Attachment_0007_LTT_TM_9-2330-392-13 P_December_2012.pdf

ARMY *TM 9-2330-392-13&P

AIR FORCE TO 36A11-5-25-1

TECHNICAL MANUAL

OPERATOR AND FIELD MAINTENANCE MANUAL

INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST

FOR

TRAILER, CARGO: TWO-WHEEL AND CHASSIS

M1101

NSN 2330-01-387-5443 (EIC CBC)

M1102

NSN 2330-01-387-5426 (EIC CBB)

CHASSIS

NSN 2330-01-387-5424 (EIC CCL)

*TM 9-2330-392-13&P dated 07 December 2012 supersedes TM 9-2330-392-14&P dated 01 October 1995, including all changes.

DISTRIBUTION STATEMENT A - Approved for public release, distribution is unlimited.

HEADQUARTERS, DEPARTMENTS OF THE ARMY AND THE AIR FORCE

07 DECEMBER 2012 03/15/2011 Rel(1.8) root(frntcover) wpno(frtcvr)

WARNING SUMMARY

This warning summary contains general safety precautions and instructions that must be understood and applied during the operation and maintenance of the M1101, M1102, and Chassis Trailers to ensure personnel against injury, long-term health hazards, or death. Failure to observe these precautions could result in serious death or injury to personnel. Also included are explanations of safety and hazardous materials icons used within the technical manual.

FOR FIRST AID INFORMATION, REFER TO FM 4-25.11.

EXPLANATION OF SAFETY WARNING ICONS

ELECTRICAL - electrical wire to hand with electricity symbol running through hand shows that shock hazard is present.

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

HEAVY OBJECT - human figure stooping over heavy object shows physical injury potential from improper lifting technique.

HEAVY PARTS - heavy object on human figure shows that heavy parts present a danger to life or limb.

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

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

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

TM 9-2330-392-13&P

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WARNING SUMMARY - Continued

HOT AREA - hand over object radiating heat shows that part is hot and can burn.

GENERAL SAFETY WARNING DESCRIPTION

WARNING

DO NOT move the trailer laterally (push/pull) using the front support leg as a third wheel or trailer dolly. Mounting bracket or front support leg may fail. Failure to comply may result in personnel death or injury, or equipment damage. Seek medical attention in event of injury.

If the trailer is not coupled to the towing vehicle, ensure that the front support leg is down and locked, the parking brakes are applied, the wheels are chocked, and the rear stabilizers are installed. Failure to follow this warning may cause trailer to roll or tilt. Failure to comply may result in personnel death or injury, or equipment damage. Seek medical attention in event of injury.

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• Drawbar is heavy – up to 420 lb (190.5 kg) loaded tongue weight. Use front support (landing) leg crank to raise and lower trailer drawbar. If support leg assembly is inoperative, use suitable lifting device to lift the drawbar. If a suitable lifting device is not available, remove load from trailer and use four or more people to lift drawbar. Failure to comply may result in personnel death or injury, or equipment damage. Seek medical attention in event of injury.

• Tailgate is heavy – weighs approximately 75 lb (34 kg). Use caution while removing or installing tailgate as it may fall. Failure to comply may result in serious injury to personnel or damage to equipment. Seek medical attention in event of injury.

• Tongue weight is 420 lb (191 kg). Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to comply may result in personnel death or injury. Seek medical attention in event of injury.

• Axle handling is normally a two-person task. A third person may be required.

The axle weight is 190 lb (86 kg). Use caution when handling the axle. Failure to comply may result in personnel injury or equipment damage. Seek medical attention in event of injury.

• Wheel assembly weighs approximately 155 lb (70.31 kg). Two people are required to lift wheel assembly. Failure to comply may result in personnel death or injury. Seek medical attention in event of injury.

Removing inflated tires could be dangerous to personnel. Removing the outer nuts that hold the rim together while the tire assembly is inflated could result in injury or death. Remove only the inner group of nuts when removing a wheel from the vehicle. Failure to comply may result in personnel death or injury. Seek medical attention in event of injury.

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Ensure jack is positioned directly under the torsion arm, next to the wheel being worked on. DO NOT place jack at any other location such as frame rails. Failure to comply may result in personnel death or injury, or equipment damage. Seek medical attention in event of injury.

When performing maintenance on brake system, ensure that wheels are securely chocked. Failure to comply may cause trailer to roll, resulting in personnel death or injury, or equipment damage. Seek medical attention in event of injury.

EXPLANATION OF HAZARDOUS MATERIALS ICONS

BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.

CHEMICAL - drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.

EYE PROTECTION - person with goggles shows that the material will injure the eyes.

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

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EXPLANATION OF HAZARDOUS MATERIALS ICONS - Continued

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

VAPOR - human figure in a cloud shows that material vapors present a danger to life or health.

