s-250 shelter manual

8/3/2019 S-250 Shelter Manual

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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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TM 10-5411-205-13

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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TM 10-5411-205-1

WARNING

Drilling creat es meta l chips which may ent er eyes and cau se seri-ous injury. Eye protection is required.

WARNING

Adhesives and solvents are flammable and toxic. Keep away fromheat and open flames. Use in a well-ventilated area. Avoid skinand eye contact and breathing of vapors. Use protective gogglesand gloves. Use in accordan ce with ma nu factu rer s instr uctions.For Art ificial Respira tion, refer to FM21-11.

WARNING

Gloves are t o be worn when mixing an d a pplying adhesive mat erialdue to possible skin irritation caused by adhesive coming into con-ta ct with th e body skin sur face. The Versam id mater ial is extr eme-ly sensitive to moisture absorption. Ther efore, ma ke su re Versam id140 cont ainer ha s lid firmly replaced after m at erial ha s been re-moved from shipping or storage container.

WARNING

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

a / (b b lank


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TECHNICAL MANUAL

No. 10-5411-205-13

* TM 10-5411-205

HEADQUARTEDEPARTMENT OF THE ARM

Washington, DC 5 May 1990

O p e r a t o r s , U n i t , a n d D i r 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 lfo r

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

AP P ROVED FOR PUBLIC RE LEASE DISTRIBUTION IS UNLIMITED.

REP ORTING ERROR S AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if 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 an d, ATTN: AMSTR-MCTS, 4300 Goodfellow Blvd., St . Louis , MO, 63120-1798. A reply will be furnished to you.

CHAPTER 1

Section ISection II

CHAPTER 2

Section ISection IISection III

CHAPTER 3

Section ISection IISection IIISection IVSection VSection VI

CHAPTER 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 . . . . . . . . . . . . . . . . . . . . . 2-4Opera tion Un der U nu sua l Condit ions . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . 3-11Preparation for Shipment and Storage . . . . 3-70

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

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

*This manual supersedes TM 10-5411-205-14 dated 9 January 1989.


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TM 10-5411-205-13

APPENDIX A

APP ENDIX B

APP ENDIX C

APPENDIX D

I N D E X

TABLE OF

REFERENCES . . . . . . .

CONTENTS (cont )

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

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

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

EXPENDABLE/DURABLE SUPPLIES AND MATERIALSLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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 Page

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

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

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

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

Shelter-

Tiedown 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, Holder Assembly, and RFI/EMI Replacement , . . . . . 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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TM 10-5411-205-13

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 manual was prepared to help keep your S-250/G Unshielded and S-250/G Shieldedshelters in good operating condition. The front cover ind ex is provided for quick reference toimportant information. There is also an alphabetical index at th e back of th e ma nua l to locat e

specific items of information.

Warning pa ges ar e locat ed at th e front of th is man ua l. You sh ould read and completely under-sta nd a ll of the warn ings before perform ing any ma intena nce on t he equipment.

Par agraphs in t his manu al are n umbered by chapter and order of appeara nce within a chapter.A subject index appears at the beginning of each chapter listing sections that are included inthat chapter. A more specific subject index is locat ed a t th e beginnin g of each section t o helpyou find the exact paragraph you are looking for.

iv


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TM 10-5411-205-13

C H A P T E R 1

I N T R O D U C T I O N

Subject

S e c t i o n I . G E N E R A L

Subject

I N F O R M A T I O N

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

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

1-1. Sco p e .

Section

I

II

Para

1-11-21-31-41-51-61-7

Page

1-11-2

Page

1-11-1

1-11-11-11-21-2

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

maintenance procedures for the S-250/G Unshielded and S-250/G Shielded shelters.

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

b. Equipment Name and Model Number. This technical manual covers Electrical

Equipment Shelter S-250/G Unshielded and S-250/G Shielded. The S-250/G Shielded shelter

is equipped with radio frequency/electromagnetic interference shielding.

c. Purpose of Equipment. The S-250/G Unshielded and S-250/G Shielded are light-weight transportable shelters designed to house a wide variety of military systems and com-

ponents.

1-2. M a i n t e n a n c e F o r m s a n d R e c o r d s . 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. R e p o r t i n g E q u i p m e n t I m p r o v e m e n t R e c o m m e n d a t i o n s ( E I R ) . If your shelter

needs improvement, let us know. Send us an EIR. You, the user, are the only one who can

tell us wh at you dont like a bout your equipmen t. Let u s kn ow why you dont like th e design

or performance. Put it on an SF 368 (Quality Deficiency Report). Mail it to: Commander, US

Army Aviation and Troop Command, ATTN: AMSAT-I-MDO, 4300 Goodfellow Blvd., St.

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

1-4. D e s t r u c t i o n o f A r m y M a t e r i e l t o P r e v e n t E n e m y U s e . Destruction of Army

equipment to prevent enemy use shall be in accordance with TM 750-244-3.

1-5. P r e p a r a t i o n f o r S h i p m e n t a n d S t o r a g e . Refer to paragraph 3-37 for shipment

and storage preparation data. Administrative storage requirements will be in accordance

with the following:

1-1


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TM 10-5411-205-13

a. Placement of equipment in administrative storage should be for short periods of time when a shortageof main ten an ce effort exists. Items sh ould be in m ission r eadiness with in 24 hours or with in th e time factors

as determined by the directing authority. During the storage period appropriate maintenance records will bekept.

b. Before placing equipment in administrat ive storage, current maintenance services and equipmentserviceable criteria (ESC) evaluations should be completed, shortcomings and deficiencies should be corrected,

an d all modificat ion work order s (MWOs) should be a pplied.

c . S torage S ite Selection. Inside st orage is preferred for items selected for a dminist ra tive storage. If insidestorage is not available, trucks, vans, conex containers and other containers may be used .

