200203 PS Magazine - The Preventive Maintenance Monthly 592.pdf

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TB 43-PS-592, The Preventive Maintenance Monthly, is an official
publication of the Department of the Army, providing information for all
soldiers assigned to combat and combat support units and all soldiers
with unit maintenance and supply duties. All information published has
been reviewed and approved by the agency responsible for the equip-
ment, publication or policy discussed. Application of the information is
optional with the user. Masculine pronouns may refer to both genders.
ISSUE 592 MARCH 2002
WHEELED VEHICLES
Lead-acid Battery PM
HMMWV Tires
HMMWV Transfer Cases
HMMWV Halfshalf Bolts
HMMWV Alternator Mounting Ears
HEMTT Fuel-Water Separator Bowl
M984 HEMTT Wrecker Crane Struts
M939A2-Series Truck In-line Fuel Filters
M1070 Tractor Headlight Wiring
M915-Series Truck Fuel Separator
Head, Clamp
M103/M105/M149-Series Trailer Brake
Line Lube
M1022A1 Dolly Set Air Tank Draining
2
2-3
4
5
6
7
8
9
9
10
10
11
11
AVIATION
37
37
AN/ALQ-144A Countermeasure Set
HGU-56/P Helmet Care & Inspection 38-39
UH-60 Black Hawk M130 Chaff
40-41
Dispenser Cover
MISSILES
42
Patriot
42-43
AMG Ladder Reinforcement
43
Avenger Missile Camouflage Net
44
Avenger Missile M3P Gun Round Count 44
ATACMS GMLA Humidity Indicator
SMALL ARMS
Rifle, Machine Gun Headspacing
M240 Machine Gun BYOI
45
45
46-47
COMBAT VEHICLES
M1000 Trailer Bradley Capacity
Chock Block NSNs
M1-Series Tank ENGINE OIL
CLOGGED FILTER
M1-Series Tank Towing Deflector
M113-Series FOV Track PM
AVLB Fire Extinguisher Change
12
12
13
14
15
16-19
20-21
NBC
M17-Series Decon Pre-op checks
M45 Masks Disks, and Inserts
48
48-50
51
COMMUNICATIONS
52
COMBAT ENGINEERING
22
M9 ACE Foot Cautions
M9 ACE Roadwheel Checks
EDITORIAL
CONTINUITY
BRIEFS
22-23
24-26
1
27
60-61
52-53
TACSAT Radiation Danger
54-55
AN/PVS-6 MELIOS Switch Guard
56
Lithium Battery Replacements
5-KW, 10-KW Main Fuel Pump Problem 57
LOGISTICS MANAGEMENT 58
DA FORM 2408-6 Vehicle Registration 58-59
You are invited to send PS your ideas for improving mainte-
nance procedures, questions on maintenance and supply prob-
lems and questions or comments on material published in PS.
Just write to:
MSG Half-Mast
PS, the Preventive Maintenance Monthly
USAMC LOGSA (AMXLS-LP)
5307 Sparkman Circle
Redstone Arsenal, AL 35898-5000
Or e-mail to:
psmag@logsa.army. i
ml
Internet address:
http://www.logsa.army. i /
m l psmag/pshome.html
By order of the Secreta y o t e Army:
r f h
ERIC K. SHINSEKI
General, United St t s Army Chief of Stff
ae
a
Offca:
iil
JOEL B. HUDSON
Administrative Assistant to the Secreta y o t e Army
r f h
0201604
PS, The Preventive Maintenance Monthly (ISSN 0475-2953) is published monthly by the Department of the Army, Redstone
Arsenal, AL 35898-5000. Periodical postage is paid at the Huntsville, AL post office and at additional mailing offices.
Postmaster: Send address changes to PS, The Preventive Maintenance Monthly, USAMC LOGSA (AMXLS-LP), 5307 Sparkman
Circle, Redstone Arsenal, AL 35898-5000.
TB 43-PS-592, The Preventive Maintenance Monthly, is an official pub-
lication of the Department of the Army, providing information for all
soldiers assigned to combat and combat support units and all soldiers
with unit maintenance and supply duties. All information published has
been reviewed and approved by the agency responsible for the equip-
ment, publication or policy discussed. Application of the information is
optional with the user. Masculine pronouns may refer to both genders.
