Vehicle Systems H983 Instructions Manual

Dolly converter, heavy, tank/plant transporter, mc4

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ELECTRICAL AND MECHANICAL

ENGINEERING INSTRUCTIONS

DOLLY CONVERTER, HEAVY, TANK/PLANT TRANSPORTER, MC4

This instruction is authorised for use by command of the Chief of Army. It provides direction, mandatory

controls and procedures for the operation, maintenance and support of equipment. Personnel are to carry out any

action required by this instruction in accordance with EMEI General A 001.

General ..................................................................................1

Introduction .......................................................................3

Associated Publications ....................................................3

Authorised Personel..........................................................3

Safety Precautions ............................................................3

General Instructions ..........................................................3

Special Tools and Gauges ................................................4

Adjustment and Calibrations .............................................5

Functional Tests................................................................5

Replacement .....................................................................5

Adjustment Procedures .........................................................5

Axle Alignment.......................................................................5

Brake Adjustment ..................................................................6

Brake System Operating And Leakage Tests........................7

Functional Tests................................................................7

Replacement Procedures ......................................................9

Axles ......................................................................................9

Wheel Hubs.......................................................................9

Figure 1

Dolly Converter Axle Alignment Diagram..................5

Figure 2

Slack Adjuster Alignment ..........................................6

Figure 3

Wheel Hub Assembly - Exploded View.....................9

Figure 4

Brake Drum and Wheel Nuts - Tightening

Sequence ....................................................................12

Table 1

Maintenance Supply Item (MSI) Identification............4

Table 2

Special Tools..............................................................4

LIGHT GRADE REPAIR

Page No

Wheels ................................................................................ 13

Brake System ...................................................................... 14

Electrical.............................................................................. 20

LIST OF FIGURES

Page No

Figure 6

Figure 7

Figure 8

LIST OF TABLES

Page No

Table 3

Table 4 12 Pin NATO Cable - Pins and Colour Codes .......... 20

Hubodometer .................................................................. 13

Specifications.................................................................. 13

Maintenance ................................................................... 13

Specifications.................................................................. 14

Brake System Maintenance............................................ 14

Brake Relay Valves ........................................................ 14

Boost Relay Valve .......................................................... 15

Spring Brake Control Valve ............................................ 16

Yard Release Valve ........................................................ 16

Spring Brake Chamber ................................................... 17

Brake Shoes. .................................................................. 18

Fault Finding ................................................................... 19

Specifications.................................................................. 20

Repairs ........................................................................... 20

Specifications.................................................................. 21

