TM 10-5411-247-13&P

TECHNICAL MANUAL OPERATOR AND FIELD MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR

CARGO BED COVER (CBC) TYPE IIIA1, 2-1/2 TON CARGO TRUCK, LMTV, AND LMTV TRAILER
(NSN 5411-01-559-8740) (CAMOUFLAGE) (NSN 5411-01-559-8739) (SAND)

DISTRIBUTION STATEMENT A Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

01 OCTOBER 2011

TM 10-5411-247-13&P

WARNING SUMMARY
This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons used within the technical manual. FIRST AID DATA For First Aid information, refer to FM 4-25.11, First Aid.

EXPLANATION OF SAFETY WARNING ICONS HEAVY OBJECTS - heavy object on human figure shows that heavy parts present a danger to life or limb.

FALLING PARTS - arrow bouncing off human shoulder and head shows that falling parts present a danger to life or limb.

SUFFOCATION DANGER - person with deflated lungs shows that there is a danger of an inability to breathe and a potential for suffocation. FLYING PARTICLES - arrows bouncing off face shows that particles flying through the air will harm face.

HEAVY PARTS - Heavy object pinning human figure against wall shows that heavy, moving parts present a danger to life or limb.

GENERAL SAFETY WARNINGS DESCRIPTION

WARNING

Do not lift the Cargo Bed Cover (CBC) in its retracted (lowered) position. Do not use the lift rings to lift a CBC with an installed payload greater than 1100 pounds (499 kg). Make sure to use handling equipment rated for the equipment it will be lifting. Do not raise the upper portion of the CBC past the warning mark on the side wall of the CBC.

TM 10-5411-247-13&P GENERAL SAFETY WARNINGS DESCRIPTION - Continued.

WARNING

Be sure to support the lift/locking assembly with a free hand before removing the clevis pin that secures the assembly to the roof mounted stowage block.

WARNING

The Personnel Door to the Cargo Bed Cover must remain open while occupied. Failure to do so may result in suffocation.

WARNING

Safety goggles must be worn during repair to protect eyes from flying metal chips.

WARNING

Methylethylketone is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame.

WARNING

To avoid injury or death to personnel, no smoking is allowed when working with flammable materials.

TM 10-5411-247-13&P GENERAL SAFETY WARNINGS DESCRIPTION - Continued.

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Whenever lifting the CBC off the ground, have guide personnel using guide lines to prevent the CBC from swinging eratically. Injury or death to the operator or observers could occur if guide lines are not used. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death. Personnel attaching the lifting sling to the lift rings or working on the roof of the CBC should use ladders or wear approved safety lines or both to prevent falls; injury or death could occur if proper safety equipment is not used.

WARNING

The CBC is not a shelter system and is not to be used to transport personnel or sentry dogs. There is a suffocation hazard. Personnel can only work inside the CBC when the unit is deployed and the ventilators and doors are open. Failure to comply may result in injury or death to personnel.

WARNING

Ensure the ladder is secure and on level ground before stepping on it. Failure to do so could cause the ladder to fall and injure personnel stepping on it. Ensure the vehicle is on level ground and the wheels are chocked before deploying the ladder. Failure to do so could cause the ladder to disengage and cause injury to personnel using it.

TM 10-5411-247-13&P GENERAL SAFETY WARNINGS DESCRIPTION - Continued.

WARNING

A maximum of no less than 7/16 thread exposure when installing the turnbuckles. If more thread is exposed than 7/16 it could cause the wire rope assembly to fail. Failure to adhere to this warning may result in injury or death. EXPLANATION OF HAZARDOUS MATERIALS ICONS CHEMICAL - drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.

POISON - skull and crossbones shows that a material is poisonous or is a danger to life.

FIRE - flame shows that a material may ignite and cause burns.

FLYING PARTICLES - arrows bouncing off face shows that particles flying through the air will harm face.

HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and harm.

HAZARDOUS MATERIALS DESCRIPTION

WARNING

METHYLETHYLKETONE, ASTM D-740 Methylethylketone is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame. Gloves and safety goggles should be worn during use.

TM 10-5411-247-13&P HAZARDOUS MATERIALS DESCRIPTION - Continued.

WARNING

EPOXY COATING KIT, MIL-PRF-22750 Two-part epoxy adhesive is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame. Gloves and safety goggles should be worn during use.

WARNING

ALODINE, MIL-C-5541 Alodine is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame. Gloves and safety goggles should be worn during use.

WARNING

SEALANT, MIL-S-8802, TYPE II, CLASS 8 Sealant is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame. Gloves and safety goggles should be worn during use.

WARNING

LUBRICATING OIL, MACHINE TOOL, A-A-59113 Lube oil is neither flammable nor toxic. Rubber/Neoprene gloves and splash goggles should be worn during use.

TM 10-5411-247-13&P HAZARDOUS MATERIALS DESCRIPTION - Continued.

WARNING

ANTI-SEIZE COMPOUND, P/N 1279K31 Anti-Seize Compound is used for equipment lubrication, lubricant for threaded connections or slides. It is neither flammable nor toxic. Gloves and safety goggles should be worn during use.

WARNING

LUBRICANT, SOLID FILM, MIL-L-23398 Spray Lube is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame. Gloves and safety goggles should be worn during use. Respirator may be required if TLV/TWA limits are exceeded.

WARNING

PRIMER, EPOXY, MIL-P-53022 Primer, Epoxy Coating is flammable and toxic and shall be used only in a well-ventilated area or in an approved spray booth away from all sparks or open flame. Respirator, impervious gloves and chemical worker goggles should be worn during use.

WARNING

POLYURETHANE COATING, MIL-DTL-53039 Polyurethane is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame. Self-contained breathing apparatus should be worn to protect against toxic and irritating vapors. Gloves and safety goggles should be worn during use

TM 10-5411-247-13&P

HAZARDOUS MATERIALS DESCRIPTION - Continued.

WARNING

RTV ADHESIVE, MIL-A-46146 RTV Silicon Adhesive is irritating to eyes and skin and shall be used only in a well-ventilated area. Do not induce vomiting if ingested obtain medical attention. Flammable above 200 F (93.3 C). Gloves and safety goggles should be worn during use.

WARNING

CARC paint dust is a health hazard. Wear protective eyewear, mask, and goggles when sanding CARC paint surfaces. Failure to observe this warning can result in personal injury.

WARNING
Personnel need to maintain three points of contact when climbing onto and moving around on top of the CBC. Failure to follow this warning can lead to serious injury or death to personnel.

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TM 10-5411-247-13&P LIST OF EFFECTIVE PAGES/WORK PACKAGES NOTE: Zero in the Change No. column indicates an original page or work package Date of issue for original manual is: Original 01 OCTOBER 2011 TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 40 AND TOTAL NUMBER OF WORK PACKAGES IS 57 CONSISTING OF THE FOLLOWING: Page/WP No. Front Cover Blank Warning Summary (8 pgs) Chp 1 Title Page WP 0001 (8 pgs) WP 0002 (6 pgs) WP 0003 (4 pgs) Chp 2 Title Page WP 0004 (2 pgs) WP 0005 (38 pgs) WP 0006 (8 pgs) WP 0007 (2 pgs) Chp 3 Title Page WP 0008 (4 pgs) WP 0009 (4 pgs) WP 0010 (4 pgs) WP 0011 (2 pgs) WP 0012 (4 pgs) WP 0013 (2 pgs) WP 0014 (2 pgs) WP 0015 (2 pgs) Chp 4 Title Page WP 0016 (2 pgs) WP 0017 (10 pgs) Chp 5 Title Page WP 0018 (4 pgs) WP 0019 (16 pgs) WP 0020 (22 pgs) WP 0021 (22 pgs) WP 0022 (16 pgs) WP 0023 (2 pgs) WP 0024 (2 pgs) WP 0025 (2 pgs) WP 0026 (2 pgs) WP 0027 (2 pgs) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0028 (2 pgs) WP 0029 (24 pgs) WP 0030 (4 pgs) WP 0031 (2 pgs) WP 0032 (8 pgs) WP 0033 (6 pgs) WP 0034 (10 pgs) WP 0035 (8 pgs) WP 0036 (6 pgs) WP 0037 (12 pgs) WP 0038 (4 pgs) WP 0039 (2 pgs) WP 0040 (4 pgs) WP 0041 (2 pgs) WP 0042 (2 pgs) Chp 6 Title Page WP 0043 (6 pgs) WP0044 (4 pgs) WP 0045 (4 pgs) WP 0046 (6 pgs) WP 0047 (4 pgs) WP 0048 (4 pgs) WP 0049 (4 pgs) WP 0050 (4 pgs) WP 0051 (2 pgs) WP 0052 (4 pgs) Chp 7 Title Page WP 0053 (2 pgs) WP 0054 (4 pgs) WP 0055 (6 pgs) WP 0056 (4 pgs) WP 0057 (2 pgs) INDEX-1 - INDEX-4 Inside Back Cover Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

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TM 10-5411-247-13&P
HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C. 01 October 2011

TECHNICAL MANUAL OPERATOR AND FIELD MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR CARGO BED COVER (CBC) TYPE IIIA1, 2-1/2 TON CARGO TRUCK, LMTV, AND LMTV TRAILER (NSN 5411-01-559-8740) (CAMOUFLAGE) (NSN 5411-01-559-8739) (SAND)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and to better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you. DISTRIBUTION STATEMENT A Approved for public release. Distribution is unlimited.

TM 10-5411-247-13&P TABLE OF CONTENTS Page No. WP Sequence No. HOW TO USE THIS MANUAL xii

CHAPTER 1 - GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION General Information .............................................................................................................. WP 0001 Figure 1. Cargo Bed Cover (CBC)................................................................................. WP 0001-1 Figure 2. CBC Mounting Plates ..................................................................................... WP 0001-2 Table 1. Nomenclature Cross-Reference List ............................................................... WP 0001-4 Table 2. List of Abbreviations and Acronyms ................................................................ WP 0001-4 Equipment Description and Data .......................................................................................... WP 0002 Figure 1. Location of Major Components ...................................................................... WP 0002-4 Table 1. Equipment Specification Data ......................................................................... WP 0002-5 Theory of Operation .............................................................................................................. WP 0003 Figure 1. CBC With M35A2, 2-1/2 Ton Cargo Truck ..................................................... WP 0003-1 Figure 2. CBC LMTV and LMTV Trailer Configurations ................................................ WP 0003-2 Figure 3. CBC Operational Concept .............................................................................. WP 0003-4 CHAPTER 2 - OPERATOR INSTRUCTIONS Description and Use of Operator Controls and Indicators .................................................... WP 0004 Figure 1. Personnel Door Controls ................................................................................ WP 0004-1 Table 1. Personnel Door Controls ................................................................................. WP 0004-1 Figure 2. Winch and Lift/Locking Assembly Controls .................................................... WP 0004-2 Table 2. Winch and Lift/Locking Assembly Controls ..................................................... WP 0004-2 Operation Under Usual Conditions ....................................................................................... WP 0005 Figure 1. Securing Ladder on CBC ............................................................................... WP 0005-2 Figure 2. Winch Location Inside CBC............................................................................ WP 0005-3 Figure 3. Installing the Ratchet Handle ......................................................................... WP 0005-3 Figure 4. Warning Mark ................................................................................................. WP 0005-4 Figure 5. Locating the Lift/Locking Assembly ................................................................ WP 0005-5 Figure 6. Lowering the Lift/Locking Assembly ........................................................ .WP 0005-5 Figure 7. Stowage Block................................................................................................... WP 0005-6 Figure 8. Rotating the Lift/Locking Assembly ................................................................... WP 0005-6 Figure 9. Align Pins in the Lift/Locking Assembly ............................................................ WP 0005-7 Figure 10. Locking the Handle of the Lift/Locking Assembly ........................................... WP 0005-7 Figure 11. Removing the Personnel Door Assembly (Lower) .......................................... WP 0005-9

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TM 10-5411-247-13&P TABLE OF CONTENTS - Continued. Page No. WP Sequence No. Figure 12. Remove Hinge from Personnel Door Assembly (Lower) ............................... WP 0005-9 Figure 13. Install Hinge on Personnel Door Assembly (Lower) ..................................... WP 0005-10 Figure 14. Install Personnel Door Assembly (Lower) .................................................... WP 0005-11 Figure 15. Secure Personnel Door Assembly (Lower) .................................................. WP 0005-12 Figure 16. Lower Door Latch Rod Installation Stowage Position .................................. WP 0005-13 Figure 17. Lower Door Latch Rod Installation Operational Position. ............................. WP 0005-14 Figure 18. Exterior Handle Position Open ..................................................................... WP 0005-15 Figure 19. Exterior Handle Position Closed ................................................................... WP 0005-16 Figure 20. Door Latch Assembly Operation.................................................................... WP 0005-17 Figure 21. Outside Door Handle Locked Position.......................................................... WP 0005-18 Figure 22. Creating Secondary Exit on the CBC ........................................................... WP 0005-20 Figure 23. Door Stop/Hold Open Device ....................................................................... WP 0005-21 Figure 24. Door Stop/Hold Open Device Operation ...................................................... WP 0005-21 Figure 25. Power and Signal Line Port .......................................................................... WP 0005-22 Figure 26. Blockout Panel .............................................................................................. WP 0005-23 Figure 27. Hoisting the CBC Using the Lift Rings .......................................................... WP 0005-25 Figure 28. Gaining Access to the Roof of the CBC ....................................................... WP 0005-27 Figure 29. Removing the Personnel Door Assembly (Lower) ....................................... WP 0005-28 Figure 30. Personnel Door Assembly (Lower) Hand Knobs .......................................... WP 0005-29 Figure 31. Personnel Door Assembly (Lower) ............................................................... WP 0005-30 Figure 32. Removal of Lower Door Hinge ..................................................................... WP 0005-30 Figure 33. Installation of Lower Door Hinge .................................................................. WP 0005-31 Figure 34. Installation of Personnel Door Assembly (Lower) ........................................ WP 0005-32 Figure 35. Stowing Each Lift/Locking Assembly ............................................................ WP 0005-33 Figure 36. Stowing the Lift/Locking Assembly ............................................................... WP 0005-34 Figure 37. Lowering the Upper Extendable Portion of the CBC .................................... WP 0005-36 Decals and Instruction Plates ........................................................................................... .WP 0006 Figure 1. Outside View of Forward End Wall Decal/Instruction Plate............................ WP 0006-1 Table 1. Outside View of Forward End Wall Decal/Instruction Plate ............................. WP 0006-1 Figure 2. Outside View of Rear End Wall Decal/Instruction Plate ................................. WP 0006-2 Table 2. Outside View of Rear End Wall Decal/Instruction Plate ................................... WP 0006-2 Figure 3. Unit Identification Plate Details ....................................................................... WP 0006-3 Table 3. Unit Identification Plate Details ........................................................................ WP 0006-3

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TM 10-5411-247-13&P TABLE OF CONTENTS - Continued. Page No. WP Sequence No. Figure 4. Outside View of Road Side and Curb Side Walls ........................................... WP 0006-4 Table 4. Outside View of Road Side and Curb Side Walls ........................................... WP 0006-4 Figure 5. Decal/Instruction Plate for Inside View of Rear End Wall............................... WP 0006-5 Table 5. Decal/Instruction Plate for Inside View of Rear End Wall ................................ WP 0006-5 Figure 6. Inside View of Side Wall (Road Side) Decal/Instruction Plates ...................... WP 0006-6 Table 6. Inside View of Side Wall (Road Side) Decal/Instruction Plates ....................... WP 0006-6 Figure 7. Inside Top Assembly Caution Decal Detail .................................................... WP 0006-7 Table 7. Inside Top Assembly Caution Decal Detail...................................................... WP 0006-7 Figure 8. Lift/Locking Assembly Decal Detail ................................................................ WP 0006-7 Table 8. Lift/Locking Assembly Decal Detail .................................................................. WP 0006-7 Operation Under Unusual Conditions ................................................................................... .WP 0007 CHAPTER 3 - TROUBLESHOOTING PROCEDURES Troubleshooting Index .......................................................................................................... WP 0008 Operator Troubleshooting Procedures Top Assembly Troubleshooting Procedures ......................................................................... WP 0009 Personnel Door Assembly Troubleshooting Procedures ...................................................... WP 0010 CBC Mounting Kit Troubleshooting Procedures ................................................................... WP 0011 Field Maintenance Troubleshooting Procedures Top Assembly Troubleshooting Procedures ......................................................................... WP 0012 Bottom Assembly Troubleshooting Procedures.................................................................... WP 0013 Personnel Door Assembly Troubleshooting Procedures ...................................................... WP 0014 CBC Mounting Kit Troubleshooting Procedures ................................................................... WP 0015 CHAPTER 4 - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) MAINTENANCE INSTRUCTIONS Preventive Maintenance Checks and Services (PMCS) Introduction .................................. WP 0016 Preventive Maintenance Checks and Services (PMCS) ...................................................... WP 0017 Table 1. Preventive Maintenance Checks and Services (PMCS) for Cargo Bed Cover ...... WP 0017-1 Figure 1. CBC Before Operation PMCS (Sheet 1 of 2)............................................... WP 0017-5 Figure 1. CBC Before Operation PMCS (Sheet 2 of 2)............................................... WP 0017-6 Figure 2. CBC During Operation PMCS ..................................................................... WP 0017-7 Figure 3. CBC After Operation PMCS.......................................................................... WP 0017-9 Lubrication Requirements ..................................................................................................... WP 0017-9 Figure 4. CBC Lubrication Point Locations ................................................................... WP 0017-10

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TM 10-5411-247-13&P TABLE OF CONTENTS - Continued. Page No. WP Sequence No. CHAPTER 5 - FIELD MAINTENANCE INSTRUCTIONS Service Upon Receipt .......................................................................................................... WP 0018 Table 1. Inspection Criteria for Packaging .................................................................... WP 0018-2 Table 2. Vehicle Type and Mounting Kit Reference ...................................................... WP 0018-3 Figure 1. Lifting the CBC from the Pallet ......................................................................... WP 0018-3 Mounting Kit for M35A2, 2-1/2 Ton Cargo Truck Installation Service Upon Receipt............ WP 0019 Figure 1. Lifting CBC onto Vehicle ................................................................................ WP 0019-2 Figure 2. Determining Mounting Position ...................................................................... WP 0019-3 Figure 3. Drilling Hole Locations.................................................................................... WP 0019-4 Figure 4. Hand-Operated Insert Installation Tools ........................................................... WP 0019-6 Figure 5. Threading the Threaded Insert Fastener .......................................................... WP 0019-6 Figure 6. Threading Insert into Hole in CBC Panel .......................................................... WP 0019-6 Figure 7. Installing Threaded Insert ................................................................................. WP 0019-7 Figure 8. Removal of the Threaded Insert Installation Tool ............................................ WP 0019-7 Figure 9. CBC Rubber Strip Installation ........................................................................... WP 0019-9 Figure 10. Identifying Gaps Between the CBC and the Vehicle Bed ............................. WP 0019-11 Figure 11. CBC Fastener Installation ............................................................................. WP 0019-13 Figure 12. CBC Fastener Size Locations....................................................................... WP 0019-14 Figure 13. RTV Adhesive Application ............................................................................ WP 0019-15 Mounting Kit for M1078, 2-1/2 Ton LMTV Installation Service Upon Receipt ...................... WP 0020 Figure 1. CBC Rubber Strip Installation ........................................................................ WP 0020-3 Figure 2. CBC Layout Orientation ................................................................................. WP 0020-5 Figure 3. Installing the Front Mounting Plate Section .................................................... WP 0020-6 Figure 4. Installing Rear, Road Side, and Curb Side Mounting Plate Sections .......... WP 0020-10 Figure 5. Tie-Down Post Assembly Installation ........................................................... WP 0020-12 Figure 6. Initial Installation of Clamp Plate Channel ...................................................... WP 0020-13 Figure 7. MTV Bed Plug Removal ................................................................................. WP 0020-14 Figure 8. Lowering the CBC onto the Vehicle Bed ........................................................ WP 0020-16 Figure 9. Identifying Gaps Between the CBC and the Vehicle Bed............................... WP 0020-18 Figure 10. Applying RTV Silicone Adhesive .................................................................. WP 0020-19 Figure 11. RTV Adhesive Application after Lowering CBC into Place .......................... WP 0020-20 Figure 12. Securing the Tie-Down Post Assemblies ..................................................... WP 0020-21 Figure 13. Final Installation of Clamp Plate Assemblies ............................................... WP 0020-22

TM 10-5411-247-13&P TABLE OF CONTENTS - Continued. Page No. WP Sequence No. Mounting Kit for M1082, 2-1/2 Ton LMTV Trailer Installation Service Upon Receipt....... .WP 0021 Figure 1. CBC Rubber Strip Installation ........................................................................ WP 0021-3 Figure 2. Rubber Strip Installation for Mounting Components ...................................... WP 0021-5 Figure 3. Mounting Gusset Plates to Front Mounting Plate .......................................... WP 0021-6 Figure 4. Installing the Front Mounting Plate Section ................................................... WP 0021-7 Figure 5. Rear, Road Side, and Curb Side Mounting Plates ....................................... WP 0021-11 Figure 6. Initial Installation of Clamp Plate Channel ...................................................... WP 0021-12 Figure 7. Lowering the CBC onto the Trailer Bed .......................................................... WP 0021-14 Figure 8. Identifying Gaps Between the CBC and the Trailer Bed ................................ WP 0021-16 Figure 9. RTV Adhesive Application for the CBC Gusset Plates .................................. WP 0021-18 Figure 10. RTV Adhesive Application for the CBC Threshold Area ............................. WP 0021-20 Figure 11. Final Installation of Clamp Plate Assembly .................................................. WP 0021-21 Mounting Kit For M35A2 2-1/2 Ton Cargo Truck Ladder Installation Service Upon Receipt .WP 0022 Figure 1. M35A2 Tailgate Ladder in Stowed and Deployed Positions .......................... WP 0022-2 Table 1. Parts Listing Entry Ladder Kit for M35A2 (17-1-0315) .................................... WP 0022-2 Figure 2. Entry Ladder Kit for M35A2 ............................................................................ WP 0022-3 Figure 3. Tailgate Position References ......................................................................... WP 0022-4 Figure 4. Mounting Ladder Stowage Brackets 1 ........................................................... WP 0022-4 Figure 5. Mounting Ladder Stowage Brackets 2 ........................................................... WP 0022-5 Figure 6. Mounting Ladder Stowage Brackets 3 ........................................................... WP 0022-5 Figure 7. Mounting Ladder Stowage Brackets 4 ........................................................... WP 0022-5 Figure 8. Mounting Ladder Stowage Brackets 5 ........................................................... WP 0022-6 Figure 9. Mounting Ladder Stowage Brackets 6 ........................................................... WP 0022-6 Figure 10. Mounting Ladder Stowage Brackets 7 ......................................................... WP 0022-6 Figure 11. Mounting Ladder Stowage Brackets 8 ......................................................... WP 0022-7

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TM 10-5411-247-13&P TABLE OF CONTENTS - Continued. Page No. WP Sequence No. Figure 12. Mounting Ladder Stowage Brackets 9 ......................................................... WP 0022-7 Figure 13. Mounting Ladder Stowage Brackets 10 ....................................................... WP 0022-7 Figure 14. Mounting Strap Assemblies for Ladder Stowage 1 ...................................... WP 0022-8 Figure 15. Mounting Strap Assemblies for Ladder Stowage 2 ...................................... WP 0022-8 Figure 16. Mounting Strap Assemblies for Ladder Stowage 3 ...................................... WP 0022-8 Figure 17. Mounting Strap Assemblies for Ladder Stowage 4 ...................................... WP 0022-9 Figure 18. Mounting Strap Assemblies for Ladder Stowage 5 ...................................... WP 0022-9 Figure 19. Mounting Strap Assemblies for Ladder Stowage 6 ...................................... WP 0022-9 Figure 20. Mounting Strap Assemblies for Ladder Stowage 7 .................................... WP 0022-10 Figure 21. Mounting Strap Assemblies for Ladder Stowage 8 .................................... WP 0022-10 Figure 22. Mounting Ladder Deployment Brackets 1 .................................................. WP 0022-11 Figure 23. Mounting Ladder Deployment Brackets 2 .................................................... WP 0022-11 Figure 24. Mounting Ladder Deployment Brackets 3 .................................................... WP 0022-11 Figure 25. Mounting Ladder Deployment Brackets 4 .................................................... WP 0022-12 Figure 26. Mounting Ladder Deployment Brackets 5 .................................................... WP 0022-12 Figure 27. Mounting Ladder Deployment Brackets 6 .................................................... WP 0022-12 Figure 28. Mounting Ladder Deployment Brackets 7 .................................................... WP 0022-13 Figure 29. Mounting Ladder Deployment Brackets 8 .................................................... WP 0022-13 Figure 30. Mounting Ladder Deployment Brackets 9 .................................................... WP 0022-14 Figure 31. Ladder Deployment .................................................................................... WP 0022-15 Figure 32. Ladder Stowage............................................................................................ WP 0022-16 Handle, Bail, Replace ........................................................................................................... WP 0023 Figure 1. Bail Handle Fitting .......................................................................................... WP 0023-2 Assembly, Ring, Lift, Replace ............................................................................................... WP 0024 Figure 1. Lift Ring Assembly Fitting ............................................................................... WP 0024-2 Pad, Filter, Cooler, Air, Replace ........................................................................................... WP 0025 Figure 1. Air Cooler Filter Pad Replacement................................................................. WP 0025-2 Step, Pole, Upper and Middle, Replace................................................................................ WP 0026 Figure 1. Folding Step Replacement ............................................................................. WP 0026-2 Assembly, Locking, Lift, Replace .......................................................................................... WP 0027 Figure 1. Lift/Locking Assembly Replacement .............................................................. WP 0027-2 Step, Folding, Bottom, Replace ............................................................................................ WP 0028 Figure 1. Folding Step (Lower Roof Access) Replacement .......................................... WP 0028-2

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TM 10-5411-247-13&P TABLE OF CONTENTS - Continued. Page No. WP Sequence No. Assembly, Rope, Wire, Replace ........................................................................................... WP 0029 Figure 1. Hoisting the CBC Using the Lift Rings ........................................................... WP 0029-3 Figure 2. Inside Supports for Wire Rope Assembly Repair ........................................... WP 0029-4 Figure 3. Wire Rope Assembly Cover Removal ............................................................ WP 0029-5 Figure 4. Wire Rope Assembly End Ball and Keyhole Slot ............................................ WP 0029-6 Figure 5. Winch Corner Assembly Replacement .......................................................... WP 0029-7 Figure 6. Winch Corner Wire Rope Assembly Components ......................................... WP 0029-9 Figure 7. Attaching Wire Rope Assembly Ball End to Keyhole ................................... WP 0029-10 Figure 8. Corner Wire Rope Assembly Installation ..................................................... WP 0029-11 Figure 9. Corner Pulley Removal ................................................................................... WP 0029-12 Figure 10. Wire Rope Assembly Retaining Block Removal ........................................... WP 0029-13 Figure 11. Turnbuckle Location ..................................................................................... WP 0029-14 Figure 12. Turnbuckle Removal ..................................................................................... WP 0029-14 Figure 13. Threading Wire Rope Assembly Over Pulleys ............................................. WP 0029-16 Figure 14. Installing/Attaching Terminal Ends ............................................................... WP 0029-17 Figure 15. Installing Wire Rope Assembly Ball End ...................................................... WP 0029-18 Figure 16. Removing Slack from Wire Rope Assembly ................................................. WP 0029-19 Figure 17. Inside Supports for Wire Rope Assembly Repair ......................................... WP 0029-21 Figure 18. Turnbuckle Adjustment ................................................................................. WP 0029-22 Figure 19. Installing Turnbuckle Locking Clips .............................................................. WP 0029-23 Figure 20. Installing Winch Cover .................................................................................. WP 0029-24 Winch, Drum, Hand-Operated, Service, Replace ................................................................. WP 0030 Figure 1. Hand-Operated Drum Winch .......................................................................... WP 0030-3 Figure 2. Hand-Operated Drum Winch Detail ............................................................... WP 0030-4 Angles, Mounting, Carrier, Replace ...................................................................................... WP 0031 Figure 1. Carrier Mounting Angle Replacement ............................................................ WP 0031-2 Assembly, Door, Personnel, Replace, Inspect, Repair ......................................................... WP 0032 Figure 1. Personnel Door Assembly (Upper and Lower) Replacement ........................ WP 0032-3 Figure 2. Personnel Door Assembly Rubber Strip Replacement .................................. WP 0032-7 M35A2, 2-1/2 Ton Cargo Truck Mounting Kit, Remove, Repair ........................................... WP 0033 Figure 1. CBC Fastener Removal ................................................................................. WP 0033-1 Figure 2. CBC Fastener Size Locations ........................................................................ WP 0033-2 Figure 3. RTV Adhesive Removal ................................................................................. WP 0033-3

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TM 10-5411-247-13&P TABLE OF CONTENTS - Continued. Page No. WP Sequence No. Figure 4. Lifting the CBC from Vehicle Bed................................................................... WP 0033-4 Mounting Kit, M1078, 2-1/2 Ton LMTV, Remove, Repair ..................................................... WP 0034 Figure 1. Clamp Plate Assembly Removal .................................................................... WP 0034-2 Figure 2. Removing Vehicle Bed Plug ........................................................................... WP 0034-3 Figure 3. Removing the Tie-Down Post Assembly ........................................................ WP 0034-4 Figure 4. RTV Adhesive Removal ................................................................................. WP 0034-5 Figure 5. Lifting the CBC from the Vehicle Bed............................................................. WP 0034-6 Figure 6. Removing the Rear, Road Side, and Curb Side Mounting Plate Sections .... WP 0034-8 Figure 7. Removing the Front Mounting Plate Section.................................................. WP 0034-9 Mounting Kit, M1082, 2-1/2 Ton LMTV Trailer, Remove, Repair ......................................... WP 0035 Figure 1. Removal of Clamp Plate Assembly ................................................................ WP 0035-2 Figure 2. CBC Gusset Plate Removal ........................................................................... WP 0035-2 Figure 3. RTV Adhesive Removal ................................................................................. WP 0035-3 Figure 4. Lifting the CBC from the Trailer Bed .............................................................. WP 0035-4 Figure 5. Removing the Rear, Road Side, and Curb Side Mounting Plate Sections .... WP 0035-6 Figure 6. Removing the Front Mounting Plate Section.................................................. WP 0035-6 Dented Skins and Core, Repair ............................................................................................ WP 0036 Figure 1. Inserting Adhesive, Two-Part Epoxy, in Drilled Holes .................................... WP 0036-3 Figure 2. Using Putty Knife to Fill Dent ......................................................................... WP 0036-4 Punctured Skins and Core, Repair ....................................................................................... WP 0037 Figure 1. Repairs to Small Punctures with Minimal Core Damage ............................... WP 0037-4 Figure 2. Damage to Single Skin Repair ....................................................................... WP 0037-6 Figure 3. Puncture Through Both Skins ...................................................................... WP 0037-11 Blind Rivet, Replace.............................................................................................................. WP 0038 Figure 1. Blind Rivet Replacement ................................................................................ WP 0038-3 Manually Extending the Upper Section of the CBC .............................................................. WP 0039 Figure 1. Manually Extending the Upper Section of the CBC ....................................... WP 0039-2

ix

TM 10-5411-247-13&P TABLE OF CONTENTS - Continued. Page No. WP Sequence No. Repair Threaded Inserts Non-Potted (Non-Adhesive Encapsulated) ................................... WP 0040 Table 1. Insert Drill Sizes ............................................................................................... WP 0040-1 Figure 1. Non-Potted (Non-Adhesive Encapsulated) Insert Replacement .................... WP 0040-2 Figure 2. Hand-Operated Insert Installation Tools ........................................................ WP 0040-2 Figure 3. Threading the Threaded Insert Fastener ....................................................... WP 0040-3 Figure 4. Inserting Threaded Insert into Hole in CBC Panel ......................................... WP 0040-3 Table 2. Thread Sizes ................................................................................................... WP 0040-4 Figure 5. Installing Threaded Insert ............................................................................... WP 0040-4 Figure 6. Removal of Threaded Insert Installation Tool ................................................ WP 0040-4 Repair Caulked Sections ...................................................................................................... WP 0041 Figure 1. Caulking Repaired Section ............................................................................. WP 0041-2 Repair Paint and Refinishing ................................................................................................ WP 0042 Table 1. Paint Data for Cargo Bed Covers .................................................................... WP 0042-1 CHAPTER 6 - PARTS INFORMATION Repair Parts and Special Tools List (RPSTL) Introduction................................................... WP 0043 Table 1. SMR Code Explanation ....................................................................................... WP 0043-2 GROUP 00 Cargo Bed Cover (CBC) Type IIIA1 ................................................................. WP 0044 Figure 1. Cargo Bed Cover (CBC) Type IIIA1 (Sheet 1 of 2) ....................................... WP 0044-1 Figure 1. Cargo Bed Cover (CBC) Type IIIA1 (Sheet 2 of 2) ........................................ WP 0044-2 GROUP 01 Assembly, Top .................................................................................................. WP 0045 Figure 2. Assembly, Top (Sheet 1 of 2) ......................................................................... WP 0045-1 Figure 2. Assembly, Top (Sheet 2 of 2) ......................................................................... WP 0045-2 GROUP 02 Assembly, Bottom ............................................................................................. WP 0046 Figure 3. Assembly, Bottom (Sheet 1 of 4) ................................................................... WP 0046-1 Figure 3. Assembly, Bottom (Sheet 2 of 4) ................................................................... WP 0046-2 Figure 3. Assembly, Bottom (Sheet 3 of 4) ................................................................... WP 0046-3 Figure 3. Assembly, Bottom (Sheet 4 of 4) .......................................................... WP 0046-4 GROUP 03 Assembly, Door, Personnel .............................................................................. WP 0047 Figure 4. Assembly, Door, Personnel (Sheet 1 of 2) ..................................................... WP 0047-1 Figure 4. Assembly, Door, Personnel (Sheet 2 of 2) ..................................................... WP 0047-2 GROUP 04 M35A2, 2-1/2 Ton Cargo Truck Mounting Kit ................................................... WP 0048 Figure 5. M35A2, 2-1/2 Ton Cargo Truck Mounting Kit................................................. WP 0048-2 GROUP 05 M1078, 2-1/2 Ton LMTV Mounting Kit.............................................................. WP 0049 Figure 6. M1078, 2-1/2 Ton LMTV Mounting Kit ........................................................... WP 0049-2 x

TM 10-5411-247-13&P TABLE OF CONTENTS - Continued. Page No. WP Sequence No. GROUP 06 M1082, 2-1/2 Ton LMTV Trailer Mounting Kit .................................................. WP 0050 Figure 7. M1082, 2-1/2 Ton LMTV Trailer Mounting Kit ................................................ WP 0050-2 National Stock Number Index ............................................................................................... WP 0051 Part Number Index ................................................................................................................ WP 0052 CHAPTER 7 - SUPPORTING INFORMATION References ............................................................................................................................ WP 0053 Maintenance Allocation Chart (MAC) Introduction ............................................................... WP 0054 Maintenance Allocation Chart (MAC) ................................................................................... WP 0055 Table 1. MAC for Cargo Bed Cover (CBC) Type IIIA1 .................................................. WP 0055-1 Table 2. Tools and Test Equipment for Cargo Bed Cover (CBC) Type IIIA1 ................ WP 0055-4 Table 3. Remarks for Cargo Bed Cover (CBC) Type IIIA1 ........................................... WP 0055-5 Components of End Item (COEI) and Basic Issue Items (BII) List ....................................... WP 0056 Table 1. Components of End Item List .......................................................................... WP 0056-2 Table 2. Basic Issue Items List ...................................................................................... WP 0056-4 Expendable and Durable Items List ...................................................................................... WP 0057 Table 1. Expendable and Durable Items List ................................................................ WP 0057-1 ALPHABETICAL INDEX

xi

TM 10-5411-247-13&P

HOW TO USE THIS MANUAL

HOW TO OBTAIN TECHNICAL MANUALS When a new system is introduced to the Army inventory, it is the responsibility of the receiving units to notify and inform the Unit Publications Clerk that a Technical Manual is available for the new system. Throughout the life cycle of the new system, the Distribution Center DOL-W will also provide updates and changes to the Technical Manual. To receive new Technical Manuals or change packages to existing Technical Manuals (TM) for fielded equipment, provide the Unit Publications Clerk the full Technical Manual number, title, date of publication, and number of copies required. The Unit Publications Clerk will justify the request through the Unit Publications Officer. When the request is approved, the Unit Publications Clerk will use DA Form 12-R to order the series of Technical Manuals from the Army Publishing Directorate (APD). Instructions for Unit Publications Clerk Obtain DA Form 12-R and request a publications account from the APD Web site at http://www.apd.army.mil. Once on the Website, click on the Orders/Subscriptions/Reports tab. From the dropdown menu, select Establish an Account, then select Tutorial and follow the instructions in the tutorial presentation. Complete information for obtaining Army publications can be found in DA PAM 25-33.

ORGANIZATION OF THIS MANUAL This Manual contains General Information, Operating Instructions, Operator Preventive Maintenance Checks and Services (PCMS), Troubleshooting, and Maintenance/Repair instructions for the Cargo Bed Cover (CBC), Type IIIA1, 2-1/2 Ton Cargo Truck, LMTV, and LMTV Trailer. Manual Content and Coverage. Chapter 1 contains introductory information on the CBC and its associated equipment as well as a theory of operation. Chapter 2 includes operating instructions under usual and unusual conditions. Chapter 3 contents include operator troubleshooting. Chapter 4 contains Operator Maintenance instructions including PMCS procedures. Chapter 5 contains Field Maintenance instructions. Chapter 6 contains the Repair Parts and Special Tools List (RPSTL) which identifies those parts or tools which are unique to the operation and maintenance of this equipment. Chapter 7 contains references and other supporting information. Manual Organization and Page Numbering System. The Manual is divided into five major chapters that detail the topics mentioned above. Within each chapter are work packages covering a wide range of topics. Each work package is numbered sequentially starting at page 1. The work package has its own page numbering scheme and is independent of the page numbering used by other work packages. Each page of a work package has a page number of the form XXXX YY-ZZ where XXXX is the work package number (e.g. 0010 is work package 10) and YY is reserved to permit unlimited expansion of the TM to incorporate new configuration data without affecting the WP sequence numbers already assigned, and to permit adding one or more WPs between any two existing WPs during any revision cycle. ZZ represents the number of the page within that work package. A page number such as 0010 00-1/2 blank means that page 1 contains information but page 2 of that work package has been intentionally left blank.

xii

TM 10-5411-247-13&P Text and Illustrations. Descriptive text and procedures are always accompanied by one or more illustrations. The text or procedure will be annotated with find numbers such as (1) that correspond to a specific callout on the illustration. In this technical manual, the descriptive text or procedure will always precede the illustration. Therefore, when reading a section in the manual, always look for the accompanying illustration to follow the section. Finding Information. The Table of Contents permits the reader to find information in the manual quickly. The reader should start here first when looking for a specific topic. The Table of Contents lists the topics contained within each chapter and the Work Package Sequence Number where it can be found. Example: If the reader were looking for instructions on Preventive Maintenance Checks and Services, which is an Operator Maintenance topic, the Table of Contents indicates that Operator Maintenance information can be found in Chapter 4. Scanning down the listings for Chapter 4, Preventive Maintenance Checks and Services information can be found in WP 0017 (i.e. Work Package 0017). The Repair Parts and Special Tools List (RPSTL) is used in the performance of maintenance. The list also includes parts which must be removed for replacement of the authorized parts. Work Package (WP) 0043 provides detail instructions on how to use the RPSTLs contained in this manual while WPs 0044 through 0053 provide the RPSTLs, to include a National Stock Number (NSN) and Part Number Indexes. There is not a Glossary at the back of this Manual. An Alphabetical Index can be found at the back of the Manual. It lists specific topics with the corresponding work package.

xiii/xiv blank

CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION FOR CARGO BED COVER (CBC) TYPE IIIA1, 2-1/2 TON CARGO TRUCK, LMTV, AND LMTV TRAILER

TM-10-5411-247-13&P

0001

OPERATOR AND FIELD MAINTENANCE GENERAL INFORMATION SCOPE This Technical Manual contains instructions for the operation, as well as installation, preventive/corrective maintenance for the CBC, Type IIIA1, M35A2, 2-1/2 Ton Cargo Truck, M1078, Light Medium Tactical Vehicle (LMTV), and M1082, LMTV Trailer (Figure 1, Item 1), as well as its installation mounting plates (Figure 2, Item 1) and (Figure 2, Item 2) used when the CBC is installed on the M1078, 2-1/2 Ton LMTV or M1082, 2-1/2 Ton LMTV Trailer. Type of Manual: Operator and Field Maintenance Manual (including Repair Parts and Special Tools Lists). Equipment Nomenclature and National Stock Numbers: Cargo Bed Cover (CBC), Type IIIA1, NSN 5411-01-5598740 (Camouflage), NSN 5411-01-599-8739 (Sand).

WARNING
The CBC is not a shelter system and is not to be used to transport personnel or sentry dogs. There is a suffocation hazard. Personnel can only work inside the CBC when the unit is deployed and the ventilators and doors are open. Failure to comply may result in injury or death to personnel. Purpose of Equipment: The CBC, Type IIIA1, 2-1/2 Ton Cargo Truck, LMTV, and LMTV Trailer is a hard shell enclosure designed to provide a secure and weather tight enclosure for equipment and is offered in either camouflage or sand color configurations. The CBC features a built-in mechanism to raise or lower the upper section, which can be accomplished by a team of two in 20 minutes. Points of Reference: The CBC is mounted to the bed of the vehicle using mounting plates (Figure 2) so that the rear door of the CBC is located at the tailgate of the vehicle. The front of the CBC is the end opposite the door and mounts on the vehicle bed so that it is directly behind the cab of the vehicle. In this technical manual, the term road side will refer to the left side (Figure 1) of the CBC as the operator faces the rear door. The term curb side will refer to the right side of the CBC as the operator faces the rear door. It is assumed that the vehicle is equipped with a steering wheel on the left side as the driver is sitting in the vehicle.

ROAD SIDE 1

FRONT

Figure 1. Cargo Bed Cover (CBC), Points of Reference. CURB SIDE REAR

Figure 1. Cargo Bed Cover (CBC). 0001-1

TM-10-5411-247-13&P

0001

VEHICLE MOUNTING PLATE FOR M1078, 2-1/2 TON LMTV

VEHICLE MOUNTING PLATE FOR M1082, 2-1/2 TON LMTV TRAILER

Figure 2. CBC Mounting Plates.

0001-2

TM-10-5411-247-13&P MAINTENANCE FORMS, RECORDS, AND REPORTS

0001

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs) If your CBC needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you dont like about your equipment. Let us know why you dont like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to go to https://aeps.ria.army.mil/aepspublic.cfm (scroll down and choose the Submit Quality Deficiency Report bar). The Internet form lets you choose to submit an Equipment Improvement Recommendation (EIR), a Product Quality Deficiency Report (PQDR) or a Warranty Claim Action (WCA). You can send your SF 368 via e-mail, regular mail, or facsimile using the addresses/facsimile numbers specified in DA PAM 750-8, the Army Maintenance Management System (TAMMS) Users Manual. We will send you a reply. CORROSION PREVENTION AND CONTROL (CPC) Corrosion Prevention and Control (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 can be made to prevent the problem in future items. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. Plastics, composites, and rubbers can also degrade. Dehydration is caused by thermal (heat), oxidation (oxygen), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking. SF 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For procedures to destroy this equipment to prevent its use by the enemy, refer to TM 750-244-3, Procedures for Destruction of Army Equipment to Prevent Enemy Use (Mobility Equipment Command). PREPARATION FOR STORAGE OR SHIPMENT Administrative Storage. The upper section of the CBC should be extended for storage or shipment. When the CBC is to be transported such that the top needs to be retracted, it will be extended after transportation and before storage or operations. Preventive Maintenance Checks and Services (PMCS) will be performed before equipment issued to and used by Army activities enters administrative storage. When equipment is removed from administrative storage, PMCS should be performed to ensure operational readiness.

CAUTION
The CBC is not to be stacked on top of one another when being stored or shipped. This could cause damage to the system and prevent normal operations of the CBC. WARRANTY INFORMATION The CBC, Type IIIA1 is warranted for 12 months. The warranty starts on the date found in block 23 of DA Form 2408-9, Equipment Control Record. Report all defects to your supervisor, who will take appropriate action.

0001-3

TM-10-5411-247-13&P NOMENCLATURE CROSS-REFERENCE LIST Table 1. Nomenclature Cross-Reference List. Common Name CBC Folding Step Mounting Plate M1078, 2-1/2 Ton LMTV M1082, 2-1/2 Ton LMTV Trailer Roof Handhold Official Nomenclature

0001

Cargo Bed Cover (CBC), Type III, 2-1/2 Ton Cargo Truck, LMTV, and LMTV Trailer Pole Step Vehicle Mounting Plate 2-1/2 Ton Light Medium Tactical Vehicle 2-1/2 Ton Light Medium Tactical Vehicle Trailer Bail Handle

LIST OF ABBREVIATIONS/ACRONYMS Table 2. List of Abbreviations and Acronyms. Abbreviation/Acronym Meaning Additional Authorization List American Standard Test Method Basic Issue Item Commercial and Government Entity Code Chemical Active Reactive Coating Cargo Bed Cover Chemical, Biological, Radiological, Nuclear Abbreviation/Acronym Meaning

AAL

Cm

centimeter

ASTM

COEI

Component of End Item Corrosion Prevention Control

BII

CPC

CAGEC

Cu ft.

Cubic Foot

CARC

Degree(s) Celsius

CBC

DECON

Decontamination

CBRN

EIR

Equipment Improvement Recommendation

0001-4

TM-10-5411-247-13&P List of Abbreviations/Acronyms - Continued. Table 2. List of Abbreviations and Acronyms - Continued. Abbreviation/Acronym Meaning Degree(s) Fahrenheit Abbreviation/ Acronym Lbs Meaning

0001

Pounds Line Replaceable Unit Light Medium Tactical Vehicle Cubic Meters Maintenance Allocation Chart Methylethylketo ne Millimeter Material Safety Data Sheet Modified Table of Organization and Equipment Next Higher Assembly Number National Stock Number Preventive Maintenance Checks and Services Part Number Petroleum, Oil, and Lubricant

Fig.

Figure

LRU

FGC

Functional Group Code In Accordance With Inch(s) Joint Table of Allowances Kilogram(s) Pounds

LMTV m3

IAW

In.

MAC

JTA Kg Lbs

MEK Mm MSDS

Degree(s) Fahrenheit

MTOE

Fig.

Figure Functional Group Code In Accordance With

NHA

FGC

NO.

IAW

NSN

In.

Inch(s)

PMCS

JTA

Joint Table of Allowances Kilogram(s)

P/N

Kg

POL

0001-5

TM-10-5411-247-13&P List of Abbreviations/Acronyms - Continued. Table 2. List of Abbreviations and Acronyms - Continued. Abbreviation/Acronym Meaning Abbreviation/Acronym

0001

Meaning Threshold Limit ValueTime Weighted Average Table of Organization and Equipment Unit of Measure Unique Identifier/ Identification Unified Course Thread Unified Fine Thread

Qty. Req.

Quantity Required

TLV/TWA

RPSTL

Repair Parts and Special Tools List Room Temperature Vulcanizing Source, Maintenance & Recoverability Specialized Repair Activity

TOE

RTV

U/M

SMR

UID

SRA

UNC

Ton(s) The Army Maintenance Management System To Be Determined Table of Distribution and Allowances Test, Measurement, Diagnostic Equipment

UNF

TAMMS

UOC

Usable On Code

TBD

UUT

Unit Under Test

TDA

WP

Work Package

TMDE

0001-6

TM-10-5411-247-13&P SAFETY, CARE, AND HANDLING

0001

When working with the CBC, always pay attention to Warnings, Cautions, and Notes appearing throughout the manual. They will appear prior to applicable procedures. Failure to read, understand, and follow these precautions may result in serious injury or death to personnel or damage to equipment. COMMON TOOLS AND EQUIPMENT For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE), CTA 50-970, Expendable/Durable Items (Except: Medical, Class V, Repair Parts, and Heraldic Items), or CTA 8100, Army Medical Department Expendable/Durable Items, as applicable to your unit. Repair parts are listed and illustrated in the repair parts and special tools list located in Work Packages (WPs) 0043 through 0050. Tools and test equipment associated with the CBC are listed in the Maintenance Allocation Chart (MAC) in WP 0055. There are no special tools, Test, Measurement, Diagnostic Equipment (TMDE), and support equipment required for the operation of the CBC.

END OF WORK PACKAGE

0001-7/8 blank

TM-10-5411-247-13&P

0002

OPERATOR AND FIELD MAINTENANCE EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES The Cargo Bed Cover, Type IIIA1 is a truck or trailer mounted CBC which contains: an Expandable Upper Section, Lower Stationary Section, Personnel Access Door, and Vehicle Mounting Plate. The CBC walls are constructed of light-weight, high-strength sandwich panels utilizing aluminum facing sheets bonded to aluminum honeycomb core. The Upper section lowers for travel/storage. The Personnel Access Door operates in heightextended and retracted mode. The CBC carrier mounting provisions require specific mounting kits and are simple to install and remove. The CBC is capable of internal air transport on vehicle and can also be air transported externally by use of hoist fittings. Two helicopter sling cable rub strips are mounted along the full length of the CBC roof to protect the cable and the CBC during external air transport. The door hardware permits opening from the inside of the CBC, even if outside is padlocked. The CBC provides security for installed contents, environmental protection of cargo space, and is chemical agent resistant. There is a ventilation opening provided on both sides of the CBC for air circulation. The roof access steps and handhold provide access to the non-skid roof. External power and signal entry ports are provided for power and signal cable access into the CBC. When the outside door handle (Figure 21, Item 2) is in the horizontal position, it may be padlocked (Figure 21, Item 3) from the outside. If the personnel door assembly (Figure 21, Item 1) is, for any reason, padlocked with personnel inside, they may exit the CBC by using the inner door handle (Figure 20, Item 2) of the personnel door assembly. The inner door handle (Figure 20, Item 2)has a center case latch with an override feature which permits the handle to be rotated from the inside of the CBC, even if the outside door handle (Figure 21, Item 2)is padlocked. If the personnel are padlocked inside the CBC and the tailgate of the vehicle is up, a secondary exit can be created by separating the lower door panel from the upper door panel and rotating the inner door handle. In this case, the lower door panel is removed from the door as detailed in the section entitled USING THE SECONDARY EXIT IF LOWER DOOR SECTION IS BLOCKED OR CANNOT BE OPENED FROM THE INTERIOR OF THE CBC. The personnel door may also be opened and closed from the inside of the CBC. When in the closed and locked position, the inner door handle (Figure 20, Item 2) is rotated counterclockwise and will point up at approximately a 45 angle from horizontal. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Expandable Upper Section The expandable upper section (Figure 1, Item 1) of the CBC, Type IIIA1, 2-1/2 Ton Cargo Truck, Light Medium Tactical Vehicle (LMTV), and LMTV Trailer can be extended while in operational mode or can be in a heightretracted mode for air transport. Ventilation Openings Two ventilation ports (Figure 1, Item 2) mounted on the outside of the CBC provide flow-through air circulation through the CBC. Air filters help to keep dust, dirt, and other debris from entering the CBC. Lower Stationary Section The lower section (Figure 1, Item 3) of the CBC remains stationary and is mounted to the cargo truck bed (or vehicle mounting plate) by means of the carrier mounting angles.

0002-1

TM-10-5411-247-13&P Location and Description of Major Components - Continued. Helicopter Cable Rub Strip

0002

Two helicopter sling cable rub strips (Figure 1, Item 4) are mounted along the full length of the CBC roof to protect the cable and the CBC during external air transport. Power and Signal Ports The two power and signal ports (Figure 1, Item 5) on the front sidewall surfaces of the CBC permit power and signal cables to be routed into and out of the CBC. Cover plates can be installed over the power and signal ports when not in use. Bail Handle The roof handhold (Figure 1, Item 6) permits access to the roof of the CBC when using the roof access steps. Roof Access Steps Two upper and one lower roof access steps (Figure 1, Item 7) have hinged footpads that swing down to permit personnel to climb the rear of the CBC and gain access to the roof. Door Latch The personnel door latch (Figure 1, Item 8) locks in place by rotating the center handle to a horizontal position. The latch can be padlocked from the outside, protecting the internal contents of the CBC. Personnel who may be inside a locked CBC can exit using the interior door handle. Personnel Door Assembly The personnel door assembly has an upper and lower portion that mate through a tongue-and-groove bracket, and are secured with three threaded studs with hand knobs. When in height-retracted mode, the upper portion of the personnel door acts as a secondary exit. The personnel door assembly upper (top) section (Figure 1, Item 13) provides a mounting base for the door latch and is not normally removed. The personnel door assembly lower (bottom) section (Figure 1, Item 9) of the personnel door is removed before the upper section of the CBC is lowered. This section is stowed in zee brackets mounted on the underside of the CBC roof.

Winch/Cable System The winch and cable system (Figure 1, Item 10) is mounted on the inside of the CBC and is accessed through the personnel door. The winch mechanism permits the upper extendable section of the CBC to be raised to its operating mode. Lift/Locking Assemblies Four upper section lift/locking assemblies (Figure 1, Item 11) are positioned in each of the four corners of the CBC. They are used to provide rigid support of the upper section in its raised and deployed mode. They are also used as jacks to raise the upper section to its final operational position. Door Stop/Hold Open Device Pivoting arm (Figure 1, Item 12) on the outside of the personnel door assembly that permits the door to be locked in an open position.

0002-2

TM-10-5411-247-13&P Location and Description of Major Components - Continued. Lift Ring There are four lift rings (Figure 1, Item 14) that permit the CBC to be hoisted for transport, movement, or installation on the vehicle bed. Carrier Mounting Angles

0002

The carrier mounting angles are mounted to the front and rear lower walls of the CBC and have a series of holes that interface with threaded inserts in the truck bed or holes in the vehicle mounting plate. A weather seal is installed between the CBC and the truck bed or between the CBC and the mounting plate that prevents water from entering the CBC when mounted to a vehicle. (Not illustrated) Zee Mounting Plates Zee mounting plates are mounted to the right and left lower walls of the CBC and have a series of holes that interface with threaded inserts in the truck bed or holes in the vehicle mounting plate. A weather seal is installed between the CBC and the truck bed or between the CBC and the mounting plate that prevents water from entering the CBC when mounted to a vehicle. (Not illustrated)

0002-3

TM-10-5411-247-13&P Location and Description of Major Components - Continued. ROAD SIDE VIEW OF CBC

0002

CURB SIDE VIEW OF CBC 2

14 5 5 13 12 2 7 9 8 6

11

10 Figure 1. Location of Major Components.

0002-4

TM-10-5411-247-13&P EQUIPMENT DATA Table 1 provides technical and identification data pertaining to the CBC and its installation hardware. Table 1. Equipment Specification Data. CBC TARE WEIGHT: Cargo Bed Cover .707 lbs (320.68 kg) M35A2, 2-1/2 Ton Cargo Truck Configuration (See Note 1) ........................... 738 lbs (334.75 kg) 2-1/2 Ton LMTV Configuration (See Note 1) ................................................... 842 lbs (381.92 kg) 2-1/2 Ton LMTV Trailer Configuration (See Note 1) ........................................ 826 lbs (374.67 kg) EXTERNAL DIMENSIONS (L x W x H): Height-extended Mode134.00 x 87.00 x 74.87 to 75.25 inches (See Note 2) Height-retracted Mode134.00 x 87.00 x 39.44 inches (See Note 2) INTERNAL DIMENSIONS (L x W x H): Height-extended Mode.................................... 128.7 x 81.7 x 73.33 to 73.71 inches (See Note 2) Height-retracted Mode .................................... 128.7 x 81.7 x 37.51 to 37.89 inches (See Note 2) USABLE INTERIOR VOLUME: Height-extended Mode...................................................................................... 446 cu ft (12.6 m3) Height-retracted Mode ....................................................................................... 228 cu ft (6.4 m3) Note 1: Weight of the production unit (including carrier mounting kit) is shown. The M35A2 mounting kit includes entry ladder. Note 2: Special mounting plates for LMTV configurations allow for use of existing mounting provisions on carrier and increase height by their thickness. COLOR CONFIGURATIONS: Camouflage NSN 5411-01-559-8740 Sand............NSN 5411-01-559-8739 INTERNAL AIR TRANSPORT: C-130, C-17, C-5 ................................................................... Drive-on/Back-off; Back-on/Drive-off STANDARD EQUIPMENT:

0002

Carrier mounting provisions (requires specific mounting plates), secondary personnel exit, power and signal entry ports, hoist fittings, two ventilation openings, environmental protection of cargo space, roof access steps and handhold, personnel access door CONSTRUCTION: Light-weight, high-strength sandwich panels utilizing aluminum facing sheets bonded to aluminum honeycomb

END OF WORK PACKAGE

0002-5/6 blank

TM-10-5411-247-13&P

0003

OPERATOR MAINTENANCE THEORY OF OPERATION

GENERAL The CBC is a light-weight, rigid cover which can be mounted to the cargo bed area of the M35A2, 2-1/2 Ton Cargo Truck as well as the M1078, 2-1/2 Ton Light Medium Tactical Vehicle (LMTV) and M1082, 2-1/2 Ton LMTV Trailer and provides environmental protection and physical security for equipment carried by the vehicle. CBC CONFIGURATIONS The CBC (Figure 1, Item 1) mounts to the bed of the M35A2, 2-1/2 Ton, Cargo Truck (Figure 1, Item 2) by means of plain nut blind rivets that are installed in the truck bed (Figure 1, Item 3). Carrier mounting angles and door threshold installed around the base of the lower stationary section of the CBC are used to bolt the CBC to the bed of the cargo truck.

1 2

Figure 1. CBC With M35A2, 2-1/2 Ton Cargo Truck.

0003-1

TM-10-5411-247-13&P CBC Configurations - Continued.

0003

When the CBC is to be installed on the M1078, 2-1/2 Ton LMTV (Figure 2, Item 2) or M1082, 2-1/2 Ton LMTV Trailer (Figure 2, Item 1), a vehicle-specific mounting plate (Figure 2, Item 3) must be installed on the bed of the LMTV or LMTV Trailer. The mounting plate is designed in such a way as to not require permanent modifications to the M1078, 2-1/2 Ton LMTV or M1082, 2-1/2 Ton LMTV Trailer. Once the mounting plate is installed on the bed of the M1078, 2-1/2 Ton LMTV or M1082, 2-1/2 Ton LMTV Trailer, the CBC is mounted to the vehicle mounting plate via the carrier mounting angles and door threshold.

3 CBC With M1082, 2-1/2 Ton LMTV Trailer

3 CBC With M1078, 2-1/2 Ton LMTV

Figure 2. CBC LMTV and LMTV Trailer Configurations. Operational Concept The CBC (Figure 3, Item 1) consists of an upper extendable section (Figure 3, Item 4) and a lower stationary section (Figure 3, Item 5). It is the lower stationary section (Figure 3, Item 5) that is mounted to the truck bed or vehicle mounting plate. The upper extendable section (Figure 3, Item 4) can be lowered for air transport or extended for operational use. The CBC (Figure 3, Item 1) is extended by means of a winch and cable system (Figure 3, Item 16) installed inside the CBC (Figure 3, Item 1). It is locked in the extended position and supported by four lift/locking assemblies (Figure 3, Item 11) and cable tension.

