TECHNICAL MANUAL MAINTENANCE INSTRUCTIONS DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE M1083 SERIES, 5-TON, 6 X 6, MEDIUM TACTICAL VEHICLES (MTV)

Transcription

1 ARMY TM AIR FORCE T.O. 36A12-1C TECHNICAL MANUAL MAINTENANCE INSTRUCTIONS DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE M1083 SERIES, 5-TON, 6 X 6, MEDIUM TACTICAL VEHICLES (MTV) VOLUME NO. 2 OF 4 MODEL NSN EIC HOW TO USE THIS MANUAL PAGE v TRK, CAR., MTV, M1083 W/WN BT3 ENGINE MAINTENANCE W/O WN BR2 PAGE 3-1 TRK, CAR., MTV, W/MATL HDLG EQPT (MHE), M BR3 FUEL SYSTEM MAINTENANCE PAGE 4-1 TRK, CAR., MTV, LWB, M1085 W/WN BT5 W/O WN BR7 ELECTRICAL SYSTEM TRK, CAR., MTV, LWB, W/MATL HDLG EQPT (MHE), M BR8 MAINTENANCE PAGE 6-1 TRK, TRACTOR, MTV, M1088 W/WN BTY W/O WN BTJ TRK, WKR, MTV, M BR4 TRANSMISSION MAINTENANCE PAGE 7-1 FRONT AXLE MAINTENANCE PAGE 9-1 TRK, DUMP, MTV, M1090 W/WN BTZ INTERMEDIATE AND REAR AXLE W/O WN BR5 MAINTENANCE PAGE 10-1 TRK, CHAS, MTV, M BRZ TRK, CAR., MTV, AIR DROP, M1093 W/WN BT4 W/O WN BR9 TRK, DUMP, MTV, AIR DROP, M1094 W/WN BT2 W/O WN BTK BRAKE SYSTEM MAINTENANCE PAGE 11-1 STEERING SYSTEM MAINTENANCE PAGE 12-1 TRK, CHAS, MTV, LWB, M BR6 FRAME MAINTENANCE PAGE 13-1 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENTS OF THE ARMY AND THE AIR FORCE 15 SEPTEMBER 1998

2 ARMY TM AIR FORCE T.O. 36A12-1C CHANGE NO. 1 HEADQUARTERS DEPARTMENTS OF THE ARMY AND THE AIR FORCE Washington, D.C., 31 July 2001 TECHNICAL MANUAL MAINTENANCE INSTRUCTIONS DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE M1083 SERIES, 5-TON, 6x6, MEDIUM TACTICAL VEHICLE (MTV) VOLUME NO. 2 OF 4 TM , 15 September 1998, is changed as follows: 1. Remove old pages and insert new pages as indicated below. 2. New or changed material is indicated by a vertical bar in the out margin of the page. 3. Added or revised illustrations are indicated by a vertical bar adjacent to the illustration. Remove Pages Insert Pages Remove Pages Insert Pages e thru kk/(ll Blank) e thru al A thru C/(D Blank) i thru v/(vi Blank) i thru vi vii/(viii Blank) 3-15 thru thru thru thru and thru thru /( Blank) 3-43 and and /( Blank) 3-45 thru thru thru thru /( Blank) 3-55 thru thru thru thru and and /( Blank) 5-1 thru 5-7/(5-8 Blank) 5-1 thru /(5-10 Blank) 6-1 and and thru and thru thru thru /( Blank) 6-37 and and thru thru /( Blank) 7-17 and and and and and and thru /( Blank) 7-27 thru thru and and 7-54 Place this change sheet in the front of the publication for reference purposes. 1 of and and and and and and thru thru thru thru thru /( Blank) 8-11 thru 8-17/(8-18 Blank) 9-1 thru thru /(9-8.2 Blank) 9-9 and and and and and thru thru /( Blank) 9-21 and and thru thru thru thru /( Blank) thru thru thru thru and and and and and and /( Blank) thru thru /( Blank) and and /( Blank) thru thru thru thru and

