Home

ARMY TM 9-1005-319-23&P AIR FORCE TO 11 W3

1. oo oo gt 16 C16A gt gt gt gt nnm SECTION IV CAGEC 19204 19204 19204 19204 19204 19204 19200 19204 19204 19204 19204 19200 19200 19204 19200 19204 19204 19204 19204 19200 19204 19204 19204 19204 19200 19204 19200 19204 19204 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 PART NUMBER 8448584 8448585 8448586 8448587 8448592 8448593 8448595 8448599 8448609 8448610 8448611 8448612 8448615 8448621 8448628 8448629 8448631 8448633 8448634 8448635 8448636 8448637 8448638 8448652 8448653 8448655 8448670 8448697 8448712 8448755 9349050 9349051 9349052 9349054 9349056 9349059 9349062 9349063 9349065 9349066 9349067 9349069 TM9 1005 319 23 amp P CROSS REFERENCE INDEXES PART NUMBER INDEX STOCK NUMBER 5315 00 992 6653 5315 00 992 6654 5360 00 992 6655 1005 00 992 7299 1005 00 992 7307 5360 00 992 7308 1005 00 992 6649 5315 00 992 6650 5315 00 992 7309 5360 00 992 6648 1005 00 01 7 9551 1005 00 937 3078 5315 00 017 9537 1005 00 01 7 9548 5360 00 992 6665 1005 00 992 6667 5360 00 056 2246 1005 00 056 2247 1005 00 999 0406 1005 00 992 7302 536
2. INSPECTION C cc Reassembly E Charging Handle Assembly AET ta alo eem DLP t Inspection EubricatiOD dest Reassembly 2 Ree Ried ited aie EM es Ai died anes Common Tools and Corrosion Prevention and Control ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Page 4 1 4 11 Lx Pe PE 4 11 4 9 4 10 4 11 RET 4 11 2 40 2 39 3 21 2 40 3 21 2 41 2 41 324 T 3 24 2 36 3 16 T 2 35 3 16 T Meaty 3 17 ditare 2 36 S 2 37 2 37 3 20 3 20 3 20 2 65 ET 2 65 EN 2 66 3 66 2 67 2 67 2 67 3 67 M 2 44 TENE 2 43 2 44 Seeders Lara edd 2 44 ES 2 44 2 1 3 1 m 1 2 Index 1 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 ALPHABETICAL INDEX CONT Subject Destruction of Army Materiel to Prevent Enemy 0 Equipment Characteristics Capabilities and Equipment Data nutu ette testen esce p bab aie Ren Equipment Description and
3. END OF FIGURE C 5 1 7 QTY ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 SECTION II 1A 3A 4A 2A M4 M4A1 Carbine Figure C 6 Upper Receiver and Barrel Assembly M16A2 9349050 and M4 and M4A1 12972680 Change 4 SECTION II 1 ITEM NO 1A 2A 3A 4A 2 SMR CODE AFFFF AFFFF PAOZZ PAOZZ PAFZZ PAFZZ PAFFF PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ TM9 1005 319 23LP 3 NSN 19200 19200 1005011343629 1005012342297 4710009781038 4710012338637 1005011467684 1005012338529 5365011441496 1005011343633 5315000586044 1005000878998 5360009781036 5325009990863 4 CAGEC 9349062 12972675 19200 19200 19200 19200 19200 19200 19200 19200 96906 19204 19204 96906 5 PART NUMBER UPPER UPPER 9349059 9390003 8448567 9390016 9349124 9390007 9349052 9349051 MS16562 106 8448712 8448555 5516626 3137 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 03 UPPER RECEIVER AND BARREL ASSEMBLY M16A2 9349050 4 AND 4 11 12972680 FIG C 6 UPPER RECEIVER AND BARREL ASSEMBLY RECEIVER ASSEMBLY 16 2 UOC AR8 RECEIVER ASSY 4 AND 1 UOC AS1 AY6 HANDGUARD ASSEMBLY 16 2 UOC AR8 GUARD HAND GUN M4 AND UOC AS1
4. Expendable Durable Supplies and Materials 5 Forward Assist Assembly Disassembly niet eie Inspection obit uitam estu teste mee eS Ee LUDE ANONA sido o te buen tp stein ttes perpe E Functional Theory of Three Round Burst Control See M16A2 Rifle Final Inspection G Gauging Requirements See M16A2 Rifle Annual Gauging Requirements General normato General Inspection Hammer Assembly 18 hie gai ISI LEDs Inspection Repalr 12 itr ED OR cr i eR ne ee UE EE a SRI How to Use This tenent nennen en Illustrated List of Manufactured Items Initial S tup EET Key and Bolt Carrier Assembly HP Reassembly 5t nte tee ete E A ER TEE E Index 2 1 1 ere a he 3 59 3 60 3 61 3 61 3 60 3 73 3 74 3 74 iii E 1 2 33 3 26 3 27 3 26 ALPHABETICAL INDEX CONT Subject Location and Description of Major Components
5. 0 471 Quarts ou le ver E Mors umo ee tik PR 0 946 Gallons ce crass Mets Le ever 3 785 Ounces Grams ier eee os 28 349 Pounds Kilograms 0 454 Short Tons Metric Poms 0 907 Pound Feet Newton Meters 1 356 Pounds Per Square inch Kilopascals 6 895 Miles Per Galion Kilometers Per 0 425 Miles Per Hour Kilometers Per Hour 1 609 MULTIPLY BY Centimeters Inches ved 0 394 Meieri Sud Ree ERE Feet 3 280 Meters 1 094 Kilometers cele 0 621 Square Centimeters Square Inches 0 155 Square Meters Square 10 764 Square Meters Square Yards 1 196 Square Kilometers Square 0 386 Square Hectometers ACHES 2 471 Cubic Meters Cubic 35 315 Cubic Meters sere Cubic Yards 308 Milliliters deep Fluid Ounces 0 034 Liters Pinis 1i id eee 2 113 re 1 057 Lit rs Gallons 6 264 Grams
6. 650 yards 600 meters Area targets 875 yards 800 meters Section Ill PRINCIPLES OF OPERATION 1 14 GENERAL 5 56mm M16A2 and M4 M4A1 carbine ls gas operated It fires in either the semiautomatic or burst mode b Has positive locking of the bolt Firing pin is part of the bolt carrier assembly and cannot strike the primer until the bolt assembly is fully locked Change 4 1 5 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Section PRINCIPLES OF OPERATION CONT 1 12 PRINCIPLES OF OPERATION A B C D E F G H MAGAZINE Holds cartridges ready for feeding and provides a guide for positioning cartridges for stripping Provides quick reload capabilities for sustained firing SLING Provides the means for carrying the weapon BOLT CARRIER ASSEMBLY Provides stripping chambering locking firing extraction and ejection of cartridges using the drive springs and projectile propelling gases for power CHARGING HANDLE ASSEMBLY Provides initial charging of the weapon The handle latch locks the charging handle assembly in the forward position during sustained fire to prevent injury to the operator M16A2 UPPER RECEIVER AND BARREL ASSEMBLY Provides support for the bolt carrier assembly The barrel chambers the cartridge for firing and directs the projectile LOWER RECEIVER AND BUTTSTOCK ASSEMBLY Provides firing control for the rifle and
7. PIN GROOVED HEADED BOLT CAM BOLT ASSEMBLY 16 2 UOC AR8 BOLT BREECH ASSEMBLY M4 AND 4 UOC AS1 AY6 KEY AND END OF FIGURE C 2 1 7 QTY ll ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 SECTION II Figure Bolt Assembly M16A2 8448509 and M4 and M4A1 12972691 Change 5 SECTION II 1 ITEM NO OND 2 SMR CODE PAFZZ XAFZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ TM9 1005 319 23LP 3 NSN 1005009927287 1005009927290 5315005975086 5360009927292 1005009927291 1005009927288 1005007603768 1005014245899 4 CAGEC 19204 19204 19204 96906 19204 19204 19204 19200 19200 5 PART NUMBER 8448511 8448510 8448513 MS16562 9B 8448516 8448515 8448512 8448755 12972692 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0101 BOLT ASSEMBLY M16A2 8448509 AND M4 AND M4A1 12972691 FIG C 3 BOLT ASSEMBLY PIN SPRING EJECTOR SPRING HELICAL COMP COMPRESSION EJECTOR CARTRIDGE centers SPRING ASSEMBLY EXT EXTRACTOR D Tra UOC AR8 SPRING ASSEMBLY EXT EXTRACTOR 4 AND creasti ne
8. d REASSEMBLY CONT NOTE The peel washer may be heated to remove thin sections Always place thin section to rear Install peel washer 11 and compensator 12 on rifle barrel assembly 2 Torque compensator 12 to 15 20 ft lb 20 27 N m using combination wrench 10 and torque wrench Torque is measured when both wrenches are used together Some portion of the opening of the third or middle slot must be straight up align with the front sight post 12 1 at proper torque level Thin sections of the peel washer may be removed or added as required Save unused sections 16 Slide gas tube 13 through the barrel nut assembly 9 and then slide forward Inserting gas tube into hole In the front sight assembly base 14 3 44 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 L 1 c 17 Align the holes in gas tube 13 and front sight assembly base 14 NOTE To assist in installing spring pin 1 modified nose pliers may be used 18 Using ball peen hammer and 5 64 inch diameter drive pin punch drive spring pin 15 into front sight assembly base 14 to secure gas tube 13 19 Install upper and lower handguard assem blies 16 e TEST The following information pertains to the use of breech bore and other gages a All M1 6A2 barrels and chambers are chromed b Barrel
9. 4 MAINTENANCE OF AUXILIARY EQUIPMENT 4 1 eise TT 4 1 Auxiliary Equipment 4 1 APPENDIX REFERENCES ttt ttt ttt APPENDIX MAINTENANCE ALLOCATION B 1 APPENDIX REPAIR PARTS AND SPECIAL TOOLS LIST ection T euet tne Section UEM Repair Parts LTS MEDIEN C 1 1 Group 5 56MM Rifle M16A2 Carbine M4 and 1 1 M4 and 4 1 Carrying Handle 1 1 00 101 4 and M4A1 Rear Sight Assembly C TB Group Bolt carrier assembly uoce adio 2 1 assembly BR RR C 3 1 Key and bolt carrier 4 1 Group Handle assembly c ccccccsssssesesesecscscsesssscsesesecesecsessseceecsesasecseseseseceesesees C 5 1 C 5 Group Upper receiver and barrel assembly sss Barrel assembly MIDAS 7 1 Replacement Barrel amp Front Sight Assembly 4 4 1 C 7 1 Upper receiver 8 1 Forward assist assembly 9 1 C 9 Rear sight assembly M16A2 cccccccssccsseescesecseecsecsecseccsecsecsaecateeeaeeas 10 1 Group Lower
10. 2 OUNCES 0 035 Kilograms 2 2 205 Metric Tons Short Tons 1 102 Newton Meters Pound Feet 0 738 Kilopascals Pounds Per Square inch 0 145 Kilometers Per Liter Miles Per Galion 2 354 Kilometers Per Hour Miles Hour 0 621 PIN 060514 005
11. 2 46 WARNING To avoid injury to your eyes use care when re moving and installing parts Remove front sight posts only if parts are damaged 3 Using a dummy cartridge or a font sight post removal and installation tool 4 removed front sight post 6 by turning counter clockwise 4 Catch front sight detent 7 and heli cal spring 8 to prevent loss ARMY TM 9 1005 319 23 amp P AIR FORCE TO 1 1W3 5 5 42 Disassemble NT NA only if repair is necessary If necessary knock out tubular rivet 9 with a hammer and punch and remove small sling swivel 10 Discard tubular rivet 9 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 1 1W3 5 5 42 2 16 UPPER RECEIVE AND BARREL ASSEMBLY RIFLE BARREL ASSEMBLY AND UPPER RECEIVER ASSEMBLY CONT a DISASSEMBLY CONT CARBINE ONLY 5A Remove two spring pins 10 1 5C Remove swivel mount 10 3 2 47 1 2 47 2 blank Change 3 CARBINE ONLY 5B Lift swivel locking bar 10 2 up and out of swivel mount 10 3 CARBINE ONLY 5D Remove rivet 10 4 Separate front swivel 10 5 from swivel blank mount 10 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 2 16 UPPER RECEIVER AND BARREL ASSEMBLY RIFLE BARREL ASSEMBLY AND UPPER RECEIVER ASSEMBLY CONT a DISASSEMBLY CONT NOTE Do not disassemble further unless repair is necessary Headless grooved 11 may bind may bind against
12. Spring Assembly Hammer Torsion Helical Spring Lower Receiver Spring Receiver Holder Magazine Cartridge Magazine Magazine Catch Spring sss Compression Helical Spring Peel a Shim crei cete bete eden foo does Rifle Grip Pivot Pin Takedown Pin Detent AE Rifle 5 56mm M16A2 Rifle Barrel Barrel Assembly Selector Lever ec cse iere ee ape Fire Control Selector Semiautomatic Lock Release Lever SIMO Small Arms Sling Trigger Spring Torsion Helical Spring Upper Rece Upper Cartridge Receiver 1 6 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS EIR If your M16A2 rifle needs improvement let us know Send us an EIR You the user are the only one who can tell us what you don t like about your equipment Let us know why you don t like the design Army users submit SF 368 Product Quality Deficiency Report to Commander U S Army Armament Research Development and Engineering Center ATTN AMSTA AR QAW R Customer Feedback Center Rock Island IL 61299 7300 Air Force users submit Materiel Deficiency Repo
13. UOC AS1 AY6 END OF FIGURE C 3 1 7 QTY anl ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 SECTION II Figure C 4 Key and Bolt Carrier Assembly 8448505 SECTION II 1 2 ITEM SMR NO CODE 1 PAFZZ 2 PAFZZ 3 PAFZZ TM9 1005 319 23LP 3 4 5 PART NSN CAGEC NUMBER 5305009927284 19204 8448508 1005009927283 19200 8448506 19200 8448507 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0102 KEY AND BOLT CARRIER ASSEMBLY 8448505 FIG C 4 KEY AND BOLT CARRIER ASSEMBLY SCREW CARRIER AND KEY KEY BOLT CARRIER een CARRIER BOLT teinte e rente petens END OF FIGURE 4 1 7 QTY ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 SECTION II Figure C 5 Handle Assembly 8448517 SECTION II 1 2 ITEM SMR NO CODE 1 PAOZZ 2 PAOZZ 3 PAOZZ 4 XAOZZ TM9 1005 319 23LP 3 4 NSN CAGEC 5315010489372 19204 5340009990405 19200 5360009990404 19204 19204 5 PART NUMBER 8448521 2 8448519 8448520 8448518 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 02 HANDLE ASSEMBLY 8448517 FIG C 5 HANDLE ASSEMBLY PIN SPRING CHARGING LATCH CHARGING HAND HANDLE SPRING HELICAL COMP COMPRESSION CHARGING HANDLE
14. Chamber Cyclic rate of fire Carbine approximate Cyclic rate of fire Rifle approximate 1 4 2 Change 5 US CUSTOMARY 6 Ib 7 oz 76807 4 oz 4 oz 11b 1 oz 7 10 1202 8 Ib 13 oz 10 5 oz 5 02 33 0 29 75 in 39 63 in 14 5 in 20 in 15 5 in 21 in right hand twist 6 grooves 1 turn in 7 inches 17 78 cm direct gas rotating bolt magazine air 5 5 to 9 5 Ib 5 5 to 8 5 16 223 ball blank dummy and tracer 2 970 fps 3 100 fps 52 000 psi 700 970 rds m 700 900 rds m METRIC 2 91 kg 3 40 kg 0 11 kg 0 11 kg 0 48 kg 3 51 kg 4 00 kg 0 30 kg 0 14 kg 83 82 cm 75 57 cm 100 66 cm 36 83 cm 50 8 cm 39 37 cm 53 34 cm 2 49 to 4 31kg 2 49 to 3 86 kg 5 56mm 905 85 mps 945 5 mps 358 540 kPa ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 1 10 EQUIPMENT DATA CONT US CUSTOMARY METRIC Maximum rate of fire 45 rds m 90 rds m Sustained rate fire 12 15 rds m Maximum 3 938 Approximately 3 600 meters Maximum effective range Individual point targets Carbine 547 yards 500 meters Individual point targets 602 yards 550 meters Area targets
15. 3 3 Eallue to feed AA 3 3 Failure to chiamb er iet eX 3 3 Failure to lock dti E EN 3 4 xung alee 3 5 Fallure to unlock evade e el oot e edu 3 6 as Iud 3 6 AR Debian aate nt 3 6 Failure tO COCK PEDE 3 7 MOM es El 3 9 Hifle cannot be 7 3 10 Failure to cycle with selector lever set o n 3 11 Fires two rounds with one pull of trigger with selector lever set on SEMI double firing itecto ehe E poete tecnico 3 13 Fires with selector lever on SAFE on when trigger is released with selector leveron SEMI ER 3 13 Hanmer pin i em 3 14 Bolt assembly fails to lock to rear after firing last round sse nen 3 14 3 2 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCF 1 1W3 5 5 42 TROUBLESHOOTING MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1 FAILURE OF MAGAZINE TO LOCK IN RIFLE Step 1 Dirty or corroded magazine catch 1 Disassemble and clean Step 2 Defective magazine catch spring 2 Replace magazine catch spring 2 p 3 62 Step 3 Worn or broken magazine catch 1 Replace magazine catch 1 p 3 62
16. EE 2 23 2 24 Fal re tO UN 2 26 Failure eer eerte RF 2 26 BENEA ELN E e EE II ET EEE E 2 27 REACH E A PE IC Re 2 28 SNOR TEC N a N EA E E S E A N 2 28 Hifle cannot be zeroed 2 een ee a dened ee bee ia dakad aiaa 2 30 Failure to cycle with selector lever set ON 5 2 31 Fires two rounds with one pull of trigger with selector lever set on SEMI double firing i com oe tt eod n cose Daft ded oti eti edet bi od ea dais 2 31 Fires with selector lever on SAFE or when trigger is released with selector lever om SEM itl TE 2 31 Bolt assembly falls to lock to rear after firing last 2 32 TROUBLESHOOTING MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1 FAILURE OF MAGAZINE TO LOCK IN RIFLE Step 1 Dirty or corroded magazine catch 1 Disassemble and clean Step 2 Defective magazine catch spring 2 Evacuate to support maintenance Step 3 Worn or broken magazine catch 1 Evacuate to support maintenance 2 21 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 9 TROUBLESHOOTING PROCEDURES CONT TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 2 F
17. Free length of spring shall be between 11 3 4 and 13 1 2 inches 29 84 and 34 29 cm M16A2 ONLY and 10 1 16 and 11 1 4 inches 25 56 and 28 58 cm M4 M4A1 ONLY Inspect handguard assembly for breaks separations and cracks Breaks and separations of material which prevent proper retention or interfere with functioning of the weapon will be cause for handguard rejection and replacement Cracks up to 1 inch 2 54 cm in length are acceptable provided they do not extend into the handguard retaining flange 1 critical area M16A2 ONLY Each handguard assembly may have up to two of the three front retaining tabs 2 missing If all three front tabs are missing the handguard assembly must be replaced M4 M4A1 ONLY No tabs can be missing ALL WEAPONS Replace severely cracked handguards Handguards that have a heat shield loose enough to rattle when installed on the weapon must be replaced Inspect buttstock assembly for dents cracks and chips Check for breaks and separation of material which could prevent proper func tioning of weapon M4 M4A1 inspect for proper functioning Repair as required ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 Table 3 1 5 56MM Rifle M16A2 M4 M4A1 Carbine Cont Item Standard M16A2 ONLY Under the following conditions hairline cracks originating from buttplate end of buttstock are acceptable No chipped away material is allowed a One hairline crack not to exceed 1 inch
18. Lock Plate Ec ItaStallatlODi etre iint orto eee ti cete ce cie cuv erepti ma qued Tr Lower Receiver and Buttstock Assembly marae e ce eno eo el e o ee rura Disassembly nebst InSpection z s is e RB ameta aM Dep ieee Pa Reassembly eed d ETLICHE P ot e ee HD Tee fers c m Lower Receiver and Receiver Extension DiSassernbly ierit Imi tm i RE EE Dena idera heap th UE DEED Heassemlbly 3 m Repat Mody easier ekian ia i ei a Lubrication General eerta e ne tae Maintenance Allocation 00000 2 Maintenance Forms Records and Reports Maintenance Procedu res 1 tete eee cte Major Components of M16A2 Rifle See M16A2 Rifle Mechanical Zero Procedures e idee eodein erre Deere EU M15A12 Blank Firing Attachment See Blank Firing Attachment M15A12 2 PM EE Disassembly tete ate e a ee e ent INSPECTION Lm Reassembly 2 oin cepere eda i Had d aiid Ie ET E M16A2 Rifle Annual
19. check cont to vertical position Allow the lubricant to work Its way around the helical compres sion spring and takedown pin detent 11 Check buttstock assembly 12 compo nents for damage RIFLE ONLY Under the following conditions hairline Components are cracks no chipped away material damaged allowed originating from the buttplate end of the buttstock are acceptable 2 16 Change 5 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Interval Item to be Not Fully Mission No Checked or Procedure Capable if Serviced RIFLE ONLY 6 Quarterly Lower receiver a One hairline crack not to exceed The buttstock is cont and buttstock 1 in 2 54 cm in length per side of cracked in the assembly serv buttstock critical area or iceability check does not meet the cont crack criteria b Two additional hairline cracks up to 0 25 in 0 64 cm in length per side of buttstock c A total of three cracks per side of the buttstock originating from the buttplate end are allowable Cracks in the critical area at the front end of the buttstock are not accept able Check buttstock assembly 12 for Lower receiver forward to rear movement and or a extension cannot 1 32 in 0 079 cm gap between the be tightened buttstock assembly 12 and the lower receiver 13 If forward to rear movement and or a 1 32 in 0 079 cm gap
20. 1005 01 144 1468 5360 01 144 1492 1005 01 148 0172 5360 01 136 5471 1005 01 134 3630 5340 01 144 1499 5340 01 145 7910 5360 01 135 0353 1005 01 135 4973 5305 01 144 1494 1005 01 146 7684 1005 01 148 4805 5305 01 147 8585 1005 01 146 7685 5340 01 225 8339 1005 01 228 8504 1005 01 234 2297 1005 01 233 8529 1005 01 233 8636 5340 01 233 8638 4710 01 233 8637 1005 01 233 8531 5310 01 233 8625 1005 01 233 8530 5360 01 233 8617 1005 01 231 3138 5315 01 233 8608 1 6 FIG C 1B C 10 C 8 C 1A C 8 C 10 C 1B C 10 C 1B C 10 C 1B C 10 C 9 C 8 C 1 C 11 C 16 C 11 C 13 C 13 C 13 C 13 C 11 C 11 C 11 C 15 C 15 C 11 C 12 C 12 C 6 C 11 C 11 C 12 C 11 C 12 C 6 C 6 C 7 C 1 C 11 C12A C12A C16A C 6 C16A C16A C16A C 11 C 11 C12A ITEM ANOU 0019090 0000990 SECTION IV CAGEC 19200 19200 19200 19200 19200 19200 19200 TM9 1005 319 23 amp P CROSS REFERENCE INDEXES PART NUMBER INDEX PART NUMBER STOCK NUMBER FIG 9390026 5310 01 233 8626 C12A 9390027 5360 01 233 8616 C12A 9390031 3040 01 247 7969 C 13 9390032 C 11 9390035 5120 01 324 6631 C 17 9390736 C 15 C 15 9392518 1005 01 219 2402 C 14 1 7 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 APPENDIX D EXPENDABLE DURABLE SUPPLIES AND MATERIALS LIST Section I INTRODUCTION D 1 SCOPE This appendix lists expendable durable supplies and materials you will n
21. 2 19 MAJOR COMPONENTS OF M16A2 RIFLE This task covers a Reassembly c Stowage b Inspection INITIAL SETUP References TM 9 1005 319 10 Equipment Conditions Rifle disassembled into major components General Safety Instructions To avoid injury to eyes use care when removing and installing spring loaded parts a REASSEMBLY Do not Interchange bolt assemblies from one rifle to another Doing so may result In Injury to or death of personnel Do not keep live ammunition near the work area Refer to operator s manual and assemble lower receiver and buttstock assembly 1 upper receiver and barrel assembly 2 charging handle assembly 3 bolt carrier assembly 4 sling 5 and magazine 6 2 68 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 b INSPECTION Perform the following function checks on assembled weapon 1 10 11 12 Remove magazine if installed Pull charging handle assembly to rear Check that chamber is clear Let bolt and bolt carrier close Do not pull trigger Leave hammer in cocked position WARNING If rifle fails any of the following tests continued use of the rifle could result in injury to or death of personnel Place selector lever in SAFE position and pull trigger Hammer should not fall Place selector lever in SEMI position Pull trigger Hammer should fall M16A2 and M4 ONLY NOTE For the
22. ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 M4 M4A1 Change 4 1 4 1 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 1 10 EQUIPMENT DATA Weight Carbine M4 M4A1 without magazine and sling Rifle MI 6A2 without magazine and sling Sling Empty Loaded 2 Carbine M4 M4A1 w sling and loaded magazine Rifle M16A2 w sling and loaded magazine Bayonet Knife Scabbard M10 o Length Carbine with compensator buttstock extended Carbine with compensator buttstock closed Rifle with compensator Barrel Barrel Barrel with compensator Carbine Barrel with compensator Rifle Mechanical features RAL late ec tier ete etre Method of Type of breech mechanism Method een E Trigger pull M16A2 8 Trigger pull Ammunition Caliber 5 Firing characteristics Muzzle velocity Carbine approximate Muzzle velocity Rifle approximate
23. ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 CAUTION Extreme care must be exercised during the following procedure to assure that the striking force is not directed to the attaching screws and that the tube portion is not enlarged or flared beyond original requirement Such enlargement would permit loss of gas pressure when the key and gas tube come together during functioning 6 Repair small dents and or distortions in carrier key 6 using bolt carrier key tool as follows Place the key and bolt carrier assembly 3 in a vertical position supported In a manner that contact is made with the rear surface of the carrier key 6 Insert the small end of the key tool 8 into the tube portion of the carrier key 6 Strike the large end of the key tool 8 lightly with a 3 ounce soft brass hammer Repeat striking gently until carrier key 6 is reformed to original configuration If carrier key 6 cannot be reformed to original configuration evacuate the weapon to support maintenance ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 d LUBRICATION Lubricate all Items 2 33 operators manual e REASSEMBLY WARNING Do not Interchange bolt assemblies from one rifle to another Doing so may result In Injury or death of personnel Bolt cam pin must be Installed or rifle will blow up while firing the first round If the bolt cam pin is not Installed Injury to or death of personnel may result NOTE B
24. BU WES TOGK UOC AR8 SWIVEL SLING sees UOC AR8 PIN STRAIGHT HEADLE HEADLESS ACCESS 2 UOC AR8 SCREW MACHINE BUTT PLATE UOC AR8 END OF FIGURE C 12 1 7 QTY ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 42 SECTION II Figure C12A M4 and M4A1 Buttstock Assembly 9390012 Change 4 SECTION II 1 2 ITEM SMR NO CODE 1 22 2 PAOZZ 3 PAOZZ 4 PAOZZ 5 PAOZZ 6 22 TM9 1005 319 23 amp P 3 NSN 1005012338636 5315012338608 5360012338616 5340012338638 5310012338626 5315008439487 4 CAGEC 19200 19200 19200 19200 19200 96906 5 PART NUMBER 9390013 9390025 9390027 9390014 9390026 MS16562 202 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0401A M4 AND M4A1 9390012 BUTTSTOCK ASSEMBLY FIG C12A M4 AND M4A1 BUTTSTOCK ASSEMBLY STOCK GUN SHOULDER eese UOC AS1 AY6 PIN SHOULDER UOC AS1 AY6 SPRING HELICAL COMP COMPRESSION UOC AS1 AY6 LEVER LOCK RELEASE sese UOC AS1 AY6 NUT SELF LOCKING UOC AS1 AY6 PIN SPRING ttr tentent UOC AS1 AY6 END OF FIGURE C12A 1 7 QTY ARMY 9 1005 319 23 amp AIR FORCE TO 11W3 5 42 SECTION II M16A2 and M4 4A 1A S Figure C 13 Hammer Assembly M16A2
25. Carefully remove pistol grip 1 Hold detent helical spring 4 in place ARMY TM 9 1005 319 23 amp P AIR FORCE TO 1 1W3 5 5 42 Install lock plate 5 with the detent helical spring 4 passing through the hole In the right side of the lock plate and the arm on the outside of the receiver The selector lever just point to the SAFE position 4 Carefully compress detent helical grip 1 Using screwdriver secure pistol by Installing lockwasher 131 spring 4 and position pistol grip 1 and screw 12 4 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 4 2 LOCK PLATE CONT b REMOVAL Using a screwdriver reach inside pistol grip I and remove screw 2 and lockwasher 3 WARNING To avoid Injury to your eyes use care when removing and installing spring loaded parts Carefully remove pistol grip 1 Hold detent helical spring 4 In place ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 Remove lock plate 51 while continuing to hold detent helical spring 4 In place The selector lever must point to the SAFE position 5 Using a screwdriver secure pistol by installing lockwasher 3 spring 4 and position pistol grip 1 and screw 2 Carefully compress detent helical grip 1 c INSPECTION Inspect lock plate for serviceability and broken arm Replace If unserviceable or if arm is broken off 4 5 ARMY TM 9 1005 319 23 amp A
26. SECTION A A z 00510 013 9A 0 098 0 04 DIA 0 00 0 249 0 10 0 00 THRU FABRICATE FROM 0 245 IN STEEL AISI 1095 OR EQUIVALENT HARDEN AND TEMPER TO RC 57 61 FOR LENGTH A FINISH 5 3 1 2 OR 5 3 2 2 OF MIL STD 171 NOTE ALL DIMENSIONS SHOWN ARE IN INCHES WITH THE METRIC CONVERSION TO CEN TIMETERS IN PARENTHESES Figure E 4 Pivot pin installation tool E 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 VIEW A 0 625 1 5881 VIEW B 0 1540 0 0005 0 3912 00127 0 625 1 588 FABRICATE FROM OLD TRIGGER PIN VIEW Al P N 8448609 OR FABRICATE SLAVE PIN VIEW B FROM MATERIAL BLOCK WIRE STEEL ALLOY GRADE 4140 ASTM A547 OR EQUIVALENT NOTE ALL DIMENSIONS SHOWN ARE IN INCHES WITH THE METRIC CONVERSION TO CEN TIMETERS IN PARENTHESES Figure E 5 Slave pin E 5 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 E 3 MANUFACTURED ITEMS ILLUSTRATIONS FORMAT AND CONTENT CONT 91 12 11 4 11 4 3 175 3 175 45 4 A 1 1 2 3 81 11 2 3 81 FABRICATE FROM 1 1 2 INCH BY 1 1 2 INCH BY 1 8 INCH ANGLE IRON NSN 9520 00 277 4902 OR EQUIVALENT PAINT WITH OLIVE DRAB ENAMEL PAINT NSN 8010 01 350 5249 OR EQUIVALENT NOTE ALL DIMENSIONS SHOWN ARE IN INCHES WITH THE METRIC CONVERSION TO CENTIMETERS IN PARENTHESES Figure E 6 Adapter bar for M12 arms rack PIN 06051 4 004 U S Government Printing Off
27. 9349106 4 9390032 and M4A1 8448610 Change 4 SECTION II 1 2 ITEM SMR NO CODE 1 PAFZZ 1A PAFZZ 2 PAFZZ 3 PAFZZ PAFZZ 4 PAFZZ 4A PAFZZ TM9 1005 319 23 amp P 3 NSN 5360011441492 5360009926648 5360011365471 1005011480172 3040012477969 1005011343630 1005000179551 4 5 PART CAGEC NUMBER 19200 9349107 19204 8448611 19200 9349109 19200 9349108 19200 9390031 19200 9349110 19200 8448612 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0402 HAMMER ASSEMBLY M16A2 9349106 M4 9390032 AND M4A1 8448610 FIG C 13 HAMMER ASSEMBLY SPRING HELICAL TORS HAMMER 6 2 S oo set o e PL ILLA E IN eL UOC AR8 AS1 SPRING HELICAL TORS 1 UOC AY6 SPRING HELICAL TORS BURST M16A2 AND MA UOC AR8 AS1 CAM BURST M16A2 BLACK UOC AR8 CAM CONTROL 4 NICKEL SHINY UOC AS1 HAMMER AND HAMMER P PIN RETAINER ASSEMBLY MI6A2 AND UOC AR8 AS1 HAMMER FIRING SMALL 1 UOC AY6 END OF FIGURE C 13 1 7 QTY ARMY 9 1005 319 23 amp AIR FORCE TO 11W3 5 42 SECTION II M16A2 M EN Figure C 14 Trigger Assembly M16A2 9349115 M4 12972697 and
28. C 15 C 1B C 10 C 8 C 11 C 13 C 9 C 1B C 10 C 13 C 12 C 6 C 11 C 11 C 6 C 12 C 11 C 13 C 8 C 1B C 10 C 11 C 1 C 14 C 11 C 12 C 11 C 6 C16A C16A C12A C12A C 11 C16A TM9 1005 319 23 amp P CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX ITEM gt 0 AaaokhPOWONAONOINH WW NODD AN gt gt STOCK NUMBER 5310 01 233 8626 1005 01 233 8636 4710 01 233 8637 5340 01 233 8638 1005 01 234 2297 3040 01 247 7969 1010 01 264 6517 5340 01 264 6530 5365 01 267 2169 5305 01 268 1191 5315 01 310 0370 5120 01 324 6631 1005 01 368 9852 5360 01 381 6183 5340 01 382 3201 5310 01 382 6793 1005 01 382 6795 5355 01 382 6801 5360 01 382 6802 1005 01 382 7083 1005 01 382 7086 1005 01 382 7089 1005 01 395 4257 5360 01 396 0256 1005 01 422 3770 1005 01 424 5899 999 SECTION IV TM9 1005 319 23 amp P CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX STOCK NUMBER FIG ITEM STOCK NUMBER 88044 AN5010416 18 5305 01 268 1191 96906 MS16562 103 5315 00 058 6678 96906 MS16562 106 5315 00 058 6044 96906 MS16562 119 5315 00 812 3312 96906 MS16562 121 5315 00 840 3812 96906 MS16562 129 5315 00 058 6081 96906 MS16562 202 5315 00 843 9487 96906 MS16562 98 5315 00 597 5086 96906 MS16626 3137 5325 00 999 0863 96906 MS16632 3012 5325 0
29. CAUTION Do not use a wire brush on aluminum surfaces NOTE If a weapons lower receiver is missing one third or more of its exterior protective finish resulting in an unprotected light reflecting surface it is candidate for overhaul This missing finish will be considered a shortcoming This shortcoming requires action to obtain a replacement weapon Once a replacement has been received evacuate the original weapon to depot for overhaul Solid Film Lubricant SFL is the only authorized touchup for the weapon and may be used on up to one third of the exterior finish of the weapon FOR ARMY CONUS USE ONLY AND AIR FORCE TRAINING WEAPONS ONLY SFL may be used as a touchup without limitation on the upper receiver and barrel assembly This is to say that units which DO NOT fall under the category of Divisional Combat Units or rapid deployment type units may have up to 100 percent of the exterior surface of the upper receiver and barrel assembly protected with SFL if necessary c REPAIR Repair or replace all parts of lower receiver and buttstock assembly if defective Change 4 3 67 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 3 13 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY CONT d TEST With the upper receiver attached to the lower receiver and the pivot pin and takedown pins in place perform the following test a Apply hand pressure to push the upper receiver as far to one side as possible b Attempt to insert a 0 0
30. M4 AND M4A1 LOWER RECEIVER AND RECEIVER EXTENSION ASSEMBLY NPN FIG C16A M4 AND M4A1 LOWER RECEIVER AND RECEIVER EXTENSION ASSEMBLY EXTENSION LOWER RECEIVER M4 AND ET NB VETERES TEUER UR UOC AS1 AY6 NUT PLAIN ROUND M4 AND 1 2 2 244 2222 0 UOC AS1 AY6 PLATE RECEIVER END M4 AND 1 UOC AS1 AY6 PIN SHOULDER HEADLE M4 AND MAAt UOC AS1 AY6 SPRING HELICAL COMP M4 AND 4 1 UOC AS1 AY6 RECEIVER 4 UOC AS1 LOWER RECEIVER 4 1 UOC AY6 GUARD TRIGGER M4 AND 1 PIN SPRING TRIGGER GUARD PIN M4 PIN GROOVED HEADED TAKE DOWN M4 PIN STRAIGHT HEADLE HEADLESS 4 UOC AS1 AY6 SPRING HELICAL COMP COMPRESSION M4 AND bu UOC AS1 AY6 END OF FIGURE C16A 1 ARMY 9 1005 319 23 amp AIR FORCE TO 11W3 5 42 SECTION II 8 Figure C 17 Special Tools Change 3 Section 1 2 ITEM SMR NO CODE PEFZZ 1 PAFZZ 2 PAFZZ 3 PAFZZ 4 PAFZZ 5 PAFZZ 6 PAFZZ 7 PAFZZ 8 22 9 PAFZZ 10 22 11 PAOZZ 12 PAFZZ TM9 1005 319 23 amp P 3 NSN 1005000567106 4933010355607 4933008007508 5220010755004 5220010148183 5220002219391 5220000707814 6695000707815 4933000709151 5120000709152 5220010439473 5315013100370 5120013246
31. M4A1 12972676 Change 4 SECTION II 1 ITEM NO 1A 2A 2B 2 SMR CODE PAFFF PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ TM9 1005 319 23 amp P 3 NSN 1005012192402 1005013954257 5360009927308 5360009927308 5360009927308 5360013960256 1005009927307 4 CAGEC 19200 19200 19204 19204 19204 19200 19204 5 PART NUMBER 9392518 12972696 8448593 8448593 8448593 12972695 8448592 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0403 TRIGGER ASSEMBLY M16A2 9349115 M4 12972697 AND M4A1 12972676 FIG C 14 TRIGGER ASSEMBLY TRIGGER SUB ASSEMBL 16 2 UOC AR8 TRIGGER SUBASSEMBLY UOC AS1 SPRING HELICAL TORS TORSION TRIGGER UOC AR8 SPRING HELICAL TORS UOC ASI SPRING HELICAL TORS 1 UOC AY6 SPRING HELICAL COMP DISCONNECT Laon ead an UOC AY6 TRIGGER UOC AY6 END OF FIGURE C 14 1 7 QTY ARMY TM9 1005 319 23 amp P AIR FORCE TO 11W3 5 42 SECTION II 1B 1A 1 2 M4 M16A2 Figure C 15 Trigger Subassembly M16A2 9392518 M4 12972696 Change 4 SECTION II TM9 1005 319 23 amp P 1 2 3 4 5 6 7 ITEM SMR NSN
32. PREVENTIVE MAINTENANCE CHECKS AND SERVICES CONT PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Interval Item to be Not Fully Mission No Checked or Procedure Capable if Serviced 4 Quarterly Upper receiver NOTE cont and barrel as If front or rear sight sembly service is moved return to ability check original position cont Check front sight post de Charging handle tent and spring 7 for dam 8 is defective age and corrosion Clean and lubricate Check charg ing handle 8 and election port cover 9 for defects and proper function Check sling swivel 10 and rivet 11 for damage and proper function SH Other corn ponents are defective re place as necessary CAUTION Do not use a wire brush to roughen surfaces Use a well ventilated area during cleaning and application of solid film lubricant If solid film lubricant comes in contact with moving parts or functioning surfaces of the rifle remove lubricant immediately by washing with dry cleaning solvent NOTE Shiny metal exterior surfaces of the rifle should be recoated with solid film lubricant Item 21 app D Clean surface with dry cleaning solvent item 16 app D dry roughen with abrasive cloth Item 13 app D and apply solid film lubricant Item No ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Interval Quarterly Upper receiver and barrel
33. Reassemble magazine and check for binding during operation of follower 4 SH Replace the magazine if the follower binds WARNING If the rifle falls any of the following selector lever tests evacuate It to sup port maintenance Continued use of the rifle could result In injury to or death of personnel 2 5 Not Fully Mission Capable if A magazine is not available fu use with the rifle ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 T PREVENTIVE MAINTENANCE CHECKS AND SERVICES CONT PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Interval Item to be Not Fully Mission Checked or Procedure Capable if Serviced 2 Quarterly Charging handle Pull charging handle 1 to rear Check Charging handle cont assembly and that chamber is clear Let bolt carrier does not lock in selector lever assembly 2 close Leave hammer in place when in the cont cocked position Do not pull trigger forward position Place selector lever 3 in SAFE position Hammer falls Pull trigger Place selector lever 3 in SEMI position NOTE For the purpose of the following test SLOW is defined as 1 4 to 1 2 the normal rate of trigger H release Pull trigger Hammer does not fall Nu LA A 2 Hold trigger to the rear charge Hammer falls E weapon and release the trigger with Esch a slow smooth motion without hesi tations or stops until t
34. Remove punch 3 72 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 WARNING To avoid injury to your eyes use care when removing or installing spring loaded parts NOTE gt Rounded end of pivot detent must be in the groove of the pivot pin 22 when assembly is complete 11 12 Position pivot 22 and removing fabricated pivot pin installation tool 19 while maintaining pressure slide pivot pin 22 into hole Rotate pivot pin to receive pivot pin detent 13 Assemble rifle refer to page 3 82 3 14 HAMMER ASSEMBLY This task covers a Disassembly c Reassembly b Inspection Repair INITIAL SETUP Equipment Conditions 3 62 Hammer assembly removed a DISASSEMBLY M16A2 M4 M4A1 NOTE M16A2 burst cam is black M4 burst cam is nickel colored shiny M16A2 M4 remove hammer spring 1 cam clutch spring 2 and burst cam 3 from hammer and hammer pin retainer assembly 4 M4A1 remove hammer spring 5 from hammer 6 Change 4 3 73 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 14 HAMMER ASSEMBLY CONT b INSPECTION REPAIR Inspect hammer spring for deformities breaks and bends Pay special attention to the large coil Replace hammer spring if defective Inspect cam clutch spring and burst cam for deformities breaks and bends replace if defective Inspect hammer and hammer pin retainer assembly for chips and breaks Hammer pin should click ho
35. The maintenance code entered in the third position tells you the lowest maintenance level authorized to remove replace and use an Item The maintenance code entered In the third position will indicate authorization to one of the following levels of maintenance Code Application Explanation C Crew or operator maintenance done within unit or aviation unit maintenance Unit or aviation unit level can remove replace and use the Item F Direct support or aviation intermediate level can remove replace and use the Item H General support level can remove replace and use the Item L Specialized repair activity can remove replace and use the Item D Depot level can remove replace and use the Item ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 EXPLANATION OF COLUMNS SECTIONS II AND III CONT b The maintenance code entered In the fourth position tells whether or not the Item is to be repaired and Identifies the lowest maintenance level with the capability to do complete repair e perform all authorized repair functions NOTE Some limited repair may be done on the Item at a lower level of maintenance If authorized by the Maintenance Allocation Chart MAC and SMR codes I This position will contain one of the following maintenance codes Code Application Explanation Unit or aviation unit is the lowest level that do complete repair of the item F Direct support or aviation Intermediate is the lowest leve
