SHOP EQUIPMENT, GENERAL PURPOSE REPAIR, SEMITRAILER MOUNTED MODEL: SGPRSMD (NSN )

Transcription

1 TECHNICAL MANUAL OPERATOR, ORGANIZATIONAL, DIRECT SUPPORT & GENERAL SUPPORT MAINTENANCE REPAIR MANUAL INCLUDING PARTS LIST FOR SHOP EQUIPMENT, GENERAL PURPOSE REPAIR, SEMITRAILER MOUNTED MODEL: SGPRSMD (NSN ) MARCH 1984 HEADQUARTERS, DEPARTMENT OF THE ARMY

2 TABLE OF CONTENTS Para. Page CHAPTER 1. Section I. II. INTRODUCTION General Description and Data CHAPTER 2. Section CHAPTER 3. Section CHAPTER 4. Section I. II. III. I. II. III. IV. I. II III. IV. V. VI. VII. VIII. OPERATING INSTRUCTIONS Operating Procedures Operation of Auxiliary Materiel Used In Conjunction With the Shop Set Operation Under Unusual Conditions OPERATOR/CREW MAINTENANCE INSTRUCTIONS Lubrication Preventive Maintenance Checks and Services Troubleshooting Operator/Crew Maintenance......, GENERAL MAINTENANCE INSTRUCTIONS Repair Parts, Special Tools, and Equipment Service Upon Receipt of Material Movement to a New Work Site Lubrication Preventive Maintenance Checks and Services Troubleshooting General Maintenance Radio Interference Suppression CHAPTER 5. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS CHAPTER 6 MAINTENANCE OF ELECTRICAL SYSTEMS CHAPTER 7. CHAPTER 8. CHAPTER 9. CHAPTER 10. CHAPTER 11. CHAPTER 12. CHAPTER 13. CHAPTER 14. ENGINE ELECTRICAL SYSTEM 7-1 ENGINE FUEL SYSTEM 8-1 ENGINE COOLING SYSTEM 9-1 ENGINE LUBRICATION SYSTEM 10-1 INTAKE AND EXHAUST SYSTEMS 11-1 ENGINE ASSEMBLY 12-1 MAINTENANCE OF DYNAMOTOR-WELDER 13-1 MAINTENANCE OF THE AIR COMPRESSOR 14-1 AND RELATED PARTS i

3 TABLE OF CONTENTS-Continued Para. Page CHAPTER 15. CHAPTER 16. CHAPTER 17. CHAPTER 18. CHAPTER 19. APPENDIX A MAINTENANCE OF BODY COMPONENTS MAINTENANCE OF PERSONNEL HEATER MAINTENANCE OF SIDE LIFTING HYDRAULIC SYSTEM MAINTENANCE OF CONTROL CUBICLE TRAILER CHASSIS AND COMPONENTS REFERENCES A-1 APPENDIX B APPENDIX C SHOP SET TOOL LOCATION LOADING AND PACKING LIST EXPENDABLE/CONSUMABLE MAINTENANCE SUPPLIES AND MATERIALS INDEX FOLDOUT PAGES B-1 C-1 Index 1 ii

4 Figure Shop Set, Shop Set, Shop Set, Hydraulic LIST OF ILLUSTRATIONS Title Doors Closed..... Doors Open Tent Installed.... System Comtrols... Engine Controls and Instruments Air Compressor Drive Motor Control and Air Receiver Tank Pressure Gage. Electrical System Control Panel Overspend Safety Switch..... Starting the Shop Set Engine.. Stopping the Shop Set Engine.. Personnel Heater Controls and Operation... Shop Set Blocking and Tiedown Instructions.. Flatcar with Ramp in Place... Batteries, Removal, Installation and Service. Raising and Lowering Shop Set Side Doors... Opening Shop Set Rear Doors and Panels.... Laying Out Tent Framing.... Erecting Tent Planning (Sheet 1 of 2).... Erecting Tent Planning (Sheet 2 of 2).... Erecting Tenting (Sheet 1 of 3) Erecting Tenting (Sheet 2 of 3) Erecting Tenting (Sheet 3 of 3) External Power Supply, Disconnection and Reconnection.. Grounding the Shop Set..... Voltage and Frequency Conversion Interference Suppression Components, Removal and Installation (Sheet 1 of 2) Interference Suppression Components, Removal and Installation (Sheet 2 of 2) Engine Enclosure, Removal and Installation.. Engine and Dynamotor-Welder, Removal and Installation.. Control Cubicle, Removal and Installation.. Shop Body, Removal and Installation Volt Electrical Installation (Sheet 1 of 6) Volt Electrical Installation (Sheet 2 of 6) Volt Electrical Installation (Sheet 3 of 6) Volt Electrical Installation (Sheet 4 of 6) Volt Electrical Installation (Sheet 5 of 6) Volt Electrical Installation (Sheet 6 of 6) Volt DC Electrical Installation (Sheet lof2). 24 Volt DC Electrical Installation (Sheet 2of2) Service and Blackout Clearance Lights, Removal and Installation. Convenience Receptacles, Lamp Bases, and Toggle Switches Page iii

