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*T M 1 0 - 5 4 1 1 - 2 0 5 - 1 3

T E C H N I C A L M A N UA L

O P E R A T O R S , U N I T ,

AN D D IR E C T S U P P O R T

M A I N T E N A N C E M A N U A L

F O R

S H E L T E R , E L E C T R I C A L

E Q U I P M E N T

S - 2 5 0 / G ( U N S H I E L D E D )

( N S N 5 4 1 1 - 0 0 - 9 9 9 - 4 9 3 5 )

S - 2 5 0 / G ( S H I E L D E D )

(N S N 5 4 1 1 - 0 0 - 4 8 9 - 6 0 7 6 )

T h i s Ma n u a l Su p e r s e d e s T M 1 0 -5 4 1 1 - 2 0 5 - 1 4 d a t e d 9 J a n u a r y 1 9 8 9 .

A P P R O V E D F O R P U B L I C R E L E A S E D I S T R I B U T I O N I S U N L I M I T E D .

H E A D Q U A R T E R S , D E P A R T M E N T O F T H E A R M Y

5 M a y 1 9 9 0

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C 2

CHANGE

NO. 2

HEADQUARTERS

DEPARTMENT OF THE ARMY

WASHINGTON, D.C., 30 MAY 1995

Operators, Unit, and Direct Support Maintenance Manual

for

SHELTER, ELECTRICAL EQUIPMENT

S-250/G (Unshielded)(NSN 5411-00-999-4935)

S-250/G (Shielded)(NSN 5411-00-489-6076)

DISTRIBUTION STATEMENT A Approved for public release; distribution is unlimited

TM 10-5411-205-13, 5 MAY 1990, is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar

in the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages

1-1 and 1-2 1-1 and 1-2

A-1/(A-2 Blank) A-1/(A-2 Blank)

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

GORDON R. SULLIVAN

General, United States Army

Chief of Staff

Distribution:

To be distributed in accordance with DA Form 12-25-E, block no. 3646, requirements for

TM 10-5411-205-13.

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WARNING

Drilling creat es metal chips which ma y enter eyes and cause seri-ous injury. Eye protection is required.

WARNING

Adhesives and solvents a re flamma ble and t oxic. Keep a wa y fromheat and open f lames. Use in a well-ventilated area. Avoid skina nd eye conta ct a nd brea thing of va pors. U se protective gogglesand gloves. U se in a ccordance with ma nufacturers instructions.For Artificial Respiration, refer to FM21-11.

WARNING

G loves a re to be worn when mixing and a pplying adhesive ma terialdue to possible skin irritation caused by adhesive coming into con-ta ct w ith th e body skin surface. The Versa mid m a teria l is extreme-ly sensitive to moisture absorption. Therefore, make sure Versamid140 container ha s lid firmly replaced aft er ma terial h a s been re-moved from shipping or storage container.

WARNING

All personnel must remain clear of truck while shelter is being low-ered into pla ce.

a/(b blank

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TECHNICAL MANUAL

No. 10-5411-205-13

* TM 10-5411-205

HEADQUARTEDEPARTMENT OF THE AR

Wa shington, DC 5 May 1990

Operators, Unit, and Direct Support Maintenance Manualfor

SHELTER, ELECTRICAL EQUIPMENTS-250/G (Unshielded) (NSN 5411-00-999-4935)S-250/G (Shielded) (NSN 5411-00-489-6076)

APPROVED FOR PUBLIC RELEASE DISTRIBUTION IS UNLIMITED.

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this m a nua l. I f you find a ny m ista kes or i f you know of away to improve the procedures, please let us know, Mail your letter, DA Form2028 (Recommended Changes to Publications and Blank Forms), or DA Form2028-2 located in the back of this manual direct to: US Army Troop Supportc orem a nd , ATTN: AMSTR-MC TS , 4300 G oodfellow B lvd., S t. Louis, MO, 63120-1798. A reply will be furnished to you.

CH AP TER 1

Section ISection II

CH AP TER 2

Section ISection IISection III

CH AP TER 3

Section ISection IISection IIISection IVSection VSection VI

CH AP TER 4

Section ISection IISection III

TABLE OF CONTENTSPage

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . 1-2

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Preventive Maintenance Checks and Services (PMCS) . . 2-1Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . 2-4Operat ion U nder U nus ua l Conditions . . . . . . . . . . . . . . . . . . 2-4

UNIT MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . 3-1

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Repair Parts, Special Tools, TMDE, and Support Equipment . . , . 3-1Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Maintenance Instructions . . . . . . . . . . . . . . . . . . . . 3-11P re pa ra t ion f or S h ipment a nd S tora g e . . . . 3-70

DIRECT SUPPORT MAINTENANCE INSTRUCTIONS . . . . . . . . 4-1

Repair Parts, Special Tools, TMDE, and Support Equipment . . . . 4-1Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

*This ma nu a l su persedes TM 10-5411-205-14 da t ed 9 J a nu a ry 1989.

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APPENDIX A

AP PE NDIX B

AP PE NDIX C

APPENDIX D

I N D E X

TABLE OF

REFERENCES . . . . . . .

CONTENTS (cont)

. . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . .

COMPONENTS OF END ITEM AND BASIC ISSUE ITEMSLISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXP END AB LE /DU RAB LE SU P P LIE S AND MATERI ALSLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-1

B -1

C-1

D-1

Index 1

i i

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1 3

3 35

TM 10-5411-205

LIST OF

FigureNumber

1-11-2

3-13-23-33-43-53-63-73-83 -93-103-11

3-123-133-143-153-163-173-183-193-203-213-223-233-243-253-263-273-283-293-303-313-323-333-343-353-36

3-373-383-394 -14 -24-34-44-5

Major Shelter Components . . .Shelter MarkingInstruction and Warning PlatesLifting and Loading ShelterSecuring Shelter on Truck .::

ILLUSTRATIONS

Title P a g e

. . . . . . ... . . . . . . . . . . . . . . . . 1-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

. . .... . . . . . . . . . . . . . . . . . . . . . 1-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33-4

Shelter-

Tiedow n on M1028 Truck 3-6

Securing Shelter on M1037 Shelter Carrier . . . . . . . . . . . . . . . . . . . . 3-8Rivet Types 3-12

3-14

Removing Blind Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Rivnuts (Threaded Inserts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Installing Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Removing Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19Repair of Turning Rivnut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Overall Shelter Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3-24Trough Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25Bail Handle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Recessed Step Pan Assembly Replacement . . . . . . . . , . . . . . , . . . . . . 3-28

Drain Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Instruction Plate Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30Outer Door Assembly Replacement 3-32

Weather Gasket and Seal Pressure Adjustment . , , , . . . , . . . . . , . . . . 3-36

Door Handle Assembly and Latching Mechanism Replacement . . . . . . . 3-40Keeper Assembly Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42Hinge Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44Door Hasp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Inner Door Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 3-47Louver Assembly, H older Assembly, a nd RF I/EM I R epla cement , . . . . . 3-50Directional Vane Assembly and Air Intake Filter Replacement . . . . . . . 3-52Louver Cover Assembly Latch Replacement . . . . . . . . . , . . . . . . . . . . 3-54

Shield (Rain Flap) Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55Louver Cover Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 3-57Data Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Louver Cover Assembly Strike Replacement . . . . . . . . . . . . . . . . . . . . 3-59Louver Cover Assembly Clip Replacement . . . . . . . . . . . . . . . . . . . . . 3-60Door Stay Assembly Repair and Replacement . . . . . . . . . . . . . . . . . . . 3-62

Skid Assembly Replacement .,. . . , . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

Skid Assembly Repair 3-66

3-67Lifting Bracket Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Sling Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69Skin Panel Delamination Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Shelter Wall Repair of Small Dent. . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Shelter Wall Repair of Large Dent. . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Shelter Wall Repair of Small Skin Puncture . . . . . . . . . . . . . . . . . . . 4-12Shelter Wall Repair of Large Skin Puncture or Cut . . . , , . . . , , . . . . 4-15

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LIST OF TABLES

TableNumber

2-13-1

3-23-33-44-1

Title

Operator Preventive Maintenance Checks and Services . . . . . . . . . . . .Troubleshooting

Rivnuts

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO USE THIS MANUAL

Page

2-23-9

3-133-173-204-2

This m a nu a l wa s prepa red t o help keep your S -250/G U nsh ielded a nd S -250/G Sh ieldedshelters in good operating condition. The front cover index is provided for quick reference toimportant information. There is a lso a n a lphabetical index at the ba ck of the ma nua l to loca te

specific items of inform a tion.

Wa rning pa ges are loca ted a t t he front of this ma nua l. You should read a nd completely under-sta nd a ll of the wa rnings before performing a ny ma intena nce on th e equipment.

P ara graphs in this ma nua l are numbered by cha pter a nd order of appeara nce within a cha pter .A subject index appears at the beginning of each chapter listing sections that are included inthat chapter . A more specific subject index is located at the beginning of each section to helpyou find t he exa ct para gra ph you a re looking for.

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CHAPTER 1

INTRODUCTION

Subject

Section I. GENERAL

Subject

INFORMATION

Reporting Equipment Improvement Recommendations . . . . . . . . . .Destruction of Army Materiel to Prevent Enemy Use . . . . . . . . . . .Preparation for Shipment and Storage . . . . . . . . . . . .

List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Scope.