36. the level of maintenance If the number of complexity of the t asks within the listed maintenance function vary at different maintenance levels appropriate work time figures will be shown for each level The work time figure represents the average time required to restore an item assembly subassembly component module end it4m or System or a serviceable condition under typicalfield operating conditions This time includes preparation time including any necessary disassembly assembly time troubleshooting fault location time and quality assurance quality control time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized i the maintenance allocation chart The symbol designations for the varies maintenance levels are as follows CETUR Operator or Crew Unit Maintenance Direct Support Maintenance General Support Maintenance Specialized Repair Activity p Depot Maintenance e Column 5 Tools and Equipment Column 5 specifies by code those common tool sets not individual tools and special tools TMDE and support equipment required to perform the designated function f Column 6 Remarks This column shall when applicable contain a lett4er code alphabetic order which shall be keyed to the remarks contained in Section IV This maintenance level is not included in Section II column 4 of the Maintenance Allocation Chart
37. 1 which retains the gas tube out of front sight assembly 2 2 Slide gas tube 3 back into upper receiver assembly 4 to clear front sight assembly 2 Then lift slightly pull forward and remove gas tube 3 3 30 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Position upper receiver and barrel assembly 5 in barrel removal fixture 6 and secure both In machinist s vise 7 Using combination wrench 8 and 12 inch drive handle remove compensator 9 Remove peel washer 10 being careful not to lose or bend thin sections Remove upper receiver and barrel assembly 5 from barrel removal fixture and machinist s vise 3 31 ARMY TM 9 1005 319 23 amp AIR FORCE 11W3 5 5 42 3 10 UPPER RECEIVER AND BARREL ASSEMBLY CONT a DISASSEMBLY CONT 7 Place upper receiver and barrel assembly 5 Into barrel removal fixture 6 and clamp Into machinist s vise 7 NOTE Be sure all three drive pins on combination wrench are fully engaged with barrel nut assembly Wrench must be pushed toward upper receiver assembly to compress the slip ring spring In barrel nut assembly Do not use a torque wrench to loosen the barrel nut assembly 8 Using 2 Inch drive handle and combination wrench 8 loosen barrel nut assembly 11 9 Separate upper receiver assembly 4 from barrel assembly 12 10 Remove barrel assembly 12 from machinis
38. 2 28 T FAILURE TO EXTRACT Step 1 Defective extractor pin 1 cartridge extractor 2 and or extractor spring assembly 3 Replace extractor pin 1 cartridge extractor 2 and or extra tor spring assembly 3 p 2 381 Step 2 Short recoil Refer to page 2 28 NOTE Rubber insert and spring are an assembly Illustration shows Insert out of assembly for clarification only Do not remove the rubber Insert from the extractor spring assembly 2 26 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 8 FAILURE TO EJECT Step 1 Broken cartridge ejector 1 Replace p 2 38 Step 2 Cartridge ejector 1 stuck in bolt body 2 Disassemble and clean p 2 38 Step 3 Weak or broken ejector spring 3 Replace p 2 38 Step 4 Short recoil Refer to page 2 28 2 27 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 9 TROUBLESHOOTING PROCEDURES CONT TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 9 FAILURE TO COCK Step 1 Worn broken or missing parts of firing mechanism Evacuate to support maintenance Step 2 Short recoil Refer to below 10 SHORT RECOIL Step 1 Broken or damaged action spring 1 Replace action spring p 2 57 Step 2 Unlubricated or dirty action spring and receiver extension Clean and lubricate Step3 Improper gap space or worn missing or broken
39. 2 54 cm in length per side of buttstock b Two additional hairline cracks up to 0 22 inch 0 55 cm in length per side of buttstock Buttstocks with unauthorized markings stamped into their surfaces will be replaced Unauthorized markings scratched etched carved etc are acceptable if they do not extend into the fiber of the buttstock which may weaken it These marks may lie at any location on the buttstock Cracks in the critical area at the front end of the buttstock are not acceptable and these buttstocks must be replaced Change 4 3 103 3 104 blank ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 CHAPTER 4 MAINTENANCE OF AUXILIARY EQUIPMENT CHAPTER OVERVIEW This chapter contains information and instructions to keep auxiliary equipment used with your weapon in good repair Section AUXILIARY EQUIPMENT REPAIR 4 1 GENERAL a The following items of auxiliary equipment are used in conjunction with the Weapons 1 40mm Grenade Launcher M203 NSN 1010 00 179 6447 M16A2 ONLY 2 Lock Plate NSN 1005 00 233 9031 3 Top Sling Adapter NSN 1005 00 406 1570 4 Blank Firing Attachment M15A2 NSN 1005 00 118 6192 M16A2 ONLY Blank Firing Attachment M23 NSN 1005 01 361 8208 M4 ONLY Change 4 5 ARMY ONLY Conversion Kit M261 caliber 22 rimfire adapter NSN 1005 01 010 1561 6 Bayonet Knife M7 NSN 1005 00 073 9238 7 Bayonet Knife Scabbard M10 NSN 1095 00 223 7164 8 M9 Multi Purpose Bayonet System
40. 22 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 Inspect bolt for cracks In the locking lugs and the bolt cam pin hole area otherwise use a glass of no more than 3X magnification or use a penetrant kit item 25 app D Pay close attention to the area where the locking lugs meet the body Replace bolt assembly if bolt is defective 4 Use penetrant kit Item 25 app D to check for cracks in bolt as follows a b c d e f WARNING Dry cleaning solvent is flammable and toxic and should be used in a well ventilated area The use of rubber gloves is necessary to protect the skin when washing rifle parts The area to be inspected must be clean free of oil etc Spray a small amount of remover on the area to be inspected let dry and wipe off with a wiping rag Spray penetrant only enough to wet the area on the area of the bolt 1 to be inspected Spray developer over the penetrant and let the developer work Cracks will be indicated by a change in color where there is a crack If there are cracks the component 1 unserviceable Pay close attention to the area where the locking lugs 2 meet the body If there are no cracks spray remover on the area let dry and wipe off with a wiping rag Oil the area to prevent corrosion Replace bolt assembly If bolt 1 is defective NOTE Replacement of the bolt assembly will require that the headspace be tested p 3 45 TEST Use
41. 29 Step 4 Partially plugged gas system because of carbon build up in the gas tube 2 Replace gas tube 2 p 3 29 3 9 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 1 1W3 5 5 42 3 5 TROUBLESHOOTING PROCEDURES CONT TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 10 SHORT RECOIL CONT WARNING When using carbon removing compound Item 8 app D avoid skin contact If it comes in contact with the skin wash off thoroughly with running water The use of a good lanolin base cream after exposure to compound Is helpful The use of gloves and protective equipment Is required Step 5 Carbon build up in barrel gas port 5 Remove carbon build up by soaking barrel In carbon removing compound item 8 app D Use rubber gloves Item 18 app D with carbon removing compound Use a bore small arms cleaning brush Item 4 app D 11 RIFLE CANNOT BE ZEROED Step 1 Inspect for defective or bent barrel assembly 1 p 3 29 Replace barrel assembly 1 p 3 29 Step 2 For windage barrel assembly 1 out of alignment with rear sight on up per receiver Align barrel assembly 1 and upper receiver p 3 291 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 11W3 5 5 42 TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 3 For elevation defective front sight 2 or rear sight 3 Repair as required p 3 48 A 12 FAILURE TO CYCLE WITH SELECTOR LEVER SET ON BURST M1
42. 4 3 75 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 15 TRIGGER ASSEMBLY AND TRIGGER SUBASSEMBLY CONT b INSPECTION REPAIR Inspect trigger spring for kinks deformities and weakness Replace if defective Inspect disconnector springs for deformities bends breaks and weakness Replace if defective Inspect trigger for chips wear and cracks Inspect for damaged searing surface on the trigger nose Replace if defective c REASSEMBLY M16A2 AND M4 ONLY NOTE Use bolt carrier key tool to install disconnector springs Use the following procedures to install two disconnector springs 1 using the bolt carrier key tool Secure the trigger 2 in a soft vise jaws or similar device Place one spring 1 firmly on the tool with large diameter coils outward Press spring 1 into recess to solid height 2 Hold spring at solid height and slide spring i into one of the holes until the punch is flush and perpendicular with the recess wall Turn the spring one to two turns opposite of coil winding of the spring Discontinue winding when an audible click or snap is heard or felt This indicates that the spring is seated Hold the spring 1 in place when removing the tool to avoid unseating or damaging the spring M4 CARBINE ONLY NOTE The semi and burst disconnector springs are not the same The Semi disconnector spring left side figure C 15 item 1B is black while the burst disconnector spring
43. 4808 9349075 12011987 9349077 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 030202 M16A2 REAR SIGHT ASSEMBLY 9349072 FIG C 10 REAR SIGHT ASSEMBLY PIN SPRING seen BASE REAR SIGHT sese UOC ARB SPRING HELICAL COMP REAR SIGHT UOC AR8 BALL BEARING 4 tiii iei ette da UOC AR8 APERTURE SIGHT cece cece eee SPRING FLAT REAR SIGHT E KNOB WINDAGE nnt rennen END OF FIGURE C 10 1 7 QTY ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 SECTION II M4 M4A1 Figure C 11 Lower Receiver and Buttstock Assembly MI 6A2 9349100 M4 9390011 and M4A1 12972690 Change 4 SECTION II TM9 1005 319 23 amp P 1 2 3 4 5 6 7 ITEM SMR NSN PART DESCRIPTION AND NO CODE CAGEC NUMBER USABLE ON CODE UOC QTY GROUP 04 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY M16A2 9349100 M4 9390011 AND M4A1 12972690 FIG C 11 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY 1 PAOZZ 5360009926665 19204 8448629 SPRING HELICAL COMP ACTION 16 2 VOCARE 1 22 5360012338617 19200 9390022 SPRING HELICAL COMP COMPRESSION M4 AND UOC AS1 AY6 2 PAOZZ 1005009373078 19200 8448615 BUFFER ASSEMBLY MI6A2 WOGIAR BE 2 PAOZZ 1005012313138 19200 9390
44. 6 or firing pin does not meet gage protrusion requirement Replace firing pin 6 p 3 16 Change 4 3 5 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 5 TROUBLESHOOTING PROCEDURES CONT TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 6 FAILURE TO UNLOCK Step 1 Burred locking lugs 1 bolt assembly Remove burrs Step 2 Burred lugs 2 on barrel extension Remove burrs Step 3 Short recoil Refer to page 3 9 7 FAILURE TO EXTRACT Step 1 Inspect cartridge extractor and extractor spring assembly Replace if cracked or broken p 2 35 Step 2 Inspect badly pitted chamber with reflector tool Item 2 fig C 1 7 Replace barrel assembly If chamber Is badly pitted p 3 29 8 FAILURE TO EJECT Short recoil Refer to page 3 9 3 6 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 9 FAILURE TO COCK Step 1 Worn or broken trigger nose 1 or trigger spring 2 Replace trigger 3 or defective trigger spring 2 p 3 62 Step 2 Worn or broken hammer trigger notch 4 Replace hammer 5 p 3 62 Step 3 Worn or broken hammer disconnector hook 6 Replace hammer 5 p 3 62 Step 4 Worn or broken hammer automatic sear hook 7 Replace hammer 5 p 3 62 N S M16A2 and M4 ONLY M4A1 ONLY Change 4 3 7 ARMY TM 9 1005 319 23 amp AIR FORCE T
45. AIR FORCE TO 11W3 5 5 42 2 T PREVENTIVE MAINTENANCE CHECKS AND SERVICES CONT PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Interval Item to be Not Fully Mission Checked or Procedure Capable if Serviced M4 M4A1 4 Quarterly Upper receiver Inspect carrying handle assembly 16 cont and barrel assem and mounting surface 17 of upper bly Serviceability receiver for damage If the carrying check cont handle is missing or can not be correctly mounted repair as authorized or evacuate to support maintenance Inspect carrying handle assembly 16 to insure unit applied identification ID code matches unit applied ID code on carbine If it doesn t match locate correct carrying handle assembly and match up to correct M4 M4A1 carbine If a match can not be found the weapon should be re zeroed by the operator 2 11 1 2 11 2 blank Change 4 1 1 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 T Item No 2 12 C PREVENTIVE MAINTENANCE CHECKS AND SERVICES CONT Interval hange 5 PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Item to be Checked or Serviced Procedure WARNING Not Fully Mission Capable if Below direct support maintenance do not interchange bolt assemblies from one rifle to another Doing so may result in injury to or death of personnel Quarterly Key ana poit carrier assem bly and bolt assemb
46. Bolt carrier group Inspect bolt for elongated or oversized firing pin hole using plain cylinder gage 12620101 Firing pinholes which permit the plain cylinder plug gage to fully penetrate at any position on the circumference will be rejected Bolt face with a cluster of pits which are touching or tightly grouped covering an area measuring approximately 1 8 inch 0 31 cm across will be rejected Bolts which contain pits extending into the firing pinhole will not be rejected unless firing pin hole gaging check determines rejection Bolts which contain individual pits or scattered pits will not be cause for rejection Only phosphated bolt carriers are acceptable Both phosphated and chrome plated bolts are acceptable Bolt locking lugs and bolt cam pin hole Inspect for cracks in the locking lugs and cam pin hole area Use a black light if available otherwise use a glass of no more than 3X magnification or use inspection penetrant item 25 app D Use instructions contained in kit for application If cracks are detected the bolts will be replaced NOTE Particular attention must be given to the area where the lugs meet the bolt body and around the side walls of the cam pin hole Bolt rings must not be broken Ring gaps must be properly spaced approximately 1 3 turn apart and not in line Firing pin protrusion must be not less than 0 028 inch 0 071 cm or more than 0 036 inch 0 091 cm Use firing pin protru sion gage 7799735
47. Both finishes are acceptable under certain operational requirements and or restrictions Phosphate coated bolt carriers are required for divisional combat units Chrome plated bolt carriers are acceptable for divisional noncombat units and training center units Chrome plated and phosphate coated bolt assemblies bolt carrier assemblies and repair parts for these assemblies may be intermixed In any combination with the following exception Phosphate coated bolt carriers are required for all deployable and deploying units Chrome plated bolt carriers are acceptable for nondeployable and training center units 0 025 MAX 4 PLACES A ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 3 7 BOLT CARRIER ASSEMBLY CONT INSPECTION CONT 2 Inspect firing pin 131 tip for proper con tour Inspect for pitting wear and burrs Pits or wear in area 4 Is permissible Replace firing pin If defective 3 Prior to reassembly insert bolt assembly 5 Into key and bolt carrier assembly 6 do not insert bolt cam pin and exercise bolt assembly in and out of key and bolt carrier assembly Check for binding 4 Check bolt assembly 5 for proper fit with bolt cam pin removed Turn key and bolt carrier assembly 61 and suspend so the bolt assembly is pointed down NOTE The bolt assembly must not drop out If weight of bolt assembly allows It to drop out of key and bolt carrier assem
48. Code The source code tells you how to get an item needed for maintenance repair or overhaul of an end item equipment Explanations of source codes follow Explanation Stocked items use the applicable NSN to request requisi tion Items with these source codes They are authorized to the level indicated by the code entered In the 3d position of the SMR code Items coded PC are subject to deterioration Items with these codes are not to be requested requisi KD toned Individually They are part of a kit which is author KF gt zed to the maintenance level indicated In the 3d posi KB ton of the SMR code The complete kit must be requisi tioned and applied MO Made at Unit Items with these codes are not to be requested requisi AVUM Level tioned Individually They must be made from bulk material MF Made at DS which Is identified by the part number In the DESCRIPTION AVIM Level AND USABLE ON CODE UOC column and listed In the MH Made at GS Bulk Material group of the repair parts list in this RPSTL If Level the Item Is authorized to you by the 3d position code of ML Made at Spe cialized Repair Act SRA MD Made at Depot the SMR code but the source code Indicates It is made at a higher level order the Item from the higher level of maintenance C 2 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Code Explanation AO Assembled by unit AVUM Level AF Assembl
49. Equipment TB 43 0002 73 Maintenance Expenditures Limits for FSC Group 10 FSC Classes 1005 1010 1015 1030 1055 1090 and 1095 TI 05538A 15 24 mte Early Warning Indications of Malfunctions 05538 3 5 12 Checking Muzzle and Breech Erosion Barrel T1 8005 24 20 tiit Prefire Inspection Small Arms Weapons Ordnance Material TM 9 1005 237 23 amp Organizational and Direct Support Maintenance Manual Including Repair Parts and Special Tools List for Bayonet Knife M6 and M7 with Bayonet Knife Scabbard M10 and M9 Multipurpose Bayonet System TM 9 1005 319 10 Operator s Manual for 5 56mm M16A2 Rifle and M4 M4A1 Carbine 9 1010 221 23 amp Organizational Direct Support and General Support Maintenance Manual Including Repair Parts and Special Tools List for Launcher Grenade 40mm M203 W E NSN 1010 00 179 6447 TM 9 6920 363 128 M261 Conversion Kit TM 9 6920 746 128 M2 Practice Bolt TM 11 5855 213 23 amp Night Vision Sight Individual Served Weapon AN PVS 4 TM 750 244 7 sese Procedures for Destruction of Equipment in Federal Supply Classifications 1000 1005 1015 1020 1025 1030 1055 1090 and 1095 to Prevent Enemy Use TM 470
50. F G LOCATION AND DESCRIPTION OF MAJOR COMPONENTS MAGAZINE 30 cartridge capacity SLING The sling is adjustable and provides a means to carry the weapon BOLT CARRIER ASSEMBLY Carries bolt assembly to chamber and fires the weapon Contains the firing pin cartridge extractor bolt assembly cartridge ejector and bolt cam pin CHARGING HANDLE ASSEMBLY Provides a means of charging the weapon M16A2 UPPER RECEIVER AND BARREL ASSEMBLY Upper receiver contains rear sight assembly ejection port ejection port cover and a housing for the key and bolt carrier assembly and bolt assembly Rifle barrel assembly is air cooled contains compensator and front sight assembly and holds the two handguard assemblies and the sling swivel LOWER RECEIVER AND BUTTSTOCK ASSEMBLY Lower receiver contains the trigger assembly sear hammer assembly selector lever rifle grip bolt catch and buttstock assembly The buttstock assembly houses the action spring buffer assembly and extension assembly M4 M4A1 CARRYING HANDLE Provides a means of carrying carbine M4 M4A1 UPPER RECEIVER AND BARREL ASSEMBLY Upper receiver contains ejection port ejection port cover a housing for key and bolt carrier assembly and bolt assembly and mounting surface for the carrying handle assembly Carbine barrel assembly is air cooled contains compensator and front sight assembly and holds the two handguard assemblies and the sling swivel 1 4 Change 4 M16A2
51. FORCE TO 11W3 5 5 42 M4A1 NOTE Use of fabricated slave pin will allow removal of the following parts as a unit Remove trigger pin 14 by pushing from the left side of lower receiver 9 with fabricated slave pin 15 and a drive pin punch Remove semiautomatic disconnector 16 burst disconnector 17 and trigger assembly 18 If furthe disassembly of trigger assembly is required see page 3 75 M4A1 ONLY Remove disconnector 19 disconnector spring 19 1 and trigger assembly 20 from lower receiver and extension subassembly 21 Change 4 3 65 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 3 13 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY CONT b INSPECTION NOTE Refer to page 3 35 for repair of corroded surfaces Inspect lower receiver and buttstock assembly for corrosion in the lower receiver lobes of the pivot area or hinge pin area If extensive corrosion appears in these areas the receiver will not be repaired turn rifle in for replacement SHINY SURFACES SHINY SURFACES CORRODED AND NO HOLES CORRODED REPARABLE REPARABLE REPARABLE REPARABLE SHINY SURFACES REPARABLE CORRODED REPARABLE CORRODED WITH HOLE CORRODED LOBES WEAKENING NONREPARABLE PIVOT PIN AREA NONREPARABLE THIN WALLS HOLES AND THIN WALLS 3 66 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 WARNING When using solid film lubricant or dichloromethane be sure the area is well ventilated
52. Gauging Requirements sees M16A2 Rifle Final Final Inspections oi oH Functional Theory of Three Round Burst ucc niet eae Dace a ee a ea Official Nomenclature Names and Preembarkation Inspection of Materiel in Units Alerted for Overseas Mee eai ainni naa taaa Preparation for Storage or Preventive Maintenance Checks and Principles of 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Page 4 5 4 2 4 4 2 59 RIS 2 57 3 62 TT 6 0 3 66 TET 2 61 2 62 3 70 2 61 3 67 3 68 3 77 TET 3 79 3 80 3 79 2 33 1 1 1 2 33 3 15 2 54 3 58 LE 2 34 3 15 2 69 NNI DAE EU OU 2 68 3 83 E 2 70 M 3 83 3 94 3 85 3 88 mo 3 88 1 1 Index 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 ALPHABETICAL INDEX CONT Subject Page R Rear Sight Assembly See Upper Receiver Assembly and Rear Sight Assembly Helerencesim 1 2 1 3 1 Rep
53. Manual FMEM 3A tee Field Firing Techniques SB 740 1 reif d e ten ba Publications for Packing Army General Supplies SPI 00 856 6885 Special Packaging Instructions for M16 Rifle A 5 FORMS AFTO Form 22 Technical Order System Publications Improvement Report AFTO Form 105 Inspection Maintenance and Firing Data for Ground Weapons DA Form 2028 Recommended Changes to Publications and Blank Forms DA Form 2028 2 Recommended Changes to Equipment Technical Manuals DA Form 2404 Equipment Inspection and Maintenance Worksheet DA Form 24085 9 Equipment Control Record DD Form 314 nies Preventive Maintenance Schedule and Record A 2 Change 5 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 NAVMC 10772 sse Recommended Changes to Technical Publications 11003 sse Ordnance Serialized Items Subsidiary Records Report of Discrepancy ROD 9E 368 Product Quality Deficiency Report A 6 SUPPLY CATALOGS SUPPLY LISTS SC 4933 95 11 2 Shop Set Small Arms Field Maintenance SC 5180 95 07 Tool Kit Small Arms Repair A 3 A 4 blank ARMY TM 9 1005 319 23 amp P AIR FORCE TO 1 1W3 5 5 42 APPENDIX B MAINTE
54. New or changed illustrations are indicated by a miniature pointing hand highlighting the change Remove Pages a thru ii 1 1 and 1 2 1 4 1 thrul 6 2 12 2 15 and 2 16 2 31 and 2 32 2 35 thru 2 36 1 2 36 2 blank 2 49 and 2 50 2 57 and 2 58 3 25 and 3 26 3 29 and 3 30 3 45 and 3 46 3 57 thru 3 62 3 82 thru 3 84 4 1 and 4 2 A 1 and A 2 C 5 thru 1 12 E 1 and E 2 None Insert Pages SEM 11 1 1 2 thru 1 6 2 15 and 2 16 and 2 32 2 35 thru 2 361 2 36 2 blank 2 49 and 2 50 2 57 and 2 58 3 25 and 3 26 3 29 and 3 30 3 45 and 3 46 3 57 thru 3 62 3 89 thru 3 84 4 1 and 4 2 A 1 and 2 C thru 1 7 I 8 blank E 2 4 File this change sheet in the front of the publication for reference purposes By Order of the Secretary of the Army DENNIS J REIMER General United States Army Chief of Staff Official JOEL HUDSON Administrative Assistant to the Secretary of the Army 03287 DISTRIBUTION To be distributed in accordance with the initial distribution number IDN 400020 requirements for TM 9 1005 319 23 amp P CHANGE No 4 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 HEADQUARTERS DEPARTMENTS OF THE ARMY AND AIR FORCE Washington D C 5 May 1995 UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST RIFLE 5 56MM M16A2 W E 1005 01 128 9936 EIC 4GM TM 9 1005 319 23 amp P May 1991 is changed as follow
55. Paint all bare metal surfaces with olive drab enamel paint NSN 8010 01 350 5249 or equivalent Change 4 2 71 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 19 MAJOR COMPONENTS OF M16A2 RIFLE CONT c STOWAGE CONT 5 Reinsert the adapter bar into position on the arms rack Using two 3 8 inch x 2 inch machine screws MS35206 315 NSN 5305 00 984 5695 or equivalent four washers MS21306 1C NSN 5310 01 327 9713 or equivalent and two nuts MS35649 2382 NSN 5310 00 056 3395 or equivalent assemble adapter bar to arms rack and tighten securely The bolts can be inserted from either the back or the front to meet your requirements If the rack is placed close to a wall or another rack It is recommended that the bolts be inserted from the back 6 Tack weld braze or peen the threaded end of the bolt to the nut to prevent easy removal 7 Place rack back into position and replace the weapons NOTE Adapter bar must be removed from arms rack prior to turning in the arms rack to the supply system d remove the adapter bar from the arms rack remove the head of the bolt or the nut using a hand held grinder or file to avoid damage to the aluminum arms rack legs A hammer and cold chisel may be used If no other way to remove the adapter exist e lt is recommended that the rail protector NSN 1005 01 394 7677 app D item 26 1 be used during storage of the carbines when the carrying handle assemb
56. Socket head capscrews must be staked Carrier key must not be dented where end mates with gas tube Repair or replace damaged carrier keys Headspace Inspect headspace using headspace gage 7799734 Excessive headspace will be cause for rejection Trigger pull Inspect trigger pull using trigger measuring fixture 7274758 Trigger pull must be minimum 5 5 pounds 2 49 kg maxi mum for M16A2 and M4 is 9 5 pounds 4 31 kg and maximum for 4 is 8 5 pounds 3 86 kg Test trigger pull refer to page 3 83 steps a b c and d Change 4 3 101 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 25 GENERAL INSPECTION CRITERIA CONT Table 3 1 Lower receiver Action Handguaird iet teens Stock 3 102 Change 4 5 56MM Rifle M16A2 M4 M4A1 Carbine Cont Standard Inspect hammer and trigger pin holes using plain cylinder plug gage 12006472 Penetration of the gage in any one or more of the four holes will be cause for rejection Inspect for cracks corrosion or mutilation which would affect functioning Small dents or gouges will not be cause for rejection Inspect receiver for corrosion in the lobes of the pivot or hinge pin area Width between lobes shall not exceed 0 515 inch 1 30 cm Inspect receiver for break through of metal Inspect receiver and receiver extension for initial loss of protective coating
57. and repair parts special tools special test measurement and diagnostic equipment TMDE and other special support equipment required for performance of unit and direct support maintenance of the M16A2 rifle and M4 M4A1 carbines It authorizes the requisitioning issue and disposition of spares repair parts and special tools as indicated by the source maintenance and recoverability SMR codes C 2 GENERAL In addition to Section Introduction this Repair Parts and Special Tools List is divided into the following sections a Section Il Repair Parts List A list of spares and repair parts authorized by this RPSTL for use in the performance of maintenance The list also includes parts which must be removed for replacement of the authorized parts Parts lists are composed of functional groups in ascending alphanumeric sequence with the parts in each group listed in ascending figure and item number sequence Bulk materials are listed by item name in FIG BULK at the end of the section Repair parts kits or sets are listed separately in their own functional group within Section Il Repair parts for repairable special tools are also listed in the section b Section Special Tools List A list of special tools special TMDE and other special support equipment authorized by this RPSTL as indicated by Basis of Issue BOI information in DESCRIPTION AND USABLE ON CODE UOC column for the performance of maintenance Section IV Cross Refer
58. appears tighten self locking screw If still not tight remove butt stock assembly and check for loose lower receiver extension If loose evacuate to support maintenance If not loose replace buttplate 14 CRITICAL AREA Change 4 2 17 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 7 PREVENTIVE MAINTENANCE CHECKS AND SERVICES CONS Interval Item to be No Checked or Serviced 6 Quarterly Lower receiver cont and buttstock 2 18 Change 3 PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT assembly serviceability check cont Not Fully Mission Procedure Capable if RIFLE ONLY Small amounts of side to side up and down or rotational movement of the buttstock assembly is acceptable 1 Cracks visible around the butt plate mounting holes while screws are mounted SH Cracks are visible around mount ing holes when installed on rifle 2 Cracks or separations around the door assembly are visible when the door assembly is closed SH Cracks are visible when door assembly is closed 3 If buttplate is cracked in excess of 0 25 in O 64 cm in length and ex tends through the buttplate 14 see pg 2 64 for repair SH If cracked in excess of 0 25 in extends thru buttplate 4 The buttplate 14 should not be removed other than for repair or re placement of parts at which time a new self locking screw NSN 5305 01 147 8585 must be used ARMY T
59. assembly 1 2 3 or 3 1 for cracks or damage RIFLE ONLY a Some old buffers 1 have a hole with pin installed which protrudes equally on each side approximately 1 32 inch O 08 cm 2 b Some buffers 2 have a hole In the housing but no 7 RIFLE c New buffers 3 do not have a hole In buffer body or a pin BOTH WEAPONS 2 If cracked or damaged replace CARBINE 9 ONLY 3 Check free length of action spring 4 The free length FOR RIFLE ONLY must be between 11 3 4 inches 29 85 cm mini mum and 13 1 2 inches 34 29 cm maximum FOR CARBINE ONLY must be between 10 1716 inches 25 56 cm minimum and 11 114 Inches 28 58 cm maximum If not replace Do not attempt to adjust the length by stretching the action spring FREE LENGTH 4 Inspect lower receiver 5 without further disassembly for legibility of serial number ARMY ONLY If the serial number is hard to read evacuate to direct support maintenance AIR FORCE ONLY If the serial number is hard to read evacuate to depot maintenance 2 60 Change 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 NOTE AIR FORCE ONLY Only depot maintenance is authorized to restamp the serial number 5 Inspect for missing or damaged parts Inspect finish of lower receiver for shiny spots Touch up with solid film lubricant as required p 2 34 NOTE If a M16A2 rifle or M4 M4A1 carbine lower rec
60. be straightened or replaced See page 3 38 for straightening instructions procedures 3 46 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Assemble charging handle assembly 4 bolt assembly and key and bolt carrier assembly 5 into upper receiver assembly 6 Insert headspace gage 7 PN 7799734 in chamber NOTE For the purpose of this test light finger pressure is defined as 8 1 2 to 8 3 4 pounds 8 Check headspace by pressing key and bolt carrier assembly 5 and charging handle assembly 4 forward using light finger pressure Bolt should not rotate to locked position Key and bolt carrier assembly 5 must protrude from rear of upper receiver assembly 6 for proper headspace If excessive headspace first replace old bolt assembly with an unused bolt assembly and then recheck If headspace is not corrected replace rifle barrel assembly then recheck with the original bolt assembly to determine if the bolt assembly is still good or if the bolt assembly should be replaced also Remove key and bolt carrier assembly bolt assembly charging handle assembly and headspace gage Reassemble rifle refer to page 3 77 NOTE Rifles which have been rebarreled must be function fired with seven rounds of 5 56mm ball ammunition After rebarreling the rifle must be targeted with three rounds of 5 56mm ball ammunition at 25 meter range using target Refer to TM 9 1005 319 10 and FM 23 9 Change 4 3 47 AR
61. black light If available 3 23 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 8 BOLT ASSEMBLY CONT c TEST Test bolt 1 for elongated or oversized firing pin hole using special no go plug gage 2 PN 12620101 NOTE Bolts with firing pin holes which permit the special no go plug gage to fully penetrate at any position on the circumference will be rejected and replaced d REASSEMBLY NOTE To install a bolt ring carefully place one end in the bolt ring groove and hold In place with the thumb of one hand With the index finger of the other hand gently guide and push the rest of the bolt ring into the groove a little bit at a time until the entire bolt ring is in place 1 Install the three bolt rings 1 one at a time onto the bolt 2 using care not to bend or spring new bolt rings Stagger the bolt ring gaps approximately turn apart 3 24 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 NOTE Make certain bolt ring gaps staggered to prevent loss of gas pressure New bolt rings will make installing the bolt assembly difficult Lubricate inside key and bolt carrier assembly and use gentle pressure when installing 2 Reassemble rifle refer to page 3 77 3 9 KEY AND BOLT CARRIER ASSEMBLY This task covers a Disassembly Reassembly b Repair INITIAL SETUP Tools Materials Parts Fiel
62. carbine M16A2 ONLY provides storage for basic cleaning materials M4 M4A1 CARRYING HANDLE ASSEMBLY Provides a means of carrying the carbine contains rear sight assembly and can be removed for mounting various optics M4 M4A1 UPPER RECEIVER AND BARREL ASSEMBLY Provides support for the bolt carrier assembly The barrel chambers the cartridge for firing and directs the projectile M16A2 M4 M4A1 1 6 Change 5 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS CHAPTER OVERVIEW This chapter provides information and Instructions to help keep the rifle in good repair and contains the following sections Repair Parts Special Tools TMDE and Support Equipment Service Upon Receipt Preventive Maintenance Checks and Services PMCS Troubleshooting Maintenance Procedures Dang Section REPAIR PARTS SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT 2 1 COMMON TOOLS AND EQUIPMENT For authorized common tools and equipment refer to the Modified Table of Organization and Equipment MTOE applicable to your unit Air Force users must maintain the following common tools 3 ounce soft brass hammer Tweezers round nose pliers Vise Hammer Flat tip screwdriver Needle nose pliers Punch 2 2 SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT Special tools required for unit support are listed in appendixes B and C Fabricated tools are listed and illustrated in appendix E 2 3 REPAIR PARTS Repai
63. covered equipment to be less than fully ready to perform its assigned mission Change 3 2 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 T PREVENTION MAINTENANCE CHECKS AND SERVICES CONT PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Item to be Not Fully Mission Checked or Procedure Capable if Serviced WARNING Before starting an inspection be sure to clear the weapon Do not pull the trigger until the weapon has been cleared Inspect the chamber to ensure that it is empty and no ammunition is in position to be chambered Do not keep live ammunition near work area NOTE An inactive weapon is a weapon which has been stored in an arms room for a period of 90 days without use The weapon may or may not have been assigned to an individual Inactive weapons shall receive quarterly PMCS unless inspection reveals more frequent servicing is necessary Normal cleaning PMCS of an inactive weapon will be performed every 90 days Should the unit armorer detect corrosion on a weapon prior to the end of the 90 day period the PMCS should be performed immediately Solid Film Lubricant SFL is the authorized touch up for the M16A2 Rifle and M4 M4A1 Carbine and may be used on up to one third of the exterior finish of the weapon FOR ARMY CONUS USE ONLY AND AIR FORCE TRAINING WEAPONS ONLY Solid Film Lubricant may be used as a touch up without limitation on the upper receiver and barrel assembly This i
64. for repair procedures c REPAIR 1 Repair corroded upper receiver assembly surfaces as follows a Sand corroded area with abrasive cloth and make sure all corrosion has been removed WARNING When using solid film lubricant or dichloromethane be sure the area is well ventilated b c d Wash area with technical dichloromethane methylenechloride to re move all dirt grease and foreign material Apply sealing compound mixed In accordance with manufacturer s directions to areas to be filled Spread sealing compound smoothly as possible Into defective area using a putty knife or similar tool CORRODED REPARABLE CORRODED NONREPARABLE Change 1 3 35 ARMY TM 9 1005 319 23 amp P AIR FORCE TO IIW3 5 5 42 3 10 UPPER RECEIVER AND BARREL ASSEMBLY CONT c REPAIR CONT NOTE Do not feather edges e Place a sheet of polyethylene Item 32 app D cut to size over filled area Rub by hand to smooth BREAKTHROUGH HOLE ACCEPTABLE 2 After curing remove polyethylene sheet In accordance with Instructions by the manufacturer WARNING When using solid film lubricant or dichloromethane be sure the area is well ventilated CAUTION Solid film lubricant is to be used only as an exterior surface protective finish and touchup If solid film lubricant comes in contact with recoiling parts or functional surfaces of
65. from projectiles are allowable c Definitely ringed bores or bores ringed sufficiently to bulge the outside surface of the barrel are cause for rejection Replace barrel assembly if defective 4 lf the upper receiver is separated from the barrel assembly Inspect chamber for pits utilizing a flashlight Pits 1 8 inch 10 32 cm In length are cause for rejection Replace rifle barrel assembly If defective 5 f upper receiver and barrel assembly is assembled Inspect chamber using reflector tool 1 and flashlight Pits 1 8 inch O 32 cm In length are cause for rejection Replace rifle barrel assembly If defective If rifle barrel assembly Is replaced Inspect headspace p 3 45 3 34 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Inspect upper receiver assembly for cracks corrosion wear or damage a Small dents or gouges that do not affect functioning will not be cause for rejection b Inspect all parts for damage and wear Replace all defective parts If upper receiver assembly contains cracks or holes the upper receiver assembly will be replaced NOTE Damaged or missing teeth of the barrel nut is not cause for rejection provided the proper torque value can be obtained during installation using the tools depicted If removal of the barrel is not possible with the combination tool a pipe wrench or other such tool may be used during removal Inspect front sight guards for bends if bent see page 3 37