GENERAL HAZARDOUS MATERIALS WARNING DESCRIPTION

Accidental or intentional introduction of liquid contaminants into the environment is a violation of state, federal, and military regulations. Refer to Army Petroleum, Oils, and Lubricants (POL) for information concerning storage, use, and disposal of these liquids. Failure to comply may cause damage to environment and health of personnel. Seek medical attention in the event of an injury.

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GENERAL HAZARDOUS MATERIALS WARNING DESCRIPTION - Continued

• Solvent cleaning compound MIL-PRF-680 may be irritating to the eyes and skin. Wear protective gloves and goggles. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. Failure to comply may result in personnel death or injury. Seek medical attention in event of injury.

• Use solvent cleaning compound MIL-PRF-680 in a well-ventilated area. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and respiratory tract. May cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for ingestion: DO NOT induce vomiting. Seek immediate medical attention. First aid for inhalation:

move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Failure to comply may result in personnel death or injury. Seek medical attention in event of injury.

• MIL-PRF-680 solvent is combustible; DO NOT use or store near heat, sparks, flame, or other ignition sources. Use mechanical ventilation whenever product is used in a confined space, heated above ambient temperatures, or agitated. Keep container sealed when not in use. Failure to comply may result in personnel death or injury. Seek medical attention in event of injury.

• Improper cleaning methods and use of unauthorized cleaning liquids or solvents can injure personnel and damage equipment. Failure to comply may result in personnel death or injury. Seek medical attention in event of injury.

• Cloths or rags saturated with solvent cleaning compound must be disposed of in accordance with authorized facility procedures. Failure to comply may result in personnel death or injury. Seek medical attention in event of injury.

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GENERAL HAZARDOUS MATERIALS WARNING DESCRIPTION - Continued

DO NOT handle brakeshoes, brakedrums. or other brake components unless area has been properly cleaned. There may be hazardous dust on these components, which can be dangerous if you touch it or breathe it. Wear an approved filter mask and gloves. NEVER use compressed air or a dry brush to clean brake components.

Dust may be removed using an industrial-type vacuum cleaner. Clean dust or mud away from brake components with water and a wet, soft brush or cloth. Failure to comply may result in personnel death or injury. Seek medical attention in event of injury.

Eye injury may result if brake fluid comes in contact with eyes. Always wear eye protection when working with brake fluid. Failure to comply may result in personnel injury. Seek medical attention in event of injury.

Wear eye protection when driving heads off rivets. Failure to comply may result in eye injury or loss of vision. Seek medical attention in event of injury.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: This manual supersedes TM 9-2330-392-14&P dated 01 October 1995, including all changes. Zero in the "Change No." column indicates an original page or work package.

Date of issue for the original manual is:

Original 07 December 2012

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 46 AND TOTAL NUMBER OF

WORK PACKAGES IS 96 CONSISTING OF THE FOLLOWING:

Page/WP No. Change No.

0Front Cover a-g/h blank i-xvii/xviii blank Chapter 1 title page 0 WP 0001 (4 pgs) 0 WP 0002 (12 pgs) 0 WP 0003 (4 pgs) 0 Chapter 2 title page 0 WP 0004 (2 pgs) 0 WP 0005 (10 pgs) 0 WP 0006 (4 pgs) 0 WP 0007 (4 pgs) 0 WP 0008 (10 pgs) 0 Chapter 3 title page 0 WP 0009 (2 pgs) 0 WP 0010 (2 pgs) 0 WP 0011 (2 pgs) 0 WP 0012 (2 pgs) 0 WP 0013 (2 pgs) 0 WP 0014 (2 pgs) 0 WP 0015 (2 pgs) 0 WP 0016 (2 pgs) 0 WP 0017 (2 pgs) 0 WP 0018 (4 pgs) 0 WP 0019 (2 pgs) 0 WP 0020 (2 pgs) 0 WP 0021 (2 pgs) 0 Chapter 4 title page 0 WP 0022 (2 pgs) 0 WP 0023 (4 pgs) 0 Chapter 5 title page 0 WP 0024 (4 pgs) 0 WP 0025 (4 pgs) 0 Chapter 6 title page 0 WP 0026 (4 pgs) 0 WP 0027 (6 pgs) 0 WP 0028 (4 pgs) 0 WP 0029 (8 pgs) 0 WP 0030 (6 pgs) 0

Page/WP No. Change No.

