100-300_Manual_Rev_B3.pdf

U s e r ’ s I n s t r u c t i o n M a n u a l

100, 200, 300 Series

Engineered to move with you

TABLE OF CONTENTS

Section

Disclaimer ...........................................................................................................................................� 100, 200 and 300 Series Shelter Setup Instructions.........................................................................� Load Cable Installation Instructions (300 Series Only)...................................................................� 100, 200 and 300 Series Shelter Take-Down (Striking) and Packing ............................................� Complexing........................................................................................................................................� Maintenance and Repair.................................................................................................................� Parts Replacement............................................................................................................................� NSN’s and Kit Component Listings Illustrated Parts Breakdown

Warranty .............................................................................................................................................�

Section 1–1

Disclaimer Warranty Caution and care must be taken when deploying and striking the Base-X Shelter. Failure to follow proper procedures may result in damage to the shelter voiding the warranty or causing personal injury.

Anchoring Shelters must always be properly anchored with the Stake Kits provided and wind lines should be used during windy conditions. Because weather conditions can change quickly without warning, shelters should be anchored during any deployment regardless of duration. Details for anchoring follow in the manual.

Loads There are load cables included in the 300 series that should be used in times of heavy snow or ice.

Personnel The proper number of personnel should be used when striking, deploying, and moving the shelter at all times.

Hazards When deploying shelters pay close attention to surrounding hazards, such as overhead power lines, buried power lines, tree limbs, etc.

Warnings All points on the shelter that may cause injury are clearly marked with CAUTION labels, most notable is the pinch point on the leg assemblies.

100, 200 and 300 Series Shelters Setup Instructions

The following is the minimum recommended number of team members to setup:

These instructions illustrate the Model 305 set-up.

1. Accountability Open shelter bag(s) and inspect contents. Identify all components as follows:

A. Frame and Cover (figure 2-1)

Frame and Cover are secured with two nylon straps.

Model 102 — 2 Model 103 — 2 Model 105 — 4

Model 203 — 2 Model 205 — 4

Model 303 — 2 Model 305 — 4 Model 307 — 6

Section 2–1

(figure 2-1)

2–2

B. Liner (figures 2-2 & 2-3) Liner bag should also contain: Stake kit, Repair kit and Wind-Line Kit.

Liner has no additional straps other than the three on the bag.

C. Stake Kit (figure 2-4) A detailed stake kit breakdown can be found in Section 8.

D. Repair Kit (figure 2-5) A detailed repair kit breakdown can be found in Section 8.

E. Wind-line Kit (figure 2-6) A detailed wind-line kit breakdown can be found in Section 8.

(figure 2-5)

(figure 2-6)

(figure 2-2)

(figure 2-3) (figure 2-4)

2. Upright Frame and Outer Cover (2 to 6 people) With shelter in the bag lying on the ground, undo all straps, open bag and tuck bottom fabric of bag under legs (figure 2-7), upright the frame and outer cover (figure 2-8). Remove the bag and orient the shelter in the desired position and remove the compression straps.

(figure 2-7) (figure 2-8) (figure 2-9)

Note: The legs are on the side of the shelter, indicated by the wind-line attachments. Shaking the frame can help ensure there are no clevis pins or cables hung on leg assemblies.

3. Extend Legs (Partial) (2 to 6 people) Identify leg assemblies and pull legs out partially (figures 2-9 & 2-10). Check to make sure that there are no cables hung up on leg brackets or fabric sections impeding the frame expansion.

4. Extend Shelter (2 to 6 people) Once legs have been partially extended, position required number of people on each side with the leg assemblies, grab the leg in the area indicated by the “Grip Here to Expand Frame” markings (figure

2–3

2-10), then lift up and move away from the center gradually expanding the frame, be sure bottom portion of the hub does not drag on the ground as this will cause the frame to hang up. If fabric gathers under corners of frame, pull fabric out and place on the roof to avoid damage to fabric. Continue to expand the frame by pulling at the “Grip Here to Expand Frame” labels until hubs locks are 2”-3” apart and can be easily engaged (figures 2-11 & 2-12).

Note: DO NOT USE EXCESSIVE FORCE. It may take several attempts to fully extend the frame. Stop if you meet resistance and investigate the cause.

(figure 2-10) (figure 2-11) (figure 2-12)

5. Lift Cover Material Lift and place the corner fabric sections on the top of the shelter to allow access to the perimeter hubs (figures 2-11 & 2-12).

2–4

2–5

(figure 2-13) (figure 2-14) 6. Lock Hubs Lock all hubs (yellow colored) along the sides of the shelter. DO NOT crawl underneath the shelter and lock the center hubs or the hubs on the ends until one side has been raised. To lock perimeter hubs, place your knee at the top of the leg assembly, align the top and bottom portions of the hub, press bottom button in and put a little weight on the hub. The top and bottom portions go together, let off of button so it will engage and lock the two sections together (figures 2-15 through 2-17).

