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TM 9-2510-247-13&P - Liberated Manuals

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1. 0045 00 1 Special Tools and Support 00810 8 Standard Tool 0038 00 6 Stencils Location Of miracle 0002 00 6 Storage Preparation for 0001 00 1 0078 00 1 Strobe Light Repair and Replacement 0049 00 1 Support EQUIPMENT ciar 0081 00 8 T Tagging Wires and tte t 0038 00 6 Tape A m 0038 00 9 Technical gt ort t 0080 00 2 Technical 0080 00 2 Tiedown and Accessory Controls and 0004 00 4 Tiedown Procedures 44 nnne nennen nne 0014 00 1 Iz 0081 00 8 Tool Box 0071 00 1 Tool Requirements 22 0038 00 6 Tools and Test Equipment Requirements 0081 00 8 Tools and Equipment 0081 00 8 TorGUe LIMIS c 0089 00 1 Torque Table How to Use 0089 00 2 Torque Values for Threaded Fasteners 0089 00 1 Tow Light Assembly Repair 24 Volt sss 0047 00 1 To
2. TM 9 2510 247 13 amp P 0082 00 0 2 3 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC GROUP 0613 HULL CHASSIS WIRING HARNESS 8 CHASSIS WIRING HARNESS 37 MOOZZ 81348 JC580 14 WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N J C 580TFF6CF1 16 TUJ5 14 INCHES 1 38 MOOZZ 81349 M5086 14 1 2 WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M5086 1 16 19 14 1 2 INCHES LONG scanners 1 39 MOOZZ 81349 M16878 5BJE 14 WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M16878 5BJE2 14 INCHES iuis s 7 40 PAOZZ 5940000426317 00779 34148 TERMINAL LUG RED EYELET 41 MOOZZ 81349 M16878 4BJE 8 WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M16878 4BJEO 11 1 2 INCHES LONG sis 7 42 272 5925012068136 75915 813040 CIRCUIT BREAKER 40 43 22 81349 M16878 4BJE 16 WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M16878 4BJEO 16 INCHES 1 44 22 81349 M5086 7 WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M5086 1 10 9 7 INCHES LONG icant 1 45 MOOZZ 81349 M16878 5BJE 7 WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M16878 5BJE2 7 INCHES LONG nine 2 46 MOOZZ 81349 M16878 5BKE 8 WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M16878 5BKEO 8 INCHES 2 47 22 81349 M16878 6BFE 6 WIRE ELECTRICAL MAKE FROM WIRE
3. 0006 00 2 Hydraulic Systemi 0004 00 1 Tiedown 2 0004 00 4 INDEX 1 TM 9 2510 247 13 amp P INDEX Subject WP Sequence No Page No C continued Corrosion Prevention and 0001 00 3 E 0006 00 1 Coupling and Connectors Controls and Indicators 0004 00 3 D Decals Location Of iri EVE Doa ra AR OE 0002 00 6 Definition of Administrative 0078 00 1 Description and Use of Operator s Controls and 0004 00 1 Destruction of Army Materiel to Prevent Enemy Use 0001 00 1 Disassembly and Assembly 0038 00 4 E Electrical Connectors iot ea 0032 00 1 Electrical Control Box Repair Replacement 0044 00 1 Electrical Ground Points eit ee 0038 00 8 Electrical Mn 0038 00 11 Electrical System 2 0040 00 1 Equipment Characteristics Capabilities and Features 0002 00 1 Equipment Data coi E a 0002 00 7 Equipment Description and 0002 00 1 Equipment Improvement Recommendations reporting Of aiii 0001 00 2 Equipment Loading
4. DA Form 2407 Preventive Maintenance Schedule and DA Form 5988 Processing and Deprocessing Record for Shipment Storage and Issue of Vehicles and Spare DD Form 1397 Product Quality Deficiency SF Form 368 Recommended Changes to Equipment Technical Publications DA Form 2028 2 Recommended Changes to Publications and Blank Forms DA Form 2028 Report of Discrepancy inns SF Form 364 FIELD MANUALS Basic Cold Weather Manual sse eene nennen nennen FM 31 70 Chemical and Biological Contamination FM 3 3 Field Behavior of NBC Agents Including Smoke and Incendiaries FM 3 6 FirstAld for Soldiers ae 21 11 Manual for Wheeled Vehicle Driver FM 21 305 Chemical and Biological Decontamination FM 3 5 Chemical and Biological FM 3 4 Northern OperatiOhs eere ca FM 31 71 Operation and Maintenance of Ordnance Materiel in Gold Weather 10 65 eee na len FM 9 207 Operational Terms and Symbols
5. WP 0024 Hydraulic Functions do not Operate with Remote Control WP 0024 END OF WORK PACKAGE 0023 00 2 9 2510 247 13 amp P 0024 00 TABLE 1 OPERATOR TROUBLESHOOTING MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION KINGPIN KINGPIN FAILS TO LOCK IN FIFTH WHEEL Step 1 Check kingpin size and location for compatibility with prime mover fifth wheel Replace kingpin in accordance with WP 0034 Step 2 Check kingpin for damage Notify Unit Maintenance if kingpin is damaged ELECTRICAL SYSTEM 1 ALLLIGHTS INOPERABLE Step 1 Check that all electrical switches are set in the correct position WP 0015 Step 2 Check electrical connections at cable receptacles Reconnect cables if not properly connected Step 3 Check connectors for dirty corroded or damaged pins Clean in accordance with procedures WP 0035 Notify Unit Maintenance if pins are damaged Step 4 Check voltmeter on control box for reading of 12 volt dc Notify Unit Maintenance if voltage reading is below 12 volts dc 0024 00 1 9 2510 247 13 amp P 0024 00 TABLE 1 OPERATOR TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL SYSTEM 2 ONE OR MORE LIGHTS INOPERABLE Step 1 Check for burned out or defective bulbs lights Notify Unit Maintenance Step 2 Check for broken lead wires or loose connections Notify Unit Maintenance
6. 0031 00 1 General PMCS Procedures 420228 0037 00 2 Gladhand 0053 00 1 5 0016 00 1 0033 00 1 Heat Shrinkable Tubing 0038 00 7 Heat Extreme 0022 00 2 Hoses and Wires Tagging 0038 00 6 Flow to Use this Manual iv Humidity High 0022 00 2 Hydraulic Cylinder Main Frame to Mast Replacement 0063 00 1 Hydraulic Cylinder Mast to Boom 0064 00 1 Flydraulic FIOW Valve See tnn rae 0003 00 1 Hydraulic Motor Assembly 0057 00 1 Hydraulic Pressure Relieving 0056 00 5 Hydraulic Reservoir Fittings Replacement 0065 00 1 Hydraulic Safety Valve Replacement 0058 00 1 Hydraulic System MECA 0056 00 1 Hydraulic System Controls and 0004 00 1 Hydraulic System Charge of sss 0056 00 1 Hydraulic System Fill and Purge 0056 00 1 Hydraulic System Repair Meth
7. 0059 00 1 Maintenance Allocation Chart 0081 00 1 Maintenance ah 0032 00 1 Maintenance Forms Records and 0001 00 1 Maintenance 0081 00 1 Maintenance Instructions 0038 00 1 Major Components Location and Description 0002 00 5 Mandatory Replacement 0082 00 1 Manuals 0080 00 1 TSChNICAl 0080 00 2 Manufactured Items Illustrated 2 4 0088 00 1 Mast Frame Assembly Pivot Pin 0072 00 1 Metal Fasteners 0 0089 00 4 Mud Flap 0069 00 1 Mud Operation in asus TIED LITT 0022 00 2 N EN riadas 0001 00 1 Noinenclalt le 2 i ronda nd anna dao 0001 00 1 INDEX 4 TM 9 2510 247 13 amp P INDEX Subject WP Sequence No Page No Official Nomenclature Names Designations and ADDTeVvIatIONS resistant let 0001 00 1 Oil Filter Assembly 0061 00 1 Operate
8. 0010 00 4 Equipment Preparation for Shipment 0021 00 1 Equipment a 0018 00 1 Expendable and Durable Items List e 0085 00 1 Extreme Cold nnns 0022 00 1 Extreme Heat and High Humidity Operation 0022 00 2 F Fastener Grade 2 22 ada 0087 00 6 Fastener Size and Thread Pattern 0085 00 5 Fender 4 44 004 0 eene enne nennen 0070 00 1 Field Man alS 0080 00 1 Fill and Purge Hydraulic System 2 0056 00 1 Fittings Adjustable Installation 0056 00 4 Fixed Worklight 2 0048 00 1 ad BICI 0038 00 11 Folding to Shipping Storage 0021 00 1 aee 0022 00 3 Forms Maintenance 0031 00 1 T M 0080 00 1 INDEX 2 9 2510 247 13 INDEX Subject WP Sequence No Page No G General Hydraulic System Repair Methods 0056 00 1 General Lubrication 0039 00 1 General Maintenance 0038 00 1 General Preventive Maintenance Checks and Services PMCS
9. TM 743 200 1 Lead ACID Storage TM 9 6140 200 14 Inspection Care and Maintenance of Antifriction TM 9 214 OTHER PUBLICATIONS Army Medical Department Expendable Durable Items CTA 8 100 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic CTA 50 970 Fuels and Lubricants Standardization Policy for Equipment Design Operation and Logistic 70 12 Functional Users Guide for the Army Maintenance Management System DA PAM 738 750 Military Standard Abbreviations for Use on Drawings Specifications Standards and in Technical MIL STD 12D Prevention of Motor Vehicle Accidents AR 385 55 Operations Circular Welding Theory and Application TC 9 237 0080 00 2 9 2510 247 13 amp P 0081 00 MAINTENANCE ALLOCATION CHART SECTION I INTRODUCTION 1 THE ARMY MAINTENANCE SYSTEM MAINTENANCE ALLOCATION CHART MAC a This introduction Section provides a general explanation of all maintenance and repair functions authorized at various maintenance levels under the standard Army Maintenance system concept b The Maintenance Allocation Chart MAC in Section designates overall authority and responsibility
10. cion 4 END OF FIGURE 0082 00 9 2510 247 13 amp P View Figure 24 1 of 5 Hydraulic Hoses and Fittings 0082 00 TM 9 2510 247 13 amp P Front View BAS Y 1 ZEN Figure 24 2 of 5 Hydraulic Hoses and Fittings 0082 00 TM 9 2510 247 13 amp P Top View TT I n n AL HL e NAE 1I ww ee 4 po et MEL EET _ FEST EL ILLA I Jr Mp ml E OQ di Mr Hd ot 1 gt Hu 4 qd ie r f Figure 24 3 of 5 Hydraulic Hoses and Fittings 0082 00 TM 9 2510 247 13 amp P Top View Nail eo E T o e TR Ea vg ggg 11 KALAI A a Li d 9d Pw L5 dp 5 Figure 24 4 of 5 Hydraulic Hoses and Fittings 0082 00 TM 9 2510 247 13 amp P Front View 1273 AE 7 AN 15 L 11 Rz al ZB ae 8H NE 10 a 7 15 E Ly Figure 24 5 of 5 Hydraulic Hoses and Fittings 9 2510 247 13 amp P 0082 00 0 2 3 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC
11. Chart Introduction Essai rian RPSTLEntrodHuctior vin Gross Reference Indexes ideal Components of End Item and Basic Issue Items Lists Additional Authorization Expendable and Durable Items Illustrated List of Manufactured Torque Values for Threaded Fasteners Schematics aaa aaa a aa a a Authorized Vehicle Combinations sass 0000 00 0 9 2510 247 13 amp P 0080 00 REFERENCES SCOPE This appendix lists all forms field manuals technical manuals and other publications referenced in this manual and that apply to the operation and maintenance of the 250M Fifth Wheel Towing Device FWTD PUBLICATION INDEX DA Pam 25 30 Consolidated Index of Army Publications and Blank Forms should be consulted frequently for latest changes or revisions and for new publications relating to material covered in this technical manual FORMS Refer to DA Pam 738 750 Functional Users Manual for the Army Maintenance Management System TAMMS for instructions on the use of maintenance forms Equipment Inspection and Maintenance Worksheet DA Form 2404 Equipment Log Assembly DA Form 2408 Maintenance
12. 4 SCREW CAP HEXAGON 3 8 DIA X 16 UNC X 1 INCH LONG 4 END OF FIGURE 0082 00 TM 9 2510 247 13 amp P Figure 20 Winch Assembly 1 ITEM SMR NO CODE 1 XDOZZ 2 PAOZZ 3 PAOZZ 4 PAOZZ 5 XDOZZ 6 PAOZZ 2 3 NSN 5305014958188 4730009747313 5305012726543 5305007252317 4 60287 1BZD4 96906 81495 OGRFO 80204 TM 9 2510 247 13 amp P 0082 00 5 PART NUMBER 1878 1103 1 551527 10 1200 59 WA WLC3840 1821 038 150 6 7 DESCRIPTION AND USABLE CODES UOC QTY GROUP 20 HOIST WINCH CAPSTAN WINDLASS POWER CONTROL UNIT AND POWER TAKE OFF GROUP 2001 HOIST CAPSTAN WINDLASS CRANE OR WINCH ASSEMBLY FIG 20 WINCH ASSEMBLY WINCH HYDRAULIC 1 SET SCREW 1 ELBOW TUBE TO 2 SCREW CAP HEXAGON 3 8 DIA 16 UNC X 1 INCH LONG 8 CABLE WINCH W CHAIN cene 1 SCREW CAP HEXAGON H 3 8 DIA X 16 UNC X 1 1 2 INCHES 4 END OF FIGURE TM 9 2510 247 13 amp P 0082 00 Figure 21 Hydraulic Motor Assembly 0 2 ITEM SMR NO CODE 1 PAOZZ 2 PAOZZ 3 22 4 PAOZZ 5 22 6 22 7 22 8 22 9 PAOZZ 10 22 11 PAOZZ 12 22 3 NSN 5305012726543 4730001856837 4730014419417 4820015022001 473000534414
13. 1 BRACKET ANGLE 1 SCREW TAPPING 6 SCREW CAP HEXAGON 2 CLAMP LOOP n ree 2 2 BRACKET MOUNTING NUT PLAIN HEXAGON 1 1 2 DIA X 18 UNEF X 2 INCHES LONG 1 WASHER LOCK 1 1 2 DIA HOLE NUT PLAIN WING eee u STOP 0 2 1 1 1 1 4 4 LAMP INCANDESCENT 2 1 1 LIGHT MARKER CLEARA 1 SCREW SHOULDER 5 16 DIA X 18 UNC X 2 1 2 2 STRAP WEBBINQi ica iiri tent near 4 WASHER FLAT 3 8 DIA 2 NUT PLAIN HEXAGON 3 16 DIA X 24 DNO e EU ida 4 WASHER LOCK 3 16 DIA 4 SCREW MACHINE 3 16 DIA X 24 UNC X 3 4 INCHES 2 4 6 5 2 SCREW CAP HEXGON 3 8 DIA X 16 UNC X 2 INCHES 4 WASHER LOCK 1 4 DIA HOLE 8 5 2 NUT SELF LOCKING HE 5 16 DIA X UNC asena esa Raa E 2 WIRING HARNESS BRAN 1 TERMINAL sss 11 JINSULATOR BUSHING AA 11 SHELL ELECTRICAL CO SLEEVING TEXTILE EL MAKE FROM SLEEVING TEXTILE ELECTRICAL P N 50010013 16 INC
14. 0037 00 2 Unit oot tis ees ux ME REI eme 0037 00 1 Preparation for Storage or 0001 00 1 0078 00 1 Preparation of Equipment for Administrative CSIO M le e 0078 00 2 Preparation of Equipment for Shipment 7 0200 0078 00 5 Prepare Towing Device ntes ete rine ee 0008 00 1 Preservation PANS ssa SE ico 0038 00 3 Preventive Maintenance Checks and Services PMCS Operator etre 0031 00 1 Preventive Maintenance Checks and Services PMCS MEE 0037 00 1 Publication OOX sessed e e 0080 00 1 Publications Other sia a a 0080 00 2 Purge and Fill Hydraulic 0056 00 5 INDEX 5 TM 9 2510 247 13 amp P INDEX Subject WP Sequence No Page No R Receiver and Wheel Stop Assembly Replacement 0068 00 1 Receptacle Replacement 12 Volt 0042 00 1 Receptacle Replacement 24 Volt 0041 00 1 References EE 0080 00 1 Relieve Hydraulic nennen 0056 00 5 Removal of Equipment from Administrative Storage sie 0078 00 5 Remote Control Assembly 0046 00 1 Repair Air Brake FINOS xica iaa 0055 00 3 maior 0038 00 1
15. 0015 00 1 Operation in Extreme sass sass 0022 00 1 Operation in Extreme Heat and High 0022 00 2 Operation Mud and 0022 00 2 Operation on Rocky 0022 00 3 Operation in Saltwater 0022 00 2 Operation in Sandy or Dusty Areas 0022 00 2 Operation Under Unusual 0022 22 1 Operation Under Usual 0005 00 1 Operator 0031 00 1 Operator Preventive Maintenance Checks and services PMO Scuola ia 0031 00 1 Operator Troubleshooting 0024 00 1 Operator Troubleshooting Procedures 0023 00 1 Operator Troubleshooting Symptom 0023 00 2 Other Publications un 0080 00 2 PAINUNG E E E a E E 0038 00 3 Parts and Kits Service Replacement 0038 00 11 Parts Preservation Ol ita dels 0038 00 3 Plates Location Orsini aiii dd dd 0002 00 6 Setup 0037 00 3 PMCS Operator ae e XR RR nue eR RR aa 0031 00 1 PMCS Procedures
16. Va IIR AT SNP NON RT CP Winches Assembly Replacement 4 400440 020 00 Preparation for Storage or Shipment ee CHAPTER 7 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS General Maintenance Instructions ccccccccssecssccsecsssecsecceecsseessecceccseecsaeesaeeeccseeeseeenseeaeenas CHAPTER 8 SUPPORTING INFORMATION References ctt A MAC Chart Introduction 001 enne ennt ntn ennt nnns ernst nnn RPSTL Cross Reference Indexes sensn rasis Components of End Item and Basic Issue Items Lists Additional Authorization List Expendable and Durable Items 0 240240 0 nnne nnn Illustrated List of Manufactured Items esses enne Torque Values for Threaded A AS Authorized Vehicle Combinations 08 0091 00 TM 9 2510 247 13 amp P HOW TO USE THIS MANUAL This manual is designed to help you operate and maintain the 250M Fifth Wheel Towing Device FEATURES OF THIS MANUAL A table of contents is provid
17. GROUP 2406 STRAINERS FILTERS LINES AND FITTINGS ETC FIG 24 HYDRAULIC HOSES AND FITTINGS 1 PAOZZ 4720014966037 1BZD4 01126 HOSE ASSEMBLY NONME 1 2 PAOZZ 4720014964914 1BZD4 01124 HOSE ASSEMBLY NONME 1 3 PAOZZ 4720014965327 1BZD4 01125 HOSE ASSEMBLY NONME 1 4 PAOZZ 4720014966067 1BZD4 01123 HOSE ASSEMBLY NONME 1 5 PAOZZ 4720014963775 1BZD4 01110 HOSE ASSEMBLY NONME 1 6 PAOZZ 4720014964523 1BZD4 01111 HOSE ASSEMBLY NONME 2 7 PAOZZ 4720014961588 1BZD4 01109 HOSE ASSEMBLY NONME 1 8 PAOZZ 4720014964550 1BZD4 01112 HOSE ASSEMBLY NONME 2 9 PAOZZ 4720014970042 1BZD4 01114 HOSE ASSEMBLY NONME 4 10 PAOZZ 4720014964647 1BZD4 01118 HOSE ASSEMBLY NONME 1 11 PAOZZ 4720014966466 1BZD4 01115 HOSE ASSEMBLY NONME 1 12 PAOZZ 4720014966337 1BZD4 01117 HOSE ASSEMBLY NONME 1 13 77 4720014966429 1BZD4 01116 HOSE ASSEMBLY NONME 1 14 PAOZZ 4720014966001 1BZD4 01121 HOSE ASSEMBLY NONME 2 15 24 89346 417202C2 7 HOSE NONMETALLIC MAKE FROM HOSE P N 417202C2 7 INCHES LONG as 2 16 PAOZZ 4720014966048 1BZD4 01119 HOSE ASSEMBLY NONME 1 17 PAOZZ 4720014970107 1BZD4 01120 HOSE ASSEMBLY NONME 1 END OF FIGURE 0082 00 TM 9 2510 247 13 amp P Figure 25 Oil Filter Assembly TM 9 2510 247 13 amp P 0082 00 2 3 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC QTY GROUP 2406 STRAINERS F
18. 0002 00 4 9 2510 247 13 amp P 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Figure 9 Kingpin 12 24 Volt Light Bars Pivot Pin Component Description Kingpin A removable kingpin is inserted from the bottom and extends below the towing device to attach to the prime mover fifth wheel plate for towing Two kingpins are provided for use with different prime movers The second kingpin is stored in a kingpin holder on the frame 12 Volt Light Bar The 12 volt light bar has combination stop turn taillights and AAL red clearance lights on either side 24 Volt Light Bar The 24 volt light bar has combination stop turn taillights and red clearance lights on either side and blackout lights The 24 volt light bar is stowed in the tool box Pivot Pin Two pivot pins are inserted into the mast assembly to allow boom section to move into vertical position The pivot pins are stored in the toolbox 0002 00 5 9 2510 247 13 amp P LOCATION AND CONTENTS PLATES DECALS AND STENCILS FIFTH WHEEL TOWING DEVICE MODEL No 250M NSN 2510 01 458 8253 Gross Lift Capacity Tr 30 000 Ibs Capacity 120 000 Iba Hitch Weight With Attachments 7 200 ibs MFD BY TRU HITCH INC TORRINGTON CT 06790 860 489 7333 FAX 860 489 8786 WWW TRUMITCH COM CONTRACT GS 3QF 1003H TECHNICAL MANGA 77 seso WARRANTY LL 12 U 5 PROPERTY FRONT REAR TIE DOWN RATING LBS UFT PONT
19. A POSITION 1 FRONT Figure 73 Kingpin Placement END OF WORK PACKAGE 0034 00 2 TM 9 2510 247 13 amp P 0035 00 CLEANING WARNING After washing the fifth wheel towing device ensure appropriate breather valve is opened prior to operation of the fifth wheel towing device Failure to comply may result in death or injury to personnel CAUTION Ensure both breather valves are closed during washing of the fifth wheel towing device Failure to comply may result in water contamination in hydraulic reservoir 1 Usea high pressure stream of water to clean the exterior 2 Use a stiff broom or scrub brush Item 1 WP 0085 and detergent Item 4 WP 0085 to remove remaining dirt from exterior 3 Use a stiff broom or scrub brush Item 1 WP 0085 and detergent Item 4 WP 0085 to remove remaining dirt from underside of towing device END OF WORK PACKAGE 0035 00 1 9 2510 247 13 amp P 6 UNIT MAINTENANCE INSTRUCTIONS 9 2510 247 13 0000 00 UNIT MAINTENANCE INSTRUCTIONS INDEX WP Sequence No UNIT MAINTENANCE INSTRUCTIONS Service Upon Receipts Unit Preventive Maintenance Checks and Services PMCS General Maintenance Instructions 1 L bricationiInstr ctlOns a Electrical System Maintenance 24 Volt Receptacle Replacement
20. nente inte retten ticae 1 KINGPIN WRENCH PIN RETAINING KINGPIN FIFTH WHEEL 2 INCHES 1 PLUGWOOD CAP PROTECTIVE DUST NUT PLAIN WING END OF FIGURE TM 9 2510 247 13 amp P 0082 00 10 Figure 13 Receiver and Wheelstop Assembly 0 2 ITEM SMR NO CODE PAOZZ XDOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ XDOZZ XDOZZ XDOZZ PAOZZ BQN 3 NSN 5340014961903 5315012823483 5315014960453 5360014960434 5310010132395 5306014957002 5315011334382 5315014984029 4 CAGEC 1BZD4 OATA2 39428 1BZD4 1BZD4 98523 1BZD4 39428 1BZD4 1BZD4 1BZD4 1BZD4 TM 9 2510 247 13 amp P 5 PART NUMBER 1054 1 2001 98296A255 1057 1 1058 1 A200151C007 1040 1 98296A559 1053 1 1052 1 1041 1 02540 6 DESCRIPTION AND USABLE ON CODES UOC 0082 00 7 QTY GROUP 1503 PINTLES AND TOWING ATTACHMENTS HANDLE MANUAL CONTR FITTING GREASE PIN SPRING PIN STRAIGHT HEADLE SPRING HELICAL COMP WASHER FLAT 3 4 DIA HOLE BOLT TEE HEAD PIN SPRING tienne RECEIVER ASSEMBLY LEFT SIDE RECEIVER ASSEMBLY RIGHT SIDE WHEEL STOP s PIN STRAIGHT HEADED END OF FIGURE FIG 13 RECEIVER AND WHEELSTOP ASSEMBLY 0082 00 TM 9 2510 247 13 amp P Figure 14 Fenders and Mud Flaps 9 2510 247 13 0082
21. 4 Position hinge mounting bracket 4 on tool box and secure with two screws 8 new lockwashers 9 and nuts 10 Install new weather strip 7 Position hinge mounting bracket 4 on tool box door 5 and secure with 3 4 inch screw 6 1 inch screw 1 new lockwashers 2 and nuts 3 Repeat steps 1 through 3 for remaining hinge assemblies Figure 122 Hinge Assembly for Tool Box 0071 00 3 TM 9 2510 247 13 amp P 0071 00 INSTALLATION 1 Install new weather strip 7 2 Repeat step 1 for remaining tool box door 8 3 Position tool box 6 on fender and secure with six screws 1 flatwashers 2 flatwashers 3 new lockwashers 4 and nuts 5 Figure 121 Tool Box Follow on Tasks None END OF WORK PACKAGE 0071 00 4 9 2510 247 13 0072 00 MAST FRAME ASSEMBLY PIVOT PIN REPLACEMENT INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in Nut self locking 4 MS17830 6C storage configuration 0002 Personnel Required 2 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General None NSN 5180 00 177 7033 REMOVAL NOTE There are two mast frame assembly pivot pins Both are removed the same way 1 Remove two screws 1 and locknuts 2 from pivot pin 3 2 Remove pivot pin 3 from mast frame 4 and boom assembly 5 INSTALLATION 1 Position boom assembly 5 on mast frame 4 to align holes and inser
22. 9 2510 247 13 amp P 5 UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL WITH REPAIR PARTS AND SPECIAL TOOLS LIST FOR FIFTH WHEEL TOWING DEVICE MODEL 250M NSN 2510 01 458 8253 FOR SERIAL NUMBERS 250M499 THROUGH 250M999 Approved for public release distribution is unlimited HEADQUARTERS DEPARTMENT OF THE ARMY July 1 2004 TM 9 2510 247 13 amp P SAFETY WARNING ICONS FOR INFORMATION ON FIRST AID REFER TO FM 21 11 EAR PROTECTION headphones over ears shows that noise level will harm ears ELECTRICAL electrical wire to arm with electricity symbol running through human body shows that shock hazard is present ELECTRICAL electrical wire to hand with electricity symbol running through hand shows that shock hazard is present FALLING PARTS arrow bouncing off human shoulder and head shows that falling parts present a danger to life or limb FLYING PARTICLES arrows bouncing off face shows that particles flying through the air will harm face FLYING PARTICLES arrows bouncing off face with face shield shows that particles flying through the air will harm face HEAVY OBJECT human figure stooping over heavy object shows physical injury potential from improper lifting technique 9 2510 247 138 SAFETY WARNING ICONS Continued HEAVY PARTS hand with heavy object on top shows that heavy parts can A crush and harm HEAVY PARTS foot with heavy object on t
23. 12 13 Figure 113 Hydraulic Cylinder Main Frame to Mast Install elbows 3 on cylinders 5 and 7 Install straight adapter 6 on cylinder 7 Install tee fitting 2 on straight adapter 6 Install elbow 1 on tee fitting 2 Install hydraulic hose 4 on cylinder 5 Install hydraulic hoses on elbows 3 Install hydraulic hose on tee fitting 2 and upper safety valve 12 Install hydraulic hose on elbow 1 Follow on Tasks Charge hydraulicg WP 0056 0015 Check reservoir fluid levels and adjust level as required WP 0056 0015 END OF WORK PACKAGE 0063 00 3 9 2510 247 13 0064 00 HYDRAULIC CYLINDER MAST BOOM REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in None loading configuration WP 0002 pressure relieved WP 0056 00 5 Personnel Required 2 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General None NSN 5180 00 177 7033 A suitable lifting device for 115 Ibs 53 kg REMOVAL Ed WARNING HYDRAULICS Ensure hydraulic protection valve is open breather switch in line with breather prior to operating hydraulics Failure to comply could cause injury or death to personnel or damage to equipment High pressure is present in the 250M Fifth Wheel Towing Device hydraulic system Do not disconnect any hydraulic system component unless hydraulic system pressure
24. 12 Volt Receptacle Replacement 0220 0 0 0010000 ncnnanonanos 12 24 Volt Junction Box Replacement c cccccccsccesseccsssecssesesseccsseeccseseseeccsaeeccsusesaucesaeescseeesaees Electrical Control Box Maintenance cccccccccessscccsecessecesseeccseecssseccsseecseecsaecccsesessecesaeeceseecsaass Solenoid Assembly Remote Control Assembly Replacement ccsccccssccssseecssesesseccsseecesesesaeccsaeeccseeesaueccsuesesecaass 24 Volt Tow Light Assembly Repair Fixed Worklight 2 04022 20 0 eene nnne Strobe Light Maintenarice 3 2 errat Ta Ha RUE CERE ee oed ado da Battery Battery Box Replacement sss Wiring Harness Cable Maintenance Brake System Maintenance eene tanen nter Gladhand Replacement cinta is de hand Air Brake Protection Valve Air Brake Fittings Maintenance General Hydraulic System Repair 2 4222 0 0000 eene enne nnn nnne nes Hydraulic Motor Assembly Hydraulic Safety Valve 02 2 000 0000 01 0 Main V
25. 18204 8 865 19207 98441 1BZD4 1BZD4 1BZD4 1BZD4 1BZD4 1BZD4 9 2510 247 13 amp P 5 NUMBER 1082 1 MS16997 78 10 10 0703206 02505 0507 12 12 12 3 4F50G S 12 12 12 140424C 3 4X1 4PRT S 1078 1 MS35313 44 1075 1 5 16 18 UNC 2A X 2 1 2 12387272 45 12HP50NS 1105 1 1106 1 1107 1 1104 1 1108 1 02640 0082 00 6 7 DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 2402 MANIFOLD AND OR CONTROL VALVES FIG 23 MAIN VALVE ASSEMBLY COVER ACCESS esses 1 SCREW CAP SOCKET HE 5 16 DIA X 18 2 UNC X 3 4INCH LONG ELBOW TUBE TO BOSS MANIFOLD ASSEM HYDR ADAPTER STRAIGHT PI ADAPTER STRAIGHT PI TEE PIPE utet ete terere re ADAPTER STRAIGHT P 1 GAUGE PRESSURE DIAL 1 SCREW CAP HEXAGON 5 16 DIA X 18 INCHES LONG 1 eese 11 SCREW CAP HEXAGON 5 16 DIA X 18 UNC X 2 1 2 INCHES LONG 2 WASHER LOCK 5 16 DIA 2 PLUG MACHINE THREAD esee 1 PIN GOTTER nn rien tentis ica 15 PIN STRAIGHT HEADED 5 PIN RETAINING SINGLE 5 5 PLATE 5
26. Source Code The source code tells you how you get an item needed for maintenance repair or overhaul of an end item equipment Explanations of source codes follow Source Code KD KF KB MO Made at unit level MF Made at DS level MH Made at GS level ML Made at SRA MD Made at depot Application Explanation Stock items use the applicable NSN to requisition request items with these source codes They are authorized to the level indicated by the code entered in the 3rd position of the SMR code NOTE Items coded PC are subject to deterioration Items with these codes are not to be requested requisitioned individually They are part of a kit which is authorized to the maintenance level indicated in the 3rd position of the SMR code The complete kit must be requisitioned and applied Items with these codes are not to be requisitioned requested individually They must be made from bulk material which is identified by the P N in the DESCRIPTION AND UOC column and listed in the bulk material group work package of the RPSTL If the item is authorized to you by the 3rd position code of the SMR code but the source code indicates it is made at higher level order the item from the higher level of maintenance 00082 00 2 9 2510 247 13 3 EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGE Continued AO Assembled by Items with these codes are not to be unit AVUM level requeste
27. TRANSPORTING LOADS Continued CAUTION DO NOT over steer during small radius turns Know the position of the fifth wheel towing device in conjunction with the prime mover Failure to comply may result in vehicle contact between the fifth wheel towing device and the primemover and may cause damage to equipment e Turning When turning corners allow extra room The towed vehicle wheels will follow a track that is inside the radius of the prime mover wheels For right turns drive about halfway into the intersection and then cut sharply to the right The forces affecting the stability of a tractor combination are increased during turning The smaller the radius the greater the force trying to pull the vehicle over Therefore the tighter the curve the slower the speed must be in order to avoid a rollover WARNING Stopping distances greatly increase when the towed vehicle has nonfunctioning brakes Care should be taken to ensure adequate stopping distance is obtained and speed is adjusted accordingly Failure to comply may result in injury or death to personnel Towing of a single vehicle with non functioning brakes must be limited to not more than 25 mph on the highway and 15 mph off road Failure to comply may result in injury or death to personnel Towing of vehicle combinations with non functioning brakes is prohibited Failure to comply may result in injury or death to personnel f Stopping In normal operation brake pressure
28. injury or death to personnel General Safety Instructions Remove all power to towing device prior to making any repairs on electrical system NOTE Both strobe light assemblies are removed the same way Left side shown 1 Remove four screws 1 from cover 2 Remove cover 2 from baseplate 3 2 Disconnect strobe light wire 4 Figure 91 Strobe Light Assembly 0049 00 1 0049 00 TM 9 2510 247 13 amp P REMOVAL NOTE Perform step 3 ONLY IF strobe light assembly is damaged 3 Remove four screws 5 from base plate mounting brackets 6 Remove strobe light assembly from mounting brackets NOTE Perform step 4 ONLY IF mounting bracket is damaged 4 Remove three screws 7 and lockwashers 8 from mounting bracket 9 Remove mounting bracket 9 from mast assembly Discard lockwashers NOTE DO NOT touch bulb with bare hands Body oil may shorten the operating life of the bulb Use gloves item 6 Appendix F or a rag item 10 WP 0085 when handling bulbs BULB REMOVAL Remove four screws 1 from cover 2 Remove cover from base plate 3 1 2 Remove bulb securing clip 10 and bulb 11 BULB INSTALLATION Install bulb 11 and secure with bulb securing clip 10 1 2 Position cover 2 on base plate 3 and secure with four screws 1 Figure 91 Strobe Light Assembly 0049 00 2 9 2510 247 13 amp P 0049 00 INSTALLATION NOTE Both strobe light assemb
29. 5310004699202 3130014970388 5310010739803 5310013894257 5305012726543 4 CAGEC 96906 39428 1BZD4 1BZD4 1BZD4 18204 18204 96906 80204 18204 18204 18204 18204 99862 18204 96906 14541 39428 19200 96906 81495 9 2510 247 13 amp P 5 PART NUMBER 21044N8 982964255 1031 1 1032 1 1066 1 02650 1029 1 MS90727 125 B1821 1028 1 1046 1 1047 1 1044 1 CL 4 PPK 4 1045 1 MS16997 78 5913 44 12279371 1 535338 046 1200 59 0082 00 6 7 DESCRIPTION AND USABLE ON CODES UOC GROUP 1812 SPECIAL PURPOSE BODIES FIG 19 TRANSPORT LEG ASSEMBLY NUT SELF LOCKING HE 1 4 DIA X 20 Wd E 4 9 PIN RETAINING UPPER SECTION 2 PIN RETAINING LOWER SECTION 2 WASHER FLAT 3 4 DIA HOLE 4 BOLT BALLEND nio atado aludida 4 CONNECTING LINK ROD 2 21 4 22 2 SCREW CAP HEXAGON H 1 2 DIAX 20 UNC X 4 1 2 INCHES LONG 2 BHO50F300N SCREW CAP HEXAGON H 1 2 DIA X 20 UNC X 3 INCHES LONG 2 BRACKET EYE ROTATIN LEFT SIDE 2 FRAME LEG LEFT SIDE 1 1 RIGHT SIDE 1 BAR TRANSPORT LEG 1 ee 1 HANDLE MANUAL CONTR 1 SCREW CAP SOCKET HE 5 16 DIA X 18 UNC X 3 4 INCHES LONG 1 WASHER FLAT 3 4 DIA 4 4 2 WASHER FLAT 3 8 DIA HOLE 4 WASHER LOCK 3 8 DIA HOLE
30. 8B865 TM 9 2510 247 13 amp P 5 NUMBER 845 FS 08X08 N 800 S 8 8 1401375 8 8 140237C 02840 02855 MS35311 38 5 16 18 UNC 2A 0082 00 6 7 DESCRIPTION AND USABLE ON GROUP 2402 MANIFOLD AND OR CONTROL VALVES FIG 22 HYDRAULIC SAFETY VALVE TEE TUBE annia uem VALVE GLOBE ociosas arias NIPPLE PIPE asen ELBOW PIPE nta VALVE CHECK naa VALVE SAFETY 4 PORTS SCREW CAP HEXAGON H 5 16 DIA X 18 UNC X 1 1 2 INCHES SCREW CAP HEXAGON H 5 16 DIA X 18 X 2 1 2 UNC X 2 1 2 INCHES LONG END OF FIGURE TM 9 2510 247 13 amp P 9 S Figure 23 Main Valve Assembly A 0082 00 1 2 ITEM SMR NO CODE 1 PAOZZ 2 PAOZZ 3 PAOZZ 4 PAOFL 5 PAOZZ 6 PAOZZ 7 PAOZZ 8 PAOZZ 9 PAOZZ 10 PAOZZ 11 PAOZZ 12 PAOZZ 13 PAOZZ 14 PAOZZ 15 77 16 77 17 PAOZZ 18 77 19 77 20 22 3 NSN 5340014962166 5305009835346 4730003858795 4730014963695 4730013263049 4730004070509 4730007572910 4730010505756 6685014968423 5305008195108 5945014958071 5305002829607 5310013782903 5365004069320 5315014958223 5340014958298 5315014958164 5340014961906 5340014961897 4 CAGEC 1BZD4 96906 81343 1BZD4 30780 30780 81343 30780 18204 96906
31. Continued 3 RELIEVE HYDRAULIC PRESSURE FROM ONE OR MORE LEVERS Step 1 Is hydraulic breather valve in CLOSED position WP 0021 If no go to step 2 If yes move breather valve to OPEN position WP 0021 Step 2 Is return line obstructed WP 0056 00 5 steps 3 thru 5 If no replace breather valve WP 0065 If yes clean or replace return line 4 CYLINDERS DO NOT EXTEND OR RETRACT WHEN PUSH SWITCH ON ELECTRIC CONTROL BOX AND LEVERS ARE ACTIVATED Step 1 Are hydraulic motors running and hydraulic pressure being maintained If no check to see if there is voltage at push button switch and solenoid If yes adjust hydraulic flow control valves WP 0003 5 HYDRAULIC FLUID COMING FROM BREATHER VALVE Step 1 Is oil at correct level WP 0056 If no adjust oil level WP 0056 and ensure breather valve on top of reservoir is open at all times If yes adjust hydraulic flow valves WP 0003 Step 2 Is hydraulic pressure gauge showing pressure If no adjust hydraulic flow valves WP 0003 If yes go to step 2 0028 00 2 9 2510 247 13 amp P 0028 00 UNIT TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION HYDRAULIC SYSTEM Continued 6 BOOM WILL NOT OPERATE Step 1 Is hydraulic pressure gauge showing pressure If no adjust hydraulic flow valves WP 0003 If yes go to step 2 Step 2 Are hydraulic motors running If no check batteries for voltage Check I
32. NSN 4910 00 754 0654 WARNING Remove all power to fifth wheel towing device prior to making any repairs on the electrical system Failure to do so may result in serious injury or death NOTE Wiring harnesses can be replaced or repaired depending on the type of damage Broken wires can be spliced and sealed with heat shrink tubing or electrical tape WP 0038 00 6 tagging wires and hoses WP 0038 00 7 soldering WP 0038 00 7 heat shrinkable tubing and WP 0038 00 8 electrical ground points for general wiring harness maintenance instructions There are three loop clamps securing the wiring harnesses 0051 00 1 TM 9 2510 247 13 amp P 0051 00 REMOVAL Remove screw 1 and washer 2 from loop clamp 3 Remove loop clamp from wiring harness REPLACEMENT REPAIR Wiring harnesses are not ordinarily removed except if they need to be replaced Badly damaged wiring harnesses must be replaced Wiring harness connections must be tightly attached and connected See wiring schematics WP 0088 for additional information INSTALLATION Position loop clamp 3 around wiring harness and secure with screw 1 and washer 2 Figure 96 Loop Clamp Follow on Tasks Check electrical system for proper operation END OF WORK PACKAGE 0051 00 2 TM 9 2510 247 13 amp P 00052 00 BRAKE SYSTEM MAINTENANCE GENERAL REPLACEMENT REPAIR GENERAL WARNING Air under 100 psi pressure is used in the operation of the air bra
33. PURGE AND FILL HYDRAULIC SYSTEM Continued 20 Couple fifth wheel towing device to prime mover and fold coupled towing device onto prime mover using TRANSPORT CONFIGURATION steps 1 through 9 WP 0007 DO NOT remove pivot pins 21 Return fifth wheel towing device to oil fill configuration Figure 104 Check oil level Add new oil as necessary INSERT PIN INTO THE 2ND HOLE DOWN T ANGLE TO 90 FULLY EXTEND BOOM EXTENSIONS LAY BOOMS FLAT ON LEVEL GROUND Figure 104 Hydraulic System NOTE Use kingpin wrench as hydraulic reservoir dipstick END OF WORK PACKAGE 0056 00 7 9 2510 247 13 amp P 00057 00 HYDRAULIC MOTOR ASSEMBLY REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in coupling Washer lock 4 M326 3 configuration WP 0002 Washer lock 4 MS35333 046 Disconnect batteries WP 0050 Sealant item 11 WP 0085 Hydraulic pressure relieved WP 0056 00 5 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General None NSN 5180 00 177 7033 ToolKit Common No 1 NSN 4910 00 754 0654 REMOVAL OF PRIMARY MOTOR Ed WARNING High pressure is present in the 250M Fifth Wheel Towing Device hydraulic system Do not disconnect any hydraulic system component unless hydraulic system pressure has been relieved Ensure each hydraulic control lever is moved several times through all position
34. 0600 65 INCHES LONG WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N QQW343E04G1B 36 INCHES LONG ert tnnt tenens CLAMP LOOP 1 2 INCH DIA WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N QQW343E04G18 10 INCHES LONG rte e tetti CABLE POWER ELECTRI MAKE FROM CABLE POWER ELECTRICAL P N M2564 3143 0600 4 INCHES LONG TERMINAL LUG YELLOW EYELET TERMINAL LUG BLUE EYELET CABLE POWER ELECTRICAL MAKE FROM CABLE POWER ELECT P N 2SJ 12 60 INCHES EONG in tentes WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M76MWPC1619A1 10 INCHES LONG TERMINAL LUG RED OPEN SLOTTED WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N J C 580TFF6CF116TUJ 10 1 2 INCHES LONG WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M81381 7 16 6 11 INCHES LONG WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M5086 1 16 60 11 1 2 INCHES LONG WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M16878 4BJE3 11 1 2 INCHES LONG nnne WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M5086 1 16 30 11 1 2 INCHES LONG WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M22759 34 16 4 13 INCHES EONG nea WIRE ELECTRICAL MAKE FROM WIRE 13 1 2 ELECTRICAL P N M16878 1BJE80 13 1 2 INCHES
35. 11001 nennen nes FM 101 5 1 Railway Operating and Safety Rules FM 55 21 VISUAL DEI RE FM 21 60 Desert Operations ERE 90 3 Rigging Techniques assures e FM5 125 0080 00 1 9 2510 247 13 amp P 0080 00 TECHNICAL BULLETINS Color Marking and Camouflage Painting of Military Vehicles Construction Equipment and Materiels Handling Equipment TB 43 209 Corrosion Prevention and Control Including Rustproofing Procedures for Tactical Vehicles and Trailers TB 43 0213 Equipment Improvement Report and Maintenance Digest for Tank Automotive Armament and Chemical TB 43 0001 62 1 Safety Inspection and Testing of Lifting Devices TB 43 0142 TECHNICAL MANUALS Materials Used for Cleaning Preserving Abrading and Cementing Ordnance Materiel and Related Materials Including Chemicals TM 9 247 Painting Instructions for Army Materiel TM 43 0139 Procedures for Destruction of Tank Automotive Equipment to Prevent IDA tM 750 244 3 Transportability Guide for Application of Blocking Bracing and Tiedown Materials for Rail TM 55 2200 001 12 Storage and Materials Handling
36. 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC QTY GROUP 06 ELECTRICAL SYSTEMS GROUP 0608 MISCELLANEOUS ITEMS FIG 1 12 24 VOLT JUNCTION BOX a PAOZZ 5305002253843 80204 B1821BH025C100N SCREW CAP HEXAGON 1 4 DIA X 20 UNC X 1 4 2 PAOZZ 5310006858308 04773 125 10497 07 WASHER FLAT 1 4 DIA HOLE a 5 3 PAOZZ 5935012114434 26697 0031 CONNECTOR RECEPTACL 4 d 4 PAOZZ 5310005501130 96906 MS35333 40 WASHER LOCK 1 4 DIA HOLE 5 PAOZZ 5310000115120 24617 115120 NUT PLAIN HEXAGON 1 4 DIA X 20 UNC 12 6 PAOZZ 5935014943538 1BZD4 1092 1 CONNECTOR RECEPTACL 24 V ss d 7 XDOZZ 1BZD4 9003 1 BOX JUNCTION 12 24 1 8 PAOZZ 5975014816824 39428 69915K55 BUSHING STRAIN REL 3 4 INCH 1 9 PAOZZ 4730014818114 39428 69915 53 ADAPTER STRAIGHT PI 1 2 INCH 4 10 XDOZZ 1BZD4 1056 1 BOLT THREADED 1 4 DIA X 20 UNC X 1 2 INCH LONG BOTH 4 END OF FIGURE TM 9 2510 247 13 amp P 0082 00 Figure 2 Electrical Control Box 9 2510 247 13 amp P 0082 00 1 2 3 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC QTY GROUP 0608 MISCELLANEOUS ITEMS FIG 2 ELECTRICAL CONTROL BOX 1 XDOZZ 1BZD4 1022 1 COVER ELECTRICAL CONTROL BOX 1 2 PAOZZ 6110014995311 1BZ
37. 75915 813040 5925 01 206 8136 8 42 70485 832 5340 00 600 5937 4 27 19207 8338561 5935 00 833 8561 4 36 19207 8338562 5970 00 833 8562 4 35 19207 8338564 5940 00 399 6676 4 34 19207 8338566 5935 00 572 9180 4 15 19207 4 48 19207 8338567 5310 00 833 8567 4 16 19207 4 49 30327 845 FS 08X08 4730 01 334 5719 22 1 39428 8451A62 9390 01 469 7255 BULK 2 39428 8451A62 26 7 8 98441 8AOGSJGS S 4730 01 497 6338 21 6 98441 8F50HAO SS 4730 00 534 4140 21 5 30780 8F650X SS 4730 01 441 9417 21 3 1BZD4 9003 1 1 7 39428 900454453 5310 01 467 4644 26 5 89346 91916R91 2520 00 446 7518 30 1 11939 93602345 5310 01 082 2058 4 24 39428 93695K 13 15 3 39428 93695K62 5640 01 462 4252 BULK 27 39428 982964255 5315 01 282 3483 13 3 39428 19 2 39428 29 11 39428 982964548 5315 01 496 6348 11 4 39428 98296 556 5315 01 133 4382 11 10 39428 98296 559 5315 01 133 4382 13 8 81348 52463 10 6240 01 447 3779 4 18 98523 200151 007 5310 01 013 2395 13 6 58536 52463 1 08 6240 00 019 0877 4 45 58536 52463 1 09 6240 00 019 3093 4 14 58536 52484 1 4730 00 595 0083 10 5 58536 AA59551 E04G1B 6145 00 023 6778 BULK 4 0084 00 6 80204 OTWA7 80204 80204 80204 80204 80204 80204 80204 80204 80204 80204 80204 06721 60592 81346 98410 OTWA7 81349 81349 98410 7HO66 99862 75272 45152 45152 14541 20038 81348 81348 81348 81348 81348 26697 26697 OTWA7 OTWA7 81349 81349 81349 81349 81349 81349 81349 81349 81349 81349
38. Coupling Configuration LOADING CONFIGURATION The fifth wheel towing device connected to the fifth wheel of the prime mover with the boom extended at a right angle to the mast and 0 5 in 1 3 cm above the ground The boom extensions are fully retracted The transport legs are locked in the down position with the fifth wheel towing device resting on the transport legs 0009 Figure 5 Loading 0002 00 3 9 2510 247 13 amp P 0002 00 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES Continued d TRANSPORTATION CONFIGURATION The fifth wheel towing device connected folded and secured to the fifth wheel of the prime mover WP 0007 Figure 6 Transport Confituration e TOWING CONFIGURATION 1 Towing Configuration Connected The fifth wheel towing device connected to the fifth wheel of the prime mover The boom extended at a right angle to the mast with the boom extensions extended The tow vehicle connected and the boom at appropriate towing height WP 001 7 2 Towing Configuration Disconnected Same position as connected position except the boom is lowered until the fifth wheel towing device is supported by the weight of the towed vehicle and the main frame weight is off of the 5th wheel plate The prime mover is disconnected and removed from the configuration WP 0007 or WPO017 NA M KV OUr mmi HON Figure 8 Towing Configuration Disconnected
39. Dry cleaning solvent Item 31 Five lockwashers Eighteen preformed packings Personnel Required 3 General Safety Instructions Have a suitable container available to catch spilled hydraulic fluid REMOVAL Ed WARNING High pressure is present in the 250M Fifth Wheel Towing Device hydraulic system Do not disconnect any hydraulic system component unless hydraulic system pressure has been relieved Ensure each hydraulic control lever is moved several times through all positions and hydraulic tank relief valve is slowly loosened to relieve pressure Faiure to comply may result in severe injury or death to personnel Spilled hydraulic oil is very slippery Be careful when entering or working in area Wipe up any spilled oil immediately Failure to comply may result in severe injury or death to personnel CAUTION Always clean around fittings before disconnecting or connecting hoses or fittings Ensure area is clean before installing hydraulic components Failure to comply may result in damage to equipment Cover cap or plug all openings ports and tube or hose ends when they are disconnected Failure to comply may result in damage to equipment Fittings must be installed and hand tightened If a fitting cannot be handtightened it may be cross threaded or have damaged threads Use wrench only for final tightening Failure to comply may result in damage to equipment Do not use Teflon tape as a sealer on any fittings It can se
40. HOW USE TORQUE TABLE a Measure the diameter of the screw to be installed b Count the number of threads per inch or use a pitch gage c Underthe heading SIZE in Table 5 look down the left hand column until the diameter of screw to be installed is found there will usually be two lines beginning with the same size d In second column under SIZE find the number of threads per inch that matches the number of threads counted in step 2 e To find the grade of the screw that is to be installed match the markings the head to the correct picture of CAPSCREW HEAD MARKINGS on the table Manufacturer s marks may vary These are all SAE Grade No 5 3 lines f Look down the column under the picture found in step 5 until the torque limit in foot pounds for the diameter and threads per inch of the screw being installed is found CAPSCREW HEAD MARKINGS 0089 00 2 TM 9 2510 247 13 amp P 0089 00 4 HOW TO USE TORQUE TABLE Continued Table 5 Torque Limits for Dry Fasteners SAE CAPSCREW HEAD m MARKINGS TT SAE GRADE SAE GRADE SAE GRADE SAE GRADE No 1 of 2 No 5 No 6 or 7 No 8 DIA FOOT FOOT FOOT FOOT 20 6 35 6 78 80 10 85 10 13 56 12 16 27 T ss es 120 167 280 eso 0089 00 3 9 2510 247 13 0089 00 4 HOW USE TORQUE TABLE Continued Table 6 Torque Limits for Wet Fasteners SAE GRADE SAE GRADE SAE GRADE SAE GRADE No 1 or 2 No 5 No 6
41. Hardness Critical A support item that provides the equipment with special protection from electromagnetic pulse EMP damage during a nuclear attack 4 The statement END OF FIGURE appears just below the last item description in column 6 for a given figure in both the repair parts list and special tools list work packages QTY Column 7 The QTY quantity per figure column indicates the quantity of the item used in the breakout shown on the illustration figure which is prepared for a functional group subfunctional group or an assembly A V appearing in this column instead of a quantity indicates that the quantity is variable and quantity may change from application to application 4 EXPLANATION OF CROSS REFERENCE INDEXES WORK PACKAGE FORMAT AND COLUMNS a National Stock Number NSN Index Work Package 1 STOCK NUMBER COLUMN This column lists the NSN in National item identification number NIIN sequence The NIIN consists of the last nine digits of the NSN When using this column to locate NSN an item ignore the first four digits Pu of the NSN However the 6 0 7 complete NSN should be used when ordering items by stock number 2 FIG COLUMN This column lists the number of the figure where the item is identified located The figures are in numerical order in the repair parts list and special tools list work packages 3 ITEM COLUMN The item number identifies the item associated with the figure lis
42. NSN P N index work packages and the bulk material list in the repair parts list work package 6 HOW TO LOCATE REPAIR PARTS a When NSNs or P Ns Are Not Known 1 Using the table of contents determine the assembly group to which the item belongs This is necessary since figures are prepared for assembly groups and subassembly groups and lists are divided into the same groups 2 Find the figure covering the functional group or the subfunctional group to which the item belongs 3 Identify the item on the figure and note the number s 4 Lookin the repair parts list work packages for the figure and item numbers The NSNs and part numbers are on the same line as the associated item numbers When NSN Is Known 1 If you have the NSN look in the STOCK NUMBER column of the NSN index work package The NSN is arranged in NIIN sequence Note the figure and item number next to the NSN 2 Turn to the figure and locate the item number Verify that the item is the one you are looking for When P N Is Known 1 If you have the P N and not the NSN look in the PART NUMBER column of the P N index work package Identify the figure and item number 2 Look up the item on the figure in the applicable repair parts list work package Verify that the item is the one you are looking for 0082 00 7 TM 9 2510 247 13 amp P 0082 00 Figure 1 12 24 Volt Junction Box 0082 00 8 TM 9 2510 247 13 amp P 0082 00 2 3
43. REMOVAL Continued NS ES gt 8 TE a 2 Figure 116 Boom Extension Cylinder Assembly WARNING With power off position control levers to the EXTEND and RETRACT positions to relieve hydraulic pressure before removing hoses Failure to comply may result in severe injury or death to personnel Spilled hydraulic oil is very slippery Be careful when entering or working in area Wipe up any spilled oil immediately Failure comply may result in severe injury or death to personnel 4 Remove hydraulic hoses from two fittings 3 5 Remove fittings 3 from cylinder 6 Remove one roll pin 4 and flatwasher 5 from retaining pin 6 Discard roll pin 7 Remove retaining pin 6 from boom extension assembly 7 CAUTION Boom extension assemblies are heavy and require the aid of an assistant to remove install 8 Remove boom extension 8 from boom 9 Remove two screws 9 from boom extension 8 and remove cylinder 10 from boom extension 8 0066 00 2 9 2510 247 13 amp P 0066 00 INSTALLATION CAUTION Boom extension assemblies are heavy and require the aid of an assistant to remove install 1 Install cylinder 10 in boom extension 8 and secure with two screws 9 2 Install boom extension 8 in boom and secure with retaining pin 6 new roll pin 4 and flatwasher 5 3 Using the cylinder alignment tool align cylinder to install fittings 3 4 Install retaining pin 6 thr
44. Step 3 Check for dirty or corroded connectors at back of light Clean in accordance with procedures in paragraph WP 0032 Notify Unit Maintenance AIR BRAKE SYSTEM BRAKES ON TOWED VEHICLE FAIL TO DISENGAGE Step 1 Check Control blue service Air Line connection at gladhand If line is not properly connected remove and If no air is flowing from prime mover notify Unit Maintenance and use another prime mover Step 2 Check for dirty or damaged packing in the gladhand Clean in accordance with procedures WP 0033 Notify Unit Maintenance if packing 15 leaking Step 3 Inspect Control blue service Air Line for damage Notify Unit Maintenance if damage is found Step 4 Check brake system hardware for damaged or missing components Notify Unit Maintenance for further inspections and or repairs 0024 00 2 TM 9 2510 247 13 amp P 0024 00 TABLE 1 OPERATOR TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION HYDRAULIC SYSTEM 1 HYDRAULIC FUNCTIONS SLOW OR INOPERATIVE Step 1 Check that ELECTRIC POWER ON OFF Switch is in ON position WP 0005 Step2 Check outside temperature If temperature is less then 0 F 17 C hydraulic oil may not flow easily Step Check hydraulic reservoir oil level Figure 104 WP 0056 00 5 Step4 Check hydraulic operating pressure WP 0002 00 7 Notify Unit Maintenance if pressure is below operating limits Step5 Check hydraulic valves t