WP 0031 (6 pgs) 0

WP 0032 (4 pgs) 0 WP 0033 (6 pgs) 0 WP 0034 (4 pgs) 0 WP 0035 (6 pgs) 0 WP 0036 (6 pgs) 0 WP 0037 (4 pgs) 0 WP 0038 (20 pgs) 0 WP 0039 (4 pgs) 0 WP 0040 (2 pgs) 0 WP 0041 (4 pgs) 0 WP 0042 (10 pgs) 0 WP 0043 (4 pgs) 0 WP 0044 (4 pgs) 0 WP 0045 (8 pgs) 0 WP 0046 (8 pgs) 0 WP 0047 (2 pgs) 0 WP 0048 (4 pgs) 0 WP 0049 (8 pgs) 0 WP 0050 (6 pgs) 0 WP 0051 (2 pgs) 0 WP 0052 (2 pgs) 0 WP 0053 (4 pgs) 0 WP 0054 (2 pgs) 0 WP 0055 (2 pgs) 0 WP 0056 (2 pgs) 0 WP 0057 (8 pgs) 0 WP 0058 (4 pgs) 0 WP 0059 (4 pgs) 0 WP 0060 (4 pgs) 0 WP 0061 (4 pgs) 0 WP 0062 (2 pgs) 0 WP 0063 (6 pgs) 0 WP 0064 (6 pgs) 0 WP 0065 (2 pgs) 0 WP 0066 (6 pgs) 0 WP 0067 (2 pgs) 0 Chapter 7 title page 0 WP 0068 (8 pgs) 0 WP 0069 (4 pgs) 0

TM 9-2330-392-13&P

A USA USA 03/15/2011 Rel(1.8) root(loepwp) wpno(loep)

LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued

Page/WP No. Change No.

WP 0070 (4 pgs) 0 WP 0071 (6 pgs) 0 WP 0072 (4 pgs) 0 WP 0073 (4 pgs) 0 WP 0074 (4 pgs) 0 WP 0075 (4 pgs) 0 WP 0076 (4 pgs) 0 WP 0077 (4 pgs) 0 WP 0078 (4 pgs) 0 WP 0079 (4 pgs) 0 WP 0080 (4 pgs) 0 WP 0081 (4 pgs) 0 WP 0082 (4 pgs) 0 WP 0083 (6 pgs) 0 WP 0084 (6 pgs) 0

Page/WP No. Change No.

WP 0085 (4 pgs) 0 WP 0086 (4 pgs) 0 WP 0087 (2 pgs) 0 WP 0088 (4 pgs) 0 WP 0089 (4 pgs) 0 Chapter 8 title page (2 pgs) 0 WP 0090 (2 pgs) 0 WP 0091 (4 pgs) 0 WP 0092 (4 pgs) 0 WP 0093 (2 pgs) 0 WP 0094 (4 pgs) 0 WP 0095 (4 pgs) 0 WP 0096 (2 pgs) 0 Index-1 -- Index-3/4 blank 0 Back Cover 0

B USA

HEADQUARTERS

DEPARTMENTS OF THE ARMY

AND THE AIR FORCE

WASHINGTON, D.C., 07 DECEMBER 2012

TECHNICAL MANUAL

OPERATOR AND FIELD MAINTENANCE MANUAL

INCLUDING REPAIR PARTS AND SPECIAL TOOLS LISTS

TRAILER, CARGO: TWO-WHEEL AND CHASSIS

NSN 2330-01-387-5443 (EIC CBC)

NSN 2330-01-387-5426 (EIC CBB)

NSN 2330-01-387-5424 (EIC CCL)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. Service should be submitted as follows: (A) Army - Mail your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the internet on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and to better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. (F) Air Force - For users without access to JCALS, submit AFTO Form 22 directly to WR/ALC/GRVEB, Robins AFB GA. Send in your recommended changes via electronic mail. Our e‐mail address is robins.ce.afto22@robins.af.mil.

*TM 9-2330-392-13&P dated 07 December 2012 supersedes TM 9-2330-392-14&P dated 01 October 1995, including all changes.

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

*TM 9-2330-392-13&P

TO 36A11-5-25-1

i/ii blank 03/15/2011 Rel(1.8) root(titleblk) wpno(titleblk)

M1101

M1102

CHASSIS

FOR

TABLE OF CONTENTS

Page No.

WP Sequence No.

