Chapter VII


MAINTENANCE

The tank must always be in complete fighting readiness. Reliable performance is only possible if the tank is properly maintained. Regular maintenance increases she life of the machine. Tank maintenance consists of :
1. Filling up with fuel, oil and water.
2. Periodical technical inspection.
3. Periodical lubrication.
4. Systematic checking of the adjustment of assemblies and of the controls.

FILLING UP
The fuel tanks should be filled with DT Diesel fuel or "gasoil" mark "3" through a double thickness of silk cloth. If a silk cloth is not available then it is possible to use a flannel with the nap upwards. The funnel must have a mesh filter (mesh size not less than No. 60).

The fuel should be filled into four tanks - 150 litres into the front tanks and 80 litres into the rear tanks and up to the level of the middle ring marked on the filter. The quantity of fuel is measured by a dipstick.

Diesel fuel, summer grade, is suitable for use at temperatures not less than +5°C and winter grade for use at temperatures of less then +5°C. Winter fuel can be used in summer. At temperatures below - 20°C, tractor kerosine should be added to DT winter fuel in the following proportions:

from -20 to -30°G 10% kerosine
from -30 to -35°C 25% kerosine
from -35 to -50°C 70% kerosine

The fuel can be drained from the drain plugs underneath the tanks. To do this the end of a flexible tube should be screwed on to the threaded plug which should then be unscrewed from 2 to 3 turns.

Oil
The oil tanks are filled with "Avia" oil MK or MS or MZS through the mesh filter (mesh size not being less than No. 60). In winter at temperatures below -20°C it is recommended to fill up with MZS "Avia" oil. Of the oil tanks two of 57 litre capacity each, are filled up to 40 litres. The quantity of oil is measured by a dipstick. The minimum permissible quantity of oil in the tanks is 20 litres.

The oil is drained through plugs situated in the base of the tanks. In winter it is recommended to drain off the oil before long halts. In winter the oil should only be filled after the engine has been warmed with water (warmed to 80-90°C) filled into the tanks and 5-6 litres into the engine.

Water
The cooling system is filled with water through the mouth of the filler opening over the engine. Into the mouth of the opening is introduced a funnel with mesh filter. If the steam valve is opened the water can be poured in more quickly.

The system will take 95 litres of water and the level should come to about 2-3 mm. from the base of the filler mouth.

A tap is fitted to the water plug to drain the water. To do this the hand lever of the tap on the engine bulkhead should be turned to the vertical position.

To clear the pump of water it is necessary to turn the crank shaft round 2-3 turns.

In winter at temperatures lower than -20°C the cooling system should be filled either with anti-freeze or a mixture of glycerine, spirit and water. Anti-freeze Expands on heating and therefore the cooling system should be filled with 5-6 litres less than when filling with water.

Sometimes anti-freeze will not flow, as at -50°C it is transformed into a porous mass but this does not cause cracks in the system.

Anti-freeze is a costly product and care must be taken to prevent wastage.

TECHNICAL INSPECTION OF THE VEHICLE
External Inspection
1. Inspect the condition of the tracks, track pins and their keepers, (split pins). Each track should be hit with a hammer to reveal any cracks.
2. Check the track tension.
3. Test the joint between the idler crank arm and the hull for firmness.
4. Check the lubricator plugs of the suspension for tightness.
5. Inspect the brackets and fixtures of the entrenching tool, spare tracks, jettison tanks, tarpaulin and tool box.

Inspection of Engine and Transmission Compartment
1. Every accessible place should be cleaned with a rag.
2. See that there are no foreign bodies on the floor under the fan.
3. Check the fuel, oil and water systems for correct flow. Test the "durite" hoses for firmness. Sec that the fuel system is hermetically sealed under 0.2 - 0.3 m/m.
4. See what the clearance between the brake bands and drums is 1.5 - 2.0 mm. all round.
5. See that there is no leakage of oil from the gearbox.
6. Test the tie rods and split pins of the control linkages.

Inspection of the Fighting And Driving Compartment
1. Test the locking of the nut of the idler wheel nut.
2. See that the accessories are not on the floor under the control-rods.
3. Test the working of the driving controls and see that the ball and socket joints are not disconnected, that the levers are not resting on the floor and that the split pins are properly secured.
4. Test the pressure in the air bottles. The maximum pressure is 15O atm. The minimum pressure is 30 atm. in summer and 65 atm. in winter.
5. Check the position of the hand levers of the drain cock:- horizontal position - cock closed, vertical - open.
6. Check the position of the fuel change-over cock. The hand lever should be pointing downwards - all tanks switched off.
7. Test the quality of grease in the water pump pressure lubricator.
8. Inspect the earth switch.
9. Check the fire extinguisher.
10. Inspect the working parts of the electrical circuit for damage.
11. Test the horn and lights.

