TECHNICAL BULLETIN INSTALLATION PROCEDURES FOR MOBILE SUBSCRIBER EQUIPMENT KITS USED ON TRUCK, UTILITY: S250 SHELTER CARRIER,

Transcription

1 TECHNICAL BULLETIN INSTALLATION PROCEDURES FOR MOBILE SUBSCRIBER EQUIPMENT KITS USED ON TRUCK, UTILITY: S250 SHELTER CARRIER, AND TRUCK, UTILITY: S250 EXTENDED SHELTER CARRIER, 4X4, M1037 (NSN ) (EIC: BBK); TRUCK, UTILITY: HEAVY VARIANT, 4X4, M1097 ( )(EIC: BBM) Distribution authorized to U.S. Government agencies and their contractors is for official use or for administration or operational purposes only. This determination was made on 17 February Other requests for the document will be referred to Commander, U.S. Army Communication Electronics Command and Fort Monmouth, ATTN: AMSEL-LC-LM- LT, Fort Monmouth, NJ DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of the document. HEADQUARTERS, DEPARTMENT OF THE ARMY 1 JULY 1995

2 WARNING EXHAUST GASES CAN KILL Brain damage or death can result from heavy exposure Precautions must be followed to ensure crew safety when the personnel heater, main, or auxiliary engine of any vehicle is operated for any purpose. 1. Do not operate your vehicle engine In enclosed areas.. 2. Do not idle vehicle engine with vehicle windows closed. 3. Be alert at all times for exhaust odors. 4. Be alert for exhaust poisoning symptoms They are: Headache Dizziness Sleepiness Loss of muscular control 5. If you see another person with exhaust poisoning symptoms. Remove person from area Expose to open air Keep person warm Do not permit physical exercise Administer artificial respiration, if necessary* Notify a medic *For artificial respiration, refer to FM BE AWARE, the field protective mask for nuclear, biological or chemical (NBC) protection will not protect you from carbon monoxide poisoning. THE BEST DEFENSE AGAINST EXHAUST POISONING IS ADEQUATE VENTILATION. a

3 WARNING SUMMARY Direct all personnel to stand clear during hoisting operations A heavy, swinging load can be extremely dangerous. b

4 Technical Bulletin HEADQUARTERS, DEPARTMENT OF THE ARMY No Washington, DC, 1 July 1995 INSTALLATION PROCEDURES FOR MOBILE SUBSCRIBER EQUIPMENT KITS USED ON TRUCK, UTILITY: S250 SHELTER CARRIER, AND TRUCK, UTILITY: S250 EXTENDED SHELTER CARRIER, 4X4, M1 037; TRUCK, UTILITY: HEAVY VARIANT, 4X4, M1097 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can improve this bulletin. If you find any mistakes or know of a way to improve the procedures, please let us know Mall your letter, DA Form 2028 (Recommended Changes to Publications and Blank forms), or DA Form located in back of this directly to Commander, US Army Communications-Electronics Command and Fort Monmouth, ATTN AMSEL-LC-LM-LT, Fort Monmouth, New Jersey A reply will be furnished directly to you. CHAPTER 1 INTRODUCTION Page 1-1. Purpose Identification Maintenance Forms, Records, and Reports Reporting Equipment Improvement Recommendations (EIR) Equipment Improvement Report and Maintenance Digest (EIR MD) Warranty Information Mandatory Replacement Parts M1037 and M1097 Standard Shelter (S250) carrier Information CHAPTER 2 S250 EXTENDED SHELTER MOUNTING COMPONENTS MAINTENANCE 2-1. S 250 Extended Shelter Mounting Components Maintenance Task List Shelter Support Reinforcement Replacement Shelter Mounting Bracket Replacement Shelter Carrier Tailgate and Hinge Maintenance Shelter Carrier Tailgate Chain and Bracket Replacement Step Plate Assembly and Rubber Block Replacement Shelter Replacement Shelter Support Assembly Replacement Shelter Carrier Rear Composite Light Jumper Harness Replacement Shelter Carrier Rear Composite Light Replacement Shelter Carrier Taillight Extension Bracket Replacement i

5 CHAPTER 3 AUXILIARY MAINTENANCE INSTRUCTIONS APPENDIX A REFERENCES... A-1 APPENDIX B INSTALLATION KITS... B-1 APPENDIX C REPAIR PARTS... C-1 Section I. Introduction... C-1 Section II. Repair Parts List... C-1 Section III. National Stock Number and Part Number Index... C-12 ii

6 CHAPTER 1 INTRODUCTION 1-1. PURPOSE a. This technical bulletin provides Installation instructions for the M1037 S250 shelter carrier Mobile Subscriber Equipment (MSE) modification kit part number and the S250E extended shelter carrier modification kit part number b. Also provides installation Instructions for the M1097 S250 shelter carrier MSE modification part number kit and the S250E extended shelter carrier modification kit part number This technical bulletin will be used in conjunction with the following technical manuals: TM LO TM TM P TM TM TM TM P TM TM TM TM TM TM &P TM &P TB TB When in conflict, this technical bulletin takes precedence over existing M998 series publications. The Installation information contained In this technical bulletin is the official authorization to perform the Installation at the unit level maintenance. NOTE This technical bulletin IS NOT an authorization for requisition or turn-in of equipment. This technical bulletin DOES NOT establish quantity or types of equipment assigned to using units. This technical bulletin IS NOT an authorization for requisition or turn-in of installation kit equipment. 1-1