HOW TO USE THIS MANUAL ...............................................................................................................................xv

Chapter 1 - GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF

OPERATION

GENERAL INFORMATION................................................................................................................ WP 0001

EQUIPMENT DESCRIPTION AND DATA......................................................................................... WP 0002

Table 1. Maximum Towing Speeds With Maximum Payload....................................................... 0002-1

Figure 1. Trailer Chassis.............................................................................................................. 0002-2

Table 2. Components and Description........................................................................................ 0002-2

Figure 2. Trailer Chassis – Breakaway Cable Through Axle....................................................... 0002-3

Table 3. Components and Description........................................................................................ 0002-3

Figure 3. Trailer Chassis – Tailgate Through Reflectors............................................................. 0002-4

Table 4. Components and Description........................................................................................ 0002-4

Figure 4. M1101 Cargo Trailer..................................................................................................... 0002-5

Figure 5. M1102 Cargo Trailer..................................................................................................... 0002-6

Figure 6. Trailer Chassis.............................................................................................................. 0002-7

Table 5. Differences Between Models......................................................................................... 0002-8

Table 6. Equipment Data........................................................................................................... 0002-10

THEORY OF OPERATION................................................................................................................ WP 0003

Figure 1. Hydraulic Brake System............................................................................................... 0003-3

Figure 2. Handbrakes.................................................................................................................. 0003-4

Chapter 2 - OPERATOR MAINTENANCE INSTRUCTIONS

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS.................................. WP 0004

Table 1. Operator Controls and Indicators................................................................................... 0004-2

Figure 1. Controls and Indicators................................................................................................. 0004-2

OPERATION UNDER USUAL CONDITIONS.................................................................................... WP 0005

Figure 1. Chock Block Placement on Level Surface With Neither Side of Trailer Raised........... 0005-1

Figure 2. Chock Block Placement on Level Surface With One Side of Trailer Raised................ 0005-2

Figure 3. Chock Block Placement on Incline With Front of Trailer Facing Uphill......................... 0005-2 iii 03/15/2011 Rel(1.8) root(contents) wpno(TOC)

TABLE OF CONTENTS - Continued

WP Sequence No.

Figure 4. Chock Block Placement on Incline With Front of Trailer Facing Downhill.................... 0005-2

Figure 5. Load Distributed Evenly Over Trailer............................................................................ 0005-4

Figure 6. Safety Pin Removed From Pintle Hitch........................................................................ 0005-5

Figure 7. Trailer Coupled to Towing Vehicle................................................................................ 0005-6

Figure 8. Breakaway Cable Attached to Towing Vehicle............................................................. 0005-7

OPERATION UNDER UNUSUAL CONDITIONS.............................................................................. WP 0006

WHEEL AND TIRE ASSEMBLY REPLACEMENT (OLD JACK)....................................................... WP 0007

Figure 1. Wheel and Tire Assembly Removal and Installation.................................................... 0007-3

WHEEL AND TIRE ASSEMBLY REPLACEMENT (NEW JACK)...................................................... WP 0008

Figure 1. HMMWV Jack and Saddle............................................................................................ 0008-2

Figure 2. Trailer Jack Adapter..................................................................................................... 0008-3

Figure 3. Pump Unit Hydraulic Hose Quick-Disconnect.............................................................. 0008-3

Figure 4. Jack Positioning............................................................................................................ 0008-5

Figure 5. Wheel Assembly Removal............................................................................................ 0008-6

Figure 6. Wheel Assembly Installation......................................................................................... 0008-7

Figure 7. Jack Removal............................................................................................................... 0008-8

Figure 8. Lug Nut Tightening Sequence...................................................................................... 0008-9

Chapter 3 - TROUBLESHOOTING PROCEDURES

OPERATOR TROUBLESHOOTING SYMPTOM INDEX................................................................... WP 0009

FIELD TROUBLESHOOTING SYMPTOM INDEX............................................................................. WP 0010

OPERATOR TROUBLESHOOTING – ELECTRICAL........................................................................ WP 0011

OPERATOR TROUBLESHOOTING – BRAKES............................................................................... WP 0012

OPERATOR TROUBLESHOOTING – WHEELS AND TIRES.......................................................... WP 0013

OPERATOR TROUBLESHOOTING – FRONT SUPPORT LEG....................................................... WP 0014

OPERATOR TROUBLESHOOTING – SUSPENSION...................................................................... WP 0015

FIELD TROUBLESHOOTING – ELECTRICAL.................................................................................. WP 0016

FIELD TROUBLESHOOTING – AXLE............................................................................................... WP 0017 iv 03/15/2011 Rel(1.8) root(contents) wpno(TOC)

WP Sequence No.

