CHAPTER 1. GENERAL INFORMATION FOR M15 BRIDGE ADAPTER PALLET (BAP) NSN 3990-01-442-1939
GENERAL INFORMATION
PREPARATION FOR STORAGE OR SHIPMENT
Table 2. List of Abbreviations and Acronyms - Continued
Table 2. List of Abbreviations and Acronyms - Continued
EQUIPMENT DESCRIPTION AND DATA
Figure 1. BAP Components
Figure 2. BAP Locks and Rollers
Table 4. The BAP (Empty)
THEORY OF OPERATION
CHAPTER 2. OPERATOR INSTRUCTIONS FOR M15 BRIDGE ADAPTER PALLET (BAP) NSN 3990-01-442-1939
LOCATION AND USE OF CONTROLS AND INDICATORS
Figure 2. Analog and Digital Control Panels.
Figure 3. LHS Remote Control Unit
Figure 4. Main Hydraulic Manifold.
Figure 5. Free-Flow Valve.
Figure 6. Hydraulic Hand Pump.
Table 1. Load Handling System (LHS) Cab Controls and Indicators - Continued
LOADING BRIDGE ADAPTER PALLET (BAP) FROM THE GROUND
Figure 1. Lock Winch Frame to BAP.
Figure 2. Stow Air Line
Figure 3. Checking Front Pin Locks and Rear Guides.
Figure 4. Stowing Hydraulic Hoses
Figure 6. Cab LHS Controls
OPERATION - Continued
Figure 7. Cab LHS Controls
Figure 8. Checking BAP Hold Down Locks.
UNLOADING BRIDGE ADAPTER PALLET (BAP) TO THE GROUND
Figure 1. Brake and Transmission Controls.
Figure 2. Lock Winch Frame to BAP
Figure 3. Disconnect Hydraulic Hoses
Figure 5. Stow Air Line
Figure 6. Checking Front Pin Locks and Rear Guides.
Figure 8. Cab LHS Controls
Figure 9. Cab LHS Controls
OPERATION - Continued
LOADING BRIDGE BAY FROM THE GROUND
Figure 1. Brake and Transmission Controls.
Figure 2. Setting BAP Hold Down Locks.
Figure 4. Lock Winch Frame to LHS Hook Arm
Figure 5. Setting Front Pin Locks
Figure 7. Cab LHS Controls
Figure 8. Picking Up Bridge Bay
LOADING BRIDGE BAY FROM THE GROUND - Continued
Figure 9. Parking Brake Control.
Figure 10. Stowing Winch Cable
Figure 11. Cab and Remote Control Unit Controls.
LOADING BRIDGE BAY FROM THE GROUND - Continued
Figure 12. Stow Remote Control Unit
UNLOADING BRIDGE BAY TO THE GROUND
Figure 1. Position BAP Locks.
Figure 2. Lock Winch Frame to Hook Arm.
Figure 3. Connect Hydraulic Hoses.
Figure 4. Connect Remote Control Unit
Figure 5. Cab Controls
Figure 6. Check and Set Winch Cable Tension
Figure 8. Front Pin Locks
Figure 9. Rear Guides.
Figure 10. Unload Hook Arm
Figure 11. Lowering Bridge Bay to the Ground.
UNLOADING BRIDGE BAY TO THE GROUND - Continued
Figure 12. Stowing Winch Cable
Figure 13. PTO Engage Switch
Figure 14. Stowing Remote Control Unit
Figure 15. Setting Front Pin Locks.
Figure 16. Stowing Rear Guides.
BRIDGE BAY LAUNCHING INTRODUCTION
BRIDGE BAY LAUNCHING INTRODUCTION - Continued
CONTROLLED BRIDGE BAY LAUNCH
Figure 1. Check BAP Hold Down Locks
Figure 2. Lock Winch Frame to LHS Hook Arm
Figure 3. Connect Hydraulic Hoses.
Figure 4. Cab LHS Controls
Figure 5. Connect Remote Control Unit.
Figure 6. Check Winch Cable Hook
Figure 7. Release Bridge Bay Latches
Figure 8. Release Front Pin Locks
Figure 10. Open Rear Guides.
Figure 11. Brake and Transmission Controls.
Figure 12. Launch Bridge Bay.
Figure 13. Brake and Transmission Controls.
Figure 14. Stow Winch Cable Hook.
Figure 15. Cab LHS Controls.
Figure 16. Stow Remote Control Unit.
Figure 17. Secure Front Pin Locks
CONTROLLED BRIDGE BAY LAUNCH - Continued
BRIDGE BAY FREE LAUNCH
BRIDGE BAY FREE LAUNCH - Continued
Figure 1. Cab LHS Controls
Figure 2. Check Front Pin Locks
Figure 3. Connect Remote Control Unit
Figure 4. Attach Lanyard to Air Release Valve.
Figure 5. Connect Air Hose
Figure 6. Position Rear Guides
Figure 7. Center Roller Location
Figure 8. Position Center Roller.
Figure 9. Remote Control Unit
Figure 10. Lock Winch Frame to BAP
Figure 11. Release IRB Foldlock Latches
Figure 13. Stow Remote Control Unit.
Figure 14. Brake and Transmission Controls.
Figure 15. Release Front Pin Locks
Figure 16. Cab LHS Controls.
Figure 17. Remove Lanyard
Figure 18. Lock Air Release Valve
Figure 20. Disengage Front Pin Locks.
Figure 22. Lower Center Roller
CALM OR FAST WATER BRIDGE BAY RETRIEVAL
Figure 1. Setting BAP Locks.
Figure 2. Lock Winch Frame to LHS Hook Arm
Figure 3. Connect Hydraulic Hoses.
Figure 4. Position Front Pin Locks
Figure 6. Connect Remote Control Unit.
Figure 7. Cab LHS Controls
Figure 8. Remote Control Unit Controls.
Figure 9. Brake and Transmission Controls.
Figure 10. Engage IRB Foldlock Latches
Figure 11. Remote Control Unit Controls.
Figure 12. Brake and Transmission Controls.
Figure 13. Remote Control Unit Controls.
Figure 14. Cab LHS Controls.
Figure 15. Stow Remote Control Unit
NORMAL TRANSFER OF BRIDGE ADAPTER PALLET (BAP) FROM VEHICLE TO TRAILER
Figure 1. Retract Trailer Locks.
Figure 3. Lock Winch Frame to BAP
Figure 4. Unlock BAP from CBT.
Figure 6. Position Transload Rollers
Figure 8. Cab LHS Controls and Initial Contact with Trailer
NORMAL TRANSFER OF BRIDGE ADAPTER PALLET (BAP) FROM VEHICLE TO TRAILER - Continued
Figure 9. Cab LHS Controls and Final Stopping Point on Trailer
Figure 10. Lower BAP to Trailer.
Figure 12. Cab LHS Controls and Hook Disengage
NORMAL TRANSFER OF BRIDGE ADAPTER PALLET (BAP) FROM VEHICLE TO TRAILER - Continued
NORMAL TRANSFER OF BRIDGE ADAPTER PALLET (BAP) FROM TRAILER TO VEHICLE
Figure 1. Brake and Transmission Controls.
Figure 2. Lock Winch Frame to BAP
Figure 4. Position BAP Hold Down Locks
Figure 5. Disengage Trailer Locks
Figure 7. Cab LHS Controls
Figure 8. Trailer Bumper Point and Vehicle Bump Plate.
Figure 9. Cab LHS Controls and Bail Bar Lock.
NORMAL TRANSFER OF BRIDGE ADAPTER PALLET (BAP) FROM TRAILER TO VEHICLE - Continued
Figure 10. Stow Transload Rollers.
NORMAL TRANSFER OF BRIDGE ADAPTER PALLET (BAP) FROM TRAILER TO VEHICLE - Continued
BAP HOLD-DOWN LOCKS CHECKLIST
Figure 1. BAP Hold-Down Locks Checklist
Table 2. BAP Hold-Down Locks Checklist
Figure 2. BAP Hold-Down Locks Checklist
DECALS AND INSTRUCTION PLATES
Figure 1. Decal and Instruction Plate Locations. (Sheet 1 of 2)
Figure 1. Decal and Instruction Plate Locations. (Sheet 2 of 2)
MANUALLY LOADING BRIDGE ADAPTER PALLET (BAP) FROM THE GROUND
Figure 2. Check Hold-Down Locks
Figure 3. Cab LHS Controls
MANUALLY LOADING BRIDGE ADAPTER PALLET (BAP) FROM THE GROUND - Continued
Figure 4. Check BAP Hold-Down Locks.