45. Washer lock 2 MS35333 40 Disconnect batteries WP 0050 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General Remove all power to towing device prior to NSN 5180 00 177 7033 making any repairs on electrical system REMOVAL WARNING Remove all power to fifth wheel towing device prior to making any repairs on the electrical system Failure to do so may result in serious injury or death NOTE Mark and tag all wires prior to disconnecting There are two 12 volt receptacles one on 12 24 volt junction box and one on electrical control box Both are removed the same way 1 Remove two screws 1 flatwashers 2 lockwashers 3 and nuts 4 and remove receptacle 5 Discard lockwashers 2 Loosen seven screws 6 and remove wires from receptacle 5 Figure 76 Plug Assembly 0042 00 1 9 2510 247 13 0042 00 INSTALLATION NOTE There are two 12 volt receptacles one on 12 24 junction box and one on electrical control box Both are installed the same way 1 Install wires into receptacle 5 and tighten screws 6 2 Position receptacle 5 in place and secure with two screws 1 flatwashers 2 new lockwashers 3 and nuts 4 3 Connect both fifth wheel towing device batteries WP 0050 4 Inspect operation of 12 volt system by performing function check using 12 volt tow light bar Figure 76 Plug Assembly Follow on Tasks None END OF WORK PACKAGE 0
46. and clearance lights 4 on 12 volt light bar for proper operation and cleanliness 5 Before Check strobe lights 6 and work Any damaged light 7 for proper operation and components or parts cleanliness a Pa SS oe MA 777777 A AS 0031 00 7 9 2510 247 13 amp P 0031 00 Table 2 Operator Preventive Maintenance Checks and Services 5 for 250 Fifth Wheel Towing Device To Check Not Fully Mission Service Procedure Capable If BRAKES Have an assistant actuate the Brakes fail to hold or air service brakes on prime mover leaks are found Listen for air leaks at the gladhands OVERALL VIEW Check fifth wheel towing device for Class oil leak evidence of fluid leakage evident OVERALL VIEW Check fifth wheel towing device for Class III oil leak evidence of fluid leakage evident Check fifth wheel towing device for Damaged or missing obvious damaged or missing parts parts that impair that would impair operation operation Check fifth wheel towing device for Non operational gauges damage to any gauges 0031 00 8 9 2510 247 13 0031 00 Table 2 Operator Preventive Maintenance Checks and Services 5 for 250 Fifth Wheel Towing Device To Check Service Procedure KINGPIN Visually inspect kingpins 9 for cracks damage or excessive wear Inspect for chips nicks gouges and wear Inspect kingpin plate for cracks a
47. and remove four washers 5 Remove two screws 3 lockwashers 4 and composite taillight 1 from composite taillight bracket 2 Discard lockwashers Figure 86 Composite Taillight Assembly 0047 00 4 9 2510 247 13 amp P 0047 00 Composite Taillight Installation 1 2 Install two bumpers 1 on tube 2 with screws 3 Install four bumpers 4 on two brackets 5 with four screws 6 new lockwashers 7 and nuts 8 Install two brackets 5 on tube 2 with screws 9 washers 10 and wingnuts 11 Install two composite lights 12 on tube 2 with three screws 13 and new lockwashers 14 NOTE All three clearance lights are installed the same way Install gasket 15 and lampholder 16 on clearance light bracket 17 with four screws 18 Install bulb 19 and lens 20 in lampholder 16 with two screws 21 Install eight pins 22 on wires 23 Install eight wires 23 in connector 24 Figure 87 Taillight Assembly 0047 00 5 9 2510 247 13 amp P 0047 00 Composite Taillight Installation Continued 9 Install clearance light bracket 17 wiring harness 25 and clips 26 with two screws 27 new lockwashers 28 and nuts 29 10 Install connector 30 in tow light tab 31 with new lockwasher 32 and nut 33 11 Install connector 34 on two ground wires 35 12 Install connector 34 with screw 36 and new lockwasher 37 13 Install ele
48. retaining 15 1105 1 configuration WP 0002 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General None NSN 5180 00 177 7033 REMOVAL NOTE Handles can only be removed from left to right 1 Remove retaining pin 1 and pin 2 2 Remove retaining pins 3 and connecting links 4 and 5 3 Remove control lever 6 Figure 109 Hydraulic Control Lever 0060 00 1 9 2510 247 13 amp P 0060 00 INSTALLATION NOTE Handles can only be replaced from right to left 1 Install control lever 6 2 Install connecting links 4 and 5 and retaining pins 3 3 Install retaining pin 1 and pin 2 Figure 109 Hydraulic Control Lever Follow on Maintenance Check for proper operation END OF WORK PACKAGE 0060 00 2 9 2510 247 13 amp P 0061 00 OIL FILTER ASSEMBLY REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Hydraulic pressure relieved WP 0056 0015 Washer lock 2 MS35333 40 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General None NSN 5180 00 177 7033 Ed WARNING High pressure is present in the 250M Fifth Wheel Towing Device hydraulic system Do not disconnect any hydraulic system component unless hydraulic system pressure has been relieved Ensure each hydraulic control lever is moved several times through all positions and hydraulic tank relief valve is slowly loosened to relieve pressure Fa
49. 0077 00 3 TM 9 2510 247 13 amp P 0077 00 CABLE ASSEMBLY REMOVAL Continued NOTE If winch is inoperative it can be removed only by cutting the cable Use a suitable container to catch fluid draining from hoses and fittings Wipe up any spillage with a rag 1 If winch can be operated play out winch cable 1 If winch cannot be operated to play out winch cable cut cable 1 close to hex screw 2 NOTE Cable drum can be set up for clockwise or counterclockwise installation of winch cable To aid in installation make note of cable anchor slot used to secure cable on winch drum 2 Remove hex screw 2 and winch cable 1 Remove cable 1 from around hex screw 2 and pull cable 1 from winch 3 CABLE ASSEMBLY INSTALLATION 1 Install cable 1 through cable anchor slot and around hex screw 2 Firmly seat hex screw 2 in cable anchor slot of winch 3 2 Reelin winch cable Figure 129 Cable Assembly Follow on Tasks Test hydraulic system for leaks WP 0056 0045 e Check hydraulic fluid level WP 0056 00 5 Check winch for proper operation WP 0013 END OF WORK PACKAGE 0077 00 4 9 2510 247 13 0078 00 PREPARATION FOR STORAGE SHIPMENT GENERAL 1 This chapter contains requirements and procedures for administrative storage of equipment that is issued to and in use by Army activities worldwide The requirements specified herein are necessary to maintain equipment in adminis
50. 081 0798 5310 01 082 2058 5935 01 084 1942 5999 01 085 6244 5315 01 282 3483 CROSS REFERENCE INDEXES WORK PACKAGE NATIONAL STOCK NUMBER INDEX STOCK NUMBER FIG BULK 4 17 4 8 23 28 4 9 2510 247 13 amp P O O N 6145 01 091 0241 6220 01 093 4439 2530 01 095 8752 6145 01 099 0050 6145 01 099 4741 5310 01 100 5145 4730 01 103 6840 4730 01 103 6840 6145 01 104 6028 4730 01 106 1757 5310 01 109 5292 4730 01 125 5179 4730 01 126 9758 4730 01 126 9758 5940 01 129 2678 5315 01 133 4382 5940 01 141 2881 5935 01 148 4523 6220 01 163 4900 5305 01 163 8191 5940 01 169 6391 5970 01 175 2052 5310 01 183 5514 6145 01 202 7748 5925 01 206 8136 6220 01 210 3225 5935 01 211 4434 5935 01 211 4434 6220 01 217 8316 5995 01 222 5497 5340 01 227 3483 5340 01 227 6808 5340 01 227 9471 6145 01 236 1935 5940 01 258 2108 5340 01 272 2729 5305 01 272 6543 5305 01 272 6543 5305 01 272 6543 5305 01 272 6543 5305 01 272 6543 5305 01 272 6543 5305 01 272 6543 5315 01 282 3483 5315 01 282 3483 4730 01 315 8250 5315 01 495 8223 0083 00 2 BULK BULK BUL ROAARAAARAND 0083 00 9 2510 247 13 amp P 0083 00 CROSS REFERENCE INDEXES WORK PACKAGE NATIONAL STOCK NUMBER INDEX STOCK NUMBER FIG ITEM STOCK NUMBER FIG ITEM 6220 01 284 2709 4 19 5315 01 495 8282 17 13 4720 01 289 8293 BULK 25 5340 01 495 8298 23 16 5310 01 308 8205 26
51. 1 6 PAOZZ 4730002784822 81343 6 6 130239 ELBOW PIPE ttti 1 7 PAOZZ 4730014964148 1BZD4 1072 1 ELBOW PIPE TO TUBE 1 8 PAOZZ 4730010651817 89346 586049 1 PLUG PIPE MAGNETIC 8 9 PAOZZ 5340014964081 1BZD4 02000 FITTINGCOMPRESSION 2 10 PAOZZ 4730013158250 7H066 C3609X16 TEEPIBE repete Hiper 1 END OF FIGURE 1 2 3 4 ITEM SMR NO CODE NSN CAGEC 1 PAOZZ 5970011752052 81851 2 22 9390014697255 39428 3 PAOZZ 5970000083295 81349 4 PAOZZ 6145000236778 58536 5 22 5970014818421 81349 6 PAOZZ 6145012027748 81349 7 PAOZZ 6145002950806 81349 8 22 6145008548211 81348 9 PAOZZ 6145003435767 81349 10 PAOZZ 6145010990050 81349 11 PAOZA 6145006006173 81349 12 PAOZZ 6145010994741 81349 13 PAOZZ 6145014560311 81349 14 PAOZZ 6145013812385 81349 15 PAOZZ 6145011046028 81348 16 77 6145012361935 81349 17 PAOCZA 6145010910241 81349 18 PAOZA 6145006006052 81349 19 PAOZZ 6145001779527 81349 20 PAOZZ 6145010910239 81349 21 PAOZA 6145000825172 81349 22 PAOZZ 6145000236923 81349 23 PAOZZ 6145000443579 81349 24 22 5970004704575 81349 25 PAOZZ 4720012898293 29510 26 22 9330009122707 99806 27 PAOZZ 5640014624252 39428 28 PAOZZ 4720013477388 89346 TM 9 2510 247 13 amp P 5 PART NUMBER 50010013035 8451 62 23053 10 004 0 AA59551 E04G1B M23053 12 106 2 M24643 43 06U0 M76MWPC1619A1 J C 580TFF6CF 1 16TUJ M81381 7 16 6 M5086 1 16 60 M22759 11 16 3 M5086 1 16 30 M22759 34 16 4 M1
52. 29 2 5340 01 496 4081 18 6 3040 01 495 2850 28 6 5340 01 496 4081 29 10 5306 01 495 6997 11 3 5340 01 496 4093 18 1 5306 01 495 7002 13 7 5340 01 496 4114 19 13 3040 01 495 7628 19 9 4730 01 496 4148 30 7 3040 01 495 7880 19 6 2510 01 496 4441 12 3 4820 01 495 8070 26 2 4720 01 496 4523 24 6 5945 01 495 807 1 23 11 4720 01 496 4550 24 8 5305 01 495 8137 29 7 4720 01 496 4647 24 10 5315 01 495 8164 23 17 4720 01 496 4914 24 2 5305 01 495 8170 27 9 5331 01 496 5156 25 7 5305 01 495 8188 20 2 4720 01 496 5327 24 3 2940 01 497 0077 25 3 0083 00 3 TM 9 2510 247 13 amp P 0083 00 CROSS REFERENCE INDEXES WORK PACKAGE NATIONAL STOCK NUMBER INDEX STOCK NUMBER FIG ITEM STOCK NUMBER FIG ITEM 2540 01 496 5769 14 8 6150 01 497 6831 8 63 2590 01 496 5997 15 6 5310 01 498 1892 19 4 4720 01 496 6001 24 14 5310 01 498 1892 29 12 2540 01 496 6004 15 1 5310 01 498 1951 12 11 4720 01 496 6037 24 1 5310 01 498 4029 13 11 4720 01 496 6048 24 16 5120 01 498 4965 7 11 4720 01 496 6067 24 4 5930 01 499 5311 2 2 4720 01 496 6337 24 12 5310 01 500 2707 12 2 5315 01 496 6348 11 4 2540 01 501 5365 11 11 4720 01 496 6429 24 13 5310 01 501 9194 7 3 4720 01 496 6446 24 11 5310 01 501 9196 7 4 2540 01 496 7132 29 4 5930 01 502 1048 2 12 6685 01 496 8423 23 9 4820 01 502 1995 22 5 5935 01 496 8429 8 56 4820 01 502 2001 21 4 4720 01 497 0042 24 9 4820 01 502 2006 22 6 2940 01 497 0073 25 4 5940 01 502 2111 8 61 2940 01 497 0077 25 5 6220 01 502 2419 6 1 4720 01 497
53. 5 NUMBER 1100363 2 M23053 10 004 2 QQ W 343 5 QQ W 343 18 JC30 63 B205010 QQ W 343 8 1085 1 QQ W 343 37 QQ W 343 80 QQ W 343 70 QQ W 343 90 M23053 12 2 1200 59 12279371 1 521919 48 QQ W 343 40 QQ W 343 45 6 DESCRIPTION AND USABLE ON CODES UOC 0082 00 7 GROUP 0613 HULL CHASSIS WIRING HARNESS FIG 8 CHASSIS WIRING HARNESS TERMINAL LUG een INSULATION SLEEVING MAKE FROM INSULATION SLEEVING ELECTRICAL P N M23010 004 0 1 2 BLACK X 2 INCHES WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N QQW343E04G1B 5 INCHES WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N QQW343E04G1B 18 INCHES CABLE POWER ELECTRI MAKE FROM CABLE POWER ELECTRICAL P N THWO6CF7 10TPJ 63 INCHES LONG BOOT DUST AND WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N QQW343E04G1B 8 INCHES HARNESS BLACKOUT JU MAKE FROM WIRE ELECTRICAL P N QQW343E04G1B 11 INCHES WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N QQW343E04G1B 37 INCHES WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N QQW343E04G1B 80 INCHES LONG WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N QQW343E04G1B 70 INCHES WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N QQW343E04G1B 90 INCHES 2 INSULATION SLEEVING MAKE FROM INSULAT
54. 5310 00 685 8308 1 2 04773 2 7 04773 9 13 04773 14 5 98441 12C50X S 4730 01 394 8793 25 8 98441 12HP50NS 5365 00 406 9320 23 14 21450 131245 5310 00 013 1245 15 8 45152 1462260W 5340 01 272 2729 4 6 45152 1462270 5340 01 227 3483 4 2 45152 1462280 5340 01 227 6808 4 28 45152 1462290U 6220 01 217 8316 4 1 45152 1462310U 5995 01 222 5497 4 33 45152 1462340 5340 01 227 9471 4 22 12020 1726 1610 5305 00 109 0282 15 4 60287 1878 20 1 OATA2 2001 11 8 OATA2 13 2 OATA2 17 14 OATA2 27 11 OATA2 28 3 OATA2 2006 27 4 06853 2021945 10 3 OATA2 2023 17 12 06853 204000 5310 00 220 6668 10 2 01276 2068 8 8S 4730 00 051 3731 27 8 01276 28 7 06853 213605 10 11 0084 00 4 06853 45152 06853 77326 06853 06853 35510 06853 45152 45152 06853 81349 81349 81349 81349 81349 81349 81349 30780 00779 32770 89346 29510 29510 29510 29510 89346 89346 21450 89346 8 865 8 865 81851 81851 81851 OTWA7 28548 00779 82366 60592 19204 89346 39428 81343 1BZD4 39428 39428 CROSS REFERENCE INDEXES WORK PACKAGE PART NUMBER INDEX PART NUMBER 213630 2196790 235646 24 353 240233 240407 2434 243655 2447HX 2467 H 281865 2SJ 12 163 2SJ 12 36 2SJ 12 4 2SJ 12 40 2SJ 12 48 2SJ 12 60 2SJ 12 65 3 4X1 4PRT S 34148 403 09081 01 414506C1 417200C2 417200C2 32 417200C2 34 417200C2 56 417202 2 417202 2 7 444530 4772 6 5 16 18 2 2 1 2 50010013035 50010013035 16 50010013035 4 5005008 5
55. 6837 21 2 6145 00 600 6052 BULK 18 4730 00 200 0257 9 4 6145 00 600 6173 BULK 11 5310 00 209 0786 4 30 5310 00 655 9544 4 51 5310 00 220 6668 10 2 5340 00 680 3261 8 16 4730 00 222 1838 30 4 5310 00 685 8308 1 2 5305 00 225 3843 1 1 5310 00 685 8308 2 7 5305 00 225 3843 2 6 5310 00 685 8308 9 13 5305 00 225 3843 25 1 5310 00 685 8308 14 5 4730 00 229 3402 22 4 5305 00 719 5243 19 8 4730 00 244 9848 10 1 5305 00 719 5274 19 7 5310 00 245 3424 4 32 5305 00 725 2317 20 6 5305 00 269 3217 4 4 5340 00 725 5280 4 5 2530 00 270 3878 10 10 6220 00 726 1916 4 42 5310 00 274 7758 3 1 6220 00 729 9295 4 46 4730 00 277 7331 30 2 5310 01 086 7725 4 7 4730 00 757 2910 23 7 5305 00 757 8122 4 3 0083 00 1 STOCK NUMBER 6145 01 091 0239 5310 00 775 5139 5305 00 781 3927 5305 00 782 9489 5940 00 804 9184 5305 00 819 5108 4730 00 822 5609 5935 00 833 8561 5970 00 833 8562 5310 00 833 8567 5310 00 833 8567 4730 00 844 3308 6145 00 854 8211 5310 00 877 5795 5315 00 878 1994 9905 00 893 3570 9330 00 912 2707 5305 00 940 9445 5935 00 941 5436 5305 00 957 6272 5305 00 964 0691 4730 00 974 7313 5305 00 983 5346 5305 00 983 5346 5305 00 983 5346 5305 00 983 5346 5305 00 983 5346 5305 00 983 5346 5305 00 984 4981 5305 00 984 6212 5305 00 984 6221 5305 00 988 7603 5310 01 013 2395 4730 01 050 5756 5305 01 061 9674 4730 01 065 1817 4730 01 066 3363 5310 01 073 9803 5310 01 073 9803 5310 01 073 9803 4820 01 075 7224 5305 01 078 2010 5310 01
56. 9150 01 197 7688 9150 01 197 7690 9150 01 197 7689 9150 01 197 7692 9150 01 197 7691 9150 00 252 6383 9150 00 223 4134 9150 00 082 7524 9150 00 265 9408 4 Item Name Description CAGEC Part Number BRUSH Scrub 81348 H B 1490 7 P1 BRUSH Wire 17987 3577 CORROSION PREVENTIVE 09137 WD 40 Box of 12 Aerosol Cans 9 Ounces Each DETERGENT General Purpose Liquid 83421 1 Gallon Can FLUX Soldering TY1 Form A 58536 A A 51145 1 Pound Can GLOVES Protective 58536 A A 50022 GREASE Automotive and Artillery GAA 81349 MIL G 10924 14 Ounce Cartridge 2 1 4 Ounce Tube 1 3 4 Pound Can 6 1 2 Pound Can 35 Pound Pail 120 Pound Drum HYDRAULIC FLUID Petroleum Based Artic 81349 MIL H 5606 1 Quart Can 1 Gallon Can 10 Gallon Drum 55 Gallon Drum 0087 00 2 9 2510 247 13 amp P 0087 00 SECTION Il EXPENDABLE AND DURABLE ITEMS LIST Continued 1 Item Number 3 National Stock Number 9150 01 422 9346 9150 01 152 4118 9150 01 152 4119 7920 00 205 1711 8040 00 833 9563 8030 01 054 0740 3439 00 247 6921 3439 00 265 7102 6850 01 474 2320 6850 01 474 2321 9905 00 537 8954 5640 00 103 2254 8030 00 889 3535 4 Name Description CAGEC Part Number OIL Lubricating Engine OE HDO 15W 40GRADE 81349 MIL PRF 2104 1 Quart Can 5 Gallon Can 55 Gallon Drum RAG Wiping 64067 50 Pound Bale Adhesive Silicone Rubber
57. 94833 52498 5 Ounce Tube SEALING COMPOUND Locite 592 05972 592 31 5 ounce bottle SOLDER Lead Alloy 81348 QQ S 571 1 Pound Bar 1 Pound Spool Roll SOLVENT Dry Cleaning Type 81349 MIL PRF 680 5 Gallon Can 55 Gallon Drum TAG Marker 64067 50 Each TAPE Duct 2 Inch Width 39428 1791 70 60 Yard Roll TAPE Antiseize 1 2 inch width 81755 P5025 2R 260 Inch Roll 0087 00 3 TM 9 2510 247 13 amp P 0087 00 SECTION Il EXPENDABLE AND DURABLE ITEMS LIST Continued 3 4 National Item Name Description Stock Number Part Number TIE WIRE Strap Tiedown Electrical Components Black Nylon 06383 PLT3S C 0 5975 01 379 4997 100 Each TUBING Heat Shrinkable 5970 00 815 1295 81349 M23053 5 106 0 END OF WORK PACKAGE 0087 00 4 9 2510 247 13 amp P 0088 00 ILLUSTRATED LIST OF MANUFACTURED ITEMS SECTION 1 INTRODUCTION 1 SCOPE a This work package includes complete instructions for making items authorized to be manufactured or fabricated A part number index in alphanumeric order is provided for cross referencing the part number of the item to be manufactured to the paragraph which covers fabrication criteria All bulk materials needed for manufacture of an are listed by Part Number and CAGEC or specification number d Only items requiring complicated manufacturing instructions are illustrated e No manufactured items list has been a
58. Are hydraulic motors running If no check batteries for voltage Check IVEC cable connection from prime mover Check for voltage at solenoids If yes go to step 3 Step 3 Will boom extension and winch functions operate using the valve control levers If no remove hose from hydraulic lock valve to base end of boom hydraulic cylinder Hold oil drain pail under open port in hydraulic cylinder Operate control lever MAST RETRACT gradually If oil returns from cylinder but there is no movement of mast or cylinder the cylinder packing is allowing oil to bypass and the hydraulic cylinder must be replaced If oil does not return from cylinder when operating MAST RETRACT lever put end of removed hose in drain pan and gradually operate MAST EXTEND control lever If oil does not flow out of hose remove hose between control valve and lock valve Re attach swivel end at control valve and put other end of hose in drain pan Operate MAST EXTEND control lever If oil does not flow out of hose replace control valve If oil does flow out of hose replace lock valve If yes go to step 4 Step 4 Will mast operate using the remote control If no replace remote control If yes return to step 3 END OF WORK PACKAGE 0028 00 4 9 2510 247 13 UNIT TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION AIR BRAKE SYSTEM AIR BRAKE SYSTEM WILL NOT OPERATE Step 1 Are gladhands properly fitted and secure If no
59. B 4 Replace stud nuts on batteries and lift batteries from battery box FRONT Figure 94 Battery Box Assembly BATTERY INSTALLATION 1 Position batteries in battery box 2 Position three cables 5 on positive nylon stud of Battery and two cables 5 on positive stud of Battery A Secure with nylon stud nuts 3 and 4 3 Position one cable 8 on negative nylon stud of Battery B and two cables 8 on negative stud of Battery A Secure with nylon stud nuts 6 and 7 4 Position lid 2 on battery box and secure with four wing nuts 1 5 On electrical control box switch ELECTRIC toggle to ON position 6 Ensure electrical power is on by viewing the voltage meter or by pushing the push switch on the electrical control box for approximately 2 seconds activating the hydraulic pump 7 electrical control box switch ELECTRIC toggle to OFF position 0050 00 2 9 2510 247 13 amp P 0050 00 BATTERY INSTALLATION Continued Wear safety glasses or goggles when checking batteries Always check electrolyte level with engine stopped Do not smoke or use exposed flame when checking battery explosive gases are present and severe injury to personnel can result 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 clothin
60. BOOM RETRACT until boom is slightly off ground and using remote control or valve control levers RETRACT RIGHT IN 4 and RETRACT LEFT IN 5 retract boom extensions to storage position and pull prime mover and towing device away from towed vehicle COUNTER CLOCKWISE Figure 63 Remote Control and Support Leg Assembly END OF WORK PACKAGE 0018 00 4 TM 9 2510 247 13 amp P 0019 00 STOWAGE OF TOW BAR ASSEMBLIES 1 Remove upper section 1 of tow bar assembly from lower section 2 and set aside 2 Loosen all four T bolts 3 amp 4 on lower section 2 and remove lower section from boom NOTE If necessary use same procedure of tilting lower section of towbar assembly to insert upper section Refer to steps 1 through 5 in WP 009 3 Position lower section 2 onto storage bracket 5 slide to inner position and tighten all T bolts 3 amp 4 CAUTION Ensure offset mounting plates are facing forward to avoid contact with the mast during operation Damage to equipment may occur 4 Position upper section 1 onto lower section 2 and secure with hitch pin 6 and spring pin 7 5 Repeat steps 1 through 4 for remaining tow bar assembly Figure 64 Tow Bar Assembly and Storage END OF WORK PACKAGE 0019 00 1 9 2510 247 13 0020 00 UNCOUPLING E WARNING All persons not involved in coupling uncoupling operation must stand clear of prime mover and towing device to prevent serious injury or d
61. DI MM 12 Volt Solenoids Primary cocina a cl anda iaa 12 Volt Solenoids Isolated etn 12 Volt WARNING BRAKES Stopping distances greatly increase when the towed vehicle has nonfunctioning brakes Care should be taken to ensure adequate stopping distance is obtained and speed is adjusted accordingly Failure to comply may result in injury or death to personnel SPEED Transport Highway and Improved 50 mph 80 5 KpH Unimproved Roads Graded Gravel and Cross Country 50 mph 80 5 KpH Towing Max Load Must not exceed lowest top allowable speed stated in prime mover TM or towed vehicle TM Highway and Improved 25 mph 80 5 KpH Unimproved Roads Graded Gravel and Cross Country 15 mph 40 2 KpH 0002 00 7 TM 9 2510 247 13 amp P 0002 00 EQUIPMENT DATA Continued HYDRAULIC SYSTEM tense neret 18 0 gal 68 14 L HYDRAULIC RESERVOIR 7 8 75 gal 33 1 1 HYDRAULIC OPERATING PRESSURE with no load during MAST and BOOM 300 800 psi with load during Mast and BOOM up to 3000 psi 10 000 Ibs 4 536 kg with pulley
62. ELECTRICAL P N M16878 6BFEO 6 INCHES LONG iis 48 PAOZZ 5940008049184 96906 MS27429 2 TERMINAL QUICK DISC 49 MOOZZ 81349 28J 12 36 CABLE POWER ELECTRI MAKE FROM CABLE POWER ELECTRICAL P N M24643 43 0600 36 INCHES LONG 1 50 MOOZZ 81349 28J 12 40 CABLE POWER ELECTRI MAKE FROM CABLE POWER ELECTRICAL P N 24643 43 0600 40 INCHES LONG eects 1 51 MOOZZ 81349 28J 12 48 CABLE POWER ELECTRI MAKE FROM CABLE POWER ELECTRICAL P N M24643 43 0600 48 INCHES LONG 1 52 MOOZZ 81349 C0 12MGF 76 CABLE POWER ELECTRI MAKE FROM CABLE POWER ELECTRICAL P N C0 12MGF 12 18 0685 76 INCHES LONG 1 53 PAOZZ 5940011412881 14726 S05360SF TERMINAL QUICK DISC PINK FLAG 54 PAOZZ 5940011696391 14726 S05363SF TERMINAL QUICK DISC BLUE FLAG 55 MOOZZ 81349 M5086 1 3 WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M5086 1 12 0 3 INCHES LONG niens 3 0 2 3 ITEM SMR NO CODE NSN 56 PAOZZ 5935014968429 57 22 5940001138183 58 MOOZZ 59 MOOZZ 60 MOOZZ 61 PAOZZ 5940015022111 62 PAOZZ 5975014970117 63 77 6150014976831 4 CAGEC 60592 98410 81349 81349 81349 60592 39428 39428 TM 9 2510 247 13 amp P 0082 00 5 PART NUMBER 533 25NLB C530 56 M23053 10 002 2 M5086 1 20 2SJ 12 163 B31WN 69915K51 7088K11 6 7 DESCRIPTION AND USABLE ON CODE
63. INSTRUCTIONS Description and Use of Operator s Controls and Indicators Operation Under Usual Conditions ccccccscsssscscsecsesssscsecsessscsececsesecseseceesecsesesecseeesseseeseseenes Transport Configuration di sats reino Prepare Towing Device A ee he Prepare Tow Bar Assemblies 1 5 22 ds Connecting to Towed Vehicle i n Performance of Pre Picking Lifts trtn ertt REY Tuan aas Winching Operations PN PT A Preparing Equipment for TOWING assassin SUNG O ey Gladhands Rs ci Disconnecting Towed Vehicle curras ia NAR x uad ER rs Stowage of Tow Bar Assemblies sa A einen Prepare for 0021 00 Operation Under UnusuallG ndlions wenn 0000 00 0 TM 9 2510 247 13 amp P 0004 00 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS HYDRAULIC SYSTEM CONTROLS AND INDICATORS Figure 11 Hydraulic and Electrical Controls KEY CONTROL OR INDICATOR FUNCTION Hydraulic Control Levers Provides manual operation of equipment Electrical Control Box Cover Step Doubles as a cover for ele
64. Instructions Winch assembly weighs approximately 120 lbs 54 4kg Use caution when lifting REMOVAL V ARNIN LIMA WINCHES All personnel must stand clear during winching operations A snapped cable or shifting load could cause injury or death to personnel Ensure cable is properly mounted before operating reel Failure to do so may result in injury to personnel If winch cable has to be cut to remove winch assembly wrap cut end of cable in tape and secure loose end of cable to prevent it from swinging free during winch assembly removal Failure to follow this warning could result in injury to personnel WIRE ROPE Wire rope can become frayed or contain broken wires Wear heavy leather palmed work gloves when handling wire rope Frayed or broken wires can injure hands Never let moving wire rope slide through hands even when wearing gloves A broken wire could cut through glove and cut hand HEAVY COMPONENTS To avoid personal injury use a hoist or get assistance when lifting components that weigh more than 50 Ibs 23 kg Winch assembly weighs approximately 120 105 54 4kg Use caution when removing and handling to prevent injury or death to personnel and damage to equipment 0077 00 1 9 2510 247 13 0077 00 REMOVAL Continued 1 2 With towing device coupled to prime mover BOOM RETRACT to upright position Remove eight screws 1 from winch bracket 2 BOOM EXTEND to lower boom to ground
65. It is also not identified Procedure is continued from another page but cap is not removed add step to procedure PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBERS SIGN HERE Doe John CPL 755 1313 CPL John Doe DA car 2028 2 PREVIOUS EDITIONS YOUR OUTFIT WANTS TO KNOW ABOUT YOUR ARE OBSOLETE DATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS REVERSE OF DA FORM 2028 2 Q E DEPARTMENT OF THE ARMY CPL John Doe PLACE APO NY POSTAGE HERE Commander U S Army Tank automotive and Armaments Command ATTN AMSTA AC NML Rock Island IL 61299 7630 A pani ij ig A M TEAR ALONG PERFORATED UNE RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WITH THIS PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS PUBLICATION NUMBER PUBLICATION DATE PUBLICATION TITLE Unit DS Maintenance TM 9 2510 247 13 8 RPSTL for FWTD BE EXACT PIN POINT WHERE IT IS IN THIS SPACE TELL WHAT I WRONG a 0 2028 2 PREVIOUS EDITIONS P S iF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR JUL ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT IN THE MAIL A wd 4 REVERSE OF DA FORM 2028 2 FILL IN YOUR UNIT S ADDRESS DEPARTMENT OF THE ARM
66. Item Identification Number last 9 digits NIIN National 5 a ena NSN Preventive Maintenance Checks and Services 2 40 2 0 PMCS Quality Deficiency irc a e e bin ce eaa QDR Repair Parts and Special Tools List ut tee ee ea alles RPSTL Tables of Organization and 4 4 000 0000 eene nennen renis TOE Unit OF 0001 00 1 9 2510 247 13 0001 00 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS ElRs If your fifth wheel towing device needs improvement let us know Send us an SF Form 368 Product Quality Deficiency Report You the user are the only one who can tell us what you don t like about your equipment Let us know why you don t like the design or performance Mail it to us at Commander U S Army Tank automotive and Armaments Command ATTN AMSTA AC NML Rock Island IL 61299 7630 We ll send you a reply WARRANTY INFORMATION Tru Hitch Inc Tru Hitch snet net 1 800 450 8659 warrants to the first user purchaser of each new fifth wheel towing device that it is free from defects in material and workmanship under normal use and service its obligation under this warranty being limited to repairing or replacing as Tru Hitch Inc may elect any part or parts thereof including equipment or trade accessories which shall be returned to
67. P O0D0OOONPRO O DD TM 9 2510 247 13 amp P 0084 00 CROSS REFERENCE INDEXES WORK PACKAGE PART NUMBER INDEX CAGEC PART NUMBER STOCK NUMBER FIG ITEM 99806 M200SER 8 31 15 2 99806 M200SERIES1X1 8 9330 00 912 2707 BULK 26 81349 M22759 13 8 35 81349 M22759 11 16 0 6145 00 600 6052 BULK 18 81349 M22759 11 16 3 6145 00 600 6173 BULK 11 81349 M22759 34 16 4 6145 01 456 0311 BULK 13 81349 M22759 9 14 0 6145 01 091 0239 BULK 20 81349 M22759 9 16 2 6145 01 091 0241 BULK 17 81349 M23053 10 002 0 5970 00 470 4575 BULK 24 81349 M23053 10 002 2 8 58 81343 M23053 10 004 0 5970 00 008 3295 BULK 3 81349 M23053 10 004 2 8 2 81349 M23053 12 106 2 5970 01 481 8421 BULK 5 81349 M23053 12 2 8 13 81349 24643 43 0600 6145 01 202 7748 BULK 6 81349 M43436 1 3 9905 00 893 3570 4 47 81349 M5086 11 1 2 8 32 81349 M5086 12 1 2 8 34 81349 M5086 14 1 2 8 38 81349 M5086 7 8 44 81349 5086 1 10 9 6145 00 003 9527 BULK 19 81349 5086 1 12 0 6145 00 044 3579 BULK 23 81349 M5086 1 16 19 6145 01 236 1935 BULK 16 81349 5086 1 16 30 6145 01 099 4741 BULK 12 81349 5086 1 16 60 6145 01 099 0050 BULK 10 81349 M5086 1 20 8 59 81349 M5086 1 3 8 55 81349 M76MWPC 10 8 28 81349 M76MWPC1619A1 6145 00 295 0806 BULK 7 81349 M7928 4 112 5940 01 129 2678 8 25 81349 81381 11 8 31 81349 M81381 7 16 6 6145 00 343 5767 BULK 9 80205 MS16562 87 5315 00 878 1994 29 6 80205 MS16995 27 5305 00 988 7603 6 2 96906 MS16997 78 5305 00 983 5346 16 3 96906 17 1 96906 18 4 96
68. PAINT Continued DO NOT let skin or eyes come in contact with CARC paint Always wear protective equipment gloves ventilation mask safety goggles etc DO NOT use CARC paint without adequate ventilation Failure to comply may result in injury or death to personnel NEVER weld or cut CARC coated materials Failure to comply may result in injury or death to personnel DO NOT grind or sand painted equipment without high efficiency air purifying respirators in use Failure to comply may result in injury or death to personnel BE AWARE of CARC paint exposure symptoms symptoms can occur a few days after initial exposure Seek medical help immediately if symptoms are detected Failure to comply may result in injury or death to personnel WARNING HEAVY COMPONENTS Tow bars weigh 47 lbs each Use caution when removing and handling them to prevent injury or death to personnel and damage to equipment To avoid personal injury or death use a hoist or get assistance when lifting components that weigh more than 50 lbs 23 kg When tilting towbar assembly upper section is not secure and may fall out and cause personal injury or death Winch assembly weighs approximately 120 lbs 54 4 kg Use caution when removing and handling to prevent injury or death to personnel and damage to equipment Some personnel may have difficulty operating the FWTD because of heavy components Use additional personnel when necessary and always use cautio
69. Parts Parked on level ground Washer lock 16 MS35333 40 e Plastic strip 31 inches MS200SER 8 31 Weather strip 13 inches 93695K 13 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General CARC paint debris may be hazardous during NSN 5180 00 177 7033 removal Use extreme care when cutting or Shop Equipment Common Set No 1 grinding on metal surfaces NSN 4910 00 754 0654 0071 00 1 REMOVAL 9 2510 247 13 amp P 0071 00 WARNING CARC PAINT CARC paint contains isocyanate HDI which highly irritating to skin and respiratory system High concentrations of HDI can produce symptoms of itching and reddening of skin a burning sensation in throat and nose and watering of the eyes In extreme concentrations can cause cough shortness of breath pain during respiration increased sputum production and chest tightness The following precautions must be taken whenever using CARC paint ALWAYS use air line respirators when using CARC paint unless air sampling shows exposure to be below standards Use chemical cartridge respirator if air sampling is below standards DO NOT let skin or eyes come in contact with CARC paint Always wear protective equipment gloves ventilation mask safety goggles etc DO NOT use CARC paint without adequate ventilation Failure to comply may result in death or injury to personnel NEVER weld or cut CARC coated materials Failure to comply m
70. RATING 15 586 15 586 AWARNING Weighs 47 lbs Handle and remove by two personnel to prevent injury or damage Figure 10 Data Plates 0002 00 6 0002 00 9 2510 247 13 amp P 0002 00 EQUIPMENT DATA TOWING DEVICE Overall Dimensions Length Fully Extended ee 28 ft 6 in 868 7 cm Transport 12 ft 6 in 381 cm 91 231 1 Height Transport Configuration 64 in 153 cm Towing Configuration 9 ft 4 in 284 5 cm Maximum Height on 13 ft 411 5 Maximum Height Coupled Boom Vertical 11 ft 7 in Fifth Wheel 353 1 cm Fifth Wheel The height of the fifth wheel must be added to achieve the minimum overhead allowable height for performing some indoor maintenance tasks VEHICLE WEIGHTS Empty Net Weight a pad 7 200 lbs 3 266 kg Maximum Towing Weight Highway or Improved eene eene 120 000 Ibs 54 431 kg CTOSS COUNUY a 120 000 lbs 54 431 kg ELECTRICAL ITEM A O 12 24 Volt LIOR O 12 24 Volt Hydraulic Electrical Motor Primary 12 Volt Hydraulic Electrical Motor Isolated 12 Volt Balones
71. REMOVAL Continued 1 Disconnect remote control harness 1 2 Disconnect junction box to electrical control box harness 2 Disconnect ground cable 3 from control box 4 5 Disconnect electrical control box to battery cable 5 5 Disconnect electrical control box to solenoid cable 6 D Disconnect strobe light wires 7 Disconnect hydraulic solenoid valve cable 8 Disconnect worklight cable 9 x Disconnect blackout control cable 10 NOTE ALL CABLES WIRING REMOVED FOR CLARITY Figure 78 Electrical Control 0044 00 2 9 2510 247 13 0044 00 REMOVAL Continued 10 11 12 13 14 15 16 17 WARNING Remove all power to fifth wheel towing device prior to making any repairs on electrical system Failure to do so could cause injury to personnel or damage to equipment Remove four nuts 11 and lockwashers 12 from fender and electrical control box 13 Discard lockwashers Remove electrical control box 13 from fender Remove four threaded bolts 14 from bottom of electrical control box 13 Loosen six screws 15 securing lid to box Remove nut 16 from bushing 17 and remove bushing from control box Remove four screws 18 and locknuts 19 from remote control receptacle 20 Discard locknuts Remove remote control receptacle 20 from control box Remove seven nuts 21 from straight adapters 22 and remove straight
72. REPAIR B WARNING ET WINCHES All personnel must stand clear during winching operations A snapped cable or shifting load could cause injury or death to personnel Ensure cable is properly mounted on rear winch shaft before operating reel Failure to do so may result in injury to personnel WIRE ROPE Wire rope can become frayed or contain broken wires Wear heavy leather palmed work gloves when handling wire rope Frayed or broken wires can injure hands Never let moving wire rope slide through hands even when wearing gloves A broken wire could cut through glove and cut hand HEAVY COMPONENTS To avoid personal injury use a hoist or get assistance when lifting components that weigh more than 50 Ibs 23 kg Some personnel have difficulty operating the FWTD because of heavy components Use additional personnel when necessary and always use caution when operating to prevent injury or death to personnel END OF WORK PACKAGE 0076 00 1 9 2510 247 13 amp P 0077 00 WINCH ASSEMBLY REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts e Coupled to prime mover WP 0006 00 5 Gloves protective item 6 Fifth Wheel Towing Device in WP 0085 loading configuration WP 0002 Sealing Compound item 12 e Remove winch cable WP 0077 WP 0085 Sealant item 11 WP 0085 Tools Test Equipment Personnel Requirements 2 Tool Kit Mechanics General NSN 5180 00 177 7033 General Safety
73. Relieve hydraulic pressure WP 0056 00 5 CAUTION To prevent contamination of hydraulic system cap and or plug hydraulic lines and ports after disconnecting lines NOTE Mark hydraulic hoses prior to disconnecting Disconnect both winch hydraulic hoses Remove two elbows 3 from winch motor 4 Remove four screws 5 from winch bracket 2 and winch assembly 6 Lift winch assembly 6 from bracket 2 Figure 128 Winch Assembly 0077 00 2 9 2510 247 13 amp P 0077 00 INSTALLATION 1 Position winch assembly 6 in bracket 2 CAUTION To prevent contamination of hydraulic system DO NOT remove caps and or plugs from hydraulic lines and ports until ready to connect 2 Install four screws 3 on winch bracket 2 and winch assembly 4 3 Install two elbows 5 on winch motor 6 4 Connect both winch hydraulic hoses 5 Charge hydraulic WP 0056 00 5 6 BOOM RETRACT to bring boom to upright position 7 Install eight screws 1 on winch bracket 2 Figure 128 Winch Assembly CABLE ASSEMBLY REMOVAL ER WARNING If winch cable has to be cut to remove winch assembly wrap cut end of cable in tape and secure loose end of cable to prevent it from swinging free during winch assembly removal Failure to follow this warning could result in injury or death to personnel CAUTION To prevent contamination of hydraulic system cap and or plug hydraulic lines and ports after disconnecting lines
74. Seller s place of business with transportation charges prepaid and as to which examination shall disclose to the satisfaction of Tru Hitch Inc to have been thus defective provided that such part or parts shall be so returned not later than twelve 12 months after the delivery of such Equipment to the first user purchaser Such defective part or parts will be repaired or replaced free of charge for installation to the first user purchaser at Seller s place of business The warranty shall not apply 1 to normal maintenance service or adjustments including but not limited to hydraulic inspection or adjustment nor to replacement of hydraulic fluids lubricants or filters when such adjustments or replacements are made as part of normal maintenance service or 2 to any Equipment which shall have been repaired or altered in any way so as to in Seller s judgment affect adversely its stability or reliability or 3 to any Equipment which shall have been subject to misuse negligence or accident or loaded beyond the factory rated load capacity Neither seller nor Tru Hitch Inc makes any warranty other than that which is specifically described herein This warranty is expressly in lieu of all other warranties expressed or implied There are no implied warranties of merchant ability or fitness for a particular purpose This warranty states the entire and exclusive liability of seller and Tru Hitch Inc and purchaser s exclusive remedy for any claim fo
75. UNC X 3 4 INCHES LONG END OF FIGURE TM 9 2510 247 13 amp P 0082 00 Figure 18 Boom Assembly 2 ITEM SMR CODE PAOZZ PAOZZ XDFLL PAOZZ PAOZZ PAOZZ 3 NSN 5340014964093 5305014315149 5305009835346 5340015023308 5340014964081 4 1BZD4 45152 1BZD4 96906 1BZD4 18204 9 2510 247 13 amp P 0082 00 5 NUMBER 1077 1 2196790 1089 1 MS16997 78 1060 1 1006 1 6 7 DESCRIPTION AND USABLE ON CODES UOC GROUP 1812 SPECIAL PURPOSE BODIES FIG 18 BOOM ASSEMBLY BUMPER NONMETALLIC 2 2 2 SCREW CAP SOCKET HE 3 8 DIA X 16 UNC X 1 1 4 INCHES LONG 4 FRAME BOOM ASSEMBLY 1 SCREW CAP SOCKET HE 5 16 DIA X 18 UNC X 3 4 INCHES LONG PAD RETAINING 2 END OF FIGURE 9 2510 247 13 amp P 0082 00 Figure 19 Transport Leg Assembly 1 2 ITEM SMR NO CODE 1 PAOZZ 2 PAOZZ PAOZZ 3 PAOZZ 4 PAOZZ 5 PAOZZ 6 PAOZZ 7 77 8 PAOZZ 9 PAOZZ 10 XDOZZ 10 0022 11 PAOZZ 12 PAOZZ 13 PAOZZ 14 77 15 PAOZZ 16 PAOZZ 17 PAOZZ 18 77 19 77 3 NSN 5310008775795 5315012823483 5315014962299 5315014962317 5310014981892 5340015023323 3040014957880 5305007195274 5305007195243 3040014957628 2540014970751 5355014412838 5340014964114 5305009835346
76. Use recommended torque values WP 0087 to tighten nut If this fitting is overtorqued the ferrule will be deformed and the fitting will leak COMPRESSION BAND 4 ECO AT FERRULE Figure 102 Flareless Fitting INSTALLATION OF ADJUSTABLE FITTINGS 1 Apply light weight oil OE HDO 10 to O ring preformed packing CAUTION Packing must be positioned fully into groove and not on threads Failure to comply may result in damage to equipment 2 Gently push backup washer and O ring all the way into groove 3 Turn locknut down until locknut contacts backup washer 4 Install fitting on boss until backup washer contacts face of boss 5 Position fitting to desired position by backing out fitting up to one full turn Hold fitting in desired position and tighten locknut 6 Connect tube to fitting after fitting is properly positioned and tightened 6 LOCKNUT 7 e LOCKNUT BOSS O RING PACKING BACKUP WASHER Figure 103 Adjustable Fittings 0056 00 4 9 2510 247 13 amp P 0056 00 RELIEVE HYDRAULIC PRESSURE 1 Remove electrical control box cover from electrical control box and switch ELECTRIC toggle to OFF position WP 0005 2 Using the hydraulic valve control levers EXTEND AND RETRACT all hydraulic cylinders and winch CHARGE HYDRAULIC SYSTEM 1 On electrical control box switch ELECTRIC toggle to ON position 2 Using the hydraulic valve control
77. WARNING Remove all power to fifth wheel towing device prior to making any repairs on the electrical system Failure to do so may result in serious injury or death 1 The 250M Fifth Wheel Towing Device is equipped with two intervehicular cable receptacles located on the side and rear of the 12 24 volt junction box 2 The 12 pin 24 volt receptacle is located on the side of the 12 24 volt junction box 3 The 7 pin 12 volt receptacle is located on the rear of the 12 24 volt junction box 4 The 250M fifth wheel towing device is also equipped with a work light on the left fender 5 Referto wiring schematics WP 0088 for locating any untagged disconnected wires END OF WORK PACKAGE 0040 00 1 9 2510 247 13 amp P 0041 00 24 VOLT RECEPTACLE REPLACEMENT REMOVAL AND INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in coupling Washer lock 2 MS35333 40 configuration WP 0002 Tag Marker item 15 WP 0085 e Disconnect Batteries WP 0050 Tools Test Equipment General Safety Instructions ToolKit Mechanics General Remove all power to towing device prior to NSN 5180 00 177 7033 making any repairs on the electrical system Shop Equipment Common No 2 NSN 4910 00 754 0650 WARNING Remove all power to fifth wheel towing device prior to making any repairs on the electrical system Failure to do so may result in serious injury or death REMOVAL 1 Disconnect the
78. adapters from control box NOTE WIRING REMOVED FOR CLARITY porn 30 11 Figure 79 Electrical Control Box 0044 00 3 9 2510 247 13 amp P 0044 00 REMOVAL Continued 18 Loosen nut 23 from push switch 24 and remove push switch from control box 19 Loosen three nuts 25 and remove three toggle switches 26 and rubber boots 27 from electric control box 20 Remove four nuts 28 from voltmeter 29 and remove cover 30 from back of voltmeter INSTALLATION 1 Position voltmeter 29 on control box 13 Install cover 30 on voltmeter 29 and secure with four nuts 28 2 Install rubber boots 27 on toggle switches 26 3 Position toggle switches 26 on control box and secure with nuts 25 4 Install push switch 24 on control box and secure with nut 23 5 Position seven straight adapters 22 on control box and secure with nuts 21 6 Position remote control receptacle 20 on control box and secure with four screws 18 and new locknuts 19 7 Position bushing 17 on control box and secure with nut 16 8 Tighten six screws 15 securing lid to box 9 Install four threaded bolts 14 on bottom of electrical control box 13 10 Position electrical control box on fender and secure with four new lockwashers 12 and nuts 11 por 4 30 Figure 79 Electrical Control Box 0044 00 4 9 2510 247 13
79. adjust gladhand connections WP 0016 If yes go to step 2 Step 2 Are there any air leaks If no replace air brake protection valve WP 0054 If yes replace and repair air lines and fittings or gladhands as necessary WP 0055 END OF WORK PACKAGE 0029 00 1 0029 00 9 2510 247 13 amp P 0030 00 UNIT TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION WINCH WINCH WILL NOT OPERATE Step 1 Is free spool lever engaged If no engage free spool lever WP 0012 step 3 If yes go to step 2 Step 2 Is hydraulic pressure present and shown at the pressure gauge If no charge hydraulic system WP 0056 If yes go to step 3 Step 3 Are there leaks in the hydraulic system If no replace winch WP 0077 If yes repair leaks as necessary WP 0056 END OF WORK PACKAGE 0030 00 1 9 2510 247 13 amp P 5 OPERATOR MAINTENANCE INSTRUCTIONS 9 2510 247 13 0000 00 OPERATOR MAINTENANCE INSTRUCTIONS INDEX WP Sequence No OPERATOR MAINTENANCE INSTRUCTIONS Operator Preventive Maintenance Checks and Services PMCS Electrical Connectors teer dd Gladhatids ee Kingpin Placement iie niente tendo pe CM ENS EP 0000 00 0 9 2510 247 13 0031 00 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS GENERAL To ensure that the fifth
80. appearing in your PMCS table should always be observed WARNINGS and CAUTIONS appear before applicable procedures You must observe these WARNINGS to prevent serious injury to yourself and others and CAUTIONS to prevent your equipment from being damaged 4 Procedure Column This column gives the procedure you must perform to check or service the item listed in the Item to Check Service column to know if the equipment is ready or available for its intended mission or for operation You must perform the procedure at the time stated in the interval column 5 Fully Mission Capable if Column Information in this column tells you what faults will keep your equipment from being capable of performing its primary mission If you perform check and service procedures that show faults listed in this column do not operate the equipment Follow standard operating procedures for maintaining the equipment or reporting equipment failure 0031 00 1 9 2510 247 13 amp P 0031 00 GENERAL PMCS PROCEDURES 1 3 NOTE Prior to the performance of the monthly PMCS checks and services ensure the fifth wheel towing device is placed into the hydraulic oil fill position Figure 104 WP 0056 00 7 This position may be adjusted to accommodate particular steps being performed Always perform PMCS in the same order so it gets to be a habit Once you ve had some practice you ll spot anything wrong in a hurry If the fifth wheel towing device doe
81. block 20 000 Ibs 9 072 kg END OF WORK PACKAGE 0002 00 8 9 2510 247 13 amp P 0003 00 THEORY OF OPERATION KINGPIN Removable Kingpin Two are provided one is 3 5 inch 88 9 mm the other is 2 inch 50 8 mm for fifth wheel plate and kingpin coupling For kingpin used with prime mover and placement on fifth wheel towing device see WP 0034 Kingpin Placement HYDRAULIC FLOW VALVE Hydraulic Flow Valves Adjustment Located on hydraulic safety valves on center mast This procedure for flow valve adjustment is to be used from 120 F to 50 F 49 C to 46 C As oil viscosity varies with temperatures it will be required to change the hydraulic flow valve for the boom and mast functions The adjustment is made at the flow control knobs located on the hydraulic safety valves located on the front side of the center mast frame To adjust turn control knob COUNTERCLOCKWISE TO LOWER back pressure and CLOCKWISE TO INCREASE back pressure System should maintain 300 800 psi back pressure when the boom or mast is operated using MAST RETRACT or BOOM EXTEND with no load The hydraulic flow valves will need to be adjusted as necessary as temperatures vary or when OHA 5606 is replaced with standard hydraulic fluid reference 0004 item 7 END WORK PACKAGE 0003 00 1 TM 9 2510 247 13 amp P CHAPTER 2 OPERATOR INSTRUCTIONS 9 2510 247 13 amp P 0000 00 OPERATOR INSTRUCTIONS INDEX WP Sequence No OPERATOR
82. box on fender and secure with four new lockwashers 7 and nuts 6 3 Insert five wires 1 four straight adapter assemblies 3 and one bushing assembly 4 into junction box 5 4 Connect five wires 1 to terminals 2 Figure 77 Junction Box Assembly Follow on Tasks Install 24 volt receptacle 0041 Install 12 volt receptacle WP 0042 Connect batteries WP 0050 Perform functional check of electrical systems END OF WORK PACKAGE 0043 00 2 9 2510 247 13 amp P 0044 00 ELECTRICAL CONTROL BOX MAINTENANCE REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in coupling Washer lock 4 MS35333 40 configuration WP 0002 Nut lock 4 115120 Disconnect batteries WP 0050 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General Remove all power to towing device prior to NSN 5180 00 177 7033 making any repairs on electrical system REMOVAL WARNING Remove all power to fifth wheel towing device prior to making any repairs on the electrical system Failure to do so may result in serious injury or death NOTE For repair remove and replace only those items necessary for the item s to be repaired or replaced wires have been removed from the illustration for clarity Refer to WP 0088 for wiring Mark and tag all wires prior to disconnecting 0044 00 1 9 2510 247 138 0044 00
83. cesses 0091 00 1 lure e E E O a Warranty 0001 00 2 Welding riot ac 0038 00 11 0077 00 1 Winch Assembly 0 0 0077 00 1 Winches General 0076 00 1 Wires and Hoses Tagging 0 44 0038 00 6 Wiring Harness Cable Replacement and az ici tivas 0051 00 1 Work Safety an een 0038 00 2 INDEX 9 By Order of the Secretary of the Army PETER J SCHOOMAKER General United States Army Chief of Staff Official JOEL B HUDSON Administrative Assistant to the Secretary of the Army 0416101 DISTRIBUTION To be distributed in accordance with the initial distribution requirements for IDN 256692 TM 9 2510 247 138P RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG ms rusucanon FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS Your Mailing Address FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT IN THE MAIL DATE SENT Date you filled out this form PUBLICATION NUMBER PUBLICATION DATE PUBLICATION TITLE TM X XXXX XXX XXX Date of TM Title of TM BE EXACT PIN POINT WHERE IT IS IN THIS SPACE TELL WHAT 15 WRONG AND WHAT SHOULD BE DONE ABOUT IT Step No 1 says to connect LH 4 SPNSN Unit 8 hose from where to what
84. equivalent to 0 Celsius 9 5 32 F APPROXIMATE CONVERSION FACTORS TO CHANGE TO MULTIPLY BY Liters Quarts 1 057 Gallons 0 264 Ounces PIN 0 035 IAN 2 205 Metric Tons Short Tons voice 1 102 Newton Meters sn 0 738 Pounds Per Square Inch 0 145 Kilometers Per Liter Miles Per Gallon is 2 354 081630 000 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to share republish sell and so on not asking you for donations fees or hando