FIELD TROUBLESHOOTING – BRAKES......................................................................................... WP 0018

FIELD TROUBLESHOOTING – WHEELS AND TIRES.................................................................... WP 0019

FIELD TROUBLESHOOTING – FRONT SUPPORT LEG AND CASTER......................................... WP 0020

FIELD TROUBLESHOOTING – SUSPENSION................................................................................ WP 0021

Chapter 4 - OPERATOR PMCS INSTRUCTIONS

OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

INTRODUCTION...................................................................................................................... WP 0022

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS).......................... WP 0023

Table 1. Operator Preventive Maintenance Checks and Services (PMCS)................................ 0023-1

Figure 1. Spring Clip.................................................................................................................... 0023-2

Chapter 5 - FIELD PMCS INSTRUCTIONS

FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION........ WP 0024

FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS).................................... WP 0025

Table 1. Field Preventive Maintenance Checks and Services (PMCS)....................................... 0025-1

Figure 1. Tire............................................................................................................................... 0025-2

Figure 2. Axle Mounting............................................................................................................... 0025-3

Chapter 6 - FIELD MAINTENANCE INSTRUCTIONS

SERVICE UPON RECEIPT............................................................................................................... WP 0026

GENERAL MAINTENANCE INSTRUCTIONS................................................................................... WP 0027

WIRING HARNESS CLIP REPLACEMENT...................................................................................... WP 0028

Figure 1. Wiring Harness Clip Removal and Installation............................................................. 0028-3

TAILLIGHT MAINTENANCE.............................................................................................................. WP 0029

Figure 1. Lamp Bulb/LED Replacement...................................................................................... 0029-3

Figure 2. Taillight with Bulb Removal and Installation................................................................. 0029-5

Figure 3. Taillight with LED Removal and Installation................................................................. 0029-6

FRONT AND SIDE MARKER LIGHTS MAINTENANCE................................................................... WP 0030

Figure 1. Lamp Bulb Replacement.............................................................................................. 0030-2

Figure 2. Lamp Assembly with Bulb Removal............................................................................. 0030-3 v 03/15/2011 Rel(1.8) root(contents) wpno(TOC)

WP Sequence No.

Figure 3. Lamp Assembly with Bulb Installation.......................................................................... 0030-4

Figure 4. Lamp Assembly with LED Removal and Installation.................................................... 0030-5

REAR MARKER LIGHTS MAINTENANCE........................................................................................ WP 0031

Figure 1. Marker Light Assembly View From Back Side and Rear of Vehicle............................. 0031-3

Figure 2. Lamp Assembly with LED Removal and Installation.................................................... 0031-5

BRANCHED WIRING HARNESS REPLACEMENT.......................................................................... WP 0032

Figure 1. Branched Wiring Harness Removal and Installation.................................................... 0032-3

BRANCHED WIRING HARNESS REPAIR........................................................................................ WP 0033

Figure 1. Typical Panel Mounting Receptacle Replacement....................................................... 0033-2

Figure 2. Typical Plug Replacement............................................................................................ 0033-3

Figure 3. Terminal-Type Cable Connector Replacement............................................................ 0033-4

Figure 4. Male Cable Connector Replacement............................................................................ 0033-4

Figure 5. Female Cable Connector (With Washer) Replacement............................................... 0033-5

Figure 6. Female Cable Connector (With Sleeve) Replacement................................................. 0033-5

INTERVEHICULAR CABLE REPLACEMENT................................................................................... WP 0034

Figure 1. Intervehicular Cable Removal and Installation............................................................. 0034-3

AXLE ASSEMBLY INSPECTION AND REPLACEMENT.................................................................. WP 0035

Figure 1. Axle Assembly Inspection............................................................................................. 0035-2

Figure 2. Axle Assembly Removal and Installation...................................................................... 0035-5

HANDBRAKE LEVER REPLACEMENT............................................................................................ WP 0036

Figure 1. Handbrake Lever Removal........................................................................................... 0036-2

Figure 2. Handbrake Lever Cleaning and Inspection.................................................................. 0036-4

Figure 3. Handbrake Lever Installation........................................................................................ 0036-5

Figure 4. Handbrake Lever Engaged/Disengaged...................................................................... 0036-6

HANDBRAKE CABLE AND SHEATH REPLACEMENT.................................................................... WP 0037

Figure 1. Handbrake Cable and Sheath Removal and Installation.............................................. 0037-3

SERVICE BRAKE MAINTENANCE................................................................................................... WP 0038 vi 03/15/2011 Rel(1.8) root(contents) wpno(TOC)

WP Sequence No.

Figure 1. Brakeshoe Inspection................................................................................................... 0038-2

Figure 2. Brakedrum Inspection................................................................................................... 0038-3

Figure 3. Front/Rear Shoe Spring Removal................................................................................ 0038-4

Figure 4. Brakeshoe Retainer Removal....................................................................................... 0038-5

Figure 5. Brake Adjuster Removal............................................................................................... 0038-5

Figure 6. Service Brakeshoe Disassembly.................................................................................. 0038-6

Figure 7. Backing Plate Removal................................................................................................ 0038-8

Figure 8. Backing Plate Installation............................................................................................. 0038-9

Figure 9. Service Brakeshoe Assembly..................................................................................... 0038-11

Figure 10. Brake Adjuster Installation........................................................................................ 0038-11