MANUALLY UNLOADING BRIDGE ADAPTER PALLET (BAP) TO THE GROUND
Figure 3. Position Vehicle.
Figure 4. Disengage Locks.
Figure 5. Manually Unload BAP to the Ground.
MANUALLY UNLOADING BRIDGE ADAPTER PALLET (BAP) TO THE GROUND - Continued
MANUALLY UNLOADING BRIDGE ADAPTER PALLET (BAP) TO THE GROUND - Continued
MANUALLY BYPASSING SOLENOID DURING ELECTRIC POWER LOSS
Figure 2. Instructional Placard
Figure 4. Valve Plunger Tool
PREPARATION FOR EMERGENCY MANUAL REMOVAL OF BRIDGE ADAPTER PALLET (BAP)
Figure 1. Winch Frame Locking Levers.
Figure 3. Release BAP Hold Down Locks.
Figure 4. Lift Points and Bail Bar Lock
PREPARATION FOR EMERGENCY MANUAL REMOVAL OF BRIDGE ADAPTER PALLET (BAP) - Continued
MANUALLY REMOVING LOAD DURING HYDRAULIC POWER LOSS
Figure 2. Disconnect Hoses from Operable Vehicle.
Figure 4. Connect Hoses to Operable Vehicle
Figure 6. Return LHS to the Stowed Position.
Figure 8. Open M1977 A2 Cover
Figure 10. Set Cab Switches
Figure 11. Disconnect Hoses to Operable Vehicle.
Figure 13. Connect Hoses to Disabled Vehicle
Figure 15. Install M1977 A2 LHS Control Box Cover.
CHEMICAL, BIOLOGICAL, RADIOLOGICAL, AND NUCLEAR (CBRN) DECONTAMINATION PROCEDURES
CHEMICAL, BIOLOGICAL, RADIOLOGICAL, AND NUCLEAR (CBRN) DECONTAMINATION PROCEDURES - Continued
CHAPTER 3. OPERATOR TROUBLESHOOTING PROCEDURES
CENTER ROLLER AND/OR TRANSLOAD ROLLERS WILL NOT OPERATE
Figure 1. Hand Pump Selector Lever.
Figure 2. Hand Pump Selector Lever and Center Roller Assembly.
Figure 3. Hand Pump Selector Lever and Transload Roller Extension Cylinders
FRONT PIN LOCK AIR RELEASE WILL NOT OPERATE DURING LAUNCH OF BRIDGE BAY
FRONT PIN LOCK AIR RELEASE WILL NOT OPERATE DURING LAUNCH OF BRIDGE BAY - Continued
WINCH ASSEMBLY WILL NOT WIND OUT
Figure 2. BAP Winch Hydraulic System Quick-Disconnect Connectors
Figure 3. Remote Control Unit.
WINCH ASSEMBLY WILL NOT WIND IN
Figure 2. BAP Winch Hydraulic System Quick-Disconnect Connectors
Figure 3. Remote Control Unit.
WINCH ASSEMBLY WILL NOT LIFT LOAD OR OPERATES SLOWLY
Figure 1. Winch Cable
WINCH ASSEMBLY WILL NOT LIFT LOAD OR OPERATES SLOWLY - Continued
Figure 4. Remote Control Unit
FRONT PIN LOCK WILL NOT ALIGN WITH BRIDGE BAY PIN
Figure 2. BAP Front Pin Lock
CHAPTER 4. FIELD TROUBLESHOOTING PROCEDURES
CENTER ROLLER AND/OR TRANSLOAD ROLLERS WILL NOT OPERATE
Figure 1. Roller Hydraulic Hoses/Lines.
Figure 2. Hand Pump
Figure 3. Center Roller Manifold and Cylinders
Figure 4. Transload Roller Manifold and Cylinders.
FRONT PIN LOCK WILL NOT OPERATE
Figure 1. Air Supply Hose.
Figure 2. Control Valve.
Figure 3. Control Valve Outlet Ports.
Figure 4. Air Cylinder.
Figure 5. Control Valve Lever
Figure 6. Air Cylinder Breather
Figure 7. Latch Handle.
WINCH DOES NOT OPERATE
Figure 1. Winch Quick-Disconnect Couplings (Model A Shown).
Figure 3. Access Cover, Connector J2, and Connector P2.
Figure 4. Cab Digital Mode Select Switch.
Figure 5. Hydraulic Cabinet Cover.
Figure 7. Connector P2.
Figure 8. Connector J3.
Figure 9. WINCH IN Valve and Solenoid.
Figure 10. WINCH OUT Valve and Solenoid.
WINCH DOES NOT WIND OUT
Figure 1. Winch Quick-Disconnect Couplings (Model A Shown).
Figure 3. Left (Connector J8A) and Right (Connector J8B) Remote Locations.
Figure 4. Remote Control Unit
Figure 5. Remote Control Cable Connectors P8 And P9.
Figure 6. Left (Connector J8A) and Right (Connector J8B) Remote Locations
Figure 8. Left (Connector J8A) and Right (Connector J8B) Remote Locations.
Figure 9. Main Frame Junction Box (Wiring Removed For Clarity).
Figure 10. WINCH OUT Solenoid Connector.
Figure 11. Main Frame Junction Box (Wiring Removed For Clarity).
Figure 12. Cab Interface Wiring Harness Access Cover.
WINCH DOES NOT WIND OUT - Continued
Figure 14. Hydraulic Cabinet Cover, WINCH OUT Solenoid Connector, and Connector J4.
Figure 15. Connector P2.
Figure 16. WINCH OUT Solenoid Connector and Connector J3.
Figure 17. WINCH OUT Solenoid Connector.
WINCH DOES NOT WIND IN
Figure 1. Winch Quick-Disconnect Couplings (Model A Shown).
Figure 3. Left (Connector J8A) And Right (Connector J8B) Remote Locations.
Figure 4. Remote Control Unit
Figure 5. Remote Control Cable Connectors P8 And P9.
Figure 6. Left (Connector J8A) and Right (Connector J8B) Remote Locations
WINCH DOES NOT WIND IN - Continued
Figure 9. Main Frame Junction Box (Wiring Removed For Clarity).
Figure 10. WINCH IN Solenoid Connector.
Figure 11. Main Frame Junction Box (Wiring Removed For Clarity).
Figure 12. Cab Interface Wiring Harness Access Cover.
Figure 14. Hydraulic Cabinet Cover, WINCH OUT Solenoid Connector, and Connector J4
Figure 15. Connector P2
Figure 16. WINCH IN Solenoid Connector and Connector J3.
WINCH DOES NOT WIND IN - Continued
Figure 17. WINCH IN Solenoid Connector.
CHAPTER 5 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
GENERAL MAINTENANCE PROCEDURES
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 1. Operator Preventive Maintenance Checks and Services - Continued
Table 1. Operator Preventive Maintenance Checks and Services - Continued
Table 1. Operator Preventive Maintenance Checks and Services - Continued
Table 1. Operator Preventive Maintenance Checks and Services - Continued
Figure 6. Control Valve.
Figure 8. Center Roller.
Figure 9. Rear Guide Assemblies
Figure 11. Winch Cable.
Figure 12. Remote Control Unit
Figure 14. Main Frame Switch.
Figure 15. Winch Switch
Figure 16. Disconnect Remote Control Unit.
Figure 17. Front Pin Locks.
Figure 19. Rear Rollers.
FIELD LEVEL PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Figure 1. Catwalk.
Figure 2. BAP Frame Assembly.
Figure 4. Winch Assembly.
Figure 6. Hand Pump.
Figure 7. Hand Pump Hydraulic System
Figure 8. Rear Guide Assembly.
Figure 9. BAP Labels.
Figure 10. Winch Assembly Drain.
CHAPTER 6. MAINTENANCE INSTRUCTIONS
CHAPTER CONTENTS - Continued
SERVICE UPON RECEIPT
PRELIMINARY SERVICING OF EQUIPMENT - Continued
GENERAL MAINTENANCE AND WELDING INSTRUCTIONS
GENERAL CLEANING INSTRUCTIONS
GENERAL CLEANING INSTRUCTIONS - Continued
GENERAL INSPECTION INSTRUCTIONS
GENERAL REPAIR INSTRUCTIONS
GENERAL INSTALLATION INSTRUCTIONS
Figure 1. General Air Tubing Repair
Figure 2. A-Frame
Figure 3. Outriggers and Main Rails.
Main Frame Structure
Figure 4. Winch Frame.