INSPECTION OF THE TANK AFTER EVERY 10 - 12 HOURS TRAVEL OR AFTER COVERING 250-300 KM
What to Inspect What to do Method
Fuel Distributor cock Inspect and clean the mesh filter of the fuel distributor cock. To clean the filter unscrew the plug in the body of the cock and remove filter. Clean the filter in "gasoil" or petrol and afterwards blow out with air.
Oil and water radiators (and after travel through dust in summer) Inspect and when necessary clean the cooling surfaces from oil and dust. When possible it is recommended to clean the grooves of the radiators with compressed air.
Air cleaner (in summer) Remove, take down, clean and replace. Remove the cover of the air cleaner in one piece with its sections and wire-wool, clean the wire-wool in kerosine, place the cover and wire-wool in an oil bath so that the wire-wool absorbs the oil, remove is and allow the superfluous oil to drip off. Change the oil in the air cleaner oil bath.
Engine Clutch Test the engagement of the clutch and tightness of the control linkage. The travel of the presser plate should be 6-7 mm. If the travel of the presser plate is less than 6 mm the adjustment described in Chapter III should be carried out.

INSPECTION OF THE TANK AFTER EVERY 25 - 30 HOURS TRAVEL OR AFTER COVERING 500-600 KM
(IN ADDITION TO INSPECTION AFTER 10-12 HOURS)
What to Inspect What to do Method
Engine fuel and oil systems Inspect the oil and fuel leads. The hoses should be without cracks, twists, or kinks.
Engine fuel injection pump Inspect the fixture of the fuel injection pump on the crankcase.  
Filters of the drain plugs of the oil tanks Inspect and clean the mesh filters of the radiator tanks Clean with "Gasoil"
Air cleaner (winter) Remove, take down, clean and replace. Remove the cover of the air cleaner in one piece with its sections and wire-wool, clean the wire-wool in kerosine, place the cover and wire-wool in an oil bath so that the wire-wool absorbs the oil, remove is and allow the superfluous oil to drip off. Change the oil in the air cleaner oil bath.
Tachometer and speedometer cables Inspect the attachment of the ends of the cables and the cable themselves.  
Engine fuel filter Remove, take down, clean and replace according to instructions issued for maintenance of the engine lubrication system.  
Oil filter Remove, take down, clean and replace according to instructions issued for maintenance of the engine lubrication system.  
Engine clutch Check that the flywheel is seated firmly on the crankshaft. For this test the fan must be gripped by hand and rocked to and fro. There should be no play.

INSPECTION OF THE TANK AFTER EVERY 50 HOURS TRAVEL OR AFTER COVERING 1000 KM
(IN ADDITION TO INSPECTION AFTER 25-30 HOURS)
What to Inspect What to do Method
Final Drive Check the assembly locking spindles of the driven gear (by adjusting the conical bearing). If the play (looseness) of the assembly locking spindles is more than 0.15 mm, tighten the nut accordingly. Then slacken the nut 1/6 of a turn and fix split pin. To test the tightness of the assembly locking spindles it is necessary to disconnect the track and remove the sprocket wheel cap.
Assembly locking spindles of suspension arms. Check the tension of assembly locking spindles of the suspension arm. It is necessary to unscrew the cap on the ends of the suspension shaft (on one side of the tank). Tighten the nuts of the assembly locking spindles as required then slacken off 3/4 of a turn. For the suspension arms of four bogies it is necessary to tighten the nuts of the assembly locking spindle on both sides and slacken off 1/2 a turn.
Engine suspension Test the tension of the nuts securing the engine to the engine chassis. The nuts must be firmly tightened and fitted with split pins.

