AB-621_mast_serv_TM11-5985-334-34_1983.pdf

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1、TM 11-5985-334-34 TECHNICAL MANUAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL MAST AB-621/G (NSN 5985-00-782-5278) MAST AB-621A/G (NSN 5985-01-061-2828) EXTENSION KIT MK2044/G (NSN 5985-01-119-2925) HEADQUARTERS, DEPARTMENT OF THE ARMY FEBRUARY 1983 SAFETY STEPS TO FOLLOW IF SOMEONE IS TH

2、E VICTIM OF ELECTRICAL SHOCK DO NOT TRY TO PULL OR GRAB THE INDIVIDUAL IF POSSIBLE , TURN OFF THE ELECTRICAL POWER IF YOU CANNOT TURN OFF THE ELECTRICAL POWER, PULL, PUSH, OR LIFT THE PERSON TO SAFETY USING A WOODEN POLE OR A ROPE OR SOME OTHER INSULATING MATERIAL SEND FOR HELP AS SOON AS POSSIBLE A

3、FTER THE INJURED PERSON IS FREE OF CONTACT WITH THE SOURCE OF ELECTRICAL SHOCK, MOVE THE PERSON A SHORT DISTANCE AWAY AND IMMEDIATELY START ARTIFICIAL RESUSCITATION WARNINGS Before beginning any work on this equipment, review the general safety precautions and procedures in TB 385-4, Safety Precauti

4、ons for Main- tenance of Electrical and Electronic Equipment. Do not work on equipment alone. Be sure that a person capable of rendering first aid is present. To prevent personal injury when applying or removing steel strapping on crates or cartons, wear heavy gloves and protective eye glasses. Do n

5、ot handle cartons by the steel straps. Adequate ventilation should be provided while using TRICHLOROTRI- FLUOROETHANE. Prolonged breathing of vapor should be avoided. The solvent should not be used near heat or open flame; the products of decomposition are toxic and irritating. Since TRICHOLORTRIFLU

6、ORO- ETHANE dissolves natural oils, prolonged contact with the skin should be avoided. When necessary, use gloves which the solvent cannot penetrate. If the solvent is taken internally, consult a physician immediately. Compressed air shall not be used for cleaning purposes except where reduced to le

7、ss than 29 psi and then only with effective chip guarding and personnel protective equipment. Do not use compressed air to dry parts when TRICHLOROTRIFLUOROETHANE has been used. Compressed air is dangerous and can cause serious bodily harm if protective means or methods are not observed to prevent c

8、hip or particle (of whatever size) from being blown into the eyes or unbroken skin of the operator or other person- nel. Do not attempt to lift or move the heavy components of the AB-621(*)/G or MK-2044/G without adequate manpower. a HOW TO USE THIS MANUAL This technical manual covers maintenance pr

9、ocedures for use by direct and general support level repair personnel to maintain the AB-621(*)/G An- tenna Mast, and MK-2044/G Extension Kit. The following equipment are covered: AB-621/G Mast, 50 foot. AB-621A/G Mast, 50 or 100 foot. MK-2044/G Extension Kit, (to 100 foot) used with AB-621A/G. Inst

10、ructions apply to all AB-621(*)/G installations except when specific nomenclature notes appear. This notation method is used to identify items that are different between AB-621/G and AB-621A/G installations. The notation MK-2044/G is used to identify items used with the extension kit. Carefully foll

11、ow all the cautions and warnings in this manual. b *TM 11-5985-334-34 Technical Manual HEADQUARTERS DEPARTMENT OF THE ARMY No. 11-5985-334-34 WASHINGTON, DC, 16 February 1983 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL Chapter 1. Section I. II. Chapter 2. Section I. II. III. IV. V. VI. Cha

12、pter 3. Section I. II. Appendix A. B. C. MAST AB-621/G (NSN 5985-00-782-5278) MAST AB-621A/G (NSN 5985-01-061-2828) EXTENSION KIT MK-2044/G (NSN 5985-01-119-2925) REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to impr

13、ove the procedures, please let us know. Mail your letter, DA Form 2028, (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual direct to: Commander, US Army CommunicationsElectronics Command and Fort Monmouth, ATTN: DRSEL-ME-MP, Fort Monmouth, NJ

14、07703. A reply will be furnished to you. Page HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b INTRODUCTION General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS General . . . . . . . . . . . . . .

16、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Disassembly and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Maintenance Procedures MK-2044G . . .

17、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Cleaning, Inspection, and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Testing . . . . . . . . .

