interrupted Inspect fuel line for damage or
or F02) loose connections.
If loose, tighten. Reset and restart
hydronic heater.
If damaged, contact next level of
maintenance.
Fuel filter clogged Remove and inspect fuel filter for
debris. If filter is clogged, replace
filter (WP 0094).
Fuel pump inoperative Set AUXILIARY HEAT to OFF and
restart hydronic heater.
Reset and restart hydronic heater.
Attempt to start ECU.
Listen/feel for fuel pump operation.
If fuel pump does not operate,
disconnect wiring and test for 24 to
28 VDC.
If 24 to 28 VDC present, replace
fuel pump (WP 0094).
If 24 to 28 VDC not present,
inspect wiring harness for damage.
If damaged, contact next level of
maintenance.
Hydronic heater faulty Check fuses, if bad, replace
(WP 0094). If fuses are good,
replace hydronic heater
(WP 0094).
Replace hydronic heater
(WP 0094).
Contact next level of maintenance.
13 Hydronic heater (fault code F03) Hydronic heater faulty Set AUXILIARY HEAT to OFF and
restart hydronic heater.
Replace hydronic heater
(WP 0094).
14 Hydronic heater (fault code F07) Fuel source interrupted Inspect fuel line for damage or
loose connections.
If loose, tighten. Reset and restart
hydronic heater.
0030-15
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
14 Hydronic heater (fault code F07) Fuel source interrupted If fuel line damaged replace it
(cont.) (WP 0064).
If fuel line frozen, verify fuel line
heater works by actuating the Fuel
Line Heater switch at the genset
and feeling warmth of element.
Fuel filter clogged Remove and inspect fuel filter for
debris. If filter is clogged, replace
filter (WP 0094).
Fuel pump inoperative Set AUXILIARY HEAT to OFF and
restart hydronic heater.
Attempt to start ECU.
Listen/feel for fuel pump operation.
If fuel pump does not operate,
disconnect wiring and test for 24 to
28 VDC.
If 24 to 28 VDC present, replace
fuel pump.
If 24 to 28 VDC not present,
inspect wiring harness for damage.
Use multimeter to measure
between 22 to 26 VDC across blue
wire (+) and the brown (-) fuel
pump wire.
If within tolerance, replace fuel
pump (WP 0064).
If not within tolerance, replace
hydronic heater or fuel pump.
Bad hydronic heater fuses Check fuses, if bad replace
(WP 0094). If fuses are good,
replace hydronic heater
(WP 0094).
Hydronic heater faulty Replace hydronic heater
(WP 0094).
Contact next level of maintenance.
Fuel contaminated Drain and replace fuel in genset
fuel tank (WP 0085).
0030-16
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
15 Hydronic heater (fault code F04, Hydronic heater faulty Replace hydronic heater
F05, F06, F08, F09, F010) (WP 0094).
16 Coolant leaking from hydronic Coolant hoses leaking Inspect all coolant hoses of
heater/hoses hydronic heater for damage or
loose clamps.
Tighten clamps.
Coolant reservoir leaking Inspect reservoir for loose cap,
leaks, loose clamps, damaged
hose. If damage present, replace.
Contact next level of maintenance.
Coolant hose, reservoir, or Shutdown ECU and allow system
evaporator coil bad to cool. Wipe coolant from all
surfaces. Inspect for leaks.
Actuate CB1 and CB2 with MSS
switch set to OFF.
Set AUXILIARY HEAT switch to
MANUAL. Inspect surface for leak.
Allow heater to reach normal
operating condition if necessary.
Visually isolate source of leak and
replace faulty component
(WP 0064).
17 Fuel leaking from hydronic heater Fuel filter leaking Inspect filter for signs of leaking. If
leaks are identified, replace filter
(WP 0094).
Fuel lines leaking Inspect fuel lines for leaking,
damage, or loose clamps. If
clamps loose, tighten.
Hydronic heater fuel pump If fuel pump is leaking, replace
leaking (WP 0094).
Hydronic heater body leaking If hydronic heater body is leaking,
replace hydronic heater.
0030-17
TM 11-6115-742-13&P 0030
Table 1. Maintainer Troubleshooting – ECU (Electrical)/Hydronic Heater – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
17 Fuel leaking from hydronic heater Fuel lines, fuel pump, fuel Shutdown ECU and allow system
(cont.) filter, or heater leaking to cool. Wipe fuel from all
surfaces. Inspect for leaks.
Actuate CB1 and CB2 with MSS
switch set to OFF.
Set AUXILIARY HEAT switch to
MANUAL. Inspect surface for leak.
Allow heater to reach normal
operating condition if necessary.
Visually isolate source of leak and
replace faulty component.
0030-18
TM 11-6115-742-13&P 0030
NOTE
When AUXILIARY HEAT switch (on ECU control panel) flashes, there is a
problem with the hydronic heater. The number of flashes indicates a specific
fault code (i.e., one flash is F01, two flashes is F02).
There is a sequence of slow and fast flashes. Count the slow flashes.
Table 2. ECU Hydronic Heater Fault Codes.
FAULT
DESCRIPTION POSSIBLE CAUSE
CODE
F01 No Start-up •Fuel Supply
•Restricted Air Flow Through Intake or Exhaust
F02 Flame Extinguished •Fuel Supply
•Restricted Air Flow Through Intake or Exhaust
F03 Under/Over voltage •Vehicle Charging System
F04 Premature Flame Detection •Heater faulty
F05 Circulating Pump Interruption or Short Circuit •Open or Shorted Wiring
•Defective Pump
F06 Temperature Sensor Interruption or Short •Heater faulty
Circuit
F07 Metering Pump (Fuel pump) Interruption or •Open or Shorted Wiring
Short Circuit
F08 Combustion Fan Motor Interruption, Short •Heater faulty
Circuit or Incorrect fan Speed
F09 Pencil Type Glow Plug/Flame Detector •Heater faulty
Interruption or Short Circuit
F10 Overheating Condition •Coolant Flow Restriction
•Circulation Pump
0030-19
TM 11-6115-742-13&P 0030
CB1 CB2 CB3
CB1, CB2 and CB3
OUT OF
P OW ER ON PH ASE
EN M
HOURS 1/10
TEMPER ATU RE
AUXI LI ARY HEAT MODE SELEC T
OFF
H EAT
MA NUA L AUTO
OFF
FAN
C OOL EMSP
(ECU evaporator)
CMSP CMSP EMSP
(ECU condenser)
Figure 1. Circuit Breaker Location for TMSS-MED ECU (Version 1).
CB1, CB2, CB3,
C B1 CB2 CB3 CB4 C B5 CB4, and CB5
OUT OF
POWERON PHASE
ENM
HOURS 1/10
TEMPERATURE
MODESELECT
AUXILIARY HEAT HEATHIGH
18KW
OFF
MANUAL AUTO HEAT LOW
9KW
OFF
FAN
COOL
EMSP
CMSP (ECU evaporator)
CMS P EM SP
(ECU condenser)
Figure 2. Circuit Breaker Location for TMSS-MED ECU (Version 2).
0030-20
TM 11-6115-742-13&P 0030
Fuse
Box
AHSS Hydronic
Off Heater
Man Auto
F1
X1-1
5A ON Signal
xoo Black
F2 CMSP EMSP
15A (V2 only) oox
CHT (V1)
+ CHT LOW (V2) Diag X1-5
X2-1 Bat (+) Light
X1-6
Red
BR Bat (-) FP
X2-2
Blue
Green
+
- Bridge
Rectifier X1-2 Fuel
G
Brown
Pump
- Diagnostic
LED
Brown (P/OAHSS
Switch)
Figure 3. Hydronic (Auxiliary) Heater Circuit.
END OF TASK
0030-21
TM 11-6115-742-13&P 0030
MODE SELECT SWITCH – TEST
NOTE
There are two different versions of MODE SELECT switch. Version 1 allows for
just HEAT selection. Version 2 allows for selection of HEAT HIGH (18 KW) and
HEAT LOW (9 KW).
Refer to (Figures FO-1 and FO-2) for schematic and wiring diagram of Version 1
of the ECU.
Refer to (Figures FO-3 and FO-4) for schematic and wiring diagram of Version 2
of the ECU.
TEST
Version 1
Using a multimeter, make continuity measurement. See (Table 3).
Table 3. MODE SELECT (Version 1) Switch Test.
FROM TO
METER READING
(Terminal #) (Terminal #)
Fan 11 12/14/15 2 Ω or less
Heat 21 22 2 Ω or less
Cool 21 25 2 Ω or less
Version 2
Using a multimeter, make continuity measurement. See (Table 4).
Table 4. MODE SELECT (Version 2) Switch Test.
FROM TO
METER READING
(Terminal #) (Terminal #)
Fan 11 12/13/15/16 2 Ω or less
Heat (9 KW) 31 32 2 Ω or less
Heat (18 KW) 41 42/43 2 Ω or less
Cool 21 22 2 Ω or less
END OF TASK
0030-22
TM 11-6115-742-13&P 0030
THERMOSTAT– TEST
NOTE
Refer to (Figures FO-1 and FO-2) for schematic and wiring diagram of Version 1
of the ECU.
Refer to Figures (FO-3 and FO-4) for schematic and wiring diagram of Version 2
of the ECU.
TEST
Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start Procedure
(WP 0005) of this TM.
COOL MODE
1. Ensure that return duct baffle is closed.
2. Set thermostat to 100°F.
3. Set MODE SELECT switch on ECU Control Panel to COOL.
4. Listen for audible whistle from Hot Gas By-pass Valve.
5. Slowly turn thermostat temperature down.
6. Once thermostat falls below ambient temperature, the Hot Gas By-pass Valve should close and whistling will
cease indicating a operational thermostat.
7. If thermostat does not pass test replace as described below.
END OF TASK
HEAT MODE
1. Ensure that return duct baffle is closed.
2. Set thermostat to 40°F.
NOTE
If heater contacts do not pull in verify that thermostat is bad by testing heater
contactors.
3. Slowly raise thermostat temperature. When thermostat temperature reaches ambient temperature, observe
heater contacts operating.
4 If thermostat does not pass test replace as described below.
END OF TASK
0030-23
TM 11-6115-742-13&P 0030
CIRCUIT BREAKERS– TEST
NOTE
Refer to (Figures FO-1 and FO-2) for schematic and wiring diagram of Version 1
of the ECU.
Refer to (Figures FO-3 and FO-4) for schematic and wiring diagram of Version 2
of the ECU.
TEST
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Open ECU control panel door.
3. Set multimeter to read resistance.
WARNING
Prior to performing the following test, ensure that all power to ECU has been
disconnected. Failure to comply with this warning could result in electrical shock
or death to the individual and/or damage to the equipment.
4. Place Circuit breaker in the OFF position.
5. Place meter probes across associated terminals of circuit breaker and measure resistance. Multimeter
should read open (infinite). If a readable resistance is measured, circuit breaker is bad, replace.
6. Place Circuit breaker in the ON position.
7. Place meter probes across associated terminals of circuit breaker and measure resistance. Multimeter
should read short (0 Ω). If any resistance is measured circuit breaker is bad, replace.
END OF TASK
0030-24
TM 11-6115-742-13&P 0030
COMPRESSOR CONTACTOR– TEST
NOTE
Refer to (Figures FO-1 and FO-2) for schematic and wiring diagram of Version 1
of the ECU.
Refer to (Figures FO-3 and FO-4) for schematic and wiring diagram of Version 2
of the ECU.
STATIC
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Open ECU control panel door.
3. Set multimeter to read resistance.
4. Place meter probes across associated terminals of contactor and activate contactor by pushing in on actuator.
Multimeter should read a short (0 Ω). If any resistance is measured across contactor, contactor is bad,
replace.
END OF TASK
ACTIVE
1. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
2. Set MODE SELECT switch to COOL.
3. Set thermostat to 40°F.
4. Observe contactor pulling in. If contactor does not pull in, use multimeter to measure between wire # 45 and
# 33H on contactor for 24 VAC.
5. If 24 VDC is present, replace contactor.
NOTE
Compressor is on a 24 second time delay.
6. If 24 VDC is not present, troubleshoot time delay.
END OF TASK
0030-25
TM 11-6115-742-13&P 0030
HEATER CONTACTOR– TEST
NOTE
Refer to (Figures FO-1 and FO-2) for schematic and wiring diagram of Version 1
of the ECU.
Refer to (Figures FO-3 and FO-4) for schematic and wiring diagram of Version 2
of the ECU.
TEST (STATIC)
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Open ECU control panel door.
3. Set multimeter to read resistance.
4. Place meter probes across associated terminals of contactor and activate contactor by pushing in on actuator.
Multimeter should read a short (0 Ω). If any resistance is measured across contactor, contactor is bad,
replace.
END OF TASK
TEST (ACTIVE)
1. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
2. Set MODE SELECT switch as follows:
• Version 1 – Set MODE SELECT switch to HEAT
• Version 2 – Set MODE SELECT switch to HEAT HIGH 18 KW
3. Set thermostat to 100°F.
4. Observe contactors pulling in. If contactor does not pull in, using a multimeter, measure for 24 VAC. See
(Table 5).
Table 5. Heater Contactor Measurements.
FROM TO READING
Heater contactor (CHT) (V1) 40 33I 24 VAC
Heater contactor (CHT LOW) (V2) 40B 33I 24 VAC
Heater contactor (CHT HI) (V2) 40C 33K 24 VAC
5. If 24 VDC is present, replace contactor.
6. If 24 VDC is not present:
• Version 1 – Troubleshoot thermostat.
• Version 2 – Troubleshoot MODE SELECT switch and thermostat.
END OF TASK
0030-26
TM 11-6115-742-13&P 0030
TRANSFORMER– TEST
NOTE
Refer to (Figures FO-1 and FO-2) for schematic and wiring diagram of Version 1
of the ECU.
Refer to (Figures FO-3 and FO-4) for schematic and wiring diagram of Version 2
of the ECU.
TEST
1. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
2. Using multimeter, measure across terminals H1 and H2 of transformer for 208 VAC.
3. If 208 VAC present, measure across terminals X1 and X2 of transformer for 24 VAC.
4. If 208 VAC not present, verify that all connections are correct and CB1 on Genset is energized.
5. If 24 VAC is not present at X1 and X2 of transformer, replace transformer.
END OF TASK
BRIDGE RECTIFIER– TEST
NOTE
Refer to (Figures FO-1 and FO-2) for schematic and wiring diagram of Version 1
of the ECU.
Refer to (Figures FO-3 and FO-4) for schematic and wiring diagram of Version 2
of the ECU.
TEST
1. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
2. Place MODE SELECT switch into HEAT mode, and AUXILIARY HEAT switch into MANUAL and operate
hydronic heater.
3. Using multimeter, measure across terminals 33 and 32A bridge rectifier for 24 VAC.
4. If 24 VAC not present, all connections are correct and check transformer for 24 VAC as described above.
5. If 24 VAC present, set multimeter to measure DC and measure across terminals 57 and 58 of bridge rectifier
for 24 VDC.
6. If 24 VDC not present, at 57 and 58 of bridge rectifier, replace bridge rectifier.
END OF TASK
0030-27
TM 11-6115-742-13&P 0030
CMSP/EMSP– TEST
NOTE
The CMSP receives input signals from the thermostat (via wire # 41D) and the
terminal board pin # TB-8. The EMSP receives input signals from the MODE
SELECT switch (pin 15) (via wire # 37C) and the CMSP (via wire # 51). Verify
that these connections are correct and that these components are operating
properly.
Refer to (Figures FO-1 and FO-2) for schematic and wiring diagram of Version 1
of the ECU.
Refer to (Figures FO-3 and FO-4) for schematic and wiring diagram of Version 2
of the ECU.
TEST
1. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
2. Verify that CMSP/EMSP are set to OFF.
3. Using multimeter, measure terminals listed in (Table 6) for 208 VAC.
Table 6. CMSP/EMSP Voltage Inputs.
CMSP EMSP
Meter connections Meter reading
208 VAC Input Connections 208 VAC Input Connections
From To Terminal Wire Terminal Wire
L1 L2 208 VAC L1 12B L1 12A
L2 L3 208 VAC L2 13B L2 13A
L3 L1 208 VAC L3 14B L3 14A
4. If 208 VAC not present, troubleshoot input power to ECU from Genset.
5. If 208 VAC present, energize CMSP/EMSP and measure across terminals listed in (Table 7) for 208 VAC.
Table 7. CMSP/EMSP Voltage Outputs.
CMSP EMSP
Meter connections Meter reading
208 VAC Input Connections 208 VAC Input Connections
From To Terminal Wire Terminal Wire
T1 T2 208 VAC T1 18 T1 15
T2 T3 208 VAC T2 19 T2 16
T3 T1 208 VAC T3 20 T3 17
6. If 208 VAC not present, replace CMSP/EMSP.
7. Measure across terminals listed in (Table 8) for 28 VAC.
0030-28
TM 11-6115-742-13&P 0030
TEST – Continued
Table 8. CMSP/EMSP 28 VAC Outputs.
Terminal/ (Wire marker) Meter reading
CMSP
From To
21 (50B) 22 (51) 28 VAC
A1 (41D) A2 (33F/33G) 28 VAC
EMSP
13 (51) 14 (52A) 28 VAC
A1 (37C) A2 (33G/33H) 28 VAC
8. If 28 VAC not present, replace CMSP/EMSP.
END OF TASK
END OF WORK PACKAGE
0030-29/30 blank
TM 11-6115-742-13&P 0031
MAINTAINER TROUBLESHOOTING PROCEDURES
TMSS-MED
ECU (HEATING & COOLING)/HYDRONIC HEATER
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit (WP 0162, Item 1) WP 0005, WP 00030, WP 0092
Multimeter (WP 0162, Item 2) WP 0095 - WP 0103, WP 0113
Personnel Required
Two
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by maintainer-level
qualified personnel. This work package provides a systematic approach to locating and correcting malfunctions of
the TMSS-MED. Each section is arranged according to the condition/indication of a problem. The corrective
action items have been arranged in order of complexity, with simpler actions listed first. The manual cannot
identity all malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be
corrected by the corrective actions provided, contact your supervisor.
WARNING
Special caution must be taken during troubleshooting since protective covers and
safety devices may be removed or disabled to gain access and make tests.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand brakes are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0031-1
TM 11-6115-742-13&P 0031
NOTE
There are two different circuit designs for the ECU control panel. Refer to
(Figures 1 and 2 of WP 0030) for location and identification of circuit breakers.
Refer to the fold-outs at the end of this TM for electrical and refrigeration
schematics of the ECU.
Table 1. Maintainer Troubleshooting – ECU (Heating & Cooling).
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
1 Conditioned air too warm ECU Circuit breaker tripped Disconnect power source from
(in Cool mode) ECU (WP 0005).
Open ECU control panel.
Inspect circuit breaker(s)
(Figures 1 or 2 of WP 0030). If
tripped, reset and test system.
If circuit breaker(s) (Figures 1
or 2 of WP 0030) trip again,
contact next level of maintenance.
Blower motor bad/inoperative Fan belt damaged/out of
adjustment. Shut down ECU and
inspect blower motor and belt for
operation. If necessary, adjust fan
belt (WP 0098). If blower motor is
still inoperative, contact next level
of maintenance.
Condenser fan bad/ Shut down ECU and inspect
inoperative condenser fan for operation.
Remove any debris that may
impede operation. If condenser
fan is still inoperative, contact next
level of maintenance.
Evaporator coil dirty Inspect evaporator coil. If
necessary, clean.
Condenser coil fins blocked Inspect condenser grill and coil. If
with debris necessary remove condenser grill
and clean coils (WP 0092).
High pressure switch tripped Shut down ECU and check high
pressure switch. If necessary,
reset switch and attempt to restart
ECU. If high pressure switch trips
again, contact next level of
maintenance.
Contact next level of maintenance.
0031-2
TM 11-6115-742-13&P 0031
Table 1. Maintainer Troubleshooting – ECU (Heating & Cooling) - Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
1 Conditioned air too warm Thermostat or solenoid valve Set all circuit breakers OFF.
(cont.) (in Cool mode) faulty
Set DMM to VAC. Clip (or hold)
DMM neutral lead to neutral wire at
TB-2.
Set circuit breakers CB2 and CB1
to ON.
Set Mode Select Switch (MSS) to
COOL.
Set thermostat to coldest setting.
If condenser fan is not working,
proceed to electrical
troubleshooting (WP 0030) for fan
failure.
Use DMM to measure between 22
to 26 VAC across solenoid valve at
TB-1 and neutral TB-2.
If not within tolerance, replace
thermostat (WP 0103).
If within tolerance and sight glass
does not indicate low refrigerant
replace solenoid valve (WP 0100).
ECU circuit breaker, Proceed to electrical
contactor, or motor protector troubleshooting (WP 0030).
tripping
Refrigerant charge low. Inspect sight glass for indication of
low charge or contamination.
Recharge/replace refrigerant
(WP 0113).
Blower motor bad If mechanical damage replace
blower or motor (WP 0096).
Condenser fan bad If mechanical damage replace fan
or motor (WP 0097).
Condenser coil If coil shows signs of physical
damage, refer to next level of
maintenance.
0031-3
TM 11-6115-742-13&P 0031
Table 1. Maintainer Troubleshooting – ECU (Heating & Cooling) - Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
1 Conditioned air too warm Evaporator coil If coil shows signs of physical
(cont.) (in Cool mode) damage, refer to next level of
maintenance.
Check evaporator coil overall
temperature. If part of coil is
relatively warm and evaporator
inlet is sweaty or frosty, thermal
expansion valve or distributor may
be obstructed or damaged.
If coil is iced and sight glass does
not indicate low refrigerant, replace
High Gas By-pass Valve (HGBV)
(WP 0100).
TEV/D bad/inoperative Verify sensing bulb is correctly
installed (WP 0100).
If TEV/D frozen thaw with warm
water and replace filter/dryer
(WP 0102).
If TEV/D is obstructed or damaged
replace it (WP 0100).
Clogged filter/dryer If filter/dryer is cold to touch,
frosted, sweating, or if discharge
end colder then input replace it
(WP 0102).
Pressure switch fault or Recover and recharge refrigerant
refrigerant charge incorrect. (WP 0113). If condition reoccurs,
replace switch (WP 0095).
2 Conditioned air too cold Filters clogged/damaged Inspect filter(s). If necessary,
(in Heat mode) clean/replace (WP 0101).
Blower motor bad/inoperative Fan belt damaged/out of
adjustment. Shut down ECU and
inspect blower motor and belt for
operation. If necessary, adjust fan
belt (WP 0098). If blower motor is
still inoperative, contact next level
of maintenance.
Contact next level of maintenance.
0031-4
TM 11-6115-742-13&P 0031
Table 1. Maintainer Troubleshooting – ECU (Heating & Cooling) - Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
3 Blower does not operate Fan belt damaged/out of Shut down ECU and inspect
adjustment blower motor and belt for
operation. If necessary,
adjust/replace fan belt (WP 0098).
If blower motor is still inoperative,
contact next level of maintenance.
Contact next level of maintenance.
4 Discharge pressure too high Condenser fan inoperative Inspect condenser fan for
operation. If necessary, tighten
belts (WP 0098). If fan(s) are still
inoperative, contact next level of
maintenance.
Condenser coil fins blocked Inspect condenser grill and coil. If
with debris necessary, remove condenser grill
and clean coils (WP 0092).
Contact next level of maintenance.
5 Discharge pressure too low Contact next level of maintenance.
6 Suction pressure too high Condenser coil fins blocked Inspect condenser grill and coil. If
with debris necessary, remove condenser grill
and clean coils (WP 0092).
Voltage supplied to ECU Check meters on Genset control
incorrect (too high/too low) panel. If necessary, adjust
VOLTAGE ADJUST potentiometer.
Contact next level of maintenance.
7 Suction pressure too low Contact next level of maintenance.
8 Compressor fails to start Compressor overload open Shut down ECU and allow
compressor to reset.
Contact next level of maintenance.
9 Compressor "short cycles" Evaporator coil dirty Inspect evaporator coil. If
necessary, clean coils.
Evaporator coil iced Inspect evaporator coil. If iced up,
shut system down and allow ice to
melt.
10 Compressor noisy Condenser fan inoperative Inspect condenser fan for
operation. If necessary, tighten
belts (WP 0098). If fan(s) are still
inoperative, contact next level of
maintenance.
0031-5
TM 11-6115-742-13&P 0031
Table 1. Maintainer Troubleshooting – ECU (Heating & Cooling) - Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
10 Compressor noisy Condenser coil fins blocked Inspect condenser grill and coil. If
(cont.) with debris necessary, remove condenser grill
and clean coils (WP 0092).
Contact next level of maintenance.
11 Compressor starts normally but TEV/D or HGBV Perform Superheat Adjustment
shuts down due to overload (WP 0100). If adjustment cannot
be made replace the TEV/D,
HGBV, and compressor in that
order.
12 Compressor excessively noisy TEV/D or Quench Valve (QV) If compressor makes knocking
faulty noise check suction line for low
temperature indicating that
refrigerant is returning to
compressor.
Perform Superheat Adjustment
(WP 0100). If adjustment doesn’t
correct problem replace QV,
TEV/D, or compressor in that
order.
Refrigerant overcharge Recover and recharge refrigerant
(WP 0113). If condition reoccurs,
replace compressor (WP 0099).
Compressor phase rotation Use schematic to verify wiring is
wrong correct for proper compressor
rotation.
13 Conditioned air too cold (in Heat Electrical control circuit or Proceed to ECU electrical
mode) heater element faulty troubleshooting (WP 0030).
END OF TASK
END OF WORK PACKAGE
0031-6
TM 11-6115-742-13&P 0032
MAINTAINER TROUBLESHOOTING PROCEDURES
TMSS-MED
TRAILER (ELECTRICAL) TROUBLESHOOTING PROCEDURES
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit (WP 0165, Item 1) WP 0124
Multimeter (WP 0165, Item 2)
Personnel Required
Two
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by maintainer-level
qualified personnel. This work package provides a systematic approach to locating and correcting malfunctions of
the TMSS-MED. Each section is arranged according to the condition/indication of a problem. The corrective
action items have been arranged in order of complexity, with simpler actions listed first. The manual cannot
identify all malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be
corrected by the corrective actions provided, contact your supervisor.
WARNING
Special caution must be taken during troubleshooting since protective covers and
safety devices may be removed or disabled to gain access and make tests.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand brakes are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
NOTE
If trailer currently has incandescent tail lights and tail light and/or cable is
damaged and must be replaced, entire incandescent system must be replaced
with LED type tail light, and inter-vehicular cable.
0032-1
TM 11-6115-742-13&P 0032
Table 1. Maintainer Troubleshooting – Trailer (Electrical).
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
1 Tail light intermittent Loose electrical connection Verify that connections
(including ground) are properly
connected.
NOTE
For incandescent bulb only.
Bulb(s) Inspect connection at bulb
socket for corrosion. Clean and
reconnect.
Inter-vehicular cable intermittent Inspect entire length of inter-
vehicular cable for damage (i.e.,
cuts, gashes). If damage is
present, replace inter-vehicular
cable (WP 0124).
Inspect connector pins/contacts
for corrosion. Clean and
reconnect.
If necessary, measure continuity
of Inter-vehicular cable. If DMM
reads greater than 5Ω for any
continuity reading, inter-
vehicular cable is bad, replace
(WP 0124).
Contact next level of
maintenance.
2 Tail light does not work Tail light damaged Inspect tail light assembly for
damage. If damaged, replace
(WP 0124).
Loose electrical connection Verify that connections
(including ground) are properly
connected.
NOTE
For incandescent bulb only.
Bulb(s) Replace bulb (WP 0124).
0032-2
TM 11-6115-742-13&P 0032
Table 1. Maintainer Troubleshooting – Trailer (Electrical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
2 Tail light does not work Inter-vehicular cable inoperative Measure continuity of Inter-
(Cont) vehicular cable. If DMM reads
greater than 5Ω or for any
continuity reading, inter-
vehicular cable is bad, replace
(WP 0124).
Contact next level of
maintenance.
END WORK PACKAGE
0032-3/4 blank
TM 11-6115-742-13&P 0033
MAINTAINER TROUBLESHOOTING PROCEDURES
TMSS-MED
TRAILER (MECHANICAL) TROUBLESHOOTING PROCEDURES
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit (WP 0165, Item 1) WP 0022, WP 0119, WP 0121
WP 0126 thru WP 0129
Personnel Required
Two
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by maintainer-level
qualified personnel. This work package provides a systematic approach to locating and correcting malfunctions of
the TMSS-MED. Each section is arranged according to the condition/indication of a problem. The corrective
action items have been arranged in order of complexity, with simpler actions listed first. The manual cannot
identity all malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be
corrected by the corrective actions provided, contact your supervisor.
WARNING
Special caution must be taken during troubleshooting since protective covers and
safety devices may be removed or disabled to gain access and make tests.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand brakes are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0033-1
TM 11-6115-742-13&P 0033
Table 1. Maintainer Troubleshooting – Trailer (Mechanical).
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
1 Hand brake does not engage Damage to hand brake Inspect hand brake handle/cable
handle/cable for damage.
Hand brake out of adjustment Adjust hand brake (WP 0128).
Hand brake cable seized or Replace damaged hand brake
damaged cable (WP 0128).
Hand brake assembly bent or Replace damaged hand brake
damaged handle/cable (WP 0128).
2 Hand brake does not disengage Hand brake cable seized or Replace damaged hand brake
damaged cable (WP 0128).
Hand brake assembly bent or Replace damaged hand brake
damaged handle/cable (WP 0128).
Parking brake link in wheel Replace damaged parking break
assembly bent or damaged link (WP 0126).
3 Brake fluid present under trailer Loose connection Tighten connection.
Brake lines kinked or damaged Replace damaged brake line(s)
(WP 0127).
Damage to master cylinder or Inspect master cylinder/brake
brake lines lines for leaks or loose
connections. Replace damaged
master cylinder (WP 0127).
Damage to wheel cylinder Replace wheel cylinder
(WP 0126).
4 Brake actuator does not engage Damage to brake actuator Inspect brake actuator for
damage. Contact next level of
maintenance.
5 Hydraulic brakes exhibit failure Loose connection Tighten connection.
Brake line(s) kinked or damaged Replace damaged brake line(s)
(WP 0127).
Damage to brake actuator Replace damaged brake
actuator (WP 0128).
Damage to master cylinder Replace damaged master
cylinder (WP 0127).
Damage to brakes and/or Replace brakes or brake
components. component (WP 0126).
0033-2
TM 11-6115-742-13&P 0033
Table 1. Maintainer Troubleshooting – Trailer (Mechanical) – Continued.
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
5 Hydraulic brakes exhibit failure Lock out pin installed in actuator Remove pin.
(cont.)
6 Trailer does not track straight Lockout pin in place in actuator Remove pin.
when towed or leans to side
Master cylinder fluid low or Add fluid to master cylinder
empty (WP 0022).
Tire(s) not rotating evenly Check tire(s) for proper inflation
(20 psi – highway; 17 psi off
road). Add/remove air as
necessary.
Tire(s) damaged Inspect tire(s) for uneven/
excessive wear. Replace tire
(WP 0129).
One of the hand brakes Release hand brake.
engaged
Trailer frame or suspension Inspect frame/suspension. If
damaged. damage present contact next
level maintenance.
7 Tire(s) will not hold air pressure Tire unserviceable Replace tire (WP 0129).
8 Tongue jack assembly will not Tongue jack assembly damaged Inspect all movable joints and
raise/lower areas for damage. If damaged,
replace tongue jack assembly
(WP 0119).
9 Trailer stabilizer leg does not Stabilizer leg damaged Inspect stabilizer leg for damage.
raise/lower If damaged, replace stabilizer leg
(WP 0121).
10 Excessive motion of lunette Shock absorber damaged Replace shock absorber
(WP 0128).
END OF WORK PACKAGE
0033-3/4 blank
TM 11-6115-742-13&P 0034
MAINTAINER TROUBLESHOOTING PROCEDURES
TMSS-MED
SHELTER (ELECTRICAL) TROUBLESHOOTING PROCEDURES
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit (WP 0165, Item 1) WP 0130
Multimeter (WP 0165, Item 2)
Personnel Required
One
TROUBLESHOOTING PROCEDURES
This work package contains general information for troubleshooting of the TMSS-MED by maintainer-level
qualified personnel. This work package provides a systematic approach to locating and correcting malfunctions of
the TMSS-MED. Each section is arranged according to the condition/indication of a problem. The corrective
action items have been arranged in order of complexity, with simpler actions listed first. The manual cannot
identify all malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be
corrected by the corrective actions provided, contact your supervisor.
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0034-1
TM 11-6115-742-13&P 0034
Table 1. Maintainer Troubleshooting – Shelter (Electrical).
ITEM CONDITION/INDICATION POSSIBLE MALFUNCTION CORRECTIVE ACTION
1 Shelter lighting does not come Check light bulb Verify that bulb is good. If
on necessary replace (WP 0130).
Check fuse Verify that fuse is good. If
necessary replace (WP 0130).
PDU malfunctioning Verify that PDU is properly
connected and is operating
properly. If necessary,
troubleshoot PDU (see below).
Bad cable(s) Replace cable. If necessary, verify
by using multimeter to measure
continuity of cable.
Lighting fixture Replace lighting fixture.
2 No power from PDU Check power from source to Verify that source (i.e., Genset) is
PDU operating properly.
• Circuit breakers have not
tripped.
• Sufficient fuel.
• Meters on Genset control
panel are giving proper
indications.
• Cable from source to PDU is
not damaged. If necessary
measure voltage at end of
source cable (208 VAC, 3Ø,
60 HZ).
Verify that PDU is operating
properly by measuringL
• 208 VAC, 3Ø, 60 HZ at J2.
• 120 VAC at J3 through J8 of
PDU.
Verify that 120 VAC cable(s) are
connected properly and that no
damage is present. If possible
replace output cable with "known
good" cable.
3 Power indicator lights inoperable PDU Replace PDU.
END OF WORK PACKAGE
0034-2
TM 11-6115-742-13&P
CHAPTER 6
MAINTAINER MAINTENANCE INSTRUCTIONS
FOR
TMSS-MED
GENSET
TM 11-6115-742-13&P 0035
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
SERVICE UPON RECEIPT
INITIAL SETUP:
Tools and Special Tools References
General mechanic's tool kit (WP 0162, Item 1) WP 0005, WP 0019, WP 0037,
WP 0039 – WP 0086
Personnel Required
Two to four
GENERAL
The following procedures are required to be performed by Maintainer level maintenance in order to prepare the
TMSS-MED for use.
SITING
For minimal problems with set-up and operation of TMSS-MED and equipment being used insure area is:
• Dry.
• Level with adequate room for trailer, shelter, system grounding, and all other associated equipment.
• Free of items (trees, buildings, or other structures) that would impede set-up of TMSS-MED or cause
physical interference for trailer, shelter, system grounding, and all other associated equipment.
• Free of items (e.g., towers, power lines, radar, trees, buildings) that would cause interference with
electronic equipment being used inside of shelter.
SHELTER/TRAILER REQUIREMENTS
The TMSS-MED shelter requires a footprint of 23 feet (7.01 meters) by 32 feet (9.75 meters). In addition, the
TMSS-MED trailer requires a foot print of 16 feet (4.85 meters) by 7 feet (2.16 meters) for set-up and installation.
SERVICE UPON RECEIPT
Inspect system components for damage incurred during shipment. If any damage is visible, notify supervisor.
Report the damage on DD Form 361, Transportation Discrepancy Report. Check the equipment against the
packing slip to see if the shipment is complete. Report all discrepancies in accordance with applicable service
instructions.
Once all covers are removed, inspect the trailer, shelter, and each piece of equipment for damage incurred during
shipment. Inspect all loose pieces of equipment located in the trailer cargo box.
INSTALLATION INSTRUCTIONS
The TMSS-MED requires some assembly depending on the mode of operation. To setup the TMSS-MED in a
fixed mode of operation, refer to Operation Under Usual Conditions (WP 0005) for setup and power-up
procedures.
0035-1
TM 11-6115-742-13&P 0035
PRELIMINARY SERVICING OF EQUIPMENT
WARNING
When working on the TMSS-MED, do not operate electric equipment if floors,
ceiling or walls of the individual enclosure show evidence of water intrusion.
Electrical shock can cause personnel injury or death.
Do not apply power if grounding is not connected. Electrical shock can cause
personnel injury or death.
The TMSS-MED trailer carries an expandable shelter. Care must be taken in the removal and replacement of this
equipment from the trailer to avoid damage. Maintainer PMCS for the TMSS-MED is in (WP 0037). For
Maintainer level removal and replacement procedures of components and assemblies refer to (WP 0039 through
WP 0086).
Once the TMSS-MED has been placed into service, the following maintenance should be performed after the first
50 hours of operation.
• Change oil & filter
• Check tension on all belts
• Check coolant level
PRELIMINARY CHECK AND ADJUSTMENTS OF EQUIPMENT
Before placing the equipment into service, ensure that all Crew PMCS (WP 0019) and Maintainer PMCS
(WP 0037) have been performed.
END OF WORK PACKAGE
0035-2
TM 11-6115-742-13&P 0036
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
PMCS INTRODUCTION – GENSET
GENERAL
This work package provides data necessary to keep the TMSS-MED operational ready. PMCS are performed to
keep the TMSS-MED Genset in operational condition. The checks are used to find, correct, and report problems.
Maintenance personnel are required to perform the tasks as indicated in Maintainer PMCS (WP 0037, Table 1).
PMCS are performed by the Maintainer each time the equipment is operated. Prior to performing any
maintenance that requires climbing on or under TMSS-MED Genset, ensure cage bolts are not inserted and
wheels are chocked. Injury to personnel could result from TMSS-MED Genset suddenly rolling or tipping.
Before you begin operating the TMSS-MED Genset, do Before PMCS.
Once a week do Weekly PMCS. If TMSS-MED Genset has not been operated in a week, perform Before PMCS.
Do Monthly PMCS once a month. If TMSS-MED Genset has not been operated in a month, perform PMCS as
outlined in (WP 0037).
If you are operating the TMSS-MED Genset for the first time, perform Weekly PMCS the first time you do your
Before PMCS.
If you find something wrong when performing PMCS, fix it if you can. Otherwise, notify your supervisor.
WARNINGS AND CAUTIONS
Special attention should be paid to the WARNINGS and CAUTIONS appearing in the Maintainer PMCS table. A
WARNING means someone could be injured. A CAUTION means equipment could be damaged.
LEAKAGE DEFINITION
It is necessary for you to know how fluid leakage affects the status of the trailer. The following are definitions of
the classes of leakage you need to know to be able to determine the status of the trailer. Learn these leakage
definitions when in doubt, contact next level of maintenance.
CAUTION
Maintainers must perform appropriate maintenance when Operators report Class
III leaks. Failure to comply may result in damage to equipment.
NOTE
The following not applies to non-flammable liquids only. Any leakage of
flammable liquid is unacceptable.
Equipment operation is allowable with minor leakages (Class I or II).
Consideration must be given to fluid capacity of the item or system being
checked. When in doubt, notify your supervisor.
When operating with Class I or II leaks, continue to check fluid levels as required
in your PMCS.
0036-1
TM 11-6115-742-13&P 0036
LEAKAGE DEFINITION – Continued
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.
CLASS III - Leakage of fluid great enough to form drops that fall from the item being checked.
INSPECTION
Look for signs of a problem or trouble. Senses help here. You can feel, smell, hear, or see many problems. Be
alert when on the TMSS-MED Genset.
Inspect to see if items are in good condition. Are they correctly assembled, stowed, and secured, or excessively
worn, leaking, corroded, or improperly lubricated? Correct any problems found or notify your supervisor.
There are some common items to check all over the TMSS-MED Genset. These include the following:
1. Bolts, clamps, nuts, and screws: Continuously check for looseness. Look for chipped paint, rust, or corrosion
around bolt and screw heads and nuts. Tighten them when you find them loose. If tools are not available,
notify your supervisor.
2. Welds: Many items on the TMSS-MED Genset are welded. To check these welds, look for chipped paint, rust
corrosion, or gaps. When these conditions exist, Maintainer must notify their supervisor.
3. Electrical wires, connectors, and harnesses: Tighten loose connectors. Look for cracked or broken insulation,
bare wires, and broken connectors. If any damage is found, Maintainer must repair/replace as required. If
beyond Maintainer Level Maintenance, Maintainer must notify next their supervisor.
4. Hoses and fluid lines: Look for wear, damage and leaks, and make sure clamps and fittings are tight. Wet
spots mean a leak. A stain by a fitting or connector can also mean a leak. If any leaks or damage is found,
Maintainer must repair/replace as required. If beyond Maintainer Level Maintenance, Maintainer must notify
their supervisor.
5. Belts and pulleys: Check belt tension. Look for cracks, excessive wear and damage. Check pulleys for rust
corrosion, or damage. If any damage is found, Maintainer Level Maintenance must repair/replace as required.
If beyond Maintainer Level Maintenance, Maintainer must notify their supervisor.
LUBRICATION MAINTAINER INTERVALS - NORMAL CONDITIONS
General
For safer, more trouble-free operations, make sure that your TMSS-MED Genset is serviced when it needs it.
Proper lubrication and maintenance intervals which are the responsibility of the Maintainer level maintenance are
found in this work package.
Adherence
Intervals (on-condition or hard time) and the related man-hour times are based on normal operation. The man-
hour time specified is the time needed to do all the maintenance prescribed for a particular interval. On-condition
(OC) oil sample intervals shall be applied. Change the hard time interval if lubricants are contaminated or if
operating the equipment under adverse operating conditions, included longer-than-usual operating hours. The
calendar interval may be extended during periods of low activity. If extended, adequate preservation precautions
must be taken. Hard time intervals must be applied during the warranty period.
0036-2
TM 11-6115-742-13&P 0036
Cleaning Fittings Before Lubrication
WARNING
Cleaning solvents may be toxic and flammable. Wear protective goggles and
gloves; use only in well-ventilated area; avoid contact with skin, eyes, and clothes,
and do not breath vapors. Keep away from heat or flame. Never smoke when
using cleaning solvent. Failure to comply may result in serious injury or death to
personnel.
If personnel become dizzy while using cleaning solvents, immediately get fresh air
and medical help. If cleaning solvent contacts skin or clothes, flush with cold
water. If cleaning solvent contacts eyes, immediately flush eyes with water and
get medical attention. Failure to comply may result in serious injury or death to
personnel.
Clean parts with cleaning solvent. Dry before lubricating.
Lubrication After Fording
If a fording operation occurs, lubricate all fittings below fording depth and check submerged gear boxes for
presence of water.
Lubrication After High Pressure Washing
After a thorough washing, lubricate all grease fittings and oil can points outside and underneath trailer.
Corrosion Control
Refer to Corrosion Prevention and Control (CPC), (WP 0001), for appropriate corrosion control procedures.
Hard Time Lubrication Intervals
For equipment under manufacturer’s warranty, hard time lubrication intervals shall be followed. Intervals shall be
shortened if lubricants are known to be contaminated or if operation is under adverse conditions (e.g. longer than
usual operating hours, extended idling periods, extreme dust).
EXPLANATION OF TABLE ENTRIES
Item Number - Numbers in this column are for reference. When completing DA Form 2404/DA Form 5988E
(Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indicating a
fault. Item numbers appear in the order in which the checks/services are performed for the interval listed.
Interval - This column indicates when a procedure must be performed (i.e., Before, During, or After an operation.)
Item to Be Checked or Serviced - This column provides the item that is to be checked or serviced.
Procedure - This column describes the procedure that must be followed to ensure that the equipment is capable
of performing its intended mission.
Equipment Not Ready/Available If - This column lists conditions that make the TMSS-MED not fully mission
capable. If the problem can be fixed using the troubleshooting procedures and/or maintenance procedures in this
manual, do so. If not, document the items not able to be fixed on DA Form 2404 for the next level of
maintenance. For further information on how to use this form, see DA PAM 750-8. Be sure to observe and
annotate all special circumstances that appear/occur.
0036-3
TM 11-6115-742-13&P 0036
EXPLANATION OF TABLE ENTRIES - Continued
Other Entries - Be sure to observe and annotate all special circumstances that appear/occur.
NOTE
If the equipment must be kept in continuous operation, only perform those
procedures that will not disturb operation. Complete checks and services when
the equipment is shut down.
END OF WORK PACKAGE
0036-4
TM 11-6115-742-13&P 0037
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
PMCS (GENSET)
INITIAL SETUP:
Tools and Special Tools References
General mechanic's tool kit (WP 0162, Item 1) WP 0039 – WP 0086
Personnel Required
Two
Table 1. Maintainer Preventive Maintenance Checks and Services – Genset.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
GENSET
1 Weekly
NOTE
Refer to (WP 0039 through
WP 0086) for Genset
maintenance procedures.
WARNING
Ensure radiator is fully cooled.
Hot coolant could erupt into
operator’s face and cause
severe injury.
1. Check radiator associated hoses Damage to radiator and
and clamps for any type of damage or associated hoses (to
deterioration. Ensure that hoses are include cuts, tears, holes,
not collapsed, swollen, excessively and leaks) or associated
soft, or spongy. Ensure that no clamps present.
damage or corrosion is present to
associated clamps. Replace hoses
and clamps as necessary.
2. Check water pump for cracks, Electrical connections are
leaks, or other damage. Replace if not correct. Battery fuse
necessary. bad. Damage to battery,
cables, terminals, or
warmer present.
0037-1
TM 11-6115-742-13&P 0037
Table 1. Maintainer Preventive Maintenance Checks and Services – Genset – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
1 3. Check battery, cables, battery Electrical connections are
(cont.) fuse, and warmer. Ensure that all are not correct. Battery fuse
securely fastened. Ensure that no bad. Damage to battery,
physical damage, (i.e., cracks) is cables, terminals, or
present to battery, cables, associated warmer present.
terminals, battery fuse, and warmer.
Ensure that electrical connections are
correct. Ensure that all are clean and
free of excessive dirt, grease, and
grime. Replace battery, cables,
battery fuse, or warmer as necessary.
4. Check muffler, spark arrestor, Physical damage or
and exhaust pipes for excessive excessive corrosion
corrosion, dents, dings, holes, present. Parts missing.
leaks. Replace as necessary.
5. Check Genset Control Panel Fuse blown.
fuses.
First 50 Change oil and filter.
Hours
50 1. Check fluid levels. Verify that Low fluid, discolored
Hours fluids (i.e., oils, coolants) are at their fluids.
proper levels, no discoloration or
indication of burning/overheating is
present.
2. Check all belts and associated Damage or excessive
pulleys. Belts should not show any wear to belts and
signs of excessive wear, cracking or associated pulleys
other damage. Check belts for present. Belt tension not
proper tension. Pulleys should not adjusted properly.
contain any deformities or other signs
of physical damage. Replace/adjust
belts as necessary.
125 1. Check fuel filter. If excessively Fuel filter excessively
Hours dirty or discolored, change. dirty or discolored.
2. Check and clean air filter. If Air filter excessively dirty.
beyond cleaning, replace. If
operating in a hot climate, change air
filter.
0037-2
TM 11-6115-742-13&P 0037
Table 1. Maintainer Preventive Maintenance Checks and Services – Genset – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
1 250 Check tightness of CB terminal Cannot tighten or terminal
(cont.) Hours screws. Torque to 45 in-lbs. screw damaged.
250 1. Change oil and filter. Oil and filter has not been
Hours changed.
2. Clean air filter.
500 1. Perform overall inspection of Missing/incomplete
Hours TMSS-MED. Check all components hardware causing
for damage. Check for improper operation of
completeness. system.
2. Perform 250 hour PMCS.
3. Change fuel and air filter.
1,000 1. Check all external fittings for leaks Fittings leak or
Hours and completeness. inoperative.
2. Perform 500 hour PMCS.
2,000 1. De-carbonize engine. If Engine does not operate
Hours performing poorly, contact next level efficiently.
of maintenance.
2. Replace filters and fan belt.
3. Change engine coolant.
4. Drain and clean fuel tank. Fuel contaminated.
END OF WORK PACKAGE
0037-3/4 blank
TM 11-6115-742-13&P 0038
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET MAINTENANCE INDEX
GENERAL
This section contains an index of repair/removal/replacement or maintenance procedures that may be needed
during maintenance or repair of the TMSS-MED Genset by Maintainer personnel. Maintenance is limited to those
failures that may be repaired at the Maintainer level. The index identifies the maintenance function, which is
followed by a column that identifies the work package and page(s) where Maintainer level procedure(s) may be
found. The index is provided to assist in the quick location of a procedure. The manual cannot list all
malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be corrected by the
corrective actions provided, notify the supervisor.
Maintenance Function Procedure
GENSET – DIESEL ENGINE
1. Access panels removal/replacement ............................................................................................ 0039-2
2. Access panels latch removal/replacement ................................................................................... 0039-10
3. Access cover removal/replacement.............................................................................................. 0039-12
4. Genset – control panel latches removal/replacement .................................................................. 0040-2
5. Fuse test/removal/replacement .................................................................................................... 0040-4
6. Battery fuse removal/replacement (version 1).............................................................................. 0041-2
7. Battery fuse removal/replacement (version 2 and 3).................................................................... 0041-5
8. Battery, retainer, and mounting bracket removal/replacement (version 1) .................................. 0041-8
9. Battery, retainer, and mounting bracket removal/replacement (version 2) .................................. 0041-13
10. Battery, retainer, and mounting bracket removal/replacement (version 3) .................................. 0041-19
11. Battery warmer removal/replacement (version 1) ........................................................................ 0041-25
12. Battery warmer removal/replacement (version 2 and 3) .............................................................. 0041-28
13. Oil and oil filter removal/replacement ........................................................................................... 0042-2
14. Air intake filter removal/replacement ............................................................................................ 0043-2
15. Fuel filter removal/inspect/replacement ........................................................................................ 0044-2
16. Fuel tank service........................................................................................................................... 0045-2
17. Low oil pressure cut-off switch removal/replacement................................................................... 0046-2
18. Electric fuel pump removal/replacement ...................................................................................... 0047-2
17. Fuel injector removal/clean/replacement ...................................................................................... 0048-2
19. Fuel injector pump removal/replacement ..................................................................................... 0048-6
20. Fuel injection system lines removal/replacement ......................................................................... 0048-10
21. Prime fuel system ......................................................................................................................... 0048-16
22. Glow plug and connector strip removal/inspect/test/replacement ................................................ 0049-2
23. Oil pressure switch removal/replacement .................................................................................... 0050-2
24. Oil pressure sending unit removal/replacement ........................................................................... 0051-2
25. K2 or K3 solenoid removal/replacement ...................................................................................... 0052-2
26. K4 solenoid removal/replacement ................................................................................................ 0052-5
27. K4 solenoid circuit breaker removal/replacement ........................................................................ 0052-8
28. Starter removal/replacement ........................................................................................................ 0053-2
29. Diesel speed sensor removal/inspect/test/replacement ............................................................... 0054-2
30. Coolant temperature sensor removal/replacement ...................................................................... 0055-2
31. Coolant temperature switch removal/replacement ....................................................................... 0056-2
32. Thermostat removal/replacement ................................................................................................. 0057-2
33. Engine coolant removal/replacement ........................................................................................... 0058-2
34. Engine coolant reservoir bottle removal/replacement .................................................................. 0058-5
35. Radiator, hoses and clamps removal/replacement ...................................................................... 0059-2
36. Alternator removal/replacement ................................................................................................... 0060-2
37. Fan belt inspection/adjustment/removal/replacement.................................................................. 0061-2
38. Fan removal/replacement ............................................................................................................ 0062-2
0038-1
TM 11-6115-742-13&P 0038
Maintenance Function Procedure
GENSET – DIESEL ENGINE – Continued
39. Water pump removal/replacement ............................................................................................... 0063-2
40. Engine heater (hydronic) removal/replacement ........................................................................... 0064-2
41. Engine heater (hydronic) fuel pump and fuel filter removal/replacement ..................................... 0064-6
42. Engine heater (hydronic) hose removal/replacement................................................................... 0064-11
43. Engine heater (hydronic) fuse removal/replacement.................................................................... 0064-19
44. Exhaust flex pipe, elbow and muffler removal/replacement ......................................................... 0065-2
45. Exhaust manifold and gasket removal/replacement..................................................................... 0066-2
GENSET – CONTROL PANEL
46. Torque specifications .................................................................................................................... 0067
47. AC meters adjustment/removal/replacement ............................................................................... 0068-2
48. Gauges and meters test/removal/replacement ............................................................................ 0069-2
49. Hour meter test/removal/replacement .......................................................................................... 0069-7
50. Voltage adjust potentiometer test/removal/replacement .............................................................. 0070-2
51. Rotary switches removal/replacement ......................................................................................... 0070-5
52. Toggle switches removal/replacement ......................................................................................... 0070-9
53. Panel lights removal/replacement ................................................................................................ 0071-2
54. Indicator lights removal/replacement ............................................................................................ 0071-4
55. Battery switch removal/replacement............................................................................................. 0072-2
56. Emergency stop switch removal/replacement .............................................................................. 0072-5
57. Control panel wiring harness removal/replacement ..................................................................... 0073-2
GENSET – POWER DISTRIBUTION PANEL
58. Power distribution panel lights removal/replacement (old version) .............................................. 0074-2
59. Power distribution panel lights removal/replacement (new version) ............................................ 0074-5
60. Connector (J1 & J4) removal/replacement ................................................................................... 0074-8
61. Connector (J2 & J3) removal/replacement ................................................................................... 0074-12
62. Connector (J5) removal/replacement ........................................................................................... 0074-16
63. Connector (J6) removal/replacement ........................................................................................... 0074-20
GENSET – BARRIER PANEL
64. Current transformer removal/replacement ................................................................................... 0075-2
65. Transducer removal/replacement ................................................................................................. 0076-2
66. Relay (K4, K5, K6, K7) removal/replacement............................................................................... 0077-2
67. Time delay removal/replacement ................................................................................................. 0078-2
68. Voltage regulator removal/replacement/adjustment ..................................................................... 0079-2
69. Speed sensor removal/replacement ............................................................................................. 0080-2
70. Precision governor removal/replacement/adjustment .................................................................. 0081-2
71. Circuit breaker removal/replacement............................................................................................ 0082-2
72. Battery charger test/removal/replacement ................................................................................... 0083-2
GENSET – FUEL
73. Fuel selector switch removal/replacement ................................................................................... 0084-2
74. Auxiliary fuel ports removal/replacement ..................................................................................... 0084-5
75. Fuel gauge removal/inspect/replacement .................................................................................... 0085-2
76. Fuel tank removal/replacement .................................................................................................... 0085-5
77. Fuel hose removal/replacement ................................................................................................... 0085-10
78. Fuel line heater removal/replacement .......................................................................................... 0085-12
ENGINE/GENERATOR
79. Genset (including enclosure) – removal and replacement ........................................................... 0086-2
80. Engine generator assembly – removal/replacement .................................................................... 0086-7
81. Separating engine generator assembly – removal and replacement ........................................... 0086-26
END OF WORK PACKAGE
0038-2
TM 11-6115-742-13&P 0039
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET ACCESS PANELS AND LATCHES MAINTENANCE
ACCESS PANELS REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic's tool kit WP 0005
(WP 0165, Item 1)
Equipment Condition
Materials/Parts Genset shut down
Latch
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of the Genset access panels, access
panel latches, and access covers. They consist of:
• Side access panels removal/replacement
• Power distribution panel (PDP) access panel removal/replacement
• Control panel access panel removal/replacement
• Top access panel removal/replacement
• Access panel latch removal/replacement
• Access cover removal/replacement
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0039-1
TM 11-6115-742-13&P 0039
In event of a venting, clear area until pungent odor of Sulfur Dioxide is cleared.
Handle leaking batteries with rubber or plastic gloves. Get immediate medical
attention for any skin or respiratory irritation.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
SIDE ACCESS PANELS
REMOVAL
1. Verify that Genset has been shut down, engine is cool, and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. If applicable, remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Lift up latch (Figure 1, Item 3) on access panel (Figure 1, Item 2).
4. Turn latch (Figure 1, Item 3) counter clockwise to open.
5. Repeat steps 3 and 4 for other latch.
6. Remove access panel (Figure 1, Item 2) from generator (Figure 1, Item 1).
END OF TASK
REPLACEMENT
1. Install access panel (Figure 1, Item 2) onto generator (Figure 1, Item 1).
2. Turn latch (Figure 1, Item 3) clockwise to lock.
3. Press down latch (Figure 1, Item 3) on access panel (Figure 1, Item 2).
4. Repeat steps 2 and 3 for other latch.
5. If applicable, install cargo restraints (not shown) to rear of Genset.
6. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0039-2
TM 11-6115-742-13&P 0039
Figure 1. Side Access Panels Removal/Replacement.
END OF TASK
0039-3
TM 11-6115-742-13&P 0039
POWER DISTRIBUTION PANEL (PDP) ACCESS PANEL
REMOVAL
1. Verify that Genset has been shut down, engine is cool, and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. If applicable, remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Lift up latch (Figure 2, Item 3) on PDP access panel (Figure 2, Item 2).
4. Turn latch (Figure 2, Item 3) counter clockwise to open.
5. Repeat steps 3 and 4 for other latch and open PDP access panel (Figure 2, Item 2).
6. Remove screw (Figure 2, Item 5) and self-locking nut (Figure 2, Item 4) that secures locking stay (Figure 2,
Item 9) to PDP access panel (Figure 2, Item 2). Repeat for locking stay.
7. Remove thirteen screws (Figure 2, Item 6) that secure the PDP access panel (Figure 2, Item 2) to the
generator (Figure 2, Item 1) via hinge.
8. Remove PDP access panel (Figure 2, Item 2).
9. Remove two screws (Figure 2, Item 7) and self-locking nuts (Figure 2, Item 8) that secure locking stay
(Figure 2, Item 9) to generator (Figure 2, Item 1). Repeat for other locking stay.
10. Remove locking stays (Figure 2, Item 9) from generator (Figure 2, Item 1). If damaged, discard.
END OF TASK
REPLACEMENT
1. Install locking stays (Figure 2, Item 9) to generator (Figure 2, Item 1) and secure with screws (Figure 2,
Item 7) and self-locking nuts (Figure 2, Item 8).
2. Install PDP access panel (Figure 2, Item 2) to generator (Figure 2, Item 1) and secure with thirteen screws
(Figure 2, Item 6) via hinge.
3. Install locking stays (Figure 2, Item 9) to PDP access panel (Figure 2, Item 2) and secure with screws
(Figure 2, Item 5) and self-locking nuts (Figure 2, Item 4).
4. Close PDP access panel (Figure 2, Item 2).
5. Turn latch (Figure 2, Item 3) on PDP access panel (Figure 2, Item 2) clockwise to lock.
6. Press down on the latch to secure.
7. Repeat steps 5 and 6 for other latch.
8. If applicable, install cargo restraints (not shown) to rear of Genset.
9. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0039-4
TM 11-6115-742-13&P 0039
1 2
4
9
3
6
8
Figure 2. Power Distribution Panel (PDP) Access Panel Removal/Replacement.
END OF TASK
0039-5
TM 11-6115-742-13&P 0039
CONTROL PANEL ACCESS PANEL
REMOVAL
1. Verify that Genset has been shut down, engine is cool, and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. If applicable, remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Lift up latch (Figure 3, Item 3) on control panel access panel (Figure 3, Item 4).
4. Turn latch (Figure 3, Item 3) counter clockwise to open.
5. Repeat steps 3 and 4 for other latch and open control panel access panel (Figure 3, Item 4).
6. Remove ten screws (Figure 3, Item 2) that secure control panel access panel (Figure 3, Item 4) to generator
(Figure 3, Item 1) via hinge.
7. Remove control panel access panel (Figure 3, Item 4).
END OF TASK
REPLACEMENT
1. Install control panel access panel (Figure 3, Item 4) to generator (Figure 3, Item 1) and secure with ten
screws (Figure 3, Item 2).
2. Close control panel access panel (Figure 3, Item 4).
3. Turn latch (Figure 3, Item 3) clockwise to lock.
4. Press down on latch (Figure 3, Item 3) to secure.
5. Repeat steps 3 and 4 for other latch.
6. If applicable, install cargo restraints (not shown) to rear of Genset.
7. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0039-6
TM 11-6115-742-13&P 0039
Figure 3. Control Panel Access Panel Removal/Replacement.
END OF TASK
0039-7
TM 11-6115-742-13&P 0039
TOP ACCESS PANEL
REMOVAL
1. Verify that Genset has been shut down, engine is cool, and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. If applicable, remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove screw (Figure 4, Item 3) and nut (Figure 4, Item 1) that secure exhaust pipe cap (Figure 4, Item 2) to
exhaust pipe (Figure 4, Item 4).
4. Remove exhaust pipe cap (Figure 4, Item 2).
5. Around the perimeter of the generator, remove twenty screws (Figure 4, Item 7), flat washers (Figure 4,
Item 8), and lock washers (Figure 4, Item 9) that secure the top access panel (Figure 4, Item 5) to the
generator (Figure 4, Item 6).
6. Carefully lift and remove top access panel (Figure 4, Item 5) from generator (Figure 4, Item 6).
END OF TASK
REPLACEMENT
1. Carefully set the top panel access cover (Figure 4, Item 5) on top of the generator (Figure 4,
Item 6).
2. Secure top access panel (Figure 4, Item 5) to generator (Figure 4, Item 6) with twenty screws
(Figure 4, Item 7), flat washers (Figure 4, Item 8), and lock washers (Figure 4, Item 9).
3. Install exhaust pipe cap (Figure 4, Item 2) onto exhaust pipe (Figure 4, Item 4).
4. Secure exhaust pipe cap (Figure 4, Item 2) to the exhaust pipe (Figure 4, Item 4) with screw
(Figure 4, Item 3) and nut (Figure 4, Item 1).
5. If applicable, install cargo restraints (not shown) to rear of Genset.
6. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0039-8
TM 11-6115-742-13&P 0039
3
2
9
8
7
5
Figure 4. Top Access Panel Removal/Replacement.
END OF TASK
0039-9
TM 11-6115-742-13&P 0039
ACCESS PANEL LATCH REMOVAL/REPLACEMENT
NOTE
The following procedure is typical for all latches on the Genset and its access
panels.
When attempting to perform the following step, if panel will not become
unlatched, DO NOT force the access panel. If necessary, attempt to gain access
to the damaged panel through the Genset. If this is necessary, make sure
Genset is not in an operational status.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. If applicable, remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove the Genset access panel (Figure 5, Item 4) with the broken latch.
4. Remove and retain screw (Figure 5, Item 6) and back plate (Figure 5, Item 5) from rear of the latch (Figure 5,
Item 1).
5. Remove latch (Figure 5, Item 1) from access panel (Figure 5, Item 4).
END OF TASK
REPLACEMENT
1. Insert new latch (Figure 5, Item 1) into access panel (Figure 5, Item 4).
2. Secure latch (Figure 5, Item 1) to access panel (Figure 5, Item 4) using screw (Figure 5, Item 6) and back
plate (Figure 5, Item 5).
NOTE
The following step does not apply to all latch assemblies.
3. If necessary, adjust screw (Figure 5, Item 2) and stop nut (Figure 5, Item 3) to proper level so latch (Figure 5,
Item 1) operates properly.
0039-10
TM 11-6115-742-13&P 0039
REPLACEMENT – Continued
4. Reattach the repaired Genset access panel (Figure 1, Item 4).
5. If applicable, install cargo restraints (not shown) to rear of Genset.
6. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
6
4
(TYPICAL)
Figure 5. Genset Access Panel Latches Removal/Replacement.
END OF TASK
0039-11
TM 11-6115-742-13&P 0039
ACCESS COVER REMOVAL/REPLACEMENT
REMOVAL
1. Verify that Genset has been shut down, engine is cool, and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. If applicable, remove cargo restraints (not shown) to gain access to rear access panel of
Genset.
3. Remove tapping screw (Figure 6, Item 2) that secures access cover (Figure 6, Item 3) to
access cover mounting bracket (Figure 6, Item 4) via attached string.
4. Remove access cover with attached string (Figure 6, Item 3). Discard if damaged.
5. Remove the remaining five tapping screws (Figure 6, Item 2) that secure the access cover
mounting bracket (Figure 6, Item 4) to the generator (Figure 6, Item 1).
6. Remove access cover mounting bracket (Figure 6, Item 4). Discard if damaged.
END OF TASK
REPLACEMENT
1. Install access cover mounting bracket (Figure 6, Item 4) onto generator (Figure 6, Item 1).
Make sure that the screw holes of the access cover mounting bracket (Figure 6, Item 4) align
properly with the mounting holes on the generator (Figure 6, Item 1).
2. Secure access cover mounting bracket (Figure 6, Item 4) to generator (Figure 6, Item 1) with
five tapping screws (Figure 6, Item 2).
3. Install access cover (Figure 6, Item 3) onto access cover mounting bracket (Figure 6, Item 4)
via attached string. Secure using remaining tapping screw (Figure 6, Item 2).
4. If applicable, install cargo restraints (not shown) to rear of Genset.
5. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0039-12
TM 11-6115-742-13&P 0039
Figure 6. Access Cover Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0039-13/14 blank
TM 11-6115-742-13&P 0040
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET CONTROL PANEL LATCH AND FUSE MAINTENANCE
GENSET – CONTROL PANEL LATCHES AND FUSE MAINTENANCE
INITIAL SETUP:
Tools and Special Tools Reference
General mechanic’s tool kit (WP 0165, Item 1) WP 0005, WP 0041
Materials/Parts
Latches Equipment Condition
Fuse Genset Shut Down
Personnel Required BATTERY SWITCH - OFF
One
GENERAL
This work package provides information on the service and removal/replacement of sub assemblies for the
Genset. They consist of:
• Control panel latches removal/replacement
• Fuse removal/replacement
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
In event of a venting, clear area until pungent odor of Sulfur Dioxide is cleared.
Handle leaking batteries with rubber or plastic gloves. Get immediate medical
attention for any skin or respiratory irritation.
0040-1
TM 11-6115-742-13&P 0040
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset is in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
CONTROL PANEL LATCHES REMOVAL
1. Verify that Genset has been shut down, engine is cool, and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Undo control panel latches and open.
3. Remove lock nut (Figure 1, Item 8), spacer (Figure 1, Item 7), latch (Figure 1, Item 6), lock washer (Figure 1,
Item 5), nut (Figure 1, Item 4), retainer nut (Figure 1, Item 3), flat washer (Figure 1, Item 2), and latch handle
(Figure 1, Item 9) from control panel (Figure 1, Item 1) and discard.
END OF TASK
REPLACEMENT
1. Insert new latch handle (Figure 1, Item 9) into opening in control panel (Figure 1, Item 1).
2. Secure latch handle (Figure 1, Item 9) with flat washer (Figure 1, Item 2) and retainer nut (Figure 1, Item 3).
Tighten retainer nut (Figure 1, Item 3).
3. Attach nut (Figure 1, Item 4), lock washer (Figure 1, Item 5), latch (Figure 1, Item 6), spacer (Figure 1,
Item 7), and lock nut (Figure 1, Item 8). Tighten assembly.
4. Close control panel (Figure 1, Item 1).
5. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0040-2
TM 11-6115-742-13&P 0040
40 60
80 58 60 62 10 20
25 100 150 200 25
20 5 50 0
10 65 30 30
0 0 50 0 0 0
0 000 0
1 6 8
7
5
4
3
2
Figure 1. Control Panel Latch Removal/Replacement.
END OF TASK
0040-3
TM 11-6115-742-13&P 0040
FUSE TEST/REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
FUSE TEST
1. Set BATTERY switch to ON.
2. Set engine START switch to RUN.
3. Open control panel (Figure 2, Item 3) and observe LEDs (Figure 2, Item 2). If LED is on, fuse is bad, replace.
END OF TASK
FUSE REMOVAL
1. Verify that Genset has been shut down, engine is cool, and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Open control panel (Figure 2, Item 3).
3. Remove retainer (Figure 2, Item 4) from inside of control panel cavity.
4. Open cover (Figure 2, Item 6) and remove fuse (Figure 2, Item 5).
END OF TASK
REPLACEMENT
1. Install new fuse (Figure 2, Item 5) and snap cover (Figure 2, Item 6) into place.
2. Insert retainer (Figure 2, Item 4) into empty slot in control panel cavity.
3. Close control panel (Figure 2, Item 3) and secure.
4. Start Genset as outlined in Genset Start Procedure (WP 0005) of this TM.
0040-4
TM 11-6115-742-13&P 0040
3
4
(REF)
5 2
6 (REF)
Figure 2. Fuse Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0040-5/6 blank
TM 11-6115-742-13&P 0041
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET BATTERY, BATTERY FUSE, SUPPORT BRACKET, AND WARMER
GENSET BATTERY, BATTERY FUSE, SUPPORT BRACKET, AND WARMER MAINTENANCE
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit (WP 0165, Item 1) WP 0005
Materials/Parts Equipment Condition
Fuse, battery Genset shut down
Battery BATTERY SWITCH - OFF
Battery Mounting Bracket
Battery Retainer
Teflon Tape (WP 0168, Item 58)
Rubber Gloves (WP 0168, Item 24)
Battery Warmer
Personnel Required
One
GENERAL
This work package provides information on the service and removal/replacement of sub assemblies for the
Genset battery components. They consist of:
• Battery fuse removal/replacement
• Battery, retainer and bracket removal/replacement
• Battery warmer removal/replacement
There are three versions of the battery assembly. Refer to appropriate version. If necessary, refer to (WP 0004)
for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
0041-1
TM 11-6115-742-13&P 0041
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following service.
In event of a venting, clear area until pungent odor of Sulfur Dioxide is cleared.
Handle leaking batteries with rubber or plastic gloves. Get immediate medical
attention for any skin or respiratory irritation.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
In event of a venting, clear area until pungent odor of Sulfur Dioxide is cleared.
Handle leaking batteries with rubber or plastic gloves. Get immediate medical
attention for any skin or respiratory irritation.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
The following Removal/Replacement procedure for the battery fuse is for
Version 1. For Version 2 or Version 3, refer to appropriate procedure located in
this WP.
BATTERY FUSE (VERSION 1)
REMOVAL
1. Verify that Genset has been shut down, engine is cool, and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel (Figure 1, Item 1) of Genset
(Figure 1, Item 2).
3. Remove rear access panel (Figure 1, Item 1) from Genset (Figure 1, Item 2) and set aside.
0041-2
TM 11-6115-742-13&P 0041
REMOVAL – Continued
4. Remove and retain nut (Figure 1, Item 6) that secures black cable (Figure 1, Item 7) to negative (-) terminal of
battery (Figure 1, Item 8). (ALWAYS DISCONNECT GROUND WHEN CONDUCTING ANY PROCEDURES
ON TRAILER).
5. Loosen but do not remove both nuts (Figure 1, Items 3 and 5) that secure the ends of the battery fuse
(Figure 1, Item 4) to the battery terminals (Figure 1, Item 9).
6. Rotate the battery fuse (Figure 1, Item 4) up away from the right battery terminal and lift away from left battery
terminal.
7. Remove and discard battery fuse (Figure 1, Item 4).
END OF TASK
REPLACEMENT
1. Slide straight slotted end of battery fuse (Figure 1, Item 4) onto left battery terminal (Figure 1, Item 9). Rotate
the battery fuse (Figure 1, Item 4) down so that the right angle slot slides around the bolt of the right battery.
2. Secure the ends of battery fuse (Figure 1, Item 4) to battery terminals (Figure 1, Item 9) with nuts (Figure 1,
Items 3 and 5).
3. Install black cable (Figure 1, Item 7) to negative (-) terminal of battery (Figure 1, Item 8) and secure with nut
(Figure 1, Item 6).
4. Install and secure rear access panel (Figure 1, Item 1).
5. Install cargo restraints (not shown).
6. Start Genset (Figure 1, Item 2) in accordance with Genset Start Procedure (WP 0005) of this TM.
0041-3
TM 11-6115-742-13&P 0041
TO
STARTER
3 4
5
(+) 6
(-) 7
(+)
(-)
8
Figure 1. Battery Fuse Removal/Replacement (Version 1).
END OF TASK
0041-4
TM 11-6115-742-13&P 0041
BATTERY FUSE, FUSE HOLDER, AND CABLES REMOVAL/REPLACEMENT (VERSION 2 AND 3)
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following service.
In event of a venting, clear area until pungent odor of Sulfur Dioxide is cleared.
Handle leaking batteries with rubber or plastic gloves. Get immediate medical
attention for any skin or respiratory irritation.
NOTE
The battery fuse for Version 2 and Version 3 are removed and replaced in the
same manner. For Version 1, refer to appropriate procedure earlier in this WP.
FUSE (VERSION 2 AND 3)
REMOVAL
1. Verify that Genset has been shut down, engine is cool, and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove access door (Figure 1, Item 1) from Genset (Figure 1, Item 2) and set aside.
3. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
this WP). (ALWAYS DISCONNECT GROUND WHEN CONDUCTING ANY PROCEDURES ON TRAILER).
4. Remove and retain two nuts (Figure 2, Item 5), lock washers (Figure 2, Item 4), and flat washers
(Figure 2, Item 3) that secure the fuse (Figure 2, Item 2) to the fuse holder (Figure 2, Item 8).
5. Remove and discard fuse (Figure 2, Item 2).
END OF TASK
0041-5
TM 11-6115-742-13&P 0041
REPLACEMENT
NOTE
Ensure that battery cables (Figure 2, Item 1) are installed onto fuse holder
(Figure 2, Item 8).
1. Install new battery fuse (Figure 2, Item 2) onto fuse holder (Figure 2, Item 8).
2. Secure using two nuts (Figure 2, Item 5), lock washers (Figure 2, Item 4), and flat washers (Figure 2, Item 3).
3. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in this WP).
4. Install and secure access door (Figure 1, Item 1) on Genset (Figure 1, Item 2).
5. Start Genset (Figure 1, Item 2) in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
CABLE AND FUSE HOLDER
REMOVAL
1. Verify that Genset (Figure 1, Item 2) has been shut down, engine is cool, and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove access door (Figure 1, Item 1) of Genset (Figure 1, Item 2) and set aside.
3. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
this WP). (ALWAYS DISCONNECT GROUND WHEN CONDUCTING ANY PROCEDURES ON TRAILER).
4. Remove insulator covers (Figure 2, Item 6) to allow access to hardware.
5. Remove and retain two nuts (Figure 2, Item 5), lock washers (Figure 2, Item 4), four flat washers (Figure 2,
Item 3), and one fuse (Figure 2, Item 2) that secure short battery cables (Figure 2, Item 1) to battery terminals
(Figure 2, Item 9) via fuse holder (Figure 2, Item 8).
6. Disconnect battery cable leads (Figure 2, Item 7) from positive and negative terminals (Figure 2, Item 10).
7. Remove battery cables (Figure 2, Item 1) from battery terminals (Figure 2, Item 9).
8. Remove fuse holder (Figure 2, Item 8). Discard if damaged.
END OF TASK
REPLACEMENT
1. Slide two insulator covers (Figure 2, Item 6) onto end of battery cables (Figure 2, Item 1) to be installed onto
fuse holder (Figure 2, Item 8).
2. Position fuse holder (Figure 2, Item 8), fuse (Figure 2, Item 2), and two battery cables (Figure 2, Item 1) onto
battery terminals (Figure 2, Item 9). Secure using two nuts (Figure 2, Item 5), lock washers (Figure 2, Item 4),
and four flat washers (Figure 2, Item 3).
3. Connect battery cables leads (Figure 2, Item 7) to positive and negative terminals (Figure 2, Item 10).
4. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in this WP).
0041-6
TM 11-6115-742-13&P 0041
REPLACEMENT – Continued
5. Install and secure access door (Figure 1, Item 1) on Genset (Figure 1, Item 2).
6. Start Genset (Figure 1, Item 2) in accordance with Genset Start Procedure (WP 0005) of this TM.
5
2
1
10
8 7
Figure 2. Battery Fuse (Version 2 and 3) and Associated Cables Removal/Replacement.
END OF TASK
0041-7
TM 11-6115-742-13&P 0041
WARNING
High DC voltage, (24 VDC) (12 VDC per battery), and amperage present at
electrical connections. Do not enter Genset when operational. To prevent
serious injury to personnel or damage to equipment, DO NOT enter enclosure
with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Never lay tools in or around battery area. Metal tools could cause batteries to
short and cause damage to batteries, electrical parts of engine, or injury to
personnel.
In event of a battery venting, clear area until pungent odor of Sulfur Dioxide is
cleared. Handle leaking batteries with acid resistant rubber or plastic gloves.
Get immediate medical attention for any skin or respiratory irritation.
NOTE
The following Removal/Replacement procedures for the battery, retainer, and
mounting bracket are for Version 1. For Version 2 or Version 3, refer to
appropriate procedure located in this WP.
RETAINER (VERSION 1)
REMOVAL
1. Verify that Genset (Figure 3, Item 4) has been shut down, engine is cool, and that BATTERY SWITCH is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove rear access panel (Figure 3, Item 3) of Genset (Figure 3, Item 4) and set aside.
4. Loosen two nuts (Figure 3, Item 10) and remove battery fuse (Figure 3, Item 9).
5. Remove battery retainers (Figure 3, Item 6) from batteries (Figure 3, Items 13 and 20) by removing two nuts
(Figure 3, Item 18) and flat washers (Figure 3, Item 19) from battery bolts (Figure 3, Item 1).
0041-8
TM 11-6115-742-13&P 0041
REMOVAL – Continued
NOTE
Cable clamp (Figure 3, Item 5) is present at one spot only.
6. Remove and retain cable clamp (Figure 3, Item 5). Lift retainer (Figure 3, Item 6), two bolts (Figure 3, Item 1),
and flat washers (Figure 3, Item 2) off of battery (Figure 3, Items 13 and 20).
END OF TASK
REPLACEMENT
1. Place battery retainers (Figure 3, Item 6) onto batteries (Figure 3, Items 13 and 20), aligning holes in retainer
(Figure 3, Item 6) with holes on mounting bracket (Figure 3, Item 17).
2. Insert two bolts (Figure 3, Item 1) and flat washers (Figure 3, Item 2). Install cable clamp (Figure 3, Item 5).
Secure using two nuts (Figure 3, Item 18) and flat washers (Figure 3, Item 19).
3. To ensure equal pressure, alternately tighten bolts (Figure 3, Item 1) until battery retainer (Figure 3, Item 6) is
secure.
4. Install battery fuse (Figure 3, Item 9). See Replacement procedure in this WP.
5. Install and secure access door (Figure 3, Item 3).
6. Install cargo restraints (not shown).
7. Start Genset (Figure 3, Item 4) in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
BATTERY (VERSION 1)
REMOVAL
WARNING
High DC voltage, (24 VDC) (12 VDC per battery), and amperage present at
electrical connections. Do not enter Genset when operational. To prevent
serious injury to personnel or damage to equipment, DO NOT enter enclosure
with Genset operating.
Depleted batteries should be turned in to designated personnel for disposal
processing (CDD activation) and disposal in accordance with local regulations or
through Defense Reutilization Marketing Office.
In event of a venting, clear area until pungent odor of Sulfur Dioxide is cleared.
Handle leaking batteries with rubber or plastic gloves. Get immediate medical
attention for any skin or respiratory irritation.
1. Verify that Genset (Figure 3, item 4) has been shut down, engine is cool, and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
0041-9
TM 11-6115-742-13&P 0041
REMOVAL – Continued
3. Remove rear access panel (Figure 3, Item 3) of Genset (Figure 3, Item 4) and set aside.
4. Remove battery fuse (Figure 3, Item 9). See Removal procedure described in this WP.
5. Remove nut (Figure 3, Item 11) that secures black cable (Figure 3, Item 12) to negative (-) terminal of battery
(Figure 2, Item 8). Disconnect black cable (Figure 2, Item 12) and move away from battery.
6. Remove and retain nut (Figure 3, Item 7) that secures red positive battery cables (Figure 3, Items 21 and 22)
to positive (+) terminal of battery (Figure 3, Item 8). Disconnect red cables (Figure 3, Items 21 and 22) and
move away from battery.
7. Remove cable clamp (Figure 3, Item 5) and black cable (Figure 3, Item 12) and move away from battery.
8. Remove two battery retainers (Figure 3, Item 6) and set aside. See Removal procedure described in this WP.
9. Remove batteries (Figure 3, Items 13 and 20) from battery bracket (Figure 3, Item 17) and set aside.
END OF TASK
REPLACEMENT
WARNING
When installing new battery, be observant of battery polarity (positive and
negative terminals). Like polarities should NOT be next to each other. Serious
injury to personnel or damage to equipment may occur.
NOTE
Ensure that hardware is present in battery terminals.
1. Set batteries (Figure 3, Items 13 and 20) into battery mounting bracket (Figure 3, Item 17).
2. Place two battery retainer(s) (Figure 3, Item 6) in approximate position over batteries (Figure 3, Items 13
and 20).
3. Install cable clamp (Figure 3, Item 5) and black cable (Figure 3, Item 12), bolt (Figure 3, Item 1) and flat
washer (Figure 3, Item 2), through battery retainer (Figure 3, Item 6) and mounting bracket (Figure 3,
Item 17). Secure with nut (Figure 3, Item 18) and flat washer (Figure 3, Items 19).
4. Loosely install three bolts (Figure 3, Item 1), flat washers (Figure 3, Item 2) through battery retainers
(Figure 3, Item 6) and mounting bracket (Figure 3, Item 17) secure with three nuts (Figure 3, Item 18) and flat
washers (Figure 3, Items 19).
5. To ensure equal pressure, alternately tighten nuts (Figure 3, Item 18) until battery retainer (Figure 3, Item 6) is
secure.
6. Install positive battery cables (Figure 3, Items 21 and 22) to positive (+) terminal of battery (Figure 3, Item 8)
and secure with nut (Figure 3, Item 7).
7. Install battery fuse (Figure 3, Item 9). See Replacement procedure described in this WP.
8. Install black cable (Figure 3, Item 12) to negative (-) terminal of battery (Figure 3, Item 8) and secure using
nut (Figure 3, Item 11).
0041-10
TM 11-6115-742-13&P 0041
REPLACEMENT – Continued
9. Install and secure access door (Figure 3, Item 3).
10. Install cargo restraints (not shown).
11. Start Genset (Figure 3, Item 4) in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
MOUNTING BRACKET (VERSION 1)
REMOVAL
1. Remove two batteries (Figure 3, Items 13 and 20). See Removal procedure described in this WP.
2. Remove and retain two bolts (Figure 3, Item 14), lock washers (Figure 3, Item 15), and flat washers (Figure 3,
Item 16) that secure battery mounting bracket (Figure 3, Item 17) to Genset (Figure 3, Item 9).
3. Remove and properly discard battery mounting bracket (Figure 3, Item 17).
END OF TASK
REPLACEMENT
1. Install battery mounting bracket (Figure 3, Item 17) into Genset (Figure 3, Item 4) and secure using two bolts
(Figure 3, Item 14), lock washers (Figure 3, Item 15), and flat washers (Figure 3, Item 16).
WARNING
When installing batteries, be observant of battery polarity (positive and negative
terminals). Like polarities should NOT be next to each other. Serious injury to
personnel or damage to equipment may occur.
2. Install two batteries (Figure 3, Items 13 and 20). See replacement procedure described in this WP.
3. Install cargo restraints (not shown).
4. Install and secure access door (Figure 3, Item 3).
5. Start Genset (Figure 3, Item 4) in accordance with Operation Under Usual Conditions (WP 0005) of this TM.
0041-11
TM 11-6115-742-13&P 0041
1
4
2
3
22
21
5
6
10
7
8 9
20
(+)
11
12
(-)
(+)
(-)
13
14
15
16
17
19
18
Figure 3. Battery, Retainer, and Mounting Bracket Removal/Replacement (Version 1).
END OF TASK
0041-12
TM 11-6115-742-13&P 0041
WARNING
High DC voltage, (24 VDC) (12 VDC per battery), and amperage present at
electrical connections. Do not enter Genset when operational. To prevent
serious injury to personnel or damage to equipment, DO NOT enter enclosure
with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Never lay tools in or around battery area. Metal tools could cause batteries to
short and cause damage to batteries, electrical parts of engine, or injury to
personnel.
In event of a battery venting, clear area until pungent odor of Sulfur Dioxide is
cleared. Handle leaking batteries with acid resistant rubber or plastic gloves.
Get immediate medical attention for any skin or respiratory irritation.
NOTE
The following Removal/Replacement procedures for the battery, retainer, and
mounting bracket are for Version 2. For Version 1 or Version 3, refer to
appropriate procedure located in this WP.
RETAINER (VERSION 2)
REMOVAL
1. Verify that Genset (Figure 4, Item 7) has been shut down, engine is cool, and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove rear access panel (Figure 4, Item 6) from Genset (Figure 4, Item 7) and set aside.
3. Move terminal cover (Figure 4, Item 10) to allow access to hardware and connections.
4. Disconnect negative battery cable (Figure 4, Item 11) from battery (Figure 4, Item 9) by removing nut (Figure
4, Item 12) and bolt (Figure 4, Item 19).
5. Remove battery fuse (Figure 4, Item 8). See Removal procedure in this WP.
0041-13
TM 11-6115-742-13&P 0041
REMOVAL – Continued
6. Move terminal cover (Figure 4, Item 3) and remove bolt (Figure 4, Item 21) and nut (Figure 4. Item 22) to
disconnect positive battery cables (Figure 4, Items 4 and 5) from battery (Figure 4, Item 20).
7. Remove battery retainers (Figure 4, Item 23) from batteries (Figure 4, Items 9 and 20) by removing two nuts
(Figure 4, Item 16) and flat washers (Figure 4, Item 17) from battery bolts (Figure 4, Item 1).
NOTE
Cable clamp (Figure 4, Item 2) is present at one spot only.
8. Remove and retain cable clamp (Figure 4, Item 2). Lift retainer (Figure 4, Item 23), two bolts (Figure 4,
Item 1), and flat washers (Figure 4, Item 24) off of batteries (Figure 4, Items 9 and 20).
END OF TASK
REPLACEMENT
1. Place battery retainers (Figure 4, Item 23) onto batteries (Figure 4, Items 9 and 20), aligning holes in retainer
(Figure 4, Item 23) with holes on mounting bracket (Figure 4, Item 18).
2. Insert two bolts (Figure 4, Item 1) and flat washers (Figure 4, Item 24). Install cable clamp (Figure 4, Item 2).
Secure using two nuts (Figure 4, Item 16) and flat washers (Figure 4, Item 17).
3. To ensure equal pressure, alternately tighten bolts (Figure 4, Item 1) until battery retainer (Figure 4, Item 23)
is secure.
4. Connect positive battery cables (Figure 4, Items 4 and 5) to battery (Figure 4, Item 20) and secure with bolt
(Figure 4, Item 21) and nut (Figure 4, Item 22). Cover connection with terminal cover (Figure 4, Item 3).
5. Install battery fuse (Figure 4, Item 8). See Replacement procedure in this WP.
6. Connect negative battery cable (Figure 4, Item 11) to battery (Figure 4, Item 9) and secure with bolt (Figure 4,
Item 19) and nut (Figure 4, Item 12). Cover connection with terminal cover (Figure 4, Item 10).
7. Install and secure access door (Figure 4, Item 6) to Genset (Figure 4, Item 7).
8. Start Genset (Figure 4, Item 7) in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
0041-14
TM 11-6115-742-13&P 0041
BATTERY (VERSION 2)
REMOVAL
WARNING
High DC voltage, (24 VDC) (12 VDC per battery), and amperage present at
electrical connections. Do not enter Genset when operational. To prevent
serious injury to personnel or damage to equipment, DO NOT enter enclosure
with Genset operating.
Deplete batteries should be turned in to designated personnel for disposal
processing (CDD activation) and disposal in accordance with local regulations or
through Defense Reutilization Marketing Office.
In event of a venting, clear area until pungent odor of Sulfur Dioxide is cleared.
Handle leaking batteries with rubber or plastic gloves. Get immediate medical
attention for any skin or respiratory irritation.
1. Verify that Genset (Figure 4, Item 7) has been shut down, engine is cool, and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear panel of Genset.
3. Remove access panel (Figure 4, Item 6) of Genset (Figure 4, Item 7) and set aside.
4. Remove and retain nut (Figure 4, Item 12) and bolt (Figure 4, Item 19) that secures black cable (Figure 4,
Item 11) to negative (-) terminal of battery (Figure 4, Item 9). Move black cable (Figure 4, Item 11) away from
battery (Figure 4, Item 9).
5. Remove battery fuse (Figure 4, Item 8). See Removal procedure described in the WP.
6. Remove and retain nut (Figure 4, Item 22) and bolt (Figure 2, Item 21) that secure positive battery cables
(Figure 4, Items 4 and 5) to positive (+) terminal of battery (Figure 4, Item 20).
7. Remove battery retainer (Figure 4, Item 23) and set aside. See Removal procedure described in this WP.
8. Remove batteries (Figure 4, Items 9 and 20) from battery bracket (Figure 4, Item 18) and set aside.
END OF TASK
0041-15
TM 11-6115-742-13&P 0041
REPLACEMENT
WARNING
When installing a new battery, be observant of polarity (positive and negative
terminals). Like polarities should NOT be next to each other. Serious injury to
personnel or damage to equipment may occur.
NOTE
Ensure that hardware is present in battery terminals.
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for generic torque requirements.
1. Set batteries (Figure 4, Items 9 and 20) into battery mounting bracket (Figure 4, Item 18).
2. Place two battery retainer(s) (Figure 4, Item 23) in approximate position over batteries (Figure 4, Items 9
and 20).
3. Insert black cable (Figure 4, Item 11) through cable clamp (Figure 4, Item 2) and position cable clamp over
battery retainer (Figure 4, Item 23).
4. Loosely install four bolts (Figure 4, Item 1) and flat washers (Figure 4, Item 24), through battery retainers
(Figure 4, Item 23) and mounting bracket (Figure 4, Item 18) and secure with four flat washers (Figure 4,
Item 17) and nuts (Figure 4, Item 16). For more detailed information on the replacement of the battery
retainers, see Retainer Replacement procedure in this WP.
5. To ensure equal pressure, alternately tighten nuts (Figure 4, Item 16) until battery retainer (Figure 4, Item 23)
is secure.
6. Install positive battery cables (Figure 4, Items 4 and 5) to positive (+) terminal of battery (Figure 4, Item 20)
and secure with bolt (Figure 4, Item 21) and nut (Figure 4, Item 22). Cover connection with terminal cover
(Figure 4, Item 3).
7. Install battery fuse (Figure 4, Item 8). See Replacement procedure described in this WP.
8. Install black cable (Figure 4, Item 11) to negative (-) terminal of battery (Figure 4, Item 9) and secure with bolt
(Figure 4, Item 19) and nut (Figure 4, Item 12). Cover connection with terminal cover (Figure 4, Item 10).
9. Install and secure access door (Figure 4, Item 6) onto Genset (Figure 4, Item 7).
10. Install cargo restraints (not shown).
11. Start Genset (Figure 4, Item 7) in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
0041-16
TM 11-6115-742-13&P 0041
MOUNTING BRACKET (VERSION 2)
REMOVAL
1. Verify that Genset (Figure 4, Item 7) has been shut down, engine is cool, and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove access door (Figure 4, Item 6) from Genset (Figure 4, Item 7) and set aside.
3. Remove two batteries (Figure 4, Items 9 and 20). See Removal procedure described in this WP.
4. Remove and retain two bolts (Figure 4, Item 13), lock washers (Figure 4, Item 14), and flat washers (Figure 4,
Item 15) that secure battery mounting bracket (Figure 4, Item 18) to Genset (Figure 4, Item 7).
5. Remove and properly discard battery mounting bracket (Figure 4, Item 18).
END OF TASK
REPLACEMENT
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for generic torque requirements.
1. Install battery mounting bracket (Figure 4, Item 18) into Genset (Figure 4, Item 7) and secure using two bolts
(Figure 4, Item 13), lock washers (Figure 4, Item 14), and flat washers (Figure 4, Item 15).
WARNING
When installing a new battery, be observant of polarity (positive and negative
terminals). Like polarities should NOT be next to each other. Serious injury to
personnel or damage to equipment may occur.
2. Install two batteries (Figure 4, Items 9 and 20). See Replacement procedure described in this WP.
3. Install and secure access door (Figure 4, Item 6) onto Genset (Figure 4, Item 7).
4. Start Genset (Figure 4, Item 7) in accordance with Genset Start Procedure (WP 0005) of this TM.
0041-17
TM 11-6115-742-13&P 0041
7
24
3
4 5
23
22
8
9
21
10 11
20
19
13
12
14
18
15
17
16
Figure 4. Battery, Retainer, and Mounting Bracket Removal/Replacement (Version 2).
END OF TASK
0041-18
TM 11-6115-742-13&P 0041
WARNING
High DC voltage, (24 VDC) (12 VDC per battery), and amperage present at
electrical connections. Do not enter Genset when operational. To prevent
serious injury to personnel or damage to equipment, DO NOT enter enclosure
with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Never lay tools in or around battery area. Metal tools could cause batteries to
short and cause damage to batteries, electrical parts of engine, or injury to
personnel.
In event of a battery venting, clear area until pungent odor of Sulfur Dioxide is
cleared. Handle leaking batteries with acid resistant rubber or plastic gloves.
Get immediate medical attention for any skin or respiratory irritation.
NOTE
The following Removal/Replacement procedures for the battery, retainer, and
mounting bracket are for Version 3. For Version 1 or Version 2, refer to
appropriate procedure located in this WP.
RETAINER (VERSION 3)
REMOVAL
1. Verify that Genset (Figure 5, Item 11) has been shut down, engine is cool, and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove rear access panel (Figure 5, Item 7) from Genset (Figure 5, Item 11) and set aside.
4. Remove two nuts (Figure 5, Item 15) and bolts (Figure 5, Item 13) that secure negative battery cable
(Figure 5, Item 16) to battery (Figure 5, Item 21) via terminal lug (Figure 5, Item 14). Remove terminal lug
(Figure 5, Item 14) and set off to side.
5. Remove battery fuse (Figure 5, Item 12). See Removal procedure in this WP.
0041-19
TM 11-6115-742-13&P 0041
REMOVAL – Continued
6. Remove two nuts (Figure 5, Item 26) and bolts (Figure 5, Item 10) that secure positive battery cables
(Figure 5, Items 2 and 8) to battery (Figure 5, Item 25) via terminal lug (Figure 5, Item 9) and terminal cover
(Figure 5, Item 27). Remove terminal lug (Figure 5, Item 9) and set off to side.
7. Remove bolt (Figure 5, Item 6), lock washer (Figure 5, Item 5), flat washer (Figure 5, Item 4) and two cable
clamps (Figure 5, Item 3) that secure positive battery cables (Figure 5, Items 2 and 8) to battery
(Figure 5, Item 25).
8. Remove battery retainer (Figure 5, Item 28) by removing two nuts (Figure 5, Item 22) and flat washers (Figure
5, Item 23) from battery bolts (Figure 5, Item 1). Remove and retain cable clamp (Figure 5, Item 30). Lift
retainer (Figure 5, Item 28), two bolts (Figure 5, Item 1), and flat washers (Figure 5, Item 29) off of batteries
(Figure 5, Items 21 or 25).
END OF TASK
REPLACEMENT
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for generic torque requirements.
1. Place battery retainer(s) (Figure 5, Item 28) onto batteries (Figure 5, Items 21 or 25), aligning holes in retainer
(Figure 5, Item 28) with holes on mounting bracket (Figure 5, Item 24).
2. Insert two bolts (Figure 5, Item 1) and flat washers (Figure 5, Item 29). Install cable clamp (Figure 5, Item 30).
Secure using two nuts (Figure 5, Item 22) and flat washers (Figure 5, Item 23).
3. To ensure equal pressure, alternately tighten bolts (Figure 5, Item 1) until battery retainer (Figure 5, Item 28)
is secure.
4. Position terminal lug (Figure 5, Item 9) onto positive (+) terminal on battery (Figure 5, Item 25).
5. Connect positive battery cables (Figure 5, Items 2 and 8) and secure with two bolts (Figure 5, Item 10) and
nuts (Figure 5, Item 26) via terminal lug (Figure 5, Item 9) and cover terminal (Figure 5, Item 27).
6. Position terminal lug (Figure 5, Item 14) onto negative (-) terminal on battery (Figure 4, Item 21).
7. Connect negative battery cable (Figure 5, Item 16) and secure with two bolts (Figure 5, Item 13) and nuts
(Figure 5, Item 15) via terminal lug (Figure 5, Item 14).
8. Install battery fuse (Figure 5, Item 12). See Replacement procedure in this WP.
9. Secure positive cables (Figure 5, Items 2 and 8) with bolt (Figure 5, Item 6), lock washer (Figure 5, Item 5),
flat washer (Figure 5, Item 4), and two cable clamps (Figure 5, Item 3).
10. Install and secure access door (Figure 5, Item 7) onto Genset (Figure 5, Item 11).
11. Install cargo restraints (not shown).
12. Start Genset (Figure 5, Item 11) in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
0041-20
TM 11-6115-742-13&P 0041
BATTERY (VERSION 3)
REMOVAL
WARNING
High DC voltage, (24 VDC) (12 VDC per battery), and amperage present at
electrical connections. Do not enter Genset when operational. To prevent
serious injury to personnel or damage to equipment, DO NOT enter enclosure
with Genset operating.
Deplete batteries should be turned in to designated personnel for disposal
processing (CDD activation) and disposal in accordance with local regulations or
through Defense Reutilization Marketing Office.
In event of a venting, clear area until pungent odor of Sulfur Dioxide is cleared.
Handle leaking batteries with rubber or plastic gloves. Get immediate medical
attention for any skin or respiratory irritation.
1. Verify that Genset (Figure 5, Item 11) has been shut down, engine is cool, and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear panel of Genset.
3. Remove access panel (Figure 5, Item 7) of Genset (Figure 5, Item 11) and set aside.
4. Remove two nuts (Figure 5, Item 15) and bolts (Figure 5, Item 13) that secure black cable (Figure 5, Item 16)
to negative (-) terminal of battery (Figure 5, Item 21) via terminal lug (Figure 5, Item 14). Move black cable
(Figure 5, Item 16) away from battery (Figure 5, Item 21).
5. Remove battery fuse (Figure 5, Item 12). See Removal procedure described in this WP.
6. Remove two nuts (Figure 5, Item 26) and bolts (Figure 5, Item 10) that secure positive battery cables
(Figure 5, Items 2 and 8) to positive (+) terminal of battery (Figure 5, Item 25) via terminal lug (Figure 5,
Item 9) and terminal cover (Figure 5, Item 27). Move positive cables (Figure 5, Items 2 and 8) away from
battery (Figure 5, Item 25).
7. Remove battery retainer (Figure 5, Item 28) and set aside. See Removal procedure described in this WP.
8. Remove batteries (Figure 5, Items 21 and 25) from battery bracket (Figure 5, Item 24) and set aside.
END OF TASK
0041-21
TM 11-6115-742-13&P 0041
REPLACEMENT
WARNING
When installing a new battery, be observant of polarity (positive and negative
terminals). Like polarities should NOT be next to each other. Serious injury to
personnel or damage to equipment may occur.
NOTE
Ensure that hardware is present in battery terminals.
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for generic torque requirements.
1. Set batteries (Figure 5, Items 21 and 25) into battery mounting bracket (Figure 5, Item 24).
2. Place two battery retainer(s) (Figure 5, Item 28) in approximate position over batteries (Figure 5, Items 21
and 25).
3. Install battery retainers (Figure 5, Item 28) as described in this WP.
4. Position terminal lug (Figure 5, Item 9) onto positive (+) terminal on battery (Figure 5, Item 25).
5. Install positive battery cables (Figure 5, Items 2 and 8) to positive (+) terminal of battery (Figure 5, Item 25)
and secure with two bolts (Figure 5, Item 10) and nuts (Figure 5, Item 26) via terminal lug (Figure 5, Item 9)
and terminal cover (Figure 5, Item 27).
6. Install battery fuse (Figure 5, Item 12). See Replacement procedure described in this WP.
7. Position terminal lug (Figure 5, Item 14) onto (-) terminal on battery (Figure 5, Item 21).
8. Install negative battery cable (Figure 5, Item 16) to negative (-) terminal of battery (Figure 5, Item 21) and
secure with two bolts (Figure 5, Item 13) and nuts (Figure 5, Item 15) via terminal lug (Figure 5, Item 14).
9. Install and secure access door (Figure 5, Item 7) onto Genset (Figure 5, Item 11).
10. Install cargo restraints (not shown).
11. Start Genset (Figure 5, Item 11) in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
0041-22
TM 11-6115-742-13&P 0041
MOUNTING BRACKET (VERSION 3)
REMOVAL
1. Verify that Genset (Figure 5, item 11) has been shut down, engine is cool and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove access door (Figure 5, Item 7) of Genset (Figure 5, Item 11) and set aside.
3. Remove two batteries (Figure 5, Items 21 and 25). See Removal procedure described in this WP.
4. Remove and retain two bolts (Figure 5, Item 18), lock washers (Figure 5, Item 19), and flat washers (Figure 5,
Item 20) that secure battery mounting bracket (Figure 5, Item 24) to Genset (Figure 5, Item 11).
5. Remove and properly discard battery mounting bracket (Figure 5, Item 24).
END OF TASK
REPLACEMENT
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for generic torque requirements.
1. Install battery mounting bracket (Figure 5, Item 24) into Genset (Figure 5, Item 11) and secure using two bolts
(Figure 5, Item 18), lock washers (Figure 5, Item 19), and flat washers (Figure 5, Item 20).
WARNING
When installing a new battery, be observant of polarity (positive and negative
terminals). Like polarities should NOT be next to each other. Serious injury to
personnel or damage to equipment may occur.
2. Install two batteries (Figure 5, Items 21 and 25). See Replacement procedure described in this WP.
3. Install and secure access door (Figure 5, Item 7) to Genset (Figure 5, Item 11).
4. Start Genset (Figure 5, Item 11) in accordance with Genset Start Procedure (WP 0005) of this TM.
0041-23
TM 11-6115-742-13&P 0041
6
5 7
4 3
3
1 8
2
10
9 10
26 11
30
29
27 12
15
28 26 14
13
25 16
17
21
24
18
23
19
22 20
Figure 5. Battery, Retainer, and Mounting Bracket Removal/Replacement (Version 3).
END OF TASK
0041-24
TM 11-6115-742-13&P 0041
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Ensure that TMSS-MED is level and ground is stable (not soggy or soft). Trailer
could sink into soft or unstable ground. Injury to personnel or damage to TMSS-
MED trailer and/or its components could result from trailer suddenly rolling or
tipping.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following service.
NOTE
The following Removal/Replacement procedure for the battery warmer is for
Version 1. For Version 2 or Version 3, refer to appropriate procedure located in
this WP.
BATTERY WARMER (VERSION 1)
REMOVAL
1. Verify that Genset (Figure 6, Item 2) has been shut down, engine is cool, and that BATTERY switch is set to
OFF (WP 0005, Genset Stop Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel (Figure 6, Item 1) of Genset.
3. Remove rear access panel (Figure 6, Item 1) from Genset (Figure 6, Item 2) and set aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
this WP) or, if necessary, remove batteries as described in this WP.
0041-25
TM 11-6115-742-13&P 0041
REMOVAL – Continued
NOTE
When performing the following step, use two wrenches. One to loosen hose
(Figure 6, Item 3) and one to keep associated hardware on battery warmer
(Figure 6, Item 4) stationary.
5. Disconnect two hoses (Figure 6, Item 3) (located on under side of Genset) from battery warmer (Figure 6,
Item 4) and place into drain bucket.
NOTE
The following step may require two personnel.
6. Remove and retain bolt (Figure 6, Item 8), flat washer (Figure 6, Item 7), lock washer (Figure 6, Item 6), and
nut (Figure 6, Item 5) that secure battery warmer (Figure 6, Item 4) to Genset (Figure 6, Item 2).
7. Remove battery warmer (Figure 6, Item 4).
END OF TASK
REPLACEMENT
1. Wrap threads on battery warmer (Figure 6, Item 4) with anti-seize tape.
NOTE
The following step may require two personnel.
2. Install battery warmer (Figure 6, Item 4) to underside of Genset (Figure 6, Item 2) and secure with bolt
(Figure 6, Item 8), flat washer (Figure 6, Item 7), lock washer (Figure 6, Item 6), and nut (Figure 6, Item 5).
Tighten hardware finger loose at this time.
NOTE
When performing the following step, use two wrenches, one to tighten hose
(Figure 6, Item 3) and one to keep associated hardware on battery warmer
(Figure 6, Item 4) stationary.
3. Connect two hoses (Figure 6, Item 3) (located on under side of Genset) to battery warmer (Figure 6, Item 4).
4. Finish tightening bolt (Figure 6, Item 8), flat washer (Figure 6, Item 7), lock washer (Figure 6, Item 6), and nut
(Figure 6, Item 5).
5. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in this WP or
if batteries were removed to perform this procedure, reinstall batteries as described in this WP).
6. Install and secure rear access panel (Figure 6, Item 1) on Genset (Figure 6, Item 2).
7. Install cargo restraints (not shown).
8. Start Genset (Figure 6, Item 2) in accordance with Genset Start Procedure (WP 0005) of this TM.
0041-26
TM 11-6115-742-13&P 0041
2
1
4
7
6
5
Figure 6. Battery Warmer Removal/Replacement (Version 1).
END OF TASK
0041-27
TM 11-6115-742-13&P 0041
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Ensure that TMSS-MED is level and ground is stable (not soggy or soft). Trailer
could sink into soft or unstable ground. Injury to personnel or damage to TMSS-
MED trailer and/or its components could result from trailer suddenly rolling or
tipping.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following service.
NOTE
The battery warmer for Version 2 and Version 3 are removed and replaced in the
same manner. For Version 1, refer to procedure earlier in this WP.
BATTERY WARMER (VERSION 2 AND 3)
REMOVAL
1. Verify that Genset (Figure 7, Item 2) has been shut down, engine is cool, and that BATTERY switch is set to
OFF (WP 0005, Genset Stop Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel (Figure 7, Item 1) of Genset.
3. Remove rear access panel (Figure 7, Item 1) of Genset (Figure 7, Item 2) and set aside.
4. Disconnect battery ground cable (black) from battery ground terminal (Figure 7, Item 3) (if necessary, refer to
procedure in this WP) or, if necessary, remove batteries as described in this WP.
0041-28
TM 11-6115-742-13&P 0041
REMOVAL – Continued
NOTE
When performing the following step, use two wrenches. One to loosen hose
(Figure 7, Item 4) and one to keep associated hardware on battery warmer
(Figure 7, Item 5) stationary.
5. Disconnect two hoses (Figure 7, Item 4) (located on underside of Genset) from battery warmer
(Figure 7, Item 5) and place into drain bucket.
NOTE
The following step may require two personnel.
6. Remove and retain bolt (Figure 7, Item 9), two flat washers (Figure 7, Items 7 and 8), and nut (Figure 7,
Item 6) that secure battery warmer (Figure 7, Item 5) to Genset (Figure 7, Item 2).
7. Remove battery warmer (Figure 7, Item 5).
END OF TASK
REPLACEMENT
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for generic torque requirements.
1. Wrap threads on battery warmer (Figure 7, Item 5) with anti-seize tape.
NOTE
The following step may require two personnel.
2. Install battery warmer (Figure 7, Item 5) to underside of Genset (Figure 7, Item 2) and secure with bolt
(Figure 7, Item 9), two flat washers (Figure 7, Items 7 and 8), and nut (Figure 7, Item 6). Tighten hardware
finger loose at this time.
NOTE
When performing the following step, use two wrenches, one to tighten hose
(Figure 7, Items 4) and one to keep associated hardware on battery warmer
(Figure 7, Item 5) stationary.
3. Connect two hoses (Figure 7, Item 4) (located on underside of Genset) to battery warmer (Figure 7, Item 5).
4. Finish tightening bolt (Figure 7, Item 9), flat washers (Figure 7, Items 7 and 8), and nut (Figure 7, Item 6).
5. Connect battery ground cable (black) to battery ground terminal (Figure 7, Item 3) (if necessary, refer to
procedure in this WP or if batteries were removed to perform this procedure, reinstall batteries as described in
this WP).
6. Install and secure rear access panel (Figure 7, Item 1).
7. Install cargo restraints (not shown).
8. Start Genset (Figure 7, Item 2) in accordance with Genset Start Procedure (WP 0005) of this TM.
0041-29
TM 11-6115-742-13&P 0041
7
5
Figure 7. Battery Warmer Removal/Replacement (Version 2 and 3).
END OF TASK
END OF WORK PACKAGE
0041-30
TM 11-6115-742-13&P 0042
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET OIL AND OIL FILTER
OIL AND OIL FILTER REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit One
(WP 0165, Item 1)
Drain pan References
Oil filter wrench WP 0005, WP 0041
Materials/Parts
Oil filter Equipment Condition
Oil (WP 0168, Items 35 or 36) Genset shut down
Cloth, cleaning (WP 0168, Item 14) BATTERY SWITCH - OFF
Teflon tape (WP 0168, Item 58)
Rubber gloves (WP 0168, Item 24)
GENERAL
This work package provides information on the service, removal and replacement of the oil and oil filter for the
Genset engine.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset is in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
0042-1
TM 11-6115-742-13&P 0042
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
NOTE
If needed, run the Genset (Figure 1, Item 1) to bring engine to operating
temperature.
1. Verify that Genset has been shut down, engine is cool, and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove the front and rear access panels (Figure 1, Items 2 and 5) on Genset (Figure 1, Item 1) and set
aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
Oil drain plug (Figure 1, Item 7) is located on the front base of the Genset
enclosure.
5. Place drain pan under oil drain plug (Figure 1, Item 7). Remove and retain oil drain plug (Figure 1, Item 7).
NOTE
If an oil drain hose is available, insert one end into the engine oil outlet and place
opposite end in drain pan. Use of an oil drain hose will reduce spillage.
Collect oil in an appropriate chemical-resistant container for disposal through the
local servicing Defense Reutilization and Marketing Office.
6. Open the engine oil drain valve (Figure 1, Item 6) inside the Genset enclosure. Drain oil into drain pan.
0042-2
TM 11-6115-742-13&P 0042
REMOVAL - Continued
NOTE
Prior to performing the following step, place absorbent towels under oil filter.
When performing the following step, be observant of all items around the oil filter.
7. Loosen oil filter (Figure 1, Item 3) from oil filter mount (Figure 1, Item 4) with oil filter wrench until finger loose.
Finish removing oil filter by hand.
8. Discard oil, oil filter, and any oil soaked rags in accordance with proper HAZMAT procedures.
9. Using a clean lint free cloth clean the oil filter mount.
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following step, inspect oil filter for gasket. Inspect gasket
for cuts, nicks, or other damage. If gasket is missing or damaged, do not use oil
filter.
1. Using clean oil, apply a thin coat of oil to the oil filter seal.
CAUTION
When the following step is being performed, do not force oil filter (Figure 1,
Item 3) or cross thread. Failure to observe this caution can result in damage to
the engine.
2. Install oil filter (Figure 1, Item 3) onto oil filter mount (Figure 1, Item 4). Tighten until hand tight.
NOTE
When performing the following step, DO NOT over tighten oil filter (Figure 1,
Item 3).
3. Tighten oil filter (Figure 1, Item 3) an additional ¼ turn with oil filter wrench.
4. If using a drain hose, remove hose and close oil drain valve (Figure 1, Item 6).
5. Wrap oil drain plug (Figure 1, Item 7) with Teflon tape, install, and tighten.
6. Remove and retain oil filler cap.
NOTE
When performing the following step, use heave duty lubricating oil meeting the
requirements of MIL-L-2104C/D, AAPICD Series 3. See Engine Oil Recommendations
(Table 1) for proper oil viscosity.
Refer to Expendable and Durable Items (WP 0165) for NSN and other information on oil
listed in table below.
0042-3
TM 11-6115-742-13&P 0042
REPLACEMENT – Continued
NOTE
When performing the following step, DO NOT over fill engine.
7. Add 8.6 quarts (8.13 liters) of oil to engine and allow oil to settle (approximately 1 min).
8. Check engine oil level at dipstick. If necessary, add more oil until dipstick reads between lines.
9. Replace engine oil filler cap.
10. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
11. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM and allow engine to run for a
few minutes to circulate oil through engine.
12. Shut down the Genset in accordance with Genset Stop Procedure (WP 0005) and allow a few minutes for the
oil to settle.
NOTE
Engine must be turned off to obtain an accurate reading on the dipstick. The
reading on the dipstick should be between the two marks on the dipstick.
13. Check oil level with the dipstick. If oil level is still low, add additional oil. If dipstick indicates proper oil level,
re-insert the dipstick and verify that oil filler cap is secure.
14. Wipe off any oil that has spilled.
15. Install front and rear access panels (Figure 1, Items 2 and 5).
16. Install cargo restraints (not shown).
17. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
Table 1. Engine Oil Recommendations.
Ambient Mono- Multi-
Temperature grade Grade
Below 5°F (–15°C) 5W 5W/20
Between 5°F (–15°C) and 50°F (10°C) 10W 10W/30
Between 40°F (5°C) and 85°F (30°C) 20W 10W/30 or 15W/40
Above 85°F (30°C) 30W 15W/40 or 20W/40
0042-4
TM 11-6115-742-13&P 0042
63
7
4
56
35
7
4
Figure 1. Oil and Filter Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0042-5/6 blank
TM 11-6115-742-13&P 0043
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET AIR FILTER
AIR INTAKE FILTER REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit (WP 0165, Item 1) WP 0005
Safety Glasses
Materials/Parts Equipment Condition
Air filter Genset shut down
BATTERY SWITCH - OFF
Personnel Required
One
GENERAL
This work package provides information on the removal/replacement of the Genset air intake filter.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
In event of a venting, clear area until pungent odor of Sulfur Dioxide is cleared.
Handle leaking batteries with rubber or plastic gloves. Get immediate medical
attention for any skin or respiratory irritation.
0043-1
TM 11-6115-742-13&P 0043
WARNING
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing the following service.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel (Figure1, Item 2) of Genset
(Figure1, Item 6).
3. Remove rear access panel (Figure1, Item 2) of Genset (Figure1, Item 6) and set aside.
4. Open clasps (Figure1, Item 3) on engine air intake filter cover (Figure1, Item 4). Remove air intake filter cover
(Figure1, Item 4) and set aside.
5. Remove air intake filter (Figure1, Item 1) and properly discard.
END OF TASK
REPLACEMENT
1. Insert new air intake filter (Figure1, Item 1).
NOTE
Drain (Figure1, Item 5) on air intake filter cover (Figure1, Item 4) should face
down.
When air intake filter cover (Figure1, Item 4) is properly locked into place, cover
should not rotate.
2. Replace air intake filter cover (Figure1, Item 4) and rotate slightly to ensure proper seating.
3. Align clasps (Figure1, Item 3) on engine air intake filter cover (Figure1, Item 4) and secure.
4. Install rear access panel (Figure1, Item 2) of Genset (Figure1, Item 6).
0043-2
TM 11-6115-742-13&P 0043
REPLACEMENT – Continued
5. Install cargo restraints (not shown).
6. Start Genset (Figure1, Items 6) in accordance with Genset Start Procedure (WP 0005) of this TM.
1
5
5
6 4 3
16
Figure 1. Air Intake Filter Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0043-3/4 blank
TM 11-6115-742-13&P 0044
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET FUEL FILTER
FUEL FILTER REMOVAL/INSPECT/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic's tool kit, (WP 0165, Item 1) One
Drain pan
Oil filter wrench References
Rubber gloves (WP 0168, Item 24) WP 0005, WP 0041, WP 0045
Safety Glasses
Equipment Condition
Materials/Parts Genset shut down
Fuel filter BATTERY SWITCH - OFF
GENERAL
This work package provides information on the services and removal/replacement of the Genset fuel filter. If
necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
0044-1
TM 11-6115-742-13&P 0044
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following procedure.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
REMOVAL
NOTE
If needed, run the Genset (Figure 1, Item 1) to bring engine to operating
temperature.
1. Verify that Genset (Figure 1, Item 4) has been shut down, engine is cool, and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove rear access panel (Figure 1, Item 2) and set aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
The fuel filter (Figure 1, Item 1) is located by the batteries and the low oil
pressure cut-off SWITCH.
Place absorbent pads under fuel filter (Figure 1, Item 1) to catch any spillage.
5. Using the oil filter wrench, loosen fuel filter (Figure 1, Item 1).
6. Remove fuel filter (Figure 1, Item 1) and pour fuel into a clean clear container.
END OF TASK
0044-2
TM 11-6115-742-13&P 0044
INSPECT
1. After fuel filter has been removed, inspect fuel filter (Figure 1, Item 1) and fuel for signs of water or sediment.
If excessive sediment or water is found, drain fuel tank, as described in (WP 0045), and replace fuel filter
(Figure 1, Item 1).
END OF TASK
REPLACEMENT
1. Fill fuel filter (Figure 1, Item 1) with clean fuel.
2. Install fuel filter (Figure 1, Item 1) onto fuel filter mount (Figure 1, Item 3). Tighten until hand tight.
NOTE
When performing the following step, DO NOT over tighten fuel filter (Figure 1,
Item 1).
3. Tighten fuel filter (Figure 1, Item 1) an additional 1/4 turn with oil filter wrench.
4. Prime the fuel system.
5. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM) and install rear access panel (not shown).
6. Install access panel (Figure 1, Item 2).
7. Install cargo restraints (not shown).
8. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0044-3
TM 11-6115-742-13&P 0044
1
2
4 3
Figure 1. Fuel Filter Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0044-4
TM 11-6115-742-13&P 0045
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET FUEL TANK
FUEL TANK SERVICE
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit, (WP 0165, Item 1) WP 0005
Rubber gloves (WP 0168, Item 24)
Safety Glasses Equipment Condition
Drain pan Genset shut down
Funnel BATTERY SWITCH – OFF
Personnel Required)
One
GENERAL
This work package provides information on the services and removal/replacement of the Genset fuel filter and fuel
tank. If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0045-1
TM 11-6115-742-13&P 0045
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
SERVICE
WARNING
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT
perform maintenance with Genset operating.
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Ensure that TMSS-MED is level and ground is stable (not soggy or soft). Trailer
could sink into soft or unstable ground. Injury to personnel, or damage to TMSS-
MED trailer and/or its fluid and components could result from trailer suddenly
rolling or tipping.
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
1. Verify that Genset (Figure 1, Item 1) has been shut down, engine is cool, and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Stop Procedure).
NOTE
The drain valve is located under the trailer behind the curbside tire. If necessary,
remove fuel cap to expedite fuel flow.
Collect fuel in an appropriate chemical-resistant container for disposal through
the local servicing Defense Reutilization and Marketing Office.
2. Open fuel cap.
3. Place drain pan under drain valve (Figure 1, Item 2).
4. Remove and retain plug (Figure 1, Item 3) and open drain valve (Figure 1, Item 2).
5. Once fuel tank is empty, close drain valve (Figure 1, Item 2) and install drain plug (Figure 1, Item 3).
0045-2
TM 11-6115-742-13&P 0045
SERVICE – Continued
6. Replenish fuel tank.
7. Start Genset (Figure 1, Item 1) in accordance with Genset Start Procedure (WP 0005) of this TM.
Figure 1. Genset Fuel Tank Drain Location.
END OF TASK
END OF WORK PACKAGE
0045-3/4 blank
TM 11-6115-742-13&P 0046
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET LOW OIL PRESSURE CUT-OFF SWITCH
LOW OIL PRESSURE CUT-OFF SWITCH REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit (WP 0165, Item 1) WP 0005, WP 0041
Safety glasses
Materials/Parts Equipment Condition
Low oil pressure cut-off switch Genset shut down
Anti-seize compound (WP 0168, Item 3) BATTERY SWITCH - OFF
Cloth, cleaning (WP 0168, Item 14)
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of the Genset low oil pressure cut off
switch. If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
0046-1
TM 11-6115-742-13&P 0046
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset (Figure 1, Item 1).
3. Remove the access panel (Figure 1, Item 2) and set aside.
NOTE
The low oil pressure cut-off switch (Figure 1, Item 5) is located on the right side
of engine next to oil pressure sending unit.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
5. Remove two flat tip screws (Figure 1, Item 4) securing wires (Figure 1, Item 3) to low oil pressure cut-off
switch (Figure 1, Item 5). Mark and disconnect wires (Figure 1, Item 3).
NOTE
Use a second wrench to keep mounting elbow from turning.
Be cautious of items surrounding low oil pressure cut-off switch (Figure 1,
Item 5).
0046-2
TM 11-6115-742-13&P 0046
REMOVAL – Continued
6. Remove low oil pressure cut-off switch (Figure 1, Item 5) from engine.
END OF TASK
REPLACEMENT
1. Clean off old anti-seize compound from all threaded areas.
WARNING
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
NOTE
Do not get anti-seize compound on end of low oil pressure cut-off switch
(Figure 1, Item 5).
2. Apply anti-seize compound to threads of low oil pressure cut-off switch (Figure 1, Item 5).
CAUTION
When the following step is being performed, do not force low oil pressure cut-off
switch (Figure 1, Item 5) or cross thread. Failure to observe this caution can
result in damage to the engine.
NOTE
When performing the following step, use a second wrench to keep mounting
elbow from turning.
3. Install low oil pressure cut-off switch (Figure 1, Item 5) onto mounting elbow and tighten.
NOTE
Prior to performing the following step, inspect wires (Figure 1, Item 3) and
terminal for connectivity. Ensure that wire has not become brittle and that there
are no nicks, cuts or other damage to wire.
4. Install wires (Figure 1, Item 3) onto low oil pressure cut-off switch (Figure 1, Item 5) and secure with flat tip
screws (Figure 1, Item 4).
5. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
6. Install access panel (Figure 1, Item 2).
7. Install cargo restraints (not shown).
REPLACEMENT- Continued
0046-3
TM 11-6115-742-13&P 0046
8. Start Genset (Figure 1, Item 1) in accordance with Genset Start Procedure (WP 0005) of this TM.
Figure 1. Low Oil Pressure Cut-Off Switch Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0046-4
TM 11-6115-742-13&P 0047
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET ELECTRIC FUEL PUMP
ELECTRIC FUEL PUMP REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit, (WP 0165, Item 1) WP 0005, WP 0041
Safety Glasses
Equipment Condition
Materials/Parts Genset shut down
Electric fuel pump BATTERY SWITCH - OFF
Cloth, cleaning (WP 0168, Item 14)
Personnel Required
One
GENERAL
This work package provides information on the services and removal/replacement of the Genset electric fuel
pump. If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
0047-1
TM 11-6115-742-13&P 0047
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following procedure.
1. Verify that Genset (Figure 1, Item 1) has been shut down, engine is cool and that BATTERY SWITCH is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel (Figure 1, Item 2).
3. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
The electric fuel pump (Figure 1, Item 4) is located above the oil filter.
4. Disconnect electrical pig tail (Figure 1, Item 11) from wiring harness.
5. Remove and retain nut (Figure 1, Item 12) from electric fuel pump mounting bracket (Figure 1, Item 14) and
mounting plate (Figure 1, Item 15).
6. Disconnect electric fuel pump ground wire (Figure 1, Item 13).
0047-2
TM 11-6115-742-13&P 0047
REMOVAL – Continued
NOTE
Fuel lines may still have fuel present or be under pressure. Care must be taken
to prevent fuel from spilling and to avoid exposure of skin to diesel fuel.
7. Loosen two clamps (Figure 1, Item 5) and disconnect input and output fuel lines (Figure 1, Items 6 and 10).
8. Remove and retain two bolts (Figure 1, Item 9), flat washers (Figure 1, Item 8), and rubber grommets
(Figure 1, Item 7).
9. If necessary, remove bolt (Figure 1, Item 3) to remove fuel pump mounting bracket (Figure 1, Item 14).
Discard if damaged.
10. Properly dispose of electric fuel pump (Figure 1, Item 4).
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following steps, inspect grommets (Figure 1, Item 7) and
fuel lines (Figure 1, Items 6 and 10) for cracks, dryness, or other visible signs of
wear or damage. If grommets (Figure 1, Item 7) or fuel lines (Figure 1, Items 6
and 10) appear excessively worn or are damaged, do not use.
Prior to performing the following steps, inspect electrical pig tail (Figure 1,
Item 11), ground wire (Figure 1, Item 13) and terminals for connectivity. Ensure
that wire has not become brittle and that there are no nicks, cuts, or other
damage to wire. Ensure that electrical connectors are free and clear of grease,
dirt or other contaminates that may impede electrical connectivity.
1. If removed, install fuel pump mounting bracket (Figure 1, Item 14) and secure with bolt (Figure 1, Item 3).
2. Mount two rubber grommets (Figure 1, Item 7) onto electric fuel pump (Figure 1, Item 4).
3. Secure electric fuel pump (Figure 1, Item 4) to electric fuel pump mounting bracket (Figure 1, Item 14) and
mounting plate (Figure 1, Item 15) using two bolts (Figure 1, Item 9) and flat washers (Figure 1, Item 8).
4. Connect electric fuel pump ground wire (Figure 1, Item 13) to electric fuel pump mounting bracket (Figure 1,
Item 14) and mounting plate (Figure 1, Item 15) and secure using nut (Figure 1, Item 12).
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
5. Connect input and output fuel lines (Figure 1, Items 6 and 10) and tighten clamps (Figure 1, Item 5).
6. Connect electrical pig tail (Figure 1, Item 1`) on electric fuel pump (Figure 1, Item 4) to wiring harness.
0047-3
TM 11-6115-742-13&P 0047
REPLACEMENT - Continued
7. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
8. Install rear access panel (Figure 1, Item 2).
9. Install cargo restraints (not shown).
10. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0047-4
TM 11-6115-742-13&P 0047
15
14 4 6
5
13
7
12
11 8
9
5
10
Figure 1. Electric Fuel Pump Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0047-5/6 blank
TM 11-6115-742-13&P 0048
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET FUEL INJECTION SYSTEM
FUEL INJECTOR REMOVAL/CLEAN/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit, (WP 0165, Item 1) WP 0005, WP 0041
Safety glasses
Equipment Condition
Materials/Parts Genset shut down
Fuel injector BATTERY SWITCH - OFF
Cloth, cleaning (WP 0168, Item 14)
Brush, soft cleaning (WP 0168, Item 10)
Personnel Required
One
GENERAL
This work package provides information on the services and removal/replacement of the Genset electric fuel
pump. It consists of:
• Fuel injector removal/clean/replacement
• Fuel injector pump removal/replacement
• Fuel line removal/replacement
• Prime fuel system
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0048-1
TM 11-6115-742-13&P 0048
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
If Genset has been in operation, components may be extremely hot. To prevent
serious injury to personnel, allow the Genset to cool down before performing
procedures.
CAUTION
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, components may be extremely hot. To prevent
serious injury to personnel, allow the Genset to cool down before performing the
following procedure.
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel.
3. Remove front and rear access panels.
4. Disconnect battery ground cable (black) from battery ground terminal (f necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
Fuel lines may still have fuel present or be under pressure. Care must be taken
to prevent fuel from spilling and to avoid exposure of skin to diesel fuel.
It is not necessary to disconnect the fuel line from the fuel injector rail to remove
fuel injectors.
It is necessary to rotate oil dipstick mount 180 degrees to gain access to fuel
nd
system on 2 cylinder.
0048-2
TM 11-6115-742-13&P 0048
REMOVAL – Continued
5. For 2nd cylinder fuel system access, remove two mounting bolts (Figure 1, Item 2) and two lock washers
(Figure 1, Item 3) from oil dipstick mount (Figure 1, Item 1) and rotate mount (Figure 1, Item 1) 180 degrees.
Otherwise proceed to step 6.
Figure 1. Oil Dipstick Mount.
CAUTION
Each bolt has a hole to allow fuel to pass through into the injector. When
removing bolts, place in a clean, dry area to prevent dirt and debris from clogging
holes.
NOTE
It is not necessary to disconnect fuel line from fuel injector rail to remove fuel
injectors. Only disconnect fuel line if replacing rail.
0048-3
TM 11-6115-742-13&P 0048
REMOVAL – Continued
6. Remove four bolts (Figure 2, Item 1) from fuel rail (Figure 2, Item 9).
7. Lift fuel rail (Figure 2, Item 9) away from fuel injectors (Figure 2, Item 8) and set on top of valve cover.
8. Ensure that brass seals (Figure 2, Item 2) from fuel injector rail (Figure 2, Item 9) remain secured to rail.
CAUTION
When disassembling fuel system take care not to mix parts. Keep each cylinders
injector, fuel line, and bolts separate and reattach to appropriate cylinder when
reassembling.
9. Disconnect injector fuel line (Figure 2, Item 5) from corresponding injector pump (Figure 3, Item 5).
10. Disconnect injector fuel line (Figure 2, Item 5) from fuel injector (Figure 2, Item 8).
11. Remove injector fuel line (Figure 2, Item 5) and set aside.
12. Remove bolt (Figure 2, Item 3) from fuel injector hold down (Figure 2, Item 4) and set aside.
13. Remove fuel injector hold down (Figure 2, Item 4) and set aside.
14. Using a flat tip screw driver, pry up on fuel injector (Figure 2, Item 8) to remove from engine block.
END OF TASK
CLEAN
1. Wipe excess fuel from fuel injector.
2. Remove any loose carbon build up on tip of fuel injector (Figure 2, Item 7) with lint free cleaning cloth.
3. Using a soft cleaning brush and solvent, clean carbon buildup from tip of fuel injector (Figure 2, Item 7).
4. Allow fuel injector to dry completely before reassembly.
END OF TASK
REPLACEMENT
1. Ensure fuel injector O-ring (Figure 2, Item 6) is in proper position and serviceable.
2. Press fuel injector (Figure 2, Item 8) into position until seated.
3. Install fuel injector hold down (Figure 2, Item 4) and bolt (Figure 2, Item 3).
4. Using torque wrench, tighten bolts (Figure 2, Item 3) on fuel injector hold down (Figure 2, Item 4) to
23~30 ft./lb (31~41 n-m/3.2~4.2 kgf-m).
5. Align fuel rail (Figure 2, Item 9) with fuel injectors (Figure 2, Item 8).
6. Insert four bolts (Figure 2, Item 1) through fuel rail (Figure 2, Item 9) and brass seals (Figure 2, Item 2) into
fuel injector heads.
