TM TECHNICAL MANUAL UNIT MAINTENANCE HEADQUARTERS, DEPARTMENT OF THE ARMY 11 JULY Change 4

Transcription

1 TECHNCAL MANUAL UNT MANTENANCE CARRER, PERSONNEL, FULL TRACKED, ARMORED, M113A CARRER, COMMAND POST, LGHT TRACKED, M577A CARRER, MORTAR, 107-MM, M30; SELF-PROPELLED, M106A CARRER, MORTAR, 81-MM, M29A1; SELF-PROPELLED, M125A CARRER, MORTAR, 120-MM, M121; SELF-PROPELLED, M CARRER, SMOKE GENERATOR, FULL TRACKED, M COMBAT VEHCLE, ANT-TANK, MPROVED TOW VEHCLE, M901A CARRER, STANDARDZED NTEGRATED COMMAND POST SYSTEM, M This manual supersedes TM dated July 1985, including all changes. DSTRBUTON STATEMENT A: Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENT OF THE ARMY 11 JULY 1990 Change 4

2 Technical Manual No HEADQUARTERS DEPARTMENT OF THE ARMY Washington, D.C., 11 July 1990 TECHNCAL MANUAL UNT MANTENANCE CARRER, PERSONNEL, FULL TRACKED, ARMORED, M113A CARRER, COMMANDPOST, LGHT TRACKED, M577A CARRER, MORTAR, 107-MM, M30; SELF-PROPELLED, M106A CARRER, MORTAR, 81-MM, M29A1; SELF-PROPELLED, M125A CARRER, MORTAR, 120-MM, M121; SELF-PROPELLED, M CARRER, SMOKE GENERATOR, FULL TRACKED, M COMBAT VEHCLE, ANT-TANK, MPROVED TOW VEHCLE, M901A CARRER. STANDARDZED NTEGRATED COMMAND POST SYSTEM, M REPORTNG ERRORS AND RECOMMENDNG MPROVEMENTS You can help improve this manual. f you find any mistakes, or if you know a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form located in the back of this manual, directly to: Commander, U.S. Army Tank-automotive and Armaments Command, ATTN:AMSTA-AC-NML, Rock sland, L A reply will be furnished to you. This manual supersedes TM dated July, 1985, including all changes. DSTRBUTON STATEMENT A: Approved for public release; distribution is unlimited. Change 4 i

3 TABLE OF CONTENTS HOW TO USE THS MANUAL vi 1 2 V V NTRODUCTON General nformation Equipment Description and Data PRNCPLES OF OPERATON ntegrated systems ntegrated Components Service Upon Receipt of Material General Maintenance Procedures Unit Preventive Maintenance Checks and Services (PMCS) GENERAL TROUBLESHOOTNGPROCEDURES How to Use Troubleshooting Troubleshooting... 3-B STE/CE-R Troubleshooting ENGNE-RELATED COMPONENTS MANTENANCE POWER PLANT MANTENANCE V V V V V FUEL SYSTEM MANTENANCE Fuel System Hose Replacement, Diagrams, and Tests nside Fuel Tank and Hoses, Tubes, and Fittings (M113A2, M1059, M577A2, and M901A1 only) External Fuel Tanks and Hoses, Tubes, and Fittings (M981 and M1064 Only) Sponson Mounted Fuel Tanks and Lines (M577A2 Only) Fuel Compartment and Hoses, Tubes and Fittings (M125A2 and M106A2 Only) Fuel Compartment, Bladder, Hoses, Tubes, and Fittings (M741A1 Only) Bulkhead to njectors Engine Fuel and Air Hoses Fuel System Components SECTON 7 8 AR NDUCTON AND EXHAUST SYSTEM MANTENANCE Air nduction System Engine Exhaust System COOLNG SYSTEM MANTENANCE Engine Coolant Pump, Radiator, and Tubes Fan and Drive Components ii Change 4