(figure 2-15) (figure 2-16) (figure 2-17)

Note: Ensure the fabric does not cover the peak on the ends of the shelter (figure 2-13). Correct end fabric (figure 2-14).

Note: It is important to ensure all perimeter hubs are locked before proceeding. Hubs are located at the top on each side of the leg assembly and/or in-between each scissor assembly.

7. Lift One Side (3-6 people) With a person in-between each leg assembly on one side of the shelter, grab the scissor of the frame in-between the top of the leg assembly (figure 2-18). Simultaneously lift (figure 2-19) until the legs lock into the extended position (figure 2-20), a clicking sound can be heard. If the legs do not lock into place try lifting the frame higher and/or moving the leg assembly side-to-side.

Verify the buttons have engaged by turning around and feeling for the button protruding from the leg or pull back the hook & loop fastener and conduct a visual inspection (figures 2-21 & 2-22) Legs should be staked down on this side if windy conditions exist.

2–6

(figure 2-18)

(figure 2-19)

(figure 2-20) (figure 2-21)

(figure 2-22)

8. Lock Remaining Hubs Go underneath the shelter and lock ALL remaining hubs (yellow colored) down the center of the frame.

Place palm on bottom of hub, push up on the hub allowing the weight of shelter to be counter pressure, depress the bottom button & engage top & bottom sections together. (figures 2-23 through 2-25)

Note: Before continuing ensure ALL hubs have been locked. 100 Series: Has no center rows of hubs. 200 Series: Has one center row of hubs.

9. Install Liner Unroll the liner under the frame. There are rows of clips in the liner. The center rows of liner clips will be designated by a yellow disk and the outer rows by a black disk (figures 2-26 & 2-27). Working from one side of the liner, move fabric to the center (figure 2-28), allowing you to install the center rows of liner clips first. Install the clips into the bottom of the hub lock facing away from the center peak of the frame (figures 2-29 & 2-33). Working your way back to the outside, install the outer row facing away from the center peak (figure 2-34). The other side of clips will be installed after second side has been raised.

2–7

(figure 2-23) (figure 2-24) (figure 2-25)

2–8

(figure 2-26) (figure 2-27) (figure 2-28)

(figure 2-29) (figure 2-30) (figure 2-31)

(figure 2-32) (figure 2-33) (figure 2-34)

100 Series: The center row is hook & loop fastener which connects over the scissor assembly.

200 Series: Has only one center row to connect. These can face either way.

10. Raise Other Side of Shelter (3-6 people) Grab frame at scissors located in-between each leg assembly and raise the remaining side of the shelter until legs lock into place (figures 2-35 through 2-36). If the legs do not lock into place, try lifting the frame higher and/or moving the leg assembly side-to-side. Verify the buttons have engaged by turning around and feeling for the button protruding from the leg or pull back the hook & loop fastener and conduct a visual inspection (figures 2-21 & 2-22). Legs should be staked down immediately if windy conditions exist. Insert remaining liner clips into remaining hubs (figure 2-37).

(figure 2-35) (figure 2-36) (figure 2-37)

2–9

2–10

Note: If heavy snow or ice conditions are a concern, load cables are provided in liner bag (300 series). Reference section 3 prior to staking.

11. Stake Down Shelter Anchor frame using the 24” steel stakes through hole in foot bracket (figure 2-38). After 24” stakes have been installed attach leg straps around the leg (figures 2-39 through 2-40). This will help position the liner floor. Detach side wall fabric and use the 12” aluminum stakes to secure the outer and liner stake loops. The same stake is used for both (figures 2-41 through 2-42). Start at one corner of the shelter, work across the end and then down the shelter to dress the floor of the liner. It is important to be sure that the outer fabric is attached to the stake to prevent wind from getting under the shelter.

(figure 2-38) (figure 2-39) (figure 2-40)

(figure 2-41) (figure 2-42)

Note: In order to have enough aluminum stakes you must stake both liner and cover with the same stake. If high winds are present, anchor frame on one side of shelter immediately after it is raised (Step 7) to properly secure 1/2 of the shelter to the terrain. Please execute good judgment and caution when erecting the shelter(s) in high winds to prevent injury to personnel and damage to the shelter.

*Drive stakes in at the same angle as the legs to avoid possible wear or puncture of outer cover. Wind-lines can be attached to the spring-link at the top of each leg assembly and anchored to the ground for additional security. When driving 24” steel stakes do not strike the leg assembly with the mallet.

This may cause the leg to not properly telescope.

Note: Proper set-up of this Base-X Tent System requires the use and application of stakes at each leg.

2–11

12. Hang Lights Once the liner has been installed, identify the hanging point in the ceiling. The fluorescent lights have two clips located on an adjustable strap at the ends of the light. Connect these light clips into the hanging eye circle hooks located overhead. Plug lights into any electrical outlet. The lights may also be plugged into each other in series.