7. Using torque wrench, tighten fuel rail bolts (Figure 2, Item 1) to 7 to 10 ft./lb (10~14 n-m/1.0~1.4 kgf-m).
0048-4
TM 11-6115-742-13&P 0048
REPLACEMENT – Continued
8. Place injector fuel line (Figure 2, Item 5) into position.
9. Finger tighten fuel line (Figure 2, Item 5) to corresponding injector pump (Figure 3, Item 5).
10. Finger tighten fuel line (Figure 2, Item 5) to corresponding fuel injector (Figure 2, Item 8).
11. Tighten fuel line connectors. Using torque wrench, tighten fuel lines to 11 to 18 ft./lb (19~28 n-m/
1.9~2.9 kgf-m).
12. If necessary, reattach oil dipstick mount (Figure 1, Item 1) using two mounting bolts (Figure 1, Item 2) and two
lock washers (Figure 1, Item 3). Tighten down mounting bolts (Figure 1, Item 2).
13. Reconnect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
14. Install front and rear access panels and cargo restraints.
15. Start Genset in accordance with Genset Power Up Procedure (WP 0005).
0048-5
TM 11-6115-742-13&P 0048
9 8
5
Figure 2. Fuel Injector Removal/Replacement.
END OF TASK
0048-6
TM 11-6115-742-13&P 0048
FUEL INJECTOR PUMP REMOVAL
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, components may be extremely hot. To prevent
serious injury to personnel, allow the Genset to cool down before performing the
following procedure.
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel.
3. Remove front and rear access panels.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
Fuel lines may still have fuel present or be under pressure. Care must be taken
to prevent fuel from spilling and to avoid exposure of skin to diesel fuel.
It is not necessary to disconnect the fuel line from the fuel injector pump rail to
remove fuel injector pumps.
It is necessary to rotate oil dipstick mount 180 degrees to gain access to fuel
system on 2nd cylinder.
5. For 2nd cylinder fuel system access, remove two mounting bolts (Figure 1, Item 2) and two lock washers
(Figure 1, Item 3) from oil dipstick mount (Figure 1, Item 1) and rotate mount (Figure 1, Item 1) 180 degrees.
Otherwise proceed to step 6.
6. Remove four bolts (Figure 3, Item 1) from fuel injector pump fuel rail (Figure 3, Item 11).
7. Remove four brass seals (Figure 3, Item 2) from top of fuel injector pump fuel rail (Figure 3, Item 11).
CAUTION
When disassembling fuel system take care not to mix parts. Keep each cylinders
injector, pump, fuel line, bolts, and seals separate and reattach to appropriate
cylinder when reassembling.
8. Lift fuel rail (Figure 3, Item 11) away from fuel injector pumps (Figure 3, Item 5).
9. Remove 4 brass seals (Figure 3, Item 10) from bottom of fuel injector pump fuel rail (Figure 3 Item 11).
10. Disconnect fuel line (Figure 3, Item 3) from corresponding injector pump (Figure 3, Item 5).
11. Disconnect fuel line (Figure 3, Item 3) from fuel injector (Figure 2, Item 8).
0048-7
TM 11-6115-742-13&P 0048
REMOVAL- Continued
12. Remove injector fuel line (Figure 3, Item 3) and set aside.
13. Remove two mounting bolts (Figure 3, Item 9) from fuel injector pump (Figure 3, Item 5).
14. Remove two mounting nuts (Figure 3, Item 4) from fuel injector pump mounting studs (Figure 3, Item 7).
15. Remove fuel injector pump (Figure 3, Item 5) and set aside. Remove old fuel injector pump seal (Figure 3,
Item 6) and discard.
END OF TASK
REPLACEMENT
1. Place new fuel injector pump seal (Figure 3, Item 6) on engine block. Seat seal over mounting studs
(Figure 3, Item 7) to position.
2. Check alignment of actuator slide to ensure it will seat into actuator rail (Figure 3, Item 8) inside engine block.
3. Slide fuel injector pump (Figure 3, Item 5) into position on mounting studs (Figure 3, Item 7).
4 Install two bolts (Figure 3, Item 9) into injector pump (Figure 3, Item 5).
5. Install two nuts (Figure 3, Item 4) onto injector pump mounting studs (Figure 3, Item 7).
6. Using torque wrench, tighten bolts (Figure 3, Item 9) and nuts (Figure 3, Item 4) to 11~18 ft./lb (19~28 n-m/
1.9~2.9 kgf-m).
7. Align fuel rail (Figure 3, Item 11) with fuel injector pumps (Figure 3, Item 5).
8. Place original brass seals (Figure 3, Item 10) between fuel rail (Figure 3, Item 11) and pump (Figure 3,
Item 5).
9. Insert four fuel rail bolts (Figure 3, Item 1) through top brass seals (Figure 3, Item 2), fuel rail (Figure 3,
Item 11), and bottom brass seal (Figure 3, Item 10) and into fuel injector pump (Figure 3, Item 5).
10. Using torque wrench, tighten fuel rail bolts (Figure 3, Item 1) to 15~18 ft/lbs (20~25 n-m/ 2.0~2.5 kgf-m).
11. Place injector pump fuel line (Figure 3, Item 3) into position.
12. Finger tighten fuel line (Figure 3, Item 3) to corresponding injector pump (Figure 3, Item 5).
13. Finger tighten fuel line (Figure 3, Item 3) to corresponding fuel injector (Figure 2, Item 8).
14. Using torque wrench, tighten fuel line connectors fuel to 11~18 ft lbs. (19~28 n-m/1.9~2.8 kgf-m).
15. If necessary, reattach oil dipstick mount (Figure 1, Item 1) using two mounting bolts (Figure 1, Item 2) and two
lock washers (Figure 1, Item 3). Tighten down mounting bolts (Figure 1, Item 2).
16. Reconnect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
17. Install front and rear access panels and install cargo restraints.
18. Start Genset in accordance with Genset Power Up Procedure (WP 0005).
0048-8
TM 11-6115-742-13&P 0048
10 4
11
Figure 3. Fuel Injector Pump Removal/Replacement.
END OF TASK
0048-9
TM 11-6115-742-13&P 0048
REMOVAL (Fuel Injector Fuel Line)
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, components may be extremely hot. To prevent
serious injury to personnel, allow the Genset to cool down before performing the
following procedure.
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints to gain access to rear access panel.
3. Remove front and rear access panels.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
Fuel lines may still have fuel present or be under pressure. Care must be taken
to prevent fuel from spilling and to avoid exposure of skin to diesel fuel.
It is necessary to rotate oil dipstick mount 180 degrees to gain access to fuel
system on 2nd cylinder.
5. For 2nd cylinder fuel system access, remove two mounting bolts (Figure 1, Item 2) and two lock washers
(Figure 1, Item 3) from oil dipstick mount (Figure 1, Item 1) and rotate mount (Figure 1, Item 1) 180 degrees.
Otherwise proceed to step 6.
6. Disconnect fuel injector line (Figure 4, Item 7) from fuel injector (Figure 4, Item 5).
7. Disconnect fuel injector line (Figure 4, Item 7) from corresponding fuel injector pump (Figure 4, Item 8).
END OF TASK
0048-10
TM 11-6115-742-13&P 0048
REPLACEMENT (Fuel Injector Fuel Line)
CAUTION
When assembling fuel system take care not to mix parts. Keep each cylinders
injector, pump, fuel line, bolts, and seals separate and reattach to appropriate
cylinder.
1. Place fuel injector line (Figure 4, Item 7) into position.
2. Finger tighten fuel injector line (Figure 4, Item 7) to corresponding fuel injector pump (Figure 4, Item 8).
3. Finger tighten fuel injector line (Figure 4, Item 7) to corresponding fuel injector (Figure 4, Item 5).
4. Using torque wrench, tighten fuel line connectors to 11~18 ft./lb (19~28 n-m/1.9~2.9 kgf-m).
5. If necessary, reattach oil dipstick mount (Figure 1, Item 1) using two mounting bolts (Figure 1, Item 2) and two
lock washers (Figure 1, Item 3). Tighten down mounting bolts (Figure 1, Item 2).
6. Reconnect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
7. Install front and rear access panels and install cargo restraints.
8. Start Genset as described in Genset Power Up Procedure (WP 0005).
END OF TASK
REMOVAL (Fuel Injector Rail)
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints to gain access to rear access panel.
3. Remove front and rear access panels.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
CAUTION
When disassembling fuel system take care not to mix parts. Keep each cylinders
injector, pump, fuel line, bolts, and seals separate and reattach to appropriate
cylinder when reassembling.
NOTE
Fuel lines may still have fuel present or be under pressure. Care must be taken
to prevent fuel from spilling and to avoid exposure of skin to diesel fuel.
5. Disconnect rubber fuel hose (Figure 4, Item 6) from fuel injector rail (Figure 4, Item 1).
0048-11
TM 11-6115-742-13&P 0048
REMOVAL (Fuel Injector Rail) – Continued
CAUTION
Each bolt has a hole to allow fuel to pass through into the injector. When
removing bolts, place in a clean, dry area to prevent dirt and debris from clogging
holes.
6. Remove four bolts (Figure 4, Item 2) from fuel injector rail (Figure 4, Item 1).
7. Lift fuel injector rail (Figure 4, Item 1) and brass seals (Figure 4, Item 3) away from fuel injector heads
(Figure 4, Item 4).
END OF TASK
REPLACEMENT (Fuel Injector Rail)
CAUTION
When assembling fuel system take care not to mix parts. Keep each cylinders
injector, pump, fuel line, bolts, and seals separate and reattach to appropriate
cylinder.
1. Align fuel injector rail (Figure 4, Item 1) with fuel injector heads (Figure 4, Item 4).
2. Insert four bolts (Figure 4, Item 2) through fuel injector rail (Figure 4, Item 1) and brass seals (Figure 4,
Item 3) into fuel injector heads (Figure 4, Item 4).
3. Using torque wrench, tighten fuel injector rail bolts (Figure 4, Item 2) to 7~10 ft./lb (10~14 n-m/1.0~1.4 kgf-m)
4. Connect rubber fuel hose (Figure 4, Item 6) to fuel injector rail (Figure 4, Item 1).
5. Reconnect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
6. Install front and rear access panels and install cargo restraints.
7. Start Genset as described in Genset Power Up Procedure (WP 0005).
END OF TASK
REMOVAL (Fuel Injector Pump Fuel Rail)
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel.
3. Remove front and rear access panels.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
CAUTION
When disassembling fuel system take care not to mix parts. Keep each cylinders
injector, pump, fuel line, bolts, and seals separate and reattach to appropriate
cylinder when reassembling.
0048-12
TM 11-6115-742-13&P 0048
REMOVAL (Fuel Injector Pump Fuel Rail) – Continued
NOTE
Fuel lines may still have fuel present or be under pressure. Care must be taken
to prevent fuel from spilling and to avoid exposure of skin to diesel fuel.
5. Disconnect fuel source hose (Figure 4, Item 12) from fuel injector pump fuel rail (Figure 4, Item 11).
6. Disconnect rubber hose (Figure 4, Item 6) from fuel injector pump fuel rail (Figure 4, Item 11).
7. Disconnect fuel return hose (Figure 4, Item 9) from fuel injector pump fuel rail (Figure 4, Item 11).
8. Remove four bolts (Figure 4, Item 14) from fuel injector pump fuel rail (Figure 4, Item 11).
9. Remove four brass seals (Figure 4, Item 13) from top of fuel injector pump fuel rail (Figure 4, Item 11).
10. Lift fuel injector pump fuel rail (Figure 4, Item 11) away from fuel injector pumps (Figure 4, Item 8).
11. Remove four brass seals (Figure 4, Item 10) from bottom of fuel injector pump fuel rail (Figure 4, Item 11).
END OF TASK
REPLACEMENT (Fuel Injector Pump Fuel Rail)
CAUTION
When assembling fuel system take care not to mix parts. Keep each cylinders
injector, pump, fuel line, bolts, and seals separate and reattach to appropriate
cylinder.
1. Align fuel injector pump fuel rail (Figure 4, Item 11) with fuel injector pumps (Figure 4, Item 8).
2. Place four brass seals (Figure 4, Item 10) between fuel injector pump fuel rail (Figure 4, Item 11) and fuel
injector pumps (Figure 4, Item 8).
3. Place four brass seals (Figure 4, Item 13) on top of fuel injector pump fuel rail (Figure 4, Item 11) and insert
four bolts (Figure 4, Item 14).
4. Using torque wrench, tighten fuel rail bolts (Figure 4, Item 14) to 15~18 ft./lb (20~25 n-m/2.0~2.5 kgf-m)
5. Attach fuel return hose (Figure 4, Item 9) to fuel injector pump fuel rail (Figure 4, Item 11).
6. Attach rubber hose (Figure 4, Item 6) to fuel injector pump fuel rail (Figure 4, Item 11).
7. Attach fuel source hose (Figure 4, Item 12) to fuel injector pump fuel rail (Figure 4, Item 11).
8. Reconnect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
9. Install front and rear access panels and install cargo restraints.
10. Start Genset as described in Genset Power Up Procedure (WP 0005).
END OF TASK
0048-13
TM 11-6115-742-13&P 0048
REMOVAL (Rubber Fuel Supply Hose)
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel.
3. Remove front and rear access panels.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
Fuel lines may still have fuel present or be under pressure. Care must be taken
to prevent fuel from spilling and to avoid exposure of skin to diesel fuel.
5. Disconnect rubber hose (Figure 4, Item 6) from fuel injector fuel rail (Figure 4, Item 1).
6. Disconnect rubber hose (Figure 4, Item 6) from fuel injector pump fuel rail (Figure 4, Item 11).
END OF TASK
REPLACEMENT (Rubber Fuel Supply Hose)
1. Attach rubber hose (Figure 4, Item 6) to fuel injector fuel rail (Figure 4, Item 1).
2. Attach rubber hose (Figure 4, Item 6) to fuel injector pump fuel rail (Figure 4, Item 11).
3. Reconnect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
4. Install front and rear access panels and install cargo restraints.
5. Start Genset as described in Genset Power Up Procedure (WP 0005).
0048-14
TM 11-6115-742-13&P 0048
2
3
1 4
5 6
14
13
9
10
11
8
12
Figure 4. Fuel Injection System Lines Removal/Replacement.
END OF TASK
0048-15
TM 11-6115-742-13&P 0048
NOTE
To prime fuel system using auxiliary fuel source, refer to (WP 0005) Fueling
Genset from Auxiliary Fuel Source.
PRIME FUEL SYSTEM USING FUEL PUMP
1. Open fuel level access panel and check fuel level, fill if required (if necessary, refer to (WP 0004) of this TM
for location and identification of controls and indicators).
2 Close fuel level access panel.
3. Open rear engine access panel.
4. Open engine control panel.
5. Turn engine start switch to run position, engine fuel pump will run.
6. Allow engine fuel pump to run for 15 to 30 seconds or until fuel pump becomes noticeable quieter (this
signifies fuel is moving through fuel pump).
7. Start Genset as per (WP 0005), Genset Power Up Procedure.
END OF TASK
END OF WORK PACKAGE
0048-16
TM 11-6115-742-13&P 0049
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET GLOW PLUG AND GLOW PLUG CONNECTOR
GLOW PLUG AND CONNECTOR STRIP REMOVAL/INSPECT/TEST/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic's tool kit One
(WP 0165, Item 1)
Multimeter (WP 0165, Item 2) References
WP 0005
Materials/Parts WP 0041
Glow Plug
Connector strip Equipment Condition
Anti-seize compound (WP 0168, Item 3) Genset shut down
Cloth, cleaning (WP 0168, Item 14) BATTERY SWITCH - OFF
GENERAL
This work package provides information on the inspection, removal and replacement of the Genset glow plugs
and connector strip. If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from heat and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
0049-1
TM 11-6115-742-13&P 0049
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following procedure.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel (Figure 1, Item 3) of Genset.
3. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
Steps 4 and 5 allow easier access to the glow plugs.
4. Loosen but do not remove nut and bolt that secures exhaust pipe cap (not shown). Remove exhaust pipe cap
and set aside.
5. Remove and retain 20 bolts, lock washers, and flat washers (not shown) that secures top access panel
(Figure 1, Item 2) to Genset (Figure 1, Item 1). Remove top access panel (Figure 1, Item 2) and set aside.
0049-2
TM 11-6115-742-13&P 0049
REMOVAL - Continued
NOTE
The dip-stick bracket may need to be removed to allow access to glow plug #2.
6. Remove and retain four nuts (Figure 1, Item 5) and washers (Figure 1, Item 6) that secure glow plug
connector (Figure 1, Item 8) and terminal lug (Figure 1, Item 7) to glow plugs (Figure 1, Items 4, 9
through 11).
7. Disconnect terminal lug (Figure 1, Item 7) from glow plug #1 (Figure 1, Item 4) and set aside.
8. Remove connector strip (Figure 1, Item 8) from glow plugs (Figure 1, Items 4, 9 through 11) and set aside.
NOTE
If glow plugs are to be re-used, identify location and mark glow plug so it may be
returned to same spot.
9. Remove four glow plugs (Figure 1, Items 4, 9 through 11).
END OF TASK
INSPECT
1. Inspect glow plugs for slagging or melting. If either condition is present discard glow plug and replace.
2. Inspect glow plugs for excessive soot. If condition is present, clean glow plug and test.
END OF TASK
TEST
To measure resistance of glow plug:
a) Set multimeter to read resistance (X1 scale).
b) Touch outside threaded ring of the glow plug with black meter lead.
c) Touch threaded glow plug connector strip stud with red meter lead.
If multimeter reads less than 3Ω or greater then 4Ω replace the glow plug.
END OF TASK
0049-3
TM 11-6115-742-13&P 0049
REPLACEMENT
1. Clean off old sealant from all threaded areas.
WARNING
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from heat and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
NOTE
Do not get anti-seize compound on ends of glow plugs.
2. Apply anti-seize compound to threads of glow plugs (Figure 1, Items 4, 9 through 11).
CAUTION
When the following step is being performed, glow plugs (Figure 1, Items 4, 9
through 11) should screw in without resistance. Do not force glow plugs
(Figure 1, Items 4, 9 through 11) or cross thread. Failure to observe this caution
can result in damage to the engine.
NOTE
If reusing glow plugs (Figure 1, Items 4, 9 through 11), insert glow plugs
(Figure 1, Items 4, 9 through 11) back into the cylinder from which they were
removed.
3. Install glow plugs (Figure 1, Items 4, 9 through 11) and tighten finger tight.
4. Using torque wrench, tighten glow plugs (Figure 1, Items 4, 9 through 11) to 11~14 ft./lb (15~20 n-m/1.5~2.0
kgf-m).
NOTE
Prior to performing the following step, inspect terminal lug (Figure 1, Item 7) and
wire for connectivity. Ensure that wire has not become brittle and that there are
no nicks, cuts or other damage to wire.
Prior to performing the following step, inspect glow plug connector (Figure 1,
Item 8). Ensure that glow plug connector (Figure 1, Item 8) is in good working
order and that no grease, dirt, paint, corrosion or other damage is present.
5. Install connector strip (Figure 1, Item 8). Connect terminal lug (Figure 1, Item 7) to glow plug #1
(Figure 1, Item 4).
6. Secure glow plug connector (Figure 1, Item 8) and terminal lug (Figure 1, Item 7) to glow plugs (Figure 1,
Items 4, 9 through 11) using four nuts (Figure 1, Item 5) and washers (Figure 1, Item 6).
0049-4
TM 11-6115-742-13&P 0049
REPLACEMENT - Continued
NOTE
If the dip-stick bracket was removed to allow access to glow plug #2, re install at
this time.
7. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
8. Install top access panel (Figure 1, Item 2) and secure to Genset using 20 bolts, lock washers, and flat
washers (not shown).
9. Install exhaust pipe cap (not shown) and secure.
10. Install rear access panel (Figure 1, Items 3).
11. Install cargo restraints (not shown).
12. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
3 5
6
4
1
7
(#1)
9
10
(#2)
11
(#3)
(#4)
8
Figure 1. Glow Plug/Connector Strip Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0049-5/6 blank
TM 11-6115-742-13&P 0050
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET OIL PRESSURE SWITCH
.
OIL PRESSURE SWITCH REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit (WP 0165, Item 1) WP 0005, WP 0041
Safety glasses WP 0051, WP 0044
Materials/Parts Equipment Condition
Oil pressure switch Genset shut down
Anti-seize compound (WP 0168, Item 3) BATTERY SWITCH - OFF
Personnel Required
One
GENERAL
This work package provides information on the removal/replacement of the Genset oil pressure switch.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
0050-1
TM 11-6115-742-13&P 0050
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to (WP 0067) for torque requirements
REMOVAL
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following procedure.
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel (Figure 1, Item 2) of Genset.
3. Remove the rear access panel (Figure 1, Item 2) and set aside.
NOTE
The oil pressure switch (Figure 1, Item 3) is located between the oil pressure
sending unit (WP 0051) and the fuel filter (WP 0044).
Prior to performing the following step, mark wires (Figure 1, Items 5) and
terminals for connectivity.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
5. Remove and retain two screws (Figure 1, Item 4) and wires (Figure 1, Items 5) connected to oil pressure
switch (Figure 1, Items 3).
NOTE
When performing the following step, be cautious of items surrounding oil
pressure switch (Figure 1, Item 3).
0050-2
TM 11-6115-742-13&P 0050
REMOVAL – Continued
NOTE
When performing the following step, use a second wrench to keep mounting
elbow from turning.
6. Remove oil pressure switch (Figure 1, Item 3) from engine.
END OF TASK
REPLACEMENT
1. Clean off old anti-seize compound from all threaded areas.
WARNING
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
NOTE
Do not get anti-seize compound on end of oil pressure switch (Figure 1, Item 3)
or associated terminals.
2. Apply anti-seize compound to threads of oil pressure switch (Figure 1, Item 3).
CAUTION
When the following step is being performed, do not force oil pressure switch
(Figure 1, Item 3) or cross thread. Failure to observe this caution can result in
damage to the engine.
NOTE
When performing the following step, use a second wrench to keep mounting
elbow from turning.
3. Install oil pressure switch (Figure 1, Item 3) onto mounting elbow and tighten.
NOTE
Prior to performing the following step, inspect wires (Figure 1, Item 5) and
terminals for connectivity. Ensure that wire has not become brittle and that there
are no nicks, cuts or other damage to wire.
4. Secure two wires (Figure 1, Item 5) to oil pressure switch (Figure 1, Item 3) with two screws (Figure 1,
Item 4).
5. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
6. Install access panel (Figure 1, Item 2).
0050-3
TM 11-6115-742-13&P 0050
REPLACEMENT - Continued
7. Install cargo restraints (not shown).
8. Start Genset (Figure 1, Item 1) in accordance with Genset Start Procedure (WP 0005) of this TM.
3
1
5
4
Figure 1. Oil Pressure Switch Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0050-4
TM 11-6115-742-13&P 0051
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET OIL PRESSURE SENDING UNIT
OIL PRESSURE SENDING UNIT REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit, (WP 0165, Item 1) WP 0005, WP 0041
Safety Glasses
Materials/Parts Equipment Condition
Oil pressure sending unit Genset shut down
Anti-seize compound (WP 0168, Item 3) BATTERY SWITCH - OFF
Cloth, cleaning (WP 0168, Item 14)
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of the Genset oil pressure sending unit.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0051-1
TM 11-6115-742-13&P 0051
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove the access panel (Figure 1, Item 2) and set aside.
NOTE
The oil pressure sending unit (Figure 1, Item 7) is located next to the oil filter.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
5. Remove nut (Figure 1, Item 3), lock washer (Figure 1, Item 4) and flat washer (Figure 1, Item 5) securing wire
(Figure 1, Item 6) to oil pressure sending unit (Figure 1, Item 7). Mark and disconnect wire (Figure 1, Item 6).
NOTE
0051-2
TM 11-6115-742-13&P 0051
Use a second wrench to keep mounting elbow from turning.
Be cautious of items surrounding oil pressure sending unit (Figure 1, Item 7).
REMOVAL – Continued
6. Remove oil pressure sending unit (Figure 1, Item 7) from engine.
END OF TASK
REPLACEMENT
1. Clean off old anti-seize compound from all threaded areas.
WARNING
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
NOTE
Do not get anti-seize compound on end of oil pressure sending unit (Figure 1,
Item 7).
2. Apply anti-seize compound to threads of oil pressure sending unit (Figure 1, Item 7).
CAUTION
When the following step is being performed, do not force oil pressure sending
unit (Figure 1, Item 7) or cross thread. Failure to observe this caution can result
in damage to the engine.
NOTE
When performing the following step, use a second wrench to keep mounting
elbow from turning.
3. Install oil pressure sending unit (Figure 1, Item 7) onto mounting elbow and tighten.
NOTE
Prior to performing the following step, inspect wire (Figure 1, Item 6) and terminal
for connectivity. Ensure that wire has not become brittle and that there are no
nicks, cuts or other damage to wire.
4. Install wire (Figure 1, Item 6) onto oil pressure sending unit (Figure 1, Item 7) and secure with nut (Figure 1,
Item 3) lock washer (Figure 1, Item 4) and flat washer (Figure 1, Item 5).
5. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
6. Install access panel (Figure 1, Item 2).
REPLACEMENT- Continued
0051-3
TM 11-6115-742-13&P 0051
7. Install cargo restraints (not shown).
8. Start Genset (Figure 1, Item 1) in accordance with Genset Start Procedure (WP 0005) of this TM.
3
5 4
6
1
Figure 1. Oil Pressure Sending Unit Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0051-4
TM 11-6115-742-13&P 0052
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET SOLENOID AND CIRCUIT BREAKER MAINTENANCE
GENSET SOLENOID AND CIRCUIT BREAKER REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic's tool kit, (WP 0165, Item 1) WP 0005, WP 0041
Safety glasses
Equipment Condition
Materials/Parts Genset shut down
Solenoid BATTERY SWITCH - OFF
Circuit Breaker
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of the Genset solenoids and associated
circuit breaker. If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0052-1
TM 11-6115-742-13&P 0052
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following procedure.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
NOTE
The following procedure is applicable to the K2 and K3 solenoid assemblies
associated with the TMSS-MED.
K2 OR K3 SOLENOID REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove rear access panel (not shown) and set aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
5. Identify solenoid (Figure 1, Items 1 or 2) to be replaced.
NOTE
If markings on wire(s) and/or solenoid terminal(s) are missing, tag wire(s) and/or
solenoid terminal(s) to help with identifying proper connections when replacing
solenoid.
5. Remove and retain four nuts (Figure 1, Item 11) and lock washers (Figure 1, Item 10) that secure terminal
lugs (Figure 1, Item 9) to solenoid terminals (Figure 1, Item 8).
0052-2
TM 11-6115-742-13&P 0052
REMOVAL – Continued
6. Disconnect terminal lugs (Figure 1, Item 9) from solenoid terminals (Figure 1, Item 8). Loosely install nuts
(Figure 1, Item 11) and lock washers (Figure 1, Item 10) back onto solenoid terminals (Figure 1, Item 8).
7. Remove and retain two nuts (Figure 1, Item 3), bolts (Figure 1, Item 6), and four flat washers (Figure 1,
Item 5) that secure solenoid (Figure 1, Items 1 or 2) to mounting bracket (Figure 1, Item 4).
8. Remove solenoid (Figure 1, Items 1 or 2) from mounting bracket (Figure 1, Item 4) on Genset and discard.
END OF TASK
REPLACEMENT
1 Secure solenoid (Figure 1, Items 1 or 2) to mounting bracket (Figure 1, Item 4) on Genset using two nuts
(Figure 1, Item 3), bolts (Figure 1, Item 6), and four flat washers (Figure 1, Item 5).
NOTE
Prior to performing the following step, inspect terminal lugs (Figure 1, Item 8) and
associated wiring. Ensure that wire has not become brittle and that there are no
nicks, cuts or other damage to wire. Inspect solenoid terminals (Figure 1, Item 9)
ensure that no damage or corrosion exists.
2. Connect terminal lugs (Figure 1, Item 9) to solenoid terminals (Figure 1, Item 8). Secure using four nuts
(Figure 1, Item 11) and lock washers (Figure 1, Item 10). (See Table 1).
3 Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
4. Install access panel(s) (not shown) and cargo restraints (not shown).
5. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
Table 1. Electronic Connections for Genset Solenoids.
Solenoid/ # of Wire
From To
location wires Color
Pin #
One Red Power-in 1 Starter (Pin #1)
Starter (K2) Two Green Ground 2 Engine Ground Block
Near starter Grey 2 Glow Plug Solenoid (K3) pin 2
One Grey Trigger 3 Connector CF1 (Pin #4)
One Red Power-out 4 Starter (Pin #2)
One Grey Power-in 1 Starter solenoid (K2) (Pin #4)
Glow Plug (K3)
One Grey Ground 2 Starter solenoid (K2) (pin #2)
Under Starter
One Grey Trigger 3 Connector CF1 (Pin #5)
One Grey Power-out 4 Alternator (Pin #1)
One Red Power-in 4 BAT1 (+)/Circuit breaker (load side)
Fuel Heater (K4)
One Grey Ground 2 Engine Ground Block
Near oil filter
One Green Trigger 3 Connector CF1 (Pin #50)
One Red Power-out 1 Fuel Line Heater
0052-3
TM 11-6115-742-13&P 0052
2
1
3
5
10
11 9 7
Solenoid
1 (K2 or K3) 4
Power OUT Power IN
2 3
Ground Trigger
Figure 1. K2 or K3 Solenoid Removal/Replacement.
END OF TASK
0052-4
TM 11-6115-742-13&P 0052
K4 SOLENOID REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following procedure.
NOTE
The following procedure is applicable to the K4 solenoid assembly associated
with the TMSS-MED.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove rear access panel (not shown) and set aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
If markings on wire(s) and/or solenoid terminal(s) are missing, tag wire(s) and/or
solenoid terminal(s) to help with identifying proper connections when replacing
solenoid.
5. Remove and retain four nuts (Figure 2, Item 13) and lock washers (Figure 2, Item 12) that secure terminal
lugs (Figure 2, Item 11) to solenoid terminals (Figure 2, Item 10).
0052-5
TM 11-6115-742-13&P 0052
REMOVAL – Continued
6. Disconnect terminal lugs (Figure 2, Item 11) from solenoid terminals (Figure 2, Item 10). Loosely install nuts
(Figure 2, Item 13) and lock washers (Figure 2, Item 12) back onto solenoid terminals (Figure 2, Item 10).
7. Remove and retain two nuts (Figure 2, Item 4), bolts (Figure 2, Item 8), and four flat washers (Figure 2,
Item 5) that secure solenoid (Figure 2, Item 7) to mounting bracket (Figure 2, Item 6).
8. Remove solenoid (Figure 2, Item 7) from mounting bracket (Figure 2, Item 6) on Genset and discard.
END OF TASK
REPLACEMENT
1 Secure solenoid (Figure 2, Item 7) to mounting bracket (Figure 2, Item 6) on Genset using two nuts (Figure 2,
Item 4), bolts (Figure 2, Item 8), and four flat washers (Figure 2, Item 5).
NOTE
Prior to performing the following step, inspect terminal lugs (Figure 2, Item 11)
and associated wiring. Ensure that wire has not become brittle and that there are
no nicks, cuts or other damage to wire. Inspect solenoid terminals (Figure 2,
Item 10) ensure that no damage or corrosion exists.
2. Connect terminal lugs (Figure 2, Item 11) to solenoid terminals (Figure 2, Item 10). Secure using four nuts
(Figure 2, Item 13) and lock washers (Figure 2, Item 12). (See Table 1).
3 Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
4. Install access panel(s) (not shown) and cargo restraints (not shown).
5. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0052-6
TM 11-6115-742-13&P 0052
1
4
3 5
2
18
17 6
16
5
15
8
15
10
14
12
13 11 9
Solenoid
1 (K4) 4
Power IN Power OUT
2 3
Ground Trigger
Figure 2. K4 Solenoid and Circuit Breaker Removal/Replacement.
END OF TASK
0052-7
TM 11-6115-742-13&P 0052
K4 SOLENOID CIRCUIT BREAKER REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following procedure.
NOTE
The following procedure is applicable to the K4 solenoid assembly associated
with the TMSS-MED.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove rear access panel (not shown) and set aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
If markings on wire(s) and/or solenoid terminal(s) are missing, tag wire(s) and/or
solenoid terminal(s) to help with identifying proper connections when replacing
solenoid.
5. Remove and retain two nuts (Figure 2, Item 1) and lock washers (Figure 2, Item 2) that secure terminal lugs
(Figure 2, Item 3) to circuit breaker terminals (Figure 2, Item 18).
0052-8
TM 11-6115-742-13&P 0052
REMOVAL – Continued
6. Disconnect terminal lugs (Figure 2, Item 3) from circuit breaker terminals (Figure 2, Item 18). Loosely install
nuts (Figure 2, Item 1) and lock washers (Figure 2, Item 2) back onto circuit breaker terminals (Figure 2,
Item 18).
7. Remove and retain two lock nuts (Figure 2, Item 16), machine screws (Figure 2, Item 14), and four flat
washers (Figure 2, Item 15) that secure circuit breaker (Figure 2, Item 17) to mounting bracket (Figure 2,
Item 6).
8. Remove circuit breaker (Figure 2, Item 17) from mounting bracket (Figure 2, Item 6) on Genset and discard.
END OF TASK
REPLACEMENT
1 Secure circuit breaker (Figure 2, Item 17) to mounting bracket (Figure 2, Item 6) on Genset using two lock
nuts (Figure 2, Item 16), machine screws (Figure 2, Item 14), and four flat washers (Figure 2, Item 15).
NOTE
Prior to performing the following step, inspect terminal lugs (Figure 2, Item 3) and
associated wiring. Ensure that wire has not become brittle and that there are no
nicks, cuts or other damage to wire. Inspect circuit breaker terminals (Figure 2,
Item 18) ensure that no damage or corrosion exists.
2. Connect terminal lugs (Figure 2, Item 3) to circuit breaker terminals (Figure 2, Item 18). Secure using two
nuts (Figure 2, Item 1) and lock washers (Figure 2, Item 2). (See Table 1).
3 Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
4. Install access panel(s) (not shown) and cargo restraints (not shown).
5. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
END OF WORK PACKAGE
0052-9/10 blank
TM 11-6115-742-13&P 0053
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET STARTER
STARTER REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic's tool kit, (WP 0165, Item 1) WP 0005, WP 0041
Safety glasses
Materials/Parts Equipment Condition
Starter Genset shut down
BATTERY SWITCH - OFF
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of the Genset starter. If necessary,
refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If Genset has been in operation, components may be extremely hot. To prevent
serious injury to personnel, allow the Genset to cool down before performing
procedures.
0053-1
TM 11-6115-742-13&P 0053
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, components may be extremely hot. To prevent
serious injury to personnel, allow the Genset to cool down before performing the
following procedure.
1. Verify that Genset (Figure 1, Item 1) has been shut down, engine is cool, and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove front access panel (Figure 1, Item 2) and set aside.
4. Remove rear access panel (not shown) and disconnect battery ground cable (black) from battery ground
terminal (if necessary, refer to procedure in (WP 0041) of this TM).
CAUTION
To prevent serious injury to personnel place battery cable far enough away from
battery terminal so that cable does not inadvertently touch positive (+) terminal
on battery.
5. Disconnect red cable(s) from positive (+) terminal of battery and set aside (if necessary, refer to procedure in
(WP 0041) of this TM).
6. Remove and retain nut (Figure 1, Item 9) from starter terminal (Figure 1, Item 4).
7. Disconnect battery cable (Figure 1, Item 8) from starter terminal (Figure 1, Item 4) and set aside. Loosely
install nut (Figure 1, Item 10) and lock washer (Figure 1, Item 9) onto starter terminal (Figure 1, Item 4).
8. Disconnect terminal (Figure 1, Item 7) from terminal on starter.
0053-2
TM 11-6115-742-13&P 0053
REMOVAL – Continued
9. Remove and retain lower mounting bolt (Figure 1, Item 6) from starter (Figure 1, Item 5).
10. Remove and retain upper mounting bolt (Figure 1, Item 3) from starter (Figure 1, Item 5).
11. Pull starter (Figure 1, Item 5) away from starter mount on engine assembly and set aside.
END OF TASK
REPLACEMENT
1. Insert starter (Figure 1, Item 5) into the starter mount on engine and secure using two bolts (Figure 1, Items 3
and 6).
2. Using torque wrench, tighten two bolts (Figure 1, Items 3 and 6) on starter (Figure 1, Item 5) to 93~113 ft./lb
(69~83 n-m/9.5~11.5 kgf-m).
NOTE
Prior to performing the following step, inspect terminals on battery cable
(Figure 1, Item 8) and second red wire (Figure 1, Item 7) and wire for
connectivity. Ensure that wire has not become brittle and that there are no nicks,
cuts or other damage to wire.
3. Connect battery cable (Figure 1, Item 8) to starter terminal (Figure 1, Item 4). Secure to starter terminal
(Figure 1, Item 4) with nut (Figure 1, Item 9).
4. Connect terminal lug (Figure 1, Item 7) to terminal on starter (Figure 1, Item 5).
5. Connect battery cable (Figure 1, Item 8) to positive (+) terminal of battery (if necessary, refer to procedure in
(WP 0041) of this TM).
6. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM) and install rear access panel (not shown).
7. Install front access panel (Figure 1, Item 2).
8. Install cargo restraints (not shown).
9. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0053-3
TM 11-6115-742-13&P 0053
2
5
3 4
8 7
Figure 1. Starter Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0053-4
TM 11-6115-742-13&P 0054
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET DIESEL SPEED SENSOR
DIESEL SPEED SENSOR REMOVAL/INSPECT/TEST/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit, (WP 0165, Item 1) One
Multimeter (WP 0165, Item 2)
Safety glasses References
WP 0005, WP 0041
Materials/Parts
Speed sensor, diesel Equipment Condition
Anti-seize compound (WP 0168, Item 3) Genset shut down
Cloth, cleaning (WP 0168, Item 14) BATTERY SWITCH - OFF
GENERAL
This work package provides information on the removal and replacement of the Genset diesel speed sensor. If
necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
0054-1
TM 11-6115-742-13&P 0054
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following procedure.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
The diesel speed sensor (Figure 1, Item 4) is located just left of the fuel pump.
TEST
1. Start Genset (Figure 1, Item 1) in accordance with Genset Start Procedure (WP 0005) of this TM.
2. Set multimeter to read VAC.
3. Touch terminals (figure 1, items 5 and 6) of diesel engine speed sensor (Figure 1, Item 4) with meter leads.
Multimeter should read between 2.5 and 5 VAC. If meter indication not with-in spec replace pickup sensor.
END OF TASK
REMOVAL
1. Shut Genset (Figure 1, Item 1) down and set BATTERY SWITCH to OFF (WP 0005, Genset Shut Down
Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel (Figure 1, Item 2).
3. Remove rear access panel (Figure 1, Item 2) and set aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
0054-2
TM 11-6115-742-13&P 0054
REMOVAL – Continued
5. Disconnect two terminals (Figure 1, Items 5 and 6) coming off of diesel speed sensor (Figure 1, Item 4) from
engine harness.
NOTE
When performing the following step, be observant of all items around the diesel
speed sensor (Figure 1, Item 4).
6. Loosen locking nut (Figure 1, Item 3) on diesel speed sensor (Figure 1, Item 4).
7. Loosen diesel speed sensor (Figure 1, Item 4) and remove from engine.
END OF TASK
INSPECTION
Check head of diesel speed sensor (Figure 1, Item 4) for evidence of scraping or striking the fly wheel. If damage
is evident replace sensor with new one.
END OF TASK
REPLACEMENT
1. Clean off old anti-seize compound from all threaded areas.
WARNING
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
NOTE
Do not get anti-seize compound on ends of diesel speed sensor (Figure 1,
Item 4).
2. Apply anti-seize compound to threads of diesel speed sensor (Figure 1, Item 4).
CAUTION
When the following step is being performed, diesel speed sensor (Figure 1,
Item 4) should screw in without resistance. Do not force diesel speed sensor
(Figure 1, Item 4) or cross thread. Failure to observe this caution can result in
damage to the engine.
3. Install diesel speed sensor (Figure 1, Item 4). Tighten until diesel speed sensor (Figure 1, Item 4) bottoms
out.
0054-3
TM 11-6115-742-13&P 0054
REPLACEMENT – Continued
NOTE
Failure to back diesel speed sensor (Figure 1, Item 4) off 1/4 turn can result in
magnetic pickup on diesel speed sensor (Figure 1, Item 4) striking the fly wheel
and becoming damaged thus making it unserviceable.
Backing diesel speed sensor (Figure 1, Item 4) off more than 1/4 turn can
prevent magnetic pickup on diesel speed sensor (Figure 1, Item 4) from detecting
the rotation of the fly wheel.
4. Turn diesel speed sensor (Figure 1, Item 4) back counter clockwise 1/4 turn.
5. Tighten locking nut (Figure 1, Item 3) (clockwise).
6. Connect two terminals (Figure 1, Items 5 and 6) coming off of diesel speed sensor (Figure 1, Item 4) to
engine harness.
7. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
8. Install rear access panel (Figure 1, Item 2).
9. Install cargo restraints (not shown).
10. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0054-4
TM 11-6115-742-13&P 0054
3
4
1
5
6
Figure 1. Diesel Speed Sensor Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0054-5/6 blank
TM 11-6115-742-13&P 0055
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET COOLANT TEMPERATURE SENSOR
COOLANT TEMPERATURE SENSOR REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic's tool kit, (WP 0165, Item 1) WP 0005, WP 0041, WP 0058
Safety glasses
Materials/Parts Equipment Condition
Temperature coolant sensor Genset shut down
Teflon tape (WP 0168, Item 58) BATTERY SWITCH – OFF
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of the engine coolant temperature
sensor.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0055-1
TM 11-6115-742-13&P 0055
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
Engine coolant temperature sensor is located on the front of the engine
in the thermostat housing.
REMOVAL
1. Verify that Genset (Figure 1, Item 15) has been shut down, engine is cool and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove the front and rear access panels (Figure 1, Items 8 and 16) on Genset (Figure 1, Item 15) and set
aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
Steps 5 and 6 are optional.
5. Loosen but do not remove nut (Figure 1, Item 4) and bolt (Figure 1, Item 2) that secures exhaust pipe cap.
Remove exhaust pipe cap (Figure 1, Item 3) and set aside.
6. Remove and retain 20 bolts (Figure 1, Item 7), lock washers (Figure 1, Item 6), and flat washers (Figure 1,
Item 5) that secure top access panel (Figure 1, Item 1) to Genset (Figure 1, Item 15). Remove top access
panel (Figure 1, Item 1) and set aside.
0055-2
TM 11-6115-742-13&P 0055
REMOVAL – Continued
7. Drain engine coolant as described in (WP 0058).
NOTE
Place towels or pads below radiator to absorb any excess fluid.
8. Remove nut (Figure 1, Item 13) and washer (Figure 1, Item 12) securing terminal lug (Figure 1, Item 11) to
coolant temperature sensor (Figure 1, Item 10). Mark and disconnect terminal lug (Figure 1, Item 11).
NOTE
When performing the following step, use a second wrench to keep mounting
elbow from turning.
When performing the following step, be cautious of items surrounding coolant
temperature sensor (Figure 1, Item 10).
9. Remove coolant temperature sensor (Figure 1, Item 10) from thermostat housing (Figure 1, Item 9).
END OF TASK
REPLACEMENT
1. Apply teflon tape to threads of coolant temperature sensor (Figure 1, Item 10).
CAUTION
When the following step is being performed, do not force coolant temperature
sensor or cross thread. Failure to observe this caution can result in damage to
the engine.
NOTE
When performing the following step, use a second wrench to keep mounting nut
(Figure 1, Item 14) from turning.
2. Install coolant temperature sensor (Figure 1, Item 10) onto thermostat housing (Figure 1, Item 9) and tighten.
3. Using torque wrench, tighten coolant temperature sensor (Figure 1, Item 10) on thermostat housing (Figure 1,
Item 9) to 9~13 ft./lb (12~18 n-m/1.2~1.8 kgf-m).
NOTE
Prior to performing the following step, inspect terminal lug (Figure 1, Item 11) and
terminal for connectivity. Ensure that terminal lug has not become brittle and that
there are no nicks, cuts or other damage to terminal lug.
4. Install terminal lug (Figure 1, Item 11) onto coolant temperature sensor (Figure 1, Item 10) and secure with
nut
(Figure 1, Item 13) and washer (Figure 1, Item 12).
5. Install top access panel (Figure 1, Item 1) onto Genset (Figure 1, Item 15) and secure using 20 bolts
(Figure 1, Item 7), lock washers (Figure 1, Item 6) and flat washers (Figure 1, Item 5).
6. Install exhaust pipe cap (Figure 1, Item 3) and tighten nut (Figure 1, Item 4) and bolt (Figure 1, Item 2) that
secure exhaust pipe cap (Figure 1, Item 3).
0055-3
TM 11-6115-742-13&P 0055
REPLACEMENT – Continued
7. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
8. Replace front and rear access panels (Figure 1, Items 8 and 16) on Genset (Figure 1, Item 15).
9. Install cargo restraints (not shown).
10. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
3
2 5
4 6
7
16
15 10
11
12
13
14
Figure 1. Coolant Temperature Sensor Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0055-4
TM 11-6115-742-13&P 0056
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET COOLANT TEMPERATURE SWITCH
COOLANT TEMPERATURE SWITCH REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic's tool kit, (WP 0165, Item 1) WP 0005, WP 0041
Safety glasses
Equipment Condition
Materials/Parts Genset shut down
Coolant temperature switch BATTERY SWITCH - OFF
Teflon tape (WP 0168, Item 58)
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of the engine coolant temperature
switch.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0056-1
TM 11-6115-742-13&P 0056
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
1. Verify that Genset (Figure 1, Item 1) has been shut down, engine is cool and that BATTERY SWITCH is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove front access panel (Figure 1, Item 2) and set aside.
3. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
4. Remove rear access panel (not shown) and disconnect battery ground cable (black) from battery ground
terminal (if necessary, refer to procedure in (WP 0041) of this TM).
NOTE
The coolant temperature switch (Figure 1, Item 3) is located above the alternator.
Prior to performing the following step, mark terminal lugs (Figure 1, Items 5) and
terminals for connectivity.
5. Remove and retain two screws (Figure 1, Item 4) and terminal lugs (Figure 1, Items 5) connected to coolant
temperature switch (Figure 1, Item 3).
NOTE
When performing the following step, be cautious of items surrounding coolant
temperature switch (Figure 1, Item 3).
0056-2
TM 11-6115-742-13&P 0056
REMOVAL – Continued
NOTE
When performing the following step, use a second wrench to keep mounting
elbow from turning.
6. Remove coolant temperature switch (Figure 1, Item 3) from engine.
END OF TASK
REPLACEMENT
1. Apply Teflon tape to threads of coolant temperature switch (Figure 1, Item 3).
CAUTION
When the following step is being performed, do not force temperature coolant
switch (Figure 1, Item 3) or cross thread. Failure to observe this caution can
result in damage to the engine.
NOTE
When performing the following step, use a second wrench to keep mounting
elbow from turning.
2. Install coolant temperature switch (Figure 1, Item 3) onto mounting elbow and hand tighten.
3. Using torque wrench, tighten coolant temperature switch (Figure 1, Item 3) to 9~13 ft./lb (12~18 n-m/
1.2~1.8 kgf-m).
NOTE
Prior to performing the following step, inspect terminal lugs (Figure 1, Item 5) and
terminals for connectivity. Ensure that terminal lug has not become brittle and
that there are no nicks, cuts or other damage to terminal lug.
4. Secure two terminal lugs (Figure 1, Item 5) to coolant temperature switch (Figure 1, Item 3) with two screws
(Figure 1, Item 4).
5. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM) and install rear access panel (not shown).
6. Install front access panel (Figure 1, Item 2).
7. Install cargo restraints (not shown).
8. Start Genset (Figure 1, Item 1) in accordance with Genset Start Procedure (WP 0005) of this TM.
0056-3
TM 11-6115-742-13&P 0056
1
5
3 4
Figure 1. Coolant Temperature Switch Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0056-4
TM 11-6115-742-13&P 0057
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET THERMOSTAT
THERMOSTAT REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic's tool kit, (WP 0165, Item 1) One
Safety glasses
References
Materials/Parts WP 0005, WP 0041
Thermostat
Gasket Equipment Condition
Abrasive mesh cloth (WP 0168, Item 13) Genset shut down
Cloth, cleaning (WP 0168, Item 14) BATTERY SWITCH - OFF
Gasket sealant (WP 0168, Item 49)
GENERAL
This work package provides information on the removal and replacement of the Genset thermostat. If necessary,
refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
0057-1
TM 11-6115-742-13&P 0057
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in a operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
1. Verify that Genset (Figure 1, Item 16) has been shut down, engine is cool and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove the front and rear access panels (Figure 1, Items 5 and 17) on Genset (Figure 1, Item 16) and set
aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
5. Loosen but do not remove nut (Figure 1, Item 3) and bolt (Figure 1, Item 1) that secures exhaust pipe cap.
Remove exhaust pipe cap (Figure 1, Item 2) and set aside.
6. Remove and retain 20 bolts (Figure 1, Item 18), lock washers (Figure 1, Item 19) and flat washers (Figure 1,
Item 20) that secure top access panel (Figure 1, Item 4) to Genset (Figure 1, Item 16). Remove top access
panel (Figure 1, Item 4) and set aside.
NOTE
Place towels or pads below radiator to absorb any excess fluid.
7. Loosen clamp (Figure 1, Item 10) and remove coolant hose (Figure 1, Item 11) from thermostat housing
(Figure 1, Item 8).
8. Remove and retain nut (Figure 1, Item 15) and washer (Figure 1, Item 14) that secures wire terminal
(Figure 1, Item 6) to thermostat housing (Figure 1, Item 8).
0057-2
TM 11-6115-742-13&P 0057
REMOVAL-Continued
9. Remove and retain two bolts (Figure 1, Item 7) that secure thermostat housing (Figure 1, Item 8) to water
pump (Figure 1, Item 13).
10. Remove and retain thermostat housing (Figure 1, Item 8) from water pump housing (Figure 1, Item 13).
11. Tap on thermostat (Figure 1, Item 12) to break seal and remove thermostat (Figure 1, Item 12).
12. Remove gasket (Figure 1, Item 9) from thermostat (Figure 1, Item 12) and water pump housing (Figure 1,
Item 13).
END OF TASK
REPLACEMENT
CAUTION
When performing the following step, do not damage the water pump or
thermostat housing.
1. Scrape off old gasket material from thermostat housing and water pump housing. If necessary, clean area
with 220 grit sandpaper or abrasive mesh cloth to remove all residue.
WARNING
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
2. Place thin layer of gasket sealant to top and bottom of gasket (Figure 1, Item 9) to hold in place during
assembly.
3. Install gasket (Figure 1, Item 9) onto water pump housing (Figure 1, Item 13).
4. Install thermostat (Figure 1, Item 12) and thermostat housing (Figure 1, Item 8) onto water pump housing
(Figure 1, Item 13).
5. Secure thermostat housing (Figure 1, Item 8) to water pump housing (Figure 1, Item 13) using two bolts
(Figure 1, Item 7).
6. Using torque wrench, tighten two bolts (Figure 1, Item 7) on thermostat housing (Figure 1, Item 8) to
14~21 ft./lb (19~28 n-m/1.9~2.9 kgf-m).
NOTE
Prior to performing the following step: inspect coolant hose for cracks, swelling,
or other obvious deterioration. Inspect clamp, verify that no damage, corrosion,
or other obvious deterioration is present.
7. Install coolant hose (Figure 1, Item 11) onto thermostat housing (Figure 1, Item 8) and tighten clamp
(Figure 1, Item 10).
0057-3
TM 11-6115-742-13&P 0057
REPLACEMENT – Continued
NOTE
Prior to performing the following step, inspect wire and terminal for connectivity.
Ensure that wires have not become brittle and that there are no nicks, cuts or
other damage to wire.
8. Connect wire terminal (Figure 1, Item 6) to thermostat housing (Figure 1, Item 8) secure with nut (Figure 1,
Item 15) and washer (Figure 1, Item 14).
9. Install top access panel (Figure 1, Item 4) onto Genset (Figure 1, Item 16) and secure using 20 bolts
(Figure 1, Item 18), lock washers (Figure 1, Item 19) and flat washers (Figure 1, Item 20).
10. Install exhaust pipe cap (Figure 1, Item 2) and tighten nut (Figure 1, Item 3) and bolt (Figure 1, Item 1) that
secure exhaust pipe cap (Figure 1, Item 2).
11. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM) and install rear access panel (not shown).
12. Replace front and rear access panels (Figure 1, Items 5 and 17) on Genset (Figure 1, Item 16).
13. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0057-4
TM 11-6115-742-13&P 0057
19
18
17
7
5 6
15
8 10
14
11
9
12
16
13
Figure 1. Thermostat Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0057-5/6 blank
TM 11-6115-742-13&P 0058
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET ENGINE COOLANT SERVICE
ENGINE COOLANT REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit, (WP 0165, Item 1) One
Safety glasses
Drain pan References
WP 0005
Materials/Parts
Coolant (WP 0168, Item 2) Equipment Condition
Cloth, cleaning (WP 0168, Item 14) Genset shut down
Teflon tape (WP 0168, Item 58) BATTERY SWITCH - OFF
Coolant Bottle
GENERAL
This work package provides information on the removal and replacement of engine coolant in the Genset engine.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0058-1
TM 11-6115-742-13&P 0058
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
REMOVAL
1. Verify that Genset (Figure 1, Item 6) has been shut down, engine is cool and that BATTERY SWITCH is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove the front and rear access panels (Figure 1, Items 1 and 5) on Genset (Figure 1, Item 6) and set
aside.
NOTE
Coolant drain plug (Figure 1, Item 7) is located on the front base of the Genset
enclosure.
4. Place drain pan under coolant drain plug (Figure 1, Item 7). Remove and retain coolant drain plug (Figure 1,
Item 7).
5. Insert one end of a drain hose into the engine coolant outlet and place opposite end in drain pan. Use of a
drain hose will reduce spillage.
NOTE
Collect coolant in an appropriate chemical-resistant container for disposal
through the local servicing Defense Reutilization and Marketing Office.
6. Open coolant drain valves (Figure 1, Item 8 and 9) inside Genset enclosure. Allow coolant to drain into drain
pan.
WARNING
Do not remove radiator cap until coolant temperature is below its boiling point.
Radiator can erupt and cause severe burns. Once cooling has occurred, loosen
cap slightly to relieve any excess pressure before removing the cap completely.
Failure to observe this warning can result in severe injury to personnel.
7. Once flow of coolant starts to slow, remove radiator cap (Figure 1, Item 2).
8. Loosen clamp (Figure 1, Item 4), remove coolant reservoir bottle (Figure 1, Item 3) and dump contents into
drain pan. Rinse coolant reservoir bottle (Figure 1, Item 3) with clean water.
END OF TASK
0058-2
TM 11-6115-742-13&P 0058
REPLACEMENT
1. Return coolant reservoir bottle (Figure 1, Item 3) to holder and secure with clamp (Figure 1, Item 4).
2. Close coolant drain valves (Figure 1, Items 8 and 9).
3. Remove drain hose and return to storage.
4. Wrap coolant drain plug threads (Figure 1, Item 7) with Teflon tape, install and tighten.
NOTE
Prior to performing the following step:
• Inspect radiator for dents, holes, or leaks.
• Inspect radiator hoses for cracks, swelling, or other obvious deterioration.
• Inspect hose clamps. Verify that clamps are secure and that no damage or
other obvious deterioration is present.
5. Place funnel into radiator cap (Figure 1, Item 2) through access hole on top of the Genset.
6. Add proper coolant/water mix (see Table 1) as necessary to bring the radiator to proper level. Replace the
radiator cap (Figure 1, Item 2) and tighten.
7. Add coolant mix as necessary to bring the coolant reservoir bottle (Figure 1, Item 3) 1/3 to 1/2 full.
8. Install reservoir bottle cap and tighten.
9. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM. Run for 15 minutes until
operational temperature.
10. Shut down Genset (Figure 1, Item 6) in accordance with Genset Stop Procedure (WP 0005).
WARNING
Do not remove radiator cap until coolant temperature is below its boiling point.
Radiator can erupt and cause severe burns. Once cooling has occurred, loosen
cap slightly to relieve any excess pressure before removing the cap completely.
Failure to observe this warning can result in severe injury to personnel.
11. Check Genset coolant levels. Coolant should be one inch below the overflow level. Bottle should be 1/3 to
1/2 full when cool. If levels do not meet these requirements repeat steps 4 through 9 until levels are reached.
0058-3
TM 11-6115-742-13&P 0058
REPLACEMENT – Continued
12. Replace front and rear access panels (Figure 1, Items 1 and 5) on Genset (Figure 1, Item 6).
13. Install cargo restraints (not shown) to rear of Genset.
14. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
NOTE
Table 1. Radiator Coolant to Water Ratios.
Coolant Water
Conditions Freezing point Boiling point
(by volume) (by volume)
Normal 40% 60% -10°F (-23.33°C) 260°F (126.66°C)
50% 50% -34°F(-36.66°C) 265°F (129.44°C)
Arctic 60% 40% -62°F (-52.22°C) 270°F (132.22°C)
72
3
9
31
4
8
25
58 69
16
4
7
Figure 1. Engine Coolant Removal/Replacement.
END OF TASK
0058-4
TM 11-6115-742-13&P 0058
ENGINE COOLANT RESERVOIR BOTTLE REMOVAL/REPLACEMENT
WARNING
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
REMOVAL
1. Verify that Genset (Figure 2, Item1) has been shut down, engine is cool and that BATTERY SWITCH is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove the rear access panel (Figure 2, Item 2) on Genset (Figure 2, Item 1) and set aside.
3. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
4. Disconnect overflow tube (Figure 2, Item 7) from coolant reservoir bottle (Figure 2, Item 3).
5. Loosen, but do not remove, bolt (Figure 2, Item 4), nut (Figure 2, Item 6) and two flat washers (Figure 2,
Item 5).
6. Remove coolant reservoir bottle (Figure 2, Item 3) and properly dispose of reservoir bottle (Figure 2, Item 3)
and contents.
END OF TASK
REPLACEMENT
1. Insert coolant reservoir bottle (Figure 2, Item 3) and secure using bolt (Figure 2, Item 4), nut (Figure 2, Item 6)
and two flat washers (Figure 2, Item 5).
2. Connect overflow tube (Figure 2, Item 7) to coolant reservoir bottle (Figure 2, Item 3).
3. Add coolant mix as necessary to bring the coolant reservoir bottle (Figure 2, Item 3) 1/3 to 1/2 full.
0058-5
TM 11-6115-742-13&P 0058
REPLACEMENT - Continued
4. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
5. Start Genset (Figure 2, Item 1) in accordance with Genset Start Procedure (WP 0005) of this TM. Run for 15
minutes until operational temperature and observe coolant level in reservoir bottle (Figure 2, Item 3). If
necessary add coolant mix.
6. Replace rear access panel (Figure 2, Item 2) on Genset (Figure 2, Item 1).
7 6 5
Figure 2. Engine Coolant Reservoir Bottle Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0058-6
TM 11-6115-742-13&P 0059
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET RADIATOR
RADIATOR, HOSES AND CLAMPS REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit, (WP 0165, Item 1) One
Drain pan
Safety glasses References
WP 0005, WP 0041, WP 0058
Materials/Parts WP 0062
Radiator hose(s)
Clamps Equipment Condition
Cloth, cleaning (WP 0168, Item 14) Genset shut down
Coolant (WP 0168, Item 2) BATTERY switch – OFF
GENERAL
This work package provides information on the removal and replacement of the Genset radiator, hoses, and
clamps. If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
0059-1
TM 11-6115-742-13&P 0059
WARNING
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Do not remove radiator cap until coolant temperature is below its boiling point.
Radiator can erupt and cause severe burns. Once cooling has occurred, loosen
cap slightly to relieve any excess pressure before removing the cap completely.
Failure to observe this warning can result in severe injury to personnel.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
HOSE AND CLAMPS
REMOVAL
1. Verify that Genset (Figure 1, Item 12) has been shut down, engine is cool and that BATTERY switch is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove the front and rear access panels (Figure 1, Items 14 and 18) on Genset (Figure 1, Item 12) and set
aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
5. Loosen but do not remove nut (Figure 1, Item 3) and bolt (Figure 1, Item 1) that secures exhaust pipe cap
(Figure 1, Item 2). Remove exhaust pipe cap (Figure 1, Item 2) and set aside.
6. Remove and retain 20 bolts (Figure 1, Item 19) lock washers (Figure 1, Item 20) and flat washers (Figure 1,
Item 21) that secures top access panel (Figure 1, Item 22) to Genset (Figure 1, Item 12). Remove top access
panel (Figure 1, Item 22) and set aside.
0059-2
TM 11-6115-742-13&P 0059
REMOVAL – Continued
7. Drain coolant from radiator as describe in (WP 0058).
8. Loosen hose clamps (Figure 1, Item 9) of radiator hose(s) (Figure 1, Items 8 and 13) to be replaced.
NOTE
Place a drip bucket or absorbent pad under radiator hose(s) to be replaced in
case of spillage.
9. Pull radiator hose(s) (Figure 1, Items 8 and 13) away from connection using a twisting motion. Remove
radiator hose(s) (Figure 1, Items 8 and 13).
10. Remove and retain hose clamps (Figure 1, Item 9) and discard radiator hose(s) (Figure 1 Items 8 and 13).
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following steps:
• Inspect radiator for dents, holes, or leaks
• If re-using radiator hose(s) (Figure 1, Items 8 and 13), inspect for cracks,
swelling, or other obvious deterioration
• If re-using inspect hose clamps (Figure 1, Item 9), verify that no damage or
other obvious deterioration is present.
Ensure hose clamps (Figure 1, Item 9) are placed on radiator hoses (Figure 1,
Items 8 and 13) so that screws will be accessible after installation.
1. Loosely place hose clamps (Figure 1, Item 9) onto radiator hose(s) (Figure 1, Items 8 and 13) and slide
toward center of radiator hose (Figure 1, Items 8 and 13).
NOTE
To ensure a good seal, when the hose clamp (Figure 1, Item 9) is tightened down
most radiator connections have a ridge built into them.
2. Install radiator hose(s) (Figure 1, Items 8 and 13) onto radiator and engine connection(s). Ensure radiator
hose(s) (Figure 1, Items 8 and 13) are slid back far enough.
CAUTION
Over tightening hose clamps (Figure 1, Item 9) can damage radiator hose(s)
(Figure 1, Items 8 and 13) and cause premature failure.
3. Slide hose clamps (Figure 1, Item 9) into proper positions and tighten hose clamps (Figure 1, Item 9), until
hose clamps (Figure 1, Item 9) begin to press into radiator hose(s) (Figure 1, Items 8 and 13).
4. Replace coolant as describe in (WP 0058).
5. Install top access panel (Figure 1, Item 22) onto Genset (Figure 1, Item 12) and secure using 20 bolts
(Figure 1, Item 19), lock washers (Figure 1, Item 20), and flat washers (Figure 1, Item 21).
0059-3
TM 11-6115-742-13&P 0059
REPLACEMENT – Continued
6. Install exhaust pipe cap (Figure 1, Item 2) and tighten nut (Figure 1, Item 3) and bolt (Figure 1, Item 1) that
secure exhaust pipe cap (Figure 1, Item 2).
7. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM) and install rear access panel (Figure 1, Item 18).
8. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM. Run for 15 minutes until
engine has reached operational temperature.
WARNING
Do not remove radiator cap until coolant temperature is below its boiling point.
Radiator can erupt and cause severe burns. Once cooling has occurred, loosen
cap slightly to relieve any excess pressure before removing the cap completely.
Failure to observe this warning can result in severe injury to personnel.
9. Check Genset coolant levels. Coolant should be one inch below the overflow level. Bottle should be 1/3 to
1/2 full when cool.
10. Replace front and rear access panels (Figure 1, Items 14 and 18) on Genset (Figure 1, Item 12).
11. Install cargo restraints (not shown) to rear of Genset.
12. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
RADIATOR
REMOVAL
1. Verify that Genset (Figure 1, Item 12) has been shut down, engine is cool and that BATTERY switch is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove the front and rear access panels (Figure 1, Items 14 and 18) on Genset (Figure 1, Item 12) and set
aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
5. Loosen but do not remove nut (Figure 1, Item 3) and bolt (Figure 1, Item 1) that secures exhaust pipe cap
(Figure 1, Item 2). Remove exhaust pipe cap (Figure 1, Item 2) and set aside.
6. Remove and retain 20 bolts (Figure 1, Item 19), lock washers (Figure 1, Item 20), and flat washers (Figure 1,
Item 21), that secures top access panel (Figure 1, Item 22) to Genset (Figure 1, Item 12). Remove top
access panel (Figure 1, Item 22) and set aside.
0059-4
TM 11-6115-742-13&P 0059
REMOVAL – Continued
WARNING
Do not remove radiator cap or drain until coolant temperature is below its boiling
point. Radiator can erupt and cause severe burns. Once cooling has occurred,
loosen cap slightly to relieve any excess pressure before removing the cap
completely. Failure to observe this warning can result in severe injury to
personnel.
7. Drain coolant from radiator (Figure 1, Item 7) as described in (WP 0058).
8. Disconnect overflow hose (Figure 1, Item 5) from radiator (Figure 1, Item 7) and move aside.
9. Remove fan and shroud as described in (WP 0062).
10. Loosen clamp (Figure 1, Item 10) and disconnect drain hose (Figure 1, Item 11) from radiator (Figure 1,
Item 7).
11. Remove clamps (Figure 1, Items 9) and hoses (Figure 1, Items 8 and 13).
12. Remove and retain six bolts (Figure 1, Item 17), lock washers (Figure 1, Item 16), and flat washers (Figure 1,
Item 15), that secure radiator (Figure 1, Item 7) to frame (Figure 1, Item 4).
13. Remove radiator (Figure 1, Item 7) from frame (Figure 1, Item 4).
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following steps:
• Inspect radiator for dents, holes, or leaks
• If re-using radiator hose(s) (Figure 1, Items 8 and 13), inspect for cracks,
swelling, or other obvious deterioration
• If re-using hose clamps (Figure 1, Item 9), inspect and verify that no
damage or other obvious deterioration is present.
• Inspect fan, fan belt, water pump and all other exposed engine parts, verify
that no damage or other obvious deterioration is present.
Ensure hose clamps (Figure 1, Item 9) are placed on radiator hoses (Figure 1,
Items 8 and 13) so that screws will be accessible after installation.
1. Install radiator (Figure 1, Item 7) and secure to frame (Figure 1, Item 4) using six bolts (Figure 1, Item 17),
lock washers (Figure 1, Item 16) and flat washers (Figure 1, Item 15),
2. Connect drain hose (Figure 1, Item 11) to radiator (Figure 1, Item 7) and secure with clamp (Figure 1,
Item 10).
3. Install fan and shroud as described in (WP 0062).
4. Connect overflow hose (Figure 1, Item 5) to radiator (Figure 1, Item 7).
5. Install hoses (Figure 1, Items 8 and 13) and clamps (Figure 1, Items 9).
6. Add coolant to radiator (Figure 1, Items 7) as described in (WP 0058).
0059-5
TM 11-6115-742-13&P 0059
REPLACEMENT – Continued
7. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
8. Install top access panel (Figure 1, Item 22) onto Genset (Figure 1, Item 12) and secure using 20 bolts
(Figure 1, Item 19), lock washers (Figure 1, Item 20) and flat washers (Figure 1, Item 21).
9. Install exhaust pipe cap (Figure 1, Item 2) and tighten nut (Figure 1, Item 3) and bolt (Figure 1, Item 1) that
secure exhaust pipe cap (Figure 1, Item 2).
10. Start Genset (Figure 1, Items 12) in accordance with Genset Start Procedure (WP 0005) of this TM. Run for
15 minutes until operational temperature.
WARNING
Do not remove radiator cap until coolant temperature is below its boiling point.
Radiator can erupt and cause severe burns. Once cooling has occurred, loosen
cap slightly to relieve any excess pressure before removing the cap completely.
Failure to observe this warning can result in severe injury to personnel.
11. Check Genset coolant levels. Coolant should be one inch below the overflow level. Bottle should be 1/3 to
1/2 when cool.
12. Replace front and rear access panels (Figure 1, Items 14 and 18) on Genset (Figure 1, Item 12).
13. Install cargo restraints (not shown) to rear of Genset.
14. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0059-6
TM 11-6115-742-13&P 0059
1
2
22
21
20
19
18
17
16 4
15
5
14
8
10
11
9
13
9 12
Figure 1. Radiator, Hoses, and Clamps Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0059-7/8 blank
TM 11-6115-742-13&P 0060
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET ALTERNATOR
ALTERNATOR REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit, (WP 0165, Item 1) WP 0005, WP 0041
Safety glasses
Equipment Condition
Materials/Parts Genset shut down
Alternator BATTERY SWITCH - OFF
Personnel Required
One
GENERAL
This work package provides information on the services, adjustments removal and replacement of the Genset
alternator.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0060-1
TM 11-6115-742-13&P 0060
WARNING
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
1. Verify that Genset (Figure 1, Item 1) has been shut down, engine is cool and that BATTERY SWITCH is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset (Figure 1, Item 1).
3. Remove the front access panel (Figure 1, Item 2) on Genset (Figure 1, Item 1) and set aside.
4. Remove rear access panel (not shown) and disconnect battery ground cable (black) from battery ground
terminal (if necessary, refer to procedure in (WP 0041) of this TM).
5. Loosen but do not remove bottom mounting bolt (Figure 1, Item 12) and nut (Figure 1, Item 10).
6. Loosen but do not remove alignment bolt (Figure 1, Item 14) on alternator bracket (Figure 1, Item 15).
7. Loosen but do not remove hinge bolt (Figure 1, Item 16) on alternator bracket (Figure 1, Item 15).
8. Push alternator (Figure 1, Item 11) towards engine and loosen fan belt (Figure 1, Item 13).
9. Remove and retain nut (Figure 1, Item 3), lock washer (Figure 1, Item 4) and wire (Figure 1, Item 5) from main
output stud on alternator (Figure 1, Item 11). Re-install nut (Figure 1, Item 3), lock washer (Figure 1,Item 4).
10. Disconnect wire terminal (Figure 1, Item 9) from alternator (Figure 1, Item 11).
11. Remove and retain nut (Figure 1, Item 6), lock washer (Figure 1, Item 7) and ground wire (Figure 1, Item 8)
from ground stud on alternator (Figure 1, Item 11). Re-install nut (Figure 1, Item 6) and lock washer
(Figure 1, Item 7).
0060-2
TM 11-6115-742-13&P 0060
REMOVAL – Continued
12. Remove and retain bottom mounting bolt (Figure 1, Item 12) and nut (Figure 1, Item 10).
13. Remove and retain top mounting bolt (Figure 1, Item 14).
14. Remove alternator (Figure 1, Item 11) from guides in the engine block.
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following step, inspect ground wire (Figure 1, Item 8) wire
terminal (Figure 1, Item 9), and wire (Figure 1, Item 5) for connectivity. Ensure
that wires have not become brittle and that there are no nicks, cuts or other
damage to wire.
1. Insert alternator (Figure 1, Item 11) onto guides in the engine block.
2. Align bottom bolt hole of alternator (Figure 1, Item 11) with corresponding hole on engine block.
3. Insert bottom mounting bolt (Figure 1, Item 12) and nut (Figure 1, Item 10) and tighten until touching engine
mount. Leave slack in bolt to allow movement.
4. Rotate alternator (Figure 1, Item 11) into the up position. Align bolt hole with groove in adjusting slide.
5. Insert alignment bolt (Figure 1, Item 14) through adjusting groove and alternator. Finger tighten.
NOTE
Fan belt should have no more than 0.3~0.33 in. (7.5~8.5 mm) of play when
flexed on longest side.
6. Install fan belt (Figure 1, Item 13) and perform adjustment procedure.
7. Using torque wrench, tighten bottom mounting bolt (Figure 1, Item 12) and nut (Figure 1, Item 10), alignment
bolt (Figure 1, Item 14) to 14~21 ft./lb (19~28 n-m/1.9~2.9 kgf-m).
8. Using torque wrench, tighten alternator bracket hinge bolt (Figure 1, Item 16) to 25~34 ft./lb (34~46 n-
m/3.5~4.7 kgf-m).
9. Connect ground wire (Figure 1, Item 8) (green with looped connector) to ground stud on alternator (Figure 1,
Item 11) and secure with nut (Figure 1, Item 6) and lock washer (Figure 1, Item 7)
10. Connect wire (Figure 1, Item 5) (loop connector) to main output stud on alternator (Figure 1, Item 11) and
secure with nut (Figure 1, Item 3) and lock washer (Figure 1, Item 4).
11. Connect wire terminal (Figure 1, Item 9) to alternator (Figure 1, Item 11).
12. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM) and install rear access panel (not shown).
0060-3
TM 11-6115-742-13&P 0060
REPLACEMENT - Continued
13. Install front access panel (Figure 1, Item 2) on Genset (Figure 1, Item 1) and set aside.
14. Install cargo restraints (not shown).
15. Start Genset (Figure 1, Item 1) in accordance with Genset Start Procedure (WP 0005) of this TM.
5
6
7
4
3
8
9
16
15 10
14 11
13 12
Figure 1. Alternator Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0060-4
TM 11-6115-742-13&P 0061
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET FAN BELT
FAN BELT INSPECTION/ADJUSTMENT/REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit, (WP 0165, Item 1) WP 0005, WP 0041
Safety glasses
Equipment Condition
Materials/Parts Genset shut down
Fan belt BATTERY SWITCH - OFF
Personnel Required
One
GENERAL
This work package provides information on the inspection, adjustment, removal and replacement of the Genset
fan belt. If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0061-1
TM 11-6115-742-13&P 0061
WARNING
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
INSPECTION
1. Verify that Genset (Figure 1, Item 1) has been shut down, engine is cool and that BATTERY switch is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove the front access panel (Figure 1, Item 3) on Genset (Figure 1, Item 1) and set aside.
3. Inspect fan belt (Figure 1, Item 11) for excessive wear, nicks, cuts or other visible damage. Fan belt
(Figure 1, Item 11) should be flush with pulleys on water pump and alternator (Figure 1, Item 8). If fan belt
(Figure 1, Item 11) is not flush with top of groove in each pulley, replace fan belt (Figure 1, Item 11).
4. Check fan belt (Figure 1, Item 11) for deflection. When flexed, no more than 0.3~0.33 in.
(7.5 mm ~8.5 mm) deflection on longest side of engine fan belt (Figure 1, Item 11) should be present.
5. Replace front access panel (Figure 1, Item 3) on Genset (Figure 1, Item 1).
6. Start Genset (Figure 1, Item 1) in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
ADJUSTMENT
1. Verify that Genset (Figure 1, Item 1) has been shut down, engine is cool and that BATTERY switch is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove the front access panel (Figure 1, Item 3) on Genset (Figure 1, Item 1) and set aside.
0061-2
TM 11-6115-742-13&P 0061
ADJUSTMENT – Continued
3. Loosen but do not remove bottom mounting bolt (Figure 1, Item 10) and nut (Figure 1, Item 9) of alternator
(Figure 1, Item 8).
4. Loosen but do not remove adjustment bolt (Figure 1, Item 7) on alternator bracket (Figure 1, Item 6).
CAUTION
Do not over tighten fan belt. This could cause undo stress and excessive wear
on fan belt, alternator and pulley. When flexed, no more than 0.3~0.33 in.
(7.5 mm ~8.5 mm) deflection on longest side of engine fan belt (Figure 1,
Item 11) should be present.
5. To tighten fan belt (Figure 1, Item 11) as follows:
a. Place pry bar between the alternator (Figure 1, Item 8) and water pump (Figure 1, Item 2).
b. Apply a downward force (towards alternator) on the pry bar to achieve proper tension on fan belt.
NOTE
Keep tension on alternator (Figure 1, Item 8) with pry bar while performing the
following two steps.
6. Tighten bottom mounting bolt (Figure 1, Item 10) and nut (Figure 1, Item 9) of alternator (Figure 1, Item 8).
7. Tighten adjustment bolt (Figure 1, Item 7) on alternator bracket (Figure 1, Item 6).
8. Replace front access panel (Figure 1, Item 3) on Genset (Figure 1, Item 1).
9. Start Genset (Figure 1, Item 1) in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
REMOVAL
1. Verify that Genset (Figure 1, Item 1) has been shut down, engine is cool and that BATTERY switch is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove the front access panel (Figure 1, Item 3) on Genset (Figure 1, Item 1) and set aside.
3. Remove rear access panel (not shown) and disconnect battery ground cable (black) from battery ground
terminal (if necessary, refer to procedure in (WP 0041) of this TM).
4. Loosen but do not remove bottom mounting bolt (Figure 1, Item 10) and nut (Figure 1, Item 9) of alternator
(Figure 1, Item 8).
5. Loosen but do not remove adjustment bolt (Figure 1, Item 7) on alternator bracket (Figure 1, Item 6).
6. Push alternator (Figure 1, Item 8) towards engine to loosen fan belt (Figure 1, Item 11).
7. Remove fan belt (Figure 1, Item 11) from alternator (Figure 1, Item 8), crank shaft pulley (Figure 1, Item 4)
and water pump (Figure 1, Item 2) and place onto fan neck.
0061-3
TM 11-6115-742-13&P 0061
REMOVAL – Continued
WARNING
If Genset has been in operation, fluid and components may be extremely hot. Be
cautious of radiator and associated hoses.
8. Push fan belt (Figure 1, Item 11) into fan shroud and slide fan belt (Figure 1, Item 11) under lowest fan blade.
9. Rotate the fan blades (Figure 1, Item 5), sliding fan belt (Figure 1, Item 11) under each fan blade (Figure 1,
Item 5) until fan belt (Figure 1, Item 11) is released.
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following steps:
• Inspect radiator for dents, holes, or leaks
• Inspect water pump (Figure 1, Item 2), crank shaft pulley (Figure 1, Item 4)
and alternator (Figure 1, Item 8).
• Inspect fan blade assembly for damage corrosion or other signs that would
indicate replacement is necessary.
1. Insert fan belt (Figure 1, Item 11) into fan shroud to allow fan belt (Figure 1, Item 11) to fit over fan blade.
2. While rotating fan blades (Figure 1, Item 5), slide fan belt (Figure 1, Item 11) under fan blades (Figure 1,
Item 5) until fan belt (Figure 1, Item 11) is around fan neck.
3. Mount fan belt (Figure 1, Item 11) onto grooves of water pump (Figure 1, Item 2) and crank shaft pulley
(Figure 1, Item 4).
4. Mount fan belt (Figure 1, Item 11) onto alternator (Figure 1, Item 8).
CAUTION
Do not over tighten fan belt. This could cause undo stress and excessive wear
on fan belt, alternator and pulley. Fan belt should have no more than 0.3~0.33 in.
(7.5~8.5 mm) of play when flexed on longest side.
5. Perform adjustment procedure as described in this WP.
6. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in (WP 0041)
of this TM) and install rear access panel (not shown).
7. Replace front access panel (Figure 1, Item 3) on Genset (Figure 1, Item 1).
8. Install cargo restraints (not shown) to rear of Genset.
9. Start Genset (Figure 1, Item 1) in accordance with Genset Start Procedure (WP 0005) of this TM.
0061-4
TM 11-6115-742-13&P 0061
2
3
10
2
1
86
7 11
5
68
5 49
10
113
9
4
Figure 1. Fan Belt Adjustment, Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0061-5/6 blank
TM 11-6115-742-13&P 0062
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET FAN
FAN REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit, (WP 0165, Item 1) One
Safety glasses
Drain pan References
WP 0005, WP 0041
Materials/Parts WP 0058 – WP 0061
Fan
Sealing compound (WP 0168, Item 50) Equipment Condition
Coolant (WP 0168, Item 2) Genset shut down
Strap ties (WP 0168, Item 55 to 57) BATTERY SWITCH - OFF
Cloth, cleaning (WP 0168, Item 14)
GENERAL
This work package provides information on the removal and replacement of the Genset fan. If necessary, refer to
(WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
0062-1
TM 11-6115-742-13&P 0062
WARNING
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
1. Verify that Genset (Figure 1, Item 11) has been shut down, engine is cool and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Start Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset (Figure 1, Item 11).
3. Remove the front and rear access panels (Figure 1, Items 9 and 22) on Genset (Figure 1, Item 11) and set
aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
5. Loosen but do not remove nut (Figure 1, Item 7) and bolt (Figure 1, Item 5) that secures exhaust pipe cap
(Figure 1, Item 6). Remove exhaust pipe cap (Figure 1, Item 6) and set aside.
6. Remove and retain 20 bolts (Figure 1, Item 19), lock washers (Figure 1, Item 20), and flat washers (Figure 1,
Item 21) that secure top access panel (Figure 1, Item 8) to Genset (Figure 1, Item 11). Remove top access
panel (Figure 1, Item 8) and set aside.
7. Drain coolant from radiator, as described in (WP 0058).
0062-2
TM 11-6115-742-13&P 0062
REMOVAL – Continued
NOTE
Place towels or pads below radiator to absorb any excess fluid.
8. Remove top radiator hose as described in (WP 0058).
9. Remove strap ties that secure radiator over flow tube (Figure 1, Item 4) to fan shroud (Figure 1, Item 2).
10. Remove radiator overflow tube (Figure 1, Item 4) from radiator cap (Figure 1, Item 3) and set aside.
11. Remove and retain eight bolts (Figure 1, Item 1) that secure fan shroud (Figure 1, Item 2) and slide fan
shroud (Figure 1, Item 2) back to give access to the engine fan (Figure 1, Item 15).
NOTE
If necessary, loosen alternator (Figure 1, Item 10) and release tension on fan belt
(Figure 1, Item 12) as described in (WP 0060).
12. Remove and retain four bolts (Figure 1, Item 14) that secure engine fan (Figure 1, Item 15), spacer
(Figure 1, Item 16), and spacer sleeve (Figure 1, Item 17) to pulley assembly (Figure 1, Item 13).
13. Remove two bolts (Figure 1, Item 13) that secure pulley assembly (Figure 1, Item 18) to alternator (Figure 1,
Item 10).
14. Remove engine fan (Figure 1, Item 15), outer fan shroud (Figure 1, Item 2), spacer (Figure 1, Item 16), and
spacer sleeve (Figure 1, Item 17).
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following step:
• Inspect radiator for dents, holes, or leaks.
• Inspect radiator hoses for cracks, swelling, or other obvious deterioration.
• Inspect hose clamps. Verify that clamps are secure and that no damage
or other obvious deterioration is present.
If outer fan shroud (Figure 1, Item 2) was removed from the Genset enclosure,
place outer fan shroud (Figure 1, Item 2) in position over pulley assembly
(Figure 1, Item 18).
1. If removed, install pulley assembly (Figure 1, Item 18) onto alternator (Figure 1, Item 10) and secure with two
bolts (Figure 1, Item 13).
2. Install engine fan (Figure 1, Item 15), spacer (Figure 1, Item 16), and spacer sleeve (Figure 1, Item 17) onto
pulley assembly (Figure 1, Item 18).
0062-3
TM 11-6115-742-13&P 0062
REPLACEMENT – Continued
WARNING
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in a well ventilated area. If adhesive, solvent, or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
3. Apply sealing compound to four bolts (Figure 1, Item 14). Secure engine fan (Figure 1, Item 15), spacer
(Figure 1, Item 16), and spacer sleeve (Figure 1, Item 17) to pulley assembly (Figure 1, Item 18) with four
bolts (Figure 1, Item 14).
4. Using torque wrench, tighten four bolts (Figure 1, Item 14) of engine fan (Figure 1, Item 15) to 17.4 ft./lb
(23.5 n-m/2.4 kgf-m).
5. Install outer fan shroud (Figure 1, Item 2) and secure to radiator with eight bolts (Figure 1, Item 1).
6. Install radiator overflow tube (Figure 1, Item 4) and radiator cap (Figure 1, Item 3). Attach radiator overflow
tube (Figure 1, Item 4) to outer fan shroud (Figure 1, Item 2) with strap ties.
7. Replace engine fan belt (Figure 1, Item 12) and adjust tension as described in (WP 0061).
8. Replace the upper radiator hose as described in (WP 0058).
9. Refill the radiator with coolant as described in (WP 0059).
10. Install top access panel (Figure 1, Item 8) and secure using 20 bolts (Figure 1, Item 19), lock washers
(Figure 1, Item 20), and flat washers (Figure 1, Item 21).
11. Install exhaust pipe cap (Figure 1, Item 6) and tighten nut (Figure 1, Item 7) and bolt (Figure 1, Item 5).
12. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
13. Install front and rear access panels (Figure 1, Items 9 and 22) onto Genset (Figure 1, Item 11).
14. Install cargo restraints (not shown).
15. Start Genset (Figure 1, Item 11) in accordance with Genset Start Procedure (WP 0005) of this TM.
0062-4
TM 11-6115-742-13&P 0062
8
5 6
22
9
21
20
19
18
17
16
15 10
14
11
13
12
Figure 1. Fan Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0062-5/6 blank
TM 11-6115-742-13&P 0063
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET WATER PUMP
WATER PUMP REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit, (WP 0165, Item 1) One
Safety glasses
References
Materials/Parts WP 0005, WP 0041,
Water pump WP 0057 – WP 0060,
Gasket WP 0062
Abrasive mesh cloth (WP 0168, Item 13)
Cloth, cleaning (WP 0168, Item 14) Equipment Condition
Gasket sealant (WP 0168, Item 49) Genset shut down
BATTERY SWITCH - OFF
GENERAL
This work package provides information on the removal and replacement of the Genset engine water pump. If
necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
0063-1
TM 11-6115-742-13&P 0063
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
1. Verify that Genset (Figure 1, Item 20) has been shut down, engine is cool and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove the front and rear access panels (Figure 1, Items 5 and 21) on Genset (Figure 1, Item 20) and set
aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
5. Loosen but do not remove nut (Figure 1, Item 3) and bolt (Figure 1, Item 1) that secures exhaust pipe cap
(Figure 1, Item 2). Remove exhaust pipe cap (Figure 1, Item 2) and set aside.
6. Remove and retain 20 bolts (Figure 1, Item 22), lock washers (Figure 1, Item 23), and flat washers (Figure 1,
Item 24) that secure top access panel (Figure 1, Item 4) to Genset (Figure 1, Item 20). Remove top access
panel (Figure 1, Item 4) and set aside.
7. Drain engine coolant as describe in (WP 0058).
NOTE
Place towels or pads below radiator to absorb any excess fluid.
0063-2
TM 11-6115-742-13&P 0063
REMOVAL – Continued
8. Remove two clamps (Figure 1, Items 7 and 13) and coolant hoses (Figure 1, Items 6 and 12) from water
pump (Figure 1, Item 14) and thermostat (Figure 1, Item 8).
9. Remove top radiator hose as describe in (WP 0059).
10. Remove thermostat (Figure 1, Item 8) as describe in (WP 0057).
11. Loosen alternator (Figure 1, Item 17) as describe in (WP 0060).
12. Remove cooling fan (Figure 1, Item 19) and fan belt (Figure 1, Item 16) as describe in (WP 0062).
NOTE
Water pump bolts are different sizes. Attempting to mount water pump with bolts
in incorrect positions could result in damage to bolts or failure of water pump
seal. Note which holes each bolt came from.
13. Remove and retain five bolts (Figure 1, Item 15) from water pump (Figure 1, Item 14).
14. Remove and retain two nuts (Figure 1, Item 18) from water pump alignment studs (Figure 1, Item 11).
15. Tap on water pump (Figure 1, Item 14) to break seal and pry away from engine block (Figure 1, Item 10).
16. Discard water pump (Figure 1, Item 14).
17. Remove water pump gasket (Figure 1, Item 9).
END OF TASK
REPLACEMENT
CAUTION
When performing the following step, do not damage the water pump or
thermostat housing.
1. Scrape off old gasket material from engine block (Figure 1, Item 10). If necessary, clean area with abrasive
mesh cloth to remove all residue.
WARNING
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
2. Apply thin layer of gasket sealant to mating surfaces on water pump (Figure 1, Item 14) and engine block
(Figure 1, Item 10)
3. Attach new water pump gasket (Figure 1, Item 9) to water pump (Figure 1, Item 14).
0063-3
TM 11-6115-742-13&P 0063
REPLACEMENT – Continued
NOTE
Water pump bolts (Figure 1, Item 15) are different sizes. Attempting to mount
water pump with bolts in incorrect positions could result in damage to bolts or
failure of water pump seal.
4. Place five bolts (Figure 1, Item 15) through appropriate holes of water pump (Figure 1, Item 14) and gasket
(Figure 1, Item 9).
NOTE
Gasket (Figure 1, Item 9) should hold bolts (Figure 1, Item 15) in position during
alignment of the water pump (Figure 1, Item 14).
5. Align the water pump (Figure 1, Item 14) alignment studs (Figure 1, Item 11) on the engine block (Figure 1,
Item 10) and insert water pump (Figure 1, Item 14) onto alignment studs (Figure 1, Item 11).
6. Tighten five bolts (Figure 1, Item 15) finger tight.
7. Install two nuts (Figure 1, Item 18) onto alignment studs (Figure 1, Item 11) and finger tighten.
NOTE
When performing the following step, tighten five bolts (Figure 1, Item 15) and two
nuts (Figure 1, Item 18) using a cross pattern to ensure a good seat (i.e. tighten a
bolt first on one side, than the opposite. Work your way around the water pump).
8. Using torque wrench, tighten two nuts (Figure 1, Item 18) and five bolts (Figure 1, Item 15) to 14~21 ft./lb
(19~28 n-m/1.9~2.9 kgf-m).
9. Install cooling fan (Figure 1, Item 19) and fan belt (Figure 1, Item 16) as describe in (WP 0062).
10. Install thermostat (Figure 1, Item 8) as describe in (WP 0057).
11. Install alternator (Figure 1, Item 17) as describe in (WP 0060).
NOTE
Ensure that clamps (Figure 1, Items 7 and 13) are present on coolant hoses
(Figure 1, Items 6 and 12) before performing the next step.
12. Install two coolant hoses (Figure 1, Items 6 and 12) onto water pump (Figure 1, Item 14) and thermostat
(Figure 1, Item 8) and secure using two clamps (Figure 1, Items 7 and 13).
13. Install top radiator hose as describe in (WP 0059).
14. Replace engine coolant as describe in (WP 0058).
15. Install top access panel (Figure 1, Item 4) onto Genset (Figure 1, Item 20) and secure using 20 bolts
(Figure 1, Item 22), lock washers (Figure 1, Item 23) and flat washers (Figure 1, Item 24).
0063-4
TM 11-6115-742-13&P 0063
REPLACEMENT – Continued
16. Install exhaust pipe cap (Figure 1, Item 2) and tighten nut (Figure 1, Item 3) and bolt (Figure 1, Item 1) that
secure exhaust pipe cap (Figure 1, Item 2).
17. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
18. Replace front and rear access panels (Figure 1, Items 5 and 21) on Genset (Figure 1, Item 20).
19. Install cargo restraints (not shown).
20. Start Genset (Figure 1, Items 20) in accordance with Genset Start Procedure (WP 0005) of this TM.
0063-5
TM 11-6115-742-13&P 0063
2
1 3
24
23
21
22
10
20 9
6 8
18
19 11
13
14
12
15 17
16
Figure 1. Water Pump Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0063-6
TM 11-6115-742-13&P 0064
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET ENGINE HEATER (HYDRONIC) MAINTENANCE
ENGINE HEATER (HYDRONIC) MAINTENANCE
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit, (WP 0165, Item 1) One
Safety glasses
Rubber gloves (WP 0168, Item 24) References
WP 0005, WP 0041
Materials/Parts
Engine heater (hydronic) Equipment Condition
Cloth, cleaning (WP 0168, Item 14) Genset shut down
Drain pan BATTERY SWITCH - OFF
Fuel Pump
Fuel Filter
Enginer Heater Hose (hydronic)
Strap, tie-down (WP 0168, Items 44 to 46)
Fuse
GENERAL
This work package provides information on the service and removal/replacement of the Genset engine heater
(hydronic). It consists of:
• Engine heater (hydronic) removal/replacement
• Engine heater (hydronic) fuel pump and fuel filter removal/replacement
• Engine heater (hydronic) fuse removal/replacement
• Engine heater (hydronic) hoses removal/replacement
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0064-1
TM 11-6115-742-13&P 0064
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
1. Verify that Genset (Figure 1, Item 26) has been shut down, engine is cool and that BATTERY SWITCH is set
to OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Loosen but do not remove nut (Figure 1, Item 4) and bolt (Figure 1, Item 2) that secures exhaust pipe cap
(Figure 1, Item 3). Remove exhaust pipe cap (Figure 1, Item 3) and set aside.
4. Remove and retain 20 bolts (Figure 1, Item 28), lock washers (Figure 1, Item 29) and flat washers (Figure 1,
Item 30) that secure top access panel (Figure 1, Item 1) to Genset (Figure 1, Item 26). Remove top access
panel (Figure 1, Item 1) and set aside.
5. Remove front access panel (Figure 1, Item 5) and set aside.
6. Remove rear access panel (Figure 1, Item 27) and set aside.
7. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
0064-2
TM 11-6115-742-13&P 0064
REMOVAL – Continued
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
8. Loosen hose clamp (Figure 1, Item 21) on engine heater (hydronic) fuel line (Figure 1, Item 18) at the fuel
pump (Figure 1, Item 17) and disconnect fuel line (Figure 1, Item 18). Guide fuel line (Figure 1, Item 18) to
spill bucket and allow fuel to drain out of system.
9. Loosen clamp (Figure 1, Item 20) that secures cool fluid input hose (Figure 1, Item 19) on the heater body
(Figure 1, Item 14) and disconnect cool fluid input hose (Figure 1, Item 19).
10. Loosen clamp (Figure 1, Item 22) that secures fresh air intake hose (Figure 1, Item 23). Remove the fresh air
intake hose (Figure 1, Item 23) from engine heater (hydronic) body (Figure 1, Item 14).
11. Loosen clamp (Figure 1, Item 25) that secures hot output hose (Figure 1, Item 24) to the heater body
(Figure 1, Item 14). Remove hot output hose (Figure 1, Item 24) from engine heater (hydronic) body
(Figure 1, Item 14).
12. Loosen clamp (Figure 1, Item 15) that secures exhaust hose (Figure 1, Item 16) to the heater body (Figure 1,
Item 14). Remove the exhaust hose (Figure 1, Item 16) from engine heater (hydronic) body (Figure 1,
Item 14).
13. Remove engine heater (hydronic) wiring harness access cover by carefully prying out on side of cover.
14. Remove engine heater (hydronic) external wiring harness connectors.
15. Loosen four bolts (Figure 1, Item 10) that secure generator cover (Figure 1, Item 6). Remove generator cover
and set aside.
WARNING
High AC voltage (208 VAC) and amperage present at electrical connections. Do
not enter if Genset is operational. To prevent serious injury to personnel or
damage to equipment, DO NOT enter enclosure with Genset operating.
16. Remove and retain three nuts (Figure 1, Item 8), two flat washers (Figure 1, Item 7) and one large flat washer
(Figure 1, Item 9) that secure engine heater (hydronic) body (Figure 1, Item 14) to side panel.
17. Remove engine heater (hydronic) body (Figure 1, Item 14), three threaded studs (Figure 1, Item 13), spacers
(Figure 1, Item 12) and flat washers (Figure 1, Item 11).
END OF TASK
0064-3
TM 11-6115-742-13&P 0064
REPLACEMENT
NOTE
Prior to performing the following steps:
• Inspect all clamps and hoses. Ensure that hoses are not damaged (cuts,
nicks, etc.). Ensure that all hoses are not excessively worn or appear to
be unserviceable. Ensure that clamps are in good working order.
• Inspect engine heater (hydronic) fuel filter. Ensure that fuel filter
is not excessively dirty, worn or is in other need of servicing.
• Inspect engine heater (hydronic) fuel pump. Ensure that fuel pump is not
excessively damaged or otherwise appears to be unserviceable.
1. Insert three spacers (Figure 1, Item 12) and flat washers (Figure 1, Item 11) onto threaded studs (Figure 1,
Item 13) on engine heater (hydronic) body (Figure 1, Item 14).
2. Align engine heater (hydronic) body (Figure 1, Item 14) with proper holes on side panel and secure using two
flat washers (Figure 1, Item 7) and one large flat washer (Figure 1, Item 9) and three nuts (Figure 1, Item 8).
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
3. Connect engine heater (hydronic) fuel line (Figure 1, Item 18) from fuel pump (Figure 1, Item 17) to engine
heater (hydronic) (Figure 1, Item 14). Secure with clamp (Figure 1, Item 21).
4. Connect cool fluid input hose (Figure 1, Item 19) to proper port on engine heater (hydronic) (Figure 1,
Item 14) Secure with hose clamp (Figure 1, Item 20).
5. Connect fresh air intake hose (Figure 1, Item 23) to proper port on engine heater (hydronic) body (Figure 1,
Item 14). Secure with clamp (Figure 1, Item 22).
6. Connect hot output hose (Figure 1, Item 24) to the engine heater (hydronic) body (Figure 1, Item 14). Secure
with clamp (Figure 1, Item 25).
7. Connect exhaust hose (Figure 1, Item 16) to proper port on heater body (Figure 1, Item 14) and secure with
clamp (Figure 1, Item 15).
8. Clean up any excess spillage from base of Genset.
9. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
10. Install generator cover (Figure 1, Item 6) and secure using four bolts (Figure 1, Item 10).
11. Connect engine heater (hydronic) external wiring harness and close access cover on engine heater (hydronic).
12. Install top access panel (Figure 1, Item 1) onto Genset (Figure 1, Item 26) and secure using 20 bolts
(Figure 1, Item 28), lock washers (Figure 1, Item 29) and flat washers (Figure 1, Item 30).
13. Install exhaust pipe cap (Figure 1, Item 3) and tighten nut (Figure 1, Item 4) and bolt (Figure 1, Item 2) that
secure exhaust pipe cap (Figure 1, Item 3).
0064-4
TM 11-6115-742-13&P 0064
REPLACEMENT - Continued
14. Install access panels (Figure 1, Items 5 and 27).
15. Install cargo restraints (not shown).
16. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
1
30
29
28
27
7 8
5
26
12
25 13
24
9
23
10
11
22
14
FRESH AIR
INTAKE 21
20 15
HOT
19
OUTPUT (EXHAUST)
COOL 16
INPUT
18 17 TO FILTER AND
FUEL SUPPLY
Figure 1. Engine Heater (Hydronic) Removal/Replacement.
END OF TASK
0064-5
TM 11-6115-742-13&P 0064
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following service.
FUEL PUMP
REMOVAL
1. Verify that Genset (Figure 2, Item 2) has been shut down, engine is cool and that BATTERY SWITCH is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove front and rear access panels (Figure 2, Items 1 and 3) of Genset (Figure 2, Item 2) and set aside.
4. Disconnect battery ground cable (black) from battery ground terminal (If necessary, refer to procedure in
(WP 0041) of this TM).
5. Disconnect electrical cable (Figure 2, Item 6) from fuel pump (Figure 2, Item 11).
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
6. Loosen hose clamp (Figure 2, Item 8) and disconnect fuel line (Figure 2, Item 7) (heater side) from fuel pump
(Figure 2, Item 11). Guide fuel line (Figure 2, Item 7) to spill bucket and allow fuel to drain.
0064-6
TM 11-6115-742-13&P 0064
REMOVAL – Continued
7. Loosen second hose clamp (Figure 2, Item 12) and disconnect fuel line (Figure 2, Item 4) (filter side) from fuel
pump (Figure 2, Item 11). Guide fuel line (Figure 2, Item 4) to spill bucket and allow fuel to drain.
8. Remove and retain bolt (Figure 2, Item 10) and flat washer (Figure 2, Item 9) that secures fuel pump
(Figure 2, Item 11) and clamp (Figure 2, Item 5) to frame (Figure 2, Item 17).
9. Remove fuel pump (Figure 2, Item 11) and clamp (Figure 2, Item 5).
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following steps:
• Inspect all clamps and hoses. Ensure that hoses are not damaged (cuts,
nicks, etc.). Ensure that all hoses are not excessively worn or appear to be
unserviceable. Ensure that clamps are in good working order.
• Inspect engine heater (hydronic) fuel filter. Ensure that fuel filter is not
excessively dirty, worn or is in need of other servicing.
Verify that fuel pump (Figure 2, Item 11) is installed in the proper direction.
Arrow should point towards fuel line going to engine heater (hydronic).
1. Install clamp (Figure 2, Item 5) onto fuel pump (Figure 2, Item 11). Secure assembly to frame (Figure 2,
Item 17) with bolt (Figure 2, Item 10) and flat washer (Figure 2, Item 9).
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
2. Connect fuel line (Figure 2, Item 4) (filter side) to fuel pump (Figure 2, Item 11) and secure with clamp
(Figure 2, Item 12).
3. Connect fuel line (Figure 2, Item 7) (heater side) to fuel pump (Figure 2, Item 11) and secure with hose clamp
(Figure 2, Item 8).
4. Connect electrical cable (Figure 2, Item 6) to fuel pump (Figure 2, Item 11).
5. Clean up any excess spillage from base of Genset (Figure 2, Item 2).
6. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
7. Install and secure front and rear access panels (Figure 2, Items 1 and 3).
8. Install cargo restraints (not shown).
9. Start Genset (Figure 2, Item 2) in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
0064-7
TM 11-6115-742-13&P 0064
FUEL FILTER
REMOVAL
1. Verify that Genset (Figure 2, Item 2) has been shut down, engine is cool and that BATTERY SWITCH is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Unlatch and remove front and rear access panels (Figure 2, Items 1 and 3) of Genset (Figure 2, Items 2) and
set aside.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
5. Loosen hose clamp (Figure 2, Item 13) and disconnect fuel line (Figure 2, Item 4) (fuel pump side) from fuel
filter (Figure 2, Item 14).
NOTE
When performing the following step do not let fuel line fall through frame.
6. Loosen second hose clamp (Figure 2, Item 15) and disconnect fuel line (Figure 2, Item 16) (fuel tank side)
from fuel filter (Figure 2, Item 14).
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following steps:
• Inspect all clamps and hoses. Ensure that hoses are not damaged (cuts,
nicks, etc.). Ensure that all hoses are not excessively worn or appear to be
unserviceable. Ensure that clamps are in good working order.
• Inspect Engine heater (hydronic) fuel pump. Ensure that fuel pump is not
excessively damaged or otherwise appears to be unserviceable.
When performing the following steps verify that fuel filter (Figure 2, Item 14) is
installed in the proper direction. Arrow should point towards fuel line going to
engine heater (hydronic).
1. Connect fuel line (Figure 2, Item 16) (fuel tank side) to fuel filter (Figure 2, Item 14) and secure with hose
clamp (Figure 2, Item 15).
0064-8
TM 11-6115-742-13&P 0064
REPLACEMENT
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
2. Connect fuel line (Figure 2, Item 4) (fuel pump side) to fuel filter (Figure 2, Item 14) and secure with hose
clamp (Figure 2, Item 13).
3. Clean up any excess spillage from base of Genset.
4. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
5. Install and secure front and rear access panels (Figure 2, Items 1 and 3).
6. Install cargo restraints (not shown).
7. Start Genset (Figure 2, Item 2) in accordance with Genset Start Procedure (WP 0005) of this TM.
0064-9
TM 11-6115-742-13&P 0064
12
21
1
3
9 8
13
17
64
4
9 5
12 TO
HYDRONIC
HEATER
7
TO 9
11 68
FUEL
SUPPLY 5
11
8
12
16
17 14
13 10
15
16 15
14
Figure 2. Engine Heater (Hydronic) Fuel Pump and Fuel Filter Removal/Replacement.
END OF TASK
0064-10
TM 11-6115-742-13&P 0064
ENGINE HEATER (HYDRONIC) HOSE REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following service.
REMOVAL (AIR INTAKE HOSE)
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Loosen but do not remove nut (Figure 3, Item 7) and bolt (Figure 3, Item 5) that secures exhaust pipe cap
(Figure 3, Item 6). Remove exhaust pipe cap (Figure 3, Item 6) and set aside.
4. Remove and retain 20 bolts (Figure 3, Item 1), lock washers (Figure 3, Item 2) and flat washers (Figure 3,
Item 3) that secure top access panel (Figure 3, Item 4) to Genset (Figure 3, Item 20). Remove top access
panel (Figure 3, Item 4) and set aside.
5. Remove front and rear access panels (Figure 3, Items 8 and 21) of Genset and set aside.
6. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
WARNING
Cut end of air intake is extremely sharp. Exercise care to prevent injury.
7. Cut zip ties that secure air intake hose, wiring harness and coolant hoses together.
0064-11
TM 11-6115-742-13&P 0064
REMOVAL (AIR INTAKE HOSE) – Continued
8. Loosen air intake hose clamp (Figure 3, Item 17) where it connects at the front of the engine heater (hydronic)
(Figure 3, Item 10).
9. Grasp air intake hose (Figure 3, Item 18) and using a twisting motion pull away from the engine heater
(hydronic) (Figure 3, Item 10).
10. Remove air intake hose from enclosure and set aside.
END OF TASK
REPLACEMENT (AIR INTAKE HOSE)
1. Position air intake hose (Figure 3, Item 18) so that cut end is located near air inlet on the engine heater
(hydronic) (Figure 3, Item 10) and intake is pointed towards condenser coil on bottom of chamber.
2. Using a twisting motion slide the air intake hose (Figure 3, Item 18) over the intake port on the front of the
engine heater (hydronic) (Figure 3, Item 10) approximately 1 inch.
3. Slide air intake hose clamp (Figure 3, Item 17) into position.
4. Tighten air intake hose clamp (Figure 3, Item 17).
5. Secure air intake hose, wiring harness and coolant hoses together with zip ties.
6. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
7. Install top access panel (Figure 3, Item 4) onto Genset (Figure 3, Item 20) and secure using 20 bolts
(Figure 3, Item 1), lock washers (Figure 3, Item 2) and flat washers (Figure 3, Item 3).
8. Install exhaust pipe cap (Figure 3, Item 6) and tighten nut (Figure 3, Item 7) and bolt (Figure 3, Item 5) that
secure exhaust pipe cap (Figure 3, Item 6).
9. Install front and rear access panels (Figure 3, Items 8 and 21).
10. Install cargo restraints (not shown).
11. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
REMOVAL (EXHAUST HOSE)
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Loosen but do not remove nut (Figure 3, Item 7) and bolt (Figure 3, Item 5) that secures exhaust pipe cap
(Figure 3, Item 6). Remove exhaust pipe cap (Figure 3, Item 6) and set aside.
4. Remove and retain 20 bolts (Figure 3, Item 1), lock washers (Figure 3, Item 2) and flat washers (Figure 3,
Item 3) that secure top access panel (Figure 3, Item 4) to Genset (Figure 3, Item 20). Remove top access
panel (Figure 3, Item 4) and set aside.
0064-12
TM 11-6115-742-13&P 0064
REMOVAL (EXHAUST HOSE) – Continued
5. Remove front and rear access panels (Figure 3, Items 8 and 21) of Genset and set aside.
6. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
WARNING
If heater has been operating exhaust may be extremely hot. Allow time to cool
before removing.
Cut end of exhaust is extremely sharp. Exercise care to prevent injury.
7. Loosen exhaust hose clamp (Figure 3, Item 11) at base of engine heater (hydronic) (Figure 3, Item 10).
8. Grasp exhaust hose (Figure 3, Item 12) and using a twisting motion pull down on hose.
9. Remove exhaust hose from enclosure and set aside.
END OF TASK
REPLACEMENT (EXHAUST HOSE)
1. Position exhaust hose (Figure 3, Item 12) so that its aligned with the exhaust port of the engine heater
(hydronic) (Figure 3, Item 10).
2. Using a twisting motion slide the exhaust hose over exhaust port approximately 1 inch.
3. Slide exhaust hose clamp (Figure 3, Item 11) into position.
4. Tighten exhaust hose clamp.
5. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
6. Install top access panel (Figure 3, Item 4) onto Genset (Figure 3, Item 20) and secure using 20 bolts
(Figure 3, Item 1), lock washers (Figure 3, Item 2) and flat washers (Figure 3, Item 3).
7. Install exhaust pipe cap (Figure 3, Item 6) and tighten nut (Figure 3, Item 7) and bolt (Figure 3, Item 5) that
secure exhaust pipe cap (Figure 3, Item 6).
8. Install front and rear access panels (Figure 3, Items 8 and 21).
9. Install cargo restraints (not shown).
10. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
REMOVAL (FUEL HOSE)
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
0064-13
TM 11-6115-742-13&P 0064
REMOVAL (FUEL HOSE) – Continued
3. Loosen but do not remove nut (Figure 3, Item 7) and bolt (Figure 3, Item 5) that secures exhaust pipe cap
(Figure 3, Item 6). Remove exhaust pipe cap (Figure 3, Item 6) and set aside.
4. Remove and retain 20 bolts (Figure 3, Item 1), lock washers (Figure 3, Item 2) and flat washers (Figure 3,
Item 3) that secure top access panel (Figure 3, Item 4) to Genset (Figure 3, Item 20). Remove top access
panel (Figure 3, Item 4) and set aside.
5. Remove front and rear access panels (Figure 3, Items 8 and 21) of Genset and set aside.
6. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
Fuel lines may still have fuel present or be under pressure. Care must be taken
to prevent fuel from spilling and to avoid exposure of skin to diesel fuel.
7. Using either a flat tip screw driver or socket and ratchet, loosen the fuel hose clamp (Figure 3, Item 15) at the
engine heater (hydronic) (Figure 3, Item 10). Repeat for other end of fuel hose.
8. Place a drip bucket or absorbent pad under the connection to be broken in case of spillage.
9. Grasp the fuel hose (Figure 3, Item 16) and rotate the hose close to the connection to break the connection.
10. Pull the fuel hose (Figure 3, Item 16) away from the connection using a twisting motion until it comes free.
Repeat for other end of fuel hose.
11. Remove the fuel hose clamps if they are to be reused and discard hose.
END OF TASK
REPLACEMENT (FUEL HOSE)
NOTE
Ensure that replacement hose is the same length and diameter of the original
hose.
Ensure that the hose clamps are placed on the hose in such a way that the
screws will be accessible once slid into place.
1. Place hose clamps onto replacement hose loosely and slide to center of hose.
2. Most connections have a ridge built into them to facilitate a good seal when the hose clamp is tightened
down. Identify the location of the ridge on the first side.
3. Using a twisting motion slide the fuel hose (Figure 3, Item 16) onto fuel port of engine heater (hydronic)
(Figure 3, Item 10). Ensure hose is slid back far enough.
4. Slide fuel hose clamp (Figure 3, Item 15) into position. Repeat for other end of fuel hose.
5. Ensure hose is not twisted.
0064-14
TM 11-6115-742-13&P 0064
REPLACEMENT (FUEL HOSE) – Continued
6. Tighten down hose clamp (Figure 3, Item 15) using flat tip screwdriver or socket and ratchet, until hose clamp
begins to press into hose. Repeat for other end of fuel hose.
NOTE
Over tightening the hose clamp can result in damage to the hose and premature
failure.
7. Clean up any excess spillage from base of the Genset.
8. Connect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
9. Install top access panel (Figure 3, Item 4) onto Genset (Figure 3, Item 20) and secure using 20 bolts
(Figure 3, Item 1), lock washers (Figure 3, Item 2) and flat washers (Figure 3, Item 3).
10. Install exhaust pipe cap (Figure 3, Item 6) and tighten nut (Figure 3, Item 7) and bolt (Figure 3, Item 5) that
secure exhaust pipe cap (Figure 3, Item 6).
11. Install front and rear access panels (Figure 3, Items 8 and 21).
12. Install cargo restraints (not shown).
13. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
REMOVAL (INPUT and OUTPUT COOLANT HOSE)
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Loosen but do not remove nut (Figure 3, Item 7) and bolt (Figure 3, Item 5) that secures exhaust pipe cap
(Figure 3, Item 6). Remove exhaust pipe cap (Figure 3, Item 6) and set aside.
4. Remove and retain 20 bolts (Figure 3, Item 1), lock washers (Figure 3, Item 2) and flat washers (Figure 3,
Item 3) that secure top access panel (Figure 3, Item 4) to Genset (Figure 3, Item 20). Remove top access
panel (Figure 3, Item 4) and set aside.
5. Remove front and rear access panels (Figure 3, Items 8 and 21) of Genset and set aside.
6. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
7. Identify coolant hose to be replaced (Figure 3, Item 13 or 19).
8. Drain engine coolant in accordance with (WP 0058) of this TM.
9. Cut zip ties that secure air intake hose, wiring harness and coolant hoses together.
10. Using either a flat tip screw driver or a socket and ratchet, loosen the coolant hose clamp (Figure 3,
Item 13 or 14) on the engine heater (hydronic) (Figure 3, Item 10). Repeat for other end of coolant hose.
0064-15
TM 11-6115-742-13&P 0064
REMOVAL (INPUT and OUTPUT COOLANT HOSE) – Continued
11. Place a drip bucket or absorbent pad under the connection to be broken in case of spillage.
12. Grasp the coolant hose (Figure 3, Item 13 or 19) and rotate the hose close to the connection to break the
connection.
13. Pull the coolant hose (Figure 3, Item 13 or 19) away from the connection using a twisting motion until it comes
free. Repeat for other end of coolant hose.
14. Remove the hose clamps if they are to be reused and discard hose.
END OF TASK
REPLACEMENT (INPUT and OUTPUT COOLANT HOSE)
NOTE
Ensure that replacement hose is the same length and diameter of the original
hose.
1. Place hose clamps onto replacement hose loosely and slide to center of hose.
NOTE
Ensure that the hose clamps are placed on the hose in such a way that the
screws will be accessible once slid into place.
2. Most connections have a ridge built into them to facilitate a good seal when the hose clamp is tightened
down. Identify the location of the ridge on the first side.
3. Using a twisting motion slide the coolant hose (Figure 3, Item 13 or 19) onto the coolant port of the engine
heater (hydronic) (Figure 3, Item 10). Ensure hose is slid back far enough.
4. Slide coolant hose clamp (Figure 3, Item 9 or 14) down into position. Repeat for other end of hose.
5. Ensure hose is not twisted.
6. Tighten down hose clamps (Figure 3, Item 9 or 14) using flat tip screwdriver or socket and ratchet, until hose
clamp begins to press into hose. Repeat for other end of coolant hose.
NOTE
Over tightening the hose clamp can result in damage to the coolant hose and
premature failure.
7. Refill coolant in accordance with (WP 0058) of this TM.
8. Clean up any excess spillage from base of the Genset.
9. Secure air intake hose, wiring harness and coolant hoses together with zip ties.
10. Connect battery ground cable (black) to battery ground terminal (If necessary, refer to procedure in
(WP 0041) of this TM).
11. Install top access panel (Figure 3, Item 4) onto Genset (Figure 3, Item 20) and secure using 20 bolts
(Figure 3, Item 1), lock washers (Figure 3, Item 2) and flat washers (Figure 3, Item 3).
0064-16
TM 11-6115-742-13&P 0064
REPLACEMENT (INPUT and OUTPUT COOLANT HOSE) Continued
12. Install exhaust pipe cap (Figure 3, Item 6) and tighten nut (Figure 3, Item 7) and bolt (Figure 3, Item 5) that
secure exhaust pipe cap (Figure 3, Item 6).
13. Install and secure front and rear access panels (Figure 3, Items 8 and 21).
14. Install cargo restraints (not shown).
15. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0064-17
TM 11-6115-742-13&P 0064
6
7
4
3
2
1
21
8
20
19
18
17
10
FRESH AIR
INTAKE 15
14 11
HOT
OUTPUT 13
(EXHAUST)
COOL 12
INPUT
16 TO FILTER AND
FUEL SUPPLY
Figure 3. Engine Heater (Hydronic) Hose Removal/Replacement.
END OF TASK
0064-18
TM 11-6115-742-13&P 0064
ENGINE HEATER (HYDRONIC) FUSE REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following service.
REMOVAL
1. Verify that Genset (Figure 4, Item 1) has been shut down, engine is cool and that BATTERY SWITCH is set to
OFF (WP 0005, Genset Shut Down Procedure).
2. Remove front access door (Figure 4, Item 2) on Genset (Figure 4, Item 1) and set aside.
3. Locate fuse holder (Figure 4, Item 4) on engine heater (hydronic) (Figure 4, Item 3) and open cover.
4. Identify and remove bad fuse (Figure 4, Items 5 and 6).
END OF TASK
REPLACEMENT
1. Replace fuse (Figure 4, Items 5 and 6) with proper type and value.
2. Close fuse holder (Figure 4, Item 4).
3. Install access door (Figure 2, Items 2) on Genset (Figure 2, Item 1).
4. Start Genset/engine heater (hydronic) in accordance with Genset Start Procedure (WP 0005) of this TM and
check engine heater (hydronic) for leaks.
0064-19
TM 11-6115-742-13&P 0064
FRSH AIR
INTAKE
HYDRONIC HEATER HOT
WIRING HARNESS OUTPUT
CONNECTION
6 P/O (EXHAUST)
COOL
5 INPUT
TO FILTER AND
FUEL SUPPLY
Figure 4. Engine Heater (Hydronic) Hose Fuse Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0064-20
TM 11-6115-742-13&P 0065
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET EXHAUST SYSTEM
EXHAUST FLEX PIPE, ELBOW AND MUFFLER REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit, (WP 0165, Item 1) One
Safety glasses
References
Materials/Parts WP 0005
Exhaust flex pipe
Exhaust elbow Equipment Condition
Muffler Genset shut down
BATTERY SWITCH - OFF
GENERAL
This work package provides information on the removal and replacement of the exhaust flex pipe, elbow and
muffler for the Genset.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0065-1
TM 11-6115-742-13&P 0065
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
FLEX PIPE
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove front and rear access panels (Figure 1, Items 7 and 8) and set aside.
CAUTION
Due to moisture and constant heating and cooling of exhaust system, hardware
can become rusted and brittle. Hardware can be extremely difficult to loosen and
disassemble. Do not force. Hardware damage could occur to exhaust pipe
clamps and U-bolts or to exhaust flex pipe.
4. Remove and retain two nuts (Figure 1, Item 16) from clamp (Figure 1, Item 15) and U-bolt (Figure 1, Item 18).
5. Remove and retain clamp (Figure 1, Item 15) and U-bolt (Figure 1, Item 18).
6. Remove and retain two nuts (Figure 1, Item 13) from clamp (Figure 1, Item 14) and U-bolt (Figure 1, Item 21).
7. Remove and retain clamp (Figure 1, Item 14) and U-bolt (Figure 1, Item 21).
REMOVAL – Continued
NOTE
When performing the following step, it may be necessary to grip the exhaust pipe
and twist in a clockwise/counter clockwise motion to break seal.
8. Remove exhaust flex pipe (Figure 1, Item 19) from exhaust manifold (Figure 1, Item 17) and exhaust elbow
(Figure 1, Item 23) (located on the enclosure wall).
9. Slide exhaust flex pipe (Figure 1, Item 19) out of exhaust blanket (Figure 1, Item 20).
END OF TASK
0065-2
TM 11-6115-742-13&P 0065
REPLACEMENT
NOTE
New exhaust flex pipe (Figure 1, Item 19) is not pre-bent. Care must be taken to
ensure that exhaust flex pipe (Figure 1, Item 19) is not twisted when assembled
to reduce excessive stress on the exhaust flex pipe (Figure 1, Item 19) and
cause premature failure.
1. Slide exhaust blanket (Figure 1, Item 20) onto exhaust flex pipe (Figure 1, Item 19) so that angle in heat
shield is aligned with 90 degree bend in exhaust flex pipe (Figure 1, Item 19).
2. Insert exhaust flex pipe (Figure 1, Item 19) into the exhaust manifold (Figure 1, Item 17).
NOTE
If reusing exhaust system parts, parts may be crimped from prior installation.
Use of pipe wrench may be necessary to insert pipe fully.
3. If necessary, bend exhaust flex pipe (Figure 1, Item 19) to align with exhaust elbow (Figure 1, Item 23).
4. Insert the exhaust flex pipe (Figure 1, Item 19) into the exhaust pipe elbow (Figure 1, Item 23).
5. Install two U-bolts (Figure 1, Items 18 and 21) and clamps (Figure 1, Items 15 and 14). Secure with four nuts
(Figure 1, Items 13 and 16).
6. Install two access panels (Figure 1, Items 7 and 8).
7. Install cargo restraints (not shown).
8. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM
END OF TASK
0065-3
TM 11-6115-742-13&P 0065
EXHAUST ELBOW
REMOVAL
WARNING
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following procedure.
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove front and rear access panels (Figure 1, Items 7 and 8) and set aside.
4. Loosen but do not remove nut (Figure 1, Item 6) and bolt (Figure 1, Item 4) that secures exhaust pipe cap
(Figure 1, Item 5). Remove exhaust pipe cap (Figure 1, Item 5) and set aside.
5. Remove and retain 20 sheet metal screws (Figure 1, Item 1), lock washers (Figure 1, Item 2) and flat washers
(Figure 1, Item 3) that secure top access panel to Genset enclosure. Remove top access panel and set
aside.
CAUTION
Due to moisture and constant heating and cooling of exhaust system, hardware
can become rusted and brittle. Hardware can be extremely difficult to loosen and
disassemble. Do not force hardware; damage could occur to clamps (Figure 1,
Items 14 and 26) and U-bolts (Figure 1, Items 21 and 26) or to exhaust flex pipe
(Figure 1, Item 19) or exhaust pipe elbow (Figure 1, Item 23).
6. Remove and retain two nuts (Figure 1, Item 13) from clamp (Figure 1, Item 14) and U-bolt (Figure 1, Item 21).
7. Remove and retain clamp (Figure 1, Item 14) and U-bolt (Figure 1, Item 21).
8. Remove exhaust flex pipe (Figure 1, Item 19) from exhaust pipe elbow (Figure 1, Item 23).
9. Remove and retain two nuts (Figure 1, Item 28) from clamp (Figure 1, Item 27) and U-bolt (Figure 1,
Item 26).
10. Remove and retain clamp (Figure 1, Item 27) and U-bolt (Figure 1, Item 26).
11. Loosen but do not remove bolt (Figure 1, Item 29), nut (Figure 1, Item 33), and two flat washers (Figure 1,
Item 32) that secure mounting bracket (Figure 1, Item 25) to muffler (Figure 1, Item 34).
NOTE
When performing the following step, do not slide muffler (Figure 1, Item 34) out
of mounting bracket (Figure 1, Item 31). Allow mounting bracket (Figure 1,
Item 31) to support muffler (Figure 1, Item 34).
12. Slide muffler (Figure 1, Item 34) away from exhaust pipe elbow (Figure 1, Item 23).
13. Remove and retain four nuts (Figure 1, Item 25), flat washers (Figure 1, Item 24), bolts (Figure 1, Item 12)
and flat washers (Figure 1, Item 11) that secure exhaust plate (Figure 1, Item 22) and exhaust pipe elbow
(Figure 1, Item 23) to Genset frame.
0065-4
TM 11-6115-742-13&P 0065
REMOVAL – Continued
14. Remove exhaust plate (Figure 1, Item 22) and exhaust pipe elbow (Figure 1, Item 23).
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following steps, inspect all parts for wear and tear and
corrosion. If excessive wear or corrosion is present, replace affected parts.
Before tightening various clamps and associated hardware, align top of Genset
with exhaust stack to ensure all openings align properly.
1. Install exhaust plate (Figure 1, Item 22) and exhaust pipe elbow (Figure 1, Item 23) and secure using four
nuts (Figure 1, Item 25), bolts (Figure 1, Item 12) and eight flat washers (Figure 1, Items 11 and 24)
2. Slide muffler (Figure 1, Item 34) into exhaust pipe elbow (Figure 1, Item 23).
3. Assemble U-bolt (Figure 1, Item 26) and clamp (Figure 1, Item 27) and position on exhaust pipe elbow
(Figure 1, Item 23) and secure using two nuts (Figure 1, Item 28).
NOTE
Ensure that exhaust bracket has not separated from the inside of the enclosure
wall. The exhaust bracket is held onto the wall with glue, but extreme heat can
cause the glue to fail.
4. Position muffler (Figure 1, Item 34) in mounting bracket (Figure 1, Item 31) and tighten bolt (Figure 1,
Item 29), nut (Figure 1, Item 33), and two flat washers (Figure 1, Item 32).
5. Install exhaust flex pipe (Figure 1, Item 19) onto exhaust pipe elbow (Figure 1, Item 23).
6. Assemble U-bolt (Figure 1, Item 21) and clamp (Figure 1, Item 14). Position on exhaust pipe elbow (Figure 1,
Item 23) and secure using two nuts (Figure 1, Item 13).
7. Tighten all hardware associated with clamps and brackets.
8. Install top access panel to Genset enclosure and secure with 20 sheet metal screws (Figure 1, Item 1), lock
washers (Figure 1, Item 2) and flat washers (Figure 1, Item 3).
9. Install exhaust pipe cap (Figure 1, Item 5) and tighten nut (Figure 1, Item 6) and bolt (Figure 1, Item 4).
10. Install two access panels (Figure 1, Items 7 and 8).
11. Install cargo restraints (not shown) to gain access to rear of Genset.
12. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
END OF TASK
0065-5
TM 11-6115-742-13&P 0065
MUFFLER
REMOVAL
WARNING
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing the following procedure.
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Loosen but do not remove nut (Figure 1, Item 6) and bolt (Figure 1, Item 4) that secures exhaust pipe cap
(Figure 1, Item 5). Remove exhaust pipe cap (Figure 1, Item 5) and set aside.
4. Remove and retain 20 sheet metal screws (Figure 1, Item 1), lock washers (Figure 1, Item 2) and flat washers
(Figure 1, Item 3) that secures top access panel to Genset enclosure. Remove top access panel.
5. Remove and retain two nuts (Figure 1, Item 28) from clamp (Figure 1, Item 27) and U-bolt (Figure 1,
Item 26).
6. Remove and retain clamp (Figure 1, Item 27) and U-bolt (Figure 1, Item 26).
7. Loosen but do not remove bolt (Figure 1, Item 29), nut (Figure 1, Item 33), and two flat washers (Figure 1,
Item 32) that secure mounting bracket (Figure 1, Item 31) to muffler (Figure 1, Item 34).
8. Slide muffler (Figure 1, Item 34) away from exhaust pipe elbow (Figure 1, Item 23) and out of mounting
bracket (Figure 1, Item 31).
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following steps, inspect all parts for wear and tear and
corrosion. If excessive wear or corrosion is present, replace affected pieces.
Before tightening various clamps and associated hardware, align top of Genset
with exhaust stack to ensure all openings align properly.
Ensure that exhaust bracket has not separated from the inside of the enclosure
wall. The exhaust bracket is held onto the wall with glue, but extreme heat can
cause the glue to fail.
1. Slide muffler (Figure 1, Item 34) into mounting bracket (Figure 1, Item 31) and connect to exhaust pipe elbow
(Figure 1, Item 23).
2. Position muffler (Figure 1, Item 34) in mounting bracket (Figure 1, Item 31) and tighten bolt (Figure 1,
Item 29), nut (Figure 1, Item 33) and two flat washers (Figure 1, Item 32).
3. Install clamp (Figure 1, Item 27) and U-bolt (Figure 1, Item 26) and secure using two nuts (Figure 1,
Item 28).
0065-6
TM 11-6115-742-13&P 0065
REPLACEMENT – Continued
4. Install top access panel to Genset enclosure and secure with 20 sheet metal screws (Figure 1, Item 1) lock
washers (Figure 1, Item 2) and flat washers (Figure 1, Item 3).
5. Install exhaust pipe cap (Figure 1, Item 5) and tighten nut (Figure 1, Item 6) and bolt (Figure 1, Item 4).
6. Install cargo restraints (not shown).
7. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0065-7
TM 11-6115-742-13&P 0065
3
2
1
29 34
30 32
33
31
28
27
26 7
8
25
24
23 9
10
11
12
13
16
14
22 17
15
21 18
19
20
Figure 1. Exhaust Flex Pipe, Elbow and Muffler Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0065-8
TM 11-6115-742-13&P 0066
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET EXHAUST MANIFOLD
EXHAUST MANIFOLD AND GASKET REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit, (WP 0165, Item 1) One
Safety glasses
References
Materials/Parts WP 0005
Exhaust manifold
Exhaust manifold gasket Equipment Condition
T-slot gasket Genset shut down
Anti-seize compound BATTERY SWITCH – OFF
(WP 0168, Item 3)
GENERAL
This work package provides information on the removal and replacement of the exhaust manifold and gasket for
the Genset. If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the Genset.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Never attempt to perform maintenance when Genset is in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
0066-1
TM 11-6115-742-13&P 0066
WARNING
If Genset has been in operation, fluid and components may be extremely hot. To
prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel of Genset.
3. Remove front and rear access panels and set aside.
CAUTION
Due to moisture and constant heating and cooling of exhaust system, hardware
can become rusted and brittle. Hardware can be extremely difficult to loosen and
disassemble. Do not force. Hardware damage could occur to exhaust pipe
clamps and U-bolts or to exhaust flex pipe.
4. Remove three locking clips securing manifold heat shield to manifold. Remove heat shield.
5. Remove U-bolt (Figure 1, Item 11), clamp (Figure 1, Item 9), and two nuts (Figure 1, Item 8) from exhaust
pipe (Figure 1, Item 10) and T-slot (Figure 1, Item 7).
6. Remove four mounting nuts (Figure 1, Item 12) and lock washers (Figure 1, Item 13) to remove T-slot
(Figure 1, Item 7) and gasket (Figure 1, Item 6) from manifold (Figure 1, Item 4). Discard gasket.
REMOVAL – Continued
7. Remove four mounting bolts (Figure 1, Item 15) from manifold (Figure 1, Item 4).
8. Remove four locking nuts (Figure 1, Item 14) from manifold (Figure 1, Item 4).
9. Slide exhaust manifold (Figure 1, Item 4) off of engine (Figure 1, Item 1) and discard old gasket (Figure 1,
Item 3).
END OF TASK
0066-2
TM 11-6115-742-13&P 0066
REPLACEMENT
NOTE
Prior to performing replacement procedure, ensure area is clean and free of dirt,
grime and old gasket residue.
