TM 05539-IN U.S. MARINE CORPS TECHNICAL MANUAL ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE MANUAL WITH REPAIR PARTS LIST (RPL) FOR SNIPER RIFLE, 7.62 MM, M40A3 NSN: 1005-01-495-0843 PN: 99004A1000 SNIPER RIFLE, 7.62 MM, M40A5 NSN: 1005-01-567-7827 PN: 08009A0000 MARINE CORPS SYSTEMS COMMAND QUANTICO, VA 22134-6050 DISTRIBUTION STATEMENT: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS. THIS PUBLICATION IS REQUIRED FOR ADMINISTRATION AND OPERATIONAL PURPOSES.
DEPARTMENT OF THE NAVY Headquarters, U.S. Marine Corps Washington, DC 20380-0001 31 October 2008 1. This Technical Manual (TM), authenticated for Marine Corps use and effective upon receipt, provides information on the Sniper Rifle, 7.62 mm, M40A3, NSN: 1005-01-495-0843 and the Sniper Rifle, 7.62 mm, M40A5, NSN: 1005-01-567-7827; TM 05539-IN. 2. Submit notice of discrepancies or suggested changes on a NAVMC 10772. The NAVMC may be submitted via the Internet using website https://pubs.ala.usmc.mil/ front.
TM 05539-IN WARNING SUMMARY This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. WARNING Use only authorized ammunition manufactured to U.S. or North Atlantic Treaty Organization (NATO) specifications.
TM 05539-IN WARNING DO NOT store the weapon with live ammunition in either the chamber or magazine. Failure to follow this warning may cause injury or death to personnel. WARNING Under NO circumstances should live ammunition be shipped with the weapon, either in the shipping box, magazine or chamber. Failure to follow this warning may cause injury or death to personnel.
TM 05539-IN TECHNICAL MANUAL TM 05539-IN MARINE CORPS SYSTEMS COMMAND Quantico, VA, October 2008 U.S. MARINE CORPS TECHNICAL MANUAL ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE MANUAL WITH REPAIR PARTS LIST (RPL) FOR SNIPER RIFLE, 7.62 MM, M40A3 NSN: 1005-01-495-0843 PN: 99004A1000 AND SNIPER RIFLE, 7.62 MM, M40A5 NSN: 1005-01-567-7827 PN: 08009A0000 DISTRIBUTION STATEMENT: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS.
TM 05539-IN Table of Contents - Continued WP/Page Number CHAPTER 3 ORGANIZATIONAL MAINTENANCE WP 0007 00 Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-1 WP 0008 00 Preventive Maintenance Checks and Services (PMCS) Including Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1 WP 0009 00 General Maintenance Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM 05539-IN HOW TO USE THIS MANUAL INTRODUCTION 1. This manual contains operating instructions, maintenance procedures, emergency procedures, and troubleshooting procedures for the 7.62 mm, M40A3/A5 Sniper Rifle. It is divided into five chapters. 2. This manual is written in work package format: 3. a. Chapters divide the manual into major categories of information (e.g., General Information, Equipment Description and Data, and Principles of Operation). b.
TM 05539-IN FEATURES OF THIS MANUAL 1. This manual contains information on operating and maintaining the M40A3/A5 Sniper Rifle. 2. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD print as a visual aid. WARNING A WARNING indicates a hazard which may result in injury or death to personnel. CAUTION A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment.
TM 05539-IN CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND DATA, AND PRINCIPLES OF OPERATION
4 TM 05539-IN GENERAL INFORMATION 0001 00 SCOPE 1. Type of Manual. Organizational and Intermediate Maintenance Manual for the 7.62 mm, M40A3/M40A5 Sniper Rifle. Basic operator’s procedures are outlined in TM 05539-OR_, Operator’s Manual with Components List for Sniper Rifle, 7.62 mm, M40A3/M40A5. 2. Equipment Name and Model Number. The weapon, 7.
TM 05539-IN GENERAL INFORMATION - CONTINUED 0001 00 FORMS, RECORDS, AND REPORTS - CONTINUED b. Page 3. The using unit will complete this page when the weapon is received. The only further entries required are the telescope serial number, if replaced. The accumulated rounds fired count should be recorded from the previous Weapon Record Book, when replaced. c. Page 5, Unit Commander’s Record. Record the daily total of rounds fired. Make entries as shown in Table 1.
TM 05539-IN GENERAL INFORMATION - CONTINUED 0001 00 FORMS, RECORDS, AND REPORTS - CONTINUED M40-001 0001 00-3
TM 05539-IN GENERAL INFORMATION - CONTINUED 0001 00 LIST OF ABBREVIATIONS/ACRONYMS 0001 00 ABBREVIATION/ACRONYM DEFINITION CAGEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial and Government Entity Code CLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaner, Lubricant, and Preservative FPS . . . . . . . . . . . . . . . . . . . . . . .
8 TM 05539-IN EQUIPMENT DESCRIPTION AND DATA 0002 00 DESCRIPTION 0002 00 General. The M40A3/A5 Sniper Rifle is a bolt action, manually operated, magazine fed, air cooled, shoulder fired weapon with an optical sight. The closed bolt design of the weapon offers a high degree of accuracy and control while providing a greater degree of safety. The M40A5 is also equipped with a barrel muzzle break and quickly attachable/detachable sound suppressor. NOMENCLATURE 1. 0002 00 Left Side.
TM 05539-IN EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00 DESCRIPTION OF MAJOR COMPONENTS 0002 00 1. The major components of the M40A3/A5 are barrel and receiver assembly (14 and 17), bolt assembly (13), stock assembly (10), trigger guard (8), magazine assembly (9), telescope assembly (2), accessory rail (1), bipod assembly (15), and optical platform (4). 2 1 13 14 4 17 8 15 10 M40-004 9 2. Barrel and Receiver Assembly.
TM 05539-IN EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00 DESCRIPTION OF MAJOR COMPONENTS - CONTINUED 3. Bolt Assembly. The bolt assembly (13) is housed in the receiver (17). The bolt feeds and fires the cartridge and extracts and ejects the empty cartridge case after firing. 13 17 4. M40-006 Stock Assembly. The fiberglass stock (10) contains the trigger guard (8), magazine assembly (9), and supports the barrel (14), and receiver assembly (17).
TM 05539-IN EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00 DESCRIPTION OF MAJOR COMPONENTS - CONTINUED 5. 8 Trigger Guard. The trigger guard assembly (8) helps protect the trigger assembly. M40-008 6. Magazine Assembly. The magazine assembly (9) consists of the follower (22), magazine spring (23), and floor plate (24). 22 23 9 24 M40-028 7. Telescope Assembly with Ring Mounts. The telescope assembly (2) is mounted to the optical platform (4).
TM 05539-IN EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00 DESCRIPTION OF MAJOR COMPONENTS - CONTINUED 8. Bipod Assembly. The bipod assembly (15) is mounted to the stock. It can be used to help stabilize the weapon system in certain tactical situations. The bipod assembly pivots and locks in any left or right position. 15 M40-010 9. Optical Platform. The ring mounts (25) attach to the optical platform (4) that supports the telescope assembly (2).
TM 05539-IN EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00 DESCRIPTION OF MAJOR COMPONENTS - CONTINUED 10. Muzzle Break. (M40A5 Only) - The muzzle break (26) is attached to the weapon’s barrel (14) for the purpose of providing a mounting point for a sound suppressor (28). The bearing surfaces and interface notch on the muzzle break provide a highly precise fit between the suppressor and the muzzle break.