3 Remove Pages Insert Pages Remove Pages Insert Pages thru thru /( Blank) and and and and /(10-62 Blank) 11-1 and and thru 11-9/ 11-7 thru 11-9/ (11-10 Blank) (11-10 Blank) 12-1 and and and /(12-16 Blank) and and and and and thru thru and and and and thru thru thru thru /( Blank) thru thru and and thru thru thru thru thru thru thru thru thru thru thru thru thru thru thru thru thru thru thru thru and and and and /( Blank) and thru /( Blank) 14-1 thru thru /( Blank) and and and and and and and and /(14-52 Blank) A-1 and A-2 A-1 and A-2 C-1 thru C-8 C-1 thru C-8 C-9/(C-10 Blank) D-1 and D-2 D-1 and D-2 D-4.1/(D-4.2 Blank) D-5 and D-6 D-5 and D-6 D-25 thru D-28 D-25 thru D-28 D-31 and D-32 D-31 and D-32 D-39 thru D-48 D-39 thru D-48 D-81 thru D-86 F-1 thru F-15/(F-16 Blank) F-1 thru F-16 F-17/(F-18 Blank) G-1/(G-2 Blank) G-1/(G-2 Blank) Place this change sheet in the front of the publication for reference purposes. 2 of 2 H-1 thru H-4 INDEX-1 thru INDEX-7/ INDEX-1 thru INDEX-7/ (INDEX-8 Blank) (INDEX-8 Blank) DA Form Sample DA Form 2028 Sample DA Form DA Form 2028 DA Form DA Form 2028 DA Form DA Form 2028 FO-1 FP-1/(FP-2 Blank) FO-1 FP-1/(FP-2 Blank) thru FP-21/(FP-22 Blank) thru FP-21/(FP-22 Blank) FO-1 FP-25/(FP-26 Blank) FO-1 FP-25/(FP-26 Blank) FO-1 FP-29/(FP-30 Blank) FO-1 FP-29/(FP-30 Blank) thru FP-67/(FP-68 Blank) thru FP-67/(FP-68 Blank) FO-1 FP-75/(FP-76 Blank) FO-1 FP-75/(FP-76 Blank) thru FP-79/(FP-80 Blank) thru FP-79/(FP-80 Blank) BackCover BackCover

4 By Order of the Secretary of the Army: Official: ERIC K. SHINSEKI General, United States Army Chief of Staff JOEL B. HUDSON Administrative Assistant to the Secretary of the Army DISTRIBUTION: To be distributed in accordance with the initial distribution number (IDN) , requirements for TM

5 SUMMARY EXHAUST GASES CAN KILL 1. DO NOT operate your vehicle engine in an enclosed area. 2. DO NOT idle vehicle engine with cab windows enclosed. 3. DO NOT drive vehicles with inspection plates or covers removed. 4. BE ALERT at all times for exhaust odors. 5. BE ALERT for exhaust poisoning symptoms, they are: Headache Dizziness Sleepiness Loss of Muscular Control 6. IF YOU SEE another person with exhaust poisoning symptoms: Remove person from area. Expose to open air. Keep person warm. Do not permit person to move. Administer cardiopulmonary resuscitation, if necessary.* * For cardiopulmonary resuscitation, refer to FM Remove rings, bracelets, watches, necklaces, and any other jewelry before working around vehicle. Jewelry can catch on equipment and cause injury or short across electrical circuit and cause severe burns or electrical shock. Batteries can explode from a spark. Battery acid is harmful to skin and eyes. Always wear eye protection and rubber gloves when working with batteries. Failure to comply may result in injury to personnel. Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber gloves, and do not smoke when performing maintenance on batteries. Injury will result if acid contacts skin or eyes. Wear rubber apron to prevent clothing being damaged. Failure to comply may result in injury to personnel. a

