GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
GENERAL INFORMATION INDEX
GENERAL INFORMATION -816300033
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)
CORROSION PREVENTION AND CONTROL (CPC)
EQUIPMENT DESCRIPTION AND DATA
EQUIPMENT CHARACTERISTICS, CAPABILITIES AND FEATURES
Figure 4. Coupling Configuration.
Figure 6. Transport Confituration
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
LOCATION AND CONTENTS OF PLATES, DECALS, AND STENCILS
EQUIPMENT DATA -816300043
EQUIPMENT DATA - Continued
THEORY OF OPERATION -816300045
OPERATOR INSTRUCTIONS
OPERATOR INSTRUCTIONS INDEX
DESCRIPTION AND USE OF OPERATOR'S CONTROLS AND INDICATORS
HYDRAULIC SYSTEM CONTROLS AND INDICATOR
COUPLING AND CONNECTORS CONTROLS AND INDICATORS
TIEDOWN AND ACCESSORY ITEMS CONTROLS AND INDICATORS
UNFOLDING FROM SHIPPING/STORAGE CONFIGURATION
Figure 15. Electrical Control boxes
Figure 16. Hydraulic Control Levers and Pin alignment
Figure 18. Hydraulic Control Levers and Unfolded FWTD
Figure 20. Control Levers, Mast, and Clevis
COUPLING
Figure 21. Master Controls
Figure 22. Rear Gladhands and Support Leg Assembly
TRANSPORT CONFIGURATION
Figure 24.Hydraulic Controls and Electric Control Box
Figure 25. Hydraulic Controls and Clevis
Figure 27. Pin Alignment and Valve
Figure 29. Pin Alignment Items
PREPARE TOWING DEVICE
Figure 33. Hydraulic and Electrical Controls
Figure 35. Hydraulic Controls
Figure 37. Remote Control and Pin Alignment
Figure 39. Mast Alignment
PREPARE TOW BAR ASSEMBLIES
Figure 42. Tow Bar Assembly Preparation
CONNECTING TO TOWED VEHICLE
Figure 44. Towing Connection Location
Figure 45. Support Leg Assembly
Figure 47. Frame Hooks and Tow Bars
Figure 48. Towing Configuration
Figure 50. Tow Bar Assembly
Figure 51. Lock Pin Placement
PERFORMANCE OF PRE-PICKING LIFTS
WINCHING OPERATIONS
Figure 52. Winch Free Spool Lever
PREPARING EQUIPMENT FOR TOWING
SECURING EQUIPMENT
Figure 55. Tie Down - Example #1
OPERATE LIGHTS
Figure 58. Light Controls and Connections
GLADHANDS -816300097
TRANSPORTING LOADS
TRANSPORTING LOADS - Continued
DISCONNECTING TOWED VEHICLE
Figure 60. Mast Pin Placement
Figure 61. Pad and Tow Bar Assembly Locations
Figure 62. Frame Hook Connection
Figure 64. Tow Bar Assembly and Storage
UNCOUPLING
Figure 67. Master Controls and Transport Legs
UNCOUPLING - Continued
PREPARE FOR SHIPPING/STORAGE
Figure 19. Breather Valve
Figure 69. Pin Alignment
OPERATION UNDER UNUSUAL CONDITIONS
OPERATION IN EXTREME HEAT AND HIGH HUMIDITY
OPERATION ON ROCKY TERRAIN
ROLL-ON/ROLL-OFF (RORO) OPERATIONS
OPERATOR TROUBLESHOOTING
OPERATOR TROUBLESHOOTING PROCEDURES INDEX
OPERATOR TROUBLESHOOTING PROCEDURES
OPERATOR TROUBLESHOOTING SYMPTOM INDEX
TABLE 1. OPERATOR TROUBLESHOOTING
ELECTRICAL SYSTEM -816300126
HYDRAULIC SYSTEM -816300127
UNIT TROUBLESHOOTING -816300129
UNIT TROUBLESHOOTING PROCEDURES INDEX
UNIT TROUBLESHOOTING PROCEDURES
UNIT TROUBLESHOOTING SYMPTOM INDEX
UNIT TROUBLESHOOTING -816300135
ELECTRICAL SYSTEM -816300137
ELECTRICAL SYSTEM - Continued -816300138
ELECTRICAL SYSTEM - Continued -816300139
ALL LIGHTS ARE INOPERABLE
LIGHT BAR ASSEMBLY INOPERABLE
STROBE LIGHTS INOPERABLE
