For Use With Power Units Mounted on M200A1 Trailers Only

Transcription

1 TASK COMPLETION WORKSHEET WORK ORDER# SERIAL # Form : Each task shall be completed by an individual working in the section listed for the task. This individual shall write their employee number in the space provided and the date that the work was completed. Each task shall be completed in the order that it is presented in this worksheet. Highlighted Items require an inspection signature before the equipment can proceed to the next work process Task Section Task Description Individual Completing Task 01 AUTO STAMP WORK ORDER # INTO TRAILER FRAME AND PREPARE FOR BLASTING PER ENCLOSED DISASSEMBLE WORKSHEET 02 AUTO INSPECT TRAILER FRAME FOR RUST DAMAGE, PITTING, CRACKED/BROKEN WELDS, OR OTHER FRAME DAMAGE 03 AUTO REPAIR ANY DEFICIENCIES IDENTIFIED IN TASK INSP POST BLAST INSPECTION 05 PAINT PRIME AND PAINT 06 AUTO SERVICE AND REPAIR TRAILER PER ENCLOSED SERVICE AND REPAIR WORKSHEET. 07 AUTO FUNCTION TEST TAILLIGHTS, AIR, AND HYDRAULIC SYSTEMS 08 AUTO REPAIR ALL DEFICIENCIES & RETEST AS APPLICABLE 09 INSP IN-PROCESS INSPECTION 10 AUTO INSTALL FRONT PERSONNEL PLATFORM 11 PREP PREPARE FOR FINAL PAINT 12 PAINT PAINT 13 PAINT STENCIL 14 AUTO INSTALL GENERATOR AS NECESSARY FOR CONFIGURATION LISTED ON INCLUDED PU/PP COMPONENT DISPOSITION WORKSHEET (ORQF ) 15 AUTO FUNCTION TEST LEGS, JACKS, AND/OR STABILIZERS WITH GENERATOR SET INSTALLED INSP INSP COLLECT GEN WORK ORDER(S) AND PLACE INTO SUSPENSE ASSIGN POWER UNIT IDENTIFICATION AND RECORD BELOW: Date of Task Completion POWER UNIT SERIAL # TRAILER SERIAL # REGISTRATION # DATE OF MANUFACTURE: 18 INSP MOUNT INSPECTION 19 CRATE DEMASK 20 CRATE STAMP AND INSTALL DATA PLATES 21 CRATE INSTALL BRAKE FLUID DECAL 22 CRATE SECURE TOW CHAINS, IV CABLE, AND AIR HOSES 23 INSP FINAL INSPECTION 24 CRATE DRAIN FUEL 25 CRATE INSTALL COVERS, BANDING, AND LABELS 26 CRATE BUILD BII BOX AND INSTALL BII LISTED ON BII CHECKSHEET 27 INSP INSPECT BII AND COMPLETE BII CHECKSHEET 28 INSP CRATE INSPECTION Task Completion Worksheet Page 1 of 1 Version: 3 1 of 8

2 FOR USE WITH 15 KW MEP-804A ONLY Work Packet Contents Worksheet : The Initial Work Packet list below contains the listing of the forms and other items to be included in the initial (opening) work order packet. The completed work packet list contains the list of forms and documents required to be present in a work packet prior to closing. The Optional forms list consists of forms that are added to the work packet on an as needed basis. Initial Work Packet 1) Maintenance Request form (DA Form 5990-E or ORQF ) 2) M200A1 Work Packet () Which consists of the following Task Completion Worksheet Contents worksheet Mandatory Parts Worksheet Disassemble Worksheet Service & Repair Worksheet Conversion Worksheet 3) Power Unit & Power Plant Component Disposition Worksheet (ORQF ) Completed Work Packet 1) Maintenance Request form (DA Form 5990-E or ORQF ) 2) M200A1 Work Packet () Which consists of the following Task Completion Worksheet Contents worksheet Mandatory Parts Worksheet Disassemble Worksheet Service & Repair Worksheet Conversion Worksheet 3) MAINTENANCE PARTS REQUIREMENTS / USAGE WORKSHEET A 4) Registration Number Printout from LOGSA website (for power unit identity listed on ORQF ) 5) Work Order Detail Optional Forms DA Form 2404(s) IUID Registration Printout from UID Compliance Results Sheet Work Packet Contents Worksheet Page 1 of 1 Version: 3 2 of 8