0003-2

TM-10-5411-247-13&P CBC Configurations - Continued.

0003

WARNING

The CBC should not be entered prior to raising the upper section. Access to the winch handle should be from the outside of the CBC only. Failure to adhere to this warning may result in injury or death to personnel. To extend the upper extendable section (Figure 3, Item 4) of the CBC (Figure 3, Item 1), access the winch handle through the upper portion (Figure 3, Item 20) of the personnel door assembly. Once a person has accessed the winch handle through the upper portion (Figure 3, Item 20) of the personnel door assembly, the upper extendable section (Figure 3, Item 4) of the CBC (Figure 3, Item 1) is extended using the ratcheting handle (Figure 3, Item 12) attached to the winch and cable assembly (Figure 3, Item 13). As the handle is turned, the upper extendable section (Figure 3, Item 4) extends upward. The upper extendable section (Figure 3, Item 4) is raised until the mark (Figure 3, Item 15) stenciled on the inside wall of the upper extendable section (Figure 3, Item 4) is visible. When the upper extendable section (Figure 3, Item 4) has been raised to the stenciled warning mark (Figure 3, Item 15), a second person removes the cotter pin (Figure 3, Item 10) and clevis pin (Figure 3, Item 9) that secures the lift/locking assemblies (Figure 3, Item 11) in each corner of the CBC to the ceiling of the upper extendable section (Figure 3, Item 4). A cotter pin (Figure 3, Item 17) that secures the handle (Figure 3, Item 18) to the main body of the lift/locking assembly (Figure 3, Item 11) is also removed. The handle (Figure 3, Item 18) is positioned so that it is 90 from the main body of the lift/locking assembly. Each lift/locking assembly (Figure 3, Item 11) is then swung down from its stowed position on the ceiling and rotated 180 counterclockwise into position over the lower section corner fitting pulley assembly (Figure 3, Item 16) located in each corner of the CBC. The base (Figure 3, Item 14) at the bottom of the lift/locking assembly (Figure 3, Item 11) is positioned over the corner fitting pulley assembly (Figure 3, Item 16) on the lower section. Pins (Figure 3, Item 8) protruding from the base (Figure 3, Item 14) of the lift/locking assembly (Figure 3, Item 11) are aligned with slots located in the interlocking extrusion at the corner fitting pulley assembly (Figure 3, Item 16). The handle (Figure 3, Item 18) is then swung up and locked into position using the cotter pin (Figure 3, Item17) removed earlier. The CBC (Figure 3, Item 1) is now in its fully-extended and locked position. The personnel door assembly (lower) (Figure 3, Item 19) is stored in an area on the inside ceiling surface when the CBC (Figure 3, Item 1) is in the retracted mode. The lower panel is installed when the CBC (Figure 3, Item 1) is fully extended. Once the CBC (Figure 3, Item 1) is in its fully-extended, operational position, the personnel door assembly (lower) (Figure 3, Item 19) must have its hinge relocated from its stowed position before installing the personnel door assembly (lower) (Figure 3, Item 19) below the personnel door assembly (upper) (Figure 3, Item 20) using three hand knob screws (Figure 3, Item 21), completing the personnel door assembly (Figure 3, Item 3). A door stop/hold open device (Figure 3, Item 2) is provided on the outside of the personnel door to lock the door into an open position, if desired. Ventilation ports (Figure 3, Item 23) are provided on the left and right sidewalls of the CBC (Figure 3, Item 1) permitting air to enter the interior. Signal and power entry ports (Figure 3, Item 22) are provided on the sidewalls of the CBC (Figure 3, Item 1) that permit power and signal cables to enter and/or exit from the CBC (Figure 3, Item 1). Block out panels on the inside of the CBC (Figure 3, Item 1) are provided that allow the ports to be covered when not in use. Three roof access steps (Figure 3, Item 7) are located to the right of the personnel door assembly at the rear of the CBC (Figure 3, Item 1) to provide a foothold for personnel climbing to the roof of the CBC (Figure 3, Item 1). A handhold (Figure 3, Item 6) is installed on the top of the CBC (Figure 3, Item 1) to assist personnel in climbing onto the roof. Lift rings (Figure 3, Item 24) are provided on each corner of the roof to permit the CBC (Figure 3, Item 1) to be lifted into position or removed from the bed of the M35A2, 2-1/2 Ton Cargo Truck, M1078, 2-1/2 Ton LMTV, or M1082, 2-1/2 Ton LMTV Trailer. 0003-3

TM-10-5411-247-13&P CBC Configurations - Continued. 1 2

0003

5 24

REAR VIEW OF CBC WITH PERSONNEL DOOR CLOSED

23 22 21 20

19 7 11 8 18 15 9 17 11 16 14 10 13 12 INSIDE VIEW OF CBC SHOWING LIFT/LOCKING ASSEMBLY STOWAGE LOCATION ON CEILING

Figure 3. CBC Operational Concept.

END OF WORK PACKAGE 0003-4

CHAPTER 2 OPERATOR INSTRUCTIONS FOR CARGO BED COVER (CBC) TYPE IIIA1, 2-1/2 TON CARGO TRUCK, LMTV, AND LMTV TRAILER

TM-10-5411-247-13&P

0004

OPERATOR MAINTENANCE DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS

INTRODUCTION The following tables and illustrations provide the description and use of the controls and indicators pertaining to personnel door, winch and lift/locking assemblies, and labels/instruction plates of the Cargo Bed Cover (CBC). Controls 1

5 4 3 2

Figure 1. Personnel Door Controls. Table 1. Personnel Door Controls. KEY 1 CONTROL PULL STRAP FUNCTION Allows the door to be pulled closed from the vehicle bed to permit grasping the inside door latch handle. Fasten the upper section of the personnel door to the lower section personnel door. Permits the personnel door to be opened or closed from the inside of the CBC. Permits the personnel door to be opened or closed from the outside of the CBC. Allows the personnel door to be locked in an open position.

HAND KNOB SCREWS

INSIDE DOOR LATCH HANDLE

OUTSIDE DOOR LATCH HANDLE

DOOR STOP/HOLD OPEN DEVICE

0004-1

TM 10-5411-247-13&P

0004

INTRODUCTION - Continued. 2

4 8 6 7 5 Figure 2. Winch and Lift/Locking Assembly Controls. Table 2. Winch and Lift/Locking Assembly Controls. KEY 1 CONTROL LIFT/LOCKING ASSEMBLY FUNCTION Used to secure the CBC in its extended operating position. Used to lock the lift/locking assembly in a vertical position. Engage in the interlock extrusion on the lower section of the CBC to lock and align the lift/locking assembly. Provides a docking mechanism for the lift/locking assembly when the CBC is in retracted mode. Controls winch assembly and is used to raise and lower upper expandable section of CBC. Engages with the corner fitting pulley assembly on the lower section to align the lift/locking assembly. Engages the base of the lift/locking assembly to support and align. Used to release the handle from the main body tube of the lift/locking assembly.

LIFT/LOCKING ASSEMBLY HANDLE LIFT/LOCKING ASSEMBLY BASE PLATE ALIGNMENT PINS LIFT/LOCKING ASSEMBLY ROOF STOWAGE BLOCK RATCHET HANDLE

LIFT/LOCKING ASSEMBLY BASE PLATE

CORNER FITTING PULLEY ASSEMBLY LIFT/LOCKING ASSEMBLY HANDLE RELEASE COTTER PIN

END OF WORK PACKAGE

0004-2

TM 10-5411-247-13&P

0005

OPERATOR MAINTENANCE OPERATION UNDER USUAL CONDITIONS

INITIAL SETUP: Personnel Required Operator (91B) (2) Crane Operator (21F) (1) References WP 0007 WP 0017 WP 0018

EXTENDING THE CBC TO AN OPERATIONAL POSITION Instructions for the installation of the CBC and Vehicle Mounting Plate (if required) on the bed of a vehicle are covered in WP 0018 entitled Service Upon Receipt. All instructions for normal operations covered in WP 0005 pertain to the M35A2 Cargo Truck, M1078 LMTV, and M1082 LMTV trailer. Only the M35A2 Cargo Truck is illustrated.

CAUTION
Any excess snow or ice should be cleared from the roof of the CBC before the CBC is raised or lowered. Excess snow or ice will increase the weight of the top assembly of the CBC and place excessive strain on the lift/lowering components. The CBC cannot be raised or lowered while ice remains on the sidewalls. All ice should be removed from the sidewall before the CBC is raised or lowered. Failure to follow this caution may result in equipment damage. 1. Lower the tailgate (Figure 1, Item 6) on the M35A2 2-1/2 Ton Cargo Truck (Figure 1, Item 1). 2. Remove the ladder (Figure 1, Item 7) from its storage area on the inside surface of the tailgate (Figure 1, Item 6) of the cargo truck (Figure 1, Item 1) or under the cargo bed of the trailer.

WARNING

Ensure the ladder is secure and on level ground before stepping on it. Failure to do so could cause the ladder to fall and injure personnel stepping on it. Ensure the vehicle is on level ground and the wheels are chocked before deploying the ladder. Failure to do so could cause the ladder to disengage and cause injury to personnel using it. 3. Install the ladder hooks (Figure 1, Item 2) in position on the rear of the cargo truck (Figure 1, Item 1) or trailer. 4. Stand on the ladder (Figure 1, Item 7). 5. Rotate the outside door handle (Figure 1, Item 5) fully clockwise and then back to a horizontal position. 6. Open the personnel door assembly (upper) (Figure 1, Item 5) of the CBC (Figure 1, Item 8).

0005-1

TM 10-5411-247-13&P Extending the CBC to an Operational Position - Continued.

0005

WARNING
The CBC top assembly should not be entered prior to raising the top assembly. Access to the winch handle should be from the outside of the CBC only. Failure to adhere to this warning may result in severe injury to personnel. If winch is inoperable, CBC upper section can be extended by using a hoist/sling. 7. Access the winch (Figure 1, Item 3) through the personnel door assembly (upper) (Figure 1, Item 5).

7 6

3 2 Figure 1. Securing Ladder on CBC.

0005-2

TM 10-5411-247-13&P Extending the CBC to an Operational Position - Continued. 8. Locate the winch assembly (Figure 2, Item 2) located inside the left side of the personnel door assembly (Figure 2, Item 1).

0005

Figure 2. Winch Location Inside CBC. 9. Install the ratchet handle (Figure 3, Item 4) by engaging the male portion (Figure 3, Item 3) of the handle with the female socket (Figure 3, Item 2) located just inside the round opening in the winch cover (Figure 3, Item 1). 10. Move the lever on the back of the ratchet handle (Figure 3, Item 4) so that the handle engages positively when turned in a clockwise direction.

3 4

Figure 3. Installing the Ratchet Handle.

0005-3

TM 10-5411-247-13&P Extending the CBC to an Operational Position - Continued.

0005

WARNING

Do not raise the upper portion of the CBC more than one inch past the warning mark on the sidewall of the CBC. Raising the upper portion one inch beyond this mark will cause undue stress to the cables and may cause the cables to snap and the top assembly of the CBC to drop. Failure to stop at the warning mark, when extending the CBC, may result in severe injury to personnel. 11. Begin turning the ratchet handle (Figure 3, Item 4) in a clockwise direction until the upper extendable section (Figure 4, Item 3) of the CBC begins to rise. 12. Continue to raise the upper portion of the CBC until the warning mark line (Figure 4, Item 2) is visible on the sidewall of the CBC, just to the right of the winch assembly. 13. Stop turning the ratchet handle as soon as the warning mark (Figure 4, Item 2) is visible. 14. Leave the ratchet handle (Figure 3, Item 4) in place on the winch.

2 Figure 4. Warning Mark. END OF TASK

0005-4

TM 10-5411-247-13&P POSITIONING THE LIFT/LOCKING ASSEMBLIES

0005

WARNING

Be sure to support the lift/locking assembly with a free hand before removing the clevis pin that secures the assembly to the ceiling mounted stowage block. Removing the clevis pin without supporting the lift/locking assembly will permit the assembly to swing down freely, causing a possible injury to personnel. 1. Locate the lift/locking assembly (Figure 5, Item 1) nearest the winch, located in its stowed position on the underside of the ceiling (Figure 5, Item 2). 2. Remove the cotter pin (Figure 5, Item 5) that secures the lift/locking assembly (Figure 5, Item 1) to the stowage block (Figure 5, Item 4) installed on the ceiling (Figure 5, Item 2) of the upper extendable section while supporting the lift/locking assembly (Figure 5, Item 1) with a free hand. 3. Pull the clevis pin (Figure 5, Item 3) out. 1 2

Figure 5. Locating the Lift/Locking Assembly. 4. Allow the lift/locking assembly (Figure 6, Item 1) to swing down and come to rest.

1 2

Figure 6. Lowering the Lift/Locking Assembly. 0005-5

TM 10-5411-247-13&P Positioning the Lift/Locking Assemblies - Continued. 5. Replace the clevis pin (Figure 7, Item 3) in the stowage block (Figure 7, Item 2). 6. Install the cotter pin (Figure 7, Item 1). 2 1 3

0005

Figure 7. Stowage Block. 7. Rotate the lift/locking assembly (Figure 8, Item 1) 180 from its stowed position. 8. Remove the cotter pin (Figure 8, Item 3) that secures the handle (Figure 8, Item 2) to the main body of the lift/locking assembly (Figure 8, Item 1). 9. After rotating 180, swing the handle (Figure 8, Item 2) down until it forms a 90 angle with the main body of the lift/locking assembly (Figure 8, Item 1).

Figure 8. Rotating the Lift/Locking Assembly. 10. Install the cotter pin (Figure 8, Item 3) in the clevis pin that secures the handle (Figure 8, Item 2). 11. Place the base (Figure 9, Item 1)of the lift/locking assembly (Figure 8, Item 1) over the corner fitting pulley assembly (Figure 9, Item 2) on the lower section of the CBC (Figure 8, Item 3).

0005-6

TM 10-5411-247-13&P Positioning the Lift/Locking Assemblies - Continued. NOTE It may be necessary to move the handle (Figure 9, Item 2) up and down in a wiggling motion to get the base (Figure 9, Item 3) of the lift/locking assembly (Figure 9, Item 1) into the desired position.

0005

12. Align pins (Figure 9, Item 4)protruding from base (Figure 9, Item 1) of the lift/locking assembly (Figure 9, Item 2) with slots located in the interlock extrusion at the corner fitting pulley assembly (Figure 9, Item 3). 1

4 3 Figure 9. Align Pins in the Lift/Locking Assembly.

CAUTION
Ensure that the pins protruding from the base line up with the slots on the interlock extrusion. If the pins are outside or on top of the interlock extrusion, it could damage the CBC. 13. Engage the pins (Figure 9, Item 4)on the base (Figure 9, Item 1)of the lift/locking assembly (Figure 9, Item 2) in the slots located in the interlock extrusion at the corner fitting pulley assembly (Figure 9, Item 2). 14. Remove the cotter pin (Figure 10, Item 3) that secures the handle (Figure 10, Item 2).

CAUTION
Do not force the handle of the lift/locking assembly into place. Forcing the handle up could damage the CBC. 15. Swing the handle (Figure 10, Item 2) up.

1 2

Figure 10. Locking the Handle of the Lift/Locking Assembly. 0005-7

TM 10-5411-247-13&P Positioning the Lift/Locking Assemblies - Continued.

0005

16. Lock it into position by positioning the hole in the handle (Figure 10, Item 2) over the portion of the clevis pin protruding from the main body tube of the lift/locking assembly (Figure 10, Item 1). 17. Replace the cotter pin (Figure10, Item 3) removed earlier to secure the handle (Figure 10, Item 2). 18. Repeat the above sequence moving clockwise inside the CBC for each of the remaining three lift/locking assemblies in each corner of the CBC. 19. Once all four lift/locking assemblies are locked in position, the CBC will be in its fully-extended and locked position END OF TASK
16B

ASSEMBLING THE PERSONNEL DOOR ASSEMBLY Removing the Personnel Door Assembly (Lower) from its Storage Position

NOTE
Before the CBC is retracted, the lower section of the personnel door panel is separated from the upper personnel door and stowed. Once the CBC is in its fully-extended position, the personnel door assembly (lower) (Figure 11, Item 1) must be installed under the upper personnel door assembly (upper). The lower personnel door panel (Figure 11, Item 1) is stowed just inside the door opening on the inside ceiling surface (Figure 11, Item 2) of the CBC. Two personnel will be need to assemble the personnel door assembly (lower) 1. Stand inside the CBC facing the door opening while under the personnel door assembly (lower) (Figure 11, Item 1).

WARNING

Be sure to support the personnel door assembly (lower) (Figure 11, Item 1 ) with a free hand before removing the three hand knobs with threaded studs (Figure 11, Item 4) that secure the personnel door assembly (lower) (Figure 11, Item 1) to its stowage bracket on the inside ceiling surface (Figure 11, Item 2) of the CBC. Removing the hand knobs with threaded studs (Figure 11, Item 4) without supporting the personnel door assembly (lower) (Figure 11, Item 1) will permit the assembly to fall freely, causing a possible injury. 2. Support the personnel door assembly (lower) (Figure 11, Item 1) with a free hand. 3. Remove the three hand knobs with threaded studs (Figure 11, Item 4) that secure the top edge (Figure 11, Item 5) of the personnel door assembly (lower) (Figure 11, Item 1) to the left hand zee bracket (Figure 11, Item 6). 4. Lower the top edge (Figure 11, Item 5) of the personnel door assembly (lower) (Figure 11, Item 1) until the lower edge (Figure 11, Item 7) of the personnel door assembly (lower) (Figure 11, Item 1) can be removed from the right hand zee bracket (Figure 11, Item 8).

0005-8

TM 10-5411-247-13&P Assembling the Personnel Door Assembly - Continued.

0005

5. Lower the personnel door assembly (lower) (Figure 11, Item 1) from its stowage location and set near the door opening along with the three hand knobs with threaded studs (Figure 11, Item 4).

3 5 Figure 11. Removing the Personnel Door Assembly (Lower).

END OF TASK Installing the Personnel Door Assembly (Lower) to the Personnel Door Assembly (Upper)

CAUTION
Always use two personnel when assembling or installing the door or door panels. Personnel may be injured if a door panel drops on an installer.

NOTE
The personnel door assembly (lower) (Figure 12, Item 1) must be lowered from its stowage location to perform the following steps. 1. Remove the two hex head bolts, two lockwashers, and two washers (Figure 12, Item 3) that are used to store the lower door hinge (Figure 12, Item 2) of the personnel door assembly (lower) (Figure 12, Item 1) on the inside surface of the personnel door assembly (lower) (Figure 12, Item 1). Discard old lockwashers. 2. Remove the lower door hinge (Figure 12, Item 2). 2

Figure 12. Remove Hinge from Personnel Door Assembly (Lower).

0005-9

TM 10-5411-247-13&P Assembling the Personnel Door Assembly - Continued.

0005

3. Install the lower door hinge (Figure 13, Item 3) in its permanent location on the lower left corner (Figure 13, Item 1) of the outside surface of the personnel door assembly (lower) (Figure 13, Item 2). 4. Rotate personnel door assembly (lower) (Figure 13, Item 2) 180 so the lower door hinge (Figure 13, Item 3) is on the outside. 5. Place the lower door hinge (Figure 13, Item 3) in position so that the pivot pin (Figure 13, Item 5) is outside the edge of the personnel door assembly (lower) (Figure 13, Item 2). 6. Install the two hex head bolts (Figure 13, Items 6 and 7), two lockwashers (Figure 13, Item 5), and two washers (Figure 13, Item 4) removed earlier (lockwashers need to be replaced). The longer hex head bolt (Figure 13, Item 7) goes closest to the pivot pin (Figure 13, Item 8) of the lower door hinge (Figure 13, Item 3).

1 8

4 5

3 7 6 5 4

Figure 13. Install Hinge on Personnel Door Assembly (Lower). 7. Open the personnel door assembly (upper) (Figure 14, Item 1). 8. Place the personnel door assembly (lower) (Figure 14, Item 3) and the three hand knobs with threaded studs and lockwashers (both removed earlier) near the door opening and within easy reach.

0005-10

TM 10-5411-247-13&P Assembling the Personnel Door Assembly - Continued.

0005

9. Place the lower personnel door panel hinge pin (Figure 14, Item 4) in the hinge pivot block (Figure14, Item 5) located at the lower left corner of the personnel door assembly opening (Figure 14, Item 2).

5 4 3

Figure 14. Install Personnel Door Assembly (Lower).

NOTE
When properly installed, the tabs (Figure 15, Item 5) on the personnel door assembly (lower) (Figure 15, Item 2) will fit into the cutouts (Figure 15, Item 6) of the personnel door assembly (upper) (Figure 15, Item 1). Two people are required to perform the following steps: 10. Mate the tabs (Figure 15, Item 5) on the personnel door assembly (lower) (Figure 15, Item 2) into the cutouts (Figure 15, Item 6) of the personnel door assembly (upper) (Figure 15, Item 1).

0005-11

TM 10-5411-247-13&P Assembling the Personnel Door Assembly - Continued.

0005

CAUTION
When using the three hand knobs, avoid cross threading. Damage to threaded studs may occur. 11. Secure the personnel door assembly (lower) (Figure 15, Item 2) to the personnel door assembly (upper) (Figure 15, Item 1) with the three hand knobs with threaded studs (Figure 15, Item 3) and three washers (Figure 15, Item 4).

5 4 3

Figure 15. Secure Personnel Door Assembly (Lower). END OF TASK

Installing the Lower Door Latch Rod To install the lower door latch rod (Figure 16, Item 4) in its operational position, the following steps should be conducted:

NOTE
When the CBC has been retracted and the lower door panel is in its stowage location, the lower door latch rod (Figure 16, Item 4) is stored on the inside surface of the upper door panel (Figure 16, Item 2). 1. Remove the two cotter pins (Figure 16, Item 1) that secure the door handle (Figure 16, Item 5) to the door latch mechanism. 2. Remove the door handle (Figure 16, Item 5) and remove the lower door latch rod (Figure 16, Item 4) from behind the door handle (Figure 16, Item 5).

0005-12

TM 10-5411-247-13&P Assembling the Personnel Door Assembly - Continued.

0005

3. Slide the lower door latch rod (Figure 16, Item 4) out of its storage guide (Figure 16, Item 3) on the personnel door assembly (upper) (Figure 16, Item 2). 2 1 4 3

4 6

Figure 16. Lower Door Latch Rod Installation Stowage Position. 4. Install the lower door latch rod (Figure 17, Item 4) in its operational position by sliding it down through the two door-latch rod guides (Figure 17, Item 5) located on the personnel door assembly (lower) (Figure 17, Item 3). 5. Engage the upper hole (Figure 17, Item 6) of the lower door latch rod (Figure 17, Item 4) onto the door handle pin (Figure 17, Item 8) of the door handle (Figure 17, Item 7). 6. Attach the door handle (Figure 17, Item 7) over the upper hole (Figure 17, Item 6) of the lower door latch rod (Figure 17, Item 4). 7. Secure the door handle (Figure 16, Item 5) in place using a cotter pin (Figure 16, Item 1).

0005-13

TM 10-5411-247-13&P Assembling the Personnel Door Assembly - Continued.

0005

CAUTION
To minimize door latch operating failures, insert the cotter pin (Figure 17, Item 1) fully. Failure to adhere to this caution may result in damage to the CBC. 8. Install the cotter pin (Figure 17, Item 1) to secure the lower door latch rod (Figure 17, Item 4).

2 1

6 9 3

5 8 4

Figure 17. Lower Door Latch Rod Installation Operational Position. 9. Test the action of the door latch assembly (Figure 17, Item 9) by opening and closing the personnel door assembly. 10. Ensure that the door closes properly, that the door latch rods at the upper and lower edges of the door engage properly in their contact points, and that the center case latch engages the strike plate properly. 11. Ensure that the door operates freely and that the weather seal surrounding the door is positioned properly to block all openings.

NOTE
If the personnel door does not operate smoothly, check to make sure that the lower panel of the personnel door has been installed correctly and that the tabs and cutouts on the inside surface of the personnel door are aligned correctly. 12. Ensure that the three hand knobs with threaded studs are securely tightened.

END OF TASK

0005-14

TM 10-5411-247-13&P OPERATING THE PERSONNEL DOOR

0005

WARNING

The Personnel Door to the CBC must remain open while occupied. Failure to do so may result in suffocation or heat stress.

WARNING

The Personnel Door to the CBC must be locked in the fully-open position or secured in the closed position at all times. If not secured, wind gusts may cause the door to close or open violently resulting in damage to the CBC and injury to personnel.

NOTE
Once the CBC is in its fully-extended position, entry to the CBC can be gained through the Personnel Door (Figure 18, Item 1). Remove the ladder from the LMTV and the LMTV trailer when operating the personnel door assembly. 1. Open the personnel door assembly (Figure 18, Item 1) by rotating the door handle (Figure 18, Item 2) upward to a vertical position. 1

Figure 18. Exterior Handle Position Open. 0005-15

TM 10-5411-247-13&P Operating the Personnel Door - Continued.

0005

NOTE
In the vertical position (Figure 18, Item 2), the door latch rods on the inside of the door are released from their contact points at the top and bottom of the door and the center case latch near the door handle and releases from its contact point. 2. The door latching mechanism locks in place by rotating the door handle (Figure 19, Item 1) downward to a vertical position (Figure 19, Item 2).

Figure 19. Exterior Handle Position Closed.

0005-16

TM 10-5411-247-13&P Operating the Personnel Door - Continued.

0005

NOTE
In the downward vertical position (Figure 19, Item 2), the door latch assembly (Figure 20, Item 5) on the inside of the personnel door assembly engages at the top (Figure 20, Item 1) and bottom (Figure 20, Item 4) of the personnel door assembly and the center case latch (Figure 20, Item 3) near the door handle (Figure 20, Item 2) engages into its contact point. If personnel are locked inside the CBC and the tailgate of the vehicle is up, a secondary exit can be created by separating the lower door panel from the upper door panel and rotating the inner door handle. In this case, the lower door panel is removed from the door as detailed in the section entitled Using the Secondary Exit. The personnel door may also be opened and closed from the inside of the CBC. When in the closed and locked position, the inner door handle (Figure 20, Item 2) is rotated counterclockwise and will point up at approximately a 45 angle from horizontal. 3. To open the door, the inside door handle (Figure 20, Item 2) is rotated clockwise and points down at approximately a 45 angle. 1

Figure 20. Door Latch Assembly Operation. 0005-17

TM 10-5411-247-13&P Operating the Personnel Door - Continued. 4. Turn the door handle (Figure 21, Item 2) to the closed position then to the horizontal position, to allow a padlock (Figure 21, Item 3) to be installed from the outside.

0005

3 Figure 21. Outside Door Handle Locked Position. When the outside door handle (Figure 21, Item 2) is in the horizontal position, it may be padlocked (Figure 21, Item 3) from the outside. If the personnel door assembly (Figure 21, Item 1) is, for any reason, padlocked with personnel inside, they may exit the CBC by using the inner door handle (Figure 20, Item 2) of the personnel door assembly. The inner door handle (Figure 20, Item 2) has a center case latch with an override feature which permits the handle to be rotated from the inside of the CBC, even if the outside door handle (Figure 21, Item 2) is padlocked. If the personnel are padlocked inside the CBC and the tailgate of the vehicle is up, a secondary exit can be created by separating the lower door panel from the upper door panel and rotating the inner door handle. In this case, the lower door panel is removed from the door as detailed in the section entitled USING THE SECONDARY EXIT IF LOWER DOOR SECTION IS BLOCKED OR CANNOT BE OPENED FROM THE INTERIOR OF THE CBC. The personnel door may also be opened and closed from the inside of the CBC. When in the closed and locked position, the inner door handle (Figure 20, Item 2) is rotated counterclockwise and will point up at approximately a 45 angle from horizontal.

END OF TASK

0005-18

TM 10-5411-247-13&P EXITING THE CBC FROM THE INSIDE WHEN THE DOOR HAS BEEN PADLOCKED

0005

The CBC personnel door may be opened from the inside even if it has been padlocked from the outside. This provides any personnel that may locked inside a means of emergency exit. Open the personnel door from the inside of the CBC by grasping the handle on the inside of the personnel door and rotate in a counterclockwise direction. END OF TASK EMERGENCY EXIT PROCEDURES Create the Second Exit from the Interior of the CBC

NOTE
The secondary exit (Figure 22, Item 1) may only be used if the CBC is in its fully-extended position. It permits personnel to exit the interior of the CBC even if some blockage prohibits the personnel door assembly (lower) from being opened, i.e., the tailgate of the vehicle is in the up and locked position. The secondary exit is created by separating the personnel door assembly (upper) (Figure 22, Item 8) from the personnel door assembly (lower) (Figure 22, Item 7) from the inside of the CBC. This creates a situation where the personnel door assembly (upper) (Figure 22, Item 8) can swing open while the personnel door assembly (lower) (Figure 22, Item 7) remains in place, allowing personnel to exit. 1. Remove the two cotter pins that secure the door handle to the door latch mechanism (Figure 22, Item 9). 2. Remove the door handle (Figure 22, Item 10). 3. Remove lower door latch rod (Figure 22, Item 5) from door latch mechanism (Figure 22, Item 9).

NOTE
Lower door latch rod (Figure 22, Item 5) should be placed with the bent portion facing outward when attached to door latch mechanism (Figure 22, Item 9). 4. Slide lower door latch rod (Figure 22, Item 5) horizontally through the door-latch rod guides (Figure 22, Item 3) on the personnel door assembly (upper) (Figure 22, Item 8). 5. Place the door handle back on to the door latch mechanism (Figure 22, Item 9). 6. Install the two cotter pins (Figure 22, Item 2) removed earlier to secure the door handle on door latch mechanism (Figure 22, Item 9). 7. Remove the three hand knobs with threaded studs (Figure 22, Item 4) that secure the personnel door assembly (lower) (Figure 22, Item 7) to the personnel door assembly (upper) (Figure 22, Item 8). 8. Push inside door handle (Figure 22, Item 10) in the open position and open the door. 9. Remove the personnel door assembly (lower) (Figure 22, Item 7) from the hinge pin on the CBC, and place it inside the CBC (Figure 22, Item 6). 10. Exit the CBC through the opening (Figure 22, Item 1) created in the CBC.

0005-19

TM 10-5411-247-13&P Create the Second Exit from the Interior of the CBC - Continued. 1 2 10 3

0005

4 9 5

Figure 22. Creating Secondary Exit on the CBC. END OF TASK USING THE DOOR STOP/HOLD OPEN DEVICE 1. Pull the cotter pin (Figure 23, Item 5) on the right bracket (Figure 23, Item 4) of the door stop/hold open device (Figure 23, Item 1). 2. Remove the clevis pin (Figure 23, Item 3). The cotter pin (Figure 23, Item 5) is attached to the door stop/hold open device (Figure 23, Item 1) by means of a lanyard (Figure 23, Item 2).

0005-20

TM 10-5411-247-13&P Using the Door Stop/Hold Open Device - Continued. 1 2 3

0005

4 5

Figure 23. Door Stop/Hold Open Device. 3. Swing the door stop/hold open device (Figure 24, Item 3) to the left. 4. Open the personnel door assembly (Figure 24, Item 2) until the hole at the end of the door stop/hold open device (Figure 24, Item 3) is aligned with the hole in the bracket (Figure 24, Item 5), mounted to the left of the personnel door assembly (Figure 24, Item 2).

WARNING

Do not install clevis pin from inside CBC. Use step device to perform the following steps from exterior of CBC. Failure to adhere to this warning may result in injury to personnel. 5. Install the clevis pin (Figure 24, Item 1) through the holes in the door stop/hold open device (Figure 24, Item 3) and the bracket (Figure 24, Item 5), mounted to the left of the personnel door assembly (Figure 24, Item 2). 6. Install the cotter pin (Figure 24, Item 4) in the clevis pin (Figure 24, Item 5).

4 3 Figure 24. Door Stop/Hold Open Device Operation. 7. To release the door stop/hold open device (Figure 24, Item 3) and allow the personnel door assembly (Figure 24, Item 2) to close, perform the following procedures. 8. Remove the clevis pin (Figure 24, Item 1) from the holes in the door stop/hold open device (Figure 24, Item 3) and the bracket (Figure 24, Item 5), mounted to the left of the personnel door assembly (Figure 24, Item 2). 9. Swing the door stop/hold open device (Figure 24, Item 3) to the right. 10. Place the clevis pin (Figure 24, Item 1) 1n the right bracket (Figure 23, Item 4) of the door stop/hold open device (Figure 24, Item 3). 11. Install the cotter pin (Figure 24, Item 4) in the clevis pin (Figure 24, Item 4). END OF TASK 0005-21

TM 10-5411-247-13&P PREPARING THE POWER AND SIGNAL LINE PORTS FOR USE There are two power and signal line ports (Figure 25, Items 2 and 3) on the lower stationary section (Figure 25, Item 1) of the CBC. These ports are designed to permit power and signal cables to enter and/or exit the interior of the CBC. Both ports are located on the sidewalls of the CBC. One is the road side power and signal line port (Figure 25, Item 3) at the forward end and the other is located on the curb side power and signal line port (Figure 25, Item 2) toward the forward end of the CBC. Each port is lined with an aluminum tube to protect the cables from cuts and abrasion. A square blockout panel (Figure 26, Item 3) is provided that permits the port to be covered when not in use.

0005

2 3 Figure 25. Power and Signal Line Port.

0005-22

TM 10-5411-247-13&P Remove Blockout Panels

0005

NOTE
If desired, move to the power and signal line port on the opposite side of the CBC and repeat the procedure. Once the blockout panels have been removed, the power and signal ports are ready for use. The power and signal line port cover on a new CBC may adhere to the sidewall due to new paint. It may require pushing the cover from the outside of the CBC to free the cover from the sidewall. 1. Enter the CBC. 2. Remove the four screws (Figure 26, Item 5), four lockwashers (Figure 26, Item 4), and four washers (Figure 26, Item 3) at each corner of the blockout panel (Figure 26, Item 6) that attach the blockout panel (Figure 26, Item 6) to the sidewall (Figure 26, Item 7). Discard old lockwashers. 3. Place the blockout panel (Figure 26, Item 6) in position above the open port (Figure 26, Item 2). 4. Align the blockout panel (Figure 26, Item 6) with the four holes (Figure 26, Item 1) supplied above the open port (Figure 27, Item 2). 5. Install the four screws (Figure 26, Item 5), four lockwashers (Figure 26, Item 4), and four washers (Figure 26, Item 3) removed earlier. Replace the old lockwashers with new lockwashers. END OF TASK Re-Installing Blockout Panels
3B

1. Remove the four screws (Figure 26, Item 5), four lockwashers (Figure 26, Item 4), and four washers (Figure 26, Item 3) that attach the blockout panel (Figure 26, Item 6) to the sidewall (Figure 27, Item 7). Discard the old lockwashers. 2. Place the blockout panel (Figure 26, Item 6) in place over the power and signal line port opening (Figure 26, Item 3). 3. Install the four screws (Figure 26, Item 5), four new lockwashers (Figure 26, Item 4), and four washers (Figure 26, Item 3). 1 7

6 2 5 3 4 Figure 26. Blockout Panel. END OF TASK 0005-23

TM 10-5411-247-13&P HOISTING THE CBC USING THE LIFT RINGS

0005

WARNING

Do not lift the CBC in its retracted (lowered) position. The CBC must be in its extended (fullyraised) position prior to using the lift rings for lifting. Do not use the lift rings to lift a CBC with an installed payload greater than 1100 pounds. Lift rings should only be used to lift an empty CBC that is not mounted to a vehicle. A CBC that has been installed on a vehicle should only be hoisted using the lifting points on the vehicle. Make sure to use handling equipment rated for the equipment it will be lifting. Do not use handling equipment rated for less than the gross weight of the CBC when handled by itself or the CBC plus the vehicle when the CBC has been installed on a vehicle. Failure to follow these lift warnings may result in severe injury or death to personnel or damage to equipment.

CAUTION
Do not attach a hoisting sling to the CBC lift rings in such a way as to create an angle between the cable and the CBC roof surface that is LESS THAN 45. Attaching the cable at any angle less than 45 will result in excessive strain on the lift rings which may result in damage to the CBC.

NOTE
Lift rings (Figure 13, Item 1) are provided on the front and rear top edges of the CBC to allow it to be lifted onto and off a vehicle bed. The lift rings must be used only to lift a CBC that is mechanically detached from the vehicle. To lift the CBC using the lift rings, the CBC must first be in its fully-extended and locked position. 1. Attach the hoisting sling (Figure 27, Item 2) to a crane or similar piece of equipment. 2. Attach the hooks (Figure 27, Item 1) from the hoisting sling to each of the lift rings (Figure 27, Item 3) making sure that they are securely locked in place.

0005-24

TM 10-5411-247-13&P Hoisting the CBC Using the Lift Rings - Continued.

0005

NOTE
The angle created between each cable and the roof surface of the CBC must not be less than 45. Since the weight of the CBC is not distributed evenly, the CBC may tilt toward the rear when lifted with the hoisting sling. To compensate for this condition and to ensure that the CBC is level, additional weight, such as two 50-pound sandbags or other weight, should be placed toward the front edge of the roof. Guide ropes may be attached to the lift rings on the four corners of the CBC to help keep the CBC straight and level when lowering the CBC on to the vehicle bed. 3. Hoist the CBC into the desired position. THE ANGLE FORMED BETWEEN THE HOISTING CABLE AND CBC ROOF SURFACE MUST NOT BE LESS THAN 45.

45

Figure 27. Hoisting the CBC Using the Lift Rings. END OF TASK

0005-25

TM 10-5411-247-13&P HOISTING A VEHICLE WITH AN INSTALLED CBC

0005

WARNING

Do not use the lift rings to lift a CBC that is installed on a vehicle. Lift rings should be used to lift an empty, non-vehicle-mounted CBC only. A CBC that has been installed on a vehicle should be in a retracted condition. It should only be hoisted using the lifting points on the vehicle. Make sure to use handling equipment rated for the equipment it will be lifting. Do not use handling equipment rated for less than the gross weight of the CBC when handled alone. When the CBC has been installed on a vehicle the same precautions should be taken. Failure to follow these lift warnings may result in severe injury or death to personnel or damage to equipment.

NOTE
To hoist a CBC while it is installed on a vehicle, the CBC must be retracted. Helicopter rub strips are provided along the length of the roofline to protect the CBC from cables that may rub against the unit while the vehicle is being lifted. 1. Attach a hoisting sling rated to lift the combined gross weight of the vehicle, CBC, and payload. 2. Attach the end of the cables at the vehicle lifting points in accordance with the vehicles technical manual. 3. Attach the other end of the hoisting sling to a crane or equivalent equipment rated to lift the combined gross weight of the vehicle, CBC, and payload. 4. Hoist the vehicle with installed CBC. 5. Move to the desired location. END OF TASK GAINING ACCESS TO THE ROOF OF THE CBC

WARNING
Be sure that three points of contact are maintained when accessing the roof of the CBC. Failure to follow this warning may result in personnel falling from the CBC and cause severe injury or death to personnel.

CAUTION
Be sure to return the lower roof access step to its upright, stowed position prior to retracting the CBC. Failure to stow the lower roof access step will cause damage to the top assembly and the step as the top assembly is lowered. 1. Flip the hinged footpads on the lower (Figure 28, Item 4) and upper (Figure 28, Item 3) roof access steps down. They should be perpendicular to the wall of the CBC and locked in position. 2. Use the steps to reach the roof (Figure 28, Item 2) of the CBC.

0005-26

TM 10-5411-247-13&P Gaining Access to the Roof of the CBC - Continued.

0005

NOTE
A handhold (Figure 28, Item 1) is provided on the roof (Figure 28, Item 2) of the CBC to assist in climbing on top of the CBC. 2 1

4 Figure 28. Gaining Access to the Roof of the CBC. END OF TASK RETRACTING THE CBC

CAUTION
Any excess snow or ice should be cleared from the roof, side walls, and personnel door hinges of the CBC before the CBC is extended or retracted. Excess snow or ice will increase the weight of the top assembly of the CBC and place excessive strain on the lift/lowering components. Refer to WP 0007 entitled Operation Under Unusual Conditions for more information on raising and lowering the CBC under conditions of excess snow and/or ice.
41B

Removing and Stowing the Personnel Door Assembly (Lower) Before retracting the CBC, the personnel door assembly (lower) (Figure 29, Item 5) must be removed and stowed. 1. Remove both cotter pins (Figure 29, Item 1) that secure the lower door latch rod (Figure 29, Item 4) to the door latch mechanism (Figure 29, Item 8).

0005-27

TM 10-5411-247-13&P Removing and Stowing the Personnel Door Assembly (Lower) - Continued.

0005

2. Remove the door handle (Figure 29, Item 7) off the door latch mechanism (Figure 29, Item 8) to access the lower door latch rod (Figure 29, Item 4). 3. Slide the lower door latch rod (Figure 29, Item 4) up and out of the door-latch rod guides (Figure 29, Item 6) on the personnel door assembly (lower) (Figure 29, Item 5). 4. Place the door handle (Figure 29, Item 7) back on the door latch mechanism (Figure 29, Item 8).

NOTE
Lower door latch rod (Figure 29, Item 4) should be placed with the bent portion facing outward when attached to door latch mechanism(Figure 29, Item 8). 5. Slide the Lower door latch rod (Figure 29, Item 4) horizontally through the storage guide (Figure 29, Item 3) on the personnel door assembly (upper) (Figure 29, Item 2). 6. Install the cotter pins (Figure 29, Item 1) removed earlier, in place on the door latch mechanism (Figure 29, Item 8).

2 1

8 6 7

5 4

Figure 29. Removing the Personnel Door Assembly (Lower).

0005-28

TM 10-5411-247-13&P Removing and Stowing the Personnel Door Assembly (Lower) - Continued.

0005

WARNING

A second person is needed to support the personnel door assembly (lower) before removing the three hand knobs with threaded studs that secure the lower door panel to the upper door panel. Removing the hand knobs without supporting the door panel will permit the assembly to fall freely, causing possible injury to personnel or damage to the lower door panel. 7. The second personnel shall support the personnel door assembly (lower) (Figure 30, Item 3). 8. Remove the three hand knobs with threaded studs (Figure 30, Item 2) that secure the personnel door assembly (lower) (Figure 30, Item 3) to the personnel door assembly (upper) (Figure 30, Item 1). Retain the three hand knobs with threaded studs (Figure 30, Item 2) for later use.

2 1

Figure 30. Personnel Door Assembly (Lower) Hand Knobs. 9. Swing personnel door assembly (upper) (Figure 31, Item 1) open and out of the way. 10. Lift the lower personnel door assembly (lower) hinge pin (Figure 31, Item 2) up and out of the hinge pivot hole (Figure 31, Item 3) located in the threshold at the lower left corner of the personnel door opening while being supported by another personnel.

0005-29

TM 10-5411-247-13&P Removing and Stowing the Personnel Door Assembly (Lower) - Continued.

0005

3 2

Figure 31. Personnel Door Assembly (Lower).

NOTE
The lower door hinge (Figure 32, Item 2) on the outside surface of the personnel door assembly (lower) (Figure 32, Item 1) is removed and stowed on the inside surface of the personnel door assembly (lower) when the personnel door assembly (lower) is stowed on the underside of the roof. 11. Set the personnel door assembly (lower) (Figure 32, Item 1) on a work surface and remove the two screws, two lockwashers, and two washers (Figure 32, Item 3) that secure the lower door hinge (Figure 32, Item 2) to the outside surface of the personnel door assembly (lower) (Figure 32, Item 1). Discard old lockwashers. 12. Remove the lower door hinge (Figure 32, Item 2).

3 Figure 32. Removal of Lower Door Hinge. 0005-30

TM 10-5411-247-13&P Removing and Stowing the Personnel Door Assembly (Lower) - Continued.

0005

13. Turn the personnel door assembly (lower) (Figure 33, Item 1) over so that the outside surface is face down. 14. Position the lower door hinge (Figure 33, Item 2) in its stowage location (Figure 33, Item 3) on the inside surface of the personnel door assembly (lower) (Figure 33, Item 1). 15. Secure the lower door hinge (Figure 33, Item 2) in place using the two screws, two lockwashers, and two washers (Figure 32, Item 3) removed in step 12. 1

Figure 33. Installation of Lower Door Hinge.

NOTE
The personnel door assembly (lower) (Figure 34, Item 1) is stowed on the ceiling (the ceiling is the underside of the roof) when the CBC is to be retracted. Ensure that the side of the personnel door assembly with the hinge installed (inside surface of door) is facing the floor of the CBC when installed in the bracket.

NOTE
The floor of the CBC is the truck or trailer bed. The CBC does not have a floor panel. 16. Stand under the two zee brackets (Figure 34, Items 1 and 4) installed just inside the personnel door assembly opening. 17. Hold the personnel door assembly (lower) (Figure 34, Item 5) at an angle, as seen in illustration (Figure 34, Item 5). 18. Slide the bottom edge (Figure 34, Item 3) of the personnel door assembly (lower) (Figure 34, Item 5) inside the right hand zee bracket (Figure 34, Item 4), just to the right of the rubber strip installed on the ceiling surface (Figure 34, Item 2).

0005-31

TM 10-5411-247-13&P Removing and Stowing the Personnel Door Assembly (Lower) - Continued.

0005

19. Hold the personnel door assembly (lower) (Figure 34, Item 5) in place in the right hand zee bracket (Figure 34, Item 4). 20. Swing the upper edge of the personnel door assembly (lower) (Figure 34, Item 5) into position against the left hand zee bracket (Figure 34, Item 1). 21. Align the holes on the door panel tabs (Figure 34, Item 8) with the threaded inserts installed in the left hand zee bracket (Figure 34, Item 1).

CAUTION
When installing the three hand knobs, avoid cross threading. Failure to adhere to this caution may result in damage to threaded studs. 22. Install the three hand knobs with threaded studs (Figure 34, Item 6) and lockwashers (Figure 34, Item 7) that were removed when disassembling the personnel door. 2 3 1 4

8 7

Figure 34. Installation of Personnel Door Assembly (Lower). END OF TASK

0005-32

TM 10-5411-247-13&P STOWING EACH LIFT/LOCKING ASSEMBLY

0005

CAUTION
Be sure that the wire rope assemblies do not have any slack prior to releasing and stowing the four lift/locking assemblies. If the cables have slack, move the lever on the ratchet handle to the right and turn the ratchet handle clockwise SLIGHTLY to take up the slack in the wire rope assembly. Turn the ratchet handle just enough to take up any slack in the cables. 1. Remove the cotter pin (Figure35, Item 6) that secures the handle (Figure 35, Item 2). Retain cotter pin for installation. 2. Swing the handle (Figure 35, Item 2) down so that it is approximately perpendicular to the main tube of the lift/locking assembly (Figure 35, Item 1). 3. Place the cotter pin (Figure 35, Item 6) removed in the first step back on the lift/locking assembly (Figure 35, Item 1). 4. Move the handle (Figure 35, Item 2) slightly up and down as needed to disengage the base plate (Figure 35, Item 5) with protruding pins (Figure 35, Item 4) from the slots (Figure 35, Item 3) formed by the interlock extrusion.

4 3 Figure 35. Stowing Each Lift/Locking Assembly.

5. Swing the handle (Figure 35, Item 2) up until the hole in the handle clip slides over the clevis pin. 6. Replace the cotter pin (Figure 35, Item 6) in the clevis pin, locking the handle(Figure 35, Item 2) in place against the lift/locking assembly (Figure 35, Item 1). END OF TASK

0005-33

TM 10-5411-247-13&P Stow Each Lift/Locking Assembly

0005

1. Remove the cotter pin (Figure 36, Item 5) on the clevis pin (Figure 36, Item 4) installed on the roof stowage block (Figure 36, Item 2). 2. Slide the clevis pin (Figure 36, Item 4) out of the stowage block (Figure 36, Item 2). Keep the cotter pin (Figure 36, Item 5) and clevis pin (Figure 36, Item 3) close by. 3. Rotate the entire lift/locking assembly (Figure 36, Item 1) 180. 4. Swing the lift/locking assembly (Figure 36, Item 1) up towards its stowage block (Figure 36, Item 2) on the underside of the ceiling. 2 3 1

2 6

4 5 7 3 Figure 36. Stowing the Lift/Locking Assembly.

5. Swing base plate (Figure 36, Item 6) upward so protruding pins (Figure 36, Item 7) align with recessed holes in ceiling. 6. Stow the lift/locking assembly (Figure 36, Item 1) so that the bracket (Figure 36, Item 3) straddles the stowage block (Figure 37, Item 2).

NOTE
Force may be needed to align the holes in the bracket with the holes in the stowage block. This may be accomplished by tapping on the lift/locking assembly by hand, to align the holes. 7. Ensure that the holes in the bracket (Figure 36, Item 3) are aligned with the holes (in the stowage block (Figure 36, Item 2), and the protruding pins (Figure 36, Item 7) are inserted in the matching hole in the ceiling. 8. Install the clevis pin (Figure 36, Item 4) removed earlier through one side of the bracket (Figure 36, Item 3), through the stowage block (Figure 36, Item 2), and out the opposite side of the bracket (Figure 36, Item 3). 9. Install the cotter pin (Figure 36, Item 5) removed earlier in the end of the clevis pin (Figure 36, Item 4). 10. Repeat these procedures for each of the three remaining lift/locking assemblies (Figure 36, Item 1) until all are in their stowed positions against the ceiling. END OF TASK 0005-34

TM 10-5411-247-13&P LOWERING THE UPPER EXTENDABLE PORTION OF THE CBC

0005

NOTE
Once all the lift/locking assemblies are in their stowed positions, the winch assembly must be used to lower the upper extendable portion of the CBC to its full-retracted position. While positioned in front of the winch assembly: 1. Install the ratchet handle (Figure 37, Item 6) (if not already in place). 2. Engage the male portion (Figure 37, Item 4) of the handle with the female socket (Figure 37, Item 3) located just inside the round opening in the winch cover (Figure 37, Item 1). 3. Move the lever (Figure 37, Item 5) on the back of the ratchet handle (Figure 37, Item 6) so that the ratchet handle (Figure 37, Item 6) engages positively when turned in a counterclockwise direction.

WARNING

Be sure to position the lever on the back of the ratchet handle so as to LOWER the upper portion of the CBC. When turning the ratchet handle, if the CBC starts moving upward, STOP IMMEDIATELY. Extending the upper portion of the CBC past the warning mark will cause undue stress to the cables and may cause the cables to snap and the top assembly of the CBC to drop. Failure to stop at the warning mark when extending the CBC may result in severe injury. Do not enter the interior of the CBC while in the process of lowering the top assembly. Personnel should be positioned outside the CBC and reach into the personnel door opening to operate the winch. Standing inside the CBC while the top assembly is being lowered may result in severe injury.

CAUTION
Be sure to return the lower roof access step to its upright, stowed position prior to retracting the CBC. Failure to stow the lower roof access step will cause damage to the top assembly and the step as the top assembly is lowered.

4. Turn the ratchet handle (Figure 37, Item 6) in a counterclockwise direction until the upper extendable section (Figure 37, Item 2) of the CBC begins to lower.

0005-35

TM 10-5411-247-13&P Lowering the Upper Extendable Portion of the CBC - Continued. 2 4 5 1 6

0005

Figure 37. Lowering the Upper Extendable Portion of the CBC. 5. Lower the upper extendable section (Figure 37, Item 2) of the CBC until it stops. 6. Exit the personnel door opening. 7. Close and latch the remaining top assembly of the personnel door. 8. The CBC is now in its fully-retracted position. END OF TASK PREPARATION FOR MOVEMENT 1. When preparing to move from one field location to another for continued operation, the CBC can be left installed on the vehicle. It may be left in either the extended or retracted position. 2. If the CBC is in the extended position prior to movement, any cables entering the power and signal line ports on the sidewalls of the CBC should be removed and the ports covered as detailed earlier in this work package. 3. The personnel door should be closed and locked securely. 4. The ladder should be stowed and secured in place at the rear of the vehicle. END OF TASK

0005-36

TM 10-5411-247-13&P PREPARATION FOR STORAGE

0005

1. The CBC may be stored on or off the vehicle. Prior to going into storage, all After Operation PMCS procedures, as outlined in WP 0017, should be completed. Reasonable steps should be taken to provide a dry place for storage, protected from environmental extremes such as dust and rain. 2. If the CBC will be stored off vehicle, it should be left in its fully-extended position with the door closed and locked. 3. If any CBC assemblies are in need of repair, the appropriate requests should be forwarded to Field Maintenance as required. 4. All lubrication should be performed as detailed in WP 0017, paragraph LUBRICATION REQUIREMENTS, prior to storage. END OF TASK END OF WORK PACKAGE

0005-37/38 blank

TM 10-5411-247-13&P

0006

OPERATOR MAINTENANCE DECALS AND INSTRUCTION PLATES

DECALS AND INSTRUCTION PLATES Outside View of Forward End Wall

Figure 1. Outside View of Forward End Wall Decal/Instruction Plate. Table 1. Outside View of Forward End Wall Decal/Instruction Plate. ITEM NUMBER 1 DECAL/INSTRUCTION PLATE LIFT HERE ONLY WHEN CLOSURE IS RAISED

0006-1

TM 10-5411-247-13&P Decals and Instruction Plates - Continued. Outside View of Rear End Wall 1

0006

2 1

Figure 2. Outside View of Rear End Wall Decal/Instruction Plate. Table 2. Outside View of Rear End Wall Decal/Instruction Plate. ITEM NUMBER 1 2 3 4 5 6 DECAL/INSTRUCTION PLATE LIFT HERE ONLY WHEN CLOSURE IS RAISED HAND HOLD (with arrow pointing to roof) OPEN (with sweeping curved arrow) Unique Item Identifier (UII) Plate CBC Identification Plate FOLD STEP INTO POCKET BEFORE LOWERING"

0006-2

TM 10-5411-247-13&P Decals and Instruction Plates - Continued. Detail of Identification Plate

0006

Figure 3. Unit Identification Plate Details. Table 3. Unit Identification Plate Details. ITEM NUMBER DECAL/INSTRUCTION PLATE FUNCTION Provides important information regarding the CBC, such as the Serial Number (Ser No.), contract number, design account, Manufacturer (MFR), Part Number (Part No.), and National Stock Number (NSN).

UNIT IDENTIFICATION PLATE

0006-3

TM 10-5411-247-13&P Decals and Instruction Plates - Continued.

0006

Figure 4. Outside View of Road Side and Curb Side Walls. Table 4. Outside View of Road Side and Curb Side Walls. ITEM NUMBER 1 2 DECAL/INSTRUCTION PLATE VENT CLOSED VENT OPEN

0006-4

TM 10-5411-247-13&P Inside View of Rear End Wall 1

0006

Figure 5. Decal/Instruction Plate for Inside View of Rear End Wall. Table 5. Decal/Instruction Plate for Inside View of Rear End Wall. ITEM NUMBER DECAL/INSTRUCTION PLATE OPEN (with sweeping curved arrow) WARNING: SUFFOCATION HAZARD. DOOR MUST REMAIN OPEN WHILE OCCUPIED.

1 2

0006-5

TM 10-5411-247-13&P Decals and Instruction Plates - Continued.

B

0006

Inside View of Side Wall (Road Side) 1 1

2 3

Figure 6. Inside View of Side Wall (Road Side) Decal/Instruction Plates. Table 6. Inside View of Side Wall (Road Side) Decal/Instruction Plates. ITEM NUMBER DECAL/INSTRUCTION PLATE CAUTION Ensure the (2) lift/locking base plate pins are in their slots before rotating the lift/locking assy. handle to its final up position; otherwise, damage may occur to the pulley retainer brackets. (Refer to Figure 8)

2 3

DO NOT RAISE ABOVE THIS LINE WITH WINCH RAISE, LOWER (with sweeping arrow)

0006-6

TM 10-5411-247-13&P Decals and Instruction Plates - Continued. Inside Top Assembly Caution Decal Detail

0006

Figure 7. Inside Top Assembly Caution Decal Detail. Table 7. Inside Top Assembly Caution Decal Detail. ITEM NUMBER 1 DECAL/INSTRUCTION PLATE FUNCTION Provides caution to operator, when top assembly of CBC is being raised, to prevent damage to equipment.

CAUTION DECAL

Figure 8. Lift/Locking Assembly Decal Detail. Table 8. Lift/Locking Assembly Decal Detail. ITEM NUMBER 1 DECAL/INSTRUCTION PLATE CAUTION DECAL FUNCTION Provides caution to operator, when securing lift/locking assembly handle, to prevent damage to equipment. (Refer to Figure 6)

END OF WORK PACKAGE

0006-7/8 blank

TM-10-5411-247-13&P

0007

OPERATOR MAINTENANCE OPERATION UNDER UNUSUAL CONDITIONS

INITIAL SETUP: Personnel Required Operator (1) (91B) References WP 0005 WP 0017 WP 0025 FM 3-11.5

GENERAL

NOTE
Refer to Operation Under Usual Conditions (WP 0005) for specific operating instructions, and use this work package for further instruction if operating the CBC in unusual conditions. Read all sections which apply to the conditions to which the CBC will be exposed. If excessive sand, dust, wind, or water enters the CBC during unusual conditions, notify Field Maintenance to reapply RTV adhesive as appropriate. Operation in Dusty and Sandy Condition When using the CBC in sandy or dusty conditions, it may be necessary to clean the exterior and interior of the CBC more frequently to prevent sand or dust from getting into the CBC lifting mechanism as well as to protect the payload from debris. Refer to Preventive Maintenance Checks and Services (PMCS) WP 0017 for cleaning intervals. It may be necessary to clean the air filter assembly. Check the condition of the air filter and clean in accordance with PMCS. Replace the air filter if it is not possible to clean it sufficiently to ensure proper airflow. Refer to Preventive Maintenance Checks and Services (PMCS) WP 0017 for cleaning and interval replacement of filter. Refer to WP 0025 for replacement procedures. Operations in Snowy or Snow Covered Conditions

CAUTION
No attempt should be made to raise or lower the CBC until all excess snow and ice have been removed. Failure to adhere to this caution may result in damage to the CBC. Any excess snow or ice should be cleared from the roof, sidewalls, and personnel door hinges of the CBC before the CBC is extended or retracted. Excess snow or ice will increase the weight of the upper section of the CBC and place excessive strain on the lifting/lowering components. CBRN Decontamination Procedures

NOTE
During thorough DECON and reconstitution efforts, rubber/foam gaskets, adhesive sealants, and wire rope cables may need to be replaced. When the CBC is subjected to Chemical, Biological, Radiological, and Nuclear (CBRN) contamination, perform operational decontamination procedures in accordance with FM 3-11.5, until a thorough DECON (Decontamination) can be performed. END OF WORK PACKAGE 0007-1/2 blank

CHAPTER 3 TROUBLESHOOTING PROCEDURES FOR CARGO BED COVER (CBC) TYPE IIIA1, 2-1/2 TON CARGO TRUCK, LMTV, AND LMTV TRAILER

TM-10-5411-247-13&P

0008

OPERATOR AND FIELD MAINTENANCE TROUBLESHOOTING INDEX

GENERAL TROUBLESHOOTING INFORMATION The operator troubleshooting procedures Work Packages (WPs) are designed to give general instruction for resolving the most common problems associated with the CBC. TROUBLESHOOTING INFORMATION The troubleshooting procedures found in WP 0009, WP 0010, WP 0011, WP 0012, WP 0013, WP 0014, and WP 0015 list the symptoms, malfunctions, and corrective actions required to return the CBC to normal operation. Perform all the steps in the order they appear in the WP. Troubleshooting procedures are listed according to symptom, followed by the malfunction, then any corrective action(s). All necessary references to procedure/instructions can be found within the Troubleshooting WP. DO NOT START THE TASK UNTIL: You understand the task You have the tools and equipment you need INTRODUCTION TO TROUBLESHOOTING The Malfunction/Symptom Index lists common malfunctions that may occur during the inspection and operation of the CBC. Find the malfunction the CBC is experiencing in the index and go to the given troubleshooting procedure in the following Work Packages (WPs). MALFUNCTION/SYMPTOM INDEX The malfunction/symptom index is a quick reference for locating troubleshooting procedures. Each malfunction/symptom references a number representing a starting point in the troubleshooting procedures table. Troubleshooting procedures are arranged based upon the location of the malfunction (i.e., engine, transmission, or brakes). Specific Troubleshooting Procedures This manual cannot list all malfunctions that may occur, all tests or inspections and corrective actions. If a malfunction is not listed in, or is not corrected by the listed corrective actions, notify your supervisor/contact Field Maintenance. SYMPTOM INDEX The Symptom Index tells the operator what to do when a fault occurs. The index is arranged by Line Replaceable Unit (LRU) or functional area. When a fault occurs, carefully inspect the equipment for abnormal indicator responses to decide which Fault Indication to follow. Use the Action for a given Fault Indication in their order of appearance. If the Action(s) does not solve the problem, choose another Fault Indication to resolve the problem. Notify Unit Maintenance if you cannot solve the problem. The Fault Indication and Action apply to the CBC as indicated.