TM 05539-IN EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00 REFERENCE DATA 0002 00 Table 1. M40A3/A5 Sniper Rifle Specifications. SPECIFICATIONS Caliber 7.62 mm NATO Weight w/o suppressor w/ suppressor 16.05 lb 17.20 lb Weight of telescope 2.0 lb Total weight w/o suppressor w/ suppressor 18.25 lb 19.45 lb Overall length w/o suppressor w/ suppressor 44 in. 49.75 in. Barrel length 24 in. Suppressor weight 19 oz Suppressor length 9.8 in. Suppressor diameter 1.5 in.
2 TM 05539-IN PRINCIPLES OF OPERATION 0003 00 GENERAL DESCRIPTION 1. Cycle of Operation. Knowledge of what happens during the cycle of operation will help the operator understand the cause of and remedy for various stoppages. 2. Eight Steps. The cycle of operation consists of eight steps: 3. a. Firing b. Unlocking c. Cocking d. Extracting e. Ejecting f. Feeding g. Chambering h. Locking Description of Eight Steps.
TM 05539-IN PRINCIPLES OF OPERATION - CONTINUED 0003 00 GENERAL DESCRIPTION - CONTINUED f. Feeding. While pushing the bolt handle forward into battery, a live cartridge is stripped from the magazine by the nose of the bolt. The live cartridge is guided toward the chamber by the feed ramp of the receiver. g. Chambering. The bolt continues the forward movement of the live cartridge toward the breech until the bolt handle (3) makes contact with the primary extraction surface of the receiver.
TM 05539-IN CHAPTER 2 TROUBLESHOOTING
2 TM 05539-IN TROUBLESHOOTING INTRODUCTION 0004 00 GENERAL This chapter contains troubleshooting information for locating and correcting malfunctions that may occur with the M40A3/A5 Sniper Rifle. This manual cannot list all of the possible malfunctions, tests or inspections, and corrective actions for the M40A3/A5. If a malfunction is not listed (except when the malfunction and cause are obvious) or if it is not corrected by the listed action, evacuate the weapon to the next higher level of maintenance.
2 TM 05539-IN TROUBLESHOOTING SYMPTOM INDEX 0005 00 TROUBLESHOOTING PROCEDURES This symptom index is provided for a quick reference of the malfunctions covered in Table 1, Organizational and Intermediate Troubleshooting Chart (WP 0006 00). Malfunction/Symptom Troubleshooting Procedure Page 1. 2. Magazine Inserts with Difficulty.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-1 Magazine Cannot be Retained in Weapon. . .
2 TM 05539-IN TROUBLESHOOTING PROCEDURES 0006 00 GENERAL Table 1 lists possible malfunctions, tests or inspections, and corrective action for troubleshooting the M40A3/A5 Sniper Rifle at the Organizational and Intermediate Maintenance level. Table 1. Organizational and Intermediate Troubleshooting Chart. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1. Magazine Inserts with Difficulty. 1. Check for bent or deformed magazine. Replace magazine. 2.
TM 05539-IN TROUBLESHOOTING PROCEDURES - CONTINUED 0006 00 Table 1. Organizational and Intermediate Troubleshooting Chart - Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 5. Failure to Chamber. 1. Check for dirty/defective ammunition. Clean ammunition with dry cloth or replace. Refer to TM 05539-OR_. 2. Check for dirty chamber. Clean barrel and chamber. Refer to TM 05539-OR_. 6. Failure to Cock. Check for defective/dirty trigger and sear assembly.
TM 05539-IN CHAPTER 3 ORGANIZATIONAL MAINTENANCE
2 TM 05539-IN SERVICE UPON RECEIPT 0007 00 SERVICE UPON RECEIPT Service the weapon upon receipt. Perform limited technical inspection in accordance with the Quality Assurance Checklist in WP 0033 00 of this manual.
6 TM 05539-IN PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS 0008 00 GENERAL This work package contains inspection, disassembly and reassembly procedures required for corrective maintenance on the M40A3/A5 Sniper Rifle. 1. Organizational Maintenance. Organizational Maintenance is performed at the using unit beyond the capabilities of the operator as identified in TM 05539-OR_.
TM 05539-IN PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED 0008 00 INSPECTING THE WEAPON NOTE A MOS 2111 (Small Weapons Repairman) must be trained by a MOS 2112 (Precision Weapons Repairman) on procedures prior to performing a limited technical inspection (LTI) or a pre-fire inspection (PFI). Inspections reveal the need for repairs, cleaning, or lubrication.
TM 05539-IN PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED 0008 00 INTERMEDIATE PREVENTIVE MAINTENANCE CHECKS AND SERVICES A MOS 2112 conducts a semi-annual inspection at the Intermediate Maintenance Activity (IMA). Conduct the inspection in accordance with the instructions outlined in this work package. Table 1. Intermediate Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule.
TM 05539-IN PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED 0008 00 INTERMEDIATE PREVENTIVE MAINTENANCE CHECKS AND SERVICES - CONTINUED Table 1. Intermediate Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - Continued. ITEM INSPECTED PROCEDURE/CONDITIONS Scope Assembly Scope Rings 1. Ensure scope rings are firmly attached to the optical platform and the scope itself is secure inside the scope rings.
TM 05539-IN PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED 0008 00 INTERMEDIATE PREVENTIVE MAINTENANCE CHECKS AND SERVICES - CONTINUED Table 1. Intermediate Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - Continued. ITEM INSPECTED PROCEDURE/CONDITIONS Barrel and Receiver Assembly 1. Inspect the barrel for bulges, burrs, obstructions, or pits in the chamber or bore. Refer to WP 0016 00. 2.
TM 05539-IN PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS - CONTINUED 0008 00 INTERMEDIATE PREVENTIVE MAINTENANCE CHECKS AND SERVICES - CONTINUED Table 1. Intermediate Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - Continued. ITEM INSPECTED PROCEDURE/CONDITIONS Bolt Assembly - Continued Firing Pin Assembly 1. Using the bolt disassembly tool, disassemble the bolt (WP 0013 00) and remove the firing pin assembly from the bolt. 2.
4 TM 05539-IN GENERAL MAINTENANCE INSTRUCTIONS 0009 00 THIS WORK PACKAGE COVERS Scope Repair Instructions Work Safety Lubrication Instructions General Information Standard Tool Requirements Cleaning Instructions Applying Torque Inspection Instructions Tagging Instructions INITIAL SETUP Maintenance Level References Organizational TM 4750-OD/1A_ TM 9-247_ WP 008 00 SCOPE 0009 00 These general maintenance instructions contain general shop practices and specific methods you must be familiar w
TM 05539-IN GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED 0009 00 CLEANING INSTRUCTIONS 0009 00 WARNING • Use only Cleaner, Lubricant, and Preservative (CLP) for cleaning and lubrication of the M40A3/A5 Sniper Rifle in all but the most severe conditions. • Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment.
TM 05539-IN GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED 0009 00 CLEANING INSTRUCTIONS - CONTINUED 0009 00 4. Mated Surfaces. Lightly coat with oil and wrap all parts subject to rust before storing. INSPECTION INSTRUCTIONS 0009 00 1. General. All components and parts must be carefully checked to determine if they are serviceable for reuse, if they can be repaired, or if they must be scrapped. 2. Drilled and Tapped (Threaded) Holes. 3. a.