7 1-2. IDENTIFICATION a. The M1037 and M1097 extended shelter carriers are modified versions of the standard M1037 and M1097 shelter carriers The extended shelter carriers are specifically designed to accommodate S250 mounting and operational requirements of MSE The extended shelter carrier modifications include. Extended shelter support frame Tall light extension Tall gate and chain mounting Tall gate and step plate assembly b. Extended shelter carrier modifications included but not covered in detail in this TB are covered in TMs listed below. 200 ampere alternator replacement 200 ampere alternator fuse replacement TM TM TM P M

8 1-2. IDENTIFICATION (Cont'd) M1037 W/EXTENDED SHELTER M1097 (WITH 2-MAN SOFT TOP INSTALLED) 1-3

9 1-2. IDENTIFICATION (Cont'd) TYPICAL EXTENDED SHELTER, VEHICLE AND POWER UNIT CONFIGURATION 1-3. MAINTENANCE FORMS, RECORDS, AND REPORTS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA Pam , The Army Maintenance Management System (TAMMS) REPORTING EQUIPMENT IMPROVEMENT If your extended shelter vehicle 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 Put it on an SF 368 (Product Quality Deficiency Report) Mall It to Commander, US Army Communications-Electronics Command and Fort Monmouth, ATTN AMSEL-LC-ED-CFO, Fort Monmouth, New Jersey We'll send you a reply EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE DIGEST (EIR MD) The quarterly Equipment Improvement Report and Maintenance Digest, TB series, contains valuable field information on the equipment covered In this bulletin The information in the TB series is compiled from some of the Equipment Improvement Reports that you prepared on the vehicles covered in this bulletin Many of these articles resulted from comments, suggestions, and improvement recommendations that you submitted to the EIR program The TB series contains information on equipment improvements, minor alterations, proposed Modification Work Orders(MWO's), warranties (if applicable), actions taken on some of your DA Form 2028's (Recommended Changes to Publications), and advance Information on proposed changes that may affect this bulletin The Information will help you in doing your job better and will help In keeping you advised of the latest changes to this bulletin Also refer to DA Pam 25-30, Consolidated Index of Army Publications and Blank Forms WARRANTY INFORMATION Warranty Information for the extended shelter can be found in TB

10 1-7. MANDATORY REPLACEMENT PARTS The maintenance Instructions contained herein make reference to removing and discarding piece parts such as gaskets, lockwashers, cotter pins, "0" ring seals, etc; these items should be considered mandatory replacement items and replaced with new parts during assembly/installation M1037 AND M1097 STANDARD SHELTER (S250) CARRIER INFORMATION The M1037 and M1097 standard shelter S250 carrier modifications are contained In the following technical manuals. TM TM TM P 1-5/(1-6 Blank)

11 CHAPTER 2 S250 EXTENDED SHELTER MOUNTING COMPONENTS MAINTENANCE 2-1. S250 EXTENDED SHELTER MOUNTING COMPONENTS MAINTENANCE TASK LIST TASK PAGE PARA PROCEDURES NO. 2-2 Shelter Support Reinforcement Replacement Shelter Mounting Bracket Replacement Shelter Carrier Tailgate and Hinge Maintenance Shelter Carrier Tailgate Chain and Bracket Replacement Step Plate Assembly and Rubber Block Replacement Shelter Replacement Shelter Support Assembly Replacement Shelter Carrier Rear Composite Light Jumper Harness Replacement Shelter Carrier Rear Composite Light Replacement Shelter Carrier Taillight Extension Bracket Replacement 2-19 Removal and Installation of S250 Rear Suspension Tiedown Kit See TM

12 2-2. SHELTER SUPPORT REINFORCEMENT REPLACEMENT This task covers: a. Removal b. Installation INITIAL SETUP: Applicable Models M1037 M1097 Materials/Parts Two lockwashers Two capscrews a. Removal NOTE It may be necessary to detach cab rear panel straps and turn-buttons and roll cab rear panel upward to gain access to front support reinforcements Remove two capscrews (6), lockwashers (5), and washers (4) securing reinforcement (3) to mounting bracket (2) and remove reinforcement (3) from support (1) Discard capscrews (6) and lockwashers (5). b. Installation NOTE Ensure correct positioning of shims, If Installed, upon installation of capscrews Install reinforcement (3) to support (1) and secure to mounting bracket (2) with two capscrews (6), lockwashers (5), and washers (4) Tighten capscrews (6) to 90 Ib-ft (122 N-m). 2-2

13 2-3. SHELTER MOUNTING BRACKET REPLACEMENT This task covers a. Removal b. Installation INITIAL SETUP: Applicable Models Equipment Condition M1037, M1097 Shelter removed (para 2-7) Materials/Parts Capscrew Lockwasher a. Removal Remove capscrew (5), lockwasher (4), and washer (3) securing mounting bracket (1) to shelter (2) and remove mounting bracket (1) Discard capscrew (5) and lockwasher (4). b. Installation Install mounting bracket (1) to shelter (2) and secure with two capscrew (5), lockwasher (4), and washer (3) Do not tighten capscrew (5) until shelter Is installed. FOLLOW ON TASK: Install shelter (para. 2-7). 2-3