1-6. Wa r r a n t y I n fo r m a t i o n . The S-250/G Unshielded and S-250/G Shielded shelters are warranted 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 workmanshipto your super visor who will tak e app ropriat e action. Refer t o War ra nt y Techn ical Bulletin TB 10-5411-205-23

(Gichner ) or TB 1 0-5411-205-23-1 (Ram im).

1-7. L i s t o f A bbrev ia t ions .

E MI Electromagnetic InterferenceR F I Radio Frequency InterferenceRT V Room Tempera tu re Vulcan izing

TMDE Test, Measurement, and Diagnostic Equipment

Sect ion I I . EQUIPMENT DESCRIPTION AND DATA

Subject 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. E q u i p m e n t C h a r a c t e r i s t i c s , Capabil i t ies, and Features. The S-250/G Unshielded and 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 sheltersar e equipped with ra dio frequen cy/electr omagnetic inter feren ce (RFI/EMI) shielding t o protect th e electr onicequipment contained inside. The shield is a continuous metallic surface which includes the shelter panel outerface sheets and conductive materials which maintain continuity around joints, door openings, and otherpossible sour ces of radiat ion leak . Shielded shelters a lso ha ve a RFI/EMI filter inside t he inn er (emergency)door. Shielded shelters can be identified by the metallic door gasket which mates with another conductivesur face on the door jam b.

1 -2 C h a n g e 2


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TM 10-5411-205-13

1-9. L o c a t i on a n d D e s cr i p t i o n o f Ma j o r C o m p o n e n t s . ( F ig u r e 1 -1)

1 .

2.

3 .

4 .

I T E M D E S C R I P T I 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 are provided with an RFI/EMI filter.

Lifting 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 pa n a ssembly

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.

Figu re 1-1. M aj or S he l t er C omp one n t s .

1-10. E q u i p m e n t D a t a .

H e i g h t

W i d t hL e n g t hGross weight

C u b a g eLoad 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

C h a n g e 1 1 - 3


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TM 10-5411-205-13

1 - 1 1 . Sh e l t e r Mar k in g . Shelter markings are shown in Figure 1-2. Lettering is stenciled or silkscreenedin accordance with MIL-M-13231 GR II. The color used is black, MIL-C-46168; for camouflage paintedshelter s, ma rkin gs sha ll be Green 383, MIL-C-46168; for black background, an d black, MIL-

-C-46168; for

green or brown backgrounds.

Figure 1-2. Shelter Marking.

1 - 1 2 . I n s t r u c t i o n a n d W a r n i n g P l a t e s . (Figure 1-3)

1.

2 .

ITEM CONTENT

Warning Plate WARNING Keep drain plug loose during air and railtransport

Instruction Plate 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 airliftKeep vent cover open when shelter is occupiedRemove drain plug during air an d ra il transport

3. Instruction Plate

4. Instruction Plate

5. Instruction Plate Insert pin in holes to hold door open.

1-4 C h a n g e 1


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TM 10-5411-205-

C H A P T E R 2

O P E R A T I N G I N S T R U C T I O N S

Subject Section

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

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

Sect ion I . OP ER ATOR P RE VENTIVE MAINTENANCECHECKS AND SERVICES (PMCS)

Subject Para

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Purpose of PMCS Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Explanation of Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Pag

2-1

2-42-4

Pag

2-12-12-1

2-1. G e n e r a l . To be sure the shelter is always ready for use, it must be inspected atspecific intervals so defects can be located and corrected before they result in serious damagor failur e.

Before You Operate. AIways keep in mind the CAUTIONS and WARNINGS. Perfoyour before (B) PMCS.

While You Operate. Always keep in mind the CAUTIONS and WARNINGS. Perfory o u r dur ing (D) PMCS.

c . Afler Y ou Operate. Be sure to perform your after (A) PMCS.

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

e. Once Ea ch Month . Perform your monthly (M) PMCS.

f . If Your Equipment Fails to Operate. If your equipment does not perform as requirnotify higher level of main ten an ce. Report an y ma lfun ctions or failures on t he pr oper DAForm 2404 or refer to DA Pam 738-750.

2-2. P u r p o s e o f P MC S Ta b le . Th e Preventive Maintenance Checks and Services tabllists the inspections required to keep the equipment in good operating condition.

2-3. Ex p la n a t i o n o f C o lu m n s .

Item Number. The item number is to be used as a source number for the TM number colum n on DA Form 2404, Equipmen t Inspection an d Maintena nce Worksh eet, whenrecording PMCS results.

b. Item to Be In spected. 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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TM 10-5411-205-13

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.

2-2


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Item

4

5

6

10

11

TM 10-5411-205

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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2-7

TM 10-5411-205-13

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.

2-4


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TM 10-5411-205

CH A P T E R 3

UNIT MAINTENANCE INSTRUCTIONS

Subject Section Pag.

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

Sect ion I . LUBRICATION

3-1. L u b r i c a t i o n I n d u c t i on s . Lubricate door hinges, latches an d locking m echa nismdoor brace assemblies, roof access steps, and lifting and towing bracket assemblies to preventrust and corrosion. Check these part s frequen tly to be sure th ey ar e adequat ely lubricat ed.

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

Sec t ion I I . REP AIR P ARTS. SPECIAL TOOLS, TMDE,AND SUPP ORT EQUIPMENT

Subject

Common Tools . . . . . . . . . . . . . . . . . . . . . .Special Tools, TMDE, an d Su pport Equipmen t .Repair Parts . . . . . . . . . . . . . . . . . . . . . . . .

Pa r a P a g

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

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

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

3-2. Co m m o n T o o ls . A complete list of common t ools a nd tool kits is given in S ection

III ofAppendix B, Mainten an ce Allocation Ch ar t.

3-3. Spec ia l Too l s , TMDE, and Support Equipment. All special tools, TMDE, andsupport equipmen t a re listed in Section III of Append ix B, Maintena nce Allocat ion Ch ar t, anin t he Repa ir P ar ts an d Special Tools List m an ua l, TM 10-5411-205-23P, S-250/G Shielded aS-250/G Unsh ielded Electrical E quipment Shelters.

