CHAPTER 1. GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF OPERATION FOR MACHINE AND WELDING SHOP
GENERAL INFORMATION
PREPARATION FOR STORAGE OR SHIPMENT
LIST OF ABBREVIATIONS/ACRONYMS
SAFETY, CARE, AND HANDLING
SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
Figure 1. Machine and Welding Shop.
Figure 2. Expanded Wall Transport Mode Component View (SC4920-99-CLA63).
Figure 3. Expanded Wall Transport Mode Component View (1035458).
Figure 4. Fixed Wall Transport Mode Component View (SC4920-99-CLA63).
Figure 5. Fixed Wall Transport Mode Component View (1035458).
Figure 6. Operational Mode Component View (SC4920-99-CLA63).
Figure 7. Operational Mode Component View (1035458).
DIFFERENCES BETWEEN MODELS
THEORY OF OPERATION
CHAPTER 2. OPERATOR INSTRUCTIONS FOR MACHINE AND WELDING SHOP
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS
Table 1. Oil/Water Separator Controls and Indicators.
OPERATION UNDER USUAL CONDITIONS: SITING REQUIREMENTS
Figure 1. Leveling Support Jack Assemblies.
Figure 2. Leveling Support Jack Install.
Figure 3. Load Balancer Slide Stops, Upper Positions.
Figure 4. Cam Lock Handles.
Figure 5. Load Balancer Slide Stops, Lower Position.
Figure 6. Positioning Hinged Wall.
Figure 8. Hinged Jack Assemblies.
Figure 9. Hinged Jack Assemblies Extensions.
Figure 10. Positioning Hinged Jack Assemblies.
Figure 11. Solar Bar Handles.
Figure 12. Raised Hinged Roof.
Figure 13. Positioning Roof and Hinged End Walls.
Figure 14. Hinged Roof Support Strut Assemblies.
Figure 15. Shelter Leveling.
Figure 16. Remove Sidewall Support Braces.
CONNECTING POWER TO THE SHELTER
CONNECTING POWER DISTRIBUTION BOX (PDB) TO GENERATOR (IF NECESSARY)
Figure 3. Main Circuit Breaker.
Figure 4. Relocation of Cable Reel Assembly and 100 amp Power Cable Assembly.
Figure 5. Extending Main Power Cable.
Figure 7. Connecting Main Power Cable to PDB.
INSTALL LIGHTING
Figure 2. Installing Ceiling Lights.
Figure 3. Connecting Ceiling Lights.
Figure 4. Installing Cable and Receptacle Assembly.
Figure 5. Installing Area Light.
PREPARING SHELTER FOR ECU INSTALLATION
Figure 1. Hinged Floor Cable Guide Housing Removal.
Figure 2. Hinged Floor Cable Guide Housing Reinstall.
Figure 3. Removing Plugs on ECU Fold-down Panel.
Figure 4. ECU Fold-down Panel Latches.
Figure 6. Installing T-Seal.
SAFEGUARDING ATTACHING HARDWARE
POSITIONING SHELTER BASIC ISSUE ITEMS (BII) BOX FOR OPERATIONAL MODE
POSITIONING ECU S FOR OPERATIONAL MODE
Figure 1. Unsecure ECU (A).
Figure 2. Placing ECU (A) on ECU Fold-down Panel.
Figure 4. Aligning Bolt Holes of ECU (A) with ECU Fold-down Panel.
Figure 6. Unsecure ECU (B).
Figure 7. Placing ECU (B) on ECU Fold-down Panel.
Figure 9. Aligning Bolt Holes of ECU (B) with ECU Fold-down Panel.
Figure 11. Connecting Power to ECU s.
POSITIONING STRAIGHT STOOLS FOR OPERATIONAL MODE
Figure 1. Unsecure Straight Stools (SC4920-99-CLA63).
Figure 2. Unsecure Straight Stools (1035458).
POSITIONING EYEWASH STATION ASSEMBLY AND BRACKET FOR OPERATIONAL MODE
Figure 1. Unsecure Eyewash Station (SC4920-99-CLA63).
Figure 2. Position Eyewash Station (SC4920-99-CLA63).
Figure 3. Unsecure Eyewash Station (1035458).
Figure 4. Position Eyewash Station (1035458).
POSITIONING GAS CART FOR OPERATIONAL MODE
Figure 1. Unsecure Gas Cart.
POSITIONING SHELF CABINET (E) FOR OPERATIONAL MODE
Figure 1. Unsecure Four Drawer Cabinet (E) .
POSITIONING SHELF CABINET (D) FOR OPERATIONAL MODE
Figure 1. Unsecure Shelf Cabinet (D).
POSITIONING ANVIL AND ANVIL STAND FOR OPERATIONAL MODE
Figure 1. Unsecure Anvil Stand with Anvil.
POSITIONING WELDING MACHINE FOR OPERATIONAL MODE
Figure 1. Unsecure Welding Machine.
POSITIONING PLASMA CUTTER FOR OPERATIONAL MODE
Figure 1. Unsecure Plasma Cutter.
CONNECTING COMPRESSED AIR AND WATER
Figure 2. Connecting Compressed Air.
CHECKING SHELTER LEVEL
DISCONNECTING COMPRESSED AIR AND WATER
Figure 2. Replacing Protective Dust Cap.
POSITIONING ECUS FOR TRANSPORT MODE
Figure 2. Removing ECU (B) Hardware from ECU Fold-down Panel.
Figure 3. Secure ECU (B).
Figure 4. Removing ECU (A) Hardware from ECU Fold-down Panel.
Figure 5. Secure ECU (A).