66. gage does not pass through the barrel when it is flexed replace the rifle barrel assembly c Place the barrel in a vise using appropriate protective laws Clamp the barrel between the front sight assembly and the compensator approximately 1 inch 2 54 cm from the front sight assembly The rifle barrel assembly should be in a horizontal position with the side noted in step b toward you 3 38 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 CAUTION Do not apply pressure to the receiver Grasp the BARREL near the receiver so that when force is applied the barrel will flex In the same direction as noted In step b Give the barrel a sharp jerk of approximately 20 to 40 pounds of force f Remove the barrel from the vise and recheck straightness step al If gage still will not pass through the barrel perform step b to determine direction of bend If the barrel is still bent in the same direction as before perform steps c through f using slightly more force If the barrel Is now bent In the opposite direction replace the rifle barrel assembly If the gage passes freely through the barrel the barrel shall be considered straight and continue In service If the barrel has been straightened the rifle must be targeted p 3 45 d REASSEMBLY Position barrel nut 1 by sliding it to the rear of rifle barrel assembly 2 as far as possible Slide handguard slip ring 3 over barrel nut 1 P
67. manual a DISASSEMBLY General Safety Instructions To avoid injury to your eyes use care when removing and installing spring loaded parts When using solid film lubricant or dichloro methane be sure the area is well ventilated 1 Remove screw 1 and lockwasher 2 WARNING To avoid injury to you eyes use care when removing and installing spring loaded parts 2 Carefully remove pistol grip 3 and catch helical spring 4 and safety detent 5 to prevent loss Change 5 2 57 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 2 17 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY CONT la DISASSEMBLY CONT RIFLE ONLY NOTE If the self locking screw is removed it must be discarded and replaced with a new one 3 Remove self locking screw 6 RIFLE ONLY WARNING To avoid injury to your eyes use care when removing and installing spring loaded parts 4 Remove buttstock assembly 7 carefully and catch helical spring 8 takedown pin detent 9 takedown pin 10 and stepped spacer 11 to prevent loss NOTE If detent 9 will not come out use a wire to push it out CARBINE ONLY 4A Extend buttstock assembly 11 1 4B Grasp the lock release lever 11 2 in the area of the retaining nut 11 3 pull down ward and slide buttstock to the rear to separate the buttstock assembly from the lower receiver extension 2 58 Change 3
68. position bolt carrier key 2 on bolt carrier 1 Install two carrier and key screws 3 Always use new screws Use a tight fitting 1 8 inch socket head screw wrench attachment and an Inch pound torque wrench to torque the carrier and key screws 3 to 35 to 40 Inch pounds 3 95 to 4 52 N m 3 27 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 42 3 9 KEY AND BOLT CARRIER ASSEMBLY CONT c REASSEMBLY CONT 3 28 NOTE Field staking method will be used by field units Use solid center punch and hand hammer to stake the two carrier and key screws 3 In three places 0 025 MAX 4 PLACES SURFACE A 53 FIELD REPLACEMENT STAKING 5 Reassemble rifle refer to page 3 77 CAUTION If blanks are used blank firing attachment BFA must be attached NOTE If the bolt carrier key is replaced three to eight rounds of blank or ball ammunition must be fired to ensure a seal is created Manual operation of the rifle may be required If blank ammunition is utilized M16A2 Blank Firing Attachment must be adapted ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 10 UPPER RECEIVER AND BARREL ASSEMBLY This task covers a Disassembly d Reassembly b Inspection Cleaning e Test c Repair INITIAL SETUP Test Equipment References Tool and Gage Set item 2 app B FM 23 9 Tools ARMY Small Arms Repairman Tool Kit item 3 app B Fiel
69. post front sight detent and helical spring for damage If damaged replace Change 5 2 49 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 2 16 UPPER RECEIVER AND BARREL ASSEMBLY RIFLE BARREL ASSEMBLY AND UPPER RECEIVER ASSEMBLY CONT c INSPECTION CONT 5 Inspect barrel for pits in bore burrs broken or worn locking lugs and surface cracks defects Pits no wider than a land or groove and 3 8 inch 0 953 cm or less in length are allowable in the bore Uniformly fine pits in a densely pitted area of the bore are allowable Lands that appear dark due to coating of gliding metal from projectiles are allowable Striping of lands and grooves shall not be cause for rejection unless support maintenance determines by use of the barrel erosion gage For pits other than mentioned above broken or burred locking lugs or surface cracks evacuate to support maintenance Inspect bore for ringing Definitely ringed bores or bores ringed sufficiently to bulge the outside surfaces of the barrel are causes for rejection Evacuate to support maintenance Inspect chamber for pitting Fine pits or fine pits in a densely pitted area are allowable Pits 1 8 inch 0 318 cm in length are cause for rejection Evacuate to support maintenance Hand check compensator 3 for looseness on barrel The third middle slot 4 must be straight up at top dead center TDC The al
70. purpose of the following check SLOW is defined as 1 4 to 1 2 the normal rate of trigger release Hold trigger to the rear charge weapon and release the trigger with a slow smooth motion without hesitations or Stops until the trigger is fully forward an audible click should be heard Hammer should not fall Repeat the SEMI position test five times The weapon must not malfunction during any of these five tests If the weapon malfunctions during any of these five tests evacuate rifle to support maintenance for repair Place selector lever in BURST position Charge weapon and pull trigger Hammer should fall Hold trigger to the rear pull charging handle assembly to rear and release three times Release trigger Hammer should not fall The burst disconnector should have held the hammer to the rear while the trigger was in the pulled position Pull trigger Hammer should fall This should be the first round of a three round burst With hammer in forward position attempt to place the selector lever in the SAFE position If selector lever can be placed on SAFE evacuate the weapon to support maintenance M4A1 ONLY Place selector lever in AUTO position Charge weapon and pull trigger Hammer should fall Hold trigger to the rear charge weapon and release trigger Pull trigger Hammer should not fall AUTO sear should have released hammer while holding trigger in the squeezed position before releasing and resqueezing the trigger With hammer
71. rear sight assembly base is under tension of the ball bearing and helical spring The 300 meter mark should align with the mark on the receiver c If the 300 meter mark is not aligned with the mark on receiver slip the range scale in the following manner 1 Position the 300 meter mark with the mark on the receiver 2 Insert a 1 16 inch alien wrench through the access hole of the rear sight assembly base and into the index screw 3 Loosen the index screw three turns and leave the wrench in place 4 Rotate lower portion of elevation knob counterclockwise until it stops range scale should not have moved Elevation knob should be positioned on its last whole click 5 Tighten index screw and remove wrench 6 Check for proper setting Pull charging handle assembly to rear Check that chamber is clear Leave hammer in cocked position Place selector lever is SAFE position and pull trigger Hammer should not fall WARNING If rifle falls any of the following inspections continued use of the rifle could result In injury to or death of personnel NOTE For the purpose of the following tests SLOW is defined as 1 4 to 1 2 the normal rate of trigger release Place selector lever in SEMI position 3 86 Change 4 16 17 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Pull trigger Hammer should fall Hold trigger to the rear charge rifle and release the trigger with a slow smooth motion without hesitations o
72. standards are provided to ensure that the user is furnished equipment which will perform its mission without early failure or major maintenance problems Change 4 3 95 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 21 SCOPE a The standards prescribed provide for a high percentage of remaining life in affected rifles therefore rifles designated for overseas shipment must qualify under the standards contained in the following paragraph table and in referenced DA publications before they can be approved for shipping action b Provisions of this standard apply to all US Army agencies activities selecting or preparing rifles for shipment to US troops overseas It also applies to CONUS troops preparing rifles for shipment overseas Provisions do not apply either to rifles being prepared for shipment to MAP MAS recipients unless specifically prescribed by MAP MAS transaction for the materiel or to rifle being returned to CONUS from overseas The maintenance instructions and standards contained herein do not apply to rifles once the material has arrived at the overseas destination At that time maintenance instructions contained in the applicable TM s will be used This applies to rifles which are the logistic responsibility of the US Army Armament Munitions and Chemical Command 3 22 GENERAL a Only rifles which have been classified as serviceable condition code A B or C under AR 725 50 will be considered for overseas sh
73. support maintenance 2 30 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 12 FAILURE TO CYCLE WITH SELECTOR LEVER SET ON BURST 16 2 AND 4 Faulty selector lever or broken cam cam clutch spring or burst disconnector Evacuate to support maintenance 12 1 FAILURE TO CYCLE WITH SELECTOR LEVER SET ON AUTO 4 1 Faulty selector lever Evacuate to support maintenance 13 FIRES TWO ROUNDS WITH ONE PULL OF TRIGGER WITH SELECTOR LEVER SET ON SEMI DOUBLE FIRING Perform function test If any part of function test p 2 68 fails evacuate to support mainte nance 14 FIRES WITH SELECTOR LEVER ON SAFE OR WHEN TRIGGER IS RELEASED WITH SELECTOR LEVER ON SEMI Worn broken or missing parts of firing mechanism Evacuate to support maintenance o SEMI Ca SAFE Change 4 2 31 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 9 TROUBLESHOOTING PROCEDURES CONT TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 15 BOLT ASSEMBLY FAILS TO LOCK TO REAR AFTER FIRING LAST ROUND Step 1 Magazine follower 1 worn or broken Replace magazine Step 2 Magazine catch spring 2 weak or broken Replace magazine Step 3 Magazine feeder lips 3 bent or broken Replace magazine Step 4 Magazine follower 1 binds during operation Replace magazine Step 5 Broken bol
74. the blank firing attachment USE HANDS ONLY Push slide 2 into compensator 3 and hand tighten NOTE Check for tightness after firing approximately 50 blank rounds CAUTION Do not use tools to tighten the blank firing attachment USE HANDS ONLY Unscrew slide 1 to remove from compensator 2 Unhook blank firing attachment 3 from behind the first groove of the compensator 2 4 10 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCE 1 1 3 5 5 42 Screw slide 1 all the way in on blank firing attachment 3 c CLEANING Clean blank firing attachment with CLP wipe dry and coat with CLP d INSPECTION Inspect blank firing attachment for cracks or distortion Be sure the parts in the slide are clear and clean lf blank firing attachment is cracked or distorted it is unserviceable e REPAINTING Repaint blank firing attachment using enamel coating compound Red for M16A2 rifle or Yellow for M4 M4A1 carbine Painting is the only repair authorized f REPLACEMENT Replace blank firing attachment if unserviceable Change 4 4 11 4 12 blank ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 APPENDIX A REFERENCES A 1 TECHNICAL BULLETINSINSTRUCTIONS MANUALS ORDERS TB 9 1000 24734 Standards for Overseas Shipment or Domestic Issue of Small Arms Aircraft Armament Toward Howitzers Mortars Recoilless Rifles Rocker Launchers and Associated Fire Control
75. the front hook of the first disconnector Is now fully in the next stop notch which is deeper than the others 3 92 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 REAR HOOK u Because a stop notch is deeper than the others It allows the front hook of the burst disconnector further forward than before This allows the rear hook of the burst disconnector to latch on the rear hammer notch This holds the hammer fully to the rear even though the trigger is still to the rear This happens when the burst Is over and the firing Is stopped v Once the trigger is released the trigger nose comes up and holds the hammer back NOTE Pulling the trigger to the rear and holding it back again will fire another three round burst This will continue until the magazine is empty However the trigger must be released between each burst 3 93 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 3 19 MI 6 2 RIFLE AND M4 M4A1 CARBINE ANNUAL GAGING REQUIREMENTS This task covers a Inspection INITIAL SETUP Test Equipment Tool and Gage Set item 2 app B Tools ARMY Small Arms Repairman Tool Kit item 3 app B Field Maintenance Basic Less Power Small Arms Shop Equipment item 1 app B References DA PAM 738 750 TM 9 1005 319 10 AFR 50 36 AFTO Form 105 General Safety Instructions To avoid injury to your eyes use care when removing and installing spring loaded parts Initial gaging is required 1 y
76. varies use longest as 22 and the shortest as 9 Insert threaded portion of rear sight assembly base 10 into upper receiver 3 and rotate elevation knob assembly until threads engage Insert helical spring 11 and ball bearing 12 in their hole as rear sight assembly base is lowered into upper receiver as elevation knob assembly is further rotated Rotate elevation knob assembly until rear sight assembly base is all the way down Then come up 22 clicks before installing spring pin Check spring action of helical spring 11 on upper receiver ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 Change 4 3 55 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 11 UPPER RECEIVER ASSEMBLY AND REAR SIGHT ASSEMBLY CONT e REASSEMBLY CONT CAUTION Ensure that spring pin 1 3 passes over helical spring 14 not through its coils Insert helical spring 14 through underside of upper receiver 15 Compress helical spring with a small tip screwdriver 16 to install spring pin 1 3 Spring pin must pass over helical spring not through its coils Rotate elevation knob 17 until rear sight base 18 Is all the way down Install flat spring 19 and sight aperture 20 In rear sight assembly base 10 Install windage screw 21 with screwdriver Insert helical spring 22 and ball bearing 123 In windage knob 24 NOTE Tilt upper receiver toward wind age knob during positioning to p
77. 0 AND M4A1 CARBINE 5 56MM 12972700 FIG C 1 M16A2 RIFLE M4 AND CM4A1 CARBINES HANDLE ASSEMBLY CHA BOLT CARRIER ASSEMBLY 16 2 UOC AR8 UOC AS1 AY6 UPPER RECEIVER AND BARREL ASSEMBLY uu E UOC AR8 RECEIVER AND BARREL M4 AND MAU esee iie UOC AS1 AY6 MAGAZINE CARTRIDGE 30 ROUND SLING SMALL ARMS M164A2 UOC AR8 SLING SMALL ARMS 4 AND M4A1 UOC AS1 AY6 RECEIVER AND BUTTSTOCK ASSEMBLY M16A2 UOC AR8 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY A Sean ea UOC AS1 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY MAT sicot Ede cesi ceni UOC AY6 CARRYING HANDLE ASS 4 AND M4A1 UOC AS1 AY6 END OF FIGURE C 7 ON CODE UOC ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 SECTION II Figure C 1A M4 and M4A1 Carrying Handle Assembly 12951011 Change 4 SECTION II 1 2 ITEM SMR NO CODE 1 AFFFF 2 PAFZZ 3 PAFZZ 4 PAFZZ 5 PAFZZ 6 22 7 PAFZZ 8 22 9 22 10 22 11 PAFZZ TM9 1005 319 23LP 3 NSN 5305011343622 1005013827089 5355013826801 5360011343710 3110001839175 5360013826802 53150084038
78. 0 00 992 7301 1005 00 056 2201 1005 00 403 0964 5340 00 463 3892 5315 00 463 3894 1005 00 921 5004 5320 01 063 7635 1005 00 087 8998 1005 00 760 3768 1005 01 134 3633 5365 01 144 1496 1005 01 134 3625 1005 01 134 3629 1005 01 134 3701 5305 01 134 3622 1005 01 134 3621 5355 01 135 4972 5360 01 148 1751 l 5 299900 2 0000000000000 gt SECTION IV CAGEC 19200 19200 19200 19200 19200 19200 19200 19200 19204 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 19200 PART NUMBER 9349069 9349070 9349072 9349074 9349075 9349076 9349077 9349085 9349086 9349100 9349101 9349102 9349106 9349107 9349108 9349109 9349110 9349113 9349114 9349115 9349116 9349119 9349120 9349121 9349124 9349127 9349128 9349130 9381367 9381380 9390003 9390007 9390009 9390011 9390012 9390013 9390014 9390015 9390016 9390019 9390020 9390021 9390022 9390023 9390025 TM9 1005 319 23 amp P CROSS REFERENCE INDEXES PART NUMBER INDEX STOCK NUMBER 5360 01 148 1751 5360 01 134 3710 1005 01 134 3631 1005 01 135 3697 5305 01 144 1490 5355 01 134 3627
79. 0 15 1 seen Equipment Record Procedures TO 00 350 54 Materiel Deficiency Reporting and Investigating System 11 13 10 7 Storage and Maintenance Procedures for Small Arms Ammunition Historical Data Recording of Inspection Maintenance and Firing Data for Ground Weapons 3 1 100 sess ens Interval Calibration and Repair Reference Guide and Work Unit Code anua Change5 1 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 I1W3 5 5 42 A 2 FIELD MANUALS EM 21 11 eoe First Aid for Soldiers 2329 M16A1 M16A2 Rifle and Rifle Marksmanship A 3 PAMPHLETS DA PAM 25 30 Consolidated Index of Army Publications and Blank Forms DA PAM 738 750 The Army Maintenance Management System TAMMS A 4 RELATED PUBLICATIONS AFM 36 2227 Vol 1 Combat Arms Training Management and Range Operation 310 9 ith elato mede Equipment Publications Listing 725 50 inei GUN Requisitioning Receipt and Issue System ABRUZ50 1 5 i ete ctatets nantes ium Army Materiel Policies GTA 8 100 Army Medical Department Expendable Durable Items 50 970 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items DOD 4160 21 M 1 Defense Demilitarization
80. 0 999 0864 96906 MS19060 4808 3110 00 183 9175 96906 MS35335 61 5310 00 527 3634 96906 MS39086 93 5315 00 690 0544 99999 NPN 19204 11010032 4933 00 070 9151 19204 11010033 5120 00 070 9152 19204 12006359 4933 01 035 5607 19204 12006472 5220 01 043 9473 19200 12011849 19200 12011987 5360 01 381 6183 19200 12011996 1005 01 368 9852 19200 12597640 5365 01 267 2169 19200 12598617 1010 01 264 6517 19200 12598618 5340 01 264 6530 19200 12620101 5220 01 075 5004 19204 12624561 1005 01 216 4510 19200 12926769 5315 01 310 0370 19200 12951011 19200 12951017 5340 01 382 3201 19200 12951018 1005 01 382 7089 19200 12951019 5355 01 382 6801 19200 12951020 5360 01 382 6802 19200 12951021 1005 01 382 7083 19200 12951023 5310 01 382 6793 19200 12951026 19200 12951028 1005 01 382 7086 19200 12972652 19200 12972670 1005 01 382 6795 19200 12972675 19200 12972680 19200 12972690 19200 12972691 1005 01 422 3770 l 3 LO LoU Luuuucocuco 1 ee 000000 LOLOL ogres gt gt gt gt gt gt gt gt 1411 1 oa a ea nl ITEM gt SECTION IV CAGEC 19200 19200 19200 19200 19200 19204 19204 19204 19204 19204 19204 19204 19204 19204 19204 19204 19200 19200 19204 19200 19204 19204 19204 19204 19
81. 00 992 7302 1005 00 992 7307 5360 00 992 7308 5315 00 992 7309 5360 00 999 0404 5340 00 999 0405 1005 00 999 0406 5325 00 999 0863 5325 00 999 0864 1005 00 999 1509 5220 01 014 8183 4933 01 035 5607 5220 01 043 9473 5315 01 048 9372 1 1 FIG C 7 7 13 11 11 16 C16A C 16 C16A 11 C16A 11 11 C16A 11 11 16 11 11 C 4 C 4 2 C 3 C 3 C 3 C 3 C 11 2 C 16 C 16 C16A C 11 C 11 C 14 C 14 C 14 C 14 C 11 5 5 C 11 C 6 C 8 2 17 17 17 5 C 9 MOARONAPHWNADWNHHRHD SECTION IV STOCK NUMBER 5320 01 063 7635 5220 01 075 5004 1005 01 134 3621 5305 01 134 3622 1005 01 134 3625 5355 01 134 3627 1005 01 134 3629 1005 01 134 3630 1005 01 134 3631 1005 01 134 3633 1005 01 134 3701 5360 01 134 3710 5360 01 135 0353 1005 01 135 3697 5355 01 135 4972 1005 01 135 4973 5360 01 136 5471 1005 01 144 1468 5305 01 144 1490 5360 01 144 1492 5305 01 144 1494 5365 01 144 1496 5340 01 144 1499 5340 01 145 7910 1005 01 146 7684 1005 01 146 7685 5305 01 147 8585 1005 01 148 0172 5360 01 148 1751 1005 01 148 4805 1005 01 216 4510 1005 01 219 2402 5340 01 225 8339 1005 01 228 8504 1005 01 231 3138 1005 01 233 8529 1005 01 233 8530 1005 01 233 8531 5315 01 233 8608 5360 01 233 8616 5360 01 233 8617 5310 01 233 8625 FIG C 7 C 17 C 8 C 8 C 1A C 7 C 1B C 10 C 6 C 13 C 10 C 6 C 8 C 8 C 1A C 15
82. 00 Sy Centimeters 10 76 Sq Feet i Sq Kilometer 1 000 000 Sy Meters 0 386 Sy Miles CUBIC MEASURE Cu Centimeter 1 000 Cu 0 06 Cu Inches 1 Cu Meter 1 000 000 Cu Centimeters 35 31 Cu Feet APPROXIMATE CONVERSION FACTORS LIQUID MEASURE 1 Miliiliter 0 001 Liters 0 0338 Fluid Ounces 1 Liter 1 000 Milliters 33 82 Fiuid Ounces TEMPERATURE 5 9 oR 32 212 Fahrenheit is equivalent to 1005 Celsius 90 Fahrenheit is equivalent to 22 25 Celsius 32 Fahrenheit is equis alent to 0 Celsius 9 5 12 FS WEIGHTS Gram 0 001 Kilograms 1 000 Milligrams 0 035 Ounces Kilogram 1 000 Grams 2 21 b Metric Ton 1 000 Kilograms 1 1 1 Short Tons Megagram A TO CHANGE TO MULTIPLY BY Inches eve Centimeters 2 540 Rect cite seve veis Melers 0 305 0 94 m Miles Kilometers 609 m Square inches Square Centimeters 6 451 Square Feet Square Meters 0 093 Square Yardy Square Meters 0 536 Square Miles Square Kilometers 2 590 eese eite e Rex me dem Square Hectameters 0 408 Cubic Feet Cubic Meters oo eee eee 0 02 Cubic Yards Cubic 0 765 Fluid Ounces Millilit rs ovS 29 571 BINS
83. 005 00 017 9547 1005 00 01 7 9548 1005 00 017 9551 1005 00 056 2201 5360 00 056 2246 1005 00 056 2247 1005 00 056 7106 5315 00 058 6044 5315 00 058 6081 5315 00 058 6678 5220 00 070 7814 6695 00 070 7815 4933 00 070 9151 5120 00 070 9152 1005 00 087 8998 3110 00 183 9175 5220 00 221 9391 1005 00 403 0964 5340 00 463 3892 5315 00 463 3894 5360 00 523 8084 5310 00 527 3634 5315 00 597 5086 5315 00 690 0544 1005 00 738 6213 1005 00 760 3768 4933 00 800 7508 5315 00 812 3312 5315 00 840 3812 5315 00 843 9487 1005 00 921 5004 1005 00 937 3078 1005 00 978 1022 5315 00 978 1023 5360 00 978 1025 5360 00 978 1036 4710 00 978 1038 12 12 12 9 11 7 4 C 3 17 11 8 12 9 1005 319 23 amp CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX ITEM 1 gt WODWOAONA DAN STOCK NUMBER 5315 00 979 3930 5360 00 979 3931 5360 00 992 6648 1005 00 992 6649 5315 00 992 6650 5315 00 992 6651 5360 00 992 6652 5315 00 992 6653 5315 00 992 6654 5360 00 992 6655 5360 00 992 6665 1005 00 992 6667 1005 00 992 7283 5305 00 992 7284 1005 00 992 7285 1005 00 992 7287 1005 00 992 7288 1005 00 992 7290 1005 00 992 7291 5360 00 992 7292 5315 00 992 7294 5340 00 992 7297 1005 00 992 7299 5360 00 992 7301 1005
84. 023 BUFFER ASSEMBLY M4 AND UOG AST AYO nieder ree 3 AFFFF 19200 9349106 HAMMER ASSEMBLY M16A2 AFFFD 19200 9390032 HAMMER ASSEMBLY 4 UOG AS Tide ies AFFFF 19204 8448610 HAMMER ASSY 4 1 4 PAFZZ 1005009926649 19200 8448595 DEAR 5 PAFZZ 5340012258339 19200 9381367 SELECTOR FIRE 6 PAFZZ 5360000562246 19204 8448633 SPRING HELICAL COMP COMPRESSION BOLT enne 7 PAFZZ 1005000562247 19204 8448634 PLUNGER BOLT 8 PAFZZ 1005000179548 19200 8448628 CATCH BOLT 9 PAFZZ 5315008123312 96906119 MS16562 119 PIN SPRING BOLT CATCH 10 PAFZZ 1005000562201 19204 8448638 CATCH 21 11 PAOZZ 5360009926655 19204 8448586 SPRING HELICAL COMP COMPRESSION TAKE DOWN PIVOT PIN M16A2 UOC ARG e cede E brine edet 11 PACZZ 5360009926655 19204 8448586 SPRING HELICAL COMP COMPRESSION M4 AND MAAI eerte S YOGASI e Leste b GON LT 12 PAOZZ 5315009926654 19204 8448585 PIN STRAIGHT HEADLE DETENT TAKEDOWN PIN M16A2 sess WOC ARS D re Ee 12A PAOZZ 5315009926654 19204 8448585 PIN STRAIGHT H
85. 1005 319 23 amp P AIR FORCE 11 W3 5 5 42 2 16 UPPER RECEIVER AND BARREL ASSEMBLY RIFLE BARREL ASSEMBLY AND UPPER RECEIVER ASSEMBLY CONT f REASSEMBLY CONT NOTE Refer to operator s manual for buddy system procedure on installing hand guard assemblies 8 Install top of upper handguard assembly 12 In tube cap 13 while pushing down on handguard slip ring 14 Push bottom of upper handguard assembly 12 in place and release handguard slip ring 14 to lock handguard assembly In place 9 Install top of lower handguard assembly 1 5 In tube cap 13 while pushing down on handguard slip ring 14 Push bottom of lower handguard assembly 15 In place and release handguard slip ring 14 to lock both handguard assemblies In place 10 Reassemble rifle refer to page 2 68 2 56 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 2 17 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY This task covers a Disassembly b Cleaning d Repair e Lubrication c Inspection f Reassembly INITIAL SETUP Tools Equipment Conditions ARMY Small Arms Repairman Tol Kit 2 34 Lower receiver and buttstock assembly item 3 app B removed Pivot Pin Removal Tool fig E 3 app E Pivot Pin Installation Tool fig E 4 app E Materials Parts Lubricant solid film SFL item 21 app D Screw self locking item 6 p C 1 1 References TM 9 1005 319 10 operator s
86. 12 5310013826793 5340013823201 1005013827083 4 CAGEC 19200 19200 19200 19200 19200 96906 19200 96906 19200 19200 19200 5 PART NUMBER 12951026 9349065 12951018 12951019 9349070 MS19060 4808 12951020 MS16562 121 12951023 12951017 12951021 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 00 1 M4 AND M4A1 CARRYING HANDLE ASSEMBLY 12951011 FIG C 1A M4 AND M4A1 CARRYING HANDLE ASSEMBLY REAR UOC AS1 AY6 SCREW INDEX ere 5 een eire terrere reine ELEVATING MECHANISM essere UOC AS1 6 UOC AS1 AY6 SPRING BALL BEARING x ttr rte deae ri p ended UOC AS1 AY6 SPRING HELICAL COMP UOC AS1 AY6 PIN SPRING UOC AS1 AY6 BRACKET MOUNTING essent UOC AS1 AY6 HANDLE GUN 2 UOC AS1 AY6 END OF FIGURE C 1A 1 7 QTY ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 SECTION II Figure C 1B M4 and M4A1 Rear Sight Assembly 12951026 Change 4 SECTION II 1 2 ITEM SMR NO CODE 1 PAFZZ 2 PAFZZ 3 PAFZZ 4 PAFZZ 5 22 6 22 7 PAFZZ 8 22 TM9 1005 319 23LP 3 NSN 5315000586678 1005013827086 5305011441490 5360011481751 3110001839175 1005011353697 5360013816183 5
87. 124 AND M4 AND M4A1 REPLACEMENT BARREL AND FRONT SIGHT ASSEMBLY 9390007 FIG C 7 M16A2 BARREL ASSEMBLY AND M4 AND M4A1 REPLACEMENT BARREL AND FRONT SIGHT ASSEMBLY 9349056 POST FRONT SIGHT ccscsscesssseesssssessssesssseessssesssstesssseesssnees 8448573 PIN SHOULDER HEADLE HEADLESS i DETENT FRONT SIGHT 8448574 SPRING HELICAL COMP COMPRESSION FRONT SIGHT 8448571 SWIVEL SLING SMALL e 8448697 RIVET TUBULAR ees i 9349054 BARREL AND BARREL ASSEMBLY 16 2 UOC AR8 9390009 BARREL AND BARREL ASSEMBLY 4 AND UOC AS1 AY6 12598618 CLAMP RIM CLENCHING M4 AND 4 1 UOC AS1 AY6 MS39086 93 PIN SPRING 4 AND UOC AS1 AY6 12598617 MOUNT SWIVEL 4 AND M4A1 UOC AS1 AY6 END OF FIGURE C 7 1 7 QTY N o5 Y m LO N io c oz Lo oT TE O zd co lt lt SECTION II 9349062 and M4 and M4A1 12972675 Figure C 8 Upper Receiver Assembly M16A2 Change 4 SECTION II 1 ITEM NO 2 SMR CODE PAFZZ PAFZZ AFFFF PAFZZ PAFZZ PAFZZ PAFZZ PAOZZ PAOZZ PAOZZ PAOZZ PAFZZ PAFZZ PAFZZ AFFFF PAFZZ PAFZZ TM9 1005 319 23LP 3 NSN 1005011343621 5305011343622 19200 31100018391
88. 14 FIRES WITH SELECTOR LEVER ON SAFE OR WHEN TRIGGER IS RELEASED WITH SELECTOR LEVER ON SEMI Step 1 Defective selector lever 1 Replace selector lever 1 p 3 62 Step 2 Worn or broken trigger rear portion 2 Replace trigger 3 p 3 62 Se 3 e m 9 ES Ny M 2 72 27 M16A2 4 M4A1 Change 4 3 13 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 5 TROUBLESHOOTING PROCEDURES CONT TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 15 HAMMER PIN WALKS Hammer pin 1 walks or works loose during firing or hammer pin Is very easy to push out of receiver when hammer Is Installed Replace hammer assembly p 3 62 16 BOLT ASSEMBLY FAILS TO LOCK TO REAR AFTER FIRING LAST ROUND Step 1 Broken bolt catch 1 Replace bolt catch 1 p 3 62 Step 2 Weak or broken bolt catch spring 2 Replace bolt catch spring 2 p 3 62 Step 3 Restricted movement of bolt catch 1 Disassemble and clean ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Section MAINTENANCE PROCEDURES FOR THE M16A2 RIFLE AND M4 M4A1 CARBINES 3 6 MAJOR COMPONENTS OF M16A2 RIFLE AND M4 M4A1 CARBINES This task covers disassembly INITIAL SETUP Tools General Safety Instructions ARMY Small Arms Repairman Tool Kit Before starting an inspection be sure to clear the item 3 app B weapo
89. 2 FAILURE TO FEED Step 1 Magazine catch spring 1 weak or broken Replace magazine catch spring 11 p 3 62 Step 2 Short recoil Refer to page 3 9 3 FAILURE TO CHAMBER Short recoil Refer to page 3 9 3 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 5 TROUBLESHOOTING PROCEDURES CONT TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 4 FAILURE TO LOCK Step 1 Damaged bolt carrier key 1 Repair or replace bolt carrier key 1 p 3 25 Step 2 Loose screws 2 on bolt carrier key 1 a Disassemble and repair p 3 25 b Reassemble using new screws Step 3 Bent gas tube 3 a Adjust by bending gas tube 13 In area of handguards b Replace gas tube 3 and check alignment p 3 29 Step 4 Short recoil Refer to page 3 9 8 4 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 5 FAILURE TO FIRE Step 1 Broken hammer 1 Replace hammer 1 p 3 73 Step 2 Weak or broken hammer spring 2 Replace hammer spring 2 p 3 73 Step 3 Hammer spring 2 improperly assembled Assemble properly Step 4 M16A2 and M4 ONLY Burst cam 3 and or cam spring 4 frozen or improperly assembled Disassemble clean lubricate and reassemble correctly p 3 73 ep M16A2 and M4 M4A1 Step 5 Selector lever 5 frozen on SAFE position Disassemble and clean p 3 62 Step 6 Broken firing pin
90. 20 as filler to create a tight pack a Fiber board containers shall be in accordance with PPP B 636 and may be Class Domestic Gross weight and size of material shall determine grade of fiberboard container PPP B 640 may also be used b Wood containers shall be in accordance with PPP B 601 or PPP B 621 5 Equivalent materials may be used NSNs are not assigned to all the specified material If it is necessary to specify an NSN in the TMs the packing materials will have to be spared and part numbers and NSNs assigned The specifications used are 1 MIL B 121 Barrier Material Greaseproofed Waterproofed Flexible NSN 8135 00 753 4661 2 MIL B 117 Bag Sleeve and Tubing Interior Packaging NSN 8135 00 543 6574 3 PPP B 636 Boxes Shipping Fiberboard 4 PPP B 601 Boxes Wood Cleated Plywood 5 MIL STD 129 Marking for Shipment and Storage 69 PPP T 76 Tape Packaging Paper 7 MIL STD 1186 Cushioning Anchoring Bracing Blocking and Waterproofing with Appro priated Test Methods 8 843 Cushioning Material Cellulosic 9 PPP F 320Fiberboard Corrugated and Solid Sheet Stock Container Grade and Cut Shapes 10 PPP B 640 Boxes Fiberboard Corrugated Triple Wall 11 PPP B 621 Boxes Wood Nailed and Locked Corner Change 4 2 73 2 74 blank ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 CHAPTER 3 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS CHAPTER OVERVIEW This chapter provides informati
91. 20 inch thickness gage between the pivot pin lugs of the upper lower receivers c If the thickness gage penetrates to the pivot pin at all accessible locations repair by replacement of the upper receiver see b below or replacement of rifle is required If the rifle fails the above test remove the upper receiver and install a NEW upper receiver and perform the test again If the rifle now passes the above test it shall be considered serviceable and continue in use If the rifle falls the test with a new upper receiver this failure shall be considered a shortcoming This shortcoming requires action to obtain a replacement rifle Once a replacement has been received evacuate the original rifle to depot for overhaul 3 68 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 NOTE If the lower receiver is not disassembled visually inspect for broken or damaged parts and to ensure that the hammer and trigger springs are correctly installed before beginning this test It is not necessary to disassemble the lower receiver for the sole purpose of this visual Inspection If broken or damaged parts are found disassemble p 3 62 and repair as authorized 12006472 This test may be 5 Test two hammer pin holes and two trigger pin holes using not go plug gage PN onducted by disassembly of the lower receiver p 3 62 or by pushing the pin far enough to disengage the end of the pin receiver which is being tested If the lo
92. 204 19204 19204 19204 19200 19204 19204 19204 19204 19204 19200 19200 19204 19204 19204 19200 19204 19204 19204 19200 19204 19200 PART NUMBER 12972692 12972695 12972696 12972697 12972698 7799734 7799735 8426685 8448201 8448202 8448496 8448501 8448502 8448503 8448504 8448505 8448506 8448507 8448508 8448509 8448510 8448511 8448512 8448513 8448515 8448516 8448517 8448518 8448519 8448520 8448521 2 8448525 8448532 8448533 8448540 8448542 8448543 8448544 8448555 8448567 8448571 8448573 8448574 8448581 8448582 8448583 TM9 1005 319 23 amp P CROSS REFERENCE INDEXES PART NUMBER INDEX STOCK NUMBER 1005 01 424 5899 5360 01 396 0256 1005 01 395 4257 5220 00 070 7814 6695 00 070 7815 1005 00 056 7106 4933 00 800 7508 5220 00 221 9391 5220 01 014 8183 5315 00 992 7294 1005 00 017 9547 1005 00 999 1509 1005 00 992 7283 1005 00 738 6213 5305 00 992 7284 1005 00 992 7285 1005 00 992 7287 1005 00 992 7288 1005 00 992 7290 1005 00 992 7291 5360 00 992 7292 1005 00 017 9546 5340 00 999 0405 5360 00 999 0404 5315 01 048 9372 1005 00 978 1022 5360 00 978 1025 5315 00 978 1023 5360 00 017 9541 5360 00 523 8084 3040 00 01 7 9539 1005 00 017 9540 5360 00 978 1036 4710 00 978 1038 1005 00 017 9543 5315 00 979 3930 5360 00 979 3931 5340 00 992 7297 5315 00 992 6651 5360 00 992 6652 4 FIG 20000200000 NNN
93. 3 5 5 42 d Lubrication e Reassembly General Safety Instructions Bolt cam pin must be installed or rifle will blow up while firing the first round If the bolt cam pin is not installed injury to or death of personnel may result Do not interchange bolt assemblies from one rifle to another Doing so may result in injury to or death of personnel Change 5 2 35 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 13 BOLT CARRIER ASSEMBLY CONT b CLEANING lean all items operator s manual Remove carbon deposits INSPECTION REPAIR 1 Inspect bolt assembly 1 as follows Check to see that the bolt ring 2 gaps are staggered Install bolt assembly 1 into key and bolt carrier assembly 3 Check for worn rings by holding the key and bolt carrier assembly 3 with the bolt assembly facing down If bolt assembly falls out after firing pin retaining pin 4 and bolt cam pin 5 are removed the rings are worn Evacuate to support maintenance 2 Inspect carrier key 6 for dents distortion or looseness If dented or loose evacuate to support maintenance Inspect firing pin retaining pin 4 and bolt cam pin 5 for cracks damage or excessive wear Replace if unserviceable Inspect firing pin 7 for damage or If tip is chipped Evacuate rifle to support maintenance if unserviceable Inspect key and bolt carrier assembly 3 for damage or wear If unserviceable evacuate to support maintenance
94. 3 69 and 3 70 3 87 and 3 88 3 93 thru 3 96 C 2 1 and Figure C 3 C 6 1 thru Figure C 8 10 1 and Figure C 1 1 C 17 1 1 1 thru 1 4 1 7 and 1 8 Insert Pages 2 7 and 2 8 2 57 thru 2 60 3 35 and 3 36 3 65 and 3 66 3 69 and 3 70 3 87 and 3 88 3 93 thru 3 96 C 2 1 and Figure C 3 C 6 1 thru Figure C 8 and Figure C 11 DLE C C 1 1 1 1 4 1 8 ru nd 4 File this change sheet In the front of the publication for reference purposes By Order of the Secretary of the Army GORDON R SULLIVAN General United States Army Chief of Staff Official MILTON H HAMILTON Administrative Assistant to the Secretary of the Army DISTRIBUTION To be distributed in accordance with DA Form 12 40 E Block 0020 Unit Direct and General Support Maintenance requirements for TM 9 1005 319 23 amp P ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 WARNING ALL WARNINGS in this technical manual pertain to both the rifle and the carbines unless otherwise specified Before starting an inspection be sure to clear the rifle Do not pull the trigger until the rifle has been cleared Inspect the chamber to ensure that it is empty and no ammunition is in position to be chambered Do not keep live ammunition near work area To avoid injury to your eyes use care when removing and installing spring loaded parts All M1 6A2 rifles and M4 carbines must be inspected and gaged at least once annually for safety a
95. 355011343627 4 CAGEC 96906 19200 19200 19200 96906 19200 19200 19200 5 PART NUMBER MS16562 103 12951028 9349076 9349069 MS19060 4808 9349075 12011987 9349077 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 00 101 M4 AND M4A1 REAR SIGHT ASSEMBLY 12951026 FIG C 18 M4 AND M4A1 REAR SIGHT ASSEMBLY PINSSPIRING atria BASE REAR SIGHT irent rates UOC AS1 AY6 SCREW EXTERNALLY RE esee SPRING HELICAL COMP sees UOC AS1 AY6 BAEL BEARING intet eter eR eed UOC AS1 AY6 APERTURE SIGH Torana on n peregre SPRING FLAT KNOB WINDAGE eI recen END OF FIGURE C 1B 1 7 QTY ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 SECTION II Figure C 2 Bolt Carrier Assembly M16A2 8448501 and 4 and M4A1 12011849 Change 5 SECTION II 1 2 ITEM SMR NO CODE 1 PAFZZ 2 PAOZZ 3 PAOZZ 4 PAFFF 4A PAFFF 5 AFFFF TM9 1005 319 23LP 3 NSN 1005000179547 1005009991509 5315009927294 1005009927285 1005014223770 4 CAGEC 19204 19204 19204 19200 19200 19204 5 PART NUMBER 8448503 8448504 8448502 8448509 12972691 8448505 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 01 BOLT CARRIER ASSEMBLY M16A2 8448501 AND M4 AND M4A1 12011849 FIG C 2 BOLT CARRIER ASSEMBLY PIN FIRING oett eerte ret re cea PIN FIRING PIN RETA