3 Mandatory Parts Worksheet Automotive Shop NIN / PN NOUN QTY NIN / PN NOUN QTY GLAD HAND, SERVICE WASHER, KEY GLAD HAND, EMERGENCY SEAL, PLAIN, ENCASED BEARING, ROLLER, TAPE SHIELD, BRAKE DISK CHAMBER, AIR BRAKE WHEEL CYL ASSEMBLY REFLECTOR, INDICATING AMBER SHIELD,BRAKE DISK,LOWER REFLECTOR, INDICATING RED CABLE, HANDBRAKE GASKET TUBE ASSY, R BACK PLATE ELBOW, PIPE BRAKE TUBE, L BACK PLATE CLAMP, LOOP AIR FILTER, BRAKE LI COUPLING, TUBE PIN, STRAIGHT HEADED LEVER ASSY, PARKING NUT, PLAIN, HEXAGON NIPPLE, PIPE COCK, AIR TANK DRAIN TEE, TUBE WIRING HARNESS (IV Cable) CONNECTOR, MULTIPLE CLEVIS, ROD END BRAKE TUBE MASTER CYL VENT PLATE, ID EMERGENCY & SERVICE SPRING, HELICAL, EXTE RELAY VALVE BRAKE TUBE, AXLE RIGHT TIRE&WHEEL ASSY BRAKE TUBE, AXLE LEFT LOCAL MASTER CYLINDER BRAKE TUBE, MASTER CYL LOCAL BRAKE HOSE, FLEX BRAKE TUBE, CHASSIS L WIRING HARNESS (Chassis) HOSE ASSEMBLY, NONME L TAILLIGHT COMPOSITE BRAKE SHOE 4 5T906 FIRE EXTINGUISHER BRACKET SPRING, HELICAL, EXTE 4 T VALVE ADAPTER AIR RELAY BOLT, FLUID PASSAGE 2 Crate Shop PU Set Data Plates NIN / PN NOUN QTY Part Number Description Qty DATA PLATE TRAILER ID DATA PLATE PU SET ID PU DATA PLATE LIFT & TIEDOWN E DATA PLATE PU SET ID PU E DATA PLATE PU SET ID PU BII Items Technical Manuals (To include with BII) NIN / PN NOUN QTY TM Number Publication Date Qty 5T900 Fire Extinguisher 5lb 1 PU Ground Rod Assembly* 1 LO July Hammer Hand Engineers 8lb 1 TM February Auxiliary Fuel Hose* 1 TM &P 15 November Parallel Cable* 1 PU Adapter Assembly Fuel Drum 1 LO October N/A Oil Drain Assembly (elbow, clamp, & 1 TM September hose) TM &P 30 May Elbow, for oil drain hose 1 PU Hammer Slide 1 LO October TM &P 1 September 1984 Change 2 1 TM March *Include in BII box but billed to generator TM &P 31 May Work Packet Contents Worksheet Page 1 of 1 Version: 3 3 of 8

4 Disassemble Worksheet : If equipped, remove items listed below prior to cleaning and staging the trailer frame for blasting. Front Personnel Platform Air lines Air Filters Air Brake Chamber Relay Valve Taillights Wire Harness Intervehicular Cable Wire harness clamps and clips Brake Lines Brake Hose Brake Tee Brake Line clamps Master Cylinder Rear Step Legs Rear Step Leg Pins, Chains, and Clips Wheels, Hubs, and Service Brake Components Parking Brake Handles Reflectors Data Plates Rear fender extensions Sledge Hammer Mounting Brackets Stamp Trailer Work Order Number into Lunette Mounting Plate Block (see figure below) Inspect safety chains for serviceability, remove if unserviceable Drill trailer frame for trailer and lift & tiedown data plates. Drill right fender for PU set ID data plate Inspect for rust or corrosion at or near the dummy glad hands, the master cylinder mounting bracket, and parking brake handle brackets. If rust or corrosion is present remove the bracket(s). Inspect the fenders for serviceability and reparability, remove un-repairable fenders. Retain all non wear and rebuildable parts, such as brackets, spacers, brake adjusters, and landing legs for reuse. Dual wheel hubs are not reused and can be scrapped. Location of work order number stamp Disassemble Worksheet page 1 of 1 Version: 3 4 of 8