POSITIONING SHELTER BII BOX FOR TRANSPORT MODE
POSITIONING EYEWASH STATION ASSEMBLY BRACKET AND HARDWARE FOR TRANSPORT MODE
POSITIONING EYEWASH STATION ASSEMBLY BRACKET AND HARDWARE FOR TRANSPORT MODE - Continued
Figure 2. Secure Eyewash Station (1035458).
POSITIONING STRAIGHT STOOLS FOR TRANSPORT MODE
Figure 1. Secure Straight Stools (SC4920-99-CLA63).
Figure 2. Secure Straight Stools (1035458).
POSITIONING FOUR DRAWER CABINET (E) FOR TRANSPORT MODE
POSITIONING FOUR DRAWER CABINET (E) FOR TRANSPORT MODE - Continued
POSITIONING SHELF CABINET (D) FOR TRANSPORT MODE
POSITIONING SHELF CABINET (D) FOR TRANSPORT MODE - Continued
POSITIONING GAS CART FOR TRANSPORT MODE
Figure 1. Secure Gas Cart.
POSITIONING GAS CART FOR TRANSPORT MODE - Continued
POSITIONING ANVIL AND ANVIL STAND FOR TRANSPORT MODE
Figure 1. Secure Anvil Stand with Anvil.
POSITIONING WELDING MACHINE FOR TRANSPORT MODE
Figure 1. Secure Welding Machine.
POSITIONING WELDING MACHINE FOR TRANSPORT MODE - Continued
POSITIONING PLASMA CUTTER FOR TRANSPORT MODE
Figure 1. Secure Plasma Cutter.
PREPARING SHELTER FOR ECU STOWAGE
Figure 2. Closing ECU Fold-down Panel.
Figure 4. Installing Plugs on ECU Fold-down Panel.
Figure 6. Hinged Floor Cable Guide Housing Installation.
DISCONNECTING POWER FROM SHELTER
Figure 2. Disconnecting Main Power Cable from PDB.
Figure 3. Disconnecting Main Power Cable from Shelter.
Figure 4. Securing Cable Reel Assembly.
Figure 5. Disconnecting PDB from Generator.
Figure 6. Removing External Grounding Rod.
REMOVING LIGHTING
Figure 2. Removing Cable and Receptacle Assembly.
Figure 3. Repositioning Ceiling Lights.
PREPARING SHELTER FOR TRANSPORT
Figure 1. Releasing Shelter Walls.
Figure 3. Lowering Shelter Roof.
Figure 4. Secure Support Strut Assemblies.
Figure 6. Hinged Jack Assemblies Extension.
Figure 7. Load Balancers Slide Stops, Upper Position.
Figure 8. Cam Lock Handles.
Figure 9. Load Balancers Slide Stops, Lower Position.
Figure 10. Lowering Leveling Support Jack Assemblies.
Figure 11. Stowing Leveling Support Jack Assemblies.
OPERATION UNDER UNUSUAL CONDITIONS
Figure 2. Installing Ground Anchors.
Figure 3. Loops and Clamps Installation.
Figure 4. Securing Loops and Clamps.
OPERATION IN SNOW, ICE OR EXTREME COLD
OPERATION FOR IMPROVING SOIL CONDUCTIVITY FOR SHELTER GROUNDING
CHAPTER 3. FIELD LEVEL MAINTENANCE TROUBLESHOOTING PROCEDURES FOR MACHINE AND WELDING SHOP
TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING PROCEDURES - Continued
CHAPTER 4. FIELD LEVEL MAINTENANCE INSTRUCTIONS FOR MACHINE AND WELDING SHOP
SERVICE UPON RECEIPT
PREVENTIVE MAINTENANCE CHECKS AND SERVICE (PMCS) INTRODUCTION
Corrosion Prevention and Control (CPC)
PREVENTIVE MAINTENANCE CHECKS AND SERVICE (PMCS)
Table 1. Field Level Preventive Maintenance Checks and Services for Machine and Welding Shop.
Table 1. Field Level Preventive Maintenance Checks and Services for Machine and Welding Shop. - Continued
Table 1. Field Level Preventive Maintenance Checks and Services for Machine and Welding Shop. - Continued
Table 1. Field Level Preventive Maintenance Checks and Services for Machine and Welding Shop. - Continued
Table 1. Field Level Preventive Maintenance Checks and Services for Machine and Welding Shop. - Continued
Table 1. Field Level Preventive Maintenance Checks and Services for Machine and Welding Shop. - Continued
MAINTENANCE INSTRUCTIONS FOR CABINET ASSEMBLIES
Figure 2. Drawers, Slides, and Shelves Remove and Install.
DRAWERS, SLIDES, AND SHELVES
Figure 3. Cabinet (A) and Cabinet (B).
SIX DRAWER CABINET (A) AND SIX DRAWER CABINET (B)
SIX DRAWER CABINET (A) AND SIX DRAWER CABINET (B) CONTINUED
Figure 4. Cabinet (C) .
REPAIR OR REPLACEMENT
INSPECTION OF INSTALLED ITEMS
REPAIR OR REPLACEMENT
FOUR DRAWER CABINET (E)
FOUR DRAWER CABINET (E)
MAINTENANCE INSTRUCTIONS FOR CABINET INTEGRATION HARDWARE
MAINTENANCE INSTRUCTIONS FOR CABINET INTEGRATION HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR CABINET INTEGRATION HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR CABINET INTEGRATION HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR EYEWASH STATION ASSEMBLY BRACKET AND HARDWARE
MAINTENANCE INSTRUCTIONS FOR EYEWASH STATION ASSEMBLY BRACKET AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR MILLING/DRILLING MACHINE AND HARDWARE
Figure 2. Continuity Check on Plug Connector.