6 (CONT) Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury to personnel. Dry cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves; use only in well ventilated area; avoid contact with skin, eyes, and clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when using solvent; the flashpoint for Type I dry cleaning solvent is 100 F (38 C) and for Type II is 130 F (50 C). Failure to comply may result in serious injury or death to personnel. If personnel become dizzy while using dry cleaning solvent, immediately get fresh air and medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes, immediately flush eyes with water and get immediate medical attention. Failure to comply may result in injury to personnel. Diesel fuel is flammable. If fuel is spilled, clean it up immediately. Failure to comply may result in serious injury or death to personnel. Use care when moving oxygen/acetylene bottles. Oxygen/acetylene bottles can act as projectiles if punctured and discharge explosive gases. Failure to comply may result in serious injury or death to personnel or damage to equipment. Diesel fuel is flammable. Do not fill fuel tank with engine running, while smoking, or when near an open flame. Never overfill the tank or spill fuel. If fuel is spilled, clean it up immediately. Failure to comply may result in serious injury or death to personnel. Adhesive Sealant MIL-S can damage your eyes. Wear safety goggles/glasses when using; avoid contact with eyes. If sealant contacts eyes, flush eyes with water and get immediate medical attention. Failure to comply may result in injury to personnel. Use care when removing springs. Springs are under tension and can act as projectiles when being removed. Failure to comply can cause injury to personnel. b

7 After Nuclear, Biological, or Chemical (NBC) exposure of vehicle, all air filters shall be handled with extreme caution. Unprotected personnel may experience serious injury or death if residual toxic agents or radioactive material are present. If vehicle is exposed to chemical or biological agents, servicing personnel shall wear protective mask, hood, protective overgarments, and chemical protective gloves and boots in accordance with FM-3-4. All contaminated air filters shall be placed in double-lined plastic bags and moved swiftly to a segregation area away from the worksite. The same procedure applies for radioactive dust contamination. The Company NBC team should measure radiation prior to filter removal to determine extent of safety procedures required per the NBC Annex to the unit Standard Operating Procedures (SOP). The segregation area in which the contaminated air filters are temporarily stored shall be marked with appropriate NBC placards. Final disposal of contaminated air filters shall be in accordance with local SOP. Decontamination operation shall be in accordance with FM-3-5 and local SOP. Failure to comply may result in serious injury or death to personnel. Use care when installing springs. Springs are under tension and can act as projectiles when removed. Failure to comply may result in injury to personnel. Ensure exhaust system is cool before performing maintenance. Failure to comply may result in injury to personnel. Wear appropriate eye protection when working under vehicle due to the possibility of falling debris. Failure to comply may result in injury to personnel. Do not operate MTV vehicle with muffler removed. Toxic exhaust fumes may enter cab, resulting in serious injury or death to personnel. Do not work on fuel system when engine is hot; fuel can be ignited by a hot engine. Post signs that read "NO SMOKING WITHIN 50 FEET" when working with open fuel, fuel lines or fuel tanks. Failure to comply may result in injury to personnel or damage to equipment. c

8 (CONT) Exhaust pipe, transmission oil lines, and transmission scavenge pump hose may be hot to the touch. Extreme care should be taken when checking exhaust pipe, transmission oil lines, and transmission scavenge pump hose for leaks. Failure to comply may result in injury to personnel. Compressed air used for cleaning purposes will not exceed 30 psi (207 kpa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc). Failure to comply may result in injury to personnel. Wheel drum weighs approximately 90 lbs (41 kgs). Use the aid of an assistant to help remove wheel drum. Failure to comply may result in injury to personnel. Wheel drum weighs approximately 90 lbs (41 kgs). Use the aid of an assistant to help install wheel drum. Failure to comply may result in injury to personnel. Brake shoes may be covered with dust. Breathing this dust may be harmful to your health. Do not used compressed air to clean brake shoes. Wear a filter mask approved for use against brake dust. Failure to comply may result in injury to personnel. Cage spring brake before air chamber is removed or severe injury to personnel will occur. Ensure air chamber is caged prior to installation. injury to personnel. Failure to comply may result in Ensure that tire is totally deflated before removing self-locking nuts. Failure to comply may result in serious injury or death to personnel. d