Section

I

I I

P a r a

1-11-2

1-31-41-51-61-7

P a g e

1-1

1-2

P a g e

1-11-1

1-11-11-11-21-2

a. Type of M anual . This technical manual includes operator, unit and direct support

ma int ena nce procedures for t he S -250/G U nsh ielded a nd S-250/G Sh ielded shelters.

Additional maintenance data relevant to a specifically configured shelter can be found in theapplicable end item technical manual.

b. Equi pment N ame and M odel N um ber. This technical manual covers Electrical

E qu ipmen t S helt er S -250/G U nsh ielded a nd S -250/G S hielded . The S -250/G S hielded s helt er

is equipped wit h ra dio frequency/electr oma gnet ic int erference shielding.

c. Purpose of Equipment. The S -250/G U nsh ielded a nd S -250/G S hielded a re ligh t -weight transportable shelters designed to house a wide variety of military systems and com-

ponents.

1-2. Maintenance Forms and Records. Department of the Army forms and proce-dures used for equipment maintenance will be those prescribed by DA Pam 738-750, The

Army Maintenance Management System (TAMMS).

1-3. Reporting Equipment Improvement Recommendations (EIR). If your shelterneeds 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. Put it on an SF 368 (Quality Deficiency Report). Mail it to: Commander, US

Arm y Aviat ion a nd Troop Comm a nd , ATTN: AMS AT-I-MDO, 4300 G oodfellow B lvd., S t .

Louis, MO 63120-1798. Well send you a reply.

1-4. Destruction of Army Materiel to Prevent Enemy Use. Destruction of Armyequipment to prevent enemy use shall be in accordance with TM 750-244-3.

1-5. Preparation for Shipment and Storage. Refer to paragraph 3-37 for shipmentand storage preparation data. Administrative storage requirements will be in accordance

with the following:

1-1

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a. Placement of equipment in administrative storage should be for short periods of time when a shortageof maintena nce effort exists. It ems should be in mission rea diness within 24 hours or within the t ime factors

as determined by the directing a uthority. Dur ing the stora ge period appropriate ma intena nce records will be

kept.

b. Before p l ac ing equ ipment in admin is t r a t ive s to rage , current maintenance services and equipment

serviceable criteria (ESC) evaluations should be completed, shortcomings and deficiencies should be corrected,

a nd a ll modifica tion w ork orders (MWOs) should be a pplied.

c . Storage Site Sel ection. Inside stora ge is preferred for i tems selected for a dministra tive storage. I f insidestorage is not a vailable, trucks, van s, conex containers a nd other conta iners may be used .

1-6. Warranty Information. The S -250/G U nshielded a nd S -250/G Sh ielded shelters a re w a rra nt ed byGichner Shelter Systems or Ramim Engineering Works, Ltd. for 24 months. Warranty starts on the date foundon DA Form 2408-9 (Equipment Control Record) in the logbook. Report all defects in material or workmanship

to your supervisor w ho will t a ke a ppropria te a ction. Refer to Warra nt y Technica l B ulletin TB 10-5411-205-23

(Gich ner ) or TB 10-5411-205-23-1 (Ra mim ).

1-7. List of Abbreviations.

E M I Electroma gnetic Int erferenceR F I Radio Frequency Inter ferenceR TV Room Temperat ure Vulca nizing

TMDE Test, Measurement, a nd D iagnostic Equipment

Section II. EQUIPMENT DESCRIPTION AND DATA

Subjec t P a r a P a g e

Equipment Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . 1-8 1-2

Location and Description of Major Components . . . . . . . . . . . . . . . . . . . . . . . . 1-9 1-3

Equipment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1-3

Shelter Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 1-4

Instruction and Warning Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1-4

Safety, Care, and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1-5

1-8. Equipment Characteristics, Capabi l i t i es , and Fea tures . The S -250/G U ns hiel ded a nd S -250/GShielded shelters are lightweight, relocatable shelters used to transport and house various types of equipment.

The foam and beam shelter construction consists of aluminum face sheets enclosing a polyurethane foamcomposition core. The shelters are designed for outdoor use in all weather conditions. The shielded sheltersa re equipped w ith ra dio frequency/electr omag netic int erference (RFI /EMI ) shielding t o protect t he electr onicequipment contained inside. The shield is a continuous metallic surface which includes the shelter panel outer

face sheets and conductive materials which maintain continuity around joints, door openings, and otherpossible sources of ra dia tion leak. Sh ielded shelters a lso ha ve a RF I/EMI filter inside th e inner (emergency)door. Shielded shelters can be identif ied by the metall ic door gasket which mates with another conductivesurface on the door jamb.

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1-9. Location and Description of Major Components. (Figure 1-1)

1 .

2.

3 .

4 .

I T E M D E S C R I P TI O N

Door assembly Provides personnel access to interior of shelter.

Inner (emergency) door assembly Provides emergency personnel exit and allows fresh air to

enter shelter through an air vent with filter. The shielded

shelters a re provided with an RFI/EMI filter.

Lift ing bracket assembly Provides hookup point for sling assembly when lifting

shelter and when securing shelter onto truck.

Towing bracket assembly Provides hookup point for guide rope when guiding sling-

lifted shelter into position and when securing shelter onto

5. Recessed step pan assembly

6. Skid assemblies

t r u c k .

Allows access to roof.

Permit a fully equipped shelter to be seated on rough

terrain. They also provide forklifting access.

F igu r e 1-1 . Ma jo r Shel t er Componen t s .

1-10. Equipment Data.

H e i g h t

W i d t hL e n g t h

Gross weight

C u b a g e

Load on skids

70.125 in (178.11 cm)

79.0625 in (200.82 cm)86.625 in (220.03 cm)

Shield 770 lb (349 kg) empty

Unshielded 782 lb (355 kg) fully loaded

Empty 1.8 psi

Fully loaded 6.2 psi

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1-11. Shelter Marking. Shelter markings are shown in Figure 1-2. Lettering is stenciled or silkscreened in accordance with MIL-M-13231 GR II. The color used is black, MIL-C-46168; for camouflage paintedshelters, markings shall be Green 383, MIL-C-46168; for black background, and black, MIL-

-

C-46168; forgreen or brown backgrounds.

Fi gur e 1-2. Shelt er M ark in g.

1-12. Instruction and Warning Plates. (Figure 1-3)

1.

2 .

ITEM CONTENT

Warning P la te WARNING Keep drain plug loose during air and railtransport

Instruct ion P la te The surfaces of this shelter have been painted with CARCFor touch-upExterior - Use only lusterless green 383 polyurethane IAW

MILC-46168Interior - Use only epoxy polyamide IAW MILC-22750

For emergency exit remove wing screw and turn handle

Unlatch vent cover during airli f tKeep vent cover open when shelter is occupiedRemove drain plug during air and rail transport

3. Ins t ruc t ion P la te

4 . Ins t ruc t ion P la te

5 . Ins t ruc t ion P la te Insert pin in holes to hold door open.

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1-12. Instruction and Warning Plates (cent).

Fi gure 1-3. In str uction and Warn in g Plates.

1-13. Safety, Care, and Handling. Warnings, cautions, and notes designed to protectpersonnel and equipment when handling the shelter are located throughout this manual.Know the warnings before attempting to perform any maintenance on the shelter, and observ

all warnings, cautions, and notes as you come upon them in the text.

1-5/( 1-6 blan

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CHAPTER 2

OPERATING INSTRUCTIONS

Subject Section

Operator Preventive Maintenance Checks and Services (PMCS) . . . . . . . I

Operation Under Usual Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . IIOperation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . III

Section I. OPERATOR PREVENTIVE MAINTENANCECHECKS AND SERVICES (PMCS)

Subject P a r a

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1P urpose of PM CS Ta ble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Explanation of Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Pag

2-1

2-42-4

Pag

2-1

2-12-1

2-1. General. To be sure the shelter is always ready for use, i t must be inspected atspecific intervals so defects can be located and corrected before they result in serious damagor failure.

Befor e You Oper at e. AIways keep in mind the CAUTIONS and WARNINGS. Perfoyour before (B) PMCS.

Wh i l e You Oper ate. Always keep in mind the CAUTIONS and WARNINGS. Perforyour during (D) PMC S.

c . Afl er You Oper ate. Be sure to perform your after (A) PMCS.

d . Weekly. Perform your weekly (W) PMCS.

e. Once Each M onth. Perform your monthly (M) PMCS.

f . I f Your E qui pment F ail s to Operat e. If your equipment does not perform as requirnotify higher level of maintenance. Report a ny ma lfunctions or fa ilures on th e proper D AForm 2404 or r efer t o DA P a m 738-750.

2-2. Purpose of PMCS Table. The Preventive Maintenance Checks and Services tabllists the inspections required to keep the equipment in good operating condition.

2-3. Explanation of Columns.

I tem N um ber . The i tem number is to be used as a source number for the TM number column on DA Form 2404, Eq uipment Inspection an d Ma intena nce Worksheet, whenrecording P MCS results .

b. I tem to Be I nspected. This column list the components that require inspection.

c. Procedure. This column lists the faults to check for and procedures to follow.

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2-3. Explanation of columns (cont).

d . Equipment is Not Ready/Available If. This column tells you when and why your

equipment cannot be used.

Item

1

2

3

4

NOTE

Perform your weekly checks in addition to the before checks ifyou are the assigned operator and have not operated the equipmentsince the last weekly check was performed, or if you are operatingthe equipment for the frost time.

Table 2-1. Operator Preventive Maintenance Checks and Services.

NOTE

Within designated interval, these checks are to be performed in theorder listed.