Figure 3. Replace Plug Connector.
Figure 4. Milling/Drilling Machine.
MILLING/DRILLING MACHINE MOUNTING HARDWARE CONTINUED
MAINTENANCE INSTRUCTIONS FOR BENCH GRINDER AND HARDWARE
MAINTENANCE INSTRUCTIONS FOR BENCH GRINDER AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR MACHINIST VISE AND HARDWARE
MAINTENANCE INSTRUCTIONS FOR CYLINDER BRACKET ASSEMBLY AND HARDWARE
MAINTENANCE INSTRUCTIONS FOR CYLINDER BRACKET ASSEMBLY AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR PLASMA CUTTER
Figure 2. Continuity Check on Plug Connector.
Figure 3. Replace Plug Connector.
MAINTENANCE INSTRUCTIONS FOR WELDING MACHINE
Figure 2. Continuity Check on Plug Connector.
Figure 3. Replace Plug Connector.
MAINTENANCE INSTRUCTIONS FOR WELDING TABLE AND HARDWARE
Figure 1. Welding Table and Hardware.
MAINTENANCE INSTRUCTIONS FOR WELDING TABLE AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR 10 TON PRESS AND HARDWARE
Figure 1. 10 Ton Press.
MAINTENANCE INSTRUCTIONS FOR 10 TON PRESS AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR ANVIL AND ANVIL/SHEAR STAND ASSEMBLY AND HARDWARE
Figure 1. Anvil and Anvil/Shear Stand Assembly and Hardware.
ANVIL/THROATLESS SHEAR STAND ASSEMBLY
MAINTENANCE INSTRUCTIONS FOR LATHE MACHINE BRACKETS AND HARDWARE
Figure 1. Lathe Machine Brackets and Hardware.
LATHE MACHINE
MAINTENANCE INSTRUCTIONS FOR SETSCREWS AND INSERTS
Figure 2. Wall and Floor Insert Inspection.
MAINTENANCE INSTRUCTIONS FOR BAYONET NEILL-CONCELMAN (BNC) CONNECTOR ASSEMBLY
MAINTENANCE INSTRUCTIONS FOR BAYONET NEILL-CONCELMAN (BNC) CONNECTOR ASSEMBLY - Continued
Figure 2. Replace BNC Connector Assembly.
MAINTENANCE INSTRUCTIONS FOR BAYONET NEILL-CONCELMAN (BNC) CONNECTOR ASSEMBLY - Continued
MAINTENANCE INSTRUCTIONS FOR FIRST AID BRACKET ASSEMBLY AND HARDWARE
MAINTENANCE INSTRUCTIONS FOR FIRST AID BRACKET ASSEMBLY AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR 60 AMP RECEPTACLE
MAINTENANCE INSTRUCTIONS FOR 60 AMP RECEPTACLE - Continued
Figure 2. Inspect 45 Degree Angle Adapter.
Figure 4. 45 Degree Angle Adapter Replacement.
Figure 5. 45 Degree Angle Adapter Removal from Power Entry Panel Cover.
MAINTENANCE INSTRUCTIONS FOR 60 AMP RECEPTACLE - Continued
MAINTENANCE INSTRUCTIONS FOR 240V OUTLET BOX ASSEMBLY AND COVER
MAINTENANCE INSTRUCTIONS FOR 240V OUTLET BOX ASSEMBLY AND COVER - Continued
Figure 2. Box Connector.
Figure 3. Retaining Strap.
MAINTENANCE INSTRUCTIONS FOR ECU POWER CABLE ASSEMBLY
Figure 1. Testing ECU Power Cable.
Figure 2. Removing ECU Power Cable.
MAINTENANCE INSTRUCTIONS FOR ECU POWER CABLE ASSEMBLY - Continued
Figure 3. Replacing ECU Power Cable.
Figure 4. Box Connector.
Figure 5. Box Connector Replacement.
BOX CONNECTOR FOR ECU POWER CABLE CONTINUED
Figure 6. Electrical Plug Connector.
ELECTRICAL PLUG CONNECTOR CONTINUED
MAINTENANCE INSTRUCTIONS FOR CIRCUIT BREAKERS
Figure 1. Testing Circuit Breakers.
Figure 2. Replacing Circuit Breakers.
MAINTENANCE INSTRUCTIONS FOR CIRCUIT BREAKERS - Continued
MAINTENANCE INSTRUCTIONS FOR DOOR LOCK TABS
Figure 2. Door Lock Tabs Placement.
Figure 3. Door Lock Tabs Installation.
MAINTENANCE INSTRUCTIONS FOR WATER AND AIR FEED-THRU CONNECTOR ASSEMBLIES
Figure 2. Disassembly of Water Feed-thru Connector Assembly.
Figure 3. Removal of Water Feedthru Connector Assembly.
Figure 4. Water Feed-thru Connector Flange.
Figure 6. Attach Water Feed-Thru Connector Assembly.
Figure 7. Inspect Air Feed-thru Connector Assembly.
Figure 9. Removal of Air Feed-thru Connector Assembly.
Figure 11. Install Air Feed-thru Connector Assembly.
MAINTENANCE INSTRUCTIONS FOR FIRE EXTINGUISHER BRACKETS AND HARDWARE
MAINTENANCE INSTRUCTIONS FOR FIRE EXTINGUISHER BRACKETS AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR OIL/WATER SEPARATOR
Figure 1. Inspect Hose and Fittings.
Figure 2. Hose Clamp Removal.
