TECHNICAL MANUAL

UNIT AND DIRECT MAINTENANCE MANUAL

INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST

M60D, 7.62 MM, MACHINE GUN

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 U.S. ORDNANCE

M60D
PROVEN UNDER FIRE

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 U.S. Ordnance | M60D 7.62MM Machine Gun | Technical Manual

WARNING

The M60D Series Machine Guns should be inspected and gauged at least once annually for safety and
serviceability. Initial gauging is required one year from receipt of the weapons.

A two year interval may be maintained by some units unless preventive maintenance checks and services
(PMCS) or other physical evidence indicates that an individual unit’s M60D Machine Guns require
inspection/gauging 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. That will not affect other units in regard to the
interval of inspection.

Dry cleaning solvent (SD) is flammable.

Do not clean parts near an open flame or in a smoking area. Dry cleaning solvent evaporates quickly and
has a drying effect on the skin. When used without protective gloves, solvent may cause irritation to or
cracking of the skin.

Personnel operating vapor degreaser are warned not to breathe the vapor fumes.

Before starting an inspection, be sure to clear the weapon. Do not actuate the trigger before clearing the
weapon. 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.

Using paint thinners, gasoline, kerosene, benzene (benzol), water, steam, or air for cleaning the weapon
is prohibited. Use only authorized cleaning materials.

Be careful when removing and installing spring-loaded components. Carelessness could cause injury.

To prevent possible body injuries and aircraft damage, personnel should not stand the weapon on its
barrel assembly when disassembling or assembling the weapon.

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INDEX

WARNING PAGE
CHAPTER 1 INTRODUCTION
General Information 01 pg. 2
Equipment Description and Data 02 pg. 3

CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS

Repair Parts, Special Tools, and Support Equipment 03 pg. 7
Service Upon Receipt 04 pg. 8
Preventive Maintenance Checks and Services (PMCS) 05 pg. 10
Troubleshooting 06 pg. 27
Maintenance Procedures 07 pg. 42
Maintenance: Grip and Trigger Assembly 08 pg. 52
Maintenance: Breech Bolt Assembly 09 pg. 56
Maintenance: Operating Rod Assembly 10 pg. 63
Maintenance: Sear and Safety Housing Assembly 11 pg. 64
Maintenance: Barrel and Carry Handle Assembly 12 pg. 68
Maintenance: Cover Assembly 13 pg. 74
Maintenance: Cartridge Feed Tray Assembly 14 pg. 82
Lubrication Instructions 15 pg. 80
Preparation for Storage or Shipment 16 pg. 87

CHAPTER 3 DIRECT MAINTENANCE INSTRUCTIONS

Repair Parts, Special tools and Support Equipment 17 pg. 89
Troubleshooting 18 pg. 90
Maintenance Procedures 19 pg. 91
Maintenance: M60D Machine Gun (Section 1 of 2) 20 pg. 92
Maintenance: M60D Machine Gun (Section 2 of 2) 21 pg. 102
Maintenance: Breech Bolt Assembly 22 pg. 110
Maintenance: Breech Bolt Assembly 23 pg. 112
Maintenance: Barrel 24 pg. 114
Maintenance: Bipod 25 pg. 120
Maintenance: Bipod Legs 26 pg. 124
Maintenance: Cover Assembly 27 pg. 125
Maintenance: Feed Cam Assembly 28 pg. 126
Maintenance: Feed Lever Assembly 29 pg. 128
Maintenance: Feed Pawl Assembly 30 pg. 130
Maintenance: Cover Housing Assembly 31 pg. 132
Maintenance: Rear Sight 32 pg. 137
Maintenance: Cocking Handle Assembly 33 pg. 139
Maintenance: Gun Receiver Assembly 34 pg. 140
Preembarking Inspection of Material Units 35 pg. 144
Alerted for Overseas Movement
Preparation for Storage or Shipment 36 pg. 145

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INDEX

APPENDIX A MAINTENANCE ALLOCATION CHART

Maintenance Allocation Chart 37 pg. 147

APPENDIX B REPAIR PARTS AND SPECIAL TOOLS LIST

Group 00 Machine Gun, 7.62-mm M60D Repair Parts List 38 pg. 158
Group 00 Machine Gun, 7.62-mm M60D Repair Parts List (cont) 39 pg. 160
Group 01 Grip and Trigger Assembly Repair List 40 pg. 162
Group 02 Breech Bolt Assembly, Repair Parts List 41 pg. 164
Group 03 Operating Rod Assembly Repair Parts List 42 pg. 166
Group 04 Sear and Safety Housing Assembly Repair Parts List 43 pg. 168
Group 05 Barrel Assembly Repair Parts List 44 pg. 170
Group 0701 Machine Gun Bipod Repair Parts List 45 pg. 172
Group 07 Cover and Feed Tray Assembly Repair Parts List 46 pg. 174
Group 0801 Feed Cam Assembly Repair Parts List 47 pg. 176
Group 0801 Feed Lever Repair Parts List
Group 0803 Feed Pawl Assembly Repair Parts List 48 pg. 177
Group 0804 Cover Housing Assembly Repair Parts List 49 pg. 178
Group 9 Cartridge Feed Tray Assembly Repair Parts List 50 pg. 180
Group 10 Rear Sight Repair Parts List 51 pg. 181
Group 11 Cocking Handle Assembly Repair Parts List 52 pg. 182
Group 12 Gun Receiver Assembly Repair Parts List 53 pg. 183

ECHELON TOO KIT

Group 9500 54 pg. 184

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 M60D 7.62-MM MACHINE GUN
Full External View

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CHAPTER 1 | INTRODUCTION

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 U.S. Ordnance | M60D 7.62MM Machine Gun | Technical Manual

GENERAL INFORMATION 01

SCOPE
Type of Manual:
Unit, Direct Support, Maintenance.

Model Number and Equipment Names:

M60D 7.62-mm machine gun.

Purpose:
The M60D 7.62-mm machine gun is a general purpose weapon capable of being fired from
several mounts. The weapon is mainly used for support of ground operations. The M60D is
an aircraft door-mounted, or vehicle mounted machine gun.

OFFICIAL NOMENCLATURE, NAMES AND DESIGNATIONS

This listing includes nomenclature cross-references used in this manual:

Common Name Official Nomenclature

Bipod Legs Leg, Machine Gun, RH
Leg, Machine Gun, LH

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 U.S. Ordnance | M60D 7.62MM Machine Gun | Technical Manual

EQUIPMENT DESCRIPTION AND DATA 02

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

M60D Machine Gun. The M60D machine gun is an air-cooled, disintegrating link, belt fed, gas operated weapon.
The operating cycle begins from an open bolt position. The weapon features fixed head space, which permits rapid
changing of barrels.

M60D 7.62-MM MACHINE GUN

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EQUIPMENT DESCRIPTION AND DATA 02

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

The M60D machine gun consists of the following major external components:

A GRIP AND TRIGGER ASSEMBLY. Provides handles to move machine gun toward the target and houses
the machine gun trigger.

B COVER ASSEMBLY. Positions and holds cartridges in place for stripping, feeding link belt, and
chambering rounds.

C CARTRIDGE FEED TRAY ASSEMBLY. Guides cartridges for positioning and feeding.

D REAR SIGHT. Provides a means to aim the machine gun in the general area of the target. The rear sight
is non-adjustable.

E BARREL AND CARRYING HANDLE ASSEMBLY. The barrel assembly houses cartridges for firing and directing
projectiles. The Carrying Handle Assembly provides a means to carry the machine gun with one hand.
The carrying handle assembly folds down when the rear sight is used and the machine gun is fired.

F RECEIVER AND BIPOD ASSEMBLY. The receiver supports all major components. Major components houses
internal parts and, through a series of cam ways, controls operation of weapon. The bipod assembly
provides a semistable platform when the machine gun is fired from other than the designated mount.

G COCKING HANDLE ASSEMBLY. Provides a means to manually move the bolt assembly Ato the rear.

H SEAR AND SAFETY HOUSING. Provides controls for firing the machine gun.

D
E
F
C

B
A

H G

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EQUIPMENT DESCRIPTION AND DATA 02

M60D EQUIPMENT DATA

Weight 25 Ibs (10.42 kg)
Length 43.5 in. overall (1.1 m overall)
Rate of fire (cyclic) 550 rd per min (approx)
Muzzle velocity 2800 FPS

Rifling:
Number of lands 4
Right hand twist One turn in 12 in. (30.54 Cm).

Trigger pull at sear activator:

Maximum 20 lb (9.06 kg)
Minimum 10.5 lb (4.75 kg)

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 UNIT MAINTENANCE
CHAPTER 2 | INSTRUCTIONS

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 U.S. Ordnance | M60D 7.62MM Machine Gun | Technical Manual

REPAIR PARTS, SPECIAL TOOLS, 03

AND SUPPORT EQUIPMENT

COMMON TOOLS AND EQUIPMENT

For authorized common tools and equipment, refer to Modified Table of Organization and Equipment
(MTOE) applicable to your unit.

SPECIAL TOOLS AND SUPPORT EQUIPMENT

Tools and test equipment are listed in work package 54, pg. 184. Special tools and support equipment
are listed and illustrated in work package 54, pg. 184.

REPAIR PARTS
Repair parts are listed and illustrated in work packages 38, pg. 158 through 53, pg. 183 of this manual.

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SERVICE UPON RECEIPT 04

GENERAL
a. Inspect the machine gun for damage incurred during shipment.

b. Check the machine gun against the packing slip to see if shipment is complete.

c. Check to see whether the equipment has been modified.

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SERVICE UPON RECEIPT 04

SERVICE UPON RECEIPT OF MATERIALS

WARNING
Before starting an inspection, be sure to clear the weapon. Do not
actuate the trigger before clearing the weapon. Inspect the chamber to
make sure it is empty and free of obstructions. Check to see there
are obstructions in the barrel and no ammunition is in position to
be chambered.

Table 1. Service Upon Receipt (cont)

LOCATION ITEM ACTION

1. Container a. Machine gun a. Remove machine gun from container.

b. Inspect the equipment for damage

incurred during shipment.

b. Basic issue c. Check the equipment against the

items packing list to see if the shipment is
complete.

2. Machine Gun a. Barrel Remove volatile corrosion inhibitor (VCI)

assembly bore tube from barrel and discard.

b. All parts a. Field-strip machine gun and inspect

for missing, damaged, and rusted or
corroded parts.

b. Clean and lubricate.

c. Reassemble.

d. Operate by hand using

belted dummy cartridges.

e. Check to see whether the

equipment has been modified.

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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)

General
This work package contains the procedures and instructions necessary to perform preventive
maintenance checks and services. These services are to be performed by unit maintenance
personnel with the assistance, where practical, of the operator/crew who will clean and lubricate.

NOTE
Maintenance of some assemblies are not authorized by the maintenance
allocation chart Appendix A (37, pg. 146) to unit maintenance. Ensure
that no work is being accomplished beyond the scope authorized to unit
maintenance. Evacuate to direct support maintenance for repairs when
necessary.

The PMCS procedures are contained in the table following. 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.

Item No. Column. Checks and services are numbered in disassembly sequence.

Interval Column. This column gives the designated interval when each check is to be performed.

Item To Be Checked Or Serviced Column. This column lists the items to be checked or serviced.

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.

“Not Fully Mission Capable If:” Column. This column contains a brief statement of the condition
(e.g., malfunction, shortage) that would cause the covered equipment to be less than fully ready
to perform its assigned mission.

WARNING
Before starting an inspection, be sure to clear the weapon. Do not
actuate the trigger before clearing the weapon. Inspect the chamber to
make sure it is empty and free of obstructions. Check to see there are
no obstructions in barrel and no ammunition is in position to be
chambered.

NOTE
When weapon has not been used, perform preventive maintenance
every 90 days unless inspection reveals more frequent servicing is
necessary.

If the M60D machine gun has to go to direct support maintenance for any
repair, both barrel assemblies must be turned in with the weapon.

Coordinate cleaning and lubrication with crew/operator as part of

quarterly service.

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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)
WARNING
INTERVAL: It is recommended that PMCS is performed at a quarterly
interval by qualified personnel certified by the manufacturer. PMCS
intervals may be adjusted if quarterly maintenance or other physical
evidence indicate an individual unit’s M60 D machine guns require
PMCS at a more frequent/less frequent interval. If it is determined that a
biannual PMCS interval is necessary for an individual unit, only that unit
will be affected. That will not affect other units in regard to the interval
of PMCS.

Manufacturer recommends that machine gun part replacements are made

only after following PMCS procedures done by qualified personnel.

PMCS must be completed by a direct unit support level by qualified

personnel prior to issuance to firing units.

At a minimum, gauging must be conducted annually at the direct unit

support level by qualified personnel.
NOTE
For machine guns loaded on aircraft in ready condition, manufacturer
recommends the operator clean, dry, inspect, and lightly lubricate
immediately following flight status.

Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

ITEM MAN- ITEM CHECK NOT FULLY MISSION

NO. INTERVAL HOUR OR SERVICE PROCEDURE CAPABLE IF:

1 M60D Machine Gun a. Visually inspect machine gun for

general appearance, condition, and
operation. Operate the weapon by
hand using dummy rounds/cartridges.

b. Make sure all serial numbers and

identification numbers are legible.

c. Inspect for burrs or damage on exterior

of weapon.

d. Check to make sure weapon is properly

assembled.

e. Field-strip the weapon, as necessary, to

perform detail inspection.

f. Repair or replace all authorized

components (07, pg. 42). If additional
repair is needed, notify direct
support maintenance.

g. Unit maintenance personnel should Barrel and spare barrel

confirm assigned barrel and spare not properly headspaced/
barrel are headspaced and tagged to tagged to weapon.
the receiver.
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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)
Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)

ITEM MAN- ITEM CHECK NOT FULLY MISSION

NO. INTERVAL HOUR OR SERVICE PROCEDURE CAPABLE IF:

1 h. Check that flat leaf spring is the proper Leaf spring is incorrect
(cont) type for weapon and is installed type or improperly
correctly. installed.

i. Assemble the weapon Make sure all

components are lubricated and installed
correctly.

j. Visually inspect all external aluminum Annual gauging has not

parts for a dull black finish. been performed.

k. Check to ensure annual direct support

maintenance safety and serviceability
inspection and gauging has been done
and that the next gauging and inspection
is scheduled. If annual gauging has not
been performed within the last year,
notify direct support maintenance.

2 Grip and Trigger a. Check for burred, bent, and damaged Damaged so as to
Assembly components. prevent proper operation
of trigger assembly or
cannot be retained on
receiver.

b. Check trigger (1) for free movement. Trigger is not free.

c. Check sear assembly link and spring (2) Sear assembly link and
for proper adjustments. (Refer to spring are out of
07 for adjustments.) adjustment.

d. Check that grip and trigger assembly (3) Grip and trigger
is securely fastened to the receiver assembly are
assembly. not secure.

e. Repair or replace (08, pg. 52).

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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)
Table 2. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

ITEM MAN- ITEM CHECK NOT FULLY MISSION

NO. INTERVAL HOUR OR SERVICE PROCEDURE CAPABLE IF:

CAUTION
Do not allow breech bolt to slam closed when the weapon is empty, as
this will cause damage to locking surfaces on the breech bolt or barrel
socket.
NOTE
Burrs or raised surfaces may be removed or smoothed using a fine grit
sharpening stone. DO NOT change the dimensions of any component
by stoning. Cracks, chips, dents, or gouges on components shall be
reported to direct support maintenance for repair or replacement.

Cracks, chips, dents, or gouges on breech bolt locking surfaces can

damage the barrel socket. Damage to barrel socket locking surfaces
can damage the breech bolt. If either condition exists, notify direct
support maintenance for replacement or repair.

3 Breech Bolt a. Inspect firing pin helical compression

Assembly spring for tension.

NOTE
Check spring tension. Remove the bolt from operating rod, turn bolt so
you can see spring guide and firing pin, shake bolt moderately, if firing
pin moves; replace firing pin spring.

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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)

Table 2. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)

ITEM MAN- ITEM CHECK NOT FULLY MISSION

NO. INTERVAL HOUR OR SERVICE PROCEDURE CAPABLE IF:

3 b. Inspect bolt body for burrs or damage Damaged beyond repair

(cont) in the areas indented. by stoning.

c. Make sure breech bolt operates Roller and cam actuator

correctly. Roller (1) on cam actuator assembly do not rotate
assembly (2) should rotate freely, and freely. Parts missing or
cam actuator assembly should rotate broken.
freely on breech bolt (3). Inspect bolt
assembly for missing headless straight
pin (4) securing plug assembly (5).

