1006313, Dhs Tmss Med

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TECHNICAL MANUAL

OPERATOR AND FIELD MAINTENANCE MANUAL

INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST

FOR

Trailer Mounted Support System - MEDIUM

System Part Numbers: TMSS100G, Green NSN: 8340-01-533-5396 TMSS100T, Tan, NSN: 8340-01-533-5344

33 Kings Highway

,

Orangeburg, NY 10962

Phone: 845-359-6066 Fax: 845-365-2114 Hotline: 800-977-3647

TECH MANUAL PART NUMBER: 1006313 Web:

www.drash.com

11 NOV 09 E

mail: [email protected]

This document contains information proprietary to DHS Technologies LLC and its subsidiaries and is intended solely for use by its customers. No portion of this document may be reproduced for release to a third party without written consent of DHS Technologies LLC.

ISO 9001: 2000 Registered

Quality Management System

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Part Number 1006313 a DHS Systems LLC

This document contains information proprietary to DHS Systems LLC and is intended solely for use by its customers. No portion of this document may be reproduced release to a third party without written consent of DHS Systems LLC.

SAFETY STEPS TO FOLLOW IF SOMEONE IS

VICTIM OF ELECTRICAL SHOCK.

SEND FOR HELP AS SOON AS POSSIBLE.

DO NOT TRY TO PULL OR GRAB INDIVIDUAL.

IF POSSIBLE, TURN OFF ELECTRICAL POWER.

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.

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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Part Number 1006313 b DHS Systems LLC

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.

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Part Number 1006313 c DHS Systems LLC

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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Part Number 1006313 d DHS Systems LLC

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: Handling Function One-Person Max. Lift Two-Person Max. Lift Two-Person Max. Lift (Male Only) Lift object from floor and place it on surface not

greater than 5 feet above floor.

37 lb. 74 lb. 112 lb.

Lift object from floor and place it on surface not greater than 3 feet above floor.

44 lb. 88 lb. 174 lb.

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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Part Number 1006313 e DHS Systems LLC

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.

WARNING

SERIOUS INJURY OR DEATH CAN RESULT IF THE FOLLOWING ARE NOT CAREFULLY OBSERVED WHEN INSTALLING AND USING THE ANTENNAS USED

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Part Number 1006313 f DHS Systems LLC

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.

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Part Number 1006313 g DHS Systems LLC

ESD

CLASS 1

GENERAL HANDLING PROCEDURES FOR ESD ITEMS

• USE WRIST GROUND STRAPS OR MANUAL GROUNDING PROCEDURES.

• PERIODICALLY CHECK CONTINUITY AND RESISTANCE OF GROUNDING SYSTEM.

• KEEP ESD ITEMS IN PROTECTIVE COVERING WHEN NOT IN USE.

• USE ONLY METALIZED SOLDER SUCKERS.

• GROUND ALL ELECTRICAL TOOLS AND TEST EQUIPMENT.

• HANDLE ESD ITEMS IN PROTECTED AREAS ONLY.

MANUAL GROUNDING PROCEDURES

• MAKE CERTAIN EQUIPMENT IS POWERED DOWN.

• TOUCH PACKAGE OR

REPLACEMENT ESD ITEM TO GROUND BEFORE OPENING.

• TOUCH GROUND PRIOR TO REMOVING ESD ITEMS.

• TOUCH GROUND PRIOR TO 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.

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Part Number 1006313 h DHS Systems LLC

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. When using LiSO2 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.

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Part Number 1006313 i DHS Systems LLC

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

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Part Number 1006313 j DHS Systems LLC

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

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Part Number 1006313 k DHS Systems LLC

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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Part Number 1006313 l DHS Systems LLC

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.

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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.

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

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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.

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.

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Part Number 1006313 c DHS Systems LLC

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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Part Number 1006313 d DHS Systems LLC

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.

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.

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.

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.

CAUTION

Do not overfill reservoir. Space must be allowed for the expansion of the heated coolant or overheating will result.

CAUTION

When the following step is being performed, do not force low oil pressure cut-off switch or cross thread. Failure to observe this caution can result in damage to the engine.

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.

CAUTION

Cut end of air intake is extremely sharp. Exercise care to prevent injury.

CAUTION

If heater has been operating exhaust may be extremely hot. Allow time to cool before removing.

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.

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CAUTION

Do not damage trailer cargo cross-member or tail light assemblies.

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.

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.

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.

CAUTION

Always disconnect battery ground cable (black) from battery ground terminal ground when conducting any procedures on the TMSS-MED Genset.

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.

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.

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.

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.

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.

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CAUTION

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.

CAUTION

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A LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: Zero in the “Change No.” column indicates an original page or work package. Date of issue for the original manual is:

Original: 15 October 2008

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 120 AND TOTAL NUMBER OF WORK PACKAGES IS 165, CONSISTING OF THE FOLLOWING:

Page/WP No. Change No. Page/WP No. Change No.