Table 1. Weld Joint Materials
Table 1. Weld Joint Materials - Continued
PLS FOOT STOWAGE
Figure 2. PLS Foot Stowage
Figure 3. PLS Hitch Pin Installation
STENCILS
STENCILS - Continued
CATWALK REPLACEMENT
Figure 1. Catwalk Locations.
Figure 2. Hydraulic Tubes Removal
Figure 3. Catwalk Removal.
Figure 4. Tube Support Removal
Figure 5. Tube Support Installation
Figure 6. Catwalk Installation.
Figure 7. Hydraulic Tubes Installation.
PLUNGER REPLACEMENT
Figure 2. Plunger Installation.
TOOLBOX ASSEMBLY REPAIR
Figure 2. Toolbox Disassembly.
Figure 3. Toolbox Assembly.
Figure 4. Toolbox Assembly Installation.
CENTER ROLLER REPAIR
Figure 2. Center Roller Installation
CENTER ROLLER REPAIR - Continued
REAR GUIDE REPAIR
Figure 1. Rear Guide Removal
Figure 2. Reaction Bracket Removal
Figure 3. Reaction Bracket Installation
Figure 4. Rear Guide Installation
Figure 5. Rear Guide Adjustment
FRONT ROLLER ASSEMBLY REPLACEMENT
Figure 2. Front Roller Assembly Installation
FRONT ROLLER ASSEMBLY REPLACEMENT - Continued
REAR ROLLER ASSEMBLY REPLACEMENT
Figure 2. Rear Roller Assembly Installation.
REAR ROLLER ASSEMBLY REPLACEMENT - Continued
REAR BUMPER ASSEMBLY REPLACEMENT
Figure 2. Rear Bumper Assembly Installation.
TRANSLOAD ROLLER REPLACEMENT
Figure 2. Transload Roller Removal.
Figure 3. Transload Roller Pin Removal.
Figure 4. Transload Roller Pin Installation.
Figure 6. Quick Release Pin Installation.
REFLECTOR REPLACEMENT
Figure 2. Left Front Amber Reflector Removal.
Figure 4. Red Reflector Installation
Figure 6. Front Amber Reflector Installation
LABEL REPLACEMENT
Figure 1. Label Removal. (Sheet 1 of 2)
Figure 1. Label Removal. (Sheet 2 of 2)
Figure 2. Label Installation. (Sheet 1 of 2)
Figure 2. Label Installation. (Sheet 2 of 2)
FRONT PIN LOCK ASSEMBLY ADJUSTMENT AND REPAIR
Figure 1. Air Hose Removal
Figure 3. BAP Front Pin Lock Guide Assembly Disassembly.
Figure 4. BAP Front Pin Lock Assembly Disassembly.
Figure 5. BAP Front Pin Disassembly.
Figure 6. BAP Front Pin Lock Assembly Inspection.
Figure 8. BAP Front Pin Lock Assembly
Figure 9. BAP Front Pin Lock Guide Assembly.
Figure 10. BAP Front Pin Lock Assembly Installation
LABEL REPLACEMENT - Continued
SHEAVE ASSEMBLY REPAIR
Figure 1. Roller Assembly Removal.
Figure 2. Sheave Assembly Removal
Figure 3. Sheave Assembly Installation.
Figure 4. Roller Assembly Installation.
WINCH FRAME LOCKING LEVER OUTBOARD RETAINER BLOCKS FIELD REPLACEMENT
Figure 2. Winch Frame Locking Lever Outboard Retainer Blocks Field Installation
Figure 4. Winch Frame Locking Lever Outboard Retainer Blocks Field Installation.
WINCH HYDRAULIC SYSTEM REPLACEMENT
Figure 1. Winch Quick Disconnect Removal.
Figure 2. Winch Hydraulic Tube Bracket Removal.
Figure 3. Winch Hydraulic Tubes Removal.
WINCH HYDRAULIC SYSTEM REPLACEMENT - Continued
Figure 4. Winch Quick Disconnect Bracket Removal.
Figure 5. Winch Quick Disconnect Bracket Installation
Figure 6. Winch Hydraulic Tubes Installation.
WINCH HYDRAULIC SYSTEM REPLACEMENT - Continued
Figure 7. Winch Hydraulic Tube Bracket Installation.
Figure 8. Winch Quick Disconnect Installation
WINCH HYDRAULIC SYSTEM REPLACEMENT - Continued
WINCH CABLE TENSIONER REPAIR
Figure 1. Retainer Bar and Cable Assembly Removal.
Figure 2. Base Assembly Removal
Figure 3. Handle Assembly Removal.
Figure 4. Spring and U-bolt Removal
Figure 5. Spring and U-bolt Installation.
Figure 6. Handle Assembly Installation
Figure 7. Base Assembly Installation.
Figure 8. Retainer Bar and Cable Assembly Installation.
CABLE ASSEMBLY REPLACEMENT
Figure 1. Cable Anchor Removal.
Figure 2. Cable Assembly Removal
Figure 4. Cable Assembly.
Figure 5. Cable Assembly Installation.
CABLE ASSEMBLY REPLACEMENT - Continued
WINCH ASSEMBLY REPLACEMENT
Figure 1. Drain Winch
Figure 2. Upper Cable guide Shaft Removal.
Figure 3. Lower Cable Guide Shaft Removal
Figure 4. Pivot Plates Removal.
Figure 5. Winch Assembly Removal.
Figure 6. Winch Assembly Installation
Figure 7. Pivot Plates Installation
Figure 8. Lower Cable Guide Shaft Installation
Figure 9. Upper Cable Guide Shaft Installation.
Figure 11. Winch Tubes Installation
WINCH MOTOR ASSEMBLY REPLACEMENT
Figure 1. Winch Motor Tubes Removal.
Figure 2. Winch Motor Assembly Removal
Figure 3. Winch Motor Assembly Installation.
Figure 4. Winch Motor Tubes Installation
WINCH MOTOR ASSEMBLY REPLACEMENT - Continued
CENTER ROLLER HYDRAULIC SYSTEM REPAIR
Figure 1. Center Roller Hydraulic System Pressure Relief.
Figure 3. Rear Carriage Removal
Figure 4. Manifold Removal.
Figure 5. Manifold Installation
Figure 6. Rear Carriage Installation.
CENTER ROLLER HYDRAULIC SYSTEM REPAIR - Continued
TRANSLOAD ROLLER HYDRAULIC SYSTEM REPAIR
Figure 1. Transload Roller Hydraulic System Guard Plate Removal
Figure 2. Transload Roller Hydraulic System Hose Removal.
Figure 4. Transload Roller Hydraulic Cylinder Removal.
Figure 5. Transload Roller Hydraulic System Cushion Clamps Removal.
Figure 6. Transload Roller Hydraulic System Cushion Clamps Installation.
Figure 8. Transload Roller Hydraulic System Tube Installation.
Figure 10. Transload Roller Hydraulic System Fittings Installation
Figure 11. Transload Roller Hydraulic System Guard Plate Installation.
HYDRAULIC HAND PUMP REPLACEMENT
Figure 1. Hydraulic Hand Pump Removal.
Figure 2. Hydraulic Hand Pump Installation.
Figure 3. Hydraulic Hand Pump Bleeding
CONTROL VALVE REPLACEMENT
Figure 1. Control Valve Removal.
CONTROL VALVE REPLACEMENT - Continued
Figure 2. Control Valve Installation
CONTROL VALVE REPLACEMENT - Continued
AIR LINES AND FITTINGS REPLACEMENT (OLD CONFIGURATION)
Figure 1. Tubing Removal.
AIR LINES AND FITTINGS REPLACEMENT (OLD CONFIGURATION) - Continued
Figure 2. Tube Nuts Removal
AIR LINES AND FITTINGS REPLACEMENT (OLD CONFIGURATION) - Continued
Figure 3. Tube Nuts Installation.
Figure 4. Tubing Installation.
AIR LINES AND FITTINGS REPLACEMENT (OLD CONFIGURATION) - Continued
AIR LINES AND FITTINGS REPLACEMENT (NEW CONFIGURATION)
Figure 1. Clamp and Tubing Removal
AIR LINES AND FITTINGS REPLACEMENT (NEW CONFIGURATION) - Continued
Figure 2. Adapter and Tube Nuts Removal.
AIR LINES AND FITTINGS REPLACEMENT (NEW CONFIGURATION) - Continued
Figure 3. Adapter and Clamps installation
AIR LINES AND FITTINGS REPLACEMENT (NEW CONFIGURATION) - Continued
Figure 4. Coupling and Hose Installation.
