TM 10-8400-203-23&P. Manual - part 15

 

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TM 10-8400-203-23&P. Manual - part 15

 

 

  

TM 

10-8400-203-23&P 

0014 

GENERAL REPAIR – CONTINUED  

0014-5 

Binding Tape Repair 
 
Overlap the binding tape using material specified in Section Ill; extending the new tape at least 1/2 inch 
(1.27 cm) beyond the damaged area. Turn the binding edges under 1/2 inch (1.27 cm) and stitch 1/8 inch 
(0.33 cm) in from the edge of the tape. Material lengths and widths for specific applications are listed in 
Table 3. 
 

Table 3. Binding Material Lengths. 

 

ITEM APPLICATION 

WIDTH 

LENGTH 

Vests 

Right and left Panel Seams 

AR 

Vests 

Shoulder Strap Seams 

AR 

Vests Back 

Assembly 

AR 

Vest (TLB) 

Pouches (Magazine and Grenade) 

AR 

Vest (Gr) 

Pouches (Grenade) 

1 ½  

AR 

Vests 

D-Ring Holder 

1 ½  

Patrol Pack 

Pull Tabs 

3/8 

Patrol Pack 

Pocket Flaps 

33 

Field Pack 

Side Pocket (Long) Assembly 

18 

Field Pack 

Side Pocket (Short) Assembly 

11 5/8 

Field Pack 

Spindrift Collar 

14 ¼  

Field Pack 

Basket, Radio Assembly 

22 ½  

Field Pack 

Rt/L Side Pocket Assembly 

Field Pack 

Pocket Flap 

12 ¾  

 
END OF TASK 
 
Hardware Repair 
 
Replace damaged missing, or malfunctioning D-rings, double bar, and quick release fasteners as 
necessary. Remove stitching holding damaged hardware or trim any raveled yarns from torn stitching, Cut 
appropriate webbing specified in Section Ill, to the length indicated. Thread hardware to be replaced 
through webbing. Sew webbing as in original construction and bartack as appropriate. 
 
Replace Staves and Lower Back Pad 
 
These items are removed by sliding the staves out of their tunnel and the webbing slots of the pad. Install 
serviceable items by reinstalling the staves. 
 
END OF TASK 
 

  

TM 

10-8400-203-23&P 

0014 

GENERAL REPAIR – CONTINUED  

0014-6 

Torso Track Channel and Yoke Repair 
 
When the yoke does not move freely along the track channel after the screws have been loosened, or is 
damaged so that it cannot serve its intended function, it must be replaced. To replace the torso track, 
remove stitching along the damaged torso track panel. Trim any raveling yarns from the field pack back 
panel. Stitch the new torso track to the pack back panel using type 301 stitching, size F yarn, and six to 
eight stitches per inch (2.54 cm). To replace the yoke, remove stitching that holds the yoke to the 
shoulder straps. Trim any raveling yarns from the shoulder straps. Stitch the new yoke to the shoulder 
straps using type 301 stitching size F yarn and six to eight stitches per inch (2.54 cm). Slide new yoke 
onto the track from the bottom and secure with friction screws. 
 

END OF TASK 

END OF WORK PACKAGE 

 

 TM 

10-8400-203-23&P 

0015 

 

0015-1 

FIELD MAINTENANCE 

ALL-PURPOSE LIGHTWEIGHT INDIVIDUAL CARRYING EQUIPMENT 

INSPECT, SERVICE, REPAIR 

 

 

INITIAL SETUP: 

 

 

 

Tools Personnel 

Required 

 

 

Knife, Hot Metal (WP 0046, Item 9) 

Non-MOS Specific (1) 

Ruler, Tab, Metal, 16-inch (WP 0046, Item 39) 

 

Sewing Machine, Bar Tack (WP 0046, Item 25) 

References 

Sewing Machine, Medium Duty (WP 0046, Item 
34) 

 
WP 0005 

Tape, Measuring (WP 0046, Item 39) 

WP 0007 

Shears (WP 0046, Item 36

WP 0030 

Stitch Removal Tool (WP 0046, Item 38) 

WP 0046 

Detergents, General Purpose, Type II of MlL-D-
16791 (WP 0047, Item 20) 

