TM T.O. 36A12-1B

Transcription

1 T.O. 36A12-1B TECHNICAL MANUAL Chapter 13 VOLUME 3 OF 3 PART 2 OF 4 MAINTENANCE ORGANIZATIONAL LEVEL 2½-TON, 6x6, M44A1 AND M44A2 SERIES TRUCKS (MULTIFUEL) Chapter 14 Chapter 15 Chapter 16 TRUCK, CARGO: M35A1, M35A2, M35A2C, M36A2; TRUCK, TANK, FUEL: M49A1C, M49A2C; TRUCK, TANK, WATER: M50A1, M50A2, M50A3; TRUCK, VAN, Chapter 17 SHOP: M109A2, M109A3; TRUCK, REPAIR SHOP: M185A2, M185A3; TRUCK, TRACTOR: M275A1, M275A2; TRUCK, DUMP: M342A2; TRUCK, MAINTENANCE, PIPELINE CONSTRUCTION: M756A2; TRUCK, MAINTENANCE, EARTH BORING AND POLESETTING: M764 NOTE: THE STYLE OF THIS TM IS EXPERIMENTAL. IT IS BEING TRIED BY THE ARMY ONLY ON A LIMITED BASIS DEPARTMENTS OF THE ARMY AND THE AIR FORCE MAY 1981

2 * T.O. 36A12-1B TECHNICAL MANUAL DEPARTMENTS OF THE ARMY NO AND TECHNICAL ORDER THE AIR FORCE NO. 36A12-1B Washington, D. C., 27 May 1981 TECHNICAL MANUAL VOLUME 3 OF 3 PART 2 OF 4 MAINTENANCE ORGANIZATIONAL LEVEL 2½-TON 6X6, M44A1 AND M44A2 SERIES TRUCKS (MULTIFUEL) Model NSN without Winch NSN with Winch Truck, Cargo M35A1 M35A2 M35A2C M36A Truck, Tank, Fuel M49A1C M49A2C Truck, Tank, Water M50A1 M50A2 M50A Truck, Van, Shop M109A2 M109A Truck, Repair Shop M185A2 M185A Truck, Tractor M275A1 M275A Truck, Dump M342A Truck, Maintenance, Pipeline Construction M756A Truck, Maintenance, Earth Boring and Polesetting M *This manual, together with TM , 27 May 1981; TM , 27 May 1981; TM , 27 May 1981; TM , 27 May 1981; TM , 27 May 1981; and TM , 27 May 1981 supersedes TM , 31 August i

3 REPORTING OF 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 procedure, 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 direct to: Commander, US Army Tank-Automotive Command, ATTN: DRSTA-MB, Warren, Michigan A reply will be furnished to you. TABLE OF CONTENTS CHAPTER 13. BRAKE SYSTEM GROUP MAINTENANCE Section I. Section II. Section III. Scope Equipment Items Covered Equipment Items Not Covered Handbrake Assembly and Related Parts Handbrake Brake Drum Removal and Handbrake Brakeshoes Removal and... Handbrake Cable Assembly Removal and Removal of Overcentering Locking Handbrake Lever Cable Removal of Ratchet and Pawl Handbrake Lever Cable Replacement of Overcenter Locking Handbrake Lever Cable Replacement of Ratchet and Pawl Handbrake Lever Cable Handbrake Lever Assembly Removal and Handbrake Cable and Lever Assembly Adjustment Service Brake Service Brakeshoe Assembly Removal and Replacement a 13-3b 13-3c a 13-4b a 13-5b 13-5c 13-5d 13-5e a 13-6b a 13-8b 13-8C ii

4 TABLE OF CONTENTS-CONT Service Brakes Minor Adjustment Service Brakes Major Adjustment Section IV. Hydraulic Brake System Hydraulic Wheel Cylinder Removal and a b c Master Cylinder Assembly Removal and a b Hydraulic Lines, Hoses, and Fittings Removal and Replacement a b Air Hydraulic Cylinder Removal and 4 4a b 07. 4c 12 Bleeding Service Brake System Using Bleeder Tank Connecting Bleeding Tank a 17 Bleeding Air Hydraulic Cylinder Bleeding Wheel Cylinders b 5c Disconnecting Bleeder Tank d 24 Bleeding Service Brake System Without Using Bleeder Tank Filling Master Cylinder a Bleeding Air Hydraulic Cylinder b 28 Bleeding Wheel Cylinders c 31 Section V. Section VI. Mechanical Brake System Brake Pedal Removal and Replacement Brake Pedal Pad Removal and Replacement Service Brake Pedal Adjustment Air Brake System Vent Air System Pressure Air System Lines and Fittings a 7b 7c 8 8a 8b a 13-21b 13-21c iii