5
14 4
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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)

Table 2. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)

ITEM MAN- ITEM CHECK NOT FULLY MISSION

NO. INTERVAL HOUR OR SERVICE PROCEDURE CAPABLE IF:

3 d. Inspect firing pin (6) in breech bolt. Firing pin

(cont) Firing pin (6) must not be cracked or broken/cracked.
bent and must have a well-rounded Point flattened.
point.

e. Inspect cartridge ejector (7) for freedom Parts damaged

of movement. When cartridge ejector or missing.
is depressed/released, helical
compression spring must return
cartridge ejector to normal position.

f. Inspect cartridge extractor (8) for Parts damaged

chipped or damaged hook portion or missing.
and for freedom of movement. When
cartridge extractor is depressed/
released, helical compression spring
must return cartridge extractor to
normal position.

g. Inspect for pits on breech bolt face. Major pits on bolt face.
Make sure that firing pin hole is round Elongated/out-of-round
and not elongated. firing pin hole.

h. Repair or replace all authorized

components (09, pg. 56). If addition
repair is needed, notify direct support
maintenance.

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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)

Table 2. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)

ITEM MAN- ITEM CHECK NOT FULLY MISSION

NO. INTERVAL HOUR OR SERVICE PROCEDURE CAPABLE IF:

4 Operating Rod a. Inspect buffer assembly (1) for damage, Buffer assembly
Assembly and rust, and burrs. Depress plunger to is faulty.
Hydraulic Buffer check its movement. If buffer
Assembly assembly is faulty, replace buffer
assembly.

b. Inspect helical compression spring (2) Spring is damaged/broken

for damage and for signs of weakness, or less than 23-1/4 in
burrs, or sharp edges. The minimum length.
length of the drive spring will be 23-1/4
inches long with no maximum length.

c. Inspect operating rod assembly (3) for Parts are missing/

damage or obstructions in the helical damaged. Roller does not
compression spring hole. Linear-rotary rotate freely. Pin is loose.
roller (4) must be free of cracks and
rotate freely. Inspect both sear notches.

d. If pin is loose or missing, notify direct Any part other

support maintenance. Make sure that than the roller is
yoke and tube assembly (5) is tight on loose. Retaining
operating rod assembly and that spring pin protrudes.
pin (6) does not protrude on either side.
Check yoke and tube assembly for
damage.

e. Notify direct support maintenance for Guide is broken or bent

replacement or repair of operating rod beyound standards.
beyond assembly.

f. Inspect guide assembly (7) for Rod is distorted

straightness; the drive spring guide so as to cause
will only be considered unserviceable binding.
when the rod becomes so distorted as
to cause binding of the spring or when
the rod with the spring installed cannot
be inserted in the operating rod well.

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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)

NOTE
Primary (P) notch is normal sear notch. Secondary (S) notch is short
recoil sear notch.

1 7

5 3
4

(S) (P)
6
SEAR NOTCH

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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)

Table 2. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)

ITEM MAN- ITEM CHECK NOT FULLY MISSION

NO. INTERVAL HOUR OR SERVICE PROCEDURE CAPABLE IF:

5 Sear and Safety a. Check components for freedom of

Housing Assembly movement.

b. Check for broken or missing parts, and Parts are missing/

deformed or weak springs. broken. Springs are
deformed/weak
and prevent proper
functioning.

c. When safety is in safe position, make Safety does not

sure small arms safety (1) prevents function properly or
sear (2) from being activated. Make sear assembly activator
sure sear (2) can be actuated when does not move.
small arms safety (1) is in fire position
and sear assembly activator (3) is
moved.

d. Repair or replace sear and safety

housing assembly (11).

2
1

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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)

Table 2. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)

ITEM MAN- ITEM CHECK NOT FULLY MISSION

NO. INTERVAL HOUR OR SERVICE PROCEDURE CAPABLE IF:

NOTE
Check both barrel assemblies when performing PMCS.

Burrs or raised surfaces may be removed or smoothed using a fine grit

sharpening stone. DO NOT change the dimensions of any components
by stoning. Components with cracks, chips, dents, or gouges shall be
reported to direct support maintenance for repair or replacement.

Cracks, chips, dents, or gouges on breech bolt locking surfaces can

damage the barrel socket. Damage to barrel socket locking surfaces
can damage the breech bolt. Notify direct support maintenance for
replacement or repair if either condition exists.

6 Barrel and Carry a. Inspect barrel assembly and carry handle Barrel assembly
Handle Assemblies assembly for damage. Headless straight damaged. Suppressor
pin (1) must be tight and staked at straight pin missing.
both ends to hold flash suppressor (2). Suppressor loose.
Check suppressor for looseness, if
loose notify direct support maintenance.

b. Tilt barrel (3) to make sure gas piston Gas piston does
moves freely, make sure bleeder hole not move.
is open.

NOTE
Check for broken or cracked gas piston when it is removed for cleaning.

c. Inspect carrying handle assembly (6).

Check gas cylinder vent plug for wiring.
Replace if missing. See (12, pg. 68) for
instructions.

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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)

Table 2. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)

ITEM MAN- ITEM CHECK NOT FULLY MISSION

NO. INTERVAL HOUR OR SERVICE PROCEDURE CAPABLE IF:

6 Barrel and Carrying d. Inspect front sight (11) for looseness or Front sight is
(cont) Handle Assembly any damage (bent). loose.
(cont)
e. Inspect key washers (12) for broken
tabs. If broken, replace, and notify
direct support for additional repair if
necessary.

Inspect gas cylinder (14) for Gas cylinder

looseness. If loose notify direct support loose.
maintenance.

f. Inspect for loose or cracked barrel Socket loose or cracked.

socket (15).

g. Repair (see 12, pg. 68). If additional

repair is necessary, notify direct
support maintenance.

h. Inspect carrying handle assembly (6) for

cracks. It must be held securely by
spring tension. Rubber coating must not
be gummy or retain finger impressions.
Abrasions, cuts, gouges, or holes in the
rubber are acceptable. Loose bonding of
rubber near cuts, etc., is acceptable
provided cuts do not interfere with the
operator’s grip on the weapon.

11
6

2
1

15 12 14 12

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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)

Table 2. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)

ITEM MAN- ITEM CHECK NOT FULLY MISSION

NO. INTERVAL HOUR OR SERVICE PROCEDURE CAPABLE IF:

7 Bipod Assembly a. Check bipod legs for ease of extension Bipod legs come fully off.
and retraction by:

1. Check bipod legs do not come off.

Grasp each leg and pull sharply
down to ensure they fully extend but
do not come off the bipod assembly.

2. Press leg locks and ensure legs fully

retract.

3. Check leg locks (7) for retention at

each detent (9) by pushing on leg
bottom (11) at each detent (9)
position.

4. Press leg locks and pull sharply

downward. Bipod legs should
not come off.

5. Check bipod shoulder screws (13)

for tightness and staking.

13

7 7

3 9
11

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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)

Table 2. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)

ITEM MAN- ITEM CHECK NOT FULLY MISSION

NO. INTERVAL HOUR OR SERVICE PROCEDURE CAPABLE IF:

8 Cover Assembly a. Inspect for proper operation. Cover Cover latch does not hold
assembly (1) must be held open by cover closed.
spring (2) tension, and held closed by
cover latch (3).

b. Make sure cover assembly opens and Parts missing,

closes freely. loose or damaged

c. Inspect for damaged or missing

components.

d. Check that front and rear cartridge Cover components do not

guides (4) operate smoothly. Ensure operate smoothly.
that flat washers are not damaged and
that shouldered pins are not loose
(no movement).

e. Make sure springs allow feed lever

assembly (5) feed cam assembly (6),
and feed pawl assembly (7) to operate
freely. Check that latch lever assembly
8 shaft (8) operates freely.
3
f. Repair or replace all authorized
components (13, pg.74). If additional
repair is necessary, notify direct
support maintenance.

g. Visually inspect that all external Missing finish allows light

1 aluminum parts have a dull black finish. reflection.

5
4
2

22 6 7
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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)

Table 2. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)

ITEM MAN- ITEM CHECK NOT FULLY MISSION

NO. INTERVAL HOUR OR SERVICE PROCEDURE CAPABLE IF:

9 Cartridge Feed a. Inspect feed tray assembly for cracks Tray cracked or
Tray Assembly or distortion. Inspect belt holding distorted.
cartridge retainer pawl (1) and helical
torsion spring for weakness or damage.

b. Inspect linear rotary rollers (2) for

freedom of movement.

c. Inspect spot welds for evidence of Welds cracked

separation or failure. or separated.

d. Repair (14, pg. 82).

10 Rear Sight a. Check for burred, bent, or damaged Parts bent or

components. damaged.

b. Make sure rear sight assembly is Sight loose on

secured to receiver assembly. receiver.

1 c. Make sure sight ring (1) and rear sight Rear sight does
retainer (2) are secured to rear sight not stay in
base (3). vertical position.

d. Make sure sight ring rotates smoothly Sight ring does

from horizontal to vertical position. not rotate
smoothly.
e. Make sure sight ring is retained when
placed in vertical position by spring
tension.
2 3
f. Notify direct support maintenance if
repair is necessary.

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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)

Table 2. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)

ITEM MAN- ITEM CHECK NOT FULLY MISSION

NO. INTERVAL HOUR OR SERVICE PROCEDURE CAPABLE IF:

11 Gun Receiver a. Inspect barrel lock (1) and barrel lock Barrel does not lock
Assembly ring (2). Make sure barrel assembly is onto receiver.
secured to receiver assembly.

b. Inspect magazine bracket assembly (3) Magazine bracket

for damage and positive spring tension assembly damaged
of latches (4). or loose.

c. Make sure cocking handle assembly (6) Cocking handle binds.

works without binding. Reassemble
weapon and perform operation check.

d. Make sure forward rail is secure and held Spring pin is missing.
in place by spring pin.

e. Inspect quick release pin (8) to make Ball bearing is missing or

sure that bearing ball works properly, not working properly.
and that wire rope assembly secures
quick release pin (8) to rear sight.

f. Repair or replace authorized

components (07, pg. 42). If additional
repair is necessary, notify direct
support maintenance.

g. Check for loose receiver bridge and/or Rivets loose or missing.

rivets. If loose return to depot level
maintenance.

h. Inspect for missing finish. Apply solid Finish is missing from

film lubricant on shiny surfaces. one third or more of the
receiver.

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PREVENTIVE MAINTENANCE CHECKS 05

AND SERVICES (PMCS)

NOTE
Coordinate cleaning and lubrication with crew/operator as part of
quarterly services.

The breakthrough of the wall in the forearm spring catch notch of the
receiver extension (tube) is not cause for rejection.

1
6

25
 U.S. ORDNANCE

M60D
PROVEN UNDER FIRE

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TROUBLE SHOOTING PROCEDURES 06

INITIAL SETUP
MAINTENANCE LEVEL: Unit and Direct Support

GENERAL
This section contains troubleshooting information for locating and correcting most of the operating
troubles which may develop in your machine gun. Each malfunction for an individual component, unit,
or system is followed by a list of tests or inspections which will help you to determine corrective actions
to take. You should perform the tests/inspections and corrective actions in the order listed.

This manual cannot list all possible malfunctions that may occur, nor all tests or inspections and corrective
actions. If a malfunction is not listed (except when malfunction and cause are obvious) or is not corrected
by listed corrective actions, notify your supervisor.

TROUBLE SHOOTING PROCEDURES

SYMPTOM INDEX
SYMPTOM
PAGE
Failure to feed 28 - 30
Failure to chamber 30 - 31
Failure to lock 32
Failure to fire 33 - 34
Failure to unlock 34
Failure to extract 35 - 36
Failure to eject 36 - 37
Failure to cock 37 - 38
Sluggish operation 39
Uncontrolled fire (runaway gun) 40 - 41

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TROUBLE SHOOTING PROCEDURES 06

Table 1. TROUBLE SHOOTING PROCEDURES

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

1. Failure To Feed 1. Check cover assembly for weak feed pawl Notify direct support maintenance.
assembly and helical torsion spring. Inspect
feed lever assembly for damage.

2. Check cartridge guides and helical compression Notify direct support maintenance.
springs for defects. Ensure that flat washers are
not damaged and that shouldered pins are not
loose (no movement).

3. Check cover assembly for defective cover latch. If repair is necessary, notify direct
support maintenance.

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TROUBLE SHOOTING PROCEDURES 06

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

1. FAILURE TO 4. Check feed cam assembly for defects. Notify direct support maintenance.
FEED (cont)

5. Check operating rod assembly for broken Replace defective helical

helical compression spring. compression spring.

6. Check receiver assembly for obstruction. Remove obstruction, clean and

lubricate.

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TROUBLE SHOOTING PROCEDURES 06

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

1. FAILURE TO 7. Check cam actuator assembly for proper Replace cam actuator assembly
FEED (cont) assembly and defects. (09, pg. 56).

8. Check for lubrication. Lubricate.

9. Check for blockage in gas cylinder gas port Clean gas port.

*NOTE: Cutaway Image.

2. FAILURE TO 1. Check for ruptured cartridge case. Remove.

CHAMBER

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TROUBLE SHOOTING PROCEDURES 06

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

2. FAILURE TO 2. Check cam actuator assembly for proper Replace cam actuator assembly
CHAMBER assembly and defects. (09, pg. 56).
(cont)

3. Check chamber for dirt. Clear barrel and clean and

lubricate as required.

4 . Check gas cylinder for carbon buildup. Remove carbon.

5. Check receiver assembly for carbon buildup. Remove carbon.

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TROUBLE SHOOTING PROCEDURES 06

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

3. FAILURE TO 1. Check for broken or short helical compression Replace helical compression spring.
LOCK spring (23 1/4 inches minimum).

2. Check chamber, receiver extension, and receiver Clean and lubricate.

assembly for foreign matter.

3. Check barrel socket to make sure there is no Notify direct support maintenance.
burr, mutilation, and/or chipping.

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TROUBLE SHOOTING PROCEDURES 06

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

4. FAILURE TO 1. Check breech bolt assembly for broken firing Replace firing pin or helical
FIRE pin or broken helical compression spring. compression spring (09, pg. 56).

2. Check that grip and trigger assembly is properly Connect and secure components
connected and secured to the sear and safety (11, pg. 64).
housing assembly by inspecting the sear
assembly activator, sear link nut, and the
sear assembly link and spring.

3. Check sear assembly link and spring for Adjust sear assembly link and
adjustment. spring (07, pg. 42).

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TROUBLE SHOOTING PROCEDURES 06

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

4. FAILURE TO 4. Check for broken or defective sear plunger Replace sear plunger and/or
FIRE (cont) and/or helical compression spring. helical compression spring.

5. Check to make sure breech bolt assembly See FAILURE TO LOCK for
goes into lock position. correction.

5. FAILURE TO 1. Check breech bolt assembly for a broken Replace firing pin (09, pg. 56).
UNLOCK firing pin.

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TROUBLE SHOOTING PROCEDURES 06

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

6. FAILURE TO 1. Check for chipped or broken cartridge extractor. Replace cartridge extractor
EXTRACT (09, pg. 56).

2. Check for broken extractor helical

compression spring. Replace extractor helical
compression spring (09, pg. 56).
3. Check for defective extractor plunger.
Replace extractor plunger
(09, pg. 56).

4. Check operating rod assembly, operating rod Clean and lubricate operating rod
tube of receiver assembly, and gas cylinder and receiver assemblies. Clean gas
system for carbon. Carbon on these cylinder system only if necessary.
components can cause short recoil.

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TROUBLE SHOOTING PROCEDURES 06

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

6. FAILURE TO 5. Check for dirty or pitted chamber. Clean and lubricate.

EXTRACT
(cont)

7. FAILURE TO 1. Check for frozen or damaged cartridge ejector Replace cartridge ejector or helical
EJECT or weak helical compression spring. compression spring (09, pg. 56).

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TROUBLE SHOOTING PROCEDURES 06

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

7. FAILURE TO 2. Check operating rod assembly, operating rod Clean and lubricate operating rod
EJECT (cont) tube of receiver assembly, and gas cylinder and receiver assemblies. Clean gas
system for carbon. Carbon on these cylinder system only if necessary.
components can cause short recoil.

8. FAILURE TO 1. Check to see if sear is broken or worn. Replace sear (11, pg. 64).
COCK

2. Check operating rod sear notch (P) for damage Notify direct support maintenance.
or rounding.

S P
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TROUBLE SHOOTING PROCEDURES 06

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

8. FAILURE TO 3. Check sear plunger and helical compression Replace sear plunger and helical
COCK (cont) spring for breaks or defects. compression spring (11, pg. 64).

4. Check operating rod assembly, operating rod Clean and lubricate operating rod
tube of receiver assembly, and gas cylinder and receiver assemblies. Clean gas
system for carbon. Carbon on these cylinder system only if necessary.
components can cause a short recoil.