Front Cover 0 WP 0026 (8 pgs) 0

Blank 0 Chp 5 title page 0

Warning summary (16 pgs) 0 Blank 0

i – xxx 0 WP 0027 (4 pgs) 0 Chp 1 title page 0 WP 0028 (10 pgs) 0 Blank 0 WP 0029 (4 pgs) 0 WP 0001 (6 pgs) 0 WP 0030 (4 pgs) 0 WP 0002 (10 pgs) 0 WP 0031 (22 pgs) 0 WP 0003 (22 pgs) 0 WP 0032 (4 pgs) 0 Chp 2 title page 0 WP 0033 (2 pgs) 0 Blank 0 WP 0034 (2 pgs) 0 WP 0004 (10 pgs) 0 Chp 6 title page 0 WP 0005 (46 pgs) 0 WP 0035 (2 pgs) 0 WP 0006 (12 pgs) 0 WP 0036 (2 pgs) 0 WP 0007 (2 pgs) 0 WP 0037 (6 pgs) 0 WP 0008 (12 pgs) 0 WP 0038 (4 pgs) 0 WP 0009 (4 pgs) 0 WP 0039 (4 pgs) 0 Chp 3 title page 0 WP 0040 (6 pgs) 0 Blank 0 WP 0041 (6 pgs) 0 WP 0010 (2 pgs) 0 WP 0042 (4 pgs) 0 WP 0011 (4 pgs) 0 WP 0043 (10 pgs) 0 WP 0012 (8 pgs) 0 WP 0044 (14 pgs) 0 WP 0013 (4 pgs) 0 WP 0045 (6 pgs) 0 WP 0014 (4 pgs) 0 WP 0046 (4 pgs) 0 WP 0015 (4 pgs) 0 WP 0047 (8 pgs) 0 WP 0016 (2 pgs) 0 WP 0048 (12 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 (6 pgs) 0 WP 0018 (2 pgs) 0 WP 0052 (4 pgs) 0 WP 0019 (12 pgs) 0 WP 0053 (4 pgs) 0 WP 0020 (6 pgs) 0 WP 0054 (4 pgs) 0 WP 0021 (4 pgs) 0 WP 0055 (4 pgs) 0 WP 0022 (8 pgs) 0 WP 0056 (4 pgs) 0 WP 0023 (6 pgs) 0 WP 0057 (4 pgs) 0 WP 0024 (6 pgs) 0 WP 0058 (16 pgs) 0 WP 0025 (6 pgs) 0 WP 0059 (10 pgs) 0

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B

LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued

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WP 0164 (2 pgs) 0 Inside back cover 0

WP 0165 (6 pgs) 0 Back cover 0 INDEX-1 – INDEX-16 0 FP-1 0 FP-2 blank 0 FP-3 0 FP-4 blank 0 FP-5 0 FP-6 blank 0 FP-7 0 FP-8 blank 0 FP-9 0 FP-10 blank 0 FP-11 0 FP-12 blank 0 FP-13 0 FP-14 blank 0 HEADQUARTERS DEPARTMENT OF THE ARMY

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WASHINGTON, D.C., 15 October 2008

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 N/A) PU-822A/T (NSN 6115-01-547-6738) (EIC N/A)

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.monmouth.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 Life Cycle Management Command (CECOM LCMC) and Fort Monmouth, ATTN: AMSEL-LC-LEO-E-ED, Fort Monmouth, NJ 07703-5006. The fax number is 732-532-3421, DSN 992-3421.

In any case, we will send you a reply.

This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Army of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

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 1 January 2007. Other requests for this document will be referred to Commander, U.S. Army Communications-Electronics Life Cycle Management Command (CECOM LCMC) and Fort Monmouth, ATTN: AMSEL-LC-LEO-E-ED, Fort Monmouth, New Jersey 07703-5006.

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.

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TABLE OF CONTENTS

WP Sequence No. Page No.

How to Use This Manual xxvi

Chapter 1 – General Information, Equipment Description, and Theory of Operation for TMSS-MED

General Information... WP 0001 Figure 1. TMSS-MED System Configuration... 0001-1

Table 1. Nomenclature Cross-Reference List ... 0001-3 Table 2. Abbreviation/Acronym List ... 0001-4

Equipment Description and Data ... 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 Figure 4. TMSS-MED Genset... 0002-4 Figure 5. TMSS-MED ECU... 0002-5 Figure 6. TMSS-MED Cargo Bay ... 0002-5 Figure 7. TMSS-MED Chassis ... 0002-6 Figure 8. TMSS-MED PDU... 0002-6 Figure 9. TMSS-MED Tent Lighting Set... 0002-7