Brake Relay Valve Mounting .................................. 15

Spring Brake Control Valve Mounting .................... 16

Wheel Brake Assembly .......................................... 18

Dolly Converter Electrical Circuit Diagram ............. 20

Brake System Fault Finding..................................... 19

VEHICLE H 983

Issue 1, Jul 11

Page No

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Page 1: Table Of Contents
ELECTRICAL AND MECHANICAL VEHICLE H 983 ENGINEERING INSTRUCTIONS Issue 1, Jul 11 DOLLY CONVERTER, HEAVY, TANK/PLANT TRANSPORTER, MC4 LIGHT GRADE REPAIR This instruction is authorised for use by command of the Chief of Army. It provides direction, mandatory controls and procedures for the operation, maintenance and support of equipment. Personnel are to carry out any action required by this instruction in accordance with EMEI General A 001.
Page 2 VEHICLE H 983 ELECTRICAL AND MECHANICAL Issue 1, Jul 11 ENGINEERING INSTRUCTIONS Blank Page...
Page 3: General
ELECTRICAL AND MECHANICAL VEHICLE H 983 ENGINEERING INSTRUCTIONS Issue 1, Jul 11 GENERAL Introduction This EMEI details all Light Grade Repair procedures for the Dolly Converter, Heavy, Tank/Plant Transporter, MC4. Associated Publications Reference may be necessary to the latest issue of the following documents: Defence Road Transport Instructions (DRTI);...
Page 4: Special Tools And Gauges
VEHICLE H 983 ELECTRICAL AND MECHANICAL Issue 1, Jul 11 ENGINEERING INSTRUCTIONS Replace all devices with stripped threads or damaged parts. Table 1 lists the location of the identification information on the Maintenance Supply Items. Table 1 Maintenance Supply Item (MSI) Identification Serial Item Location...
Page 5: Adjustment And Calibrations
ELECTRICAL AND MECHANICAL VEHICLE H 983 ENGINEERING INSTRUCTIONS Issue 1, Jul 11 Adjustment and Calibrations Light Grade Repairs include the following procedures: Axle alignment, and Brake adjustment Functional Tests Light Grade Repair includes the following procedures: Brake System Operating and Leakage Tests Replacement Light Grade Repair includes replacement and/or repair of the following components: Axles:...
Page 6: Brake Adjustment
VEHICLE H 983 ELECTRICAL AND MECHANICAL Issue 1, Jul 11 ENGINEERING INSTRUCTIONS Preliminary Checks. Prior to carrying out any axle alignment adjustment: Unload the trailer if fitted. Ensure that all suspension components are in good condition. Ensure that all tyre pressures are correct. Ensure the dolly is on flat, level ground.
Page 7: Brake System Operating And Leakage Tests
ELECTRICAL AND MECHANICAL VEHICLE H 983 ENGINEERING INSTRUCTIONS Issue 1, Jul 11 BRAKE SYSTEM OPERATING AND LEAKAGE TESTS The following tests are to be performed to determine the presence of operating faults in the dolly converter air brake system. Check the prime mover air pressure gauge against a calibrated test gauge before carrying out these tests. Functional Tests Before carrying out these tests ensure that the dolly converter wheels are securely chocked.
Page 8 VEHICLE H 983 ELECTRICAL AND MECHANICAL Issue 1, Jul 11 ENGINEERING INSTRUCTIONS When the air pressure has dropped to the minimum pressure attained in Para 32, apply the service brakes and release. NOTE Two applications of the service brakes should be possible. Close the air tank drain valves and allow the air pressure to return to normal.
Page 9: Replacement Procedures
ELECTRICAL AND MECHANICAL VEHICLE H 983 ENGINEERING INSTRUCTIONS Issue 1, Jul 11 REPLACEMENT PROCEDURES AXLES Wheel Hubs Removal. To remove the wheel hubs (Figure 3): Hub seal sleeve Wheel hub Wheel hub nut lock plate Hub seal Outer wheel bearing cup Wheel hub lock nut Inner wheel bearing cone Outer wheel bearing cone...
Page 10 VEHICLE H 983 ELECTRICAL AND MECHANICAL Issue 1, Jul 11 ENGINEERING INSTRUCTIONS Remove the bearing adjusting nut (8) using the hub nut tube wrench (Table 2, Serial 3). Support the wheel hub and brake drum assembly with a suitable trolley jack. Remove the outer bearing cone (7) from the hub and stub axle.
Page 11 ELECTRICAL AND MECHANICAL VEHICLE H 983 ENGINEERING INSTRUCTIONS Issue 1, Jul 11 Inspect the bearing cone for: discolouration of the tapered rollers; chipping or scoring of the case hardening; flaking of the case hardening; acceptable wear limits on the wear back surface (the large end of the tapered roller); and the condition of the tapered roller cage.
Page 12: Figure 4 Brake Drum And Wheel Nuts - Tightening Sequence
VEHICLE H 983 ELECTRICAL AND MECHANICAL Issue 1, Jul 11 ENGINEERING INSTRUCTIONS Hub Installation. Prior to installation of the hub and brake drum assembly, ensure that: The brake drum mounting bolts are serviceable and correctly tensioned in the sequence shown at Figure 4.
Page 13: Hubodometer
ELECTRICAL AND MECHANICAL VEHICLE H 983 ENGINEERING INSTRUCTIONS Issue 1, Jul 11 Fit the wheel to the hub and secure with the five clamps and hexagon nuts. Tighten the wheel nuts evenly in the sequence shown in Figure 4. Raise the axle clear of the safety stand, remove the stand and lower the wheel to the ground. Wheel nuts shall be checked and retentioned after travelling approximately 50 Tighten the wheel nuts to the torque specified in Para 54.
Page 14: Specifications
VEHICLE H 983 ELECTRICAL AND MECHANICAL Issue 1, Jul 11 ENGINEERING INSTRUCTIONS Tighten the clamp nuts evenly to the torque specified in Para 57. Specifications The wheel specifications are as follows: Maximum wheel run out ........................2 mm Tyre pressures (cold) laden ......................800 kPa Tyre pressures (cold) unladen.......................
Page 15: Boost Relay Valve
ELECTRICAL AND MECHANICAL VEHICLE H 983 ENGINEERING INSTRUCTIONS Issue 1, Jul 11 Figure 5 Brake Relay Valve Mounting Chock and hold the trailer or dolly. Drain the brake system reservoir. Tag all air lines connected to the valve to facilitate installation (Figure 5). Disconnect the air lines from the valve.
Page 16: Spring Brake Control Valve
VEHICLE H 983 ELECTRICAL AND MECHANICAL Issue 1, Jul 11 ENGINEERING INSTRUCTIONS Connect all air lines to the correct ports, using the identification markings of the lines made before the valve was removed. Test all reconnected air line fittings for leakage. Test the valve as detailed in Para 22.
Page 17: Spring Brake Chamber
ELECTRICAL AND MECHANICAL VEHICLE H 983 ENGINEERING INSTRUCTIONS Issue 1, Jul 11 Installation. Install the yard release valve as follows: Install the valve in the mounting bracket, securing it with the panel mounting nut. Connect the air lines. Install the button. Install the roll pin to secure the button to the plunger.
Page 18: Brake Shoes
VEHICLE H 983 ELECTRICAL AND MECHANICAL Issue 1, Jul 11 ENGINEERING INSTRUCTIONS Brake Shoes. Removal. Remove the brake shoes as follows: Remove the spring brake chamber as detailed in Para 67. Remove the wheel hub and brake drum assembly as detailed in Para 45. Move the slack adjuster and camshaft into the fully released position.
Page 19: Fault Finding
ELECTRICAL AND MECHANICAL VEHICLE H 983 ENGINEERING INSTRUCTIONS Issue 1, Jul 11 Fault Finding Table 3 Brake System Fault Finding Serial Symptom Probable Cause Action Insufficient braking Check for damaged parts, replace as Mechanical components damaged required Worn brake linings Replace brake linings Check supply pressure from the Low pressure in the brake system...
Page 20: Specifications
VEHICLE H 983 ELECTRICAL AND MECHANICAL Issue 1, Jul 11 ENGINEERING INSTRUCTIONS Specifications The specifications for the brakes are as follows: Brake chamber clamp torque..................35 N.m (25 lb. ft) Maximum brake chamber pushrod travel ..................51 mm Brake chamber to clevis centre line....................150 mm ELECTRICAL Repairs When carrying out repairs to the electrical system ensure that the following points are observed:...
Page 21: Specifications
ELECTRICAL AND MECHANICAL VEHICLE H 983 ENGINEERING INSTRUCTIONS Issue 1, Jul 11 Specifications The electrical system specifications are as follows: System voltage ..........................12 V DC Remote control current (winch) ......................1 A Solenoid valve current (winch) ......................2.5 A Connector plug ........................12 pin NATO Distribution List: VEH H 08.0 –...

Vehicle Systems H983 Instructions Manual

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