Figure 4. Hose Removal.
Figure 6. Hose Reinstallation.
Figure 8. Inspect Oil/Water Separator.
OIL AND WATER SEPARATOR
MAINTENANCE INSTRUCTIONS FOR ECU CABLE ASSEMBLY
MAINTENANCE INSTRUCTIONS FOR ECU SECURITY SCREENS
ECU SECURITY SCREENS
MAINTENANCE INSTRUCTIONS FOR GROUND ROD
Figure 2. Test Ground Rod.
MAINTENANCE INSTRUCTIONS FOR GROUND ROD - Continued
ILLUSTRATED LIST OF MANUFACTURED ITEMS
Figure 1. Lathe, Front Bracket.
Figure 2. Lathe, Upper Bracket (Sheet 1 of 3).
Figure 2. Lathe, Upper Bracket (Sheet 2 of 3).
Figure 2. Lathe, Upper Bracket (Sheet 3 of 3).
Figure 3. Single Cylinder Bracket Assembly (Sheet 1 of 2).
Figure 3. Single Cylinder Bracket Assembly (Sheet 2 of 2).
Figure 4. Ring Bracket Assembly (Sheet 1 of 2).
Figure 4. Ring Bracket Assembly (Sheet 2 of 2).
Figure 5. Lathe, Side Bracket.
Figure 6. Cabinet Bracket.
Figure 7. Angle Bracket.
Figure 8. Single Cylinder Bracket Assembly.
Figure 10. First Aid Bracket (Sheet 1 of 3).
Figure 10. First Aid Bracket (Sheet 2 of 3).
Figure 11. Anvil Stand (Sheet 1 of 4).
Figure 11. Anvil Stand (Sheet 2 of 4).
Figure 11. Anvil Stand (Sheet 3 of 4).
Figure 11. Anvil Stand (Sheet 4 of 4).
TORQUE LIMITS
CHAPTER 5. SUPPORTING INFORMATION FOR MACHINE AND WELDING SHOP
REFERENCES
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
Aviation Support Company (ASC) in the Aviation Support Battalion (ASB).
Maintenance Functions
Maintenance Functions - Continued
Explanations of Entries in the MAC
Explanation of Entries in the Tools and Test Equipment Requirements
MAINTENANCE ALLOCATION CHART (MAC)
Table 1. MAC for MACHINE AND WELDING SHOP Continued
Table 1. MAC for MACHINE AND WELDING SHOP Continued
Table 1. MAC for MACHINE AND WELDING SHOP Continued
Table 2. Tools And Test Equipment Requirements For Machine and Welding Shop.
REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) INTRODUCTION
SOURCE CODE
Maintenance Code
Recoverability Code
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGES FORMAT AND COLUMNS
Fabrication Instructions.
HOW TO LOCATE REPAIR PARTS
REPAIR PARTS AND SPECIAL TOOLS LIST
Figure 1. Machine and Welding Shop Set.
Figure 1. Machine and Welding Shop Set. - Continued
Figure 2. Machine and Welding Shop Set Equipment Installation.
Figure 2. Machine and Welding Shop Set Equipment Installation. - Continued
Figure 2. Machine and Welding Shop Set Equipment Installation. - Continued
Figure 3. Machine and Welding Shop Set Cabinet Assembly.
Figure 3. Machine and Welding Shop Set Cabinet Assembly. - Continued
Figure 4. Machine and Welding Shop Set Cabinet Assembly.
Figure 4. Machine and Welding Shop Set Cabinet Assembly. - Continued
Figure 5. Machine and Welding Shop Set Cabinet Assembly.
Figure 5. Machine and Welding Shop Set Cabinet Assembly. - Continued
Figure 6. Machine and Welding Shop Set Cabinet Assembly.
Figure 6. Machine and Welding Shop Set Cabinet Assembly. - Continued
Figure 7. Single Cylinder Bracket Assembly.
Figure 7. Single Cylinder Bracket Assembly - Continued
Figure 8. Plasma Cutter Modification.
Figure 8. Plasma Cutter Modification. - Continued
Figure 9. Welding Machine Modification.
Figure 9. Welding Machine Modification. - Continued
Figure 10. Welding Table Modification.
Figure 11. Lathe Machine Modification.
Figure 11. Lathe Machine Modification. - Continued
Figure 12. 100 Amp Shelter Modification (Sheet 1 of 2).
Figure 12. 100 Amp Shelter Modification (Sheet 2 of 2).
Figure 12. 100 Amp Shelter Modification - Continued
Figure 12. 100 Amp Shelter Modification - Continued
Figure 13. BNC Connector Assembly.
Figure 14. Machine and Welding Shop Set Electrical Install.
Figure 14. Machine and Welding Shop Set Electrical Install. - Continued
Figure 15. Electrical Installation.
Figure 15. Electrical Installation. - Continued
Figure 16. Oil and Water Separator.
Figure 16. Oil and Water Separator. - Continued
Figure 17. ECU Cable Assembly.
Figure 18. Ground Rod.
NATIONAL STOCK NUMBER INDEX
NATIONAL STOCK NUMBER INDEX - Continued
PART NUMBER INDEX
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
Figure 1. Components of End Item.
Figure 2. BII Items (Sheet 1 of 2).
Figure 2. BII Items (Sheet 2 of 2).
Table 2. Basic Issue Items List.