3-4. R e p a i r P a r t s . Repair pa rts for u nit m aintena nce of the shelter ar e listed an dillustrated in TM 10-5411-205-23P.

S e c t i on I I I. SE RV ICE U P O N RE CE I P T

S u b j e c t Para Pag

Service Upon Receipt of Mat eriel . .. . . . . . . . . . . . . . . . . 3 -5 3-1Site Requ irem ent s . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3-7

3-5. S e r v i c e U p o n R e c e i p t o f Ma t e r i e l . Inspect the shelter for dam age incur red duing shipment. If the shelter ha s been dama ged, report the dama ge on SF 361 Tran sporta tioDiscrepa ncy Report (TDR). If the dr ain plug ha s been loosened for s hipmen t, t ighten it. Ifth e shelter is cra ted or pallet-mount ed, refer to th e end item technical man ua l for u npa ckin


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TM 10-5411-205-13

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 toanother, 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 t o restore RFI\ EMI shielding in shelters having this require-

ment .

a. Lifting S kelter. (Figur e 3-1)

(1)

(2)

(3)

(4)

(5)

Att ach sling assembly to all four lifting rings on sh elter so tha t t ur nbuckle ends of cables ar e

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

Place sling assembly on top of shelter.

Insert liftin g hook of lifting device (cra ne) int o lifting ring.

Tie a1/2-inch rope, at least 15 feet long, to each rear towing 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 with crane.

b. Loading S helter onto Truck.(Figure 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.

3 - 2 C h a n g e 1


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3-5.

TM 10-5411-205-

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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TM 10-5411-205-1

3-5. Serv ice Upon Rece ip t o f Mate r ie l ( con t ) .

(5) Insert appropriate size wooden blocks between shelter skids and sides of truckbed to prevent sideway movement strain on sling cables.

(6) Insert appropriate size wooden blocks between shelter skids and cab wall of bedto protect cab wall and shelter towing eyes.

(7) Raise and secure truck tailgate.

d . S ecuring S helter on 1-1/ 4-T on (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.

Ins ta ll tiedown pr ovisions a s described in SB 11-640.

Un hook four sling legs from liftin g rin g of sling ass embly.

Remove hooks from t ur nbu ckle end of each sling leg.

Temporarily store lifting ring and four hooks 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 hardwarewhich h ad been used t o at ta ch h ooks t o tu rn buckles.

CAUTION

Do not overtighten tu rn buckles. Overt ight ening may t ear liftingand 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-half tur n with a bar or r od insert ed in tu rn buckle slot.

(9) Raise and secure truck tailgate.

e . Securing S helter on 1-1/ 4-Ton (M1028) Truck.

(1) Fabricate a wooden dunnage and install wooden dunnage and tiedown provisionin t ru ck 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 frameas sh own in Figur e 3-3.

3


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TM 10-5411-205-13

3-5. Service Upon Receip t of Mater iel (con t) .

CAUTION

Do not overtight en tu rn buckles. Overtightening may tea r liftingan d tiedown bra cket a ssemblies from shelter or damage bra cketassembly or sh elter.

(5) Tighten all tur nbuckles evenly by ha nd. Then t ur n ea ch t ur nbuckle an a ddi-tiona l one-ha lf tu rn with a bar or r od inserted in t ur nbuckle slot.

Figure 3-3. S helter Tiedown on M1028 Tru ck.

3-6


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TM 10-5411-205-

3-5. Serv ice Upon Rece ip t o f Mate r ie l ( cen t ) .

f . Securing Shelter on M1037 Shelter Carrier.

(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 truck tailgate and place in loading position.

Conn ect s ling assem bly to shelter liftin g brackets onshelter and lifting device.

the top four corners of

Remove and r etain a bolt a nd n ut at ta ching each towing eye to towing brackeand remove towing eye.

Position each mount ing bracket in place on t owing bracket an d secur e withcapscrew, lock washer, and flat washer, as shown in Figure 3-4. Do not tightecapscrew until shelter is installed.

Position sh elter over su pport an d gradu ally lower shelter ont o support in t ru ck

NOTE

Shelter should be tightly fitted to front of support. Shims shouldonly be added to rear shelter m oun ts.

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

Secur e rea r of shelter (Figure 3-4) to support with four bolts, lock washers,washer s, and two reinforcements. Do not tighten capscrews.

Add shims as necessary to rear shelter mounts to ensure snug fit betweenmounting 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 ta ilgate.

3-6. S it e R e q u i r e m e n t s . Site requirements will depend on the requirements of the equiment contained in the shelter. Refer to the end item technical manual for siting instruction

Sec t ion IV. TROUBLESHOOTING

3-7. Tro u b lesh o o t in g . This section contains troubleshooting information for malfunctionwhich ma y develop in t he sh elter. Fa ult isolation is limited to th ose components which ma ybe 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 an d corr ective actions sh ould be perform ed in t he order listed. This ma nu al cannot lisall malfunctions that may occur.cannot be corrected by the listed

If you en count er a malfunction t ha t is n ot listed or th atcorrective actions, notify your supervisor.

3


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3-5.

TM 10-5411-205-13

Figure 3-4. S ecurin g S helter on M 1037 S helter Carrier.

3-8


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TM 10-5411-205-1

Table 3-1. Troubleshooting.

MALFUNCTIONT E S T O R I N S P E CT I ON

CORRECTIVE ACTION

1.

2.

3.

4.

5.

OUTER DOOR OR INNER DOOR DOES NOT OPEN OR CLOSE SMOOTHLY

Step 1. Inspect hinges for adequate lubrication.

Lubricat e as required (para graph 3-1).

Step 2. Adjust or repair door as necessary (paragraph 3-19).

OUTER DOOR OR INNE R DOOR DOES NOT STAY OPEN

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

Install detent pin in chann el.

Step 2. Check to see if detent pin is missing.

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

DOOR HANDLE IS J AMMED OR DOES N OT OPERATE SMOOTHLY

Step 1. Inspect components for adequate lubrication.