5 LIST OF ILLUSTRATIONS Continued Figure Title Page Floodlights, Removal and Installation.... Lamp Replacement. Light Assembly, Removal and Installation... Front Ventilator, Removal and Installation.. Rear Ventilator Fan Assembly, Removal and Installation Rear Ventilators, Disassembly and Removal.. Emergency and External Power Receptacle, Removal and Installation... Clearance Lights, Removal and Installation.. Composite Light Assembly, Disassembly and Assembly.... Junction Box, Removal and Installation.... Rear Wiring to Floodlight, Removal and Installation.. Batteries and Battery Box, Removal and Installation.. Starter Assembly, Removal and Installation.. Starter, Disassembly and Assembly Starter Assembly Motoring Test Circuit.... Alternator, Removal and Installation..... Alternator, Disassembly and Assembly..... Rotor Assembly Current Draw Test Circuit... Alternator Positive Output Circuit Test... Total Circuit Voltage Test... Excitation Voltage Tests.... Faulty Voltage Regulator Circuit Test.... Field Current Test Output and Voltage Protection Test Coolant Thermostat and Sensors, Removal and Installation Oil Sending Units, Removal and Installation. Fuel Tank, Lines, and Fittings, Removal and Installation Fuel Transfer Dump, Removal and Installation. Primary Fuel Filter, Removal and Installation Secondary Fuel Filter, Removal and Installation Fuel Injection Pump, Removal and Installation Fuel Injection Pump Governor.. Fuel Injection Pump Linkage and Control... Fuel Injection Pump End Plates and Blades.. Fuel Injection Pump, Pivot Shaft and Arm Assembly.. Fuel Injection Pump Piston and Damper Spring. Fuel Injection Pump Rotor Assembly Fuel Injection Pump Housing and Drive Shafts. Adjusting Fuel Injection Pump Roller-to-Roller Dimension... Fuel Injection Lines and Fittings iv

6 Figure LIST OF ILLUSTRATIONS Continued Title Fuel Nozzle and Holder..... Quick Start System Radiator and Support Rods.. Front Support and Tire Rod... Fan and Water Pump Assembly.. Checking Impeller to Cover Plate Clearance.. Oil Filter and Hose Assembly.. Oil Pan..... Oil Pump Assembly Oil Pump Assembly Dimension.. Air Cleaner and Tube Muffler and Cap. Intake and Exhaust Manifolds.. Flywheel and Housing Checking Flywheel Concentricity and Alignment Gear Housing and Covers.... Cylinder Head and Valve Mechanism Rocker Aim Mounting Blocks Installation... Rocker Arm Shaft Positioning.. Cylinder Head Nut Tightening Sequence.... Valve Tappet Clearnace Adjustment Camshaft, Exploded View... Dimensional Inspection of Camshaft Piston and Connecting Rods... Cylinder Block Assembly (Sheet 1 of 2).... Cylinder Block Assembly (Sheet 2 of 2)... Clutch and Cover. Clutch Assembly, Removal, Disassembly, Reassembly and Installation. Ventilating Air Filters, Removal and Installation.. Dynamotor-Welder End Wrappers, Removal and Installation Dynamotor-Welder Brush Replacement and Tension Adjustment Overspeed Safety Switch Adjustment Overspeed Safety Switch, Exploded View.... End Cover and Bearing Cap, Removal and Installation.. Dynamotor-Welder Armature, Removal and Installation.. Dynamotor-Welder Armature, Disassembly and Assembly. Dynamotor-Welder Frames, Field Coils, Pole Shoes, Brush Holders and Mounting Rings, Exploded View (Sheet l of 3). Dynamotor-Welder Frames, Field Coils, Pole Shoes, Brush Holders and Mounting Rings, Exploded View (Sheet 2 of 3) Page v