WP 0047 

Materials/Parts  

 

 

Cord, Fibrous, Type II (WP 0030, Item 14

 

Washer, Flat, Style A, Size 4096, Black Chemical 
Finish (WP 0030, Item 15) 

 

Eyelet, Metallic, Style A, Size 4094, Black 
Chemical Finish (WP 0030, Item 16) 

 

Fastener, Snap, Style 2, Black Chemical Finish 
(WP 0030, Item 17) 

 

Loop, Strap Fastener, Type IV (WP 0030, Item 
18) 

 

 

 

 
INSPECT 
 
Perform PMCS inspection on all items IAW WP 0005 and determine serviceability IAW WP 0007. 

END OF TASK

 

 

 

 TM 

10-8400-203-23&P 

0015 

 

0015-2 

SERVICE 

Cleaning 

CAUTION 

 

Do not use Chlorine Bleach, yellow soap, cleaning fluids or solvents.  Such products will 
discolor and deteriorate component materials. 

 

Do not launder or dry items in fixed, commercial/home laundry equipment.  Material will be 
degraded. 

 

1.  Scrape dirt or mud from the equipment using a flat stick or a dull instrument which will not cut the 

fabric or webbing. 

2.  Remove loose dirt from soiled surfaces using a cloth or soft brush. 

3.  Clean the exceedingly dirty areas by wetting out the surface and applying a warm solution of Type II 

powdered laundry detergent per gallon (3.79 L) of water.  

4.  Scrub with soft brush, cloth, or sponge. 

5.  Flush the item thoroughly with clean, warm water until all the cleaning solution has been rinsed away. 

6.  Dry the item or equipment away from direct sunlight, direct heat, and open flames. 

END OF TASK 

 

LARGE AND MEDIUM RUCK REPAIR 

Restitching  
 
Use machine stitching for all sewing. Re-sew loose, broken or defective stitches using thread specified in 
Table 1. Maintain proper thread tension to prevent loose stitches, backstitch breaks and ends not less 
than 1 inch (2.54 cm) to prevent raveling. Use the types of stitches, thread size, and stitches per inch for 
sewing as shown in Table 1. 
 

Table 1. Sewing Machine and Thread Chart. 

 

COMPONENT 

RECOMMENDED 

SEWING MACHINE 

(CODE SYMBOL) 

STITCHES 

PER INCH 

TYPE 

THREAD 

SIZE 

Large Ruck 

General 

Medium Duty 

8 to 10 

301 

Reinforcements Bar 

Tack 

28 

301 

Medium Ruck 

General 

Medium Duty 

8 to 10 

301 

Reinforcements Bar 

Tack 

28 

301 

 
Darning
  
 
Darn rips, tears, and holes in areas one inch (2.54 cm) or less in greatest dimension. 
There is no limit to the number of darns which may be applied. 
 
END OF TASK 
 
 

 TM 

10-8400-203-23&P 

0015 

 

0015-3 

LARGE AND MEDIUM RUCK REPAIR – CONTINUED  
 
Patching 
 
Patch rips, tears, and holes exceeding one inch (2.54 cm) with a single patch of nylon cloth using thread 
as specified in Table 1.   
 
1.  Cut the patch of sufficient size to extend at least 1/2 inch (1.27 cm) beyond the hole or area to be 

patched, allowing for a 3/8-inch (0.952 cm) turn under.  

2.  Place the patch on the outside and sew it 1/8-inch (0.318 cm) from the edge of the patch. 

3.  Cut away the damaged area to a square or rectangular shape, depending upon the shape of the hole.  

4.  Turn the raw edges under 3/8-inch (0.952 cm). 

5.  Using a medium duty sewing machine, size F thread, 8 to 10 stitches per inch, sew 1/8-inch (0.318 

cm) from the edge. 

END OF TASK 

Binding Tape Repair  
 
Overlap the binding tape using nylon tape. 
 
1.  Place marks at least ½ inch (1.27 cm) from both edges of the damaged area.  

2.  Measure between the marks. 

3.  Cut a new piece of 1-inch wide nylon tape the length of the measurement in step 2.  

4.  Sear the cut ends of the tape. 

5.  Place the new tape between the marks made in step 1.  

6.  Turn the binding- edges under 1/2-inch (1.27 cm). 

7.  Using a medium duty sewing machine, size E thread, 8 to 10 stitches per inch, sew 1/8-inch (0.318 

cm) in from edge of tape, with a ½-inch overstitch. 