AIR LINES AND FITTINGS REPLACEMENT (NEW CONFIGURATION) - Continued
FRONT BAP LOCK REPLACEMENT
Figure 1. Front BAP Lock Bracket Removal
Figure 2. Front BAP Lock Handle Removal.
Figure 3. Front BAP Lock Removal.
Figure 4. Front BAP Lock Rubber Stop Removal
Figure 6. Front BAP Lock Installation.
FRONT BAP LOCK REPLACEMENT - Continued
Figure 7. Front BAP Lock Handle Installation
Figure 8. Front BAP Lock Bracket Installation
REMOTE CONTROL UNIT REPAIR
Figure 2. Remote Control Unit Disassembly
Figure 3. Remote Control Unit Disassembly.
Figure 4. Remote Control Unit Disassembly.
igure 5. Remote Control Unit Disassembly.
Figure 6. Remote Control Unit Assembly
Figure 7. Remote Control Unit Assembly.
Figure 8. Remote Control Unit Assembly
Figure 9. Remote Control Unit Assembly
Figure 10. Remote Control Unit Assembly.
WINCH REPAIR
Figure 1. Brake Hub Assembly Removal.
Figure 2. Brake Hub Subassembly Removal
FINAL DRIVE ASSEMBLY REMOVAL
Figure 3. Final Drive Assembly Removal.
Figure 4. Brake Housing Removal.
Figure 5. Cable Drum Assembly Removal.
Figure 6. Final Housing Removal
Figure 7. Final Housing Installation
Figure 8. Cable Drum Assembly Installation.
Figure 9. Brake Housing Installation
Figure 10. Final Drive Assembly Installation.
Figure 11. Brake Hub Subassembly Assembly
Figure 12. Brake Hub Assembly Installation.
BRAKE HUB ASSEMBLY INSTALLATION
PREPARATION FOR STORAGE OR SHIPMENT
PREPARATION OF EQUIPMENT FOR ADMINISTRATIVE STORAGE - Continued
CARE OF EQUIPMENT IN ADMINISTRATIVE STORAGE
STORAGE MAINTENANCE PROCEDURES - Continued
PREPARATION OF EQUIPMENT FOR SHIPMENT
LUBRICATION INSTRUCTIONS
LUBRICATION CHART
Figure 1. Monthly Lubrication Intervals
Figure 2. Semiannual Lubrication Intervals.
Figure 3. Localized Views of Lubrication Points. (Sheet 1 of 5)
ure 3. Localized Views of Lubrication Points. (Sheet 2 of 5)
Figure 3. Localized Views of Lubrication Points. (Sheet 3 of 5)
Figure 3. Localized Views of Lubrication Points. (Sheet 4 of 5)
Figure 3. Localized Views of Lubrication Points. (Sheet 5 of 5)
Table 1. Lubricant Requirements
Table 2. Notes
Table 2. Notes - Continued.
GENERAL TORQUE LIMITS
Figure 3. Capscrew Head Markings.
Table 2. Torque Limits for Wet Socket Head Capscrews
Table 3. Torque Limits for Dry Fasteners - Continued.
Table 4. Torque Limits for Dry Metric Fasteners.
Table 5. Torque Limits for Wet Fasteners.
Table 5. Torque Limits for Wet Fasteners - Continued
CHAPTER 7. FIELD MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST
FIELD MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST INTRODUCTION
Table 2. Source Code 1st and 2nd Positions.
Table 2. Source Code 1st and 2nd Positions - Continued.
Table 4. Maintenance Code 4th Position.
Table 5. Recoverability Code 5th Position - Continued
Table 6. Usable On Code.
REPAIR PARTS AND SPECIAL TOOLS LIST
Figure 1. CATWALKS
Figure 1. CATWALKS - Continued
Figure 2. TOOL BOX ASSEMBLY
Figure 2. TOOL BOX ASSEMBLY - Continued
Figure 3. PLS FOOT
Figure 3. PLS FOOT - Continued
Figure 4. CENTER ROLLERS
Figure 4. CENTER ROLLERS - Continued
Figure 5. REAR GUIDE
Figure 5. REAR GUIDE - Continued
Figure 5. REAR GUIDE - Continued
Figure 6. FRONT AND REAR ROLLER ASSEMBLIES
Figure 6. FRONT AND REAR ROLLER ASSEMBLIES - Continued
Figure 7. REAR BUMPER ASSEMBLY (OLDER MODELS ONLY)
Figure 7. REAR BUMPER ASSEMBLY (OLDER MODELS ONLY) - Continued
Figure 8. GUARD PLATE AND TRANSLOAD ROLLER
Figure 8. GUARD PLATE AND TRANSLOAD ROLLER - Continued
Figure 9. REFLECTORS
Figure 9. REFLECTORS - Continued
Figure 10. BAP LABELS
Figure 10. BAP LABELS - Continued
Figure 11. FRONT TRUNNION
Figure 11. FRONT TRUNNION - Continued
Figure 11. FRONT TRUNNION - Continued
Figure 12. SHEAVE ASSEMBLY
Figure 12. SHEAVE ASSEMBLY - Continued
Figure 13. CABLE TENSIONER
Figure 13. CABLE TENSIONER - Continued
Figure 14. WINCH HYDRAULIC LINES
Figure 14. WINCH HYDRAULIC LINES - Continued
Figure 14. WINCH HYDRAULIC LINES - Continued
Figure 15. WINCH CABLE ASSEMBLY
Figure 15. WINCH CABLE ASSEMBLY - Continued
Figure 16. WINCH ASSEMBLY
Figure 16. WINCH ASSEMBLY - Continued
Figure 17. WINCH MOTOR ASSEMBLY
Figure 17. WINCH MOTOR ASSEMBLY - Continued
Figure 18. WINCH PRIMARY AND SECONDARY DRIVES
Figure 18. WINCH PRIMARY AND SECONDARY DRIVES - Continued
Figure 19. WINCH FINAL DRIVE ASSEMBLY
Figure 19. WINCH FINAL DRIVE ASSEMBLY - Continued
Figure 20. WINCH BRAKE HUB ASSEMBLY
Figure 20. WINCH BRAKE HUB ASSEMBLY - Continued
Figure 21. WINCH BRAKE HUB SUBASSEMBLY
Figure 21. WINCH BRAKE HUB SUBASSEMBLY - Continued
Figure 22. BAP HYDRAULIC INSTALLATION
Figure 22. BAP HYDRAULIC INSTALLATION - Continued
Figure 22. BAP HYDRAULIC INSTALLATION - Continued
Figure 23. HYDRAULIC HAND PUMP
Figure 23. HYDRAULIC HAND PUMP - Continued
Figure 24. BAP AIR LINES INSTALLATION (Sheet 1 of 2)
Figure 24. BAP AIR LINES INSTALLATION (Sheet 2 of 2)
Figure 24. BAP AIR LINES INSTALLATION - Continued
Figure 24. BAP AIR LINES INSTALLATION - Continued
Figure 24. BAP AIR LINES INSTALLATION - Continued
Figure 25. FRONT BAP LOCK
Figure 25. FRONT BAP LOCK - Continued
Figure 26. REMOTE CONTROL UNIT
Figure 26. REMOTE CONTROL UNIT - Continued
Figure KITS. REPAIR KITS
Figure KITS. REPAIR KITS - Continued
Figure BULK. BULK MATERIAL
Figure BULK. BULK MATERIAL - Continued
NATIONAL STOCK NUMBER INDEX
NATIONAL STOCK NUMBER INDEX - Continued
NATIONAL STOCK NUMBER INDEX - Continued
NATIONAL STOCK NUMBER INDEX - Continued
NATIONAL STOCK NUMBER INDEX - Continued
PART NUMBER INDEX
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
CHAPTER 8. SUPPORTING INFORMATION
REFERENCES
REFERENCES - Continued
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - Continued
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - Continued
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - Continued
Table 1. MAINTENANCE ALLOCATION CHART (MAC)
Table 1. MAINTENANCE ALLOCATION CHART (MAC) - Continued
Table 2. TOOLS AND TEST EQUIPMENT
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
Table 1. Basic Issue Items (BII)
ADDITIONAL AUTHORIZATION LIST
EXPENDABLE AND DURABLE ITEMS LIST
Table 1. EXPENDABLE AND DURABLE ITEMS
Table 1. EXPENDABLE AND DURABLE ITEMS - Continued
MANDATORY REPLACEMENT PARTS
Table 1. MANDATORY REPLACEMENT PARTS LIST - Continued
Table 1. MANDATORY REPLACEMENT PARTS LIST - Continued
Table 1. MANDATORY REPLACEMENT PARTS LIST - Continued
GENERAL INFORMATION
PREPARATION FOR STORAGE OR SHIPMENT
Table 2. List of Abbreviations and Acronyms - Continued
Table 2. List of Abbreviations and Acronyms - Continued
EQUIPMENT DESCRIPTION AND DATA
Figure 1. BAP Components
Figure 2. BAP Locks and Rollers
Table 4. The BAP (Empty)
THEORY OF OPERATION
CHAPTER 2. OPERATOR INSTRUCTIONS FOR M15 BRIDGE ADAPTER PALLET (BAP) NSN 3990-01-442-1939
LOCATION AND USE OF CONTROLS AND INDICATORS
Figure 2. Analog and Digital Control Panels.