HYDRAULIC SYSTEM -816300143
CANNOT RELIEVE HYDRAULIC PRESSURE FROM ONE OR MORE LEVERS
BOOM WILL NOT OPERATE
MAST WILL NOT OPERATE
AIR BRAKE SYSTEM
WINCH WILL NOT OPERATE
OPERATOR MAINTENANCE INSTRUCTIONS
OPERATOR MAINTENANCE INSTRUCTIONS INDEX
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
GENERAL PMCS PROCEDURES -816300156
Leakage Definitions of PMCS
Figure 70. General PMCS Procedure Chart
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300160
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300161
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300162
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300163
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300164
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300165
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300166
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300167
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300168
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300169
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300170
ELECTRICAL CONNECTORS
GLADHANDS -816300173
KINGPIN PLACEMENT
INSTALLATION -816300176
CLEANING -816300177
UNIT MAINTENANCE INSTRUCTIONS
UNIT MAINTENANCE INSTRUCTIONS INDEX
SERVICE UPON RECEIPT
UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
GENERAL PMCS PROCEDURES -816300186
PMCS INITIAL SETUP
LUBRICATION DATA
Table 3. Unit Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (FWTD)
GENERAL MAINTENANCE INSTRUCTIONS -816300191
WORK SAFETY
CLEANING INSTRUCTIONS
INSPECTION INSTRUCTIONS
LUBRICATION INSTRUCTIONS -816300195
STANDARD TOOL REQUIREMENTS
SOLDERING
ELECTRICAL GROUND POINTS
LINES AND PORTS
TUBES AND COMPRESSION FITTINGS
FLUID DISPOSAL
LUBRICATION INSTRUCTIONS -816300203
LUBRICATION CHART
250M FIFTH WHEEL TOWING DEVICE (FWTD)
250M FIFTH WHEEL TOWING DEVICE (FWTD) (cont.)
LUBRICATION CHART (cont.) -816300207
LUBRICATION CHART (cont.) -816300208
LUBRICATION CHART (cont.) -816300209
ELECTRICAL SYSTEM MAINTENANCE
24-VOLT RECEPTACLE REPLACEMENT REMOVAL AND INSTALLATION
Figure 75. Receptacle Box
12-VOLT RECEPTACLE REPLACEMENT REMOVAL AND INSTALLATION
Figure 76. Plug Assembly
12-24 VOLT JUNCTION BOX REPLACEMENT. REMOVAL, INSTALLATION
Figure 77. Junction Box Assembly
ELECTRICAL CONTROL BOX MAINTENANCE
Figure 78. Electrical Control Box
Figure 79. Electrical Control Box
INSTALLATION -816300222
INSTALLATION - Continued
SOLENOID ASSEMBLY REPLACEMENT
Figure 81. Solenoid Assembly
REMOTE CONTROL ASSEMBLY REPLACEMENT
Figure 82. Remote Control Cable Assembly
24-VOLT TOW LIGHT ASSEMBLY REPAIR.
Figure 84. Tow Light Assembly
Figure 85. Tow Light Assembly
Composite Taillight Removal
Composite Taillight Installation
Figure 88. Complete Taillight Assemblyv
INSTALLATION -816300235
FIXED WORKLIGHT REPAIR
Figure 90. Fixed Worklight Assembly
STROBE LIGHT MAINTENANCE
Figure 91. Strobe Light Assembly
INSTALLATION -816300241
Figure 92. Retractable Cord Assembly
BATTERY/BATTERY BOX REPLACEMENT
Figure 94. Battery Box Assembly
BATTERY INSTALLATION
BATTERY BOX REMOVAL
WIRING HARNESS/CABLE MAINTENANCE
Figure 96. Loop Clamp
BRAKE SYSTEM MAINTENANCE
GLADHAND REPLACEMENT.