1. Place new manifold gasket (Figure 1, Item 3) over exhaust mounting studs (Figure 1, Item 2).
2. Slide exhaust manifold (Figure 1, Item 4) into position on mounting studs (Figure 1, Item 2).
3. Install four locking nuts (Figure 1, Item 14) on the manifold mounting studs (Figure 1, Item 2).
WARNING
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
4. Apply anti-seize compound on the exhaust manifold bolts (Figure 1, Item 15) and install into exhaust manifold
(Figure 1, Item 4) and engine (Figure 1, Item 1).
5. Using torque wrench, tighten manifold bolts (Figure 1, Item 15) and locking nuts (Figure 1, Item 14) to
14~21 ft./lb (19~28 n-m/1.9~2.9 kgf-m). (Tighten in a cross pattern, starting from the center and working out.)
6. Install new gasket (Figure 1, Item 6) onto manifold studs (Figure 1, Item 5).
7. Install T-Slot (Figure 1, Item 7) onto the manifold (Figure 1, Item 4).
8. Install four lock washers (Figure 1, Item 13) and mounting nuts (Figure 1, Item 12) and tighten.
9. Install U-bolt (Figure 1, Item 11), clamp (Figure 1, Item 9), and 2 nuts (Figure 1, Item 8) onto exhaust pipe
(Figure 1, Item 10) and T-slot (Figure 1, Item 7).
10. Install heat shield and secure with 3 locking clips.
0066-3
TM 11-6115-742-13&P 0066
2
3
4
8
5
6
7
10
14
13
15 12
11
Figure 1. Exhaust Manifold and Gasket Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0066-4
TM 11-6115-742-13&P 0067
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
TORQUE SPECIFICATIONS
GENERAL
This section provides general torque limits for bolts used on the TMSS-MED. Special torque limits are indicated
in the maintenance procedures for applicable components. The general torque limits given in this work package
shall be used when specific torque limits are not indicated in the maintenance procedure. These general torque
limits cannot be applied to bolts that retain rubber components. The rubber components will be damaged before
the correct torque limit is reached. If a special torque limit is not given in the maintenance instructions, tighten the
bolt or nut until it touches the metal bracket, then tighten it one more turn.
TIGHTENING METAL FASTENERS
When torqueing a fastener, select a torque wrench that’s range fits the required torque value. A torque wrench is
most accurate from 25 percent to 75 percent of its stated range. A torque wrench with the stated range of 0 to
100 will be most accurate from 25 to 75 foot-pounds. The accuracy of readings will decrease as you approach
0 foot-pounds or 100 foot-pounds. The ranges are based on this principle.
CONVERSION TABLES
Because much of the hardware used on the engine for the Genset is metric. It may be necessary to convert the
torque requirements from metric [Newton-meters (N-m) or Kilogram meters (kgf)] to English (Foot Pounds).
TORQUE LIMITS
(Table 3) lists torque limits for standard metric bolts. (Table 4) lists torque limits for flanged metric bolts.
HOW TO USE TORQUE TABLES
1. Measure the diameter of the bolt to be installed.
Diameter Pitch
Figure 1. Bolt Diameter and Thread Pitch.
2. Count the number of threads per inch or use a pick gauge.
3. Under the heading SIZE, look down the left hand column until the diameter of bolt to be installed is found
(there will usually be two lines beginning with the same size).
4. In the second column under SIZE, find the number of threads per inch that matches the number of threads
counted in step 2.
0067-1
TM 11-6115-742-13&P 0067
COMPONENT SPECIFIC TORQUE LIMITS
(Table 1) lists torque limits for specific components of the TMSS-MED. These torque limits are also listed in their
associated WPs.
Table 1. Component Torque Specifications.
Engine Torque Requirements Work
Component lb. ft N-m kgf-m Package
Alternator Mounting Bolts 14-21 19-28 1.9-2.9 0067
Alternator Bracket Hinge Bolt 25-34 34-46 3.5-4.7 0067
Cap screws 12.58-15.42 17.1-20.9 1.74-2.13 0125
Backing plate 45-55 62-76 6.32-7.75 0125
Brakes
Pre brake adjustment 12.75-15.58 17.1-20.9 1.74-2.13 0125
Post brake adjustment 16.5-20.16 21.6-26.4 2.2-2.69 0125
Coolant Temperature Sensor 9-13 12-18 1.2-1.8 0062
Coolant Temperature Switch 9-13 12-18 1.2-1.8 0063
Exhaust Manifold Bolts 14-21 19-28 1.9-2.9 0073
Fan blade 17.4 23.5 2.4 0069
Hold-down bolt 23-30 31-41 3.2-4.2 0058
injector line hardware 11-18 19-28 1.9-2.9 0058
Fuel
pump hardware 14-21 19-28 1.9-2.9 0058
injector
Injector rail bolts 7-10 10-14 1.0-1.4 0058
Injector pump rail bolts 15-18 20-25 2.0-2.5 0058
Alignment studs 35-40 47.45-54.23 4.84-5.53 0123
Flex plate mounting bolts 17-20 23.05-27.11 2.35-2.76 0123
Generator
Generator mounting bolts 35-40 47.45-54.23 4.84-5.53 0123
Metal grille 7-10 9.49-13.55 0.97-1.38 0123
Engine Mounting nuts (4 ea.) 51 69.15 7.05 0123
Glow Plug 11-14 15-20 1.5-2.0 0051
Starter Bolts 93-113 69-83 9.5-11.5 0060
Thermostat housing 14-21 19-28 1.9-2.9 0064
Tire and Wheel Assembly 95-105 129-143 13.2-14.6 0080
Water Pump 14-21 19-28 1.9-2.9 0070
0067-2
TM 11-6115-742-13&P 0067
GENERAL TORQUE REQUIREMENTS
NOTE
The torque specifications in (Table 2) and (Table 3) apply only when other torque
specifications are not stated in the procedure.
The asterisk (*) indicates that bolts are used for female threaded parts that are
made of soft materials.
Table 2. Flanged Head Bolt Torque Specifications.
Bolt
Identification 4 8 9
Bolt
Dia x N-m kgf m N-m kgf m N-m kgf m
Pitch (mm)
M6 x 4.6-8.5 0.5-0.9 6.6-12.2 0.6-1.2
M8 x 1.25 10.5-19.6 1.1-2.0 151.3-28.4 1.6-2.9 18.1-33.6 2.1-3.4
M10 x 1.25 23.1-38.5 2.4-3.9 35.4-58.9 3.6-6.1 42.3-70.5 4.3-7.2
٭M10 x 1.5 22.3-37.2 2.3-3.8 34.5-57.5 3.5-5.8 40.1-66.9 4.1-6.8
M12 x 1.5 54.9-82.3 5.6-8.4 77.7-117.0 77.9-11.9 85.0-128.0 8.7-13.0
٭M12 x 1.25 51.0-76.5 5.2-7.8 71.4-107.0 7.3-10.9 79.5-119.0 8.1-12.2
M14 x 1.5 83.0-125.0 8.5-12.7 115-172.0 11.7-17.6 123.0-185.0 12.6-18.9
٭M14 x 2.0 77.2-116.0 7.9-11.8 108.0-162.0 11.1-16.6 116.0-173.0 11.8-17.7
M16 x 1.5 116.0-173.0 11.8-17.7 171.0-257.0 17.4-26.2 117.0-165.0 18.0-27.1
٭M16 x 2.0 109.0-164.0 11.2-16.7 163.0-244.0 16.6-24.9 169.0-253.0 17.2-25.8
Table 3. Standard Bolt Torque Specifications.
4 8 8 9
Bolt
Identification
Bolt
Dia x N-m kgf m N-m kgf m N-m kgf m
Pitch (mm)
M6 x 3.9-7.8 0.4-0.8 4.9-9.8 0.5-1.0
M8 x 1.0 7.8-17.7 0.8-1.8 11.8-22.6 1.2-2.3 16.7-30.4 1.7-3.1
M10 x 1.25 20.6-34.3 2.1-3.5 27.5-46.1 2.8-4.7 37.3-62.8 3.8-6.4
٭M10 x 1.5 19.6-33.4 2.0-3.4 27.5-45.1 2.8-4.6 36.3-59.8 3.7-6.1
M12 x 1.5 49.1-73.6 5.0-7.5 60.8-91.2 6.2-9.3 75.5-114.0 7.7-11.6
٭M12 x 1.25 45.1-68.7 4.6-7.0 56.9-84.4 5.8-8.6 71.6-107.0 7.3-10.9
M14 x 1.5 76.5-115.0 7.8-11.7 93.2-139.0 9.5-14.2 114.0-171.0 11.6-17.4
٭M14 x 2.0 71.6-107.0 7.3-10.9 88.3-131.0 9.0-13.4 107.0-160.0 10.9-16.3
M16 x 1.5 104.0-157.0 10.6-16.0 135.0-204.0 13.8-20.8 160.0-240.0 19.3-24.5
٭M16 x 2.0 100.0-149.0 10.2-15.2 129.0-194.0 13.2-19.8 153.0-230.0 15.6-23.4
M18 x 2.0 151.0-226.0 15.4-23.0 195.0-293.0 19.9-29.9 230.0-345.0 23.4-35.2
٭M18 x 2.5 151.0-226.0 15.4-23.0 196.0-294.0 20.0-30.0 231.0-346.0 23.6-35.3
0067-3
TM 11-6115-742-13&P 0067
GENERAL TORQUE REQUIREMENTS – Continued
Table 3. Standard Bolt Torque Specifications - Continued.
4 8 8 9
Bolt
Identification
Bolt
Dia x N-m kgf m N-m kgf m N-m kgf m
Pitch (mm)
M20 x 1.5 206.0-310.0 21.0-31.6 270.0-405.0 27.5-41.3 317.0-476.0 32.3-48.5
٭M20 x 2.5 190.0-286.0 19.4-29.2 249.0-375.0 25.4-38.2 293.0-440.0 29.9-44.9
M22 x 1.5 251.0-414.0 25.6-42.2 363.0-544.0 37.0-55.5 425.0-637.0 43.3-64.9
٭M22 x 2.5 218.0-328.0 22.2-33.4 338.0-507.0 34.5-51.7 394.0-592.0 40.2-60.4
M24 x 2.0 359.0-540.0 36.6-55.0 431.0-711.0 43.9-72.5 554.0-831.0 56.5-84.7
٭M24 x 3.0 338.0-507.0 34.5-51.7 406.0-608.0 41.4-62.0 521.0-782.0 53.1-79.7
CONVERSION TABLES
Table 4. Newton-Meters to Kilogram-Meters.
n-m 0 10 20 30 40 50 60 70 80 90
---- kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m
---- ---- 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177
100 10.197 11.217 12.236 13.256 14.276 15.296 16.315 17.335 18.355 19.374
200 20.394 21.414 22.433 23.453 24.473 25.493 26.512 27.532 28.552 29.571
300 30.591 31.611 32.630 33.650 34.670 35.690 36.709 37.729 38.749 39.768
400 40.788 41.808 42.827 443867 44.867 45.887 46.906 47.926 448.946 49.965
500 50.985 52.005 53.024 55.064 55.064 56.084 57.103 58.123 59.143 60.162
600 61.182 62.202 63.221 65.261 65.261 66.281 57.103 68.320 69.340 70.359
700 71.379 72.399 73.418 75.458 75.458 76.478 67.300 78.157 79.537 80.556
800 81.576 82.596 83.615 84.635 85.655 86.675 87.694 88.714 89.734 90.753
900 91.773 92.793 93.812 94.832 95.852 96.872 97.891 98.911 99.931 100.950
1000 101.970 102.990 104.009 105.029 106.049 107.069 108.088 109.108 110.128 111.147
Table 5. Kilogram-Meters to Foot Pounds.
kgf-m 0 1 2 3 4 5 6 7 8 9
---- ft. lbs ft. lbs ft. lbs ft. lbs ft. lbs ft. lbs ft. lbs ft. lbs ft. lbs ft. lbs
---- ---- 7.23 14.47 21.70 28.93 36.17 43.40 50.63 57.86 65.10
10 72.33 79.56 86.80 94.03 101.26 108.50 115.73 122.96 130.19 137.43
20 144.66 151.89 159.13 166.36 173.59 180.83 188.06 195.29 202.52 209.76
30 216.99 224.22 231.46 238.69 245.92 253.16 260.39 267.62 274.85 282.09
40 289.32 296.55 303.79 311.02 318.25 325.49 332.72 339.95 347.18 354.42
50 361.65 368.88 376.12 383.35 390.58 397.82 405.05 412.28 419.51 426.75
60 433.98 441.21 448.45 455.68 462.91 470.15 477.38 484.61 491.84 499.08
70 506.31 513.54 520.78 528.01 535.24 542.48 549.71 556.94 564.17 571.41
80 578.64 585.87 593.11 600.34 607.57 614.81 622.04 629.27 636.50 643.74
90 650.97 658.20 665.44 672.67 679.57 687.14 694.37 701.60 708.83 716.07
100 723.30 730.53 737.77 745.00 752.23 759.47 766.70 773.93 781.16 788.40
0067-4
TM 11-6115-742-13&P 0067
CONVERSION TABLES - Continued
Table 6. Newton-Meters to Foot Pounds.
n-m ft. lb. n-m ft. lb. n-m ft. lb. n-m ft. lb. n-m ft. lb.
1.356 1 35.256 26 69.156 51 103.056 76 142.38 105
2.712 2 36.612 27 70.512 52 104.412 77 149.16 110
4.068 3 37.968 28 71.868 53 105.768 78 155.94 115
5.424 4 39.324 29 73.224 54 107.124 79 162.72 120
6.78 5 40.68 30 74.58 55 108.48 80 169.5 125
8.136 6 42.036 31 75.936 56 109.836 81 176.28 130
9.492 7 43.392 32 77.292 57 111.192 82 183.06 135
10.848 8 44.748 33 78.648 58 112.548 83 189.84 140
12.204 9 46.104 34 80.004 59 113.904 84 196.62 145
13.56 10 47.46 35 81.36 60 115.26 85 203.4 150
14.916 11 48.816 36 82.716 61 116.616 86 210.18 155
16.272 12 50.172 37 84.072 62 117.972 87 216.96 160
17.628 13 51.528 38 85.428 63 119.328 88 223.74 165
18.984 14 52.884 39 86.784 64 120.684 89 230.52 170
20.34 15 54.24 40 88.14 65 122.04 90 237.3 175
21.696 16 55.596 41 89.496 66 123.396 91 244.08 180
23.052 17 56.952 42 90.852 67 124.752 92 250.86 185
24.408 18 58.308 43 92.208 68 126.108 93 257.64 190
25.764 19 59.664 44 93.564 69 130.176 96 264.42 195
27.12 20 61.02 45 94.92 70 128.82 95 271.2 200
28.476 21 62.376 46 96.276 71 130.176 96 305.1 225
29.832 22 63.732 47 97.632 72 131.532 97 339 250
31.188 23 65.088 48 98.988 73 132.888 98 372.9 275
32.544 24 66.444 49 100.344 74 134.244 99 406.8 300
33.9 25 67.8 50 101.7 75 135.6 100 678 500
END OF WORK PACKAGE
0067-5/6 blank
TM 11-6115-742-13&P 0068
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET – CONTROL PANEL AC METERS
.
AC METERS ADJUSTMENT/REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041, WP 0027,
Multimeter (WP 0165, Item 2) FO-6 through FO-13
Safety glasses
Materials/Parts Equipment Condition
Meter(s) Genset Shut Down
BATTERY SWITCH - OFF
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset control
panel. They consist of:
• AC AMPERES meter
• HERTZ meter
• A-C KILOWATTS meter
• A-C VOLTS meter
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0068-1
TM 11-6115-742-13&P 0068
WARNING
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-13) for electrical schematics and wiring diagrams
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
The following procedure is common to the following meters:
• AC AMPERES meter
• HERTZ meter
• A-C KILOWATTS meter
• A-C VOLTS meter
ADJUSTMENT
1. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
2. Open door and control panel, allow control panel to drop down and hang from lanyards.
3. Set multimeter for appropriate function and range.
4. Using multimeter, measure across meter and compare readings.
5. If necessary, adjust meter to match reading on multimeter.
6. If meter will not adjust in, replace as described in this WP.
END OF TASK
0068-2
TM 11-6115-742-13&P 0068
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
3. Disconnect negative terminal from battery (see WP 0041).
4. Open door and control panel, allow control panel to drop down and hang from lanyards.
5. Remove and retain two nuts (Figure 1, Item 5) and lock washers (Figure 1, Item 6) that secure terminals
(Figure 1, Item 7) to meter (Figure 1, Item 8).
6. Mark and disconnect terminals (Figure 1, Item 7) from meter (Figure 1, Item 8).
7. Remove and retain three nuts (Figure 1, Item 4), lock washers (Figure 1, Item 3) and flat washers (Figure 1,
Item 2) that secure meter (Figure 1, Item 8) to control panel (Figure 1, Item 1).
8. Remove meter (Figure 1, Item 8) from control panel (Figure 1, Item 1).
END OF TASK
REPLACEMENT
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-13) for electrical schematics and wiring diagrams.
1. Insert meter (Figure 1, Item 8) into control panel (Figure 1, Item 1).
2. Secure meter (Figure 1, Item 8) to control panel (Figure 1, Item 1) using three flat washers (Figure 1, Item 2),
lock washers (Figure 1, Item 3) and nuts (Figure 1, Item 4).
3. Connect terminals (Figure 1, Item 7) to appropriate connections on meter (Figure 1, Item 8) (See Table 1).
4. Secure terminals (Figure 1, Item 7) using two nuts (Figure 1, Item 5) and lock washers (Figure 1, Item 6).
5. Close control panel and secure to Genset.
6. Connect negative terminal to battery (see WP 0041) and start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
7. Observe readings on meter (Figure 1, Item 8). If readings are not correct proceed to adjustment procedure.
Table 1. Meter Connections.
METER CONNECTIONS
METER ID SCHEMATIC ID
+ -
79-SW1-13
AC AMPERES M1 AmA 0-100 AMPS 80-CF2-21 78-SW1-19
50A-PNL-GND
HERTZ M2 FM 55-65 Hz 76-CF2-22 75-SW1-3
A-C KILOWATTS M3 kWm 0-30 kW 82-CF2-13 81-CF2-22
A-C VOLTS M4 VmA 0-300 VOLTS 84-SW1-6 83-SW1-6
0068-3
TM 11-6115-742-13&P 0068
40 60
80 58 60 62 10 20 2 100 150
200
25
20 5 5 50 0
10 65 30 30
0 0 50 0 0 0
0 0 00 0
1
4
3
5
2
6
7
Figure 1. Meter Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0068-4
TM 11-6115-742-13&P 0069
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET CONTROL PANEL – GAUGES AND METERS
GAUGES AND METERS TEST/REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041,
Multimeter (WP 0165, Item 2) WP 0046, WP 0055,
Safety glasses FO-6 through FO-13
Materials/Parts Equipment Condition
Oil pressure gauge Genset Shut Down
Coolant temp gauge BATTERY SWITCH - OFF
DC volts meter
Battery charger meter
Hour Meter
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset control
panel. They consist of:
• DC VOLTS meter
• COOLANT TEMP gauge
• HOUR meter
• OIL PRESSURE gauge
• BATTERY CHARGER AMPS meter
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0069-1
TM 11-6115-742-13&P 0069
WARNING
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-13) for electrical schematics and wiring diagrams.
METER TESTS
DC VOLTS Meter
NOTE
The DC VOLTS meter receives signal from Engine Start Switch.
1. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
2. Open door and control panel, allow control panel to drop down and hang from lanyards.
3. Set multimeter to measure 28 VDC.
4. Attach ground (negative) lead of multimeter to ground wire (# 44-M6-G) of DC VOLTS meter.
5. Attach positive lead of multimeter to positive wire (#31-SW3-6) of DC VOLTS meter.
6. On front of control panel:
a. Set BATTERY SWITCH to ON.
b. Set ENGINE switch to RUN.
7. Compare reading on multimeter to reading on DC VOLTS meter. If readings do not match, replace DC
VOLTS meter.
END OF TASK
0069-2
TM 11-6115-742-13&P 0069
BATTERY CHARGER AMPS Meter
NOTE
During normal operation Battery Charger should read 3-4 amps.
1. Open door and control panel, allow control panel to drop down and hang from lanyards.
2. Set multimeter to measure DC Amps.
3. Disconnect wire (# 38-SW2-1) from BATTERY CHARGER AMPS meter and connect to positive lead of
multimeter.
4. Disconnect wire (# 39-CF2-12) from BATTERY CHARGER AMPS meter and connect to negative lead of
multimeter.
5. Plug in Battery Charger and check reading on multimeter.
6. Connect wire (# 38-SW2-1) to BATTERY CHARGER AMPS meter.
7. Connect wire (# 39-CF2-12) to BATTERY CHARGER AMPS meter.
8. Compare reading on BATTERY CHARGER AMPS meter to reading recorded on multimeter, if readings are
not consistent replace as described in this WP.
END OF TASK
GAUGE TESTS
OIL PRESSURE Gauge
1. Open door and control panel, allow control panel to drop down and hang from lanyards.
2. Set multimeter to measure resistance.
3. Disconnect wire (# 15-CF2-6) from OIL PRESSURE gauge and connect to positive lead of multimeter.
4. Attach ground (negative) lead of multimeter to center connection on OIL PRESSURE gauge.
5. Using multimeter, take resistance reading from sensor on OIL PRESSURE gauge.
6. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM and allow to run for 1 minute.
7. Using multimeter, take second resistance reading from sensor on OIL PRESSURE gauge. Resistance should
reduce as oil pressure goes up.
a. If resistance does not reduce, replace oil pressure sensor (see WP 0046 of this TM).
b. If resistance does reduce disconnect multimeter and connect wire (# 15-CF2-6) to OIL PRESSURE
gauge.
8. Observe OIL PRESSURE gauge. If OIL PRESSURE gauge does not move replace as described in this WP.
END OF TASK
0069-3
TM 11-6115-742-13&P 0069
COOLANT TEMP Gauge
1. Start with cold engine.
2. Open door and control panel, allow control panel to drop down and hang from lanyards.
3. Set multimeter to measure resistance.
4. Disconnect wire (# 14-CF2-5) from COOLANT TEMP gauge and attach to positive lead of multimeter.
5. Attach ground (negative) lead of multimeter to center connection on COOLANT TEMP gauge.
6. Using multimeter, take resistance reading from sensor on COOLANT TEMP gauge.
7. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM and allow to run for 15
minutes.
8. Using multimeter, take second resistance reading from sensor on COOLANT TEMP gauge. Resistance
should decrease as temperature goes up.
a. If resistance does not decrease, replace temperature sensor (see WP 0055 of this TM).
b. If resistance decreases, disconnect multimeter and connect wire (# 14-CF2-5) to COOLANT TEMP
gauge.
9. Observe COOLANT TEMP gauge. If gauge does not move replace as described in this WP.
END OF TASK
REMOVAL
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
NOTE
The following procedure is common to the following meters:
• DC VOLTS meter
• BATTERY CHARGER meter
• COLANT TEMP gauge
• OIL PRESSURE gauge
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel, allow control panel to drop down and hang from lanyards.
0069-4
TM 11-6115-742-13&P 0069
REMOVAL - Continued
NOTE
DC VOLTS and BATTERY CHARGER have connections on two of three
terminals. COOLANT TEMP and OIL PRESSURE have connections on all three
terminals.
4. Remove and retain nuts(s) (Figure 1, Item 4) and lock washer(s) (Figure 1, Item 3) that secure terminals
(Figure 1, Item 2) to meter/gauge (Figure 1, Item 13).
5. Mark and disconnect terminals (Figure 1, Item 2) from meter/gauge (Figure 1, Item 13).
6. Remove and retain two nuts (Figure 1, Item 7), lock washers (Figure 1, Item 6) and bracket (Figure 1, Item 5)
that secure meter/gauge (Figure 1, Item 13) to control panel (Figure 1, Item 1).
7. Remove meter/gauge (Figure 1, Item 13) from control panel (Figure 1, Item 1).
END OF TASK
REPLACEMENT
1. Install meter/gauge (Figure 1, Item 13) through control panel (Figure 1, Item 1).
2. Secure meter/gauge (Figure 1, Item 13) to control panel (Figure 1, Item 1) with bracket (Figure 1, Item 5) two
nuts (Figure 1, Item 7) and lock washers (Figure 1, Item 6).
NOTE
DC VOLTS and BATTERY CHARGER have connections on two of three
terminals. COOLANT TEMP and OIL PRESSURE have connections on all three
terminals. Refer to Table 1 or FO-6 through FO-13 for proper connections.
3. Connect terminals (Figure 1, Item 2) to meter/gauge (Figure 1, Item 13).
4. Secure terminals (Figure 1, Item 2) to meter/gauge (Figure 1, Item 13) using nuts(s) (Figure 1, Item 4) and
lock washer(s) (Figure 1, Item 3).
5. Close control panel and secure to Genset.
6. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
Table 1. Meter/Gauge Connections.
METER CONNECTIONS
METER/GAUGE ID SCHEMATIC ID Negative Positive Ground
(I) (S) (G)
DC VOLTS M5 VmD 31-SW3-6 no connection 44-M6-G
COOLANT TEMP M6 CTG 30-R2-2 14-CF2-5 44-M5-G
50B-SW8-1
40-CF2-13
OIL PRESSURE M8 OPG 30-R2-2 15-CF2-6 41-M6-G
47-1 5-1
46-1 4-1
BATTERY CHARGER M9 AmD 38-SW2-1 39-CF2-12 no connection
0069-5
TM 11-6115-742-13&P 0069
40 60
80 58 60 62 10 20 2 100 150 200 25
20 5 5 50 0
10 65 30 30
0 0 50 0 0 0
I S -
G
+ 00 0 0 0
DC VOLTS HOUR METER
BATTERY CHARGER
COOLANT TEMP
OIL PRESSURE
NOTE:
(S) - POSITIVE
(I) - NEGATIVE
(G) - GROUND
4
7
3
6
2 5
8
9
10
11
13
12
Figure 1. Meter/Gauge Removal/Replacement.
END OF TASK
0069-6
TM 11-6115-742-13&P 0069
HOUR METER TEST/REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
TEST
1. Open door and control panel, allow control panel to drop down and hang from lanyards.
2. Set multimeter to measure 24 VDC.
3. Disconnect wire (# 26-CF2-8) from positive (+) terminal on HOUR METER and connect to positive lead of
multimeter.
4. Disconnect wire (# 44-M6-G) from (-) negative terminal on HOUR METER and connect to negative lead of
multimeter.
5. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
6. Observe multimeter. Multimeter should read approximately 24 VDC.
a. If multimeter does not read 24 VDC, troubleshoot engine/wiring.
b. If multimeter does read 24 VDC, replace HOUR METER as described in this WP.
END OF TASK
REMOVAL
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel, allow control panel to drop down and hang from lanyards.
4. Mark and disconnect two terminals (Figure 1, Item 11) from hour meter (Figure 1, Item 12).
5. Remove and retain nut (Figure 1, Item 8), lock washer (Figure 1, Item 9) and bracket (Figure 1, Item 10) that
secures hour meter (Figure 1, Item 12) to control panel (Figure 1, Item 1).
0069-7
TM 11-6115-742-13&P 0069
REMOVAL-Continued
6. Remove hour meter (Figure 1, Item 12) from control panel (Figure 1, Item 1).
END OF TASK
REPLACEMENT
1. Install hour meter (Figure 1, Item 12) through control panel (Figure 1, Item 1).
2. Secure hour meter (Figure 1, Item 12) to control panel (Figure 1, Item 1) with bracket (Figure 1, Item 10) nut
(Figure 1, Item 8) and lock washer (Figure 1, Item 9).
3. Connect two terminals (Figure 1, Item 11) to hour meter (Figure 1, Item 12).
4. Close control panel and secure to Genset.
5. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
Table 2. Hour Meter Connections.
METER CONNECTIONS
METER/GAUGE ID SCHEMATIC ID
(+) (-)
HOUR METER M7 HM 26-CF2-8 44-M6-G
END OF TASK
END OF WORK PACKAGE
0069-8
TM 11-6115-742-13&P 0070
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET CONTROL PANEL – SWITCHES AND POTENTIOMETER
GENSET CONTROL PANEL – SWITCHES AND POTENTIOMETER MAINTENANCE
INITIAL SETUP:
Tools and Special Tools Personnel Required
Electronic equipment tool kit (WP 0165, Item 4) One
Multimeter (WP 0165, Item 2)
Safety glasses Reference
WP 0005, WP 0041
Materials/Parts
Potentiometer Equipment Condition
Desoldering wick (WP 0168, Item 15) Genset Shut Down
Heat shrink (WP 0168, Items 31 to 34) BATTERY SWITCH - OFF
Strap ties (WP 0168, Item 55 to 57)
Alchohol, Isopropyl (WP 0168, Item 1)
Solder, electrical (WP 0168, Item 53)
Brush, acid (WP 0168, Item 9)
Switches
GENERAL
This work package provides information on the removal and replacement of components on the Genset control
panel. They consist of:
• VOLTAGE ADJUST potentiometer
• BATTLE SHORT toggle switch
• ENGINE HEATER toggle switch
• FUEL LINE HEATER toggle switch
• VOLT/AMP rotary switch
• PANEL LIGHT rotary switch
• ENGINE rotary switch
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0070-1
TM 11-6115-742-13&P 0070
WARNING
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-13) for electrical schematics and wiring diagrams.
VOLTAGE ADJUST POTENTIOMETER TEST/REMOVAL/REPLACEMENT
TEST
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Verify that wiper (center post) is shorted to the Max terminal (shorted to wiper) .
3. Disconnect wiring from potentiometer.
4. Set multimeter to reads resistance (1K Ω).
5. Place meter leads on wiper and Min terminal (NOT shorted to wiper) of potentiometer.
6. Adjust potentiometer:
a. If meter deflects smoothly and measure 1KΩ at maximum, potentiometer is good.
b. If meter deflects erratically, suddenly drops to 0 Ω, or does not measure 1KΩ at maximum, potentiometer
is bad, replace
END OF TASK
0070-2
TM 11-6115-742-13&P 0070
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel (Figure 1, Item 1), allow control panel (Figure 1, Item 1) to drop down and hang
from lanyards. Remove any strap-ties securing associated wiring to control panel (Figure 1, Item 1).
4. Mark and disconnect terminals from leads (Figure 1, Item 3) hanging off of potentiometer (Figure 1, Item 2).
5. Remove and retain nut (Figure 1, Item 4) that secures potentiometer (Figure 1, Item 2) to control panel
(Figure 1, Item 1).
6. Remove potentiometer (Figure 1, Item 2) from control panel (Figure 1, Item 1).
7. Desolder leads (Figure 1, Item 3) from potentiometer (Figure 1, Item 2). Disconnect leads (Figure 1, Item 3)
and set aside.
END OF TASK
REPLACEMENT
NOTE
If wires/terminals to be soldered to potentiometer are not usable, fabricate new
leads using (16 AWG) wire and appropriate terminal.
If necessary, tin joints on potentiometer and clean with alcohol in preparation to
receive solder.
1. Strip, tin and prep leads (Figure 1, Item 3) for soldering.
2. Place heat shrink over prepared leads (Figure 1, Item 3). Form J-hook with tinned wire.
3. Solder leads (Figure 1, Item 3) to terminals on potentiometer (Figure 1, Item 2) (see Figure 1) and allow to
cool.
4. Remove excess flux with acid brush and isopropyl alcohol and inspect joints.
5. Slide heat shrink over soldered joints and apply heat using heat gun.
6. Insert potentiometer (Figure 1, Item 2) into control panel (Figure 1, Item 1) (terminals towards edge of control
panel) and secure using nut (Figure 1, Item 4). Secure wiring to control panel (Figure 1, Item 1) using strap-
ties.
7. Close control panel (Figure 1, Item 1) and secure.
8. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
0070-3
TM 11-6115-742-13&P 0070
40 60
80 58 60 62 10 20 2 100 150 200
25
20 5 5 50 0
10 65 30 30
0 0 50 0 0 0
0 00 0 0
2
2
(R1) (REF)
(WIPER)
(MAX)
(MIN)
3
(REF)
TO 3
86-CF2-25
TO
85-CF2-24
Figure 1. Potentiometer Removal/Replacement.
END OF TASK
0070-4
TM 11-6115-742-13&P 0070
ROTARY SWITCHES REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
NOTE
The following procedure covers the following assemblies:
• VOLT/AMP rotary switch
• PANEL LIGHT rotary switch
• ENGINE rotary switch
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY rotary switch is set to OFF
(WP 0005, Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel (Figure 2, Item 1), allow control panel (Figure 2, Item 1) to drop down and hang
from lanyards. Remove any strap-ties securing associated wiring harness to control panel (Figure 2, Item 1).
4. Remove and retain screw (Figure 2, Item 7) and knob (Figure 2, Item 6) from rotary switch being replaced.
5. Carefully pry off silver cover (Figure 2, Item 5) exposing mounting plate (Figure 2, Item 3) and four screws
(Figure 2, Item 4) that secure rotary switch (Figure 2, Item 2) to control panel (Figure 2, Item 1).
6. Remove and retain four mounting screws (Figure 2, Item 4) that secure mounting plate (Figure 2, Item 3) and
rotary switch (Figure 2, Item 2) to control panel (Figure 2, Item 1).
7. Remove and retain mounting plate (Figure 2, Item 3) from control panel (Figure 2, Item 1).
NOTE
Be observant of jumpers on rotary switches. Ensure they do not fall out when
hardware is loosened.
8. Remove rotary switch (Figure 2, Item 2) being observant of orientation and positioning on control panel.
(Figure 2, Item 2).
9. Loosen but do not remove hardware securing terminal leads to rotary switch (Figure 2, Item 2). Remove
wiring from rotary switch (Figure 2, Item 2) and re-tighten hardware.
END OF TASK
0070-5
TM 11-6115-742-13&P 0070
REPLACEMENT
NOTE
If necessary, refer to (Table 1) or (FO-6 through FO-13) for electrical schematics
and wiring diagrams.
Be observant of jumpers on rotary switches. Ensure they are in the proper
locations on the switch.
1. Loosen but do not remove hardware securing terminal leads to rotary switch (Figure 2, Item 2). Install
terminals from wiring harness to appropriate terminals on rotary switch (Figure 2, Item 2) and re-tighten
hardware.
2. Insert rotary switch (Figure 2, Item 2) being observant of orientation and positioning through rear of control
panel (Figure 2, Item 1).
3. Place mounting plate (Figure 2, Item 3) on front of control panel (Figure 2, Item 1) and loosely install four
mounting screws (Figure 2, Item 4). Once hardware is aligned, tighten four mounting screws (Figure 2,
Item 4)
4. Install silver cover (Figure 2, Item 5) onto mounting plate (Figure 2, Item 3).
5. Install knob (Figure 2, Item 6) onto rotary switch (Figure 2, Item 2) and secure with screw (Figure 2, Item 7).
6. Close control panel (Figure 1, Item 1) and secure.
7. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
0070-6
TM 11-6115-742-13&P 0070
Table 1. Genset Control Panel - Rotary Switch Connections.
SWITCH HARNESS
SWITCH ID SCHEMATIC ID JUMPERS
TERMINAL ID
1 71-CF2-17
2 no connection
3 75-M2
4 Jumper to pin #8
5 73-CF2-19
6 84-M4
7 72-CF2-18
8 83-M4 Jumper to pin #4
9 no connection
10 no connection
VOLT/AMP SW1
11 Jumper to pin #19
12 Jumper to pin #16
13 79-M1 Jumper to pin #17
14 67-CF2-14
15 no connection
16 69-CF2-16 Jumper to pin #12
17 Jumper to pin #13
18 no connection
19 78-M1 Jumper to pin #11
20 68-CF2-15
1 23-SW3-11
38-M9
PANEL LIGHT SW2 (PLS) 2 24-L1, L2
3 no connection
4 no connection
1 1-CF2-2
2 20-CF2-7
3 Jumper to pin #7
4 8-CF2-2
5 no connection
30-R2-1
6
ENGINE SW3 (ESS) 31-MS-1
7 Jumper to pins #3 and #11
8 10-CF2-4
9
10 25-L3-L5
11 Jumper to pin #7
12 9-CG2-3
0070-7
TM 11-6115-742-13&P 0070
40 60
80 58 60 62 10 20 2 100 150 200
25
20 5 5 50 0
10 65 30 30
0 0 50 0 0 0
000 0 0
5 4
2
7 6 2
3 3
7 4
5 2
4
6 5 6
7
Figure 2. Rotary Switch Removal/Replacement.
END OF TASK
0070-8
TM 11-6115-742-13&P 0070
TOGGLE SWITCHES REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
FUEL LINE HEATER/ ENGINE HEATER
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY rotary switch is set to OFF
(WP 0005, Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel (Figure 3, Item 1), allow control panel (Figure 3, Item 1) to drop down and hang
from lanyards. Remove any strap-ties securing associated wiring harness to control panel (Figure 3, Item 1).
4. Mark and disconnect all wires from toggle switch (Figure 3, Item 2) being observant of terminal association.
5. Remove and retain nut (Figure 3, Item 5) and plate (Figure 3, Item 4) from toggle switch (Figure 3, Item 2)
being replaced.
6. Remove toggle switch (Figure 3, Item 2) from control panel (Figure 3, Item 1).
END OF TASK
REPLACEMENT
NOTE
Ensure nut (Figure 3, Item 3) is present on switch (Figure 3, Item 2). If
necessary, adjust to allow sufficient threads to protrude through control panel.
1. Install toggle switch (Figure 3, Item 2) into control panel (Figure 3, Item 1) being observant of orientation.
2. Install plate (Figure 3, Item 4) and secure to control panel (Figure 3, Item 1) with nut (Figure 3, Item 5).
NOTE
If necessary, refer to (Table 2) or (FO-6 through FO-13) for electrical schematics
and wiring diagrams.
3. Connect all wires to toggle switch (Figure 3, Item 2).
4. Close control panel (Figure 1, Item 1) and secure.
5. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
END OF TASK
0070-9
TM 11-6115-742-13&P 0070
BATTLE SHORT
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY rotary switch is set to OFF
(WP 0005, Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel (Figure 3, Item 1), allow control panel (Figure 3, Item 1) to drop down and hang
from lanyards. Remove any strap-ties securing associated wiring harness to control panel (Figure 3, Item 1).
4. Mark and disconnect all wires from toggle switch (Figure 3, Item 9) being observant of terminal association.
5. Remove and retain nut (Figure 3, Item 8), lock washer (Figure 3, Item 7), and guard (Figure 3, Item 6).
6. Remove toggle switch (Figure 3, Item 9) from control panel (Figure 3, Item 1).
END OF TASK
REPLACEMENT
NOTE
Ensure nut (Figure 3, Item 3) is present on switch (Figure 3, Item 9). If
necessary, adjust to allow sufficient threads to protrude through control panel.
1. Install toggle switch (Figure 3, Item 9) into control panel (Figure 3, Item 1) being observant of orientation.
2. Install guard (Figure 3, Item 6) and secure to control panel (Figure 3, Item 1) with lock washer (Figure 3,
Item 7) and nut (Figure 3, Item 8)
NOTE
If necessary, refer to (Table 2) or (FO-6 through FO-13) for electrical schematics
and wiring diagrams.
Once BATTLE SHORT switch is installed, multimeter should read short (0Ω)
when BATTLE SHORT switch is in the up position
3. Connect all wires to toggle switch (Figure 3, Item 9).
4. Close control panel (Figure 3, Item 1) and secure.
5. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
0070-10
TM 11-6115-742-13&P 0070
Table 2. Genset Control Panel - Toggle Switch Connections.
SWITCH HARNESS
SWITCH ID SCHEMATIC ID
TERMINAL ID
1 29B-CF2-31
BATTLE SHORT SW5
2 1B-CF2-30
1 425-SW8-1
2 424-SW8-2
ENGINE HEAT SW6
3 BK-CF2-33
4 GN-CF2-35
425-SW6-1
1
50B-M8-G
424-SW6-2
FUEL LINE HEAT SW8 2
RD-CF-34
3 50-CF-36
4 425-SW8-3-4
0070-11
TM 11-6115-742-13&P 0070
40 60
80 58 60 62 10 20 2 100 150 200 25
20 5 5 50 0
10 65 30 30
0 0 50 0 0 0
00 00 0
6
7
8
4 3
Figure 3. Toggle Switch Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0070-12
TM 11-6115-742-13&P 0071
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
CONTROL PANEL – LIGHTS
CONTROL PANEL LIGHTS REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041,
FO-6 through FO-13
Materials/Parts
Panel light Equipment Condition
Indicator light Genset Shut Down
Personnel Required BATTERY SWITCH - OFF
One
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
CONTROL PANEL LIGHT REMOVAL
1. Verify that Genset has been shut down, engine is cool, and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel (Figure 1, Item 1). Allow control panel (Figure 1, Item 1) to drop down and hang
from lanyards.
4. Mark and disconnect terminal coming from panel light (Figure 1, Item 12) from wiring harness.
5. Remove and retain nut (Figure 1, Item 3) and lock washer (Figure 1, Item 2) that secures panel light
(Figure 1, Item 12) to control panel (Figure 1, Item 1).
6. Remove panel light (Figure 1, Item 12) from control panel (Figure 1, Item 1).
END OF TASK
REPLACEMENT
NOTE
If necessary, remove cover (Figure 1, Item 10) and bulb (Figure 1, Item 11) from
old panel light and install onto new panel light.
1. Insert panel light (Figure 1, Item 12) through front of control panel (Figure 1, Item 1).
0071-1
TM 11-6115-742-13&P 0071
2. Secure using nut (Figure 1, Item 3) and lock washer (Figure 1, Item 2).
3. Connect terminal from panel light (Figure 1, Item 12) to wiring harness.
4. Close control panel (Figure 1, Item 1) and secure.
REPLACEMENT - Continued
5. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
0071-2
TM 11-6115-742-13&P 0071
40 60
80 58 60 62 10 20 2 100 150 200
25
20 5 5 50 0
10 65 30 30
0 0 50 0 0 0
00 00 0
12
11
10
5
5 6 4
7
8
9
Figure 1. Light Assemblies Removal/Replacement.
END OF TASK
0071-3
TM 11-6115-742-13&P 0071
INDICATOR LIGHTS REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
NOTE
The following procedure covers the following assemblies:
• HIGH COOLANT TEMP light
• OVERSPEED light
• LOW OIL PRESSURE light
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel (Figure 1, Item 1). Allow control panel (Figure 1, Item 1) to drop down and hang
from lanyards.
4. Mark and disconnect three terminals (Figure 1, Item 4) coming from wiring harness from indicator light
(Figure 1, Item 7).
5. Remove and retain nut (Figure 1, Item 5) and lock washer (Figure 1, Item 6) that secures indicator light
(Figure 1, Item 7) to control panel (Figure 1, Item 1).
6. Remove indicator light (Figure 1, Item 7) from control panel (Figure 1, Item 1).
END OF TASK
0071-4
TM 11-6115-742-13&P 0071
REPLACEMENT
NOTE
If necessary, remove cover (Figure 1, Item 9) and bulb (Figure 1, Item 8) from old
indicator light (Figure 1, Item 7) and install onto new indicator light (Figure 1,
Item 7).
1. Insert indicator light (Figure 1, Item 7) through front of control panel (Figure 1, Item 1).
2. Secure using nut (Figure 1, Item 5) and lock washer (Figure 1, Item 6).
NOTE
If necessary, refer to (Table 1) or (FO-6 through FO-13) for electrical schematics
and wiring diagrams.
3. Connect three terminals (Figure 1, Item 4) from wiring harness indicator light (Figure 1, Item 7).
4. Close control panel (Figure 1, Item 1) and secure.
5. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
Table 1. Indicator Light(s) Connections.
TERMINAL CONNECTIONS
INDICATOR LIGHT ID SCHEMATIC ID
1 2 3
HIGH COOLANT TEMP L3 45-M6-G 34-CF2-9 25-SW3-9
LOW OIL PRESSURE L4 46-M8-G 35-CF2-10 25-SW3-9
OVERSPEED L5 47-M8-G 36-CF2-11 25-SW3-9
END OF TASK
END OF WORK PACKAGE
0071-5/6 blank
TM 11-6115-742-13&P 0072
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET CONTROL PANEL – SWITCHES
GENSET CONTROL PANEL SWITCHES REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041
Materials/Parts Equipment Condition
Switch Genset Shut Down
BATTERY SWITCH - OFF
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset control
panel. They consist of:
• BATTERY SWITCH
• EMERGENCY STOP
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0072-1
TM 11-6115-742-13&P 0072
WARNING
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-12) for electrical schematics and wiring diagrams.
BATTERY SWITCH
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Remove and retain eight screws (Figure 1, Item 14), lock washers (Figure 1, Item 13), and flat washers
(Figure 1, Item 12) from circuit breaker cover plate (Figure 1, Item 11). Remove and retain circuit breaker
cover plate (Figure 1, Item 11) from control panel (Figure 1, Item 1).
4. Remove and retain two countersunk screws (Figure 1, Item 17) from control panel (Figure 1, Item 1).
5. Remove and retain four screws (Figure 1, Item 22), lock washers (Figure 1, Item 23), and flat washers
(Figure 1, Item 24) that secure control panel (Figure 1, Item 1) to Genset.
6. Raise control panel (Figure 1, Item 1) to gain access to electrical connections on switch (Figure 1, Item 2).
Remove and retain two nuts (Figure 1, Item 4) and lock washers (Figure 1, Item 3) that secure electrical
connections (Figure 1, Item 5) to switch (Figure 1, Item 2).
7. Mark and remove wiring harness terminals (Figure 1, Item 5) from switch (Figure 1, Item 2).
8. Remove and retain screw (Figure 1, Item 18) and knob (Figure 1, Item 19) from switch (Figure 1, Item 2).
9. Remove and retain nut (Figure 1, Item 20) and lock washer (Figure 1, Item 21). Remove switch (Figure 1,
Item 3) from control panel (Figure 1, Item 1).
END OF TASK
0072-2
TM 11-6115-742-13&P 0072
REPLACEMENT
1. Insert switch (Figure 1, Item 2) through control panel (Figure 1, Item 1) and secure using lock washer
(Figure 1, Item 21) and nut (Figure 1, Item 20).
2. Place knob (Figure 1, Item 19) onto switch (Figure 1, Item 2) and secure with screw (Figure 1, Item 18).
3. Connect wiring harness terminals (Figure 1, Item 5) to switch (Figure 1, Item 2) and secure using two nuts
(Figure 1, Item 4) and lock washers (Figure 1, Item 3).
4. Align two countersunk screws (Figure 1, Item 15) with clips (Figure 1, Item 10) and secure control panel
(Figure 1, Item 1) to barrier panel.
5. Install circuit breaker cover plate (Figure 1, Item 11) and secure to control panel (Figure 1, Item 1) using eight
screws (Figure 1, Item 14), lock washers (Figure 1, Item 13), and flat washers (Figure 1, Item 12).
6. Secure control panel (Figure 1, Item 1) to Genset using four screws (Figure 1, Item 22), lock washers
(Figure 1, Item 23), and flat washers (Figure 1, Item 24).
7. Connect negative terminal to battery (see WP 0041). Start Genset (Figure 1, Item 1) in accordance with
Genset Start Procedure (WP 0005) of this TM.
0072-3
TM 11-6115-742-13&P 0072
40 60
80 58 60 62 10 20 2 100 150
200
25
20 5 5 50 0
10 65 30 30
0 0 50 0 0 0
0 000 0
3
4
2 5 7
1
5 7
24 8
23 9 P/O BARRIER
PANEL
22
21
20
19
10
18
16
15
17
11
14
12
13
Figure 1. Battery Switch Removal/Replacement.
END OF TASK
0072-4
TM 11-6115-742-13&P 0072
EMERGENCY STOP SWITCH REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
EMEREGENCY STOP
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Remove and retain eight screws (Figure 1, Item 15), lock washers (Figure 1, Item 14), and flat washers
(Figure 1, Item 13) from circuit breaker cover plate (Figure 1, Item 12). Remove and retain circuit breaker
cover plate (Figure 1, Item 12) from control panel (Figure 1, Item 1).
4. Remove and retain two countersunk screws (Figure 1, Item 16) from control panel (Figure 1, Item 1).
5. Remove and retain four screws (Figure 1, Item 22), lock washers (Figure 1, Item 23) and flat washers
(Figure 1, Item 24) that secure control panel (Figure 1, Item 1) to Genset.
6. Raise control panel (Figure 1, Item 1) to gain access to electrical connections on switch (Figure 1, Item 9).
7. Loosen but do not remove two screws securing electrical connections (Figure 1, Item 10) to switch (Figure 1,
Item 9).
8. Mark and remove electrical connections (Figure 1, Item 10) from switch (Figure 1, Item 9).
9. Remove and retain switch (Figure 1, Item 9) by prying up on metal latch of switch (Figure 1, Item 9).
10. Remove and retain bracket (Figure 1, Item 8) by expanding metal clamp with small screw driver.
11. Remove and retain mounting nut (Figure 1, Item 7).
12. Remove plunger (Figure 1, Item 18) and label (Figure 1, Item 17) from front of control panel (Figure 1, Item 1).
END OF TASK
REPLACEMENT
1. Insert plunger (Figure 1, Item 18) through label (Figure 1, Item 17) and control panel (Figure 1, Item 1).
Secure using mounting nut (Figure 1, Item 7).
2. Expand metal clamp of bracket (Figure 1, Item 8) with small screw driver and install onto plunger (Figure 1,
Item 18).
3. Orientate and install switch (Figure 1, Item 9) onto bracket (Figure 1, Item 8).
0072-5
TM 11-6115-742-13&P 0072
REPLACEMENT- Continued
4. Connect wiring harness terminals (Figure 1, Item 10) to switch (Figure 1, Item 9) and secure by tightening set
screws.
5. Align two countersunk screws (Figure 1, Item 16) with clips (Figure 1, Item 11) and secure control panel
(Figure 1, Item 1) to barrier panel.
6. Install circuit breaker cover plate (Figure 1, Item 12) and secure to control panel (Figure 1, Item 1) using eight
screws (Figure 1, Item 15), lock washers (Figure 1, Item 14), and flat washers (Figure 1, Item 13).
7. Secure control panel (Figure 1, Item 1) to Genset using four screws (Figure 1, Item 22), lock washers
(Figure 1, Item 23) and flat washers (Figure 1, Item 24).
8. Connect negative terminal to battery (see WP 0041). Start Genset (Figure 1, Item 1) in accordance with
Genset Start Procedure (WP 0005) of this TM.
END OF TASK
END OF WORK PACKAGE
0072-6
TM 11-6115-742-13&P 0073
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET – CONTROL PANEL
CONTROL PANEL WIRING HARNESS REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041
Safety glasses FO-6 through FO-12
Materials/Parts
Wiring harness Equipment Condition
Strap-ties (WP 0168, Item 55 to 57) Genset Shut Down
BATTERY SWITCH - OFF
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset control
panel. It consists of:
• Control panel wiring harness removal/replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0073-1
TM 11-6115-742-13&P 0073
WARNING
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-12) for electrical schematics and wiring diagrams.
REMOVAL
NOTE
If necessary, refer to (Figure 1) for component location and to (Figures FO-6
through FO-12) for electrical schematic/wiring diagrams.
Replacing the entire wiring harness should be a last resort. Always attempt to
replace individual terminals or individual wires before doing a total replacement
of the wiring harness.
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel, allow control panel to drop down and hang from lanyards.
4. Remove and retain nuts and lock washers that secure wiring harness to all AC meters (A-C- AMPERES,
HERTZ, A-C KILOWATTS, A-C VOLTS) on control panel.
5. Mark and disconnect all wiring harness terminals from all AC meters of control panel.
6. Remove and retain nuts and lock washers that secure wiring harness to gauges (COOLANT TEMP and OIL
PRESSURE) and remaining meters (DC VOLTS, HOURMETER and BATTERY CHARGER AMPS) on
control panel.
7. Mark and disconnect all wiring harness terminals from gauges and meters of control panel.
8. Loosen but do not remove hardware that secures wiring harness terminals to rotary switches (VOLT/AMP,
PANEL LIGHT and ENGINE).
9. Mark and disconnect all wiring harness terminals from rotary switches on control panel.
10. Disconnect all wiring harness terminals from toggle switches (BATTLE SHORT, ENGINE HEATER and FUEL
LINE HEATER) on control panel.
11. Disconnect leads coming off of VOLTAGE ADJUST potentiometer from wiring harness.
12. Disconnect leads coming off of panel lights, HIGH COOLANT TEMP, OVERSPEED, and LOW OIL
PRESSURE from wiring harness.
13. Disconnect wiring harness connector CF2 from mating plug.
14. Remove all strap ties securing wiring harness to control panel and remove wiring harness.
0073-2
TM 11-6115-742-13&P 0073
END OF TASK
REPLACEMENT
NOTE
If necessary, refer to (Figure 1) for component location and to (Figures FO-6
through FO-12) for electrical schematics and wiring diagrams.
1. Inspect new wiring harness for completeness. Verify that all terminals are present, wiring harness is not
damaged and CF2 connector is complete.
2. Lay wiring harness onto control panel and loosely strap tie into place.
3. Connect appropriate wiring harness leads to panel lights, HIGH COOLANT TEMP, OVERSPEED, and LOW
OIL PRESSURE lights.
4. Connect appropriate wiring harness leads coming off of VOLTAGE ADJUST potentiometer.
5. Connect appropriate wiring harness leads to toggle switches (BATTLE SHORT, ENGINE HEATER and FUEL
LINE HEATER).
6. Connect appropriate wiring harness leads to rotary switches (VOLT/AMP, PANEL LIGHT and ENGINE) and
tighten all set screws.
7. Connect appropriate wiring harness leads to gauges (COOLANT TEMP and OIL PRESSURE) and meters
(DC VOLTS, HOURMETER and BATTERY CHARGER AMPS) and install all associated hardware.
8. Connect appropriate wiring harness leads to AC meters (A-C- AMPERES, HERTZ, A-C KILOWATTS, A-C
VOLTS) and install all associated hardware.
9. Connect CF2 connector to mating end.
10. Lay wiring harness against control panel and tighten all strap ties.
11. Close and secure control panel to Genset.
12. Connect negative terminal to battery (see WP 0041). Start Genset (Figure 1, Item 1) in accordance with
Genset Start Procedure (WP 0005) of this TM.
0073-3
TM 11-6115-742-13&P 0073
L2 L1
+ + + +
M4 M3 M2 M1
M9 M8 - + M6 M5
SW6 G G G G
I S I S
M7 I S
I S
SW8 SW3 L5 L4 L3 SW2 SW1 SW5
R1 1
3
1
3
1
3
2 2 2
CF2
Figure 1. Control Panel Component Identification.
Table 1. Component Identification.
Component Component
Control Panel Marking Control Panel Marking
Identifier Identifier
M1 A-C- AMPERES meter SW1 VOLT/AMP switch
M2 HERTZ meter SW2 PANEL LIGHT switch
M3 A-C KILOWATTS meter SW3 ENGINE switch
M4 A-C VOLTS meter SW5 BATTLE SHORT switch
M5 DC VOLTS meter SW6 FUEL LINE HEATER switch
M6 COOLANT TEMP gauge SW8 ENGINE HEATER switch
M7 HOURMETER meter
M8 OIL PRESSURE gauge L1 Panel light
M9 BATTERY CHARGER AMPS meter L2 Panel light
L3 HIGH COOLANT TEMP light
R1 VOLTAGE ADJUST potentiometer L4 OVERSPEED light
L5 LOW OIL PRESSURE light
CF2 Cable connector
END OF TASK
END OF WORK PACKAGE
0073-4
TM 11-6115-742-13&P 0074
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET – POWER DISTRIBUTION PANEL CONNECTORS AND PANEL LIGHTS
POWER DISTRIBUTION PANEL LIGHTS AND CONNECTORS REMOVAL/REPLACEMENT (Old Version)
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041, FO-6 through FO-12
Materials/Parts Equipment Condition
Panel light Genset Shut Down
Connector BATTERY SWITCH - OFF
Gasket
Strap ties (WP 0168, Item 55 to 57)
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset control
panel. They consist of:
• Power distribution panel lights removal/replacement
• Power distribution panel J1 and J4 connector removal/replacement
• Power distribution panel J2 and J3 connector removal/replacement
• Power distribution panel J5 connector removal/replacement
• Power distribution panel J6 connector removal/replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0074-1
TM 11-6115-742-13&P 0074
WARNING
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-12) for electrical schematics and wiring diagrams.
The following procedure is applicable to all lights on the power distribution panel.
POWER DISTRIBUTION PANEL LIGHTS REMOVAL/REPLACEMENT (Old Version)
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. If necessary, raise door and latch in open position.
4. If necessary, disconnect all cables from power distribution panel (Figure 1, Item 1).
5. Remove and retain 12 bolts (Figure 1, Item 7) and flat washers (Figure 1, Item 6) that secure power
distribution panel (Figure 1, Item 1) to Genset.
6. Remove power distribution panel (Figure 1, Item 1) and lay face down.
7. Slide wire cover (Figure 1, Item 4) off of light (Figure 1, Item 12) being replaced.
8. Mark and disconnect three terminals (Figure 1, Item 5) from light (Figure 1, Item 12) being replaced.
9. Remove and retain nut (Figure 1, Item 3) and lock washer (Figure 1, Item 2) that secures light (Figure 1,
Item 12) to power distribution panel (Figure 1, Item 1).
10. Remove indicator light (Figure 1, Item 12) from power distribution panel (Figure 1, Item 1).
END OF TASK
0074-2
TM 11-6115-742-13&P 0074
REPLACEMENT
NOTE
Inspect all terminals and associated wires. If necessary replace or repair.
1. Adjust nut (Figure 1, Item 10) on indicator light (Figure 1, Item 12) to allow sufficient threads to come though
power distribution panel (Figure 1, Item 1).
2. Insert indicator light (Figure 1, Item 12), lock washer (Figure 1, Item 11) and nut (Figure 1, Item 10) through
power distribution panel (Figure 1, Item 1).
3. Install nut (Figure 1, Item 3) and lock washer (Figure 1, Item 2) and secure indicator light (Figure 1, Item 11)
to power distribution panel (Figure 1, Item 1).
NOTE
If necessary, refer to (FO-6 through FO-12) for electrical schematic.
4. Connect three terminals (Figure 1, Item 5) to light (Figure 1, Item 12) and slide wire cover (Figure 1, Item 4)
over connections.
5. Place power distribution panel (Figure 1, Item 1) onto Genset and secure using 12 bolts (Figure 1, Item 7) and
flat washers (Figure 1, Item 6).
6. Connect all cables to power distribution panel (Figure 1, Item 1).
7. Connect negative terminal to battery (see WP 0041). Start Genset (Figure 1, Item 1) in accordance with
Genset Start Procedure (WP 0005) of this TM.
Table 1. Genset Power Distribution Panel – Light Connections (Old Version).
SCHEMATIC CONNECTION
LIGHT LOCATION
ID
1 2 3
J1
120/208 VOLTS L6 117-CF3-6 106-CF3-3 149-CF3-9
60 AMP
J2
120 VOLTS L7 117-CF3-6 116-CF3-5 149-CF3-9
20 AMPERE
J3
120 VOLTS L8 117-CF3-6 126-CF3-7 149-CF3-9
20 AMPERE
J4
120/208 VOLTS L9 117-CF3-6 128-CF3-8 149-CF3-9
30 AMP
J5
120 VOLTS L10 117-CF3-6 99-CF3-1 149-CF3-9
INPUT
0074-3
TM 11-6115-742-13&P 0074
40 60
80 58 60 62 10 20 25 100 150 200 25
20 5 50 0
10 65 30 30
0 0 50 0 0 0
000 0 0
4
1 3
12
11
10
9
8 6
7
Figure 1. Power Distribution Panel Lights (old version) Removal/Replacement.
END OF TASK
0074-4
TM 11-6115-742-13&P 0074
POWER DISTRIBUTION PANEL LIGHTS REMOVAL/REPLACEMENT (New Version)
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
NOTE
The following procedure is applicable to all lights on the new version power
distribution panel.
REMOVAL
1. Verify that Genset has been shut down, engine is cool, and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. If necessary, raise door and latch in open position.
4. If necessary, disconnect all cables from power distribution panel (Figure 2, Item 1).
5. Remove and retain 12 bolts (Figure 2, Item 7) and flat washers (Figure 2, Item 6) that secure power
distribution panel (Figure 2, Item 1) to Genset.
6. Remove power distribution panel (Figure 2, Item 1) and lay face down.
7. Slide wire cover (Figure 2, Item 4) off of light (Figure 2, Item 12) being replaced.
8. Mark and disconnect two terminals (Figure 2, Item 5) from light (Figure 2, Item 8) being replaced.
9. Remove and retain nut (Figure 2, Item 3) and metal gasket (Figure 2, Item 2) that secures light (Figure 2,
Item 8) to power distribution panel (Figure 2, Item 1).
10. Remove light (Figure 2, Item 8), black out cover (Figure 2, Item 9), and rubber gasket (Figure 2, Item 10) from
power distribution panel (Figure 1, Item 1).
END OF TASK
0074-5
TM 11-6115-742-13&P 0074
REPLACEMENT
NOTE
Inspect all terminals and associated wires. If necessary replace or repair.
1. Insert indicator light (Figure 2, Item 8), Black out cover (Figure 2, Item 9) and Rubber gasket (Figure 2,
Item 10) through power distribution panel (Figure 2, Item 1).
2. Install metal gasket (Figure 2, Item 2) and nut (Figure 2, Item 3) and secure indicator light (Figure 2, Item 11)
to power distribution panel (Figure 2, Item 1).
NOTE
If necessary, refer to (Table 2) or:
• (Figure FO-15) for schematics (with EMI shielding) (New Version).
• (Figure FO-16) for schematics (without EMI shielding) (New Version).
3. Connect two terminals (Figure 2, Item 5) to indicator light (Figure 2, Item 8) and slide wire cover (Figure 2,
Item 4) over connections.
4. Install one side of hinge and secure using two screws and bolts (not shown).
5. Place power distribution panel (Figure 2, Item 1) onto Genset and secure using 12 bolts (Figure 2, Item 7) and
flat washers (Figure 2, Item 6).
6. Connect all cables to power distribution panel (Figure 2, Item 1).
7. Connect negative terminal to battery (See WP 0045). Start Genset (Figure 1, Item 1) in accordance with
Genset Start Procedure (WP 0006) of this TM.
Table 2. Genset Power Distribution Panel – Light Connections (New Version).
SCHEMATIC CONNECTION
LIGHT LOCATION
ID
1 2
J1
120/208 VOLTS L6 117-CF3-6 106-CF3-3
70 AMP
J2
120 VOLTS L7 117-CF3-6 116-CF3-5
20 AMPERE
J3
120 VOLTS L8 117-CF3-6 126-CF3-7
20 AMPERE
J4
120/208 VOLTS L9 117-CF3-6 128-CF3-8
30 AMP
J5
120 VOLTS L10 117-CF3-6 99-110-2
INPUT
0074-6
TM 11-6115-742-13&P 0074
NOTE
The door covering the circuit breakers in (Figure 2) has been removed for clarity.
4
1
3
2
10
9
8
6
7
Figure 2. Power Distribution Panel Lights (New Version) Removal/Replacement.
END OF TASK
0074-7
TM 11-6115-742-13&P 0074
CONNECTOR (J1 & J4) REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
NOTE
The following procedure is applicable to both the old and new version (J1 or J4
connectors). For clarity the door protecting the circuit breakers has been
removed.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. If necessary, raise door and latch in open position.
4. If necessary, disconnect all cables from power distribution panel (Figure 3, Item 1).
5. Remove and retain 12 bolts (Figure 3, Item 6) and lock washers (Figure 3, Item 5) that secure power
distribution panel (Figure 3, Item 1) to Genset.
6. Remove and retain two screws and bolts (not shown) from one side of hinge (Figure 5, Item 2) and lift hinge
(Figure 5, Item 2) out of the way.
7. Remove power distribution panel (Figure 3, Item 1) and lay face down.
8. Remove and retain four bolts (Figure 3, Item 9), flat washers (Figure 3, Item 8), nuts (Figure 3, Item 4), lock
washers (Figure 3, Item 3) and flat washers (Figure 3, Item 2) that secure connector (J1 or J4) (Figure 3,
Item 7), gasket (Figure 3, Item 11) and dust cover (Figure 3, Item 10) to power distribution panel (Figure 3,
Item 1).
9. Remove connector shell (J1 or J4) (Figure 3, Item 7) from power distribution panel (Figure 3, Item 1) (wires
will be attached).
10. Loosen ring (Figure 3, Item 17) from rear of connector shell (Figure 3, Item 12).
11. Slide ring (Figure 3, Item 17) and slide assembly out of connector shell (Figure 3, Item 12).
12. Slide rear insulator (black) (Figure 3, Item 15) and front insulator (red) (Figure 3, Item 13) back to gain access
to pins (Figure 3, Item 14) and wiring (Figure 3, Item 16).
NOTE
If replacing connector shell only proceed to step 11 of replacement procedure.
13. Remove pins (Figure 3, Item 14) from associated wires (Figure 3, Item 16).
0074-8
TM 11-6115-742-13&P 0074
REMOVAL- Continued
14. Mark and remove wires (Figure 3, Item 16) from rear insulator (black) (Figure 3, Item 15) and ring (Figure 3,
Item 17). Set all pieces aside.
END OF TASK
REPLACEMENT/REPAIR
1. Inspect all wires (Figure 3, Item 16) for nicks, cuts, burn marks or other damage. If necessary replace with
appropriate gauge and color of wire.
2. Inspect gasket (Figure 3, Item 11) for damage or excessive wear and tear, if necessary replace.
3. Feed all wires (Figure 3, Item 16) through power distribution panel (Figure 3, Item 1).
4. Insert wires (Figure 3, Item 16) through ring (Figure 3, Item 17) and appropriate holes in rear insulator (black)
(Figure 3, Item 15).
5. Install pins (Figure 3, Item 14) onto wires (Figure 3, Item 16) and secure.
6. Insert pins (Figure 3, Item 14) through front insulator (red) (Figure 3, Item 13).
7. Compress rear insulator (black) (Figure 3, Item 15) and front insulator (red) (Figure 3, Item 13) together and
insert into connector shell (Figure 3, Item 12). Slide ring (Figure 3, Item 17) forward and tighten.
8. Properly orientate connector assembly (Figure 3, Item 7) to power distribution panel (Figure 3, Item 1) and
insert.
NOTE
When performing the following step, do not tighten hardware until all hardware
has been installed.
9. Secure connector assembly (Figure 3, Item 7), gasket (Figure 3, Item 11) and dust cover (Figure 3, Item 10)
to power distribution panel (Figure 3, Item 1) using four bolts (Figure 2, Item 9), flat washers (Figure 3,
Item 8), nuts (Figure 3, Item 4), lock washers (Figure 3, Item 3) and flat washers (Figure 3, Item 2).
10. Place power distribution panel (Figure 3, Item 1) onto Genset and secure using 12 bolts (Figure 3, Item 6),
and washers (Figure 3, Item 5).
0074-9
TM 11-6115-742-13&P 0074
REPLACEMENT/REPAIR - Continued
11. Install one side of hinge (Figure 5, Item 2) and secure using two screws and bolts (not shown).
12. Connect all cables to power distribution panel (Figure 3, Item 1).
13. Connect negative terminal to battery (see WP 0041). Flatt Genset in accordance with Genset Flatt Procedure
(WP 0005) of this TM.
NOTE
If necessary, refer to (Table 3) or (FO-6 through FO-12) for electrical schematics
and wiring diagrams.
Refer to Figure 7 for pin layout of J1 and J4.
Table 3. J1 and J4 Connections.
CONNECTIONS
CONNECTOR
A B C N G
J1
120/208 VOLTS 228-CB1-2 229-CB1-4 230-CB1-6 221-PTB2-11 220-GB-16
60 AMP
J4
120 VOLTS 252-CB4-2 253-CB4-4 254-CB4-6 255-PTB2-9 251-GB-7
20 AMPERE
0074-10
TM 11-6115-742-13&P 0074
NOTE
For clarity the door protecting the circuit breakers has been removed.
40 60
80 58 60 62 10 20
25 100 150 200 25
20 5 50 0
10 65 30 30
0 0 50 0 0 0
0 00 0 0
J1 J4
120/208 VOLTS J2 J3 120/208 VOLTS
120 VOLTS 120 VOLTS 30 AMPERES
80 AMPERES
20 AMPERES 20 AMPERES
J5 J6
120 VOLTS
INPUT 24 VOLTS DC
4
3
2
4
3
2
11
7 1
REF 10
(REF)
10 (REF)
5
8
9 6
16 15 14 13 12
17 11 (REF)
Figure 3. Connector (J1 and J4) Removal/Replacement.
END OF TASK
0074-11
TM 11-6115-742-13&P 0074
CONNECTOR (J2 & J3) REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
NOTE
The following procedure is applicable to both the old and new version (J2 or J3
connectors).
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. If necessary, raise door and latch in open position.
4. If necessary, disconnect all cables from power distribution panel (Figure 4, Item 1).
5. Remove and retain 12 bolts (Figure 4, Item 6) and lock washers (Figure 4, Item 5) that secure power
distribution panel (Figure 4, Item 1) to Genset.
6. Remove and retain two screws and bolts (not shown) from one side of hinge (Figure 4, Item 2) and lift hinge
(Figure 4, Item 2) out of the way.
7. Remove power distribution panel (Figure 4, Item 1) and lay face down.
8. Remove and retain four bolts (Figure 4, Item 7), flat washers (Figure 3, Item 8), nuts (Figure 4, Item 4), lock
washers (Figure 4, Item 3) and flat washers (Figure 4, Item 2) that secure connector (J2 or J3) (Figure 4,
Item 9) and gasket (Figure 4, Item 10) to power distribution panel (Figure 4, Item 1).
0074-12
TM 11-6115-742-13&P 0074
REMOVAL - Continued
9. Remove connector shell (J2 or J3) (Figure 4, Item 9) from power distribution panel (Figure 4, Item 1) (wires
will be attached).
10. Remove screw (Figure 4, Item 14) from rear of connector (Figure 4, Item 9).
11. Slide backplate (Figure 4, Item 12) away from connector (Figure 4, Item 9) to gain access to pins (Figure 4,
Item 11) and wiring (Figure 4, Item 13).
12. Remove pins (Figure 4, Item 11) from associated wires (Figure 4, Item 13).
13. Mark and remove wires (Figure 4, Item 13) from backplate (Figure 4, Item 12). Set all pieces aside.
END OF TASK
REPLACEMENT/REPAIR
NOTE
If necessary, refer to (Table 4) and (FO-6 through FO-12) for electrical
schematics and wiring diagrams.
Refer to (Figure 7) for pin layout of J2 and J3.
1. Inspect all wires (Figure 4, Item 13) for nicks, cuts, burn marks or other damage. If necessary replace with
appropriate gauge and color of wire.
2. Inspect gasket (Figure 4, Item 10) for damage or excessive wear and tear, if necessary replace.
3. Feed all wires (Figure 4, Item 13) through power distribution panel (Figure 4, Item 1).
4. Insert wires (Figure 4, Item 13) through backplate (Figure 4, Item 12).
5. Install pins (Figure 4, Item 11) onto wires (Figure 4, Item 13).
6. Secure backplate (Figure 4, Item 12) using screw (Figure 4, Item 14).
7. Properly orientate connector assembly (Figure 4, Item 9) to power distribution panel (Figure 4, Item 1) and
insert.
NOTE
When performing the following step, do not tighten hardware until all hardware
has been installed.
8. Secure connector assembly (Figure 4, Item 9), gasket (Figure 4, Item 10) to power distribution panel
(Figure 4, Item 1) using four bolts (Figure 4, Item 7), flat washers (Figure 4, Item 8), nuts (Figure 4, Item 4),
lock washers (Figure 4, Item 3), and flat washers (Figure 4, Item 2).
9. Place power distribution panel (Figure 4, Item 1) onto Genset and secure using 12 bolts (Figure 4, Item 6),
and washers (Figure 4, Item 5).
10. Install one side of hinge (Figure 5, Item 2) and secure using two screws and bolts (not shown).
0074-13
TM 11-6115-742-13&P 0074
REPLACEMENT/REPAIR – Continued
11. Connect all cables to power distribution panel (Figure 4, Item 1).
12. Connect negative terminal to battery (see WP 0041). Flatt Genset in accordance with Genset Flatt Procedure
(WP 0005) of this TM.
Table 4. J2 and J3 Connections.
CONNECTIONS
CONNECTOR
N L G
J2
120 VOLTS 108-CF4-3 145-CF4-10 114-CF4-6
20 AMP
J3
120 VOLTS 109-CF4-4 146-CF4-11 115-CF4-7
20 AMP
0074-14
TM 11-6115-742-13&P 0074
NOTE
For clarity the door protecting the circuit breakers has been removed.
40 60
80 58 60 62 10 20 25 100 150
200
25
20 5 50 0
10 65 30 30
0 0 50 0 0 0
4 00 00 0
3
1 2
J1 J4
120/208 VOLTS J2 J3 120/208 VOLTS
120 VOLTS 120 VOLTS 30 AMPERES
80 AMPERES
20 AMPERES 20 AMPERES
J5 J6
120 VOLTS
INPUT 24 VOLTS DC
10
9 1 (REF)
7
5
6
14
13
12 11 9 (REF)
10 (REF)
Figure 4. Connector (J2 and J3) Removal/Replacement.
END OF TASK
0074-15
TM 11-6115-742-13&P 0074
CONNECTOR (J5) REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
NOTE
The following procedure is applicable to both the old and new version
(J5 connector).
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. If necessary, raise door and latch in open position.
4. If necessary, disconnect all cables from power distribution panel (Figure 5, Item 1).
5. Remove and retain twelve bolts (Figure 5, Item 8) and lock washers (Figure 5, Item 9) that secure power
distribution panel (Figure 5, Item 1) to Genset.
NOTE
It may be necessary to remove one latch (Figure 5, Item 2) to remove power
distribution panel (Figure 5, Item 1).
6. Remove and retain two screws and bolts (not shown) from one side of hinge (Figure 5, Item 2) and lift hinge
(Figure 5, Item 2) out of the way.
7. Remove power distribution panel (Figure 5, Item 1) and lay face down.
0074-16
TM 11-6115-742-13&P 0074
REMOVAL – Continued
8. Disconnect three terminals (Figure 5, Item 3) from wiring harness (Figure 5, Item 4) and remove strap tie
securing wires to power distribution panel (Figure 5, Item 1).
9. Remove and retain four screws (Figure 5, Item 5) that secure connector (Figure 5, Item 6) and dust cover
(Figure 5, Item 7) to power distribution panel (Figure 5, Item 1).
10. Remove connector (Figure 5, Item 6) (wires will be attached) from power distribution panel (Figure 5, Item 1).
END OF TASK
REPLACEMENT
NOTE
If necessary, refer to (Table 5) and (FO-6 through FO-12) for electrical
schematics and wiring diagrams.
Refer to (Figure 7) for pin layout of J5.
Inspect backside of power distribution panel (Figure 5, Item 1) for four clinch
nuts. Ensure that clinch-nuts are securely fastened to power distribution panel
(Figure 5, Item 1).
1. Inspect all wires (Figure 5, Items 3 and 4) for nicks, cuts, burn marks, or other damage. If necessary replace
with appropriate gauge and color of wire.
2. Feed wires (Figure 5, Item 3) through power distribution panel (Figure 5, Item 1).
3. Connect wires (Figure 5, Item 3) to terminals on chassis wiring harness (Figure 5, Item 4).
4. Properly orientate connector assembly (Figure 5, Item 6) to power distribution panel (Figure 5, Item 1) and
insert.
NOTE
When performing the following step, do not tighten hardware until all hardware
has been installed.
5. Secure connector assembly (Figure 5, Item 6) and dust cover (Figure 5, Item 7) to power distribution panel
(Figure 5, Item 1) using four screws (Figure 5, Item 5).
6. Secure loose wires (Figure 5, Item 3) and chassis wiring harness (Figure 5, Item 4) to power distribution panel
(Figure 5, Item 1) using strap ties.
7. Install one side of hinge (Figure 5, Item 2) and secure using two screws and bolts (not shown).
8. Place power distribution panel (Figure 5, Item 1) onto Genset and secure using 12 bolts (Figure 5, Item 8),
and washers (Figure 5, Item 9).
0074-17
TM 11-6115-742-13&P 0074
REPLACEMENT – Continued
NOTE
If latch (Figure 5, Item 2) was removed, reinstall.
9. Connect all cables to power distribution panel (Figure 5, Item 1).
10. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
Table 5. J5 Connections.
CONNECTIONS
CONNECTOR
A B C
J5
120 VOLTS 96-CF4-1 119-CF4-9 98-CF4-2
INPUT
0074-18
TM 11-6115-742-13&P 0074
40 60
80 58 60 62 10 20 25 100 150
200
25
20 5 50 0
10 65 30 30
0 0 50 0 0 0
0 0 00 0
1
J1 J4
120/208 VOLTS J2 J3 120/208 VOLTS
120 VOLTS 120 VOLTS 30 AMPERES
80 AMPERES
20 AMPERES 20 AMPERES
J5 J6
120 VOLTS
INPUT 24 VOLTS DC
7
6
1
(REF)
5 2
4 3 7
(REF)
Figure 5. Connector (J5) Removal/Replacement.
END OF TASK
0074-19
TM 11-6115-742-13&P 0074
CONNECTOR (J6) REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
NOTE
The following procedure is applicable to both the old and new version (J6
connectors).
REMOVAL
1. Verify that Genset has been shut down, engine is cool, and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. If necessary, raise door and latch in open position.
4. If necessary, disconnect all cables from power distribution panel (Figure 6, Item 1).
5. Remove and retain 12 bolts (Figure 6, Item 13) and lock washers (Figure 6, Item 12) that secure power
distribution panel (Figure 6, Item 1) to Genset.
6. Remove and retain two screws and bolts (not shown) from one side of hinge (Figure 5, Item 2) and lift hinge
(Figure 5, Item 2) out of the way.
7. Remove power distribution panel (Figure 6, Item 1) and lay face down.
8. Ensure that two terminals (Figure 6, Item 6) are properly identified. Remove and retain two bolts (Figure 6,
Item 8), lock washers (Figure 6, Item 7), and terminals (Figure 6, Item 6) from J6 (Figure 6, Item 2).
0074-20
TM 11-6115-742-13&P 0074
REMOVAL – Continued
9. Remove and retain four bolts (Figure 6, Item 13), flat washers (Figure 6, Item 14), nuts (Figure 6, Item 5), lock
washers (Figure 6, Item 4), and flat washers (Figure 6, Item 3) that secure J6 connector (Figure 6, Items 2
and 12) and dust cover (Figure 6, Item 15) to power distribution panel (Figure 6, Item 1).
10. Remove connector (Figure 6, Items 2 and 12) from power distribution panel (Figure 6, Item 1).
END OF TASK
REPLACEMENT
NOTE
If necessary, refer to (Table 6) or (FO-6 through FO-12) for electrical schematics
and wiring diagrams.
Refer to (Figure 7) for layout of J6.
1. Inspect wires and terminals (Figure 6, Item 6) for nicks, cuts, burn marks, or other damage. If necessary
replace.
2. Inspect connector (Figure 6, Items 2 and 12) for damage or excessive wear and tear, if necessary replace.
3. Install connector (Figure 6, Item 2 and 12) onto power distribution panel (Figure 6, Item 1).
NOTE
When performing the following step, do not tighten hardware until all hardware
has been installed.
4. Secure connector (Figure 6, Item 12) and dust cover (Figure 6, Item 15) to power distribution panel (Figure 6,
Item 1) using four bolts (Figure 6, Item 13), flat washers (Figure 6, Item 14), nuts (Figure 6, Item 5), lock
washers (Figure 6, Item 4) and flat washers (Figure 6, Item 3).
5. Connect terminals (Figure 6, Item 6) to connector (Figure 6, Item 2) using two bolts (Figure 6, Item 8) and lock
washers (Figure 6, Item 7).
6. Install one side of hinge (Figure 5, Item 2) and secure using two screws and bolts (not shown).
7. Place power distribution panel (Figure 6, Item 1) onto Genset and secure using 12 bolts (Figure 6, Item 10),
and washers (Figure 6, Item 9).
8 Connect all cables to power distribution panel (Figure 6, Item 1).
9. Connect negative terminal to battery (see WP 0041). Flatt Genset in accordance with Genset Flatt Procedure
(WP 0005) of this TM.
Table 6. J6 Connections.
CONNECTIONS
CONNECTOR
1 2
J6
226-BAT1 (+) 225-BAT1 (-)
24 VOLTS DC
0074-21
TM 11-6115-742-13&P 0074
NOTE
For clarity the door protecting the circuit breakers has been removed.
40 60
80 58 60 62 10 20 25 100 150 200 25
20 5 50 0
10 65 30 30
0 0 50 0 0 0
1
00 00 0
J1 J4
120/208 VOLTS J2 J3 120/208 VOLTS
120 VOLTS 120 VOLTS 30 AMPERES
80 AMPERES
20 AMPERES 20 AMPERES
J5
120 VOLTS
INPUT
J6
24 VOLTS DC
5
4
3
2
6
7
8
14 15
13
11
12
9
10
Figure 6. Connector (J6) Removal/Replacement.
0074-22
TM 11-6115-742-13&P 0074
N A
B C
G
J1 & J4
(-)
L
N G
(+)
J6 J2 & J3
C A
J5
Figure 7. Connector Pin Identification.
END OF TASK
END OF WORK PACKAGE
0074-23/24 blank
TM 11-6115-742-13&P 0075
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET BARRIER PANEL – CURRENT TRANSFORMER
CURRENT TRANSFORMER REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041, WP 0074,
Safety glasses/ FO-6 through FO-12
Materials/Parts Equipment Condition
Current transformer Genset Shut Down
Strap ties (WP 0168, Item 55 to 57) BATTERY SWITCH - OFF
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset barrier
panel. They consist of:
• Current Transformer removal/replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0075-1
TM 11-6115-742-13&P 0075
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-12) for electrical schematics and wiring diagrams.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Remove power distribution panel as described in (WP 0074), steps 3 through 6.
4. If necessary, remove plastic cover (Figure 1, Item 10) protecting terminal block (Figure 1, Item 1) associated
with current transformer (Figure 1, Item 4) being replaced.
5. Loosen but do not remove terminal screw (Figure 1, Item 2) on terminal block (Figure 1, Item 1) associated
with current transformer (Figure 1, Item 4) being replaced. Disconnect wire (Figure 1, Item 3) from terminal
block (Figure 1, Item 1) and feed through current transformer (Figure 1, Item 4) being replaced.
6. Remove and retain nut (Figure 1, Item 6) and lock washer (Figure 1, Item 7) securing electrical terminals
(Figure 1, Item 8) to current transformer (Figure 1, Item 4) being replaced.
7. Mark and disconnect electrical terminals (Figure 1, Item 8) from current transformer (Figure 1, Item 4) being
replaced.
8. Remove strap tie securing current transformer (Figure 1, Item 4) to barrier panel (Figure 1, Item 5) and
remove current transformer (Figure 1, Item 4).
END OF TASK
0075-2
TM 11-6115-742-13&P 0075
REPLACEMENT
NOTE
If necessary, refer to (FO-6 through FO-12) for electrical schematic.
1. Place current transformer (Figure 1, Item 4) onto barrier panel (Figure 1, Item 5) and secure using strap tie.
2. Feed wire (Figure 1, Item 3) through current transformer (Figure 1, Item 4) and connect to terminal block
(Figure 1, Item 1) and tighten terminal screw (Figure 1, Item 2). If applicable, secure plastic cover (Figure 1,
Item 10) protecting terminal block (Figure 1, Item 1).
3. Connect electrical terminals (Figure 1, Item 8) to current transformer (Figure 1, Item 4) and secure using nut
(Figure 1, Item 6) and lock washer (Figure 1, Item 7).
4. Replace power distribution panel as described in (WP 0074, step 5).
5. Connect all cables to power distribution panel (Figure 1, Item 1).
6. Connect negative terminal to battery (see WP 0041). Start Genset (Figure 1, Item 1) in accordance with
Genset Start Procedure (WP 0005) of this TM.
Table 1. Genset Barrier Panel – Current Transformer Connections.
TERMINAL
CURRENT CONNECTIONS FEED THROUGH
TRANSFORMER CONNECTION
X1- X2
CT1 57-TB2-1-2 91-TB2-4-2 111-CB5-1 (black)
CT2 58-TB2-2-3 92-TB2-5-2 112-CB5-3 (red)
CT3 59-TB2-3-2 93-TB2-6-2 113-CB5-5 (blue)
0075-3
TM 11-6115-742-13&P 0075
10
8 3
4
7
5
6
Figure 1. Current Transformer Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0075-4
TM 11-6115-742-13&P 0076
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET BARRIER PANEL – TRANSDUCER
TRANSDUCER REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041
Multimeter (WP 0165, Item 2) FO-6 through FO-12
Materials/Parts Equipment Condition
Transducer Genset Shut Down
Strap ties (WP 0168, Item 55 to 57) BATTERY SWITCH - OFF
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset barrier
panel. They consist of:
• Watt Transducer removal/replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0076-1
TM 11-6115-742-13&P 0076
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-12) for electrical schematics and wiring diagrams.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel, allow control panel to drop down and hang from lanyards.
4. Loosen but do not remove terminal screws (Figure 1, Item 5) on transducer (Figure 1, Item 1).
5. Mark and disconnect electrical terminals (Figure 1, Item 4) from transducer (Figure 1, Item 1).
6. Remove strap ties securing transducer (Figure 1, Item 1) to mounting strip (Figure 1, Item 2).
7. Release locking tab (Figure 1, Item 3) and remove transducer (Figure 1, Item 1) from mounting strip (Figure 1,
Item 2).
END OF TASK
REPLACEMENT
NOTE
If necessary, refer to (FO-6 through FO-12) for electrical schematic.
Due to excessive weight, transducer may separate from mount if strap ties are
not used.
1. Install transducer (Figure 1, Item 1) onto mounting strip (Figure 1, Item 2) and secure locking tab (Figure 1,
Item 3).
2. Connect electrical terminals (Figure 1, Item 4) to transducer (Figure 1, Item 1) and tighten terminal screws
(Figure 1, Item 5).
3. Secure transducer (Figure 1, Item 1) to mounting strip (Figure 1, Item 2) using strap ties.
4. Close and latch control panel.
5. Connect all cables to power distribution panel (Figure 1, Item 1).
6. Connect negative terminal to battery (see WP 0041). Start Genset (Figure 1, Item 1) in accordance with
Genset Start Procedure (WP 0005) of this TM.
0076-2
TM 11-6115-742-13&P 0076
NOTE
Terminals #10 and 12 are not present on transducer.
Table 1. Genset Barrier Panel – Transducer Connections.
TRANSDUCER TERMINAL TRANSDUCER TERMINAL
TERMINAL CONNECTIONS TERMINAL CONNECTIONS
1 239-TB2-1-1 9 69-CM2-16
2 94-F1-3
3 67-CM2-14 11 87-PTB2-10
4 240-TB2-2-1
5 no connection 13 no connection
6 68-CM2-15 14 no connection
7 241-TB2-3-1 15 82-CM2-23
8 95-F3-3 16 81-CM2-22
0076-3
TM 11-6115-742-13&P 0076
4 multitek !
WATT TRANSDUCER
3 Phase 4 Wire Unbalanced Load
Type M100-WA5
Ser-No 236-62-43387
Aux UH Self Powered
Class 0.2% at 60 Hz
Input 120V/208V L-N/L-L
CT 100/5A 4 17A
Output 0-1mA <15kOhm
Range 0-30kW
PS & S
multitek
149 Main Street, Stanhope, NJ 07874
TEL (973) 448-9400 FAX (973)-448-1574
3 BOTTOM VIEW
Figure 1. Transducer Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0076-4
TM 11-6115-742-13&P 0077
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET BARRIER PANEL – RELAYS
RELAY (K4, K5, K6, K7) REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041
Materials/Parts
Current transformer Equipment Condition
Strap ties (WP 0168, Item 55 to 57) Genset Shut Down
BATTERY SWITCH - OFF
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset barrier
panel. They consist of:
• Over temperature relay (K4) removal/replacement
• Engine over speed relay (K5) removal/replacement
• Oil pressure low relay (K6) removal/replacement
• Governor controller relay (K7) removal/replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0077-1
TM 11-6115-742-13&P 0077
WARNING
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-12) for electrical schematics and wiring diagrams.
Relays K4, K5 and K6 operate of off 24 VDC and are interchangeable. Relay K7
operates off of 115 VAC.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel, allow control panel to drop down and hang from lanyards.
4. Remove relay (Figure 1, Item 3) from socket (Figure 1, Item 2) on barrier panel (Figure 1, Item 1) and set
aside.
END OF TASK
REPLACEMENT
1. Properly orientate relay (Figure 1, Item 3) (DC LED at bottom) and insert into socket (Figure 1, Item 2).
2. Close control panel and latch.
3. Connect all cables to power distribution panel (Figure 1, Item 1).
4. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
0077-2
TM 11-6115-742-13&P 0077
Figure 1. Relay Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0077-3/4 blank
TM 11-6115-742-13&P 0078
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET BARRIER PANEL –TIME DELAY
TIME DELAY REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041
Materials/Parts
Current transformer Equipment Condition
Strap ties (WP 0168, Item 55 to 57) Genset Shut Down
BATTERY SWITCH - OFF
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset barrier
panel. They consist of:
• Time delay removal/replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0078-1
TM 11-6115-742-13&P 0078
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-12) for electrical schematics and wiring diagrams.
The time delay should be set for a four second delay.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel, allow control panel to drop down and hang from lanyards.
4. Mark and disconnect two terminals (Figure 1, Item 8) from time delay (Figure 1, Item 3).
5. Remove and retain two screws (Figure 1, Item 4), lock washers (Figure 1, Item 5) and flat washers (Figure 1,
Item 6) that secure time delay (Figure 1, Item 3) to barrier panel (Figure 1, Item 1).
END OF TASK
REPLACEMENT
1. Place time delay (Figure 1, Item 3) onto rail (Figure 1, Item 2) of barrier panel (Figure 1, Item 1).
2. Secure using two screws (Figure 1, Item 4), lock washers (Figure 1, Item 5) and flat washers (Figure 1,
Item 6).
3. Verify that DIP switches (Figure 1, Item 7) are set for a four second delay (see Figure 1).
4. Connect two terminals (Figure 1, Item 8) to time delay (Figure 1, Item 3).
5. Close and latch control panel.
0078-2
TM 11-6115-742-13&P 0078
REPLACEMENT – Continued
6. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
3 Dip Switch Settings
6
5
4 1 512
2 256
4 128
8 64
16 32
Figure 1. Time Delay Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0078-3/4 blank
TM 11-6115-742-13&P 0079
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET BARRIER PANEL – VOLTAGE REGULATOR
VOLTAGE REGULATOR REMOVAL/REPLACEMENT/ADJUSTMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041
FO-6 through FO-12
Materials/Parts
Voltage Regulator Equipment Condition
Genset Shut Down
Personnel Required BATTERY SWITCH - OFF
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset barrier
panel. They consist of:
• Voltage regulator removal/replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0079-1
TM 11-6115-742-13&P 0079
WARNING
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-12 )for electrical schematics and wiring diagrams.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel, allow control panel to drop down and hang from lanyards.
4. Remove and retain two screws (Figure 1, Item 3), lock washers (Figure 1, Item 4) and flat washers (Figure 1,
Item 5) securing voltage regulator (Figure 1, Item 2) to stand-offs (Figure 1, Item 7).
5. Remove voltage regulator (Figure 1, Item 2) from stand-offs (Figure 1, Item 7).
NOTE
If voltage regulator has no output, inspect fuse on backside of voltage regulator.
If fuse is bad, replace and check for operational status before replacing.
6. Mark and disconnect terminals (Figure 1, Item 6) from voltage regulator (Figure 1, Item 2) and set voltage
regulator (Figure 1, Item 2) aside.
END OF TASK
0079-2
TM 11-6115-742-13&P 0079
REPLACEMENT
NOTE
If necessary, refer to (FO-6 through FO-12) or (Table 1) for electrical schematics
and wiring diagrams.
1. Connect terminals (Figure 1, Item 6) to voltage regulator (Figure 1, Item 2) (see Table 1).
2. Place voltage regulator (Figure 1, Item 2) onto stand-offs (Figure 1, Item 7) and secure using two screws
(Figure 1, Item 3), lock washers (Figure 1, Item 4) and flat washers (Figure 1, Item 5).
3. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
4. If necessary adjust voltage regulator as described below.
5; Close and latch control panel.
6. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
Table 1. Voltage Regulator Connections.
Voltage Regulator
CONNECTION
Connections
60
no connection
Hz
50
no connection
Hz
4 74-F7-3
6 86-CM2-25
7 85-CM2-24
F- 238-TB1-49-1
F+ 237-TB1-48-1
3 70-F1-2
0079-3
TM 11-6115-742-13&P 0079
5
4
3
2
Figure 1. Voltage Regulator Removal/Replacement.
END OF TASK
0079-4
TM 11-6115-742-13&P 0079
ADJUSTMENT
Voltage Output
1. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
2. Set VOLT/AMP switch to any leg.
3. Check voltage on A-C VOLTS meter.
4. Adjust voltage output using VOLTAGE ADJUST potentiometer on control panel. If voltage can not be
adjusted far enough, perform the following adjustment procedure:
a) On control panel:
1. Center VOLTAGE ADJUST potentiometer on control panel.
2. Adjust VOLTAGE ADJUST potentiometer on control panel fully clockwise and note
position on A-C VOLTS meter.
3. Adjust VOLTAGE ADJUST potentiometer on control panel fully counter-clockwise
and count note position on A-C VOLTS meter.
4. Adjust VOLTAGE ADJUST potentiometer on control panel clockwise until centered
between two noted positions on A-C VOLTS meter.
5. Check and calibrate A-C VOLTS meter.
b) On barrier panel:
1. Identify voltage regulator on center line of barrier panel on the left.
2. Identify VOLT adjust set screw on left of voltage-regulator (see Figure 2).
3. Adjust VOLT set screw while monitoring voltage on multi-meter.
4. Adjust voltage to exactly 208 volts.
5. Check voltage on A-C VOLTS meter.
END OF TASK
Voltage Stability
NOTE
System stability is the ability of the generator to respond to load transients.
Decreasing the stability makes the generator less sluggish and faster to respond
to load transients. If the stability of the regulator is decreased too much, the
generator will tend to hunt under steady state condition.
To increase stability, adjust STAB potentiometer (see Figure 2) clockwise. This will increase the response time of
the generator.
To decrease stability, adjust STAB potentiometer counter-clockwise. This will decrease the response time of the
generator.
END OF TASK
0079-5
TM 11-6115-742-13&P 0079
V/HZ ROLL-OFF FREQUENCY SELECTION
NOTE
The roll off point is the frequency where the generator voltage starts to decrease.
This reduces the Kilowatt load to the engine, which allows the engine to recover
in speed under any load transient condition. In 60Hz mode the roll-off frequency
has a range of 54-61 Hz.
This voltage regulator has the roll-off point preset to 58Hz in the 60Hz mode.
1. Adjust engine speed to the desired rated speed.
2. Set the voltage to the desired setting at rated speed.
3. Adjust engine speed to the desired roll-off point.
4. Adjust the U/F potentiometer (see Figure 2) counter-clockwise until the voltage starts to drop off.
5. Adjust the U/F potentiometer (see Figure 2) clockwise until the voltage returns to rated voltage.
6. Re-adjust engine speed to rated speed.
60 50 4 6 7 F- F+
Hz Hz
TERMINAL IDENTIFIERS
(VIEW ROTATED 180° FOR CLARIETY)
POTENTIOMETERS
VOLT - Voltage
STAB - Stability
U/F - Under Frequency
Figure 2. Voltage Regulator Connections and Potentiometer Identification.
END OF TASK
END OF WORK PACKAGE
0079-6
TM 11-6115-742-13&P 0080
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET BARRIER PANEL – SPEED SENSOR
SPEED SENSOR REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041
FO-6 through FO-12
Materials/Parts
Speed Sensor Equipment Condition
Genset Shut Down
Personnel Required BATTERY SWITCH - OFF
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset barrier
panel. They consist of:
• Speed sensor removal/replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0080-1
TM 11-6115-742-13&P 0080
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-12) for electrical schematics and wiring diagrams.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel, allow control panel to drop down and hang from lanyards.
NOTE
It is not necessary to disconnect jumper wire running from terminal #12 to
terminal # 1 of speed sensor.
4. Mark and disconnect terminals (Figure 1, Item 3) from speed sensor (Figure 1, Item 2).
5. Remove one screw (Figure 1, Item 4) and flat washer (Figure 1, Item 5) securing speed sensor (Figure 1,
Item 2) to barrier panel (Figure 1, Item 1).
6. Remove two ground terminals (Figure 1, Item 6), second screw (Figure 1, Item 4) and flat washer (Figure 1,
Item 5) securing speed sensor (Figure 1, Item 2) to barrier panel (Figure 1, Item 1).
7. Remove speed sensor (Figure 1, Item 2) from barrier panel (Figure 1, Item 1).
END OF TASK
0080-2
TM 11-6115-742-13&P 0080
REPLACEMENT
NOTE
If necessary, refer to (FO-6 through FO-12) or (Table 1) for electrical schematics
and wiring diagrams.
1. Place speed sensor (Figure 1, Item 2) onto barrier panel (Figure 1, Item 1) and secure using one screw
(Figure 1, Item 4) and flat washer (Figure 1, Item 5).
2. Secure two ground terminals (Figure 1, Item 6) to speed sensor (Figure 1, Item 2) and secure using second
screw (Figure 1, Item 4) and flat washer (Figure 1, Item 5).
2. Connect remaining terminals (Figure 1, Item 3) to speed sensor (Figure 1, Item 2).
3; Close and latch control panel.
4. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
Table 1. Speed Sensor Connections.
SPEED SENSOR
CONNECTION
TERMINALS
1 213-SS-12
214-SS-G
2
242-TB1-2-1
3 18-TB1-18b-1
4 19-TB1-19-1
5 no connection
6 no connection
7 no connection
8 no connection
9 no connection
10 no connection
11 32-K5-6
28-K6-8
12
213-SS-1
13 no connection
SH-TB1-20-1
ground
214-SS-2
0080-3
TM 11-6115-742-13&P 0080
13
11
12
7
8
9
6
2
5
4
3
1
2
3
4
5
6
GROUND
TERMINAL IDENTIFICATION
Figure 1. Speed Sensor Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0080-4
TM 11-6115-742-13&P 0081
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET BARRIER PANEL – PRECISION GOVERNOR
PRECISION GOVERNOR REMOVAL/REPLACEMENT/ADJUSTMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041,
WP 0068, FO-6 through FO-12
Materials/Parts
Precision governor Equipment Condition
Genset Shut Down
Personnel Required BATTERY SWITCH - OFF
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset barrier
panel. They consist of:
• Precision Governor removal/replacement/adjustments
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0081-1
TM 11-6115-742-13&P 0081
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-12) for electrical schematics and wiring diagrams.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and control panel, allow control panel to drop down and hang from lanyards.
4. Remove and retain four screws (Figure 1, Item 6), lock washers (Figure 1, Item 5), and flat washers (Figure 1,
Item 4) securing precision governor (Figure 1, Item 3) to stand-offs (Figure 1, Item 2) on barrier panel
(Figure 1, Item 1).
5. Mark and disconnect terminals (Figure 1, Item 7) from precision governor (Figure 1, Item 3).
6. Remove precision governor (Figure 1, Item 3) from barrier panel (Figure 1, Item 1).
END OF TASK
REPLACEMENT
NOTE
If necessary, refer to (FO-6 through FO-12) or (Table 1) for electrical schematics
and wiring diagrams. See (Figure 1) for terminal identification.
1. Connect terminals (Figure 1, Item 7) to precision governor (Figure 1, Item 3).
2. Install precision governor (Figure 1, Item 3) and secure to stand-offs (Figure 1, Item 2) on barrier panel
(Figure 1, Item 1) using four screws (Figure 1, Item 6), lock washers (Figure 1, Item 5), and flat washers
(Figure 1, Item 4).
3. Close and latch control panel.
4. Connect negative terminal to battery (see WP 0041). Start Genset in accordance with Genset Start
Procedure (WP 0005) of this TM.
0081-2
TM 11-6115-742-13&P 0081
Table 1. Precision Governor Connections.
PRECISION GOVERNOR
CONNECTION
TERMINALS
1
+ 236-TB1-21-1
PWR
2
22-TB1-22-1
GND
3
SIG 233-TB1-18-1
+
4
SIG 234-TB1-19b-1
–
5
16-TB1-16-1
ACT
6
17-TB1-17-1
ACT
7
AUX no connection
1
8
AUX no connection
2
0081-3
TM 11-6115-742-13&P 0081
10
7 2
4
5
6
8 7 6 5 4 3 2 1
AUX AUX ACT ACT SIG SIG GND +
2 1 - + PWR
TERMINAL IDENTIFICATION
Figure 1. Precision Governor Removal/Replacement.
END OF TASK
0081-4
TM 11-6115-742-13&P 0081
ADJUSTMENTS
The following adjustments can cause the main speeds to change; once any changes are made to the derivative,
integral and/or gain verify that the main speed is set at its desired setting.
Speed (Frequency) Adjustment (P4) – Controls frequency of the Genset output.
Derivative Adjustment (P6) – Controls how the governor reacts immediately after a load change. Increasing the
derivative gain will significantly reduce the engine speed “spike” after a load change
Integral Adjustment (P3) – Controls how quickly the engine completely recovers from large load changes, that is
the time period after 1 second from a load change.
Gain Adjustment (P2) – Adjusts the overall response of the governor. When adjusting Gain on a warm engine, it
is recommended to adjust the gain so the engine is stable then reduce it slightly. This allows the governor to
properly control an engine when it is cold and responds slower.
NOTE
The P1 and P5 pots are not used in this configuration and are not present on the
board, the location is shown for reference only.
INTEGRAL
OVERSPEED (FACTORY)
SPEED SET DERIVATIVE
ADJUST
SET (P5) (P6)
(P3)
(P4) (NOT USED)
AUXILLARY GAIN
SPEED (P2)
SET (P1)
(NOT USED)
Figure 2. Potentiometer Location and Identification.
0081-5
TM 11-6115-742-13&P 0081
SPEED (FREQUENCY) (P4) ADJUST
NOTE
By adjusting the speed potentiometer clockwise (CW) speed increases.
By adjusting the speed potentiometer counter clockwise (CCW) speed
decreases.
The adjustment range of the pot is 25 full turns.
One full turn will change speed about 100 - 200 rpm.
This potentiometer is protected by a slip clutch at each end and will not be
harmed by moderate over-adjustment. However, the governor will not function
while the pot is past full travel.
If you suspect you may have over-adjusted the Speed Set pot or have lost track
of where you are, turn the pot 25-30 turns CCW, then back 10-12 turns CW to
get back into the range of normal adjustment.
1. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
2. Check frequency reading on HERTZ meter.
3. Open control panel and allow control panel to drop down and hang from lanyards.
4. Check and calibrate the HERTZ meter (see WP 0068).
5. Remove and retain two screws (Figure 1, Item 8) on right side of access cover (Figure 1, Item 10).
6. Loosen but do not remove two screws (Figure 1, Item 9) on left side of access cover (Figure 1, Item 10).
7. Remove access cover (Figure 1, Item 10) and locate speed set potentiometer (P4) (upper left corner of circuit
card (see Figure 2).
8. Adjust the frequency to 60 hertz by adjusting speed set potentiometer (P4) screw while monitoring the
frequency on the HERTZ meter.
9. Replace access cover (Figure 1, Item 10), install two screws (Figure 1, Item 8).
10. Tighten four screws (Figure 1, Items 8 and 9).
11. Close and latch control panel.
12. Check HERTZ meter and verify proper operational frequency.
END OF TASK
0081-6
TM 11-6115-742-13&P 0081
DERIVATIVE (P6) ADJUST
CAUTION
The derivative potentiometer (P6) is a single –turn potentiometer. Be gentle, this
pot turns 270°, and over-turning will break the internal stops, making adjustment
impossible.
1. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
3. Open control panel and allow control panel to drop down and hang from lanyards.
5. Remove and retain two screws (Figure 1, Item 8) on right side of access cover (Figure 1, Item 10).
6. Loosen but do not remove two screws (Figure 1, Item 9) on left side of access cover (Figure 1, Item 10).
7. Remove access cover (Figure 1, Item 10) and locate derivative potentiometer (P6) (upper middle of circuit
card. See Figure 2).
NOTE
Turning the derivative potentiometer (P6) CW increases governor sensitivity.
Too much derivative will cause a very quick engine surge, possibly up to several
strokes a second.
Turning derivative potentiometer (P6) CCW decreases governor sensitivity. Too
low of a derivative setting will show up as sluggish response.
8. Adjust derivative potentiometer (P6) screw to desired setting.
9. Replace access cover (Figure 1, Item 10), install two screws (Figure 1, Item 8).
10. Tighten four screws (Figure 1, Items 8 and 9).
11. Close and latch control panel.
END OF TASK
0081-7
TM 11-6115-742-13&P 0081
INTEGRAL (P3) ADJUST
The integral adjust potentiometer (P3) is set at the factory and should not be adjusted unless absolutely
necessary.
CAUTION
The integral adjust potentiometer (P3) is a single –turn potentiometer. Be gentle,
this pot turns 270°, and over-turning will break the internal stops, making
adjustment impossible.
NOTE
Increasing the integral gain shortens the time to achieve the desired engine
speed.
Too low of an integral adjustment causes the engine to slowly achieve the
desired speed.
Excessive integral gain will cause the engine to “over respond” for a second or
two before settling at the desired speed. It can also result in a slow wander of
the engine speed.
1. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
3. Open control panel and allow control panel to drop down and hang from lanyards.
5. Remove and retain two screws (Figure 1, Item 8) on right side of access cover (Figure 1, Item 10).
6. Loosen but do not remove two screws (Figure 1, Item 9) on left side of access cover (Figure 1, Item 10).
7. Remove access cover (Figure 1, Item 10) and locate integral adjust potentiometer (P3) upper left corner of
circuit card (See Figure 2).
NOTE
Turning the integral adjusts potentiometer (P3) CW increases gain.
Turning integral adjust potentiometer (P3) CCW decreases gain.
8. Adjust integral adjust potentiometer (P3) to desired setting.
9. Replace access cover (Figure 1, Item 10); install two screws (Figure 1, Item 8).
10. Tighten four screws (Figure 1, Items 8and 9).
11. Close and latch control panel.
END OF TASK
0081-8
TM 11-6115-742-13&P 0081
GAIN (P2) ADJUST
CAUTION
The gain adjust potentiometer (P2) is a single –turn potentiometer. Be gentle,
this pot turns 270°, and over-turning will break the internal stops, making
adjustment impossible.
NOTE
Increasing the gain adjustment will cause the governor to respond quicker.
Setting the gain too high typically causes an engine speed surge that occurs on
every ½ to 1 second.
Decreasing this adjustment will cause the governor to respond slower.
Setting the gain too low causes sluggish engine performance.
1. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
3. Open control panel and allow control panel to drop down and hang from lanyards.
5. Remove and retain two screws (Figure 1, Item 8) on right side of access cover (Figure 1, Item 10).
6. Loosen but do not remove two screws (Figure 1, Item 9) on left side of access cover (Figure 1, Item 10).
7. Remove access cover (Figure 1, Item 10) and locate the gain potentiometer (P2) (lower left of circuit card
(see Figure 2).
NOTE
Turning the gain potentiometer (P2) CW gain increases.
Turning the gain potentiometer (P2) CCW gain decreases.
8. Adjust the gain potentiometer (P2) to desired setting.
9. Replace access cover (Figure 1, Item 10), install two screws (Figure 1, Item 8).
10. Tighten four screws (Figure 1, Items 8and 9).
11. Close and latch control panel.
END OF TASK
END OF WORK PACKAGE
0081-9/10 blank
TM 11-6115-742-13&P 0082
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET BARRIER PANEL – CIRCUIT BREAKER
CIRCUIT BREAKER REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041,
WP 0074, FO-6 through FO-12
Materials/Parts
Circuit Breaker Equipment Condition
Genset Shut Down
Personnel Required BATTERY SWITCH - OFF
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset barrier
panel. Consisting of:
• Circuit Breaker (CB1) 50 AMP: ECU POWER SUPPLY removal/replacement
• Circuit Breaker (CB2) 20 AMP ON BOARD POWER LEAD removal/replacement
• Circuit Breaker (CB3) 20 AMP: ON BOARD POWER LEAD removal/replacement
• Circuit Breaker (CB4) 30 AMP: PDU POWER SUPPLY removal/replacement
• Circuit Breaker (CB5) 80 AMP: MAIN POWER BREAKER removal/replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0082-1
TM 11-6115-742-13&P 0082
WARNING
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-12) for electrical schematics and wiring diagrams.
The following procedures apply to all circuit breakers.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and remove bottom half of control panel (see WP 0074).
4. Mark electrical connections (Figure 1, Item 5) on circuit breaker (Figure 1, Item 3) being replaced.
5. Loosen terminal screws (Figure 1, Item 6) securing electrical connections (Figure 1, Item 5).
6. Remove electrical connections (Figure 1, Item 5) from circuit breaker (Figure 1, Item 3).
NOTE
For CB1 through CB4, tab (Figure 1, Item 2) is located at top. For CB5, two tabs
(not shown) are located at bottom of circuit breaker.
7. Lift up on tab (Figure 1, Item 2) of circuit breaker (Figure 1, Item 3) being replaced.
8. Remove circuit breaker (Figure 1, Item 3) from mounting bracket (Figure 1, Item 4) on barrier panel (Figure 1,
Item 1).
END OF TASK
REPLACEMENT
NOTE
For CB1 through CB4, tab (Figure 1, Item 2) is located at top. For CB5, two tabs
(not shown) are located at bottom of circuit breaker.
0082-2
TM 11-6115-742-13&P 0082
REPLACEMENT- Continued
1. Install circuit breaker (Figure 1, Item 3) onto mounting bracket (Figure 1, Item 4) of barrier panel (Figure 1,
Item 1) and secure with tab (Figure 1, Item 2).
NOTE
If necessary, refer to (Table 1) or (FO-6 through FO-12) for electrical schematic.
2. Loosen terminal screws (Figure 1, Item 6) of circuit breaker (Figure 1, Item 3) and install electrical
connections (Figure 1, Item 5). Torque terminal screws (Figure 1, Item 6) of circuit breaker (Figure 1,
Item 3) to 45 in-lbs.
3. Install bottom half of control panel (see WP 0074).
4. Connect negative terminal to battery (see WP 0041).
5. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
Table 1. Battery Charger Connections.
CIRCUIT
TERMINAL HARNESS CONNECTION TERMINAL HARNESS CONNECTION
BREAKER
1 131-PTB1-2 106-CM3-3
2
3 132-PTB1-8 228-J1-A-#6 THNN BK
CB1
4 229-J1-B-#6 THNN RD
5 133-PTB2-2
6 230-J1-C-#6 THNN BL
116-CM3-5
CB2 1 141-PTB1-1 2
145-CM4-10
126-CM3-7
CB3 1 142-PTB1-7 2
146-CM4-11
128-CM3-8
1 151-PTB1-4 2
252-J4-A-#6 THNN BK
CB4
3 152-PTB1-10 4 253-J4-B-#6 THNN RD
5 153-PTB2-4 6 254-J4-C-#6 THNN BL
51-F1-1
1 111-PTB1-L1 2
248-GEN-BLK
52-F2-1
CB5 3 112-PTB1-L2 4
249-GEN-RED
53-F3-1
5 113-PTB2-L3 6
250-GEN-BLUE
0082-3
TM 11-6115-742-13&P 0082
3
4
Figure 1. Circuit Breaker Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0082-4
TM 11-6115-742-13&P 0083
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET BARRIER PANEL – BATTERY CHARGER
BATTERY CHARGER TEST/REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0041, WP 0074,
Multimeter (WP 0165, Item 2) FO-6 through FO-12
Materials/Parts
Battery Charger Equipment Condition
Genset Shut Down
Personnel Required BATTERY SWITCH - OFF
One
GENERAL
This work package provides information on the removal and replacement of components on the Genset barrier
panel. Consisting of:
• Battery charger removal/replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
0083-1
TM 11-6115-742-13&P 0083
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figures FO-6 through
FO-12) for electrical schematics and wiring diagrams.
TEST
1. Using multimeter, measure input voltage across (L) and (N) connectors for 110 VAC.
(95 VAC to 135 VAC is acceptable.)
2. Using multimeter, measure output voltage across (+) and (-) (or N/O and N/C) for 27.2 VDC @ 3 amps output.
END OF TASK
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Open door and remove power distribution panel (see WP 0074).
NOTE
Be observant of where out put connections are on battery charger. On older
battery chargers output is connected to N/O and N/C connections. On newer
battery chargers output is connected to OUTPUT + and OUTPUT – connections.
4. Mark and disconnect terminals (Figure 1, Item 3) from battery charger (Figure 1, Item 2).
5. Remove and retain four screws (Figure 1, Item 4), lock washers (Figure 1, Item 5), and flat washers (Figure 1,
Item 6) securing battery charger (Figure 1, Item 2) to barrier panel (Figure 1, Item 1).
6. Remove battery charger (Figure 1, Item 2).
END OF TASK
0083-2
TM 11-6115-742-13&P 0083
REPLACEMENT
1. Install battery charger (Figure 1, Item 2) and secure to barrier panel (Figure 1, Item 1) using four screws
(Figure 1, Item 4), lock washers (Figure 1, Item 5), and flat washers (Figure 1, Item 6).
NOTE
If necessary, refer to (Table 1) or (FO-6 through FO-12) for electrical schematic.
Be observant of output connections on battery charger. On older battery
chargers output is connected to N/O and N/C connections. On newer battery
chargers output is connected to OUTPUT + and OUTPUT – connections.
2. Connect terminals (Figure 1, Item 3) to battery charger (Figure 1, Item 2).
3. Install power distribution panel (see WP 0074).
4. Connect negative terminal to battery (see WP 0041).
5. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
NOTE
On older battery chargers output is connected to N/O and N/C connections. On
newer battery chargers output is connected to OUTPUT + and OUTPUT –
connections.
Table 1. Battery Charger Connections.
BATTERY CHARGER
CONNECTION
TERMINALS
Old Style New Style
COM no connection no connection
N/O 39-CM2-12 no connection
N/C 37-TB1-22b-2 no connection
(+) POS no connection 39-CM2-12
(-) NEG no connection 37-TB1-22b-2
(╧) GND 333-GB-3 333-GB-3
L 97-F8-3 97-F8-3
N 328-PTB2-10 328-PTB2-10
0083-3
TM 11-6115-742-13&P 0083
10 k
S N-u33 M275 Wu
Z2 8
M 10166 8707 C
UFR O 6 0 C 5 0
SA465-2 AVP
1 21K
7
1 0nJ1 000
E 000-2465
F1
2 3
STAB ILITY
0
F2
5
9
6
1 0nJ1 000 8 7
300-34 851
VOLTS
1
12 3 L L DR OOP S1 S2 A 1 A 2 T RIM
6
5
4
2
3
COM
N/O
N/C
+
OUTPUT
-
AC INPUT
L N
CONNECTIONS
Figure 1. Battery Charger Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0083-4
TM 11-6115-742-13&P 0084
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET FUEL PANEL
FUEL PANEL SWITCH AND PORTS REMOVE AND REPLACE
INITIAL SETUP:
Tools and Special Tools Reference
General mechanic’s tool kit (WP 0165, Item 1) WP 0005, WP 0041
Materials/Parts Equipment Condition
Fuel selector switch Trailer parked in operational position
Cloth, cleaning (WP 0168, Item 14) Trailer handbrakes engaged
Teflon tape (WP 0168, Item 58) Wheels chocked
Fuel Ports
Personnel Required ECU shut down
One Genset shut down
GENERAL
This work package provides information on the removal and replacement of components on the Genset fuel
panel. They consist of:
• Fuel selector switch removal and replacement
• Auxiliary fuel line connectors removal and replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
If Genset has been in operation, components may be extremely hot. To prevent
serious injury to personnel, allow the Genset to cool down before performing
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
If Genset has been in operation, components may be extremely hot. To prevent
serious injury to personnel, allow the Genset to cool down before performing
procedures.
CAUTION
Never attempt to connect or disconnect cables or hoses with Genset in an
operational status. Always ensure Genset is shut down before attempting to
perform any of the following procedures.
0084-1
TM 11-6115-742-13&P 0084
FUEL SELECTOR SWITCH REMOVAL/REPLACEMENT
REMOVAL
NOTE
Prior to performing the following procedure, ensure fuel tank is below 3/4 tank.
To ease installation, tag input and output hoses for proper connections prior to
performing the following step (see Figure 1 for connections).
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Remove and retain sixteen bolts (Figure 2, Item 5), lock washers (Figure 2, Item 4), and flat washers
(Figure 2, Item 3) that secure radiator access panel (Figure 2, Item 2) to Genset (Figure 2, Item 1). Remove
radiator access panel (Figure 2, Item 2).
4. Remove and retain locking screw (Figure 2, Item 6) from selector switch handle (Figure 2, Item 7).
5. Remove and retain selector switch handle (Figure 2, Item 7) from selector switch (Figure 2, Item 14).
6. Remove and retain two bolts (Figure 2, Item 8), lock washers (Figure 2, Item 9), and flat washers (Figure 2,
Item 10) that secure selector switch (Figure 2, Item 14) to bracket (Figure 2, Item 11).
7. Loosen clamps (Figure 2, Item 12) that secure input and output hoses (Figure 2, Item 13) to selector switch
(Figure 2, Item 14).
8. Remove input and output hoses (Figure 2, Item 13) from ports on selector switch (Figure 2, Item 14).
Remove selector switch (Figure 2, Item 14).
END OF TASK
0084-2
TM 11-6115-742-13&P 0084
REPLACEMENT
1. Inspect input and output hoses (Figure 2, Item 13) and replace as necessary.
2. Install input and output hoses (Figure 2, Item 13) onto proper ports of selector switch (Figure 2, Item 14).
Tighten clamps.
3. Place selector switch (Figure 2, Item 14) onto bracket (Figure 2, Item 11) and secure using two bolts
(Figure 2, Item 8), lock washers (Figure 2, Item 9), and flat washers (Figure 2, Item 10).
NOTE
If necessary, refer to (Figure 1) for proper connections of input and output hoses.
4. Install selector switch handle (Figure 2, Item 7) and secure using locking screw (Figure 2, Item 6).
5. Install radiator access panel (Figure 2, Item 2) onto Genset (Figure 2, Item 1) and secure using sixteen bolts
(Figure 2, Item 5), lock washers (Figure 2, Item 4), and flat washers (Figure 2, Item 3).
6. Connect negative terminal to battery (see WP 0041).
7. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
TO FUEL HEATER
TO AUXILLARY FROM
FUEL SUPPLY FUEL TANK
TO AUXILLARY
FUEL RETURN TO FUEL TANK
FROM FUEL
HEATER LINE
Figure 1. Fuel Selector Switch Connections.
0084-3
TM 11-6115-742-13&P 0084
1 2
3
4
5
14
12
13 11 10
12 9
8
13
Figure 2. Fuel Selector Switch Removal/Replacement.
END OF TASK
0084-4
TM 11-6115-742-13&P 0084
AUXILIARY FUEL PORTS REMOVAL/REPLACEMENT
REMOVAL
NOTE
Prior to performing the following procedure, ensure fuel tank is below 3/4 tank.
To ease installation, tag input and output hoses for proper connection.
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Disconnect negative terminal from battery (see WP 0041).
3. Verify that external hoses have been disconnected from auxiliary fuel port(s) (Figure 3, Item 7).
4. Remove and retain sixteen bolts (Figure 3, Item 5) lock washers (Figure 3, Item 4), and flat washers
(Figure 3, Item 3) that secure radiator access panel (Figure 3, Item 2) to Genset (Figure 3, Item 1). Remove
radiator access panel (Figure 3, Item 2).
5. Place wrench on 90° elbow (Figure 3, Item 6) to prevent from turning and remove auxiliary fuel port (Figure 3,
Item 7) from Z-panel (Figure 3, Item 8).
6. Loosen clamp (Figure 3, Item 10) that secures input/output hose (Figure 3, Item11) to adapter (Figure 3,
Item 9).
7. Remove input/output hose (Figure 3, Item11) from adapter (Figure 3, Item 9) and set aside (if necessary
place in small container to collect residual fuel).
8. Remove adapter (Figure 3, Item 9).and 90° elbow (Figure 3, Item 6) from auxiliary fuel port (Figure 3, Item 7).
END OF TASK
0084-5
TM 11-6115-742-13&P 0084
REPLACEMENT
NOTE
Wrap all threaded joints with teflon tape.
1. Install auxiliary fuel port (Figure 3, Item 7) onto 90° elbow (Figure 3, Item 6) on Z-panel (Figure 3, Item 8) and
tighten.
2. Install adapter (Figure 3, Item 9) onto 90° elbow (Figure 3, Item 6).
3. Inspect input/output hoses (Figure 3, Item 11) and replace as necessary.
4. Insert input/output hoses (Figure 3, Item 11) onto adapter (Figure 3, Item 9) and tighten clamp (Figure 3,
Item 10).
5. Install radiator access panel (Figure 3, Item 2) onto Genset (Figure 3, Item 1) and secure using sixteen bolts
(Figure 3, Item 5), lock washers (Figure 3, Item 4), and flat washers (Figure 3, Item 3).
6. Connect negative terminal to battery (see WP 0041).
7. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
0084-6
TM 11-6115-742-13&P 0084
1 2
3
4
5
10
11
Figure 3. Auxiliary Fuel Port Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0084-7/8 blank
TM 11-6115-742-13&P 0085
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET FUEL SYSTEM
FUEL GAUGE REMOVAL/INSPECT/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
General mechanic’s tool kit (WP 0165, Item 1) WP 0005, WP 0041, WP 0045
Standard automotive tool set (WP 0165, Item 5)
Safety glasses Equipment Condition
Trailer parked in operational position
Materials/Parts Trailer handbrakes engaged
Fuel gauge Wheels chocked
Cloth, cleaning (WP 0168, Item 14) Genset Shut Down
Sealing compound (WP 0168, Item 50) BATTERY SWITCH - OFF
Drain Pan
Pry Bar
Fuel Line Heater
Fuel Tank
Personnel Required
Two
GENERAL
This work package provides information on the removal and replacement of the following Genset fuel system
components:
• Fuel gauge removal, inspect, and replacement
• Fuel tank removal and replacement
• Fuel hose removal and replacement
• Fuel line heater removal and replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure hand breaks are engaged and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If Genset has been in operation, components may be extremely hot. To prevent
serious injury to personnel, allow the Genset to cool down before performing
procedures.
0085-1
TM 11-6115-742-13&P 0085
CAUTION
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel.
3. Remove rear access panel.
4. Disconnect battery ground cable (black) from battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
Fuel lines may still have fuel present or be under pressure. Care must be taken
to prevent fuel from spilling and to avoid exposure of skin to diesel fuel.
The fuel gauge is a float style fuel gauge.
5. If fuel tank is full, drain off 1/3 of fuel as per (WP 0045).
6. Remove front access panel (Figure 1, Item 3) to gain access to fuel gauge.
7. Using a 1 ¾ inch wrench or pipe wrench, rotate gauge (Figure 1, Item 1) counterclockwise to release.
8. Lift gauge (Figure 1, Item 1) out of fuel tank (Figure 1, Item 2).
END OF TASK
0085-2
TM 11-6115-742-13&P 0085
INSPECT
1. Ensure that float has ease of movement.
2. Ensure that two screws are installed in float to provide additional weight.
END OF TASK
REPLACEMENT
1. Insert gauge (Figure 1, Item 1) into hole in fuel tank (Figure 1, Item 2).
2. Using a 1 ¾ inch wrench or pipe wrench, rotate the gauge (Figure 1, Item 1) clockwise to tighten. DO NOT
over tighten.
3. Fill fuel tank as per (WP 0045).
4. Check operation of gauge.
5. Clean up any excess spillage from base of the Genset.
6. Reconnect battery ground cable (black) to battery ground terminal (If necessary, refer to procedure in
(WP 0041) of this TM).
7. Install rear access panel and cargo restraints.
8. Start Genset as per Genset Power Up Procedure(WP 0005).
0085-3
TM 11-6115-742-13&P 0085
Figure 1. Genset Fuel Gauge Removal/Replacement.
END OF TASK
0085-4
TM 11-6115-742-13&P 0085
FUEL TANK REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset is in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
REMOVAL
1. Remove cargo net (see WP 0121), cargo restraints, and applicable cargo cage sections (see WP 0123) to
gain access to cargo.
2. Remove cargo.
3. Remove rear access panels of Genset and set aside.
4. Disconnect battery ground cable (black) from battery ground terminal. If necessary, refer to procedure in
(WP 0041) of this TM.
5. Drain fuel tank completely (see WP 0045).
NOTE
Fuel lines may still have fuel present or be under pressure. Care must be taken
to prevent fuel from spilling and to avoid exposure of skin to diesel fuel.
6. Using either a flat tip screw driver or socket and ratchet, loosen the fuel source hose clamp (Figure 2, Items 8)
on the fuel source hose (Figure 2, Item 7).
7. Place a drain pan or absorbent pad under the connection to be broken in case of spillage.
0085-5
TM 11-6115-742-13&P 0085
REMOVAL – Continued
NOTE
When performing the following step, DO NOT attempt to remove hose from
fitting.
8. Grasp the hose (Figure 2, Item 7) and rotate the hose close to the connection to break the connection.
9. Loosen and remove hose connector (Figure 2, Item 6) with an open end wrench.
10. Using either a flat tip screw driver or socket and ratchet, loosen the fuel return hose clamp (Figure 2, Items 4)
on the fuel return hose (Figure 2, Item 5).
11. Place a drain pan or absorbent pad under the connection to be broken in case of spillage.
NOTE
When performing the following step, DO NOT attempt to remove hose from
fitting.
12. Grasp the hose (Figure 2, Item 5) and rotate the hose close to the connection to break the connection.
13. Loosen and remove hose connector (Figure 2, Item 3) with an open end wrench.
14. Using either a flat tip screw driver or socket and ratchet, loosen the two fuel filler hose clamps (Figure 2,
Items 2) on the fuel filler hose (Figure 2, Item 1).
15. Loosen the Genset heater (hydronic) fuel hose clamp (Figure 2, Item 19).
16. Remove the Genset heater (hydronic) fuel hose from the fuel tank.
17. Loosen the ECU heater (hydronic) fuel hose clamp (Figure 2, Item 17).
18 Remove the ECU heater (hydronic) fuel hose from the fuel tank.
19. Remove two mounting bolts (Figure 2, Item 13), four washers (Figure 2, Item 14), two spacers (Figure 2,
Item 9) and two lock nuts (Figure 2, Item 15) securing both brackets to roadside of fuel tank (Figure 2,
Item 26) to enclosure base.
20. Disconnect internal chassis ground from Genset and trailer ground.
21. Loosen but do not remove two mounting bolts (Figure 2, Item 11) securing curbside of fuel tank (Figure 2,
Item 26) to enclosure base.
22. Remove four mounting bolts (Figure 2, Item 24), eight flat washers (Figure 2, Item 22) and four lock nuts
(Figure 2, Item 21) from road side fuel tank support strut (Figure 2, Item 23).
23. Remove one bolt (Figure 2, Item 25), two washers (Figure 2, Item 27), and lock nut (Figure 2, Item 29) from
each side of Genset enclosure support bracket (curbside). See (Figure 2) for bolt location on each side of
enclosure support bracket.
24. Rotate drain valve (Figure 2, Item 18) to clear fuel tank support strut (Figure 2, Item 23) opening.
25. Lift tank (Figure 2, Item 26) to clear drain valve (Figure 2, Item 18) and remove support strut (Figure 2,
Item 23).
0085-6
TM 11-6115-742-13&P 0085
REMOVAL – Continued
26. Remove two mounting bolts (Figure 2, Item 11), four washers (Figure 2, Item 10), two spacers (Figure 2,
Item 9) and two lock nuts (Figure 2, Item 12) securing both sides of fuel tank (Figure 2, Item 26) to enclosure
base (curbside).
27. To remove fuel filler hose (Figure 2, Item 1) from fuel tank port (Figure 2, Item 30), pry the fuel tank away from
the enclosure wall using a pry bar, loosening fuel filler hose from fuel tank port (Figure 2, Item 30).
28. Once fuel filler hose is free from fuel tank port, lower fuel tank until tank rests on L-bracketed I-beams of
trailer frame.
NOTE
The Genset enclosure must be removed from the trailer bed for the fuel tank to
be removed.
29. Remove Genset from trailer bed, perform steps 6, 8 through 13 of Genset Removal (WP 0086) of this TM,.
WARNING
Empty fuel tank weighs 33 pounds and may require two persons to safely
remove to avoid injury to personnel.
30. Remove fuel tank (Figure 2, Item 26) from trailer bed.
31. Remove and retain fuel gauge (Figure 2, Item 28), connectors (Figure 2, Items 16, and 20), and drain valve
(Figure 2, Item 18) for use on replacement tank.
END OF TASK
REPLACEMENT
WARNING
Empty fuel tank weighs 33 pounds and may require two persons to safely replace
tank to avoid injury to personnel.
NOTE
When replacing heater (hydronic) fuel hose connectors (Figure 2, Items 16
and 20), ensure connector is oriented so that inserted fuel pickup line rests on
the bottom of fuel tank.
When replacing heater (hydronic) fuel hose connectors (Figure 2, Items 16
and 20), apply a thin layer of sealing compound to connector threads.
1. Inspect, replace if necessary, and install fuel gauge (Figure 2, Item 28), connectors (Figure 2, Items 16,
and 20), and drain valve (Figure 2, Item 18) in replacement fuel tank.
2. Place replacement fuel tank (Figure 2, Item 26) in approximate location in trailer bed.
CAUTION
When lowering Genset enclosure onto trailer bed, ensure fuel tank top brackets
clear enclosure frame.
0085-7
TM 11-6115-742-13&P 0085
REPLACEMENT – Continued
3. Reposition Genset enclosure on trailer as per Genset Replacement, steps 5 through 8, 10, and 11 (WP 0086)
of this TM,
4. Ensure two fuel filler hose clamps (Figure 2, Item 2) are loosely positioned on fuel filler hose (Figure 2, Item 1)
and press fuel filler hose (Figure 2, Item 1) onto fuel tank port (Figure 2, Item 30). DO NOT tighten hardware
at this time.