Figure 3. LHS Remote Control Unit
Figure 4. Main Hydraulic Manifold.
Figure 5. Free-Flow Valve.
Figure 6. Hydraulic Hand Pump.
Table 1. Load Handling System (LHS) Cab Controls and Indicators - Continued
LOADING BRIDGE ADAPTER PALLET (BAP) FROM THE GROUND
Figure 1. Lock Winch Frame to BAP.
Figure 2. Stow Air Line
Figure 3. Checking Front Pin Locks and Rear Guides.
Figure 4. Stowing Hydraulic Hoses
Figure 6. Cab LHS Controls
OPERATION - Continued
Figure 7. Cab LHS Controls
Figure 8. Checking BAP Hold Down Locks.
UNLOADING BRIDGE ADAPTER PALLET (BAP) TO THE GROUND
Figure 1. Brake and Transmission Controls.
Figure 2. Lock Winch Frame to BAP
Figure 3. Disconnect Hydraulic Hoses
Figure 5. Stow Air Line
Figure 6. Checking Front Pin Locks and Rear Guides.
Figure 8. Cab LHS Controls
Figure 9. Cab LHS Controls
OPERATION - Continued
LOADING BRIDGE BAY FROM THE GROUND
Figure 1. Brake and Transmission Controls.
Figure 2. Setting BAP Hold Down Locks.
Figure 4. Lock Winch Frame to LHS Hook Arm
Figure 5. Setting Front Pin Locks
Figure 7. Cab LHS Controls
Figure 8. Picking Up Bridge Bay
LOADING BRIDGE BAY FROM THE GROUND - Continued
Figure 9. Parking Brake Control.
Figure 10. Stowing Winch Cable
Figure 11. Cab and Remote Control Unit Controls.
LOADING BRIDGE BAY FROM THE GROUND - Continued
Figure 12. Stow Remote Control Unit
UNLOADING BRIDGE BAY TO THE GROUND
Figure 1. Position BAP Locks.
Figure 2. Lock Winch Frame to Hook Arm.
Figure 3. Connect Hydraulic Hoses.
Figure 4. Connect Remote Control Unit
Figure 5. Cab Controls
Figure 6. Check and Set Winch Cable Tension
Figure 8. Front Pin Locks
Figure 9. Rear Guides.
Figure 10. Unload Hook Arm
Figure 11. Lowering Bridge Bay to the Ground.
UNLOADING BRIDGE BAY TO THE GROUND - Continued
Figure 12. Stowing Winch Cable
Figure 13. PTO Engage Switch
Figure 14. Stowing Remote Control Unit
Figure 15. Setting Front Pin Locks.
Figure 16. Stowing Rear Guides.
BRIDGE BAY LAUNCHING INTRODUCTION
BRIDGE BAY LAUNCHING INTRODUCTION - Continued
CONTROLLED BRIDGE BAY LAUNCH
Figure 1. Check BAP Hold Down Locks
Figure 2. Lock Winch Frame to LHS Hook Arm
Figure 3. Connect Hydraulic Hoses.
Figure 4. Cab LHS Controls
Figure 5. Connect Remote Control Unit.
Figure 6. Check Winch Cable Hook
Figure 7. Release Bridge Bay Latches
Figure 8. Release Front Pin Locks
Figure 10. Open Rear Guides.
Figure 11. Brake and Transmission Controls.
Figure 12. Launch Bridge Bay.
Figure 13. Brake and Transmission Controls.
Figure 14. Stow Winch Cable Hook.
Figure 15. Cab LHS Controls.
Figure 16. Stow Remote Control Unit.
Figure 17. Secure Front Pin Locks
CONTROLLED BRIDGE BAY LAUNCH - Continued
BRIDGE BAY FREE LAUNCH
BRIDGE BAY FREE LAUNCH - Continued
Figure 1. Cab LHS Controls
Figure 2. Check Front Pin Locks
Figure 3. Connect Remote Control Unit
Figure 4. Attach Lanyard to Air Release Valve.
Figure 5. Connect Air Hose
Figure 6. Position Rear Guides
Figure 7. Center Roller Location
Figure 8. Position Center Roller.
Figure 9. Remote Control Unit
Figure 10. Lock Winch Frame to BAP
Figure 11. Release IRB Foldlock Latches
Figure 13. Stow Remote Control Unit.
Figure 14. Brake and Transmission Controls.
Figure 15. Release Front Pin Locks
Figure 16. Cab LHS Controls.
Figure 17. Remove Lanyard
Figure 18. Lock Air Release Valve
Figure 20. Disengage Front Pin Locks.
Figure 22. Lower Center Roller
CALM OR FAST WATER BRIDGE BAY RETRIEVAL
Figure 1. Setting BAP Locks.
Figure 2. Lock Winch Frame to LHS Hook Arm
Figure 3. Connect Hydraulic Hoses.
Figure 4. Position Front Pin Locks
Figure 6. Connect Remote Control Unit.
Figure 7. Cab LHS Controls
Figure 8. Remote Control Unit Controls.
Figure 9. Brake and Transmission Controls.
Figure 10. Engage IRB Foldlock Latches
Figure 11. Remote Control Unit Controls.
Figure 12. Brake and Transmission Controls.
Figure 13. Remote Control Unit Controls.
Figure 14. Cab LHS Controls.
Figure 15. Stow Remote Control Unit
NORMAL TRANSFER OF BRIDGE ADAPTER PALLET (BAP) FROM VEHICLE TO TRAILER
Figure 1. Retract Trailer Locks.
Figure 3. Lock Winch Frame to BAP
Figure 4. Unlock BAP from CBT.
Figure 6. Position Transload Rollers
Figure 8. Cab LHS Controls and Initial Contact with Trailer
NORMAL TRANSFER OF BRIDGE ADAPTER PALLET (BAP) FROM VEHICLE TO TRAILER - Continued
Figure 9. Cab LHS Controls and Final Stopping Point on Trailer
Figure 10. Lower BAP to Trailer.
Figure 12. Cab LHS Controls and Hook Disengage
NORMAL TRANSFER OF BRIDGE ADAPTER PALLET (BAP) FROM VEHICLE TO TRAILER - Continued
NORMAL TRANSFER OF BRIDGE ADAPTER PALLET (BAP) FROM TRAILER TO VEHICLE
Figure 1. Brake and Transmission Controls.
Figure 2. Lock Winch Frame to BAP
Figure 4. Position BAP Hold Down Locks
Figure 5. Disengage Trailer Locks
Figure 7. Cab LHS Controls
Figure 8. Trailer Bumper Point and Vehicle Bump Plate.
Figure 9. Cab LHS Controls and Bail Bar Lock.
NORMAL TRANSFER OF BRIDGE ADAPTER PALLET (BAP) FROM TRAILER TO VEHICLE - Continued
Figure 10. Stow Transload Rollers.
NORMAL TRANSFER OF BRIDGE ADAPTER PALLET (BAP) FROM TRAILER TO VEHICLE - Continued
BAP HOLD-DOWN LOCKS CHECKLIST
Figure 1. BAP Hold-Down Locks Checklist
Table 2. BAP Hold-Down Locks Checklist
Figure 2. BAP Hold-Down Locks Checklist
DECALS AND INSTRUCTION PLATES
Figure 1. Decal and Instruction Plate Locations. (Sheet 1 of 2)
Figure 1. Decal and Instruction Plate Locations. (Sheet 2 of 2)
MANUALLY LOADING BRIDGE ADAPTER PALLET (BAP) FROM THE GROUND
Figure 2. Check Hold-Down Locks
Figure 3. Cab LHS Controls
MANUALLY LOADING BRIDGE ADAPTER PALLET (BAP) FROM THE GROUND - Continued
Figure 4. Check BAP Hold-Down Locks.
