TM OPPOSING FORCES SURROGATE VEHICLE (OSV) M113A3/BMP (EIC AUK) HULL TECHNICAL MANUAL UNIT MAINTENANCE MANUAL FOR

Transcription

1 TECHNICAL MANUAL UNIT MAINTENANCE MANUAL FOR OPPOSING FORCES SURROGATE VEHICLE (OSV) M113A3/BMP (EIC AUK) HULL DISTRIBUTION STATEMENT A Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENT OF THE ARMY 26 July 2001

2 HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 26 JULY 2001 TECHNICAL MANUAL UNIT MAINTENANCE MANUAL OPPOSING FORCES SURROGATE VEHICLE (OSV)M113A3/BMP-2 NSN (EIC AUK) HULL REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is If you need a password, scroll down and click on ACCESS REQUEST FORM. The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax, or your letter or DA Form 2028 directly to: AMSTA-LC-CI/TECH PUBS, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL The address is TACOM-TECH-PUBS@ria.army.mil. The fax number is DSN or Commercial (309) DISTRIBUTION STATEMENT A Approved for public release; distribution is unlimited. TABLE OF CONTENTS Volume 1 WARNING SUMMARY HOW TO USE THIS MANUAL CHAPTER 1 UNIT INTRODUCTORY INFORMATION WITH THEORY OF OPERATION GENERAL INFORMATION EQUIPMENT DESCRIPTION AND DATA THEORY OF OPERATION REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT CHAPTER 2 UNIT TROUBLESHOOTING PROCEDURES INTRODUCTION TO TROUBLESHOOTING MALFUNCTION/SYMPTOM INDEX WP ENGINE OVERHEATS i

3 ENGINE DOESN T CRANK ENGINE DOES NOT START (COLD WEATHER ONLY) WAIT INDICATOR FLASHES DURING START ATTEMPTS (PREGLOW OR AFTERGLOW) WAIT INDICATOR LIGHT DOESN T LIGHT ENGINE CRANKS SLOWLY ENGINE CRANKS BUT WILL NOT START ENGINE CRANKS BUT WON T START BELOW 40 F (GLOW PLUGS ARE USED) ENGINE RUNS ROUGH, STALLS, OR DOES NOT PUT OUT FULL POWER GENERATOR MALFUNCTIONS AS INDICATED BY BATTERY/GENERATOR INDICATOR ENGINE OIL LOW PRESSURE INDICATOR COMES ON ENGINE OPERATES AT LESS THAN NORMAL TEMPERATURE ENGINE CHARGING SYSTEM SCHEMATIC ENGINE FUEL SYSTEM SCHEMATIC ENGINE STARTER CIRCUIT SCHEMATIC NO POWER TO TURRET NO EXTERIOR LIGHTS OPERATE BLACKOUT DRIVE LIGHT DOES NOT WORK SERVICE HEADLIGHTS DO NOT WORK SERVICE AND/OR BLACKOUT STOP LIGHTS MALFUNCTION BLACKOUT MARKER LIGHTS DO NOT WORK SERVICE TAILLIGHT(S) DO NOT WORK HORN DOES NOT WORK INSTRUMENT PANEL AND/OR TRANS CONTROLLER ILLUMINATION LIGHTS MALFUNCTION DOME LIGHT(S) DO NOT WORK ELECTRICAL INSTALLATION WIRING DIAGRAM MASTER SWITCH ON INDICATOR DOES NOT LIGHT FUEL LEVEL INDICATOR MALFUNCTIONS HIGH BEAM INDICATOR LIGHT DOES NOT WORK BATTERY/GENERATOR INDICATOR MALFUNCTIONS PARKING BRAKE INDICATOR MALFUNCTIONS COOLANT TEMP INDICATOR MALFUNCTIONS STEERING LOCKED INDICATOR MALFUNCTIONS ENGINE OIL LOW PRESSURE INDICATOR MALFUNCTIONS TRANSMISSION OIL LOW PRESSURE INDICATOR MALFUNCTIONS TRANS OIL HI TEMP INDICATOR MALFUNCTIONS ENGINE COOLANT LOW LEVEL INDICATOR MALFUNCTIONS TRANS FILTER CLOGGED INDICATOR MALFUNCTIONS INDICATORS SCHEMATIC DRIVER S VENTILATION FAN DOES NOT BLOW AIR ii