14 2-4. SHELTER CARRIER TAILGATE AND HINGE MAINTENANCE This task covers a. Removal c. Assembly b. Disassembly d. Installation INITIAL SETUP: Applicable Models Equipment Condition M1037, M1097 Tailgate chains removed (para 2-5) Step plate assembly removed (para 2-6) Materials/Parts Sixteen locknuts a. Removal Remove six locknuts (1), washers (2), capscrews (3), and washers (2) securing tailgate (8) to support frame (4) and remove tailgate (8) Discard locknuts (1). b. Disassembly 1. Remove ten locknuts (7), washers (6), capscrews (5), and washers (6) securing hinges (9) to tailgate extension hinges (10) Remove lower extension hinges (10) and discard locknuts (7). NOTE Perform steps b 2 and c 1 only when replacing defective hinge components. 2. Remove hinge pin (11) securing upper extension hinge (12) and lower extension hinge (10) Separate lower extension hinges (10) and (12). c. Assembly 1. Install upper extension hinge (12) to lower extension hinge (10) and secure with pin (11). 2. Install two lower extension hinges (10) to hinges (9) and secure with ten washers (6), capscrews (5), washers (6), and locknuts (7) Tighten capscrews (5) to 15 Ib-ft (20 N-M). d. Installation Install tailgate (8) to support frame (4) and secure with six washers (2), capscrews (3), washers (2), and locknuts (1) Tighten capscrews (3) to 15 Ib-ft (20 N-m). 2-4

15 2-4. SHELTER CARRIER TAILGATE AND HINGE MAINTENANCE (Cont'd) FOLLOW-ON-TASKS Step plate assembly Installed (para 2-6) Tailgate chains installed (para 2-5) 2-5

16 2-5. SHELTER CARRIER TAILGATE CHAIN AND BRACKET REPLACEMENT This task covers a. Removal b. Installation INITIAL SETUP. a. Removal Applicable Models Materials/Parts M1037, M1097 Connecting link Five locknuts Personnel Required One mechanic One assistant 1. Remove two hooks (9) from brackets (4) and lower tailgate (6). 2. Pry open connecting link (7) securing chain assembly (10) to tailgate (6) and remove connecting link (7) Discard link (7). 3. Remove hook (11) from bracket (4) and remove chain assembly (10). NOTE Perform step 4 only if replacing tailgate chain bracket. 4. Remove five locknuts (1), washers (2), capscrews (5), and washers (2) securing bracket (4) to body (3) Remove bracket (4) and discard locknuts (1). b. Installation 1. Install hook (11) In bracket (4). 2. Install end link (8) of chain assembly (10) to tailgate (6) and secure with connecting link (7). 3. Raise tailgate (6) and secure with two hooks (9) into brackets (4). NOTE Perform step 4 only if replacing tailgate chain bracket. 4. Install bracket (4) to body (3) and secure with five washers (2), capscrews (5), washers(2), and locknuts (1) Tighten capscrews (5) to 15 Ib-ft (20 N-m). 2-6

17 2-6. STEP PLATE ASSEMBLY AND RUBBER BLOCK REPLACEMENT This task covers a. Removal b. Installation INITIAL SETUP: Applicable Models Equipment Condition M1037, M1097 Tailgate lowered a. Removal Personnel Required Seven lockwashers Two locknuts NOTE All rubber blocks must be removed if step plate assembly is being replaced. Perform steps a 2 and b 2 only if rubber blocks are being replaced or removed. 1. Remove seven capscrews (1) and lockwashers (2) securing step plate assembly (6) to tailgate (8) and remove step plate assembly (6) Discard lockwashers (2). 2. Remove two locknuts (3), washers (4), and screws (7) securing rubber blocks (5) to step plate assembly (6) and remove rubber block (5) Discard locknuts (3). b. Installation 1. Install step plate assembly (6) to tailgate (8) and secure with seven lockwashers (2) and capscrews (1). 2. Install rubber block (5) to step plate assembly (6) and secure with two screws (7), washers (4), and locknuts (3). FOLLOW-ON-TASKS: Raise Tailgate 2-7

18 2-7. SHELTER REPLACEMENT This task covers a. Removal b. Installation INITIAL SETUP: Applicable Models Equipment Condition M1037, M1097 Tailgate lowered RAU radio power cable disconnected Materials/Parts (TM ). Seven lockwashers Two locknuts General Safety Instructions Direct all personnel to stand clear during hoisting Personnel Required operations One mechanic One assistant a. Removal WARNING Direct all personnel to stand clear during hoisting operations A heavy, swinging load can be extremely dangerous. NOTE It may be necessary to detach cab rear panel strips and turn buttons, and roll cab rear panel upward to gain access to front mounting bracket. It may be necessary to temporarily raise tailgate when removing and installing rear reinforcement capscrews. 1. Position chain hoist (2) over top of shelter (3). 2. Connect lifting chains (1) to chain hoist (2) and four corners of shelter (3). 2-8