96. 6 8448631 8448609 8448599 8448584 12597640 9349119 9390012 9349128 9349101 NPN NPN 6 DESCRIPTION AND USABLE ON CODE UOC UOC AR8 51 UOC AS1 GRIP RIFLE PLASTIC BLACK WASHER LOCK RIFLE GRIP SCREW MACHINE RIFLE GRIP SPRING HELICAL COMP SAFETY atte DETENT SAFETY nc dean PIN GROOVED HEADLES TRIGGER AND LOWER RECEIVER ASSY ASSEMBLY 4 UOC AST n uel om POW RECEIVER Sy MAA 11 2 k k SECTION II Change 3 ARMY 9 1005 319 23 amp AIR FORCE TO 11W3 5 42 d Figure C 12 M16A2 Buttstock Assembly 9349119 SECTION II 1 2 ITEM SMR NO CODE 1 PAOZZ 2 PAOZZ 3 PAOZZ 4 XAOZZ 5 PAOZZ 6 22 7 22 TM9 1005 319 23 amp P 3 NSN 1005012288504 1005011467685 5340004633892 1005004030964 5315004633894 5305011441494 4 CAGEC 19200 19200 19200 19200 19204 19204 5 PART NUMBER 9381380 9349130 8448653 9349121 8448652 8448655 19200 9349120 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0401 M16A2 BUTTSTOCK ASSEMBLY 9349119 FIG C 12 M16A2 BUTTSTOCK ASSEMBLY DOOR ASSEMBLY UOC AR8 PLATE BUTT SHOULDER GUN STOCK UOC AR8 HINGE ACCESS DOOR UOC AR8
97. 631 4 5 PART CAGEC NUMBER 19204 8426685 19204 12006359 19204 8448201 19200 12620101 19204 8448496 19204 8448202 19204 7799734 19204 7799735 19204 11010032 19204 11010033 19204 12006472 19200 12926769 19200 9390035 6 7 DESCRIPTION AND USABLE ON CODE UOC QTY GROUP 9500 SPECIAL TOOLS FIG C 17 SPECIAL TOOLS MAINTENANCE KIT GUN DS GS SUPPORT MAINTENANCE FOR 5 S6MM RIFLE M16 RIFLE SERIES BOI 2 PER SUPPORTING REFLECTOR TOOL CHAMBER PART OF KIT P N 8426685 5e eerte Pri ade GAGE PLUG PLAIN PART OF KIT P N GAGE BARREL EROSION BARREL EROSION PART OF KIT P N 8426685 CHROME BARREL sese GAGE STRAIGHTNESS PART OF KIT P N 84206685 5 credet e RU ibtd eins GAGE HEADSPACE PART OF KIT P N GAGE FIRING PIN PROTRUSION PART OF KIT P N 8426685 5 cect cites iens FIXTURE BARREL REMOVAL PART OF 8426685 WRENCH COMBINATION PART OF KIT P IN 8426685 iic emm ete aed ined der GAGE PLUG TAPER CYLINDER PART OF KIT P N 8426685 eret e aetates KEY MACHINE KEY 2 PER ORGANIZATIONAL OR DIRECT SUPPORT WRENCH SPANNER 2 PER DS GS SUPPORT SHOP A R FOR M4 M4A1 CARBINE sees UOC AS1 AY6 END OF FIGURE 17 1 Section IV STOCK NUMBER 5315 00 01 7 9537 3040 00 01 7 9539 1005 00 017 9540 5360 00 017 9541 1005 00 017 9543 1005 00 017 9546 1
98. 6A2 and M4 ONLY Step 1 Broken automatic sear 1 or spring 2 Replace automatic sear assembly 1 p 3 62 Step 2 Faulty selector lever 3 Replace selector lever 3 p 3 62 Step Broken tooth on burst cam 4 Replace burst cam 4 p 3 73 M16A2 and M4 Change 4 3 11 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 5 TROUBLESHOOTING PROCEDURES CONT TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 12 FAILURE TO CYCLE WITH SELECTOR LEVER SET ON BURST M16A2 and M4 ONLY CONT Step4 Broken cam clutch spring 5 Cam clutch spring should be bent and properly formed without any sharp edges or corners Inspect and replace If required Step5 bend In the cam clutch spring 5 installed backwards toward outside Install cam clutch spring 5 properly with the bend to the inside p 3 73 NOTE When hammer Is rotated back to cocked position cam should rotate to allow the burst disconnector to latch in the next notch Step 6 Cam clutch spring 5 fails to clutch and burst cam 4 fails to rotate back with hammer 6 Replace cam clutch spring 5 p 3 73 If problem continues replace hammer 6 and cam 4 p 3 73 Step 7 Broken front hook 7 on burst disconnector 8 Replace burst disconnector 8 p 3 62 Step 8 Short recoil Refer to page 3 9 M16A2 and MA 3 12 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 TROU
99. 75 5360011481751 1005011343701 1005013826795 5325009990864 5315009781023 1005009781022 5360009781025 5315008403812 5315008403812 5360000179541 5360011343710 5355011354972 4 CAGEC 19200 19200 9349072 96906 19200 19200 19200 96906 19204 19204 19204 96906 96906 19200 19204 19200 19200 5 PART NUMBER 9349066 9349065 REAR MS19060 4808 9349069 9349063 12972670 MS16632 3012 8448533 8448525 8448532 M5S16562 121 M5S16562 121 8448540 9349086 9349070 9349067 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0302 UPPER RECEIVER ASSEMBLY M16A2 9349062 M4 AND M4A1 12972675 FIG C 8 UPPER RECEIVER ASSEMBLY INDEX ELEVATION 16 2 UOC AR8 SCREW INDEX M1642 s SIGHT ASSEMBLY 16 2 UOC AR8 BALL BEARING 16 2 UOC AR8 SPRING HELICAL COMP COMPRESSION INDEX 16 2 UOC AR8 RECEIVER UPPER 16 2 c UOC AR8 RECEIVER CARTRIDGE 4 AND 4 1 UOC AS1 AY6 RING RETAINING PIN GROOVED HEADLES COVER COVER EJECTION PORT SPRING HELICAL TORS COVER PIN SPRING FORWARD ASSIST PIN SPRING 1 2 2 SPRING HELICAL COMP FORWARD ASSIST corn en dotes ie rab iced FORWARD ASSIST ASSY ASSEMBLY
100. 9 1 CN ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 EXPENDABLE DURABLE SUPPLIES AND MATERIALS LIST CONT 1 3 4 NATIONAL DESCRIPTION ITEM STOCK NUMBER NUMBER PART NUMBER AND CAGE 5350 00 221 0872 CLOTH ABRASIVE 58536 A A 1206 Deleted See Item 23 2 DICHLOROMETHANE TECHNICAL 81346 ASTM D 4701 6810 00 244 0290 5 gal 18 93 1 pail 6810 00 616 9188 600 Ib 272 16 kg drum 6850 00 281 1985 DRY CLEANING SOLVENT 58536 A A 711 1 gal 3 79 11 can 8010 00 297 0560 ENAMEL olive drab no 3407 81348 TT E 527 1 gal 3 791 can GLOVES CHEMICAL AND OIL PROTECTIVE 81348 ZZ G 381 8415 00 823 7455 Size 9 8415 00 823 7456 Size10 8415 00 823 7457 Size 11 F 9150 00 754 2595 GREASE MOLYBDENUM DISULFIDE 81349 MIL G 21164 1005 01 113 0321 HANDLE SECTION CLEANING ROD SMALL ARMS 19204 8436776 9150 01 260 2534 LUBRICANT SOLID FILM 81349 MIL L 23398 16 OZ 473 18 ml spray can 9150 00 292 9689 LUBRICATING OIL WEAPONS LAW 81349 MIL L 14107 1 qt 0 95 1 can ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 EXPENDABLE DURABLE SUPPLIES AND MATERIALS LIST CONT 1 2 3 4 NATIONAL DESCRIPTION ITEM STOCK NUMBER LEVEL NUMBER PART NUMBER AND CAGE LUBRICATING OIL WEAPONS LSA semifluid 81349 MIL L 46000 C 9150 00 935 6597 2 oz 59 15 ml plastic btl OZ C 9150 00 889 3522 4 oz 118 30 ml plastic btl OZ 9150 00 687 4241 1 qt 0 95 11 can C
101. AILURE TO FEED Step 1 Magazine catch spring weak or broken Evacuate to support maintenance Step 2 Magazine catch 1 defective Evacuate to support maintenance Step 3 Magazine catch 1 out of adjustment will not retain magazine Refer to operator s manual Step 4 Short recoil Refer to page 2 28 3 FAILURE TO CHAMBER Step 1 Weak or broken action spring 1 RIFLE ONLY free length 11 3 4 inches 29 85 cm minimum to 13 1 2 Inches 34 29 cm maximum CARBINE ONLY 10 1 16 inches 2S 56 cm minimum to 11 1 4 inches 28 58 cm maximum Replace action spring p 2 57 2 22 Change ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 2 Short recoil Refer to page 2 28 4 FAILURE TO LOCK Step 1 Bolt cam pin 1 missing Replace p 2 35 Step 2 Loose or damaged bolt carrier key 2 a Evacuate to support maintenance b Dented bolt carrier key may be repaired p 2 35 Step 3 Improperly assembled extractor spring assembly 3 Assemble correctly p 2 38 9 8 CS 2 23 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 9 TROUBLESHOOTING PROCEDURES CONT TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 4 FAILURE TO LOCK CONT Step 4 Bent gas tube 14J a Adjust to Its original configuration by bending in area of hand guard assembly b If the gas tube cannot be ret
102. AND AIR FORCE Washington DC 1 May 1991 Unit and Direct Support Maintenance Manual Including Repair Parts and Special Tools List For RIFLE 5 56MM M16A2 W E 1005 01 128 9936 CARBINE 5 56MM M4 1005 01 231 0973 AND CARBINE 5 56MM M4A1 1005 01 382 0953 Current as of December 1996 DISTRIBUTION STATEMENT APPROVED FOR PUBLIC RELEASE DISTRIBUTION IS UNLIMITED REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual If you find any mistakes or if you know of a way to improve the procedures please let us know Army users 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 Director Armament and Chemical Acquisition and Logistics Activity ATTN AMSTA AC NML Rock Island IL 61299 7630 Air Force users submit AFTO Form 22 Technical Order System Publication Improvement Report and Reply to WR ALC MMDET Robins AFB GA 31098 5609 A reply will be furnished to you HOW TO USE THIS MANUAL 1 2 2 2 11 02 tenete 1 1 External View of 5 56mm Rifle 16 2 1 0 External View of 5 56mm Carbine 1 0 1 External View of 5 56mm Carbine M4A1 sess 1 0 1 Chapter 1 1 Section I G
103. ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 WARNING To avoid injury to your eyes use care when removing and installing spring loaded parts NOTE Catch pivot pin detent and helical spring as pivot pin is removed see step 6 on next page Depress pivot pin detent and spring and remove pin or Insert fabricated pivot pin removal tool 12 to compress pivot pin detent Turn pivot pin 13 a quarter turn Remove tool and pivot pin Change 3 2 58 1 2 58 2 blank ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 6 Be sure to hold cupped hand in front of pivot pin detent 14 and helical spring 15 to prevent loss of pivot pin detent and helical spring NOTE If helical spring 15 will not come out use a wire to pull it out NOTE Make sure the hammer is cocked and the selector lever is not set on BURST or AUTOMATIC before removing the buffer assembly 7 Press buffer assembly 16 in about 1 4 inch 0 635 cm Depress buffer retainer 17 and release buffer assembly 16 and action spring 18 Remove buffer assembly 16 and action spring 18 from receiver while depressing buffer retainer 17 b CLEANING Clean all items operator s manual Remove carbon deposits Change 4 2 59 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 12 17 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY CONT INSPECTION 1 Inspect buffer
104. ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11 W3 5 5 42 Supersedes Copy Dated August 1987 TECHNICAL MANUAL UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST INTRODUCTION 1 1 UNIT MAINTENANCE INSTRUCTIONS 2 1 DIRECT SUPPORT RIFLE 5 56MM M16A2 W E MAINTENANCE 1005 01 128 9936 EIC 4GM INSTRUCTIONS 3 1 MAINTENANCE OF AUXILIARY EQUIPMENT REFERENCES 1 MAINTENANCE ALLOCATION CHART REPAIR PARTS AND SPECIAL CARBINE 5 56MM M4 22 cH 1005 01 231 0973 EIC 4FJ F EXPENDABLE DURABLE SUPPLIES AND sc v uu m MATERIALS LIST D i Maeg zd a ILLUSTRATED LIST OF 4 MANUFACTURED ITEMS CARBINE 5 56MM 4 1 ALPHABETICAL INDEX 1005 01 382 0953 EIC 4GC DISTRIBUTION STATEMENT Approved for public release distribution is unlimited DEPARTMENTS OF THE ARMY AND AIR FORCE MAY 1991 CHANGE 5 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 HEADQUARTERS DEPARTMENTS OF THE ARMY AND AIR FORCE Washington D C 9 April 1997 UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST RIFLE 5 56MM M16A2 W E 1005 01 128 9936 EIC 4GM TM 9 1005 319 23 amp P May 1991 is changed as follows 1 Remove old pages and insert new pages as indicated below 2 New or changed material is indicated by a vertical bar adjacent to the material 3
105. ASSEMBLY CONT 3 16 LOWER RECEIVER AND RECEIVER EXTENSION ASSEMBLY CONT 7T Install trigger guard 6 into lower receiver 3 8 Install spring pin 7 using 1 8 inch drive pin punch and hand hammer 9 Deleted 3 17 MAJOR COMPONENTS OF M16A2 RIFLE This task covers a Reassembly c Inspection INITIAL SETUP Test Equipment General Safety Instructions Tool and Gage Set item 2 app B To avoid injury to your eyes use care when removing and installing spring loaded parts Tools Live ammunition must not be near the work area ARMY Small Arms Repairman Tool Kit item 3 app B Reference TM 9 1005 319 10 3 82 Change 5 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 a REASSEMBLY Refer to TM 9 1005 319 10 Install charging handle assembly 1 and bolt carrier assembly 2 into upper receiver and barrel assembly 3 Join upper receiver and barrel assembly 3 and lower receiver and buttstock assembly 4 Snap on sling 5 and install magazine 6 Test trigger pull as follows M16A2 and M4 ONLY a Clear the weapon Place selector to BURST Pull the trigger and hold it to the rear Pull the 3LB charging handle to the rear and return to the bolt 1361 G closed position three times This will place the 2LB BURST disconnector in the deep notch of the 907 G BURST Release the trigger Place the selector to SEMI Hold the rifle in the vertical position Using trigger pull meas
106. AT 3 45 Upper Receiver and Barrel Assembly Rifle Barrel Assembly and Upper Receiver Assembly Gleaning ie eb Mende Ee dre ee Hester agg ea idis 2 48 Disassembly nrinn dapes ped pede MERI p A Idi ir PER IIR 2 45 INSPECTIONS icu co le e ete Pet cr ten ele e et nae ner rrt od eve HORT 2 49 cnin etd Om ted e e aia retenir TR SR Ee d SR eg 2 52 3 ig ree ei ee iare eid iuri iiu cip id 2 52 ire PD pn i eei imi uiti euet id 2 52 Index 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Subject Page Upper Receiver Assembly See Upper Receiver and Barrel Assembly Barrel Assembly and Upper Receiver Assembly or Upper Receiver Assembly and Rear Sight Assembly Upper Receiver Assembly and Rear Sight Assembly Disassembly 2 as ie evans inns 3 48 IniSpectiOrtac iue Io cathe cach bete Ino 3 51 3 53 CIE Pea 3 54 pire 3 53 LEID a Index 5 Index 6 blank By Order of the Secretary of the Army CARL E VUONO General United States Army Chief of Staff Official PATRICIA P HICKERSON Brigadier General United States Army The Adjutant General By Order of the Secretary of the Air Force MERRILL A M
107. AY6 TUBE BENT METALLIC 16 2 UOC AR8 TUBE BENT METALLIC M4 AND M4A1 UOC AS1 AY6 BARREL ASSEMBLY 16 2 UOC AR8 BARREL AND FRONT SI SIGHT ASSEMBLY REPLACEMENT M4 AND 1 UOC AS1 AY6 SHIM COMPENSATOR 5 PIN SPRING 6 RING SLIP HAND GUAR 0 SPRING SLIP RING HA HANDGUARD UPPER RECEIVER eene 22 RING BETAINING inr tr eene ene END OF FIGURE C 6 1 7 QTY ao ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 SECTION II eo ga M16A2 RIFLE M4 and M4A1 CARBINE Figure C 7 M16A2 Barrel Assembly 9349124 and M4 and M4A1 Replacement Barrel and Front Sight Assembly 9390007 Change 4 SECTION II 1 ITEM NO 6A 2 SMR CODE PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ XAFZZ XAFZZ PAOZZ PAOZZ PAOZZ TM9 1005 319 23LP 3 NSN 1005011343625 5315009793930 5360009793931 1005000179543 5320010637635 5340012646530 5315006900544 1010012646517 4 CAGEC 19200 19204 19204 19204 19204 19200 19200 19200 96906 19200 5 6 PART DESCRIPTION AND NUMBER USABLE ON CODE UOC GROUP 0301 M16A2 BARREL ASSEMBLY 9349
108. BLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 12 1 FAILURE TO CYCLE WITH SELECTOR LEVER SET ON AUTO M4A1 ONLY Step 1 Broken automatic sear 1 or spring 2 Replace automatic sear assembly 1 Step 2 Faulty selector lever 3 Replace selector lever 3 Step 3 Short recoil Refer to page 3 9 13 FIRES TWO ROUNDS WITH ONE PULL OF TRIGGER WITH SELECTOR LEVER SET ON SEMI DOUBLE FIRING Step 1 Defective semiautomatic disconnector 1 Replace semiautomatic disconnector 1 p 3 62 Step 2 Worn or broken trigger notch 2 of hammer 3 searing portion Replace hammer 3 p 3 62 Step 3 Worn or broken disconnector notch 4 of hammer 3 Replace hammer 3 p 3 62 M16A2 and M4 M4A1 Change 4 3 12 1 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 5 TROUBLESHOOTING PROCEDURES CONT TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 13 FIRES TWO ROUNDS WITH ONE PULL OF TRIGGER WITH SELECTOR LEVER SET ON SEMI DOUBLE FIRING CONT Step4 Worn or broken trigger 5 searing portion Replace trigger 5 p 3 62 Step5 Worn trigger or hammer pin hole 6 Gage trigger pin hole 7 and hammer pin hole 6 p 3 62 If test falls replace weapon M16A2 and M4 M4A1 3 12 2 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION
109. CATION Lubricate all metal components p 2 33 operator s manual RIFLE ONLY 1 Position hinge 1 on door assembly 2 and Install straight pin 3 RIFLE ONLY 2 Install door assembly 2 into buttplate 4 and press plunger 5 to lock RIFLE ONLY 8 Position buttplate group 6 and small sling swivel 7 to the buttstock 8 and secure with self locking screw 9 NOTE See page 2 62 reassembly for reassembly of buttstock assembly to lower receiver Change 3 2 67 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 2 18 BUTTSTOCK ASSEMBLY CONT f REASSEMBLY CONT CARBINE ONLY 4 Insert locking pin spring 10 onto locking pin 11 5 Insert locking pin 11 and spring 10 Into the hole on top of the buttstock 12 threaded end first 6 Insert your index finger into the forward end of the buttstock 12 and push down on locking pin 11 7 Install the release lever 13 onto the threaded portion of the locking pin 11 protruding through the bottom of the buttstock 12 8 Screw on the locking nut 14 until flush with locking pin 11 Align the slot In locking nut 14 with the spring pin hole in the locking pin 11 9 Lightly tap in spring pin 15 until flush on both sides of the retaining nut 14 a 2 67 1 2 67 2 blank Change 3 ARMY TM 9 1005 319 23 amp P AIR FORCE 11W3 5 5 42
110. CEIVER AND RECEIVER EXTENSION ASSEMBLY CONT d REASSEMBLY CONT CARBINE ONLY Lubricate threads of lower receiver 5 1 and lower receiver extension 5 2 with molybdenum disulfide greasg item 19 app D before reassembly Pre position the spring 5 3 and buffer retainer 5 4 into the retaining hole of the lower receiver 5 1 Screw the locking nut 5 5 onto the lower receiver extension 5 1 with the three notches on the locking ring 5 5 facing forward Align the receiver end plate 5 6 onto the lower receiver extension 5 2 with the lug of the receiver end plate 5 6 facing forward Pre position the takedown pin 5 7 detent 5 8 and spring 5 9 in lower receiver assembly 5 1 Push down on the buffer retainer 5 4 and spring 5 3 and at the same time screw the lower receiver extension 5 2 in until it retains the buffer retainer 5 4 in position Align the lug of the receiver end plate 5 6 into the rear of the lower receiver 5 1 Screw the locking nut 5 5 forward until it contacts the receiver end plate 5 6 Using the special tool Item 12 app C tighten the locking nut 5 5 until snug Using the special tool item 12 app C and torque wrench torque locking nut 5 5 to 40 2 inch pounds Stake the receiver end plate 5 6 in 2 places across from the notches in the locking nut 5 5 3 81 1 8 81 2 blank Change 3 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 d RE
111. EADLE HEADLESS 4 UOC AS1 AY6 13 PAFZZ 5360009927301 19204 8448637 SPRING HELICAL COMP COMPRESSION MAGAZINE 14 PAFZZ 1005009927302 19204 8448636 BUTTON MAGAZINE CAT vies 15 PAOZZ 5315000179537 19204 8448621 PIN GROOVED HEADED PIVOT 16 PAFZZ 5340011457910 19200 9349114 LEVER LOCK RELEASE SEMI M16A2 AND eus lea cer teens UOC ARS 51 16A PAFZZ 1005009990406 19200 8448635 DISCONNECTOR 4 1 UOC AYO aeren e 17 PAFZZ 5340011441499 19200 9349113 LEVER LOCK RELEASE BURST MI6A2 AND MA a5 11 1 SECTION II 1 2 ITEM SMR NO CODE 18 AFFFF 18A AFFFF 18B AFFFF 19 PAOZZ 20 PAOZZ 21 PAOZZ 22 PAOZZ 23 PAOZZ 24 PAFZZ 25 PAFZZ 26 PAFZZ 27 PAOZZ 28 28A 29 22 30 XAFFA 30A 30B TM9 1005 319 23 amp P 3 NSN 1005011484805 5310005273634 5305012681 191 5360009927292 1005009926667 5315009927309 5315009926650 5315009926653 5365012672169 1005011354973 5305011478585 4 CAGEC 19200 19200 19200 19200 96906 88044 19204 19204 19204 19204 19204 19200 19200 19200 19200 19200 99999 99999 5 PART NUMBER 9349115 12972697 12972698 9349127 MS35335 61 AN501D416 18 844851
112. FLE AND M4 M4A1 CARBINES 2 3 4 MAINTENANCE LEVEL MAINTENANCE COMPONENT ASSEMBLY FUNCTION M16A2 5 56 Inspect RIFLE AND M4 Test 4 1 5 56 Service CARBINES Replace Overhaul CARRYING Inspect HANDLE Service ASSEMBLY Remove M4 M4A1 Install Replace Repair Rear Sight Inspect Assembly M4 Replace M4A1 Repair BOLT CARRIER Inspect ASSEMBLY Service Remove Install Replace Repair Bolt Assembly Inspect Test Service Remove Install Replace Repair Worktimes are included in DMWR 9 1005 249 Change 4 5 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 2 COMPONENT ASSEMBLY Key and Bolt Carrier Assembly HANDLE ASSEMBLY UPPER RECEIVER AND BARREL ASSEMBLY M16A2 Barrel As sembly and M4 M4A1 Replacement Barrel Upper Receiver Assembly 030201 Forward Assist Assembly 030202 Rear Sight Assem bly M16A2 MAINTENANCE ALLOCATION CHART CONT MAINTENANCE LEVEL MAINTENANCE FUNCTION UNIT Inspect Service Remove Install Replace Repair Inspect Service Remove Install Replace Repair Inspect Test Service Remove Install Replace Repair Inspect Replace Repair Inspect Replace Repair Inspect Replace Repair Inspect Replace Repair COMPONENT ASSEMBLY LOWER RECEIVER AND BUTTSTOCK ASSEMBLY 0401and Buttstock Assembly Hammer Assembly Trigger Assembly 040301 Trigger Subassem bly M16A2 and M4 0404 and Lower
113. GENERAL There are several things you need to know to use this manual efficiently 1 All references in the manual are to pages only Reference to maintenance procedures is to the page where the respective initial setup appears 2 Illustrations for the maintenance procedures show only those parts affected by the operation being performed 3 Whenever the male gender is mentioned in the manual i e crewman repairman it also pertains to females 4 When the term evacuate to support maintenance is used the entire rifle must be evacuated 5 When a procedure is common to M16A2 rifle and M4 M4A1 carbine ONLY the M16A2 configuration will be depicted If a procedure is not common to both weapons the procedure will be incorporated 6 When the word rifle is referenced in text it will reference the rifle and the carbines INDEXES This manual is organized to help you find the information you need quickly There are several useful indexes 1 Table of Contents Lists in order all chapters sections and appendixes Gives page references 2 Nomenclature Cross References List 3 Chapter Overviews Summarize material covered in the chapter Are located at the beginning of each chapter 4 Symptom Index Located just before the troubleshooting table in each maintenance chapter Lists in alphabetical order parts of the rifle with possible malfunctions References pages of the troubleshooting table 5 Alphabetical Index L
114. ICATE FROM 0 08 IN MUSIC WIRE OR EQUIVALENT FINISH NO 5 3 1 2 OR 5 3 2 2 OF MIL STD 17 NOTE ALL DIMENSIONS SHOWN ARE IN INCHES WITH THE METRIC CONVERSION TO CENTIMETERS IN PARENTHESIS Figure E 1 Front sight detent depressor 5 16 INCH DRILL TIP ty 1 16 0 16 FOUR EQUALLY SPACED TEETH 0 070 IN 0 18 CM WIDE 0 32 FABRICATE FROM 0 375 INCH ROUND METAL BAR ASTM A686 FSCM 81346 GRADE C CLASS W2 09 NSN 9510 00 640 4407 OR EQUIVALENT NOTES 1 ALL DIMENSIONS SHOWN ARE IN INCHES WITH THE METRIC CONVERSION TO CENTIMETERS IN PARENTHESIS 2 TEETH MUST BE HAND FILED TO FIT FRONT SIGHT POST Figure E 2 Front sight post removal and Installation tool ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 1 4 0 64 jt FABRICATE FROM 1 16 IN SOCKET HEAD SCREW KEY NSN 5120 00 198 5398 OR EQUIVALENT NOTE ALL DIMENSIONS SHOWN ARE IN INCHES WITH THE METRIC CONVERSION TO CEN TIMETERS IN PARENTHESES Figure E 3 Pivot pin removal tool E 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 E 3 MANUFACTURED ITEMS ILLUSTRATIONS FORMAT AND CONTENT CONT 2 50 0 05 6 35 0 13 250 63 1 4 381 MIN 0 005 0 013 MAX BOW FOR 150 005 LENGTH 381 0 13 pes 8 10 318 0 25 0 05R 110 64 0 13 mm 0 245 0 000 DIA STOCK 1 0 0 01 0 025 x 45 MAX CHAMFER 0 004 0 622 0 000 0 010
115. IR FORCE 11 W3 5 5 42 4 3 TOP SLING ADAPTER This task covers a Installation c Inspection b Removal INITIAL SETUP Materials Parts Top sling adapter kit PN 8448471 References TM 9 1005 319 10 a INSTALLATION Refer to TM 9 1005 319 10 to remove sling RIFLE ONLY Install top sling adapter strap 1 through sling swivel 2 and tie CARBINE ONLY Install top sling adapter strap 1 through sling opening 2 1 and tie CARBINE 4 6 Change 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 3 Remove upper handguard assembly 4 Use pliers to install clamp 3 on front sight base 4 5 Attach sling 5 to top sling adapter strap 1 and to clamp 3 6 Reinstall upper handguard assembly 6 7 Adjust sling 5 Change3 4 7 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 4 3 TOP SLING ADAPTER CONT b REMOVAL 1 Remove upper handguard assembly 2 Remove sling 1 from clamp 2 and top sling adapter strap 3 3 Use pliers to remove clamp 2 from front sight base 4 5 4 Reinstall upper handguard assembly 4 7 1 Change 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 RIFLE CARBINE Untie top sling adapter strap 3 and remove from buttstock 6 Refer to TM 9 1005 319 10 and install sling Change 3 4 7 2 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 4 3 TOP SLING ADAPTER CONT c INSPECTION Visu
116. Item Standard RIFLE General Clear rifle of any ammunition and Inspect In accordance with paragraph 3 25 Barrel and barrel extension Check barrel erosion Use barrel erosion gage 8448496 for chrome lined barrels Stripping of lands and grooves shall not be cause for rejection unless so determined by barrel erosion gage Visually inspect using chamber reflector tool 8448201 Pits 1 8 inch 0 31 cm In length and those pits large enough to extend from the body of the chamber into the shoulder stop area and forcing cone area are cause for rejection Large pits are defined as those 1 8 inch 0 31 cm or more in diameter as determined by visual Inspection Only closed flash suppressors are accept able Check barrel for straightness using bore straightness gage 8448202 Gage must pass freely through the bore to be acceptable either dropped from the muzzle or chamber end Front sight and gas tube Inspect gas tube for proper alignment with carrier key Gas tube must not bind when mating with the key Evidence of gas leaks around the front sight connection of the gas tube shall be cause for rejection until rifle has been function fired to determine if the loss of gas is sufficient to cause malfunction If function firing malfunctions occur repairs are neces sary Inspect front sight for damage 3 100 ARMY TM 9 1005 319 23 amp AIR FORCE 1 1 3 5 5 42 Table 3 1 5 56MM Rifle M16A2 M4 M4A1 Carbine Cont Item Standard
117. LE ON CODE The usable on code appears in the lower left corner of the DESCRIPTION column heading Usable on codes are shown as UOC in DESCRIPTION column justified left on the first line applicable item description nomenclature Uncoded items are applicable to all models Identification of the usable on codes used in the RPSTL are Code Used On AR8 M16A2 Rifle AS1 M4 Carbine AY6 M4A1 Carbine C 6 HOW TO LOCATE REPAIR PARTS a When National Stock Number or Part Number is Not Known 1 First Using the table of contents determine the assembly group or subassembly group to which the item belongs This is necessary since figures are prepared for assembly groups and subassembly groups and listings are divided into the same groups Change 5 C 7 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 C 6 HOW TO LOCATE REPAIR PARTS CONT 2 Second Find the figure covering the assembly group or subassembly group to which the item belongs 3 Third Identify the item on the figure and use the Figure and Item Number Index to find the NSN b When National Stock Number or Part Number is Known 1 First Using the National Stock Number or the Part Number Index find the pertinent National Stock Number or Part Number The NSN index is in National Item Identification Number NIIN sequence See C4 a 1 The pat numbers in the Part Number Index are listed in ascending alpha numeric sequence See C4 b Both indexes cross reference yo
118. M 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Interval Item to be Not Fully Mission Checked or Procedure Capable if Serviced 6 Quarterly Lower receiver NOTE cont and buttstock If a weapons lower re assembly ceiver is missing one serviceability third or more of its ex check cont terior protective finish resulting in an unprotect ed light reflecting surface it is candidate for over haul This missing finish will be considered a shortcoming This shortcoming re quires action to obtain a replacement weapon Once a replacement has been received evacuate the original weapon to depot for overhaul If scratched or worn shiny in spots repair in the same manner as out lined for upper receiver see item 4 above 7 Quarterly M16A2 Rifle Assemble as in TM 9 1005 319 10 operator s manual Check sling for damage If damaged replace Check for improperly assembled broken missing or damaged parts Check over all general appearance Replace parts as required and authorize evacuation to support main tenance for repair Change 4 2 19 ARMY TM 9 1005 319 23 amp AIR FORCE 11W3 5 5 42 2 T PREVENTIVE MAINTENANCE CHECKS AND SERVICES CONT Item to be Not Fully Mission Checked or Procedure Capable if Serviced Quarterly Annual DS safety Check to ensure annual DS safety and Annual gaging and serviceability service
119. MBLY EXTENSION LOWER REC RECEIVER LOWER RECEIVER EXTENSION 1 UOC AR8 PIN SHOULDER HEADLE RETAINER 16 2 sse UOC AR8 SPRING HELICAL COMP COMPRESSION BUFFER RETAINER 6 2 UOC AR8 GUARD TRIGGER 16 2 PIN SPRING TRIGGER GUARD 16 2 RECEIVER 16 2 UOC AR8 END OF FIGURE C 16 1 7 QTY ARMY 9 1005 319 23 amp AIR FORCE TO 11W3 5 42 SECTION II Figure C16A M4 and M4A1 Lower Receiver and Receiver extension Assembly NPN Change 4 SECTION II 1 ITEM NO 10 11 2 SMR CODE PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ XAFDA XAFDA PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ TM9 1005 319 23 amp P 3 NSN 1005012338531 5310012338625 105012338530 5315009926651 5360009926652 1005009927299 5315000586081 5315009926653 5315009926654 5360009926655 4 CAGEC 19200 19200 19200 19204 19200 19200 19200 19204 96906 19204 19204 19204 5 PART NUMBER 9390019 9390020 9390021 8448582 8448583 9390015 12972652 8448587 MS16562 129 8448584 8448585 8448586 6 7 DESCRIPTION AND USABLE ON CODE UOC QTY GROUP 0404A
120. MY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 10 UPPER RECEIVER AND BARREL ASSEMBLY CONT e TEST CONT a If the test fails using finger pressure remove the gage and perform the test again as follows With the muzzle down stack 8 1 2 to 8 3 4 pounds of trigger weights 8 on a locally fabricated spacer weight 9 on the bolt carrier assembly 10 Insert headspace gage 11 and test per above instructions b Remove trigger weights 8 spacer weight 9 bolt carrier assembly 10 charging handle 12 and headspace gage 11 c If excessive headspace first replace bolt assembly and then recheck If headspace is not corrected replace barrel assembly then recheck with the original bolt to determine if the bolt is still good or If the bolt should be replaced also ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 11 UPPER RECEIVER ASSEMBLY AND REAR SIGHT ASSEMBLY This task covers a Disassembly b Inspection c Repair INITIAL SETUP Tools ARMY Small Arms Repairman Tool Kit item 3 app B Field Maintenance Basic Less Power Small Arms Shop Set item 1 app B Materials Parts Cleaner lubricant and preservative CLP item 9 app D Lubricant solid film item 21 app D Index screw 9349065 a DISASSEMBLY d Lubrication e Reassembly f Mechanical Zero Procedures Only Equipment Conditions 3 29 Upper receiv
121. MY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 d LUBRICATION Lightly lubricate all items p 2 33 operators manual e REASSEMBLY WARNING To avoid Injury to your eyes use care when removing and Installing spring loaded parts Do not Interchange bolt assemblies from one rifle to another Doing so may result In injury to or death of personnel CAUTION Be sure to use vise jaw protective caps Place bolt body 1 in a vise and start spring pin 2 In hole Install ejector spring 3 and cartridge ejector 4 Align groove on cartridge ejector 4 so that spring pin 12 can be Installed Compress and hold ejector spring and cartridge ejector In place with a 3 8 inch punch Using hammer and 1 16 Inch punch complete Installation of spring pin 2 so that the ends are flush with the out side of bolt body 1 2 41 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 14 BOLT ASSEMBLY CONT e REASSEMBLY CONT 5 NOTE Do not disassemble rubber Insert from extractor spring assembly If removed Insert large end of extractor spring assembly 5 into cartridge extractor 6 and seat by pushing and turning clockwise Position cartridge extractor 6 and ex tractor spring assembly 5 on bolt body 1 Compress extractor spring assembly 5 and cartridge extractor 6 to align holes Install extractor pin 7 by hand Reassemble rifle refer to page 2 68 2 42 ARMY TM 9 1005 319 23 a
122. N 9150 00 753 4686 1 gal 3 79 11 0 5340 01 230 3181 MOUNTING BRACKET M4 M4A1 ONLY EA 19200 12556036 0 8010 00 087 0102 PAINT ENAMEL SEMIGLOSS EA paint for blank firing attachment M1 5A2 81348 TT E 529 1 qt can RED M16A2 0 8010 01 031 1274 PAINT ENAMEL SEMIGLOSS EA paint for blank firing attachment M23 81348 TT E 529 1 pt can YELLOW M4 M4A1 0 4940 00 795 3595 PAN WASH EA 94453 1211 F 6850 00 826 0981 PENETRANT KIT KT 81349 MIL I 25135 F 8135 01 019 1691 POLYETHYLENE SHEET EA 84744 PE88 80 2 0 1005 01 394 7677 PROTECTOR RAIL M4 M4A1 ONLY EA 19200 12972676 C 7920 00 205 1711 RAG WIPING LB 58536 A A 531 50 Ib 22 68 kg C 1005 00 050 6357 ROD SECTION CLEANING EA SMALL ARMS 19204 8436775 3 REQUIRED F 8030 00 670 8553 SEALING COMPOUND KT 16059 DEVCONF ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 EXPENDABLE DURABLE SUPPLIES AND MATERIALS LIST CONT 1 3 4 NATIONAL DESCRIPTION ITEM STOCK NUMBER NUMBER PART NUMBER AND CAGE 1005 00 937 2250 SWAB HOLDER SECTION CLEANING ROD SMALL ARMS 19204 11686327 1005 00 912 4248 SWAB SMALL ARMS 19204 11686408 6920 01 395 2949 TARGET 25 METER ZEROING M16A2 19200 12012024 Change 4 D 5 D 6 blank ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 APPENDIX E ILLUSTRATED LIST OF MANUFACTURED ITEMS E 1 INTRODUCTION a This appendix includes complete instructio
123. N CONT c FUNCTIONAL THEORY OF THREE ROUND BURST CONTROL CONT i The front hook of the burst disconnector is now fully In the second notch j As the key and bolt carrier assembly travels forward the automatic sear releases the hammer and the hammer falls When the hammer falls the SECOND ROUND is fired I As the key and bolt carrier assembly moves to the rear the hammer is forced back to the rear 3 90 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 m m The clutch spring of the burst cam clutches against the burst cam and causes It to rotate one notch as the haiimmer is forced back n When the hammer is fully to the rear the automatic sear catches It The front hook of the burst disconnector IS now fully In the third notch p As the key and bolt carrier assembly travels forward the automatic sear releases the hammer and the hammer falls ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 3 18 16 2 RIFLE FINAL INSPECTION CONT c FUNCTIONAL THEORY OF THREE ROUND BURST CONTROL CONT q When the hammer falls the THIRD ROUND Is fired r As the key and bolt carrier assembly moves to the rear the hammer is forced back to the rear s The clutch spring of the burst cam clutches against the burst cam and causes it to rotate one notch as the hammer is forced back When the hammer Is fully to the rear It Is initially caught the automatic sear However
124. NANCE ALLOCATION CHART Section I INTRODUCTION B 1 GENERAL a This section provides a general explanation of all maintenance and repair functions authorized at various maintenance levels b The Maintenance Allocation Chart MAC In section designates overall authority and responsibility for the performance of maintenance functions on the identified end Item or component The application of the maintenance functions to the end Item or component will be consistent with the capacities and capabilities of the designated maintenance levels c Section Ill lists the tools and test equipment both special tools and common tool sets required for each maintenance function as referenced from section d Section IV contains supplemental instructions and explanatory notes for a particular maintenance function B 2 MAINTENANCE FUNCTIONS Maintenance functions will be limited to and defined as follows except for ammunition MAC a Inspect To determine the serviceability of an Item by comparing Its physical mechanical and or electrical characteristics with established standards through examination leg by sight sound or feel b Test To verify serviceability by measuring the mechanical pneumatic hydraulic or electrical characteristics of an Item and comparing those characteristics with prescribed standards Service Operations required periodically to keep an Item In proper operating condition e to clean includes decont
125. NG When utilizing the enhanced rifle grip it has a bump between the second third finger for a better grip PN 9349127 rifle grip screw PN 5010416 18 1 1 8 in or AN 501 D416 16 1 in is authorized to be used with the enhanced grip Any screw longer than 1 1 8 In used with 9349127 could cause a hazardous situation Also ensure the washer Is in 11place CAUTION Do not kink helical spring 15 during assembly 7 Install safety detent 16 pointed end first and helical spring 1 5 into bottom of lower receiver 17 NOTE A portion of the helical spring will fit In a hole in the pistol grip 8 Carefully install pistol grip 18 to compress helical spring 115 Secure pistol grip 118 in place with lockwasher 19 and screw 120 9 Reassemble rifle refer to page 2 68 2 18 BUTTSTOCK ASSEMBLY This task covers a Disassembly d Repair b Cleaning e Lubrication c Inspection f Reassembly INITIAL SETUP Tools Equipment Conditions ARMY Small Arms Repairman Tool Kit 2 57 Buttstock assembly removed from item 3 app B lower receiver and buttstock as sembly 2 64 a DISASSEMBLY ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 RIFLE ONLY 1 Remove self locking screw 1 small sling swivel 2 and buttplate group 3 from buttstock 4 out of buttplate 7 RIFLE ONLY 2 Push down on plunger 5 and lift door assembly 6 3 Remove straigh
126. NSN 1005 01 227 1739 9 Night Vision Sight Individual Served Weapon AN PVS 4 NSN 5855 00 629 5334 M16A2 ONLY 10 M2 Practice Bolt NSN 1005 01 184 4041 M16A2 ONLY b Referto TM 9 1010 221 23 amp P for unit maintenance for the Grenade Launcher M203 ARMY ONLY Refer to TM 9 6920 363 12 amp P for unit maintenance for the M261 Conversion Kit caliber rimfire adapter M16 M16A1 and M16A2 Rifles d Refer to TM 9 1005 237 23 amp P for repair instructions and repair parts for Bayonet Knife M7 and Bayonet Knife Scabbard M10 and 9 Multi Purpose Bayonet System e Refer to TM 11 5855 213 23 amp P for maintenance for the Night Vision Sight Individual Served Weapon AN PVS 4 f Refer to TM 9 6920 746 128 for unit maintenance for the M2 Practice Bolt Change 5 4 1 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 4 2 LOCK PLATE This task covers a Installation c Inspection b Removal INITIAL SETUP Tools ARMY Small Arms Repairman Tool Kit item 3 app B WARNING The lock plate prevents the selector lever from being placed in BURST and will be installed at the discretion of the unit commander It is mandatory for use in civil disturbance riot control Do not keep live ammunition near work area a INSTALLATION Using a screwdriver reach inside pistol grip 1 and remove screw 2 and lockwasher 3 WARNING To avoid injury to your eyes use care when removing and installing spring loaded parts