Lubricat e as required (para graph 3-1).

step 2. Insp ect door h an dle and lat ching mecha nism for m issing or da ma ge com-p o n e n t s .

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

LOUVER COVER DOES N OT STAY OPE N

Step 1. Check to see if holder ass embly is at ta ched to louver cover.

Att ach holder a ssembly t o louver cover.

Step 2. Check to see if holder ass embly is secur e or dam aged.

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

WATER IS GETTING INTO SH ELTER

Step 1. Check condit ion of weat her gasket s a round th e inside edge of each door,

Replace deteriorated gaskets (paragraph 3-18).

3


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TM 10-5411-205-13

Table 3-1. Troubleshooting (cont).

MALFUNCTIONTEST O R I N SP EC TI O N

CORRE CTIVE ACTION

Step 2. Check condition of troughs (drip moulding) above each door.

Replace defective trough (para graph 3-12).

Step 3.

Step 4.

Step 5.

Step 6.

Check to see if roof access st eps h ave pu lled away from sh elter wall.

Apply sealer (Item 28, Appendix D) to gaps a roun d st ep flan ge, orreplace step (paragraph 3-14).

Inspect shelter walls and ceiling for leaks.

If repair is r equired, refer t o direct support.

Check t ha t a ll exterior wall and ceiling patches ar e firmly mounted a ndbonded to shelter wall.

Apply sealer (Item 28, Appendix D) ar oun d edge of patch. If replacement

of patch is necessary, refer to direct support.

Check if lifting bracket assemblies or towing bracket assemblies havepulled away from shelter comers.

a. Apply sealer (Item 28, Appendix D) to gaps a round bra cket edges.

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

6. THERE IS EVIDENCE OF RADIO FREQUENCY/ELECTROMAGNETICINTERFERENCE.

Step 1. In spect sh elter walls, ceiling, an d floor for holes.

If repair is requir ed, refer t o direct support.

Step 2. Check t o see th at all exterior wa ll and ceiling pat ches a re firmly mount edand bonded.

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

Step 3. Check condit ion of RFI/EMI filter in d oor.

Replace dam aged or m issing falter (par agraph 3-24).

3-10


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TM 10-5411-205-

Sect ion V. MAINTENANCESu bje ct

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Repair Procedures . . . . . . . . . . . . . . . . . .Shelter AssemblyOverall Shelter Assembly

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

Outer Door AssemblyDoor Gaskets..........,.. . . . . . . . . . . . . . . .Door H an dle Assembly an d Lat ching Mechan ism . . . .Keeper Assembly . . . . . . . . . . . . . . . . . . . . . . . . .Hinge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .Door Hasp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inner Door Assembly . . . . . . . . . . . . . . . . . . . . . . .

INSTRUCTIONS

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

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

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

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

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

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

. . . . . . . . . . .

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

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

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

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

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

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

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

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

. . . . . . . . . . . . . .Louver Assembly, Holder Assembly, and RFI/EMI Filter . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Para

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

Page

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. G e n e r a l . Since most shelters contain sensitive electronic equipment that cannot beeasily removed, unit level maint ena nce an d repa ir will prima rily involve shelter exter iors oreasily accessible interior areas, unless floors, ceilings or walls have evidence of water intrusiowhich can jeopardize operation of the equipment. The shelter shall be returned to the depofor rep air if any of the following condit ions exist:

a . Panel damages pans a structural member.

b . Replacement of an entire wall, ceiling, or

c . Exten sive equipment rem oval beyond t he

d . Welding is required.

e . Dama ge to a st ructur al member is severeespecially in edge or corn er a rea s.

floor is required.

capa bility of the u sing un it is required.

enough t o cau se distort ion of a wall,

f . Lift, t ow, or t iedown fittings or corn er cast ings ar e dam aged severely enough toindicate possible damage to the underlying structural member.

3-


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TM 10-5411-205-13

3-8. G e n e r a l ( c on t ).NOTE

If nature of damage warrants, print a caution notice using 4-inchhigh letters on all outside walls of the shelter as follows:CAUTION: DAMAGED SHELTER. DO NOT SLING LIFT.

Coat th reads of all screws an d bolts with sea ler before inst alling.Coat rivet an d rivnut bodies with sealer before u sing.

Unless oth erwise noted, all procedur es can be perform ed by oneperson u sing stan dar d tools listed in Appendix B, Section III.

3-9. G e n e r a l R e p a i r P r o c ed u r e s . The procedures described in this paragraph aregeneral procedures that may be needed during repair or replacement of many of th e sheltercomponents. Wherever these general procedures apply, they are referenced at the appropriatepoint in the specific maintenance procedure paragraph.

a . Blind Rivet Installation and Removal. Blind rivets ar e used in locat ions where onlyone side of the area to be worked on is accessible. Blind pop rivets must be used in the

shelter foam a nd beam pan els, since th e ham mering required t o insta ll convent iona l rivetswould damage the material. The types of rivets used in the shelter are shown in Figure 3-5and described in Table 3-2. When inst alling floor pa tches, coun tersu nk head rivets (styles Kand T) are preferred, but dome head rivets (styles R and S) are an acceptable alternate. Wheninsta lling interior wall patches, coun tersu nk head rivets sha ll be used in an y locat ion in whichdome h ead r ivets will int erfere with th e proper insta llat ion of equipment . Closed end r ivets(styles K and R) must be used for exterior repairs an d floor r epairs t o prevent m oistur e an ddirt from entering panels.

NOTE

Open end rivets may be used only where moisture and dirtent ra nce will not a ffect t he sh elter.

Figure 3 -5 . R i v e t T y p e s .

3-12


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TM 10-5411-205-1

T a b le 3 -2 . B l i n d R i v et s .

Part No. 1/

AD42H

AD43H

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

1/ Part Number Code Explanations

Rivet Body

A =

Head Style

D =

K =

Material

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

Countersunk

Rivet Diameter in 32nds of an Inch

Example: 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 Material

Exam ple: 4 = 4/16 or 1 /4 inch

maximum grip range

A = AluminumNo letter = Carbon steel

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

3-1


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TM 10-5411-205-13

3-9. Genera l Repai r

(1) Installation.