Figure 11. Brakeshoe Retainer Installation................................................................................ 0038-12

Figure 12. Front/Rear Shoe Spring Installation......................................................................... 0038-13

Figure 13. Service Brake Adjustment........................................................................................ 0038-15

Table 1. Torque Measurements................................................................................................. 0038-16

Figure 14. Service Brake Adjustment........................................................................................ 0038-17

Figure 15. Jack Placement........................................................................................................ 0038-19

WHEEL CYLINDER REPLACEMENT............................................................................................... WP 0039

Figure 1. Wheel Cylinder Removal.............................................................................................. 0039-2

Figure 2. Wheel Cylinder Installation........................................................................................... 0039-4

BREAKAWAY LEVER AND LEAF SPRING REPLACEMENT.......................................................... WP 0040

Figure 1. Breakaway Lever and Leaf Spring Removal and Installation....................................... 0040-2

HYDRAULIC BRAKE SYSTEM BLEEDING...................................................................................... WP 0041

Figure 1. Hydraulic Brake System Bleeding................................................................................ 0041-3

HYDRAULIC BRAKE ACTUATOR REPLACEMENT........................................................................ WP 0042

Figure 1. Hydraulic Brake Actuator Removal............................................................................... 0042-2

Figure 2. Hydraulic Brake Actuator Disassembly........................................................................ 0042-3

Figure 3. Hydraulic Brake Actuator Disassembly........................................................................ 0042-4 vii 03/15/2011 Rel(1.8) root(contents) wpno(TOC)

WP Sequence No.

Figure 4. Hydraulic Brake Actuator Cleaning and Inspection...................................................... 0042-6

Figure 5. Hydraulic Brake Actuator Assembly............................................................................. 0042-7

Figure 6. Hydraulic Brake Actuator Assembly............................................................................. 0042-8

Figure 7. Hydraulic Brake Actuator Installation............................................................................ 0042-9

LUNETTE REPLACEMENT............................................................................................................... WP 0043

Figure 1. Lunette Removal.......................................................................................................... 0043-2

Figure 2. Lunette Installation....................................................................................................... 0043-4

MASTER CYLINDER REPLACEMENT............................................................................................. WP 0044

Figure 1. Master Cylinder Removal and Installation.................................................................... 0044-3

HYDRAULIC BRAKE LINES REPLACEMENT.................................................................................. WP 0045

Figure 1. Front Flex Brake Line Removal and Installation........................................................... 0045-2

Figure 2. Front Solid Brake Line Removal and Installation.......................................................... 0045-3

Figure 3. Rear Flex Brake Line Removal and Installation........................................................... 0045-5

Figure 4. Rear Solid Brake Line Removal and Installation.......................................................... 0045-7

HUB/DRUM, RACE, AND BEARING SEAL MAINTENANCE............................................................ WP 0046

Figure 1. Hub/Drum, Race, and Bearing Seal Removal.............................................................. 0046-2

Figure 2. Hub/Drum, Race, and Bearing Seal Disassembly........................................................ 0046-3

Figure 3. Hub/Drum, Race, and Bearing Seal Cleaning and Inspection...................................... 0046-5

Figure 4. Hub/Drum, Race, and Bearing Seal Assembly............................................................. 0046-6

Figure 5. Hub/Drum, Race, and Bearing Seal Installation........................................................... 0046-7

WHEEL AND TIRE ASSEMBLY REPAIR.......................................................................................... WP 0047

SAFETY CHAIN REPLACEMENT..................................................................................................... WP 0048

Figure 1. Safety Chain Removal and Installation......................................................................... 0048-3

FRONT SUPPORT LEG AND PIVOT REPAIR................................................................................. WP 0049

Figure 1. Front Support Leg Removal......................................................................................... 0049-2

Figure 2. Caster Removal............................................................................................................ 0049-3

Figure 3. Pivot Removal and Installation..................................................................................... 0049-5 viii 03/15/2011 Rel(1.8) root(contents) wpno(TOC)

WP Sequence No.

Figure 4. Caster Installation......................................................................................................... 0049-6

Figure 5. Front Support Leg Installation...................................................................................... 0049-7

SHOCK ABSORBER MAINTENANCE.............................................................................................. WP 0050

Figure 1. Shock Absorber Disassembly....................................................................................... 0050-2

Figure 2. Shock Absorber Removal............................................................................................. 0050-3

Figure 3. Shock Absorber Mount Bracket Removal and Installation........................................... 0050-4

Figure 4. Shock Absorber Assembly........................................................................................... 0050-5

Figure 5. Shock Absorber Installation.......................................................................................... 0050-6

TAILGATE REPLACEMENT.............................................................................................................. WP 0051

Figure 1. Tailgate Removal and Installation................................................................................ 0051-2