Table 2. Basic Issue Items List. - Continued
Table 2. Basic Issue Items List. - Continued
Table 2. Basic Issue Items List. - Continued
Table 2. Basic Issue Items List. - Continued
EXPENDABLE AND DURABLE ITEMS LIST
GENERAL INFORMATION
PREPARATION FOR STORAGE OR SHIPMENT
LIST OF ABBREVIATIONS/ACRONYMS
SAFETY, CARE, AND HANDLING
SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
Figure 1. Machine and Welding Shop.
Figure 2. Expanded Wall Transport Mode Component View (SC4920-99-CLA63).
Figure 3. Expanded Wall Transport Mode Component View (1035458).
Figure 4. Fixed Wall Transport Mode Component View (SC4920-99-CLA63).
Figure 5. Fixed Wall Transport Mode Component View (1035458).
Figure 6. Operational Mode Component View (SC4920-99-CLA63).
Figure 7. Operational Mode Component View (1035458).
DIFFERENCES BETWEEN MODELS
THEORY OF OPERATION
CHAPTER 2. OPERATOR INSTRUCTIONS FOR MACHINE AND WELDING SHOP
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS
Table 1. Oil/Water Separator Controls and Indicators.
OPERATION UNDER USUAL CONDITIONS: SITING REQUIREMENTS
Figure 1. Leveling Support Jack Assemblies.
Figure 2. Leveling Support Jack Install.
Figure 3. Load Balancer Slide Stops, Upper Positions.
Figure 4. Cam Lock Handles.
Figure 5. Load Balancer Slide Stops, Lower Position.
Figure 6. Positioning Hinged Wall.
Figure 8. Hinged Jack Assemblies.
Figure 9. Hinged Jack Assemblies Extensions.
Figure 10. Positioning Hinged Jack Assemblies.
Figure 11. Solar Bar Handles.
Figure 12. Raised Hinged Roof.
Figure 13. Positioning Roof and Hinged End Walls.
Figure 14. Hinged Roof Support Strut Assemblies.
Figure 15. Shelter Leveling.
Figure 16. Remove Sidewall Support Braces.
CONNECTING POWER TO THE SHELTER
CONNECTING POWER DISTRIBUTION BOX (PDB) TO GENERATOR (IF NECESSARY)
Figure 3. Main Circuit Breaker.
Figure 4. Relocation of Cable Reel Assembly and 100 amp Power Cable Assembly.
Figure 5. Extending Main Power Cable.
Figure 7. Connecting Main Power Cable to PDB.
INSTALL LIGHTING
Figure 2. Installing Ceiling Lights.
Figure 3. Connecting Ceiling Lights.
Figure 4. Installing Cable and Receptacle Assembly.
Figure 5. Installing Area Light.
PREPARING SHELTER FOR ECU INSTALLATION
Figure 1. Hinged Floor Cable Guide Housing Removal.
Figure 2. Hinged Floor Cable Guide Housing Reinstall.
Figure 3. Removing Plugs on ECU Fold-down Panel.
Figure 4. ECU Fold-down Panel Latches.
Figure 6. Installing T-Seal.
SAFEGUARDING ATTACHING HARDWARE
POSITIONING SHELTER BASIC ISSUE ITEMS (BII) BOX FOR OPERATIONAL MODE
POSITIONING ECU S FOR OPERATIONAL MODE
Figure 1. Unsecure ECU (A).
Figure 2. Placing ECU (A) on ECU Fold-down Panel.
Figure 4. Aligning Bolt Holes of ECU (A) with ECU Fold-down Panel.
Figure 6. Unsecure ECU (B).
Figure 7. Placing ECU (B) on ECU Fold-down Panel.
Figure 9. Aligning Bolt Holes of ECU (B) with ECU Fold-down Panel.
Figure 11. Connecting Power to ECU s.
POSITIONING STRAIGHT STOOLS FOR OPERATIONAL MODE
Figure 1. Unsecure Straight Stools (SC4920-99-CLA63).
Figure 2. Unsecure Straight Stools (1035458).
POSITIONING EYEWASH STATION ASSEMBLY AND BRACKET FOR OPERATIONAL MODE
Figure 1. Unsecure Eyewash Station (SC4920-99-CLA63).
Figure 2. Position Eyewash Station (SC4920-99-CLA63).
Figure 3. Unsecure Eyewash Station (1035458).
Figure 4. Position Eyewash Station (1035458).
POSITIONING GAS CART FOR OPERATIONAL MODE
Figure 1. Unsecure Gas Cart.
POSITIONING SHELF CABINET (E) FOR OPERATIONAL MODE
Figure 1. Unsecure Four Drawer Cabinet (E) .
POSITIONING SHELF CABINET (D) FOR OPERATIONAL MODE
Figure 1. Unsecure Shelf Cabinet (D).
POSITIONING ANVIL AND ANVIL STAND FOR OPERATIONAL MODE
Figure 1. Unsecure Anvil Stand with Anvil.
POSITIONING WELDING MACHINE FOR OPERATIONAL MODE
Figure 1. Unsecure Welding Machine.
POSITIONING PLASMA CUTTER FOR OPERATIONAL MODE
Figure 1. Unsecure Plasma Cutter.
CONNECTING COMPRESSED AIR AND WATER
Figure 2. Connecting Compressed Air.
CHECKING SHELTER LEVEL
DISCONNECTING COMPRESSED AIR AND WATER
Figure 2. Replacing Protective Dust Cap.
POSITIONING ECUS FOR TRANSPORT MODE
Figure 2. Removing ECU (B) Hardware from ECU Fold-down Panel.
Figure 3. Secure ECU (B).
Figure 4. Removing ECU (A) Hardware from ECU Fold-down Panel.
Figure 5. Secure ECU (A).