4 CREW VENTILATION FAN DOES NOT BLOW AIR VENTILATION FAN SCHEMATIC VEHICLE MOVES WITH TRANSMISSION IN SL VEHICLE DOES NOT MOVE IN ANY SHIFT LEVER POSITION VEHICLE DRIFTS OR DOES NOT STEER SERVICE AND/OR PARKING BRAKE WILL NOT HOLD VEHICLE TRANSMISSION WILL NOT UPSHIFT OR SHIFTS ERRATICALLY IN 1-4 POSITION TRANSMISSION DOES NOT DOWNSHIFT IN 1-4 POSITION TRANSMISSION DOES NOT HOLD 1ST POSITION TRANSMISSION DOES NOT HOLD 2ND POSITION TRANSMISSION DOES NOT HOLD 3RD POSITION TRANSMISSION DOES NOT REVERSE TRANSMISSION DOES NOT PIVOT STEER TRANSMISSION HIGH TEMP INDICATOR COMES ON TRANSMISSION OIL LOW PRESSURE INDICATOR COMES ON TRANSMISSION SYSTEM SCHEMATIC STEERING LOCK MALFUNCTIONS STEERING LOCK SCHEMATIC BILGE PUMP AND/OR LIGHT DON T WORK BILGE PUMP SCHEMATIC PERSONNEL HEATER MALFUNCTIONS PERSONNEL HEATER SCHEMATIC SPEEDOMETER MALFUNCTIONS TACHOMETER MALFUNCTIONS HOOK UP/REMOVE STE/ICE TEST SET TO DCA STE/ICE TEST 10 ENGINE RPM STE/ICE TEST 24 FUEL SUPPLY PRESSURE STE/ICE TEST 25 FUEL RETURN PRESSURE STE/ICE TEST 32 AIR BOX PRESSURE STE/ICE TEST 67 BATTERY VOLTAGE STE/ICE TEST 68 STARTER MOTOR VOLTAGE STE/ICE TEST 69 STARTER NEGATIVE CABLE VOLTAGE DROP STE/ICE TEST 70 STARTER SOLENOID VOLTAGE STE/ICE TEST 71 STARTER CURRENT (AVERAGE) STE/ICE TEST 72 STARTER CURRENT (FIRST PEAK) STE/ICE TEST 73 BATTERY RESISTANCE AND STE/ICE TEST 75 BATTERY RESISTANCE CHANGE (PACK) STE/ICE TEST 74 STARTER CIRCUIT RESISTANCE STE/ICE TEST 80 BATTERY CURRENT STE/ICE TEST 82 GENERATOR OUTPUT VOLTAGE iii

5 STE/ICE TEST 83 GENERATOR FIELD VOLTAGE STE/ICE TEST 84 GENERATOR NEGATIVE CABLE VOLTAGE DROP STE/ICE BLANK DISPLAY DIAGNOSTIC TROUBLESHOOTING STE/ICE CONFIDENCE TEST DIAGNOSTIC TROUBLESHOOTING STE/ICE TEST 10, 12 AND 13 DIAGNOSTIC TROUBLESHOOTING DCA BATTERY VOLTAGE DIAGNOSTIC TROUBLESHOOTING DCA CURRENT SHUNT DIAGNOSTIC TROUBLESHOOTING STE/ICE TEST 24 FUEL SUPPLY PRESSURE DIAGNOSTIC TROUBLESHOOTING STE/ICE TEST 25 FUEL RETURN PRESSURE DIAGNOSTIC TROUBLESHOOTING STE/ICE TEST 32 AIR BOX PRESSURE DIAGNOSTIC TROUBLESHOOTING STE/ICE TEST 68 STARTER MOTOR VOLTAGE DIAGNOSTIC TROUBLESHOOTING STE/ICE TEST 69 STARTER NEGATIVE CABLE VOLTAGE DROP DIAGNOSTIC TROUBLESHOOTING STE/ICE TEST 70 STARTER SOLENOID VOLTAGE DIAGNOSTIC TROUBLESHOOTING STE/ICE TEST 82 GENERATOR OUTPUT VOLTAGE DIAGNOSTIC TROUBLESHOOTING STE/ICE TEST 83 GENERATOR FIELD VOLTAGE DIAGNOSTIC TROUBLESHOOTING STE/ICE TEST 84 GENERATOR NEGATIVE CABLE VOLTAGE DROP DIAGNOSTIC TROUBLESHOOTING STE/ICE SCHEMATIC CHAPTER 3 UNIT MAINTENANCE INSTRUCTIONS FOR VEHICLE HULL GENERAL SERVICE UPON RECEIPT PREVENTIVE MAINTENANCE CHECKS AND SERVICES REPLACE DATAPLATES, STENCILS, MARKERS, AND DECALS CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS FOR ENGINE REMOVE/INSTALL POWER PLANT ASSEMBLY BLOCK POWER PLANT REPLACE ENGINE MOUNTS REPLACE LEFT AIR BOX DRAIN CHECK VALVE AND TUBES REPLACE RIGHT AIR BOX DRAIN CHECK VALVE AND TUBES REPLACE ENGINE LIFTING BRACKET REPLACE ENGINE OIL FILLER CAP REPLACE ENGINE OIL SAMPLING VALVE AND HOSE REPLACE OIL GAUGE ROD AND TUBE REPLACE STARTER CHAPTER 5 UNIT MAINTENANCE INSTRUCTIONS FOR FUEL SYSTEM REPLACE ENGINE FUEL PUMP iv