Pr ocedu res (cont ) .

(Figure 3-6)

N O T E

When inst alling new rivet in same locat ion as a rivet th at ha s been

removed an d if diameter of hole in str uctur e has been en largeddur ing removal of rivet, use next la rger diam eter r ivet forreplacement.

Clean rivets with solvent before insta lling.

P RO P ER INSTALLATION IMPROPER INSTALLATION

Figure 3-6. Installing Blind Rivets.

(a) Deter min e type, size an d grip ra nge of rivet t o be used. Grip lengthequals combined th ickness of ma ter ials being riveted together. Grip r an geof rivet must encompass grip length.

Drilling crea tes met al chips which may enter eyes and cause ser i-ous injury. Eye protection is requ ired.

CAUTION

Do not drill deeper t ha n necessary toth rough other side of panel.

N O T E

inst all rivet as you ma y drill

Drill hole size must ma tch size of rivet being used.

Quan tit ies of sheets m aybe drilled at th e same time when h eldtogether with sheet fasteners.

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3-9. G e n e r a l R e p a i r P r o c e d u r e s ( c o n t ) .

(2)

(b )

(c )

(d )

(e )

(f )

(g )

(h )

(i )

(j )

Drill hole in st ru ctu re.

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.

Coat all rivet bodies with sealer (Item 28, Appendix D) before inst alling.

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

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

Insert stem of rivet int o 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 parts are not loose, rivet does not rotate, and rivet heis seated tightly against riveted surface. If rivet is loose or improperlyinsta lled, remove it a nd inst all a n ew one.

Removal. (Figure 3-7)

WARNING

Drilling creat es meta l chips which m ay 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.

D R I L L P RY OFF

T H R O U G H H EA D

HEAD

P USH OUT

SHANK

Figure 3-7. Removing Blind Rivets,

3-


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TM 10-5411-205-13

3-9 . Genera l Repa i r P rocedures ( con t ) .

(a) Drill through head of rivet only, using hole in rivet as a guide. Use proper drill size asfollows:

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 pun ch, pry off rivet h ead.

CAUTION

D o n o t p u n c h r i ve t s h a n k s o u t a s y ou m a y d a m a g e t h e o t h e r s i d e o f t h e p a n e l.

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

b. Rivn ut Installation 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 usedwherever head thickness will not interfere with installation of equipment. Countersunk head rivnuts (style

C) are used for flush installation. Keyed rivnuts are used in locations which are subject to vibration and

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.

Figure 3-8. Rivnuts (Threaded Inserts).

3-16 C h a n g e 1


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Table 3-3. R i v n u t s .

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

P a r t N o .

S25B151

S25B211S25B451S1OB366S25B140S8B106S31B350S31B125S31B481S8B201S8B161S25B320S31B425S81B350

S t y l e 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 UNC-3B

1/4-20 UNC-3B1/4-20 UNC-3B10-32 UNC-3B1/4-20 UNC-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-3B

5/16-18 UNC-3B4/16-18 UNC-3B

Dim C

0.058

0.0620.062

0.0580.0620.062

G r i p R a n

.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 s t a l l a t i o n . ( F i g u r e 3 -9 )

NOT E

When installing 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.

Figu re 3-9. I n s t a l l i n g R i v n u t s .

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3-9. General Repair Procedures (cont).

(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. G e n e r a l R e p a i r P r o ce d u r e s

(2) Removal (Figure 3-10)

(cont) .

WARNING

Drilling creat es meta l chips which m ay ent er eyes an d cause seri-ous injury. Eye protection is required.

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

(b) Remove head of rivnut.

Figure 3-10. Removing R ivnuts.

CAUTION

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

(c) Pu nch out shan k of rivnut, using a pin punch slight ly smaller t han 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 m aximumtorque requirement for hardware to prevent rivnut turning. To correct aturning rivnut, proceed as follows:

(a) Drill a .062 (+.003, -.001) diameter hole by 1.00 inch long on the stem othe t urn ing rivnut as shown in Figur e 3-11.

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

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3-9. Gener a l Repa i r Pr ocedur es (con t ) .

T able 3-4. Maxim um Torque Requirem ent for Rivnu t S crews.

Screw Size

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

Torque (lbs/inch)

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

Figure 3-11. Repair of Tu rning Rivnu t

c . Tem porary Panel Repair. An y puncture in the shelter exterior, including puncturesin the door skin, must be patched immediately to prevent water intrusion. Dents without

pun ctu res do not requir e pat ching. However, if bare meta l is exposed, touch-up pa int sha ll beapplied (paragraph 3-9.d).

Materials/Parts Adhesive (It em 30, Appendix D) Sealer, Silicone (Item 26,Tape, Polyeth ylene (Item 29, Appendix D)Appendix D) Clean Cloth , Cott on (Item 10,

San dpaper , Grit Nos. 60 (Item Appendix D)15, Appendix D) Solvent (Item 9, Appendix D)

Gloves (Item 1, Appendix D)

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3-9. G e n e r a l R e p a i r P r o ce d u r e s (c on t ) .

WARNING

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

Solvents are flammable and toxic. Keep away from heat and openflames. Use in a well-ventilated area. Avoid skin and eye contactand breath ing of vapors. Use protective goggles and gloves.

CAUTION

Pa int st rippers can conta minat e panel core,Do not use paint str ippers to remove paint.

NOTE

adhesive, and sealers.

Ceiling and floor panel compositions are the same as wall panelcomposition. The same method of repair applies to all panels.

Bend edges of puncture in below surface of unbroken face sheet. Do not allowbroken edges t o cont act opposite face sheet .

Remove loose fra gment s of foam an d dus t.

Clean and dry area surrounding puncture usingWipe off solvent.

