(dd research note 84-14 maintenance performance system (organizational) training materials for...

(D RESEARCH NOTE 84-14

MAINTENANCE PERFORMANCE SYSTEM (ORGANIZATIONAL)

TRAINING MATERIALS FOR ORGANIZATIONAL MAINTENANCE TASKS ON M60A1/M113A1 EQUIPMENT

00 CO

Walter R. Harper Anacapa Sciences, Inc.

Michael Drillings and Melissa Berkowltz, Contracting Officer's Representatives

8

Submitted by

Robert J. Seidel, Chief TRAINING AND SIMULATION TECHNICAL AREA

and

Harold F. O'Neil, Jr., Director TRAINING RESEARCH LABORATORY

O DTIC ELECTE MAR 0 1 1984 D

U- S. Army

Research Institute for the Behavioral and Social Sciences

January 1984

Apprewd for public raltatt: distribution unlimittd.

Thto ripen, M tubmimd by tlM cmitraetw. to ton dMrtd for rtlMw to ^ (DTIC) to eemply with niulatory raquirwnMit*. It IIM bMn |ivtn no primary distribution ottwr than to OTIC •nd wHi te mMablt only thmifh DTIC or othtr raftrtnoa wrvicai Midi at tha National Taehnkal Information tarviea (NTIS). Tba iricm. opiniew, and/br findinp eontainad in tMi raport art thoia of tha autherb) and ihould not ba comtruad at an officW Oapaitmant of tha Army position, policy, or daeMon, unlan to datignatad by otnar official documaniaiion.

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UHULASSiriEU SECURITY CLASSIFICATION OF THIS PACE (Whrnt Dim Bntfdi

REPORT DOCUMENTATION PAGE READ INSTRUCTIONS BEFORE COMPLETING FORM

I. REPORT NUMBER

Research Note 84-14

2. SOVT ACCESSION NO 3. RECIPIENT'S CATALOG NUMBER

MAßi mi 4. TITLE fand SubMU*)

Maintenance Performance System-{OrganizationalJ Training Materials for Organizational Maintenance Tasks on M60A1/M113A1 Equipment

5. TYPE OF REPORT ft PERIOD COVERED

Contractor Report

6. PERFORMING ORG. REPORT NUMBER TR465-23

7. AUTHORft)

Walter R. Harper

8. CONTRACT OR GRANT NUMBERfa)

MDA 903-81-C-0032

S. PERFORMING ORGANIZATION NAME AND ADDRESS Anacapa Sciences, Inc. Drawer Q Santa Barbara, CA 93102

10. PROGRAM ELEMENT, PROJECT, TASK AREA ft WORK UNIT NUMBERS

2Q263743A794

«I. CONTROLLING OFFICE NAME AND ADDRESS US Army Research Institute for the Behavioral & Social Sciences 5001 Eisenhower Ave. Alexandria. VA 22333

12. REPORT DATE

19. NUMBER OF PAGES 69

14. MONITORING AGENCY NAME ft AOORESSflf dtf/*f«n( frooi CantrelHn« Ottlemi IS. SECURITY CLASS, (ot IM* npott)

UNCLASSIFIED

IS«. DECLASSIFICATION/DOWN6RADINO SCHEDULE

I«. DISTRIBUTION STATEMENT fef Ml« JttparO

Approved for public release; distribution unlimited.

17. DISTRIBUTION STATEMENT (al tkm abalrael «nfmrf in Btoek 20, If dTOafMil AMI Rtpoit)

IS. SUPPLEMENTARY NOTES

This project was monitored technically by Dr. Michael Drillings and Dr. Melissa Berkowitz

IS. KEY WORDS fCanlfaHM en nrmt— *l4m II n*e*aa«y and IdanMiy by block numb»)

Maintenance, Management Information System, Maintenance Training

J^L » ABBTWACT (SiSSäiä a»f»«r— aM> 5 n—aaay m* JSHSUr br Ma«* mmbm)

This document was designed to help unit-level trainers and training managers 'identify the training materials needed to conduct effective training on organizational maintenance tasks. The document provides a list of training materials for conducting corrective and preventive maintenace training on two items of equipment—the M60A1 tank and Ml13 family of armored personnel carriers This document is a product of a project to develop, implement, and evaluate a Maintenace Performance System-Organizational (MPS-0). MPS-0 is an integrated system for measuring maintenance performance, diagnosing performance problems,'

DD i jMrn 1473 m-noN er t HOV •> is OMOLCTK UNCLASSIFIED SECURI^V CLASSIFICATIOR OF TW* PAttE fBM* Data CntaHMQ

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TABLE OF CONTENTS

Page

INTRODUCTION 1

Why Do We Need Unit-ievel Training Materials? 1

Where Are These Training Materials? , 2

HOW TO USE THE TRAINING RESOURCE LISTINGS ,. i

A Note oh the Resource Categories 5

TRAINING MATERIALS FOR M60A1/M113A1 MAINTENANCE TASKS INDEXED BY MOS TASKS AND PERFORMANCE STEPS .... 6

MOS 11C and MOS 19D 7

MOS 19E/F 10

MOS 45N 21

MOS 63N 37

MOS 63N/T 50

TRAINING MATERIALS FOR M60A1/M113A1 MAINTENANCE TASKS USTED BY CATEGORY, NUMBER, TITLE 60

Correspondence Courses 61

Field Manuals 61

Graphic Training Aids 62

Skill Performance Aid/Extension Training Materials (SPA) 63

Training Extension Courses 63

Training Films 65

Technical Manuals 66

Video Tape Recordings 66

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INTRODUCTION

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This document was written to help unit-level trainers and training managers

identify the training materials needed to conduct effective training on organiza-

tional maintenance tasks. Many such resources exist, although unit trainers often

have difficulty identifying the precise ones needed in a particular training

situation. This document contains an organized listing of these materials, and will

considerably simplify the task of finding what is needed.

This document focuses on the training materials available for conducting

corrective and preventive maintenance training on two items of equipment—the

M60A1 tank and M113 family of armored personnel carriers. The MOS's covered

are the following:

MOS CODE TITLE

uc Indirect Fire Infantryman 19D Cavalry Scout 19E Armor Crew member (19F Now combined with 19E) 45N M6PA1/A3 Turret Mechanic 63N M60A:/A3 Tank System Mechanic 63T IFV/CFV System Mechwüc

Why Do We Need Unit-level Training Materials?

Training goes on continuously at unit level. Personnel from AIT must be

trained in tasks not covered at the school. Experienced personnel must also be

trained—changes in equipment and procedures require constant updating and

improving of skill levels through additional training. Army doctrine requires that

this training be done at unit level, with unit resources. Much of the training may

be accomplished with self-planned, self-paced individual training programs. This

document identifies the training materials available to accomplish such training.

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Accession For

NTIS GRAAI DTIC TAB Unannouncsd Justification

By Distribution/

Availability Codes

Dist

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Avail and/or Special

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Where Are These Training Materials?

The Skill Development Center (SDC) is run by a training specialist who

reports to the oattalion S3. The SDC obtains and stores training materials of all

kinds, particularly those that can be used on an individual basis.

The materials identified in this document should be available in your SDC.

If they are not, they can be ordered from the SDC's training resource catalogues.

The latest and most useful of these catalogues is DAPAM 350-100, Extension

Training Materials Catalog (CONSOLIDATED MOS CATALOG) 5 March 1982. This

catalog lists training materials for each MOS by Common Tasks, General Subject

Areas, and general support of MOS training. It does not, however, list training

materials specifically keyed to maintenance tasks.

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HOW TO USE THE TRAINING MATERIALS LISTINGS

The listings are keyed by MOS. Each MOS is broken down by equipment.

The maintenance tasks for the equipment are listed by corrective tasks and

preventive tasks. (To be sure the task description means the same to each reader,

the performance steps to accomplish each task are also described.)

The training materials that apply to each maintenance task are identified in

a cross-reference matrix by their code number only. If you want to find out the

exact title of a training resource, look in the green pages of the report. (Figure 1

shows the breakdown of the listings in graphic form.)

To find materials for a particular task, follow these steps:

1. Find the MOS reference in the pages that follow.

2. Find the equipment of interest.

3. Decide whether you need information on eorrective or preventive maintenance tasks and go to the appropriate section.

4. Find the task in the task list.

5. Check the performance steps shown under each task to ensure that the task is what you think it is. /

6. Go to the fold-out materials matrix and find the Une listing the task of interest.

7. Each time a "dot" is shown in a square on that line, read up and note the materials listing number.

8. Take your materials listing numbers to the SDC and borrow the materials.

9. If the materials are not in stock in the SDC, look up the full title in the green pages and have the SDC staff order the items.

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TRAINING RESOURCES

V.

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^EQUIPMENT ^

>

I CORRECTIVE

MAINTENANCE TASK #1

I PREVENTIVE

MAINTENANCE TASK#1

PERFORMANCE STEP 1

I PERFORMANCE

STEP 2

r---4.T--. PERFORMANCE

STEP "N"

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! ( Figure 1. Listing breakdown for training materials identification.

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A Note on the Training Materials

This document breaks down training materials into eight different cate-

gories. Those categories, and their abbreviations (used in the listings), are as

follows:

I :

• COR CRS - Correspondence Course

• FM - Field Manual

• GTA - Graphic Training Aid

• SPA - Skill Performance Aid/Ext Training Materials

• TEC - Training Extension Course

• TF - Training Films

• TM - Technical Manual

• VTR - Video Tape Recording

TRAINING MATERIALS FOR M60A1/M113A1 MAINTENANCE TASKS INDEXED BY MOS TASKS AND PERFORMANCE STEPS

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CORRECTIVE MAINTENANCE JOB TASKS AND RELATED PERFORMANCE STEPS

FOR

MOS 11C AND MOS 19D

VEHICLE TYPE JOB TASK PERFORMANCE STEPS

CARRIER M113A1 FAMILY

1. REPLACE TRACK SHOES.

2. REPLACE ROADWHEEL.

3. REPLACE AIR CLEANER ELEMENT.

4. MAINTAIN .50 CALIBER HBM2 MACHINEGUN.

a. Remove track shrouds. b. Loosen track tension. c. Install track fixtures. d. Remove pins. e. Remove track fixtures. f. Remove track shoe. g. Install in reverse order, h. Adjust track tension.

a. Remove track shroud. b. Loosen track tension. c. Break track. d. Position lifter under arm. e. Loosen nuts. f. Drive carrier forward to lift

wheel. g. Remove nuts, h. Remove wheel. i. Install in reverse order, j. Adjust track tension.

a. Unlatch clamps. b. Remove container.. c. Remove element from container. d. Install in reverse order.

a. Disassemble weapon. b. Clean and dry components. c. Lubricate components. d. Reassemble weapon.

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PREVENTIVE MAINTENANCE JOB TASKS AND RELATED PERFORMANCE STEPS

FOR

MOS 11C AND MOS 19D



1. BEFORE OPERATION CHECKS.

2. DURING OPERATION CHECKS.

3.

a. Make a visual inspection of vehicle exterior.

b. Check coolant. c. Check fire extinguishers. d. Check oil levels. e. Check and clean periscopes. f. Check instrument and warning light

panels. g. Clean air cleaner restriction

indicator. h. Start and check engine. i. Check communications. j. Check machinegun mount. k. Check personnel heater. 1. Check personnel heater electrical

circuits, m. Check coolant heater, n. Check coolant heater electrical

circuits, o. Check roadwheels. p. Check U joints, q. Check windshield (cold weather only).

a. Check and clean air cleaner restriction indicator.

b. Check steering, braking, shifting, and throttle controls.

c. Check roadwheel, idler wheel, final drive bearings and shock absorbers.

d. Check instrument panel gauges.

AFTER OPERATION a. Check tracks. CHECKS. b. Check roadwheels, idler wheels, final

drive bearings, sprockets, and shock absorbers.

c. Check V-belts. d. Check engine oil level. e. Check lights. f. Check fuel system and top off. ?• Check hull access and drain covers,

and drain plugs. h. Check air cleaner element. i. Check exhaust system.