Theory of Operation ... WP 0003 Figure 1. Genset Fault System... 0003-3

Figure 2. Fuel System ... 0003-5 Figure 3. Engine Heater Flow Diagram ... 0003-6 Figure 4. Engine Coolant System... 0003-7 Figure 5. Engine Lubrication System ... 0003-8 Figure 6. Output Supply System... 0003-10 Figure 7. Barrier Panel Component Location ... 0003-11 Figure 8. Governor Control System... 0003-12 Figure 9. Battery Charging System ... 0003-13

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TABLE OF CONTENTS – Continued

Theory of Operation – Continued ...WP 0003 Figure 10. ECU (Version 1) Control Panel Component Location ...0003-15

Figure 11. Power Distribution/Fault System (Version 1)...0003-16 Figure 12. ECU (Version 2) Control Panel Component Location ...0003-17 Figure 13. Power Distribution/Fault System (Version 2)...0003-18 Chapter 2 – Operator Instructions for TMSS-MED

Description and Use of Operator Controls, Indicators, and Connectors ...WP 0004 Figure 1. Genset Control Panel (Top Panel) – Controls, Indicators,

and Connectors...0004-1 Table 1. Genset Control Panel (Top Panel) – Controls, Indicators,

and Connectors...0004-1 Figure 2. Genset Control Panel (Bottom Panel) – Controls,

Indicators, and Connectors...0004-3 Table 2. Genset Control Panel (Bottom Panel) – Controls,

Indicators, and Connectors...0004-3 Figure 3. Power Distribution Panel – Controls, Indicators, and

Connectors...0004-4 Table 3. Power Distribution Panel – Controls, Indicators, and

Connectors...0004-4 Figure 4. Fuel Control Panel – Controls, Indicators, and Connectors ...0004-5 Table 4. Fuel Control Panel – Controls, Indicators, and Connectors ...0004-5 Figure 5. Fuel Gauge – Controls, Indicators, and Connectors ...0004-6 Table 5. Fuel Gauge – Controls, Indicators, and Connectors ...0004-6 Figure 6. ECU Control Panel – Controls, Indicators, and Connectors...0004-7 Table 6. ECU Control Panel – Controls, Indicators, and Connectors...0004-7 Figure 7. PDU Control Panel – Controls, Indicators, and Connectors...0004-9 Table 7. PDU Control Panel – Controls, Indicators, and Connectors...0004-9

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Operation Under Usual Conditions ... WP 0005 Figure 1. TMSS-MED System Deployment Footprint ... 0005-1

Figure 2. Shelter Site Dimensions ... 0005-2 Figure 3. Correct Trailer Operating Positions... 0005-3 Figure 4. Wheel/Skid Plate Assembly Mounting Positions... 0005-4 Figure 5. Wheel Chocks ... 0005-5 Figure 6. Remove the Crossbar ... 0005-7 Figure 7. Remove and Position Shelter End Caps... 0005-8 Figure 8. Lower Shelter Transport Bag to Ground ... 0005-9 Figure 9. Expand and Lift Shelter ... 0005-10 Figure 10. Red Flag Locations ... 0005-11 Figure 11. Shelter Resting on Four Push Poles ... 0005-11 Figure 12. Position of Additional Red Flagged Keepers ... 0005-12 Figure 13. Position End Caps Next to Center Section ... 0005-13 Figure 14. Secure End Cap Frame to Center Section Frame ... 0005-13 Figure 15. Secure End Cap Covers to Center Section Covers ... 0005-14 Figure 16. Shelter in Erected Position... 0005-15 Figure 17. Shelter Lift Locations... 0005-16 Figure 18. Attach Floor to Shelter... 0005-17 Figure 19. Shelter Installation Complete ... 0005-18 Figure 20. Connect Ducts to Shelter ... 0005-19 Figure 21. Typical Shelter Lighting Arrangement ... 0005-20 Figure 22. Location of PDU with Respect to Trailer and Shelter... 0005-22 Figure 23. Location of Fuel Control Panel... 0005-24 Figure 24. Aux Fuel Lines to External Fuel Supply ... 0005-25 Figure 25. Tie Back Doorways ... 0005-31

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Operation Under Usual Conditions – Continued ...WP 0005 Figure 26. Grip Shelter by Hubs ...0005-32

Figure 27. Secure First Cinch Strap...0005-34 Figure 28. Roll Up Shelter with Floor ...0005-34 Figure 29. Ready for Assisted Lift of Shelter ...0005-35 Figure 30. Lift Transport Bag ...0005-35 Figure 31. Push Transport Bag onto Trailer...0005-36 Figure 32. Trailer Leveled and Secured...0005-37 Figure 33. Attach Trailer to Tow Vehicle...0005-38 Figure 34. Secure Tongue Jack Assembly ...0005-40 Figure 35. Trailer Safety Brake Lockout ...0005-41 Figure 36. Trailer Properly Chocked and Positioned on Transport