4 9 ELECTRCAL SYSTEM MANTENANCE - POWER RECEPTACLES, GENERATOR, AND REGULATOR Auxiliary Power Receptacles Maintenance of Master Switch Panel Assembly Maintenance of Generator, Regulator, and Circuit 49 Lead Wire Assemblies STARTER SYSTEM MANTENANCE ELECTRCAL SYSTEM MANTENANCE - NSTRUMENT AND WARNNG LGHT PANELS nstrument Panel Warning Light Panel ELECTRCAL SYSTEM MANTENANCE - HORN AND LGHTNG SYSTEM Horn and Exterior Lights Maintenance of Wiring Harness (M741A1 Only) Maintenance of Distribution Box V Maintenance of Stop Light, Dome Lights Buzzer and Door Switches, and Tent Light V Maintenance of Wiring Harness V Maintenance of Stop Light Switch and nfrared Power Supply ELECTRCAL SYSTEM MANTENANCE - BATTERES ELECTRCAL SYSTEM MANTENANCE - WRNG HARNESS, RECEPTACLE, AND CABLE REPAR ELECTRCAL SYSTEM MANTENANCE - POWER PLANT WRNG HARNESS AND RELATED COMPONENTS ELECTRCAL SYSTEM MANTENANCE - BLGE PUMP, WRNG, AND RELATED COMPONENTS TRALER HARNESS, RECEPTACLES, BLOWER, SWTCHES, AND VENTLATON SYSTEM MANTENANCE Trailer Harness Communication and Utility Receptacles Rear Compartment Blower and Fuel Quantity Selector Switch (M577A2 Only) V Deleted TRANSMSSON RELATED COMPONENTS MANTENANCE TRANSFER GEARCASE-RELATED COMPONENTS DRVE SHAFTS, UNVERSAL JONTS, AND FNAL DRVE MANTENANCE Change 4 iii

5 21 22 DFFERENTAL RELATED COMPONENTS MANTENANCE TRACKS AND SUSPENSON MANTENANCE V 24 V V V V V X X X X X XV XV XV DRVER S CONTROLS Steering Controls Accelerator and Transmission Linkage, Throttle Linkage, and Fuel Cutoff Cable Transmission Controls and Engine Power Disconnect Pivot Steer and Controls HULL MANTENANCE Lifting Eyes, Towing Eyes, Pintle, and Tow Rope Stowage Pads Trim Vane, Power Plant Front Door, and Power Plant Access Door Hull Bottom Covers, Drain Plugs, and Box Beam Plugs Driver s and Rear Compartment Floor Plates Grill Assembly, Top Deck Hatches, Ventilator, and Generator Set Enclosure Armor and Support Maintenance (M901A1 Only) Driver s Seat and Commander s Seat Platform (All Configurations) Personnel Seats- Rear Compartment Blackout Curtain and Tables (M577A2, M1068, and M901A1 Only) Tent and Frame Ammunition and Fuze Racks (M106A2, M1064, and M125A2 Only) Ammunition Containers and Components (M741A1 Only) Turret Guard, Gun Travel Lock, and Flotation Pods (M741A1 Only) Dataplates, Stencils, Markers, Decals, and Miscellaneous Stowage tems Stowage System Maintenance Antenna Mast Maintenance RAMP CONTROLS, RAMP, AND RAMP DOOR MANTENANCE WELDNG CAUTONS, WARNNGS, AND NSTRUCTONS SMOKE GRENADE LAUNCHER AND AMMUNTON SPACERS V HYDRAULC SYSTEM RAMP AND SUSPENSON LOCKOUT Hydraulic Tank, Valves, and Lines (All Except M741A1) Hydraulic Tank, Valves, and Lines (M741A1 Only) Suspension Lockout System (M741A1 Only) Ramp Pump, Ramp Control Valve, and Ramp Cylinder AUXLARY GENERATOR PERSONNEL HEATER KT COMPONENT MANTENANCE DRVER'S WNDSHELD KT iv Change 3

6 31 ELECTRONC EQUPMENT HEATER KT (M577A2 Only) Heater Component Maintenance (Stewart Warner Corp., Model 10560M24B1) Heater Component Maintenance (Hupp Corp., Model MF510B) Electronic Equipment Heater ENGNE COOLANT HEATER KT Description and Data Coolant Heater Component Maintenance Kit Component Maintenance - Engine Coolant Heater RAMP NON-SKD WNTERZATON KT MANTENANCE (M106A2, M125A2, and M1064 Only) CAPSTAN KT (M113A2 and M1059 Only) MARNE RECOVERY KT (M113A2 and M1059 Only) LTTER KT MANTENANCE (M113A2 Only) ARTLLERY COMMUNCATON KTS (M577A2 Only) Deleted Artillery Communication Kit M577A2 Only) MACHNE GUN ARMOR SHELD KT MANTENANCE NBC KT MANTENANCE (ALL VEHCLES EXCEPT M NBC Kits (All vehicles except M1064 and M981) Ventilation System Maintenance (M981 Only) SMOKE GENERATOR EQUPMENT MANTENANCE (M1059 Only) ELECTRCAL/COMMUNCATON EQUPMENT MANTENANCE (M1068 Only) Curbside Electrical/Communication Equipment (M1068 Only) Roadside Electrical/Communication Equipment (M1068 Only) Electrical/Communication Equipment Cables (M1068 Only) COMMUNCATON SYSTEM MANTENANCE FXED FRE EXTNGUSHER SYSTEM MANTENANCE DELETED CHEMCAL AGENT AUTOMATC ALARM KT (M113A2 Only) Change 4 iv.1 (iv.2 blank)