18、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19、.3 - 1 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 EXPENDABLE SUPPLIES AND MATERIALS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20、 . . .C-1 11-5985-334-15, 2 October 1971. *This manual together with TM 11-5985-334-10, 17 November 1982, TM 11-5985-334-20, 16 November 1982, supersedes TM i/(ii blank) TM 11-5985-334-34 CHAPTER 1 INTRODUCTION Section I. GENERAL INFORMATION 1-1. Scope Type of Manual: Direct and General Support Main

21、tenance Model Number and Equipment Name: AB-621(*)/G-Mast, Antenna (Includes AB-621/G and AB-621A/G) MK-2044/G-Kit, Extension Purpose of Equipment: Portable antenna mast used to support a variety of directional radio antennas, to an elevation of 50 or 100 feet. 1-2. Maintenance Forms, Records, and R

22、eports a. Reports of Maintenance and Unsatisfactory Equipment. Department of the Army forms and procedures used for equipment maintenance will be those prescribed by TM 38-750, The Army Maintenance Management System. b. Reportingof Packagingand Handling Deficiencies. Fill out and forward SF 364 (Rep

23、ort of Discrepancy(ROD) as prescribed in AR 735-11-2/DLAR 4140.55/NAVMATINST 4355.73/AFR 400-54/MCO 4430.3E. c. Discrepancy in Shipment Report (DISREP) (SF 361). Fill out and forward Discrepancy in Shipment Report (DISREP) (SF 361) as prescribed in AR 55-38/NAVSUPINST 4610.33B/AFR 75-18/MCO P4610.19

24、C/DLAR 4500.15. 1-3. Destruction of Army Materiel to Prevent Enemy Use Destruction of Army electronics materiel to prevent enemy use shall be in accordance with TM 750-244-2. 1-4. Preparation for Storage or Shipment a. Refer to TM 11-5985-334-10 to remove the AB-621(*)/G and MK-2044/G from service a

25、nd pack for storage. b. Administrative storage of the AB-621(*)/G and MK-2044/G will be handled as follows. The requirements apply whether the mast is stored with an associated radio, or stored alone. (1) Before and after storage, perform the following (a) Clean the unit and spot-paint bare metal pa

26、rts (refer to TM 11-5985-334-20). (b) Perform monthly preventive maintenance checks and services (refer to TM 11-5985-334-20). Correct all deficiencies. (2) Store in dry, moisture free area. Records and reports shall be maintained as prescribed in TM 38-750 for equipment in use. 1-5. Official Nomenc

27、lature, Names, and Designation The following nomenclatures are covered in this manual; these designations are used to identify specific items that are used at your installation. DesignationModel/Equipment AB-621/GMast, Antenna 50 foot AB-621A/GMast, Antenna 50 or 100 foot MK-2044/GKit, Extension NOT

28、E The designation AB-621(*)/G when used in this manual means that the in- formation applies to both the AB-621/G and AB-621A/G. Also, when instructions are given for a component without model reference, the information applies to both models. MK-2044/G is used to identify those items which are used

29、exclusively with the extension kit. 1-6. Reporting Equipment Improvement Recommendations (EIR) If your AB-621(*)/G or MK-2044/G needs im- provement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you dont like about your equipment. Let us know why you dont like the

30、 design. Put it on an SF 368 (Quality Deficiency Report). Mail it to us at Commander, US Army CommunicationsElectronics Command and Fort Monmouth, ATTN: DRSEL-ME-MP, Fort Monmouth, NJ 07703. Well send a reply. 1-7. Consolidated Index of Army Publications and Blank Forms Refer to the latest issue of

31、DA Pam 310-1 to determine whether there are new editions, changes or additional publications pertaining to the equipment. 1-1 TM 11-5985-334-34 Section Il. EQUIPMENT DESCRIPTION AND DATA 1-8. Equipment Description and Datafor complete equipment description and data on the Refer to TM 11-5985-334-10,

32、 Operators Manual, AB-621(*)/G and MK-2044/G. 1-2 TM 11-5985-334-34 CHAPTER 2 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS 2-1. The Section I. GENERAL General Maintenance Instructions b. Providing support cooperator personnel when maintenance procedures performed at direct systems are operational. The eq

33、uipment will remain support are actions normally provided in response operational during this time. To lower the mast for to organizational support requests. Further, direct inspection, provide an alternate mast and antenna. Alternatively, the mast can be lowered for in- support maintenance is desig

34、ned to anticipate potential problem areas before they result in spection when the radio set is nonoperational during equipment outage. The action to be taken depends periods such as: (1) When no operation is scheduled. on the operational status of the unit involved and (2) When the associated radio

35、equipment is consists principally of the following: being repaired. a. Providing support to installation teams during (3) When modifications on the equipment are erection of the mast. being performed. Section Il. TROUBLESHOOTING 2-2. General Instructionsstallation has been accomplished. Identificati