19 2-7. SHELTER REPLACEMENT (Cont'd) 3. Remove eight capscrews (12), lockwashers (11), washers (10), and four reinforcements (9) securing four mounting brackets (6) to support (4) and remove shims (7) if present Discard capscrews (12) and lockwashers (11). 4. Remove shelter (3) from support (4) and vehicle body with chain hoist (2). 5. Remove mounting brackets (para 2-3). b. Installation WARNING Direct all personnel to stand clear during hoisting operations A heavy, swinging load can be extremely dangerous. 1. Install mounting brackets (para 2-3). 2. Position shelter (3) over support (4) and gradually lower shelter (3) onto support (4). NOTE Shelter should be tightly fitted to front of support and centered from side to side Shims should only be added to rear shelter mounts. 3. Position shelter (3) to support (4) front mounting points (5) Secure shelter (3) to front of support (4) with four capscrews (12), lockwashers (11), washers (10), and two reinforcements (9) Tighten capscrews (8) to 60 Ib-ft (81 N-m) Tighten capscrews (12) to 90 Ib-ft (122 N-m). 4. Secure rear of shelter (3) to support (4) with four capscrews (12), lockwashers (11), washers (10), and two reinforcements (9) Do not tighten capscrews (12). 5. Add shims (7) as necessary to rear shelter mounts to ensure snug fit between mounting brackets (6) and support (4) Tighten capscrews (8) to 60 Ib-ft (81 N-m) Tighten capscrews (12) to 90 Ib-ft (122 N-m). 6. Disconnect chains (1) from shelter (3). FOLLOW-ON-TASKS: Raise and secure tailgate Connect RAU radio power cable (TM ). 2-9

20 12-8. SHELTER SUPPORT ASSEMBLY REPLACEMENT TB This task covers a. Removal b. Installation INITIAL SETUP: Applicable Models Equipment Condition M1037, M1097 Shelter removed (para 2-7) Shelter carrier taillight extension bracket Materials/Parts removed (para 2-11) Twenty locknuts Tailgate removed (para 2-4) Cab enclosure panels removed (TM ) Personnel Required Fuel filler housing removed (TM ) One mechanic Rear soft top curtain removed (TM ) One assistant a. Removal Manual References TM TM Remove two capscrews (4), washers (5), and spacers (6) securing support assembly (16) to cargo floor (27). 2. Remove Six locknuts (29), washers (2), two reinforcements plates (30) and (28), six capscrews (3), washers (2), and spacers (1) securing support assembly (16) to "B" beam (31) Discard locknuts (29). 3. Remove two capscrews (9) and washers (10) securing support assembly (16) to cargo floor (27). 4. Remove locknut (37), washer (34), capscrew (33), and washer (34) securing clamp (36) and fuel filler spout (32) to body (35) and pull fuel spout (32) away for access to nut (19) Discard locknut (37). 5. Remove two locknuts (19), washers (7), capscrews (8), and washers (7) securing support assembly (16) to cargo floor (27) Discard locknuts (19). 6. Remove four locknuts (22), washers (15), capscrews (14), and washers (15) securing support assembly (16) to cargo floor (27) Discard locknut (26). 7. Remove locknut (26), washer (24), capscrew (13), and washer (24) securing plate (25) to support assembly (16) Discard locknut (26). 8. Remove locknut (20), washer (11), capscrew (12), and washer (11) securing plate (25) to cargo floor (27) and remove plate (25) Discard locknut (20). 9. Remove five locknuts (23), washers (17), capscrews (18), and washers (17) securing support assembly (16) to "D" beam (21) and remove support assembly (16). 2-10

21 2-8. SHELTER SUPPORT ASSEMBLY REPLACEMENT (Cont'd) b. Installation 1. Install support assembly (16) on cargo floor (27) and secure to "D" beam (21) with five washers (17), capscrews (18), washers (17), and locknuts (23) Do not tighten. 2. Install plate (25) to cargo floor (27) and secure with washer (11), capscrew (12), washer (11), and locknut (20) Do not tighten. 3. Secure plate (25) to support assembly (16) with washer (24), capscrew (13), washer (24), and locknut (26) Do not tighten. 4. Secure support assembly (16) to cargo floor (27) with four washers (15), capscrews (14), washers (15), and locknuts (22) Do not tighten. 5. Secure support assembly (16) to cargo floor (27) with four washers (7), capscrews (8), washers (7), and locknuts (19) Do not tighten. 6. Secure support assembly (16) to "B" beam (31) with six spacers (1), washers (2), capscrews (3), two reinforcement plates (28) and (30), six washers (2), and locknuts (29) Do not tighten. 7. Secure support assembly (16) to cargo floor (27) with two spacers (6), washers (5), and capscrews (4) Do not tighten. 8. Secure support assembly (16) to cargo floor (27) with two washers (10) and capscrews (9). 9. Tighten four nuts (22) to 26 Ib-ft (35 N-m). 10. Tighten capscrews (3),(4),(8),(9),(18),(12), and (13) to 65 Ib-ft (88 N-m). 11. Install fuel filler spout (32) and clamp (36) to body (35) and secure with washer (34), capscrew (33), washer (34), and locknut (37). 2-11

22 2.8. SHELTER SUPPORT ASSEMBLY REPLACEMENT (Cont'd) FOLLOW-ON-TASKS: Install fuel filler housing (TM ) Install cab enclosure panels (TM ) Install tailgate (para 2-4). Install shelter carrier taillight extension bracket removed (para 2-11) Install shelter (para. 2-7). Secure rear soft top curtain (TM ) 2-12