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TRAINING MATERIALS FOR FM TM TEC VTR 31 IS

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M113 Al MAINTENANCE TASKS

MOS11C & 19D

CORRECTIVE MAINTENANCE TASKS

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1. Replace Track Shoes • • 2. Replace Roadwheel • • • 3. Replace Air Cleaner Element • • • 4. Maintain 50 eal. HB M2 Machineffun • • • • • • • • • • •

PREVENTIVE MAINTENANCE TASKS 1. Before Operation Checks • • • • • • • • • • • • 2. During Operation Checks • • • • • • • • • • • 3. After Operation Checks • • • • • • • • • • •

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CORRECTIVE MAINTENANCE JOB TASKS AND RELATED PERFORMANCE STEPS

FOR

MOS 19E/F

VEfflCLE TYPE JOB TASK PERFORMANCE STEPS

TANK 1. REPLACE TRACK OR a. Diagnose/verify fault. M60A1 TRACK BLOCK. b. Loosen track tension.

c. Loosen end connectors and partially remove.

d. Position track jacks and tighten. e. Remove end connectors. t. Remove track jacks. &• Remove center guide. h. To replace track block, remove

additional end connectors and center guide.

i. To remove entire track, back tank up until old track is off.

j- Install new track or track block in reverse sequence.

k. Adjust track tension.

2. REPLACE ROAD WHEEL a. DiagiiOse/verify fault. AND/OR BEARINGS.* b. Break track, if necessary.

c. Remove road wheel. d. Inspect hub and bearings. e. Remove and replace hub/bearings

if necessary. f. Install replacement parts in

reverse order. g. Join track. h. -Adjust track tension.

3. REPLACE ROAD WHEEL a. Diagnose/verify fault. • " ARM.* b. Break track.

c. Remove road wheel and hub. d. Remove torsion bar.

. - e. Disconnect retainer. f. Use adapter and puller to remove arm. g- Remove old gaskets and seals, if

required. 1 i 1 h. Install new gaskets and seals.

I i. Replace arm, torsion bar and

road wheel.

i r j. Join track.

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k. Adjust track tension.

\ •Mechanic task - done by crew.

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10


TANK 4. REPLACE TORSION a. Diagnose/verify fault. M60A1 BAR.* b. Block up support arm.

c. Screw adapter onto end of torsion bar.

d. Attach puller. e. Remove torsion bar. f. Partially install replacement

torsion bar. g. Align splines of bar and anchor. h. Completely install torsion bar. i. Pack cavity with lubricant.

5. REPLACE SHOCK ABSORBERS.*

a. Diagnose/verify fault. b. Remove cotter pins. c. Remove shock absorber. d. Install in reverse order.

6. REPLACE COMPEN- SATING IDLER WHEEL HUB AND ARM.*

7. REPLACE COMPEN- SATING IDLER ASSEMBLY.*

8. REPLACE DRIVE SPROCKET.*

a. Diagnose/verify fault. b. Break track. c. Remove compensating idler wheel. d. Remove hub. e. Remove outer bearing, f. Remove inner bearing. g. Replace inner bearing cup. h. Install replacement parts in

reverse order, i. Adjust track tension.

a. Diagnose/verify fault. b. Break track. c. Remove compensating idler wheel. d. Remove track adjusting link assembly. e. Remove compensating idler. f. Remove packing from hull. g. Disassemble idler. h. Replace components as necessary. i. Install spacer. j. Lubricate all bearing surfaces. k. Install in reverse order. 1. Adjust track tension.

a. Diagnose/verify fault. b. Remove rear fender. c. Break track. d. Remove hub and sprocket assembly. e. Install in reverse order. f. Adjust track tension.

•Mechanic task - done by crew.

11

k.

I VEHICLE

TYPE JOB TASK PERFORMANCE STEPS

TANK 9. REPLACE FINAL a. Diagnose/verify fault. M60A1 DRIVE.* b. Remove top deck and transmission

shroud. c Remove powerpack. d. Remove rear fender. e. Remove drain plug and drain oil. f. Break track and remove from

sprocket. g. Disconnect final drive adapter. h. Remove final drive. i. Install in reverse order. j. Fill with oil.

10. REPLACE POWER- a. Diagnose/verify fault. PACK.* b. Block tank front and rear.

c. Traverse turret 90 degrees to left or right.

d. Put transmission lever in park and turn off master switch.

e. Remove top deck and transmission shroud.

f. Remove access plates. g. Disconnect generator air duct. h. Disconnect tachometer. i. Disconnect fuel lines. j. Disconnect air cleaner hoses and

fire extinguisher tubing. k. Disconnect brake control rods,

steering and shifting linkage. 1. Disconnect brake cylinder and

lines. m. Disconnect universal joint and final

drive adapter. n. Disconnect transmission mounting

bracket. o. Install sling and raise power plant

slightly. p. Disconnect wiring harness. q. Remove powerpack. r. Install in reverse order.

11. REPLACE AIR CLEANER a. Open access door. FILTER. b. Remove filter.

c. Clean element as required. d. Install in reverse order.

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12. BORESIGHT THE 105 mm MAIN GUN.

With tank level, place cross threads on muzzle.

r 'Mechanic task - done by crew.

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I VEHICLE


TANK M60A1

13. BORESIGHT A COAX MACHINEGUN.

14. REPLACE EVACUATOR CHAMBER GROUP.

15. REPLACE AN M32/M36 PERISCOPE.

b. Select target 1200 meters away. c. Set tank/target range on range-

finder. d. Set computer (rangefinder) switch

to off. e. Set super-elevation counter to

zero. f. Remove firing pin and use hole

in breechblock as sight. g. Use right telescope of Ml7Al

binocular (over hole) to cl'gn gun on target.

h. Align gunner's periscope on target and slip scales

i. Align telescope on target and slip scales,

j. Align rangefinder on target and slip scales,

k. Replace firing pin assembly.

a. Clear the machinegun and disconnect solenoid lead.

b. Remove receiver assembly. c. Loosen support set-screws in gun-

mount collar. d. Select target 1200 meters away. e. Sight through gun, using M17A1

binoculars, and align on target. f. When aligned on target, tighten

all lock and jam screws. g. Adjust brightness of reticle on

M44C infinity sight, and align sight on target.

h. Replace receiver assembly.

a. Remove retaining ring. b. Remove evacuator chamber group. c. Clean fouled gun surface. d. Replace sealing rings, if required. e. Lubricate replacement evacuator. f. Install evacuator chamber. g. Replace retaining ring.

a. Remove passive elbow. b. Remove daylight body. c. Install in reverse order.

I I

13

I I VEHICLE


TANK M60A1

16. REPLACE THE M37 PERISCOPE.

17. BORESIGHTTHE SEARCHLIGHT.

18.

19.

20.

REPAIR BREECH BLOCK.*

a. b. c. d. e. f.

REPAIR BREECH OPERATING MECHANISM.*

a. b. c. d.

e.

f.

h. i.

MAINTAIN THE COAX MACHINEGUN.

a. b.

a. Hold periscope and push up on release bar.

b. Remove periscope. c. Install periscope and push up

until release bar locks in place.

a. Loosen azimuth lock screws. b. Loosen azimuth adjustment screws,

jam nuts, and center beam on target.

c. Adjust elevation adjustment screws and center beam in elevation on target.

4. Elevate gun 4 mils. e. Realign searchlight and tighten all

screws.

Diagnose/verify fault. Remove breech block. Disassemble breech block. Replace defective parts. Clean and lubricate components. Assemble and install in reverse order.

Diagnose/verify fault. Remove firing pin components. Install eyebolt. Secure breech block with chein hoist. Lower breech block onto turret floor. Remove and inspect components. Clean and lubricate components. Replace unserviceable parts. Assemble and install in reverse order.

Disassemble the weapon. Clean the weapon.

c. Replace defective parts. Q. Lubricate and reassemble the weapon.

•Mechanic task - done by crew.

14

1- •■^'~i-'isj

PREVENTIVE MAINTENANCE JOB TASKS AND RELATED PERFORMANCE STEPS

FOR MOS19E/F


TANK 1. BEFORE OPERATION a. Check torsion bars. M60A1 CHECKS.* b. Check fire extinguisher handles

(external). c. Check loader's and commander's

hatches. d. Check manual traverse, manual ele-

vation and turret lock. e. Check driver's hatch. f. Check driver's seat. g. Check driver's escape hatch. h. Check fire extinguisher system. i. Check hydraulic brake system. j. Check master battery indicator

light and power plant warning light,

k. Check air cleaner housings and doors.

1. Check top deck grille doors, m. Check engine and transmission oil

coolers, n. Check air cleaner elbows, hoses,

and clamps. o. Check restriction indicators, p. Check engine compartment for

presence of oil or fuel, q. Check external telephone.

2. DURING OPERATION CHECKS (Engine running).

a.

c.

e.

f.

Check air cleaner blower fans, right and left sides. Check restriction indicators, right and left sides. Check engine idle speed and accelerator control. Check power plant warning light. Check gauges on driver's indicator panel. Check steering control.

•NOTE: Common to all tasks:

Clean as needed Check bolts, nuts, screws Check welds Check wires and connections Check hoses and lines

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TANK M60A1

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Check shifting control. Check hydraulic brake system. Check air induction system. Check ammunition stowage racks and ammunition ready racks. Check gunner's and commander's seats. Check intercom sets C-2297/VRC (driver) and 2298/VRC (commander, gunner, and loader). Check azimuth control and elevation control. Check fire control (elevation) quadrant Ml 3 A3 and light source control. Check azimuth indicator M28E2. Check turret powered traverse, main gun powered elevation and depression, and hydraulic power. Check personnel heater (only when heater is used). Check and clean rangefinder lenses, periscope windows, and telescope lens (exterior).

4.

AFTER OPERATION a. Check engine and transmission oil CHECKS. level (engine still running).

b. Check rear grille doors. c. Check final drive and sprockets. d. Check roadwheels and hubs. e. Check roadwheel arms. f. Check shock absorbers. g- Check track support rollers and

hubs. h. Check track end connectors and

wedges. i. Check track center guides. j. Check track pads. k. Check compensating idler wheels

and hubs.

BEFORE-FIRING CHECKS a. Check gas-particulata system. b. Check stabilization circuits,

emergency shut-off and ventilating blower.

c. Check hydraulic power supply. d. Check main gun and breech operating

group.

16

V_

TRAINING MATERIALS FOR FM TM MPS(0) TASKS - MOS 19E/F

TASKS BY EQUIPMENT M60A1

CORRECTIVE MAINTENANCE 17-1

9E 1

/2

17-1

9E/C

M

17-1

9F 1

/2

17-1

9F/C

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1. Replace Track or Track Block • • • • • • • «

2. Replace Road Wheel and/or Bearings • • • • • 3. Replace Road Wheel Arm • • • • • 4. Replace Torsion Bar • 5. Replace Shock Absorbers • 6. Replace Compensating I »er Wheel Hub and Arm • 7. Replace Compensating Idler Assembly • 8. Replace Drive Sprocket • 9. Replace Final Drive • • • • • 10. Replace Powerpack • 11. Replace Air Cleaner Filter 12. Boresight the 105 mm Main Gun • • • • 13. Boresfcht a Coax Machinegun • • • • 14. Replace Evacuator Chamber Group IS. Replace an M32/M36 Periscope • • • • 16. Replace the M37 Periscope • • 17. Boresiirht the Searchlight • • • • 18. Repair Breech Block • • • • 19. Repair Breech Operating Mechanism • • • • 20. Maintain the Coax Machinegun • • • • • • •

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1 1 1 1 1 1 1 1 1 1 1 i 1 1 0O0O>HrHr-lrHi-tr-li-lrH^(^l cje-je^csit-t-t-c-t-t-t-t-t-t- 0000.-liHrH»Hr^r-<r-lTHi-li-l ■^.->.^.-^ 1 1 1 1 1 1 1 1 1 1

1 | | | | |OOOOOCC(0<0

• • • • • • • • • • • • • • • • • •

• • • • •

• • • • • • • • • • • • •

• • • • • • • • • • • • • • • • • • • • • • • • • •

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • _

TRAINING MATERIALS FOR COR.CRS. GTA MPS(O) TASKS - MOS 19E/F


CORRECTIVE MAINTENANCE

AR

O 4

51

AR

O 4

52

HC

6306

O

D

0007

O

D

0085

O

D04

11

C 1

7-2-

3 SL

C 9

-9-4

T

C 9

-1-1

67

TC 9

-1-1

69

TC 9

-1-1

78

1, Replace Track of Track Block 2. Replace Road Wheel and/or Bearings • 3. Replace Road Wheel Arm • • 4. Replace Torsion Bar • 5. Replace Shock Absorbers • 6. Replace Compensating Idler Wheel Hub and Arm 7. Replace Compensating Idler Assembly 8. Replace Drive Sprocket 9. Replace Final Drive • • 10. Replace Powerpack • 11. Replace Air Cleaner Filter • 12. Boresight the 105 mm Main Gun • • • 13. Boresight a Coax Machinegun • • • • 14. Replace Evacuator Chamber Group • IS. Replace an M32/M36 Periscope • 16. Replace the M37 Periscope • 17. Boresight the Searchlight • • 18. Repair Breech Block • • 19. Repair Breech Operating Mechanism • • 20. Maintain the Coax Machinegun • •