Item to beInspected

Door Handles

Louver Cover

Assembly (InnerDoor)

Door Stay

Assemblies

Door Assemblies,

Inner and Outer

ProceduresCheck for and have repaired

or adjusted as necessary

Make sure handles on inner

and outer doors operate smoothly without binding or jamming.

a. Make sure louver coverassembly can be held in theopen position.

b. Make sure weather gasketis in good condition.

c. Make sure air filter,louvers and directional vanesare not blocked.

Make sure that each door stay

assembly rod slides smoothly inchannel and rotates easily inbracket. Check for loose ormissing hardware or detent pin

a. Make sure doors open and

close smoothly without bindingCheck hinges for loose looseor missing hardware. Lubri-cate hinges.

b. Make sure rain flap abovelouver cover assembly is intact.

Item isNot Ready/Available if

Door cannot be

opened or cannotbe closed securely.

a. Louver cover

assembly cannot beheld open.

c. Air filters,louvers or vanes areblocked.

a. Door cannot beopened or cannotbe closed securely.

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Item

4

5

6

10

11

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Table 2-1. Operator Preventive Maintenance Checks and Services (cont).

Item to beInspected

Door Assemblies,Inner and Outer(rent)

Lifting and Tow-ing BracketAssemblies

Roof Access Steps

Roof Handle

Drain Plug

RFI/EMI

Components

Wall Floor, and

Ceiling Panels

skids

ProceduresCheck for and have repaired

or adjusted as necessary

c. Make sure troughs (drip

moldings) above each door aremounted securely.

d. Check door surfaces forpunctures.

e. Make sure weather gasketsare in good condition.

a Inspect for excessive wear.

b. Inspect for rust, loose ormissing hardware.

c. Make sure rings and pinsrotate freely.

a. Make sure steps stay in up

or down position as required.

b. Check for loose or missinghardware.

Make sure handle is securely

mounted to roof.

Make sure drain plug is in

place.

a Make sure metal door

gaskets are complete and intact

b. Make sure filter is inplace and undamaged.

Inspect for punctures and

delamination.

Make sure skids are securely

mounted to shelter and areundamaged.

Item isNot Ready/Available if:

Drain plug is mi

ing (shieldedshelters).

a. Gasket is not

intact.

b. Filter is notintact.

Punctures are

present.

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Section II. OPERATION UNDER USUAL CONDITIONS

Subject Para Page

Assembly and Preparation for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2-4Initial Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2-4

2-6 2-4

2-4

2-4. Assembly and Preparation for Use. There are no assembly or preparationprocedures that must be performed before using the basic shelter. For all asssembly and prep-aration procedures applicable to a specifically configured shelter, refer to the end item techni-cal manual.

2-5. Initial Adjustments. The shelter itself requires no adjusting. However, the oper-ator must make certain the shelter is positioned so the door can be fully opened and closedand that any external equipment required for operation of the shelter-contained equipment canbe properly installed. Refer to the end item technical manual for anv adjustment proceduresapplicable to the configured shelter.

2-6. Operating Procedure. Thereshelter. Refer to the end item technicalspecifically configured shelter.

2-7. Preparation for Movement.

are no operating procedures applicable to the basicmanual for operating procedures applicable to a

Before moving the shelter, make sure the door isclosed and padlocked. If the shelter is being moved by truck, make sure the shelter is proper-ly tied down and blocked to prevent movement. Refer to paragraph 3-5 for instructions forsecuring the shelter on a truck. If the shelter must be loaded onto a truck for movement,refer to paragraph 3-5 for lifting and loading instructions. Refer to the end item technicalmanual for additional preparation instructions applicable to a specifically configured shelter.

Section III. OPERATION UNDER UNUSUAL CONDITIONS

Subject Para Page

Operation in Unusual Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2-4Emergency Procedures.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2-4

2-8. Operation in Unusual Weather. The S-250/G Unshielded and S-250/G Shieldedshelters are designed for use in all weather. However, shelters located at sites subject to saltair deterioration, or areas subject to wind-driven sand or coral dust shall be inspected by sitepersonnel at least once every week to assure timely determination of maintenance and repairneeds. Additional requirements for operation in unusual weather can be found in the end

item technical manual.

2-9. Emergency Procedures. Any damage to the shelter walls or ceiling must bepatched immediately to prevent possible water intrusion. In an emergency, any kind of tapeor water-resistent materials may be used to cover a puncture or a large hole. Temporarypatches must be replaced with permanent patches as soon as possible. In shielded shelter,temporary patches must be replaced as soon as possible to restore RFI/EMI suppression.

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CHAPTER 3

UNIT MAINTENANCE INSTRUCTIONS

Subject Section P a g.

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 3-1Repair Parts, Special Tools, TMDE, and Support Equipment . . . . . . . . . . II 3-1Service Upon ..Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I I 3 -1Troubleshooting . . . .... . ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV 3 -7Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V 3-1Preparation for Shipment and Storage . . . . . . . . . . . . . . . . . . . . . . . . VI 3-7

Section I. LUBRICATION

3-1. Lubrication Inductions. Lubricate door hinges, latches and locking mechanismdoor brace assemblies, roof access steps, and lifting and towing bracket assemblies to prevenrust a nd corrosion. Check these par ts frequently t o be sure they a re adequa tely lubrica ted.

Lubricate with Solid Film Lubricant, MIL-L-23398 (Item 22, Appendix D).

Section II. REPAIR PARTS. SPECIAL TOOLS, TMDE,AND SUPPORT EQUIPMENT

Subject

Common Tools . . . . . . . . . . . . . . . . . . . . . .Special Tools, TMDE , a nd S upport Eq uipment .Repair Parts . . . . . . . . . . . . . . . . . . . . . . . .

P a r a P a g

. . . . . . . . . . . . . . . . . . 3 -2 3 -1

. . . . . . . . . . . . . . . . . . 3 -3 3 -1

. . . . . . . . . . . . . . . . . . 3 -4 3 -1

3-2. Common Tools. A complete list of common t ools a nd t ool kits is g iven in S ect ion

III of Appendix B, Maintenance Allocation Chart.

3-3. Special Tools, TMDE, and Support Equipment. All special tools, TMDE, andsupport eq uipment a re listed in Section II I of Appendix B, Ma intena nce Allocat ion Ch a rt , anin t he Repa ir P a rt s a nd Special Tools List ma nu a l, TM 10-5411-205-23P , S-250/G Sh ielded aS-250/G U nshielded E lectr ica l E quipment Sh elters.

3-4. Repair Parts. Repair pa rts for unit ma intenan ce of the shelter are listed andillus t ra ted in TM 10-5411-205-23P .

Section III. SERVICE UPON RECEIPT

S u b j e c t P a r a P a g

Service Upon Receipt of Ma teriel . . . . . . . . . . . . . . . . . . . 3 -5 3-1Sit e Requirement s . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3-7

3-5. Service Upon Receipt of Materiel. Inspect the shelter for damage incurred duing shipment. If t he shelter ha s been da ma ged, report the da ma ge on S F 361 Tra nsporta tioDiscrepan cy Report (TDR ). If t he dra in plug ha s been loosened for shipment, t ight en it. Ifthe shelter is crated or pallet-mounted, refer to the end item technical manual for unpackin

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3-5. Service Upon Receipt of Materiel (cont).

instructions. If it is necessary for the shelter to be loaded onto a truck or transferred from one truck to

another, lift, load, and secure the shelter as follows:

If shelter panel is punctured during loading or securing, contact direct sup-

port to repair puncture as soon as possible to prevent moisture from seepinginto panels, and to restore RFI\EMI shielding in shelters ha ving this require-

m en t .

a. Li f t in g Skelter. (Figure 3-1)

(1)

(2)

(3)

(4)

(5)

Attach sling assembly to all four lifting rings on shelter so that turnbuckle ends of cables are

next to lifting rings. Be sure to use correct sling assembly. (See Appendix C.)

Place sling assembly on top of shelter.

Insert lifting h ook of lifting device (crane) into lifting ring.

Tie a1/2-inch rope, a t lea st 15 feet long, t o each rea r t owing eye.

CAUTION

Do not jerk, bounce, or jar shelter when lifting. Avoid swinging shelter from

side to side. Do not attempt to butt or push shelter into place with a forklift.

Slowly lift shelter w ith cran e.

b. L oadi ng Shelt er onto Tr uck. (Figur e 3-1)

To avoid injury to personnel and damage to shelter, only personnel actuallyengaged in loading operation should be permitted near truck, lifting device,and shelter. To eliminate confusion, all instructions must come from loading

crew supervisor.

NOTE

The entrance door of the shelter must be at the rear of the truck, and thefront rnd of the shelter must be placed flush against the front of the truckbody.

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3 5.

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Figure 3-1. Lifting and Loading Shelter

NOTE

Some procedures require the addition of dunnage to truck bed or

the attachment of tiedown eyes to truck before loading shelter ontotruck Refer to TM 9-2320-280 for Ml037 and Ml042 trucks andTM 9-2320-289 for M1028 trucks.

Lower truck tailgate and make sure all tools and equipment have been removefrom truck bed.

Position one person at free end of each rope to guide shelter into place.

Lift shelter to a position high enough to clear truck bed.

Back truck into position under shelter.

All personnel must remain clear of truck while shelter is being low-ered into place.