Trailer Deck...0005-44 Table 1. Weight of TMSS-MED Trailer ...0005-45 Figure 37. CG Tag Location on TMSS-MED Trailer ...0005-45 Figure 38. CG of TMSS-MED Trailer ...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 ...0008-1 Table 1. Identification and Data Plates on Trailer Rear...0008-1 Figure 2. Location of Identification and Data Plates on Trailer Curbside ....0008-2 Table 2. Identification and Data Plates on Trailer Curbside ...0008-2 Figure 3. Location of Identification and Data Plates on Trailer Front ...0008-3 Table 3. Identification and Data Plates on Trailer Front ...0008-3 Figure 4. Location of Identification and Data Plates on Trailer Roadside....0008-4 Table 4. Identification and Data Plates on Trailer Roadside ...0008-4

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Stowage and Decal/Data Plate Guide – Continued ... WP 0008 Figure 5. Location of Identification and Data Plates on ECU Front... 0008-5

Table 5. Identification and Data Plates on ECU Front ... 0008-5 Figure 6. Location of Identification and Data Plates on ECU Curbside

and Rear... 0008-6 Table 6. Identification and Data Plates on ECU Curbside and Rear ... 0008-6 Figure 7. Location of Identification and Data Plates on Genset Front ... 0008-7 Table 7. Identification and Data Plates on Genset Front ... 0008-7 Figure 8. Location of Identification and Data Plates on Genset Curbside .. 0008-8 Table 8. Identification and Data Plates on Genset Curbside ... 0008-8 Figure 9. Location of Identification and Data Plates on Genset Rear ... 0008-9 Table 9. Identification and Data Plates on Genset Rear... 0008-9 Figure 10. Location of Identification and Data Plates on Genset Control

Panel and Circuit Breaker Panel ... 0008-10 Table 10. Identification and Data Plates on Genset Control Panel and

Circuit Breaker Panel ... 0008-10 Figure 11. Location of Identification and Data Plates on Genset Control

Panel Access Door... 0008-11 Table 11. Identification and Data Plates on Genset Control Panel

Access Door ... 0008-12

On-Vehicle Equipment Loading Plan ... WP 0009 Figure 1. TMSS-MED Shelter Loading Plan... 0009-1

Table 1. TMSS-MED Shelter Loading Plan... 0009-1 Figure 2. TMSS-MED Trailer Loading Plan... 0009-2 Table 2. TMSS-MED Trailer Loading Plan... 0009-3 Chapter 3 – Operator Troubleshooting Procedures for TMSS-MED

Operator Troubleshooting Index ... WP 0010 Table 1. Operator Troubleshooting Index ... 0010-1

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ECU Troubleshooting Procedures ...WP 0011 Table 1. Operator Troubleshooting – ECU ...0011-2

Table 2. ECU Hydronic Heater Fault Codes...0011-4

Genset (Engine) Troubleshooting Procedures ...WP 0012 Table 1. Operator Troubleshooting – Genset (Engine) ...0012-2

Table 2. Engine Heater (Hydronic) Fault Codes...0012-7

Genset (Electrical) Troubleshooting Procedures ...WP 0013 Table 1. Operator Troubleshooting – Genset (Electrical) ...0013-2

Trailer Troubleshooting Procedures ...WP 0014 Table 1. Operator Troubleshooting – Trailer...0014-2

Shelter (Mechanical) Troubleshooting Procedures ...WP 0015 Table 1. Operator Troubleshooting – Shelter (Mechanical)...0015-2

Shelter (Electrical) Troubleshooting Procedures ...WP 0016 Table 1. Operator Troubleshooting – Shelter Lighting...0016-2

Chapter 4 – Operator Maintenance Instructions for TMSS-MED

Service Upon Receipt ...WP 0017 PMCS Introduction...WP 0018 PMCS...WP 0019

Table 1. Operator Preventive Maintenance Checks and Service...0019-1 Table 2. Operator Functional Checks and Services ...0019-12

ECU Control Panel Operator Maintenance...WP 0020 Figure 1. ECU Control Panel Lens Indicator and Mode Select Switch

Knob Removal/Replacement ...0020-3 Figure 2. ECU Heater (Hydronic) Coolant Reservoir ...0020-5

Genset – Bulbs and Covers Operator Maintenance...WP 0021 Figure 1. Control Panel Indicator Lights Removal/Replacement ...0021-4

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Operator Maintenance – Fluids ... WP 0022 Table 1. Engine Oil Recommendations... 0022-3

Figure 1. Oil Fill Tube and Dip Stick on Engine Location... 0022-3 Figure 2. Location of Radiator and Radiator Overflow Bottle... 0022-5 Figure 3. Master Brake Cylinder Service... 0022-7

Operator Maintenance – Electrical... WP 0023 Table 1. Normal Meter Reading for Battery ... 0023-3

Figure 1. Location of Connectors and Meters for 24 VDC Battery

Charging... 0023-4

Operator Maintenance – Shelter Cover Maintenance... WP 0024 Figure 1. Repair of Shelter Cover... 0024-3