85. exposed surfaces should be cleaned and lubricated daily Refer td WP 0039 for proper lubrication in high humidity and saltwater areas When equipment is inactive unpainted parts should be coated with lubricating oil refer WP 0039 All covers and caps should be in place 0022 00 2 9 2510 247 13 0022 00 OPERATION ROCKY TERRAIN Before driving over stumps or rocks make sure the towing device can clear them Such objects can damage components on the underside of the towing device Beware of low hanging limbs that can damage cargo FORDING 1 Before Fording a Referto operating instructions in prime mover technical manual for information on fording operations Towing vehicle fording instructions are also applicable b The fording depth of fifth wheel towing device is limited to the fording depth limit of the prime mover or the towed vehicle whichever is lower c Before entering the water check bottom surface conditions If bottom is too soft do not ford d Cables and terminals must be protected by applying silicone compound item 11 WP 0085 2 After Fording a Drain or dry all areas where water has collected b Lubricate all unpainted surfaces See lubrication chart WP 0039 c Dryall lubrication points and lubricate See lubrication chart WP 0039 ROLL ON ROLL OFF RORO OPERATIONS The following procedures are roll on roll off RORO procedures for shipment of the fifth wheel towing device 1 P
86. flatwashers 1 from underneath fender 4 Discard lockwashers 2 Drop fender from mounting brackets Figure 119 Fender with Mounting Brackets 0070 00 1 9 2510 247 13 amp P 0070 00 FENDER MOUNTING BRACKET REMOVAL 1 Remove five bolts 1 from mounting bracket 2 and remove mounting bracket from frame 3 2 Repeat step 2 for remaining mounting brackets Figure 120 Fender Mounting Bracket FENDER MOUNTING BRACKET INSTALLATION 1 Position mounting bracket 2 on frame 3 and secure with five bolts 1 2 Repeat step 1 for remaining mounting brackets 0070 00 2 9 2510 247 13 amp P 0070 00 FENDER INSTALLATION Position fender to mounting brackets Secure fender 4 using bolts 5 flat washers 1 new lockwashers 2 and nuts 3 Figure 119 Fender with Mounting Brackets Follow on Tasks Install tow bar assembly if removed WP 0008 Install tool box if removed WP 0071 Install worklight assembly if removed WP 0047 Install electric control box if removed CT Install 12 24 volt junction box if removed WP 0043 Install air brake protection valve if PI WP 0054 Install air brake hoses if removed WP 0055 Install gladhand assembly if removed WP 0053 Test air brake assembly for leaks if required WP 0054 END OF WORK PACKAGE 0070 00 3 9 2510 247 13 amp P 0071 00 TOOL BOX REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials
87. follow this warning could result in serious injury or death NOTE Vehicle weights can be found on the vehicle data plate or operator s manual NOTE Refer to the prime mover operator s manual for authorized vehicle combinations 0091 00 1 Change 1 TM 9 2510 247 13 amp P 0091 00 AUTHORIZED VEHICLE COMBINATIONS Continued Prime Authorized Towed Vehicles Gross Combination Weight Rating GCWR M915 A1 A2 M915s M818 M931 and M932 Models 105 000 Ibs A3 A4 FMTV Series PLS Series M1070 47 641 kg M916 A1 A2 A3 M915s M916s M818 M931 and M932 120 000 Ibs Models FMTV Series PLS Series M1070 54 446 kg M920 M915s M916s M920 M931 and M932 120 000 Ibs Models Series PLS Series M1070 54 446 kg M931 M911 M915s M916s M920 M818 M931 and 59 589 Ibs M932 Models FMTV Series PLS Series M1070 27 036 kg M932 911 9155 9165 920 818 931 and M932 59 742 Ib Models FMTV Series PLS Series M1070 27 106kg Bou M818 M931 and M932 Models M915 57 665 Ibs FMTV Series M1070 26 164 kg M1088 FMTV M911 M915s M916s M920 M818 M931 and 80 775 lbs M932 Models FMTV Series PLS Series M1070 36 649 kg 911 9155 9165 920 818 931 and M932 120 000 Ibs Models FMTV Series PLS Series M1070 54 446 kg m 911 9155 9165 920 818 931 and M932 100 000 Ibs Models M983 FMTV Series PLS Series M1070 45 372 kg Special Connection PLS with M915 located WP 0010 00 0091 00
88. for the performance of maintenance functions on the identified end item or component The application of the maintenance functions to the end item or component will be consistent with the capacities and capabilities of the designated maintenance levels which are shown on the MAC in column 4 as Unit includes two subcolumns C Operator Crew and O Unit Maintenance Direct Support includes an F subcolumn General Support includes an H subcolumn Depot includes a D subcolumn Section lists the tools and test equipment both special tools and common tool sets required for each maintenance function as referenced from Section Il d Section IV contains supplemental instructions and explanatory notes for a particular maintenance function 2 MAINTENANCE FUNCTIONS Maintenance functions are limited to and defined as follows a Inspect To determine the serviceability of an item by comparing its physical mechanical and or electrical characteristics with established standards through examination e g by sight sound or feel b Test To verify serviceability by measuring the mechanical pneumatic hydraulic or electrical characteristics of an item end item and comparing those characteristics with prescribed standards C Service Operations required periodically to keep an item in proper operating condition e g to clean includes decontaminate when required to preserve to drain to paint or to replenish fuel l
89. functions to be performed on the item listed in Column 2 For detailed explanation of these functions see paragraph 2 1 Services Inspect test service adjust align calibrate and or replace 2 Fault location troubleshooting The process of investigating and detecting the cause of equipment malfunctioning the act of isolating a fault within a system or unit under test UUT 3 Disassembly assembly The step by step breakdown taking apart of a spare function group coded item to the level of its least component that is assigned an SMR code for the level of maintenance under consideration i e identified as maintenance significant 4 Actions Welding grinding riveting straightening facing machining and or resurfacing 00081 00 2 TM 9 2510 247 13 amp P 0081 00 3 EXPLANATION OF COLUMNS IN THE MAC Continued NOTE When a complete replace or repair task performed at higher level maintenance includes lower level maintenance tasks equipment condition follow on tasks the lower level work time figures in the MAC must be added to the higher level work time shown in the MAC to determine the total to accomplish that maintenance function d Column 4 Maintenance Level Column 4 specified each level of maintenance authorized to perform each function listed in Column 3 by indicating a work time required expressed as manhours in whole hours or decimals in the appropriate subcolumn This work time figure represents
90. hose coupling 3 to a vertical position and align outlet holes Rotate coupling to the horizontal locked position Figure 59 Gladhand Connection END OF WORK PACKAGE 0016 00 1 TM 9 2510 247 13 amp P 0017 00 TRANSPORTING LOADS General a The 250M Fifth Wheel Towing Device with its prime mover will have different operational characteristics based on gross weight differences between loaded and unloaded weight and suspension characteristics Safe operating limits are affected by the interaction of the vehicle characteristics load road surface weather driver skill and vehicle speed Before operating the towing device ensure that all the operating procedures contained in this manual have been read and fully understood The 250M Fifth Wheel Towing Device when coupled to a prime mover and loaded acts in the same manner as a trailer All precautions contained in prime movers operating instructions in reference to towing a trailer apply to the fifth wheel towing device The batteries on the fifth wheel towing device will run low during extended operation of the strobe lights and must be recharged by connecting the 24 volt NATO slave cable to the IVEC connector and allowing the prime mover to idle for an extended period of time WARNING Prior to transporting loads ensure the transport leg assembly is locked in the vertical position or the handle may swing free and cause injury or death to personnel Pre Trip Inspec
91. item mentioned in troubleshoot ing refer to paragraphs WP 0002 00 8 and WP 0002 00 6 WP 0004 00 1 through WP 0004 00 3 0031 Before performing troubleshooting read and follow all safety instructions found in the warning summary at the front of this manual This section cannot list all malfunctions that may occur nor all tests or inspections and corrective actions If a malfunction is not listed or is not corrected by the listed corrective actions notify your supervisor When troubleshooting a malfunction a Locate the symptom or symptoms WP 0025 00 2 that best describes the malfunction If the appropriate symptom is not listed notify your supervisor b Turn to the work package where the troubleshooting procedures for the malfunction in question are described Headings at the top of each page show how each troubleshooting procedure is organized Malfunction Test or Inspection in step number order and Corrective Action c Perform each step in the order listed until the malfunction is corrected and the item being inspected is operational DO NOT perform any maintenance task unless the troubleshooting procedure tells you to do so EXPLANATION OF COLUMNS The columns are defined as follows a MALFUNCTION Avisual or operational indication that something is wrong with the equipment b TEST OR INSPECTION A procedure to isolate the problem in a system or component c CORRECTIVE ACTION A procedure to co
92. kingpin 2 Using kingpin wrench 3 align tabs on wrench 3 with slots on kingpin nut 4 Remove kingpin nut 4 and grommet 5 Rotate kingpin 2 to disengage safety 6 and lower kingpin from main frame If changing location of kingpin remove wing nut 7 and wooden plug 8 SAS Sq ES 8 2 BIER LY FRONT Figure 73 Kingpin Placement 0034 00 1 TM 9 2510 247 13 amp P 0034 00 KINGPIN PLACEMENT Continued INSTALLATION gt m The size and location of kingpin installation is determined by the prime mover used 911 Truck Tractor and M920 Truck Tractor require the 3 1 2 inch 88 9 mm kingpin to be installed in position A The M915 series Truck Tractor requires the 2 inch 50 8 mm kingpin to be installed in position B The M916 M916A1 and M916A2 Truck Tractor require the 3 1 2 inch 88 9 mm kingpin to be installed in position B From bottom of main frame insert kingpin 2 up through position A or position B as determined in note above If changing location of kinpin install wooden plug 8 in unused position and secure with wing nut 7 Rotate kingpin 2 to engage safety 6 and secure with grommet 5 and kingpin nut 4 Tighten kingpin nut until seated Using kingpin wrench 3 align tabs on wrench 3 with slots on kingpin nut 4 Tighten kingpin nut until two notches pass springpin hole Install spring pin 1 through top of kingpin 2
93. main valve assembly 13 Remove four flow restrictor valves and springs 18 from main valve ports 19 Remove two screws 11 and lockwashers 12 Discard lockwashers Remove main valve assembly 13 from frame Remove pressure gauge 14 from straight adapter 15 Remove straight adapter 15 from tee pipe 6 0059 00 2 9 2510 247 13 amp P 0059 00 REMOVAL Continued 16 Remove tee pipe 6 from straight adapter 16 17 Remove straight adapter 16 from main valve assembly 13 KJ ZE NO ANG PAIR es DANOS up TEE O ama NAS im RU 1 ij RU LR ON 7 Figure 107 Hydraulic Control System 0059 00 3 9 2510 247 13 amp P 0059 00 SOLENOID REMOVAL NOTE Tag all electrical wires prior to disconnecting to ease installation 1 Disconnect electrical connectors 1 from eleven solenoids 2 2 Remove solenoids 2 from main valve assembly SOLENOID INSTALLATION 1 Install solenoids 2 in main valve assembly 2 Connect electrical connectors 1 to solenoids 2 T TA 3 NT DS 25 Figure 108 Main Valve Assembly 0059 00 4 TM 9 2510 247 13 amp P 0059 00 INSTALLATION NOTE Hydraulic hoses must not be uncapped and or unplugged until ready to connect to prevent contamination of hydraulic system Use sealing compound on all threads before installing fittings Inst
94. order to be mission ready at all times b The Lubrication Chart shows lubrication points items to be lubricated the required lubricants and recommended intervals for lubrication Any special lubrication instructions required for specific components are contained in the NOTES section of the chart The KEY provides information needed to select the proper lubricant for various temperature ranges and uses and identifies the capacities and intervals d Recommended intervals are based on normal conditions of operation temperature and humidity When operating under extreme conditions lubricants should always be changed more frequently When in doubt notify your supervisor 2 SPECIFIC LUBRICATION INSTRUCTIONS a Keep all lubricants in a closed container and store in a clean dry place away from extreme heat Keep container covers clean and do not allow dust dirt or other foreign material to mix with lubricants Keep lubrication equipment clean and ready for use b Maintain a record of lubrication performed and report any problems noted during lubrication Refer to DA Pam 738 750 for maintenance forms and procedures to record and report any findings Keep all external parts of equipment not requiring lubrication free of lubricants After lubrication wipe off excess lubricant to prevent accumulation of foreign matter 3 ARCTIC PROCEDURE NOTE This procedure is to be used from 20 F to 50 F As oil viscosity varies with
95. pins and spring pins 12 Using remote control box or valve control levers MAST EXTEND 19 to line up arrows 20 and 21 DO NOT EXTEND ps 5 THIS POINT An y 00 J OF 21 KS I n lij np T BOTE Y Wi Figure 29 Pin Alignment Items 13 Install two 3 8 inch safety chains 11 as shown 14 Using remote control box or hydraulic valve control levers MAST RETRACT until safety chains 11 are tight Figure 30 Chain Tightening Items END OF WORK PACKAGE 0007 00 5 9 2510 247 13 amp P 0008 00 PREPARE TOWING DEVICE The following operations assume the fifth wheel towing device is coupled to a prime mover and in transport configuration WARNING 5 Ensure hydraulic pressure release valve is open breather switch inline with breather prior to operating hydraulics Failure to comply could cause injury or death to personnel or damage to equipment Figure 31 Top Breather Valve 1 Set 12 24 volt junction box 1 to proper voltage 2 Remove electrical control box cover 2 from electrical control box 3 and switch electric toggle 4 to ON position Figure 32 Electrical Control Boxes 0008 00 1 TM 9 2510 247 13 amp P 0008 00 PREPARE TOWING DEVICE Continued 3 Remove remote control box 5 from tool box and press power ON 6 NOTE Electric motor switch 7 on electrical control box 8 must be depressed at all times
96. receptacle 9 to terminal cable 1 at terminal 2 2 Remove two nuts 3 two lockwashers 4 one flatwasher 5 one grounding cable 6 two screws 7 and two flat washers 8 Discard lockwashers 3 Remove receptacle 9 from junction box 10 4 Pull rubber boot 11 down cable 1 and disconnect wire cable 1 from receptacle 9 by heating wire end to melt solder Figure 75 Receptacle Box 0041 00 1 9 2510 247 13 amp P 0041 00 REMOVAL Continued Figure 75 Receptacle Box INSTALLATION 1 Insert wire cable 1 into back of receptacle 9 and attach by soldering cable end to receptacle After wire end has cooled pull rubber boot 11 into place over back of receptacle 9 Position receptacle 9 on junction box 10 and secure with two screws 7 flatwashers 8 one flatwasher 5 ground cable 6 two new lockwashers 4 and nuts 3 Connect the receptacle 9 to terminal cable 1 at terminal 2 Connect fifth wheel towing device battery cables WP 0050 Using a multimeter switch the 12 24 volt selector switch to 24 volts and check for 24 volt reading at center pin of receptacle Follow on Tasks None END OF WORK PACKAGE 0041 00 2 9 2510 247 13 amp P 0042 00 12 VOLT RECEPTACLE REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in coupling Marker tags item 15 WP 0085 configuration WP 0002
97. reote EUR ura apex ad Gladhand ET ae Transporting Eo ds 5 Banken nalen Disconnecting Towed Vehicle 40440 0 000 eene enne nnne Stowage of Tow Bar Assemblies 2 22 2 0 enne nnne nnns nennen A TRE Prepare for Operation Under Unusual 0 OPERATOR TROUBLESHOOTING PROCEDURES Operator Troubleshooting Procedures Operator Troubleshooting iret nennen san MET RARE TR MT VRAT RR DER UTR apa aa CHAPTER 4 UNIT TROUBLESHOOTING PROCEDURES MOOK MR Y rer Unit Troubleshooting Procedures nennen nnn nnn Mine mE Electrical Hydraulic System Alt Brako System re sxx ieee MAINTENANCE INSTRUCTIONS MOOK MEIN T Operator Preventive Maintenance Checks and Services Electrical Gladliands se ee da os Kingpin Place M
98. report it to your supervisor e Electrical Wires and Connectors Look for cracked or broken insulation bare wires and loose or broken connectors Tighten loose connectors and ensure that the wires are in good condition f Hoses Look for wear damage and signs of leaks Ensure that clamps and fittings are tight Wet spots indicate leaks but a stain around a fitting or connector may also indicate a leak If a leak comes from a loose fitting or connector tighten If something is broken or worn out report it to your supervisor 0031 00 2 9 2510 247 13 amp P 0031 00 GENERAL PMCS PROCEDURES Continued 9 Fluid Leakage It is necessary for you to know how fluid leakage affects the status of your fifth wheel towing device The following are definitions of the types classes of leakage you need to know to be able to determine the status of your equipment Be familiar with them and remember when in doubt notify your supervisor Leakage Definitions of PMCS Class Leakage indicated by wetness or discoloration but not great enough to form drops Class II Leakage great enough to form drops but not enough to cause drops to drip from the item being checked inspected Class III Leakage great enough to form drops that fall from the item being checked inspected CAUTION Operation is allowable with Class I and Class Il leakage WHEN IN DOUBT NOTIFY YOUR SUPERVISOR When operating with Class I or Class Il leaks check fluid l
99. safety valve 3 2 Install elbow 2 to check valve 9 3 Install straight adapter 8 to safety valve 3 4 Install globe valve 7 to straight adapter 8 5 Install tee fitting 1 to globe valve 7 6 Position safety valve 3 on bracket 5 and install 2 1 2 inch 63 5 mm screw 6 through lower position on safety valve and mast 7 Install 1 1 2 inch 38 1 mm screw 4 through upper position on safety valve and mast 8 Install hydraulic hoses on safety valve 0058 00 3 9 2510 247 13 0058 00 INSTALLATION Continued 9 Install hydraulic hoses on elbow 2 10 Install hydraulic hoses on tee fitting 1 Figure 106 Hydraulic Safety Valve Assembly Follow on Tasks Charge hydraulic system WP 0056 00 5 Adjust the flow valves as required WP 0004 END OF WORK PACKAGE 0058 00 4 9 2510 247 13 0059 00 MAIN VALVE ASSEMBLY MAINTENANCE REMOVAL REPAIR INSTALLATION INITIAL SETUP Equipment Conditions Hydraulic pressure relieved WP 0056 Disconnect batteries WP 0050 00 5 Remove valve control levers Tools Test Equipment Tool Kit Mechanics General NSN 5180 00 177 7033 Tool Kit Common No 1 NSN 4910 00 754 0654 Materials Parts Washer lock 2 12387272 45 Sealing Compound Item 12 WP 0085 Hydraulic fluid Item 15 Rags Item 28 WP 0085
100. steps are for the removal and installation of the primary and isolated solenoid assemblies Adjust maintenance steps as required to accommodate required maintenance 1 Disconnect solenoid to hydraulic motor wire 1 from terminal post 2 2 Disconnect solenoid to battery wire 3 from terminal post 4 Figure 80 Solenoid Assembly 0045 00 1 9 2510 247 13 amp P 0045 00 REMOVAL Continued 3 4 e Disconnect ground wire 5 from terminal post 6 Disconnect solenoid to control box wire 7 and jumper wire 8 from terminal post 9 Remove nuts 10 and lockwashers 11 Discard lockwashers Remove mounting bracket 12 from solenoid 13 Remove solenoid 13 Figure 81 Solenoid Assembly INSTALLATION 1 6 Position solenoid 13 and secure with mounting bracket 12 nuts 10 new lockwashers 11 Connect solenoid to control box wire 7 and jumper wire 8 to terminal post 9 Connect ground wire 5 to terminal post 6 Connect solenoid to battery wire 3 to terminal post 4 Connect solenoid to hydraulic motor wire 1 to terminal post 2 Connect batteries WP 0050 Turn ELECTRICAL switch to ON Push motor control button for 2 seconds and release to ensure the solenoids activate the hydraulic motors Follow on Tasks None END OF WORK PACKAGE 0045 00 2 9 2510 247 13 0046 00 REMOTE CONTROL ASSEMBLY REPLACEMENT REMOVAL INSTALLATI
101. temperatures it will be required to change the hydraulic fluid to 5606 Arctic hydraulic fluid Following the oil change procedures WP 0056 it will be necessary to adjust the hydraulic flow valve for the boom and the mast functions located on the vertical slide section Turn the control knob of the hydraulic flow valve clockwise to restrict flow counter clockwise to increase volume size to obtain 300 800 lbs system hydraulic pressure while the boom function is lowered with no load attached In the same way adjust the mast hydraulic flow valve when the mast is being lowered with no load attached This may need to be readjusted as necessary as temperatures vary from 50 F to 120 F or when 5606 is replaced with standard hydraulic fluid When the fifth wheel towing device is exposed to a temperature increase from 25 F or below to 10 F the functions should not be left under pressure and it is recommended that each function be operated at 10 to release pressure created by expansion caused by an increase in temperature 0039 00 1 9 2510 247 13 amp P 0039 00 LUBRICATION CHART FIFTH WHEEL TOWING DEVICE 250M NSN 2510 01 458 8253 This Lubrication Chart is for operator crew C and Unit Maintenance O Lubrication intervals on condition or hardtime are based on normal operation Lubricate more during constant use and less during inactive periods Use correct grade of lubricant for seasonal temperature expect
102. the procedure All tags and forms attached to the equipment must be checked to learn the reason for removal of equipment from service Modification Work Orders MWOs and Technical Bulletins TBs must also be checked for equipment changes and updates 0038 00 1 TM 9 2510 247 13 amp P 0038 00 GENERAL Continued WORK SAFETY 5 EN WARNING No personnel shall perform maintenance above or below the main frame without the main frame being supported at the front by use of a jack stand or the prime mover Failure to comply may result in death or injury to personnel Before beginning a procedure think about the safety risks and hazards to yourself and to others Wear protective gear such as safety goggles or lenses safety shoes rubber apron or gloves Before beginning a procedure ensure that the following conditions have been observed unless otherwise specified a Towing device if coupled should be parked on level ground with prime mover parking brake set and chock blocks in place b If prime mover is coupled to towing device engine must be off unless otherwise indicated Immediately clean up spilled fluids to avoid slipping When lifting heavy parts have someone help you Ensure that lifting equipment or jack is working properly that it meets weight requirement of part being lifted and that it is securely fastened to part Always use power tools carefully CLEANING INSTRUCTIONS EN WARNING Improper c
103. the appropriate electrical schematic Identify lines when you are taking off more than one line at the same time Mark tags with points to which lines and hoses must be connected If it is not obvious which end of a line goes where tag each end of the line Identify and tag other parts as required by name and installed location 0038 00 6 9 2510 247 13 amp P 0038 00 SOLDERING CAUTION Use low wattage soldering gun when soldering electrical wires connectors terminal lugs and receptacles High wattage soldering guns may damage parts by overheating 1 Solder connection must be bright and clean before soldering Remove dirt and grease with a wire tinned for good connection and maximum transfer of heat rush 2 WP 0085 or a pocket knife Solder used must be of lead alloy item 13 P 0085 with soldering flux item 5 WP 0085 wires parts and soldering gun must be 2 To prevent overheating damage to electrical parts when soldering and unsoldering connections hold bare wire lead or terminal lug close to soldering point with long roundnose pliers Pliers act as heat sink and absorb excess heat HEAT SHRINKABLE TUBING Use the heat shrinkable tubing item 19 WP 0085 to insulate soldered and crimped electrical connections as follows a C Cut desired length of new heat shrinkable tubing twice the length of the connection to be covered Slide the heat shrinkable tubing onto the wire and out of th
104. the appropriate symptom is not listed notify your supervisor b Turn to the page in Table 1 where the troubleshooting procedures for the malfunction in question are described Headings at the top of each page show how each troubleshooting procedure is organized Malfunction Test or Inspection in step number order and Corrective Action Perform each step in the order listed until the malfunction is corrected and the item being inspected is operational DO NOT perform any maintenance task unless the troubleshooting procedure tells you to do so EXPLANATION OF COLUMNS The columns are defined as follows 1 MALFUNCTION A visual or operational indication that something is wrong with the equipment 2 TEST OR INSPECTION A procedure to isolate the problem in a system or component 3 CORRECTIVE ACTION A procedure to correct the problem 0023 00 1 9 2510 247 13 amp P 0023 00 OPERATOR TROUBLESHOOTING SYMPTOM INDEX Troubleshooting Procedure Page KINGPIN Kingpin Fails to Lock in Fifth nennen nnne WP 0024 ELECTRICAL SYSTEM All Lights WP 0024 One or More Lights Inoperable sse enne nnns nnns WP 0024 AIR BRAKE SYSTEM Brakes on Towed Vehicle Fail to Disengage WP 0024 HYDRAULIC SYSTEM Hydraulic Functions Slow or
105. the lowest level that can do complete repair of the item Depot is the lowest level that can do complete repair of the item Nonreparable No repair is authorized No repair is authorized No parts or special tools are authorized for maintenance of B coded item However the item may be reconditioned by adjusting lubricating etc at the user level 0082 00 4 9 2510 247 13 amp P 0082 00 3 EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGE Continued e Recoverability Code Recoverability codes are assigned to items to indicate the disposition action on unserviceable items The recoverability code is shown in the fifth position of the SMR code as follows Recoverability Code Application Explanation 2 Nonreparable item When unserviceable condemn and dispose of the item at the level of maintenance shown in the third position of the SMR code O Reparable item When uneconomically reparable condemn and dispose of the item at the unit level Reparable item When uneconomically reparable condemn and dispose of the item at the direct support level H Reparable item When uneconomically reparable condemn and dispose of the item at the general support level D Reparable item When beyond lower level repair capability return to depot Condemnation and disposal of item are not authorized below depot level L Reparable item Condemnation and disposal not authorized below Specialize
106. to operate hydraulic valve control levers 9 All operations can be performed using either the hydraulic valve controls or the remote control LI LLLI HRHRKRGRE Figure 33 Hydraulic and Electrical Controls 0008 00 2 9 2510 247 13 amp P 0008 00 PREPARE TOWING DEVICE Continued CAUTION DO NOT extend past arrows on mast Damage to equipment may result 7 4 DO NOT EXTEND PAST THIS POINT Figure 34 4 Using remote control box 10 or hydraulic valve control levers 9 MAST EXTEND until there is slack in safety chains 11 5 Remove safety chains 11 from rear of towing device 6 Remove two spring pins 12 from two clevis pins 13 and remove two clevises 14 from mast 15 Figure 36 Shipping Chains and Clevis 0008 00 3 9 2510 247 13 amp P 0008 00 PREPARE TOWING DEVICE Continued F3 WARNING DO NOT operate boom until mast is in track Failure to comply could cause serious injury or death to personnel or damage to equipment 7 Using remote control box 28 or valve control levers MASS RETRACT 16 to line up arrows 17 and 18 Figure 37 Remote Control and Pin Alignment 8 Insert pivot pins 19 into aligned holes Do not insert spring pins onto pivot pins Ensure pivot pin lanyards are free from moving parts RETRACT nd RETRACT e WINCH gon em m Figure 38 Main Valve Controls 9 Using remote control box 28 or
107. until booms are resting on the ground 10 Slowly drive the prime mover away from towing device END OF WORK PACKAGE 0020 00 3 9 2510 247 13 amp P 0021 00 PREPARE FOR SHIPPING STORAGE 1 Uncouple towing device from prime 0020 2 Using remote control or valve control levers MAST EXTEND to lower mast until arrow 1 is approximately 4 inches 101 6 mm below frame 2 Figure 68 Mast Alignment 3 Lock transport legs in up position EN ES n Operators must take caution while folding the mast assembly to the vertical position The transport leg assembly does not stay locked in the vertical position The handle will swing free and may cause injury or death to personnel Ensure tool boxes are closed and the main frame is free of all unsecured items Failure to comply may result in death or injury to personnel or equipment 0021 00 1 TM 9 2510 247 13 amp P PREPARE FOR SHIPPING STORAGE Continued 4 Using valve control levers BOOM RETRACT to fold towing device 5 With kingpin in vertical position close top pressure relief valve 6 by turning breather switch 5 elbow 90 from breather NOTE With main frame in the vertical position the bottom breather is on the fifth wheel side of the hydraulic tank and the top breather is located towards the rear of the fifth wheel towing device Both breathers look the same Figure 19 Breather Valve 0021 00 2 TM 9 2510 247
108. 0 9 2510 247 13 amp P 0038 00 FLUID DISPOSAL WARNING When servicing this vehicle performing maintenance or disposing of materials such as engine coolant transmission fluid lubricants battery acids or batteries and CARC paint consult your Unit Local Hazardous Waste Disposal Center or safety office for local regulatory guidance If further information is needed please contact the Army Environmental Hotline at 1 800 872 3845 Failure to comply may result in injury or death to personnel SERVICE REPLACEMENT PARTS AND KITS Many service replacement parts are available in standard sizes as well as various undersized and or oversized sizes Service kits for reconditioning certain parts and service sets which include all parts necessary to complete a procedure are also available WELDING CAUTION If welding towing device it must be uncoupled from prime mover Failure to follow this warning may damage electronic components Refer to TC 9 237 Operator s Manual for Welding Theory and Application for instructions on welding components ELECTRICAL REPAIR Specific electrical system maintenance tasks are covered WP 0040 through WP 0051 pf this manual END OF WORK PACKAGE 0038 00 11 9 2510 247 13 amp P 0039 00 LUBRICATION INSTRUCTIONS 1 GENERAL NOTE These instructions are mandatory a The 250M Fifth Wheel Towing Device FWTD must receive lubrication with approved lubricants at recommended intervals in
109. 0 4040 1 7 PAOZZ 5305005804786 27192 11 1625 SCREW SHOULDER 5 16 DIA X 18 UNC X 1 3 4 INCHES LONG 4 END OF FIGURE TM 9 2510 247 13 amp P 0082 00 Figure 27 Main Frame to Mast 0 2 ITEM SMR NO CODE PAOZZ PAOZZ PAOZZ XDOZZ PAOZZ PAOZZ O PAOZZ PAOZZ PAOZZ PAOZZ XDOZZ 3 NSN 4730003594717 5315014962322 4730011269758 3040014959856 4730011036840 4730000513731 5305014958170 5315014963062 4 CAGEC 1BZD4 81343 1BZD4 OATA2 98441 1BZD4 30780 01276 1BZD4 1BZD4 OATA2 TM 9 2510 247 13 amp P 5 NUMBER 1062 1 8 8 140230CA 1036 1 2006 8 1 2F50G S 02040 1 2 MMS S 2068 8 85 1067 1 1035 1 2001 0082 00 6 7 DESCRIPTION AND USABLE ON CODES UOC GROUP 2407 HYDRAULIC CYLINDERS 27 FRAME TO MAST SCREW SQUARE 6 ELBOWPIPE 2 1 PIN STRAIGHT HEADLE 2 FITTING GREASE 45 DEGREE 2 1 CYLINDER ASSEMBLY A MAIN FRAME MAST FRAME ss 2 TEE PIPE 1 ELBOW PIPE TO 2 SET SCREW 2 PIN STRAIGHT HEADLE LOWER 2 FITTING GREASE 2 21 101 2 2 42 9807 12228 2 END OF FIGURE 0082 00 9 2510 247 138 Figure 28 Mast to Boom TM 9 2510 247 13 amp P 0082 00 0 2 3 4
110. 0 4730014976338 4730004898198 2540014943530 4730015027273 2540014943529 5310013894257 5310010739803 4 CAGEC 81495 98441 30780 1BZD4 98441 98441 59257 1BZD4 1BZD4 1BZD4 96906 19200 TM 9 2510 247 13 amp P 5 PART NUMBER 1200 59 8 CTXS S 8F650X SS 02845 8F50HAO SS 8AOG5JG5 S 10 85 6 1087 1 02000 1086 1 535338 046 12279371 1 0082 00 6 7 DESCRIPTION AND USABLE CODES UOC QTY GROUP 24 HYDRAULIC AND FLUID SYSTEMS GROUP 2401 PUMP AND MOTOR FIG 21 HYDRAULIC MOTOR ASSEMBLY SCREW CAP HEXAGON H 3 8 DIA X 16 UNC 1 ELBOW PIPE TO TUBE ADAPTER STRAIGHT TU VALVE CHECK UNION TUBE TEE STRAIGHT THREAD ELBOW TUBE BOSS tan MOTOR HYDRAULIC ISO FITTINGCOMPRESSION MOTOR HYDRAULIC PRI WASHER LOCK 3 8 DIA HOLE WASHER FLAT 3 8 DIA END OF FIGURE 1 9 2510 247 13 amp P Figure 22 Hydraulic Safety Valve 0082 00 0 2 4 6 ITEM SMR NO CODE CODES UOC PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ J O PAOZZ 3 NSN 4730013345719 4820010757224 4730011255179 4730002293402 4820015021995 4820015022006 5305002829646 5305002829607 30327 09990 81343 81343 1BZD4 1BZD4 96906
111. 0 1 XEM 0038 00 9 Army Maintenance System Maintenance Allocation Chicco sen een erraten 0081 00 1 Army Materiel Destruction of to Prevent Enemy 0001 00 1 Assembly Disassembly Instructions 2 0038 00 4 Authorized Vehicle Combinations 0091 00 1 B Basic Iss e tems tete 0083 00 2 Battery Battery Box Replacement essem 0050 00 1 Bil EE 0083 00 2 2 0 a aaa 0038 00 1 Boom Extension Cylinder Replacement 0066 00 1 Brake System Maintenance 0052 00 1 Bulletins Technical ic a ae 0080 00 2 Bumper Pad 0074 00 1 Cam Valve Assembly Replacement 0062 00 1 Care of Equipment in Administrative Storage 0078 00 4 Center Mast Frame Replacement 0073 00 1 Cleaning aS 0035 00 1 AS 0038 00 2 voz 0083 00 1 Cold Extreme 0022 00 1 Common Tools and 0081 00 8 Components of End 0085 00 1 Compression Fittings Tubes 0038 00 10 Controls and Indicators Couplings and
112. 0 59 1061 1 B1821BH038C350N 1043 1 517830 6 2023 1037 1 2001 6 0082 00 2 3 6 7 DESCRIPTION AND USABLE CODES UOC QTY GROUP 1812 SPECIAL PURPOSE BODIES FIG 16 FRAME ASSEMBLY SCREW CAP SOCKET HE 5 16 DIA X 18 UNC x 3 4 INCHES LONG PAD SLIP ee PIN STRAIGHT HEADLE SCREW SQUARE HEAD FRAME CENTER MAST 1 FRAME MAST ASSEMBLY 1 SCREW CAP HEXAGON H 3 8 DIAX 16 UNC X 1 INCH LONG 4 CLAMP LOOP HOSE RETAINING 2 SCREW CAP HEXAGON H 3 8 DIA X 16 UNC 1 2 INCHES 4 PIN STRAIGHT HEADLE eee 2 NUT SELF LOCKING HE 3 8 DIA X 16 a e 4 FITTING GREASE 4 PIN STRAIAGHT HEADLE 1 2 rre ttti 4 END OF FIGURE 9 2510 247 13 0082 00 Figure 17 Main Frame Assembly PAOZZ 5340014964081 PAOZZ 5315009835346 TM 9 2510 247 13 amp P 0082 00 5 NUMBER 1090 1 02440 1038 1 6 7 DESCRIPTION AND USABLE ON CODES UOC GROUP 1812 SPECIAL PURPOSE BODIES FIG 17 MAIN FRAME ASSEMBLY FRAME MAIN ASSEMBLY 1 PLATE MOUNTING 16 SCREW CAP SOCKET 5 16 DIA X 18 64
113. 0 757 8122 4 3 80205 MS51975 23 5305 00 940 9445 4 21 96906 552125 2 6220 01 093 4439 4 10 80205 590725 67 5305 00 269 3217 4 4 96906 590727 125 5305 00 719 5274 19 7 96906 59349 04 5340 00 081 4718 8 22 09990 N 800 S 4820 01 075 7224 22 2 81348 QQ W 343 10 8 23 81348 QQ W 343 18 8 4 81348 QQ W 343 36 8 21 81348 QQ W 343 37 8 9 81348 QQ W 343 40 8 17 81348 QQ W 343 45 8 18 81348 QQ W 343 47 8 19 81348 QQ W 343 5 8 3 81348 QQ W 343 70 8 11 81348 QQ W 343 8 8 7 81348 QQ W 343 80 8 10 81348 QQ W 343 90 8 12 0084 00 9 PART NUMBER STOCK NUMBER FIG 14726 5053605 5940 01 141 2881 8 14726 5053635 5940 01 169 6391 8 OGRFO WA WLC3840 20 74410 XA T 653 6 12 74410 XA0403 5325 01 496 0432 12 74410 XA0404 5310 01 500 2707 12 74410 XA0409 2510 01 496 4441 12 74410 0411 2510 01 496 1811 12 1BZD4 XB T 360 5315 01 496 0452 12 74410 XB0360 5510 01 496 1818 12 74410 0418 5310 01 498 1951 12 END OF WORK PACKAGE TM 9 2510 247 13 amp P CROSS REFERENCE INDEXES WORK PACKAGE PART NUMBER INDEX 0084 00 10 0084 00 ITEM 00 _ _ 9 2510 247 13 amp P 0085 00 COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS SECTION 1 INTRODUCTION 1 SCOPE This work package lists Components of End and Basic Issue Items for the 250M Fifth Wheel Towing Device FWTD to help you inventory items required for safe and efficient operation 2 GENERAL The COEI and
114. 00 0 2 3 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC QTY GROUP 18 BODY CAB HOOD AND HULL GROUP 1802 FENDERS RUNNING BOARDS WITH MOUNTING AND ATTACHING PARTS FIG 14 FENDERS AND MUDFLAPS PAOZZ 5305012726543 81495 1200 59 SCREW CAP HEXAGON H 3 8 DIA X 16 UNC X 1 INCH LONG 40 XDOZZ 18204 1055 1 BRACKET FENDER 8 PAOZZ 5305002907156 96906 MS35311 18 SCREW CAP HEXAGON H 1 4 DIA X 20 UNC X INCHES LONG 25 4 PAOZZ 5305000712513 80204 1821 025 250 SCREW CAP HEXAGON H 1 4 DIA X 20 UNC X 2 1 2 INCHES LONG seen 15 5 22 5310006858308 04773 125 10497 07 WASHER FLAT 1 4 DIA 51 6 22 5310005501130 96906 MS35333 40 WASHER LOCK 1 4 DIA HOLE 40 7 22 5310000115120 24617 115120 NUT PLAIN HEXAGON 1 4 DIA X 20 40 8 22 2540014965769 18204 1063 1 2 9 XDOZZ 18704 034 01559 FENDER mS NT 2 10 XDOZZ 18204 1023 1 BRACKET ELECTRIC MT LEFT SIDE 1 11 XDOZZ 1BZD4 1024 1 BRACKET ELECTRIC MT RIGHT SIDE 1 END OF FIGURE 0082 00 TM 9 2510 247 13 amp P Figure 15 Tool Box 0 2 3 4 ITEM SMR NO CODE NSN CAGEC 1 PAOZZ 2540014966004 1 2 4 2 MOOZZ 99806 3 MOOZZ 39428 4 22 5305001090282 12020 5 22 5305010782010 82366 6 PAOZZ 2590014965997 1BZD4 7 PAOZZ 53100
115. 00 177 7033 REMOVAL NOTE Removal and installation steps may be adjusted to accommodate the required maintenance task 1 Remove screw 1 lockwasher 2 and flatwasher 3 from mounting bracket 4 and remove mounting bracket 4 from transport leg bar 5 Repeat step 1 for remaining mounting bracket Remove transport leg assembly from fifth wheel towing device Remove ball knob 6 from handle 7 5 Remove screw 8 and spring pin 9 and remove handle 7 from transport leg bar 5 Discard spring pin 6 Remove spring pin 10 and flatwasher 11 from retaining pin 12 Discard spring pin 7 Remove retaining pin 12 from leg frame 13 and support foot 14 Remove support foot 14 from leg frame 13 Figure 127 Transport Leg Assembly 0075 00 1 TM 9 2510 247 13 amp P 0075 00 REMOVAL Continued 8 Repeat steps 6 and 7 for remaining support foot 9 Remove nut 15 from ball end bolt 16 Discard nut 10 Remove spring pin 17 and flat washer 18 from retaining pin 19 Discard spring pin 11 Remove leg frame 13 from center link 20 and frame 12 Repeat steps 10 and 11 for remaining leg frame 13 Remove locknut 21 from ball end bolt 22 Discard locknut 14 Remove center link 20 from transport leg bar 5 15 Repeat steps 13 and 14 for remaining center link 16 Remove 4 5 inch 114 3mm screw 23 and 3 inch 76 2 mm screw 24 from center link 20 Remove center lin
116. 0107 24 17 6240 01 502 2421 6 4 5310 01 500 2707 12 2 6240 01 502 2530 5 5 5975 01 497 0117 8 62 6625 01 502 2946 2 14 3130 01 497 0388 19 16 5340 01 502 3308 18 5 5945 01 497 0549 3 4 5340 01 502 3323 19 5 4730 01 497 6338 21 6 6220 01 502 7230 6 3 5315 01 497 9960 11 6 5120 01 507 1183 12 6 5315 01 133 4382 13 8 4730 01 502 7273 21 9 5340 01 496 4081 29 10 0083 00 4 TM 9 2510 247 13 amp P 0084 00 CROSS REFERENCE INDEXES WORK PACKAGE PART NUMBER INDEX CAGEC PART NUMBER STOCK NUMBER FIG ITEM 1BZD4 00775 5340 01 496 2171 7 6 1BZD4 00870 9 6 1BZD4 01109 4720 01 496 1588 24 7 1BZD4 01110 4720 01 496 3775 24 5 1BZD4 01111 4720 01 496 4523 24 6 1BZD4 01112 4720 01 496 4550 24 8 1BZD4 01114 4720 01 497 0042 24 9 1BZD4 01115 4720 01 496 6446 24 11 1BZD4 01116 4720 01 496 6429 24 13 1BZD4 01117 4720 01 496 6337 24 12 1BZD4 01118 4720 01 496 4647 24 10 1BZD4 01119 4720 01 496 6048 24 16 1BZD4 01120 4720 01 497 0107 24 17 1BZD4 01121 4720 01 496 6001 24 14 1BZD4 01123 4720 01 496 6067 24 4 1BZD4 01124 4720 01 496 4914 24 2 1BZD4 01125 4720 01 496 5327 24 3 1BZD4 01126 4720 01 496 6037 24 1 1BZD4 02000 4730 01 502 7273 21 9 1BZD4 30 9 1BZD4 02040 3040 01 495 9856 27 6 1BZD4 02055 3040 01 495 2850 28 6 1BZD4 02065 3040 01 495 2848 29 2 1BZD4 02145 2940 01 497 0073 25 4 1BZD4 02146 2940 01 497 0077 25 5 1BZD4 02147 2940 01 497 0092 25 6 1BZD4 02148 5331 01 496 5156 25 7 1BZD4 02240 5315 01 496 0426 12 7 1BZD4 02505 4730 01 496 3695 23 4
117. 042 00 2 TM 9 2510 247 13 amp P 0043 00 12 24 VOLT JUNCTION BOX REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in coupling Washer lock 8 MS35333 40 configuration WP 0002 Tag marker item 15 WP 0085 Disconnect batteries WP 0050 Wire tie item 18 WP 0085 WP 0041 24 volt receptacle removed 12 volt receptacle removed WP 0042 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General Remove all power to towing device prior to NSN 5180 00 177 7033 making any repairs on electrical system REMOVAL WARNING Remove all power to fifth wheel towing device prior to making any repairs on the electrical system Failure to do so may result in serious injury or death 1 Disconnect five wires 1 from terminals 2 2 Remove five wires 1 four straight adapter assemblies 3 and one bushing assembly 4 from junction box 5 3 From underneath fender remove four nuts 6 and lockwashers 7 Discard lockwashers 4 Remove junction box 5 from fender 5 From inside junction box 5 remove four nuts 8 and lockwashers 9 Discard lockwashers 6 Remove threaded bolts 10 Figure 77 Junction Box Assembly 0043 00 1 9 2510 247 13 amp P 0043 00 INSTALLATION 1 Position threaded bolts 10 on junction box 5 and secure with four new lockwashers 9 and nuts 8 2 Position junction
118. 05501130 96906 8 22 5310000131245 21450 9 2510 247 13 amp P 5 PART NUMBER 1095 1 M200SER 8 31 93695K 13 1726 1610 530 50031 1059 1 MS35333 40 131245 0082 00 6 7 DESCRIPTION AND USABLE ON CODES UOC QTY GROUP 1808 STOWAGE RACKS BOXES STRAPS CARRYING CASES CABLE REELS HOSE REELS ETC FIG 15 rOOL BOX BOX ACCESSORIES STO PLASTIC STRIP MAKE FROM PLASTIC STRIP P N M200SERIES1X1 8 31 INCHES LONG crit tene WEATHER STRIP MAKE FROM WEATHER STRIP P N 93695 62 13 INCHES LONG SCREW MACHINE 1 4 DIA X 20 UNC X 3 4 INCHES SCREW MACHINE 1 4 DIA X 20 UNC X 1 INCH ON Gino nas WASHER LOCK 1 4 DIA NUT SELF LOCKING HE 1 4 DIA X 20 xcci desit a tenu b a END OF FIGURE TM 9 2510 247 13 amp P Figure 16 Mast Frame Assembly 0082 00 1 ITEM SMR NO CODE NSN 1 PAOZZ 5305009835346 2 PAOZZ 5340014964081 3 PAOZZ 5315014962280 4 XDOZZ 5 XDOZZ 6 7 PAOZZ 5305012726543 8 PAOZZ 9 PACZZ 5305007813927 10 PAOZZ 5315014960454 11 PAOZZ 5310000506646 12 XDOZZ 13 PAOZZ 5315014958282 14 XDOZZ 4 96906 18204 18204 18204 18204 18204 81495 18204 80204 18204 96906 2 18204 2 TM 9 2510 247 13 amp P 5 PART NUMBER MS16997 78 02440 1038 1 1062 1 1051 1 1088 1 120
119. 057 00 INSTALLATION OF PRIMARY MOTOR 1 2 Position primary motor 3 on bracket 9 and tighten two screws 10 Install two screws 6 new lockwashers 7 and flatwasher 8 onto bracket 9 and primary motor 3 Connect two straight adapters 5 Install hose onto elbow 4 on primary motor 3 Install solenoid to motor wire 2 onto primary motor 3 Tighten two mounting bolts 1 INSTALLATION OF ISOLATED MOTOR Slide primary and isolated motors into position and tighten two screws 20 Install two screws 16 new lockwashers 17 and flatwashers 18 onto bracket 19 and isolated motor 11 Connect two straight adapters 5 Install hose 14 onto elbow 15 on isolated motor 11 Connect hose onto elbow 4 on isolated motor 11 Install solenoid to motor wire 12 and ground wire 13 onto isolated motor 11 Tighten two mounting bolts 1 on primary motor 3 and two mounting bolts 1 on isolated motor 11 0057 00 4 9 2510 247 13 amp P 0057 00 INSTALLATION ISOLATED MOTOR Continued Figure 105 Hydraulic Motor Assembly Follow on Tasks Connect batteries WP 0050 Test motor assembly connections for leaks WP 0056 00 5 END OF WORK PACKAGE 0057 00 5 9 2510 247 13 amp P 0058 00 HYDRAULIC SAFETY VALVE REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Hydraulic pressure relieved Towing devi
120. 1 END OF WORK PACKAGE 0027 00 6 9 2510 247 13 amp P 0028 00 UNIT TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION HYDRAULIC SYSTEM 1 HYDRAULIC FUNCTIONS SLOW OR INOPERATIVE Step 1 Is there minimum12VDC on batteries If no go to step 2 If yes go to step 3 Step 2 Is NATO slave cable connected If no install NATO cable in receptacle on prime mover and receptacle on 12 24 volt junction box If yes go to step 3 Step 3 Is pressure gauge reading 300 800 psi when performing MAST RETRACT and BOOM EXTEND functions during folding and unfolding WP 0005land WP 0021 If no adjust flow control valves WP 0003 If yes go to step 4 Step 4 Is the temperature below 0 F 18 C If no purge hydraulic oil WP 0056 00 5 fill with new hydraulic fluid If yes purge hydraulic oil WP 0056 00 5 land fill with 5606 Arctic oil WP 0056 00 5 2 BOOMHYDRAULIC CYLINDER LEAKS Step 1 Is pressure gauge reading 300 800psi when performing MAST RETRACT and BOOM EXTEND functions during folding and unfolding WP 0005 0021 If no adjust flow control valves WP 0003 If yes go to step 2 Step 2 Did adjusting the flow valves stop leak If no replace hydraulic cylinder WP 0064 If yes discontinue with troubleshooting 0028 00 1 TM 9 2510 247 13 amp P 0028 00 UNIT TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION HYDRAULIC SYSTEM
121. 1 Electrical Control een 0044 00 1 Fixed e 0048 00 1 General Hydraulic System 40004000 0056 00 1 Strobe Light EP 0049 00 1 Tow Light Assembly 24 Volt 0047 00 1 laor 0076 00 1 Wiring 0051 00 1 Repair Parts and Special Tools Lists RPSTL 0082 00 1 Explanation 0082 00 1 Explanation of Cross Reference Indexes 0082 00 6 0082 00 7 How to Locate Repair 0082 00 7 Repair Parts EE 0082 00 1 Repair Parts How to Locate 0082 00 7 Replacement Air Brake FINOS i i rtt dte ere be ex 0055 00 3 Air Brake Protection Valve 0054 00 1 Battery Battery 0050 00 1 Boom Extension Cylinder 0066 00 1 0074 00 1 Cam Valve Assembly AN 0062 00 1 Center Mast entres anne ca nnn nennen 0073 00 1 Electrical Control BOX coil aaa 0044 00 1 Fender 0070 00 1 Gladhand Em 0053 00 1 Hydraulic Cylinder Main Fra
122. 1 and back to boom extension clevis 12 Repeat step 8 for remaining frame hook Using remote control or hydraulic valve lever controls BOOM EXTEND to tighten rear safety chains NOTE Remove wheel chocks from towed vehicle and disengage parking brake air line may need to be attached to towed vehicle WP 016 If the vehicle being recovered is not equipped with front towing eyes skip to step 11 Position upper section 4 to towing eye 5 of towed vehicle and secure with hitch pin 6 and spring clip 7 Figure 47 Frame Hooks and Tow Bars 0010 00 4 Change 1 9 2510 247 138 0010 00 TOWED VEHICLE Continued NOTE Iftowed vehicle is not equipped with fronttowing eyes ensure the distance from the front bumper of the towed vehicle to the bumpers on the fifth wheel towing device is approximately 12 in 305 mm and front tires are firmly placed against tire stops Distance can be adjusted by extending or retracting both boom extensions simultaneously 12 INCHES 305 MM Figure 48 Towing Configuration NOTE If U bolts are not present use rubber pads between crossmember and boom 14 Position rubber blocks 16 between towed vehicle U bolts 17 and boom 15 Using remote control or hydraulic valve lever controls BOOM EXTEND to raise boom assembly until blocks touch U bolts Figure 49 Pad Location 0010 00 5 Change 1 TM 9 2510 247 13 amp P 0010 00 CONNECTING TO
123. 1 494 3529 21 10 1BZD4 1087 1 2540 01 494 3530 21 8 1BZD4 1088 1 17 6 1BZD4 1089 1 18 3 1BZD4 1090 1 16 1 1BZD4 1091 1 5305 01 495 8137 29 7 1BZD4 1092 1 5935 01 494 3538 1 6 1BZD4 1095 1 2540 01 496 6004 15 1 1BZD4 1099 1 5340 01 496 4055 12 5 27192 11 1625 26 7 83298 1100363 2 5940 00 142 2212 8 1 1BZD4 1102 1 9 11 1BZD4 1103 1 5305 01 495 8188 20 2 1BZD4 1104 1 5340 01 496 1906 23 18 1BZD4 1105 1 5315 01 495 8223 23 15 1BZD4 1106 1 5340 01 495 8298 23 16 1BZD4 1107 1 5315 01 495 8164 23 17 1BZD4 1108 1 5340 01 496 1897 23 19 1BZD4 1127 1 5120 01 498 4965 7 11 1BZD4 1137 1 29 3 11139 114020 90 5310 01 086 7725 4 7 11139 114021 5310 01 081 0798 4 8 24617 115120 5310 00 011 5120 1 5 24617 2 9 24617 9 9 0084 00 3 9 2510 247 13 amp P 0084 00 CROSS REFERENCE INDEXES WORK PACKAGE PART NUMBER INDEX CAGEC PART NUMBER STOCK NUMBER FIG ITEM 24617 14 7 19207 11639519 2 5331 00 462 0907 4 13 19207 11639522 6220 01 163 4900 4 17 5A910 11639537 5342 01 355 8732 4 12 19207 11639538 1 6220 01 210 3225 4 11 30780 12 F50X S 4730 01 457 0813 25 3 81343 12 12 12 140424C 4730 00 757 2910 23 7 30780 12 3 4F50G S 4730 00 407 0509 23 6 81495 1200 59 5305 01 272 6543 6 7 81495 8 14 81495 14 1 81495 17 7 81495 19 19 81495 20 4 81495 21 1 19200 12279371 1 5310 01 073 9803 8 15 19200 19 17 19200 21 12 19207 12360850 1 6220 01 284 2709 4 19 19207 12360850 2 6220 01 387 4250 4 20 19207 12387272 45 5310 01 378 2903 23 13 04773 125 10497 07
124. 13 amp P 0021 00 PREPARE FOR SHIPPING STORAGE Continued 11 12 13 14 Open bottom pressure relief valve by turning breather switch inline with fitting Remove both mast clevises from unit Using valve control levers MAST EXTEND to line up arrows 3 and 4 and insert pivot pin 5 Do not insert spring clips Using valve control levers MAST RETRACT to fold main frame assembly over onto mast Continue mast retract until pivot pin loosens Remove pivot pin Using valve control levers MAST EXTEND to center main frame over booms and re install both mast clevises to unit Using valve control levers RETRACT LEFT IN and RETRACT RIGHT IN fully retract boom extensions Switch electric control box to OFF Ensure electric control box tool boxes and 12 24 volt junction box are secured with locks Towing device can now be transported by forklift Figure 69 Pin Alignment END OF WORK PACKAGE 0021 00 3 TM 9 2510 247 13 amp P 0022 00 OPERATION UNDER UNUSUAL CONDITIONS GENERAL 1 This section contains special instructions for operating and servicing the towing device under unusual conditions 2 addition to performing all the usual PMCS procedures special care must be taken in regard to cleaning and lubrication when extremes in temperature humidity and terrain conditions are present or anticipated Proper cleaning lubrication storage and handling ensures proper operation and function and guar