0008-1

TM-10-5411-247-13&P

0008

SYMPTOM INDEX - Continued. OPERATOR Malfunction/Symptom TOP ASSEMBLY Top assembly will not retract or extend..........................................................................................WP 0009-1 Winch assembly will not operate...WP 0009-1 Top assembly is uneven or not even....WP 0009-2 Lift/locking assemblies will not operate properly.....WP 0009-2 Lift/locking assemblies will not turn to stow or deploy........WP 0009-2 Lift/locking assemblies will not lock into place in the deployed position.........WP 0009-2 Cannot manually extent the upper section of the CBC...................................................................WP 0009-3 Wire rope assembly preventing the CBC from being manually lifted..............................................WP 0009-4 Cannot hoist CBC............................................................................................................................WP 0009-4 Cannot connect lifting device to hoist the CBC................................................................................WP 0009-4 Cannot access Cargo Bed Cover (CBC) roof from the upper assembly..........................................WP 0009-4 Upper and middle folding steps will not deploy................................................................................WP 0009-4 Cannot access bail handle on top of the CBC..................................................................................WP 0009-4 PERSONNEL DOOR ASSEMBLY Gaps can be seen around the door....WP 0010-1 Door will not close properly......WP 0010-1 Door does not operate properly........................................................................................................WP 0010-2 Door binds on closing....WP 0010-2 Door latch will not engage properly.....WP 0010-2 Strike rod does not engage in hole in threshold...........WP 0010-2 Door will not open......WP 0010-3 Turning door handle will not release door latch.........WP 0010-3 Work Package

0008-2

TM-10-5411-247-13&P

0008

SYMPTOM INDEX - Continued. MAINTAINER Malfunction/Symptom CBC MOUNTING KIT Gaps between CBC and vehicle bed....WP 0011-1 Evidence of accumulating water, dust, or sand detected inside CBC.....WP 0011-1 CBC Leaking..WP 0011-1 Cracked or missing RTV adhesive around threshold area of the CBCWP 0011-1 D-rings not operating properly ...WP 0011-2 Cannot access the D-rings for operation...WP 0011-2 TOP ASSEMBLY Top Assembly will not retract or extend.....WP 0012-1 Winch assembly will not operate.....WP 0012-1 Top Assembly is uneven or not level..WP 0012-2 Lift/locking assemblies not properly deployed...WP 0012-2 Lift/locking assembly will not operate properly......WP 0012-2 Lift/locking Assemblies will not turn to stow or deploy..WP 0012-2 Lift/locking assemblies will not lock into place in the deployed position....WP 0012-3 CBC will not manually extend...WP 0012-3 Cannot connect lifting device to lift the CBC......WP 0012-3 Wire rope assembly preventing top of CBC from lifting....WP 0012-3 Cannot hoist the CBC.WP 0012-4 Cannot connect lifting device to hoist the CBC..WP 0012-4 Cannot access Cargo Bed Cover (CBC) roof from the upper assembly...WP 0012-4 Upper and middle folding steps will not deploy..WP 0012-4 Cannot access bail handle on top of the CBC...WP 0012-4 Work Package

0008-3

TM-10-5411-247-13&P

0008

SYMPTOM INDEX - Continued. MAINTAINER Malfunction/Symptom BOTTOM ASSEMBLY Cannot raise Top Assembly..........WP 0013-1 Winch assembly will not operate...WP 0013-1 Cannot access Cargo Bed Cover (CBC) roof from the lower assembly.WP 0013-2 Lower folding step will not deploy..WP 0013-1 PERSONNEL DOOR ASSEMBLY Gaps can be seen around the door......WP 0014-1 Door will not close properly....WP 0014-1 Upper and lower door latch will not engage properly.WP 0014-1 Lower door latch rod does not engage in hole in threshold..WP 0014-1 CBC MOUNTING KIT Evidence of accumulating water, dust, or sand detected inside CBC........WP 0015-1 Gaps between CBC and vehicle bedWP 0015-1 Vehicle mounting kit is damaged or missing parts..WP 0015-1 CBC leaking...WP 0015-2 Cracked or missing RTV adhesive around threshold area of the CBC....WP 0015-1 Work Package

END OF WORK PACKAGE

0008-4

TM 10-5411-247-13&P

0009

OPERATOR MAINTENANCE TOP ASSEMBLY TROUBLESHOOTING PROCEDURES

INITIAL SETUP: Personnel Required Operator References WP 0005 WP 0039

TROUBLESHOOTING PROCEDURE TOP ASSEMBLY SYMPTOM Top Assembly will not retract or extend. MALFUNCTION Winch assembly will not operate. CORRECTIVE ACTION STEP 1. If CBC cannot extend, lift the top section of the CBC with lifting device and visually check if wire rope assemblies are damaged or broken. Refer to WP 0039 for lifting the CBC manually. a. b. If wire rope assemblies are damaged, cut, or have separated strands, notify Field Maintenance. If wire rope assemblies are not damaged, cut, or have separated strands, go to next procedural step.

STEP 2. Check winch assembly for damaged or broken parts. a. b. If winch assembly is damaged or broken, notify Field Maintenance. If loose parts/assemblies are not found, go to next procedural step.

STEP 3. Turn ratchet to move winch. a. b. If winch assembly does not move, notify Field Maintenance. If winch assembly moves properly, go to next procedural step.

STEP 4. Check corner pulley assemblies for damage. a. b. END OF TASK If corner pulley assemblies are damaged, notify Field Maintenance. If symptoms continue, notify Field Maintenance.

0009-1

TM 10-5411-247-13&P TOP ASSEMBLY - Continued. SYMPTOM Top Assembly is uneven or not level. MALFUNCTION Lift/locking assemblies not properly deployed. CORRECTIVE ACTION STEP 1. Check that the lift/locking assemblies are properly seated in the channel. a. b. c.

0009

Properly seat lift/locking assemblies that are not seated properly. Refer to WP 0005 for instructions. If problem corrected, return to normal operations. If symptom continues, go to next procedural step.

STEP 2. Visually inspect lift/locking assemblies for damage. a. b. END OF TASK SYMPTOM Lift/locking assemblies will not operate properly. MALFUNCTION Lift/locking Assemblies will not turn to stow or deploy. CORRECTIVE ACTION STEP 1. Visually inspect lift/locking assemblies for damage. a. b. MALFUNCTION Lift/locking assemblies will not lock into place in the deployed position. CORRECTIVE ACTION STEP 1. Visually inspect lift/locking assemblies for damage. a. b. If lift/locking assemblies are damaged, notify Field Maintenance. If symptom continues, go to next procedural step. If lift/locking assemblies are damaged, notify Field Maintenance. If symptoms continue, notify Field Maintenance. If lift/locking assemblies are damage, notify Field Maintenance. If symptom continues, notify Field Maintenance.

0009-2

TM 10-5411-247-13&P TOP ASSEMBLY - Continued.

0009

STEP 2. Inspect to see if top assembly is bowed away from the bottom assembly when trying to engage the lift/locking assemblies. a. b. c. Push on the center wall of the lower assembly and try to engage the upper assembly and lower assembly interlocks. If problem corrected, deploy the lift/locking assemblies for operation. If symptoms continue, go to next procedural step.

NOTE
These procedures may require two personnel to perform tasks. d. Perform the following steps: 1) 2) 3) 4) Stow the lift/locking assemblies. Lower the top assembly 12 inches using the corner winch. Raise the top assembly using the corner winch and push on the wall that is bowed of the lower assembly. As the top assembly is raised near the line that indicates not to raise above the line, ensure that enough force is used to ensure the interlocks of the upper section and lower section come together. If there is no bow in the side wall after the steps have been performed, put the lift/locking assemblies in place. Maintain pressure on the wall that was bowed until lift/locking assemblies are in place. Use a second person for this step. If problem corrected, return to normal operations.

5) 6) 7) e. END OF TASK SYMPTOM

If symptom continues, notify Field Maintenance.

Cannot manually extend the upper section of the CBC. MALFUNCTION Cannot connect lifting device to extend the CBC. CORRECTIVE ACTION STEP 1. Visually inspect the four lift rings on the top of the CBC for damage. a. b. If lift rings are damaged, notify Field Maintenance. If symptoms continue, notify Field Maintenance.

MALUFUNCTION Wire rope assembly preventing top of CBC from being manually lifted. CORRECTIVE ACTION STEP 1. Visually inspect to see if wire rope assembly is visible from the outside of the CBC.

0009-3

TM 10-5411-247-13&P TOP ASSEMBLY - Continued. a. b. If wire rope assembly is visible or hanging on the outside of the CBC, notify Field Maintenance.

0009

If wire rope assembly is not visible on the outside of the CBC, look on the inside to see if it is out of the channel and preventing the top assembly from being manually extended.

END OF TASK SYMPTOM Cannot hoist the CBC. MALFUNCTION Cannot connect lifting device to hoist the CBC. CORRECTIVE ACTION STEP 1. Visually inspect the four lift rings on the top of the CBC for damage. a. b. END OF TASK SYMPTOM Cannot access Cargo Bed Cover (CBC) roof from the upper assembly. MALFUNCTION Upper and middle folding steps will not deploy. CORRECTIVE ACTION STEP 1. Visually inspect to see if upper and middle folding steps are damaged or broken. a. b. MALFUNCTION Cannot access bail handle on top of the CBC. CORRECTIVE ACTION STEP 1. Visually inspect to see if the bail handle is damaged or broken. a. b. If the bail handle is broken, notify Field Maintenance. If symptoms continue, notify Field Maintenance. If the upper or middle step is broken, notify Field Maintenance. If the upper or middle step is not broken, proceed to next procedure. If lift rings are damaged, notify Field Maintenance. If symptoms continue, notify Field Maintenance.

END OF TASK END OF WORK PACKAGE

0009-4

TM 10-5411-247-13&P

0010

OPERATOR MAINTENANCE PERSONNEL DOOR ASSEMBLY TROUBLESHOOTING PROCEDURES

INITIAL SETUP: Personnel Required Operator (1) References WP 0005 WP 0017

TROUBLESHOOTING PROCEDURE PERSONNEL DOOR ASSEMBLY SYMPTOM Gaps can be seen around the door. MALFUNCTION Door will not close properly. CORRECTIVE ACTION STEP 1. Inspect that nothing is blocking the door from operating properly. a. b. Remove any objects or debris that may prevent door from closing properly. If nothing is blocking the door, go to next procedural step.

STEP 2. Inspect door for damage or missing parts that do not allow for proper operation. a. b. If door is damaged or missing parts, notify your supervisor/contact Field Maintenance. If door is not damaged or missing parts, go to next procedural step.

STEP 3. Check that the lift/locking assemblies are working properly and in place. a. b. c. Check that the pins at the base of the lift/locking assemblies in each corners are properly seated. If problem corrected, return to normal operations. If symptoms continue, go to next procedural step.

STEP 4. Check door alignment. a. b. c. Check that lower door panel mates to upper door panel. If problem corrected, return to normal operations. If symptoms continue, go to next procedural step.

STEP 5. Inspect to see if the three hand knobs are loose or missing. a. b. c. d. END OF TASK 0010-1 Tighten the three hand knob if they are loose. Replace hand knobs if missing. If problem corrected, return to normal operations. If symptoms continue, notify your supervisor.

TM 10-5411-247-13&P PERSONNEL DOOR ASSEMBLY - Continued. SYMPTOM Door does not operate properly. MALFUNCTION Door binds on closing. CORRECTIVE ACTION STEP 1. Check to ensure that the CBC is on a level surface. a. b. Move the CBC to a level surface. If CBC is on a level surface, go to next procedural step.

0010

STEP 2. Check that the lift/locking assemblies are working properly and in place. a. b. If lift/locking assemblies are not working properly, refer to STEP 3 of Door will not close properly malfunction. If lift/locking assemblies are working properly, go to next procedural step

STEP 3. Check door alignment. a. b. c. d. Ensure that the lower door panel mates to upper door panel. Ensure that the tongue-and-groove assembly mates are engaged. If problem corrected, return to normal operations. If symptoms continue, go to next procedural step.

STEP 4. Ensure that the hinges are cleaned of dirt or sand. Lubricate hinges, refer to WP 0017. STEP 5. Be sure the three hand knobs are tightened securely. Refer to (WP 0005) for hinge instructions. STEP 6. Open and close door to make sure it operates and closes properly. a. b. END OF TASK SYMPTOM Door latch will not engage properly. MALFUNCTION Strike rod does not engage in hole in threshold. CORRECTIVE ACTION STEP 1. Check to ensure that hole in threshold is clear and free of debris. a. b. c. Clear any debris or objects from the threshold that may prevent proper operation. If problem corrected, return to normal operations. If symptoms continue, go to next procedural step. If problem corrected, return to normal operations. If symptoms continue, notify your supervisor.

0010-2

TM 10-5411-247-13&P PERSONNEL DOOR ASSEMBLY - Continued.

0010

STEP 2. Check that the lift/locking assemblies are working properly and in place. a. b. Check that the pins at the base of the lift/locking assemblies in each corner are properly seated in the channel. If lift/locking assemblies are properly seated, go to next procedural step.

STEP 3. Ensure that the door latch rod is installed correctly and passes through the door rod guides on the personnel door (WP 0005). STEP 4. Ensure that all door latch cotter pins are installed and not missing. a. b. If door latch cotter pins are missing, notify your supervisor. If door latch cotter pins are installed properly, go to next procedural step.

STEP 5. Ensure that bolts on both door hinges are tightened securely and not damaged. a. b. If hinges are not secure or damaged, notify your supervisor. If hinges are not damaged and secure, go to next procedural step.

STEP 6. Check that lower door panel mates to upper door panel and that the tongue-and-groove assembly mates correctly. STEP 7. Be sure to tighten the three hand knobs securely. a. b. END OF TASK SYMPTOM Door will not open. MALFUNCTION Turning door handle will not release door latch. CORRECTIVE ACTION STEP 1. Check to ensure that the CBC is on a level surface. a. b. c. Move the CBC to a level surface. If problem is corrected, return to normal operations. If symptoms continue, notify your supervisor. If problem corrected, return to normal operations. If symptoms continue, notify your supervisor.

END OF TASK END OF WORK PACKAGE

0010-3/4 blank

TM-10-5411-247-13&P

0011

OPERATOR MAINTENANCE CBC MOUNTING KIT TROUBLESHOOTING PROCEDURES

INITIAL SETUP: Personnel Required Operator

TROUBLESHOOTING PROCEDURE CBC MOUNTING KIT SYMPTOM Evidence of accumulating water, dust, or sand detected inside CBC. MALFUNCTION Gaps between CBC and vehicle bed. CORRECTIVE ACTION STEP 1. Visually inspect for gaps between the CBC and vehicle bed in the area of accumulation. a. b. c. END OF TASK SYMPTOM CBC leaking. MALFUNCTION Cracked or missing RTV adhesive around threshold area of the CBC. CORRECTIVE ACTION STEP 1. Check for cracked or missing RTV adhesive around threshold area at the rear of the CBC. a. b. END OF TASK If there are cracks or missing RTV adhesive around threshold area at the rear of the CBC, notify Field Maintenance. If CBC continues to leak, notify your supervisor. Refer to Service Upon Receipt, Identifying Gaps Between the CBC and the Vehicle Bed, to identify how much gap space there is. If gaps are found between the CBC and vehicle bed, notify your supervisor. If there are no gaps identified, go to next procedural step.

0011-1

TM-10-5411-247-13&P CBC MOUNTING KIT - Continued. SYMPTOM D-rings not operating properly. MALFUNCTION Cannot access the D-rings for operation. CORRECTIVE ACTION STEP 1. Check for accumulation coming from D-rings in the bed of the carrier. a. b. END OF TASK END OF WORK PACKAGE

0011

If accumulation is found coming from D-rings in the bed of the carrier, notify your supervisor/contact Field Maintenance. If problem continues, notify your supervisor.

0011-2

TM 10-5411-247-13&P

0012

FIELD MAINTENANCE TOP ASSEMBLY TROUBLESHOOTING PROCEDURES

INITIAL SETUP: Personnel Required Maintainer References WP 0013 WP 0024 WP 0026 WP 0027 WP 0029 WP 0030 WP 0039

TROUBLESHOOTING PROCEDURE TOP ASSEMBLY SYMPTOM Top Assembly will not retract or extend. MALFUNCTION Winch assembly will not operate. CORRECTIVE ACTION STEP 1. If CBC cannot extend, lift the top section of the CBC with lifting device and visually check if wire rope assembly is damaged or broken. Refer to WP 0039 for lifting the CBC manually. a. b. If cables are damaged, cut, or have separated strands, replace the wire rope assembly. Refer to WP 0029. If cables are not damaged, cut, or have separated strands, go to next procedural step.

STEP 2. Check winch assembly for damaged or broken parts. a. b. If winch assembly is damaged or broken, replace the winch assembly. Refer to WP 0030. If loose parts/assemblies are not found, go to next procedural step.

STEP 3. Check corner pulley assemblies for damage. a. b. END OF TASK If corner pulley assemblies are damaged, notify your supervisor. If symptoms continue, notify your supervisor.

0012-1

TM 10-5411-247-13&P TOP ASSEMBLY - Continued. SYMPTOM Top Assembly is uneven or not level. MALFUNCTION Lift/locking assemblies not properly deployed. CORRECTIVE ACTION STEP 1. Visually inspect to see if lift/locking assembly is damaged or broken. a. b. c.

0012

If the lift/locking assembly is damaged or broken, replace the lift/locking assembly. Refer to WP 0027. If problem corrected, return to normal operations. If symptoms continue, go to next procedural step.

STEP 2. Visually inspect to see if corner fitting assembly is damaged so that the lift/locking assembly will not fit in the channel around the corner fitting assembly. a. b. If corner fitting assembly is damaged, notify supervisor. If symptoms continue, go to next procedural step.

STEP 3. Perform cable adjustment. Refer to WP 0029 for adjustment procedures. STEP 4. Refer to troubleshooting procedure Winch Assembly Will Not Operate. Refer to WP 0013. STEP 5. If the prior procedure does not solve the problem, notify your supervisor. END OF TASK SYMPTOM Lift/locking assemblies will not operate properly. MALFUNCTION Lift/locking assemblies will not turn to stow or deploy. CORRECTIVE ACTION STEP 1. Visually inspect lift/locking assemblies for damage. a. b. If lift/locking assemblies are damaged, replace the lift/lock assembly. Refer to WP 0027. If lift/locking assemblies are not damaged, perform the following steps: 1) 2) 3) c. Remove the shoulder screw and associated hardware from the lift/locking assembly. Add thread locker to the shoulder screw. Reinstall the shoulder screw and associated hardware into lift/locking assembly. Do not over tighten the shoulder screw when securing the lift/locking assembly.

If symptom continues, notify your supervisor.

0012-2

TM 10-5411-247-13&P TOP ASSEMBLY - Continued. MALFUNCTION Lift/locking assemblies will not lock into place in the deployed position. CORRECTIVE ACTION STEP 1. Visually inspect lift/locking assemblies for damage or missing parts. a. b. If lift/locking assemblies are damaged or missing parts, replace the lift/locking assembly. Refer to WP 0027. If symptoms continue, go to next procedural step.

0012

STEP 2. Perform cable adjustment. Refer to WP 0029 for adjustment procedures. a. END OF TASK SYMPTOM CBC will not manually extend. MALFUNCTION Cannot connect lifting device to lift the CBC. CORRECTIVE ACTION STEP 1. Visually inspect the four lift rings on the top of the CBC for damage. a. b. c. MALUFUCTION Wire rope assembly preventing top of CBC from lifting. STEP 1. Visually inspect to see if wire rope assembly is damaged. a. b. c. END OF TASK Remove the wire rope assembly from the CBC. Refer to WP 0029 for removal instructions. If problem is corrected, return to normal operations. If the prior procedure does not solve the problem, notify your supervisor. If any of the four lift rings is damaged, replace the lift ring that is damaged. Refer to WP 0024. If problem is corrected, return to normal operations. If the prior procedure does not solve the problem, notify your supervisor. If symptom continues, notify your supervisor.

0012-3

TM 10-5411-247-13&P TOP ASSEMBLY - Continued. SYMPTOM Cannot hoist the CBC. MALFUNCTION Cannot connect lifting device to hoist the CBC. STEP 1. Visually inspect the four lift rings on the top of the CBC for damage. a. d. c. END OF TASK SYMPTOM Cannot access Cargo Bed Cover (CBC) roof from the upper assembly. MALFUNCTION Upper and middle folding steps will not deploy. CORRECTIVE ACTION STEP 1. Visually inspect to see if upper or middle folding step is damaged or broken. a. b. c. MALFUNCTION Cannot access bail handle on top of the CBC. CORRECTIVE ACTION STEP 1. Visually inspect to see if the bail handle is damaged or broken. a. b. If the bail handle is broken, replace the bail handle. Refer to WP 0023. If symptoms continue, notify your supervisor.

0012

If any of the four lift rings are damaged, replace the lift ring that is damaged. Refer to WP 0024. If problem is corrected, return to normal operations. If the prior procedure does not solve the problem, notify your supervisor.

If the upper or middle step is damaged, replace the upper or middle step. Refer to WP 0026. If problem corrected, return to normal operations. If symptom continues, notify your supervisor.

END OF TASK END OF WORK PACKAGE

0012-4

TM 10-5411-247-13&P

0013

FIELD MAINTENANCE BOTTOM ASSEMBLY TROUBLESHOOTING PROCEDURES

INITIAL SETUP: Personnel Required Maintainer (1) References WP 0028 WP 0029 WP 0030

TROUBLESHOOTING PROCEDURE BOTTOM ASSEMBLY SYMPTOM Cannot raise top assembly. MALFUNCTION Winch assembly will not operate. CORRECTIVE ACTION STEP 1. Visually inspect to see if wire rope assembly is damaged. a. b. c. If cables are not damaged, cut, or have separated strands, go to next procedural step. If cables are damaged, cut, or have separated strands, replace wire rope assembly. Refer to WP 0029. If symptoms continue, go to next procedural step

STEP 2. Inspect to see if hand-operated drum is damaged and will not operate. a. b. c. END OF TASK If hand-operated drum is damaged, replace the hand-operated drum. Refer to WP 0030. If problem corrected, return to normal operations. If the prior procedure does not solve the problem, notify your supervisor.

0013-1

TM 10-5411-247-13&P BOTTOM ASSEMBLY - Continued. SYMPTOM Cannot access Cargo Bed Cover (CBC) roof from the lower assembly. MALFUNCTION Lower folding step will not deploy. CORRECTIVE ACTION STEP 1. Visually inspect to see if lower folding step is damaged or broken. a. b. c. If the lower step is broken, replace the lower step. Refer to WP 0028. If problem corrected, return to normal operations. If symptoms continue, notify your supervisor.

0013

END OF TASK END OF WORK PACKAGE

0013- 2

TM-10-5411-247-13&P

0014

FIELD MAINTENANCE PERSONNEL DOOR ASSEMBLY TROUBLESHOOTING PROCEDURES

INITIAL SETUP: Personnel Required Maintainer (1) References WP 0005 WP 0032

TROUBLESHOOTING PROCEDURE PERSONNEL DOOR ASSEMBLY SYMPTOM Gaps can be seen around the door. MALFUNCTION Door will not close properly. CORRECTIVE ACTION STEP 1. Inspect the personnel door assembly for damage. a. b. c. If personnel door assembly is damaged, replace personnel door assembly. Refer to WP 0032. If personnel door assembly is not damaged, go to next procedural step. If problem corrected, return to normal operations.

STEP 2. If symptoms continue, notify your supervisor. END OF TASK SYMPTOM Upper and lower door latch will not engage properly. MALFUNCTION Lower door latch rod does not engage in hole in threshold. CORRECTIVE ACTION STEP 1. Inspect lower door latch rod to see if door latch is damaged. a. b. c. If lower door latch rod is damaged, replace lower door latch rod. Refer to WP 0005. If problem corrected, return to normal operations. If lower door latch rod is not damaged, go to next procedural step.

0014-1

TM-10-5411-247-13&P

0014

PERSONNEL DOOR ASSEMBLY - Continued. STEP 2. Inspect upper door latch rod to see if door latch is damaged. a. If upper door latch rod is damaged, replace lower door latch rod. Proceed with steps below: 1) Remove the two cotter pins that secure the door handle to the door latch mechanism. 2) Remove the door handle and remove the upper door latch rod from behind the door handle.

3) Insert a new upper door latch rod through the door-latch rod guide. 4) Attach the door handle over the upper hole of the upper door latch rod. 5) Secure the door handle in place using a cotter pin. b. c. If problem corrected, return to normal operations. f lower door latch rod is not damaged, go to next procedural step

STEP 3. If symptom continues, notify your supervisor. END OF TASK END OF WORK PACKAGE

0014-2

TM-10-5411-247-13&P

0015

FIELD MAINTENANCE CBC MOUNTING KIT TROUBLESHOOTING PROCEDURES

INITIAL SETUP: Personnel Required Maintainer References WP 0033 WP 0034 WP 0035

TROUBLESHOOTING PROCEDURE CBC MOUNTING KIT SYMPTOM Evidence of accumulating water, dust, or sand detected inside CBC. MALFUNCTION Gaps between CBC and vehicle bed. CORRECTIVE ACTION STEP 1. Check for gaps between the CBC and vehicle bed in the area of accumulation. a. b. If there are no gaps identified, proceed to next malfunction. If gaps are found along the front wall of the CBC, apply RTV adhesive to the area. Refer to WP 0033, WP 0034, or WP 0035, depending on which vehicle mounting kit being dealt with, for instructions on applying RTV. If gaps are found along side walls or the rear of the CBC, apply RTV. Refer to WP 0033, WP 0034, or WP 0035, depending on which vehicle mounting kit being dealt with, for instructions on applying RTV. If symptoms continue, go to next procedural step.

c.

d. MALFUNCTION

Vehicle mounting kit is damaged or missing parts. CORRECTIVE ACTION STEP 1. Visually inspect to see if the vehicle mounting kit is damaged or missing parts. a. If the vehicle mounting kit is damaged, replace the vehicle mounting kit. Refer to WP 0033, WP 0034, or WP 0035, depending on which vehicle mounting kit being dealt with. If the prior procedure does not solve the problem, notify your supervisor.

b. END OF TASK

0015-1

TM-10-5411-247-13&P CBC MOUNTING KIT - Continued SYMPTOM CBC leaking. MALFUNCTION Cracked or missing RTV adhesive around threshold area of the CBC. CORRECTIVE ACTION STEP 1. Check for cracked or missing RTV adhesive around threshold area at the rear of the CBC. a.

0015

If there are cracks or missing RTV adhesive around threshold area at the rear of the CBC, refer to WP 0033, WP 0034, or WP 0035, Gaps Between the CBC and the Vehicle Bed. If the prior procedure does not solve the problem, notify your supervisor.

b.

END OF TASK END OF WORK PACKAGE

0015-2

CHAPTER 4 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) MAINTENANCE INSTRUCTIONS FOR CARGO BED COVER (CBC) TYPE IIIA1, 2-1/2 TON CARGO TRUCK, LMTV, AND LMTV TRAILER

TM 10-5411-247-13&P

0016

OPERATOR MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION

INTRODUCTION This section contains information needed to perform operator Preventive Maintenance Checks and Services (PMCS). Illustrated steps are included to help perform these procedures easily and quickly. PMCS consists of scheduled maintenance items used to make sure the Cargo Bed Cover (CBC) is ready for operation at all times. Inspect the system regularly and carefully to find any defects and correct or prevent them. General PMCS is performed to keep the equipment in operating condition. The checks are used to find, correct, or report problems. Pay attention to WARNING and CAUTION statements. A WARNING indicates the possibility of injury or death to personnel. A CAUTION means the equipment could be damaged. Before operation, perform Before PMCS. During operation, perform During PMCS. After operation, perform After PMCS.

Corrosion Definition Component damage is caused when material has been dissolved or eaten away, especially by chemical action. Rust Definition Any various scaly or powdery reddish-brown or reddish-yellow materials that form on iron and iron-coated materials in the presence of moisture, deteriorating as a result of disuse or neglect. Deterioration Definition Any condition that causes material to be impaired or lessens the quality or value of the material. Cracking Definition When material is found to be split or broken, either completely or partially. Inspection Always look for signs of problems or trouble. Most easily-fixed problems can be detected by feel, smell, or sound. Be alert when around the CBC. Inspect to ensure that all components are in good condition. Are they correctly assembled, stowed, or secured? Are any components worn, corroded, or rusty? Correct any problems found or notify immediate supervisor. There are common items that should be checked. These include the following: Bolts, clamps, screws, and nuts: Continuously inspect for looseness. Inspect for chipped paint, bare metal, rust, or corrosion around bolt and screw heads and nuts. Replace as necessary. Tighten hardware as required and if tools are not available, notify immediate supervisor. Inspect welds: Some components of the CBC set are welded. To inspect welds, look for chipped paint, rust, corrosion, or gaps. When these conditions are noted, notify immediate supervisor.

0016-1

TM 10-5411-247-13&P CLEANING AND LUBRICATION Proper cleaning and lubrication can aid in avoiding possible problems or trouble. Make it a habit to do the following:

0016

CAUTION
Follow all cleaning and lubrication instructions carefully. Failure to do so could result in damage to the equipment. Under harsh environmental conditions, PMCS should be conducted more frequently. Use only the recommended cleaning solutions and lubricants listed in the Expendable and Durable Items List (WP 0057). EXPLANATION OF THE COLUMNS FOUND IN THE PMCS TABLE Item No. The item number lists the checks and services in the order they are to be performed. This column will be used as a source of item for the TM Number Column on DA Form 2404 or Form 5988E (electronic version), Equipment Inspection and Maintenance Worksheet, in recording the result of the PMCS. Interval. References when the PMCS should be performed. Application/Explanation Before an operation During an operation After an operation Monthly Quarterly Semi-Annually Annually Man-hour. Specifies man-hours required to complete all prescribed lubrication services, stated to the nearest tenth of an hour. Item to be Checked or Serviced. Identifies the portion of the system to be inspected. Procedures. Provides the procedures for performing the checks. Equipment not Ready/Available if. Contains the criteria that will render the system incapable of performing its primary mission. If system does not perform as required, refer to Chapter 3, Operator Troubleshooting Procedures. If anything looks wrong and cannot be fixed, immediately report it to immediate supervisor and report it on DA Form 2404. END OF WORK PACKAGE

0016-2

TM 10-5411-247-13&P

0017

OPERATOR MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) Table 1. Preventive Maintenance Checks and Services (PMCS) for Cargo Bed Cover. ITEM NO. INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF:

NOTE Ensure CBC is in its extended position. Refer to WP 0005. 1 Before Assembly, Door, Personnel (Upper) a. Inspect to see that the personnel door assembly (upper) (Figure 1, Item 1) is properly engaged. Personnel door assembly (upper) does not open or close properly. The three hand knobs with screws are missing, and the personnel door assembly (upper) and personnel door assembly (lower) will not attach together. Door latch mechanism does not operate properly or cotter pin is missing. Pull strap is damaged or missing. Door stop/hold open device is damaged or does not operate properly. Door latch rods are missing or damaged to prevent operation. Personnel door assembly (upper) is punctured and is allowing leaking into the CBC. Refer to WP 0032 for repair procedures.

b. Verify that the three hand knobs with screws (Figure 1, Item 3,) that secure the personnel door assembly (upper) (Figure 1, Item 1) and personnel door assembly (lower) (Figure 1, Item 7) are tightened securely.

c.

Verify that the cotter pins (Figure 1, Item 9) in the door latch mechanism (Figure 1, Item 10) are installed an not damaged.

d. Verify that the pull strap (Figure 1, Item 2) is undamaged.

e. Check for free and easy operation of the personnel door latch mechanism (Figure 1, Item 10) and door stop/hold open device. f. Verify that door latch rods (Figure 1, Item 5) are not damaged or missing.

g. Inspect personnel door assembly (upper) for punctures that can cause leaking.

0017-1

TM 10-5411-247-13&P

0017

Table 1. Preventive Maintenance Checks and Services (PMCS) for Cargo Bed Cover - Continued. ITEM NO. INTERVAL ITEM TO BE CHECKED OR SERVICED Assembly, Door, Personnel (Upper) Continued. PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: Inspect personnel door assembly (upper) is dented as to prevent proper operation. Refer to WP 0032 for repair procedures.

Before

h. Inspect personnel door assembly (upper) for dents.

Before

Assembly, Door, Personnel (Lower)

a. Inspect to see that the personnel door assembly (lower) (Figure 1, Item 7) is properly engaged and secured to the personnel door assembly (upper) (Figure 1, Item 1). b. Inspect personnel door assembly (lower) for punctures that can cause leaking.

Personnel door assembly (lower) does not attach securely to the personnel door assembly (upper). Personnel door assembly (lower) is punctured and is allowing leaking into the CBC. Refer to WP 0032 for repair procedures. Inspect personnel door assembly (lower) is dented as to prevent proper operation. Refer to WP 0032 for repair procedures. Roof access steps are cracked, broken, or otherwise damaged. Roof access step hardware is missing. Lift rings cracked, broken, or otherwise damaged. Lift rings do not operate properly.

c.

Inspect personnel door assembly (lower) for dents.

Before

Step, Pole, Upper and Step, Pole, Lower and Step, Folding, Bottom

a. Inspect for free and easy operation of the roof access folding steps (Figure 1, Item 11).

Before

Assembly, Ring, Lift

a. Check for free and easy operation of lift rings (Figure 1, Item 14).

b. Ensure that the lift rings (Figure 1, Item 14) operate properly.

0017-2

TM 10-5411-247-13&P

0017

Table 1. Preventive Maintenance Checks and Services (PMCS) for Cargo Bed Cover - Continued. ITEM NO. INTERVAL ITEM TO BE CHECKED OR SERVICED Assembly, Ring, Lift Continued. c. PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: Area around lift rings is damaged that would prevent the lift rings from operating properly. Lift rings hardware missing.

Before

Check for any cracks or breaks in the assembly that would create an unsafe condition.

d. Check for any loose or missing attaching hardware (Figure 1, Item 13) that would create an unsafe condition. 5 Before Assembly, Locking, Lift a. Inspect the condition of the lift/locking assemblies (Figure 1, Item 18).

Lift/locking assembly does not swing into position properly. Roof access handhold attaching hardware missing or not secure. Ventilation ports blocked or air cooler filter pad dirty. Air cooler filter pad is missing.

Before

Handle, Bail

a. Inspect that the roof access step handhold attaching hardware (Figure 1, Item 17) is secure and not missing (WP 0023). a. Inspect to make sure that the ventilation ports (Figure 1, Item 15) are not blocked. b. Ensure air cooler filtering pad is not missing (Figure 1, Item 16) and clean if necessary.

Before

Port, Ventilation

Before

Assembly, Rope, Wire

a. Inspect the visible portion of the cabling in the lower section cable channel. a. Inspect that all carrier mounting hardware (Figure 1, Item 21) is securely tightened. b. Ensure that all vehicle/trailer mounting kit hardware (Figure 1, Item 20) is tightened securely.

Cable damaged, frayed, or abraded.

Before

Bolts, Mounting, Carrier

Carrier hardware missing or not secure. Vehicle/trailer mounting kit hardware missing or not secure. Carrier mounting angles are damaged.

10

Before

Angles, Mounting, Carrier

a. Visually inspect carrier mounting angles are not damaged or secured (Figure 1, Item 20).

0017-3

TM 10-5411-247-13&P

0017

Table 1. Preventive Maintenance Checks and Services (PMCS) for Cargo Bed Cover - Continued. ITEM NO. INTERVAL ITEM TO BE CHECKED OR SERVICED Mounting Kit PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: Any part of the vehicle/trailer kit is missing or damaged. Vehicle/trailer mounting kit hardware missing or not secure. Refer to Service Upon Receipt Identifying Gaps Between the CBC and the Vehicle Bed.

11

Before

a. Visually inspect that all pieces to the vehicle/trailer kit are in place.

b. Ensure that all vehicle/trailer mounting kit hardware (Figure 1, Item 20) is tightened securely.

c.

Visually inspect for gaps between the CBC and the vehicle/trailer kit.

0017-4

TM 10-5411-247-13&P

0017

Preventive Maintenance Checks and Services (PMCS) for Cargo Bed Cover - Continued. 1 2

6 8 3

5 7 4

9 11

12 13

10

14

18

17

16 15

Figure 1. CBC Before Operation PMCS (Sheet 1 of 2).

0017-5

TM 10-5411-247-13&P Preventive Maintenance Checks and Services (PMCS) for Cargo Bed Cover - Continued. 19

0017

20 21

21

Figure 1. CBC Before Operation PMCS (Sheet 2 of 2).

0017-6

TM 10-5411-247-13&P

0017

Table 1. Preventive Maintenance Checks and Services (PMCS) for Cargo Bed Cover - Continued. ITEM NO. INTERVAL ITEM TO BE CHECKED OR SERVICED Assembly, Locking, Lift PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF:
Lift/locking assemblies do not swing down or lock properly in a vertical position.

12

Before

a. Inspect that the lift/locking

assemblies (Figure 2, Item 2) operate smoothly and install in a vertical and locked position (WP 0027).

13

After

Winch, Drum, HandOperated

a. Inspect winch mechanism (Figure 3, Item 1) for damage to worm gear or drum. a. Inspect hinges (Figure 3, Item 2) on the upper and lower sections of the personnel door for damage or loose hardware.

Winch mechanism has damage to worm gear or drum. Door hinges are damaged or missing hardware.

14

After

Assembly, Door, Personnel

Figure 2. CBC During Operation PMCS.

0017-7

TM 10-5411-247-13&P

0017

Table 1. Preventive Maintenance Checks and Services (PMCS) for Cargo Bed Cover - Continued. ITEM NO. INTERVAL ITEM TO BE CHECKED OR SERVICED Strip, Rub, Cable, Helicopter PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: Burrs on helicopter rub strip that would abrade or cut helicopter airlift cables.

15

After

a. Inspect the condition of the helicopter cable rub strip (Figure 3, Item 5) for burrs or any damage that could cause damage to the helicopter cable during airlift. a. Inspect and clean the inside (Figure 3, Item 4) of the CBC with a rag and mildly soapy water. a. Inspect and wash the outside of the CBC (Figure 3, Item 3) as necessary. a. Visually inspect for gaps between the CBC and the vehicle/trailer kit and vehicle/trailer bed.

16

After

Surface, Interior, CBC

Cleaning is required to ensure normal operation. Cleaning is required to ensure normal operation. Refer to Service Upon Receipt Identifying Gaps Between the CBC and the Vehicle Bed. Winch mechanism has not been lubricated according to schedule or exhibits evidence of requiring additional lubrication. Door hinges have not been lubricated according to schedule or exhibit evidence of requiring additional lubrication.
Upper section of the CBC does not rise smoothly, or the winch assembly appears to be binding.

17

After

Surface, Exterior, CBC

18

After

Mounting Kit

19

Quarterly

Winch, Drum, HandOperated

a. Inspect and lubricate winch mechanism (Figure 3, Item 1) in accordance with the lubrication schedule.

20

Quarterly

Assembly, Door, Personnel

a. Inspect and lubricate hinges (Figure 3, Item 2) on the upper and lower sections of the personnel door in accordance with the lubrication schedule.

21

Annually

Assembly, Door, Personnel

a. Inspect that the winch mechanism

(Figure 2, Item 3) and the upper CBC section (Figure 2, Item 1) operates smoothly. Refer to (WP 0005).

b.

Inspect that no unusual effort is required to operate the winch. Inspect wire rope assembly for proper cable adjustment. Perform wire rope assembly adjustment. Refer to WP 0029.

22

Annually

Assembly, Rope, Wire

a.

0017-8

TM 10-5411-247-13&P Preventive Maintenance Checks and Services (PMCS) for Cargo Bed Cover - Continued.

0017

3 4

Figure 3. CBC After Operation PMCS. END OF TASK LUBRICATION REQUIREMENTS Personnel Door Assembly The door hinges (Figure 4, Item 1) of the personnel door assembly should be lubricated with lithium based grease every 3 months (quarterly) or if there is any resistance to casual movement of the door or if the door squeaks when opened or closed. 1. Clean part with cotton cloth prior to lubricating. 2. Lubricate part, being careful not to over lubricate. 3. Wipe any excess lubricant from part. END OF TASK Folding Steps (Upper, Middle, and Lower) The folding steps (Figure 4, Item 2) of the CBC should be lubricated with lithium based grease every 3 months (quarterly) or if there is any resistance to casual movement when deploying the folding steps. 1. Clean part with cotton cloth prior to lubricating. 2. Lubricate part, being careful not to over lubricate. 3. Wipe any excess lubricant from part. END OF TASK

0017-9

TM 10-5411-247-13&P Hand-Operated Winch Drum Assembly

0017

NOTE
The hand-operated winch cover assembly should be lubricated every 3 months (quarterly). 1. In order to lubricate the hand operated winch cover assembly, remove the winch cover assembly as described in WP 0030. 2. Lubricate the worm gear where it contacts the drum gear (Figure 4, Item 3). 3. Check that the winch works smoothly. 4. Replace the winch cover assembly as described in WP 0030.

1 2

Figure 4. CBC Lubrication Point Locations. END OF TASK END OF WORK PACKAGE

0017-10

CHAPTER 5 FIELD MAINTENANCE INSTRUCTIONS FOR CARGO BED COVER (CBC) TYPE IIIA1, 2-1/2 TON CARGO TRUCK, LMTV, AND LMTV TRAILER

TM-10-5411-247-13&P OPERATOR AND FIELD MAINTENANCE SERVICE UPON RECEIPT

0018

INITIAL SETUP: Equipment Condition CBC on shipping pallet in position near vehicle. Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Lifting Device (1 Ton minimum) Gloves (WP 0057, Table 1, Item 12) Goggles (WP 0055, Table 2, Item 12) Personnel Required Light-Wheel Vehicle Mechanic (91B) (2) References DA Form 361 DA PAM 750-8 WP 0005 WP 0019 WP 0020 WP 0021

GENERAL The Cargo Bed Cover is shipped mounted to a modified pallet that must be removed prior to installation. The Field Maintenance technician should inspect the equipment before it is used. Following is a list of functions which must be performed upon receipt of the CBC: procedures to remove straps for shipping purposes are below.

WARNING

Safety goggles must be worn during repair to protect eyes from flying metal chips. The metal straps that secure the CBC to the shipping skid can cause severe damage or even death to personnel if not removed with care. Be sure to follow the instructions when removing the metal straps. 1. Hold the metal strap with one hand. 2. Using cutting shears, cut the metal strap. 3. Discard the metal strap. 4. Repeat for metal strap on each corner of the CBC.

CHECKING UNPACKED EQUIPMENT Inspect the equipment for damage incurred during shipment. If the equipment has been damaged, report the damage on DA Form 361, Transportation Discrepancy Report. Check the equipment against the packing slip to see if the shipment is complete. Report all discrepancies in accordance with applicable service instructions (e.g., for Army instructions, see DA PAM 750-8).

0018-1

TM-10-5411-247-13&P Checking Unpacked Equipment - Continued. Table 1. Inspection Criteria for Packaging. COMPONENT ACCEPTABLE REPAIRABLE NONREPAIRABLE

0018

Wooden Boxes and Crates Metal Ends Minor rust, cracks, indentations, or splits that would not impair water proofing or serviceability of container. No leaks, cuts, or gouges. None. Perforations, excessive rust, or ends which are crushed or not securely crimped to body.

Body and Cap

Cuts, tears, gouges not closer than 1 inch to closure, less than 1/2 square inch in area, and impenetrable layers that can be spot painted. Splits more than 3 in. but no closer than 1 in. to edge of board or adjoining split or 1/2 in. wide that can be repaired by use of corrugated fasteners.

Cuts, tears, or gouges closer than 1 inch to closure, more than 1/2 square inch in area, or through all impregnated layers. Splits closer than 1 in to edge of board or adjoining split or over 1/2 in. wide.

Wood

Splits less than 3 inches (in) long, no closer than 1 in. to edge of board or adjoining split. The board must be secured by at least one nail on each side of the split when it extends to the end of the board. Operative and tight: Nails, screws, and fasteners. Free from damage. Attached to skid with no damage that would cause leaking. Properly functioning ratchet inside box.

Hardware

Inoperative or loose: Nails, screws, and fasteners. Broken or missing cleats and handles. None.

None.

Ends Box with hand socket wrench inside on pallet.

Damage that requires disassembly of box. None.

END OF TASK PACKING LIST VERIFICATION Check the equipment against the packing list, located inside the box containing the mounting kit, to see if the shipment is complete. Report all discrepancies in accordance with DA PAM 750-8. Pre-Operation Services Service any damaged equipment, as necessary, using Field Maintenance procedures in Chapter 5 to restore equipment to operable condition.

0018-2

TM-10-5411-247-13&P REMOVING THE CARGO BED COVER FROM ITS WRAPPING AND SHIPPING PALLET

0018

NOTE
If the CBC is not being mounted, leave it attached to shipping pallet for storage. For mounting kit installation instructions, refer to Table 2. Vehicle Type and Mounting Kit Reference. Table 2. Vehicle Type and Mounting Kit Reference. Vehicle Type M35A2, 2 1/2 Ton Cargo Truck M1078, 2 1/2 Ton LMTV M1082, 2 1/2 Ton LMTV Trailer END OF TASK REMOVAL OF THE CBC FROM THE SHIPPING PALLET Mounting Kit Required 7045247 7045253 7045254 TM Work Package Describing Installation WP 0019 WP 0020 WP 0021

NOTE
CBC is on the pallet in the extended position. 1. Remove two hex head screws (Figure 17, Item 2) and two flat washers (Figure 17, Item 3) from the inside of the CBC (Figure 17, Item 5) that secure the CBC (Figure 17, Item 5) to the pallet (Figure 17, Item 4). 2. Remove four hex head screws (Figure 17, Item 2) and four washers (Figure 17, Item 3) from the outside of the CBC (Figure 17, Item 5) that secure the CBC (Figure 17, Item 5) to the pallet (Figure 17, Item 4).

2 5 4 3

Figure 1. Lifting the CBC from the Pallet.

0018-3

TM-10-5411-247-13&P

0018

Removal of the CBC from the Shipping Pallet - Continued.

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Whenever lifting the CBC off the ground have guide personnel using guide lines to prevent the CBC from swinging eratically. Injury or death to the operator or observers could occurr if guide lines are not used. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death. Personnel attaching the lifting sling to the lift rings or working on the roof of the CBC should use ladders or wear approved safety lines or both to prevent falls; injury or death could occur if proper safety equipment is not used.

NOTE
Leave the CBC on the pallet until the mounting kit is ready to be mounted. This will keep the CBC clean of debris. 3. Attach the proper lifting sling to the CBC lift rings (Figure 17, Item 1) 4. Lift the CBC (Figure 17, Item 5) from the pallet (Figure 17, Item 4) using the lifting device when installing the mounting kit. Refer to WP 0005 entitled HOISTING THE CBC USING THE LIFT RING. 5. Install mounting kit to the bottom of the CBC (Figure 17, Item 5). Refer to Table 2, "Vehicle Type and Mounting Kit Reference," for the correct mounting kit and installation reference. END OF TASK END OF WORK PACKAGE

0018-4

TM 10-5411-247-13&P

0019

FIELD MAINTENANCE MOUNTING KIT FOR M35A2, 2-1/2 TON CARGO TRUCK INSTALLATION SERVICE UPON RECEIPT

INITIAL SETUP: Equipment Condition Vehicle bed clean and free of debris. CBC unpacked as detailed in WP 0018 and positioned on pallet near the vehicle. Mounting Kit unpacked and hardware organized (WP 0018). Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Dispenser, RTV adhesive (WP 0055 Table 2, Item 2) Lifting Device (1 Ton minimum) 5/16-18 UNC tap Riveter, Blind, Hand (WP 0055, Table 2, Item 16) Gloves (WP 0057, Table 1, Item 12) Goggles (WP 0055, Table 2, Item 12) References WP 0005 WP 0022 WP 0057 Material/Parts Anti-seize Lubricant (WP 0057, Table 1, Item 5) Adhesive, RTV-732 (WP 0057, Table 1, Item 1) Bag, Sand (WP 0057, Table 1, Item 6) Four Wood Support Blocks 4x4x12 inches in length (WP 0057, Table 1, Item 28) Rubber strip, 3/8 inch thk x 1.00 inch wide x 25 feet long, adhesive backed, color black, closed cell, epdm sponge rubber strip. (WP 0057, Table 1, Item 20) Personnel Required Operator (1) Light-Wheel Vehicle Mechanic (91B) (1) Crane Operator (21F) (1)

GENERAL Before the CBC can be installed on the bed of the M35A2, 2-1/2 Ton Cargo Truck, the bed surface should be cleared of any foreign matter or other debris that would interfere with the installation process. A mounting kit must be installed to the truck bed that will allow the CBC to be secured to the vehicle. The lift rings should always be pointed to the inside of truck bed for operation when CBC is mounted. Unless it is already in an extended position, once the CBC has been separated from its shipping pallet and prepared for installation as outlined in the REMOVING THE CARGO BED COVER FROM ITS WRAPPING AND SHIPPING PALLET, paragraph of WP 0018, it must be extended to its operational position as outlined in WP 0005 paragraph EXTENDING THE CBC TO AN OPERATIONAL POSITION.

0019-1

TM 10-5411-247-13&P LIFTING THE CBC INTO POSITION ONTO THE VEHICLE BED

0019

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. When the CBC (Figure 1, Item 1) is in its fully-extended position, it must be lifted into position using the four Lift Rings (Figure 1, Item 2) positioned along the front and rear roof lines of the CBC (Figure 1, Item 1). The CBC (Figure 1, Item 1) should be lifted into position over the vehicle bed (Figure 1, Item 3) in accordance with the paragraph of WP 0005 entitled HOISTING THE CBC USING THE LIFT RINGS.

Figure 1. Lifting CBC onto Vehicle. END OF TASK

0019-2

TM 10-5411-247-13&P DETERMINING CORRECT MOUNTING LOCATION

0019

NOTE
In order to ensure that the tie-down rings are free to be used, place them in an upright position prior to mounting the CBC to the truck bed. 1. Determine the proper mounting position for the CBC on the vehicle bed from front to back by lowering the CBC into position on the vehicle bed so that the forward end of the top section (Figure 2, Item 2) is 1-1/2 inches back (3.0 inches from the bottom section) from the inside front wall of truck bed (Figure 2, Item 1) of the vehicle. Do not remove the hoisting sling at this time since it will be necessary to remove the CBC from the vehicle bed in a later step. 2. Position the CBC with respect to the vehicle bed from left to right, the CBC is centered on the bed of the vehicle by ensuring that the distance from the CBC sidewalls (Figure 2, Item 3) to the outer edge of the vehicle bed (Figure 2, Item 4) is equal at all four corners.

1 2

1-1/2 INCHES

3 4 POSITION THE CBC ON THE VEHICLE BED SO THAT EACH SIDE OF THE CBC IS THE SAME DISTANCE AWAY FROM THE EDGE OF THE VEHICLE BED AT THE FOUR CORNERS

TOP VIEW OF 2-1/2 TON TRUCK WITH CBC POSITIONED ON REAR BED

Figure 2. Determining Mounting Position. END OF TASK

0019-3

TM 10-5411-247-13&P MARKING THE LOCATION OF THE CARRIER MOUNTING ANGLE HOLES

0019

1. The bottom edge of the bottom section of the CBC is attached to the vehicle bed by means of a series of carrier mounting angles (Figure 3, Item 1). These angles and threshold have a total of 27 predrilled mounting holes where only 19 of the holes (Figure 3, Item 2) are used. 2. Transfer the position of the carrier mounting holes to the vehicle bed, use the 3/8 inch punch (Figure 3, Item 3) supplied with the mounting kit and mark the vehicle bed in 19 places. There are four holes each in the carrier mounting angles at the front (Figure 3, Item 4), curb side (Figure 3, Item 5), and road side (Figure 3, Item 6) of the CBC. There are two holes in each of the two smaller carrier-mounting angles (Figure 3, Item 7) at the rear of the CBC located on either side of the door opening and a total of three holes in the threshold. 3. Once all 19 hole positions (Figure 3, Item 2) have been marked, the CBC can be removed from the vehicle bed and returned to its shipping pallet while the holes are drilled in the vehicle bed and blind rivet nuts installed. 3( 0.13) INCHES VEHICLE CAB CENTER LINE OF CBC AND VEHICLE

2 2 1 4 NOTE: ONLY THOSE CARRIER MOUNTING ANGLE HOLES INDICATED ON THIS FIGURE BY A SHORT ARROW ON THE INSIDE OF THE CBC REQUIRE DRILLING. THE ADDITIONAL EIGHT HOLES SHOWN ON THE SIDE CARRIER MOUNTING ANGLES DO NOT REQUIRE DRILLING AND BLIND RIVET NUT INSTALLATION. 2 2 2 2 2 2

CARGO BED COVER BOTTOM SECTION 6

M35A2 TRUCK BED 2

2 3

7 Figure 3. Drilling Hole Locations. END OF TASK

0019-4

TM 10-5411-247-13&P DRILLING THE MOUNTING HOLES AND INSTALLING BLIND RIVET NUTS IN THE VEHICLE BED

0019

WARNING

Safety goggles or face shield must be worn during repair to protect eyes from flying metal chips.

WARNING

ANTI-SEIZE COMPOUND Anti-Seize Compound is use for equipment lubrication, lubricant for threaded connections or slides. It is neither flammable nor toxic. Gloves and safety goggles should be worn during use.

CAUTION
Always apply anti-seize lubricant to bolt and screw threads before installation to prevent galling. During the installation of blind rivet nuts, the threads inside the blind rivet nut can sometimes be damaged by the installation tool and may result in the bolts and screws binding. If this occurs, run a 5/16-18 UNC tap into the threaded area. This will clear and straighten the threads, making for easier and faster assembly. Care should be taken using this method since the tap has the ability to remove and/or cross thread existing threads. Be sure to work slowly and deliberately when clearing the threads. Failure to adhere to this caution may result in thread damage.

NOTE
Drilling is made easier by starting with a smaller diameter drill bit. Increase the drill bit diameter in steps until the required diameter is met. All tools needed for installation are included in mounting kit. Once the CBC has been removed from the vehicle bed to allow access to the hole positions marked previously, blind rivet nut installation holes must be drilled at each of the 3/8 inch transfer punch locations (19 total), to their final size using a letter Z (0.413 inch) diameter drill bit. Make sure that the drill bit is positioned in the center of the punched mark. 1. When all holes are drilled, install blind rivet nuts in each of the 19 installation holes using the hand-operated blind rivet nut installation tool (Figure 4, Item 1), hex key (Figure 4, Item 2), and 3/4 inch wrench (or 1 1/16 inch depending on header tool used).

0019-5

TM 10-5411-247-13&P Drilling the Mounting Holes and Installing Blind Rivet Nuts in the Vehicle Bed - Continued.

0019

2 1

Figure 4. Hand-Operated Insert Installation Tools.

NOTE
Before using the installation tool, inspect the condition of the jackscrew threads before use. If the tool has been used previously, the jackscrew threads may require a few drops of light machine oil. If this is the initial use of the tool, no additional lubrication will be required. 2. Apply anti-seize lubricant to the blind rivet nut threads before installation to prevent galling. 3. Thread the blind rivet nut fastener (Figure 5, Item 2) onto the threaded end (Figure 5, Item 3) of the installation tool (Figure 5, Item 1). 4. Ensure that the end of the installation tool is tight against the head of the fastener.

3 Figure 5. Threading the Threaded Insert Fastener.

5. With the blind rivet nut (Figure 6, Item 2) installed on the installation tool (Figure 6, Item 1), insert the blind rivet nut into the hole (Figure 6, Item 3) previously drilled in the vehicle bed (Figure 6, Item 4).

1 2 4

3 Figure 6. Threading Insert into Hole in CBC Panel.

0019-6

TM 10-5411-247-13&P Drilling the Mounting Holes and Installing Blind Rivet Nuts in the Vehicle Bed - Continued.

0019

6. Insert the hex key (Figure 7, Item 1) into the socket (Figure 7, Item 2) at the top of the installation tool (Figure 8, Item 3). 7. While holding the hex key (Figure 7, Item 1) stationary and the installation tool (Figure 8, Item 3) at a right angle to the vehicle bed (Figure 7, Item 4), turn the installation tool (Figure 8, Item 3) in a clockwise direction keeping track of the number of turns. 8. Turn the installation tool (Figure 8, Item 3) in a clockwise direction until firm resistance indicates that the fastener is completely set. This will be approximately 1-1/2 to 2 turns. 9. Turn the wrench in a counter-clockwise direction to break its grip with the blind rivet nut. 10. Remove hex key and wrench from the installation tool. 1 2

4 Figure 7. Installing Threaded Insert. 11. Remove the blind rivet nut installation tool (Figure 8, Item 1) from the blind rivet nut (Figure 8, Item 2) by turning the entire tool by hand in a counterclockwise direction. 12. Repeat steps for the remaining blind rivets.

Figure 8. Removal of Threaded Insert Installation Tool. END OF TASK

0019-7

TM 10-5411-247-13&P INSTALLING RUBBER STRIP ON THE CBC

0019

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Whenever lifting the CBC off the ground have guide personnel using guide lines to prevent the CBC from swinging eratically. Injury or death to the operator or observers could occur if guide lines are not used. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death. Personnel attaching the lifting sling to the lift rings or working on the roof of the CBC should use ladders or wear approved safety lines or both to prevent falls; injury or death could occur if proper safety equipment is not used.