MANUALLY UNLOADING BRIDGE ADAPTER PALLET (BAP) TO THE GROUND
Figure 3. Position Vehicle.
Figure 4. Disengage Locks.
Figure 5. Manually Unload BAP to the Ground.
MANUALLY UNLOADING BRIDGE ADAPTER PALLET (BAP) TO THE GROUND - Continued
MANUALLY UNLOADING BRIDGE ADAPTER PALLET (BAP) TO THE GROUND - Continued
MANUALLY BYPASSING SOLENOID DURING ELECTRIC POWER LOSS
Figure 2. Instructional Placard
Figure 4. Valve Plunger Tool
PREPARATION FOR EMERGENCY MANUAL REMOVAL OF BRIDGE ADAPTER PALLET (BAP)
Figure 1. Winch Frame Locking Levers.
Figure 3. Release BAP Hold Down Locks.
Figure 4. Lift Points and Bail Bar Lock
PREPARATION FOR EMERGENCY MANUAL REMOVAL OF BRIDGE ADAPTER PALLET (BAP) - Continued
MANUALLY REMOVING LOAD DURING HYDRAULIC POWER LOSS
Figure 2. Disconnect Hoses from Operable Vehicle.
Figure 4. Connect Hoses to Operable Vehicle
Figure 6. Return LHS to the Stowed Position.
Figure 8. Open M1977 A2 Cover
Figure 10. Set Cab Switches
Figure 11. Disconnect Hoses to Operable Vehicle.
Figure 13. Connect Hoses to Disabled Vehicle
Figure 15. Install M1977 A2 LHS Control Box Cover.
CHEMICAL, BIOLOGICAL, RADIOLOGICAL, AND NUCLEAR (CBRN) DECONTAMINATION PROCEDURES
CHEMICAL, BIOLOGICAL, RADIOLOGICAL, AND NUCLEAR (CBRN) DECONTAMINATION PROCEDURES - Continued
CHAPTER 3. OPERATOR TROUBLESHOOTING PROCEDURES
CENTER ROLLER AND/OR TRANSLOAD ROLLERS WILL NOT OPERATE
Figure 1. Hand Pump Selector Lever.
Figure 2. Hand Pump Selector Lever and Center Roller Assembly.
Figure 3. Hand Pump Selector Lever and Transload Roller Extension Cylinders
FRONT PIN LOCK AIR RELEASE WILL NOT OPERATE DURING LAUNCH OF BRIDGE BAY
FRONT PIN LOCK AIR RELEASE WILL NOT OPERATE DURING LAUNCH OF BRIDGE BAY - Continued
WINCH ASSEMBLY WILL NOT WIND OUT
Figure 2. BAP Winch Hydraulic System Quick-Disconnect Connectors
Figure 3. Remote Control Unit.
WINCH ASSEMBLY WILL NOT WIND IN
Figure 2. BAP Winch Hydraulic System Quick-Disconnect Connectors
Figure 3. Remote Control Unit.
WINCH ASSEMBLY WILL NOT LIFT LOAD OR OPERATES SLOWLY
Figure 1. Winch Cable
WINCH ASSEMBLY WILL NOT LIFT LOAD OR OPERATES SLOWLY - Continued
Figure 4. Remote Control Unit
FRONT PIN LOCK WILL NOT ALIGN WITH BRIDGE BAY PIN
Figure 2. BAP Front Pin Lock
CHAPTER 4. FIELD TROUBLESHOOTING PROCEDURES
CENTER ROLLER AND/OR TRANSLOAD ROLLERS WILL NOT OPERATE
Figure 1. Roller Hydraulic Hoses/Lines.
Figure 2. Hand Pump
Figure 3. Center Roller Manifold and Cylinders
Figure 4. Transload Roller Manifold and Cylinders.
FRONT PIN LOCK WILL NOT OPERATE
Figure 1. Air Supply Hose.
Figure 2. Control Valve.
Figure 3. Control Valve Outlet Ports.
Figure 4. Air Cylinder.
Figure 5. Control Valve Lever
Figure 6. Air Cylinder Breather
Figure 7. Latch Handle.
WINCH DOES NOT OPERATE
Figure 1. Winch Quick-Disconnect Couplings (Model A Shown).
Figure 3. Access Cover, Connector J2, and Connector P2.
Figure 4. Cab Digital Mode Select Switch.
Figure 5. Hydraulic Cabinet Cover.
Figure 7. Connector P2.
Figure 8. Connector J3.
Figure 9. WINCH IN Valve and Solenoid.
Figure 10. WINCH OUT Valve and Solenoid.
WINCH DOES NOT WIND OUT
Figure 1. Winch Quick-Disconnect Couplings (Model A Shown).
Figure 3. Left (Connector J8A) and Right (Connector J8B) Remote Locations.
Figure 4. Remote Control Unit
Figure 5. Remote Control Cable Connectors P8 And P9.
Figure 6. Left (Connector J8A) and Right (Connector J8B) Remote Locations
Figure 8. Left (Connector J8A) and Right (Connector J8B) Remote Locations.
Figure 9. Main Frame Junction Box (Wiring Removed For Clarity).
Figure 10. WINCH OUT Solenoid Connector.
Figure 11. Main Frame Junction Box (Wiring Removed For Clarity).
Figure 12. Cab Interface Wiring Harness Access Cover.
WINCH DOES NOT WIND OUT - Continued
Figure 14. Hydraulic Cabinet Cover, WINCH OUT Solenoid Connector, and Connector J4.
Figure 15. Connector P2.
Figure 16. WINCH OUT Solenoid Connector and Connector J3.
Figure 17. WINCH OUT Solenoid Connector.
WINCH DOES NOT WIND IN
Figure 1. Winch Quick-Disconnect Couplings (Model A Shown).
Figure 3. Left (Connector J8A) And Right (Connector J8B) Remote Locations.
Figure 4. Remote Control Unit
Figure 5. Remote Control Cable Connectors P8 And P9.
Figure 6. Left (Connector J8A) and Right (Connector J8B) Remote Locations
WINCH DOES NOT WIND IN - Continued
Figure 9. Main Frame Junction Box (Wiring Removed For Clarity).
Figure 10. WINCH IN Solenoid Connector.
Figure 11. Main Frame Junction Box (Wiring Removed For Clarity).
Figure 12. Cab Interface Wiring Harness Access Cover.
Figure 14. Hydraulic Cabinet Cover, WINCH OUT Solenoid Connector, and Connector J4
Figure 15. Connector P2
Figure 16. WINCH IN Solenoid Connector and Connector J3.
WINCH DOES NOT WIND IN - Continued
Figure 17. WINCH IN Solenoid Connector.
CHAPTER 5 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
GENERAL MAINTENANCE PROCEDURES
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 1. Operator Preventive Maintenance Checks and Services - Continued
Table 1. Operator Preventive Maintenance Checks and Services - Continued
Table 1. Operator Preventive Maintenance Checks and Services - Continued
Table 1. Operator Preventive Maintenance Checks and Services - Continued
Figure 6. Control Valve.
Figure 8. Center Roller.
Figure 9. Rear Guide Assemblies
Figure 11. Winch Cable.
Figure 12. Remote Control Unit
Figure 14. Main Frame Switch.
Figure 15. Winch Switch
Figure 16. Disconnect Remote Control Unit.
Figure 17. Front Pin Locks.
Figure 19. Rear Rollers.
FIELD LEVEL PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Figure 1. Catwalk.
Figure 2. BAP Frame Assembly.
Figure 4. Winch Assembly.
Figure 6. Hand Pump.
Figure 7. Hand Pump Hydraulic System
Figure 8. Rear Guide Assembly.
Figure 9. BAP Labels.
Figure 10. Winch Assembly Drain.
CHAPTER 6. MAINTENANCE INSTRUCTIONS
CHAPTER CONTENTS - Continued
SERVICE UPON RECEIPT
PRELIMINARY SERVICING OF EQUIPMENT - Continued
GENERAL MAINTENANCE AND WELDING INSTRUCTIONS
GENERAL CLEANING INSTRUCTIONS
GENERAL CLEANING INSTRUCTIONS - Continued
GENERAL INSPECTION INSTRUCTIONS
GENERAL REPAIR INSTRUCTIONS
GENERAL INSTALLATION INSTRUCTIONS
Figure 1. General Air Tubing Repair
Figure 2. A-Frame
Figure 3. Outriggers and Main Rails.
Main Frame Structure
Figure 4. Winch Frame.