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TROUBLE SHOOTING PROCEDURES 06

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

9. SLUGGISH 1. Check for loose machine-threaded plug. Tighten machine-threaded plug

OPERATION (12, pg. 68).

2. Check gas cylinder and gas port for Clean gas cylinder and gas port
carbon buildup. (15, pg. 86).

*NOTE: Cutaway Image.

3. Check machine gun for lubrication.

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TROUBLE SHOOTING PROCEDURES 06

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

10. UNCONTROLLED
FIRE
(runaway gun)

WARNING
A runaway gun will not be reloaded until all corrective actions have
been completed.

1. Check for broken or defective sear. Replace sear (11, pg. 64).
Reinstall.

2. Make sure sear is not installed backwards. Reinstall properly (11, pg. 64).

3. Check sear plunger and spring for damage. Replace sear plunger or spring
as necessary.

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TROUBLE SHOOTING PROCEDURES 06

MALFUNCTION TEST TO INSPECT CORRECTIVE ACTION

10. UNCONTROLLED 4. Check operating rod for damaged sear notch (P). Notify direct support maintenance.
FIRE
(runaway gun)

5. Check gas cylinder and gas port for carbon Clean gas cylinder and gas port
buildup. (12, pg. 68).

*NOTE: Cutaway Image.

6. Check sear assembly link and spring for Adjust sear assembly link and
adjustments. spring (07, pg. 42).

41
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MAINTENANCE: M60D MACHINE GUN 07

THIS TASK COVERS: Inspection, Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level Materials/Parts
Unit Brush, cleaning, tool and parts
Cloth, abrasive (crocus)
Tools and Special Tools Dry cleaning solvent (SD)
Echelon Tool Kit Gloves, rubber (item 8, app D)
Lubricant (as required)
Trouble shooting References Lubricant, solid film
Refer to 06, pg. 27 Rag, wiping

General Safety Instructions

WARNING
Make sure weapon is cleared and there are no obstructions in the barrel
or chamber. Be careful when removing and installing spring-loaded
components. Carelessness could cause injury.

INSPECTION

WARNING
Before starting an inspection, be sure to clear the weapon. Do not
actuate the trigger before clearing the weapon. 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.
CAUTION
Do not allow breech bolt to slam closed when the weapon is empty, as
this will cause damage to locking surfaces on the barrel socket and
breech bolt.

Burrs or raised surfaces may be removed or smoothed using a fine grit

sharpening stone. DO NOT change the dimensions of any component
by stoning. Components with cracks, chips, dents, or gouges shall be
reported to direct support maintenance for repair or replacement.

1. Inspect general condition of machine gun.

2. Inspect for missing, loose, or damaged parts.
3. Check for proper cleaning and lubrication.
4. Make sure latches and controls operate properly.
5. Check to make sure gas cylinder extension is secured and safety wired.

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MAINTENANCE: M60D MACHINE GUN 07

DISASSEMBLY
1. Field-strip the weapon.

NOTE
The following procedures are performed only when a specific repair
is required.

2. Remove spring pin (1), barrel lock ring (2) and helical compression spring (3) using a 3/32-inch
drive pin punch and hammer. Push out barrel lock (4).

1
4

3. Remove spring pin (5) and barrel lock ring (6) using a 3/32-inch drive pin punch and hammer.
Carefully slide out carrying handle assembly (7), while catching detent plunger (8) and helical
compression spring (9). Remove carrying handle assembly (7).

5
7

6 9
8

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MAINTENANCE: M60D MACHINE GUN 07

DISASSEMBLY (cont)
4. Remove assembled washer screw (10) and cocking handle guide (11) using a flat tip screwdriver.

11

10

REPAIR

WARNING
Dry cleaning solvent (SD) is flammable. Do not clean parts near
an open flame or in a smoking area. Dry cleaning solvent evaporates
quickly and has a drying effect on the skin. When used without
protective gloves, solvent may cause irritation to or cracking of
the skin.

Using paint thinner, gasoline, kerosene, benzene (benzol), water, steam,

or air for cleaning the weapon is prohibited. Use only authorized
cleaning materials.

CAUTION
Before starting an inspection, be sure to clear the weapon. Do not
actuate the trigger before clearing the weapon. 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.

1. Repair by replacing all authorized parts.

2. Clean rusted or shiny metal surfaces with crocus cloth. Wash thoroughly with dry cleaning solvent (SD).

CAUTION
If solid film lubricant comes in contact with any moving or internal part,
clean part with dry cleaning solvent.

3. Following manufacturers instructions for use, apply solid film lubricant to all external surfaces
showing wear and allow weapon to dry 12 hours before being used.

4. Once repair/replacement is completed, lubricate according to operator’s manual.

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MAINTENANCE: M60D MACHINE GUN 07

REASSEMBLY

NOTE
The following procedures are only performed when a specific repair
is required.

1. Place cocking handle guide (1) against receiver assembly (2) and engage tabs into receiver slots
and position over end of cocking handle assembly (3).

3
1
2
4

2. Install assembled washer screw (4) and tighten using flat tip screwdriver.

3. Install helical compression spring (5), detent plunger (6), and carrying handle assembly (7) on barrel assembly.

8 5
6

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MAINTENANCE: M60D MACHINE GUN 07

REASSEMBLY (cont)
4. Install barrel lock ring (8) and secure with spring pin (9) using a 1/8-inch drive pin punch and hammer.

9
7

8 5
6

5. Install barrel lock (10) from the right side of receiver assembly (2).

6. Install helical compression spring (11) and barrel lock ring (12).

10
13

11

12

7. Apply pressure to barrel lock (10) and barrel lock ring (12), and slip a 3/32-inch drive pin punch into
pin hole of barrel lock ring to align.

8. Remove drive pin punch by driving spring pin (13) into pin hole using hammer.

END OF TASK
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MAINTENANCE: M60D MACHINE GUN 07

DISASSEMBLY
1. Field-strip weapon.

WARNING
The following procedures are only performed when a specific repair
is required.
WARNING
Check chamber area to make sure there is no ammunition present.
If ammunition is present, remove it.

2. Disengage quick release pin (1). Using a 1/16-inch drive pin punch and hammer, drive out spring
pin (2) and remove gun adapter (3).

WARNING
Wire rope assembly must be replaced whenever quick release pin
is replaced.

3. Using diagonal pliers, cut both loops in end of and discard wire rope assembly (4), remove
quick release pin (1).

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MAINTENANCE: M60D MACHINE GUN 07

REPAIR

WARNING
Dry cleaning solvent (SD) is flammable. Do not clean parts near an
open flame or in a smoking area. Dry cleaning solvent evaporates
quickly and has a drying effect on the skin. When used without
protective gloves, solvent may cause irritation to or cracking of
the skin.

Using paint thinners, gasoline, kerosene, benzene (benzol), water,

steam, or air for cleaning the weapon is prohibited. Use only authorized
cleaning materials.

CAUTION
The buffer assembly will not be submerged in solvents or other cleaning
fluids. Using lubricant on a cloth, wipe exterior surfaces to prevent
corrosion.

Care MUST be exercised to avoid getting cleaner, lubricant and

preservative (CLP/RBC) in the gas cylinder when cleaning the barrel.
Position the gas cylinder above the barrel during cleaning. The gas
cylinder components will be removed and cleaned only when inspection
reveals that the piston will no longer move within the cylinder under its
own weight when the barrel is tilted end to end. If gas cylinder
components are cleaned, wipe interior of cylinder and piston dry before
reassembly. After reassembly, check for movement of gas piston by
manually tilting the barrel assembly. Rewire gas cylinder vent plug.

NOTE
Do not dilute CLP/RBC. Shake well before using.

1. Repair by replacing all authorized parts.

2. Once repair/replacement is completed, clean and lubricate.
3. Repair of subassemblies is covered in the following work packages:

Barrel assembly 12 pg. 68

Breech bolt assembly 09 pg. 56
Cartridge feed tray assembly 14 pg. 82
Cover assembly 13 pg. 74
Grip and trigger assembly 08 pg. 52
Operating rod assembly 10 pg. 63
Sear and safety housing assembly 11 pg. 64

4. Clean rusted or shiny metal surfaces with crocus cloth. Wash thoroughly with dry cleaning solvent.

CAUTION
If solid film lubricant comes in contact with any moving or internal part,
clean part with dry cleaning solvent.

5. Following manufacturer’s instructions for use, apply solid film lubricant to all external surfaces
showing wear and allow weapon to dry 12 hours before being used.

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MAINTENANCE: M60D MACHINE GUN 07

REPAIR (cont)
6. On component parts which have a hard carbon residue, it may be necessary to use CLP/RBC to begin
repair. Depending on the amount of carbon residue, coat parts 2 to 16 hours, brush, wipe dry
with wiping rag, and lubricate as necessary.

NOTE
The following procedures are performed only when a specific repair
is required.

7. Remove cotter pin and headed grooved pin (2).

7 6 3 4 5

2
6 4
5

8. Grasp sear link and spring assembly (3) and push forward until sear assembly activator (4) just
touches sear (5). Hold sear link and spring assembly (3) while you position sear link nut (6) to fit
in slot of grip and trigger assembly (7).

9. With sear link nut (6) in slot of grip and trigger assembly (7), sight through the holes to determine
the amount of adjustment required to align holes. Pull sear link nut (6) out of slot and adjust by
turning sear link nut (6), repeating procedures until holes align.

10. Lift sear link nut (6) out of slot and rotate one-half turn clockwise. Push sear assembly link and
spring (3) rearward and insert headed grooved pin (2). There should be a slight gap between sear
(5) and sear assembly activator (4). Reinstall cotter pin. Lock sear link nut (6) and sear assembly
link and spring (3) with safety wire.

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MAINTENANCE: M60D MACHINE GUN 07

REASSEMBLY

NOTE
The following procedures are performed only when a specific repair
is required.

1. For maintenance on cocking handle guide, carrying handle assembly, and barrel lock, refer to maintenance
procedures (07, pg. 42).

2. With new wire rope assembly (1) and new swaging sleeves (2), securely connect quick release pin (3)
using the following procedures:

a. Insert one end of wire rope assembly (1) through swaging sleeve (2) and through the
opening in base of rear sight (4). Loop wire assembly (1) around the front of rear sight
(4) base and insert end back through swaging sleeve (2). Using parallel pliers, crimp
swaging sleeve (2) to wire rope assembly (1).

b. Insert other end of wire rope assembly (1) through another swaging sleeve (2) and through
ring of quick release pin (3). Loop wire rope assembly (1) around quick release pin (3), and
insert the end back through swaging sleeve (2). Using parallel pliers, crimp swaging sleeve
(2) to wire rope assembly (1).

2 2

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MAINTENANCE: M60D MACHINE GUN 07

REASSEMBLY (cont)
3. Place gun adapter (5) on bottom of receiver assembly (6), align holes, and install spring pin (7).
Using hammer, drive in spring pin (7) until flush.

4. Insert quick release pin (3).

END OF TASK
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 U.S. Ordnance | M60D 7.62MM Machine Gun | Technical Manual

MAINTENANCE: GRIP AND TRIGGER ASSEMBLY 08

THIS TASK COVERS: Inspection, Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level Materials/Parts
Unit Cloth, abrasive (crocus)
Dry cleaning solvent (SD)
Tools and Special Tools Gloves, rubber
Echelon Tool Kit Lubricant, solid film

General Safety Instructions

WARNING
Be careful when removing and installing spring-loaded components.
Carelessness could cause injury.

INSPECTION
1. Inspect general condition of grip and trigger assembly.

2. Inspect for missing, loose, or damaged parts.

3. Inspect for no binding of parts.

DISASSEMBLY
1. Remove retaining ring (1) and slide out knob and pin assembly (2).

2
1

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MAINTENANCE: GRIP AND TRIGGER ASSEMBLY 08

DISASSEMBLY (cont)
2. Hold down headless shoulder pin (3) and helical compression spring (4) while removing spring pin (5).

4 3
5

3. Remove cotter pins (6) and push out headed grooved pins (7).

7
6

4. Raise up grip and trigger assembly (8) and remove helical compression springs (9).
8

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MAINTENANCE: GRIP AND TRIGGER ASSEMBLY 08

REPAIR
WARNING
Dry cleaning solvent (SD) is flammable. Do not clean parts near an
open flame or in a smoking area. Dry cleaning solvent evaporates
quickly and has a drying effect on the skin. When used without
protective gloves, solvent may cause irritation to or cracking of the skin.

1. Repair by replacing all authorized parts.

2. Clean rusted or shiny metal surfaces with crocus cloth. Wash thoroughly with dry cleaning solvent (SD).

CAUTION
If solid film lubricant comes in contact with any moving or internal part,
clean part with dry cleaning solvent.

3. Following manufacturer’s instructions for use, apply solid film lubricant to all external surfaces
showing wear and allow weapon to dry 12 hours before being used.

4. Damage not repaired by minor replacement of parts will cause replacement of entire assembly.

REASSEMBLY
1. Raise up grip blocks (3). and trigger assembly (1) and insert helical compression springs (2) into trigger stop.

2. Align holes in grip and trigger assembly (1), install headed grooved pins (7), and secure with cotter pins (6).
7

7
6

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MAINTENANCE: GRIP AND TRIGGER ASSEMBLY 08

REASSEMBLY
3. Place helical compression spring (6) and headless shoulder pin (7) in back plate (8), and align
holes in headless shoulder pin (7) with slot (9) in back plate (8).

6 7
10

4. Press in on headless shoulder pin (7) and insert spring pin (10) through slot (9) and into hole of
headless shoulder pin (7). Using a hammer, drive spring pin (10) into hole.

5. Install knob and pin assembly (11) through back plate (8) and secure with retaining ring (12).

11
12

END OF TASK
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MAINTENANCE: BREECH BOLT ASSEMBLY 09

THIS TASK COVERS: Inspection, Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level Materials/Parts
Unit Lubricant (as required)

Tools and Special Tools

Echelon Tool Kit

General Safety Instructions

WARNING
Be careful when removing and installing spring-loaded components.
Carelessness could cause injury.

The weapon’s breech bolt assembly will be used to check headspace.

Do not intermix the breech bolt assembly or barrel and bipod assembly
without checking headspace requirements.

CAUTION
Do not allow breech bolt to slam closed when the weapon is empty, as
this will cause damage to the locking surfaces on the barrel socket and
breech bolt.

NOTE
Headspace will be gauged annually, using appropriate gauges, by direct
support maintenance personnel. If space is faulty, a new breech bolt
or test bolt gauge is required to determine if the barrel or breech bolt
is defective.

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MAINTENANCE: BREECH BOLT ASSEMBLY 09

INSPECT
NOTE
No cracks are permitted in this area. Notify direct support maintenance
if cracks are found.

1. Inspect back side of breech bolt assembly bottom 1

lug (1) for minor chips, dents, gouges, and burrs.
These conditions may be corrected by stoning.

CAUTION
If sharp edges or burrs are present, notify direct support maintenance
for replacement.

2. Inspect front side of breech bolt assembly bottom lug (1) for sharp edges or burrs.

NOTE
Raised or rough surfaces can be repaired by stoning. Notify direct
support maintenance for replacement if stoning fails.

3. Inspect breech bolt assembly cam area (2)

for raised or rough surfaces. 2

NOTE
Rounding or mutilation found on breech bolt locking surfaces will cause
damage to mating locking surfaces on the barrel socket. If breech bolt is
rounded or mutilated, notify direct support maintenance.

4. Inspect left front corner of breech bolt assembly

stripping lug (3). A stripping lug showing complete
loss of original radius surface area due to chipping 3
may still be used.

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MAINTENANCE: BREECH BOLT ASSEMBLY 09

5. Inspect back side of breech bolt assembly stripping lug (3). Burrs may be smoothed by stoning but
cracks, chips, dents, or gouges are not repairable in this area. If cracks, chips, dents, or gouges
are present, notify direct support maintenance.

DISASSEMBLY EXTRACTOR

1. Place extractor tool “tooth” (1) onto extractor plunger detent (2).

2
1

2. Thread extractor tool (3) until helical spring is full compressed.

3. At this point, extractor is no longer under spring tension and can be removed.

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MAINTENANCE: BREECH BOLT ASSEMBLY 09

DISASSEMBLY EXTRACTOR (cont)

4. While controlling (4) extractor plunger and helical spring, release tension on extractor tool (3).

5. Slide extractor plunger (5) and helical spring (6) free from bolt.

6
5

DISASSEMBLY EJECTOR
1. Using a punch, hammer ejector spring pin (7) free from breech bolt.

2. Slide ejector helical spring (6) and plunger (5) free from breech bolt.

6
5

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MAINTENANCE: BREECH BOLT ASSEMBLY 09

INSPECT
1. Repair by replacing all authorized components.