Inject adhesive into punctur e an d fill.

clean cloth soaked with solven

Apply a bead of adhesive approximately 1/4 inch wide over cuts in face sheet.Do not smooth out.

Plan applicat ion of tape. Length a nd width , num ber of str ips, overlaps, andmethod of application will affect sealing capability of repair. Each piece of tapshall extend approximately 1-1/2 inches beyond adhesive. Tape must be applito bare clean metal. If width of damaged area exceeds width of tape, overlaptape strips at least 1/2 inch. If three or more strips of tape are required, appcenter str ip first.

Stretch tape and apply lightly. Do not apply with rolling 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 squeezeadhesive out from un der ta pe.

Touch up with paint as r equired (par agraph 3-9.d).

d . Touch-up painting. When required, to prevent r ust an d corr osion, touch u p sma llareas of damaged or chipped paint in accordance with TM 43-0139. If large areas needrepa int ing, notify higher level of ma int ena nce.

3-10. She l te r Assembly . Shelter Assembly maintenance consists of the following

a . Overall shelter assembly inspection (paragraph 3-11).

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3-10 She lter Assembly (cont ) .

b . Trough (above each door) repla cemen t (paragraph 3-12).

c . Bail handle (roof) replacement (par agra ph 3-13).

d . Recessed step pan a ssembly replacement (3-14).

e . Drain plug replacement (par agra ph 3-15).

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TM 10-5411-205-1

3-11. Overa l l She l t e r Assemb ly .

This task 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 dent s, punctur es, or a ny oth er dam age.

Inspect shelter exterior for m issing or loose part s an d mount ing har dwar e.

Inspect outer door assembly (1) and inner door assembly (2) for ease of opera-tion.

Inspect louver cover a ssembly (3) for missing or da ma ged ha rdwar e an d for easeof opening.

Inspect bail hand (4) and recessed steps (5) on shelter exterior for loose,missing, or dama ged pa rts, a nd for proper operat ion.

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 dam aged or missing par ts, an d for proper operation.

Inspect door latching mechanism (8), keeper assembly (9), and door stay assem-bly (10) for damaged or missing parts, and for proper operation.

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

3-2


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TM 10-5411-205

3-12. T r o u g h

This t ask covers Replace

INITIAL SE TUP

TO O l S Mater ia ls / Parts

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

Replace.

(1 )

(2 )

(3 )

(4 )

(5 )

(Figure 3-13)

NOTE

The trough mounted to the shelter rear panel just above the door

is identical to the trough on the outer door except that the rearpanel t rough is longer an d is mounted with six screws instea d off i v e .

Remove five t appin g screws (1) moun tin g tr ough (2) to out er door (3).

Take trough (2) off door (3).

Apply sealer to back of trough (2).

Position trough (2) on top edge of outer door (3).

Dip in sealer an d inst all five ta pping screws (1), and coat hea ds of screws wits e a l e r .

Figure 3-13. Trough Replacem ent.

3


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TM 10-5411-205-13

3-13. B a i l H a n d le .

This task covers: Replace

INITIAL SE TUP

Too l s Mater ia ls/ Parts

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

Appendix D)

R ep l ace .

(1 )

(2 )

(3 )

(4 )

(5 )

(Figure 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.

Position bail ha ndle (2) on s helt er r oof.

Fa st en with five rivets (1). (Refer t o par agra ph 3-9.a for rivet installationinstructions.)

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

Figure 3-14. Bail H and le Replacem ent.

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TM 10-5411-205-

3-14. Re c e sse d S t e p P a n Asse m b l y .


INITIAL SETUP

T ool s Materials/ Parts

Genera l Mecha nics Aut omotive Tool Kit Conductive Compound (Item 33,Appendix D)

Sealer (Item 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 pa n (5) to shelter wa ll and r emove 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 screws (3) an d lock wa sher s (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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TM 10-5411-205-13

3-14. R e c e s s e d S t e p P a n As s e m b ly (c o n t ) .

Figure 3-15. Recessed S tep Pan Assem bly Replacem ent.

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TM 10-5411-205-1

3-15. D r a i n P lu g .

This tack covers: Replace

INITIAL SETUP

T o o l s

General Mechanic's Automotive Tool Kit

Materia ls / Parts


dr ain plug cha in (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).

Figure 3-16. Drain Plug Replacement.

3


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3-16. I n s t r u c t i o n P l a t e s.

This task covers Replace

SETUP

Materials/ Parts

INITIAL

T o o l s

Gener al Mechan ics Automotive Tool Kit Sealer (Item 28, Appendix D)


(1) Remove four tapping screws

(2) Take plate (2 or 3) off door

(3) Position plate (2 or 3) on door (4).

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

(1 )

(4 )

Figure 3-17. Instruction Plate Replacament

3 - 3 0


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TM 10-5411-205-

3-17. O u te r D o or As s e m b ly .

This ta sk covers a . Inspectb. Removec. Repair

d . Ins ta l l

INITIAL SE TUP

T o o l s Materials/ Parts

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

Appendix D)

a . Inspect. (Figure 3-18)

(1) In spect th e

(2) Inspect the

(3) In spect th eshe l te r .

(4) In spect th e

b . Remove. (Figure

outer door a ssembly (6) for exter na l dam age.

silicone weat her

RFI/EMI gasket

door for positive

3-1 8)

gasket

(9) for

(8) for tight ness.

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 panel, and pull channel away from door panel.

(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) Door gasket (silicone and RFI/EMI) replacement (paragraph 3-18).

(2) Door ha ndle assem bly and lat ching m echa nism replacement (paragraph 3-19).

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

(4) Hinge assembly replacement (paragraph 3-21).

3


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TM 10-5411-205-13

3-17. O u t e r D o o r A sse m b l y (c o n t ) .

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

a . Install. (Figure 3-18)

(1)

(2)

(3)

(5)

Coat both sides of each hinge spacer (7) with conductive compound.

Position each spa cer (7) an d outer door ass embly (6) in place and secure ea chhinge t o shelter with four hex hea d screws (3), lock wash ers (4), an d n ut s (5).