Click for larger view of Plate 56
Plate 56 : Lubrication Chart

TABLE OF LUBRICATION

I. Lubricate every hour of engine running
No. on Chart Components No. of lubrication points Lubricant Method of lubricating
1 Water pump spindle 1 Summer - "Soilidol"
Winter - mixture of 50% "Soilidol" and 50% "Aviation Oil" or special winter grade of "Soilidol" 		Turn the handle of the pressure lubricator fixed in the engine bulkhead 1 or 2 turns

II. Lubricate after completion of 100 Km
No. on Chart Components No. of lubrication points Lubricant Method of lubricating
1 Shaft of steering clutch control levers (after completion of 100km) 4 "Avia" oil Oil-can through special openings
2 Pedal shafts of engine clutch and foot brake 2 "Avia" oil Oil-can through special openings
3 Hinge pins connecting the engine clutch pedal and foot brake with front tie rod 2 "Avia" oil Oil-can
4 Compensating shaft 6 "Avia" oil Using oil-can fill 18-20 drops through the special openings
5 Compensating shaft 1 "Solidol" Apply threaded grease gun to MTK lubricator
6 Shaft of hand control to fuel injection pump 1 "Avia" oil Using oil-can fill some drops into the special opening

III. Lubricate at 250-300 Km or 10-12 engine running hours
No. on Chart Components No. of lubrication points Lubricant Method of lubricating
7 Engaging clutch withdrawl mechanism bearings 1 "Konstalin" Half a stroke os the threaded grease gun applied to the MTK lubricator in front part of crank case
8 Bearing of the driven drum of engine clutch 1 "Konstalin" Quarter of a stroke of the threaded grease gun applied to the lubricator on the hub of the driven drum
9 Steering clutch bearings 2 "Konstalin" Half a stroke of the threaded grease gun applied to the MTK lubricator on the gear box
10 Starter moter (control side) 1 "Avia" oil Appliy 15-20 drops using oil-can
10 Starter moter (commutator side) 1 "Solidol" Remove cover and pack the bearing with grease

IV. Lubricate at 500 Km or 25 engine running hours
No. on Chart Components No. of lubrication points Lubricant Method of lubricating
11 Bogie wheel bearings (in summer) 10 "Solidol" Applying the threaded grease gun to the MTK lubricator. Fill up with 0.3 kg in each wheel
12 Gearbox 1 MK "Alia" oil. In winter at temperatures lower than -20°C use MZS "Avia" oil Unscrew the plug on the top of the gearbox casing and measure the oil level. If lower than 40mm, top up to 45-55 mm level
  Fuel injection pump 1 "Avia" oil Top up with oil to the second mark on the gauge
  Fuel injection pump governor 1 "Avia" oil. In winter a mixture 50% "Avia" oil plus 50% "Gasoil" Fill up oil into the governor casing up to the level of the inspection plug

V. Lubricate at 1000 Km or 50 engine running hours
No. on Chart Components No. of lubrication points Lubricant Method of lubricating
12 Final drive 2 70% "Avia" oil plus 30% "Konstalin" Insert 1kg through the opening into the cover of the casing and 1.5kg into the casing
11 Bogie wheel bearings (winter) 10 "Solidol" 0.3kg into each bogie using the threaded grease gun and the MKS lubricator
14 The rods of the inclined springs and of the front bogie spring 10 In summer - a mixture 75% "Solidol" plus 25% "Alia" oil
In winter - a mixture 60% "Solidol" plus 40% "Alia" oil 		Remove covers over the spring cases and fill the seatings of the rods with 100g
19 Bogie arm bronze buses 10 "Solidol" Unscrew the plugs on the ends of the shafts of the suspension arms and force the grease into the shaft with a grease gun
15 Idler wheel bearings 2 "Solidol" Remove idler wheel. Clean bearings and pack with grease
16 Vertical shaft of gear selector mechanism 1 "Solidol" Using grease gun force grease through the MTK lubricator into the end of the shaft
17 Gear selector casing 1 "Solidol" Take down casing and fill with grease
  Turret traverse motor 1 "Avia" oil" Fill through lubricator
  Electric fan motor 1 "Avia" oil Fill through lubricator

VI. Lubricate at 2000 Km or 100 engine running hours
No. on Chart Components No. of lubrication points Lubricant Method of lubricating
18 Track adjusting mechanism 2 "Solidol" Fill the casing with grease
  Bush of suspension arm lever for front bogie 2 Mixture 10% Graphite plus 90% "Solidol" Insert through openings in the bush
  Suspension arm bushes 8 "Solidol" Remove cap and fill the hollows of the bush with grease
  Generator 1 "Avia" oil Fill up through lubricator
  Turret traverse gear 1 Summer - mixture 75% "Solidol" plus 25% "Avia" oil
Winter - mixture 50% "Solidol" plus 50% "Avia" oil 		Fill casing through the MTK lubricator using threaded grease gun
  Turret race (using lifting device) 1 "Solidol" Remove turret, clean cage, balls and races
  Gearbox 1 "Avia" oil Drain off oil, blow air through and fill up with 11 litres "Avia" oil (up to 45-55mm level on the dipstick)