5 TABLE OF CONTENTS-CONT Air Brake Valve Removal and a b c 64 Air Brake Hand Control Valve Repair a b 68 Air Brake Hand Control Valve Removal and Replacement a b 74 Air System Safety Valve Removal and a 13-25b Air Reservoirs Removal and Replacement 13-25c 82 (Trucks M275A1, M2725A2, and M342A2) a b 83. Air Reservoirs Removal and Replacement 13-26c 87 (Trucks M49A1C and M49A2C) a b c 97 Air Reservoirs Removal and Replacement (Trucks M35A2C, M50A2, M109A3, M185A3 and M756A2) a b Air Reservoirs Removal and Replacement 13-28c (Truck M764) a b c Air Reservoirs Removal and Replacement (Truck M35A1) Preliminary Procedures a b Replacement c Section VII. Compressed Air System Air Compressor Removal and Replacement Preliminary Procedures a b c iv

6 TABLE OF CONTENTS-CONT Section VIII. Air Compressor Service Disassembly and Service Assembly Replacement Air Compressor Belt and Pulley Removal and Replacement Air Compressor Drive Belt Removal, Replacement, and Adjustment Replacement and Adjustment Air Compressor Governor Assembly Removal and Replacement Air Compressor Governor Pressure Check and Adjustment Pressure Check Adjustment (Air Pressure More Than 105 psi) Adjustment (Air Pressure Less Than 105 psi) Trailer Brake Connections Quick Disconnect Coupling Half Removal and Replacement Quick Disconnect Coupling Half Repair Air Brake Cutoff Cocks and Couplings Removal and Replacement (All Trucks Except M764) Air Brake Cutoff Cocks and Couplings Removal and Replacement (Truck M764) a 13-32b 13-32c 13-32d 13-32e a 13-33b 13-33c a 13-34b 13-34c a 13-35b 13-35c a 13-36b 13-36c a 13-37b 13-37c a 13-39b 13-39c a 13-40b 13-40c v

7 TABLE OF CONTENTS -CONT Air Brake Hose Removal and Replacement Preliminary Procedure Air Brake Hose Repair Repair CHAPTER 14. WHEEL GROUP MAINTENANCE Section I. Section II. Section III. Scope Equipment Items Covered Equipment Items Not Covered Front Wheel Assembly Front Wheel and Brake Drum Assembly Removal and Replacement Front Hub and Brake Drum Assembly Removal and Replacement Front and Rear Hub and Brake Drum Assembly Repair Front Hub and Brake Drum Rear Hub and Brake Drum Front Wheel Bearing Cover and Seals Removal and Replacement for Service Removal Cleaning Inspection Lubrication Replacement Front Inner and Outer Wheel Bearings and Seals Removal and Replacement Cleaning Inspection Lubrication Rear Wheel Assembly Rear Wheels and Brake Drum Assembly Removal and Replacement Preliminary Procedure Replacement a 13-41b 13-41c a 13-42b a 14-3b 14-3c a 14-4b 14-4c a 14-5b 14-5c a 14-6b 14-6c 14-6d 14-6e 14-6f a 14-7b 14-7c 14-7d 14-7e 14-7f a 14-8b 14-8c vi

8 TABLE OF CONTENTS-CONT Rear Hub and Brake Drum Assembly Removal and Replacement Preliminary Procedure Rear Inner and Outer Wheel Bearings and Seals Removal and Replacement Cleaning Inspection Lubrication Rear Wheel Bearing Cones and Seals Removal and Replacement for Service Cleaning Inspection Lubrication Section IV. Tires Tire and Tube Preliminary Procedure CHAPTER 15. STEERING SYSTEM GROUP MAINTENANCE Section I. Scope Equipment Items Covered Section II. Equipment Items Not Covered Mechanical Steering Gear Assembly Front Wheel Alinement Toe-in Check and Adjustment Pitman Arm Removal and Replacement Steering Gear Adjustment Preliminary Procedure Adjustment Tie Rod End Removal and Replacement Replacement Drag Link Assembly Removal and a 14-9b 14-9c 0 0a 0b 0c 0d 0e 14-l0f 1 1a 1b 1c 1d 1e 1f 2 2a 2b 2c a 15-3b a 15-4b a 15-5b a 15-6b 15-6c a 15-7b 15-7c vii