••/

COR.CRS. GTA TF 1

AR

Ö 4

51

AR

O 4

52

HC

63

06

OD

0007

O

D

0035

O

D 0

411

C 1

7-2-

3 SL

C 9

-9-4

T

C 9

-1-1

67

TC 9

-1-1

69

TC 9

-1-1

78

TC 9

-3-8

6 T

C 1

7-6-

5 9-

4321

9-

4322

9-

4355

17

-342

9 17

-465

1 • •

• • • • • • •

• • • • • •

nd Arm • • • e • •

• • • • • • •

• • • • • • • • • •

• • • • • •

• • • • • •

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TRAINING MATERIALS FOR FM TM Tl MPS(O) TASKS - MOS19E/F


PREVENTIVE MAINTENANCE

17-1

9E 1

/2

17-1

9E/C

M

17-1

9F 1

/2

17-1

9F/C

M

9-23

50-2

15-1

0 9-

2350

-257

-10

9-23

50-2

57-2

0 02

0-17

1-11

31

020-

171-

1132

02

0-17

1-16

86

020-

171-

1684

02

0-17

1-53

05

020-

171-

5306

02

0-17

1-53

33

020-

171-

5334

1. Before Operation Checks • • • • • • • • 2. During Operation Checks • • • • • • • 3« After Operation Checks • • • • • 4. Before Firing Checks • • • • • • 5. During Firing Checks • 6. After Firing Checks • • • • • • 7. Weekly Checks •

! 1

ü

r 19

/

FM TM TEC VTR :ORCRSJ

17-1

9E 1

/2

17-1

9E/C

M

17-1

9F 1

/2

17-1

9F/C

M

9-23

50-2

15-1

0 9-

2350

-257

-10

9-23

50-2

57-2

0

eo

ft 1

o

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00

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AR

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51

AR

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52

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •1 • • • • • * • • • • • • • • • •

• • • • • • • • • • • • • • • •

_ _ •

TRAINING MATERIALS FOR GTA TF MPS(O) TASKS - MOS 19E/F



SLC 3

-4-9

SL

C 9

-9-4

T

C 9

-1-1

78

TC 9

-9-3

T

C 1

7-2-

7 T

C 1

7-6-

5 T

C 1

7-6-

8

(O C- O» i-l t

c>)Nirtc-t-i'eoe eoMCSMe^co^»1«! ■* •* '* J J ' J ^ i i i t- t- t- t-t

1. Before Operation Checks • • • • 2. During Operation Checks • • • 3. After Operation Checks • • 4. Before Firing Checks • • • • • • • • • <

5. During Firing Checks • • • • 6. After Firine Checks • • • • • • 7. Weekly Checks •

20

r

r-- i i

CORRECTIVE MAINTENANCE JOB TASKS AND RELATED KEY STEPS

FOR MOS45N


TANK M60A1

REPLACE TURRET SLIP RING BOX

2. REPLACE SLIP RING INTERFERENCE SWITCH.

REPLACE LOADER SAFETY SWITCH.

4. REPLACE RESISTOR ASSEMBLY.

a. Diagnose/verify fault. b. Remove cover shield. c. Turn off master switch and dis-

connect upper and lower electrical connectors.

d. Remove locking wire, ground strap, and cover plate.

e. Remove gas pa.-ticulate hoses. f. Remove slip ring box and mounting

bracket from hull. g. Remove all fittings from box.

Reinstall on replacement box. h. Install in reverse order. i. Test operation.

a. Diagnose/verify fault. b. Turn off master switch. c. Drain hydraulic system. d. Place gun in travel lock. e. Remove slip ring cover shields

and plates. f. Disconnect electrical connectors. g. Remove defective switch. h. Install in reverse order. i. Test and adjust.

a. Diagnose/verify faal*. b. Turn off master switch. c. Disconnect electrical connectors. d. Remove safety switch and guard. e. Remove switch lead clamps. f. Remove defective switch. g. Install in reverse order, h. Test operation.

a. Diagnose/verify fault. b. Turn off master switch. c. Disconnect electrical connectors. d. Remove control selector assembly. e. Remove screws and nuts. f. Remove gunner's control cover

assembly. g. Remove the traverse control

bracket assembly.

I \

> L

21


TANK M60A1

h.

i.

j- k. I.

5. REPAIR MAIN GUN a. FIRING CIRCUIT. b.

c.

6. REPAIR STABILIZA- a. TION SYSTEM. b.

c. d.

7. REPLACE SUPER- a. ELEVATION ACTUATOR. b.

c. d. e. f. S- h. i. j.

8. PRIME (CHARGE) a. MANUAL ELEVATION b. SYSTEM. c.

d. e.

9. REPLACE ANTI- a. BACKLASH CYLINDER. b.

c. d. e. f. g- h.

10. ADJUST TRAVERSING a. BACKLASH GEAR, b.

c. d.

Remove the elevation control bracket. Remove nut-retaining receptacle. Remove the resistor assembly. Install in reverse order. Test operation.

Diagnose/verify fault. Repair faulty circuits. Test operation.

Diagnose/verify fault. Replace faulty parts. Reconnect all electrical connectors. Test operation.

Diagnose/verify fault. Release hydraulic pressure. Remove flexible shaft. Remove drive shaft. Disconnect hydraulic line. Plug open lines and ports. Remove superelevation actuator. Install in reverse order. Charge and bleed system. Test operation.

Diagnose/verify fault. Release gun travel lock. Elevate gun under power operation. Bleed manual elevation system. Prime manual elevation accumulator and recheck manual elevation.

Diagnose/verify fault. Release hydraulic pressure. Disconnect hydraulic lines. Remove backlash cylinder. Disassemble defective parts. Assemble and install in reverse order. Charge and bleed system. Test operation.

Diagnose/verify adjustment needed. Remove traverse backlash assembly cover. Remove adjusting screw and spring. Remove pinion guard plates.

22


TANK M60A1

11. REPAIR PIN LOCK.

12. REPLACE TURRET MOTOR.

s

13.

14.

REPAIR MAGNETIC BRAKE.

SERVICE MAIN ACCUMULATOR.

15.

e. Remove snap rings and drive pinions. f. Adjust hand-traversing drive. g. Install in reverse order, h. Test operation.

a. Diagnose/verify fault. b. Turn off master switch. c. Release hydraulic pressure. d. Drain traversing gearbox. e. Disconnect hydraulic lines. f. Plug open lines and ports. g. Remove pin lock and gasket. h. Replace defective components. i. Install in reverse order. j. Charge and bleed system, k. Test operation.

a. Diagnose/verify fault. b. Turn off master switch. c. Reduce hydraulic pressure. d. Disconnect electrical connector. e. Remove hoses. f. Disconnect electrical ground lead. g. Remove relay box cover, h. Remove motor. i. Install in reverse order, j. Charge and bleed system. k. Check for leaks.

a. Diagnose/verify fault. b. Replace defective components. c. Test operation.

a. b. c. d. e.

f.

REPLACE HYDRAULIC a. SYSTEM PRESSURE b. GAUGE. c.

d. e. f. g.

Diagnose/verify service needed. Turn off turret power. Check accumulator pressure. Charge accumulator, if necessary Check oil level in reservoir, and fill if necessary. Turn on turret power and recharge hydraulic system. Bleed air from system, if necessary.

Diagnose/verify fault. Release hydraulic pressure. Loosen gauge locking nut. Remove gauge and gasket. Install in reverse order. Charge and bleed system. Check for leaks.

23


TANK M60A1

16. REPLACE GUNNER'S/ COMMANDER'S POWER

*

17. REPLACE SOLENOID VALVE.

a. Diagnose/verify fault. b. Turn off master switch. c. Reduce hydraulic pressure. d. Remove connecting rod lever. e. Disconnect hydraulic lines. f. Disconnect electrical connectors. g. Remove gunner's switchbox control

selector box and mounting bracket. h. Remove gunner's control from riser, i. Coat replacement packings with

fire-resistant hydraulic fluid, j. Install packings into replacement

gunner's control. k. Install in reverse order. 1. Charge and bleed system, m. Check for leaks.

a. Diagnose/verify fault. b. Turn off master switch. c. Release hydraulic pressure. d. Remove tee fitting and packing ("O"

ring). e. Remove nipple and packing from valve. f. Remove defective valve. g. Install in reverse order. h. Charge and bleed system. i. Check for leaks.

18. SERVICE M32/M36 PERI- SCOPE.

19. PERFORM SYNCHRONI- ZATION CHECK - (RAMP METHOD).

a. Diagnose/verify fault. b. Make sure mount is seated. c. Clean eye lens and head window. d. Observe operation throughout full

diopter movement. e. Check condition of optics. f. Focus eyepiece to assure clear

definition. g. Check reticle illumination. h. Check for presence of parallax.

a. Diagnose/verify synchronization needed.

b. Place tank on level ground with rear toward ramp.

c Remove firing mechanism. d. Select a target at a range of

1,200 meters. e. Remove superelevation from

computer. f. Charge manual elevation system.

r-

24


TANK M60A1

20. REPLACE M13A2/M13A1D BALLISTIC COMPUTER.

21, REPLACE BALLISTIC COMPUTER CIRCUIT BREAKER.

22. REPLACE RANGEFINDER.

g-

h. i. j.

k. 1.

Determine corrective factors using gunner's quadrant for end test. Align boresight cross with target. Adjust sights. Boresight weapon at 89, 178, and 267 mils. Back tank up on ramp. Check backlash corrective factor at 89, 178, 267 mils. .

m. Check superelevation, n. Install firing mechanism.

a. Diagnose/verify fault. b. Turn off master switch. c. Disconnect power cable. d. Remove locking wire from couplings. e. Remove flexible shaft. f. Slide back collar. g. Separate driveshaft and computer

output shaft. h. Remove computer. i. Install in reverse order. j. Test and adjust tolerance.

a. Diagnose/verify fault. b. Turn off master switch. c. Disconnect power cable. d. Remove housing. e. Remove defective circuit breaker. f. Disconnect electrical leads. g. Install in reverse order. h. Test operation.

a. Diagnose/verify fault. b. Turn off master switch. c. Disconnect electrical lead. d. Disconnect ground lead. e. Disconnect mechanical linkage from

rangefinder to computer. f. Disconnect on/off switch to computer

from rangefinder. g. Remove ballistic shields. h. Remove end housings. i. Use rangefinder housing puller, j. Remove rangefinder. k. Install in reverse order. 1. Test and adjust.

li 25


TANK M60A1

23.

24.

REPLACE FIRING SWITCH IN COM- MANDER'S CUPOLA.

REPAIR BREECH BLOCK GROUP.

25. REPLACE BREECH OPERATING MECHANISM

26. REPLACE REPLEN- ISHER ASSEMBLY.

a. Diagnose/verify fault. b. Turn off master switch. c. Remove firing trigger switch. d. Install replacement switch. e. Test operation.

a. Diagnose/verify fault. b. Remove breech block. c. Disassemble breech block. d. Replace defective parts. e. Clean and lubricate components. f. Assemble and install in reverse

order. g. Test operation.

a. Diagnose/verify fault. b. Remove firing pin components. c. Install eyebolt. d. Secure breech block with chain hoist. e. Lower breech block onto turret floor. f. Remove and inspect components. g. Clean and lubricate components, h. Replace unserviceable parts. i. Assemble and install in reverse order, j. Test operation

a. Diagnose/verify fault. b. Drain oil. c. Remove hose assembly. d. Remove replenisher. e. Remove elbow from replenisher. f. Install in reverse order. g. Fill replenisher. h. Check for leaks.