NOTE
Burrs or raised surfaces may be removed or smoothed using a fine grit
sharpening stone. DO NOT change the tolerances of any component by
stoning. Components with cracks, chips, dents, or gouges shall be
reported to direct support maintenance for repair or replacement.

Cracks, chips, dents, or gouges on breech bolt locking surfaces and

rounding/mutilation of the rear locking surface can damage the mating
locking surfaces of the barrel socket. Damage to barrel socket locking
surfaces can damage the breech bolt. Notify direct support maintenance
for replacement or repair if either condition exists.

2. Repair by stoning burrs and raised surfaces from bottom lug’s (1) forward corner and rear locking
surface. No cracks, chips, dents, and gouges are permitted on the rear locking surface.

3. Repair cam area (2) by stoning raised or rough surfaces.

4. Repair camming surface of stripping lug (3) by stoning the forward edge. A stripping lug showing
complete loss of original radius surface area may still be used.

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MAINTENANCE: BREECH BOLT ASSEMBLY 09

5. Repair by stoning burrs or raised surfaces from rear locking surface of stripping lug (4). No cracks,
chips, dents, or gouges are permitted in this area.

REASSEMBLY EXTRACTOR
1. Slide extractor replacement tool underneath extractor detent until tooth on tool catches edge inside bolt recess.

2. Place the compression tool (1) into the extractor detent and compress spring (2).

3. Replace extractor.

4. Release spring tension with extractor tool (3).

3

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MAINTENANCE: BREECH BOLT ASSEMBLY 09

REASSEMBLY EJECTOR
1. Slide ejector cartridge (6) and helical spring (5) back into breech bolt.

2. Re-tap spring pin (7) back into its original position.

3. Secure by tapping spring pin (7) until it is flush with body of breech bolt (3).

4. Apply lubricant sparingly to bolt locking lugs (8), actuator roller (9), and camming recess (10).

8
10

END OF TASK
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MAINTENANCE: OPERATING ROD ASSEMBLY 10

THIS TASK COVERS: Inspection, Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level Materials/Parts
Unit Lubricant (as required)

Tools and Special Tools

Echelon Tool Kit

REPAIR

1. Check for burrs, cracks, distortion, and mutilation on yoke area (1), firing pin bearing area (2), guide
ways (3), and sear notches (4).

2. Raised or upset areas are unacceptable on tower area (5), firing pin bearing area (2), and
guide ways (3). Remove burrs and sharp edges by stoning.

3. Apply lubricant sparingly on linear-rotating roller (6) and surfaces (7) immediately below the yoke
which ride within the receiver assembly rails.

5
2
3
6
1

4
7

END OF TASK
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MAINTENANCE: SEAR AND 11

SAFETY HOUSING ASSEMBLY

THIS TASK COVERS: Inspection, Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level Materials/Parts
Unit Cloth, abrasive (crocus)
Dry cleaning solvent (SD)
Tools and Special Tools Gloves, rubber
Echelon Tool Kit Lubricant, solid film

Troubleshooting References
Refer to 06, pg. 27

General Safety Instructions

WARNING
Be careful when removing and installing spring-loaded components.
Carelessness could cause injury.

INSPECTION
1. Inspect sear and safety housing assembly for bent, broken, or missing parts.

2. Inspect that small arms safety prevents sear from moving when in safe (S) position but allows sear
to move freely when in fire (F) position.

DISASSEMBLY
1. Field-strip weapon.

NOTE
The following procedures are in addition to field-stripping.

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MAINTENANCE: SEAR AND 11

SAFETY HOUSING ASSEMBLY

DISASSEMBLY (cont)
2. Hold sear and safety housing firmly. Depress safety plunger (2) while removing small arms safety (3).
Release pressure on safety plunger (2).

3
2

3. Lift out safety plunger (2) and helical compression spring (4) from the sear housing (5).

4 2
5

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MAINTENANCE: SEAR AND 11

SAFETY HOUSING ASSEMBLY

REPAIR

WARNING
Dry cleaning solvent (SD) is flammable. Do not clean parts near an
open flame or in a smoking area. Dry cleaning solvent evaporates
quickly and has a drying effect on the skin. When used without
protective gloves, solvent may cause irritation to or cracking of the skin.

1. Repair by replacing all authorized components.

2. Clean rusted metal surfaces with crocus cloth. Wash thoroughly with dry cleaning solvent.

CAUTION
If solid film lubricant comes in contact with any moving or internal part,
clean part with dry cleaning solvent.

3. Following manufacturer’s instructions for use, apply solid film lubricant to all external surfaces
showing wear and allow weapon to dry 12 hours before being used.

REASSEMBLY
1. Hold sear and safety housing (1) securely in hand.

2 3
1

2. Install helical compression spring (2) and safety plunger (3) into sear housing (1).

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MAINTENANCE: SEAR AND 11

SAFETY HOUSING ASSEMBLY

REASSEMBLY (cont)
3. Press in on safety plunger (3) with scribe while installing small arms safety (4).

4
3

4. Reassemble the weapon.

END OF TASK
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MAINTENANCE: BARREL ASSEMBLY 12

THIS TASK COVERS: Inspection, Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level Materials/Parts
Unit Cloth, abrasive (crocus)
Dry cleaning solvent (SD)
Tools and Special Tools Gloves, rubber
Echelon Tool Kit Lubricant (as required)
Lubricant, solid film
Troubleshooting References Rag, wiping
Refer to 06, pg. 27

INSPECTION
1. Inspect gas extension for tightness and safety wiring.

2. Inspect general appearance of barrel and carry handle assembly.

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MAINTENANCE: BARREL ASSEMBLY 12

DISASSEMBLY
1. Using diagonal cutting pliers, cut safety wire (2) and (3), and discard.

2. Using combination wrench, remove lock nut (1) and vent plug (2). Tilt barrel, gas piston (7) should fall out.

7 2 1

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MAINTENANCE: BARREL ASSEMBLY 12

REPAIR

WARNING
Dry cleaning solvent (SD) is flammable. Do not clean parts near an
open flame or in a smoking area. Dry cleaning solvent evaporates
quickly and has a drying effect on the skin. When used without
protective gloves, solvent may cause irritation to or cracking of the skin.

CAUTION
Care MUST be exercised to avoid getting lubricant or oil in the gas
cylinder when cleaning the barrel. Position the gas cylinder above the
barrel during cleaning. The gas cylinder components will be removed
and cleaned only when inspection reveals that the piston will no longer
move within the cylinder under its own weight when the barrel is tilted
end for end. If gas cylinder components are cleaned, wipe interior of
cylinder and piston dry before reassembly. After reassembly, check for
movement of gas piston by manually tilting the barrel assembly. Rewire
vent plug.

NOTE
Do not dilute lubricant. Shake well before using.

Burrs or raised surfaces may be removed or smoothed using a fine grit

sharpening stone. DO NOT change the tolerances of any component by
stoning. Cracks, chips, dents, or gouges on components shall be
reported to direct support maintenance for repair or replacement.

Cracks, chips, dents, or gouges on breech bolt locking surfaces can

damage the barrel socket. Damage to barrel socket locking surfaces
can damage the breech bolt. Notify direct support maintenance for
replacement or repair if either condition exists.

No abrasive materials will be used to clean the gas piston or the inside of
the gas cylinder (i.e. green pads, steel wool or crocus cloth). The receiver
brush will not be used to clean inside of gas cylinder.

1. The use of crocus cloth is restricted for external surfaces only.

CAUTION
If solid film lubricant comes in contact with any moving or internal part,
clean part with dry cleaning solvent.

2. Following manufacturers instructions for use, apply solid film lubricant to all external surfaces
showing wear and allow weapon to dry 12 hours before being used.

3. Repair by replacing safety wire.

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MAINTENANCE: BARREL ASSEMBLY 12

REPAIR (cont)

NOTE
Restore gas cylinder assembly to a serviceable condition by performing
the following procedures.

4. Insert reamer (1) all the way in the machine thread plug hole (2) to make sure all carbon is removed
from holes in gas cylinder (4) and wipe carbon residue from gas cylinder (4).

4 1

*NOTE: Cutaway Image.

5. Remove carbon from gas piston and wipe carbon residue from gas piston.

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MAINTENANCE: BARREL ASSEMBLY 12

REASSEMBLY
1. Install gas piston (1) in gas cylinder (2).

2. Install and tighten vent plug (3) and then lock nut (4).

2 1 3 4

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MAINTENANCE: BARREL ASSEMBLY 12

REASSEMBLY (cont)
3. Tilt barrel (7) up and down. Gas piston should click as it moves inside gas cylinder (2).
If click is not heard, disassemble, clean, and assemble again.

4. Secure gas extension assembly shown, using safety wire.

END OF TASK
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MAINTENANCE: COVER ASSEMBLY 13

THIS TASK COVERS: Inspection, Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level Materials/Parts
Unit Brush, cleaning, tool and parts
Dry cleaning solvent (SD)
Tools and Special Tools Gloves, rubber
Echelon Tool Kit Lacquer
Lubricant (as required)
Troubleshooting References Rag, wiping
Refer to 06. pg. 27

General Safety Instructions

WARNING
Dry cleaning solvent (SD) is flammable. Do not clean parts near an
open flame or in a smoking area. Dry cleaning solvent evaporates
quickly and has drying effect on the skin. When used without protective
gloves, solvent may cause irritation to or cracking of the skin.

INSPECTION
1. Inspect cover assembly for broken, bent, worn, or missing parts.
2. Inspect cover assembly for proper cleaning and lubrication.
4. Visually inspect external surfaces for dull black finish.

DISASSEMBLY
1. Remove guide cotter pin (1) and straight shaft (2).

2
1

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MAINTENANCE: COVER ASSEMBLY 13

2. Push down and over to remove front (3) and rear (4) cartridge guides.

4 3

3. Pull back on feed cam retainer (5) with punch and lift out feed cam assembly (6).

5 6

4. Press in on spring lever clip (7) and lift out feed lever assembly (8).

7
9

5. Lift out helical torsion spring (9).

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MAINTENANCE: COVER ASSEMBLY 13

6. Slide feed pawl assembly (10) in slot (11) and guide it toward feed lever stud (12). Remove feed
pawl assembly (10).
10

12

11

REPAIR
1. Replace damaged helical torsion spring (1).

2. Clean powder-fouled parts with CLP/Break Free/RBC and a brush. Wipe all parts clean and remove excess
CLP/RBC with a wiping rag.

3. Apply a coating of lubricant on the lower surfaces and frame mating areas of feed pawl assembly (2).

4. Dampen wiping rag with lubricant and wipe each part before reassembling cover assembly (3).

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MAINTENANCE: COVER ASSEMBLY 13

REPAIR (cont)
5. Refinish exterior of all aluminum parts not having a dull black finish by painting with a black
lusterless lacquer.

6. Clean worn or flaking surfaces with crocus cloth. Wash thoroughly with dry cleaning solvent.

7. Following manufacturer’s instructions for use, apply lacquer to all external aluminum surfaces
showing wear and allow to dry for appropriate length of time before being used.

REASSEMBLY
1. Place feed pawl assembly (1) in slot (2) near feed lever stud (3) and slide it into narrow leg of slot (2).

3 2

2. Place helical torsion spring (4) around feed lever stud (3) and hook one end of helical torsion
spring in slot (2).

4
3

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MAINTENANCE: COVER ASSEMBLY 13

3. Position feed lever assembly (5) so slot (6) is aligned above projection (7) on feed pawl assembly (1).

6
5

4. Press spring lever clip (8) in feed lever assembly (5) and place on feed lever stud (3). Make sure
helical torsion spring (4) rests against side of feed lever assembly (5).

4 8
3

5. Align feed cam assembly (9) with feed lever assembly (5) so cam stud (10) enters slot in the end of
feed lever assembly (5). Align hole (11) over cover stud (12).

9
11

10
12

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MAINTENANCE: COVER ASSEMBLY 13

REASSEMBLY (cont)
6. Pull back on feed cam retainer (13) with punch and press down on feed cam assembly (9) to latch it.

13

7. Move feed pawl assembly (1) back and forth several times to check it for freedom of movement.
Make sure feed pawl assembly (1) does not bind. If binding is present, notify direct support
maintenance.

8. Install front (14) and rear (15) cartridge guides. Secure with straight shaft (16).

16
14
15

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MAINTENANCE: COVER ASSEMBLY 13

REASSEMBLY (cont)
9. Install guide cotter pin (17) bend prongs of guide retaining pin around straight shaft so ends do not stick out.

17

END OF TASK
80
U.S. ORDNANCE

M60D
PROVEN UNDER FIRE

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MAINTENANCE: CARTRIDGE FEED 14

TRAY ASSEMBLY
THIS TASK COVERS: Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level Tools and Special Tools
Unit Echelon Tool Kit

DISASSEMBLY
1. Slowly tap cartridge shaft (1) part way out with a hammer and 3/32-inch drive pin punch and
remove one yoke roller (2), helical torsion spring (3), and cartridge retainer pawl (4) from underside
of cartridge tray frame assembly (5).

5
2

4 1

2. Remove cartridge shaft (1) and separate second yoke roller (2) from cartridge tray frame assembly (5).

REPAIR
Repair by replacing all authorized components.

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MAINTENANCE: CARTRIDGE FEED 14

TRAY ASSEMBLY
REASSEMBLY
1. Attach one yoke roller (1) to cartridge tray frame assembly (2) and insert cartridge shaft (3) in part way.

2
1

2. Insert cartridge retainer pawl (4) and helical torsion spring (5) as a unit from underside of cartridge
tray frame assembly (2) and align helical torsion spring (5) with cartridge shaft (3).

3. Insert second yoke roller (6) in cartridge tray frame assembly (2). Insert 3/32-inch drive pin punch in
other side and work it through cartridge retainer pawl (4) and helical torsion spring (5) to help keep
all parts in line.

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MAINTENANCE: CARTRIDGE FEED 14

TRAY ASSEMBLY

REASSEMBLY (cont)
4. Use hammer to tap cartridge shaft (3) and drive it through retainer pawl (4), helical torsion
spring (5) until it drives out drive pin punch. Flush both ends of the cartridge shaft (3).

END OF TASK
84
U.S. ORDNANCE

M60D
PROVEN UNDER FIRE

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LUBRICATION INSTRUCTIONS 15

Weapons NOT in use or that are to be stored in the arms room for prolonged periods should have all
interior and exterior metal parts lubricated and a light film of lubricant applied to the interior of the gas
cylinder and the gas piston following cleaning and inspection.

The use of lubricant will not eliminate periodic cleaning and/or inspection to ensure that corrosion is not forming.
Remove excess lubricant from the remainder of the weapon. Avoid lubricant contact with non-metallic surfaces.

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PREPARATION FOR STORAGE OR SHIPMENT 16

ADMINISTRATIVE STORAGE
Refer to Chapter 3, 36 (pg. 145).

Manufacturer recommends use of a dry, temperature controlled storage area for long-term storage. Machine guns
should be packaged in protective cases to prevent any damage to due to falls.

Weapons placed in long-term storage should be inspected every 90 days. Weapons must be inspected for any visual
indicators of corrosion.

Before being placed into storage, machine guns must be clean, dry, and lubricated with a light coat of CLP/Break Free.

87
 DIRECT SUPPORT
CHAPTER 3 | MAINTENANCE INSTRUCTIONS

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REPAIR PARTS, SPECIAL TOOLS 17

AND SUPPORT EQUIPMENT

COMMON TOOLS AND EQUIPMENT

For authorized common tools and equipment refer to Modified Table of Organization and Equipment
(MTOE) applicable to your unit.

SPECIAL TOOLS AND SUPPORT EQUIPMENT

Tools and Test equipment requirements are listed in 37, pg. 147. Echelon Tool Kit tools and support equipment
are listed and illustrated in 54, pg. 184 of this manual.

REPAIR PARTS
Repair parts are listed and illustrated in 37, pg. 147 through 53, pg. 183 of this manual.

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TROUBLESHOOTING 18

TROUBLESHOOTING PROCEDURES
Refer to work package 06, pg. 27 of this manual.

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MAINTENANCE PROCEDURES 19

GENERAL
Without a gauge, or inspection criteria, to determine if any component part or assembly of a weapon has
excessive wear and/or how deep of a crescent/half-moon appearance make the component/assembly
unserviceable, the determining factors will have to remain as follows:

a. The functional/operational check with dummy cartridges.

b. The experience and judgmental expertise of the DS armorer and/or maintenance personnel
to determine that a component, assembly or repair part needs replacement.

NOTE
When a weapon is received by direct support with a maintenance
request, all gauging requirements must be checked as a standard
maintenance procedure. In addition, the weapon must be inspected and
any other deficiencies found will be repaired, or noted for repair, at the
appropriate maintenance level. As a minimum requirement, for active
duty M60D guns the headspace and gauging must be verified
annually by direct support personnel.