Figure 2. Shelter Cover(s) Removal/Replace... 0024-6

Operator Maintenance – Shelter Strut Maintenance... WP 0025 Figure 1. Field Repair of Shelter Strut... 0025-3

Figure 2. Shelter Struts Removal/Replacement ... 0025-6

Operator Maintenance – Shelter Repair Using Field Repair Kit ... WP 0026 Figure 1. Shelter Keepers Removal/Replacement ... 0026-3

Figure 2. Shelter Main Hub(s) Removal/Replacement... 0026-5 Figure 3. Main Staking Bracket Removal/Replacement... 0026-7 Chapter 5 – Service Troubleshooting Procedures for TMSS-MED

Service Troubleshooting Index... WP 0027 Table 1. Service Troubleshooting Index... 0027-1

ECU (Electrical)/Hydronic Heater Troubleshooting Procedures ... WP 0028 Table 1. Service Troubleshooting – ECU/Hydronic Heater... 0028-2

Table 2. ECU Hydronic Heater Fault Codes ... 0028-8 Figure 1. Circuit Breaker Location for TMSS-MED ECU (Version 1) ... 0028-9 Figure 2. Circuit Breaker Location for TMSS-MED ECU (Version 2) ... 0028-9

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ECU (Heating & Cooling) Troubleshooting Procedures ...WP 0029 Table 1. Service Troubleshooting – ECU ...0029-2

Genset (Electrical) Troubleshooting Procedures ...WP 0030 Table 1. Service Troubleshooting – Genset (Electrical) ...0030-2

Genset (Engine) Troubleshooting Procedures ...WP 0031 Table 1. Service Troubleshooting – Genset (Engine)...0031-2

Figure 1. Solenoids ...0031-6 Figure 2. Flywheel Location in Speed Sensor Port...0031-9 Table 2. Engine Heater (Hydronic) Fault Codes...0031-21

Trailer (Electrical) Troubleshooting Procedures ...WP 0032 Table 1. Service Troubleshooting – Trailer (Electrical)...0032-2

Trailer (Mechanical) Troubleshooting Procedures...WP 0033 Table 1. Service Troubleshooting – Trailer (Mechanical) ...0033-2

Shelter (Electrical) Troubleshooting Procedures ...WP 0034 Table 1. Service Troubleshooting – Shelter (Electrical) ...0034-2

Chapter 6 – Service Maintenance Instructions for TMSS-MED

Service Upon Receipt ...WP 0035 PMCS Introduction...WP 0036 PMCS...WP 0037

Table 1. Service Preventive Maintenance Checks and Services ...0037-1

Service Maintenance Index ...WP 0038 ECU Access Panel Service Maintenance...WP 0039

Figure 1. ECU Access Panel Catch Removal/Replacement ...0039-3

ECU Condenser Coil and Grill Service Maintenance ...WP 0040 Figure 1. Condenser Coil Cleaning...0040-3

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ECU Evaporator Motor Belt Service Maintenance ... WP 0041 Figure 1. ECU Evaporator Motor Belt Adjustment... 0041-3

Figure 2. ECU Evaporator Motor Belt Removal/Replacement ... 0041-6

ECU Air Filter Service Maintenance... WP 0042 Figure 1. ECU Air Filter Locations ... 0042-3

ECU Duct Cover, Sliding Door, Evaporator Panel, Damper Service Maintenance ... WP 0043 Figure 1. ECU Duct Cover Removal/Replacement ... 0043-3

Figure 2. ECU Sliding Door Removal/Replacement... 0043-5 Figure 3. ECU Evaporator Panel Assembly Removal/Replacement... 0043-7 Figure 4. ECU Damper Assembly Removal/Replacement... 0043-9

ECU Hydronic Heater Service Maintenance ... WP 0044 Figure 1. Hydronic Heater Removal/Replacement... 0044-4

Figure 2. Hydronic Heater Fuel Pump and Fuel Filter

Removal/Replacement ... 0044-8 Figure 3. Hydronic Heater Hose Removal/Replacement ... 0044-11 Figure 4. Hydronic Heater Fuse Removal/Replacement... 0044-13

ECU Service Maintenance ... WP 0045 Figure 1. ECU Removal/Replacement ... 0045-5

Genset Access Panel Service Maintenance ... WP 0046 Figure 1. Genset Access Panel Latches Removal/Replacement... 0046-3

Genset Control Panel Bulbs, Covers and Fuse Service Maintenance ... WP 0047 Figure 1 Control Panel Latch Removal/Replacement ... 0047-3

Figure 2. Control Panel Indicator Lights Removal/Replacement ... 0047-5 Figure 3. Fuse Removal/Replacement... 0047-7

Genset Battery, Battery Fuse, Support Bracket, and Warmer Service Maintenance ... WP 0048 Figure 1. Battery Fuse Removal/Replacement ... 0048-3

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Genset Battery, Battery Fuse, Support Bracket, and Warmer Service