5. Insert two mounting bolts (Figure 2, Item 11), four washers (Figure 2, Item 10), two spacers (Figure 2, Item 9),
and two lock nuts (Figure 2, Item 12) through curbside fuel tank (Figure 2, Item 26) mounting bracket. DO
NOT tighten at this time.
6. Ensure drain valve (Figure 2, Item 18) is rotated away from support strut (Figure 2, Item 23) opening.
7. Lift tank (Figure 2, Item 26) to clear drain valve (Figure 2, Item 18) and slide support strut (Figure 2, Item 23)
along trailer infrastructure into position.
8. Insert four mounting bolts (Figure 2, Item 24), eight flat washers (Figure 2, Item 22), and four lock nuts
(Figure 2, Item 21) into each roadside support strut mounting bracket. DO NOT tighten.
9. Insert two mounting bolts (Figure 2, Item 13), four washers (Figure 2, Item 14), two spacers (Figure 2,
Item 9) and two lock nuts (Figure 2, Item 15) securing both sides of fuel tank (Figure 2, Item 26) (roadside) to
enclosure base.
10. Tighten all mounting hardware of fuel tank (Figure 2, Item 26) and support strut (Figure 2, Item 23).
11. Install one bolt (Figure 2, Item 25), two washers (Figure 2, Item 27), and lock nut (Figure 2, Item 29) to each
side of Genset enclosure support bracket (curbside).
NOTE
Over tightening the hose clamps can result in damage to the hose and premature
failure.
12. Install the ECU heater (hydronic) fuel hose (Figure 2, Item 17) onto the ECU heater (hydronic) fuel connector
(Figure 2, Item 16) and tighten clamp.
13. Install the Genset heater (hydronic) fuel hose (Figure 2, Item 19) onto the Genset heater (hydronic) fuel
connector (Figure 2, Item 20) and tighten clamp.
14. Slide two fuel hose clamps (Figure 2, Item 2) into position over fuel filler hose (Figure 2, Item 1) and fuel tank
port (Figure 2, Item 30) and tighten.
15. Install the fuel source connector (Figure 2, Item 6), with fuel source hose (Figure 2, Item 7) attached, into fuel
tank (Figure 2, Item 26) using an open end wrench. Tighten fuel source hose clamp (Figure 2, Item 8).
16. Install the fuel return connector (Figure 2, Item 3), with fuel return hose (Figure 2, Item 5) attached, into fuel
tank (Figure 2, Item 26) using an open end wrench. Tighten fuel return hose clamp (Figure 2, Item 4).
17. Connect battery ground cable (black) to battery ground terminal. If necessary, refer to procedure in
(WP 0041) of this TM.
18. Ensure drain valve (Figure 2, Item 18) is shut. Fill tank with fuel and check for leaks.
19. Perform all necessary PMCS (refer to WP 0019 and WP 0037) on engine.
0085-8
TM 11-6115-742-13&P 0085
REPLACEMENT – Continued
20. Prime engine as described in (WP 0048) and start Genset in accordance with Genset Start Procedure
(WP 0005) of this TM.
21. Install access panels.
22. Install cargo and cargo restraints.
7
11
1 8 10
5 9
2 4
6
10
13
12
3
30 14
9
14
15
16
28
27
18
25 17
26
20
19
27
29
21
22
23
24
22
Figure 2. Genset Fuel Tank Removal/Replacement.
END OF TASK
0085-9
TM 11-6115-742-13&P 0085
FUEL HOSE REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel.
3. Remove front and rear access panels.
4. Disconnect battery ground cable (black) from battery ground terminal (If necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
Identify the fuel hose to be replaced. Refer to (WP 0139) and (WP 0141) for
location and part number of the various fuel hoses.
Fuel lines may still have fuel present or be under pressure. Care must be taken
to prevent fuel from spilling and to avoid exposure of skin to diesel fuel.
5. Loosen both ends of the fuel hose to be replaced.
6. Place a drain pan or absorbent pad under the connection to be broken in case of spillage.
7. Pull the fuel hose away from the connector. Repeat for other end of fuel hose.
8. Discard hose but retain workable hardware.
END OF TASK
0085-10
TM 11-6115-742-13&P 0085
REPLACEMENT
NOTE
Ensure that replacement hose is the same length and diameter of the original
hose.
Identify the fuel hose to be replaced. Refer to (WP 0139) and (WP 0141) for
location and part number of the various fuel hoses.
Ensure that the hose clamps are placed on the hose in such a way that the
screws will be accessible once slid into place.
1. Install fuel hose onto the first connection using retained hardware.
2. Repeat for other end of fuel hose.
3. Ensure hose is not twisted.
4. Tighten connections.
NOTE
Over tightening a hose can result in damage to the hose and premature failure.
5. Clean up any excess spillage from base of the Genset.
6. Reconnect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
7. Install front and rear access panels and cargo restraints.
8. Start Genset as per Genset Power Up Procedure (WP 0005).
9. Prime fuel system as per (WP 0048).
END OF TASK
0085-11
TM 11-6115-742-13&P 0085
FUEL LINE HEATER REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Never attempt to perform maintenance when Genset in an operational status.
To prevent serious injury to personnel or damage to equipment, DO NOT enter
enclosure with Genset operating.
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY SWITCH is set to OFF (WP 0005,
Genset Shut Down Procedure).
2. Remove cargo restraints (not shown) to gain access to rear access panel.
3. Remove front and rear access panel.
4. Disconnect battery ground cable (black) from battery ground terminal (If necessary, refer to procedure in
(WP 0041) of this TM).
NOTE
Fuel lines may still have fuel present or be under pressure. Care must be taken
to prevent fuel from spilling and to avoid exposure of skin to diesel fuel.
5. Remove and retain twelve bolts (Figure 3, Item 6), lock washers (Figure 3, Item 7), and flat washers (Figure 3,
Item 8) that secure radiator access panel (Figure 3, Item 5) to Genset. Remove radiator access panel
(Figure 3, Item 5).
6. Disconnect fuel heater line (Figure 3, Item 10) from the fuel selector switch (Figure 3, Item 9) behind fuel
control panel (Figure 3, Item 4).
7. Disconnect fuel filter line (Figure 3, Item 2) from fuel heater line (Figure 3, Item 10).
0085-12
TM 11-6115-742-13&P 0085
REMOVAL – Continued
8. Disconnect fuel heater controller (Figure 3, Item 11) from K4 solenoid (Figure 3, Item 1). Refer to (WP 0052,
Table 1) for electric connections of the K4 solenoid. Label unmarked wiring for future installation.
9. Remove fuel heater controller (Figure 3, Item 11) and fuel heater line (Figure 3, Item 10).
END OF TASK
REPLACEMENT
1. Connect fuel heater controller (Figure 3, Item 11) and fuel heater line (Figure 3, Item 10) to K4 solenoid
(Figure 3, Item 1). Refer to (WP 0052, Table 1) for electric connections of the K4 solenoid.
2. Secure fuel heater controller wires to wiring harness with zip ties.
3. Connect fuel filter line (Figure 3, Item 2) to fuel heater line (Figure 3, Item 10).
4. Connect fuel heater line (Figure 3, Item 10) to the fuel selector switch (Figure 3, Item 9) behind fuel control
panel (Figure 3, Item 4).
5. Install radiator access panel (Figure 3, Item 5) onto Genset and secure using twelve bolts (Figure 3, Item 6),
lock washers (Figure 3, Item 7), and flat washers (Figure 3, Item 8).
6. Reconnect battery ground cable (black) to battery ground terminal (if necessary, refer to procedure in
(WP 0041) of this TM).
7. Install front and rear access panels and cargo restraints.
8. Start Genset as per Genset Power Up Procedure (WP 0005).
9. Prime fuel system as per (WP 0048).
0085-13
TM 11-6115-742-13&P 0085
1
4 6
7
8
2 3
9
11 10
Figure 3. Genset Fuel Line Heater Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0085-14
TM 11-6115-742-13&P 0086
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
GENSET REMOVAL/REPLACEMENT
GENSET (including enclosure) – REMOVAL AND REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
Standard Automotive Tool Set (WP 0165, Item 5) Two
Lifting Device (Hoist/Tow truck/Crane)
Chains/straps References
Drain pans WP 0005, WP 0019, WP 0037,
Safety glasses/face shield WP 0041, WP 0042, WP 0045,
Support Lumber (4/4 apprx. 42” 4 ea.) WP 0058, WP 0059, WP 0064,
Materials/Parts WP 0065, WP 0066, WP 0072,
Coolant (WP 0168, Item 2) WP 0074, FO-6 through FO-12
Cloth, cleaning (WP 0168, Item 14)
Rubber gloves (WP 0168, Item 24) Equipment Condition
Oil (WP 0168, Items 35 or 36) ECU shut down
Teflon tape (WP 0168, Item 58) Genset shut down
Strap ties (WP 0168, Items 55 to 57) BATTERY SWITCH – OFF
Cardboard/plywood All power cables disconnected from
J1-J6 on Genst
GENERAL
This work package provides information on the Field maintenance of the Genset. The tasks included in this WP
consist of the following:
• Genset Removal/Replacement
• Engine Generator Assembly (EGA) Removal/Replacement
• Separation of Engine from Generator Assembly (EGA)
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure wheels are chocked. Injury to personnel could result from trailer suddenly
rolling or tipping.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0086-1
TM 11-6115-742-13&P 0086
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures. The Genset assembly for the TMSS-MED weighs 1350
lbs (612.35 kg). Use only a mechanical lift to move equipment. Do not attempt
to lift, carry, or move the Genset without a mechanical lift. Failure to observe this
warning can result in serious injury or death to personnel.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure wheels are chocked. Injury to personnel could result from trailer suddenly
rolling or tipping.
Once the Genset is removed, do not allow unit to hang from lifting device.
Failure to observe this warning can result in serious injury or death to personnel
or damage to Genset.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow sufficient time for fluids and
components to cool down.
Do not enter Genset when operational. Exposed moving parts (i.e. fan blade)
present. To prevent serious injury to personnel or damage to equipment, DO
NOT enter enclosure with Genset operating.
To avoid possibility of counter balance, ensure that tongue jack and jack
assemblies are lowered to ground level to support trailer.
CAUTION
Never attempt to connect or disconnect cables with Genset in an operational
status. Always ensure Genset is shut down before attempting to perform any of
the following procedures.
Always disconnect battery ground cable (black) from battery ground terminal
ground when conducting any procedures on the TMSS-MED Genset.
NOTE
If necessary, refer to (Figures FO-1 through FO-5) for electrical schematics and
wiring diagrams.
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
0086-2
TM 11-6115-742-13&P 0086
REMOVAL
1. Prior to performing the following steps ensure that:
• Genset has been shut down in accordance with Genset Shut Down Procedure (WP 0005).
• ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
• Genset is at ambient temperature.
• All cables have been disconnected from power distribution panel on Genset.
• If applicable, disconnect auxiliary fuel lines from Genset.
• Fuel has been drained (see WP 0045).
• Trailer is level.
• Wheels are chocked.
• All bags have been removed, trailer and immediate area around Genset is free and clear of
Items (i.e., storage bags, ground cables, etc.).
• Ample room to operate lifting device, maneuver and place Genset is present.
2. Remove cargo restraints (not shown) to gain access to rear access panel (Figure 1, Item 4) of Genset
(Figure 1, Item 10).
3. Remove access doors (Figure 1, Items 4 and 9) of Genset (Figure 1, Item 10) and set aside.
4. Disconnect battery ground cable (black) from battery ground terminal. If necessary, refer to procedure in
(WP 0041) of this TM.
5. Loosen hose clamp and disconnect fuel line (Figure 1, Item 8) going to hydronic heater of ECU. Disconnect
fuel line (Figure 1, Item 8) and place into spill bucket. Plug lines coming from fuel tank to avoid excessive
spillage of fuel.
6. Disconnect ground cable from external ground stud on Genset (Figure 1, Item 10).
7. Disconnect internal chassis ground from Genset (Figure 1, Item 10) and trailer ground.
8. Loosen but do not remove nut (Figure 1, Item 3) and bolt (Figure 1, Item 2) that secures exhaust pipe cap
(Figure 1, Item 1). Remove exhaust pipe cap (Figure 1, Item 1) and set aside.
9. Remove and retain 20 bolts (Figure 1, Item 11), lock washers (Figure 1, Item 12) and twelve flat washers
(Figure 1, Item 13) that secure top access panel (Figure 1, Item 14) to Genset (Figure 1, Item 10). Remove
top access panel (Figure 1, Item 14) and set aside.
10. Remove and retain six bolts (Figure 1, Item 7), six lock nuts (Figure 1, Item 6) and twelve flat washers
(Figure 1, Item 5) from bottom of Genset (Figure 1, Item 10).
11. Attach chain/sling to the two lift points (Figure 1, Items 15 and 16 ). One lift point (Figure 1, Item 15) is
located on the engine and one lift point (Figure 1, Item 16) is located on the generator.
NOTE
When performing the following step, ensure that area where Genset is to be
placed is dry and level. Ensure that supports allow adequate room below Genset
so that no Items on bottom become damaged.
12. Place supports (i.e., treated lumber) along ground for Genset (Figure 1, Item 10) to be placed on once
removed from trailer.
0086-3
TM 11-6115-742-13&P 0086
REMOVAL- Continued
CAUTION
When performing the following step, guides should be observant of Genset to
ensure no pieces from Genset and/or trailer get caught while lifting is in process.
When performing the following step, guides should be observant of Genset to
ensure supports are properly placed and that nothing on Genset gets damaged
when placing Genset onto supports.
13. Using a suitable lifting device, raise Genset (Figure 1, Item 10) off of trailer and place on supports. Once
Genset (Figure 1, Item 10) is safely lowered, remove chain/sling from two lift points.
END OF TASK
REPLACEMENT
NOTE
It is assumed that the Genset has been removed from any shipping crates and is
"loose" waiting to be installed onto the TMSS-MED trailer.
1. Remove access doors (Figure 1, Items 4 and 9) of Genset (Figure 1, Item 10) and set aside.
2. Disconnect battery ground cable (black) from battery ground terminal. If necessary, refer to procedure in
(WP 0041) of this TM.
3. Loosen but do not remove nut (Figure 1, Item 3) and bolt (Figure 1, Item 2) that secures exhaust pipe cap
(Figure 1, Item 1). Remove exhaust pipe cap (Figure 1, Item 1) and set aside.
4. Remove and retain 20 bolts (Figure 1, Item 11), lock washers (Figure 1, Item 12) and flat washers (Figure 1,
Item 13) that secure top access panel (Figure 1, Item 14) to Genset (Figure 1, Item 10). Remove top access
panel (Figure 1, Item 14) and set aside.
5. Attach chain/sling to the two lift points (Figure 1, Items 15 and 16). One lift point (Figure 1, Item 15) is located
on the engine and one lift point (Figure 1, Item 16) is located on the generator.
CAUTION
When performing the following step, guides should be observant of Genset to
ensure proper positioning of Genset and that no pieces from Genset and/or
trailer get caught while lowering Genset onto trailer.
Use caution when lowering Genset to avoid damage to ground rods and/or
ground rod brackets.
6. Using a suitable lifting device, raise Genset (Figure 1, Item 10). Insert three bolts (Figure 1, Item 7) and three
washers (Figure 1, Item 5) in rear mounting holes of Genset enclosure to be used as guides for mounting
holes while lowering Genset enclosure onto trailer bed.
7. With Genset (Figure 1, Item 10) in place on trailer, insert remaining three bolts (Figure 1, Item 7) and washers
(Figure 1, Item 5) in front mounting holes of Genset enclosure.
8. Install six lock nuts (Figure 1, Item 6) and flat washers (Figure 1, Item 5) and secure Genset (Figure 1,
Item 10) to trailer.
9. Once Genset (Figure 1, Item 10) is secured to trailer, remove chain/sling from two lift points (Figure 1,
Items 15 and 16).
0086-4
TM 11-6115-742-13&P 0086
REPLACEMENT- Continued
10. Connect fuel line (Figure 1, Item 8) from hydronic heater of ECU to fuel tank connector (WP 0085, Figure 2,
Item 16) and tighten hose clamp.
11. Replace top access panel (Figure 1, Item 14) onto Genset and secure using 20 bolts (Figure 1, Item 11), lock
washers (Figure 1, Item 12), and flat washers (Figure 1, Item 13).
12. Install exhaust pipe cap (Figure 1, Item 1) and tighten nut (Figure 1, Item 3) and bolt (Figure 1, Item 2) that
secures exhaust pipe cap (Figure 1, Item 1).
13. Connect battery ground cable (black) to battery ground terminal. If necessary, refer to procedure in
(WP 0041) of this TM.
14. Fill tank with fuel and check for leaks.
15. Perform all necessary PMCS (refer to WP 0019 and WP 0037) on engine.
16. Prime engine as described in (WP 0048) and start Genset in accordance with Genset Start Procedure
(WP 0005) of this TM.
17. Install two access panels (Figure 1, Items 4 and 9).
18. Install cargo restraints (not shown).
END OF TASK
RETURNING GENSET ENCLOSURE TO OPERATION
1. Replace top access panel (Figure 1, Item 14) onto Genset and secure using 20 bolts (Figure 1, Item 11), lock
washers (Figure 1, Item 12) and flat washers (Figure 1, Item 13).
2. Install exhaust pipe cap (Figure 1, Item 1) and tighten nut (Figure 1, Item 3) and bolt (Figure 1, Item 2) that
secures exhaust pipe cap (Figure 1, Item 1).
3. Install access doors (Figure 1, Items 4 and 9) onto Genset (Figure 1, Item 10).
0086-5
TM 11-6115-742-13&P 0086
2
1
3
14
13
12
11
10
TO ECU
7 5
HYDRONIC
HEATER 6 5
15
16
LIFT POINTS
Figure 1. Genset Removal/Replacement.
END OF TASK
0086-6
TM 11-6115-742-13&P 0086
ENGINE GENERATOR ASSEMBLY – REMOVAL/REPLACEMENT
REMOVAL
WARNING
The engine generator assembly (EGA) weighs 1020 lbs (462.66 kg). The engine
weighs 680 lbs (308.44 kg) and the generator weighs 340 lbs (154.22 kg). Use
only a mechanical lift to move equipment. Do not attempt to lift, carry, or move
the engine or generator without a mechanical lift. Failure to observe this warning
can result in serious injury or death to personnel.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure wheels are chocked. Injury to personnel could result from trailer suddenly
rolling or tipping.
Once the EGA is removed, do not allow unit to hang from lifting device. Failure
to observe this warning can result in serious injury or death to personnel or
damage to EGA.
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow sufficient time for fluids and
components to cool down.
Do not enter Genset when operational. Exposed moving parts (i.e. fan blade)
present. To prevent serious injury to personnel or damage to equipment, DO
NOT enter enclosure with Genset operating.
To avoid possibility of counter balance, ensure that tongue jack and jack
assemblies are lowered to ground level to support trailer.
0086-7
TM 11-6115-742-13&P 0086
Preparation
1. Prior to performing the following steps ensure that:
• Genset has been shut down in accordance with Genset Shut Down Procedure (WP 0005).
• ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
• Genset is at ambient temperature.
• Trailer is level.
• Wheels are chocked.
• All electrical cables have been disconnected from power distribution panel on Genset.
• If applicable, auxiliary fuel lines have been disconnected from Genset.
• All bags have been removed trailer and immediate area around Genset is free and clear of
Items (i.e., storage bags, ground cables, etc.).
• Ample room to operate lifting device, maneuver and place Genset is present.
2. Remove cargo restraints (not shown) to gain access to rear access panel (Figure 2, Item 5) of Genset
(Figure 2, Item 7).
3. Remove access doors (Figure 2, Items 5 and 6) of Genset (Figure 2, Item 7) and set aside.
4. Loosen but do not remove nut (Figure 2, Item 3) and bolt (Figure 2, Item 2) that secures exhaust pipe cap
(Figure 2, Item 1). Remove exhaust pipe cap (Figure 2, Item 1) and set aside.
5. Remove and retain 20 bolts (Figure 2, Item 12), lock washers (Figure 2, Item 13) and flat washers (Figure 2,
Item 14) that secure top access panel (Figure 2, Item 4) to Genset (Figure 2, Item 7). Remove top access
panel (Figure 2, Item 4) and set aside.
6. Remove and retain 16 bolts (Figure 2, Item 11), lock washers (Figure 2, Item 10) and flat washers (Figure 2,
Item 9) that secure radiator access panel (Figure 2, Item 8) to Genset (Figure 2, Item 7). Remove radiator
access panel (Figure 2, Item 8) and set aside.
1 3
14
13 4
12
11
10
9
5
8
Figure 2. Preparation for Engine/Generator Removal/Replacement.
END OF TASK
0086-8
TM 11-6115-742-13&P 0086
Removing Electrical Connections
NOTE
Once steps 1 through 3 have been completed, cover battery terminals with a
non-conductive material (i.e., clean rag or towel) to prevent possibility of
accidental shorting.
1. Disconnect battery ground cable (black) (Figure 3, Item 12) from battery negative(–) terminal. If necessary,
refer to procedure in (WP 0041) of this TM.
2. Disconnect starter cable (Figure 3, Item 10), hydronic heater cable (Figure 3, Item 11 and J6 cable (Figure 3,
Item 9) from positive battery terminal. If necessary, refer to procedure in (WP 0041) of this TM.
3. Disconnect fuse (Figure 3, Item 13) from battery terminals. If necessary, refer to (WP 0041) of this TM.
4. Disconnect battery cable (red) (Figure 3, Item 10) from starter (Figure 3, Item 17). Follow cable around
engine. Remove and retain any cable clamps and associated hardware securing the cable.
5. Disconnect ground cable (black) (Figure 3, Item 12) from engine. Follow cable around engine. Remove and
retain any cable clamps and associated hardware securing the cable.
6 Loosen four bolts (Figure 3, Item 8) that secure generator cover (Figure 3, Item 7). Remove generator cover
(Figure 3, Item 7) and set aside.
7. Remove and retain four nuts (Figure 3, Item 3) and lock washers (Figure 3, Item 4) that secure
(Figure 3, Item 2) wires (red, white, blue, and black) to output side of generator.
NOTE
Prior to performing the following steps, ensure that four wires (red, white, blue,
and black) and associated terminals are appropriately marked for easy
connection during replacement.
If necessary refer to schematics, (Figures FO-6 through FO-12).
When performing step 8 do not remove black wires going to interior generator
coil.
8. Mark and disconnect four wires (Figure 3, Item 2) (red, white, blue, and black) from output side of generator,
routed through harness to circuit breaker CB5 on barrier panel.
9. Install four nuts (Figure 3, Item 3) and lock washers (Figure 3, Item 4) back onto terminals of generator
securing black generator coil wires to terminal.
10. Remove and retain screw (Figure 3, Item 5) that secures ground wire (green) (Figure 3, Item 6) to generator.
Return screw to generator.
11. Remove circuit breaker cover from Genset bottom control panel as described in step 3 of Removal procedure
of (WP 0072).
12. Remove power distribution panel as described in (WP 0074).
NOTE
If necessary refer to (Table 1) or schematics, (Figures FO-6 through FO-12).
13. Mark and disconnect three wires (Figure 3, Item 2) (red, blue, and black) from input side of circuit breaker
CB5 of barrier panel.
0086-9
TM 11-6115-742-13&P 0086
Removing Electrical Connections – Continued
14. Mark and disconnect white wire from neutral terminal block (PTB2) of barrier panel.
15. Mark and disconnect green wire from ground terminal block (GB) of barrier panel.
Table 1. Generator to Barrier Panel Wiring Connections.
Barrier Panel Generator
Wire Color
Connection/Identifier Connection
Black 248-CB5-2 T7
Red 249-CB5-4 T8
Blue 250-CB5-6 T9
White 247-PTB2-TP T4,T5,T6
Green 218-GB-13 GGL (Generator junction box)
16. Remove jam nut (Figure 3, Item 24) securing conduit (Figure 3, Item 1) to barrier panel (Figure 3, Item 25).
Disconnect conduit (Figure 3, Item 1) from barrier panel (Figure 3, Item 25).
17. Pull five wires (Figure 3, Item 2) (red, white, blue, black and green) disconnected in previous steps through
conduit (Figure 3, Item 1). (To avoid damage, pull wires through conduit from barrier panel to
generator/engine side ).
18. Disconnect CM1 from CF1 (on barrier panel side). Pull harness from barrier panel to generator/engine side.
19. Mark and disconnect two terminals (Figure 3, Item 23).
20. Remove and retain four bolts (Figure 3, Item 22) securing shroud(Figure 3, Item 21) to generator and lay
shroud back out of the way.
21. Remove and retain hardware securing ground cable to GROUND on frame of Genset. Disconnect ground
cable and replace hardware.
END OF TASK
0086-10
TM 11-6115-742-13&P 0086
2 3
4
5
6
1
TO ENGINE
10 11
26 7
12
13
25 9 (SEE
NOTE)
8
24 23
21
22 14
15
TO
BATTERY (-)
12 (REF)
16
20
10 (REF)
19 17
18
Note:
Battery Fuse may or may not
be connected with cables.
Old Style Fuse connects
directly to battery terminals.
TO
BATTERY (+)
Figure 3. Electrical and Hydronic Heater Connections for
Engine/Generator Removal/Replacement.
END OF TASK
0086-11
TM 11-6115-742-13&P 0086
Removing Oil Connections
WARNING
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
NOTE
Collect fluids in appropriate chemical-resistant containers. If disposing of fluids,
dispose of properly through local servicing Defense Reutilization and Marketing
Office.
Prior to performing the following steps, place absorbent towels under oil pan. =
1. Drain engine oil from LUBE OIL plug (Figure 4, Item 10) as described in (WP 0042).
2. Disconnect drain line (Figure 4, Item 1) from bottom of oil pan (Figure 4, Item 3) and set aside. =
3. Plug oil pan (Figure 4, Item 3).
END OF TASK
Removing Fuel Line Connections
NOTE
Collect fluids in appropriate chemical-resistant containers. If disposing of fluids,
dispose of properly through local servicing Defense Reutilization and Marketing
Office.
Prior to performing the following steps, place absorbent towels under fuel tank
and associated lines being removed.
1. Drain fuel from fuel tank as described in (WP 0045).
2. Remove and retain two mounting bolts (Figure 4, Item 7) and flat washers (Figure 4, Item 6) from bracket
(Figure 4, Item 5) supporting the fuel line heater (Figure 4, Item 8) from the side of the engine.
3. Pull back the protective cover (near K4 solenoid) from fuel line heater (Figure 4, Item 9) and remove heat
shrink. Mark and disconnect fuel heater electrical connections.
4. Disconnect the inlet fuel line (Figure 4, Item 4) running from fuel line heater (Figure 4, Item 8) to the fuel filter.
If necessary, move fuel line heater below I-beam out of the way. If necessary, refer to procedure in
(WP 0048) of this TM.
5. Disconnect the engine return fuel line (Figure 4, Item 2) from the fuel injector rail. If necessary, cut any strap
ties securing engine return fuel line and move out of the way.
0086-12
TM 11-6115-742-13&P 0086
10
4
FUEL
K4
FILTER
SOLENOID
5
6
7
9 8
Figure 4. Oil and Fuel Preparation for Engine/Generator Removal/Replacement.
END OF TASK
0086-13
TM 11-6115-742-13&P 0086
Removing Radiator Connections
WARNING
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
NOTE
Collect fluids in appropriate chemical-resistant containers. If disposing of fluids,
dispose of properly through local servicing Defense Reutilization and Marketing
Office.
Prior to performing the following steps, place absorbent towels under hoses and
lines being removed.
1. Drain coolant from COOLANT DRAIN plug (Figure 5, Item 16). If necessary, refer to procedure in (WP 0058)
of this TM.
2. Disconnect upper radiator hoses (Figure 5, Item 1) from radiator (Figure 5, Item 2) and water pump. If
necessary, refer to procedure in (WP 0059) of this TM.
3. Disconnect lower radiator hose (Figure 5, Item 3) from engine and radiator (Figure 5, Item 2). If necessary,
refer to procedure in (WP 0059) of this TM.
4. Remove and retain six bolts (Figure 5, Item 6) that secure outer fan blade cover (Figure 5, Item 7). Remove
fan blade cover (Figure 5, Item 7) and set aside.
5. Remove and retain six bolts (Figure 5, Item 5) that secure inner fan blade cover (Figure 5, Item 4). Remove
fan blade cover (Figure 5, Item 4) and slide back over fan blades.
6. Remove fan blade from water pump pulley. If necessary, refer to procedure in (WP 0059).
7. Place protective cover (i.e., cardboard, plywood, etc.) over radiator fins to avoid damage during lifting of EGA.
8. Disconnect engine drain line (Figure 5, Item 18) from COOLANT DRAIN plug connection (Figure 5, Item 16)
on Genset.
END OF TASK
Removing Exhaust Connection
WARNING
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
NOTE
If necessary, loosen thermal insulation (Figure 5, Item 13) around exhaust flex
pipe (Figure 5, Item 12).
1. Loosen two nuts (Figure 5, Item 11) from clamp/U-bolt (Figure 5, Item 10) and slide exhaust flex pipe
(Figure 5, Item 12) from exhaust pipe “T” (Figure 5, Item 9) on exhaust manifold (Figure 5, Item 8). If
necessary, refer to procedure in (WP 0066) of this TM.
2. Loosen two nuts (Figure 5, Item 15) from clamp/U-bolt (Figure 5, Item 14) and slide exhaust flex pipe
(Figure 5, Item 12) from elbow going to muffler. If necessary, refer to procedure in (WP 0066) of this TM.
0086-14
TM 11-6115-742-13&P 0086
2
3 4
18
17
6
16
15
11
14
13
8
9
10
12
Figure 5. Radiator and Exhaust Manifold Connections Removal/Replacement.
END OF TASK
0086-15
TM 11-6115-742-13&P 0086
Removing Engine (Hydronic) Heater Connections
WARNING
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
NOTE
Collect fluids in appropriate chemical-resistant containers. If disposing of fluids,
dispose of properly through local servicing Defense Reutilization and Marketing
Office.
Prior to performing the following steps, place absorbent towels under hoses and
lines being removed.
1. Loosen hose clamp on Genset hydronic heater fuel line (Figure 6, Item 7) at the hydronic heater and
disconnect fuel line. Place fuel line into spill bucket. If necessary, refer to procedure in (WP 0064) of this TM.
2. Disconnect power connection (Figure 6, Item 6) from hydronic heater fuel pump (Figure 6, Item 10). Follow
wiring and remove any strap ties/cable clamps securing wiring.
3. Remove and retain bolt (Figure 6, Item 8) and washer (Figure 6, Item 9) that secures hydronic heater fuel
pump (Figure 6, Item 10) and ground cable (Figure 6, Item 11) to I-beam (Figure 6, Item 1).
4. Remove and retain bolt (Figure 6, Item 2) and washer (Figure 6, Item 3) that secures hydronic heater exhaust
line clamp (Figure 6, Item 5) to I-beam (Figure 6, Item 1).
END OF TASK
Removing Battery Warming Plate Connections
WARNING
If Genset has been in operation, fluids and components may be extremely hot.
To prevent serious injury to personnel, allow the Genset to cool down before
performing procedures.
NOTE
Collect fluids in appropriate chemical-resistant containers. If disposing of fluids,
dispose of properly through local servicing Defense Reutilization and Marketing
Office.
Prior to performing the following steps, place absorbent towels under hoses and
lines being removed.
1. Disconnect input and output hoses (Figure 6, Items 12) from battery warming plate (Figure 6, Item 13). Place
input and output hoses (Figure 6, Items 12) into spill bucket. If necessary, refer to procedure in (WP 0041) of
this TM.
2. Follow input and output hoses (Figure 6, Items 12) around engine and remove any strap ties/cable clamps
securing hoses.
0086-16
TM 11-6115-742-13&P 0086
2 4
3
11 TO
HYDRONIC
10 HEATER
TO
FUEL 7
SUPPLY
12
13
Figure 6. Engine (hydronic) Heater and Battery Warming Plate
Connections Removal/Replacement.
END OF TASK
0086-17
TM 11-6115-742-13&P 0086
Removing EGA
WARNING
The engine generator assembly (EGA) weighs 1020 lbs (462.66 kg). The engine
weighs 680 lbs (308.44 kg) and the generator weighs 340 lbs (154.22 kg). Use
only a mechanical lift to move equipment. Do not attempt to lift, carry, or move
the engine or generator without a mechanical lift. Failure to observe this warning
can result in serious injury or death to personnel.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure wheels are chocked. Injury to personnel could result from trailer suddenly
rolling or tipping.
Once the EGA is removed, do not allow unit to hang from lifting device. Failure
to observe this warning can result in serious injury or death to personnel or
damage to EGA.
To avoid possibility of counter balance to TMSS, ensure that tongue jack and
jack assemblies are lowered to ground level to support trailer.
When performing the following step, ensure that chain/sling has two lift points. If
all lift points are not utilized, EGA will be off balance causing EGA to tilt. Damage
could occur to TMSS/EGA.
NOTE
One lift point (Figure 7, Item 7) is located on the engine and one lift point
(Figure 7, Item 6) is located on the generator.
1. Attach chain/sling to two lift points (Figure 7, Items 6 and 7).
2. Remove and retain four mounting nuts (Figure 7, Item 1) and washers (Figure 7, Item 2) securing EGA
(Figure 7, Item 3) to shock mounts (Figure 7, Item 4) on frame (Figure 7, Item 5).
NOTE
When performing the following step, ensure that area where EGA is to be placed
is dry and level. Ensure that supports allow adequate room below EGA so that
no Items on bottom become damaged.
3. If setting EGA on dirt, sand or other unstable ground, place supports (i.e., treated lumber) along ground for
EGA (Figure 7, Item 3) to be placed on once removed from trailer.
4. Inspect around EGA. Ensure ALL cables, hoses, clamps, and other connections have been removed and
EGA is free and clear of any obstructions or interference.
CAUTION
When performing the following step, guides should be observant of EGA to
ensure no pieces from EGA get caught while lifting is in process. Be observant
of radiator fins,
When performing the following step, guides should be observant of EGA to
ensure supports are properly placed and that nothing on EGA gets damaged
when placing onto supports.
5. Using a suitable lifting device, raise EGA (Figure 7, Item 3) off of trailer and place on supports. Once EGA
(Figure 7, Item 3) is safely lowered, remove chain/sling from lift points.
END OF TASK
0086-18
TM 11-6115-742-13&P 0086
LIFT POINTS 6
Figure 7. EGA Removal/Replacement.
END OF TASK
0086-19
TM 11-6115-742-13&P 0086
REPLACEMENT
Installing EGA
WARNING
The engine generator assembly (EGA) weighs 1020 lbs (462.66 kg). The engine
weighs 680 lbs (308.44 kg) and the generator weighs 340 lbs (154.22 kg). Use
only a mechanical lift to move equipment. Do not attempt to lift, carry, or move
the engine or generator without a mechanical lift. Failure to observe this warning
can result in serious injury or death to personnel.
Prior to performing any maintenance that requires climbing on or under trailer,
ensure wheels are chocked. Injury to personnel could result from trailer suddenly
rolling or tipping.
Once the EGA is raised do not allow unit to hang from lifting device. Failure to
observe this warning can result in serious injury or death to personnel or damage
to EGA.
1. Prior to installing the EGA:
• Inspect all hoses and belts and ensure they are in good working order (i.e., no dry-rot, cracks,
fraying, or other damage). If necessary, replace as described in the appropriate work package
of this TM.
• Inspect radiator and fuel tank. Ensure they are in good working order. If necessary, replace as
described in the appropriate work package of this TM.
• Inspect all shock mounts ensure they are in good working order (i.e., no dry-rot, cracks or other
damage). If necessary, replace.
• All electrical connections are in good working order (i.e., no fraying, loose connections,
corrosion).
• Ensure engine and generator are properly connected and all mounting hardware between
engine and generator is secure.
2. Inspect inside of enclosure and area around EGA is free and clear of any obstructions or interference.
3. Attach chain/sling to the two lift points (Figure 7, Items 6 and 7).
CAUTION
When performing the following step, guides should be observant of EGA to
ensure no pieces from EGA get caught while lifting is in process. Be observant
of radiator fins.
4. Using a suitable lifting device, raise EGA (Figure 7, Item 3) up over enclosure and begin lowering.
5. Guide EGA (Figure 7, Item 3) onto shock mounts (Figure 7, Item 4) and secure using four mounting nuts
(Figure 7, Item 1) and washers (Figure 7, Item 2).
6. Using torque wrench, tighten four mounting nuts (Figure 7, Item 1) to 51 ft./lb (69.15 n-m/7.05 kgf-m).
7. Once EGA (Figure 7, Item 3) is secured, remove chain/sling from lift points.
END OF TASK
0086-20
TM 11-6115-742-13&P 0086
Connecting Radiator
1. Install inner fan blade cover (Figure 5, Item 4) over water pump pulley.
2. Install fan blade onto water pump pulley. Refer to (WP 0067) of this TM for procedure and torque
requirements.
3. Slide inner fan blade cover (Figure 5, Item 4) over fan blades and secure to radiator using six bolts (Figure 5,
Item 5).
4. Ensure that fan belt is proper tension. Refer to (WP 0061) of this TM for procedure and torque requirements.
5. Install outer fan blade cover (Figure 5, Item 7) and secure using six bolts (Figure 5, Item 6).
6. Ensure overflow tube is secured to fan blade cover (Figure 5, Item 7) with strap ties.
7. Connect upper radiator hoses (Figure 5, Item 1) from radiator (Figure 5, Item 2) to water pump. Refer to
procedure in (WP 0059) of this TM.
8. Connect lower radiator hose (Figure 5, Item 3) from engine to radiator (Figure 5, Item 2). Refer to procedure
in (WP 0059) of this TM.
9. Connect engine drain line (Figure 5, Item 17) to COOLANT DRAIN plug connection (Figure 5, Item 15) on
Genset.
END OF TASK
Connecting Exhaust
NOTE
If necessary, loosen thermal insulation (Figure 5, Item 13) around exhaust flex
pipe (Figure 5, Item 12).
1. Install exhaust flex pipe (Figure 5, Item 12) onto elbow going to muffler. Secure using clamp/U-bolt (Figure 5,
Item 14) and two nuts (Figure 5, Item 15).
2. Install exhaust flex pipe (Figure 5, Item 12) onto exhaust pipe “T” (Figure 5, Item 9) on exhaust manifold
(Figure 5, Item 8). Secure using clamp/U-bolt (Figure 5, Item 10) and two nuts (Figure 5, Item 11).
END OF TASK
Connecting Engine (Hydronic) Heater Connections
1. Connect hydronic heater fuel line (Figure 6, Item 7) to hydronic heater and secure with hose clamp. If
necessary, refer to (WP 0064) of this TM.
2. Secure hydronic heater exhaust line (Figure 6, Item 4) to I-beam (Figure 6, Item 1) with clamp (Figure 6,
Item 5), bolt (Figure 6, Item 2) and washer (Figure 6, Item 3).
3. Connect power connection (Figure 6, Item 6) to hydronic heater fuel pump (Figure 6, Item 10). Follow wiring
and secure with strap ties/cable clamps as required.
0086-21
TM 11-6115-742-13&P 0086
Connecting Engine (Hydronic) Heater Connections - Continued
4. Secure hydronic heater fuel pump (Figure 6, Item 10) and ground cable (Figure 6, Item 11) to I-beam
(Figure 6, Item 1) with bolt (Figure 6, Item 8) and washer (Figure 6, Item 9).
END OF TASK
Connecting Battery Warming Plate
NOTE
Prior to connecting input and output hoses wrap threads with Teflon tape.
1. Connect input and output hoses (Figure 6, Items 12) to battery warming plate (Figure 6, Item 13) and tighten.
If necessary, refer to (WP 0041) of this TM.
2. Follow input and output hoses (Figure 6, Items 12) around engine and secure with strap ties/cable clamps.
END OF TASK
Connecting Oil Line
NOTE
Prior to connecting drain line wrap threads with Teflon tape.
1. Connect drain line (Figure 4, Item 1) to bottom of oil pan (Figure 4, Item 3) and tighten.
2. Ensure valve to LUBE OIL plug (Figure 4, Item 10) is closed.
END OF TASK
Connecting Fuel Lines
1. If necessary, move fuel line heater below I-beam out of the way.
2. Connect the inlet fuel line (Figure 4, Item 4) running from fuel line heater (Figure 4, Item 9) to the fuel filter.
3. Connect the engine return fuel line (Figure 4, Item 2) to the fuel injector rail. If necessary, refer to (WP 0048)
of this TM. Install any strap ties needed to secure engine return fuel line.
NOTE
Refer to (Table 2)or (Figure FO-9) for electrical schematic.
4. Pull back the protective cover (near K4 solenoid) from fuel line heater (Figure 4, Item 9) and secure fuel
heater electrical connections. Insulate connections with electrical tape.
Table 2. Fuel line Heater Connections.
Fuel Line Heater Connector Identifier
Connections
1 402-K4S-3
2 407-EBGL
0086-22
TM 11-6115-742-13&P 0086
Connecting Fuel Lines - Continued
NOTE
When specific torque requirements are NOT stated in the procedures, refer to
(WP 0067) for torque requirements.
5. Secure fuel line (Figure 4, Item 8) to engine with bracket (Figure 4, Item 5), two mounting bolts (Figure 4,
Item 7), and two flat washers (Figure 4, Item 6).
END OF TASK
Electrical Connections
1. Connect ground cable to GROUND on frame of Genset.
2. Connect ground cable (black) (Figure 3, Item 12) to engine block with mounting bolt (Figure 3, Item 16).
3. Route ground cable (black) (Figure 3, Item 12) around engine and place near negative(–) battery terminal.
Secure ground cable (black) (Figure 3, Item 12) with any cable clamps removed during disassembly. If
necessary, refer to procedure in (WP 0041) of this TM.
4. Verify that shroud (Figure 3, Item 21) has been installed onto generator and secured using four bolts
(Figure 3, Item 22).
5. Insert conduit (Figure 3, Item 1) from generator through barrier panel wall (Figure 3, Item 25) and secure
using jam nut (Figure 3, Item 24).
6. Feed harness through barrier panel wall and connect CM1 to CF1 (on barrier panel side).
7. Remove and retain four nuts (Figure 3, Item 3) and lock washers (Figure 3, Item 4) from terminals of
generator.
NOTE
If necessary, refer to (Table 3) or (Figure FO-9) for electrical schematic.
8. Connect four wires (Figure 3, Item 2) (red, white, blue, and black) to generator and secure using four nuts
(Figure 3, Item 3) and lock washers (Figure 3, Item 4).
9. Remove and retain screw (Figure 3, Item 5) from generator. Connect ground wire (green) (Figure 3, Item 6)
and secure using screw (Figure 3, Item 5).
10. Feed all five wires (Figure 3, Item 2) (red, white, blue, black and green) through conduit (Figure 3, Item 1) to
barrier panel side.
11. Connect three wires (Figure 3, Item 2) (red, blue, and black) to input side of circuit breaker CB5 on barrier
panel.
12. Connect white wire to neutral terminal block (PTB2) on barrier panel.
13. Connect green wire to ground terminal block (GB) on barrier panel.
14. Install circuit breaker cover to Genset bottom control panel as described in (WP 0072).
15. Install power distribution panel as described in (WP 0074).
0086-23
TM 11-6115-742-13&P 0086
Electrical Connections - Continued
Table 3. Generator to Barrier Panel Connections.
Wire Generator Barrier Panel
Color Connections Connections
Black T7 248-CB5-2
Red T8 249-CB5-4
Blue T9 250-CB5-6
White T4,T5,T6 247-PTB2-TP
Green GGL (Generator junction box) 218-GB-13
16. Install generator cover (Figure 3, Item 7) and secure using four bolts (Figure 3, Item 8).
WARNING
DO NOT connect cables to battery terminals until instructed to do so. Premature
connections will create a complete circuit and cause an unsafe working condition.
17. Connect battery cable (red) (Figure 3, Item 10) to starter (Figure 3, Item 17) and secure using bolt (Figure 3,
Item 18) and washer (Figure 3, Item 19).
18. Route starter cable (red) (Figure 3, Item 10) around engine and place near positive battery terminal. Secure
starter cable (red) (Figure 3, Item 10) with any cable clamps removed during disassembly.
19. Route hydronic heater cable (red) (Figure 3, Item 11) around engine and place near positive battery terminal.
Secure hydronic heater cable (red) (Figure 3, Item 11) with any cable clamps removed during disassembly.
20. Route J6 cable (red) (Figure 3, Item 9) around engine and place near positive battery terminal. Secure J6
cable (red) (Figure 3, Item 9) with any cable clamps removed during disassembly.
21. Reconnect all battery cables to battery as described in (WP 0041) of this TM.
22. Connect fuse (Figure 3, Item 13) to battery terminals. If necessary, refer to (WP 0041) of this TM.
END OF TASK
0086-24
TM 11-6115-742-13&P 0086
Fluids
NOTE
Prior to performing the following steps:
• Ensure all fluid valves are closed.
• Inspect all hoses for cracks, swelling, or other obvious deterioration.
• Inspect all clamps verify that no damage or other obvious deterioration is
present.
1. Fill fuel tank as described in (WP 0045).
NOTE
Refer to Expendable and Durable Items (WP 0168) for NSN and other
information on oil and coolant.
2. Add 8.6 quarts (8.13 liters) of oil to engine as described in (WP 0042) of this TM.
3. Add proper coolant/water mix as necessary to bring the engine/radiator to proper level as described in
(WP 0058) of this TM.
4. After all fluids have been added and are at their proper levels, inspect EGA for fluid leaks.
END OF TASK
Preparation for Operation
1. Install radiator access panel (Figure 2, Item 8) onto Genset (Figure 2, Item 7) secure using 16 bolts (Figure 2,
Item 11), lock washers (Figure 2, Item 10) and flat washers (Figure 2, Item 9).
2. Install top access panel (Figure 2, Item 4) onto Genset (Figure 2, Item 7) and secure using 20 bolts
(Figure 2, Item 12), lock washers (Figure 2, Item 13), and flat washers (Figure 2, Item 14).
3. Install exhaust pipe cap (Figure 2, Item 1) and tighten nut (Figure 2, Item 3) and bolt (Figure 2, Item 2).
4. Install all access doors (Figure 2, Items 5 and 6) onto Genset (Figure 2, Item 7).
5. Perform all necessary PMCS (refer to WP 0019 and WP 0037) on engine.
6. Prime engine as described in (WP 0048) and start Genset in accordance with Genset Start Procedure
(WP 0005) of this TM.
7. Install cargo restraints (not shown).
END OF TASK
0086-25
TM 11-6115-742-13&P 0086
SEPARATING ENGINE GENERATOR ASSEMBLY – REMOVAL AND REPLACEMENT
WARNING
The engine generator assembly (EGA) weighs 1020 lbs (462.66 kg). The engine
weighs 680 lbs (308.44 kg) and the generator weighs 340 lbs (154.22 kg). Use
only a mechanical lift to move equipment. Do not attempt to lift, carry, or move
the engine or generator without a mechanical lift. Failure to observe this warning
can result in serious injury or death to personnel.
Once the generator assembly is removed, do not allow unit to hang from lifting
device or tilt forward main stator may slide out of position. Failure to observe this
warning can result in serious injury or death to personnel or damage to internal
parts of the generator.
NOTE
Engine Generator Assembly must be removed from Genset enclosure before
performing this proceude
REMOVAL
1. Remove EGA as described in this WP.
2. Remove any strap ties/cable clamps securing engine (hydronic) heater hoses and wiring harnesses around
engine (hydronic) heater.
3. Remove engine (hydronic) heater (Figure 8, Item 21) from generator (Figure 8, Item 19). If necessary, refer
to procedure in (WP 0064) of this TM.
4. Remove and retain four bolts (Figure 3, Item 22) securing shroud (Figure 3, Item 21) to generator
(Figure 8, Item 19). Remove shroud (Figure 3, Item 21) and lay back.
5. Remove and retain bolt (Figure 8, Item 3), flat washers (Figure 8, Items 4, 5, and 6), lock washer (Figure 8,
Item 7), and nut (Figure 8, Item 8) securing metal grille (Figure 8, Item 9).
6. Remove any strap ties/cable clamps securing hoses and wiring harnesses around metal grille (Figure 8,
Item 9) of generator.
7. Remove and retain metal grille (Figure 8, Item 9).
8. Remove and retain eight bolts (Figure 8, Item 16) and lock washers (Figure 8, Item 15) from flex plate
(Figure 8, Item 12).
9. Attach chain/sling to the two lift points on the engine. Remove any slack from chain/sling and support engine.
0086-26
TM 11-6115-742-13&P 0086
REMOVAL - Continued
10. Remove and retain six mounting bolts (Figure 8, Item 14) securing the generator (Figure 8, Item 19) to the
engine (Figure 8, Item 1).
11. Remove two nuts (Figure 8, Item 17) securing the generator (Figure 8, Item 19) to the two alignment studs
(Figure 8, Item 18).
CAUTION
When performing the following step, ensure that flex plate (Figure 8, Item 12) on
generator and engine flywheel do not stick together causing main stator to slide
out of generator. Failure to observe this caution can result in serious damage to
the generator.
Prior to beginning the following steps, ensure that engine and generator are
supported separately using a bottle jack (Figure 8, Item 10) or lumber support
(Figure 8, Items 2 and 11). Failure to observe this caution can result in serious
damage to engine or generator.
12. Pry generator (Figure 8, Item 19) away from the engine (Figure 8, Item 1).
WARNING
The generator weighs 340 lbs (154.22 kg). Use only a mechanical lift to move
equipment. Do not attempt to lift, carry, or move the engine or generator without
a mechanical lift. Failure to observe this warning can result in serious injury or
death to personnel.
CAUTION
When performing the following step, ensure that generator does NOT lean
forward; the main stator may slide out of position. Failure to observe this caution
can result in serious damage to the generator.
13. Using a suitable lifting device, slightly raise generator (Figure 8, Item 19) and slide away from the engine
(Figure 8, Item 1). Ensure generator is tilted back slightly to keep stator from falling out.
14. Using, strap ties, secure flex plate (Figure 8, Item 9) to frame of generator (Figure 8, Item 19).
0086-27
TM 11-6115-742-13&P 0086
22
21
3
2
20 4
5
6
7
8
19 10 9
17 18 11
12
13
15 14
16
Figure 8. Separating Engine Generator Assembly.
END OF TASK
0086-28
TM 11-6115-742-13&P 0086
REPLACEMENT
WARNING
The generator weighs 340 lbs (154.22 kg). Use only a mechanical lift to move
equipment. Do not attempt to lift, carry, or move the engine or generator without
a mechanical lift. Failure to observe this warning can result in serious injury or
death to personnel.
CAUTION
Prior to beginning the following steps, ensure that engine and generator are
supported separately using a bottle jack (Figure 8, Item 10) or lumber support
(Figure 8, Items 2 and 11). Failure to observe this caution can result in serious
damage to the engine or generator.
1. Attach suitable lifting device to the two lift points (Figure 8, Items 20 and 22) on the generator (Figure 8,
Item 19). Remove any slack from chain/sling.
2. Remove any strap-ties securing flex plate (Figure 8, Item 12) to frame of generator (Figure 8, Item 19).
CAUTION
When performing the following step, ensure that generator does NOT lean
forward; the main stator may slide out of position. Failure to observe this caution
can result in serious damage to the generator.
3. Using a suitable lifting device, lift generator (Figure 8, Item 19) and guide onto two alignment studs (Figure 8,
Item 18) on engine (Figure 8, Item 1). Ensure generator is tilted back slightly to keep stator from falling out.
2. Loosely install two nuts (Figure 8, Item 17) onto two alignment studs (Figure 8, Item 18) on engine (Figure 8,
Item 1).
3. Loosely install six mounting bolts (Figure 8, Item 14) and secure generator (Figure 8, Item 19) to engine
(Figure 8, Item 1).
4. Align flex plate (Figure 8, Item 12) with engine (Figure 8, Item 1). Loosely install eight bolts (Figure 8,
Item 16) and lock washers (Figure 8, Item 15).
5. Using torque wrench, tighten two nuts (Figure 8, Item 17) on alignment studs (Figure 8, Item 18) to 35 to
40 ft./lb (47.45~54.23 n-m/4.84~5.53 kgf-m).
6. Using torque wrench, tighten six mounting bolts (Figure 8, Item 11) to 35 to 40 ft./lb (47.45~54.23
n-m/4.84~5.53 kgf-m).
7. Using torque wrench, tighten eight bolts (Figure 8, Item 16) and lock washers (Figure 8, Item 15) on flex plate
(Figure 8, Item 12) to 17 to 20 ft./lb (23.05~27.11 n-m/2.35~2.76 kgf-m).
8. Install metal grille (Figure 8, Item 9) onto generator (Figure 8, Item 19) and secure with bolt (Figure 8, Item 3),
flat washers (Figure 8, Items 4, 5, and 6), lock washer (Figure 8, Item 7), and nut (Figure 8, Item 8). Using
torque wrench, tighten bolt (Figure 8, Item 3) to 7 to 10 ft./lb (9.49~13.55 n-m/0.97~1.38 kgf-m).
9. Install shroud (Figure 3, Item 21) onto generator (Figure 8, Item 19). Secure using four bolts (Figure 3,
Item 22).
10. Install engine (hydronic) heater (Figure 8, Item 21) to generator (Figure 8, Item 19). If necessary, refer to
procedure in (WP 0064) of this TM.
0086-29
TM 11-6115-742-13&P 0086
REPLACEMENT – Continued
11. Secure engine (hydronic) heater hoses and wiring harnesses using strap ties and/or cable clamps.
12. Install EGA as described in this WP.
END OF TASK
END OF WORK PACKAGE
0086-30
TM 11-6115-742-13&P
CHAPTER 7
MAINTAINER MAINTENANCE INSTRUCTIONS
FOR
TMSS-MED
ECU
TM 11-6115-742-13&P 0087
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
SERVICE UPON RECEIPT – ECU
INITIAL SETUP:
Tools and Special Tools References
General mechanic's tool kit (WP 0165, Item 1) WP 0005, WP 0019, WP 0089,
WP 0090 – WP 0114
Personnel Required
Two to four
GENERAL
The following procedures are required to be performed by Maintainer level maintenance in order to prepare the
TMSS-MED ECU for use.
SITING
For minimal problems with set-up and operation of TMSS-MED ECU and equipment being used insure area is:
• Dry.
• Level with adequate room for trailer, shelter, system grounding, and all other associated equipment.
• Free of items (trees, buildings, or other structures) that would impede set-up of TMSS-MED or cause
physical interference for trailer, shelter, system grounding, and all other associated equipment.
• Free of items (e.g., towers, power lines, radar, trees, buildings) that would cause interference with
electronic equipment being used inside of shelter.
ECU REQUIREMENTS
The TMSS-MED ECU requires 208 VAC, 60 Hz, 3Ø input for operation. The ECU is designed to be operated
mounted on the TMSS-MED trailer. It may operate as a stand-alone unit. However, if operated as a stand-alone
unit, the TMSS-MED ECU must be elevated off the ground to avoid damage to hoses and components which
extend below the ECU. This requires two pieces of 48 in. (1.21 m) 6x6 (15.24 cm x 15.24 cm) timber.
SERVICE UPON RECEIPT
Inspect the ECU and its components for damage incurred during shipment. If any damage is visible, notify
supervisor. Report the damage on DD Form 361, Transportation Discrepancy Report. Check the equipment
against the packing slip to see if the shipment is complete. Report all discrepancies in accordance with applicable
service instructions.
Once all covers are removed, inspect the trailer, shelter, and each piece of equipment for damage incurred during
shipment. Inspect all loose pieces of equipment located in the trailer cargo box.
INSTALLATION INSTRUCTIONS
The TMSS-MED ECU requires some assembly depending on the mode of operation. To setup the TMSS-MED
ECU in a fixed mode of operation, refer to Operation Under Usual Conditions (WP 0005) for setup and power-up
procedures.
0087-1
TM 11-6115-742-13&P 0087
PRELIMINARY SERVICING OF ECU
WARNING
When working on the TMSS-MED, do not operate electric equipment if floors,
ceiling or walls of the individual enclosure show evidence of water intrusion.
Electrical shock can cause personnel injury or death.
Do not apply power if grounding is not connected. Electrical shock can cause
personnel injury or death.
The TMSS-MED ECU contains R-407c refrigerant. Care must be taken when purging, charging, vacuuming, leak
checking. Maintainer PMCS for the TMSS-MED ECU is in (WP 0089). For Maintainer level removal and
replacement procedures of components and assemblies of the TMSS-MED ECU, refer to (WP 0090 through WP
0114).
Once the TMSS-MED ECU has been placed into operation, the following maintenance should be performed after
the first 50 hours of operation.
• Check air filters
• Check hydronic heater fuel filter
• Check tension on belts
• Check refrigerant level
• Check fluid level of hydronic heater
• Check lines for leaks
PRELIMINARY CHECK AND ADJUSTMENTS OF EQUIPMENT
Before placing the TMSS-MED ECU into service, ensure that all Crew PMCS (WP 0019) and Maintainer PMCS
(WP 0089) have been performed.
END OF WORK PACKAGE
0087-2
TM 11-6115-742-13&P 0088
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
PMCS INTRODUCTION – ECU
GENERAL
This work package provides data necessary to keep the TMSS-MED ECU operational ready. PMCS are
performed to keep the TMSS-MED ECU in operational condition. The checks are used to find, correct, and report
problems. Maintenance personnel are required to perform the tasks as indicated in Maintainer PMCS (WP 0089,
Table 1). PMCS are performed by the Maintainer each time the equipment is operated. Prior to performing any
maintenance that requires climbing on or under TMSS-MED, ensure cage bolts are not inserted and wheels are
chocked. Injury to personnel could result from TMSS-MED suddenly rolling or tipping.
Before you begin operating the TMSS-MED ECU and/or its equipment, do Before PMCS.
Once a week do Weekly PMCS. If TMSS-MED ECU has not been operated in a week, perform Before PMCS.
Do Monthly PMCS once a month. If TMSS-MED trailer has not been operated in a month, perform PMCS as
outlined in (WP 0089).
If you are operating the TMSS-MED ECU for the first time, perform Weekly and Monthly PMCS the first time you
do your Before PMCS.
If you find something wrong when performing PMCS, fix it if you can. Otherwise, notify your supervisor.
WARNINGS AND CAUTIONS
Special attention should be paid to the WARNINGS and CAUTIONS appearing in the Maintainer PMCS table. A
WARNING means someone could be injured. A CAUTION means equipment could be damaged.
LEAKAGE DEFINITION
It is necessary for you to know how fluid leakage affects the status of the trailer. The following are definitions of
the classes of leakage you need to know to be able to determine the status of the trailer. Learn these leakage
definitions when in doubt, contact your supervisor.
CAUTION
Maintainers must perform appropriate maintenance when Operators report Class
III leaks. Failure to comply may result in damage to equipment.
NOTE
The following note applies to non-flammable liquids only. Any leakage of
flammable liquid is unacceptable.
Equipment operation is allowable with minor leakages (Class I or II).
Consideration must be given to fluid capacity of the item or system being
checked. When Maintainer is in doubt, notify your supervisor.
When operating with Class I or II leaks, continue to check fluid levels as required
in your PMCS.
0088-1
TM 11-6115-742-13&P 0088
LEAKAGE DEFINITION – Continued
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.
CLASS III - Leakage of fluid great enough to form drops that fall from the item being checked.
INSPECTION
Look for signs of a problem or trouble. Senses help here. You can feel, smell, hear, or see many problems. Be
alert when on the TMSS-MED ECU.
Inspect to see if components are in good condition. Are they correctly assembled, stowed, and secured, or
excessively worn, leaking, corroded, or damaged? Correct any problems found or notify your supervisor.
There are some common items to check all over the TMSS-MED ECU. These include the following:
1. Bolts, clamps, nuts, and screws: Continuously check for looseness. Look for chipped paint, rust, or corrosion
around bolt and screw heads and nuts. Tighten them when you find them loose. If tools are not available,
notify your supervisor.
2. Welds: Many items on the TMSS-MED ECU are welded. To check these welds, look for chipped paint, rust
corrosion, or gaps. When these conditions exist, Maintainer must notify their supervisor.
3. Electrical wires, connectors, and harnesses: Tighten loose connectors. Look for cracked or broken insulation,
bare wires, and broken connectors. If any damage is found, Maintainer must repair/replace as required. If
beyond Maintainer Level Maintenance, Maintainer must notify their supervisor.
4. Hoses and fluid lines: Look for wear, damage and leaks, and make sure clamps and fittings are tight. Wet
spots mean a leak. A stain by a fitting or connector can also mean a leak. If any leaks or damage is found,
Maintainer must repair/replace as required. If beyond Maintainer Level Maintenance, Maintainer must notify
their supervisor.
5.Belts and pulleys. Check belt tension. Look for cracks, excessive wear and damage. Check pulleys for rust
corrosion, or damage. If any damage is found, Maintainer Level Maintenance must repair/replace as
required. If beyond Maintainer Level Maintenance, Maintainer must notify their supervisor.
LUBRICATION MAINTAINER INTERVALS - NORMAL CONDITIONS
General
For safer, more trouble-free operations, make sure that your TMSS-MED ECU is serviced when it needs it.
Proper maintenance intervals which are the responsibility of the Maintainer level maintenance are found in this
chapter.
Adherence
Intervals (on-condition or hard time) and the related man-hour times are based on normal operation. The man-
hour time specified is the time needed to do all the maintenance prescribed for a particular interval. On-condition
(OC) oil sample intervals shall be applied. Change the hard time interval if lubricants are contaminated or if
operating the equipment under adverse operating conditions, included longer-than-usual operating hours. The
calendar interval may be extended during periods of low activity. If extended, adequate preservation precautions
must be taken. Hard time intervals must be applied during the warranty period.
0088-2
TM 11-6115-742-13&P 0088
Cleaning Fittings Before Lubrication
WARNING
Cleaning solvents may be toxic and flammable. Wear protective goggles and
gloves; use only in well-ventilated area; avoid contact with skin, eyes, and clothes,
and do not breath vapors. Keep away from heat or flame. Never smoke when
using cleaning solvent. Failure to comply may result in serious injury or death to
personnel.
If personnel become dizzy while using cleaning solvents, immediately get fresh air
and medical help. If cleaning solvent contacts skin or clothes, flush with cold
water. If cleaning solvent contacts eyes, immediately flush eyes with water and
get medical attention. Failure to comply may result in serious injury or death to
personnel.
Clean parts with cleaning solvent. Dry before lubricating.
Lubrication After Fording
If a fording operation occurs, lubricate all fittings below fording depth and check submerged gear boxes for
presence of water.
Lubrication After High Pressure Washing
After a thorough washing, lubricate all grease fittings and oil can points outside and underneath trailer.
Corrosion Control
Refer to Corrosion Prevention and Control (CPC), (WP 0001), for appropriate corrosion control procedures.
Hard Time Lubrication Intervals
For equipment under manufacturer’s warranty, hard time lubrication intervals shall be followed. Intervals shall be
shortened if lubricants are known to be contaminated or if operation is under adverse conditions (e.g. longer than
usual operating hours, extended idling periods, extreme dust).
EXPLANATION OF TABLE ENTRIES
Item Number - Numbers in this column are for reference. When completing DA Form 2404/DA Form 5988E
(Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indicating a
fault. Item numbers appear in the order in which the checks/services are performed for the interval listed.
Interval - This column indicates when a procedure must be performed (i.e., Before, During, or After an operation.)
Item to Be Checked or Serviced - This column provides the item that is to be checked or serviced.
Procedure - This column describes the procedure that must be followed to ensure that the equipment is capable
of performing its intended mission.
Equipment Not Ready/Available If - This column lists conditions that make the TMSS-MED not fully mission
capable. If the problem can be fixed using the troubleshooting procedures and/or maintenance procedures in this
manual, do so. If not, document the items not able to be fixed on DA Form 2404 for the next level of
maintenance. For further information on how to use this form, see DA PAM 750-8. Be sure to observe and
annotate all special circumstances that appear/occur.
0088-3
TM 11-6115-742-13&P 0088
EXPLANATION OF TABLE ENTRIES - Continued
Other Entries - Be sure to observe and annotate all special circumstances that appear/occur.
NOTE
If the equipment must be kept in continuous operation, only perform those
procedures that will not disturb operation. Complete checks and services when
the equipment is shut down.
END OF WORK PACKAGE
0088-4
TM 11-6115-742-13&P 0089
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
PMCS (ECU)
INITIAL SETUP:
Tools and Special Tools References
General mechanic's tool kit (WP 0165, Item 1) WP 0091 – WP 0114
Personnel Required
Two
Table 1. Maintainer Preventive Maintenance Checks and Services – ECU.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
1 ECU
NOTE
Refer to (WP 0091 through
WP 0114) for ECU maintenance
procedures.
Weekly 1. Check damper assembly and
sliding door. Verify that mechanism
is operating properly. Repair or
replace as necessary.
2. Check all components (i.e., Damaged components,
switches, knobs, meter, lights, bulbs burnt out.
thermostat) for damage. Replace
bulbs if necessary.
3. Check condenser grill for damage.
Replace if necessary.
50 Check blower motor fan belt. Check
Hours for excessive wear and proper
tension. Replace if necessary.
125 1. Check air filters, verify that filters
Hours are clean and free of excessive dirt,
grease, and grime. Clean or replace
if necessary.
2. Check fuel filter, verify that filter is
clean and free of excessive dirt and
debris. Replace if necessary.
0089-1
TM 11-6115-742-13&P 0089
Table 1. Maintainer Preventive Maintenance Checks and Services – ECU – Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
500 Perform overall inspection of
Hours TMSS-MED ECU.
1. Check all components for Missing or damaged
damage. components causing
unsafe or improper
operation of system.
2. Check for completeness.
2,000 1. Replace fan belts (WP 0098)
Hours
2. Change ECU coolant.
END OF WORK PACKAGE
0089-2
TM 11-6115-742-13&P 0090
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU MAINTENANCE INDEX
GENERAL
This section contains an index of repair/removal/replacement or maintenance procedures that may be needed
during maintenance or repair of the TMSS-MED ECU by Maintainer personnel. Maintenance is limited to those
failures that may be repaired at the Maintainer level. The index identifies the maintenance function, which is
followed by a column that identifies the work package and page(s) where Maintainer level procedure(s) may be
found. The index is provided to assist in the quick location of a procedure. The manual cannot list all
malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be corrected by the
corrective actions provided, notify the supervisor.
Maintenance Function Procedure
ENVIRONMENTAL CONTROL UNIT
1. Access panels catch removal/replacement .................................................................................. 0091-2
2. Condenser grill(s) removal/replacement ...................................................................................... 0092-2
3. Condenser coil cleaning ............................................................................................................... 0092-4
4. Duct cover removal/replacement .................................................................................................. 0093-2
5. Sliding door removal/replacement ................................................................................................ 0093-4
6. Evaporator panel assembly removal/replacement ....................................................................... 0093-6
7. Damper assembly removal/replacement ...................................................................................... 0093-8
8. Hydronic heater removal/replacement ......................................................................................... 0094-2
9. Hydronic heater fuel pump and fuel filter removal/replacement ................................................... 0094-5
10 Hydronic heater hose removal/replacement................................................................................. 0094-9
11. Hydronic heater fuse removal/replacement.................................................................................. 0094-11
12. ECU high temperature cut-off switch removal/replacement ......................................................... 0095-2
13. ECU high pressure cut-off switch removal/replacement .............................................................. 0095-4
14. ECU Low Pressure Cut-Off Switch Removal/Replacement ......................................................... 0095-7
15. ECU evaporator motor removal/replacement/adjustment ............................................................ 0096-2
16. ECU evaporator blower fan removal/replacement ....................................................................... 0096-5
17. ECU condenser fan motor removal/replacement ......................................................................... 0097-2
18. Evaporator motor belt tension adjustment .................................................................................... 0098-2
19. Evaporator motor belt removal/replacement ................................................................................ 0098-4
20. ECU – compressor removal/replacement .................................................................................... 0099-2
21. ECU – vibration damper removal/replacement ............................................................................ 0099-6
22. ECU – thermal expansion valve (TEV) removal/replacement ...................................................... 0100-2
23. ECU – thermal expansion valve superheat adjustment ............................................................... 0100-5
24. ECU – quench valve removal/replacement .................................................................................. 0100-7
25. ECU – hot gas bypass valve removal/replacement/adjustment ................................................... 0100-10
26. ECU – high pressure relief valve removal/replacement ............................................................... 0100-14
27. ECU – solenoid valve removal/replacement ................................................................................ 0100-17
28. Air filter cleaning/removal/replacement ........................................................................................ 0101-2
29 ECU – filter/drier removal/replacement ........................................................................................ 0102-2
ECU CONTROL PANEL – (Door Components)
30. ECU control panel door – lights and meter removal/replacement................................................ 0103-2
31. ECU control panel door – mode select switch removal/replacement ........................................... 0103-4
32. ECU control panel door – auxiliary heat switch test/removal/replacement .................................. 0103-6
33. ECU control panel – thermostat test/removal/replacement .......................................................... 0103-8
34. ECU control panel (door) components removal/replacement ...................................................... 0104-2
0090-1
TM 11-6115-742-13&P 0090
Maintenance Function Procedure
ECU CONTROL PANEL – (Internal components)
35. ECU control panel contactors test/removal/replacement ............................................................. 0105-2
36. ECU control panel relays removal/replacement ........................................................................... 0106-2
37. ECU control panel transformer removal/replacement .................................................................. 0107-2
38. ECU control panel bridge rectifier removal/replacement .............................................................. 0107-4
39. ECU control panel CMSP/EMSP removal/replacement ............................................................... 0108-2
ECU – Misc.
40. ECU removal/replacement ........................................................................................................... 0109-2
41. ECU – system purging .................................................................................................................. 0110-3
42. ECU – debrazing .......................................................................................................................... 0110-4
43. ECU – brazing .............................................................................................................................. 0110-5
44. ECU – leak testing ........................................................................................................................ 0111-2
45. ECU – system evacuation ............................................................................................................ 0112-2
46. ECU – refigerant system recovery................................................................................................ 0113-2
47. ECU – refigerant system charging................................................................................................ 0113-4
48. ECU – subcool checking/adjusting ............................................................................................... 0114-2
END OF WORK PACKAGE
0090-2
TM 11-6115-742-13&P 0091
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU ACCESS PANEL
ACCESS PANEL CATCH REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit (WP 0165, Item 1) WP 0005
Materials/Parts Equipment Condition
Catch, clamping ECU shut down
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of the ECU access panel catches.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the ECU.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
NOTE
Removal of the access panels during operations will prevent the ECU from
properly conditioning the air.
NOTE
Removal of the access panels during operations will prevent the ECU from
properly conditioning the air.
The following procedure is typical for all catches on the ECU and its access
panels.
0091-1
TM 11-6115-742-13&P 0091
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
NOTE
When attempting to perform the following step, if panel will not become
unlatched, DO NOT force the access panel. If necessary attempt to gain access
to the damaged panel through the ECU. If this is necessary, make sure ECU is
not in an operational status.
2. Remove the ECU access panel (Figure 1, Item 6) with the broken catch.
3. Remove and retain screw (Figure 1, Item 5) and back plate (Figure 1, Item 4) from rear of the catch (Figure 1,
Item 1).
4. Remove catch (Figure 1, Item 1) from access panel (Figure 1, Item 6).
END OF TASK
REPLACEMENT
1. Insert new catch (Figure 1,Item 1) into access panel (Figure 1, Item 6).
2. Secure catch (Figure 1, Item 1) to access panel (Figure 1, Item 6) using screw (Figure 1, Item 5) and back
plate (Figure 1, Item 4).
NOTE
The following step does not apply to all catch assemblies.
3. If necessary adjust screw (Figure 1, Item 2) and stop nut (Figure 1, Item 3) to proper level so catch (Figure 1,
Item 1) operates properly.
0091-2
TM 11-6115-742-13&P 0091
REPLACEMENT – Continued
4. Reattach the repaired ECU access panel (Figure 1, Item 6).
5. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
5
6
( TYPICAL)
Figure 1. ECU Access Panel Catch Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0091-3/4 blank
TM 11-6115-742-13&P 0092
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU CONDENSER COIL AND GRILL
CONDENSER GRILL REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit One
(WP 0165, Item 1)
References
Materials/Parts WP 0005
Spray bottle (WP 0168, Item 54)
Sealing compound Equipment Condition
(WP 0168, Item 50) ECU shut down
GENERAL
This work package provides information on the cleaning, removal and replacement of the ECU condenser grill.
They consist of:
• Condenser grill removal/replacement.
• Condenser coil cleaning.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the ECU.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Sudden or irreversible tissue damage can result from freezing. Wear gloves and
a face protector or safety glasses in any situation where skin or eye contact with
refrigerant is possible.
Never attempt to perform maintenance when ECU is in operation. To prevent
serious injury to personnel or damage to equipment, DO NOT enter enclosure
with ECU operating.
0092-1
TM 11-6115-742-13&P 0092
Wear appropriate eye protection when performing maintenance. Metal pieces,
fluids, dirt, grease, corrosion, and escaping vapors and gasses present. Failure
to comply may result in injury to personnel.
Remove rings, bracelets, wrist watches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across electrical circuits and cause severe burns or electrical
shock. Failure to observe this warning can result in serious injury or death.
Never attempt to connect or disconnect cables with ECU in operation. Always
ensure ECU is shutdown before attempting to perform any of the following
procedures.
NOTE
Removal of the access panels during operations will prevent the ECU from
properly conditioning the air.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
2. Remove and retain eight screws (Figure 1, Item 1) that secure ECU condenser grill (Figure 1, Item 2) to ECU.
3. Remove condenser grill (Figure 1, Item 2) and set aside.
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following steps, inspect condenser coils (Figure 1,
Item 3). If necessary, perform cleaning procedure as described in this WP. If the
condenser coils are damaged, contact your superior.
1. Coat eight screws (Figure 1, Item 1) with sealing compound.
NOTE
When performing the following step, ensure lattice is on outside of condenser grill
(Figure 1, Item 2).
2. Position condenser grill (Figure 1, Item 2) on to ECU.
3. Secure condenser grill (Figure 1, Item 2) to ECU using eight screws (Figure 1, Item 1).
0092-2
TM 11-6115-742-13&P 0092
REPLACEMENT – Continued
4. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
3 2
Figure 1. Condenser Grill Removal/Replacement.
END OF TASK
0092-3
TM 11-6115-742-13&P 0092
CONDENSER COIL CLEANING
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
CLEANING
1. Verify that ECU (Figure 2, Item 1) has been shut down in accordance with ECU Shut Down Procedure,
(WP 0005).
2. Unlatch and remove rear access panel (Figure 2, Item 2) and forward access panel (Figure 2, Item 6) from
ECU.
3. Remove and retain eight screws (Figure 2, Item 3) that secure ECU condenser coil grill (Figure 2, Item 4) to
the ECU (Figure 2, Item 1).
4. Remove and retain condenser grill (Figure 2, Item 4) and set aside.
CAUTION
When performing the following step, be careful not to blow debris into chamber
from outside.
When performing the following step, be cautious not to damage coil fins. Do not
use compressed air for cleaning purposes unless it is less than 30 pounds per
square inch gauge (30 psig) and then only with effective chip guarding and
personnel protective equipment (industrial safety glasses or full face shield).
5. Using low pressure air, blow debris from the inside of condenser chamber (Figure 2, Item 7) outwards.
6. Using low pressure water (spray bottle is preferred), rinse debris from the inside of condenser chamber
outwards.
7. If necessary, clean condenser coil (Figure 2, Item 5).
8. Allow inside of condenser chamber (Figure 2, Item 6) to dry completely before replacing rear access panel
(Figure 2, Item 2) and forward access panel (Figure 2, Item 6) covers.
0092-4
TM 11-6115-742-13&P 0092
CLEANING – Continued
9. Coat eight screws (Figure 2, Item 3) with sealing compound.
10. Install ECU condenser grill (Figure 2, Item 4) and secure using eight screws (Figure 2, Item 3).
11. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
4
5
Figure 2. Condenser Coil Cleaning.
END OF TASK
END OF WORK PACKAGE
0092-5/6 blank
TM 11-6115-742-13&P 0093
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU DUCT COVER, SLIDING DOOR, EVAPORATOR PANEL, DAMPER
DUCT COVER REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic's tool kit WP 0005
(WP 0168, Item 1)
Equipment Condition
Materials/Parts ECU shut down
Duct cover
Door, Sliding
Evaporator Panel
Damper Assembly
Personnel Required
One
GENERAL
This work package provides information on the inspection, cleaning, adjustments, removal and replacement of the
ECU duct cover, sliding door, evaporator panel, and damper assembly. They consist of:
• Duct cover removal/replacement
• Sliding door removal/replacement
• Evaporator panel assembly removal/replacement
• Damper assembly removal/replacement
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the ECU.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
NOTE
Removal of the access panels during operations will prevent the ECU from
properly conditioning the air.
0093-1
TM 11-6115-742-13&P 0093
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
2. If necessary, remove supply and/or return duct assembly.
3. Remove screw (Figure 1, Item 2) and washer (Figure 1, Item 3) that secures lanyard (Figure 1, Item 4) of duct
storage cover (Figure 1, Item 1) to the ECU evaporator assembly panel (Figure 1, Item 5).
4. If the duct cover (Figure 1, Item 1) is unserviceable, discard.
END OF TASK
REPLACEMENT
1. Slide the lanyard (Figure 1, Item 4) through hole in duct storage cover (Figure 1, Item 1).
2. Bend the nylon mounting strap over and insert male locking clasp into female locking clasp.
3. Press clasps together until locked.
4. Attach washer (Figure 1, Item 3) to mount screw (Figure 1, Item 2) and insert through loop in end of the
lanyard (Figure 1, Item 4).
5. Insert screw (Figure 1, Item 2) into hole in ECU evaporator assembly panel (Figure 1, Item 5) and tighten
down.
6. If necessary, reconnect supply and/or return duct assembly.
7. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0093-2
TM 11-6115-742-13&P 0093
4
3
2
Figure 1. ECU Duct Cover Removal/Replacement.
END OF TASK
0093-3
TM 11-6115-742-13&P 0093
SLIDING DOOR REMOVAL/REPLACEMENT
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
2. Remove sliding door (Figure 2, Item 1) by turning knob (Figure 2, Item 2) counter clockwise until loose.
3. Remove and retain knob (Figure 2, Item 2).
4. Remove sliding door (Figure 2, Item 1) out of housing (Figure 2, Item 3).
END OF TASK
REPLACEMENT
1. Insert sliding door (Figure 2, Item 1) down into the housing (Figure 2, Item 3).
2. Insert knob (Figure 2, Item 2) and turn clockwise to tighten.
3. Adjust the fresh air intake level by loosening knob (Figure 2, Item 2) and sliding fresh air intake gate (Figure 2,
Item 1) to desired position. Tighten knob (Figure 2, Item 2).
4. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0093-4
TM 11-6115-742-13&P 0093
Figure 2. ECU Sliding Door Removal/Replacement.
END OF TASK
0093-5
TM 11-6115-742-13&P 0093
EVAPORATOR PANEL ASSEMBLY REMOVAL/REPLACEMENT
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
NOTE
Removal of the access panels during operations will prevent the ECU from
properly conditioning the air.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
2. Disconnect the ECU power cable (Figure 3, Item 1) from the J1 connector on the Genset or from a shore
power supply.
3. Remove supply and/or return duct assembly and set aside.
4. Remove sliding door (Figure 3, Item 5) from evaporator panel assembly (Figure 3, Item 4). (See procedure in
this WP.)
5. Remove and retain six screws (Figure 3, Item 3) and washers (Figure 3, Item 2) that secure evaporator panel
assembly (Figure 3, Item 4) to ECU.
6. Lift evaporator panel assembly (Figure 3, Item 4) up about one inch until the guide pins clear the center holes.
7. Place evaporator panel assembly (Figure 3, Item 4) out of immediate work area.
END OF TASK
0093-6
TM 11-6115-742-13&P 0093
REPLACEMENT
1. Lift evaporator panel assembly (Figure 3, Item 4) into position above the ECU enclosure opening.
2. Lower evaporator panel assembly (Figure 3, Item 4) so that the two guide pins drop into guide pin holes.
3. Push evaporator panel assembly (Figure 3, Item 4) forward until it is firmly against the ECU enclosure.
4. Secure evaporator panel assembly (Figure 3, Item 4) to ECU using six screws (Figure 3, Item 3) and washers
(Figure 3, Item 2).
5. Install sliding door (Figure 3, Item 5) and secure to evaporator panel assembly (Figure 3, Item 4).
(See procedure in this WP).
6. Install supply and/or return duct assembly or duct cover.
7. Verify that ECU power cable (Figure 3, Item 1) is connected to J1 of Genset and start ECU in accordance with
ECU Start Procedure (WP 0005) of this TM.
2 3
1
Figure 3. ECU Evaporator Panel Assembly Removal/Replacement.
END OF TASK
0093-7
TM 11-6115-742-13&P 0093
DAMPER ASSEMBLY REMOVAL/REPLACEMENT
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
2. If necessary, remove supply and/or return duct assembly or duct cover.
3. Set damper rod (Figure 4, Item 1) to the open position.
4. Remove and retain screw (Figure 4, Item 2) and nut (Figure 4, Item 3) that secures damper plate (Figure 4,
Item 4) to damper rod (Figure 4, Item 1).
NOTE
When performing the following step, be aware of the spring (Figure 4, Item 5)
located on the damper rod (Figure 4, Item 1).
5. Slide damper rod (Figure 4, Item 1) out through damper plate (Figure 4, Item 4), spring (Figure 4, Item 5),
lower duct work (Figure 4, Item 6) and duct wall clip (Figure 4, Item 7).
6. Properly discard of all damaged items.
END OF TASK
REPLACEMENT
1. Insert damper rod (Figure 4, Item 1) into duct wall clip (Figure 4, Item 7) and slide through lower duct work
(Figure 4, Item 6) approximately three inches.
2. Place spring (Figure 4, Item 5) and damper plate (Figure 4, Item 4) onto damper rod (Figure 4, Item 1).
Continue inserting assembly through lower duct work (Figure 4, Item 6).
0093-8
TM 11-6115-742-13&P 0093
REPLACEMENT – Continued
3. Ensure that damper rod (Figure 4, Item 1) and damper plate (Figure 4, Item 4) are positioned properly.
Secure damper plate (Figure 4, Item 4) to damper rod (Figure 4, Item 1) with screw (Figure 4, Item 2) and nut
(Figure 4, Item 3).
4. Install supply and/or return duct assembly or duct cover.
5. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
4
5
1
Figure 4. ECU Damper Assembly Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0093-9/10 blank
TM 11-6115-742-13&P 0094
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU HYDRONIC HEATER
HYDRONIC HEATER REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit One
(WP 0165, Item 1)
References
Materials/Parts WP 0005, WP 0022
Hydronic heater
Drain pan Equipment Condition
Cloth, cleaning (WP 0168, Item 14) ECU shut down
Rubber gloves (WP 0168, Item 24)
Safety Glasses
Fuel Pump
Fuel Filter
Fuse
Hydronic Heater hoses
GENERAL
This work package provides information on the removal and replacement of the ECU Hydronic heater and its
components. They consist of:
• Hydronic heater removal/replacement
• Hydronic heater fuel pump and fuel filter removal/replacement
• Hydronic heater hoses removal/replacement
• Hydronic heater fuse removal/replacement
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the ECU.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock
0094-1
TM 11-6115-742-13&P 0094
WARNINIG
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
NOTE
Removal of the access panels during operations will prevent the ECU from
properly conditioning the air.
REMOVAL
1. Verify that ECU (Figure 1, Item 1) has been shut down in accordance with ECU Shut Down Procedure
(WP 0005).
2. Unlatch and remove front and rear access panels (Figure 1, Item 2) and set aside.
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
3. Loosen hose clamp (Figure 1, Item 8) on hydronic heater fuel line (Figure 1, Item 7) at the fuel pump
(Figure 1, Item 9) and disconnect fuel line (Figure 1, Item 7). Guide fuel line (Figure 1, Item 7) to spill bucket
and allow fuel to drain out of system.
4. Loosen hose clamp (Figure 1, Item 6) that secures cool fluid input hose (Figure 1, Item 10) on the heater body
(Figure 1, Item 3) and disconnect cool fluid input hose (Figure 1, Item 10).
5. Loosen spring clamp (Figure 1, Item 14) that secures fresh air intake hose (Figure 1, Item 13) to the heater
body (Figure 1, Item 3). Remove fresh air intake hose (Figure 1, Item 13) from the heater body (Figure 1,
Item 3).
6. Loosen spring clamp (Figure 1, Item 12) that secures hot output hose (Figure 1, Item 11) to the heater body
(Figure 1, Item 3). Remove hot output hose (Figure 1, Item 11) from the heater body (Figure 1, Item 3).
0094-2
TM 11-6115-742-13&P 0094
REMOVAL - Continued
7. Loosen spring clamp (Figure 1, Item 4) that secures exhaust hose (Figure 1, Item 5). Remove exhaust hose
(Figure 1, Item 5) from the heater body (Figure 1, Item 3).
8. Remove and retain three nuts (Figure 1, Item 15) and washers (Figure 1, Item 16) that secure hydronic heater
body (Figure 1, Item 3) to hydronic heater tank mounting bracket (Figure 1, Item 17).
9. Remove the hydronic heater body (Figure 1, Item 3) from the ECU enclosure.
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following steps:
• Inspect all clamps and hoses. Ensure that hoses are not damaged (cuts,
nicks, etc.). Ensure that all hoses are not excessively worn or appear to be
unserviceable. Ensure that clamps are in good working order.
• Inspect hydronic heater fuel filter. Ensure that fuel filter is not excessively
dirty, worn, or is in other need of servicing.
• Inspect hydronic heater fuel pump. Ensure that fuel pump is not
excessively damaged or otherwise appears to be unserviceable.
1. Align hydronic heater body (Figure 1, Item 3) with proper holes on hydronic heater tank mounting bracket
(Figure 1, Item 17) and secure using three nuts (Figure 1, Item 15) and washers (Figure 1, Item 16).
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
2. Connect hydronic heater fuel line (Figure 1, Item 7) to fuel pump (Figure 1, Item 9). Secure with hose clamp
(Figure 1, Item 8).
3. Connect cool fluid input hose (Figure 1, Item 10) to proper port on heater body (Figure 1, Item 3). Secure with
hose clamp (Figure 1, Item 6).
4. Connect fresh air intake hose (Figure 1, Item 13) to proper port on heater body (Figure 1, Item 3). Secure
with spring clamp (Figure 1, Item 14).
5. Connect exhaust hose (Figure 1, Item 5) to proper port on heater body (Figure 1, Item 3) and secure with
spring clamp (Figure 1, Item 4).
6. Connect hot output hose (Figure 1, Item 11) to the heater body (Figure 1, Item 3). Secure with spring clamp
(Figure 1, Item 12).
7. Check and refill coolant levels in accordance with Crew Maintenance Instructions (WP 0022) of this TM.
8. Clean up any excess spillage from base of ECU.
0094-3
TM 11-6115-742-13&P 0094
REPLACEMENT - Continued
9. Install and secure front and rear access panels (Figure 1, Item 2).
10. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
1 2
15
16
17
3
14
13
4
Exhaust.
6
12
8 5
7
11 9
Cool
10
Input
To Fuel Tank
Figure 1. Hydronic Heater Removal/Replacement.
END OF TASK
0094-4
TM 11-6115-742-13&P 0094
HYDRONIC HEATER FUEL PUMP AND FUEL FILTER REMOVAL/REPLACEMENT
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Do not enter ECU
with ECU operating or power applied. Damage to equipment or serious injury to
personnel may result.
FUEL PUMP
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
2. Disconnect the ECU power cable from the J1 connector on the Genset or from a shore power supply.
3. Unlatch and remove rear access panel (Figure 2, Item 1) and set aside.
4. Disconnect electrical cable (Figure 2, Item 16) from fuel pump (Figure 2, Item 4).
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
5. Loosen hose clamp (Figure 2, Item 3) and disconnect fuel line (Figure 2, Item 2) (heater side) from fuel pump
(Figure 2, Item 4). Guide fuel line (Figure 2, Item 2) to spill bucket and allow fuel to drain.
6. Loosen second hose clamp (Figure 2, Item 8) and disconnect fuel line (Figure 2, Item 9) (filter side) from fuel
pump (Figure 2, Item 4).
0094-5
TM 11-6115-742-13&P 0094
REMOVAL – Continued
7. Remove and retain screw (Figure 2, Item 6), flat washer (Figure 2, Item 7), and nut (Figure 2, Item 15), that
secures fuel pump (Figure 2, Item 4) and clamp (Figure 2, Item 5) to bracket (Figure 2, Item 14).
8. Remove fuel pump (Figure 2, Item 4) and clamp (Figure 2, Item 5).
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following steps:
• Inspect all clamps and hoses. Ensure that hoses are not damaged (cuts,
nicks, etc.). Ensure that all hoses are not excessively worn or appear to be
unserviceable. Ensure that clamps are in good working order.
• Inspect hydronic heater fuel filter. Ensure that fuel filter is not excessively
dirty, worn, or is in other need of servicing.
When performing the following steps verify that fuel pump (Figure 2, Item 3) is
installed in the proper direction. Arrow should point towards fuel line going to
hydronic heater.
1. Install clamp (Figure 2, Item 5) onto fuel pump (Figure 2, Item 4). Secure assembly to bracket (Figure 2,
Item 14) with screw (Figure 2, Item 6), flat washer (Figure 2, Item 7), and nut (Figure 2, Item 15).
2. Connect fuel line (Figure 2, Item 9) (filter side) to fuel pump (Figure 2, Item 4) and secure with clamp
(Figure 2, Item 8).
3. Connect fuel line (Figure 2, Item 2) (heater side) to fuel pump (Figure 2, Item 4) and secure with hose clamp
(Figure 2, Item 3).
4. Connect electrical cable (Figure 2, Item 16) to fuel pump (Figure 2, Item 4).
5. Clean up any excess spillage from base of ECU.
6. Install and secure front and rear access panels (Figure 2, Item 1).
7. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
END OF TASK
FUEL FILTER
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
2. Disconnect the ECU power cable from the J1 connector on the Genset or from a shore power supply.
3. Unlatch and remove access panel (Figure 2, Item 1) and set aside.
0094-6
TM 11-6115-742-13&P 0094
REMOVAL – Continued
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
4. Loosen hose clamp (Figure 2, Item 10) and disconnect fuel line (Figure 2, Item 9) (fuel pump side) from fuel
filter (Figure 2, Item 11).
NOTE
When performing the following step, do not let fuel line fall through frame.
5. Loosen second hose clamp (Figure 2, Item 12) and disconnect fuel filter (Figure 2, Item 11) from fuel line
(Figure 2, Item 13) (fuel tank side).
END OF TASK
REPLACEMENT
NOTE
Prior to performing the following steps:
• Inspect all clamps and hoses. Ensure that hoses are not damaged (cuts,
nicks, etc.). Ensure that all hoses are not excessively worn or appear to be
unserviceable. Ensure that clamps are in good working order.
• Inspect hydronic heater fuel pump. Ensure that fuel pump is not
excessively damaged or otherwise appears to be unserviceable.
When performing the following steps verify that fuel filter (Figure 2, Item 11) is
installed in the proper direction. Arrow should point towards fuel line going to
hydronic heater.
1. Connect fuel filter (Figure 2, Item 11) to fuel line (Figure 2, Item 13) (fuel tank side) and secure with hose
clamp (Figure 2, Item 12).
2. Connect fuel line (Figure 2, Item 9) (fuel pump side) to fuel filter (Figure 2, Item 11) and secure with hose
clamp (Figure 2, Item 10).
3. Clean up any excess spillage from base of ECU.
4. Install and secure access panel (Figure 2, Item 1).
5. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0094-7
TM 11-6115-742-13&P 0094
To Hydr onic Heater
2
3
4
5
8 6
7
16 9
10
11
12
15 13
To Fuel Tank
14
Figure 2. Hydronic Heater Fuel Pump and Fuel Filter Removal/Replacement.
END OF TASK
0094-8
TM 11-6115-742-13&P 0094
HYDRONIC HEATER HOSE REMOVAL/REPLACEMENT
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Do not enter ECU
with ECU operating or power applied. Damage to equipment or serious injury to
personnel may result.
REMOVAL
1. Verify that ECU (Figure 3, Item 1) has been shut down in accordance with ECU Shut Down Procedure
(WP 0005).
2. Unlatch and remove front and rear access panels (Figure 3, Item 2) and set aside. Identify hose to be
replaced, air (Figure 3, Item 6), fuel (Figure 3, Item 4), coolant (Figure 3, Item 5), or exhaust (Figure 3,
Item 3).
NOTE
When coolant hoses are disconnected, the coolant reservoir will drain. Drain
coolant into a clean container to allow reuse.
3. Using either a flat tip screw driver or the appropriate socket and ratchet, loosen the hose clamps on both ends
of the hose to be replaced.
4. Place a drip bucket or absorbent pad under the connection to be broken in case of spillage.
5. Grasp the hose with hands or a pair of pliers and rotate the hose close to the connection to break the
connection.
6. Pull the hose away from the connection using a twisting motion until it comes free.
7. Repeat steps 4 through 6 to remove the other end of the hose.
8. Remove the hose clamps if they are to be reused and discard hose.
END OF TASK
0094-9
TM 11-6115-742-13&P 0094
REPLACEMENT
NOTE
Ensure that replacement hose is the same length and diameter of the original
hose.
1. Place hose clamps onto replacement hose loosely and slide to center of hose.
NOTE
Ensure that the hose clamps are placed on the hose in such a way that the
screws will be accessible once slid into place.
2. Most connections have a ridge built into them to facilitate a good seal when the hose clamp is tightened
down. Identify the location of the ridge on the first side.
3. Using a twisting motion slide the hose onto the first connection. Ensure hose is slid back far enough.
4. Slide hose clamp down into position.
5. Repeat steps 2 through 4 for other end of hose.
6. Ensure hose is not twisted.
7. Tighten down hose clamps using flat tip screwdriver or socket and ratchet, until hose clamp begins to press
into hose.
NOTE
Over tightening the hose clamp can result in damage to the hose and premature
failure.
If replacing coolant hose, see Crew Maintenance Instructions (WP 0022) to
check and refill engine coolant levels.
8. Clean up any excess spillage from base of ECU.
9. Install and secure access panels (Figure 3, Item 2).
10. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0094-10
TM 11-6115-742-13&P 0094
1 2
Exhaust.
6
5
Coolant 4
Input
To Fuel Tank
Figure 3. Hydronic Heater Hose Removal/Replacement.
END OF TASK
0094-11
TM 11-6115-742-13&P 0094
HYDRONIC HEATER FUSE REMOVAL/REPLACEMENT
WARNING
High voltage and amperage present at electrical connections. Do not enter ECU
with power applied. To prevent serious injury to personnel or damage to
equipment, DO NOT enter enclosure with ECU operating.
REMOVAL
1. Verify that ECU (Figure 4, Item 1) has been shut down in accordance with ECU Shut Down Procedure
(WP 0005).
2. Remove front access door (Figure 4, Item 2) on Genset and set aside.
3. Locate fuse holder (Figure 4, Item 6) on hydronic heater (Figure 4, Item 3) and open cover.
4. Identify and remove bad fuse (Figure 4, Items 4 or 5).
END OF TASK
REPLACEMENT
1. Replace fuse (Figure 4, Items 4 or 5) with proper type and value.
2. Close cover on fuse holder (Figure 4, Item 6).
3. Install access door (Figure 4, Item 2).
4. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0094-12
TM 11-6115-742-13&P 0094
E
INTAK UT HYDRONIC HEATER
IR TP WIRING HARNESS
S H A T OU CONNECTION
E
FR HO P/O 3
4
COOLANT
INPUT 5
EXHAUST
TO FUEL TANK
Figure 4. Hydronic Heater Fuse Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0094-13/14 blank
TM 11-6115-742-13&P 0095
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU – CUT-OFF SWITCHES
CUT-OFF SWITCHES REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0027, WP 0102,
Refrigeration service tool kit (WP 0165, Item 3) WP 0110, WP 0111, WP 0113,
Safety glasses/face shield FO-1 through FO-5
Gloves, rubber (WP 0168, Item 24)
Materials/Parts Equipment Condition
Switch ECU Shut Down
CB1 on Genset Control Panel - Off
Personnel Required ECU Power cable disconnected
One from J1 on Genset
GENERAL
This work package provides information on removal and replacement of the following components on the ECU:
• High temperature cut-off switch
• High Pressure cut-off switch
• Low Pressure cut-off switch
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
AC voltage (208 VAC, 3Ø), (28 VAC), and DC voltage (+28 VDC), and current
sufficient to cause serious injury or death are present. Before starting this task,
ensure all power is de-energized and disconnected from shelter. Failure to
comply with this warning could result in electrical shock or death to the
individual.
The following procedures require the use of open flame (brazing). Be observant
of all fluids and components surrounding area being brazed. Do not damage,
equipment or fluids and components. Only properly trained personnel should
attempt to perform brazing procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0095-1
TM 11-6225-742-13&P 0095
REFRIGERANT UNDER PRESSURE
Death or severe injury may result if you fail to observe safety precautions. Never
use a heating torch on any part of the system that contains refrigerant. Do not let
liquid refrigerant touch you, and do not inhale refrigerant gas
Death or severe damage may result if personnel fail to observe safety
precautions. Use great care to avoid contact with liquid refrigerant or refrigerant
gas being discharged under pressure. Sudden and irreversible tissue damage
can result from freezing. Wear thermal protective gloves and a face protector or
goggles in any situation where skin/eye contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly toxic and corrosive gas.
NOTE
If necessary, refer to (WP 0027) for troubleshooting and (Figures FO-1 through
FO-5) for schematics/wiring diagrams.
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties
HIGH TEMPERATURE CUT-OFF SWITCH REMOVAL
NOTE
If necessary refer to (WP 0027) for test of switch.
The high temperature cut-off is located on the blower assembly frame near the
blower motor.
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access panel (Figure 1, Item 1) from ECU and set aside.
3. Mark and disconnect two terminals (38A and 39A) (Figure 1, Item 3) from temperature cut-off switch
(Figure 1, Item 4).
4. Rotate temperature cut-off switch (Figure 1, Item 4) until tabs (Figure 1, Item 2) align with notches and
remove temperature cut-off switch (Figure 1, Item 4).
END OF TASK
REPLACEMENT
NOTE
If necessary refer to (Figures FO-1 through FO-5) for schematic/wiring diagram
of ECU.
1. Align notches in temperature cut-off switch (Figure 1, Item 4) with tabs (Figure 1, Item 2) in mount and insert.
Twist temperature cut-off switch (Figure 1, Item 4) until it is locked into place.
2. Connect two terminals (38A and 39A) (Figure 1, Item 3) to temperature cut-off switch (Figure 1, Item 4).
0095-2
TM 11-6115-742-13&P 0095
REPLACEMENT- Continued
3. Replace access panel (Figure 1, Item 1).
4. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
4
3
Figure 1. High Temperature Cut-off Switch Removal/Replacement.
END OF TASK
0095-3
TM 11-6225-742-13&P 0095
HIGH PRESSURE CUT-OFF SWITCH REMOVAL/REPLACEMENT
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
The following procedures require the use of open flame (brazing). Be observant
of all fluids and components surrounding area being brazed. Do not damage,
equipment or fluids and components. Only properly trained personnel should
attempt to perform brazing procedures.
Death or severe damage may result if personnel fail to observe safety
precautions. Use great care to avoid contact with liquid refrigerant or refrigerant
gas being discharged under pressure. Sudden and irreversible tissue damage
can result from freezing. Wear thermal protective gloves and a face protector or
goggles in any situation where skin/eye contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly toxic and corrosive gas.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
If necessary refer to (WP 0027) for test of switch.
The high pressure cut-off switch is located near the condenser coil.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access panel (Figure 2, Item 1) from ECU and set aside.
3. Recover refrigerant as described in (WP 0113) of this TM.
0095-4
TM 11-6115-742-13&P 0095
REMOVAL - Continued
4. Mark and disconnect two terminals (43B and 44A) (Figure 2, Item 4) from high pressure cut-off switch
electrical connection (Figure 2, Item 3) and set aside.
5. Un-braze mounting joint as described in (WP 0110) of this TM and remove high pressure cut-off switch
(Figure 2, Item 2).
END OF TASK
REPLACEMENT
WARNING
The following procedures require the use of open flame (brazing). Be observant
of all fluids and components surrounding area being brazed. Do not damage,
equipment or fluids and components. Only properly trained personnel should
attempt to perform brazing procedures.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties
1. Install high pressure cut-off switch (Figure 2, Item 2) and braze mounting joint as described in (WP 0110) of
this TM.
2. Connect two terminals (43B and 44A) (Figure 2, Item 4) from wiring harness to high pressure cut-off switch
electrical connection (Figure 2, Item 3) and cover with appropriate insulation.
3. Replace filter/dryer as described in (WP 0102).
4. Leak test as described in (WP 0111) of this TM.
5. Charge system with 8.4 lbs. (3.18 Kg) of R-407c refrigerant as described in (WP 0113) of this TM.
6. Replace access panel (Figure 2, Item 1).
7. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0095-5
TM 11-6225-742-13&P 0095
Figure 2. High Pressure Cut-Off Switch Removal/Replacement.
END OF TASK
0095-6
TM 11-6115-742-13&P 0095
LOW PRESSURE CUT-OFF SWITCH REMOVAL/REPLACEMENT
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
Death or severe damage may result if personnel fail to observe safety
precautions. Use great care to avoid contact with liquid refrigerant or refrigerant
gas being discharged under pressure. Sudden and irreversible tissue damage
can result from freezing. Wear thermal protective gloves and a face protector or
goggles in any situation where skin/eye contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly toxic and corrosive gas.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
If necessary refer to (WP 0027) for test of switch. The low pressure cut-off
switch is located near the condenser coil.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access panel (Figure 3, Item 1) from ECU and set aside.
3. Recover refrigerant as described in (WP 0113) of this TM.
0095-7
TM 11-6225-742-13&P 0095
REMOVAL – Continued
4. Mark and disconnect two terminals (41C and 43A) (Figure 3, Item 3) from low pressure cut-off switch
electrical connection (Figure 3, Item 4) and set aside.
5. Unscrew low pressure cut-off switch (Figure 3, Item 2) and remove.
END OF TASK
REPLACEMENT
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
1. Install low pressure cut-off switch (Figure 3, Item 2) and tighten.
2. Connect two terminals (41C and 43A) (Figure 2, Item 3) from wiring harness to low pressure cut-off switch
electrical connection (Figure 3, Item 4).
3. Replace filter/dryer as described in (WP 0102).
4. Leak test as described in (WP 0111) of this TM.
5. Charge system with 8.4 lbs. (3.18 Kg) of R-407c refrigerant as described in (WP 0113) of this TM.
6. Replace access panel (Figure 3, Item 1).
7. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0095-8
TM 11-6115-742-13&P 0095
Figure 3. Low Pressure Cut-Off Switch Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0095-9/10 blank
TM 11-6115-742-13&P 0096
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU – EVAPORATOR FAN MOTOR
EVAPORATOR MOTOR REMOVAL/REPLACEMENT/ADJUSTMENT
INITIAL SETUP:
Tools and Special Tools Reference
General mechanic’s tool kit (WP 0165, Item 1) WP 0005, WP 0098
Electronic equipment tool kit (WP 0165, Item 4)
Safety glasses Equipment Condition
ECU Shut Down
Materials/Parts CB1 on Genset Control Panel - Off
Motor ECU Power cable disconnected
Blower Fan from J1 on Genset
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of components on the ECU evaporator
fan motor.
WARNING
AC voltage (120 VAC), DC voltage (+28 VDC), and current sufficient to cause
serious injury or death are present at the PDP. Before starting this task, ensure
all power is de-energized and disconnected from shelter. Failure to comply with
this warning could result in electrical shock or death to the individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
To avoid electrical shock and damage to equipment, ensure circuit breaker(s)
are set to OFF and power cable is disconnected at power source before
removing or replacing any cables.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
Be observant of the fire extinguisher and its associated bracket when working
around the TMSS-MED. It is located in such a spot where it may catch on
equipment and cause damage or on personnel and cause injury.
0096-1
TM 11-6115-742-13&P 0096
NOTE
If necessary, refer to (WP 0027) for troubleshooting and (Figures FO-1 through
FO-5) for schematics/wiring diagrams.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Open rear evaporator chamber access panel (Figure 1, Item 7) on ECU.
3. Loosen but do not remove four mounting nuts (Figure 1, Item 2), lock washers (Figure 1, Item 3), and flat
washers (Figure 1, Item 4) on evaporator fan motor mounting studs (Figure 1, Item 8).
4. Push the evaporator fan motor (Figure 1, Item 9) upwards along the mounting studs (Figure 1, Item 8) to
decrease tension on belt (Figure 1, Item 11).
5. Slide belt (Figure 1, Item 11) off of evaporator motor pulley (Figure 1, Item 10) and blower pulley (Figure 1,
Item 12).
6. Finish removing four nuts (Figure 1, Item 2), lock washers (Figure 1, Item 3), and flat washers (Figure 1,
Item 4)
CAUTION
When performing the following step, be observant of heater coils. Do not allow
motor to damage heater coil. Electrical connections are still present on
evaporator motor.
7. Remove evaporator motor (Figure 1, Item 9) from studs (Figure 1, Item 8) and turn to gain access to electrical
connections.
8. Remove and retain two screws (Figure 1, Item 5) and cover (Figure 1, Item 6) on evaporator motor (Figure 1,
Item 9) mark and disconnect electrical wiring.
9. Remove evaporator motor (Figure 1, Item 9) from ECU and set aside.
END OF TASK
0096-2
TM 11-6115-742-13&P 0096
REPLACEMENT
WARNING
Be observant of the fire extinguisher and its associated bracket when working
around the TMSS-MED. It is located in such a spot where it may catch on
equipment and cause damage or on personnel and cause injury.
1. Remove and retain two screws (Figure 1, Item 5) and cover (Figure 1, Item 6) on evaporator motor (Figure 1,
Item 9) and connect electrical wiring (see Table 1). Install cover and secure using two screws.
Table 1. Evaporator Motor Electrical Connections.
Wire Color Motor Connection Harness Connection
(Wire #)
Green Ground 11B
White T1/T7 15
Red T2/T8 16
Black T3/T9 17
T4/T5/T6 No Connection
2. Place evaporator motor (Figure 1, Item 9) onto mounting studs (Figure 1, Item 8) and loosely install four nuts
(Figure 1, Item 2), lock washers (Figure 1, Item 3), and flat washers (Figure 1, Item 4).
NOTE
Prior to performing the following step inspect evaporator motor belt. Ensure that
no visible damage is present.
3. Slide belt (Figure 1, Item 11) over evaporator motor pulley (Figure 1, Item 10) and blower pulley (Figure 1,
Item 12).
NOTE
When performing the following steps, deflection of belt (Figure 1, Item 11) should
not be greater than one inch.
4. Move evaporator fan motor (Figure 1, Item 9) to make proper tension adjustment to belt (Figure 1, Item 11).
• Down to increase the tension on the evaporator motor belt (Figure 1, Item 11).
• Up to the decrease tension on the evaporator motor belt (Figure 1, Item 11).
5. Tighten four mounting nuts (Figure 1, Item 2), lock washers (Figure 1, Item 3), and flat washers (Figure 1,
Item 4) on the evaporator fan motor mounting studs (Figure 1, Item 8).
6. Verify tension of evaporator motor belt (Figure 1, Item 11) as described in (WP 0098).
7. Replace rear evaporator chamber access panel (Figure 1, Item 7).
8. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0096-3
TM 11-6115-742-13&P 0096
2
3
4
12
7
6
11
10 8
9 TMSS MED V1
Figure 1. Evaporator Motor Removal/Replacement.
END OF TASK
0096-4
TM 11-6115-742-13&P 0096
EVAPORATOR BLOWER FAN REMOVAL/REPLACEMENT
REMOVAL
WARNING
Be observant of the fire extinguisher and its associated bracket when working
around the TMSS-MED. It is located in such a spot where it may catch on
equipment and cause damage or on personnel and cause injury.
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
NOTE
If necessary, refer to procedure in this WP for steps 2 through 4.
2. Remove rear evaporator chamber access panel (Figure 1, Item 7) and set aside.
3. Loosen hardware that supports evaporator fan motor.
4. Push the evaporator fan motor upwards along the mounting studs to decrease tension on the belt (Figure 2,
Item 7).
5. Slide belt (Figure 2, Item 7) off of blower pulley (Figure 2, Item 8).
6. Remove and retain three nuts (Figure 2, Item 10) and bolts (Figure 2, Item 11) that secure bearing supports
(Figure 2, Item 4) onto bearing (Figure 2, Item 6).
7. Loosen but do not remove three bolts (Figure 2, Item 12) that secure brackets (Figure 2, Item 4) on control
panel side of ECU.
8. Remove and retain three nuts (Figure 2, Item 10) and bolts (Figure 2, Item 11) that secure bearing supports
(Figure 2, Item 4) on control panel side of ECU.
9. Loosen three bolts (Figure 2, Item 5) that secure bearing supports (Figure 2, Item 4) onto fan shroud
(Figure 2, Item 3) and rotate bearing supports (Figure 2, Item 4) away from bearing (Figure 2, Item 6).
10. Remove and retain six mounting bolts (three loosened in previous step and three additional) (Figure 2,
Items 5 and 12) that secure blower fan (Figure 2, Item 2) to enclosure (Figure 2, Item 1).
0096-5
TM 11-6115-742-13&P 0096
REMOVAL - Continued
11 Slide blower fan (Figure 2, Item 2) out and place on a suitable work area.
12. Remove and retain fan shroud (Figure 2, Item 3) and bearing supports (Figure 2, Item 4).
13. Using a center puller, remove pulley assembly (Figure 2, Item 8) and key (Figure 2, Item 9) from shaft of
blower fan (Figure 2, Item 2).
END OF TASK
REPLACEMENT
WARNING
Be observant of the fire extinguisher and its associated bracket when working
around the TMSS-MED. It is located in such a spot where it may catch on
equipment and cause damage or on personnel and cause injury.
1. Place blower fan (Figure 2, Item 2) on a suitable work area and mount pulley assembly (Figure 2, Item 8) and
key (Figure 2, Item 9) onto shaft of blower fan (Figure 2, Item 2).
2. Install fan shroud (Figure 2, Item 3) and bearing supports (Figure 2, Item 4) onto blower fan (Figure 2, Item 2).
Support by installing three nuts (Figure 2, Item 10) and bolts (Figure 2, Item 11) onto bearing supports
(Figure 2, Item 4).
3. Install assembled blower fan (Figure 2, Item 2) into enclosure (Figure 2, Item 1) and align bearing supports
(Figure 2, Item 4).
4. Install three bearing supports (Figure 2, Item 4) onto bearing (Figure 2, Item 6) (on control panel side of ECU)
and loosely install three mounting bolts (Figure 2, Item 12) and nuts (Figure 2, Item 10).
5. Properly position bearing supports (Figure 2, Item 4) (on Genset side of ECU) and install three bolts (Figure 2,
Item 5).
6. Verify that all hardware has been properly tightened.
NOTE
Prior to performing the following step inspect evaporator motor belt. Ensure that
no visible damage is present.
7. Slide belt (Figure 2, Item 7) over blower pulley (Figure 2, Item 8) and evaporator motor pulley (Figure 1,
Item 10).
NOTE
When performing the following steps, deflection of belt (Figure 2, Item 7) should
not be greater than one inch.
If necessary, refer to procedure in this WP for steps 2 through 4.
8. Move motor to make proper tension adjustment to belt.
• Down to increase the tension on belt.
• Up to the decrease tension on belt.
0096-6
TM 11-6115-742-13&P 0096
REPLACEMENT – Continued
NOTE
When performing the following step, tighten hardware on control panel side of
ECU first.
9. Tighten hardware on fan motor mounting studs.
10. Verify tension of evaporator motor belt (Figure 1, Item 11).
11. Replace rear evaporator chamber access panel.
12. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
12
11
10
8 9
2
3
4
Figure 2. Evaporator Blower Fan Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0096-7/8 blank
TM 11-6115-742-13&P 0097
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU – CONDENSER FAN MOTOR
CONDENSER FAN MOTOR REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
General mechanic’s tool kit (WP 0165, Item 1) WP 0005, WP 0030
Electronic equipment tool kit (WP 0165, Item 4) FO-1 through FO-5
Safety glasses
Equipment Condition
Materials/Parts ECU Shut Down
Motor CB1 on Genset Control Panel - Off
ECU Power cable disconnected
Personnel Required from J1 on Genset
Two
GENERAL
This work package provides information on the removal and replacement of components on the ECU condenser
fan motor.
WARNING
AC voltage (120 VAC), DC voltage (+28 VDC), and current sufficient to cause
serious injury or death are present at the PDP. Before starting this task, ensure
all power is de-energized and disconnected from shelter. Failure to comply with
this warning could result in electrical shock or death to the individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
To avoid electrical shock and damage to equipment, ensure circuit breaker(s)
are set to OFF and power cable is disconnected at power source before
removing or replacing any cables.
If ECU has been in operation, components may be extremely cold or extremely
hot. To prevent serious injury to personnel, allow sufficient time for components
to warm up/cool down before performing procedures.
NOTE
If necessary, refer to (WP 0027) for troubleshooting and (Figures FO-1 through
FO-5) for schematics/wiring diagrams.
0097-1
TM 11-6225-742-13&P 0097
REMOVAL
NOTE
If necessary refer to (WP 0030) for test of the blower.
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access panel (Figure 1, Item 10) from ECU and set aside.
3. Remove and retain four screws (Figure 1, Item 1) that secure fan guard (Figure 1, Item 2) to top of ECU.
Remove fan guard (Figure 1, Item 2).
4. Mark and disconnect electrical wiring from condenser fan motor (Figure 1, Item 6).
NOTE
The following steps require two personnel, one inside the ECU and one on top.
5. Remove and retain four nuts (Figure 1, Item 9), bolts (Figure 1, Item 3) and flat washers (Figure 1, Item 8)
that secure condenser fan motor (Figure 1, Item 6) to frame (Figure 1, Item 7).
6. Remove and retain two screws (Figure 1, Item 5) and cover (Figure 1, Item 4) on condenser fan motor
(Figure 1, Item 6).
WARNING
HEAVY EQUIPMENT
Improperly lifting or carrying heavy equipment can result in serious injury or
death. Refer to weight limits as outlined in front matter of this TM.
7. Remove condenser fan motor (Figure 1, Item 6) from top of ECU and set aside.
8. Using puller, remove fan blade assembly (Figure 1, Item 11) and key (Figure 1, Item 12) from shaft of
condenser fan motor (Figure 1, Item 6).
END OF TASK
0097-2
TM 11-6115-742-13&P 0097
REPLACEMENT
NOTE
If necessary refer to (Figures FO-1 through FO-5) for schematic/wiring diagram
of ECU.
The following steps require two personnel, one inside the ECU and one on top.
1. If applicable, install fan blade assembly (Figure 1, Item 11) and key (Figure 1, Item 12) onto shaft of
condenser fan motor (Figure 1, Item 6).
2. Place condenser fan motor (Figure 1, Item 6) on top of ECU.
3. If applicable, remove and retain two screws (Figure 1, Item 5) and cover (Figure 1, Item 4) on condenser fan
motor (Figure 1, Item 6).
4 Connect electrical wiring to condenser fan motor (Figure 1, Item 6) (see Table 1).
Table 1. Condenser Fan Motor Electrical Connections.
Wire Color Motor Connection Harness Connection
(Wire #)
Green Ground 11C
Black T1/T7 18
Red T2/T8 19
White T3/T9 20
T4/T5/T6 No Connection
5 Install cover (Figure 1, Item 4) and secure using two screws (Figure 1, Item 5).
NOTE
The following step requires two personnel, one inside the ECU and one on top.
6. Lower condenser fan motor (Figure 1, Item 6) into ECU and align with frame (Figure 1, Item 7). Secure to
frame (Figure 1, Item 7) using four nuts (Figure 1, Item 9), bolts (Figure 1, Item 3) and flat washers (Figure 1,
Item 8).
7. Install fan guard (Figure 1, Item 2) to top of ECU and secure using four screws (Figure 1, Item 1).
8. Replace access panel (Figure 1, Item 10).
9. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0097-3
TM 11-6225-742-13&P 0097
12
11
1 2
6
(REF)
FAN BLADE AND KEY
4
5
6
10
8
9
Figure 1. Condenser Fan Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0097-4
TM 11-6115-742-13&P 0098
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU EVAPORATOR MOTOR BELT
EVAPORATOR MOTOR BELT TENSION ADJUSTMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit WP 0005
(WP 0165, Item 1)
Equipment Condition
Materials/Parts ECU shut down
Belt, evaporator motor
Personnel Required
One
GENERAL
This work package provides information on the maintenance of the ECU evaporator motor belt. They consist of:
• Evaporator motor belt tension adjustment
• Evaporator motor belt removal/replacement
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the ECU.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock
NOTE
Removal of the access panels during operations will prevent the ECU from
properly conditioning the air.
0098-1
TM 11-6115-742-13&P 0098
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
ADJUSTMENT
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
2. Unlatch and remove rear evaporator chamber access panel (Figure 1, Item 2). Set aside.
3. Loosen but do not remove four mounting nuts (Figure 1, Item 3), lock washers (Figure 1, Item 4) and flat
washers (Figure 1, Item 5) on evaporator fan motor mounting studs (Figure 1, Item 6).
NOTE
When performing the following steps, deflection of evaporator motor belt
(Figure 1, Item 8) should not be greater than one inch.
4. Move evaporator fan motor (Figure 1, Item 7) to make proper tension adjustment to evaporator motor belt
(Figure 1, Item 8).
• Down to increase the tension on the evaporator motor belt (Figure 1, Item 8).
• Up to the decrease tension on the evaporator motor belt (Figure 1, Item 8).
5. Tighten four mounting nuts (Figure 1, Item 3) on the evaporator fan motor mounting studs (Figure 1, Item 6)
6. Verify tension of evaporator motor belt (Figure 1, Item 8).
7. Replace rear evaporator chamber access panel (Figure 1, Item 2).
8. Reconnect ECU power supply cable (Figure 1, Item 1).
9. Verify that ECU power cable (Figure 1, Item 1) is connected to J1 of Genset and start ECU in accordance with
ECU Start Procedure (WP 0005) of this TM
0098-2
TM 11-6115-742-13&P 0098
3
4
5
1
7
6
Figure 1. ECU Evaporator Motor Belt Adjustment.
END OF TASK
0098-3
TM 11-6115-742-13&P 0098
EVAPORATOR MOTOR BELT REMOVAL/REPLACEMENT
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
NOTE
Removal of the access panels during operations will prevent the ECU from
properly conditioning the air.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure, (WP 0005).
2. Unlatch and remove rear evaporator chamber access panel (Figure 2, Item 2). Set aside.
NOTE
When performing the following step, loosen but do not remove four mounting
nuts (Figure 2, Item 3).
3. Loosen but do not remove four mounting nuts (Figure 2, Item 3), lock washers (Figure 2, Item 4), and flat
washers (Figure 2, Item 5) on evaporator fan motor mounting studs (Figure 2, Item 6).
4. Push the evaporator fan motor (Figure 2, Item 7) upwards along the mounting studs (Figure 2, Item 6) to
decrease tension on the evaporator motor belt (Figure 2, Item 9).
5. Slide evaporator motor belt (Figure 2, Item 9) off of evaporator motor pulley (Figure 2, Item 10) and motor
pulley (Figure 2, Item 8).
END OF TASK
0098-4
TM 11-6115-742-13&P 0098
REPLACEMENT
NOTE
Prior to performing the following step inspect evaporator motor belt. Ensure that
no visible damage is present.
1. Slide new evaporator motor belt (Figure 2, Item 9) over evaporator motor pulley (Figure 2, Item 10) and motor
pulley (Figure 2, Item 8).
2. Push the evaporator fan motor (Figure 2, Item 7) upwards along the mounting studs (Figure 2, Item 6).
3. Slide the new evaporator motor belt (Figure 2, Item 9) over the motor pulley (Figure 2, Item 8).
4. Push the evaporator fan motor (Figure 2, Item 7) up along the mounting studs (Figure 2, Item 6).
5. Slide the evaporator motor belt (Figure 2, Item 9) over the pulley (Figure 2, Item 10) on the evaporator motor
pulley (Figure 2, Item 8).
NOTE
When performing the following steps, deflection of evaporator motor belt (Figure
2, Item 9) should not be greater than one inch.
6. Move evaporator fan motor (Figure 2, Item 7) to make proper tension adjustment to evaporator motor belt
(Figure 2, Item 9).
• Down to increase the tension on the evaporator motor belt (Figure 2, Item 9).
• Up to the decrease tension on the evaporator motor belt (Figure 2, Item 9).
7. Tighten four mounting nuts (Figure 2, Item 3), lock washers (Figure 2, Item 4), and flat washers (Figure 2,
Item 5) on the evaporator fan motor mounting studs (Figure 2, Item 6).
8. Verify tension of evaporator motor belt (Figure 2, Item 9).
9. Replace rear evaporator chamber access panel (Figure 2, Item 2).
10. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0098-5
TM 11-6115-742-13&P 0098
3
4
5
10
8
7
6
Figure 2. ECU Evaporator Motor Belt Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0098-6
TM 11-6115-742-13&P 0099
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU – COMPRESSOR AND VIBRATION DAMPERS
COMPRESSOR AND VIBRATION DAMPERS REMOVAL/REPLACEMENT
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0027, WP 0094,
Refrigeration service tool kit (WP 0165, Item 3) WP 0102, WP 0110, WP 0111,
Safety glasses/face shield WP 0113, FO-1 through FO-5
Gloves, rubber (WP 0168, Item 24)
Materials/Parts
Compressor Equipment Condition
Vibration Damper CB1 on Genset Control Panel - Off
ECU Power cable
Personnel Required disconnected from J1 on Genset
One ECU Shut down
GENERAL
This work package provides information on the removal and replacement of components on the ECU. They
consist of:
• Compressor removal/replacement
• Vibration dampers removal/replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, components may be extremely cold or extremely
hot. To prevent serious injury to personnel, allow sufficient time for components
to warm up/cool down before performing procedures.
AC voltage (208 VAC, 3Ø), (28 VAC), and DC voltage (+28 VDC), and current
sufficient to cause serious injury or death are present. Before starting this task,
ensure all power is de-energized and disconnected from shelter. Failure to
comply with this warning could result in electrical shock or death to the
individual.
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
0099-1
TM 11-6115-742-13&P 0099
REFRIGERANT UNDER PRESSURE
Death or severe injury may result if you fail to observe safety precautions. Never
use a heating torch on any part of the system that contains refrigerant. Do not
let liquid refrigerant touch you, and do not inhale refrigerant gas.
Death or severe damage may result if personnel fail to observe safety
precautions. Use great care to avoid contact with liquid refrigerant or refrigerant
gas being discharged under pressure. Sudden and irreversible tissue damage
can result from freezing. Wear thermal protective gloves and a face protector or
goggles in any situation where skin/eye contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly toxic and corrosive gas.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figure FO-5) for
refrigeration schematic and (Figure FO-1 through FO-4) for electrical schematics
and wiring diagrams.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access panel from ECU and set aside.
CAUTION
Be cautious of thermostat wire, and all other electrical cables associated with the
ECU control panel. Avoid damage to thermostat wire, and all other electrical
cables associated with the ECU control panel.
3.Remove bracket that secures hydronic heater pump and filter. If necessary, refer to (WP 0094).
0099-2
TM 11-6115-742-13&P 0099
REMOVAL - Continued
4. Remove insulation (Figure 1, Item 2) from compressor (Figure 1, Item 3), vibration dampers (Figure 1,
Item 13) and surrounding pipes to safely allow brazing.
5. Recover refrigerant as described in (WP 0113) of this TM.
6. Remove cover (Figure 1, Item 7) to allow access to electrical connections of compressor (Figure 1, Item 3).
7. Remove and retain nuts (Figure 1, Item 8) that secure electrical connections (T1, T2, T3 and ground)
(Figure 1, Item 9) to compressor (Figure 1, Item 3). Remove electrical connections (T1, T2, T3 and ground)
(Figure 1, Item 9) and loosely install hardware.
NOTE
When un-brazing vibration dampeners, de-solder on side furthest from
compressor to avoid damage to vibration dampeners.
8. Un-braze vibration dampeners (Figure 1, Item 13). If necessary refer to (WP 0110) of this TM for brazing
procedures.
9. Remove and retain four bolts (Figure 1, Item 11) and flat washers (Figure 1, Item 10) from base of
compressor (Figure 1, Item 3).
10. Remove and retain four bolts (Figure 1, Item 4), flat washers (Figure 1, Item 5), and locking nuts (Figure 1,
Item 6) from compressor mounting band (Figure 1, Item 12).
WARNING
HEAVY EQUIPMENT
Improperly lifting or carrying heavy equipment can result in serious injury or
death. Refer to weight limits as outlined in front matter of this TM.
11. Remove compressor (Figure 1, Item 3) through opening on Genset side of ECU.
12. To prevent oil from spilling out of open lines, crimp and braze lines coming off of compressor (if necessary,
refer to (WP 0110) of this TM).
END OF TASK
0099-3
TM 11-6115-742-13&P 0099
REPLACEMENT
WARNING
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
HEAVY EQUIPMENT
Improperly lifting or carrying heavy equipment can result in serious injury or
death. Refer to weight limits as outlined in front matter of this TM.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
If necessary, refer to (WP 0027) for troubleshooting, (Figure FO-5) for
refrigeration schematic and (Figure FO-1 through FO-4) for electrical schematics
and wiring diagrams.
1. Install compressor (Figure 1, Item 3) through the area vacated when ECU control panel was removed.
2. Install compressor mounting band (Figure 1, Item 12). Loosely install four bolts (Figure 1, Item 4) through
compressor mounting band (Figure 1, Item 12) and secure with flat washers (Figure 1, Item 5) and lock nuts
(Figure 1, Item 6).
3. Loosely install four bolts (Figure 1, Item 11) and flat washers (Figure 1, Item 10) into base of compressor
(Figure 1, Item 3) securing compressor (Figure 1, Item 3) to base of ECU.
4. Remove cover (Figure 1, Item 7) to allow access to electrical connections (Figure 1, Item 9) of compressor
(Figure 1, Item 3).
5. Remove and retain nuts (Figure 1, Item 8) that secure electrical connections (Figure 1, Item 9) to compressor
(Figure 1, Item 3). Install electrical connections (Figure 1, Item 9) (see Table 1) and install hardware.
Table 1. Compressor Connections.
FROM TO
Wire # Wire Color
(Compressor) (Compressor Contactor)
T1 T1 24 Black
T2 T2 25 Red
T3 T3 26 White
Ground 11D
6. Install vibration dampeners (Figure 1, Item 13) onto associated plumbing of compressor (Figure 1, Item 3) and
braze vibration dampeners (Figure 1, Item 13) into place. If necessary refer to (WP 0110) of this TM for
brazing procedures.
7. Replace filter/dryer as described in (WP 0102).
8. Leak test as described in (WP 0111) of this TM.
9. Charge system with 8.4 lbs. (3.18 Kg) of R-407c refrigerant as described in (WP 0113) of this TM.
0099-4
TM 11-6115-742-13&P 0099
REPLACEMENT - Continued
10. Install insulation (Figure 1, Item 2) onto compressor (Figure 1, Item 3) and surrounding pipes.
11. Install bracket that secures hydronic heater pump and filter. If necessary, refer to (WP 0094).
12. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
1 BRAZING 3
POINT 4
13 5
6
12
11
10 8
9
7
Figure 1. Compressor Removal/Replacement.
END OF TASK
0099-5
TM 11-6115-742-13&P 0099
VIBRATION DAMPER REMOVAL/REPLACEMENT
WARNING
If ECU has been in operation, components may be extremely cold or extremely
hot. To prevent serious injury to personnel, allow sufficient time for components
to warm up/cool down before performing procedures.
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
Death or severe damage may result if personnel fail to observe safety
precautions. Use great care to avoid contact with liquid refrigerant or refrigerant
gas being discharged under pressure. Sudden and irreversible tissue damage
can result from freezing. Wear thermal protective gloves and a face protector or
goggles in any situation where skin/eye contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly toxic and corrosive gas.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
If necessary, refer to (WP 0027) for troubleshooting, (Figure FO-5) for
refrigeration schematic.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access panel from ECU and set aside.
3. Remove insulation (Figure 1, Item 2) from vibration dampers (Figure 1, Item 13) and surrounding pipes to
safely allow brazing.
4. Recover refrigerant as described in (WP 0113) of this TM.
0099-6
TM 11-6115-742-13&P 0099
REMOVAL - Continued
5. Un-braze vibration dampers (Figure 1, Item 13) and remove. If necessary refer to (WP 0110) of this TM for
brazing procedures.
END OF TASK
REPLACEMENT
1. Install vibration dampers (Figure 1, Item 13) onto associated plumbing of compressor (Figure 1, Item 3) and
braze vibration dampers (Figure 1, Item 13) into place. If necessary refer to (WP 0110) of this TM for brazing
procedures.
2. Replace filter/dryer as described in (WP 0102).
3. Leak test as described in (WP 0110) of this TM.
4. Charge system with 8.4 lbs. (3.18 Kg) of R-407c refrigerant as described in (WP 0112) of this TM.
5. Install insulation (Figure 1, Item 2) onto compressor (Figure 1, Item 3) and surrounding pipes.
6. Replace access panel.
7. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
END OF TASK
END OF WORK PACKAGE
0099-7/8 blank
TM 11-6115-742-13&P 0100
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU – VALVES
VALVE MAINTENANCE REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
General mechanics tool kit (WP 0165, Item 1) WP 0005, WP 0027, WP 0102,
Refrigeration service tool kit (WP 0165, Item 3) WP 0110, WP 0111, WP 0113,
Safety glasses/face shield FO-1 through FO-5
Gloves, rubber (WP 0168, Item 24)
Materials/Parts Equipment Condition
Thermal expansion valve ECU Shut Down
Quench valve CB1 on Genset Control Panel - Off
Hot gas by-pass valve ECU Power cable
High pressure relief valve disconnected from J1 on Genset
Loc-tite (air conditioning grade) (WP 0165, Item 50)
Solenoid
Personnel Required
One disconnected from J1 on Genset
WARNING
If ECU has been in operation, components may be extremely cold or extremely
hot. To prevent serious injury to personnel, allow sufficient time for components
to warm up/cool down before performing procedures.