TM 05539-IN GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED 0009 00 LUBRICATION INSTRUCTIONS 0009 00 Refer to PMCS (WP 0008 00) for detailed instructions on proper lubrication. The following are some general practices to remember: a. Use correct lubricant. b. Keep lubricants clean. c. Lubricate clean, disassembled, and new parts to prevent rust. STANDARD TOOL REQUIREMENTS 0009 00 Some maintenance tasks may require special or fabricated tools.
2 TM 05539-IN CLEANING THE WEAPON 0010 00 THIS WORK PACKAGE COVERS Cleaning INITIAL SETUP Maintenance Level Equipment Conditions Weapon cleared (WP 0012 00) Organizational References TM 05539-OR_ CLEANING CAUTION DO NOT allow Cleaner, Lubricant, and Preservative (CLP) or any other solvent to come in contact with the telescope lenses. Cleaning is a vital part of organizational preventive maintenance.
2 TM 05539-IN MAGAZINE ASSEMBLY 0011 00 THIS WORK PACKAGE COVERS Inspection INITIAL SETUP Maintenance Level Equipment Conditions Organizational Weapon cleared (WP 0012 00) WARNING Always assume every weapon is loaded until it is determined through visual and physical inspection that it is not. Procedures for clearing/unloading the weapon are outlined in WP 0012 00. Failure to follow this warning may cause injury or death to personnel. INSPECTION 1.
4 TM 05539-IN DISASSEMBLY OF WEAPON 0012 00 THIS WORK PACKAGE COVERS Clearing and Unloading the Weapon, Field Stripping the Weapon INITIAL SETUP Maintenance Level References Organizational WP 0016 00 CLEARING AND UNLOADING THE WEAPON WARNING • Always assume that every weapon is loaded until it is determined through visual and physical inspection that it is not. • After unloading the weapon, and with the bolt handle to the rear, visually and physically check the chamber for ammunition.
TM 05539-IN DISASSEMBLY OF WEAPON - CONTINUED 0012 00 FIELD STRIPPING THE WEAPON - CONTINUED 1. If inserted, remove magazine assembly. 2. Remove floor plate (2) from magazine assembly (1). 1 2 M40-039 3. Remove spring (4) and follower assembly (3) from magazine assembly (1).
TM 05539-IN DISASSEMBLY OF WEAPON - CONTINUED 0012 00 FIELD STRIPPING THE WEAPON - CONTINUED 4. Remove follower (3) from spring (4). 3 4 M40-041 5. Depress and hold the bolt release while pulling the bolt body assembly to the rear and out of the barrel and receiver assembly. If further disassembly of the bolt is required, refer to Bolt Body Assembly Maintenance (WP 0013 00). 6. Disassembly is now complete.
6 TM 05539-IN BOLT BODY ASSEMBLY MAINTENANCE 0013 00 THIS WORK PACKAGE COVERS Inspection, Disassembly, Reassembly INITIAL SETUP Equipment Conditions Maintenance Level Weapon cleared (WP 0012 00) Organizational Bolt assembly removed (WP 0012 00) Tools and Special Tools Bolt disassembly tool Firing pin protrusion gage E2900/E7900 Tool Kit WARNING DO NOT interchange bolt body assemblies from one weapon to another. INSPECTION 1.
TM 05539-IN BOLT BODY ASSEMBLY MAINTENANCE - CONTINUED 0013 00 DISASSEMBLY 1. Place the bolt body assembly (7) in a vertical position with the handle up. 2. Place the hook (6) of the bolt disassembly tool (5) into the disassembly notch (3) in the firing pin cap (2). WARNING The firing pin is under spring tension. Release it slowly to prevent injury to personnel. 3.
TM 05539-IN BOLT BODY ASSEMBLY MAINTENANCE - CONTINUED 0013 00 DISASSEMBLY - CONTINUED 5. Once the firing pin assembly (1) is separated from the bolt body assembly (7), use a 1/16-in. punch and a 4-oz hammer to drive out the ejector retaining pin (10). WARNING The ejector is under spring tension. Use care to prevent it from flying free. Failure to follow this warning may result in injury or death to personnel. NOTE Replace knurled retaining pin with required spring pin.
TM 05539-IN BOLT BODY ASSEMBLY MAINTENANCE - CONTINUED 0013 00 REASSEMBLY - CONTINUED 4. Place the hook (6) of the bolt disassembly tool (5) into the disassembly notch (2) on the firing pin cap (3) and pull the handle (4) to compress the firing pin spring. 5. Screw in firing pin assembly (1) until the cocking leg is fully seated and in the fired position to the back of the bolt body assembly (7). Ensure the firing pin protrudes from the bolt face, then measure firing pin protrusion.
TM 05539-IN BOLT BODY ASSEMBLY MAINTENANCE - CONTINUED 0013 00 REASSEMBLY - CONTINUED 7. Turn clockwise until cocking leg on firing pin assembly goes into the small notch (14) on rear rim of the bolt body assembly (7). The bolt assembly is now cocked.
2 TM 05539-IN FIRING PIN ASSEMBLY 0014 00 THIS WORK PACKAGE COVERS Disassembly, Inspection, Reassembly INITIAL SETUP Equipment Conditions Maintenance Level Weapon cleared (WP 0012 00) Organizational Firing pin removed from bolt (WP 0013 00) References WP 0022 00 WARNING Always assume every weapon is loaded until it is determined through visual and physical inspection that it is not. Procedures for clearing/unloading the weapon are outlined in WP 0012 00.
TM 05539-IN FIRING PIN ASSEMBLY - CONTINUED 0014 00 DISASSEMBLY No disassembly of the firing pin assembly (1) is authorized. Remove the firing pin assembly from the bolt body assembly. Refer to Bolt Assembly Maintenance (WP 0013 00) in this manual. 1 M40-019 INSPECTION NOTE DO NOT disassemble the firing pin assembly. Any worn or unserviceable part requires replacement of complete assembly. 1. Inspect the firing pin assembly for cracks or damages. Ensure that the firing pin tip is smooth and round.
2 TM 05539-IN TRIGGER GUARD AND MAGAZINE WELL INSPECTION 0015 00 THIS WORK PACKAGE COVERS Disassembly, Inspection, Reassembly INITIAL SETUP Maintenance Level Equipment Conditions Weapon cleared (WP 0012 00) Organizational Tools and Special Tools E2900/E7900 Tool Kit WARNING Always assume every weapon is loaded until it is determined through visual and physical inspection that it is not. Procedures for clearing/unloading the weapon are outlined in WP 0012 00.
TM 05539-IN TRIGGER GUARD AND MAGAZINE WELL INSPECTION - CONTINUED 0015 00 INSPECTION 1. Inspect trigger guard (2) and magazine well (4) for cracks or damage. If cracks or damage exist, evacuate to a higher level of maintenance. 2. Insert magazine into magazine well (4) of trigger guard (2). Ensure magazine locks into magazine well. 3. Ensure magazine release (5) has spring tension. If unserviceable, evacuate to higher level maintenance. 2 4 M40-030 5 REASSEMBLY 1.