ISSUE 592 MARCH 2002
WHEELED VEHICLES
Lead-acid Batterty PM
HMMWV Tires
HMMWW Transfer Cases
HMMWW Halfshalf Bolts
HMMWV Alternator Mounting Ears
HEMTT Fuel-Water Separator Bowl
M984 HEMTT Wrecker Crane Struts
M939A2-Series Truck In-line Fuel Filters
M1070 Tractor Headlight Wiring
M915-Series Truck Fuel Separator
Head, Clamp
M103/M105/M149-Series Trailer Brake
Line Lube
M1022A1 Dolly Set Air Tank Draining
2
2-3
4
5
6
7
8
9
9
10
10
11
11
AVIATION
AN/ALQ-144A Countermeasure Set
HGU-56/P Helmet Care & Inspection
UH-60 Black Hawk M130 Chaff
Dispenser Cover
37
37
38-39
40-41
MISSILES
42
Patriot AMG Ladder Reinforcement
42-43
Avenger Missile Camouflage Net
43
Avenger Missile M3P Gun Round Count 44
ATACMS GMLA Humidity Indicator
44
SMALL ARMS
Rifle, Machine Gun Headspacing
M240 Machine Gun BYOI
45
45
46-47
COMBAT VEHICLES
M1000 Trailer Bradley Capacity
Chock Block NSNs
M1-Series Tank ENGINE OIL
CLOGGED FILTER
M1-Series Tank Towing Deflector
M113-Series FOV Track PM
AVLB Fire Extinguisher Change
12
12
13
14
15
16-19
20-21
NBC
M17-Series Decon Pre-op checks
M45 Masks Disks, and Inserts
48
48-50
51
COMMUNICATIONS
52
I
f you want your aircraft to operate better and go longer between maintenance
downtime, get in the habit of doing regular preventive maintenance. A habit
like that means the difference between breakdowns with costly repairs and
equipment readiness.
Make PM a habit by doing
all
daily checklist aircraft inspections everyday.
And get in the habit of using common sense during PM, too.
For instance, when you’re doing pre-flight checks, if your aircraft sounds
funny or the lights don’t come on, check it out right then and there. Don’t wait
‘til later. If you smell fuel or feel something unusual, find out what it is. If
anything seems out of place, don’t ignore it.
If you find a problem that requires AVIM repair, get them involved so they
can fix the problem.
Habitual PM will help you spot problems early. Being your own PM
inspector will spot even more.
Make no-nonsense, common sense PM a regular habit, sort of second
nature. It’ll lead to functional, mission-ready equipment.
COMBAT ENGINEERING
M9 ACE Foot Cautions
M9 ACE Roadwheel Checks
22
52-53
TACSAT Radiation Danger
54-55
AN/PVS-6 MELIOS Switch Guard
56
Lithium Battery Replacements
5-KW, 10-KW Main Fuel Pump Problem 57
22-23
24-26
LOGISTICS MANAGEMENT 58
DA FORM 2408-6 Vehicle Registration 58-59
You are invited to send PS your ideas for improving mainte-
nance procedures, questions on maintenance and supply
problems and questions or comments on material published
in PS.
Just write to:
MSG Half-Mast
PS, the Preventive Maintenance Monthly
USAMC LOGSA (AMXLS-LP)
5307 Sparkman Circle
Redstone Arsenal, AL 35898-5000
Or e-mail to:
psmag@logsa.army.mil
Internet address:
http://www.logsa.army.mil/psmag/pshome.html
By order of the Secretary of the Army:
ERIC K. SHINSEKI
General, United States Army Chief of Staff
Official:
JOEL B. HUDSON
Administrative Assistant to the Secretary of the Army
0201604
PS, The Preventive Maintenance Monthly
(ISSN 0475-2953) is published monthly by the Department of the Army, Redstone
Arsenal, AL 35898-5000. Periodical postage is paid at the Huntsville, AL post office and at additional mailing offices.
Postmaster:
Send address changes to PS, The Preventive Maintenance Monthly, USAMC LOGSA (AMXLS-LP), 5307 Sparkman Circle,
Redstone Arsenal, AL 35898-5000.
Lead-acid Batteries…
Just a Little
Maintenance
What’s your
problem?
Why won’t
you
start?
It’s the
big mission
we’ve been
waiting for!
head ‘em
up and
move’ em
out!
no pm, no
start!
It’s
as simple
as that!
W
hen that big mission comes along, you operators must be sure there's power in
your vehicle's batteries.
You do that by performing the preventive maintenance required by the vehicle's
-10 TM, and by letting your mechanics know about problems you can't correct.
Just to make sure you know the basics—those PM items that apply to all vehicu-
lar batteries—eyeball this list:
• At least weekly, check the
batteries and battery box for
corrosion. Cables, connnections
and the box itself should be free
of that fluffy white stuff. If you
spot any corrosion, let your
mechanics know pronto.
Do not pull or jerk
on any battery cable
Check
batteries
and box for
corrosion
• If the temperature in
your area is 90° F or higher
for more than a week,
remove the battery caps and
check the electrolyte level.
If the level is low, let your
mechanic know the battery
needs distilled water.
After water is added,
start your vehicle and run it
at 1,200 rpm for about 20
minutes to mix the water
with the electrolyte.
Check electrolyte
level if outdoor
temps stay over
90° for a week
Electrolyte level
low
Electrolyte level
OK
Run engine at
1,200 rpm for 20
minutes to mix
electrolyte
Note any missing
batteries, missing or
damaged terminals,
and missing or dam-
aged battery caps.