If the M60D machine gun has to go to direct support maintenance

for any repair, both barrel assemblies must be turned in with the weapon.

Burrs or raised surfaces may be removed or smoothed using a fine grit

sharpening stone. DO NOT change the dimensions of any components
by stoning. Cracks, chips, dents, or gouges on components shall be
reported to the appropriate maintenance level for repair or replacement.

Cracks, chips, dents, or gouges on breech bolt locking surfaces can

damage the barrel socket. Damage to barrel socket locking surfaces
can damage the breech bolt.

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MAINTENANCE: M60D MACHINE GUN 20

SECTION 1 of 2

THIS TASK COVERS: Disassembly, Repair, Test/Inspection, Reassembly

INITIAL SETUP
Materials/Parts
Maintenance Level Identification tag
Direct Support Lacquer
Wire, Nonelectrical (MS20995C32)
Tools and Special Tools
Combination square (GGG-S-656) Troubleshooting References
or equivalent) Refer to 06, pg. 27
Dial indicating scale (AAA-S-133)
or equivalent)
Firing pin protrusion gauge (7274754)
Headspace gauge (7274790)
Machinist’s steel rule (GGG-R-791
or equivalent)
Plain cylindrical plug gauge (7458598)
Small Arms Gauge Kit MS (5910297)
Echelon Tool Kit
Test bolt gauge (7799699)

General Safety Instructions

CAUTION
The ability to detect oil movement on or around the rivet head and/or
between riveted components does not classify rivets as being loose, and
is an unauthorized procedure.

NOTE
The disassembly/reassembly procedures in this paragraph are additions
to those described in organizational maintenance (07, pg. 42).

Before doing the trigger pull test for M60D, the weapons must
be reassembled.

No stamping or etching is authorized. Use tags for identification.

DISASSEMBLY
WARNING
Make sure weapon is cleared and that there are no obstructions in
the barrel.

1. Field-strip weapon.

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MAINTENANCE: M60D MACHINE GUN 20

DISASSEMBLY (cont)
2. Remove rear sight (1) from receiver assembly (2).

REPAIR
1. Repair by replacing all authorized components.

2. Additional maintenance procedures for subassemblies are contained in the followin work packages:

Barrel and carrying handle assembly 12 pg. 68

Breech bolt assembly 09 pg. 56
Cocking handle assembly 33 pg. 139
Cover assembly 13 pg. 74
Operating rod assembly 10 pg. 63
Gun receiver assembly 34 pg. 140

TEST/INSPECTION

WARNING
Make sure weapon is cleared and that there are no obstructions in
the barrel.

LOOSE RECEIVER TEST

1. a. Check for loose receiver. Remove all major assemblies and internal components.

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MAINTENANCE: M60D MACHINE GUN 20

TEST/INSPECTION (cont)
LOOSE RECEIVER TEST (cont)
b. Clamp receiver assembly (1) securely in machinist’s vise equipped with jaw caps.

2. Place combination square (2) against receiver assembly (1). Combination square (2) should be
parallel to receiver assembly (1) with the edge of its blade touching the side of receiver assembly (1).

3 1

3. Attach dial indicating scale (3) to rear of receiver assembly (1).

WARNING
In the following step, after obtaining 10 pounds of pressure on dial
indicating scale, release pressure and do not move combination square.

4. Pull dial indicating scale (3) to 10 pounds of pressure and allow combination square (2) to move
with receiver assembly (1).

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MAINTENANCE: M60D MACHINE GUN 20

TEST/INSPECTION (cont)
LOOSE RECEIVER TEST (cont)
5. Attach dial indicating scale (3) on other side of receiver assembly (1) and pull to 10 pounds of
pressure. Butt machinist’s steel rule (4) against receiver assembly (1) while holding pressure.

2
3
1

6. Read distance between receiver assembly (1) and blade of combination square (2). Total horizontal
movement should not exceed 3/32 (0.094) of an inch.

7. Remove dial indicating scale (3).

8. Move combination square (2) against receiver assembly (1), and attach dial indicating scale (3)
to bottom of receiver assembly (1).

1 2

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MAINTENANCE: M60D MACHINE GUN 20

TEST/INSPECTION (cont)
LOOSE RECEIVER TEST (cont)
9. Mark receiver assembly (1) at whole number increments for reference point.

10. Pull dial indicating scale (3) to 10 pounds of pressure and hold it. Mark a line on the blade of
combination square (2), or on the rear of receiver assembly (1), with pencil.

1 2

11. Remove dial indicating scale (3).

12. Attach dial indicating scale (3) to upper side of receiver assembly (1), pull dial indicating scale (3) to
10 pounds of pressure, and hold it.
3

2
1

13. Measure vertical movement by using scribe line as a reference and reading against combination
square (2). Total vertical movement should not exceed 3/32 (0.094) of an inch.

14. Remove dial indicating scale (3) from receiver assembly (1).

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MAINTENANCE: M60D MACHINE GUN 20

TEST/INSPECTION (cont)
LOOSE RECEIVER TEST (cont)

NOTE
Receiver assemblies exceeding the maximum looseness tolerance of
3/32 (0.094) of an inch vertically or horizontally will be judged
unserviceable. Receiver assemblies having tolerances of less than 3/32
(0.094) of an inch in either direction will be judged serviceable.

15. Inspect receiver assembly (1) and weld areas (5, 6, and 7). Minute or full length cracks in welds
are considered serviceable providing they pass the looseness check of 3/32 (0.094) of an inch,
Cracks in the base metal of the receiver assembly (1) are a reason to consider it unserviceable.

1
5

16. Raise barrel muzzle up to about 30 to 45 degree angle so locking surface can be seen clearly.

17. Moderate to severe mutilation or chipping on either surface shall be cause for removing barrel
from service.

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MAINTENANCE: M60D MACHINE GUN 20

TEST/INSPECTION (cont)
LOOSE RECEIVER TEST (cont)
18. Lower barrel muzzle to about 30 to 45 degree angle so cam curved surfaces can be seen clearly.

19. Raised burr on cam cover shall be removed with a smooth half round file and crocus cloth.

20. Return back to service if headspace check is within tolerance.

BREECH BOLT TEST

1. Disassemble bolt assembly.

2. Using a firing pin protrusion gauge and plain cylindrical plug gauge test breech bolt assembly.

3. Push forward firing pin (8) and measure the exposed length with firing pin protrusion gauge (9).
Firing pin (8) should protrude a minimum of 0.035 inches to a maximum of 0.043 inches.

4. Push firing pin (8) rearward using plain cylindrical plug gauge (10). The gauge shall not enter the
firing pin hole. The body of breech bolt assembly (11) will be replaced if the hole is oversized.

11

10

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MAINTENANCE: M60D MACHINE GUN 20

TEST/lNSPECTlON (cont)
BREECH BOLT TEST (cont)

NOTE
The breech bolt assembly used with the weapon will be the only one
used when checking headspace. New breech bolt assemblies or test
bolt gauges will not be used as a standard.

Do not intermix breech bolt assembly or barrel assembly without

checking headspace requirements.

NOTE
If headspace is faulty, a test bolt gauge is required to determine if the
barrel or breech bolt is defective. Use of a new breech bolt assembly is
authorized only in a contingency situation, where it becomes imperative
for deployment of the weapon or to put the weapon on-line, until a test
bolt gauge is available.

For annually verified headspace, both barrels (issue and spare) will be
checked.

5. Check breech bolt assembly and barrel for proper headspace using a headspace gauge,
a test bolt gauge, or a new breech bolt assembly.

6. Insert headspace gauge (12) in chamber of barrel assembly (13).

12

13

NOTE
Leading edge of breech bolt assembly locking lugs must not touch the
locking recess edge of barrel socket when rotated.

If breech bolt assembly locks in chamber of barrel assembly with

headspace gauge installed, headspace is incorrect. The following
procedures can be used to determine fault.

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MAINTENANCE: M60D MACHINE GUN 20

TEST/lNSPECTlON (cont)
BREECH BOLT TEST (cont)
7. Insert breech bolt assembly (11) in socket of barrel assembly (13), and turn breech bolt
assembly (11) with light finger pressure. Breech bolt assembly (11) should not close.

11 12 13

NOTE
A new breech bolt assembly may be used if test bolt gauge is not
available.

8. Remove breech bolt assembly from socket of barrel assembly (13), and insert test bolt
gauge (14) in chamber.

14
13

12

9. If test bolt gauge (14) does not close, breech bolt assembly (11) is defective. If test bolt gauge
closes, barrel assembly (13) is defective.

10. Remove test bolt gauge (14) and headspace gauge (12) from barrel assembly (13).

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MAINTENANCE: M60D MACHINE GUN 20

REASSEMBLY
1. Install and center rear sight (1) in grooved space on receiver assembly (2).

1
2

2. Locate original stake marks (3) on receiver assembly (2) used to secure rear sight (1).

3 4

3 4

3. Stake new stake marks (4) in four different locations.

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MAINTENANCE OF M60D MACHINE GUN 21

SECTION 2 of 2

THIS TASK COVERS: Disassembly, Repair, Test/Inspection, Reassembly

INITIAL SETUP
Maintenance Level Tools and Special Tools (cont)
Depot level maintenance Machinist’s steel rule (GGG-R-791)
or equivalent)
Tools and Special Tools Plain cylindrical plug gauge (7458598)
Anvil assembly Small Arms Gauge Kit M8 (5910297)
Combination square (GGG-S-656 Echelon Tool Kit
or equivalent) Test bolt gauge (7799699)
Dial indicating scale (AAA-S-133)
or equivalent) Materials/Parts
Firing pin protrusion gauge (7274754) Lubricant (as required)
Headspace gauge (7274790)

General Safety Instructions

CAUTION
Do not allow breech bolt to slam closed when the weapon is empty, as
this will cause damage to the locking surfaces on the barrel socket and
breech bolt.
NOTE
The disassembly/reassembly procedures in this paragraph are in
addition to those described in organizational maintenance (07, pg. 42).

Before doing the trigger pull test for both M60D the weapon must be
reassembled.

DISASSEMBLY
1. Remove cotter pin (1), headed straight pin (2), lock-release lever (3), and helical compression spring (4).
2

3 4
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MAINTENANCE: M60D MACHINE GUN 21

DISASSEMBLY (cont)
2. Remove cotter pin (5), headed straight pin (6), pawl (7), and helical compression spring (8).

6
5

3. Remove solid rivets (9) from magazine bracket (10) only if replacement is necessary.

10

9
9

NOTE
Do not remove rear sight unless rear sight base is damaged.

4. Using 1/2-inch brass punch and hammer, drive rear sight (11) out of grooved area on receiver assembly (12).

11

12

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MAINTENANCE: M60D MACHINE GUN 21

REPAIR
Repair by replacing all authorized components.

Additional maintenance procedures for subassemblies are contained in the following work packages:

Barrel and carrying handle assembly 12 pg. 68

Breech bolt assembly 22 pg. 110
Cocking handle assembly 33 pg. 139
Cover assembly 13 pg. 74
Gun receiver assembly 34 pg. 140
Operating rod assembly 10 pg. 63
Rear sight 32 pg. 137

REASSEMBLY
1. Insert solid rivets (1) in magazine bracket (2) and through receiver assembly (3).

2
1
3
1

2. Insert fabricated anvil assembly (4) in receiver assembly (3) by placing grooved plate (5) in left side rails
of receiver assembly (3). Once anvil assembly (4) is properly fitted in receiver assembly (3), push smooth
surfaced plate (6) in receiver assembly (3).

5 3

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MAINTENANCE: M60D MACHINE GUN 21

REASSEMBLY (cont)
3. Insert and secure back plate (7) in machinist’s vise equipped with jaw caps.

4. Position receiver assembly (3) atop back plate (7). Using a drive pin punch and hammer, tighten
solid rivets (1). Pull out smooth surfaced plate (6) and remove anvil assembly (4).

3 4

5. Position helical compression spring (8) and pawl (9) in magazine bracket (2). Insert headed
straight pin (10) and secure with cotter pin (11).

10
11

2
8

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MAINTENANCE: M60D MACHINE GUN 21

REASSEMBLY (cont)
6. Position helical compression spring (12) and lock-release lever (13) in magazine bracket (2).
Insert headed straight pin (14) and secure with cotter pin (15).

14 15

13
12

7. Install and center rear sight (16) in grooved space on receiver assembly (3).

16

8. Look for old stake marks (17) and restake new stake marks (18) in a different location. Using a
center punch and hammer, stake receiver assembly to base of rear sight (16) in four places.

17 18

17 18

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MAINTENANCE: M60D MACHINE GUN 21

TRIGGER PULL TEST

NOTE
The weapon must be reassembled before doing trigger pull test.

1. Check trigger pull using two trigger pull fixtures and a dummy round.

2. Press in on “F’ to place small arms safety (1) in fire (F) position.

3. Pull cocking handle assembly (2) to the rear, and then push it forward.

4. Press in on “S” to place small arms safety (1) in safe (S) position.

5. Load dummy rounds on cartridge feed tray.

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MAINTENANCE: M60D MACHINE GUN 21

TRIGGER PULL TEST (cont)

6. Attach one trigger pull fixture (3) to each of the triggers (4). position. Place small arms safety (1) in fire (F).

3 3

7. Tilt the weapon about 35 to 40 degrees and carefully add weights (5) until sear releases breech bolt
assembly. The sear should not release with less than 10 pounds of weight, but should release with
less than 20 pounds of weight.

3
3

8. Remove weights (5), trigger pull fixtures (3), and the dummy rounds.

END OF TASK
108
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M60D
PROVEN UNDER FIRE

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MAINTENANCE: BREECH BOLT ASSEMBLY 22

THIS TASK COVERS: Repair, Test

INITIAL SETUP
Maintenance Level
Direct Support

Tools and Special Tools

Firing pin protrusion gauge (7274754)
Plain cylindrical plug gauge (7458598)
Echelon Tool Kit

General Safety Instructions

WARNING
The breech bolt assembly used in the weapon will be the only one used
to check the headspace.

Do not intermix the breech bolt assembly or barrel assembly without

checking headspace requirements.

CAUTION
Do not allow breech bolt to slam closed when the weapon is empty, as
this will cause damage to the locking surfaces or the barrel socket and
breech bolt.

NOTE
If headspace is faulty, a new breech bolt or test bolt gauge is required to
determine whether the barrel or breech bolt is defective.

REPAIR
Repair by replacing all authorized components or by stoning (see 09, pg. 56).

WARNING
Burrs or raised surfaces may be removed or smoothed using a
fine grit sharpening stone. DO NOT change the dimensions of
any components by stoning. Cracks, chips, dents, or gouges on
components shall be reported to the appropriate maintenance
level for repair or replacement.

Cracks, chips, dents, or gouges on breech bolt locking surfaces

can damage the barrel socket. Damage to barrel socket locking
surfaces can damage the breech bolt.

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MAINTENANCE: BREECH BOLT ASSEMBLY 22

TEST

NOTE
Small arms gauges will be inspected and certified annually. The gauges
will not be used unless they are accompanied with the appropriate gauge
record.

Perform BREECH BOLT TEST (see 23, pg. 139).

END OF TASK
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MAINTENANCE: OPERATING ROD ASSEMBLY 23

THIS TASK COVERS: Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level
Direct Support

Tools and Special Tools

Echelon Tool Kit

NOTE
Disassembly, reassembly, and stoning procedures are covered in 09, pg. 56.

DISASSEMBLY
Remove spring pin (1), headless straight pin (2), and yoke roller (3) from operating rod assembly (4).

REPAIR
Repair by replacing all authorized components.

REASSEMBLY
Insert yoke roller (3) in slot of operating rod (4). Insert headless straight pin (2) and spring pin (1).

END OF TASK
112
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M60D
PROVEN UNDER FIRE

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MAINTENANCE: BARREL 24

THIS TASK COVERS: Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level Materials/Parts
Direct Support Cloth, abrasive (crocus)
Dry cleaning solvent
Tools and Special Tools Gloves, rubber)
Headspace gauge (7274790) Lubricant (as required)
Small Arms Gauge Kit M8 (5910297) Lubricant, solid film
Echelon Tool Kit Rag, wiping
Test bolt gauge (7799699)
Troubleshooting References
Refer to 06, pg. 27

WARNING
The breech bolt assembly used in the weapon will be the only one used
to check headspace.

Do not intermix the breech bolt assembly or barrel assembly without

checking headspace requirements.

NOTE
Headspace will be gauged annually using appropriate gauges.

If headspace is faulty, a new breech bolt or test bolt gauge is required to

determine whether the barrel or breech bolt is defective.

DISASSEMBLY
1. Turn barrel (1) upside down, and place it in a machinist’s vise equipped with vise jaw caps.
Tighten vise just enough to hold barrel securely.