6 REPLACE FUEL SUPPLY PRESSURE TRANSDUCER REPLACE FUEL RETURN PRESSURE TRANSDUCER REPLACE TURBO OUTLET PRESSURE TRANSDUCER REPLACE AIR BOX PRESSURE TRANSDUCER REPLACE FUEL FILTER DIFFERENTIAL PRESSURE SWITCH REPLACE AUXILIARY TANK FLUID LEVEL DETECTOR DRAIN TANKS REPLACE FUEL QUANTITY TRANSMITTER REPLACE FUEL SELECT SWITCH TO GAUGE LEAD REPLACE GLOW PLUG HARNESS AND GLOW PLUGS REPLACE GLOW PLUG CONTROLLER REPLACE GLOW PLUG POWER HARNESS REPLACE GLOW PLUG CONTROLLER MOUNTING BRACKET REPLACE ENGINE FUEL SUPPLY HOSE REPLACE ENGINE FUEL RETURN HOSE REPLACE PRIMARY AND SECONDARY FUEL FILTERS AND BRACKET REPLACE PRIMARY AND SECONDARY FUEL FILTER ELEMENTS REPLACE FUEL SUPPLY PRESSURE TRANSDUCER REPLACE FUEL RETURN PRESSURE TRANSDUCER REPLACE FUEL FILTER DIFFERENTIAL PRESSURE SWITCH REPLACE GOVERNOR ASSEMBLY CHAPTER 6 UNIT MAINTENANCE INSTRUCTIONS FOR AIR CLEANER SERVICE AIR CLEANER FILTER ELEMENT REPLACE AIR CLEANER AND ELBOW REPAIR AIR CLEANER ASSEMBLY REPAIR AIR CLEANER RETAINER REPLACE AIR CLEANER RESTRICTION INDICATOR REPLACE AIR CLEANER RESTRICTION INDICATOR HOSE REMOVE/INSTALL AIR INTAKE ELBOW REPLACE GRILL AIR INTAKE ELBOW AND HOSE REPLACE EXHAUST EVACUATOR VALVE AND CONNECTOR ADJUST VENTILATING FAN DRIVE BELT REPLACE VENTILATING FAN DRIVE BELT CHAPTER 7 UNIT MAINTENANCE INSTRUCTIONS FOR EXHAUST SYSTEM REPLACE ENGINE EXHAUST ELBOWS AND DOUBLE FLEX JOINT REPAIR DOUBLE FLEX EXHAUST JOINT REPLACE MUFFLER EXTENSION AND CAP REPLACE EXHAUST MUFFLER AND BRACKET REPLACE ENGINE LEFT/RIGHT EXHAUST ELBOWS REPLACE LEFT/RIGHT TURBO EXHAUST PIPE HEAT SHIELD v