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8 APPENDX A. REFERENCES A-1 APPENDX B. V MANTENANCE ALLOCATON CHART B-1 ntroduction b-1 Maintenance Allocation Chart B-4 Tools and Test Equipment Requirements B-14 Remarks B-21 APPENDX APPENDX APPENDX C. D. E. EXPENDABLE/DURABLE SUPPLES AND MATERALS LST C-1 ntroduction C-1 Expendable/Durable Supplies and Materials List C-3 COMMON TOOLS AND SUPPLEMENTS AND SPECAL TOOL/FXTURES LST D-1 ntroduction D-1 Common Tools and Supplements and Special Tools/Fixtures List D-3 FABRCATED TOOLS E-1 ALPHABETCAL NDEX DA FORM Behind ndex WRNG DAGRAMS FO-1 thru FO-11 METRC CONVERSON CHART nside Back Cover Change 3 v

9 HOW TO USE THS MANUAL This manual tells you how to perform unit maintenance for the M113A2, M106A2, M125A2, M577A2, M741A1, M1059, M1064, M1068, and M901A1 Carriers. Before starting a task or procedure, read HOW TO USE THS MANUAL and 2, PRNCPLES OF OPERATON. USNG YOUR MANUAL ON THE JOB The best way to learn about this manual is to practice using it. Knowing how to use this manual will save both time and energy. WHCH TYPE OF TASK DO YOU USE? There are two different types of tasks in this manual. They are maintenance tasks and troubleshooting tasks. Decide which type of task you need to use. TROUBLESHOOTNG TASKS Troubleshooting tasks help you locate faulty parts. They direct you to the maintenance task to correct these faults. 3, TROUBLESHOOTNG, contains detailed information on how to perform troubleshooting tasks. Read 3,, before performing the troubleshooting tasks in the chapter. MANTENANCE TASKS Doing maintenance tasks will keep the carrier in shape to operate. Maintenance tasks are used to present maintenance instructions. Each maintenance task details steps which you need to perform f the vehicle and parts need maintenance that is not included in any task in the manual, report this to your supervisor. HOW DO YOU FND THE CORRECT TASK? Pick a key word from the carrier part or system to be used during the task. Look in the ALPHABETCAL NDEX for this key word or the name of the action you will perform. Tum to the page indicated. The ALPHABETCAL NDEX lists each task under one or more headings. The task, REPLACE TOWNG PNTLE, could be found: Under P Pintle, towing: Repair: 24-4 Under T Towing pintle: Repair: 24-4 HOW DO YOU READ MANTENANCE TASKS? Be sure to read all warnings, cautions, and notes. These are in all types of tasks. They help you avoid harm to yourself, other personnel and equipment. They also tell you things you should know about the task. vi Change 3

10 HOW TO USE THE REPAR PARTS AND SPECAL TOOLS LST (RPSTL) WTH THS MANUAL The RPSTL (TM P) gives the National Stock Number NSN required to order parts used in the maintenance tasks. To use the RPSTL to identify and order a part, do the following: n this manual, turn to the first page of the task to be performed. Find Materials/Parts under NTAL SETUP, and read the part(s) that need replacement. f required, find the illustrated part in the task steps. Go to the RPSTL and find the same illustrated part. That part will have an item number assigned to it. Look this item number up in the listing for that figure. The NSN can be found in the NSN column. f you inspect an item and find that it is damaged, go to the RPSTL and find the SMR code for the item. f the SMR code does not authorize you to repair the item, reassemble it and send it to the authorized level of maintenance. The usable on code in the RPSTL appears in the lower left comer of the Description column heading. Usable encodes are shown as UOC in the Description Column (justified left) on the first line following the item description/homenclature. Uncoded items are applicable to all models. dentification of the usable on codes in the RPSTL are: Code V35 V36 V37 V38 V83 V ACP Used On M113A2 Carrier, Personnel M125A2 Carrier, 81 mm Mortar M577A2 Carrier, Command Post M106A2 Carrier, 107 mm Mortar M981 Carrier, Personnel, Armored Fire Support M741A1 Chassis, 20 mm Anti-Aircraft Gun M901A1 Combat Vehicle, Anti-Tank mproved TOW Vehicle M1059 Carrier, Personnel, Smoke M1064 Carrier, 120 mm Mortar M1068 Carrier, Standardized ntegrated Command Post System Change 3 xiii(xiv blank)