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MAINTENANCE: BARREL 24

DISASSEMBLY (cont)

2. Using a portable electric drill and 7/64-inch twist drill, drill off stake marks from both sides of flash
suppressor (2).

3. Using a drive pin punch, drive out headless straight pin (3) and discard.

4. Unscrew and remove flash suppressor (2) from barrel (4). Remove barrel (4) from machinist’s vise.

4
2

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MAINTENANCE: BARREL 24

REPAIR

WARNING
Dry cleaning solvent (SD) is flammable. Do not clean parts near an
open flame or in a smoking area. Dry cleaning solvent evaporates
quickly and has a drying effect on the skin. When used without
protective gloves, solvent may cause irritation to or cracking of the skin.

NOTE
No abrasive materials will be used to clean the gas piston or the inside of
the gas cylinder (i.e., green pads, steel wool, or crocus cloth). The
receiver brush will not be used to clean inside of gas cylinder.

1. Repair by replacing all authorized components.

2. The use of crocus cloth is restricted to external surfaces only.

3. Following manufacturer’s instructions for use, apply solid film lubricant to all external surfaces
showing wear and allow weapon to dry 12 hours before being used.

4. Clean and lubricate.

5. Additional maintenance procedures for subassemblies of the barrel assembly are listed
in the following work packages:

Maintenance: Bipod 25 pg. 120

Maintenance: Bipod Leg 26 pg. 124

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MAINTENANCE: BARREL 24

NOTE
When a new flash suppressor or barrel is used, it must be drilled for a
headless straight pin. Re-drilling may be required on originally installed
equipment if tolerances changed.

REASSEMBLY

1. Screw flash suppressor (1) on end of barrel (2). Tighten and position flash suppressor (1) so one
prong will align with gas cylinder.

2
1

2. Clamp barrel (2) in a machinist’s vise equipped with vise jaw caps. Using flash suppressor (3) as a
guide, drill #31 drill (0.120) for the new headless straight pin.

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MAINTENANCE: BARREL 24

REASSEMBLY (cont)
3. Drive headless straight pin (4) in hole (5), center the pin in the flash suppressor and stake to secure
both ends of headless straight pin (4). Loosen machinist’s vise and remove barrel assembly (6).

4. Clean rusted metal surfaces with crocus cloth. Wash thoroughly with dry cleaning solvent (SD).

CAUTION
Make sure solid film lubricant does not enter into the gas cylinder.

5. Following manufacturer’s instructions for use, apply solid film lubricant to all external surfaces
showing wear and allow weapon to dry 12 hours before being used.

6. Refer to 15, pg. 86 for reassembly procedures for the gas cylinder assembly.

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MAINTENANCE: BARREL 24

TEST

WARNING
The breech bolt assembly used in the weapon will be the only one
used to check headspace.

Do not intermix the breech bolt assembly or barrel and barrel assembly
without checking headspace requirements.

NOTE
Headspace will be gauged annually using appropriate gauges.

If headspace is faulty, a new breech bolt or test bolt gauge is required to

determine whether the barrel or breech bolt is defective.

The test procedure below is in addition to those performed in BARREL

TEST (see 20, pg. 92).

1. Visually check the barrel extension locking surfaces for cracks.

NOTE
If barrel is replaced, remove ID tag, and attach to new barrel.

END OF TASK
119
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MAINTENANCE: BIPOD 25

THIS TASK COVERS: Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level Materials/Parts
Direct Support Lubricant, solid film

Tools and Special Tools

Echelon Tool Kit

NOTE
The following procedures are performed when disassembling and
reassembling both bipod legs.

DISASSEMBLY
1. Using a standard screwdriver (1) unscrew pivot leg screw (2) and separate bipod leg assembly (3) from bipod
pivot assembly (4).

2. Slide screwdriver (1) between pivot leg screw (2) and leg spring plunger (4) and push pivot leg screw free.

1
2

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MAINTENANCE: BIPOD 25

REASSEMBLY (cont)
3. Separate bipod leg (1) from bipod assembly pivot (3) pivot leg screw (2).

4. Remove leg spring plunger (4) and helical compression spring (6) from bipod leg (1).

4 6

REASSEMBLY (cont)
1. Repair by replacing all authorized components.

WARNING
Dry cleaning solvent (SD) is flammable. Do not clean parts near an
open flame or in a smoking area. Dry cleaning solvent evaporates
quickly and has a drying effect on the skin. When used without
protective gloves, solvent may cause irritation to or cracking of the skin.

2. Clean rusted metal surfaces with crocus cloth. Wash thoroughly with dry cleaning solvent (SD).

3. Following manufacturer’s instructions for use, apply solid film lubricant to all external surfaces
showing wear and allow weapon to dry 12 hours before being used.

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MAINTENANCE: BIPOD 25

REASSEMBLY (cont)
1. Insert headed straight pin (1) and helical compression spring (2) in bipod leg (3).

1 2

2. Use standard screwdriver to compress leg spring plunger and helical spring while sliding pivot leg screw (6)
back into position.

3. Position bipod leg (3) against bipod pivot assembly pivot (7) and tighten pivot leg screw (6).

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MAINTENANCE: BIPOD 25

REASSEMBLY (cont)
4. Using a hammer and punch, stake pivot leg screw (6) in two places.

END OF TASK
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MAINTENANCE: BIPOD LEGS 26

THIS TASK COVERS: Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level
Direct Support

Tools and Special Tools

Echelon Tool Kit

DISASSEMBLY
NOTE
If foot of bipod leg rotates replace the entire leg assembly.

1. Slide inner (1) and outer (2) leg assemblies until inside and outside holes line up.

2. Use punch to remove dowel pin (3) from inner and outer leg assemblies.

3. Slide inner and outer leg assemblies free.

2 3

REPAIR
Replace parts as needed. Reassemble.

REASSEMBLY
1. Slide inner and outer leg assemblies together.

2. Slide inner and outer leg assemblies until inside and outside holes line up.

3. Replace dowel pin.

END OF TASK
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MAINTENANCE: COVER ASSEMBLY 27

THIS TASK COVERS: Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level
Direct Support

Tools and Special Tools

Echelon Tool Kit

DISASSEMBLY
Refer to 16, pg. 87 for disassembly of cover assembly.

REPAIR
1. Repair by replacing all authorized components.

2. Additional maintenance procedures for subassemblies of the cover assembly are contained in the
following work packages:

Cover housing assembly 32 pg. 137

Feed cam assembly 28 pg. 126
Feed lever assembly 29 pg. 128
Feed pawl assembly 31 pg. 132

REASSEMBLY
Refer to 13, pg. 74 for reassembly of cover assembly.

END OF TASK
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MAINTENANCE: FEED CAM ASSEMBLY 28

THIS TASK COVERS: Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level
Direct Support

Tools and Special Tools

Echelon Tool Kit

DISASSEMBLY
1. Push retainer plunger (1) back and hold it while feed cam retainer (2) is pushed out. Slowly release
pressure on retainer plunger (1).

2. Shake retainer plunger (1) and helical compression spring (3) from cam assembly (4).

1 3

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MAINTENANCE: FEED CAM ASSEMBLY 28

REPAIR
Repair by replacing all authorized components.

REASSEMBLY (cont)
1. Install helical compression spring (1) and retainer plunger (2) in cam assembly (3).

2 1

2. Press against retainer plunger (2) with a drive pin punch, and install feed cam retainer (4) in slot.
Release pressure and withdraw drive pin punch.

END OF TASK
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MAINTENANCE: FEED LEVER ASSEMBLY 29

THIS TASK COVERS: Disassembly, Repair, Reassembly

INITIAL SETUP
MAINTENANCE LEVEL
Direct Support

TOOLS AND SPECIAL TOOLS

Echelon Tool Kit

NOTE
The following pages show disassembly/reassembly of the Feed lever
Assembly, but the manufacturer suggests replacement of entire assembly
if necessary.

DISASSEMBLY
Carefully use a screwdriver to free and separate end of spring lever clip (1) from feed lever (2).

REPAIR
Repair by replacing all authorized components.

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MAINTENANCE: FEED LEVER ASSEMBLY 29

REASSEMBLY
Attach spring lever clip (1) to feed lever (2), and slide them together until end of spring lever clip (1)
enters slot in rear of feed lever (2).

1 2

END OF TASK
129
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MAINTENANCE: FEED PAWL ASSEMBLY 30

THIS TASK COVERS: Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level
Direct Support

Tools and Special Tools

Echelon Tool Kit

NOTE
The following pages show disassembly/reassembly of the Feed Pawl
Assembly, but the manufacturer suggests replacement of entire assembly
if necessary.

DISASSEMBLY
1. Push out shouldered shaft (1) and remove helical torsion spring (2). Separate chassis assembly (3) from pawl (4).

4
1

REPAIR
Repair by replacing all authorized components.

REASSEMBLY
1. Assemble chassis assembly (1) into center of pawl (2). Insert 1/16-inch drive pin punch into left
side of pawl (2) and through chassis assembly (1) slightly.
1

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MAINTENANCE: FEED PAWL ASSEMBLY 30

REASSEMBLY (cont)
2. Position torsion spring (1) and insert shouldered shaft (2).

END OF TASK
131
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MAINTENANCE: COVER HOUSING ASSEMBLY 31

THIS TASK COVERS: Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level Materials/Parts
Direct Support Lever Assembly, Latch (7269137)
Rivet bucking tool
Tools and Special Tools Rivet heading tool
Echelon Tool Kit

DISASSEMBLY
1. Remove solid rivets (1), and cam bumper assembly (2).

132
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MAINTENANCE: COVER HOUSING ASSEMBLY 31

DISASSEMBLY (cont)
2. Using a 1/8-inch twist drill and electric drill, drive punch end off of headed shoulder pins (5).
Remove and discard headed shoulder pins (5). Lift out flat washers (6) and helical compression
springs (7).

3. Using a 3/16-inch twist drill and an electric drill, drill end of latch lever assembly (8) to remove peened area.
Remove latch lever assembly (8). Remove cover latch (9) and helical torsion spring (10).

9 10

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MAINTENANCE: COVER HOUSING ASSEMBLY 31

REPAIR
1. Repair by replacing all authorized components.

REASSEMBLY
1. Insert torsion spring (3) and cover latch (4). Insert new latch lever assembly (5) from the straight
side of the cover. Slowly guide the latch lever assembly (5) through spring.

5
3
5

4 3

2. Insert headless straight pin (6) while holding down torsion spring leg (3) so it is underneath headless
straight pin.

6 3

3. Use screwdriver to hold down torsion spring leg (3) then insert headless straight pin (6).

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MAINTENANCE: COVER HOUSING ASSEMBLY 31

REASSEMBLY (cont)

4. Assemble shoulder pins (5), flat washers (6), and helical compression springs (7) and install in
cover frame assembly (2). Using ballpeen end of hammer, peen ends of headed shoulder pins (5).
Ensure that shoulder pins are tight (no movement). Repeat procedures for other pin.

5. Install cam bumper assembly (2) and align holes. Install and secure solid rivets (1).

END OF TASK
135
 U.S. ORDNANCE

M60D
PROVEN UNDER FIRE

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MAINTENANCE: REAR SIGHT 32

THIS TASK COVERS: Inspection, Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level Materials/Parts
Direct Support Cloth, abrasive (crocus)
Dry cleaning solvent (SD)
Tools and Special Tools Gloves, rubber
Echelon Tool Kit Lubricant, solid film

INSPECTION
1. Inspect sight ring for breaks, bends, or cracks.

2. Check to see if sight ring remains in both upright and folded positions when under spring tension.

DISASSEMBLY
Using a 3/32-inch drive pin punch and hammer, fold sight ring (1) down flat and remove spring pin (2).
Using an open end adjustable wrench and flat tip screwdriver, remove hexagon self-locking nut (3). Apply
slight pressure on sight ring (1) and remove rear sight retainer (4), bearing ball (5), and helical
compression spring (6) from rear sight base (7).

5
3
6

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MAINTENANCE: REAR SIGHT 32

REPAIR
WARNING
Dry cleaning solvent (SD) is flammable. Do not clean parts near an
open flame or in a smoking area. Dry cleaning solvent evaporates
quickly and has a drying effect on the skin. When used without
protective gloves, solvent may cause irritation to or cracking of the skin.

1. Repair by replacing all authorized parts.

2. Clean rusted metal surfaces with crocus cloth. Wash thoroughly with dry cleaning solvent.

WARNING
If solid film lubricant comes in contact with any moving or internal part,
clean part with dry cleaning solvent.

3. Following manufacturer’s instructions for use, apply solid film lubricant to all external metal surfaces
showing wear and allow weapon to dry 12 hours before being used.

REASSEMBLY
1. Following manufacturer’s instructions for use, apply solid film lubricant to all external metal surfaces
showing wear and allow weapon to dry 12 hours before being used.
4

1
2
5
8

2. Position sight ring (4) on top of bearing ball (3) and rear sight base (2). Press down on rear sight
and insert rear sight retainer (5) from the right side (largest hole).

3. Install hexagon self-locking nut (1) on end of rear sight retainer (5).

4. Using an open end adjustable wrench and flat tip screwdriver, center sight ring (4) so pin hole (7)
aligns with groove (8) of rear sight retainer (5).

5. Using 1/8-inch drive pin punch and hammer, install spring pin (9).

END OF TASK
138
 U.S. Ordnance | M60D 7.62MM Machine Gun | Technical Manual

MAINTENANCE: COCKING HANDLE ASSEMBLY 33

THIS TASK COVERS: Inspection, Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level
Direct Support

Tools and Special Tools

Echelon Tool Kit

DISASSEMBLY
Compress and hold helical compression spring (1). Remove cocking handle retainer (2) and helical
compression spring (1) from cocking handle slide assembly (3).

3
1

REPAIR
Repair by replacing all authorized components.

REASSEMBLY
Insert helical compression spring (1) in cocking handle slide assembly (3). Press helical compression
spring (1) and slide cocking handle retainer (2) in cocking handle slide assembly (3). Release pressure
on helical compression spring (1).

END OF TASK
139
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MAINTENANCE: GUN RECEIVER ASSEMBLY 34

THIS TASK COVERS: Inspection, Disassembly, Repair, Reassembly

INITIAL SETUP
Maintenance Level Tools and Special Tools (CONT)
Depot Level Support Dial indicating scale (AAA-S-133 or equivalent)
Machinist’s steel rule (GGG-R-791 or equivalent)
Tools and Special Tools Small Arms Tool Kit (SC 4933-95-CL-A11)
Anvil bucking bar
Combination square (GGG-S-656
or equivalent)

DISASSEMBLY
1. Remove headless straight pin (1).

2. Remove safety pin (2).

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MAINTENANCE: GUN RECEIVER ASSEMBLY 34

DISASSEMBLY (cont)
3. Carefully drill out and discard solid rivets (4). Remove mounting plate (5).

4. Drill out and discard countersunk solid rivets (6). Do not remove bridge (7) from receiver assembly (8).

6 8

REPAIR
Repair by replacing all authorized components.

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MAINTENANCE: GUN RECEIVER ASSEMBLY 34

REASSEMBLY
Repair by replacing all authorized components.

1. Insert and tighten countersunk solid rivets (1) with a anvil bucking bar (2) by sliding the anvil
bucking bar in rear of receiver assembly (3) near bridge (4). Make sure countersunk solid rivets do
not protrude more than 0.010 of an inch inside or 0.005 of an inch outside, and peen countersunk
solid rivets.
3

2. Position mounting plate (5) on bottom of receiver assembly (3) and align holes. Install solid rivets
(6) and rivet securely. Rivets must not protrude more than 0.005 of an inch inside and must be
flush outside.

5
3

3. Slide safety pin (7) in holes of receiver assembly (3).

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MAINTENANCE: GUN RECEIVER ASSEMBLY 34

REASSEMBLY (cont)
4. Drive headless straight pin (1) into hole in receiver assembly (3) and center it.

3 1

TEST/INSPECTION

NOTE
Small arms gauges will be inspected and certified annually. The gauges
will not be used unless they are accompanied with the appropriate
gauge record.

Perform LOOSE RECEIVER TEST (see 20, pg. 92).

END OF TASK
143
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PREEMBARKATION INSPECTION OF MATERIEL 35

UNITS ALERTED FOR OVERSEAS MOVEMENT

GENERAL
This section provides special instructions for direct support personnel inspecting materiel in alerted units
scheduled for overseas duty. Inspection is for:

a) Determining serviceability.
b) Recognizing conditions that would cause failure.
c) Assuring proper maintenance at prescribed level.
d) Determining the ability of a unit to accomplish its maintenance and supply mission.

INSPECTION PROCEDURES
a. Exercise judgment regarding degree of inspection of integral parts within assemblies. Refer to PMCS procedures.

(1) Check headspace.