Maintenance – Continued...WP 0048 Figure 2. Battery, Retainer, and Mounting Bracket

Removal/Replacement ...0048-8 Figure 3. Battery Warmer Removal/Replacement ...0048-11

Genset Oil and Oil Filter Service Maintenance...WP 0049 Table 1. Engine Oil Recommendations ...0049-4

Figure 1. Oil and Filter Removal/Replacement ...0049-5

Genset Air Filter Service Maintenance ...WP 0050 Figure 1. Air Intake Filter Removal/Replacement ...0050-3

Genset Glow Plug and Glow Plug Connector Service Maintenance...WP 0051 Figure 1. Glow Plug/Connector Strip Removal/Replacement...0051-5

Genset Oil Pressure Switch Service Maintenance ...WP 0052 Figure 1. Oil Pressure Switch Removal/Replacement...0052-4

Genset Oil Pressure Sending Unit Service Maintenance ...WP 0053 Figure 1. Oil Pressure Sending Unit Removal/Replacement...0053-4

Genset Low Oil Pressure Cut-Off Switch Service Maintenance...WP 0054 Figure 1. Low Oil Pressure Cut-Off Switch Removal/Replacement ...0054-4

Genset Fuel Tank Service Maintenance...WP 0055 Figure 1. Genset Fuel Tank Drain Location ...0055-3

Genset Fuel Filter Service Maintenance...WP 0056 Figure 1. Fuel Filter Removal/Replacement ...0056-4

Genset Electric Fuel Pump Service Maintenance ...WP 0057 Figure 1. Electric Fuel Pump Removal/Replacement ...0057-4

Genset Fuel Injection System Service Maintenance ...WP 0058 Figure 1. Oil Dipstick Mount ...0058-3

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Genset Fuel Injection System Service Maintenance – Continued ... WP 0058 Figure 3. Fuel Injector Pump Removal/Replacement ... 0058-9

Figure 4. Fuel Injection System Lines Removal/Replacement... 0058-15

Genset Solenoid Service Maintenance ... WP 0059 Table 1. Electronic Connections for Genset Solenoids... 0059-3

Figure 1. K2 or K3 Solenoid Removal/Replacement... 0059-4 Figure 2. K4 Solenoid and Circuit Breaker Removal/Replacement ... 0059-7

Genset Starter Service Maintenance ... WP 0060 Figure 1. Starter Removal/Replacement ... 0060-4

Genset Diesel Speed Sensor Service Maintenance ... WP 0061 Figure 1. Diesel Speed Sensor Removal/Replacement... 0061-4

Genset Coolant Temperature Sensor Service Maintenance ... WP 0062 Figure 1. Coolant Temperature Sensor Removal/Replacement ... 0062-4

Genset Coolant Temperature Switch Service Maintenance ... WP 0063 Figure 1. Coolant Temperature Switch Removal/Replacement ... 0063-4

Genset Thermostat Service Maintenance... WP 0064 Figure 1. Thermostat Removal/Replacement... 0064-5

Genset Engine Coolant Service Maintenance ... WP 0065 Table 1. Radiator Coolant to Water Ratios ... 0065-4

Figure 1. Engine Coolant Removal/Replacement ... 0065-4 Figure 2. Engine Coolant Reservoir Bottle Removal/Replacement ... 0065-6

Genset Radiator Service Maintenance ... WP 0066 Figure 1. Radiator, Hoses, and Clamps Removal/Replacement... 0066-7

Genset Alternator Service Maintenance ... WP 0067 Figure 1. Alternator Removal/Replacement ... 0067-4

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Genset Fan Belt Service Maintenance ...WP 0068 Figure 1. Fan Belt Adjustment, Removal/Replacement...0068-5

Genset Fan Service Maintenance ...WP 0069 Figure 1. Fan Removal/Replacement ...0069-5

Genset Water Pump Service Maintenance...WP 0070 Figure 1. Water Pump Removal/Replacement ...0070-5

Genset Engine Heater (Hydronic) Service Maintenance...WP 0071 Figure 1. Engine Heater (Hydronic) Removal/Replacement...0071-5

Figure 2. Engine Heater (Hydronic) Fuel Pump and Fuel Filter

Removal/Replacement ...0071-10 Figure 3. Engine Heater (Hydronic) Hose Removal/Replacement ...0071-18 Figure 4. Engine Heater (Hydronic) Hose Fuse Removal/Replacement ...0071-20

Genset Exhaust System Service Maintenance ...WP 0072 Figure 1. Exhaust Flex Pipe, Elbow, and Muffler Removal/Replacement ...0072-7

Genset Exhaust Manifold Service Maintenance...WP 0073 Figure 1. Exhaust Manifold and Gasket Removal/Replacement ...0073-4

Torque Specifications Service Maintenance...WP 0074 Figure 1. Bolt Diameter and Thread Pitch...0074-1