13 Connect Environmental Control Unit Ducts If an ECU, is present, connect the input duct to the outer most duct hole. Connect the return duct to the inner most duct hole. First pull the sleeve from the liner through the outer cover. Use the strap(s) provided to secure ducts to the liner and outer cover. Slide duct back into the shelter. Arrange material so water will not puddle.

Note: The outer duct hole is always the input and the inner duct hole is always the return . If ECU has a thermostat it can be inserted through the duct hole if desired. Improper installation of ducts will restrict air flow and reduce cooling/heating performance.

2–12

Section 3–1

Load Cables – Installation Instructions

Load cables are supplied with the 300 series shelters. The load cables can be found inside the inner pocket of the liner bag.

1. Anchor one side of the shelter frame and install load cables to the anchored side first. From the inside of the liner, insert the keyhole connector end of the load cable through the pre-cut, reinforced slit in the liner material located at the ends of cable sleeves on the side of shelter (figure 3-1). Hook the end of the keyhole connector over the head of the hub clevis-pin (figure 3-2). Repeat this procedure for the additional cables.

2. Move to the opposite side and feed the loose end of the each load cable through the liner fabric (figure 3-1). Attach the keyhole connector on the end of the load cable to the head of the hub clevis pin (figure 3-2). When attaching second side, frame will need to be pulled together to allow cable to reach. Having one side staked or secure, pull second side toward cable. Do this by pushing or pulling on leg assembly.

(figure 3-1)

(figure 3-2)

Once installed the load cables will appear as shown in figure 3-3.

Note: The Base-X Shelters have been designed to withstand snow/ice accumulation. However, it is advised that users actively prevent snow/ice from accumulating on the roof of the shelters. The 300 series shelters are equipped with load cables that, when properly installed, will increase the load capability.

3–2

(figure 3-3)

3–3

3–4

Section 4–1

100, 200 and 300 Series Shelters Take Down (STRIKING) & Packing Procedures

The following is the minimum recommended number of team members to take down:

1. Rollup all outer doors Rollup all the outer doors (figure 4-1). Let the liner doors down but DO NOT zip them, connect the hook & loop fastener at the bottom (figure 4-2). This is to allow air to escape when rolling the liner.

(figure 4-1) (figure 4-2)

Model 103 — 2 Model 105 — 4

Model 203 — 2 Model 205 — 4

Model 303 — 2 Model 305 — 4 Model 307 — 6

2. Remove Lights and Disconnect Electric Disconnect electrical wire from support trailer or power distribution box and unplug lights from wire harness. Place lights back into case.

Note: Remove load cables if installed. Do not remove wiring harness from sleeve.

3. Remove Stakes Remove the 12 inch aluminum stakes from liner and outer cover stake loops (figures 4-3 & 4-4). Remove the 24 inch steel stakes from the leg brackets (figure 4-5). Place all stakes back in the stake kit bag.

(figure 4-3) (figure 4-4) (figure 4-5)

Connect the stake loops on the outer cover to the spring links on the eave of the shelter (figures 4-6 & 4-7). Fold the fabric neatly to aid in strapping.

4–2

4–3

(figure 4-6) (figure 4-7) (figure 4-8)

4. Disconnect Liner Disconnect the liner from the hubs along one side of the shelter (figures 4-8 through 4-10). Push the fabric and floor towards the center of the shelter away from the side (figure 4-11). This is done so that the frame will not be lowered down on the liner and cause damage to the fabric.

(figure 4-9) (figure 4-10) (figure 4-11)

5. Lower One Side (4-6 people) Lower the side of the shelter where the liner was disconnected by positioning a person at each leg assembly. Grip the scissor above the leg assembly and lift (leg assembly must be off the ground). Have another person push in on the buttons that are located mid-way up the legs beneath the black hook & loop fastener. Keep fastner over button when depressing button. This will allow the legs to swing out. Once all legs are free simultaneously lower the side of the shelter to the ground (figures 4-12 through 4-14). The person holding the shelter must keep the leg slightly lifted in order to keep the button from re-engaging;

keep hands free of pinch point in leg assembly.

CAUTION: DO NOT HOLD FRAME AT THE YELLOW WARNING LABEL — THIS IS A POTENTIAL PINCH POINT!

(figure 4-12) (figure 4-13) (figure 4-14)

Note: Ensure no one is under the shelter during this procedure.

6. Disconnect Liner Go underneath the shelter and completely disconnect the rest of the liner and disconnect leg straps.

Drag the liner from beneath the frame (figures 4-15 through 4-17).

4–4

(figure 4-15) (figure 4-16) (figure 4-17)

7. Unlock Center Hubs Only Go underneath the shelter and unlock the center rows of hubs (figures 4-18 & 4-19).

(figure 4-18) (figure 4-19)

Note: Do not disengage perimeter hub locks until they are on the ground.

100 Series: Has no center rows of hubs 200 Series: Has one center row of hubs

4–5

CAUTION:

Pay attention not to hit head on frame.