27. ADJUST/REPLACE MINOR COMPONENTS.

Performance steps for these minor jobs consist basically of removing the defective part and installing replacement part. (See Technical Manual for details.) Equipment components would include, e.g.:

- Deck Clearance Switch - Gas Particulate Heaters - Controller Units - No-back - Magnetic Brake Switch - Tank Commander's Override - Periscopes and Sights - Turret Relay Box - Cupola Periscope Linkage - Elevation Cylinder - Palm Switch

n 26

TRAINING MATERIALS FOR SPA MPS(0) TASKS - MOS 45N

TASKS BY EQUIPMENT M60A1 Tank


r-IC»W^»<lO«0000>Or-tC»e«5^'lOb-OI OOOOOOOOr-ti-l»-lr-lr-tT-l»-li-

i i i i t I i I i i i i I i i I t-lrHi-(i-li-t»-lr-li-<»-lr-lr-trHt-lrHrHr'

oooooooooooooooc 1 1 1 1 1 1 1 1 1 1 1 1 1 ' 1 1 eowcococjcocscocscjeococjeocser

<0<0(OCOCOCOCO<ÖCO(OCD<0<OCO<D<C

1. Replace Turret Slip Ring Box •

2. Replace Slip Ring Interference Switch • 3. Replace Loader Safety Switch 4. Replace Resistor Assembly • 5. Repair Main Gun Firing Circuit • 6. Repair Stabilization System • 7. Replace Superrelevation Actuator • 8. Prime (Charge) Manual Elevation System 9. Replace Anti-Backlash Cylinder • 10. Adjust Traversing Backlash Gear • 11. Repair Pin Lock • 12. Replace Turret Motor 13. Repair Magnetic Brake 14. Service Main Accumulator 15. Replace Hydraulic System Pressure Gauge 16. Replace Gun.'s/Commdr.'s Pwr Cntrl Handle 17. Replace Solenoid Valve • 18. Service M32/M36 Periscope • 19. Perform Synchronization Check (Ramp Method) • 20. Replace M13A2/M13AID Ballistic Computer • 21. Replace Ballistic Computer Circuit Breaker 22. Replace Range Finder • 23. Replace Firing Switch in Commander's Cupola 24. Repair Breech Block Group • 25. Replace Breech Operating Mechanism • 26. Replace Replenisher Assembly •

27

/

t

SPA GTA TF |

OOOOOOOOlHrHfHiHrHfHt-li-l

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

oooooooooooooooo i i i i i I i i i i i t i i i i

CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO

tOCO<Ö<OCÖ<OtDtOCÖ(OCOCO(0(OtO(0 TC 9

-3-7

6 T

C 9

-3-8

3 T

C 9

-3-8

6 T

C 9

-665

T

C 1

7-6-

5 M

F 9-

5818

M

F 9-

5840

9-

4322

17

-465

1 17

-609

7

• •

• •

• • • • r-■

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1 •

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27

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TRAINING MATERIALS FOR FM | TM j TEC

i

i

<

< r

MPS(O) TASKS - MOS 45N

TASKS BY EQUIPMENT MSOAl Tank


2!Z in ir

o> 0

38-750

750-116

9-2350-215-10

9-2350-215-20

9-2350-257-10

9-2350-257-20

11-6625-366-35

020-171-5334

020-171-5335

029-171-5340

020-171-5341

020-171-5342

020-171-5344

101-113-4775

101-113-4776

1. Replace Turret Slip Ring Box c • • t

2. Replace Slip Ring Interference Switch » " i

3. Replace Loader Safety Switch • « 4. Replace Resistor Assembly • • 4

5. Repair Main Gun Firing Circuit • « 6. Repair Stabilization System — • • 7. Replace Superrelevation Actuator 8. Prime (Charge) Manual Elevation System 9. Replace Anti-Backlash Cylinder 10. Adjust Traversing Backlash Gear 11. Repair Pin Lock * • • 12. Replace Turret Motor • • • 13. Repair Magnetic Brake 14. Service Ma n Accumulator • • • 15. Replace Hydraulic System Pressure Gauge —^

16. Replace Gun.'s/Commdr.'s Pwr Cntrl Handle • • • 17. Replace Solenoid Valve • • • 18. Service M32/M36 Periscope • • • • 19. Perform Synchronization Check (Ramp Method) o • ' 20. Replace M13A2/M13AID Ballistic Computer * • • • • • • 21. Replace Ballistic Computer Circuit Breaker e • • • • 22. Replace Range Finder • • • • • • 23. Replace Firing Switch in Commander's Cupola • • • 24. Repair Breech Block Group m • • 25. Replace Breech Operating Mechanism • • 26. Replace Replenisher Assembly • •

28

/

1

f-/*i.r^ ■>'■■}

1 FM| TM TEC VTR 1 COR.CRS. 1! 1 r

FM 9

-45N

1/2

FM

9-4

5N/C

M

j

38-

750

750-

116

9-23

50-2

15-1

0 9-

2350

-215

-20

9-23

50-2

57-1

0 9-

2350

-257

-20

11-6

625-

366-

35

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1 1 1 t 1 1 1 1 1 OOOOOOr-trHi-4 C<I(NC4C4C4C4000 OOOOOOiHfHrH -2

E/0

20-1

71-0

026

-2E

/020

/171

-110

1 -2

E/0

20/1

71-1

108

-2E

/020

/171

-704

7 02

0-17

1-90

43

1

020-

171-

9044

610-

091-

0795

64

0-17

1-90

22

643-

091-

0148

64

3-09

1-01

68

643-

091-

0180

67

0-09

1-00

42

AR

O 4

51

HK 4

501

HK 4

502

HK 4

503

OD 0

008

OD 0

102

SY 6

301

# • e — • •

• • ^

^ • • 5^ • • •

• e • •

•

■

• • • • r • • • •

• • • • • •

• • • • L_- • • • • L • • • • •

• • • • • • • • • • • • •

• • • • • • • • • • • • • • •

* • • • • . • • • • • • • • • r • • • • • • • • ( • % • • • • • •

/ i^

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TRAINING MATERIALS FOR FM TM TEC MPS(0) TASKS - MOS 45N


27. Adjust/Replace Minor Components

FM 9

-45N

1/2

FM

9-4

5N/C

M

38-7

50

750-

116

9-23

50-2

15-1

0 9-

2350

-215

-20

9-23

50-2

57-1

0 9-

2350

-257

-20

11-6

625-

366-

35

^rmOf-id^intot» eoco'9'Tf^"<j<e-t-t- cocococococo t»»c*t^ inininininin««'^«

i i i I I i i I i ^Hl—l»HiHl-MrHCOCOeO

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co <

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1 r-l i t- 1 iH l

1 * o < C4 C O (

- Desk Clearance Valve Solenoid • • • • • - Gas Particulate Heaters • • • • • - Controller Units • • • - No-back • • • • • - Magnetic Brake Switch • • • • • - Tank Commander's Override • • • • • - Periscopes and Sights • • • • • • • - Turret Relay Box • • • • • - Cupola Periscope Linkage (M36) • • - Elevation Cylinder • • - Palm Switch • • •

29

FM TM TEC VTR COR.CRS. 1

FM 9

-45N

1/2

FM

9-4

5N/C

M

38-7

50

750-

116

9-23

50-2

15-1

0 9-

2350

-215

-20

9-23

50-2

57-1

0 9-

2350

-257

-20

11-6

625-

366-

35

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1 1 1 1 1 1 1 1 1 000000.-H.HlH esesesc^esesooo OOOOOOfHlHlH -2

E/0

20-1

71-0

026

I -2

E/0

20/1

71-1

101

-2E

/020

/171

-110

8 -2

E/0

20/1

71-7

047

020-

171-

9043

02

0-17

1-90

44

610-

091-

0795

64

0-17

1-90

22

643-

091-

0148

64

3-09

1-01

68

643-

091-

0180

67

0-09

1-00

42

AR

O 4

51

HK 4

501

HK 4

502

HK 4

503

OD 0

008

OD 0

102

SY 6

301

• • • • • • • • • • • • • • • •

• • • • • • • • • • • • • • • • • • • • • • • • • • •

• • • • • • • • • • • • • • • •

• • » • • • •

• • • • •

t—

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TRAINING MATERIALS FOR SPA MPS(0) TASKS - MOS 45N


27. Adjust/Replace Minor Components

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- Desk Clearance Valve Solenoid - Gas Particulate Heaters - Controller Units - No-back • - Magnetic Brake Switch • - Tank Commander's Override - Periscopes and Sights • - Turret Relay Box - Cupola Periscope Linkage M36) • Elevation Cylinder - Palm Switch -

30

v-, VS

1

\

SPA GTA TF 1

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PREVENTIVE MAINTENANCE JOB TASKS AND RELATED KEY STEPS

FOR MOS45N


TANK M60A1

1. TURRET INSPECTION

3.

INSPECTION OF INFRA- RED SIGHTING AND FIRE CONTROL.

MAIN GUN AND GUN MOUNT INSPECTION.

CUPOLA INSPECTION.

5. MACHINE GUN INSPECTION.

a. Check gun shield cover. b. Check gun shield cover. c. Check ammunition racks and stowage

boxes, d. Check main accumulator. e. Check turret traversing and

hydraulic system. f. Check elevating mechanism. g. Check dischargers and covers. h. Check grenade launcher harnesses,

harness guards, and harness housing assembly cover.

i. Check discharger brackets and grenade stowage bins.

j. Check push button unit.

a. Check M36 commander's periscope. b. Check M32 gunner's periscope.

a. Check bore evacuator chamber. b. Check gun tube. c. Check breech operating mechanism. d. Check breechblock closing mech-

anism and operating handle. e. Check firing contact. f. Check replenisher assembly. g. Check emergency firing device

(blasting machine).

a. Check hatch assembly. b. Check cupola access doors. c. Check terminal board assembly. d. Check cupola assembly ring gear. e. Check azimuth lock assembly. f. Check cradle assembly. g. Check cupola attaching screws, h. Check azimuth gear box. i. Check elevation screw jack, j. Check electrical parts.

a. Check machine gun functioning. b. Lubricate if necessary. c. Check cover assembly. d. Check jacket assembly with flash

hider or suppressor. e. Check receiver assembly.

31


TANK 6. INSPECTION OF CON- a. Check M28C commander's periscope. M60A1 VENTIONAL SIGHTING b. Check M31 gunner's periscope.

AND FIRE CONTROL c. Check sighting system super- SYSTEM. elevation check.

d. Check periscope M31 and periscope mount M115.

e. Check infinity sight M44C and 8635446,

f. Check telescope M105C or M105D and telescope mount M114.

g. Check rangefinder M17A1 or M17L. h. Check ballistic computer M13A1D or

M13A2. i. Check gunner's quadrant, j. Check elevation quadrant M13A1 or

Ml 3 A3. I k. Check azimuth indicator M28A1.

1. Check sighting system.

32

TRAINING MATERIALS FOR FM| TM 1 TE( MPS(0) TASKS - MOS 45N


PREVENTIVE MAINTENANCE TASKS

9-45

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1. Turret Inspection a. Check gun shield cover • b. Check ammunition racks and storage boxes #

c. Check main accumulator • • -

d. Check turret traversing &. hydraulic system e. Check elevating mechanism f. Check dischargers and covers • • 1

g. Check grenade launcher, etc. h. Check discharger brackets & grenade

storage bins i. Check push button unit

2. Inspection of Infrared Sighting & Fire Control a. Check M36 commander's periscope j • b. Check M32 gunner's periscope • • •

3. Main Gun & Gun Mount Inspection a. Check bore evacuator chamber • b. Check gun tube c. Check breech operating mechanism • d. Check breechblock closing mechanism &

operating handle • •

e. Check firing contact • f. Check replenisher assembly • g. Check emergency firing device

33

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1. Turret Inspection a. Check gun shield cover b. Check ammunition racks and storage boxes c. Check main accumulator d. Check turret traversing & hydraulic system • e. Check elevating mechanism • f. Check dischargers and covers g. Check grenade launcher, etc. h. Check discharger brackets & grenade

storage bins i. Check push button unit

2. Inspection of Infrared Sighting & Fire Control a. Check M36 commander's periscope • • b. Check M32 gunner's periscope •

3. Main Gun & Gun Mount Inspection ...

a. Check bore evacuator chamber b. Check gun tube c. Check breech operating mechanism • • d. Check breechblock closing mechanism &

operating handle • •

e. Check firing contact f. Check replenisher assembly • g. Check emergency firing device •

34

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4. Cupola Inspection a. Check hatch assembly • •

b. Check cupola access doors • •

c. Check terminal board assembly • • d. Check cupola assembly ring gear • • e. Check azimuth lock assembly • • • • f. Check cradle assembly • c • e. Check cupola attaching screws • • h. Check azimuth gear box • •

i. Check elevation screw jack • •

j. Check electrical parts • • • • 5. Machine Gun Inspection

a. Check machine gun functioning • • • • • • b. Lubricate, if necessary • • c. Check cover assembly • • • • d. Check jacket assembly with flash hider/suppressor • • e. Check receiver assembly • • • •