Death or severe damage may result if personnel fail to observe safety
precautions. Use great care to avoid contact with liquid refrigerant or refrigerant
gas being discharged under pressure. Sudden and irreversible tissue damage
can result from freezing. Wear thermal protective gloves and a face protector or
goggles in any situation where skin/eye contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly toxic and corrosive gas.
CAUTION
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
The filter/drier removes moisture and debris and stops contaminants from
clogging expansion valve. The filter must be replaced anytime there is a major
component malfunction or the integrity of the system will be severely
compromised.
0100-1
TM 11-6115-742-13&P 0100
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
REPLACEMENT THERMAL EXPANSION VALVE (TEV) REMOVAL/REPLACEMENT
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access panel from ECU and set aside.
3. Remove insulation (Figure 1, Item 1) from thermal expansion valve (Figure 1, Item 2), sensing bulb (Figure 1,
Item 3), and surrounding pipes to safely allow brazing.
4. Recover refrigerant as described in (WP 0113) of this TM.
5. Wrap wet rag around thermal expansion valve (Figure 1, Item 2), distribution tube (Figure 1, Item 5), and
capillary tubes (Figure 1, Item 4), to prevent damage from overheating.
6. Un-braze TEV (Figure 1, Item 2) at brazing points (see Figure 1). If necessary refer to (WP 0110) of this TM
for brazing procedures.
7. Remove and retain any copper hose clamps securing sensing bulb (Figure 1, Item 3) to surrounding pipes
8. Remove TEV (Figure 1, Item 2), sensing bulb (Figure 1, Item 3) and associated tubing.
END OF TASK
REPLACEMENT
WARNING
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
If necessary, refer to (WP 0027) for troubleshooting, (Figure FO-5) for
refrigeration schematic, and (Figure FO-1 through FO-4) for electrical schematics
and wiring diagrams.
1. Install TEV (Figure 1, Item 2), sensing bulb (Figure 1, Item 3) and associated tubing.
2. Wrap wet rag around thermal expansion valve (Figure 1, Item 2), distribution tube (Figure 1, Item 5), and
capillary tube (Figure 1, Item 4), to prevent damage from overheating.
0100-2
TM 11-6115-742-13&P 0100
REPLACEMENT- Continued
3. Braze TEV at brazing points (see Figure 2). If necessary refer to (WP 0110) of this TM for brazing
procedures.
4. Run sensing bulb (Figure 1, Item 3) to suction line of evaporator coil clamping into place as required with
clamps removed earlier.
NOTE
Sensing bulb must be insulated to avoid thermal contamination from ambient air.
5. Install insulation (Figure 1, Item 1) onto sensing bulb (Figure 1, Item 3) and surrounding pipes.
6. Remove wet rag from around TEV (Figure 1, Item 2).
7. Replace filter/dryer as described in (WP 0102).
8. Leak test as described in (WP 0111) of this TM.
9. Charge system with 8.4 lbs. (3.18 Kg) of R-407c refrigerant as described in (WP 0113) of this TM.
10. Replace access panel.
11. Perform adjustment procedure as described below.
0100-3
TM 11-6115-742-13&P 0100
BRAZING
POINT
BRAZING
POINT 2
6 BRAZING
POINT
Figure 1. TEV Removal/Replacement.
END OF TASK
0100-4
TM 11-6115-742-13&P 0100
THERMAL EXPANSION VALVE SUPERHEAT ADJUSTMENT
ADJUSTMENT
NOTE
Return (ambient) air must be above 70°F (21.11°C).
1. Verify that all access panels on ECU are properly installed.
2. Attach red gauge/line to LIQUID HIGH PRESSURE and blue gauge/line to SUCTION LOW PRESSURE.
3. Verify that all duct work or covers are properly installed.
4. Place thermocouple wire near expansion sensing bulb (Figure 1, Item 3) (near discharge of the evaporator
coil) and secure into place with tape.
5. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
6. Set MODE SELECT to COOL and adjust TEMPERATURE to 70°F (21.11°C) and allow unit to stabilize
(approx. 30 min)
NOTE
R-407c has glide. Low pressure gauge will modulate, use mean pressure
reading.
7. Read low pressure gauge and convert gauge pressure to temperature using dew point column on refrigerant
chart for R-407c.
8. Subtract dew point temperature from the thermocouple temperature. The resulting temperature difference is
the super heat value. The resultant (the super heat value) should be between 7 and 12.
9. If resultant is NOT between 7 and 12:
a) Remove cap (Figure 1, Item 6) from end of TEV (Figure 1, Item 2).
b) Hold nut on TEV with 7/8" wrench.
c) If below 7, turn adjustment screw 1/2 turn clockwise.
d) Above 12, turn adjustment screw 1/2 turn counter-clockwise.
e) Allow system to stabilize (approx. 10 min.)
f) Recalculate superheat as described in steps 7 and 8.
0100-5
TM 11-6115-742-13&P 0100
ADJUSTMENT - Continued
10. Replace cap (Figure 1, Item 6) on TEV (Figure 1, Item 2) and remove thermocouple wire.
11. Disconnect red gauge/line from LIQUID HIGH PRESSURE and blue gauge/line from SUCTION LOW
PRESSURE and replace caps.
12. Replace access panel.
13. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
END OF TASK
0100-6
TM 11-6115-742-13&P 0100
QUENCH VALVE REMOVAL/REPLACEMENT
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
Death or severe damage may result if personnel fail to observe safety
precautions. Use great care to avoid contact with liquid refrigerant or refrigerant
gas being discharged under pressure. Sudden and irreversible tissue damage
can result from freezing. Wear thermal protective gloves and a face protector or
goggles in any situation where skin/eye contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly toxic and corrosive gas.
CAUTION
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
The filter/drier removes moisture and debris and stops contaminants from
clogging expansion valve. The filter must be replaced anytime there is a major
component malfunction or the integrity of the system will be severely
compromised.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access panel from ECU and set aside.
0100-7
TM 11-6115-742-13&P 0100
REMOVAL - Continued
3. Remove insulation (Figure 2, Item 4) from quench valve (Figure 2, Item 1), sensing bulb (Figure 2, Item 3),
and surrounding pipes to safely allow brazing.
4. Recover refrigerant as described in (WP 0113) of this TM.
5. Un-braze quench valve (Figure 2, Item 1) at brazing points (see Figure 2). If necessary refer to (WP 0110) of
this TM for brazing procedures.
6. Remove and retain any copper hose clamps securing distribution tube (Figure 2, Item 2) and sensing bulb
(Figure 2, Item 3) to surrounding pipes.
7. Remove quench valve (Figure 2, Item 1) distribution tube (Figure 2, Item 2) and sensing bulb (Figure 2,
Item 3).
END OF TASK
REPLACEMENT
CAUTION
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
If necessary, refer to (WP 0027) for troubleshooting, (Figure FO-5) for
refrigeration schematic, and (Figure FO-1 through FO-4) for electrical schematics
and wiring diagrams.
1. Install quench valve (Figure 2, Item 1).
2. Wrap wet rag around quench valve (Figure 2, Item 1), distribution tube (Figure 2, Item 2), and sensing bulb
(Figure 2, Item 3) to prevent damage from overheating.
3. Braze quench valve (Figure 2, Item 1) into place. If necessary refer to (WP 0110) of this TM for brazing
procedures.
4. Run distribution tube (Figure 2, Item 2) and sensing bulb (Figure 2, Item 3) to suction line of evaporator coil
clamping into place as required.
5. Install insulation (Figure 2, Item 4) onto sensing bulb (Figure 2, Item 3) and surrounding pipes.
6. Remove wet rag from around quench valve (Figure 2, Item 1).
7. Replace filter/dryer as described in (WP 0102).
8. Leak test as described in (WP 0111) of this TM.
0100-8
TM 11-6115-742-13&P 0100
REPLACEMENT – Continued
9. Charge system with 8.4 lbs. (3.18 Kg) of R-407c refrigerant as described in (WP 0113) of this TM.
10. Replace access panel.
11. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
BRAZING
POINT
BRAZING
POINT
4 3
Figure 2. Quench Valve Removal/Replacement.
END OF TASK
0100-9
TM 11-6115-742-13&P 0100
HOT GAS BY-PASS VALVE REMOVAL/REPLACEMENT/ADJUSTMENT
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
Death or severe damage may result if personnel fail to observe safety
precautions. Use great care to avoid contact with liquid refrigerant or refrigerant
gas being discharged under pressure. Sudden and irreversible tissue damage
can result from freezing. Wear thermal protective gloves and a face protector or
goggles in any situation where skin/eye contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly toxic and corrosive gas.
CAUTION
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
The filter/drier removes moisture and debris and stops contaminants from
clogging expansion valve. The filter must be replaced anytime there is a major
component malfunction or the integrity of the system will be severely
compromised.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access panel from ECU and set aside.
0100-10
TM 11-6115-742-13&P 0100
REMOVAL – Continued
3. Remove insulation (Figure 3, Item 3) from hot gas by-pass valve (Figure 3, Item 1), and surrounding pipes to
safely allow brazing.
4. Recover refrigerant as described in (WP 0113) of this TM.
5. Un-braze hot gas by-pass valve (Figure 3, Item 1) at brazing points (see Figure 3). If necessary refer to
(WP 0110) of this TM for brazing procedures.
6. Remove hot gas by-pass valve (Figure 3, Item 1).
END OF TASK
REPLACEMENT
CAUTION
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
If necessary, refer to (WP 0027) for troubleshooting, (Figure FO-5) for
refrigeration schematic and (Figure FO-1 through FO-4) for electrical schematics
and wiring diagrams.
1. Install hot gas by-pass valve (Figure 3, Item 1).
2. Braze hot gas by-pass (Figure 3, Item 1) into place. If necessary refer to (WP 0110) of this TM for brazing
procedures.
3. Install insulation (Figure 3, Item 3) onto hot gas by-pass valve (Figure 3, Item 1) and surrounding pipes.
4. Replace filter/dryer as described in (WP 0102).
5. Leak test as described in (WP 0111) of this TM.
6. Charge system with 8.4 lbs. (3.18 Kg) of R-407c refrigerant as described in (WP 0113) of this TM.
7. Replace access panel.
8. Perform adjustment procedure as described below.
0100-11
TM 11-6115-742-13&P 0100
1
BRAZING
POINT
BRAZING
POINTS
Figure 3. Hot Gas By-Pass Valve Removal/Replacement.
END OF TASK
0100-12
TM 11-6115-742-13&P 0100
ADJUSTMENT
1. Verify that all access panels on ECU are properly installed.
2. Attach red gauge/line to LIQUID HIGH PRESSURE and blue gauge/line to SUCTION LOW PRESSURE.
3. Verify that all duct work or covers are properly installed.
4. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
NOTE
Once the following step has been completed, an audible whistle should be
coming from the hot-gas by-pass valve.
5. Set MODE SELECT to COOL and adjust TEMPERATURE to maximum setting (110°F) (43.33°C) Lo
Pressure gauge should read 55 psig. If Lo pressure gauge does not read 55 psig:
a) Remove cap (Figure 3, Item 2) from hot-gas by-pass valve
b) If Lo pressure gauge reading is ABOVE 55 psig adjust screw 1/2 turn counter-clockwise.
c) If Lo pressure gauge reading is BELOW 55 psig adjust screw 1/2 turn clockwise.
d) Allow system to stabilize (apporx. 10 minutes) and read low pressure gauge. If necessary repeat until
Lo pressure gauge reads 55 psig.
6. Replace cap (Figure 3, Item 2) on hot gas by-pass valve (Figure 3, Item 1).
7. Adjust TEMPERATURE to 72°F (22.22°C). If setting is below return air temperature, solenoid valve will close
and audible whistle will stop, head pressure and suction pressure will increase.
8. Disconnect red gauge/line from LIQUID HIGH PRESSURE and blue gauge/line from SUCTION LOW
PRESSURE and replace caps.
END OF TASK
0100-13
TM 11-6115-742-13&P 0100
HIGH PRESSURE RELIEF VALVE REMOVAL/REPLACEMENT
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
Death or severe damage may result if personnel fail to observe safety
precautions. Use great care to avoid contact with liquid refrigerant or refrigerant
gas being discharged under pressure. Sudden and irreversible tissue damage
can result from freezing. Wear thermal protective gloves and a face protector or
goggles in any situation where skin/eye contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly toxic and corrosive gas.
CAUTION
The filter/drier removes moisture and debris and stops contaminants from
clogging expansion valve. The filter must be replaced anytime there is a major
component malfunction or the integrity of the system will be severely
compromised.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access panel from ECU and set aside.
3. Recover refrigerant as described in (WP 0113) of this TM.
4. Remove any insulation from high pressure relief valve (Figure 4, Item 1). to allow removal.
5. Unscrew high pressure relief valve (Figure 4, Item 1) from plumbing joint (Figure 4, Item 2).
END OF TASK
0100-14
TM 11-6115-742-13&P 0100
REPLACEMENT
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
If necessary, refer to (WP 0027) for troubleshooting, (Figure FO-5) for
refrigeration schematic and (Figure FO-1 through FO-4) for electrical schematics
and wiring diagrams.
1. Coat threaded joint with refrigerant grade loc-tite.
2. Install high pressure relief valve (Figure 4, Item 1) into threaded plumbing joint (Figure 4, Item 2) and tighten.
3. Install any insulation removed to install high pressure relief valve (Figure 4, Item 1).
4. Replace filter/dryer as described in (WP 0102).
5. Leak test as described in (WP 0111) of this TM.
6. Charge system with 8.4 lbs. (3.18 Kg) of R-407c refrigerant as described in (WP 0113) of this TM.
7. Replace access panel.
8. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0100-15
TM 11-6115-742-13&P 0100
Figure 4. High Pressure Relief Valve Removal/Replacement.
END OF TASK
0100-16
TM 11-6115-742-13&P 0100
SOLENOID VALVE REMOVAL/REPLACEMENT
WARNING
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
Death or severe damage may result if personnel fail to observe safety
precautions. Use great care to avoid contact with liquid refrigerant or refrigerant
gas being discharged under pressure. Sudden and irreversible tissue damage
can result from freezing. Wear thermal protective gloves and a face protector or
goggles in any situation where skin/eye contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly toxic and corrosive gas.
CAUTION
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
The filter/drier removes moisture and debris and stops contaminants from
clogging expansion valve. The filter must be replaced anytime there is a major
component malfunction or the integrity of the system will be severely
compromised.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access panel from ECU and set aside.
0100-17
TM 11-6115-742-13&P 0100
REMOVAL – Continued
3. Recover refrigerant as described in (WP 0113) of this TM.
4. Remove any insulation (Figure 5, Item 2) from solenoid valve (Figure 5, Item 1), and surrounding pipes to
allow brazing.
5. Remove and retain four bolts that secure ECU control panel to frame.
CAUTION
When performing the following step, be observant of wires, cables and
thermostat sense line being fed into the ECU control panel. Do not damage,
equipment or components.
6. Remove ECU control panel and lay face down out of the way.
7. Remove power head (Figure 5, Item 3) from solenoid valve (Figure 5, Item 1).
8. Un-braze solenoid valve (Figure 5, Item 1) at brazing points (see Figure 5). If necessary refer to (WP 0110)
of this TM for brazing procedures.
9. Mark and remove wires (33J and 42B) from power head (Figure 5, Item 3).
END OF TASK
REPLACEMENT
CAUTION
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
If necessary, refer to (WP 0027) for troubleshooting, (Figure FO-5) for
refrigeration schematic and (Figure FO-1 through FO-4) for electrical schematics
and wiring diagrams.
1. Connect wires (33J and 42B) to power head (Figure 5, Item 3).
2. Install solenoid valve (Figure 5, Item 1) and braze into place. If necessary refer to (WP 0110) of this TM for
brazing procedures.
3. Install ECU control panel and secure with four bolts.
4. Replace filter/dryer as described in (WP 0102).
5. Leak test as described in (WP 0111) of this TM.
0100-18
TM 11-6115-742-13&P 0100
REPLACEMENT - Continued
6. Charge system with 8.4 lbs. (3.18 Kg) of R-407c refrigerant as described in (WP 0113) of this TM.
7. Install power head (Figure 5, Item 3) onto solenoid valve (Figure 5, Item 1).
8. Install any insulation onto solenoid valve (Figure 5, Item 2), and surrounding pipes.
9. Replace access panel.
10. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
1
BRAZING
POINT
BRAZING
POINT
Figure 5. Solenoid Valve Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0100-19/20 blank
TM 11-6115-742-13&P 0101
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU AIR FILTER
AIR FILTER CLEANING/REMOVAL/REPLACEMENT
INITIAL SETUP:
Personnel Required Equipment Condition
One ECU shut down
References
WP 0005
GENERAL
This work package provides information on the inspection, cleaning, removal and replacement of the ECU air
filter.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the ECU.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
NOTE
Removal of the access panels during operations will prevent the ECU from
properly conditioning the air.
0101-1
TM 11-6115-742-13&P 0101
REMOVAL
1. Verify that ECU (Figure 1, Item 1) has been shut down in accordance with ECU Shut Down Procedure
(WP 0005).
2. Unlatch and remove forward and rear access panels (Figure 1, Items 2 and 4) from ECU.
3. Slide both ECU air filters (Figure 1, Item 3) out of holders.
4. Inspect air filters (Figure 1, Item 3) for cleanliness and general physical condition.
5. If dirty, clean with warm water and allow air filters (Figure 1, Item 3) to dry.
END OF TASK
REPLACEMENT
1. Slide both ECU air filters (Figure 1, Item 3) into holders inside of enclosure access panels.
2. Replace rear access panel (Figure 1, Item 2) and forward access panel (Figure 1, Item 2) to ECU and secure
with latches.
3. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0101-2
TM 11-6115-742-13&P 0101
4 3
Figure 1. ECU Air Filter Locations.
END OF TASK
END OF WORK PACKAGE
0101-3/4 blank
TM 11-6115-742-13&P 0102
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU – FILTER/DRIER
FILTER/DRIER REMOVAL/REPLACEMENT
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0110,
Refrigeration service tool kit (WP 0165, Item 3) WP 0111, WP 0113
Safety glasses/face shield
Gloves, rubber (WP 0168, Item 24) Equipment Condition
ECU Shut Down
Materials/Parts CB1 on Genset Control Panel - Off
Filter/drier ECU Power cable disconnected
from J1 on Genset
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of the filter/drier on the ECU used in the
TMSS-MED.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, components may be extremely cold or extremely
hot. To prevent serious injury to personnel, allow sufficient time for components
to warm up/cool down before performing procedures.
AC voltage (208 VAC, 3Ø), (28 VAC), and DC voltage (+28 VDC), and current
sufficient to cause serious injury or death are present. Before starting this task,
ensure all power is de-energized and disconnected from shelter. Failure to
comply with this warning could result in electrical shock or death to the
individual.
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
0102-1
TM 11-6115-742-13&P 0102
REFRIGERANT UNDER PRESSURE
Death or severe injury may result if you fail to observe safety precautions. Never
use a heating torch on any part of the system that contains refrigerant. Do not
let liquid refrigerant touch you, and do not inhale refrigerant gas.
Death or severe damage may result if personnel fail to observe safety
precautions. Use great care to avoid contact with liquid refrigerant or refrigerant
gas being discharged under pressure. Sudden and irreversible tissue damage
can result from freezing. Wear thermal protective gloves and a face protector or
goggles in any situation where skin/eye contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly toxic and corrosive gas.
WARNING
If ECU has been in operation, components may be extremely cold or extremely
hot. To prevent serious injury to personnel, allow sufficient time for components
to warm up/cool down before performing procedures.
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
Death or severe damage may result if personnel fail to observe safety
precautions. Use great care to avoid contact with liquid refrigerant or refrigerant
gas being discharged under pressure. Sudden and irreversible tissue damage
can result from freezing. Wear thermal protective gloves and a face protector or
goggles in any situation where skin/eye contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly toxic and corrosive gas.
CAUTION
The filter/drier removes moisture and debris and stops contaminants from
clogging expansion valve. The filter/dryer must be replaced anytime a non-
electronic HVAC component is replaced.
NOTE
If necessary, refer to (WP 0027) for troubleshooting, (Figure FO-5) for
refrigeration schematic and (Figure FO-1 through FO-4) for electrical schematics
and wiring diagrams.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
0102-2
TM 11-6115-742-13&P 0102
REMOVAL- Continued
2. Remove access panel from ECU and set aside.
3. Remove insulation (Figure 1, Item 1) from filter/drier (Figure 1, Item 2) and surrounding pipes to safely allow
brazing.
4. Recover refrigerant as described in (WP 0113) of this TM.
5. Un-braze filter/drier (Figure 1, Item 2) at mounting joints (Figure 1, Item 3) as described in (WP 0110) of this
TM and remove filter/drier (Figure 1, Item 2).
END OF TASK
REPLACEMENT
WARNING
The following procedures require the use of open flame (brazing). Be observant
of all components surrounding area being brazed. Do not damage, equipment
or components. Only properly trained personnel should attempt to perform
brazing procedures.
NOTE
A technician certified to perform such duties in accordance with EPA restrictions
must perform refrigeration system repairs. Performing repairs without proper
certification may be a violation of public law and subject to severe penalties.
1. Install filter/drier (Figure 1, Item 2) and braze mounting joints (Figure 1, Item 3) as described in (WP 0110) of
this TM.
2. Leak test as described in (WP 0111) of this TM.
3. Charge system with 8.4 lbs. (3.18 Kg) of R-407c refrigerant as described in (WP 0113) of this TM.
4. Install insulation (Figure 1, Item 1) onto filter/drier (Figure 1, Item 2) and surrounding pipes.
5. Replace access panel.
6. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0102-3
TM 11-6115-742-13&P 0102
1
1
Figure 1. Filter/Drier Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0102-4
TM 11-6115-743-13&P 0103
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU CONTROL PANEL DOOR
ECU CONTROL PANEL DOOR – LIGHTS SWITCHES AND METER REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, FO-1 through FO-5
Multimeter (WP 0165, Item 2)
Safety glasses Equipment Condition
ECU Shut Down
Materials/Parts CB1 on Genset Control Panel - Off
Hour Meter ECU Power cable disconnected
Light sockets from J1 on Genset
MODE SELECT switch
Switch
Thermostatic switch
Strap ties (WP 0168, Items 55 to 57)
Silicone sealant (RTV) (WP 0168, Item 51)
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of components on the ECU control
panel. They consist of:
• POWER ON light
• OUT OF PHASE light
• Hour Meter
• MODE SELECT Switch
• AUX Heat Switch
• Thermostat Assembly
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the ECU.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
0103-1
TM 11-6115-742-13&P 0103
WARNING
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
NOTE
If necessary, refer to (WP 0027) for troubleshooting and (Figures FO-1 through
FO-5) for schematics/wiring diagrams.
POWER ON and OUT OF PHASE LIGHTS
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access cover and open ECU control panel door.
3. Turn lens cap (Figure 1, Item 9) counter clockwise to release and remove. Set aside.
4. Label each wire attached to lampholder (Figure 1, Item 5).
5. Loosen lock screws (Figure 1, Item 4) and remove wires from lampholder (Figure 1, Item 5).
6. Using flat tip screw driver press in on lampholder latch (Figure 1, Item 3) to release lampholder (Figure 1,
Item 5) from panel socket (Figure 1, Item 8).
7. If replacing panel socket (Figure 1, Item 8) and panel socket fastener (Figure 1, Item 6), use a flat tip screw
driver to pry panel socket fastener (Figure 1, Item 6) from control panel door (Figure 1, Item 7) and remove.
END OF TASK
REPLACEMENT
1. If replacing panel socket (Figure 1, Item 8) and panel socket fastener (Figure 1, Item 6), insert panel socket
(Figure 1, Item 8) into control panel door (Figure 1, Item 7) and snap panel socket fastener (Figure 1, Item 6)
onto end.
2. Position lampholder (Figure 1, Item 5) so that numbering on back is right side up.
3. Press lampholder (Figure 1, Item 5) into panel socket (Figure 1, Item 8) until it snaps into place.
NOTE
If necessary refer to (Figures FO-1 through FO-5) for schematic/wiring diagram
of ECU.
0103-2
TM 11-6115-743-13&P 0103
REPLACEMENT – Continued
4. Connect wires to lampholder (Figure 1, Item 5) using lock screws (Figure 1, Item 4).
5. Install lens cap (Figure 1, Item 9). Ensure grooves and studs align and press cap in.
6. Turn lens cap (Figure 1, Item 9) clockwise to lock.
7. Close ECU control panel door and install access cover.
8. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
END OF TASK
HOUR METER
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access cover and open ECU control panel door.
3. Mark and disconnect wires from hour meter (Figure 1, Item 13).
4. Remove and retain two screws (Figure 1, Item 14), lock washers (Figure 1, Item 21) and nuts (Figure 1,
Item 22) that secure hour meter (Figure 1, Item 13) to control panel (Figure 1, Item 7).
5. Remove hour meter (Figure 1, Item 13) from ECU control panel door (Figure 1, Item 7).
END OF TASK
REPLACEMENT
1. Insert hour meter (Figure 1, Item 13) into ECU control panel door (Figure 1, Item 7).
2. Secure to control panel door (Figure 1, Item 7) using two screws (Figure 1, Item 14), lock washers (Figure 1,
Item 21) and nuts (Figure 1, Item 22).
NOTE
If necessary refer to (Figures FO-1 through FO-5) for schematic/wiring diagram
of ECU.
3. Connect wires to hour meter (Figure 1, Item 13).
4. Close ECU control panel door and install access cover.
5. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
END OF TASK
0103-3
TM 11-6115-742-13&P 0103
ECU CONTROL PANEL DOOR – MODE SELECT SWITCH REMOVAL/REPLACEMENT
REMOVAL
NOTE
If necessary refer to (WP 0030) for test of the MODE SELECT switch.
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access cover and open ECU control panel door.
3. Mark and disconnect wires from mode select switch (Figure 1, Item 1).
4. Loosen set screw (Figure 1, Item 12) and remove knob (Figure 1, Item 11) from mode select switch (Figure 1,
Item 1).
5. Remove and retain nut (Figure 1, Item 10) from front of mode select switch (Figure 1, Item 1).
6. Remove mode select switch (Figure 1, Item 1) and washer (Figure 1, Item 2) from ECU control panel
(Figure 1, Item 7).
END OF TASK
REPLACEMENT
1. Insert mode select switch (Figure 1, Item 1) and washer (Figure 1, Item 2) onto ECU control panel (Figure 1,
Item 7) and loosely install nut (Figure 1, Item 10).
NOTE
If necessary refer to (Figures FO-1 through FO-5) for schematic/wiring diagram
of ECU.
2. Secure wires to appropriate terminals on mode select switch (Figure 1, Item 1).
3. Properly position mode select switch (Figure 1, Item 1) onto ECU control panel (Figure 1, Item 7) and tighten
nut (Figure 1, Item 10).
0103-4
TM 11-6115-743-13&P 0103
REPLACEMENT – Continued
4. Properly position knob (Figure 1, Item 11) onto mode select switch (Figure 1, Item 1). Tighten set screw
(Figure 1, Item 12).
5. Close ECU control panel door and install access cover.
6. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
END OF TASK
0103-5
TM 11-6115-742-13&P 0103
ECU CONTROL PANEL DOOR – AUXILIARY HEAT SWITCH TEST/REMOVAL/REPLACEMENT
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access cover and open ECU control panel door.
3. Ensure wires from auxiliary heat switches (Figure 1, Items 18 and 19) are properly marked.
4. Loosen lock screws (Figure 1, Item 20) and remove wiring.
5. Using flat tip screw driver press latch to release switch (Figure 1, Item 18 or 19) from bracket (Figure 1,
Item 17).
6. If replacing auxiliary heat switch socket (Figure 1, Item 15) and panel socket fastener (Figure 1, Item 16), use
a flat tip screw driver to pry panel socket fastener (Figure 1, Item 16) from control panel door (Figure 1,
Item 7) and remove.
END OF TASK
REPLACEMENT
1. Insert auxiliary heat switch socket (Figure 1, Item 15) into ECU control panel (Figure 1, Item 7) and secure
using panel socket fastener (Figure 1, Item 16).
2. Ensure bracket (Figure 1, Item 17) is properly positioned.
3. Position auxiliary heat switches (Figure 1, Items 18 and 19) so that numbering on back is right side up.
4. Press auxiliary heat switches (Figure 1, Items 18 and 19) into bracket (Figure 1, Item 17) until they snap into
place.
NOTE
If necessary refer to (Figures FO-1 through FO-5) for schematic/wiring diagram
of ECU.
5. Connect wires to auxiliary heat switches (Figure 1, Items 18 and 19) using lock screws (Figure 1, Item 20).
0103-6
TM 11-6115-743-13&P 0103
REPLACEMENT - Continued
6. Close ECU control panel door (Figure 1, Item 18) and install access cover (Figure 1, Item 1).
7. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
4
5
3
7
2
22 8
21 9
10
11
20
19
18 13
12
17
16 14
15
Figure 1. ECU Control Panel Faceplate Fluids and components Removal/Replacement.
END OF TASK
0103-7
TM 11-6115-742-13&P 0103
ECU CONTROL PANEL – THERMOSTAT TEST/REMOVAL/REPLACEMENT
REMOVAL
NOTE
If necessary refer to (WP 0030) for test of the thermostat.
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access cover and open ECU control panel door.
3. Remove and retain screw (Figure 2, Item 1) and cover (Figure 2, Item 2) from thermostat assembly
(Figure 2, Item 4).
4. Verify that all electrical wires (Figure 2, Item 11) connected to thermostat (Figure 2, Item 4) are properly
identified.
5. Remove and retain four terminal screws (Figure 2, Item 3) from thermostat (Figure 2, Item 4) and disconnect
electrical wires (Figure 2, Item 11). Loosely install terminal screws (Figure 2, Item 3) back onto thermostat
(Figure 2, Item 4).
6. Remove and retain ground terminal screw (Figure 2, Item 8) from thermostat (Figure 2, Item 4) and
disconnect ground wire (Figure 2, Item 9). Loosely install ground terminal screw (Figure 2, Item 8) back into
thermostat (Figure 2, Item 4).
7. Remove and retain four screws (Figure 2, Item 7) and washers (Figure 2, Item 6) that secure thermostat
(Figure 2, Item 4) to control panel (Figure 2, Item 5).
8. Remove door seal from bottom right corner of control panel.
9. Follow sensor wire (Figure 2, Item 10) along control panel (Figure 2, Item 5) to feed through. Remove rubber
grommet protecting sensor wire (Figure 2, Item 10). Slide sensor wire (Figure 2, Item 10) out of control panel
(Figure 2, Item 5).
0103-8
TM 11-6115-743-13&P 0103
REMOVAL – Continued
10. Follow sensor wire (Figure 2, Item 10) through ECU, removing all strap ties and silicon sealant where
applicable.
11. Carefully pull sensor wire (Figure 2, Item 10) through all ECU openings back to thermostat (Figure 2, Item 4)
and remove thermostat (Figure 2, Item 4) and sensor wire (Figure 2, Item 10) from control panel (Figure 2,
Item 5).
END OF TASK
REPLACEMENT
1. Install thermostat (Figure 2, Item 4) and sensor wire (Figure 2, Item 10) into control panel (Figure 2, Item 5)
and secure using four screws (Figure 2, Item 7) and washers (Figure 2, Item 6).
2. If necessary, straighten out sensor wire (Figure 2, Item 10) and begin feeding through control panel (Figure 2,
Item 5) and associated ECU feed throughs.
3. Install rubber grommet and door seal to bottom right corner of control panel.
4. Continue feeding sensor wire (Figure 2, Item 10) through ECU around evaporator chamber and blower
chamber following same path sensor wire (Figure 2, Item 10) took when being removed.
5. Once sensor wire (Figure 2, Item 10) has been installed, wrap any remaining sensor wire (Figure 2, Item 10)
around itself to temporarily secure in place.
WARNING
Adhesives, solvents and sealing compounds can burn easily, give off harmful
vapors and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well ventilated area. If adhesive, solvent or sealing
compound gets in contact with skin or clothing wash immediately with soap and
water.
6. Where applicable strap tie sensor wire (Figure 2, Item 10) and apply silicone sealant to openings.
NOTE
If necessary refer to (Figures FO-1 through FO-5) for schematic/wiring diagram
of ECU.
7. Connect electrical wires (Figure 2, Item 11) to thermostat (Figure 2, Item 4) using four terminal screws
(Figure 2, Item 3).
8. Connect ground wire (Figure 2, Item 9) to thermostat (Figure 2, Item 4) using ground terminal screw (Figure 2,
Item 8).
9. Mount cover (Figure 2, Item 2) onto thermostat assembly (Figure 2, Item 4) and secure with screw (Figure 2,
Item 1).
10. Close ECU control panel door and install access cover.
11. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0103-9
TM 11-6115-742-13&P 0103
4
5
60
3
6
7
9
1 10
Figure 2. ECU Thermostat Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0103-10
TM 11-6115-742-13&P 0104
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU CONTROL PANEL – CIRCUIT BREAKERS
ECU CONTROL PANEL (DOOR) COMPONENTS REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0030,
Multimeter (WP 0165, Item 2) FO-1 through FO-5
Safety glasses
Equipment Condition
Materials/Parts ECU Shut Down
Circuit breaker(s) CB1 on Genset Control Panel - Off
ECU Power cable
Personnel Required disconnected from J1 on Genset
One
GENERAL
This work package provides information on the removal and replacement of components on the ECU control
panel. They consist of:
• Circuit breaker (CB1)
• Circuit breaker (CB2)
• Circuit breaker (CB3)
• Circuit breaker (CB4) (Version 2)
• Circuit breaker (CB5) (Version 2)
WARNING
AC voltage (120 VAC), DC voltage (+28 VDC), and current sufficient to cause
serious injury or death are present at the PDP. Before starting this task, ensure
all power is de-energized and disconnected from shelter. Failure to comply with
this warning could result in electrical shock or death to the individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
To avoid electrical shock and damage to equipment, ensure circuit breaker(s)
are set to OFF and power cable is disconnected at power source before
removing or replacing any cables.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0104-1
TM 11-6115-742-13&P 0104
NOTE
The following procedures apply to all circuit breakers listed in the beginning of
this WP. Where applicable differences between Version 1 and Version 2 control
panels will be noted.
If necessary, refer to (WP 0027) for troubleshooting and )Figures FO-1 through
FO-5) for schematics/wiring diagrams.
REMOVAL
NOTE
If necessary refer to (WP 0030) for test of the circuit breakers.
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access cover and open ECU control panel door.
3. Verify that all electrical wires (Figure 1, Item 7) connected to circuit breaker (Figure 1, Item 3) being replaced
are properly identified.
4. Loosen but do not remove terminal screws (Figure 1, Item 6) securing electrical wires (Figure 1, Item 7) to
circuit breaker (Figure 1, Item 3). Remove electrical wires (Figure 1, Item 7) from circuit breaker(s) (Figure 1,
Item 3).
5. Remove and retain four screws (Figure 1, Item 1) that secure hold down clamp (Figure 1, Item 8) to control
panel (Figure 1, Item 4) remove hold down clamp (Figure 1, Item 8).
6. Pull out grey hold down tabs (Figure 1, Item 2) located on top and bottom of circuit breaker (Figure 1, Item 3)
and pull circuit breaker (Figure 1, Item 3) away from mounting bracket (Figure 1, Item 5).
END OF TASK
REPLACEMENT
1. Pull out grey hold down tabs (Figure 1, Item 2) located on top and bottom of circuit breaker (Figure 1, Item 3).
2. Insert circuit breaker (Figure 1, Item 3) onto mounting bracket (Figure 1, Item 5) and close grey hold down
tabs (Figure 1, Item 2).
NOTE
If necessary refer to (Figures FO-1 through FO-5) for schematic/wiring diagram
of ECU.
3. Loosen but do not remove terminal screws (Figure 1, Item 6). Insert electrical wires (Figure 1, Item 7) into
circuit breaker(s) (Figure 1, Item 3) and tighten terminal screws (Figure 1, Item 6).
0104-2
TM 11-6115-742-13&P 0104
REPLACEMENT – Continued
4. Install hold down clamp (Figure 1, Item 8) across circuit breakers (Figure 1, Item 3). Secure to control panel
(Figure 1, Item 4) using four screws (Figure 1, Item 1).
5. Close ECU control panel door and install access cover.
6. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
NOTE
If necessary, refer to Figures (FO-1 through FO-5) for schematics/wiring
diagrams.
Table 1. Circuit Breaker Connections/Wire ID Numbers.
VERSION 1 VERSION 2
CIRCUIT CIRCUIT
AMPS INPUT OUTPUT AMPS INPUT OUTPUT
BREAKER BREAKER
CB1 5 Amp 32 34A CB1 5 Amp 32 34A
CB2 1.6 Amp 12D 30A CB2 1.6 Amp 12F 30A
13D 31A 13F 31A
14D 32A 14F 10
CB3 63 Amp 12C 21A CB3 32 Amp 12C 21A
13C 22A 13C 22A
14C 23A 14C 23A
CB4 32 Amp 12D 21B
13D 22B
14D 23B
CB5 32 Amp 12E 21C
13E 22C
14E 23C
0104-3
TM 11-6115-742-13&P 0104
TX1 CB1 CB2 CB3 PSR TD
L1 L2 L3 L1 L2 L3
12 14 11 12 14 11
BR TB PDB-2 PDB-1
S3S4
EMSP EMSP CCR CHT GB
SIEMENS SIEMENS
5
3
8 6
Figure 1. Circuit Breaker Removal/Replacement (Version 1).
0104-4
TM 11-6115-742-13&P 0104
TX1 CB1 CB2 CB3 CB4 CB5
BR TB PSR TD PDB-1
S3S4
L1 L2 L3 L1 L2 L3
12 14 11 12 14 11
CHT CHT
EMSP EMSP CCR LOW HIGH GB
SIEMENS SIEMENS SIEMENS
3 5
8 6
Figure 2. Circuit Breaker Removal/Replacement (Version 2).
END OF TASK
END OF WORK PACKAGE
0104-5/6 blank
TM 11-6115-743-13&P 0105
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU CONTROL PANEL – CONTACTORS
ECU CONTROL PANEL CONTACTORS TEST/REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0030,
Multimeter (WP 0165, Item 2) FO-1 through FO-5
Safety glasses
Equipment Condition
Materials/Parts ECU Shut Down
Contactors CB1 on Genset Control Panel - Off
ECU Power cable disconnected
Personnel Required from J1 on Genset
One
GENERAL
This work package provides information on the removal and replacement of components on the ECU control
panel. They consist of:
• Heater contactor (CHT) (Version 1)
• Heater contactor low (CHT LOW) (Version 2)
• Heater contactor high (CHT HI) (Version 2)
• Compressor contactor (CCR)
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
ensure cage bolts are not inserted and wheels are chocked. Injury to personnel
could result from trailer suddenly rolling or tipping.
AC voltage (120 VAC), DC voltage (+28 VDC), and current sufficient to cause
serious injury or death are present at the PDP. Before starting this task, ensure
all power is de-energized and disconnected from shelter. Failure to comply with
this warning could result in electrical shock or death to the individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
To avoid electrical shock and damage to equipment, ensure circuit breaker(s)
are set to OFF and power cable is disconnected at power source before
removing or replacing any cables.
0105-1
TM 11-6115-743-13&P 0105
WARNING
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
NOTE
The following procedures apply to all contactors listed in the beginning of this
WP. Where applicable differences between Version 1 and Version 2 control
panels will be noted.
If necessary, refer to (WP 0027) for troubleshooting and (Figures FO-1 through
FO-5) for schematics/wiring diagrams.
REMOVAL
NOTE
If necessary refer to (WP 0030) for test of the contactors.
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access cover and open ECU control panel door.
3. Verify that all electrical wires (Figure 1, Item 5) connected to contactor being replaced are properly identified.
4. Loosen but do not remove terminal screws (Figure 1, Item 6) securing all electrical wires (Figure 1, Item 5) to
contactor (Figure 1, Item 1) being replaced. Remove electrical wires (Figure 1, Item 5) from contactor
(Figure 1, Item 1).
5. Remove and retain four screws (Figure 1, Item 4) that secure bracket (Figure 1, Item 2) to control panel
(Figure 1, Item 3).
6. Remove contactor (Figure 1, Item 1) from control panel (Figure 1, Item 3).
END OF TASK
REPLACEMENT
1. Install contactor (Figure 1, Item 1) onto control panel (Figure 1, Item 3).
2. Secure bracket (Figure 1, Item 2) to control panel (Figure 1, Item 3) with four screws (Figure 1, Item 4).
3. Inspect all electrical wires (Figure 1, Item 5) being connected. Ensure no physical damage is present. If
necessary, repair or replace.
NOTE
If necessary refer to (Figures FO-1 through FO-5) for schematic/wiring diagram
of ECU.
4. Loosen but do not remove terminal screws (Figure 1, Item 6) on contactor (Figure 1, Item 1). Install all
electrical wires (Figure 1, Item 5) and tighten terminal screws (Figure 1, Item 6).
0105-2
TM 11-6115-743-13&P 0105
REPLACEMENT – Continued
5. Close ECU control panel door and install access cover
6. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
4
6
5 4
Figure 1. Contactor Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0105-3/4 blank
TM 11-6115-743-13&P 0106
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU CONTROL PANEL – RELAYS
ECU CONTROL PANEL RELAYS REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0030,
Multimeter (WP 0165, Item 2) FO-1 through FO-5
Safety glasses
Materials/Parts Equipment Condition
Relay ECU Shut Down
CB1 on Genset Control Panel - Off
Personnel Required ECU Power cable
One disconnected from J1 on Genset
GENERAL
This work package provides information on the removal and replacement of components on the ECU control
panel. They consist of:
• Phase sense relay (PSR)
• Time Delay Relay (TD)
WARNING
AC voltage (120 VAC), DC voltage (+28 VDC), and current sufficient to cause
serious injury or death are present at the PDP. Before starting this task, ensure
all power is de-energized and disconnected from shelter. Failure to comply with
this warning could result in electrical shock or death to the individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
To avoid electrical shock and damage to equipment, ensure circuit breaker(s)
are set to OFF and power cable is disconnected at power source before
removing or replacing any cables.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0106-1
TM 11-6115-742-13&P 0106
NOTE
The following procedures apply to all relays listed in the beginning of this WP.
Where applicable differences between Version 1 and Version 2 control panels
will be noted.
REMOVAL
NOTE
If necessary refer to (WP 0030) for test of the relays.
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access cover and open ECU control panel door.
3. Verify that all electrical wires (Figure 1, Item 4) connected to relay being replaced are properly identified.
4. Loosen but do not remove terminal screws (Figure 1, Item 5) securing electrical wires (Figure 1, Item 4) to
relay (Figure 1, Item 2). Remove electrical wires (Figure 1, Item 4) from relay (Figure 1, Item 2).
5. Remove and retain two screws (Figure 1, Item 1) that secure relay (Figure 1, Item 2) to control panel
(Figure 1, Item 3) and remove relay (Figure 1, Item 2).
END OF TASK
REPLACEMENT
1. Install relay (Figure 1, Item 2) onto control panel (Figure 1, Item 3) and secure using two screws (Figure 1,
Item 1).
2. Inspect all electrical wires (Figure 1, Item 4) being connected. Ensure no physical damage is present. If
necessary, repair or replace.
NOTE
If necessary refer to (Figures FO-1 through FO-5) for schematic/wiring diagram
of ECU.
3. Loosen but do not remove terminal screws (Figure 1, Item 5) on relay (Figure 1, Item 2). Install all electrical
wires (Figure 1, Item 4) and tighten terminal screws (Figure 1, Item 5).
.
0106-2
TM 11-6115-743-13&P 0106
REPLACEMENT – Continued
4. Close ECU control panel door and install access cover.
5. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
TX1 CB1 CB2 CB3 PSR TD TX1 CB1 CB2 CB3 CB4 CB5
L1 L2 L3 L1 L2 L3
12 14 11 12 14 11
BR TB PDB-2 PDB-1
BR TB PSR TD PDB-1
S3S4 S3S4
L1 L2 L3 L1 L2 L3
12 14 11 12 14 11
CHT CHT
EMSP EMSP CCR CHT GB EMSP EMSP CCR LOW HIGH GB
SIEMENS SIEMENS SIEMENS SIEMENS SIEMENS
Figure 1. Relay Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0106-3/4 blank
TM 11-6115-743-13&P 0107
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU CONTROL PANEL – TRANSFORMER AND BRIDGE RECTIFIER
ECU CONTROL PANEL TRANSFORMER REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0030,
Multimeter (WP 0165, Item 2) Figure FO-1 through FO-5
Safety glasses
Equipment Condition
Materials/Parts ECU Shut Down
Transformer CB1 on Genset Control Panel - Off
Bridge Rectifier ECU Power cable disconnected
Personnel Required from J1 on Genset
One
GENERAL
This work package provides information on the removal and replacement of components on the ECU control
panel. They consist of:
• Transformer, step-down (TX1)
• Bridge rectifier (BR)
WARNING
AC voltage (120 VAC), DC voltage (+28 VDC), and current sufficient to cause
serious injury or death are present at the PDP. Before starting this task, ensure
all power is de-energized and disconnected from shelter. Failure to comply with
this warning could result in electrical shock or death to the individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
To avoid electrical shock and damage to equipment, ensure circuit breaker(s)
are set to OFF and power cable is disconnected at power source before
removing or replacing any cables.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0107-1
TM 11-6115-742-13&P 0107
NOTE
The following procedures apply to all relays listed in the beginning of this WP.
Where applicable differences between Version 1 and Version 2 control panels
will be noted.
If necessary, refer to (WP 0027) for troubleshooting and (Figures FO-1 through
FO-5) for schematics/wiring diagrams.
REMOVAL
NOTE
If necessary refer to (WP 0030) for test of the transformer.
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure, (WP 0005), CB1 on
Genset is shut down and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access cover and open ECU control panel door.
3. Verify that all electrical wires (Figure 1, Item 1) connected to transformer (Figure 1, Item 4) are properly
identified.
4. Remove and retain terminal screws (Figure 1, Item 5) securing electrical wires (Figure 1, Item 1) to
transformer (Figure 1, Item 4). Remove electrical wires (Figure 1, Item 1) away from transformer (Figure 1,
Item 4).
5. Remove and retain four screws (Figure 1, Item 3) that secure transformer (Figure 1, Item 4) to control panel
(Figure 1, Item 2).
6. Remove transformer (Figure 1, Item 4) and set aside.
END OF TASK
REPLACEMENT
1. Install transformer (Figure 1, Item 4) onto control panel (Figure 1, Item 2) and secure using four screws
(Figure 1, Item 3).
2. Inspect all electrical wires (Figure 1, Item 1) being connected. Ensure no physical damage is present. If
necessary, repair or replace.
NOTE
If necessary refer to (Figures FO-1 through FO-5) for schematic/wiring diagram
of ECU.
0107-2
TM 11-6115-743-13&P 0107
REPLACEMENT – Continued
3. Remove terminal screws (Figure 1, Item 5) from transformer (Figure 1, Item 4). Connect all electrical wires
(Figure 1, Item 1) and install terminal screws (Figure 1, Item 5).
4. Close ECU control panel door and install access cover.
5. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
Figure 1. Transformer Removal/Replacement.
END OF TASK
0107-3
TM 11-6115-742-13&P 0107
ECU CONTROL PANEL BRIDGE RECTIFIER REMOVAL/REPLACEMENT
REMOVAL
NOTE
If necessary refer to (WP 0030) for test of the bridge rectifier.
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access cover and open ECU control panel door.
3. Verify that all electrical wires (Figure 2, Item 5) connected to bridge rectifier (Figure 2, Item 1) are properly
identified.
4. Disconnect electrical wires (Figure 2, Item 5) from bridge rectifier (Figure 2, Item 1).
5. Remove and retain screw (Figure 2, Item 4) and flat washer (Figure 2, Item 3) that secure bridge rectifier
(Figure 2, Item 1) to control panel (Figure 2, Item 2) and remove bridge rectifier (Figure 2, Item 1).
END OF TASK
REPLACEMENT
1. Install bridge rectifier (Figure 2, Item 1) onto control panel (Figure 2, Item 2) and secure using screw
(Figure 2, Item 4) and flat washer (Figure 2, Item 3).
2. Inspect all electrical wires (Figure 2, Item 5) being connected. Ensure no physical damage is present. If
necessary, repair or replace.
NOTE
If necessary refer to (Figures FO-1 through FO-5) for schematic/wiring diagram
of ECU.
3. Connect all electrical wires (Figure 2, Item 5) to appropriate terminals on bridge rectifier (Figure 2, Item 1).
0107-4
TM 11-6115-743-13&P 0107
REPLACEMENT - Continued
4. Close ECU control panel door and install access cover.
5. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
Figure 2. Bridge Rectifier Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0107-5/6 blank
TM 11-6115-743-13&P 0108
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU CONTROL PANEL – STARTER PROTECTORS
ECU CONTROL PANEL CMSP/EMSP REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
Electronic equipment tool kit (WP 0165, Item 4) WP 0005, WP 0030,
Multimeter (WP 0165, Item 2) FO-1 through FO-5
Safety glasses
Equipment Condition
Materials/Parts CB1 on Genset Control Panel - Off
CMSP/EMSP ECU Power cable disconnected
from J1 on Genset
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of components on the ECU control
panel. They consist of:
• Evaporator Motor Starter Protector (EMSP)
• Compressor Motor Starter Protector (CMSP)
WARNING
AC voltage (120 VAC), DC voltage (+28 VDC), and current sufficient to cause
serious injury or death are present at the PDP. Before starting this task, ensure
all power is de-energized and disconnected from shelter. Failure to comply with
this warning could result in electrical shock or death to the individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
If a circuit breaker does not stay in ON position when energized, DO NOT
attempt to energize repeatedly. That could create an overload situation
hazardous to personnel and equipment. Instead, investigate and identify cause
of problem. Correct situation before attempting to energize breaker again.
To avoid electrical shock and damage to equipment, ensure circuit breaker(s)
are set to OFF and power cable is disconnected at power source before
removing or replacing any cables.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0108-1
TM 11-6115-742-13&P 0108
NOTE
The following procedures apply to all relays listed in the beginning of this WP.
Where applicable differences between Version 1 and Version 2 control panels
will be noted.
If necessary, refer to (WP 0027) for troubleshooting and (Figures FO-1 through
FO-5) for schematics/wiring diagrams.
REMOVAL
NOTE
If necessary refer to (WP 0030) for test of the CMSP/EMSP.
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down and, that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access cover and open ECU control panel door.
3. Verify that all electrical wires (Figure 1, Item 4) connected to the CMSP/EMSP being replaced are properly
identified.
4. Loosen but do not remove terminal screws (Figure 1, Item 5) securing electrical wires (Figure 1, Item 4) to
CMSP/EMSP (Figure 1, Item 1). Remove electrical wires (Figure 1, Item 4) from CMSP/EMSP (Figure 1,
Item 1).
5. Remove and retain four screws (Figure 1, Item 3) that secure CMSP/EMSP (Figure 1, Item 1) to control panel
(Figure 1, Item 2) remove CMSP/EMSP (Figure 1, Item 1).
END OF TASK
REPLACEMENT
1. Install CMSP/EMSP (Figure 1, Item 1) onto control panel (Figure 1, Item 2) and secure using four screws
(Figure 1, Item 3).
2. Inspect all electrical wires (Figure 1, Item 4) being connected. Ensure no physical damage is present. If
necessary, repair or replace.
NOTE
If necessary refer to (Figures FO-1 through FO-5) for schematic/wiring diagram
of ECU.
3. Loosen but do not remove terminal screws (Figure 1, Item 5) on CMSP/EMSP (Figure 1, Item 1). Install all
electrical wires (Figure 1, Item 4) and tighten terminal screws (Figure 1, Item 5).
0108-2
TM 11-6115-743-13&P 0108
REPLACEMENT – Continued
4. Close ECU control panel door and install access cover.
5. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
1 2 1 2
3 3
5 5
4 3 4 3
Figure 1. CMSP/EMSP Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0108-3/4 blank
TM 11-6115-742-13&P 0109
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU REMOVAL/REPLACEMENT
ECU REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic's tool kit Two
(WP 0165, Item 1)
Lifting device References
Sling WP 0005
Drip pan
Rubber gloves Equipment Condition
Safety glasses ECU shut down
Materials/Parts
Lumber (4 in x 4 in x 4 ft.) – (4 ea)
(10.16 cm x 10.16 cm x 1.21 m)
GENERAL
This work package provides information on the removal and replacement of the ECU used in the TMSS-MED.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the ECU.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
The ECU for the TMSS-MED weighs 520 lbs. (235.86 kg). Use only a
mechanical left to move equipment. Do not attempt to lift, carry, or move the
ECU without a mechanical lift. Failure to observe this warning can result in
serious injury or death to personnel.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
Wear appropriate eye protection when performing maintenance. Metal pieces,
fluids, dirt, grease, corrosion, and escaping vapors and gasses present. Failure
to comply may result in injury to personnel.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
0109-1
TM 11-6115-742-13&P 0109
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
HEAVY EQUIPMENT
The ECU weighs 520 lbs. Use only a mechanical lift to move equipment. Do not
attempt to lift, carry, or move the ECU without a mechanical lift. Failure to
observe this warning can result in serious injury or death to personnel.
Prior to removing the ECU, verify that the TMSS-MED trailer is on level ground
and trailer wheels are chocked. Failure to do so can result in serious injury and
equipment damage from unplanned rollout of the ECU.
Once the ECU is removed, do not allow unit to hang from lifting device. Place on
level ground until ready to replace. Failure to observe this warning can result in
serious injury or death to personnel or damage to ECU.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
NOTE
Removal of the access panels during operations will prevent the ECU from
properly conditioning the air.
REMOVAL
1. Prior to performing the following steps ensure that:
• ECU is shut down in accordance with ECU Shut Down Procedure (WP 0005).
• ECU is at ambient temperature.
• Duct work is disconnected and duct covers are installed on ECU.
• Genset is shut down in accordance with Genset Shut Down Procedure (WP 0005).
• Trailer is level.
• Wheels are chocked.
• Ample room to perform the following procedure is present.
• Area immediately around ECU is free and clear of items.
(i.e., Storage bags, grounding, etc.).
0109-2
TM 11-6115-742-13&P 0109
REMOVAL – Continued
2. Disconnect the ECU power cable (Figure 1, Item 5) from the J1 connector on the Genset or from a shore
power supply.
3. Unlatch and remove rear access panel and set aside.
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
4. Loosen hose clamp (Figure 1, Item 2) and disconnect fuel line (Figure 1, Item 3) from fuel filter (Figure 1,
Items 1). Guide fuel line (Figure 1, Item 3) down through ECU and place in spill bucket and allow excess fuel
to drain.
5. Install rear access panel.
6. Loosen two hose clamps (Figure 1, Item 9) (located on underside of ECU) and remove two drip valves
(Figure 1, Item 10).
WARNING
HEAVY EQUIPMENT
The ECU weighs 520 lbs. Use only a mechanical lift to move equipment. Do not
attempt to lift, carry, or move the ECU without a mechanical lift. Failure to
observe this warning can result in serious injury or death to personnel.
7. Using a suitable lifting device, attach chain/sling to the four lifting eyes (Figure 1, Item 4) on the ECU. Raise
the lift only far enough to place tension (no slack) on the chain.
8. Remove and retain four bolts (Figure 1, Item 8), lock washers (Figure 1, Item 6), and flat washers (Figure 1,
Item 7) from underside of ECU.
NOTE
When performing the following step, ensure that area where ECU is to be placed
is dry and level. Ensure that supports allow adequate room below ECU for
drainage of ECU and so that no items on bottom of ECU become damaged.
9. Place supports (i.e., 4x4 treated lumber) along ground for ECU to be placed on once removed from trailer.
CAUTION
When performing the following step, guides should be observant of ECU to
ensure no pieces from ECU and/or trailer get caught while lifting is in process.
When performing the following step, guides should be observant of ECU to
ensure supports are properly placed and that nothing on ECU gets damaged
when placing ECU onto supports.
10. Using appropriately trained personnel, lift ECU off of trailer base and place on supports. Once ECU is safely
lowered, remove chain/sling.
END OF TASK
0109-3
TM 11-6115-742-13&P 0109
REPLACEMENT
WARNING
HEAVY EQUIPMENT
The ECU weighs 520 lbs. Use only a mechanical lift to move equipment. Do not
attempt to lift, carry, or move the ECU without a mechanical lift. Failure to
observe this warning can result in serious injury or death to personnel.
1. Using a suitable lifting device, attach chain/sling to the four lifting eyes (Figure 1, Item 4) on the ECU. Raise
the lift only far enough to place tension (no slack) on the chain.
CAUTION
When performing the following step, guides should be observant of ECU to
ensure safety of personnel and that no pieces from ECU and/or trailer get
caught/damaged while lifting is in process.
NOTE
When performing the following step:
• Ensure that ECU is properly orientated for placement on trailer (evaporator
panel should be on same side of trailer as control panel(s) of Genset).
• Lower ECU close enough to trailer to allow slight movement for alignment
of hardware during installation.
• Be aware of all items on underside of ECU (i.e., drain, feed throughs, etc.).
• Inspect fuel lines for leaks or other damage.
2. Using appropriately trained personnel, lift ECU off of ground and place on trailer. Do not disconnect from
chains/sling until directed to do so.
3. Install four bolts (Figure 1, Item 8), lock washers (Figure 1, Item 6), and flat washers (Figure 1, Item 7)
through trailer frame and to underside of ECU. Hand tighten bolts at this time.
4. Finish lowering ECU onto trailer. Tighten all bolts previously installed. Remove chain/sling.
5. Install two drip valves (Figure 1, Item 10) (located on underside of ECU) and secure with hose clamps
(Figure 1, Item 9).
6. Unlatch and remove rear access panel and set aside.
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of TMSS-MED.
7. Feed fuel line (Figure 1, Item 3) through bottom of ECU and connect to fuel filter (Figure 1, Item 1) and secure
using hose clamp (Figure 1, Item 2).
0109-4
TM 11-6115-742-13&P 0109
REPLACEMENT – Continued
8. Install rear access panel.
9. Connect the ECU power cable (Figure 1, Item 5) to J1 on the Genset or to shore power.
10. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
11. Start ECU in accordance with ECU Start Procedure (WP 0005) of this TM.
0109-5
TM 11-6115-742-13&P 0109
TO HYDRONIC
HEATER
1
4 2
3
TO FUEL
4
TANK
6
9 7
10 8
Figure 1. ECU Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0109-6
TM 11-6115-742-13&P 0110
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU – PURGING AND BRAZING
PURGING AND BRAZING
INITIAL SETUP:
Tools and Special Tools Reference
General mechanics tool kit (WP 0165, Item 1) WP 0005
Refrigeration service tool kit (WP 0165, Item 3)
Nitrogen pressure regulator (WP 0165, Item 6) Equipment Condition
Gloves, rubber (WP 0168, Item 24) ECU Shut Down
Safety glasses/face shield CB1 on Genset Control Panel - Off
ECU Power cable disconnected
Materials/Parts from J1 on Genset
Nitrogen (WP 0168, Item 40)
Brazing alloy, solder – QQ-S-57 (WP 0168, Item 7 or 8)
Brazing flux, soldering (WP 0168, Item 22)
Cleaning cloth (WP 0168, Item 14)
Abrasive cloth (WP 0168, Item 12)
Personnel Required
One
GENERAL
This work package provides information on purging and brazing. The refrigeration system must be purged with
dry nitrogen before brazing is performed on any component or tubing. A flow of dry nitrogen, at a rate less than
1-2 cfm (0.028-0.057 m3/minute), must be continued during all brazing operations to minimize internal oxidation
and scaling of fluids and components or tubing. Brazing is required when removing/replacing plumbing
components and associated piping inside of the ECU.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
AC voltage (208 VAC, 3Ø), (28 VAC), and DC voltage (+28 VDC), and current
sufficient to cause serious injury or death are present. Before starting this task,
ensure all power is de-energized and disconnected from the ECU. Failure to
comply with this warning could result in electrical shock or death to the
individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
0110-1
TM 11-6115-742-13&P 0110
WARNING
The following procedures require the use of open flame (brazing). Be observant
of all fluids and components surrounding area being brazed. Do not damage,
equipment or fluids and components. Only properly trained personnel should
attempt to perform brazing procedures.
Brazing alloys and flux contain materials that are hazardous to health. Avoid
breathing vapors or fumes from brazing operations. Perform operations only in
well ventilated areas. Wash hands with soap and water after handling brazing
alloys and flux. Wear gloves and protective goggles or face shield to protect
against burns.
Never use a heating torch on any part that contains refrigerant. Heat may cause
the refrigerant to decompose and release irritating, toxic, and corrosive gases.
All refrigerant must be removed and recovered from the system and the entire
system must be purged with dry nitrogen before beginning any brazing
operation.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
CAUTION
The following procedures require the use of open flame (brazing). Be observant
of all fluids and components surrounding area being brazed. Do not damage,
equipment or fluids and components. Only properly trained personnel should
attempt to perform brazing procedures.
Cylinders are pressurized containers. The pressure in the cylinder can exceed
2000 psi. A nitrogen pressure regulator should be used at all times when
nitrogen is used for leak check or purge operations. Nitrogen is an inert gas.
However, it also presents danger as a suffocant and, therefore, must be
discharged in a ventilated location.
If heat is applied slowly, or only on one side of a connection, the entire
component or length of connecting tubing will become heated and filler alloy in
adjacent joints may melt.
NOTE
It may be easier to access a component by cutting or debrazing the copper lines
in accessible areas and removing part of the interconnecting tubing with the
component.
If necessary, refer to (WP 0027) for troubleshooting, (Figure FO-5) for
refrigeration schematic and (Figure FO-1 through FO-4) for electrical schematics
and wiring diagrams.
0110-2
TM 11-6115-742-13&P 0110
NOTE
All tubing in the refrigeration system is seamless copper with a bright internal
finish that permits thorough cleaning and prevents entrapment of moisture or
other impurities. Rigid grade copper is used for straight sections and soft grade
for sections that must be bent. All interconnecting fittings, such as elbows, tees,
etc., are also copper. The bodies of valves and connections on other fluids and
components are brass. Joints, except for those with flare fittings, are brazed in
accordance with the American Welding Society (AWS) C3.4, Specification for
Torch Brazing, except that radiographic examination is not required.
The refrigeration system must be purged with dry nitrogen before brazing is
performed on any component or tubing. A flow of dry nitrogen, at a rate less than
1-2 cfm (0.028-0.057 m3/minute), must be continued during all brazing
operations to minimize internal oxidation and scaling of fluids and components or
tubing.
SYSTEM PURGING
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access cover(s).
3. Attach red gauge/line to LIQUID HIGH PRESSURE and blue gauge/line to SUCTION LOW PRESSURE.
4. Disconnect refrigerant hose (yellow) from gauge manifold and allow to hang open to ambient air.
5. Open valves to both gauges.
6. Observe gauges. Once both gauges read 0 psig, close valves, disconnect red gauge/line from LIQUID HIGH
PRESSURE and blue gauge/line from SUCTION LOW PRESSURE.
7. Re-connect all refrigerant hoses to gauge manifold.
8. Replace covers on LIQUID HIGH PRESSURE and SUCTION LOW PRESSURE ports on ECU.
9. Proceed to brazing procedures as described in this WP.
END OF TASK
0110-3
TM 11-6115-742-13&P 0110
DEBRAZING
1. Protect wiring harnesses and other electronic fluids and components with appropriate heat shields, heat
sinks.
NOTE
It may be easier to access a component by cutting or debrazing the copper lines
in accessible areas and removing part of the interconnecting tubing with the
component.
2. If debrazing a joint on a valve, disassemble the valve to the fullest extent possible and wrap all but the joint
with a wet rag to act as a heat sink.
WARNING
Never use a heating torch on any part that contains refrigerant. Heat may cause
the refrigerant to decompose and release irritating, toxic, and corrosive gases.
All refrigerant must be removed and recovered from the system and the entire
system must be purged with dry nitrogen before beginning any brazing operation.
CAUTION
If heat is applied slowly, or only on one side of a connection, the entire
component or length of connecting tubing will become heated and filler alloy in
adjacent joints may melt.
3. Check that the system is being purged and apply sufficient heat uniformly around the joint to quickly melt the
filler alloy. Remove heat as soon as the joint is separated.
a. All filler alloy must be cleaned from debrazed joints before reassembly.
b. Heat each piece of the joint until the filler alloy is melted and then wipe it away with a damp cloth. Be
sure no filler alloy or other debris is left inside any tubing, fitting or component. Use abrasive cloth as
necessary to clean joints.
END OF TASK
BRAZING
1. Protect wiring harnesses and other fluids and components with appropriate heat shields and heat sinks.
NOTE
Joints, except for those with flare fittings, are brazed using Grade IV or VI brazing
alloy (15% silver) and Type-B flux must be used for all copper to brass joints.
Grade III (45% silver) brazing alloy may be substituted for Grade IV or VI for
copper-to-copper joints; flux is not required for copper-to-copper joints.
2. If brazing a joint on a valve, disassemble the valve to the fullest extent possible and wrap all but the joint with
a wet rag to act as a heat sink.
NOTE
If interconnecting tubing was removed with a component, braze tubing to the new
fluids and components before installation.
3. Clean all internal and external areas to be brazed with abrasive cloth.
0110-4
TM 11-6115-742-13&P 0110
BRAZING – Continued
4. Apply flux to all internal and external areas to be brazed.
5. Position component(s) or assembly into place.
WARNING
Never use a heating torch on any part that contains refrigerant. Heat may cause
the refrigerant to decompose and release irritating, toxic, and corrosive gases.
All refrigerant must be removed and recovered from the system and the entire
system must be purged with dry nitrogen before beginning brazing operations.
CAUTION
If heat is applied slowly, or to one side of a connection, the entire component or
length of tubing will become heated and filler alloy in adjacent joints may melt.
Brazing a joint without nitrogen flow through the tubing will cause deposits to
form on the inside of the tube and may cause obstructions in the refrigeration
system or equipment damage.
6. Check that the system is being purged (see procedure in this WP) and apply sufficient heat uniformly around
the joint to quickly melt the filler alloy. Remove heat as soon as brazing is completed. Continue purging for at
least five (5) minutes or until the connection has cooled.
END OF TASK
END OF WORK PACKAGE
0110-5/6 blank
TM 11-6115-742-13&P 0111
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU – LEAK TESTING
LEAK TESTING
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit (WP 0165, Item 1) One
Refrigeration service tool kit (WP 0165, Item 3)
Nitrogen pressure regulator (WP 0165, Item 6) Reference
Refrigerant recovery/recycling unit (WP 0165, Item 7) WP 0110
Safety glasses/face shield
Gloves, rubber (WP 0168, Item 24) Equipment Condition
ECU Shut Down
Materials/Parts CB1 on Genset Control Panel - Off
Nitrogen (WP 0168, Item 40) ECU Power cable disconnected
Refrigerant (R407c) (WP 0168, Item 47) from J1 on Genset
GENERAL
This work package provides information on leak testing (using nitrogen). The ECU must be a closed, sealed,
system any leakage will inhibit the system and the ECU will not operate properly.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, components may be extremely cold or extremely
hot. To prevent serious injury to personnel, allow sufficient time for components
to warm up/cool down before performing procedures.
AC voltage (208 VAC, 3Ø), (28 VAC), and DC voltage (+28 VDC), and current
sufficient to cause serious injury or death are present. Before starting this task,
ensure all power is de-energized and disconnected from the ECU. Failure to
comply with this warning could result in electrical shock or death to the
individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Sudden and irreversible tissue damage can result from freezing. Wear gloves
and a face protector or safety glasses in any situation where skin or eye contact
with refrigerant is possible.
Heat may cause the refrigerant to decompose and release irritating, toxic, and
corrosive gases. Prevent contact of refrigerant with flame or hot surfaces.
Never introduce high discharge pressure into a refrigerant cylinder. This can
cause the cylinder to rupture and injure personnel.
0111-1
TM 11-6115-742-13&P 0111
CAUTION
Cylinders are pressurized containers. The pressure in the cylinder can exceed
2000 psi. A nitrogen pressure regulator should be used at all times when
nitrogen is used for leak check or purge operations. Nitrogen is an inert gas.
However, it also presents danger as a suffocant and, therefore, must be
discharged in a ventilated location.
NOTE
The electronic refrigerant gas leak detector is highly sensitive to the presence of
minute quantities of gas in the air, due to this fact it is quite effective in the
detection of small leaks. However, because of the rapid dispersion of refrigerant
gas into the surrounding air, difficulty may be encountered in pinpointing large
leaks. The detector must be used in a well ventilated but draft-free area.
ADDING NITROGEN HOLDING CHARGE
NOTE
Prior to beginning the following procedure, make sure all valves are closed.
1. Attach red gauge/line to LIQUID HIGH PRESSURE and blue gauge/line to SUCTION LOW PRESSURE.
2. Attach refrigerant hose (yellow) to refrigerant bottle.
3. With refrigerant recovery/recycling unit inverted (valve at the bottom) open the valve on the unit.
4. Open the high side valve (red) on the gauge manifold and add 15 psig of refrigerant to the system.
5. Once 15 psig of refrigerant has been added, close the valves on the refrigerant recovery/recycling unit and
the high side valve (red) on the gauge manifold.
6. Disconnect the refrigerant hose (yellow).
7. Set the nitrogen regulator to 400 psgi.
8. Connect the refrigerant hose (yellow) to the pressure regulator on the nitrogen tank.
9. Slowly open valves on nitrogen tank and high side valve (red) on the gauge manifold and slowly add nitrogen.
10. When gauge manifold reads 350 psig close high side valve (red) on gauge manifold then close valve on the
nitrogen regulator and check for leaks as described in this WP.
END OF TASK
0111-2
TM 11-6115-742-13&P 0111
LEAK TESTING
Using Electronic Refrigerant Leak Detector
1. Allow system to "stand idle" for 30 minutes.
2. Check pressure gauges for excessive drops in pressure.
NOTE
The electronic refrigerant gas leak detector is highly sensitive to the presence of
minute quantities of gas in the air, due to this fact it is quite effective in the
detection of small leaks. However, because of the rapid dispersion of refrigerant
gas into the surrounding air, difficulty may be encountered in pinpointing large
leaks. The detector must be used in a well ventilated but draft-free area.
3. If no excessive leaks are observed, check ECU components and joints with electronic refrigerant leak
detector.
4. If no excessive leaks are found with electronic refrigerant leak detector, purge system as described in
(WP 0110) of this TM.
5. If leaks are found, continue purging system and repair leaks and or replace parts as required. Once repairs
are completed, re-test for leaks.
END OF TASK
Using Soap Solution
1. Allow system to "stand idle" for 30 minutes.
2. Check pressure gauges for excessive drops in pressure.
If no excessive leaks are observed:
3. Mix a solution of liquid detergent and water.
4. Brush solution onto all possible leakage points
5. Observe for the formation of bubbles.
6. If no excessive leaks are found, purge system as described in (WP 0110) of this TM.
7. If leaks are found, repair leaks and or replace parts as required. Once repairs are completed, re-test for
leaks.
END OF TASK
END OF WORK PACKAGE
0111-3/4 blank
TM 11-6115-742-13&P 0112
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU – SYSTEM EVACUATION
SYSTEM EVACUATION
INITIAL SETUP:
Tools and Special Tools Reference
General mechanic’s tool kit (WP 0165, Item 1) WP 0005, WP 0102, WP 0111,
Refrigeration service tool kit (WP 0165, Item 3) WP 0113
Pump, vacuum (WP 0165, Item 8)
Equipment Condition
Materials/Parts ECU Shut Down
Hoses 1/2" ID CB1 on Genset Control Panel - Off
ECU Power cable disconnected
Personnel Required from J1 on Genset
One
GENERAL
This work package provides information on system evacuation (vacuuming). The ECU must be evacuated to
remove all moisture and air before it is charged. These procedures describe how to accomplish such tasks.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
AC voltage (208 VAC, 3Ø), (28 VAC), and DC voltage (+28 VDC), and current
sufficient to cause serious injury or death are present. Before starting this task,
ensure all power is de-energized and disconnected from the ECU. Failure to
comply with this warning could result in electrical shock or death to the
individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Sudden and irreversible tissue damage can result from freezing. Wear gloves
and a face protector or safety glasses in any situation where skin or eye contact
with refrigerant is possible.
Heat may cause the refrigerant to decompose and release irritating, toxic, and
corrosive gases. Prevent contact of refrigerant with flame or hot surfaces.
Never introduce high discharge pressure into a refrigerant cylinder. This can
cause the cylinder to rupture and injure personnel.
0112-1
TM 11-6115-742-13&P 0112
CAUTION
Cylinders are pressurized containers. The pressure in the cylinder can exceed
2000 psi. A nitrogen pressure regulator should be used at all times when nitrogen
is used for leak check or purge operations. Nitrogen is an inert gas. However, it
also presents danger as a suffocant and, therefore, must be discharged in a
ventilated location.
NOTE
The electronic refrigerant gas leak detector is highly sensitive to the presence of
minute quantities of gas in the air, due to this fact it is quite effective in the
detection of small leaks. However, because of the rapid dispersion of refrigerant
gas into the surrounding air, difficulty may be encountered in pinpointing large
leaks. The detector must be used in a well ventilated but draft-free area.
PREPERATION
NOTE
The following procedure may be accomplished from the LIQUID HIGH
PRESSURE and SUCTION LOW PRESSURE connections located on the
outside of the ECU. However, manufacturer recommends that this process be
accomplished from the internal ports.
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005), CB1 on
Genset is shut down, and that power cable has been disconnected from J1 of power distribution panel on
Genset.
2. Remove access cover(s).
3. Ensure that system refrigerant has been removed and recovered as described in (WP 0113).
4. Ensure that system has been leak tested as described in (WP 0111).
5. Ensure that new filter/dryer has been properly installed as described in (WP 0102).
SHOP METHOD
1. Connect valve core removal isolation valves to the high pressure port (located next to the evaporator/dryer)
inside the ECU (see Figure 1).
2. Connect valve core removal isolation valves to the low pressure port (located behind the evaporator/dryer)
inside the ECU (see Figure 1).
3. Connect vacuum hoses to the pump inlet (see Figure 1).
4. Connect micron gauge to vacuum pump.
5. Remove valve cores and close isolation valve.
0112-2
TM 11-6115-742-13&P 0112
MICRON
GAUGE
PUMP
120 VAC
FILTER/
DRYER
Figure 1. Evacuation Set-up (Shop Method).
FIELD METHOD
1. Connect high pressure hose (red) from gauges to high pressure port (located next to the evaporator/dryer)
inside the ECU (see Figure 2).
2. Connect low pressure hose (blue) from gauges to low pressure port (located behind to the evaporator/dryer)
inside the ECU (see Figure 2).
3. Connect micron gauge to vacuum pump.
4. Connect vacuum line (yellow) from gauges to micron gauge.
MICRON
GAUGE
(YELLOW)
(BLUE)
(LOW)
(RED) PUMP
(HIGH)
120 VAC
FILTER/
DRYER
Figure 2. Evacuation Set-up (Field Method).
0112-3
TM 11-6115-742-13&P 0112
PROCEDURE
1. Check level and quality of oil in the vacuum pump.
2. Start pump and open valve on the pump inlet.
3. Set micron gauge to ON. After micron gauge reads 500 or less for several minutes, open isolation valves and
reinstall service valve cores.
NOTE
While waiting for vacuum to complete, set up equipment for charging of system
with R-407c (see WP 0113).
4. Once vacuum process is complete, de-energize pump and micron gauge.
5. Remove low pressure hose (blue), high pressure hose (red) and vacuum line (yellow) and replace service
caps on the high pressure port (located next to the evaporator/dryer) and low pressure port (located behind
the evaporator/dryer) inside the ECU.
END OF TASK
END OF WORK PACKAGE
0112-4
TM 11-6115-742-13&P 0113
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU – SYSTEM CHARGING AND RECOVERY
REFIGERANT SYSTEM RECOVERY
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanics tool kit (WP 0165, Item 1) One
Refrigeration service tool kit (WP 0165, Item 3)
Refrigerant recovery/recycling unit (WP 0165, Item 7) Equipment Condition
Charging manifold (WP 0165, Item 9) ECU Shut Down
Charging cylinder (WP 0165, Item 10) CB1 on Genset Control Panel - Off
Rubber gloves (WP 0168, Item 24) Power cable disconnected
Safety glasses/face shield from J1 on Genset
Materials/Parts
Refrigerant (WP 0168, Item 47)
GENERAL
This work package provides information on system evacuation (vacuuming). The ECU must be evacuated to
remove all moisture and air before it is charged. These procedures describe how to accomplish such tasks.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, components may be extremely cold or extremely
hot. To prevent serious injury to personnel, allow sufficient time for components
to warm up/cool down before performing procedures.
AC voltage (208 VAC, 3Ø), (28 VAC), and DC voltage (+28 VDC), and current
sufficient to cause serious injury or death are present. Before starting this task,
ensure all power is de-energized and disconnected from the ECU. Failure to
comply with this warning could result in electrical shock or death to the
individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Sudden and irreversible tissue damage can result from freezing. Wear gloves
and a face protector or safety glasses in any situation where skin or eye contact
with refrigerant is possible.
Heat may cause the refrigerant to decompose and release irritating, toxic, and
corrosive gases. Prevent contact of refrigerant with flame or hot surfaces.
Never introduce high discharge pressure into a refrigerant cylinder. This can
cause the cylinder to rupture and injure personnel.
0113-1
TM 11-6115-742-13&P 0113
WARNING
Never introduce liquid refrigerant into the suction shut off valve. This can cause
damage to the compressor.
CAUTION
Cylinders are pressurized containers. The pressure in the cylinder can exceed
2000 psi. A nitrogen pressure regulator should be used at all times when
nitrogen is used for leak check or purge operations. Nitrogen is an inert gas.
However, it also presents danger as a suffocant and, therefore, must be
discharged in a ventilated location.
NOTE
The electronic refrigerant gas leak detector is highly sensitive to the presence of
minute quantities of gas in the air, due to this fact it is quite effective in the
detection of small leaks. However, because of the rapid dispersion of refrigerant
gas into the surrounding air, difficulty may be encountered in pinpointing large
leaks. The detector must be used in a well ventilated but draft-free area.
RECOVERY PROCEDURE
NOTE
Prior to beginning the following procedure, make sure all valves are closed. After
completing the procedure, perform a Confidence Check.
The refrigerant recovery/recycling unit should be fitted with a filter/dryer for
improved performance and preservation of the refrigerant.
When recovering refrigerant, never exceed 80% capacity of the recovery
cylinder. This will allow for expansion of refrigerant due to heat during storage
and/or transportation.
1. Connect red gauge/line to LIQUID HIGH PRESSURE and blue gauge/line to SUCTION LOW PRESSURE.
2. Connect refrigerant hose (yellow) to refrigerant recovery unit inlet (see Figure 1).
3. Connect refrigerant recovery unit to vapor valve (blue) on recovery cylinder (see Figure 1).
4. Open vapor valve (blue) on recovery cylinder.
5. Power on recovery unit.
6. Open outlet ball valve on the refrigerant recovery unit.
7. Open liquid valve (red) on service gauge.
8. On recovery unit, press compressor start switch.
9. Open inlet ball valve on recovery unit until gauges show 0 psig.
10. Once gauges read 0 psig, close all valves on recovery cylinder, service gauge, recovery unit.
11. Remove all hoses and return all equipment to its appropriate storage.
0113-2
TM 11-6115-742-13&P 0113
RED (HIGH) TO LIQUID
HIGH PRESSURE
BLUE (LOW) TO SUCTION
LOW PRESSURE
RECOVERY UNIT
YELLOW
(INLET)
(OUTLET)
RECOVERY
TANK FLOW
Figure 1. Refrigerant Recovery Layout.
END OF TASK
0113-3
TM 11-6115-742-13&P 0113
REFIGERANT SYSTEM CHARGING
PROCEDURE
WARNING
Never introduce liquid refrigerant into the suction shut off valve. This can cause
damage to the compressor.
Heat may cause the refrigerant to decompose and release irritating, toxic, and
corrosive gases. Prevent contact of refrigerant with flame or hot surfaces.
The system must be evacuated before charging. Moisture and air in the system
will prevent the refrigeration unit from operating properly.
NOTE
The refrigerant should be fitted with a filter/dryer for improved performance and
preservation of the refrigerant.
Prior to beginning the following procedure, make sure all valves are closed. After
completing the procedure, perform a Confidence Check.
Using Electronic Refrigerant Scale.
1. Connect refrigerant hose (red) from service gauges to input high pressure line (inside ECU, near filter/Dryer).
2. Connect refrigerant hose (blue) from service gauges to low pressure line (inside ECU, behind filter/Dryer).
3. Connect refrigerant hose (yellow) from service gauges to output on electronic refrigerant scale (see Figure 2).
4. Connect refrigerant hose from bottle of R-407c to input side of electronic refrigerant scale (see Figure 2).
5. Open valve on bottle of R-407c (valve at top).
6. Place electronic refrigerant scale on flat level surface and prepare scale for use.
7. Invert bottle of R-407c (valve at bottom) and place on electronic refrigerant scale.
8. Set electronic refrigerant scale for 8.4 pounds of refrigerant and start electronic refrigerant scale.
9. SLOWLY open hi pressure valve (red) on service gauges.
0113-4
TM 11-6115-742-13&P 0113
Using Electronic Refrigerant Scale – Continued
10. When electronic refrigerant scale closes and alarm sounds, close hi pressure valve (red) on service gauges.
11. Close valve on bottle of R-407c and remove bottle of R-407c from electronic refrigerant scale.
12. Disconnect refrigerant hose (yellow) from electronic refrigerant scale.
13. Disconnect refrigerant hose (red) from input high pressure line (inside ECU, near filter/Dryer) and replace cap.
14. Disconnect refrigerant hose (blue) from low pressure line (inside ECU, behind filter/Dryer) and replace cap.
R-407c
(HIGH) RED (INVERTED)
(LOW) BLUE
YELLOW
(OUTPUT) (INPUT)
REFRIGERANT
SCALE
FLOW
EVAPORATOR
DRYER
Figure 2. System Charging (Using Electronic Refrigerant Scale).
END OF TASK
Using Standard Scale
1. Connect refrigerant hose (red) from service gauges to input high pressure line (inside ECU, near filter/Dryer)
(see Figure 3).
2. Connect refrigerant hose (blue) from service gauges to low pressure line (inside ECU, behind filter/Dryer).
3. Place bottle of R-407c on scale noting starting weight of bottle of R-407c and calculate desired end weight for
desired charge.
4. Connect refrigerant hose (yellow) from service gauges to output bottle of R-407c (see Figure 3).
0113-5
TM 11-6115-742-13&P 0113
Using Standard Scale - Continued
5. Open valve on bottle of R-407c (valve at top).
6. Place scale on flat level surface.
7. Invert bottle of R-407c (valve at bottom) and place on scale.
8. SLOWLY open hi pressure valve (red) on service gauges and monitor weight of bottle on scale.
9. When scale reads desired calculated weight, close hi pressure valve (red) on service gauges.
10. Close valve on bottle of R-407c and remove bottle from scale.
11. Disconnect refrigerant hose (yellow) from bottle of R-407c.
12. Disconnect refrigerant hose (red) from input high pressure line (inside ECU, near filter/Dryer) and replace cap.
13. Disconnect refrigerant hose (blue) from low pressure line (inside ECU, behind filter/Dryer) and replace cap.
R-407c
(INVERTED)
(LOW) BLUE
(HIGH) RED
YELLOW
SCALE
FLOW
EVAPORATOR
DRYER
Figure 3. System Charging (Using Standard Scale).
END OF TASK
0113-6
TM 11-6115-742-13&P 0113
Confidence Check
1. Connect refrigerant hose (red) from service gauges to input high pressure line (inside ECU, near filter/Dryer).
2. Connect refrigerant hose (blue) from service gauges to low pressure line (inside ECU, behind filter/Dryer).
3. Turn on ECU (WP 0005) and allow system to stabilize for half an hour.
4. Verify that the HPC or LPC switch does not shut down the compressor.
NOTE
The HPC switch cutout is 500 PSIG +/- 3% and cutin (with manual reset button)
is 375 PSIG +/- 8%.
The LPC switch cutout is 25 PSIG +/- 3 % and cutin is 50 PSIG +/- 3%.
5. Verify that the ECU provides conditioned air.
6. Turn off ECU (WP 0005) and allow system components to cool before completing step 7.
7. Disconnect refrigerant hose (red) from input high pressure line (inside ECU, near filter/Dryer) and replace cap.
8. Disconnect refrigerant hose (blue) from low pressure line (inside ECU, behind filter/Dryer) and replace cap.
9. Return ECU to service.
END OF TASK
END OF WORK PACKAGE
0113-7/8 blank
TM 11-6115-742-13&P 0114
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
ECU – SUBCOOL SETTING
SUBCOOL CHECKING/ADJUSTING
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit (WP 0165, Item 1) One
Refrigeration service tool kit (WP 0165, Item 3)
Refrigerant recovery/recycling unit (WP 0165, Item 7) Reference
Charging cylinder (WP 0165, Item 10) WP 0005, WP 0113
Gloves, rubber (WP 0168, Item 24)
Safety glasses/face shield Equipment Condition
ECU Shut Down
Materials/Parts CB1 on Genset Control Panel - Off
Refrigerant (WP 0168, Item 47) Power cable disconnected
from J1 on Genset
GENERAL
This work package provides information on checking, setting and adjusting subcool. Subcool is the difference in
degrees between the saturation temperature of the refrigerant at its current pressure and the actual temperature
of the liquid. In other words, the refrigerant pressure remains constant while the temperature is lowered. The
number of degrees F below the condensation point is the amount of subcool.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
AC voltage (208 VAC, 3Ø), (28 VAC), and DC voltage (+28 VDC), and current
sufficient to cause serious injury or death are present. Before starting this task,
ensure all power is de-energized and disconnected from the ECU. Failure to
comply with this warning could result in electrical shock or death to the
individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Sudden and irreversible tissue damage can result from freezing. Wear gloves
and a face protector or safety glasses in any situation where skin or eye contact
with refrigerant is possible.
Heat may cause the refrigerant to decompose and release irritating, toxic, and
corrosive gases. Prevent contact of refrigerant with flame or hot surfaces.
0114-1
TM 11-6115-742-13&P 0114
WARNING
Never introduce high discharge pressure into a refrigerant cylinder. This can
cause the cylinder to rupture and injure personnel.
Never introduce liquid refrigerant into the suction shut off valve. This can cause
damage to the compressor.
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry
before working around TMSS-MED. Jewelry can catch on equipment and cause
injury or may short across an electrical circuit and cause severe burns or
electrical shock.
CAUTION
Cylinders are pressurized containers. The pressure in the cylinder can exceed
2000 psi. A nitrogen pressure regulator should be used at all times when
nitrogen is used for leak check or purge operations. Nitrogen is an inert gas.
However, it also presents danger as a suffocant and, therefore, must be
discharged in a ventilated location.
SET-UP
NOTE
Prior to beginning the following procedure, make sure ALL valves are closed.
The refrigerant recovery/recycling unit should be fitted with a filter/dryer for
improved performance and preservation of the refrigerant.
When recovering refrigerant, never exceed 80% capacity of the recovery
cylinder. This will allow for expansion of refrigerant due to heat during storage
and/or transportation.
Return air ambient temperature must be above 70°F to perform the following
procedure.
1. Place thermocouple wire near discharge side of condenser and tape as close to inlet side of filter/dryer as
possible.
2. Install all access panels to ensure no ambient temperatures may be introduced.
3. Verify that ductwork is connected. If ductwork is not available, cover ends to restrict return air flow.
4. Connect red line to LIQUID HIGH PRESSURE.
5. Connect blue line to SUCTION LOW PRESSURE.
6. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
7. Set MODE SELECT switch to COOL and adjust TEMPERATURE to 70°F.
END OF TASK
0114-2
TM 11-6115-742-13&P 0114
CHECKING
NOTE
R-407c has a glide, pressure on gauge will modulate, use mean pressure for
determining reading.
1. After allowing ECU to stabilize (approx. 30 minutes), read temperature on thermocouple and pressure on high
pressure gauge and record.
2. Using refrigerant chart for R-407c, convert reading from high pressure gauge to temperature.
3. Subtract thermocouple temperature from refrigerant chart for R-407c temperature (bubble point). The result
is the subcool value. (i.e., using R-407C. The liquid refrigerant temperature is 110°F. The refrigerant pressure
gauge reads 298 psig. From the Bubble Pressure in (Table 1), 298 psig converts to 120°F. Therefore, the
subcooling is: 120°F minus 110°F equals 10°F).
END OF TASK
ADJUSTING
NOTE
If subcool is not between 14 and 19 perform the following.
Refer to (WP 0113) for charging and recovery procedures.
1. If subcool is below 14:
a. Add four ounces of refrigerant to the low pressure service port.
b. After allowing ECU to stabilize (approx. 10 minutes), read temperature on thermocouple and pressure on
high pressure gauge and record.
c. Subtract thermocouple temperature from refrigerant chart for R-407c temperature (bubble point). The
result is the subcool value. (i.e., using R-407C. The liquid refrigerant temperature is 110°F. The
refrigerant pressure gauge reads 298 psig. From the Bubble Pressure in (Table 1), 298 psig converts to
120°F. Therefore, the subcooling is: 120°F minus 110°F equals 10°F).
d. If necessary repeat procedure until subcool is met.
2. If subcool is above 19:
a. Remove four ounces of refrigerant to the low pressure service port.
b. After allowing ECU to stabilize (approx. 10 minutes), read temperature on thermocouple and pressure on
high pressure gauge and record.
c. Subtract thermocouple temperature from refrigerant chart for R-407c temperature (bubble point). The
result is the subcool value. (i.e., using R-407C. The liquid refrigerant temperature is 110°F. The
refrigerant pressure gauge reads 298 psig. From the Bubble Pressure in (Table 1), 298 psig converts to
120°F. Therefore, the subcooling is: 120°F minus 110°F equals 10°F).
d. If necessary repeat procedure until subcool is met.
END OF TASK
0114-3
TM 11-6115-742-13&P 0114
Table 1. R407c Conversion Table.
R-407c
TEMPERATURE BUBBLE PRESSURE DEW PRERSSURE
°F °C (psig) (psig)
-60 -51.1 9.1 ("Hg Vac) 15.9 ("Hg Vac)
-55 -48.3 5.9 ("Hg Vac) 13.5 ("Hg Vac)
-50 -45.5 2.4 ("Hg Vac) 10.9 ("Hg Vac)
-45 -42.7 0.7 7.9 ("Hg Vac)
-40 -40 2.9 4.5 ("Hg Vac)
-35 -37.2 5.2 0.7 ("Hg Vac)
-30 -34.4 7.9 1.7
-25 -31.6 10.7 4.0
-20 -28.8 13.9 6.5
-15 -26.1 17.3 9.3
-10 -23.3 21.1 12.4
-5 -20.5 25.2 15.8
0 -17.7 29.6 19.5
5 -15 34.4 23.6
10 -12.2 39.6 28.0
15 -9.4 45.2 32.7
20 -6.6 51.3 37.9
25 -3.8 57.8 43.6
30 -1.1 64.7 49.6
35 1.6 72.2 55.2
40 4.4 80.2 63.2
45 7.2 88.7 70.7
50 10 97.6 78.8
55 12.7 107.5 87.5
60 15.5 117.7 96.8
65 18.3 128.7 105.7
70 21.1 140.2 117.2
75 23.8 152.5 128.4
80 26.6 165.5 140.4
85 29.4 179.2 153.1
90 32.2 193.6 166.5
95 35 208.8 180.8
100 37.7 224.9 195.8
105 40.5 241.8 211.8
110 43.3 259.6 228.7
115 46.1 278.2 246.5
120 48.8 297.8 265.3
125 51.6 318.3 285.2
130 54.4 339.9 306.1
135 57.2 362.4 328.2
140 60 386.0 351.4
145 62.7 410.7 375.9
150 65.5 436.5 401.7
END OF WORK PACKAGE
0114-4
TM 11-6115-742-13&P
CHAPTER 8
MAINTAINER MAINTENANCE INSTRUCTIONS
FOR
TMSS-MED
TRAILER & SHELTER
TM 11-6115-742-13&P 0115
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
SERVICE UPON RECEIPT – TRAILER & SHELTER
INITIAL SETUP:
Tools and Special Tools References
General mechanic's tool kit (WP 0165, Item 1) WP 0005, WP 0019, WP 0037,
WP 0039 – WP 0081
Personnel Required
Two to four
GENERAL
The following procedures are required to be performed by Maintainer level maintenance in order to prepare the
TMSS-MED trailer for use.
SITING
For minimal problems with set-up and operation of TMSS-MED and equipment being used insure area is:
• Dry.
• Level with adequate room for trailer, shelter, system grounding, and all other associated equipment.
• Free of items (trees, buildings, or other structures) that would impede set-up of TMSS-MED or cause
physical interference for trailer, shelter, system grounding, and all other associated equipment.
• Free of items (e.g., towers, power lines, radar, trees, buildings) that would cause interference with
electronic equipment being used inside of shelter.
SHELTER/TRAILER REQUIREMENTS
The TMSS-MED trailer requires dry, level, obstruction free area for operation. The trailer is designed to be towed
by a vehicle capable of pulling 4,200 lbs. It is capable of being connected to the towing vehicle’s electronics via a
standard MIL-type connector or a commercial vehicle connector. It also requires the towing vehicle to have
pneumatic brakes. The trailer requires an area of 15 ft 11 in L x 7 feet 1 inch W x 6 feet 6 in H
(4.85 m L x 2.16 m W x 1.97 m H). See (WP 0002) for full technical specifications.
The TMSS-MED shelter requires a footprint of 23 feet (7.01 meters) by 32 feet (9.75 meters). In addition, the
TMSS-MED trailer requires a foot print of 16 feet (4.85 meters) by 7 feet (2.16 meters) for set-up and installation.
SERVICE UPON RECEIPT
Once all covers are removed, inspect the trailer, shelter, and each piece of equipment for damage incurred during
shipment. Inspect all loose pieces of equipment located in the trailer cargo box. Inspect the trailer (including
under carriage) and its components (i.e. frame, electrical, brakes and associated lines and components) for
damage incurred during shipment. If any damage is visible, notify supervisor. Report the damage on DD Form
361, Transportation Discrepancy Report. Check the equipment against the packing slip to see if the shipment is
complete. Report all discrepancies in accordance with applicable service instructions.
INSTALLATION INSTRUCTIONS
The TMSS-MED trailer requires some assembly depending on the mode of operation. To setup the TMSS-MED
trailer in a fixed mode of operation, refer to Operation Under Usual Conditions (WP 0005) for setup and power-up
procedures.
0115-1
TM 11-6115-742-13&P 0115
PRELIMINARY SERVICING OF EQUIPMENT
WARNING
If trailer has been in operation, fluids and components may be extremely cold or
extremely hot. To prevent serious injury to personnel, allow sufficient time for
fluids and components to warm up/cool down before performing procedures.
AC voltage (208 VAC, 3Ø), (28 VAC), and DC voltage (+28 VDC), and current
sufficient to cause serious injury or death are present. Before starting this task,
ensure all power is de-energized and disconnected from the trailer. Failure to
comply with this warning could result in electrical shock or death to the individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
When working on the TMSS-MED, do not operate electric equipment if floors,
ceiling or walls of the individual enclosure show evidence of water intrusion.
Electrical shock can cause personnel injury or death.
Do not apply power if grounding is not connected. Electrical shock can cause
personnel injury or death.
The TMSS-MED trailer carries an expandable shelter. Care must be taken in the removal and replacement of this
equipment from the trailer to avoid damage. Maintainer PMCS for the TMSS-MED trailer is in (WP 0037). For
Maintainer level removal and replacement procedures of components and assemblies refer to (WP 0039 through
WP 0081).
Once the TMSS-MED has been placed into service, the following maintenance should be performed after the first
50 hours of operation.
• Change oil & filter
• Check tension on all belts
• Check coolant level
PRELIMINARY CHECK AND ADJUSTMENTS OF EQUIPMENT
Before placing the TMSS-MED trailer into service, ensure that all Crew PMCS (WP 0019) and Maintainer PMCS
(WP 0032 and WP0033) have been performed.
END OF WORK PACKAGE
0115-2
TM 11-6115-742-13&P 0116
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
PMCS INTRODUCTION – TRAILER & SHELTER
GENERAL
This work package provides data necessary to keep the TMSS-MED trailer operational ready. PMCS are
performed to keep the TMSS-MED trailer and shelter in operational condition. The checks are used to find,
correct, and report problems. Maintenance personnel are required to perform the tasks as indicated in Maintainer
PMCS (WP 0117, Table 1). PMCS are performed the Maintainer each time the equipment is operated. Prior to
performing maintenance that requires climbing on or under TMSS-MED trailer, ensure cage bolts are not inserted
and wheels are chocked. Injury to personnel could result from TMSS-MED trailer suddenly rolling or tipping.
Before you begin operating the TMSS-MED trailer and/or its equipment, do Before PMCS.
Once a week do Weekly PMCS. If TMSS-MED trailer has not been operated in a week, perform Before PMCS.
Do Monthly PMCS once a month. If TMSS-MED trailer has not been operated in a month, perform PMCS as
outlined in (WP 0117).
If you are operating the TMSS-MED trailer for the first time, perform Weekly and Monthly PMCS the first time you
do your Before PMCS.
If you find something wrong when performing PMCS, fix it if you can. Otherwise, notify your supervisor.
WARNINGS AND CAUTIONS
Special attention should be paid to the WARNINGS and CAUTIONS appearing in the Maintainer PMCS table. A
WARNING means someone could be injured. A CAUTION means equipment could be damaged.
LEAKAGE DEFINITION
It is necessary for you to know how fluid leakage affects the status of the trailer. The following are definitions of
the classes of leakage you need to know to be able to determine the status of the trailer. Learn these leakage
definitions when in doubt contact your supervisor.
CAUTION
Maintainers must perform appropriate maintenance when Operators report Class
III leaks. Failure to comply may result in damage to equipment.
NOTE
The following note applies to non-flammable liquids only. Any leakage of
flammable liquid is unacceptable.
Equipment operation is allowable with minor leakages (Class I or II).
Consideration must be given to fluid capacity of the item or system being
checked. When Maintainer is in doubt, notify your supervisor.
When operating with Class I or II leaks, continue to check fluid levels as required
in your PMCS.
0116-1
TM 11-6115-742-13&P 0116
LEAKAGE DEFINITION – Continued
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.
CLASS III - Leakage of fluid great enough to form drops that fall from the item being checked.
INSPECTION
Look for signs of a problem or trouble. Senses help here. You can feel, smell, hear, or see many problems. Be
alert when on the TMSS-MED trailer.
Inspect to see if components are in good condition. Are they correctly assembled, stowed, and secured, or
excessively worn, leaking, corroded, or damaged? Correct any problems found or notify your supervisor.
There are some common items to check all over the TMSS-MED trailer. These include the following:
1. Bolts, clamps, nuts, and screws: Continuously check for looseness. Look for chipped paint, rust, or corrosion
around bolt and screw heads and nuts. Tighten them when you find them loose. If tools are not available,
notify your supervisor.
2. Welds: Many items on the TMSS-MED trailer are welded. To check these welds, look for chipped paint, rust
corrosion, or gaps. When these conditions exist, Maintainer must notify their supervisor.
3. Electrical wires, connectors, and harnesses: Tighten loose connectors. Look for cracked or broken insulation,
bare wires, and broken connectors. If any damage is found, Maintainer must repair/replace as required. If
beyond Maintainer Level Maintenance, Maintainer must notify their supervisor.
4. Hoses and fluid lines: Look for wear, damage and leaks, and make sure clamps and fittings are tight. Wet
spots mean a leak. A stain by a fitting or connector can also mean a leak. If any leaks or damage is found,
Maintainer must repair/replace as required. If beyond Maintainer Level Maintenance, Maintainer must notify
their supervisor.
5. Tires, and associated brake components. Look for excessive wear and damage. Check tires for excessive or
un-even wear. Check brake shoes and all associated components for leaks, excessive wear or damage. If
excessive/ un-even wear or damage is found, Maintainer must repair/replace as required. If beyond
Maintainer Level Maintenance, Maintainer must notify their supervisor.
LUBRICATION MAINTAINER INTERVALS - NORMAL CONDITIONS
General
For safer, more trouble-free operations, make sure that your TMSS-MED trailer is serviced when it needs it.
Proper maintenance intervals which are the responsibility of the Maintainer level maintenance are found in this
chapter.
Adherence
Intervals (on-condition or hard time) and the related man-hour times are based on normal operation. The man-
hour time specified is the time needed to do all the maintenance prescribed for a particular interval. On-condition
(OC) oil sample intervals shall be applied. Change the hard time interval if lubricants are contaminated or if
operating the equipment under adverse operating conditions, included longer-than-usual operating hours. The
calendar interval may be extended during periods of low activity. If extended, adequate preservation precautions
must be taken. Hard time intervals must be applied during the warranty period.
0116-2
TM 11-6115-742-13&P 0116
Cleaning Fittings Before Lubrication
WARNING
Cleaning solvents may be toxic and flammable. Wear protective goggles and
gloves; use only in well-ventilated area; avoid contact with skin, eyes, and clothes,
and do not breath vapors. Keep away from heat or flame. Never smoke when
using cleaning solvent. Failure to comply may result in serious injury or death to
personnel.
If personnel become dizzy while using cleaning solvents, immediately get fresh air
and medical help. If cleaning solvent contacts skin or clothes, flush with cold
water. If cleaning solvent contacts eyes, immediately flush eyes with water and
get medical attention. Failure to comply may result in serious injury or death to
personnel.
Clean parts with cleaning solvent. Dry before lubricating.
Lubrication After Fording
If a fording operation occurs, lubricate all fittings below fording depth and check submerged gear boxes for
presence of water.
Lubrication After High Pressure Washing
After a thorough washing, lubricate all grease fittings and oil can points outside and underneath trailer.
Corrosion Control
Refer to (WP 0001), Corrosion Prevention and Control (CPC), for appropriate corrosion control procedures.
Hard Time Lubrication Intervals
For equipment under manufacturer’s warranty, hard time lubrication intervals shall be followed. Intervals shall be
shortened if lubricants are known to be contaminated or if operation is under adverse conditions (e.g. longer than
usual operating hours, extended idling periods, extreme dust).
EXPLANATION OF TABLE ENTRIES
Item Number - Numbers in this column are for reference. When completing DA Form 2404/DA Form 5988E
(Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indicating a
fault. Item numbers appear in the order in which the checks/services are performed for the interval listed.
Interval - This column indicates when a procedure must be performed (i.e., Before, During, After, Monthly).
Item to Be Checked or Serviced - This column provides the item that is to be checked or serviced.
Procedure - This column describes the procedure that must be followed to ensure that the equipment is capable
of performing its intended mission.
Equipment Not Ready/Available If - This column lists conditions that make the TMSS-MED not fully mission
capable. If possible, fix the problem using the troubleshooting procedures and/or maintenance procedures in this
manual. If not, document the items not able to be fixed on DA Form 2404 for the next level of maintenance. For
further information on how to use this form, see DA PAM 750-8. Be sure to observe and annotate all special
circumstances that appear/occur.
0116-3
TM 11-6115-742-13&P 0116
EXPLANATION OF TABLE ENTRIES - Continued
Other Entries - Be sure to observe and annotate all special circumstances that appear/occur.
NOTE
If the equipment must be kept in continuous operation, only perform those
procedures that will not disturb operation. Complete checks and services when
the equipment is shut down.
END OF WORK PACKAGE
0116-4
TM 11-6115-742-13&P 0117
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
PMCS (TRAILER & SHELTER)
INITIAL SETUP:
Tools and Special Tools References
General mechanic's tool kit (WP 0165, Item 1) WP 0119 – WP 0130
Personnel Required
Two
Table 1. Maintainer Preventive Maintenance Checks and Services – Trailer and Shelter.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
1 TRAILER
Monthly NOTE
Refer to (WP 0119 through
WP 0130) for trailer maintenance
procedures.
1. Check wheels and tires for Wheels/tires damaged,
damage, foreign objects, loose or extreme wear, lug nuts
missing lug nuts, or unusual tread missing/not properly
wear. Verify that tire pressure is tightened. Tires
correct. unserviceable.
Highway: 20 psi
Off Road: 17 psi
Replace tire if necessary.
2. Check trailer brakes to include Breaks/master cylinder
master cylinder. Ensure that trailer not in proper working
breaks are in proper working order. order.
3. Check brake hoses. Ensure that Brake hoses damaged,
hoses are not collapsed, swollen, leaking, excessive
excessively soft, or spongy. Ensure cracking present.
that no damage, to include cracks
excessive wear is present. Check
connections to ensure that no
leakage of brake fluid, excessive
corrosion, or other wear is present.
4. Check brake fluid. Ensure that Brake fluid reservoir low
brake fluid is full and is not on fluid/leaking or fluid is
contaminated. If necessary, add contaminated.
brake fluid.
0117-1
TM 11-6115-742-13&P 0117
Table 1. Maintainer Preventive Maintenance Checks and Services – Trailer and Shelter - Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
NOTE
The following step must be
performed with the trailer connected
to a vehicle.
5. Check brake lights for
functionality.
WARNING
When performing the following step,
DO NOT attempt to pull trailer beyond
point where cables, duct work, and
other items would be damaged.
CAUTION
Prior to performing the following
step, ensure that dolly wheel
assembly is raised, safety chain is
engaged, and parking breaks are
released.
6. Attempt to tow trailer with vehicle. Wheels are locked up/ do
Trailer should NOT drag. not turn.
7. Check safety chains for Safety chains loose,
insecure mounting, damage, damaged, corroded, or
corroded, or loose hardware. missing.
Replace/repair if necessary.
8. Check for missing or damaged, Lens light or hardware
lens lights. Replace/repair if loose, corroded, or
necessary. missing.
9. Check condition of skid plate/dolly Skid plate/dolly wheel
wheel assembly for proper mounting tongue jack missing or
to landing post or tongue jack. inoperative.
Repair or replace if necessary.
10. Check crank handle for proper Crank handle damaged,
operation. Verify that no corrosion is missing, or inoperative.
present on mechanism. Grease if
necessary.
11. Attempt to tow trailer with Wheels are locked up/ do
vehicle. Trailer should NOT drag. not turn.
0117-2
TM 11-6115-742-13&P 0037
Table 1. Maintainer Preventive Maintenance Checks and Services – Trailer and Shelter - Continued.
ITEM TO BE EQUIPMENT
ITEM
INTERVAL CHECKED PROCEDURE NOT READY/
NO.
OR SERVICED AVAILABLE IF:
2 SHELTER
Monthly NOTE
Refer to (WP 0130) for Maintainer
procedures applicable to the shelter.
1. Check interior and exterior covers, Damaged beyond repair.
end caps, doors for excessive wear,
cracks, or other damage. Repair as
necessary.
2. Check for missing/damaged hubs, Hubs, struts, risers
struts, risers, and other support missing or damaged
components. Repair/replace as beyond repair.
necessary.
3. Check wind lines for excessive wear Wind lines frayed,
or damage. Repair/replace as missing, or damaged
necessary. beyond repair.
Monthly Light Set, Shelter 1. Check lamps. Verify that no visible
damage is present. If necessary
replace bulb.
2. Check fuse. Verify that fuse is good
and properly installed. If necessary,
replace fuse.
END OF WORK PACKAGE
0117-3/4 blank
TM 11-6115-742-13&P 0118
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
TRAILER & SHELTER MAINTENANCE INDEX
GENERAL
This section contains an index of repair/removal/replacement or maintenance procedures that may be needed
during maintenance or repair of the TMSS-MED shelter by Maintainer personnel. Maintenance is limited to those
failures that may be repaired at the Maintainer level. The index identifies the maintenance function, which is
followed by a column that identifies the work package and page(s) where Maintainer level procedure(s) may be
found. The index is provided to assist in the quick location of a procedure. The manual cannot list all
malfunctions that may occur. If a malfunction is encountered that is not listed or that cannot be corrected by the
corrective actions provided, notify the supervisor.
Maintenance Function Procedure
TRAILER
1. Trailer level removal/replacement ............................................................................................ 0119-2
2. Safety chain removal/replacement ........................................................................................... 0119-3
3. Tongue jack assembly removal/replacement ........................................................................... 0119-4
4. Lift sling removal/replacement .................................................................................................. 0120-2
5. Stabilizer leg removal/replacement .......................................................................................... 0121-2
6. Cargo net removal/replacement ............................................................................................... 0121-5
7. Reflector removal/replacement ................................................................................................ 0122-2
8. Ground stud removal/replacement ........................................................................................... 0122-4
9. Lanyard assembly removal/replacement.................................................................................. 0122-6
10. Fire extinguisher bracket removal/replacement ....................................................................... 0122-8
11. Cargo restraint cage removal/replacement .............................................................................. 0123-2
12. Vehicle stop light lamp (incandescent) and blackout light removal/replacement/test .............. 0124-2
13. Vehicle stop light (incandescent) removal/replacement/test .................................................... 0124-4
14. Vehicle stop light (LED) removal/replacement/test .................................................................. 0124-6
15. Vehicle stop light wiring harness (inter-vehicular cable) removal/replacement/test................. 0125-2
16. Brake hub/drum removal/clean and inspect/replacement ........................................................ 0126-2
17. Wheel cylinder removal/clean and inspect/replacement .......................................................... 0126-6
18. Brakeshoe removal/clean and inspect/replacement ................................................................ 0126-9
19. Backing plate removal/replacement ......................................................................................... 0126-13
20. Brake adjustment...................................................................................................................... 0126-15
21. Master cylinder removal/replacement ...................................................................................... 0127-2
22. Brake line removal/replacement ............................................................................................... 0127-4
23. Bleed brake system .................................................................................................................. 0127-8
24. Brake actuator components removal/replacement ................................................................... 0128-4
25. Brake actuator assembly removal/replacement ....................................................................... 0128-9
26. Hand brake assembly removal/inspect/replacement ............................................................... 0128-11
27. Hand brake cable and sheath removal/replacement ................................................................ 0128-14
28. Tire and wheel assembly service/removal/replacement .......................................................... 0129-2
LIGHTING
29. Fluorescent lamp removal/replacement ................................................................................... 0130-2
30. Fuse removal/replacement ....................................................................................................... 0130-4
END OF WORK PACKAGE
0118-1/2 blank
TM 11-6115-742-13&P 0119
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
TRAILER LEVEL, SAFETY CHAIN, AND TONGUE JACK
TRAILER LEVEL, SAFETY CHAIN, TONGUE JACK ASSEMBLY REVOMAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit One
(WP 0165, Item 1)
Equipment Condition
Materials/Parts Trailer parked in operational position
Level Trailer handbrakes engaged
Safety chain Wheels chocked
Pin w/ retainer
Tongue Jack Assembly
Grease (WP 0168, Item 25)
GENERAL
This work package provides information on the removal and replacement of the trailer level, safety chain, and
tongue jack assembly. It consists of:
• Trailer level removal/replacement
• Safety chain removal/replacement
• Tongue jack assembly removal/replacement
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the trailer.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Ensure that TMSS-MED is level and ground is stable (not soggy or soft). Trailer
could sink into soft or unstable ground. Injury to personnel, or damage to TMSS-
MED trailer and/or its components could result from trailer suddenly rolling or
tipping.
Observe all lifting and weight restrictions. Failure to observe this warning can
result in serious injury or death to personnel or damage to the TMSS-MED trailer
and/or its contents.
TRAILER LEVEL
REMOVAL
1. Remove and retain three screws (Figure 1, Item 2).
2. Remove and properly discard of level (Figure 1, Item 1).
END OF TASK
0119-1
TM 11-6115-742-13&P 0119
REPLACEMENT
1. Install level (Figure 1, Item 1) secure to trailer using three screws (Figure 1, Item 2).
1
2
Figure 1. Trailer Level Removal/Replacement.
END OF TASK
0119-2
TM 11-6115-742-13&P 0119
SAFETY CHAIN REMOVAL/REPLACEMENT
REMOVAL
1. Identify safety chain (Figure 2, Item 1) requiring replacement.
2. Rotate locking ring (Figure 2, Item 2) and remove locking pin (Figure 2, Item 3).
3. Remove safety chain (Figure 2, Item 1) from slot in trailer frame.
END OF TASK
REPLACEMENT
1. Insert safety chain (Figure 2, Item 1) into slot in trailer frame.
2. Insert locking pin (Figure 2, Item 3) through safety chain (Figure 2, Item 1).
3. Secure safety chain (Figure 2, Item 1) by rotating locking ring (Figure 2, Item 2) over locking pin (Figure 2,
Item 3).
Figure 2. Safety Chain Removal/Replacement.
END OF TASK
0119-3
TM 11-6115-742-13&P 0119
TONGUE JACK ASSEMBLY REMOVAL/REPLACEMENT
REMOVAL
1. Attach trailer to vehicle or stationary trailer stand.
2. Verify that both trailer wheels are chocked, hand brakes are locked and stabilizer leg not being changed is in
its shortest positions.
3. Raise tongue jack assembly (Figure 3, Item 1) until skid plate assembly (Figure 3, Item 3) is off the ground.
4. Remove two mounting pins (Figure 3, Item 4) and remove skid plate assembly (Figure 3, Item 3).
NOTE
If replacing only the skid plate assembly (Figure 3, Item 3) by-pass step 5.
5. Remove four bolts (Figure 3, Item 2) and lock nuts (Figure 3, Item 5) from tongue jack assembly (Figure 3,
Item 1)
6. Remove tongue jack assembly (Figure 3, Item 1).
END OF TASK
REPLACEMENT
NOTE
Ensure tongue jack assembly (Figure 3, Item 1) is compressed to the fully closed
position.
1. Install tongue jack assembly (Figure 3, Item 1) and secure to trailer assembly with four bolts (Figure 3,
Item 2) and lock nuts (Figure 3, Item 5).
2. Install skid plate assembly (Figure 3, Item 3) and secure to tongue jack assembly (Figure 3, Item 1) with two
mounting pins (Figure 3, Item 4)
NOTE
If necessary, grease tongue jack assembly (Figure 3, Item 1).
3. Raise and lower tongue jack assembly (Figure 3, Item 1) to verify operation.
0119-4
TM 11-6115-742-13&P 0119
REPLACEMENT – Continued
4. Lower tongue jack assembly (Figure 3, Item 1) until the skid plate assembly (Figure 3, Item 3) on the ground.
5. Raise the trailer using the tongue jack assembly (Figure 3, Item 1), remove tow vehicle or trailer stand and
level trailer.
1
2
4 3
Figure 3. Tongue Jack Assembly Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0119-5/6 blank
TM 11-6115-742-13&P 0120
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
TRAILER LIFT SLING
LIFT SLING REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit (WP 0165, Item 1) WP 0005
Common No.1 shop set (WP 0165, Item 5)
Equipment Condition
Materials/Parts Trailer parked in operational position
Lift sling Trailer handbrakes engaged
Wheels chocked
Personnel Required ECU shut down
One Genset shut down
GENERAL
This work package provides information on the removal and replacement of the front and rear trailer lift slings.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the trailer.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Ensure that TMSS-MED is level and ground is stable (not soggy or soft). Trailer
could sink into soft or unstable ground. Injury to personnel, or damage to TMSS-
MED trailer and/or its components could result from trailer suddenly rolling or
tipping.
Observe all lifting and weight restrictions. Failure to observe this warning can
result in serious injury or death to personnel or damage to the TMSS-MED trailer
and/or its contents.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Prior to performing the following procedure ensure that TMSS-MED is level and
ground is stable (not soggy or soft). Trailer could sink into soft or unstable
ground. Injury to personnel, or damage to TMSS-MED trailer and/or its
components could result from trailer suddenly rolling or tipping.
0120-1
TM 11-6115-742-13&P 0120
CAUTION
Prior to performing the following procedure ensure that TMSS-MED is out of
service. No power cables or duct should be connected to the ECU or Genset.
Failure to observe this caution could result in serious damage to the TMSS-MED
trailer and/or its contents.
REMOVAL
1. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
2. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF.
(WP 0005, Genset Shut Down Procedure).
NOTE
If replacing trailer bed lift sling, remove equipment from trailer bed.
3. Remove two hex bolts (Figure 1, Item 1) from lift sling (Figure 1, Item 2).
NOTE
Front lift slings have a detachable mounting block (Figure 1, Item 4) within the
trailer frame. Secure mounting block (Figure 1, Item 4) when removing hardware
and set aside.
Rear lift slings have a permanent mounting block attached beneath trailer bed
(Figure 1, Item 3).
4. Pull lift sling (Figure 1, Item 2) up from trailer superstructure.
END OF TASK
0120-2
TM 11-6115-742-13&P 0120
REPLACEMENT
1. Position lift sling (Figure 1, Item 2) over bolt holes in trailer superstructure.
2. Install two hex bolts (Figure 1, Item 1) into lift sling (Figure 1, Item 2) and through trailer superstructure.
NOTE
Front lift slings have a detachable mounting block (Figure 1, Item 4). Align
mounting block with hardware within frame.
Rear lift slings have a permanent mounting block attached beneath trailer bed
(Figure 1, Item 3).
3. Tighten bolts (Figure 1, Item 1).
4. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
5. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
1 1
Figure 1. Lift Sling Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0120-3/4 blank
TM 11-6115-742-13&P 0121
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
TRAILER STABILIZER LEG AND CARGO NET
STABILIZER LEG REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
5 ton floor jack WP 0005
Materials/Parts Equipment Condition
Stabilizer leg Trailer parked in operational position
Cargo Net Trailer handbrakes engaged
Personnel Required Wheels chocked
One ECU shut down
Genset shut down
GENERAL
This work package provides information on the removal and replacement of the trailer stabilizer leg and cargo net.
It consists of:
• Stabilizer leg removal/replacement
• Cargo net removal/replacement
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the trailer.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Ensure that TMSS-MED is level and ground is stable (not soggy or soft). Trailer
could sink into soft or unstable ground. Injury to personnel, or damage to TMSS-
MED trailer and/or its components could result from trailer suddenly rolling or
tipping.
Observe all lifting and weight restrictions. Failure to observe this warning can
result in serious injury or death to personnel or damage to the TMSS-MED trailer
and/or its contents.
0121-1
TM 11-6115-742-13&P 0121
WARNING
When the following procedure is being performed, the trailer is in a very unstable
position. This procedure should be performed in a timely manner and the trailer
should not be left unattended. Failure to observe this warning can result in
serious injury or death to personnel or damage to the TMSS-MED trailer and/or
its contents.
Personnel performing this procedure should have another person near by incase
an adverse situation occurs. Failure to observe this warning can result in serious
injury or death to personnel or damage to the TMSS-MED trailer and/or its
contents.
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Prior to performing the following procedure ensure that TMSS-MED is level and
ground is stable (not soggy or soft). Trailer could sink into soft or unstable
ground. Injury to personnel, or damage to TMSS-MED trailer and/or its
components could result from trailer suddenly rolling or tipping.
CAUTION
Prior to performing the following procedure ensure that TMSS-MED is out of
service. No power cables or duct should be connected to the ECU or Genset.
Failure to observe this caution could result in serious damage to the TMSS-MED
trailer and/or its contents.
REMOVAL
1. Remove all loose items from trailer and cargo area.
2. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
3. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF.
(WP 0005, Genset Shut Down Procedure).
4. Verify that ducts are disconnected from ECU and all cables are disconnected from Genset and ECU.
0121-2
TM 11-6115-742-13&P 0121
REMOVAL – Continued
5. Raise both stabilizer legs (Figure 1, Item 4) to the fully stowed position.
6. Verify that opposite trailer wheel is chocked and hand brakes are locked.
7. Ensure skid plate (Figure 1, Item 6) is in the down position and dolly wheel is facing rear of trailer.
8. Remove pin (Figure 1, Item 7) and raise tongue jack assembly (Figure 1, Item 1) to highest position to lower
tongue assembly to lowest point.
9. Position floor jack (Figure 1, Item 5) beneath trailer axle on same side as stabilizer leg being replaced.
10. Remove two locking pins (Figure 1, Item 2) that secure the trailer stabilizer leg (Figure 1, Item 4) being
replaced and lower stabilizer leg as far as possible.
11. Raise floor jack (Figure 1, Item 5) until sufficient height is attained to remove stabilizer leg (Figure 1, Item 4)
from receptacle (Figure 1, Item 3) on trailer.
END OF TASK
REPLACEMENT
1 Insert stabilizer leg (Figure 1, Item 4) into receptacle (Figure 1, Item 3) on trailer and raise stabilizer leg to the
fully stowed position.
2. Insert two locking pins (Figure 1, Item 2) and secure stabilizer leg (Figure 1, Item 4).
3. Lower and remove floor jack (Figure 1, Item 5).
4. Adjust the tongue jack assembly (Figure 1, Item 1) and stabilizer legs (Figure 1, Item 4) to appropriate
operational height. Replace pin (Figure 1, Item 7) in tongue jack assembly (Figure 1, Item 1).
5. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
6. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0121-3
TM 11-6115-742-13&P 0121
Figure 1. Stabilizer Leg Removal/Replacement.
END OF TASK
0121-4
TM 11-6115-742-13&P 0121
CARGO NET REMOVAL/REPLACEMENT
REMOVAL
1. Disconnect six quick disconnects (Figure 2, Item 9) that secure cargo net (Figure 2, Item 8).
2. Remove and retain two bolts (Figure 2, Item 1), four flat washers (Figure 2, Item 3), and two lock nuts
(Figure 2, Item 4) that secure mounting pole (Figure 2, Item 2) to trailer frame.
3. Remove and retain four bolts (Figure 2, Item 7), eight flat washers (Figure 2, Item 6), and four lock nuts
(Figure 2, Item 10) that secure center bracket (Figure 2, Item 5) to trailer frame.
4. Remove and retain center bracket (Figure 2, Item 5).
5. Remove mounting pole (Figure 2, Item 2) and cargo net (Figure 2, Item 8) from trailer frame.
6. Remove cargo net (Figure 2, Item 8) from mounting pole (Figure 2, Item 2). Retain mounting pole (Figure 2,
Item 2) and properly discard cargo net (Figure 2, Item 8).
END OF TASK
REPLACEMENT
1. Insert mounting pole (Figure 2, Item 2) into loops on cargo net (Figure 2, Item 8).
2. Secure mounting pole (Figure 2, Item 2) and cargo net (Figure 2, Item 8) to trailer frame with two bolts
(Figure 2, Item 1), four flat washers (Figure 2, Item 3), and two lock nuts (Figure 2, Item 4).
3. Install center bracket (Figure 2, Item 5) to trailer frame and secure with four bolts (Figure 2, Item 7), eight flat
washers (Figure 2, Item 6), and four lock nuts (Figure 2, Item 10).
4. Secure cargo net (Figure 2, Item 8) to trailer with six quick disconnects (Figure 2, Item 9).
0121-5
TM 11-6115-742-13&P 0121
5
10 6
6
7
Figure 2. Cargo Net Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0121-6
TM 11-6115-742-13&P 0122
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
TRAILER BASIC
TRAILER HARDWARE REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Equipment Condition
General mechanic’s tool kit (WP 0165, Item 1) Trailer parked in operational position
Standard automotive tool set (WP 0165, Item 5) Trailer handbrakes engaged
Wheels chocked
Materials/Parts ECU shut down
Reflector Genset shut down
Ground bolt and hardware
Lanyard assembly
Fire extinguisher bracket
Personnel Required
One
GENERAL
This work package provides information on the removal and replacement of the following components:
• Reflector removal and replacement
• Ground stud removal and replacement
• Lanyard assembly removal and replacement
• Fire extinguisher bracket removal and replacement
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, components may be extremely cold or extremely
hot. To prevent serious injury to personnel, allow sufficient time for components
to warm up/cool down before performing procedures.
AC voltage (208 VAC, 3Ø), (28 VAC), and DC voltage (+28 VDC), and current
sufficient to cause serious injury or death are present. Before starting this task,
ensure all power is de-energized and disconnected from shelter. Failure to
comply with this warning could result in electrical shock or death to the
individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
0122-1
TM 11-6115-742-13&P 0122
CAUTION
Be aware of wiring harness behind reflectors when drilling or damage may result.
NOTE
This procedure applies to all reflectors at various locations of the trailer.
REFLECTOR
REMOVAL
1. Unload any ancillary devices from trailer that will interfere with replacement of reflector.
2. Drill out the center of the two rivets (Figure 1, Item 2) securing reflector (Figure 1, Item 3) to the trailer
superstructure (Figure 1, Item 1) using a 3/16” drill bit.
3. Remove reflector (Figure 1, Item 3).
END OF TASK
REPLACEMENT
1. Insert new rivets (Figure 1, Item 4) through reflector (Figure 1, Item 3) and through mounting holes in the
superstructure of the trailer (Figure 1, Item 1).
2. Using rivet gun, lock rivets (Figure 1, Item 4) into place.
3. Reload ancillary devices in trailer.
0122-2
TM 11-6115-742-13&P 0122
REPLACEMENT – Continued
1
4
Figure 1. Reflector Removal/Replacement.
END OF TASK
0122-3
TM 11-6115-742-13&P 0122
GROUND STUD REMOVAL/REPLACEMENT
REMOVAL
1. Remove wing nut (Figure 2, Item 7), nut (Figure 2, Item 6), lock washer (Figure 2, Item 5), and finishing
washer (Figure 2, Item 4) from ground bolt (Figure 2, Item 1).
2. Remove ground bolt (Figure 2, Item 1), washer (Figure 2, Item 2), and ground wire(s) (Figure 2, Item 8) from
trailer superstructure (Figure 2, Item 3).
END OF TASK
REPLACEMENT
NOTE
Prior to beginning the following step, ensure area around hole is free of paint,
grease, dirt, and other debris that would prevent a good electrical connection.
1. Insert ground bolt (Figure 2, Item 1), washer (Figure 2, Item 2), and ground wire(s) (Figure 2, Item 8) to trailer
superstructure (Figure 2, Item 3).
2. Install wing nut (Figure 2, Item 7), nut (Figure 2, Item 6), lock washer (Figure 2, Item 5), and finishing washer
(Figure 2, Item 4) to ground bolt (Figure 2, Item 1).
0122-4
TM 11-6115-742-13&P 0122
1
2
4
5
6
7
Figure 2. Ground Stud Removal/Replacement.
END OF TASK
0122-5
TM 11-6115-742-13&P 0122
LANYARD ASSEMBLY REMOVAL/REPLACEMENT
REMOVAL
1. Unload any ancillary devices from trailer that will interfere with replacement of lanyard assembly.
2. Drill out center of lanyard rivet (Figure 3, Item 1) using a 3/16” drill bit.
3. Remove and discard rivet (Figure 3, Item 1). Remove lanyard assembly (Figure 3, Item 2).
END OF TASK
REPLACEMENT
1. Using rivet gun, place rivet through lanyard assembly (Figure 3, Item 2) hole and hole in trailer structure.
2. Lock down rivet (Figure 3, Item 1).
3. Reload ancillary devices in trailer.
0122-6
TM 11-6115-742-13&P 0122
Figure 3. Lanyard Assembly Removal/Replacement.
END OF TASK
0122-7
TM 11-6115-742-13&P 0122
FIRE EXTINGUISHER BRACKET REMOVAL/REPLACEMENT
CAUTION
Be aware of wiring harness behind bracket when drilling or damage may result.
REMOVAL
1. Unload any ancillary devices from trailer that will interfere with replacement of fire extinguisher bracket.
2. Remove fire extinguisher (Figure 4, Item 6) from bracket (Figure 4, Item 3).
3. Drill out four rivets (Figure 4, Item 5) from fire extinguisher bracket (Figure 4, Item 3) using a drill with 3/16”
bit.
5. Remove and discard fire extinguisher bracket (Figure 4, Item 3).
END OF TASK
REPLACEMENT
1. Position fire extinguisher bracket (Figure 4, Item 3) over Genset enclosure mounting holes (Figure 4, Item 4)
and insert four rivets (Figure 4, Item 2).
NOTE
To ensure proper alignment, insert all four rivets through bracket and into Genset
enclosure holes before locking down rivets.
2. Lock down four rivets (Figure 4, Item 2).
3. Ensure adhesive cushions (Figure 4, Item 1) are placed at contact points between bracket (Figure 4, Item 3)
and fire extinguisher (Figure 4, Item 6).
4. Secure fire extinguisher (Figure 4, Item 6) in bracket (Figure 4, Item 3).
5. Reload ancillary devices in trailer.
0122-8
TM 11-6115-742-13&P 0122
4
2
1 5
Figure 4. Fire Extinguisher Bracket Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0122-9/10 blank
TM 11-6115-742-13&P 0123
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
TRAILER CARGO RESTRAINT CAGE
CARGO RESTRAINT CAGE REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit WP 0005
(WP 0165, Item 1)
Equipment Condition
Materials/Parts Trailer parked in operational position
Cage Trailer handbrakes engaged
Wheels chocked
Personnel Required ECU shut down
Two Genset shut down
GENERAL
This work package provides information on the removal and replacement of the trailer cargo restraint cage
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the trailer.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Ensure that TMSS-MED is level and ground is stable (not soggy or soft). Trailer
could sink into soft or unstable ground. Injury to personnel, or damage to TMSS-
MED trailer and/or its components could result from trailer suddenly rolling or
tipping.
Observe all lifting and weight restrictions. Failure to observe this warning can
result in serious injury or death to personnel or damage to the TMSS-MED trailer
and/or its contents.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Prior to performing the following procedure ensure that TMSS-MED is level and
ground is stable (not soggy or soft). Trailer could sink into soft or unstable
ground. Injury to personnel, or damage to TMSS-MED trailer and/or its
components could result from trailer suddenly rolling or tipping.
0123-1
TM 11-6115-742-13&P 0123
CAUTION
Prior to performing the following procedure ensure that TMSS-MED is out of
service. No power cables or duct should be connected to the ECU or Genset.
Failure to observe this caution could result in serious damage to the TMSS-MED
trailer and/or its contents.
REMOVAL
1. Remove all loose items from trailer and cargo area.
2. Verify that ECU has been shut down in accordance with ECU Shut Down Procedure (WP 0005).
3. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF.