END OF TASK 

Securing Strap Buckle Repair 
 
1.  Carefully cut and remove stitching for a distance of two inches (5.08 cm) from the buckle end. 

2.  Cut the single bottom layer of the strap webbing and discard buckle. 

3.  Sear cut ends of webbing. 

4.  Replace with new buckle. 

5.  Secure webbing by stitching with 1 1/2 inch (3.81 cm) three point ww stitch pattern 1/2 inch (1.27 cm) 

from folded webbing edge. 

END OF TASK 

Radio Pocket Strap Repair 
 
1.  Cut stitching which secures the strap to the pack. 

2.  Cut a 12-inch (30.5 cm) length of new webbing, with one end diagonally cut and sear ends. 

3.  Place the buckle strap in the original location and secure the webbing by stitching with one row of 

stitching. 

END OF TASK 

 

 

 TM 

10-8400-203-23&P 

0015 

 

0015-4 

LARGE AND MEDIUM RUCK REPAIR – CONTINUED 
 
Frame Buckle Chape Repair 
 
1.  Cut stitch pattern which secures the chape to the pack and discard. 

2.  Cut a 4-inch (10.2 cm) length of new webbing using item 27, Figure 14-7, and sear ends. If buckle is 

damaged discard and use item 29, Figure 14-7. 

3.  Fold webbing ½ and 2 ½ inches (1.27 and 6.35 cm) from one end. 

4.  Place the buckle chape in the original location and secure the webbing with a 1 ½ inch (3.81 cm) 

three point WW stitch pattern. 

END OF TASK 

 
Strap Pocket Repair 
 
1.  Replace by cutting webbing and remove from buckle and discard. 

2.  Cut a 14 ½-inch (36.8 cm) length of webbing.  

3.  Sear both ends. 

4.  Fold webbing 3 ¼ inches (8.26 cm) and stitch with one row 1/8 inch (0.318 cm) from edge around 

folded strap. 

5.  Install a new snap fastener (with proper sized dies) according to the original construction and 

locations, 

6.  Thread webbing through buckle as other pocket straps, double fold free end of webbing ½-inch (1.27 

cm) length, and stitch with one ¾-inch (1.91 cm) bar tack or three rows of stitching in the center of the 
fold. 

END OF TASK 

 
Loop Chape Repair 
 
1.  Cut the webbing as close to the 1 inch (2.54 cm) reinforcement webbing as possible. 

2.  Cut a 5 inch (12.7 cm) length of new webbing.  

3.  Sear ends or replace loop. 

4.  Fold webbing ½ and 2 ½ inches (1.27 and 6.35 cm) from one end. 

5.  Place the loop chape on top of the original and secure the webbing with a 1 ½-inch (3.81 cm) three 

point ww stitch pattern. 

6.  Stitch with one 1-inch (2.54 cm) bar tack or three rows of stitching 1/8 inch (0.318 cm) from edge of 1-

inch (2.54 cm) reinforcement webbing (stitching should be sewn through reinforcement webbing). 

END OF TASK 

 
Frame Tie-down Strap 
 
1.  Replace strap by carefully cutting off the webbing as close to the bar tack as possible. 

2.  Cut a 14 ½-inch (36.8 cm) length of new webbing with one end at an angle. 

3.  Fold end ½ inch (1.27 cm) and stitch with a 1 1/2 inch (3.81 cm) three-point ww stitch positioned on 

top of the cut original tie down strap. 

END OF TASK 

 
 

 TM 

10-8400-203-23&P 

0015 

 

0015-5 

LARGE AND MEDIUM RUCK REPAIR – CONTINUED  
 
D-Ring Chape Repair (Medium Ruck Only) 
 
1.  Replace by carefully cutting off the webbing as close to the bar tack as possible. 

2.  Cut a 3 inch (7.62 cm) length of webbing, and sear ends or replace D ring. 

3.  Fold webbing in half with D ring in center, place the chape on top of the original location of D ring and 

secure the webbing with two, 1-inch (2.54 cm) bar tacks located close to the D ring and 3/16 inch 
(0.476 cm) from the seared edges. 