Table 1. Weld Joint Materials
Table 1. Weld Joint Materials - Continued
PLS FOOT STOWAGE
Figure 2. PLS Foot Stowage
Figure 3. PLS Hitch Pin Installation
STENCILS
STENCILS - Continued
CATWALK REPLACEMENT
Figure 1. Catwalk Locations.
Figure 2. Hydraulic Tubes Removal
Figure 3. Catwalk Removal.
Figure 4. Tube Support Removal
Figure 5. Tube Support Installation
Figure 6. Catwalk Installation.
Figure 7. Hydraulic Tubes Installation.
PLUNGER REPLACEMENT
Figure 2. Plunger Installation.
TOOLBOX ASSEMBLY REPAIR
Figure 2. Toolbox Disassembly.
Figure 3. Toolbox Assembly.
Figure 4. Toolbox Assembly Installation.
CENTER ROLLER REPAIR
Figure 2. Center Roller Installation
CENTER ROLLER REPAIR - Continued
REAR GUIDE REPAIR
Figure 1. Rear Guide Removal
Figure 2. Reaction Bracket Removal
Figure 3. Reaction Bracket Installation
Figure 4. Rear Guide Installation
Figure 5. Rear Guide Adjustment
FRONT ROLLER ASSEMBLY REPLACEMENT
Figure 2. Front Roller Assembly Installation
FRONT ROLLER ASSEMBLY REPLACEMENT - Continued
REAR ROLLER ASSEMBLY REPLACEMENT
Figure 2. Rear Roller Assembly Installation.
REAR ROLLER ASSEMBLY REPLACEMENT - Continued
REAR BUMPER ASSEMBLY REPLACEMENT
Figure 2. Rear Bumper Assembly Installation.
TRANSLOAD ROLLER REPLACEMENT
Figure 2. Transload Roller Removal.
Figure 3. Transload Roller Pin Removal.
Figure 4. Transload Roller Pin Installation.
Figure 6. Quick Release Pin Installation.
REFLECTOR REPLACEMENT
Figure 2. Left Front Amber Reflector Removal.
Figure 4. Red Reflector Installation
Figure 6. Front Amber Reflector Installation
LABEL REPLACEMENT
Figure 1. Label Removal. (Sheet 1 of 2)
Figure 1. Label Removal. (Sheet 2 of 2)
Figure 2. Label Installation. (Sheet 1 of 2)
Figure 2. Label Installation. (Sheet 2 of 2)
FRONT PIN LOCK ASSEMBLY ADJUSTMENT AND REPAIR
Figure 1. Air Hose Removal
Figure 3. BAP Front Pin Lock Guide Assembly Disassembly.
Figure 4. BAP Front Pin Lock Assembly Disassembly.
Figure 5. BAP Front Pin Disassembly.
Figure 6. BAP Front Pin Lock Assembly Inspection.
Figure 8. BAP Front Pin Lock Assembly
Figure 9. BAP Front Pin Lock Guide Assembly.
Figure 10. BAP Front Pin Lock Assembly Installation
LABEL REPLACEMENT - Continued
SHEAVE ASSEMBLY REPAIR
Figure 1. Roller Assembly Removal.
Figure 2. Sheave Assembly Removal
Figure 3. Sheave Assembly Installation.
Figure 4. Roller Assembly Installation.
WINCH FRAME LOCKING LEVER OUTBOARD RETAINER BLOCKS FIELD REPLACEMENT
Figure 2. Winch Frame Locking Lever Outboard Retainer Blocks Field Installation
Figure 4. Winch Frame Locking Lever Outboard Retainer Blocks Field Installation.
WINCH HYDRAULIC SYSTEM REPLACEMENT
Figure 1. Winch Quick Disconnect Removal.
Figure 2. Winch Hydraulic Tube Bracket Removal.
Figure 3. Winch Hydraulic Tubes Removal.
WINCH HYDRAULIC SYSTEM REPLACEMENT - Continued
Figure 4. Winch Quick Disconnect Bracket Removal.
Figure 5. Winch Quick Disconnect Bracket Installation
Figure 6. Winch Hydraulic Tubes Installation.
WINCH HYDRAULIC SYSTEM REPLACEMENT - Continued
Figure 7. Winch Hydraulic Tube Bracket Installation.
Figure 8. Winch Quick Disconnect Installation
WINCH HYDRAULIC SYSTEM REPLACEMENT - Continued
WINCH CABLE TENSIONER REPAIR
Figure 1. Retainer Bar and Cable Assembly Removal.
Figure 2. Base Assembly Removal
Figure 3. Handle Assembly Removal.
Figure 4. Spring and U-bolt Removal
Figure 5. Spring and U-bolt Installation.
Figure 6. Handle Assembly Installation
Figure 7. Base Assembly Installation.
Figure 8. Retainer Bar and Cable Assembly Installation.
CABLE ASSEMBLY REPLACEMENT
Figure 1. Cable Anchor Removal.
Figure 2. Cable Assembly Removal
Figure 4. Cable Assembly.
Figure 5. Cable Assembly Installation.
CABLE ASSEMBLY REPLACEMENT - Continued
WINCH ASSEMBLY REPLACEMENT
Figure 1. Drain Winch
Figure 2. Upper Cable guide Shaft Removal.
Figure 3. Lower Cable Guide Shaft Removal
Figure 4. Pivot Plates Removal.
Figure 5. Winch Assembly Removal.
Figure 6. Winch Assembly Installation
Figure 7. Pivot Plates Installation
Figure 8. Lower Cable Guide Shaft Installation
Figure 9. Upper Cable Guide Shaft Installation.
Figure 11. Winch Tubes Installation
WINCH MOTOR ASSEMBLY REPLACEMENT
Figure 1. Winch Motor Tubes Removal.
Figure 2. Winch Motor Assembly Removal
Figure 3. Winch Motor Assembly Installation.
Figure 4. Winch Motor Tubes Installation
WINCH MOTOR ASSEMBLY REPLACEMENT - Continued
CENTER ROLLER HYDRAULIC SYSTEM REPAIR
Figure 1. Center Roller Hydraulic System Pressure Relief.
Figure 3. Rear Carriage Removal
Figure 4. Manifold Removal.
Figure 5. Manifold Installation
Figure 6. Rear Carriage Installation.
CENTER ROLLER HYDRAULIC SYSTEM REPAIR - Continued
TRANSLOAD ROLLER HYDRAULIC SYSTEM REPAIR
Figure 1. Transload Roller Hydraulic System Guard Plate Removal
Figure 2. Transload Roller Hydraulic System Hose Removal.
Figure 4. Transload Roller Hydraulic Cylinder Removal.
Figure 5. Transload Roller Hydraulic System Cushion Clamps Removal.
Figure 6. Transload Roller Hydraulic System Cushion Clamps Installation.
Figure 8. Transload Roller Hydraulic System Tube Installation.
Figure 10. Transload Roller Hydraulic System Fittings Installation
Figure 11. Transload Roller Hydraulic System Guard Plate Installation.
HYDRAULIC HAND PUMP REPLACEMENT
Figure 1. Hydraulic Hand Pump Removal.
Figure 2. Hydraulic Hand Pump Installation.
Figure 3. Hydraulic Hand Pump Bleeding
CONTROL VALVE REPLACEMENT
Figure 1. Control Valve Removal.
CONTROL VALVE REPLACEMENT - Continued
Figure 2. Control Valve Installation
CONTROL VALVE REPLACEMENT - Continued
AIR LINES AND FITTINGS REPLACEMENT (OLD CONFIGURATION)
Figure 1. Tubing Removal.
AIR LINES AND FITTINGS REPLACEMENT (OLD CONFIGURATION) - Continued
Figure 2. Tube Nuts Removal
AIR LINES AND FITTINGS REPLACEMENT (OLD CONFIGURATION) - Continued
Figure 3. Tube Nuts Installation.
Figure 4. Tubing Installation.
AIR LINES AND FITTINGS REPLACEMENT (OLD CONFIGURATION) - Continued
AIR LINES AND FITTINGS REPLACEMENT (NEW CONFIGURATION)
Figure 1. Clamp and Tubing Removal
AIR LINES AND FITTINGS REPLACEMENT (NEW CONFIGURATION) - Continued
Figure 2. Adapter and Tube Nuts Removal.
AIR LINES AND FITTINGS REPLACEMENT (NEW CONFIGURATION) - Continued
Figure 3. Adapter and Clamps installation
AIR LINES AND FITTINGS REPLACEMENT (NEW CONFIGURATION) - Continued
Figure 4. Coupling and Hose Installation.