Position d oor st ay a ssembly cha nn el (2) in place an d secure t o out er door pa nel

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

Apply a cont inuous bead of sealer a round s pacer (7) an d hinge bra cket, a ndaround head of screws (5).

Figure 3-18. Outer Door Assem bly R eplacem ent .

3-32


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TM 10-5411-205-

3-18. D o or G a s k e t s .

This task covers: a. Inspectb. Testc . Adjust

d. Replace

INITIAL SETUP

T o o l s Materials/ Parts

General Mechanics Automotive Tool Kit Silicone Sealer (Item 26, Appendix D)Gask et, Silicone (Item 27, Appendix D)EMI/RFI Ga sket (Item 31, Appendix D)Conductive Compound (Item 33,

Appendix D)

NOTE

RFI/EMI gaskets ar e only on outer an d inner doors of shieldedshelters.


(1) Inspect the

(2) Inspect the

(3) Inspect the

door assembly (2) for external damage.

silicone weather gasket (15) for tightness.

RFI/EMI gasket for wear an d secur e mounting.

b . Test. (Figure 3-19) Test of the door assembly consists of testing for proper sealpressure on the silicone weather gasket. The procedure listed below shall be per-formed at the center top and bottom of the door, and three places along each side the door, as shown in Figur e 3-19.

(1) Place a single piece of paper (0.005 incheswide) between the silicone weather gasket

(2) Close and lock the door.

NOTE

maximum thickness byan d its bearing sur face.

2-1/2 inche

The absence of any resistan ce to the with dra wal of the paper indi-cates that the gasket is not touching its bearing surface, thus in-dicating insufficient pressure.

3


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TM 10-5411-205-13

3-18. D o o r G a sk e t s ( co n t ).

c .w e a t h e rdoor, as

(3) With dra w th e paper . Resistance to the withdrawal of the paper indicates properseal pressure. If there is no resistance, perform the adjustment procedure con-ta ined in th e following para graph s.

(4) Ifthere is resistance to the withdrawal at all of the test points, sufficient sealpressure exists on the silicone weather gasket and adjustments are not neces-

sa ry .

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 th e following par agra phs:

(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), an d t hr ee self-locking nu ts (3) atta ching t he h inge to the door.

(b) Coat each n ew shim with condu ctive compoun d on both sides.

( c ) Inser t sh im (4), approxima tely 0.032 inches th ick an d ma tching the h ingebody 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), an d t hr ee self-locking nu ts (3).

(e) Repeat the test procedures of paragraph 3-18.b. and repeat this adjustmentprocedure as necessar y.

(f) After completion of adjustment procedure, apply a continuous bead ofsealer a round shim (4) an d hin ge leaf, and a round hea d of bolts (1).

(2) Seal Pressu re Adjustm ent. To increase th e seal pressu re on th e roller latchside of the door, proceed as follows

(a) Open the door and remove and retain the hex head screws (5 and 6), flatwash ers (7), and lock wa sher s (8) from th e top an d bottom hole att achingthe keeper (9) to the wall, and remove keeper and shim (10). Removedeten t pin (11) from center keeper.

NOTE

If more than one shim (12) is required, additional shims may beadded, up to a ma ximu m th ickness of 0.096 inches.

If the seals are not tight after the maximum allowable thickness isobtained, the seal should be replaced as the material has likelybroken down.

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

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TM 10-5411-205-

3-18. D o or G a s k e t s (c o n t ) .

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

(d) Repeat th is process un til sufficient sea l pressur e is developed or un til thmaximum allowable thickness is obtained.

d . Replace. (Figure 3-20) To replace the RFI/EMI gasket (13), remove gasket fromtrack and clean track of any dirt. Place new gasket over track and snap in place. To replaceth e silicone weat her gasket (14), pr oceed a s follows

(1) Remove gasket (14) an d clean tra ck from adh esive residu e.

(2) Apply sealer in tra ck groove all around door an d snap new gask et in place intrack on door.

CAUTION

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

Figure 3-19. Typical Locations for Door Gasket T estin g.

3-


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TM 10-5411-205-13

3-18. Door Gask e ts (con t ).

Figure 3-20. Weather Gasket an d S eal Pressure Ad justm ent.

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TM 10-5411-205-

3-19. D o or H a n d le As s e m b ly a n d La t c h in g Me c h a n i s m .

This task covers: a . Inspectb. Servicec. Disassembled. Assemblee. Repair

INITIAL SE TUP

Tools Materials/ Parts

Gen er al Mecha nics Au tom ot ive Tool Kit Sea ler (It em 28, Appendix D)Solid Film Lubricant (Item 22, Appendix Conductive Compound (Item 33,

Appendix D)

NOTE

Except for the length of the latch assembly rods (items 4 and 5,Figure 3-21), the inn erident ical. Ma intena nce

a . Inspect.

(1) Ins pect the door lat ch

door and outerprocedures ar e

door handle mechanisms areth e sam e for both.

assembly for secure mount ing and br oken or worn par ts

(2) Ins pect for ea se of operat ion.

(3) Inspect the door ha ndle for tightn ess and for worn or dama 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

consist s of lubricat ing th e

Disassembly procedures are similar for top and bottom sections ofdoor latch 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.

Pu nch out spring pin (6) att aching the inside ha ndle (7) to out side han dle andshaft (8). Remove inside handle (7).

3-


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TM 10-5411-205-13

3-19. D o or H a n d le As s e m b ly a n d La t c h in g Me c h a n i s m ( c on t ).

(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-rin g (15) from place on out side h an dle sh aft (8).

Turn th e bearing sleeve nu t (16) coun terclockwise to release th e ha ndle sha ftsleeve (17) and rem ove nu t (16) and sha ft sleeve (17).

Punch out spring pin (11) and release the roller extension (12) and roller latch(13) from latch arm (14).