END OF TASK 

 
Lower Equipment Hanger Repair (Medium Ruck Only) 
 
1.  Carefully cut webbing 5/8-inch (1.59 cm) from the pocket, side seam and cut stitching which secures 

the hanger to the pack. 

2.  Cut a 6 ½ inch (16.5 cm) length of webbing. 

3.  Sear both ends. 

4.  Make a mark 3 ¼ inches (8.26 cm) for the center line location. From the center line make a mark 1 ¼ 

inches (3.18 cm) from each side ½-inch (1.27 cm) from webbing edge. Install a new eyelet and 
washer (with proper sized dies). 

5.  Fold webbing ½ inch (1.27 cm) each end and position as in original location and stitch with a ½-inch 

(1.27 cm) wide box stitch on the folded ends and center of the hanger. 

END OF TASK 

 
Keeper Repair 
 
1.  Carefully cut stitching which secures the keeper to the side or bottom of the pack. 

2.  Cut a 2 3/8-inch (6.03 cm) length of webbing. 

3.  Sear both ends. 

4.  Fold webbing ½ inch (1.27 cm) each end and position as in original location and stitch with two, 1-

inch (2.54 cm) bar tacks or three rows of stitching. 

END OF TASK 

 
Upper Equipment Hanger Repair (Medium Ruck Only) 
 
1.  Cut a length of webbing of sufficient length to overlap the stitch patterns ½ inch (1.27 cm). 

2.  Sear both ends. 

3.  Fold webbing ½ inch (1.27 cm) each end and position over damaged section and stitch with a ½- inch 

(1.27 cm) wide box stitch 1/8 inch (0.318 cm) from the folded ends. 

END OF TASK 

 

 

 TM 

10-8400-203-23&P 

0015 

 

0015-6 

LARGE AND MEDIUM RUCK REPAIR – CONTINUED 
 
Drawstring Repair 
 
1.  Remove cord from grommets and plastic clamp cord. 

2.  Cut a 55-inch (140 cm) (large ruck), or a 72-inch (183 cm) (medium ruck) length of cord. 

3.  Thread cord through the back panel center two grommets and tie with a square knot on the outside. 

4.  Thread each cord end through the six grommets. 

5.  Thread each end of cord through plastic clamp cord, tie with overhand knot and sear ends. 

END OF TASK 

 
Upper and Lower Equipment Hanger Repair (Large Ruck Only) 
 
1.  Carefully cut stitching which secures the hanger to the pack. 

2.  Cut a 6-inch (15.2 cm) length of webbing.  

3.  Sear both ends. 

4.  Make a mark 3 inches (7.62 cm) for the center line location. From the centerline make a mark 1 ¼ 

inches (3.18 cm) from each side 1/2-inch (1.27 cm) from webbing edge. 

5.  Install a new eyelet and washer (with proper sized dies). 

6.  Fold webbing 1/2 inch (1.27 cm) each end and position as in original location and stitch with two 1-

inch (2.54 cm) bar tacks or three rows stitching on the folded ends and center of the hanger. 

END OF TASK 

 

FIELD PACK COVER REPAIR 

Elastic Cord Repair 
 
1.  Carefully cut stitching on hem for a distance of approximately three inches (7.62 cm) and cut cord. 

2.  Cut a 40 inch (102 cm) length of elastic cord.  

3.  Dip cut ends of cord in adhesive by at least ½ inch (1.27 cm). 

4.  Attach heavy string to existing cord in channel and new cord with a square knot.  

5.  Pull existing cord and string until new cord ends are at hem opening. 

6.  Remove string and overlap cord ends 1 ½ inches (3.81 cm) and clamp (with proper sized dies). 

7.  Restitch hem as in original, overlapping stitching a minimum of 1 inch (2.54 cm). 

END OF TASK 

 

WATER CANTEEN COVER REPAIR 

Repair of the water canteen cover is limited to replacement of the canteen cap, canteen cap strap, and 
canteen cup. 

END OF TASK 

 

END OF WORK PACKAGE 

 

 

 

 

 

 

 

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