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 02 04 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 7.5.3-02) 15 AUTO FUNCTION TEST LEGS, JACKS, AND/OR STABILIZERS WITH GENERATOR SET INSTALLED 16 17 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
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 7.1.1-01) 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 7.5.3-02) Completed Work Packet 1) Maintenance Request form (DA Form 5990-E or ORQF 7.1.1-01) 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 7.5.3-02) 5) Work Order Detail Optional Forms DA Form 2404(s) IUID Registration Printout from https://iuid.logisticsinformationservice.dla.mil/publicsearch.aspx UID Compliance Results Sheet Work Packet Contents Worksheet Page 1 of 1 Version: 3 2 of 8
Mandatory Parts Worksheet Automotive Shop NIN / PN NOUN QTY NIN / PN NOUN QTY 441126 GLAD HAND, SERVICE 1 00-741-1378 WASHER, KEY 2 441127 GLAD HAND, EMERGENCY 1 00-741-1429 SEAL, PLAIN, ENCASED 2 00-100-5951 BEARING, ROLLER, TAPE 4 00-741-2050 SHIELD, BRAKE DISK 2 00-106-4377 CHAMBER, AIR BRAKE 1 00-741-2065 WHEEL CYL ASSEMBLY 4 00-202-3639 REFLECTOR, INDICATING AMBER 2 00-741-2068 SHIELD,BRAKE DISK,LOWER 2 00-205-2795 REFLECTOR, INDICATING RED 4 00-777-3069 CABLE, HANDBRAKE 2 00-246-8223 GASKET 2 00-791-8077 TUBE ASSY, R BACK PLATE 1 00-249-3885 ELBOW, PIPE 2 00-791-8078 BRAKE TUBE, L BACK PLATE 1 00-275-6042 CLAMP, LOOP 2 00-797-9295 AIR FILTER, BRAKE LI 2 00-278-8886 COUPLING, TUBE 1 00-815-8840 PIN, STRAIGHT HEADED 2 00-330-3262 LEVER ASSY, PARKING 2 00-835-2037 NUT, PLAIN, HEXAGON 1 00-335-4728 NIPPLE, PIPE 2 00-849-1220 COCK, AIR TANK DRAIN 1 00-419-9425 TEE, TUBE 2 00-860-0538 WIRING HARNESS (IV Cable) 1 00-463-1588 CONNECTOR, MULTIPLE 1 00-985-0823 CLEVIS, ROD END 2 00-511-1692 BRAKE TUBE MASTER CYL VENT 1 00-999-7369 PLATE, ID EMERGENCY & SERVICE 2 00-535-1924 SPRING, HELICAL, EXTE 1 01-095-8752 RELAY VALVE 1 00-630-9923 BRAKE TUBE, AXLE RIGHT 1 01-528-9461 TIRE&WHEEL ASSY 2 00-630-9924 BRAKE TUBE, AXLE LEFT 1 002044800LOCAL MASTER CYLINDER 1 00-630-9925 BRAKE TUBE, MASTER CYL 1 007744040LOCAL BRAKE HOSE, FLEX 1 00-630-9926 BRAKE TUBE, CHASSIS 1 011671827L WIRING HARNESS (Chassis) 1 00-679-0923 HOSE ASSEMBLY, NONME 2 013723883L TAILLIGHT COMPOSITE 2 00-693-1007 BRAKE SHOE 4 5T906 FIRE EXTINGUISHER BRACKET 1 00-699-9018 SPRING, HELICAL, EXTE 4 T-243505 VALVE ADAPTER AIR RELAY 1 00-729-6437 BOLT, FLUID PASSAGE 2 Crate Shop PU Set Data Plates NIN / PN NOUN QTY Part Number Description Qty 8742396-1 DATA PLATE TRAILER ID 1 12-1313 DATA PLATE PU SET ID PU-802 1 12-2878 DATA PLATE LIFT & TIEDOWN 1 13229E5666-23 DATA PLATE PU SET ID PU-803 1 13230E7022-56 DATA PLATE PU SET ID PU-805 1 BII Items Technical Manuals (To include with BII) NIN / PN NOUN QTY TM Number Publication Date Qty 5T900 Fire Extinguisher 5lb 1 PU-802 00-878-3791 Ground Rod Assembly* 1 LO 9-6115-643-12 31 July 2008 1 00-251-4489 Hammer Hand