4 TM 05539-IN REMOVAL OF BARRELED RECEIVER FROM STOCK 0016 00 THIS WORK PACKAGE COVERS Disassembly, Inspection, Reassembly INITIAL SETUP Maintenance Level References Organizational WP 0020 00 Tools and Special Tools Equipment Conditions E2900/E7900 Tool Kit Weapon cleared (WP 0012 00) Vise with padded jaws Suppressor removed (If necessary) (M40A5 only) T30 Torx wrench Telescope removed DISASSEMBLY 1. Hold the weapon with one hand and support heel of stock on workbench. 2.
TM 05539-IN REMOVAL OF BARRELED RECEIVER FROM STOCK - CONTINUED 0016 00 INSPECTION 1. On the stock, check the bedding on top and under trigger guard for cracks, powdering and shrinkage. Pay special attention to the bridge on stock. Check for cracks. Check that all edges are rounded. Using a rag dampened with acetone, clean glass bedding surfaces of the stock of all oil, grease, dirt, and debris. Remove all excess oil from the barreled action where it contacts the glass bedding. 2.
TM 05539-IN REMOVAL OF BARRELED RECEIVER FROM STOCK - CONTINUED 0016 00 INSPECTION - CONTINUED 5. Inspect the trigger guard screws (2 and 4) for wear, unserviceable threads, and correct length. If unserviceable or incorrect length, evacuate to higher level maintenance. 4 2 M40-023 REASSEMBLY 1. Place the barreled receiver in the stock and press straight down on the receiver over the recoil lug. Ensure barreled receiver is fully seated in stock.
8 TM 05539-IN MUZZLE BREAK MAINTENANCE 0017 00 THIS WORK PACKAGE COVERS Inspection, Removal, Installation, Timing Wheel Instructions INITIAL SETUP Materials/Parts Maintenance Level Shim kit Organizational Acetone Tools and Special Tools Cotton swabs E2900/E7900 Tool Kit Thread sealant (Rocksett®) Wrench, combination Equipment Conditions Weapon cleared (WP 0012 00) Torque wrench INSPECTION NOTE Removal of muzzle break is not necessary for inspection.
TM 05539-IN MUZZLE BREAK MAINTENANCE - CONTINUED 0017 00 REMOVAL 1. Secure the barrel (3) in a vise or fixture. 2. Using the combination wrench, loosen and remove the muzzle break (1) by rotating it counter-clockwise while facing the muzzle of the barrel (3). 3 1 M40-091 3. Remove and discard any/all shims (4) from the barrel (3). 4. Remove the barrel (3) from the vise or fixture.
TM 05539-IN MUZZLE BREAK MAINTENANCE - CONTINUED 0017 00 INSTALLATION 1. With the barrel (3) pointing up (vertical), install the shims (4) on the barrel. Ensure the shims are centered on the barrel. 2. Install the muzzle break (1) over the shims and onto the barrel (3) and slowly tighten by hand. 3. Secure the barrel (3) in a vise or fixture. 4. Using the combination wrench and a torque wrench, tighten the muzzle break (1) to 20-23 lb-ft. 5.
TM 05539-IN MUZZLE BREAK MAINTENANCE - CONTINUED 0017 00 INSTALLATION - CONTINUED 6. Remove muzzle break (1) after proper alignment has been achieved. Use care to not lose shims. 1 M40-090 7. Remove the barrel (3) from the vise or fixture. 8. Clean and degrease the threads (6) and contact area (7) of the barrel with acetone. 9. Clean the internal threads of the muzzle break with a cotton swab and acetone. 10.
TM 05539-IN MUZZLE BREAK MAINTENANCE - CONTINUED 0017 00 INSTALLATION - CONTINUED 6 3 7 4 8 M40-092 16. Using the combination wrench and a torque wrench, tighten the muzzle break (1) onto the barrel (3), to 20-23 lb-ft. 3 1 M40-091 17. Run a dry patch through the bore after assembly to ensure no sealant (Rocksett®) is present in the bore. 18. Allow the sealant (Rocksett®) to cure for 24 hours prior to firing the weapon.
TM 05539-IN MUZZLE BREAK MAINTENANCE - CONTINUED 0017 00 TIMING WHEEL INSTRUCTIONS 1. Screw adapter onto muzzle until firmly hand tight. 2. Slide timing wheel over adapter with printed side facing toward you and printed TDC pointing straight up (12 o’clock position). 3. With eyes in front of muzzle, note which timing wheel “pie slice” lines up with adapter indexing notch, and note the shim listed on that pie slice.
TM 05539-IN MUZZLE BREAK MAINTENANCE - CONTINUED 0017 00 FOR 24 THREADS PER INCH AND 1 MM METRIC TIMING WHEEL Adapter notch should be in shaded area before final torquing to 6 o’clock position Correct final position of indexing notch END OF WORK PACKAGE 0017 00-7/(0017 00-8 Blank)
2 TM 05539-IN BIPOD ASSEMBLY MAINTENANCE 0018 00 THIS WORK PACKAGE COVERS Bipod Assembly: Removal, Inspection, Installation INITIAL SETUP Maintenance Level Equipment Conditions Organizational Weapon cleared (WP 0012 00) BIPOD ASSEMBLY REMOVAL WARNING Always assume every weapon is loaded until it is determined through visual and physical inspection that it is not. Procedures for clearing/unloading the weapon are outlined in WP 0012 00.
TM 05539-IN BIPOD ASSEMBLY MAINTENANCE - CONTINUED 0018 00 BIPOD ASSEMBLY INSTALLATION 1. Pinch mounting clamps (3) together, position bipod (2) on weapon stock (1) and release clamps. 2. Tighten bipod screw (4).
2 TM 05539-IN REASSEMBLY OF WEAPON 0019 00 THIS WORK PACKAGE COVERS Reassembling the Weapon, Safety Check INITIAL SETUP Equipment Conditions Maintenance Level Weapon cleared (WP 0012 00) Organizational Bolt body assembly removed (WP 0012 00) References WP 0020 00 REASSEMBLING THE WEAPON WARNING DO NOT exchange or switch bolt assemblies from one weapon to another. Doing so may cause injury or death to personnel. 1. Bolt Body Assembly. a.
TM 05539-IN REASSEMBLY OF WEAPON - CONTINUED 0019 00 REASSEMBLING THE WEAPON - CONTINUED 2. 3. Magazine Assembly. 1 a. Compress spring (4) to identify longest leg. b. Slide the longest magazine spring leg underneath the magazine floor plate (2) until it is fully seated. Slide the short leg inside the follower (3) until it is fully seated. To avoid feeding problems, ensure that the short leg of the spring is inside the follower, not the floor plate. c.
2 TM 05539-IN FUNCTION CHECK 0020 00 THIS WORK PACKAGE COVERS Function Check INITIAL SETUP Equipment Conditions Maintenance Level Weapon cleared (WP 0012 00) Organizational References WP 0019 00 FUNCTION CHECK WARNING Always assume every weapon is loaded until it is determined through visual and physical inspection it is not. Procedures for clearing/unloading the weapon are outlined in WP 0012 00. Failure to follow this warning may cause injury or death to personnel.
TM 05539-IN FUNCTION CHECK - CONTINUED 0020 00 FUNCTION CHECK - CONTINUED 8. Load five dummy rounds in magazine assembly. 9. With safety on, insert magazine assembly with dummy rounds into magazine well. 10. Cycle bolt in and out of battery to check feeding, chambering, extracting, and ejecting. WARNING The ability of the weapon to fire by manipulation of the bolt in and out of battery without pulling the trigger is known as “slam firing”.