TAILGATE LANYARD AND MOUNT REPLACEMENT..................................................................... WP 0052

Figure 1. Tailgate Lanyard and Mount Removal and Installation................................................ 0052-2

TAILGATE LATCH ASSEMBLY, LATCH ASSEMBLY PIN, AND LATCHING PIN LANYARD

REPLACEMENT...................................................................................................................... WP 0053

Figure 1. Tailgate Latch Assembly and Latch Assembly Pin Removal and Installation.............. 0053-3

Figure 2. Tailgate Latching Pin Lanyard Removal and Installation.............................................. 0053-4

CARGO TIEDOWN REPLACEMENT................................................................................................ WP 0054

Figure 1. Cargo Tiedown Removal and Installation..................................................................... 0054-2

SHACKLE REPLACEMENT.............................................................................................................. WP 0055

Figure 1. Shackle Removal and Installation................................................................................ 0055-2

TAILGATE HINGE AND SHIM REPLACEMENT............................................................................... WP 0056

Figure 1. Tailgate Hinge Removal and Installation...................................................................... 0056-2

CARGO BODY MAINTENANCE........................................................................................................ WP 0057

Figure 1. Rivet Pattern................................................................................................................. 0057-2

Figure 2. Rivet Spacing............................................................................................................... 0057-3

Figure 3. Rivet Loading................................................................................................................ 0057-4

Figure 4. Bolts Replacing Rivets Loaded in Tension................................................................... 0057-4

Table 1. Stop-Drill Sizes for Negligible Cracks............................................................................ 0057-5 ix 03/15/2011 Rel(1.8) root(contents) wpno(TOC)

WP Sequence No.

Figure 5. Repair by Patching....................................................................................................... 0057-6

Figure 6. Repair by Insertion....................................................................................................... 0057-7

REFLECTOR AND TIEDOWN LOOP REPLACEMENT.................................................................... WP 0058

Figure 1. Reflector and Tiedown Loop Removal and Installation................................................ 0058-3

DECONTAMINATION BRACKET MAINTENANCE........................................................................... WP 0059

Figure 1. Decontamination Bracket Removal and Installation..................................................... 0059-3

DATA PLATE AND SHIPPING PLATE REPLACEMENT.................................................................. WP 0060

Figure 1. Data Plate Removal and Installation............................................................................ 0060-2

Figure 2. Shipping Plate Removal and Installation...................................................................... 0060-3

SOFT TOP KIT................................................................................................................................... WP 0061

Figure 1. Soft Top Kit Removal and Installation.......................................................................... 0061-3

PAINTING AND IDENTIFICATION MARKING.................................................................................. WP 0062

PREPARATION FOR STORAGE OR SHIPMENT............................................................................ WP 0063

Table 1. Scheduled Services....................................................................................................... 0063-4

LUBRICATION INSTRUCTIONS....................................................................................................... WP 0064

Table 1. Lubrication Chart........................................................................................................... 0064-3

ILLUSTRATED LIST OF MANUFACTURED ITEMS......................................................................... WP 0065

Table 1. Manufacturing Instructions............................................................................................. 0065-1

TORQUE LIMITS............................................................................................................................... WP 0066

Table 1. Metal Fasteners............................................................................................................. 0066-1

Figure 1. Torque Wrench Formulas............................................................................................. 0066-2

Figure 2. Torque Wrench Adapter Setups................................................................................... 0066-2

Table 2. M1101, M1102, and Chassis Torque Values................................................................. 0066-3

Table 3. Torque Limits – SAE Fasteners..................................................................................... 0066-4

Table 4. Torque Limits – Metric Fasteners.................................................................................. 0066-5

Table 5. Thread Classes.............................................................................................................. 0066-5

Figure 3. Thread Description....................................................................................................... 0066-6 x 03/15/2011 Rel(1.8) root(contents) wpno(TOC)

WP Sequence No.

Figure 4. Bolt and Nut Description............................................................................................... 0066-6

WIRING DIAGRAMS.......................................................................................................................... WP 0067

Table 1. Trailer Lighting Configuration......................................................................................... 0067-1

Figure 1. Wiring Diagram............................................................................................................. 0067-2

Chapter 7 - PARTS INFORMATION

REPAIR PARTS AND SPECIAL TOOLS LIST INTRODUCTION...................................................... WP 0068

Table 1. SMR Code Explanation................................................................................................. 0068-1

GROUP 0608 MISCELLANEOUS ITEMS.......................................................................................... WP 0069

Figure 1. Wiring Harness Clip...................................................................................................... 0069-2

GROUP 0609 LIGHTS........................................................................................................................WP 0070

Figure 2. Tail Lights..................................................................................................................... 0070-2