NOTE
After verifying that the CBC (Figure 9, Item 1) has been raised to an operational position, the CBC must be lifted approximately eight inches and placed on supporting blocks (Figure 9, Item 8) in order to gain access to the lower edge of the CBC for the installation of the rubber strip. A hoisting sling must be attached to lift the CBC in accordance with WP 0005. When initially positioning the blocks, it is best to place them first at the front and rear ends to allow access to the road side and curb side of the CBC and then to move them to the left and right sides to gain access to the front and rear ends. Once the CBC has been safely blocked, the rubber strip can be installed. The thickness of rubber strip is 3/8 inch and supplied in rolls of 25 feet. 1. On the zee brackets (Figure 9, Item 6) on the road side and curb side of the CBC, install the rubber strip (3/8 inch thick x 1 inch wide) (Figure 9, Item 3) on the inside edge by removing the protective paper (Figure 9, Item 4) backing and pressing the adhesive side of the rubber strip (3/8 inch thick x 1 inch wide) (Figure 9, Item 3) in place on the zee bracket (Figure 9, Item 6). 2. In order to apply the rubber strip (Figure 9, Item 3) around the entire perimeter of the CBC (Figure 9, Item 1), it will be necessary to lift the CBC (Figure 9, Item 1) and reposition the blocks (Figure 9, Item 7).

NOTE
Do NOT apply the rubber strip (Figure 9, Item 3) to the bottom of the carrier mounting angles (Figure 9, Item 2). 3. On the front and rear of the CBC (Figure 9, Item 1), install the rubber strip (3/8 inch thick x 1 inch wide) (Figure 9, Item 3) where the threshold and outer CBC edge meet by removing the protective paper (Figure 9, Item 4) backing and pressing the adhesive side rubber strip (3/8 inch thick x 1 inch wide) (Figure 9, Item 3) in place. Rubber stripping is NOT applied to the carrier mounting angles (Figure 9, Item 2) at the front of the CBC.

0019-8

TM 10-5411-247-13&P

0019

Installing Rubber Strip on the CBC - Continued.

NOTE
The purpose of the extra rubber stripping is to fill the gaps where rubber stripping is missing from where the zee bracket (Figure 9, Item 6) stops on the outside edge of the CBC (Figure 9, Item 1) and the front and rear of the CBC (Figure 9, Item 1). Be sure to place the stripping under the CBC edge as to fill any voids between the zee brackets (Figure 9, Item 6) on the side of the CBC (Figure 9, Item 1) and the front and rear of the CBC (Figure 9, Item 1). 4. At the four corners of the CBC (Figure 9, Item 1), an eight-inch piece of rubber strip (3/8 inch thick x 1 inch wide) will be applied to the CBC where the rubber stripping ends on the zee bracket (Figure 9, Item 6). Extend the stripping 2 inches beyond the end of the CBC (Figure 9, Item 1) for proper insulation. 2 3/8 IN 1 4 5

6 3

Figure 9. CBC Rubber Strip Installation. END OF TASK 0019-9

TM 10-5411-247-13&P IDENTIFYING GAPS BETWEEN THE CBC AND THE VEHICLE BED

0019

NOTE
Once the CBC is in its final mounting position on the vehicle bed, the rubber strip seal must be inspected in order to detect any gaps that may exist between the rubber strip on the underside of the mounting plate (Figure 10, Item 1) and the vehicle bed (Figure 10, Item 2). These gaps are typically caused by dents and other irregularities in the surface of the vehicle bed. 1. Inspect the quality of the rubber strip seal by using a flashlight and walk around the outside of the CBC at vehicle bed level. 2. Shine the light where the rubber strip and vehicle bed meet. 3. Use chalk, masking tape, or other temporary marking instrument to mark those areas of the CBC where gaps can be seen. 4. Inspect the quality of the rubber strip seal at the front of the CBC, it will be necessary to enter the CBC and conduct the inspection from the inside. 5. Estimate the width of each gap area in order to determine how much rubber strip is required to properly fill the gap. 6. Make a note of the thickness required with chalk or on a piece of masking tape placed in the area of the gap.

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (full- raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Whenever lifting the CBC off the ground have guide personnel using guide lines to prevent the CBC from swinging eratically. Injury or death to the operator or observers could occurr if guide lines are not used. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death. Personnel attaching the lifting sling to the lift rings or working on the roof of the CBC should use ladders or wear approved safety lines or both to prevent falls; injury or death could occur if proper safety equipment is not used.

NOTE
Note that in some cases it may be necessary to use some combination of both sizes of rubber strip in order to properly close the gap. 7. Once the gaps have been identified and marked, raise the CBC using the hoisting sling to a comfortable working height and lower onto blocking. 8. Add rubber strip (3/8 inch thick x 1 inch wide) to the areas marked in the previous step. 9. Lower the CBC back into position on the vehicle bed. 10. Inspect the quality of the seal using the method described above. If any gaps are still seen, mark the areas and apply additional layers of rubber strip as required. 0019-10

TM 10-5411-247-13&P Identifying Gaps Between the CBC and the Vehicle Bed - Continued.

0019

11. Add a second complete layer of rubber strip (3/8 inch thick x 1 inch wide) over the first layer (3/8 inch thick x 1 inch wide). 12. Continue this process until minimal gaps of 1/8 inch or less are present. 13. Once all rubber stripping has been installed, RTV adhesive must applied to the underside of the installed rubber stripping as detailed in the next paragraph.

1 MAX GAP BETWEEN CBC AND VEHICLE BED SHOULD NOT EXCEED 1/8 INCH

Figure 10. Identifying Gaps Between the CBC and the Vehicle Bed. END OF TASK

0019-11

TM 10-5411-247-13&P APPLYING RTV ADHESIVE TO THE RUBBER STRIP SURFACE

0019

WARNING

Do not stand inside or directly under the CBC while applying the RTV adhesive. Standing under a suspended CBC may result in injury should the hoisting sling fail to support the CBC. Failure to adhere to this warning may result in injury or death.

NOTE
RTV adhesive should be applied only when the CBC is to be immediately mounted to the vehicle bed. The RTV adhesive has a working time of approximately 20 minutes and will start to cure after that time. Installing the CBC on the vehicle after the RTV adhesive begins to cure may adversely affect the RTV adhesives ability to properly bond with the vehicle bed. 1. Once all rubber stripping has been applied as detailed in the previous section, a bead of RTV (silicone) RTV adhesive must be applied where the rubber stripping contacts the vehicle bed.

WARNING

RTV ADHESIVE, MIL-A-46146 RTV Silicon Adhesive is irritating to eyes and skin and shall be used only in a well-ventilated area. Do not induce vomiting if ingested obtain medical attention. Flammable above 200 F (93.3 C). Gloves and safety goggles should be worn during use. 2. Apply the RTV adhesive by raising the CBC to a comfortable working height using the hoisting sling. 3. Install the supplied cartridge of RTV adhesive into a standard caulking gun. Trim the tip of the cartridge so that a bead approximately 3/16 to 1/4 inch in width can be applied. 4. Apply a continuous bead of RTV adhesive 3/16 to 1/4 inch in width on the surface of the rubber stripping along the outer edge. 5. Start at one point on the underside of the CBC and move around the entire perimeter of the CBC applying RTV adhesive to all rubber strip surfaces. 6. Once RTV adhesive has properly applied to all rubber strip surfaces, the CBC should be lowered into position on the vehicle bed as described in the next section. END OF TASK

0019-12

TM 10-5411-247-13&P SECURING THE CBC TO THE VEHICLE BED

0019

NOTE
Use the hoisting sling to position the CBC on the vehicle bed so that all 19 holes in the carrier mounting angles align with the blind rivet nuts that were installed earlier. 1. Apply anti-seize lubricant to bolt and screw threads before installation to prevent galling 2. Bolt the CBC to the vehicle bed at the 12 locations (Locations marked C in Figure 12) using one 1/4-28 UNF x 1.00 inch long hex head bolt (Figure 11, Item 1), flat washer (Figure 11, Item 3), and lockwasher (Figure 11, Item 2) per hole. The flat washer is placed so that it contacts the mounting angle (Figure 11, Item 4) surface attaching front and rear walls or zee plate (Figure 11, Item 7) attaching the side walls. The lockwasher (Figure 11, Item 2) is placed under the head of the bolt (Figure 11, Item 1). 3. At the four hole locations in the carrier mounting angles on either side of the threshold (Locations marked B in Figure 12), install one 1/4-28 UNF x 1.25 inch hex head bolt, flat washer, and lockwasher per hole. Install the bolts as described above. 4. In the remaining three hole locations on the threshold (Locations marked A in Figure 12), install three pan head screws (Figure 11, Item 5) with lockwasher (Figure 11, Item 6) placed under its head. 5. Tighten all fasteners securely.

5 2 1 3 6

1 2 3 7

Figure 11. CBC Fastener Installation.

0019-13

TM 10-5411-247-13&P Securing the CBC to the Vehicle Bed - Continued.

0019

VEHICLE CAB

C C C

C C

M35A2 TRUCK BED

CENTER LINE OF CBC AND VEHICLE BED

NOTE: THE LETTERS A, B, AND C ON THE ILLUSTRATION DENOTE THE DIFFERENT SIZE HARDWARE TO BE USED IN SECURING THE CBC TO THE VEHICLE BED. REFER TO THE PRECEDING TEXT FOR ADDITIONAL DETAIL.

CARGO BED COVER BOTTOM ASSEMBLY

C C B A B

C C

Figure 12. CBC Fastener Size Locations. END OF TASK

0019-14

TM 10-5411-247-13&P APPLYING RTV ADHESIVE TO THE THRESHOLD

0019

1. Once the CBC has been lowered into position and secured to the vehicle bed, RTV adhesive must be applied around the threshold area (Figure 13, Item 2) at the rear of the CBC.

WARNING

RTV ADHESIVE, MIL-A-46146 RTV Adhesive is irritating to eyes and skin and shall be used only in a well-ventilated area. Do not induce vomiting if ingested obtain medical attention. Flammable above 200 F (93.3 C). Gloves and safety goggles should be worn during use. 2. Apply RTV adhesive around the threshold area by starting at the left corner (Figure 13, Item 1) of the CBC and inject RTV adhesive (Figure 13, Item 4) under the area where the threshold (Figure 13, Item 2) meets the vehicle bed (Figure 13, Item 3). 3. Fill the area sufficiently to create a good weather seal. 4. Continue to apply a bead of RTV adhesive all along the edge of the threshold (Figure 13, Item 2) at the point where it meets the vehicle bed (Figure 13, Item 3). 5. Apply RTV adhesive around the hinge pivot pin area (Figure 13, Item 7). Continue around the right corner (Figure 13, Item 5) of the CBC. 6. Inject RTV adhesive under the right side of the threshold (Figure 13, Item 6) as was done with the left corner. 7. Add a continuous bead of RTV adhesive around the entire base CBC and the vehicle bed. This will help prevent leakage into the CBC. 1 2

4 3

5 2 6 3

7 END OF TASK

Figure 13. RTV Adhesive Application.

0019-15

TM 10-5411-247-13&P INSTALL LADDER

0019

The M35A2, 2-1/2 Ton Cargo Truck may already come with a ladder installed on to the tailgate. If the ladder is already, installed no installation of a ladder is needed. If the M35A2, 2-1/2 Ton Cargo Truck does not come with a ladder installed on the tailgate one will need to be installed for access to the CBC. Refer to WP 0022 for instructions for the installation of the ladder. END OF TASK END OF WORK PACKAGE

0019-16

TM 10-5411-247-13&P

0020

FIELD MAINTENANCE MOUNTING KIT FOR M1078, 2-1/2 TON LMTV INSTALLATION SERVICE UPON RECEIPT

INITIAL SETUP: Equipment Condition Vehicle bed clean and free of debris. CBC unpacked as detailed in WP 0018 and positioned on pallet near the vehicle. Mounting Kit unpacked and hardware organized (WP 0018). Side panels and tailgate removed (TM 9-2330-39413&P). Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Dispenser, RTV adhesive (WP 0055, Table 2, Item 2) Lifting Device (1 Ton minimum) Gloves (WP 0057, Table 1, Item 12) Goggles (WP 0055, Table 2, Item 12) References WP 0005 Materials/Parts Anti-seize Lubricant (WP 0057, Table 1, Item 5) Adhesive, RTV-732 (WP 0057, Table 1, Item 1) Bag, Sand (WP 0057, Table 1, Item 6) Four Wood Support Blocks 4x4 12 inches long (WP 0057, Table 1, Item 29) Rubber strip, 3/8 inch thk x 1.00 inch wide x 25 feet long, adhesive backed, color black, closed cell, epdm sponge rubber strip. (WP 0057, Table 1, Item 20) Masking Tape, Masking (1 inch wide) (WP 0057, Item 26) Personnel Required Operator (1) Light-Wheel Vehicle Mechanic (91B) (1) Crane Operator (21F) (1)

GENERAL Before the CBC can be installed on the bed of the M1078, 2-1/2 Ton LMTV, the bed surface should be cleaned of any foreign matter or other debris that would interfere with the installation process. A mounting kit must be installed to the truck bed that will allow the CBC to be secured to the vehicle. The lift rings should always be pointed to the inside of trailer bed for operation when CBC is mounted. Unless it is already in an extended position, once the CBC has been separated from its shipping pallet and prepared for installation as outlined in the REMOVING THE CARGO BED COVER FROM ITS WRAPPING AND SHIPPING PALLET paragraph of WP 0018, it must be extended to its operational position as outlined in WP 0005 paragraph EXTENDING THE CARGO BED COVER TO AN OPERATIONAL POSITION.

0020-1

TM 10-5411-247-13&P INSTALLING RUBBER STRIP ON THE CBC

0020

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Whenever lifting the CBC off the ground, have guide personnel using guide lines to prevent the CBC from swinging eratically. Injury or death to the operator or observers could occur if guide lines are not used. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death. Personnel attaching the lifting sling to the lift rings or working on the roof of the CBC should use ladders or wear approved safety lines or both to prevent falls; injury or death could occur if proper safety equipment is not used.

NOTE
After verifying that the CBC (Figure 1, Item 1) has been raised to an operational position, the CBC must be lifted approximately eight inches and placed on supporting blocks (Figure 1, Item 8) in order to gain access to the lower edge of the CBC for the installation of the rubber strip. A hoisting sling must be attached to lift the CBC in accordance with WP 0005. When initially positioning the blocks, it is best to place them first at the front and rear ends to allow access to the left and right sides of the CBC and then to move them to the left and right sides to gain access to the front and rear ends. Once the CBC has been safely blocked, the rubber strip can be installed. The thickness of rubber strip is 3/8 inch and supplied in rolls of 25 feet. 1. On the zee brackets (Figure 1, Item 6) on the left and right side of the CBC, install the rubber strip (3/8 inch thick x 1 inch wide) (Figure 1, Item 3) on the inside edge by removing the protective paper (Figure 1, Item 4) backing and pressing the adhesive side of the rubber strip (3/8 inch thick x 1 inch wide) (Figure 1, Item 3) in place on the zee bracket (Figure 1, Item 6). 2. In order to apply the rubber strip (Figure 1, Item 3) around the entire perimeter of the CBC (Figure 1, Item 1), it will be necessary to lift the CBC (Figure 1, Item 1) and reposition the blocks (Figure 1, Item 7).

NOTE
Do NOT apply the rubber strip (Figure 1, Item 3) to the bottom of the carrier mounting angles (Figure 1, Item 2). 3. On the front and rear of the CBC (Figure 1, Item 1), install the rubber strip (3/8 inch thick x 1 inch wide) (Figure 1, Item 3) where the threshold and outer CBC edge meet by removing the protective paper (Figure 1, Item 4) backing and pressing the adhesive side rubber strip (3/8 inch thick x 1 inch wide) (Figure 1, Item 3) in place. Rubber stripping is NOT applied to the carrier mounting angles (Figure 1, Item 2) at the front of the CBC.

0020-2

TM 10-5411-247-13&P

0020

Installing Rubber Strip on the CBC - Continued.

NOTE
The purpose of the extra rubber stripping is to fill the gaps where rubber stripping is missing from where the zee bracket (Figure 1, Item 6) stops on the outside edge of the CBC (Figure 1, Item 1) and the front and rear of the CBC (Figure 1, Item 1). Be sure to place the stripping under the CBC edge as to fill any voids between the zee brackets (Figure 1, Item 6) on the side of the CBC (Figure 1, Item 1) and the front and rear of the CBC (Figure 1, Item 1). 4. At the four corners of the CBC (Figure 1, Item 1), an eight-inch piece of rubber strip (3/8 inch thick x 1 inch wide) will be applied to the CBC where the rubber stripping ends on the zee bracket (Figure 1, Item 6). Extend the stripping 2 inches beyond the end of the CBC (Figure 1, Item 1) for proper insulation. 2 3/8 IN 1 4 5

6 3

Figure 1. CBC Rubber Strip Installation. END OF TASK 0020-3

TM 10-5411-247-13&P INSTALLING RUBBER STRIP TO THE MOUNTING PLATE COMPONENTS NOTE When laying the side plates along the sides of the CBC, place the holes towards the middle of the CBC.

0020

1. There are four components to the mounting plate assembly, a front section (Figure 2, Item 1), rear section (Figure 2, Item 2), left side (Figure 2, Item 3), and right side (Figure 2, Item 4). Lay the four mounting plate pieces out on the bed of the truck oriented as shown in Figure 3. 2. Slide plates to be placed so edge are flush and holes align with the front and rear plates. 3. Using one of the side plates as a straight edge, stand it on edge over the traced outline. If a space caused by bed unevenness exceeds 3/4 inch, the truck bed must be repaired before the CBC can be properly mounted onto the truck. 4. Any place where the unevenness is between 3/8 inch and 3/4 inch, a double layer of rubber stripping must be applied in that area. NOTE Rubber stripping must go on the side of the mounting plate that has contact with the vehicle. 5. Rubber strip must be installed on the side of each mounting plate component as shown in Figure 2. Rubber strip is also applied on the ends of each side plate (Figure 2, Items 3 and 4) where the plates will eventually butt against the front (Figure 2, Item 1) and rear sections (Figure 2, Item 2). 6. Install the rubber strip (Figure 2, Item 5) to the mounting plate components as shown in figure 2. Remember that this will be the side of the mounting plate that will contact the vehicle bed once it is installed on the CBC and secured to the vehicle. 7. Remove the protective backing (Figure 2, Item 6) from the rubber strip (Figure 2, Item 5). 8. Apply the adhesive side of the rubber strip on the mounting plate component as illustrated. An outline on the mounting plate shows where the rubber strip is to be applied. Sections of rubber strip should be cut and applied at a right angle whenever the rubber strip changes direction. 9. Continue applying the rubber strip (Figure 2, Item 5) until it has been applied to all mounting plate components. 10. Press all rubber strips firmly in place. 11. Apply two sections of rubber stripping approximately four inches in length to cover extra holes (Figure 2, Items 7 and 8). Ensure that the rubber strips are centered over the holes when applied.

0020-4

TM 10-5411-247-13&P Installing the Rubber Strip on the Mounting Plate Components - Continued. 5 FRONT OF VEHICLE 5

0020

3 4 CURB SIDE MOUNTING PLATE ROAD SIDE MOUNTING PLATE

MOUNTING KIT IS VIEWED AS IF THE CBC WAS SITTING ON ITS ROOF

REAR OF VEHICLE 8 5 7 Figure 2. CBC Layout Orientation. END OF TASK

0020-5

TM 10-5411-247-13&P INSTALLING THE FRONT MOUNTING PLATE SECTION

0020

NOTE
The mounting plate assembly mounts to the carrier mounting angles in the front of the CBC and the zee brackets on the sides of the CBC. The individual sections are secured to the carrier mounting angles using carriage bolts, pan head screws, flat washers, lockwashers, and nuts supplied with the mounting plate installation kit Before installing the front and rear mounting plate sections, be sure that the supporting blocks are located under the sidewalls of the CBC and are approximately 25 inches from the corners. This will provide adequate room to install the front and rear sections. 1. Install the front mounting plate section (Figure 3, Item 2) to the CBC (Figure 3, Item 1), position the section under the front carrier-mounting angle (Figure 3, Item 6) of the CBC so that the face of the mounting plate section with the applied rubber strip faces DOWN and toward the vehicle bed. 2. Press the mounting plate (Figure 3, Item 2) up into position and align the holes (Figure 3, Item 8) on the mounting plate with the holes (Figure 3, Item 9) on the carrier mounting angles (Figure 3, Item 6). 3. Have a second person hold the mounting plate section (Figure 3, Item 2) securely in position against the carrier mounting angle. 4. Secure the mounting plate to the carrier mounting angle (Figure 3, Item 6) using four 5/16-18 UNC x 1 inch long carriage bolts (Figure 3, Item 7), four lockwashers (Figure 3, Item 5), four flat washers (Figure 3, Item 4), and four 5/16-UNC hex nuts (Figure 3, Item 3). 5. Secure the zee bracket on each side of the CBC to the front mounting plate using four 5/16-18 UNC x 1 inch long carriage bolts (Figure 3, Item 7), four lockwashers (Figure 3, Item 5), four flat washers (Figure 3, Item 4), and four 5/16-UNC hex nuts (Figure 3, Item 3) . 6. Do not tighten securely at this time. 2 1 3 4 5

9 8 7

Figure 3. Installing the Front Mounting Plate Section. END OF TASK

0020-6

TM 10-5411-247-13&P INSTALLING THE REAR MOUNTING PLATE SECTION NOTE The threaded insert on the rear mounting plate will go against the CBC threshold.

0020

1. Position the mounting plate (Figure 4, Item 18) under the threshold (Figure 4, Item 10) of the CBC so that the face of the mounting plate section with the applied rubber strip faces DOWN and toward the vehicle bed. The threshold is the area on either side of the personnel door opening. 2. Press the mounting plate (Figure 4, Item 18) up into position and align the holes on the mounting plate with the holes in the threshold (Figure 4, Item 10). 3. Align the holes at the ends of the rear mounting plate with the holes on the side wall carrier mounting angle sections nearest the corners of the CBC. 4. Have a second person hold the mounting plate section in position. 5. Install a total of four 5/16-18 UNC x 1 1/4 inch long carriage bolts (Figure 4, Item 12) up through the mounting plate and the holes in the CBC threshold on either side of the personnel door opening. 6. Install one 5/16-inch flat washer (Figure 4, Item 13) over the end of the bolt and against the surface of the threshold (Figure 4, Item 10) followed by a 5/16-inch lockwasher (Figure 4, Item 14) and 5/16-UNC hex nut (Figure 4, Item 15). 7. Install four 5/16-18 UNC x 1 inch long carriage bolts (Figure 4, Item 12) up through the ends of the rear mounting plate (Figure 4, Item 18) and the holes in the CBC threshold along the sidewalls nearest the corners. 8. Install four 5/16-inch flat washer (Figure 4, Item 13) over the end of the bolt and against the surface of the threshold followed by four 5/16-inch lockwasher (Figure 4, Item 14) and four 5/16-UNC hex nut (Figure 4, Item 15) over each of the four 5/16-18 UNC x 1 inch long carriage bolts (Figure 4, Item 12). 9. Install three 5/16-18 UNC x 0.63 inch long pan head screws (Figure 4, Item 16) DOWN through the section of the CBC threshold at the door opening and into threaded inserts (Figure 4, Item 11) mounted in the mounting plate with a 5/16-inch lockwasher (Figure 4, Item 17) under each head. 10. Do not tighten securely at this time. END OF TASK

0020-7

TM 10-5411-247-13&P INSTALLING THE ROAD SIDE MOUNTING PLATE SECTION

0020

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death.

NOTE
Before installing the road side and curb side mounting plate sections, be sure that the supporting blocks are located under the front and rear of the CBC. Do not put the blocks under the personnel door (lower) when placing the blocks under the front of the CBC. This will provide adequate room to install the front and rear sections. 1. Before installing the side mounting plate sections (Figure 4, Items 19 and 9), to the CBC, position the sections so that the face of the mounting plate section with the applied rubber strip faces down and is toward the outside edge.

NOTE
The holes for the side mounting plate sections may be partially obscured by the rubber strip installed earlier. To install the carriage bolt properly, move the rubber strip aside slightly to gain access to the hole. Install the carriage bolt so that it seats properly against the mounting plate. Make sure that the square portion under the head of the bolt fits into the square hole of the mounting plate. Reposition the rubber strip over the head of the carriage bolt. 2. Install the road side mounting plate section (Figure 4, Item 19) in the same fashion as for the front (Figure 4, Item 8) and rear section (Figure 4, Item 18) sections detailed above. Be sure to butt the ends (Figure 4, Item 20) of the side section with the additional sections of rubber strip against the end of the front section (Figure 4, Item 8) and rear section (Figure 4, Item 18). 3. Press the road side mounting plate section (Figure 4, Item 19) up into position and align the holes (Figure 4, Item 6) on the mounting plate with the holes (Figure 4, Item 5) on the carrier mounting angles (Figure 4, Item 2). 4. Have a second person hold the road side mounting plate section (Figure 4, Item 19) in position. 5. Install a total of four 5/16-18 UNC x 1 inch long carriage bolts (Figure 4, Item 7) up through the mounting plate (Figure 4, Item 19) and the CBC carrier mounting angle (Figure 4, Item 2). 6. Install one 5/16-inch flat washer (Figure 4, Item 4) over the end of the bolt and against the surface of the carrier mounting angle (Figure 4, Item 2) followed by a 5/16-inch lockwasher (Figure 4, Item 3) and 5/16-UNC hex nut (Figure 4, Item 1) for each of the remaining bolts. 7. Do not tighten securely at this time. END OF TASK

0020-8

TM 10-5411-247-13&P INSTALLING THE CURB SIDE MOUNTING PLATE SECTION 1. Install the right side mounting plate section (Figure 4, Item 9) in the same fashion as for the left mounting plate section (Figure 4, Item 19) detailed previously. 2. Press the right side mounting plate section (Figure 4, Item 9) up into position. 3. Align the holes (Figure 4, Item 9) on the mounting plate with the holes (Figure 4, Item 5) on the carrier mounting angles (Figure 4, Item 2). 4. Have a second person hold the right side mounting plate section (Figure 4, Item 9) in position.

0020

5. Install a total of four 5/16-18 UNC x 1 inch long carriage bolts (Figure 4, Item 7) up through the mounting plate and the CBC carrier mounting angle (Figure 4, Item 2). 6. Install one 5/16-inch flat washer (Figure 4, Item 4) over the end of the bolt (Figure 4, Item 7) and against the surface of the carrier-mounting angle (Figure 4, Item 2) followed by a 5/16-inch lockwasher (Figure 4, Item 3) and 5/16-inch UNC hex nut (Figure 4, Item 1) for each of the remaining bolts. 7. Once all four sections of the mounting plate assembly have been installed, tighten all hardware securely. END OF TASK

0020-9

TM 10-5411-247-13&P Installing the Mounting Plate to the CBC - Continued.

0020

3 3 4 4 20 5 7 19 8 7 6

9 18

15 14 16 13 17

12

11 10

Figure 4. Installing Rear, Road Side, and Curb Side Mounting Plate Sections. END OF TASK

0020-10

TM 10-5411-247-13&P INSTALLING TIE-DOWN POST ASSEMBLIES

0020

NOTE
In order to mount the tie-down post assemblies to the mounting plate assembly, the supporting blocks used to raise the CBC/mounting plate combination must be selected to raise the CBC at least 8-1/2 inches in order to allow adequate clearance for the installation of the tie-down post assemblies. In order to ensure that the tie-down rings are free to be used, place them so that they are at a more inboard position prior to mounting the CBC to the mounting bed. 1. Four tie-down post assemblies (Figure 5, Item 8) are installed at the four corners of the mounting plate assembly (Figure 5, Item 4). These tie-down post assemblies will later be lowered into holes (Figure 5, Item 5) on the vehicle bed (Figure 5, Item 6) and help to secure the CBC and Mounting Plate combination to the vehicle bed. 2. Install the rear tie-down post assemblies (Figure 5, Item 8). 3. Locate the tie-down post mounting holes (Figure 5, Item 11) located at the corners of the rear mounting plate sections. Be sure to use the holes nearest the CBC when installing the rear tie-down post assemblies. 4. Position one tie-down post spacer plate (Figure 5, Item 7) under one corner of the mounting plate. 5. Align the mounting holes (Figure 5, Item 10) in the spacer plate with the rear mounting holes (Figure 5, Item 11) in the mounting plate. 6. Position one tie-down post assembly (Figure 5, Item 8) in position under and against the spacer plate (Figure 5, Item 7) positioned above. 7. Align all mounting holes. 8. Install two 5/16-inch (0.328 inch ID x 1.375 inch OD x 0.063 inch thick) flat washers (Figure 5, Item 3), followed by 5/16-inch lockwasher (Figure 5, Item 2) and 5/16-inch UNC x 1 3/4 inch long hex head screw (Figure 5, Item 1) down through the mounting plate (Figure 5, Item 4), spacer plate (Figure 5, Item 7), and into the tie-down post assembly (Figure 5, Item 8). 9. Repeat for the second mounting hole. 10. Hand tighten the screws into the rivnuts (Figure 5, Item 9) installed in the tie-down post assembly (Figure 5, Item 8). 11. Do not tighten the screws securely at this time. The screw installation holes are oversized slightly to allow the tie-down posts to move slightly. 12. Install the other rear tie-down post assembly. 13. Install the two front tie-down post assemblies in the corners of the front mounting plate assembly in similar fashion.

002011

TM 10-5411-247-13&P Installing the Tie-down Post Assemblies - Continued.

0020

2 3 11

4 10

6 5

Figure 5. Tie-Down Post Assembly Installation. END OF TASK

002012

TM 10-5411-247-13&P INITIAL INSTALLATION OF CLAMP PLATE CHANNEL

0020

NOTE
Before the CBC and mounting plate combination are mounted on the vehicle bed, the clamp plate channel must be installed. A clamp plate channel is installed on either side of the mounting plate and helps to secure the CBC/mounting plate combination to the vehicle bed. 1. Install the initial portion of the clamp plate assembly by positioning one clamp plate assembly spacer plate (Figure 6, Item 9) on the underside of the extension (Figure 6, Item 2) that extends from the side of the rear mounting plate section (Figure 6, Item 1). 2. Position the spacer plate (Figure 6, Item 8) with the countersunk hole side facing down. 3. Align the holes in the spacer plate (Figure 6, Item 8) with the router holes in the mounting plate extension (Figure 6, Item 2). 4. Position the clamp plate channel (Figure 6, Item 7) on the top surface of the mounting plate extension (Figure 6, Item 2). 5. Align the holes in the clamp plate channel (Figure 6, Item 7) with the holes in the mounting plate extension (Figure 6, Item 2). 6. Hold the spacer plate (Figure 6, Item 8) and clamp plate channel (Figure 6, Item 7) in position on the mounting plate extension (Figure 6, Item 2). 7. Install a 5/16-24 UNF x 1.28 inch long flat head screw (Figure 6, Item 9) up through the spacer plate (Figure 6, Item 8), mounting plate extension (Figure 6, Item 2), and exiting the top of the clamp plate channel (Figure 6, Item 7). 8. Secure the screw (Figure 6, Item 9) with one 5/16-inch flat washer (Figure 6, Item 6), and 5/16-inch UNF hex locknut (Figure 6, Item 5). 9. Install the remaining flat head screw and associated hardware. 10. Install two 5/16-18 UNC carriage bolts (Figure 6, Item 10), flat washer (Figure 6, Item 3), and, nut (Figure 6, Item 4) to the inside holes going through the mounting plate (Figure 6, Item 2). 11. Tighten all hardware securely. 12. Repeat for the opposite side of the CBC mounting plate.

4 2 3 5

10 9 Figure 6. Initial Installation of Clamp Plate Channel. END OF TASK 002013

TM 10-5411-247-13&P REMOVING THE PLUGS IN THE MTV BED

0020

NOTE
In order to ensure that the side carrier tie-down rings are free for operation, place them so that they are laying outboard on the vehicle bed. Before the CBC and mounting plate combination can be lowered into the pockets located on the vehicle bed, the protective plugs in the bed must be removed. 1. Remove the plugs (Figure 7, Item 3) in the vehicle bed (Figure 7, Item 1) by reaching under the bed. 2. Pull the retaining pin (Figure 7, Item 2) that secures the plug in place. 3. Push the plug (Figure 7, Item 3) down and through the vehicle bed pocket (Figure 7, Item 5). 4. Push the plugs in the remaining three holes through the vehicle bed (Figure 7, Item 1). 5. Ensure that all debris has been removed from the vehicle bed pocket (Figure 7, Item 5) prior to mounting the CBC. 6. The plugs are attached to the vehicle bed with a wire rope tether (Figure 7, Item 4). The plugs will be secured to the base of the tie-down post assembly in a later step. 1

4 3

Figure 7. MTV Bed Plug Removal. END OF TASK

0020-14

TM 10-5411-247-13&P LOWERING THE CBC ONTO THE VEHICLE BED

0020

1. Once the mounting plate assembly (Figure 8, Item 3) has been completely installed on the bottom of the CBC (Figure 8, Item 2), the CBC (Figure 8, Item 2) can be carefully lowered onto the vehicle bed (Figure 8, Item 5).

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Whenever lifting the CBC off the ground have guide personnel using guide lines to prevent the CBC from swinging eratically. Injury or death to the operator or observers could occurr if guide lines are not used. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death. Personnel attaching the lifting sling to the lift rings or working on the roof of the CBC should use ladders or wear approved safety lines or both to prevent falls; injury or death could occur if proper safety equipment is not used.

NOTE
It is important to ensure that the CBC and mounting plate combination is level when lowered into position on the vehicle bed or the Tie-down post assemblies may bind as they are lowered into the vehicle bed pockets. Since the weight of the CBC is not distributed evenly, the CBC may tilt toward the rear when lifted with the hoisting sling. To compensate for this condition and to ensure that the CBC is level, additional weight such as two 50 pound sandbags or other weight should be placed toward the front edge of the roof. Guide ropes may be attached to the lift rings on the four corners of the CBC to help keep the CBC straight and level when lowering the CBC on to the vehicle bed. 2. Secure the CBC (Figure 8, Item 2) and mounting plate combination to the vehicle bed of the LMTV by lifting the CBC (currently supported by blocks), using the hoisting sling (Figure 8, Item 1). 3. Slowly lower it into position on the vehicle bed (Figure 8, Item 5) of the LMTV. Be sure that the CBC (Figure 8, Item 2) is level as it is suspended in the air. 4. Align the four tie-down post assemblies (Figure 8, Item 4) into the four corresponding pockets (Figure 8, Item 6) in the vehicle bed (Figure 8, Item 5). 5. Once all four Tie-down posts (Figure 8, Item 4) are engaged in the pockets (Figure 8, Item 6) in the vehicle bed (Figure 8, Item 5), lower the CBC (Figure 8, Item 2) all the way to the surface of the vehicle bed. 6. DO NOT SECURE THE TIE-DOWN POST ASSEMBLIES AT THIS TIME.

002015

TM 10-5411-247-13&P Lowering the CBC Onto the Vehicle Bed - Continued.

0020

SANDBAGS OR OTHER WEIGHT MAY BE USED ALONG THE FRONT EDGE OF THE CBC ROOF IN ORDER TO LEVEL THE UNIT DURING LIFTING AND LOWERING.

Figure 8. Lowering the CBC onto the Vehicle Bed. END OF TASK

0020-16

TM 10-5411-247-13&P IDENTIFYING GAPS BETWEEN THE CBC AND THE VEHICLE BED

0020

NOTE
Once the CBC is in its final mounting position on the vehicle bed, the rubber strip seal must be inspected in order to detect any gaps that may exist between the rubber strip on the underside of the mounting plate (Figure 9, Item 1) and the vehicle bed (Figure 9, Item 2). These gaps are typically caused by dents and other irregularities in the surface of the vehicle bed. 1. Inspect the quality of the rubber strip seal by using a flashlight and walk around the outside of the CBC at vehicle bed level. 2. Shine the light where the rubber strip and vehicle bed meet. 3. Use chalk, masking tape, or other temporary marking instrument to mark those areas of the CBC where gaps can be seen. 4. Inspect the quality of the rubber strip seal at the front of the CBC, it will be necessary to enter the CBC and conduct the inspection from the inside. 5. Estimate the width of each gap area in order to determine how much rubber strip is required to properly fill the gap. 6. Make a note of the thickness required with chalk or on a piece of masking tape placed in the area of the gap.

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Whenever lifting the CBC off the ground have guide personnel using guide lines to prevent the CBC from swinging eratically. Injury or death to the operator or observers could occurr if guide lines are not used. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death. Personnel attaching the lifting sling to the lift rings or working on the roof of the CBC should use ladders or wear approved safety lines or both to prevent falls; injury or death could occur if proper safety equipment is not used.

NOTE
Note that in some cases it may be necessary to use some combination of both sizes of rubber strip in order to properly close the gap. 7. Once the gaps have been identified and marked, raise the CBC using the hoisting sling to a comfortable working height and lower onto blocking. 8. Add rubber strip (3/8 inch thick x 1 inch wide) to the areas marked in the previous step. 9. Lower the CBC back into position on the vehicle bed. 10. Inspect the quality of the seal using the method described above. If any gaps are still seen, mark the areas and apply additional layers of rubber strip as required.

0020-17

TM 10-5411-247-13&P Identifying Gaps Between the CBC and the Vehicle Bed - Continued.

0020

11. Add a second complete layer of rubber strip (3/8 inch thick x 1 inch wide) over the first layer (3/8 inch thick x 1 inch wide). 12. Continue this process until minimal gaps of 1/8 inch or less are present. 13. Once all rubber stripping has been installed, RTV adhesive must applied to the underside of the installed rubber stripping as detailed in the next paragraph.

MAX GAP BETWEEN CBC AND VEHICLE BED SHOULD NOT EXCEED 1/8 INCH

Figure 9. Identifying Gaps Between the CBC and the Vehicle Bed. END OF TASK

0020-18

TM 10-5411-247-13&P APPLYING RTV SILICONE ADHESIVE

0020

NOTE
RTV adhesive should be applied only if the CBC is to be immediately mounted to the vehicle bed. The RTV adhesive has a working time of approximately 20 minutes and will start to cure after that time. Installing the CBC on the vehicle after the RTV adhesive begins to cure may adversely affect the RTV adhesives ability to properly bond with the vehicle bed. 1. Once all gaps have been identified and eliminated as described previously, a bead of RTV (silicone) RTV adhesive must be applied where the rubber strip contacts the vehicle bed and around the threshold area.

WARNING

RTV ADHESIVE, MIL-A-46146 RTV Silicon Adhesive is irritating to eyes and skin and shall be used only in a well-ventilated area. Do not induce vomiting if ingested obtain medical attention. Flammable above 200 F (93.3 C). Gloves and safety goggles should be worn during use. 2. Apply the RTV adhesive by raising the CBC to a comfortable working height using the hoisting sling and blocking. 3. Install the supplied cartridge of RTV adhesive into a standard caulking gun. 4. Trim the tip of the cartridge so that a bead approximately 3/16 to 1/4 inch in width can be applied. 5. Apply a continuous bead of RTV adhesive (Figure 10, Item 1) 3/16 to 1/4 inch in width on the surface of the rubber strip (Figure 10, Item 2) along the outer edge. 6. Start at one point at the underside of the CBC. 7. Move around the entire perimeter of the CBC applying RTV adhesive to all rubber strip surfaces. 8. Once RTV adhesive has properly applied to all rubber strip surfaces, the CBC should be lowered into position on the vehicle bed.

Figure 10. Applying RTV Silicone Adhesive.

0020-19

TM 10-5411-247-13&P Applying RTV Silicone Adhesive - Continued.

0020

9. Once the CBC has been lowered into position on the vehicle bed, RTV adhesive must be applied around the threshold area (Figure 11, Item 1) at the rear of the CBC. 10. Apply RTV adhesive around the threshold area by starting at the left corner (Figure 11, Item 2) of the CBC and inject RTV adhesive (Figure 11, Item 3) under the area where the threshold (Figure 11, Item 1) meets the mounting plate (Figure 11, Item 4). 11. Fill the area sufficiently to create a good weather seal. 12. Continue to apply a bead of RTV adhesive all along the edge of the threshold (Figure 11, Item 1) at the point where it meets the mounting plate (Figure 11, Item 4). 13. Apply RTV adhesive around the hinge pivot pin area (Figure 11, Item 5). 14. Continue around the right corner (Figure 11, Item 6) of the CBC and inject RTV adhesive under the right side of the threshold (Figure 11, Item 7) as was done with the left corner. 15. Apply RTV adhesive at joints between side mounting bracket, front and rear bracket. 16. Add a continuous bead of RTV adhesive around the entire base CBC and the vehicle bed. This will help prevent leakage into the CBC. 2 1

3 1 6

4 Figure 11. RTV Adhesive Application after Lowering CBC into Place. END OF TASK 0020-20

TM 10-5411-247-13&P SECURING THE TIE-DOWN POST ASSEMBLIES

0020

1. Secure the tie-down post assemblies by tightening the two bolts (Figure 12, Item 1) located at the top of each Tie-down post assembly (Figure 12, Item 3). 2. Install one bottom plate (Figure 12, Item 4) to the bottom of a tie-down post assembly (Figure 12, Item 3) from the underside of the vehicle bed (Figure 12, Item 9). 3. Place the vehicle bed plug (Figure 12, Item 5) over the bottom plate (Figure 12, Item 4). 4. Align the hole in the plug with the hole in the bottom plate (this is done simply to secure the plug). 5. Secure the plug (Figure 12, Item 5) and bottom plate (Figure 12, Item 4) to the base of the tie-down post (Figure 12, Item 3) using one 3/8 inch flat washer (Figure 12, Item 8),one 3/8 inch lockwasher (Figure 12, Item 7), and 3/8-16 UNC x 2 inch long bolt (Figure 12, Item 6). 6. Tighten securely. 7. Repeat for the remaining tie-down post assemblies. 8. Install the pin (Figure 12, Item 2) that previously secured the vehicle bed plugs into the side of the tie-down post assemblies. 1

3 9 4 8 7 6 Figure 12. Securing the Tie-Down Post Assemblies. END OF TASK 5

0020-21

TM 10-5411-247-13&P FINAL INSTALLATION OF CLAMP PLATE ASSEMBLIES

0020

NOTE
Clamp-plate assemblies (Figure 13, Item 5) are installed on either side of the mounting-plate assembly (Figure 13, Item 2). Work in conjunction with the tie-down post assemblies to secure the CBC/mounting plate combination to the vehicle bed. A hinge used to install the side wall of the vehicle may need to be removed in order to install the clamp plate assembly. 1. Install two 1/2-13 UNC x 4.5 inch hex head bolts (Figure 13, Item 3) through the holes in the clamp plate channel (Figure 13, Item 1).

NOTE
The rubber pad on the spacer block (Figure 13, Item 4) faces up when installing. 2. Install a spacer block (Figure 13, Item 4) and clamp plate assembly (Figure 13, Item 5) onto the bolts (Figure 13, Item 3) and secure with 1/2 inch flat washer (Figure 13, Item 6) and 1/2-13 UNC hex locknut (Figure 13, Item 7). 3. Ensure that the side of the clamp plate assembly (Figure 13, Item 5) with the rubber pad (Figure 13, Item 8) engages securely on the underside of the truck bed (Figure 13, Item 9). 4. Repeat for the second clamp plate assembly located on the opposite side of the CBC. 5. Tighten all clamp plate assembly hardware securely.

2 3

8 5 9

6 7

Figure 13. Final Installation of Clamp Plate Assemblies. END OF TASK END OF WORK PACKAGE 0020-22

TM 10-5411-247-13&P

0021

FIELD MAINTENANCE MOUNTING KIT FOR M1082, 2-1/2 TON LMTV TRAILER INSTALLATION SERVICE UPON RECEIPT

INITIAL SETUP: Equipment Condition Trailer bed clean and free of debris. CBC unpacked as detailed in WP 0018 and positioned on pallet near the trailer. Mounting Kit unpacked and hardware organized (WP 0018). Side panels and tailgate removed (TM 9-2330-39413&P). Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Dispenser, RTV adhesive (WP 0055, Table 2, Item 2) Lifting Device (1 Ton minimum) Gloves (WP 0057, Table 1, Item 12) Goggles (WP 0055, Table 2, Item 12) References WP 0005 WP 0017 WP 0018 WP 0057 Materials/Parts Anti-seize Lubricant (WP 0057, Table 1, Item 5) Adhesive, RTV-732 (WP 0057, Table 1, Item 1) Bag, Sand (WP 0057, Table 1, Item 6) Four Wood Support Blocks 4x4 12 inches long (WP 0057, Table 1, Item 29) Sandpaper (WP 0057, Table 1, Item 21) Rubber strip, 3/8 inch thk x 1.00 inch wide x 25 feet long, adhesive backed, color black, closed cell, epdm sponge rubber strip. (WP 0057, Table 1, Item 20) Masking Tape, Masking (1 inch wide) (WP 0057, Item 26) Personnel Required Operator (1) Light-Wheel Vehicle Mechanic (91B) (1) Crane Operator (21F) (1)

GENERAL Before the CBC can be installed on the bed of the M1082, 2-1/2 Ton LMTV Trailer, the bed surface should be cleaned of any foreign matter or other debris that would interfere with the installation process. A mounting kit must be installed to the trailer that will allow the CBC to be secured to the trailer. The lift rings should always be pointed to the inside of trailer bed for operation when CBC is mounted. Unless it is already in an extended position, once the CBC has been separated from its shipping pallet and prepared for installation as outlined in the REMOVING THE CARGO BED COVER FROM ITS WRAPPING AND SHIPPING PALLET paragraph of WP 0018, it must be extended to its operational position as outlined in WP 0005 paragraph EXTENDING THE CARGO BED COVER TO AN OPERATIONAL POSITION.

0021-1

TM 10-5411-247-13&P INSTALLING RUBBER STRIP ON THE CBC

0021

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Whenever lifting the CBC off the ground have guide personnel using guide lines to prevent the CBC from swinging eratically. Injury or death to the operator or observers could occur if guide lines are not used. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death. Personnel attaching the lifting sling to the lift rings or working on the roof of the CBC should use ladders or wear approved safety lines or both to prevent falls; injury or death could occur if proper safety equipment is not used.

NOTE
After verifying that the CBC (Figure 1, Item 1) has been raised to an operational position, the CBC must be lifted approximately eight inches and placed on supporting blocks (Figure 1, Item 8) in order to gain access to the lower edge of the CBC for the installation of the rubber strip. A hoisting sling must be attached to lift the CBC in accordance with WP 0005. When initially positioning the blocks, it is best to place them first at the front and rear ends to allow access to the left and right sides of the CBC and then to move them to the left and right sides to gain access to the front and rear ends. Once the CBC has been safely blocked, the rubber strip can be installed. The thickness of rubber strip is 3/8 inch and supplied in rolls of 25 feet. 1. On the zee brackets (Figure 1, Item 6) on the left and right side of the CBC, install the rubber strip (3/8 inch thick x 1 inch wide) (Figure 1, Item 3) on the inside edge by removing the protective paper (Figure 1, Item 4) backing and pressing the adhesive side of the rubber strip (3/8 inch thick x 1 inch wide) (Figure 1, Item 3) in place on the zee bracket (Figure 1, Item 6). 2. In order to apply the rubber strip (Figure 1, Item 3) around the entire perimeter of the CBC (Figure 1, Item 1), it will be necessary to lift the CBC (Figure 1, Item 1) and reposition the blocks (Figure 1, Item 7).

NOTE
Do NOT apply the rubber strip (Figure 1, Item 3) to the bottom of the carrier mounting angles (Figure 1, Item 2). 3. On the front and rear of the CBC (Figure 1, Item 1), install the rubber strip (3/8 inch thick x 1 inch wide) (Figure 1, Item 3) where the threshold and outer CBC edge meet by removing the protective paper (Figure 1, Item 4) backing and pressing the adhesive side rubber strip (3/8 inch thick x 1 inch wide) (Figure 1, Item 3) in place. Rubber stripping is NOT applied to the carrier mounting angles (Figure 1, Item 2) at the front of the CBC.

0021-2

TM 10-5411-247-13&P

0021

Installing Rubber Strip on the CBC - Continued.

NOTE
The purpose of the extra rubber stripping is to fill the gaps where rubber stripping is missing from where the zee bracket (Figure 1, Item 6) stops on the outside edge of the CBC (Figure 1, Item 1) and the front and rear of the CBC (Figure 1, Item 1). Be sure to place the stripping under the CBC edge as to fill any voids between the zee brackets (Figure 1, Item 6) on the side of the CBC (Figure 1, Item 1) and the front and rear of the CBC (Figure 1, Item 1). 4. At the four corners of the CBC (Figure 1, Item 1), an eight- inch piece of rubber strip (3/8 inch thick x 1 inch wide) will be applied to the CBC where the rubber stripping ends on the zee bracket (Figure 1, Item 6). Extend the stripping 2 inches beyond the end of the CBC (Figure 1, Item 1) for proper insulation. 2 3/8 IN 1 4 5

6 3

Figure 1. CBC Rubber Strip Installation. END OF TASK

0021-3

TM 10-5411-247-13&P INSTALLING RUBBER STRIP TO THE MOUNTING PLATE COMPONENTS NOTE When laying the side plates along the sides of the CBC, place the holes towards the middle of the CBC.

0021

1. There are four components to the mounting plate assembly, a front section (Figure 2, Item 1), rear section (Figure 2, Item 2), left side (Figure 2, Item 3), and right side (Figure 2, Item 4). Lay the four mounting plate pieces out on the bed of the trailer oriented as shown in Figure 3. 2. Slide plates to be placed so edge are flush and holes align with the front and rear plates. 3. Using one of the side plates as a straight edge, stand it on edge over the traced outline. If a space caused by bed unevenness exceeds 3/4 inch, the trailer bed must be repaired before the CBC can be properly mounted onto the trailer. 4. Any place where the unevenness is between 3/8 inch and 3/4 inch, a double layer of rubber stripping must be applied in that area. NOTE Rubber stripping must go on the side of the mounting plate that has contact with the trailer. 5. Rubber strip must be installed on the side of each mounting plate component as shown in Figure 2. Rubber strip is also applied on the ends of each side plate (Figure 2, Items 3 and 4) where the plates will eventually butt against the front (Figure 2, Item 1) and rear sections (Figure 2, Item 2). 6. Install the rubber strip (Figure 2, Item 5) to the mounting plate components as shown in figure 2. Remember that this will be the side of the mounting plate that will contact the trailer bed once it is installed on the CBC and secured to the trailer. 7. Remove the protective backing (Figure 2, Item 6) from the rubber strip (Figure 2, Item 5). 8. Apply the adhesive side of the rubber strip on the mounting plate component as illustrated. An outline on the mounting plate shows where the rubber strip is to be applied. Sections of rubber strip should be cut and applied at a right angle whenever the rubber strip changes direction. 9. Continue applying the rubber strip (Figure 2, Item 5) until it has been applied to all mounting plate components. 10. Press all rubber strips firmly in place. 11. Apply two sections of rubber stripping approximately four inches in length to cover extra holes (Figure 2, Items 7 and 8). Ensure that the rubber strips are centered over the holes when applied.

0021-4

TM 10-5411-247-13&P Installing Rubber Strip to the Mounting Plate Components - Continued. 1

0021

(CURB SIDE)

FRONT OF TRAILER

7 6 MOUNTING KIT IS VIEWED AS IF THE 2 CBC WAS SITTING ON ITS ROOF 7 5

7 (ROAD SIDE) 3

REAR OF TRAILER

4 Figure 2. Rubber Strip Installation for Mounting Components. END OF TASK

0021-5

TM 10-5411-247-13&P MOUNT GUSSET PLATES TO FRONT MOUNTING PLATE

0021

1. Once the rubber strip has been applied to the underside of all four mounting plates, flip all four plates over on the work surface so that the rubber strip applied earlier now faces down on the work surface.

NOTE
Flat side of gusset plates face toward outside of trailer. 2. Align the spacer plate (Figure 3, Item 6) with the front mounting plate (Figure 3, Item 4). 3. Install three 1.03-inch countersink screws (Figure 3, Item 5). 4. Install the left gusset plate (Figure 3, Item 1) and attach it using 5/16-inch flat washers (Figure 3, Item 3) and 5/16-UNC locknut (Figure 3, Item 2). 5. Repeat this procedure for installing the curb side gusset plate. 6. Tighten all hardware securely.

2 3

5 6

Figure 3. Mounting Gusset Plates to Front Mounting Plate. END OF TASK

0021-6

TM 10-5411-247-13&P INSTALLING THE FRONT MOUNTING PLATE SECTION

0021

NOTE
The mounting plate assembly mounts to the carrier mounting angles in the front of the CBC and the zee brackets on the sides of the CBC. The individual sections are secured to the carrier mounting angles using carriage bolts, pan head screws, flat washers, lockwashers, and nuts supplied with the mounting plate installation kit Before installing the front and rear mounting plate sections, be sure that the supporting blocks are located under the sidewalls of the CBC and are approximately 25 inches from the corners. This will provide adequate room to install the front and rear sections. 1. Install the front mounting plate section (Figure 4, Item 2) to the CBC (Figure 4, Item 1), position the section under the front carrier-mounting angle (Figure 4, Item 6) of the CBC so that the face of the mounting plate section with the applied rubber strip faces DOWN and toward the trailer bed. 2. Press the mounting plate (Figure 4, Item 2) up into position and align the holes (Figure 4, Item 8) on the mounting plate with the holes (Figure 4, Item 9) on the carrier mounting angles (Figure 4, Item 6). 3. Have a second person hold the mounting plate section (Figure 4, Item 2) securely in position against the carrier mounting angle. 4. Secure the mounting plate to the carrier mounting angle (Figure 4, Item 6) using four 5/16-18 UNC x 1 inch long carriage bolts (Figure 4, Item 7), four lockwashers (Figure 4, Item 5), four flat washers (Figure 4, Item 4), and four 5/16-UNC hex nuts (Figure 4, Item 3). 5. Secure the zee bracket on each side of the CBC to the front mounting plate using four 5/16-18 UNC x 1 inch long carriage bolts (Figure 4, Item 7), four lockwashers (Figure 4, Item 5), four flat washers (Figure 4, Item 4), and four 5/16-UNC hex nuts (Figure 4, Item 3) . 6. Do not tighten securely at this time. 2 3 4 5 1 6

9 8 7

Figure 4. Installing the Front Mounting Plate Section.

END OF TASK 0021-7

TM 10-5411-247-13&P INSTALLING THE REAR MOUNTING PLATE SECTION NOTE The threaded insert on the rear mounting plate will go against the CBC threshold.

0021

1. Position the mounting plate (Figure 5, Item 18) under the threshold (Figure 5, Item 10) of the CBC so that the face of the mounting plate section with the applied rubber strip faces DOWN and toward the trailer bed. The threshold is the area on either side of the personnel door opening. 2. Press the mounting plate (Figure 5, Item 18) up into position and align the holes on the mounting plate with the holes in the threshold (Figure 5, Item 10). 3. Align the holes at the ends of the rear mounting plate with the holes on the side wall carrier mounting angle sections nearest the corners of the CBC. 4. Have a second person hold the mounting plate section in position. 5. Install a total of four 5/16-18 UNC x 1 1/4 inch long carriage bolts (Figure 5, Item 12) up through the mounting plate and the holes in the CBC threshold on either side of the personnel door opening. 6. Install one 5/16-inch flat washer (Figure 5, Item 13) over the end of the bolt and against the surface of the threshold (Figure 4, Item 10) followed by a 5/16-inch lockwasher (Figure 5, Item 14) and 5/16-UNC hex nut (Figure 5, Item 15). 7. Install four 5/16-18 UNC x 1 inch long carriage bolts (Figure 5, Item 12) up through the ends of the rear mounting plate (Figure 5, Item 18) and the holes in the CBC threshold along the sidewalls nearest the corners. 8. Install four 5/16-inch flat washer (Figure 5, Item 13) over the end of the bolt and against the surface of the threshold followed by four 5/16-inch lockwasher (Figure 5, Item 14) and four 5/16-UNC hex nut (Figure 5, Item 15) over each of the four 5/16-18 UNC x 1 inch long carriage bolts (Figure 5, Item 12). 9. Install three 5/16-18 UNC x 0.63 inch long pan head screws (Figure 5, Item 16) DOWN through the section of the CBC threshold at the door opening and into threaded inserts (Figure 5, Item 11) mounted in the mounting plate with a 5/16-inch lockwasher (Figure 5, Item 17) under each head. 10. Do not tighten securely at this time. END OF TASK

0021-8

TM 10-5411-247-13&P INSTALLING THE ROAD SIDE MOUNTING PLATE SECTION

0021

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death.

NOTE
Before installing the road side and curb side mounting plate sections, be sure that the supporting blocks are located under the front and rear of the CBC Do not put the blocks under the personnel door (lower) when placing the blocks under the front of the CBC. This will provide adequate room to install the front and rear sections. 1. Before installing the side mounting plate sections (Figure 5, Items 19 and 9) to the CBC, position the sections so that the face of the mounting plate section with the applied rubber strip faces down and is toward the outside edge.

NOTE
The holes for the side mounting plate sections may be partially obscured by the rubber strip installed earlier. To install the carriage bolt properly, move the rubber strip aside slightly to gain access to the hole. Install the carriage bolt so that it seats properly against the mounting plate. Make sure that the square portion under the head of the bolt fits into the square hole of the mounting plate. Reposition the rubber strip over the head of the carriage bolt. 2. Install the road side mounting plate section (Figure 5, Item 19) in the same fashion as for the front (Figure 5, Item 8) and rear section (Figure 5, Item 18) sections detailed above. Be sure to butt the ends (Figure 5, Item 20) of the side section with the additional sections of rubber strip against the end of the front section (Figure 5, Item 8) and rear section (Figure 5, Item 18). 3. Press the road side mounting plate section (Figure 5, Item 19) up into position and align the holes (Figure 5, Item 6) on the mounting plate with the holes (Figure 5, Item 5) on the carrier mounting angles (Figure 5, Item 2). 4. Have a second person hold the road side mounting plate section (Figure 5, Item 19) in position. 5. Install a total of four 5/16-18 UNC x 1 inch long carriage bolts (Figure 5, Item 7) up through the mounting plate (Figure 5, Item 19) and the CBC carrier mounting angle (Figure 5, Item 2). 6. Install one 5/16-inch flat washer (Figure 5, Item 4) over the end of the bolt and against the surface of the carrier mounting angle (Figure 5, Item 2) followed by a 5/16-inch lockwasher (Figure 5, Item 3) and 5/16-UNC hex nut (Figure 5, Item 1) for each of the remaining bolts. 7. Do not tighten securely at this time. END OF TASK

0021-9

TM 10-5411-247-13&P INSTALLING THE CURB SIDE MOUNTING PLATE SECTION 1. Install the right side mounting plate section (Figure 5, Item 9) in the same fashion as for the left mounting plate section (Figure 5, Item 19) detailed previously. 2. Press the right side mounting plate section (Figure 5, Item 9) up into position. 3. Align the holes (Figure 5, Item 9) on the mounting plate with the holes (Figure 5, Item 5) on the carrier mounting angles (Figure 5, Item 2). 4. Have a second person hold the right side mounting plate section (Figure 5, Item 9) in position.

0021

5. Install a total of four 5/16-18 UNC x 1 inch long carriage bolts (Figure 5, Item 7) up through the mounting plate and the CBC carrier mounting angle (Figure 5, Item 2). 6. Install one 5/16-inch flat washer (Figure 5, Item 4) over the end of the bolt (Figure 5, Item 7) and against the surface of the carrier-mounting angle (Figure 5, Item 2) followed by a 5/16-inch lockwasher (Figure 5, Item 3) and 5/16-inch UNC hex nut (Figure 5, Item 1) for each of the remaining bolts. 7. Once all four sections of the mounting plate assembly have been installed, tighten all hardware securely.

0021-10

TM 10-5411-247-13&P Installing the Mounting Plates to the CBC - Continued.