2 TM 05539-IN PREPARATION FOR STORAGE AND SHIPMENT 0021 00 STORAGE PROCEDURES WARNING • DO NOT store the weapon with live ammunition in either the chamber or magazine. • Always assume every weapon is loaded until it is determined through visual and physical inspection that it is not. Procedures for clearing/unloading the weapon are outlined in WP 0012 00. • Failure to follow these warnings may cause injury or death to personnel. 1. Stored for Extended Periods.
TM 05539-IN CHAPTER 4 INTERMEDIATE MAINTENANCE
4 TM 05539-IN BARRELED RECEIVER 0022 00 THIS WORK PACKAGE COVERS Inspection INITIAL SETUP Equipment Conditions Maintenance Level Weapon cleared (WP 0012 00) Intermediate Bolt body assembly removed (WP 0012 00) Tools and Special Tools Barreled receiver separated from stock (WP 0016 00) E2900/E7900 Tool Kit Vise with padded jaws Suppressor removed (M40A5 only) (TM 05539-OR_) T30 Torx wrench References WP 0026 00 INSPECTION WARNING Ensure the weapon is cleared before performing these procedures.
TM 05539-IN BARRELED RECEIVER - CONTINUED 0022 00 INSPECTION - CONTINUED 2. Inspect the muzzle end of the barrel (1) for a serviceable crown (2). The lands and grooves should come to a sharp end with no nicks or burrs. If required, re-crown using a 45-degree cut crowning tool. a. Secure barrel (1) in padded vise. b. Mount 45-degree cut crowning tool onto a .308 caliber mandrel. c. Lubricate crowning tool with cutting fluid and fully insert mandrel until the crowning tool touches the muzzle.
TM 05539-IN BARRELED RECEIVER - CONTINUED 0022 00 INSPECTION - CONTINUED 3. Inspect barrel and receiver for burrs. Check chamber area for nicks or burrs that would cause hard extraction or chambering. Burrs in chamber area may also cause a ruptured case or a failure to extract. If there are visible cracks in the barrel and receiver, chamber, or muzzle break, request WIR disposition from Material Manager, Albany, GA. NOTE • Front and rear trigger guard screws are identical when new.
4 TM 05539-IN BOLT BODY ASSEMBLY 0023 00 THIS WORK PACKAGE COVERS Disassembly, Inspection, Reassembly, Headspace INITIAL SETUP References Maintenance Level WP 0020 00 Intermediate WP 0021 00 Tools and Special Tools Equipment Conditions E2900/E7900 Tool Kit Bolt disassembly tool Weapon cleared (WP 0012 00) Headspace gage, 1.630 in. Bolt assembly removed (WP 0012 00) Headspace gage, 1.638 in. Firing pin removed from bolt (WP 0013 00) Jeweler’s screwdriver (.
TM 05539-IN BOLT BODY ASSEMBLY - CONTINUED 0023 00 DISASSEMBLY 1. Once the firing pin is separated from the bolt body, use a 1/16-in. punch and 4-oz hammer to drive out the ejector retaining pin (5) from bolt body assembly (1). 2. Remove the ejector (4) and the ejector spring (3) from bolt body assembly (1). 3. Use a jeweler’s screwdriver (.080), pry and lift the extractor (2) out of the recess rim in the bolt body assembly (1). 1 2 3 4 6 5 M40-046 INSPECTION 1.
TM 05539-IN BOLT BODY ASSEMBLY - CONTINUED 0023 00 HEADSPACE WARNING The firing pin is under spring tension. Release it slowly to prevent injury to personnel. NOTE • The M40A3/A5 has a 10,000 round life expectancy and is to be auto-retrograded to the Weapons Training Battalion in Quantico, VA. • Shipping procedures are outlined in WP 0021 00. 1. Clean chamber, bolt lugs, and bolt face thoroughly before checking headspace. NOTE The extractor does not have to be removed. 2.
12 TM 05539-IN SAFETY AND TRIGGER MECHANISM 0024 00 THIS WORK PACKAGE COVERS Disassembly, Assembly, Inspection, Staking the Receiver, Replace Unserviceable Trigger, Testing the Trigger Pull INITIAL SETUP Materials/Parts Maintenance Level Intermediate Sealing compound (Loctite 290) (Item 18, WP 0030 00) Tools and Special Tools E2900/E7900 Tool Kit References Jeweler’s screwdriver (.080) WP 0020 00 Trigger test fixture Equipment Conditions Trigger test weights 1/8-in.
TM 05539-IN SAFETY AND TRIGGER MECHANISM - CONTINUED 0024 00 DISASSEMBLY NOTE The sear and sear spring are released upon removing the front trigger pin. Take caution when removing the trigger assembly from the receiver. 1. From right side of receiver (2), use a 1/8-in. punch and 4-oz hammer to drive out the rear trigger pin (1). Remove bolt stop release (3) and bolt stop spring (5) from trigger housing assembly (4).
TM 05539-IN SAFETY AND TRIGGER MECHANISM - CONTINUED 0024 00 DISASSEMBLY - CONTINUED 2. Tap out front trigger pin (6) and remove trigger housing assembly (4) from receiver (2).
TM 05539-IN SAFETY AND TRIGGER MECHANISM - CONTINUED 0024 00 DISASSEMBLY - CONTINUED 3. Remove sear (7) and sear spring (8) from trigger housing assembly (4).
TM 05539-IN SAFETY AND TRIGGER MECHANISM - CONTINUED 0024 00 DISASSEMBLY - CONTINUED 4. Using a jeweler’s screwdriver (.080), remove the retainer clip (11), safety spring (12), safety ball (10), and safety pivot pin (13) from trigger housing assembly (4). 5. Slide the safety (9) off of trigger housing assembly (4).
TM 05539-IN SAFETY AND TRIGGER MECHANISM - CONTINUED 0024 00 DISASSEMBLY - CONTINUED 6. Using a 1/8-in. punch and 4-oz hammer, drive out the trigger pin (14) from trigger housing assembly (4). 7. Remove trigger (15) and connector from trigger housing assembly (4). 8. Clean or replace trigger parts as required. 4 14 15 M40-055 ASSEMBLY 1. Align trigger (15) and connector in trigger housing assembly (4) and install trigger pin (14) using a 1/8-in. punch and 4-oz hammer. 2.
TM 05539-IN SAFETY AND TRIGGER MECHANISM - CONTINUED 0024 00 ASSEMBLY - CONTINUED 11 9 10 14 4 3 15 13 M40-056 12 0024 00-7
TM 05539-IN SAFETY AND TRIGGER MECHANISM - CONTINUED 0024 00 ASSEMBLY - CONTINUED 4. Install sear spring (8) and sear (7) into the trigger housing assembly (4).
TM 05539-IN SAFETY AND TRIGGER MECHANISM - CONTINUED 0024 00 ASSEMBLY - CONTINUED 5. Using jaw pads, hold barreled receiver in vise. 6. Ensure safety is set in the “SAFE” position. While holding the sear spring and sear together, insert trigger assembly in trigger slot in the bottom of the receiver. NOTE • The front trigger pin is shorter than the rear trigger pin. • Insert tapered ends of trigger pins first. 7.
TM 05539-IN SAFETY AND TRIGGER MECHANISM - CONTINUED 0024 00 ASSEMBLY - CONTINUED 10. Check the operation of the bolt stop and bolt stop release by pressing on the bottom of the bolt stop release. The bolt stop release should travel freely along the trigger housing and return to the resting position under spring tension without binding. The bolt stop should also pivot and travel freely without binding or dragging on the receiver or front trigger pin.