6. Conventional Sighting/Fire Control Inspection a. Check M28C commander's periscope • • • • b. Check M31 gunner's periscope • • • • c. Check sighting system superelevation • • d. Check M31 periscope and M115 mount • • • • e. Check infinity sight M44C and 8635446 • • • • f. Check telescope M105C/D and mount M114 • • • • g. Cheek rangefinder M17A1 or M1TL • • • • • • • h. Check ballistic computer M13A1D • • • • • • i. Check gunner's quadrant • • 1. Check elevation quadrant M13A1 or M13A3 • • • • k. Check azimuth indicator M28A1 • • • • 1. Check sighting system • •

Lr. ,

35

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TRAINING MATERIALS FOR GTA iTF 1 MPS(0) TASKS - MOS 45N



SLC 9

-9-4

T

C 9

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68

TC 9

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C 9

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4. Cupola Inspection a. Check hatch assembly b. Check cupola access doors c. Check terminal board assembly d. Check cupola assembly ring gear e. Check azimuth lock assembly f. Check cradle assembly g. Check cupola attaching screws h. Check azimuth gear box i. Check elevation screw jack i. Check electrical parts

5. Machine Gun Inspection a. Check machine gun functioning b. Lubricate, if necessary c. Check cover assembly d. Check jacket assembly with flash hider/suppressor e. Check receiver assembly

6. Conventional Sighting/Fire Control Inspection a. Check M28C commander's periscope b. Check M31 gunner's periscope c. Check sighting system superelevation d. Check M31 periscope and MUS mount e. Check infinity sight M44C and 8635446 f. Check telescope M105C/D and mount MI14 g. Check rangefinder M17A1 or M1TL • h. Check ballistic computer MI3A10 r» i. Check gunner's quadrant r- 1. Check elevation quadrant M13A1 or M13A3 r r-

k. Check azimuth indicator M28A1 n 1. Check sighting system 1 1

36


FOR

MOS 63N


TANK M60A1

1. REPLACE POWERPACK.

2. REPLACE VOLTAGE CONTROL BOX.

3. REPLACE STARTER.

a. Diagnose/verify fault. b. Block tank front and rear. c. Traverse turret 90 degrees to left

or right. d. Put transmission lever in park and

turn off master switch. e. Remove top deck and transmission

shroud. f. Remove access plates. g. Disconnect generator air duct, h. Disconnect tachometer. i. Disconnect fuel lines. j. Disconnect air cleaner hoses and

fire extinguisher tubing, k. Disconnect brake control rods,

steering and shifting linkage. 1. Disconnect brake cylinder and

lines, m. Disconnect universal joint and

final drive adapter, n. Disconnect transmission mounting

bracket. o. Install sling and raise power

plant slightly, p. Disconnect wiring harness, q. Remove powerpack, r. Install in reverse order.

a. Diagnose/verify fault. b. Turn master switch off and disconnect

battery. c. Disconnect electrical connectors. d. Remove control box. e. Install new control box and adjust,

if appropriate. f. Reconnect electrical connectors.

a. Diagnose/verify fault. b. Remove powerpack. c. Remove cable. d. Remove starter. e. Install replacement starter. f. Check starter operation (via

"ground-hop"). g. Replace powerpack.

37


t

TANK 4. REPLACE GENERATOR. a. Diagnose/verify fault. M60A1 b. Remove powerpack.

c. Remove clamps and boot. d. Disconnect electrical connectors. e. Remove cradle and ground strap. f. Remove generator. e- Install in reverse order.

5. REPLACE ENGINE OIL a. Diagnose/verify fault. COOLER, b. Remove powerpack.

c. Drain engine oil cooler. d. Disconnect oil lines. e. Remove wiring harness and bracket. f. Remove screen. g. Remove oil cooler. h. Install replacement oil cooler. i. Ground-hop and check for leaks. j. Install powerpack.

6. REPLACE AIR CLEANER a. Diagnose/verify fault. BLOWER MOTOR. b. Turn master switch off.

c. Remove air cleaner cover. d. Remove rubber bushing. e. Disconnect electrical connectors. f. Disconnect hose. g. Remove blower motor. h. Install in reverse order.

7. REPLACE FAN TOWER a. Diagnose/verify fault. SEAL. b. Remove back deck.

c. Remove fan tower shield. d. Cut lacing wire. e. Remove bolts. f. Remove fan tower. g- Remove seal. h. Install in reverse order.

8. REPLACE OIL COOLER a. Diagnose/verify fault. LINES. b. Remove transmission shroud and

back deck. c. Remove line. d. Install in reverse order.

9. ADJUST STEERING a. Diagnose/verify fault. CONTROLS AND b. Remove transmission shroud. LINKAGE. c. Disconnect rear steering and

shifting rods. d. Disconnect batteries. e. Remove powerpack, if necessary.

38


TANK M60A1

f. Adjust upper steering tube. g. Adjust lower tube. h. Adjust rear steering rod. i. Replace transmission shroud/

powerpack, j. Road test.

10. ADJUST SERVO BANDS.

11. ADJUST HYDRAULIC BRAKE CONTROLS AND LINKAGE.

12. REPLACE FIXED FIRE EXTINGUISHERS.

13. REPLACE ROAD WHEELS AND/OR BEARINGS.

14. REPLACE ROAD WHEEL ARM.

a. Diagnose/verify fault. b. Remove transmission shroud. c. Remove lock plate. d. Position lock nut. e. Adjust adjusting screw by torquing

and backing off. f. Align adjusting screw with lock

plate and secure lock nut. g. Install lock plate. h. Adjust as necessary. i. Replace transmission shroud.

a. Diagnose/verify fault. b. Remove transmission shroud. c. Disconnect cable rod end and bell-

crank, and insert pins. d. Remove powerpack. e. Remove brake housing covers. f. Adjust brakes. g. Install in reverse order.

a. Diagnose/verify fault. b. Unscrew connecting head from cylinder. c. Remove discharge line. d. Release straps and remove. e. Install in reverse order. f. Check and reset release valve if

necessary.

a. Diagnose/verify fault. b. Break track, if necessary. c. Remove road wheel. d. Inspect hub and bearings. e. Remove and replace hub/bearings,

if necessary. f. Install replacement parts in

reverse order. g. Join track. h. Adjust track tension.

a. Diagnose/verify fault. b. Break track. c. Remove road wheel and hub. d. Remove torsion bar.

39


TANK M60A1

15. REPLACE TORSION BAR.

16. REPLACE SHOCK ABSORBERS.

e. Disconnect retainer. f. Use adapter and puller to remove

arm. g. Remove old gaskets and seals,

if required. h. Install new gaskets and seals, i. Replace arm, torsion bar and

road wheel, j. Join track, k. Adjust track tension.

a. Diagnose/verify fault. b. Block up support arm. c. Screw adapter onto end of

torsion bar. d. Attach puller. e. Remove torsion bar. f. Partially install replacement

torsion bar. g. Align splines of bar and

anchor. h. Completely install torsion bar. i. Pack cavity with lubricant.

a. Diagnose/verify fault. b. Remove cotter pins. c. Remove shock absorber. d. Install in reverse ordere

17. REPLACE COMPEN- SATING IDLER WHEEL HUB AWD ARM/ BEARING.

i ..

18. REPLACE COMPENSAT- ING IDLER ASSEMBLY.

I 11

I

a. b. c. d. e. f. g- h.

i. j.

a. b. e. d.

e. f.

40

Diagnose/verify fault. Break track. Remove compensating idler wheel. Remove hub. Remove outer bearing. Remove inner bearing. Replace inner bearing cup. Install replacement parts in reverse order. Join track. Adjust track tension.

Diagnose/verify fault. Break track. Remove compensating idler wheels. Remove track adjusting link assembly. Remove hub. Remove compensating idler. Remove packing from hull.


TANK M60A1

19. REPLACE DRIVE SPROCKET/HUB.

h. Disassemble idler. i. Replace components as necessary. j. Install spacer. k. Lubricate all bearing surfaces. 1. Install in reverse order of removal. m. Adjust track tension.

a. Diagnose/verify fault. b. Remove rear fender. c. Break track. d. Remove hub and sprocket assembly. e. Install in reverse order. f. Torque mounting bolts. g. Adjust track tension.

I |

■I

I I I

41

Ä.-

TRAINING MATERIALS FOR IFM | TM TEC MPS(O) TASKS - MOS 63N



9-63

N 1

/2

9-63

N/C

M

11-6

625-

366-

35

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50

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1. Replace Powerpack •

2. Replace Voltage Control Box • • • • • • • • • • • • • 3. Replace Starter • • • • • • • • • • • • • • • • • 4. Replace Generator • • • • • • • • • • • • 5. Replace Engine Oil Cooler • • • 6. Replace Air Cleaner Blower Motor • • • • • • • • 7. Replace Fan Tower Seal • 8. Replace oil Cooler Lines • 9. Adjust Steering Controls and Linkage • • • 10. Adjust Servo Bands • • • 11. Adjust Hydraulic Brake Controls and

Linkage •

12. Replace Fixed Fire Extinguishers • 13. Replace Road Wheels and/or Bearings • • •

14. Replace Road Wheel Arm • • • • •

15. Replace Torsion Bar • IP, Replace Shock Absorbers • 17. Replace Compensating Idler Wheel Hub

and Arm/Bearing • • •

■-

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18. Replace Compensating Idler Assembly • • • • • 19. Replace Drive Sprocket/Hub • •1 • • •

42 I •■-»%■

1

IFM | TM TEC

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TRAINING MATERIALS FOR 1 VTR MPS(O) TASKS - MOS 63N



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1. Replace Powerpack • • • 2. Replace Voltage Control Box • • • • • • • • • • • • 3. Replace Starter • • • • • • • • • • • • • 4. Replace Generator • • • • • • • • • • • • • 5. Replace Engine Oil Cooler • 6. Replace Air Cleaner Blower Motor • • • • • • • 7. Replace Fan Tower Seal • • 8. Replace oil Cooler Lines • 9. Adjust Steering Controls and Linkage • 10. Adjust Servo Bands • • • • 11. Adjust Hydraulic Brake Controls and

Linkage •

12. Replace Fixed Fire Extinguishers • 13. Replace Road Wheels and/or Bearings • 14. Replace Road Wheel Arm • 15. Replace Torsion Bar • 16. Replace Shock Absorbers • 17. Replace Compensating Idler Wheel Hub

and Arm/Bearing •

18. Replace Compensating Idler Assembly • 19. Replace Drive Sprocket/Hub •

43

/

1 VTR COR.CRS. GTA TF |

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84

TC 9

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58

TC 9

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67

TC 9

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70

TC 9

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71

TC 9

-104

-39

TC 9

-105

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TF 9

-353

6 T

F 9

-365

0 T

F 9

-492

6 T

F 9

-493

4

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

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FOR

MOS 63N


TANK 1. BEFORE ROAD TEST a. Lubricate the vehicle. M60A1 INSPECTION. b. Check wheels, rollers, arms and (Hull)

■

hubs, and sprockets. c. Check shock absorber, bumper

springs, and torsion bars. d. Check tracks, track components,

and tension adjuster. e. Check access covers, fenders,

and fender storage boxes. f. Check air cleaner. g. Check external telephone. h. Check tow pintle, hooks, and

lifting eyes. i. Check lights, j. Check top deck, grille doors, and

gun travel lock, k. Check oil coolers, shroud seal,

and air cleaner hoses, 1. Check power plant, m. Check oil levels, n. Check engine, transmission, u-

joints, final drive, and fuel system,

o. Check seats, p. Check batteries and electrical

wiring and components, q. Check fire extinguisher system, r. Check gas particulate filter and

assembly. s. Check driver's hatches and peri-

scope, t. Check drain valves and hull

turret seal, u. Check hydraulic brake system, v. Check personnel heater and interior

lights, rheostats, and switches.

2. DURING ROAD TEST INSPECTION.

; i.

a. Check starter switch, fuel shutoff, and purge pump.

b. Check instrument gages and warning light.

c. Check steering controls. d. Check shifting controls. e. Check brake controls. f. Check RPM of governed engine and

performance.

n 44

!l

i •


TANK 3. AFTER ROAD TEST M60A1 INSPECTION.

a. Check tf -"perature of wheel hubs and sho ' absorbers.

b. Check '.,.- leaks. c. Confirm corrections made for

operational deficiencies via final road test.