9 Spring brakes must be caged before attempting replacement of a rear axle wheel stud. Failure to comply may result in severe injury to personnel. Wear protective goggles to protect against possible injury from release of high pressure air. Failure to comply may result in injury to personnel. Prolonged contact with lubricating oil (MIL-L-2104) may cause a skin rash. Skin and clothing that come in contact with lubricating oil should be thoroughly washed immediately. Saturated clothing should be removed immediately. Areas in which lubricating oil is used should be well ventilated to keep fumes to a minimum. Failure to comply may result in injury to personnel. Hydraulic fluid (MIL-H-5606) is TOXIC. Wear protective goggles and gloves; use only in well ventilated area; avoid contact with skin, eyes, and clothes. Skin and clothing that come in contact with hydraulic oil should be washed immediately. Saturated clothing should be removed immediately. Failure to comply may result in injury to personnel. Wire rope can become frayed or contain broken wires. Wear heavy leather-palmed gloves when handling wire rope. Frayed or broken wires can injure hands. Failure to comply may result in injury to personnel. Never let moving wire rope slide through hands, even when wearing gloves. A broken wire could cut through gloves and cut hands. Wear appropriate eye protection when drilling out rivets. Failure to comply may result in injury to personnel. Wear leather gloves at all times when handling winch cable. Do not allow cable to slide through hands even with gloves on. Broken wires may cause injury. e

10 SUMMARY (CONT) Use extreme caution when working around moving cable. Failure to do so may result in serious injury to personnel. Caution must be exercised while cab is raised. Ensure that locking mechanism is functioning properly before proceeding. Failure to comply may result in death or serious injury to personnel and damage to equipment. Hydraulic components are hot when hydraulic oil reaches operating temperature. Use caution when handling hydraulic components. Wear gloves or use rags to hold metal objects. Failure to comply may result in injury to personnel. Do not remove radiator cap when the engine is hot; steam and hot coolant can escape and burn skin. Failure to comply may result in injury to personnel. Use extreme care when opening cab door with cab raised. result in injury to personnel or damage to equipment. Failure to comply may Ensure engine is cool before performing troubleshooting. result in severe burns. Failure to comply may Ensure exhaust system is cool before performing troubleshooting. Failure to comply may result in injury to personnel. Drop hydraulic pressure to zero before disconnecting any hydraulic hose, tube, or fitting. Failure to comply may result in injury to personnel. f Change 1

11 Wear approved eye protection when performing pressure checks. Failure to comply may result in oil getting into eyes. If oil contacts eyes, seek medical attention immediately. Fuel and oil are slippery and can cause falls. Wipe up spilled fuel or oil with rags. Failure to comply may result in injury to personnel. Ensure all pressure is released from engine container. Failure to comply may result in injury to personnel. Engine container cover weighs approximately 130 lbs (59 kgs). Attach a suitable lifting device prior to unpacking. Failure to comply may result in injury to personnel or damage to equipment. Engine assembly weighs approximately 1500 lbs (681 kgs). Attach a suitable lifting device prior to removal. Failure to comply may result in serious injury or death to personnel or damage to equipment. Engine assembly weighs approximately 1500 lbs (681 kgs). Attach a suitable lifting device prior to packing. Failure to comply may result in serious injury or death to personnel or damage to equipment. Storage container cover weighs approximately 130 lbs (59 kg). Attach a suitable lifting device prior to installation. Failure to comply may result in injury to personnel or damage to equipment. Wear appropriate eye protection when drilling holes. Failure to comply may result in injury to personnel. Change 1 g

12 SUMMARY (CONT) Alternator weighs approximately 50 lbs (23 kgs). The aid of an assistant is required to remove alternator. Failure to comply may result in injury to personnel. Alternator weighs approximately 50 lbs (23 kgs). The aid of an assistant is required to install alternator. Failure to comply may result in injury to personnel. Cylinder head weighs approximately 150 lbs (68 kgs). Attach a suitable lifting device prior to removal. Failure to comply may result in injury to personnel or damage to equipment. Cylinder head weighs approximately 150 lbs (68 kgs). Attach a suitable lifting device prior to installation. Failure to comply may result in injury to personnel or damage to equipment. Adhesive causes immediate bonding on contact with eyes, skin, or clothing and also gives off harmful vapors. Wear protective goggles and use in well-ventilated area. If adhesive get in eyes, try to keep eyes open, flush eyes with water for 15 minutes, and get immediate medical attention. Failure to comply may result in injury to personnel. Flywheel housing weighs approximately 75 lbs (34 kgs). Attach a suitable lifting device prior to removal. Failure to comply may result in injury to personnel or damage to equipment. Flywheel housing weighs approximately 75 lbs (34 kgs). Attach a suitable lifting device prior to installation. Failure to comply may result in injury to personnel or damage to equipment. Use care when removing springs. Springs are under tension and can act as projectiles when removed. Failure to comply may result in injury to personnel. h Change 1