With one person at each rope, guide shelter into position so it is aligned abovetruck bed, and maintain that position while lowering shelter into place on truck

Change 1 3-

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(6) Remove lifting ring from lifting hook andRemove sling hooks from lifting eyes a nd

separate lifting ring from sling hooks.remove ropes from rear towing eyes.

c. Secur in g Shel ter on 1-1/ 4-T on(M561) Tr uck. (Figure 3-2)

(1) Install plate and eye bolt assemblies on cargo bed siderails of truck as describedin TM 9-2320-242.

(2) Hook ends of four sling assemblies to tiedown eyes at each top corner of shel-ter, using hooks at furthest end of cables from turnbuckles.

Fi gur e 3-2. Secur i ng Shel ter on T r uck.

(3) Hook sling hooks at opposite end of cables to appropriate. eye bolts on truck.

Make sure sling hooks point a wa y from shelter.

(4) Tighten all turnbuckles evenly by hand. Then turn each turnbuckle an addi-tional one-ha lf turn with a bar or rod inserted in tur nbuckle slot.

CAUTION

Do not overtighten turn buckles. Overtight ening may tear l i ft inga nd t iedown eyes from sh elter or da ma ge eye assembly or shelter.

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(5) Insert appropriate size wooden blocks between shelter skids and sides of truckbed to prevent sidewa y m ovement stra in on sling cables.

(6) Insert appropriate size wooden blocks between shelter skids and cab wall of bedto protect ca b w a ll and sh elter t owing eyes.

(7) Raise and secure truck tailgate.

d . Secur i ng Shel t er on 1-1/ 4-Ton(M880) Truck .

(1)

(2)

(3)

(4)

(5)

(6)

(7)

Fabricate and install wooden dunnage in truck in accordance with Departmentof Army Supply Bulletin SB-11-640.

In sta ll tiedow n provisions a s described in S B 11-640.

Unhook four sling legs from lifting ring of sling assembly.

Remove hooks from t urn buckle end of each sling leg.

Tempora rily st ore lifting r ing a nd four h ooks inside shelter.

Secure hooks remainin g in sling legs to four lifting eyes of shelter.

Secure turnbuckle end of sling legs to truck tiedown provisions using hardwarewh ich ha d been used to a tt a ch hooks to turnbuckles.

CAUTION

Do not overtighten turnbuckles. Overtightening may tear l i f t ingand tiedown bracket assemblies from shelter or damage bracketassembly or shelter.

(8) Tighten all turnbuckles evenly by hand. Then turn each turnbuckle an addi-tional one-ha lf turn wit h a bar or rod inserted in t urnbuckle slot.

(9) Raise and secure truck tailgate.

e . Secur i ng Shelt er on 1-1/ 4-Ton (M1028) T r uck.

(1) Fabricate a wooden dunnage and install wooden dunnage and tiedown provisionin truck as described in TM 9-2320-289.

(2) Unhook four cable assemblies from sling ring assembly.

(3) Attach each cable hook from turnbuckle end to each lifting ring of shelter.

(4) Secure hook at other end of cable to corresponding U bracket on truck framea s show n in F igure 3-3.

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CAUTION

Do not overt ighten tu rnbuckles. Overt ightening ma y tea r liftinga nd t iedown bra cket a ssemblies from shelter or dama ge bracketa ssembly or shelter.

(5) Tight en a ll tur nbuckles evenly by h a nd. Then t urn each t urn buckle an a ddi-tional one-ha lf turn wit h a bar or rod inserted in t urnbuckle slot.

Fi gur e 3-3. Shel ter T i edown on M 1028 Tr uck.

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3-5. Service Upon Receipt of Materiel (cent).

f . SecuringShel ter on M 1037 Shelt er Car r i er .

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

To install shelter support provisions on truck bed refer to TM 9-2320-280.

Lower tr uck t ailga te a nd place in loa ding position.

Connect sling assembly to shelter lifting brackets onshelter and lifting device.

the top four corners of

Remove and retain a bolt and nut attaching each towing eye to towing bracketand remove towing eye.

P osition each mount ing bra cket in place on t ow ing bra cket a nd secure w ithcapscrew, lock wa sher, an d flat wa sher, as shown in F igure 3-4. Do not tight ecapscrew until shelter is installed.

P osition sh elter over support a nd gr a dua lly lower shelter onto support in t ruck

NOTE

Shelter should be tightly f i t ted to front of support. Shims shouldonly be add ed to rear shelter mounts.

Position shelter to support front mounting points. Secure shelter to front ofsupport w ith four bolts, lock w a shers, w a shers, a nd t w o reinforcements. Tightcapscrews to 60 ft-lb (81 n-m). Tighten bolts to 90 ft-lb (122 n-m).

Secure rear of shelter (Figure 3-4) to support with four bolts, lock washers,washers, and two reinforcements. Do not tighten capscrews.

Add shims a s necessary to rear sh elter mounts t o ensure snug fi t betw eenmounting brackets and support. Tighten capscrews to 60 R-lb (81 n-m). Tighen bolts to 90 ft-lb (122 n-m).

Disconnect sling from shelter.

Raise and secure tailgate.

3-6. Site Requirements. Site requirements will depend on the requirements of the equiment contained in the shelter. Refer to the end item technical manual for siting instruction

Section IV. TROUBLESHOOTING

3-7. Troubleshooting. This section contains troubleshooting information for malfunctionwhich may develop in the shelter. Fault isolation is l imited to those components which maybe repaired or replaced at the unit or direct support level. Table 3-1 lists the common mal-unctions you may encounter during operation or maintenance of the shelter, Each malfunc-tion is followed by a list of tests or inspections and corrective actions. These tests or inspec-tions and corrective actions should be performed in the order listed. This manual cannot listall malfunctions that may occur.cannot be corrected by the listed

If you encounter a malfunction that is not l isted or thatcorrective actions, notify your supervisor.

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Fi gur e 3-4. Secur i ng Shel ter on M 1037 Shelt er Car r ier .

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Tabl e 3-1. T r oubl eshooti ng.

MALFUNCTIONTEST OR INSPECTION

CORRECTIVE ACTION

1.

2.

3.

4.

5.

OUTER DOOR OR INNE R DOOR D OES NOT OPE N OR CLOSE SMOOTHL Y

Step 1. Inspect hinges for adequate lubrication.

Lubrica te a s required (par a gra ph 3-1).

Step 2. Adjust or r epair d oor a s necessa ry (par a gra ph 3-19).

OUTER DOOR OR INNER DOOR DOES NOT STAY OPEN

St ep 1. Check to see if detent pin is installed in door stay channel.

Install detent pin in channel.

St ep 2. Check to see if detent pin is missing.

Install detent pin on door (paragraph 3-32.f).

DOOR H ANDLE IS J AMMED OR DOE S NOT OPE RATE SMOOTHL Y

Step 1. Inspect components for adequate lubrication.

Lubricate as required (paragraph 3-1).

step 2. Inspect door ha ndle an d lat ching mecha nism for missing or da ma ge com-p o n e n t s .

Repair or replace components as required (paragraph 3-19).

LOUVER COVER DOES NOT STAY OPEN

Step 1. Check to see if holder assembly is attached to louver cover.

Att a ch holder a ssembly t o louver cover.

Step 2. Check to see if holder assembly is secure or damaged.

Repair or replace components as required (paragraph 3-24).

WATER IS GETTING INTO SHELTER

Step 1. Check condition of weather gaskets around the inside edge of each door,

Replace deteriora ted ga skets (pa ra gra ph 3-18).

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Table 3-1. Troubleshooting (cont).

MALFUNCTIONTEST OR INSPECTION

CORRECTIVE ACTION

Step 2. Ch eck condit ion of t roughs (drip m oulding) a bove ea ch door.

Replace defective trough (paragraph 3-12).

Step 3.

Step 4.

Step 5.

St ep 6.

Check to see if roof access steps have pulled away from shelter wall.

Apply sealer (Item 28, Appendix D ) to ga ps a round step fla nge, orreplace step (paragraph 3-14).

Inspect shelter walls and ceiling for leaks.

If repair is required, refer to direct support.

Check th a t a ll exterior w a ll and ceiling pa tches are f irmly mounted an dbonded to shelter wall.

Apply sea ler (It em 28, Appendix D ) around edge of pat ch. If r epla cement

of patch is necessary, refer to direct support.

Check if l i f ting bra cket a ssemblies or towing bra cket a ssemblies ha vepulled a wa y from shelter comers.

a. Apply sealer (Item 28, Appendix D) to gaps around bracket edges.

b. If replacement is required, notify higher level of maintenance.

6. THE RE IS EVIDE NCE OF RADIO FRE QUE NCY/EL EC TROMAG NETICINTERFERENCE.

Step 1. In spect s helter w a lls, ceiling, a nd floor for holes.

If repair is required, refer to direct support.

Step 2. Check to see tha t a ll exterior w a ll and ceiling pa tches ar e f irmly m ount eda nd bonded.

If replacement of patches is necessary, refer to direct support.

Step 3. Ch eck cond ition of RF I/E MI filt er in d oor.

Replace da ma ged or missing fa lter (pa ra gra ph 3-24).

3-10

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Section V. MAINTENANCESubject

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Repair Procedures . . . . . . . . . . . . . . . . . .Shelter AssemblyOverall S helter Assembly

Trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bail Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Recessed Step Pan Assembly . . . . . . . . . . . . . . . . .Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outer Door AssemblyDoor Gaskets. . . . . . . . . . , . . . . . . . . . . . . . . . . .Door H a ndle Assembly a nd La tching Mecha nism . . . .Keeper Assembly . . . . . . . . . . . . . . . . . . . . . . . . .Hinge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .Door Hasp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inner Door Assembly . . . . . . . . . . . . . . . . . . . . . . .