CLEANING -816300252
INSTALLATION -816300253
AIR BRAKE PROTECTION VALVE REPLACEMENT
CLEANING -816300256
Figure 98. Air Brake Protection Valve Assembly
AIR BRAKE FITTINGS MAINTENANCE
Figure 99. Air Brake Fittings Assembly -816300260
INSPECTION AND REPLACEMENT OR REPAIR
Figure 99. Air Brake Fittings Assembly -816300262
GENERAL HYDRAULIC SYSTEM REPAIR METHODS
GENERAL HYDRAULIC SYSTEM REPAIR -816300264
Figure 100. National Pipe Thread (NPT)
INSTALLATION OF ADJUSTABLE FITTINGS
RELIEVE HYDRAULIC PRESSURE
PURGE AND FILL HYDRAULIC SYSTEM
Figure 104. Hydraulic System
HYDRAULIC MOTOR ASSEMBLY REPLACEMENT
REMOVAL OF PRIMARY MOTOR
REMOVAL OF ISOLATED MOTOR
INSTALLATION OF PRIMARY MOTOR
Figure 105. Hydraulic Motor Assembly
HYDRAULIC SAFETY VALVE REPLACEMENT
Figure 106. Hydraulic Safety Valve Assembly
INSTALLATION -816300279
Illustration
MAIN VALVE ASSEMBLY MAINTENANCE
REMOVAL -816300282
Figure 107. Hydraulic Control System
SOLENOID REMOVAL
INSTALLATION -816300285
Figure 107. Hydraulic Control Assembly
HYDRAULIC VALVE CONTROL LEVER REPLACEMENT
Figure 109. Hydraulic Control Lever
OIL FILTER ASSEMBLY REPLACEMENT
Figure 110. Oil Filter Assembly
Figure 111. Oil Filter Assembly
CAM VALVE ASSEMBLY REPLACEMENT
Figure 112. Cam Valve Assembly
INSTALLATION -816300295
HYDRAULIC CYLINDER (MAIN FRAME TO MAST) REPLACEMENT
REMOVAL -816300298
Figure 113. Hydraulic Cylinder (Main Frame to Mast)
HYDRAULIC CYLINDER (MAST TO BOOM) REPLACEMENT
Figure 114. Hydraulic Cylinder (Mast to Boom)
INSTALLATION -816300303
HYDRAULIC RESERVOIR FITTINGS REPLACEMENT
Figure 115. Hydraulic Reservoir Fittings Assembly -816300306
INSTALLATION -816300307
Figure 115. Hydraulic Reservoir Fittings Assembly -816300308
BOOM EXTENSION CYLINDER REPLACEMENT
Figure 116. Boom Extension Cylinder Assembly
INSTALLATION -816300311
GENERAL HYDRAULIC SYSTEM REPAIR -816300313
RECEIVER AND WHEEL STOP ASSEMBLY REPLACEMENT
Figure 117. Receiver and Wheel Stop
MUD FLAP REPLACEMENT
FENDER REPLACEMENT
FENDER MOUNTING BRACKET REMOVAL
FENDER INSTALLATION
TOOL BOX REPLACEMENT
Figure 121. Tool Box
HINGE ASSEMBLY REMOVAL
INSTALLATION -816300326
MAST FRAME ASSEMBLY PIVOT PIN REPLACEMENT
CENTER MAST FRAME REPLACEMENT
Figure 124. Center Mast Frame
BUMPER PAD, SLIP PAD REPLACEMENT
SLIP PAD REMOVAL
TRANSPORT LEG ASSEMBLY REPLACEMENT
REMOVAL -816300334
Figure 127. Transport Leg Assembly
WINCHES
WINCH ASSEMBLY REPLACEMENT
Figure 128. Winch Assembly
INSTALLATION -816300341
CABLE ASSEMBLY REMOVAL
PREPARATION FOR STORAGE OR SHIPMENT
PREPARATION OF EQUIPMENT FOR ADMINISTRATIVE STORAGE
General Cleaning, Painting, and Preservation.
CARE OF EQUIPMENT IN ADMINISTRATIVE STORAGE
Table 4. Exercise Schedule
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS -816300349
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS INDEX
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS -816300353
SUPPORTING INFORMATION
SUPPORTING INFORMATION INDEX
REFERENCES -816300359
TECHNICAL BULLETINS -816300360
MAINTENANCE ALLOCATION CHART
MAINTENANCE FUNCTIONS
EXPLANATION OF COLUMNS IN THE MAC
EXPLANATION OF COLUMNS IN TOOLS AND TEST EQUIPMENT REQUIREMENTS, SECTION III
Section II. MAINTENANCE ALLOCATION CHART FOR FIFTH WHEEL TOWING DEVICE
Section II. MAINTENANCE ALLOCATION CHART - Continued -816300366
Section II. MAINTENANCE ALLOCATION CHART - Continued -816300367
Section III. TOOLS AND TEST EQUIPMENT REQUIREMENTS
REPAIR PARTS AND SPECIAL TOOLS LISTS (RPSTL)
EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGE
Maintenance Code -816300371
FOURTH POSITION
Recoverability Code -816300373
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGE FORMAT AND COLUMNS
SPECIAL INFORMATION
Figure 1. 12/24 Volt Junction Box
Repair Parts List -816300377
Figure 2. Electrical Control Box
Repair Parts List -816300379
Figure 3. Solenoid Assembly
Repair Parts List -816300381
Figure 4. 24 Volt Towlight Assembly
Repair Parts List -816300383
Repair Parts List (cont.) -816300384
Figure 5. Fixed Worklight
Repair Parts List -816300387
Figure 6. Strobe Light Assembly
Repair Parts List -816300389
Figure 7. Battery Box Assembly
Repair Parts List -816300391