7 CHAPTER 8 UNIT MAINTENANCE INSTRUCTIONS FOR RADIATOR AND EXPANSION TANK DRAIN AND FILL COOLING SYSTEM CLEAN RADIATOR REPLACE RADIATOR AND PARTS REPLACE AUXILIARY TANK CHAPTER 9 UNIT MAINTENANCE INSTRUCTIONS FOR HEADERS/THERMOSTATS/ HOUSINGS REPLACE THERMOSTATIC FAN SPEED SWITCH REPLACE UPPER COOLANT HOSE AND TUBE REPLACE RADIATOR OUTLET TUBE AND HOSE REPLACE BALANCE HOSE REPLACE DRAIN COCK AND HOSE REPLACE COOLANT AIR SEPARATOR REPLACE THERMOSTAT/COVER REPLACE THERMOSTAT TUBE/HOSES CHAPTER 10 UNIT MAINTENANCE INSTRUCTIONS FOR WATER PUMP ADJUST COOLANT PUMP BELTS REPLACE COOLANT PUMP IDLER PULLEY/BELTS REPLACE ENGINE COOLANT PUMP CHAPTER 11 UNIT MAINTENANCE INSTRUCTIONS FOR GENERATOR REPLACE GENERATOR TURNBUCKLE PARTS REPLACE GENERATOR/BRACKET ADJUST GENERATOR DRIVE BELT REPLACE GENERATOR DRIVE BELT REPLACE FLAT PULLEYS AND BEARINGS REPLACE IDLER ARM AND SPRING TENSIONER ADJUST VOLTAGE REGULATOR REPLACE REGULATOR ASSEMBLY REPLACE FAN AND GENERATOR VARIABLE SPEED DRIVE CHAPTER 12 UNIT MAINTENANCE INSTRUCTIONS FOR WIRING HARNESSES REMOVE/REPLACE WIRING HARNESS 1W13 (CIRCUIT BREAKER TO FAN SWITCH) REMOVE/REPLACE WIRING HARNESS 1W19 (DRIVER S FAN TO INSTRUMENT PANEL) REMOVE/REPLACE WIRING HARNESS 1W3, TURRET POWER REMOVE/REPLACE CABLE ASSEMBLY 1W2, SPECIAL PURPOSE REMOVE/REPLACE WIRING HARNESS 1W1, DRIVERS COMMUNICATION BOX REPLACE WARNING PANEL WIRING HARNESS REPLACE RIGHT HEADLIGHT VEHICLE WIRING HARNESS vi

8 REMOVE/REPLACE WIRING HARNESS 1W5 OR 1W6, HEADLIGHT EXTENSION REPLACE REAR MAIN WIRING HARNESS 1W REPLACE TRANSMISSION CONTROLLER WIRING HARNESS REPAIR WIRING HARNESS REPLACE TRANSMISSION WIRING HARNESS REPLACE ENGINE WIRING HARNESS CHAPTER 13 UNIT MAINTENANCE INSTRUCTIONS FOR DISTRIBUTION BOX REPLACE MASTER SWITCH TO DISTRIBUTION BOX LEAD (CIRCUIT 49) REPAIR DISTRIBUTION BOX REPLACE DISTRIBUTION BOX ASSEMBLY Volume 2 CHAPTER 14 UNIT MAINTENANCE INSTRUCTIONS FOR GAUGES SERVICE SPEEDOMETER/TACHOMETER CABLE FLEXIBLE CORE REPLACE SPEEDOMETER REPLACE SPEEDOMETER CABLE AND ADAPTER REPAIR SPEEDOMETER CABLE REPLACE TACHOMETER REPLACE TACHOMETER ENGINE ADAPTER REPLACE TACHOMETER CABLE REPAIR TACHOMETER CABLE REPLACE DRIVER S LEVEL INDICATOR AND MOUNT PLATE CHAPTER 15 UNIT MAINTENANCE INSTRUCTIONS FOR INSTRUMENT AND WARNING INDICATORS REPLACE ENGINE OIL LOW PRESSURE TRANSMITTER AND HARDWARE REPLACE COOLANT TEMPERATURE TRANSMITTER REPLACE TRANSMISSION OIL HIGH TEMPERATURE SWITCH REPLACE HOSES FROM THERMOSTAT TO VARIABLE SPEED DRIVE REPLACE TRANSMISSION OIL SUPPLY AND RETURN HOSES REPLACE TURBO OUTLET PRESSURE TRANSDUCER REPLACE AIR BOX PRESSURE TRANSDUCER REPLACE INSTRUMENT PANEL MOUNTS AND GROUND LEAD REPLACE WARNING PANEL LIGHTS REPLACE WARNING LIGHT PANEL REPLACE WARNING LIGHT PANEL ASSEMBLY REPLACE INSTRUMENT PANEL SPECIAL PURPOSE CABLE REPLACE INSTRUMENT PANEL BATTERY-GENERATOR GAUGE WIRING HARNESS REPLACE INSTRUMENT WARNING LIGHT PANEL REPLACE INSTRUMENT PANEL WARNING LIGHTS vii