INSTRUCTIONS

. . . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . .

. . .. . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .Louver Assembly, H older Assembly, a nd RF I/EM I F ilter . . . . . . . . . . . .Directional Vane Assembly and Air Intake Filter . . . . . . . . . . . . . . . . . .Louver Cover Assembly Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shield (Rain Flap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Louver Cover Assembly, .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Data Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Louver Cover Assembly Strikes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Louver Cover Assembly Clips ... . . . . . . . . . . . . . . . . . . . . . . . . . . .Door Stay Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Skid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Towing Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lifting Bracket Assembly ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P a r a

3-83-93-103-11

3-123-133-143-153-163-173-183-193-203-213-223-233-243-253-263-273-283-293-303-313-323-333-343-353-36

P a g e

3-113-123-213-23

3-253-263-273-293-303-313-333-373-413-433-453-463-483-513-533-553-563-583-593-603-613-633-673-683-69

3-8. General. Since most shelters contain sensitive electronic equipment that cannot beeasily removed, unit level ma intena nce a nd r epair w ill prima rily involve shelter exteriors oreasily a ccessible interior a rea s, unless floors, ceilings or w a lls ha ve evidence of w a ter int rusiowhich can jeopardize operation of the equipment. The shelter shall be returned to the depofor r epair if a ny of the follow ing condit ions exist:

a . P anel dama ges pans a s tructura l member.

b . Replacement of an entire w a ll, ceiling, or

c . Extensive equipment removal beyond the

d . Welding is required.

e . Da ma ge to a st ructura l member is severeespecia lly in edge or corner a rea s.

floor is required.

ca pability of th e using unit is required.

enough to cause distortion of a wall,

f . Lift , tow, or tiedown fi tt ings or corner cast ings a re da ma ged severely enough t oindicate possible damage to the underlying structural member.

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3-8. General (cont).NOTE

I f nature of damage warrants, print a caution notice using 4-inchhigh letters on a ll outside wa lls of the shelter a s follows:CAUTION: DAMAGED SHELTER. DO NOT SLING LIFT.

Coat threa ds of a l l screws a nd bolts w ith sealer before insta ll ing.Coat rivet a nd rivnut bodies w ith sea ler before using.

Unless otherwise noted, all procedures can be performed by oneperson using standard tools listed in Appendix B, Section III.

3-9. General Repair Procedures. The procedures described in this paragraph aregeneral procedures tha t m a y be needed during repair or repla cement of ma ny of the sheltercomponents. Wherever these general procedures apply, they are referenced at the appropriatepoint in the specific maintenance procedure paragraph.

a . Bl in d Rivet In stal l at i on and Removal.B lind rivets a re used in locations w here onlyone side of the area to be worked on is accessible. Blind pop rivets must be used in the

shelter foa m a nd beam panels, since the ha mmering required to insta ll conventional r ivetswould da ma ge the ma teria l. The types of r ivets used in th e shelter ar e shown in F igure 3-5a nd d escribed in Ta ble 3-2. When inst a lling floor pa tches, count ersunk h ead rivets (styles Ka nd T) a re preferred, but dome head rivets (styles R a nd S ) a re a n a ccepta ble alterna te. Wheninsta lling interior wa ll patches, countersunk hea d rivets sha ll be used in a ny loca tion in w hichdome head rivets w ill interfere w ith t he proper inst a llat ion of equipment. C losed end rivets(styles K a nd R) must be used for exterior repa irs a nd floor repairs to prevent m oisture a nddirt from entering panels.

NOTE

Open end rivets ma y be used only w here moisture a nd dirtentra nce w ill not a ffect the shelter.

F i g u r e 3 - 5 . R i v e t T ype s .

3-12

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Ta b l e 3-2 . B l i n d R i ve t s.

Part No. 1/

AD42HAD43H

AD45HAD62HAD64HAD68HAD42SMS20470AD6-8NAS1398D43NAS1398D4-4NAS1398D6-3NM1398D6-5NAS1398D6-8NAS1399D4-4NAS1399D6-6NAS1739E43

1/Part Number Code Explanations

Rivet Body

A =

Head S ty le

D =

K =

Mater ia l

Dim A

0.2360.236

0.2360.3750.3750.3750.2360.3750.2500.2500.3750.3750.3750.2250.3530.286

Aluminum

Dim H

0.0510.051

0.0510.0810.0810.0810.0510.0800.0670.0670.0800.0800.0800.0420.0700.047

Dome head

C ountersunk

Rivet Diameter in 32nds of an Inch

Exa mple: 4 = 4/32 or 1/8 inch

body diameter

Max. Grip in 16ths of an Inch

Dim D

1/81/8

1/83/163/163/161/83/160.1560.1560.1870.1870.1870.1250.1870.173

Mandrel Materia l

E xa mple: 4 = 4/16 or 1/4 inch

maximum grip range

A = AluminumNo letter = Ca rbon s teel

Core Design

H = Hollow core

S = Solid core

Dim L

0.3610.377

0.5020.3450.4700.7200.3610.3750.3260.3880.3500.4750.6620.3850.5370.375

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3-9. General Repair

(1) Installation.

Procedures (cont).

(Figure 3-6)

NOTE

When insta lling new rivet in sa me loca tion as a rivet tha t ha s been

removed and if diameter of hole in st ructure ha s been enlar gedduring removal of rivet, use next la rger dia meter rivet forreplacement.

Clean rivets wit h solvent before insta lling.

PROPER INSTALLATION IMPROPER INSTALLATION

Fi gure 3-6. Instal l i ng Bl in d R ivets.

(a) Determine ty pe, size and grip ra nge of rivet to be used. G rip lengthequa ls combined thickness of ma teria ls being riveted togeth er. Gr ip ran geof rivet must encompass grip length.

Drilling creat es meta l chips which may enter eyes and cau se seri-ous injury. Ey e protection is required.

CAUTION

Do not d rill deeper tha n necessar y t othrough other side of panel.

NOTE

install rivet a s you may drill

Drill hole size must match size of rivet being used.

Quan tit ies of sheets ma ybe drilled a t t he same time w hen heldtogether with sheet fasteners.

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3-9. General Repair Procedures (cont).

(2)

( b )

(c)

( d )

( e)

( f )

( g )

( h )

( i )

( j )

Drill hole in structure.

Remove all metal chips and remove burrs from drilled holes.

If flush head rivet is being installed, countersink hole using a 100-degree

or 120-degree machine countersink.

Coa t a ll rivet bodies w ith sealer (It em 28, Appendix D ) before inst a lling.

Insert rivet in hole. Make sure sheets are held tightly together beforeupsett ing or pulling rivet.

Select proper pulling head for rivet being installed and install pulling heon r ivet gun.

Insert stem of rivet into pulling head .

With pulling head parallel to axis of rivet, upset rivet. Exert firm pres-sure but do not bend or buckle metal sheets. Stem will break off belowrivet head surface. No trimmin g should be required.

Make sure riveted part s a re not loose, rivet does not rota te, an d rivet heis seated tightly against riveted surface. If rivet is loose or improperlyinsta lled, remove it a nd inst a ll a new one.

Removal. (Figure 3-7)

WARNING

Drill ing creates meta l chips wh ich m a y enter eyes an d cause seri-

ous injury. Eye protection is required.

NOTE

When drilling through rivet head, be careful to avoid enlarging holein structure. Keep drill perpendicular to material being drilled anddo not exert excessive pressure on drill, or replacement rivets willbe too loose.

DRILL PRY OFF

THROUGH HEAD

HEAD

PUSH OUTSHANK

Fi gur e 3-7. Removin g Bli nd R ivets,

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(a) Dr i l l t hr ough h ead of r i vet only , using hole in rivet as a guide. Use proper drill size asfo l lows :

Rivet Size (in.) Drill size

1 /8 No. 30

5/32 No. 20

3/16 No. 11

1 /4 1/4 inch

(b) Using a pin punch, pry off rivet head.

CAUTION

Do not punch rivet shanks out as you may damage the other side of the panel.

(c) Using pin punch, push out remainder of rivet shank. If shank will not push out easily,

drill it out.

b. Rivnu t I nstal lat i on and Removal. Rivnuts (threaded inserts) are tubular rivets with internal threadsand are used throughout the shelter wherever blind threads are required. The types of rivnuts used in theshelter are shown in Figure 3-8 and described in Table 3-3. Flat head rivnuts (style D and E) may be used

wherever head thickness will not interfere with installation of equipment. Countersunk head rivnuts (style

C) are used for flush insta llation. Keyed rivnuts are used in locations which a re subject to vibration a nd

torque. Closed end rivnuts (styles C and E) must be used for all interior or exterior repairs to keep moisture

and dirt from entering panels. Open end rivnuts (style D) maybe used only where rivnut to be replaced is

open end and not subject to water penetration.

Fi gur e 3-8. Ri vnu ts (Th readed I nser ts).

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Ta b le 3 -3 . R i vnu ts .

Dash No.

SM-C-563711-1

SM-C-563711-2SM-C-563711-3SM-C-563711-4SM-C-563711-5SM-C-563711-6SM-C-563711-7SM-C-563711-8SM-C-563711-9SM-C-563711-1OSM-C-563711-11SM-C-563711-12SM-C-563711-13SM-C-563711-14

Part No.