127. O 11 W3 5 5 42 3 5 TROUBLESHOOTING PROCEDURES CONT TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 3 8 Change 4 CORRECTIVE ACTION M4A1 has only 1 disconnector Worn or broken disconnector hooks 8 Replace defective disconnectors 9 p3 62 M4A1 has only 1 spring Weak broken or missing disconnector springs 10 Replace disconnector springs 10 p 3 62 Worn broken or missing automatic sear 11 Replace automatic sear 11 p 3 62 Weak or broken automatic sear spring 12 Replace automatic sear 11 p 3 62 Long leg 13 of automatic sear spring incorrectly assembled in receiver Remove automatic sear assembly 11 and install correctly p 3 62 M16A2 and M4 ONLY Burst cam 14 or clutch spring 15 frozen or improperly assembled Disassemble inspect clean lubricate or replace as required p 3 73 M4A1 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 10 SHORT RECOIL Step 1 Improper gap space or worn missing or broken bolt rings 1 a Stagger bolt ring gaps p 3 21 b Replace bolt rings 1 and stagger gaps p 3 21 Step 2 Broken or bent gas tube 2 Adjust by in area of handguards or replace gas tube 2 p 3 29 lt Step 3 Gas tube spring pin 3 missing from front sight 4 Replace gas tube spring pin 3 p 3
128. PART DESCRIPTION AND NO CODE CAGEC NUMBER USABLE ON CODE UOC QTY GROUP 040301 TRIGGER SUBASSEMBLY M6A2 9392518 AND M4 12972696 FIG C 15 TRIGGER SUBASSEMBLY 1 PAFZZ 5360011350353 19200 9349116 SPRING HELICAL COMP DISCONNECT UOC AR8 1A PAFZZ 5360011350353 19200 9349116 SPRING HELICAL COMP DISCONNECT 4 UOC AS1 1B PAFZZ 5360013960256 19200 12972695 SPRING HELICAL COMP DISCONNECT MA s BEACK UOC AS1 2 XAFZZ 19200 9390736 TRIGGER M16A2 since Rete aa UOC AR8 3 XAFZZ 19200 9390736 TRIGGER MA oreet perenne e ne en enne UOC AS1 END OF FIGURE C 15 1 ARMY 9 1005 319 23 amp AIR FORCE TO 11W3 5 42 SECTION II Figure C 16 M16A2 Lower Receiver and Receiver extension Assembly 9349101 Change 3 SECTION II 1 2 ITEM SMR NO CODE 1 PAFZZ 2 PAFZZ 3 PAFZZ 4 PAFZZ 5 PAFZZ 6 XAFDA TM9 1005 319 23 amp P 3 NSN 5340009927297 5315009926651 5360009926652 1005009927299 5315000586081 4 CAGEC 19200 19204 19200 19204 96906 19200 5 PART NUMBER 8448581 8448582 8448583 8448587 MS16562 129 9349102 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0404 M16A2 LOWER RECEIVER AND RECEIVER EXTENSION ASSEMBLY 9349101 FIG C 16 M16A2 LOWER RECEIVER AND RECEIVER EXTENSION ASSE
129. Receiver and Receiver Ex tension Assembly MAINTENANCE ALLOCATION CHART CONT MAINTENANCE LEVEL UNIT MAINTENANCE FUNCTION Inspect Test Service Repair Inspect Remove Install Replace Repair Inspect Remove Install Replace Repair Inspect Remove Install Replace Repair Inspect Replace Repair Inspect Test Repair ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 C D E Change 4 7 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 Section TOOL AND TEST EQUIPMENT REQUIREMENTS FOR M16A2 RIFLE AND M4 M4A1 CARBINES 2 3 4 TOOL OR MAINTENANCE EQUIPMENT CATEGORY NOMENCLATURE NATIONAL NATO REF CODE STOCK NUMBER Shop Set Small 4933 00 754 0664 Tool and gage Set 4933 00 056 7106 DS GS Maintenance for 5 56mm Rifle M16 Series Tool Kit Small Arms 5180 00 357 7770 Repairman Torque Wrench ft lb 5120 00 640 6365 Torque Wrench 5120 00 230 6380 Trigger Weights 4933 00 647 3696 Section IV REMARKS Tool Front Sight Post Removal and Installation Depressor Front Sight Detent Tool Pivot Pin Removal Tool Pivot Pin Installation Pin Slave B 8 Change 4 5 TOOL NUMBER SC 4933 95 CL A11 8426685 SC 5180 95 CL A07 411 12 7274758 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 APPENDIX C REPAIR PARTS AND SPECIAL TOOLS LIST Section I INTRODUCTION C 1 SCOPE This RPSTL lists and authorizes spares
130. S AND REPORTS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 738 750 The Army Maintenance Management System Air Force users refer to TO 11W 1 10 for applicable forms and records 1 3 DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE See TM 750 244 7 1 4 PREPARATION FOR STORAGE OR SHIPMENT Refer to page 2 70 Air Force users refer to Special Package Instruction SPI 00 856 6885 1 5 OFFICIAL NOMENCLATURE NAMES AND DESIGNATIONS NOMENCLATURE CROSS REFERENCE LIST Common Name Official Nomenclature ACTION SPNO ient rece tie ege eae Compression Helical Spring Ball Bearing Ens Bearing Ball Bolt Catch Spring sess Compression Helical Spring Bolt Carrier Key Machine Key Burst Lock Release Lever Cam Clutch Helical Spring Carbine herede ree pee M4 M4A1 Carbine Charging Handle Handle Assembly Change 5 1 1 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 1 5 OFFICIAL NOMENCLATURE NAMES AND DESIGNATIONS CONT NOMENCLATURE CROSS REFERENCE LIST Common Name Official Nomenclature Disconnector Springs 2 2 2 Compression Helical Spring Ejector Helical Spring Extractor Spring
131. SEMBLY RIFLE BARREL ASSEMBLY AND UPPER RECEIVER ASSEMBLY CONT t REASSEMBLY CONT 7 Mechanical Zero Procedures Only a Mark a piece of plastic card stock or rigid paper with lines from 1 to 5mm in 1 mm increments Set the card on the front sight frame and check the height of the top of the front sight post b Using a dummy round or front sight post tool adjust the front sight so the top of the front sight post is 5mm above the machined surfaces of the front sight frame 2 54 Change 4 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 1 1W3 5 5 42 c Visually check the front sight post top height by using the marked plastic or paper card Card must set level on the machined surfaces of the front sight frame to obtain an accurate reading 5mm NOTE This procedure when used In conjunction with rear sight mechanical zero adjustment will give an approximate battle sight zero to most M16A2 rifles The above steps can also be used before firing a new or newly assigned rifle Use the procedures to check rifles stored In preferred packaging during routine Inspections This will help ensure people armed with the rifles will stand a better chance of hitting an enemy If the rifles must be used before a live fire zero can be made Whenever possible zeroing of the rifle should be accomplished using ball ammunition on a 25 meter zeroing target using the L aperture 2 55 ARMY TM 9
132. SPRING HELICAL COMP COMPRESSION ELEVATION 16 2 KNOB ELEVATION 16 2 UOC AR8 END OF FIGURE C 8 1 7 QTY ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 11W3 5 5 42 SECTION II Figure C 9 Forward Assist Assembly 9349086 SECTION II 1 2 ITEM SMR NO CODE 1 PAFZZ 2 PAFZZ 3 PAFZZ 4 PAFZZ 5 PAFZZ TM9 1005 319 23LP 3 NSN 1005011441468 5315010489372 5360005238084 1005000179540 3040000179539 4 CAGEC 19200 19204 19200 19204 19204 5 PART NUMBER 9349085 8448521 2 8448542 8448544 8448543 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 030201 FORWARD ASSIST ASSEMBLY 9349086 FIG C 9 FORWARD ASSIST ASSEMBLY DETENT PAWL PAWL FORWARD ASSIST END OF FIGURE C 9 1 7 QTY ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 SECTION II Figure C 10 M16A2 Rear Sight Assembly 9349072 Change 5 SECTION II 1 2 ITEM SMR NO CODE 1 PAFZZ 2 PAFZZ 3 PAFZZ 4 PAFZZ 5 PAFZZ 6 22 7 PAFZZ 8 22 TM9 1005 319 23LP 3 NSN 5315000586678 1005011343631 5305011441490 5360011481751 3110001839175 1005011353697 5360013816183 5355011343627 4 CAGEC 96906 19200 19200 19200 96906 19200 19200 19200 5 PART NUMBER MS16562 103 9349074 9349076 9349069 M5S19060
133. STICS CAPABILITIES AND FEATURES a Characteristics 1 Light weight 4 Magazine fed 2 Air cooled 5 Semiautomatic or burst fire 3 Gas operated b Capabilities Provides personnel an offensive defensive capability to engage targets with direct small arms fire c Features 1 Receivers are made of light weight aluminum alloys however the safety durability and function of the rifles are in no way reduced The portability and logistical values are greatly increased particularly when air transport is used 2 The bolt locking action is one of the mechanical features of the rifle The bolt assembly and barrel extension contain locking lugs which engage and lock the bolt assembly firmly in the barrel extension The initial force of the explosion of the cartridge is absorbed by the barrel barrel extension and bolt assembly Change 4 1 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 1 8 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES CONT 3 The trigger guard is easily adaptable to winter operations A spring loaded retaining pin is depressed to allow ready access to the trigger when wearing arctic mittens 4 The ejection port cover prevents dirt or sand from getting into the ejection port The ejection port cover must be closed during periods when firing is not anticipated It opens automatically by the forward or rearward movement of the bolt carrier assembly 1 9 A B C D E
134. TO 11W3 5 5 42 a DISASSEMBLY CONT 3 16 LOWER RECEIVER AND RECEIVER EXTENSION ASSEMBLY CONT RIFLE ONLY 4 Clamp lower receiver 2 in a machinist s vise using vise jaw caps and tighten on solid portion just tight enough to hold WARNING To avoid injury to your eyes use care when removing and installing spring loaded parts NOTE As lower receiver extension is removed catch buffer retainer and helical spring Lower receiver is a serial number controlled item 5 Remove lower receiver extension 4 from lower receiver 2 using combination wrench wrench handle Catch buffer retainer 6 and helical spring 7 3 78 Change 3 CARBINE ONLY Clamp lower receiver 8 in vise and tighten on solid portion just tight enough to hold NOTE Use wooden vise jaws in place of brass vise jaw Caps Remove the lower receiver extension 9 by loosening the extension locking nut 10 using the special tool item 12 app C Catch buffer retainer and spring 11 CAUTION While performing the following step care should be taken to restrain the pivot pin spring and detent Loosen the locking nut 10 to allow the receiver end plate 12 to disengage from the lower receiver Hold the buffer retainer and spring 11 in position with your index finger and unscrew the lower receiver extension 9 from the lower receiver 8 ARMY TM 9 1005 319 23 amp AIR FORCE 11W3 5 5 42 CAUTION Change 3 3 78 1 3 78 2
135. To avoid injury to your eyes use care when removing and installing spring loaded parts 1 Drive out spring pin 1 using 1 16 inch drive pin punch and hand hammer 2 Remove forward assist pawl 2 pawl detent 3 and helical spring 4 from plunger assembly 5 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 12 FORWARD ASSIST ASSEMBLY CONT b INSPECTION Inspect forward assist pawl 1 for burrs chips and cracks Minor burrs may be removed using fine files or stones as required Replace forward assist pawl if defective Inspect pawl detent 2 for burrs and cracks Minor burrs may be removed using fine files or stones as required Replace pawl detent if defective Inspect helical spring 3 for kinks breaks and wear Replace helical spring if defective Inspect plunger assembly 4 for wear burrs chips and breaks Minor burrs may be removed using fine files or stones as required Replace forward assist assembly if defective Inspect spring pin 5 for wear Replace if defective c REPAIR Repair forward assist pawl using fine files or stones as required to smooth burrs Do not deform forward assist pawl Repair pawl detent using fine files or stones as required to smooth burrs Do not deform pawl detent Repair plunger assembly using fine files or stones as required to smooth burrs Do not deform plunger assembly 3 60 Change 5 ARMY TM 9 1005 319 23
136. To identify functions to this level of maintenance enter a work time figure in the column of section 11 column 4 and use an associated reference code in the Remarks column 6 Key the c ode to Section IV Remarks and explain the SRA complete repair application there The explanatory remarks s shall reference the specific Repair Parts and Special Tools List RPSTL TM which contains additional SRA criteria and the authorized spare repair parts B 3 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 B 4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS SECTION a Column 1 Reference Code The tool and test equipment reference code correlates with a code used In the MAC Section Il Column 5 b Column 2 Maintenance Level The lowest level of maintenance authorized to use the tool or test equipment c Column 3 Nomenclature Name or identification of the tool or test equipment d Column 4 National Stock Number The National stock number of the tool or test equipment e Column 5 Tool Number The manufacturer s part number B 5 EXPLANATION OF COLUMNS IN REMARKS SECTION IV a Column 1 Reference Code The code recorded In column 6 Section II b Column 2 Remarks This column lists information pertinent to the maintenance function being performed as indicated In the MAC Section Il ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 Section Il MAINTENANCE ALLOCATION CHART FOR M16A2 RI
137. ability inspection and gaging has has not been inspection and been done and that the next gaging performed gaging and inspection is scheduled If annual gaging has not been performed within the last year notify support mainte nance Section IV TROUBLESHOOTING 2 8 GENERAL a This section contains unit level troubleshooting information for locating and correcting most of the operating troubles which may develop in the M16A2 rifle M4 M4A1 carbine Each malfunction for the individual part or assembly is followed by a list of tests or inspections which will help you to determine the corrective actions in the order listed b This manual cannot list all malfunctions that may occur nor all tests or inspections and corrective actions If a malfunction is not listed or is not corrected by listed corrective actions see individual repair sections in the maintenance procedures on each major assembly 2 9 TROUBLESHOOTING PROCEDURES Refer to troubleshooting table for malfunctions tests and corrective actions The symptom index is provided for a quick reference of the malfunctions covered in the table 2 20 Change4 ARMY TM 9 1005 319 23 amp P AIR FORCE 11W3 5 5 42 SYMPTOM INDEX Troubleshooting Procedures Page Failure of magazine to lock in nennen nennen enn nnne 2 21 Fall ed0 66d Mui mente eth eee E 2 22 ce 2 22 6
138. age knobs for cracks Detent indexing surfaces should be well formed Check rear sight assembly base 81 for serviceability Clear drain holes for springs Threaded portion of rear sight assembly base and elevation knob should be well formed Inspect rear sight guards for bends if bent refer to the following page for repair procedures Inspect all parts for damage and wear Replace all defective parts Co 6 9 3 52 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 c REPAIR To straighten bent rear sight assembly guards 1 remove rear sight assembly components Place carrying handle 2 In a vise using jaw clamps Tighten vise to firmly hold upper receiver 3 Using two adjustable wrenches gradually bend guards 1 to straighten When bending the guards 1 gradually bend beyond the straight point as the guard will partially return when bending pressure is stopped After straightening use a flat file to remove any nicks kinks or burrs that remain on the inside of guards 1 CAUTION Do not use wire brush on aluminum surfaces Apply solid film lubricant to brightened area for final protective coating Replace rear sight assembly components and check that rear sight assembly functions properly If rear sight assembly functions check out return upper receiver assembly to service If rear sight guards cannot be straightened utilizing the above procedures replace the upper receiv
139. air Parts and Special Tools C 1 Parts Lists E C 1 1 Repair Parts Special Tools TMDE and Support 2 1 3 1 Reporting Equipment Improvement Recommendations 1 2 Reporting Errors and Recommending Improvements Service Upon en tenens entree 2 2 Sp cial TOONS ASE eate dede rrt erac 17 1 Special Tools TMDE and Support 2 1 TTE ART LT IDOL UE 2 21 3 2 T Top Sling Adapter ieu 4 8 Installation 2 3 5 2 EUER eR SU dated bee Ie tastes 4 6 eoe Hte tite aetate tatu eet 4 7 Trigger Assembly and Trigger Subassembly Disassembly nino uei 3 75 INSPECTION P epalr ni m ere mr der rei prid mp iE 3 76 Heassembly IDEE REO 3 76 Trigger Subassembly See Trigger Assembly and Trigger Subassembly Troubleshooting 1 tee Pees deca dee teret eere 2 21 3 2 U Unit Level Auxiliary Equipment 4 1 Upper Receiver and Barrel Assembly PER 3 30 Inspection Cleaning hier ede EE dete ea oce 3 33 Fieasserriblyz ic edi imt de iE di d HE edi n 3 39 rie EE 3 35 auccm REM EE
140. al bar adjacent to the material 3 New or changed illustrations are indicated by a miniature pointing hand highlighting the change Remove Pages Insert Pages 1 3 and 1 4 1 3 and 1 4 4 File the change sheet in the front of the publication for reference purposes By Order of the Secretary of the Army GORDON R SULLIVAN General United States Army Chief of Staff Official MILTON H HAMILTON Administrative Assistant to the Secretary of the Army By Order of the Secretary of the Air Force MERRILL A McPEAK General USAF Chief of Staff Offical CHARLES C McDONALD General USAF Commander Air Force Logistics Command DISTRIBUTION TO BE DISTRIBUTED IN ACCORDANCE WITH DA FORM 12 40 E BLOCK 0020 REQUIREMENTS FOR TM 9 1005 319 23 amp P CHANGE NO 1 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 HEADQUARTERS DEPARTMENTS OF THE ARMY AND AIR FORCE Washington DC 2 April 1992 UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST TM 9 1005 319 23 amp P May 1991 Is changed as follows RIFLE 5 68MM M16A2 W E 1005 01 128 9936 EIC 4GM 1 Remove old pages and Insert new pages as indicated below 2 New changed material is indicated by a vertical bar adjacent to the material 3 New or changed lllustrations are Indicated by a miniature pointing hand highlighting the change Remove Pages 2 7 and 2 8 2 57 thru 2 60 3 35 and 3 36 3 65 and 3 66
141. ally Inspect top sling adapter strap and replace If it is badly worn or damaged 4 8 Change 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 4 4 BLANK FIRING ATTACHMENTS M15A2 M16A2 AND M23 M4 M4A1 This task covers a Installation d Inspection b Removal e Repainting c Cleaning f Replacement INITIAL SETUP Materials Parts Only blank cartridge M200 is to be used when Cleaner lubricant and preservative CLP the blank firing attachment is attached to item 9 app D the weapon Coating compound enamel Red Do not fire blank ammunition at a representative M16A2 item 23 2 app D enemy at distances of less than 20 feet 6 10m Coating compound enamel Yellow The unburned propellant grains can cause M4 MAA1 item 23 3 app D injury within this distance General Safety Instructions Do not keep live ammunition near the Work area a INSTALLATION NOTE M23 blank firing attachment is stamped M4 Carbine Only painted yellow and may be used on the M4 and M4A1 carbines M15A2 BFA is painted red and is used on the M16A2 rifle 1 Unscrew and pull slide 1 all the way out on blank firing attachment 2 2 Hook blank firing attachment 2 behind the first groove of the compensator 3 Change4 4 9 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 4 4 BLANK FIRING ATTACHMENTS 15 2 M16A2 AND M23 4 4 1 a INSTALLATION CONT CAUTION Do not use tools to tighten
142. aminate when required to preserve to drain to paint or to replenish fuel lubricants chemical fluids or gases d Adjust To maintain or regulate within prescribed limits by bringing Into proper or exact position or by setting the operating characteristics to specified parameters Exception is authorized for ammunition MAC to permit the redesignation redefinition of maintenance function headings to more adequately identify ammunition maintenance functions The heading designations and definitions will be Included In the appropriate technical manual for each category of ammunition B 1 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 B 2 MAINTENANCE FUNCTIONS CONT e Align To adjust specified variable elements of an item to bring about optimum or desired performance NOTE Air Force Precision Measurement Equipment Laboratory PMEL person will calibrate small arms Inspection gages In accordance with TO 33K 1 100 f Calibrate To determine and cause corrections to be made or to be adjusted on Instruments or test measuring and diagnostic equipments used In precision measurement Consists of comparisons of two Instruments one of which Is a certified standard of known accuracy to detect and adjust any discrepancy in the accuracy of the Instrument being compared g Remove install To remove and Install the same item when required to perform service or other maintenance functions Install may be the act of emplacing seati
143. amp AIR FORCE TO 11W3 5 5 42 d LUBRICATION Lubricate helical spring pawl detent and forward assist pawl with CLP p 2 33 before installation e REASSEMBLY WARNING To avoid injury to your eyes use care when removing and installing spring loaded parts Install helical spring 1 pawl detent 2 and forward assist pawl 3 into plunger assembly 4 Align holes and install spring pin 5 using 1 16 inch drive pin punch and hand hammer Spring pin must be flush or slightly below flush after reassembly Assemble rifle refer to page 3 77 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 13 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY This task covers a Disassembly c Repair e Reassembly b Inspection d Test INITIAL SETUP Test Equipment Lubricant solid film item 21 app D Tool and Gage Set item 2 app B Screw self locking item 6 p C 11 Tools Equipment Conditions ARMY Small Arms Repairman Tool Kit 3 15 Lower receiver and buttstock assembly item 3 app B removed Field Maintenance Basic Less Power 2 57 Buttstock assembly and pistol grip Small Arms Shop Set item 1 app B removed Pivot pin removal tool fig E 3 app E Slave pin fig E 5 app E General Safety Instructions To avoid injury to your eyes use care when Materials Parts removing and installing spring loaded parts Cleaner lubricant and preservative CLP When using solid film lubricant or dic
144. and 4 2 4 5 thru 4 10 B 5 thru B 8 C 7 and C 8 C 9 blank Fig C 1 thru Fig C 2 C 5 1 thru Fig C 9 C 10 1 thru Fig C 14 C 15 1 thru C 17 1 1 1 thru 1 10 Cover Insert Pages a thru iv v blank 1 0 1 1 0 2 blank 1 3 thru 1 6 2 3 and 2 4 2 13 thru 2 18 2 2 21 thru 2 24 2 27 and 2 28 2 47 thru 2 48 2 53 and 2 54 2 57 thru 2 60 2 63 thru 2 72 3 39 and 3 40 3 57 and 3 58 3 77 thru 3 82 4 1 and 4 2 4 5 thru 4 10 B 5 thru B 8 C 7 and C 8 C 9 blank Fig C 1 thru Fig C 2 C 5 1 thru Fig C 9 C 10 1 thru Fig C 14 C 15 1 thru C 17 1 1 thru 1 10 Cover 4 File this change sheet in the front of the publication for reference purposes By Order of the Secretary of the Army GORDON R SULLIVAN General United States Army Chief of Staff Official MILTON H HAMILTON Administrative Assistant to the Secretary of the Army 05909 DISTRIBUTION To be distributed in accordance with DA Form 12 40 E Block 0020 requirements for TM 9 1005 319 23 amp P ARMY TM 9 1005 319 23 amp P AIR FORCE 11W3 5 5 42 CHANGE HEADQUARTERS DEPARTMENTS OF THE ARMY No 2 AND AIR FORCE Washington DC 17 AUGUST 1992 UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST RIFLE 5 56MM M16A2 W E 1005 01 1 28 9936 EIC 4GM 9 1005 319 23 amp May 1991 is changed as follows 1 Remove old pages and insert new pages as indicated below 2 Newor changed material is indicated by a vertic
145. ar groove on upper surface of trigger pin 6 3 Install hammer assembly 7 4 Install hammer pin 8 using drive pin punch Push in until flush Change 4 3 70 1 3 70 2 blank ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 NOTE Hammer assembly should be cocked prior to installing the selector lever Selector lever 9 if installed must be positioned to BURST Long leg of automatic sear 10 spring must rest on top of selector lever 5 Install selector lever 9 and automatic sear 10 6 Install automatic sear pin 11 install on the right side into receiver using drive pin punch Push in until flush 7 Install magazine catch spring 12 and magazine button 13 NOTE Drive pin punch should be larger than hole in magazine button 8 Install magazine catch 14 Push in on magazine button 13 using a drive pin punch and turn magazine catch 14 clockwise until threaded end of magazine catch is flush with magazine button head 3 71 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 13 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY CONT e REASSEMBLY CONT 9 Install bolt catch spring 15 bolt catch plunger 16 and bolt catch 17 10 Secure by installing spring pin 18 using 3 32 inch drive pin punch and hand hammer 11 Install fabricated pivot pin installation tool 19 Insert helical spring 20 and pivot pin detent 21 Compress pivo pin detent in recess with punch and rotate tool
146. are met in accordance with instructions on page 3 83 k Chips flat spots or bent striker points on firing pins will be cause for rejection The cartridge engaging surfaces on extractors must not be chipped or deformed m Evidence of any damage to sights will be cause for a sight alignment check Rear sight bases should have no movement n Rear sight elevating and windage mechanisms must operate with distinct clicks without binding Sights must have sufficient tension to retain their setting during firing Graduations and numerals must be legible Graduation filler Is not required o Safeties must positively position in both the ON and OFF position When in the ON or safe position the rifle must not fire when the trigger is squeezed when in the OFF or fire position the rifle must fire when the trigger is squeezed 3 99 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 3 25 GENERAL INSPECTION CRITERIA CONT p Alllocking devices such as latches magazine latches or detents must be positive in action and must not become disengaged due to normal handling and firing Retaining pins and similar devices must not be subject to accidental loss during use or transportation q Each rifle must be hand functioned to check for unusual binding positive cocking action and general operation Dummy ammunition must be used to assure positive feeding chambering extraction and ejection action Table 3 1 5 56MM Rifle M16A2
147. aring 15 and helical spring 16 Use 1 16 Inch allen wrench to remove index screw 17 Discard Index screw 1 7 Separate elevation index 11 from elevation knob 18 by hand 3 50 9 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Remove pin 1 9 using 3 32 Inch drive pin punch and hand hammer WARNING To avoid Injury to your eyes use care when removing and installing spring loaded parts Remove forward assist assembly 20 and helical spring 21 from upper receiver 8 For further disassembly of forward assist assembly see page 3 59 b INSPECTION Check rear sight parts for serviceability Inside of apertures should be round and distinct Replace If defective Visually inspect rear sight assembly helical springs 1 ball bearings 2 and helical spring 3 for breaks bends and missing parts Ball bearings should be smooth and round Replace If defective Check upper receiver for cracks corrosion and damage Clear drain hole with a piece of wire Repair p 3 29 or replace If defective Check that flat spring 4 retains sight aperture 5 firmly In either position Replace flat spring 4 If sight aperture is not firm ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 3 11 UPPER RECEIVER ASSEMBLY AND REAR SIGHT ASSEMBLY CONT b INSPECTION CONT Check elevation Index 161 and windage knob 71 for legibility of markings Check underside of wind
148. arts Tool and Gage Set Item 2 app B Penetrant kit item 25 app D Rag wiping item 26 app D Tools ARMY Small Arms Repairman Tool Kit Equipment Conditions Item 3 app B 3 16 Bolt assembly removed a DISASSEMBLY NOTE Do not remove bolt rings unless they require replacement and three new replacement bolt rings are on hand Using small flat tip jewelers screwdriver remove the three bolt rings 1 from the bolt 2 b INSPECTION REPAIR 1 Visually Inspect bolt rings for cracks kinks and bends Replace all three bolt rings if one or more bolt rings is damaged See page 3 16 for bolt ring wear check 3 21 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 8 BOLT ASSEMBLY CONT b INSPECTION REPAIR CONT 2 Inspect bolt for pits burrs and wear as follows a Bolt faces with a cluster of pits which are touching or tightly grouped covering an area measuring approximately 1 8 Inch across will be rejected and replaced UNSERVICEABLE SERVICEABLE b Bolts which contain individual pits or a scattered pattern will not be cause for rejection c Bolts that contain pits extending Into the firing pin hole will not be rejected unless firing pin hole gaging check determines excess wear d Rings on the bolt face machine tool marks grooves or ridges less than approximately 0 010 inch will not be cause for rejection 3
149. assembly serviceability check cont cont Item to be Checked or Serviced Procedure Inspect upper receiver 3 finish for scratches or worn shiny spots If scratched or worn shiny in spots disassemble and re move all lubricant from sur face with dry cleaning sol vent item 16 app D Wear rubber gloves item 18 app D and use a wash pan item 24 app D to apply solvent Let parts dry thoroughly Roughen the surface using abrasive cloth item 1 3 app D and apply solid film lubri cant item 16 app D Allow 16 to 24 hours to dry before handling Hold barrel 2 at 40 degree angle muzzle down Pull charging handle 8 to rear Hold bolt carrier assembly 12 to rear and push charg ing handle forward Release bolt carrier assembly 12 The bolt carrier assembly should close and lock under its own weight If It does not remove the bolt assem bly 13 from the key and bolt carrier assembly 14 and slide the key and bolt carrier assembly without bolt back and forth In the upper receiver and barrel as sembly If the gas tube 4 hits the carrier key 1 5 or If the gas tube binds in the carrier key try to correct the malfunction by adjusting slightly bending the gas tube In the area of the hand guard assemblies If unable to adjust evacuate to sup port maintenance Not Fully Mission Capable if Adjustment does not correct the malfunction ARMY TM 9 1005 319 23 amp
150. be sure to clear the rifle Do not actuate the trigger until the rifle has been cleared Inspect the bore and chamber to ensure that It is empty and free from obstructions and check to see that no ammunition Is In position to be Introduced a Before Inspection the materiel must be thoroughly cleaned of all grease dirt or other foreign matter that might Interfere with Its proper function or the use of gages and tools during inspection b Materiel must be free of burrs rust or corrosion on functional surfaces ARMY TM 9 1005 319 23 amp P AIR FORCE TO 1 1W3 5 5 42 3 25 GENERAL INSPECTION CRITERIA CONT c Parts must not be cracked bent distorted or damaged and must be free of detrimental wear or looseness d Minor defects In metal components do not normally affect their acceptability For example scratches and tool marks are ordinarily of no Importance e Inspect finish of metal surface 1 General Satisfactory metal surfaces for rifles range from black to light gray A worn shiny metal surface is objectionable only when It is capable of reflecting light No rifle will be reelected unless exterior parts have a shine All rear sights must have a dull gray or black finish of all surfaces that would cause a glare 2 M16A2 Rifle Minor loss of finish shiny spots nicks scratches on exterior surfaces of the barrel and flash suppressor shall not be cause for rejection of M16A2 rifles located In hands of troops at training centers Larg
151. blank ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 b INSPECTION Inspect lower receiver extension 1 for corrosion dents and wear Repair or replace if defective Inspect buffer retainer 2 for wear Replace if defective Inspect helical springs 3 for deformities and breaks Replace if defective Inspect lower receiver 4 See page 3 66 INSPECTION Inspect trigger guard 5 for deformities and check operation of plunger and spring Replace trigger guard if defective CARBINE ONLY Inspect receiver end plate 6 and locking nut 7 for damage Replace if damaged c REPAIR MODIFY 1 Repair lower receiver extension by using abrasive cloth to remove light corrosion Retouch using solid fil lubricant NOTE AIR FORCE ONLY Only depot maintenance is authorized to restamp the serial number on rifle ARMY ONLY Only direct support level is authorized to restamp serial number Change 3 3 79 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 16 LOWER RECEIVER AND RECEIVER EXTENSION ASSEMBLY CONT c REPAIR MODIFY CONT 2 ARMY ONLY If serial number is hard to read on rifle restamp as follows a Support the receiver In the stamping area to prevent bending and distortion of the receiver b Exercise extreme care to restamp the same serial number as the original c Restamp the serial number the same size as the original serial number NOTE Most rifle serial numbers are 1 8 inch 0 31 cm in heig
152. ble to the specific rifle being considered for shipment overseas must have been applied d Refer to SB 746 1 for pertinent publications relating to equipment processing and marking information e Refer to AMC P 310 9 for publications containing applicable overhaul standards 3 23 SHIPMENT OR ISSUE a Organizational Repair Parts Tools and Equipment Rifles must be complete with all Items required by applicable Department of the Army publications including those In the basic Issue items list of the appropriate operator s manual b Publications Operator publications applicable to the equipment log book must accompany the equipment All log book entries must be complete and up to date including those covering any repairs replacements or adjustments made to the rifle In complying with this section c Documentation Prepare DA Form 2408 9 Equipment Control Record at time of overseas shipment or Issue to another stock record or property book account in accordance with the provisions of DA PAM 738 750 d Preparation Process rifles for shipment as required by shipping documents and pertinent regulations 3 24 DISPOSITION Disqualified rifles which do not qualify for shipment will either be redistributed within the camp post or station be repaired or become candidates for overhaul cannibalization or other disposition as required by existing regulations 3 25 GENERAL INSPECTION CRITERIA WARNING Before starting an Inspection
153. bly replace bolt rings p 3 21 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 This page is blank Procedures and figure were moved to page 2 36 Change 4 3 19 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 7 BOLT CARRIER ASSEMBLY CONT d TEST 1 Insert firing pin 1 through bolt 2 2 Position firing pin protrusion gage 3 PN 7799735 to check for proper firing pin 1 protrusion minimum 0 028 in 0 07 cm maximum 0 036 In 0 09 cm NOTE Firing pin should touch the gage on minimum but should not touch on maximum 3 Replace a defective firing pin e REPAIR Replace all authorized unserviceable items Retest all replaced parts f REASSEMBLY 1 Install bolt assembly 1 into key and bolt carrier assembly 2 2 Install bolt cam pin 3 and rotate one quarter turn to secure bolt assembly 1 3 Hold key and bolt carrier assembly 2 with bolt assembly 1 down and drop In firing pin 4 4 Install firing pin retaining pin 5 from left side only to ensure proper Installation Check Installation by attempting to shake out firing pin 5 Reassemble rifle refer to page 3 77 3 20 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 8 BOLT ASSEMBLY This task covers a Disassembly Test b Inspection Repair d Reassembly INITIAL SETUP Test Equipment Materials P
154. bolt rings 2 a Stagger bolt ring gaps approximately 13 turn apart b Evacuate to support maintenance if bolt rings are worn broken or missing 2 28 Change 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 4 Carbon build up or foreign matter In the narrow passage of the bolt carrier key 3 Clean with CLP Item 9 app D and a pipe cleaner Item 11 app D Step 5 Gas leakage caused by broken or loose gas tube 4 around front sight base Evacuate to support maintenance Step 6 Improper alignment of gas tube and carrier key a Adjust gas tube alignment by bending in area of handguard assembly to Its original configuration b If gas tube cannot be returned to Its original configuration evacuate the rifle to support maintenance 2 29 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 9 TROUBLESHOOTING PROCEDURES CONT TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 11 RIFLE CANNOT BE ZEROED Step 1 Defective barrel assembly 1 Evacuate to support maintenance Step 2 Barrel assembly out of alignment with rear sight assembly 2 on upper receiver Evacuate to support maintenance Step 3 Defective front sight 3 Remove front sight post 4 front sight detent 5 and helical spring 6 If damaged replace Step 4 Defective ear sight assembly 2 Evacuate to
155. cPEAK General United States Air Force Chief of Staff CHARLES C McDONALD General United States Air Force Commander Air Force Logistics Command DISTRIBUTION To be distributed in accordance with DA Form 12 40E 0020 Unit and Direct and General Support Maintenance requirements for TM 9 1005 319 23 amp P U S GOVERNMENT PRINTING OFFICE 1992 0 311 831 60977 RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG wim mis FROM YOUR UNIT S COMPLETE ADDRESS PUBLICATION NUMBER PUBLICATION DATE 1 BE EXACT PIN POINT WHERE IT 15 IN THIS SPACE TELL WHAT i WRONG T 2028 2 PREVIOUS EDITIONS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR autre OBSOLETE RECOMMENDATION CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT OUT FOLD IT AND DROP IT IN THE MAIL amne TEAR ALONG PERFORATED LINE cere AMD CED QUNM CUN MEME GM THE METRIC SYSTEM AND EQUIVALENTS LINEAR MEASURE Centimeter 10 Millimeters 0 01 Meters 0 3937 Inches Meter 100 Centimeters 1 000 Millimeters 39 37 Inches Kilometer 1 000 Meters 0 621 Miles SQUARE MEASURE 1 54 Centimeter 100 Sq Millimeters 0 155 Sq Inches Sq Meter 10 0
156. ce of hitting an enemy if the rifles must be used before a live fire zero can be made Whenever possible zeroing of the rifle should be accomplished using ball ammunition on a 25 meter zeroing target using the L aperture After the rifle is assembled the rear sight is centered and placed at the 300 meter mark perform the following check While looking at a light background sight through the rear sight and obtain good sight alignment with the front sight placed in the center of the rear sight aperture If while performing this check the hole in the rear sight aperture appears oval instead of round the rear sight base or upper receiver should be replaced To determine which part requires replacement replace the rear sight base first If this does not resolve the problem replace the upper receiver Change 5 3 58 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 12 FORWARD ASSIST ASSEMBLY This task covers a Disassembly c Repair e Reassembly b Inspection d Lubrication INITIAL SETUP Tools Equipment Conditions ARMY Small Arms Repairman Tool Kit 3 48 Forward assist assembly removed item 3 app B Field Maintenance Basic Less Power General Safety Instructions Small Arms Shop Set item 1 app B To avoid injury to your eyes use care when removing and installing spring loaded Materials Parts parts Cleaner lubricant and preservative CLP item 9 app D a DISASSEMBLY WARNING