8. Lower Other side (3-6 people) Lower remaining side of shelter (as described in step 5). Position a person inside each leg assembly. Lift the frame then push in on the buttons that are mid-way up the legs beneath the black hook & loop fastener. This will allow the legs to swing out and lower the remaining side of the shelter. Wait for all other legs to be disengaged, then lower frame simultaneously (figures 4-20 through 4-22).

(figure 4-20) (figure 4-21) (figure 4-22)

9. Unlock Remaining Hubs (figure 4-23) Perimeter hubs are now on the ground. Press down on top of lock and depress bottom lock button and pull apart.

Note: Ensure all yellow hubs are unlocked at this time.

�� FAILURE TO DO SO MAY RESULT IN DAMAGE!! ��

4–6

(figure 4-23)

10. Fold Frame: (4-6 people) Position one person at each side door of the shelter and grip the frame where it is marked “Grip Here to Fold Frame” (figure 4-24). Lift simultaneously and the frame will begin to fold (figure 4-25).

Note: � Stop if frame does not immediately begin to fold or if resistance if encountered and investigate possible problems. �

Problems may be caused by remaining locked hub or fabric/cable hung up.

(figure 4-24) (figure 4-25) (figure 4-26)

When the frame begins to fold, walk toward each other (figure 4-26).

4–7

4–8

(figure 4-27) (figure 4-28) (figure 4-29)

Continue folding frame until approximately 75% collapsed (figure 4-27). Stop & telescope legs to their original position (figure 4-28). Ensure no fabric is caught in the telescoping portion of the leg assembly when folding. Pull sidewall fabric out before collapsing frame completely, exposing roof bolts (figure 4-28). Leg assembly should lay against frame with no fabric in-between (figures 4-29 & 4-30).

(figure 4-30)

4–9

(figure 4-31) (figure 4-32)

11. Prepare Bundle Continue to fold frame, removing any fabric that may cause frame not to close. Place one compression strap in the middle and one toward the bottom (figure 4-31). Capture as much fabric at the bottom as possible. Pull tight on straps until resistance is met, then lay the shelter on the ground and continue to compress straps using the weight of the shelter to assist (figure 4-32).

4–10

(figure 4-33) (figure 4-34) (figure 4-35)

Once frame is compressed, stand up and place the bag over shelter, then strap bag closed (figure 4-33 & 4-35).

4–11

12. Pack Liner Spread liner out by grabbing onto the four corners and pulling the floor flat on the ground, then pull the corners of the roof toward the corners of the floor (figure 4-36 & 4-37). Fold the floor over onto the roof from each side, meeting at the center (figure 4-38), then fold one side over top of the other (figure 4-39).

Place the liner bag at the end of the liner and begin to roll the liner into the bag (figure 4-40 & 4-41).

Place repair kit, stake, and wind line kits back into the liner bag and close (figure 4-42 & 4-44).

4–12

(figure 4-36) (figure 4-37) (figure 4-38)

(figure 4-39) (figure 4-40) (figure 4-41)

(figure 4-42) (figure 4-43) (figure 4-44)

Section 5–1

Complexing

5–2

5–3

5–4

Section 6–1

Maintenance and Repair

1. Outer Cover

A. Material

1. Maintenance — Wash with soap and water. Hard bristle brushes may be used, scratch pads are not recommended. For more persistent stains or dirty patches use cleaning supplies such as:

Simple Green, Greased Lightning or like cleaners. These should be used IAW manufacture's suggested usage listed on container. Note: If pressure sprayer is used, do not get too close to fabric with spray nozzle.

2. Repair. Repair can be done as a field expedient repair with the adhesive back vinyl.

Before proceeding make sure surface is dry.

GENERAL TEARS NOT ON AN EDGE

Cut: Patch may be cut to size with scissors. Trim corners round before removing liner. Overlap patches 1" on tears larger than patch. Extend patch 1" from edge of all tears.

Peel: Carefully peel back 1/2" of protective liner. Tearing the disposable back liner a little will aid in liner removal when the patch has been cut into smaller pieces.

Stick: Position and anchor exposed 1/2" edge. Slowly remove liner on patch taking care to remove air pockets and seal edges. Rub entire patch aggressively. Do not put into washer or dryer.

TEARS ON AN OUTSIDE EDGE

Follow Step 1 through Step 5 with the following change! Position the patch leaving a one inch tab extended beyond the outside edge of the material and tear to be fixed.

Apply the edge reinforcement line along the edge of the material by sticking it to the patch. The reinforcement line should be perpendicular to the open end of the tear creating a tough solid edge

Fold the 1” tab over the reinforcement line and adhere to the other side of the material. Rub entire patch aggressively and trim excess line. Apply another patch to the backside of the tear

B. Screens

1. Maintenance — Wash with soap and water. SOFT bristle brush may be used, scratch pads are not recommended. For more persistent stains or dirty patches use cleaning supplies such as:

Simple Green, Greased Lightning or similar type cleaners. These should be used IAW manufacture suggested usage listed on container.