125. 1BZD4 02540 5315 01 498 4029 13 11 1BZD4 02545 5315 01 497 9960 11 6 1BZD4 02560 2540 01 501 5365 11 11 1BZD4 02650 5340 01 502 3323 19 5 1BZD4 02765 5930 01 502 1048 2 12 1BZD4 02795 6110 01 499 5311 2 2 1BZD4 02840 4820 01 502 1995 22 5 1BZD4 02845 4820 01 502 2001 21 4 1BZD4 02855 4820 01 502 2006 22 6 1BZD4 02870 4820 01 502 2946 2 14 71468 031 0560 161 5935 01 148 4523 2 19 1BZD4 034 01559 14 9 30780 0507 12 12 4730 01 326 3049 23 5 30780 1 2 MMS S 4730 01 103 6840 27 7 30780 28 5 81343 10 10 0703206 4730 00 385 8795 23 3 59257 10 85 6 4730 00 489 8198 21 7 1BZD4 1007 1 5340 01 496 4081 16 2 1BZD4 17 2 0084 00 1 9 2510 247 13 amp P 0084 00 CROSS REFERENCE INDEXES WORK PACKAGE PART NUMBER INDEX CAGEC PART NUMBER STOCK NUMBER FIG ITEM 1BZD4 5340 01 496 4081 18 6 1BZD4 5340 01 496 4081 29 10 1BZD4 1010 1 5315 01 496 2435 29 13 1BZD4 1013 1 3 3 1BZD4 1014 1 11 2 1BZD4 1015 1 11 1 1BZD4 1020 1 11 9 1BZD4 1022 1 2 1 1BZD4 1023 1 14 10 1BZD4 1024 1 14 11 1BZD4 1025 1 4820 01 495 8070 26 2 1BZD4 1026 1 9 7 1BZD4 1027 1 10 4 1BZD4 1028 1 3040 01 495 7628 19 9 1BZD4 1029 1 3040 01 495 7880 19 6 1BZD4 1030 1 11 5 1BZD4 1031 1 5315 01 496 2299 19 3 1BZD4 1032 1 5315 01 496 2317 19 3 1BZD4 1033 1 5315 01 496 2436 28 1 1BZD4 1034 1 5315 01 496 3057 28 8 1BZD4 1035 1 5315 01 496 3062 27 10 1BZD4 1036 1 5315 01 496 2322 27 3 1BZD4 1037 1 5315 01 495 8282 17 13 1BZD4 1038 1 5315 01 496 2280 17 3 1BZD4 1039 1 6 8 1BZD4 10
126. 2 Change 1 TM 9 2510 247 13 amp P 0091 00 TOWBAR ASSEMBLY POSITIONING When using towbar assemblies for loading the towed vehicle refer to the diagram below for proper towbar pin size and location TOWED VEHICLE PIN SIZE LOCATION M818 1 1 2 inch 1 M911 Truck Prime Mover 8X6 1 1 2 inch 1 M915 Series Truck Tractor Line Haul 6X4 1 1 4 inch 1 M916 Truck Light Equipment Transporter LET 6X6 1 1 2 inch 4 M920 1 1 2 inch 1 M939 Series M931 amp M932 Models 1 inch 2 M983 HEMTT 1 1 4 inch 3 M1088 FMTV Series 1 1 4 inch 3 M1074 1075 PLS 1 1 2 inch 1 M1070 HETS 1 1 2 inch 1 NOTE The towbar assemblies are built with the top and bottom pieces offset so they can be rotated to match the spacing between the front towing eyes END OF WORK PACKAGE 0091 00 3 Change 1 TM 9 2510 247 13 amp P INDEX Subject WP Sequence No Page No A Additional Authorization nnn 0086 00 1 Adhesives Application e 0038 00 5 Adjustable Fittings Installation 0056 00 4 Administrative Storage Gare of Equipment in ciar aan a 0078 00 4 BID 0078 00 1 Preparation of Equipment 0078 00 1 Removal of Equipment 0078 00 5 Air Brake Fittings Replacement and Repair 0055 00 3 Air Brake Protection Valve Replacement 0054 00 1 Air Brake SYSIOM 2 50 0029 0
127. 228623 52412 530 50031 533 25NLB 572929 586049C1 5913K44 6 6 130239B 6007 1 69915K51 69915K53 TM 9 2510 247 13 amp P STOCK NUMBER 5330 00 090 2128 5305 01 431 5149 4030 00 102 9687 5930 00 008 0514 4730 01 106 1757 5305 01 163 8191 5310 00 775 5139 5310 01 109 5292 5305 01 061 9674 2530 01 095 8752 4730 01 050 5756 5940 00 042 6317 5310 01 100 5145 4730 01 066 3363 4720 01 289 8293 4720 01 347 7388 4730 00 277 7331 4820 01 494 6076 5305 00 282 9607 5970 01 175 2052 4730 00 244 9848 5940 01 258 2108 5305 01 078 2010 5935 01 496 8429 5999 00 057 2929 4730 01 065 1817 3130 01 497 0388 4730 00 278 4822 5975 01 497 0117 4730 01 481 8114 4730 01 481 8114 0084 00 5 10 00000000000 ha 00 A 0084 00 ITEM 9 2510 247 13 amp P 0084 00 CROSS REFERENCE INDEXES WORK PACKAGE PART NUMBER INDEX CAGEC PART NUMBER STOCK NUMBER FIG ITEM 39428 69915K55 5975 01 481 6824 1 8 39428 2 15 39428 7088K11 6150 01 497 6831 8 63 19207 7338409 2530 00 270 3878 10 10 19207 7366032 4010 00 551 9921 10 13 19207 7390150 4730 00 200 0257 9 4 19207 7974634 5935 00 941 5436 2 16 98441 8 CTXS S 4730 00 185 6837 21 2 98441 8 1 2F50G S 4730 01 126 9758 27 5 98441 28 4 81343 8 6 120102BA 4730 00 142 3076 9 8 81343 8 8 070122C 4730 00 435 8015 29 1 81343 8 8 1401375 4730 01 125 5179 22 3 81343 8 8 140230CA 4730 00 359 4717 27 2 81343 8 8 140237C 4730 00 229 3402 22 4
128. 247 13 amp P HAZARDOUS MATERIALS WARNINGS ICONS BIOLOGICAL abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health CHEMICAL drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue CRYOGENIC hand in block of ice shows that the material is extremely cold and can injure human skin or tissue EXPLOSION rapidly expanding symbol shows that the material may explode if subjected to high temperatures sources of ignition or high pressure EYE PROTECTION person with goggles shows that the material will injure the eyes FIRE flame shows that a material may ignite and cause burns 9 2510 247 13 amp P HAZARDOUS MATERIALS WARNINGS ICONS Continued POISON skull and crossbones shows that a material is poisonous or is a danger to life RADIATION three circular wedges shows that the material emits radioactive energy and can injure human tissue VAPOR human figure in a cloud shows that material vapors present a danger to life or health 9 2510 247 13 WARNING SUMMARY WARNING GENERAL After washing the fifth wheel towing device ensure appropriate breather valve is opened prior to operation of the fifth wheel towing device Failure to comply may result in injury or death to personnel Improper cleaning methods and use of unauthorized cleaning liquids or solvents can cause injury or death to perso
129. 250M Fifth Wheel Towing Device FWTD is first received determine whether it has been properly prepared for service and is in condition to perform its mission Follow the service before operation instructions in Service Before Operation SERVICE BEFORE OPERATION 1 Upon receipt of a new used or reconditioned fifth wheel towing device the receiving organization must see if it has been properly prepared for service and in good condition Inspect all assemblies subassemblies and accessories to insure they are in proper working order Secure clean correctly adjust and lubricate as needed 2 Remove all packing and shipping material such as tape tiedowns protective covers and shipping seals 3 Remove all Basic Issue Item BII Additional Authorization List AAL and Component of End Item COEI equipment and store properly 4 lf batteries have not been serviced refer to TM 9 6140 200 14 5 Service the vehicle in accordance with TM and Unit PMCS 6 Referto TM and perform functional checks of all major vehicle systems END OF WORK PACKAGE 0036 00 1 9 2510 247 13 amp P 0037 00 UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES 5 GENERAL To ensure that the towing device is ready for operation at all times it must be lubricated and inspected on a regular basis so that defects may be found before they result in serious damage equipment failure or injury to personnel Table 3 contains systematic instructio
130. 2510 247 13 amp P Figure 8 3 of 9 Chassis Wiring Harness TM 9 2510 247 13 amp P 0082 00 Figure 8 4 of 9 Chassis Wiring Harness 9 2510 247 13 amp P e A o eu Figure 8 5 of 9 Chassis Wiring Harness Ls Jam 0082 00 9 2510 247 13 amp P 0082 00 E E EA _ 5 zen Qa 2 Cis Hl Eme _ 224 SE gt e orgs b Figure 8 6 of 9 Chassis Wiring Harness TM 9 2510 247 13 amp P 0082 00 TO WORK LIGHT TO STROBE LIGHT TO GROUND amp p iy af 49 Y TA e A IA ee Figure 8 7 of 9 Wiring Harness 9 2510 247 13 amp P 0082 00 Fon Aor mn p Tm AO 57 Hy MATA gt OR LE Al SOCK rta 8 Ly Figure 8 8 of 9 Wiring Harness 0082 00 TM 9 2510 247 13 amp P Figure 8 9 of 9 Wiring Harness 1 2 ITEM SMR NO CODE 1 PAOZZ 2 MOOZZ 3 MOOZZ 4 0077 5 MOOZZ 6 PAOZZ 7 MOOZZ 8 MOOZZ 9 0022 10 24 11 MOOZZ 12 24 13 MOOZZ 14 77 15 77 16 PAOZZ 17 MOOZZ 18 MOOCZZ 3 NSN 5940001422212 5975013148107 5305012726543 5310010739803 5340006803261 4 83298 81349 81348 81348 81348 06721 81348 1BZD4 81348 81348 81348 81348 81349 81495 19200 96906 81348 81348 9 2510 247 13 amp P
131. 287 7750A 0085 00 3 9 2510 247 13 amp P 0085 00 SECTION 11 BASIC ISSUE ITEMS Continued 2 3 National Description Stock Number Part Number 3390 01 213 1746 LOAD BINDER 27410 R 45 4030 01 502 1985 18204 1131 1 5340 01 496 2171 BELTING 3 PLY 1BZD4 00775 5315 01 502 2510 CLEVIS ASSEMBLY 18204 1136 1 5340 01 502 3320 CLEVIS AND U BOLT 18204 1079 2 0085 00 4 TM 9 2510 247 13 amp P SECTION Ill BASIC ISSUE ITEMS Continued 2 National Stock Number 4720 01 502 2108 4720 01 502 2123 5935 01 502 2014 6150 01 502 2043 3 Description CAGEC Part Number HOSE ASSEMBLY NONMETALLIC 1 204 1133 1 HOSE ASSEMBLY NONMETALLIC 1BZD4 1132 1 PLUG DUMMY 1BZD4 1135 1 PULLER MECHANICAL 1BZD4 1018 1 CABLE ASSEMBLY POWER 18204 1094 1 0085 00 5 17 0085 00 9 2510 247 13 amp P 0085 00 SECTION Ill BASIC ISSUE ITEMS Continued 20 22 2 3 National Description Stock Number Part Number 2510 01 496 4441 KINGPIN 3 1 2 INCHES 74410 XA0409 2510 01 496 1811 KINGPIN 2 INCHES 74410 XA0411 WRENCH SPANNER 18204 1081 1 0085 00 6 9 2510 247 13 SECTION Ill BASIC ISSUE ITEMS Continued 1 2 3 4 llus National Description Usable Number Stock Number CAGEC Part Number On Code 6220 01 217 8316 LIGHT BAR 24 VOLT 45152 1462290U CABLE ASSEMBLY P
132. 2VDC on batteries If no go to step 2 If yes go to step 3 Step 2 Is NATO slave cable connected If no install NATO cable in receptacle on prime mover and receptacle on 12 24 volt junction box If yes go to step 3 Step 3 Are there any broken or frayed wires If no go to step 4 If yes repair or replace wires as necessary WP 0051 Step 4 Are all bulbs working properly If no replace bulbs WP 0047 WP 0048 or WP 0049 If yes replace light nn WP 0047 WP 0048 of WP WP 0049 6 WORK LIGHT INOPERABLE Step 1 Is WORK LIGHT switch ON If no put WORKLIGHT switch in ON position If yes go to step 2 Step 2 Is there minimum12VDC on batteries If no go to step 3 If yes go to step 4 Step 3 Is NATO slave cable connected If no install NATO cable in receptacle on prime mover and receptacle on 12 24 volt junction box If yes go to step 4 0027 00 4 9 2510 247 13 amp P 0027 00 UNIT TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL SYSTEM Continued Step 3 Are there any broken or frayed wires If no go to step 5 If yes repair or replace wires as necessary WP 0051 Step 4 Is the bulb working properly If no replace bulb WP 0048 If yes replace worklight assembly WP 0048 7 LIGHT BAR ASSEMBLY INOPERABLE Step 1 Is light bar cable properly installed in receptacle on prime mover If no install light bar cable in recep
133. 3 NSN 6220012178316 5340012273483 5305007578122 5305002693217 5340007255280 5340012722729 5310010867725 5310010810798 5310011095292 6220010934439 6220012103225 5342013558732 5331004620907 6240000193093 5935005729180 5310008338567 6220011634900 6240014473779 6220012842709 6220013874250 5305009409445 5340012279471 5310000806004 5310010822058 5310007755139 5305009846212 5340006005937 5340012276808 5305007829489 5310002090786 5305010619674 5310002453424 5995012225497 5940003996676 5970008338562 5935008338561 4 45152 45152 96906 80205 96906 45152 11139 11139 45152 96906 19207 5A910 19207 58536 19207 19207 19207 81348 19207 19207 80205 45152 96906 11939 35510 96906 70485 45152 80204 96906 45152 96906 45152 19207 19207 19207 81851 81851 TM 9 2510 247 13 amp P 5 NUMBER 1462290U 1462270 MS51851 64 MS90725 67 MS21333 125 1462260W 114020 90 114021 2447HX MS52125 2 11639538 1 11639537 11639519 2 A52463 1 09 8338566 8338567 11639522 A A 52463 B10 12360850 1 12360850 2 NS51975 23 1462340 MS27183 14 93602345 2434 MS35206 265 832 1462280 B1821BHO38C200N MS35335 33 2467 H MS17829 5C 1462310U 8338564 8338562 8338561 50010013035 16 50010013035 4 0082 00 6 7 DESCRIPTION AND USABLE CODES UOC GROUP 0609 LIGHTS 4 24 VOLT TOW LIGHT ASSEMBLY TOWLIGHT ASSEMBLY
134. 3 Remove o ring 3 from filter 2 4 Discard o ring and filter FILTER INSTALLATION 1 Install new o ring 3 onto new filter 2 2 Install filter 2 into assembly 3 Install protective cover 1 Figure 111 Oil Filter Assembly Follow on Tasks Charge hydraulic system WP 0056 0015 e Check oil level see illustration WP 0056 0015 END OF WORK PACKAGE 0061 00 3 TM 9 2510 247 13 amp P 0062 00 CAM VALVE ASSEMBLY REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in coupling Nut self locking 4 90045A453 configuration WP 0002 Hydraulic pressure relieved WP 0056 00 5 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General None NSN 5180 00 177 7033 REMOVAL Ed WARNING Spilled hydraulic oil is very slippery Be careful when entering or working in area Wipe up any spilled oil immediately Failure to comply may result in severe injury or death to personnel NOTE Hydraulic hose must be capped and or plugged when disconnected to prevent contamination Tag all hoses prior to disconnecting 0062 00 1 9 2510 247 13 amp P 0062 00 REMOVAL Continued 1 Remove hydraulic hose 1 from elbow 2 2 Remove hydraulic hose 3 from straight adapter 4 3 While relieving tension on spring 9 remove four screws 5 washers 6 and locknuts 7 from cam valve 8 Discard locknuts 4 Re
135. 3 amp P 0009 00 PREPARE TOW ASSEMBLIES Continued 10 N WARNING When tilting towbar assembly upper section is not secure and may fall out and cause personal injury or death Loosen T bolts 4 and 5 Tilt lower section of towbar assembly 6 away from storage bracket and remove upper section 3 Set aside for future use Loosen T bolts 7 and 8 and remove lower section 6 Set aside for future use Loosen all four T bolts on inner towbar assembly and slide to outer position Tighten T bolts 7 and 8 Repeat steps 2 through 4 for remaining towbar assembly NOTE Both the upper and lower sections are offset to allow for variations in the distance between the towing eyes on the towed vehicle Refer to WP 0089 for correct pin size and pin location Position lower section 6 onto boom and line up center hole 9 with the second hole from mast Do not tighten lower section T bolts Install upper section 3 into lower section 6 Repeat steps 7 and 8 for remaining tow bar assembly Estimate position of tire stop assembly 10 so front tires of towed vehicle meet the tire stop assembly and the tow bar assemblies are not moved beyond the fourth hole 11 from the mast 2 Figure 42 Tow Bar Assembly Preparation END OF WORK PACKAGE 0009 00 2 TM 9 2510 247 13 amp P 0010 00 TOWED VEHICLE Ifthe upper receiver connection holes too high to be conn
136. 310011005145 32770 403 09081 01 NUT PLAIN ASSEMBLED 6 32 DIA X 32 UNC nens 19 PAOZZ 5935011484523 71468 031 0560 161 SOCKET CRIMP END OF FIGURE TM 9 2510 247 13 amp P 0082 00 Figure 3 Solenoid Assembly 0 2 ITEM SMR NO CODE 1 PAOZZ 2 PAOZZ 3 XDOZZ 4 22 3 NSN 5310002747758 5310002090971 5945014970549 4 96906 80204 1BZD4 1BZD4 9 2510 247 13 amp P 0082 00 5 PART NUMBER 535649 286 ASAB27 1 1950 HEAVYSERIES 1013 1 1064 1 6 7 DESCRIPTION AND USABLE ON CODES UOC GROUP 0608 MISCELLANEOUS ITEMS FIG 3 SOLENOID ASSEMBLY NUT PLAIN HEXAGON 10 32 DIA X 32 UNC 3 WASHER LOCK 10 32 DIA HOLE 3 BRACKET MOUNTING 1 eene 2 SOLENOID ELECTRICAL 2 END OF FIGURE TM 9 2510 247 13 amp P 0082 00 1 TE 0 33 34 thru 411 42 43 thru 501 Figure 4 24 Towlight Assembly 1 2 ITEM SMR NO CODE 1 PAOOO 2 PGOZZ 3 PAOZZ 4 PAOZZ 5 PAOZZ 6 PFOZZ 7 77 8 PAOZZ 9 PAOZZ 10 11 PAOZZ 12 PAOZZ 13 PAOZZ 14 PAOZZ 15 PAOZZ 16 22 17 PAOZZ 18 PAOZZ 19 PAOZZ 20 PAOZZ 21 PAOZZ 22 PGOZZ 23 22 24 22 25 22 26 PAOZZ 27 22 28 PAOZZ 29 22 30 PAOZZ 31 PAOZZ 32 22 33 PAOOO 34 PAOZZ 35 PAOZZ 36 77 37 MOOZZ 38 MOOZZ
137. 4 11 Install compression fittings 2 on tee fitting 3 12 Install hydraulic motor hose 1 on compression fitting 2 Figure 115 Hydraulic Reservoir Fittings Assembly Follow on Tasks Fill hydraulic reservoir WP 0056 00 5 Charge hydraulic system WP 0056 0015 Test hydraulic system for leaks WP 0056 0045 END OF WORK PACKAGE 0065 00 4 9 2510 247 13 amp P 0066 00 BOOM EXTENSION CYLINDER REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Hydraulic pressure relieved WP 0056 00 5 Pin roll 4 982964255 Fifth Wheel Towing Device in storage Sealant item 11 WP 0085 configuration 0002 Personnel Required 2 Tools Test Equipment Tool Kit Mechanics General General Safety Instructions NSN 5180 00 177 7033 None Cylinder Alignment Tool supplied with cylinder REMOVAL 1 BOOM RETRACT to raise boom to approximately 45 angle to allow for removal of slip pad NOTE Use adequate support to prevent accidental collapse of boom Place rubber blocks under mast for support Mark hoses prior to removal Hydraulic hoses must be capped and or plugged when disconnected to avoid contamination Oylinder alignment tool will aid in removal of retaining pin 2 Remove four screws 1 from bottom of boom and remove slip pad 2 3 BOOM EXTEND to lower boom to ground Figure 116 Boom Extension Cylinder Assembly 0066 00 1 9 2510 247 13 amp P 0066 00
138. 4 6220 01 495 9757 5 1 5975 01 314 8107 8 6 3040 01 495 9856 27 6 4730 01 315 8250 30 10 5315 01 496 0426 12 7 4730 01 326 3049 23 5 5325 01 496 0432 12 4 4730 01 334 5719 22 1 5360 01 496 0434 13 5 4720 01 347 7388 BULK 28 5360 01 496 0436 26 3 5342 01 355 8732 4 12 5315 01 496 0452 12 1 5310 01 378 2903 23 13 5315 01 496 0453 13 4 6145 01 381 2385 BULK 14 5315 01 496 0454 17 10 6220 01 387 4250 4 20 4720 01 496 1588 24 7 5310 01 389 4257 6 6 2510 01 496 1811 12 8 5310 01 389 4257 19 18 5510 01 496 1818 12 9 5310 01 389 4257 21 11 5340 01 496 1897 23 19 4730 01 394 8793 25 8 5340 01 496 1903 13 1 5305 01 431 5149 18 2 5340 01 496 1906 23 18 5355 01 441 2838 19 12 5340 01 496 2166 23 1 4730 01 441 9417 21 3 5340 01 496 2171 7 6 6240 01 447 3779 4 1 8 5315 01 496 2280 17 3 6145 01 456 0311 BULK 13 5315 01 496 2299 19 3 4730 01 457 0813 25 3 5315 01 496 2317 19 3 6140 01 457 4260 7 5 5315 01 496 2322 27 3 5640 01 462 4252 BULK 27 5315 01 496 2435 29 13 5310 01 467 4644 26 5 5315 01 496 2436 28 1 9390 01 469 7255 BULK 2 5315 01 496 3057 28 8 5975 01 481 6824 1 8 5315 01 496 3059 29 5 5975 01 481 6824 2 15 5315 01 496 3062 27 10 4730 01 481 8114 1 9 4730 01 496 3143 30 5 4730 01 481 8114 2 3 5930 01 496 3656 2 13 5970 01 481 8421 BULK 5 4730 01 496 3695 23 4 2540 01 494 3529 21 10 4720 01 496 3775 24 5 2540 01 494 3530 21 8 5340 01 496 4055 12 5 5935 01 494 3538 1 6 5340 01 496 4081 16 2 4820 01 494 6076 30 3 5340 01 496 4081 17 2 3040 01 495 2848
139. 40 1 5306 01 495 7002 13 7 1BZD4 1041 1 13 10 1BZD4 1042 1 5306 01 495 6997 11 3 1BZD4 1043 1 5315 01 496 0454 17 10 1BZD4 1044 1 2540 01 497 0751 19 11 1BZD4 1045 1 5340 01 496 4114 19 13 1BZD4 1046 1 19 10 1BZD4 1047 1 19 10 1BZD4 1048 1 7 7 1BZD4 1049 1 7 2 1BZD4 1051 1 17 5 1BZD4 1052 1 13 9 1BZD4 1053 1 13 9 1BZD4 1054 1 5340 01 496 1903 13 1 1BZD4 1055 1 14 2 1BZD4 1056 1 1 10 2 11 1BZD4 1057 1 5315 01 496 0453 13 4 1BZD4 1058 1 5360 01 496 0434 13 5 1BZD4 1059 1 2590 01 496 5997 15 6 1BZD4 1060 1 5340 01 502 3308 18 5 1BZD4 1061 1 17 8 1BZD4 1062 1 17 4 0084 00 2 TM 9 2510 247 13 amp P 0084 00 CROSS REFERENCE INDEXES WORK PACKAGE PART NUMBER INDEX CAGEC PART NUMBER STOCK NUMBER FIG ITEM 1BZD4 27 1 1BZD4 28 2 1BZD4 1063 1 2540 01 496 5769 14 8 1BZD4 1064 1 5945 01 497 0549 3 4 1BZD4 1065 1 5360 01 496 0436 26 3 1BZD4 1067 1 5305 01 495 8170 27 9 1BZD4 1068 1 5310 01 501 9194 7 3 1BZD4 1069 1 5310 01 501 9196 7 4 1BZD4 1070 1 4730 01 496 3143 30 5 1BZD4 1071 1 5930 01 496 3656 2 13 1BZD4 1072 1 4730 01 496 4148 30 7 1BZD4 1073 1 9 3 1BZD4 1074 1 5310 01 498 1892 19 4 1BZD4 29 12 1BZD4 1075 1 5945 01 495 8071 23 11 1BZD4 1076 1 6220 01 495 9757 5 1 1BZD4 1077 1 5340 01 496 4093 18 1 1BZD4 1078 1 6685 01 496 8423 23 9 1BZD4 1079 1 2540 01 496 7132 29 4 1BZD4 1080 1 5315 01 496 3059 29 5 1BZD4 1081 1 5120 01 507 1183 12 6 1BZD4 1082 1 5340 01 496 2166 23 1 1BZD4 1083 1 2 4 1BZD4 1085 1 8 8 1BZD4 1086 1 2540 0
140. 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC GROUP 2407 HYDRAULIC CYLINDERS FIG 28 MASTTO BOOM 1 PAOZZ 5315014962436 1BZD4 1033 1 PIN STRAIGHT HEADLE UPPER 6 75 X 1 50 INCHES ntes 2 2 XDOZZ 1BZD4 1062 1 SCREW SQUARE HEAD 5 16 18NC SQ HD ae 8 3 XDOZZ 2 2001 4 4 PAOZZ 4730011269758 98441 8 1 2F50G S ADAPTER STRAIGHT P 1 5 PAOZZ 4730011036840 30780 1 2 MMS S TEE PIPE ittis eite etes 1 6 PAOZZ 3040014952850 1BZD4 02055 CYLINDER ASSEMBLY A MAST FRAME TO BOOM S 2 7 PAOZZ 4730000513731 01276 2068 8 85 ELBOW PIPE TO 2 8 PAOZZ 5315014963057 1BZD4 1034 1 PIN STRAIGHT HEADLE LOWER 5 00 X 1 50 INCHES etes 2 9 PAOZZ 4730008225609 96906 MS51527A8 ELBOW TUBE TO 1 END OF FIGURE 0082 00 9 2510 247 13 amp P i ff fio 4 jj af Fr ow 27 4 7 d ft Vas 1 g N y SA fe in mi ug ve mt HET e Ye W Je Figure 29 Boom Extensions TM 9 2510 247 13 amp P 0082 00 2 3 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC QTY GROUP 2407 HYDRAULIC CYLINDERS 29 BOOM EXTENSIONS 1 PAOZZ 4730004358015 81343 8 8070122 ADAPTER STRAIGHT TU 4 2 22 3040014952848 1BZD4 02065 CYLINDER ASSEMBLY A es 2 3
141. 506 1 Tools Test Equipment Tool Kit Mechanics General NSN 5180 00 177 7033 REMOVAL CAUTION Failure to cap or plug hose connections to prevent contamination may result in damage to equipment NOTE Air hoses are not ordinarily removed except if they need to be replaced 1 Remove gladhand retaining nut 1 from straight adapter 2 or 45 fitting 3 NOTE Gladhand connections on prime mover side have straight adapters Gladhand connections on towed vehicle side have 45 fittings Perform step 2a for prime mover side and step 2b for towed vehicle side 2a Remove straight adapter 2 from air hose 4 and remove insert 5 Discard insert 2b Remove 45 compression fitting 3 from air hose 4 and remove insert 5 Discard insert NOTE Tag brake hoses and connection points prior to disconnecting Note location of plastic cable ties prior to removal Remove plastic cable ties as required Air hoses are not ordinarily removed except if they need to be replaced 0055 00 1 9 2510 247 13 0055 00 REMOVAL Continued 3 10 Remove screw 6 flatwasher 7 loop clamp 8 spacer 9 loop clamp 8 lockwasher 10 flatwasher 11 and nut 12 from frame Discard lockwasher Remove loop clamps 8 from hoses 4 Remove two hoses 4 from 45 13 Remove insert 5 Discard insert Remove two 45 fittings 13 from reducer 14 Remove two reducers 14 from air brake protection valve 15 Re
142. 6878 1BJE80 J C 580TFF6CF1 16TUJ5 5086 1 16 19 22759 9 16 2 22759 11 16 0 5086 1 10 9 22759 9 14 0 16878 6 C0 12MGF 12 18 0 685 5086 1 12 0 23053 10 002 0 417200 2 M200SERIES1X1 8 93695K62 417202 2 0082 00 6 7 DESCRIPTION AND USABLE CODES UOC QTY GROUP 95 GROUP 9501 BULK MATERIEL FIG BULK ITEMS NOT ILLUSTRATED SLEEVING TEXTILE EL eene V NONMETALLIC CHANNEL eene V INSULATION SLEEVING eene V WIRE ELECTRICAL sesenta V INSULATION SLEEVING eene V V WIRE etre V WIRE ELECTRIGAL sissies V WIRE ELECTRICAL V WIRE ELECTRICAL V WIRE ELECTRICAL V WIRE ELECTRICAL V WIRE ELECTRICAL V WIRE ELECTRICAL V WIRE ELECTRICAL V WIRE ELECTRICAL V WIRE ELECTRICAL V WIRE ELECTRICAL V WIRE ELECTRICAL V WIRE ELECTRICAL V WIRE ELECTRICAL V V WIRE ELECTRICAL assassins V INSULATION SLEEVING V TUBING NONMETALLIC V PLASTIC STRIP PRESS V WEATHERB STRIP tii itt ttt dtes en V HOSE NONMETALLLIC eene V END OF FIGURE TM 9 2510 247 13 amp P 0083 00 CROSS REFERENCE INDEXES WORK PACKAGE NATIONAL STOCK NUMBER INDEX STOCK NUMBER FIG ITEM STOCK NUMBER FIG ITEM 6145 00 003 9527
143. 82 00 85 pgs WP 0083 00 4 pgs WP 0084 00 10 pgs WP 0085 00 8 pgs WP 0086 00 2 pgs WP 0087 00 4 pgs WP 0088 00 1 pg WP 0089 00 6 pgs WP 0090 00 5 pgs WP 0091 00 3 pgs Index 9 pgs Change No Page WP No Change No Zero in this column indicates an original page B Change 1 9 2510 247 13 TECHNICAL MANUAL HEADQUARTERS 9 2510 247 13 DEPARTMENT OF THE ARMY WASHINGTON D C July 1 2004 OPERATOR S UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL WITH REPAIR PARTS AND SPECIAL TOOLS LIST FOR FIFTH WHEEL TOWING DEVICE MODEL 250M NSN 2510 01 458 8253 REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS You can improve this manual 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 2 Recommended Changes to Equipment Technical Publications through the Internet on the Army Electronic Product Support AEPS website The Internet address is http aeps ria army mil 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 email your letter DA Form 2028 o
144. 85 and dry with clean rags item 10 WP 0085 Remove grease and accumulated deposits with a scrub brush item 1 WP 0085 WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury or death to personnel Clear all threaded holes with compressed air to remove dirt and cleaning fluids CAUTION DO NOT wash electrical cable and flexible hoses with dry cleaning solvent or mineral spirits Serious damage or destruction of material will result 3 Electrical Cables and Flexible Hoses Wash electrical cables and flexible hoses with a solution of detergent item 4 WP 0085 and water and wipe dry with a clean rag item 10 WP 0085 4 General Cleaning Covered by Other Manuals Refer to TM 9 247 Materials Used for Cleaning Preserving Abrading and Cementing Ordnance Materiel and Related Materials Including Chemicals PRESERVATION OF PARTS Unpainted metal parts that will not be installed immediately after cleaning should be covered with a thin coat of lubricating oil item 9 WP 0085 PAINTING On painted areas where paint has been removed paint in accordance with procedures outlined in TM 43 0139 and TB 43 209 0038 00 3 TM 9 2510 247 13 amp P 0038 00 INSPECTION INSTRUCTIONS NOTE All damaged areas should be marked for repair or replacement 1 All components a
145. 906 19 14 96906 23 2 96906 29 9 96906 MS17828 4C 5310 00 031 0920 7 10 96906 MS17829 5C 5310 00 245 3424 4 32 96906 MS17830 6C 5310 00 050 6646 17 11 96906 MS21044N8 5310 00 877 5795 19 1 96906 MS21333 125 5340 00 725 5280 4 5 96906 MS21919WH48 5340 00 680 3261 8 16 96906 MS25036 114 5940 00 113 9826 4 41 96906 MS27183 14 5310 00 080 6004 4 23 0084 00 8 9 2510 247 13 amp P 0084 00 CROSS REFERENCE INDEXES WORK PACKAGE PART NUMBER INDEX CAGEC PART NUMBER STOCK NUMBER FIG ITEM 96906 MS27183 48 5310 01 308 8205 26 4 96906 MS27429 2 5940 00 804 9184 8 48 80205 MS35190 269 5305 00 957 6272 4 43 96906 MS35206 224 5305 00 984 4981 6 9 96906 MS35206 234 5305 00 984 6221 2 17 96906 MS35206 265 5305 00 984 6212 4 26 96906 MS35311 18 5305 00 290 7156 14 3 96906 MS35311 38 5305 00 282 9646 22 7 96906 MS35313 44 5305 00 819 5108 23 10 96906 MS35333 40 5310 00 550 1130 1 4 96906 2 8 96906 9 10 96906 14 6 96906 15 7 96906 25 2 96906 MS35335 33 5310 00 209 0786 4 30 96906 MS35338 046 5310 01 389 4257 6 6 96906 19 18 96906 21 11 96906 MS35421 2 6220 00 299 7426 4 44 96906 MS35422 1 6220 00 729 9295 4 46 96906 MS35423 2 6220 00 726 1916 4 42 96906 MS35649 286N 5310 00 274 7758 3 1 96906 MS35690 604 5310 00 655 9544 4 51 96906 MS51468 03 5310 01 183 5514 7 1 96906 MS51500A8 4 4730 00 44 1 8700 26 1 96906 MS51504A8 4 4730 00 844 3308 26 6 96906 MS51527 A10 4730 00 974 7313 20 3 96906 MS51527A8 4730 00 822 5609 28 9 96906 MS51851 64 5305 0
146. ANDRA R RILEY Administrative Assistant to the Secretary of the Army 0511009 DISTRIBUTION To be distributed in accordance with the Initial Distribution Number IDN 256692 requirements for TM 9 2510 247 13 amp P 9 2510 247 138 INSERT LATEST CHANGED PAGES WORK PACKAGES DESTROY SUPERSEDED DATA LIST EFFECTIVE PAGES WORK PACKAGES Original 1 July 2004 Change 1 15 May 2005 TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 35 AND TOTAL NUMBER OF WORK PACKAGES IS 91 CONSISTING OF THE FOLLOWING Page WP No Change No Page WP No Change No Title WP 0029 00 1 pg Warnings WP 0030 00 1 pg i iv Chapter 1 Title page WP 0001 00 3 pgs Chapter 5 Title page WP 0031 00 16 pgs WP 0032 00 1 pg WP 0002 00 8 pgs WP 0033 00 1 pg WP 0003 00 1 pg WP 0034 00 2 pgs Chapter 2 Title page WP 0035 00 1 pg WP 0004 00 4 pgs Chapter 6 Title page WP 0005 00 5 pgs WP 0006 00 3 pgs WP 0007 00 5 pgs WP 0008 00 5 pgs WP 0009 00 2 pgs WP 0010 00 7 pgs WP 0036 00 1 pg 0037 00 5 pgs WP 0038 00 11 pgs 0039 00 7 pgs WP 0040 00 1 WP 0041 00 2 pgs WP 0011 00 1 pg WP 0042 00 2 pgs WP 0012 00 2 pgs 0043 00 2 pgs WP 0013 00 1 pg 0044 00 5 pgs WP 0014 00 2 pgs 0045 00 2 pgs WP 0015 00 2 pgs WP 0046 00 2 pgs WP 0016 00 1 pg 0047 00 7 pgs WP 0017 00 2 pgs W
147. AST BOOM EXTEND EXTEND EXTEND WHT GND BEUBEK GND GRN BLK EXTEND WHITE BLK WHT BLUE BLACK ORANGE BLACK GREEN BLACK BLACK WHITE RED BLACK ORANGE WHITE BLACK RIGHT BLACK RETURN MAST RETRACT GND BOOM WINCH RETRACT IN GND GND RED BLK WHT BLK BLUE UTILITY GND UPDATED 3 5 03 861 72 01 lt 2 6 NL 00 0600 5 00 0600 J39VA9Vd MHOM 40 oinejp H MAST B DRIVER BOOM DRIVER 9 PASSENGER EXTENSION EXTENSION DRIVER PASSENGER he H Pi au mc E fia emos em TEX c Hop TT MAIN CONTROL VALVE TT eooe el UPDATED 3 5 03 Tresewon d 9 L Zvc 0LSc 6 NL 00 0600 TM 9 2510 247 13 amp P 0091 00 AUTHORIZED VEHICLE COMBINATIONS SCOPE This work package lists the authorized towed vehicle combinations for use with the Fifth Wheel Towing Device FWTD and the size and location of the connection holes on the tow bar assembly AUTHORIZED PRIME MOVERS TOWED VEHICLES WARNING Total towed weight towed vehicle and or trailer and payload cannot exceed the figures in the Maximum Allowed Towed Load column in the following chart Failure to follow this warning could result in serious injury or death WARNING M1074 and M1075 PLS Series can only be transported with no payload Failure to
148. BII Lists are divided into the following sections a Section Il Components of End This listing is for informational purposes only and is not authority to requisition replacements These items are part of the end item but are removed and separately packaged for transportation or shipment As part of the end item these items must be with the end item whenever it is issued or transferred between property accounts Illustrations are furnished to assist you in identifying the items b Section Ill Basic Issue Items These are the minimum essential items required to place the towing device in operation to operate it and to perform emergency repairs must be with the towing device during operation and whenever it is transferred between property accounts The illustrations will assist you with hard to identify items This manual is your authority to request requisition replacement based TOE MTOE authorization of end item 3 EXPLANATION OF COLUMNS Below is an explanation of columns found in the tabular listings a Column 1 Illustration Number Number This column indicates the number of the illustration that shows the item b Column 2 National Stock Number Indicates the National Stock Number NSN assigned to the item and will be used for requisitioning purposes Colulmn 3 Description CAGEC and Part Number identifies the Federal item name in all capital letters followed by a minimum descript
149. BULK 19 4730 00 278 4822 30 6 5930 00 008 0514 2 10 5305 00 282 9607 22 8 5970 00 008 3295 BULK 3 5305 00 282 9607 23 12 5310 00 011 5120 1 5 5305 00 282 9646 22 7 5310 00 011 5120 2 9 5305 00 290 7156 14 3 5310 00 011 5120 9 9 6145 00 295 0806 BULK 7 5310 00 011 5120 14 7 6220 00 299 7426 4 44 5310 00 013 1245 15 8 6145 00 343 5767 BULK 9 6240 00 019 0877 4 45 4730 00 359 4717 27 2 6240 00 019 3093 4 14 4730 00 385 8795 23 3 6145 00 023 6778 BULK 4 5940 00 399 6676 4 34 6145 00 023 6923 BULK 22 5340 00 404 4101 9 12 5310 00 031 0920 7 10 5365 00 406 9320 23 14 5940 00 042 6317 8 40 4730 00 407 0509 23 6 6145 00 044 3579 BULK 23 4730 00 435 8015 29 1 5310 00 050 6646 17 11 4730 00 441 8700 26 1 4730 00 051 3731 27 8 2520 00 446 7518 30 1 4730 00 051 3731 28 7 5331 00 462 0907 4 13 5999 00 057 2929 4 50 5310 00 469 9202 19 15 5305 00 071 2511 7 9 5970 00 470 4575 BULK 24 5305 00 071 2513 14 4 4730 00 489 8198 21 7 5305 00 071 2519 9 14 4730 00 534 4140 21 5 5310 00 080 6004 4 23 5310 00 550 1130 1 4 5340 00 081 4718 8 22 5310 00 550 1130 2 8 6145 00 082 5172 BULK 21 5310 00 550 1130 9 10 5330 00 090 2128 10 8 5310 00 550 1130 14 6 4030 00 102 9687 10 12 5310 00 550 1130 15 7 5305 00 109 0282 15 4 5310 00 550 1130 25 2 5940 00 113 8179 8 26 4010 00 551 9921 10 13 5940 00 113 8183 8 57 5935 00 572 9180 4 15 5940 00 113 9826 4 41 5935 00 572 9180 4 48 5940 00 142 2212 8 1 4730 00 595 0083 10 5 4730 00 142 3076 9 8 5340 00 600 5937 4 27 4730 00 185
150. CROSS REFERENCE INDEXES WORK PACKAGE PART NUMBER INDEX PART NUMBER ASAB27 1 1950 HEA VY SERIES B 4411 1821 025 100 1821 025 200 1821 025 250 1821 025 400 1821 038 1500 1821 038 150 1821 038 200 1821 038 350 1821 050 300 205010 B31WN B687R 39B BB 837 06 BH 1 C0 12MGF 12 18 0685 C0 12MGF 76 0530 56 C3609X16 CL 4 PPK 4 1313 101241 101253 FS11P HC 31D 31 J C 580TFF6CF1 16TUJ J C 580TFF6CF1 16TUJ JC 30 63 JC580 10 1 2 JC580 14 0031 LP15A LP15AA 3 M16878 1BJE 13 1 2 M16878 1BJE80 M16878 4BJE 12 M16878 4BJE 16 M16878 4BJE 8 M16878 5BJE 14 M16878 5BJE 7 M16878 5BKE 8 M16878 6BFE 6 16878 6 TM 9 2510 247 13 amp P STOCK NUMBER 6240 01 502 2530 5305 00 225 3843 5305 00 071 2511 5305 00 071 2513 5305 00 071 2519 5305 00 964 0691 5305 00 725 2317 5305 00 782 9489 5305 00 781 3927 5305 00 719 5243 5975 01 314 8107 5940 01 502 2111 4730 00 222 1838 5940 00 113 8179 6240 01 502 2421 6145 00 023 6923 5940 00 113 8183 4730 01 315 8250 5355 01 441 2838 5340 00 404 4101 5999 01 085 6244 5935 01 084 1942 5310 00 469 9202 6140 01 457 4260 6145 00 854 8211 6145 01 104 6028 5935 01 211 4434 6220 01 502 2419 6145 01 381 2385 6145 00 082 5172 0084 00 7 BULK BULK BUL O N CO BUL 0084 00 ITEM
151. D4 02795 CONTROL ROTARY SWIT WITH TETHER 1 3 PAOZZ 4730014818114 39428 69915K53 ADAPTER STRAIGHT 1 2 1 6 4 XDOZZ 1BZD4 1083 1 BOX ELECTRICAL CONT dea 1 5 PAOZZ 5935012114434 26697 JPO 0031 CONNECTOR RECEPTACL 1 6 22 5305002253843 80204 1821 025 100 SCREW CAP HEXAGON H 1 4 DIA X 20 UNC X 1 2 7 PAOZZ 5310006858308 047738 125 10497 07 WASHER FLAT 1 4 DIA 2 8 PAOZZ 5310005501130 96906 MS35333 40 WASHER LOCK 1 4 DIA 6 9 PAOCZ 5310000115120 24617 115120 NUT PLAIN HEXAGON 1 4 DIA X 20 6 10 PAOZZ 5930000080514 77326 24 353 SWITCH PUSH tne 1 11 XDOZZ 1BZD4 1056 1 BOLT THREADED 1 4 DIA X 20 UNC X 1 2 INCH LONG BOTH ENDS 4 12 PAOZZ 5930015021048 1BZD4 02765 SWITCH TOGGLE 3 13 77 5930014963656 1BZD4 1071 1 BOOT RUBBER ES 3 14 PAOZZ 6625015022946 1BZD4 02870 VOLTMETER 1 15 24 5975014816824 39428 69915 55 BUSHING STRAIN RELI 3 4 INCH 1 16 PAOZZ 5935009415436 19207 7974634 1 17 PAOZZ 5305009846221 96906 535206 234 SCREW MACHINE 6 32 DIA 32 UNC X 1 INCH LONG tnra 4 18 PAOZZ 5
152. E ON CODES UOC GROUP 12 BRAKES GROUP 1208 AIR BRAKE SYSTEM FIG 9 AIR BRAKE SYSTEM TUBING NONMETALLIC MAKE FROM TUBING NONMETALLIC P N 417200C2 32 INCHES 2 1 TUBING NONMETALLIC MAKE FROM TUBING NONMETALLIC P N 417200C2 34 INCHES cnn 1 TUBING NONMETALLIC MAKE FROM TUBING NONMETALLIC P N 417200C2 0082 00 7 5 22 2 INSERT TUBE FITTING THREE PIECES 8 4 REDUCER PIPE accuses 2 VALVE RELAY AIR PRE 1 BUSHING BRASS 1 BRACKET REG essere 1 ADAPTER STRAIGHT 3 NUT PLAIN HEXAGON 1 4 DIA X 20 1 WASHER LOCK 1 4 DIA 1 SPACER 1 enenatis 2 WASHER FLAT 1 4 DIA 2 SCREW CAP HEXAGON H 1 4 DIA X 20 UNC X 4 INCHES LONG END OF FIGURE 9 2510 247 13 amp P 0082 00 1 2 thru 3 5 6 thru 21 10 11 thru 13 Figure 10 Gladhands 9 2510 247 13 amp P 0082 00 0 2 3 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC QTY GROUP 1208 AIR BRAKE SYSTEM FIG 10 BLADHANDS 1 PAOZZ 4730002449848 28548 5228623 NIPPLE TANK 4 2 22 5310002206668 06853 204000 NUT PLAINHEXAGON 1 3 XAOZZ 06853 2021945 REDUCER P
153. EMS CONTROLS AND INDICATORS Figure 14 Tiedown Accessories Chain Assemblies Two chain assemblies 3 8 inch 9 52 mm Two chain assemblies 1 2 inch 12 7m Load Binders Two load binders used to secure loads to towing device Clevises Two clevises provide tiedown point for chains and additional safety to prevent mast from disengaging track Six D rings provide tiedown point for chains END OF WORK PACKAGE 0004 00 4 TM 9 2510 247 13 amp P 0005 00 OPERATION UNDER USUAL CONDITIONS SCOPE 1 This section provides instructions on operating the 250M Fifth Wheel Towing Device under usual conditions 2 Referta WP 0022 operating instructions under unusual conditions 3 Perform applicable Operator PMCS before during and after operation WP 0031 UNFOLDING FROM SHIPPING STORAGE CONFIGURATION The following operation assumes the fifth wheel towing device is on the ground and folded into the shipping storage configuration NAE Operators must take caution while folding the mast assembly to the vertical position The transport leg assembly does not stay locked in the vertical position The handle will swing free and may cause injury or death to personnel Control box cover is heavy Caution must be used during removal if in shipping configuration to prevent injury to personnel Some personnel may have difficulty operating the FWTD because of heavy components Use additional personnel when necessary and alw
154. ENSIONS Figure 25 Hydraulic Controls and Clevis 5 Remove two clevises 10 clevis pins 11 and spring pins 12 from mast assembly 13 6 Using remote control box or valve control levers MAST EXTEND 14 to line up LA An A arrows 15 and 16 Figure 26 Remote Control and Pin Alignment 0007 00 3 9 2510 247 138 0007 00 TRANSPORT CONFIGURATION Continued E WARNING DO NOT operate boom until mast is in track Failure to comply could cause serious injury or death to personnel or damage to equipment 7 Main frame fifth wheel area should be clear of obstructions 8 Insert pivot pins 17 into aligned holes 15 and 16 Figure 27 Pin Alignment and Valve 9 Using remote control box or valve control levers MAST RETRACT 18 to fold mast onto main frame NOTE Hydraulic pressure gauge should read 300 800 psi If adjustment is needed refer to WP 0003 a Be BH if RELLY y MAY AT lt lt x XE my DNS AA i poe A irem f e 18 il ING E 33 18 SS Figure 28 Hydraulic Controls 10 Remove pivot pins 17 0007 00 4 9 2510 247 13 amp P 0007 00 TRANSPORT CONFIGURATION Continued CAUTION DO NOT over extend mast This could cause damage to mast supports 11 Install two clevises on mast and secure with clevis
155. F WORK PACKAGE 0073 00 2 9 2510 247 13 0074 00 BUMPER PAD SLIP PAD REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in storage None configuration WP 0002 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General None NSN 5180 00 177 7033 BUMPER PAD REMOVAL 1 Remove two screws 1 from bumper pad 2 and remove bumper pad from boom assembly 3 2 Repeat for remaining bumper pad BUMPER PAD INSTALLATION 1 Position bumper pad 2 on boom assembly 3 and secure with two screws 1 2 Repeat for remaining bumper pad Figure 125 Bumper Pad 0074 00 1 9 2510 247 13 amp P 0074 00 SLIP PAD REMOVAL NOTE All slip pads are removed installed the same way Remove four screws 1 and remove slip pad 2 from frame SLIP PAD INSTALLATION Position slip pad 2 on frame and secure with four screws 1 1 0 Figure 126 Slip Pad Follow on Tasks None END OF WORK PACKAGE 0074 00 2 9 2510 247 13 amp P 0075 00 TRANSPORT LEG ASSEMBLY REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in Pin spring 9 98296A255 coupling configuration WP 0002 e Washer lock 4 122905 513 Nut self locking 4 MS4913 1 8FG5C Tools Test Equipment General Safety Instructions Tool Kit Mechanics General None NSN 5180
156. GHT HEADED eene 4 7 PAOZZ 5305009640691 80204 B1821BH038C150D SCREW CAP HEXAGON H 3 8 DIAX 16 UNC X 1 1 4INCHES LONG 7 8 XDOZZ 2 2001 00422 ER 8 9 XDOZZ 1BZD4 1020 1 ATTACHMENT TOWBAR LEFT SIDE 1 10 PAOZZ 5315011334382 39428 98296A556 PIN SPRING PART OF ITEM 10 2 11 PAOZZ 2540015015365 1BZD4 02560 sass aan 2 END OF FIGURE 0082 00 TM 9 2510 247 13 amp P Figure 12 Kingpin Assembly 1 ITEM SMR NO O 2 CODE PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ 3 NSN 5315014960452 5310015002707 2510014964441 5325014960432 5340014964055 5120015071183 5315014960426 2510014961811 5510014961818 5310014981951 4 CAGEC 1BZD4 74410 74410 74410 1BZD4 18204 18204 74410 74410 74410 74410 TM 9 2510 247 13 amp P 5 PART NUMBER XB T 360 XA0404 XA0409 0403 1099 1 1081 1 02240 0411 0360 653 6 0418 6 0082 00 7 DESCRIPTION AND USABLE CODES UOC QTY GROUP 15 FRAME TOWING ATTACHMENETS GROUP 1503 PINTLES AND TOWING ATTACHMENTS FIG 12 KINGPIN ASSEMBLY PIN SPRING NUT PLAIN CASTELLAT KINGPIN FIFTH WHEEL 3 1 2 INCHES RING HOUSING INTERC eese 1 BRACKET ANGLE
157. HES 1 SLEEVING TEXTILE EL MAKE FROM SLEEVING TEXTILE ELECTRICAL P N 50010013 4 INCHES LONG 1 TM 9 2510 247 13 amp P 0082 00 0 2 3 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC GROUP 0609 LIGHTS FIG 4 24 VOLT TOW LIGHT ASSEMBLY 39 PAOZZ 5999010856244 45152 EE 101241 CONTACT ELECTRICAL 8 40 PAOZZ 5935010841942 45152 EE 101253 CONNECTOR RECEPTACL 1 41 PAOZZ 5940001139826 96906 MS25036 114 TERMINAL LUG sn d 42 6220007261916 96906 MS35423 2 3 43 PAOZZ 5305009576272 96906 MS35190 269 SCREW MACHINE 3 16 DIA X 24 UNC X 3 8 INCHES 1 45 PAOZZ 6240000190877 58536 52463 1 08 LAMP INCANDESCENT 1 46 22 6220007299295 96906 MS35422 1 LIGHT MARKER CLEARA 1 47 22 9905008933570 81349 43436 1 3 1 48 22 5935005729180 19207 8338566 SHELL ELECTRICAL CO 1 49 PAOZZ 5310008338567 19207 8338567 WASHER SLOTTED su 1 50 22 5999000572929 19204 572929 esee 1 51 PAOZZ 5310006559544 96906 535690 604 NUT PLAIN HEXAGON 3 8 DIA X 16 D o 2 END OF FIGURE 9 2510 247 13 amp P 0082 00 Figure 5 Fixed Workligh
158. ILTERS LINES AND FITTINGS ETC FIG 25 DIL FILTER ASSEMBLY PAOZZ 5305002253843 80204 B1821BH025C100N SCREW CAP HEXAGON H 1 4 DIA X 20 UNC X 1 INCH 2 2 PAOZZ 5310005501130 96906 MS35333 40 WASHER LOCK 1 4 DIA HOLE 22 3 PAOZZ 4730014570813 30780 12 F50X S CONNECTOR TUBE TO e 4 PAOZZ 2940014970073 1BZD4 02145 FILTER BODY FLUID 1 5 PAOZZ 2940014970077 1BZD4 02146 FILTER ELEMENT FLUI ed 6 PAOZZ 2940014970092 1BZD4 02147 COVER FLUID FILTER 1 7 PAOZZ 5331014965156 1BZD4 02148 O RING iniecit T 8 PAOZZ 4730013948793 98441 12C50X S CONNECTOR MULTIPLE esee 1 END OF FIGURE 9 2510 247 13 amp P 0082 00 tl Sp Figure 26 Cam Valve Assembly 9 2510 247 13 amp P 0082 00 0 2 3 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC GROUP 2406 STRAINERS FILTERS LINES AND FITTINGS ETC FIG 26 VALVE ASSEMBLY 1 PAOZZ 4730004418700 96906 MS51500A8 4 ADAPTER STRAIGHT P1 1 2 22 4820014958070 18204 1025 1 VALVE SAFETY RELIEF 1 3 PAOZZ 5360014960436 18204 1065 1 SPRING HELICAL COMP 1 4 PAOZZ 5310013088205 96906 MS27183 48 WASHER FLAT 5 16 DIA HOLE 1 4 5 PAOZZ 5310014674644 39428 90045A453 NUT SELF LOCKING HE 5 16 DIA X 18 4 6 227 4730008443308 96906 551504 8 4 ELBOW PIPE TO TUBE 20242
159. ION SLEEVING ELECTRICAL P N M23053 12 106 2 1 2 RED X 2 INCHES SCREW CAP HEXAGON 3 8 DIA X 16 UNC X 1 seen WASHER FLAT 3 8 DIA HOLE CLAMP LOOP 3 INCHES DIA WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N QQW343E04G1B 40 INCHES WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N QQW343E04G1B 45 INCHES aeri 1 2 ITEM SMR NO CODE 19 0022 20 MOOCZZ 21 MOOZZ 22 22 23 0072 24 MOOZZ 25 22 26 PAOZZ 27 MOOZZ 28 22 29 22 30 MOOZZ 31 0072 32 22 33 MOOZZ 34 MOOZZ 35 0072 36 MOOZZ NSN 5340000814718 5940011292678 5940001138179 5940012582108 4 CAGEC 81348 81349 81348 96906 81348 81349 81349 96906 81349 81349 00779 81348 81349 81349 81349 81349 81349 81349 TM 9 2510 247 13 amp P 5 PART NUMBER QQ W 343 47 28J 12 65 QQ W 343 36 MS9349 04 QQ W 343 10 28J 12 4 M7928 4 112 MS25036 107 2SJ 12 60 M76MWPC 10 52412 JC580 10 1 2 M81381 11 M5086 11 1 2 M16878 4BJE 12 M5086 12 1 2 M22759 13 M16878 1BJE 6 0082 00 7 DESCRIPTION AND USABLE CODES UOC QTY GROUP 0613 HULL OR CHASSIS WIRING HARNESS FIG 8 CHASSIS WIRING HARNESS WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N QQW343E04G1B 47 INCHES LONG CABLE POWER ELECTRI MAKE FROM CABLE POWER ELECTRICAL P N M24643
160. IPE uo aaa isa 1 4 XDOZZ 1BZD4 1027 1 BRACKET MOUNTING 2 5 22 4730005950083 58536 A52484 1 COUPLING HALF QUICK SUPPLIED WITH BLUE AND RED ARM LOCK 4 6 22 5305011638191 06853 240407 SCREW ASSEMBLED WAS 2 7 PAOZZ 4730011061757 06853 240233 ARM LOCK HOSE COUPL 1 8 PAOZZ 5330000902128 06853 213630 PACKING PREFORMED s 1 9 XAOZZ 06853 243655 BODY COUPLING QDISC 1 10 PAOZZ 2530002703878 19207 7338409 DUMMY COUPLING AUTO 4 11 XAOZZ 06853 213605 COUPLING BODY 1 12 PAOZZ 4030001029687 06853 235646 HOOK CHAIN S sie 2 13 PAOZZ 4010005519921 19207 7366032 CHAIN ASSEMBLY SING 1 END OF FIGURE TM 9 2510 247 13 amp P 0082 00 Figure 11 Tow Bar Assembly 9 2510 247 13 amp P 0082 00 2 3 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC QTY GROUP 15 FRAME TOWING ATTACHMENTS GROUP 1503 PINTLES AND TOWING ATTACHMENTS FIG 11 TOW BAR ASSEMBLY 1 XDOZZ 1BZD4 1015 1 ATTACHMENT TOWBAR RIGHT SIDE 1 2 XDOZZ 1BZD4 1014 1 RECEIVER TOWBAR 2 3 PAOZZ 5306014956997 1BZD4 1042 1 BOLT TEE TOWBAR 8 4 22 5315014966348 39428 98296A548 PIN SPRING 8 5 XDOZZ 1BZD4 1030 1 FRAME TOWBAR MOUNTI T 1 6 PAOZZ 5315014979960 1BZD4 02545 PIN STRAI
161. MOVAL 1 Remove nuts 3 five flatwashers 1 and lockwashers 2 from underneath fender 4 Discard lockwashers 2 Loosen screws 6 and remove mudflap 5 3 Repeat steps 1 and 2 for remaining side mudflap mounting hardware INSTALLATION 1 Position mud flap 5 on fender 4 2 Line up holes on mudflap 5 with screws 6 in mounting bracket 7 3 Secure with flatwashers 1 new lockwashers 2 and nuts 3 4 Repeat step 1 through 3 for remaining mud flap Figure 118 Mud Flap Assembly Follow on Tasks None END OF WORK PACKAGE 0069 00 1 9 2510 247 13 amp P 0070 00 FENDER REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in coupled Washer Lock 15 MS35333 40 configuration 0002 Gladhand assembly removed if required WP 0053 Air brake hoses removed if required 0055 Air brake protection valve removed if required WP 0054 12 24 volt junction box removed if required WP 0043 Electric control box removed if required WP 0044 Worklight assembly removed if required WP 0047 Tool box removed if required WP 0071 Tow bar assembly removed if required WP 0009 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General None NSN 5180 00 177 7033 FENDER REMOVAL NOTE Note location of mounting hardware prior to removal 1 Remove nuts 3 lockwashers 2 and
162. N ELECTRICAL SYSTEM Continued 3 VOLTMETER DOES NOT WORK Continued Step 3 Are there any broken or frayed wires If no go to step 4 If yes repair or replace wires as necessary WP 0051 Step 4 Is voltage found at plus side of voltmeter If no ensure connection is clean and there is a good connection on feed wire WP 0088 If yes replace voltmeter 4 REMOTE CONTROL DOES NOT OPERATE Step 1 Is ON switch on remote in on position If no place ON switch in on position WP 0007 step 3 If yes go to step 2 Step 2 Is there minimum12VDC on batteries If no go to step 3 If yes go to step 4 Step 3 Is NATO slave cable connected If no install NATO cable in receptacle on prime mover and receptacle on 12 24 volt junction box If yes go to step 4 Remote Control Cable Step 4 Is voltage coming into remote control Connector Pin View If no ensure connection is clean and there is a good connection on feed wire WP 0088 If yes go to step 5 ONO 9 T Ky oF Step 5 Is voltage coming out of remote control If no replace remote control If yes test solenoids on control valve and replace as necessasry WP 0045 0027 00 3 TM 9 2510 247 13 amp P 00027 00 UNIT TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL SYSTEM Continued 5 ALL LIGHTS ARE INOPERABLE Step 1 Is there minimum 1
163. ND OF FIGURE TM 9 2510 247 13 amp P 0082 00 Figure 7 Battery Box Assembly 9 2510 247 13 amp P 0082 00 1 2 3 4 5 6 7 SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC QTY GROUP 0812 BATTERIES STORAGE FIG BOX ASSEMBLY 1 PAOZZ 5310011835514 96906 MS 51468 03 NUT PLAIN WING 5 16 4 2 XDOZZ 18204 1049 1 LID BATTERY BOX 2 2 1 3 PAOZZ 5310015019194 18204 1068 1 NUT PLASTIC RED nem 2 4 PAOZZ 5310015019196 18204 1069 1 NUT PLASTIC BLACK 2 0 2 5 PAOZZ 6140014327882 20038 HC 31D BATTERY STORAGE 2 6 PAOZZ 5340014962171 18204 00775 PAD CUSHIONING ine sen 2 7 XDOZZ 1BZD4 1048 1 BOX BATTERY STEEL 1 8 MOOZZ 39428 8451A62 26 NONMETALLIC CHANNEL MAKE FROM NONMETALLIC CHANNEL P N 8451A62 28 INCHES LONG unse a 1 9 PAOZZ 5305000712511 80204 1821 025 200 SCREW CAP HEXAGON H 4 DIA X 20 UNC 2 Y INCHES LONG 2 10 PAOZZ 5310000310930 96906 MS17828 4C SELF LOCKING HE DIA X 20 UNC oen 2 2 11 PAOZZ 5120014984965 18204 1127 1 CARRIER STORAGE BATTERY 1 END OF FIGURE Change 1 TM 9 2510 247 13 amp P 0082 00 Figure 8 1 of 9 Chassis Wiring Harness 0082 00 9 2510 247 13 amp P id i Figure 8 2 of 9 Chassis Wiring Harness 0082 00 TM 9
164. NING COMPRESSED AIR Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury or death to personnel Air under 100 psi pressure is used in the operation of the air brake system Serious injury or death can result if precautions are not taken WARNING WORK SAFETY Unless otherwise specified perform all lubrication and preventive maintenance checks with fifth wheel towing device on level ground and uncoupled Failure to follow this warning may result in injury or death to personnel If personnel becomes dizzy while using cleaning solvent immediately get fresh air and medical help If solvent contacts eyes immediately wash your eyes and get medical attention Failure to comply may result in injury or death to personnel WARNING ELECTRICAL SYSTEM When troubleshooting an electrical malfunction or performing electrical maintenance ALWAYS disconnect intervehicular electrical cable from towing vehicle Failure to do so may result in injury or death due to electric shock Remove all power to fifth wheel towing device prior to making any repairs on the electrical system Failure to do so may result in serious injury or death Although battery ground cable must be connected in order to test electrical circuit voltage disconnect battery ground cable from prime mover before performing resistan