(WP 0005, Genset Shut Down Procedure).
4. Verify that ducts are disconnected from ECU and all cables are disconnected from Genset and ECU.
5. Attach trailer to vehicle or stationary trailer stand.
6. Verify that both trailer wheels are chocked and hand brakes are locked.
NOTE
Genset and ECU removed for clarity. It is not necessary to remove the Genset
or ECU to replace a cage section.
7. Remove retaining pins as applicable to the section of cage that will be replaced, see (Figure 1).
8. Remove cage section.
END OF TASK
0123-2
TM 11-6115-742-13&P 0123
REPLACEMENT
1. Install cage section.
2. Insert retaining pins as applicable to the section of cage being replaced, see (Figure 1).
3. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
4. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
0123-3
TM 11-6115-742-13&P 0123
TM2030
Figure 1. Cargo Restraint Cage Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0123-4
TM 11-6115-742-13&P 0124
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
TRAILER VEHICLE STOP LIGHT
VEHICLE LIGHTS REPLACEMENT/TEST
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit One
(WP 0165, Item 1)
Equipment Condition
Materials/Parts Trailer parked in operational position
Lamp incandescent Trailer handbrakes engaged
Blackout lamp
Vehicle stop light
Strap tie (WP 0168, Items 55 to 57)
GENERAL
This work package provides information on the service, removal and replacement of the vehicle stop light and
inter-vehicular cable. It consists of:
• Stop light, vehicle, bulb (incandescent) removal/replacement/test
• Stop light vehicle (incandescent) removal/replacement/test
• Stop light vehicle (LED) removal/replacement/test
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the trailer.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Ensure that TMSS-MED is level and ground is stable (not soggy or soft). Trailer
could sink into soft or unstable ground. Injury to personnel, or damage to TMSS-
MED trailer and/or its components could result from trailer suddenly rolling or
tipping.
Observe all lifting and weight restrictions. Failure to observe this warning can
result in serious injury or death to personnel or damage to the TMSS-MED trailer
and/or its contents.
0124-1
TM 11-6115-742-13&P 0124
VEHICLE STOP LAMP AND INCANDESCENT BULB
REMOVAL
1. Remove six screws (Figure 1, Item 4) that secures lens (Figure 1, Item 5). Remove lens (Figure 1, Item 5)
and o-ring gasket (Figure 1, Item 3).
2. Remove and properly discard incandescent lamp(s) (Figure 1, Items 1 and 2).
3. Remove and properly discard blackout tail light (Figure 1, Item 6) and blackout stop light (Figure 1, Item 7).
END OF TASK
REPLACEMENT
1. Install incandescent lamp(s) (Figure 1, Items 1 and 2).
2. Install blackout tail light (Figure 1, Item 6) and blackout stop light (Figure 1, Item 7).
NOTE
Inspect o-ring (Figure 1, Item 3). If o-ring is damaged order new lens (Figure 1,
Item 5).
3. Install lens (Figure 1, Item 5) and secure using six screws (Figure 1, Item 4).
END OF TASK
TEST
1. Connect inter-vehicular cable to tow vehicle and vehicle quick disconnect.
2. Have driver turn on running lights, observe that trailer running lights activate.
3. While driver pushes down on brake pedal, observe that trailer brake lights activate.
4. While driver activates turn signals and hazard lights, observe that turn signal and hazard light on trailer
activate.
5. While driver activates black-out drive lights, observe that trailer blackout lights activate.
6. If any of the above steps fail, troubleshoot system.
0124-2
TM 11-6115-742-13&P 0124
6
4
Figure 1. Vehicle Stop Light, Lamp (Incandescent) and Blackout Light Removal/Replacement.
END OF TASK
0124-3
TM 11-6115-742-13&P 0124
VEHICLE STOP LIGHT (INCANDESCENT) REMOVAL/REPLACEMENT/TEST
CAUTION
There are two different types of stop light assemblies, incandescent and LED.
The incandescent stop light will only be issued until the supply runs out. If you
have to replace the incandescent style vehicle stop light with a LED style stop
light you MUST replace the assembly cable which connects these lights to the
vehicle. Before beginning this procedure, make sure you have all necessary
parts.
REMOVAL
1. Remove two strap ties that secure the vehicle stop light connectors (Figure 2, Items 2 and 6).
2. Disconnect stop light pig-tail (Figure 2, Item 6) from the cable assembly (Figure 2, Item 3).
3. Remove and retain two bolts (Figure 2, Item 4) and flat washers (Figure 2, Item 5) from rear of the vehicle
stop light assembly (Figure 2, Item 1).
4. Remove and properly discard vehicle stop light assembly (Figure 2, Item 1).
END OF TASK
REPLACEMENT
1. Feed stop light pig-tail (Figure 2, Item 6) through trailer and insert vehicle stop light assembly (Figure 2,
Item 1).
2. Secure vehicle stop light assembly (Figure 2, Item 1) to trailer using two bolts (Figure 2, Item 4) and flat
washers (Figure 2, Item 5).
3. Connect stop light pig-tail (Figure 2, Item 6) to cable assembly (Figure 2, Item 3).
4. Secure connection using two strap ties. Trim off excess.
END OF TASK
TEST
1. Connect inter-vehicular cable to tow vehicle and vehicle quick disconnect.
2. Have driver turn on running lights, observe that trailer running lights activate.
0124-4
TM 11-6115-742-13&P 0124
TEST – Continued
3. While driver pushes down on brake pedal, observe that trailer brake lights activate.
4. While driver activates turn signals and hazard lights, observe that turn signal and hazard light on trailer
activate.
5. While driver activates black-out drive lights, observe that trailer blackout lights activate.
6. If any of the above steps fail troubleshoot system.
4 3 2
Figure 2. Vehicle Stop Light (Incandescent) Removal/Replacement.
END OF TASK
0124-5
TM 11-6115-742-13&P 0124
VEHICLE STOP LIGHT (LED) REMOVAL/REPLACEMENT/TEST
REMOVAL
CAUTION
There are two different types of stop light assemblies, incandescent and LED.
The incandescent stop light will only be issued until the supply runs out. If you
have to replace the incandescent style vehicle stop light with a LED style stop
light you MUST replace the assembly cable which connects these lights to the
vehicle. Before beginning this procedure make sure you have all necessary
parts.
NOTE
The following procedure applies to vehicles with ID beginning with
26-11863E-009.
When performing the following steps, be observant of trailer and cable assembly
(Figure 3, Item 2) or stop light pig tail (Figure 3, Item 4).
1. Remove two strap ties that secure the vehicle stop light connectors on cable assembly (Figure 3, Item 2) and
stop light pig tail (Figure 3, Item 4).
NOTE
Prior to performing the following step, inspect all connectors. Verify that all
connectors are properly tagged and identified.
2. Disconnect stop light pig-tail (Figure 3, Item 4) from the cable assembly (Figure 3, Item 2).
3. Remove and retain two bolts (Figure 3, Item 1) and flat washers (Figure 3, Item 6) and ground connection
(Figure 3, Item 5) from rear of the vehicle stop light assembly (Figure 3, Item 3).
4. Remove and properly discard vehicle stop light assembly (Figure 3, Item 3).
END OF TASK
0124-6
TM 11-6115-742-13&P 0124
REPLACEMENT
1. Feed stop light pig-tail (Figure 3, Item 4) through trailer and insert vehicle stop light assembly (Figure 3,
Item 3).
NOTE
When performing the following step, make sure that area where ground cable
(Figure 3, Item 5) is free and clear of all paint, grease, dirt or other Items which
may prevent good electrical connection.
2. Secure vehicle stop light assembly (Figure 3, Item 3) and ground cable (Figure 3, Item 5) to trailer using two
bolts (Figure 3, Item 1) and flat washers (Figure 3, Item 6).
3. Connect stop light pig-tail (Figure 3, Item 4) to cable assembly (Figure 3, Item 2).
4. Secure connection using two strap ties. Trim off excess.
END OF TASK
TEST
1. Connect inter-vehicular cable to tow vehicle and vehicle quick disconnect.
2. Have driver turn on running lights, observe that trailer running lights activate.
3. While driver pushes down on brake pedal, observe that trailer brake lights activate.
4. While driver activates turn signals and hazard lights, observe that turn signal and hazard light on trailer
activate.
5. While driver activates black-out drive lights, observe that trailer blackout lights activate.
6. If any of the above steps fail troubleshoot system.
0124-7
TM 11-6115-742-13&P 0124
Figure 3. Vehicle Stop Light (LED) Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0124-8
TM 11-6115-742-13&P 0125
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
TRAILER INTER-VEHICULAR CABLE
VEHICLE STOP LIGHT WIRING HARNESS (INTER-VEHICULAR CABLE) REMOVAL/REPLACEMENT/TEST
INITIAL SETUP:
Tools and Special Tools References
General mechanic’s tool kit WP 0005
(WP 0165, Item 1)
Equipment Condition
Materials/Parts Trailer parked in operational position
Cable assembly, special purpose, electrical Trailer handbrakes engaged
Strap tie (WP 0168, Items 55 to 57) Wheels chocked
BATTERY SWITCH set to OFF
Personnel Required
One
GENERAL
This work package provides information on the service, removal and replacement of the vehicle stop light and
inter-vehicular cable. It consists of:
• Inter-vehicular cable removal/replacement/test
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the trailer.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Ensure that TMSS-MED is level and ground is stable (not soggy or soft). Trailer
could sink into soft or unstable ground. Injury to personnel, or damage to TMSS-
MED trailer and/or its components could result from trailer suddenly rolling or
tipping.
Observe all lifting and weight restrictions. Failure to observe this warning can
result in serious injury or death to personnel or damage to the TMSS-MED trailer
and/or its contents.
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
0125-1
TM 11-6115-742-13&P 0125
NOTE
There are two different types of cables depending upon the type of stop light
assembly present on the trailer. Before beginning this procedure make sure
inter-vehicular cable assembly is the correct one.
Trailers with ID numbers up to 26-11863D-008 were manufactured with the
incandescent style of vehicle stop light and cable assembly.
Trailers with ID numbers 26-11863E-009 or up were manufactured with the LED
style of vehicle stop light and cable assembly.
The old style vehicle stop light and inter-vehicular cable will only be issued until
supplies are depleted. If you replace either (cable assembly for vehicle stop
lights) you may have to order and replace both.
Prior to performing the following procedure, verify that inter-vehicular cable is
bad. Using a multimeter, measure continuity of cable assembly. If readings are
5 ohms or less cable is good. (See Table 1 for connections.)
REMOVAL
1. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF.
(WP 0005, Genset Stop Procedure).
NOTE
Prior to performing step, ensure that all electrical connections on both the cable
assembly being installed and the mating connections on the vehicle stop lights
are properly identified. If cable markings are missing or illegible properly mark
connections.
2. Remove ten self-locking nuts (Figure 1, Item 5) that secure cable clamps (Figure 1, Item 3)/ inter-vehicular
cable (Figure 1, Item 6) to mounting studs (Figure 1, Item 2) on trailer frame (Figure 1, Item 1). Retain self-
locking nuts (Figure 1, Item 5).
3. Disconnect ground wire (Figure 1, Item 4) from mounting stud (Figure 1, Item 2).
4. Remove ten cable clamps (Figure 1, Item 3) that secure inter-vehicular cable (Figure 1, Item 6) to trailer frame
(Figure 1, Item 1).
NOTE
When performing the following steps, be observant of vehicle stop light
assembly. Do not cut or damage associated pig-tail.
5. Cut strap ties from vehicle stop light assembly wiring connectors.
6. Disconnect inter-vehicular cable (Figure 1, Item 6) from pigtail of vehicle stop light assemblies.
7. Cut strap tie securing excess cable.
8. Pull inter-vehicular cable (Figure 1, Item 6) through feed through hole in frame and through opening in front of
trailer frame. Discard inter-vehicular cable (Figure 1, Item 6).
END OF TASK
0125-2
TM 11-6115-742-13&P 0125
REPLACEMENT
NOTE
When performing the following steps, be observant of trailer and cable assembly.
Do not cut or damage inter-vehicular cable (Figure 1, Item 6).
Leave approximately 5 ½ feet of inter-vehicular cable (Figure 1, Item 6) to allow
electrical connection to towing vehicle.
1. Feed inter-vehicular cable (Figure 1, Item 6) through opening in front of trailer frame (Figure 1, Item 1).
2. Route cable assembly (Figure 1, Item 6) along curbside of trailer frame (Figure 1, Item 1). Be observant of
ten mounting studs (Figure 1, Item 2).
3. Feed inter-vehicular cable (Figure 1, Item 6) through opening in center of trailer frame
NOTE
When performing the following step, do not attach cable clamps (Figure 1,
Item 3) to rear of trailer frame (Figure 1, Item 1).
4. Starting at front of trailer frame (Figure 1, Item 1), install seven of the ten cable clamps (Figure 1, Item 3).
Secure cable clamps (Figure 1, Item 3) to mounting studs (Figure 1, Item 2) with self-locking nuts (Figure 1,
Item 5).
NOTE
When performing the following step, do not force connections damage to cable/
vehicle stop light assembly could occur. If connectors will not mate, inspect both
connections for bent pins, keys that do not mate, or other damage.
5. Make electrical connections between inter-vehicular cable (Figure 1, Item 6) and pig-tails on vehicle stop
lights (see Table 1).
6. Install cable clamp (Figure 1, Item 3) and ground terminal (Figure 1, Item 4) and secure with self locking nut
(Figure 1, Item 5) to stud (Figure 1, Item 2) on curbside rear of trailer frame (Figure 1, Item 1).
NOTE
When performing the following steps, be observant of trailer and cable assembly.
Do not cut or damage cable assembly.
7. Using two strap ties, secure stop light pig tails/ inter-vehicular cable connection to back side of trailer vehicle
stop light assembly mounting bracket. Trim excess length from zip ties.
8. Install cable clamp (Figure 1, Item 3) located at rear center of trailer. Secure to stud (Figure 1, Item 2) using
self locking nut (Figure 1, Item 5).
9. Draw excess inter-vehicular cable through cable clamp (Figure 1, Item 5) towards roadside rear of trailer
(Figure 1, Item 1). Install cable clamp (Figure 1, Item 3) and secure to stud with self-locking nut (Figure 1,
Item 5).
10. Coil up any excess inter-vehicular cable and secure with strap tie above roadside vehicle stop light assembly.
11. Install final cable clamp (Figure 1, Item 3) and secure with self locking nut (Figure 1, Item 5) to stud
(Figure 1, Item 2) on roadside rear of trailer frame (Figure 1, Item 1).
0125-3
TM 11-6115-742-13&P 0125
END OF TASK
TEST
1. Connect inter-vehicular cable to tow vehicle and vehicle quick disconnect.
2. Have driver turn on running lights, observe that trailer running lights activate.
3. While driver pushes down on brake pedal, observe that trailer brake lights activate.
4. While driver activates turn signals and hazard lights, observe that turn signal and hazard light on trailer
activate.
5. While driver activates black-out drive lights, observe that trailer blackout lights activate.
6. If any of the above steps fail troubleshoot system.
0125-4
TM 11-6115-742-13&P 0125
1 (Ref) 1 (Ref)
4
3 3
2 2
5
5
6 (Ref)
6 (Ref)
Figure 1. Inter-Vehicular Cable Removal/Replacement.
0125-5
TM 11-6115-742-13&P 0125
Table 1. Cable Assembly/Stop Light (LED) Connections.
TO
FROM CIRCUIT
Tail-light
(Vehicle connector ) NUMBER
connections
A 24-484 LH Black-out
B 24-461 LH Signal
C 24-483 RH Black-out
D 90 Ground
E 21-489 Stop lights
F 23 Black-out Stop
H 490 N/C
J 22-460 RH signal
K 37 N/C
L 90 Ground
M 53 N/C
N 53 N/C
J A
H K B
D A
N L
C B
F M C
E D
Vehicle StopLight
Vehicle Stop Light
(Old)
(Incandescent)
VehicleVehicle
Connection
Connection
Figure 2. Inter-Vehicular Cable Connectors (Incandescent).
Table 2. Cable Assembly/Stop Light (Incandescent) Connections.
TO LH TO RH
FROM CIRCUIT Tail-light
Tail-light Tail-light
(Vehicle connector ) NUMBER connections
connectors connectors
A 24-484 LH Black-out A
B 24-461 LH Signal B
C 24-483 RH Black-out A
D 90 Ground
E 21-489 Stop lights C B
F 23 Black-out Stop D C
H 490 N/C
J 22-460 RH signal D
K 37 N/C
L 90 Ground
M 53 N/C
N 53 N/C
END OF TASK
END OF WORK PACKAGE
0125-6
TM 11-6115-742-13&P 0126
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
TRAILER BRAKES (WHEEL ASSEMBLY)
TRAILER BRAKES REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
General mechanic’s tool kit (WP 0165, Item 1) WP 0129
Standard automotive tool set (WP 0165, Item 5)
Equipment Condition
Materials/Parts Trailer parked in operational position
Brake hub/drum Trailer handbrakes engaged
Dry cleaning solvent (WP 0168, Item 11) Wheels chocked
Wheel bearing grease (WP 0168, Item 25) ECU shut down
Cotter pin Genset shut down
Wheel cylinder
Cloth, cleaning (WP 0168, Item 14)
Brakeshoes
Backing plate
Personnel Required
Two
GENERAL
This work package provides information on the removal and replacement of the following components:
• Brake hub/drum removal, clean and inspect, and replacement
• Wheel cylinder removal, clean and inspect, and replacement
• Brakeshoe removal, clean and inspect, and replacement
• Backing plate removal and replacement
• Brake adjustment
WARNING
When performing maintenance on brake system, ensure that wheels are securely
chocked. Failure to follow this warning may cause trailer to roll, resulting in
serious injury or death to personnel or damage to equipment.
DO NOT allow grease to contact brakeshoe linings. Wipe excess lubricant from
the brakeshoe linings to prevent grease soaking into the materials. Brakeshoe
linings can absorb grease and oil, causing early glazing of linings and very poor
breaking action. Failure to follow this warning may cause brakes to malfunction,
resulting in injury or death to personnel or damage to equipment.
DO NOT handle brakeshoes, drum/hubs, or other brake components unless area
has been properly cleaned. There may be asbestos dust on these components
which can be dangerous if touched or inhaled. Wear an approved filter mask and
gloves.
NEVER use compressed air or a dry brush to clean brake components. Injury
may result.
0126-1
TM 11-6115-742-13&P 0126
WARNING
Never replace only one brakeshoe. Combinations of old and new brakeshoes
will cause uneven braking. Accidents causing serious injury or death to
personnel or damage to equipment may result.
When performing maintenance on brake system, ensure that wheels are securely
chocked. Failure to follow this warning may cause trailer to roll, resulting in
serious injury or death to personnel or damage to equipment.
DO NOT allow grease to contact brakeshoe linings. Wipe excess lubricant from
the brakeshoe linings to prevent grease soaking into the materials. Brakeshoe
linings can absorb grease and oil, causing early glazing of linings and very poor
breaking action. Failure to follow this warning may cause brakes to malfunction,
resulting in injury or death to personnel or damage to equipment.
DO NOT handle brakeshoes, drum/hubs, or other brake components unless area
has been properly cleaned. There may be asbestos dust on these components
which can be dangerous if touched or inhaled. Wear an approved filter mask and
gloves.
NEVER use compressed air or a dry brush to clean brake components. Injury
may result.
BRAKE HUB/DRUM REMOVAL/CLEAN AND INSPECT/REPLACEMENT
REMOVAL
1. Remove tire and wheel assembly as per (WP 0129) of this TM.
2. Using a pry bar and hammer remove the axle grease cap (Figure 1, Item 1).
3. Remove o-ring (Figure 1, Item 12), if applicable, and cotter pin (Figure 1, Item 3) and discard cotter pin.
4. Remove spindle nut (Figure 1, Item 2) and washer (Figure 1, Item 4).
5. Remove hub/drum (Figure 1, Item 7) with bearings and grease seal installed.
6. Remove grease seal (Figure 1, Item 10) from hub/drum (Figure 1, Item 7).
7. Remove inner bearing (Figure 1, Item 9) and outer bearing (Figure 1, Item 5) from hub/drum (Figure 1,
Item 7).
8. Remove outer bearing race (Figure 1, Item 6) from hub/drum (Figure 1, Item 7).
9. Remove inner bearing race (Figure 1, Item 8) from hub/drum (Figure 1, Item 7).
END OF TASK
0126-2
TM 11-6115-742-13&P 0126
CLEAN AND INSPECT
WARNING
Dry cleaning solvent MIL-PRF-680 is toxic and flammable. Always wear
protective goggles and gloves, and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and DO NOT breath vapors. DO NOT use
near open flame or excessive heat.
1. Clean all removed components with dry cleaning solvent and allow to dry.
2. Inspect components for wear, cracks, corrosion, or other damage. Replace if damaged.
3. Inspect race and bearing, replace both as a pair if necessary.
4. Remove any corrosion with a wire brush.
WARNING
Removing metal parts could be dangerous to personnel. Always wear eye
protection when replacing wheel studs. Failure to follow this warning may result
in injury to personnel.
NOTE
Perform steps 5 and 6 only if any studs are damaged.
5. Drive stud (Figure 1, Item 11) out of hub/drum (Figure 1, Item 7). Discard stud.
6. Align splines on stud (Figure 1, Item 11) with splines in hub/drum (Figure 1, Item 7) and press stud (Figure 1,
Item 11) into hub/drum (Figure 1, Item 7) until stud shoulder seats against hub/drum.
END OF TASK
REPLACEMENT
1. Install outer bearing race (Figure 1, Item 6) and apply a thin film of grease to surface of outer bearing race.
2. Install inner bearing race (Figure 1, Item 8) and apply a thin film of grease to surface of inner bearing race.
3. Pack both bearings (Figure 1, Items 5 and 9) with grease by pressing fresh bearing grease into bearing roller
area.
4. Install inner bearing (Figure 1, Item 9) in hub/drum (Figure 1, Item 7).
5. Apply a thin film of grease to the outer edge of grease seal (Figure 1, Item 10) and install grease seal
(Figure 1, Item 10) in hub/drum (Figure 1, Item 7). Wipe excessive grease from outer surface of seal.
6. Install hub/drum (Figure 1, Item 7), with inner bearing and seal, on axle.
0126-3
TM 11-6115-742-13&P 0126
REPLACEMENT – Continued
7. Install outer bearing (Figure 1, Item 5), washer (Figure 1, Item 4), and spindle nut (Figure 1, Item 2).
8. Ensure spindle nut (Figure 1, Item 2) turns freely on the spindle and the brakes are not dragging.
9. While turning the hub/drum (Figure 1, Item 7) slowly, tighten the spindle nut (Figure 1, Item 2) to seat
bearings.
10. Back off the spindle nut (Figure 1, Item 2) as required to align the cotter pin hole. Hub/drum must turn freely.
WARNING
Do not over tighten spindle nut or bearing damage will result.
The cotter pin (Figure 1, Item 3) prevents the spindle nut (Figure 1, Item 2) from
coming loose. Failure to install the cotter pin properly will cause the spindle nut
to back off of the spindle causing loss of wheel assembly.
11. Install a cotter pin (Figure 1, Item 3) and bend ends to secure the spindle nut (Figure 1, Item 2).
12. If applicable, press o-ring (Figure 1, Item 12) over spindle nut (Figure 1, Item 2).
13. Apply grease to surface of grease cap (Figure 1, Item 1).
14. Install grease cap (Figure 1, Item 1) on hub/drum (Figure 1, Item 7).
15. Install tire and wheel assembly as per (WP 0129) of this TM.
0126-4
TM 11-6115-742-13&P 0126
REPLACEMENT – Continued
8
7
5 6
4
3
2
10
1
9
11
12
Figure 1. Brake Hub/Drum Removal/Replacement.
END OF TASK
0126-5
TM 11-6115-742-13&P 0126
WHEEL CYLINDER REMOVAL/CLEAN AND INSPECT/REPLACEMENT
WARNING
When performing maintenance on brake system, ensure that wheels are securely
chocked. Failure to follow this warning may cause trailer to roll, resulting in
serious injury or death to personnel or damage to equipment.
DO NOT allow grease to contact brakeshoe linings. Wipe excess lubricant from
the brakeshoe linings to prevent grease soaking into the materials. Brakeshoe
linings can absorb grease and oil, causing early glazing of linings and very poor
breaking action. Failure to follow this warning may cause brakes to malfunction,
resulting in injury or death to personnel or damage to equipment.
DO NOT handle brakeshoes, drum/hubs, or other brake components unless area
has been properly cleaned. There may be asbestos dust on these components
which can be dangerous if touched or inhaled. Wear an approved filter mask and
gloves.
NEVER use compressed air or a dry brush to clean brake components. Injury
may result.
REMOVAL
1. Remove tire and wheel assembly as per (WP 0129) of this TM.
2. Remove hub/drum assembly as per this WP.
3. Remove front shoe spring (Figure 2, Item 15) from front brakeshoe (Figure 2, Item 13) and backing plate
anchor pin (Figure 2, Item 5).
4. Remove rear shoe spring (Figure 2, Item 16) from rear brakeshoe (Figure 2, Item 24) and backing plate
anchor pin (Figure 2, Item 5).
5. Remove two capscrews (Figure 2, Item 1) with integral lock washers securing wheel cylinder (Figure 2,
Item 6) to backing plate (Figure 2, Item 4).
6. Pull wheel cylinder (Figure 2, Item 6) loose from backing plate (Figure 2, Item 4) while compressing push rod
(Figure 2, Item 7); remove push rod (Figure 2, Item 7) from brakeshoe (Figure 2, Item 13).
0126-6
TM 11-6115-742-13&P 0126
REMOVAL – Continued
7. Disconnect flexible brake line (Figure 2, Item 3) from cross over brake line, retain clip (WP 0127, Figure 2,
Item 11).
8. Install two temporary plugs in flexible brake line (Figure 2, Item 3) and cross over brake line.
9. Remove flexible brake line (Figure 2, Item 3) from wheel cylinder (Figure 2, Item 6). Set flexible brake line
(Figure 2, Item 3) aside. Discard wheel cylinder.
END OF TASK
CLEAN AND INSPECT
WARNING
Dry cleaning solvent MIL-PRF-680 is toxic and flammable. Always wear
protective goggles and gloves, and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and DO NOT breath vapors. DO NOT use
near open flame or excessive heat.
1. Clean all removed components except wheel cylinder (Figure 2, Item 6) with dry cleaning solvent and allow to
dry.
2. Inspect components for cracks, breaks, corrosion, or damaged threads. Replace if damaged.
END OF TASK
REPLACEMENT
1. Attach flexible brake line (Figure 2, Item 3) to wheel cylinder (Figure 2, Item 6) and tighten.
2. Remove two temporary plugs from flexible brake line (Figure 2, Item 3) and cross over brake line.
3. Connect flexible brake line (Figure 2, Item 3) to cross over brake line and install clip (WP 0127, Figure 2,
Item 11).
4. Install push rod (Figure 2, Item 7) in brakeshoe (Figure 2, Item 13) and wheel cylinder (Figure 2, Item 6) and
mount onto backing plate (Figure 2, Item 4). Retighten all lines.
NOTE
For ease of installation, install the rear capscrew first.
5. Install two capscrews (Figure 2, Item 1) with integral lock washers and tighten finger tight. Torque capscrews
(Figure 2, Item 1) to 168 ± 17 in-lb (19 ± 1.9 N·m).
6. Install rear shoe spring (Figure 2, Item 16) to rear brakeshoe (Figure 2, Item 24) and backing plate anchor pin
(Figure 2, Item 5).
7. Install front shoe spring (Figure 2, Item 15) to front brakeshoe (Figure 2, Item 13) and backing plate anchor
pin (Figure 2, Item 5).
8. Install hub/drum assembly as per this WP.
9. Bleed brakes as per (WP 0127) of this TM.
10. Install tire and wheel assembly as per (WP 0129) of this TM.
0126-7
TM 11-6115-742-13&P 0126
1
3 4
5
29
7 10
9
28 6
8 13
12
27 11
26 22
CURBSIDE
25 21 14
24 17
20 19 18
15
23
16
4 1
2
5 3
29
7
10
9
8
6 26 28
13
12
11 27
14
22 ROADSIDE
21 25
15 17 18 19 24
16 20 23
Figure 2. Wheel Cylinder, Brakeshoe, and Backing Plate Removal/Clean and Inspect/Replacement.
END OF TASK
0126-8
TM 11-6115-742-13&P 0126
BRAKESHOE REMOVAL/CLEAN AND INSPECT/REPLACEMENT
WARNING
When performing maintenance on brake system, ensure that wheels are securely
chocked. Failure to follow this warning may cause trailer to roll, resulting in
serious injury or death to personnel or damage to equipment.
DO NOT allow grease to contact brakeshoe linings. Wipe excess lubricant from
the brakeshoe linings to prevent grease soaking into the materials. Brakeshoe
linings can absorb grease and oil, causing early glazing of linings and very poor
breaking action. Failure to follow this warning may cause brakes to malfunction,
resulting in injury or death to personnel or damage to equipment.
DO NOT handle brakeshoes, drum/hubs, or other brake components unless area
has been properly cleaned. There may be asbestos dust on these components
which can be dangerous if touched or inhaled. Wear an approved filter mask and
gloves.
NEVER use compressed air or a dry brush to clean brake components. Injury
may result.
Never replace only one brakeshoe. Combinations of old and new brakeshoes
will cause uneven braking. Accidents causing serious injury or death to
personnel or damage to equipment may result.
REMOVAL
1. Remove tire and wheel assembly as per (WP 0129) of this TM.
2. Remove hub/drum assembly as per this WP.
3. Remove front shoe spring (Figure 2, Item 15) from front brakeshoe (Figure 2, Item 13) and backing plate
anchor pin (Figure 2, Item 5).
4. Remove rear shoe spring (Figure 2, Item 16) from rear brakeshoe (Figure 2, Item 24) and backing plate
anchor pin (Figure 2, Item 5).
5. Remove front brakeshoe hold down cup and spring (Figure 2, Item 17) from front brakeshoe hold down pin
securing front brakeshoe (Figure 2, Item 13) to backing plate (Figure 2, Item 4).
0126-9
TM 11-6115-742-13&P 0126
REMOVAL – Continued
6. Remove parking shoe lever (Figure 2, Item 14) and set parking shoe lever aside.
7. Remove travel link (Figure 2, Item 12) from anchor pin (Figure 2, Item 5) and front brakeshoe (Figure 2,
Item 13).
8. Rotate and lower front brakeshoe (Figure 2, Item 13). Remove adjuster (Figure 2, Item 20) and adjuster
spring (Figure 2, Item 19) from front brakeshoe. Remove adjuster spring from rear brakeshoe and set aside.
9. Remove rear brakeshoe hold down cup and spring (Figure 2, Item 23) from rear brakeshoe hold down pin
(Figure 2, Item 28) securing rear brakeshoe (Figure 2, Item 24) to backing plate (Figure 2, Item 4).
10. While holding rear brakeshoe, remove parking brake cable (Figure 2, Item 26) from parking brake link
(Figure 2, Item 25). If necessary, see (WP 0128, Figure 7, Items 3 and 5) of this TM.
11. Set rear brakeshoe and parking brake link aside.
12. Using a flat tip screw driver, pry retainer (Figure 2, Item 21) from parking brake link (Figure 2, Item 25) on rear
brakeshoe assembly (Figure 2, Item 24). Remove washer (Figure 2, Item 22) and set parking brake link,
retainer, and washer aside.
13. Slide parking brake link (Figure 2, Item 25) out of rear brakeshoe (Figure 2, Item 24) and set parking brake
link aside. Discard rear brakeshoe.
14. Release top of tension spring (Figure 2, Item 8) on rear of front brakeshoe (Figure 2, Item 13).
15. Remove washer (Figure 2, Item 9) from rear of front brakeshoe (Figure 2, Item 13).
16. Remove bolt (Figure 2, Item 11) and lock nut (Figure 2, Item 18) holding front brakeshoe (Figure 2, Item 13)
and backing shoe lever (Figure 2, Item 10) together.
17. Slide backing shoe lever (Figure 2, Item 10) off of front brakeshoe (Figure 2, Item 13).
18. Remove tension spring (Figure 2, Item 8) from back of backing shoe lever (Figure 2, Item 10). Set backing
shoe lever and tension spring aside. Discard front brakeshoe.
END OF TASK
CLEAN AND INSPECT
WARNING
Dry cleaning solvent MIL-PRF-680 is toxic and flammable. Always wear
protective goggles and gloves, and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and DO NOT breath vapors. DO NOT use
near open flame or excessive heat.
1. Clean all parts with dry cleaning solvent and rag.
2. Inspect all parts for damage. Replace any damaged parts.
3. Inspect brakeshoe surface for cracks, distortion, and excessive wear. Brakeshoe linings should have a
minimum thickness of 1/8 inch (3.2 mm). Replace brakeshoe if cracked or if lining thickness is less that 1/8
inch (3.2 mm).
END OF TASK
0126-10
TM 11-6115-742-13&P 0126
REPLACEMENT
1. Slide backing shoe lever (Figure 2, Item 10) onto front brakeshoe (Figure 2, Item 13).
2. Insert bolt (Figure 2, Item 11) and lock nut (Figure 2, Item 18) through front brakeshoe (Figure 2, Item 13) and
backing shoe lever (Figure 2, Item 10) and tighten.
3. Attach washer (Figure 2, Item 9) to stud on rear of front brakeshoe (Figure 2, Item 13).
4. Attach tension spring (Figure 2, Item 8) to rear of front brakeshoe (Figure 2, Item 13) and set assembly aside.
5. Slide parking brake link (Figure 2, Item 25) into rear brakeshoe (Figure 2, Item 24).
6. Attach washer (Figure 2, Item 22) to parking brake link stud (Figure 2, Item 25) of rear brakeshoe (Figure 2,
Item 24) and slide retainer (Figure 2, Item 21) onto parking brake link stud (Figure 2, Item 25).
7. Squeeze retainer (Figure 2, Item 21) with pliers to lock into place and set rear brakeshoe assembly aside.
8. Install travel link (Figure 2, Item 12) on front brakeshoe (Figure 2, Item 13).
9. Hold front brakeshoe assembly (Figure 2, Item 13) in position and slide travel link (Figure 2, Item 12) onto
backing plate anchor pin (Figure 2, Item 5).
10. Rotate front brakeshoe assembly down and insert wheel cylinder push rod (Figure 2, Item 7) into backing
shoe lever (Figure 2, Item 10).
11. Install front brakeshoe hold down cup and spring (Figure 2, Item 17) into front brakeshoe hold down pin to
secure front brakeshoe (Figure 2, Item 13) to backing plate (Figure 2, Item 4). Install front shoe spring
(Figure 2, Item 15) to backing plate anchor pin (Figure 2, Item 5).
12. Install parking shoe lever (Figure 2, Item 14) into front brakeshoe (Figure 2, Item 13).
13. Insert adjuster spring (Figure 2, Item 19) into front brakeshoe (Figure 2, Item 13).
14. While holding rear brakeshoe assembly (Figure 2, Item 24), attach parking brake cable (Figure 2, Item 26) to
parking brake link (Figure 2, Item 25). If necessary, see (WP 0128, Figure 7, Items 3 and 5) of this TM.
15. Insert adjuster (Figure 2, Item 20) into front brakeshoe (Figure 2, Item 13).
16. Hold rear brakeshoe assembly (Figure 2, Item 24) in position and insert adjuster spring (Figure 2, Item 19)
into rear brakeshoe hole (Figure 2, Item 24).
17. Rotate rear brakeshoe assembly (Figure 2, Item 24) around adjuster (Figure 2, Item 20) until adjuster
(Figure 2, Item 20) fits into slot of rear brakeshoe assembly (Figure 2, Item 24).
18. Install parking shoe lever (Figure 2, Item 14) into rear brakeshoe (Figure 2, Item 24).
19. Install rear brakeshoe hold down cup and spring (Figure 2, Item 23) onto rear brakeshoe hold down pin
(Figure 2, Item 28) to secure rear brakeshoe (Figure 2, Item 24) to backing plate (Figure 2, Item 4).
20. Install rear brakeshoe spring (Figure 2, Item 16) from rear brakeshoe (Figure 2, Item 24) into backing plate
anchor pin (Figure 2, Item 5).
21. Install hub/drum assembly as per this WP.
0126-11
TM 11-6115-742-13&P 0126
REPLACEMENT – Continued
22. Install tire and wheel assembly as per (WP 0129) of this TM.
23. Perform brake adjustment as per this WP.
END OF TASK
0126-12
TM 11-6115-742-13&P 0126
BACKING PLATE REMOVAL/REPLACEMENT
WARNING
When performing maintenance on brake system, ensure that wheels are securely
chocked. Failure to follow this warning may cause trailer to roll, resulting in
serious injury or death to personnel or damage to equipment.
DO NOT allow grease to contact brakeshoe linings. Wipe excess lubricant from
the brakeshoe linings to prevent grease soaking into the materials. Brakeshoe
linings can absorb grease and oil, causing early glazing of linings and very poor
breaking action. Failure to follow this warning may cause brakes to malfunction,
resulting in injury or death to personnel or damage to equipment.
DO NOT handle brakeshoes, drum/hubs, or other brake components unless area
has been properly cleaned. There may be asbestos dust on these components
which can be dangerous if touched or inhaled. Wear an approved filter mask and
gloves.
NEVER use compressed air or a dry brush to clean brake components. Injury
may result.
REMOVAL
1. Remove tire and wheel assembly as per (WP 0129) of this TM.
2. Remove hub/drum assembly as per this WP.
3. Remove brakeshoes as per this WP.
4. Remove wheel cylinder as per this WP.
5. Remove parking brake cable from backing plate (Figure 2, Item 4). If necessary, see (WP 0128, Figure 7,
Items 3 and 5) of this TM.
6. Remove 5 nuts (Figure 2, Item 27) from mounting studs (Figure 2, Item 29) securing backing plate
(Figure 2, Item 4) to axle spindle (Figure 2, Item 2). Remove backing plate (Figure 2, Item 4).
END OF TASK
0126-13
TM 11-6115-742-13&P 0126
REPLACEMENT
WARNING
DO NOT allow grease to contact brakeshoe linings. Wipe excess lubricant from
the brakeshoe linings to prevent grease soaking into the materials. Brakeshoe
linings can absorb grease and oil, causing early glazing of linings and very poor
breaking action. Failure to follow this warning may cause brakes to malfunction,
resulting in injury or death to personnel or damage to equipment.
1. Install backing plate (Figure 2, Item 4) on axle spindle (Figure 2, Item 2). Install 5 nuts (Figure 2, Item 27)
onto mounting studs (Figure 2, Item 29). Tighten nuts and torque to 50 ± 5 ft-lb
(69 ± 7 N·m).
2. Install parking brake cable to backing plate (Figure 2, Item 4). If necessary, see (WP 0128, Figure 7, Items 3
and 5) of this TM.
3. Install wheel cylinder as per this WP.
4. Install brakeshoes as per this WP.
5. Install hub/drum assembly as per this WP.
6. Install tire and wheel assembly as per (WP 0129) of this TM.
7. Perform brake adjustment as per this WP.
END OF TASK
0126-14
TM 11-6115-742-13&P 0126
BRAKE ADJUSTMENT
ADJUSTMENT
NOTE
Service brake adjustment should be performed on all wheels to compensate for
normal brakeshoe lining wear.
1. Remove wheel choke on side being adjusted. Ensure opposite wheel is choked.
2. Place 3 ton hydraulic jack under trailer frame near wheel assembly to be adjusted.
NOTE
Prior to raising trailer make sure that stabilizer leg on opposite side of trailer is
not down.
3. Using three-ton jack, raise trailer to sufficient height where fully inflated wheel assembly (Figure 3, Item 2)
may be rotated freely.
4. Place three-ton jack stand (Figure 3, Item 1) under trailer axle between wheel assembly and axle mount.
Raise jack stand (Figure 3, Item 1) to meet trailer axle. Lower trailer onto jack stand.
WARNING
When the following step is being performed, the trailer is in a very unstable
position. This procedure should be performed in a timely manner and the trailer
should not be left unattended. Failure to observe this warning can result in
serious injury or death to personnel or damage to the TMSS-MED trailer and/or
its contents.
5. Release hand brake on side being adjusted.
6. Remove protective plug (Figure 3, Item 4) from backing plate.
7. Rotate star wheel (Figure 3, Item 3) upward, 20 to 25 clicks, to tighten brakes.
0126-15
TM 11-6115-742-13&P 0126
ADJUSTMENT – Continued
NOTE
The brake adjustment is performed by rotating the wheel using a torque wrench
(Figure 3, Item 5) and measuring the force required to turn the wheel. While
checking the adjustment, the wheel must be turned in the forward direction to
ensure correct adjustment. Rotate wheel in the forward direction from taillight
toward the tongue.
The torque wrench must be properly aligned on the wheel to ensure accurate
measurement of force. Proper placement for the torque wrench is with the
handle pointing away from the center of the wheel and in a straight line with the
center of the grease cap.
If the wheel rotates in the reverse or backwards direction, the brake shoes must
be aligned by starting the procedure again.
8. Rotate the wheel three or four revolutions in the forward direction and stop the wheel where two opposing lug
nuts are directly above and below the center of the grease cap.
9. Set torque wrench to 170 ± 17 in-lb (19 ± 1.9 N·m) and place on the top lug nut and turn the wheel 90
degrees, 1/4 rotation, in the forward direction checking whether the torque wrench exceeded the setting.
10. Move the torque wrench back to the top, checking every other lug nut and repeating step 9. Continue until
four lug nuts have been checked, one full rotation of the wheel.
11. Reset the torque wrench to 220 ± 22 in-lb (24 ± 2.4 N·m) and repeat steps 9 and 10. If the torque
measurements at two or more lugs are less than 170 in-lbs, tighten the brakes and repeat steps 9 through 11.
If the torque measurement at two or more lugs is greater than 220 in-lbs, loosen the brakes and repeat steps
9 through 11.
12. Loosen brakes by rotating star wheel in the opposite direction 25 clicks.
13. Install protective plug (Figure 3, Item 4) in backing plate.
14. Using three-ton jack, raise trailer to sufficient height to remove jack stand (Figure 3, Item 1).
15. Remove three-ton jack.
16. Repeat steps 5 through 15 for other side.
0126-16
TM 11-6115-742-13&P 0126
3
5
FORWARD
1 4
2 4
Figure 3. Brake Adjustment.
END OF TASK
END OF WORK PACKAGE
0126-17/18 blank
TM 11-6115-742-13&P 0127
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
TRAILER BRAKE CYLINDER
MASTER CYLINDER REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Equipment Condition
General mechanic’s tool kit (WP 0165, Item 1) Trailer parked in operational position
Standard automotive tool set (WP 0165, Item 5) Trailer handbrakes engaged
Wheels chocked
Materials/Parts ECU shut down
Master cylinder Genset shut down
Drain pans
Strap ties (WP 0168, Items 55 to 57)
Brake lines
Tow vehicle
Personnel Required
Two
GENERAL
This work package provides information on the removal and replacement of the following components:
• Master cylinder removal and replacement
• Brake lines removal and replacement
• Bleed brake system
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, components may be extremely cold or extremely
hot. To prevent serious injury to personnel, allow sufficient time for components
to warm up/cool down before performing procedures.
AC voltage (208 VAC, 3Ø), (28 VAC), and DC voltage (+28 VDC), and current
sufficient to cause serious injury or death are present. Before starting this task,
ensure all power is de-energized and disconnected from shelter. Failure to
comply with this warning could result in electrical shock or death to the
individual.
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
0127-1
TM 11-6115-742-13&P 0127
NOTE
When disconnecting brake line, brake fluid will drain out. Use drain pan to catch
old brake fluid and discard properly.
MASTER CYLINDER REMOVAL/REPLACEMENT
REMOVAL
1. Remove the main hydraulic brake line (Figure 1, Item 6) from master cylinder (Figure 1, Item 4).
2. Remove 2 mounting bolts (Figure 1, Item 8) and lock nuts (Figure 1, Item 3) from trailer frame (Figure 1,
Item 2) and master cylinder (Figure 1, Item 4).
3. Retain 4 spacers (Figure 1, Item 5) from between master cylinder (Figure 1, Item 4) and trailer frame
(Figure 1, Item 2).
4. Slide master cylinder (Figure 1, Item 4) back toward trailer bed, being careful not to damage actuator shaft
(Figure 1, Item 1).
END OF TASK
REPLACEMENT
1. Lift actuator shaft (Figure 1, Item 1) while sliding master cylinder (Figure 1, Item 4) into trailer frame (Figure 1,
Item 2).
2. Slide actuator shaft (Figure 1, Item 1) into slot in master cylinder plunger (Figure 1, Item 7).
3. Position spacers (Figure 1, Item 5) in between master cylinder (Figure 1, Item 4) and trailer frame (Figure 1,
Item 2).
4. Insert mounting bolts (Figure 1, Item 8) and lock nuts (Figure 1, Item 3) into trailer frame (Figure 1, Item 2),
master cylinder (Figure 1, Item 4), and spacers (Figure 1, Item 5) and tighten.
5. Attach main hydraulic brake line (Figure 1, Item 6) to master cylinder (Figure 1, Item 4) and tighten.
6. Bleed brakes as per this WP.
0127-2
TM 11-6115-742-13&P 0127
REPLACEMENT – Continued
1
2 3
4
8
7
5
6
5
Figure 1. Master Cylinder Removal/Replacement.
END OF TASK
0127-3
TM 11-6115-742-13&P 0127
BRAKE LINE REMOVAL/REPLACEMENT
WARNING
When performing maintenance on brake system, ensure that wheels are securely
chocked. Failure to follow this warning may cause trailer to roll, resulting in
serious injury or death to personnel or damage to equipment.
REMOVAL (MAIN HYDRAULIC LINE)
1. Ensure hand brakes are locked.
2. Ensure brake lockout is not engaged.
NOTE
When disconnecting brake line, brake fluid will drain out. Use drain pan to catch
old brake fluid and discard properly.
3. Place drain pans under the hydraulic brake line distribution block (Figure 2, Item 9) and the master cylinder
(Figure 2, Item 13).
4. Remove five lock nuts (Figure 2, Item 1) from the main hydraulic brake line mounting studs (Figure 2, Item 3).
5. Remove five mounting clamps (Figure 2, Item 2) from mounting studs (Figure 2, Item 3).
6. Disconnect the main brake line (Figure 2, Item 12) from the hydraulic brake line distribution block (Figure 2,
Item 9).
7. Drain brake fluid into drain pan.
8. Disconnect the main hydraulic brake line (Figure 2, Item 12) on master cylinder (Figure 2, Item 13).
9. Remove and retain mounting clamps (Figure 2, Item 2) from brake line and discard brake line.
END OF TASK
0127-4
TM 11-6115-742-13&P 0127
REPLACEMENT (MAIN HYDROLIC LINE)
1. Place the main hydraulic brake line (Figure 2, Item 12) into position through the trailer frame.
2. Place the five mounting clamps (Figure 2, Item 2) onto the main hydraulic brake line (Figure 2, Item 12) in the
vicinity of the five mounting studs (Figure 2, Item 3) and place the opening of the clamps onto the studs.
3. Attach the main hydraulic brake line (Figure 2, Item 12) onto the master cylinder (Figure 2, Item 13) and
tighten down.
4. Connect the main hydraulic brake line connector (Figure 2, Item 5) to the distribution block (Figure 2, Item 9)
and tighten down.
5. Install the five lock nuts (Figure 2, Item 1) onto the main hydraulic brake line mounting studs (Figure 2, Item 3)
and tighten down.
6. Bleed brakes as per this WP.
END OF TASK
REMOVAL (CROSS-OVER HYDRAULIC LINE)
1. Ensure hand brakes are locked.
2. Ensure brake lockout is not engaged.
NOTE
When disconnecting brake line, brake fluid will drain out. Use drain pan to catch
old brake fluid and discard properly.
3. Place a drain pan under each end of cross over hydraulic brake line.
4. Cut any zip ties securing the cross over brake line to the axle.
5. Disconnect cross over hydraulic brake line (Figure 2, Item 8) from the flexible brake line (Figure 2, Item 10).
Remove and retain clip (Figure 2, Item 11).
6. Disconnect cross over hydraulic brake line (Figure 2 Item 8) from hydraulic brake line distribution block
(Figure 2, Item 9).
7. Remove and discard brake line.
END OF TASK
REPLACEMENT (CROSS-OVER HYDRAULIC LINE)
1. Place the cross over brake line (Figure 2, Item 8) into position.
2. Finger tighten the cross over brake line (Figure 2, Item 8) onto the hydraulic brake line distribution block
(Figure 2, Item 9) on curb side of trailer.
3. Finger tighten cross over brake line (Figure 2, Item 8) onto the flexible brake line (Figure 2, Item 10) on street
side of trailer and secure with clip (Figure 2, Item 11).
4. Tighten down both connections.
0127-5
TM 11-6115-742-13&P 0127
REPLACEMENT (CROSS-OVER HYDRAULIC LINE) - Continued
5. Place a zip tie around the cross over hydraulic brake line and axle. Tighten down.
6. Trim the end of the zip tie off.
7. Bleed brakes as per this WP.
END OF TASK
REMOVAL (FLEXIBLE LINE)
1. Ensure hand brakes are locked.
2. Ensure brake lockout is not engaged.
NOTE
When disconnecting brake line, brake fluid will drain out. Use collection
container to catch old brake fluid and discard properly.
3. Place drain pans under both ends of the flexible brake lines (Figure 2, Item 3).
4. Disconnect the flexible brake line (Figure 2, Item 7) from the wheel cylinder (Figure 2, Item 6).
5. Disconnect the flexible brake line (Figure 2, Item 7) from the distribution block (Figure 2, Item 9). Remove
and retain clip (Figure 2, Item 11).
6. Disconnect the flexible brake line (Figure 2, Item 10) from the wheel cylinder.
7. Disconnect the flexible brake line (Figure 2, Item 10) from the cross over hydraulic brake line (Figure 2,
Item 8). Remove and retain clip (Figure 2, Item 11).
8. Discard brake lines.
END OF TASK
REPLACEMENT (FLEXIBLE LINE)
1. 1.Place the flexible line (Figure 2, Item 10) into position.
2. Finger tighten the flexible brake line (Figure 2, Item 10) onto the cross over brake line (Figure 2, Item 8).
Retain with clip (Figure 2, Item 11).
3. Finger tighten the flexible brake line (Figure 2, Item 10) onto the wheel cylinder.
4. Tighten down connections.
5. Finger tighten the flexible brake line (Figure 2, Item 7) onto the distribution block (Figure 2, Item 9). Retain
with clip (Figure 2, Item 11).
6. Finger tighten the flexible brake line (Figure 2, Item 7) onto the wheel cylinder (Figure 2, Item 6).
7. Tighten down connections.
8. Bleed brakes as per this WP.
0127-6
TM 11-6115-742-13&P 0127
2
1
13
12
5
9
11
8
10
7
Figure 2. Brake Line Removal/Replacement.
END OF TASK
0127-7
TM 11-6115-742-13&P 0127
BLEED BRAKE SYSTEM
WARNING
When performing maintenance on brake system, ensure that wheels are securely
chocked. Failure to follow this warning may cause trailer to roll, resulting in
serious injury or death to personnel or damage to equipment.
Personnel must maintain a safe distance from the rear of trailer during this
procedure.
NOTE
The preferred method to bleed brakes is to use a Filler and Bleeder Kit as per the
individual kit’s instruction manual. If a Filler and Bleeder Kit is not available,
perform the Bleed Brake System procedure in this WP as an alternate procedure.
BLEED BRAKE SYSTEM
1. Back trailer against a wall or other solid object to restrict personnel from rear of trailer.
CAUTION
Do not damage trailer cargo cross-member or tail light assemblies.
2. Ensure hand brakes are locked.
3. Ensure brake lockout is not engaged.
4. Fill master cylinder brake fluid reservoir as per (WP 0022) if necessary.
5. Attach tow vehicle to trailer and secure tongue jack assembly.
WARNING
Trailer may move during process. DO NOT lie under trailer while moving vehicle.
Severe injury may result to personnel.
6. Using tow vehicle, push back against trailer to compress master cylinder.
7. Remove the rubber dust cover (Figure 3, Item 2) from the cylinder bleed valve (Figure 3, Item 1) on the curb
side brake cylinder and set aside.
0127-8
TM 11-6115-742-13&P 0127
BLEED BRAKE SYSTEM – Continued
8. Connect plastic tube (Figure 3, Item 3) to the end of cylinder bleed valve (Figure 3, Item1) and route tube into
drain pan (Figure 3, Item 4).
9. Turn the curb side cylinder bleed valve (Figure 3, Item 1) 1/4 turn counter clockwise to loosen until air or fluid
escapes valve.
10. When air/ fluid flow decreases, turn the cylinder bleed valve (Figure 3, Item 1) 1/4 turn clockwise to tighten.
11. Check master cylinder reservoir level and fill as per (WP 0022) if necessary.
12. Using tow vehicle, pull and push back against trailer 3 times, ending with vehicle pulling against trailer.
13. Repeat steps 6 through 10, until no air escapes cylinder bleed valve (Figure 3, Item 1).
14. Remove tube (Figure 3, Item 3) and replace rubber dust cover (Figure 3, Item 2) on to cylinder bleed valve
(Figure 3, Item 1).
15. Repeat for street side brake cylinder.
16. Check master cylinder reservoir level and fill as per (WP 0022) if necessary.
17. Release trailer hand brakes.
18. Tow vehicle and stop, check that trailer tires brake.
19. Park trailer and disconnect tow vehicle.
1
2
Figure 3. Bleed Brake System.
END OF TASK
END OF WORK PACKAGE
0127-9/10 blank
TM 11-6115-742-13&P 0128
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
TRAILER BRAKES (BRAKE ACTUATOR AND HAND BRAKES)
BRAKE ACTUATOR COMPONENTS REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Reference
General mechanic’s tool kit (WP 0162, Item 1) WP 0127
Standard Automotive Tool Set (WP 0162, Item 5)
Equipment Condition
Materials/Parts Trailer parked in operational position
Actuator components Handbrakes engaged
Actuator assembly Wheels chocked
Hand brake assembly ECU shut down
Dry cleaning solvent (WP 0168, Item 11)
Cloth, cleaning (WP 0168, Item 14)
Hand brake cable and sheath
Personnel Required
Two Genset shut down
GENERAL
This work package provides information on the removal and replacement of the following components:
• Brake actuator components removal and replacement
• Brake actuator assembly removal and replacement
• Hand brake assembly removal, inspect, and replacement
• Hand brake cable and sheath removal and replacement
NOTE
The following brake actuator removal/replacement procedures are for the current
production model (fixed lunette). Due to safety issues, any brake actuator with
an adjustable lunette needs to be replaced with a brake actuator that has a fixed
lunette.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
If ECU has been in operation, components may be extremely cold or extremely
hot. To prevent serious injury to personnel, allow sufficient time for components
to warm up/cool down before performing procedures.
AC voltage (208 VAC, 3Ø), (28 VAC), and DC voltage (+28 VDC), and current
sufficient to cause serious injury or death are present. Before starting this task,
ensure all power is de-energized and disconnected from shelter. Failure to
comply with this warning could result in electrical shock or death to the
individual.
0128-1
TM 11-6115-742-13&P 0128
WARNING
Voltage sources, in addition to being an electrical shock hazard, may also
potentially produce serious burns. Care should be exercised when using hand
tools around exposed power connectors, never letting the tool bridge two
terminals. Failure to observe this warning can result in serious injury or death.
Lunette is heavy. Use caution when removing and replacing.
BRAKE ACTUATOR COMPONENTS REMOVAL/REPLACEMENT
REMOVAL
1. Remove master cylinder as per (WP 0127).
2. Remove bolt (Figure 3, Item 1) and lock nut (Figure 3, Item 3) from shock absorber (Figure 3, Item 4).
3. Remove four lock nuts (Figure 1, Item 1) from sides of actuator mounting studs (Figure 1, Item 4).
4. Remove two actuator mounting brackets (Figure 1, Item 2) and four spacers (Figure 1, Item 3) from same
side of actuator assembly and set aside.
5. Tap actuator mounting studs (Figure 1, Item 4), brackets (Figure 1, Item 2), spacers (Figure 1,
Item 3), and lock nuts (Figure 1, Item 1) through to other side. Set parts aside.
6. Lower tow pintle (Figure 2, Item 4) and actuator (Figure 2, Item 3) down from actuator assembly (Figure 2,
Item 2). Remove actuator (Figure 2, Item 3).
7. If replacing breakaway lever, remove bolt (Figure 2, Item 5) and lock nut (Figure 2, Item 6) from actuator
assembly (Figure 2, Item 2) and lift breakaway lever (Figure 2, Item 1) from actuator assembly (Figure 2,
Item 2).
8. If replacing shock absorber (Figure 3, Item 4), remove bolt (Figure 3, Item 5) and lock nut (Figure 3, Item 12)
from actuator (Figure 3, Item 10).
WARNING
Use caution when removing hydraulic push rod assembly due to spring tension.
9. If replacing hydraulic push rod (Figure 3, Item 6), washer (Figure 3, Item 8), and spring (Figure 3, Item 7),
place actuator (Figure 3, Item 10) on a suitable work surface and remove bolt (Figure 3, Item 9) and self-
locking nut (Figure 3, Item 11) from hydraulic push rod assembly (Figure 3, Item 13).
END OF TASK
0128-2
TM 11-6115-742-13&P 0128
REPLACEMENT
WARNING
Use caution when installing hydraulic push rod assembly due to spring tension.
1. If replacing hydraulic push rod (Figure 3, Item 6), washer (Figure 3, Item 8), and spring (Figure 3, Item 7),
place actuator (Figure 3, Item 10) on a suitable work surface and insert bolt (Figure 3, Item 9) through
actuator (Figure 3, Item 10) and hydraulic push rod assembly (Figure 3, Item 13). Secure with self-locking nut
(Figure 3, Item 11) and tighten.
2. If replacing shock absorber (Figure 3, Item 4), insert bolt (Figure 3, Item 5) through shock absorber (Figure 3,
Item 4) and actuator (Figure 3, Item 10) and secure with lock nut (Figure 3, Item 12).
3. If replacing breakaway lever, slide breakaway lever (Figure 3, Item 1) into slot in actuator assembly (Figure 2,
Item 2) and insert bolt (Figure 2, Item 5) through actuator assembly (Figure 2, Item 2) and breakaway lever
(Figure 2, Item 1) and secure with lock nut (Figure 2, Item 6).
4. Raise tow pintle (Figure 2, Item 4) and actuator (Figure 2, Item 3) into actuator assembly (Figure 2, Item 2).
5. Ensure that breakaway lever (Figure 2, Item 1) slides into slot in actuator groove (Figure 2, Item 3).
6. Insert actuator mounting studs (Figure 1, Item 4), mounting brackets (Figure 1, Item 2), spacers (Figure 1,
Item 3), and lock nuts (Figure 1, Item 1) into one side of actuator assembly (Figure 1, Item 5).
7. Install actuator mounting brackets (Figure 1, Item 2), spacers (Figure 1, Item 3), and lock nuts
(Figure 1, Item 1) on other side of actuator assembly (Figure 3, Item 5).
8. Install bolt (Figure 3, Item 1) through shock absorber (Figure 3, Item 4) and actuator (Figure 3, Item 2).
Secure with lock nut (Figure 3, Item 3). Tighten all hardware.
9. Install master cylinder as per (WP 0127).
0128-3
TM 11-6115-742-13&P 0128
1
2
2
1
Figure 1. Brake Actuator Mounting Brackets Removal/Replacement.
0128-4
TM 11-6115-742-13&P 0128
1
REF.
2 REF.
5 6
3
REF.
HITCH RELEASE DETAIL
ROTATED 90°
Figure 2. Tow Pintle and Breakaway Lever Removal/Replacement.
0128-5
TM 11-6115-742-13&P 0128
1
2
13
12
4
6
5
10
8
11 13(REF)
9
10
(REF)
Figure 3. Brake Actuator Shock Absorber and Hydraulic Push Rod Removal/Replacement.
END OF TASK
0128-6
TM 11-6115-742-13&P 0128
BRAKE ACTUATOR ASSEMBLY REMOVAL/REPLACEMENT
BRAKE ACTUATOR ASSEMBLY (New Version)
NOTE
The new version of the Brake Actuator Assembly features a fixed lunette. This
actuator is a “Recessed” 4 Bolt Type.
REMOVAL
1. Remove main hydraulic brake line from master cylinder (refer to WP 0127, if necessary).
2. Remove two bolts (Figure 4, Item 6), split lock washers (Figure 4, Item 7), and flat washers (Figure 4, Item 8)
that secure brake actuator assembly (Figure 4, Item 1) to trailer (Figure 4, Item 9) from underneath trailer.
3. Remove two bolts (Figure 4, Item 2), split lock washers (Figure 4, Item 4), locknuts (Figure 4, Item 5), and
four flat washers (Figure 4, Item 3) that secure brake actuator assembly (Figure 4, Item 1) to trailer (Figure 4,
Item 9) from above trailer.
4. Carefully lift and remove actuator assembly (Figure 4, Item 1) from trailer tongue (Figure 4, Item 9).
END OF TASK
REPLACEMENT
1. Place actuator assembly (Figure 4, Item 1) into recessed area of trailer tongue (Figure 4, Item 9).
2. From underneath the trailer tongue and actuator assembly, insert two bolts (Figure 4, Item 6), flat washers
(Figure 4, Item 8), and split washers (Figure 4, Item 7) through trailer tongue (Figure 4, Item 9) and actuator
assembly (Figure 4, Item 1).
3. From above the trailer tongue, insert two bolts (Figure 4, Item 2) and flat washers (Figure 4, Item 4) through
actuator assembly (Figure 1, Item 1) and trailer tongue (Figure 1, Item 9). Secure with two flat washers
(Figure 4, Item 3), split washers (Figure 4, Item 4), and lock nuts (Figure 4, Item 5) (refer to WP 0067 for
torque requirements).
4. Attach main hydraulic brake line to master cylinder (refer to WP 0127, if necessary).
5. Fill master cylinder and bleed brakes as necessary (refer to WP 0127).
0128-7
TM 11-6115-742-13&P 0128
8
4
7
6 5
Figure 4. Brake Actuator Assembly (New Version) Removal/Replacement.
END OF TASK
0128-8
TM 11-6115-742-13&P 0128
BRAKE ACTUATOR ASSEMBLY (Old Version)
NOTE
The old version of the Brake Actuator Assembly features a fixed lunette. This
actuator is side-bolted and is a 6 BOLT-ON Type.
If removing a brake actuator that has an adjustable lunette, replace with one that
has a fixed lunette.
REMOVAL
1. Remove main hydraulic brake line from master cylinder (refer to WP 0127, if necessary).
2. Remove six lock nuts (Figure 5, Item 5), twelve flat washers (Figure 5, Item 4), and six bolts (Figure 5, Item 3)
from actuator assembly (Figure 5, Item 1).
3. Remove actuator assembly (Figure 5, Item 1) from trailer tongue (Figure 5, Item 2).
END OF TASK
REPLACEMENT
1. Place actuator assembly (Figure 5, Item 1) onto trailer tongue (Figure 5, Item 2).
2. Insert six bolts (Figure 5, Item 3) and twelve washers (Figure 5, Item 4) into actuator assembly (Figure 5,
Item 1) and trailer tongue (Figure 5, Item 2). Secure with six lock nuts (Figure 5, Item 5) (refer to WP 0067 for
torque requirements).
3. Attach main hydraulic brake line to master cylinder (refer to WP 0127, if necessary).
4. Fill master cylinder and bleed brakes as necessary (refer to WP 0127).
0128-9
TM 11-6115-742-13&P 0128
NOTE
Any brake actuator with an adjustable lunette needs to be replaced with a brake
actuator that has a fixed lunette.
5
4
REPLACEMENT MODEL
Figure 5. Brake Actuator Assembly Removal/Replacement.
END OF TASK
0128-10
TM 11-6115-742-13&P 0128
HAND BRAKE ASSEMBLY REMOVAL/INSPECT/REPLACEMENT
WARNING
When performing maintenance on brake system, ensure that wheels are securely
chocked. Failure to follow this warning may cause trailer to roll, resulting in
serious injury or death to personnel or damage to equipment.
REMOVAL
1. Unlock hand brake to be removed.
2. Turn adjustment knob (Figure 6, Item 17) on hand brake lever to be removed to provide slack in cable
(Figure 6, Item 3).
3. Remove two locknuts (Figure 6, Item 13), two spacers (Figure 6, Item 14), and two bolts (Figure 6, Item 15)
securing hand brake assembly (Figure 6, Item 16) to frame. Discard locknuts.
4. Remove two bolts (Figure 6, Item 5), spacers (Figure 6, Item 6), and lock nuts (Figure 6, Item 9) from hand
brake lever assembly (Figure 6, Item 16). Retain front (Figure 6, Item 7) and back (Figure 6, Item 8) cable
mounting plates.
5. Using long nose pliers, remove cotter pin (Figure 6, Item 2) from clevis pin (Figure 6, Item 18) and remove
clevis pin and washer (Figure 6, Item 1) from hand brake lever assembly (Figure 6, Item 16). Discard cotter
pin.
6. Remove cable (Figure 6, Item 3) from hand brake lever assembly (Figure 6, Item 16).
END OF TASK
0128-11
TM 11-6115-742-13&P 0128
INSPECT
WARNING
Dry cleaning solvent, P-D-680, is toxic and flammable. Always wear protective
goggles and gloves and use solvent only in a well-ventilated area. Avoid contact
with skin, eyes, and clothes, and DO NOT breathe vapors. DO NOT use near
open flame or excessive heat. The solvent’s flash point is 100°F to 138°F (38°C
to 59°C). If you become dizzy while using cleaning solvent, immediately get
fresh air and medical help. If solvent contacts eyes, immediately wash your eyes
and get medical aid.
1. If reusing any components of hand brake assembly, clean components with dry cleaning solvent and allow to
dry.
2. Inspect hand brake cable end (Figure 6, Item 19) for excessive wear or damage. Replace if necessary.
3. Inspect clevis pin (Figure 6, Item 18) for excessive wear or damage. Replace if necessary.
4. Inspect cable assembly (Figure 6, Item 3) for frays, cracks, distortion, or seized cable in sheath. Replace if
necessary.
5. Inspect all threaded surfaces for damage. Replace any component if damaged.
6. Inspect hand brake lever (Figure 6, Item 4) and replace if necessary.
END OF TASK
REPLACEMENT
CAUTION
Do not push cable back through sheath. Cable may disconnect from hand brake
lever in wheel assembly which will cause hand brake failure.
1. Install clevis pin (Figure 6, Item 18) and washer (Figure 6, Item 1) through hand brake assembly (Figure 6,
Item 16), hand brake lever (Figure 6, Item 4) and hand brake cable (Figure 6, Item 3) and secure with cotter
pin (Figure 6, Item 2).
2. Position front (Figure 6, Item 7) and back (Figure 6, Item 8) cable mounting plates around hand brake cable
(Figure 6, Item 3).
3. Install two bolts (Figure 6, Item 5), spacers (Figure 6, Item 6), and nuts (Figure 6, Item 9) into hand brake
lever assembly (Figure 6, Item 16).
4. Install two bolts (Figure 6, Item 15), two spacers (Figure 6, Item 14), and two new locknuts (Figure 6, Item 13)
securing hand brake assembly (Figure 6, Item 16) to frame.
5. Turn adjustment knob (Figure 6, Item 17) until hand brake lever has one-third slack travel from the
disengaged position to the engaged position.
6. Turn adjustment knob slightly to make minor adjustments to hand brake tension.
0128-12
TM 11-6115-742-13&P 0128
Figure 6. Hand Brake Removal/Replacement.
END OF TASK
0128-13
TM 11-6115-742-13&P 0128
HAND BRAKE CABLE AND SHEATH REMOVAL/REPLACEMENT
WARNING
When performing maintenance on brake system, ensure that wheels are securely
chocked. Failure to follow this warning may cause trailer to roll, resulting in
serious injury or death to personnel or damage to equipment.
REMOVAL
1. Remove hand brake assembly as per this WP.
2. Remove three bolts (Figure 6, Item 11) and lock nuts (Figure 6, Item 12) securing clamps (Figure 6, Item 10)
and hand brake cable sheath (Figure 6, Item 3) to frame.
3. Remove clamps (Figure 6, Item 10) from cable sheath (Figure 6, Item 3).
4. Remove hand brake cable (Figure 6, Item 3) from frame.
5. Remove tire and wheel assembly as per (WP 0129).
6. Remove brake hub/drum as per (WP 0126).
7. Using a flat tip screw driver pry the end of the parking brake cable (Figure 7, Item 5) from the parking brake
lever (Figure 7, Item 3).
8. Grasp the nut (Figure 7, Item 7) on the lock securing the outer brake cable (Figure 7, Item 1) to the back of
the backing plate (Figure 7, Item 4) with vice grips or channel locks.
9. While pressing on the internal flanges (Figure 7, Item 6), using a twisting motion twist and pull the brake cable
lock (Figure 7, Item 2) away from the backing plate (Figure 7, Item 4) to release.
10. Remove brake cable (Figure 7, Item 2).
END OF TASK
0128-14
TM 11-6115-742-13&P 0128
REPLACEMENT
1. Insert cable (Figure 7, Item 1) through hole in backing plate (Figure 7, Item 4).
2. Holding nut (Figure 7, Item 7) with vice grips or channel locks, twist and push cable into hole in back of
backing plate (Figure 7, Item 4) to lock internal flanges (Figure 7, Item 6) into position.
3. Using needle nose channel locks, pull spring back from tip of cable to expose cable.
4. Lower cable (Figure 7, Item 5) into groove on hand brake lever (Figure 7, Item 3) so that clip is fully seated in
lever.
5. Release needle nose channel locks.
6. Place clamps in approximate locations on cable (Figure 6, Item 3) and place cable in approximate location
along frame.
7. Install three bolts (Figure 6, Item 11) and lock nuts (Figure 6, Item 12) to secure clamps (Figure 6, Item 10)
and hand brake cable sheath (Figure 6, Item 3) to frame.
8. Install hand brake assembly as per this WP.
9. Replace brake drum as per (WP 0126).
10. Replace tire and wheel assembly as per (WP 0129).
0128-15
TM 11-6115-742-13&P 0128
1 2
7
4
6
Figure 7. Hand Brake and Sheath Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0128-16
TM 11-6115-742-13&P 0129
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
TRAILER TIRE AND WHEEL ASSEMBLY
TIRE AND WHEEL ASSEMBLY SERVICE/REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools References
Standard automotive tool set WP 0005
(WP 0165, Item 1)
Jack stand Equipment Condition
Tire gauge Trailer parked in operational position
Trailer handbrakes engaged
Materials/Parts Wheels chocked
Wheel and run-flat assembly ECU shut down
Genset shut down
Personnel Required
Two
GENERAL
This work package provides information on the service, removal and replacement of the trailer tire and wheel
assembly.
If necessary, refer to (WP 0004) for the controls, indicators, and connectors of the trailer.
WARNING
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Ensure that TMSS-MED is level and ground is stable (not soggy or soft). Trailer
could sink into soft or unstable ground. Injury to personnel, or damage to TMSS-
MED trailer and/or its components could result from trailer suddenly rolling or
tipping.
Observe all lifting and weight restrictions. Failure to observe this warning can
result in serious injury or death to personnel or damage to the TMSS-MED trailer
and/or its contents.
0129-1
TM 11-6115-742-13&P 0129
SERVICE
1. Remove and retain tire valve cover.
2. Place tire pressure gauge on air valve and press down firmly. Tire pressure gauge should read 17 psi for off-
road and 20 psi for on road.
3. Read the tire pressure indicated on the gauge.
4. If necessary, add or delete air.
5. Repeat steps 2 through 4 until appropriate reading on tire pressure gauge is obtained.
6. Replace valve cover.
END OF TASK
REMOVAL
WARNING
When the following procedure is being performed, the trailer is in a very unstable
position. This procedure should be performed in a timely manner and the trailer
should not be left unattended. Failure to observe this warning can result in
serious injury or death to personnel or damage to the TMSS-MED trailer and/or
its contents.
Personnel performing this procedure should have another person near by incase
an adverse situation occurs. Failure to observe this warning can result in serious
injury or death to personnel or damage to the TMSS-MED trailer and/or its
contents.
Prior to performing any maintenance that requires climbing on or under trailer,
set trailer handbrakes and chock wheels. Injury to personnel could result from
trailer suddenly rolling or tipping.
Prior to performing the following procedure ensure that TMSS-MED is level and
ground is stable (not soggy or soft). Jack could sink into soft or unstable ground
Injury to personnel, or damage to TMSS-MED trailer and/or its components could
result from trailer suddenly rolling or tipping.
0129-2
TM 11-6115-742-13&P 0129
REMOVAL – Continued
WARNING
Tire and wheel assembly weight in excess of 110 lbs. Removal and replacement
require a two person lift to avoid personal injury.
CAUTION
Prior to performing the following procedure ensure that TMSS-MED is out of
service. No power cables or duct should be connected to the ECU or Genset.
Failure to observe this caution could result in serious damage to the TMSS-MED
trailer and/or its contents.
1. Remove all loose items from trailer and cargo area.
2. Verify that ECU has been shut down in accordance with ECU Stop Procedure (WP 0005).
3. Verify that Genset has been shut down, engine is cool and that BATTERY switch is set to OFF.
(WP 0005, Genset Stop Procedure).
4. Verify that trailer wheels are chocked, hand brakes are locked.
NOTE
If lug nut does not break loose, do not attempt to force, wheel stud could break.
Threads on some wheel studs are reversed (right is loose, left is tight).
5. Loosen but do not remove eight lug nuts (Figure 1, Item 1).
6. Place 3 ton hydraulic jack under trailer frame near wheel assembly (Figure 1, Item 2) to be removed.
NOTE
If tire is flat when performing the following step, trailer will need to be raised to a
height sufficient enough to install a fully inflated wheel assembly (Figure 1,
Item 2).
Prior to raising trailer make sure that stabilizer leg on opposite side of trailer is
not down.
7. Using three-ton jack, raise trailer to sufficient height where fully inflated wheel assembly (Figure 1, Item 2)
may be installed.
8. Place three-ton jack stand (Figure 1, Item 4) under trailer axle between wheel assembly (Figure 1, Item 2) and
axle mount. Raise jack stand (Figure 1, Item 4) to meet trailer axle. Lower trailer onto jack stand (Figure 1,
Item 4).
0129-3
TM 11-6115-742-13&P 0129
REMOVAL – Continued
WARNING
Never remove tire and wheel assembly with trailer supported on hydraulic jack.
Jack may collapse, causing injury to personnel and damage to equipment.
When the following step is being performed, the trailer is in a very unstable
position. This procedure should be performed in a timely manner and the trailer
should not be left unattended. Failure to observe this warning can result in
serious injury or death to personnel or damage to the TMSS-MED trailer and/or
its contents.
9. Remove and retain eight lug nuts (Figure 1, Item 1).
10. Remove wheel assembly (Figure 1, Item 2) and set aside.
END OF TASK
REPLACEMENT
1. Verify that trailer is high enough to accept wheel assembly (Figure 1, Item 2).
NOTE
Prior to installing wheel assembly, perform visual inspection of trailer area now
visible by tire assembly being removed. If any leaks or other visible damage is
present, notify your supervisor.
Prior to installing wheel assembly, perform visual inspection of wheel assembly.
Make sure tread is not excessively worn, no excessive cracking or wear of side
walls or no deterioration of rubber is present.
Prior to installing wheel assembly check pressure (off-road - 17 psi; on road -20
psi). If necessary adjust pressure.
2 Install wheel assembly (Figure 1, Item 2) by aligning lug nut studs (Figure 1, Item 3) with corresponding holes
in wheel assembly (Figure 1, Item 2).
CAUTION
When the following step is being performed, do not force lug nuts or cross
threads. Failure to observe this caution can result in damage to the TMSS-MED
trailer.
3. Keeping wheel assembly (Figure 1, Item 2) straight up and down, slide wheel assembly (Figure 1, Item 2)
onto studs (Figure 1, Item 3) and hold back. Install eight lug nuts (Figure 1, Item 1) and tighten finger tight.
4. Alternately tighten lug nuts using a crossing pattern.
5. Place three-ton hydraulic jack under trailer frame (near wheel assembly (Figure 1, Item 2) being replaced and
raise trailer high enough to remove jack stand (Figure 1, Item 4).
6. Slowly lower trailer so that wheel assembly (Figure 1, Item 2) is supporting weight of trailer.
0129-4
TM 11-6115-742-13&P 0129
REPLACEMENT – Continued
CAUTION
When the following step is being performed, do not over tighten lug nuts. Studs
could break off or wheels could be extremely difficult to remove next time.
7. Using a crossing pattern, verify that all lug nuts (Figure 1, Item 1) are tight. Torque lug nuts to 100 ± 5 lb – ft
(136 ± 7 N·m).
8. Start Genset in accordance with Genset Start Procedure (WP 0005) of this TM.
9. Verify that ECU power cable is connected to J1 of Genset and start ECU in accordance with ECU Start
Procedure (WP 0005) of this TM.
1 6
3 4
8 7
5 2
Tightening Patter n
4
3
Figure 1. Wheel Assembly Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0129-5/6 blank
TM 11-6115-742-13&P 0130
MAINTAINER MAINTENANCE INSTRUCTIONS
TMSS-MED
SHELTER LIGHTING
SHELTER LIGHTING REMOVAL/REPLACEMENT
INITIAL SETUP:
Tools and Special Tools Personnel Required
General mechanic’s tool kit One
(WP 0165, Item 1)
Equipment Condition
Materials/Parts Lighting fixture de-energized
Lamp, fluorescent
Fuse
GENERAL
This work package provides information on the removal and replacement of shelter lighting components. It
consists of:
• Fluorescent lamp removal/replacement
• Fuse removal/replacement
WARNING
High voltage and amperage present at electrical connections. Do not disconnect
lamp with power applied. To prevent serious injury to personnel or damage to
equipment ensure item is de-energized before performing the following
procedures.
If lighting fixture (Figure 1, Item 1) has been in operation components could be
hot. To prevent serious injury to personnel, allow sufficient time for components
to cool down before performing the following procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
NOTE
Recommended power-on, operating, and power-off procedures must be followed
to ensure proper equipment operation.
Observe all cautions and warnings when performing removal and replacement
procedures.
0130-1
TM 11-6115-742-13&P 0130
FLUORESCENT LAMP REMOVAL/REPLACEMENT
REMOVAL
1. Disconnect lighting fixture (Figure 1, Item 1) from power source.
2. Hold the lighting fixture (Figure 1, Item 1) so that the clear panel (Figure 1, Item 3) is facing up.
3. Remove and retain six screws (Figure 1, Item 5) that secure side panel (Figure 1, Item 4) (opposite end
of fuse and switch).
4. Tilt the side panel (Figure 1, Item 4) away from lighting fixture (Figure 1, Item 1) and slide down 1/2 inch.
5. Slide the clear panel (Figure 1, Item 3) out of the groove, over the side panel (Figure 1, Item 4).
6. Press red locking tab on connector down and hold to release the fluorescent lamp (Figure 1, Item 2).
7. Carefully lift fluorescent lamp (Figure 1, Item 2) out of connector.
CAUTION
Prior to removing fluorescent lamp (Figure 1, Item 2) inspect for damage. If
fluorescent lamp (Figure 1, Item 2) is cracked or broken do not grab with bare
hands.
8. Slide fluorescent lamp (Figure 1, Item 2) out and discard of properly.
END OF TASK
0130-2
TM 11-6115-742-13&P 0130
REPLACEMENT
NOTE
Prior to installing fluorescent lamp (Figure 1, Item 2) inspect for damage that
would prevent functionality. If fluorescent lamp (Figure 1, Item 2) appears burnt
(excessive black ring around ends) do not use.
1. Slide fluorescent lamp (Figure 1, Item 2) into securing clamp sleeve.
2. Align connectors with grooves in connection.
3. Press connectors into grooves to lock into place. When fluorescent lamp (Figure 1, Item 2) locks into place
red tab will pop up.
4. Slide clear panel (Figure 1, Item 3) over side panel (Figure 1, Item 4) and into groove.
5. Slide the side panel (Figure 1, Item 4) back into position. Groove in side panel (Figure 1, Item 4) should fit
over lighting fixture (Figure 1, Item 1).
6. Install six screws (Figure 1, Item 5) that secure side panel (Figure 1, Item 4) to lighting fixture (Figure 1,
Item 1).
NOTE
Do not over tighten.
Prior to returning lighting fixture (Figure 1, Item 1) to service, inspect fuse.
7. Connect lighting fixture (Figure 1, Item 1) to power source and return to service.
5
2
4
Figure 1. Fluorescent Lamp in Lighting Fixture Removal/Replacement.
END OF TASK
0130-3
TM 11-6115-742-13&P 0130
FUSE REMOVAL/REPLACEMENT
WARNING
If lighting fixture has been in operation components could be hot. To prevent
serious injury to personnel, allow sufficient time for components to cool down
before performing the following procedures.
High voltage and amperage present at electrical connections. Ensure that all
switches and circuit breakers have been de-energized prior to performing any
procedures.
REMOVAL
1. Disconnect lighting fixture (Figure 2, Item 1) from power source.
2. Press down on fuse cover (Figure 2, Item 2), twist counter-clockwise to release.
3. Remove cover (Figure 2, Item 2) and fuse (Figure 2, Item 3).
4. Remove fuse (Figure 2, Item 3) from cover (Figure 2, Item 2) and properly discard.
END OF TASK
REPLACEMENT
NOTE
Ensure fuse is proper type and value.
If uncertain weather fuse is good, measure fuse with multimeter (set on ohms). If
meter indicates short (0 ohms) fuse is good if meter indicates open (high
resistance) fuse is bad.
1. Insert fuse (Figure 2, Item 3) into cover (Figure 2, Item 2).
2. Insert assembly into socket, push down and twist clockwise.
3. Connect lighting fixture (Figure 2, Item 1) to power source and return to service.
0130-4
TM 11-6115-742-13&P 0130
Figure 2. Fuse in Lighting Fixture Removal/Replacement.
END OF TASK
END OF WORK PACKAGE
0130-5/6 blank
TM 11-6115-742-13&P
CHAPTER 9
PARTS INFORMATION
FOR
TMSS-MED
TM 11-6115-742-13&P 0131
PARTS INFORMATION
TMSS-MED
INTRODUCTION
SCOPE
This RPSTL lists the authorized spares and repair parts; special tools; special test, measurement, and diagnostic
equipment (TMDE); and other special support equipment required for performance of the field maintenance of the
POWER PLANT UTILITY, PU-821/T, PU822A/T. It authorizes the requisitioning, issue, and disposition of spares,
repair parts, and special tools as indicated by the source, maintenance, and recoverability (SMR) codes.
GENERAL
In addition to the Introduction work package, this RPSTL is divided into the following work packages.
1. Repair Parts List Work Packages. Work packages containing lists of spare and repair parts authorized for use
in the performance of maintenance at the levels determined by the MAC/SMR code. These work packages also
include parts which must be removed for replacement of the authorized parts. Parts lists are composed of
functional groups in ascending alphanumeric sequence, with the parts in each group listed in ascending Figure
and item number sequence. Sending units, brackets, filters, and bolts are listed with the component they mount
on. Bulk materials are listed by item name in the Bulk Items work package which follows the last Parts List work
package. Repair parts kits are listed separately in their own functional group and work package. Repair parts for
reparable special tools are also listed in a separate work package. Items listed are shown on the associated
illustrations.
2. Special Tools List Work Packages. This work package lists those special tools, special TMDE, and special
support equipment authorized by this RPSTL (as indicated by Basis of Issue (BOI) information in the
DESCRIPTION AND USABLE ON CODE (UOC) column). Tools that are components of common tool sets
and/or Class VII are not listed.
3. Cross-Reference Indexes Work Packages. There are two cross-reference indexes work packages in this
RPSTL. The National Stock Number (NSN) Index work package refers you to the Figure and item number for
each NSN listed in the RPSTL. The Part Number Index work package refers you to the Figure and item number
for each part number listed in the RPSTL.
EXPLANATION OF ENTRIES IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGES
ITEM NO. (Column (1)). Indicates the number used to identify items called out in the illustration.
SMR CODE (Column (2)). The SMR code containing supply/requisitioning information, maintenance level
authorization criteria, and disposition instruction, as shown in the following breakout. This entry may be
subdivided into 4 subentries, one for each service.
Table 1. SMR Code Explanation.
Source Maintenance Recoverability
Code Code Code
XX XX X
1st two 3rd position: 4th position: 5th position:
positions: Who can install, Who can do Who determines
How to get an replace, or use complete repair disposition action on
item. the item. on the item. unserviceable items.
0131-1
TM 11-6115-742-13&P 0131
NOTE
Complete Repair: Maintenance capacity, capability, and authority to perform
all corrective maintenance tasks of “Repair” function in a use/user
environment in order to restore serviceability to a failed item
Source Code. The source code tells you how to get an item needed for maintenance, repair, or overhaul of an
end item/equipment. Explanations of source codes follow:
Table 2. Source Code Explanation.
Source Code Application/Explanation
PA
PB
PC Stock items; use the applicable NSN to requisition/request items with
PD these source codes. They are authorized to the level indicated by the
PE code entered in the third position of the SMR code.
PF
PG NOTE
PH
PR Items coded PC are subject to deterioration.
PZ
KD Items with these codes are not to be requisitioned /requested individually.
KF They are part of a kit that is authorized to the maintenance level
KB indicated in the third position of the SMR code. The complete kit must be
requisitioned and applied.
MF-Made at Items with these codes are not to be requested/requisitioned individually.
maintainer class They must be made from bulk material which is identified by the P/N
MH-Made at below in the DESCRIPTION AND USABLE ON CODE (UOC) column
depot/sustainment class and listed in the bulk material group work package of the RPSTL. If the
ML-Made at SRA item is authorized to you by the third position code of the SMR code,
MD-Made at depot but the source code indicates it is made at higher level, order the item
from the higher level of maintenance.
AF–Assembled by Items with these codes are not to be requested/requisitioned individually.
maintainer class The parts that make up the assembled item must be requisitioned or
AH–Assembled by below fabricated and assembled at the level of maintenance indicated by the
depot sustainment class source code. If the third position of the SMR code authorizes you to
AL–Assembled by SRA replace the item, but the source code indicates the item is assembled at
AD–Assembled by depot a higher level, order the item from the higher level of maintenance.
XA Do not requisition an “XA” coded item. Order the next higher assembly.
(Refer to NOTE below).
XB If an item is not available from salvage, order it using the CAGEC and
P/N.
XC Installation drawings, diagrams, instruction sheets, field service drawings;
identified by the manufacturer’s P/N.
XD Item is not stocked. Order an XD-coded item through local purchase or
normal supply channels using the CAGEC and P/N given, if no
NSN is available.
0131-2
TM 11-6115-742-13&P 0131
NOTE
Cannibalization or controlled exchange, when authorized, may be used as a
source of supply for items with the above source codes except for those items
source coded “XA” or those aircraft support items restricted by requirements of
AR 750-1.
Maintenance Code. Maintenance codes tell you the level(s) of maintenance authorized to use and repair support
items. The maintenance codes are entered in the third and fourth positions of the SMR codes as follows:
Third Position. The maintenance code entered in the third position tells you the lowest maintenance class
authorized to remove, replace, and use an item. The maintenance code entered in the third position will indicate
authorization to the following classes of maintenance:
Maintenance
Code Application/Explanation
C- Crew
F- Maintainer maintenance can remove, replace, and use the item
H- Below Depot Sustainment maintenance can remove, replace, and use the item.
L- Specialized repair activity can remove, replace, and use the item.
K- Contractor facility can remove, replace, and use the item.
Z- Item is not authorized to be removed, replaced, or used at any maintenance
level.
D- Depot can remove, replace, and use the item.
NOTE
Army will use C in the third position. However, for joint service publications, other services
may use O
Fourth position. The maintenance code entered in the fourth position tells you whether or not the item is to be
repaired and identifies the lowest maintenance class with the capability to do complete repair (perform all
authorized repair functions).
Maintenance
Code Application/Explanation
C- Crew (operator) is the lowest class that can do complete repair
F- Maintainer is the lowest class that can do complete repair of the item.
H- Below Depot Sustainment is the lowest class that can do complete repair of
the item.
L- Specialized repair activity (enter specialized repair activity or
TASMG designator) is the lowest class that can do complete repair
of the item.
0131-3
TM 11-6115-742-13&P 0131
Maintenance
Code Application/Explanation
D- Depot is the lowest class that can do complete repair of the item.
K- Complete repair is done at contractor facility.
Z- Nonreparable. No repair is authorized.
B- No repair is authorized. No parts or special tools are authorized for
maintenance of “B” coded item. However, the item may be reconditioned
by adjusting, lubricating, etc., at the user level.
Recoverability Code. Recoverability codes are assigned to items to indicate the disposition action on
unserviceable items. The recoverability code is shown in the fifth position of the SMR code as follows:
Recoverability
Code Application/Explanation
Z- Nonreparable item. When unserviceable, condemn and dispose of the item at the level of
maintenance shown in the third position of the SMR code.
F- Reparable item. When uneconomically reparable, condemn and dispose of the item at
the field level.
H- Reparable item. When uneconomically reparable, condemn and dispose of the item at
the below depot sustainment.
D- Reparable item. When beyond lower level repair capability, return to depot.
Condemnation and disposal of item are not authorized below depot.
L- Reparable item. Condemnation and disposal not authorized below Specialized Repair
Activity (SRA).
A- Item requires special handling or condemnation procedures because of specific reasons
(such as precious metal content, high dollar value, critical material, or hazardous
material). Refer to appropriate manuals/directives for specific instructions.
NSN (Column (3)). The NSN(s) for the item is listed in this column.
CAGEC (Column (4)). The Commercial and Government Entity Code (CAGEC) is a five-digit code which is used
to identify the manufacturer, distributor, or Government agency/activity that supplies the item.
PART NUMBER (Column (5)). Indicates the primary number used by the manufacturer (individual, company, firm,
corporation, or Government activity), which controls the design and characteristics of the item by means of its
engineering drawings, specifications, standards, and inspection requirements to identify an item or range of items.
NOTE
When you use an NSN to requisition an item, the item you receive may have a
different part number from the number listed.
0131-4
TM 11-6115-742-13&P 0131
DESCRIPTION AND USABLE ON CODE (UOC) (Column (6)). This column includes the following information:
1. The federal item name, and when required, a minimum description to identify the item.
2. Part numbers of any bulk materials required if the item is to be locally manufactured or fabricated.
3. Hardness Critical Item (HCI). Items that require special handling or procedures to ensure protection against
electrostatic pulse (EMP) damage are marked with the letters “HCI”.
4. The statement END OF FIGURE appears below the last item description in column (6) for each Figure in the
repair parts list, special tools repair parts, kits, bulk items, and special tools list work packages.
QTY (Column (7)). The QTY (quantity per Figure) column indicates the quantity of the item used in the breakout
shown on the illustration/Figure. A “V” appearing in this column instead of a quantity indicates that the quantity is
variable and quantity may change from application to application.
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGES FORMAT AND COLUMNS
1. National Stock Number (NSN) Index Work Package. NSN’s in this index are listed in National Item
Identification Number (NIIN) sequence.
STOCK NUMBER Column. This column lists the NSN in NIIN sequence. The NIIN consists of the last nine digits
of the NSN. When using this column to locate an item, ignore the first four digits of the NSN. However, the
complete NSN should be used when ordering items by stock number.
For example, if the NSN is 5385-01-574-1476, the NIIN is 01-574-1476.
FIG. Column. This column lists the number of the Figure where the item is identified/located. The Figures are in
numerical order in the repair parts list and special tools list work packages.
ITEM Column. The item number identifies the item associated with the Figure listed in the adjacent FIG. column.
This item is also identified by the NSN listed on the same line.
2. Part Number (P/N) Index Work Package. Part Numbers in this index are listed in ascending alphanumeric
sequence (vertical arrangement of letter and number combinations which places the first letter or digit of each
group in order A through Z, followed by the numbers 0 through 9 and each following letter or digit in like order).
PART NUMBER Column. This column indicates the part number assigned to the item.
FIG. Column. This column lists the number of the Figure where the item is identified/located in the repair parts list
and special tools list work packages.
ITEM Column. The item number is the number assigned to the item as it appears in the Figure referenced in the
adjacent Figure number column.
SPECIAL INFORMATION
UOC. The UOC appears in the lower left corner of the Description Column heading. Usable on codes are shown
as "UOC:" in the Description Column (justified left) on the first line under the applicable item/nomenclature.
Uncoded items are applicable to all models. Examples of the UOCs used in the RPSTL are:
Code Used On
89W POWER PLANT UTILITY, PU-821/T
89X POWER PLANT UTILITY, PU-822A/T
0131-5
TM 11-6115-742-13&P 0131
Associated Publications. The publication listed below pertains to the Power Utility Plant, PU-821/T, PU-822A/T.
Publication Short Title
TM 9-2330-392-14&P Trailer, Cargo
Fabrication Instructions. Bulk materials required to manufacture items are listed in the bulk material work
package of this RPSTL. Part numbers for bulk material are also referenced in the Description Column of the line
item entry for the item to be manufactured/fabricated. Detailed fabrication instructions for items source coded to
be manufactured or fabricated are found in (enter applicable TM number).
Index Numbers. Items which have the word BULK in the Figure column will have an index number shown in the
item number column. This index number is a cross-reference between the NSN / Part Number (P/N) Index work
packages and the bulk material list in the bulk items work package.
HOW TO LOCATE REPAIR PARTS
1. When NSNs or Part Numbers Are Not Known.
First. Using the table of contents, determine the assembly group to which the item belongs. This is necessary
since Figures are prepared for assembly groups and subassembly groups, and lists are divided into the same
groups.
Second. Find the Figure covering the functional group or subfunctional group to which the item belongs.
Third. Identify the item on the Figure and note the number(s).
Fourth. Look in the repair parts list work packages for the Figure and item numbers. The NSNs and part
numbers are on the same line as the associated item numbers.
2. When NSN Is Known.
First. If you have the NSN, look in the STOCK NUMBER column of the NSN index work package. The NSN is
arranged in NIIN sequence. Note the Figure and item number next to the NSN.
Second. Turn to the Figure and locate the item number. Verify that the item is the one for which you are looking
for.
3. When Part Number Is Known.
First. If you have the part number and not the NSN, look in the PART NUMBER column of the part number index
work package. Identify the Figure and item number.
Second. Look up the item on the Figure in the applicable repair parts list work package.
ABBREVIATIONS
Not Applicable.
END OF WORK PACKAGE
0131-6
TM 11-6115-742-13&P 0132
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
POWER PLANT, UTILITY, A1-38283D-001 (PU-821/T), A1-38283D-002 (PU-822A/T)
0132-1
TM 11-6115-742-13&P 0132
Figure 1. Power Plant, Utility, A1-38283D-001 (PU-821/T), A1-38283D-002 (PU-822A/T).
0132-2
TM 11-6115-742-13&P 0132
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 00
FIGURE 1 POWER PLANT, UTILITY
A1-38283D-001(PU821/T),
A1-38283D-002(PU822A/T)
1 PDFDD 8340-01-533-5396 0WFM3 TMSS100G TENT,MODULAR,GENERAL
PURPOSE (SEE FIGURE 2
FOR BREAKDOWN) .................... 1
UOC: 89W
1 PDFDD 8340-01-533-5344 0WFM3 TMSS100T TENT,MODULAR,GENERAL
PURPOSE (SEE FIGURE 2
FOR BREAKDOWN) .................... 1
UOC: 89X
END OF FIGURE
0132-3/4 blank
TM 11-6115-742-13&P 0133
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
TENT, MODULAR, GENERAL PURPOSE SYSTEM, TMSS100/G/TMSS100T
3 4
Figure 2. Tent, Modular, General Purpose System, TMSS100G/TMSS100T (Sheet 1 of 2).
0133-1
TM 11-6115-742-13&P 0133
15
14
10
11
11
13
11
10 12
Figure 2. Tent, Modular, General Purpose System, TMSS100G/TMSS100T (Sheet 2 of 2).
0133-2
TM 11-6115-742-13&P 0133
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 01
FIGURE 2 TENT, MODULAR,
GENERAL PURPOSE
SYSTEM
TMSS100G/TMSS100T
1 PAFZZ 2540-01-558-8455 0WFM3 SH535-0007G TARPAULIN ................................. 1
UOC: 89W
1 PAFZZ 2540-01-558-7518 0WFM3 SH535-0007T COVER, FITTED, VEHICULAR
BODY ........................................... 1
UOC: 89X
2 PAFZZ 8340-01-572-0253 0WFM3 SH535-0008G TARPAULIN ................................. 1
UOC: 89W
2 PAFZZ 2540-01-558-8554 0WFM3 SH535-0008T TARPAULIN ................................. 1
UOC: 89X
3 PAFZZ 5340-01-554-2739 1KDE3 C408115 EYE HOOK .................................. 14
4 PAFZZ 3990-01-552-8296 0WFM3 SH535-0006 TIE DOWN,CARGO,VEHICLE .... 1
5 XBFDD 0WFM3 T256250G AIR CONDITIONER (SEE
FIGURE 3 FOR BREAKDOWN) .. 1
UOC: 89W
5 XBFDD 0WFM3 T256250T AIR CONDITIONER (SEE
FIGURE 3 FOR BREAKDOWN) .. 1
UOC: 89X
6 PACDD 8340-01-538-1822 0WFM3 MXA2000G TENT (SEE FIGURE 23 FOR
BREAKDOWN) ............................ 1
UOC: 89W
6 PACDD 8340-01-538-1823 0WFM3 MXA2000T TENT (SEE FIGURE 23 FOR
BREAKDOWN) ............................ 1
UOC: 89X
7 PAFDA 8340-01-491-3057 0WFM3 T2-93000-1 POWER DISTRIBUTION UNIT,
TENT ............................................ 1
8 PAFFF 6230-01-568-4487 0WFM3 H300070 LIGHT SET,TENT (SEE
FIGURE 26 FOR
BREAKDOWN) ............................ 1
9 PAFZZ 6150-01-552-6358 0WFM3 T295004 CABLE ASSEMBLY,POWER,
ELECTRICAL ............................... 1
10 PAFZZ 5305-01-552-6246 1KDE3 50C175HCS1 SCREW.CAP,HEXAGON
HEAD ........................................... 10
11 PAFZZ 5310-01-554-1192 1KDE3 50N125WSP1 WASHER,FLAT ........................... 16
12 PAFZZ 5310-01-559-2446 1KDE3 50CNNE1 NUT,SELF-LOCKING,
HEXAGON ................................... 6
13 PAFZZ 5310-01-552-6251 1KDE3 50NLOC1 WASHER,LOCK .......................... 4
0133-3
TM 11-6115-742-13&P 0133
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
14 XBDDD 0WFM3 T215125G CHASSIS,TRAILER
ASSEMBLY (SEE FIGURE 18
FOR BREAKDOWN) .................... 1
UOC: 89W
14 XBDDD 0WFM3 T215125T CHASSIS,TRAILER
ASSEMBLY (SEE FIGURE 18
FOR BREAKDOWN) .................... 1
UOC: 89X
15 PAFDD 0WFM3 1007206 GENERATOR,DIESEL
ENGINE (SEE FIGURE 8 FOR
BREAKDOWN) ............................ 1
UOC: 89W
15 PAFDD 0WFM3 1007205 GENERATOR,DIESEL
ENGINE (SEE FIGURE 8 FOR
BREAKDOWN) ............................ 1
UOC: 89X
END OF FIGURE
0133-4
TM 11-6115-742-13&P 0134
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
AIR CONDITIONER, T256250G/T256250T
0134-1
TM 11-6115-742-13&P 0134
Figure 3. Air Conditioner, T256250G/T256250T.
0134-2
TM 11-6115-742-13&P 0134
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 0101
FIGURE 3 AIR CONDITIONER
T256250G/T256250T
1 XBFDD 0WFM3 T250250G AIR CONDITIONER
ENCLOSURE (SEE FIGURE 4
FOR BREAKDOWN) ...................... 1
UOC: 89W
1 XBFDD 0WFM3 T250250T AIR CONDITIONER
ENCLOSURE (SEE FIGURE 4
FOR BREAKDOWN) ...................... 1
UOC: 89X
2 PAFZZ 4720-01-553-5758 0WFM3 T291433 HOSE,AIR DUCT ........................... 1
UOC: 89W
2 PAFZZ 4720-01-558-9393 0WFM3 T291527 HOSE,AIR DUCT ........................... 1
UOC: 89X
3 PAFZZ 4720-01-553-5827 0WFM3 T291434 HOSE,AIR DUCT ........................... 1
UOC: 89W
3 PAFZZ 4720-01-559-2546 0WFM3 T291528 HOSE,AIR DUCT ........................... 1
UOC: 89X
4 PAFZZ 8105-01-575-2509 0WFM3 A602126 BAG,DUCT TRANSPORT.............. 2
END OF FIGURE
0134-3/4 blank
TM 11-6115-742-13&P 0135
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
AIR CONDITIONER ENCLOSURE, T250250G/T250250T
0135-1
TM 11-6115-742-13&P 0135
P/O 2
P/O 2
7
2
14
LIFT
D
AN N
1
R
TU
SH
PU
TURN
AND
LIFT
PUSH
13
3
P/O 13
P/O 13
12
5
A 11
B
C
6
7
10 4
1 8
Figure 4. Air Conditioner Enclosure, T250250G/T250250T (Sheet 1 of 5).
0135-2
TM 11-6115-742-13&P 0135
15
16
17
19 18
20
19
HYDRONIC HEATER
19 WIRING HARNESS
19
20
CONNECTION
19 P/O 18
25 23 19 21
26 23 24
19 22
26 25
26
TO ADAPTER
OR BOTTOM
TO HEATING OF COOLANT
ELEMENT TANK
(LOWER PIPE) 27
26 28 6
30
23
23 24
24 23
23
29
23
31
23
15 30
24
Figure 4. Air Conditioner Enclosure, T250250G/T250250T (Sheet 2 of 5).
0135-3
TM 11-6115-742-13&P 0135
39
38
37
36
35
34
33
E 32
Figure 4. Air Conditioner Enclosure, T250250G/T250250T (Sheet 3 of 5).
0135-4
TM 11-6115-742-13&P 0135
P/O 41
P/O 41
40
41
42
P/O 42
43
Figure 4. Air Conditioner Enclosure, T250250G/T250250T (Sheet 4 of 5).
0135-5
TM 11-6115-742-13&P 0135
TO HEATING 19
ELEMENT
(UPPER PIPE)
19
44
48
47
46
26
45
TO
19 HYDRONIC
HEATER
25
19
D
50
49 51
6
15
52
P/O 51 53
P/O 51
Figure 4. Air Conditioner Enclosure, T250250G/T250250T (Sheet 5 of 5).
0135-6
TM 11-6115-742-13&P 0135
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 010101
FIGURE 4 AIR CONDITIONER
ENCLOSURE
T250250G/T250250T
1 XBFZZ 0WFM3 1002764 PANEL,ACCESS ......................... 1
UOC: 89W
1 XBFZZ 0WFM3 1002757 PANEL,ACCESS ......................... 1
UOC: 89X
2 PAFZZ 5340-01-468-1309 94222 C2-32-35 CATCH,CLAMPING..................... 8
3 XBFZZ 0WFM3 1002765 PANEL,ACCESS ......................... 2
UOC: 89W
3 XBFZZ 0WFM3 1002758 PANEL,ACCESS ......................... 2
UOC: 89X
4 PAFZZ 3C0M7 024T115 FILTER ELEMENT,
INTAKE,AIR CLEANER ............... 2
5 XBFFF 0WFM3 1002761 PANEL,EVAPORATOR
ASSEMBLY (SEE FIGURE 5
FOR BREAKDOWN) .................... 1
UOC: 89W
5 XBFFF 0WFM3 1002754 PANEL,EVAPORATOR
ASSEMBLY (SEE FIGURE 5
FOR BREAKDOWN) .................... 1
UOC: 89X
6 PAFZZ 5310-01-552-2776 1KDE3 25NWFL1 WASHER,FLAT ........................... 18
7 PAFZZ 5305-01-552-8706 3C0M7 100T330 SCREW,MACHINE ...................... 8
8 PAFZZ 5315-01-552-8316 3C0M7 021T116 PIN,RETAINING .......................... 8
9 PAFZZ 5305-00-959-4158 80205 MS24693-C273 SCREW,MACHINE ...................... 16
10 XBFZZ 0WFM3 1002763 PANEL,ACCESS ......................... 1
UOC: 89W
10 XBFZZ 0WFM3 1002756 PANEL,ACCESS ......................... 1
UOC: 89X
11 XCFDD 0WFM3 TG423-0901 BLOWER ASSEMBLY (SEE
FIGURE 7 FOR BREAKDOWN) .. 1
12 XBFDD 3C0M7 088T103 CONTROL ENCLOSURE,AIR
CONDITIONER (SEE FIGURE
6 FOR BREAKDOWN) ................. 1
13 PAFZZ 5340-01-552-0719 94222 62-74-25 CATCH,FLUSH ............................ 1
14 XBFZZ 3C0M7 081T102G GRILL,CONDENSER .................. 1
UOC: 89W
14 XBFZZ 3C0M7 081T102T GRILL,CONDENSER .................. 1
UOC: 89X
0135-7
TM 11-6115-742-13&P 0135
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
15 PAFZZ 5310-01-552-3984 1KDE3 25CNNE1 NUT,SELF-LOCKING,
HEXAGON ................................... 8
16 PAFZZ 5365-01-559-2443 1KDE3 25N62ZR5A SPACER,PLATE.......................... 3
17 PAFZZ 5307-01-558-7259 44MG9 91887A STUD,SHOULDERED ................. 3
18 PAFZZ 2990-01-552-6325 44MG9 97359A HEATER,COOLANT,ENGINE ..... 1
19 PAFZZ 4730-01-492-6678 39428 5388K18 CLAMP,HOSE ............................. 8
20 PAFZZ 4210-01-568-9442 44MG9 5023298A HOSE,METALLIC ........................ 2
21 PAFZZ 5920-01-123-5212 58536 AA55569/01- FUSE,INCLOSED LINK ............... 1
005
22 PAFZZ 5920-01-149-6952 58536 AA55569/01- FUSE,INCLOSED LINK ............... 1
008
23 PAFZZ 4730-01-552-2772 44MG9 330027 CLAMP,HOSE ............................. 8
24 PAFZZ 4720-01-552-9960 44MG9 484032 HOSE,NONMETALLIC ................ 4
25 PAFZZ 4730-01-569-7756 39428 5520K302 REDUCER,PIPE .......................... 2
26 PAFZZ 4730-01-556-5477 0Y3H3 62008 CLAMP,HOSE ............................. 7
27 PAFZZ 5305-01-552-3987 1KDE3 25C100HCS1 SCREW,CAP,HEXAGON
HEAD ........................................... 1
28 PAFZZ 4730-01-552-6415 44MG9 1310763A CLAMP,HOSE ............................. 1
29 PAFZZ 2910-01-553-0046 44MG9 50487171A FILTER ELEMENT,FLUID ........... 1
30 XBFZZ 44MG9 50483931A FUEL LINE,PLASTIC................... 1
31 PAFZZ 2910-01-553-0047 44MG9 86116A PUMP,FUEL,ELECTRICAL ......... 1
32 PAFZZ 5340-01-568-7761 3C0M7 063T103 MOUNT RESILIENT,GENERAL
PURPOSE.................................... 1
33 PAFZZ 5930-01-568-7581 4BDY7 SLP2550 SWITCH,PRESSURE .................. 1
34 PAFZZ 0LCG1 29PSL020-33- SWITCH,PRESSURE .................. 1
500
35 PAFZZ 5340-01-569-2970 3C0M7 063T105 MOUNT,RESILIENT,GENERAL
PURPOSE.................................... 1
36 PAFZZ 4130-00-903-8372 70255 EK-165S FILTER-DRIER,
REFRIGERANT ........................... 1
37 PAFZZ 4820-01-333-6042 21013 RV5100025C VALVE,SAFETY RELIEF............. 1
38 PAFZZ 3835-01-568-7074 78462 EFVE-1-L1 VALVE SECTION,PIPELINE ....... 1
39 PAFZZ 4820-01-165-7825 78462 ADRSE-2-0/80- VALVE,EXPANSION ................... 1
3/8ODF
40 PAFZZ 9999-01-568-8609 3C0M7 053T102 COIL,SOLENOID ......................... 1
41 PAFZZ 4810-01-568-7071 78462 OE10S240 VALVE,SOLENOID...................... 1
42 PAFZZ 5930-01-568-9799 0WFM3 1000947 SWITCH,PUSH ............................ 1
43 PAFZZ 4830-01-568-7079 78462 EFVE-5-CP100 VALVE,EXPANSION ................... 1
44 PAFZZ 2930-01-569-1146 0WFM3 1000905 CAP,FILLER OPENING............... 1
0135-8
TM 11-6115-742-13&P 0135
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
45 PAFZZ 4730-01-539-9942 39428 5346K66 ADAPTER,STRAIGHT,PIPE
TO HOSE ..................................... 1
46 PAFZZ 5320-01-568-6990 39428 97447A220 RIVET,BLIND ............................... 2
47 XBFZZ 3C0M7 006T102 TANK,COOLANT,DIESEL ........... 1
48 PAFZZ 4730-01-569-1177 39428 53525K22 ELBOW,TUBE TO BOSS ............ 1
49 XBFZZ 3C0M7 60-B-176 PLATE,COMPRESSOR
MOUNTING.................................. 1
50 PAFZZ 5305-01-529-4402 2V507 92865A540 SCREW,CAP,HEXAGON
HEAD ........................................... 8
51 PAFDD 70255 ZR72KCE-TF5- COMPRESSOR
250 UNIT,REFRIGERATION .............. 1
52 PAFZZ 5305-01-569-1152 39428 91247A548 SCREW,CAP,HEXAGON
HEAD ........................................... 4
53 PAFZZ 5340-01-520-7456 14569 527-0116-00 BUMPER...................................... 1
END OF FIGURE
0135-9/10 blank
TM 11-6115-742-13&P 0136
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
PANEL, EVAPORATOR ASSEMBLY, 1002761, 1002754
0136-1
TM 11-6115-742-13&P 0136
4
5
8
7
1
2
Figure 5. Panel, Evaporator Assembly, 1002761, 1002754.
0136-2
TM 11-6115-742-13&P 0136
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 01010101
FIGURE 5 PANEL, EVAPORATOR
ASSEMBLY
1002761,
1002754
1 PAFZZ 5310-01-552-2776 1KDE3 25NWFL1 WASHER,FLAT .............................. 6
2 PAFZZ 5305-01-552-8706 3C0M7 100T330 SCREW,MACHINE ........................ 6
3 PAFZZ 5355-01-552-3328 39428 7921K216 KNOB ............................................. 1
4 XBFZZ 0WFM3 TG423-0451-2G DOOR,SLIDING ............................. 1
UOC: 89W
4 XBFZZ 0WFM3 1006024 DOOR,SLIDING ............................. 1
UOC: 89X
5 XBFZZ 0WFM3 TG423-0501-1G PLATE,DAMPER ............................ 1
UOC: 89W
5 XBFZZ 0WFM3 1006026 PLATE,DAMPER ............................ 1
UOC: 89X
6 PAFZZ 5340-01-552-7835 0WFM3 T295161G COVER,PROTECTIVE,DUST
AND MOISTURE SEAL .................. 2
UOC: 89W
6 PAFZZ 5340-01-558-6141 0WFM3 T295161T COVER,PROTECTIVE,DUST
AND MOISTURE SEAL .................. 2
UOC: 89X
7 PAFZZ 5305-01-568-3945 5N835 1166-278 SCREW,MACHINE ........................ 1
8 XBFZZ 0WFM3 TG423-0551-1G ROD,DAMPER ............................... 1
UOC: 89W
8 XBFZZ 0WFM3 1006025 ROD,DAMPER ............................... 1
UOC: 89X
9 PAFZZ 5310-01-479-5890 0Y3H3 70862 NUT,SELF-LOCKING,
HEXAGON...................................... 1
END OF FIGURE
0136-3/4 blank
TM 11-6115-742-13&P 0137
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
CONTROL, ENCLOSURE, AIR CONDITIONER, 088T103
0137-1
TM 11-6115-742-13&P 0137
P/O 3
3
P/O 2
2 P/O 4
P/O 5
1
P/O 1
13 4
12 P/O 4
P/O 11 11
P/O 2 5
P/O 11 P/O 5
6
7
11
2
8
P/O 10 P/O 7
P/O 10 9
10
VERSION 1
Figure 6. Control, Enclosure, Air Conditioner, 088T103 (Sheet 1 of 11).
0137-2
TM 11-6115-742-13&P 0137
P/O 3
3
P/O 2
2 P/O 4
P/O 5
14
P/O 14
13 4
12 P/O 4
P/O 11 11
P/O 2 5
P/O 11 P/O 5 6
7
11
2
8
P/O 7
P/O 10
P/O 10 9
10
VERSION 2
Figure 6. Control, Enclosure, Air Conditioner, 088T103 (Sheet 2 of 11).
0137-3
TM 11-6115-742-13&P 0137
VERSION 1 VERSION 2
16
15
Figure 6. Control, Enclosure, Air Conditioner, 088T103 (Sheet 3 of 11).
0137-4
TM 11-6115-742-13&P 0137
VERSION 1
18
17
21
19
20
Figure 6. Control, Enclosure, Air Conditioner, 088T103 (Sheet 4 of 11).
0137-5
TM 11-6115-742-13&P 0137
VERSION 2
18
17
22
21
22
22
23
Figure 6. Control, Enclosure, Air Conditioner, 088T103 (Sheet 5 of 11).
0137-6
TM 11-6115-742-13&P 0137
VERSION 1 VERSION 2
25
24
24
26
Figure 6. Control, Enclosure, Air Conditioner, 088T103 (Sheet 6 of 11).
0137-7
TM 11-6115-742-13&P 0137
VERSION 1 VERSION 2
27
28
29
Figure 6. Control, Enclosure, Air Conditioner, 088T103 (Sheet 7 of 11).
0137-8
TM 11-6115-742-13&P 0137
VERSION 1 VERSION 2
30
15
15
Figure 6. Control, Enclosure, Air Conditioner, 088T103 (Sheet 8 of 11).
0137-9
TM 11-6115-742-13&P 0137
VERSION 1 VERSION 2
31
60
P/O 31
P/O 31
32
21
P/O 31
P/O 31
P/O 31
Figure 6. Control, Enclosure, Air Conditioner, 088T103 (Sheet 9 of 11).
0137-10
TM 11-6115-742-13&P 0137
VERSION 1 VERSION 2
33 35
34 34
24 24
Figure 6. Control, Enclosure, Air Conditioner, 088T103 (Sheet 10 of 11).
0137-11
TM 11-6115-742-13&P 0137
VERSION 1 VERSION 2
36
15
15
Figure 6. Control, Enclosure, Air Conditioner, 088T103 (Sheet 11 of 11).
0137-12
TM 11-6115-742-13&P 0137
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 01010102
FIGURE 6 CONTROL, ENCLOSURE,
AIR CONDITIONER
088T103
1 PAFZZ 5930-00-832-5174 97403 13211E6931 SWITCH,ROTARY ........................... 1
2 PAFZZ 6250-01-568-1030 08VG8 3SB3400-1PC LAMPHOLDER ................................ 2
3 PAFZZ 6250-01-568-0001 08VG8 3SB3400-1PB LAMPHOLDER ................................ 1
4 PAFZZ 6210-01-552-1332 82121 3SB3001-6BA20 INDICATOR,LIGHT .......................... 1
5 PAFZZ 6210-01-552-1327 82121 3SB3001-6BA40 INDICATOR,LIGHT .......................... 1
6 PAFZZ 5930-00-496-7492 81349 M5423/09-04 BOOT,DUST AND MOISTURE ....... 1
7 PAFZZ 5355-01-552-8299 82121 088T101-32 KNOB ............................................... 1
8 PAFZZ 6645-01-567-8282 56252 T51E430 METER,TIME TOTALIZING............. 1
9 PAFZZ 5305-01-138-6292 39428 91772A110 SCREW,MACHINE .......................... 2
10 PAFZZ 5355-01-568-3921 08VG8 3SB3001- KNOB ............................................... 1
2DA41
11 PAFZZ 5999-01-568-1074 08VG8 1000861 CONTACT,ELECTRICAL ................ 2
12 PAFZZ 5310-01-568-0727 39428 92146A530 WASHER,LOCK .............................. 2
13 PAFZZ 5310-00-934-9748 80205 MS35649-244 NUT,PLAIN,HEXAGON ................... 2
14 PAFZZ 5930-00-556-9791 96906 MS25002-4 SWITCH,ROTARY ........................... 1
15 PAFZZ 5305-01-568-1062 1KDE3 10F37MXP1 SCREW,MACHINE……………….. 28
16 PAFZZ 5950-01-412-4121 56365 9070T250D14 TRANSFORMER,POWER............... 1
17 PAFZZ 5925-01-568-0000 08VG8 5SY4106-7 CIRCUIT BREAKER ........................ 1
18 PAFZZ 5925-01-568-1099 08VG8 5SY4315-8 CIRCUIT BREAKER ........................ 1
19 PAFZZ 5925-01-567-9995 08VG8 5SY4363-8 CIRCUIT BREAKER ........................ 1
20 XBFZZ 3C0M7 035T112 BRACKET,MOUNTING ................... 1
21 PAFZZ 5305-01-446-0679 39428 91772A144 SCREW,MACHINE .......................... 12
22 PAFZZ 5925-01-567-9997 08VG8 5SY4332-8 CIRCUIT BREAKER ........................ 3
23 XBFZZ 3C0M7 035T113 BRACKET,MOUNTING ................... 1
24 PAFZZ 5305-01-568-4710 0WFM3 T270130 SCREW,MACHINE .......................... 8
25 PAFZZ 5895-01-569-2953 3C0M7 089T108 MONITOR,PHASE ........................... 1
26 PAFZZ 5945-01-568-7389 08VG8 3RP1512- RELAY,SOLID STATE ..................... 1
1AQ30
27 PAFZZ 5961-01-148-3364 26916 KBPC3501 RECTIFIER,SEMICONDUCTOR
DEVICE ............................................ 1
28 PAFZZ 5310-01-553-0370 1KDE3 8NWFL1 WASHER,FLAT................................ 1
29 PAFZZ 5305-01-568-9503 39428 91249A196 SCREW,MACHINE .......................... 1
0137-13
TM 11-6115-742-13&P 0137
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
30 PAFZZ 5940-01-568-7575 26405 1323580 CONTACT ASSEMBLY,
ELECTRICAL ............................... 2
31 PAFZZ 5930-01-568-7446 06541 A28AA-28C SWITCH,THERMOSTATIC ......... 1
32 PAFZZ 5310-01-552-7435 39428 92141A006 WASHER,FLAT ........................... 4
33 PAFZZ 5999-01-568-7586 0WFM3 1000902 CONTACT ASSEMBLY,
ELECTRICAL ............................... 1
34 PAFZZ 5305-00-054-6668 96906 MS51957-43 SCREW,MACHINE ...................... 4
35 PAFZZ 5999-01-569-5921 0WFM3 PECU05T23B CONTACT ASSEMBLY,
ELECTRICAL ............................... 1
36 PAFZZ 5945-00-778-3922 23826 41EB30AJ RELAY,ELECTROMAGNETIC .... 3
END OF FIGURE
0137-14
TM 11-6115-742-13&P 0138
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
BLOWER ASSEMBLY, 054T102
1
2
3
P/O 4
5 6
A
P/O 5
10
7
8
9 B
Figure 7. Blower Assembly, 054T102 (Sheet 1 of 2).
0138-1
TM 11-6115-742-13&P 0138
11
P/O 11
P/O 11
P/O 11
14
P/O 11
P/O 11
P/O 11
12
13
15 14
A
P/O 20
16
P/O 18 17
18
17
19
23
21 20
22
B
Figure 7. Blower Assembly, 054T102 (Sheet 2 of 2).
0138-2
TM 11-6115-742-13&P 0138
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 01010103
FIGURE 7 BLOWER ASSEMBLY
054T102
1 PAFZZ 5305-01-564-6941 0Y3H3 28957 SCREW,TAPPING ......................... 4
2 XBFZZ 3C0M7 081T106 GUARD,FAN IMPELLER ............... 1
3 PAFZZ 5305-01-568-9387 3C0M7 31C125HCS1/F SCREW,CAP,HEXAGON HEAD.... 2
T
4 XBFZZ 3C0M7 054T109 IMPELLER,FAN,AXIAL .................. 1
5 PAFZZ 6105-01-568-7464 3C0M7 013T112 MOTOR,ALTERNATING
CURRENT ...................................... 1
6 PAFZZ 5306-01-558-7187 1KDE3 50C150HCS1 BOLT,MACHINE ............................ 4
7 PAFZZ 5310-01-558-7720 1KDE3 50NWFL1 WASHER,FLAT .............................. 4
8 PAFZZ 5310-01-559-2446 1KDE3 50CNNE1 NUT,SELF-LOCKING,
HEXAGON ...................................... 4
9 PAFZZ 0WFM3 1009749 CABLE ASSEMBLY,POWER,
ELECTRICAL .................................. 1
10 PAFZZ 3030-00-869-3419 20796 AX38 BELT,V ........................................... 1
11 PAFZZ 4140-01-569-1023 3C0M7 054T102 IMPELLER,FAN,CENTRIFUGAL ... 1
12 XBFZZ 3020-01-099-6277 71176 AK54H PULLEY,GROOVE ......................... 1
13 XBFZZ 71176 H25MM PULLEY,GROOVE ......................... 1
14 PAFZZ 5305-01-553-0350 1KDE3 25C75HCS1W SCREW,CAP,HEXAGON HEAD.... 2
15 PAFZZ 5315-01-308-1154 39428 98493A117 KEY,MACHINE ............................... 1
16 PAFZZ 5306-01-552-9111 3C0M7 100T339 BOLT,MACHINE ............................ 4
17 PAFZZ 5310-01-522-8619 3C0M7 100T503 WASHER,FLAT .............................. 8
18 XBFZZ 3C0M7 017T101 BRACKET,MOUNTING .................. 1
19 PAFZZ 5310-01-479-5890 0Y3H3 70862 NUT,SELF-LOCKING,
HEXAGON ...................................... 4
20 PAFZZ 6105-01-553-1609 0WFM3 TG903-5001 MOTOR,ALTERNATING 1
CURRENT ......................................
21 XBFZZ 71176 BK45X5/8 PULLEY,GROOVE ......................... 1
22 PAFZZ 5305-01-569-6914 39428 92311A578 SETSCREW ................................... 1
23 PAFZZ 5315-01-569-3362 39428 98493A137 KEY,MACHINE ............................... 1
END OF FIGURE
0138-3/4 blank
TM 11-6115-742-13&P 0139
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
GENERATOR, DIESEL ENGINE, T282271G/T282271T
P/O 3
2 3
P/O 6
1 P/O 6
P/O 6
27
26
25
4
6
9
8
6 6
6 6
11 10
5 P/O 24
14 10 12
12
P/O 24
23
24 21
22
21 19
20 13
19
20
21 15
22
21 16
18
17
Figure 8. Generator, Diesel Engine, T282271G/T282271T (Sheet 1 of 10).
0139-1
TM 11-6115-742-13&P 0139
28 31
29
30
32
37
36
33
A
34
35
Figure 8. Generator, Diesel Engine, T282271G/T282271T (Sheet 2 of 10).
0139-2
TM 11-6115-742-13&P 0139
38 38
39 39
40
41
38
42
57 40
41
42 HYDRONIC HEATER
WIRING HARNESS
CONNECTION
40 P/O 43
41 43
42 46 44
56 45
46
46
INTAKE
46
48
50 48 49
46 47
46
46 50
46
46
46 EXHAUST
TO TO HOLE IN
DRAIN
BASE OF ECU
TO
WARMER 51
55 52 49
39 49
53 TO FUEL
TANK
51 54
49 48
48
48
Figure 8. Generator, Diesel Engine, T282271G/T282271T (Sheet 3 of 10).
0139-3
TM 11-6115-742-13&P 0139
58
58
62
ENGINE 39
59 FUEL LINES
58 60 61
58
60
63
39
64
48
49
70
48
69
63 65
39
39
62 61
48
49 68
48
67
66
39 63
62 39
Figure 8. Generator, Diesel Engine, T282271G/T282271T (Sheet 4 of 10).
0139-4
TM 11-6115-742-13&P 0139
71
TO
RADIATOR 72 TO ENGINE
29 TO ENGINE
BLOCK OIL PAN
71
74 72
29 73
COOLANT
DRAIN OIL DRAIN
ASSEMBLY ASSEMBLY
P/O 74
P/O 73
Figure 8. Generator, Diesel Engine, T282271G/T282271T (Sheet 5 of 10).
0139-5
TM 11-6115-742-13&P 0139
27
75 76 77
25
78
60
79
78
85
84
82 80
83 81
Figure 8. Generator, Diesel Engine, T282271G/T282271T (Sheet 6 of 10).
0139-6
TM 11-6115-742-13&P 0139
87
92 86
78
92 91
91
78
92
88
89
90
78
91
78
60 93
92 92
91 92
78
78 78
94
78
78
78
60
Figure 8. Generator, Diesel Engine, T282271G/T282271T (Sheet 7 of 10).
0139-7
TM 11-6115-742-13&P 0139
95
96
97
97
88
88
98
99
88
88
100
100
Figure 8. Generator, Diesel Engine, T282271G/T282271T (Sheet 8 of 10).
0139-8
TM 11-6115-742-13&P 0139
78
78
92
101
94
Figure 8. Generator, Diesel Engine, T282271G/T282271T (Sheet 9 of 10).
0139-9
TM 11-6115-742-13&P 0139
102
103 9
10
103
104
Figure 8. Generator, Diesel Engine, T282271G/T282271T (Sheet 10 of 10).
0139-10
TM 11-6115-742-13&P 0139
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND USABLE
NO. CODE NSN CAGEC PART NUMBER ON CODES (UOC) QTY.
GROUP 0102
FIGURE 8 GENERATOR, DIESEL
ENGINE
T282271G/T282271T
1 XBFZZ 0WFM3 1006874 PANEL,ACCESS ........................... 1
UOC: 89W
1 XBFZZ 0WFM3 1006873 PANEL,ACCESS ........................... 1
UOC: 89X
2 PAFZZ 5305-01-583-5489 1KDE3 8D50TXP10 SCREW,TAPPING ........................ 6
3 PAFZZ 5340-01-497-5810 0MCS5 DP40-B COVER,ACCESS .......................... 1
4 XBFFF 0WFM3 T235064 BATTERY ASSEMBLY (SEE
FIGURE 9 FOR BREAKDOWN) .... 1
5 XBFZZ 0WFM3 1009994 PANEL,ACCESS ........................... 2
UOC: 89W
5 XBFZZ 0WFM3 1009995 PANEL,ACCESS ........................... 2
UOC: 89X
6 PAFZZ 5340-01-533-1330 94222 62-40-251-3 LEVER,MANUAL CONTROL ........ 8
7 XCDDD 0WFM3 T225250-5 BARRIER PANEL ASSEMBLY
(SEE FIGURE 17 FOR
BREAKDOWN) .............................. 1
8 XCDDD 0WFM3 T225453 CONTROL PANEL ASSEMBLY
(SEE FIGURE 15 FOR
BREAKDOWN) .............................. 1
9 XBFZZ 0WFM3 1007404 PANEL,ACCESS ........................... 1
UOC: 89W
9 XBFZZ 0WFM3 1007405 PANEL,ACCESS ........................... 1
UOC: 89X
10 XBFZZ 0WFM3 TG430-2005G PANEL,ACCESS ........................... 1
UOC: 89W
10 XBFZZ 0WFM3 TG430-2005T PANEL,ACCESS ........................... 1
UOC: 89X
11 XCDDD 0WFM3 T225853 POWER DISTRIBUTION (SEE
FIGURE 16 FOR BREAKDOWN) 1
12 PAFZZ 5310-01-569-2130 1KDE3 8CNNE1 NUT,SELF-LOCKING,
HEXAGON ..................................... 6
13 PAFZZ 5305-01-569-1803 1KDE3 8C75MXP1 SCREW,MACHINE ........................ 4
14 PAFZZ 5340-01-315-8389 57068 49-6080 STAY,LOCKING ............................ 2
15 PAFZZ 5305-01-568-4710 0WFM3 T270130 SCREW,MACHINE ........................ 2
16 XBFZZ 4210-01-259-5634 19207 12340842 BRACKET,FIRE
EXTINGUISHER ............................ 1
0139-11
TM 11-6115-742-13&P 0139
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND USABLE
NO. CODE NSN CAGEC PART NUMBER ON CODES (UOC) QTY.