9 REPLACE PANEL LIGHTS AND INDICATOR LIGHTS REPLACE INSTRUMENT PANEL ASSEMBLY REPLACE INSTRUMENT PANEL GAUGES CHAPTER 16 UNIT MAINTENANCE INSTRUCTIONS FOR VEHICLE LIGHTS REPAIR DOME LIGHT REPLACE DOME LIGHT LENS REPLACE REAR DOME LIGHT SWITCH AND CIRCUIT BREAKER REPLACE DOMELIGHT INTERLOCK SWITCH REPAIR BLACKOUT MARKER LIGHT REPLACE BLACKOUT MARKER LIGHT REPAIR BLACKOUT HEADLIGHT REPLACE BLACKOUT HEADLIGHT REPAIR SERVICE HEADLIGHTS REPLACE SERVICE HEADLIGHTS REPLACE STOP LIGHT-TAIL LIGHT AND GUARDS REPAIR LEFT STOP LIGHT-TAIL LIGHT REPAIR RIGHT STOP LIGHT-TAIL LIGHT REPLACE HEADLIGHT HIGH BEAM SELECTOR SWITCH REPLACE DOME LIGHT CHAPTER 17 UNIT MAINTENANCE INSTRUCTIONS FOR BATTERIES DISCONNECT/CONNECT BATTERY GROUND STRAP REPLACE BATTERY LEADS AND TERMINALS REPLACE BATTERIES AND RETAINERS REPAIR BATTERY BOX REPLACE BATTERY TO MASTER SWITCH LEAD (CIRCUIT 6) CHAPTER 18 UNIT MAINTENANCE INSTRUCTIONS FOR AUXILIARY POWER REPLACE AUXILIARY POWER (SLAVE) RECEPTACLE REPLACE AUXILIARY POWER (SLAVE) RECEPTACLE GROUND LEAD REPLACE MASTER SWITCH TO AUXILIARY POWER RECEPTACLE LEAD (CIRCUIT 50) CHAPTER 19 UNIT MAINTENANCE INSTRUCTIONS FOR SWITCHES REPLACE MASTER SWITCH REPLACE MASTER SWITCH PANEL ASSEMBLY REPLACE INSTRUMENT PANEL ON-OFF SWITCHES REPLACE MAIN LIGHT SWITCH REPLACE ENGINE START SWITCH REPLACE HORN SWITCH REPLACE CREW FAN SWITCH AND CIRCUIT BREAKER REMOVE/REPLACE DRIVER S HATCH SWITCH 1S viii

10 REMOVE/REPLACE DRIVER S HATCH SWITCH 1S REPLACE TRANSMISSION OIL HIGH TEMPERATURE SWITCH REPLACE GENERATOR FIELD PRESSURE SWITCH REPLACE STARTER RELAY SWITCH REPLACE CIRCUIT BREAKER REPLACE BILGE PUMP CIRCUIT BREAKER CHAPTER 20 UNIT MAINTENANCE INSTRUCTIONS FOR VENTILATING FANS REMOVE/INSTALL CREW VENTILATION FAN ASSEMBLY REMOVE/REPLACE DRIVER S VENTILATION FAN ASSEMBLY MOUNTING BRACKET AND HARDWARE REMOVE/INSTALL EXTERNAL FRESH AIR DUCT ASSEMBLY REMOVE/INSTALL CREW INTERNAL FRESH AIR DUCT ASSEMBLY REMOVE/INSTALL EXTERNAL FRESH AIR SYSTEM FILTER CHAPTER 21 UNIT MAINTENANCE INSTRUCTIONS FOR TRANSMISSION REPLACE TRANSMISSION OIL DRAIN TUBES AND BRACKET REPLACE TRANSMISSION MOUNTS REPLACE TRANSMISSION RANGE CONTROLLER/BRACKET CHAPTER 22 UNIT MAINTENANCE INSTRUCTIONS FOR TRANSFER AND FINAL DRIVES OPERATIONAL CHECK/ADJUST TRANSMISSION STEERING REPLACE TRANSMISSION OIL LEVEL DIPSTICK, TUBE, AND ADAPTER REPLACE TRANSMISSION OIL AND OIL FILTER ELEMENT REPLACE TRANSMISSION OIL COOLER HOSES, FITTINGS, AND MOUNTING REPLACE TRANSMISSION OIL SAMPLING VALVE AND PRESSURE SWITCH REPLACE DIFFERENTIAL PRESSURE SWITCH AND BYPASS PLUG REPLACE FINAL DRIVE FILLER TUBE AND DIPSTICK REPLACE FINAL DRIVE REPLACE FINAL DRIVE DIFFERENTIAL OIL SEAL REPLACE PROPELLER SHAFT AND UNIVERSAL JOINTS CHAPTER 23 UNIT MAINTENANCE INSTRUCTIONS FOR BRAKES ADJUST PARKING BRAKE ADJUST SERVICE BRAKE CONTROL LINKAGE ADJUST TRANSMISSION BRAKES CHECK TRANSMISSION BRAKE ADJUSTMENT REPLACE PARKING BRAKE CONTROL LEVER ASSEMBLY REPLACE SERVICE BRAKE CONTROL LINKAGE REPLACE PARKING BRAKE CONTROL CABLE ASSEMBLY REPLACE UPPER AND LOWER SERVICE BRAKE PEDAL REPLACE STOP SWITCH ix