Engineers 8lb 1 TM 9-6115-643-10 15 February 2010 1 00-021-3320 Auxiliary Fuel Hose* 1 TM 9-6115-661-13&P 15 November 2009 1 01-406-9533 Parallel Cable* 1 PU-803 00-066-1235 Adapter Assembly Fuel Drum 1 LO 9-6115-644-12 30 October 1996 1 N/A Oil Drain Assembly (elbow, clamp, & 1 TM 9-6115-644-10 15 September 2010 1 hose) TM 9-6115-662-13&P 30 May 2010 1 00-809-9703 Elbow, for oil drain hose 1 PU-805 01-013-1676 Hammer Slide 1 LO 9-6115-645-12 30 October 1996 1 TM 9 2330 205 14&P 1 September 1984 Change 2 1 TM 9-6115-645-10 15 March 2010 1 *Include in BII box but billed to generator TM 9-6115-663-13&P 31 May 2010 1 Work Packet Contents Worksheet Page 1 of 1 Version: 3 3 of 8
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
1 Frame and Body Service and Repair Service & Repair Worksheet Part Number / NIIN Item Description Qty Used 00-205-2795 REFLECTOR, INDICATING RED 4 00-202-3639 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 013723883L STOP LIGHT-TAILLIGHT COMPOSITE 2 00-860-0538 WIRING HARNESS (IV Cable) 1 00-535-1924 SPRING, HELICAL, EXTENSION 1 00-275-6042 CLAMP, LOOP 1 011671827L 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
3 Air System Service and Repair Service & Repair Worksheet Part Number / NIIN Item Description Qty Used 00-335-4728 NIPPLE, PIPE 2 00-106-4377 CHAMBER, AIR BRAKE 1 00-999-7369 PLATE, IDENTIFICATION SERVICE & EMERGENCY 2 00-797-9295 AIR FILTER, BRAKE LINE 2 01-095-8752 RELAY VALVE 1 00-249-3885 ELBOW, PIPE 2 00-679-0923 HOSE ASSEMBLY, NONMETALLIC 2 441126 GLAD HAND, SERVICE 1 441127 GLAD HAND, EMERGENCY 1 00-849-1220 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 00-511-1692 BRAKE TUBE MASTER CYL VENT 1 00-100-5951 BEARING, ROLLER, TAPE 4 00-246-8223 GASKET 2 00-278-8886 COUPLING, TUBE 1 00-330-3262 LEVER ASSY, PARKING 2 00-419-9425 TEE, TUBE 2 00-463-1588 CONNECTOR, MULTIPLE 1 00-630-9923 BRAKE TUBE, AXLE RIGHT 1 00-630-9924 BRAKE TUBE, AXLE LEFT 1 00-630-9925 BRAKE TUBE, MASTER CYL 1 00-630-9926 BRAKE TUBE, CHASSIS 1 00-693-1007 BRAKE SHOE 4 00-699-9018 SPRING, HELICAL, EXTENSION 4 00-729-6437 BOLT, FLUID PASSAGE 2 00-741-1378 WASHER, KEY 2 00-741-1429 SEAL, PLAIN, ENCASED 2 Service & Repair Worksheet Page 2 of 3 Version: 3 6 of 8
Service & Repair Worksheet 4 Brake System Service and Repair (continued) 00-741-2050 SHIELD, BRAKE DISK UPPER 2 00-741-2065 WHEEL CYL ASSEMBLY 4 00-741-2068 SHIELD, BRAKE DISK LOWER 2 00-777-3069 CABLE, HANDBRAKE 2 00-791-8077 TUBE ASSY, R BACK PLATE 1 00-791-8078 BRAKE TUBE, L BACK PLATE 1 00-815-8840 PIN, STRAIGHT HEADED 2 00-835-2037 NUT, PLAIN, HEXAGON 1 00-985-0823 CLEVIS, ROD END 2 01-528-9461 TIRE AND WHEEL ASSEMBLY 2 002044800LOCAL MASTER CYLINDER 1 007744040LOCAL 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 (00-741-2068) 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 105-110 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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