AIR LINES AND FITTINGS REPLACEMENT (NEW CONFIGURATION) - Continued
FRONT BAP LOCK REPLACEMENT
Figure 1. Front BAP Lock Bracket Removal
Figure 2. Front BAP Lock Handle Removal.
Figure 3. Front BAP Lock Removal.
Figure 4. Front BAP Lock Rubber Stop Removal
Figure 6. Front BAP Lock Installation.
FRONT BAP LOCK REPLACEMENT - Continued
Figure 7. Front BAP Lock Handle Installation
Figure 8. Front BAP Lock Bracket Installation
REMOTE CONTROL UNIT REPAIR
Figure 2. Remote Control Unit Disassembly
Figure 3. Remote Control Unit Disassembly.
Figure 4. Remote Control Unit Disassembly.
igure 5. Remote Control Unit Disassembly.
Figure 6. Remote Control Unit Assembly
Figure 7. Remote Control Unit Assembly.
Figure 8. Remote Control Unit Assembly
Figure 9. Remote Control Unit Assembly
Figure 10. Remote Control Unit Assembly.
WINCH REPAIR
Figure 1. Brake Hub Assembly Removal.
Figure 2. Brake Hub Subassembly Removal
FINAL DRIVE ASSEMBLY REMOVAL
Figure 3. Final Drive Assembly Removal.
Figure 4. Brake Housing Removal.
Figure 5. Cable Drum Assembly Removal.
Figure 6. Final Housing Removal
Figure 7. Final Housing Installation
Figure 8. Cable Drum Assembly Installation.
Figure 9. Brake Housing Installation
Figure 10. Final Drive Assembly Installation.
Figure 11. Brake Hub Subassembly Assembly
Figure 12. Brake Hub Assembly Installation.
BRAKE HUB ASSEMBLY INSTALLATION
PREPARATION FOR STORAGE OR SHIPMENT
PREPARATION OF EQUIPMENT FOR ADMINISTRATIVE STORAGE - Continued
CARE OF EQUIPMENT IN ADMINISTRATIVE STORAGE
STORAGE MAINTENANCE PROCEDURES - Continued
PREPARATION OF EQUIPMENT FOR SHIPMENT
LUBRICATION INSTRUCTIONS
LUBRICATION CHART
Figure 1. Monthly Lubrication Intervals
Figure 2. Semiannual Lubrication Intervals.
Figure 3. Localized Views of Lubrication Points. (Sheet 1 of 5)
ure 3. Localized Views of Lubrication Points. (Sheet 2 of 5)
Figure 3. Localized Views of Lubrication Points. (Sheet 3 of 5)
Figure 3. Localized Views of Lubrication Points. (Sheet 4 of 5)
Figure 3. Localized Views of Lubrication Points. (Sheet 5 of 5)
Table 1. Lubricant Requirements
Table 2. Notes
Table 2. Notes - Continued.
GENERAL TORQUE LIMITS
Figure 3. Capscrew Head Markings.
Table 2. Torque Limits for Wet Socket Head Capscrews
Table 3. Torque Limits for Dry Fasteners - Continued.
Table 4. Torque Limits for Dry Metric Fasteners.
Table 5. Torque Limits for Wet Fasteners.
Table 5. Torque Limits for Wet Fasteners - Continued
CHAPTER 7. FIELD MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST
FIELD MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST INTRODUCTION
Table 2. Source Code 1st and 2nd Positions.
Table 2. Source Code 1st and 2nd Positions - Continued.
Table 4. Maintenance Code 4th Position.
Table 5. Recoverability Code 5th Position - Continued
Table 6. Usable On Code.
REPAIR PARTS AND SPECIAL TOOLS LIST
Figure 1. CATWALKS
Figure 1. CATWALKS - Continued
Figure 2. TOOL BOX ASSEMBLY
Figure 2. TOOL BOX ASSEMBLY - Continued
Figure 3. PLS FOOT
Figure 3. PLS FOOT - Continued
Figure 4. CENTER ROLLERS
Figure 4. CENTER ROLLERS - Continued
Figure 5. REAR GUIDE
Figure 5. REAR GUIDE - Continued
Figure 5. REAR GUIDE - Continued
Figure 6. FRONT AND REAR ROLLER ASSEMBLIES
Figure 6. FRONT AND REAR ROLLER ASSEMBLIES - Continued
Figure 7. REAR BUMPER ASSEMBLY (OLDER MODELS ONLY)
Figure 7. REAR BUMPER ASSEMBLY (OLDER MODELS ONLY) - Continued
Figure 8. GUARD PLATE AND TRANSLOAD ROLLER
Figure 8. GUARD PLATE AND TRANSLOAD ROLLER - Continued
Figure 9. REFLECTORS
Figure 9. REFLECTORS - Continued
Figure 10. BAP LABELS
Figure 10. BAP LABELS - Continued
Figure 11. FRONT TRUNNION
Figure 11. FRONT TRUNNION - Continued
Figure 11. FRONT TRUNNION - Continued
Figure 12. SHEAVE ASSEMBLY
Figure 12. SHEAVE ASSEMBLY - Continued
Figure 13. CABLE TENSIONER
Figure 13. CABLE TENSIONER - Continued
Figure 14. WINCH HYDRAULIC LINES
Figure 14. WINCH HYDRAULIC LINES - Continued
Figure 14. WINCH HYDRAULIC LINES - Continued
Figure 15. WINCH CABLE ASSEMBLY
Figure 15. WINCH CABLE ASSEMBLY - Continued
Figure 16. WINCH ASSEMBLY
Figure 16. WINCH ASSEMBLY - Continued
Figure 17. WINCH MOTOR ASSEMBLY
Figure 17. WINCH MOTOR ASSEMBLY - Continued
Figure 18. WINCH PRIMARY AND SECONDARY DRIVES
Figure 18. WINCH PRIMARY AND SECONDARY DRIVES - Continued
Figure 19. WINCH FINAL DRIVE ASSEMBLY
Figure 19. WINCH FINAL DRIVE ASSEMBLY - Continued
Figure 20. WINCH BRAKE HUB ASSEMBLY
Figure 20. WINCH BRAKE HUB ASSEMBLY - Continued
Figure 21. WINCH BRAKE HUB SUBASSEMBLY
Figure 21. WINCH BRAKE HUB SUBASSEMBLY - Continued
Figure 22. BAP HYDRAULIC INSTALLATION
Figure 22. BAP HYDRAULIC INSTALLATION - Continued
Figure 22. BAP HYDRAULIC INSTALLATION - Continued
Figure 23. HYDRAULIC HAND PUMP
Figure 23. HYDRAULIC HAND PUMP - Continued
Figure 24. BAP AIR LINES INSTALLATION (Sheet 1 of 2)
Figure 24. BAP AIR LINES INSTALLATION (Sheet 2 of 2)
Figure 24. BAP AIR LINES INSTALLATION - Continued
Figure 24. BAP AIR LINES INSTALLATION - Continued
Figure 24. BAP AIR LINES INSTALLATION - Continued
Figure 25. FRONT BAP LOCK
Figure 25. FRONT BAP LOCK - Continued
Figure 26. REMOTE CONTROL UNIT
Figure 26. REMOTE CONTROL UNIT - Continued
Figure KITS. REPAIR KITS
Figure KITS. REPAIR KITS - Continued
Figure BULK. BULK MATERIAL
Figure BULK. BULK MATERIAL - Continued
NATIONAL STOCK NUMBER INDEX
NATIONAL STOCK NUMBER INDEX - Continued
NATIONAL STOCK NUMBER INDEX - Continued
NATIONAL STOCK NUMBER INDEX - Continued
NATIONAL STOCK NUMBER INDEX - Continued
PART NUMBER INDEX
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
CHAPTER 8. SUPPORTING INFORMATION
REFERENCES
REFERENCES - Continued
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - Continued
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - Continued
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - Continued
Table 1. MAINTENANCE ALLOCATION CHART (MAC)
Table 1. MAINTENANCE ALLOCATION CHART (MAC) - Continued
Table 2. TOOLS AND TEST EQUIPMENT
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
Table 1. Basic Issue Items (BII)
ADDITIONAL AUTHORIZATION LIST
EXPENDABLE AND DURABLE ITEMS LIST
Table 1. EXPENDABLE AND DURABLE ITEMS
Table 1. EXPENDABLE AND DURABLE ITEMS - Continued
MANDATORY REPLACEMENT PARTS
Table 1. MANDATORY REPLACEMENT PARTS LIST - Continued
Table 1. MANDATORY REPLACEMENT PARTS LIST - Continued
Table 1. MANDATORY REPLACEMENT PARTS LIST - Continued