Figure 8 (1 of 9). Chassis Wiring Harness
Figure 8 (2 of 9). Chassis Wiring Harness
Figure 8 (3 of 9). Chassis Wiring Harness
Figure 8 (4 of 9). Chassis Wiring Harness
Figure 8 (5 of 9). Chassis Wiring Harness
Figure 8 (6 of 9). Chassis Wiring Harness
Figure 8 (7 of 9). Chassis Wiring Harness
Figure 8 (8 of 9). Chassis Wiring Harness
Figure 8 (9 of 9). Chassis Wiring Harness
Repair Parts List -816300401
Repair Parts List (cont.) -816300402
Repair Parts List (cont.) -816300403
Repair Parts List (cont.) -816300404
Figure 9. Air Brake System
Repair Parts List -816300407
Figure 10. Gladhands
Repair Parts List -816300409
Figure 11. Tow Bar Assembly
Repair Parts List -816300411
Figure 12. Kingpin Assembly
Repair Parts List -816300413
Figure 13. Receiver and Wheelstop Assembly
Repair Parts List -816300415
Figure 14. Fenders and Mud Flaps
Repair Parts List -816300417
Figure 15. Tool Box
Repair Parts List -816300419
Figure 16. Mast Frame Assembly
Repair Parts List -816300421
Figure 17. Main Frame Assembly
Repair Parts List -816300423
Figure 18. Boom Assembly
Repair Parts List -816300425
Figure 19. Transport Leg Assembly
Repair Parts List -816300427
Figure 20. Winch Assembly
Repair Parts List -816300429
Figure 21. Hydraulic Motor Assembly
Repair Parts List -816300431
Figure 22. Hydraulic Safety Valve
Repair Parts List -816300433
Figure 23. Main Valve Assembly
Repair Parts List -816300435
Figure 24 (1 of 5). Hydraulic Hoses and Fittings
Figure 24 (2 of 5). Hydraulic Hoses and Fittings
Figure 24 (3 of 5). Hydraulic Hoses and Fittings
Figure 24 (4 of 5). Hydraulic Hoses and Fittings
Figure 24 (5 of 5). Hydraulic Hoses and Fittings
Repair Parts List -816300441
Figure 25. Oil Filter Assembly
Repair Parts List -816300443
Figure 26. Cam Valve Assembly
Repair Parts List -816300445
Figure 27. Main Frame to Mast
Repair Parts List -816300447
Figure 28. Mast to Boom
Repair Parts List -816300449
Figure 29. Boom Extensions
Repair Parts List -816300451
Figure 30. Reservoir and Fittings
Repair Parts List -816300453
Repair Parts List (cont.) -816300454
NATIONAL STOCK NUMBER INDEX -816300455
NATIONAL STOCK NUMBER INDEX (cont.) -816300456
NATIONAL STOCK NUMBER INDEX (cont.) -816300457
NATIONAL STOCK NUMBER INDEX (cont.) -816300458
PART NUMBER INDEX -816300459
PART NUMBER INDEX (cont.) -816300460
PART NUMBER INDEX (cont.) -816300461
PART NUMBER INDEX (cont.) -816300462
PART NUMBER INDEX (cont.) -816300463
PART NUMBER INDEX (cont.) -816300464
PART NUMBER INDEX (cont.) -816300465
PART NUMBER INDEX (cont.) -816300466
PART NUMBER INDEX (cont.) -816300467
PART NUMBER INDEX (cont.) -816300468
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
SECTION III. BASIC ISSUE ITEMS
SECTION III. BASIC ISSUE ITEMS - Continued -816300471
SECTION III. BASIC ISSUE ITEMS - Continued -816300472
SECTION III. BASIC ISSUE ITEMS - Continued -816300473
SECTION III. BASIC ISSUE ITEMS - Continued -816300474
SECTION III. BASIC ISSUE ITEMS - Continued -816300475
SECTION III. BASIC ISSUE ITEMS - Continued -816300476
ADDITIONAL AUTHORIZATION LIST
ADDITIONAL AUTHORIZATION LIST (cont.)
EXPENDABLE AND DURABLE ITEMS LIST -816300479
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST - Continued -816300481
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST - Continued -816300482
ILLUSTRATED LIST OF MANUFACTURED ITEMS
TORQUE VALUES FOR THREADED FASTENERS
HOW TO USE TORQUE TABLE
Table 5. Torque Limits for Dry Fasteners
Table 6. Torque Limits for Wet Fasteners
TIGHTENING METAL FASTENERS
FASTENER GRADE -816300490
SCHEMATICS -816300491
Electrical Schematic
Electrical Schematic (cont.) -816300493
Electrical Schematic (cont.) -816300494
Hydraulic Schematic
AUTHORIZED VEHICLE COMBINATIONS
AUTHORIZED VEHICLE COMBINATIONS - Continued
TOWBAR ASSEMBLY POSITIONING
TM-9-2510-247-13-P Fifth Wheel Towing Device Model 250M (NSN 2510-01-458-8253) Manual
GENERAL INFORMATION INDEX
GENERAL INFORMATION -816300033
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)
CORROSION PREVENTION AND CONTROL (CPC)
EQUIPMENT DESCRIPTION AND DATA
EQUIPMENT CHARACTERISTICS, CAPABILITIES AND FEATURES
Figure 4. Coupling Configuration.