165. Not Fully Mission Capable if Column Information in this column tells you what fault will keep your equipment from being capable of performing its primary mission If you make check and service procedures that show faults listed in this column the equipment is not mission capable Follow standard operating procedures for maintaining the equipment or reporting equipment failure 0037 00 1 9 2510 247 13 0037 00 GENERAL PMCS PROCEDURES 1 Always perform PMCS in the same order so it gets to be a habit Once you ve had some practice you ll spot anything wrong in a hurry If any deficiency is discovered perform the appropriate troubleshooting task Chapter 4 If any component or system is not serviceable or if the given service does not correct the deficiency notify your supervisor Before performing preventive maintenance read all the checks required for the applicable interval and prepare all tools needed to make all checks Have several clean rags Item 10 WP 0085 handy Perform ALL inspections at the applicable interval a Keep lt Clean Dirt grease oil and debris get in the way and may cover up a serious problem Clean as you work and as needed Use dry cleaning solvent Item 14 WP 0085 on all metal surfaces Use detergent Item 4 WP 0085 and water when you clean rubber plastic and painted surfaces b Deterioration Rust and Corrosion 1 Be alert for deterioration of plastic and rubber materials Report i
166. ON INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in supported coupling Tag marker item 15 WP 0085 configuration or coupled AP uration WP 0002 Tie wire item 18 WP 0085 Disconnect batteries WP 0050 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General Remove all power to towing device prior to NSN 5180 00 177 7033 making any repairs on electrical system REMOVAL 1 2 3 4 5 WARNING Remove all power to fifth wheel towing device prior to making any repairs on the electrical system Failure to do so may result in serious injury or death Remove remote control connector 1 from electrical control box 2 Remove right side electrical bracket Reference WP 0070 Remove remote control tether 3 from loop clamps 4 on left and right side of frame Remove tool box rubber grommet 5 Remove remote control tether 3 Figure 82 Remote Control Cable Assembly 0046 00 1 9 2510 247 13 amp P 0046 00 INSTALLATION 1 2 Install rubber grommet 5 in tool box Install remote control tether 3 through grommet 5 Position remote control tether through loop clamps 4 and secure Install rght side electrical bracket Reference WP 0070 Install remote control connector 1 on electrical control box 2 Figure 82 Remote Control Cable Assembly Follow on Tasks Connect Batteries WP 0050 P
167. OPERATOR TROUBLESHOOTING 9 2510 247 13 amp P 0000 00 OPERATOR TROUBLESHOOTING PROCEDURES INDEX WP Sequence No OPERATOR TROUBLESHOOTING PROCEDURES Operator Troubleshooting 0023 00 Operator Troubleshooting 0024 00 0000 00 0 9 2510 247 13 0023 00 OPERATOR TROUBLESHOOTING PROCEDURES GENERAL 1 This section provides information for identifying and correcting malfunctions that you may find while operating the fifth wheel towing device 2 The Troubleshooting Symptom Index WP 0023 00 2 lists common malfunctions which may occur and refers you to the proper page in Table 1 for a troubleshooting procedure 3 Ifyou are unaware of the location of an item mentioned in troubleshooting refer to WP 0002 00 5 WP 0002 00 6 0004 00 1 0004 00 3 0004 00 4 4 Before performing troubleshooting read and follow all safety instructions found the warning summary at the front of this manual 5 This section cannot list all malfunctions that may occur nor all tests or inspections and corrective actions If a malfunction is not listed or is not corrected by the listed corrective actions notify your supervisor 6 When troubleshooting a malfunction a Locate the symptom or symptoms in WP 0023 00 2 hat best describes the malfunction If
168. OVAL Ed WARNING Ensure hydraulic protection valve is open breather switch inline with breather prior to operating hydraulics Failure to comply could cause injury or death to personnel or damage to equipment High pressure is present in the 250M Fifth Wheel Towing Device hydraulic system Do not disconnect any hydraulic system component unless hydraulic system pressure has been relieved Ensure each hydraulic control lever is moved several times through all positions Failure to comply may result in severe injury or death to personnel Spilled hydraulic oil is very slippery Be careful when entering or working in area Wipe up any spilled oil immediately Failure to comply may result in severe injury or death to personnel While operating or performing maintenance on any hydraulic systems never place personnel or equipment in a potentially hazardous position i e between moving parts or under hydraulic supported equipment Failure to comply may result in injury or death to personnel NOTE All hydraulic hoses must be capped and or plugged when disconnecting to prevent contamination of hydraulic system Cut plastic ties as needed Note location of plastic ties and hydraulic hoses prior to removal The following procedures are for the removal of the main frame to mast cylinders Adjust maintenance steps performed to accommodate the required maintenance 0063 00 1 TM 9 2510 247 13 amp P 0063 00 REMOVAL Continued Remov
169. OWER 24 VOLT 70 FT 1BZD4 00805 0085 00 7 0085 00 TM 9 2510 247 13 amp P 0085 00 SECTION Ill BASIC ISSUE ITEMS Continued DAN 1 2 3 Illus National Description Number Stock Number CAGEC Part Number 2540 01 502 2031 PIN STRAIGHT HEADED 1 INCH used with 5 Ton 1BZD4 02530 2540 01 501 5365 PIN STRAIGHT HEADED 1 1 4 INCH used with FMTV 1BZD4 02560 2540 01 502 2034 PIN STRAIGHT HEADED 1 1 2 INCH used with 911 915 916 920 and PLS 1BZD4 02561 END OF WORK PACKAGE 0085 00 8 9 2510 247 13 amp P 0086 00 ADDITIONAL AUTHORIZATION LIST This technical manual lists additional items authorized for the support of the 250M Fifth Wheel Towing Device 1 GENERAL This list identifies items that do not have to accompany the 250M Fifth Wheel Towing Device and that do not have to be turned in with it These items are all authorized by CTA TDA or 2 EXPLANATION OF COLUMNS a Column 1 Illustration Number Number This column indicates the number of the illustration that shows the item Column 2 National Stock Number This column indicates the National Sstock Number NSN assigned to the item and will be used for requisitioning purposes Colulmn 3 Description CAGEC and Part Number identifies the Federal item name in all capital letters followed by a minimum description when needed The last line below the description is the CAGEC Comme
170. P 0048 00 2 pgs WP 0018 00 4 pgs 0049 00 4 pgs WP 0019 00 1 pg WP 0050 00 4 pgs WP 0020 00 3 pgs WP 0051 00 2 pgs WP 0021 00 3 pgs WP 0052 00 1 pg WP 0022 00 4 pgs WP 0053 00 3 pgs Chapter 3 Title page WP 0054 00 3 pgs WP 0023 00 2 pgs WP 0055 00 4 pgs WP 0024 00 3 pgs 0056 00 7 pgs Chapter 4 Title page WP 0057 00 5 pgs WP 0025 00 2 pgs WP 0058 00 4 pgs 0026 00 1 pg 0059 00 6 pgs WP 0027 00 6 pgs 0060 00 2 pgs WP 0028 00 4 pgs WP 0061 00 3 pgs Zero in this column indicates an original page 1 TM 9 2510 247 13 amp P LIST OF EFFECTIVE PAGES WORK PACKAGES Continued Original 1 July 2004 Change 1 15 May 2005 TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 35 AND TOTAL NUMBER OF WORK PACKAGES IS 91 CONSISTING OF THE FOLLOWING Page WP No WP 0062 00 WP 0063 00 WP 0064 00 WP 0065 00 WP 0066 00 WP 0067 00 WP 0068 00 WP 0069 00 WP 0070 00 WP 0071 00 WP 0072 00 WP 0073 00 WP 0074 00 WP 0075 00 WP 0076 00 1 pg WP 0077 00 4 pgs WP 0078 00 5 pgs Chapter 7 Title page WP 0079 00 1 pg Chapter 8 Title page WP 0080 00 2 pgs WP 0081 00 8 pgs 3 pgs 3 pgs 3 pgs 4 pgs 3 pgs 1 pg 2 pgs 1 pg 3 pgs 4 pgs 1 pg 2 pgs 2 pgs 3 pgs pp WP 00
171. Reporting Equipment Improvement ee ee ea 0001 00 2 Rocky Terrain Operation nennen 0022 00 3 Roll On Roll Off RORO 0022 00 3 PPP 0082 00 1 Explanation of Columns 0082 00 1 Explanation of Cross Reference Indexes 0082 00 6 Special Information 5 222 0082 00 7 How to Locate Repair 0082 00 7 S Safety Care and Handling sse nnns 0001 00 2 Saltwater Areas 0022 00 2 Sandy or Dusty Areas Operation in sse 0022 00 2 SChHEM llcS m EDT 0088 00 1 Service Before 0031 00 1 Service Replacement Parts and 0038 00 11 Service Upon Receipt nennen 0036 00 1 Shipment Preparation of Equipment 0001 00 1 0078 00 5 Shipping Storage Configuration 0021 00 1 Shipping Storage Configuration Unfolding from 0005 00 1 INDEX 7 9 2510 247 13 amp P INDEX Subject WP Sequence No Page No S continued Snow Operation IN KKK 0022 00 2 Soldering et 0038 00 7 Solenoid Assembly
172. S UOC GROUP 0613 HULL OR CHASSIS WIRING HARNESS FIG 8 CHASSIS WIRING HARNESS TERMINAL QUICK DISC YELLOW FLAG RING CONNECTING 1 INSULATION SLEEVING MAKE FROM INSULATION SLEEVING ELECTRICAL P N M23053 10 002 0 1 4 BLACK X 2 INCHES LONG unite ni nena ences 1 WIRE ELECTRICAL MAKE FROM WIRE ELECTRICAL P N M5086 1 12 0 20 INCHES LONG iint ert cr sna 2 CABLE POWER ELECTRI MAKE FROM CABLE POWER ELECTRICAL P N M24643 43 06U0 163 INCHES 1 CONNECTOR WIRE 2 BUSHING STRAIN RELI 3 8 INCH sies 2 CORD ELECTRICAL niian ences 1 END OF FIGURE 9 2510 247 13 amp P 0082 00 Figure 9 Air Brake System 1 2 ITEM SMR NO YO CO rn 10 11 12 14 CODE MOOZZ MOOZZ MOOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ XDOZZ PAOZZ PAOZZ PAOZZ XDOZZ PAOZZ PAOZZ PAOZZ 3 NSN 4730010663363 4730002000257 2530010958752 4730001423076 5310000115120 5310005501130 5340004044101 5310006858308 5305000712519 4 29510 29510 29510 89346 1BZD4 19207 06853 1BZD4 1BZD4 81343 24617 96906 1BZD4 75272 81348 80204 9 2510 247 13 amp P 5 PART NUMBER 417200C2 32 417200C2 34 417200C2 56 414506C1 1073 1 7390150 281865 00870 1026 1 8 6 120102BA 115120 MS35333 40 1102 1 1313 FFW92 B1821BH025C400N 6 DESCRIPTION AND USABL
173. T has Do not attempt to connect NPT and female straight threads Do not apply sealant to the first threads of NPT fittings If sealant enters the hydraulic system it may cause components to fail When connecting NPTs care must be exercised If overtightened the female pipe thread will split Replace it If a connection leaks disconnect and apply thread sealant Reconnect the threads and snug up with an open end wrench Failure to comply may result in damage to equipment Be careful when installing preformed packings Sharp threads can nick the packing causing it to leak If fitting leaks check packing for nicks or cuts and replace if necessary Do not overtighten a flareless connection Observe torque values in appendix for hydraulic fittings Overtightening can cause leakage requiring replacement of entire tube assembly When connecting a hose to a fitting always use two wrenches Use one wrench to turn the swivel nut onto the fitting and use another wrench to keep the hose from rotating If the hose rotates it can loosen the other end of the hose or loosen the fitting at the other end 0056 00 2 9 2510 247 13 amp P 0056 00 GENERAL HYDRAULIC SYSTEM REPAIR Continued The following information is provided to familiarize personnel with the various types of hydraulic fittings Refer to this section and the warning and cautions on the previous pages when working on hydraulic systems 1 National Pipe Thread is c
174. TOWED VEHICLE Continued 16 17 18 19 NOTE If the vehicle being recovered is not equipped with front towing eyes skip steps 15through 18 If PLS System is being towed by M915 insure hitch pin 13 is in the fourth hole from the top Install hitch pin 13 through upper tow bar assembly 14 and secure with spring clip 15 Repeat step 13 for remaining tow bar assembly BOOM EXTEND to raise the lower tow bar assembly 14 until hitch pin 13 seats in lower towbar assembly 15 Install second hitch pin 18 through both upper and lower tow bar assembly and secure with spring clip 19 to bolts on lower section of tow bar assembly and tighten Repeat step 16 for remaining tow bar assembly Figure 50 Tow Bar Assembly 0010 00 6 Change 1 9 2510 247 138P 0010 00 CONNECTING TO TOWED VEHICLE Continued NOTE When towing PLS System with M915 place hitch pin 20 in third hole of mast 20 Using valve lever controls BOOM EXTEND to level fifth wheel and install hitch pin 20 into center boom lock 21 21 Using valve lever controls BOOM RETRACT to lock hitch pin 20 into position Secure hitch pin with spring pin and lanyard 22 Install 3 8 inch chain to secure front axle to boom Refer to section WP 0014 23 Using valve laver controls MAST EXTEND to raise towed vehicle to towing height required for terrain 24 Install pivot pin 22 in slot above arrow 23 and MAST RETRACT to lock pin into pos
175. VEC cable connection from prime mover Check for voltage at solenoids If yes go to step 3 Step 3 Will mast extensions and winch functions operate using the valve control levers If no remove hose from hydraulic lock valve to base end of boom hydraulic cylinder Hold oil drain pail under open port in hydraulic cylinder Operate control lever BOOM RETRACT gradually If oil returns from cylinder but there is no movement of booms or cylinder the cylinder packing is allowing oil to bypass and the hydraulic cylinder must be replaced If oil does not return from cylinder when operating boom retract lever put end of removed hose in drain pan and gradually operate BOOM EXTEND control lever If oil does not flow out of hose remove hose between control valve and lock valve Re attach swivel end at control valve and put other end of hose in drain pan Operate BOOM EXTEND control lever If oil does not flow out of hose replace control valve If oil does flow out of hose replace lock valve If yes go to step 4 Step 4 Will boom operate using the remote control If no replace remote control If yes return to step 3 0028 00 3 TM 9 2510 247 13 amp P 0028 00 UNIT TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION HYDRAULIC SYSTEM Continued 7 MAST WILL NOT OPERATE Step 1 Is hydraulic pressure gauge showing pressure If no adjust hydraulic flow valves WP 0003 If yes go to step 2 Step 2
176. WP 0056 0045 Check reservoir fluid level and adjust level as required WP 0056 00 5 END OF WORK PACKAGE 0064 00 3 9 2510 247 13 0065 00 HYDRAULIC RESERVOIR FITTINGS REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Hydraulic pressure relieved WP 0056 00 5 Sealing compound item 12 WP 0085 Hydraulic reservoir drained WP 0056 00 5 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General None NSN 5180 00 177 7033 WARNING High pressure is present in the 250M Fifth Wheel Towing Device hydraulic system Do not disconnect any hydraulic system component unless hydraulic system pressure has been relieved Ensure each hydraulic control lever is moved several times through all positions Failure to comply may result in severe injury or death to personnel REMOVAL Spilled hydraulic oil is very slippery Be careful when entering or working in bowl area Wipe up any spilled oil immediately Failure to comply may result in severe injury or death to personnel CAUTION Hydraulic hoses must be capped and or plugged when disconnected to avoid contamination 0065 00 1 9 2510 247 13 amp P 0065 00 REMOVAL Continued 1 2 12 Remove hydraulic motor hose 1 from compression fitting 2 Remove compression fitting 2 from tee fitting 3 Remove tee fitting 3 from hydraulic reservoir 4 Remove hose from elbow 5 and remove e
177. XDOZZ 1BZD4 1137 1 CYLINDER CASE 2 4 22 2540014967132 18204 1079 1 COUPLER DRAWBAR RIN 2 5 PAOZZ 5315014963059 18204 1080 1 PIN CLEVIS 1 6 22 5315008781994 80205 516562 87 SPRING 2 7 PAOZZ 5305014958137 18204 1091 1 4 8 XDOZZ 18204 6007 1 PIN RETAINING 2 9 22 5305009835346 96906 516997 78 SCREW CAP SOCKET HE 5 16 DIA X 18 UNG X 3 4 INCHES LONG 24 10 PAOZZ 5340014964081 18204 1007 1 PAD 2 11 PAOZZ 5315012823483 39428 982964255 PIN SPRING 4 12 PAOZZ 5310014981892 18204 1074 1 MOT 4 13 PAOZZ 5315014962435 1 204 1010 1 PIN STRAIGHT HEADLE 2 14 PAOZZ 1BZD4 6009 1 PAD SLIP 4 END OF FIGURE TM 9 2510 247 13 amp P 0082 00 Figure 30 Reservoir and Fittings 9 2510 247 13 amp P 0082 00 0 2 3 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC GROUP 2408 LIQUID TANKS OR RESERVOIRS FIG 30 RESERVOIR AND FITTINGS 1 PAOZZ 2520004467518 89346 91916R91 BREATHER 2 2 22 4730002777331 21450 444530 MEE RIPE icons aida 1 3 PAOZZ 4820014946076 89346 4772K6 VALVE RELIEF PRESSU 1 4 PAOZZ 4730002221838 81346 B687R 39B NIPPLE PIPE 2 5 PAOZZ 4730014963143 1BZD4 1070 1 BUSHING PIPE 1 1 4 X 3 8
178. Y PLACE POSTAGE HERE Commander U S Army Tank automotive and Armaments Command ATTN AMSTA AC NML Rock Island IL 61299 7630 IA AA TEAR ALONG PERFORATED LINE RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT 18 N 25 BLICATION DATE PUBLICATION TITLE Unit DS Maintenance 9 2510 247 13 amp P amp RPSTL for FWTD BE EXACT PIN POINT WHERE IT IS IN THIS SPACE TELL WHAT I WRONG BE EXACT PINPOINT WHERE WHAT SHOULD BE DONE ABOUT IT DA e 2028 2 PREVIOUS EDITIONS P S iF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS mmt REVERSE DA FORM 2028 2 FILL IN YOUR UNIT S ADDRESS DEPARTMENT OF THE ARMY PLACE POSTAGE HERE Commander U S Army Tank automotive and Armaments Command ATTN AMSTA AC NML Rock Island IL 61299 7630 A TEAR ALONG PERFORATED LINE RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT IN THE MAIL 4 PUBLICATION NUMBER PUBLICATION TITLE DS Maintenance 9 2510 247 13 amp P amp RPSTL
179. acer 9 flatwasher 11 new lockwasher 10 and nut 12 NOTE Gladhand connections on prime mover side have straight adapters Gladhand connections towed vehicle side have 45 fittings Install new insert 5 into air hose 4 and install onto straight adapter 2 Install new insert 5 into air hose 4 and install onto 45 compression fitting 3 Install nut 1 onto straight adapter 2 and 45 compression fitting 3 0055 00 3 9 2510 247 138 0055 00 INSTALLATION Continued Figure 99 Air Brake Fittings Assembly Follow on Tasks Install gladhands WP 0053 Check air brake systems for leaks END OF WORK PACKAGE 0055 00 4 TM 9 2510 247 13 amp P 0056 00 GENERAL HYDRAULIC SYSTEM REPAIR METHODS GENERAL HYDRAULIC SYSTEM REPAIR WARNING High pressure is present in the 250M Fifth Wheel Towing Device hydraulic system Do not disconnect any hydraulic system component unless hydraulic system pressure has been relieved Ensure each hydraulic control lever is moved several times through all positions Failure to comply may result in severe injury or death to personnel Spilled hydraulic oil is very slippery Be careful when entering or working in area Wipe up any spilled oil immediately Failure to comply may result in severe injury or death to personnel While operating or performing maintenance on any hydraulic systems never place personnel or equipment in a potentially hazardous posi
180. act boom extensions 12 Connect gladhands 6 to towing device CAUTION Inter vehicular electrical cable IVEC may get caught and damaged on rear wheel of prime mover if IVEC is too long If IVEC hangs near tire secure excess cable to prevent contact with rear tire Items in tool box may fall out when opening Use caution to prevent injury 13 Connectthe inter vehicular electrical cable IVEC to the 12 24 volt junction box on towing device and prime mover a Ensure that the IVEC station on the prime mover is in the vertical position If not or if the IVEC is too long it may get caught on the rear wheel especially during left hand turns b If excess slack exists in the IVEC secure it prior to movement 14 Towing device is now operational 5 COUNTER CLOCKWISE Figure 22 Rear Gladhands and Support Leg Assembly END OF WORK PACKAGE 0006 00 3 9 2510 247 13 amp P 0007 00 TRANSPORT CONFIGURATION The transport configuration will be used to move the fifth wheel towing device when not loaded This task assumes the fifth wheel towing device is coupled to a prime mover and transport legs are engaged WARNING Ensure hydraulic protection valve is open breather switch inline with breather prior to operating hydraulics Failure to comply could cause injury to personnel or damage to equipment Never walk under Booms during any operations Failure to comply may cause injury or death to personnel CAUTION Never transp
181. air Solenoid Assembly Replace i Remote Control Replace 24 light Replace Repair Fixed Worklight Replace Repair Strobe Light Replace Repair Battery Box Replace Battery Wiring Harness Replace Cable Repair Gladhands Service 5 Replace Protection Valve Replace Air Brake Fittings Replace Repair j 0081 00 5 9 2510 247 13 amp P Section MAINTENANCE ALLOCATION CHART Continued 2 Component Assembly Frame Towing Attachments Drawbar and Articulation Towbar Assembly King Pin Inspect Receiver and Wheel Stop Assembly Body Cab Hood and Hull Mud Flaps Fender Tool Box Main Frame Assembly Mast Frame Assembly Boom Assy Mast Frame Pivot Pin Center Mast Frame 3 4 5 Maintenance Level Tools and Maintenance Function Inspect Service Replace Service Replace Replace Replace Replace Inspect Replace Inspect Replace Inspect Replace Inspect Replace Replace Replace 00081 00 6 0081 00 9 2510 247 13 0081 00 Section MAINTENANCE ALLOCATION CHART Continued 2 Component Assembly Slip Pad Bumper Pad Transport Leg Assembly Hoist Winch Capstan Windlass Power Control Unit and Power Takeoffs Winch Cable Assembly Hydraulic and Fluid Systems Motor Assembly Safety Valve Main Valve Valve Control Levers Hos
182. all straight adapter 16 to main valve assembly 13 Install tee pipe 6 to straight adapter 16 Install straight adapter 15 to tee pipe 6 Install pressure gauge 14 to straight adapter 15 Install main valve assembly 13 to frame Install two screws 11 and new lockwashers 12 Install four flow restrictor valves and springs 18 to main valve parts 19 Install ten elbows 4 to main valve assembly 13 Install plug 17 to main valve assembly 13 Install straight adapter 8 to main valve assembly 13 Connect all wires to solenoids Install two screws 1 to solenoid cover 2 and install solenoid cover 2 to main valve assembly Install screw 9 and ground wire 10 to main valve assembly Install hydraulic hose 7 to straight adapter 8 0059 00 5 TM 9 2510 247 13 amp P 0059 00 INSTALLATION Continued 15 Connect hydraulic hose 5 to tee pipe 6 16 Tighten swivel nut at opposite end of hydraulic hose 5 17 Connect ten hydraulic hoses 3 to elbows 4 Figure 107 Hydraulic Control Assembly Follow on Tasks Replace handles e Connect batteries WP 0050 e Charge hydraulics WP 0056 0015 e Check hydraulic fluid level WP 0056 00 5 END OF WORK PACKAGE 0059 00 6 TM 9 2510 247 13 amp P 0060 00 HYDRAULIC VALVE CONTROL LEVER REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in coupling Spring
183. alve Assembly Replacement Hydraulic Valve Control Lever Replacement sess nter ennt nnns Oil Filter Assembly Cam Valve Assembly Replacement sss sss Hydraulic Cylinder Main Frame to Mast Replacement Hydraulic Cylinder Mast to Boom Hydraulic Reservoir Fittings Boom Extension Cylinder General Hydraulic System Repair Receiver and Wheel Stop Assembly Replacement 20400 11011 Mud Flap Replacement ii ida Fender Replacement ccccccccssccssseccssecesseccsseeccsecesaeccsseecsesessecscsseesseecssaeccaeaecnescssaeccseesenseceaaes Tool Box Replacemieni a a ee Mast Frame Assembly Pivot Pin Replacement Center Mast Frame Bumper Pad Slip Pad Replacement esses Transport Leg Assembly Replacement A aa Winches Assembly Replacement Preparation for Storage or Shipment sss 0000 00 0 TM 9 2510 247 13 amp P 0036 00 SERVICE UPON RECEIPT GENERAL When new used or reconditioned
184. amp P 0044 00 INSTALLATION Continued 11 Connect blackout control cable 10 12 Connect worklight cable 9 13 Connect hydraulic solenoid valve cable 8 14 Connect strobe light wires 7 15 Connect electrical control box to solenoid cable 6 16 Connect electrical control box to battery cable 5 17 Connect ground cable 3 to control box 4 18 Connect junction box to electrical control box harness 2 19 Connect remote control harness 1 NOTE ALL CABLES WIRING REMOVED FOR CLARITY Figure 78 Electrical Control Box Follow on Tasks Connect batteries WP 0050 e Check for proper operation of electrical control box END OF WORK PACKAGE 0044 00 5 TM 9 2510 247 13 amp P 0045 00 SOLENOID ASSEMBLY REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in supported coupling Washer lock 3 ASAB27 1 1950 configuration or coupled configuration WP 0002 Tag marker item 15 WP 0085 e Disconnect batteries WP 0050 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General Remove all power to towing device prior to NSN 5180 00 177 7033 making any repairs on electrical system REMOVAL WARNING Remove all power to fifth wheel towing device prior to making any repairs on the electrical system Failure to comply may result in injury to personnel or damage to equipment NOTE The following
185. around examination of all equipment to detect any deficiencies Inspect equipment in open storage weekly and equipment in covered storage monthly Inspect all equipment immediately after any severe storm or environmental change The following are examples of things to look for during a visual inspection a Oil leaks b Condition of preservatives seals and wraps Corrosion or other deterioration d Missing or damaged parts e Water in compartments f other readily recognizable shortcomings or deficiencies Repair During Administrative Storage Keep equipment in an optimum state of readiness Accomplish the required services and repairs as quickly as possible Whenever possible perform all maintenance on site Exercising Exercise equipment in accordance with Table 4 Exercise Schedule and the following instructions a Equipment Major Exercise Depreserve equipment by removing only that material restricting exercise Perform all BEFORE operational checks While exercising and when it is safe and convenient operate all other functional components and perform all DURING and AFTER operational checks b Scheduled Services Scheduled services will include inspection per subparagraph b and will be conducted in accordance with WP 0037 Unit Preventive Maintenance Checks and Services PMCS Lubricate in accordance with instructions WP 0039 C Corrective Action Immediately take action to correct shortcomings and deficiencies no
186. assembly to rear of towed vehicle 6 Ifthe prime mover is a 24 volt system the 24 volt light bar 4 will be used If equipped connect IVEC cable to 24 volt receptacle 5 on electrical control box 3 Figure 57 Light Components 0015 00 1 9 2510 247 13 0015 00 OPERATE LIGHTS Continued 7 Connect 24 volt light assembly to 24 volt receptacle 6 on fifth wheel towing device 8 Connect 24 volt tow light assembly to rear of towed vehicle and connect the 24 volt tow light cable to the light bar 9 To operate tow light assembly switch electrical control box ELECTRIC switch 7 to ON position 10 To operate worklight switch electrical control box WORKLIGHT switch 8 to ON position 11 To operate strobe lights switch electrical control box STROBE switch 9 to ON position 12 To shut off strobe lights switch electrical control box STROBE switch 9 to OFF position 13 To shut off worklight switch electrical control box WORKLIGHT switch 8 to OFF position 14 To shut off tow light assembly disconnect tow light assembly m SN GFE A Figure 58 Light Controls and Connections END OF WORK PACKAGE 0015 00 2 9 2510 247 13 amp P 0016 00 GLADHANDS NOTE There are two sets of gladhands Both sets are operated in the same manner Remove dummy coupling 1 from gladhand 2 Raise prime mover or towed vehicle air
187. ate store equipment from equipment in use Conspicuously mark the area Administrative Storage Covered space is preferred Open sites should be improved hardstand if available Unimproved sites should be firm well drained and free of vegetation 2 Storage Plan a C Store equipment so as to provide maximum protection from the elements and to provide access for inspection maintenance and exercising Anticipate removal or deployment problems and take suitable precautions Take into consideration environmental conditions such as extreme heat or cold high humidity blowing sand dust or loose debris soft ground mud heavy snows or any combination thereof and take adequate precautions Establish a fire plan and provide for adequate fire fighting equipment and personnel 3 Maintenance Services and Inspections a b Maintenance Services Prior to storage perform the next scheduled PMCS Inspection Inspect and approve the equipment prior to storage Do not place nonmission capable equipment in storage 4 Correction of Shortcomings and Deficiencies Correct all shortcomings and deficiencies prior to storage or obtain a deferment from the approving authority 5 Lubrication Lubricate equipment in accordance with WP 0039 0078 00 2 9 2510 247 13 amp P 0078 00 PREPARATION OF EQUIPMENT FOR ADMINISTRATIVE STORAGE Continued 6 General Cleaning Painting and Preservation CAUTION DO NOT direct w
188. ater under pressure against unsealed electrical systems of any exterior opening Failure to follow this caution may result in damage to equipment Cleaning Clean the equipment of dirt grease and other contaminants but do not use vapor degreasing b Painting Remove rust and damaged paint by scraping wire brushing sanding or buffing Sand to a smooth finish and spot paint as necessasry TB 43 0209 Preservation After cleaning and drying immediately coat unpainted metal surfaces with oil or grease as appropriate NOTE Place a piece of barrier material between desiccant bags and metal surfaces Air circulation under draped covers reduces deterioration from moisture or heat d Weatherproofing Sunlight heat moisture humidity and dirt tend to accelerate deterioration Close and secure all openings except those required for venting and draining Seal openings to prevent the entry of rain snow or dust Insert desiccant when complete seal is required Place equipment and provide blocking or framing to allow for ventilation and water drainage 7 Place FWTD in shipping storage configuration WP 0021 0078 00 3 9 2510 247 13 0078 00 CARE EQUIPMENT IN ADMINISTRATIVE STORAGE 1 Maintenance Services After equipment has been placed in administrative storage inspect service and exercise as specified herein Inspection Inspection will usually be visual and must consist of at least a walk
189. ay result in death or injury to personnel DO NOT grind or sand painted equipment without high efficiency air purifying respirators in use Failure to comply may result in death or injury to personnel BE AWARE of CARC paint exposure symptoms symptoms can occur a few days after initial exposure Seek medical help immediately if symptoms are detected Failure to comply may result in death or injury to personnel 1 Remove six screws 1 flatwashers 2 flatwashers 3 lockwashers 4 and nuts 5 securing tool box 6 to fender Discard lockwashers 2 Remove tool box from fender 3 Remove weather strip 7 from tool box door 8 Discard weather strip 4 Repeat step 3 for remaining tool box door FUE T TT Figure 121 Tool Box 0071 00 2 9 2510 247 13 amp P 0071 00 ASSEMBLY REMOVAL 5 6 Remove 1 inch screw 1 lockwasher 2 and nut 3 from hinge mounting bracket 4 and tool box door 5 Discard lockwasher Remove 3 4 inch screw 6 lockwasher 2 and nut 3 from hinge mounting bracket 4 and tool box door 5 Discard lockwasher Remove weather strip 7 from tool box Discard weather strip Remove two screws 8 lockwashers 9 and nuts 10 from hinge mounting bracket 4 and tool box Discard lockwashers Remove hinge assembly from tool box Repeat steps 1 through 5 for remaining hinge assemblies HINGE ASSEMBLY INSTALLATION 1 2 3
190. ays use caution when operating to prevent injury or death to personnel 0005 00 1 TM 9 2510 247 13 amp P 0005 00 UNFOLDING FROM SHIPPING STORAGE CONFIGURATION Continued NOTE Illustrations are upside down because they are in shipping configuration 1 Unlock control box 3 and 12 24 volt junction box 1 2 Set selector switch on 12 24 volt junction box 1 to 12 volts 3 Switch electrical control box 2 to ON position Figure 15 Electrical Control boxes 0005 00 2 9 2510 247 13 amp P 0005 00 UNFOLDING FROM SHIPPING STORAGE CONFIGURATION Continued 4 Using valve control levers EXTEND LEFT OUT and EXTEND RIGHT OUT fully extend boom extensions 5 Using valve control levers MAST RETRACT until arrow 1 at pivot pin hole is aligned with arrow 2 on mast Figure 16 Hydraulic Control Levers and Pin alignment 6 Insert both pivot pins 3 do not insert spring clips into pivot pins and remove both clevises 4 from mast Figure 17 Clevis 0005 00 3 9 2510 247 13 amp P 0005 00 UNFOLDING FROM SHIPPING STORAGE CONFIGURATION Continued 7 Using remote control or valve control levers MAST EXTEND to unfold main frame assembly to a vertical position onto mast Figure 18 Hydraulic Control Levers and Unfolded FWTD 8 Remove both pivot pins 9 Close bottom breather relief valve by turning breather lever 5 to a 90 angle with the fit
191. be followed and extreme caution used when backing to prevent damage to equipment and injury or death to personnel Use extremely low speed when loading and unloading vehicles Higher speeds will exaggerate motions and create hazardous conditions which could result in personnel injury or death or damage to equipment HEAVY COMPONENTS Tow bars weigh 47 Ibs Use caution when removing and handling them to prevent injury or death to personnel and damage to equipment NOTE Set parking brake and chock wheels on towed vehicle Turn electrical control box power switch to ON position Disconnect 70 ft cable from fifth wheel towing device and light assembly Remove towlight assembly on rear of towed vehicle and store properly Ensure towed vehicle s steering wheel is unsecured 0018 00 1 9 2510 247 138 0018 00 DISCONNECTING TOWED VEHICLE Continued 4 Using remote control or valve control levers MAST EXTEND to unlock pivot pin 22 and remove pin 5 Repeat step 5 for remaining pivot pin 6 Using remote control or valve control levers MAST RETRACT to lower towed vehicle 7 Using remote control or valve control levers BOOM EXTEND to unlock hitch pin 20 from center mast 21 and remove pin Figure 60 Mast Pin Placement 0018 00 2 9 2510 247 13 0018 00 DISCONNECTING TOWED VEHICLE Continued Using remote control or valve control levers MAST RETRACT until rubber blocks 16 are loose Remove rubber
192. be those prescribed by DA Pam 738 750 Functional User s Manual for the Army Maintenance Management System as contained in the Maintenance Management Update DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE Refer to TM 750 244 3 for procedures for destruction of Army materiel to prevent enemy use PREPARATION FOR STORAGE OR SHIPMENT Refer to WP 0021 of WP 0078 for instructions for preparing the fifth wheel towing device for storage or shipment OFFICIAL NOMENCLATURE NAMES DESIGNATIONS AND ABBREVIATIONS NOTE Refer to MIL STD 12D for standard abbreviations Official Name Common Name or Abbreviation Army Master Data 08 000 AMDF Basic TOI pe E BII Commercial and Government Entity CAGEC Components of End ltem Corrosion Prevention and nnn CPC Equipment Improvement EIR A GVW International Standards Organization ISO Intervehicular Electrical Cable sass sss Maintenance Allocation MAC Modified Table of Organization and MTOE National
193. ble terminal lug to ground point Ensure that all hardware is tight 0038 00 8 TM 9 2510 247 13 amp P 0038 00 LINES AND PORTS To keep dirt from contaminating fluid systems when removing and installing lines perform the following steps a Clean fittings and surrounding area before disconnecting lines b Cover cap plug or tape lines and ports after disconnecting lines Use cap and plug set on air lines When these are not available use hand carved wooden plugs clean rags item 10 WP 0085 duct tape item 16 WP 0085 or other similar materials to prevent dirt from entering system c Ensure that new and used parts are clean before installing d Wait to remove covers caps plugs or tape from lines and ports until just before installing lines ANTISEIZE TAPE CAUTION Apply antiseize tape only to pipe threads of male fittings of air system or damage to air valves may result When connecting air lines and fittings without compression sleeves or packings antiseize tape item 17 0085 may be used to keep connections from leaking Use as follows a Ensure that threads are clean and dry b Start antiseize tape one or two threads from small or leading edge of fitting joining tape together with an overlap of about 1 8 in 3 18 mm for fittings with fine threads For fittings with coarse threads tape should be wrapped around threads two or three times c Tightly wrap antiseize tape in same direction as you woul
194. blocks 16 from between towed vehicle U bolts 17 and boom NOTE Prime mover may be moved slightly forward or backward to relieve tension on hitch pin 13 Using remote control or valve control levers BOOM EXTEND to raise boom until hitch pins 13 and 18 are loose Remove hitch pins 13 and 18 from tow bar assembly Disconnect air lines from fifth wheel towing device to towed vehicle Repeat step 11 for remaining tow bar assembly BOOM RETRACT and MAST RETRACT to position booms on the ground Remove hitch pin 6 and spring clip 7 from upper section 4 of tow bar assembly and front towing eye 5 of towed vehicle Figure 61 Pad and Tow Bar Assembly Locations 0018 00 3 9 2510 247 13 amp P 0018 00 DISCONNECTING TOWED VEHICLE Continued CAUTION When loosening rear safety chains do not allow boom extensions to contact underside of towed vehicle Damage to towed vehicle may occur 16 Using remote control or valve control levers BOOM RETRACT to loosen rear safety chains 17 Remove chains 10 from boom extension clevis 12 and frame hook clevis 11 18 Remove frame hook 8 from frame flange 9 19 Repeat steps 17 and 18 for remaining frame hook Figure 62 Frame Hook Connection 20 Using remote control or valve control levers BOOM EXTEND until transport leg assembly can be lowered Rotate handle 3 clockwise and lower transport legs 21
195. ce in storage configuration 0002 Sealant item 11 WP 0085 WP 0056 00 5 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General None NSN 5180 00 177 7033 REMOVAL Ed WARNING High pressure is present in the 250M Fifth Wheel Towing Device hydraulic system Do not disconnect any hydraulic system component unless hydraulic system pressure has been relieved Ensure each hydraulic control lever is moved several times through all positions and hydraulic tank relief valve is slowly loosened to relieve pressure Failure to comply may result in severe injury or death to personnel Spilled hydraulic oil is very slippery Be careful when entering or working in area Wipe up any spilled oil immediately Failure to comply may result in severe injury or death to personnel CAUTION Always clean around fittings before disconnecting or connecting hoses or fittings Ensure area is clean before installing hydraulic components Failure to comply may result in damage to equipment Cover cap or plug all openings ports and tube or hose ends when they are disconnected Failure to comply may result in damage to equipment Ensure you couple only fittings designed to be coupled with each other Never depend on trial and error Just because two fittings will screw together is no guarantee that the connection will not leak See illustrations of fitting types in this chapter Failure to comply may result in damage to equipm
196. ce tests or replacing parts This will prevent shock to personnel and damage to parts and equipment DO NOT touch heat shrinkable tubing for at least 30 seconds after heating Heat shrinkable tubing is hot and will burn you causing serious injury or death 9 2510 247 13 amp P WARNING COUPLING UNCOUPLING Al Al During coupling to prime mover it may be required to adjust the angle of the main frame WP 0005 to accommodate the height of the fifth wheel plate Always ensure when coupling that the transport legs and bottom pressure relief valve assembly do not make contact with the prime mover Failure to comply may result in injury or death to personnel All persons not involved in coupling uncoupling operation must stand clear of prime mover and fifth wheel towing device to prevent serious injury or death Never stand between the prime mover and fifth wheel towing device when the prime mover is being backed up to the fifth wheel towing device Serious injury or death may result WARNING LOADING UNLOADING OPERATION All persons involved in the loading or unloading operation must stand clear of prime mover and fifth wheel towing device Failure to comply may result in injury or death to personnel Due to the dimensions and center of gravity of some loads proper procedures must be followed when loading and unloading equipment to prevent damage to equipment and injury or death to personnel Visibility from the prim
197. ck Service Semi annual Brake Air System Semi annual Hydraulic Lines Hydraulic Fluid Boom Safety Mast Safety Cam Valve END OF WORK PACKAGE Not Fully Mission Procedure Capable If WARNING Unless otherwise specified perform all lubrication and preventive maintenance checks with fifth wheel towing device on level ground and uncoupled Failure to follow this warning may result in injury or death to personnel NOTE Perform all Operator PMCS as appropriate while performing Item No 2 checks Operate through all hydraulic functions to detect malfunctions Check all air hoses for leaks kinks Leaks kinks or cracks cracks and missing mounting clamps evident Check all hydraulic hoses for leaks Leaks kinks or cracks kinks bends cracks and missing evident Shield is missing mounting hardware Ensure rubber or unserviceable shield around hoses is present and serviceable Change hydraulic fluid WP 0056 Position main frame 2 inches 5 1 cm Main frame contacts above a suitable support device With support device all power OFF operate BOOM valve lever to extend and retract positions Position main frame 2 inches 5 1 cm Main frame contacts above a suitable support device With support device all power OFF operate MAST valve lever to extend and retract positions Fifth wheel towing device in coupling Travel does not stop position MAST EXTEND until cam automatically valve rolle
198. code is keyed to Section IV Remarks and the SRA complete repair application is explained there 00081 00 3 TM 9 2510 247 13 amp P 0081 00 4 EXPLANATION OF COLUMNS IN TOOLS AND TEST EQUIPMENT REQUIREMENTS SECTION a Column 1 Tool or Test Equipment Reference Code The tool or test equipment reference code correlates with a code used in the MAC Section II column 5 b Column 2 Maintenance Level The lowest level of maintenance authorized to use the tool or test equipment c Column 3 Nomenclature Name or identification of the tool or test equipment d Column 4 National Stock Number The National Stock Number of the tool or test equipment e Column 5 Tool Number The manufacturer s part number model number or type number 5 EXPLANATION OF COLUMNS IN REMARKS SECTION IV a Column 1 Remarks Code The code recorded in Section Il column 6 b Column 2 Remarks This column along with the related codes clarifies maintenance and inspection functions by different MOS involved in maintaining some components 0081 00 4 9 2510 247 13 amp P 0081 00 Section MAINTENANCE ALLOCATION CHART FOR FIFTH WHEEL TOWING DEVICE 2 3 4 5 6 Maintenance Level Tools and Remarks Component Maintenance Assembly Function Electrical System 24 Volt Receptacle Replace 12 Volt Receptacle Replace 12 24 Volt Junction Box Replace Electrical Control Box Replace Rep
199. crew external threads and threads of the attaching nut or tapped hole internal threads of the attaching nut or tapped hole internal threads The most common thread class for bolts and screws is Class 2 Table 8 Thread Classes and Description EXTERNAL INTERNAL INTERNAL 1B LOOSE FIT 2B MEDIUM FIT 3B CLOSE FIT NOMINAL SIZE 34 NO THREADSANCH 3 THREAD 1 34 10 A 2A NOTE Unless followed with LH e g 314 10 UNC 2A LH threads are right hand 0089 00 5 TM 9 2510 247 13 amp P 0089 00 7 FASTENER GRADE In addition to being classified by thread type thread fasteners are also classified by material The most familiar fastener classification system is the SAE grading system Table 9 Table 9 SAE Screw and Bolt Markings SCREWS BOLTS SAE GRADE 2 SAE GRADE 6 NO MARKING 4 RADIAL DASHES 90 APART GRADE 3 2 RADIAL DASHES SAE GRADE 7 180 APART 5 RADIAL DASHES 72 APART SAE GRADE 5 3 RADIAL DASHES SAE GRADE 8 120 APART 8 RADIAL DASHES 60 APART Markings on Hex Locknuts GRADE A No Marks GRADE A Marks GRADE B 3 Marks GRADE B Letter B GRADE C 6 Marks GRADE C Letter C GRADE Na Matches GRADE B One Notch GRADE Two Notches END OF WORK PACKAGE 0089 00 6 9 2510 247 13 amp P 0090 00 SCHEMATICS This work package contains electrical and hydraulic schematic Refer to these schematics when performing electrical or hydra
200. ctive clothing goggles shield gloves etc and use caution to avoid injury to personnel Failure to comply may result in injury or death to personnel WARNING AIR SYSTEM Apply antiseize tape only to pipe threads of male fittings of air system or damage to air valves may result Failure to comply may result in injury or death to personnel DO NOT overtighten or use power tools to tighten fittings taped with antiseize tape Over tightening could damage fitting threads and cause connection to leak Failure to comply may result in injury or death to personnel 9 2510 247 138P HEADQUARTERS DEPARTMENT OF THE ARMY CHANGE WASHINGTON DC 15 May 2005 NO 1 TECHNICAL MANUAL OPERATOR S UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL WITH REPAIR PARTS AND SPECIAL TOOLS LIST FOR FIFTH WHEEL TOWING DEVICE MODEL 250M NSN 2510 01 458 8253 FOR SERIAL NUMBERS 250M499 THROUGH 250M999 DISTRIBUTION STATEMENT Approved for public release distribution is unlimited TM 9 2510 247 13 amp P 1 July 2004 is updated as follows 1 New or changed material is indicated by a vertical bar in the margin 2 Replace the following work packages with their revised version Remove and Replace Work Packages WP 00100 WP 0082 0 WP 0091 0 3 File this change sheet in front of publication for reference purposes By Order of the Secretary of the Army PETER J SCHOOMAKER General United States Army Official Chief of Staff Sundin KK E S
201. ctrical control box and a step for aid in reaching valve control levers during operation Voltmeter Provides ability to monitor voltage of fifth wheel towing device Electric Motor Switch Must be depressed at all times to operate hydraulic control levers 0004 00 1 9 2510 247 13 amp P 0004 00 HYDRAULIC SYSTEM CONTROLS AND INDICATORS Continued Top Hydraulic Relief Valve Provides remote point for air to be drained from reservoirs Pressure Gauge Provides ability to monitor hydraulic fluid pressure Must maintain back pressure of 300 to 800 psi when the boom or mast is operated with no load Hydraulic Flow Valves Provides ability to adjust hydraulic back pressure WP 0003 Hydraulic Safety Valves Control hydraulic pressure and contain hydraulic flow valves to allow for adjustment of back pressure 0004 00 2 TM 9 2510 247 13 amp P 0004 00 COUPLING AND CONNECTORS CONTROLS AND INDICATORS Kingpins removable Secures fifth wheel towing device to fifth wheel of prime mover Kingpins are removable and two sizes are provided Gladhands Connect to the prime mover and towed vehicle to supply air for the towed vehicle brakes Electrical Connector Connection point for the 24 volt inter vehicular electrical cable from prime mover Electrical Connector Connection point for the 12 volt inter vehicular electrical cable from prime mover 0004 00 3 9 2510 247 13 amp P 0004 00 TIEDOWN AND ACCESSORY IT
202. d raise the front of the booms approximately 1 foot above the ground Lock transport legs into the stowed position 5 Place one of four 6 inch blocks under each boom assembly to create a pivot point 6 Using remote control or valve control levers BOOM RETRACT to lower front of booms and raise the rear of the booms Ensure the 2 and 6 inch blocks remain in place Boom retract until the front wheels of the disabled vehicle are approximately 7 8 inches above the ground 7 Insert the second set of 6 inch blocks under the front tires of the disabled vehicle 8 Using remote control or valve control levers BOOM EXTEND until the front wheels of the disabled vehicle are resting on the lift blocks the booms are free of the U bolts and the 6 inch pivot blocks under the booms are free Remove pivot blocks 9 Place transport legs in the down position 10 Using remote control or valve control levers BOOM RETRACT until the unit rests on the transport legs and the booms are again 1 inch above and parallel to the ground 11 With the booms 1 inch above the ground connect towed vehicle accordingly to WP 0010 END OF WORK PACKAGE 0011 00 1 9 2510 247 13 amp P 0012 00 WINCHING OPERATIONS WARNING WINCHES All personnel must stand clear during winching operations A snapped cable or shifting load could cause injury or death to personnel Winch is not designed for recovery of vehicles in mired conditions Failure to comply may result in dea
203. d Repair Activity SRA A Item requires special handling or condemnation procedures because of specific reasons such as precious metal content high dollar value critical material or hazardous material Refer to appropriate manuals directives for specific instructions f Column 3 The NSN for the item is listed in this column 9 CAGEC Column 4 The Commercial and Government Entity Code CAGEC is a five digit code which is used to identify the manufacturer distributor or Government agency activity that supplies the item h Part Number Column 5 Indicates the primary number used by the manufacturer individual company firm corporation or Government activity which controls the design and characteristics of the item by means of its engineering drawings specifications standards and inspection requirements to identify an item or range of items NOTE When you use an NSN to requisition an item the item you receive may have a different P N from the number listed 0082 00 5 9 2510 247 13 amp P 0082 00 3 EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGE Continued Description and Usable on Code UOC Column 6 This column includes the following information 1 The federal item name and when required a minimum description to identify the item 2 P Ns of bulk materials are referenced in this column in the line entry to be manufactured or fabricated 3