(2) Check firing pin protrusion using firing pin protrusion gauge.

(3) Check firing pin hole using plain cylindrical plug gauge 7458598 (20, pg 92).

(4) Measure operating rod helical compression spring. Spring must be a minimum of
23 1/4 inches long.

(5) Check sear cocking surface for roundness. Cocking surface must not be rounded more than
3/64 of an inch on top rear corner.

(6) Test receiver for looseness 20, pg. 92.

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PREPARATION FOR STORAGE OR SHIPMENT 36

SECURITY
Weapons will be stored in suitable containers to prevent theft, and as stated by the above security regulations.
The storage area must be covered and as moisture-free as possible.

CAUTION
Avoid contaminating the gas cylinder with lubricants.

NOTE
Manufacturer recommends the use of CLP/Break Free or other military
grade cleaning, lubrication, protection product for cleaning and preser-
vation of M60 D machine guns.

CLEANING AND PRESERVATION

1. Disassemble the M60D machine gun as necessary to accomplish cleaning and lubrication.

2. Clean all metallic surfaces of the M60D machine gun and all items with lubricating oil and dry with
clean, dry wiping rags. Clean nonmetallic surfaces with clean, dry wiping rags.

3. Preserve all metallic surfaces with lubricating.

4. Reassemble weapon except for barrel assembly.

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 MAINTENANCE
APPENDIX A | ALLOCATION CHART

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MAINTENANCE ALLOCATION CHART 37

INTRODUCTION
This introduction provides a general explanation of all maintenance and repair functions authorized
at various maintenance levels under the standard Army Maintenance System concept.

The Maintenance Allocation Chart (MAC) immediately following the introduction 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 shall be
consistent with the capacities and capabilities of the designated maintenance levels, which are shown
on the MAC in column (4) as:

Unit Includes two subcolumns, C (operator/crew) and O (unit) maintenance

Direct Support Includes an F subcolumn
General Support Includes a H subcolumn
Depot Includes a D subcolumn

The tools and test equipment requirements (immediately following the MAC) list the tools and test
equipment (both special tools and common tool sets) required for each maintenance function as
referenced from the MAC.

The remarks (immediately following the tools and test equipment requirements) contain supplemental
instructions and explanatory notes for a particular maintenance function.

MAINTENANCE FUNCTIONS
Maintenance functions will be limited to and defined as follows:

1. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or
electrical characteristics with established standards through examination (e.g., by sight, sound, or
feel). This includes scheduled inspection and gaugings and evaluation of cannon tubes.

2. Test. To verify serviceability by measuring the mechanical pneumatic, hydraulic, or electrical

characteristics of an item and comparing those characteristics with prescribed standards on a
scheduled basis, e. g., load testing of lift devices and hydrostatic testing of pressure hoses.

3. Service. Operations required periodically to keep an item in proper operating condition, e.g., to
clean (includes decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel,
lubricates, chemical fluids, or gases. This includes scheduled exercising and purging of recoil
mechanisms.

4. Adjust. To maintain or regulate, within prescribed limits, by bringing in proper position, or by

setting the operating characteristics to specified parameters.

5. Align. To adjust specified variable elements of an item to bring about optimum or desired
performance.

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MAINTENANCE ALLOCATION CHART 37

MAINTENANCE FUNCTIONS (cont)

6. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments of
test, measuring and diagnostic equipment used in precision measurement. Consist 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.

7. 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, seating, 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.

8. Replace. To remove an unserviceable item and install a serviceable counterpart in its place.
“Replace” is authorized by the MAC and assigned maintenance level is shown as the third position
code of the Source, Maintenance and Recoverability (SMR) code.

9. Repair. The application of maintenance services, including fault location/troubleshooting,

removal/installation, disassembly/assembly 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.

CAUTION
The following definitions are applicable to the “repair” maintenance
function:

Service - Inspect, test, service, adjust, align, calibrate, and/or replace.

Fault location/troubleshooting - The process of investigating and

detecting the cause of equipment malfunctioning: the act of isolating a
fault within a system or Unit Under Test (ET).

Disassembly/assembly - The step-by-step breakdown (taking apart) of a

spare/functional group coded item to the level of its least component,
that is assigned an SMR code for the level of maintenance under
consideration (i.e., identified as maintenance significant).

Actions - Welding, grinding, riveting, straightening, facing, remachinery,

and/or resurfacing.

10. 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. Overhaul does not normally return an item to like new condition.

11. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable
equipment to a like new condition in accordance with original manufacturing standards.

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MAINTENANCE ALLOCATION CHART 37

EXPLANATION OF COLUMNS IN THE MAC

Column (1). Group Number. Column (1) lists functional group code (FGC) numbers, the purpose of
which is to identify maintenance significant components, assemblies, subassemblies, and
modules with the next higher assembly (NHA).

Column (2). Component/Assembly. Column (2) contains the item names of components, assemblies,
sub-assemblies, and modules for which maintenance is authorized.

Column (3). Maintenance Function. Column (3) lists the functions to be performed on the item listed in
column (2). (For detailed explanation of these functions, refer to “Maintenance Functions”
outlined above).

Column (4). Maintenance Level. Column (4) specifies each level of maintenance authorized to perform
the function listed in column (3), by indicating work time required. This work time
figure represents the active time required to perform that maintenance function at the
indicated level of maintenance. If the number or complexity of the tasks within the listed
maintenance function varies 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 item, or system) to a
serviceable condition under typical field operating conditions. This time includes preparation
time (including any necessary disassembly/assembly time), troubleshooting/fault location
time, and quality assurance time in addition to the time required to perform the specific tasks
identified for the maintenance functions authorized in the MAC. The symbol designations
for the various maintenance levels are as follows:

C - Operator or Crew Maintenance

O - Unit Maintenance
F - Direct Support Maintenance
L - Specialized Repair Activity (SRA)
H - General Support Maintenance
D - Depot Maintenance

NOTE
The ‘L” maintenance level is not included in column (4) of the MAC.
Functions to this level of maintenance are identified by a work time figure
in the “H” column of column (4), and an associated reference code is
used in the REMARKS column (6). The code is keyed to the remarks
and the SRA complete repair application is explained there.

Column (5). Tools and Equipment Reference Code. Column (5) specifies, by code, those common tool
sets (not individual tools), common Test, Measurement and Diagnostic Equipment (TMDE),
and special tools, special TMDE and special support equipment required to perform the
designated function. Codes are keyed to the entries in the tools and test equipment table.

Column (6). Remarks Code. When applicable, this column contains a letter code, in alphabetic order,
which is keyed to the remarks table entries.

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MAINTENANCE ALLOCATION CHART 37

EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS

Column (1). Tool or Test Equipment Reference Code. The tool or test equipment reference code
correlates with a code used in Column (5) of the MAC.

Column (2). Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment.

Column (3). Nomenclature. Name or identification of the tool or test equipment.

Column (4). National Stock Number (NSN). The NSN of the tool or test equipment.

Column (5). Tool Number. The manufacturer’s part number, model number, or type number.

EXPLANATION OF COLUMNS IN REMARKS

Column (1). Reference Code. The code recorded in column (6) of the MAC.

Column (2). Remarks. Remarks. This column lists information pertinent to the maintenance function being
performed as indicated in the MAC.

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MAINTENANCE ALLOCATION CHART 37

Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(1) (2) (3) (4) (5) (6)

GROUP COMPONENT MAINTENANCE MAINTENCE TOOLS REMARKS
NUMBER ASSEMBLY FUNCTION LEVEL AND
UNIT DS GS DEPOT EQPT
REF CODE
C O F H D
00 MACHINE GUN, Inspect, Test 0.1 0.2 0.2 C and N
7.62-MM, M60D 0.5 1 thru 8, A, D, F &
(11699750) 10 G
15.0 9 and 13 C, E, F, G,
J
01 GRIP AND Inspect 0.1 0.1 N
TRIGGER Service 0.1
ASSEMBLY Remove/ 0.1
(11699751) Install
Replace 0.1 9 and 13
Repair 0.3 9

02 BREECH BOLT Inspect 0.1 0.1 N

ASSEMBLY Test 0.1 A, F and G
(11010357) Service 0.1 0.1 1 and 4
Remove/ 0.1
Install
Replace 0.1
Repair 0.2 0.2 9 and 13 I and

03 OPERATING ROD Inspect 0.1 0.1 0.1

ASSEMBLY Service 0.1
(9362510) Remove/ 0.1
Install 0.1
Replace 0.1 0.1 9 and 13 H and
Repair

04 SEAR AND Inspect 0.1 0.1 0.1 N

SAFETY Service 0.1
HOUSING Remove/ 0.1
ASSEMBLY Install
(11699773) Replace 0.1
Repair 0.1 13

05 BARREL Inspect 0.1 0.1 0.1 N

ASSEMBLY Test 0.3 2, 3, 5, & A, E, F &
(7269027) 6 G
Service 0.1
Remove/ 0.1
Install 0.1
Replace 0.2
Repair 0.1

070101 Machine Gun Leg Replace 0.1

(Right)A Repair 0.1 9
(7269047)

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MAINTENANCE ALLOCATION CHART 37

Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)

(1) (2) (3) (4) (5) (6)

GROUP COMPONENT MAINTENANCE MAINTENCE TOOLS REMARKS
NUMBER ASSEMBLY FUNCTION LEVEL AND
UNIT DS GS DEPOT EQPT
REF CODE
C O F H D
070102 Machine Gun Leg Replace 0.1
(Left) Repair 0.1 9
(7269046)

06 COVER Inspect 0.1 0.1 0.1

ASSEMBLY Service 0.1
(7269114) Replace 0.1
Repair 0.1 0.3 9 and 13

0801 Feed Cam Replace 0.1

Assembly Repair 0.1 9 and 13
(11699814)

0802 Lever Assembly Replace 0.1

(7269119) Repair 0.1 9

0803 Feed Pawl Replace 0.1

Assembly Repair 0.1 9
(7269120)

0804 Cover Housing Replace 0.5

Assembly Repair 0.2 0.5 9
(7269118)

07 CARTRIDGE Inspect 0.1 0.1 N

FEED TRAY Service 0.1
ASSEMBLY Replace 0.1
(7792096) Repair 0.2 13

08 REAR SIGHT Inspect 0.1 0.1 0.1

(11699796) Service 0.1
Replace 0.2
Repair 0.2 13

09 COCKING Inspect 0.1 0.1 0.1 N

HANDLE Service 0.1 0.2
ASSEMBLY Replace 0.2
(7791621) Repair 0.2 9

10 GUN RECEIVER Inspect 0.1 0.1 0.1 N

ASSEMBLY Test 0.3 7 and 8 A and D
(11699805) Service 0.1 0.2
Repair 9,10&13 B, C, J, K

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MAINTENANCE ALLOCATION CHART 37

Table 2. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

TOOL OR
TEST NATIONAL TOOL
EQUIPMENT MAINTENANCE NOMENCLATURE
LEVEL STOCK NUMBER NUMBER
REF CODE

1 F GAUGE, FIRING PIN PROTRUSION 4933-00-653-3373 7274754

2 F GAUGE, HEADSPACE: 1.6455 in. 4933-00-647-3698 7274790

3 F GAUGE, PLUG PLAIN CYLINDRICAL 5220-00-745-8598 7458598

4 F GAUGE, TEST BOLT 4933-00-653-9550 7799699

5 F RULE, STEEL, MACHINIST’S 5210-00-234-5223 5910297

6 F SCALE, DIAL INDICATING 5210-00-254-4634 GGG-R-791

or equivalent

7 F TOOL KIT, SMALL ARMS: FIELD 4933-00-754-0664 AAA-S-133

MAINTENANCE, POST, CAMP, AND or equivalent
STATION

8 F SQUARE, COMBINATION 5120-00-078-8949 SC 4933-95-

CL-A11

9 F STOP, TOOL, SCREW 5120-00-077-2081 GGG-S-656

or equivalent

10 F TOOL BOX, PORTABLE 5140-00-473-6260 8436748

11 O TOOL KIT, SMALL ARMS REPAIRMAN 5180-00-357-7770 D5-15-2119

12 F DRILL, TWIST: 1/8 in. dia., 5 1/8 in. 5133-00-262-2180 GGG-D-751

long

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MAINTENANCE ALLOCATION CHART 37

Table 3. Remarks for Machine Gun M60D

REFERENCE REMARKS
CODE

A Gauge annually using appropriate gauges.

B Receiver is a serialized item and not replaceable below depot level maintenance.

C Restamping or altering the serial number is prohibited.

D Receiver looseness check will be accomplished at time of repair and/or annual gauging cycle.

E Barrel and carry handle assembly will not be interchanged between weapons due to
headspace requirements.

F Barrel and carry handle assembly will be issued only when complete weapon is checked for
headspace requirements using the bolt that will be used in barrel.

G Breech bolt assembly will not be interchanged between weapons, and new breech bolt
assembly will be checked for proper headspace requirements before returning to service.

H Burrs on the operating rod tower and yoke area is an inherent condition of the weapon.
Organizational maintenance will remove small burrs and upset metal. Operating rod
will not be rejected for this condition.

I Breech bolt assembly feed lug is prone to chipping and is an inherent condition of the
weapon. Organizational maintenance will smooth surfaces by stoning. Breech bolt will
not be rejected for this condition until the bottom camming lug begins to wear.

J Fabricated bucking bar anvil will be used to tighten rivets in receiver bridge.

K Riveting fixture will be used to tighten rivets in the magazine bracket to receiver surface.

L When a weapon is received by direct support with a maintenance request, all gaging
requirements must be checked as a standard maintenance procedure. In addition, the
weapon must be inspected and any other deficiencies found will be repaired, or noted
for repair, at the appropriate maintenance level. As a minimum requirement, the M60D
headspace must be verified annually by direct support personnel. This requirement could
be increased to four times a year or after each training cycle depending on usage factors.

154
U.S. ORDNANCE

M60D
PROVEN UNDER FIRE

155
 U.S. ORDNANCE

M60D
PROVEN UNDER FIRE

156
 REPAIR PARTS AND
APPENDIX B | SPECIAL TOOLS LIST

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GROUP 00: MACHINE GUN, 7.62MM, M60D 38

REPAIR PARTS (1 OF 2)

4
1
3
10
15
14 *
12

8
9 7
11

13

*SEE FIGURE 2 FOR FURTHER DISASSEMBLY

Figure 1. Group 00 Machine Gun, 7.62-MM, M60D

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Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)

GROUP 00: MACHINE GUN, 7.62-MM, M60D

(1 of 2)

FIG. 1: MACHINE GUN,7.62-MM

1 PAOZZ 96906 MS17990C519 550 PIN, QUICK RELEASE 1

2 AOOOO 19205 7792096 445 TRAY ASSEMBLY, CARTRIDGE FEED 1

(SEE FIG. 21 FOR BREAKDOWN)

3 PAOZZ 19205 8427869-7 551 WIRE ROPE ASSEMBLY 2

4 PAOZZ 19204 8427871 552 SLEEVE, SWAGING 1

5 PAOZZ 96906 MS16562-151 546 PIN, SPRING 1

6 PAOZZ 19205 11699793 548 ADAPTER, GUN 1

7 PAOZZ 19204 11699785 549 SPRING, FLAT 1

8 AOOOO 19205 11699773 566 SEAR AND SAFETY HOUSING 1

(SEE FIG. 10 FOR BREAKDOWN)

9 PAFZZ 19200 11699790 553 LINK AND SPRING, SEAR ASSEMBLY 1

10 MOOZZ 19204 MS20995C32 434 WIRE, SAFETY 0.032 IN. 1

(MAKE FROM NSN 9505-00-293-4208)

11 PAOZZ 19205 11699789 544 NUT, SEAR LINK 1

12 PAOZZ 19204 11699787 545 BOOT, DUST AND MOISTURE 1

13 PAOZZ 96906 MS24665-18 892 PIN, COTTER 2

14 PAOOO 19200 11699751 497 GRIP AND TRIGGER ASSEMBLY 1

(SEE FIG. 6 FOR BREAKDOWN)

15 PAOZZ 19205 11699788 542 PIN, GROOVED, HEADED 1

END OF FIGURE
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GROUP 00: MACHINE GUN, 7.62MM, M60D 39

REPAIR PARTS LIST (2 OF 2)

2 4

3
1 9
8
9 6
5
8

Figure 2. Group 00 Machine Gun, 7.62-MM, M60D

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Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)

GROUP 00: MACHINE GUN, 7.62-MM, M60D

(2 of 2)

FIG. 2: MACHINE GUN,7.62-MM

1 PAFZZ 19204 7790554 380 LEVER, LOCK-RELEASE 1

2 PAFZZ 19204 7792069 479 PIN, STRAIGHT, HEADED 2

3 PAFZZ 19204 7790553 381 PAWL 1

4 PAOOO 19205 11699796 550 SIGHT, REAR 1

(SEE FIG. 25 FOR BREAKDOWN)

5 XAFDD 19205 11699805 877 RECEIVER ASSEMBLY, GUN 1

(SEE FIG. 28 FOR BREAKDOWN)

6 PAFZZ 19204 11686976 663 BRACKET, MAGAZINE 1

7 PAFZZ 19204 7792086 486 RIVET, SOLID 4

8 PAFZZ 19204 7790551 892 SPRING, HELICAL 2

9 PAFZZ 96906 MS24665-18 382 PIN, COTTER 2

END OF FIGURE
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GROUP 01: GRIP AND TRIGGER ASSEMBLY 40

REPAIR PARTS LIST

5 4
3

8
7

Figure 3. Group 01 Grip and Trigger Assembly.