157. d Maintenance Basic Less Power Small Arms Shop Set item 1 app B Modified Needle Nose Pliers fig E 7 app E Materials Parts Brush cleaning small item 3 app D Carbon removing compound item 8 app D Cloth abrasive item 13 app D Dichloromethane technical item 15 app D Dry cleaning solvent item 16 app D Gloves chemical and oil protective item 18 app D Grease molybdenum disulfide item 19 app D Lubricant solid film item 21 app D Pan wash item 24 app D Polyethylene item 32 app D Sealing compound item 28 app D Target item 31 app D TM 9 1005 319 10 Equipment Conditions 3 15 Upper receiver and barrel assembly removed 2 43 Handguard assemblies removed General Safety Instructions To avoid injury to your eyes use care when removing and installing spring loaded parts When using solid film lubricant or dichlorometh ane be sure the area is well ventilated When using carbon removing compound avoid skin contact If carbon removing compound comes in contact with the skin wash thoroughly with running water Using a good lanolin base cream after exposure to the compound is helpful Using gloves and protective equipment is required Change 5 3 29 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 10 UPPER RECEIVER AND BARREL ASSEMBLY CONT a DISASSEMBLY 1 Using ball peen hammer and 5 64 inch diameter drive pin punch drive spring pin
158. d Maintenance Basic Less Power Carrier and key screws 2 8448508 Small Arms Shop Set item 1 app B ARMY Small Arms Repairman Tool Kit Equipment Conditions item 3 app B 3 16 Key and bolt carrier assembly removed 3 25 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 9 KEY AND BOLT CARRIER ASSEMBLY CONT a DISASSEMBLY NOTE Do not disassemble the key and bolt carrier assembly unless the bolt carrier key is defective as determined by inspection procedures described in section preceding 1 Using socket wrench handle and tight fitting 1 8 inch socket head screw socket wrench attachment remove two carrier and key screws 1 NOTE The heads and part of the bolt carrier key may be ground off in order to remove bolt carrier key from bolt carrier if carrier and key screws cannot otherwise be removed 2 Remove bolt carrier key 2 from bolt carrier 3 b REPAIR NOTE Do not retorque carrier and key screws if staking marks do not indicate loosening screws Repair by replacing torquing and restaking carrier and key screws Refer to the following reassembly procedures 3 26 Change 5 c REASSEMBLY ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 NOTE Do not reuse old carrier and key screws New carrier and key screws must be used at assembly If disassembled place bolt carrier 1 In vise using vise law caps Install and
159. d in a well ventilated area The use of rubber gloves is necessary to protect the skin when washing rifle parts When using solid film lubricant or dichloromethane be sure the area is well ventilated When using carbon removing compound item 8 app D avoid skin contact If carbon removing compound comes In contact with the skin wash thoroughly with running water using a good lanolin base cream after exposure to the compound is helpful Using gloves and protective equipment is required The lock plate prevents the selector lever from being placed in BURST and will be installed at the discretion of the unit commander It is mandatory for use in civil disturbance riot control Only blank cartridge M200 is to be used when the blank firing attachment is attached to the rifle carbine Change 5 a ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 WARNING CONT Do not fire blank ammunition at a representative enemy at distances of less than 20 feet 6 10 Om The unburned propellant grains can cause injury within this distance For further information on safety care and handling of ammunition Army and Air Force users refer to M16A2 Rifle Operator s Manual For additional first aid data see Field Manual FM 21 11 b ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 TECHNICAL MANUAL ARMY TM 9 1005 319 23 amp P ARMY NO 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 AIR FORCE TO 11W3 5 5 42 DEPARTMENTS OF THE ARMY
160. e b CLEANING Clean all items operator s manual Change 4 2 48 1 2 48 2 blank ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 INSPECTION 2nd Rib From Rear to the end of Handguard 1st Rib Critical Area Forward Shaded 1 Inspect handguard assemblies for breaks separation and cracks using the following guidelines a Breaks and separations of material which prevent proper retention or interfere with functioning of the rifle will be cause for handguard assembly rejection and replacement b M16A2 handguard assemblies may have up to two of the three front retaining tabs missing 1 M4 M4A1 may not have any front retaining tabs 1 missing If all front retaining tabs for the M1 6A2 are missing or any of the tabs for the M4 M4A1 are missing handguard assemblies must be replaced c Cracks up to one inch in length are acceptable provided they do not extend into the retaining flange RENS d AREA 2 Replace severely cracked or damaged handguard assemblies Handguard assemblies which have a heat shield which is loose enough to rattle when installed on the rifle must be replaced Inspect front sight assembly for chips breaks and cracks Evacuate to support maintenance if broken cracked or bent i Inspect front sight area for evidence of gas leakage around gas tube Evacuate to support maintenance if short recoil results from gas leakage 4 Inspect front sight
161. e 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 EXTERNAL VIEW OF 5 56 MM RIFLE M16A2 UPPER RECEIVER AND REAR SIGHT ASSEMBLY BARREL ASSEMBLY LOWER RECEIVER AND BUTTSTOCK ASSEMBLY RIGHT SIDE FRONT SIGHT SELECTOR LEVER COMPENSATOR MAGAZINE PISTOL GRIP LEFT SIDE 1 0 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 EXTERNAL VIEW OF 5 56MM CARBINE M4 M4A1 ELEVATION KNOB REAR SIGHT WINDAGE KNOB SPENT BRASS DEFLECTOR FRONT SIGHT ASSEMBLY HAND GUARD CHARGING HANDLE OT 2 4 gun p eee re Se ee sees D gt rr PORT COVER BAYONET STUD FORWARD AS SLING MAGAZINE TRIGGER MAGAZINE RELEASE BUTTON RIGHT SIDE SQUARE FRONT SIGHT POST CARRYING HANDLE ASSEMBLY BOLT CATCH BUTTSTOCK LEFT SIDE Change 4 1 0 1 1 0 2 blank ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 CHAPTER 1 INTRODUCTION CHAPTER OVERVIEW This chapter contains general information equipment description and data and principles of operation for the M16A2 rifle and M4 M4A1 carbines Section 1 GENERAL INFORMATION 1 1 SCOPE a Type of Manual Unit and Direct Support Maintenance b Model Number and Equipment Name 5 56mm Rifle M16A2 M4 and M4A1 Carbines c Purpose of Equipment Provides personnel an offensive defensive capability to engage targets with small arms fire 1 2 MAINTENANCE FORMS RECORD
162. e buttstock Cutting Into the fiber of the buttstock may weaken it These marks may be at any location on the buttstock Unauthorized markings are not desirable However previously applied they will be allowed to continue In use due to the cost of the buttstock 1 Inspect buttstock for cracks using the following guidelines a b Under the following conditions hairline cracks no chipped away material allowed originating from buttplate end of buttstock are acceptable 1 One hairline crack not to exceed 1 in 12 54 In length per side of buttstock 2 Two additional hairline cracks up to 0 25 in 0 64 cm In length per side of buttstock 3 A total of three cracks per side of buttstock originating from buttplate end are allowable Cracks In the critical area at the front end of the buttstock are not acceptable and these buttstocks must be replaced 2 While buttplate Is Installed on rifle Inspect for cracks around the mounting holes Check for cracks In excess of 0 25 In 3 Inspect door assembly for cracks corrosion stuck plunger separations on outer face or other damage Replace If defective O 64 cm In length which extend through the buttplate Replace If cracked 2 66 d REPAIR Replace all authorized unserviceable Items Unserviceable Items are those Items which are damaged f REASSEMBLY ARMY TM 9 1005319 23 amp P AIR FORCE TO 11W3 5 542 e LUBRI
163. e shiny surfaces nicks scratches etc can be restored by the use of solid film lubricant Item 21 app D Rifles small arms missing in excess of one third or more of the exterior finish resulting In an unprotected light reflecting surface are considered candidates for overhaul The only authorized level of maintenance to phosphate finish small arms Is depot f Plastic components must not be cracked or damaged In such a way as to Interfere with their structural strength Surface cracks bruises or dents that do not affect their strength will not be cause for rejection Cracks will be cause for rejection Criteria for determining which cracks are repairable are on page 2 1 4 g Barrels must be clean and free of corrosion such as that caused by moisture and powder fouling Standards of serviceability are indicated In 1 through 9 1 Pits In the chamber are allowable If they do not cause extraction difficulties 2 Pits as wide as a land and 3 8 Inch O 95 cm or less in length are allowable for 5 56 mm barrels Pits not greater than the width of a land and less than 3 8 inch O 95 cm long are permissible 3 Scattered or uniformly fine pits or fine pits In a densely pitted area are allowable 4 Tool marks are acceptable regardless of length They will appear as lines running laterally In the grooves or may run spirally across the top of lands 3 98 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 5 Ringed bores or bores ri
164. e wrench 6 Check for proper setting NOTE After the rifle is assembled the rear sight is centered and placed at the 300 meter mark perform the owing check While looking at a light background obtain good sight alignment If the hole in the rear sight aperture appears oval Instead of round the rear sight base or upper receiver should be replaced To determine which part requires replacement replace the rear sight base first If this does not resolve the problem replace the upper receiver 14 Assemble rifle refer to page 3 77 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 11 UPPER RECEIVER ASSEMBLY AND REAR SIGHT ASSEMBLY CONT f MEACHANICAL ZERO PROCEDURES A F ONLY 2 Always push in on windage screw head after Center rear sight by moving windage knob in 4 9 9 making rear sight adjustments the appropriate direction Visually check rear sight to ensure it is centered after making adjustments Also ensure the rear sight is set in the shortrange unmarked aperture position NOTE This procedure when used in conjunction with front sight mechanical zero adjustment p 2 54 will give an approximate battle site zero to most M16A2 rifles The above steps can also be used before firing a new or newly assigned rifle Use the procedure to check rifles stored in preferred packaging during routine inspections This will help ensure people armed with the rifles will stand a better chan
165. ear from receipt of the weapons All rifles and carbines must be gaged at least once annually for safety a INSPECTION b Gaging All Army Reserve and Army National Guard M16A2 rifles must be inspected and gaged at least once every 2 years after the initial inspection gaging procedures have been accomplished This 2 year interval may be maintained unless preventive maintenance checks and services PMCS or other physical evidence indicates that an individual unit s rifles require inspection gaging at a more frequent interval If it is determined that a yearly inspection is necessary for an individual unit only that unit will be affected This will not affect other units in regard to the interval of inspection t is recommended that training units inspect gage all rifles at the end of each training cycle Training units will inspect gage all rifles at least once annually Air Force M16 rifles will be inspected in accord ance with AFR 50 36 Vol 1 Chapter 5 Visually inspect general appearance of weapon Overall appearance will be approximately that of new weapon For inspection criteria refer to final inspection page 3 84 All visual and functional Inspection requirements must be met NOTE To perform the following tests disassemble weapon only as far as allowed in chapter 2 Unit Maintenance Instructions unless a deficiency is uncovered Perform a general inspection of weapon per section of t
166. ed by DS AVIM Level AH Assembled by Items with these codes are not to be requested requisi tioned Individually The parts that make up the assembled Item must be requisitioned or fabricated and assembled at the level of maintenance indicated by the source code If the 3d position code of the SMR code authorizes you to GS Level replace the Item but the source code Indicates the Item AL Assembled by Is assembled at a higher level order the Item from the SRA higher level of maintenance AD Assembled by Depot XA Do not requisition an XA coded item Order Its next higher assembly Also refer to the NOTE below XB If an XB item is not available from salvage order It using the CAGEC and part number given XC installation drawing diagram instruction sheet field service drawing that is identified by manufacturer s part number XD Item is not stocked Order an XD coded Item through normal supply channels using the CAGEC and part number given If no NSN Is available NOTE Cannibalization or controlled exchange when authorized may be used as a source of supply for items with the above source codes except for those source coded XA or those aircraft support Items restricted by requirements of AR 750 1 2 Maintenance Code Maintenance codes tell you the level s of maintenance authorized to USE and REPAIR support items The maintenance codes are entered In the third and fourth positions of the SMR code as follows a
167. eed to operate and maintain the M16A2 Rifle This listing is for informational purposes only and Is not authority to requisition the listed Items These items are authorized to you by CTA 50 970 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items or CTA 8 100 Army Medical Department Expendable Durable Items D 2 EXPLANATION OF COLUMNS a Column 1 Item Number This number is assigned to the entry in the listing and is referenced In the narrative instructions to identify the material e g Use cloth abrasive crocus Item 12 app D b Column 2 Level This column identifies the lowest level of maintenance that requires the listed Item C Operator Crew Maintenance O Unit Maintenance F Direct Support Maintenance c Column 3 National Stock Number This is the National stock number assigned to the Item use It to request or requisition the Item d Column 4 Description Indicates the Federal Item name and if required a description to identify the item The last line for each Item indicates the Commercial and Government Entity Code CAGEO in parentheses followed by the part number e Column 5 Unit of Measure U M Indicates the measure used in performing the actual maintenance function This measure is expressed by a two character alphabetical abbreviation e g ea In pr If the unit of measure differs from the unit of issue requisition the lowest unit of issue that will satisfy y
168. efore installing bolt assembly check to see that the bolt ring gaps are staggered to prevent loss of gas pressure 1 Install bolt assembly 1 In key and bolt carrier assembly 2 2 Install bolt cam pin 3 and rotate one quarter turn ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 13 BOLT CARRIER ASSEMBLY CONT e REASSEMBLY CONT Hold key and bolt carrier assembly 2 with bolt assembly 1 down and drop in firing pin 4 Install firing pin retaining pin 5 from left side only to ensure proper installation Check for proper installation by holding key and bolt carrier assembly 2 with bolt assembly 1 up then attempt to shake out firing pin Reassemble rifle refer to page 2 68 2 14 BOLT ASSEMBLY This task covers a Removal d Lubrication b Cleaning e Reassembly c Inspection INITIAL SETUP Tools General Safety Instructions ARMY Small Arms Repairman Tool Kit Do not Interchange bolt assemblies from item 3 app B one rifle to another Doing so may result in injury to or death of Equipment Conditions personnel 2 35 Bolt assembly removed To avoid injury to your eyes use care when removing and installing spring loaded parts 2 38 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 a DISASSEMBLY NOTE Do not separate cartridge extractor and extractor spring assembly unless replacement of either or both is required Do not remove the rubber Insert from the extractor s
169. eiver is missing one third or more of its exterior protective finish resulting in an unprotected light reflecting surface it is candidate for overhaul This missing finish will be considered a shortcoming This shortcoming requires action to obtain a replacement weapon Once a replacement has been received evacuate the original weapon to depot maintenance for overhaul d REPAIR Replace all authorized unserviceable parts If repair is not authorized at this level evacuate to support maintenance e LUBRICATION Lightly lubricate all metal components p 2 33 operator s manual Change 4 2 61 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 1 1W3 5 5 42 2 17 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY CONT f REASSEMBLY WARNING To avoid Injury to your eyes use care when removing and Installing spring loaded parts NOTE Make sure the hammer Is cocked and the selector lever is not set on BURST before Installing the buffer assembly 1 Press action spring 1 and buffer assembly 2 In until buffer retainer 3 snaps up and holds them In place 2 Install fabricated pivot pin installation tool 4 Insert helical spring 151 and pivot pin detent 6 Compress pivot pin detent in recess with 3 32 inch punch and rotate tool Remove 3732 Inch punch 2 62 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 NOTE Rounded end of pivot pin detent must be In
170. ence Indexes A list in National item identification number NIIN sequence of all National stock numbered items appearing in the listings followed by a list in alohanumeric sequence of all part numbers appearing in the listing National stock numbers and part numbers are cross referenced to each illustration figure and item number in alphanumeric sequence and cross references NSN CAGEC and part number C 3 EXPLANATION OF COLUMNS SECTIONS II AND III a ITEM NO Column 1 Indicates the number used to identify items called out in the illustration b SMR CODE Column 2 The Source Maintenance and Recoverability SMR code is a 5 position code containing supply requisitioning information maintenance level authorization criteria and disposition instruction as shown In the following breakout Change4 1 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 C 3 EXPLANATION OF COLUMNS SECTION II AND III CONT Source Maintenance Recoverability Code Code Code XX 1sttwo XX X positions How you get an item 3d position 4th position Who determines disposition action on an unserviceable Who can install Who can do item replace or use complete repair the item see note on the item Complete Repair Maintenance capacity capability and authority to perform all corrective maintenance tasks of the Repair function in a use user environment In order to restore serviceability to a failed item 1 Source
171. eneral Information eene 1 1 Section Equipment Description and Data 5 rnnt tutte tennis 1 3 Section ML qPunciples of Operation aa 1 6 This manual supersedes ARMY TM 9 1005 319 23 amp P dated 28 August 1987 including all changes Change 5 i ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Illus Page Figure 2 UNIT MAINTENANCE 2 1 21 1 2 1 Repair Parts Special Tools TMDE and Support Equipment 2 1 IT Service Upon 2 1 Preventive Maintenance Checks and Services PMCS 2 3 Troubleshootifig cote ente 2 20 Section V Maintenance 2 33 Preparation for Storage or 2 70 3 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS 3 1 Chapter Repair Parts Special Tools TMDE and Support Equipment 3 1 ECT TNS NG GUND 3 2 Maintenance Procedures for the M16A2 Rifle 4 and M4A1 Carbine IV Preembarkation Inspection of Materiel in Units Alerted for Overseas Movement
172. er d LUBRICATION Lubricate upper receiver assembly and rear sight assembly Apply CLP to helical springs and ball bearings three each and threaded portion of screws before installation Lubricate helical springs and ball bearings through their respective drain holes 3 53 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 11 UPPER RECEIVER ASSEMBLY AND REAR SIGHT ASSEMBLY CONT e REASSEMBLY WARNING To avoid injury to your eyes use care when removing and Installing spring loaded parts Apply CLP to helical spring 1 and forward assist assembly 2 and Install them into upper receiver 3 Install spring pin 4 using 3 32 Inch drive pin punch and hand hammer Assemble elevation knob 5 elevation index 6 and new index screw 7 using 1 16 Inch alien wrench Do not overtighten Index screw as scale will require adjustment Install ball bearing 8 and helical spring 9 using needle nose pliers or tweezers Depress ball bearing 8 with a punch Inserted through access hole and slide elevation knob assembly In upper receiver 3 from the side Center elevation knob assembly 3 54 WARNING To avoid injury to your eyes use care when removing and installing spring loaded parts NOTE All springs are identical when new Once disassembled from the rifle their free length may vary due to different amounts of compression when installed If the length of springs
173. er under the provisions of the note on page C 3 If these parts are interchanged the rifle must be checked inspected as depicted on pages 3 17 3 21 and 3 33 While performing these checks and inspections pay special attention to the headspace requirements on page 3 47 Change 4 3 1 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Section Il TROUBLESHOOTING 3 4 GENERAL a This section contains direct support level troubleshooting information for locating and correcting most of the operating troubles which may develop in the M16A2 rifle and M4 M4A1 carbine Each malfunction for the individual part or assembly is followed by a list of tests or inspections which will help you to determine the corrective action to take You should perform the tests inspections and corrective actions in the order listed b This manual cannot list all malfunctions that may occur nor all tests or inspections and corrective actions malfunction is not listed or is not corrected by listed corrective actions see individual repair sections in the maintenance procedures on each major assembly 3 5 TROUBLESHOOTING PROCEDURES Refer to troubleshooting table for malfunctions tests and corrective actions The symptom index is provided for a quick reference of the malfunctions covered in the table SYMPTOM INDEX Troubleshooting Procedures Page Failure of magazine to lock in
174. er assembly removed General Safety Instructions To avoid injury to your eyes use care when removing and installing spring loaded parts When using solid film lubricant or dichloromethane be sure the area is well ventilated WARNING To avoid injury to your eyes use care when removing and installing springloaded parts 3 48 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 CAUTION Be sure to catch small parts 1 2 3 and 4 AIR FORCE ONLY Use magnet to keep from losing small parts 1 3 and 4 Drive out spring pin 1 using a hammer and 1 16 inch punch Catch rear sight assembly windage knob 2 helical spring 3 and ball bearing 4 3 Using a flat bladed screwdriver remove rear sight assembly windage screw 5 4 Remove sight aperture 6 and flat spring 7 from upper receiver 8 3 49 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 11 UPPER RECEIVER ASSEMBLY AND REAR SIGHT ASSEMBLY CONT a DISASSEMBLY CONT WARNING To avoid injury to your eyes use care when removing and installing spring loaded parts Drive out spring pin 9 using a 3 32 Inch punch Catch helical spring 10 when punch is withdrawn Rotate elevation index 11 until rear sight assembly base 12 clears upper receiver 8 Catch ball bearing 13 and helical spring 14 as rear sight base clears Push elevation index 11 out with thumb using slight rotation motion Catch ball be
175. erosion gage PN 8448496 normally used on 16 1 fully chromed barrels can be used to gage M16A2 barrels c The bore straightness gage PN 8448202 is required for use on all barrels The gage must pass through the barrel without being forced Change 5 3 45 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 10 UPPER RECEIVER AND BARREL ASSEMBLY CONT e TEST CONT Use barrel erosion gage 1 PN 8448496 Install key mM REJECT MARK and bolt carrier assembly with bolt assembly and firing pin removed Hold rifle vertical with receiver up Insert gage into rear of key and bolt carrier assembly The reject line must be read at the rear edge of the key and bolt carrier assembly If the reject mark passes beyond the rear surface of the key and bolt carrier assembly the barrel is unserviceable and shall be replaced NOTE Ensure barrel is clean prior to performing the following test Check straightness of bore using straightness gage 2 PN 8448202 Put gage in barrel Tilt barrel and allow gage to fall through Catch gage Gage must pass freely through barrel If gage does not pass through barrel recheck as follows Hold upper receiver and barrel assembly 3 in vertical position with muzzle pointed down insert gage into chamber end of barrel Release gage and catch it as it exits muzzle end If gage passes freely through the barrel barrel is acceptable If it does not the barrel must
176. ers ARMY Small Arms Repairman Tool Kit item 3 app B Front sight post removal and installation tool fig E 2 app E Front sight detent depressor fig E 1 app E Materials Parts Lubricants app D loaded parts a Disassembly e Lubrication b Cleaning f Reassembly c Inspection d Repair INITIAL SETUP Tools References TM 9 1005 319 10 operator s manual Equipment Conditions 2 34 Upper receiver and barrel assembly removed from lower receiver General Safety Instructions To avoid injury to your eyes use care when removing and installing spring a DISASSEMBLY CAUTION Do not use a screwdriver or any other tool when removing the handguard assemblies Doing so may damage the handguard assemblies and or slip ring Do not remove heat shield for any reason Doing So will damage the heat shield and the handguard assemblies will have to be replaced NOTE Refer to operator s manual for buddy system procedure on removing handguard assemblies 2 45 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 1 1W3 5 5 42 2 16 UPPER RECEIVER AND BARREL ASSEMBLY RIFLE BARREL ASSEMBLY AND UPPER RECEIVER ASSEMBLY CONT a DISASSEMBLY CONT 1 Push down on handguard slip ring 1 and lift upper handguard assembly 2 up and out 2 Push down on handguard slip ring 1 and lift the lower handguard assembly 3 up and out
177. g the barrel nut assembly to the next hole to allow for proper alignment of gas tube NOTE Do not attempt to hold the upper receiver assembly with a pry bar however If the rifle barrel assembly turns In the holding fixture a pry bar may be used through the front sight assembly base to help prevent the rifle barrel assembly from turning In the holding fixture Use care not to distort or bend front sight assembly or retaining pins Use buddy system to hold pry bar Torque the barrel nut assembly again to 30 ft lb 40 5 N m while maintaining sight alignment The barrel nut assembly may be tightened beyond 30 ft lb 40 5 N m to align the barrel nut assembly serrations for proper gas tube clearance Never loosen the barrel nut assembly to align for gas tube clearance Check alignment of barrel nut assembly 9 with upper receiver assembly 8 The front 8 inches 20 32 cm of a gas tube may be used as an alignment tool see Illustration This Is Inserted Into the bolt carrier key and then Inserted into the rear of the receiver If the parts of the barrel nut assembly are properly aligned the tool will pass freely and lay top dead center along the top of the barrel A number 15 twist drill 0 180 inch may also be needed as an alignment tool If necessary tighten barrel nut assembly to next hole to allow proper alignment 3 43 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 10 UPPER RECEIVER AND BARREL ASSEMBLY CONT
178. ght when the arms rack is opened The bracket can be turned around when not in use for the carbine to allow storage of the M16A2 rifle c When storing the M4 M4A1 Carbine in the M12 arms rack an adapter bar fig E 6 app E MUST be used for security reasons To install the adapter bar to the M12 arms rack 1 Remove all weapons from the rack and position the rack to gain access to the back 2 70 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 2 The side of the adapter bar with the corners 1 cut off is the top and the side with square corners 2 is the back The portion of the bar must be placed so the cut off corners 1 face the front of the rack 3 Holding the adapter bar at an angle place one end into position inside the rear leg of the arms rack Lower the other end of the bar into position Allow the adapter bar to rest on the rack 4 Clamp both ends of the adapter bar into position Mark the center line of the leg and adapter bar where they meet see illustration Using a center punch mark the location of the holes to be drilled where the center lines cross The holes must be centered on both the leg and the adapter bar Drill a 1 8 inch pilot hole through both arms rack legs and the ends of the adapter bar Drill a 3 8 inch hole through both arms rack legs and the ends of the adapter bar using the pilot hole as a guide Remove the adapter bar File the edges of all holes smooth
179. he trigger is fully forward an audible click should el be heard Repeat the above SEMI position test The weapon mal five times functions during any of these five tests ltem No ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Interval Quarterly Charging handle cont Item to be Checked or Serviced assembly and selector lever cont Procedure M16A2 and M4 ONLY Place selector lever 3 in BURST position Charge weapon and squeeze trigger Hold trigger to the rear pull the charging handle to the rear and release it three times Release trigger Squeeze trigger NOTE The burst disconnector should have held the hammer to the rear when it engaged the deep notch of the burst cam M4A1 ONLY Place selector lever 3 in AUTO position Charge carbine and squeeze trigger Hammer should fall Hold trigger to the rear charge carbine and release trigger Squeeze trigger Hammer should not fall fln C Er E BUS sar Auro i M15A2 M4 M4A1 Not Fully Mission Capable if Hammer does not fall Hammer does not fall Hammer does not fall Hammer falls 2 7 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 T PREVENTIVE MAINTENANCE CHECKS AND SERVICES CONT PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Interva
180. his chapter Repair as required and authorized ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Gage bolt carrier assembly for firing pin protrusion using firing pin protrusion gage PN 7799735 See page 3 20 TEST Gage bolt carrier assembly for firing pin hole wear using not go plug gage PN 12620101 See page 3 24 TEST Inspect chamber in upper receiver and barrel assembly using chamber reflector tool PN 8448201 See page 3 33 INSPECTION CLEANING Gage barrel in upper receiver and barrel assembly using barrel erosion gage PN 8448496 and bore straightness gage PN 8448202 See page 3 45 TEST Check headspace in upper receiver and barrel assembly by inserting headspace gage PN 7799734 in chamber See page 3 45 TEST Gage pivot pin lug area clearance in lower receiver assembly using 0 020 thickness gage See page 3 68 Gage hammer and trigger pin holes in lower receiver assembly using taper plug gage PN 12006472 See page 3 68 TEST Gage trigger pull using trigger pull measuring fixture PN 7274758 See page 3 83 TEST Document inspection with DA PAM 738 750 AFTO Form 105 or NAVMC 11003 when completed Section IV PREEMBARKATION INSPECTION OF MATERIEL IN UNITS ALERTED FOR OVERSEAS MOVEMENT NOTE This section refers to all the weapons MI 16A2 rifle M4 and M4A1 unless otherwise stated 3 20 PURPOSE This section establishes standards for overseas shipment pre embarkation in section criteria for all weapons These
181. hloro item 9 app D methane be sure the area is well ventilated Dichloromehtane technical item 15 app D a DISASSEMBLY WARNING To avoid injury to your eyes use care when removing and installing spring loaded parts 3 62 Change 5 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 1 Remove spring pin 1 using 3 32 inch drive pin punch and hand hammer 2 Remove bolt catch 2 bolt catch plunger 3 and bolt catch spring 4 WARNING To avoid injury to your eyes use care when removing and installing spring loaded parts 3 Using drive pin punch press in on magazine button 5 and turn magazine catch 16 counterclockwise to unscrew and remove 4 Remove magazine button 5 and magazine catch spring 7 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 13 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY CONT a DISASSEMBLY CONT 5 Use a rounded tip drive pin punch to push automatic sear pin 8 out of lower receiver 9 NOTE To remove automatic sear selector lever must be positioned to BURST if installed 6 Remove automatic sear 10 and selector lever 11 NOTE To remove hammer assembly should be forward place selector lever if installed to SEMI position 7 Use drive pin punch to push hammer pin 12 from lower receiver 9 8 Remove hammer assembly 13 If further disassembly is required see page 3 73 3 64 ARMY TM 9 1005 319 23 amp AIR
182. ht or close enough that this size is acceptable for such restamping In the event that a rifle has a serial number that cannot be reproduced by the use of the die sets contained In the Set D Field Maintenance Post Camp and Station Small Arms Shop Set local purchase of an appropriate size die set is authorized d REASSEMBLY RIFLE ONLY WARNING To avoid injury to your eyes use care when removing and installing spring loaded parts Install helical spring 1 and buffer retainer 2 into lower receiver 3 3 80 Change 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 RIFLE ONLY Lubricate threads of lower receiver 3 and lower receiver extension 4 with molybdenum disulfide HOLD BUFER grease item 19 app D before reassembly RETAINER Install lower receiver extension 4 into lower receiver 3 while depressing buffer retainer TIGHTEN RIFLE ONLY Use padding between lower receiver and brass vise jaws Use vise jaws in vise and brass vise jaw caps i available Clamp solid portion of lower receiver 3 in a machinist s vise using vise jaws Grip the solid portion of the lowe receiver with vise jaws which conform to the shape of the lower receiver in this area Using combination wrench 5 and torque wrench torque lower receiver extension to 35 39 ft lb 47 25 52 6 Nem Torque is read when both wrenches are used to gether ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 3 16 LOWER RE
183. ice 1995 648 378 E 6 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 0 0625 0 015 DIA 0 250 0 0625 FABRICATE FROM NEEDLE NOSE PLIERS NSN 5120 00 268 3579 OR EQUIVALENT NOTE ALL DIMENSIONS ARE IN INCHES Figure E 7 Modified needle nose pliers U S GOVERNMENT PRINTING OFFICE 1997 545 039 4 077 Change 5 7 8 blank ALPHABETICAL INDEX Subject Auxliary Equipirient tene aite a Ene a Barrel Assembly See Upper Receiver and Barrel Assembly Barrel Assembly and Upper Receiver Assembly Blank Firing Attachment M 15A12 Gleaning uii e d Ie e etate uh deer ie iie Installations tret ctn ene n ext ner rer ere ee ee ree ertet eed estet eti eee ner ce et Plepalntlng ui oec i dealt Replaceme nite E RET HE ER Ace Hevea ts Bolt Assembly MIRI IUE Disassembly ERE Bolt Carrier Assembly cx o xat s Exec cer cr Disassembly c tenis ijo Em Inspection Repair 2 t nue EubriCation x metr eel tere t tere ER Reassembly ate e ie Een ana deter Buttstock Assembly
184. ignment may vary as much as one half the width of the slot either direction If loose or out of alignment evacuate to support maintenance Inspect all items for serviceability in and tightness of latch assembly on ejection port cover If items are damaged or nonfunctional they are unserviceable ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 LO gt oa 1 Ba Rotate and test elevation index 5 and windage knob 6 for ease of functioning and legibility of markings 11 Inspect elevation knob zero as follows a Rotate elevation knob 7 counterclockwise until the rear sight assembly is all the way down If a whole click is not felt as the rear sight assembly stops the rear sight assembly has bottomed out and will not pivot freely b Position elevation knob back slightly to Its last whole click so the rear sight assembly base 8 is under tension of the ball bearing 9 and helical spring 10 The 300 meter mark should align with the mark on the receiver If the 300 meter mark is not aligned with the mark on receiver slip the range scale in the following manner 1 Position the 300 meter mark with the mark on the receiver 2 Insert a 1 16 inch allen wrench through the access hole of the rear sight assembly base and into the Index screw 11 3 Loosen the index screw three turns and leave the wrench in place 4 Rotate lower portion of elevation knob counterclock
185. in forward position attempt to place the selector lever in the SAFE position If selector lever can be placed on SAFE evacuate the weapon to support maintenance Change 4 2 69 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 12 19 MAJOR COMPONENTS OF M16A2 RIFLE CONT c STOWAGE Prior to stowing the weapon in arms room perform the following procedures NOTE Weapon passed into arms room issue window should be passed butt first with the bolt locked to the rear Clear Refer to operator s manual Place selector lever in SEMI position Pull trigger Hammer should fall Close ejection port dust cover Place weapon in rack OP OX e 6 M4 M4A1 Carbine Only use M12 Arms Rack a 12 arms rack is the correct arms rack in which to store the M4 M4A1 Carbine The carbine must be stored with buttstock extended When storing the M4 M4A1 Carbine in the M12 arms rack a mounting bracket NSN 5340 01 230 3181 app D item 23 1 may be used for each M4 M4A1 Carbine being stored This option is for the convenience of the person who opens and closes the arms rack to store the carbines b install the mounting bracket on the M12 arms rack for use with the M4 M4A1 Carbine install the bracket with the hooks of the bracket facing toward the carbine so that the lower receiver extension will contact the bent end of the bracket The bent end of the bracket will hold the carbine upri