Note: If a pressure sprayer is used do not get too close to fabric with spray nozzle.

6–2

6–3

C. Velcro

1. Maintenance — Wash with soap and water. Hard bristle brush may be used, scratch pads are not recommended. If grass or weeds are caught in the Velcro use a stiff DRY brush to comb the debris out or if time allows picking it out by hand may be more effective.

2. Repair —See Replacement Procedures.

D. Air Supply Ducts

1. Maintenance — Wash with soap and water. Hard bristle brush may be used, scratch pads are not recommended. For more persistent stains or dirty patches use cleaning supplies such as Simple Green, Greased Lightning or like cleaners. These should be used IAW manufacture suggested usage listed on container. Note: If pressure sprayer is used do not get too close to fabric with spray nozzle.

2. Repair — If the duct is torn it can be taped with duct tape or the material can be repaired IAW paragraph 1.A.2.a or 1.A.2.b.

E. Zippers

1. Maintenance — Wash with soap and water. Hard bristle brush may be used, scratch pads are not recommended. Also, dry brushing to remove caked on dirt may be necessary for proper operation. Visually inspect the zipper and slider. If the slider is showing signs of spreading, squeeze the sides together being careful not over tighten and cause the zipper to function improperly or in a difficult manner.

2. Repair — If the slider comes off, make a cut across the top of the zipper ONLY about 1½ to 2 inches down from the top (depending on the size of the zipper). Slide the slider up to the top of the zipper, put the other side of the zipper in the end of the zipper and slide the slider down until the teeth of the zipper go together. The more lined up you can get the ends of the zipper, the better it will work at the bottom. The repair is now complete.

6–4

6–5

2. Frame A. Leg Assemblies

1. Maintenance — Wash with soap and water. Hard bristle brush may be used, scratch pads are not recommended. If leg assembly does not lower under its own weight while setting up the tent lubrication of the telescoping leg may be required.

a. The Leg Assembly can be removed from the frame by removing the split-ring and clevis pins at the top of the assembly and at the bottom of the Leg Arm Strut. Remove the telescoping portion of the leg by depressing the button and sliding it out of the lower leg. Wipe down this portion of the leg with a dry cloth. Attach a small portion of a cloth to a wire or wooden handle, turn the lower leg assembly upside down (if possible) and swab the lower portion of the leg assembly. The objective is to remove any dirt or debris from the assembly. A very light coat of lubricant can be applied to the telescoping portion of the leg assembly. Another option is removing the plug from the bottom of the leg assembly. This would require the removal of a cotter pin before removing the clevis pin and cap.

2. Repair. Repair parts for the leg assembly are not included in the kit because a complete assembly is included. Sub-assembly parts can be ordered by calling 1-800-969-8527.

B. Frame* Inspect split rings, scissors, hubs and cables. Replace as needed.

Note: Parts are serviceable as long as functionality is not affected. Some small surface cracks and worn powder-coating may be noted but replacement of the part is not necessary at this time.

3. Liner — See Outer Cover, section 1.

4. Stake Kit

A. Bag. See Outer Cover, section 1.

B. Stake Assembly.

1. Maintenance. Scrub with hard bristle brush or scratch pads. A light coat of lubrication will help keep the stake from rusting.

5. Repair Kit

A. Accountability. See enclosure 1 of this manual.

B. Ordering Replacement Parts. See section 7 of this manual. Visit www.hdtglobal.com and click on the sales link to submit your request or call 1-800-969-8527.

6–6

Section 7–1

Parts Replacement

1. Outer Cover. Before replacing the outer cover, all attempts should be made to repair it. If the damage is too extensive for the unit to repair, contact the company directly at 1-800-969-8527 and speak to a representative about repair by the manufacturer or to seek expert advice.

IF replacement by the unit is decided to be the most feasible option, the new cover will come with bolt holes already in it and new hardware for mounting the cover. After removing the old cover, lay the new cover across the frame to the peak of the shelter, starting at one side, bolt the cover to the frame. Only the two outer rows of bolts should have the wind-line attachments. If the rivet nut (zinc coated) at the top of the hub/lock assembly starts to turn, a small pair of needle-nose vise-grips or pliers can be used to hold it while the bolt is tightened.

The proper orders for the bolt assemblies are:

a. With Wind-line attachment b. Without Wind-line attachment

Head of ¼ - 20 X 1" bolt Head of ¼ - 20 X 1" bolt Metal Washer Metal Washer Wind-line attachment Rubber Washer Rubber Washer Outer Cover Outer Cover Rubber Washer Rubber Washer Metal Washer Metal Washer Plastic Disk Plastic Disk Frame Frame

Note: For proper bolt assembly remove the Wind-line attachment and follow the place-ment order.

7–2

Note: 7/16” wrench and split ring pliers in repair kit.