9 TABLE OF CONTENTS-CONT Drag Link Assembly Repair Drag Link Adjustment Steering Wheel Removal and Replacement..... Removal a 15-10b 15-10c CHAPTER 16. FRAME AND TOWING ATTACHMENTS GROUP Section I. Section II. MAINTENANCE Scope Equipment Items Covered Equipment Items Not Covered Pintle and Towing Attachments Front Lifting Shackle Removal and a 16-3b 16-3c Section III. Rear Lifting Shackle Removal and Pintle Hook Removal and Replacement Pintle Hook Repair Disassembly Assembly Spare Wheel Carrier Spare Wheel Carrier Removal and a 16-4b a 16-5b a 16-6b 16-6c Replacement (All Trucks Except (M342A2) Preliminary Procedures a 16-7b 16-7c Spare Wheel Carrier Repair (All Trucks Except Truck M342A2) Preliminary Procedure Disassembly Assembly a 16-8b 16-8c Spare Wheel Carrier Removal and Replacement (Truck M342A2) Preliminary Procedure Removal Replacement Spare Wheel Carrier Repair (Truck M342A2)... Preliminary Procedure Disassembly Repair Assembly a 16-9b 16-9c a 16-10b 16-10c 16-10d viii

10 TABLE OF CONTENTS-CONT Section IV. CHAPTER 17. Section I. Section II. Fifth Wheel Assembly Fifth Wheel Assembly Removal and... SPRINGS AND SHOCK ABSORBERS GROUP MAINTENANCE Scope Equipment Items Covered Equipment Items Not Covered Springs Front Springs Removal and Replacement.. Front Leaf Spring Assembly Repair Disassembly Cleaning, Inspection, and Repair Assembly Front Spring Seat Removal and.. Rear Spring Removal and Replacement Rear Leaf Spring Assembly Repair Disassembly Cleaning, Inspection, and Repair Assembly Rear Spring Seat Removal and. Rear Spring Seat Repair Disassembly Assembly Rear Spring Seat With Bearings Removal and Replacement a 16-11b a 17-3b a 17-4b 17-4c 17-4d a 17-5b 17-5c a 17-6b 17-6c a 17-7b 17-7c 17-7d a 17-8b 17-8c a 17-9b 17-9c a 17-10b 17-10c ix

11 TABLE OF CONTENTS-CONT Section III. Section IV. Shock Absorbers Shock Absorber Removal Preliminary Procedure and Replacement a Removal b Replacement c Torque Rods Torque Rods Removal and Replacement a b c x

12 TM CHAPTER 13 BRAKE SYSTEM GROUP MAINTENANCE Section I. SCOPE. EQUIPMENT ITEMS COVERED. This chapter gives equipment maintenance procedures for the handbrake assembly and related parts, service brake, hydraulic brake system, mechanical brake system, air brake system, compressed air system, and trailer brake connections for which there are authorized corrective maintenance tasks at the organizational maintenance level EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective maintenance is authorized at the organizational maintenance level are covered in this chapter. Section II. HANDBRAKE ASSEMBLY AND RELAYED PARTS HANDBRAKE BRAKE DRUM REMOVAL TOOLS: Pliers 6-inch ruler Torque wrench, 150 pound-feet capacity Container Adapter, 1/2 inch to 3/4 inch 3-inch extension, 3/4-inch drive Hammer SUPPLIES: Cotter pin PERSONNEL: One EQUIPMENT CONDITION: Truck parked, engine off, chocked. a. Preliminary Procedure. Remove propeller shaft AND REPLACEMENT. 3/4-inch wrench 1 7/16-inch wrench 1 5/16-inch wrench 1 1/2-inck socket Flat-tip screwdriver 6-inch adjustable wrench Brass punch handbrake set, wheels Refer to Part 2, para

13 b. Removal. FRAME 1 1. Using pliers, take cotter pin (1) out of handbrake drum near output shaft (2). Throw cotter pin away. 2. Using 1 1/2-inch wrench, unscrew and take off slotted nut (3) and flat washer (4). 3. Put handbrake (in cab) in brake off (down) position. GO TO FRAME

14 FRAME 2 NOTE On trucks with exhaust pipe going to rear, exhaust pipe must be loosened and pushed away from brakeshoes. For trucks with engine LD 427, refer to Part 1, para 5-5. For trucks with engine LD 465, refer to Part 1, para 5-3. For all other trucks, refer to Part 1, para Using screwdriver, lift spring (1) off screw (2). 2. Using pliers, unhook spring (3) from lever (4). 3. Using adjustable wrench, hold cable (5). Using 3/4-inch wrench, unscrew and take off nut (6). 4. Pull cable (5) out of eye of lever (4). GO TO FRAME

15 F R A M E 3 1. Using 1 7/16-inch wrench, unscrew and take off jamnut (l). 2. Using 1 5/16-inch wrench, unscrew and take out anchor screw (2) and spacer (3). 3. Pull lever assembly (4) with brakeshoes (5) away from handbrake brake drum (6). GO TO FRAME