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

Remove nu t (19) to release was her (20), spacer (21), latch a rm ass embly (10),spacers (22, 24, and 25), latch arm detent (23), (at the bottom latch installationonly), and bolt (26).

Remove rivet (27) at ta chin g padlock a nd cha in (28) to pan el and rem ovepadlock. (Refer to paragraph 3-9.a for rivet removal instructions.)

d. Assemble.

(1)

(2)

(3)

(4)

NOTE

Assembly procedur es ar e similar for t op and bott om s ections of doorlatch assembly.

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

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

NOTE

When installing the latch arm detent (23) at the bottom section ofth e assembly, have the lat ch m echa nism fully open so th at th era ised surface is engaged in t he hole of the lat ch a rm assembly

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

Apply conductive compoun d u nder hea d of each bolt (26) an d pla ce bolt t hr oughmoun tin g hole on d oor.

Insert spacers (24 and 25), latch arm detent (23), spacer (22), (at top of installa-tion), lat ch ar m assem bly (10), spacer (21), an d wa sher (20) on bolt (26), an dsecure with nut (19).

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3-19. D o or H a n d l e As s e m b l y a n d L a t c h i n g M e c h a n i sm (c o n t ).

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)

(13)

(14)

Put washer (2) onto pin (18), insert pin (18) through hole on rod latch (4 and5), and secur e with spring pin (1).

Apply conductive compound under mounting surface of handle shaft sleeve (17)an d bear ing sleeve nu t (16).

Inser t h an dle sha ft s leeve (17) into hole from outside of door pa nel a nd secur ewith bea ring sleeve nut (16) from t he inside of pan el.

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

Inser t door h an dle shaft (8) th rough h an dle shaft sleeve (17).

Inser t la tch a rm (10) ont o door h an dle shaft (8) an d secure with s pring pin (9).

Place inside ha ndle (7) ont o door s ha ft a nd secur e with spring pin (6).

Align holes on latch rod assemblies (4 and 5) with hole on latch arm (10) andinsert pin (3). Place washer (2) onto the pin (3) and secure with spring pin (1)

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

Lubricate as required (para graph 3-1).

e . R epair. Repair of the door latch consists of replacing defective parts.

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3-19. D o or H a n d le As s e m b ly a n d La t c h in g Me c h a n i s m (c o n t ) .

Figure 3-21. Door Han dle Assem bly and Latching M echan ism Replacem ent.

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3-20. Keeper Assembly .

This t a sk covers : a . Inspectb . R e p la c e

INITIAL SETUP

T o o l s

General Mechanics

Materials/ Parts

Automotive Tool Kit N o n e


(1) Inspect for wear and other physical damage.

(2) Ins pect for secure moun tin g.

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

b . Replace. (Figure 3-22)

(1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

NOTE

The middle keeper on ea ch door is t apped for at ta chmen t of a latchlock a ssembly. Maintena nce procedures ar e th e sam e for all keep-ers a nd on both th e out er door a nd inn er door a ssemblies.

Remove an d r eta in h ex-hea d screw (1), lock wa sher (2), an d flat wa sher (3) fromtop (upper) hole of keeper assembly (4).

Remove an d r eta in h ex-hea d screw (5), lock was her (2), and flat wa sher (3) frombottom (lower) hole of keeper (4) attaching each of the keepers (4) and shim (6an d lamina ted shim (7) to wall an d rem ove.

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

wash er (3).

Secure keeper (4) to wall at bottom hole using hex-head screw (5), lock washer(2), an d flat wash er (3).

If only lat ch lock assem bly (8) has to be inst alled, position lat ch lock ta b inplace over bottom mounting hole of center keeper (4), and secure using hex-hea d screw (5), lock wa sher (2), an d flat wash er (3).

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3-20. Keeper Assembly (cont).

(7 ) Check latch torque. Latch torque should be 10 foot-pounds without RFI/EMI gasket or20 foot-pounds with RFI/EMI gasket. Add or subtract shims (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 Assemb ly (con t ) .

e . I n s ta 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).

Figure 3-23. Hinge Assembly Replacement.

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3-22. D o or H a s p .


INITIAL SETUP

Tools

General Mechanics Automotive Tool Kit

Materials / Parts


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).

Inst all th umb screw (1) with crimp mesh wash er (2).

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

Figure 3-24. Door Hasp Replacem ent.

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3-23. Inner Door Assembly.

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

INITIAL SETUP

Tools Materials/Parts

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

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 repair consists of the following

(1)

(2)

(3)

(4)

Door gasket replacement (paragraph 3-18).

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

Keeper assembly replacement (paragraph 3-20).

Hinge assembly replacement (paragraph 3-21).

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paragraph 3-18b.

paragraph 3-18c.

TM 10-5411-205-

3-23. Inne r Door Assembly (con t ) .

(5) Louver assembly, holder assembly, and RFI/EMI filter replacement (paragraph3-24).

(6) Directional van e assembly and air inta ke falter r eplacement (par agraph 3-26).

(7) Louver cover assembly latches replacement (paragraph 3-26).

d . I n s ta l l .

(1) Coat both sides of each h inge spacer (7) with condu ctive compoun d.

(2) Position each spacer (7) and inner door panel (6) in place and secure to outerdoor pan el with four h ex-hea d screws (3), lock wash ers (4), an d n ut s (5).

(3) Position door stay assembly channel (2) in place and secure to inner door pane

(6) with t hr ee phillips hea d screws (1).

(4) Apply a continuous bead of sealer around spacer (7) and hinge bracket, andaround head of screws (5).

Figure 3-25. Inner Door Assembly Replacement.

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3-24. Louver Assembly , Holder Assembly and RFI /EMI F i l t e r .

This ta sk covers a . Inspectb. Removec . Repair

d. Insta l l

INITIAL SETUP

Tools

General Mechanics

Materia ls / Parts

Automotive Tool Kit Sealer (Item 28, Appendix D)Sealer, Silicone (Item 26, Appendix D)

NOTE

RFI/EMI falters ar e on inn er door a ssembly are on s

s-250 shelter manual

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