17 PAFZZ 5320-01-025-6328 02126 AA-44-D RIVET,BLIND ................................ 4
18 PAFZZ 4210-01-552-5109 49376 B402T EXTINGUISHER,FIRE .................. 1
19 PAFZZ 5310-01-533-2915 3A054 92771A535 NUT,PLAIN,WING ........................ 2
20 PAFZZ 5310-01-563-2566 3A054 93496A031 WASHER,LOCK ........................... 2
21 PAFZZ 5310-01-569-5414 39428 92916A405 WASHER,FLAT............................. 36
22 PAFZZ 5310-01-485-7896 53711 123-1680562 PC NUT,PLAIN,HEXAGON ................ 2
93
23 PAFZZ 5307-01-569-2135 1KDE3 37C200RFTB STUD,CONTINUOUS THREAD ... 1
24 PAFZZ 5340-01-267-2904 94277 62-70-15 FASTENER,PAWL ........................ 1
25 PAFZZ 5305-01-553-0345 1KDE3 10C100HCS10 SCREW,CAP,HEXAGON HEAD .. 36
26 PAFZZ 5310-01-555-6402 1KDE3 10DLOC1 WASHER, LOCK .......................... 20
27 PAFZZ 5310-01-555-7064 1KDE3 10DWFL10 WASHER,FLAT............................. 36
28 PAFZZ 5305-01-552-4509 1KDE3 8C225MXP1 SCREW,MACHINE ....................... 6
29 PAFZZ 5310-01-553-0370 1KDE3 8NWFL1 WASHER,FLAT............................. 10
30 PAFZZ 5310-01-552-4523 1KDE3 10DWFL1 WASHER,FLAT............................. 6
31 XCFFF 0WFM3 TG421-9000 RADIATOR INSTALLATION
(SEE FIGURE 13 FOR
BREAKDOWN).............................. 1
32 XCFFF 0WFM3 T235005 EXHAUST ASSEMBLY (SEE
FIGURE 14 FOR BREAKDOWN) . 1
33 XBFZZ 8340-01-557-3403 0WFM3 MA100155 BAG,TENT FRAME PART ............ 1
34 PAFZZ 5995-01-552-6935 0WFM3 T295101 CABLE ASSEMBLY,SPECIAL
PURPOSE,ELECTRICAL ............. 2
35 PAFZZ 5995-01-552-8232 0WFM3 T295111 CABLE ASSEMBLY,SPECIAL
PURPOSE,ELECTRICAL ............. 1
36 XBFDD 0WFM3 T245264 ENGINE ASSEMBLY (SEE
FIGURE 10 FOR BREAKDOWN) . 1
37 PAFZZ 5995-01-552-6934 0WFM3 T295145 CABLE ASSEMBLY,SEPCIAL
PURPOSE,ELECTRICAL ............. 1
38 PAFZZ 5310-01-552-3984 1KDE3 25CNNE1 NUT,SELF-LOCKING,
HEXAGON .................................... 3
39 PAFZZ 5310-01-552-2776 1KDE3 25NWFL1 WASHER,FLAT............................. 19
40 PAFZZ 5310-01-533-2191 39428 94709A317 WASHER,SEAL ............................ 3
41 XBFZZ 5365-01-559-2443 1KDE3 25N62ZR5A SPACER,PLATE ........................... 3
42 PAFZZ 5307-01-558-7259 44MG9 91887A STUD,SHOULDERED .................. 3
43 PAFZZ 2990-01-552-6325 44MG9 97359A HEATER,COOLANT,ENGINE ...... 1
44 PAFZZ 5920-01-123-5212 58536 AA55569/01-005 FUSE,INCLOSED LINK ................ 1
45 PAFZZ 5920-01-149-6952 58536 AA55569/01-008 FUSE,INCLOSED LINK ................ 1
46 PAFZZ 4730-01-492-6678 39428 5388K18 CLAMP,HOSE............................... 12
0139-12
TM 11-6115-742-13&P 0139
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
47 PAFZZ 4720-01-570-0499 44MG9 50900126A HOSE,METALLIC ........................ 1
48 PAFZZ 4730-01-552-2772 44MG9 330027 CLAMP,HOSE ............................. 8
49 PAFZZ 4720-01-552-9960 44MG9 484032 HOSE,NONMETALLIC ................ 5
50 PAFZZ 4730-01-569-7756 39428 5520K302 REDUCER,PIPE .......................... 2
51 XBFZZ 44MG9 50483931A FUEL LINE,PLASTIC................... 2
52 PAFZZ 2910-01-553-0046 44MG9 50487171A FILTER ELEMENT,FLUID ........... 1
53 PAFZZ 4730-01-552-6415 44MG9 1310763A CLAMP,HOSE ............................. 1
54 PAFZZ 2910-01-553-0047 44MG9 86116A PUMP,FUEL,ELECTRICAL ......... 1
55 PAFZZ 5305-01-552-3987 1KDE3 25C100HCS1 SCREW,CAP,HEXAGON
HEAD ........................................... 1
56 PAFZZ 4120-01-568-9442 44MG9 5023298A HOSE,METALLIC ........................ 1
57 PAFZZ 5310-01-523-1028 2V507 90313A109 WASHER,FLAT ........................... 1
58 PAFZZ 35871 150072751 CLAMP,HOSE ............................. 4
59 PAFZZ 4720-01-570-8936 04NP0 543-123 FUEL HOSE ................................ 1
60 PAFZZ 4730-01-552-0695 39428 5346K16 NIPPLE,HOSE ............................. 5
61 PAFZZ 5970-01-569-6555 0S745 282-200-7 INSULATOR,WASHER ............... 4
62 PAFZZ 5305-01-559-2700 2KDE3 25C150HCS1 SCREW,CAP,HEXAGON
HEAD ........................................... 8
63 PAFZZ 5310-01-497-7828 39428 90257A029 NUT.............................................. 8
64 XBFZZ 0WFM3 1003632 TUBE ASSEMBLY,METAL .......... 1
65 XBFZZ 0WFM3 1003631 TUBE ASSEMBLY,METAL .......... 1
66 PAFZZ 4730-00-014-4027 51900 8W8X543 PLUG,PIPE .................................. 1
67 PAFZZ 4810-01-569-5481 3P3A1 S92D41 VALVE,BALL ............................... 1
68 PAFZZ 4730-01-481-4962 39428 4568K173 NIPPLE,PIPE ............................... 1
69 PAFZZ 6680-00-838-1829 09393 8680-00032 GAGE,LIQUID QUANTITY,
FLOAT TYPE ............................... 1
70 PAFZZ 0WFM3 TG430-5001G TANK,FUEL,ENGINE .................. 1
UOC: 89W
70 PAFZZ 0WFM3 TG430-5001T TANK,FUEL,ENGINE .................. 1
UOC: 89X
71 PAFZZ 5305-01-569-5454 1KDE3 8C175MXP1 SCREW,MACHINE ...................... 4
72 PAFZZ 5310-01-569-4411 1KDE3 8NLOC1 WASHER,LOCK .......................... 4
73 PAFZZ 4930-01-569-3237 0WFM3 T230020 OIL DRAIN ASSEMBLY .............. 1
74 PAFZZ 4820-01-570-4489 0WFM3 T230019 COOLANT DRAIN ASSEMBLY ... 1
75 PAFZZ 5340-01-334-5735 10203 5557-9 CAP,FILLER OPENING............... 1
0139-13
TM 11-6115-742-13&P 0139
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
76 XBFZZ 0WFM3 1002734 PANEL,ACCESS ......................... 1
UOC: 89W
76 XBFZZ 0WFM3 1002735 PANEL,ACCESS ......................... 1
UOC: 89X
77 PAFZZ 5310-01-569-0373 1KDE3 10DLOC10 WASHER,LOCK .......................... 16
78 PAFZZ 4730-01-424-5432 39428 5321K14 CLAMP,HOSE ............................. 12
79 PAFZZ 4730-01-569-5438 4ELU8 116C ELBOW,PIPE............................... 1
80 PAFZZ 4730-00-795-6959 0C3R0 TH2-16-002 PLUG,QUICK DISCONNECT ...... 1
81 PAFZZ 5340-01-569-5472 0XUE9 FCB2DP CAP,PROTECTIVE,DUST AND
MOISTURE SEAL ........................ 1
82 PAFZZ 4730-00-602-5342 0C3R0 TH3-21-002 COUPLING,HALF,QUICK
DISCONNECT ............................. 1
83 PAFZZ 5340-01-569-5997 0XUE9 FCB3DP CAP,PROTECTIVE,DUST AND
MOISTURE SEAL ........................ 1
84 PAFZZ 4730-01-569-4203 4ELU8 116E ELBOW, PIPE.............................. 1
85 PAFZZ 4730-01-399-1866 39428 5346K26 ADAPTER,STRAIGHT,PIPE
TO HOSE ..................................... 1
86 PAFZZ 5340-01-569-5467 70411 8X61 LEVER,MANUAL CONTROL ...... 1
87 PAFZZ 5305-01-569-7937 39428 91785A240 SCREW,MACHINE ...................... 1
88 PAFZZ 5310-01-552-8314 1KDE3 37NWFL1 WASHER,FLAT ........................... 18
89 PAFZZ 5310-01-558-7178 1KDE3 37NLOC1 WASHER,LOCK .......................... 2
90 PAFZZ 5305-01-531-7264 39428 92620A622 SCREW,CAP,HEXAGON
HEAD ........................................... 2
91 PAFZZ 4730-01-561-5843 3A054 50785K66 BUSHING,PIPE ........................... 4
92 PAFZZ 4730-01-581-3294 39428 53525K18 ELBOW,HOSE TO BOSS............ 7
93 PAFZZ 2910-00-977-5495 70411 SK1036 VALVE FUEL ............................... 1
94 PAFZZ 4730-01-568-4716 0PHX5 0203-8-10 ADAPTER BUSHING .................. 2
95 PAFZZ 5310-01-559-2446 1KDE3 50CNNE1 NUT,SELF-LOCKING,
HEXAGON……………………… 4
96 PAFZZ 5310-01-554-1192 1KDE3 50N125WSP1 WASHER,FLAT………………… 4
97 PAFZZ 5305-01-553-0414 1KDE3 37C125HCS1 SCREW,CAP,HEXAGON
HEAD……………………………. 8
98 PAFZZ 5P059 52545-1 MOUNT,RESILIENT,GENERAL
PURPOSE………………………. 4
99 PAFZZ 5305-01-570-2471 1KDE3 50C125HCS1 SCREW,CAP,HEXAGON
HEAD……………………………. 4
100 PAFZZ 5310-01-558-7184 1KDE3 37CNFH1 NUT,PLAIN,HEXAGON……….. 8
101 PAFZZ 4720-01-570-0575 47886 D3085-2118- HOSE ASSEMBLY,
DHS NONMETALLIC ........................... 1
0139-14
TM 11-6115-742-13&P 0139
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
102 PAFZZ 0WFM3 1002532 FOAM KIT,REPLACEMENT ........ 1
103 PAFZZ 1QNZ3 72662 SCREW,MACHINE ...................... 23
104 PAFZZ 0WFM3 1002533 FOAM KIT,REPLACEMENT ........ 1
END OF FIGURE
0139-15/16 blank
TM 11-6115-742-13&P 0140
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
BATTERY ASSEMBLY, T235064
0140-1
TM 11-6115-742-13&P 0140
4
1
5
6
3 7
8
6 9 P/O 12
10
21 11
20
12 13
14
15
19
16
18
17
15
5
16
VERSION 1
Figure 9. Battery Assembly, T235064 (Sheet 1 of 3).
0140-2
TM 11-6115-742-13&P 0140
P/O P/O
1 25 25
22 P/O
2 25
P/O 23
25 P/O
6 25
8
3 7
21
10
26
P/O P/O 24
12 25
25
12 10
11
27
12
P/O
12
13
19 14
15
16
18
17
16
VERSION 2
Figure 9. Battery Assembly, T235064 (Sheet 2 of 3).
0140-3
TM 11-6115-742-13&P 0140
5
28 29
6 P/O
25 P/O
29 7 25
P/O
3 22 25
P/O
30 23
29
30 P/O
25
P/O 25
10
P/O 24
30
6 P/O P/O
30 25
35
34 31 P/O 31
25 26
P/O P/O
30 P/O 31
31
P/O
31
33
11
10
19
6
13
16
14
15
32
17
16
VERSION 3
Figure 9. Battery Assembly, T235064 (Sheet 3 of 3).
0140-4
TM 11-6115-742-13&P 0140
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 010201
FIGURE 9 BATTERY ASSEMBLY
T235064
1 PAFZZ 5305-01-552-0691 39428 92240A559 SCREW,CAP,HEXAGON
HEAD ............................................. 4
2 PAFZZ 39428 15K200140-53 CLAMP,CABLE ............................. 7
3 PAFZZ 6150-01-552-5717 4DZX8 106538R LEAD,STORAGE BATTERY ......... 1
4 PAFZZ 5305-01-552-3987 1KDE3 25C100HCS1 SCREW,CAP,HEXAGON
HEAD ............................................. 1
5 PAFZZ 5310-01-552-3994 1KDE3 25NLOC1 WASHER,LOCK ............................ 2
6 PAFZZ 5310-01-552-2776 1KDE3 25NWFL1 WASHER,FLAT ............................. 10
7 PAFZZ 6150-01-552-6221 4DZX8 105038R LEAD,STORAGE BATTERY ......... 1
8 PAFZZ 5940-01-552-9284 4DZX8 5726-050-R COVER,TERMINAL ....................... 1
9 PAFZZ 5920-01-552-0369 25795 1EM94 FUSE LINK,ELECTRICAL ............. 1
10 PAFZZ 5940-01-552-9497 4DZX8 5724-050-B COVER,TERMINAL....................... 1
11 PAFZZ 6150-01-553-0934 4DZX8 108038B LEAD,STORAGE BATTERY ......... 1
12 PAFZZ 5306-01-552-9145 4DZX8 99051 BOLT,MACHINE............................ 4
13 PAFZZ 5305-01-553-0414 1KDE3 37C125HCS1 SCREW,CAP,HEXAGON
HEAD ............................................. 2
14 PAFZZ 5310-01-552-3975 1KDE3 31NLOC1 WASHER,LOCK ............................ 2
15 PAFZZ 5310-01-552-8314 1KDE3 37NWFL1 WASHER,FLAT ............................. 3
16 PAFZZ 5310-01-552-3984 1KDE3 25CNNE1 NUT,SELF-LOCKING,
LOCKING,HEXAGON .................... 5
17 XBFZZ 29186 BH-2124 WARMER,BATTERY..................... 1
18 PAFZZ 5305-01-552-9209 1KDE3 25C200HCS1 SCREW,CAP,HEXAGON
HEAD ............................................. 1
19 XBFZZ 0WFM3 T220076 BRACKET,BATTERY
SUPPORT ..................................... 1
20 PCFZZ 6140-01-482-9031 56309 PS-12750 BATTERY,STORAGE ................... 2
21 XBFZZ 0WGM8 10-15-55P RETAINER,BATTERY ................... 2
22 PAFZZ 6150-01-581-6751 4DZX8 101038N LEAD,STORAGE BATTERY ......... 1
23 PAFZZ 5920-01-581-6939 7Z043 MFC336175 FUSE,LINK,ELECTRICAL ............. 1
24 PAFZZ 6150-01-581-6746 4DZX8 101038P LEAD,STORAGE BATTERY ......... 1
25 PAFZZ 5920-01-581-6929 7Z043 MFB736N9N02 FUSEHOLDER,BLOCK ................. 1
26 PAFZZ 5940-01-581-6740 4DZX8 5724-050-R COVER,TERMINAL....................... 1
27 PCFZZ 0CV85 24AGM BATTERY,STORAGE ................... 2
28 PAFZZ 0Y3H3 10332-04277 SCREW,CAP,HEXAGON
HEAD ............................................. 4
0140-5
TM 11-6115-742-13&P 0140
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
29 PAFZZ 5340-01-570-3916 0Y3H3 0708779 CLAMP,LOOP ............................... 3
30 PAFZZ 5940-01-338-1965 33609 5350 TERMINAL,LUG ............................ 1
31 PAFZZ 5940-01-337-3316 33609 5349 TERMINAL,LUG ............................ 1
32 PAFZZ 5305-01-558-7714 1KDE3 25C175HCS1 SCREW,CAP,HEXAGON
HEAD ............................................. 1
33 PCFZZ 0CV85 9A34 BATTERY,STORAGE ................... 2
34 PAFZZ 4DZX8 5730-000R COVER,TERMINAL....................... 1
35 XBFZZ 0WGM8 12-1004 RETAINER,BATTERY ................... 1
END OF FIGURE
0140-6
TM 11-6115-742-13&P 0141
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
ENGINE ASSEMBLY, T245264
0141-1
TM 11-6115-742-13&P 0141
B
3
4
9 10
5
6
7 11
12
8
A
16
14 11
15 12
24 20 14
13
25
19 21
18
17
22
23
Figure 10. Engine Assembly, T245264 (Sheet 1 of 5).
0141-2
TM 11-6115-742-13&P 0141
26
28
27
29
30
32 31
36
35
34 37
38
39
33
37
40
Figure 10. Engine Assembly, T245264 (Sheet 2 of 5).
0141-3
TM 11-6115-742-13&P 0141
P/O 44
42
41 43
45
46
47
44
43
50
48 52
49 51
51 53
54
57 56
55
65
58
64
63 58
59
58 66 59
58 59
62
61
60
59
Figure 10. Engine Assembly, T245264 (Sheet 3 of 5).
0141-4
TM 11-6115-742-13&P 0141
P/O
70
P/O
70
71
68
70
16
14
69 20
15
14
13
68
19
18
67
17
P/O
15
Figure 10. Engine Assembly, T245264 (Sheet 4 of 5).
0141-5
TM 11-6115-742-13&P 0141
76
75
74 77
73
72
60
87
14
86
14
85
62
78
85
79
80
ENGINE
GENERATOR
81
83 82
84
Figure 10. Engine Assembly, T245264 (Sheet 5 of 5).
0141-6
TM 11-6115-742-13&P 0141
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND USABLE
NO. CODE NSN CAGEC PART NUMBER ON CODES (UOC) QTY.
GROUP 010202
FIGURE 10 ENGINE ASSEMBLY
T245264
1 PAFZZ 6685-01-553-1307 29186 MACK906 TRANSMITTER,
TEMPERATURE,ELECTRICAL
RESISTANCE ................................ 1
2 PAFZZ 2920-01-552-6309 29186 8-97047604-0 GLOW PLUG ................................. 4
3 XBFZZ 29186 8-97229381-0 CONNECTOR STRIP .................... 1
4 PAFZZ 5930-01-553-5296 85814 SM-2B- SWITCH,PRESSURE.................... 1
15FVTAU
5 PAFZZ 2910-01-552-9726 29186 8-97172549-0 FILTER ELEMENT,FLUID ............. 1
6 PAFZZ 6620-01-553-4096 29186 02504-0 TRANSMITTER,PRESSURE ........ 1
7 PAFZZ 2940-01-552-6301 29186 8-94456741-2 FILTER ELEMENT,FLUID ............. 1
8 PAFZZ 5945-01-552-1084 29186 010-9229 ELECTROMAGNETIC
ACTUATOR ................................... 1
9 XBFZZ 29186 MACK1067 BRACKET, MOUNTING ................ 1
10 PAFZZ 29186 65202400 FILLER NECK,LIQUID .................. 1
11 PAFZZ 5310-01-553-0365 29186 80277 WASHER,LOCK ............................ 2
12 PAFZZ 5305-01-553-0377 1KDE3 80C160HCS193 SCREW,CAP,HEXAGON HEAD ... 2
3
13 PAFZZ 5305-01-553-0350 1KDE3 25C75HCS1W SCREW,CAP,HEXAGON HEAD ... 6
14 PAFZZ 5310-01-552-2776 1KDE3 25NWFL1 WASHER,FLAT ............................. 13
15 PAFZZ 5945-01-553-3177 1AS48 24063 SOLENOID,ELECTRICAL ............. 3
16 PAFZZ 5310-01-552-3984 1KDE3 25CNNE1 NUT, SELF-LOCKING,
HEXAGON ..................................... 6
17 PAFZZ 5305-01-559-4711 1KDE3 37C75HCS1 SCREW,CAP,HEXAGON HEAD ... 6
18 PAFZZ 5310-01-558-7178 1KDE3 37NLOC1 WASHER,LOCK ............................ 6
19 PAFZZ 5310-01-552-8314 1KDE3 37NWFL1 WASHER,FLAT ............................. 6
20 XBFZZ 0WFM3 T230007 BRACKET, DOUBLE-ANGLE ....... 3
21 PAFZZ 2920-01-552-6314 29186 8972248131 STARTER,ENGINE,
ELECTRICAL ................................. 1
22 PAFZZ 5306-01-552-8662 29186 0-28181230-0 BOLT,MACHINE............................ 2
23 PAFZZ 5310-01-552-8308 29186 9-09111408-0 NUT,PLAIN,HEXAGON ................. 1
24 XCFFF 0WFM3 1003392 AIR INTAKE INSTALLATION
(SEE FIGURE 12 FOR
BREAKDOWN) .............................. 1
0141-7
TM 11-6115-742-13&P 0141
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND USABLE
NO. CODE NSN CAGEC PART NUMBER ON CODES (UOC) QTY.
25 PAOZZ 5930-01-553-4145 29186 TM-2A-230RAU SWITCH,THERMOSTATIC……. 1
26 XCFFF 0WFM3 TG440-0001 COOLING SYSTEM
INSTALLATION (SEE FIGURE
11 FOR BREAKDOWN) ................ 1
27 PAFZZ 4N530 028050-8450 BOLT,MACHINE............................ 1
28 PAFZZ 5310-01-552-8613 29186 0-91150210-0 NUT,PLAIN,HEXAGON ................. 1
29 PAFZZ 2920-01-553-0314 29186 8-97233412-1 GENERATOR,ENGINE
ACCESSORY ................................ 1
30 XBFZZ 5340-01-548-4360 4N530 897231-5790 BRACKET,MOUNTING ................. 1
31 PAFZZ 5306-01-552-8738 29186 0-28081070-0 BOLT,MACHINE............................ 1
32 PAFZZ 5306-01-552-8648 29186 0-28080820-0 BOLT,MACHINE............................ 1
33 XBFZZ 29186 X-14330186-0 SPACER ........................................ 4
34 PAFZZ 5310-01-552-3971 29186 X-09150-002 WASHER,LOCK ............................ 4
35 PAFZZ 5306-01-552-4514 29186 X-09055-048 BOLT,MACHINE............................ 4
36 PAFZZ 5306-01-552-8668 29186 X-09055-006 BOLT,MACHINE............................ 2
37 PAFZZ 5310-01-552-8350 29186 X-09150-001 WASHER,LOCK ............................ 2
38 XBFZZ 29186 X-14210-056 BRACKET,SUPPORT ................... 1
39 XBFZZ 29186 X-14330-193 BRACKET,MOUNTING ................. 1
40 PAFZZ 5310-01-552-8714 29186 0-91150208-0 NUT,PLAIN,EXTENDED
WASHER,HEXAGON .................... 2
41 PAFZZ 4N530 897217-2492 TUBE ASSEMBLY,METAL............ 1
42 PAFZZ 5330-01-569-0386 4N530 897232-3341 GASKET ........................................ 4
43 PAFZZ 5340-01-547-8512 4N530 509707-0051 CLIP,RETAINING .......................... 2
44 PAFZZ 4N530 897247-9890 HOSE,RUBBER ............................ 1
45 PAFZZ 5306-01-569-7926 4N530 894433-7171 BOLT,MACHINE............................ 1
46 XBFZZ 4N530 897195-2593 BRACKET,MOUNTING ................. 4
47 PAFZZ 2910-01-569-0390 4N530 897289-2930 INJECTOR ASSEMBLY,FUEL ...... 4
48 PAFZZ 5330-01-569-0380 29186 894326-4390 GASKET ........................................ 4
49 PAFZZ 5330-01-569-0369 29186 897171-3310 GASKET ........................................ 4
50 PAFZZ 5306-01-547-8487 4N530 894379-6880 BOLT,EYE ..................................... 4
51 PAFZZ 5330-01-226-8689 04627 324444 GASKET ........................................ 8
52 PAFZZ 4N530 898097-1600 TUBE ASSEMBLY,METAL............ 4
53 PAFZZ 5310-01-570-5993 4N530 091180-2080 NUT,PLAIN,HEXAGON ................. 8
54 PAFZZ 4N530 898096-5800 PUMP,INJECTION ........................ 4
55 PAFZZ 5365-01-569-7918 4N530 897227-2851 SHIM .............................................. 4
56 PAFZZ 5306-01-547-8472 4N530 028080-8200 BOLT,MACHINE............................ 8
57 PAFZZ 4N530 897314-8610 TUBE ASSEMBLY,METAL............ 1
58 PAFZZ 4730-01-569-0826 29186 58832 CLAMP,HOSE ............................... 4
0141-8
TM 11-6115-742-13&P 0141
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND USABLE
NO. CODE NSN CAGEC PART NUMBER ON CODES (UOC) QTY.
59 PAFZZ 1KNF0 RE0062-0470 COVER,PROTECTIVE .................. 4
60 PAFZZ 5305-01-554-5224 39428 91280A334 SCREW,CAP,HEXAGON
HEAD ............................................. 3
61 PAFZZ 5310-01-553-6196 39428 91202A234 WASHER,LOCK ............................ 2
62 PAFZZ 5310-01-466-2747 39428 93475A250 WASHER,FLAT ............................. 3
63 PAFZZ 2910-01-553-1272 29186 8-94425751-1 PUMP,FUEL,ELECTRICAL ........... 1
64 PAFZZ 5306-01-570-6401 4N530 028050-6120 BOLT,MACHINE............................ 1
65 XBFZZ 29186 MACK1065 BRACKET,MOUNTING ................. 1
66 PAFZZ 5310-01-570-5969 4N530 897329-6220 NUT,BLANK .................................. 1
67 PAFZZ 5305-01-569-1803 1KDE3 8C75MXP1 SCREW,MACHINE........................ 2
68 PAFZZ 5310-01-553-0370 1KDE3 8NWFL1 WASHER,FLAT…………………. 4
69 PAFZZ 2815-01-552-9950 29186 X-83121-014-0 SPEED SENSOR,DIESEL ............ 1
70 PAFZZ 5925-01-569-0250 82647 SDLA-350749 CIRCUIT BREAKER ...................... 1
71 PAFZZ 5310-01-569-2130 1KDE3 8CNNE1 NUT,SELF-LOCKING
HEXAGON ..................................... 2
72 PAFDD 0WFM3 T240200 GENERATOR SET,DIESEL
ENGINE…………………………... 1
73 PAFDD 0WFM3 1006230 ENGINE,DIESEL………………... 1
74 PAFZZ 4N530 894329-5490 BREATHER FILTER,EMISSION
CONTROL ..................................... 1
75 PAFZZ 4N530 036220-4100 SCREW,SELF-LOCKING .............. 4
76 PAFZZ 2590-01-450-6882 4N530 894133-2075 CAP,FILLER,OPENING ................ 1
77 PAFZZ 4N530 894123-6231 GASKET ........................................ 1
78 PAFZZ 5310-01-552-3994 1KDE3 25NLOC1 WASHER,LOCK………………… 1
79 PAFZZ 5310-01-572-6753 39428 92497A350 NUT,PLAIN,HEXAGON………… 1
80 XBFZZ 6115-01-577-7123 38151 720366-01 GUARD,FAN IMPELLER............... 1
81 PAFZZ 5310-01-569-0412 29186 87511 WASHER,FLAT…………………. 8
82 PAFZZ 5305-01-569-0843 29186 82149 SCREW,CAP,HEXAGON HEAD 6
83 PAFZZ 5310-01-569-0415 29186 87510 WASHER,FLAT…………………. 8
84 PAFZZ 5305-01-569-0831 29186 4282 SCREW,CAP,HEXAGON HEAD 8
85 PAFZZ 5310-01-569-0403 29186 80253 NUT,PLAIN,HEXAGON………… 2
86 PAFZZ 5306-01-569-1824 38151 801125-01 BOLT,MACHINE………………… 4
87 XBFZZ 38151 723272-02 COVER,ACCESS……..………… 1
END OF FIGURE
0141-9/10 blank
TM 11-6115-742-13&P 0142
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
COOLING SYSTEM INSTALLATION, TG440-0001
0142-1
TM 11-6115-742-13&P 0142
10
11
6
12
5
4
2 3 13
1
14
1
15
Figure 11. Cooling System Installation, TG440-0001.
0142-2
TM 11-6115-742-13&P 0142
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND USABLE
NO. CODE NSN CAGEC PART NUMBER ON CODES (UOC) QTY.
GROUP 01020201
FIGURE 11 COOLING SYSTEM
INSTALLATION
TG440-0001
1 PAFZZ 5306-01-552-8636 29186 0-28080845-0 BOLT,MACHINE ............................. 5
2 XBFZZ 29186 MACK913 FAN ................................................. 1
3 XBFZZ 29186 9-89136423-0 SPACER ......................................... 1
4 PAFZZ 5365-01-548-4417 4N530 897063-4003 SPACER,SLEEVE .......................... 1
5 PAFZZ 5306-01-570-6401 4N530 028050-6120 BOLT,MACHINE ............................. 2
6 XBFZZ 29186 8-97226855-0 PULLEY .......................................... 1
7 PAFZZ 5310-01-552-8714 29186 0-91150208-0 NUT,PLAIN,EXTENDED
WASHER,HEXAGON ...................... 2
8 PAFZZ 5306-01-552-8656 29186 0-28680825-0 BOLT,MACHINE ............................. 2
9 XBFZZ 29186 8-97258479-2 HOUSING,THERMOSTAT.............. 1
10 PAFZZ 5330-01-552-4522 29186 8-97264690-1 GASKET .......................................... 1
11 PAFZZ 6685-01-553-1277 29186 8-97361770-0 THERMOSTAT,FLOW
CONTROL ....................................... 1
12 PAFZZ 5330-01-552-9907 29186 8-97289543-0 GASKET .......................................... 1
13 PAFZZ 2930-01-553-4605 29186 8-97254148-3 PUMP,COOLING SYSTEM ............ 1
14 PAFZZ 5306-01-552-8639 29186 0-28080840-0 BOLT,MACHINE ............................. 2
15 PAFZZ 3030-01-552-5720 29186 8-97224999-0 BELT,V ............................................ 1
END OF FIGURE
0142-3/4 blank
TM 11-6115-742-13&P 0143
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
AIR INTAKE INSTALLATION, 1003392
0143-1
TM 11-6115-742-13&P 0143
4 4
10
9 4
4
5
7 6
8 5
9 4
Figure 12. Air Intake Installation, 1003392.
0143-2
TM 11-6115-742-13&P 0143
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND USABLE
NO. CODE NSN CAGEC PART NUMBER ON CODES (UOC) QTY.
GROUP 01020202
FIGURE 12 AIR INTAKE
INSTALLATION,
1003392
1 PAFZZ 2940-01-584-3314 4N530 X-14210-057-0 FILTER,BODY,INTAKE AIR
CLEANER........................................ 1
2 PAFZZ 4310-01-552-5118 29186 MACK262 FILTER,ELEMENT,INTAKE AIR
CLEANER........................................ 1
3 PAFZZ 2940-01-553-1319 29186 MACK922 AIR CLEANER,INTAKE .................. 1
4 PAFZZ 4730-01-552-9598 29186 X-09915-004 CLAMP,HOSE................................. 5
5 XBFZZ 29186 24032-2 EXTENSION,FLEXIBLE.................. 2
6 XBFZZ 29186 X-14111-050-0 TUBE,INTAKE................................. 1
7 XBFZZ 4N530 897227-6030 PIPE,ELBOW .................................. 1
8 PAFZZ 4N530 897094-6411 STUD,CONTINUOUS THREAD ..... 1
9 PAFZZ 5310-01-570-5969 4N530 897329-6220 NUT,BLANK .................................... 2
10 PAFZZ 4N530 041010-6160 STUD,CONTINUOUS THREAD ..... 1
END OF FIGURE
0143-3/4 blank
TM 11-6115-742-13&P 0144
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
RADIATOR INSTALLATION, TG421-9000
0144-1
TM 11-6115-742-13&P 0144
Figure 13. Radiator Installation, TG421-9000.
0144-2
TM 11-6115-742-13&P 0144
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND USABLE
NO. CODE NSN CAGEC PART NUMBER ON CODES (UOC) QTY.
GROUP 010203
FIGURE 13 RADIATOR
INSTALLATION
TG421-9000
1 PAFZZ 2930-01-552-6338 29186 MACK1180 CAP,FILLER OPENING ................ 1
2 XBFZZ 29186 MACK1011 RADIATOR .................................... 1
3 PAFZZ 5310-01-552-3984 1KDE3 25CNNE1 NUT,SELF-LOCKING,
HEXAGON ..................................... 1
4 PAFZZ 5310-01-552-2776 1KDE3 25NWFL1 WASHER,FLAT ............................. 2
5 XBFZZ 39428 42305T47 BOTTLE,OVERFLOW ................... 1
6 PAFZZ 5305-01-552-9209 1KDE3 25C200HCS1 SCREW,CAP,HEXAGON
HEAD ............................................. 1
7 XBFZZ 0WFM3 T230050 HOSE,DRAIN……………………. 2
8 XBFZZ 29186 79100204 GUARD,FAN IMPELLER………. 1
9 PAFZZ 5306-01-521-5240 39428 92865A535 BOLT,MACHINE………………… 6
10 XBFZZ 29186 79600107 COVER,PROTECTIVE…………. 1
11 PAFZZ 5305-01-559-0882 39428 92316A536 SCREW,CAP,HEXAGON HEAD 6
12 PAFZZ 4730-01-479-1934 7Z588 64010H B CLAMP,HOSE ............................... 4
13 PAFZZ 4720-01-552-3979 29186 X892140300 HOSE,PREFORMED .................... 1
14 PAFZZ 4730-01-552-0695 39428 5346K16 NIPPLE,HOSE ............................... 1
15 PAFZZ 4730-01-424-5432 39428 5321K14 CLAMP,HOSE ............................... 2
16 PAFZZ 4730-01-534-5870 39428 53525K14 ELBOW,PIPE TO HOSE ............... 1
17 PAFZZ 4720-01-553-0305 29186 MACK1078 HOSE,PREFORMED .................... 1
END OF FIGURE
0144-3/4 blank
TM 11-6115-742-13&P 0145
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
EXHAUST ASSEMBLY, T235005
0145-1
TM 11-6115-742-13&P 0145
3
2
24 28
25
25
27
26
P/O
18
18
23
6
13
22 4
12
5 11
6
7
8
10
9
14
P/O
18 P/O 15
21 18
16
17
18 18
19
20
Figure 14. Exhaust Assembly, T235005.
0145-2
TM 11-6115-742-13&P 0145
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND USABLE
NO. CODE NSN CAGEC PART NUMBER ON CODES (UOC) QTY.
GROUP 010204
FIGURE 14 EXHAUST ASSEMBLY
T235005
1 PAFZZ 5310-01-497-7828 39428 90257A029 NUT .............................................. 1
2 XBFZZ 29186 35512 CAP,ASSEMBLY,
PROTECTIVE,MUFFLER-
EXHAUST PIPE ........................... 1
3 PAFZZ 5305-01-552-9209 1KDE3 25C200HCS1 SCREW,CAP,HEXAGON
HEAD ........................................... 1
4 PAFZZ 5310-01-552-4510 1KDE3 31NWFL1 WASHER,FLAT ........................... 2
5 PAFZZ 5305-01-553-0377 1KDE3 80C160HCS1933 SCREW,CAP,HEXAGON
HEAD ........................................... 2
6 PAFZZ 5310-01-552-2776 1KDE3 25NWFL1 WASHER,FLAT ........................... 8
7 PAFZZ 5305-01-552-3987 1KDE3 25C100HCS1 SCREW,CAP,HEXAGON
HEAD ........................................... 4
8 PAFZZ 5310-01-552-4536 39428 94800A730 PUSH ON NUT ............................ 4
9 PAFZZ 5310-01-553-2165 29186 83526 NUT,PLAIN,HEXAGON ............... 4
10 PAFZZ 5310-01-553-0365 29186 80277 WASHER,LOCK .......................... 4
11 PAFZZ 5310-01-548-4288 4N530 091150-2080 NUT,PLAIN,EXTENDED
WASHER,HEXAGON .................. 4
12 XBFZZ 2815-01-548-4249 4N530 897117-5901 MANIFOLD,EXHAUST ................ 1
13 PAFZZ 5330-01-480-0820 4N530 897126-1860 GASKET ...................................... 1
14 PAFZZ 5306-01-547-7741 4N530 028080-8700 BOLT,SHOULDER....................... 4
15 PAFZZ 5330-01-547-8616 4N530 897042-0280 GASKET ...................................... 1
16 XBFZZ 29186 010-MACK1071 FLANGE,EXHAUST..................... 1
17 XBFZZ 0WFM3 T231250 BLANKET,EXHAUST .................. 1
18 PAFZZ 5340-01-552-9135 29186 MACK1047 CLAMP,LOOP.............................. 3
19 XBFZZ 29186 MACK1072 FLEX PIPE,EXHAUST ................. 1
20 XBFZZ E0194 1394 BLANKET,EXHAUST .................. 1
21 XBFZZ 29186 MACK1070A PLATE,EXHAUST........................ 1
22 XBFZZ 29186 MACK1070 ELBOW,EXHAUST ...................... 1
23 PAFZZ 5310-01-552-3984 1KDE3 25CNNE1 NUT,SELF-LOCKING,
HEXAGON ................................... 4
24 PAFZZ 39428 92198A679 SCREW,CAP,HEXAGON
HEAD ........................................... 1
25 PAFZZ 0Y3H3 33084 WASHER,FLAT ........................... 2
26 XBFZZ 29186 MACK930 BRACKET, MOUNTING .............. 1
0145-3
TM 11-6115-742-13&P 0145
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND USABLE
NO. CODE NSN CAGEC PART NUMBER ON CODES (UOC) QTY.
27 PAFZZ 5310-01-559-1648 1KDE3 43CNNE1 NUT,SELF-LOCKING,
HEXAGON ................................... 1
28 PAFZZ 2990-01-553-0029 29186 MACK932 MUFFLER,EXHAUST .................. 1
END OF FIGURE
0145-4
TM 11-6115-742-13&P 0146
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
CONTROL PANEL ASSEMBLY, T225453
P/O 1
1 2 P/O 4
3 P/O 11
4, 5
P/O 4 P/O 11
5
4 P/O 11
11
10
9
7
6
7
8
Figure 15. Control Panel Assembly, T225453 (Sheet 1 of 4).
0146-1
TM 11-6115-742-13&P 0146
12
P/O 19
P/O 12 P/O 19
P/O 19
P/O 18
20
P/O 12
13
14 P/O 13
15
17
16
19
18 P/O 16
P/O 13 P/O 15
P/O 16
Figure 15. Control Panel Assembly, T225453 (Sheet 2 of 4).
0146-2
TM 11-6115-742-13&P 0146
21
22
P/O 24
P/O 21
24, 25 23
24, 25
P/O 24
25
24
P/O 22
P/O 23
Figure 15. Control Panel Assembly, T225453 (Sheet 3 of 4).
0146-3
TM 11-6115-742-13&P 0146
P/O 26
26
P/O 26
27
29
30
33
P/O 27
P/O 26
P/O 27
32
28
29
30
31
Figure 15. Control Panel Assembly, T225453 (Sheet 4 of 4).
0146-4
TM 11-6115-742-13&P 0146
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 010205
FIGURE 15 CONTROL PANEL
ASSEMBLY,
T225453
1 PAFZZ 5340-01-552-2466 94222 62-10-35 FASTENER,PAWL ...................... 2
2 PAFZZ 6625-01-567-9791 32AV2 50365A100A AMMETER ................................... 1
3 PAFZZ 6625-01-569-3217 32AV2 5036HZ5565 METER,ELECTRICAL
FREQUENCY............................... 1
4 PAFZZ 6210-00-643-0339 13445 DL21 LIGHT,PANEL ............................. 2
5 PAFZZ 6240-00-019-3093 58536 AA52463-A09 LAMP,INCANDESCANT.............. 2
6 PAFZZ 5310-01-569-1792 1KDE3 8CNFH1 NUT,PLAIN,HEXAGON ............... 2
7 PAFZZ 5310-01-553-0370 1KDE3 8NWFL1 WASHER,FLAT ........................... 4
8 PAFZZ 4010-01-553-2369 39428 30345T4 WIRE ROPE ASSEMBLY,
SINGLE LEG ................................ 2
9 PAFZZ 5305-01-568-4710 0WFM3 T270130 SCREW,MACHINE ...................... 2
10 PAFZZ 6625-01-569-3262 32AV2 5036300V VOLTMETER ............................... 1
11 PAFZZ 6625-01-569-7929 32AV2 50351MA-0- WATTMETER .............................. 1
30KW
12 PAFZZ 5930-01-569-0257 OWFM3 T260487 SWITCH,TOGGLE....................... 1
13 PAFZZ 5930-01-569-5312 47886 D30161-1584 SWITCH,TOGGLE....................... 1
14 PAFZZ 6625-01-567-9749 1AS48 102480 AMMETER ................................... 1
15 PAFZZ 5895-01-569-2664 3SUZ0 753-5147 SWITCH,ELECTRONIC .............. 1
16 PAFZZ 5930-01-569-1334 47886 0737R SWITCH,TOGGLE....................... 1
17 PAFZZ 6620-01-569-3313 1AS48 101574 INDICATOR,PRESSURE ............ 1
18 PAFZZ 6645-01-263-9434 16476 100222 METER,TIME TOTALIZING ........ 1
19 PAFZZ 6625-01-569-2369 16476 101586 METER,SPECIAL SCALE ........... 1
20 PAFZZ 6625-01-569-2419 1AS48 100184 VOLTMETER ............................... 1
21 PAFZZ 5895-01-569-3150 10983 CA11US6512- SWITCH,ELECTRONIC .............. 1
600E
22 PAFZZ 5895-01-569-3119 10983 CA11A204-600E SWITCH,ELECTRONIC .............. 1
23 PAFZZ 5895-01-569-3179 10983 CA11US6522- SWITCH,ELECTRONIC .............. 1
600E
24 PAFZZ 6210-00-686-4999 96906 MS25331-2 LIGHT,INDICATOR ..................... 3
25 PAFZZ 6240-01-552-6210 3FXU2 197-DP-287- LAMP,INCANDESCENT.............. 3
FT28V DC
26 PAFZZ 5930-01-330-2858 30003 1771AS661-1 SWITCH,ROTARY....................... 1
27 PAFZZ 5930-01-569-0283 1RW76 XB5AS8445GC SWITCH,PUSH-PULL ................. 1
F
0146-5
TM 11-6115-742-13&P 0146
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
28 XBFZZ 0WFM3 T220034-1 PLATE,MOUNTING ..................... 1
29 PAFZZ 5310-01-555-7064 1KDE3 10DWFL10 WASHER,FLAT ........................... 12
30 PAFZZ 5310-01-555-6402 1KDE3 10DLOC1 WASHER,LOCK .......................... 12
31 PAFZZ 5305-01-567-1777 1KDE3 10C50MXP10 SCREW,MACHINE ...................... 8
32 PAFZZ 5305-01-569-1758 39428 91771A207 SCREW,MACHINE ...................... 2
33 PAFZZ 5305-01-569-1782 1KDE3 10C125MXP10 SCREW,MACHINE ...................... 4
END OF FIGURE
0146-6
TM 11-6115-742-13&P 0147
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
POWER DISTRIBUTION PANEL ASSEMBLY, T225853
1 A
B
E
D
2
3
4
Figure 16. Power Distribution Panel Assembly, T225853 (Sheet 1 of 4).
0147-1
TM 11-6115-742-13&P 0147
P/O 5
P/O 5
6
5
VERSION 1
A
P/O 7
P/O 7
8
VERSION 2
A
Figure 16. Power Distribution Panel Assembly, T225853 (Sheet 2 of 4).
0147-2
TM 11-6115-742-13&P 0147
P/O 12
11
10
9
11
10
9
2
13
12
P/O 12
P/O
12 12
2
13
11
10
9
P/O 14
11
10
9 14
2
13
P/O 14
14
2
13
Figure 16. Power Distribution Panel Assembly, T225853 (Sheet 3 of 4).
0147-3
TM 11-6115-742-13&P 0147
11
10
9
P/O 15
P/O
15
11
2 9 10
13
P/O 15
P/O
15 15
2
13
D
17
P/O
16 16
17
E
Figure 16. Power Distribution Panel Assembly, T225853 (Sheet 4 of 4).
0147-4
TM 11-6115-742-13&P 0147
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 010206
FIGURE 16 POWER DISTRIBUTION
PANEL ASSEMBLY,
T225853
1 XBFZZ 0WFM3 T220035-1 PANEL,ELECTRICAL
EQUIPMENT ................................ 1
2 PAFZZ 5310-01-555-7064 1KDE3 10DWFL10 WASHER,FLAT ........................... 44
3 PAFZZ 5310-01-569-0373 1KDE3 10DLOC10 WASHER,LOCK .......................... 24
4 PAFZZ 5305-01-558-7195 1KDE3 10C75HCS10 SCREW,CAP,HEXAGON
HEAD ........................................... 12
5 PAFZZ 6210-01-108-2600 96906 MS25331-4 LIGHT,INDICATOR ..................... 5
6 PAFZZ 6240-01-552-5498 3FXU2 197-DP-1207- LAMP ASSEMBLY....................... 5
FT120VAC
7 PAFZZ C4647 19411132M LAMP ASSEMBLY....................... 5
8 PAFZZ 0WFM3 1009000 COVER,BLACKOUT
INDICATOR ................................. 5
9 PAFZZ 5310-01-552-4523 1KDE3 10DWFL1 WASHER,FLAT ........................... 20
10 PAFZZ 5310-01-555-6402 1KDE3 10DLOC1 WASHER,LOCK .......................... 20
11 PAFZZ 5310-01-569-1766 1KDE3 10CNFH1 NUT,LOCKING ............................ 20
12 PAFZZ 5935-01-569-4429 0PCR1 CD90555C32412 CONNECTOR, RECEPTACLE,
S ELECTRICAL ............................... 2
13 PAFZZ 5305-01-553-0345 1KDE3 10C100HCS10 SCREW,CAP,HEXAGON
HEAD ........................................... 20
14 PAFZZ 5935-01-569-0794 7Y971 519316 CONNECTOR,RECEPTACLE,
ELECTRICAL ............................... 2
15 PAFZZ 5935-01-097-9974 19207 11674728 CONNECTOR,RECEPTACLE,
ELECTRICAL ............................... 1
16 PAFZZ 5935-01-568-9835 3SUZ0 605-3008 CONNECTOR,RECEPTACLE,
ELECTRICAL ............................... 1
17 PAFZZ 5305-01-569-1811 1KDE3 4C37MP10 SCREW,MACHINE ...................... 4
END OF FIGURE
0147-5/6 blank
TM 11-6115-742-13&P 0148
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
BARRIER PANEL ASSEMBLY, T225250-5
0148-1
TM 11-6115-742-13&P 0148
A
B
C
D
M
L
K
F
J
H
Figure 17. Barrier Panel Assembly, T225250-5 (Sheet 1 of 7).
0148-2
TM 11-6115-742-13&P 0148
1
2
P/O 2
6
P/O 6
Figure 17. Barrier Panel Assembly, T225250-5 (Sheet 2 of 7).
0148-3
TM 11-6115-742-13&P 0148
10
11
12
13
Figure 17. Barrier Panel Assembly, T225250-5 (Sheet 3 of 7).
0148-4
TM 11-6115-742-13&P 0148
1
7 8
1 1
7 8
1
7
8
14 1
14
14
15
16
12
13
17
Figure 17. Barrier Panel Assembly, T225250-5 (Sheet 4 of 7).
0148-5
TM 11-6115-742-13&P 0148
18
1
1
18
22
21
21
20
19
12
13
24
23
Figure 17. Barrier Panel Assembly, T225250-5 (Sheet 5 of 7).
0148-6
TM 11-6115-742-13&P 0148
12
13
24
12
13
24
25 25
26
26
P/O
26
12 P/O
13 25
24 26 26
27
12 27
13
24
J
1
28
28
28
29
30 1 28
30
28
30
28 29
1
30
30
K
Figure 17. Barrier Panel Assembly, T225250-5 (Sheet 6 of 7).
0148-7
TM 11-6115-742-13&P 0148
12
13 31
32
15
33
12
13 34
32
Figure 17. Barrier Panel Assembly, T225250-5 (Sheet 7 of 7).
0148-8
TM 11-6115-742-13&P 0148
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 010207
FIGURE 17 BARRIER PANEL
ASSEMBLY,
T225250-5
1 PAFZZ 5340-99-519-4305 K6F01 249-116 END STOP .................................. 18
2 PAFZZ 5963-01-569-0378 32AV2 M100-WA5 ELECTRONIC MODULE,
STANDARDIZED ......................... 1
3 PAFZZ 2920-99-690-7498 K6F01 281-610 TERMINAL BLOCK ..................... 6
4 PAFZZ K6F01 281-326 PLATE,MOUNTING ..................... 1
5 PAFZZ 5920-01-327-2572 71400 GMC-4A FUSE,CARTRIDGE ..................... 6
6 PAFZZ 5920-01-480-3209 65996 281-512 FUSE,PLUG ................................ 6
7 PAFZZ 2920-99-983-9545 K6F01 280-610 TERMINAL BLOCK ..................... 17
8 PAFZZ K6F01 280-326 PLATE,MOUNTING ..................... 4
9 PAFZZ 5945-99-360-1748 K6F01 286-555 SWITCH,ELECTRONIC .............. 1
10 PAFZZ 5999-01-113-0824 0AGK2 438USA DELAY LINE ................................ 1
11 PAFZZ 5310-01-553-0370 1KDE3 8NWFL1 WASHER,FLAT ........................... 34
12 PAFZZ 5310-01-569-4411 1KDE3 8NLOC1 WASHER,LOCK .......................... 34
13 PAFZZ 5305-01-569-7811 1KDE3 8C125MXP1 SCREW,MACHINE ...................... 2
14 PAFZZ 5945-99-598-7263 K6F01 286-320 RELAY,SWITCH……………….. 3
15 PAFZZ 5340-01-569-5498 39428 92700A459 STANDOFF,THREADED,
SNAP-IN....................................... 2
16 PAFZZ 6110-01-569-1448 29186 010-9336 CONTROLLER,MOTOR .............. 1
17 PAFZZ 5305-01-569-1803 1KDE3 8C75MXP1 SCREW,MACHINE ...................... 4
18 PAFZZ 0WFM3 T260605 BRACKET,MOUNTING ............... 2
19 PAFZZ 5929-01-569-0391 1RW76 MG27186 CIRCUIT BREAKER .................... 1
20 PAFZZ 5925-01-043-9283 56303 QOU330 CIRCUIT BREAKER .................... 1
21 PAFZZ 5925-01-040-7979 56303 QOU120 CIRCUIT BREAKER .................... 2
22 PAFZZ 5925-01-569-0297 56303 QOU360 CIRCUIT BREAKER .................... 1
23 PAFZZ 6130-01-569-2725 32AV2 SM82243ELACF POWER SUPPLY ........................ 1
PC
24 PAFZZ 5305-01-568-4710 0WFM3 T270130 SCREW,MACHINE ...................... 24
25 PAFZZ 5940-01-568-9122 005K5 16325-2 TERMINAL BLOCK ..................... 3
26 PAFZZ 5930-01-569-0337 32AV2 546-100-00T TRANSFORMER,CURRENT ...... 3
27 XBFZZ 7Y971 CPBD-2 COVER,PROTECTIVE ................ 2
28 PAFZZ 5940-01-528-7120 65996 281-901 TERMINAL JUCTION BLOCK,
SECTION A .................................. 39
29 PAFZZ K6F01 281-329 PLATE,MOUNTING ..................... 2
30 PAFZZ 5940-01-349-6763 65996 281-402 JUMPER,ELECTRICAL,
SPECIAL ...................................... 10
0148-9
TM 11-6115-742-13&P 0148
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
31 PAFZZ 5895-01-569-1469 1PMV3 DYN3-60030 SWITCH,ELECTRONIC .............. 1
32 PAFZZ 5305-01-569-7744 1KDE3 8C100MXP1 SCREW,MACHINE ...................... 4
33 PAFZZ 6110-01-533-9768 38151 SE350 VOLTAGE REGULATOR
SUBASSEMBLY .......................... 1
34 PAFZZ 5920-01-285-9879 75915 218004 FUSE,CARTRIDGE……………. 1
END OF FIGURE
0148-10
TM 11-6115-742-13&P 0149
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
CHASSIS, TRAILER ASSEMBLY, T215125G/T215125T
9
2
1
1,2 2
7
3
6
5
4
Figure 18. Chassis, Trailer Assembly, T215125G/T215125T (Sheet 1 of 4).
0149-1
TM 11-6115-742-13&P 0149
13
10
10
12
11
19
18
15
14
16
P/O 17 P/O 17
17
Figure 18. Chassis, Trailer Assembly, T215125G/T215125T (Sheet 2 of 4).
0149-2
TM 11-6115-742-13&P 0149
21
20
28
29
30
22
27
26
22
2
26
25
24
23
Figure 18. Chassis, Trailer Assembly, T215125G/T215125T (Sheet 3 of 4).
0149-3
TM 11-6115-742-13&P 0149
31
P/O 32
32
43
41
42
41 P/O 32
P/O 32
33
28
40 32
35
37
34
38
35
36
38
39
Figure 18. Chassis, Trailer Assembly, T215125G/T215125T (Sheet 4 of 4).
0149-4
TM 11-6115-742-13&P 0149
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 0103
FIGURE 18 CHASSIS, TRAILER
ASSEMBLY,
T215125G/T215125T
1 PAFZZ 6260-01-558-9874 12662 B472R REFLECTOR, LIGHT................... 4
2 PAFZZ 5320-01-025-6328 02126 AA-44-D RIVET, BLIND .............................. 20
3 PAFFF 6220-01-552-6229 5A910 12375837-BK-SP STOP LIGHT,VEHICULAR
(SEE FIGURE 19 FOR
BREAKDOWN)............................. 2
3 PAFZZ 6210-01-549-6409 13548 07415 LIGHT EMITTING DIODE ............ 2
4 PAFZZ 5310-01-553-0366 1KDE3 100NLIT4 WASHER,LOCK .......................... 4
5 PAFZZ 5305-01-552-6254 1KDE3 37C100HCS1 SCREW,CAP,HEXAGON
HEAD ........................................... 4
6 XBFZZ 0WFM3 T211205G LEG,STABILIZER ........................ 2
6 XBFZZ 0WFM3 T211205T LEG,STABILIZER ........................ 2
7 PAFZZ 5310-01-553-8822 62161 T20018C NUT,PLAIN, CONE SEAT,
HEXAGON ................................... 16
8 PCFHH 2530-01-493-5859 19207 12460176 WHEEL AND RUNFLAT
(REFER TO TM 9-2330-392-
14&P FOR MAINTENANCE
AND REPAIR PARTS) ................. 2
9 PAFZZ 6260-01-558-9867 12662 B472A REFLECTOR,LIGHT
(AMBER) ...................................... 2
10 PAFZZ 5995-01-552-6224 5A910 AC-13306 CABLE ASSEMBLY,SPECIAL
PURPOSE,ELECTRICAL ............ 1
(CABLE TO BE USED WITH
INCANDESCENT TAILLIGHT)
10 PAFZZ 5995-01-552-6936 0WFM3 TG903-6752 WIRING HARNESS ..................... 1
(HARNESS TO BE USED
WITH LED TAILLIGHT)
11 PAFZZ 5306-01-554-4332 1KDE3 62C200HCS1 BOLT,MACHINE .......................... 4
12 XBFFF 0WFM3 PCHA0175G TONGUE JACK ASSEMBLY
(SEE FIGURE 20 FOR
BREAKDOWN)............................. 1
UOC: 89W
12 XBFFF 0WFM3 PCHA0175T TONGUE JACK ASSEMBLY
(SEE FIGURE 20 FOR
BREAKDOWN)............................. 1
UOC: 89X
13 PAFZZ 5310-01-553-0357 74949 NN5811GR8Z NUT,SELF-LOCKING,
HEXAGON ................................... 4
14 PAFZZ 2540-01-552-6428 0WFM3 T295153 TAILGATE WEB STRAP ............. 1
0149-5
TM 11-6115-742-13&P 0149
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
15 PAFZZ 5305-01-553-8832 0WFM3 T270034 SCREW,MACHINE ...................... 3
16 PAFZZ 5210-01-516-7126 57163 36078 LEVEL,CYLINDRICAL,
CIRCULAR VIAL .......................... 1
17 PAFZZ 4030-01-553-8070 3TKE1 HKCS312G43EG HOOK,GRAB ............................... 2
WL
18 XBFZZ 0WFM3 T210965 CHAIN,SAFETY ........................... 2
19 PAFZZ 5315-01-558-6154 0WFM3 PCHA0171 PIN,LOCK .................................... 2
20 XBFZZ 0WFM3 TG404-0829G RESTRAINT,CARGO .................. 1
UOC: 89W
20 XBFZZ 0WFM3 TG404-0829T RESTRAINT,CARGO .................. 1
UOC: 89X
21 XBFZZ 0WFM3 TG404-0830G TAILGATE.................................... 1
UOC: 89W
21 XBFZZ 0WFM3 TG404-0830T TAILGATE.................................... 1
UOC: 89X
22 PAFZZ 4010-01-481-1699 4X630 863-000309 WIRE ROPE ASSEMBLY,
SINGLE LEG ................................ 12
23 PAFZZ 5310-01-533-2915 3A054 92771A535 NUT,PLAIN,WING ....................... 1
24 PAFZZ 5310-01-563-2566 3A054 93496A031 WASHER,LOCK .......................... 2
25 PAFZZ 5310-01-485-7896 53711 123-1680562 PC NUT,PLAIN,HEXAGON ............... 1
93
26 PAFZZ 5310-01-569-5414 39428 92916A405 WASHER,FLAT ........................... 2
27 PAFZZ 5305-01-569-5822 39428 92941A626 SCREW,CAP,HEXAGON
HEAD ........................................... 1
28 PAFZZ 5310-01-552-3984 1KDE3 25CNNE1 NUT,SELF-LOCKING,
HEXAGON ................................... 4
29 PAFZZ 5340-01-476-7532 39428 3225T2 CLAMP,LOOP.............................. 5
30 PAFZZ 5975-01-552-6937 0WFM3 T295146 ROD SECTION,GROUND ........... 1
31 XCFFF 0WFM3 TG421-9006G BRAKE INSTALLATION (SEE
FIGURE 21 FOR
BREAKDOWN) ............................ 1
UOC: 89W
31 XCFFF 0WFM3 TG421-9006T BRAKE INSTALLATION (SEE
FIGURE 21 FOR
BREAKDOWN) ............................ 1
UOC: 89X
32 XBFZZ 0WFM3 PCHA0161G LINK,HOISTING........................... 4
UOC: 89W
32 XBFZZ 0WFM3 PCHA0161T LINK,HOISTING........................... 4
UOC: 89X
0149-6
TM 11-6115-742-13&P 0149
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
33 XBFZZ 0WFM3 T295154 BAR,CARGO NET ....................... 1
34 XBFZZ 0WFM3 T210949 BRACKET,MOUNTING ............... 1
35 PAFZZ 5310-01-552-8314 1KDE3 37NWFL1 WASHER,FLAT ........................... 2
36 PAFZZ 5306-01-553-0517 1KDE3 25C300HCS1 BOLT,MACHINE .......................... 4
37 PAFZZ 5306-01-553-7509 1KDE3 37C300HCS1 BOLT,MACHINE .......................... 2
38 PAFZZ 5310-01-552-2776 1KDE3 25NWFL1 WASHER,FLAT ........................... 8
39 PAFZZ 5310-01-479-5890 0Y3H3 70862 NUT,SELF-LOCKING,
HEXAGON ................................... 2
40 PAFZZ 5306-01-558-7187 1KDE3 50C150HCS1 BOLT,MACHINE .......................... 10
41 PAFZZ 5310-01-559-0602 74949 WFSAE127H2 WASHER,FLAT ........................... 16
42 XBFZZ 0WFM3 HW903-4024G PAD EYE ..................................... 2
UOC: 89W
42 XBFZZ 0WFM3 HW903-4024T PAD EYE ..................................... 2
UOC: 89X
43 PAFZZ 5310-01-559-2446 1KDE3 50CNNE1 NUT,PLAIN,HEXAGON ............... 8
END OF FIGURE
0149-7/8 blank
TM 11-6115-742-13&P 0150
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
STOP LIGHT, VEHICULAR, 12375837-BK-SP
0150-1
TM 11-6115-742-13&P 0150
P/O 3
P/O 3
P/O 3
Figure 19. Stop Light, Vehicular, 12375837-BK-SP.
0150-2
TM 11-6115-742-13&P 0150
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 010301
FIGURE 19 STOP LIGHT,
VEHICULAR
12375837-BK-SP
1 PAFZZ 6240-00-019-3093 58536 AA52463-A09 LAMP,INCANDESCENT ................... 2
2 PAFZZ 6240-00-924-7526 58536 W-L-00111/64 LAMP,INCANDESCENT ................... 2
3 PAFZZ 6220-01-359-2870 19207 12375841 LENS,LIGHT ..................................... 2
END OF FIGURE
0150-3/4 blank
TM 11-6115-742-13&P 0151
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
TONGUE JACK ASSEMBLY, PCHA0175G/PCHA0175T
0151-1
TM 11-6115-742-13&P 0151
1
2
Figure 20. Tongue Jack Assembly, PCHA0175G/PCHA0175T.
0151-2
TM 11-6115-742-13&P 0151
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 010302
FIGURE 20 TONGUE JACK
ASSEMBLY
PCHA0175G/PCHA0175T
1 PAFZZ 0WFM3 1005514 PIN,RETAINING ............................... 3
2 XBFZZ 0WFM3 PCHA0131G PLATE,SKID/WHEEL ....................... 1
UOC: 89W
2 XBFZZ 0WFM3 PCHA0131T PLATE,SKID/WHEEL ....................... 1
UOC: 89X
END OF FIGURE
0151-3/4 blank
TM 11-6115-742-13&P 0152
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
BRAKE INSTALLATION, T6421-9006G/T6421-9006T
0152-1
TM 11-6115-742-13&P 0152
A C
B
12 1
2
3
4
5
6
7
8
9
10
11
Figure 21. Brake Installation, T6421-9006G/T6421-9006T (Sheet 1 of 5).
0152-2
TM 11-6115-742-13&P 0152
13
P/O 13
P/O 13
P/O 13
P/O 13 P/O 13
P/O 13
P/O 13
P/O 13
Figure 21. Brake Installation, T6421-9006G/T6421-9006T (Sheet 2 of 5).
0152-3
TM 11-6115-742-13&P 0152
14
15
17
P/O 14
16
P/O 14
P/O 14
P/O 14
P/O 14
P/O 14
P/O 14
P/O 14
P/O 14
Figure 21. Brake Installation, T6421-9006G/T6421-9006T (Sheet 3 of 5).
0152-4
TM 11-6115-742-13&P 0152
18 19
21 24
38 23
20 27
22
P/O 27
26
37 25
P/O
36
36 29
35
CURBSIDE 34 28
27
33 32 31 P/O
P/O 27 27 30
C
18
21
24
23 38
22 P/O
42 41 P/O 42
26 40
41
25 37
28 39
35 ROADSIDE
34
42
29 31 P/O
P/O 32 33 42
30
42
D
Figure 21. Brake Installation, T6421-9006G/T6421-9006T (Sheet 4 of 5).
0152-5
TM 11-6115-742-13&P 0152
45
44
43
46
VERSION 1
E
47
48
45
48
48
49
49
51
50
VERSION 2
E
Figure 21. Brake Installation, T6421-9006G/T6421-9006T (Sheet 5 of 5).
0152-6
TM 11-6115-742-13&P 0152
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 010303
FIGURE 21 BRAKE
INSTALLATION,
TG421-9006G/
TG421-9006T
1 PAFZZ 5330-01-569-5966 15460 010-054-00 SEAL,PLAIN ................................ 2
2 PAFZZ 3110-00-100-3541 60038 25580 CONE AND ROLLERS,
TAPERED ROLLER BEARING ... 2
3 PAFZZ 3110-01-524-7337 15460 031-030-01 RING,BEARING,INNER .............. 2
4 PAFZZ 1630-01-570-4484 15460 008-219-13 BRAKE DRUM ............................. 2
5 PAFZZ 5307-01-554-0463 15460 007-132-00 STUD,SELF-LOCKING................ 16
6 PAFZZ 3110-01-568-0751 15460 031-017-01 BEARING, OUTER RACE ........... 2
7 PAFZZ 3110-01-550-0132 07070 031-017-02 CONE,TAPERED ROLLER ......... 2
8 PAFZZ 5310-01-533-1836 15460 005-057-00 WASHER,FLAT ........................... 2
9 PAFZZ 5310-01-455-4394 15460 006-176-00 NUT,PLAIN,HEXAGON ............... 2
10 PAFZZ 5331-01-524-8032 15460 010-045-00 O-RING ........................................ 2
11 PAFZZ 2530-01-192-8464 15460 021-039-00 CAP,GREASE ............................. 2
12 PAFZZ 5315-01-519-8470 15460 019-002-00 PIN,COTTER ............................... 2
13 PAFZZ 0WFM3 TG903-6704 KIT,TORSION BRAKE LINE ....... 1
14 XBFZZ 01428 165-508-168 LEVER,MANUAL CONTROL ...... 1
15 PAFZZ 0WFM3 TG903-5103 CABLE AND CONDUIT
ASSEMBLY,VEHICULAR ............ 1
16 PAFZZ 5310-01-479-5890 0Y3H3 70862 NUT, SELF-
LOCKING,HEXAGON .................. 2
17 PAFZZ 5305-01-558-7717 1KDE3 37C200HCS8Y/F SCREW,CAP,HEXAGON
T HEAD ........................................... 2
18 PAFZZ 5305-01-521-8564 15460 087-001-00 SCREW,CAP,HEXAGON
HEAD ........................................... 4
19 XBFZZ 15460 036-093-26 PLATE,BACK ASSEMBLY .......... 1
20 PAFZZ 2530-01-375-8150 15460 054-065-00 CYLINDER ASSEMBLY,
HYDRAULIC BRAKE ................... 1
21 PAFZZ 2530-01-522-0151 15460 054-060-00 PUSH ROD, HYDRAULIC
BRAKE MASTER......................... 2
22 PAFZZ 5360-01-568-6048 15460 046-108-01 SPRING ....................................... 2
23 PAFZZ 5310-01-569-5989 15460 005-064-00 WASHER ..................................... 2
24 PAFZZ 15460 040-244-01 LEVER,BRAKE SHOE 2
25 PAFZZ 5305-01-569-5976 15460 007-210-00 SCREW ....................................... 2
26 PAFZZ 2530-01-569-5950 15460 037-069-02 LINK,TRAVEL…………………... 2
0152-7
TM 11-6115-742-13&P 0152
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
27 PAFZZ 2530-01-552-7040 15460 K71-395-00 BRAKE SHOE ............................. 1
28 PAFZZ 2530-01-461-0178 15460 047-119-01 LINK,ANCHOR,BRAKE SHOE .... 2
29 PAFZZ 5360-01-569-6055 15460 046-107-01 SPRING ....................................... 2
30 PAFZZ 5360-01-569-6046 15460 046-101-00 SPRING,RETRACTOR................ 2
31 PAFZZ 5310-01-569-5955 15460 006-011-00 LOCKNUT .................................... 2
32 PAFZZ 5360-01-569-6043 15460 046-123-00 SPRING,ADJUSTING SCALE ..... 2
33 PAFZZ 2530-01-456-9099 15460 043-028-00 ADJUSTING SCREW
ASSEMBLY .................................. 2
34 PAFZZ 5340-01-454-6358 15460 069-055-00 CLIP,SPRING TENSION ............. 2
35 PAFZZ 5310-01-454-2325 15460 005-112-00 WASHER,SPRING TENSION ..... 2
36 PAFZZ 2530-01-456-9107 15460 047-111-01 LEVER AND PIN ......................... 1
37 PAFZZ 5310-01-569-5984 15460 006-193-00 NUT,WASHER ASSEMBLY ........ 10
38 PAFZZ 5340-01-535-4672 15460 046-007-00 PLUG,PROTECTIVE,DUST ........ 2
39 XBFZZ 15460 036-093-15 PLATE,BACK ASSEMBLY .......... 1
40 PAFZZ 2530-01-375-8149 15460 054-064-00 CYLINDER ASSEMBLY,
HYDRAULIC BRAKE,WHEEL ..... 1
41 PAFZZ 2530-01-457-0173 15460 047-110-01 LEVER AND PIN ......................... 1
42 PAFZZ 2530-01-552-7044 15460 K71-394-00 BRAKE SHOE ............................. 1
43 PAFZZ 5306-01-558-7187 1KDE3 50C150HCS1 BOLT,MACHINE .......................... 6
44 PAFZZ 5310-01-559-0602 74949 WFSAE127H2 WASHER,FLAT ........................... 6
45 PAFFF 2530-01-568-0725 0WFM3 TG404-0819G ACTUATOR ASSEMBLY (SEE
FIGURE 22 FOR
BREAKDOWN) ............................ 1
UOC: 89W
45 PAFFF 2530-01-568-0031 0WFM3 TG404-0819T ACTUATOR ASSEMBLY (SEE
FIGURE 22 FOR
BREAKDOWN) ............................ 1
UOC: 89X
45 PAFFF 0WFM3 1002330 ACTUATOR ASSEMBLY (SEE
FIGURE 22 FOR
BREAKDOWN) ............................ 1
UOC: 89W
45 PAFFF 0WFM3 1002331 ACTUATOR ASSEMBLY (SEE
FIGURE 22 FOR
BREAKDOWN) ............................ 1
UOC: 89X
46 PAFZZ 5310-01-559-2446 1KDE3 50CNNE1 NUT,PLAIN,HEXAGON ............... 6
47 PAFZZ 5306-01-503-8991 1YHH8 8310084 BOLT,1.2-20NF X2.0 ................... 2
48 PAFZZ 5310-01-457-8573 0Y3H3 33817 WASHER,FLAT ........................... 6
49 PAFZZ 5310-01-598-5134 0Y3H3 33895 WASHER,LOCK .......................... 4
0152-8
TM 11-6115-742-13&P 0152
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
50 PAFZZ 0Y3H3 18912 BOLT,MACHINE .......................... 2
51 PAFZZ 0Y3H3 1137084 NUT, SELF-
LOCKING,HEXAGON .................. 2
END OF FIGURE
0152-9/10 blank
TM 11-6115-742-13&P 0153
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
ACTUATOR ASSEMBLY, TG404-0819G/TG404-0819T OR 1002330/1002331
9 14
13
10
8 12
7 11
1 2
6 7
3 6
1
2 5
4
7
3 7
6
15
4
15
16
3
2
15
1
22
28
3
21 20 18 17 1
1
23
3 24
1 16 25
2
3 19
26
1
3
4 1
3
27 4 VERSION 1
Figure 22. Actuator Assembly, TG404-0819G/TG404-0819T or 1002330/1002331 (Sheet 1 of 2).
0153-1
TM 11-6115-742-13&P 0153
9 14
13
10
8 12
7 11
1 2
6 7
3 6
1
2 5
4
7
3 7
6
15
4
15
16
3
2
15
1
22
28
3
21 20 18 17 1
1
23
3 24
1 16 25
2
3 19
26
3
4
3
27 4 1
VERSION 2
Figure 22. Actuator Assembly, TG404-0819G/TG404-0819T or 1002330/1002331 (Sheet 1 of 2).
0153-2
TM 11-6115-742-13&P 0153
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 01030301
FIGURE 22 ACTUATOR
ASSEMBLY,
TG404-0819G/
TG404-0819T OR
1002330/1002331
1 PAFZZ 5310-00-877-5795 80205 MS21044-N8 NUT, SELF-LOCKING,
HEXAGON ................................... 8
2 PAFZZ 0WFM3 1005629 LINK, CHAIN................................ 4
UOC: 89W
2 PAFZZ 0WFM3 1005995 LINK, CHAIN................................ 4
UOC: 89X
3 PAFZZ 3120-01-052-1151 33968 35360957 BEARING, SLEEVE..................... 8
4 PAFZZ 2540-01-051-6354 2X264 1829 SHAFT, CHAIN ............................ 4
5 PAFZZ 5305-00-710-4205 80205 MS90726-99 SCREW, CAP, HEXAGON
HEAD ........................................... 1
6 PAFZZ 5305-00-709-8423 80204 B1821BH044F35 SCREW, CAP, HEXAGON
0N HEAD ........................................... 3
7 PAFZZ 5365-01-053-6898 19207 12356021 SPACER, SLEEVE ...................... 4
8 PAFZZ 5330-00-291-6658 11083 9B1545 GASKET ...................................... 1
9 PAFZZ 0WFM3 1009832 CAP, FILLER OPENING.............. 1
UOC: 89W
9 PAFZZ 0WFM3 1009833 CAP, FILLER OPENING.............. 1
UOC: 89X
10 PAFZZ 2530-01-050-8929 55683 1441-10614 CYLINDER ASSEMBLY,
HYDRAULIC BRAKE ................... 1
11 PAFZZ 5310-00-275-6635 94988 FC602 WASHER, FLAT .......................... 1
12 PAFZZ 5340-01-570-9063 19207 12362746 CONNECTOR.............................. 1
13 PAFZZ 5310-00-209-1761 19207 10896710 WASHER, FLAT .......................... 1
14 PAFZZ 4730-01-053-8468 19207 8762000 BOLT, FLUID PASSAGE ............. 1
15 PAFZZ 5310-00-959-1488 81349 M45913/2- NUT, SELF-LOCKING,
6FG5C HEXAGON ................................... 3
16 PAFZZ 5310-00-057-7080 81349 M45913/1- NUT, SELF-LOCKING,
7FG5C HEXAGON ................................... 2
17 PAFZZ 5340-01-456-6458 19207 12356020 BOOT, DUST AND MOISTURE
SEAL ............................................ 1
18 PAFZZ 2530-01-167-1999 19207 12356014 PUSH ROD, HYDRAULIC
BRAKE MASTER......................... 1
0153-3
TM 11-6115-742-13&P 0153
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
19 PAFZZ 2510-00-050-7136 1JZ80 1844-2 SHOCK ABSORBER, DIRECT
ACTION ....................................... 1
20 PAFZZ 5360-01-054-2281 19207 12356018 SPRING ....................................... 1
21 PAFZZ 2530-01-050-7698 1JZ80 1804 LEVER BREAKAWAY ................. 1
22 PAFZZ 5340-01-385-9852 96508 760-4131#1408 SNAP, HOOK .............................. 1
23 PAFZZ 5310-01-050-8832 19207 12356017 WASHER, PUSH ROD ................ 1
24 PAFZZ 5310-00-074-2328 80205 MS21083C7 NUT, SELF-LOCKING,
HEXAGON ................................... 1
25 PAFZZ 5305-00-949-6184 80205 MS51975-2 SCREW, SHOULDER ................. 1
26 PAFZZ 5305-00-709-8542 80204 B1821BH044F20 SCREW, CAP, HEXAGON
0N HEAD ........................................... 1
27 PAFZZ 0WFM3 1009945 COUPLER,DRAWBAR
RING ............................................ 1
UOC: 89W
27 PAFZZ 0WFM3 1009946 COUPLER,DRAWBAR
RING ............................................ 1
UOC: 89X
28 PAFZZ 5315-01-569-5347 0WFM3 1001136 PIN, LOCKING............................. 1
END OF FIGURE
0153-4
TM 11-6115-742-13&P 0154
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
TENT, MXA2000G/MXA2000T
0154-1
TM 11-6115-742-13&P 0154
3 INTERIOR
A C
B
4 E
G
E
EXTERIOR G F C D
J H
J H
Figure 23. Tent, MXA2000G/MXA2000T (Sheet 1 of 3).
0154-2
TM 11-6115-742-13&P 0154
10
11
12
13
Figure 23. Tent, MXA2000G/MXA2000T (Sheet 2 of 3).
0154-3
TM 11-6115-742-13&P 0154
17 21
14 19 19
15 18 20
P/O 17 P/O 21
17
16
A G B
P/O 24 P/O 21
24 21
22 23
19
19
25
26
27
C E D 28
P/O 17 P/O 17
17 P/O 21 17
19 21
19 19
F 29 H J
Figure 23. Tent, MXA2000G/MXA2000T (Sheet 3 of 3).
0154-4
TM 11-6115-742-13&P 0154
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 0104
FIGURE 23 TENT
MXA2000G/MXA2000T
1 XBCFF 8340-01-589-9512 0WFM3 MXA2020G BAG.TENT FRAME PARTS (SEE
FIGURE 24 FOR BREAKDOWN) ... 2
UOC: 89W
1 XBCFF 8340-01-589-9518 0WFM3 MXA2020T BAG.TENT FRAME PARTS(SEE
FIGURE 24 FOR BREAKDOWN) ... 2
UOC: 89X
2 XBCFF 0WFM3 MXA2035G TENT,ROOF AND SIDES (SEE
FIGURE 25 FOR BREAKDOWN) ... 1
UOC: 89W
2 XBCFF 0WFM3 MXA2035T TENT,ROOF AND SIDES (SEE
FIGURE 25 FOR BREAKDOWN) ... 1
UOC: 89X
3 PACZZ 4020-01-570-4924 0WFM3 A602050 ROPE,FIBROUS ............................. 16
4 PACZZ 8340-01-571-6948 0WFM3 MXA2025F TENT FLOOR.................................. 1
5 PACZZ 8340-01-556-7416 0WFM3 MA100735 REPAIR KIT,COVERS
(SEE EXPENDABLE ITEMS LIST
FOR CONTENTS) ........................... 1
UOC: 89W
5 PACZZ 5410-01-570-4998 0WFM3 MA100740 REPAIR KIT,COVERS
(SEE EXPENDABLE ITEMS LIST
FOR CONTENTS) ........................... 1
UOC: 89X
6 PACZZ 5340-01-558-9644 0WFM3 A600250 ADAPTER,TIE DOWN .................... 3
7 PACZZ 8340-01-553-0054 0WFM3 MXA2040B CASE,TENT .................................... 1
8 PACZZ 8340-01-540-7600 0WFM3 MXA1054G CONNECTOR,TENT GUSSET ....... 4
UOC: 89W
8 PACZZ 8340-01-540-7608 0WFM3 MXA1054T CONNECTOR,TENT GUSSET ....... 4
UOC: 89X
9 PACZZ 0WFM3 MA100165 TENT STAKE BAG ......................... 1
10 PACZZ 5120-01-399-9252 1CV05 1434G HAMMER,HAND ............................. 1
11 PACZZ 8340-01-571-6274 0WFM3 A601250 STAKE PIN,STEEL ......................... 25
12 PACZZ 5340-01-558-7299 0WFM3 A602650 POLE,PUSH .................................... 4
13 PACZZ 8340-01-540-7490 0WFM3 MXA1055G PASSAGEWAY,TENT .................... 1
UOC: 89W
13 PACZZ 8340-01-540-7495 0WFM3 MXA1055T PASSAGEWAY,TENT .................... 1
UOC: 89X
0154-5
TM 11-6115-742-13&P 0154
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
14 PACZZ 5340-01-553-1413 0WFM3 MA100720 BRACKET,MOUNTING ................... 10
15 PACZZ 5305-01-553-0673 1KDE3 25K100MX81 SCREW,MACHINE ......................... 70
16 PACZZ 5340-01-558-8890 0WFM3 A601651 KEEPER,BELT-STRAP .................. 10
UOC: 89W
16 PACZZ 5365-01-558-6149 0WFM3 A601661 PLUG,MACHINE THREAD ............. 10
UOC: 89X
17 PACZZ 5340-01-558-8820 0WFM3 SH410-0201G CONNECTOR,ROD END ............... 70
UOC: 89W
17 PACZZ 3010-01-558-7646 0WFM3 SH410-0201T HUB,COUPLING,FLEXIBLE ........... 70
UOC: 89X
18 PACZZ 5340-01-558-9652 0WFM3 JA201005 KEEPER,BELT-STRAP .................. 10
UOC: 89W
18 PACZZ 5340-01-558-9289 0WFM3 JA201000 KEEPER,BELT-STRAP .................. 10
UOC: 89X
19 PACZZ 5305-01-553-7511 IKDE3 25K75MX71 SCREW,MACHINE ......................... 1,104
20 PACZZ 5340-01-558-7324 0WFM3 JA200980 KEEPER,LOOPED .......................... 26
21 PACZZ 5340-01-558-9807 0WFM3 SH410-0201W CONNECTOR,ROD END ............... 64
22 PACZZ 5340-01-558-8848 0WFM3 F329905 CONNECTOR,ROD END ............... 24
23 PACZZ 5340-01-558-7292 0WFM3 A601681 KEEPER,PLAIN .............................. 24
24 PACZZ 5430-01-570-4415 0WFM3 SH410-0202 HUB,MAIN W/PIN,WHITE............... 4
25 PACZZ 4020-01-553-0415 0WFM3 T270923 CORD ASSEMBLY,FIBROUS ........ 4
26 PACZZ 5315-01-552-8301 0WFM3 A600115 PIN,QUICK RELEASE .................... 4
27 PACZZ 5340-01-559-0471 0WFM3 A600116 CONNECTOR,ROD END ............... 4
28 PACZZ 5340-01-558-7288 0WFM3 JA200921 KEEPER,PLAIN .............................. 10
29 PACZZ 5340-01-558-9804 0WFM3 JA200881 KEEPER,BELT-STRAP .................. 46
UOC: 89W
29 PACZZ 5340-01-558-8533 0WFM3 JA200901 KEEPER,BELT-STRAP .................. 46
UOC: 89X
END OF FIGURE
0154-6
TM 11-6115-742-13&P 0155
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
TENT, END CAP, MXA2020G/MXA2020T
0155-1
TM 11-6115-742-13&P 0155
Figure 24. Tent, End Cap, MXA2020G/MXA2020T (Sheet 1 of 3).
0155-2
TM 11-6115-742-13&P 0155
A
6 A
C
B
5 7
INTERIOR
8
B D
9
B D
10
D
11
E
D
12
G
E EXTERIOR
G
E
13
Figure 24. Tent, End Cap, MXA2020G/MXA2020T (Sheet 2 of 3).
0155-3
TM 11-6115-742-13&P 0155
17
14
15
16
14
P/O 17
P/O 15
A B
20
17 P/O 17
17 14
14 19
P/O 20
P/O 17 14
C 18 D E
P/O 20
20 20
14
21
P/O 20
14
F G
Figure 24. Tent, End Cap, MXA2020G/MXA2020T (Sheet 3 of 3).
0155-4
TM 11-6115-742-13&P 0155
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 010401
FIGURE 24 TENT, END CAP
MXA2020G/MXA2020T
1 PACZZ 8340-01-572-0658 0WFM3 MXS1015G COVER,EXTERIOR,END CAP,
GREEN ............................................ 1
UOC: 89W
1 PACZZ 8340-01-571-8798 0WFM3 MXS1015T COVER,EXTERIOR,END CAP,
TAN ................................................. 1
UOC: 89X
2 PACZZ 8340-01-572-0505 0WFM3 MXS1020G DOOR,EXTERIOR,END CAP ......... 2
UOC: 89W
2 PACZZ 8340-01-571-6458 0WFM3 MXS1020T DOOR,EXTERIOR,END CAP ......... 2
UOC: 89X
3 PACZZ 8340-01-571-9776 0WFM3 MXS1020W DOOR,INTERIOR END CAP .......... 2
4 PACZZ 8340-01-571-6878 0WMF3 MXS1015W COVER,INTERIOR, END CAP ....... 1
5 XBCFF 0WMF3 MXA2016G TENT FRAME,END CAP ................ 2
UOC: 89W
5 XBCFF 0WMF3 MXA2016T TENT FRAME,END CAP ................ 2
UOC: 89X
6 PACZZ 8340-01-571-9871 0WFM3 F329601 STRUT,A-SIDE BLUE ..................... 5
7 PACZZ 8340-01-571-9552 0WFM3 F329631 STRUT,B-SIDE RED ....................... 4
8 PACZZ 5340-01-558-8848 0WFM3 F329905 CONNECTOR,ROD END ............... 2
9 PACZZ 8340-01-571-6590 0WFM3 F329781 STRUT,B-SIDE YELLOW ............... 8
10 PACZZ 5340-01-558-8873 0WFM3 F329908 CONNECTOR,ROD END ............... 1
11 PACZZ 8340-01-571-9857 0WFM3 F329751 STRUT,A-SIDE GREEN ................. 4
12 PACZZ 5340-01-558-9644 0WFM3 A600250 ADAPTER,TIE DOWN .................... 2
13 PACZZ 8340-01-589-9473 0WFM3 MXA2045B TRANSPORT BAG,END CAP ........ 1
14 PACZZ 5305-01-552-8305 1KDE3 8D50TXP1 SCREW,MACHINE ......................... 192
15 PACZZ 5340-01-558-9666 0WFM3 SH410-0401R CONNECTOR,ROD END ............... 2
16 PACZZ 5340-01-558-7313 0WFM3 A601680 KEEPER,LOOPED .......................... 6
17 PACZZ 5340-01-558-8758 0WFM3 SH410-0001W CONNECTOR,ROD END ............... 9
18 PACZZ 5340-01-558-7292 0WFM3 A601681 KEEPER,PLAIN .............................. 3
19 PACZZ 5340-01-558-9677 0WFM3 A601650 KEEPER,BELT-STRAP .................. 7
UOC: 89W
19 PACZZ 5340-01-558-9133 0WFM3 A601660 KEEPER,BELT-STRAP .................. 7
UOC: 89X
0155-5
TM 11-6115-742-13&P 0155
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
20 PACZZ 5340-01-558-8752 0WFM3 SH410-0001G CONNECTOR,ROD END ............... 11
UOC: 89W
20 PACZZ 5340-01-558-8512 0WFM3 SH410-0001T CONNECTOR,ROD END ............... 11
UOC: 89X
21 PACZZ 5340-01-558-8890 0WFM3 A601651 KEEPER,BELT-STRAP .................. 2
UOC: 89W
21 PACZZ 5365-01-558-6149 0WFM3 A601661 PLUG,MACHINE THREAD ............. 2
UOC: 89X
END OF FIGURE
0155-6
TM 11-6115-742-13&P 0156
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
TENT, ROOF AND SIDES, MXA2035G/MXA2035T
0156-1
TM 11-6115-742-13&P 0156
5
7
10
Figure 25. Tent, Roof and Sides, MXA2035G/MXA2035T.
0156-2
TM 11-6115-742-13&P 0156
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 010402
FIGURE 25 TENT, ROOF AND SIDES
MXA2035G/MXA2035T
1 XBCZZ 0WFM3 MXA2010W COVER,INTERIOR ......................... 1
2 XBCZZ 0WFM3 MXA2005G COVER,EXTERIOR,GREEN .......... 1
UOC: 89W
2 XBCZZ 0WFM3 MXA2005T COVER,EXTERIOR,TAN ................ 1
UOC: 89X
3 PACZZ 8340-01-572-0624 0WFM3 MA100130 SIDE DOOR,EXTERIOR,
GREEN ............................................ 2
UOC: 89W
3 PACZZ 8340-01-571-6456 0WFM3 MA100530 SIDE DOOR,EXTERIOR,TAN ........ 2
UOC: 89X
4 PACZZ 8340-01-571-9444 0WFM3 MA100310 SIDE DOOR,INTERIOR,WHITE ..... 2
5 XBCZZ 0WMF3 MXA2015G TENT FRAME,MAIN ....................... 1
UOC: 89W
5 XBCZZ 0WMF3 MXA2015T TENT FRAME,MAIN ....................... 1
UOC: 89X
6 PACZZ 8340-01-572-0722 0WFM3 MF300140 STRUT,B-SIDE,RED ....................... 37
7 PACZZ 8340-01-572-7030 0WFM3 MF300150 STRUT,B-SIDE,YELLOW ............... 96
8 PACZZ 8340-01-571-6673 0WFM3 MF300130 STRUT,A-SIDE,BLUE ..................... 28
9 PACZZ 8340-01-571-9659 0WFM3 MF300200 STRUT,CANOPY ............................ 4
10 PACZZ 8340-01-572-0876 0WFM3 MF300160 STRUT,RISER ................................ 16
END OF FIGURE
0156-3/4 blank
TM 11-6115-742-13&P 0157
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
LIGHT SET, TENT, H300070
0157-1
TM 11-6115-742-13&P 0157
3
5
P/O 2
Figure 26. Light Set, Tent, H300070.
0157-2
TM 11-6115-742-13&P 0157
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 0106
FIGURE 26 LIGHT SET, TENT
H300070
1 PAFZZ 5920-00-010-6652 81349 F02A250V3A FUSE,CARTRIDGE ........................ 4
2 PAFZZ 6210-01-552-7806 0WFM3 H300000 FIXTURE,LIGHTING ....................... 4
3 PAFZZ 6240-01-552-6217 1FHF4 FT55DL841 LAMP,FLUORESCENT................... 4
4 PAFZZ 0WFM3 MA100170 BAG,LIGHT SET ............................. 2
5 XCFFF 0WFM3 T2-95205 WIRING KIT,ELECTRICAL (SEE
FIGURE 27 FOR BREAKDOWN) ... 1
END OF FIGURE
0157-3/4 blank
TM 11-6115-742-13&P 0158
PARTS INFORMATION
TMSS-MED
REPAIR PARTS LIST
WIRING KIT, ELECTRICAL, T2-95205
0158-1
TM 11-6115-742-13&P 0158
Figure 27. Wiring Kit, Electrical, T2-95205.
0158-2
TM 11-6115-742-13&P 0158
(1) (2) (3) (4) (5) (6) (7)
ITEM SMR DESCRIPTION AND
NO. CODE NSN CAGEC PART NUMBER USABLE ON CODE (UOC) QTY.
GROUP 010601
FIGURE 27 WIRING KIT,
ELECTRICAL
T2-95205
1 PAFZZ 6150-01-553-0094 0WFM3 T295114 CABLE ASSEMBLY,POWER,
ELECTRICAL .................................... 1
2 PAFZZ 6150-01-552-6419 0WFM3 T295116 CABLE ASSEMBLY,POWER,
ELECTRICAL .................................... 1
3 PAFZZ 5920-01-501-0678 65836 ISOBAR4 ARRESTER,ELECTRICAL
SURGE.............................................. 1
4 PAFZZ 6150-01-553-0088 1WXV7 SL-103-66593- CABLE ASSEMBLY,POWER,
01A ELECTRICAL .................................... 1
5 PAFZZ 8340-01-589-9618 0WFM3 MA100160 BAG,TENT FRAME PARTS ............. 1
END OF FIGURE
0158-3/4 blank
TM 11-6115-742-13&P 0159
PARTS INFORMATION
TMSS-MED
NATIONAL STOCK NUMBER INDEX
STOCK NUMBER FIG. ITEM STOCK NUMBER FIG. ITEM
5920-00-010-6652 26 1 5360-01-054-2281 22 20
4730-00-014-4027 8 66 5935-01-097-9974 16 15
6240-00-019-3093 15 5 3020-01-099-6277 7 12
19 1 6210-01-108-2600 16 5
5305-00-054-6668 6 34 5999-01-113-0824 17 10
5310-00-057-7080 22 16 5920-01-123-5212 4 21
5310-00-074-2328 22 24 8 44
3110-00-100-3541 21 2 5305-01-138-6292 6 9
5310-00-209-1761 22 13 5961-01-148-3364 6 27
5310-00-275-6635 22 11 5920-01-149-6952 4 22
5330-00-291-6658 22 8 8 45
5930-00-496-7492 6 6 4820-01-165-7825 4 39
5930-00-556-9791 6 14 2530-01-167-1999 22 18
4730-00-602-5342 8 32 2530-01-192-8464 21 11
6210-00-643-0339 15 4 5330-01-226-8689 10 51
6210-00-686-4999 15 24 4210-01-259-5634 8 16
5305-00-709-8423 22 6 6645-01-263-9434 15 18
5305-00-709-8542 22 26 5340-01-267-2904 8 24
5305-00-710-4205 22 5 5920-01-285-9879 17 34
5945-00-778-3922 6 36 5315-01-308-1154 7 15
4730-00-795-6959 8 80 5340-01-315-8389 8 14
5930-00-832-5174 6 1 5920-01-327-2572 17 5
6680-00-838-1829 8 69 5930-01-330-2858 15 26
3030-00-869-3419 7 10 4820-01-333-6042 4 37
5310-00-877-5795 22 1 5340-01-334-5735 8 75
4130-00-903-8372 4 36 5940-01-337-3316 9 31
6240-00-924-7526 19 2 5940-01-338-1965 9 30
5310-00-934-9748 6 13 5940-01-349-6763 17 30
5305-00-949-6184 22 25 6220-01-359-2870 19 3
5310-00-959-1488 22 15 2530-01-375-8149 21 40
5305-00-959-4158 4 9 2530-01-375-8150 21 20
2910-00-977-5495 8 93 5340-01-385-9852 22 22
5320-01-025-6328 8 17 4730-01-399-1866 8 85
18 2 5120-01-399-9252 23 10
5925-01-040-7979 17 21 5950-01-412-4121 6 16
5925-01-043-9283 17 20 4730-01-424-5432 8 78
2510-01-050-7136 22 19 13 15
2530-01-050-7698 22 21 5305-01-446-0679 6 21
5310-01-050-8832 22 23 2590-01-450-6882 10 76
2530-01-050-8929 22 10 5310-01-454-2325 21 35
2540-01-051-6354 22 4 5340-01-454-6358 21 34
3120-01-052-1151 22 3 5310-01-455-4394 21 9
5365-01-053-6898 22 7 5340-01-456-6458 22 17
4730-01-053-8468 22 14 2530-01-456-9099 21 33
0159-1
TM 11-6115-742-13&P 0159
STOCK NUMBER FIG. ITEM STOCK NUMBER FIG. ITEM
2530-01-456-9107 21 36 4730-01-534-5870 13 16
2530-01-457-0173 21 41 5340-01-535-4672 21 38
5310-01-457-8573 21 48 8340-01-538-1822 2 6
2530-01-461-0178 21 28 8340-01-538-1823 2 6
5310-01-466-2747 10 62 4730-01-539-9942 4 45
5340-01-468-1309 4 2 8340-01-540-7490 23 13
5340-01-476-7532 18 29 8340-01-540-7495 23 13
4730-01-479-1934 13 12 8340-01-540-7600 23 8
5310-01-479-5890 5 9 8340-01-540-7608 23 8
7 19 5306-01-547-7741 14 14
18 39 5306-01-547-8472 10 56
21 16 5306-01-547-8487 10 50
5330-01-480-0820 14 13 5340-01-547-8512 10 43
5920-01-480-3209 17 6 5330-01-547-8616 14 15
4010-01-481-1699 18 22 2815-01-548-4249 14 12
4730-01-481-4962 8 68 5310-01-548-4288 14 11
6140-01-482-9031 9 20 5340-01-548-4360 10 30
5310-01-485-7896 8 22 5365-01-548-4417 11 4
18 25 6210-01-549-6409 18 3
8340-01-491-3057 2 7 3110-01-550-0132 21 7
4730-01-492-6678 4 19 5920-01-552-0369 9 9
8 46 5305-01-552-0691 9 1
2530-01-493-5859 18 8 4730-01-552-0695 8 60
5340-01-497-5810 8 3 13 14
5310-01-497-7828 8 63 5340-01-552-0719 4 13
14 1 5945-01-552-1084 10 8
5920-01-501-0678 27 3 6210-01-552-1327 6 5
5306-01-503-8991 21 47 6210-01-552-1332 6 4
5210-01-516-7126 18 16 5340-01-552-2466 15 1
5315-01-519-8470 21 12 4730-01-552-2772 4 23
5340-01-520-7456 4 53 8 48
5306-01-521-5240 13 9 5310-01-552-2776 4 6
5305-01-521-8564 21 18 5 1
2530-01-522-0151 21 21 8 39
5310-01-523-1028 8 57 9 6
3110-01-524-7337 21 3 10 14
5331-01-524-8032 21 10 13 4
5940-01-528-7120 17 28 14 6
5305-01-529-4402 4 50 18 38
5305-01-531-7264 8 90 5355-01-552-3328 5 3
5340-01-533-1330 8 6 5310-01-552-3971 10 34
5310-01-533-1836 21 8 5310-01-552-3975 9 14
5310-01-533-2191 8 40 5310-01-552-3984 4 15
4010-01-533-2369 15 8 8 38
5310-01-533-2915 8 19 9 16
18 23 10 16
8340-01-533-5344 1 1 13 3
8340-01-533-5396 1 1 5310-01-552-3984 14 23
6110-01-533-9768 17 33 18 28
0159-2
TM 11-6115-742-13&P 0159
STOCK NUMBER FIG. ITEM STOCK NUMBER FIG. ITEM
5305-01-552-3987 4 27 5315-01-552-8301 23 26
8 55 5305-01-552-8305 24 14
9 4 5310-01-552-8308 10 23
14 7 5310-01-552-8314 8 88
5310-01-552-3994 9 5 9 15
10 78 10 19
5305-01-552-4509 8 28 18 35
5310-01-552-4510 14 4 5315-01-552-8316 4 8
5306-01-552-4514 10 35 5310-01-552-8350 10 37
5330-01-552-4522 11 10 5310-01-552-8613 10 28
5310-01-552-4523 8 30 5310-01-552-8619 7 17
16 9 5306-01-552-8636 11 1
5310-01-552-4536 14 8 5306-01-552-8639 11 14
4210-01-552-5109 8 18 5306-01-552-8648 10 32
4310-01-552-5118 12 2 5306-01-552-8656 11 8
6240-01-552-5498 16 6 5306-01-552-8662 10 22
6150-01-552-5717 9 3 5306-01-552-8668 10 36
3030-01-552-5720 11 15 5305-01-552-8706 4 7
6240-01-552-6210 15 25 5 2
6240-01-552-6217 26 3 5310-01-552-8714 10 40
6150-01-552-6221 9 7 11 7
5995-01-552-6224 18 10 5306-01-552-8738 10 31
6220-01-552-6229 18 3 5306-01-552-9111 7 16
5305-01-552-6246 2 10 5340-01-552-9135 14 18
5310-01-552-6251 2 13 5306-01-552-9145 9 12
5305-01-552-6254 18 5 5305-01-552-9209 9 18
2940-01-552-6301 10 7 13 6
2920-01-552-6309 10 2 14 3
2920-01-552-6314 10 21 5940-01-552-9284 9 8
2990-01-552-6325 4 18 5940-01-552-9497 9 10
8 43 4730-01-552-9598 12 4
2930-01-552-6338 13 1 2910-01-552-9726 10 5
6150-01-552-6358 2 9 5330-01-552-9907 11 12
4730-01-552-6415 4 28 2815-01-552-9950 10 69
8 53 4720-01-552-9960 4 24
6150-01-552-6419 27 2 8 49
2540-01-552-6428 18 14 2990-01-553-0029 14 28
5995-01-552-6934 8 37 2910-01-553-0046 4 29
5995-01-552-6935 8 34 8 52
5995-01-552-6936 18 10 2910-01-553-0047 4 31
5975-01-552-6937 18 30 8 54
2530-01-552-7040 21 27 8340-01-553-0054 23 7
2530-01-552-7044 21 42 6150-01-553-0088 27 4
5310-01-552-7435 6 32 6150-01-553-0094 27 1
6210-01-552-7806 26 2 4720-01-553-0305 13 17
5340-01-552-7835 5 6 2920-01-553-0314 10 29
5995-01-552-8232 8 35 5305-01-553-0345 8 25
3990-01-552-8296 2 4 5305-01-553-0345 16 13
5355-01-552-8299 6 7 5305-01-553-0350 7 14
0159-3
TM 11-6115-742-13&P 0159
STOCK NUMBER FIG. ITEM STOCK NUMBER FIG. ITEM
10 13 16 2
5310-01-553-0357 18 13 4730-01-556-5477 4 26
5310-01-553-0365 10 11 8340-01-556-7416 23 5
14 10 8340-01-557-3403 8 33
5310-01-553-0366 18 4 5340-01-558-6141 5 6
5310-01-553-0370 6 28 5365-01-558-6149 23 16
8 29 24 21
10 68 5315-01-558-6154 18 19
15 7 5310-01-558-7178 8 89
17 11 10 18
5305-01-553-0377 10 12 5310-01-558-7184 8 100
14 5 5306-01-558-7187 7 6
5305-01-553-0414 8 97 18 40
9 13 21 43
4020-01-553-0415 23 25 5305-01-558-7195 16 4
5306-01-553-0517 18 36 5307-01-558-7259 4 17
5305-01-553-0673 23 15 8 42
6150-01-553-0934 9 11 5340-01-558-7288 23 28
2910-01-553-1272 10 63 5340-01-558-7292 23 23
6685-01-553-1277 11 11 24 18
6685-01-553-1307 10 1 5340-01-558-7299 23 12
2940-01-553-1319 12 3 5340-01-558-7313 24 16
5340-01-553-1413 23 14 5340-01-558-7324 23 20
6105-01-553-1609 7 20 2540-01-558-7518 2 1
5310-01-553-2165 14 9 3010-01-558-7646 23 17
5945-01-553-3177 10 15 5305-01-558-7714 9 32
6620-01-553-4096 10 6 5305-01-558-7717 21 17
5930-01-553-4145 10 25 5310-01-558-7720 7 7
2930-01-553-4605 11 13 2540-01-558-8455 2 1
5930-01-553-5296 10 4 5340-01-558-8512 24 20
4720-01-553-5758 3 2 5340-01-558-8533 23 29
4720-01-553-5827 3 3 2540-01-558-8554 2 2
5310-01-553-6196 10 61 5340-01-558-8752 24 20
5306-01-553-7509 18 37 5340-01-558-8758 24 17
5305-01-553-7511 23 19 5340-01-558-8820 23 17
4030-01-553-8070 18 17 5340-01-558-8848 23 22
5310-01-553-8822 18 7 24 8
5305-01-553-8832 18 15 5340-01-558-8873 24 10
5307-01-554-0463 21 5 5340-01-558-8890 23 16
5310-01-554-1192 2 11 24 21
8 96 5340-01-558-9133 24 19
5340-01-554-2739 2 3 5340-01-558-9289 23 18
5306-01-554-4332 18 11 4720-01-558-9393 3 2
5305-01-554-5224 10 60 5340-01-558-9644 23 6
5310-01-555-6402 8 26 24 12
15 30 5340-01-558-9652 23 18
16 10 5340-01-558-9666 24 15
5310-01-555-7064 8 27 5340-01-558-9677 24 19
15 29 5340-01-558-9804 23 29
0159-4
TM 11-6115-742-13&P 0159
STOCK NUMBER FIG. ITEM STOCK NUMBER FIG. ITEM
5340-01-558-9807 23 21 3835-01-568-7074 4 38
6260-01-558-9867 18 9 4830-01-568-7079 4 43
6260-01-558-9874 18 1 5945-01-568-7389 6 26
5340-01-559-0471 23 27 5930-01-568-7446 6 31
5310-01-559-0602 18 41 6105-01-568-7464 7 5
21 44 5940-01-568-7575 6 30
5305-01-559-0882 13 11 5930-01-568-7581 4 33
5310-01-559-1648 14 27 5999-01-568-7586 6 33
5365-01-559-2443 4 16 5340-01-568-7761 4 32
8 41 9999-01-568-8609 4 40
5310-01-559-2446 2 12 5940-01-568-9122 17 25
7 8 5305-01-568-9387 7 3
8 95 4210-01-568-9442 4 20
18 43 8 56
21 46 5305-01-568-9503 6 29
4720-01-559-2546 3 3 5930-01-568-9799 4 42
5305-01-559-2700 8 62 5935-01-568-9835 16 16
5305-01-559-4711 10 17 5925-01-569-0250 10 70
4730-01-561-5843 8 91 5930-01-569-0257 15 12
5310-01-563-2566 8 20 5930-01-569-0283 15 27
18 24 5925-01-569-0297 17 22
5305-01-564-6941 7 1 5950-01-569-0337 17 26
5330-01-567-5966 21 1 5330-01-569-0369 10 49
6645-01-567-8282 6 8 5310-01-569-0373 8 77
6625-01-567-9749 15 14 16 3
6625-01-567-9791 15 2 5963-01-569-0378 17 2
5925-01-567-9995 6 19 5330-01-569-0380 10 48
5925-01-567-9997 6 22 5330-01-569-0386 10 42
5925-01-568-0000 6 17 2910-01-569-0390 10 47
6250-01-568-0001 6 3 5929-01-569-0391 17 19
2530-01-568-0031 21 45 5310-01-569-0403 10 85
2530-01-568-0725 21 45 5310-01-569-0412 10 81
5310-01-568-0727 6 12 5310-01-569-0415 10 83
3110-01-568-0751 21 6 5935-01-569-0794 16 14
6250-01-568-1030 6 2 4730-01-569-0826 10 58
5305-01-568-1062 6 15 5305-01-569-0831 10 84
5999-01-568-1074 6 11 5305-01-569-0843 10 82
5925-01-568-1099 6 18 4140-01-569-1023 7 11
5355-01-568-3921 6 10 2930-01-569-1146 4 44
5305-01-568-3945 5 7 5305-01-569-1152 4 52
6230-01-568-4487 2 8 4730-01-569-1177 4 48
5305-01-568-4710 6 24 5930-01-569-1334 15 16
8 15 6110-01-569-1448 17 16
15 9 5895-01-569-1469 17 31
17 24 5305-01-569-1758 15 32
4730-01-568-4716 8 94 5310-01-569-1766 16 11
5360-01-568-6048 21 22 5305-01-569-1777 15 31
5320-01-568-6990 4 46 5305-01-569-1782 15 33
4810-01-568-7071 4 41 5310-01-569-1792 15 6
0159-5
TM 11-6115-742-13&P 0159
STOCK NUMBER FIG. ITEM STOCK NUMBER FIG. ITEM
5305-01-569-1803 8 13 5305-01-569-7744 17 32
10 67 4730-01-569-7756 4 25
17 17 8 50
5305-01-569-1811 16 17 5306-01-569-7926 10 45
5306-01-569-1824 10 86 5305-01-569-7811 17 13
5310-01-569-2130 8 12 5365-01-569-7918 10 55
10 71 6625-01-569-7929 15 11
5307-01-569-2135 8 23 5305-01-569-7937 8 87
6625-01-569-2369 15 19 4720-01-570-0575 8 101
6625-01-569-2419 15 20 4720-01-570-0499 8 47
5895-01-569-2664 15 15 5305-01-570-2471 8 99
6130-01-569-2725 17 23 5340-01-570-3916 9 29
5895-01-569-2953 6 25 5430-01-570-4415 23 24
5340-01-569-2970 4 35 1630-01-570-4484 21 4
5895-01-569-3119 15 22 4820-01-570-4489 8 74
5895-01-569-3150 15 21 4020-01-570-4924 23 3
5895-01-569-3179 15 23 5410-01-570-4998 23 5
6625-01-569-3217 15 3 5310-01-570-5969 10 66
4930-01-569-3237 8 73 12 9
6625-01-569-3262 15 10 5310-01-570-5993 10 53
6620-01-569-3313 15 17 5306-01-570-6401 10 64
5315-01-569-3362 7 23 11 5
4730-01-569-4203 8 84 4720-01-570-8936 8 59
5310-01-569-4411 8 72 5340-01-570-9063 22 12
17 12 8340-01-571-6274 23 11
5935-01-569-4429 16 12 8340-01-571-6456 25 3
5930-01-569-5312 15 13 8340-01-571-6458 24 2
5315-01-569-5347 22 28 8340-01-571-6590 24 9
5310-01-569-5414 8 21 8340-01-571-6673 25 8
18 26 8340-01-571-6878 24 4
4730-01-569-5438 8 79 8340-01-571-6948 23 4
5305-01-569-5454 8 71 8340-01-571-8798 24 1
5340-01-569-5467 8 86 8340-01-571-9444 25 4
5340-01-569-5472 8 81 8340-01-571-9552 24 7
4810-01-569-5481 8 67 8340-01-571-9659 25 9
5340-01-569-5498 17 15 8340-01-571-9776 24 3
5305-01-569-5822 18 27 8340-01-571-9853 24 11
5999-01-569-5921 6 35 8340-01-571-9871 24 6
2530-01-569-5950 21 26 8340-01-572-0253 2 2
5310-01-569-5955 21 31 8340-01-572-0505 24 2
5305-01-569-5976 21 25 8340-01-572-0624 25 3
5310-01-569-5984 21 37 8340-01-572-0658 24 1
5310-01-569-5989 21 23 8340-01-572-0722 25 6
5340-01-569-5997 8 83 8340-01-572-0876 25 10
5360-01-569-6043 21 32 5310-01-572-6753 10 79
5360-01-569-6046 21 30 8340-01-572-7030 25 7
5360-01-569-6055 21 29 8105-01-575-2509 3 4
5970-01-569-6555 8 61 6115-01-577-7123 10 80
5305-01-569-6914 7 22 4730-01-581-3294 8 92
0159-6
TM 11-6115-742-13&P 0159
STOCK NUMBER FIG. ITEM
5940-01-581-6740 9 26
6150-01-581-6746 9 24
6150-01-581-6751 9 22
5920-01-581-6929 9 25
5920-01-581-6939 9 23
5305-01-583-5489 8 2
2940-01-584-3314 12 1
8340-01-589-9473 24 13
8340-01-589-9512 23 1
8340-01-589-9518 23 1
5310-01-598-5134 21 49
5945-99-360-1748 17 9
5340-99-519-4305 17 1
5945-99-598-7263 17 14
2920-99-690-7498 17 3
2920-99-983-9545 17 7
0159-7/8 blank
TM 11-6115-742-13&P 0160
PARTS INFORMATION
TMSS-MED
PART NUMBER INDEX
PART NUMBER FIG. ITEM PART NUMBER FIG. ITEM
005-057-00 21 8 028080-8700 14 14
005-064-00 21 23 0-28081070-0 10 31
005-112-00 21 35 0-28181230-0 10 22
006-011-00 21 31 0-28680825-0 11 8
006-176-00 21 9 031-017-01 21 6
006-193-00 21 37 031-017-02 21 7
006T102 4 47 031-030-01 21 3
007-132-00 21 5 035T112 6 20
007-210-00 21 25 035T113 6 23
008-219-13 21 4 036-093-15 21 39
010-045-00 21 10 036-093-26 21 19
010-054-00 21 1 036220-4100 10 75
010-9229 10 8 037-069-02 21 26
010-9336 17 16 040-244-01 21 24
010-MACK1071 14 16 041010-6160 12 10
013T112 7 5 043-028-00 21 33
017T101 7 18 046-007-00 21 38
019-002-00 21 12 046-101-00 21 30
0203-8-10 8 94 046-107-01 21 29
021-039-00 21 11 046-108-01 21 22
021T116 4 8 046-123-00 21 32
024T115 4 4 047-110-01 21 41
02504-0 10 6 047-111-01 21 36
028050-6120 10 64 047-119-01 21 28
028050-6120 11 5 053T102 4 40
028050-8450 10 27 054-060-00 21 21
0-28080820-0 10 32 054-064-00 21 40
028080-8200 10 56 054-065-00 21 20
0-28080840-0 11 14 054T102 7 11
0-28080845-0 11 1 054T109 7 4
0160-1
TM 11-6115-742-13&P 0160
PART NUMBER FIG. ITEM PART NUMBER FIG. ITEM
063T103 4 32 1002757 4 1
063T105 4 35 1002758 4 3
069-055-00 21 34 1002761 4 5
0708779 9 29 1002763 4 10
0737R 15 16 1002764 4 1
07415 18 3 1002765 4 3
081T102G 4 14 1003392 10 24
081T102T 4 14 1003631 8 65
081T106 7 2 1003632 8 64
087-001-00 21 18 1005514 20 1
088T101-32 6 7 1005629 22 2
088T103 4 12 1005995 22 2
089T108 6 25 1006024 5 4
0-91150208-0 10 40 1006025 5 8
0-91150208-0 11 7 1006026 5 5
091150-2080 14 11 1006230 10 73
0-91150210-0 10 28 1006873 8 1
091180-2080 10 53 1006874 8 1
1000861 6 11 1007205 2 15
1000902 6 33 1007206 2 15
1000905 4 44 1007404 8 9
1000947 4 42 1007405 8 9
1001136 22 28 1009000 16 8
100184 15 20 1009749 7 9
100222 15 18 1009832 22 9
1002330 21 45 1009833 22 9
1002331 21 45 1009945 22 27
1002532 8 102 1009946 22 27
1002533 8 104 1009994 8 5
1002734 8 76 1009995 8 5
1002735 8 76 100NLIT4 18 4
1002754 4 5 100T330 4 7
1002756 4 10 100T330 5 2
0160-2
TM 11-6115-742-13&P 0160
PART NUMBER FIG. ITEM PART NUMBER FIG. ITEM
100T339 7 16 116C 8 79
100T503 7 17 116E 8 84
101038N 9 22 12-1004 9 35
101038P 9 24 123-1680562 PC 93 8 22
10-15-55P 9 21 123-1680562 PC 93 18 25
101574 15 17 12340842 8 16
101586 15 19 12356014 22 18
102480 15 14 12356017 22 23
10332-04277 9 28 12356018 22 20
105038R 9 7 12356020 22 17
106538R 9 3 12356021 22 7
108038B 9 11 12362746 22 12
10896710 22 13 12375837-BK-SP 18 3
10C100HCS10 8 25 12375841 19 3
10C100HCS10 16 13 12460176 18 8
10C125MXP10 15 33 1310763A 4 28
10C50MXP10 15 31 1310763A 8 53
10C75HCS10 16 4 13211E6931 6 1
10CNFH1 16 11 1323580 6 30
10DLOC1 8 26 1394 14 20
10DLOC1 15 30 1434G 23 10
10DLOC1 16 10 1441-10614 22 10
10DLOC10 8 77 150072751 8 58
10DLOC10 16 3 15K200140-53 9 2
10DWFL1 8 30 16325-2 17 25
10DWFL1 16 9 165-508-168 21 14
10DWFL10 8 27 1771AS661-1 15 26
10DWFL10 15 29 1804 22 21
10DWFL10 16 2 1829 22 4
10F37MXP1 6 15 1844-2 22 19
1137084 21 51 18912 21 50
1166-278 5 7 19411132M 16 7
11674728 16 15 197-DP-1207-
16 6
FT120VAC
0160-3
TM 11-6115-742-13&P 0160
PART NUMBER FIG. ITEM PART NUMBER FIG. ITEM
197-DP-287-FT28V 25NWFL1 4 6
15 25
DC
25NWFL1 5 1
1EM94 9 9
25NWFL1 8 39
218004 17 34
25NWFL1 9 6
24032-2 12 5
25NWFL1 10 14
24063 10 15
25NWFL1 13 4
249-116 17 1
25NWFL1 14 6
24AGM 9 27
25NWFL1 18 38
25580 21 2
280-326 17 8
25C100HCS1 4 27
280-610 17 7
25C100HCS1 8 55
281-326 17 4
25C100HCS1 9 4
281-329 17 29
25C100HCS1 14 7
281-402 17 30
25C150HCS1 8 62
281-512 17 6
25C175HCS1 9 32
281-610 17 3
25C200HCS1 9 18
281-901 17 28
25C200HCS1 13 6
282-200-7 8 61
25C200HCS1 14 3
286-320 17 14
25C300HCS1 18 36
286-555 17 9
25C75HCS1W 7 14
28957 7 1
25C75HCS1W 10 13
29PSL020-33-500 4 34
25CNNE1 4 15
30345T4 15 8
25CNNE1 8 38
31C125HCS1/FT 7 3
25CNNE1 9 16
31NLOC1 9 14
25CNNE1 10 16
31NWFL1 14 4
25CNNE1 13 3
3225T2 18 29
25CNNE1 14 23
324444 10 51
25CNNE1 18 28
330027 4 23
25K100MX81 23 15
330027 8 48
25K75MX71 23 19
33084 14 25
25N62ZR5A 4 16
33817 21 48
25N62ZR5A 8 41
33895 21 49
25NLOC1 9 5
35360957 22 3
25NLOC1 10 78
0160-4
TM 11-6115-742-13&P 0160
PART NUMBER FIG. ITEM PART NUMBER FIG. ITEM
35512 14 2 5023298A 8 56
36078 18 16 50351MA-0-30KW 15 11
37C100HCS1 18 5 5036300V 15 10
37C125HCS1 8 97 50365A100A 15 2
37C125HCS1 9 13 5036HZ5565 15 3
37C200HCS8Y/FT 21 17 50483931A 4 30
37C200RFTB 8 23 50483931A 8 51
37C300HCS1 18 37 50487171A 4 29
37C75HCS1 10 17 50487171A 8 52
37CNFH1 8 100 50785K66 8 91
37NLOC1 8 89 50900126A 8 47
37NLOC1 10 18 509707-0051 10 43
37NWFL1 8 88 50C125HCS1 8 99
37NWFL1 9 15 50C150HCS1 7 6
37NWFL1 10 19 50C150HCS1 18 40
37NWFL1 18 35 50C150HCS1 21 43
3RP1512-1AQ30 6 26 50C175HCS1 2 10
3SB3001-2DA41 6 10 50CNNE1 2 12
3SB3001-6BA20 6 4 50CNNE1 7 8
3SB3001-6BA40 6 5 50CNNE1 8 95
3SB3400-1PB 6 3 50CNNE1 18 43
3SB3400-1PC 6 2 50CNNE1 21 46
41EB30AJ 6 36 50N125WSP1 2 11
42305T47 13 5 50N125WSP1 8 96
4282 10 84 50NLOC1 2 13
438USA 17 10 50NWFL1 7 7
43CNNE1 14 27 519316 16 14
4568K173 8 68 52545-1 8 98
484032 4 24 527-0116-00 4 53
484032 8 49 5321K14 8 78
49-6080 8 14 5321K14 13 15
4C37MP10 16 17 5346K16 8 60
5023298A 4 20 5346K16 13 14
0160-5
TM 11-6115-742-13&P 0160
PART NUMBER FIG. ITEM PART NUMBER FIG. ITEM
5346K26 8 85 70862 5 9
5346K66 4 45 7 19
5349 9 31 18 39
5350 9 30 21 16
53525K14 13 16 720366-01 10 80
53525K18 8 92 723272-02 10 87
53525K22 4 48 72662 8 103
5388K18 4 19 753-5147 15 15
5388K18 8 46 760-4131#1408 22 22
543-123 8 59 79100204 13 8
546-100-00T 17 26 7921K216 5 3
5520K302 4 25 79600107 13 10
5520K302 8 50 801125-01 10 86
5557-9 8 75 80253 10 85
5724-050-B 9 10 80277 10 11
5724-050-R 9 26 80277 14 10
5726-050-R 9 8 80C160HCS1933 10 12
5730-000R 9 34 80C160HCS1933 14 5
58832 10 58 82149 10 82
5SY4106-7 6 17 8310084 21 47
5SY4315-8 6 18 83526 14 9
5SY4332-8 6 22 86116A 4 31
5SY4363-8 6 19 86116A 8 54
605-3008 16 16 863-000309 18 22
60-B-176 4 49 8680-00032 8 69
62008 4 26 87510 10 83
62-10-35 15 1 87511 10 81
62-40-251-3 8 6 8762000 22 14
62-70-15 8 24 894123-6231 10 77
62-74-25 4 13 894133-2075 10 76
62C200HCS1 18 11 894326-4390 10 48
64010H B 13 12 894329-5490 10 74
65202400 10 10 894379-6880 10 50
0160-6
TM 11-6115-742-13&P 0160
PART NUMBER FIG. ITEM PART NUMBER FIG. ITEM
8-94425751-1 10 63 898097-1600 10 52
894433-7171 10 45 8C100MXP1 17 32
8-94456741-2 10 7 8C125MXP1 17 13
897042-0280 14 15 8C175MXP1 8 71
8-97047604-0 10 2 8C225MXP1 8 28
897063-4003 11 4 8C75MXP1 8 13
897094-6411 12 8 8C75MXP1 10 67
897117-5901 14 12 8C75MXP1 17 17
897126-1860 14 13 8CNFH1 15 6
897171-3310 10 49 8CNNE1 8 12
8-97172549-0 10 5 8CNNE1 10 71
897195-2593 10 46 8D50TXP1 24 14
897217-2492 10 41 8D50TXP10 8 2
8972248131 10 21 8NLOC1 8 72
8-97224999-0 11 15 8NLOC1 17 12
8-97226855-0 11 6 8NWFL1 6 28
897227-2851 10 55 8NWFL1 8 29
897227-6030 12 7 8NWFL1 10 68
8-97229381-0 10 3 8NWFL1 15 7
897231-5790 10 30 8NWFL1 17 11
897232-3341 10 42 8W8X543 8 66
8-97233412-1 10 29 8X61 8 86
897247-9890 10 44 90257A029 8 63
8-97254148-3 11 13 90257A029 14 1
8-97258479-2 11 9 90313A109 8 57
8-97264690-1 11 10 9070T250D14 6 16
897289-2930 10 47 9-09111408-0 10 23
8-97289543-0 11 12 91202A234 10 61
897314-8610 10 57 91247A548 4 52
897329-6220 10 66 91249A196 6 29
897329-6220 12 9 91280A334 10 60
8-97361770-0 11 11 91771A207 15 32
898096-5800 10 54 91772A110 6 9
0160-7
TM 11-6115-742-13&P 0160
PART NUMBER FIG. ITEM PART NUMBER FIG. ITEM
91772A144 6 21 9B1545 22 8
91785A240 8 87 A28AA-28C 6 31
91887A 4 17 A600115 23 26
91887A 8 42 A600116 23 27
92141A006 6 32 A600250 23 6
92146A530 6 12 A600250 24 12
92198A679 14 24 A601250 23 11
92240A559 9 1 A601650 24 19
92311A578 7 22 A601651 23 16
92316A536 13 11 A601651 24 21
92497A350 10 79 A601660 24 19
92620A622 8 90 A601661 23 16
92700A459 17 15 A601661 24 21
92771A535 8 19 A601680 24 16
92771A535 18 23 A601681 23 23
92865A535 13 9 A601681 24 18
92865A540 4 50 A602050 23 3
92916A405 8 21 A602126 3 4
92916A405 18 26 A602650 23 12
92941A626 18 27 AA-44-D 8 17
93475A250 10 62 AA-44-D 18 2
93496A031 8 20 AA52463-A09 15 5
93496A031 18 24 AA52463-A09 19 1
94709A317 8 40 AA55569/01-005 4 21
94800A730 14 8 AA55569/01-005 8 44
97359A 4 18 AA55569/01-008 4 22
97359A 8 43 AA55569/01-008 8 45
97447A220 4 46 AC-13306 18 10
98493A117 7 15 ADRSE-2-0/80-
4 39
3/8ODF
98493A137 7 23
AK54H 7 12
9-89136423-0 11 3
AX38 7 10
99051 9 12
B1821BH044F200N 22 26
9A34 9 33
B1821BH044F350N 22 6
0160-8
TM 11-6115-742-13&P 0160
PART NUMBER FIG. ITEM PART NUMBER FIG. ITEM
B402T 8 18 H25MM 7 13
B472A 18 9 H300000 26 2
B472R 18 1 H300070 2 8
BH-2124 9 17 HKCS312G43EGWL 18 17
BK45X5/8 7 21 HW903-4024G 18 42
C2-32-35 4 2 HW903-4024T 18 42
C408115 2 3 ISOBAR4 27 3
CA11A204-600E 15 22 JA200881 23 29
CA11US6512-600E 15 21 JA200901 23 29
CA11US6522-600E 15 23 JA200921 23 28
CD90555C32412S 16 12 JA200980 23 20
CPBD-2 17 27 JA201000 23 18
D30161-1584 15 13 JA201005 23 18
D3085-2118-DHS 8 101 K71-394-00 21 42
DL21 15 4 K71-395-00 21 27
DP40-B 8 3 KBPC3501 6 27
DYN3-60030 17 31 M100-WA5 17 2
EFVE-1-L1 4 38 M45913/1-7FG5C 22 16
EFVE-5-CP100 4 43 M45913/2-6FG5C 22 15
EK-165S 4 36 M5423/09-04 6 6
F02A250V3A 26 1 MA100130 25 3
F329601 24 6 MA100155 8 33
F329631 24 7 MA100160 27 5
F329751 24 11 MA100165 23 9
F329781 24 9 MA100170 26 4
F329905 23 22 MA100310 25 4
F329905 24 8 MA100530 25 3
F329908 24 10 MA100720 23 14
FC602 22 11 MA100735 23 5
FCB2DP 8 81 MA100740 23 5
FCB3DP 8 83 MACK1011 13 2
FT55DL841 26 3 MACK1047 14 18
GMC-4A 17 5 MACK1065 10 65
0160-9
TM 11-6115-742-13&P 0160
PART NUMBER FIG. ITEM PART NUMBER FIG. ITEM
MACK1067 10 9 MXA1055T 23 13
MACK1070 14 22 MXA2000G 2 6
MACK1070A 14 21 MXA2000T 2 6
MACK1072 14 19 MXA2005G 25 2
MACK1078 13 17 MXA2005T 25 2
MACK1180 13 1 MXA2010W 25 1
MACK262 12 2 MXA2015G 25 5
MACK906 10 1 MXA2015T 25 5
MACK913 11 2 MXA2016G 24 5
MACK922 12 3 MXA2016T 24 5
MACK930 14 26 MXA2020G 23 1
MACK932 14 28 MXA2020T 23 1
MF300130 25 8 MXA2025F 23 4
MF300140 25 6 MXA2035G 23 2
MF300150 25 7 MXA2035T 23 2
MF300160 25 10 MXA2040B 23 7
MF300200 25 9 MXA2045B 24 13
MFB736N9N02 9 25 MXS1015G 24 1
MFC336175 9 23 MXS1015T 24 1
MG27186 17 19 MXS1015W 24 4
MS21044-N8 22 1 MXS1020G 24 2
MS21083C7 22 24 MXS1020T 24 2
MS24693-C273 4 9 MXS1020W 24 3
MS25002-4 6 14 NN5811GR8Z 18 13
MS25331-2 15 24 OE10S240 4 41
MS25331-4 16 5 PCHA0131G 20 2
MS35649-244 6 13 PCHA0131T 20 2
MS51957-43 6 34 PCHA0161G 18 32
MS51975-2 22 25 PCHA0161T 18 32
MS90726-99 22 5 PCHA0171 18 19
MXA1054G 23 8 PCHA0175G 18 12
MXA1054T 23 8 PCHA0175T 18 12
MXA1055G 23 13 PECU05T23B 6 35
0160-10
TM 11-6115-742-13&P 0160
PART NUMBER FIG. ITEM PART NUMBER FIG. ITEM
PS-12750 9 20 T215125T 2 14
QOU120 17 21 T220034-1 15 28
QOU330 17 20 T220035-1 16 1
QOU360 17 22 T220076 9 19
RE0062-0470 10 59 T225250-5 8 7
RV5100025C 4 37 T225453 8 8
S92D41 8 67 T225853 8 11
SDLA-350749 10 70 T230007 10 20
SE350 17 33 T230019 8 74
SH410-0001G 24 20 T230020 8 73
SH410-0001T 24 20 T230050 13 7
SH410-0001W 24 17 T231250 14 17
SH410-0201G 23 17 T235005 8 32
SH410-0201T 23 17 T235064 8 4
SH410-0201W 23 21 T240200 10 72
SH410-0202 23 24 T245264 8 36
SH410-0401R 24 15 T250250G 3 1
SH535-0006 2 4 T250250T 3 1
SH535-0007G 2 1 T256250G 2 5
SH535-0007T 2 1 T256250T 2 5
SH535-0008G 2 2 T260487 15 12
SH535-0008T 2 2 T260605 17 18
SK1036 8 93 T270034 18 15
SL-103-66593-01A 27 4 T270130 6 24
SLP2550 4 33 T270130 8 15
SM-2B-15FVTAU 10 4 T270130 15 9
SM82243ELACFPC 17 23 T270130 17 24
T20018C 18 7 T270923 23 25
T210949 18 34 T291433 3 2
T210965 18 18 T291434 3 3
T211205G 18 6 T291527 3 2
T211205T 18 6 T291528 3 3
T215125G 2 14 T2-93000-1 2 7
0160-11
TM 11-6115-742-13&P 0160
PART NUMBER FIG. ITEM PART NUMBER FIG. ITEM
T295004 2 9 TG903-6704 21 13
T295101 8 34 TG903-6752 18 10
T295111 8 35 TH2-16-002 8 80
T295114 27 1 TH3-21-002 8 82
T295116 27 2 TM-2A-230RAU 10 25
T295145 8 37 TMSS100G 1 1
T295146 18 30 TMSS100T 1 1
T295153 18 14 WFSAE127H2 18 41
T295154 18 33 WFSAE127H2 21 44
T295161G 5 6 W-L-00111/64 19 2
T295161T 5 6 X-09055-006 10 36
T2-95205 26 5 X-09055-048 10 35
T51E430 6 8 X-09150-001 10 37
TG404-0819G 21 45 X-09150-002 10 34
TG404-0819T 21 45 X-09915-004 12 4
TG404-0829G 18 20 X-14111-050-0 12 6
TG404-0829T 18 20 X-14210-056 10 38
TG404-0830G 18 21 X-14210-057-0 12 1
TG404-0830T 18 21 X-14330186-0 10 33
TG421-9000 8 31 X-14330-193 10 39
TG421-9006G 18 31 X-83121-014-0 10 69
TG421-9006T 18 31 X-892140300 13 13
TG423-0451-2G 5 4 XB5AS8445GCF 15 27
TG423-0501-1G 5 5 ZR72KCE-TF5-250 4 51
TG423-0551-1G 5 8
TG423-0901 4 11
TG430-2005G 8 10
TG430-2005T 8 10
TG430-5001G 8 70
TG430-5001T 8 70
TG440-0001 10 26
TG903-5001 7 20
TG903-5103 21 15
0160-12
TM 11-6115-742-13&P
CHAPTER 10
DESTRUCTION OF EQUIPMENT TO PREVENT ENEMY USE
FOR
TMSS-MED
TM 11-6115-742-13&P 0161
DESTRUCTION OF EQUIPMENT TO PREVENT ENEMY USE
TMSS-MED
GENERAL INFORMATION
SCOPE
This work package is for guidance of those whose duty it is to render inoperable or destroy equipment which is in
imminent danger of capture by an enemy.
AUTHORIZATION
Only division or higher commanders have the authority to order destruction of equipment. They may however,
delegate this authority to subordinate commanders when the situation demands it.
REPORTING DESTRUCTION
Destruction of equipment will be reported through command channels.
METHODS OF DESTRUCTION
Choose methods of destruction which will cause such damage that it will be impossible to restore the equipment
to a usable condition within the combat zone. The following methods of destruction may be used separately or in
combination, depending on the type of equipment and the degree to which each method is used.
Self-Destruction
Built-in self-destruction devices should be set off even if the major item containing equipment with self-destruction
devices is to be destroyed. These devices should be permitted to do their work at least partially before
incendiaries or explosives (especially the latter) are set off. Currently, the TMSS-MED contains no built-in self-
destruction devices.
Improper Operation
The short circuiting of a power source and the application of an over voltage to equipment are examples of
improper operation. This method of destruction has a limited application to electronics material.
Fire
The starting of fires on or near electronic equipment is particularly useful in destroying predominantly nonmetallic
components such as transistors, diodes, resistors, capacitors, switches, and printed circuit boards. Fires should
be lit after setting off explosives and/or completing mechanical destruction. Fires within partially closed cabinets
tend to be less effective than open fires, since a closed area does not allow sufficient oxygen necessary for an
intense flame. Heat sources which do not require an air supply, such as thermite-based devices or incendiary
grenades, are not subject to this limitation. The use of fire is associated with numerous hazards, including the
possibility of disclosing positions which are under enemy visual or infrared surveillance.