Figure 6. Transport Confituration
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
LOCATION AND CONTENTS OF PLATES, DECALS, AND STENCILS
EQUIPMENT DATA -816300043
EQUIPMENT DATA - Continued
THEORY OF OPERATION -816300045
OPERATOR INSTRUCTIONS
OPERATOR INSTRUCTIONS INDEX
DESCRIPTION AND USE OF OPERATOR'S CONTROLS AND INDICATORS
HYDRAULIC SYSTEM CONTROLS AND INDICATOR
COUPLING AND CONNECTORS CONTROLS AND INDICATORS
TIEDOWN AND ACCESSORY ITEMS CONTROLS AND INDICATORS
UNFOLDING FROM SHIPPING/STORAGE CONFIGURATION
Figure 15. Electrical Control boxes
Figure 16. Hydraulic Control Levers and Pin alignment
Figure 18. Hydraulic Control Levers and Unfolded FWTD
Figure 20. Control Levers, Mast, and Clevis
COUPLING
Figure 21. Master Controls
Figure 22. Rear Gladhands and Support Leg Assembly
TRANSPORT CONFIGURATION
Figure 24.Hydraulic Controls and Electric Control Box
Figure 25. Hydraulic Controls and Clevis
Figure 27. Pin Alignment and Valve
Figure 29. Pin Alignment Items
PREPARE TOWING DEVICE
Figure 33. Hydraulic and Electrical Controls
Figure 35. Hydraulic Controls
Figure 37. Remote Control and Pin Alignment
Figure 39. Mast Alignment
PREPARE TOW BAR ASSEMBLIES
Figure 42. Tow Bar Assembly Preparation
CONNECTING TO TOWED VEHICLE
Figure 44. Towing Connection Location
Figure 45. Support Leg Assembly
Figure 47. Frame Hooks and Tow Bars
Figure 48. Towing Configuration
Figure 50. Tow Bar Assembly
Figure 51. Lock Pin Placement
PERFORMANCE OF PRE-PICKING LIFTS
WINCHING OPERATIONS
Figure 52. Winch Free Spool Lever
PREPARING EQUIPMENT FOR TOWING
SECURING EQUIPMENT
Figure 55. Tie Down - Example #1
OPERATE LIGHTS
Figure 58. Light Controls and Connections
GLADHANDS -816300097
TRANSPORTING LOADS
TRANSPORTING LOADS - Continued
DISCONNECTING TOWED VEHICLE
Figure 60. Mast Pin Placement
Figure 61. Pad and Tow Bar Assembly Locations
Figure 62. Frame Hook Connection
Figure 64. Tow Bar Assembly and Storage
UNCOUPLING
Figure 67. Master Controls and Transport Legs
UNCOUPLING - Continued
PREPARE FOR SHIPPING/STORAGE
Figure 19. Breather Valve
Figure 69. Pin Alignment
OPERATION UNDER UNUSUAL CONDITIONS
OPERATION IN EXTREME HEAT AND HIGH HUMIDITY
OPERATION ON ROCKY TERRAIN
ROLL-ON/ROLL-OFF (RORO) OPERATIONS
OPERATOR TROUBLESHOOTING
OPERATOR TROUBLESHOOTING PROCEDURES INDEX
OPERATOR TROUBLESHOOTING PROCEDURES
OPERATOR TROUBLESHOOTING SYMPTOM INDEX
TABLE 1. OPERATOR TROUBLESHOOTING
ELECTRICAL SYSTEM -816300126
HYDRAULIC SYSTEM -816300127
UNIT TROUBLESHOOTING -816300129
UNIT TROUBLESHOOTING PROCEDURES INDEX
UNIT TROUBLESHOOTING PROCEDURES
UNIT TROUBLESHOOTING SYMPTOM INDEX
UNIT TROUBLESHOOTING -816300135
ELECTRICAL SYSTEM -816300137
ELECTRICAL SYSTEM - Continued -816300138
ELECTRICAL SYSTEM - Continued -816300139
ALL LIGHTS ARE INOPERABLE
LIGHT BAR ASSEMBLY INOPERABLE
STROBE LIGHTS INOPERABLE
HYDRAULIC SYSTEM -816300143
CANNOT RELIEVE HYDRAULIC PRESSURE FROM ONE OR MORE LEVERS
BOOM WILL NOT OPERATE
MAST WILL NOT OPERATE
AIR BRAKE SYSTEM
WINCH WILL NOT OPERATE
OPERATOR MAINTENANCE INSTRUCTIONS