204. d requisitioned individually AF Assembled by The parts that make up the assembled DS AVIM level item must be requisitioned or fabricated AH Assembled by and assembled at the level of GS level maintenance indicated by the source AL Assembled by code If the 3rd position of the SMR SRA code authorizes you to replace the item AD Assembled by but the source code indicates the item depot is assembled at a higher level order the item from the higher level of maintenance Source Code Application Explanation XA Do not requisition an XA coded item Order the next higher assembly refer to NOTE below XB If an item is not available from salvage order it using the CAGE Code and P N XC Installation drawings diagrams instruction sheets field services drawings identified by manufacturer s P N XD Item is not stocked Order an XD coded item through normal supply channels using the CAGE Code and P N given if no NSN is available NOTE Cannibalization or controlled exchange when authorized may be used as a source of supply for items with the above source codes except for those items source coded XA d Maintenance Code Maintenance codes tell you the level s of maintenance authorized to use and repair support items The maintenance codes are entered in the third and fourth positions of the SMR code as follows 1 THIRD POSITION The maintenance code entered in the third position tells you the lowest maintenance level a
205. d tighten a nut Tape must be pressed into threads without cutting or ripping CAUTION DO NOT overtighten or use power tools to tighten fittings taped with antiseize tape Over tightening could damage fitting threads and cause connection to leak d Using hand tools tighten fittings 0038 00 9 9 2510 247 13 0038 00 TUBES AND COMPRESSION FITTINGS 1 Tubes with inverted nuts and compression fittings are designed for one time assembly Once assembled they must be replaced as a unit if any parts are found defective Used parts may not seal properly when used with new ones 2 Used tube assemblies in good condition can be installed to their original location without leaking 3 Assemble new tubes compression sleeves and inverted nuts as follows a Slide inverted nut onto end of tube b Slide compression sleeve onto end of tube Repeat previous two steps for other end of tube as required INVERTED NUT TUBE COMPRESSION SLEEVE Figure 74 Tube Assembly 4 Install new tube assemblies as follows a Insert end of tube as far as it will go into compression fitting to which tube is being installed b Twist inverted nut into compression fitting and tighten inverted nut against compression sleeve with open end wrench Compression sleeve will clamp down around tube and conform to internal surface of compression fitting and inverted nut c Repeat previous two steps for other end of tube as required 0038 00 1
206. d towed vehicle If required continue winching operation until towed vehicle is positioned to connect to towing bars on boom 7 Continue towed vehicle connection Refer to WP 0010 END OF WORK PACKAGE Figure 53 Winch During Use 0012 00 2 9 2510 247 13 amp P 0013 00 PREPARING EQUIPMENT FOR TOWING WARNING Secure any materials or equipment loaded in the beds of towed equipment Failure to comply may result in death or injury to personnel When loaded shut down towed equipment turn off all switches close doors and hatches and swing in mirrors Failure to comply may result in death or injury to personnel NOTE Reduce towed equipment to lowest height configuration consistent with the operational requirements Reference towed vehicle TM for drive train disconnect requirements 1 Setparking brakes on prime mover and towed vehicle 2 Follow instructions for loading equipment 0019 prior to securing towed vehicle NOTE Prior to transporting towed vehicle ensure parking brakes and wheel chocks are released END OF WORK PACKAGE 0013 00 1 9 2510 247 13 amp P 0014 00 SECURING EQUIPMENT NK Malba AS Put transmissions in neutral on towed equipment Make sure gun turrets or other rotating parts are properly secured Make sure all items are properly stowed on the fifth wheel towing device Remote shoud be stored with control switches t oward the top of the tool box Check the prime mover and
207. death or injury to personnel Due to the dimensions and center of gravity of some loads proper procedures must be followed when loading and unloading equipment to prevent damage to equipment and injury or death to personnel Visibility from the prime mover is significantly reduced when backing whether the fifth wheel towing device is loaded or not Proper procedures must be followed and extreme caution used when backing to prevent damage to equipment and injury or death to personnel Use extremely low speed when loading and unloading vehicles Higher speeds will exaggerate motions and create hazardous conditions which could result in personnel injury or death or damage to equipment Tow bar assemblies weigh 47 lbs Use an assistant and caution when removing and handling them to prevent injury or death to personnel and damage to equipment NOTE Refer to WP 0091 for authorized prime movers and towed vehicles Prime mover and disabled vehicle should be on the same plane when coupling If planes are uneven use winch to maneuver disabled vehicle to even plane with prime mover If the vehicle being recovered is not equipped with front towing eyes skip to step b 2 1 Tow bar assemblies should be in stowage position 2 Remove spring pin 1 from hitch pin 2 and remove hitch pin from upper section of tow bar assembly 3 Set aside hitch pin 2 for future use 3 Figure 41 Tow Bar Assemblies 0009 00 1 9 2510 247 1
208. ds against excessive wear 3 When chronic failure of material results from subjection to extreme conditions report the condition on SF Form 368 OPERATION IN EXTREME COLD CAUTION Cil level must be checked in cold temperatures after fifth wheel towing device has been winterized and removed from maintenance facility Damage to equipment may occur if oil level is not maintained 1 Operation a b C Insulation may crack and cause electrical short circuits Construction materials can become hard brittle and easily damaged or broken Handle construction materials with care in extreme cold Refer to FM 9 207 and FM 21 305 for special instruction on driving hazards in extreme cold Refer tg WP 0039 for proper lubrication during extreme cold weather conditions 2 At Halt Parking a b When parking short term park in a sheltered area out of the wind When parking long term prepare a footing of planks or brush if high dry ground is not available Remove all buildup of ice and snow as soon as possible after shutdown Cover and shield the towing device with canvas covers if available Keep ends of covers off the ground to keep them from freezing to the ground 0022 00 1 9 2510 247 138 0022 00 OPERATION EXTREME HEAT AND HIGH HUMIDITY 1 Refer to WP 0039 for proper lubrication during extreme heat conditions Adequate lubrication is essential Extreme heat will cause oil films to evaporate res
209. e hydraulic hose from elbow 1 2 Remove hydraulic hose from tee fitting 2 and upper safety valve 12 3 Remove hydraulic hoses from elbows 3 4 Remove hydraulic hose 4 from cylinder 5 5 Remove tee fitting 2 from straight adapter 6 6 Remove straight adapter 6 from cylinder 7 7 Remove elbows 3 from cylinders 5 and 7 8 Loosen two screws 8 and remove retaining pin 9 9 Using a suitable lifting device and two personnel lower cylinder assembly 5 or 7 to mast It may be necessary to release some pressure from the cylinder to allow the cylinder to collapse enough to clear the mounts 10 Loosen two screws 10 and remove retaining pin 11 11 Remove cylinder assembly 12 Repeat steps 8 through 11 for remaining main frame to mast cylinder assembly INSTALLATION 1 Using a suitable lifting device and two personnel position bottom of cylinder assembly in bracket and secure with retaining pin 11 2 Tighten two screws 10 3 Raise cylinder assembly and install retaining pin 9 4 Tighten two screws 8 5 Repeat steps 1 through 4 for remaining main frame to mast cylinder assembly NOTE Use sealing compound on all threads before installing fittings All hydraulic hoses must not be recapped and or unplugged untin connecting to prevent contamination of hydraulic system Replace plastic ties as needed 0063 00 2 9 2510 247 13 0063 00 INSTALLATION Continued 10 11
210. e mover is significantly reduced when backing whether the fifth wheel towing device is loaded or not Proper procedures must be followed and extreme caution used when backing to prevent damage to equipment and injury or death to personnel Use extremely low speed when loading and unloading vehicles Higher speeds will exaggerate motions and create hazardous conditions which could result in personnel injury or death or damage to equipment Tow bar assemblies weigh 47 lbs Use an assistant and caution when removing and handling them to prevent injury or death to personnel and damage to equipment The location of the boom extension clevis tiedown chains should be located between the rear of the cab and the forward rear axle on towed vehicle frame Failure to comply may result in injury or death to personnel 9 2510 247 13 WARNING HAZARDOUS WASTE DISPOSAL When servicing this equipment performing maintenance or disposing of materials such as engine coolant transmission fluid lubricants battery acids or batteries and CARC paint consult your Unit Local Hazardous Waste Disposal Center safety office for local regulatory guidance If further information is needed please contact the Army Environmental Hotline at 1 800 872 3845 Failure to comply may result in injury or death to personnel WARNING BATTERIES Wear safety glasses or goggles when checking batteries Always check electrolyte level with engine stopped Do not smoke o
211. e way before making electrical connection After making electrical connection slide heat shrinkable tubing into place over electrical connection WARNING DO NOT touch heat shrinkable tubing for at least 30 seconds after heating Heat shrinkable tubing is hot and will burn you causing serious injury or death Hold hot air blow gun 4 5 in 10 2 12 7 cm away from heat shrinkable tubing and apply heat for approximately 30 seconds Stop applyling heat as soon as heat shrinkable tubing forms to the shape of the electrical connection 0038 00 7 9 2510 247 13 amp P 0038 00 ELECTRICAL GROUND POINTS Many electrical problems are the result of poor ground connection You can ensure that ground connections are good by performing the following steps WARNING Although battery ground cable must be connected in order to test electrical circuit voltage disconnect battery ground cable from prime mover before performing resistance tests or replacing parts This will prevent shock to personnel and damage to parts and equipment a Remove hardware connecting ground cable terminal lug to ground point b Clean mounting hardware ground cable terminal lugs and ground point with dry cleaning solvent 14 WP 0085 and scrub brush item 1 WP 0085 c Remove any rust with wire brush item 2 WP 0085 d Look for cracks loose terminal lugs and stripped threads Replace any defective parts e Install hardware connecting ground ca
212. eath CAUTION To prevent damage to the equipment uncoupling should be done by two people the first person in the prime mover cab and the second acting as a ground guide 1 Setprime mover parking brake 2 Unhook gladhands 1 and 24 volt NATO slave cable 2 Figure 66 NATO Slave Cable 0020 00 1 9 2510 247 13 amp P 0020 00 UNCOUPLING Continued Figure 67 Master Controls and Transport Legs 3 Set junction box selector switch 3 to 12 volt NOTE Power switch 4 must be in the on position The electric motor button 5 must be pushed to use the valve control levers 4 Using remote control or valve control levers 6 EXTEND RIGHT OUT and EXTEND LEFT OUT fully extend boom extensions 5 Using remote control or valve control levers bring main frame to a level position and allow stowage of transport legs 7 6 Unlock the fifth wheel in accordance with prime movers operating procedures 0020 00 2 TM 9 2510 247 13 amp P 0020 00 WARNING All persons not involved in coupling uncoupling operation must stand clear of prime mover and fifth wheel towing device to prevent serious injury or death UNCOUPLING Continued 7 Release the prime mover parking brake and slowly drive the prime mover forward allowing the towing device to release from the fifth wheel 8 Stop the prime mover when towing device is released from fifth wheel 9 Using remote control or valve control levers BOOM RETRACT
213. ected to the disabled vehicle perform the pre pick lifting WP 0011 prior to performing step 3 Wheels on towed vehicle should be chocked and parking brakes engaged If valve control levers are used an assistant must monitor boom extensions to ensure boom extensions do not contact towed vehicle Remove front towing clevis from towed vehicle Using tire stop as a guide reference Figure 43 align boom to frame of towed vehicle and back prime mover and towing device under vehicle Adjust tire stop so front of towed vehicle is 6 to 12 inches from bump stop when not using tow bar assembly Front tire towed vehicle aligned Tire Stop Figure 43 Tire Stop 0010 00 1 Change 1 9 2510 247 13 amp P 0010 00 TOWED VEHICLE Continued WARNING The location of the boom extension clevis tiedown chains should be located between the rear of the cab and the forward rear axle on towed vehicle frame AUTHORIZED LOCATION FOR BOOM EXTENSION CLEVIS TIEDOWN CHAINS Figure 44 Towing Connection Location 4 Using remote or valve control levers EXTEND LEFT OUT 1 and EXTEND RIGHT OUT 2 extend boom extensions to required length 0010 00 2 Change 1 9 2510 247 13 amp P 0010 00 TOWED VEHICLE Continued 5 Using remote control or valve control levers BOOM EXTEND until transport leg assemby is free of fifth wheel Rotate handle 3 counter clock
214. ed For equipment under manufacturer s warranty hardtime oil service intervals shall be followed Intervals shall be shortened if lubricants are known to be contaminated or if operation is under adverse conditions e g longer than usual operating hours extended idling periods extreme dust etc Clean area around lubrication points with dry cleaning solvent 19 WP 0085 or equivalent before lubricating equipment After lubrication wipe off excess lubricant to prevent accumulation of foreign matter Before you start your lubrication service ALWAYS a Clean area around lubrication point before lubricating NEVER a Use wrong type grade lubricant b Use too much lubricant 0039 00 2 9 2510 247 13 amp P 0039 00 250 FIFTH WHEEL TOWING DEVICE FWTD LUBRICANT INTERVAL OE HDO10 M Hydraulic Tank Battery Mast Cylinder Mast Cylinder Boom Cylinder C See View 13 C See View 2 C See View 4 C See View 3 C See View 9 Pickup Plate Landing Legs Roller Block Tire Stop Assembly See View 1 See View 5 See View 14 C See View 11 NOTE Vehicle must be Kingpin transport position para 1 10 C See View 1 to accomplish this step NOTE Dotted leader lines indicate that lubrication is required on both sides of the equipment All lubrication is done with vehicle in cou
215. ed at the begining of this manual WARNINGs CAUTIONs NOTEs subject headings and other important information are highlighted in BOLD print as visual aid WARNING A WARNING indicates a hazard which can result in death or serious injury CAUTION A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment NOTE A NOTE is a statement containing information that will make the procedure easier to perform Statements and words of particular importance are printed in CAPITAL LETTERS to create emphasis Instructions are located with illustrations that show the specific task the operator or mechanic is performing Dashed leader lines used in illustrations indicate that called out items are not visible i e they are located within the structure Dashed leader lines in the Lubrication Chart indicate that lubrication is required on BOTH sides of the equipment Technical instructions include metric units in addition to standard units A metric conversion chart is provided on the inside back cover An alphabetical index is provided at the end of the manual to assist in locating information not readily found in the Table of Contents FOLLOW THESE GUIDELINES WHEN YOU USE THIS MANUAL Read through this manual and become familiar with its contents before attempting to operate or maintain the fifth wheel towing device A warning summary is provided at the beginning of this man
216. ed level and cross country 2 The prime movers for the fifth wheel towing device are listed in WP 0091 3 The following fifth wheel towing device positions are supplied for operator maintenance personnel reference a SHIPPING STORAGE CONFIGURATION The fifth wheel towing device shall be shipped or stored inverted in the smallest configuration WP 0021 Figure 1 Primary Shipping Configuration Storage 0002 00 1 TM 9 2510 247 13 amp P 0002 00 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES Continued NOTE The storage configuration may be modified to accommodate space and operating time 1 STORAGE CONFIGURATION A Storage position with the boom extensions left in the extended position 2 STORAGE CONFIGURATION B Storage position with the boom extensions left in the extended position and the main frame left in the vertical position with the main frame cylinders fully retracted 3 The SHIPPING CONFIGURATION may be modified to accommodate mode of shipping WP 0021 Figure 2 Storage Configuration A Figure 3 Storage Configuration B 0002 00 2 9 2510 247 13 0002 00 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES Continued b COUPLING CONFIGURATION The fifth wheel towing device set on the ground with the boom extended at a right angle to mast The boom extensions are fully extended The transport legs are locked in the up position WP 0006 Figure 4
217. edicina ea ia Een cita Rap eren M H CHAPTER 6 UNIT MAINTENANCE INSTRUCTIONS RS A E TUE Service Receipt 2 Unit Preventive Maintenance Checks and Services General Maintenance Instructions 0 0 1 1 eene Lubrication Instructions Electrical System Maintenance 24 Volt Receptacle Replacement 440000 00 0100 00000 12 Volt Receptacle Replacement 12 24 Volt Junction Box Electrical Control Box Maintenance asas Solenoid Assembly Remote Control Assembly 24 Volt Tow Light Assembly Repair sss FixediWorklight Repair EEE TM 9 2510 247 13 amp P TABLE OF CONTENTS Continued WP Sequence No CHAPTER 6 UNIT MAINTENANCE INSTRUCTIONS Continued Strobe Light Maintenance seen eie iata taa saei ce scusa bo A Battery Battery Box Replacement dani ia Wiring Harness Cable Maintenance Brake System Maldini cd Gladhand Rep
218. ent Fittings must be installed and hand tightened If a fitting cannot be handtightened it may be cross threaded or have damaged threads Use wrench only for final tightening Failure to comply may result in damage to equipment 0058 00 1 9 2510 247 13 0058 00 REMOVAL Continued 10 11 NOTE There are two safety valves Both valves are removed the same way Maintenance personnel must note the position of all parts prior to removal to ease the installation process The upper safety valve controls the mast functions and the lower safety valve controls the boom functions Remove hydraulic hoses from tee fitting 1 Remove hydraulic hose from elbow 2 Remove hydraulic hoses from bottom of safety valve 3 Remove 1 1 2 inch 38 1 mm screw 4 from safety valve 3 and bracket 5 Remove 2 1 2 inch 63 5 screw 6 from safety valve 3 and bracket 5 Remove safety valve 3 from bracket 5 Remove tee fitting 1 from globe valve 7 Remove globe valve 7 from straight adapter 8 Remove straight adapter 8 from safety valve 3 Remove elbow 2 from check valve 9 Remove check valve 9 from safety valve 3 Figure 106 Hydraulic Safety Valve Assembly 0058 00 2 9 2510 247 13 amp P 0058 00 INSTALLATION NOTE There are two safety valves Both valves are installed the same way Use sealing compound on all threads before installing fittings 1 Install check valve 9 to
219. er let moving wire rope slide through hands even when wearing gloves A broken wire could cut through glove and cut Never walk under booms during any operations Failure to comply may cause injury or death to personnel 9 2510 247 13 amp P WARNING WINCHES E All personnel must stand clear during winching operations A snapped cable or shifting load could cause injury or death to personnel Ensure cable is properly mounted on rear winch shaft before operating reel Failure to do so may result in injury or death to personnel Winch is not designed for recovery of vehicles in mired conditions Failure to comply may result in injury or death to personnel If winch cable has to be cut to remove winch assembly wrap cut end of cable in tape and secure loose end of cable to prevent it from swinging free during winch assembly removal Failure to follow this warning could result in injury or death to personnel WARNING WIRE ROPES Wire can become frayed or contain broken wires Wear heavy leatherpalmed work gloves when handling wire rope Frayed or broken wires can injure hands WARNING TOWING Secure any materials or equipment loaded in the beds of towed equipment Failure to comply may result in injury or death to personnel When loaded shut down towed equipment turn off all switches close doors and hatches and swing in mirrors Failure to comply may result in injury or death to person
220. erform operational check of all remote control functions END OF WORK PACKAGE 0046 00 2 9 2510 247 13 amp P 0047 00 24 VOLT TOW LIGHT ASSEMBLY REPAIR REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Tow light assembly removed from tool box Tags marker item 15 Appendix Ties wire item 18 Appendix F Tools Test Equipment Washer lock 1 114021 Tool Kit Mechanics General Washer lock 4 2434 NSN 5180 00 177 7033 Washer lock 6 MS35335 35 Nut self locking 2 MS17829 5C General Safety Instructions Remove all power to towing device prior to making any repairs on electrical system REMOVAL WARNING Remove all power to fifth wheel towing device prior to making any repairs on the electrical system Failure to do so may result in serious injury or death 1 Remove two locknuts 1 screws 2 and four emergency straps 3 Discard locknuts Figure 83 Tow Light Assembly 0047 00 1 9 2510 247 13 amp P 0047 00 REMOVAL Continued NOTE Tag and mark wires before removing Cut plastic cable ties as necessary 2 Disconnect eleven connectors 4 from connectors 5 3 Push eleven connectors 4 back on wires 6 and remove pins 7 and washers 8 NOTE Mark position of ground wire and screw to aid installation 4 Remove screw 9 lockwasher 10 and connector 11 Discard lockwasher 5 Remove two ground wires 12 from connector 11 6 Remove n
221. es and Fittings Oil Filter Cam Valve Main Frame to Mast Cylinder Mast to Boom Cylinder Boom Extensions Cylinder Reservoir and Fittings 3 4 5 Maintenance Level Tools and Maintenance Unt DS GS Depot Function Ref Code Remarks Replace Replace Replace Replace Replace Replace Replace Replace Repair Replace Repair Replace Repair Replace Replace Replace Replace Replace Replace 00081 00 7 9 2510 247 13 amp P 0081 00 Section TOOLS AND TEST EQUIPMENT REQUIREMENTS 1 2 4 Tool or Test Equipment Maintenance National Reference Code Level Nomenclature Stock Number Tool Number Tool Kit General Mechanics 5180 00 177 7033 Shop Equipment 4910 00 754 0654 Common No 1 Shop Equipment 4910 00 754 0650 Common No 2 Tool Cylinder Alignment 1BZD4 1084 1 Section IV REMARKS Reference Code The cylinder alignment tool 18204 1084 1 is supplied with each cylinder when shipped to the unit Contractor logistics support Component assembly goes to manufacturer for repair END OF WORK PACKAGE 0081 00 8 9 2510 247 13 0082 00 REPAIR PARTS AND SPECIAL TOOLS LISTS RPSTL SECTION I INTRODUCTION 1 SCOPE This RPSTL lists and authorizes spares and repair parts special tools special Test Measurement and Diagnostic Equipment TMDE and other special support equipment required for performance of Unit and Direct sup
222. evels more frequently Class leaks must be reported immediately to your supervisor Failure to do this will result in damage to vehicle and or components 0031 00 3 9 2510 247 13 0031 00 ee START KING PIN SPAREKINGPIN GLADHAND LIES FRONT HE KINGPIN 12 24 JUNCTION BOX ELECTRICAL 7 CONTROL BOX COVERISTEP FILTER TOW BAR ASSEMBLY REGULATION VALVE MAIN VALVE ASSEMBLY WORKLIGHT GLADHAND STROBE TIEDOWN POINTS TIEDOWN POINTS 1 BOOMEXTENSIONS X Figure 70 General PMCS Procedure Chart 0031 00 4 9 2510 247 13 amp P 0031 00 Table 2 Operator Preventive Maintenance Checks and Services 5 for 250M Fifth Wheel Towing Device To Check Not Fully Mission Service Procedure Capable If NOTE Prior to the performance of the monthly PMCS checks and services ensure the fifth wheel towing device is placed into the hydraulic oil fill position Figure 104 WP 0056 00 7 This position may be adjusted to accommodate particular steps being performed Review ALL WARNINGS CAUTIONS and NOTES before performing PMCS and operating the fifth wheel towing device Perform all PMCS checks if a You are the assigned operator but have not operated the fifth wheel towing device since the last Weekly inspection You are operating the fifth wheel towing device for the first time OVERALL VIEW 1 Before Check fifth whee
223. for FWTD CO aa AND WHAT SHOULD BE DONE ABOUT IT DA 2 2028 2 PREVIOUS EDITIONS P 5 IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR 1 79 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS DATE REVERSE OF DA FORM 2028 2 FILL IN YOUR UNIT S ADDRESS DEPARTMENT OF THE ARMY PLACE POSTAGE HERE Commander U S Army Tank automotive and Armaments Command ATTN AMSTA AC NML Rock Island IL 61299 7630 6 5 AAA AS TEAR ALONG PERFORATED UNE THE SYSTEM AND EQUIVALENTS LINEAR MEASURE SQUARE MEASURE 1 Centimeter 10 Millimeters 0 01 Meters 0 3937 Inches 1 Sq Centimeter 100 Sq Millimeters 0 155 Sq Inches 1 Meter 100 Centimeters 1 000 Millimeters 39 37 Inches 1 Sq Meter 10 000 Sq Centimeters 10 76 Sq Feet 1 Kilometer 1 000 Meters 0 621 Miles 1 Sq Kilometer 1 000 000 Sq Meters 0 386 Sq Miles WEIGHTS CUBIC MEASURE 1 Gram 0 001 Kilograms 1 000 Milligrams 0 035 Ounces 1 Cu Centimeter 1 000 Cu Millimeters 0 06 Cu Inches 1 Kilogram 1 000 Grams 2 2 Lb 1 Cu Meter 1 000 000 Cu Centimeters 35 31 Cu Feet 1 Metric Ton 1 000 Kliograms 1 Megagram 1 1 Short Tons TEMPERATURE LIQUID MEASURE 5 9 F 32 1 Milliliter 0 001 Liters 0 0338 Fluid Ounces 212 Fahrenheit is equivalent to 100 Celsius 1 Lilter 1 000 Millimeters 33 82 Fluid Ounces 90 Fahrenheit is equivalent to 32 2 Celsius 32 Fahrenheit is
224. from towing device Repeat steps 4 through 7 for remaining cylinder assembly 10 Remove tee fitting 2 from straight adapter 11 Remove straight adapter 11 from cylinder assembly 7 Remove elbow 3 from cylinder assembly 7 Remove elbow 1 from cylinder assembly 10 Remove elbow 4 from cylinder assembly 10 Figure 114 Hydraulic Cylinder Mast to Boom 0064 00 2 9 2510 247 13 0064 00 INSTALLATION 12 NOTE Use sealing compound on all threads before installing fittings Install elbow 4 on cylinder assembly 10 Install elbow 1 on cylinder assembly 10 Install elbow 3 on cylinder assembly 7 Install straight adapter 11 on cylinder assembly 7 Install tee fitting 2 on straight adapter 11 Using a suitable lifting device position bottom of cylinder assemby 7 on boom and secure with retaining pin 9 and tighten two screws 8 Raise cylinder assembly 7 to mast and secure with retaining pin 6 and tighten two screws 5 Repeat steps 6 and 7 for remaining cylinder assembly 10 Rotate center mast frame forward and install lower mast retaining pin in center mast and tighten two lower retaining pin screws WP 0073 steps 1 and 2 Connect hydraulic hoses to elbows 3 and 4 Connect two hydraulic hoses to tee fitting 2 Connect hydraulic hose to elbow 1 b Ya Figure 114 Hydraulic Cylinder Mast to Boom Follow on Tasks Charge hydraulics
225. g being damaged Failure to comply may result in injury or death to personnel Remove all jewelry such as rings ID tags bracelets etc If jewelry contacts battery terminal a direct short may result in instant heating of tools damage to equipment and injury or death to personnel 0050 00 3 9 2510 247 13 0050 00 BATTERY BOX REMOVAL 1 Remove protective strip 1 from battery box 2 2 Remove two screws 3 and locknuts 4 from battery box 2 Discard locknuts 3 Remove battery box from frame BATTERY BOX INSTALLATION 1 Position battery box 2 on frame with the recessed leading edge of the battery box facing forward and secure with two screws 3 and new locknuts 4 Ensure battery box will swing 2 Install protective strip 1 on battery box 1 P HA AD JP N ad e gt FRONT Figure 95 Battery Box Follow on Tasks Check battery box for freedom of movement Check electrical power at electrical control box END OF WORK PACKAGE 0050 00 4 9 2510 247 13 amp P 0051 00 WIRING HARNESS CABLE MAINTENANCE REMOVAL REPLACEMENT REPAIR INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Parked on level ground Tie plastic item 19 WP 0085 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General Remove all power to towing device prior to NSN 5180 00 177 7033 making any repairs on the electrical system Shop Equipment Common Set No 1
226. gt x WARNING Wear safety glasses or goggles when checking batteries Always check electrolyte level with engine stopped Do not smoke or use exposed flame when checking battery explosive gases are present and severe injury or death to personnel can result 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 death or injury to personnel Remove all jewelry such as rings ID tags bracelets etc If jewelry contacts battery terminal a direct short may result in instant heating of tools damage to equipment and injury or death to personnel Battery box is not a step Stepping on battery box can cause it to swivel causing injury or death to personnel 1 Remove four wing nuts 1 from battery box lid 2 and remove lid 2 amp o 00 FRONT Figure 93 Battery Box 0050 00 1 TM 9 2510 247 13 amp P 0050 00 BATTERY REMOVAL Continued CAUTION Battery negative ground cables must be removed prior to positive cables 2 Remove negative nylon stud nuts 6 and 7 and remove two cables 8 from Battery A and one cable 8 from Battery B 3 Remove positive nylon stud nuts 3 and 4 and remove two cables 5 from Battery A and three cables 5 from Battery
227. gure 117 Receiver and Wheel Stop 0068 00 1 TM 9 2510 247 13 amp P 0068 00 REMOVAL WHEEL STOP HANDLE Continued 3 Remove split pin 11 from rod 10 4 Remove rod 10 from wheel stop handle assembly and spring 12 5 Remove spring 12 and washer 13 from wheel stop handle assembly INSTALL WHEEL STOP HANDLE 1 Position spring 12 and washer 13 in wheel stop handle assembly 2 Install rod 10 through wheel stop handle assembly and spring 12 and secure with split pin 11 3 Position handle 8 on wheel stop handle assembly and secure with split pin 9 11 Sy G lt p 2 2 H Figure 117 Receiver and Wheel Stop INSTALLATION NOTE There is a driver side and a passenger side receiver Both are installed the same way 1 Position receiver 4 on boom and lock handle 8 2 Install tee bolt 7 and tee bolt 6 on receiver 4 3 Install split pins 5 onto tee bolts 6 and 7 4 Position wheel stop 3 on receiver 4 and secure with spring pin 1 and hitch pin 2 Follow on Tasks Check for proper operation END OF WORK PACKAGE 0068 00 2 TM 9 2510 247 13 amp P 0069 00 MUD FLAP REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in coupling Washer Lock 7 MS35333 40 configuration WP 0002 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General None NSN 5180 00 177 7033 RE
228. has been relieved Ensure each hydraulic control lever is moved several times through all positions Failure to comply may result in severe injury or death to personnel Spilled hydraulic oil is very slippery Be careful when entering or working in area Wipe up any spilled oil immediately Failure to comply may result in severe injury or death to personnel NOTE Hydraulic hoses should be capped and or plugged when disconnecting to prevent contamination of hydraulic system The following procedures are for removal of both mast to boom cylinders Adjust maintenance steps as necessary to achieve required maintenance 0064 00 1 9 2510 247 13 amp P 0064 00 REMOVAL Continued 1 2 10 11 12 13 14 Disconnect hydraulic hose from elbow 1 Disconnect two hydraulic hoses from tee fitting 2 Disconnect hydraulic hoses from elbows 3 and 4 Loosen two lower retaining pin screws and remove the lower retaining pin from the center mast frame WP 0073 steps 3 and 4 Rotate center mast frame to the rear until the boom cylinder upper retaining pin has clearance to be removed Loosen two screws 5 and remove retaining pin 6 Using a suitable lifting device lower cylinder assembly 7 to boom It may be necessary to release some pressure from the cylinder to allow the cylinder to colapse enough to clear the mast upper frame Loosen two screws 8 and remove retaining pin 9 Remove cylinder assembly 7
229. ilure to comply may result in severe injury or death to personnel REMOVAL Spilled hydraulic oil is very slippery Be careful when entering or working in area Wipe up any spilled oil immediately Failure to comply may result in severe injury or death to personnel 0061 00 1 9 2510 247 13 0061 00 REMOVAL Continued NOTE Tag all hoses prior to disconnecting 1 Remove hydraulic hose from tube to boss connector 1 2 Remove hydraulic hose from multiple connector 2 3 Remove tube to boss connector 1 from oil filter assembly 3 4 Remove multiple connector 2 from oil filter assembly 3 5 Remove oil filler assembly 3 from bracket 6 by removing two screws 4 and lockwashers 5 from bracket 6 and oil filter assembly 3 Discard lockwashers ml 5 y YA EE Lo X Ec FN EA r N 4 3 Figure 110 Oil Filter Assembly NOTE Use sealing compound on all threads before installing fittings INSTALLATION 1 Position oil filter assembly 3 on bracket 6 and secure with two screws 4 and new lockwashers 5 2 Install multiple connector 2 to oil filter assembly 3 3 Install tube to boss connector 1 to oil filter assembly 3 4 Connect hydraulic hose to multiple connector 2 5 Connect hydraulic hose to boss connector 1 0061 00 2 TM 9 2510 247 13 amp P 0061 00 FILTER REMOVAL 1 Remove protective cover 1 from oil filter assembly 2 Remove filter 2 from assembly
230. ion when needed The last line below the description is the CAGEC Commercial and Government Entity Code in parentheses and the part number d Column 4 Usable on Code When applicable gives the code if the item needed is not the same for different models of equipment e Column 5 Unit of Issue U I Indicates how the item is issued for the National Stock Number shown in Column 2 f Column 6 Quantity Required Qty Rqd Indicates the quantity of the item authorized to be used with the equipment 0085 00 1 9 2510 247 13 amp P 0085 00 SECTION Il COMPONENTS OF END ITEM No components of end item have been assigned to the 250M Fifth Wheel Towing Device FWTD SECTION Ill BASIC ISSUE ITEMS 2 National Description Stock Number Part Number 4010 01 502 2010 CHAIN ASSEMBLY 3 8 INCH 1BZD4 1128 1 4010 01 502 2008 CHAIN ASSEMBLY 1 2 INCH 1BZD4 1129 1 5315 01 502 2507 PIN PIVOT 1 1 4 x 8 1 2 1BZD4 02535 5315 01 497 9960 PIN STRAIGHT HEADED 3 4 x 6 1BZD4 02545 5315 01 498 4029 PIN STRAIGHT HEADED 3 4 x 4 1BZD4 02540 0085 00 2 9 2510 247 138 008500 SECTION Ill BASIC ISSUE ITEMS Continued 1 2 3 4 llus National Description Usable Number Stock Number Part Number On Code 4030 01 501 9637 FRAME HOOK 1BZD4 1130 1 BLOCK RUBBER 4 INCH 1BZD4 00785 BLOCK RUBBER 2 INCH 1BZD4 00790 3940 01 502 2517 BLOCK PULLEY 60
231. is being used Switch voltage selector box 1 to 12 volts Switch electric control box to ON position 2 depress and hold electric motor switch 3 and BOOM RETRACT control valve lever 4 to align kingpin with fifth wheel Figure 21 Master Controls CAUTION On prime movers equipped with a fifth wheel lockout device ensure lockout is disengaged before traveling off road to prevent damage to equipment Unlock the fifth wheel in accordance with prime movers operation procedures Slowly back the prime mover underthe towing device allowing the frame to slide up the approach ramps to the fifth wheel plate Using remote control or valve control levers BOOM EXTEND to raise the main frame to a level position Slowly back prime mover under towing device until kingpin engages and locks in place 0006 00 2 9 2510 247 13 amp P 0006 00 COUPLING Continued NOTE The NATO slave cable should be connected and the prime mover left idling at all times while operating the fifth wheel towing device to prevent battery drainage 9 Using remote control or valve control levers BOOM EXTEND to raise rear of main frame to allow the transport legs to be engaged 10 Rotate handle 5 clockwise to lower and lock transport legs in the down position Using valve control levers BOOM RETRACT to lower rear of main frame onto transport legs 11 Using remote control or valve control levers RETRACT RIGHT IN and RETRACT LEFT IN fully retr
232. ition using valve lever control 25 Ensure towed vehicle s steering wheel is secured in place to prevent rotation while in transport 26 Connect 70 ft cable from fifth wheel towing device to light assembly Install lowlight assembly on rear of towed vehicle Refer to section WP 0015 27 If not connected after step 11 connect air lines from fifth wheel towing device to towed vehicle Refer to section WP 0016 28 Inspect lights and brakes on towed vehicle for proper operation 29 Ensure electrical control box power switch is in OFF position Ensure remote control power switch is in OFF position Figura 51 Lock Pin Placement END OF WORK PACKAGE 0010 00 7 Change 1 9 2510 247 13 amp P 0011 00 PERFORMANCE OF PRE PICKING LIFTS Pre picking operations shall be performed with the fifth wheel towing device in the coupled configuration with the booms 1 inch above and parallel to the ground Position prime mover in front of the disabled vehicle 2 Using remote control or valve control levers EXTEND LEFT OUT and EXTEND RIGHT OUT extending the boom extensions under the front of the disabled vehicle so the boom extensions pass under the front axle and are extended under and approximately 1 foot to the rear of the front axle U bolts or cross members 3 Place one 2 inch block between the U bolt ends and the boom extensions if necessary 4 Usingremote control or valve control levers BOOM EXTEND to lower rear of booms an
233. k INSTALLATION 1 Position ball end bolt 22 on transport leg bar 5 and secure with new nut 21 2 Position ball end bolt 16 on leg frame 13 and secure with new nut 15 3 Repeat steps 1 and 2 for remaining ball end bolts 4 Position leg frame 13 on frame and secure with retaining pin 19 flatwasher 18 and new spring pin 17 5 Repeat step 4 for remaining leg frame 6 Position support foot 14 on leg frame 13 and secure with retaining pin 12 flatwasher 11 and new spring pin 10 7 Repeat step 6 for remaining support foot 8 Position transport leg bar 5 on frame 9 Position center link 20 on ball end bolt 22 and secure with 4 5 inch 114 3 mm screw 23 10 Position center link 20 on ball end bolt 16 and secure with 3 inch 76 2 mm screw 24 0075 00 2 9 2510 247 13 amp P 0075 00 INSTALLATION Continued 11 Repeat steps 9 and 10 for remaining center link 12 Position mounting bracket 4 on transport leg bar 5 and secure with screw 1 new lockwasher 2 and flatwasher 3 13 Repeat step 12 for remaining mounting bracket 14 Position handle 7 on transport leg bar 5 and secure with screw 8 and new spring pin 9 15 Install ball knob 6 on handle 7 Figure 127 Transport Leg Assembly Follow on Tasks Check for proper operation END OF WORK PACKAGE 0075 00 3 TM 9 2510 247 13 amp P 0076 00 WINCHES GENERAL REPAIR REPLACEMENT GENERAL
234. ke system Serious injury or death can result if precautions are not taken 1 The following paragraphs cover procedures for testing removal disassembly assembly and installation of gladhand assembly relay valve and air lines These paragraphs also cover cleaning inspection and repair of air lines 2 The service brakes are straight air type with automatic break away protection When the semitrailer brake system is properly connected to the service brake system of the towed vehicle the towing vehicle brake pedal operates the brakes on both vehicles END OF WORK PACKAGE 0052 00 1 9 2510 247 13 amp P 00053 00 GLADHAND REPLACEMENT REMOVAL CLEANING REPLACEMENT INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in coupling Packing ring 213630 configuration Washer lock 4 535333 40 Drycleaning solvent item 14 WP 0085 Tools Test Equipment Rags item 10 Tool Kit Mechanics General Brush scrub item 2 WP 0085 NSN 5180 00 177 7033 Thread sealing compound Shop Equipment Common No 1 NSN 4910 00 754 0654 General Safety Instructions None REMOVAL NOTE All gladhands are removed the same way Service gladhand shown 1 Remove dummy coupling 1 from gladhand 2 2 Remove two screws 3 arm lock 4 and chain assembly 5 from gladhand 2 3 Remove gladhand 2 from tank fitting 6 4 Remove retaining nut 7 from tank fitting 6 Remove tank fitti
235. l towing device for Class III oil leak evidence of fluid leakage evident Check fifth wheel towing device for Damaged missing obvious damaged or missing parts parts that impair that would impair operation operation Check fifth wheel towing device for Non operational gauges damage to any gauges 0031 00 5 9 2510 247 13 amp P 0031 00 Table 2 Operator Preventive Maintenance Checks and Services 5 for 250M Fifth Wheel Towing Device Before Location To Service Procedure ELECTRICAL CONTROL BOX Check electrical control box for proper operation of electric motor switch 1 and ON OFF switch 2 Vehicle operation with damaged or non operational lights may violate AR 385 55 If present check all brake tail stop blackout lights 5 on 24 volt light bar for proper operation and cleanliness Check blackout light system for proper function When blackout is initiated the Fifth Wheel Towing Device worklight should remain functional 0031 00 6 Not Fully Mission Capable If Electric motor switch or ON OFF switch non operational Any damaged components or parts Any damaged components or parts 9 2510 247 13 0031 00 Table 2 Operator Preventive Maintenance Checks and Services 5 for 250 Fifth Wheel Towing Device To Check Not Fully Mission Service Procedure Capable If LIGHTS 4 Before If present check all brake tail stop lights 3
236. lace Menta ls cit Air Brake Protection Valve Replacement sse Air Brake Fittings Malinalco btt General Hydraulic System Repair Hydraulic Motor Assembly Replacement assesses Hydraulic Safety Valve Replacement sass Main Valve Assembly 4 Hydraulic Valve Control Lever Replacement 20 4000100001 00 tentent Oil Filter Assembly Replacement sss Cam Valve Assembly Replacement Hydraulic Cylinder Main Frame to Mast Replacement Hydraulic Cylinder Mast to Boom 0 Hydraulic Reservoir Fittings Boom Extension Cylinder Replacement u sea General Hydraulic System ki ii ak Rd Receiver and Wheel Stop Assembly Replacement sss Mud Flap Replacement u a c Rx nae UNE a ee Tool BOX Replacement audacter A A Rn red Mast Frame Assembly Pivot Pin Replacement Center Mast Frame Replacement cei aptis bra a Bumper Pad Slip Pad Replacement 5 2 airis Transport Leg Assembly Replacement wits aciem etn spa sera tnn phas cia
237. lass Ill Leakage great enough to form drops that fall from the item being checked inspected CAUTION Operation is allowable with Class and Class Il leakage WHEN IN DOUBT NOTIFY YOUR SUPERVISOR When operating with Class I or Class Il leaks check components more frequently Class Ill leaks must be reported immediately to your supervisor Failure to do this will result in damage to vehicle and or components PMCS INITIAL SETUP 1 General a This paragraph lists tools materials and personnel required for PMCS and lubrication b Nomandatory replacement parts are required while performing unit PMCS Tools a Drain pan b General mechanic s tool kit Item 1 0081 Section Shop equipment Common No 1 Item 2 0081 Section 111 d Prime mover as required for specific tasks 0037 00 3 TM 9 2510 247 13 amp P 0037 00 PMCS INITIAL SETUP Continued 3 Materials a Corrosion preventive Item 3 WP 0085 b Detergent Item 4 WP 0085 c Lubricating OE HDO 15W Item 9 WP 0085 d Rags Item 10 WP 0085 e Dry cleaning solvent Item 14 0085 f Sealing compound Item 12 WP 0085 4 Personnel a Driver Operator b Unit Maintenance Mechanic LUBRICATION DATA Lubricate in accordance with WP 0039 0037 00 4 TM 9 2510 247 13 amp P 0037 00 Table 3 Unit Preventive Maintenance Checks and Services PMCS for 250M Fifth Wheel Towing Device FWTD Location Item To Che
238. lbow 5 from hydraulic reservoir 4 Remove pressure relief valve assembly 6 from top of hydraulic reservoir 4 Remove breather 7 from tee fitting 8 Remove pressure relief valve 9 from tee fitting 8 Remove tee fitting 8 from straight adapter 10 Remove straight adapter 10 from bushing 11 Remove pressure relief valve assembly 6 from bottom of hydraulic reservoir 4 Remove elbow fitting 12 from breather 7 Remove drain plug 13 from hydraulic reservoir 4 Figure 115 Hydraulic Reservoir Fittings Assembly 0065 00 2 9 2510 247 13 amp P 0065 00 INSTALLATION CAUTION Hydraulic hoses must NOT be uncapped and or unplugged until ready to make connection NOTE Use sealing compound on all threads before installing fittings 1 Install drain plug 13 in hydraulic reservoir 4 2 Install breather 7 on elbow fitting 12 3 Install pressure relief valve assembly 6 on bottom of hydraulic reservoir 4 4 Install bushing 11 on straight adapter 10 5 Install tee fitting 8 on straight adapter 10 6 Install pressure relief valve 9 on tee fitting 8 7 Install breather 7 on tee fitting 8 8 Install pressure relief valve assembly 6 on top of hydraulic reservoir 4 0065 00 3 9 2510 247 13 amp P 0065 00 INSTALLATION Continued 9 Install elbow 5 on hydraulic reservoir 4 and install hose on elbow 5 10 Install tee fitting 3 on hydraulic reservoir
239. leaning methods and use of unauthorized cleaning liquids or solvents can cause injury or death to personnel and damage equipment To prevent this refer to TM 9 247 for further instructions After washing the fifth wheel towing device ensure the appropriate breather valve is opened prior to operation of the fifth wheel towing device Failure to comply can result in death or injury to personnel CAUTION Ensure both breather valves are closed prior to washing the fifth wheel towing device Failure to comply could result in water contamination of hydraulic system NOTE Keep it clean Dirt grease oil and debris get in the way and may cover up a serious problem Clean as you work and as needed Use detergent item 4 WP 008 0038 00 2 TM 9 2510 247 13 amp P 0038 00 CLEANING INSTRUCTIONS Continued 1 General Cleaning instructions will be the same for the majority of parts and components which make up the equipment The following applies to all cleaning operations a b C Clean all parts before inspection after repair and before assembly Keep hands free of grease which can collect dust dirt and grit After cleaning all parts should be covered or wrapped to protect them from dust and dirt Parts that are subject to rust should be lightly oiled after cleaning See Preservation of Parts 2 Castings Forgings and Machined Metal Parts a Clean inner and outer surfaces with dry cleaning solvent item 14 WP 00
240. levers FULLY EXTEND and RETRACT all hydraulic cylinders and exercise winch 3 Visually inspect hydraulic system component s hose s and connection s related to the maintenance task for evidence of leaking fluid 4 If leaking fluid is found perform necessary required maintenance repeat steps 1 through 3 5 On electrical control box switch ELECTRICAL toggle to OFF position PURGE AND FILL HYDRAULIC SYSTEM Ed WARNING Spilled hydraulic oil is very slippery Be careful when entering or working in area Wipe up any spilled oil immediately Failure to comply may result in severe injury or death to personnel CAUTION Hydraulic system contains approximately 18 gal 68L of hydraulic oil An adequate container must be used to maintain purged fluid 1 Fold COUPLED fifth wheel towing device onto prime mover using transport configuration steps 1 through 9 WP 0007 Do not remove pivot pins Remove plug and drain reservoir Figure 114 WP 0065 Loosen hydraulic hose from straight adapter on main valve assembly Figure 107 WP 0059 Remove hydraulic hose from elbow on reservoir Figure 114 WP 0065 Tighten hydraulic hose to straight adapter on main valve assembly Figure 107 WP 0059 NOTE a v Reinstall drain plug prior to filling reservoir 6 Remove fill port plug COMPLETELY fill reservoir with new oil see WP 0039 Ensure return line is draining into a suitable container Loosely replace fill port pl
241. lies are installed the same way Left side shown Perform step 1 ONLY IF mounting bracket was removed 1 Feed strobe light wire 4 through mounting bracket 9 Position mounting bracket 9 on mast assembly and secure with three screws 7 and new lockwashers 8 NOTE Perform step 2 ONLY IF strobe light assembly was removed 2 Position strobe light assembly on base plate mounting brackets 6 and secure with four screws 5 3 Connect strobe light wire 4 Position cover 2 on baseplate 3 and secure with four screws 1 0049 00 3 9 2510 247 13 amp P 0049 00 RETRACTABLE CORD REPAIR 1 Remove quick disconnect 1 from wire connector 2 2 Pull wire connector 2 through frame and remove wire connector 2 and insulation sleeving 3 from wire 3 Separate two parts of quick disconnect 1 and remove retractable cord 4 Figure 92 Retractable Cord Assembly Follow on Tasks Connect Batteries WP 0050 e Check for proper operation of strobe light END OF WORK PACKAGE 0049 00 4 TM 9 2510 247 13 amp P 0050 00 BATTERY BATTERY BOX REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Parked on level ground Nut lock 2 MS17828 4C Tag marker item 15 WP 0085 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General Remove all power to towing device prior to NSN 5180 00 177 7033 disconnecting batteries BATTERY REMOVAL SN
242. lieved Ensure each hydraulic control lever is moved several times through all positions and hydraulic tank relief valve is slowly loosened to relieve pressure Failure to comply may result in severe injury or death to personnel Spilled hydraulic oil is very slippery Be careful when entering or working in area Wipe up any spilled oil immediately Failure to comply may result in severe injury or death to personnel No personnel shall perform maintenance above or below the main frame without the main frame being supported at the front by use of a jack stand or the prime mover Failure to comply may result in injury or death to personnel NOTE There are two hydraulic motors primary 3 and isolated 11 The solenoid to isolated motor wire and ground wire must be removed from isolated motor prior to removal 1 Loosen two mounting bolts 1 on primary motor 3 and two mounting bolts 1 on isolated motor 11 2 Remove solenoid to motor wire 12 and ground wire 13 from isolated motor 11 3 Disconnect hose from elbow 4 on isolated motor 11 4 Remove hose 14 from elbow 15 on isolated motor 11 5 Disconnect two straight adapters 5 6 Remove two screws 16 lockwashers 17 and flatwashers 18 from bracket 19 on isolated motor 11 Discard lockwashers 7 Loosen two screws 20 and slide primary and isolated motors to allow for removal of isolated motor from bracket 0057 00 3 TM 9 2510 247 13 amp P 0