11 REPLACE PARKING BRAKE SWITCH/BRACKET CHAPTER 24 UNIT MAINTENANCE INSTRUCTIONS FOR SUSPENSION REPLACE TORSION BAR REPLACE TORSION BAR ANCHOR REPLACE ROAD WHEEL SUPPORT ARM, BEARINGS, AND SEALS REPLACE ROAD WHEEL HUB REPLACE ROAD WHEEL REPLACE IDLER WHEEL CHAPTER 25 UNIT MAINTENANCE INSTRUCTIONS FOR TRACK IDLERS, DRIVE SPROCKETS, AND TRACKS REPLACE IDLER WHEEL ARM ASSEMBLY REPLACE IDLER WHEEL ARM BEARINGS AND SEALS REPLACE TRACK TENSION ADJUSTER AND MOUNT REPLACE DRIVE SPROCKET AND CARRIER ASSEMBLY REPAIR DRIVE SPROCKET CARRIER ASSEMBLY REPLACE TRACK REPLACE TRACK SHOE ASSEMBLY REPLACE TRACK SHOE PAD CHAPTER 26 UNIT MAINTENANCE INSTRUCTIONS FOR STEERING REPLACE PUSH-PULL CONTROL ASSEMBLY, BRACKET, LINKS, AND PINS ADJUST STEERING WHEEL LINKAGE REPLACE STEERING LOCK SWITCH REPLACE STEERING SUPPORT, BRACKETS, AND SHAFT REPLACE QUICK-RELEASE PIN AND LANYARD REPLACE STEERING WHEEL LINKAGE CHAPTER 27 UNIT MAINTENANCE INSTRUCTIONS FOR HULL ACCESS COVERS AND DOORS REMOVE/REPLACE VISMOD ACCESS DOORS REMOVE/REPLACE ENGINE ACCESS COVER PLATE REPAIR/REPLACE POWER PLANT REAR ACCESS PANELS REMOVE/INSTALL FAN DRIVE PULLEY ACCESS COVER REPLACE RADIATOR ACCESS DOOR REPLACE DRIVER S POWER PLANT ACCESS PANEL REMOVE/INSTALL HULL NOSE ASSEMBLY REMOVE/REPLACE VISMOD PANEL, LEFT AND RIGHT SIDE REPLACE HULL FRONT ACCESS COVER REPLACE POWER PLANT BOTTOM ACCESS COVER CHAPTER 28 UNIT MAINTENANCE INSTRUCTIONS FOR HULL ASSEMBLIES REPAIR HULL BY WELDING x

12 REPLACE HORN AND GROUND LEAD REPLACE UTILITY OUTLET RECEPTACLE REPLACE POWER PLANT GRILL SCREEN REMOVE/REPLACE ENGINE ACCESS COVER PLATE SEAL REPLACE TOWING HOOK AND EYE REPLACE REAR TIEDOWN PLATES REPLACE LIFTING EYE REPLACE HEADLIGHT GUARD REMOVE/REPLACE REAR DOOR CATCH HOOKS REMOVE/REPLACE REAR DOOR BUMPER REMOVE/REPLACE RIGHT REAR DOOR HANDLES, HINGES, LATCHES, AND CHAIN REPLACE REAR DOORS, HINGES, AND GASKETS REPLACE LEFT REAR DOOR INSIDE HINGES AND LATCH ADJUST TOW START CONTROL CABLE ASSEMBLY REPLACE TOW START CONTROL ASSEMBLY AND BEARING REPLACE TOW START CONTROL ASSEMBLY COVER CHAPTER 29 UNIT MAINTENANCE INSTRUCTIONS FOR HULL DRAIN PLUGS REPLACE HULL DRAIN PLUGS CHAPTER 30 UNIT MAINTENANCE INSTRUCTIONS FOR POWER PLANT GRILL REMOVE/INSTALL POWER PLANT GRILLE INSPECT POWER PLANT SLING CHAPTER 31 UNIT MAINTENANCE INSTRUCTIONS FOR DRIVER S HATCH AND FLOOR PLATES REPLACE DRIVER S HATCH CUSHION PAD REPLACE DRIVER S HATCH INTERIOR LOCK AND LATCH REPLACE VEHICLE PERISCOPE LOCKS AND SEALS REPAIR DRIVER S HATCH REPLACE REAR COMPARTMENT AIR VENTILATOR REPLACE DRIVER S COMPARTMENT FLOOR PLATES REPLACE FLOOR PLATES/RUBBER STRIPS CHAPTER 32 UNIT MAINTENANCE INSTRUCTIONS FOR TURRET SHIELD REPAIR TURRET SHIELD DOOR LATCH ASSEMBLY REPLACE TURRET SHIELD DOOR REPLACE TURRET SHIELD DOOR LOWER TRACKS REPLACE TURRET SHIELD DOOR UPPER TRACK (EAK) REPLACE TURRET SHIELD DOOR LATCH STRIKE REPLACE TURRET SHIELD DOOR SWITCH ASSEMBLY REPLACE RIGHT TURRET SHIELD PANEL xi