OPERATOR MAINTENANCE INSTRUCTIONS INDEX
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
GENERAL PMCS PROCEDURES -816300156
Leakage Definitions of PMCS
Figure 70. General PMCS Procedure Chart
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300160
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300161
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300162
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300163
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300164
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300165
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300166
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300167
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300168
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300169
Table 2. Operator Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (cont.) -816300170
ELECTRICAL CONNECTORS
GLADHANDS -816300173
KINGPIN PLACEMENT
INSTALLATION -816300176
CLEANING -816300177
UNIT MAINTENANCE INSTRUCTIONS
UNIT MAINTENANCE INSTRUCTIONS INDEX
SERVICE UPON RECEIPT
UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
GENERAL PMCS PROCEDURES -816300186
PMCS INITIAL SETUP
LUBRICATION DATA
Table 3. Unit Preventive Maintenance Checks and Services (PMCS) for 250M Fifth Wheel Towing Device (FWTD)
GENERAL MAINTENANCE INSTRUCTIONS -816300191
WORK SAFETY
CLEANING INSTRUCTIONS
INSPECTION INSTRUCTIONS
LUBRICATION INSTRUCTIONS -816300195
STANDARD TOOL REQUIREMENTS
SOLDERING
ELECTRICAL GROUND POINTS
LINES AND PORTS
TUBES AND COMPRESSION FITTINGS
FLUID DISPOSAL
LUBRICATION INSTRUCTIONS -816300203
LUBRICATION CHART
250M FIFTH WHEEL TOWING DEVICE (FWTD)
250M FIFTH WHEEL TOWING DEVICE (FWTD) (cont.)
LUBRICATION CHART (cont.) -816300207
LUBRICATION CHART (cont.) -816300208
LUBRICATION CHART (cont.) -816300209
ELECTRICAL SYSTEM MAINTENANCE
24-VOLT RECEPTACLE REPLACEMENT REMOVAL AND INSTALLATION
Figure 75. Receptacle Box
12-VOLT RECEPTACLE REPLACEMENT REMOVAL AND INSTALLATION
Figure 76. Plug Assembly
12-24 VOLT JUNCTION BOX REPLACEMENT. REMOVAL, INSTALLATION
Figure 77. Junction Box Assembly
ELECTRICAL CONTROL BOX MAINTENANCE
Figure 78. Electrical Control Box
Figure 79. Electrical Control Box
INSTALLATION -816300222
INSTALLATION - Continued
SOLENOID ASSEMBLY REPLACEMENT
Figure 81. Solenoid Assembly
REMOTE CONTROL ASSEMBLY REPLACEMENT
Figure 82. Remote Control Cable Assembly
24-VOLT TOW LIGHT ASSEMBLY REPAIR.
Figure 84. Tow Light Assembly
Figure 85. Tow Light Assembly
Composite Taillight Removal
Composite Taillight Installation
Figure 88. Complete Taillight Assemblyv
INSTALLATION -816300235
FIXED WORKLIGHT REPAIR
Figure 90. Fixed Worklight Assembly
STROBE LIGHT MAINTENANCE
Figure 91. Strobe Light Assembly
INSTALLATION -816300241
Figure 92. Retractable Cord Assembly
BATTERY/BATTERY BOX REPLACEMENT
Figure 94. Battery Box Assembly
BATTERY INSTALLATION
BATTERY BOX REMOVAL
WIRING HARNESS/CABLE MAINTENANCE
Figure 96. Loop Clamp
BRAKE SYSTEM MAINTENANCE
GLADHAND REPLACEMENT.