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Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 01: GRIP AND TRIGGER ASSEMBLY

FIG. 3: M60D GRIP AND TRIGGER

ASSEMBLY

1 XAOZZ 19200 11699752 498 SPADE GRIP TRIGGER AND FRAME ASSEMBLY 1
2 PAOZZ 19205 11699769 539 KNOB AND PIN ASSEMBLY 1
3 PAOZZ 96906 MS16562-127 1952 PIN. SPRING 1
4 PAOZZ 19205 11699768 534 PIN, SHOULDER 1
5 PAOZZ 19204 11699767 535 SPRING, HELICAL COMPRESSION 1
6 PAOZZ 19204 11699756 524 SPRING, HELICAL 2
7 PAOZZ 96906 MS24665-86 522 PIN, COTTER 2
8 PAOZZ 19205 11699757 523 PIN, GROOVED, HEADED 2
9 PAOZZ 19205 11699772 538 RING, RETAINING 1

END OF FIGURE
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GROUP 02: BREECH BOLT ASSEMBLY. 41

REPAIR PARTS LIST

3 8

7
6
2

9
1
10

11
12

13

Figure 4. Group 02 Breech Bolt Assembly.

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Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 02: BREECH BOLT ASSEMBLY
11010357

FIG. 4: BREECH BOLT ASSEMBLY

1 PAOZZ 19200 9362505 889 PLUG ASSEMBLY, BOLT 1

2 PAOZZ 19204 7269063 70 ACTUATOR ASSEMBLY, CAM 1

3 PAOZZ 19204 7269087 67 SPRING, HELICAL 1

4 PAOZZ 19204 7269065 59 GUIDE, FIRING PIN 1

5 PAOZZ 19204 11010376 2548 PIN, FIRING 1

6 PAOZZ 96906 MS39086-81 581 PIN, SPRING 1

7 PAOZZ 19204 7269085 903 SPRING, HELICAL 1

8 PAOZZ 19204 11010375 627 EJECTOR, CARTRIDGE 1

9 PAOZZ 19204 7269083 65 PLUNGER, EXTRACTOR 1

10 PAOZZ 19204 7269086 69 SPRING, HELICAL 1

11 PAOZZ 19204 7790907 2551 EXTRACTOR, CARTRIDGE 1

12 PAOZZ 19204 11010358 626 BOLT, BREECH 1

13 PAOZZ 19204 7792920 417 PIN, STRAIGHT, HEADLESS 1

END OF FIGURE
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GROUP 03: OPERATING ROD ASSEMBLY 42

REPAIR PARTS LIST

Figure 5. Group 03 Operating Rod Assembly.

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Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 03: OPERATING ROD ASSEMBLY

FIG. 5: OPERATING ROD ASSEMBLY

1 PAFZZ 19200 9362506 2555 ROLLER, YOKE 1

2 XAFZZ 19200 9362509 2558 YOKE AND TUBE ASSEMBLY 1

3 PAFZZ 96906 MS51923-105 636 PIN, SPRING 1

4 PAFZZ 19200 9362507 2556 PIN, STRAIGHT, HEADLESS 1

END OF FIGURE
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GROUP 04: SEAR AND SAFETY HOUSING ASSEMBLY 43

REPAIR PARTS LIST

3
7

10

Figure 6. Group 04 Sear and Safety Housing Assembly.

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Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 04: SEAR AND SAFETY HOUSING ASSEMBLY

FIG. 6: M60D SEAR AND SAFETY

HOUSING ASSY

1 PAOZZ 19204 11699775 578 SPRING, HELICAL 1

2 PAOZZ 19205 11699776 577 PLUNGER, SAFETY 1

3 PAOZZ 19204 11699779 574 PIN, GROOVED, HEADED 1

4 PAOZZ 19204 11699778 576 BUSHING, SLEEVE 1

5 PAOZZ 19204 7269209 201 SEAR 1

6 PAOZZ 19204 7269207 199 PLUNGER, SEAR 1

7 PAOZZ 19204 7269211 203 SPRING, HELICAL 1

8 PAOZZ 19204 11699777 575 SAFETY, SMALL ARMS 1

9 PAOZZ 19205 11699780 568 ACTIVATOR, SEAR 1

10 XAOZZ 19205 11699774 567 HOUSING, SEAR 1

END OF FIGURE
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GROUP 05: BARREL ASSEMBLY 44

REPAIR PARTS LIST

7
8

13 2
10 11
3
12

1 6

Figure 7. Group 05 Barrel and Carry Handle Assembly.

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Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 05: BARREL ASSEMBLY

FIG. 7: BARREL ASSEMBLY

1 PAFZZ 19204 7269028 2402 BARREL AND CARRY HANDLE ASSEMBLY 1

2 PAFZZ 19204 7269031 758 LOCKNUT, GAS, CYLINDER 1

3 PAFZZ 19204 7269035 762 PLUG, VENT 2

4 PAFZZ 19204 7791247 2413 PISTON, GAS 1

5 NPNLW 19204 MS2099SC32 434 WIRE, SAFETY 0.032 IN. CUT FROM 1
NSN 9505-00-293-4208

6 PAFZZ 19204 7269030 2531 EXTENSION, GAS CYLINDER 1

7 PAFZZ 19204 7269034 761 SUPPRESSOR, FLASH 1

8 PAFZZ 96906 12599983 913 PIN, STRAIGHT 1

9 PAOZZ 19205 7269213 CARRY HANDLE ASSEMBLY 1

10 PAOZZ 19205 7269302 HELICAL COMPRESSION SPRING 2

11 PAOZZ 19204 7269250 DETENT PLUNGER 2

12 PAOZZ 19205 11010377 BARREL LOCK RING 1

13 PAOZZ 96906 MS30986-81 SPRING PIN 1

END OF FIGURE
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GROUP 0701: MACHINE GUN BIPOD 45

REPAIR PARTS LIST

10
10 9
9 1
11
11

3 3

7 7

6 8
8
5

Figure 8. Group 0701 Machine Gun Bipod.

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Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 0701: BIPOD ASSEMBLY

FIG. 8: MACHINE GUN BIPOD

1 SB2804 2804 PIVOT ASSEMBLY, BIPOD 1

2 SC2807 2807 LEG ASSEMBLY, BIPOD 1

3 SB2808 2808 LEG ASSEMBLY INNER 2

4 SB2811 2811 LEG ASSEMBLY, OUTER 2

5 SB2814 2814 LOCK, LEG, BIPOD 2

6 SB2815 2815 RING, LOCK, BIPOD 2

7 SB2816 2816 PIN, LOCK, BIPOD 2

8 2843 2843 PIN, DOWEL 2

9 SB25064 2666 SPRING, HELICAL COMPRESSION 2

10 7269050 753 PLUNGER, SPRING, LEG 2

11 SC2817 2817 SCREW, PIVOT, LEG 2

END OF FIGURE
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GROUP 07: COVER AND FEED LEVER ASSEMBLY, 46

REPAIR PARTS LIST

2
1

6
5

7
8

Figure 9. Group 07 Cover and Lever Assembly.

174
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Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 07: COVER AND FEED LEVER ASSEMBLY

FIG. 9: COVER AND FEED LEVER ASSEMBLY

1 PAFFF 19204 11699814 653 CAM ASSEMBLY, FEED (SEE FIG.16 FOR 1
ASSEMBLY BREAKDOWN)

2 PAFZZ 19204 7269117 100 GUIDE, CARTRIDGE REAR 1

3 PAFZZ 19204 7269116 99 GUIDE, CARTRIDGE FRONT 1

4 AFFFF 19204 7269119 147 LEVER ASSEMBLY, FEED (SEE FIG.16 1

FOR ASSEMBLY BREAKDOWN)

5 PAOZZ 19204 11686315 599 SPRING, HELICAL 1

6 PAFFF 19204 7269120 150 PAWL ASSEMBLY, CAM FEED (SEE FIG.17 1
FOR ASSEMBLY BREAKDOWN)

7 PAFZZ 19204 11010152 593 SHAFT, STRAIGHT 1

8 PAOZZ 96906 MS24665-18 892 PIN, COTTER 1

9 PAFHH 19204 7269118 29056 HOUSING ASSEMBLY, COVER (SEE FIG. 1

18 FOR ASSEMBLY BREAKDOWN)

END OF FIGURE
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GROUP 0801: FEED CAM ASSEMBLY, 47

GROUP 0802: FEED LEVER ASSEMBLY,
REPAIR PARTS LIST

2
1

4 6
5

Figure 10. Group 0801 and 0802 Feed Cam Assembly and Feed Lever Assembly

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 0801: FEED CAM ASSEMBLY
GROUP 0802: FEED LEVEL ASSEMBLY

FIG. 10: FEED CAM ASSEMBLY AND

FEED LEVER ASSEMBLY

1 PAFZZ 19204 7269123 132 PLUNGER, RETAINER 1

2 PAFZZ 19204 7269125 134 SPRING, HELICAL 1

3 XAFZZ 19204 11699817 654 CAM ASSEMBLY 1

4 PAFZZ 19204 7269124 133 RETAINER, FEED CAM 1

5 PAFZZ 19204 7269146 148 CLIP, SPRING LEVER 1

6 PAFZZ 19204 7269145 149 LEVER, FEED 1

END OF FIGURE
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GROUP 0803: FEED PAWL ASSEMBLY, 48

REPAIR PARTS LIST

Figure 11. Group 0803 Feed Pawl Assembly.

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 0803: FEED PAWL ASSEMBLY

FIG. 11: FEED PAWL ASSEMBY

1 7269120 FEED PAWL 1

END OF FIGURE
177
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GROUP 0804: COVER HOUSING ASSEMBLY, 49

REPAIR PARTS LIST

3 8

4 6

2
1

Figure 12. Group 0804 Cover Housing Assembly

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Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 0804: COVER HOUSING ASSEMBLY

FIG. 12: COVER HOUSING ASSEMBLY

1 PAFZZ 19204 7269136 104 LATCH, COVER 1

2 PAFZZ 19204 7791271 109 SPRING, HELICAL 1

3 PAHZZ 19205 7791270 413 LATCH LEVER ASSEMBLY 1

4 PAFZZ 19204 7269137 126 PIN, LATCH LEVER 1

5 PAFZZ 19200 9362520 888 SPRING BUMPER CAM 1

6 PAHZZ 19204 7269141 108 SPRING, HELICAL 2

7 PAHZZ 19204 7269144 111 WASHER, FLAT 2

8 PAHZZ 19205 7269143 110 PIN, SHOULDER, HEADED 2

9 XAHZZ 19204 7269128 641 FRAME ASSEMBLY, COVER 1

END OF FIGURE
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 U.S. Ordnance | M60D 7.62MM Machine Gun | Technical Manual

GROUP 9: CARTRIDGE FEED TRAY ASSEMBLY 50

REPAIR PARTS LIST

4 6
5

Figure 13. Group 9 Cartridge Feed Tray Assembly.

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 9: CARTRIDGE FEED TRAY ASSY

FIG. 13: CARTRIDGE FEED TRAY ASSY

1 7792096 445 CARTRIDGE FEED TRAY ASSEMBLY 1

2 XAOZZ 19204 7792097 446 FRAME ASSEMBLY, CARTRIDGE TRAY 1

3 PAOZZ 19204 7790724 320 SHAFT, CARTRIDGE 1

4 PAOZZ 19204 7269333 319 ROLLER, LINEAR-ROTARY 2

5 PAOZZ 19204 7269332 317 PAWL, CARTRIDGE RETAINER 1

6 PAOZZ 19204 7269335 321 SPRING, HELICAL 1

END OF FIGURE
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GROUP 10: REAR SIGHT 51

REPAIR PARTS LIST

7 4

Figure 14. Group 10 Rear Sight.

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 10: REAR SIGHT

FIG. 14: M60D REAR SIGHT

1 PAFZZ 96906 MS16562-119 563 PIN, SPRING 1

2 PAFZZ 19204 11699799 565 RING, SIGHT 1

3 PAFZZ 96906 MS19059-2412 561 BALL, BEARING 1

4 PAFZZ 96906 MS24585-75 560 SPRING, HELICAL 1

5 PAFZZ 19205 11699798 562 RETAINER, REAR SIGHT 1

6 PAFZZ 19205 11699797 559 BASE, REAR SIGHT 1

7 PAFZZ 19205 11699763 564 NUT, SELF-LOCKING 1

END OF FIGURE
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GROUP 11: COCKING HANDLE ASSEMBLY, 52

REPAIR PARTS LIST

3
2

Figure 15. Group 11 Cocking Handle Assembly.

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 11: COCKING HANDLE ASSEMBLY

FIG. 15: COCKING HANDLE ASSEMBLY

1 PAFZZ 19205 7269237 222 RETAINER, COCKING HANDLE 1

2 PAFZZ 19205 7791522 487 SPRING, HELICAL 1

3 PAFZZ 19205 7269239 225 SLIDE ASSEMBLY 1

END OF FIGURE
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GROUP 12: GUN RECEIVER ASSEMBLY 53

REPAIR PARTS LIST

2
1

3
4

Figure 16. Group 12 Gun Receiver Assembly.

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 12: GUN RECEIVER ASSEMBLY

FIG. 16: M60D GUN RECEIVER ASSEMBLY

1 PAFZZ 19205 7269411 364 RIVET, SOLID 4

2 PAFZZ 19204 7792972 881 RIVET, SOLID 2

3 PAFZZ 19204 7792974 401 PLATE, MOUNTING 1

4 XADDA 19200 11686307 877 RECEIVER ASSEMBLY 1

END OF FIGURE
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GROUP 9500: ECHELON TOOL KIT 54

20
19 18
1 25 24

23

2
22

3
26
4

21

10

9 27 14 15
12
8 13
11 16

17

Figure 17. Group 9500 Echelon Tool Kit.

184
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Table 1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(1) (2) (3) (4) (5) (6) (7)

ITEM SMR FSCM PART US ORD DESCRIPTION QTY
NO CODE NUMBER PART NO AND USABLE ON
CODE (UOC)
GROUP 9500: ECHELON TOOL KIT

FIG. 17: ECHELON TOO KIT

1 B123 Section, Cleaning Rod

2 B55 Holder, Cleaning Patch

3 2505 Wrench, Screwdriver and Reamer

4 B42 Extractor, Ruptured CTG

5 29026 M60 Brush, Chamber

6 29028 M60 Brush, Bore

7 29021 M60/M2 Patch, Cleaning

8 29019 Punch, Starrett 3/32”

9 29018 Punch, Starrett 1/16”

10 29025 Brush, Receiver

11 29011 Brass Punch 5/16” x ½”

12 29013 Long Nose Pliers

13 29024 M2/M60 Slip 2000 Lubrication

14 29159 Firing Pin Protrusion Gauge

15 7799699 Bolt Gauge

16 29881 Diamond Needle Files

17 29148 Spool, Safety Wire

18 29160 Safety Wire Pliers

19 29033 Pliers, 6”

20 29010 Steel Hammer

21 2537 Wrench, Cover Latch

22 29048 3/32” Allen Wrench

23 29009 Brass Hammer

24 29015 1/8” Allen Wrench

25 29016 Scribe

26 29014 Screwdriver

27 29003 Field Headspace Gauge

185
 U.S. ORDNANCE

M60D
PROVEN UNDER FIRE

186
 U.S. Ordnance | M60D 7.62MM Machine Gun | Technical Manual

CONTACT U.S. ORDNANCE IF WEAPON HAS ISSUES OR TO REPALACE PARTS

Website: W W W.USORD.COM | Phone: 7 7 5.3 4 3.1 320 | Fax : 7 7 5.3 4 3.1 331

Please be clear with your request.

Before contacting U.S. Ordnance know and refer to the
PART NUMBER, PAGE NUMBER, FIGURE NUMBER
when describing the issue or part replacemnet.

187
 USORD.COM

P h:7 7 5.34 3. 1 320 I SO 9001:2088 Fa x:7 7 5.34 3. 1 33 1

188