5 1 Frame and Body Service and Repair Service & Repair Worksheet Part Number / NIIN Item Description Qty Used REFLECTOR, INDICATING RED REFLECTOR, INDICATING AMBER 2 5T906 FIRE EXTINGUISHER BRACKET 1 TB 43-PS-669 PS Magazine Issue 669 Pages 40 and 41 December 2008 Inspect the trailer frame, lunette, fenders, cross-members, lift and tie-downs, air line hoop, and hardware for damage not previously identified and repaired. Repair or replace components as necessary, ensure that any areas that will not be exposed are properly primed and painted. Inspect the axle housing, leaf springs, hangers, brackets, bolts, shackles, and pins; replace any unserviceable components. Replace the leaf spring bushing grease fittings & pump in clean grease until clean grease comes out of the bushing. Remove top cap from front landing leg and inspect gears, pins, and bushings; repair or replace as necessary. Clean old grease from gear housing and repack with fresh, clean grease. Verify that the front landing leg operates smoothly throughout entire range of motion and ensure that the inner leg does not fall out the bottom when fully extended. Check fit in deployed and stowed positions. Replace the safety chain hook with the wider opening hook per PS Magazine article if not already installed. Refer to Local Service Bulletin if the frame hole needs to be enlarged to fit the chain eyelet. Install toolbox. If the trailer had fender extension plates install the modified cover plate. Install new reflectors and fire extinguisher bracket. Install new ground stud per end item TM. 2 Electrical System Service and Repair Part Number / NIIN Item Description Qty Used L STOP LIGHT-TAILLIGHT COMPOSITE WIRING HARNESS (IV Cable) SPRING, HELICAL, EXTENSION CLAMP, LOOP L WIRING HARNESS (Chassis) 1 Install new Intervehicular cable, chassis wire harness, and taillight assemblies using new clamps and grommets. Inspect and repair or replace wire harness connector clips and necessary. Service & Repair Worksheet Page 1 of 3 Version: 3 5 of 8

6 3 Air System Service and Repair Service & Repair Worksheet Part Number / NIIN Item Description Qty Used NIPPLE, PIPE CHAMBER, AIR BRAKE PLATE, IDENTIFICATION SERVICE & EMERGENCY AIR FILTER, BRAKE LINE RELAY VALVE ELBOW, PIPE HOSE ASSEMBLY, NONMETALLIC GLAD HAND, SERVICE GLAD HAND, EMERGENCY COCK, AIR TANK DRAIN 1 Install new air filters, elbows, adapters, and data plates to the trailer frame ensuring that the Service is on the right (curbside) and Emergency is on the left (roadside). Remove existing universal glad hands from air supply hoses and replace with the service and emergency specific glad hands and install. Inspect air tank and mounting brackets for damage, repair or replace as needed and install using a new drain valve. Install new relay valve and air brake chamber, fabricate and install the air chamber brace if not already present. Plumb with new air lines and install new air line clamps. 4 Brake System Service and Repair Part Number / NIIN Item Description Qty Used BRAKE TUBE MASTER CYL VENT BEARING, ROLLER, TAPE GASKET COUPLING, TUBE LEVER ASSY, PARKING TEE, TUBE CONNECTOR, MULTIPLE BRAKE TUBE, AXLE RIGHT BRAKE TUBE, AXLE LEFT BRAKE TUBE, MASTER CYL BRAKE TUBE, CHASSIS BRAKE SHOE SPRING, HELICAL, EXTENSION BOLT, FLUID PASSAGE WASHER, KEY SEAL, PLAIN, ENCASED 2 Service & Repair Worksheet Page 2 of 3 Version: 3 6 of 8

7 Service & Repair Worksheet 4 Brake System Service and Repair (continued) SHIELD, BRAKE DISK UPPER WHEEL CYL ASSEMBLY SHIELD, BRAKE DISK LOWER CABLE, HANDBRAKE TUBE ASSY, R BACK PLATE BRAKE TUBE, L BACK PLATE PIN, STRAIGHT HEADED NUT, PLAIN, HEXAGON CLEVIS, ROD END TIRE AND WHEEL ASSEMBLY LOCAL MASTER CYLINDER LOCAL BRAKE HOSE, FLEX 1 Assemble wheel brake system using the new parts listed above. Inspect used parts for serviceability and repair or replace as necessary. Install super single style brake hub and drum assembly with new wheel bearings. Adjust brake shoe clearances. Install new brake master cylinder, ensure that spacer ( ) is installed in the master cylinder dust boot. Install all new brake lines and fittings. Install new brake flex hose and brake backing plate tube assemblies. Fill master cylinder with fluid and bleed brakes. Clean brake backing plates and bleeders thoroughly. Install wheel and tire assemblies. 5 Final Assembly and Test No Mandatory Parts Requirements Connect test equipment to trailer. Function test service brake, taillight, blackout brake, and blackout service light functions. Verify that the wheels are free to turn. Ensure air supply to trailer is at psi. Charge air tank. Verify with air tank charged and no air supplied that the brakes are locked. Apply emergency air, verify brakes are free. Apply service air, verify brakes are locked. Using soap spray check air system for leaks. Apply service and emergency air for a minimum of 2 hours and inspect for hydraulic leaks. Service & Repair Worksheet Page 3 of 3 Version: 3 7 of 8

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