7–3

A. Screens. Before replacing the screen, all attempts should be made to repair it, see maintenance and repair procedures. If the damage is too extensive for the unit to repair, contact the company directly and speak to a representative about repair by the manufacturer or to seek expert advice.

B. Clear Window Vinyl. The clear vinyl window cover is easily removed and replaced. It has hook and loop fastener on all four sides and pulls out easily. The replacement cover fits into position easily.

C. Inner Window Cover. Before replacing the Inner window cover, all attempts should be made to repair it, see maintenance and repair procedures. If the damage is too extensive for the unit to repair, contact the company and speak to a representative about repair by the manufacturer or to seek expert advice.

D. Velcro. Before replacing the Velcro at the unit level contact the company and speak to a representative about repair by the manufacturer or to seek expert advice.

E. Air Supply Ducts. See outer Cover Material.

F. Zippers. Before replacing the Zipper all attempts should be made to repair it, see maintenance and repair procedures. If the damage is too extensive for the unit to repair, contact the company and speak to a representative about repair by the manufacturer or to seek expert advice.

2. Frame

A. Leg Assemblies. Remove the split ring and clevis pins from the bottom and then the top of the leg assembly. Paying particular attention to the direction the clevis pin was removed. Additionally, there will be a spacer and split-ring per attachment point, put these somewhere they will not get lost.

Attach the new leg assembly in the reverse order it was removed. If one or more of the parts are defective in any way, replace it with a new part located in the repair kit. If assistance is needed in re-assembly, look at another leg assembly and duplicate the installation.

B. Telescoping Leg Assembly. Detach the upper portion of the telescoping leg assembly from the frame. Press in on the locking button and slide the telescoping assembly out. Insert the new telescoping portion into the lower leg ensuring the button is aligned to protrude through the hole in the lower leg. Attach the top of the telescoping leg to the frame with the clevis pin and split ring, ensuring there are no extra parts.

C. Leg Arm Strut. Remove the split ring from the clevis pin and remove the clevis pin from the lower attachment point. Remove the cotter pin from the clevis pin and slide the clevis pin out of the upper attachment point. Paying particular attention to the direction the clevis pin was removed. Attach the new Leg Arm Strut in the reverse order it was removed. If one or more of the parts are defective in any way replace it with a new part located in the repair kit. If assistance is needed in re-assembly, look at another leg assembly and duplicate the installation. If one or more of the parts are defective in any way, replace it with a new part located in the repair kit. If assistance is needed in re-assembly;

look at another leg assembly and duplicate the installation.

7–4

Note: 7/16” wrench and split ring pliers in repair kit.

7–5

D. Cables. Cables are located throughout the framework of the shelter. When replacing them, it is imperative you install the correct cable in the correct location. Cable bags in the repair kit are marked, as well as individual cables. They are listed by nomenclature and part number breakdown enclosure of this manual.

E. Scissors. When replacing scissors it is important to the function of the frame that the proper part be replaced. Scissors are marked for identification as follows:

Part Color Marking Page 180° Complete Assembly Black No label 9-9

(2 pieces connected in the center by a Silver-headed clevis pin) 90° Complete Assembly Black Red Labels 9-10

(2 pieces connected off center by a Red-headed clevis pin) 45° Complete Assembly Black Yellow Labels 9-11

(2 pieces connected off center by a Yellow-headed clevis pin) 180° Complete Peak Row Assembly Black No label 9-12

(2 pieces connected in the center by a Silver-headed clevis pin)

The label on the scissor will identify the long ends. These parts are installed at the top or roof. The 180° scissor has no labels and both lengths are the same.

When performing repairs to scissors on the outer portion of the frame it will be best to do with the frame partially folded. This allows the best access to the part. If the replacement is to a scissor on the inside of the frame, then working with one side raised will best allow access to the part. If working in this location be sure that the eave row of hubs is locked before raising one side. If there are several parts to be replaced, it may be helpful to remove the outer cover. This can be done by removing the 7/16” bolt that secures the fabric. Be sure to keep all parts. They will be needed for reassembly.

Once the best position has been determined, unlock the hub assemblies to which the damaged scissor is connected. This will relieve the tension on the parts. Then remove the split rings and clevis pins and remove the damaged piece. If cables are attached they will need to be reinstalled properly to the new scissor. Align holes in the scissor with the holes in the hub and reinstall pins and split rings.

If working on the outer scissor, begin with the frame folded. Start by installing the bottom portion of the tube. This will allow the work area to be at eye level when finishing. If working under the shelter, begin with one side raised. Install the top parts first and finish at the bottom. Again, this will allow the work area to be at eye level when finishing. Be sure cables have been installed correctly.

7–6

7–7

F. Hub/Lock Assemblies. When performing repairs to hub on the outer portion of the frame, it will be best to do with the frame partially folded. This allows the best access to the part. If the replacement is to a hub on the inside of the frame, working with one side raised, will allow best access to the part.