Let your mechan-
ics know about these
problems, too.
Note missing batteries,
battery caps and terminals
• When you start your vehicle, make
sure the BATT/GEN or AMMETER
gauge is operating correctly. If the
gauge shows that the batteries are dis-
charging (in the yellow or red range on
the dial), there's an electrical system
problem your mechanic needs to fix.
Check BATT/GEN or AMMETER
gauge for battery condition
• Do not remove batteries unless you've been told to do so by unit maintenance per-
sonnel. Even then, a mechanic should monitor your work.
PS 592
2
MAR 02
HMMWV…
I’m sorry,
but I just
don’t like
the radial
tire.
well, of
course
not, you’re
biased!
Before
you
order a new
transfer case
for your
HMMWV
…
…make sure
you know which
one belongs to
which vehicle.
why is
that?
because Each
series uses
a
different
transfer.
“Basic
HMMWV
s originally
had a Model 218 transfer
case, NSN 2520-01-163-4999.
Only
certain
models of
HMMWV
s can
still use bias
ply tires. All
other models
must use
radial tires.
The Model 218 has a
bolt-on flange on the
rear propeller shaft.”
Bias ply or radial tires
M966
M996
M997
M998
M1025
M1026
M1035
M1036
M1037
M1038
M1042
M1043
M1044
M1045
M1046
M1121
Eventually,
all
HMMWV
s will use
radial tires.
Commanders
can convert to
radials with
updated rubber
run-flat devices
any time
at
the unit’s
expense.
Remember,
all four tires
must either be
bias
or
radial-
no mixing
allowed!
“Conversion kit,
NSN 2520-01-434-0822,
converts a basic
vehicle with the Model
218 transfer to a
Model 242 transfer.”
“The kit contains a transfer,
NSN 2520-01-409-2512, two prop
shafts and all needed hardware.”
“It is designed to be used once per vehicle.
Once the kit is installed, order the -2512
transfer when a replacement is needed.”
Model 218 transfer
Radial tires only
All
A1 and A2 models
M1097
M1097A1
M1097A2
M1109
M1113
M1114
M1123
The Model
218 transfer
is no longer
being bought.
It is available
in
small
quantities
from a
TACOM
rebuild
program.
If you need one or
two
218
s, order them
or the -0822 kits. If
you need more, order
just the kits.
“A1-series
HMMWV
s and all
the
M1097
s use a Model 242
transfer, NSN 2520-01-452-
8365, that is
different from
and
not compatible
with the
Model 242 used on A2-series
trucks, NSN 2520-01-409-2512.”
Model 242 transfer
PS 592
5
MAR 02
HMMWV…
Halfshaft Bolts Vibrate Loose
Make sure you
eyeball those
halfshaft bolts
after you clean
this truck…
…we ran it
pretty hard
and they'll
loosen up in
tough use!
STOP BREAKING THE EARS OFF
I think I’ve
got space
between my
ears, too,
sarge!
We’re
not
talking about
those
ears,
private pyle!
S
pace between
your
ears is no reason
for broken ears on 60-amp, 100-amp
and 200-amp HMMWV alternators.
But if you forget to re-install the
spacer at the rear alternator brace,
that’s what you get—a broken ear.
Tightening the brace nut without the
spacer in place puts too much strain on
the ear. Then the ear breaks off and the
alternator has to go to the rebuild shop.
“If you have to,
tie
the spacer
to a finger so
you
remember
to use it again.”
Spacer
here
I
t’s well known that vibration loosens the halfshaft bolts on HMMWVs. And you
get plenty of vibration when your HMMWV goes cross-country.
As you rock and roll over hill and dale, the bolts can back out and move closer to
the brake caliper adapter. Eventually, they catch the adapter and break off.
Then the brake rotor wobbles, wear-
ing out brake pads. That can leave you
Look for loose
halfshaft bolts
brakeless.
So eyeball the halfshaft bolts any time
you pull a service on the HMMWV—
and for sure while you’re in the field.
Look for shiny areas under and around
the bolt heads. If you see a loose bolt,
report it. Have your mechanic replace
the bolt, NSN 5306-01-185-7048, and its
lock washer, NSN 5310-01-185-7218.
Never reuse the lock washer. It won’t hold the second time around. It’s a one-use
item. Also, make sure all bolts and washers are replaced when the disc rotor or half-
shaft assembly is replaced.
Spacer, NSN
5310-01-292-5354, is
used with brace, NSN
5340-01-293-0125, on
60-amp and 100-amp
alternators.
“Eyeball
Pages 4-10
and 4-11 of
TM
9-2320-280-20-2
for details.”
Spacer,
NSN 5310-01-
337-7034, is used
with brace, NSN
5340-01-292-8404,
on 200-amp
alternators.
PS 592
6
MAR 02
PS 592
7
MAR 02

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