POSITIONING SHELTER BII BOX FOR TRANSPORT MODE
POSITIONING EYEWASH STATION ASSEMBLY BRACKET AND HARDWARE FOR TRANSPORT MODE
POSITIONING EYEWASH STATION ASSEMBLY BRACKET AND HARDWARE FOR TRANSPORT MODE - Continued
Figure 2. Secure Eyewash Station (1035458).
POSITIONING STRAIGHT STOOLS FOR TRANSPORT MODE
Figure 1. Secure Straight Stools (SC4920-99-CLA63).
Figure 2. Secure Straight Stools (1035458).
POSITIONING FOUR DRAWER CABINET (E) FOR TRANSPORT MODE
POSITIONING FOUR DRAWER CABINET (E) FOR TRANSPORT MODE - Continued
POSITIONING SHELF CABINET (D) FOR TRANSPORT MODE
POSITIONING SHELF CABINET (D) FOR TRANSPORT MODE - Continued
POSITIONING GAS CART FOR TRANSPORT MODE
Figure 1. Secure Gas Cart.
POSITIONING GAS CART FOR TRANSPORT MODE - Continued
POSITIONING ANVIL AND ANVIL STAND FOR TRANSPORT MODE
Figure 1. Secure Anvil Stand with Anvil.
POSITIONING WELDING MACHINE FOR TRANSPORT MODE
Figure 1. Secure Welding Machine.
POSITIONING WELDING MACHINE FOR TRANSPORT MODE - Continued
POSITIONING PLASMA CUTTER FOR TRANSPORT MODE
Figure 1. Secure Plasma Cutter.
PREPARING SHELTER FOR ECU STOWAGE
Figure 2. Closing ECU Fold-down Panel.
Figure 4. Installing Plugs on ECU Fold-down Panel.
Figure 6. Hinged Floor Cable Guide Housing Installation.
DISCONNECTING POWER FROM SHELTER
Figure 2. Disconnecting Main Power Cable from PDB.
Figure 3. Disconnecting Main Power Cable from Shelter.
Figure 4. Securing Cable Reel Assembly.
Figure 5. Disconnecting PDB from Generator.
Figure 6. Removing External Grounding Rod.
REMOVING LIGHTING
Figure 2. Removing Cable and Receptacle Assembly.
Figure 3. Repositioning Ceiling Lights.
PREPARING SHELTER FOR TRANSPORT
Figure 1. Releasing Shelter Walls.
Figure 3. Lowering Shelter Roof.
Figure 4. Secure Support Strut Assemblies.
Figure 6. Hinged Jack Assemblies Extension.
Figure 7. Load Balancers Slide Stops, Upper Position.
Figure 8. Cam Lock Handles.
Figure 9. Load Balancers Slide Stops, Lower Position.
Figure 10. Lowering Leveling Support Jack Assemblies.
Figure 11. Stowing Leveling Support Jack Assemblies.
OPERATION UNDER UNUSUAL CONDITIONS
Figure 2. Installing Ground Anchors.
Figure 3. Loops and Clamps Installation.
Figure 4. Securing Loops and Clamps.
OPERATION IN SNOW, ICE OR EXTREME COLD
OPERATION FOR IMPROVING SOIL CONDUCTIVITY FOR SHELTER GROUNDING
CHAPTER 3. FIELD LEVEL MAINTENANCE TROUBLESHOOTING PROCEDURES FOR MACHINE AND WELDING SHOP
TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING PROCEDURES - Continued
CHAPTER 4. FIELD LEVEL MAINTENANCE INSTRUCTIONS FOR MACHINE AND WELDING SHOP
SERVICE UPON RECEIPT
PREVENTIVE MAINTENANCE CHECKS AND SERVICE (PMCS) INTRODUCTION
Corrosion Prevention and Control (CPC)
PREVENTIVE MAINTENANCE CHECKS AND SERVICE (PMCS)
Table 1. Field Level Preventive Maintenance Checks and Services for Machine and Welding Shop.
Table 1. Field Level Preventive Maintenance Checks and Services for Machine and Welding Shop. - Continued
Table 1. Field Level Preventive Maintenance Checks and Services for Machine and Welding Shop. - Continued
Table 1. Field Level Preventive Maintenance Checks and Services for Machine and Welding Shop. - Continued
Table 1. Field Level Preventive Maintenance Checks and Services for Machine and Welding Shop. - Continued
Table 1. Field Level Preventive Maintenance Checks and Services for Machine and Welding Shop. - Continued
MAINTENANCE INSTRUCTIONS FOR CABINET ASSEMBLIES
Figure 2. Drawers, Slides, and Shelves Remove and Install.
DRAWERS, SLIDES, AND SHELVES
Figure 3. Cabinet (A) and Cabinet (B).
SIX DRAWER CABINET (A) AND SIX DRAWER CABINET (B)
SIX DRAWER CABINET (A) AND SIX DRAWER CABINET (B) CONTINUED
Figure 4. Cabinet (C) .
REPAIR OR REPLACEMENT
INSPECTION OF INSTALLED ITEMS
REPAIR OR REPLACEMENT
FOUR DRAWER CABINET (E)
FOUR DRAWER CABINET (E)
MAINTENANCE INSTRUCTIONS FOR CABINET INTEGRATION HARDWARE
MAINTENANCE INSTRUCTIONS FOR CABINET INTEGRATION HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR CABINET INTEGRATION HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR CABINET INTEGRATION HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR EYEWASH STATION ASSEMBLY BRACKET AND HARDWARE
MAINTENANCE INSTRUCTIONS FOR EYEWASH STATION ASSEMBLY BRACKET AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR MILLING/DRILLING MACHINE AND HARDWARE
Figure 2. Continuity Check on Plug Connector.