243. me mover and the trailer brakes and lights for proper operation Failure to comply may result in injury or death to personnel Check all tiedowns at first opportunity after departure Recheck all tiedowns at halts and any time you suspect a problem Failure to comply may result in injury or death to personnel Safety chains should be installed at a 45 angle to prevent shifting Failure to comply may result in injury or death to personnel 9 2510 247 13 amp P WARNING DRYCLEANING SOLVENT 2 Drycleaning solvent MIL PRF 680 Type Ill is an environmentally compliant low toxic material However it may be irritating to the eyes and skin The use of protective gloves and goggles is suggested Use in well ventilated areas Keep away from open flames and other sources of ignition Failure to comply may result in injury or death to personnel Drycleaning solvent P D 680 is toxic and flammable Always wear protective goggles and gloves and use only in a well ventilated area Avoid contact with skin eyes and clothes and DO NOT breathe vapors DO NOT use near open or excessive heat The solvent s flash point is 100 F 138 F 38 59 If you become dizzy while using cleaning solvent immediately wash your eyes and get medical aid Failure to comply may result in injury or death to personnel Compresssed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear prote
244. me to 0063 00 1 Hydraulic Cylinder Mast to 0064 00 1 Hydraulic Motor Assembly 0 2 sss 0057 00 1 Hydraulic Reservoir Fittings 0065 00 1 Hydraulic Safety 0058 00 1 Hydraulic Valve Control 0060 00 1 Junction Box 12 24 0043 00 1 INDEX 6 TM 9 2510 247 13 amp P INDEX Subject WP Sequence No Page No R continued Replacement continued 3402S a eek 0034 00 1 Main Valve 0059 00 1 Mast Frame Assembly Pivot 0072 00 1 Mud gi p 0069 00 1 Oil Filter Assembly 2204224 nennen nennen 0069 00 1 Receiver and Wheelstop Assembly 0068 00 1 Receptacle 12 Volt inicia iii ii iio 0042 00 1 Receptacle 24 volt 0041 00 1 Remote Control 0046 00 1 Solenoid Assembly 0045 00 1 ires m 0049 00 1 Mic 0071 00 1 Transport Leg 0075 00 1 Winch Assembly rta titer coe 0077 00 1 Wiring 0051 00 1 12 Volt Receptacle na an 0042 00 1 24 Volt 4 2 4 1 10 0041 00 1 Replacement Parts no nnncnnnnnnn nano 0082 00 1
245. mergency procedures in case of accident or fire 9 Before performing maintenance ensure that the fifth wheel towing device is secured against movement h When lifting heavy parts have someone help you Ensure that lifting or jacking equipment is working properly is of sufficient capacity for the assigned task and is secure against slipping CORROSION PREVENTION AND CONTROL CPC 1 CPC of Army materiel is a continuing concern It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements made to prevent the problem in future items 2 While corrosion is typically associated with rusting of metals it can also include deterioration of other materials such as rubber and plastic Unusual cracking softening swelling or breaking of these materials may be a corrosion problem 3 corrosion problem is identified it can be reported using SF 368 Product Quality Deficiency Report Use of key words such as CORROSION RUST DETERIORATION or CRACKING will ensure that the information is identified as a CPC problem The form should be submitted to the address specified in DA Pam 738 750 END OF WORK PACKAGE 0001 00 3 TM 9 2510 247 13 amp P 0002 00 EQUIPMENT DESCRIPTION AND DATA EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES 1 This fifth wheel towing device is designed to transport wheeled vehicles on highways unimproved roads grad
246. move cam valve 8 from mast 5 Remove spring 9 from cam valve 8 6 Remove elbow 2 from cam valve 8 7 Remove straight adapter 4 from cam valve 8 Figure 112 Cam Valve Assembly 0062 00 2 TM 9 2510 247 13 amp P 0062 00 INSTALLATION NOTE Use sealing compound on all threads before installing fittings 1 Install straight adapter 4 on cam valve 8 2 Install elbow 2 on cam valve 8 3 Install spring 9 on cam valve 8 4 While applying tension to spring 9 position cam valve 8 on mast and secure with four screws 5 washers 6 and new locknuts 7 5 Install hydraulic hose 3 to straight adapter 4 6 Install hydraulic hose 1 to elbow 2 Follow on Tasks Charge hydraulics WP 0056 00 5 Check oil level illustration WP 0056 00 5 END OF WORK PACKAGE 0062 00 3 9 2510 247 13 amp P 0063 00 HYDRAULIC CYLINDER MAIN FRAME 5 REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in Pin retaining upper 2 1036 1 Storage Configuration 0002 Pin retaining lower 2 1035 1 Hydraulic pressure relieved WP 0056 0015 Tie wire item 18 0085 Tag marker item 15 WP 0085 Sealing compound item 12 WP 0085 Tools Test Equipment Personnel Required 2 Tool Kit Mechanics General NSN 5180 00 177 7033 General Safety Instructions A suitable lifting device for 48 lbs 21 8 kg None REM
247. move hose 4 from straight adapter 16 Remove insert 5 Discard insert Remove straight adapter 16 from air brake protection valve 15 Remove brass bushing 17 and hose 4 from air brake protection valve 15 Remove insert 5 Discard insert Figure 99 Air Brake Fittings Assembly 0055 00 2 9 2510 247 13 amp P 0055 00 INSPECTION AND REPLACEMENT OR REPAIR 1 2 NOTE Damaged air hoses that may fail must be replaced Inspect brake air hoses and fittings for cracks kinks nicks stripped threads and cuts Replace damaged hoses INSTALLATION 10 CAUTION DO NOT remove caps or plugs from hoses until installation Removing caps or plugs may result in contamination of brake system and damage to equipment NOTE Apply thread sealing compound to threads before connecting Install plastic cable ties as required Air hoses must be tightly attached and connected Install brass bushing 17 on air brake protection valve 15 Install new insert 5 into hose 4 and install hose onto brass bushing 17 Install straight adapter 16 on air brake protection valve 15 Install new insert 5 into hose 4 and install hose onto straight adapter 16 Install reducer 14 on air brake protection valve 15 Install two 45 fittings 13 on reducer 14 Install new insert 5 into hose 4 and install hoses onto 45 fittings 13 Position loop clamps 8 on hoses 4 and secure with screw 6 flatwasher 7 sp
248. n when operating to prevent injury or death to personnel TM 9 2510 247 13 amp P WARNING HYDRAULICS AY va Ensure hydraulic protection valve is open breather switch inline with breather prior to operating hydraulics Failure to comply could cause injury or death to personnel or damage to equipment High pressure is present in the 250M Fifth Wheel Towing Device hydraulic system Do not disconnect any hydraulic system component unless hydraulic system pressure has been relieved Ensure each hydraulic control lever is moved several times through all positions Failure to comply may result in severe injury or death to personnel Spilled hydraulic oil is very slippery Be careful when entering or working in area Wipe up any spilled oil immediately Failure to comply may result in severe injury or death to personnel While operating or performing maintenance on any hydraulic systems never place personnel or equipment in a potentially hazardous position i e between moving parts or under hydraulic supported equipment Failure to comply may result in severe injuryor death to personnel WARNING BOOM MAST OPERATION AA DO NOT operate boom until mast is in track Failure to comply could cause serious injury or death to personnel or damage to equipment Clevises must be installed in mast assembly to prevent mast assembly from disengaging from track Failure to comply may cause injury or death to personnel or damage to equipment Nev
249. nd dents TIEDOWNS Check chains 10 load binders 11 and other tiedowns for serviceability and proper quantity CL 0031 00 9 Not Fully Mission Capable If Excessive wear cracks or damage Nick chip or gouges deeper than 1 8 inch 32 cm is found anywhere on wear surface or wear exceeds 1 16 inch 16 cm over 25 of wear surface Kingpin plate is cracked or dented TM 9 2510 247 13 amp P 0031 00 Table 2 Operator Preventive Maintenance Checks and Services PMCS for 250M Fifth Wheel Towing Device Item To Check Not Fully Mission Service Procedure Capable If RECEIVER ASSEMBLY Check receiver assemblies 12 for proper operation and cleanliness TOOLBOX 14 Weekly Check tool box lid 13 for proper operation and serviceability 0031 00 10 9 2510 247 13 0031 00 Table 2 Operator Preventive Maintenance Checks and Services PMCS for 250 Fifth Wheel Towing Device Location Item To Check Not Fully Mission Service Procedure Capable If 12 24 JUNCTION BOX 15 Weekly Check junction box selector switch Excessive wear 14 and electrical connection plugs present for excessive wear corrosion and serviceability BATTERIES 16 Weekly Check for corrosion on battery Excessive corrosion on posts 15 Check for leaks battery posts or leaks Apply light coat of grease item 7 present WP 0085 0031 00 11 TM 9 2510 247 13 amp P 0031 00 Table 2 Operator P
250. nd parts must be carefully checked to determine if they are serviceable for use can be repaired or must be replaced 2 Inspect drilled and tapped threaded holes for the following a Wear distortion cracks and any other damage in or around holes b Threaded areas for wear distortion stretching and evidence of cross threading 3 Inspect metal lines flexible lines or hoses and metal fittings and connectors for the following a Metal lines for sharp kinks cracks bad bends and dents b Flexible lines or hoses for fraying evidence of leakage and loose metal fittings or connectors c Metal fittings and connectors for thread damage and worn or rounded hex heads 4 Inspect castings forgings and machined metal parts for the following a Machined surfaces for nicks burrs scoring grooves raised metal wear and other damage b Inner and outer surfaces for breaks and cracks 5 Inspect bearings in accordance with TM 9 214 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS Follow these general practices when performing disassembly and assembly procedures a Keep major components together whenever possible and practical b Tag hoses electrical wires cables and harnesses to identify them and aid during installation c Keep related parts together for identification purposes d Temporarily install attaching hardware such as screws bolts washers and nuts to prevent loss e Only disassemble to the point of the problem f Ensure that par
251. nel Stopping distances greatly increase when the towed vehicle has nonfunctioning brakes Care should be taken to ensure adequate stopping distance is obtained and speed is adjusted accordingly Failure to comply may result in injury or death to personnel 9 2510 247 13 amp P WARNING TOWING Continued al 56 Towing of a single vehicle with non functioning brakes must be limited to not more than 25 mph on the highway and 15 mph off road Failure to comply may result in injury or death to personnel Towing of vehicle combinations with non functioning brakes is prohibited Failure to comply may result in injury or death to personnel Prior to transporting loads ensure the transport leg assembly is locked in the vertical position or the handle may swing free and cause injury or death to personnel 1074 and 1075 PLS Series can only be transported with no payload Failure to comply may result in injury or death to personnel WARNING TIEDOWN M al ba Put transmissions in neutral on towed equipment Failure to comply may result in injury or death to personnel Make sure gun turrets or other rotating parts are properly secured Failure to comply may result in death or injury to personnel Make sure all Bll items are properly stowed on the towing device Remote shoud be stored with control switches toward the top of the tool box Failure to comply may result in injury or death to personnel Check the pri
252. ng and is referenced in the Initial Setup of maintenance paragraphs or narrative instructions to identify the material needed e g Dry cleaning solvent Item 191 WP 0085 Column 2 Level This column identifies the lowest level of maintenance that requires the listed item C Operator Crew O Unit Maintenance F Direct Support Maintenance H General Support Maintenance Column 3 National Stock Number This is the National Stock Number assigned to the item Use it to request or requisition the item Column 4 Item Name Description Commercial and Government Entity Code CAGEC Part Number Indicates the Federal Item Name and if required a description to identify the item The last line for each item indicates the Commercial and Government Entity Code in parentheses followed by the part number if applicable Column 5 Unit of Measure U M Unit of Issue U I This measure is expressed by a two character alphabetical abbreviation e g ea in pr If the unit of measure differs from the unit of issue as shown in the Army Master Data File AMDF requisition the lowest unit of issue that will satisfy your requirements 0087 00 1 9 2510 247 13 amp P 0087 00 SECTION Il EXPENDABLE AND DURABLE ITEMS LIST 1 Item Number 3 National Stock Number 7920 00 061 0038 7920 00 900 3577 8030 01 418 9006 7930 00 282 9699 3439 00 255 9935 8415 00 268 7859 9150 01 197 7693
253. ng from mounting bracket 8 5 Remove two screws 9 flatwashers 10 lockwashers 11 and nuts 12 Remove mounting bracket 8 from fender Discard lockwashers Figure 97 Gladhand Assembly 00053 00 1 9 2510 247 13 amp P 0053 00 WARNING Drycleaning solvent MIL PRF 680 Type is an environmentally compliant and low toxic material However it may be irritating to the eyes and skin The use of protective gloves and goggles is suggested Use in well ventilated areas Keep away from open flames and other sources of ignition CLEANING 1 Clean mud and dirt from all exposed surfaces with water and a brush 2 Remove grease with drycleaning solvent and a clean rag INSPECTION AND REPLACEMENT 1 Inspect gladhand for damaged threads cracks dents holes and warps 2 Replace defective gladhand 3 Remove packing ring 13 and check for wear and deterioration PACKING RING INSTALLATION 1 Clean packing ring groove in gladhand 2 Partially collapse ring with fingers and insert one side of ring flange into groove 3 Push ring into place Face of ring must lie flat with no twist or bulge 0053 00 2 9 2510 247 138 0053 00 INSTALLATION 1 Position mounting bracket 8 on fender and secure with two screws 9 flatwashers 10 new lockwashers 11 and nuts 12 2 Install tank fitting 6 in mounting bracket 8 and secure with retaining nut 7 3 Screw gladhand 2 onto tank fitting 6 4 Position a
254. nnel and damage equipment To prevent this refer to TM 9 247 for further instructions No personnel shall perform maintenance above or below the main frame without the main frame being supported at the front by use of a jack stand or the prime mover Failure to comply may result in injury or death to personnel WARNING TRANSPORT Al A a Ensure the top hydraulic pressure release valve is open prior to operating hydraulics Failure to comply could cause injury or death to personnel or damage to equipment Ensure the boom has sufficient overhead clearance prior to folding the boom into a vertical position Failure to comply may result in injury or death to personnel DO NOT operate boom until mast is in track Failure to comply could cause serious injury or death to personnel or damage to equipment Visibility from the prime mover is significantly reduced when backing Proper procedures must be followed and extreme caution used when backing to prevent injury or death to personnel or damage to equipment WARNING FOLDING UNFOLDING Operators must take while folding the assembly to the vertical position The transport leg assembly does not stay locked in the vertical position The handle will swing free and may cause injury or death to personnel Ensure tool boxes are closed and the main frame 15 free of all unsecured items Failure to comply may result in injury or death to personnel 9 2510 247 13 WAR
255. ns on lubrications inspections adjustments and corrections to be performed by Unit Maintenance to keep your equipment in good operating condition and ready for its primary mission EXPLANATION OF TABLE ENTRIES 1 Item Number No Column Numbers in this column are for reference When completing DA Form 5988 Equipment Inspection and Maintenance Worksheet include the item number for the check service indicating a fault Item numbers also appear in the order you must perform checks and services for the interval listed Interval Column This column tells you when you must perform the procedure in the procedure column a Semiannual procedures must be done once every six months b Annual procedures must be done once each year Location Item to Check Service Column This column identifies the location and the item to be checked or serviced NOTE The WARNINGS and CAUTIONS appearing in your PMCS table should always be observed WARNINGS and CAUTIONS appear before applicable procedures These WARNINGS and CAUTIONS must be observed to prevent serious injury to yourself and others or to prevent your equipment from being damaged Procedure Column This column gives the procedure you must perform to check or service the item listed in the Item to Check Service column to know if the equipment is ready or available for its intended mission or for operation You must perform the procedure at the time stated in the interval column
256. nthly Apply grease to kingpins 22 Refer to WP 0039 Refer to prime mover lube order for fifth wheel 0031 00 14 9 2510 247 13 amp P 0031 00 Table 2 Operator Preventive Maintenance Checks and Services PMCS for 250M Fifth Wheel Towing Device Item To Check Service Procedure OVERALL VIEW Monthly Check reservoir hydraulic controls lines and fittings for looseness leaks or other damage LUBRICATION Lubricate all fittings Refer to Inspect winch 23 for broken or frayed cable or missing components Inspect winch cable IAW TB 43 0142 or FM 5 125 0031 00 15 Not Fully Mission Capable If Any hydraulic component is loose leaking or damaged Any missing components Broken kinked or frayed wire TM 9 2510 247 13 amp P 0031 00 Table 2 Operator Preventive Maintenance Checks and Services PMCS for 250M Fifth Wheel Towing Device Item To Check Not Fully Mission Service Procedure Capable If HYDRAULIC SYSTEM 28 Monthly Position fifth wheel towing device in hydraulic oil fill position refer to Figure 104 in WP 0056 00 7 Use kingpin wrench to check Hydraulic fluid low hydraulic fluid level in reservoir Any leaks are evident END OF WORK PACKAGE 0031 00 16 TM 9 2510 247 13 amp P 0032 00 ELECTRICAL CONNECTORS 1 Cleaning WARNING Remove all power to fifth wheel towing device prior to making any repairs on the electrical system Failure to do so may resul
257. o identify troubles and restore serviceability to an item by correcting specific damage fault malfunction or failure in a part subassembly module component or assembly end item or system j Overhaul That maintenance effort service action prescribed to restore an item to a completely serviceable operational condition as required by maintenance standards in the appropriate technical publications i e DMWR Overhaul is normally the highest degree of maintenance performed by the Army Overhaul does not normally return an item to like new condition k Rebuild Consists of those services actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturing standards Rebuild is the highest degree of materiel maintenance applied to Army equipment The rebuild operation includes the act of returning to zero those age measurements e g hours miles considered in classifying Army equipment components 3 EXPLANATION OF COLUMNS IN THE MAC SECTION II a Column 1 Group Number Column 1 lists functional group code numbers the purpose of which is to identify maintenance significant components assemblies subassemblies and modules with the next higher assembly b Column 2 Component Assembly Column 2 contains the item names of components assemblies subassemblies and modules for which maintenance is authorized c Column 3 Maintenance Function Column 3 lists the
258. o adjust the angle of the main frame WP 0005 to accommodate the height of the fifth wheel plate Always ensure when coupling that the transport legs and bottom pressure relief valve assembly do not make contact with the prime mover Failure to comply may result in death or injury to personnel All persons not involved in coupling uncoupling operation must stand clear of prime mover and fifth wheel towing device to prevent serious injury or death Never stand between the prime mover and fifth wheel towing device when the prime mover is being backed up to the towing device Serious injury or death may result CAUTION To prevent damage to the equipment coupling should be done by two people the first person in the prime mover cab and the second acting as a ground guide NOTE Prime mover mud flaps should be removed and stored IAW the prime movers current TM prior to coupling with the FWTD Failure to remove mud flaps may cause damage the prime mover Refer to WP 0091 ffor authorized prime movers and towed vehicles When performing operations with the towing device in conjunction with another vehicle ensure that all Warnings Cautions and special instructions in the other vehicles operator s manual are followed Refer to kingpin placement WP 0034 for proper placement of kingpin for coupling 0006 00 1 9 2510 247 13 0006 00 COUPLING Continued 1 Line up prime mover with towing device Ensure proper kingpin
259. ods General 0056 00 1 Hydraulic Valve Control Lever 0060 00 1 Illustrated List of Manufactured 0088 00 1 Inspection 0038 00 4 Installation of Adjustable 0056 00 4 J Junction Box Replacement 12 24 0043 00 1 K MOP mee TEE 0003 00 1 Kingpin Replacement u 0034 00 1 INDEX 3 9 2510 247 13 amp P INDEX Subject WP Sequence No Page No L Lights iia adi 0015 00 1 Eines andi nas 0038 00 9 List of Manufactured Items Illustrated 0088 00 1 Loading Equiprmierit cicer ida eee 0010 00 1 Loads Transperting eii its 0017 00 1 Location and Contents of Plates Decals and SENGS LS 0002 00 6 Location and Description of Major Components 0002 00 5 Lubrication 0039 00 2 Lubrication Data 0037 00 4 Lubrication Instructions nennen nennen 0039 00 1 PROCS OUI 0022 00 2 Lubrication Procedures 022 0039 00 1 oc 0081 00 1 Main Valve Assembly
260. ols before and after each use Some maintenance tasks may require special or fabricated tools The Initial Setup of the procedure will specify any special or fabricated tools needed to perform that procedure Use these special tools only for the maintenance procedures for which they are designed or called out If you are unfamiliar with a required tool see your supervisor TAGGING WIRES AND HOSES 1 Use marker tags item 15 WP 0085 to identify all electrical wires lines and any other parts which may be hard to identify or replace later Fasten tags to parts during removal by wrapping wire fasteners around or through parts and twisting ends together Position tags to be out of the way during cleaning inspection and repair Mark tags with a pencil pen or marker Whenever possible identify electrical wires with the number of the terminal or wire to which it connects If no markings can be found tag both wires or wire and terminal and use the same identifying mark for both If you cannot tag a wire because it must fit through a small hole or you cannot reach it write down the description of the wire and the point to which it connects or draw a simple diagram on paper Be sure to write down enough information so you will be able to properly connect the wires during assembly If you need to identify a loose wire look for identifying numbers near the end of the wire stamped on a permanent metal tag Compare this number to wire number on
261. ommonly found in hydraulic systems It differs from other fittings because it is tapered In order to obtain a proper seal with this thread you must use a sealant The sealant should be applied to the male fitting CAUTION Do not apply sealant to the leading edge or the first thread of hydraulic fitting or sealant may get into the hydraulic system and contaminate it Failure to comply may result in damage to equipment DO NOT APPLY SEALANT TO FIRST THREAD NOTE TAPER Figure 100 National Pipe Thread NPT 2 O ring preformed packing boss has a straight thread The seal for this termination is a preformed packing that fits at the top of the threads on the male fitting This packing is squeezed into the extra space at the top of the threads of the female fitting and seals the connection The installed packing must be free of nicks and cuts to seal properly If packing is nicked or cut it must be replaced CAUTION Do not apply sealant to the leading edge or the first thread of hydraulic fitting or sealant may get into the hydraulic system and contaminate it Failure to comply may result in damage to equipment O RING PACKING STRAIGHT THREAD O RING PACKING CAVITY Figure 101 O Ring Packing Boss 0056 00 3 9 2510 247 13 0056 00 GENERAL HYDRAULIC SYSTEM REPAIR Continued 3 Aflareless fitting uses a straight thread The female fitting contains a ferrule that couples with a cavity in the male fitting
262. onditions make it necessary 3 When a piece of equipment is received and has already been processed for domestic shipment as indicated on DD Form 1397 it does not have to be reprocessed for storage unless corrosion and deterioration are found during the inspection upon receipt List on SF Form 364 all discrepancies found because of poor preservation packaging packing marking handling loading storage or excessive preservation Repairs that cannot be handled by the receiving unit must have tags attached listing needed repairs A report of these conditions will be submitted by the unit commander for action by an ordnance maintenance unit END OF WORK PACKAGE 0078 00 5 TM 9 2510 247 13 amp P CHAPTER 7 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS 9 2510 247 13 amp P 0000 00 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS INDEX WP Sequence No DIRECT SUPPORT MAINTENANCE INSTRUCTIONS General Maintenance 20 0 007900 0000 00 0 9 2510 247 13 0079 00 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS GENERAL All direct support maintenance tasks identified in the Maintenance Allocation Chart MAC WP 0081 lare conducted by the manufacturer END OF WORK PACKAGE 0079 00 1 9 2510 247 13 amp P 8 SUPPORTING INFORMATION 9 2510 247 13 0000 00 SUPPORTING INFORMATION INDEX WP Sequence No SUPPORTING INFORMATION NUECES E
263. ool sets and or Class VII are not listed C Cross Reference Indexes Work Package There are two cross reference indexes work packages in this RPSTL The National Stock Number NSN Index work package and the Part Number P N Index work package The NSN Index work package refers you to the figure and item number The P N Index work package refers you to the figure and item number 3 EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGE a Item No Column 1 Indicates the number used to identify items called out in the illustration 0082 00 1 9 2510 247 13 amp P 00082 00 3 EXPLANATION COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGE Continued b SMR Code Column 2 The SMR code is a 5 position code containing supply requisitioning information maintenance category authorization criteria and disposition instruction as shown in the following breakout Source Code XX 1st two positions How to get an item Maintenance Recoverability Code Code XX X 3rd position 4th position 5th position Who can install Who can do Who determines replace or use complete repair disposition action the item on the item on unserviceable items complete repair Maintenance capacity capability and authority to perform all corrective maintenance tasks of the repair function in a use user environment in order to restore serviceability to a failed item
264. op shows that heavy parts can crush and harm HEAVY PARTS heavy object on human figure shows that heavy parts present a danger to life or limb HEAVY PARTS heavy object pinning human figure against wall shows that heavy moving parts present a danger to life or limb HELMET PROTECTION arrow bouncing off head with helmet shows that falling parts present a danger HOT AREA hand over object radiating heat shows that part is hot and can burn LASER LIGHT laser light hazard symbol indicates extreme danger for eyes from laser beams and reflections K 6 02 Pl 9 TM 9 2510 247 13 amp P SAFETY WARNING ICONS Continued MOVING PARTS human figure with an arm caught between gears shows that the moving parts of the equipment present a danger to life or limb MOVING PARTS hand with fingers caught between gears shows that the moving parts of the equipment present a danger to life or limb MOVING PARTS hand with fingers caught between rollers shows that the moving parts of the equipment present a danger to life or limb SHARP OBJECT pointed object in hand shows that a sharp object presents a danger to limb SHARP OBJECT pointed object in hand shows that a sharp object presents a danger to limb SHARP OBJECT pointed object in foot shows that a sharp object presents a danger to limb SLICK FLOOR wavy line on floor with legs prone shows that slick floor presents a danger for falling 9 2510
265. or 7 8 FOOT FOOT FOOT FOOT POUNDS pounos N pounns N 49 72 9 76 9 0 12 00 10 8 14 64 6 10 536 87 738 34 823 77 1110 56 1208 20 1552 13 1757 52 2221 11 2440 80 2904 57 3319 47 3856 50 4344 66 5 TIGHTENING METAL FASTENERS When torquing a fastener select a torque wrench whose range Table 7 fits the required torque value Atorque wrench is most accurate from 25 percent to 75 percent of its stated range A torque wrench with a stated range of O to 100 will be most accurate from 25 to 75 foot pounds The accuracy of readings will decrease as you approach 0 foot pounds or 100 foot pounds The ranges in Table 7 are based on this principle 0089 00 4 TM 9 2510 247 13 amp P 0089 00 5 TIGHTENING METAL FASTENERS Continued Table 7 Torque Ranges STATED RANGE MOST EFFECTIVE RANGE 0 600 Ib ft 0 813 60 Nm 150 450 Ib ft 203 40 610 20 Nm 0 170 Ib ft 0 230 52 Nm 44 131 Ib ft 59 67 177 64 Nm 15 75 lb ft 61 02 101 70 Nm 30 60 Ib ft 40 68 81 36 Nm 6 FASTENER SIZE AND THREAD PATTERN Threaded fasteners are categorized according to diameter of the fastener shank Thread styles are divided into broad groups the two most common being coarse Unified Coarse UNC and fine Unified Fine UNFO These groups are defined by the number of threads per inch on the bolt shanks In addition threads are categorized by thread class Table 8 which is a measure of the degree between threads of bolt or s
266. ort a towed vehicle with the transport legs in the down position Failure to comply could cause damage to equipment NOTE The hydraulic pressure release valve is open when the valve control handle is in line with the breather valve 1 Set12 24 volt junction box 1 to proper voltage 2 Remove electrical control box cover 2 from electrical control box 3 and switch electric toggle 4 to ON position Figure 23 Electric Control Boxes 0007 00 1 TM 9 2510 247 13 amp P 0007 00 TRANSPORT CONFIGURATION Continued 3 Remove remote control box 5 from tool box and press power ON 6 NOTE Electric motor switch 7 on electrical control box 3 must be depressed at all times to operate hydraulic valve control levers 8 All operations can be performed using either the hydraulic valve controls or the remote control PR Figure 24 Hydraulic Controls and Electric Control Box 0007 00 2 9 2510 247 13 amp P 0007 00 TRANSPORT CONFIGURATION Continued WARNING Ensure the boom has sufficient overhead clearance prior to folding the boom into a vertical position Failure to comply may result in injury or death to personnel 4 Using remote control box or valve control levers BOOM RETRACT 9 to raise boom to a closed vertical position 4 cai 5 AN 4 WW 37 t a se SS REMMCIPGIONS t mst WINCH ee I 7 esc OUT EXTEND EXT
267. ough boom extension assembly 7 and secure with flatwasher 5 and new retaining pin 4 5 Install hydraulic hoses on two fittings 3 6 BOOM RETRACT to raise boom to approximately 45 angle to allow for installation of slip pad 7 Position slip pad 2 and secure with four screws 1 Follow on Tasks Charge hydraulics WP 0056 00 5 END OF WORK PACKAGE 0066 00 3 9 2510 247 13 amp P 0067 00 GENERAL HYDRAULIC SYSTEM REPAIR GENERAL This section provides information for performing Unit level body repairs on the 250M fifth wheel towing device END OF WORK PACKAGE 0067 00 1 TM 9 2510 247 13 amp P 0068 00 RECEIVER AND WHEEL STOP ASSEMBLY REPLACEMENT INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in coupling Pins split 4 98296A255 configuration WP 0002 Pins split 4 982964559 Tools Test Equipment Personnel Required 2 None General Safety Instruction None NOTE There is a driver side and a passenger side receiver Both are removed the same way REMOVAL 1 Remove spring pin 1 from hitch pin 2 and remove hitch pin 2 and wheel stop 3 from receiver 4 2 Remove split pins 5 from tee bolts 6 and 7 3 Remove tee bolts 6 and 7 by turning in toward receiver 4 4 Lifthandle 8 and remove receiver 4 from boom REMOVE WHEEL STOP HANDLE 1 Remove split pin 9 from rod 10 2 Remove handle 8 from wheel stop handle assembly Fi
268. parate from the fittings and cause control valves relief valves and actuators to become contaminated and fail Do not apply sealant to the first threads of NPT fittings If sealant enters the hydraulic system it may cause components to fail 0059 00 1 9 2510 247 13 0059 00 REMOVAL Continued 10 11 12 13 14 15 CAUTION When connecting a hose to a fitting always use two wrenches Use one wrench to turn the swivel nut onto the fitting and use another wrench to keep the hose from rotating If the hose rotates it can loosen the other end of the hose or loosen the fitting at the other end NOTE Tag all hoses and fittings prior to disconnecting to ease installation Hydraulic hoses must be capped and or plugged when disconnecting to prevent contamination of hydraulic system Disconnect ten hydraulic hoses 3 from elbows 4 Loosen swivel nut at opposite end of hydraulic hose 5 Disconnect hydraulic hose 5 from tee pipe 6 Disconnect hydraulic hose 7 from straight adapter 8 Remove screw 9 and ground wire 10 from main valve assembly Remove two screws 1 from solenoid cover 2 and remove solenoid cover 2 from main valve assembly NOTE Tag all electrical wires prior to disconnecting to ease installation Disconnect all wires from solenoids Remove straight adapter 8 from main valve assembly 13 Remove plug 17 from main valve assembly 13 Remove ten elbows 4 from
269. pling position as shown except where noted M Monthly A Annual 0039 00 3 9 2510 247 13 amp P 0039 00 250 WHEEL TOWING DEVICE FWTD LUBRICANT INTERVAL Center Mast Cylinder See View7 C See View 6 GAA M 7 Towing Attachments C See View 12 222 GAA M Mast See View 8 00 1 Center Mast C See View 10 0039 00 4 9 2510 247 13 amp P 0039 00 KEY EXPECTED TEMPERATURE LUBRICANTS Above 32 F 40 F to 10 F OF to 65 F Above 0 C 4 C to 23 C 18 C to 54 C GAA GAA GAA GAA MIL G 10924 Grease Automotive and Artillery OE HDO 15W40 15W40 Lubricating Oil OHA 5606 5606 Oil Hydraulic Arctic Arctic operations refer top WP 0039 00 1 NOTES 1 For operation of semitrailer in protracted cold temperatures below 10 F 23 remove lubricants prescribed in the KEY for temperatures above 10 23 C Clean parts with drycleaning solvent Item 19 WP 0085 Relubricate with lubricants specified the key for temperatures below 10 F 23 C 2 sandy areas lubricate twice as frequently 0039 00 5 9 2510 247 13 0039 00 0039 00 6 9 2510 247 13 0039 00 END OF WORK PACKAGE 0039 00 7 9 2510 247 13 0040 00 ELECTRICAL SYSTEM MAINTENANCE GENERAL
270. port maintenance of the 250M Fifth Wheel Towing Device FWTD It authorizes the requisitioning issue and disposition of spares repair parts and special tools as indicated by the Source Maintenance and Recoverability SMR codes 2 GENERAL In addition to the Introduction work package this RPSTL is divided into the following work packages a Repair Parts List Work Package Work packages containing lists of spares and repair parts authorized by this RPSTL for use in the performance of maintenance These work packages also include parts which must be removed for replacement of the authorized parts Parts lists are composed of functional groups in ascending alphanumeric sequence with the parts in each group listed in ascending figure and item number sequence Sending units brackets filters and bolts shall be listed with the component they mount on Bulk materials are listed by item name in FIG BULK at the end of the work packages Repair parts kits are listed separately in their own functional group and work package Repair parts for reparable special tools are also listed in a separate work package Items listed are shown on the associated illustrations b Special Tools List Work Package Work packages containing lists of special tools special TMDE and special support equipment authorized by this RPSTL as indicated by Basis of Issue BOI information in the DESCRIPTION AND USABLE ON CODE UOC column Tools that are components of common t
271. posed surfaces with water and a brush 2 Remove grease with drycleaning solvent and a clean rag INSPECTION 1 Inspect protection valve for damaged threads cracks dents holes and warps 2 Replace defective protection valve 3 Inspect mounting bracket for cracks breaks and warps 4 Replace defective mounting bracket INSTALLATION 1 Position mounting bracket 5 on fender and secure with two screws 6 flatwashers 7 new lockwashers 8 and nuts 9 2 Position protection valve 4 onto mounting bracket 5 and secure with two screws 1 new lockwashers 2 and nuts 3 0054 00 2 9 2510 247 13 amp P 0054 00 LEAKAGE TEST 1 With air brake system connected apply a solution of detergent and water to protection valve and connections No leakage 15 permitted 2 With brake system fully pressurized disconnect gladhands tagged EMERGENCY from prime mover Make sure towed vehicle brakes apply automatically 3 Repeat step 2 for gladhands from towed vehicle 9 Figure 98 Air Brake Protection Valve Assembly Follow on Tasks None END OF WORK PACKAGE 0054 00 3 9 2510 247 13 amp P 0055 00 AIR BRAKE FITTINGS MAINTENANCE REMOVAL INSPECTION REPLACEMENT REPAIR INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Parked on level ground Tape antiseizing item 17 WP 0085 Gladhands Removed WP 0053 Tie wire item 18 0085 Tubing non metallic Insert 8 414
272. r DA Form 2028 2 direct to Commander U S Army Tank automotive and Armaments Command ATTN AMSTA AC NML Rock Island IL 61299 7630 The email address is amsta ac nml ria army mil The fax number is DSN 793 0726 or Commercial 309 782 0726 TABLE OF CONTENTS WP Sequence No GENERAL INFORMATION EQUIPMENT DESCRIPTION AND THEORY OF OPERATION lp qm M X General Information dai Equipment Description and Did nenne ea Theory of Operation OPERATOR INSTRUCTIONS Description and Use of Operator s Controls and Indicators Operation Under Usual Conditions eques sace ag darlo densae ont ns A s eet stats odes tient eA au c INE Prepare Towing Device ji Prepare Tow Bar GR as ime edad Connecting to Towed Vehicle cccccccesesssscsesscsesssecsscecsessesesssecsescsesscacsecaesusacsesecseseeseseceesecaeess 9 2510 247 13 amp P TABLE OF CONTENTS WP Sequence No CHAPTER 2 OPERATOR INSTRUCTIONS Continued Performance of Pre Picking LIS Winching Operations ss Preparing Equipment for Towing Securing 64004 0 0 0 002 0 00000 eene nan etras ent Operate Lights nenn
273. r contacts cam plate on left boom 0037 00 5 9 2510 247 13 0038 00 GENERAL MAINTENANCE INSTRUCTIONS GENERAL 1 These general maintenance instructions contain shop practices and specific methods you must be familiar with to properly maintain the equipment You should read and understand these practices and methods before performing any maintenance procedures Before beginning a task find out how much repair modification or replacement is needed to fix the equipment Sometimes the reason for equipment failure can be seen right away and complete tear down is not necessary Disassemble equipment only as far as necessary to repair or replace damaged parts In some cases a part may be damaged during removal If the part appears to be good and other parts behind it are not defective leave it in place and continue with the procedure Here are a few simple rules a Do not remove dowel pins or studs unless loose bent broken or otherwise damaged b Donotremove bearings or bushings unless damaged If you need to remove them to access parts behind carefully pull out bearings and bushings c Replace all gaskets lockwashers self locking nuts seals cotter pins and preformed packings The following Initial Setup information applies to all maintenance procedures a Resources are not listed unless they apply to the procedure b Personnel Required is listed only if more than one mechanic is required to complete
274. r damages in connection with the sale of furinishings of the equipment its design suitability for use installation or operation or for any claimed defects therein Neither seller nor Tru Hitch Inc will be liable for any incidental or consequential damages whatsoever SAFETY CARE AND HANDLING 1 First Aid For first aid information refer to FM 21 11 First Aid for Soldiers 2 Personnel Safety Precautions a Read and become familiar with all WARNINGS in the warning summary at the front of this manual b Pay attention to WARNING decals on the towing device These provide safety instructions and identify specific hazards which if not followed may result in serious injury or death to personnel c Throughout this manual WARNINGS and CAUTIONS are given immediately preceding the procedural steps to which they apply Read these WARNINGS and CAUTIONS and follow them exactly d When performing operations with the towing device in conjunction with another vehicle ensure that all Warnings Cautions and special instructions in the vehicles operators manual are followed 0001 00 2 TM 9 2510 247 13 amp P 0001 00 2 Personnel Safety Precautions Continued e When performing maintenance protect yourself against injury Wear protective gear such as safety goggles or lenses safety shoes rubber apron gloves etc f Notify others in the area if you are handling flammable materials Know the location of fire extinguishers and e
275. r use exposed flame when checking battery explosive gases are present and severe injury or death to personnel can result 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 or death to personnel Remove all jewelry such as rings ID tags bracelets etc If jewelry contacts battery terminal a direct short may result in instant heating of tools damage to equipment and injury or death to personnel Battery box is not a step Stepping on battery box can cause it to swivel causing injury or death to personnel WARNING CARC PAINT CARC paint contains isocyanate HDI which is highly irritating to skin and respiratory system High concentrations of HDI can produce symptoms of itching and reddening of skin a burning sensation in throat and nose and watering of the eyes In extreme concentrations HDI can cause cough shortness of breath pain during respiration increased sputum production and chest tightness The following precautions must be taken whenever using CARC paint ALWAYS use air line respirators when using CARC paint unless air sampling shows exposure to be below standards Use chemical cartridge respirator if air sampling is below standards 9 2510 247 13 amp P WARNING CARC
276. rallel with the prime movers chassis while coupling If no adjust position of kingpin bolster plate WP 0006 If yes go to step 3 Step 3 15 fifth wheel lockout device on prime mover open before coupling If no refer to prime mover TM to open lockout device If yes refer to prime mover TM to determine fault END OF WORK PACKAGE 0026 00 1 9 2510 247 13 0027 00 UNIT TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL SYSTEM 1 NOTHING HAPPENS WHEN ELECTRICAL CONTROL BOX ON OFF SWITCH IS ENGAGED Step 1 Is push button being engaged to activate hydraulic motors If no engage push button to activate hydraulic motors If yes go to step 2 Step 2 Is there minimum12VDC on batteries If no connect IVEC cable to prime mover and 12 24 volt junction box If yes go to step 3 Step 3 Is there voltage at on off switch If no check for broken wire that supplies on off switch WP 0088 If yes go to step 4 Step 4 Is there power on only one side of on off switch If no go to step 4 If yes replace switch Step 5 Is there power to 12 24 volt junction box If no disconnect cable connector at junction box receptacle Check for minimum 12 or 24 volt ouput from prime mover as determined by prime mover If yes go to step 5 0027 00 1 9 2510 247 13 0027 00 UNIT TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL SYSTEM Con
277. rcial and Government Entity Code in parentheses and the part number Column 4 Usable on Code When applicable gives the code if the item needed is not the same for different models of equipment Column 5 Unit of Issue indicates how the item is issued for the National Stock Number shown in column 1 Column 6 Quantity Required Qty Rqd indicates the quantity of the item authorized to be used with the equipment 0086 00 1 9 2510 247 13 amp P 0086 00 ADDITIONAL AUTHORIZATION LIST 1 2 3 4 llus National Description Usable Number Stock Number CAGEC Part Number On Code 3990 01 327 1278 TIEDOWN CARGO VEHICLE OC1E6 CR15A TOWLIGHT ASSEMBLY 12V 1BZD4 02325 6150 01 502 2047 CORD LIGHT 12V 1BZD4 1134 1 END OF WORK PACKAGE 0086 00 2 9 2510 247 13 amp P 0087 00 EXPENDABLE AND DURABLE ITEMS LIST SECTION I INTRODUCTION 1 SCOPE This work package lists expendable and durable items you will need to operate and maintain the 250M Fifth Wheel Towing Device FWTD This listing is for informational purposes only and is not authority to requisition the listed items These items are authorized to you by CTA 50 970 Expendable durable Items Except Medical Class V Repair Parts and Heraldic Items or CTA 8 100 Army Medical Department Expendable Durable Items 2 EXPLANATION OF COLUMNS a Column 1 Item Number This number is assigned to the entry in the listi
278. repare tow bar assemblies for loading equipment WP 0009 2 Connectto towed vehicld WP 0010 steps 1 through 5 3 Position rubber blocks item 6 WP 0083 between front spring saddle of towed vehicle and boom 4 Using valve control levers BOOM EXTEND to a height to allow rubber blocks item 6 WP 0083 to be placed on ground UNDER boom approximately 4 feet 48 inches forward of rubber blocks placed on top of boom in step 3 5 Using valve control levers BOOM RETRACT to position boom extensions as high as possible ensuring not to contact underside of towed vehicle 6 If frame hooks item 5 WP 0083 jare used to secure boom extensions to towed vehicle frame hooks can be coupled directly to boom extension clevis 0022 00 3 9 2510 247 13 amp P 0022 00 ROLL ON ROLL OFF RORO OPERATIONS Continued 7 Continue with connecting to towed vehicle WP 0010 steps 11 through 26 OMIT STEP 14 8 DO NOT install hitch pin into center mast WP 0010 step 19 9 MAST EXTEND to raise mast to highest position Lock pin should be inserted in fifth hole on mast section WP 0010 step 22 10 When ascending ramp it may be necessasry to BOOM EXTEND for additional height after prime mover passes the crest Use remote control to extend and retract booms as necessary 11 After towed vehicle travels over the crest BOOM RETRACT to level fifth wheel section END OF WORK PACKAGE 0022 00 4 TM 9 2510 247 13 amp P CHAPTER 3
279. reventive Maintenance Checks and Services PMCS for 250M Fifth Wheel Towing Device Item To Check Not Fully Mission Service Procedure Capable If TOW BAR ASSEMBLY 17 Check tow bar assemblies 16 for proper operation and cleanliness TIEDOWN POINTS Check D rings 17 and clevis 18 Tiedown points load for serviceability binders or chains not sufficient for proper securing of equipment 0031 00 12 TM 9 2510 247 13 amp P 0031 00 Table 2 Operator Preventive Maintenance Checks and Services PMCS for 250M Fifth Wheel Towing Device Location Item To Check Service HYDRAULIC MOTORS amp PUMPS HYDRAULIC CYLINDERS BOOM EXTENSIONS RUBBER BLOCKS Procedure Inspect hydraulic motors 19 for missing broken kinked or damaged wires Check for hydraulic fluid leaks Inspect hydraulic cylinders for scratches and wear Inspect boom extension wear pad for excessive wear Check rubber blocks 20 for serviceability 0031 00 13 Not Fully Mission Capable If Missing broken kinked or damaged wires Class III fluid leak evident Excessive wear present Excessive wear present ALL rubber blocks are missing TM 9 2510 247 13 amp P 0031 00 Table 2 Operator Preventive Maintenance Checks and Services PMCS for 250M Fifth Wheel Towing Device Item To Check Not Fully Mission Service Procedure Capable If 23 Check belting 21 for serviceability 21 KINGPIN 24 Mo
280. rm lock 4 and chain assembly 5 onto gladhand and secure with two screws 3 5 Install dummy coupling 1 on gladhand 2 Figure 97 Gladhand Assembly Follow on Tasks Check for air leaks END OF WORK PACKAGE 0053 00 3 9 2510 247 13 amp P 0054 00 AIR BRAKE PROTECTION VALVE REPLACEMENT REMOVAL CLEANING INSPECTION INSTALLATION LEAKAGE TEST INITIAL SETUP Equipment Conditions Materials Parts Air lines removed WP 0055 Washer lock 4 MS35333 40 Drycleaning solvent item 14 WP 0085 Rags item 10 WP 0085 Brush scrub item 1 WP 0085 Thread Seal Compound Tools Test Equipment General Safety Instructions Tool Kit Mechanics General None NSN 5180 00 177 7033 REMOVAL 1 Remove two screws 1 lockwashers 2 nuts 3 and protection valve 4 from mounting bracket 5 Discard lockwashers 2 Remove two screws 6 flatwashers 7 lockwashers 8 and nuts 9 from mounting bracket 5 Discard lockwashers 3 Remove mounting bracket from fender Figure 98 Air Brake Protection Valve Assembly 0054 00 1 9 2510 247 13 amp P 0054 00 WARNING Drycleaning solvent MIL PRF 680 Type is an environmentally compliant and low toxic material However it may be irritating to the eyes and skin The use of protective gloves and goggles is suggested Use in well ventilated areas Keep away from open flames and other sources of ignition CLEANING 1 Clean mud and dirt from all ex