CLEANING -816300252
INSTALLATION -816300253
AIR BRAKE PROTECTION VALVE REPLACEMENT
CLEANING -816300256
Figure 98. Air Brake Protection Valve Assembly
AIR BRAKE FITTINGS MAINTENANCE
Figure 99. Air Brake Fittings Assembly -816300260
INSPECTION AND REPLACEMENT OR REPAIR
Figure 99. Air Brake Fittings Assembly -816300262
GENERAL HYDRAULIC SYSTEM REPAIR METHODS
GENERAL HYDRAULIC SYSTEM REPAIR -816300264
Figure 100. National Pipe Thread (NPT)
INSTALLATION OF ADJUSTABLE FITTINGS
RELIEVE HYDRAULIC PRESSURE
PURGE AND FILL HYDRAULIC SYSTEM
Figure 104. Hydraulic System
HYDRAULIC MOTOR ASSEMBLY REPLACEMENT
REMOVAL OF PRIMARY MOTOR
REMOVAL OF ISOLATED MOTOR
INSTALLATION OF PRIMARY MOTOR
Figure 105. Hydraulic Motor Assembly
HYDRAULIC SAFETY VALVE REPLACEMENT
Figure 106. Hydraulic Safety Valve Assembly
INSTALLATION -816300279
Illustration
MAIN VALVE ASSEMBLY MAINTENANCE
REMOVAL -816300282
Figure 107. Hydraulic Control System
SOLENOID REMOVAL
INSTALLATION -816300285
Figure 107. Hydraulic Control Assembly
HYDRAULIC VALVE CONTROL LEVER REPLACEMENT
Figure 109. Hydraulic Control Lever
OIL FILTER ASSEMBLY REPLACEMENT
Figure 110. Oil Filter Assembly
Figure 111. Oil Filter Assembly
CAM VALVE ASSEMBLY REPLACEMENT
Figure 112. Cam Valve Assembly
INSTALLATION -816300295
HYDRAULIC CYLINDER (MAIN FRAME TO MAST) REPLACEMENT
REMOVAL -816300298
Figure 113. Hydraulic Cylinder (Main Frame to Mast)
HYDRAULIC CYLINDER (MAST TO BOOM) REPLACEMENT
Figure 114. Hydraulic Cylinder (Mast to Boom)
INSTALLATION -816300303
HYDRAULIC RESERVOIR FITTINGS REPLACEMENT
Figure 115. Hydraulic Reservoir Fittings Assembly -816300306
INSTALLATION -816300307
Figure 115. Hydraulic Reservoir Fittings Assembly -816300308
BOOM EXTENSION CYLINDER REPLACEMENT
Figure 116. Boom Extension Cylinder Assembly
INSTALLATION -816300311
GENERAL HYDRAULIC SYSTEM REPAIR -816300313
RECEIVER AND WHEEL STOP ASSEMBLY REPLACEMENT
Figure 117. Receiver and Wheel Stop
MUD FLAP REPLACEMENT
FENDER REPLACEMENT
FENDER MOUNTING BRACKET REMOVAL
FENDER INSTALLATION
TOOL BOX REPLACEMENT
Figure 121. Tool Box
HINGE ASSEMBLY REMOVAL
INSTALLATION -816300326
MAST FRAME ASSEMBLY PIVOT PIN REPLACEMENT
CENTER MAST FRAME REPLACEMENT
Figure 124. Center Mast Frame
BUMPER PAD, SLIP PAD REPLACEMENT
SLIP PAD REMOVAL
TRANSPORT LEG ASSEMBLY REPLACEMENT
REMOVAL -816300334
Figure 127. Transport Leg Assembly
WINCHES
WINCH ASSEMBLY REPLACEMENT
Figure 128. Winch Assembly
INSTALLATION -816300341
CABLE ASSEMBLY REMOVAL
PREPARATION FOR STORAGE OR SHIPMENT
PREPARATION OF EQUIPMENT FOR ADMINISTRATIVE STORAGE
General Cleaning, Painting, and Preservation.
CARE OF EQUIPMENT IN ADMINISTRATIVE STORAGE
Table 4. Exercise Schedule
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS -816300349
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS INDEX
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS -816300353
SUPPORTING INFORMATION
SUPPORTING INFORMATION INDEX
REFERENCES -816300359
TECHNICAL BULLETINS -816300360
MAINTENANCE ALLOCATION CHART
MAINTENANCE FUNCTIONS
EXPLANATION OF COLUMNS IN THE MAC
EXPLANATION OF COLUMNS IN TOOLS AND TEST EQUIPMENT REQUIREMENTS, SECTION III
Section II. MAINTENANCE ALLOCATION CHART FOR FIFTH WHEEL TOWING DEVICE
Section II. MAINTENANCE ALLOCATION CHART - Continued -816300366
Section II. MAINTENANCE ALLOCATION CHART - Continued -816300367
Section III. TOOLS AND TEST EQUIPMENT REQUIREMENTS
REPAIR PARTS AND SPECIAL TOOLS LISTS (RPSTL)
EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGE
Maintenance Code -816300371
FOURTH POSITION
Recoverability Code -816300373
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGE FORMAT AND COLUMNS
SPECIAL INFORMATION
Figure 1. 12/24 Volt Junction Box
Repair Parts List -816300377
Figure 2. Electrical Control Box
Repair Parts List -816300379
Figure 3. Solenoid Assembly
Repair Parts List -816300381
Figure 4. 24 Volt Towlight Assembly
Repair Parts List -816300383
Repair Parts List (cont.) -816300384
Figure 5. Fixed Worklight
Repair Parts List -816300387