0021

2 1 1 3 4 3

7 20 19 7 8 9 6 4 5

18

16 15 17 13

14

12

11 10 Figure 5. Rear, Road Side, and Curb Side Mounting Plates. END OF TASK

0021-11

TM 10-5411-247-13&P INITIAL INSTALLATION OF CLAMP PLATE CHANNEL

0021

NOTE
Before the CBC and mounting plate combination are mounted to the trailer bed, the clamp plate channel must be installed to guide the CBC on to the trailer bed during installation. 1. Position the spacer plate (Figure 6, Item 10), with the countersunk hole side facing down underside, under the mounting plate extension (Figure 6, Item 1) that extends from the side of the rear mounting plate section. 2. Align the holes in the spacer plate (Figure 6, Item 10) with the router holes away from the shelter in the mounting plate extension (Figure 6, Item 1). 3. Position the clamp plate channel (Figure 6, Item 4) on the top surface of the mounting plate extension (Figure 6, Item 1). 4. Align the four holes in the clamp plate channel (Figure 6, Item 4) with the four holes in the mounting plate extension (Figure 6, Item 1). 5. Install a 5/16-24 UNF x 1.28 inch long flat head screw (Figure 6, Item 9) up through the spacer plate (Figure 6, Item 10), mounting plate extension (Figure 6, Item 1), and exiting the top of the clamp plate channel (Figure 6, Item 4). 6. Secure the screw (Figure 6, Item 9) with one 5/16-inch flat washer (Figure 6, Item 3), and 5/16-inch UNF hex locknut (Figure 6, Item 2). 7. Install the remaining three flat head screws (Figure 6, Item 9) and associated hardware. 8. Install two 1/2-13 UNC x 4.5 inch long carriage bolts (Figure 6, Item 5) through the top of the mounting plate extension (Figure 6, Item 1) and clamp plate channel (Figure 6, Item 4). 9. Slide a spacer (Figure 6, Item 6) over the two 1/2-13 UNC x 4.5 inch long carriage bolts (Figure 6, Item 5). 10. Attach flat washers (Figure 6, Item 9) and two nuts (Figure 6, Item 9) to the two 1/2-13 UNC x 4.5 inch long carriage bolts (Figure 6, Item 9). Do not tighten. 11. Repeat for the other clamp plate channel location.

2 3 1 4 5 6 7 9 8

10

Figure 6. Initial Installation of Clamp Plate Channel. END OF TASK

0021-12

TM 10-5411-247-13&P LOWERING THE CBC ONTO THE TRAILER BED

0021

1. Once the mounting plate assembly has been completely installed on the bottom of the CBC (Figure 7, Item 10), the CBC (Figure 7, Item 10) can be carefully lowered onto the trailer bed (Figure 7, Item 2).

WARNING

Do not lift the CBC in its height-retracted (lowered) condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Whenever lifting the CBC off the ground, have guide personnel using guide lines to prevent the CBC from swinging eratically. Injury or death to the operator or observers could occurr if guide lines are not used. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death. Personnel attaching the lifting sling to the lift rings or working on the roof of the CBC should use ladders or wear approved safety lines or both to prevent falls; injury or death could occur if proper safety equipment is not used. 2. Secure the CBC (Figure 7, Item 2) and mounting plate combination to the trailer bed (Figure 7, Item 3) of the trailer by lifting the CBC (Figure 7, Item 2) (currently supported by blocks), using the hoisting sling (Figure 7, Item 1). 3. Slowly lower it into position on the bed of the trailer (Figure 7, Item 3). 4. Lower the CBC (Figure 7, Item 2) and mounting plate combination until it is just above the surface of the trailer bed (Figure 7, Item 3).

NOTE
The clamp plate assemblies will be on the mounting kit to allow the CBC (Figure 7, Item 2) to align with the bed of the trailer (Figure 7, Item 3) when being lowered onto the bed of the trailer. 5. Lower the CBC (Figure 7, Item 10) until it completely rests on the trailer bed (Figure 7, Item 2). 6. Ensure there are no gaps between the gusset plate (Figure 7, Item 3) and the vertical trailer support (Figure 7, Item 6). DO NOT TIGHTEN THE HARDWARE SECURELY AT THIS TIME.

0021-13

TM 10-5411-247-13&P Lowering the CBC onto the Trailer Bed - Continued.

0021

Figure 7. Lowering the CBC onto the Trailer Bed. END OF TASK IDENTIFYING GAPS BETWEEN THE CBC AND THE TRAILER BED

NOTE
Once the CBC is in its final mounting position on the trailer bed, the rubber strip seal must be inspected in order to detect any gaps that may exist between the rubber strip on the underside of the mounting plate (Figure 10, Item 1) and the trailer bed (Figure 10, Item 2). These gaps are typically caused by dents and other irregularities in the surface of the trailer bed. 1. Inspect the quality of the rubber strip seal by using a flashlight and walk around the outside of the CBC at trailer bed level. 2. Shine the light where the rubber strip and trailer bed meet. 3. Use chalk, masking tape, or other temporary marking instrument to mark those areas of the CBC where gaps can be seen. 4. Inspect the quality of the rubber strip seal at the front of the CBC, it will be necessary to enter the CBC and conduct the inspection from the inside. 5. Estimate the width of each gap area in order to determine how much rubber strip is required to properly fill the gap. 6. Make a note of the thickness required with chalk or on a piece of masking tape placed in the area of the gap.

0021-14

TM 10-5411-247-13&P Identifying Gaps Between The CBC and the Trailer Bed - Continued.

0021

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Whenever lifting the CBC off the ground have guide personnel using guide lines to prevent the CBC from swinging eratically. Injury or death to the operator or observers could occurr if guide lines are not used. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death. Personnel attaching the lifting sling to the lift rings or working on the roof of the CBC should use ladders or wear approved safety lines or both to prevent falls; injury or death could occur if proper safety equipment is not used.

NOTE
Note that in some cases it may be necessary to use some combination of both sizes of rubber strip in order to properly close the gap. 7. Once the gaps have been identified and marked, raise the CBC using the hoisting sling to a comfortable working height and lower onto blocking. 8. Add rubber strip (3/8 inch thick x 1 inch wide) to the areas marked in the previous step. 9. Lower the CBC back into position on the trailer bed. 10. Inspect the quality of the seal using the method described above. If any gaps are still seen, mark the areas, and apply additional layers of rubber strip as required. 11. Add a second complete layer of rubber strip (3/8 inch thick x 1 inch wide) over the first layer (3/8 inch thick x 1 inch wide). 12. Continue this process until minimal gaps of 1/8 inch or less are present. 13. Once all rubber stripping has been installed, RTV adhesive must applied to the underside of the installed rubber stripping as detailed in the next paragraph.

0021-15

TM 10-5411-247-13&P Identifying Gaps Between the CBC and the Trailer Bed - Continued.

0021

GAP BETWEEN CBC AND TRAILERBED SHOULD NOT BE GREATER THAN 1/8 INCH 1

Figure 8. Identifying Gaps Between the CBC and the Trailer Bed. END OF TASK

0021-16

TM 10-5411-247-13&P APPLYING RTV SILICONE ADHESIVE, FINAL ASSEMBLY OF GUSSET PLATES

0021

WARNING

RTV ADHESIVE, MIL-A-46146 RTV Silicon Adhesive is irritating to eyes and skin and shall be used only in a well-ventilated area. Do not induce vomiting if ingested obtain medical attention. Flammable above 200 F (93.3 C). Gloves and safety goggles should be worn during use.

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Whenever lifting the CBC off the ground have guide personnel using guide lines to prevent the CBC from swinging eratically. Injury or death to the operator or observers could occurr if guide lines are not used. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death.

NOTE
RTV adhesive should be applied only if the CBC is to be immediately mounted to the trailer bed. The RTV adhesive has a working time of approximately 20 minutes and will start to cure after that time. Installing the CBC on the trailer after the RTV adhesive begins to cure may adversely affect the RTV adhesives ability to properly bond with the trailer bed. Once all gaps have been identified and eliminated as described above, a bead of RTV (silicone) RTV adhesive must be applied where the rubber strip contacts the trailer bed and around the threshold area. 1. Install the supplied cartridge of RTV adhesive into a standard caulking gun. 2. Trim the tip of the cartridge so that a bead approximately 3/16 to 1/4 inch in width can be applied. 3. Apply a generous amount of RTV adhesive, (WP 0057, Table 1, Item 1) to underside of the forward wall of the CBC. 4. Raise the CBC in position over the trailer bed.

0021-17

TM 10-5411-247-13&P

0021

Applying RTV Silicone Adhesive, Final Assembly of Gusset Plates - Continued.

NOTE
Take care to return the CBC to the same position so that the holes in the gusset plates align with the slotted hole in the vertical trailer support and that the flat portion of the gusset plate contacts the vertical trailer support. 5. Lower the CBC to approximately six inches over the trailer bed. Place support blocks under the side walls of the CBC. 6. Lower the CBC onto the support blocks. 7. Apply a continuous bead of RTV adhesive, (WP 0057, Table 1, Item 1) (Figure 9, Item 1) 3/16 to 1/4 inch in width on the surface of the rubber strip (Figure 9, Item 2) along the outer edge. Start at one point at the underside of the CBC. Move around the entire perimeter of the CBC applying RTV adhesive to all rubber strip surfaces. 8. Raise CBC and remove the support blocks. 9. Apply a continuous bead of RTV adhesive, (WP 0057, Table 1, Item 1) to sections where the support blocks were positioned.

NOTE
Take care to return the CBC in the same position so that the holes in the gusset plates align with the slotted hole in the vertical trailer support and that the flat portion of the gusset plate contacts the vertical trailer support. 10. Once RTV adhesive has been properly applied to all rubber strip surfaces, the CBC should be lowered into position on the trailer bed. 11. Install one 7-inch bolt (Figure 9, Item 3) and flat washer (Figure 9, Item 8) through both slotted holes (Figure 9, Item 6) in the vertical trailer support (Figure 9, Item 7). 12. Install a flat washer (Figure 9, Item 8) and locknut (Figure 9, Item 9) on the end of the 7-inch bolt (Figure 9, Item 3). 13. Tighten the hardware on each gusset plate securely. 7 6 8 2 6 8

3 4 1 5

Figure 9. RTV Adhesive Application for the CBC Gusset Plates.

0021-18

TM 10-5411-247-13&P Applying RTV Silicone Adhesive, Final Assembly of Gusset Plates - Continued.

0021

NOTE
RTV adhesive must now be applied around the threshold area (Figure 10, Item 1) at the rear of the CBC. 14. Apply RTV adhesive around the threshold area, start at the left corner (Figure 10, Item 2) of the CBC and inject RTV adhesive (Figure 10, Item 3) under the area where the threshold (Figure 10, Item 1) meets the mounting plate (Figure 10, Item 4). 15. Fill the area sufficiently to create a good weather seal. 16. Continue to apply a bead of RTV adhesive all along the edge of the threshold (Figure 10, Item 1) at the point where it meets the mounting plate (Figure 10, Item 4). Be sure to apply RTV adhesive around the hinge pivot pin area (Figure 10, Item 7). 17. Continue around the right corner (Figure 10, Item 6) of the CBC. 18. Inject RTV adhesive under the right side of the threshold (Figure 10, Item 5) as was done with the left corner. 19. Apply RTV adhesive to four mounting plate joints. 20. Add a continuous bead of RTV around the entire base CBC and the trailer bed. This will help prevent leakage into the CBC.

0021-19

TM 10-5411-247-13&P Applying RTV Silicone Adhesive, Final Assembly of Gusset Plates - Continued.

0021

4 5

6 4

Figure 10. RTV Adhesive Application for the CBC Threshold Area. END OF TASK

0021-20

TM 10-5411-247-13&P FINAL INSTALLATION OF CLAMP PLATE ASSEMBLY

0021

NOTE
Two clamp plate assemblies (Figure 11, Item 7) (one on each side) are installed at the corners of the rear mounting plate assembly (Figure 11, Item 6) and are used to secure the CBC (Figure 11, Item 1) to the trailer bed (Figure 11, Item 8). The spacer on the mounting kit will already be in place to align the CBC on to the bed of the trailer during installation. 1. Remove two 1/2 inch flat washer (Figure 11, Item 5) and 1/2-13 UNC locknut (Figure 11, Item 4) from the bottom of the spacer (Figure 11, Item 2). 2. Make sure that the rubber pad on the bottom plate (Figure 11, Item 3) faces up and engages securely on the underside of the trailer bed (Figure 11, Item 8). 3. Secure the assembly with 1/2 inch flat washer (Figure 11, Item 5) and 1/2-13 UNC locknut (Figure 11, Item 4). 4. 5. Tighten the clamp plate assembly (Figure 11, Item 7) hardware securely. Repeat the above procedure for the clamp plate assembly located on the rear road side of the CBC. 1

5 6 4 8 7 Figure 11. Final Installation of Clamp Plate Assembly. END OF TASK END OF WORK PACKAGE

0021-21/22 blank

TM 10-5411-247-13&P

0022

FIELD MAINTENANCE MOUNTING KIT FOR M35A2 2-1/2 TON CARGO TRUCK LADDER INSTALLATION SERVICE UPON RECEIPT

INITIAL SETUP: Equipment Condition Tailgate lowered; locked in a horizontal position. Vehicle chocked. Vehicle on level ground. Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Riveter, Blind, Hand (WP 0055, Table 2, Item 16) Drill Set, Twist (WP 0055, Table 2, Item 5) Drill (WP 0055, Table 2, Item 3) References WP 0038 Personnel Required Light-Wheel Vehicle Mechanic (91B) (1)

M35A2 2-1/2 TON CARGO TRUCK TAILGATE LADDER IN STOWED AND DEPLOYED POSITIONS

NOTE
The roadside of a vehicle is on a persons left when they are standing behind the rear of the vehicle and facing it. This installation only applies to the M35A2 2-1/2 Ton Cargo Truck. It is not required with the M1078 2-1/2 Ton LMTV or M1082 2-1/2 Ton LMTV Trailer. Before the CBC can be used, a ladder must be installed on the tailgate of the M35A2, 2-1/2 Ton Cargo Truck. The ladder is stowed on the inside, left-hand surface of the tailgate (while standing and facing the rear of the vehicle). In order to install the ladder (Figure 1, Item 3), a set of stowage brackets (Figure 1, Item 1) must be installed on the road side, inside surface of the tailgate (Figure 1, Item 5). Two strap assemblies (Figure 1, Item 4) are also installed on the inside surface of the tailgate (Figure 1, Item 5). The combination of stowage brackets (Figure 1, Item 1) and strap assemblies (Figure 1, Item 4) secure the ladder in its stowed position. A set of deployment brackets (Figure 1, Item 2) is installed toward the rear, right-hand edge of the tailgate (Figure 1, Item 5). These deployment brackets (Figure 1, Item 2) are used to support the ladder (Figure 1, Item 3) in its deployed condition. The installation process for the stowage brackets (Figure 1, Item 1), deployment brackets (Figure 1, Item 2), and strap assemblies (Figure 1, Item 4) involve measuring and locating a series of holes on the tailgate, drilling out these holes, installing threaded inserts, and mounting the various brackets and straps.

0022-1

TM 10-5411-247-13&P M35A2, 2-1/2 Ton Cargo Truck Tailgate Ladder in Stowed and Deployed Positions - Continued.

0022

TAILGATE 5

LADDER IN STOWED POSITION

LADDER IN DEPLOYED POSITION

Figure 1. M35A2 Tailgate Ladder in Stowed and Deployed Positions. LADDER INSTALLATION PROCEDURE Install the ladder hardware for the 2-1/2 Ton Cargo Truck by lowering the tailgate and locking it into a horizontal position. This creates a convenient and stable work surface for the installation process. END OF TASK Ladder Installation Kit Contents Table 1 lists the parts contained within the ladder installation kit. Verify that all parts are present and in the proper quantity. Arrange the parts on a convenient work surface near the tailgate of the vehicle. Table 1. Parts Listing Entry Ladder Kit for M35A2 (17-1-0315). ITEM NO. 1 2 3 4 5 6 7 8 PART NUMBER ASME 18.2.1 MS35338-139 17-1-0315-3 17-1-0315-5 S25B140 17-1-0315-4 17-1-0323-1 AN970-4 DESCRIPTION AND USABLE ON CODE SCREW, HEX HD (1/4-20 X .75 LG) ................................... WASHER, LOCK (1/4) .......................................................... BRACKET, ANGLE ............................................................... BRACKET, ANGLE ............................................................... NUT, PLAIN, BLIND RIVET (1/4-20) ................................... BRACKET, ANGLE ............................................................... LADDER, VEHICLE .............................................................. WASHER, FLAT (1/4) ........................................................... QTY 10 8 1 1 10 1 1 4

0022-2

TM 10-5411-247-13&P Ladder Installation Kit Contents - Continued. Table 1. Parts Listing Entry Ladder Kit for M35A2 (17-1-0315) - Continued. ITEM NO. 9 10 11 12 13 14 PART NUMBER 17-1-3618-1 17-1-0315-2 C-845-2528L 2521A622 2932A28 3374A25 DESCRIPTION AND USABLE ON CODE STRAP, HANDLE .................................................................................................... BRACKET, ANGLE .................................................................................................. RIVETER, BLIND, HAND (1/4-20) ........................................................................... HAND TAP (1/4-20) ................................................................................................. DRILL BIT (LET Q) .................................................................................................. 9/32 TRANSFER PUNCH ........................................................................................

0022

QTY 2 1 1 1 1 1

NOTE
Items listed in Table 1 and Figure 2 are included in the ladder installation kit and are required for installation. 2 1 3

10 5 5

9 8 4 7 1 14 12 13 1 2 11 5

Figure 2. Entry Ladder Kit for M35A2. 0022-3

TM 10-5411-247-13&P

0022

LADDER INSTALLATION - Continued. Tailgate Position References Throughout the procedures that follow, references will be made to the four edges of the tailgate. All positions are given from the perspective of a soldier standing and facing the rear of the vehicle with the tailgate down. The left, right, front, and rear edge of the tailgate are shown in the accompanying diagram (Figure 3). HINGED EDGE

LEFT EDGE

RIGHT EDGE

FRONT EDGE

Figure 3. Tailgate Position References. Mounting Ladder Stowage Brackets 1. Install the ladder stowage brackets required to stow the ladder by using a tape measure, and make a mark 14 inches in from the left edge (Figure 4) of the tailgate at its front edge (Figure 3).

Figure 4. Mounting Ladder Stowage Brackets 1.

0022-4

TM 10-5411-247-13&P

0022

LADDER INSTALLATION Mounting the Ladder Stowage Brackets - Continued. 2. At the 14-inch mark, draw a 2-inch vertical line from the front edge (Figure 5) of the tailgate toward the rear edge (Figure 3) of the tailgate.

Figure 5. Mounting Ladder Stowage Brackets 2. 3. Measure 1-1/2 inches from the front edge (Figure 3) of the tailgate along the 2-inch vertical line and make a mark (Figure 6).

Figure 6. Mounting Ladder Stowage Brackets 3. 4. Make a second mark approximately 3 inches to the right of the 1-1/2-inch mark and draw a line connecting the two marks with a straight edge (Figure 7).

INTERSECTION

Figure 7. Mounting Ladder Stowage Brackets 4.

0022-5

TM 10-5411-247-13&P

0022

LADDER INSTALLATION Mounting the Ladder Stowage Brackets - Continued. 5. Place the first bracket in position at the intersection point located 14 inches in from the left edge (Figure 3) and 1-1/2 inches from the front edge (Figure 3) of the tailgate (Figure 8). Be sure to select the larger stowage bracket as these brackets are different from the smaller deployment brackets. Position the bracket so that the mounting holes face the rear edge of the tailgate. Ensure that the opening on the bracket faces the left edge of the tailgate. Mark the position of the two holes in the first bracket.

Figure 8. Mounting Ladder Stowage Brackets 5. 6. Use a 9/32-inch transfer punch to mark the center of the two mounting holes (Figure 9).

Figure 9. Mounting Ladder Stowage Brackets 6.

WARNING

Safety goggles or face shield must be worn to protect eyes from flying metal chips. 7. Use a Letter Q size drill bit to drill out the two marked holes. Drill only through the inside surface of the tailgate (Figure 10). Do not drill completely through the opposite side of the tailgate. Remove any burrs.

Figure 10. Mounting Ladder Stowage Brackets 7.

0022-6

TM 10-5411-247-13&P

0022

LADDER INSTALLATION Mounting the Ladder Stowage Brackets - Continued. 8. Install a 1/4-20 blind rivet nut in each of the two mounting holes using a blind rivet nut installation tool included with the mounting kit. Complete instructions for blind rivet nut installation can be found in WP 0038. 9. Once all blind rivet nuts have been installed, mount the bracket to the tailgate using 1/4-20 x 0.75 inch long hex head screws and 1/4 inch lockwashers (Figure 11). Tighten all hardware securely.

Figure 11. Mounting Ladder Stowage Brackets 8. 10. With the tailgate in a horizontal position, attach the ladder to the installed first bracket (Figure 12). INSTALLED FIRST BRACKET

LADDER

Figure 12. Mounting Ladder Stowage Brackets 9. 11. Use the ladder as a template to attach the second uninstalled bracket to the opposite side of the ladder (i.e., opposite the installed bracket). Position the second uninstalled bracket so that the mounting holes face the first bracket and toward the front edge of the tailgate (Figure 13). Ensure that the opening on the bracket faces the left edge of the tailgate. Mark the position of the two holes in the second uninstalled bracket. Remove the ladder from the tailgate. UNINSTALLED SECOND BRACKET

INSTALLED FIRST BRACKET Figure 13. Mounting Ladder Stowage Brackets 10. 12. Repeat prior Steps 6 through 9 to complete installation of the second bracket. END OF TASK

0022-7

TM 10-5411-247-13&P

0022

Mounting Strap Assemblies for Ladder Stowage 1. Install the two strap assemblies used to stow the ladder by using a tape measure and make a mark 48-1/4 inches from the left edge (Figure 3) of the tailgate at its front edge (Figure 14).

48 1/4 in Figure 14. Mounting Strap Assemblies for Ladder Stowage 1. 2. Make a second mark 48-1/4 inches from the left edge (Figure 3), but approximately 15 inches back from the front edge (Figure 15).

15 in

48 1/4 in Figure 15. Mounting Strap Assemblies for Ladder Stowage 2. 3. Draw a line connecting the two marks with a straight edge (Figure 16).

Figure 16. Mounting Strap Assemblies for Ladder Stowage 3.

0022-8

TM 10-5411-247-13&P

0022

Mounting Strap Assemblies for Ladder Stowage - Continued. 4. Measure 3 inches from the front edge (Figure 3) of the tailgate. Mark this point on the drawn line (Figure 17).

Figure 17. Mounting Strap Assemblies for Ladder Stowage 4. 5. Measure 14 1/2 inches from the front edge (Figure 3) of the tailgate and mark a second point on the drawn line (Figure 18). These marked intersecting points define the attaching points of the two strap assemblies.

Figure 18. Mounting Strap Assemblies for Ladder Stowage 5. 6. Mark the center of each hole with the included transfer punch (Figure 19).

Figure 19. Mounting Strap Assemblies for Ladder Stowage 6.

0022-9

TM 10-5411-247-13&P

0022

Mounting Strap Assemblies for Ladder Stowage - Continued.

WARNING

Safety goggles or face shield must be worn to protect eyes from flying metal chips. 7. Use a Letter Q size drill bit to drill out the two marked holes (Figure 20). Remove any burrs.

Figure 20. Mounting Strap Assemblies for Ladder Stowage 7. 8. Install a 1/4-20 blind rivet nut in each mounting hole using the blind rivet nut installation tool included in the mounting kit. Install the blind rivet nut IAW instructions for blind rivet nut installation as detailed in WP 0038. 9. Once both blind rivet nuts have been installed, align the mating attachment holes and mount the two strap assemblies so that their buckles face away from the left edge (Figure 3) of the tailgate. Secure the strap assemblies to the tailgate using a 1/4-20 x 0.75 inch long hex head screws and two large (11/8 in OD)1/4 inch flat washers. One flat washer should be on each side of the strap assembly, one under the screw head and a second between the strap and the tailgate (Figure 21). Tighten all hardware securely.

Figure 21. Mounting Strap Assemblies for Ladder Stowage 8. END OF TASK

0022-10

TM 10-5411-247-13&P

0022

Mounting Ladder Deployment Brackets 1. Install the brackets required to deploy the ladder on the tailgate by using a tape measure and make a mark 14-inches (Figure 22) from the front edge (Figure 3) and along the right edge (Figure 3) of the tailgate.

Figure 22. Mounting Ladder Deployment Brackets 1. 2. At the 14 inch mark (Figure 23), draw a 3 inch horizontal line with a straight edge from the right edge (Figure 3) of the tailgate extending toward the left edge (Figure 3) of the tailgate.

Figure 23. Mounting Ladder Deployment Brackets 2. 3. Measure 1 inch in from the right edge of the tailgate. Mark this point on the drawn 3 inch line. Note that this point marks the outer corner of the first mounting bracket (Figure 24).

Figure 24. Mounting Ladder Deployment Brackets 3.

0022-11

TM 10-5411-247-13&P

0022

Mounting Ladder Deployment Brackets - Continued. 4. Place the first bracket in position so that its outer edge lies on the line 1 inch in from the right edge (Figure 3) of the tailgate. Be sure to use the smaller deployment bracket. The hooks on the bracket should face the hinge on the tailgate. Orient the mounting holes on the first bracket to face outward and toward the right edge (Figure 3) of the tailgate. Mark the position of the two holes in the first bracket (Figure 25).

Figure 25. Mounting Ladder Deployment Brackets 4. 5. Use the 9/32 inch transfer punch included with the mounting kit to mark the center of the two mounting holes (Figure 26). Be sure to get as close to the center as possible.

Figure 26. Mounting Ladder Deployment Brackets 5.

WARNING

Safety goggles or face shield must be worn to protect eyes from flying metal chips. 6. Use a Letter Q size drill bit to drill out the two marked holes (Figure 27). Remove any burrs.

Figure 27. Mounting Ladder Deployment Brackets 6.

0022-12

TM 10-5411-247-13&P

0022

Mounting Ladder Deployment Brackets - Continued. 7. Install a 1/4-20 blind rivet nut in each of the two mounting holes with a using a blind rivet nut installation tool. Install the blind rivet nut IAW the instructions for blind rivet nut installation found in WP 0038. 8. Once all blind rivet nuts have been installed, mount the bracket with the hooks facing the rear edge of the tailgate using a 1/4-20 x 0.75 inch long hex head screw and 1/4-inch lockwasher (Figure 28). Tighten all hardware securely.

Figure 28. Mounting Ladder Deployment Brackets 7. 9. With the tailgate in a down position, attach the ladder to the installed first bracket (Figure 29).

INSTALLED FIRST BRACKET

Figure 29. Mounting Ladder Deployment Brackets 8.

0022-13

TM 10-5411-247-13&P

0022

Mounting Ladder Deployment Brackets - Continued. 10. Use the ladder as a template to attach the second uninstalled bracket to the opposite side of the ladder (i.e., opposite the installed bracket). Position the second uninstalled bracket so that the mounting holes face away from the first bracket and toward the left edge of the tailgate. Mark the position of the two holes in the second bracket (Figure 30). Remove the ladder from the tailgate.

UNINSTALLED SECOND BRACKET

Figure 30. Mounting Ladder Deployment Brackets 9. 11. Repeat prior Steps 5 through 8 to complete installation of the second bracket. END OF TASK Deploying the Ladder 1. Lower the hinged tailgate (Figure 31, Item 4) into an approximate vertical position.

WARNING
Ensure the ladder is secure before stepping on it. Failure to do so could cause the ladder to fall and injure personnel stepping on it. Ensure the vehicle is on level ground and the wheels are chocked before deploying the ladder. Failure to do so could cause the ladder to disengage and cause injury to personnel using it. 2. The ladder (Figure 31, Item 1) mounts to the deployment brackets (Figure 31, Items 2 and 3) by engaging the hooks (Figure 31, Item 5) in the end of the ladder over the hooked portion of the deployment brackets (Figure 31, Items 2 and 3). 3. The grips (Figure 31, Item 6) at the bottom of the ladder (Figure 31, Item 1) are then allowed to rest on the ground.

0022-14

TM 10-5411-247-13&P

0022

Deploying the Ladder - Continued.

2 3

5 6

Figure 31. Ladder Deployment. END OF TASK Stowing the Ladder 1. Stow the ladder (Figure 32, Item 6) by lifting and removing it from the deployment brackets (Figure 32, Items 1 and 2). 2. Place the hooks (Figure 32, Item 7) at the end of the ladder over the stowage brackets (Figure 32, Items 4 and 5). 3. Secure with strap assemblies (Figure 32, Item 3). 4. Close the tailgate (Figure 32, Item 8).

0022-15

TM 10-5411-247-13&P

0022

Stowing the Ladder - Continued.

4 6 5 Figure 32. Ladder Stowage. END OF TASK END OF WORK PACKAGE

0022-16

TM 10-5411-247-13&P

0023

FIELD MAINTENANCE HANDLE, BAIL REPLACE

INITIAL SETUP: Equipment Condition CBC clean, dry, and free of debris. Tools and Special Tools General Mechanics Tool Kit (WP 0055 Table 2, Item 21) Gloves (WP 0057, Table 1, Item 12) Goggles (WP 0055, Table 2, Item 12) Personnel Required Light-Wheel Vehicle Mechanic (91B) (1) Materials/Parts Solvent, Methylethylketone (MEK) (WP 0057, Table 1, Item 24) Sealant, Type II MIL-S-8802 (WP 0057, Table1, Item 22)

REPLACE

WARNING

Methylethylketone (MEK) ASTM D-740 is flammable and toxic and shall be used only in a wellventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. Failure to observe this warning can lead to serious injury or death to personnel. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. Personnel need to maintain three points of contact when climbing onto and moving around on top of the CBC. Failure to follow this warning can lead to serious injury or death to personnel.

1. Remove any excess sealant around the four hex head screws (Figure 1, Item 1) and bail handle (Figure 1, Item 4) on the CBC using MEK. 2. Remove four screws (Figure 1, Item 1), four lockwashers (Figure 1, Item 2), and four flat washers (Figure 1, Item 3) that secure the bail handle (Figure 1, Item 4) to the roof of the CBC. Discard the lockwashers.

NOTE
There is no hardware installed in the center hole (Figure 1, Item 5) of the bail handle (Figure 1, Item 4). 3. Remove the defective bail handle (Figure 1, Item 4) from the roof of the CBC.

0023-1

TM 10-5411-247-13&P REPLACE - Continued.

0023

WARNING

SEALANT, MIL-S-8802, TYPE II, CLASS 8 Sealant is flammable and toxic and shall be used only in a well-ventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. 4. Apply Sealant, Type II MIL-S-8802 under the new bail handle (Figure 1, Item 4) to prevent leaking into the CBC. 5. Install a new bail handle (Figure 1, Item 4) with the center hole (Figure 1, Item 5) facing towards the front of the CBC. 6. Install four screws (Figure 1, Item 1), four lockwashers (Figure 1, Item 2), and four flat washers (Figure 1, Item 3) to secure the new bail handle (Figure 1, Item 4) to the roof of the CBC.

1 2 3 4

Figure 1. Bail Handle Fitting. END OF TASK END OF WORK PACKAGE 0023-2

TM 10-5411-247-13&P

0024

FIELD MAINTENANCE ASSEMBLY, RING, LIFT REPLACE

INITIAL SETUP: Equipment Condition CBC clean, dry, and free of debris. Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Gloves (WP 0055, Table 2, Item 11) Goggles (WP 0055, Table 2, Item 12) Lockwashers Qty:10 Personnel Required Light-Wheel Vehicle Mechanic (91B) (1) Materials/Parts Solvent, Methylethylketone (MEK) (WP 0057, Table 1, Item 24) Sealant, Type II MIL-S-8802 (WP 0057, Table 1, Item 22)

REPLACE

WARNING

Methylethylketone (MEK) ASTM D-740 is flammable and toxic and shall be used only in a wellventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 1. Remove any excess sealant around the 10 hex head screws (Figure 1, Item 1) securing the lift ring assembly (Figure 1, Item 5) to the CBC (Figure 1, Item 6) using MEK. 2. Remove 10 hex head bolts (Figure 1, Item 1), 10 lockwashers (Figure 1, Item 2), and 10 flat washers (Figure 1, Item 3) securing the lift ring assembly (Figure 1, Item 5) to the CBC (Figure 1, Item 6). Discard the old lockwashers. 3. Remove the lift ring assembly (Figure 1, Item 5) from the CBC (Figure 1, Item 6).

WARNING

SEALANT, MIL-S-8802, TYPE II, CLASS 8 Sealant is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame. Gloves and safety goggles should be worn during use. 4. Apply Sealant, Type II MIL-S-8802 under the new lift ring assembly (Figure 1, Item 5) to prevent leaking into the CBC. 0024-1

TM 10-5411-247-13&P REPLACE - Continued.

0024

5. Place lift ring assembly (Figure 1, Item 5) in position on the CBC (Figure 1, Item 6) and align the holes (Figure 1, Item 4) of the lift ring assembly to the holes in the CBC (Figure 1, Item 6). 6. Install 10 flat washers (Figure 1, Item 3), 10 lockwashers (Figure 1, Item 2), and 10 hex head bolts (Figure 1, Item 1) in the corresponding mounting hole positions. 7. Tighten hex head bolts (Figure 1, Item 1). 1 2 3 4

Figure 1. Lift Ring Assembly Fitting. END OF TASK END OF WORK PACKAGE

0024-2

TM 10-5411-247-13&P

0025

FIELD MAINTENANCE PAD, FILTER, COOLER, AIR REPLACE

INITIAL SETUP: Equipment Condition CBC can be fully extended or retracted. Materials/Parts Detergent, Mild (WP 0057, Table 1, Item 11) Rags, Wiping (WP 0057, Table 1, Item19) Personnel Required Light-Wheel Vehicle Mechanic (91B) (1)

REPLACE 1. Remove the air cooler filter pad (Figure 1, Item 1) by reaching up under the ventilator port opening (Figure 1, Item 2). 2. Grasp the air filter material with both hands. 3. Pull the air cooler filter pad (Figure 1, Item 1) straight down while moving from left to right. 4. Pull until the air cooler filter pad (Figure 1, Item 1) has been completely removed from the ventilator port (Figure 1, Item 2). 5. Install air cooler filter pad (Figure 1, Item 1) by feeding one end of the filter up under the ventilator port (Figure 1, Item 2). 6. Push upwards.

NOTE
Be sure that the filter remains straight and does not fold while being pushed into position. 7. Continue to push the air cooler filter pad up into the ventilator port until the entire air filter is securely in place.

0025-1

TM 10-5411-247-13&P

0025

REPLACE - Continued.

Figure 1. Air Cooler Filter Pad Replacement. END OF TASK END OF WORK PACKAGE

0025-2

TM 10-5411-247-13&P

0026

FIELD MAINTENANCE STEP, POLE, UPPER AND MIDDLE REPLACE

INITIAL SETUP: Equipment Condition CBC clean, dry and free of debris. Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Personnel Required Light-Wheel Vehicle Mechanic (91B) (1) References WP 0028

REPLACE

NOTE
If replacing the bottom (lower) roof folding step, refer to WP 0028 for maintenance instructions. 1. Place the roof access pole (folding) step (Figure 1, Item 1) in the down position. This will allow access to the upper hex head bolt. 2. Remove the two hex head bolts (Figure 1, Item 3) and two lockwashers (Figure 1, Item 4) from the roof access folding step (Figure 1, Item 1) being replaced. Discard the old lockwashers. 3. Remove the roof access folding step (Figure 1, Item 1). 4. Place the roof access folding step (Figure 1, Item 1) into position on the sidewall of the CBC. 5. Align the holes (Figure 1, Item 2) of the roof access folding step (Figure 1, Item 1) with the holes on the sidewall of the CBC. 6. Secure the roof access folding step (Figure 1, Item 1) to the CBC using two hex head bolts (Figure 1, Item 3) and two lockwashers (Figure 1, Item 4). The two hex head bolts (Figure 1, Item 3) will thread into threaded inserts permanently installed in the sidewall of the CBC. 7. Tighten the two hex head bolts (Figure 1, Item 3) securely.

0026-1

TM 10-5411-247-13&P

0026

REPLACE - Continued.

4 2

Figure 1. Folding Step Replacement. END OF TASK END OF WORK PACKAGE

0026-2

TM 10-5411-247-13&P

0027

FIELD MAINTENANCE ASSEMBLY, LOCKING, LIFT REPLACE

INITIAL SETUP: Equipment Condition CBC fully-extended and locked position (WP 0005). Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Personnel Required Light-Wheel vehicle Mechanic (91B) (1) Materials/Parts Threadlocker (WP 0057, Item 27)

REPLACE

NOTE
The lift/locking assembly (Figure 1, Item 1) should be in the down position to remove. 1. 2. 3. 4. 5. Remove the cotter pin (Figure1, Item 9) that secures the handle (Figure 1, Item 7). Swing the handle (Figure 1, Item 7) down so that it is approximately perpendicular to the main tube of the lift/locking assembly (Figure 1, Item 1). Place the cotter pin (Figure1, Item 9), removed in step one, back on the lift/locking assembly (Figure 1, Item 1). Move the handle (Figure 1, Item 7) slightly up and down as needed to disengage the base plate (Figure 1, Item 8) with protruding pins from the slots formed by the interlock extrusion. Remove the shoulder screw (Figure 1, Item 6), 0.032 inch thick x 0.562 inch O.D. flat washer (Figure 1, Item 5) and 0.065-inch thick x 0.734 inch O.D. flat washer (Figure 1, Item 4) that secures the lift/locking assembly (Figure 1, Item 1) to the roof (Figure 1, Item 2) of the CBC. Retain hardware for installation. Remove the entire lift/locking assembly (Figure 1, Item 1). Align the hole (Figure 1, Item 3) on the top of the lift/locking assembly (Figure 1, Item 1) with the threaded insert (Figure 1, Item 2) in the CBC ceiling. Add thread locker to the shoulder screw (Figure 1, Item 6) and install the shoulder screw (Figure 1, Item 6), 0.032-inch thick x 0.562 inch O.D. flat washer (Figure 1, Item 5) and 0.065-inch thick x 0.734 inch O.D. flat washer (Figure 1, Item 4) to secure the lift/locking assembly (Figure 1, Item 1).

6. 7. 8.

9. Tighten the shoulder screw (Figure 1, Item 6) securely. 10. Place the lift/locking assembly (Figure 1, Item 1) back into operating position. Refer to WP 0005 POSITIONING THE LIFT/LOCKING ASSEMBLIES.

0027-1

TM 10-5411-247-13&P

0027

REPLACE - Continued.

2 1 3

4 5

7 6

Figure 1. Lift/Locking Assembly Replacement. END OF TASK END OF WORK PACKAGE

0027-2

TM 10-5411-247-13&P

0028

FIELD MAINTENANCE STEP, FOLDING, BOTTOM REPLACE

INITIAL SETUP: Equipment Condition CBC fully-extended and locked position (WP 0005). Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Materials/Parts Sealant, Type II MIL-S-8802 (WP 0057, Table1, Item 22) Personnel Required Light-Wheel Vehicle Mechanic (91B) (1)

REPLACE 1. Place the bottom (lower) folding step (Figure 1, Item 1) in the down position. This will allow access to the upper hex bolt. 2. Remove the sealant around the two hex bolts (Figure 1, Item 4) on the lower folding step (Figure 1, Item 1) 3. Kneel in the opening of the personnel door. 4. Place a wrench on the hex locknut (Figure 1, Item 2) on the inside of the CBC. 5. Place a second wrench on the head of the hex head bolt (Figure 1, Item 4) located on the outside of the CBC. 6. Remove the hex head bolt (Figure 1, Item 4), flat washer (Figure 1, Item 3), and locknut (Figure 1, Item 2). Discard the locknut.

NOTE
It may be necessary to use force to remove step. Tap the folding step horizontally with a hammer if force is needed. 7. Remove the lower folding step (Figure 1, Item 1). 8. Apply Sealant, Type II MIL-S-8802 under the new lower folding step (Figure 1, Item 1) to prevent leaking into the CBC 9. Install lower folding step (Figure 1, Item 1) into position in the recessed mounting plate (Figure 1, Item 5) in the sidewall of the CBC. 10. Align the holes on the lower folding step (Figure 1, Item 1) with the holes on the sidewall recessed mounting plate (Figure 1, Item 5) of the CBC. 11. Install the two hex bolts (Figure 1, Item 4) through the step and sidewall from the outside of the CBC. 12. Install two flat washers (Figure 1, Item 3) and two hex locknuts (Figure 1, Item 2) on the opposite end of the two hex head bolts (Figure 1, Item 4) located inside the CBC. Do not tighten. 13. Kneel in the personnel door opening. 14. Place a wrench on the head of the hex bolt (Figure 1, Item 4). 15. Hold the hex bolt (Figure 1, Item 4) in position. 16. Tighten the hex locknut (Figure 1, Item 2) securely. 0028-1

TM 10-5411-247-13&P REPLACE - Continued. 17. Perform steps 14 thru 16 to both hex bolts and locknuts.

0028

2 5 3

Figure 1. Folding Step (Lower Roof Access) Replacement. END OF TASK END OF WORK PACKAGE

0028-2

TM 10-5411-247-13&P

0029

FIELD MAINTENANCE ASSEMBLY, ROPE, WIRE REPLACE

INITIAL SETUP: Equipment Condition CBC in the retracted position. Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Gloves (WP 0057, Table 2, Item 11) Lifting Device References WP 0005 Personnel Required Light-Wheel Vehicle Mechanic (91B) (2) Materials/Parts Adhesive, RTV-732 (WP 0057, Table 1, Item 1) Wood, Sections 2x4, 35 inches in length (WP 0057, Table 1, Item 28) Masking Tape (WP 0057, Table 1, Item 26)

REPLACE Preparing the CBC for Wire Rope Assemblies Replacement

WARNING

Do not lift the CBC in its retracted (lowered) position. The CBC must be in its extended (fullyraised) position prior to using the lift rings for lifting the CBC for moving it off its mounting surface. Do not use the lift rings to lift a CBC with more than an additional payload of 100 pounds (equivalent weight of two 50-pound sand bags). Lift rings should only be used to lift an empty CBC that is not mounted to a vehicle. A CBC that has been installed on a vehicle may only be hoisted using the lifting points on the vehicle. Make sure to use handling equipment rated for the equipment it will be lifting. Do not use handling equipment rated for less than the gross weight of the CBC when handled by itself or the CBC plus the vehicle when the CBC has been installed on a vehicle. Failure to follow these lift warnings may result in severe injury or death to personnel or damage to equipment.

0029-1

TM 10-5411-247-13&P REPLACE - Continued.

0029

WARNING

Do not stand higher than the top of the lower section inside the CBC if one or more cables have failed until the upper section is properly blocked up as described below, injury or death may result if you do. If one or more wire rope assemblies are broken, use the lifting system to position the CBC upper section to a uniform height of 35 inches as measured from the ceiling to the top edge of the lower section.

CAUTION
Do not attach a hoisting sling to the lift rings in such a way as to create an angle between the cable and the CBC roof surface that is LESS THAN 45. Attaching the cable at any angle less than 45 will result in excessive strain on the lift rings which may result in damage to the CBC. Ensure the folding steps on the CBC outside wall are folded flat against the wall when lowering the upper section, damage to the shelter could result if you do not fold them flat.

NOTE
Lift rings (Figure 1, Item 1) are provided on the four corners of the CBC to allow it to be lifted onto and off a vehicle bed. The lift rings must be used only to lift a CBC that is mechanically detached from the vehicle. To lift the CBC using the lift rings, the CBC must first be in its fully-extended and locked position. To replace any of the wire rope assembly used to raise and lower the CBC upper section, a hoisting sling should be attached to the CBC in order to support the weight of the upper section during the repair. Raising or lowering of the CBC upper section can be accomplished using the CBC winch if the wire rope assemblies have minor damage but are not broken. If one or more wire rope assemblies are broken, it will be necessary to use a lifting hoist system to raise and/or lower the CBC upper section in order to install the four equal length (35 inch) board safety supports. The angle created between each cable and the roof surface of the CBC must not be any less than 45. 1. Attach the hoisting sling (Figure 1, Item 2) to a suitable lifting device.

0029-2

TM 10-5411-247-13&P REPLACE - Continued.

0029

2. Attach the hooks (Figure 1, Item 1) from the hoisting sling (Figure 1, Item 2) to each of the lift rings (Figure 1, Item 3) making sure that they are securely locked in place. Do not lift the CBC; simply take up the slack in the hoisting sling (Figure 1, Item 2) to support the weight of the upper section.

1 45

Figure 1. Hoisting the CBC Using the Lift Rings.

NOTE
When lifting the upper section using a hoist, the upper section must be lifted evenly on all four sides. If the upper section is not evenly lifted, it could pinch on one or more sides preventing the CBC from being extended to its fully-extendable position. 3. Use the hoist to raise the upper section CBC into the desired position to slip the four equal length (35 inch) board safety supports into position. Refer to Figure 2.

0029-3

TM 10-5411-247-13&P REPLACE - Continued.

0029

NOTE
The 2x4 wood supports (Figure 2, Item 1) are used to support the weight of the upper section of the CBC while the wire rope assembly is being replaced. Refer to Figure 2. Inside Supports for Wire Rope Assembly Repair. The four 35-inch sections must all be the same length. The 2x4 wood supports (Figure 2, Item 1) can be used both on the inside and the outside in the same manner. If using the 2x4 wood supports (Figure 2, Item 1) on the outside of the CBC (Figure 2, Item 2), do not do step 4; refer to step 6. If using the 2x4 wood supports (Figure 2, Item 1) on the inside of the CBC, do not do step 6; refer to step 4. The illustration shown in Figure 2 represents the inside placement of the 2x4 wood supports. The outside placement of the 2x4 wood supports is not shown. 4. Place the 2x4 wood supports (Figure 2, Item 1) along the sidewalls near each of the four inside corners (Figure 2, Item 2) of the CBC. Ensure that the bottom of the 2x4 is resting on the top ledge of the bottom section, and the top of the 2x4 wood supports (Figure 2, Item 1) are pointing up toward the ceiling. The supports should be placed near each corner but a sufficient distance away from the corner to allow removal of the corner fitting cover plates (Figure 2, Item 3) and pulleys. 5. Use tape (Figure 2, Item 4) to hold the 2x4 wood supports (Figure 2, Item 1) to the wall in a vertical position until the upper section is lowered onto them. 6. Place the 2x4 wood supports (Figure 2, Item 1) along the sidewalls near each of the four outside corners of the CBC (Figure 2, Item 2). Ensure that the bottom of the 2x4 wood supports (Figure 2, Item 1) are resting on the truck or trailer, and the top of the 2x4 wood supports (Figure 2, Item 1) are pointing up toward the top section of the CBC. 7. Use tape to hold the 2x4 wood supports (Figure 2, Item 1) to the wall in a vertical position until the upper section is lowered onto them. (Not shown) 8. Lower the upper section until it rests on the four 2x4 wood supports (Figure 2, Item 1), and all tension is off of the wire rope

Figure 2. Inside Supports for Wire Rope Assembly Repair. 0029-4

TM 10-5411-247-13&P REPLACE - Continued.

0029

NOTE
The screws that secure the top of the winch cover are different length the then the screws that secure the bottom of the winch cover. Keep the screws separated for installation. 9. Removing four screws (Figure 3, Item 1), four lockwashers (Figure 3, Item 2), and four flat washers (Figure 3, Item 3) that secure the winch cover (Figure 3, Item 4). Discard the lockwashers. 10. Remove the winch cover (Figure 3, Item 4) and set aside for installation.

Figure 3. Wire Rope Assembly Cover Removal.

0029-5

TM 10-5411-247-13&P REPLACE - Continued.

0029

WARNING
When working with wire rope, wear industrial gloves to prevent injury to hands and fingers.

NOTE
Use a free hand or another person to guide the wire rope assemblies (Figure 4, Item 1) while being unwound from the winch barrel (Figure 4, Item 6) to prevent tangling. 11. Use the winch ratchet (Figure 2, Item 5) to completely unwind the wire rope assemblies (Figure 3, Item 5) from the winch barrel (Figure 3, Item 6).

NOTE
It may be necessary to use force to remove the wire rope assembly end balls (Figure 4, Item 2) from the keyhole slots. 12. Remove each wire rope assembly end ball (Figure 4, Item 2) from its keyhole slot (Figure 4, Item 3) in the outside plate (Figure 4, Item 5) or middle plate (Figure 4, Item 4).

3 6

5 4 Figure 4. Wire Rope Assembly End Ball and Keyhole Slot. END OF TASK 0029-6

TM 10-5411-247-13&P REPLACE - Continued. Replacing Winch Corner Wire Rope Assembly

0029

NOTE
The following procedure applies only to the replacement of the short wire rope assembly located at the winch corner. To replace any of the other wire rope assembly assemblies, refer to the section of this work package entitled REPLACING WIRE ROPE ASSEMBLIES OTHER THAN THE WINCH CORNER. 1. Remove short screw (Figure 5, Item 1) closest to the CBC wall from the corner pulley cover plate (Figure 5, Item 3). 2. Remove long screw (Figure 5, Item 2), spacer (Figure 5, Item 4), and locknut (Figure 5, Item 6) from the corner pulley cover plate (Figure 5, Item 3) closest to the inside of the CBC. Discard the locknut. 3. Lift and remove the right hand pulley (Figure 5, Item 5) and set it aside.

2 3

4 5

Figure 5. Winch Corner Assembly Replacement.

0029-7

TM 10-5411-247-13&P REPLACE - Continued.

0029

NOTE
Sealer may have to be removed from the edges of the corner wire rope assembly retaining block (Figure 6, Item 16), along with plate (Figure 6, Item 17), before they can be removed. 4. Move to the outside of the CBC. 5. Removing two screws (Figure 6, Item 13), two lockwashers (Figure 6, Item 14) and two flat washers (Figure 6, Item 14) securing the corner wire rope assembly retaining block (Figure 6, Item 16) and plate (Figure 6, Item 17) located on the outside of the CBC at the winch corner (Figure 6, Item 1). Discard old lockwashers. 6. Remove the setscrew (Figure 6, Item 12) at the center of the block (Figure 6, Item 16). 7. Position a second person inside the CBC at the winch corner and have them feed the winch corner wire rope assembly (Figure 6, Item 2) over the vertical guide corner pulley (Figure 6, Item 11) to allow slack on the retaining block (Figure 6, Item 16) and plate (Figure 6, Item 17).

NOTE
It may be necessary to push the ball end of the wire rope assembly out with a small screwdriver. 8. Disengage the ball end (Figure 6, Item 10) of the wire rope assembly (Figure 6, Item 2) from the retaining block (Figure 6, Item 16). 9. Pull the winch wire rope assembly (Figure 6, Item 2) through to the inside of the CBC until it is totally removed from the CBC. END OF TASK Installing Winch Corner Wire Rope Assembly 1. From the inside of the CBC, install new winch corner wire rope assembly (Figure 6, Item 2) by feeding a free end through the inside opening of the CBC at the winch corner. 2. Feed the wire rope assembly (Figure 6, Item 2) through to the outside of the CBC over the vertical guide corner pulley (Figure 6, Item 11) to a second person positioned outside the winch corner. 3. Have the second person guide the wire rope assembly out the CBC. 4. Install the ball end of the wire rope assembly (Figure 6, Item 2) into the keyhole of the plate (Figure 6, Item 17) and the retaining block (Figure 6, Item 16). 5. Install the setscrew (Figure 6, Item 12) at the center of the retaining block (Figure 6, Item 16). 6. Tighten securely. 7. Place the retaining block (Figure 6, Item 16) back into position under the corner (Figure 6, Item 1) of the CBC upper section. 8. Secure the retaining block (Figure 6, Item 16) and the plate (Figure 6, Item 17) with two screws (Figure 6, Item 13), lockwashers (Figure 6, Item 14), and flat washers (Figure 6, Item 15) removed earlier. Tighten securely. 9. Pull the winch corner wire rope assembly (Figure 6, Item 2) tight from inside the CBC. 10. Align the wire rope assembly in the groove of the left hand pulley (Figure 6, Item 11).

0029-8

TM 10-5411-247-13&P REPLACE - Continued.

0029

11. Install the right-hand pulley (Figure 6, Item 8) while aligning the right-hand wire rope assembly (Figure 6, Item 7) into the groove of the right-hand pulley (Figure 6, Item 8). 12. Ensure both pulleys (Figure 6, Items 8 and 11) are in place and the wire rope assemblies (Figure 6, Items 7 and 10) aligned properly. 13. Install the short screw (Figure 6, Item 3) in the hole of the corner pulley cover plate (Figure 6, Item 5) closest to the wall of the CBC. 14. Install the screw (Figure 6, Item 4), spacer (Figure 6, Item 6), and locknut (Figure 6, Item 9) in the hole of the corner pulley cover plate (Figure 6, Item 5) closest to the inside of the CBC. 1

3 2 17 4 5

16

6 15 11 7

14 12 13 3 10 8

Figure 6. Winch Corner Wire Rope Assembly Components.

0029-9

TM 10-5411-247-13&P REPLACE - Continued. 15. Rotate the winch barrel (Figure 7, Item 1) to position the keyhole (Figure 7, Item 3) located on the middle plate of the winch barrel (Figure 7, Item 1) at the top of the winch barrel.

0029

16. Install the ball end (Figure 7, Item 4) of the wire rope assembly (Figure 7, Item 2) that was NOT replaced, in the keyhole (Figure 7, Item 3) located on the middle plate of the winch barrel (Figure 6, Item 1)

2 3

Figure 7. Attaching Wire Rope Assembly Ball End to Keyhole. 17. Slowly rotate the winch barrel (Figure 8, Item 1) clockwise approximately 1/2 turn in order to position the keyhole (Figure 8, Item 4) located on the left end plate at the top of the winch barrel (Figure 8, Item 1). 18. Install the ball end of the winch corner wire rope assembly (Figure 8, Item 2) into the keyhole (Figure 8, Item 5) located on the left plate (Figure 8, Item 4) of the winch barrel (Figure 8, Item 1). 19. Have second person wearing gloves hold both the winch corner wire rope assembly (Figure 8, Item 2) and the right hand wire rope assembly (Figure 8, Item 3) behind the winch in order to guide the wire rope assemblies onto the winch barrel (Figure 8, Item 1).

0029-10

TM 10-5411-247-13&P REPLACE - Continued.

0029

20. Rotate the ratchet handle (Figure 8, Item 5) and begin taking up the wire rope assembly (Figure 8, Item 6) onto the winch barrel (Figure 8, Item 1). Be sure the both cables start winding into the groove of the winch barrel (Figure 8, Item 1) closest to the plate. 21. Ensure that the wire rope assembly (Figure 8, Item 3) is wound into the grooved recesses on the winch barrel (Figure 8, Item 1) and that the wire rope assembly remains in a single layer, each turn parallel to the last. 22. Continue turning the winch barrel (Figure 8, Item 1) until all wire rope assembly (Figure 8, Item 6) slack is taken up and the wire rope assemblies (Figure 8, Item 6) are taut.

3 2 6 5 4

Figure 8. Corner Wire Rope Assembly Installation. 23. Perform wire rope assembly adjusting procedure located at the end of this Work Package. END OF TASK

0029-11

TM 10-5411-247-13&P Replacing Entire Wire Rope Assembly (Other than the Winch Corner Wire Rope Assembly)

0029

NOTE
The entire wire rope assembly (other than the winch corner wire rope assembly) consists of one long wire rope assembly (Figure 9, Item 4) that extends from the winch to the corner opposite the personnel door from the winch. This long wire rope assembly has three small extensions attached to it that will connect with three shorter wire rope assemblies at each corner. Three shorter, individual wire rope assemblies extend to each of the three corners (other than the winch corner). They connect to the long wire rope assembly (Figure 9, Item 4) which has extensions on it to connect the three smaller wire rope assemblies coming from each corner. Replacement of the entire wire rope assembly is detailed below. The procedure that follows applies only to the replacement of a wire rope assembly other than that located at the winch corner. To replace the winch corner wire rope assembly, refer to paragraph REPLACING WINCH CORNER WIRE ROPE ASSEMBLY. 1. Prepare the CBC for wire rope assembly replacement as detailed in paragraph PREPARING THE CBC FOR WIRE ROPE REPLACEMENT. 2. Remove short screw (Figure 9, Item 1) closest to the CBC wall from the corner pulley cover plate (Figure 9, Item 3). 3. Remove long screw (Figure 9, Item 8), spacer (Figure 9, Item 7), and locknut (Figure 9, Item 5) from the corner pulley cover plate (Figure 9, Item 2) closest to the inside of the CBC. Discard the locknut. 4. Lift and remove the left (Figure 9, Item 6) and right (Figure 9, Item 3) pulley in each corner of the CBC and set them aside.

1 2

7 3 6 4

Figure 9. Corner Pulley Removal.

0029-12

TM 10-5411-247-13&P REPLACE - Continued. 5. Move to the outside of the CBC.

0029

NOTE
Sealer may have to be removed from the edges of the corner wire rope assembly retaining block (Figure 10, Item 2), along with plate (Figure 10, Item 1), before they can be removed. 6. Remove the corner wire rope assembly retaining blocks (Figure 10, Item 2) along with the plate (Figure 10, Item 1) located on the outside of the CBC at every corner, except the winch corner, by removing the two screws (Figure 10, Item 5), two lockwashers (Figure 10, Item 6), and two flat washers (Figure 10, Item 7) securing them in place. Discard old lockwashers.

7. Remove the setscrew (Figure 10, Item 4) at the center of the retaining blocks (Figure 10, Item 2).

NOTE
It may be necessary to push the ball end of the wire rope assembly out with a small screwdriver. 8. Disengage the ball end (Figure 10, Item 3) of the wire rope assembly from the retaining blocks (Figure 10, Item 2).

1 2

7 6

Figure 10. Wire Rope Assembly Retaining Block Removal.

9. Locate the turnbuckle (Figure 11, Item 2) in the channel (Figure 11, Item 3) halfway down the sidewall to the right of the winch.

0029-13

TM 10-5411-247-13&P REPLACE - Continued.

0029

10. Lift the wire rope assembly (Figure 11, Item 1) out of the channel (Figure 11, Item 3) to gain access to the turnbuckle (Figure 11, Item 2). 1

Figure 11. Turnbuckle Location.

11. Pull the end of the left hand turnbuckle-locking clip (Figure 12, Item 1) the end closest to the center hole (Figure 12, Item 6) out of the turnbuckle with a pair of needle nose pliers and slide the locking clip (Figure 12, Item 1) out the left side of the turnbuckle (Figure 12, Item 4). 12. Repeat for the opposite side turnbuckle-locking clip (Figure 12, Item 2) except slide it out to the right. 13. Discard removed turnbuckle-locking clips (Figure 12, Item 1 and 2) as they will be replaced with new ones upon replacing the wire rope assembly. 14. Unscrew the turnbuckle body using a punch with a tip diameter that fits into the center hole (Figure 12, Item 6). 15. Rotate the turnbuckle (Figure 12, Item 4) until the threaded portion of the wire rope end terminals rod ends (Figure 12, Item 5) is completely removed from the turnbuckle (Figure 12, Item 4). 16. Set the turnbuckle (Figure 12, Item 4) aside; it will be required later. 17. Repeat for remaining two turnbuckles. 3 2 4 5

6 Figure 12. Turnbuckle Removal.

18. Position a second person outside the CBC at one of the corners.

0029-14

TM 10-5411-247-13&P REPLACE - Continued.