Figure 3. Replace Plug Connector.
Figure 4. Milling/Drilling Machine.
MILLING/DRILLING MACHINE MOUNTING HARDWARE CONTINUED
MAINTENANCE INSTRUCTIONS FOR BENCH GRINDER AND HARDWARE
MAINTENANCE INSTRUCTIONS FOR BENCH GRINDER AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR MACHINIST VISE AND HARDWARE
MAINTENANCE INSTRUCTIONS FOR CYLINDER BRACKET ASSEMBLY AND HARDWARE
MAINTENANCE INSTRUCTIONS FOR CYLINDER BRACKET ASSEMBLY AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR PLASMA CUTTER
Figure 2. Continuity Check on Plug Connector.
Figure 3. Replace Plug Connector.
MAINTENANCE INSTRUCTIONS FOR WELDING MACHINE
Figure 2. Continuity Check on Plug Connector.
Figure 3. Replace Plug Connector.
MAINTENANCE INSTRUCTIONS FOR WELDING TABLE AND HARDWARE
Figure 1. Welding Table and Hardware.
MAINTENANCE INSTRUCTIONS FOR WELDING TABLE AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR 10 TON PRESS AND HARDWARE
Figure 1. 10 Ton Press.
MAINTENANCE INSTRUCTIONS FOR 10 TON PRESS AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR ANVIL AND ANVIL/SHEAR STAND ASSEMBLY AND HARDWARE
Figure 1. Anvil and Anvil/Shear Stand Assembly and Hardware.
ANVIL/THROATLESS SHEAR STAND ASSEMBLY
MAINTENANCE INSTRUCTIONS FOR LATHE MACHINE BRACKETS AND HARDWARE
Figure 1. Lathe Machine Brackets and Hardware.
LATHE MACHINE
MAINTENANCE INSTRUCTIONS FOR SETSCREWS AND INSERTS
Figure 2. Wall and Floor Insert Inspection.
MAINTENANCE INSTRUCTIONS FOR BAYONET NEILL-CONCELMAN (BNC) CONNECTOR ASSEMBLY
MAINTENANCE INSTRUCTIONS FOR BAYONET NEILL-CONCELMAN (BNC) CONNECTOR ASSEMBLY - Continued
Figure 2. Replace BNC Connector Assembly.
MAINTENANCE INSTRUCTIONS FOR BAYONET NEILL-CONCELMAN (BNC) CONNECTOR ASSEMBLY - Continued
MAINTENANCE INSTRUCTIONS FOR FIRST AID BRACKET ASSEMBLY AND HARDWARE
MAINTENANCE INSTRUCTIONS FOR FIRST AID BRACKET ASSEMBLY AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR 60 AMP RECEPTACLE
MAINTENANCE INSTRUCTIONS FOR 60 AMP RECEPTACLE - Continued
Figure 2. Inspect 45 Degree Angle Adapter.
Figure 4. 45 Degree Angle Adapter Replacement.
Figure 5. 45 Degree Angle Adapter Removal from Power Entry Panel Cover.
MAINTENANCE INSTRUCTIONS FOR 60 AMP RECEPTACLE - Continued
MAINTENANCE INSTRUCTIONS FOR 240V OUTLET BOX ASSEMBLY AND COVER
MAINTENANCE INSTRUCTIONS FOR 240V OUTLET BOX ASSEMBLY AND COVER - Continued
Figure 2. Box Connector.
Figure 3. Retaining Strap.
MAINTENANCE INSTRUCTIONS FOR ECU POWER CABLE ASSEMBLY
Figure 1. Testing ECU Power Cable.
Figure 2. Removing ECU Power Cable.
MAINTENANCE INSTRUCTIONS FOR ECU POWER CABLE ASSEMBLY - Continued
Figure 3. Replacing ECU Power Cable.
Figure 4. Box Connector.
Figure 5. Box Connector Replacement.
BOX CONNECTOR FOR ECU POWER CABLE CONTINUED
Figure 6. Electrical Plug Connector.
ELECTRICAL PLUG CONNECTOR CONTINUED
MAINTENANCE INSTRUCTIONS FOR CIRCUIT BREAKERS
Figure 1. Testing Circuit Breakers.
Figure 2. Replacing Circuit Breakers.
MAINTENANCE INSTRUCTIONS FOR CIRCUIT BREAKERS - Continued
MAINTENANCE INSTRUCTIONS FOR DOOR LOCK TABS
Figure 2. Door Lock Tabs Placement.
Figure 3. Door Lock Tabs Installation.
MAINTENANCE INSTRUCTIONS FOR WATER AND AIR FEED-THRU CONNECTOR ASSEMBLIES
Figure 2. Disassembly of Water Feed-thru Connector Assembly.
Figure 3. Removal of Water Feedthru Connector Assembly.
Figure 4. Water Feed-thru Connector Flange.
Figure 6. Attach Water Feed-Thru Connector Assembly.
Figure 7. Inspect Air Feed-thru Connector Assembly.
Figure 9. Removal of Air Feed-thru Connector Assembly.
Figure 11. Install Air Feed-thru Connector Assembly.
MAINTENANCE INSTRUCTIONS FOR FIRE EXTINGUISHER BRACKETS AND HARDWARE
MAINTENANCE INSTRUCTIONS FOR FIRE EXTINGUISHER BRACKETS AND HARDWARE - Continued
MAINTENANCE INSTRUCTIONS FOR OIL/WATER SEPARATOR
Figure 1. Inspect Hose and Fittings.
Figure 2. Hose Clamp Removal.