TM 05539-IN SAFETY AND TRIGGER MECHANISM - CONTINUED 0024 00 STAKING THE RECEIVER CAUTION To prevent damage to the receiver, DO NOT stake receiver too close to the edge of the trigger pin hole or too deep. Be careful not to damage trigger assembly while staking. 1. Place weapon upside down in vise with trigger and trigger pins inserted. 2. Using a 1/8-in. center punch and 8-oz ball peen hammer, stake the bottom of the receiver in the three positions. 1 BOTTOM VIEW LEFT SIDE RIGHT SIDE 3 2 3.
TM 05539-IN SAFETY AND TRIGGER MECHANISM - CONTINUED 0024 00 TESTING THE TRIGGER PULL 1. Place the test fixture (17) on the work bench and add test weights (18) until minimum load of 3.0 lb is reached. Place on deck. 2. With a dummy round in chamber, cycle the bolt and move the safety lever to the “FIRE” position. 3. Hold the weapon or receiver (2) vertically. 4. Hook arm of trigger weight test fixture (17) over trigger (15) and slowly lift the weapon straight up. 2 15 17 18 M40-060 5.
4 TM 05539-IN STOCK ASSEMBLY 0025 00 THIS WORK PACKAGE COVERS Disassembly, Inspection, Reassembly INITIAL SETUP Equipment Conditions Maintenance Level Weapon cleared (WP 0012 00) Intermediate Bolt body assembly removed (WP 0012 00) Tools and Special Tools Barreled receiver separated from stock (WP 0016 00) E2900/E7900 Tool Kit References WP 0026 00 DISASSEMBLY 1. Remove sling swivel, if required. 2. Remove cheek piece screws (2) and cheek piece (1) from stock (3). 3.
TM 05539-IN STOCK ASSEMBLY - CONTINUED 0025 00 INSPECTION 1. Check all parts for excessive wear, burrs, and cracks. 2. Ensure that sling swivels (11) have spring tension. 3. Ensure that the cheek piece (1) and recoil pad screws (6) are not worn or stripped. 4. Ensure the helicoil inserts (7) on both sides of the stock (3) are not stripped or stretched. 5. Ensure that the bipod stud (8) is not loose or damaged. 6. Ensure the cheek piece (1) locks in place when tightened. 7.
TM 05539-IN STOCK ASSEMBLY - CONTINUED 0025 00 REASSEMBLY 1. Install inserts (4) and recoil pad (5) on stock (3). 2. Install recoil pad screws (6) in stock (3). 3. Install cheek piece (1) on stock (3) and install cheek piece screws (2). 2 1 3 6 5 4. 4 M40-026 Place the barreled receiver in the stock and press straight down on the receiver over the recoil lug. Ensure barreled receiver is fully seated. Refer to procedures outlined in Removal of Barreled Receiver from Stock (WP 0016 00).
8 TM 05539-IN SKIM GLASSING 0026 00 THIS WORK PACKAGE COVERS Preparation for Barrel and Receiver, Preparation for Stock, Skim Glassing, Installation of Stock Accessory Rail, Breaking Weapon Out of Glass, Skim Glass Clean Up INITIAL SETUP Maintenance Level Materials/Parts - Continued 2-in.
TM 05539-IN SKIM GLASSING - CONTINUED 0026 00 PREPARATION FOR BARREL AND RECEIVER NOTE Curing and drying time, including ambient temperature requirements, should be according to manufactures’s recommendations. 1. Insert modeling clay inside following cavities on the bottom and side of the receiver (5), gas port hole (4), right side trigger pin holes (6), and trigger guard screw holes (7). Trim clay with a putty knife flush with the receiver. Clean receiver with acetone. 2.
TM 05539-IN SKIM GLASSING - CONTINUED 0026 00 PREPARATION FOR BARREL AND RECEIVER - CONTINUED 4. Remove magazine release pin and magazine release from trigger guard assembly (11). Clay the magazine release pin hole (12). 12 11 M40-067 5. Lightly grease the trigger guard screws. 6. Mold release the trigger guard, the trigger guard screws, the action and 4 in. of the breech end of the barrel. PREPARATION FOR STOCK CAUTION • DO NOT remove the guard assembly from the stock.
TM 05539-IN SKIM GLASSING - CONTINUED 0026 00 PREPARATION FOR STOCK - CONTINUED 3. Inspect the top half of the stock (17) to ensure that all areas have been prepared for skim glassing. 4. Insert three layers of 2-in. masking tape, 1.5 inches in front of the recoil lug’s position. 5. Invert stock (17) in the vise. Using a 1/8-in. rotary tool bit, route the bottom bedding surface (18) of the stock very lightly for the trigger guard assembly.
TM 05539-IN SKIM GLASSING - CONTINUED 0026 00 SKIM GLASSING - CONTINUED 2. Insert the trigger guard (11) inside the stock (17) and secure with masking tape (19). 17 11 19 M40-070 NOTE • Ensure all areas are filled with epoxy/glass. • Fill lug mortise with epoxy/glass and pack in corners. 3. Invert stock (17) top-side up in vise and apply a light to moderate coat of epoxy/glass into the top bedding surface (15) of the stock. 15 17 M40-068b 4.
TM 05539-IN SKIM GLASSING - CONTINUED 0026 00 INSTALLATION OF STOCK ACCESSORY RAIL 1. Cover the inside bottom of the rail, any shims to be used, and the screws with a light coat of grease or mold-release agent. 2. Mix 5:1 epoxy and catalyst IAW manufacturer's instructions. 3. Fill accessory rail mortise with glass. M40-087 4. Attach any shims to be used and the top of the rail together. 5. Apply a light coat of Marine-tex® to the bottom side of the rail and any shims used. 6.
TM 05539-IN SKIM GLASSING - CONTINUED 0026 00 BREAKING WEAPON OUT OF GLASS 1. Place weapon upside-down in vise and remove the trigger guard screws and masking tape, securing trigger guard. CAUTION Be careful not to scar receiver or barrel when chipping away epoxy/glass residue. 2. Place the weapon upright in a vise and using a rawhide mallet and a wood chisel, chip away any epoxy/glass residue that will impede removal of the action from the stock. 3.
TM 05539-IN SKIM GLASSING - CONTINUED 0026 00 SKIM GLASS CLEAN UP 1. Clean the barreled receiver, trigger guard, and the receiver screws of all epoxy, tape, and clay and set them aside. NOTE Ensure bolt handle clears stock when re-bedding the stock. 2. Clean up stock and make all clearance cuts. a. Using a wood chisel, bevel glass area for recoil lug (22), front of barrel pad (28), and both front (23) and rear (24) screw holes. Use a bearing scraper on bottom of stock. b.
6 TM 05539-IN TELESCOPE ASSEMBLY AND TELESCOPE RINGS MAINTENANCE 0027 00 THIS WORK PACKAGE COVERS Inspection, Removal and Disassembly, Reassembly INITIAL SETUP Materials/Parts Maintenance Level Sealing compound (Loctite 290) (Item 18, WP 0030 00) Intermediate Tools and Special Tools Equipment Conditions Weapon cleared (WP 0012 00) Multi-tool INSPECTION NOTE • The telescope is a warranted item. • No repair is authorized at the Intermediate Maintenance level. 1.