0029

19. Have the second person feed each wire rope assembly over the vertical guide corner pulley from the outside of the CBC. 20. Pull each wire rope assembly through to the inside of the CBC until it has been removed from the CBC. END OF TASK Installing Entire Wire Rope Assembly (Other than the Winch Corner Wire Rope Assembly) 1. From the outside of the CBC, feed a new wire rope assembly (Figure 13, Item 20) in each corner (Figure 13, Item 2) of the CBC (Figure 13, Item 3) to a second person positioned inside the CBC by feeding the wire rope assembly (Figure 13, Item 20) without a ball on its end through the corner opening over the vertical guide corner pulley (Figure 13, Item 1). 2. Install the ball end (Figure 13, Item 4) of the wire rope assembly (Figure 13, Item 20) into the keyhole (Figure 13, Item 17) of each corner wire rope assembly retaining block (Figure 13, Item 18) and plate (Figure 13, Item 19). 3. Install the setscrew (Figure 13, Item 13) at the center of the retaining block (Figure 13, Item 18) and plate (Figure 13, Item 19). 4. Tighten securely. 5. Place each corner wire rope assembly retaining block (Figure 13, Item 18) along with the plate (Figure 13, Item 19) back into position under its corresponding corner of the CBC upper section. 6. Secure with the two screws (Figure 13, Item 14), lockwashers (Figure 13, Item 15), and flat washers (Figure 13, Item 16) removed earlier. Replace the lockwashers with new ones. 7. Tighten securely. 8. Repeat this procedure for each corner. 9. Install the left pulley (Figure 13, Item 8). 10. Align the left hand wire rope assembly (i.e. the short wire rope assembly that goes down the corner) (Figure 13, Item 11) in the groove of the left hand pulley (Figure 13, Item 12). 11. Starting at the corner winch, lay the long wire rope assembly (Figure 13, Item 2) in the channel (Figure 13, Item 3) on the inside of the CBC, keeping the threaded ends (Figure 13, Item 4) accessible.

NOTE
The long wire rope assembly should lay toward the inside of the CBC and the three extensions coming off the long wire assembly should lay toward the outside of the CBC. Be sure that both wire rope assemblies are in their respective pulley grooves when both pulleys are installed. 12. Align the right hand wire rope assembly (i.e. the long wire rope assembly with extends to all corners except the winch corner (Figure 13, Item 9) while installing the right hand pulley (Figure 13, Item 8). 13. Place the corner pulley cover plate (Figure 13, Item 6) on the corner assembly. 14. Install the short screw (Figure 13, Item 4) in the hole of the corner pulley plate (Figure 13, Item 6) closest to the wall of the CBC. 15. Install the longer screw (Figure 13, Item 5), spacer (Figure 13, Item 7), and locknut (Figure 13, Item 10) in the hole of the corner pulley plate (Figure 13, Item 6) toward the inside of the CBC.

0029-15

TM 10-5411-247-13&P REPLACE - Continued. 1

0029

20

4 19 5

18 4 17

1 7 12 11 8

16 15

14 13

10 Figure. 13. Threading Wire Rope Assembly Over Pulleys.

NOTE
If the 2x4 wood supports supporting the top section of the CBC are on the inside, it may be necessary to feed the wire rope assembly under the 2x4 wood supports. The turnbuckle has a ring around the one end. That end goes towards the left when threading on to the terminal rods. 16. Install the threaded end of each terminal rod (Figure 14, Item 2), one on the long wire rope assembly and one on the short wire rope assembly going down each corner (other than the winch corner) into the turnbuckle (Figure 14, Item 1) removed earlier.

0029-16

TM 10-5411-247-13&P REPLACE - Continued.

0029

WARNING

A maximum of no less than 7/16 thread exposure when installing the turnbuckles. If more thread is exposed than 7/16 it could cause the wire rope assembly to fail. Failure to adhere to this warning may result in injury or death. 17. At the same time, start screwing the threaded ends of each terminal rod (Figure 14, Item 2) into the turnbuckle body (Figure 14, Item 1) an equal amount until approximately 7/16 inch of thread are still exposed. 18. Repeat for each of the three-turnbuckle bodies.

1 2

Figure 14. Installing/Attaching Terminal Ends.

0029-17

TM 10-5411-247-13&P REPLACE - Continued.

0029

19. Once all turnbuckles are installed and all wire rope assemblies are in their respective channels, rotate the winch barrel (Figure 15, Item 5) as necessary to position the keyhole (Figure 15, Item 3) located on the middle plate (Figure 15, Item 2) of the winch barrel at the top. 20. Install the ball end (Figure 15, Item 4) of the long wire rope assembly (Figure 15, Item 1) nearest the right side of the winch (not the winch corner wire rope assembly) in the keyhole (Figure 15, Item 3) located on the middle plate (Figure 15, Item 2) of the winch barrel (Figure 15, Item 5).

3 Figure 15. Installing Wire Rope Assembly Ball End.

0029-18

TM 10-5411-247-13&P

0029

REPLACE - Continued. 21. Slowly rotate the winch barrel (Figure 16, Item 8) clockwise approximately 1/2 turn in order to position the keyhole (Figure 16, Item 3) located on the left end plate (Figure 16, Item 5) of the winch barrel (Figure 16, Item 8) at the top. 22. Install the ball end (Figure 16, Item 4) of the winch corner wire rope assembly (Figure 16, Item 2) into the keyhole (Figure 16, Item 3) located on the left end plate (Figure 16, Item 5) of the winch barrel (Figure 16, Item 8). Apply force if necessary. 23. Have a person wearing gloves hold both the winch corner wire rope assembly (Figure 16, Item 6) and the right hand wire rope assembly (Figure 16, Item 1) behind the winch in order to guide the wire rope assemblies onto the winch barrel (Figure 16, Item 8).

NOTE
Ensure that the wire rope assembly is wound into the grooved recesses on the winch barrel (Figure 16, Item 8) and that the wire rope assembly remains in a single layer, each turn parallel to the one before. 24. Rotate the ratchet handle (Figure 16, Item 7) and begin taking up the wire rope assembly onto the winch barrel (Figure 16, Item 8).

NOTE
It is important that the short cable assembly is tight. 25. Continue turning the winch barrel (Figure 16, Item 8) until all wire rope assembly slack is taken up and both wire rope assemblies are tight.

6 5 8 7

2 4 3

Figure 16. Removing Slack from Wire Rope Assembly. 0029-19

TM 10-5411-247-13&P REPLACE - Continued. 26. Extend the CBC until the upper sections stops moving when turning the winch. 27. Proceed to adjustment procedures.

0029

END OF TASK

Adjustment Procedures for the Wire Rope Assembly 1. Extend the CBC until the upper sections stops moving when turning the winch. 2. Start with the winch corner side and measure each corner height from the outside bottom of top section, to the top of the mounting edge. The height of all four corners should be within 1/8 inch using the winch corner measurement as a reference height.

NOTE
The 2x4 wood supports are used to support the weight of the upper section of the CBC while the wire rope assembly is being replaced. Refer to Figure 17. Inside Supports for Wire Rope Assembly Repair. The four 35-inch sections must all be the same length. The 2x4 wood supports can be used both on the inside and the outside in the same manner. If using the 2x4 wood supports on the outside of the CBC, do not do step 4; refer to step 6. If using the 2x4 wood supports on the inside of the CBC, do not do step 6; refer to step 4. The illustration shown in Figure 17 represents the inside placement of the 2x4 wood supports. The outside placement of the 2x4 wood supports is not shown. 3. If the corners are not even, place the 2x4 wood supports (Figure 17, Item 1) along the sidewalls near each of the four inside corners (Figure 17, Item 2) of the CBC. Ensure that the bottom of the 2x4 wood supports is resting on the top ledge of the bottom section, and the top of the 2x4 wood supports are pointing up toward the ceiling. The supports should be placed near each corner but a sufficient distance away from the corner to allow removal of the corner fitting cover plates (Figure 17, Item 3) and pulleys. 4. As each one is put in place, use tape (Figure 17, Item 4) to hold them to the wall in a vertical position until the upper section is lowered onto them. (Not shown) 5. Lower the upper section until it rests on the four 2x4 wood supports (Figure 17, Item 1), and all tension is off of the wire rope.

0029-20

TM 10-5411-247-13&P REPLACE - Continued.

0029

Figure 17. Inside Supports for Wire Rope Assembly Repair.

WARNING

A maximum of no less than 7/16 thread exposure when installing the turnbuckles. If more thread is exposed than 7/16 it could cause the wire rope assembly to fail. Failure to adhere to this warning may result in injury or death. 6. Adjust the turnbuckles (Figure 18, Item 1) to within plus or minus an 1/8 of an inch, starting with the turnbuckle (Figure 18, Item 1) closest to the winch corner. Turn the threaded rod (Figure 18, Item 2) in or out of the turnbuckle (Figure 18, Item 1) to the difference between the height of each corner. Example: If the winch corner measures 29 inches and the left front corner measures 29 inches, then turn the threaded rod (Figure 18, Item 2) in the turnbuckle (Figure 18, Item 1) so that the measurement on both sides of the threads equals the difference between the two corners. a. Turning the turnbuckle (Figure 18, Item 1) clockwise will tighten the cable and raise the corner of the CBC. b. Turning the turnbuckle (Figure 18, Item 1) counterclockwise will loosen the cable and lower the CBC. 7. Raise the CBC after the turnbuckle adjustment and measure each corner to within an 1/8 of an inch tolerance. 8. Repeat steps 6 and 7 if more adjustment to the turnbuckle is needed to the 1/8 of an inch tolerance.

0029-21

TM 10-5411-247-13&P REPLACE - Continued.

0029

Figure 18. Turnbuckle Adjustment. 9. Lower the upper section until it rests on the four 2x4 wood supports and all tension is off of the wire rope. 10. Install turnbuckle locking clips (Figure 19, Item 2) in the turnbuckles (Figure 19, Item 9). 11. Ensure that the groove on the shaft of the terminal end (Figure 19, Item 8) lined up EXACTLY with the small notched cutout (Figure 20, Item 6) located on the edge of the turnbuckle (Figure 19, Item 9). 12. If the groove (Figure 19, Item 8) is not lined up exactly with the notched cutout (Figure 19, Item 6), the locking clips (Figure 19, Item 2) will not slide into place and cannot be properly locked in the turnbuckle body in latter step. 13. Use a pair of needle nose pliers to slide the long end (straight portion) (Figure 19, Item 3) of the new turnbuckle locking clip (Figure 19, Item 2) into the left end of the turnbuckle (Figure 19, Item 9) positioned closest to the winch corner.

NOTE
The turnbuckle locking clips must be installed on the opposite sides of each other. 14. Install the bent end (Figure 19, Item 4) of the turnbuckle-locking clip (Figure 19, Item 2) into the center hole (Figure 19, Item 7) of the turnbuckle (Figure 19, Item 9). 15. Repeat for the right turnbuckle-locking clip (Figure 19, Item 5). 16. Repeat turnbuckle locking clip installation procedure for each turnbuckle body.

0029-22

TM 10-5411-247-13&P REPLACE - Continued. 1 2 3 4 5

0029

9 8

Figure 19. Installing Turnbuckle Locking Clips. 3. Using the winch handle raise the upper section, and properly place the lift/locking mechanisms to support the Upper Section as described in WP 0005. 4. Install the winch cover (Figure 20, Item 4) by installing the four screws (Figure 20, Item 1), lockwashers (Figure 20, Item 2), and flat washers (Figure 20, Item 3) that secure the cover (Figure 20, Item 4). Replace old lockwashers with new ones. 5. Remove the four supporting 2x4 wood supports. 6. Install the personnel door assembly (lower). Refer to WP 0005 Installing the Personnel Door Assembly (Lower) to the Personnel Door Assembly (Upper) for installation instructions.

0029-23

TM 10-5411-247-13&P REPLACE - Continued.

0029

1 2 3

Figure 20. Installing Winch Cover. END OF TASK END OF WORK PACKAGE

0029-24

TM 10-5411-247-13&P

0030

FIELD MAINTENANCE WINCH, DRUM, HAND-OPERATED SERVICE, REPLACE

INITIAL SETUP: Equipment Condition CBC in fully-extended position with all lift/locking assemblies locked in place (WP 0005). Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21). Lifting device for upper section; i.e., crane, rated minimum 600 lbs, if winch is inoperative (WP 0005). Personnel Required Light-Wheel Vehicle Mechanic (91B) (1) MOS Non-specific (1) References WP 0017 WP 0029

SERVICE Refer to WP 0017 paragraph entitled LUBRICATION REQUIRMENTS for servicing instructions. END OF TASK REPLACE 1. Remove the winch cover (Figure 1, Item 13) by removing the four screws (Figure 1, Item 1), four lockwashers (Figure 1, Item 2), and four flat washers (Figure 1, Item 5) that secure the winch cover (Figure 1, Item 13). Discard the lockwashers. 2. Place the winch cover (Figure 1, Item 13) and its hardware aside.

NOTE
It may require some force to pull and/or push the end ball through the keyhole slot. Take note of the relative positions of the cables. A small piece of tape marking the left and right wire rope assemblies is recommended. 3. Using a ratchet and/or by hand, unwind the cables (Figure 1, Items 9 and 11) from the winch barrel (Figure 1, Item 10). 4. Remove each wire rope assembly end ball (Figure 2, Item 5) from its keyhole slot (Figure 2, Item 2) in the outside plate (Figure 2, Item 1) or middle plate (Figure 2, Item 3).

NOTE
Remove hardware, starting from the right side of the winch. 5. Remove four hex locknuts (Figure 1, Item 6), four flat washers (Figure 1, Items 5 and 7), and four hex head bolts (Figure 1, Item 4) that secure the hand-operated drum winch (Figure 1, Item 12) to the winch assembly bracket (Figure 1, Item 8). Discard the locknuts.

0030-1

TM 10-5411-247-13&P

0030

REPLACE - Continued. 6. Remove the hand-operated drum winch (Figure 1, Item 12) from the hand-operated drum winch bracket (Figure 1, Item 8). 7. Install a new hand-operated drum winch (Figure 1, Item 12) in position onto the hand-operated drum winch bracket (Figure 1, Item 8). 8. Align the holes in each.

NOTE
Ensure that the bolts to install the winch assembly go through from the drum side. The locknuts should be on back side of the plate away from the drum. 9. Install four hex head bolts (Figure 1, Item 4), four flat washers (Figure 1, Items 5 and 7), and four locknuts (Figure 1, Item 6). 10. Rotate the hand-operated drum winch barrel (Figure 1, Item 10) to position the keyhole (Figure 2, Item 2) located on the middle plate (Figure 2, Item3) at the top of the hand-operated drum winch barrel (Figure 2, Item 6). 11. Install the ball end (Figure 2, Item 5) of the wire rope assembly of the long right hand wire rope assembly (Figure 1, Item 9), in the keyhole (Figure 2, Item 2) located on the middle plate (Figure 2, Item 3) of the handoperated drum winch barrel (Figure 1, Item 10). 12. Slowly rotate the hand-operated drum winch barrel (Figure 1, Item 6) approximately 1/2 turn in order to position the keyhole (Figure 2, Item 2) located on the left end plate (Figure 2, Item 1) at the top of the handoperated drum winch barrel (Figure 1, Item 10). 13. Install the left hand-operated drum winch corner wire rope assembly (Figure 1, Item 11) back onto the handoperated drum winch barrel (Figure 1, Item 10) by inserting its ball end (Figure 2, Item 5) into the keyhole slot (Figure 2, Item 2) located in the outside plate (Figure 2, Item 1) of the hand-operated drum winch barrel (Figure 1, Item 10). Start in the winch corner to measure and proceed clockwise measuring all four corners. 14. If the dimension varies more than an 1/8 of an inch, the turnbuckles will need to be adjusted. Refer to WP 0029 for instructions on adjusting the turnbuckles.

NOTE
The height of all four corners should be within 1/8 inch using the winch corner measurement as a reference height. If the corners are not equal, adjust the three turnbuckle bodies (refer to Figure 0029) until their respective corners are equal to the winch corner height to within 1/8 inch. 15. Re-measure all four corners as described in WP 0029.

0030-2

TM 10-5411-247-13&P

0030

REPLACE - Continued.

5 1 2 3 6 7 8 4

12 13 11 10

Figure 1. Hand-Operated Drum Winch.

0030-3

TM 10-5411-247-13&P REPLACE - Continued.

0030

2 1 OUTSIDE WINCH PLATE 3 WINCH BARREL 1 4 3 INSIDE WINCH PLATE

6 or 7

MIDDLE WINCH PLATE

WINCH CABLE DETAIL

Figure 2. Hand-Operated Drum Winch Detail. .

END OF TASK END OF WORK PACKAGE

0030-4

TM 10-5411-247-13&P

0031

FIELD MAINTENANCE ANGLES, MOUNTING, CARRIER REPLACE

INITIAL SETUP: Equipment Condition CBC fully-extended and locked position (WP 0005). Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Personnel Required Light-Wheel Vehicle Mechanic (91B) (1)

REPLACE

NOTE
The carrier mounting angle is located on the forward wall of the CBC. 1. Remove damaged carrier mounting angle (Figure 1, Item 8) by removing 13 hex bolts (Figure 1, Item 7), 13 lockwashers (Figure 1, Item 6), and 13 flat washers (Figure 1, Item 5) that secure the damaged carrier mounting angle to the front of the CBC(Figure 1, Item 2). Discard the lockwashers. 2. Remove four hex nuts (Figure 1, Item 1), four lockwashers (Figure 1, Item 10), and four flat washers (Figure 1, Item 9) that secure the carrier mounting angle (Figure 1, Item 8) to the platform. Discard the lockwashers. 3. Remove the damaged carrier mounting angle (Figure 1, Item 8). 4. Install the carrier mounting angle (Figure 1, Item 8) by aligning the holes (Figure 1, Item 4) in the angle with the holes (Figure 1, Item 3) on the CBC (Figure 1, Item 2). 5. Install 13 hex bolts (Figure 1, Item 7), 13 lockwashers (Figure 1, Item 6), and 13 flat washers (Figure 1, Item 5) in all mounting holes (Figure 1, Item 3) in the (Figure 1, Item 2) of the CBC (Figure 1, Item 2). 6. Install four hex nuts (Figure 1, Item 1), four lockwashers (Figure 1, Item 10), and four flat washers (Figure 1, Item 9) to secure the carrier mounting angle (Figure 1, Item 8) to the platform. 7. Tighten all hardware securely.

0031-1

TM 10-5411-247-13&P

0031

REPLACE - Continued.

1 2

10 3 9 8 5 6 7

5 6 4

7 Figure 1. Carrier Mounting Angle Replacement. END OF TASK END OF WORK PACKAGE

0031-2

TM 10-5411-247-13&P

0032

FIELD MAINTENANCE ASSEMBLY, DOOR, PERSONNEL REPLACE, INSPECT, REPAIR

INITIAL SETUP: Equipment Condition CBC fully-extended and locked position (WP 0005). Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Step Device/Ladder References WP 0036 WP 0037 Personnel Required Light-Wheel Vehicle Mechanic (91B) (2) Materials/Parts Sealant, Type II MIL-S-8802 (WP 0057, Table1, Item 22) Solvent, Methylethylketone (MEK) (WP 0057, Table 1, Item 24)

REPLACE Remove Personnel Door Assembly (Lower) 1. Open the personnel door assembly and remove the cotter pins (Figure 1, Item 12) that secures inner door handle (Figure 1, Item 11). 2. Remove the inner door handle (Figure 1, Item 11) to access the personnel door assembly (lower) rod (Figure 1, Item 8). 3. Pull the personnel door assembly (upper and lower) rods (Figure 1, Items 8 and 10) out of the rod guides (Figure 1, Item 9) located on the inside of the personnel door assembly. 4. Set the personnel door assembly (lower) rod (Figure 1, Item 8) aside for installation. 5. Support the lower personnel door assembly (lower) (Figure 1, Item 5) with a free hand. 6. Remove the three hand knobs (Figure 1, Item 7) with lockwashers (Figure 1, Item 6) that secure the personnel door assembly (lower) (Figure 1, Item 5) to the personnel door assembly (upper) (Figure 1, Item 3). 7. Set the three knobs (Figure 1, Item 7) and lockwashers (Figure 1, Item 6) aside for installation. 8. Lift to remove the personnel door assembly (lower) (Figure 1, Item 5).

NOTE
The hex head bolt closest to the center of the personnel door assembly (lower) is short in length than the hex head bolt near the outside of the personnel door assembly (lower). 9. Remove the two hex head bolts (Figure 1, Item 14), two lockwashers (Figure 1, Item 12), and two flat washers (Figure 1, Item 13) from the door hinge (Figure 1, Item 15) of the personnel door assembly (lower) (Figure 1, Item 7). Discard the lockwashers. 10. Set the two hex head bolts (Figure 1, Item 14), flat washers (Figure 1, Item 13) and the door hinge (Figure 1, Item 15) aside for installation. END OF TASK 0032-1

TM 10-5411-247-13&P Remove Personnel Door Assembly (Upper)

0032

NOTE
Two people are required to perform removal of personnel door assembly (upper). A step/device ladder will be needed to reach the top and bottom hinge (Figure 1, Item 1). 1. Remove the personnel door assembly (Lower) (Figure 1, Item 5). Refer to Remove Personnel Door Assembly (Lower) in this Work Package on previous page. 2. Remove sealant from hex head bolts (Figure 1, Item 18) on the top and bottom hinge (Figure 1, Item 1) of the personnel door assembly (upper) (Figure 1, Item 3). 3. Ensure the second person supports the personnel door assembly (upper) (Figure 1, Item 3).

NOTE
There are three washers (Figure 1, Item 2) used as spacers on the back side of the hinge. Retain these when removing the hinge (Figure 1, Item 1) from the personnel door assembly (upper) for installation. 4. Remove two hex bolts (Figure 1, Item 18), two lockwashers (Figure 1, Item 19), and two washers (Figure 1, Item 20) from the top hinge (Figure 1, Item 1) on the personnel door assembly (upper) (Figure 1, Item 3). Discard the lockwashers.

NOTE
There are three washers (Figure 1, Item 2) used as spacers on the back side of the hinge. Retain these when removing the hinge (Figure 1, Item 1) from the personnel door assembly (upper) for installation. 5. Remove two hex bolts (Figure 1, Item 18), two lockwashers (Figure 1, Item 19), and two washers (Figure 1, Item 20) from the bottom hinge on the personnel door assembly (upper) (Figure 1, Item 3). Discard the lockwasher. 6. Remove the personnel door assembly (upper) (Figure 1, Item 3).

END OF TASK INSPECT 1. Inspect hinge (Figure 1, Items 1 and 17) on personnel door assembly (upper and lower) (Figure 1, Items 3 and 5). Replace hinge (Figure 1, Items 1 and 17), if damaged. 2. Inspect the personnel door assembly (lower) (Figure 1, Item 5) for punctures that would cause leaking to the CBC. Refer WP 0037 for repair procedures. 3. Inspect the personnel door assembly (lower) (Figure 1, Item 5) for dents. Refer to WP 0036 for repair procedures.

0032-2

TM 10-5411-247-13&P REPLACE - Continued. 1 2

0032

20 18 19

17 5 14 16 12 15 13 11

10

6 7 8 6 7 9 8

Figure 1. Personnel Door Assembly (Upper and Lower) Replacement.

END OF TASK

0032-3

TM 10-5411-247-13&P INSTALL Install Personnel Door Assembly (Upper)

0032

NOTE
Two people are required to perform installation of personnel door assembly (upper). 1. Place personnel door assembly (upper) (Figure 1, Item 3) into position with the assistance of a second person. 2. Align the upper hinge (Figure 1, Item 1) mounting holes. 3. Install the two hex bolts (Figure 1, Item 18), two lockwashers (Figure 1, Item 19), two flat washers (Figure 1, Item 20) and three washer shims (Figure 1, Item 2). 4. Align the lower hinge mounting holes. 5. Install the two hex bolts (Figure 1, Item 18), two lockwashers (Figure 1, Item 19), two flat washers (Figure 1, Item 20) and three washer shims (Figure 1, Item 2). 6. Tighten all hardware securely. 7. Use Sealant, Type II MIL-S-8802 (WP 0057, Table1, Item 21) to seal the hex head bolts of the top and bottom hinge of the personnel door assembly (upper). END OF TASK Install Personnel Door Assembly (Lower) 1. Transfer the door hinge (Figure 1, Item 17) of the personnel door assembly (lower) (Figure 1, Item 5) from the defective personnel door assembly (lower) Figure 1, Item 5) (only if the hinge is not damaged in any way) to the new personnel door assembly (lower) (Figure 1, Item 5). 2. Secure with longer hex head bolt (Figure 1, Item 16), flat washer (Figure 1, Item 14), and lockwasher (Figure 1, Item 13). 3. Secure with shorter hex head bolt (Figure 1, Item 15), flat washer (Figure 1, Item 14), and lockwasher (Figure 1, Item 13). 4. Place the personnel door assembly (lower) (Figure 1, Items 5) into position under the personnel door assembly (upper) (Figure 1, Item 3). 5. Align the three-hand knob mounting holes. 6. Install by tightening the three hand knobs (Figure 1, Item 7) with lockwashers (Figure 1, Item 6). 7. Install the personnel door assembly (lower) rod (Figure 1, Item 8) in position through the two mounts (Figure 1, Item 9) inside the lower personnel door assembly (lower) (Figure 1, Item 5). 8. Install the personnel door assembly (upper) rod (Figure 1, Item 10) in position through top of the guide in the personnel door assembly (upper) and place the bottom on the pin of the inner door handle. 9. Install two cotter pins (Figure 1, Item 12) to secure the personnel door assembly (upper and lower) rods (Figure 1, Items 8 and 10). 10. Tighten all hardware securely. 11. Use sealant, Type II MIL-S-8802, (WP 0057, Item 21) to seal the hex head bolts of the bottom hinge of the personnel door assembly (lower).

END OF TASK

0032-4

TM 10-5411-247-13&P REPAIR Opening a Personnel Door Assembly from the Outside with a Non-Functioning Door Latch.

0032

1. Remove excess sealer from the hex head bolts on the three door hinges of the personnel door assembly. 2. Remove the four hex head bolts (Figure 1, Item 18), four lockwashers (Figure 1, Item 19), and four flat washers (Figure 1, Item 20) from the top and bottom hinge of the personnel door assembly (upper) (Figure 1, Item 3). 3. Remove the two hex head bolts (Figure 1, Items 15 and 16), two lockwashers (Figure 1, Item 13), and flat washers (Figure 1, Item 14) from the door hinge (Figure 1, Item 17) of the personnel door assembly (lower) (Figure 1, Item 5). 4. Use any available tool; i.e. crowbar, trenching tool. 5. Insert the tip into the widest opening between the upper personnel door assembly (upper) (Figure 1, Item 3) and the CBC frame. 6. Exert enough force to open the personnel door assembly (to cause it to fall off completely, or allow enough room to correct inner personnel door assembly handle malfunction). 7. Enter the CBC through the area created by prying open the personnel door assembly. 8. Remove two cotter pins (Figure 1, Item 12) on the door latch assembly. 9. Remove the door handle (Figure 1, Item 11). 10. Remove the upper and lower door latch assembly rods (Figure 1, Item 8 and 10). 11. Remove three hand knobs (Figure 1, Item 7) with lockwashers (Figure 1, Item 6) from the personnel door assembly. 12. Carefully rotate personnel door assembly (upper) (Figure 1, Item 3) to free it from the door latch assembly. And personnel door assembly (lower) (Figure 1, Item 5). 13. Remove personnel door assembly. 14. Should damage result, obtain new parts from stock. 15. Use the necessary steps needed in the paragraph REPLACE to restore the personnel door assembly (upper and lower) to operating status. END OF TASK Door Rubber Stripping 1. Remove defective seal (Figure 2, Item 2). 2. Strip old adhesive from bonding surface (Figure 2, Item 1).

WARNING

CARC paint dust is a health hazard. Wear protective eyewear, mask, and goggles when sanding CARC paint surfaces. Failure to observe this warning can result in personal injury. 3. Sand using sandpaper, only if required to remove material not taken off in preceding step.

0032-5

TM 10-5411-247-13&P REPAIR - Continued.

0032

WARNING

METHYLETHYLKETONE, ASTM D-740 Methylethylketone is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame. Gloves and safety goggles should be worn during use. Failure to adhere to this warning may cause death or permanent injury. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 4. Wipe bonding surface (Figure 2, Item 1) with a clean cloth dampened with solvent and immediately wipe solvent from surface with a clean, dry cloth.

CAUTION
Seals shall not be washed with any aromatic hydrocarbon (such as benzene, toluene, methylethylketone, or xylene) which will cause deterioration. Failure to adhere to this caution may result in damage to seals. 5. Clean seal (Figure 2, Item 2) with a lint-free cloth by dry wiping prior to bonding.

WARNING

RTV ADHESIVE, MIL-A-46146 RTV Silicon Adhesive is irritating to eyes and skin and shall be used only in a well-ventilated area. Do not induce vomiting if ingested obtain medical attention. Flammable above 200 F (93.3 C). Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials.

NOTE
Work quickly when performing the following steps since RTV adhesive cures very quickly. 6. Apply a bead of RTV adhesive on bonding surface (Figure 2, Item 1). 7. Install gasket and press firmly to seat. 8. Ensure contact with mating surface.

0032-6

TM 10-5411-247-13&P REPAIR - Continued.

0032

Figure 2. Personnel Door Assembly Rubber Strip Replacement. END OF TASK END OF WORK PACKAGE

0032-7/8 blank

TM 10-5411-247-13&P

0033

FIELD MAINTENANCE M35A2, 2-1/2 TON CARGO TRUCK MOUNTING KIT REMOVE, REPAIR

INITIAL SETUP: Equipment Condition CBC fully-extended and locked position (WP 0005). Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Dispenser, RTV adhesive (WP 0055, Table 2, Item 2) Gloves (WP 0057, Table 1, Item 12) Goggles (WP 0055, Table 2, Item 12) Lifting Device (1 Ton minimum) References WP 0005 WP 0019 REPAIR Remove CBC from M35A2, 2-1/2 Ton Cargo Truck 1. Remove one 1/4-28 UNF x 1.00 inch long hex head bolt (Figure 1, Item 1), flat washer (Figure 1, Item 3), and lockwasher (Figure 1, Item 2) per hole that attaches the CBC to the vehicle bed at the 12 locations (Locations marked C in Figure 2). 2. Remove one 1/4-28 UNF x 1.25 inch hex head bolt (Figure 1, Item 4), flat washer (Figure 1, Item 8), and lockwasher (Figure 1, Item 9) per hole at the four hole locations on either side of the threshold (Locations marked B in Figure 2). 3. Remove three pan head screws (Figure 1, Item 5) and lockwasher (Figure 1, Item 6) from the remaining three hole locations on the threshold (Locations marked A in Figure 2). 2 1 3 4 Personnel Required Light-Wheel Vehicle Mechanic (91B) (1) Crane Operator (21F) (1) Materials/Parts Adhesive, RTV-732 (WP 0057, Table 1, Item 1) Rubber strip, 3/8 inch thk x 1.00 inch wide x 25 feet long, adhesive backed, color black, closed cell, epdm sponge rubber strip. (WP 0057, Table 1, Item 20) Bag, Sand (WP 0057, Table 1, Item 6) Solvent, Methylethylketone (MEK) (WP 0057, Table 1, Item 24)

5 6

7 9 8 Figure 1. CBC Fastener Removal. .

0033-1

TM 10-5411-247-13&P REPAIR - Continued.

0033

VEHICLE CAB

C C C

C C

M35A2 TRUCK BED

CENTER LINE OF CBC AND VEHICLE BED

NOTE: THE LETTERS A, B, AND C ON THE ILLUSTRATION DENOTE THE DIFFERENT SIZE HARDWARE TO BE USED IN SECURING THE CBC TO THE VEHICLE BED. REFER TO THE PRECEDING TEXT FOR ADDITIONAL DETAIL.

CARGO BED COVER BOTTOM ASSEMBLY

C C B A B

C C

Figure 2. CBC Fastener Size Locations.

0033-2

TM 10-5411-247-13&P REPAIR - Continued.

0033

WARNING

RTV ADHESIVE, MIL-A-46146 RTV Silicon Adhesive is irritating to eyes and skin and shall be used only in a well-ventilated area. Do not induce vomiting if ingested obtain medical attention. Flammable above 200 F (93.3 C). Gloves and safety goggles should be worn during use. 4. Remove RTV adhesive around the threshold (Figure 3, Item 3) area by starting at the left (Figure 3, Item 1) or right (Figure 3, Item 4) corner of the CBC under the area where the threshold (Figure 3, Item 3) meets the vehicle bed (Figure 3, Item 2) with a putty knife.

3 1 2 4

Figure 3. RTV Adhesive Removal.

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death. 5. Lift the CBC from the vehicle bed using the four lift rings positioned along the front and rear roof lines of the CBC. The CBC should be lifted from the vehicle bed in accordance with the paragraph of WP 0005 entitled HOISTING THE CBC USING THE LIFT RING.

0033-3

TM 10-5411-247-13&P REPAIR - Continued.

0033

6. Place the CBC onto a set of supporting blocks placed between the vehicle bed and the CBC. The blocks are used in order to raise the CBC up off the vehicle bed. This will permit access to the bottom edge of the CBC that contacts the vehicle bed. 7. Scrape RTV adhesive and rubber strip from CBC and vehicle bed using a putty knife.

SANDBAGS OR OTHER WEIGHT MAY BE USED ALONG THE FRONT EDGE OF THE CBC ROOF IN ORDER TO LEVEL THE UNIT DURING LIFTING AND LOWERING.

Figure 4. Lifting the CBC from Vehicle Bed. 8. Lift the CBC from the supporting blocks and reposition supporting blocks to areas that have been previously scrapped. 9. Lower the CBC onto the supporting blocks.

0033-4

TM 10-5411-247-13&P REPAIR Continued.

0033

WARNING

METHYLETHYLKETONE, ASTM D-740 Methylethylketone is flammable and toxic and shall be used only in a well-ventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. 10. Wipe CBC and vehicle bed mounting areas with a clean cloth dampened in MEK and immediately wipe solvent from surfaces with a clean, dry cloth. 11. Repeat steps 9 through 11 until CBC and vehicle bed is completely clean. 12. Install the mounting kit to the CBC. For installation on to the vehicle bed, refer to WP 0019, Service Upon Receipt.

END OF TASK END OF WORK PACKAGE

0033-5/6 blank

TM 10-5411-247-13&P

0034

FIELD MAINTENANCE MOUNTING KIT, M1078, 2-1/2 TON LMTV REMOVE, REPAIR

INITIAL SETUP: Equipment Condition Truck bed clean and free of debris. Side Panels removed and Tailgate lowered (TM 9-2330-394-13&P). Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Lifting Device (1 Ton minimum) Dispenser, RTV adhesive (WP 0055, Table 2, Item 2) Gloves (WP 0057, Table 1, Item 12) Goggles (WP 0055, Table 2, Item 12) References WP 0020 Materials/Parts Bag, Sand (WP 0057, Table 1, Item 6) Anti-seize Lubricant (WP 0057, Table 1 Item 5) Adhesive, RTV-732 (WP 0057, Table 1, Item 1) Four Wood Support Blocks 4x4x12 inches long (WP 0057, Table1, Item 29) Rubber strip, 3/8 inch thk x 1.00 inch wide x 25 feet long, adhesive backed, color black, closed cell, epdm sponge rubber strip. (WP 0057, Table 1, Item 20) Solvent, Methylethylketone (MEK) (WP 0057, Table 1, Item 24) Personnel Required Light-Wheel Vehicle Mechanic (91B) (1) Crane Operator (21F) (1)

REPAIR Removing the Clamp Plate Assembly 1. Remove two 1/2-13 UNC hex locknut (Figure 1, Item 7) and two 1/2-inch flat washer (Figure 1, Item 6). 2. Remove clamp plate assembly (Figure 1, Item 5) and spacer block (Figure 1, Item 4) from the bolts (Figure 1, Item 3). 3. Remove two 1/2-13 UNC x 4.5 inch hex head bolts (Figure 1, Item 3) from the holes in the clamp plate channel (Figure 1, Item 1).

NOTE
Clamp plate assemblies (Figure 1, Item 5) are installed on either side of the mounting plate assembly (Figure 1, Item 2). Work in conjunction with the tie-down post assemblies to secure the CBC/mounting plate combination to the vehicle bed (Figure 1, Item 8). 4. Repeat for the second clamp plate assembly located on the opposite side of the CBC.

0034-1

TM 10-5411-247-13&P REPAIR - Continued.

0034

2 3

4 5 8 6 7 Figure 1. Clamp Plate Assembly Removal. END OF TASK Removing the Vehicle Bed Plug 1. Remove a 3/8-16 UNC x 2 inch long bolt (Figure 2, Item 6), lockwasher (Figure 2, Item 7), and flat washer (Figure 2, Item 8) that secure the plug (Figure 2, Item 5) and bottom plate (Figure 2, Item 4) to the base of the tie-down post (Figure 2, Item 3) from the underside of the vehicle bed (Figure 2, Item 1). Discard lockwasher. 2. Remove the pin (Figure 2, Item 2) that secures the tie-down post assemblies (Figure 2, Item 3) to the vehicle bed (Figure 2, Item 1). 3. Remove plug (Figure 2, Item 5) and bottom plate (Figure 2, Item 4) to the base of the tie-down post (Figure 2, Item 3). 4. Repeat for the remaining tie-down post assemblies on each corner of the vehicle bed.

0034-2

TM 10-5411-247-13&P REPAIR - Continued.

0034

3 4 8 5 7 6 Figure 2. Removing Vehicle Bed Plug. END OF TASK Lifting the CBC from the Vehicle Bed

NOTE
Once the mounting plate assembly (Figure 3, Item 6) has been completely disconnected on the bottom of the vehicle bed (Figure 2, Item 1), the CBC can be carefully lifted from the vehicle bed (Figure 3, Item 2).

0034-3

TM 10-5411-247-13&P REPAIR - Continued.

0034

WARNING

RTV ADHESIVE, MIL-A-46146 RTV Silicon Adhesive is irritating to eyes and skin and shall be used only in a well-ventilated area. Do not induce vomiting if ingested obtain medical attention. Flammable above 200 F (93.3 C). Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials.

NOTE
Four tie-down post assemblies (Figure 3, Item 4) are installed at the four corners of the mounting plate assembly (Figure 3, Item 6). 1. Remove two 5/16 inch (0.328 inch ID x 1.375 inch OD x 0.063 inch thick) flat washers (Figure 3, Item 3), followed by 5/16 inch lockwasher (Figure 3, Item 2) and 5/16 inch UNC x 1 3/4 inch long hex head screw (Figure 3, Item 1) on the mounting plate assembly (Figure 3, Item 6), spacer plate (Figure 3, Item 5), and into the tie-down post assembly (Figure35, Item 4). Discard lockwasher. 2. Repeat step 1 for the remaining tie-down post assemblies on each corner of the vehicle bed.

1 2

6 3 5

Figure 3. Removing the Tie-Down Post Assembly. 3. Leave the tie-down post assemblies in place in the vehicle bed when removing the CBC from the vehicle.

0034-4

TM 10-5411-247-13&P REPAIR - Continued. 4. Remove RTV adhesive from around the threshold area by starting at the left (Figure 4, Item 1) or right (Figure 4, Item 3) corner of the CBC under the area where the vehicle bed (Figure 4, Item 2) meets the mounting plate (Figure 4, Item 4) with a putty knife. 2

0034

4 Figure 4. RTV Adhesive Removal.

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its height extended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Once the CBC comes clear of the vehicle bed, personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death.

NOTE
A tie-own post may stay attached to the mounting kit because of the RTV around the edges. You may need to pry the tie-down posts off the mounting kit when lifting the CBC away from the vehicle bed and place them back into the vehicle bed when remove for installation. It is important to ensure that the CBC and mounting plate combination is level when lifting the CBC from the vehicle bed, or the tie-down post assemblies may bind as they are lifted from the vehicle bed pockets. Since the weight of the CBC is not distributed evenly, the CBC may tilt toward the rear when lifted with the hoisting sling. To compensate for this condition and to ensure that the CBC is level, additional weight, such as two 50-pound sandbags or other weight, should be placed toward the front edge of the roof. 5. Lift the CBC (Figure 5, Item 2) and mounting plate (Figure 5, Item 3) combination from the vehicle bed (Figure 5, Item 4) of the LMTV high enough to place support blocks under the CBC. A pry bar may be needed to pry the edges of the mounting kit away from the vehicle bed. Be aware that the CBC may shift when prying. 6. Slowly lift the CBC above the bed (Figure 5, Item 4) of the LMTV. Be sure that the CBC is level as it is suspended in the air. Remove the tie-down post assemblies if attached when the CBC is lifted. 0034-5

TM 10-5411-247-13&P REPAIR - Continued. 7. Place the CBC onto a set of supporting blocks placed between the bed of the LMTV and the CBC. 8. Scrape RTV adhesive and rubber strip from CBC and bed of LMTV using a putty knife.

0034

WARNING

METHYLETHYLKETONE, ASTM D-740 Methylethylketone is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame. Gloves and safety goggles should be worn during use. Wipe CBC and bed of the LMTV mounting areas with a clean cloth dampened in MEK and immediately wipe solvent from surfaces with a clean, dry cloth. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 9. Completely clean the CBC and vehicle bed of all rubber strip material using methylethylketone. 10. Repeat steps 6 and 7 until RTV adhesive and rubber strip have been completely removed from CBC and bed of LMTV. 11. Lift the CBC and place the support blocks on the ground.

CAUTION
Do not sit the CBC down on the supporting blocks with the tie-down post assemblies attached. 12. Lower the CBC onto the support blocks on the ground.

1 SANDBAGS OR OTHER WEIGHT MAY BE USED ALONG THE FRONT EDGE OF THE CBC ROOF IN ORDER TO LEVEL THE UNIT DURING LIFTING AND LOWERING.

Figure 5. Lifting the CBC from the Vehicle Bed. END OF TASK 0034-6

TM 10-5411-247-13&P REPAIR - Continued. Remove the Mounting Kit

0034

1. Remove four 5/16-18 UNC x 1 inch long carriage bolts (Figure 6, Item 12), four lockwashers (Figure 6, Item 14), four flat washers (Figure 6, Item 13) and four 5/16-inch UNC hex nuts (Figure 6, Item 15) from curb side of the CBC. Discard lockwashers. 2. Remove the curb side mounting plate (Figure 6, Item 3). 3. Remove four 5/16-18 UNC x 1 inch long carriage bolts (Figure 6, Item 12), four lockwashers (Figure 6, Item 14), four flat washers (Figure 6, Item 13) and four 5/16-inch UNC hex nuts (Figure 6, Item 15) from road side of the CBC. Discard lockwashers. 4. Remove the road side mounting plate (Figure 6, Item 11).

WARNING

Do not lift the Cargo Bed Cover (CBC) (Figure 6, Item 1) in its retracted (lowered) position. Do not use the lift rings to lift a CBC (Figure 6, Item 1) with an installed payload greater than 1100 pounds (499 kg). Make sure to use handling equipment rated for the equipment it will be lifting. Failure to adhere to this warning may result in injury or death. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death. 5. Lift the CBC (Figure 6, Item 1) and relocate the blocks so the front and rear mounting plate (Figure 6, Item 2 and 10) can be removed. 6. Place the supporting blocks under the sidewalls of the CBC (Figure 6, Item 1) approximately 25 inches from the corners. This will provide adequate room to remove the front and rear sections. 7. Remove four 5/16-18 UNC x 1 1/4-inch long carriage bolts (Figure 6, Item 4), four 5/16-inch flat washer (Figure 6, Item 6), four 5/16-inch lockwasher (Figure 6, Item 8), and four 5/16-UNC hex nut (Figure 6, Item 7) from up through the mounting plate and the holes in the CBC threshold on either side of the personnel door opening. Discard lockwashers. 8. Remove four 5/16-18 UNC x 1 inch long carriage bolts (Figure 6, Item 12), four 5/16-inch flat washer (Figure 6, Item 13), four 5/16-inch lockwasher (Figure 6, Item 14), and four 5/16-UNC hex nut (Figure 6, Item 15) from up through the ends of the rear mounting plate (Figure 6, Item 10) and the holes in the zee brackets along the sidewalls nearest the corners. Discard lockwashers. 9. Remove three 5/16-18 UNC x 0.63 inch long pan head screws (Figure 6, Item 9) DOWN through the section of the CBC threshold at the door opening and into threaded inserts mounted in the mounting plate with three 5/16-inch lockwashers (Figure 6, Item 4) under each head. Discard lockwashers. 10. Remove the rear mounting plate (Figure 6, Item 10).

0034-7

TM 10-5411-247-13&P REPAIR - Continued. 1

0034

15

14 2 13 11 12

10

8 7 9

6 5 4 Figure 6. Removing the Rear, Road Side, and Curb Side Mounting Plate Sections.

0034-8

TM 10-5411-247-13&P REPAIR - Continued.

0034

11. Remove four 5/16-18 UNC x 1 inch long carriage bolts (Figure 7, Item 5), four 5/16-inch flat washer (Figure 7, Item 3), four 5/16-inch lockwasher (Figure 7, Item 2) and four 5/16-UNC hex nut (Figure 7, Item 1) up through the mounting plate (Figure 7, Item 6) and through the CBC zee bracket (Figure 7, Item 4). Discard lockwashers. 12. Remove the front mounting plate (Figure 6, Item 2). 1 2

3 4 6 5

Figure 7. Removing the Front Mounting Plate Section.

END OF TASK Installing the Mounting Kit to the CBC 1. Remove all RTV from the bottom of the CBC and the mounting kit. 2. Clean the bottom edge of the CBC and the surface of the mounting kit to which the rubber stripping will be applied. 3. Remove the tie-down posts from the vehicle bed. 4. Clean all the RTV from the tie-down posts for installation. 5. Install the mounting kit to the CBC. For installation on to the vehicle bed, refer to WP 0020, Service Upon Receipt.

END OF TASK END OF WORK PACKAGE

0034-9/10 blank

TM 10-5411-247-13&P FIELD MAINTENANCE MOUNTING KIT, M1082, 2-1/2 TON LMTV TRAILER REMOVE, REPAIR

0035

INITIAL SETUP: Equipment Condition Trailer bed clean and free of debris. Side panels and tailgate removed (TM 9-2330-39413&P). Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Dispenser, RTV adhesive (WP 0055, Table 2, Item 2) Lifting Device (1 Ton minimum) Gloves (WP 0057, Table 1, Item 12) Goggles (WP 0055, Table 2, Item 12) References WP 0021 Personnel Required Light-Wheel Vehicle Mechanic (91B) (1) Crane Operator (21F) (1) Materials/Parts Anti-seize Lubricant (WP 0057, Table 1, Item 5) Adhesive, RTV-732 (WP 0057, Table 1, Item 1) Bag, Sand (WP 0057, Table 1, Item 6) Four Wood Support Blocks 4x4 12 inches long (WP 0057, Table 1, Item 29) Sandpaper (WP 0057, Table 1, Item 21) Rubber strip, 3/8 inch thk x 1.00 inch wide x 25 feet long, adhesive backed, color black, closed cell, epdm sponge rubber strip. (WP 0057, Table 1, Item 20) Masking Tape (WP 0057, Table 1, Item 26)

REPAIR Removal of Clamp Plate Assembly Two clamp plate assemblies (Figure 1, Item 10) (one on each side) are installed at the corners of the rear mounting plate assembly (Figure 1, Item 2) and are used to secure the CBC (Figure 1, Item 1) and mounting plate combination (Figure 1, Item 9) to the bed of the trailer (Figure 1, Item 11). 1. Remove a 1/2-13 UNC locknut (Figure 1, Item 8) and 1/2 inch flat washer (Figure 1, Item 7) securing the clamp plate assembly (Figure 1, Item 10) from rear passenger side. Discard locknut. 2. Remove bottom plate with rubber pad attached (Figure 1, Item 6) from the underside of the trailer bed (Figure 1, Item 11). 3. Remove the spacer (Figure 1, Item 5). 4. Remove a hex head bolt (Figure 1, Item 4) from each hole in the clamp plate (Figure 1, Item 3). 5. Repeat the above procedure for the clamp plate assembly located on the road side of the CBC.

0035-1

TM 10-5411-247-13&P REPAIR - Continued. 1 4 3

0035

5 6 11 10 9 8 7

Figure 1. Removal of Clamp Plate Assembly. END OF TASK Remove Gusset Plates

NOTE
A step/device ladder may be needed to reach the hardware that secures the mounting plate to the trailer bed. 1. Remove a locknut (Figure 2, Item 6) and flat washer (Figure 2, Item 5) from the end of the 7-inch bolt (Figure 2, Item 1). Discard locknut. 2. Remove one 7-inch bolt (Figure 2, Item 1) and flat washer (Figure 2, Item 2) through both slotted holes (Figure 2, Item 3) in the vertical trailer support (Figure 2, Item 4). 3. Repeat step 2 for opposite side gusset plate. 4 3 2 3

Figure 2. CBC Gusset Plate Removal. END OF TASK

0035-2

TM 10-5411-247-13&P Remove the CBC from the Trailer

0035

1. Remove RTV adhesive around the threshold area by starting at the left (Figure 3, Item 1) or right (Figure 3, Item 3) corner of the CBC under the area where the trailer bed (Figure 3, Item 4) meets the mounting plate (Figure 3, Item 2) with a putty knife. 2

Figure 3. RTV Adhesive Removal.

WARNING

Do not lift the CBC in its height-retracted (lowered), condition. The CBC must be in its heightextended (fully-raised) condition prior to using the lift rings for lifting. Failure to adhere to this warning may result in injury or death. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death.

NOTE
It is important to ensure that the CBC and mounting plate combination is level when lifting the CBC from the trailer bed or the tie-down post assemblies may bind as they are lifted from the trailer bed pockets. Since the weight of the CBC is not distributed evenly, the CBC may tilt toward the rear when lifted with the hoisting sling. To compensate for this condition and to ensure that the CBC is level, additional weight such as two 50-pound sandbags or other weight should be placed toward the front edge of the roof. 2. Lift the CBC (Figure 4, Item 2) and mounting plate (Figure 4, Item 3) combination from the trailer bed (Figure 4, Item 4) of the trailer by lifting the CBC (Figure 4, Item 2), using the hoisting sling (Figure 4, Item 1). A pry bar may be needed to pry the edges of the mounting kit away from the trailer bed. 3. Slowly lift the CBC (Figure 4, Item 1) into position above the bed (Figure 4, Item 4) of the trailer. Be sure that the CBC (Figure 4, Item 1) is level as it is suspended in the air. 4. Place the CBC (Figure 4, Item 1) onto a set of supporting blocks placed between the bed of the trailer (Figure 4, Item 4) and the CBC (Figure 4, Item 1).

0035-3

TM 10-5411-247-13&P REMOVE - Continued.

0035

5. Scrape RTV adhesive and rubber strip from CBC (Figure 4, Item 2) and bed of trailer (Figure 4, Item 4) using a putty knife. 6. Lift the CBC (Figure 4, Item 2) and reposition support blocks. 7. Lower the CBC (Figure 4, Item 2) onto support blocks. 8. Repeat steps 6 and 7 until RTV adhesive and rubber strip have been completely removed from CBC (Figure 4, Item 2) and bed of trailer (Figure 4, Item 4).

WARNING

METHYLETHYLKETONE, ASTM D-740 Methylethylketone is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame. Gloves and safety goggles should be worn during use. Wipe CBC and bed of the trailer mounting areas with a clean cloth dampened in MEK and immediately wipe solvent from surfaces with a clean, dry cloth. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 9. Use methylethylketone solvent to completely clean the CBC and trailer of any and all rubber strip.

SANDBAGS OR OTHER WEIGHT MAY BE USED ALONG THE FRONT EDGE OF THE CBC ROOF IN ORDER TO LEVEL THE UNIT DURING LIFTING AND LOWERING.

4 Figure 4. Lifting the CBC from the Trailer Bed. END OF TASK 0035-4

TM 10-5411-247-13&P Remove the Mounting Kit

0035

1. Remove four 5/16-18 UNC x 1 inch long carriage bolts (Figure 5, Item 12), four lockwashers (Figure 5, Item 14), four flat washers (Figure 5, Item 13) and four 5/16-inch UNC hex nuts (Figure 5, Item 15) from curb side of the CBC. Discard lockwashers. 2. Remove the curb side mounting plate (Figure 6, Item 3). 3. Remove four 5/16-18 UNC x 1 inch long carriage bolts (Figure 5, Item 12), four lockwashers (Figure 5, Item 14), four flat washers (Figure 5, Item 13) and four 5/16-inch UNC hex nuts (Figure 5, Item 15) from road side of the CBC. Discard lockwashers. 4. Remove the road side mounting plate (Figure 5, Item 11).

WARNING

Do not lift the Cargo Bed Cover (CBC) (Figure 5, Item 1) in its retracted (lowered) position. Do not use the lift rings to lift a CBC (Figure 5, Item 1) with an installed payload greater than 1100 pounds (499 kg). Make sure to use handling equipment rated for the equipment it will be lifting. Failure to adhere to this warning may result in injury or death. Personnel should stand clear of the CBC while it is being lifted and moved. Failure to do so could cause injury or death. 5. Lift the CBC (Figure 5, Item 1) and relocate the blocks so the front and rear mounting plate (Figure 5, Item 2 and 10) can be removed. 6. Place the supporting blocks under the sidewalls of the CBC (Figure 6, Item 1) approximately 25 inches from the corners. This will provide adequate room to remove the front and rear sections. 7. Remove four 5/16-18 UNC x 1 1/4 inch long carriage bolts (Figure 5, Item 5), four 5/16-inch flat washer (Figure 5, Item 6), four 5/16-inch lockwasher (Figure 5, Item 8), and four 5/16-UNC hex nut (Figure 5, Item 7) from up through the mounting plate and the holes in the CBC threshold on either side of the personnel door opening. Discard lockwashers. 8. Remove four, 5/16-18 UNC x 1 inch long carriage bolts (Figure 5, Item 12), four 5/16-inch flat washer (Figure 5, Item 13), four 5/16-inch lockwasher (Figure 5, Item 14), and four 5/16 UNC hex nut (Figure 5, Item 15) from up through the ends of the rear mounting plate (Figure 5, Item 10) and the holes in the zee brackets along the sidewalls nearest the corners. Discard lockwashers. 9. Remove three, 5/16-18 UNC x 0.63 inch long pan head screws (Figure 5, Item 9) DOWN through the section of the CBC threshold at the door opening and into threaded inserts mounted in the mounting plate with three 5/16 -inch lockwashers (Figure 5, Item 4) under each head. Discard lockwashers. 10. Remove the rear mounting plate (Figure 5, Item 10).

0035-5

TM 10-5411-247-13&P REMOVE - Continued. 1

0035

15 14 13 11 2

12

10 7 8 9

6 5 4 Figure 5. Removing the Rear, Road Side, and Curb Side Mounting Plate Sections. 11. Remove four 5/16-18 UNC x 1 inch long carriage bolts (Figure 6, Item 5), four 5/16-inch flat washer (Figure 6, Item 3), four 5/16-inch lockwasher (Figure 6, Item 2) and four 5/16-UNC hex nut (Figure 6, Item 1) up through the mounting plate (Figure 6, Item 6) and through the CBC zee bracket (Figure 6, Item 4). Discard lockwashers. 12. Remove the front mounting plate (Figure 5, Item 2). 1 2 3 4 6 5

Figure 6. Removing the Front Mounting Plate Section.

0035-6

TM 10-5411-247-13&P

0035

REMOVE - Continued.

NOTE
If gusset plate is damaged, follow steps below. 1. Remove three lockwashers, three locknuts, three flat washers. Discard lockwashers and locknuts. 2. Remove gusset plate and spacer from the mounting kit. END OF TASK Installing the Mounting Kit to the CBC

WARNING

METHYLETHYLKETONE, ASTM D-740 Methylethylketone is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame. Gloves and safety goggles should be worn during use. Wipe CBC and bed of the trailer mounting areas with a clean cloth dampened in MEK and immediately wipe solvent from surfaces with a clean, dry cloth. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 1. Remove all RTV from the bottom of the CBC and the mounting kit. 2. Clean the bottom edge of the CBC and the surface of the mounting kit that the rubber stripping will be applied. 3. Clean all the RTV from the tie down posts for installation. 4. Install the mounting kit to the CBC. For installation on to the trailer bed, refer to WP 0021, Service Upon Receipt. END OF TASK END OF WORK PACKAGE

0035-7/8 blank

TM 10-5411-247-13&P

0036

FIELD MAINTENANCE DENTED SKINS AND CORE REPAIR

INITIAL SETUP: Equipment Condition CBC is clean, free of debris, and in the fullyextended position (WP 0005). Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Light, Floor (WP 0055, Table 2, Item 14) Goggles, Industrial (WP 0055, Table 2, Item 12) Drill, Electric, Portable (WP 0055, Table 2, Item 3) Drill Set, Twist (WP 0055, Table 2, Item 5) Gloves, Rubber, Industrial (WP 0055, Table 2, Item 11) Dispenser, Sealant (WP 0055, Table 2, Item 2) References WP 0037 WP 0042 Personnel Required Metal Worker (44B) (1) Materials/Parts Sandpaper (WP 0057, Table 1, Item 21) Rags, Wiping (WP 0057, Table 1, Item 19) Tape, Masking (WP 0057, Table 1, Item 26) Adhesive, Two-part Epoxy (WP 0057, Table 1, Item 2) Alodine, Brush (WP 0057, Table 1, Item 3) Cartridges, 1/10 Gallon Empty, 7579a44 (WP 0057, Table 1, Item 7) Nozzle, 2 1/2 In Long With 1/8 In Orifice (WP 0057, Table 1, Item 16) Sticks, Mixing (WP 0057, Table 1, Item 25) Mask (WP 0057, Table 1, Item 15)

REPAIR Repair of Depression 4 Square Inches or Smaller Puncture The following procedure covers repair of a depression with a small puncture in any shelter panel skin (depression exceeding 2 square inches (12.9 square cm) or deeper than 0.25 inch (6.4 mm), but not larger than 4 square inches (25.8 square cm) or puncture not larger than 1 square inch (6.5 square cm). For larger punctures, refer to WP 0037.

0036-1

TM 10-5411-247-13&P REPAIR - Continued.

0036

WARNING

Safety goggles must be worn during repair to protect eyes from flying metal chips. Failure to wear proper eye protection may result in eye injury and/or blindness. 1. Drill two 1/8 inch (3.18 mm) diameter holes (Figure 1, Item 1) within damaged area.

WARNING

CARC paint dust is a health hazard. Wear protective eyewear, mask, and goggles when sanding CARC paint surfaces. Failure to observe this warning can result in personal injury. 2. Sand area around drilled holes so there are no sharp edges. 3. Use tape to make a box around the area being worked on.