281. rrect the problem 0025 00 1 9 2510 247 13 amp P 0025 00 UNIT TROUBLESHOOTING SYMPTOM INDEX Troubleshooting Procedure Page KINGPIN EE WP 0026 Kingpin Fails to Lock in Fifth Wheel ELECTRICAL SYSTEM coin redacta WP 0027 Hydraulic Functions do not Operate when Electric On Off Switch is On Loss of Power to 12 24 Volt Junction Box Voltmeter Inoperable Remote Control Inoperable All Lights Inoperable Work Light Inoperable Light Bar Assembly Inoperable Strobe Lights Inoperable HYDRAULIC SYSTEM lee din WP 0028 Hydraulic Functions Slow or Inoperable Boom Hydraulic Cylinder Leaks Cannot Relieve Hydraulic Pressure from One or More Levers Cylinders do not Extend or Retract when Push Switch on Electric Control Box and Levers are Activated Hydraulic Fluid Coming from Breather Valve Boom Will Not Operate Mast Will Not Operate 5 22 lt mm WP 0029 Air Brake System Will Not Operate WINCH APP HE P WP 0030 Winch Will Not Operate END OF WORK PACKAGE 0025 00 2 9 2510 247 13 00 26 00 UNIT TROUBLESHOOTING MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION KINGPIN KINGPIN FAILS TO LOCK IN FIFTH WHEEL Step 1 Is proper kingpin 2 inches or 3 1 2 inches installed in Fifth Wheel Towing Device If no install proper kingpin size for compatibility to prime mover WP 0034 If yes go to step 2 Step 2 Is kingpin bolster plate resting on the prime mover s fifth wheel and pa
282. s and hydraulic tank relief valve is slowly loosened to relieve pressure Failure to comply may result in severe injury to personnel Spilled hydraulic oil is very slippery Be careful when entering or working in area Wipe up any spilled oil immediately Failure to comply may result in severe injury or death to personnel No maintenance shall be performed on top of or below the main frame without the proper support under the front of the main frame Failure to follow this warning may result in injury or death to personnel 0057 00 1 9 2510 247 13 amp P 0057 00 REMOVAL OF PRIMARY MOTOR Continued NOTE There are two hydraulic motors primary 3 and isolated 11 The solenoid to primary motor wire must be removed from primary motor prior to removal 1 Loosen two mounting bolts 1 2 Remove solenoid to motor wire 2 from primary motor 3 3 Disconnect hose from elbow 4 on primary motor 3 4 Disconnect two straight adapters 5 5 Remove two screws 6 lockwashers 7 and flatwashers 8 from bracket 9 on primary motor 3 Discard lockwashers 6 Loosen two screws 10 and remove primary motor 3 from bracket Figure 105 Hydraulic Motor Assembly 0057 00 2 TM 9 2510 247 13 amp P 0057 00 REMOVAL OF ISOLATED MOTOR A Ed sl High pressure is present in the 250M Fifth Wheel Towing Device hydraulic system Do not disconnect any hydraulic system component unless hydraulic system pressure has been re
283. s not perform as required refer to the appropriate troubleshooting procedure in WP 0024 If anything looks wrong and you can t fix it write it on your DA Form 5988 If you find something seriously wrong IMMEDIATELY report it to your supervisor Before performing preventive maintenance read all the checks required for the applicable interval and prepare all the tools you need to make all the checks You ll always need a rag Item 10 WP 0085 or two a Keep lt Clean Dirt grease oil and debris get in the way and may cover up a serious problem Clean as you work and as needed Use dry cleaning solvent Item 14 WP 0085 on all metal surfaces Use detergent Item 4 WP 0085 and water when you clean rubber or plastic b Deterioration Rust and Corrosion 1 Be alert for deterioration of plastic and rubber materials Report it to your supervisor 2 Check metal parts of vehicle for rust and corrosion If any bare metal or corrosion exists clean and apply a light coat of oil 9 WP 0085 Report it to your supervisor c Bolts Nuts and Screws Check bolts nuts and screws for obvious looseness missing bent or broken condition You can t try them all with a tool of course but look for chipped paint bare metal or rust around bolt heads If you find one you think is loose report it to your supervisor d Welds Look for loose or chipped paint rust or gaps where parts are welded together If you find a bad weld
284. should be applied gradually and smoothly Selecting a lower gear before beginning a long downgrade is the safest most effective way to maintain control of the vehicle combination g Parking When the prime mover and the towing device are to be parked and left unattended set the parking brake on the prime mover and place chock blocks in front and behind wheels to prevent rolling E F3 WARNING Visibility from the prime mover is significantly reduced when backing Proper procedures must be followed and extreme caution used when backing to prevent damage to equipment and injury or death to personnel h Backing When backing use the assistant driver as a ground guide Adjust rear view mirrors before backing Use slow speed and extreme caution when backing this combination END OF WORK PACKAGE 0017 00 2 TM 9 2510 247 13 amp P 0018 00 DISCONNECTING TOWED VEHICLE EXE WARNING LOADING UNLOADING OPERATION All persons not involved in the loading or unloading operation must stand clear of prime mover and fifth wheel towing device Failure to comply may result in injury or death to personnel Due to the dimensions and center of gravity of some loads proper procedures must be followed when loading and unloading equipment to prevent damage to equipment and injury or death to personnel Visibility from the prime mover is significantly reduced when backing whether the fifth wheel towing device is loaded or not Proper procedures must
285. ssigned to the 250M Fifth Wheel Towing Device FWTD END OF WORK PACKAGE 0088 00 1 9 2510 247 13 amp P 0089 00 TORQUE VALUES FOR THREADED FASTENERS 1 SCOPE This work package lists standard torque values as shown in Table 5 and provides general information for applying torque Special torque values and tightening sequences are indicated in the maintenance procedures for applicable components 2 GENERAL a Always use the torque values listed in Table 5 when the maintenance procedure does not give a specific torque value b Unless otherwise indicated standard torque tolerance shall be 10 Torque values listed are based on clean dry threads Reduce torque by 10 when engine oil is used as a lubricant Reduce torque by 20 if new plated capscrews are used d Capscrews threaded into aluminum may require reductions in torque of 30 or more of Grade 5 capscrew torque Capscrew threaded into aluminum must also attain two capscrew diameters of thread engagement CAUTION If replacement capscrews are of higher grade than originally supplied use torque specifications for the original This will prevent equipment damage due to overtorquing 3 TORQUE LIMITS Table 5 lists dry torque limits which are used on screws that do not have lubricants applied to threads Table 6 lists wet torque limits which are used on screws that have high pressure lubricants applied to threads 0089 00 1 9 2510 247 13 0089 00 4
286. t 1 2 3 ITEM SMR NO 1 2 CODE NSN 6220014959757 PAOZZ 6240015022530 4 1BZD4 OTWA7 5 PART NUMBER 1076 1 4411 9 2510 247 13 amp P 0082 00 6 7 DESCRIPTION AND USABLE CODES UOC QTY GROUP 0609 LIGHTS FIG 5 WORKLIGHT EGATUTILITY inii rrr 1 LAMP INCANDESCENT 12V PART OF P N 1076 1 APP tentes 1 END OF FIGURE TM 9 2510 247 13 amp P 0082 00 Figure 6 Strobe Light Assembly TM 9 2510 247 13 amp P 0082 00 0 2 3 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODES UOC GROUP 0609 LIGHTS FIG 6 BTROBE LIGHT ASSEMBLY 1 6220015022419 OTWA7 LIGHT STROBE 12 V aan use 2 2 PAOZZ 5305009887603 80205 MS16995 27 SCREW MACHINE PART OF P N LP154A 8 3 PAOZZ 6220015027230 OTWA7 5005008 COVER PLASTIC PART OF P N LP15A a 2 4 PAOZZ 6240015022421 OTWA7 1 BULB HALOGEN SSW cinere 4 5 XDOZZ OTWA7 3 CLIP BULB RETAINING PART OF P N LP15A 4 6 PAOZZ 5310013894257 96906 M535338 046 WASHER LOCK 3 8 DIA 6 7 PAOZZ 5305012726543 81495 1200 59 SCREW CAP HEXAGON H 3 8 DIA X 16 UNC X 1 INCH LONG 6 8 XDOZZ 1BZD4 1039 1 BRACKET MOUNTING eene 2 9 PAOZZ 5305009844981 96906 MS35206 224 SCREW MACHINE 1 8 DIA X 32 UNC X T INCH LONG nnt ttt tes 8 E
287. t assembly 5 2 Remove bolt 6 flatwasher 7 flatwasher 8 lockwasher 9 and nut 10 Remove lower mounting bracket 5 from fender Discard lockwasher Figure 90 Fixed Worklight Assembly 0048 00 1 TM 9 2510 247 13 amp P 0048 00 DISASSEMBLY 1 Apply soap solution to edge of lamp 11 and pry from worklight assembly 12 2 Disconnect leads 13 from lamp 11 ASSEMBLY 1 Connect leads 13 to lamp 11 2 Install lamp 11 into worklight assembly 12 INSTALLATION 1 Install mounting bracket 5b onto fender with bolt 6 flatwasher 7 flatwasher 8 new lockwasher 9 and nut 10 2 Install worklighty assembly 12 onto mounting bracket 5 with screw 1 spacer 2 flatwasher 3 and nut 4 Figure 90 Fixed Worklight Assembly Follow on Tasks Connect batteries WP 0050 Check for proper operation of fixed worklight END OF WORK PACKAGE 0048 00 2 9 2510 247 13 amp P 0049 00 STROBE LIGHT MAINTENANCE REMOVAL INSTALLATION REPAIR INITIAL SETUP Materials Parts Bulb halogen 4 BH 1 Equipment Conditions Washers lock 3 1229 S 513 C Fifth Wheel Towing Device in a convenient configuration Disconnect Batteries WP 0050 Tools Test Equipment Tool Kit Mechanics General NSN 5180 00 177 7033 REMOVAL zf WARNING Remove all power to towing device prior to making any repairs on the electrical system Failure to do so may result in serious
288. t in serious injury or death a Disconnect inter vehicular electrical cable 1 from prime mover to towing device receptacle 2 b Use arag Item 10 WP 0085 to remove any build up of grease or dirt from exterior of connector and receptacle Allow to dry c Using a scrub brush Item 1 0085 and detergent item 4 WP 0085 clean metal surfaces Allow to dry 2 Inspection a Inspect connector for damage b Notify Unit Maintenance if any damage 15 found Figure 71 Electrical Connectors END OF WORK PACKAGE 0032 00 1 9 2510 247 13 0033 00 GLADHANDS 1 Cleaning a Use arag Item 10 WP 0085 to remove any buildup of grease and dirt from gladhands b Use arag 10 WP 0085 detergent item 4 WP 0085 and water to thoroughly clean gladhand connecting surfaces 1 to include rubber grommet Allow parts to dry thoroughly 2 Inspection a Inspect gladhands for damage 1 Check rubber grommet and screen for damage 2 Use a soapy water solution detergent Item 4j WP 0085 water to check for air leaks b Notify Unit Maintenance if damage is found Figure 72 Gladhand END OF WORK PACKAGE 0033 00 1 9 2510 247 13 0034 00 KINGPIN PLACEMENT NOTE The main frame may be lowered using MAST EXTEND to ease kingpin placement After placement return mainframe to the highest position using MAST RETRACT REMOVAL 1 Boo m Remove spring pin 1 from top of
289. t pivot pin 3 2 Secure pivot pin 3 with two screws 1 and new locknuts 2 Figure 123 Pivot Pin Replacement Assembly Follow on Tasks None END OF WORK PACKAGE 0072 00 1 9 2510 247 13 amp P 0073 00 CENTER MAST FRAME REPLACEMENT REMOVAL INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Fifth Wheel Towing Device in coupling None configuration WP 0002 Safety valves removed WP 0058 Personnel Required 2 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General When removing installing heavy components NSN 5180 00 177 7033 use appropriate lifting device and or the aid of an assistant to prevent injury REMOVAL N WARNING To avoid personal injury use a hoist or get assistance when lifting components that weigh more than 50 Ibs 23 kg 1 Loosen two screws 1 and remove retaining pin 2 2 Lower center mast 3 to boom 3 Loosen two screws 4 and remove retaining pin 5 4 Remove center mast 3 from frame Q_ EE E Hug hu 3 Figure 124 Center Mast Frame 0073 00 1 9 2510 247 13 0073 00 INSTALLATION 1 Position lower portion of center mast 3 on frame and insert retaining pin 5 2 Tighten two screws 4 3 Raise center mast to align top portion with frame 4 Insert retaining pin 2 and tighten two screws 1 Figure 124 Center Mast Frame Follow on Tasks None END O
290. t to your supervisor 2 Check metal parts for rust and corrosion If any bare metal or corrosion exists clean and apply a light coat of lubricating oil Item 9 WP 0085 Report it to your supervisor c Bolts Nuts and Screws Check bolts nuts and screws for obvious looseness missing bent or broken condition You can t try them all with a tool but look for chipped paint bare metal or rust around bolt heads If you find one you think is loose tighten it d Welds Look for loose or chipped paint rust or gaps where parts are welded together If you find a bad weld report it to your supervisor e Electric Wires and Connectors Look for cracked or broken insulation break wires and loose or broken connectors Tighten loose connectors and ensure that the wires are in good condition f Fluid Leakage It is necessary for you to know how fluid leakage affects the status of your towing device The following are definitions of the types classes of leakage you need to know to be able to determine the status of your equipment Learn and be familiar with them and remember when in doubt notify your supervisor 0037 00 2 TM 9 2510 247 13 amp P 0037 00 GENERAL PMCS PROCEDURES Continued Leakage Definitions Class Leakage indicated by wetness or discoloration but not great enough to form drops Class Il Leakage great enough to form drops but not enough to cause drops to drip from the item being checked inspected C
291. tacle on prime mover WP 0015 If yes go to step 2 Step 2 Is light bar cable damaged If no go to step 3 If yes repair or replace light bar cable as necessary WP 0047 Step 3 Is voltage going into light bar assembly If no replace light bar cable If yes replace light bar assembly and return used light bar assembly to manufacturer for evaluation 8 STROBELIGHTS INOPERABLE Step 1 Is STROBE LIGHT switch ON If no put STROBE LIGHT switch in ON position WP 0015 If yes go to step 2 Step 2 Is just one side inoperable If no go to step 4 If yes check electrical ground WP 0088 Step 3 Is bulb working properly If no replace bulb WP 0049 If yes replace strobe light assembly and send faulty assembly to manufacturer for evaluation 0027 00 5 9 2510 247 13 0027 00 UNIT TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL SYSTEM Continued Step 4 Are both strobe lights inoperable Step 5 Step 6 Step 7 If no go to step 5 If yes check electrical ground WP 0088 Is there minimum12VDC on batteries If no go to step 6 If yes go to step 7 Is NATO slave cable connected If no install NATO cable in receptacle on prime mover and receptacle on 12 24 volt junction box If yes go to step 7 Is wiring from electrical control box damaged kinked or frayed If no replace strobe light assembly WP 0049 If yes replace wiring WP 005
292. te the loading procedures END OF WORK PACKAGE 0014 00 2 9 2510 247 13 amp 0015 00 OPERATE LIGHTS 1 Connect inter vehicular electrical cable to 12 24 volt junction box receptacle NOTE The strobe lights worklights and tow light assembly can be operated with either 12 volt or 24 volt systems When operating the fifth wheel towing device strobe lights the dummy plug located in the BII must be inserted into the 12 volt receptacle on the 12 24 volt junction box When using the 70 ft tow light electric cable care should be taken to route the cable to eliminate damage during operations i e pinching binding pulling or rubbing The batteries on the fifth wheel towing device will run low during extended operation of the strobe lights and must be recharged Connect the 24 volt NATO slave cable and allow the prime mover to idle for an extended period of time if prime mover is equipped with IVEC connector When operating the towed configuration using the 24 volt light system disregard steps 3 through 5 All lights will be checked for proper function prior to operation of the prime mover or towing configuration 2 Set 12 24 volt junction box to proper voltage 3 Ifthe prime mover is a 12 volt system the 12 volt light bar 1 will be used 4 Install 12 volt tow light cable in receptacle 2 on electrical control box 3 Connect 12 volt tow light cable to tow light assembly 1 5 Connect 12 volt tow light
293. ted Record inspection and exercise results on DA Form 2404 or DA Form 5988E Record and report all maintenance actions on DA Form 2407 After exercising restore the preservation to the original condition Replenish lubricants used during exercising and note the amount on DA Form 2408 0078 00 4 TM 9 2510 247 13 amp P 00078 00 CARE OF EQUIPMENT IN ADMINISTRATIVE STORAGE Continued Table 4 Exercise Schedule wem Hydraulic Fluid Change X 5 Rotation Rotate items in accordance with any rotational plan that will keep the equipment in an operational condition and reduce the maintenance effort REMOVAL OF EQUIPMENT FROM ADMINISTRATIVE STORAGE 1 Activation Restore the equipment to normal operating condition in accordance with the instructions contained in Chapter 6 WP 0036 2 Servicing Resume the maintenance service schedule in effect at the commencement of storage or service the equipment before the scheduled dates in order to produce a staggered maintenance workload PREPARATION OF EQUIPMENT FOR SHIPMENT 1 Referto FM 55 21 TM 55 2200 001 12 and TM 743 200 1 for additional instructions on processing storage and shipment of materiel 2 Equipment that has been removed from storage for shipment does not have to be reprocessed if they will reach their destination within the administrative storage period Reprocess only if inspection reveals any corrosion or if anticipated in transit weather c
294. ted in the adjacent FIG column This item is also identified by the NSN listed on the same line Part Number P N Index Work Package P Ns in this index are listed in ascending alphanumeric sequence vertical arrangement of letter and number combinations which places the first letter or digit of each group in order A through 2 followed by the numbers 0 through 9 and each following letter or digit in like order 1 PART NUMBER COLUMN Indicates the P N assigned to the item 2 COLUMN This column lists the number of the figure where the item is identified located in the repair parts list and special tools list work packages 3 ITEM COLUMN The item number is the number assigned to the item as it appears in the figure referenced in the adjacent figure number column 0082 00 6 9 2510 247 13 amp P 0082 00 5 SPECIAL INFORMATION a b Usable on Code 2TD Fabrication Instructions Bulk materials required to manufacture items are listed in the bulk material functional group of this RPSTL Part numbers for bulk material are also referenced in the Description Column of the line item entry for the item to be manufactured fabricated Detailed fabrication instructions for items source coded to be manufactured or fabricated are found in Appendix G Index Numbers Items which have the word BULK in the figure column will have an index number shown in the item number column This index number is a cross reference between the
295. tes depending on temperature and humidity Loctite Adhesive Loctite adhesive item 12 WP 0085 provides a seal against leakage and a resistance to loosening when used in the assembly of threaded slip fitted or press fitted parts Always use grade of Loctite adhesive specified and never use when other retaining means are provided such as lockwires lockwashers lockplates and fasteners DO NOT use Loctite adhesive on brass fittings plugs or items that need frequent servicing or when operating temperature exceeds 300 F 149 Apply Loctite adhesive as follows a b Before application clean threads to remove oil grease and metal chips Apply Loctite adhesive to second and third threads DO NOT apply to first thread to ensure system cleanliness Loctite adhesive will dry in 6 24 hours at room temperature Adjustments for elbows gages and valves can be made up to 24 hours after application without affecting the seal 0038 00 5 9 2510 247 13 amp P 0038 00 STANDARD TOOL REQUIREMENTS 1 The following are general practices regarding the use of tools a Always use the proper tool kit and tools for the procedure being performed b Ensure that tools are clean and lubricated to reduce wear and to prevent rust Keep track of tools Do not be careless with them d Return tools to toolbox when finished with repair or maintenance e Return toolboxes and tools to tool storage when not in use f Inventory to
296. th or injury to personnel WIRE ROPES Wire rope can become frayed or contain broken wires Wear heavy leather palmed work gloves when handling wire rope Frayed or broken wires can injure hands Never let moving wire rope slide through hands even when wearing gloves A broken wire could cut through glove and cut hand NOTE Use a large rag or piece of cloth as a damper on the cable Ensure wheels are chocked in front of towed vehicle to prevent towed vehicle from rolling forward 1 Position boom extensions under towed vehicle Using remote control or valve lever controls BOOM EXTEND until contact is made with towed vehicle if possible If contact cannot be made line up towing device as close as possible 2 Attach chain around front axle of towed vehicle 0012 00 1 TM 9 2510 247 13 amp P 0012 00 WINCHING OPERATIONS Continued 3 Place damper on center point of cable Adjust to center of cable periodically during the winching operation 4 Pull winch free spool lever 1 to allow payout of winch cable and remove winch cable chains 4 from stowage position Figure 52 Winch Free Spool Lever 5 Using double hook 2 and pulley block 3 thread winch cable chains 4 back to front D rings 5 Reel excess cable onto winch spool 6 Remove wheel chocks Disengage brakes on towed vehicle Using remote control or valve control levers pull towed vehicle onto towing device BOOM RETRACT to allow clearance between boom an
297. the active time required to perform the maintenance function at the indicated level of maintenance If the number or complexity of the tasks within the listed maintenance function vary at different maintenance levels appropriate work time figures are shown for each level The work time figure represents the average time required to restore an item assembly subassembly assembly time troubleshooting fault location time and quality assurance time in addition to the time designations for the various maintenance levels are as follows C Operator or Crew Maintenance O Unit Maintenance Direct Support Maintenance L Specialized Repair Activity SRA H General Support Maintenance D Depot Maintenance e Column 5 Tools and Test Equipment Reference Code Column 5 specifies by code those common tool sets not individual tools common TMDE and special tools special TMDE and special support equipment required to perform the designated function Codes are keyed to Tools and Test Equipment in Section f Column 6 Remarks When applicable this column contains a letter code in alphabetical order which is keyed to the remarks contained in Section IV 5 This maintenance level is not included in Section Il column 4 of the MAC Functions to this level of maintenance are identified by a work time figure in the H column of Section Il column 4 and an associated reference code is used in the Remarks column 6 This
298. the fifth wheel towing device brakes and lights for proper operation Check all tiedowns at first opportunity after departure Recheck all tiedowns at halts and any time you suspect a problem Safety chains should be installed at a 45 angle to prevent shifting Failure to comply with these warnings may result in serious injury or death NOTE Tighten chains using the load binders Attach load binders so that a downward motion of the handle tightens and an upward motion loosens the load binder Lock handle in up position Secure excess chain to the tension bearing part of the chain Additional chains may be needed for heavier equipment Lift cam lever 1 on tire stop Lift end of tire stop and adjust to nearest 1 2 hole 2 so wheel is showing Lower cam lever 1 and lock position Repeat step 1 for remaining tire stop assembly Position safety chain 3 around axle 4 over boom 5 under tire stop 6 and through D ring 7 or tiedown bracket 8 ceo 00 9 A lt SS m 0014 00 1 9 2510 247 13 0014 00 SECURING EQUIPMENT Continued 4 If safety chain is through D ring 7 secure with load binder 9 as shown Figure 55 Tie Down Example 1 5 If safety chain is through tiedown bracket 8 secure with load binder 9 over top of winch cable 10 as shown Figure 56 Tie Down Example 2 NOTE After completion of tiedown procedures refer 19 WP 0010 steps 23 through 28 to comple
299. ting 6 Open top breather valve by turning breather lever 5 in line with breather 6 10 Turn bottom breather elbow 180 from original shipping position NOTE With main frame in the vertical position the bottom breather is on the fifth wheel side of the hydraulic tank and the top breather is located towards the rear of the fifth wheel towing device Figure 19 Breather Valves 0005 00 4 TM 9 2510 247 13 amp P 0005 00 UNFOLDING FROM SHIPPING STORAGE CONFIGURATION Continued 11 Using remote control or valve control levers MAST RETRACT until bottom of main frame assembly 7 is approximately 1 ft above the bottom of the mast slide 8 12 Reinstall both clevises 4 on mast 13 Using remote control or valve control levers BOOM EXTEND to unfold main frame assembly until fenders are horizontal with the prime mover fifth wheel NOTE Ensure transport legs are locked in the upright position Figure 20 Control Levers Mast and Clevis 14 Using remote control or valve control levers MAST RETRACT until main frame is at highest position without striking the top of the mast END OF WORK PACKAGE 0005 00 5 9 2510 247 13 amp P 0006 00 COUPLING Coupling operations will be conducted with the towing device set on the ground with the boom extended ata right angle to the mast section transport legs locked in the up position and boom extensions fully extended During coupling to prime mover it may be required t
300. tinued Step 6 Is voltage coming into and out of solenoids If no check if power is present at solenoid but not coming out of solenoid If power 15 present at solenoid but not coming out of solenoid replace solenoid If yes go to step 6 Step 7 Is voltage found at top of hydraulic motors when push button switch is on If no repeat steps 1 through 5 If yes replace on off switch 2 LOSS OF POWER TO THE 12 24 VOLT JUNCTION BOX Step 1 Is there minimum12VDC on batteries If no go to step 2 If yes go to step 3 Step 2 Is NATO slave cable connected If no install NATO cable in receptacle on prime mover and receptacle on 12 24 volt junction box If yes go to step 3 Step 3 Are there any broken or frayed wires If no go to step 4 If yes repair or replace wires as necessary WP 0051 Step 4 Do all connections inside 12 24 volt junction box have voltage If no ensure all connections are clean Pay special attention to all grounds WP 0088 If connections still do not have voltage replace 12 24 volt junction box 3 VOLTMETER DOES NOT WORK Step 1 Is there minimum12VDC on batteries If no go to step 2 If yes go to step 3 Step 2 Is NATO slave cable connected If no install NATO cable in receptacle on prime mover and receptacle on 12 24 volt junction box If yes go to step 3 0027 00 2 TM 9 2510 247 13 amp P 0027 00 UNIT TROUBLESHOOTING Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTIO
301. tion Certain items should be inspected prior to each trip Appropriate procedures for services and PMCS WP 003 will be completed prior to operating the 250M Fifth Wheel Towing Device Driving a General When driving the prime mover and towing device with attached vehicle the overall length must be kept in mind both when passing other vehicles and when turning Because the unit pivots at the fifth wheel backing is also affected CAUTION Never travel with the fifth wheel towing device boom in the vertical position Failure to comply may cause damage to equipment Road Surfaces Uneven terrain steep grades crowned roads and unimproved road surfaces can introduce forces that will make handling difficult Even a vehicle that is properly maintained and loaded can be hazardous when excessive speed and certain road conditions are combined Grades Operations on grades requires caution Use the same gear in descending a long grade as when ascending Gear selection should be made before descending a grade to minimize the chance of a missed shift Avoid excessive use of brakes on long down grades in order to maintain air pressure and prevent overheating of the brakes Side Slopes This device is not recommended to be loaded on an excessisve side slope The towing device can be safely operated with or without payloads on side slopes commonly encountered on highways or unimproved roads 0017 00 1 9 2510 247 13 amp P 0017 00
302. tion i e between moving parts or under hydraulic supported equipment Failure to comply may result in injury or death to personnel 0056 00 1 9 2510 247 13 amp P 0056 00 GENERAL HYDRAULIC SYSTEM REPAIR Continued CAUTION Always clean around fittings before disconnecting or connecting hoses or fittings Ensure area 15 clean before installing hydraulic components Failure to comply may result in damage to equipment Cover or plug all openings ports and tube or hose ends when they disconnected Failure to comply may result in damage to equipment Ensure you couple only fittings designed to be coupled with each other Never depend on trial and error Just because two fittings will screw together is no guarantee that the connection will not leak See illustrations of fitting types in this chapter Failure to comply may result in damage to equipment Fittings must be installed and hand tightened If a fitting cannot be handtightened it may be cross threaded or have damaged threads Use wrench only for final tightening Failure to comply may result in damage to equipment Do not use Teflon tape as a sealer on any fittings It can separate from the fittings and cause control valves relief valves and actuators to become contaminated and fail It is possible to install a male National Pipe Thread NPT into a female straight thread but the fitting will leak Learn to recognize the very slight taper which an NP
303. trative storage in such a way as to achieve the maximum readiness condition Equipment that is placed in administrative storage should be capable of being readied to perform its mission within one 24 hour period or as otherwise may be prescribed by the approving authority Before equipment is placed in administrative storage a current Preventive Maintenance Checks and Services PMCS should be completed and deficiencies corrected Report equipment in administrative storage as prescribed for all reportable equipment Perform inspections maintenance services and lubrication as specified herein Records and reports to be maintained for equipment in administrative storage are those prescribed by DA Pam 738 750 for equipment in use A 10 variance is acceptable on time used to determine the required maintenance actions Accomplishment of applicable PMCS as mentioned throughout this chapter will be on a semiannual basis DEFINITION OF ADMINISTRATIVE STORAGE The placement of equipment in administrative storage can be for short periods of time when a shortage of maintenance effort exists Items should be ready for use within the time factors as determined by the directing authority During the storage period appropriate maintenance records will be kept 0078 00 1 TM 9 2510 247 13 amp P 0078 00 PREPARATION OF EQUIPMENT FOR ADMINISTRATIVE STORAGE 1 Storage Site a Select the best available site for administrative storage Separ
304. ts are clean and lubricated before assembly 0038 00 4 TM 9 2510 247 13 amp P 0038 00 LUBRICATION INSTRUCTIONS Refer to WP 0039 for detailed illustrated instructions on proper lubrication Some general practices to remember a Usethe correct lubricant b Keep lubricants clean Clean all fittings prior to lubrication d Lubricate clean disassembled and new parts to prevent rust WP 0038 00 2 Preservation of Parts e Ifa lubrication fitting will not accept grease check for dirt or clogged fitting This may require removal cleaning and installation of the fitting If the fitting is on a hydraulic cylinder and will not accept grease it may be due to pressure applied by the position of the cylinder Repositioning the cylinder may resolve the fitting not accepting grease APPLICATION OF ADHESIVES 1 General Adhesives are recommended in some tasks to ensure and strengthen seals The following information describes their correct use and application Silicone Sealant Silicone sealant item 11 WP 0085 lis used to seal parts against moisture Use the following instructions when applying a d Anytime a seal is broken the part must be thoroughly cleaned to remove any remaining sealing compound and dirt Thoroughly clean surface before applying sealant When applying sealant ensure that the area is completely covered Press sealant into and around parts as necessary Silicone sealant will set in 15 30 minu
305. ual and should be read before attempting to operate or maintain the fifth wheel towing device Within a chapter or work package headings are used to help group the material to assist in quickly finding tasks Read all preliminary information found at the beginning of each task After completing a task ALWAYS perform the follow on maintenance at the end of the task TM 9 2510 247 13 amp P CHAPTER 1 GENERAL INFORMATION EQUIPMENT DESCRIPTION AND THEORY OF OPERATION 9 2510 247 13 amp P 0000 00 GENERAL INFORMATION INDEX WP Sequence No GENERAL INFORMATION EQUIPMENT DESCRIPTION AND THEORY OF OPERATION 0001 00 Equipment Description and 08 000 0002 00 Theory 0003 00 0000 00 0 9 2510 247 13 0001 00 FIFTH WHEEL TOWING DEVICE MODEL 250 GENERAL INFORMATION TYPE OF MANUAL Operator s Unit and Direct Support Maintenance Manual with Repair Parts and Special Tools List EQUIPMENT NAME AND MODEL NUMBER Fifth Wheel Towing Device FWTD 250M PURPOSE OF EQUIPMENT The Fifth Wheel Towing Device is intended to provide units as authorized TOEs with the capability to recover disabled vehicles MAINTENANCE FORMS RECORDS AND REPORTS Department of the Army forms and procedures used for equipment maintenance will
306. ubes and hoses for leaks Tighten loose connections Notify Unit Maintenance of damaged or defective components 2 HYDRAULIC FUNCTIONS DO NOT OPERATE WITH REMOTE CONTROL Step 1 Check that all electrical switches are set in the correct position WP 0005 Step2 Check electrical connections at cable receptacles on electrical control box Reconnect cables if not properly connected Step Operate hydraulic functions from valve lever controls WP 0005 If hydraulic operations function notify Unit Maintenance END OF WORK PACKAGE 0024 00 3 9 2510 247 13 amp P 4 UNIT TROUBLESHOOTING 9 2510 247 13 0000 00 UNITTROUBLESHOOTING PROCEDURES INDEX WP Sequence UNIT TROUBLESHOOTING PROCEDURES Unit Troubleshooting Procedures 2 0 0000100 eene enne tnn nennen A te Electrical iii iaa Hydraulic System ii hie Air Brake SysteMiu cistitis ada WIGHT u a ERRi 0000 00 0 TM 9 2510 247 13 amp P 0025 00 UNIT TROUBLESHOOTING PROCEDURES GENERAL 1 This section provides information for identifying and correcting malfunctions that you may find while operating and maintaining the Fifth Wheel Towing Device The Troubleshooting Symptom Index WP 0025 00 2 lists common malfunctions which may occur and refers you to the proper work package for a troubleshooting procedure If you are unaware of the location of an
307. ubricants chemical fluids or gases d Adjust To maintain or regulate within prescribed limits by bringing into proper position or by setting the operating characteristics to specific parameters e Align To adjust specified variable elements of an item to bring about optimum or desired performance f Calibrate To determine and cause corrections to be made or to be adjusted on instruments or test measuring and diagnostic equipment used in precision measurement Consists of comparisons of two instruments one of which is a certified standard of known accuracy to detect and adjust any discrepancy in the accuracy of the instrument being compared 0081 00 1 9 2510 247 13 amp P 0081 00 2 MAINTENANCE FUNCTIONS Continued g Remove Install To remove and install the same when required to perform service or other maintenance functions Install may be the act of emplacing seating or fixing onto position a spare repair part or module component or assembly in a manner to allow the proper functioning of an equipment or system h Replace To remove an unserviceable item and install a serviceable counterpart in its place Replace is authorized by the MAC and assigned maintenance level is shown as the 3rd position code of the SMR code i Repair The application of maintenance services including fault location troubleshooting removal installation and disassembly assembly procedures and maintenance actions t
308. ug 7 MAST EXTEND mast to vertical position and remove pivot pin Repeat step 6 MAST RETRACT and lower mast until lower arrow is approximately 4 inches 101 6mm below main frame WP 0008 step 11 Repeat step 6 0056 00 5 9 2510 247 13 0056 00 PURGE AND FILL HYDRAULIC SYSTEM Continued 10 11 12 13 14 15 16 17 18 19 BOOM EXTEND boom to 45 Repeat step 6 BOOM EXTEND until cylinder 15 fully extended Repeat step 6 BOOM RETRACT until boom is level to ground MAST RETRACT until boom is flat on ground Fully EXTEND LEFT OUT until boom extension is fully extended Repeat step 6 Fully EXTEND RIGHT OUT until boom extension is fully extended DO NOT repeat step 6 If needed add new oil to reservoir DO NOT fill past full mark on dipstick Operate winch WP 0012 until new oil cycles through return hose and into container Loosen hydraulic hose from straight adapter on main valve assembly Figure 107 WP 0059 item 7 Connect hydraulic hose to elbow on reservoir Figure 115 WP 0068 item 5 Tighten hydraulic hose to straight adapter on main valve assembly Figure 107 WP 0059 item 7 UNCOUPLE fifth wheel towing device from prime mover and place into OIL FILL configuration Figure 104 WP 0056 00 7 With fifth wheel towing device in oil fill configuration Figure 104 WP 0056 00 7 check oil level Add new oil as necessary 0056 00 6 9 2510 247 13 amp P 0056 00
309. ulic troubleshooting 0090 00 1 3 00 0600 e 10 e911109 3 ISOLATED BATTERY 12VDC d 105 OSI FROM CONTROL BOX BLK WHITE ISOLATED MTR SOL GND O O PRIMARY MTR SOL GND O O 12VDC 24VDC DISCONNECT PRIMARY BATTERY 12VDC NU 92 9 1 7 019 6 NL 00 0600 5 00 0600 e JO e9993 BLACKOUT HARNESS TO SEE PG 30 TO CHASIS PRIMARY TO MTR BLACK GROUND BATTERY SOL 2 MERE nore 3E WHITE BLUE BLACK Pp BLACK 44 15 qul lt WHITE 43 48 BLACK BLUE J lt BLACK EE EEE REHE YELLOW my lt RED TE lt BROWN AMPHENOL YELLOW 55 BLUE PRMERER Sool ASIA FOR TETHER veuowsuoy IAA porem ASA IO E PONES RA RN _ RED lt BLACK lt BLACK 1435 i RED 1680 40A TO 7 PIN BLACK d YELLOW js 7 CONNECTOR RED HA ION DISC LXI Ao BOX BLUE AA YA NY WHITE x x x E 5 5 5 5 BLUE B e m a t E g t ON OFF STROBE Q Q Q Q N TO HYD SOL BLICK w gt BK 7 PIN gt y CONNECTOR FOR TAIL LIGHTS gt R gt G gt BR BL 49 1 7 019 6 NL 00 0600 t 00 0600 e 10 5 e911109 3 FROM CONTROL WINCH BOX M
310. ulting in inadequate lubrication Cover inactive towing device with tarpaulins if they are available and if there is no other available shelter For several hours each week shake out and air canvas covers or other items subject to deterioration from mildew or attacks by insects or vermin If inactive for long periods in hot humid weather towing device is subject to rapid rusting and accumulation of fungi growth Frequently inspect clean and lubricate to prevent excessive deterioration OPERATION IN SANDY OR DUSTY AREAS 1 Inspect clean and lubricate towing device frequently when operating in dusty or sandy areas Refer WP 0039 for proper lubrication instructions Make sure no dust or sand enters exposed mechanisms or lubrication fittings during inspections and repair operations Cover exposed parts with tarpaulins or other suitable cover during disassembly and assembly OPERATION IN MUD AND SNOW NOTE Refer to FM 21 305 for special instructions for operation in snow Frequently clean inspect and lubricate towing device Refer jo WP 0039 for proper lubrication instructions After each operation remove ice snow and mud from underneath towing device and from hoses lines tubes and electrical connections OPERATION IN SALTWATER AREAS 1 2 Wash salt deposits from all equipment with fresh water Moist and salty areas can destroy the rust preventative qualities of oils and greases When equipment is active
311. ut 13 lockwasher 14 and connector 15 from tow light tab 16 7 Remove eight wires 17 from connector 15 8 Remove eight pins 18 from wires 17 Discard pins Figure 84 Tow Light Assembly 0047 00 2 9 2510 247 13 amp P 0047 00 REMOVAL Continued 9 Remove two nuts 19 lockwashers 20 screws 21 clips 22 wiring harness 23 clearance light bracket 24 Discard lockwashers NOTE All three clearance lights are removed the same way 10 Remove two screws 25 lens 26 and bulb 27 from lampholder 28 11 Remove four screws 29 lampholder 28 and gasket 30 from clearance light bracket 24 12 Remove three screws 31 lockwashers 32 and two composite lights 33 from tube 34 Discard lockwashers 13 Remove two wingnuts 35 washers 36 screws 37 and brackets 38 from tube 34 14 Remove four screws 39 nuts 40 lockwashers 41 and bumpers 42 from two brackets 38 Discard lockwashers 15 Remove two screws 43 and bumpers 44 from tube 34 Figure 85 Tow Light Assembly 0047 00 3 9 2510 247 13 amp P 0047 00 Composite Taillight Removal 1 2 Remove four screws 9 and lockwashers 10 from composite taillight bracket 2 Discard lockwashers Pull four wires 7 from hole 8 until four connectors 6 are showing NOTE Tag and mark wires before disconnecting Disconnect four wires 7 Push wires 7 back through connectors 6
312. uthorized to remove replace and use an item The maintenance code entered in the third position will indicate authorization to the following levels of maintenance 0082 00 3 9 2510 247 13 amp P 0082 00 3 EXPLANATION COLUMNS THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGE Continued Maintenance Code 2 Maintenance Code O F Application Explanation Crew or operator maintenance done within unit maintenance Unit level maintenance can remove replace and use the item Direct support maintenance can remove replace and use the item General support maintenance can remove replace and use the item Specialized repair activity can remove replace and use the item Depot can remove replace and use the item FOURTH POSITION The maintenance code entered in the fourth position tells you whether or not the item is to be repaired and identifies the lowest maintenance level with the capability to do complete repair perform all authorized repair functions NOTE Some limited repair may be done on the item at a lower level of maintenance if authorized by the Maintenance Allocation Chart MAC and SMR codes Application Explanation Unit is the lowest level that can do complete repair of the item Direct support is the lowest level that can do complete repair of the item General support is the lowest level that can do complete repair of the item Specialized repair activity is
313. uts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines A HREF http www liberatedmanuals com gt Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
314. valve control levers MAST EXTEND 16 to raise mast until pivot pin 19 loosens 10 Remove pivot pins 19 0008 00 4 9 2510 247 13 amp P 0008 00 PREPARE TOWING DEVICE Continued 11 Using remote control box or valve control levers MAST RETRACT 16 to lower mast until arrow 22 is approximately 4 inches 101 6 mm below frame 23 This will ensure the mast is in track Figure 39 Mast Alignment ER WARNING Clevises must be installed in mast assembly to prevent mast assembly from disengaging from track Failure to comply may cause injury or death to personnel or damage to equipment Never walk under Booms during any operation Failure to comply may cause injury or death to personnel 12 Install two clevises 24 onto mast assembly 25 and secure with clevis pins 26 and spring pins 27 13 Using remote control box or valve control levers BOOM EXTEND 16 to lower boom approximately parallel to ground Hydraulic pressure gauge should read 300 800 psi If adjustment is needed refer to WP 0003 14 MAST RETRACT 16 to lower boom to approximately 0 5 inch 12 7 mm from ground 1 2 INCH Figure 40 Clevis Valve and Boom Clearance END OF WORK PACKAGE 0008 00 5 9 2510 247 13 amp P 0009 00 PREPARE TOW ASSEMBLIES WARNING All persons not involved in the loading or unloading operation must stand clear of prime mover and fifth wheel towing device Failure to comply may result in
315. ven pins 38 and washers 39 on wires 40 14 Connect eleven connectors 41 to connectors 42 15 Install four emergency straps 43 with two screws 44 and new locknuts 45 Figure 88 Complete Taillight Assembly 0047 00 6 9 2510 247 13 amp P 0047 00 INSTALLATION 1 Install composite light 1 on composite taillight bracket 2 with two screws 3 and new lockwashers 4 2 Install four washers 5 on wires 6 and connect wires at connectors 7 3 Push four wires 6 back through hole 8 4 Install composite taillight bracket 2 with four screws 9 and new lockwashers 10 Figure 89 Composite Taillight Assembly Follow on Tasks Check operation of light functions END OF WORK PACKAGE 0047 00 7 9 2510 247 13 amp P 0048 00 FIXED WORKLIGHT REPAIR REMOVAL DISASSEMBLY ASSEMBLY INSTALLATION INITIAL SETUP Equipment Conditions Materials Parts Batteries disconnected WP 0050 Washer lock 1 MS35333 40 Detergent item 4 WP 0085 Tools Test Equipment General Safety Instructions Tool Kit Mechanics General Remove all power to towing device prior to NSN 5180 00 177 7033 making any repairs on electrical system REMOVAL WARNING Remove all power to fifth wheel towing device prior to making any repairs on the electrical system Failure to do so may result in serious injury or death to personnel 1 Remove screw 1 spacer 2 flatwasher 3 and nut 4 from mounting bracke
316. wheel towing device is ready for operation at all times it must be inspected on a regular basis so that defects may be found and corrected before they result in serious damage equipment failure or injury to personnel Table 2 contains systematic instructions on inspections adjustments and corrections to be performed by the operator crew to keep your equipment in good operating condition and ready for its primary mission EXPLANATION OF TABLE ENTRIES 1 Item Number Item No Column Numbers in this column are for reference When completing DA Form 5988 Equipment Inspection and Maintenance Worksheet include the item number for the check service indicating a fault Item numbers also appear in the order that you must perform checks and services for the interval listed 2 Interval Column This column tells you when you must perform the procedure in the procedure column a Before procedures must be done before you operate the towing device b During procedures must be done while you are operating the towing device c Afterprocedures must be done immediately after you have operated the towing device d Weekly procedures must be done once each week e Monthly procedures must be done once each month The monthly PMCS shall include the performance of a Before During After and Weekly PMCS 3 Location Item to Check Service Column This column provides the location and item to be checked or serviced NOTE The WARNINGS and CAUTIONS
317. wing Device 0008 00 1 Transport Configuration sss eene 10007 00 1 Transport Leg Assembly 0075 00 1 Transportirig Loads 0017 00 1 Troubleshooting Procedures 0023 00 1 Troubleshooting Procedures 0025 00 1 Troubleshooting Symptom Index Operator 0023 00 2 Troubleshooting Symptom Index Unit 0025 00 2 Tubes and Compression 0 0038 00 10 Tubing Heat nennen nnns 0038 00 7 U Uncoupling Under Usual 0020 00 1 Unfolding from Shipping Storage Configuration 0005 00 1 Unit Maintenance 2 42 0036 00 1 Unit Preventive Maintenance Checks and Services PMCS 0037 00 1 Unit Troubleshooting 0025 00 1 INDEX 8 9 2510 247 13 amp P INDEX Subject WP Sequence No Page No U continued Unit Troubleshooting Symptom 2 0025 00 2 Unloading Equipment 2444 4 0018 00 1 Unusual Conditions Operation Under 2 0022 00 1 Usual Conditions Operation 0005 00 1 V Vehicle Combinations Authorized
318. wise and raise transport legs PA Touren CLOCKWISE Su Figure 45 Support Leg Assembly 6 Using remote control or valve control levers BOOM RETRACT until boom touches ground NOTE If towed vehicle is not equipped with front towing eyes skip step 6 7 Position upper section 4 of towbar assembly under front towing eye 5 of towed vehicle Adjust tow bar assembly back as needed 8 Using remote control or valve control levers BOOM RETRACT to lift boom extensions to allow for ground clearance when attaching 1 2 inch chains Figure 46 Tow Bar Assembly Location 0010 00 3 Change 1 9 2510 247 13 amp P 0010 00 TOWED VEHICLE Continued 10 11 12 13 CAUTION Use care not to wrap chain around frame flange or any air hydraulic or fuel lines that may run along the frame This could bend frame flange or damage hoses and lines Chain may be wrapped over both frame rails This will not pull down on frame flange NOTE Boom extensions should be secured behind the second axle when towing the PLS systems Secure boom extensions as close to the frame as possible using one of the following methods a Frame hooks on frame covered in this task b Chain around frame must use both sides of frame Chain around area that could withstand towing force to include rear axle or spring hangers Position frame hook 8 over frame flange 9 and install 1 2 inch chain 10 through clevis 1

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