Table 1. Component Torque Specifications...0074-2 Table 2. Flanged Head Bolt Torque Specifications ...0074-3 Table 3. Standard Bolt Torque Specifications ...0074-3 Table 4. Newton-Meters to Kilogram-Meters ...0074-4 Table 5. Kilogram-Meters to Foot Pounds ...0074-4 Table 6. Newton-Meters to Foot Pounds ...0074-5

Trailer Level, Safety Chain, and Tongue Jack Service Maintenance...WP 0075 Figure 1. Trailer Level Removal/Replacement...0075-2

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Trailer Level, Safety Chain, and Tongue Jack Service Maintenance – Continued... WP 0075 Figure 3. Tongue Jack Assembly Removal/Replacement ... 0075-5

Trailer Lift Sling Service Maintenance... WP 0076 Figure 1. Lift Sling Removal/Replacement ... 0076-3

Trailer Stabilizer Leg and Cargo Net Service Maintenance ... WP 0077 Figure 1. Stabilizer Leg Removal/Replacement ... 0077-4

Figure 2. Cargo Net Removal/Replacement ... 0077-6

Trailer Cargo Restraint Cage Service Maintenance ... WP 0078 Figure 1. Cargo Restraint Cage Removal/Replacement... 0078-4

Trailer Vehicle Stop Light and Inter-Vehicular Cable Service Maintenance ... WP 0079 Figure 1. Vehicle Stop Light, Lamp (Incandescent)

Removal/Replacement ... 0079-3 Figure 2. Vehicle Stop Light (Incandescent) Removal/Replacement... 0079-5 Figure 3. Vehicle Stop Light (LED) Removal/Replacement ... 0079-8 Figure 4. Inter-Vehicular Cable Removal/Replacement... 0079-12 Table 1. Cable Assembly/Stop Light (LED) Connections ... 0079-13 Figure 5. Inter-Vehicular Cable Connectors (Incandescent) ... 0079-13 Table 2. Cable Assembly/Stop Light (Incandescent) Connections ... 0079-13

Trailer Tire and Wheel Assembly Service Maintenance ... WP 0080 Figure 1. Wheel Assembly Removal/Replacement ... 0080-5

Shelter Lighting Service Maintenance... WP 0081 Figure 1. Fluorescent Lamp in Lighting Fixture Removal/Replacement ... 0081-3

Figure 2. Fuse in Lighting Fixture Removal/Replacement ... 0081-5 Chapter 7 – Field Support Troubleshooting Procedures for TMSS-MED

Field Support Troubleshooting Index ... WP 0082 Table 1. Field Troubleshooting Index... 0082-1

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ECU (Electrical)/Hydronic Heater Troubleshooting Procedures...WP 0083 Table 1. Field Troubleshooting – ECU (Electrical) ...0083-2

Figure 1. Hydronic (Auxiliary) Heater Circuit...0083-10 Table 2. MODE SELECT (Version 1) Switch Test...0083-13 Table 3. MODE SELECT (Version 2) Switch Test...0083-13 Table 4. Heater Contactor Measurements...0083-17 Table 5. CMSP/EMSP Voltage Inputs ...0083-19 Table 6. CMSP/EMSP Voltage Outputs ...0083-19 Table 7. CMSP/EMSP 28 VAC Outputs ...0083-20

ECU (Heating & Cooling)/Hydronic Heater Troubleshooting Procedures ...WP 0084 Table 1. Field Troubleshooting – ECU (Heating & Cooling) ...0084-2

Genset (Electrical) Troubleshooting Procedures ...WP 0085 Table 1. Field Troubleshooting – Genset (Electrical) ...0085-2

Figure 1. 12V Constant Voltage Test Hookup ...0085-23

Genset (Engine) Troubleshooting Procedures ...WP 0086 Table 1. Field Troubleshooting – Genset (Engine)...0086-2

Table 2. Engine Selector Switch Function ...0086-4 Figure 1. Genset Fault System ...0086-8 Table 3. Engine Heater (Hydronic) Fault Codes...0086-14

Trailer (Mechanical) Troubleshooting Procedures...WP 0087 Table 1. Field Troubleshooting – Trailer (Mechanical) ...0087-2

Chapter 8 – Field Maintenance Instructions for TMSS-MED

ECU Control Panel Door Field Maintenance ...WP 0088 Figure 1. ECU Control Panel Faceplate Components

Removal/Replacement ...0088-7 Figure 2. ECU Thermostat Removal/Replacement ...0088-10

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ECU Control Panel – Circuit Breakers Field Maintenance... WP 0089 Table 1. Circuit Breaker Connections/Wire ID Numbers... 0089-3

Figure 1. Circuit Breaker Removal/Replacement (Version 1) ... 0089-4 Figure 2. Circuit Breaker Removal/Replacement (Version 2) ... 0089-5

ECU Control Panel – Contactors Field Maintenance... WP 0090 Figure 1. Contactor Removal/Replacement ... 0090-3