WARNING

EPOXY COATING KIT, MIL-PRF-22750 Two-part epoxy adhesive is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame. Gloves and safety goggles should be worn during use. 4. Mix a quantity of the Adhesive, Two-part Epoxy, (Figure 1, Item 3) in accordance with manufacturers instructions, components (part A and part B) sufficient for the scope of the repair in an open top container. The two adhesive components are different colors; part A is yellow and part B is blue. When properly and completely mixed, the color of the Adhesive, Two-part Epoxy is green. Personnel should mix the two parts until the Adhesive, is a uniform green, with no streaks of yellow or blue. 5. Load the epoxy (Figure 1, Item 2) into an empty 1/10 gallon cartridge. 6. Inject the mixed epoxy into the honeycomb core. 7. Load the mixed epoxy into the empty cartridge. 8. Scoop a quantity of mixed Adhesive, Two-part Epoxy onto the putty knife. 9. Install nozzle onto the end of the empty cartridge. 10. Place into the open end of the cartridge. 11. Load a sufficient amount of Adhesive, Two-part Epoxy into the cartridge for the scope of repair. When the Adhesive, Two-part Epoxy is completely loaded into the cartridge, install the end cap. 12. Install the cartridge into a sealant dispenser. 13. Inject Adhesive, Two-part Epoxy through two drilled holes (Figure 1, Item 1) to fill core cells completely. 14. Tape over holes in order to hold the epoxy in place during the curing process. 0036-2

TM 10-5411-247-13&P

0036

REPAIR - Continued.

Figure 1. Inserting Adhesive, Two-part Epoxy, in Drilled Holes. 15. Cure Adhesive, Two-part Epoxy at room temperature (75 F) for 72 hours.

CAUTION
Ensure that the surface temperatures of the CBC do not exceed 225 F. Failure to adhere to this caution may result in damage to the CBC skin and or cells.

NOTE
Alternate cures can be achieved by exposing the repaired area to 150 F for 3 to 4 hours or 200 F for 40 to 60 minutes. If 150 F or 200 F cures are used, allow additional time for repaired area to warm to curing temperature. 16. Check by tapping damaged area to ensure complete filling of cells. 17. Ensure masking tape (Figure 2, Item 1) is still in position around the sanded area. 18. Mix a small quantity of Adhesive, Two-part Epoxy (Figure 2, Item 2) in accordance with manufacturers instructions. 19. Using spatula or putty knife (Figure 2, Item 3), fill remainder of damaged area with Adhesive, Two-part Epoxy until slightly mounded above the surface.

0036-3

TM 10-5411-247-13&P

0036

REPAIR - Continued. 1 2

. Figure 2. Using Putty Knife to Fill Dent.

CAUTION
Ensure that the surface temperatures of the CBC do not exceed 225 F. Failure to adhere to this caution may result in damage to the CBC skin and or cells.

NOTE
Alternate cures can be achieved by exposing the repaired area to 150 F for 3 to 4 hours or 200 F for 40 to 60 minutes. If 150 F or 200 F cures are used, allow additional time for repaired area to warm to curing temperature. 20. Cure adhesive at room temperature (75 F) for 72 hours.

WARNING

CARC paint dust is a health hazard. Wear protective eyewear, mask, and goggles when sanding CARC paint surfaces. Failure to observe this warning can result in personal injury. 21. Sand surface of cured adhesive and damaged area with sandpaper to remove all traces of paint and excess adhesive.

0036-4

TM 10-5411-247-13&P

0036

REPAIR - Continued. 22. Remove masking tape (Figure 2, Item 1) and clean repaired surface.

WARNING

ALODINE, MIL-C-5541 Alodine is flammable and toxic and shall be used only in a well-ventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 23. Apply the alodine solution, with a brush, to the cleaned and rinsed aluminum surface, liberally, quickly, and evenly. Allow it to act from 1 to 5 minutes before rinsing.

NOTE
The solution should be applied to only as much surface as can be coated and rinsed before the alodine solution dries. 24. Proceed with the coating and rinsing until the entire surface is coated with alodine. 25. Before the alodine solution dries, wipe it from the surface with a wiping rag that is wet with clean water. The alodine solution may also be rinsed from the surface with clean water from a hose. 26. After the rinsing, allow the work to air dry.

NOTE
Drying can be speeded by wiping with clean, dry rags. Clean, dry, compressed air should be used to blow moisture from joints, and depressions to speed the drying. When the surface is entirely dry, the part is ready for service without further treatment, or if desired, it may be painted in accordance with manufacturers directions. 27. Refinish in accordance with WP 0042. END OF TASK END OF WORK PACKAGE

0036-5/6 blank

TM 10-5411-247-13&P

0037

FIELD MAINTENANCE PUNCTURED SKINS AND CORE REPAIR

INITIAL SETUP: Equipment Condition Damaged area to be cleaned of mud and dirt. Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Light, Floor (WP 0055, Table 2, Item 14) Drill, Electric, Portable (WP 0055, Table 2, Item 3) Goggles Industrial (WP 0055, Table 2, Item 12) Drill Set, Twist: W/25 Components And Metal Box, Numbered Series (WP 0055, Table 2, Item 4) Drill Set, Twist (WP 0055, Table 2, Item 5) Gloves, Rubber, Industrial (WP 0055, Table 2, Item 11) Dispenser, Adhesive (WP 0055, Table 2, Item 2) Riveter, Hand Blind with 1/8 inch nosepiece (WP 0055, Table 2, Item 16) Router, Electric, Portable (WP 0055, Table 2, Item 19) Bit, Router (WP 0055, Table 2, Item 1) References WP 0038 WP 0041 WP 0042 Personnel Required Metal Worker (44B) (1) Materials/Parts Adhesive, Two-part Epoxy (WP 0057, Table 1, Item 2) Alodine, Brush (WP 0057, Table 1, Item 3) Cartridges, 1/10 Gallon Empty (WP 0057, Table 1, Item 7) Core, 1.00 (or 1.50) Inch Thick 12 Inches 12 Inches (WP 0057, Table 1, Item 9 or 10) Oil, Machine (WP0057, Table 1, Item 17) Mask (WP 0057, Table 1, Item 15) Nozzle, 2 1/2 In Long With 1/8 In Orifice (WP 0057, Table 1, Item 16) Pail, Mixing (WP 0057, Table 1, Item 18) Rags, Wiping (WP 0057, Table 1, Item 19) Sandpaper (WP 0057, Table 1, Item 21) Sealant, Type II, MIL-S-8802 (WP 0057, Table 1, Item 22) Sheet, Aluminum, .032 Inch Thick 12 Inches 12 Inches (WP 0057, Table 1, Item 23) Solvent, Methylethylketone (WP 0057, Table 1, Item 24) Sticks, Mixing (WP 0057, Table 1, Item 25) Tape, Masking (WP 0057, Table 1, Item 26) Procedures begin on next page.

0037-1

TM 10-5411-247-13&P REPAIR Repair of Puncture with Minimal Damage to Core

0037

WARNING

Safety goggles must be worn during repair to protect eyes from flying metal chips. Failure to wear proper eye protection may result in eye injury and/or blindness.

NOTE
Sidewalls can be damaged by dents or punctures. The following procedures cover repair of panel dents or punctures through one or both skins and core with damage area not exceeding 100 square inches (645 square cm). Panel repairs larger than 100 square inches (645 square cm) are beyond the scope of this manual. Openings made to repair damage may be oval, circular, square, or rectangular with rounded corners. Ensure core ribbon direction is same as panel. Use a portable router equipped with a straight or spiral fluted (pull down) bit, or other aluminum cutting equipment, such as to cut aluminum patch (Figure 1, Item 4), one inch larger than the size of the damaged area. 1. Lay out and drill holes (Figure 1, Item 5) in patch (Figure 1, Item 4) as shown in accompanying illustration, roughly one inch apart. 2. Center patch (Figure 1, Item 4) over damaged area (Figure 1, Item 1). 3. Mark patch outline on panel skin.

WARNING

CARC paint dust is a health hazard. Wear protective eyewear, mask, and goggles when sanding CARC paint surfaces. Failure to observe this warning can result in personal injury. 4. Sand all paint from damaged panel skin within marked area with sandpaper. 5. Center patch over damaged area (Figure 1, Item 1) and drill No. 30 diameter holes (Figure 1, Item 6) in panel skin. 6. Use holes (Figure 1, Item 5) in patch (Figure 1, Item 4) as a template. 7. Index patch (Figure 1, Item 4) and panel skin (Figure 1, Item 7) with a mark to allow patch to be replaced in same orientation. 8. Deburr all drill holes (Figure 1, Items 5 and 6).

0037-2

TM 10-5411-247-13&P REPAIR - Continued.

0037

WARNING

METHYLETHYLKETONE, ASTM D-740 Methylethylketone is flammable and toxic and shall be used only in a well-ventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 9. Wipe damaged area (Figure 1, Item 1) and patch (Figure 1, Item 4) with a clean cloth dampened in MEK and immediately wipe solvent from surfaces with a clean, dry cloth. Do not allow solvent to get into exposed core.

WARNING

Two-part Epoxy adhesive is flammable and toxic and shall be used only in a well-ventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 10. Mix a quantity of the Adhesive, Two-part Epoxy in accordance with manufacturers instructions, components (part A and part B) sufficient for the scope of the repair, in an open top container. The two adhesive components are different colors; part A is yellow and part B is blue. When properly and completely mixed, the color of the adhesive is green. Personnel should mix the two parts until the adhesive is a uniform green, with no streaks of yellow or blue. 11. Pack adhesive (Figure 1, Item 2) in puncture (Figure 1, Item 3) and all exposed core cells. Use mixing sticks to pack adhesive and obtain a smooth surface. 12. Apply a thick film of remaining adhesive to mating surface of patch (Figure 1, Item 4). 13. Place patch (Figure 1, Item 4) over prepared area in same orientation used in earlier step. 14. Align holes (Figure 1, Items 5 and 6). 15. Use hand blind riveter to install 1/8-inch (3.18 mm) diameter blind rivets in accordance with WP 0038. 16. Cure adhesive at room temperature (75 F) for 72 hours. If a heat source is available, alternate cures can be achieved by exposing the repaired area to 150 F for 3 to 4 hours or 200 F for 40 to 60 minutes. If 150 F or 200 F cures are used, allow additional time for repaired area to warm to curing temperature. 17. Ensure that the surface temperature of the CBC does not exceed 225 F. 18. Proceed with Alodining, following the repairs of punctures through both skins IAW Alodine Application, at the and of the work package.

0037-3

TM 10-5411-247-13&P REPAIR - Continued.

0037

1 3

7 6

1/8 INCH (3.18 MM) 5 4

1/2 INCH (12.7 MM) TYPICAL

1/2 INCH (12.7 MM) TYPICAL

1/2 INCH (12.7 MM) TYPICAL Figure 1. Repairs to Small Punctures with Minimal Core Damage. END OF TASK

0037-4

TM 10-5411-247-13&P Repair of Puncture through One Skin and Core

0037

NOTE
Core material thickness depends on thickness of side wall being repaired. 1. Cut an opening that is one inch greater than damaged area through the damaged aluminum panel skin using a portable electric router and a straight or spiral fluted (pull down) bit, or equivalent aluminum cutting equipment. Avoid sharp corners in opening. 2. Peel damaged portion of skin from core by lifting and rolling skin with screwdriver and pliers. 3. Trim core area with a utility knife to same size as opening, while leaving small amount of core material on opposite skin. 4. Cut a rectangular-shaped aluminum patch (Figure 2, Item 1) 1-1/2 inch (3.8 cm) larger all around than cutout opening. 5. Lay out and drill 1/8-inch (3.18 mm) diameter holes (Figure 2, Item 3) in patch. 6. Cut a section of core material the same size as cutout opening. Core plug should be flush with or slightly lower than panel skin surface. 7. Center patch over cutout opening and mark patch outline (Figure 2, Item 2) on panel skin. 8. Drill No. 30 diameter holes in panel skin with patch as template.

WARNING

CARC paint dust is a health hazard. Wear protective eyewear, mask, and goggles when sanding CARC paint surfaces. Failure to observe this warning can result in personal injury.

CAUTION
Do not use power sander when removing paint. Failure to adhere to this caution may result in damage to CBC skin. 9. Sand all paint from panel skin, within marked area, with sandpaper. 10. Mark both patch and panel to ensure replacement in the same direction. 11. Deburr drill holes (Figure 2, Item 3) and sand all paint from panel skin within marked area. 12. Clean loose core material, dust, and chips from cutout opening.

0037-5

TM 10-5411-247-13&P REPAIR - Continued.

0037

1 INCH (25.4 MM) TYPICAL 1/2 INCH (12.7 MM) TYPICAL 1/8 INCH DRILL (3.18 MM) TYPICAL 2 3 1

Figure 2. Damage to Single Skin Repair.

WARNING

METHYLETHYLKETONE, ASTM D-740 Methylethylketone is flammable and toxic and shall be used only in a well-ventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 13. Wipe panel skin, within marked area and patch (Figure 2, Item 1), with a clean cloth dampened with MEK and immediately wipe solvent from surfaces with a clean, dry cloth.

0037-6

TM 10-5411-247-13&P REPAIR - Continued.

0037

WARNING

.
SEALANT, MIL-S-8802, TYPE II, CLASS 8 Sealant is flammable and toxic and shall be used only in a well-ventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 14. Mix a quantity of the sealant in accordance with manufacturers instructions, components (part A and part B) sufficient for the scope of the repair in an open top container. 15. Apply an even coat of sealant to cutout core surfaces. 16. Insert core plug in cutout opening and press firmly in place. 17. Apply an even coat of sealant around core plug. 18. Fill any gaps around plug. 19. Cure sealant at room temperature (75 F) for 72 hours. If a heat source is available, alternate cures can be achieved by exposing the repaired area to 150 F for 3 to 4 hours or 200 F for 40 to 60 minutes. If 150 F or 200 F cures are used, allow additional time for repaired area to warm to curing temperature.

NOTE
Ensure that the surface temperature of the CBC does not exceed 225 F. 20. Sand cured sealant with sandpaper to obtain a smooth contour with surface of panel skin. 21. Apply an even coat of adhesive to mating surface of patch. 22. Place patch (Figure 2, Item 1) over prepared area in same orientation as marked in earlier step. 23. Align holes. Using a hand blind riveter, install 1/8-inch (3.18 mm) diameter blind rivet in accordance with WP 0038. 24. Proceed with Alodining, following the repairs of punctures through both skins IAW Alodine Application, at the end of the work package. END OF TASK

0037-7

TM 10-5411-247-13&P Repair to Holes through Both Outer Skins and Inner Core

0037

NOTE
Core material thickness depends on thickness of side wall being repaired. 1. Cut an opening that is one inch greater than damaged area through both inner and outer panel skins using a portable electric router and a straight or spiral fluted (pull down) bit, or equivalent aluminum cutting equipment. Avoid sharp corners in opening. 2. Cut any remaining core out to the opening of the skin cutouts. 3. Cut a core plug (Figure 3, Item 2) and two aluminum patches (Figure 3, Item 1) one to three inches larger than the opening cut in Step 1 above, on all sides.

WARNING

SEALANT, MIL-S-8802, TYPE II, CLASS 8 Sealant is flammable and toxic and shall be used only in a well-ventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials 4. Mix a quantity of the sealant in accordance with manufacturers instructions; components (part A and part B) in an open top container sufficient to bond two patches (Figure 3, Item 2) to core plug (Figure 3, Item 1).

WARNING

METHYLETHYLKETONE, ASTM D-740 Methylethylketone is flammable and toxic and shall be used only in a well-ventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 5. Wipe patches (Figure 3, Item 2) with a clean cloth dampened with MEK and immediately wipe solvent from surfaces with a clean, dry cloth. 6. Apply a thick coat of sealant to one side of each patch. 7. Place core plug (Figure 3, Item 2) between two patches (Figure 3, Item 1) to create a sandwich panel (Figure 3, Item 3). 8. Cure adhesive at room temperature (75 F) for 72 hours. If a heat source is available, alternate cures can be achieved by exposing the repaired area to 150 F for 3 to 4 hours, or 200 F for 40 to 60 minutes. If 150 F or 200 F cures are used, allow additional time for repaired area to warm to curing temperature.

0037-8

TM 10-5411-247-13&P REPAIR - Continued.

0037

NOTE
Ensure that the surface temperature of the CBC does not exceed 225 F. 9. Cut bonded sandwich panel (Figure 3, Item 3) to same size as cutout opening as detailed in earlier step. Ensure core ribbon direction is same as panel. 10. Drill 1/8-inch (3.18 mm) diameter holes (Figure 3, Item 6) in the two patches. 11. Position bonded sandwich panel (Figure 3, Item 3) in cutout opening. 12. Center patches (Figure 3, Item 8), one on each side of panel, over cutout opening. 13. Drill No. 30 (3.27 mm) diameter holes (Figure 3, Item 4) in panel skins and bonded sandwich panel, with patches as templates. 14. Mark each patch outline (Figure 3, Item 5) on panel skin.

WARNING

CARC paint dust is a health hazard. Wear protective eyewear, mask, and goggles when sanding CARC paint surfaces. Failure to observe this warning can result in personal injury. 15. Sand all paint from panel skin within marked area with sandpaper. 16. Index each patch and panel skin with a mark to allow patches to be replaced with same orientation. 17. Remove patches (Figure 3, Item 8) and bonded sandwich panel (Figure 3, Item 3). 18. Deburr drill holes (Figure 3, Items 4 and 6).

WARNING

CARC paint dust is a health hazard. Wear protective eyewear, mask, and goggles when sanding CARC paint surfaces. Failure to observe this warning can result in personal injury. 19. Sand all paint from panel skin within marked areas. 20. Clean loose core material, dust, and chips from cutout opening.

0037-9

TM 10-5411-247-13&P REPAIR - Continued.

0037

WARNING

METHYLETHYLKETONE, ASTM D-740 Methylethylketone is flammable and toxic and shall be used only in a well-ventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 21. Wipe panel skin within marked areas (two patches) and bonded sandwich panel metal skin with a clean cloth dampened with MEK solvent. Immediately wipe solvent from surfaces with a clean, dry cloth. 22. Mix a sufficient amount of Two-part Epoxy in accordance with manufacturers instructions. 23. Apply a thick coat of Two-part Epoxy to inside surfaces of panel cutout opening, bonded sandwich panel, and two patches. 24. Position bonded sandwich panel in cutout opening. 25. Fill any gaps between cutout opening and bonded sandwich panel with Two-part Epoxy. 26. Place patches (Figure 3, Item 8) over prepared areas in same orientation as described in earlier step. 27. Align holes (Figure 3, Items 4 and 6). Using a hand blind riveter, install 1/8-inch (3.18 mm) diameter blind rivet (Figure 3, Item 7), in accordance with WP 0038. 28. Proceed with alodining procedures IAW Alodine Application at end of work package.

0037-10

TM 10-5411-247-13&P

0037

2 1 3

1/2 INCH (12.7 MM) TYPICAL 2 INCH (50.8 MM) TYPICAL

4 1/8 INCH DIA. (3.18 MM) TYPICAL 1 INCH (25.4 MM) TYPICAL 5

1 INCH (25.4 MM) TYPICAL

Figure 3. Puncture Through Both Skins. END OF TASK

0037-11

TM 10-5411-247-13&P REPAIR - Continued. Alodine Application 1. Clean repaired surfaces. 2. Caulk around repair patches (Figure 3, Item 8) in accordance with WP 0041.

0037

WARNING

ALODINE, MIL-C-5541 Alodine is flammable and toxic and shall be used only in a well-ventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 3. Apply alodine solution, with a brush, to the cleaned and rinsed aluminum surface liberally, quickly, and evenly. Allow it to act from 1 to 5 minutes before rinsing.

NOTE
The solution should be applied to only as much surface as can be coated and rinsed before the alodine solution dries. 4. Proceed with the coating and rinsing until the entire surface is coated with alodine. 5. Before the alodine solution dries, wipe it from the surface with a wiping rag that is wet with clean water. The alodine solution may also be rinsed from the surface with clean water from a hose. 6. After the rinsing, allow the work to air dry.

NOTE
Drying can be speeded by wiping with clean, dry rags. Clean, dry, compressed air should be used to blow moisture from joints, depressions, and to speed the drying. When the surface is entirely dry, the part is ready for service without further treatment, or if desired, it may be painted in accordance with manufacturers directions. 7. Refinish in accordance with WP 0042. END OF TASK END OF WORK PACKAGE

0037-12

TM 10-5411-247-13&P

0038

FIELD MAINTENANCE BLIND RIVET REPLACE

INITIAL SETUP: Equipment Condition CBC fully-extended and locked in position (WP 0005). Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Goggles, Industrial (WP 0055, Table 2, Item 12) Drill, Electric, Portable (WP 0055, Table 2, Item 3) Drill Set, Twist: W/25 Components And Metal Box, Numbered Series (WP 0055, Table 2, Item 4) Riveter, Blind, Hand with 1/8 inch nosepiece (WP 0055, Table 2, Item 16) Punch, Pin, 1/8 Inch Dia. (WP 0055, Table 2, Item 15) Personnel Required Light-Wheel Vehicle Mechanic (91B) (1) Materials/Parts Pail, Mixing (WP 0057, Table 1, Item 18) Rags, Wiping (WP 0057, Table 1, Item 19) Sealant, Type II (WP 0057, Table 1, Item 22) Stick, Mixing, Epoxy (WP 0057, Table 1, Item 25) Tape, Masking (WP 0057, Table 1, Item 26)

REPLACE Remove Defective Blind Rivets

WARNING

Safety goggles must be worn during repair to protect eyes from flying metal chips. Failure to wear proper eye protection may result in eye injury and/or blindness. 1. Select a drill bit (Figure 1, Item 1) that is the same diameter as installed blind rivet (Figure 1, Item 2). 2. Hold drill perpendicular to the surface to prevent enlargement or damage to existing hole. 3. Drill through center of rivet (Figure 1, Item 2) just deep enough to sever the rivet head from shank. 4. Remove remainder of rivet with a pin punch. 5. Deburr rivet hole. END OF TASK

0038-1

TM 10-5411-247-13&P REPLACE - Continued. Install Blind Rivets 1. Select proper diameter and length of blind rivet (Figure 1, Item 2) for the hole. 2. Select appropriate nosepiece (Figure 1, Item 4) for hand blind riveter (Figure 1, Item 3). 3. Install nosepiece (Figure 1, Item 4).

0038

WARNING

SEALANT, MIL-S-8802, TYPE II, CLASS 8 Sealant is flammable and toxic and shall be used only in a well-ventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials.

NOTE
Maximum application life of sealant is 2 hours. 4. Mix a small quantity of the sealant, in an open top container, sufficient for the repair being performed.

NOTE
The sealant is supplied as two components, part A, and part B. The two-sealant components are different colors; part A is black and Part B is off white. The sealant is mixed in a ratio of 10:100 (Part A: Part B) by weight. This means, for example, that one ounce of Part A would require ten ounces of Part B to achieve a proper formulation. Before mixing the two components together, each component should be measured out and mixed separately to ensure that each component is uniform in color and consistency. Once the separate components are uniformly mixed, combine Part A and Part B together and mix the combination together in order to achieve a uniform dark grey color. Personnel should mix the two-parts and ensure that there are no visible streaks of black or white. 5. Apply sealant to rivet and insert rivet into hole. 6. Hold hand blind riveter (Figure 1, Item 3) at right angle to work. 7. Install on blind rivet stem (Figure 1, Item 5). 8. Push against work with just enough force to firmly seat rivet and prevent part separation. 9. Squeeze handle of hand blind riveter (Figure 1, Item 3). 10. Pull rivet until stem (Figure 1, Item 5) breaks. 11. If necessary, trim broken stem flush with rivet head. 12. Check installed rivet to ensure tightness of installation. 13. If installation is unacceptable, remove and replace in accordance with steps above.

0038-2

TM 10-5411-247-13&P

0038

REPLACE - Continued.

2 90

Figure 1. Blind Rivet Replacement. END OF TASK END OF WORK PACKAGE

0038-3/4 blank

TM 10-5411-247-13&P FIELD MAINTENANCE MANUALLY EXTENDING THE UPPER SECTION OF THE CBC

0039

INITIAL SETUP: Equipment Condition CBC clean, dry, and free of debris. Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Personnel Required Light-Wheel Vehicle Mechanic (91B) (1) References WP 0005

MANUALLY EXTENDING THE UPPER SECTION OF THE CBC

WARNING

Do not lift the CBC in its retracted (lowered) position. The CBC must be in its extended (fullyraised) position prior to using the lift rings for lifting the CBC for moving it off its mounting surface. Do not use the lift rings to lift a CBC with more than an additional payload of 100 pounds (equivalent weight of two 50-pound sand bags). Lift rings should only be used to lift an empty CBC that is not mounted to a vehicle. A CBC that has been installed on a vehicle may only be hoisted using the lifting points on the vehicle. Make sure to use handling equipment rated for the equipment it will be lifting. Do not use handling equipment rated for less than the gross weight of the CBC when handled by itself or the CBC plus the vehicle when the CBC has been installed on a vehicle. Failure to follow these lift warnings may result in severe injury or death to personnel or damage to equipment. Manually Extending the Upper Section of the CBC

CAUTION
Do not attach a hoisting sling to the lift rings in such a way as to create an angle between the cable and the CBC roof surface that is LESS THAN 45. Attaching the cable at any angle less than 45 will result in excessive strain on the lift rings which may result in damage to the CBC. Ensure the folding steps on the CBC outside wall are folded flat against the wall when lowering the upper section. Damage to the shelter could result if you do not fold them flat.

NOTE
The angle created between each cable and the roof surface of the CBC must not be any less than 45. 1. Attach the hoisting sling (Figure 1, Item 2), approved by the safety officer, to a suitable lifting device. 0039-1

TM 10-5411-247-13&P Manually Extending the Upper Section of the CBC- Continued.

0039

2. Attach the hooks (Figure 1, Item 1) from the hoisting sling (Figure 1, Item 2) to each of the lift rings (Figure 1, Item 3) making sure that they are securely locked in place. Do not lift the CBC; simply take up the slack in the hoisting sling (Figure 1, Item 2) to support the weight of the upper section.

1 45

Figure 1. Manually Extending the Upper Section of the CBC.

NOTE
When lifting the upper section using a lifting device, the upper section must be lifted evenly on all four sides. If the upper section is not evenly lifted, it could pinch on one or more sides preventing the CBC from being extended to its fully extendable position. 3. Use the lifting device to raise the upper section CBC into the desired position. 4. Because the weight of the upper section of the CBC is not distributed evenly, the CBC may tilt toward the rear when lifted with the hoisting sling. To compensate for this condition and to ensure that the upper section of the CBC is level, additional weight, such as two 50-pound sandbags or other weight, should be placed toward the front edge of the roof. 5. Secure the upper section of the CBC in the extended position by positioning the lift/locking assemblies. Refer to WP 0005. 6. Continue setting up the CBC for operations. Refer to WP 0005. END OF TASK END OF WORK PACKAGE

0039-2

TM 10-5411-247-13&P

0040

FIELD MAINTENANCE THREADED INSERTS NON-POTTED (NON-ADHESIVE ENCAPSULATED) REPAIR

INITIAL SETUP: Equipment Condition CBC clean, dry, and free of debris. Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Drill Set, Twist (WP 0055, Table 2, Item 5) Drill, Electric, Portable (WP 0055, Table 2, Item 3) Gloves, Rubber, Industrial (WP 0055, Table 2, Item 12) Goggles, Industrial (WP 0055, Table 2, Item 12) Riveter, Blind, Hand (WP 0055, Table 2, Item 16 or 17) Light, Floor (WP 0055, Table 2, Item 14) Personnel Required Light-Wheel Vehicle Mechanic (91B) (1)

REPAIR Replacing Non-Potted (Non-Adhesive Encapsulated) Inserts

NOTE
Inserts installed in extrusions are not potted. Knock out insert and replace with same type. 1. Depending on insert size, select a drill bit in size range listed in Table 1. Table 1. Insert Drill Sizes. Insert Thread Size 10-32 1/4-28 5/16-24 3/8-24 Drill Size Range Inches (mm) 19/64 (7.6) 25/64 (9.9) 45/64 (17.5) 49/64 (19.1)

0040-1

TM 10-5411-247-13&P

0040

REPAIR - Continued.

WARNING

Wear safety goggles for eye protection against flying chips. Failure to adhere to this warning may result in eye damage or blindness. 2. Use selected drill bit (Figure 1, Item 1) to drill head flange (Figure 1, Item 2) from insert (Figure 1, Item 3). 3. Knock out remaining portion of insert. 1 2

Figure 1. Non-Potted (Non-Adhesive Encapsulated) Insert Replacement. END OF TASK Installing Threaded Inserts In Non-Potted Areas (Edge Members)

CAUTION
Always apply anti-seize lubricant to bolt and screw threads before installation to prevent galling. During the installation of threaded inserts, the threads inside the threaded insert can sometimes be damaged by the installation tool and may result in the bolts and screws binding. If this occurs, run a 5/16-18 UNF tap into the threaded area. This will clear and straighten the threads, making for easier and faster assembly. Care should be taken using this method since the tap has the ability to remove and/or cross thread existing threads. Be sure to work slowly and deliberately when clearing the threads. Failure to adhere to this caution may result in thread damage. 1. Install the threaded insert using the appropriate hand-operated threaded insert installation tool (Figure 2, Item 1), hex key (Figure 2, Item 2) (included with installation tool), and 3/4 inch (or 1-1/16 inch depending on header tool used) wrench, (adjustable, fixed, or box-end ratchet type).

2 1

Figure 2. Hand-Operated Insert Installation Tools. 0040-2

TM 10-5411-247-13&P REPAIR - Continued.

0040

NOTE
Before using the installation tool, inspect the condition of the jackscrew threads before use. If the tool has been used previously, the jackscrew threads may require a few drops of light machine oil. Lubricate as necessary. 2. Install a threaded insert. 3. Thread the threaded insert fastener (Figure 3, Item 2) onto the threaded end (Figure 3, Item 3) of the installation tool (Figure 3, Item 1). Be sure that the end of the installation tool is tight against the head of the fastener.

3 Figure 3. Threading the Threaded Insert Fastener.

4. With the threaded insert (Figure 4, Item 2) installed on the installation tool (Figure 4, Item 1), insert the threaded insert into the hole (Figure 4, Item 3) on the panel (Figure 4, Item 4).

1 2 4

3 Figure 4. Inserting Threaded Insert into Hole in CBC Panel.

5. Insert the hex key (Figure 5, Item 1) into the socket (Figure 5, Item 2) at the top of the installation tool (Figure 5, Item 3). 6. Insert the jaws of the wrench on the flat-sided center section (Figure 5, Item 5) of the installation tool. 7. While holding the hex key stationary and the installation tool at a right angle to the panel (Figure 5, Item 4), turn the wrench in a clockwise direction, keeping track of the number of turns. 8. Turn the wrench in a clockwise direction until firm resistance indicates that the fastener is completely set, but no more than the maximum number of turns indicated in Table 2.

0040-3

TM 10-5411-247-13&P REPAIR - Continued. Table 2. Thread Sizes. Thread Size 10-32 1/4-28 5/16-24 3/8-24 Maximum # of turns 1 1-1/2 1-3/4 1-1/2

0040

9. Once the threaded insert is completely set, turn the wrench in a counterclockwise direction to break its grip with the threaded insert. 10. Remove hex key and wrench from the installation tool. 2 1 3 5 4

Figure 5. Installing Threaded Insert. 11. Remove the threaded insert installation tool (Figure 6, Item 1) from the threaded insert (Figure 6, Item 2) by turning the entire tool by hand in a counterclockwise direction.

Figure 6. Removal of Threaded Insert Installation Tool. END OF TASK END OF WORK PACKAGE

0040-4

TM 10-5411-247-13&P

0041

FIELD MAINTENANCE CAULKED SECTIONS REPAIR

INITIAL SETUP: Equipment Condition CBC clean and free of debris. Tools and Special Tools General Mechanics Tool Kit (WP 0055, Table 2, Item 21) Gloves, Rubber, Industrial (WP 0055, Table 2, Item 12) Dispenser, Sealant (WP 0055, Table 2, Item 2) Personnel Required Light-Wheel Vehicle Mechanic (91B) (1) Materials/Parts Cartridges, 1/10 Gallon, Empty (WP 0057, Table 1, Item 7) Solvent, Methylethylketone (WP 0057, Table 1, Item 24) Nozzle, 2 1/2 In Long With 1/8 In Orifice (WP 0057, Table 1, Item 16) Pail, Mixing (WP 0057, Table 1, Item 18) Rags, Wiping (WP 0057, Table 1, Item 19) Sealant, Type II (WP 0057, Table 1, Item 22) Sticks, Mixing (WP 0057, Table 1, Item 25)

REPAIR

WARNING

METHYLETHYLKETONE, ASTM D-740 Methylethylketone is flammable and toxic and shall be used only in a well-ventilated area, away from all sparks or open flame. Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials. 1. Just prior to application of sealing compound, clean surface (Figure 1, Item 1) to be sealed, with cloth dampened with MEK. 2. Dry with a clean cloth before the MEK evaporates in order to prevent contamination.

0041-1

TM 10-5411-247-13&P

0041

REPAIR - Continued.

WARNING

SEALANT, MIL-S-8802, TYPE II, CLASS 8 Sealant is flammable and toxic and shall be used only in a well-ventilated area away from all sparks or open flame. Gloves and safety goggles should be worn during use. To avoid injury or death to personnel, no smoking is allowed when working with flammable materials.

NOTE
Maximum application life of sealant is 2 hours. 3. Mix a small quantity of the sealant in an open top container sufficient for the repair being performed.

NOTE
The sealant is supplied as two components, part A, and part B. The two sealant components are different colors; part A is black and Part B is off white. The sealant is mixed in a ratio of 10:100 (Part A: Part B) by weight. This means, for example, that one ounce of Part A would require ten ounces of Part B to achieve a proper formulation. Before mixing the two components together, each component should be measured out and mixed separately to ensure that each component is uniform in color and consistency. Once the separate components are uniformly mixed, combine Part A and Part B together and mix the combination together in order to achieve a uniform dark grey color. Personnel should mix the two-parts and ensure that there are no visible streaks of black or white. 4. Apply sealing compound with caulking gun (or putty knife) (Figure 1, Item 2) in 1/8 inch (3.18 mm) minimum fillets (Figure 1, Item 3). 5. Let sealant cure completely. Nominal curing time is 72 hours at 75 F.

2 1 3

Figure 1. Caulking Repaired Section. END OF TASK END OF WORK PACKAGE 0041-2

TM 10-5411-247-13&P

0042

FIELD MAINTENANCE PAINT AND REFINISHING REPAIR

INITIAL SETUP: Equipment Condition CBC clean, dry, and free of debris. Personnel Required Light-Wheel Vehicle Mechanic (91B) (1) Painter (1) Tools and Special Tools Goggles, Industrial (WP 0055, Table 2, Item 12) Gloves, Rubber, Industrial (WP 0055, Table 2, Item 12) Drill, Electric, Portable (WP 0055, Table 2, Item 3) References MIL-C-5541, Class 1A Materials/Parts Pail, Mixing (WP 0057, Table 1, Item 18) Stick, Mixing Epoxy (WP 0057, Table 1, Item 25) Tape, Masking (WP 0057, Table 1, Item 26) Rags, Wiping (WP 0057, Table 1, Item 19) Sandpaper (WP 0057, Table 1, Item 21) Primer (Refer to Table 1) Coating (Refer to Table 1)

REPAIR Table 1 below lists the paint data for the interior and exterior of Cargo Bed Covers. Table 1. Paint Data for Cargo Bed Covers. Use Type Specification Color MIL-PRF-22750 Color Code per FED-STD-595 27875

Interior

Coating, Epoxy

Interior (Personnel Door)

Coating, Aliphatic Polyurethane

MIL-C-46168 or MIL-C-53039 Green 383 MIL-C-46168 or MIL-C-53039 Sand MIL-C-46168 or MIL-C-53039 Green 383 MIL-C-46168 or MIL-C-53039 Brown 383

34094

Interior (Personnel Door)

Coating, Aliphatic Polyurethane

33303

Exterior

Coating, Aliphatic Polyurethane

34094

Exterior

Coating, Aliphatic Polyurethane

30051

0042-1

TM 10-5411-247-13&P REPAIR - Continued. Table 1. Paint Data for Cargo Bed Covers - Continued. Use Type Specification Color MIL-C-46168 or MIL-C-53039 Black MIL-C-46168 or MIL-C-53039 Sand

0042

Color Code per FED-STD-595 37030

Exterior

Coating, Aliphatic Polyurethane

Exterior

Coating, Aliphatic Polyurethane

33303

Primer

Primer, Epoxy Coating

MIL-P-23377, Type I, Class C N/A or N or MIL-P-53022, Type I or II

1. Prepare surface for painting by removing all corrosion by wire brushing, sanding, or application of corrosionremoving compounds. 2. Chemically treat all aluminum parts in accordance with MIL-C-5541, Class 1A. 3. Areas to be painted shall be free of dust, residue, and cleaning compounds before refinishing.

NOTE
Mask seals or non-metal parts with masking tape for protection. 4. Solvent, primer, or paint shall not be applied to seals or non-metal parts. 5. Mask such parts with masking tape for protection. 6. Mix and apply epoxy primer coating in accordance with manufacturers instructions. 7. Allow to dry thoroughly before applying finish coat. 8. Mix and apply paint in accordance with manufacturers instructions. 9. Apply two separate, uniform coats, allowing the first coat to dry before applying the second coat. 10. Make sure there are no sags or runs. END OF TASK END OF WORK PACKAGE

0042-2

CHAPTER 6 PARTS INFORMATION FOR CARGO BED COVER (CBC) TYPE IIIA1, 2-1/2 TON CARGO TRUCK, LMTV, AND LMTV TRAILER

TM 10-5411-247-13&P

0043

OPERATOR AND FIELD MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) INTRODUCTION

INTRODUCTION 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 operator, field and sustainment support maintenance of the Cargo Bed Cover (CBC), 2-1/2 Ton Cargo Truck, LMTV, and LMTV Trailer. It authorizes the requisitioning, issue, and disposition of spares, repair parts, and special tools as indicated by the Source, Maintenance, and Recoverability (SMR) codes. GENERAL In addition to the Introduction Work Package (WP), this RPSTL is divided into the following WPs. 1. Repair Parts List WPs. WPs containing lists of spares and repair parts authorized by this RPSTL for use in the performance of maintenance. These WPs 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 are listed with the component they mount on. Bulk materials are listed by item name in FIG. BULK at the end of the WPs. Repair parts kits are listed at the end of the individual WPs. Repair parts for reparable special tools are also listed in a separate WP. Items listed are shown on the associated illustrations. 2. Special Tools List WPs. WPs 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 tool sets and/or Class VII are not listed. 3. Cross-Reference Indexes WPs. There are 2 cross reference indexes WPs in this RPSTL: the National Stock Number (NSN) Index WP, and the Part Number (P/N) Index WP. The National Stock Number (NSN) Index WP refers you to the figure and item number. The Part Number (P/N) Index WP refers you to the figure and item number. EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGES ITEM NO. (Column (1)). Indicates the number used to identify items called out in the illustration. SMR CODE (Column (2)). The SMR code containing supply/requisitioning information, maintenance level authorization criteria, and disposition instruction, as shown in the following breakout. This entry may be subdivided into four subentries, one for each service.

0043-1

TM 10-5411-247-13&P

0043

Table 1. SMR Code Explanation. Source Code XX 1st and 2nd positions: How to get an item. Maintenance Code XX 3rd position: Who can install, replace, or use the item. 4th position: Who can do complete repair* on the item. Recoverability Code X 5th position: Who determines the disposition action 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. 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 Application/Explanation Source Code PA PB PC PD PE PF PG PH PR PZ KD KF KB MF-Made at field MH-Made at below depot/sustainment level ML-Made at SRA MD-Made at depot MG-Navy only Items with these codes are not to be requisitioned/requested individually. They must be made from bulk material which is identified by P/N in the DESCRIPTION AND USABLE ON CODE (UOC) column and listed in the bulk material group WP of the RPSTL. If the item is authorized to you by the third position code of the SMR code but the source indicates it is made at a higher level, order the item from the higher level of maintenance. 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 third position of the SMR code. The complete kit must be requisitioned and applied. Application/Explanation

NOTE
Items coded PC are subject to deterioration. 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 third position of the SMR code.

0043-2

TM 10-5411-247-13&P

0043

Source Code AF-Assembled by field level AH-Assembled by below depot/sustainment level AL-Assembled by SRA AD-Assembled by depot AG-Navy only XA XB XC XD

Application/Explanation

Items with these codes are not to be requested/requisitioned individually. The parts that make up the assembled item must be requisitioned or fabricated and assembled at the level of maintenance indicated in the source code. If the third position of the SMR code authorizes you to replace the item but the source code indicates the item is assembled at a higher level, order the item from the higher level Specialized Repair Activity (SRA) of maintenance.

Do not requisition an XA coded item. Order the next higher assembly. (Refer to NOTE below.) If an item is not available from salvage, order it using the Commercial and Government Entity Code (CAGEC) and P/N. Installation drawings, diagrams, instruction sheets, field service drawings; identified by manufacturers P/N. Item is not stocked. Order an XD-coded item through local purchase or normal supply channels using the CAGEC 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" or those aircraft support items restricted by requirements of AR 750-1. 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: Third Position. The maintenance code entered in the third position tells you the lowest maintenance level authorized to remove, replace, and use an item. The maintenance code entered in the third position will indicate authorization to the following levels of maintenance: Maintenance Code FHLGKZDApplication/Explanation Field maintenance can remove, replace, and use the item. Below Depot Sustainment maintenance can remove, replace, and use the item. Specialized repair activity can remove, replace, and use the item. Afloat and ashore intermediate maintenance can remove, replace, and use the item (Navy only). Contractor facility can remove, replace, and use the item. Item is not authorized to be removed, replaced, or used at any maintenance level. Depot can remove, replace, and use the item.

*NOTE - Army may use C in the third position. However, for joint service publications, Army will use O. 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).

0043-3

TM 10-5411-247-13&P

0043

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. Maintenance Code FHLDGKZBApplication/Explanation Field is the lowest level that can do complete repair of the item. Below Depot Sustainment is the lowest level that can do complete repair of the item. Specialized repair activity is the lowest level that can do complete repair of the item. Depot is the lowest level that can do complete repair of the item. Both afloat and ashore intermediate levels are capable of complete repair of item. (Navy only). Complete repair is done at contractor facility. 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.

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 ZFHDLAApplication/Explanation Nonreparable item. When unserviceable, condemn and dispose of the item at the level of maintenance shown in the third position of the SMR code. Reparable item. When uneconomically reparable, condemn and dispose of the item at the field level/ASB. Reparable item. When uneconomically reparable, condemn and dispose of the item at the below depot sustainment level. Reparable item. When beyond lower level repair capability, return to depot. Condemnation and disposal of item are not authorized below depot level. Reparable item. Condemnation and disposal not authorized below Specialized repair activity (SRA). 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. Field level reparable item. Condemn and dispose at either afloat or ashore intermediate levels. (Navy only). Reparable item. Condemnation and disposal to be performed at contractor facility.

GK-

NSN (Column (3)). The NSN for the item is listed in this column. CAGEC (Column (4)). The CAGEC is a five-digit code which is used to identify the manufacturer, distributor, or Government agency/activity that supplies the item. 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. 0043-4

TM 10-5411-247-13&P

0043

NOTE
When you use an NSN to requisition an item, the item you receive may have a different P/N from the number listed. 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. Hardness Critical Item (HCI). 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 WPs. 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. EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGES FORMAT AND COLUMNS 1. National Stock Number (NSN) Index Work Package. NSNs in this index are listed in National Item Identification Number (NIIN) sequence. STOCK NUMBER Column. This column lists the NSN in NIIN sequence. The NIIN consists of the last nine digits of the NSN. When using this column to locate an item, ignore the first four digits of the NSN. However, the complete NSN should be used when ordering items by stock number. For example, if the NSN is 5385-01-574-1476, the NIIN is 01-574-1476. 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 WPs. ITEM Column. The item number identifies the item associated with the figure listed in the adjacent FIG. column. This item is also identified by the NSN listed on the same line. 2. 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 Z, followed by the numbers 0 through 9 and each following letter or digit in like order). PART NUMBER Column. Indicates the P/N assigned to the item. FIG. Column. This column lists the number of the figure where the item is identified/located in the Repair Parts List and Special Tools List WPs. 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. SPECIAL INFORMATION UOC. The UOC appears in the lower left corner of the Description Column heading. Usable on codes are shown as "UOC:" in the Description Column (justified left) on the first line under the applicable item/nomenclature. Uncoded items are applicable to all models. Identification of the UOCs used in the RPSTL are: Code FZD FZE Used On Cargo Bed Cover, Type IIIA1 Camouflage Cargo Bed Cover, Type IIIA1 Sand

0043-5

TM 10-5411-247-13&P

0043

Fabrication Instructions. Bulk materials required to manufacture items are listed in the bulk material functional group of this RPSTL. P/Ns 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 (enter applicable TM number). 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 National Stock Number (NSN) Index / Part Number (P/N) Index WPs and the bulk material list in the Repair Parts List WP. HOW TO LOCATE REPAIR PARTS 1. When NSNs or P/Ns Are Not Known. First. 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. Second. Find the figure covering the functional group or the subfunctional group to which the item belongs. Third. Identify the item on the figure and note the number(s). Fourth. Look in the Repair Parts List WPs for the figure and item numbers. The NSNs and P/Ns are on the same line as the associated item numbers. 2. When NSN Is Known. First. If you have the NSN, look in the STOCK NUMBER column of the National Stock Number (NSN) Index WP. The NSN is arranged in NIIN sequence. Note the figure and item number next to the NSN. Second. Turn to the figure and locate the item number. Verify that the item is the one you are looking for. 3. When P/N Is Known. First. If you have the P/N and not the NSN, look in the PART NUMBER column of the Part Number (P/N) Index WP. Identify the figure and item number. Second. Look up the item on the figure in the applicable Repair Parts List WP. END OF WORK PACKAGE

0043-6

TM 10-5411-247-13&P FIELD MAINTENANCE CARGO BED COVER (CBC) Type IIIA1

0044

Figure 1. Cargo Bed Cover (CBC) Type IIIA1 (Sheet 1 of 2).

0044-1

TM 10-5411-247-13&P

0044

Figure 1. Cargo Bed Cover (CBC) Type IIIA1 (Sheet 2 of 2).

0044-2

TM 10-5411-247-13&P
(1) ITEM NO. (2) SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 00 FIGURE 1. CARGO BED COVER (CBC) Type IIIA1 1 1 2 PBFHH PBFHH PBFFF 5411-01-559-8740 5411-01-559-8739 29381 29381 81337 7045249-501 7045249-502 17-1-0259-1 CBC IIIA1 CAMOUFLAGE CBC IIIA1 SAND .ASSEMBLY, TOP SECTION, FOR BREAKDOWN SEE FIGURE 2 3 PBFFF 29381 17-1-0247-1 .DOOR ASSEMBLY, PERSONNEL, FOR BREAKDOWN SEE FIGURE 4 4 PBFFF 29381 7045203-501 .ASSEMBLY, BOTTOM SECTION, FOR BREAKDOWN SEE FIGURE 3 5 PAFFF 5411-01-595-4090 29381 7045247-501 .VEHICLE MOUNTING KIT M35A2, 2-1/2 TON CARGO TRUCK FOR BREAKDOWN SEE FIGURE 6

0044
(7) QTY

1 1 1

PAFFF

5411-01-595-4078

29381

7045253-501

.VEHICLE MOUNTING KIT M1078, 2-1/2 TON LMTV FOR BREAKDOWN SEE FIGURE 6

PAFFF

5411-01-595-4074

29381

7045254-501

.VEHICLE MOUNTING KIT M1082, 2-1/2,TON LMTV TRAILER FOR BREAKDOWN SEE FIGURE 6 END OF FIGURE

0044-3/4 blank

TM 10-5411-247-13&P

0045

FIELD MAINTENANCE ASSEMBLY, TOP 3 4 5 6 2 2

2 1

8 3

6 4 6 3

18 17 16 13

18

17

13 16 14 12 10 11 Figure 2. Assembly, Top (Sheet 1 of 2).

15

0045-1

TM 10-5411-247-13&P

0045

30 19 20 21 22 11 23 24 26

25 29 28 30 11

31 26

23 22

27

Figure 2. Assembly, Top (Sheet 2 of 2).

0045-2

TM 10-5411-247-13&P

0045

(1) ITEM NO.

(2) SMR CODE

(3) NSN

(4) CAGEC

(5) PART NUMBER

(6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 01 FIG. 2 ASSEMBLY, TOP 17-1-0259-1

(7) QTY

1 2 3 4

PAFZZ PAFZZ PAFZZ PAFZZ

3940-01-485-1651 5310-00-582-5677 5310-00-933-8121 5305-00-068-0508

81337 80205 80205 80204

17-1-0206-1 MS15795-810 MS35338-139 B1821BH025C075N

.RING ASSEMBLY, LIFT .WASHER, FLAT (1/4) .WASHER, LOCK (1/4) .BOLT, MACHINE (1/4-20 X 0.75) .INSERT, SCREW THREAD .INSERT, SCREW THREAD .HANDLE,BAIL .SCREW, MACHINE (1/4-20 X .625) .FILTERING PAD, AIR COOLER .THUMBSCREW (#10-24 X 0.5) .WASHER, LOCK (#10) .PLATE,SLIDE . INSERT, SCREW THREAD .RECEPTACLE,GUIDE PIN .BOLT,MACHINE (5/16-18X 1.125)

4 40 40 40

5 6 7 8

PAFZZ PAFZZ PAFZZ PAFZZ

5325-01-408-8466

78276 0VK23

AKS4-420-165 S25B2714-1 17-1-8555-1 MS51957-80

32 16 1 6

5340-01-440-4800 5305-00-071-1316

81337 96906

XDFZZ

81337

17-1-0215-1

10

XDFZZ

39428

91744A242

11 12 13 14 15

PAFZZ XDFZZ XDFZZ XDFZZ PAFZZ

5310-01-544-6555

80205 81337 0VK23

NASM35338-138 17-1-0246-5 S31B3090-1 AKS4-518-150 B1821BH031C113N

16 1 3 1 1

5325-01-545-9937 5306-00-226-4828

78276 80204

16

PAFZZ

5306-00-226-4827

80204

B1821BH031C100N

.BOLT, MACHINE (5/16-18 X 1.00) .WASHER, LOCK (5/16) .STEP, POLE

17 18

PAFZZ PAFZZ

5310-00-407-9566 5975-00-990-5354

80205 19220

MS35338-45 575709

4 2

0045-3

TM 10-5411-247-13&P

0045

(1) ITEM NO. 19 20 21 22 23 24

(2) SMR CODE PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ

(3) NSN 5310-00-773-7618 5310-00-167-0814 5305-01-597-3338 3940-01-484-6758 5310-00-619-1148 5305-00-050-9230

(4) CAGEC 80205 80205 39428 81337 80205 96906

(5) PART NUMBER MS15795-814 NAS1149C0532R 91259A576 17-1-0120-1 MS15795-808 MS51957-64

(6) DESCRIPTION AND USABLE ON CODE (UOC) .WASHER, FLAT (5/16) .WASHER, FLAT (21/64) .SCREW, SHOULDER .LOCKING ASSEMBLY, LIFT .WASHER, FLAT (#10) .SCREW, MACHINE (#10-24 X 0.63) .ZEE, DOOR STORAGE .LOCKING ASSEMBLY, LIFT .ZEE, DOOR STORAGE .SCREW, MACHINE (#10-24 X 1.00) .PIN, CLEVIS .PIN, COTTER PIN, CLEVIS END OF FIGURE

(7) QTY 4 4 4 2 12 8

25 26 27 28

XDFZZ PAFZZ XDFZZ PAFZZ 5305-00-050-9233 3940-01-487-8687

81337 81337 81337 96906

17-1-0268-1 17-1-0120-2 17-1-0269-1 MS51957-67

1 2 1 6

29 30 31

PAFZZ PAFZZ PAFZZ

5315-01-597-3356 5315-01-538-8427 5315-01-597-3347

39428 39428 39428

92390A180 92391A034 92390A169

4 8 4

0045-4

TM 10-5411-247-13&P

0046

FIELD MAINTENANCE ASSEMBLY, BOTTOM

3 2

Figure 3. Assembly, Bottom (Sheet 1 of 4).

0046-1

TM 10-5411-247-13&P

0046

6 27 5

27 23 22 DOOR OPENING

21

10 5 28

9 27 25 8 20 10 6 7 9 10

16 26 18 24 12 19 15 17 16 15 14 13 11

Figure 3. Assembly, Bottom (Sheet 2 of 4).

0046-2

TM 10-5411-247-13&P

0046

30

31

29

32 33

35

34 9

10

Figure 3. Assembly, Bottom (Sheet 3 of 4).

0046-3

TM 10-5411-247-13&P

0046

36 37

22

38

39 37 36

40 41

42

43

Figure 3. Assembly, Bottom (Sheet 4 of 4).

0046-4

TM 10-5411-247-13&P

0046

(1) ITEM NO.

(2) SMR CODE

(3) NSN

(4) CAGEC

(5) PART NUMBER

(6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 02 FIG. 3 ASSEMBLY, BOTTOM 7045203-501

(7) QTY

PAFZZ

5975-00-990-5354

19220

575709

.STEP, POLE SEE FIGURE 3 (SHEET 1 OF 4) .WASHER, FLAT (5/16) .NUT, LOCK (5/16) .BOLT, MACHINE (5/16-18 X 1.25) .WIRE ROPE ASSEMBLY (50.00 IN. LG) .ZEE, TIE DOWN, SIDE .SCREW, CAP, HEX (3/8-16 X 1.25) .WINCH, DRUM, HAND OPERATED .WIRE ROPE ASSEMBLY (3TAPS, 355.12 IN. LG) .WIRE ROPE ASSEMBLY (62.44 IN. LG) .NUT, SELF-LOCKING (3/816) .WASHER, FLAT (3/8) .HANDLE, SOCKET WRENCH .SCREW, MACHINE (#10-32 X 0.63) .WASHER, FLAT (#10) .SCREW, PAN HD (#8-32 X 0.63) .LOCKWASHER (#8) .WASHER, FLAT (#8) .COVER ASSEMBLY, WINCH .COVER ASSEMBLY, WINCH

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

PAFZZ PAFZZ PAFZZ XDFZZ XDFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ

5310-01-389-6965 5310-01-499-3569 5306-00-226-4829 4010-01-485-1647

80205 12867 80204 81337 29381

MS15795-812 20487 B1821BH031C125N 17-1-0113-1 7045200-1 B1821BH038C125N 17-1-0173-1 17-1-0191-1 17-1-0169-1 91831A127 MS15795-813 7199A11 MS51958-64 MS15795-808 MS51957-64 MS35338-138 MS15795-807 17-1-0307-2 17-1-0307-1

10 2 2 3 2 4 1 1 1 4 8 1 4 4 4 2 2 1 1

5305-00-068-0511 3950-01-485-1649 4010-01-485-1644 4010-01-542-3601 5310-01-475-9244 5310-01-389-7014 5120-00-230-6385 5305-00-059-3660 5310-00-619-1148 5305-00-050-9230 5310-00-933-8120 5310-00-880-5978 3950-01-484-6763 3950-01-484-6762

80204 81337 81337 81337 39428 80205 39428 80205 80205 96906 80205 80205 81337 81337

0046-5

TM 10-5411-247-13&P
(1) ITEM NO. 21 22 (2) SMR CODE XDFZZ XDFZZ (3) NSN (4) CAGEC 81337 81337 (5) PART NUMBER 17-1-0235-1 17-1-0210-1 (6) DESCRIPTION AND USABLE ON CODE (UOC) .ANGLE, MOUNTING .ANGLE, TIE DOWN, FWD END SEE FIGURE 3 (SHEET 4 OF 4) 23 24 25 26 27 28 XDFZZ PAFZZ PAFZZ PAFZZ XDFZZ XDFZZ 1640-00-435-9371 1640-00-010-3090 5310-00-933-8119 81337 96906 96906 80205 29381 29381 17-1-0235-2 MS21251-A5L MS21256-2 MS35338-137 7048464-501 7048466-501 .ANGLE, MOUNTING .TURNBUCKLE BODY .LOCKING CLIP .WASHER, LOCK ASSEMBLY, CORNER FITTING .ASSEMBLY, CORNER FITTING FOR BREAK DOWN SEE FIGURE 3 (SHEET 3 OF 4) 29 30 31 32 33 34 35 36 37 38 39 40 41 42 XDFZZ PAFZZ PAFZZ XDFZZ XDFZZ PAFZZ XDFZZ PAFZZ PAFZZ PAFZZ XDFZZ PAFZZ PAFZZ PAFZZ 5310-00-933-8120 5305-00-984-6212 5310-00-167-0834 5310-00-582-5677 5310-00-933-8121 5305-00-068-0508 5310-00-811-3494 5305-00-889-2991 5305-00-057-0495 29381 80205 80205 29381 29381 80205 29381 80205 80205 80204 81337 80205 80205 80205 7048465-501 MS24693C48 MS24694S11 17-1-0305-2 17-1-0089-1 MS21044N08 17-1-0194-1 MS15795-810 MS35338-139 B1821BH025C075N 17-1-0106-2 MS35338-138 MS35206-265 NAS1149F0332P ..RETAINER WELDMENT ..SCREW, MACHINE ..SCREW, MACHINE ..SPACER, CORNER FITTING ..PULLEY (1.50 DIA) ..NUT, SELF-LOCKING ..PULLEY (1.00DIA) WASHER, FLAT WASHER, LOCK BOLT MACHINE COVER, BLOCKOUT WASHER, LOCK SCREW, MACHINE WASHER, FLAT END OF FIGURE

0046
(7) QTY 1 1

1 3 6 2 3

1 1 1 1 1 1 1 13 13 13 2 8 8 8

0046-6

TM 10-5411-247-13&P

0047

FIELD MAINTENANCE ASSEMBLY, DOOR, PERSONNEL

1 2 19 18 3 4 5

17 14 13 15

16

7 16 15 9 14 13 12 11 20 21 29 10 8

15 28 22 34 27 26 25 Figure 4. Assembly, Door, Personnel (Sheet 1 of 2). 0047-1 23 24

30 31 32

33 31

TM 10-5411-247-13&P 35 36 37

0047

39

42

38

39 43 46 41 40

36 45 42 36 20 44 43 46 42 39

Figure 4. Assembly, Door, Personnel (Sheet 2 of 2).