! fi

D 45

it



PREVENTIVE MAINTENANCE TASKS BEFORE ROAD TEST INSPECTION

9-63

N 1

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N/C

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a. Lubricate the vehicle •

b. Check wheels, rollers, arms and hubs, and sprockets

c. Check shock absorber, bumper springs and torsion bars

d. Check tracks, track components, and tension adjuster

e. Check access covers, fenders, and fender storage boxes

f. Check air cleaner • •

g. Check external telephone

h. Check tow pintle, hooks, and lifting eyes

i. Check lights

j. Check top deck, grille doors, and gun travel lock

k. Check oil coders, shroud seal, and air cleaner hoses

•

1. Check power plant

m. Check oil levels and service oil filter •

n. Check engine, transmission, U-joints, final drive, fuel system, and filters • • • • • • •

46

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610-091-0110

611-171-0045

611-171-0153

611-171-0156

611-171-0165

611-171-1174

611-171-1175

611-171-9030

TVT 17-106

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TRAINING MATERIALS FOR FM TM TEC

COBJ CRS TF

MPS(0) TASKS - MOS 63N


PREVENTIVE MAINTENANCE TASKS DURING ROAD TEST INSPECTION

9-63

N 1

/2

9-63

N/C

M

o

in

i o o io in t- CO

co o> 611-

091-

6104

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1-09

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1-61

10

611-

091-

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61

1-09

1-61

12

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a. Check starter switch, fuel shutoff, and puree pump

•

b. Check instrument jjafces and warning light • • c. Check steering controls • • • • • • d. Check shifting controls • • • • • • • e. Check brake controls • • • • • • • • • • f. Check RPM of governed engine and

performance •

AFTER ROAD TEST INSPECTION a. Check temperature of wheel hubs and

shock absorbers • •

b. Check for leeks • c. Confirm corrections made for operational

deficiencies via final road test. •

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"/

FM TM TEC

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610-091-0013

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TRAINING MATERIALS FOR GTA TF MPS(O) TASKS - MOS 63N



C4 (Ot-OOt^OrHOOfHlA

•* 1 1 1 1 1 1 1 O O

CO 1 1 1 1 1 1 T 1 1

jüüüüüüüüü

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a. Lubricate the vehicle b. Check wheels, rollers, arms and

hubs, and sprockets •

c. Check shock absorber, bumper springs and torsion bars • *

d. Check tracks, track components, and tension adjuster

•

e. Check access covers, fenders, and fender storage boxes

f. Check air cleaner •

g. Check external telephone

h. Check tow pintle, hooks, and lifting eyes

i. Check lights j. Check top deck, grille doors, and

gun travel lock k. Check oil coders, shroud seal, and

air cleaner hoses 1. Check power plant

m. Check oil levels and service oil filter •

n. Check engine, transmission, U-joints, final drive, fuel system, and filters • • • • • •

48

TRAINING MATERIALS FOR MPS(O) TASKS - MOS 63N FM TM TEC



9-63

N 1

/2

9-63

N/C

M

38-7

50

9-23

50-2

15-2

0 Or-tcêsicooiocoînoJOtHWi-t oininco<oina>ooooiHrHfH<i<

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t i i i i i i i i i r i i i i rHr-tr-tiHt-tOJi-tiHtHt-lrHr-lf-trHi-l f*0>0>0>0>CM05050iO>0>0>0>0> t* v-tOOOOOOOOOOOOOrH

1 1 1 1 1 8 1 1 1 1 1 1 1 1 1 OOOOOOi-t.-l.-l.Hr1.-l.-liH.-t C4.H.H.H.H.H.H.H.H<HiHiHiH.HiH oocoocotoooocootoooô -2

E/0

20-1

71-0

245

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o. Check seats p. Check batteries and electrical

wirinjr and components • • • • • • • • • •

q. Check fire extinguisher system

r. Check gas particulate filter and assembly

s. Check drivers hatches & periscope

t. Check drain valves and hull-turret seal

u. Check hydraulic brake system • • • • • •

v. Check personnel heater and interior lights, rheostats and switches _J

49

r

TM TEC VTR COR.CRS.

o

i in in t- w

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-2E/020-171-1099

610-091-0110

611-171-0045

611-171-0153

611-171-0156

611-171-0165

611-171-1174

611-171-1175

611-171-9030

TUT 17-106

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TRAINING MATERIALS FOR UTA Tf MPS(0) TASKS - MOS 63N



■* 1 1 1 1 1 1 1 O O CoVVVVVVVlV

jüOÜUÜÜUOÜ

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o. Check seats

p. Check batteries and electrical wiring and components

q. Check fire extinguisher system

r. Check gas particulate filter and assembly

s. Check drivers hatches & periscope -1

t. Check drain valves and hull-turret seal -1

u. Check hydraulic brake system

v. Check personnel heater and interior lights, rheostats and switches

•Training materials apply to tasks a - n only.

50

—w

■ -y-s-^'fea


FOR MOS 63N/T


CARRIER 1. REPLACE POWER M113AI PLANT. FAMILY

a. b. c. d. e.

S- h. i. j. k.

1. m.

n. o. P.

Diagnose/verify fault. Turn master switch off. Disconnect battery ground lead. Remove bulkhead cables. Drain cooling system. Remove air cleaner assembly and hose. Disconnect exhaust system. Remove radiator hoses and tubes. Remove fan and drive belts. Disconnect fuel hose. Disconnect accelerator pedal linkage and fuel shutoff. Disconnect shifting linkages. Remove propeller shaft, oil temperature wire, and oil hoses from transmission differential. Disconnect starter ground wire. Remove mounting bolts. Attach power plant sling to power plant and remove Install in reverse order.

2. REPLACE FUEL TANK.

if,

h

I1

T

[ at, i

3. REPLACE FUEL SHUT- OFF CONTROL.

4. REPLACE HAND THROTTLE CONTROL.

a. b. c. d. e. f. g-

h.

i.

a. b. c. d. e. f.

a. b.

51

Diagnose/verify fault. Drain fuel tank. Lower ramp door. Disconnect batteries. Remove fuel filler neck. Remove wiring harness guard. Remove fuel line guard and ground strap. Remove inboard shield and top retaining plate. Remove fuel tank. Install in reverse order.

Diagnose/verify fault Remove all engine access panels. Remove fuel shutoff control. Install replacement fuel shutoff control. Check for proper adjustment. Replace panels.

Diagnose/verify fault. Remove panel in driver's compartment

"*-^3ifflSK8



REPLACE COOLING FAN TOWER.

REPLACE RADIATOR.

c. Remove hand throttle control. d. Install replacement throttle control. e. Check for proper adjustment. f. Replace panel.

a. Diagnose/verify fault. b. Turn master switch off. c. Raise engine deck assembly and secure. d. Drain cooling system. e. Disconnect rectifier cable, if installed. f. Disconnect exhaust pipe. g. Remove radiator hoses and fan belts, h. Remove fan assemblies. i. Replace washers, gaskets and bushings. j. Install in reverse order. k. Torque mounting bolts to specifications.

a. Diagnose/verify fault. b. Drain cooling system. c. Disconnect rectifier cables, if fitted. d. Disconnect exhaust pipe. e. Remove radiator vent hoses. f. Remove fan belts. g. Raise and secure engine deck assembly, h. Remove radiator. i. Install in reverse order, j. Fill cooling system, k. Check for leaks.

7. REPLACE COOLANT PUMP.

a. Diagnose/verify fault. b. Drain cooling system. c. Remove coolant pump drive belts. d. Remove coolant pump and gasket. e. Install in reverse order. f. Adjust pump drive belt. g. Fill cooling system, h. Ciieck for leaks.

8. REPLACE STARTER. a. Diagnose/verify fault. b. Disconnect battery cable. c. Drain cooling system. d. Disconnect radiator tubes. e. Remove exhaust pipes. f. Disconnect electrical leads. g. Remove starter. h. Install in reverse order.

I f

52

EL



9. REPLACE VOLTAGE REGULATOR.

10. ADJUST TRANS- MISSION LINKAGE.

11. REPLACE TRANS- MISSION CROSS SHAFT.

a. Diagnose/verify fault. b. Remove voltage regulator. c. Install replacement. d. Adjust voltage.

a. Diagnose/verify fault. b. Remove driver's compartment engine

access panel. c. Place transmission in neutral. d. Remove nuts/bolts on range selector

link. e. Adjust range selector link. f. Check selector position. g. Replace link bolt and nut. h. Replace panel.

a. Diagnose/verify fault. b. Remove engine compartment panel. c. Remove accelerator, pedal link, shift

link, and throttle valve link. d. Remove power plant wiring harness. e. Remove cross shaft to transmission, i". Remove cross shaft throttle arm. g. Remove transmission control outer

cross shaft, h. Install in reverse order.

12. REPLACE TRANS- MISSION OIL COOLER HOSE AND FITTINGS.

13. ADJUST DIFFERENTIAL CONTROL.

a. Diagnose/verify fault. b. Remove power plant. c. Remove transmission oil cooler hoses. d. Remove fittings from transmission. e. Replace faulty parts. f. Install in reverse order. g. Check for leaks.

a. Diagnose/verify fault. b. Lowek- trim vane. 3. Block tracks. d. Disconnect oil inlet Kne (M578

only). e. Remove differential access plugs. f. Turn brake band adjusting nut and

position steering lever. g. Measure steering lever release pressure

with a pull scale. h. Adjust brake band nut. i. Install access plugs, j. Connect oil inlet line, k. Check for leaks.

53



14. REPAIR POWER PLANT WIRING HARNESS.

15. ADJUST STEERING BRAKE BAND.

16. REPLACE IDLER WHEEL ARM AND SPINDLE.

I

17. ADJUST U-JOINT BOLTS.

18. REPLACE HOSES/FUEL LINES/DRAINCOCKS.

19, REPLACE EXHAUST SYSTEM COMPONENTS.

a. b. c. d. e.

Diagnose/verify fault. Disconnect engine wiring harness. Test wires for continuity. Isolate faulty wire. Install replacement wire and check for continuity,

f. Reconnect power plant wiring harness.

a. Diagnose/verify fault. b. Block tracks. c. Position steering levers. d. Measure pressure required to release

levers. e. Adjust differential brake. f. Road test.

a. Diagnose/verify fault. b. Remove track shroud. c. Break track. d. Remove idler wheel and spindle. e. Remove hub bearings and seal. f. Remove track adjuster. g. Tighten screws to specified torque, h. Remove idler wheel arm assembly. i. Install in reverse order. j. Adjust track tension.

a. Diagnose/verify fault. b. Remove left front access cover. c. Torque bolts to specifications. d. Replace cover.

a. Diagnose/verify fault. b. Check for leaks. c. Remove power plant if necessary. d. Remove defective hose/fuel line/

draincock. e. Install replacement hose/fuel line/

draincock in reverse order. f. Replace power plant (if removed).

a. Diagnose/verify fault. b. Disconnect exhaust pipe. c. Remove flange from muffler. d. Remove grille. e. Remove muffler. f. Install in reverse order.

54

TRAINING MATERIALS FOR FM TM

< < i i < r

T

C r

MPS(0) TASKS - MOS 63N/T


CORRECTIVE MAINTENANCE TASKS 9-63

N 1

/2

9-63

N/C

M

9-63

T 1

/2

9-63

T/C

M

38-7

50

9-23

00-2

24-2

0 9-

2300

-257

-20

11-6

625-

366-

10

101-

113-

4775

10

1-11

3-47

76

101-

113-

4777

1. Replace Power Plant • • 2. Replace Fuel Tank • • 3. Replace Fuel Shutoff Control 4. Replace Hand Throttle Control 5. Replace Cooling Fan Tower • • 6. Replace Radiator 7. Replace Coolant Pump 8. Replace Starter • • • • • • i

9. Replace Voltage Regulator • • • • • 10. Adjust Transmission Linkage • • 11. Replace Transmission Cross Shaft • • 12. Replace Transmission Oil Cooler Hose

and Fittings • •

13. Adjust Differential Control • • 14. Repair Power Plant Wiring Harness • • • • • • • 15. Adiust Steering Brake Band • • 16. Replace Idler Wheel Arm and Spindle • • • • 17. Adjust U-joint Bolts 18. Replace Hoses/Fuel Lines/Drain Cocks 19. Replace Exhaust System Components • • ^

55

>

■■

FM TM TEC VTR

9-63

N 1

/2

9-6

3 N/C

M

9-63

T 1

/2

9-63

T/C

M

38-7

50

9-23

00-2

24-2

0 9-

2300

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-20

11-6

625-

366-

10

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TRAINING MATERIALS FOR COR.CRS. MPS(0) TASKS - MOS 63N/T



c*t-e>»ioot-opo>,-itou>oa_«i ooooooo>(Ncawt-e-ooo>2o c«soooot~t-t-oooo2.« WOOOOOOOrHrHt-tt-l^jo

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1. Replace Power Plant • • • 2. Replace Fuel Tank .