S25B151

S25B211S25B451S1OB366S25B140S8B106S31B350S31B125S31B481S8B201S8B161S25B320S31B425S81B350

Style Dim A

0.529

0.5290.5290.3910.4750.3550.6650.6660.6560.355

0.6650.665

Dim D

0.332

0.3320.3320.2500.3320.2210.4130.4130.4130.2210.2210.3320.4130.413

Dim L

1.000

1.0621.3121.0941.0000.6871.0321.1871.5620.6870.6871.1871.5311.437

T

1/4-20 U NC -3B

1/4-20 UNC -3B1/4-20 U NC -3B10-32 UNC-3B1/4-20 U NC -3B8-32 UNC-3B5/16-18 UNC -3B5/16-18 UNC -3B5/16-18 UNC -3B8-32 UNC-3B8-32 UNC-3B1/4-20 UNC -3B5/16-18 U NC-3B4/16-18 U NC-3B

Dim C

0.058

0.0620.062

0.0580.0620.062

Grip Ran

.089-.151

.151-.211

.391-.451

.316-.366

.080-.140

.065-.106

.275-.350

.030-.125

.406-.481

.161-.201

.106-.161

.260-.320

.350-.425

.275-.350

( 1 ) I n st a l l a t i on . ( F i g u r e 3 - 9 )

NOTE

When instal l ing new rivnut in same location as a rivnut that has

been removed, if diameter of hole in structure has been enlargedduring removal, use next larger diameter rivnut for replacement.

F i g u r e 3 -9 . I n st a l l i n g R i v n u t s .

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(a) Determine thread size, grip range, style, and material of rivnut to be used.Grip length equals combined thickness of materials being fastened togeth-er. Grip range of rivnuts must encompass grip length.

WARNING

Drilling creates metal chips which may enter eyes and cause seri-ous injury. Eye protection is required.

CAUTION

Do not drill deeper than necessary to install rivet as you may drillthrough other side of panel.

NOTE

Drill hole size must match size of rivnut being installed. Quan-tities of sheets may be drilled at the same time whenwith sheet fasteners.

(b)

(c)

(d)

(e)

(f)

(g)

(h)

(i)

Drill hole in structure.

Remove all metal chips and remove burrs from

If a countersunk head rivnut is being installed,100-degree machine countersink.

held together

drilled holes.

countersink hole using a

Thread stem of appropriate pullup stud into rivnut. Stud should protrudethrough open end rivnuts, or be 1-1/2 threads from bottoming in closedend rivnuts.

Coat rivnut body with sealer before installing.

Insert rivnut in hole. Make sure sheets are heldpulling.

tightly together before

With pullup stud parallel to axis of rivnut, pull up on rivnut. Exert firmpressure but do not bend or buckle metal sheets.

Make sure fastened parts are not loose, rivnut does not rotate and rivnuthead is seated tightly against surface. Make sure rivnut threads are ingood condition. If threads are damaged or rivnut is improperly installed,remove it and install a new one.

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3-9. General Repair Procedures

(2) Removal (Figure 3-10)

(cont).

WARNING

Dr ill ing creat es metal chips which ma y enter eyes an d cause seri-ous injury. Eye protection is required.

(a) Drill through head of rivnut, using same size dril l used to make originalhole. Counterbore in rivnut will act a s a dril l guide.

(b) Remove head of rivnut.

Fi gur e 3-10. Removin g Rivn ut s.

CAUTION

Do not puncture opposite face sheet of panel when punching outr i v n u t s h a n k .

(c) Punch out shank of rivnut, using a pin punch slightly smaller than hole structure. Punch only enough to disengage. Move rivnut aside to instaln e w r i v n u t .

(3) Repair. (Figure 3-11) When excessive torque is applied on screws attached onrivnuts, it may cause a rivnut to turn (spin). Table 3-4 provide the maximumtorque requirement for hardware to prevent rivnut turning. To correct aturning rivnut, proceed as follows:

(a) D rill a .062 (+ .003, -.001) dia met er hole by 1.00 inch long on t he st em othe t urning r ivnut a s shown in Figure 3-11.

(b) Install a headless straight pin (Item 25, Appendix D) in hole.

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Tabl e 3-4. Maxim um Torqu e Requi r ement f or Ri vnu t Scr ews.

Screw S ize

4 - 4 06 - 3 28 - 3 210-321/4 -205/16 - 183/8 - 16

Torq ue (lbs/inch)

8 inch lb12 inch lb20 inch lb20 inch lb50 inch lb65 inch lb120 inch lb

Fi gur e 3-11. Repair of Tu r ni ng Rivn ut

c . Tempor ar y Panel Repair . Any puncture in the shelter exterior, including puncturesin the door skin, must be pat ched immedia tely to prevent w a ter intr usion. Dents w ithout

punctures do not require patching. However, if bare metal is exposed, touch-up paint shall beapplied (paragraph 3-9.d).

Mat erials/P a rt s Adhesive (It em 30, Appendix D ) Sea ler, S ilicone (It em 26,Ta pe, P olyethylene (It em 29, Appendix D)Appendix D) Clean Cloth, Cott on (It em 10,

Sa ndpa per, G rit Nos. 60 (It em Appendix D)15, Appendix D) Solvent (It em 9, Appendix D)

G loves (It em 1, Appendix D )

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WARNING

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

Solvents are f lammable and toxic. Keep away from heat and openflames. Use in a well-ventilated area. Avoid skin and eye contactand breathing of vapors. U se protective goggles an d gloves.

CAUTION

Paint strippers can contaminate panel core,Do not use paint strippers t o remove paint .

NOTE

adhesive, and sealers.

Ceiling a nd floor pa nel compositions a re the sa me a s w a ll pa nelcomposition. The same method of repair applies to all panels.

Bend edges of puncture in below surface of unbroken face sheet. Do not allowbroken edges to cont a ct opposite fa ce sheet.

Remove loose fragm ents of foa m a nd d ust.

Clean and dry area surrounding puncture usingWipe off solvent.

Inject adhesive into puncture and fill.

clean cloth soaked with solven

Apply a bead of adh esive approxima tely 1/4 inch w ide over cut s in fa ce sheet.Do not smooth out.

Plan application of tape. Length and width, number of strips, overlaps, andmethod of application will affect sealing capability of repair. Each piece of tapsh a ll exten d a pproxima tely 1-1/2 inches beyond a dh esive. Ta pe must be applito bare clean metal . I f width of damaged area exceeds width of tape, overlapta pe strips a t lea st 1/2 inch. If th ree or more strips of ta pe a re required, a ppcenter strip first.

Stretch tape and apply l ightly. Do not apply with roll ing motion from end toend or side to side and do not rub strips into place. Tape strips must tightlyadhere to each other. Rolling, rubbing, and excessive pressure will squeezea dhesive out from under ta pe.

Touch up w ith pa int a s required (pa ra gra ph 3-9.d).

d . Touch-up paint ing. When required, to prevent rust and corrosion, touch up smallareas of damaged or chipped paint in accordance with TM 43-0139. If large areas needrepainting, notify higher level of maintenance.

3-10. Shelter Assembly. Shelter Assembly maintenance consists of the following

a . Overa ll shelter a ssembly inspection (para gra ph 3-11).

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3-10 Shelter Assembly (cont).

b . Trough (above each door) replacement (paragraph 3-12).

c . B a il ha ndle (roof) replacement (pa ra gra ph 3-13).

d . Recessed step pan assembly replacement (3-14).

e . Drain plug replacement (paragraph 3-15).

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3-11. Overall Shelter Assembly.

This t a sk covers: Inspect

INITIAL SETUP

T o o l s

General Mechanics Automotive Tool Kit

Inspect. (Figure 3-12)

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

Inspect shelter exterior for dents, punctures, or a ny other da ma ge.

Inspect shelter exterior for missing or loose part s a nd m ount ing ha rdw a re.

Ins pect outer door a ssembly (1) a nd inner door a ssembly (2) for ease of opera -tion.

Inspect louver cover assembly (3) for missing or damaged hardware and for easeof opening.

Inspect bail hand (4) and recessed steps (5) on shelter exterior for loose,missing, or damaged parts, and for proper operation.

Inspect towing eye bracket assembly (6) for damaged or missing parts and forproper operation.

Inspect lifting eye bracket assembly (7) for damaged or missing parts, and forproper operation.

Inspect sling assembly for da ma ged or m issing pa rts , a nd for proper operat ion.

In spect door la tching mechan ism (8), keeper a ssembly (9), a nd d oor st a y a ssem-bly (10) for damaged or missing parts, and for proper operation.

Inspect skid assembly (11) for damaged or missing parts.

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3-11. Overall Shelter Assembly (cont).

Fi gur e 3-12. Over al l Shel ter Assembl y I nspecti on.

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3-12. Trough

This ta sk covers Replace

INI TIAL S E TU P

TOOlS M a t er i a l s/ P ar t s

General Mechanics Automotive Tool Kit Sealer (Item 28, Appendix D)

Replace.

(1)

(2)

(3)

(4)

(5)

(Figure 3-13)

NOTE

The tr ough m ount ed to th e shelter rear pan el just a bove the door

is identical to the trough on the outer door except that the rearpanel trough is longer a nd is mounted w ith six screws instea d off i v e .

Remove five tapping screws (1) mounting trough (2) to outer door (3).

Take trough (2) off door (3).

Apply sealer to back of trough (2).