TM 05539-IN TELESCOPE ASSEMBLY AND TELESCOPE RINGS MAINTENANCE - CONTINUED 0027 00 INSPECTION - CONTINUED 2. Inspect and ensure that reticle has all mil dots in place and cross hairs are attached in the proper position. If unserviceable, replace telescope (5). 3. Check that the elevation knob (3) moves freely from 1 thorough 10 on the scale and is not bent; there should be distinct clicks. Replace unserviceable scopes (5) in accordance with current directives.
TM 05539-IN TELESCOPE ASSEMBLY AND TELESCOPE RINGS MAINTENANCE - CONTINUED 0027 00 REMOVAL AND DISASSEMBLY CAUTION • THERE IS NO DISASSEMBLY AUTHORIZED OF THE TELESCOPE ASSEMBLY. • There are no user replaceable parts or disassembly procedures for parts within the telescope body such as lenses or knobs. NOTE Before removal of the telescope assembly, note the location of the telescope to the optical platform for zero retention. 1.
TM 05539-IN TELESCOPE ASSEMBLY AND TELESCOPE RINGS MAINTENANCE - CONTINUED 0027 00 REMOVAL AND DISASSEMBLY - CONTINUED 2. After removal of telescope (5) from optical platform, inspect that the objective body (8) and eyepiece lens body (9) are tight. 3. Grasp telescope (5) with one hand on the telescope objective body (8) and one hand on the eyepiece lens body (9), and twist. 4. If the bodies (8 and 9) are loose, the telescope (5) needs to be replaced. 8 9 5 5.
TM 05539-IN TELESCOPE ASSEMBLY AND TELESCOPE RINGS MAINTENANCE - CONTINUED REMOVAL AND DISASSEMBLY - CONTINUED 6. Remove 10 hex-head capscrews (12) and two top cap rings (11) from two telescope ring bases (4). 7. Inspect capscrews (12), top cap rings (11), and ring bases (4) for damage. Replace if damaged.
TM 05539-IN TELESCOPE ASSEMBLY AND TELESCOPE RINGS MAINTENANCE - CONTINUED 0027 00 REASSEMBLY 1. Clean mating surface on telescope (5) and telescope ring bases (4). NOTE Be sure to place telescope ring bases on marks made on optical platform to ensure zero retention. 2. Attach telescope ring bases (4) to optical platform (6), push ring base forward and tighten. Tighten nuts (7) to 65 lb-in. 3. Place the telescope (5) on the telescope ring bases (4).
2 TM 05539-IN SUPPRESSOR MAINTENANCE 0028 00 There is no authorized maintenance for the sound suppressor. For suppressor cleaning procedure refer, to TM 05539OR_.
TM 05539-IN CHAPTER 5 SUPPORTING INFORMATION
2 TM 05539-IN REFERENCES 0029 00 SCOPE This work package lists all forms, field manuals, technical manuals, tables, regulations, standards, and miscellaneous publications referenced in this manual. MARINE CORPS ORDERS Preparation for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MCO P4450.7 Report of Transportation Discrepancies in Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 TM 05539-IN EXPENDABLE AND DURABLE ITEMS LIST 0030 00 SCOPE This work package lists expendable supplies and materials you may need to operate and maintain the 7.62 mm, M40A3/ A5 Sniper Rifle. This listing is for information only and is not authority to requisition the listed items. EXPLANATION OF COLUMNS 1. Column (1) - Item Number. This number is assigned to the entry in the list and is referenced in the narrative instructions to identify the item [e.g., Use Paper, lens (Item 15, WP 0030 00).] 2.
TM 05539-IN EXPENDABLE AND DURABLE ITEMS LIST - CONTINUED 0030 00 Table 1. Expendable and Durable Items List for M40A3/A5 Sniper Rifle.
4 TM 05539-IN TOOL IDENTIFICATION LIST (INCLUDES SPECIAL TOOLS) 0031 00 SCOPE This work package lists all common tools and supplements, and special tools/fixtures needed to maintain the 7.62 mm, M40A3/A5 Sniper Rifle. EXPLANATION OF COLUMNS IN THE TOOL IDENTIFICATION LIST 1. Column (1) - Item Number. This column indicates the number of the illustration that shows the item. 2. Column (2) - Item Name. This column lists the item by noun nomenclature and other descriptive features (e.g., Handle, driver).
TM 05539-IN TOOL IDENTIFICATION LIST (INCLUDES SPECIAL TOOLS) - CONTINUED 0031 00 Table 1. Organizational and Intermediate Maintenance Special Tools and Equipment.
TM 05539-IN TOOL IDENTIFICATION LIST (INCLUDES SPECIAL TOOLS) - CONTINUED 0031 00 1 4 2 3 5 8 9 6 10 11 7 12 M40-037 END OF WORK PACKAGE 0031 00-3/(0031 00-4 Blank)
4 TM 05539-IN MANUFACTURED ITEMS ILLUSTRATIONS 0032 00 THIS WORK PACKAGE COVERS Manufactured Items INITIAL SETUP Maintenance Level Intermediate SCOPE This work package includes complete instructions for making items authorized to be manufactured or fabricated at the Intermediate Maintenance level.
TM 05539-IN MANUFACTURED ITEMS ILLUSTRATIONS - CONTINUED 0032 00 MANUFACTURED ITEMS M40-062 0032 00-2
TM 05539-IN MANUFACTURED ITEMS ILLUSTRATIONS - CONTINUED 0032 00 MANUFACTURED ITEMS - CONTINUED M40-063 0032 00-3
TM 05539-IN MANUFACTURED ITEMS ILLUSTRATIONS - CONTINUED 0032 00 MANUFACTURED ITEMS - CONTINUED M40-064 0032 00-4
6 TM 05539-IN QUALITY ASSURANCE CHECKLIST 0033 00 QUALITY ASSURANCE CHECKLIST M40A3/A5 SNIPER RIFLE QC CHECKLIST SECTION ONE 1. Perform Safety Check QC 2. B. Inspect chamber for ammunition. C. Function test the safety. There will be distinct clicks, positive catch, and no “mushiness”. QA A. No cracks. B. Centered. C. No burrs within splines. D. Refinished (blued or parked). E. Barrel crown clean, uniform, smooth. Crown cut at 45 degrees. QA A.
TM 05539-IN QUALITY ASSURANCE CHECKLIST - CONTINUED 0033 00 QUALITY ASSURANCE CHECKLIST - CONTINUED M40A3/A5 SNIPER RIFLE QC CHECKLIST 6. Stock QC 7. Check for cracks around screw holes, sling swivel areas, and all welds. B. Check buttstock and pads to ensure serviceability. C. Ensure adjustable cheek piece goes up and down. QA A. Quickly cycle bolt in and out of battery three (3) times to simulate firing and ensure proper function. B.
TM 05539-IN QUALITY ASSURANCE CHECKLIST - CONTINUED 0033 00 QUALITY ASSURANCE CHECKLIST - CONTINUED M40A3/A5 SNIPER RIFLE QC CHECKLIST 10. Scope QC QA A. Check elevation for serviceability. B. Check windage for serviceability. C. Inspect objective and eyepiece lenses for scratches, pits, or chips that interfere with the field of view. D. Ensure reticle has all mil dots in place and that reticle is not loose from its post. E. Check the scope; ensure it’s not bent, damaged or punctured. F.