13 Use care when removing retaining rings. Retaining rings are under tension and can act as projectiles when released. Failure to comply may result in injury to personnel. Use care when installing retaining rings. Retaining rings are under tension and can act as projectiles when released. Failure to comply may result in injury to personnel. Engine compartment and components may be hot to the touch. Extreme care should be taken when adjusting idle speed. Failure to comply may result in injury to personnel. Engine compartment includes a partially covered fan blade. Extreme care should be taken when working in the engine compartment. Failure to comply may result in injury to personnel. Use care when removing retaining clips. Retaining clips are under tension and can act as projectiles when released. Failure to comply may result in injury to personnel. Use care when installing retaining clips. Retaining clips are under tension and can act as projectiles when released. Failure to comply may result in injury to personnel. Clutch housing is assembled under tension. Use caution during disassembly. Failure to comply may result in injury to personnel. Loosen C-clamps slowly and evenly to release tension. Failure to comply may result in injury to personnel or damage to equipment. Tighten C-clamps slowly and evenly to apply tension. Failure to comply may result in injury to personnel or damage to equipment. Change 1 i

14 SUMMARY (CONT) Ensure engine is cool before performing maintenance. Failure to comply may result in injury to personnel. Torque converter module weighs approximately 65 lbs (30 kgs). Attach a suitable lifting device prior to removal. Failure to comply may result in injury to personnel. Torque converter module weighs approximately 65 lbs (30 kgs). Attach a suitable lifting device prior to installation. Failure to comply may result in injury to personnel or damage to equipment. Transmission weighs approximately 1300 lbs (590 kgs). Attach a suitable lifting device prior to removal. Failure to comply may result in injury to personnel or damage to equipment. Transmission weighs approximately 1300 lbs (590 kgs). Attach a suitable lifting device prior to installation. Failure to comply may result in injury to personnel or damage to equipment. Diesel fuel is flammable. Keep diesel fuel away from open fire and keep a fire extinguisher within easy reach when working with diesel fuel. Do not smoke when working with diesel fuel. If fuel is spilled, clean it up immediately. Failure to comply may result in serious injury or death to personnel. Use care when removing valve body parts retained by retaining pins. Valve body parts are under tension and can act as projectiles when released. Failure to comply may result in injury to personnel. Use care when installing valve body parts retained by retaining pins. Valve body parts are under tension and can act as projectiles when released. Failure to comply may result in injury to personnel. j Change 1

15 Control valve module weighs approximately 65 lbs (30 kgs). Position a floor jack under control module prior to removal. Failure to comply may result in injury to personnel or damage to equipment. Control valve module weighs approximately 65 lbs (30 kgs). Position a floor jack under control module prior to installation. Failure to comply may result in injury to personnel or damage to equipment. Front axle assembly weighs approximately 1580 lbs (717 kgs). Front axle assembly must be supported on a transmission/differential lift during removal. Failure to comply may result in injury to personnel or damage to equipment. Front axle assembly weighs approximately 1580 lbs (717 kgs). Front axle assembly must be supported on a transmission/ differential lift during installation. Failure to comply may result in injury to personnel or damage to equipment. Steering gear assembly weighs approximately 130 lbs (59 kgs). Support steering gear assembly on jack before dismounting from chassis. Failure to comply can cause injury to personnel or damage to equipment. Steering gear assembly weighs approximately 130 lbs (59 kgs). Support steering gear assembly on jack during installation. Failure to comply may cause injury to personnel or damage to equipment. Front differential carrier weighs approximately 350 lbs (159 kgs). Attach a suitable lifting device prior to removal. Failure to comply may result in injury to personnel or damage to equipment. Front differential carrier weighs approximately 350 lbs (159 kgs). Attach a suitable lifting device prior to installation. Failure to comply may result in injury to personnel or damage to equipment. Change 1 k