P osition t rough (2) on t op edge of out er door (3).

Dip in sealer a nd inst a ll five tapping screws (1), a nd coa t h eads of screws w its e a l e r .

Fi gur e 3-13. Tr ough Repl acement .

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3-13. Bail Handle.

This task covers: Replace

INI TIAL S E TU P

Too l s M a t er i a l s/ P ar t s

General Mechanics Automotive Tool Kit Sealer (Item 28,Rivets, Various

Appendix D)

Replace.

(1)

(2)

(3)

(4)

(5)

(Figu re 3-14)

Drill out five rivets (1). (Refer to paragraph 3-9.a for rivet removal instruc-t i o n s . )

Take bail handle (2) off shelter roof.

P osition ba il ha ndle (2) on shelter roof.

Fasten with five rivets (1). (Refer to paragraph 3-9.a for rivet installationinstructions.)

Apply a bead of sealer around edge of bail handle (2) and coat heads of rivetswith sealer.

Fi gur e 3-14. Bai l H and l e Repl acement .

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3-14. Recessed Step Pan Assembly.

This task covers: Replace

INITIAL SETUP

T oo l s M ater i al s/ Par ts

General Mechanics Automotive Tool Kit Conductive Compound (Item 33,Appendix D)

Sea ler (It em 28, Appendix D )

Replace. (Figure 3-15)

(1) Pull step (1) out and down to operating position.

(2) Remove two attaching locknuts (2) and remove step (1).

(3) Remove and retain ten phillips head screws (3) and lock washers (4) attachingrecessed step pan (5) to shelter wall and remove pan.

(4) If rivnuts (6) are damaged, remove and replace. (Refer to paragraph 3-9. b.)

(5) Apply conductive compound to shelter wall where it will mate with flange of.

(6) position recessed step pan (5) in place on. shelter wall and secure with tenphillips hea d screw s (3) and lock w a shers (4).

(7) Position step (1) in place over mounting studs in recessed pan (5) and securewith two locknuts.

(8) Apply a continuous bead of sealer around edge of recessed step pan (5).

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3-14. Recessed Step Pan Assembly (cont).

Fi gur e 3-15. Recessed S tep Pan Assembl y Replacement .

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3-15. Drain Plug.

This tack covers: Replace

INITIAL SETUP

T o o l s

General Mechanic's Automotive Tool Kit

M a ter i a l s/ Par t s

Sealer (Item 28, Appendix D)

drain plug chain (2) to cover (3) .


(1) Remove screw (1) attaching

(2) Pull plug (4) out of drain.

(3) Install plug (4) firmly in drain.

(4) Dip screw (1) in sealer and attach tab of chain (2) to cover (3).

Fi gure 3-16. Dr ain Plu g Replacement .

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3-16. Instruction Plates.

This task covers Replace

SETUP

M ater i a ls/ Par ts

INITIAL

T o o l s

General Mechanics Automotive Tool Kit Sealer (Item 28, Appendix D)


(1) Remove four tapping screws

(2) Ta ke pla te (2 or 3) off d oor

(3) P osit ion pla t e (2 or 3) on door (4).

(4) Dip in sealer and install four tapping screws (1).

(1)

(4)

Fi gur e 3-17. In st r uct ion Pl ate Repl acament

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3-17. Outer Door Assembly.

This t a sk covers a . I nspe c tb . Re movec . Repair

d . I n s t a l l

INI TIAL S E TU P

T o o l s M ater i a ls/ Par ts

General Mechanics Automotive Tool Kit Sealer (Item 28, Appendix D)Conductive Compound (Item 33,

Appendix D)

a . Inspect. (Figure 3-18)

(1) In spect t he

(2) Inspect the

(3) In spect t heshe l te r .

(4) In spect t he

b . Remove. (Figure

outer door a ssembly (6) for externa l da ma ge.

silicone weather

RFI /E MI ga sket

door for positive

3-18)

gasket

(9) for

(8) for tightness.

wear and secure mounting on shielded

closing and proper operation.

(1) Remove and retain three phillips head screws (1) attaching door stay channel to door pa nel, and pull cha nnel aw a y from door pa nel.

(2) Remove and retain four nuts (3), lock washers (4), and hex head screws (5)attaching each of the three hinges to shelter.

(3) Remove outer door panel (6) and three hinge spacers (7).

c . Repair. Outer door assembly repair consists of the following

(1) D oor ga sket (silicone a nd RF I/E MI ) repla cement (pa ra gra ph 3-18).

(2) Door handle assembly and latching mechanism replacement (paragraph 3-19).

(3) Keeper replacement (paragraph 3-20).

(4) H inge a ssembly replacement (par a gra ph 3-21).

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3-17. Outer Door Assembly (cont).

(5) Door hasp replacement (paragraph 3-22).

a . Install. (Figure 3-18)

(1)

(2)

(3)

(5)

Coa t both s ides of each h inge spa cer (7) w ith condu ctive compound .

P osition ea ch spa cer (7) a nd outer door a ssembly (6) in pla ce a nd s ecure ea chhinge t o shelter w ith four hex hea d screws (3), lock wa shers (4), a nd nut s (5).

Position door stay assembly channel (2) in place and secure to outer door panel

(6) with three phillips head screws (1).

Apply a continuous bead of sealer around spacer (7) and hinge bracket, anda round h ead of screw s (5).

F i gur e 3-18. Ou ter Door Assembl y Repl acement .

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3-18. Door Gaskets (cont).

c .w e a t h e rdoor, as

(3) Withd ra w th e paper. Resista nce to the w ithdra w al of the pa per indica tes properseal pressure. If there is no resistance, perform the adjustment procedure con-ta ined in the following pa ra gra phs.

(4) I f there is resista nce to the w ithdra wa l at a l l of the test points, sufficient sealpressure exists on the silicone weather gasket and adjustments are not neces-

s a r y .

Adjust. (Figure 3-20) Adjustment to increase the seal pressure on the siliconegasket can be made on the hinged side of the door and on the roller latch side of thedescribed in the following paragraphs:

(1) Weather Gasket Pressure Adjustment. To increase the weather gasket pressureon the hinged side of the door, proceed as follows

(a) Open the door and remove and retain three bolts (1), six flat washers(2), a nd th ree self-locking n ut s (3) at ta ching t he h inge to t he door.

(b) Coat each new shim with conductive compound on both sides.

( c ) In sert sh im (4), approximat ely 0.032 inches thick a nd m a tching t he hingebody in size, between the hinge leaf and the door.

(d) Secure the hinge leaf to the door using three bolts (1), six flat washers(2), and three self-locking nuts (3).

(e) Repeat the test procedures of paragraph 3-18.b. and repeat this adjustmentprocedure a s necessa ry.

(f) After completion of adjustment procedure, apply a continuous bead ofsealer around shim (4) and hinge leaf, and around head of bolts (1).

(2) Seal Pressure Adjustment. To increase the seal pressure on the roller latchside of the door, proceed as follows

(a) Open the door and remove and retain the hex head screws (5 and 6), flatwashers (7), and lock washers (8) from the top and bottom hole attachingthe keeper (9) to the wall, and remove keeper and shim (10). Removedetent pin (11) from center keeper.

NOTE

If more than one shim (12) is required, additional shims may bea dded, up to a maximum thickness of 0.096 inches.

If the seals a re not t ight a fter the ma ximum a llowa ble thickness isobta ined, the seal should be repla ced as the ma terial ha s l ikelybroken down.

(b) Add a 0.032 inch shim between the keeper (9) and the shelter.

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(c) Repeat the seal pressure test of paragraph 3-18.b. If the seal pressureremains insufficient, add another 0.032 inch shim.

(d) Repeat this process until sufficient seal pressure is developed or until thmaximum allowable thickness is obtained.

d . Repla ce. (Figu re 3-20) To repla ce th e RF I/E MI ga sket (13), rem ove ga sket fromtrack and clean track of any dirt . Place new gasket over track and snap in place. To replaceth e silicone wea th er ga sket (14), proceed a s follows

(1) Remove ga sket (14) a nd clean tra ck from a dhesive residue.

(2) Apply sealer in tr a ck groove a ll a round door an d sna p new ga sket in pla ce intrack on door.

CAUTION

Allow at least 30 minutes cure time for adhesive before using door.

Fi gur e 3-19. Typi cal L ocati ons for D oor Gasket T esti ng.

3-

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Fi gur e 3-20. Weath er Gasket and Seal Pr essur e Ad ju stm ent .

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3-19. Door Handle Assembly and Latching Mechanism.

This task covers: a . I nspe c tb . Servicec. Disassembled. Assemblee. Repa ir

INI TIAL S E TU P

Tools M ater i a ls/ Par ts

G en era l Mecha nics Aut om ot ive Tool K it S ea ler (I tem 28, Appendix D )Solid Film Lu bricant (It em 22, Appendix DConductive Compound (Item 33,

Appendix D)

NOTE

Except for the length of the latch assembly rods (items 4 and 5,Figure 3-21), the innerident ica l . Maintena nce

a . Inspect.

(1) In spect t he door la t ch

door a nd outerprocedures a re

door handle mechanisms arethe same for both.

a ssembly for secure mounting a nd broken or worn pa rts

(2) In spect for ea se of opera t ion.

(3) Inspect th e door ha ndle for tightn ess a nd for worn or da ma ged par ts.

b . Service. (Figure 3-21) Service of the door latch assemblydoor handle (8) and latch arm assemblies (10) with lubricant.

c . Disassemble. (Figure 3-21)

(1)

(2)

(3)

NOTE

consists of lubricating the

Disa ssembly procedures ar e simila r for t op a nd bott om sections ofdoor lat ch a ssembly.