ECU Control Panel – Relays Field Maintenance ... WP 0091 Figure 1. Relay Removal/Replacement... 0091-3

ECU Control Panel – Transformer and Bridge Rectifier Field Maintenance... WP 0092 Figure 1. Transformer Removal/Replacement ... 0092-3

Figure 2. Bridge Rectifier Removal/Replacement ... 0092-5

ECU Control Panel – Starter Protectors Field Maintenance ... WP 0093 Figure 1. CMSP/EMSP Removal/Replacement ... 0093-3

ECU – Evaporator Fan Motor Field Maintenance ... WP 0094 Table 1. Evaporator Motor Electrical Connections... 0094-3

Figure 1. Evaporator Motor Removal/Replacement ... 0094-4 Figure 2. Evaporator Blower Fan Removal/Replacement... 0094-7

ECU – Condenser Fan Motor Field Maintenance ... WP 0095 Table 1. Condenser Fan Motor Electrical Connections ... 0095-3

Figure 1. Condenser Fan Removal/Replacement ... 0095-4

ECU – Cut-Off Switches Field Maintenance ... WP 0096 Figure 1. High Temperature Cut-Off Switch Removal/Replacement ... 0096-3

Figure 2. High Pressure Cut-Off Switch Removal/Replacement... 0096-6 Figure 3. Low Pressure Cut-Off Switch Removal/Replacement ... 0096-9

ECU – Filter/Drier Field Maintenance ... WP 0097 Figure 1. Filter/Drier Removal/Replacement ... 0097-4

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xviii

ECU – Compressor and Vibration Eliminators Field Maintenance ...WP 0098 Table 1. Compressor Connections ...0098-4

Figure 1. Compressor Removal/Replacement...0098-5

ECU – Valves Field Maintenance ...WP 0099 Figure 1. TEV Removal/Replacement ...0099-4

Figure 2. Quench Valve Removal/Replacement...0099-9 Figure 3. Hot Gas By-Pass Valve Removal/Replacement...0099-12 Figure 4. High Pressure Relief Valve Removal/Replacement ...0099-16 Figure 5. Solenoid Valve Removal/Replacement ...0099-19

ECU – Purging and Brazing Field Maintenance ...WP 0100 ECU – Leak Testing (with Nitrogen) Field Maintenance...WP 0101 ECU – System Evacuation Field Maintenance ...WP 0102

Figure 1. Evacuation Set-up (Shop Method)...0102-3 Figure 2. Evacuation Set-up (Field Method) ...0102-3

ECU – System Charging and Recovery Field Maintenance...WP 0103 Figure 1. Refrigerant Recovery Layout ...0103-3

Figure 2. System Charging (Using Electronic Refrigerant Scale)...0103-5 Figure 3. System Charging (Using Standard Scale) ...0103-6

ECU – Subcool Setting Field Maintenance...WP 0104 Table 1. R407c Conversion Table ...0104-4

Genset – Control Panel AC Meters Field Maintenance...WP 0105 Table 1. Meter Connections...0105-3

Figure 1. Meter Removal/Replacement ...0105-4

Genset Control Panel – Gauges and Meters Field Maintenance ...WP 0106 Table 1. Meter/Gauge Connections...0106-5

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(42)

xx

Genset Control Panel – Switches and Potentiometer Field Maintenance...WP 0107 Figure 1. Potentiometer Removal/Replacement ...0107-4

Table 1. Genset Control Panel – Rotary Switch Connections ...0107-7 Figure 2. Rotary Switch Removal/Replacement ...0107-8 Table 2. Genset Control Panel – Toggle Switch Connections...0107-11 Figure 3. Toggle Switch Removal/Replacement...0107-12

Genset Control Panel Lights Field Maintenance ...WP 0108 Figure 1. Light Assemblies Removal/Replacement ...0108-4

Table 1. Indicator Light(s) Connections ...0108-6

Genset Control Panel – Switches Field Maintenance ...WP 0109 Figure 1. Battery Switch Removal/Replacement ...0109-4

Genset – Control Panel Field Maintenance ...WP 0110 Figure 1. Control Panel Component Identification ...0110-4

Table 1. Component Identification ...0110-4

Genset – Power Distribution Panel Connectors Field Maintenance...WP 0111 Table 1. Genset Power Distribution Panel – Light Connections...0111-3

Figure 1. Power Distribution Panel Lights Removal/Replacement ...0111-4 Table 2. J1 and J4 Connections ...0111-7 Figure 2. Connector (J1 and J4) Removal/Replacement...0111-7 Table 3. J2 and J3 Connections ...0111-9 Figure 3. Connector (J2 and J3) Removal/Replacement...0111-10 Table 4. J5 Connections ...0111-12 Figure 4. Connector (J5) Removal/Replacement ...0111-13 Table 5. J6 Connections ...0111-15 Figure 5. Connector (J6) Removal/Replacement ...0111-16 Figure 6. Connector Pin Identification...0111-17