23 2-9. SHELTER CARRIER REAR COMPOSITE LIGHT JUMPER HARNESS REPLACEMENT This task covers a. Removal b. Installation INITIAL SETUP: Applicable Models Manual References M1037, M1097 TM Materials/Parts Equipment Condition Two locknuts Battery ground cable disconnected Two lockwasher (TM ) Two nut and lockwasher assemblies a. Removal NOTE Prior to removal, tag all leads for installation. 1. Remove screw (5) and washer (4) securing ground lead (3) from jumper harness (6) to existing composite light (1) buss bar (2). 2. Remove two screws (9) and lockwashers (8) securing wire shield (7) to underbody (10) Pull down wire shield (7) Discard lockwashers (8). 3. Remove screw (16), washer (15), and locknut (14) securing wiring harness clamp (13) to wire shield (7) Discard locknut (14). 4. Disconnect four leads (11) from jumper harness (6) at existing wiring harness leads (12). 2-13

24 2-9. SHELTER CARRIER REAR COMPOSITE LIGHT JUMPER HARNESS REPLACEMENT (Cont'd) TB

25 2-9. SHELTER CARRIER REAR COMPOSITE LIGHT JUMPER HARNESS REPLACEMENT (Cont'd) TB Remove screw (9), washer (10), and locknut (13) securing wiring harness clamp (11) to extended shelter cradle (7) Discard locknut (13). 6. Remove two screws (6) and nut and lockwasher assemblies (16) securing reflector (5) and wiring harness clamps (8) to taillight extension bracket (4) Discard nut and lockwasher assemblies (16). 7. Remove screw (1) and washer (2) securing ground lead (3) to taillight extension bracket (4) Remove ground lead (3). 8. Disconnect four jumper harness leads (14) from composite light leads (15) and remove jumper harness (12). b. Installation 1. Connect four jumper harness leads (14) to composite light leads (15). 2. Install ground lead (3) to taillight extension bracket (4) and secure with screw (1) and washer (2). 3. Install reflector (5) and wiring harness clamps (8) with wires In place, to taillight extension bracket (4) and secure with screws (6) and nut and lockwasher assemblies (16). 4. Install wiring harness clamp (11) with jumper harness (12) In place onto extended shelter cradle (7) and secure with screw (9), washer (10), and locknut (13). 2-15

26 2-9. SHELTER CARRIER REAR COMPOSITE LIGHT JUMPER HARNESS REPLACEMENT (Cont'd). TB Install wiring harness clamp (26) with jumper harness (12) In place onto wire shield (21) and secure with screw (29), washer (28), and locknut (27). 6. Connect four leads (14) from jumper harness (12) to existing wiring harness leads (25). 7. Install wire shield (21) to underbody (24) and secure with two screws (23) and lockwashers (22). 8. Install ground lead (3) from jumper harness (12) to existing composite light (17) buss bar (18) and secure with screw (20) and washer (19). FOLLOW-ON-TASK: Connect battery ground cable (TM ). 2-16

27 2-10. SHELTER CARRIER REAR COMPOSITE LIGHT REPLACEMENT. This task covers a. Removal b. Installation INITIAL SETUP: Applicable Models Manual References M1037, M1097 TM Materials/Parts Two nut and lockwasher assemblies Equipment Condition Battery ground cable disconnected (TM ) a. Removal NOTE Prior to removal, tag all leads for installation. 1. Disconnect four composite leads (2) from jumper harness (1). 2. Remove two screws (5) and nut and lockwasher assemblies (12) securing reflector (4) and two wiring harness clamps (13) to composite light extension bracket (3) and remove clamps (13) from leads (2), Discard nut and lockwasher assemblies (12). 3. Remove two capscrews (10) and washers (9) securing rear composite light (6), buss bar (8), and ground lead (11) to composite light extension bracket (3). 4. Pull four leads (2) through hole (7) In composite light extension bracket (3) and remove rear composite light (6). b. Installation 1. Thread four leads (2) through hole (7) in composite light extension bracket (3). 2. Install rear composite light (6), buss bar (8), and ground lead (11) to composite light extension bracket (3) and secure with two capscrews (10) and washers (9). 3. Install two clamps (13) to leads (2) and secure clamps (13) and reflector (4) to composite light extension bracket (3) with two screws (5) and nut and lockwasher assemblies (12). 4. Connect four composite light leads (2) to jumper harness (1). 2-17

28 2-10. SHELTER CARRIER REAR COMPOSITE LIGHT REPLACEMENT (Cont'd) FOLLOW-ON-TASK: Connect battery ground cable (TM ). 2-18

29 2-11. SHELTER CARRIER TAILLIGHT EXTENSION BRACKET REPLACEMENT This task covers a. Removal b. Installation INITIAL SETUP: Applicable Models Equipment Condition M1037, M1097 Rear composite light removed (para 2-10) Materials/Parts Four locknuts a. Removal NOTE The upper two capscrews and washers cannot be removed with shelter installed. 1. Remove two upper locknuts (2) and washers (3) securing taillight extension bracket (1) to shelter support (4) Discard locknuts (2). 2. Remove two lower locknuts (7), washers (8), capscrews (10), and washers (9) securing taillight extension bracket (1) to support (4) and remove taillight extension bracket (1) Discard locknuts (7). b. Installation 1. Install taillight extension bracket (1) to shelter support (4) and secure upper side with two capscrews (6), washers (5), washers (3), and locknuts (2) Tighten locknuts (2) to 6 Ib-ft (8 N-m). 2. Secure taillight extension bracket (1) to shelter support (4) with two washers (9), lower capscrews (10), washers (8), and locknuts (7) Tighten locknuts (7) to 6 Ib-ft (8 N-m). 2-19

30 2-11. SHELTER CARRIER TAILLIGHT EXTENSION BRACKET REPLACEMENT (Cont'd) TB FOLLOW-ON-TASK. Install rear composite light (para 2-10). 2-20