Figure 6. Strobe Light Assembly
Repair Parts List -816300389
Figure 7. Battery Box Assembly
Repair Parts List -816300391
Figure 8 (1 of 9). Chassis Wiring Harness
Figure 8 (2 of 9). Chassis Wiring Harness
Figure 8 (3 of 9). Chassis Wiring Harness
Figure 8 (4 of 9). Chassis Wiring Harness
Figure 8 (5 of 9). Chassis Wiring Harness
Figure 8 (6 of 9). Chassis Wiring Harness
Figure 8 (7 of 9). Chassis Wiring Harness
Figure 8 (8 of 9). Chassis Wiring Harness
Figure 8 (9 of 9). Chassis Wiring Harness
Repair Parts List -816300401
Repair Parts List (cont.) -816300402
Repair Parts List (cont.) -816300403
Repair Parts List (cont.) -816300404
Figure 9. Air Brake System
Repair Parts List -816300407
Figure 10. Gladhands
Repair Parts List -816300409
Figure 11. Tow Bar Assembly
Repair Parts List -816300411
Figure 12. Kingpin Assembly
Repair Parts List -816300413
Figure 13. Receiver and Wheelstop Assembly
Repair Parts List -816300415
Figure 14. Fenders and Mud Flaps
Repair Parts List -816300417
Figure 15. Tool Box
Repair Parts List -816300419
Figure 16. Mast Frame Assembly
Repair Parts List -816300421
Figure 17. Main Frame Assembly
Repair Parts List -816300423
Figure 18. Boom Assembly
Repair Parts List -816300425
Figure 19. Transport Leg Assembly
Repair Parts List -816300427
Figure 20. Winch Assembly
Repair Parts List -816300429
Figure 21. Hydraulic Motor Assembly
Repair Parts List -816300431
Figure 22. Hydraulic Safety Valve
Repair Parts List -816300433
Figure 23. Main Valve Assembly
Repair Parts List -816300435
Figure 24 (1 of 5). Hydraulic Hoses and Fittings
Figure 24 (2 of 5). Hydraulic Hoses and Fittings
Figure 24 (3 of 5). Hydraulic Hoses and Fittings
Figure 24 (4 of 5). Hydraulic Hoses and Fittings
Figure 24 (5 of 5). Hydraulic Hoses and Fittings
Repair Parts List -816300441
Figure 25. Oil Filter Assembly
Repair Parts List -816300443
Figure 26. Cam Valve Assembly
Repair Parts List -816300445
Figure 27. Main Frame to Mast
Repair Parts List -816300447
Figure 28. Mast to Boom
Repair Parts List -816300449
Figure 29. Boom Extensions
Repair Parts List -816300451
Figure 30. Reservoir and Fittings
Repair Parts List -816300453
Repair Parts List (cont.) -816300454
NATIONAL STOCK NUMBER INDEX -816300455
NATIONAL STOCK NUMBER INDEX (cont.) -816300456
NATIONAL STOCK NUMBER INDEX (cont.) -816300457
NATIONAL STOCK NUMBER INDEX (cont.) -816300458
PART NUMBER INDEX -816300459
PART NUMBER INDEX (cont.) -816300460
PART NUMBER INDEX (cont.) -816300461
PART NUMBER INDEX (cont.) -816300462
PART NUMBER INDEX (cont.) -816300463
PART NUMBER INDEX (cont.) -816300464
PART NUMBER INDEX (cont.) -816300465
PART NUMBER INDEX (cont.) -816300466
PART NUMBER INDEX (cont.) -816300467
PART NUMBER INDEX (cont.) -816300468
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
SECTION III. BASIC ISSUE ITEMS
SECTION III. BASIC ISSUE ITEMS - Continued -816300471
SECTION III. BASIC ISSUE ITEMS - Continued -816300472
SECTION III. BASIC ISSUE ITEMS - Continued -816300473
SECTION III. BASIC ISSUE ITEMS - Continued -816300474
SECTION III. BASIC ISSUE ITEMS - Continued -816300475
SECTION III. BASIC ISSUE ITEMS - Continued -816300476
ADDITIONAL AUTHORIZATION LIST
ADDITIONAL AUTHORIZATION LIST (cont.)
EXPENDABLE AND DURABLE ITEMS LIST -816300479
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST - Continued -816300481
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST - Continued -816300482
ILLUSTRATED LIST OF MANUFACTURED ITEMS
TORQUE VALUES FOR THREADED FASTENERS
HOW TO USE TORQUE TABLE
Table 5. Torque Limits for Dry Fasteners
Table 6. Torque Limits for Wet Fasteners
TIGHTENING METAL FASTENERS
FASTENER GRADE -816300490
SCHEMATICS -816300491
Electrical Schematic
Electrical Schematic (cont.) -816300493
Electrical Schematic (cont.) -816300494
Hydraulic Schematic
AUTHORIZED VEHICLE COMBINATIONS
AUTHORIZED VEHICLE COMBINATIONS - Continued
TOWBAR ASSEMBLY POSITIONING
TM-9-2510-247-13-P Fifth Wheel Towing Device Model 250M (NSN 2510-01-458-8253) Manual