13 REPLACE LEFT TURRET SHIELD PANEL CHAPTER 33 UNIT MAINTENANCE INSTRUCTIONS FOR SHOCK ABSORBERS REPLACE SHOCK ABSORBER REPLACE SHOCK ABSORBER MOUNT REPLACE SHOCK ABSORBER PIN CHAPTER 34 UNIT MAINTENANCE INSTRUCTIONS FOR BILGE PUMPS REPLACE FRONT BILGE PUMP PIPES REPLACE FRONT BILGE PUMP AND STRAINER REPLACE FRONT BILGE VALVE CHAPTER 35 UNIT MAINTENANCE INSTRUCTIONS FOR SEATS REPLACE PERSONNEL SEATS, BACKRESTS, CUSHIONS, AND BELTS REPLACE DRIVER S SEAT ASSEMBLY REPAIR DRIVER S SEAT REPLACE DRIVER S SEAT BACK ASSEMBLY REPAIR DRIVER S SEAT BACK ASSEMBLY REPLACE DRIVER S SEAT IMPACT ABSORBER REPLACE DRIVER S SEAT POST ASSEMBLY REPAIR DRIVER S SEAT POST ASSEMBLY REPLACE DRIVER S FOOTREST REPLACE OILCAN BRACKET CHAPTER 36 UNIT MAINTENANCE INSTRUCTIONS FOR PERSONNEL HEATER REPAIR PERSONNEL HEATER DUCT REPLACE PERSONNEL HEATER DUCT AND HOSES REPAIR PERSONNEL HEATER ASSEMBLY REPLACE PERSONNEL HEATER ASSEMBLY REPAIR PERSONNEL HEATER CONTROL BOX REPLACE PERSONNEL HEATER CONTROL BOX REPLACE FUEL PUMP TO BULKHEAD CONNECTION HOSE REPLACE PERSONNEL HEATER FUEL FILTER/BRACKET REPLACE PERSONNEL HEATER FUEL PUMP REPLACE PERSONNEL HEATER FUEL PUMP HOSE REPLACE HEATER/FILTER FUEL SUPPLY HOSES REPLACE PERSONNEL HEATER FUEL TUBE REPLACE HEATER AIR INTAKE AND EXHAUST PIPES REPLACE FUEL SHUT-OFF VALVE ASSEMBLY SERVICE PERSONNEL HEATER FUEL FILTER SERVICE PERSONNEL HEATER FUEL PUMP BLEED AIR FROM PERSONNEL HEATER FUEL LINES xii

14 CHAPTER 37 UNIT MAINTENANCE INSTRUCTIONS FOR STE/ICE COMPONENTS REPLACE STE/ICE PULSE TACHOMETER REPLACE STE/ICE SHUNT REPLACE STE/ICE DISTRIBUTION BOX REPLACE STE/ICE CREW WIRING HARNESS REPLACE STE/ICE ENGINE WIRING HARNESS CHAPTER 38 UNIT MAINTENANCE INSTRUCTIONS FOR FIRE EXTINGUISHERS REPLACE FIRE EXTINGUISHER CYLINDER AND MOUNT REPLACE CYLINDER DISCHARGE TUBES REPLACE EXTERNAL HANDLE SHIELD REPLACE FIRE EXTINGUISHER CONTROL VALVE AND EXTERNAL HANDLE REPLACE EXTERNAL CABLE TUBE CHAPTER 39 UNIT SUPPORTING INFORMATION REFERENCES MAINTENANCE ALLOCATION CHART (MAC) TOOL IDENTIFICATION LIST TORQUE LIMITS EXPENDABLE AND DURABLE ITEMS LIST STENCILS, DATAPLATES, DECALS, AND MARKERS GENERAL MAINTENANCE INSTRUCTIONS xiii/xiv blank