Figure 4. Hose Removal.
Figure 6. Hose Reinstallation.
Figure 8. Inspect Oil/Water Separator.
OIL AND WATER SEPARATOR
MAINTENANCE INSTRUCTIONS FOR ECU CABLE ASSEMBLY
MAINTENANCE INSTRUCTIONS FOR ECU SECURITY SCREENS
ECU SECURITY SCREENS
MAINTENANCE INSTRUCTIONS FOR GROUND ROD
Figure 2. Test Ground Rod.
MAINTENANCE INSTRUCTIONS FOR GROUND ROD - Continued
ILLUSTRATED LIST OF MANUFACTURED ITEMS
Figure 1. Lathe, Front Bracket.
Figure 2. Lathe, Upper Bracket (Sheet 1 of 3).
Figure 2. Lathe, Upper Bracket (Sheet 2 of 3).
Figure 2. Lathe, Upper Bracket (Sheet 3 of 3).
Figure 3. Single Cylinder Bracket Assembly (Sheet 1 of 2).
Figure 3. Single Cylinder Bracket Assembly (Sheet 2 of 2).
Figure 4. Ring Bracket Assembly (Sheet 1 of 2).
Figure 4. Ring Bracket Assembly (Sheet 2 of 2).
Figure 5. Lathe, Side Bracket.
Figure 6. Cabinet Bracket.
Figure 7. Angle Bracket.
Figure 8. Single Cylinder Bracket Assembly.
Figure 10. First Aid Bracket (Sheet 1 of 3).
Figure 10. First Aid Bracket (Sheet 2 of 3).
Figure 11. Anvil Stand (Sheet 1 of 4).
Figure 11. Anvil Stand (Sheet 2 of 4).
Figure 11. Anvil Stand (Sheet 3 of 4).
Figure 11. Anvil Stand (Sheet 4 of 4).
TORQUE LIMITS
CHAPTER 5. SUPPORTING INFORMATION FOR MACHINE AND WELDING SHOP
REFERENCES
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
Aviation Support Company (ASC) in the Aviation Support Battalion (ASB).
Maintenance Functions
Maintenance Functions - Continued
Explanations of Entries in the MAC
Explanation of Entries in the Tools and Test Equipment Requirements
MAINTENANCE ALLOCATION CHART (MAC)
Table 1. MAC for MACHINE AND WELDING SHOP Continued
Table 1. MAC for MACHINE AND WELDING SHOP Continued
Table 1. MAC for MACHINE AND WELDING SHOP Continued
Table 2. Tools And Test Equipment Requirements For Machine and Welding Shop.
REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) INTRODUCTION
SOURCE CODE
Maintenance Code
Recoverability Code
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGES FORMAT AND COLUMNS
Fabrication Instructions.
HOW TO LOCATE REPAIR PARTS
REPAIR PARTS AND SPECIAL TOOLS LIST
Figure 1. Machine and Welding Shop Set.
Figure 1. Machine and Welding Shop Set. - Continued
Figure 2. Machine and Welding Shop Set Equipment Installation.
Figure 2. Machine and Welding Shop Set Equipment Installation. - Continued
Figure 2. Machine and Welding Shop Set Equipment Installation. - Continued
Figure 3. Machine and Welding Shop Set Cabinet Assembly.
Figure 3. Machine and Welding Shop Set Cabinet Assembly. - Continued
Figure 4. Machine and Welding Shop Set Cabinet Assembly.
Figure 4. Machine and Welding Shop Set Cabinet Assembly. - Continued
Figure 5. Machine and Welding Shop Set Cabinet Assembly.
Figure 5. Machine and Welding Shop Set Cabinet Assembly. - Continued
Figure 6. Machine and Welding Shop Set Cabinet Assembly.
Figure 6. Machine and Welding Shop Set Cabinet Assembly. - Continued
Figure 7. Single Cylinder Bracket Assembly.
Figure 7. Single Cylinder Bracket Assembly - Continued
Figure 8. Plasma Cutter Modification.
Figure 8. Plasma Cutter Modification. - Continued
Figure 9. Welding Machine Modification.
Figure 9. Welding Machine Modification. - Continued
Figure 10. Welding Table Modification.
Figure 11. Lathe Machine Modification.
Figure 11. Lathe Machine Modification. - Continued
Figure 12. 100 Amp Shelter Modification (Sheet 1 of 2).
Figure 12. 100 Amp Shelter Modification (Sheet 2 of 2).
Figure 12. 100 Amp Shelter Modification - Continued
Figure 12. 100 Amp Shelter Modification - Continued
Figure 13. BNC Connector Assembly.
Figure 14. Machine and Welding Shop Set Electrical Install.
Figure 14. Machine and Welding Shop Set Electrical Install. - Continued
Figure 15. Electrical Installation.
Figure 15. Electrical Installation. - Continued
Figure 16. Oil and Water Separator.
Figure 16. Oil and Water Separator. - Continued
Figure 17. ECU Cable Assembly.
Figure 18. Ground Rod.
NATIONAL STOCK NUMBER INDEX
NATIONAL STOCK NUMBER INDEX - Continued
PART NUMBER INDEX
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
Figure 1. Components of End Item.
Figure 2. BII Items (Sheet 1 of 2).
Figure 2. BII Items (Sheet 2 of 2).
Table 2. Basic Issue Items List.
Table 2. Basic Issue Items List. - Continued
Table 2. Basic Issue Items List. - Continued
Table 2. Basic Issue Items List. - Continued
Table 2. Basic Issue Items List. - Continued
EXPENDABLE AND DURABLE ITEMS LIST