186. ing solvent Always wear rubber gloves when using dry cleaning solvent 3 37 ARMY TM 9 1005 319 23 amp P AIR FORCE 11W3 5 5 42 3 10 UPPER RECEIVER AND BARREL ASSEMBLY CONT c REPAIR CONT CAUTION Do not allow solid film lubricant to flow into front sight post threaded well e Apply solid film lubricant to cover the damaged finish f If front sight guards cannot be straightened utilizing the above procedures reduce the rifle barrel assembly 7 Slightly bent barrels may be straightened as follows a Check straightness using straightness gage 8448202 p 3 45 If the barrel falls the straightness test and the gage remains in the barrel In the area of the front sight assembly perform step b to determine If it may be straightened b With the gage remaining in the bore hold the rifle in a vertical position with the end of the barrel into which the gage was inserted pointing up Ensure that if when the gage passes through the barrel it will not be damaged Using hand pressure ONLY flex the portion of the barrel between the front sight assembly and the compensator in all four directions left right forward and back If the barrel is only slightly bent the gage will drop through when the barrel is flexed in one of these directions Note the direction which allowed the gage to drop through the barrel CAUTION Remove the gage from the barrel before continuing NOTE If the
187. ipment All items of equipment for which equipment serviceability criteria have been published must as a minimum be rated green under the ESC as a prerequisite to overseas shipment In addition to the condition code standard as enumerated above and the required ESC rating prescribed herein the rifle being considered for overseas shipment must meet the requirements of this section The ESC will be discontinued as new operator manuals are revised which will be used to determine serviceability condition of rifle b Waivers to provisions can only be granted by the gaining command of any particular end Item being considered for issue deployment or shipment The issuing services may recommend issue or shipment of rifles not meeting the provisions when all the following conditions exist 1 Repair parts in required quantities cannot be obtained from the supply system prior to delivery of the end item 2 The gaining command concurs in the receipt of the end item for storage until required repair parts become available The gaining command must also state that capability facilities and funds are available to perform the necessary work when parts become available 3 Department of the Army approval is obtained on a case by case basis 4 Required repair parts are requisitioned by the issuing command for delivery to the Framing command 3 96 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 c All Department of the Army MWO s applica
188. is a 5 digit numeric code used to identify the manufacturer distributor or Government agency etc that supplies the item 2 PART NUMBER column Indicates the primary number used by the manufacturer individual firm corporation or Government activity which controls the design and characteristics of the item by means of Its engineering drawings specifications standards and inspection requirements to identify an Item or range of Items 3 STOCK NUMBER column This column lists the NSN for the associated part number and manufacturer identified In the PART NUMBER and CAGEC columns to the left C 6 Change 5 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 4 FIG column This column lists the number of the figure where the item is identified located in Sections II and Ill 5 ITEM column The item number is that number assigned to the item as it appears in the figure referenced in the adjacent figure number column C 5 SPECIAL INFORMATION a ASSEMBLY INSTRUCTION Detailed assembly instructions for items source coded to be assembled from component spare repair parts are found in Chapter 3 Items that make up the assembly are listed immediately following the assembly item entry or reference is made to an applicable figure b ASSOCIATED PUBLICATIONS The publications listed below pertain to the M16A2 rifle M4 M4A1 carbine and its components Publication Short Title TM 9 1005 319 10 M16A2 Rifle and M4 M4A1 Carbine c USAB
189. l Item to be Checked or Serviced 2 Quarterly Charging handle cont assembly and selector lever cont 2 7 1 2 7 2 blank Change 4 Procedure NOTE Automatic sear should have released hammer while holding trigger in the squeezed position before releasing and resqueez ing the trigger All weapons With hammer in forward position using moderate finger thumb pressure attempt to place the selector lever 3 in SAFE position Not Fully Mission Capable if Moderate finger thumb pressure moves selector lever to SAFE posi tion ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 T PREVENTIVE MAINTENANCE CHECKS AND SERVICES CONT PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Interval Item to be Not Fully Mission No Checked or Procedure Capable if Serviced 3 Quarterly Upper receiver CAUTION and barrel as Do not use screw sembly hand driver or any other guard assem tool when removing blies the handguard as semblies doing so may damage the handguard assem blies and or slip NOTE Refer to operator s manual for buddy System procedure on removing hand guard assemblies Remove and Inspect hand Handguard miss guard assemblies 1 intern ing or unservice ally and externally for cracks able and or damage Cracks are acceptable providing they do not extend into the handguard retaining flange or adversely affect rifle operation
190. l that can do complete repair of the Item H General support is the lowest level that can do complete repair of the item Specialized repair activity is the lowest level that can do complete repair of the item Depot is the lowest level that can do complete repair of the Item Nonreparable No repair Is authorized No repair is authorized No parts or special tools are authorized for the maintenance of a B coded item However the Item may be reconditioned by adjusting lubricating etc at the user level 3 Recoverability Code Recoverability codes are assigned to Items to Indicate the disposition action on unserviceable items The recoverability code is entered In the fifth position of the SMR code as follows Recoverability Codes Application Explanation Z Nonreparable item unserviceable condemn and dispose of the item at the level of maintenance shown In 3d position of SMR code Reparable Item When uneconomically reparable condemn and dispose of the item at unit or aviation unit level F Reparable Item When uneconomically reparable condemn and dispose of the Item at the direct support or aviation level H Reparable Item When uneconomically reparable condemn and dispose of the Item at the general support level 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Recoverability Codes Application Explanation D Reparable item When beyond lower level repair capability return to depo
191. lowing They are arranged in logical sequence requiring a minimum amount of time and motion on the part of the persons performing them and are arranged so that there will be minimum interference between persons performing checks simultaneously on the same end item b Item No Column Checks and services are numbered in disassembly sequence This column shall be used as a source of item numbers for the TM Number column on DA Form 2404 Equipment Inspection and Maintenance Worksheet in recording results of PMCS c Interval Column This column gives the designated interval when each check is to be performed d Item To Be Checked Or Serviced Column This column lists the items to be checked or serviced e Procedure Column This column contains a brief description of the procedure by which the check is to be performed It contains all the information required to accomplish the checks and services Information marked SH Indicates a specific equipment shortcoming and the procedure needed to correct the shortcoming NOTE For the purpose of this technical manual the following definition is supplied This definition is not intended to apply to any other document Shortcoming SH A fault that requires maintenance or supply action on a piece of equipment but does not render equipment Not Mission Capable f Not Fully Mission Capable If Column This column contains a brief statement of the condition e g malfunction shortage that would cause the
192. lt carrier assembly forward to detect binding between key and bolt carrier assembly and gas tube by feel Badly bent gas tube could cause damage to both the key and bolt carrier assembly and the gas tube A slightly bent gas tube will cause unnecessary wear of the key and bolt carrier assembly and gas tube Correct slight binding by removing handguard assemblies and slightly bending gas tube in the handguard area while repeating step e above until no binding is detected Badly bent gas tubes will be replaced and realigned g Remove key and bolt carrier assembly from upper receiver and barrel assembly h Reassemble bolt assembly into key and bolt carrier assembly i Reinstall key and bolt carrier assembly into upper receiver and barrel assembly Make a functional check on an assembled weapon with selector lever in SAFE SEMI and BURST AUTO positions Any portion of this check may be used alone to determine the operational condition of any specific firing position selected Change4 3 85 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 18 M16A2 RIFLE FINAL INSPECTION CONT a FINAL INSPECTION CONT I Check rear sight assembly as follows a Rotate elevation knob counterclockwise until the rear sight assembly is all the way down If a whole click Is not felt as the rear sight assembly stops the rear sight assembly has bottomed out and will not pivot freely Position elevation knob back slightly to its last whole click as the
193. ly serviceability check Hemove disassempie visually inspect bolt assembly 1 for cracks especially in the area of the bolt cam pin hole 2 Check for cracks on locking lugs 3 for a cluster of pits or chipped bolt face 4 and for an elongated firing pin hole 5 If cracked or broken evacuate to support maintenance for repair Check for worn or missing bolt rings 6 Check for proper staggering of bolt rings Insert the bolt assembly 1 into the key and bolt carrier assembly 7 Turn key and bolt carrier assembly 7 so the bolt assembly 1 points down The bolt as sembly must not drop out Remove bolt assembly p 2 35 Check for broken or missing firing pin retaining pin 8 and bolt cam pin 9 replace as necessary Vetects are found The bolt assem bly drops out of the key and bolt carrier assembly due to its own weight Missing or broken firing pin retaining pin or bolt cam pin ARMY TM 9 1005 319 23 amp AIR FORCE 11W3 5 5 42 PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Interval Item to be Not Fully Mission No Checked or Procedure Capable if Serviced 5 Quarterly Key and bolt Check cartridge extractor 10 Parts are missing cont carrier assembly extractor spring assembly 11 or unserviceable and bolt assem cartridge ejector 12 and bly serviceability ejector spring 13 for dirt and check cont serviceability If dirt
194. ly or some other accessory is not installed on the upper receiver to prevent damage to the mounting surface on the upper receiver Section VI PREPARATION FOR STORAGE OR SHIPMENT 2 20 PREPARATION FOR STORAGE OR SHIPMENT a Packaging of the M16A2 Rifle and the M4 M4A1 Carbine shall be in accordance with the following ARMY ONLY Army users shall package the rifle and the carbine in accordance with each respective Packaging Data Sheet PDS for shipment or storage which may exceed 90 days The PDS is part of the Army Master Data File Retrieval Microform System ARMS Packaging File AIR FORCE ONLY Air Force users shall package the rifle in accordance with each respective Special Packaging Instruction SPI 00 856 6885 for shipment or storage which may exceed 90 days 5 are part of the Army Master Data File Retrieval Microform System ARMS Packaging File b Packaging if required for shipping storage which will not exceed 90 days shall be as follows 1 Clean in accordance with operator s manual 2 72 Change 4 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 2 Wrap with MIL B 121 waterproof material 3 Place in barrier bag MIL B 117 Type I Class C or wrap with MIL B 121 Type 1 Grade A and seal with tape PPP T 76 4 one or more of item in minimum size container Block and brace in accordance with MIL STD 1186 Cushion the M16 and similar weight items with PPP C 843 and use PPP F 3
195. me unde strong finger pressure Install hammer pin into hole in hammer to check spring retention of the hammer pin Replace hammer and hammer pin retainer assembly if defective M16A2 M4 NOTE M16A2 burst cam is black M4 burst cam is nickel colored shiny Cam clutch spring should be assembled with bend to the inside The large loop of the hammer spring should be assembled over the burst cam M16A2 M4 install burst cam 1 cam clutch spring 2 and hammer spring 3 on hammer and hammer pin retainer assembly 4 1 install hammer spring 5 on hammer 6 3 74 Change4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 15 TRIGGER ASSEMBLY AND TRIGGER SUBASSEMBLY This task covers a Disassembly c Reassembly b Inspection Repair INITIAL SETUP Tools Equipment Conditions ARMY Small Arms Repairman Tool Kit 3 62 Trigger assembly removed item 3 app B Field Maintenance Basic Less Power General Safety Instructions Small Arms Shop Set item 1 app B To avoid injury to your eyes use care Bolt Carrier Key Tool item 11 fig C 17 when removing and installing spring loaded parts a DISASSEMBLY M16A2 AND M4 ONLY NOTE Do not remove disconnector springs 2 unless required for repair M16A2 and M4 M16A2 and M4 ONLY 1 Remove trigger spring 1 and two disconnector springs 2 from trigger 3 M4A1 ONLY 2 Remove disconnector spring 4 and trigger spring 5 from trigger 6 Change
196. mp AIR FORCE TO 11W3 5 5 42 2 15 CHARGING HANDLE ASSEMBLY This task covers a Disassembly c Inspection Repair e Reassembly b Cleaning d Lubrication INITIAL SETUP Tools References ARMY Small Arms Repairman Tool Kit TM 9 1005 319 10 operator s manual item 3 app B Equipment Conditions 2 34 Charging handle assembly re moved a DISASSEMBLY WARNING To avoid injury to eyes use care when removing and installing spring loaded parts 1 Remove spring pin 1 from charging handle 2 using a hammer and 1 16 inch punch 2 punch is withdrawn catch charging handle latch 3 and helical spring 4 to prevent loss 2 43 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 15 CHARGING HANDLE ASSEMBLY CONT b CLEANING ean all Items operators manual Remove carbon deposits INSPECTION REPAIR Inspect all Items for breaks cracks or damage Replace all unserviceable Items d LUBRICATION Lightly lubricate all Items p 2 33 operator s manual e REASSEMBLY 1 Position helical spring 11 and charging handle latch 2 chdrgiin J handle 13 Align holes and hold In position 2 Install spring pin 4 using a hammer Make sure spring pin is flush 3 Reassemble rifle refer to page 2 68 2 44 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 2 16 UPPER RECEIVER AND BARREL ASSEMBLY RIFLE BARREL ASSEMBLY AND UPPER RECEIVER ASSEMBLY This task cov
197. mp AIR FORCE TO 11W3 5 5 42 a FINAL INSPECTION I Visually inspect general appearance of rifle should look almost new All metal surfaces are to have a dull rustor corrosion resistant finish with no burrs or deep scratches Visually inspect barrel for serviceability Barrels must be straight clean free of rust powder fouling and free of bulges and rings Fine pitting is allowable Using moderate hand pressure check for rotational movement of the front sight in relation to the barrel Also using moderate hand pressure check for rotational movement of the barrel in relation to the upper receiver If movement between the front sight and the barrel exist the barrel assembly must be replaced If movement between the barrel and the upper receiver exist the barrel assembly must be aligned and tightened page 3 29 Visually inspect rifle for missing parts All parts must be attached and all modifications must be applies Steel parts must be rust free Spring pins must be secure and screws must be tight Functionally inspect key and bolt carrier assembly and gas tube alignment Refer to TM 9 1005 319 10 and use the following procedures a Disengage the takedown pin and open the receiver b Remove bolt carrier assembly c Remove bolt assembly from bolt carrier assembly d Insert key and bolt carrier assembly into upper receiver and barrel assembly The bolt assembly must not be installed while performing test Slide key and bo
198. n Do not pull the trigger until the weapon has been cleared References Inspect the chamber and receiver to ensure no TM 9 1005 319 10 operator s manual ammunition is present Do not keep live ammuni tion near work area Equipment Conditions Weapon assembled DISASSEMBLY a Referto operator s manual b Remove magazine 1 sling 2 bolt carrier assembly 3 charging handle assembly 4 and upper receiver and barrel assembly 5 carrying handle assembly 5 1 from lower receiver and buttstock assembly 6 M16A2 M4 M4A1 NOTE Solid Film Lubricant SFL is the only authorized touchup for the M16A2 rifle and M4 M4A1 carbines and may be used on up to one third of the exterior finish of the weapon FOR ARMY CONUS USE ONLY AND AIR FORCE TRAINING WEAPONS ONLY SFL may be used as touchup without limitation on the upper receiver and barrel assembly This is to say that units which DO NOT fall under the category of Divisional Combat Units or rapid deployment type units may have up to 100 percent of the exterior surface of the upper receiver and barrel assembly protected with SFL if necessary Change 4 3 15 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 7 BOLT CARRIER ASSEMBLY This task covers Disassembly d Test b Cleaning e Repair c Inspection f Reassembly INITIAL SETUP Test Equipment Materials Parts Tool and Gage Set item 2 app B Cleaner lubricant and pre
199. n accordance shipment is complete with the instructions of DA PAM 738 750 b Basic issue Check for missing items Refer to TM 9 1005 items 319 10 operator s manual 2 M16A2 a Barrel assembly If volatile corrosion inhibitor VCI rifle or is in barrel remove and discard M4 M4A1 carbine b All parts a Field strip rifle and inspect for Refer to operator s missing damaged and rusted manual or corroded parts b Clean and lubricate Refer to operator s manual c Reassemble Refer to operator s manual d Function check Refer to page 2 69 2 2 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 SERVICE UPON RECEIPT CONT LOCATION ITEM ACTION REMARKS e Check to see whether the equipment has Refer to DA PAM been modified 25 30 c Magazine Check for positive retention and functioning of bolt Refer to operator s catch manual Section PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS 2 6 GENERAL This section contains the procedures and instructions necessary to perform unit preventive maintenance checks and services These services are to be performed by unit maintenance personnel with the assistance of the operator where practical 2 7 PREVENTIVE MAINTENANCE CHECKS AND SERVICES WARNING Before starting an inspection be sure to clear the rifle Do not keep live ammunition near the work area a General The PMCS procedures are contained in the table fol
200. nd serviceability Initial gaging is required 1 year from receipt of the weapons Air Force users refer to inspection requirements in Air Force Manual AFM 36 2227 Volume 1 All Army Reserve and Army National Guard M16A2 rifles and M4 carbines must be inspected and gaged at least once every 2 years after the initial inspection gaging procedures have been accomplished This initial gaging procedure is required 1 year from receipt of the weapons This 2 year interval may be maintained unless preventive maintenance checks and services PMCS or other physical evidence indicates that an individual unit s M16A2 rifles and M4 carbines require inspection gaging at a more frequent interval If it is determined that a yearly inspection is necessary for an individual unit only that unit will be affected This will not affect other units in regard to the interval of inspection It is recommended that training units inspect gage all rifles and carbines at the end of each training cycle Training units will inspect gage all rifles and carbines at least once annually Below direct support maintenance DO NOT interchange bolt assemblies from one rifle carbine to another Doing so may result in injury to or death of personnel Bolt cam pin must be installed or rifle carbine will blow up while firing the first round If the bolt cam pin is not installed injury to or death of personnel may result Dry cleaning solvent is flammable and toxic and should be use
201. ng or fixing Into position a spare repair part or module component or assembly In a manner to allow the proper functioning of an equipment or system h Replace To remove an unserviceable Item and Install a serviceable counterpart In Its place Replace is authorized by the MAC and is shown as the 3d position code of the SMR code i Repair The application of maintenance services2 including fault location troubleshooting3 removal installation and disassembly assembly4 procedures and maintenance actions to Identify troubles and restore serviceability to an Item by correcting specific damage fault malfunction or failure In a part subassembly module component or assembly end Item or system j Overhaul That maintenance effort service action prescribed to restore an item to a completely serviceable operational condition as required by maintenance standards In appropriate technical publications i e DMWR Overhaul is normally the highest degree of maintenance performed by the Army Overhaul does not normally return an Item to like new condition k Rebuild Consists of those services actions necessary for the restoration of unserviceable equipment to a like new condition In accordance with original manufacturing standards Rebuild is the highest degree of materiel maintenance applied to Army equipment The rebuild operation Includes the act of returning to zero those age measurements hours miles etc considered In classifying Army e
202. nged sufficiently to bulge the outside surface of the barrel are cause for rejection However faint rings or shadowy depressions do not indicate an unserviceable barrel and will not be cause for rejection Gap in lined barrels will not be classified as a ringed bore 6 Lands that appear dark due to coating of gilding metal from projectiles will not be cause for rejection 7 Breech bore diameter will be checked on unlined barrels using the appropriate breech bore gage 8 Barrel erosion gages are provided for lined barrels Bore wear will be checked using barrel erosion gage for the M16A2 For detailed instructions in the use of the above gage and for serviceability limits refer to page 3 46 9 Flaking or checking fine cracks of chromium plate in barrels or chambers will not be cause for rejection unless accompanied by pitting to the degree that extraction difficulties are encountered or accuracy is unacceptable h Springs must be free of distortion and broken coils Springs must have sufficient tension to perform their intended function i Screw heads must be in serviceable condition and threads must not be stripped Internal threads must not be stripped j The sear hammer and or cocking notches must be in good condition Chipped engaging corners will be cause for rejection Slight wear on functional surfaces including engaging corners shall be acceptable providing the minimum trigger pull requirements and selector lever checks
203. ns for making items authorized to be manufactured or fabricated at unit or direct support maintenance b A part number in alphanumeric order is provided for cross referencing the part number of the item to be manufactured to the figure which covers fabrication criteria C All bulk matenals needed for manufacture of an item are listed by part number or specification number In a tabular list on the illustration E 2 MANUFACTURED ITEMS PART NUMBER INDEX INDEX Figure Item Number Front sight detent depressor acd cente peek ev e e pe e aeuo pa E 1 Front sight post removal and installation 0 E 2 Pivot PIP FEMOVAl TOOL eT E 3 Pivot PI INStallatlon tO0lz 4 reete KAA AE c bee avete LUN E 4 SLAVE PIM EM E 5 Adapter bar for M12 arms 6 Modified needle nose amp OE 7 5 1 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 E 3 MANUFACTURED ITEMS ILLUSTRATIONS FORMAT AND CONTENT 0 02 0 05 004009 0 080 0 203 DIA 4 pum 0 01 0 03 ett R x x 12222 125 003 lt 3 18 0 08 pe 10 625 0 020 R 22 158820051 075 0 05 1 91 0 13 FABR
204. nts 3 an CARBINE 2 14 Change 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Interval Item to be Not Fully Mission Checked or Procedure Capable if Serviced 6 Quarterly Lower receiver Remove pistol grip screw 3 lockwasher Components are cont and buttstock 4 pistol grip 5 helical spring 6 defective damaged assembly safety detent 7 pivot pin 8 pivot pin serviceability detent 9 and helical spring 10 Clean check cont and lubricate metal components Also clean and generously lubricate pivot pin holes and spring detent holes Replace defective damaged components as necessary Disengage takedown pin 11 and pull Components are out push back in to re engage takedown defective damaged pin an audible click should be heard If an audible click is not heard see page 2 57 for repair Change 5 2 15 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 T PREVENTIVE MAINTENANCE CHECKS AND SERVICES CONT PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Interval Item to be Not Fully Mission Checked or Procedure Capable if Serviced 6 Quarterly Lower receiver Lubricate helical compression spring and cont and buttstock takedown pin detent 11 by placing one assembly drop of lubricant on takedown pin detent serviceability and lowering the buttstock assembly 12
205. ocated at the end of the manual An extensive subject index for everything in the manual Gives page references MAINTENANCE PROCEDURES There are two maintenance chapters Army personnel use chapter two for unit maintenance procedures and chapter three for direct support maintenance procedures Change 4 iii ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 Air Force personnel Only Air Force Specialty Code 753XX Combat Arms Training and Maintenance CATM specialists technicians and gunsmiths are authorized to perform maintenance procedures contained in this manual Each maintenance task has an initial setup containing a list of the following things you will need in order to do your maintenance task 1 Tools and Special Tools For standard and special tools see appendixes B and C Army users are to use the Tool Set Gage Set and or Shop Set listed in the initial setup 2 Materials Parts Lists expendable materials and 100 percent replaceable parts Each material or part is followed by a part number or appendix reference 3 References Lists other publications containing necessary information 4 Equipment Condition Lists conditions to be met before starting the procedure The reference on the left of the condition is a page reference to instructions for setting up the condition 5 General Safety Instructions Lists safety instructions to follow before performing maintenance procedures iv v blank Chang
206. ole that the automatic sear plays when firing in the BURST position Functioning of the mechanism is explained below In a step by step manner This actually will seem to complicate something that is really very simple and happens in less than 1 second The diagrams below and on the following pages do not show the associated springs for the sake of simplicity The positioning of the burst cam is shown in detail unctional check of three round burst is as follows NOTE Assume the rifle is fully loaded with a Gu live round in the chamber and the selector lever on BURST N a Hammer is cocked b Front hook of burst lever is in stop notch 3 88 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 1 1W3 5 5 42 c Trigger Is pulled d Trigger nose drops and hammer falls firing STOP NOTCH the FIRST ROUND e Front hook of burst disconnector holds FRONT HOOK burst cam In place as hammer falls NOTE Anytime the hammer falls forward the clutch spring releases the burst cam and allows the front hook of the burst disconnector to keep It In place f As the key and bolt carrier assembly moves to the rear the hammer is forced to the rear g The clutch spring of the burst cam clutches the burst cam and causes It to rotate one notch as the hammer is forced back h When hammer is fully to the rear the automatic sear catches It ARMY TM 9 1005 319 23 amp P AIR FORCE TO 1 1W3 5 5 42 3 18 M16A2 RIFLE FINAL INSPECTIO
207. on and instructions to keep the weapon in good repair and contains the following sections Repair Parts and Special Tools Direct Support Troubleshooting Direct Support Maintenance Procedures for the M1 6A2 Rifle and M4 M4A1 Carbine Preparation for Storage or Shipment Preembarkation Inspection of Material in Units Slated for Overseas Movement Section REPAIR PARTS SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT 3 1 COMMON TOOLS AND EQUIPMENT For authorized common tools and equipment refer to the Modified Table of Organization and Equipment MTOE applicable to your unit Air Force users must maintain the following common tools Flat tip screwdriver Torque wrench 5 64 inch drive pin Socket wrench handle Retaining ring pliers punch and socket head screw Two 8 inch 1 8 inch drive pin punch socket wrench adjustable wrenches 1 16 inch drive pin Vise jaw caps Flat file punch Machinist s vise Ball peen hammer 3 32 inch drive pin Solid center punch Trigger pull test punch Hammer fixture rod and Combination wrench weights 3 2 SPECIAL TOOLS TMDE AD SUPPORT EQUIPMENT Special tools required for direct support maintenance are listed in appendixes B and C Fabricated tools are listed and illustrated in appendix E 3 3 REPAIR PARTS Repair parts are listed and illustrated in appendix C of this manual NOTE Bolt assemblies and or barrel assemblies may be interchanged at the Direct Support Maintenance level from one rifle to anoth
208. or operator safety or proper retention of hand guard assembly Discard and replace the handguard assembly 1 If the heat shield is loose enough to rattle when Installed on rifle 2 8 ltem No ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Item to be Checked or Serviced Interval Quarterly Upper receiver and barrel as sembly service ability check Not Fully Mission Procedure Capable if WARNING Dry cleaning solvent is flammable and toxic and should be used in a well venti lated area The use of rubber gloves is necessary to protect the skin when wash ing rifle parts CAUTION Damage may occur if excessive force is used to release take down pin or pivot pin Use hand pres sure ONLY Compensator or barrel is loose Release takedown pins and open and separate receivers Hand check compensator 1 for looseness on barrel 2 then hand check barrel 2 for looseness on upper receiver 3 Check center slot of compensator for alignment p 2 50 If com pensator or barrel is loose evacuate to support main tenance Check gas tube 4 forward assist assembly 5 and rear sight assembly 6 for damage The rear sight spring should retain the rear sight assembly 6 In either position with firmness SH If damaged evacuate to support maintenance ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 T
209. our requirements D 1 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Section Il EXPENDABLE DURABLE SUPPLIES AND MATERIALS LIST 1 2 3 4 NATIONAL DESCRIPTION ITEM STOCK NUMBER LEVEL NUMBER PART NUMBER AND CAGE F 8040 00 944 7292 ADHESIVE I IT KT 81348 MMM A 1754 0 8020 00 244 0153 BRUSH ARTIST S metal ferrule EA flat chisel ed i e 7 16 w 1 1 8 ex posed bristle 813481 H B 241 F 1005 00 716 2702 BRUSH CLEANING SMALL ARMS EA 192051 7162702 C 1005 00 903 1296 BRUSH CLEANING SMALL ARMS EA bore 19204 11686340 C 1005 00 999 1435 BRUSH CLEANING SMALL ARMS EA chamber 19204 8432358 C 1005 00 444 6602 BRUSH CLEANING SMALL ARMS EA tooth 1192041 8448462 7920 00 205 2401 BRUSHCLEANING TOOLS AND EA PARTS 813491 MILS43871 6850 00 965 2332 CARBON REMOVING COMPOUND GL 813481 P C 111 CLEANER LUBRICANT AND PRESERV ATIVE 27412 9150 01 079 6124 CLP 4 oz 118 30 ml bottle EA 9150 01 054 6453 CLP 1 pt 0 47 11 bottle EA 9150 01 053 6688 CLP 7 gal 26 50 11 bottle EA C 9150 01 102 1473 CLEANER LUBRICANT AND PRESERV EA ATIVE 81349i MIL L 63460 1 2 oz 14 79 ml bottle C 9920 00 292 9946 CLEANER TOBACCO PIPE cotton turf wire core 89855 DILLSPIPE cleaner 6 per pkg CLEANING COMPOUND RIFLE BORE small arms bore cleaner solution RBC 1813491 MIL C 372 C 6850 00 224 6656 2 oz 159 15 mil bottle OZ 6850 00 224 6657 8 oz 236 59 ml can CN 6850 00 224 6663 1 gal 3 7
210. pring assembly Push out extractor pin 1 and remove cartridge extractor 2 and extractor spring assembly 3 as a unit If required twist extractor spring assembly 3 counterclockwise to remove from cartridge extractor 2 CAUTION Be sure to use vise law protective caps Hold bolt body In vise and remove spring pin 4 using 1 16 Inch punch and hammer 2 39 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 14 BOLT ASSEMBLY CONT a DISASSEMBLY CONT WARNING To avoid injury to your eyes use care when removing and installing spring loaded parts Remove punch be sure to catch cartridge elector 5 and ejector spring 6 to prevent loss b CLEANING CAUTION Do not distort extractor spring assembly during cleaning Clean all Items operator s manual Remove carbon deposits INSPECTION REPAIR Check bolt rings 1 for damage and proper stagger gaps approximately 3 turn apart 90 Inspect for cracks damage especially around bolt cam pin hole 2 and locking lugs 3 If cracked or NOTE damaged evacuate to support maintenance DO NOT REMOVE Inspect cartridge extractor 4 extractor spring BOLT RINGS assembly 5 and extractor pin 6 for cracks breaks chips and other damage Pay close attention to cartridge extractor lip 7 If damaged replace Inspect cartridge ejector 8 and ejector spring 9 for cracks breaks and chips If damaged replace 2 40 AR
211. quipment components Servlces Inspect test service adjust align calibrate and or replace Fault locate troubleshoot The process of investigating and detecting the cause of equipment malfunctioning the act of isolating a fault within a system or unit under test UUT Disassemble assemble encompasses the step by step taking apart or breakdown of a spare functional group coded Item to the level of Its least competency identified as maintenance significant e assigned an SMR code for the level of maintenance under consideration Actionswelding grinding riveting straightening facing remachinery and or resurfacing B 2 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 B 3 EXPLANATION OF COLUMNS IN THE MAC SECTION II a Column 1 Group Number Column 1 lists functional group code numbers the purpose of which is to identify maintenance significant components assemblies subassemblies and modules with the next higher a assembly End item group number shall be OO b Column 2 Component Assembly Column 2 contains the names of components Assemblies subassemblies and modules forwhich maintenance is authorized c Column 3 Maintenance Function Column 3 lists the functions to be performed on the it em listed in Column 21 for detailes explanation of these functions see paragraph B 2 d Column 4 Maintenance Level Column 4 specifies by the list ing of a work time figure in the appropriate subcolumn s
212. r and barrel assembly 5 carrying handle assembly 5 1 from lower receiver and buttstock assembly 6 NOTE Solid Film Lubricant SFL is the only authorized touchup for the MI 16A2 rifle and M4 M4A1 carbines and may be used on up to one third of the exterior finish of the weapon FOR ARMY CONUS USE ONLY AND AIR FORCE TRAINING WEAPONS ONLY SFL may be used as touchup without limitation on the upper receiver and barrel assembly This is to say that units which DO NOT fall under the category of Divisional Combat Units or rapid deployment type units may have up to 100 percent of the exterior surface of the upper receiver and barrel assembly protected with SFL if necessary 12 13 BOLT CARRIER ASSEMBLY This task covers a Disassembly b Cleaning c Inspection Repair ools ARMY Small Arms Repairman Tool Kit item 3 app B Bolt Carrier Key Tool item 11 figure C 17 References TM 9 1005 319 10 operator s manual Equipment Conditions 2 34 Bolt carrier assembly removed a DISASSEMBLY CAUTION Do not spread or close legs of firing pin retaining pin 1 Remove firing pin retaining pin 1 Tilt key and bolt carrier assembly 2 and catch firing pin 3 as it drops out Rotate bolt cam pin 4 one quarter turn and lift straight up to remove Remove bolt assembly 5 from key and bolt carrier assembly 2 NOTE For disassembly of bolt assembly 5 see page 2 38 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W
213. r parts are listed and illustrated in appendix C of this manual Section Il SERVICE UPON RECEIPT 2 4 GENERAL a Inspect the rifle for damage Incurred during shipment If rifle has been damaged report the damage on SF 364 Report of Discrepancy ROD b Check the rifle against the packing slip to see If shipment is complete Army users report all discrepancies in accordance with DA PAM 738 750 Air Force users submit Materiel Deficiency Report MDR to DIR MAT MGT ROBINS AFB GA MMIBTC and Product Quality Deficiency Report to DIR MAT MGT ROBINS AFB IAW Technical Order 00 35D 54 c Checkto see whether the equipment has been modified 2 1 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 5 SERVICE UPON RECEIPT OF MATERIEL WARNING Before starting an inspection be sure to clear the rifle Do not actuate the trigger before clearing the rifle Inspect the chamber to make sure it is empty and free of obstructions Check to see there are no obstructions in the barrel and no ammunition is in position to be chambered SERVICE UPON RECEIPT LOCATION ITEM ACTION REMARKS 1 Container a M16A2 rifle or a Remove rifle from containers M4 M4A1 carbine b Inspect the equipment for dam If the equipment has age incurred during shipment been damaged report the damage on SF Form 364 Report of Discrepancy ROD c Check the equipment against Report all discrep the packing list to see if the ancies i