TM 05539-IN QUALITY ASSURANCE CHECKLIST - CONTINUED 0033 00 SECTION TWO Quality Control Inspectors’ Verification Rifle Serial Number ______________________ QC Rank and Name (Last, First, Middle) QA Rank and Name (Last, First, Middle) QC Inspector’s Signature QA Inspector’s Signature Inspection Date Inspection Date 0033 00-4
TM 05539-IN QUALITY ASSURANCE CHECKLIST - CONTINUED 0033 00 SECTION THREE Proof and Function Verification Rifle Serial Number Date Proofed and Functioned QC Rank and Name (Last, First, Middle) QA Rank and Name (Last, First, Middle) QC Inspector’s Signature QA Inspector’s Signature Rifle Test Verification Date Tested QC Rank and Name (Last, First, Middle) QA Rank and Name (Last, First, Middle) QC Inspector’s Signature QA Inspector’s Signature Group Size a.
6 TM 05539-IN REPAIR PARTS LIST (RPL) INTRODUCTION 0034 00 SCOPE This Repair Parts List (RPL) authorizes spares, repair parts, and other special support equipment required for performance of Organizational and Intermediate Maintenance of the 7.62 mm, M40A3/A5 Sniper Rifle. It authorizes the requisitioning, issue and disposition of spares, repair parts indicated by the Source, Maintenance, and Recoverability (SMR) codes. EXPLANATION OF COLUMNS 1. Item No. (Column 1).
TM 05539-IN REPAIR PARTS LIST (RPL) INTRODUCTION - CONTINUED 0034 00 EXPLANATION OF COLUMNS - CONTINUED a. Source Code. The source code indicates how to obtain an item needed for maintenance, repair, or overhaul of equipment and is entered in the first and second positions of the SMR code as follows: SOURCE CODE ECHELON PA APPLICATION/EXPLANATION Stocked items: Use the applicable National Stock Number (NSN) to requisition items with these source codes.
TM 05539-IN REPAIR PARTS LIST (RPL) INTRODUCTION - CONTINUED 0034 00 EXPLANATION OF COLUMNS - CONTINUED b. Maintenance Code. The maintenance code indicates the levels of maintenance authorized to use and repair support items and is entered in the third and fourth positions of the SMR code as follows: (1) The maintenance code entered in the third position indicates the lowest maintenance level authorized to remove, replace, and use an item.
TM 05539-IN REPAIR PARTS LIST (RPL) INTRODUCTION - CONTINUED 0034 00 EXPLANATION OF COLUMNS - CONTINUED c. Recoverability Code. The recoverability code indicates the disposition action on unserviceable items and is entered in the fifth position of the SMR code as follows: RECOVERABILITY CODE APPLICATION/EXPLANATION Z Non-repairable item. When unserviceable, condemn and dispose of the item at the level of maintenance shown in the third position of the SMR code. O Repairable item.
TM 05539-IN REPAIR PARTS LIST (RPL) INTRODUCTION - CONTINUED 0034 00 HOW TO LOCATE REPAIR PARTS 1. 2. Unknown National Stock Number (NSN) or Part Number. a. Identify the item from the illustration and note the item number. b. Look in the Repair Parts List (RPL) for the figure and item numbers. The NSNs and part numbers are on the same line as the associated item numbers. Known NSN or Part Number. a. Using the NSN or part number, locate the item in the RPL. Note the pertinent information. b.
14 TM 05539-IN Repair Parts List REPAIR PARTS LIST (RPL) 0035 00 0035 00-1
TM 05539-IN M40-5004-1 Figure 1.
TM 05539-IN (1) ITEM NO (2) SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USEABLE ON CODES (UOC) (7) QTY FIG.
TM 05539-IN M40-5001-1 Figure 2.
TM 05539-IN (1) ITEM NO (2) SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USEABLE ON CODES (UOC) (7) QTY FIG.
TM 05539-IN M40-5002 Figure 3.
TM 05539-IN (1) ITEM NO (2) SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USEABLE ON CODES (UOC) (7) QTY FIG.
TM 05539-IN M40-5005 Figure 4.
TM 05539-IN (1) ITEM NO (2) SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USEABLE ON CODES (UOC) (7) QTY FIG. 4 SUPPRESSOR CASE AND CLEANING BRUSH 1 2 PAOZZ PAOZZ 8465-01-566-6807 1005-01-566-6422 OBJZ8 OBJZ8 70014-1 CARRYING CASE, SUPPRESSOR .......... 70-03-015 BRUSH, CLEANING ....................
TM 05539-IN 0035 00-10
TM 05539-IN STOCK NUMBER 1005-00-022-9777 5325-00-587-3306 5315-00-821-1225 5310-00-887-5797 5360-00-887-5798 1005-00-999-8809 5360-00-999-8812 1005-00-999-8815 1005-00-999-8816 5360-00-999-8817 1005-00-999-8818 1005-00-999-8821 5307-01-472-3395 1005-01-511-7758 1005-01-511-8314 1005-01-511-8319 5305-01-511-8323 1005-01-511-8329 5315-01-511-8332 1005-01-511-8420 5365-01-511-8424 5365-01-511-8431 1005-01-567-4936 CROSS-REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX FIG.
TM 05539-IN CAGEC 50446 3A703 3A703 3A703 50446 50446 50446 50446 50446 3A703 50446 3A703 3A703 50446 0WXH8 0WXH8 0WXH8 0WXH8 0WXH8 0WXH8 0WXH8 0WXH8 0WXH8 4J007 OBJZ8 OBJZ8 OBJZ8 ITE83 50446 50446 3A703 3A703 1365 01365 3GUL2 L4041 L4041 0A4K4 0LB99 7R212 3A703 OBJZ8 OBJZ8 96906 19204 CROSS-REFERENCE INDEXES PART NUMBER INDEX PART NUMBER STOCK NUMBER 15224 5360-00-999-8812 15368 1005-01-518-3772 15478 1005-01-530-0452 16861 17013 1005-00-999-8809 17017 1005-00-999-8815 17019 5360-00-999-8817 17044 5310-0
TM 05539-IN CAGEC 80205 1JQC4 1JQC4 090F8 0LB99 57215 0A4K4 0LB99 0LB99 0LB99 3GUL2 3GUL2 OBJZ8 PART NUMBER MS16555-329 OP-700SA-30 OP-700SA-SC PRM8541 SAD C/P S-BRM SPA SYS SCR SPA-25 SPA-50 SPA-SYS TBD-BAR TBD-BAR 2 TBD-SLING CROSS-REFERENCE INDEXES PART NUMBER INDEX STOCK NUMBER 5315-00-821-1225 1005-01-511-8443 5305-01-511-9802 1240-01-533-1854 1005-01-511-8433 1005-01-511-7758 5365-01-511-8424 5365-01-511-8431 1005-01-511-8420 I-3 0035 00-13/(0035 00-14 Blank) FIG.
TM 05539-IN INDEX Subject Work Package/Page A Ammunition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-6 Associated Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-6 B Barreled Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM 05539-IN INDEX - Continued Subject Work Package/Page O Operation, Principles of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1 P Preparation for Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1 Preventive Maintenance Checks and Services (PMCS), Including Lubrication Instructions . . 0008 00-1 Principles of Operation . . . . . . . . . . . . . . . . . . . .
THE METRIC SYSTEM AND EQUIVALENTS Linear Measure Square Measure 1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Kilometer = 1000 Meters = 0.621 Miles 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles Weights Cubic Measure 1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.