31 CHAPTER 3 AUXILIARY MAINTENANCE INSTRUCTIONS 3-1. AUXILIARY MAINTENANCE INSTRUCTIONS MAINTENANCE TASK LIST TASK PAGE PARA PROCEDURES NO. 3-2 RAU Radio Power Cable Access Hole Drilling Instructions

32 3-2. RAU RADIO POWER CABLE ACCESS HOLE DRILLING INSTRUCTIONS This task covers: Installation INITIAL SETUP: Applicable Models Manual References M1037 TM M1097 Materials/Parts (Kit ) Equipment Condition Grommet MS Batteries removed (TM ) Installation 1. Measure 1 25 inch from inside battery box comer (1) along rear panel (4) and mark a vertical line (2). 2. Measure 2.50 inch down from inside battery box rear panel lip (7) and mark a horizontal line (6). 3. Drill a 22 mm hole (5) where lines (2) and (6) cross. 4 Using file, enlarge hole to 1.25 inch with no burrs or sharp edges and install grommet (3). FOLLOW-ON TASK: Install batteries (TM ) 3-2

33 APPENDIX A REFERENCES A-1. SCOPE This appendix lists all forms, field manuals, technical manuals, and other publications required for use with this manual. A-2. PUBLICATIONS INDEX Consolidated Index of Army Publications and Blank Forms... DA PAM A-3. FORMS Recommended Changes to Publications and Blank forms... DA Form 2028 Recommended Changes to Equipment Technical Publications... DA Form Hand Receipt/Annex Number... DA Form 2062 Exchange Tag... DA Form 2402 Equipment Inspection and Maintenance Worksheet... DA Form 2404 Maintenance Request... DA Form 2407 The Army Maintenance Management System (TAMMS)... DA PAM Preventive Maintenance schedule and Record... DD Form 314 Processing and Deprocessing Record for Shipping, Storage, and Issue of Vehicles and Spare Engines... DD Form 1397 Quality Deficiency Report Standard Form 368 A-4. FIELD MANUALS NBC Decontamination... FM-35 Operation and Maintenance of Ordnance Material in Cold Weather (0 to 65 F)... FM Vehicle Recovery and Towing... FM First Aid for Soldiers... FM Manual for the Wheeled Vehicle Driver... FM Basic Cold Weather Manual... FM Northern Operations... FM Army Motor Transport Units and Operations... FM Desert Operation... FM 90-3 Jungle Operation... FM 90-5 Mountain Operations... FM 90-6 A-5. TECHNICAL MANUALS Operator's Manual for Truck, 1-1/4 Ton, 4 x 4, M998 Series... TM Hand Receipt for Truck, 1-1/4 Ton, 4 x 4, M998 Series... TM HR Organizational Maintenance Repair Parts and Special Tools List for Truck, 1-1/4 Ton, 4 x 4, M998 Series... TM P Organizational Maintenance Manual for Truck, 1-1/4 Ton, 4 x 4, M998 Series... TM Operator's manual for Welding Theory and Application... TM Materials Used for Cleaning, Preserving, Abrading, and Cementing Ordnance Material and Related Materials (Including Chemicals)... TM Operator's, Unit, and Intermediate Direct Support Maintenance Manual Including Repair Parts and Special Tools List for AN/TSM-182, Maintenance Facility... TM &P A-1

34 Operator's Unit, and Intermediate Direct Support Maintenance Manual Including Repair Parts and Special Tools List for AN/TSM-183, Spares Facility... TM &P Operator's Unit, and Intermediate Direct Support Maintenance Manual for AN/TTC-48(V), Small Extension Node... TM Operator's and Unit Maintenance Manual for AN/TTC-46, Large Extension Node Switch... TM Operator's and Unit Maintenance Manual for AN/TTC-47, Node Center Switch... TM Operator's and Unit Maintenance Manual for Communications Central AN/TTC TM Operator's Unit, and Intermediate Direct Support Maintenance Manual for AN/TRC-191, Radio Access Unit... TM Operator's Unit, and Intermediate Direct Support Maintenance Manual for AN/TRC-190(V), Line-of-Sight Multichannel Radio Terminal... TM Operator's Unit,, and Intermediate Direct Support Maintenance Manual for AN/TSQ-154, Management Shelter... TM Operator's and Unit Maintenance Manual for AN/TYQ-46 (V), System Control Center... TM A-6. TECHNICAL BULLETINS Warranty Program for Mobile Subscriber Equipment... TB Equipment Improvement Report and Maintenance Digest... TB Maintenance and Repair Procedures for Shelters, Electrical Equipment... TB A-7. ARMY REGULATIONS identification and Distribution of DA Publications and Issue of Agency and Command Administrative Publication... AR Dictionary of United States Army Terms... AR A-8. OTHER PUBLICATIONS Lubrication Order for Truck, 1-1/4 Ton, 4 x 4, M998 Series... LO A-2

35 APPENDIX B INSTALLATION KITS B-1. SCOPE a. This appendix lists and identifies MSE Installation kits for M1037 and M1097 trucks, the S250 Shelter and S250 extended shelter and the M101A2, M116A1 3/4 ton trailers. b The material presented here provides information only and is not an authorization for requisition or turn-in of installation kit equipment. B-2. S250 and S250 EXTENDED CARRIERS The following tabular list Identifies those installation kits used on S250 and S250 Extended carriers, M1037 and M1097 trucks. B-1