If working in this location, be sure that the eave row of hubs is locked before raising one side. If replacing the top portion of the hub, then remove the 7/16” bolt that holds the fabric to the hub.

Keep all parts. They will be needed for reassembly.

When replacing the hub/lock assembly it is NOT necessary to replace both halves if one is still serviceable. Remove the split ring from the clevis pen and remove the clevis pen from the hub assembly, disconnecting any scissor assemblies. Insert the new hub portion and reattach the scissor assemblies. Pay particular attention to the direction the button is facing to ensure it lines up with the hole in the other half. Reattach the cables to the clevis pins. Reattach the Scissor Assembly in the reverse order they were removed. Unlocking the hubs at each end and in the general area of the assembly will aid in getting the new assembly installed. If assistance is needed in reassembly; look at another assembly and duplicate the installation, make sure the assembly you are copying is the same type.

Trouble Shooting Table

7–8

Problem Cause Solution Frame will not expand � Cable or fabric hung-up on frame � Clear cables or fabric from frame

� Leg assemblies not expanded � All leg assembles must expand at the same time

� Frame hung-up on the ground � Lift frame over obstacle

Hubs will not engage � Frame not expanded completely � Pull on grip here to expand labels further

� Fabric over outer peak � Remove fabric from peak of shel-ter

� Bent or incorrect scissor on frame � Replace with proper scissor

Leg buttons will not lock � Button pushed up inside of tele-scoping tube of leg assembly

� Remove top strut assembly and reinsert button into hole in tube

Frame will not fold � Hub locks still engaged � Unlock all hubs � Frame hung up on the ground � Lift frame over obstacle

Section 8–1

NSN’s and Kit Component Listings

Description P/N NSN Shelter Model 102 60102OD Shelter Model 102 60102TN Shelter Model 103 60103OD 8340-01-533-1682 Shelter Model 103 60103TN 8340-01-533-1681 Shelter Model 105 60105OD 8340-01-533-1678 Shelter Model 105 60105TN 8340-01-533-1680 Shelter Model 203 60203OD 8340-01-533-1677 Shelter Model 203 60203TN 8340-01-533-1675 Shelter Model 203 (stove pipe flange) 60203SPTN 8340-01-545-5875 Shelter Model 203 (stove pipe flange) 60203SPOD 8340-01-545-5888 Shelter Model 205 60205OD 8340-01-533-1674 Shelter Model 205 60205TN 8340-01-533-1671 Shelter Model 303 60303OD 8340-01-533-1685 Shelter Model 303 60303TN 8340-01-533-1686 Shelter Model 305 60305OD 8340-01-533-1672 Shelter Model 305 60305TN 8340-01-533-1668 Shelter Model 305 (stove pipe flange) 60305SPTN 8340-01-545-5884 Shelter Model 305 (stove pipe flange) 60305SPOD 8340-01-545-5869 Shelter Model 307 60307OD 8340-01-533-1691 Shelter Model 307 60307TN 8340-01-533-1687

Complete Shelters

8–2

Complete Kits Description P/N NSN

Wind-Line Kit 69007

Repair Kit 100 Series 69010-1 8340-01-531-7407

Repair Kit 200 Series 69010-2

Repair Kit 300 Series 69010-3 8340-01-533-1694

Stake Kit 103-203-303 690004BK

Stake Kit 105-205-305 690006BK

Stake Kit 307 690008BK

Description P/N NSN Quantity 102 103 105 203 205 303 305 307

Stake Bag 65902 1 1 1 1 1 1 1 1 Mallet 69MALLET-3 1 1 1 1 1 1 1 1 Tent Stake, 12” Aluminum, OD 69ST001 8 12 16 12 16 12 16 24 Stake 3/4” dia X 24”, Assembly 69ST010 4 4 6 4 6 4 6 8

Stake Kit (per tent)

8–3

Repair Kit (per tent) Description P/N NSN Quantity

103 105 203 205 303 305 307 Hub Lock Assembly 65001 8340-01-531-7024 1 1 1 1 1 1 1 45° Scissor Assembly 65051A 8340-01-531-7029 0 0 3 3 3 3 3 180° Scissor Assembly 65061 8340-01-531-0306 1 1 3 3 3 3 3 90° Scissor Assembly 65091A 1 1 0 0 0 0 0 Top Strut Assembly, 100 Series 65125 1 1 0 0 0 0 0 Top Strut Assembly, 300 Series 65135 0 0 0 0 1 1 1 Repair Kit Bag 65901 1 1 1 1 1 1 1 Leg Assembly 65300100 8340-01-531-7027 1 1 1 1 1 1 1 Windline Attachment Assembly 65WLA-1 1 1 1 1 1 1 1 45° Scissor Cable (Yellow) 69CA045 8340-01-531-7056 0 0 2 2 2 2 2 45° Scissor Cable Keep (White) 69CA045-1 8340-01-531-7053 0 0 1 1 1 1 1 180° Scissor Cable (Red) 69CA180 8340-010531-7058 0 0 0 0 2 2 2 180° Scissor Cable Keep (Silver) 69CA180-1 8340-01-531-7050 0 0 0 0 1 1 1 45° Diagonal Cable (Brown) 69CAD045 8340-01-531-7057 0 0 2 2 2 2 2 180° Diagonal Cable (Black) 69CAD180 8340-01-531-7051 0 0 0 0 2 2 2 Clevis Pin 3/16” x 1 ½” 69CP3010 5 5 5 5 5 5 5 Clevis pin, 3/16” x 1 ½” double head 69CPDH3010 0 0 0 0 3 3 3 Clevis Pin 3/16” x 1 ¾” 69CP3020 4 4 4 4 4 4 4 Clevis Pin 3/16” x 2 ½” 69CP301025 4 4 0 0 4 4 4