7 Figure LIST OF ILLUSTRATIONS Continued Title Dynamotor-Welder Frames, Field Coils, Pole Shoes, Brush Holders and Mounting Rings, Exploded View (Sheet 3 of 3). Terminal Board, Removal and Installation... Motor Terminal Board, Removal and Installation Air Compressor and Drive Motor Assembly, Removal and Installation... Inlet Filter, Exploded View.. Air Receiver Tank Pop-Off Valve Compressor Starter Control Box, Exploded View Pressure Switch. Frame End Cover, Exploded View. Fanwheel Aftercooler and Intercooler, Exploded View. Low Pressure Cylinder Piston, Rod, and Rings, Exploded View. High Pressure Cylinder, Piston, Rod, and Rings, Exploded View..... Crankshaft Assembly, Exploded View Belt Guard Assembly, Removal and Installation Belt Tightener and Base Assembly, Removal and Installation Side Doors, Removal and Installation..... Rear Door and Panel, Removal and Installation Tent Frame, Removal and Installation..... Grinder, Removal and Installation Milling and Grinding Attachment, Removal and Installation Valve Refacer, Removal and Installation l/2-ton Press Frame, Removal and Installation Vise, Removal and Installation. Lathe Belt, Removal and Installation..... Lathe, Removal and Installation Lathe Stand, Removal and Installation.... Hinged Table, Removal and Installation.... Cabinet Assembly, Removal and Installation.. Track and Trolley Assembly, Removal and Installation. - Miscellaneous Van Body Components, Removal and Installation Personnel Heater, Removal and Installation.. Tent Curtains.. Hydraulic Pump, Removal and Installation... Side Lifting Cylinder and Hydraulic Hose, Removal and Installation... Side Lifting Cylinder, Exploded View..... Hydraulic Pump, Exploded View. Rotary Switch (l0-range), Exploded View... Page vi

8 TM &P LIST OF ILLUSTRATIONS Continued Figure Title Page B-1 Cubicle Control Components, Removal and Installation.. Generator Output Contactor, Exploded View.. Overload Switch, Exploded View. Resistor and Relay Mounting Panel, and Emergency Power Panel.... Dynamotor-Welder Control Panel. Upper Control Panel Lower Control Panel Control Box and Coil Assembly, Removal and Installation.. Engine Control Panel, Right Hand Engine Control Panel, Left Hand Tire and Rim... Hub and Drum... Brake Adjustment. Air Reservoir and Relay Valve. Front Air Brake Lines and Air Filter..... Rear Air Brake Lines Brake Air Chamber and Master Cylinder.... Brake Shield and Shoe..... Axle Assembly. Pivot Axle.... Landing Gear, Removal and Installation.... Landing Gear... Compartment Panels and Access Doors..... Compartment Doors Compartment Panel and Brackets and Seal Assembly Frame and Brackets Towing Pintle.. Front Ladder... Frame and Wiring. Shop Set Location B-1 vii/(viii blank)

9 TM &P CHAPTER 1 INTRODUCTION Section I. GENERAL 1-1. SCOPE. a. This manual is published for the use of the personnel to whom the Truck Body Model SGPRSMD, Semitrailer Mounted General Purpose is issued. b. This manual provides information related to the contents of the shop set and includes wiring diagrams (Figures FO-1 through FO-4). For operating and maintenance instructions pertaining to the truck and components other than the shop equipment contents covered in this publication, refer to Appendix A, Reference MAINTENNACE FORMS AND RECORDS. Equipment maintenance forms and records and procedures for their use are contained in DA PAM as contained in Maintenance Management Update ADMINISTRATIVE STORAGE. For information necessary to meet Administrative Storage Requirements, refer to TM EQUIPMENT SERVICEABILITY CRITERIA (ESC). There are no Equipment Serviceability Criteria (ESC) technical manuals in existence pertinent to the end item of equipment being covered in this publication DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE. For procedures required to render this end item unusable by the enemy, refer to TM QUALITY ASSURANCE/QUALITY CONTROL (QA/QC). There is no Quality Assurance/Quality Control (QA/QC) manual in existence containing the applicable requirements for maintenance of the equipment covered in this publication REPORTING QUALITY DEFICIENCY REPORTS (QDR). QDR s will be prepared on SF 368, Quality Deficiency Report. Instructions for preparing QDR s are provided in DA PAM as contained in Maintenance Management Update. QDR s should be mailed directly to Commander, US Army Armament, Munitions and Chemical Command, ATTN: DRSMC-MAO, Rock Island, IL A reply will be furnished directly to you. Section II. DESCRIPTION AND DATA 1-8. DESCRIPTION. The Model SGPRSMD Shop Set (fig. 1-1) is semi-trailer mounted and contains tools and equipment that are used for maintenance and repair of mechanical equipment. The trailer is equipped with doors to provide easy access to the equipment in the set (fig. 1-2). A weather protected work area may be set up around the trailer (fig. 1-3). A 1-1

10 Figure