GROUP 0609 LIGHTS........................................................................................................................WP 0071

Figure 3. Clearance Lights (Sheet 1 of 3).....................................................................................0071-2

Figure 3. Clearance Lights (Sheet 2 of 3).....................................................................................0071-3

Figure 3. Clearance Lights (Sheet 3 of 3).....................................................................................0071-4

GROUP 0613 HULL OR CHASSIS WIRING HARNESS....................................................................WP 0072

Figure 4. Wiring Harness, Branched............................................................................................ 0072-2

GROUP 1000 FRONT AXLE ASSEMBLY..........................................................................................WP 0073

Figure 5. Axle Assembly.............................................................................................................. 0073-2

GROUP 1201 HAND BRAKES........................................................................................................... WP 0074

Figure 6. Handbrakes.................................................................................................................. 0074-2

GROUP 1202 SERVICE BRAKES......................................................................................................WP 0075

Figure 7. Service Brakes............................................................................................................. 0075-2

GROUP 1204 HYDRAULIC BRAKE SYSTEM................................................................................... WP 0076

Figure 8. Brake Actuator Assembly (Sheet 1 of 2)....................................................................... 0076-1

Figure 8. Brake Actuator Assembly (Sheet 2 of 2)....................................................................... 0076-2

GROUP 1311 WHEEL ASSEMBLY....................................................................................................WP 0077 xi 03/15/2011 Rel(1.8) root(contents) wpno(TOC)

WP Sequence No.

Figure 9. Brake Drum.................................................................................................................. 0077-2

GROUP 1311 WHEEL ASSEMBLY....................................................................................................WP 0078

Figure 10. Wheel and Runflat Assembly..................................................................................... 0078-2

GROUP 1313 TIRES, TUBES, TIRE CHAINS....................................................................................WP 0079

Figure 11. Tires............................................................................................................................ 0079-2

GROUP 1503 PINTLES AND TOWING ATTACHMENTS..................................................................WP 0080

Figure 12. Safety Chains............................................................................................................. 0080-2

GROUP 1507 LANDING GEAR, LEVELING JACKS (MECHANICAL OR HYDRAULIC).................. WP 0081

Figure 13. Landing Gear and Leveling Jacks.............................................................................. 0081-2

GROUP 1604 SHOCK ABSORBER EQUIPMENT.............................................................................WP 0082

Figure 14. Shock Absorbers........................................................................................................ 0082-2

GROUP 1810 CARGO BODY.............................................................................................................WP 0083

Figure 15. Tailgate, Tiedowns, and Front Support (Sheet 1 of 4).................................................0083-1

Figure 15. Tailgate, Tiedowns, and Front Support (Sheet 2 of 4).................................................0083-2

Figure 15. Tailgate, Tiedowns, and Front Support (Sheet 3 of 4).................................................0083-3

Figure 15. Tailgate, Tiedowns, and Front Support (Sheet 4 of 4).................................................0083-4

GROUP 2202 ACCESSORY ITEMS.................................................................................................. WP 0084

Figure 16. Accessory Items (Sheet 1 of 3)................................................................................... 0084-2

Figure 16. Accessory Items (Sheet 2 of 3)................................................................................... 0084-3

Figure 16. Accessory Items (Sheet 3 of 3)................................................................................... 0084-4

GROUP 2210 DATA PLATES AND INSTRUCTION HOLDERS........................................................WP 0085

Figure 17. Data Plates................................................................................................................. 0085-2

GROUP 9401 REPAIR KITS...............................................................................................................WP 0086

Figure KITS.................................................................................................................................. 0086-2

GROUP 9501 HARDWARE SUPPLIES AND BULK MATERIEL, COMMON.....................................WP 0087

NATIONAL STOCK NUMBER (NSN) INDEX.................................................................................... WP 0088

PART NUMBER (P/N) INDEX............................................................................................................ WP 0089 xii 03/15/2011 Rel(1.8) root(contents) wpno(TOC)

WP Sequence No.

Chapter 8 - SUPPORTING INFORMATION

REFERENCES................................................................................................................................... WP 0090

MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION.................................................... WP 0091

MAINTENANCE ALLOCATION CHART (MAC)................................................................................ WP 0092

Table 1. MAC for Trailer, Cargo: Light, Two-Wheel M1101; Trailer, Cargo:

Heavy, Two-Wheel M1102 Chassis, Trailer: Two-Wheel.................................................. 0092-1

Table 2. Tools and Test Equipment Requirements..................................................................... 0092-4

Table 3. Remarks........................................................................................................................ 0092-4

COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS.............................. WP 0093

Table 1. Components of End Item (COEI) List............................................................................ 0093-2

Table 2. Basic Issue Items (BII) List.........................................................