Weapons Fire
The use of weapons fire is less desirable than mechanical destruction, and is practically useless against heavy
gauge metal panels and metal castings. However, optics such as night observation equipment are easily
destroyed by correctly aimed gunfire.
0161-1
TM 11-6115-742-13&P 0161
Demolition (Explosives)
Explosives refer to TNT, plastic explosives, as well as fragmentation grenades. Explosives are most effective
against structures and components which will not burn, or are too heavy or too strong to be easily demolished by
mechanical means. The use of explosives has the disadvantage of possible disclosure of position when enemy
forces are using sound-ranging-type equipment.
Mechanical Destruction
Mechanical destruction includes smashing electronic components, bending chassis or sub chassis, slashing
cables and wiring, or any similar action. Dropping a weight on equipment and throwing lightweight equipment
over a cliff are also examples of mechanical destructions. Sledges, hammers, axes or heavy tools are examples
of the implements which can be used. Mechanical destruction should be completed before fires are lit.
Use of Natural Surroundings
The disposal or denial to the enemy of electronics material may be accomplished in the field by taking advantage
of the natural surroundings and environment.
Submergence of equipment and repair parts under water (lakes, ponds, streams, etc), concealment by hiding
material in caves or, preferably burial can be used effectively. Where the surrounding area does not lend itself to
such disposal, widely dispersed scattering of material, preferably, into heavy underbrush, can serve as a denial or
delaying measure in the event the area is recaptured.
CLASSIFIED EQUIPMENT
Classified equipment must be destroyed to such a degree as to prevent duplication by, or revealing means of
operation or function to the enemy.
ASSOCIATED CLASSIFIED DOCUMENTS
Any classified documents, notes, instructions, or other written material pertaining to function, operation,
maintenance, or employment, including drawings or parts lists, must be destroyed in a manner to render them
useless to the enemy.
END OF WORK PACKAGE
0161-2
TM 11-6115-742-13&P 0162
DESTRUCTION OF EQUIPMENT TO PREVENT ENEMY USE
TMSS-MED
DESTRUCTION PROCEDURES
SCOPE
This work package is for guidance of those whose duty it is to render inoperable or destroy the TMSS-MED which
is in imminent danger of capture by an enemy.
METHOD OF DESTRUCTION
Command decision, according to the tactical situation will determine when the using organization is to destroy a
TMSS-MED. A destruction plan will be prepared by the using organization, unless one was prepared by a higher
authority. For general vehicle destruction procedures, refer to TM 750-244-6, Procedures for Destruction of Tank
Automotive Equipment to Prevent Enemy Use (U.S. Army Tank-Automotive and Artillery Command).
TMSS-MED EQUIPMENT DESTRUCTION PROCEDURES
The following procedures should be followed when time does not permit critical equipment to be destroyed
individually.
Demolition/Explosives
WARNING
Personnel should stand clear of area being destroyed be weapons fire. Always
use a weapon of a caliber sufficient to ensure enough penetration to achieve the
desired damage and to eliminate the possibility of ricochet. Personnel unfamiliar
with explosives should not set or detonate explosives.
The use of explosives has the disadvantage of possible disclosure of position.
The TMSS-MED can be destroyed using incendiary grenades, several rounds of properly aimed weapons fire, or
a sufficient amount of explosives. When placing explosives, they should be placed within the Genset and ECU
enclosures and under the TMSS-MED shelter.
Use incendiary grenade by pulling pin and placing directly on top of engine and/or generator and on top of ECU
compressor.
Additional charges can be placed on the trailer tongue, on top of the chassis frame, and on the axle to prevent
enemy use of the trailer.
Puncture trailer tires and remove trailer lunette assembly.
WARNING
Toxic fumes may result from burning electrical equipment found in the Genset
and ECU. Fires should be lit only in open areas. Avoid inhaling fumes from
burning components.
Fire
Fires should be started after setting off explosives. Gasoline, kerosene, diesel, or oil may be used to destroy
smaller components such as the TMSS-MED shelter and accessories.
END OF WORK PACKAGE
0162-1/2 blank
TM 11-6115-742-13&P
CHAPTER 11
SUPPORTING INFORMATION
FOR
TMSS MED
TM 11-6115-742-13&P 0163
SUPPORTING INFORMATION
TMSS-MED
REFERENCES
SCOPE
This work package lists all field manuals, forms, military standards, technical manuals, and miscellaneous
publications referenced in this manual
FIELD MANUALS
FM 3-5 ............................................................. NBC Decontamination
FM 4-25.11 ...................................................... First Aid
FM 21-305 ....................................................... Manual for the Wheeled Vehicle Driver
GOVERNMENT PUBLICATIONS
AR 25-2 ............................................................ Information Assurance
AR 700-138...................................................... Army Logistics Readiness and Sustainability
CECOM TR-98-6 ............................................. Earth Grounding and Bonding Pamphlet
DA Form 2028 ................................................. Recommended Changes to Publications and Blank Forms
DA Forms 2404 and 5988E ............................. Equipment Inspection and Maintenance Worksheet
DA Form 2408-9 .............................................. Equipment Control Record.
DA Form 7399 ................................................. Survey/Decontamination Record
DA Form 7399-R.............................................. Survey/Decontamination Record
DA Form 7400 ................................................. Record of Area/Equipment Survey
DA Form 7401 ................................................. Radioactive Commodity Report
DA PAM 700-48 ............................................... Handling Procedures for Equipment Contaminated with Depleted
Uranium or Radioactive Commodities
DA PAM 700-138 ............................................. Army Logistics Readiness and Sustainability
DA PAM 750-8 ................................................. The Army Maintenance Management System (TAMMS) Users
Manual
DA PAM 738-751 ............................................. Functional Users Manual for the Army Maintenance Management
System - Aviation (TAMMS-A)
DD Form 361 ................................................... Transportation Discrepancy Report
SF 368 ............................................................. Product Quality Deficiency Report
0163-1
TM 11-6115-742-13&P 0163
TECHNICAL BULLETINS
TB 43-0134 ...................................................... Technical Bulletin Battery Disposition and Disposal
TB MED 507 .................................................... Heat Stress Control and Heat Casualty Management
TECHNICAL MANUALS
TM 11-5820-1118-13&P .................................. Operator and Unit Maintenance Manual (including Repair Parts
and Special Tools List) MK-2551A/U (SWGS) Grounding Kit
TM 9-2330-392-14&P ...................................... Operator's, Unit, Direct Support and General Support
Maintenance Manual (Including Repair Parts and Special Tools
List) Trailer, Cargo: Light, 2-Wheel M1101 (2330-01-387-5443)
EIC: CBC; Trailer, Cargo: Heavy, 2-Wheel M1102 (2330-01-387-
5426) EIC: CBB; Chassis, Trailer: 2-Wheel (2330-01-387-5424)
EIC: CCL
TM 750-244-2 .................................................. Procedures for Destruction of Electronic Material to Prevent
Enemy Use
TM 750-244-6 .................................................. Procedures for Destruction of Tank Automotive Equipment to
Prevent Enemy Use (US Army Tank-Automotive Command)
END OF WORK PACKAGE
0163-2
TM 11-6115-742-13&P 0164
SUPPORTING INFORMATION
TMSS-MED
MAC INTRODUCTION
INTRODUCTION
The Army Maintenance System Mac
This introduction provides a general explanation of all maintenance and repair functions.
The MAC (immediately following the introduction) designates overall authority and responsibility for the
performance of maintenance tasks on the identified end item or component. The application of the
maintenance tasks to the end item or component shall be consistent with the capacities and capabilities
of the designated maintenance levels/classes, which are shown on the MAC in column (4). Column (4)
is divided into two secondary columns. These columns indicate the maintence levels/classes of ‘Field’
and ‘Sustainment.’ Each maintenance level column is further divided into two sub-columns. These
subcolumns identify the maintenance classes and are as follows:
1. Field level maintenance classes:
a. Crew (operator) maintenance. This is the responsibility of a using organization to perform
maintenance on its assigned equipment. It normally consists of inspecting, servicing, lubricating,
adjusting, and replacing parts, minor assemblies, and subassemblies. Items with a “C” (“O” for
joint service reporting) in the third position of the Source, Maintenance, and Recoverability (SMR)
code may be replaced at the crew(operator) class. A code of “C” (“O” for joint service) in the
fourth position of the SMR code indicates complete repair is authorized at the crew (operator)
class.
b. Maintainer maintenance. This is maintenance accomplished on a component, accessory,
assembly, subassembly, plug-in unit, or other portion by field level units. This maintenance is
performed either on the system or after it is removed. An “F” in the third position of the SMR code
indicates replacement of assemblies, subassemblies, or other components is authorized at this
level. An “F” in the fourth position of the SMR code indicates complete repair of the identified item
is allowed at the Maintainer class. Items repaired at this level are normally returned to the user
after maintenance is performed.
2. Sustainment level maintenance classes:
a. Below depot sustainment. This is maintenance accomplished on a component, accessory,
assembly, subassembly, plug-in unit, or other portion either on the system or after it is removed.
The item subject to maintenance has normally been forwarded to a maintenance facility away
from the field level supporting units. An “H” in the third position of the SMR code indicates
replacement of assemblies, subassemblies, or other components is authorized at this class. An
"H" appearing in the fourth position of the SMR code indicates complete repair is possible at this
class. Items are normally returned to the supply system after maintenance is performed at this
class.
b. Depot. This is maintenance accomplished on a component, accessory, assembly, subassembly,
plug-in unit, or other portion either on the system or after it is removed. Assets to be repaired at
this class are normally returned to an Army Depot or authorized contractor facility. The replace
function for this class of maintenance is indicated by the letter "D" or "K" appearing in the third
position of the SMR code. A "D" or "K" appearing in the fourth position of the SMR code indicates
complete repair is possible at the depot sustainment maintenance level. Items are returned to the
supply system after maintenance is performed at this class.
The tools and test equipment requirements table (immediately following the MAC) lists the tools and test
equipment (both special tools and common tool sets) required for each maintenance task as referenced from the
MAC.
The remarks table (immediately following the tools and test equipment requirements) contains supplemental
instructions and explanatory notes for a particular maintenance task.
0164-1
TM 11-6115-742-13&P 0164
Maintenance Tasks
Maintenance tasks are limited to and defined as follows:
1. Inspect. A function to determine the serviceability of an item by comparing its physical,
mechanical, and/or electrical characteristics with established standards through examination
(e.g., by sight, sound, or feel).
2. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical
characteristics of an item and comparing those characteristics with prescribed standards on a
scheduled basis, i.e., load testing of lift devices and hydrostatic testing of pressure hoses.
3. Service. Operations required periodically to keep an item in proper operating condition such as
replenishing fuel, lubricants, chemical fluids, or gases.
4. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by
setting the operating characteristics to specified parameters.
5. Align. To adjust specified variable elements of an item to bring about optimum or desired
performance.
6. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments of
test, measuring, and diagnostic equipment used in precision measurement. It consists of
comparisons of two instruments, one of which is a certified standard of known accuracy, to
detect and adjust any discrepancy in the accuracy of the instrument being compared.
7. Remove. The act of taking a sub-component off an asset to allow repair or replacement of that sub
component, or to facilitate other maintenance.
8. Install. The act of placing, positioning, or otherwise locating a component or sub-component to make it
part of a higher level end item. Install can be to install a new asset for the first time or reinstall an asset
previously removed. The maintenance class allowed to perform an installation is determined by the third
position in the SMR code.
9. Replace. To install a serviceable component in place of one that is unserviceable or a required time
change asset. “Replace” is authorized by the MAC and assigned maintenance class is shown as the third
position code of the SMR code.
10. Repair. The application of maintenance actions, including fault location/troubleshooting, removal,
installation, disassembly, assemblyor other maintenance actions to restore serviceability to an item by
correcting specific damage, fault, malfunction, or failure in the item.
11. Paint. This is a function to prepare and apply coats of paint. When used with munitions, the paint is
applied to the ammunition can be identified and protected.
NOTE
The following definitions are applicable to the “repair” maintenance task:
Fault location/troubleshooting. The process of investigating and detecting the case of equipment
malfunctioning; the act of isolating a fault within a system or Unit Under Test (UUT).
Actions. Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing.
0164-2
TM 11-6115-742-13&P 0164
12. Overhaul. This is the maintenance effort (service/action) prescribed to restore an item to a
completely serviceable/operation condition as required by maintenance standards in the
appropriate technical publications. Overhaul is normally the highest degree of maintenance
performed by the Army. Overhaul does not normally return an item to a like new condition.
13. Rebuild. This consists of those services/actions necessary for the restoration of unserviceable equipment
to a like new condition in accordance with original manufacturing standards. Rebuild is the highest degree
of material maintenance applied to Army equipment. The rebuild operation includes the act of returning to
zero those age measurements (e.g., hours/miles) considered in classifying Army equipment/components.
14. Lubricate. The act of applying a material (e.g., oil or grease) to reduce friction and allow a component to
operate in a more efficient manner.
15. Mark. The process of restoring obliterated identification on an asset.
16. Pack. To place an item into a container for either storage or shipment after service and other
maintenance operations have been completed.
17. Unpack. The act or removing an asset from a storage or shipping container in preparation to perform
further maintenance (e.g., repair or install).
18. Preserve. The action required to treat systems and equipment whether installed or stored, to ensure a
serviceable condition.
19. Prepare for use. Those steps required to make an asset ready for other maintenance (e.g., remove
preservatives, lubricate, etc).
20. Assemble. The step-by-step instructions to join the component pieces of an asset together to make a
complete serviceable asset.
21. Disassemble. The step-by-step breakdown (taking apart) of a spare/functional group coded item to the
level of its least component, that is assigned an SMR code for the level of maintenance under
consideration (i.e., identified as maintenance significant)
22. Clean. Step-by-step instructions on how to remove dirt, corrosion or other contaminants from equipment.
23. Non destructive inspection. Step-by-step instructions on preparation and accomplishment of inspections
which do not destroy or damage the equipment.
24. Radio interference suppression. Step-by-step instructions to ensure installed equipment, either
communication or other electronics, does not interfere with installed communication equipment.
25. Place in service. Step-by-step instructions required to place an item into service that are not covered in
the service upon receipt work package.
26. Towing. The step-by-step instructions to connect one vehicle to another for the purpose of having one
vehicle moved through the motive power of the other vehicle.
27. Jacking. The step-by-step instructions to mechanically raise or lift a vehicle to facilitate maintenance on
the vehicle.
28. Parking. Step-by-step instructions to safely place a vehicle in a lot, ramp area or other designated
location.
29. Mooring. Step-by-step instructions to secure a vehicle by chains, ropes or other means to protect the
vehicle from environmental conditions or secure for transportation.
0164-3
TM 11-6115-742-13&P 0164
30. Covering. Step-by-step instructions to place a protective wrapping over a vehicle to protect it from
environmental conditions or to hide (e.g., camouflage) it.
31. Hoisting. Step-by-step instructions to allow a vehicle to be raised by cables or ropes through attaching
points.
32. Sling loading. Step-by-step instructions to place a sling around a vehicle to allow it to be raised.
33. External power. Step-by-step instructions on how to apply electrical power from any authorized power
source (e.g., external generator or facility power).
34. Preparation for storage or shipment. Those procedures necessary to prepare an item to be stored for an
extended period or shipped.
35. Arm. Detailed instructions on activating munitions prior to use.
36. Load. This may be one of two tasks:
a. For transportation, the act of placing assets onto a transportation medium (e.g., pallet, truck,
container).
b. For weapons/weapon systems, the act of placing munitions into the weapon/weapon system.
37. Unload. This may be one of two tasks:
a. For transportation, the act of removing assets from a transportation medium (e.g., pallet, truck,
container).
b. For weapons/weapon systems, the act of removing munitions from the weapon/weapon system.
38. Software maintenance. Step-by-step instructions for software maintenance (e.g., installing, un-installing,
etc.).
Explanation of Columns in the MAC
Column (1) Group Number. Column (1) lists Functional Group Code (FGC) numbers, the purpose of
which is to identify maintenance significant components, assemblies, subassemblies, and modules with
the Next Higher Assembly (NHA).
Column (2) Component/Assembly. Column (2) contains the item names of components, assemblies,
subassemblies, and modules for which a maintenance function is authorized.
Column (3) Maintenance Task. Column (3) lists the functions to be performed on the item listed in
column (2). (For detailed explanation of these functions refer to “Maintenance Functions” outlined
above).
Column (4) Maintenance Level. Column (4) specifies each level of maintenance authorized to perform
each function listed in column (3), by indicating work item required (expressed as man-hours in whole
hours or decimals) in the appropriate sub-column. This work-time figure represents the active time
required to perform that maintenance task at the indicated level/class of maintenance. If the number or
complexity of tasks within the listed maintenance task varies at different maintenance classes,
appropriate work-time figures are shown for each class.
The work-time figure represents the average time required to perform the prescribed task (assembly,
subassembly, component, module, end item, or system) on the item under typical field operating
conditions for that maintenance level/class. This time includes preparation time (including any
necessary disassembly/ assembly time), troubleshooting/fault location time, and quality assurance time
in addition to the time required to perform the specific tasks identified for the maintenance functions
authorized in the MAC. The symbol designations for the various maintenance levels under the Two-
Level Maintenance concept are as follows:
0164-4
TM 11-6115-742-13&P 0164
Field:
C Crew maintenance
F Maintainer maintenance
Sustainment:
L Specialized Repair Activity (SRA)
H Below depot maintenance
D Depot maintenance
NOTE
The “L” maintenance class is not included in column (4) of the MAC.
Functions to this level of maintenance are identified by work time
figure in the “H” column of column (4), and an associated reference
code is used in the REMARKS column (6). This code is keyed to the
remarks and the SRA complete repair application is explained there.
Column (5) Tools and Test Equipment Reference Code. Column (5) specifies, by code, those common
tools sets (not individual tools), common Test, Measurement and Diagnostic Equipment (TMDE), and
special tools, special TMDE and special support equipment required to perform the designated
function. Codes are keyed to the entries in the tools and test equipment table.
Column (6) Remarks Code. When applicable, this column contains a letter code, in alphabetical order,
which is keyed to the remarks table entries.
Explanation of Columns in the Tools and Test Equipment Requirements
Column (1) Tool or Test Equipment Reference Code. The tool and test equipment reference code
correlates with a code used in column 5 of the MAC.
Column (2) Maintenance Level. The lowest class of maintenance authorized to use the tool or test
equipment.
Column (3) Nomenclature. Name or identification of the tool or test equipment.
Column (4) National Stock Number (NSN). The NSN of the tool or test equipment.
Column (5) Tool Number. The manufacturer’s part number.
Explanation of Columns in the Remarks
Column (1) Remarks Code. The code recorded in column (6) of the MAC.
Column (2) Remarks. This column lists information pertinent to the maintenance function being
performed as indicated in the MAC.
END OF WORK PACKAGE
0164-5/6
TM 11-6115-742-13&P 0165
SUPPORTING INFORMATION
TMSS-MED
MAINTENANCE ALLOCATION CHART (MAC)
Table 1. MAC for TMSS Medium.
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL TOOLS AND
FIELD SUSTAINMENT TEST
EQUIPMENT
REF CODE REMARKS CODE
CREW FIELD BELOW DEPOT
GROUP COMPONENT/ MAINTENANCE DEPOT
NUMBER ASSEMBLY FUNCTION C F H D
00 POWER PLANT, INSPECT 0.10 A, B
UTILITY REPAIR 1 C
PU-821/T
REPAIR 3.00 J
PU-822A/T
REPAIR * X
01 TENT, MODULAR, INSPECT 0.10 A, B
GENERAL REPAIR 1 C
PURPOSE SYSTEM
REPAIR 3.00 J
TMSS100G
TMSS100T REPAIR * X
0101 AIR CONDITIONER INSPECT 0.20 D, E
TEST 0.20 H
SERVICE 0.20 G
SERVICE 1 A, F, G
REPLACE 1
REPAIR 1 J
SERVICE 1.00 1,3,7,9,10 Y
REPAIR 1.00 1,3,6-12 J
REPAIR * X
010101 AIR CONDITIONER INSPECT 0.10 A
ENCLOSURE REPLACE 1
REPAIR 1 J
TEST 1.00 2 Z
REPAIR 1.00 1, 3,6-12 J
01010101 PANEL, INSPECT 0.10 A
EVAPORATOR REPLACE 1
ASSEMBLY
REPAIR 1 J
01010102 CONTROL, INSPECT 0.10 A
ENCLOSURE, AIR
ADJUST 0.10 N
CONDITIONER
REPAIR 1 J
TEST 1.00 2 Z
REPAIR 1.00 1 J
REPLACE * X
REPAIR * X
0165-1
TM 11-6115-742-13&P 0165
Table 1. MAC for TMSS Medium – Continued.
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL TOOLS AND
FIELD SUSTAINMENT TEST
EQUIPMENT REMARKS
REF CODE CODE
CREW FIELD BELOW DEPOT
GROUP COMPONENT/ MAINTENANCE DEPOT
NUMBER ASSEMBLY FUNCTION C F H D
01010103 BLOWER INSPECT 0.10 A
ASSEMBLY ADJUST 0.10 1 I
REPLACE 0.20 1
REPAIR 0.30 1 J
TEST 1.00 2 Z
REPAIR 1.00 1 J
REPAIR * X
0102 GENERATOR, INSPECT 0.10 A,L,M
DIESEL ENGINE SERVICE 0.10 G, K, P
ADJUST 0.10 V
REPAIR 1 J
TEST 1.00 2 Z
REPLACE 1.00 1
REPAIR 1.00 1, 2, 4 J
REPAIR * X
010201 BATTERY INSPECT 0.10 A
ASSEMBLY
TEST 0.20 U
REPLACE 0.70 1
REPAIR 0.70 1, 2 J
010202 ENGINE/ TEST 1,2 Z
GENERATOR REPAIR 1, 2 J
ASSEMBLY
TEST 0.20 1,2 Z
REPLACE 3.00 1,5
REPAIR 2.00 1, 2, 4 J
01020201 COOLING SYSTEM, INSPECT 0.10 A
INSTALLATION
ADJUST 1 AA
REPLACE 1
REPAIR 1 J
0165-2
TM 11-6115-742-13&P 0165
Table 1. MAC for TMSS Medium – Continued.
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL TOOLS AND
FIELD SUSTAINMENT TEST
EQUIPMENT REMARKS
REF CODE CODE
CREW FIELD BELOW DEPOT
GROUP COMPONENT/ MAINTENANCE DEPOT
NUMBER ASSEMBLY FUNCTION C F H D
01020202 AIR INTAKE INSPECT 0.10 A
ASSEMBLY
REPAIR .10 1 J
REPAIR * X
010203 RADIATOR INSPECT 0.10 A
INSTALLATION
SERVICE 0.10 G
REPLACE 1.00 1
REPAIR 1.00 1 J
REPAIR * X
010204 EXHAUST ASSEMBLY INSPECT 0.10 A
REPLACE 0.70 1
REPAIR 1.00 1 J
010205 CONTROL PANEL INSPECT 0.10 A
REPAIR AB
TEST 0.10 2 Z
REPAIR 1.00 1, 2, 4 J
010206 POWER INSPECT 0.10 A
DISTRIBUTION PANEL REPAIR AB
TEST 0.10 2 Z
REPAIR 1.00 1, 2, 4 J
010207 BARRIER PANEL INSPECT 0.10 A
REPAIR 1 W
TEST 1.00 2 Z
REPAIR 1.00 1, 2, 4 J
REPAIR * X
0103 CHASSIS, TRAILER INSPECT 0.10 A, Q
ASSEMBLY
TEST 0.10 R
ADJUST 0.10 S
SERVICE 0.20 G
REPAIR 0.80 1, 2 J, T
REPAIR 1.00 1 J
REPAIR * X
0165-3
TM 11-6115-742-13&P 0165
Table 1. MAC for TMSS Medium – Continued.
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT
TOOLS AND TEST REMARKS
EQUIPMENT REF CODE CODE
CREW FIELD BELOW DEPOT
GROUP COMPONENT/ MAINTENANCE DEPOT
NUMBER ASSEMBLY FUNCTION C F H D
010301 STOP LIGHT, INSPECT 0.10 A
VEHICULAR
REPLACE 1
REPAIR J
010302 TONGUE JACK INSPECT 0.10 A
ASSEMBLY REPLACE 1
REPAIR 1 J
010303 BRAKE INSPECT 0.10 1 Q
INSTALLATION REPLACE 3.00 1
REPAIR 1.00 1 J
01030301 ACTUATOR INSPECT 0.10 A
ASSEMBLY
REPLACE 1.00
REPAIR 1.00 J
0104 TENT INSPECT 0.20 A
REPLACE 0.50
REPAIR 0.50 J
REPAIR * X
010401 TENT, END CAP INSPECT 0.10 A
REPLACE 0.50
REPAIR 0.50 J
010402 TENT, ROOF AND INSPECT 0.10 A
SIDES
REPLACE 0.70
REPAIR 0.50 J
0105 POWER INSPECT 0.10 A
DISTRIBUTION
REPLACE
UNIT, 60 AMP
REPAIR * X
0106 LIGHT SET, TENT INSPECT 0.10 A
REPLACE
REPAIR J
010601 WIRING KIT, INSPECT 0.10 A
ELECTRICAL
REPLACE
REPAIR J
0165-4
TM 11-6115-742-13&P 0165
Table 2. Tools and Test Equipment for TMSS Medium.
TOOL OR
TEST
EQUIPMENT MAINTENANCE NATIONAL TOOL
REF. CODE LEVEL NOMENCLATURE STOCK NUMBER NUMBER
1 F TOOL KIT, GENERAL 5180-01-483-0249 SC-5180-95-B47
MECHANIC’S
2 F MULTIMETER 6625-01-265-6000 27 W/ACCE
3 F TOOL KIT, 5180-00-596-1474 SC-5180-95-N18
SERVICE, REFRIGERATION
UNIT
4 F TOOL KIT, ELECTRONIC, TK- 5180-01-460-9328 5180-91-CL-R64
105 A/G
5 F STANDARD AUTOMOTIVE 4910-01-490-6453 4910-95-A81
TOOL SET
6 F NITROGEN PRESSURE 6680-00-503-1327
REGULATOR
7 F REFRIGERANT 4130-01-338-2707
RECOVERY/RECYCLING
UNIT
8 F PUMP, VACUUM 4130-00-289-5967
9 F CHARGING MANIFOLD, MASTER COOL
R407C TYPE PN 96561-G
10 F CHARGING CYLINDER, 4330-01-387-1501
RECOVERY TANK
11 F VALVE CORE MASTER COOL
REMOVER/INSTALLER PN: 91496
12 F QUICK RELEASE VALVE MASTER COOL
SET PN: 90262
0165-5
TM 11-6115-742-13&P 0165
Table 3. Remarks for TMSS Medium.
REMARKS CODE REMARKS
A Visual inspection of assembly and components for damage, loose or missing
hardware.
B Inspect for proper ground connection.
C Repair by replacement of power distribution unit (PDU) assembly, 25’ PDU cable
assembly, lights assembly, and fuel supply/return line.
D Inspect ECU enclosure drain ports and air return duct filters for obstruction or
damage.
E Inspect condenser and evaporator coils for dirt/dust.
F Service by cleaning condenser coil, or filters.
G Preventive Maintenance Checks and Services (PMCS).
H Test air conditioner assembly heating and cooling function.
I Adjust evaporator fan belt to proper tension.
J Repair by replacement of assemblies, subassemblies, and components.
K Service generator by priming fuel system.
L Inspect generator engine assembly for coolant leaks and proper oil and coolant
levels. Inspect for proper oil pressure and coolant temperature.
M Check for damaged or frayed cables, loose connections at alternator, starter, and
starter solenoid. Check condition of engine fan belt.
N Adjust ECU control panel by setting ECU thermostat to appropriate temperature
setting.
O Not used.
P Service generator engine assembly by charging batteries.
Q Inspect trailer assembly for surge brake fluid level, service brake operation,
parking brake operation, and proper tire air pressure.
R Test trailer brake lights, running lights, turn signals, and hazard lights operation.
S Adjust parking brakes for proper operation.
T Refer to TM 9-2330-392-14&P for Wheel and Tire Assembly replacement.
U Test batteries for proper voltage by observing voltage meter on Genset control
panel.
V Adjust Genset output voltage.
W Repair by replacement of fuses.
X Sustainment Maintenance performed by Field Service Representatives or Depot
Maintenance Teams.
Y Service by recovery and recharge of air conditioner coolant.
Z Test electrical continuity and/or functionality of circuit.
AA Adjust fan belt to proper tension.
AB Repair by replacement of indicator bulbs.
END OF WORK PACKAGE
0165-6
TM 11-6115-742-13&P 0166
SUPPORTING INFORMATION
TMSS-MED
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
INTRODUCTION
Scope
This work package lists COEI and BII for the TMSS-MED to help you inventory items for safe and efficient
operation of the equipment.
General
The COEI and BII information is divided into the following lists:
Components of End Item (COEI). This list is for information purposes only and is not authority to requisition
replacements. These items are part of the TMSS-MED. As part of the end item, these items must be with the
end item whenever it is issued or transferred between property accounts. Items of COEI are removed and
separately packaged for transportation or shipment only when necessary. Illustrations are furnished to help you
find and identify the items.
Basic Issue Items (BII). These essential items are required to place the TMSS-MED in operation, operate it, and
to do emergency repairs. Although shipped separately packaged, BII must be with the TMSS-MED during
operation and when it is transferred between property accounts. Listing these items is your authority to
request/requisition them for replacement based on authorization of the end item by the TOE/MTOE. Illustrations
are furnished to help you find and identify the items.
Explanation of Columns in the COEI List and BII List
Column (1) Illus Number. Gives you the number of the item illustrated.
Column (2) National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning
purposes.
Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name (in all capital letters) followed
by a minimum description when needed. The stowage location of COEI and BII is also included in this column.
The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC)
(in parentheses).
Column (4) Usable on Code. When applicable, gives you a code if the item you need is not the same for different
models of equipment.
Code Used on
89W Power Plant, Utility, PU-821/T, Green
89X Power Plant, Utility, PU-822A/T, Tan
Column (5) (U/I). Unit of Issue (UI) indicates the physical measurement or count of the item as issued per the
National Stock Number shown in column (2).
Column (6) Qty Rqr. Indicates the quantity required.
0166-1
TM 11-6115-742-13&P 0166
COMPONENTS OF END ITEM
1
3
4
Table 1. Components of End Item List.
(1) (2) (3) (4) (5) (6)
Illus National Description, Usable U/I Qty
Number Stock Part Number/(CAGEC) on Code Rqr
Number
1 AIR CONDITIONER [GREEN] 89W EA 1
T25050G, (0WFM3)
AIR CONDITIONER [TAN] 89X EA 1
T25050T, (0WFM3)
2 2540-01-558-8455 TARPAULIN [GREEN] 89W EA 1
SH535-0007G, (0WFM3)
2540-01-558-7518 TARP, TAN 89X EA 1
SH535-0007T, (0WFM3)
3 8105-01-575-2509 BAG, DUCT 89W, EA 2
A602126, (0WFM3) 89X
4 4720-01-553-5827 DUCT, AIR RETURN [GREEN] 89W EA 1
T291434, (0WFM3)
4720-01-559-2546 DUCT, AIR RETURN [TAN] 89X EA 1
T291528, (0WFM3)
5 4720-01-553-5758 DUCT, AIR SUPPLY [GREEN] 89W EA 1
T291433, (0WFM3)
4720-01-558-9393 DUCT, AIR SUPPLY [TAN] 89X EA 1
T291527, (0WFM3)
0166-2
TM 11-6115-742-13&P 0166
COMPONENTS OF END ITEM – Continued
Table 1. Components of End Item List – Continued.
(1) (2) (3) (4) (5) (6)
Illus National Description, Usable U/I Qty
Number Stock Part Number/(CAGEC) on Code Rqr
Number
6 GENERATOR, DIESEL ENGINE [GREEN] 89W EA 1
1007206, (0WFM3)
GENERATOR, DIESEL ENGINE [TAN] 89X EA 1
1007205, (0WFM3)
7 8340-01-572-0253 TARPAULIN [GREEN] 89W EA 1
SH535-0008G (0WFM3)
2540-01-558-8554 TARPAULIN [TAN] 89X EA 1
SH535-0008T (0WFM3)
8 6150-01-552-6358 CABLE ASSEMBLY, POWER, ELECTRICAL 89W, EA 1
T295004, (0WFM3) 89X
9 CHASSIS, TRAILER ASSEMBLY [GREEN] 89W EA 1
T215125G, (0WFM3)
CHASSIS, TRAILER ASSEMBLY [TAN] 89X EA 1
T215125T, (0WFM3)
0166-3
TM 11-6115-742-13&P 0166
COMPONENTS OF END ITEM – Continued
10
11
12
13
Table 1. Components of End Item List – Continued.
(1) (2) (3) (4) (5) (6)
Illus National Description, Usable U/I Qty
Number Stock Part Number/(CAGEC) on Code Rqr
Number
10 8340-01-557-3403 BAG, TENT FRAME PARTS 89W, EA 1
MA100155, (0WFM3) 89X
11 5995-01-552-6935 CABLE ASSEMBLY, SPECIAL PURPOSE, 89W, EA 1
ELECTRICAL 89X
T295101, (0WFM3)
12 5995-01-552-6934 CABLE ASSEMBLY, SPECIAL PURPOSE, 89W, EA 1
ELECTRICAL 89X
T295145, (0WFM3)
13 5995-01-552-8232 CABLE ASSEMBLY, SPECIAL PURPOSE, 89W, EA 1
ELECTRICAL 89X
T295111, (0WFM3)
0166-4
TM 11-6115-742-13&P 0166
14
15
16
17
18
Table 1. Components of End Item List – Continued.
(1) (2) (3) (4) (5) (6)
Illus National Description, Usable U/I Qty
Number Stock Part Number/(CAGEC) on Code Rqr
Number
14 TENT, ROOF AND SIDES [GREEN] 89W EA 1
MXA2035G, (0WFM3)
TENT, ROOF AND SIDES [TAN] 89X EA 1
MXA2035T, (0WFM3)
15 8340-01-571-6948 FLOOR, TENT 89W, EA 1
MXA2025F, (0WFM3) 89X
16 4020-01-570-4924 ROPE, FIBROUS 89W, EA 16
A602050, (0WFM3) 89X
17 8340-01-553-0054 CASE, TENT 89W, EA 1
MXA2040B, (0WFM3) 89X
18 8340-01-589-9512 BAG, TENT FRAME PARTS [GREEN] 89W EA 2
MXA2020G, (0WFM3)
8340-01-589-9518 BAG, TENT FRAME PARTS [TAN] 89X EA 2
MXA2020T, (0WFM3)
0166-5
TM 11-6115-742-13&P 0166
COMPONENTS OF END ITEM – Continued
19
20
22
21
Table 1. Components of End Item List – Continued.
(1) (2) (3) (4) (5) (6)
Illus National Description, Usable U/I Qty
Number Stock Part Number/(CAGEC) on Code Rqr
Number
19 8340-01-540-7600 CONNECTOR, TENT GUSSET [GREEN] 89W EA 4
MXA1054G, (0WFM3)
8340-01-540-7608 CONNECTOR, TENT GUSSET [TAN] 89X EA 4
MXA1054T, (0WFM3)
20 8340-01-540-7490 PASSAGEWAY, TENT [GREEN] 89W EA 1
MXA1055G, (0WFM3)
8340-01-540-7495 PASSAGEWAY, TENT [TAN] 89X EA 1
MXA1055T, (0WFM3)
21 5340-01-558-7299 POLE, PUSH 89W, EA 4
A602650, (0WFM3) 89X
22 8340-01-556-7416 REPAIR KIT, COVERS [GREEN] 89W EA 1
MA100735, (0WFM3)
(See WP 0168 for expendable items list)
5410-01-570-4998 KIT, REPAIR [TAN] 89X EA 1
MA100740, (0WFM3)
(See WP 0168 for expendable items list)
0166-6
TM 11-6115-742-13&P 0166
COMPONENTS OF END ITEM - Continued
23
24 25
26
27
Table 1. Components of End Item List – Continued.
(1) (2) (3) (4) (5) (6)
Illus National Description, Usable U/I Qty
Number Stock Part Number/(CAGEC) on Code Rqr
Number
23 8340-01-589-9618 BAG, TENT FRAME PARTS 89W, EA 1
MA100160, (0WFM3) 89X
24 6150-01-553-0094 CABLE ASSEMBLY, POWER, ELECTRICAL 89W, EA 1
T295114, (0WFM3) 89X
25 5920-01-501-0678 ARRESTER, ELECTRICAL SURGE 89W, EA 1
ISOBAR4, (65836) 89X
26 6150-01-552-6419 CABLE ASSEMBLY, POWER, ELECTRICAL 89W, EA 1
T295116, (0WFM3) 89X
27 6150-01-553-0088 CABLE ASSEMBLY, POWER, ELECTRICAL 89W, EA 1
SL-103-66593-01A, (1WXV7) 89X
0166-7
TM 11-6115-742-13&P 0166
COMPONENTS OF END ITEM – Continued
28 29
30
Table 1. Components of End Item List – Continued.
(1) (2) (3) (4) (5) (6)
Illus National Description, Usable U/I Qty
Number Stock Part Number/(CAGEC) on Code Rqr
Number
28 8430-01-491-3057 POWER DISTRIBUTION UNIT, TENT 89W, EA 1
T2-93000-1, (0WFM3) 89X
29 6210-01-552-7806 FIXTURE, LIGHTING 89W, EA 4
H300000, (0WFM3) 89X
30 BAG, LIGHTING 89W, EA 2
MA100170, (0WFM3) 89X
0166-8
TM 11-6115-742-13&P 0166
BASIC ISSUE ITEMS
2
1
Table 2. Basic Issue Items.
(1) (2) (3) (4) (5) (6)
Illus National Description, Usable U/I Qty
Number Stock Part Number/(CAGEC) on Code Rqr
Number
1 4210-01-552-5109 EXTINGUISHER, FIRE 89W, EA 1
B402T, (49376) 89X
2 FUNNEL 89W, EA 1
T295169, (0WFM3) 89X
3 5340-01-558-9644 ADAPTER, TIE-DOWN 89W, EA 3
A600250, (0WFM3) 89X
4 8430-01-467-9179 STEEL STAKE PIN SET 89W, KT 1
MA100760, (0WFM3) 89X
5 5975-01-552-6937 GROUND ROD KIT 89W, KT 1
T295146, (0WFM3) 89X
0166-9
TM 11-6115-742-13&P 0166
8
7
6
10
9
Table 2. Basic Issue Items – Continued.
(1) (2) (3) (4) (5) (6)
Illus National Description, Usable U/I Qty
Number Stock Part Number/(CAGEC) on Code Rqr
Number
6 TACTICAL UTILITY FIELD FURNITURE 89W, EA 6
BP900A001, (0WFM3) 89X
7 TECHNICAL MANUAL & RPSTL 89W, EA 1
(TM 11-6115-742-13&P) 89X
8 COMPACT DISC (CD-ROM) WARRANTY 89W, EA 1
A602260, (0WFM3) 89X
9 4910-01-301-9125 PAN, DRAIN 89W, EA 1
4204T4, (39428) 89X
10 FUEL LINES, AUXILIARY 89W, SE 1
T295180, (0WFM3) 89X
END OF WORK PACKAGE
0166-10
TM 11-6115-742-13&P 0167
SUPPORTING INFORMATION
TMSS-MED
ADDITIONAL AUTHORIZATION LIST (AAL)
INTRODUCTION
Scope
This work package lists additional items you are authorized for the support of the TMSS-MED.
General
This list identifies items that do not have to accompany the TMSS-MED and that do not have to be turned in with
it. These items are all authorized to you by CTA, MTOE, TDA, or JTA.
Explanation of Columns in the AAL
Column (1) National Stock Number (NSN) - Identifies the stock number of the item to be used for requisitioning
purposes.
Column (2) Description, Part Number/(CAGEC) - Identifies the Federal item name (in all capital letters) followed
by a minimum description when needed. The last line below the description is the part number and the
Commercial and Government Entity Code (CAGEC) (in parentheses).
Column (3) Usable on Code - When applicable, gives you a code if the item you need is not the same for different
models of equipment.
Code Used on
89W Power Plant, Utility, PU-821/T, Green
89X Power Plant, Utility, PU-822A/T, Tan
Column (4) Unit of Issue (U/I) - Indicates the physical measurement or count of the item as issued per the
National Stock Number shown in column (1).
Column (5) Qty Recm - Indicates the quantity recommended.
ADDITIONAL AUTHORIZED LIST ITEMS
Table 1. Additional Authorized List.
(1) (2) (3) (4) (5)
National Stock Usable Qty
Number (NSN) Description, Part Number/(CAGEC) On Code U/I Recom
BOOTING COLLAR, VEHICLE, GREEN FOR 1068
8340-01-537-8797 89W EA A/R
SH540-0205G, (0WFM3)
BOOTING COLLAR, VEHICLE, TAN FOR 1068
8340-01-537-8793 89X EA A/R
SH540-0205T, (0WFM3)
8340-01-537-8740 BOOT WALL, GREEN FOR COMMAND POST 89W EA A/R
SYSTEM MODULAR, SH540-0001G, (0WFM3)
BOOT WALL, TAN FOR COMMAND POST
8340-01-537-8738 SYSTEM, MODULAR, SH540-0001T, (0WFM3) 89X EA A/R
0167-1
TM 11-6115-742-13&P 0167
Table 1. Additional Authorization List – Continued.
(1) (2) (3) (4) (5)
National Stock Usable Qty
Number (NSN) Description, Part Number/(CAGEC) On Code U/I Recom
BOOTING COLLAR,VEHICLE,GREEN FOR V1-V5
8340-01-537-8769 89W EA A/R
SH540-0208G, (0WFM3)
BOOTING COLLAR,VEHICLE,TAN FOR V1-V5
8340-01-537-8767 SH540-0208T, (0WFM3) 89X EA A/R
CONNECTOR, BOOTWALL, TAN, SIDE-TO
8340-01-587-8352 SICPS, OR END-TO-SICPS 89X EA A/R
JS900340 (OWFM3)
CONNECTOR, BOOTWALL, WHITE, SIDE-TO-
8340-01-587-8327 SICPS OR END-TO-SICPS 89X EA A/R
JS900360 (0WFM3)
CONNECTOR, SET, J/MX SHELTER, SIDE-TO-
8340-01-588-2488 SIDE OR END-TO-SICPS, TAN 89X EA A/R
1006160 (0WFM3)
CONNECTOR SET, (SIDE TO SIDE) TMSS-MED,
8340-01-540-7690 89W EA A/R
GREEN, MXA1055G, (0WFM3)
CONNECTOR SET, (SIDE TO SIDE) TMSS-MED,
8340-01-540-7495 TAN, MXA1055T, (0WFM3) 89X EA A/R
SEAM REINFORCEMENT SYSTEM (SRS), WHITE 89W,
8340-01-540-0855 MXA1056, (0WFM3) EA A/R
89X
CONNECTOR SET, (END TO END) TMSS-MED,
8340-01-540-7600 GREEN, MXA1054G, (0WFM3) 89W EA A/R
8340-01-540-7608 CONNECTOR SET, (END TO END) TMSS-MED, 89X EA A/R
TAN, MXA1054T, (0WFM3)
GROUND ROD DRIVER 5/8” 89X EA A/R
TG903-7000 (OWFM3)
CONNECTOR SET(s), TMSS-LRG
CONNECTOR SET, GREEN
MXS1051G, (0WFM3) 89W EA A/R
CONNECTOR SET, TAN 89X EA A/R
MXS1051T, (0WFM3)
CONNECTOR SET, WHITE 89W,
MXS105W, 0WFM3) EA A/R
89X
0167-2
TM 11-6115-742-13&P 0167
Table 1. Additional Authorization List – Continued.
(1) (2) (3) (4) (5)
National Stock Usable Qty
Number (NSN) Description, Part Number/(CAGEC) On Code U/I Recom
CONNECTOR SET(s), CPP RWS
BOOTWALL, CONNECTOR SET, GREEN
89W EA A/R
MXA1040G, (0WFM3)
HARDWARE, for BOOTWALL, CONNECTOR SET,
5411-01-565-5225 89W EA A/R
GREEN, MXA1041G, (0WFM3)
BOOTWALL, CONNECTOR SET, TAN
89X EA A/R
MXA1051T, (0WFM3)
HARDWARE, for BOOTWALL, CONNECTOR SET,
89X EA A/R
TAN, MXA1041T, (0WFM3)
CHAIR, FOLDING (3MYY8) 12586 or equivalent 89W,
5830-01-528-2498 EA 20
89X
CARABINER [D-Ring] 89W,
7810-01-075-8135 (52403) 662-847 EA 30
89X
TABLE, UTILITY FIELD 89W,
NA EA A/R
BP300A005, (0WFM3) 89X
POWER STRIP, ELECTRICAL OUTLET 89W,
6150-01-333-1655 UL620-15, (65836) EA 5
89X
RACK, STORAGE SMALL ARMS M12 89W,
1095-00-407-0674 8449880, (19204) EA A/R
89X
FLOORING SHEET, MODULAR
89W,
5680-01-553-8745 BTS-ICMS, (1PR05) EA A/R
89X
[4’LX3.5’WX2”H W/CABLE CHANNELS] SAND
FLOORING SHEET, MODULAR
BTS-NICMS, (1PR05) 89W,
5680-01-553-8740 EA A/R
[4’LX3.5’WX2”H WO/CABLE CHANNELS] SAND 89X
COMMAND OR ACCESS CONTROL TENT
TENT SICPS-SMALL, GREEN
8340-01-F00-9891 SH202-0001G, (0WFM3) 89W EA 1
8340-01-F00-4360 TENT SICPS-SMALL, TAN 89X EA 1
SH202-0001T, (0WFM3)
TENT SICPS-SMALL, GREEN
8340-01-F00-9890 SH202-0003G, (0WFM3) (W/EMI) 89W EA A/R
TENT SICPS-SMALL, TAN
8340-01-F00-9889 SH202-0003T, (0WFM3) (W/EMI) 89X EA A/R
0167-3
TM 11-6115-742-13&P 0167
Table 1. Additional Authorization List – Continued.
(1) (2) (3) (4) (5)
National Stock Usable Qty
Number (NSN) Description, Part Number/(CAGEC) On Code U/I Recom
SHELTER OR TENT RIGID DOORWAY
ENTRY CONTROL POINT 89W,
NA 1009460, (0WFM3) [DOOR AND FRAME] EA A/R
89X
END OF WORK PACKAGE
0167-4
TM 11-6115-742-13&P 0168
SUPPORTING INFORMATION
TMSS-MED
EXPENDABLE AND DURABLE ITEMS LIST
INTRODUCTION
Scope
This work package lists expendable and durable items that you will need to operate and maintain the TMSS-MED.
This listing is for information only and is not authority to requisition the listed items. These items are authorized to
you by Common Table of Allowances (CTA) 50-790, Expendable/Durable Items (Except Medical, Class V Repair
Parts, and the Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment, or CTA 8-100, Army
Medical Department Expendable/Durable Items.
Explanation of Columns in the Expendable/ Durable Items List
Column (1) Item No. This number is assigned to the entry in the list and is referenced in the narrative instructions
to identify the item (e.g., “Use brake fluid, (WP 0098, Item 5)”).
Column (2) Level. This column provides the lowest level of maintenance that requires the listed item
(includes as applicable: C = Operator/Crew, O = AMC (Aviation Only), F = Maintainer or ASB, H = Below Depot
or TASMG, D = Depot).
Column (3) National Stock Number (NSN). This is the NSN assigned to the item which you can use to requisition
it.
Column (4) Item Name, Description, Part Number/ (CAGEC). This column provides the other information you
need to identify the item. The last line below the description is the part number and the Commercial and
Government Entity Code (CAGEC) (in parentheses).
Column (5) U/I. Unit of Issue (U/I) code shows the physical measurement or count of an item, such as gallon,
dozen, gross, etc.
EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items List.
(1) (2) (3) (4) (5)
Item Level National Item Name, Description, U/I
Number Stock Number Part Number/(CAGEC)
1 F 6810-00-075-5546 Alcohol, Isopropyl BT
7618-19-4 (53390)
2 C Anti-Freeze,
6850-00-664-1403 1-Gallon (3.78 L) Bottle GL
D3306, (81346)
6850-00-664-1409 55-Gallon (20.19 L) Drum GL
D3306, (81346)
3 F 8030-00-105-0270 Antiseize Compound LB
NSBT-16N, (5W425)
4 F 6515-01-234-6838 Applicator, Disposable PG
362 (5L934)
0168-1
TM 11-6115-742-13&P 0168
EXPENDABLE AND DURABLE ITEMS LIST – Continued
Table 1. Expendable and Durable Items List – Continued.
(1) (2) (3) (4) (5)
Item Level National Item Name, Description, U/I
Number Stock Number Part Number/(CAGEC)
5 C Blade, hack saw PG
4202A18, (39428)
6 C 9150-01-102-9455 Brake Fluid, Silicone, Automotive, All Weather, GL
Operational and Preservative, 1-Gallon (3.78 L) Bottle
MIL-B-46176 (81349)
7 F 3439-00-188-6982 Brazing alloy, (Copper) CO
3132, (70334)
8 F 3439-00-528-3882 Brazing, alloy, (Silver) TO
QQ-B-654, (81348)
9 F 7920-00-514-2417 Brush, Acid, Swabbing GR
803-12 (7S147)
10 C Brush1, 2 EA
SH903-9000, (0WFM3)
11 F 6850-01-474-2302 Cleaning Compound, Solvent, GL
MIL-PRF-680 (81349)
12 F 5350-00-192-5047 Cloth, Abrasive (80 grit) PG
051144-02460 (76381)
13 F 5350-00-174-1000 Cloth, Abrasive (Waterproof) BD
A-A-1200, (58536)
14 C 7920-00-044-9281 Cloth, Cleaning BX
MIRACLEWIPEL001, (51200)
15 F 3439-01-324-8208 Desoldering Wick EA
80-2-5 (21267)
16 C 7930-00-056-8144 Detergent, General Purpose BX
Formula409-2202 (93098)
17 C Duct Tape, Green, 1, 2 RO
2 inch x 12 yards (50.8 mm x 10.97 m)
A601350, (0WFM3)
18 C Duct Tape, Tan, 2 inch x 12 yards1,2 RO
2 inch x 12 yards (50.8 mm x 10.97 m)
A601360, (0WFM3)
19 C Fabric, Self-Adhesive, Green1,2 EA
C424017, (0WFM3)
20 C Fabric, Self-Adhesive, Tan1,2 EA
C424018, (0WFM3)
0168-2
TM 11-6115-742-13&P 0168
EXPENDABLE AND DURABLE ITEMS LIST – Continued
Table 1. Expendable and Durable Items List – Continued.
(1) (2) (3) (4) (5)
Item Level National Item Name, Description, U/I
Number Stock Number Part Number/(CAGEC)
21 C Fabric, Self-Adhesive, White1,2 EA
C424019, (0WFM3)
22 F 3439-00-914-8390 Flux, brazing, (use w/ aluminum, brass, copper and JR
steel), O-F-499, (81348)
23 F 3439-00-009-8808 Flux, Soldering (electronic) QT
FLUX R 1QT (81349)
24 C 8415-01-463-5928 Gloves, Rubber , Multipurpose DZ
8415-01-463-5928, (80244)
25 F 9150-01-305-6879 Grease, Automotive & Artillery, 14 oz Cartridge EA
MIL-G-10924C, (81349)
26 F 4720-01-221-8870 Hose, Nonmetallic 5/8 inch (15.875 mm) ID RO
28417, (24161)
27 F Hose, Nonmetallic 3/4 inch (19.05 mm) ID RO
65009, (04NP0)
28 F Hose, Nonmetallic 3/8 inch (9.5252 mm) ID RO
65213, (04NP0)
29 F Hose, Nonmetallic 5/16 inch (7.94 mm) Dia RO
535-278, (04NP0)
30 F Hose, Non-metallic, 50-feet (15.24 m) EA
7454T16, (39428)
31 F 5970-01-326-1660 Insulation Kit, Sleeving, Thermal EA
FIT-105-MS-1 (92194)
32 F Insulation Sleeving, Thermal RO
(2 inch W x 30 feet L x 1/8 inch Thk)
(50.8 mm W x 9.14 m L x 3.175 mm Thk)
014T101 (3C0M7)
33 F Insulation Sleeving, Thermal, RO
5/8 inch ID x 1/2 inch wall
(15.875 mm ID x 12.7 mm wall)
014T110 (3C0M7)
34 F Insulation Sleeving, Thermal, RO
1-3/8 inch ID x 1/2 inch wall
014T111 (3C0M7)
0168-3
TM 11-6115-742-13&P 0168
EXPENDABLE AND DURABLE ITEMS LIST – Continued
Table 1. Expendable and Durable Items List – Continued.
(1) (2) (3) (4) (5)
Item Level National Item Name, Description, U/I
Number Stock Number Part Number/(CAGEC)
35 C 9150-01-152-4117 Lubricating Oil, Engine, 1-Quart (0.947 L) QT
M2104-1-15W40, (81349)
36 C 9150-00-402-4478 Lubricating Oil, Engine, 1-Quart (0.947 L) QT
EMERY3908D, (33358)
37 F 9150-01-035-5392 Lubricating Oil Gear, GO 80W-90, CN
1-Quart (0.947 L)
M2105-1-80W90, (81349)
38 F 9150-01-035-5393 Lubricating Oil, Gear, GO 80W-90, CN
5-Gallon (18.90 L)
MIL-L-2105-3-80W90, (81349)
39 F 9150-01-035-5394 Lubricating Oil, Gear, GO 80W-90, DR
55-Gallon (208.19 L) Drum
M2105-4-80W90, (81349)
40 F 6830-00-292-0732 Nitrogen, Technical Pumped (89783) CY
41 F 5350-00-598-5537 Paper, Abrasive, Garnet HD
P-P-105 (81348)
42 F 5350-00-186-8819 Paper, Abrasive, (220 grit) PG
P-P-121 (81348)
43 F 5975-01-481-4497 Protector, Electrical Cable RO
1/2 inch (12.7 mm) black
863-000669, (4X630)
44 F 5975-01-481-4499 Protector, Electrical Cable RO
1/4 inch (6.35 mm) black
863-000670, (4X630)
45 F Protector, Electrical Cable RO
5/8 inch (15.875 mm) black
CLT62N-C630, (06383)
46 C 7920-01-447-3002 Rags, Wiping, Absorbent
41200, (0W517)
47 F Refrigerant, (R-407c)
0168-4
TM 11-6115-742-13&P 0168
EXPENDABLE AND DURABLE ITEMS LIST – Continued
Table 1. Expendable and Durable Items List – Continued.
(1) (2) (3) (4) (5)
Item Level National Item Name, Description, U/I
Number Stock Number Part Number/(CAGEC)
48 F 5320-00-865-8994 Rivet, Blind BX
M24243/1-D404 (81349)
49 F 8030-00-689-5646 Sealing compound CN
80065, (1PBQ8)
50 F 8030-00-081-2337 Sealing Compound BX
(087-21) (05972)
51 C 8040-01-331-7131 Silicone Sealant, RTV CA
MIL-A-46106 (81349)
52 C Sleeve, Repair1, 2, EA
A601750, (0WFM3)
53 F 3439-00-204-2546 Solder, Tin Alloy SL
SN95/5 SB5WS 0.094 1LB (81346)
54 C 6530-01-268-5480 Spray Bottle EA
83, (4M682)
55 F 5975-00-727-5153 Strap Tie-Down, Electrical Components, 3 3/4 inch HD
(92.25 mm), MS33671-4-9, (81343)
56 F 5975-00-570-9598 Strap Tie-Down, Electrical Components, 11 1/2 inch HD
(292.10 mm) MS3367-7-9, (81343)
57 F 5975-00-156-3253 Strap Tie-Down, Electrical Components, 14 1/2 inch HD
(368.30 mm), MS3367-2-9, (81343)
58 F 8030-00-889-3535 Tape, Antisiezing EA
AA58092-2-2, (58536)
59 F Wire, (18 AWG), Stranded KT
6808K21, (39428)
60 F Wire, (16 AWG), Stranded, Black KT
69835K361, (39428)
Wire, (16 AWG), Stranded, White KT
69835k461, (39428)
0168-5
TM 11-6115-742-13&P 0168
EXPENDABLE AND DURABLE ITEMS LIST – Continued
Table 2. Shelter Repair Kit Items.
(1) (2) (3) (4) (5)
Item Level National Item Name, Description, U/I
Number Stock Number Part Number/(CAGEC)
1 C Hack Saw1, 2, EA
A601451, (0WFM3)
2 C Ratchet1, 2 EA
JS900680, (0WFM3)
3 C Scissors, 4 inch (101.6 mm) 1, 2 EA
A601051, (0WFM3)
4 C Wrench, Spanner 3/16 inch (4.76 mm)1, 2, EA
A601150, (0WFM3)
NOTE
1. This item is part of Tent Component Kit MA100735 (WP 0166).
2. This item is part of Tent Component Kit MA100740 (WP 0166).
END OF WORK PACKAGE
0168-6
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
INDEX
Access Panels and Latches (Genset)
Access Panels Removal/Replacement ........................................................................... WP 0039-2
Access Panel Latch Removal/Replacement ................................................................... WP 0039-10
Access Cover Removal/Replacement ............................................................................. WP 0039-12
Repair Parts ..................................................................................................................... WP 0135
Actuator Brake
Removal/Replacement .................................................................................................... WP 0128-7
Repair Parts ..................................................................................................................... WP 0153
Additional Authorization List (AAL) ...................................................................................... WP 0167
Additional Authorization List ............................................................................................ WP 0167-1
Explanation of Columns in the AAL ................................................................................. WP 0167-1
Air Intake Filter
Removal/Replacement .................................................................................................... WP 0043-2
Repair Parts ..................................................................................................................... WP 0143
Air Filter (ECU)
Removal/Replacement .................................................................................................... WP 0101-2
Repair Parts ..................................................................................................................... WP 0135
Alternator
Removal/Replacement .................................................................................................... WP 0060-2
Repair Parts ..................................................................................................................... WP 0141
AUXILIARY Fuel Ports
Removal/Replacement .................................................................................................... WP 0084-5
Repair Parts ..................................................................................................................... WP 0139
AUX Heat switch
Removal/Replacement .................................................................................................... WP 0103-6
Repair Parts ..................................................................................................................... WP 0137
Barrier panel (Genset)
Removal/Replacement (individual components).............................................................. WP 0075 to
WP 0083
Repair Parts (individual components) .............................................................................. WP 0148
Troubleshooting (individual components) ........................................................................ WP 0028
Battery (Genset)
Battery Fuse (Version 1) Removal/Replacement ............................................................ WP 0041-2
Battery Fuse (Version 2 and 3) Removal/Replacement .................................................. WP 0041-5
Battery, Retainer and Bracket Removal/Replacement (Version 1) ................................. WP 0041-8
Battery, Retainer and Bracket Removal/Replacement (Version 2) ................................. WP 0041-13
Battery, Retainer and Bracket Removal/Replacement (Version 3) ................................. WP 0041-19
Battery Warmer Removal/Replacement (Version 1) ...................................................... WP 0041-25
Battery Warmer Removal/Replacement (Version 2 and 3)) ........................................... WP 0041-28
Charging .......................................................................................................................... WP 0023-2
Repair Parts ..................................................................................................................... WP 0140
Battery Charger (Genset)
Removal/Replacement ..................................................................................................... WP 0083-2
Repair Parts ..................................................................................................................... WP 0148
Brake (hand) (Trailer)
Cable and sheath Removal/Replacement ....................................................................... WP 0128-14
Hand brake Removal/Replacement................................................................................. WP 0128-11
Repair Parts ..................................................................................................................... WP 0152
Brazing ................................................................................................................................. WP 0110-5
INDEX-1
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
B – Continued
Brakes (Trailer)
Actuator Removal/Replacement ...................................................................................... WP 0128-7
Adjustment ....................................................................................................................... WP 0126-15
Bleed Brake System......................................................................................................... WP 0127-8
Brake hub/drum Removal/Replacement .......................................................................... WP 0126-2
Brake lines Removal/Replacement .................................................................................. WP 0127-4
Brakeshoe Removal/Clean and Inspect/Replacement .................................................... WP 0126-9
Backing Plate Removal/Replacement.............................................................................. WP 0126-13
Master cylinder Removal/Replacement ........................................................................... WP 0127-2
Repair Parts ..................................................................................................................... WP 0152
Bridge rectifier
Removal/Replacement ..................................................................................................... WP 0107-4
Repair Parts ..................................................................................................................... WP 0137
Bulbs (ECU)
Removal/Replacement ..................................................................................................... WP 0103-2
Repair Parts ..................................................................................................................... WP 0137
Bulbs (Genset)
Removal/Replacement ..................................................................................................... WP 0020-2
Repair Parts ..................................................................................................................... WP 0146
Cargo Net
Removal/Replacement .................................................................................................... WP 0121-5
Repair Parts ..................................................................................................................... WP 0149
Charging (ECU) .................................................................................................................... WP 0113-4
Circuit Breakers (ECU)
Removal/Replacement .................................................................................................... WP 0104-2
Repair Parts ..................................................................................................................... WP 0137
Circuit breaker (Genset)
Removal/Replacement .................................................................................................... WP 0082-2
Repair Parts ..................................................................................................................... WP 0148
Components of End Item (COEI) and Basic Issue Items (BII) Lists .................................... WP 0166
Basic Issue Items List ...................................................................................................... WP 0166-9
Components of End Item List .......................................................................................... WP 0166-2
Explanation of Columns in the COEI List and BII List ..................................................... WP 0166
Compressor (ECU)
Removal/Replacement .................................................................................................... WP 0099-2
Repair Parts ..................................................................................................................... WP 0135
Condenser Coil (ECU)
Cleaning........................................................................................................................... WP 0092-4
Condenser Fan
Removal/Replacement .................................................................................................... WP 0097-2
Repair Parts ..................................................................................................................... WP 0138
Condenser Grill
Removal/Replacement .................................................................................................... WP 0092-2
Repair Parts ..................................................................................................................... WP 0135
Connectors (Genset J1 through J6)
Removal/Replacement .................................................................................................... WP 0074
Repair Parts ..................................................................................................................... WP 0147
INDEX-2
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
C - Continued
Control Panel (ECU)
Circuit breaker removal/replacement .................................................................................. WP 0104
Contactors removal/replacement ........................................................................................ WP 0105
Indicator lights removal/replacement .................................................................................. WP 0103
Relays removal/replacement ............................................................................................... WP 0106
Repair Parts......................................................................................................................... WP 0137
Starter protectors removal/replacement .............................................................................. WP 0108
Switches removal/replacement ........................................................................................... WP 0103,
WP 0095
Thermostat removal/replacement ....................................................................................... WP 0103-8
Control Panel (Genset )
Latches removal/replacement ............................................................................................. WP 0040-2
Gauges removal/replacement ............................................................................................. WP 0069
Lights removal/replacement ................................................................................................ WP 0071
Meters removal/replacement ............................................................................................... WP 0068,
WP 0069
Switches removal/replacement ........................................................................................... WP 0070,
WP 0072
Wiring harness removal/replacement .................................................................................. WP 0073
Repair Parts......................................................................................................................... WP 0146
Coolant
Removal/Replacement ........................................................................................................ WP 0058-2
Replacement ....................................................................................................................... WP 0022-4
Coolant Temperature Sensor
Removal/Replacement ........................................................................................................ WP 0055-2
Repair Parts ........................................................................................................................ WP 0141
Coolant Temperature Switch
Removal/Replacement .......................................................................................................... WP 0056-2
Repair Parts .......................................................................................................................... WP 0141
Crew Maintenance Instructions
ECU ........................................................................................................................................ WP 0022
Genset .................................................................................................................................... WP 0020,
WP 0021,
WP 0023
Shelter..................................................................................................................................... WP 0024,
WP 0025,
WP 0026
Crew Preventive Maintenance Checks and Services (PMCS) Introduction ............................... WP 0018
Crew Preventive Maintenance Checks and Services (PMCS) ................................................... WP 0019
Crew Troubleshooting
ECU ........................................................................................................................................ WP 0013
Genset (Electrical) .................................................................................................................. WP 0012
Genset (Engine) ...................................................................................................................... WP 0011
Shelter (Electrical)................................................................................................................... WP 0016
Shelter (Mechanical) ............................................................................................................... WP 0015
Trailer ...................................................................................................................................... WP 0014
Troubleshooting Index ............................................................................................................ WP 0010
Current Transformer
Removal/Replacement .......................................................................................................... WP 0075-2
Repair Parts .......................................................................................................................... WP 0148
INDEX-3
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
D
Damper Plate
Removal/Replacement ......................................................................................................... WP 0093-8
Repair Parts ......................................................................................................................... WP 0136
Description and Use of Controls, Indicators, and Connectors ................................................ WP 0004
Destruction of Equipment to Prevent Enemy Use ................................................................... WP 0001-2
WP 0161
WP 0162
Diesel Speed Sensor
Inspect .................................................................................................................................. WP 0054-3
Removal/Replacement ......................................................................................................... WP 0054-2
Repair Parts ......................................................................................................................... WP 0141
Duct Cover
Removal/Replacement ......................................................................................................... WP 0093-2
Repair Parts .......................................................................................................................... WP 0136
ECU
Brazing WP 0110-5
Description and Use of Operator Controls, Indicators, and Connectors............................... WP 0004-7
ECU Start Procedure ............................................................................................................ WP 0005-26
ECU Shut Down Procedure .................................................................................................. WP 0005-28
Equipment Data .................................................................................................................... WP 0002-9
Equipment Description .......................................................................................................... WP 0002-5
Crew Level Maintenance ...................................................................................................... WP 0022
Crew Level Troubleshooting ................................................................................................. WP 0013
Maintainer Level Maintenance .............................................................................................. WP 0091 to
WP 0114
Maintainer Level Troubleshooting .........................................................................................
Operating ECU as a Stand-Alone Unit.................................................................................. WP 0006-5
WP 0110-3
Purging ..................................................................................................................................
Refrigerant System Charging ................................................................................................ WP 0113-4
Refrigerant System Recovery ............................................................................................... WP 0113-2
Removal/Replacement .......................................................................................................... WP 0109-2
Repair Parts ..........................................................................................................................WP 0134 to
WP 0138
Vacuuming ............................................................................................................................ WP 0112
Electric Fuel Pump
Removal/Replacement ......................................................................................................... WP 0047-2
Repair Parts .......................................................................................................................... WP 0141
Engine Coolant
Check level/add .................................................................................................................... WP 0021-4
Removal/Replacement ......................................................................................................... WP 0058-2
Engine Coolant Reservoir Bottle
Removal/Replacement ......................................................................................................... WP 0058-5
Repair Parts .......................................................................................................................... WP 0144
Engine Heater (Hydronic)
Fuel Filter Removal/Replacement ........................................................................................ WP 0064-6
Fuel Pump Removal/Replacement....................................................................................... WP 0064-6
Fuse Removal/Replacement ................................................................................................ WP 0064-19
Crew Level Troubleshooting ................................................................................................. WP 0011
Removal/Replacement ......................................................................................................... WP 0064-2
Repair Parts .......................................................................................................................... WP 0139
Maintainer Level Troubleshooting ........................................................................................ WP 0029-28
INDEX-4
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
E - Continued
Equipment Characteristics, Capabilities, and Features ........................................................... WP 0002-1
Equipment Data ....................................................................................................................... WP 0002-8
Evaporator Fan
Removal/Replacement.......................................................................................................... WP 0096-2
Repair Parts .......................................................................................................................... WP 0138
Exhaust Flex Pipe, Elbow and Muffler
Removal/Replacement.......................................................................................................... WP 0065-2
Repair Parts .......................................................................................................................... WP 0145
Exhaust Manifold and gasket
Removal/Replacement.......................................................................................................... WP 0066-2
Repair Parts .......................................................................................................................... WP 0145
Expendable and Durable Items List ......................................................................................... WP 0168
Expendable and Durable Items List Table ............................................................................ WP 0168-1
Explanation of Columns in the Expendable/Durable Items List ............................................ WP 0168-1
Introduction ........................................................................................................................... WP 0168-1
Scope .................................................................................................................................... WP 0168-1
Fan (Genset)
Removal/Replacement.......................................................................................................... WP 0062-2
Repair Parts .......................................................................................................................... WP 0142
Fan Belt- (ECU)
Adjustment ........................................................................................................................... WP 0098-2
Removal/Replacement.......................................................................................................... WP 0098-4
Repair Parts .......................................................................................................................... WP 0138
Fan Belt (Genset)
Adjustment ........................................................................................................................... WP 0061-2
Inspect .................................................................................................................................. WP 0061-2
Removal/Replacement.......................................................................................................... WP 0061-3
Repair Parts .......................................................................................................................... WP 0142
Field Repair Kit (Tent Component Kit) ..................................................................................... WP 0154,
WP 0168
Filter- Air Intake
Removal/Replacement.......................................................................................................... WP 0043-2
Repair Parts .......................................................................................................................... WP 0143
Filter/Dryer
Removal/Replacement.......................................................................................................... WP 0102-2
Repair Parts .......................................................................................................................... WP 0135
Filter-ECU
Cleaning ................................................................................................................................ WP 0101-2
Repair Parts .......................................................................................................................... WP 0135
Filter, Fuel Diesel Engine
Removal/Replacement.......................................................................................................... WP 0044-2
Repair Parts .......................................................................................................................... WP 0141
Filter, Fuel – Engine Heater (Hydronic)
Removal/Replacement.......................................................................................................... WP 0064-6
Repair Parts .......................................................................................................................... WP 0139
Filter, Fuel – Hydronic Heater (ECU)
Removal/Replacement.......................................................................................................... WP 0094-5
Repair Parts .......................................................................................................................... WP 0135
Filter, Oil - Diesel Engine
Removal/Replacement.......................................................................................................... WP 0042-2
Repair Parts .......................................................................................................................... WP 0141
INDEX-5
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
F - Continued
Fire Extinguisher bracket
Removal/Replacement............................................................................................................. WP 0122-8
Repair Parts ............................................................................................................................. WP 0139
Fold-outs
Genset Connectors (Sh 1 of 2) ............................................................................................... FP-31/32
Genset Connectors (Sh 2 of 2) ............................................................................................... FP-33/34
Genset Power Distribution Panel – New Version (with EMI) .................................................. FP-41-42
Genset Power Distribution Panel – New Version (without EMI) ............................................. FP-43-44
Schematic – ECU (V1) ........................................................................................................... FP-1/2
Schematic – ECU (V2) ........................................................................................................... FP-5/6
Schematic – ECU Refrigerant................................................................................................. FP-9/10
Schematic – Genset Barrier Panel (Sh 1 of 5) ...................................................................... FP-15/16
Schematic – Genset Barrier Panel (Sh 2 of 5) ...................................................................... FP-17/18
Schematic – Genset Barrier Panel (Sh 3 of 5) ....................................................................... FP-19/20
Schematic – Genset Barrier Panel (Sh 4 of 5) ...................................................................... FP-21/22
Schematic – Genset Barrier Panel (Sh 5 of 5) ....................................................................... FP-23/24
Schematic – Genset Control Panel......................................................................................... FP-11/12
Schematic – Genset Power Distribution Panel ...................................................................... FP-13/14
Schematic – Genset Wiring Harness ..................................................................................... FP-25/26
Schematic – Hydronic Heater ................................................................................................. FP-35/36
Wire List – Genset (Sh 1 of 2) ................................................................................................ FP-27/28
Wire List – Genset (Sh 2 of 2) ................................................................................................ FP-29/30
Wiring Diagram – Inter-vehicular cable (LED) ........................................................................ FP-37/38
Wiring Diagram – Inter-vehicular cable (Incandescent).......................................................... FP-39/40
Fuel Injection System
Fuel Injector Removal/Clean/Replacement ............................................................................. WP 0048-2
Fuel Injector Pump Removal/Replacement ............................................................................. WP 0048-6
Fuel Injection System Lines Removal/Replacement ............................................................... WP 0048-10
Prime Fuel System................................................................................................................... WP 0048-16
Repair Parts ............................................................................................................................. WP 0141
Fuel Gauge
Removal/Inspect/Replacement ................................................................................................ WP 0085-2
Repair Parts ............................................................................................................................. WP 0141
Fuel Hose
Removal/Replacement ............................................................................................................ WP 0085-10
Repair Parts ............................................................................................................................. WP 0141
Fuel Line heater
Removal/Replacement ............................................................................................................ WP 0085-12
Repair Parts ............................................................................................................................. WP 0139
Fuel Pump, Engine Heater (Hydronic)
Removal/Replacement............................................................................................................. WP 0064-6
Repair Parts ............................................................................................................................. WP 0139
Fuel Pump, Hydronic Heater (ECU)
Removal/Replacement............................................................................................................. WP 0094-5
Repair Parts ............................................................................................................................. WP 0135
Fuel Pump, Electric (Genset)
Removal/Replacement ............................................................................................................ WP 0047-2
Repair Parts ............................................................................................................................. WP 0141
Fuel Selector switch
Removal/Replacement ............................................................................................................ WP 0084-2
Repair Parts ............................................................................................................................. WP 0139
Fuel Tank
Removal/Replacement ............................................................................................................ WP 0085-5
Repair Parts ............................................................................................................................. WP 0139
Service ..................................................................................................................................... WP 0045-2
INDEX-6
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
F – Continued
Fuse (Battery)
Removal/Replacement............................................................................................................ WP 0041-2
Repair Parts ............................................................................................................................ WP 0140
Fuse (Genset)
Removal/Replacement............................................................................................................ WP 0040-4
Repair Parts ............................................................................................................................ WP 0148-5
Test ......................................................................................................................................... WP 0040-4
Fuse (Hydronic heaters)
Removal/Replacement............................................................................................................ WP 0094-12,
WP 0064-19
Repair Parts ............................................................................................................................ WP 0139,
WP 0135
Fuse (Light Fixture)
Removal/Replacement............................................................................................................ WP 0130-4
Repair Parts ............................................................................................................................ WP 0157
Gauges
COOLANT TEMP Test ......................................................................................................... WP 0069-4
OIL PRESSURE Test .......................................................................................................... WP 0069-3
Repair Parts ......................................................................................................................... WP 0146
Removal/Replacement ......................................................................................................... WP 0069-4
Troubleshooting .................................................................................................................... WP 0028
General Information
Corrosion Prevention and Control (CPC) ............................................................................. WP 0001-2
Destruction of Army Material to Prevent Enemy Use ........................................................... WP 0001-2
List of Abbreviations/Acronyms ............................................................................................ WP 0001-4
Maintenance Forms, Records, and Reports ......................................................................... WP 0001-2
Nomenclature Cross - Reference List .................................................................................. WP 0001-3
Nuclear Hardness ................................................................................................................. WP 0001-6
Ozone Depleting Substances (ODS) .................................................................................... WP 0001-2
Parts Information for Repair Parts, Special Tools, TMDE and Support Equipment ............. WP 0001-6
Preparation for Storage or Shipment .................................................................................... WP 0001-3
Quality of Material ................................................................................................................. WP 0001-5
Reporting Equipment Improvement Recommendations (EIR) ............................................. WP 0001-2
Safety, Care, and Handling................................................................................................... WP 0001-6
Scope .................................................................................................................................... WP 0001-1
Warranty Information ............................................................................................................ WP 0001-3
Genset
Crew Level Maintenance Procedures ................................................................................... WP 0020,
WP 0021
Crew Level Troubleshooting ................................................................................................ WP 0011,
WP 0012
Description and Use of Operator Controls, Indicators, and Connectors .............................. WP 0004-1
Engine Generator Assembly - Removal and Replacement .................................................. WP 0086-7
Equipment Data .................................................................................................................... WP 0002-9
Equipment Description .......................................................................................................... WP 0002-2
Generator Fueling ................................................................................................................. WP 0005-23
Genset Start Procedure ....................................................................................................... WP 0005-25
Genset Shut Down Procedure ............................................................................................. WP 0005-28
Maintainer Level Maintenance .............................................................................................. WP 0039 to
WP 0086
Maintainer Level Troubleshooting......................................................................................... WP 0028,
WP 0029
INDEX-7
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
G - Continued
Removal/Replacement including Enclosure ......................................................................... WP 0086-2
Repair Parts .......................................................................................................................... WP 0139 to
WP 0148
Separating Engine Generator Assembly – Removal and Replacement .............................. WP 0086-26
Glow Plug and Glow Plug Connector
Inspect .................................................................................................................................. WP 0049-3
Removal/Replacement ......................................................................................................... WP 0049-2
Repair Parts .......................................................................................................................... WP 0141
Test ....................................................................................................................................... WP 0049-3
Governor
Adjustments .......................................................................................................................... WP 0081-5
Removal/Replacement ......................................................................................................... WP 0081-2
Repair Parts .......................................................................................................................... WP 0148
Ground stud (trailer)
Removal/Replacement ......................................................................................................... WP 0122-4
Repair Parts .......................................................................................................................... WP 0149
Hub (Shelter)
Removal/Replacement............................................................................................................ WP 0026-4
Repair Parts ............................................................................................................................ WP 0154,
WP 0155
Hydronic Heater (ECU)
Crew Level Troubleshooting ................................................................................................. WP 0013
Fuel Filter Removal/Replacement ......................................................................................... WP 0094-5
Fuel Pump and Fuel Filter Removal/replacement ................................................................. WP 0094-5
Fuse Removal/Replacement ................................................................................................. WP 0094-12
Hoses Removal/Replacement ............................................................................................... WP 0094-9
Maintainer Level Troubleshooting ......................................................................................... WP 0030
Removal/Replacement .......................................................................................................... WP 0094-2
Repair Parts .......................................................................................................................... WP 0135
Inter-Vehicular Cable
Removal/Replacement ......................................................................................................... WP 0125
Repair Parts ......................................................................................................................... WP 0149
Testing .................................................................................................................................. WP 0023-5
Jack, Tongue
Removal/Replacement......................................................................................................... WP 0119-4
Repair Parts ......................................................................................................................... WP 0149
INDEX-8
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
K
Keeper (Shelter)
Removal/Replacement......................................................................................................... WP 0026-2
Repair Parts ......................................................................................................................... WP 0154,
WP 0155
Lamp, Fluorescent (Shelter)
Removal/Replacement ......................................................................................................... WP 0130-2
Repair Parts ......................................................................................................................... WP 0157
Lanyard (Trailer)
Removal/Replacement ......................................................................................................... WP 0122-6
Repair Parts ......................................................................................................................... WP 0149
Leak check (ECU) .................................................................................................................... WP 0111
Level (Trailer)
Removal/Replacement......................................................................................................... WP 0119-2
Repair Parts ......................................................................................................................... WP 0149
Lights (ECU control panel)
Removal/Replacement......................................................................................................... WP 0103-2
Repair Parts ......................................................................................................................... WP 0137
Lights (Genset Control panel)
Removal/Replacement......................................................................................................... WP 0071-2
Repair Parts ......................................................................................................................... WP 0146
Lights (Genset power distribution panel)
Removal/Replacement......................................................................................................... WP 0074-2
Repair Parts ......................................................................................................................... WP 0147
Lighting (Shelter)
Install Shelter Lighting.......................................................................................................... WP 0005-21
Repair Parts ......................................................................................................................... WP 0157
Lunette
Removal/Replacement......................................................................................................... WP 0128-2
Repair Parts ......................................................................................................................... WP 0153
Manifold, Exhaust (Genset)
Removal/Replacement ......................................................................................................... WP 0066-2
Repair Parts .......................................................................................................................... WP 0145
Master Cylinder Service
Fluid Replacement ................................................................................................................ WP 0021-6
Removal/Replacement ......................................................................................................... WP 0127-2
Repair Parts .......................................................................................................................... WP 0152
Maintainer Maintenance Instructions
ECU.........................................................................................................................................WP 0091 to
WP 0114
Genset..................................................................................................................................... WP 0039 to
WP 0086
Shelter and Trailer .................................................................................................................. WP 0119 to
WP 0130
Maintainer Troubleshooting
ECU (Electrical)/Hydronic Heater ........................................................................................... WP 0030
ECU (Heating & Cooling)/Hydronic Heater ............................................................................. WP 0031
INDEX-9
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
M – Continued
Maintainer Troubleshooting – Continued
Genset (Electrical) ................................................................................................................ WP 0028
Genset (Engine) .................................................................................................................... WP 0029
Shelter (Electrical)................................................................................................................. WP 0034
Trailer (Electrical) .................................................................................................................. WP 0032
Trailer (Mechanical) .............................................................................................................. WP 0033
Troubleshooting Index .......................................................................................................... WP 0027
Maintenance Allocation Chart (MAC)........................................................................................ WP 0165
Maintenance Allocation Chart (MAC) Introduction .................................................................... WP 0164
Explanation of Columns in Remarks...................................................................................... WP 0164-4
Explanation of Columns in the MAC ...................................................................................... WP 0164-3
Explanation of Columns in Tools and Test Equipment Requirements .................................. WP 0164-3
Maintenance Functions .......................................................................................................... WP 0164-1
The Army Maintenance System MAC.................................................................................... WP 0164-1
Meters
A-C AMPMETERS Removal/Replacement ......................................................................... WP 0068-2
A-C KILOWATTS meter Removal/Replacement ................................................................. WP 0068-2
A-C- VOLTS meter Removal/Replacement .......................................................................... WP 0068-2
Adjustment (Genset meters) ................................................................................................. WP 0068-2
BATTERY CHARGER AMPS meter Removal/Replacement ............................................... WP 0069-3
DC VOLTS meter Removal/Replacement ............................................................................ WP 0069-4
HERTZ meter Removal/Replacement ................................................................................. WP 0068-2
HOUR meter (ECU) Removal/Replacement ....................................................................... WP 0103-3
HOURMETER (Genset) Removal/Replacement .................................................................. WP 0069-7
Repair Parts ......................................................................................................................... WP 0146
Troubleshooting ................................................................................................................... WP 0028
Motor, Condenser Fan (ECU)
Removal/Replacement ......................................................................................................... WP 0097-2
Repair Parts .......................................................................................................................... WP 0138
Motor, Evaporator Fan (ECU)
Removal/Replacement ......................................................................................................... WP 0096-2
Repair Parts .......................................................................................................................... WP 0138
Muffler (Genset)
Removal/Replacement ......................................................................................................... WP 0065-6
Repair Parts .......................................................................................................................... WP 0145
National Stock Number Index ..................................................................................................... WP 0159
Oil (Genset)
Add ............................................................................................................................................ WP 0021-2
Removal/Replacement ............................................................................................................. WP 0042-2
Oil Filter (Genset)
Removal/Replacement ............................................................................................................ WP 0042-2
Repair Part ............................................................................................................................... WP 0141
Oil Pressure Switch (Genset)
Removal/Replacement ............................................................................................................ WP 0050-2
Repair Parts ............................................................................................................................. WP 0141
Oil Pressure Sending Unit (Genset)
Removal/Replacement ............................................................................................................ WP 0051-2
Repair Parts ............................................................................................................................. WP 0141
On-Vehicle Equipment Loading Plan ........................................................................................... WP 0009
INDEX-10
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
O –Continued
Operation Under Unusual Conditions
General .................................................................................................................................... WP 0006-1
Interim Nuclear, Biological, and Chemical (NBC) Decontamination Procedures .................... WP 0006-7
Jamming and Electronic Countermeasures (ECM) Procedure ............................................... WP 0006-11
Unusual Environment/Weather ................................................................................................ WP 0006-1
Operating ECU as a Stand-Alone Unit .................................................................................... WP 0006-5
Security Measures for Electronic Data .................................................................................... WP 0006-1
Operation Under Usual Conditions .............................................................................................. WP 0005
Assembly and Preparation for Use .......................................................................................... WP 0005-2
Connecting Cables and Equipment ........................................................................................ WP 0005-20
Disconnecting Cables and Equipment .................................................................................... WP 0005-29
General .................................................................................................................................... WP 0005-1
Generator Fueling .................................................................................................................... WP 0005-23
Preparation for Movement ....................................................................................................... WP 0005-36
Preparing Shelter Site.............................................................................................................. WP 0005-2
Security Measurements for Electronic Data ............................................................................ WP 0005-1
Shelter Setup ........................................................................................................................... WP 0005-7
Shelter Tear Down ................................................................................................................... WP 0005-30
Site Requirements ................................................................................................................... WP 0005-1
System Packing and Loading .................................................................................................. WP 0005-33
System Power-Down ............................................................................................................... WP 0005-28
System Power-Up Procedures ................................................................................................ WP 0005-25
Trailer Setup ............................................................................................................................ WP 0005-3
Weight and Center of Gravity .................................................................................................. WP 0005-45
Part Number Index ...................................................................................................................... WP 0160
PDU (ECU)
Crew Level Troubleshooting .................................................................................................... WP 0016
Description and Use of Operator Controls, Indicators, and Connectors ................................. WP 0004-9
Equipment Data ....................................................................................................................... WP 0002-10
Equipment Description ............................................................................................................. WP 0002-6
Maintainer Level Troubleshooting............................................................................................ WP 0034
Potentiometer, Voltage Adjust (Genset)
Removal/Replacement ............................................................................................................. WP 0070-2
Repair Part............................................................................................................................... WP 0146
Power cable (ECU)
Repair Part............................................................................................................................... WP 0133
Power Down Procedures............................................................................................................. WP 0005-28
Preparation for Movement ........................................................................................................... WP 0005-36
Preparation for Shipping.............................................................................................................. WP 0005-43
Quench Valve (ECU)
Removal/Replacement ............................................................................................................ WP 0100-7
Repair Parts ............................................................................................................................. WP 0135
INDEX-11
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
R
Radiator (Genset)
Removal/Replacement ............................................................................................................ WP 0059-4
Repair Parts ............................................................................................................................. WP 0144
Radiator Coolant (Genset)
Add .......................................................................................................................................... WP 0021-4
Removal/Replacement ............................................................................................................ WP 0058-2
Radiator Hoses
Removal/Replacement ............................................................................................................ WP 0059-2
Repair Parts ............................................................................................................................. WP 0144
References
Field Manuals .......................................................................................................................... WP 0163-1
Government Publications ........................................................................................................ WP 0163-1
Scope....................................................................................................................................... WP 0163-1
Technical Bulletins................................................................................................................... WP 0163-2
Technical Manuals................................................................................................................... WP 0163-2
Reflector (Trailer)
Removal/Replacement ............................................................................................................ WP 0122-2
Repair Parts ............................................................................................................................. WP 0149
Relays (ECU)
Phase Sensing Removal/Replacement ................................................................................... WP 0106-2
Time Delay Removal/Replacement ......................................................................................... WP 0106-2
Repair Part .............................................................................................................................. WP 0137
Relays (Genset)
Engine over speed (K5) Removal/Replacement ..................................................................... WP 0077-2
Governor control (K7) Removal/Replacement ........................................................................ WP 0077-2
Oil pressure Low cut-off (K6) Removal/Replacement ............................................................. WP 0077-2
Over temperature (K4) Removal/Replacement ....................................................................... WP 0077-2
Repair Part .............................................................................................................................. WP 0148
Repair Parts and Special Tools List Introduction
Abbreviations ........................................................................................................................... WP 0131-6
Explanation of Columns in the Repair Parts and Special Tools Work Packages .................. WP 0131-1
Explanation of Cross-Reference Indexes Work Packages Format and Columns................... WP 0131-5
General .................................................................................................................................... WP 0131-1
How To Locate Repair Parts ................................................................................................... WP 0131-6
Scope....................................................................................................................................... WP 0131-1
Repair Parts List, Power Plant, Utility, A1-38283D-001/A1-38283D-002 ................................... WP 0132
Repair Parts List, Tent, Modular, General Purpose System, TMSS100G/TMSS100T ............... WP 0133
Repair Parts List, Air Conditioner, T256250G/T256250T ........................................................... WP 0134
Repair Parts List, Air Conditioner Enclosure, T250250G/T250250T .......................................... WP 0135
Repair Parts List, Panel, Evaporator Assembly, TG423-0451-1G/TG423-0451-1T ................... WP 0136
Repair Parts List, Control, Enclosure, Air Conditioner, 088T103 ................................................ WP 0137
Repair Parts List, Blower Assembly, 054T102 ............................................................................ WP 0138
Repair Parts List, Generator, Diesel Engine, T282271G/T282271T ........................................... WP 0139
Repair Parts List, Battery Assembly, T235064............................................................................ WP 0140
Repair Parts List, Engine Assembly, T245264 ............................................................................ WP 0141
Repair Parts List, Cooling System, Installation, TG440-0001 ..................................................... WP 0142
Repair Parts List, Air Intake Assembly, X-14210-057-0 .............................................................. WP 0143
Repair Parts List, Radiator Assembly, TG421-9000 ................................................................... WP 0144
Repair Parts List, Exhaust Assembly, T235005 .......................................................................... WP 0145
Repair Parts List, Control Panel, T225453 .................................................................................. WP 0146
Repair Parts List, Power Distribution Panel, TG421-9007 .......................................................... WP 0147
Repair Parts List, Barrier Panel T225250-5 ................................................................................ WP 0148
INDEX-12
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
R – Continued
Repair Parts List, Chassis, Trailer Assembly, T215125G/T215125T ......................................... WP 0149
Repair Parts List, Stop Light, Vehicular, 12375837-BK-SP ........................................................ WP 0150
Repair Parts List, Tongue Jack Assembly, PCHA0175G/PCHA0175T ...................................... WP 0151
Repair Parts List, Brake, TG421-9006G/T6421-9006G/T6421-9006T ....................................... WP 0152
Repair Parts List, Actuator Assembly, TG404-0819G/TG404-D819T ........................................ WP 0153
Repair Parts List, Tent, MXA2000G/MXA2000T ......................................................................... WP 0154
Repair Parts List, Tent, End Cap, MXA2020G/MXA2020T ......................................................... WP 0155
Repair Parts List, Tent, Roof and Sides, MXA2035G/ MXA2035T ............................................. WP 0156
Repair Parts List, Power Distribution Service, Tent, T2-930001 (No Parts Authorized)
Repair Parts List, Light Set, Tent, H300070 ................................................................................ WP 0157
Repair Parts List, Wiring Kit, Electrical, T2-95205 ...................................................................... WP 0158
Repair Parts List, Stock Number Index ....................................................................................... WP 0159
Repair Parts List, Part Number Index.......................................................................................... WP 0160
Safety Chain (Trailer)
Removal/Replacement ............................................................................................................... WP 0119-3
Repair Parts ............................................................................................................................... WP 0149
Schematics FP-1 to
FP-44
Shelter
Equipment Data ......................................................................................................................... WP 0002-8
Equipment Description ............................................................................................................... WP 0002-2
Crew Level Maintenance Procedures ........................................................................................ WP 0024 to
WP 0026
Crew Level Troubleshooting ...................................................................................................... WP 0015,
WP 0016
Maintainer Level Maintenance Procedures................................................................................ WP 0130
Maintainer Level Troubleshooting .............................................................................................. WP 0034
Repair Parts ............................................................................................................................... WP 0154 to
WP 0157
Shelter Cover/End Cap
Removal/Replacement ............................................................................................................... WP 0024-4
Repair ......................................................................................................................................... WP 0024-2
Repair Parts ............................................................................................................................... WP 0154
Shelter Main Hub
Removal/Replacement ............................................................................................................... WP 0026-4
Repair Parts ............................................................................................................................... WP 0154
Shelter Main Staking Bracket
Removal/Replacement ............................................................................................................... WP 0026-6
Repair Parts ............................................................................................................................... WP 0154
Shelter Strut Removal/Replacement
Removal/Replacement ............................................................................................................... WP 0025-4
Repair ......................................................................................................................................... WP 0025-2
Repair Parts ............................................................................................................................... WP 0154
Sliding Door
Removal/Replacement ............................................................................................................... WP 0093-4
Repair Parts ............................................................................................................................... WP 0136
INDEX-13
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
S – Continued
Solenoid Valve (ECU)
Removal/Replacement ............................................................................................................... WP 0100-17
Repair Parts ............................................................................................................................... WP 0137
Solenoid (Genset)
Removal/Replacement ............................................................................................................... WP 0052-2
Repair Parts ............................................................................................................................... WP 0141
Speed sensor (Genset)
Removal/Replacement ............................................................................................................... WP 0054-2
Repair Parts ............................................................................................................................... WP 0141
Stabilizer Leg (Trailer)
Removal/Replacement ............................................................................................................... WP 0121-2
Repair Parts ............................................................................................................................... WP 0149
Starter
Removal/Replacement ............................................................................................................... WP 0053-2
Repair Parts ............................................................................................................................... WP 0141
Stowage and Decal/Data Plate Guide ........................................................................................... WP 0008
Superheat Adjustment, Thermal Expansion Valve (ECU) .............................................................. WP 0100-5
Sub-cool setting adjustment, ECU.................................................................................................. WP 0114-2
Switches (ECU)
High pressure-cut off Removal/Replacement ............................................................................ WP 0095-4
High-temp cut off Removal/Replacement .................................................................................. WP 0095-2
Low pressure cut-off Removal/Replacement ............................................................................. WP 0095-7
MODE SELECT Removal/Replacement .................................................................................... WP 0103-4
Switches (Genset)
BATTERY SWITCH Removal/Replacement .............................................................................. WP 0072-2
BATTLE SHORT Removal/Replacement .................................................................................. WP 0070-10
EMERGENCY STOP Removal/Replacement............................................................................ WP 0072-5
ENGINE Removal/Replacement ................................................................................................ WP 0070-5
ENGINE HEATER Removal/Replacement ................................................................................ WP 0070-9
FUEL LINE HEATER Removal/Replacement ............................................................................ WP 0070-9
PANEL LIGHTS Removal/Replacement .................................................................................... WP 0070-5
VOLT/AMP Removal/Replacement ........................................................................................... WP 0070-5
Temperature Sensor, Coolant (Genset)
Removal/Replacement ............................................................................................................... WP 0055-2
Repair Parts ............................................................................................................................... WP 0141
Thermal Expansion Valve (ECU)
Adjustment ................................................................................................................................. WP 0100-5
Removal/Replacement ............................................................................................................... WP 0100-2
Repair Parts ............................................................................................................................... WP 0137
Thermostat (Genset)
Removal/Replacement ............................................................................................................... WP 0057-2
Repair Parts ............................................................................................................................... WP 0142
Time delay (Genset)
Removal/Replacement ............................................................................................................... WP 0078-2
Repair Parts ............................................................................................................................... WP 0148
Time delay (ECU)
Removal/Replacement ............................................................................................................... WP 0078-2
Repair Parts ............................................................................................................................... WP 0137
Tire and Wheel Assembly (Trailer)
Removal/Replacement ............................................................................................................... WP 0129-2
Repair Parts ............................................................................................................................... WP 0152
INDEX-14
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
T - Continued
Tongue Jack
Removal/Replacement ............................................................................................................... WP 0119-4
Repair Parts ............................................................................................................................... WP 0149
Torque Requirements ....................................................................................................................... WP 0067
Towing Instructions........................................................................................................................... WP 0005-37
Trailer
Crew Level Troubleshooting ...................................................................................................... WP 0014
Equipment Data ......................................................................................................................... WP 0002-8
Equipment Description ............................................................................................................... WP 0002-3
Maintainer Level Maintenance Procedures................................................................................ WP 0119 to
WP 0129
Maintainer Level Troubleshooting Procedures .......................................................................... WP 0032,
WP 0033
Repair Parts ............................................................................................................................... WP 0149 to
WP 0153
Transducer (Genset Barrier Panel)
Removal/Replacement ............................................................................................................... WP 0076-2
Repair Parts ............................................................................................................................... WP 0148
Transformer
Removal/Replacement ............................................................................................................... WP 0107-2
Repair Parts ............................................................................................................................... WP 0148
Troubleshooting
Crew
ECU ........................................................................................................................................ WP 0013
Genset (Electrical) .................................................................................................................. WP 0012
Genset (Engine) ..................................................................................................................... WP 0011
Shelter (Electrical) .................................................................................................................. WP 0016
Shelter (Mechanical)............................................................................................................... WP 0015
Trailer...................................................................................................................................... WP 0014
Troubleshooting Index ............................................................................................................ WP 0010
Maintainer
ECU (Electrical)....................................................................................................................... WP 0030
ECU (Heating & Cooling) ........................................................................................................ WP 0031
Genset (Electrical) .................................................................................................................. WP 0028
Genset (Engine) ...................................................................................................................... WP 0029
Shelter (Electrical) ................................................................................................................... WP 0034
Trailer (Electrical) .................................................................................................................... WP 0032
Trailer (Mechanical) ................................................................................................................ WP 0033
Troubleshooting Index ............................................................................................................ WP 0027
Valves (ECU)
High Pressure Relief Valve Removal/Replacement................................................................. WP 0100-14
Hot Gas Bypass Valve Removal/Replacement........................................................................ WP 0100-10
Quench Valve Removal/Replacement ..................................................................................... WP 0100-7
INDEX-15
TM 11-6115-742-13&P
Subject WP Sequence No. – Page No.
V - Continued
Valves (ECU) – Continued
Repair Parts ............................................................................................................................. WP 0135
Solenoid Valve Removal/Replacement ................................................................................... WP 0100-17
Thermal Expansion Valve Removal/Replacement .................................................................. WP 0100-2
Vehicle Stop Light Assembly (Incandescent) (Trailer)
Removal/Replacement ............................................................................................................. WP 0124-4
Repair Parts .............................................................................................................................. WP 0149
Test ........................................................................................................................................... WP 0124-4
Vehicle Stop Light Assembly (LED) (Trailer)
Removal/Replacement ............................................................................................................ WP 0124-6
Repair Parts............................................................................................................................. WP 0149
Test .......................................................................................................................................... WP 0124-7
Vehicle Stop Light Bulb (Incandescent) (Trailer)
Removal/Replacement ............................................................................................................. WP 0124-2
Repair Parts .............................................................................................................................. WP 0149
Test ........................................................................................................................................... WP 0124-2
Vehicle Stop Light Wiring Harness (Inter-Vehicular Cable) (Trailer)
Removal/Replacement ............................................................................................................. WP 0125-2
Repair Parts .............................................................................................................................. WP 0149
Test ........................................................................................................................................... WP 0125-4
Voltage Regulator (Genset Barrier Panel)
Adjustment ................................................................................................................................ WP 0079-5
Removal/Replacement ............................................................................................................. WP 0079-2
Repair Parts .............................................................................................................................. WP 0148
V/HZ Roll-Off Frequency Selection .......................................................................................... WP 0079-6
Water Pump (Genset)
Removal/Replacement .............................................................................................................. WP 0063-2
Repair Parts .............................................................................................................................. WP 0142
Weight and Center of Gravity ....................................................................................................... WP 0005-45
Wheel
Removal/Replacement .............................................................................................................. WP 0129-2
Repair Parts .............................................................................................................................. WP 0152
Wheel Cylinder
Removal/Replacement .............................................................................................................. WP 0126-6
Repair Parts .............................................................................................................................. WP 0152
Wire harness (Genset)
Removal/Replacement .............................................................................................................. WP 0073-2
Repair Parts .............................................................................................................................. WP 0149
INDEX-16
RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part II (reverse) for Repair Parts and DATE
BLANK FORMS Special Tool Lists (RPSTL) and Supply
For use of this form, see AR 25-30; the proponent agency is OAASA Catalogs/Supply Manuals (SC/SM). 21 Nov 2011
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)
Commander, U.S. Army Communications-Electronics Jane Q. Doe, SFC
Command, 6001 Combat Drive, ATTN: AMSEL-LCL- 1234 Any Street
ECM, Aberdeen Proving Ground, MD 21005-1846 Anytown, AL 34565
PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE
TM 11-1234-567-14 15 Jan 2011 Operator, Field and Sustainment Support Maintenance Manual for
Radio, AN/ABC-123
PARA- FIGURE
ITEM PAGE LINE TABLE RECOMMENDED CHANGES AND REASON
GRAPH NO.
1 WP0005 2 Test or Corrective Action column should identify a different WP number.
PG 3
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
Jane Q. Doe, SFC 123-4567
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP DATE
Code)
PART II- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION/FORM NUMBER DATE TITLE
TOTAL NO.
OF MAJOR RECOMMENDED
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM
ITEMS ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED
PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
APD V4.00
RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part II (reverse) for Repair Parts and DATE
BLANK FORMS Special Tool Lists (RPSTL) and Supply
For use of this form, see AR 25-30; the proponent agency is OAASA Catalogs/Supply Manuals (SC/SM).
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)
PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE
PARA- FIGURE
ITEM PAGE LINE TABLE RECOMMENDED CHANGES AND REASON
GRAPH NO.
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP DATE
Code)
PART II- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION/FORM NUMBER DATE TITLE
TOTAL NO.
OF MAJOR RECOMMENDED
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM
ITEMS ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED
PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
APD V4.00
RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part II (reverse) for Repair Parts and DATE
BLANK FORMS Special Tool Lists (RPSTL) and Supply
For use of this form, see AR 25-30; the proponent agency is OAASA Catalogs/Supply Manuals (SC/SM).
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)
PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE
PARA- FIGURE
ITEM PAGE LINE TABLE RECOMMENDED CHANGES AND REASON
GRAPH NO.
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP DATE
Code)
PART II- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION/FORM NUMBER DATE TITLE
TOTAL NO.
OF MAJOR RECOMMENDED
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM
ITEMS ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED
PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
APD V4.00
RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part II (reverse) for Repair Parts and DATE
BLANK FORMS Special Tool Lists (RPSTL) and Supply
For use of this form, see AR 25-30; the proponent agency is OAASA Catalogs/Supply Manuals (SC/SM).
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)
PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE
PARA- FIGURE
ITEM PAGE LINE TABLE RECOMMENDED CHANGES AND REASON
GRAPH NO.
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP DATE
Code)
PART II- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION/FORM NUMBER DATE TITLE
TOTAL NO.
OF MAJOR RECOMMENDED
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM
ITEMS ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED
PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
APD V4.00
TM 11-6115-742-13&P
By Order of the Secretary of the Army:
Official:
RAYMOND T. ODIERNO
General, United States Army
Chief of Staff
JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
1211603
DISTRIBUTION:
To be distributed in accordance with the initial distribution number (IDN) 256981 requirements
for TM 11-6115-742-13&P.
TM 11-6115-742-13&P
A3
21 22
H2
Figure FO-1. Schematic
ECU (V1)
FP-1/FP-2 blank
TM 11-6115-742-13&P
Figure FO-2. Wiring Diagram
ECU (V1)
FP-3/FP-4 blank
TM 11-6115-742-13&P
Figure FO-3. Schematic
ECU (V2)
FP-5/FP-6 blank
TM 11-6115-742-13&P
Figure FO-4. Wiring Diagram
ECU (V2)
FP-7/FP-8 blank
TM 11-6115-742-13&P
LEGEND
CC Condenser Coil
CF Condensor Fan
CMP Compressor
EC Evaporator Coil
F/D Filter/Dryer
HGBV Hot Gas Bypass Valve
HPC High Pressure Cutout
HPRV High Pressure Relief Valve
LPC Low Pressure Cutout
QV Quench Valve
SF Supply Fan
SG Sight GLass
External
SP Service Port(Hi & Lo)
SV Solenoid Valve
TXV/D Thermal Expansion
Valve & Distributor
VI Vibration Insulator
Figure FO-5. Schematic
ECU Refrigerant
FP-9/FP-10 blank
TM 11-6115-742-13&P
Figure FO-6. Schematic
Genset Control Panel
FP-11/FP-12 blank
TM 11-6115-742-13&P
Figure FO-7. Schematic
Genset Power Distribution Panel
FP-13/FP-14 blank
TM 11-6115-742-13&P
Figure FO-8. Schematic
Genset Barrier Panel
Sheet 1 of 5
FP-15/FP-16 blank
TM 11-6115-742-13&P
Figure FO-8. Schematic
Genset Barrier Panel
Sheet 2 of 5
FP-17/FP-18 blank
TM 11-6115-742-13&P
Figure FO-8. Schematic
Genset Barrier Panel
Sheet 3 of 5
FP-19/FP-20 blank
TM 11-6115-742-13&P
Figure FO-8. Schematic
Genset Barrier Panel
Sheet 4 of 5
FP-21/FP-22 blank
TM 11-6115-742-13&P
Figure FO-8. Schematic
Genset Barrier Panel
Sheet 5 of 5
FP-23/FP-24 blank
TM 11-6115-742-13&P
Figure FO-9. Schematic
Genset Wiring Harness
FP-25/FP-26 blank
TM 11-6115-742-13&P
# GAGE COLOR TO FROM TO FROM TO FROM TO FROM # GAGE COLOR TO FROM TO FROM TO FROM TO FROM
1 14 GRAY K2S-4 CF1-1 CM1-1 TB1-1b-2 TB1-1-1 SW3-1 CM2 ——— 70 16 GRAY F1-2 VR-3 ——— ——— ——— ——— ——— ———
1B 16 GRAY TB1-1-1 CM2-1 CF2-1 SW5-2 ——— ——— ——— ——— 71 16 GRAY F1-2 CM2-17 CF2-17 SW1-1 ——— ——— ——— ———
2 14 GRAY K3S-2 CF1-2 CM1-2 TB1-2-2 TB1-2b-1 K4-9 ——— ——— 72 16 GRAY F2-2 CM2-18 CF2-18 SW1-7 ——— ——— ——— ———
3 14 GRAY ALT-1 K3S-2 ——— ——— ——— ——— ——— ——— 73 16 GRAY F3-2 CM2-19 CF2-19 SW1-5 ——— ——— ——— ———
7 16 GRAY ALT-2 CF1-3 CM1-3 TB1-7-2 TB1-7-1 K7-15 ——— ——— 74 16 GRAY F7-2 VR-4 ——— ——— ——— ——— ——— ———
8 16 GRAY K2S-3 CF1-4 CM1-4 TB1-8-2 TB1-8-1 CM2-2 CF2-2 SW3-4 75 16 GRAY SW1-3 M2-1 ——— ——— ——— ——— ——— ———
9 16 GRAY K3S-3 CF1-5 CM1-5 TB1-9-2 TB1-9-1 CM2-3 CF2-3 SW3-12 76 16 GRAY PTB2-12 CM2-20 CF2-20 M2 (+) ——— ——— ——— ———
10 16 GRAY HTS-1 CF1-6 CM1-6 TB1-10-2 TB1-10-1 CM2-4 CF2-4 SW3-8 77 16 GRAY PTB2-12 K7-9 ——— ——— ——— ——— ——— ———
11 16 GRAY LOPS-1 CF1-7 CM1-7 TB1-11-2 TB1-11-1 K7-7 ——— ——— 78 16 GRAY M1 SW1-19 ——— ——— ——— ——— ——— ———
12 16 GRAY HTS-2 CF1-8 CM1-8 TB1-12-2 TB1-12-1 K4-6 ——— ——— 79 16 GRAY M1 (+) SW1-13 ——— ——— ——— ——— ——— ———
13 16 GRAY LOPS-2 CF1-9 CM1-9 TB1-13-2 TB1-13-1 K7-10 ——— ——— 80 16 GRAY M1 (+) CF2-21 CM2-21 TB2-6-1 ——— ——— ——— ———
14 16 GRAY CTS CF1-10 CM1-10 TB1-14-2 TB1-14-1 CM2-5 CF2-5 M6-(S) 81 16 GRAY M3 CF2-22 CM2-22 XDR-16 ——— ——— ——— ———
15 16 GRAY OPS CF1-11 CM1-11 TB1-15-2 TB1-15-1 CM2-6 CF2-6 M8-(S) 82 16 GRAY M3 CF2-23 CM2-23 XDR-15 ——— ——— ——— ———
16 16 BLACK ACT-1 CF1-12 CM1-12 TB1-47-2 TB1-16-1 GC-5 ——— ——— 83 16 GRAY M4 SW1-8 ——— ——— ——— ——— ——— ———
16B 16 GRAY TB1 S7 ——— ——— ——— ——— ——— ——— 84 16 GRAY M4 SW1-6 ——— ——— ——— ——— ——— ———
16ES 16 GRAY TB1 S7 ——— ——— ——— ——— ——— ——— 85 16 BLACK R1-MIN CF3-24 CM3-24 VR-7 ——— ——— ——— ———
17 18 WHITE ACT-2 CF1-13 CM1-13 TB1-17-2 TB1-17-1 GC-6 ——— ——— 86 16 WHITE R1-MAX CF3-25 CM3-25 VR-6 ——— ——— ——— ———
18 18 RED MP-1 CF1-14 CM1-14 TB1-18b-2 TB1-18b-1 SS-3 ——— ——— 87 16 GRAY PTB2-10 XDR-11 ——— ——— ——— ——— ——— ———
19 18 BLACK MP-2 CF1-15 CM1-15 TB1-19-2 TB1-19-1 SS-4 ——— ——— 88 16 GRAY F2-3 TDM-1 ——— ——— ——— ——— ——— ———
SH 18 CM1-20 TB1-20-1 TB1-20-2 SS-G NOTE: ENCOMPASSES 18, 19 ——— 89 16 GRAY K7-6 TDM-2 ——— ——— ——— ——— ——— ———
20 16 GRAY K7-12 CM2-7 CF2-7 ——— ——— ——— ——— ——— 90 12 GREEN TB2-4-1 GB-1 ——— ——— ——— ——— ——— ———
22 16 WHITE TB1-22-1 GC-2 ——— ——— ——— ——— ——— ——— 91 16 GREEN TB2-4-2 CT1-X2 ——— ——— ——— ——— ——— ———
23 16 GRAY SW2-1 SW3-11 ——— ——— ——— ——— ——— ——— 92 16 GREEN TB2-5-2 CT2-X2 ——— ——— ——— ——— ——— ———
24 16 GRAY S2-2 I1 S2-2 I2 ——— ——— ——— ——— 93 16 GREEN TB2-6-2 CT3-X2 ——— ——— ——— ——— ——— ———
25 16 GRAY S3-9 I 3-3 S3-9 I 4-3 S3-9 I 5-3 ——— ——— 94 16 GRAY F1-3 XDR-2 ——— ——— ——— ——— ——— ———
26 16 GRAY M7 (+) CF2-8 CM2-8 K7-5 ——— ——— ——— ——— 95 16 GRAY F3-3 XDR-8 ——— ——— ——— ——— ——— ———
28 16 GRAY SS-12 K6-8 ——— ——— ——— ——— ——— ——— 96 16 GRAY F8-1 CM4-1 CF4-1 J5-B ——— ——— ——— ———
29 16 GRAY FP CF1-16 CM1-16 TB1-21-2 TB1-21B-1 K6-4 ——— ——— 97 16 GRAY BC-L F8-3 ——— ——— ——— ——— ——— ———
29B 16 GRAY TB1-21b-2 CM2-31 CF2-31 SW5-1 ——— ——— ——— ——— 98 16 GRAY PTB-10 CM4-2 CF4-2 J5-C ——— ——— ——— ———
30 16 GRAY S3-6 M8 (I) S3-6 M6 (I) ——— ——— ——— ——— 99 16 GRAY F8-2 CM3-1 CF3-1 I 10-2 ——— ——— ——— ———
31 14 GRAY S3-6 M5 (I) ——— ——— ——— ——— ——— ——— 106 16 GRAY CB1-2 CM3-3 CF3-3 I 6-2 ——— ——— ——— ———
32 16 GRAY SS-11 K5-6 ——— ——— ——— ——— ——— ——— 108 12 WHITE PTB2-8 CM4-3 CF4-3 J2-N ——— ——— ——— ———
34 16 GRAY K4-11 CM2-9 CF2-9 I 3-2 ——— ——— ——— ——— 109 12 WHITE PTB2-8 CM4-4 CF4-4 J3-N ——— ——— ——— ———
35 16 GRAY K5-11 CM2-10 CF2-10 I 4-2 ——— ——— ——— ——— 110 6 WHITE PTB2-8 CM4-5 CF4-5 CAPPED ——— ——— ——— ———
36 16 GRAY K6-11 CM2-11 CF2-11 I 5-2 ——— ——— ——— ——— 111 6 BLACK PTB1-L1 CB5-2 ——— ——— ——— ——— ——— ———
37 14 GRAY BC (-) TB1-22b-1 ——— ——— ——— ——— ——— ——— 112 6 RED PTB1-L2 CB5-4 ——— ——— ——— ——— ——— ———
38 16 GRAY S2 (-) M9 (I) ——— ——— ——— ——— ——— ——— 113 6 BLUE PTB2-L3 CB5-6 ——— ——— ——— ——— ——— ———
39 14 GRAY M9 (S) BC (+) ——— ——— ——— ——— ——— ——— 114 12 GREEN J2-G CM4-6 CF4-6 GB-3 ——— ——— ——— ———
40 16 GRAY K6-9 CM2-13 CF2-13 M8 (G) ——— ——— ——— ——— 115 12 GREEN J3-G CM4-7 CF4-7 GB-5 ——— ——— ——— ———
41 16 GRAY M6 (G) M8 (G) ——— ——— ——— ——— ——— ——— 116 16 GRAY CB2-2 CM3-5 CF3-5 I 7-2 ——— ——— ——— ———
44 16 GRAY M5 (G) M6 (G) M6 (G) M7 (-) ——— ——— ——— ——— 117 16 GRAY PTB2-12 CM3-6 CF3-6 I 6-1 I 7-1 I 8-1 I 9-1 I 10-1
45 16 GRAY M6 (G) I 3-1 ——— ——— ——— ——— ——— ——— 118 6 GREEN GB-9 CM4-7 CF4-7 CAPPED ——— ——— ——— ———
46 16 GRAY M8 (G) I 4-1 ——— ——— ——— ——— ——— ——— 119 12 GREEN GB-11 CM4-9 CF4-9 J5-B ——— ——— ——— ———
47 16 GRAY M8 (G) I 5-1 ——— ——— ——— ——— ——— ——— 126 16 GRAY CB3-2 CM3-7 CF3-7 I 8-2 ——— ——— ——— ———
48 16 BLACK TB1-48-2 CM1-17 CF1-17 GEN (+) ——— ——— ——— ——— 128 16 GRAY CB4-2 CM3-8 CF3-8 I 9-2 ——— ——— ——— ———
49 16 WHITE TB1-49-2 CM1-18 CF1-18 GEN (-) ——— ——— ——— ——— 131 6 BLACK CB1-1 PTB1-2 ——— ——— ——— ——— ——— ———
50 16 GRAY K4S-3 CM1-24 CF1-24 CM2-36 CF2-36 K4S-3 ——— ——— 132 6 RED CB1-3 PTB1-8 ——— ——— ——— ——— ——— ———
50A 16 GRAY M1 (+) INST. DOOR ——— ——— ——— ——— ——— ——— 133 6 BLUE CB1-5 PTB2-2
50B 16 GRAY M8 (G) SW8-1 ——— ——— ——— ——— ——— ——— 139 16 GRAY F9-1 PTB1-3 ——— ——— ——— ——— ——— ———
51 16 GRAY F1-1 CB5-1 ——— ——— ——— ——— ——— ——— 141 12 BLACK CB2-1 PTB1-1 ——— ——— ——— ——— ——— ———
52 16 GRAY F2-1 CB5-3 ——— ——— ——— ——— ——— ——— 142 12 RED CB3-1 PTB1-7 ——— ——— ——— ——— ——— ———
53 16 GRAY F3-1 CB5-5 ——— ——— ——— ——— ——— ——— 145 12 BLACK CB2-2 CM4-10 CF4-10 J2-L ——— ——— ——— ———
57 16 BLACK TB2-1-2 CT1-X1 ——— ——— ——— ——— ——— ——— 146 12 RED CB3-2 CM4-11 CF4-11 J3-L ——— ——— ——— ———
58 16 RED TB2-2-3 CT2-X1 ——— ——— ——— ——— ——— ——— 149 16 GRAY F9-3 CM3-9 CF3-9 I 6-3 I 7-3 I 8-3 I 9-3 I 10-3
59 16 BLUE TB2-3-2 CT3-X1 ——— ——— ——— ——— ——— ——— 151 6 BLACK CB4-1 PTB1-4 ——— ——— ——— ——— ——— ———
67 16 GRAY SW1-14 CF2-14 CM2-14 XDR-3 ——— ——— ——— ——— 152 6 RED CB4-3 PTB1-10 ——— ——— ——— ——— ——— ———
68 16 GRAY SW1-20 CF2-15 CM2-15 CDR-6 ——— ——— ——— ——— 153 6 BLUE CB4-5 PTB2-4 ——— ——— ——— ——— ——— ———
69 16 GRAY SW1-16 CF2-16 CM2-16 XDR-9 ——— ——— ——— ———
Figure FO-10. Wire List
Genset
Sheet 1 of 2
FP-27/FP-28 blank
TM 11-6115-742-13&P
# GAGE COLOR TO FROM TO FROM TO FROM TO FROM # GAGE COLOR TO FROM TO FROM TO FROM TO FROM
200 16 GRAY F3-2 F7-2 ——— ——— ——— ——— ——— ——— 328 16 GRAY BC-N PTB2-10 ——— ——— ——— ——— ——— ———
201 16 GRAY K7-8 K4-2 ——— ——— ——— ——— ——— ——— 333 12 GREEN BC-GND GB-3 ——— ——— ——— ——— ——— ———
202 16 GRAY K7-14 K6-6 ——— ——— ——— ——— ——— ——— 334 16 GRAY ——— ——— ——— ——— ——— ——— ——— ———
203 16 GRAY K4-7 K4-1 ——— ——— ——— ——— ——— ———
204 16 GRAY K4-4 K5-4 ——— ——— ——— ——— ——— ———
205 16 GRAY K4-7 K5-7 ——— ——— ——— ——— ——— ———
206 16 GRAY K4-3 K4-10 ——— ——— ——— ——— ——— ——— # GAGE COLOR TO FROM TO FROM TO FROM TO FROM
207 16 GRAY K4-12 K5-9 ——— ——— ——— ——— ——— ——— 401 RED CB-1 K4S-1 ——— ——— ——— ——— ——— ———
208 16 GRAY K5-1 K6-1 ——— ——— ——— ——— ——— ——— 402 RED K4S-4 FLH-1 ——— ——— ——— ——— ——— ———
209 16 GRAY K5-8 K6-7 ——— ——— ——— ——— ——— ——— 403 RED BAT 1 (+) CB-2 ——— ——— ——— ——— ——— ———
210 16 GRAY K5-3 K5-10 ——— ——— ——— ——— ——— ——— 404 RED BAT 1 (+) STR-2 ——— ——— ——— ——— ——— ———
211 16 GRAY K5-12 K6-12 ——— ——— ——— ——— ——— ——— 406 BLACK BAT 2(-) EBGL ——— ——— ——— ——— ——— ———
212 16 GRAY K6-3 K6-10 ——— ——— ——— ——— ——— ——— 407 GREEN FLH-2 EBGL ——— ——— ——— ——— ——— ———
213 16 GRAY SS-1 SS-12 ——— ——— ——— ——— ——— ——— 408 GREEN K4S-2 EBGL ——— ——— ——— ——— ——— ———
214 16 GRAY SS-2 SS-G ——— ——— ——— ——— ——— ———
409 GREEN WEB-2 EBGL ——— ——— ——— ——— ——— ———
217 6 GREEN PTB2-N GB-15 ——— ——— ——— ——— ——— ———
410 GREEN GB-6 GB-8 ——— ——— ——— ——— ——— ———
218 6 GREEN GB-13 GGL-GND ——— ——— ——— ——— ——— ———
SH —— GB-2 GGL-GND NOTE: ENCOMPASSES 218, 247, 248, 249, 250 ——— 424 RED S6-2 S8-2 ——— ——— ——— ——— ——— ———
219 10 GREEN GB-L2 CHASSIS ——— ——— ——— ——— ——— ——— 425 GRAY S6-1 S8-1 ——— ——— ——— ——— ——— ———
220 6 GREEN GB-16 J1-G ——— ——— ——— ——— ——— ——— 426 GRAY S8-4 S8-3 ——— ——— ——— ——— ——— ———
SH —— J1-BOLT CB-4 NOTE: ENCOMPASSES 220, 221, 226, 228, 230 ———
221 6 BLK#4 PTB2-11 J1-N ——— ——— ——— ——— ——— ———
225 2 BLACK J6-2 BATT 2(-) ——— ——— ——— ——— ——— ———
226 2 RED J6-1 BATT 1(-) ——— ——— ——— ——— ——— ———
227 16 GRAY TB1-2b-2 TB1-22-2 ——— ——— ——— ——— ——— ———
228 6 BLK#1 CB1-2 J1-A ——— ——— ——— ——— ——— ———
229 6 BLK#2 CB1-4 J1-B ——— ——— ——— ——— ——— ——— # GAGE COLOR TO FROM
230 6 BLK#3 CB1-6 J1-C ——— ——— ——— ——— ——— ——— BK BLACK WEB-X1-1 S6-3
231 10 GREEN K2S-2 EBGL ——— ——— ——— ——— ——— ——— GN GREEN WEB-X1-5 S6-4
232 10 GREEN ALT-3 EBGL ——— ——— ——— ——— ——— ——— RD RED FSB-F S6-2
233 16 BLACK TB1-18-1 GC-8 ——— ——— ——— ——— ——— ——— RD2
234 16 WHITE TB1-19B- GC-4 ——— ——— ——— ——— ——— ——— RD1 RED K3S
RD3
1
RD2 RED FSB-B RD1
235 14 GRAY GP K3S-1 ——— ——— ——— ——— ——— ———
RD3 RED FSB-E RD1
236 16 GRAY TB1-21-1 GC-1 ——— ——— ——— ——— ——— ———
RD4 RED FSB-A WEB-X2-1
237 16 BLACK VR-F+ TB1-48-1 ——— ——— ——— ——— ——— ———
238 16 WHITE VR-F- TB1-49-1 ——— ——— ——— ——— ——— ——— YL YELLOW FSB-C WEB-X1-2
239 16 GRAY XDR-1 TB2-1-1 ——— ——— ——— ——— ——— ——— BR BROWN 409 WEB-X2-2
240 16 GRAY XDR-4 TB2-2-1 ——— ——— ——— ——— ——— ——— BR1 BROWN 409 FP-2
241 16 GRAY XDR-7 TB2-3-1 ——— ——— ——— ——— ——— ——— BL BLUE FP WEB-X1-6
242 14 GRAY TB1-2-1 SS-2 ——— ——— ——— ——— ——— ———
243 10 RED K2S-1 STR-1 ——— ——— ——— ——— ——— ———
244 8 RED K2S-4 STR-2 ——— ——— ——— ——— ——— ———
245 14 GRAY K2S-4 K3S-4 ——— ——— ——— ——— ——— ———
246 16 GRAY K2S-2 K3S-2 ——— ——— ——— ——— ——— ———
247 6 BLK#4 PTB2- GEN-T4 ——— ——— ——— ——— ——— ———
TP4
248 6 BLK#1 CB5-1 GEN-T7 ——— ——— ——— ——— ——— ———
249 6 BLK#2 CB5-3 GEN-T8 ——— ——— ——— ——— ——— ———
250 6 BLK#3 CB5-5 GEN-T9 ——— ——— ——— ——— ——— ———
251 6 GREEN GB-7 J4-G ——— ——— ——— ——— ——— ———
252 6 BLACK CB4-2 J4-A ——— ——— ——— ——— ——— ———
253 6 RED CB4-4 J4-B ——— ——— ——— ——— ——— ———
254 6 BLUE CB4-6 J4-C ——— ——— ——— ——— ——— ———
255 6 WHITE PTB2-9 J4-N ——— ——— ——— ——— ——— ———
Figure FO-10. Wire List
Genset
Sheet 2 of 2
FP-29/FP-30 blank
TM 11-6115-742-13&P
4 1
10 9 8 1
8 5
26 20 15 14
12 9
39 36 35 34
16 13
69 68 67 40
1 2
3 1 3 1
3 4
20 17
76 73 72 71
106 99 108 98 96 5 6
1 6 4 6 4
7 8 1 2
4 24 21
1 2 7 8 117 116 114 110 109 9 10 3 4
85 82 81 80
5 9
9 7 9 7
11 12 1 2 5 6
9 10 11 12 13 28 25
149 128 126 119 118 115 13 14 3 4 7 8
10 15 86
14 15 16 17 18 19 15 16 9 10
32 29
12 10 12 10 Sw2
16 20 146 145 17 18 PANEL 11 12
29B 1B
29 48 49 SH LIGHT
19 20
21 24 36 33
15 13 15 13
Sw3
BK RD GN 50 50 GN RD BK
Sw1 ENGINE
VOLTMETER/AMMETER
CM1 CM2 CM3 CM4
COMBO
MALE CONNECTOR MALE CONNECTOR MALE CONNECTOR MALE CONNECTOR
(FRONT VIEW) (FRONT VIEW) (FRONT VIEW) (FRONT VIEW)
2
4 3
1
1 2
Sw5 Sw8 Sw6 1 2
BATTLE SWITCH ENGINE
SHORT HOT LINE HEATER
10
11
12
13
14
15
16
17
18
18
19
19
20
20
21
21
22
22
47
48
49
1
1
2
2
3
4
5
6
7
8
9
1
2
3
4
5
6
SWITCH Sw7 Sw9
EMERGENCY BATTLE
STOP SHORT
TB1 TB2 1 4
1 8 9 10
5 8
14 15 20 26
9 12
34 35 36 39
13 16
INDICATES JUMPERS 40 67 68 69
4 1
17 20 8 7 2 1
9 5
TERMINAL BLOCKS 71 72 73 76
13 12 11 10 9
21 24 15 10
80 81 82 85 19 18 17 16 15 14
BARRIER PANEL 25
86
28 20
SH
24
50 GN
49
RD
48
BK
29
21
16
29 32
1B 29B
33 36
BK RD GN 50
CF1
FEMALE CONNECTOR
(FRONT VIEW)
CF2
FEMALE CONNECTOR
(FRONT VIEW)
ENGINE HARNESS
CONTROL PANEL
Figure FO-11. Genset Connectors
Sheet 1 of 2
FP-31/FP-32 Blank
TM 11-6115-742-13&P
1 3
99 106
4 6
116 117 N A
7 9
126 128 149
10 12
B C
G
13 15
CF3
FEMALE CONNECTOR J1 & J4
(FRONT VIEW)
(-)
1 33
L
96 98 108
4 6 N G
109 110 114
7 9
115 118 119
10 12
145
13
146 147
15 J6 (+) J2 & J3
CF4
FEMALE CONNECTOR
(FRONT VIEW)
C A
J5
POWER DISTRIBUTION PANEL
Figure FO-11. Genset Connectors
Sheet 2 of 2
FP-33/FP-34 Blank
TM 11-6115-742-13&P
X1
X9 CONTROL
F1 RED
A 2
F2 RED BLACK
1 _1 _
X5 2
3 _1 _
X4 2
4 \1
X3
BLACK
2\
+ GREEN
5
!1
6 X2 !2
X6
- 3 4
X1
10
20 04
30
05
06
2
2 1
BLUE
X2
BROWN
1 2 1 2 1 2
X7
BROWN
1 X3 X4 X5
RED
BROWN
M M
2
Y1 E B2
HEATER
RED
BROWN
B2 TEMPERATURE SENSOR
E CERAMIC IGNITER/FLAME SENSOR
F1 FUSE 15 Amp.
F2 FUSE 5 Amp.
M1 COMBUSTION AIR FAN
BROWN M2 COOLANT CIRCULATION PUMP
X1 CONNECTOR - 6 WAY
X2 CONNECTOR - 2 WAY
X3 CONNECTOR - 2 WAY
X4 CONNECTOR - 2 WAY
X5 CONNECTOR - 2 WAY
X6 ON/OFF SWITCH
X7 CONNECTOR - 2 WAY
X8 CONNECTOR - 12 WAY
X9 CONNECTOR - 1 WAY
Y1 FUEL PUMP
A COMPUTER DIAGNOSTICS
DOWNLOAD LINK
Figure FO-12. Schematic
Hydronic Heater
FP-35/FP-36 Blank
TM 11-6115-742-13&P
E
D NOT USED
NOT USED NOT USED D
E D E E
D
D
E
D D
C
J A
K B E RH SIDE
H
N L
F
C
F M
J
E D
L
A D
E D E D B E F
NOT USED NOT USED LH SIDE
D E D E E D D E
A 24-484
D
B 24-461 E
C 24-483 C
D
D 90 D
FROM TO E
(Vehicle (Tail-light E 21-489 E
connector) connections)
F 23 F
A LH Black-Out
B LH Signal
J 22-460 J
C RH Black-Out
D Ground
E Stop Lights L 90
F Black-Out Stop L
H Not Used H N/C
J RH Signal
K Not Used K N/C
L Ground
M Not Used M N/C
N Not Used
N N/C
D E D E F E D B A
Figure FO-13. Wiring Diagram
Inter-Vehicular cable (LED)
FP-37/FP-38 Blank
TM 11-6115-742-13&P
J A
K B D A
H
RH
N L
C B
C
F M
E D
D A
C B
LH
RED-GRN
A 24-484
RED-WHT
B 24-461
RED-BLK
C 24-483 A
Cable Assembly/Stop Light (Incandescent) Connections
BLK-GRN
FROM CIRCUIT TO TO LH TO RH D 90
(Vehicle NUMBER (Tail-light (Tail-light (Tail-light
RED
connector) connections) connections) connections) E 21-489 B
A BLK-RED RIGHT
A 24-484 LH Black-Out
F 23 C
B 24-461 LH Signal B
C 24-483 RH Black-Out A BLK-WHT
J 22-460 D
D 90 Ground
E 21-489 Stop Lights C B BLK
F 23 Black-Out Stop D C L 90
H N/C Not Used
J 22-460 RH Signal D H N/C
K N/C Not Used
L 90 Ground K N/C D C B A
M N/C Not Used
N N/C Not Used M N/C LEFT
N N/C
Figure FO-14. Schematic
Wiring Diagram
Inter-Vehicular cable (Incandescent)
FP-39/FP-40 Blank
TM 11-6115-742-13&P
99-110-2
+ -
+ - + - + - + -
106
116 117
126 128
Figure FO-15. Schematic
Genset Power Distribution Panel
New Version (with EMI)
FP-41/FP-42 Blank
TM 11-6115-742-13&P
99-110-2
+ -
+ - + - + - + -
106
116 117
126 128
Figure FO-16. Schematic
Genset Power Distribution Panel
New Version (without EMI)
FP-43/FP-44 Blank
PIN: 085180-000
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