A

8–4

Plastic Dish 69DP01 2 2 2 2 2 2 2 Snap Button 69INC004 1 1 1 1 1 1 1 Liner Clip Assembly 69LCA 1 1 1 1 1 1 1 Split Ring 69SR040 10 10 10 10 10 10 10 Cotter Pin 69SR041 7 7 7 7 7 7 7 Rubber Washer 69WR006 3 3 3 3 3 3 3 Adhesive Back Fabric -- Outer Green FV44103ADHFG 1 1 1 1 1 1 1 Adhesive Back Fabric -- Outer Tan FV44103ADHTN 1 1 1 1 1 1 1 Adhesive Back Fabric -- Liner FV44423ADH 1 1 1 1 1 1 1 Bolt ¼ - 20 x ¾” Long HHHC04BLK 1 1 1 1 1 1 1 Bolt ¼ - 20 x 1” Long HHHC06BLK 3 3 3 3 3 3 3 Washer 1 ¼” HRWBLK 6 6 6 6 6 6 6 Split Ring Pliers 48-SPLTRNG-01 1 1 1 1 1 1 1 7/16 Wrench 48-BW716-01 1 1 1 1 1 1 1

Description P/N NSN Quantity

8–5

Wind-Line Kit (per tent)

Description P/N NSN Quantity 102 103 105 203 205 303 305 307

Wind-line bag 65914 2 3 4 3 4 3 4 5 Tent Stake, 12” Aluminum, OD 69ST001 8 12 16 12 16 12 16 20 Nylon Rope, 7mm WCN7MMBK 8 12 16 12 16 12 16 20 Tent Slip, 3/8”, Black 69TS02BL 8 12 16 12 16 12 16 20

Section 9–1

ILLUSTRATED PARTS BREAKDOWN

Summary of System Components

This manual should be used in conjunction with the video.

Frames, Outer Cover & Liner Section Page

100 Series Frame Assembly

200 Series Frame Assembly

300 Series Frame Assembly (End View)

300 Series Frame Assembly (Side View)

Base-X Outer Cover

Base-X Liner

9–2

100 Series Frame Assembly

The 100 Series top strut assembly is different than the 300 Series top strut assembly.

200 Series Frame Assembly

(yellow) (white)

(brown)

9–3

9–4

300 Series Frame Assembly - End View

The 100 Series top strut assembly is different than the 300 Series top strut assembly.

(black)

(brown)(brown)

(red) (silver)

(white)(yellow)

300 Series Frame Assembly - Side View

(brown) (black)

9–5

Outer Cover

The 305 and 307 models have inlet and return ducts in all four corners.

9–6

Liner

The 305 and 307 models have inlet and return ducts in all four corners.

9–7

9–8

Sub Assemblies Section Page

180° Complete Assembly

90° Complete Assembly

45° Complete Assembly

180° Complete Peak Row Strut Assembly

Leg Assembly

Hub/Lock Assembly

9–9

180° Complete Assembly

9–10

90° Complete Assembly

9–11

45° Complete Assembly

9–12

180° Complete Peak Row Assembly

Leg Assembly

(P/N 69INC004)

Top Leg Strut (P/N 65300100-3)

9–13

Leg Arm Hub Bracket

(P/N 69BRLH001)

Top Leg Hub Bracket

(P/N 69BRLH0031)

9–14

Hub/Lock Assembly

Warranty Statement

HDT Engineered Technologies (HDT) Expedition Shelters are guaranteed for a period of 3 years from the date of purchase. At the discretion of the manufacturer, HDT will repair or replace any component that fails as a result of workmanship or materials. Conditions such as tears in fabrics or screens, bent poles, stretched cables, broken tent stakes, and broken light bulbs are considered normal wear and tear and as such are not covered by this warranty. Some components may have other manufacturer warranties (such as light bulbs). Contact that component's manufacturer for more information.

The purchaser is responsible for cleaning and returning defective components to our manufacturing facility located at:

HDT Expeditionary Systems, Inc.

6051 North Lee Highway Fairfield, Virginia 24435

Section 10–1

INSTRMAN Rev. B11/09