36、on of a Troubleshooting by direct support maintenance problem by operator personnel will usually localize the trouble to the defective assembly or unit. Refer personnel is normally performed on problems to table 2-1 to troubleshoot the AB-621(*)/G. reported by operator personnel installing the an- t

37、enna mast or during visual inspection after in- Table 2-1. Troubleshooting MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1. MAST SWAYING. Step 1.Check for loose or damaged anchors. Place a second anchor into ground beside the loose anchor and transfer guys to the second anchor. Step 2.Check for g

38、uy slackness. Tighten guys. Step 3.Check tensioner slippage. Replace guy assembly. Step 4.Check if launcher is solid on ground. Tighten all guys. Reinstall the launcher on a soft earth base. 2. ANTENNA AZIMUTH SHIFTED. Step 1.Check for brake not set. Readjust antenna azimuth and set brake. Step 2.Ch

39、eck for defective brake. Repair brake (para 2-7). 3. WINCH SLIPS. Step 1.Check for damaged handle or hardware. Replace handle or hardware (para 2-4). 2-1 TM 11-5985-334-34 Table 2-1. Troubleshoot-Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 3. WINCH SLIPSCONTINUED. Step 2.Check for dam

40、aged winch mechanism. Light winchreplace if damaged. Heavy winchrepair if damaged (refer to general support). Step 3.If winch is not at fault, check elevator operation (4 below). 4. ELEVATOR WONT RAISE OR LOWER. Step 1.Check winch (3 above). Step 2.Check for broken elevator cable. Replace elevator c

41、able (para 2-11, 2-12). Step 3.Check for damaged cable pulley. Replace cable pulley (para 2-9, 2-10). Step 4.Check for damage to nut securing cable to elevator. Repair elevator mechanism (para 2-11, 2-12). 5. ELEVATOR OPERATION IS ERRATIC. Step 1.Check winch (3 above). Step 2.Check for dirt or forei

42、gn material in elevator tracks. Clean tracks (para 2-26). Step 3.Check for damaged cable pulley. Replace cable pulley (para 2-9, 2-10). Step 4.Check for damaged elevator part. Repair elevator mechanism (para 2-1 1,2-12). 6. BRAKE WONT HOLD. Step 1.Check brake adjustment. Adjust brake (para 2-8). Ste

43、p 2.Check for damaged brake. Repair brake (para 2-7). 7. GUY CONTROL DEVICE CABLE WONT PAY OUT. Step 1.Check for defective ratchet mechanism. Replace gear box (para 2-24). Step 2.Check for jammed cable. Repair cable/reel mechanism (para 2-24). Step 3.Check for damaged gear box, Replace gear box (par

44、a 2-24). 8. GUY CONTROL DEVICE HANDCRANK WONT TURN. Check for damaged gear box. Replace gear box (para 2-24). 9. NO CABLE TENSION AT GUY CONTROL DEVICE. Check reel spring for damage. Replace damaged reel spring (para 2-24). Section Ill. DISASSEMBLY AND REASSEMBLY 2-3. General This section explains h

45、ow to remove, replace, disassemble and reassemble antenna mast com- ponents. Disassemble items only when repair is required. Do not disassemble as part of routine maintenance. 2-4. Removal and Replacement of Winch Handle and Winch Studs, AB-621(*)/G (fig. 2-1) NOTE The following instructions apply t

46、o the lightwinchsuppliedwiththe AB-621(*)/G; if you have the heavy winch for the MK-2044/G, see paragraph 2-22. a. Remove the winch handle assembly (1) from the winch drive shaft (4) by removing the machine bolt (2) and self-locking nut (3). NOTE Replace the machine bolt and self-locking nut as show

47、n on figure 2-1. b. Remove the winch studs (6 and 7) from the winch faceplate by removing the self-locking nut (3) and washer (5) from the stud. c. Release the snapslide (not shown) and drive the stud out with a plastic faced hammer. 2-2 TM 11-5985-334-34 Figure 2-1. Winch assembly, AB-621(*)/G. 2-5

48、. Removal and Replacement of Base Assembly and Elevator (fig. 2-2) NOTE The launcher must be in a horizontal position for removal and replacement of the base and elevator. a. Lower the elevator platform, remove the winch assembly, and lay the launcher on its back. b. Position the elevator half-way u

49、p the launcher. c. Remove the 12 screws (17) and self-locking nuts (18) at the heel of the base assembly (19). d. Remove the four machine bolts (21) and self- locking nuts, that fasten the diagonal braces to the base assembly. e. Remove the base assembly (19) from the launcher assembly (24). f. Pull the elevator cable assembly stud out of the hole in the tube at the top of the elevator; hold the cable assembly with vise-grip pliers and remove the self-locking nut (5) to release the elevator from the cable. g. Roll the elevator out of the launcher elevator guides of the la