11 COOLNG 8 SYSTEM MANTENANCE. ENGNE COOLANT PUMP, RADATOR, AND TUBES TASK NDEX Task Page Task Page Coolant Flow Diagram Drain Coolant System Fill Cooling System Clean Radiator Replace Engine Coolant Pump dler Pulley and Belts Replace Engine Coolant Pump Replace Deaeration Elbow to Radiator nlet Elbow Coolant Tube Replace Radiator Outlet Elbow to Coolant Pump Elbow Hose and Tube Replace Thermostat, Housing, and Deaeration Elbow Replace Thermostat Housing to Engine Coolant Tube Replace Radiator and Parts Replace Balance Hose Repair Radiator Access Door Seals and Fasteners Repair Radiator Access Door Replace Auxiliary Tank and Parts Replace Auxiliary Tank to Coolant Pump Tube Replace Auxiliary Tank to Radiator Tube Replace Auxiliary Tank Deaeration Hoses Replace Combat Filler Cover and Lock

12 COOLANT FLOW DAGRAM Engine coolant maintains normal operating temperatures. Coolant flow is as follows: Coolant is drawn from the radiator by the coolant pump. t is pumped through the oil cooler, and the engine block, up to the cylinder heads, and into the thermostat housing. The coolant then passes through a deaerator elbow and back to the radiator. The deaerator elbow swirls the coolant to remove air. This air is vented back to the auxiliary tank. The auxiliary tank provides for coolant overflow from the radiator. The tank also vents air out through its cap. 8-2

13 DRAN COOLANT SYSTEM NTAL SETUP Tools: General Mechanics Tool Kit (tem 30, App D) Materials/Parts: Suitable container Personnel Required: Unit Mechanic References: See your -10 Equipment Conditions: Engine stopped/shutdown (see your 10) Carrier blocked (see your -10 ) Trim vane lowered and power plant front access door open (see your 10 ) Hull bottom access cover removed (page 24 32) Driver s power plant access panel removed (page 24-25) Power plant rear access panel removed (page or 24 29) DRAN WARNNG Hot radiator coolant can bum you. Remove cap only if cool to touch. Drain cocks may be hot. Turn cap slowly to release pressure. result. Replace cap by pressing down and turning until tight. - - CAUTON Coolant in the cooling system must flow freely. f rust, scale, or sediment prevent the free flow of coolant, flush system per TB This is to be done only as necessary. Do not operate engine above 230 F (110 C). Serious engine damage can NOTE For partial drain, attach a length of 1/2 inch (13mm) hose to the drain cock on thermostat housing or on deaerator elbow. Drain coolant into a clean container. Save coolant for reuse. Close drain cock. GO TO NEXT PAGE 8-3

14 WARNNG Hot radiator coolant can bum you. Drain cocks may be hot. Remove cap only if cool to touch Remove coolant filler cap (1) pressure. Place (2, 3, clean containers under 4, and 5). slowly to relieve drain cocks 3. Open oil cooler drain cock (4) Open three engine block drains cocks. One cock (3) is on left side of block. The other two cocks (2) are on right side. Open thermostat and deaerator elbow drain cocks (5). Allow system to drain. After system is drained, close six drain cocks (2, 3, 4, and 5). Replace filler cap (1). Tag master switch to warn others that engine coolant has been drained. Save coolant for reuse, unless check shows coolant should be changed. FOLLOW-THROUGH STEPS 1. nstall hull bottom access cover (page 24-32). END OF TASK 8-4

15 FLL COOLNG SYSTEM NTAL SETUP Tools: General Mechanics Tool Kit (tem 30, App D) Antifreeze and Battery Tester (tem 74, App D) Materials/Parts: Antifreeze (tem 3, App C) Container (14 gallon) Personnel Required: Unit Mechanic References: see your -10 See your -LO Equipment Conditions: Engine stopped/shutdown (see your -10) Carrier blocked (see your -10) Driver s power plant access panel removed (page 24-25) Power plant rear access panel removed (page or 24-29) NOTE When filling the radiator, add coolant slowly to allow trapped air to escape. Use antifreeze coolant in system at all times. t will reduce corrosion in engine block and cooling system parts. Ethylene glycol coolant will provide low temperature protection. Mix coolant and clean water based on protection label on container Make sure all six drain cocks (1,2,3 and 4) are closed and all tubes, hoses and connections are tight. Remove coolant filler cap (5). GO TO NEXT PAGE 8-5