3. Replace Fuel Shutoff Control 4. Replace Hand Throttle Control 5. Replace Cooling Fan Tower 1 • 6. Replace Radiator 7. Replace Coolant Pump • 8. Replace Starter • • • • • • • • • 9. Replace Voltage Regulator • • • • • • • 10. Adjust Transmission Linkage •

11. Replace Transmission Cross Shaft 12. Replace Transmission Oil Cooler Hose

and Fittings 13. Adjust Differential Control 14. Repair Power Plant Wiring Harness • • • • <

IS. Adjust Steering Brake Band • 16. Replace Idler Wheel Arm and Spindle • • 17. Adjust U-joint Bolts 18. Replace Hoses/Fuel Lines/Drain Cocks 19. Replace Exhaust System Components • '~ -J

—i

56

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— — — — — — - —t— i ■

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FOR

MOS 63N/T


CARRIER 1. BEFORE ROAD TEST a. Lubricate the vehicle. M113A1 INSPECTION. b. Check wheels, rollers, arms and FAMILY hubs, and sprockets.

c. Check shock absorber, bumper springs, and torsion bars.

d. Check tracks, track components, I and tension adjuster. I e. Check access covers.

f. Check tow pintle, hooks, and lifting eyes.

g. Check lights, h. Check trim vane.

| i. Check power plant door, grille, | cargo hatch cover, and ramp I door. I j. Check cooling system radiator I cap, hoses, and drive belts.

k. Check air cleaner and hoses. 1. Check final drives and universal

joints, m. Chcik oil levels, n. Check oil and fuel filters. o. Check engine, p. Check air box heater, q. Check exhaust system, transmission,

differential, and transfer gearcase,

r. Check ramp and hydraulic system, s. Check bilge pump and torsion bar

anchors, t. Check fuel system, u. Check batteries and electrical

wiring, interior light and switches.

v. Check fire extinguisher. If. w. Check commander's cupola, hatch

cover, and platform. x. Check seats, stowage boxes, clamps,

straps, tables, racks, and map board,

y. Check driver's hatch and periscopes. z. Check throttle and accelerator

controls and linkage, and neutral start switch.

L

I I

I I I

57

VEHICLE TYPE JOB TASK

CARRIER 2. DURING ROAD TEST a. M113A1 INSPECTION. FAMILY b.

c. d. e.

3. AFTER ROAD TEST INSPECTION.

a.

b. c.

PERFORMANCE STEPS

Check instruments, gages, and warning lights. Check differential steering and brakes. Check pivot steer and reservoirs. Check transmission. Check RPM of governed engine and performance.

Check temperature of wheel hubs and shock absorbers. Check for leaks. Insure correction of operational deficiencies with a short final road test.

i i

58

TRAINING MATERIALS FOR _ FM I TM 1 TEC 1 MPS(O) TASKS - MOS 63N/T



9-63

N 1

/2

9-63

N/C

M

9-63

T 1

/2

9-63

T/C

M

o c es e^

i i ■»* t- e«) ir es ev

i i o o c in o c l> cs c 00 1 I PS o» o 61

0-09

1-60

51

610-

091-

6052

61

0-09

1-62

59

610-

091-

6262

61

0-09

1-62

63

611-

171-

0141

-2

E/0

20-1

71-0

245

-2E

/020

-171

-024

6 -2

E/0

20-1

71-0

247

-2E

/020

-171

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8

Before Road Test Inspection a. Lubricate the vehicle b. Check wheels, rollers, arms, hubs and sprockets • • • • • c. Check shock absorber, bumper springs ic torsion bars • • • • • d. Check tracks, track components <5c tension adjuster • • • • • e. Check access covers f. Check tow pintle, hooks, & lifting eyes K. Check lights h. Check trim vane i. Check power plant door, grille, cargo hatch

cover &. ramp door j. Check cooling system radiator cap. hoses. &

drive belts • • • • •

k. Check air cleaner & hoses • • • 1. Check final drives and universal joints • • • • m. Check oil levels n. Check oil and fuel filters » • • • • o. Check engine p. Check air box heater q. Check exhaust system, transmission, differential &

gearcase • • • •

r. Check ramp & hydraulic system 1 s. Check bilge pump & torsion bar anchors t. Check fuel system • • • • • • u. Check batteries, elec. wiring, lights & switches • » • • • v. Check fire extinguisher w. Check Cmdr. cupola, hatch cover and platform x. Check seats, stowage boxes, etc. y. Check driver's hatch and periscopes " z. Check throttle/accelerator controls & linkage, etc.

59

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TRAINING MATERIAL FOR M60A1/M113A1 MAINTENANCE TASKS LISTED BY CATEGORY, NUMBER, TTTLE

6i

NUMBER TTTLE

CORRESPONDENCE COURSES (COR CRS)

ARO 100 Operator/Crew Maintenance Fundamentals ARO 101 Scout Vehicle Maintenance ARO 102 Tank Crew Maintenance ARO 451 Tank Gunnery-Materiel ARO 452 Tank Gunnery-Conduct of Fire HC 6302 Organizational Maintenance of the M113 Carrier Family HC 6306 Organizational Maintenance of the M60-Series Tanks and

the M728 Combat Engineer Vehicle HK 4501 Introduction to Tank Turret Maintenance HK 4502 Fundamentals of Tank Turret Components and System HK 4503 Introduction to 105MM Gun Tank M60A1 Turret INO 316 Tracked Vehicles OD 0004 Tank Turret Materiel OD 0007 Tracked Vehicle Organizational Maintenance OD 00C8 Organizational Maintenance of Tracked Vehicle Armament OD 0082 Tracked Vehicle Electrical System OD 0085 Tracked Vehicle Suspension System OD 0090 Light Tracked Vehicle Transmissions OD 0102 Turret Artillery Tanks M60 and M60A1 OD 0403 Principles of Fuels and Fuel Systems OD 0411 Machine Guns OD 0412 Tracked Vehicle Engines (Compression Ignition) OD 0420 Medium Tracked Vehicle Transmission OD 0531 Mechanical Maintenance of Tactical Wheeled and Tracked

Vehicles OD 0727 Electrical Systems and Components OD 0728 Mechanic Devices and Components OD 0729 Tracked Vehicle Maintenance RC 1010 Lead Acid Battery Maintenance SM 1071 Use and Care of the Optical Antifreeze and Battery Tester SM 1076 Use and Care of the Battery Hydrometer SM 1085 Troubleshooting the Ignition System of Tactical Vehicles SM 1092 Using the LVCT to Test Batteries Under Load SS 9448 Multimeter TS-352/U SY 6301 Organizational Maintenance for the Systems Mechanic

of the M60A1 and M60A3 Tank and M728 CEV SY 6304 Test, Iv. .asurement, and Diagnostic Equipment (TMDE)

(STE/ICE) for the Systems Mechanic SY 6307 Organizational Maintenance for the Systems Mechanic

of the M113A1 Series Vehicle and the M548 Cargo Carrier

FIELD MANUALS (FM)

7-11C 1/2 Indirect Fire Infantryman 7-11C/CM Infantryman

62

NUMBER TITLE

9-45N 1/2 9-45N/CM 9-63N 1/2 9-63N/CM 9-63T 1/2 9-63T/CM 17-19D 1/2 17-19D/CM 17-19E 1/2

17-19E/CM 23-65 31-70

C 9-1-183 C 17-2-3 SLC 3-4-9 SLC 9-9-4 TC 9-1-146 TC 9-1-147 TC 9-1-158 TC 9-1.-167 TC 9-1-168

TC9- TC9- TC9- TC9- TC9- TC9- TC9- TC9- TC9- TC9- TC9- TC9- TC9- TC9- TC9-

1-169 1-170 1-171 1-178 1-184 3-76 3-80 3-83 3-86 9-3 100-31 104-39 105-12 109-5 665

TC 17-2-7

FIELD MANUALS (FM) (Continued)

Tank Turret Mechanic Tank Turret Mechanic M60A1/A3 Tank System Mechanic M60Ä1/A3 Tank System Mechanic ITV/M113/IFV/CFV Systems Mechanic ITV/M113/IFV/CFV Systems Mechanic Cavalry Scout Armor Crewman Armor Crewman (Gunner Loader) M48A5, M60A1, M60A3

Tanks Armor Crewman Browning Machinegun, Caliber .50 HE, M2 Basic Cold Weather Manual

GRAPHIC TRAINING AIDS (GTA)

Starting System - TrouDleshooting Troubleshooting Guide M60/M60A1 Tank Crew (Turret) Gas Particular Filter Unit, Preventive Maintenance Machine Gun 7.62mm M219 CD-850-5, 6, 6A Transmissions - Power Flow CD-850-5, 6, 6A Transmissions - Oil Flow AVDS, 1790 Engine (MS0 Tank) Tank, M60A1, Organizational Maintenance - Hull Tank Combat Full Tracked 105MM Gun M69A1 - Organiza-

tional Maintenance - Turret Tank M60A1, Organizational Maintenance - Fire Control Engine, AVDS 1790-2A (M60A1 Tank) Transmission, Organizational Maintenance, M60 Tank Air Cleaners Troubleshoot Air Cleaner Blower on M60 Series Tank Rangefinder M17C (M60 Tank) Telescope, Mount, M21A1 Computer Ballistic M3 M36 Periscope (M60 Tank) Machine Gun, Caliber .50, M85 Differential, Controlled-Tracked Vehicle Generating System, 24 Volt Torsion Bar Suspension Filter, Oil, Automobile Engine Turret Traversing and Gun Evaluating System M48 and

M60 Tanks M60/M60A1 Walk Around Inspection Card

63

NUMBER TITLE

GRAPHIC TRADFÜJG AIÖS (GTA) (Continued)

TC 17-6-5 Tank Gunnery: Dfttection and Correction of Tank Gun Malfunction

TC 17-6-8 Tank Gunnery: Turret Inspection and Preventive Mainte- nance Services

SKILL PERFORMANCE AID/EXTENSION TRAINING MATERIALS (SPA)

643-019-9401 Replace Turret Electrical Slipring 643-091-9402 Service 105MM Gun Breech Assembly 643-091-9403 Service 105MM Gun Replenisher 643-091-9404 Troubleshoot Main Gun Firing Circuit 643-091-9405 Replace Elevation Shut-Off Valve Solenoid 643-091-9406 Replace Superelevation Actuator 643-091-9408 Replace M13 Ballistic Computer 643-091-9409 Replace M17 Rangefinder 643-091-9410 Synchronization and Backlash Check 6^3-091-9411 Replace Gunner M32 Periscope Infinity Sight and Perform

Parallel Check 643-091-9412 Replace Gunner's Control Handle Magnetic Brake Switch 643-091-9413 Replace No-back Assembly 643-091-9414 Replace Anti-backlash Cylinder 643-091-9415 Perform Pinlock Test 643-091-9417 Replace Resistor Assembly (Hurdle Shaping) 643-091-9418 Troubleshoot Stabilization System

TRAINING EXTENSION COURSES fTEC)

020-171-1131 Clearing, Disassembly, and Assembly of the Coax Machinegun 020-171-1132 Clean, Inspect, ani Lubricate M73/M219 Coaxial Machine

Gun 020-171-1133 Troubleshooting the Coax Machinegun 020-171-1656 Remove Track on M60 Series Tank 020-171-1657 Install Track on M60 Series Tank 020-171-1684 Assembly/Disassembly Breechblock of 105MM Gun 020-171-1686 Maintenance of Breechblock and Bore Evacuator 020-171-2000 Use the -10 Tech Manual and -12 Lube Order, M60 Tank 020-171-2101 Boresight Main Gun, Rangefinder, General Telescope,

and Periscope 020-171-5305 Air Cleaner Maintenance M60A1/A2, Pt. 1 020-171-5306 Air Cleaner Maintenance M60A1/A2, Pt. 2 020-171-5333 Place Turret in Power Operation M60/M60A1 020-171-5334 Prep Ballistic Computer for Operation; M60A1 Tank 020-171-5335 Operation of the Rangefinder 020-171-5339 Place Turret in Power Operation

64

NUMBER TITLE

TRAINING EXTENSION COURSES (TEC) (Continued)