Punch out spring pin (1) and remove flat washer (2).

Pull pin (3) and push latch rod assemblies (4 and 5) to the side.

Punch out spring pin (6) attaching the inside handle (7) to outside handle andshaft (8). Remove inside handle (7).

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3-19. Door Handle Assembly and Latching Mechanism (cont).

(4)

(5)

(6)

(7)

(8)

(9)

(10)

Punch out grooved pin (9) from underside of latch arm assembly (10) andremove grooved pin (9) to release the latch arm assembly (10). Pull outsideha ndle a ssembly (8) out of door.

Remove o-ring (15) from place on outside handle shaft (8).

Turn the bearing sleeve nut (16) counterclockwise to release the handle shaftsleeve (17) and remove nut (16) and shaft sleeve (17).

P unch out spring pin (11) a nd release t he roller extension (12) a nd roller la tch(13) from la tch a rm (14).

Punch out spring pin (1) and release flat washer (2), pin (18), and latch roda ssembly (5).

Remove nut (19) to release washer (20), spacer (21), latch arm assembly (10),spacers (22, 24, and 25), latch arm detent (23), (at the bottom latch installationonly), and bolt (26).

Remove rivet (27) a tt a ching pa dlock a nd cha in (28) to pa nel a nd r emovepadlock. (Refer to paragraph 3-9.a for rivet removal instructions.)

d. Assemble.

(1)

(2)

(3)

(4)

NOTE

Assembly procedures are similar for top and bottom sections of doorlatch assembly.

Place mounting end of padlock and chain (28) over mounting hole and securewith rivet (27). (Refer to paragraph 3-9.a for rivet installation instructions.)

Place roller extension (12) and roller latch (13) on to latch arm (14) and securewith spring pin (11).

NOTE

When installing the latch arm detent (23) at the bottom section ofthe assembly, have the latch mechanism fully open so that thera ised surfa ce is engaged in th e hole of the lat ch a rm a ssembly

(10). Then secure all components by tightening nut (19).

Apply condu ctive compound und er hea d of each bolt (26) and place bolt th roughmounting hole on door.

In sert spa cers (24 an d 25), la tch a rm detent (23), spa cer (22), (a t top of inst a lla-tion), latch arm assembly (10), spacer (21), and washer (20) on bolt (26), andsecure w ith nut (19).

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(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)

(13)

(14)

P ut w a sher (2) onto pin (18), insert pin (18) th rough h ole on rod la tch (4 a nd5), and secure with spring pin (1).

Apply condu ctive compound under mount ing su rfa ce of ha ndle sha ft s leeve (17)and bearing sleeve nut (16).

Insert handle shaft sleeve (17) into hole from outside of door panel and securew ith bea ring sleeve nut (16) from th e inside of pa nel.

Place o-ring (15) on outside handle shaft (8).

In sert d oor ha ndle sha ft (8) th rough ha ndle sha ft sleeve (17).

Insert latch arm (10) onto door handle shaft (8) and secure with spring pin (9).

Place inside handle (7) onto door shaft and secure with spring pin (6).

Align holes on latch rod assemblies (4 and 5) with hole on latch arm (10) andinsert pin (3). P la ce w a sher (2) onto th e pin (3) a nd s ecur e wit h spr ing pin (1)

Apply a continuous bead of sealer around head of bolts (26) and rivet (27).

Lubricate as required (paragraph 3-1).

e . Repai r . Repair of the door latch consists of replacing defective parts.

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Fi gur e 3-21. Door H and l e Assembl y and L atchi ng M echan i sm Repl acement .

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3-20. Keeper Assembly.

T h i s t a s k c o v e r s : a . Inspectb . R e p l a c e

INI TIAL S E TU P

To o l s

General Mechanics

M ater i a l s / Par t s

Automotive Tool Kit N o n e

a . I nspect. (Figure 3-22)

(1) Inspect for wear and other physical damage.

(2) In spect for secur e moun tin g.

(3) Inspect latch lock assembly (8) for wear or damage.

b . Repl ace. (Figure 3-22)

(1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

NOTE

The middle keeper on each door is tapped for attachment of a latchlock assembly. Maintenance procedures are the same for all keep-ers a nd on both t he outer door a nd inn er door a ssemblies.

Remove an d r eta in hex-hea d screw (1), lock wa sher (2), a nd fla t w a sher (3) fromtop (upper) hole of keeper assembly (4).

Remove an d ret a in h ex-hea d screw (5), lock w a sher (2), an d flat w a sher (3) frombottom (lower) hole of keeper (4) attaching each of the keepers (4) and shim (6a nd la mina ted shim (7) to wa ll and remove.

If only latch lock assembly (8) has to be removed, remove and retain hex-headscrew (5), lock washer (2), and flat washer (3) attaching tab of latch lock assembly (8) to center keeper at the bottom (lower) hole, and remove latch lock.

Position laminated shim (7), shim (6), and each keeper (4) in place and secureto shelter wall at top hole using hex-head screw (1), lock washer (2), and flat

washer (3).

Secure keeper (4) to wall at bottom hole using hex-head screw (5), lock washer(2), a nd flat w a sher (3).

If only latch lock assembly (8) has to be installed, position latch lock tab inplace over bottom mounting hole of center keeper (4), and secure using hex-hea d screw (5), lock w a sher (2), a nd flat w a sher (3).

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3-20. Keeper Assembly (cont).

(7) Ch eck la tch torq ue. La tch torq ue should be 10 foot-pounds wit hout RF I/EMI ga sket or20 foot-pounds w ith RFI /EMI ga sket. Add or subt ra ct shim s (6) to achieve propertorque. Use same number and thickness of shims with all three keepers.

Figure 3-22. Keeper Assembly Replacement.

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3-21. Hinge Assembly.

This task covers: a. Inspectb . Re movec. Disassembled . A sse mbl ee. I n st a ll

INITIAL SETUP

T o o l s M a ter i a l s/ Par t s


Appendix D)

b .

NOTE

The following repair procedures are the same for the inner door(par a gra ph 3-23) hinge a ssembly.

I nspect. (Figure 3-23)

(1) Inspect for damaged or non-functioning hinge assembly,

(2) Inspect for missing at ta ching ha rdw ar e.

Remove.

(1) Remove and retain three nuts (1) and flat washers (2) attaching each hingefrom the inside of door panel.

(2) Remove and retain three hex head screws (3) and flat washers (2) and removehinge a ssembly (4) a nd l aminated shim (5).

Disassemble.

(1) Grind off end of pin (6) and remove pin (6) and flat washer (7).

(2) Remove hinge leaf (8) and two flat washers (9) from bracket (10).

Assemble.

(1) Position hinge leaf (8) and and flat washers (9) in place inside bracket (10) andsecure in place with pin (6).

(2) Place flat washer (7) into pin (6) at opposite end of bracket (10) and peen endof pin (6) over to hold washer (7).

c .

d .

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3-21. Hinge Assembly (cont).

e . I n s t a l l .

(1) Apply a coat of conductive compound on mounting side of laminated shim (5)

and position shim (5) and hinge assembly (4) in place over mounting holes.

(2) Using three hex head screws (3) and flat washers (2) from the outside of doorpanel, secure with three flat washers (2) and nuts (1) from inside of panel.

(3) Apply a continuous bead of sealer around edge of hinge leaf (8) and laminatedshim (5) and around head of hex head screws (3).

F i gur e 3-23. H i nge Assembl y Repl acement .

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3-22. Door Hasp.

This ta sk covers: Repla ce

INITIAL SETUP

Tools

General Mechanics Automotive Tool Kit

M ater ia l s / Par t s

Sealer (Item 28, Appendix D)

Conductive Compound (Item 33, Appendix D)

Replace(Figure 3-24)

(1)

(2)

(3)

(4)

(5)

(6)

Remove thumb screw (1) and crimp mesh washer (2) from inside of outer door.

Take hasp (3) off outer door.

Apply conductive compound on mounting surface of hasp (3).

Position hasp (3) on outside of outer door under handle (4).

Install thumb screw (1) with crimp mesh washer (2).

Apply a continuous bead of sealer around edge of hasp (3).

Fi gur e 3-24. Door H asp Replacem ent .

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3-23. Inner Door Assembly.

This task covers: a Inspec t e. Testb. Remove f. Adjustc. Repaird. Install

INITIAL SETUP

Tools Materials/Parts


Appendix D)

a . Inspect (Figure 3-25)

(1) Inspect the inner door assembly (6) for external damage.

(2) Inspect the silicone weather gasket (8) for tightness.

(3) Inspect the RFI/EMI gasket (12) on a shielded shelter.

(4) Inspect the door for positive closing and proper operation.

(5) Inspect the air intake falter (9) for wear and cleanliness.

(6) Inspect louver assembly (10) and holder assembly (11) for damage and securemounting.

b . Remove. (Figure 3-25)

(1) Remove and retain three phillips head screws (1) attaching door stay channel (2)to door panel, and pull channel away from door panel.

(2) Remove and retain four nuts (5), lock washers (4) and hex-head screws (3)attaching each of the two hinges to outer door panel.

(3) Remove inner door assembly (6) and two hinge spacers (7).

c . Repair. Inner door assembly

Documents

S-250G TM 10-5411-205-13