15 CHAPTER 14 UNIT MAINTENANCE INSTRUCTIONS FOR GAUGES WORK PACKAGE INDEX Title Sequence No. SERVICE SPEEDOMETER/TACHOMETER CABLE FLEXIBLE CORE REPLACE SPEEDOMETER REPLACE SPEEDOMETER CABLE AND ADAPTER REPAIR SPEEDOMETER CABLE REPLACE TACHOMETER REPLACE TACHOMETER ENGINE ADAPTER REPLACE TACHOMETER CABLE REPAIR TACHOMETER CABLE REPLACE DRIVER S LEVEL INDICATOR AND MOUNT PLATE

16 SERVICE SPEEDOMETER/TACHOMETER CABLE FLEXIBLE CORE THIS WORK PACKAGE COVERS: Removal (page ). Installation (page ). INITIAL SETUP: Maintenance Level Unit Tools and Special Tools General Mechanic s Tool Kit (WP , Item 64) Materials/Parts Automotive grease (WP , Item 11) Gasket Lockwasher (2) Preformed packing Personnel Required Unit Mechanic 63T10 References TM Equipment Condition Master switch off (TM ) Engine stopped (TM ) Vehicle blocked (TM ) Engine access cover plate removed (WP ) Front VISMOD access doors removed (WP ) SERVICING REMOVAL NOTE This task applies to both tachometer cable assembly and speedometer cable assembly core servicing. Perform only those steps referring to cable that requires servicing. 1. DISCONNECT TACHOMETER CABLE (1) FROM GAUGE (2) AND/OR SPEEDOMETER CABLE (3) FROM GAUGE (4)

17 SERVICE SPEEDOMETER/TACHOMETER CABLE FLEXIBLE CORE Continued REMOVE TACHOMETER CABLE (3) AND GASKET (4) FROM STE/ICE UNIT (5). DISCARD GASKET. 3. REMOVE SCREW (7), LOCKWASHER (8), AND CLAMP (6) FROM TACHOMETER CABLE (3). DISCARD LOCKWASHER. 4. REMOVE SPEEDOMETER CABLE (9) AND PREFORMED PACKING (10) FROM FINAL DRIVE ADAPTER (11). DISCARD PACKING. 5. REMOVE SCREW (13), LOCKWASHER (14), AND CLAMP (12) FROM SPEEDOMETER CABLE (9). DISCARD LOCKWASHER

18 SERVICE SPEEDOMETER/TACHOMETER CABLE FLEXIBLE CORE Continued REMOVE CORE (1) FROM CABLE HOUSING (2). IF CORE DOES NOT COME OUT FREELY, REPLACE CABLE ASSEMBLY (WP ) OR (WP ). INSTALLATION NOTE Grease lube gun may be used in Step APPLY GREASE TO CORE (1). 2. INSTALL CORE (1) IN CABLE HOUSING (2) WITH ROTATING MOTION

19 SERVICE SPEEDOMETER/TACHOMETER CABLE FLEXIBLE CORE Continued INSTALL TACHOMETER CABLE (3) AND NEW GASKET (4) ON STE/ICE UNIT (5). 4. INSTALL CLAMP (6) ON TACHOMETER CABLE (3) WITH SCREW (7) AND NEW LOCKWASHER (8). 5. INSTALL SPEEDOMETER CABLE (9) AND NEW PREFORMED PACKING (10) ON FINAL DRIVE ADAPTER (11). 6. INSTALL CLAMP (12) ON SPEEDOMETER CABLE (9) WITH SCREW (13) AND NEW LOCKWASHER (14)

20 SERVICE SPEEDOMETER/TACHOMETER CABLE FLEXIBLE CORE Continued CONNECT TACHOMETER CABLE (1) TO GAUGE (2) AND/OR SPEEDOMETER CABLE (3) TO GAUGE (4). 8. START ENGINE. See TM OPERATE VEHICLE TO CHECK THAT TACHOMETER GAUGE WORKS PROPERLY. TACHOMETER NEEDLE SHOULD NOT PULSATE. 10. OPERATE VEHICLE TO CHECK THAT SPEEDOMETER GAUGE WORKS PROPERLY. 11. STOP ENGINE. See TM IF GAUGES DO NOT OPERATE PROPERLY, REPEAT TASK. IF PROBLEM IS NOT CORRECTED, REMOVE CABLE ASSEMBLY (WP ) OR (WP ). 13. INSTALL FRONT VISMOD ACCESS DOORS (WP ). 14. INSTALL ENGINE ACCESS COVER PLATE (WP ). END OF TASK /6 blank