0047-2

TM 10-5411-247-13&P
(1) ITEM NO. (2) SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 03 FIG. 4 ASSEMBLY, DOOR, PERSONNEL 17-1- 0247-1 1 2 3 4 XDFZZ XDFZZ XDFZZ PAFZZ 5340-01-485-1650 81337 81337 81337 81337 17-1-0283 17-1-0247-3 17-1-0247-2 17-1-0291-1 .HINGE .WASHER, FLAT .WASHER, FLAT .DOOR ACCESS (UPPER), GENERAL PURPOSE .DOOR HOLDER ASSEMBLY SEE FIGURE 4 (SHEET 2 OF 2) FOR BREAK OUT 6 XDFZZ 81337 17-1-0042-3 .SEAL, WEATHER TOP SECTION .SEAL, WEATHER BOTTOM SECTION .DOOR ACCESS (LOWER), GENERAL PURPOSE .RIVET, BLIND .RETAINER .RAIN GUARD .HINGE ASSEMBLY BOTTOM DOOR .BOLT, MACHINE .BOLT,MACHINE .WASHER, LOCK .WASHER, FLAT 5/16 .BOLT, MACHINE .WASHER, LOCK .WASHER, FLAT ..PIN,COTTER .ROD, DOOR LATCH, BOTTOM

0047
(7) QTY

2 2 4 1

PAFZZ

5340-01-486-1343

81337

17-1-0171-1

XDFZZ

81337

17-1-0042-4

PAFZZ

5340-01-485-8345

81337

17-1-0292-1

9 10 11 12

PAFZZ XDFZZ XDFZZ XDFZZ

5320-00-097-6520

07707 81337 81337 81337

AD55H 17-1-0281-1 17-1-0288-1 17-1-0245-1

22 1 1 1

13 14 15 16 17 18 19 20 21

PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ XDFZZ

5306-00-226-4826 5306-00-226-4827 5310-00-974-6623 5310-01-389-6965 5305-00-068-0510 5310-00-984-7042 5310-00-773-7618 5315-01-538-8427

80204 80204 80205 80205 80204 80205 80205 39428 81337

B1821BH031C088N B1821BH031C100N MS35338-140 MS15795-812 B1821BH038C100N MS35338-141 MS15795-814 92391A034 17-1-0285-2

3 3 9 6 4 4 4 3 1

0047-3

TM 10-5411-247-13&P

0047

(1) ITEM NO. 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

(2) SMR CODE PAFZZ XDFZZ XDFZZ PAFZZ PAFZZ XDFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ XDFZZ PAFZZ PAFZZ XDFZZ PAFZZ PAFZZ PAFZZ PAFZZ XDFZZ PAFZZ PAFZZ PAFZZ PAFZZ

(3) NSN 5355-01-242-0028

(4) CAGEC 99862 27182 81337

(5) PART NUMBER CL-3A-HK2T 311/105 17-1-0285-2 91831A029 MS15795-810 107 B1821BH025C200N 17-1-0290-1 NASM970-3 NASM35338-138 MS51957-64 105 17-1-0296-1 AN6C11 MS15795-814 17-1-0263 91831A011 MS15795-808 92390A269 NASM24665-300 17-1-0263-2 MS35206-265 AN310-6 MS35206-271 MS35338-138

(6) DESCRIPTION AND USABLE ON CODE (UOC) .KNOB .HANDLE, DOOR, INSIDE .ROD, DOOR LATCH, BOTTOM .NUT,SELF-LOCKING, HEXAGON WASHER, FLAT CENTER CONTROL SCREW, CAP, HEX HEAD .HANDLE, DOOR .WASHER, FLAT .WASHER, LOCK .SCREW, PAN HEAD .LOCK ASSEMBLY, DOOR .STRAP HANDLE, UPPER DOOR ..BOLT, MACHINE ..WASHER, FLAT ..BAR, DOOR HOLDER ..NUT, SELF LOCKING ..WASHER, FLAT ..PIN, STRAIGHT HEADED ..PIN,COTTER ..DOOR HOLDER DETAILS ..SCREW, MACHINE ..NUT, PLAIN, CASTELLATED ..SCREW, MACHINE ..WASHER, LOCK END OF FIGURE

(7) QTY 3 1 1 4 4 1 4 1 1 16 12 4 1 1 3 1 2 6 1 1 3 4 1 2 4

5310-01-416-1851 5310-00-582-5677

39428 80205 27182

5305-00-071-2511 5340-01-484-6760 5310-00-617-0765 5310-01-544-6555 5305-00-050-9230 2540-00-421-1520

80204 81337 80205 80205 96906 27182 81337

5306-00-275-9688 5310-01-773-7618

88044 80205 81337

5310-01-463-4929 5310-00-933-8120 5315-01-355-1107 5315-00-234-1863

39428 80205 39428 80205 81337

5305-00-984-6212 5310-00-582-6058 5305-00-984-6218 5310-00-933-8120

80205 88044 80205 80205

0047-4

TM 10-5411-247-13&P

0048

FIELD MAINTENANCE M35A2, 2-1/2 TON CARGO TRUCK MOUNTING KIT

0048-1

TM 10-5411-247-13&P

0048

6 7 thru 16 3 2 1

5 17 2 1 16

15 10

11 14 7 8 12 8 13

11

11 10 Figure 5. M35A2, 2-1/2 Ton Cargo Truck Mounting Kit.

0048-2

TM 10-5411-247-13&P
(1) ITEM NO. (2) SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 04 FIG. 5 M35A2, 2-1/2 TON CARGO TRUCK MOUNTING KIT

0048
(7) QTY

7045247-501
1 2 3 PAFZZ PAFZZ PAFZZ 5310-00-880-5977 5310-00-974-6623 5306-01-226-4828 80205 80205 80204 MS15795-811 MS35338-140 B1821BH031C113N .WASHER, FLAT (5/16) .WASHER, LOCK (5/16) .BOLT, MACHINE (5/16-18 X 1.125) .BOLT, MACHINE (5/16-18 X 1.375) .NUT, PLAIN, BLIND RIVET .LADDER, VEHICLE BOARDING ..BRACKET, ANGLE .. NUT, PLAIN, BLIND RIVET (1/4-20) ..BRACKET, ANGLE ..WASHER, LOCK (1/4) ..SCREW, CAP, HEX HD (1/4-20 X .75 LG) ..LADDER VEHICLE BOARDING ..WASHER, FLAT (1/4) ..STRAP, WEBBING PART OF KIT P/N 7045247 ..BRACKET, ANGLE ..BRACKET, ANGLE .BOLT, MACHINE (5/16-18 X 1.00) END OF FIGURE 16 19 12

4 5 6 7 8 9 10 11

PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ

5306-00-226-4830 5310-00-952-3628 2540-01-485-1653 5340-01-486-3213 5310-00-763-0349 5340-01-486-0257 5310-00-933-8121 5305-00-068-0508

80204 03481 81337 81337 96906 81337 80205 80204

B1821BH031C138N S31B200 17-1-0315-1 17-1-0315-5 MS27131-51 17-1-0315-3 MS35338-139 B1821BH025C075N

19 1

1 10

1 8 10

12 13 14

XDFZZ PAFZZ PAFZZ 5310-00-167-0766 5340-01-440-1182

81337 80204 81337

17-1-0323-1 AN970-4 17-1-3618-1

4 2

15 16 17

PAFZZ PAFZZ PAFZZ

5340-01-486-0256 5340-01-486-3212 5306-00-226-4827

81337 81337 80204

17-1-0315-2 17-1-0315-4 B1821BH031C100N

1 1 3

0048-3/4 blank

TM 10-5411-247-13&P

0049

FIELD MAINTENANCE M1078, 2-1/2 TON LMTV MOUNTING KIT

0049-1

TM 10-5411-247-13&P

0049

3 2 1 2 1 4 26 1 4 9 5 2 1 25 6 3

24 23 17 22 21 20 19 18 16 13 12 17 15 14 9 10 11 7 1 8

Figure 6. M1078, 2-1/2 Ton LMTV Mounting Kit.

0049-2

TM 10-5411-247-13&P
(1) ITEM NO. (2) SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 05 FIG. 6 M1078, 2-1/2 TON LMTV MOUNTING KIT

0049
(7) QTY

7045253-501
1 2 3 4 PAFZZ PAFZZ PAFZZ PAFZZ 5310-01-389-6965 5310-00-974-6623 5310-01-524-7436 5306-01-552-8677 80205 80205 39428 39428 MS15795-812 MS35338-140 95462A030 90185A583 .WASHER, FLAT (5/16) .WASHER, LOCK (5/16) .NUT, PLAIN, HEX (5/16-18) .BOLT, CARRIAGE (5/16-18 x 1.00) .PLATE, FWD END .PLATE, SIDE .NUT, SELF-LOCKING HEX (5/16-24) .CHANNEL, MOUNTING .BOLT (1/2-13 x 4.50) .MOUNTING DETAILS, SPACER .CLAMP PLATE ASSEMBLY .WASHER, FLAT (1/2) .NUT, SELF-LOCKING, HEX (1/2) .SCREW, MACHINE (5/16-24 x 1.28) .PLATE, MOUNTING 32 35 24 20

5 6 7 8 9 10 11 12 13

XDFZZ XDFZZ PAFZZ XDFZZ PAFZZ XDFZZ XDFZZ PAFZZ PAFZZ 5310-00-767-9425 5310-01-533-0511 5305-00-071-2081 5310-00-982-6816

29381 29381 80205 29381 80204 81337 81337 80205 39428

7045207-1 7045221-1 MS21044C5 7045205-1 BN1821BH050C450N 17-1-0314-2 17-1-0327-1 MS15795-818 97135A250

1 2 8

2 4 2

2 4 4

14 15

PAFZZ XDFZZ

5305-00-781-6739

80205 29381

MS24694C152 6039017-1

0049-3

TM 10-5411-247-13&P

0049

(1) ITEM NO. 16

(2) SMR CODE PAFZZ

(3) NSN 5305-01-533-3383

(4) CAGEC 3A054

(5) PART NUMBER 92865A632

(6) DESCRIPTION AND USABLE ON CODE (UOC) .SCREW CAP, HEX HEAD (3/8-16 X 2.00) .WASHER, LOCK (3/8) .WASHER, FLAT (3/8) .PLATE,BOTTOM .POST, TIE DOWN .PLATE,SPACER .WASHER, FLAT (5/16) .BOLT, MACHINE (5/16-18 X 1.75) .PLATE, AFT END-DOOR .BOLT, CARRIAGE (5/16-18 x 1.25) .SCREW, PAN HEAD (5/1618x0.63) END OF FIGURE

(7) QTY 4

17 18 19 20 21 22 23

PAFZZ PAFZZ XDFZZ XDFZZ XDFZZ PAFZZ PAFZZ

5310-00-984-7042 5310-01-389-7976

80205 80205 81337 81337 81337

MS35338-141 MS15795-814 17-1-0237-1 17-1-0197-1 17-1-0313-1 AN970-5 92865A589

4 4 4 4 4 16 8

5310-00-167-0767 5306-01-533-5601

80205 39428

24 25

XDFZZ PAFZZ 5306-01-597-3318

29381 39428

7045208-501 90185A589

1 4

26

XDFZZ

39428

90272A580

0049-4

TM 10-2-5411-247-13&P

0050

FIELD MAINTENANCE M1082, 2-1/2 TON LMTV TRAILER MOUNTING KIT

0050-1

TM 10-2-5411-247-13&P

0050

8 2 1

2 5 6 9 9 3 2 4 1 12 13 7 2 1 8 25 24 15 14 11 1 10

8 11 16 17 18 19 20

23 22

21 Figure 7. M1082, 2-1/2 Ton LMTV Trailer Mounting Kit.

0050-2

TM 10-2-5411-247-13&P
(1) ITEM NO. (2) SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 06 FIG. 7 M1082, 2-1/2 TON LMTV TRAILER MOUNTING KIT 7045254-501 1 2 3 4 5 6 7 8 9 10 PAFZZ PAFZZ XDFZZ XDFZZ XDFZZ XDFZZ XDFZZ PAFZZ XDFZZ PAFZZ 5306-01-552-8677 5310-01-524-7436 5310-01-389-6965 5310-00-974-6623 80205 80205 39428 29381 81337 29381 81337 39428 81346 39428 MS15795-812 MS35338-140 90272A580 7045221-1 17-1-0316-2 7045213-1 17-1-0316-3 95462A030 B1821BH044C700N 90185A583 .WASHER, FLAT (5/16) .WASHER, LOCK (5/16) .SCREW, PH (5/16-18 .63) .PLATE, SIDE .BRACKET, LEFT .PLATE, FWD END .BRACKET, RIGHT .NUT (5/16-18) .BOLT (7/16-20 7.00 LG.) .BOLT, SQUARE NECK (5/16-18 1.00) .NUT, SELF LOCKING, HEX (5/16-24) .WASHER, FLAT (7/16) .NUT, LOCK (7/16-20) .SPACER PLATE .SCREW, MACHINE (5/16-24 1.03) .CHANNEL, BRACKET .BOLT (1/2-13 4.50)

0050
(7) QTY

38 27 3 2 1 1 1 24 2 20

11 12 13 14 15 16 17

PAFZZ PAFZZ PAFZZ XDFZZ PAFZZ XDFZZ PAFZZ

5310-00-982-6816 5310-00-184-8628 5310-00-225-6190

80205 80205 80205 81337

MS21044C5 MS15795-816 MS21044C7 17-1-0316-4 MS24694C148 7045205-1 B1821BH050C450N

14 4 2 2 6 2 4

5305-00-781-6735

80205 29381

5305-00-071-2081

80204

0050-3

TM 10-2-5411-247-13&P
(1) ITEM NO. 18 19 20 21 22 23 24 25 (2) SMR CODE XDFZZ XDFZZ PAFZZ PAFZZ PAFZZ XDFZZ XDFZZ PAFZZ 5306-01-597-3318 5310-00-767-9425 5310-01-533-0511 5305-00-781-6739 (3) NSN (4) CAGEC 81337 81337 80205 39428 80205 29381 29381 39428 (5) PART NUMBER 17-1-0314-2 17-1-0327-1 MS15795-818 97135A250 MS24694C152 6039017-1 7045214-501 90185A589 (6) DESCRIPTION AND USABLE ON CODE (UOC) .SPACER .CLAMP PLATE/SEAL ASSEMBLY .WASHER, FLAT (1/2) .NUT (1/2). .SCREW, MACHINE (5/16-24 1.28) .PLATE, MOUNTING .PLATE, AFT END-DOOR .BOLT, CARRIAGE (5/16-18 1.25) END OF FIGURE

0050
(7) QTY 2 2 4 4 8 2 1 4

0050-4

TM 10-5411-247-13&P

0051

FIELD MAINTENANCE NATIONAL STOCK NUMBER INDEX

NATIONAL STOCK NUMBER

5305-00-050-9230

FIGURE
4 3 2

ITEM
32 16 25 29 31 14 4 38 11 17 7 8 17 9 28 9 13 22 21 42 12 13 13 16 4 14 17 3 15 4 4 13 41 35 17

NATIONAL STOCK NUMBER

2540-00-421-1520 1640-00-435-9371 5310-00-582-5677

FIGURE
4 3 2 3 4

ITEM
33 24 2 36 26 44 24 15 39 8 12 20 20 19 36 15 14 22 34 1 18 30 26 17 40 46 3 37 10 5 15 2 2 2 7

5305-00-050-9233 5305-00-057-0495 5305-00-059-3660 5305-00-068-0508

2 3 3 2 3 5

5310-00-582-6058 5310-00-619-1148

4 2 3 4

5305-00-068-0510 5305-00-068-0511 5305-00-071-1316 5305-00-071-2081

4 3 2 7 6

5310-00-763-0349 5310-00-767-9425

5 6 7

5310-00-773-7618

2 4 4

5305-00-071-2511 5320-00-097-6520 5310-00-167-0766 5310-00-167-0767 5310-00-167-0814 5310-00-167-0834 5310-00-184-8628 5310-00-225-6190 5306-00-226-4826 5306-00-226-4827

4 4 5 6 2 3 7 7 4 2 2 4 5

5305-00-781-6735 5305-00-781-6739

7 6 7

5310-00-811-3494 5310-00-880-5977 5310-00-880-5978 5305-00-889-2991 5310-00-933-8119 5310-00-933-8120

3 5 3 3 3 3 3 4

5310-00-933-8121

2 3 5

5306-00-226-4828

5 2

5306-00-226-4829 5306-00-226-4830 5120-00-230-6385 5315-00-234-1863 5306-00-275-9688 5310-00-407-9566

3 5 3 4 4 2

5310-00-952-3628 5310-00-974-6623

5 4 5 7 6

5310-00-982-6816

0051-1

TM 10-5411-247-13&P NATIONAL STOCK NUMBER

5310-00-982-6816 5305-00-984-6212

0051 FIGURE
3 4 5 5 4 5 5 2 3 6 7

FIGURE
7 3 4

ITEM
11 41 43 45 18 17 18 1

NATIONAL STOCK NUMBER

3950-01-485-1649 5340-01-485-1650 5340-01-486-0256 5340-01-486-0257 5340-01-486-1343 5340-01-486-3212 5340-01-486-3213 3940-01-487-8687 5310-01-499-3569

ITEM
8 4 15 9 5 16 7 27 3 3 8 13 21 16 23 31 20 10 11 31 14 4 10 1 1 7 6 5 25 22 32 30

5305-00-984-6218 5310-00-984-7042

4 4 6

5975-00-990-5354

2 3

5355-01-242-0028 5315-01-355-1107 5310-01-389-6965

4 4 3 4 6 7

22 40 2 16 1 1 12 18

5310-01-524-7436

5310-01-533-0511

6 7

5305-01-533-3383 5306-01-533-5601 5315-01-538-8427

6 6 2 4

5310-01-389-7014 5310-01-389-7976

3 6

4010-01-542-3601 5325-01-408-8466 5310-01-416-1851 2 4 5 25 5325-01-545-9937 5340-01-440-1182 5340-01-440-4800 5310-01-463-4929 5310-01-475-9244 3940-01-484-6758 5340-01-484-6760 3950-01-484-6762 3950-01-484-6763 4010-01-485-1644 3940-01-485-1651 2540-01-485-1653 5340-01-485-8345 4010-01-485-1647 5 2 4 3 2 4 3 3 3 2 5 4 3 14 7 38 11 23 29 20 19 9 1 6 8 5 5411-01-559-8739 5411-01-559-8740 5411-01-595-4074 5411-01-595-4078 5411-01-595-4090 5306-01-597-3318 5305-01-597-3338 5305-01-597-3347 5305-01-597-3356 5306-01-552-8677 5310-01-544-6555

3 2 4 2 6 7 1 1 1 1 1 6 2 2 2

END OF WORK PACKAGE

0051-2

TM 10-5411-247-13&P

0052

FIELD MAINTENANCE PART NUMBER INDEX

PART NUMBER
AD55H AKS4-420-165 AKS4-518-150 AN310-6 AN6C11 AN970-4 AN970-5 B1821BH025C075N

FIGURE
4 2 2 4 4 5 6 2 3 5

ITEM
9 5 14 44 35 13 22 4 38 11 28 13 16 14 17 15 3 4 4 17 7 9 9 17 22 18 23 15 39 2 36 26 1 2

PART NUMBER
MS15795-812

FIGURE
4 6 7

ITEM
16 1 1 12 19 36 18 19 12 12 20 7 11 13 34 24 25 30 31 15 14 22 8 41 43 45 17 26 17 40 46 3 37 10

MS15795-813 MS15795-814

3 4 4 6 2

MS15795-816 MS15795-818

7 6 7

B1821BH025C200N B1821BH031C088N B1821BH031C100N

4 4 2 4 5

MS21044C5

6 7

MS21044C7 MS21044N08 MS21251-A5L MS21256-2 MS24693C48 MS24694S11 MS24694C148 MS24694C152

7 3 3 3 3 3 7 6 7

B1821BH031C113N

2 5

B1821BH031C125N B1821BH031C138N B1821BH038C100N B1821BH038C125N B1821BH044C700N B1821BH050C450N

3 5 4 3 7 6 7

MS27131-51 MS35206-265

5 3 4

CL-3A-HK2T MS15795-807 MS15795-808

4 3 2 3 4

MS35206-271 MS35338-45 MS35338-137 MS35338-138

4 2 3 3 3 4

MS15795-810

2 3 4

MS35338-139

2 3 5

MS15795-811 MS15795-812

5 3

0052-1

TM 10-5411-247-13&P PART NUMBER

MS35338-140

0052 FIGURE
2 3 3 6 4 2 1 4 4 1 4 4 2 2 4 4 4 4 4 4 4 4 3 3 3 6 6 7

FIGURE
5 4 6 7

ITEM
2 15 2 2 18 17 17 16 24 32 28 8 14 41 11 31 30 20 42 6 5 13 33 27 6 7 33 39 5 22 26 10 5 8 9 35 20 1 22

PART NUMBER
17-1-0215-1 17-1-0235-1 17-1-0235-2 17-1-0237-1 17-1-0245-1 17-1-0246-5 17-1-0247-1 17-1-0247-2 17-1-0247-3 17-1-0259-1 17-1-0263-1 17-1-0263-2 17-1-0268-1 17-1-0269-1 17-1-0281-1 17-1-0283 17-1-0285-2 17-1-0288-1 17-1-0290-1 17-1-0291-1 17-1-0292-1 17-1-0296-1 17-1-0305-2 17-1-0307-1 17-1-0307-2 17-1-0313-1 17-1-0314-2

ITEM
9 21 23 19 12 12 3 3 2 2 37 42 25 27 10 1 21 11 29 4 8 34 32 20 19 21 10 18 6 15 9 16 7 5 7 14 12 11 19

MS35338-141

4 6

MS35338-45 MS51957-64

2 3 2 4

MS51957-67 MS51957-80 MS51958-64 NASM24665-300 NASM35338-138

2 2 3 4 2 4

NASM970-3 NAS1149C0532R NAS1149F0332P S25B2714-1 S31B200 S31B3090-1 105 107 17-1-0042-3 17-1-0042-4 17-1-0089-1 17-1-0106-2 17-1-0113-1 17-1-0120-1 17-1-0120-2 17-1-0169-1 17-1-0171-1 17-1-0173-1 17-1-0191-1 17-1-0194-1 17-1-0197-1 17-1-0206-1 17-1-0210-1

4 2 3 2 5 2 4 4 4 4 3 3 3 2 2 3 4 3 3 3 6 2 3

17-1-0315-1 17-1-0315-2 17-1-0315-3 17-1-0315-4 17-1-0315-5 17-1-0316-2 17-1-0316-3 17-1-0316-4 17-1-0323-1 17-1-0327-1

5 5 5 5 5 7 7 7 5 6 7

0052-2

TM 10-5411-247-13&P PART NUMBER

17-1-3618-1 17-1-8555-1 20487 311/105 575709

0052 FIGURE
3 2 2 4 2 4

FIGURE
5 2 3 4 2 3

ITEM
14 7 3 23 18 1 15 23 6 4 8 16 5 24 24 6 24 6 4 5 1 1 6 7 27 29 28 13 4 10 25 25 26 3 21 10 38 25

PART NUMBER
91831A127 92390A169 92390A180 92390A269 92391A034

ITEM
11 30 29 40 31 20 23 16 3 8 13 21

6039017-1

6 7

92865A589 92865A632 95462A030

6 6 6 7

7045199-1 7045204-501 7045205-1

3 1 6 7

97135A250

6 7

7045207-1 7045208-501

6 6 7

7045213-1 7045214-501 7045221-1

7 7 6 7

7045247-501 7045249-501 7045249-502 7045253-501 7045254-501 7048464-501 7048465-501 7048466-501 7199A11 90185A583

1 1 1 1 1 3 3 3 3 6 7

90185A589

6 7

90272A580

6 7

91259A576 91744A242 91831A011 91831A029

2 2 4 4

END OF WORK PACKAGE

0052-3/4 blank

CHAPTER 7 SUPPORTING INFORMATION FOR CARGO BED COVER (CBC) TYPE IIIA1, 2-1/2 TON CARGO TRUCK, LMTV, AND LMTV TRAILER

TM 10-5411-247-13&P

0053

OPERATOR AND FIELD MAINTENANCE REFERENCES

SCOPE This Work Package lists all field manuals, forms, technical manuals, and miscellaneous publications referenced in this manual.

PAMPHLETS The Army Maintenance Management System (TAMMS) Users Manual ................................ DA Pam 750-8

FIELD MANUALS Basic Cold Weather Manual............................................................................................................. FM 31-70 First Aid ......................................................................................................................................... FM 4-25.11 Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination ............................................................................................................................. FM 3-11.5 Mountain Operations ....................................................................................................................... FM 3-97.6 Northern Operations......................................................................................................................... FM 31-71 Packing of Materiel for Packing ..................................................................................................... FM 38-701

FORMS Transportation Discrepancy Report (TDR) ............................................................................... DD Form 361 Equipment Control Record ................................................................................................... DA Form 2408-9 Equipment Inspection and Maintenance Worksheet ...............................................................DA Form 2404 Equipment Inspection Maintenance Worksheet (EGA) ....................................................... DA Form 5988-E Recommended Changes to Equipment Technical Publications ..............................................DA Form 2028 Report of Discrepancy (ROD) ............................................................................................................ SF 364 Product Quality Deficiency Report ...................................................................................................... SF 368

TECHNICAL MANUALS Operators Field Level Manual for the M1095 Series 5 Ton Medium Tactical Vehicle Trailer (MTVT) and the M1082 Series 2-1/2 Ton Light Tactical Vehicle Trailer (LMTV) Manual ................ TM 9-2330-394-13&P Operators Manual for 2-1/2-TON, 6X6, M44A2, Series Trucks (Mult Truck, Cargo; 2-1/2-TON, 6X6, M35A2, M35A2C, M36A2, Truck, Tank, 2-1/2-TON, 6X6 M49A2C; Truck, Tank, Water: 2-1/2-TON, 6X6, M50 M50A3; Truck, Van, Shop: 2-1/2-TON, 6X6, M109A3; Truck, Instrume Shop: 2-1/2-TON, 6X6, M185A3;

0053-1

TM 10-5411-247-13&P

0053

REFERENCES - Continued. Truck, Tractor: 2-1/2-TON, 6X6, M Truck, Dump: 2-1/2-TON, 6X6, M342A2; Truck, Maintenance, Pipelin Construction: 2-1/2-TON, 6X6, M756A2; Truck, Maintenance, Earth and Polesetting: 2-1/2-TON, 6X6, M764 {Air Force TO 36A12-1B-1094} ............................................................................... TM 9-2320-361-10 Operators Instruction Manual for M1078 Series, 2-1/2-TON, 4X4, Light Medium Tactical Vehicles (LMTV) TRK, CAR., LMTV, LVAD, M1081 W/WN (2320-01-360-1891) (EIC: BHG) W/O WN (2320-01-354-3384) (EIC: BHE) TRK, CHAS, LMTV, M1080 (2320-01-3) (EIC: BHC) TRK, CAR, LMTV, LVAD, M1081 W/WN (2320-01-360-1899) (EIC: BHJ) W/O WN (2320-01-355-3063) (EIC: BHF) {Air Force TO 36A121B-1095-1} .......................................................................................................................................... TM 9-2320-365-10 Procedures for Destruction of Equipment to Prevent Enemy Use (Mobility Equipment Command) ................................................................................................................................................. TM 750-244-3

MISCELLANEOUS PUBLICATIONS Army Medical Department Expendable/Durable Items .................................................................. CTA 8-100 Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items) ......... CTA 50-970

END OF WORK PACKAGE

0053-2

TM 10-5411-247-13&P OPERATOR AND FIELD MAINTENANCE MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION INTRODUCTION The Army Maintenance System MAC

0054

This introduction provides a general explanation of all maintenance and repair functions authorized at the two maintenance levels under the Two-Level Maintenance System concept. This MAC (immediately following the introduction) designates overall authority and responsibility 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 shall be consistent with the capacities and capabilities of the designated maintenance levels, which are shown on the MAC in column (4) as: Field - includes two subcolumns, Crew (C), and Maintainer (F). Sustainment includes two subcolumns, Below Depot (H) and Depot (D). The maintenance to be performed below depot and in the field is described as follows: 1. Crew maintenance. The responsibility of a using organization to perform maintenance on its assigned equipment. It normally consists of inspecting, servicing, lubricating, adjusting, and replacing parts, minor assemblies, and subassemblies. The replace function for this level of maintenance is indicated by the letter C in the third position of the SMR code. A C appearing in the fourth position of the SMR code indicates complete repair is possible at the service maintenance level. 2. Maintainer maintenance. Maintenance accomplished on a component, accessory, assembly, subassembly, plug-in unit, or other portion either on the system or after it is removed. The replace function for this level of maintenance is indicated by the letter F appearing in the third position of the SMR code. An F appearing in the fourth position of the SMR code indicates complete repair is possible at the field maintenance level. Items are returned to the user after maintenance is performed at this level. 3. Below depot sustainment. Maintenance accomplished on a component, accessory, assembly, subassembly, plug-in unit, or other portion either on the system or after it is removed. The replace function for this level of maintenance is indicated by the letter H in the third position of the SMR code. An H appearing in the fourth position of the SMR code indicates complete repair is possible at the below depot sustainment maintenance level. Items are returned to the supply system after maintenance is performed at this level. 4. Depot Sustainment. Maintenance accomplished on a component, accessory, assembly, subassembly, plug-in unit, or other portion either on the system or after it is removed. The replace function for this level of maintenance is indicated by the letter D or K appearing in the third position of the SMR code. Depot sustainment maintenance can be performed by either depot personnel or contractor personnel. A D or K appearing in the fourth position of the SMR code indicates complete repair is possible at the depot sustainment maintenance level. Items are returned to the supply systems after maintenance is performed at this level. The tools and test equipment requirements (immediately following the MAC) list the tools and test equipment (both special tools and common tool sets) required for each maintenance function as referenced from the MAC. The remarks (immediately following the tools and test equipment requirements) contain supplemental instructions and explanatory notes for a particular maintenance function.

0054-1

TM 10-5411-247-13&P Maintenance Functions Maintenance functions will be limited to and are defined as follows:

0054

1. 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). This includes scheduled inspection, gauging, and evaluation of cannon tubes. 2. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an item and comparing those characteristics with prescribed standards on a scheduled basis, i.e., load testing of lift devices and hydrostatic testing of pressure hoses. 3. 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, lubricants, chemical fluids, or gases. This includes scheduled exercising and purging of recoil mechanisms. The following are examples of service functions: a. Unpack. To remove from packing box for service or when required for the performance of maintenance operations. b. Repack. To return item to packing box after service and other maintenance operations. c. Clean. To rid the item of contamination.

d. Touch up. To spot paint scratched or blistered surfaces. e. Mark. To restore obliterated identification. 4. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper or exact position, or by setting the operating characteristics to specified parameters. 5. Align. To adjust specified variable elements of an item to bring about optimum or desired performance. 6. Calibrate. To determine and cause corrections to be made, or to be adjusted on instruments of 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. 7. Remove/Install. To remove and install the same item when required to perform service or other maintenance functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component or assembly) in a manner to allow the proper functioning of an equipment or system. 8. Paint. (ammunition only). To prepare and spray color coats of paint so that the ammunition can be identified and protected. The color indicating primary use is applied, preferably, to the entire exterior surface as the background color of the item. Other markings are to be repainted as original so as to retain proper ammunition identification. 9. 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 third position code of the Source, Maintenance and Recoverability (SMR) code. 10. Repair. The application of maintenance services, including fault location/troubleshooting, removal/installation, disassembly/assembly procedures and maintenance actions to 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.

0054-2

TM 10-5411-247-13&P Maintenance Functions - Continued.

0054

NOTE
The following definitions are applicable to the repair maintenance function: Services. Inspect, test, service, adjust, align, calibrate, and/or replace. 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). Disassembly/assembly. The step-by-step breakdown (taking apart) of a spare/functional 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). Actions. Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing. 11. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely serviceable/operational condition as required by maintenance standards in appropriate technical publications. Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an item to like new condition. 12. 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 material maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements (hours/miles, etc.) considered in classifying Army equipment/components. Explanation of Columns in the MAC Column (1) Group Number. Column (1) lists Functional Group Code (FGC) numbers, the purpose of which is to identify maintenance significant components, assemblies, subassemblies, and modules with the Next Higher Assembly (NHA). Column (2) Component/Assembly. Column (2) contains the names of components, assemblies, subassemblies, and modules for which maintenance is authorized. Column (3) Maintenance Function. Column (3) lists the functions to be performed on the item listed in column (2). (For detailed explanation of these functions refer to Maintenance Functions outlined above). Column (4) Maintenance Level. Column (4) specifies each level of maintenance authorized to perform each function listed in column (3), by indicating work time required (expressed as man-hours in whole hours or decimals) in the appropriate sub-column. This work time figure represents the active time required to perform that maintenance function at the indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance function varies at different maintenance levels, appropriate work time figures are to be shown for each level. The work time figure represents the average time required to restore an item (assembly, subassembly, component, module, end item, or system) to a serviceable condition under typical field operating conditions. This time includes preparation time (including any necessary disassembly/assembly time), troubleshooting/fault location time, and quality assurance time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the MAC. The system designations for the various maintenance levels are as follows:

0054-3

TM 10-5411-247-13&P Maintenance Functions - Continued. Field: C F Crew maintenance Maintainer maintenance

0054

Sustainment: L H D Specialized Repair Activity (SRA) Below depot maintenance Depot maintenance

NOTE
The L maintenance level is not included in column (4) of the MAC. Functions to this level of maintenance are identified by work time figure in the H column of column (4), and an associated reference code is used in the REMARKS column (6). This code is keyed to the remarks and the SRA complete repair application is explained there. Column (5) Tools and Equipment Reference Code. Column (5) specifies, by code, those common tool sets (not individual tools), common Test, Measurement and Diagnostic Equipment (TMDE), and special tools, special TMDE, and support equipment required to perform the designated function. Codes are keyed to the entries in the tools and test equipment table. Column (6) Remarks Code. When applicable, this column contains a letter code, in alphabetic order, which is keyed to the remarks table entries. Explanation of Columns in the Tools and Test Equipment Requirements Column (1) - Tool or Test Equipment Reference Code. The tool or test equipment reference code correlates with a code used in column (5) of the MAC. Column (2) - Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment. Column (3) - Nomenclature. Name or identification of tool or test equipment. Column (4) - National Stock Number (NSN). The NSN of the tool or test equipment. Column (5) - Tool Number. The manufacturers part number. Explanation of Columns in Remarks Column (1) - Remarks Code. The code recorded in column (6) of the MAC. Column (2) - Remarks. This column lists information pertinent to the maintenance function being performed as indicated in the MAC. END OF WORK PACKAGE

0054-4

TM 10-5411-247-13&P OPERATOR AND FIELD MAINTENANCE MAINTENANCE ALLOCATION CHART (MAC)

0055

Table 1. MAC for Cargo Bed Cover (CBC) Type IIIA1.

(1) (2) (3) (4)
MAINTENANCE LEVEL FIELD GROUP NUMBER COMPONENT/ ASSEMBLY MAINTENANCE FUNCTION CREW MAINTAINER SUSTAINMENT BELOW DEPOT DEPOT TOOLS AND EQUIPMENT REFERENCE CODE REMARKS CODE

(5)

(6)

00

Cargo Bed Cover (CBC) Type IIIA1

Inspect Repair Replace

0.5

0.4 7.0 1.3 2,3,4,5,11, 12,14,15,1 8,19,21 2,3,4,5,11, 12,14,15,1 6,17,18,21

A G

01

Assembly, Top Handle, Bail

Inspect Repair Inspect Replace

0.5

0.3 2.0

21 21

A C A

0101

0.1

0.1 0.15 21

0102

Step, Pole Upper Step, Pole Middle Assembly, Ring, Lift Pad, Filter, Cooler, Air

Inspect Replace Inspect Replace Inspect Replace Inspect Service Repair Replace

0.1

0.1 0.2 21

0103

0.1

0.1 0.08 21

0104

0.1

0.1 0.25 21

0105

0.1 0.1 0.1 0.1 0.1 0.07 0.1 0.1 0.15 21 21

A D D

0106

Assembly, Locking, Lift

Inspect Replace

0055-1

TM 10-5411-247-13&P Table 1. MAC for Cargo Bed Cover (CBC) Type IIIA1- Continued.
(1) (2) (3) (4)
MAINTENANCE LEVEL FIELD GROUP NUMBER COMPONENT/ ASSEMBLY MAINTENANCE FUNCTION CREW MAINTAINER SUSTAINMENT BELOW DEPOT DEPOT TOOLS AND EQUIPMENT REFERENCE CODE

0055

(5)

(6)

REMARKS CODE

02

Assembly, Bottom Step, Folding, Bottom Assembly, Rope, Wire Winch, Drum, HandOperated Angles, Mounting, Carrier Assembly, Fitting, Corner Assembly, Door, Personnel Door, Personnel (Upper)

Inspect Repair Inspect Replace Inspect Replace Inspect Replace Service

0.4

0.4 3.0

13 21

A B A

0201

0.1

0.1 0.15 21

0202

0.1

0.2 1.5 21 13

0203

0.1

0.2 0.67

0204

Inspect Replace Inspect Repair Inspect Repair Repair Replace Inspect

0.1

0.1 0.25

21 A

0205

0.1

0.2 1.0 0.5 21 21 E A 13 11,12,21 21 A A, B

03

0.1

0.2 0.5 0.15

0301

0.1

0.1

0302

Door, Personnel (Lower)

Repair Replace Inspect 0.1

0.5 0.05 0.1

13 11,12,21 21

A, B

0055-2

TM 10-5411-247-13&P Table 1. MAC for Cargo Bed Cover (CBC) Type IIIA1- Continued.
(1) (2) (3) (4)
MAINTENANCE LEVEL FIELD GROUP NUMBER COMPONENT/ ASSEMBLY MAINTENANCE FUNCTION CREW MAINTAINER SUSTAINMENT BELOW DEPOT DEPOT TOOLS AND EQUIPMENT REFERENCE CODE

0055

(5)

(6)

REMARKS CODE

0303

Assembly, Holder

Inspect Replace

0.1

0.1 0.25

21 A

04

Mounting Kit M35A2, 2-1/2 Ton Cargo Truck

Inspect Repair Replace

0.1

0.1 2.0 2.0 2,21 21 A F

0401

Assembly, Ladder

Inspect Repair Replace

0.1

0.1 0.5 2.0 21 21

05

Mounting Kit M1078, 2-1/2 Ton LMTV

Inspect Repair Replace

0.1

0.1 2.0 2.0 2,21 21

A F

06

Mounting Kit M1082, 2-1/2 Ton LMTV Trailer

Inspect Repair Replace

0.1

0.1 2.0 2.0 2,21 21

A F

0055-3

TM 10-5411-247-13&P

0055

Table 2. Tools and Test Equipment for Cargo Bed Cover (CBC) Type IIIA1. (1) (2) (3) NOMENCLATURE (4) NATIONAL STOCK NUMBER (5) TOOL NUMBER

TOOLS OR TEST MAINTENANCE EQUIPMENT REFERENCE CODE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 LEVEL

F F F F F F F F F F F F F F F F F F F F F

Bit, Router, Carbide Dispenser, Sealant Drill, Electric, Portable Drill Set, Twist Drill Set, Twist Drill Stop Set End Mill, 1/4 (6.35mm) End Mill, 5/16 (7.94 mm) End Mill, 3/8 (9.53 mm) End Mill, 1/2 (12.7 mm) Gloves, Rubber , Industrial Goggles, Industrial Grease Gun Light, Floor Punch, Pin Riveter, Blind, Hand Riveter, Blind, Hand Riveter, Blind, Hand Router, Electric, Portable Step Device/Ladder Tool Kit, General Mechanics 5180-01-483-0250 8415-00-266-8675 4240-00-052-3776 4930-01-347-4817 6230-01-339-9660 5120-00-293-1408 5120-00-102-6847 5120-01-020-7814 5120-01-289-4310 5130-00-035-6160 5120-01-322-3634 5130-00-935-7354 5133-01-047-0258 5133-00-293-0983 5133-01-383-7665

51502 (0GXM3) 7565T4 (39428) 6635 (55111) DBM125B (55719) GGG-D-751 (81348) 8959A16 (39428) 36081 (33689) 36101 (33689) 37121 (33689) 35162 (33689) ZZ-G-381 (81348) GG-G-531 (81348) 1060K52 (39428) 8439K51 (39428) 3416A15 (39428) C-845-2528L (0VK23) C-722-3124L (0VK23) HP-2 (10054) A-A-482 (58536)

12B470000-2

0055-4

TM 10-5411-247-13&P

0055

Table 3. Remarks for Cargo Bed Cover (CBC) Type IIIA1. (1) REMARK CODES A B C D E F G Perform PMCS. Lubrication Required. Deburr helicopter rub strip prior to airlift. Clean or replace air filter as required. Weather seal should be removed and replaced when changing Carrier Mounting Angles. Only one mounting kit applies to each installation. Ensure that the proper mounting kit is being referenced. End mills must be machined as described in WP 0039 for use. (2) REMARKS

END OF WORK PACKAGE

0055-5/6 blank

TM 10-5411-247-13&P

0056

OPERATOR AND FIELD MAINTENANCE COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LIST

INTRODUCTION Scope This section lists COEI and BII for the Cargo Bed Cover (CBC) to help you inventory items for safe and efficient operation of the equipment. General The COEI and BII information is divided into the following lists: Components of End Item (COEI). This list is for information purposes only and is not authority to requisition replacements. These items are part of the CBC. As part of the end item, these must be with the end item whenever it is issued or transferred between property accounts. Items of COEI are removed and separately packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify the items. Basic Issue Items (BII). These essential items are required to place the CBC in operation, operate it, and to do emergency repairs. Although shipped separately packaged, BII must be with the CBC during operation and when it is transferred between property accounts. Listing these items is your authority to request / requisition them for replacement based on authorization of the end item by the TOE/MTOE. Illustrations are furnished to help you find and identify the items. Explanation of Columns in the COEI List and BII List Column (1), Illus Number, gives you the number of the item illustrated. Column (2), National Stock Number, identifies the stock number of the item to be used for requisitioning purposes. Column (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 (commercial and Government entity code) (in parenthesis) and the part number. Column (4), Usable on code, gives you a code if the item you need is not the same for different models of equipment. These codes are identified below: Code FZD FZE Used on Cargo Bed Cover (CBC) Assembly, Type IIIA1, Camouflage Cargo Bed Cover (CBC) Assembly, Type IIIA1, Sand

Column (5), UM (unit of measure), indicates how the item is issued for the National Stock Number shown in column 2. Column (6), Qty Rqr, indicates the quantity required.

0056-1

TM 10-5411-247-13&P COMPONENTS OF END ITEM (COEI) LIST Table 1. Components of End Item List. (1) ILLUS NUMBER (2) NATIONAL STOCK NUMBER (3) DESCRIPTION, LOCATION, PART NUMBER, AND (CAGEC) (4) USABLE ON CODE (5) U/M

0056

(6) QTY RQR

The Cargo Bed Cover (CBC) Type IIIA1, 2-1/2 Ton Cargo Truck, LMTV, and LMTV Trailer has no Components of End Item.

0056-2

TM 10-5411-247-13&P

0056

BASIC ISSUE ITEMS (BII) LIST

TM 10-5411-247-13&P TECHNICAL MANUAL OPERATOR AND FIELD MAINTENANCE MANUAL

INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) FOR CARGO BED COVER (CBC) TYPE IIIA1, 2-1/2 TON CARGO TRUCK, LMTV, AND LMTV TRAILER NSN 5411-01-559-8740 (CAMOUFLAGE) NSN 5411-01-559-8739 (SAND)

DISTRIBUTION STATEMENT A Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY XX XXXXX 2008 19 November2011

0056-3

TM 10-5411-247-13&P

0056

Table 2. Basic Issue Items List.

(1) ILLUS NUMBER (2) NATIONAL STOCK NUMBER (3) DESCRIPTION, PART NUMBER AND CAGEC (4) USABLE ON CODE FZD (5) U/M (6) QTY RQR

N/A

TM 10-5411-247-13&P

FZE

EA

5120-00-060-2004

FZD

SCREW DRIVER

FZE

EA

5120-00-228-9506

FZD

WRENCH 1/2 INCH

FZE

EA

5120-00-230-6385

FZD

HAND SOCKET WRENCH

FZE

EA

END OF WORK PACKAGE

0056-4

TM 10-5411-247-13&P

0057

OPERATOR AND FIELD MAINTENANCE EXPENDABLE AND DURABLE ITEMS LIST INTRODUCTION Scope This work package lists expendable and durable items that you will need to operate and maintain the CBC. This list is for information 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 8100, Army Medical Department Expendable/Durable Items. Explanations of Columns in the Expendable / Durable Items List Column (1) - Item Number. This number is assigned to the entry in the list and is referenced in the narrative instructions to identify the item (e.g., Use lubricating oil (WP0053, Table 1, Item 1)). Column (2) - Level. This column includes the lowest level of maintenance that requires the listed item (C=Operator/Crew and F=Field). Column (3) - National Stock Number. This is the NSN assigned to the item which you can use to requisition it. Column (4) - Item Name, Description, Commercial and Government Entity Code (CAGEC), and Part Number (P/N). This column provides the other information you need to identify the item. Column (5) Unit of Issue (U/I). This code shows the physical measurement or count of an item, such as gallon, dozen, gross, etc. Table 1. Expendable and Durable Items List. (1) ITEM NUMBER 1 2 3 4 5 6 (2) LEVEL F F F F F F 8105-01-336-6163 (3) NATIONAL STOCK NUMBER (NSN) 8040-01-501-5557 8040-00-900-6296 (4) ITEM NAME, DESCRIPTION, PART NUMBER/(CAGEC) Adhesive, RTV-732 (71984) Adhesive, Two-Part Epoxy, FE-6026 (92528) Alodine, brush, MIL-C-5541 (96906) Aluminum Plate 2 2 1/8-inch Anti-Seize Lubricant, 1279K31 (39428) Bag,Sand, A-A-52142 type 1& 2 color 2 (58536) Cartridges, 1/10 gallon, empty, 7579A44 (39428) 8040-00-097-6524 Catalyst, SRC18 (01139) Core, 1.00 inch thick 12 inches 12 inches (hexcel acg honeycomb), acg-1/2-2.3p (04621) (5) U/I TB KT QT EA TB EA

7 8

F F

PK KT

EA

0057-1

TM 10-5411-247-13&P

0057

Table 1. Expendable and Durable Items List - Continued. (1) ITEM NUMBER 10 11 12 13 14 15 16 17 18 19 20 (2) LEVEL (3) NATIONAL STOCK NUMBER (NSN) (4) ITEM NAME, DESCRIPTION, PART NUMBER/(CAGEC) Core, 1.50 inch thick 12 inches 12 inches (hexcel acg honeycomb, acg-1/2-2.3p (04621) Detergent, mild 8415-00-634-5027 9150-00-929-7946 9550-00-402-4478 Gloves, Mens and Womens Grease,general purpose,lithium, lubr1plate6302 (73219) Lubricant, Spray, MIL-L-23398 Mask Nozzle, 2 1/2 in long with 1/8 in orifice, 7579a32 (39428) 9150-00-145--0112 Oil, Machine, A-A-59113 (58536) Pail, Mixing 7920-00-205-1711 5330-01-529-3855 Rags, Wiping, A-A-2522 (58536) Rubber strip, 3/8 inch thk x 1.00 inch wide x 25 feet long, adhesive backed, color black, closed cell, epdm sponge rubber strip Sandpaper, 100 grit, A-A-1201 (58536) Sealant, Type II, MIL-S-8802 (96906) Sheet, aluminum, .032 inch 12 inch 12 inch (30003-h16, 5052-h34, or 6061-t6 aluminum alloy) 6810-00-687-8429 8020-01-382-7101 7510-00-015-0447 Solvent, Methylethylketone, ASTM D-740 (81346) Stick, Mixing, Epoxy, 804-60 (6D887) Tape, Masking (1 inch wide), 1-3m (2j209) Threadlocker, 75145A69 (39428) Wood, Section 2x4, 35 inches in length Wood Support Blocks 4x4x12 inches in length (5) U/M

F C C C C F F F C C C

EA GL PG CA CN EA PK CN EA BE CA

21 22 23

F F F

5350-00-161-9044

PG TB EA

24 25 26 27 28 29

F F F F F C

CN EA RO EA EA EA

END OF WORK PACKAGE

0057-2

TM 10-5411-247-13&P

INDEX
Subject WP Sequence No.Page No.

A
Abbreviations/Acronyms ....................................................................................................................... WP 0001-4 Army Maintenance System MAC....................................................................................................... WP 0054-1

B
Basic Issue Items (BII) List... ................................................................................................................ WP 0056-1

C
Cleaning Intervals ................................................................................................................................. WP 0016-2 Common Tools and Equipment ......................................................................................................... WP 0001-6 Components of End Item (COEI) List................................................................................................... WP 0056-1 Controls and Indicators ......................................................................................................................... WP 0004-1 Corrosion Prevention and Control (CPC) .......................................................................................... WP 0001-3

D
Decals and Instruction Plates ............................................................................................................... WP 0006-1 Description and Use of Operators Controls and Indicators ................................................................ WP 0004-1 Destruction of Army Materiel to Prevent Enemy Use .......................................................................... WP 0001-3 Description of Major Components ........................................................................................................ WP 0002-1

E
Equipment Characteristics, Capabilities and Features ........................................................................ WP 0002-1 Equipment Data .................................................................................................................................... WP 0002-5 Equipment Improvements and Recommendations, Reporting (EIR) ................................................ WP 0001-3 Expendable and Durable Items List .................................................................................................. WP 0057-1 Explanation of Columns in the MAC .................................................................................................... WP 0054-3 Explanation of Columns in the Tools and Test Equipment Requirements ......................................... WP 0054-4 Explanation of Columns in Remarks ................................................................................................. WP 0054-4

F
Field ManualsWP 0053-1 Forms .................................................................................................................................................... WP 0053-1

INDEX-1

TM 10-5411-247-13&P Subject WP Sequence No.Page No.

G
General Information .............................................................................................................................. WP 0001-1

H
How to Locate Repair Parts .................................................................................................................. WP 0043-6 How to Use This Manual..............................................................................................................................xii

I
Introduction to Components of End Item (COEI) and Basic Issue Items (BII) List ............................. WP 0056-1 Introduction to Maintenance Allocation Chart ................................................................................... WP 0054-1

L
List of Abbreviations/Acronyms ... ........................................................................................................ WP 0001-4 Location and Description of Major Components .................................................................................. WP 0002-1 Lubrication Requirements ..................................................................................................................... WP 0017-9

M
Maintenance Allocation Chart ............................................................................................................... WP 0055-1 Maintenance Forms Records and Reports .......................................................................................... WP 0001-3 Maintenance Functions ......................................................................................................................... WP 0054-2 Malfunction Symptom Index ... ............................................................................................................. WP 0008-1

N
National Stock Number Index ............................................................................................................... WP 0051-1 Nomenclature Cross-Reference List ................................................................................................. WP 0001-4

O
Operations under Usual Conditions ... ................................................................................................. WP 0005-1 Operating Procedures ... ....................................................................................................................... WP 0005-1

P
Pamphlets .............................................................................................................................................. WP 0053-1 Part Number Index ................................................................................................................................ WP 0052-1 Preparation for Movement .................................................................................................................... WP 0005-36 Preparing CBC and Associated Equipment for Storage ...................................................................... WP 0005-37 Preventive Maintenance Checks and Services (PMCS) ..................................................................... WP 0017-1

R
References ............................................................................................................................................ WP 0053-1 Remarks for CBC .................................................................................................................................. WP 0055-5 Repair Parts and Special Tools List .................................................................................................. WP 0043-1 Reporting Equipment Improvement Recommendations (EIRs) ........................................................ WP 0001-3 Reporting Errors and Recommending Improvementsi

S
Safety, Care and Handling .................................................................................................................... WP 0001-6 Service Upon Receipt ........................................................................................................................... WP 0008-1 Special Tools List .................................................................................................................................. WP 0043-1

INDEX-2

TM 10-5411-247-13&P Subject WP Sequence No.Page No.

T
Table of Contents...ii Technical Manuals ............................................................................................................................. WP 0053-1 Theory of Operation .............................................................................................................................. WP 0003-1 Tools and Test Equipment .................................................................................................................... WP 0055-4 Troubleshooting Procedures ............................................................................................................. WP 0009-1

U
Usable on Code .................................................................................................................................... WP 0043-5

W
Warnings, Cautions, and Notes............................................................................................................ WP 0001-6 Warning Summary...a

INDEX-3/4 blank

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1. From: Joe Smith 2. Unit: home 3. Address: 4300 Park 4. City: Hometown 5. St: MO 6. Zip: 77777 7. Date Sent: 19-OCT-93 8. Pub no: 55-2840-229-23 9. Pub Title: TM 10. Publication Date: 04-JUL-85 11. Change Number: 7 12. Submitter Rank: MSG 13. Submitter FName: Joe 14. Submitter MName: T 15. Submitter LName: Smith 16. Submitter Phone: 123-123-1234 17. Problem: 1 18. Page: 2 19. Paragraph: 3 20. Line: 4 21. NSN: 5 22. Reference: 6 23. Figure: 7 24. Table: 8 25. Item: 9 26. Total: 123 27. Text: This is the text for the problem below line 27.

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is ODISC4. TO: (Forward to proponent of publication or form) (Include ZIP Code)

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

21 October 2003

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP / TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000
PUBLICATION/FORM NUMBER DATE

PFC JANE DOE Co A 3RD Engineer Br. Ft Leonard Wood, MO 63108

TITLE

PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS

TM 10-1670-296-20&P
ITEM NO. PAGE NO. 0036 00-2 PARAGRAPH LINE NO. * FIGURE NO. TABLE NO.

12 December 2008

Unit Manual for Ancillary Equipment for Low Velocity Air Drop Systems

RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible).

In Table 1, Sewing Machine Code Symbols, the second sewing machine code symbol should be MDZZ not MD22 Change the manual to show Sewing Machine, Industrial: Zig-Zag; 308 stitch; medium-duty; NSN 3530-01-181-1421 as a MDZZ code symbol.

*Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE

Jane Doe, PFC DA FORM 2028, FEB 74

(508) 233-4141 DSN 256-4141

Jane Doe Jane Doe

USAPPC V3.00

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

TO: (Forward direct to addressee listed in publication)

U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP / TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000

FROM: (Activity and location) (Include ZIP Code)

DATE

PFC JANE DOE Co A 3RD Engineer Br. Ft Leonard Wood, MO 63108

DATE

21 October 2003

PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER TITLE

TM 10-1670-296-20&P
PAGE NO. 0066 00COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE NO.

12 December 2008
FIGURE NO. ITEM NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED

Unit Manual for Ancillary Equipment for Low Velocity Air Drop Systems
RECOMMENDED ACTION

Callout 16 in figure 4 is pointed to a DRing.In the Repair Part List key for Figure 4, item 16 is called a Snap Hook. Please correct one or the other.

PART III REMARKS

(Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

UASPPC V3.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is ODISC4. TO: (Forward to proponent of publication or form) (Include ZIP Code)

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECHPUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000
PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE

TM 10-5411-247-13&P
ITEM NO. PAGE NO. PARAGRAPH LINE NO. * FIGURE NO. TABLE NO.

01 OCTOBER 2011

Cargo Bed Cover (CBC) Type IIIA1, 2-1/2 Ton Cargo Truck, LMTV, and LMTV Trailer

RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible).

*Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE

DA FORM 2028, FEB 74

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward to proponent of publication or form) (Include ZIP Code)

FROM: (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECHPUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000
PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE

TM 10-5411-247-13&P
PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE NO.

01 OCTOBER 2011
FIGURE NO. ITEM NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED

Cargo Bed Cover (CBC) Type IIIA1, 2-1/2 Ton Cargo Truck, LMTV, and LMTV Trailer
RECOMMENDED ACTION

PART III REMARKS

(Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is ODISC4. TO: (Forward to proponent of publication or form) (Include ZIP Code)

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECHPUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000
PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE

TM 10-5411-247-13&P
ITEM NO. PAGE NO. PARAGRAPH LINE NO. * FIGURE NO. TABLE NO.

01 OCTOBER 2011

Cargo Bed Cover (CBC) Type IIIA1, 2-1/2 Ton Cargo Truck, LMTV, and LMTV Trailer

RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible).

*Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE

DA FORM 2028, FEB 74

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward to proponent of publication or form) (Include ZIP Code)

FROM: (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECHPUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000
PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE

TM 10-5411-247-13&P
PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE NO.

01 OCTOBER 2011
FIGURE NO. ITEM NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED

Cargo Bed Cover (CBC) Type IIIA1, 2-1/2 Ton Cargo Truck, LMTV, and LMTV Trailer
RECOMMENDED ACTION

PART III REMARKS

(Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is ODISC4. TO: (Forward to proponent of publication or form) (Include ZIP Code)

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECHPUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000
PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE

TM 10-5411-247-13&P
ITEM NO. PAGE NO. PARAGRAPH LINE NO. * FIGURE NO. TABLE NO.

01 OCTOBER 2011

Cargo Bed Cover (CBC) Type IIIA1, 2-1/2 Ton Cargo Truck, LMTV, and LMTV Trailer

RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible).

*Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE

DA FORM 2028, FEB 74

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward to proponent of publication or form) (Include ZIP Code)

FROM: (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECHPUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000
PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE

TM 10-5411-247-13&P
PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE NO.

01 OCTOBER 2011
FIGURE NO. ITEM NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED

Cargo Bed Cover (CBC) Type IIIA1, 2-1/2 Ton Cargo Truck, LMTV, and LMTV Trailer
RECOMMENDED ACTION

PART III REMARKS

(Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

TM 10-5411-247-13&P

By Order of the Secretary of the Army:

RAYMOND T. ODIERNO General, United States Army Chief of Staff Official:

JOYCE E. MORROW Administrative Assistant to the Secretary of the Army

1125501

DISTRIBUTION: To be distributed in accordance with initial distribution number (IDN) 360067 requirements for TM 10-5411-24713&P.

The Metric System and Equivalents

Linear Measure
1 centimeter = 10 millimeters = .39 inch 1 decimeter = 10 centimeters = 3.94 inches 1 meter = 10 decimeters = 39.37 inches 1 dekameter = 10 meters = 3 2.8 feet 1 hectometer = 10 dekameters = 328.08 feet 1 kilometer = 10 hectometers = 3,280.8 feet

Liquid Measure
1 centiliter = 10 milliliters = .34 fl. ounce 1 deciliter = 10 centiliters = 3.38 fl. ounces 1 liter = 10 deciliters = 33.81 fl. ounces 1 dekaliter = 10 liters = 2.64 gallons 1 hectoliter = 10 dekaliters = 26.42 gallons 1 kiloliter = 10 hectoliters = 264.18 gallons

Weights
1 centigram = 10 milligrams = .15 grain 1 decigrarn = 10 centigrams = 1.54 grains 1 gram = 10 decigrams = .035 ounce 1 dekagrarn = 10 grams = .35 ounce 1 hectogram = 10 dekagrams = 3.52 ounces 1 kilogram = 10 hectograms = 2.2 pounds 1 quintal = 100 kilograms = 220.46 pounds 1 metric ton = 10 quintals = 1.1 short tons

Square Measure
1 sq. centimeter = 100 sq. millimeters = .15 5 sq. inch 1 sq. decimeter =100 sq. centimeters = 15.5 sq. inches 1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet 1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet 1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres 1 sq. kilometer = 100 sq. hectometers = .386 sq. mile

Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch 1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches 1 cu. meter = 1000 cu. decimeters = 35.31 feet

Approximate Conversion Factors

To change
inches feet yards miles square inches square feet square yards square miles acres cubic feet cubic yards fluid ounces pints quarts gallons ounces pounds short tons pound-feet pound-inches

To
centimeters meters meters kilometers square centimeters square meters square meters square kilometers square hectometers cubic meters cubic meters milliliters Iiters Iiters Iiters grams kilograms metric tons newton-meters newton-meters

Multiply by
2.540 .305 .914 1.609 6.451 .093 .836 2.590 .405 .028 .765 29.573 .473 .946 3.785 28.349 .454 .907 1.356 .11296

To change
ounce-inches centimeters meters meters kilometers square centimeters square meters square meters square kilometers square hectometers cubic meters cubic meters milliliters liters liters liters grams kilograms metric tons

To
newton-meters inches feet yards miles square inches square feet square yards square miles acres cubic feet cubic yards fluid ounces pints quarts gallons ounces pounds short tons

Multiply by
.007062 .394 3.280 1.094 .621 .155 10.764 1.196 .386 2.471 35.315 1.308 .034 2.113 1.057 .264 .035 2.205 1.102

Temperature (Exact)
_F Fahrenheit temperature 5/9 (after subtracting 32) Celsius temperature _C

PIN: 086963-000