020-171-5340 Rangefinder, Pt. 1 - Familiarization 020-171-5341 Preparing the Ballistic Computer for Operation 020-171-5342 Preparing the Ballistic Computer for Operation 020-171-5344 Rangefinder, Pt. 2 020-171-5349 Boresighting the Main Gun, M60/M60A1 Tank, Pt. 1 020-171-5350 Boresighting the Main Gun, M60/M60A1 Tank, Pt. 2 020-171-5351 Boresight Main Gun, Rangefinder, Telescope & Periscope 020-171-5352 Boresighting the Machine Guns M60/M60A1 Tank 020-171-5354 Boresighting the Xenon Searchlight, M60/M60Ai Tank 020-171-5355 Boresighting the Main Gun, Rangefinder, Telescope/

Periscope, Pt. n 020-171-5366 Before Operations Maintenance, Pt. 1 (M60A1/A2) 020-171-5367 Before Operations Maintenance, Pt. 2 (M60A1/A2) 020-171-5368 During Operations and at Halt Maintenance Checks

and Services (M60A1/A2) 020-171-5369 After Operations Maintenance Checks and Services

Pt. 1 (M60A1/A2) 020-171-5370 After Operations Maintenance Checks and Services

Pt. 2 (M60A1/A2) 101-113-4775 Multimeter, TS-352, Pt. 1 - Resistance 101-113-4776 Multimeter, TS-352, Pt. 2 - Voltage 101-113-4777 Multimeter, TS-352, Pt. 3 - Current 101-113-7160 Measure Resistance and Voltage Using AN/URM 105 610-091-0085 Tracked Vehicle Charging System Testing 610-091-6051 Use and Care of Optical Antifreeze/Battery Tester 610-091-6052 Use and Care of the Battery Hydrometer 610-091-6053 Using the LVCT to Test Batteries Under Load, Pt. 1 610-091-6054 Using the LVCT to Test Batteries Under Load, Pt. 2 610-091-6259 Use Flow Chart to Troubleshoot and Maintain Fuel,

Air and Exhaust System 610-091-6068 Troubleshoot Ignition System - Tactical Vehicle, Pt. 1 610-091-6069 Troubleshoot Ignition System - Tactical Vehicle, Pt. 2 610-091-6262 Inspect, Repair Air Intake, Exhaust Systems 610-091-6263 Inspect Fuel System of Detroit Diesel Engine 611-091-0090 Stall Test M60 Series Tank 611-091-6056 Troubleshooting the Starting System, Pt. 1 611-091-6057 Troubleshooting the Starting System, Pt. 2 611-091-6101 Test/Adjust Generator Output, M60 Series Tank 611 -091-610 2 Troubleshoot A ir Cleaner Blower 611-091-6103 Stall Test M60 Series Tank CD850 Transmission 6U-091-6104 CD850 Transmission (M60), Oil Pressure C.^cks 611-091-6105 CD850 Transmission (M60), Check, Adjust, Shift

Linkage 611-091-6106 GD850 Transmission (M60), Adjust Low and Reverse

Range Bands

65

I

NUMBER TITLE

TRAINING EXTENSION COURSES (TEC) (Continued)

611-091-6109 M60A1 Tank Brakes 611-091-6110 M60A1 Tank Brakes 611-091-6111 Aline Service Brake Linkage 611-091-6112 Adjust Service Brakes and Brake Air Valve, Pt. 2 611-171-0141 M60A1, Changing the Main Oil Filter 611-171-0144 Test/Adjust Charging Circuit Voltage, M60A1 Tank 611-171-1600 Remove/Install Suspension System, M60, Pt. 1 611-171-1601 Remove/Install Suspension System, M60, Pt. 2 941-171-0116 Caliber .50 Machinegun, Mechanical Training 941-171-0117 Caliber .50 Machinegun, Head Space and Timing 945-171-0051 Before Operations Maintenance M113A1/M577A1, Pt. 1 945-171-0052 Before Operations Maintenance M113A1/M577A1, Pt. 2 945-171-0053 During Operations Maintenance M113A1, M577A1 945-171-0054 During, After Operation Maintenance M113A1, M577A1 945-171-0055 After Operation Maintenance M113A1, M577A1 945-171-0400 Remove Power Plant M60A1 AVDS 1790 2A 945-171-0401 Install Power Plant M60A1 AVDS 1790 2A 945-171-0402 Remove Power Plant M60A1 RISE 945-171-0403 Install Power Plant M6CA1 RISE

TRAINING FILMS (TF)

9-3129 Organizational Maintenance of the A710B Engine (M113 APC)

9-3146 Armored Personnel Carrier M113, Pt. I, Steering Brake Band Adjustments

9-3147 Armored Personnel Carrier M113, Pt. n, Shift, Steering and Throttle Control Linkage Adjustments

9-3216 Machinegun, 7.62mm 9-3334 Machinegun, Cal. 50, M85, Pt. I 9-3335 Machinegun, Cal. 50, M85, Pt. il 9-3536 Low Voltage Circuit Tester 9-3650 Tank, M60 and M60A1 - Adjustment of Steering, Shift-

ing and Accelerator Linkages 9-3691 Front End Alignment 9-3794 Lubrication of Military Vehicles - Principles of Engine

Lubrication 9-4321 M60/M60A1 and M48A3 Tank Fire Control with Infrared

Part II - Power Supplies and Periscopes 9-4322 M60/M60A1 and M48A3 Tank Fire Control with Infrared

Part in - Care and Handling of Periscopes 9-4355 Mg0/M60A1 and M48A3 Tank Fire Control with Infrared

Part i - Introduction to Infrared (and Visible) Fire Control System

9-4434 Training Film on Daily Crew Maintenance, M113A1

66

JSM

NUMBER TITLE

9-4926 9-4934 9-5818 9-5840 17-2726 17-2727 17-3429 17-4651

17-4667

17-4668

17-6097

9-1005-213-10 9-2300-224-10 9-2300-224-20 9-2300-257-10 9-2300-257-20 9-2350-215-10 9-2350-215-20 9-2350-257-10 9-2350-257-20 11-6625-366-10 11-6625-365-35 38-750 750-116

TVT 17-106

T 17-107

-2E/020-171-0009 -2E/02Ö-171-0026

-2E/020-171-0245 -2E/020-171-0246 -2E/020-171-0247

TRAINING FILMS (TF) (Continued)

Low Voltage Circuit Tester - Starting System Testing Low Voltage Circuit Tester - Charging System Testing Gun Stabilization System, M60A1 Tank, Pt. 1 The M80A1 Tank Gun Stabilization System - Pt. 2 Commander's Cupola, Ml, Machinegur« Commander's Cupola, Ml, Machinegun Crew Maintenance Services, MBT MS9 and M60A1 Disassembly and Assembly of M68 Tank Gun Breech

Mechanism Mechanical Training Cal 50, HB, M2 Machinegun -

Part I - Disassembly and Assembly Mechanical Training Cal 50, HB, M2 Machinegun -

Part H - Headspace, Timing Operation and Immediate Action

Operator Maintenance of Gas~Particulate Filter

TECHNICAL MANUALS

Operator's Manual, Machinegun, Cal .50, Browning, M2 Operator's Manual, M113 Family Organizational Maintenance Manual, M113 Family Operator's Manual, M113 Family Organizational Maintenance Manual, M113 Family Operator's Manual, M60A1 Tank Organizational Maintenance Manual, M60A1 Tank Operator's Manual, MoOAl (RISE) Tank Organizational Maintenance Manual, M60A1 (RISE) Tank Multimeter TS-352/U Multimeter, TS-352/U (Calibration) The Army Maintenance Management System (TAMMS) Purging and Charging of Fire Control Instruments

VIDEO TAPE RECORDINGS (VTR)

M60A1 Quarterly Service, Part 1, Before Road Test Inspec- tion

M60A1 Quarterly Service, Part 2, During and After Road Inspection

Boresighting and Zoroing the M60Ä1 Searchlight Set and Infrared Sight and Fire Control

Equipment M60A1 Battery Electrical (PM; Air Induction PM Track Susoension

67

i I 1

NUMBER

-2E/020- -2E/C20- -2E/020- "2E/02fl- -2E/020- -23/020- -2E/02Ö- -2E/C2D- -2E/020 -2E/020 -23/020- -2E/020 -2E/020 -2E-171 -2E-171 -2E-171 020-171 020-171 020-171 020-171 020-171 020-171 020-171 020-171

171-0248 171-0249 171-1099 171-1100 171-1101 171-1103 171-1108 171-1109 171-1112

■171-1113 171-5013 171-5014 171-5023 •0010 •0182 ■7047 -0017 0054 0055 0172 1075 8028 9022 9043

020-171-9044

113-091- 310-091- 610-091- 610-091- 610-091 610-091- 610-091- 610-091- 610-091- 610-091- 610-091- 610-091- 611-171-

0027 0013 0066 0093 0110 0117 0118 0239 0546 0649 0771 0795

■004o

611-171-0142 611-171-0152 611-171-0153

TITLE

VIDEO TAPE RECORDINGS (VTR) (Continued)

PM Cooling Systems PM Fuel and Oil Filters Suspension and Track Coincidence Rangefinder Concidence Rangefinder M85 Machinegun Recoil System and Computer Placing Turret Into Power Operation Eoresighting M68 Loading and Cleaning M85 Machinegun Familiarization with the Turret Fire Control Turret Power Operation Eoresighting the Main Gun Introduction to Eoresighting and Zeroing the M60A1 Primary Direct Fire Control Syctem Detection and Correction of Tank Gun Malfunction M60A1 Operator/Crew Maintenance M85 Machinegun PL El M8o Machinegun Pt. I M113A1, Before Operation Check Eoresighting the M60A1 Tank M240 Machinegun, Cleaning, Disassembly and Assembly M68 Gun, 105MM, Description and Functioning M68, 105MM Gun. Removal and Installation of Breech-

block Group M68, 105MM Gun, Removal and Installation of Breech

Operating Mechanism TS 352 Multimeter, Review of Test Equipment Operation CD850 Band and Brake Adjustment STE/ICE - Preventive Maintenance Checks and Services CD850 Transmission, End Cover, Brake Operation Introduction to CD850 Transmission TX-100-1 Transmission Linkage and Adjustment TX-100 Transmission Linkage and APC's STE/ICE Basic Connections and Tests TS-352 Multimeter, Construction, Function and Use TS-352 Multimeter, Demonstration Introduction to STE/ICE TS~352 Multimeter, Interpretation of Meter Readings Preventive Maintenance: Fixed Fire Extinguisher System,

M60 Changing the Vertict! Shaft Oil Seal, M60A1 Polarizing a DC Generator Battery Voltage Check

68

[

I I I I'

NUMBER TITLE

VIDEO TAPE RECORDINGS (VTR) (Continued)

611-171-0154 Voltage Line Loss Check 611-171-0155 UncontroUed Voltage Cheek 611-171-0156 Battery Specific Gravity Test 611-171-0157 Continuity Test 611-171-0165 Battery Specific Gravity Test, DUO Check 611-171-0166 Starter Relay Resistance Test 611-171-1092 Troubleshooting TM Procedures M60 611-171-1174 Combat Vehicle Power Plant M60A1 Series, Pt. 1 611-171-1175 Combat Vehicle Power Plant M60A1 Series, Pt. 2 611-171-6012 M113A1 APC Power Plant Removal 611-171-8022 Troubleshooting the M60A1 (RISE) 650 Amp Charging

System 611-171-8024 Low Voltage Circuit Tester 611-171-9030 Power Plant Removal and Tests, Part I and U, M60A1 641-091-0065 M73 Machingun, Disassembly and Assembly 641-091-0382 M85 Machinegun, Operation 641-091-0387 M73 Machinegun, Functioning 643-171-0048 M85 Machinegun Pt. II 643-171-0049 M85 Machinegun Pt. IV 643-171-0050 M85 Machinegun P. V 643-091-0148 M60 Tank, Charging the Manual Accumulator 643-091-0168 Synchronization and Alinement of M60 Tank 643-091-0180 M60A1 Tank, 105MM, Replenisher-Disassembly and As-

sembly 643-091-0451 M60A1 Tank Turret Inspection 643-091-1004 M60 Tank Turret Traversing Mechanism, Installation 646-081-0546 TS-352 Multimeter, Construction, Function, and Use 670-091-0042 Introduction to M13 Series Ballistic Computers 920-091-0565 M60A1, Powerpack Removal, Role of Enlisted Women

in Maiiuenance 921-091-0012 M60AL Powerpack Removal by All Woman Team 941-171-8071 M2, Cal .5 MB, RB, TT, Clearing, Assembly, Headspace

and Timing Adj.

69

(dd research note 84-14 maintenance performance system (organizational) training materials for...

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