36 B-2. S250 and S250 EXTENDED CARRIERS continued B-2

37 B-2. S250 and S250 EXTENDED CARRIERS continued B-3

38 B-3. CARGO CARRIERS AND TRAILERS The following tabular list identifies those Installation kits used on cargo carriers, cable trucks and trailers. B-4

39 B-5/(B-6 Blank) TB

40 APPENDIX C REPAIR PARTS SECTION I. INTRODUCTION C-1. SCOPE This Repair Parts List identifies and authorizes spare and repair parts required for performance of organizational maintenance of the S250 Extended Shelter. Carrier It authorizes the requisitioning, issue, and disposition of spares and repair parts as indicated by the Source, Maintenance, and Recoverability (SMR) codes C-2. GENERAL In addition to Section I, Introduction, this Repair Parts List is divided into the following sections: a. Section II. - Repair Parts List. A list of spare parts is authorized for use in the performance of maintenance. The list also includes parts which must be removed for replacement of the authorized parts. Parts lists are composed in ascending alphanumeric sequence, with the parts in each group listed in ascending figure and item number sequence. Items listed are shown on the associated illustration(s)/figure(s). b. Section III. - National Stock Number and Part Number Index. A list, In National Item Identification Number (NIIN) sequence, of all National stock numbered items appearing in the listing, followed by a list In alphanumeric sequence of all part numbers appearing in the listings. National stock numbers and part numbers are cross-referenced to each illustration figure and item number appearance. Section II. REPAIR PARTS LIST Title Fig No. Page No. S250 Extended Shelter Carrier Assembly and Mounting Hardware... 1 C-2 S250 Extended Shelter Carrier Taillight Extension... 2 C-6 S250 Extended Shelter Carrier Tailgate and Chain Mounting... 3 C-8 S250 Extended Shelter Carrier Tailgate hinges and Step Plate Assembly... 4 C-10 C-1

41 Figure 1. S250 EXTENDED SHELTER CARRIER ASSEMBLY AND MOUNTING HARDWARE. C-2

42 TM (1) (2) (3) (4) (5) (6) ITEM SMR PART NO CODE FSCM NUMBER DESCRIPTION AND USABLE ON CODES (UOC) QTY FIGURE 1 S250 EXTENDED SHELTER CARRIER ASSEMBLY AND MOUNTING HARDWARE. (KIT ) 1 PAOZZ MS BOLT, HEX HEAD, 1/2-13X PAOZZ SPACER, FRON SUPPORT 8 3 PAOZZ MS WASHER, FLAT, 1/ PFOZZ SUPPORT ASSEMBLY, S250E SHELTER 1 5 PAOZZ MS BOLT, HEX HEAD, 1/2-13X PAOZZ B1821BH044C250L BOLT, HEX HEAD, 7/16-14X PAOZZ MS WASHER, LOCK, 7/ PAOZZ MS WASHER; FLAT, 7/ PAOZZ BRACKET, SHELTER MOUNTING, S250E 4 10 PAOZZ SHIM, SHELTER MOUNTING, S250E, 0 12 AR IN: UOC H21 10 PAOZZ SHIM, SHELTER MOUNTING, S250E, 0.09 AR IN: 10 PAOZZ SHIM, SHELTER MOUNTING, S250E, 0.03 AR IN: 11 PAOZZ MS BOLT, HEX HEAD, 3/8-16X PAOZZ MS WASHER, FLAT, 3/ PAOZZ MS NUT, HEX, 3/ PFOZZ REINFORCEMENT, SHELTER MOUNTING 4 15 PAOZZ MS WASHER, LOCK, 1/ PAOZZ MS L BOLT, SPECIAL, 1/2-13X PAOZZ MS BOLT, HEX HEAD, 1/2-13X PAOZZ MS NUT, HEX, 1/ PFOZZ PLATE ASSY., SHELTER MOUNTING 1 20 PFOZZ REINFORCEMENT, "B" BEAM 2 21 PFOZZ REINFORCEMENT, "B" BEAM OUTER 2 C-3

43 TM Figure 2. S250 Extended Shelter Carrier Tailight Extension C-4

44 TM (1) (2) (3) (4) (5) (6) ITEM SMR PART NO CODE FSCM NUMBER DESCRIPTION AND USABLE ON CODES (UOC) QTY FIGURE 2. S250 EXTENDED SHELTER TAILLIGHT EXTENSION. (KIT ) 1 PAOZZ PLUG, DUMMY YELLOW 8 2 PAOZZ SHELL, MALE 8 3 PAOZZ MS STRAP, TIEDOWN 2 4 PAOZZ CLAMP, CUSHIONED 2 5 PAOZZ HARNESS ASSY, JUMPER 2 6 PAOZZ MS NUT, SELF-LOCKING 1/ PAOZZ CLAMP, CUSHIONED 2 8 PAOZZ MS WASHER, FLAT 1/ PAOZZ MS SCREW, CAP, HEXAGON 1/4-20X PAOZZ CLAMP, CUSHIONED 4 11 PAOZZ NUT, HEX, LOCKING 1/ PAOZZ MS WASHER, FLAT, 3/ PAOZZ MS SCREW, CAP, HEXAGON 3/8-16X PAOZZ WASHER, SHOULDERED NYLON 4 15 PAOZZ BAR, BUSS 2 16 PAOZZ DECAL NO STEP 2 17 PAOZZ BRACKET ASSY. TAILLIGHT EXTENSION, LH 1 17 PAOZZ BRACKET ASSY TAILLIGHT EXTENSION, 1 RH: 18 PAOOO STOPLIGHT-TAILLIGHT 2 19 XAOZZ *BODY ASSEMBLY COMPOSITE LIGHT 1 20 PAOZZ MS *LAMP, INCANDESCENT COMPOSITE LIGHT 1 C-5