214. r stops until the trigger is fully forward an audible click should be heard Hammer should not fall Repeat the above selector lever SEMI position test steps 10 and 11 five times The rifle must not malfunction during any of these five repetitions If the rifle malfunctions during any of these five tests refer to page 3 7 M16A2 and M4 ONLY Place selector lever in BURST position Charge rifle and pull trigger Hammer should fall While holding the trigger to the rear pull charging handle assembly to the rear and release it three times Hammer should not fall the third time the charging handle assembly is released It may or may not fall the first and second time the charging handle assembly is released When the burst disconnector reached the deep notch of the burst cam the burst disconnector should have held the hammer to the rear while the trigger was in the pulled position Release the trigger with a slow smooth motion without hesitations or stops until the trigger is fully forward The hammer should not fall Pull trigger Hammer should fall This would be the first round of a three round burst NOTE A detailed explanation of the three round burst control can be found in the following pages M4A1 ONLY Place selector lever in AUTO position Charge weapon and pull trigger Hammer should fall Hold trigger to the rear charge weapon and release trigger Pull trigger Hammer should not fall Automatic assembly sear should have released
215. receiver and buttstock assembly C 11 1 Buttstock assembly M16A2 12 1 C 12 Buttstock assembly M4 M4A1 Hammer 2 Trigger assembly ed pn p eee oa a 14 1 040301 Trigger subassembly M16A2 and 4 I Lower receiver and receiver extension assembly 16 2 C 16 1 C 16 0404A Lower receiver and receiver extension assembly 4 and MAAM 16A 1 16A ii Change 4 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 Illus Page Figure APPENDIX REPAIR PARTS AND SPECIAL TOOLS LIST Cont Section 17 Section National Stock Number and Part Number Index 1 1 APPENDIX EXPENDABLE DURABLE SUPPLIES AND MATERIALS LIST APPENDIX ILLUSTRATED LIST OF MANUFACTURED ITEMS 1 ALPHABETICAL Change 4 ii 1 ii 2 blank ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 HOW TO USE THIS MANUAL Read this manual carefully before performing required maintenance This manual will be referred to for Inspection Maintenance and Repair procedures
216. ress slip ring spring 4 from both sides and insert It Into handguard slip ring 3 Install retaining ring 5 against slip ring spring 4 using retaining ring pliers Snap retaining ring 5 to barrel nut 1 NOTE After cleaning apply molybdenum disulfide grease to threads of barrel nut assembly before Installation 3 39 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 10 UPPER RECEIVER AND BARREL ASSEMBLY CONT d REASSEMBLY CONT The alignment pin 6 must not show any signs of looseness 5 Position rifle barrel assembly 2 with alignment pin 6 up Using barrel remover fixture 7 clamp rifle barrel assembly 2 in vise NOTE The slot should fit the alignment pin perfectly with very little or no rotational play present Note the play in a new rifle barrel assembly and new upper receiver assembly and use this as a guide Align upper receiver assembly 8 or 8A using alignment pin 6 and the slot in upper receiver assembly 8 or 8A Install over end of rifle barrel assembly 2 Wipe upper receiver threads clean and ensure there are no burrs Apply molybdenum disulfide grease to the threads before installation 3 40 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Engage threads of barrel nut assembly 9 with upper receiver assembly 8 Using combination wrench 10 and torque wrench torque barrel nut assembly 9 to 30 ft lb 40 5 N m Torque is mea
217. revent loss of ball bearing Position windage knob on shaft of windage screw 211 Align holes In windage knob with hole of shaft In windage screw and hold In alignment with a small screwdriver or punch Install spring pin 25 3 56 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 S 12 Rotate and test elevation index 6 and windage knob 24 for ease of functioning 13 Inspect elevation knob zero as follows a Rotate elevation knob 5 counterclockwise until the rear sight assembly is all the way down If a whole click is not felt as the rear sight assembly stops the rear sight assembly has bottomed out and will not pivot freely Position elevation knob back slightly to its last whole click so the rear sight assembly base is under tension of the ball bearing 8 and helical spring 14 The 300 meter mark should align with the mark on to receiver If the 300 meter mark is not aligned with the mark on receiver slip the range scale in the following manner 1 Position the 300 meter mark with the mark on the receiver 2 Inserta 1 16 inch allen wrench through the access hole of the rear sight assembly base and into the index screw 7 3 Loosen the index screw three turns and leave the wrench in place 4 Rotate lower portion of elevation knob 5 counterclockwise until it stops range scale should not have moved Elevation knob should be positioned on its last whole click 5 Tighten index screw 7 and remov
218. right side figure C 15 item 1A is nickel shiny Ensure that the correct spring is installed on each side for proper functioning 3 76 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 M16A2 M4 M16A2 and M4 2 Install trigger spring 3 M4A1 ONLY 3 Install disconnector spring 4 by inserting large end of spring into trigger 5 4 Install trigger spring 6 on trigger 5 Change 4 3 76 1 3 76 2 blank ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 16 LOWER RECEIVER AND RECEIVER EXTENSION ASSEMBLY This task covers a Disassembly c Repair Modify b Inspection d Reassembly INITIAL SETUP Tool Equipment Equipment Conditions Tool and Gage Set item 2 app B 3 62 Lower receiver and receiver ex tension assembly removed Tools ARMY Small Arms Repairman Tool Kit General Safety Instructions item 3 app B To avoid injury to your eyes usecare Field Maintenance Basic Less Power when removing and installing spring Small Arms Shop Set item 1 app B loaded parts When using solid film lubricant or Materials Parts dichloromethane be sure the area is Cloth abrasive item 13 app D well ventilated Grease molybdenum disulfide item 19 app D Lubricant solid film item 21 app D a DISASSEMBLY 1 Remove spring pin 1 from lower receiver 2 using 1 8 inch drive pin punch and hand hammer 2 Remove trigger guard 3 3 77 ARMY TM 9 1005 319 23 amp P AIR FORCE
219. rt MDR to DIR MAT MGT ROBINS AFB GA MMIBTC and Product Quality Deficiency Report to DIR MAT MGT ROBINS AFB GA IMMQA IAW Technical Order 00 35D 54 A reply will be sent to you 1 7 CORROSION PREVENTION AND CONTROL CPC CPC of Army materiel is a continuing concern It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items While corrosion is typically associated with rusting of metals it can also include deterioration of other materials such as rubber and plastic Unusual cracking softening swelling or breaking of these materials may be a corrosion problem 1 2 Change4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 corrosion problem is identified it can be reported using Standard Form 368 Product Quality Deficiency Report Use of key words such as corrosion rust deterioration or cracking will assure that the information is identified as a CPC problem Army users submit Product Quality Deficiency Report SF 368 to Commander U S Army Armament Research Development and Engineering Center ATTN AMSTA AR QAW R Rock Island IL 61299 7300 Air Force users submit Materiel Deficiency Report MDR to DIR MAT MGT ATTN MMIBTC Robins AFB GA and Product Quality Deficiency Report to DIR MAT MGT ATTN MMQA Robins AFB GA Section Il EQUIPMENT DESCRIPTION AND DATA 1 8 EQUIPMENT CHARACTERI
220. s 1 Remove old pages and insert new pages as indicated below 2 New or changed material is indicated by a vertical bar adjacent to the material 3 New or changed illustrations are indicated by a miniature pointing hand highlighting the change Remove Pages a thru iv 1 0 1 1 0 2 blank thru 1 6 2 1 thru 2 8 2 11 and 2 12 2 17 thru 2 20 2 31 thru 2 34 None 2 48 thru 2 50 2 53 thru 2 54 2 59 thru 2 62 2 69 thru 2 72 3 1 and 3 2 3 5 thru 3 8 3 11 thru 3 16 3 19 and 3 20 3 39 and 3 40 3 43 and 3 44 3 47 thru 3 48 3 55 and 3 56 3 65 thru 3 70 3 73 thru 3 76 3 83 thru 3 88 3 93 thru 3 96 3 101 thru 3 103 3 104 blank Insert Pages a thru iv 1 0 1 1 0 2 blank thru 1 6 2 1 thru 2 8 2 11 and 2 12 2 17 thru 2 20 2 31 thru 2 34 2 36 1 2 36 2 blank 2 48 thru 2 50 2 53 thru 2 54 2 59 thru 2 62 2 69 thru 2 73 2 74 blank 3 1 and 3 2 3 5 thru 3 8 3 11 thru 3 16 3 19 and 3 20 3 39 and 3 40 3 43 and 3 44 3 47 thru 3 48 3 55 and 3 56 3 65 thru 3 70 1 3 70 2 blank 3 73 thru 3 76 1 3 76 2 blank 3 83 thru 3 88 3 93 thru 3 96 3 101 thru 3 103 3 104 blank Remove Pages 4 1 and 4 2 4 9 thru 4 11 4 12 blank A 1 and A 2 B 5 thru B 8 C 1 and C 2 C 7 and C 8 C 9 blank Fig C 1 thru Fig C 2 C 5 1 thru Fig C 9 C 10 1 thru C 11 2 C 12 1 thru Fig C 17 1 1 thru 1 10 D 3 and D 4 E 5 E 6 blank Cover Insert Pages 4 1 and 4 2 4 9 thru 4 11 4 12 blank A 1 and A 2 B 5 thr
221. s indicated by the parenthetical entry which is a physical security classification abbreviation e g Phy Sec C1 C Confidential Phy Sec C1 S Secret Phy Sec C1 T Top Secret 3 Items that are included in kits and sets are listed below the name of the kit or set 4 Spare repair parts that make up an assembled item are listed immediately following the assembled item line entry 5 Part numbers for bulk materials are referenced in this column In the line item entry for the Item to be manufacture red fabricated 6 When the item is not used with all serial numbers of the same model the effective serial numbers are shown on the last line s of the description before UOC 7 The usable on code when applicable see paragraph 5 Special Information Change 5 C 5 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 C 3 EXPLANATION OF COLUMNS SECTION II AND III CONT 8 In the Special Tools List section the basis of issue BOI appears as the last line s in the entry for each special tool special TMDE and other special support equipment When density of equipment supported exceeds density spread indicated in the basis of Issue the total authorization is increased proportionately 9 The statement END OF FIGURE appears just below the last item description in Column 5 for a given figure In both Section II and Section 11 g Oty Column 7 The Qty quantity per figure column indicates the quantity of the item u
222. s to say that units which DO NOT fall under the category of Divisional Combat Units or rapid deployment type units may have up to 100 percent of the exterior surface of the upper receiver and barrel assembly protected with SFL Prior to application of SFL the surface must be thoroughly cleaned and inspected for corrosion and or damage If corroded or damaged the part must be repaired or replaced prior to application of SFL Continued use under combat conditions would result in an unprotected surface when the SFL wears off This would result in a large light reflecting surface and accelerated deterioration of the unprotected surface Therefore Divisional Combat Units and units which fall under the definition of Rapid Deployment type must adhere to the limitation of NOT over one third of their exterior surface covered by SFL When determining mission capability deadline if it is a deficiency NO 4 Change 4 Item No ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Interval Item to be Checked or Serviced Quarterly Magazine serviceability check Quarterly Charging handle assembly and selector lever Procedure Disassemble as In TM 9 1005 319 10 operator s manual Inspect tube 1 for bulges dents or dam aged feeder lips 2 Inspect spring 3 and follower 4 for kinks or damage SH Replace the magazine if any of these conditions exist
223. s used 4B Install swivel mount 7 2 7 2 RIFLE ONLY CARBINE ONLY 4 If previously disassembled position small sling swivel Install front swivel 7 1 to swivel mount 7 2 with 6 and install new tubular rivet 7 using center punch new rivet 7 3 using center punch and hammer to and hammer to spread and flare the hollow head of spread and flare the hollow head of the tubular the tubular rivet rivet 74 CARBINE ONLY NOTE It is recommended that the swivel mount be CARBINE ONLY placed on the left side of the carbine for right handed operators and on the right side for left AC Place swivel locking bar 7 4 in swivel mount Change 4 2 53 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 2 16 UPPER RECEIVER AND BARREL ASSEMBLY RIFLE BARREL ASSEMBLY AND UPPER RECEIVER ASSEMBLY CONT f REASSEMBLY CONT CARBINE ONLY AD Install two spring pins 7 5 5 Position helical spring 8 and front sight detent 9 To avoid injury to your eyes use care when re moving and installing spring loaded parts 6 WARNING Install front sight post 10 by turn ing front sight post removal and in stallation tool 11 clockwise until front sight post base is flush with or slightly below front sight frame 2 53 1 2 53 2 blank Change 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 2 16 UPPER RECEIVER AND BARREL AS
224. sed in the breakout shown on the illustration figure which is prepared for a functional group subfunctional group or an assembly A V appearing In this column in lieu of a quantity indicates that the quantity is variable and the quantity may vary from application to application C 4 EXPLANATION OF COLUMNS SECTION IV a NATIONAL STOCK NUMBER NSN INDEX 1 STOCK NUMBER column This column lists the NSN by National Item Identification Number NIIN sequence The NIIN consists of the last nine digits of the NSN NSN i e 5305 01 674 1467 When using this column to locate an item ignore the first 4 digits NIIN of the NSN However the complete NSN should be used when ordering items by stock number 2 FIG column This column lists the number of the figure where the item Is Identified located The figures are in numerical order in Section and Section Ill 3 ITEM column The item number identifies the item associated with the figure listed in the adjacent FIG column This item is also identified by the NSN listed on the same line b PART NUMBER INDEX Part numbers in this index are listed by part number in ascending alphanumeric sequence i e vertical arrangement of letter and number combination which places the first letter or digit of each group In order A through Z followed by the numbers 0 through 9 and each following letter or digit in like order 1 CAGEC column The Contractor and Government Entity Code CAGEC
225. servative CLP item 9 app D Tools Cleaning compound rifle bore RBC ARMY Small Arms Repairman Tool Kit item 12 app D item 3 app B Pipe cleaner item 11 app D Equipment Conditions 3 1 5 Bolt carrier assembly removed a DISASSEMBLY 1 Remove firing pin retaining pin 1 2 Tip key and bolt carrier assembly 2 allowing firing pin 3 to drop out Catch the firing pin 3 Rotate bolt cam pin 4 one quarter turn and lift straight up to remove 4 Remove bolt assembly 5 from key and bolt carrier assembly 2 b CLEANING Clean carrier key and gas relief ports using CLP or RBC and pipe cleaner INSPECTION ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 1 Inspect bolt carrier assembly using the following guidelines a Inspect bolt carrier assembly 1 for burrs cracks wear and evidence of gas loss b Visually inspect the carrier and key screws 2 for looseness and proper staking as shown below NOTE Do not attempt to retorque if there is no loosening of the screws indicated by the staking marks Surface A must not Indicate distortion or damage which Impairs parallelism NOTE A maximum of 0 025 in 0 064 cm protrusion In an upward direction is permissible NOTE There are bolts and bolt carriers on fielded rifles some with chrome plated exterior surface finishes and some with phosphate coating
226. sured when both wrenches are used together NOTE Three times torquing procedure provides for a better thread fit and prevents barrel nuts from becoming loose Do not use the torque wrench for loosening Make certain all three drive pins on combination wrench are engaged with barrel nut assembly 91 Loosen and repeat torque operation Then loosen the barrel nut again 3 41 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 10 UPPER RECEIVER AND BARREL ASSEMBLY CONT d REASSEMBLY CONT VERTICAL TARGET LINE 11 Front sight post must be Installed Loosen the vise and align the bore on a distant vertical target Center the target In the bore from 12 o clock through 6 o clock The front sight post should be on line and vertical with the target Tighten vise Adjust the rear sight windage until a proper sight picture is obtained on the vertical target The rear sight aperture will be approximately In the center of the rear sight base If the rifle barrel assembly is properly aligned in the upper receiver assembly NOTE If rifle barrel assembly usually new is not properly aligned In the upper receiver assembly usually an old part excessive windage will be present and the upper receiver assembly will require replacement to obtain the proper fit between the alignment pin and slot 3 42 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 CAUTION Do not torque over 80 ft lb 108 N m while tightenin
227. t door assembly 61 RIFLE ONLY in 181 and separate hinge 9 and Change 3 2 65 ARMY TM1 9 1 005 31 9 28 amp P AIR FORCE TO 11 WV3 5 5 42 2 18 BUTTSTOCK ASSEMBLY CONT a DISASSEMBLY CONT CARBINE ONLY 4 Disassemble the buttstock assembly by tapping out the spring pin 10 located in he oval slot of the retaining nut 1 1 This is done using a 1 16 Inch punch 5 Insert your Index finger into the forward end of the buttstock 112 and push down on the locking pin 13 Unscrew the retaining nut 11 and remove the release lever 14 locking pin 13 and spring 15 E b CLEANING RIFLE ONLY Clean all parts with CLP operator s manual Use brush to clean knurled surface of door assembly 2 65 1 2 65 2 blank Change 3 ARMY TM 9 1005 319 23 amp P AIR FORCE 11W3 5 5 42 2 18 BUTTSTOCK ASSEMBLY CONT c INSPECTION NOTE M16A2 buttstocks PN 9349121 with unauthorized markings may be used under the following conditions The only authorized markings are those which are temporary In nature i e paint tape etc When marking a buttstock only use temporary markings Buttstocks with unauthorized markings that have been stamped into the surface of the buttstock will not be used Unauthorized markings that have previously been scratched etched carved etc may continue In use if the marks do not extend Into the fiber of th
228. t Condemnation and disposal of item not authorized below depot level L Reparable item Condemnation and disposal not authorized below Specialized Repair Activity SRA A Item requires special handling or condemnation procedures because of specific reasons e g precious metal content high dollar value critical material or hazardous material Refer to appropriate manuals directives for specific instructions c NSN Column 3 Indicates the National stock number NSN assigned to the item and which will be used for requisitioning d CAGEC Column 4 The Contractor and Government Entity Code CAGEC is a 5 digit numeric code which is used to identify the manufacturer distributor or Government agency etc that supplies the Item e PART NUMBER Column 5 Indicates the primary number used by the manufacturer individual company firm corporation or Government activity which controls the design and characteristics of the item by means of its engineering drawings specifications standards and inspection requirements to identify an item or range of items NOTE When you use an NSN to requisition an item the item you receive may have a different part number from the part ordered f DESCRIPTION AND USABLE ON CODE UOC Column 6 This column includes the following Information 1 The Federal item name and when required a minimum description to identify the Item 2 The physical security classification of the item i
229. t s vise and barrel removal fixture 3 32 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 11 Remove retaining ring 13 using retaining ring pliers 12 Remove slip ring spring 14 and handguard slip ring 15 13 Do not remove barrel nut 16 from barrel assembly 12 INSPECTION CLEANING WARNING When using carbon removing compound avoid skin contact If carbon removing compound comes In contact with the skin wash thoroughly with running water Using a good lanolin base cream after exposure to compound is help ful Using gloves and protective equipment is required 1 Inspect gas tube for cracks Replace if defective 2 Use carbon removing compound to remove carbon deposits from interior and exterior of gas tube If a large amount of carbon is found and cannot be removed replace the gas tube NOTE A small arms cleaning brush bore item 4 app D may be used to clean Interior of front sight assembly where gas tube is secured 3 33 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 3 10 UPPER RECEIVER AND BARREL ASSEMBLY CONT b INSPECTION REPAIR CONT NOT ACCEPTABLE ACCEPTABLE 3 Inspect bore for burrs cracks rust bulges and pits using the following guidelines a Pits no wider than a land or groove and no longer than 3 8 inch 0 95 cm are al lowed in the bore b Lands that appear dark blue due to coating of gliding metal
230. t catch 4 and or spring Evacuate to support maintenance 2 32 Change 5 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 Section V MAINTENANCE PROCEDURES 2 10 INITIAL SETUP The following information will reduce the space required for the initial setup portion of the maintenance procedures a Materials Parts required are not listed unless they apply to the procedure b Personnel Required is listed only if the task requires more than one person If Personnel Required Is not listed It means one person can do the job c The normal standard equipment condition Is that the item is removed from the en 1 Item or next higher assembly and is in the assembled condition Equipment Condition is not listed unless some other condition is required d The approximate time required Is listed on the applicable Maintenance Allocation Chart MAC e When the term evacuate to support maintenance is used the entire rifle must be evacuated 2 11 LUBRICATION GENERAL a Whenever the term cleaner lubricant and preservative CLP or the words lubricant lube LSA or LAW are cited In this TM they are to be interpreted to mean CLP Item 9 app D weapons lubricating oil LSA Item 23 app D or weapons lubricating oil LAW Item 22 app D can be utilized as applicable The following constraints must be adhered to b Under all but the coldest arctic conditions LSA or CLP are the lubricants to use on the rifle Either may be
231. the groove of the pivot pin 7 when assembly is complete 3 Install pivot pin 7 while removing fabricated pivot pin Installation tool 4 Maintain pressure while sliding pivot pin 7 into hole Rotate pivot pin until pivot pin detent is inserted Into pivot pin groove RIFLE ONLY CAUTION Do not kink helical spring 8 during assembly 4 Install takedown pin 9 with groove toward the rear Install takedown pin detent 10 and helical spring 8 from the rear 5 Install stepped spacer 11 on receiver extension 12 and carefully slide buttstock assembly 13 on to compress helical spring 8 NOTE Self locking screw 14 If removed must be discarded and replaced with a new one 6 Install self locking screw 14 to secure buttstock assembly 13 6 Install self locking screw 14 to secure buttstock assembly 13 Change 3 2 63 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11 W3 5 5 42 1 2 17 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY CONT f REASSEMBLY CONT CARBINE ONLY 6A Grasp the lock release lever 14 1 In the area of the retaining nut 14 2 and pull to reinstall the buttstock assembly 14 3 onto the lower receiver extension 14 3 onto the lower receiver extension 14 4 2 63 1 2 63 2 blank Change 3 ARMY TM 9 1005 319 23 amp P AIR FORCE 11W3 5 5 42 2 17 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY CONT f REASSEMBLY CONT WARNI
232. the forward assist housing and require some additional force to remove Remove retaining ring 12 and slide headles grooved pin 11 out to the rear Catch cover spring 13 and ejection port cover 14 to prevent loss as headless grooved pin is with drawn 2 48 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 M4 M4A1 ONLY NOTE Do not remove the carrying handle assembly nut 2 each or clamp for normal maintenance If carrying handle assembly nut or clamp are missing or the clamp is damaged to the point of being non functional they may be replaced 7 1 Disassemble as follows only if required to replace damaged or missing carrying handle assembly nut or clamp Observe the position of the clamp 15 in relation to the carrying handle 16 b Using care not to damage the surface finish remove carrying handle assembly nut s 17 and clamp as required c Inspect mating surfaces of the carrying handle 16 and the clamp 15 for damage If damaged replace the damaged part d Inspect for other damage rust etc Repair or replace as required e Apply a light coat of lubricant to all mating surfaces f clamp 15 must not extend past the forward end of the carrying handle 16 Taking care not to cross thread install handle assembly nut 17 Install clamp 15 paying close attention to ensure that it is installed in its original position The forward end of th
233. the hammer as the bolt closed ALL WEAPONS With the hammer in the forward position using moderate finger thumb pressure attempt to place the selector lever in the SAFE position Selector lever should not go in the SAFE position Perform the following additional functional checks and adjustments on assembled weapon a Press magazine catch button Make sure it functions properly b Press bolt catch Make certain it operates smoothly and holds bolt in open position c Inspect front sight and rear sight assembly Make certain they can be adjusted properly Actuate forward assist assembly It must work freely Change 4 3 87 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 18 M16A2 RIFLE FINAL INSPECTION CONT a FINAL INSPECTION CONT e Inspect upper receiver and barrel assembly Barrel assembly should not rotate within upper receive assembly f Check that third or middle slot of compensator is straight up TDC b TEST Check headspace using headspace gage PN 7799734 See page 3 45 TEST Check firing pin protrusion using firing pin protrusion gage PN 7799735 See page 3 45 TEST Check extent of barrel erosion using barrel erosion gage PN 8448496 See page 3 45 TEST Check barrel straightness using barrel straightness gage PN 8448202 See page 3 45 NOTE First become familiar with the functioning of the firing mechanism especially when in the SAFE and SEMI positions You should also understand the r
234. the rifle remove immediately by washing with technical dichloromethane 3 Wash area with technical dichloromethane methylenechloride to remove dirt and grease and foreign material 4 Roughen area to be refinished with abrasive cloth and clean surface again Do not touch the area with fingers 5 Repair shiny surfaces by spraying a coat of solid film lubricant in accordance with Instructions supplied by the manufacturer Dry 24 hours before handling SHINY SURFACES REPARABLE 3 36 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 6 Straighten bent front sight guards 1 as follows NOTE Remove spring before heating Heat will damage spring The sight post and plunger may be reused unless damaged a Remove front sight post detent and helical spring see p 2 43 NOTE Use copper or brass caps jaw Inserts on bench vise to prevent damage to front sight base 2 during clamping b Place front sight base 2 in a bench vise c Heat front sight guards 1 and bend with pliers The front sight guards 1 should be put back as nearly as possible to the original position Allow front sight housing to air cool WARNING Dry cleaning solvent is flammable and toxic and should be used in a well ventilated area The use of rubber gloves is necessary to protect skin when washing rifle parts d Roughen any damaged surface of front sight guards with abrasive cloth and clean with dry clean
235. u B 8 C 1 and C 2 C 7 and C 8 C 9 blank Fig C 1 thru Fig C 2 C 5 1 thru Fig C 9 C 10 1 thru C 11 2 C 12 1 thru Fig C 17 1 1 1 thru 1 12 D 3 thru D 5 D 6 blank E 5 and E 6 Cover 4 File this change sheet in the front of the publication for reference purposes By Order of the Secretary of the Army GORDON R SULLIVAN General United States Army Chief of Staff Official JOEL B HUDSON Acting Administrative Assistant to the Secretary of the Army 00175 DISTRIBUTION To be distributed in accordance with DA Form 12 40 E block 0020 requirements for TM 9 1005 319 23 amp P CHANGE No 3 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 11W3 5 5 42 HEADQUARTERS DEPARTMENTS OF THE ARMY AND AIR FORCE Washington D C 3 February 1994 UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST TM 9 1005 319 23 amp P May 1991 is changed as follows RIFLE 5 56MM M1 6A2 W E 1005 01 128 9936 EIC 4GM 1 Remove old pages and insert new pages as indicated below 2 New or changed material is indicated by a vertical bar adjacent to the material 3 New or changed illustrations are indicated by a miniature pointing hand highlighting the change Remove Pages a thru iv v blank 1 3 thru 1 6 2 3 and 2 4 2 13 thru 2 18 2 21 thru 2 24 2 27 and 2 28 2 47 and 2 48 2 53 and 2 54 2 57 thru 2 60 2 63 thru 2 71 2 72 blank 3 39 and 3 40 3 57 and 3 58 3 77 thru 3 82 4 1
236. u to the illustration figure and item number of the item you are looking for 2 Second Turn to the figure and item number verify that the item is the one you re looking for then locate the item number in the repair parts list for the figure C 7 ABBREVIATIONS Not applicable C 8 C 9 blank Change 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 SECTION II Section Il REPAIR PARTS LIST 2 2 1 N fe VERS uo E T C 2 4 5 16 2 RIFLE 1 7 2 bw fe M EAR 2A DIS cM 7 5 2 es 3A ety MM T 22 S i NL z EA 1 4 M zt fh 2 4 6A 6B AC 5A Figure C 1 M16A2 Rifle 5 56mm 9349000 M4 Carbine 5 56mm 9390000 and M4A1 Carbine 5 56mm 12972700 Change 5 SECTION II 1 ITEM NO QTY 2A 3A 5A 6A eB 2 SMR CODE PAOOO AFFFF AFFFF AFFFF AFFFF PACZZ PACZZ PACZZ XAFFA XAFFA XAFFA AFFFF TM9 1005 319 23LP 3 NSN 1005000179546 19200 1005011879716 19200 1005009215004 1005012164510 1005013689852 19200 4 CAGEC 19204 19204 12011849 19200 12972680 19200 19204 19200 9349100 19200 19200 19200 5 PART NUMBER 8448517 8448501 BOLT 9349050 UPPER 8448670 12624561 12011996 LOWER 9390011 12972690 12951011 6 DESCRIPTION AND USABLE GROUP 00 M16A2 RIFLE 5 56 9349000 M4 CARBINE 5 56MM 939000
237. uring fixture 7274758 add weights until hammer trips Determine weight 218 802 applied 1134 G Hammer must not trip when 5 5 lbs 2 49 kg have been applied hammer must trip 1LB 8 OZ applying 9 5 Ibs 4 31 kg 218 802 1134 680 Change 5 3 83 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 17 MAJOR COMPONENTS OF M16A2 RIFLE CONT M4A1 ONLY d Clear the weapon Cock weapon Place weapon in SEMI position and hold weapon in vertical position b TEST CONT e Using trigger pull measuring fixture 7274758 as shown add weights until hammer trips Determine weight applied f Hammer must not trip when 5 5 16 2 49 kg have been applied Hammer must trip on applying 8 5 16 3 86 kg ALL WEAPONS g If weapon fails trigger pull test or excessive creep is present replace trigger and or hammer NOTE Always gage trigger and hammer pin holes with not go plug gage 12006472 before replacing parts c INSPECTION tinal inspection procedures Delow 3 18 16 2 RIFLE FINAL INSPECTION This task covers a Final inspection c Functional theory of three b Test round burst control INITIAL SETUP Test Equipment General Safety Instructions Tool and Gage Set item 2 app B Live ammunition must not be near the work area References Air Force rifles will be inspected in accordance with TM 9 1005 319 10 AFM 36 2227 Vol 1 3 84 Change 5 ARMY TM 9 1005 319 23 a
238. urned to Its original configuration evacuate the rifle to support maintenance Step 5 Weak or broken action spring 5 RIFLE ONLY free length 11 3 4 inches 29 85 cm minimum to 13 1 2 Inches 34 29 cm maximum CARBINE ONLY 10 1 16 Inches 25 56 cm minimum to 11 1 4 inches 28 58 cm maximum Replace action spring p 2 571 5 FAILURE TO FIRE Step 1 Broken or chipped firing pin 1 Evacuate to support maintenance we 2 24 Change 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step2 Carbon buildup in firing pin recess inside bolt assembly Remove cartridge extractor and clean recess with pipe cleaner Item 11 app D refer to operator s manual Step3 Firing mechanism 2 and or lower receiver assembly 31 improperly assembled or has worn broken or missing parts Evacuate to support maintenance Step 4 Broken defective or missing firing pin retaining pin 4 Replace p 2 35 Step 5 Selector lever 5 frozen on SAFE position Evacuate to support maintenance 2 25 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 9 TROUBLESHOOTING PROCEDURES CONT TROUBLESHOOTING CONT MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 6 FAILURE TO UNLOCK Step 1 Burred locking lugs 1 on bolt assembly Remove burrs Step 2 Burred lugs 2 on barrel extension Remove burrs Step 3 Short recoil Refer to page
239. used at 100F 230C and above However do not use both on the same rifle at the same time LAW is the lubricant to use during cold arctic conditions 100F 12C and below d Any of the lubricants may be used from 10 F to 100F 230C to 12 C e ARMY ONLY Do not mix lubricants on the same rifle The rifle must be thoroughly cleaned during change from one lubricant to another Dry Cleaning Solvent SD Item 16 app D is recommended for cleaning during change from one lubricant to another f Rifle Bore Cleaner RBC item 12 app D may be used to remove carbon buildup In the bore and other portions of the rifle 2 33 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 12 MAJOR COMPONENTS OF M16A2 RIFLE AND CARBINES his task covers disassembl TM 9 1005 319 10 operator s manual Equipment Conditions Rifle and Carbines assembled eneral Safety Instructions Before starting an inspection be sure to clear the weapon Do not keep live ammunition near the work area DISASSEMBLY a Refer to operator s manual To avoid injury to your eyes use care when removing and installing spring loaded parts Below direct support maintenance do not inter change bolt assemblies from one weapon to another Doing so may result in injury to or death of personnel oe T 6 yi 2 b Remove magazine 1 sling 2 bolt carrier assembly 3 charging handle assembly 4 and upper receive
240. wer receiver is not disassembled and the not go plug rom the side of the disassembled and all four holes must be tested enters any hole to first shoulder A the lower receiver must be again 6 Gently insert the not go plug gage and rotate it 180 degrees If the not go plug gage passes through any one of he four pin holes the rifle is unserviceable and will be turned in for replacement The gage must extend through the wall hickness to be unserviceable 7 After completion of gaging operation visually inspect hammer and trigger springs to ensure proper location of spring legs Change 1 3 69 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 3 13 LOWER RECEIVER AND BUTTSTOCK ASSEMBLY CONT e REASSEMBLY 1 Assemble semiautomatic disconnector 1 burst disconnector 2 and trigger assembly 3 Install as a unit in lower receiver 4 using slave pin 5 2 Install trigger pin 6 using drive pin punch Push in until flush Push out slave pin 5 M4A1 ONLY 2 1 Install trigger assembly 6 1 disconnector spring 6 2 and disconnector 6 3 into lower receiver and extension subassembly 6 4 2 2 Install trigger pin 6 5 using drive pin punch Push in until flush 3 70 Change 4 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 EIS UI K PO y jih N fa NOTE Ends of hammer spring are installed to rear of trigger pin 6 resting in the annul
241. wise until it stops range scale should not have moved Elevation knob should be positioned on its last whole click 5 Tighten index screw and remove wrench 6 Check for proper setting ARMY TM 9 1005 319 23 amp P AIR FORCE TO 1 1W3 5 5 42 2 16 UPPER RECEIVER AND BARREL ASSEMBLY RIFLE BARREL ASSEMBLY AND UPPER RECEIVER ASSEMBLY CONT d REPAIR e LUBRICATION 1 Replace all authorized unserviceable parts Lightly lubricate all Items p 2 311 oper ator s manual 2 Evacuate to support maintenance f REASSEMBLY 1 If previously disassembled position election port cover 11 and helical spring 2 on Lip per receiver 3 with short leg of helical spring to the rear on Inside of ejection port cover NOTE Long legs of helical spring must be positioned and pretensioned before the headless grooved pin is installed 2 Hold helical spring 2 short leg In this position and turn long leg one half turn 180 degrees with fingers of right hand 3 Position long leg of helical spring 21 against election port cover 1 Hold helical spring and election port cover in this position and Install headless grooved pin 4 Check for proper spring tension during installation of retaining ring 5 2 52 ARMY TM 9 1005 319 23 amp P AIR FORCE TO 1 1W3 5 5 42 handed operators This will keep the sling out of the way when the carbine i
242. y clean lubricate and assemble If unserviceable replace as necessary Check key and bolt carrier Key and bolt assembly 7 and carrier key carrier assembly 14 for damage and loose or carrier key ness If damaged or loose is damaged or evacuate to support mainte carrier key is nance loose NOTE If carrier key Is dent ed evacuate to sup port maintenance Check firing pin 15 for Firing pin is chips or breaks If damaged damaged evacuate to support mainte nance Pits or wear in area Illustrat ed 16 is permissable 2 13 Change 3 ARMY TM 9 1005 319 23 amp AIR FORCE TO 11W3 5 5 42 2 T PREVENTIVE MAINTENANCE CHECKS AND SERVICES CONT PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR M16A2 RIFLE CONT Item Interval Item to be Not Fully Mission No Checked or Procedure Capable if Serviced 6 Quarterly Lower receiver Remove buffer assembly 1 and and buttstock action spring 2 Check buffer assembly assembly for cracks serviceability SH Buffer assembly is cracked check Check action spring 2 for kinks and free length Free length should be RIFLE 11 3 4 Inches 29 85 cm minimum to 13 1 2 inches 34 29 cm maximum SH If action spring is kinked or does not meet free length require ments CARBINE 10 1 16 inches 25 56 cm minimum to 11 1 4 inches 28 58 cm maximum Do not attempt to adjust spring length SH If action spring is kinked or does not meet free length require me

ARMY TM 9-1005-319-23&P AIR FORCE TO 11 W3

Contents

Download Pdf Manuals

Related Search

Related Contents

ARMY TM 9-1005-319-23&amp;P AIR FORCE TO 11 W3

Contents

Download Pdf Manuals

Related Search

Related Contents

ARMY TM 9-1005-319-23&P AIR FORCE TO 11 W3