45 TM (1) (2) (3) (4) (5) (6) ITEM SMR PART NO CODE FSCM NUMBER DESCRIPTION AND USABLE ON CODES (UOC) QTY FIGURE 2. S250 EXTENDED SHELTER CARRIER TAILLIGHT EXTENSION. (KIT ) (CONTINUED) 21 PAOZZ MS *LAMP, INCANDESCENT COMPOSITE LIGHT 1 22 PAOZZ MS *LAMP, INCANDESCENT COMPOSITE LIGHT 2 23 PAOZZ *PACKING, PREFORMED COMPOSITE LIGHT 1 24 PAOZZ *LENS, LIGHT COMPOSITE LIGHT 1 25 PAOZZ REFLECTOR, RED 2 26 PAOZZ SCREW, PHCR 1/4-20X5/8 4 C-6

46 TM Figure 3. S250 Extended Shelter Carrier Tailgate and Chain Mounting. C-7

47 TM (1) (2) (3) (4) (5) (6) ITEM SMR PART NO CODE FSCM NUMBER DESCRIPTION AND USABLE ON CODES (UOC) QTY FIGURE 3. S250 EXTENDED SHELTER CARRIER TAILGATE AND CHAIN MOUNTING. (KIT ) 1 PAOZZ MS NUT, HEX, SELF-LOCK, 5/ PAOZZ WASHER, FLAT, HARDENED, 5/ PFOZZ BRACKET, TAILGATE CHAIN 2 4 PAOZZ MS BOLT, HEX HEAD, 5/16-18X PAOZZ MS NUT, HEX, SELF-LOCK, 3/ PAOZZ WASHER, FLAT, HARDENED, 3/ PAOZZ MS BOLT, H;EX HEAD, 3/8-16X PAOZZ CONNECTOR, COLD SHUT, TAILGATE CHAIN 2 9 PAOZZ CHAIN ASSEMBLY, TAILGATE, L.H. 1 9 PAOZZ CHAIN ASSEMBLY, TAILGATE, R.H 1 C-8

48 TM * PART OF ITEM 1 Figure 4. S250 EXTENDED SHELTER CARRIER TAILGATE HINGES AND STEP PLATE ASSEMBLY C-9

49 TM (1) (2) (3) (4) (5) (6) ITEM SMR PART NO CODE FSCM NUMBER DESCRIPTION AND USABLE ON CODES (UOC) QTY FIGURE 4. S250 EXTENDED SHELTER CARRIER TAILGATE HINGES AND STEP PLATE ASSEMBLY. 1 PFOOO STEP PLATE ASSEMBLY 1 2 PAOZZ *DECAL, LIFT HERE 4 3 PAOZZ *ANTI-SKID, STEP PLATES, SET 1 4 PAOZZ *RIVET, BLIND, 3/ PFOOO *HINGE, STEP PLATE 1 6 PAOZZ SCREW, MACHINE, CROSS, RECESS, 4 1/4-20X PAOZZ SCREW, MACHINE, CROSS, RECESS, 4 5-1/4-20X PAOZZ MS27130-A37 NUT, PLAIN, BLIND, 1/4 5 9 PAOZZ MS27130-A38 NUT, PLAIN, BLIND, 1/ PAOZZ WASHER, FLAT, HARDENED, 3/ PAOZZ MS BOLT, HEX HEAD, 3/8-16X PFOOO HINGE, TAILGATE EXTENSION, LOWER 2 13 PAOZZ MS NUT, HEX, SELF-LOCKING, 3/ PAOZZ PIN, TAILGATE HINGE 2 15 PFOOO HINGE, TAILGATE EXTENSION, UPPER 2 16 PAOZZ MS SCREW, MACHINE, HEX HEAD, #10,32X PAOZZ MS WASHER, LOCK # PAOZZ MS NUT, SELF-LOCKING, 1/ PAOZZ WASHER, FLAT, HARDENED, 1/ PAOZZ BLOCK, RUBBER, TAILGATE, INNER 2 21 PAOZZ BLOCK, RUBBER, TAILGATE, OUTER 2 C-10

50 TM Section III. NATIONAL STOCK NUMBER AND PART NUMBER INDEX NATIONAL STOCK NUMBER INDEX STOCK NUMBER FIG. ITEM STOCK NUMBER FIG. ITEM C-11

51 SECTION III. NATIONAL STOCK NUMBER AND PART NUMBER INDEX (CONT D) PART NUMBER INDEX TM FSCM PART NUMBER STOCK NUMBER FIG. ITEM MS MS MS27130-A MS27130-A MS MS MS MS MS MS MS MS MS MS MS MS MS MS MS MS MS MS MS MS B1821DH044C250L MS L MS C-12

52 SECTION III. NATIONAL STOCK NUMBER AND PART NUMBER INDEX (CONT D) PART NUMBER INDEX TM FSCM PART NUMBER STOCK NUMBER FIG. ITEM C-13

53

54

55 PIN: