1993 Launcher, Grenade, 40mm, m203, We 199p

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ARMY TM 9-1010-221-23&P
AIR FORCE TO 11W3-9-4-2
MARINE CORPS TM 07700A-23&P/2
NAVY SW 370-AE-MMI-010
Supersedes copy dated August 1985
TECHNICAL MANUAL

UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL
INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST
FOR
LAUNCHER, GRENADE, 40MM, M203, W/E
(1010-00-179-6447) (EIC:4QB)
AND
LAUNCHER, GRENADE, 40MM, M203A1, W/E
(1010-01-434-9028) (EIC:4QH)
AND
(1010-01-495-8511) (EIC:4QJ)

GRENADE LAUNCHER
40MM, M203A1
CELIA AND NEIL
GRENADE LAUNCHER
40MM, M203A1
CELIA AND NEIL

SERVICE UPON RECEIPT 2-2

UNIT PREVENTIVE MAINTENANCE
CHECKS AND SERVICES

2-3

UNIT TROUBLESHOOTING 2-8

UNIT MAINTENANCE
PROCEDURES

2-14

DIRECT SUPPORT
TROUBLESHOOTING

3-1

DIRECT SUPPORT
MAINTENANCE PROCEDURES

3-4

ALPHABETICAL INDEX INDEX 1

DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government agencies and their contractors. This
publication is required for administration and operational purposes, as determined on July 1, 1991. ARMY ONLY:
Other requests for this document shall be referred to: AMSTA-LC-CIP-WT, TACOM-RI, 1 Rock Island Arsenal, Rock
Island, IL 61299-7630. AIR FORCE ONLY: Other requests for this document shall be referred to Warner Robins,
ALC/LKCB, Robins AFB, GA 31098-1640. MARINE CORPS ONLY: Other requests for this document shall be
referred to: Commander, Marine Corps Logistics Base (Code 850), Albany, GA 31704-5000. NAVY ONLY: Other
requests for this document shall be referred to: Commander, Code 2021, Bldg 2521, NAVSURF WARCENDIV, 300
Hwy 361, Crane, IN 47522-5001.

WARNING: This document contains export-controlled technical data whose export is restricted by the Arms Export
Control Act (Title 22, U.S.C. Sec 2751 et seq.) or Executive Order 12470. Violation of these export laws are subject to
severe criminal penalties.

DESTRUCTION NOTICE: For unclassified, limited documents, destroy by any method that will prevent disclosure of
contents or reconstruction of the document.
HEADQUARTERS, DEPARTMENT OF THE ARMY,
AIR FORCE, U.S. MARINE CORPS AND NAVY
JANUARY 1993
ARMY TM 9-1010-221-23&P

WARNING

Clear the weapon before starting an inspection. Do not squeeze the trigger until the weapon has been cleared.
Inspect the chamber to be sure that it is empty. Avoid having live ammunition where maintenance is performed.

Using the old style firing pin, Part Number 8448327, can cause injury to personnel and damage to equipment
when firing a live round. The old firing pin must be replaced by the new firing pin, Part Number 12002970,
whenever the old pin is identified in the weapon.

To avoid injury to your eyes, use care when removing and installing spring-loaded parts.

Dry cleaning solvent is FLAMMABLE and TOXIC and must be kept away from open flames and used in a well-
ventilated area. Use of rubber gloves is necessary to protect the skin when washing grenade launcher parts.

Appropriate eye protection is recommended when cleaning your weapon and/or its parts.

All Active Army M203/M203A1/M203A2 grenade launchers must be inspected and gaged at least once annually
for safety. All Army Reserve and Army National Guard M203/M203A1/M203A2 grenade launchers must be
inspected and gaged at least once every two years, after the initial inspection/gaging procedures have been
accomplished. The initial gaging procedures for Active Army, Army Reserve, and Army National Guard are
required one year from receipt of the weapons. This two-year interval may be maintained unless preventive
maintenance checks and services (PMCS) or other physical evidence indicates that an individual unit's
M203/M203A1/M203A2 grenade launchers require inspection at a more frequent interval. If it is determined that
a yearly inspection is necessary for an individual unit, only that unit will be affected. This will not affect other units
in regard to the interval of inspection.

For further information on first aid, refer to FM 4-25.11.

a Change 4 PIN: 070835-004

ARMY TM 9-1010-221-23&P
CHANGE HEADQUARTERS
DEPARTMENTS OF THE ARMY,
NO. 4 AIR FORCE, MARINE CORPS,
AND NAVY
Washington, DC, 15 December 2003
UNIT AND DIRECT SUPPORT
MAINTENANCE MANUAL
INCLUDING
REPAIR PARTS AND SPECIAL TOOLS LIST
FOR
(1010-00-179-6447) (EIC:4QB)
AND
(1010-01-434-9028) (EIC:4QH)
AND
(1010-01-495-8511) (EIC:4QJ)
DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government agencies and their contractors. This publication
is required for administration and operational purposes, as determined on October 1, 1997. ARMY ONLY: Other requests for
this document shall be referred to: AMSTA-LC-CIP-WT, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-7630.
AIR FORCE ONLY: Other requests for this document shall be referred to Warner Robins, ALC/LKCB, Robins AFB, GA
31098-1640. MARINE CORPS ONLY: Other requests for this document shall be referred to: Commandant of the Marine
Corps, (Code ARD), Washington, and DC 20380-0001. NAVY ONLY: Other requests for this document shall be referred to:
ommander, Code 4081, Bldg 2521, NAVSURF WARCENDIV, 300 Hwy 361, Crane, IN 47522-5001. C

DESTRUCTION NOTICE: For unclassified, limited documents, destroy by any method that will prevent disclosure of contents
r reconstruction of the document. o
TM 9-1010-221-23&P, 12 January 1993, is changed as follows:

1

. Remove old pages and insert new pages indicated below.
2. New or changed material is indicated by vertical bar in the margin of the page.

3

. New or changed illustrations are indicated by a miniature pointing hand highlighting the change.
Remove Pages Insert Pages

A/(B blank) A/(B blank)
i through iv i through iv
v and 1-0 blank/1-0
1-1 through 1-6 1-1 through 1-6
2-3 and 2-4 2-3 and 2-4
2-15 and 2-16 2-15 and 2-16
2-29 and 2-30 2-29 and 2-30
2-45/(2-46 blank) 2-45 through 2-62
3-21 and 3-22 3-21 and 3-22
3-27 and 3-28 3-27 and 3-28
4-1 through 4-19/(4-20 blank) None
A-1 and A-2 A-1 and A-2
B-5 through B-7/(B-8 blank) B-5 through B-7/(B-8 blank)
C-7 and C-8 C-7 and C-8
C-1-1 through C-10-1 C-1-1 through C-10-1
I-1 through I-4 I-1 through I-4
D-1 through D-3/(D-4 blank) D-1 through D-3/(D-4 blank)
Index 1 and Index 2 Index 1 and Index 2

Cover/Warning Cover/Warning
4. File this change sheet in the front of the publication for reference purposes.

By Order of the Secretary of the Army:

PETER J. SCHOOMAKER
General, United States Army
Chief of Staff

0322402

By Order of the Secretary of the Air Force:

Official:

JOHN P. JUMPER
General, United States Air Force
Chief of Staff
LESTER L. LYLES
General, United States Air Force
Commander, AFMC

By Order of the Marine Corps:

Official:

D. R. BLOOMER
Colonel, USMC
Director, Program Support
Marine Corps Systems Command

DISTRIBUTION: To be distributed in accordance with the Initial Distribution Number (IDN) 400545 requirements
for TM 9-1010-221-23&P.

ARMY TM 9-1010-221-23&P

CHANGE HEADQUARTERS
NO. 3 AIR FORCE, MARINE CORPS,
AND NAVY
Washington, DC, 7 September 2001

MAINTENANCE MANUAL
INCLUDING
FOR
(1010-00-179-6447) (EIC:4QB)
AND
LAUNCHER, GRENADE, 40-MM, M203A1, W/E
(1010-01-434-9028) (EIC:4QH)

is required for administration and operational purposes, as determined on October 1, 1997. ARMY ONLY: Other requests for
this document will be referred to: AMSTA-LC-CIT-WP Tech Pubs, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-
7630. AIR FORCE ONLY: Other requests for this document must be referred to Warner Robins ALC/LZDTA, Robins AFB,
GA 31098-5609. MARINE CORPS ONLY: Other requests for this document must be referred to: Commandant of the Marine
Corps, (Code ARE), Washington, D.C. 20380-0001. NAVY ONLY: Other requests for this document must be referred to:
Commander, Code 4081 Bldg 2521, NAVSURF WARCENDIV, 300 Hwy 361, Crane, IN 47522-5001.

or reconstruction of the document.

TM 9-1010-221-23&P, 12 J anuary 1993, is changed as follows:

1. Remove old pages and insert new pages indicated below.


3. New or changed illustrations are indicated by a miniature pointing hand highlighting the change.


None A/(B blank)
i through iv i through iv
2-7 and 2-8 2-7 and 2-8
2-15 and 2-16 2-15 and 2-16
2-18.1 and 2-18.2 2-18.1 and 2-18.2
4-1 and 4-2 4-1 and 4-2
4-5 through 4-19/20 blank 4-5 through 4-19/20 blank
C-1-1 and Fig C-2 C-1-1 and Fig C-2
C-2-1 and C-2-2 C-2-1 and C-2-2
C-2A-1 through C-10-1 C-2A-1 through C-10-1
I-1 through I-5 I-1 through I-4
D-1 through D-3/4 blank D-1 through D-3/4 blank
2028s 2028s



ERIC K. SHINSEKI
Chief of Staff

0114103

Distribution: To be distributed in accordance with the Initial Distribution Number (IDN) 400545 requirements for
TM 9-1010-221-23&P.

CHANGE
NO. 2
ARMY TM 9-1010-221-23&P
HEADQUARTERS
AIR FORCE, MARINE CORPS,
AND NAVY
Washington, DC, 1 October 1998
UNlT AND DIRECT SUPPORT
MAINTENANCE MANUAL
INCLUDING
FOR
(1010-00-179-6447) (EIC:4QB)
DISlRIBUTION STATEMENT C: Distribution authorized to U.S. Government agencies and their contractors. This publication
is required for administration and operational purposes, as determined on October 1,1997. ARMY ONLY: Other requests for
this document will be referred to Director, Armament and Chemical Acquisition and Logistics Activity, ATTN: AMSTA-AC-NML
Rock Island, IL 61299-7630. AIR FORCE ONLY: Other requests for this document must be referred to Warner Robins
ALC/LDTA, Robins AFB, GA 31098-5609. MARINE CORPS ONLY: Other requests for this document must be referred to:
Commandant of the Marine Corps, (Cods ARE), Washington, D.C. 20380-0001. NAVY ONLY: Other requests for this
document must be referred to: Commander, Code 4081 Bldg 2521, NAVSURF WARCENDIV, 300 Hwy 361, Crane, IN
47522-5001.
i thru iv
3-6.3 and 3-6.4
None
B-5 thru B-7/(B-8 blank)
C-7 and C-8
C-1-1 thru Fig C-5
i thru iv
3-6.3 and 3-6.4
4-1 thru 4-19/(4-20 blank)
C-7 and C-8
C-1-1 thru Fig C-5
Official:
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
05184
GARY G. BISHOP
Colonel, United States Army
Chief of Staff
CHANGE
NO. 1
ARMY TM 9-1010-221-23&P
HEADQUARTERS
AIR FORCE, MARINE CORPS,
AND NAVY
Washington, DC, 1 April 1998
MAINTENANCE MANUAL
INCLUDING
FOR
(1010-00-179-6447) (EIC:4QB)
is required for administration and operational purposes, as determined on July 1, 1991. ARMY ONLY: Other requests for
this document will be referred to Director, Armament and Chemical Acquisition and Logistics Activity, ATTN: AMSTA-AC-NML
Rock Island, IL 61299-7630. AIR FORCE ONLY: Other requests for this document must be referred to Warner Robins
ALC/LZDTA, Robins AFB, GA 31098-5609. MARINE CORPS ONLY: Other requests for this document must be referred to:
Commandant of the Marine Corps, (Code ARE), Washington, D.C. 20380-0001. NAVY ONLY: Other requests for this
document must be referred to: Commander, Code 4081 Bldg 2521, NAVSURF WARCENDIV, 300 Hwy 361, Crane, IN
47522-5001.
i thru 1-7/(1-8 blank) i thru 1-7/(1-8 blank)
2-1 thru 2-8 2-1 thru 2-8
2-13 thru 2-16 2-13 thru 2-16
2-19 thru 2-24 2-18.1 thru 2-24
2-27 and 2-28 2-27 and 2-28
2-33 and 2-34 2-33 and 2-34
2-37 thru 2-42 2-37 thru 2-42
3-3 thru 3-14 3-3 thru 3-14
3-17 thru 3-26 3-17 thru 3-26
3-29 and 3-30 3-29 and 3-30
3-33 thru 3-38 3-33 thru 3-38
Remove Pages
A-1 and A-2
C-5 thru 1-5
D-3/(D-4 blank)
Index 3/(lndex 4 blank)
Front cover and a
Insert Pages
A-1 and A-2
C-5 thru 1-4/(1-5 blank)
D-3/(D-4 blank)
Index 3/(lndex 4 blank)
Front cover and a
DISTRIBUTION: To be distributed in accordance with the initial distribution
for IDN 400545 requirements for TM 9-1010-221-23&P.
LIST OF EFFECTIVE PAGES

Dates of i ssue for ori gi nal and changed pages are:

Ori gi nal ...... 0 ....... 12 January 1993
Change....... 1 ....... 1 Apri l 1998
Change....... 2 ....... 1 October 1998
Change....... 3 ....... 7 September 2001
Change.4.. 15 December 2003

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 200, CONSISTING OF THE FOLLOWING:

Page Change Page Change
No. No. No. No.

Cover .......................................... 4 3-6.4 ...................................................... 2
a ................................................. 4 3-6.5/(3-6.6 bl ank) .................................. 1
A/(B bl ank) .................................. 4 3-7 through 3-10 ..................................... 4
i .................................................. 4 3-11 ....................................................... 3
i i ................................................. 4 3-12 ....................................................... 4
i i i ................................................ 4 3-13 ....................................................... 1
iv ................................................ 4 3-14 ....................................................... 3
1-0 through 1-5 ............................ 4 3-15 and 3-16 ......................................... 0
1-6 .............................................. 4 3-17 through 3-19 ................................... 1
1-7/(1-8 bl ank) ............................. 1 3-20 ....................................................... 0
2-1 .............................................. 0 3-21 ....................................................... 4
2-2 . ............................................ 1 3-22 and 3-23 ......................................... 1
2-3 and 2-4.4 3-24 and 3-25 ......................................... 0
2-5 through 2-7 ............................ 1 3-26 ....................................................... 1
2-8 .............................................. 3 3-27 ....................................................... 0
2-9 through 2-13 .......................... 0 3-28 ....................................................... 4
2-14 ............................................ 1 3-29 and 3-30 ......................................... 1
2-15 ............................................ 4 3-31 and 3-32 ......................................... 0
2-16 ............................................ 1 3-33 through 3-37 ................................... 1
2-17 and 2-18 .............................. 0 3-38 ....................................................... 0
2-18.1 ......................................... 3 A-1 ........................................................ 4
2-18.2 and 2-19............................ 1 A-2 ........................................................ 4
2-20 and 2-21 .............................. 0 B-1 through B-4 ...................................... 0
2-22 through 2-24......................... 1 B-5 through B-7/(B-8 bl ank) ..................... 4
2-25 and 2-26 .............................. 0 C-1 through C-4...................................... 0
2-27 ............................................ 1 C-5 and C-6............................................ 1
2-28 and 2-29 .............................. 0 C-7 ........................................................ 4
2-30 ............................................ 4 C-8 ........................................................ 0
2-31 and 2-32 .............................. 0 C-1-1 through C-9-1 ................................ 4
2-33 ............................................ 1 C-10-1 ................................................... 4
2-34 through 2-37......................... 0 I-1 through I-4 ........................................ 4
2-38 and 2-39 .............................. 4 D-1 ........................................................ 0
2-40 and 2-41 .............................. 3 D-2 and D-3/(D-4 bl ank) .......................... 4
2-42 through 2-44......................... 0 E-1 and E-2 ............................................ 0
2-45 through 2-62......................... 4 Index 1 and Index 2 ................................ 4
3-1 through 3-3 ............................ 0 Index 3/(Index 4 bl ank)............................ 1
3-4 and 3-5 .................................. 3
3-6 through 3-6.3 ......................... 1

Change 4 A/(B blank)

*ARMY TM 9-1010-221-23&P

TECHNICAL MANUAL HEADQUARTERS
ARMY TM 9-1010-221-23&P DEPARTMENT OF THE ARMY,
AIR FORCE TO 11W3-9-4-2 AIR FORCE, MARINE CORPS AND NAVY
NAVY SW 370-AE-MMI-010 Washington, DC, 12 January 1993

Unit and Direct Support Maintenance Manual Including Repair Parts and Special Tools List
for
(1010-00-179-6447) (EIC:4QB)
AND
(1010-01-434-9028) (EIC:4QH)
AND
(1010-01-495-8511) (EIC:4QJ)

is required for administration and operational purposes, as determined on July 1, 1991. ARMY ONLY: Other requests for this
document shall be referred to AMSTA-LC-CIP-WT, TACOM-Rock Island, 1 Rock Island Arsenal, Rock Island, IL 61299-7630.
AIR FORCE ONLY: Other requests for this document shall be referred to Warner Robins, ALC/LKCB, Robins AFB, GA
31098-1640. MARINE CORPS ONLY: Other requests for this document shall be referred to: Commandant of the Marine
Corps (Code ARD), Washington, DC 20380-0001. NAVY ONLY: Other requests for this document shall be referred to:
Commander, Code 4081, Bldg 2521, NAVSURF WARCENDIV, 300 Hwy 361, Crane, IN 47522-5001.

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Army users submit your DA Form 2028 (Recommended Changes to Equipment
Technical Publications), through the internet, on the Army Electronic Product Support (AEPS) website. The
internet address is http://aeps.ria.army.mil. If you need a password, scroll down and click on ACCESS
REQUEST FORM. The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS.
Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your
comments and better manage the DA Form 2028 program. You may also mail, fax or email your letter or DA
Form 2028 direct to: AMSTA-LC-CI /TECH PUBS, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-
7630. The email address is TACOM-TECH-PUBS@ria.army.mil. The fax number is DSN 793-0726 or
Commercial (309) 782-0726.

Air Force users submit AFTO Forms 22, Technical Order Improvement Report and Reply, to: WR-ALC/LKCB,
Robins AFB, GA 31098-1640.

Marine Corps users submit NAVMC 10772 to: http://pubs.ala.usmc.mil/navmc or hardcopy to Commander,
MARCORSYSCOM, 814 Radford Blvd. Suite 314, ATTN: LOG/TP, Albany, GA 31704-5000.

Navy users submit Recommended Changes to Publications to: Commander, Code 4081, Bldg 2521, NAVSURF
WARCENDIV, 300 Hwy 361, Crane, IN 47522-5001.

A reply will be furnished to you.

*This manual supersedes TM 9-1010-221-23&P, 15 August 1985, including all changes.

Change 4 i
ARMY TM 9-1010-221-23&P
Illus
Page Figure

HOW TO USE THIS MANUAL ................................................................. iii

CHAPTER 1 INTRODUCTION....................................................................................... 1-1

Section I General Information .................................................................................. 1-1
Section II Equipment Description and Data .............................................................. 1-3
Section III Principles of Operation.............................................................................. 1-7

CHAPTER 2 UNIT MAINTENANCE PROCEDURES.................................................... 2-1

Section I Lubrication Instructions ............................................................................. 2-1
Section II Repair Parts; Tools; Special Tools; Test,
Measurement and Diagnostic Equipment (TMDE);
And Support Equipment........................................................................ 2-1

Section III ..............................................................................................................

Section IV
..............................................................................................................

Section V ..............................................................................................................

Section VI ..............................................................................................................

CHAPTER 3 DIRECT SUPPORT MAINTENANCE PROCEDURES............................ 3-1

Section I Repair Parts; Tools; Special Tools; Test,
Measurement and Diagnostic Equipment (TMDE);
And Support Equipment........................................................................ 3-1

Section II ..............................................................................................................

Section III ..............................................................................................................

Section IV Preembarkation Inspection of Materiel
in Units Alerted for Overseas Movement .............................................. 3-36

Appendix A REFERENCES.......................................................................................... A-1

Appendix B MAINTENANCE ALLOCATION CHART (MAC)...................................... B-1

Appendix C UNIT AND DIRECT SUPPORT MAINTENANCE REPAIR
PARTS AND SPECIAL TOOLS LIST.................................................. C-1

Section I Introduction................................................................................................ C-1

ii Change 4
Service Upon Receipt
Unit Preventive Maintenance Checks
and Services (PMCS)
Unit Troubleshooting
Unit Maintenance Procedures
Direct Support Troubleshooting
Direct Support Maintenance Procedures
2-2
2-3
2-8
2-14
3-1
3-4
ARMY TM 9-1010-221-23&P

Illus
Page Figure

Section II Repair Parts List........................................................................................ C-1-1
Group 00 40MM Grenade Launcher M203 W/E 11838703, M203A1 W/E
12597125 and M203A2 W/E 12999553................................................. C-1-1 C-1
Group 01 40MM Grenade Launcher M203 8448300, M203A1 12982965
and M203A2 12999552.......................................................................... C-2-1 C-2
0101 Mounting Bracket Assembly C-2-1 C-2
02 Quick Release Bracket, 12973116 ........................................................... C-2A-1 C-2A
0201 Left Bracket Assembly, 12973117................................................. C-2B-1 C-2B
03 Leaf Sight and Rail Grabber Assembly, 12598117 ................................... C-2C-1 C-2C
04 Leaf Sight Assembly M203 and M203A1 8448330, M203A2 12598115... C-3-1 C-3
05 Barrel Assembly, 12012005....................................................................... C-4-1 C-4
06 Receiver Assembly M203 8448380-1, M203A1 8448380-2 and
M203A2 8448380-3 .............................................................................. C-5-1 C-5
Group 07 Quadrant Sight Assembly M203,
M203A1 and M203A2 12598114.......................................................... C-6-1 C-6
0701 Quadrant, Range Assembly M203 9346305 and M203A1/
M203A2 12598116 ..................................................................... C-7-1 C-7
0702 Latch Assembly, 9346306............................................................... C-8-1 C-8
0703 Sightarm Assembly, 12002885....................................................... C-9-1 C-9
Section III Special Tools List ...................................................................................... C-10-1
Group 9500 Special Tools............................................................................................. C-10-1 C-10
Section IV Cross-Reference Indexes
National Stock Number Index............................................................. I-1
Part Number Index (includes figure and item number index) ............. I-3

Appendix D EXPENDABLE AND DURABLE ITEMS LIST ......................................... D-1

Appendix E ILLUSTRATED LIST OF MANUFACTURED ITEMS............................... E-1

ALPHABETICAL INDEX

Index 1

HOW TO USE THIS MANUAL

Read this manual carefully before performing required maintenance. This manual will be referred to for
Inspection/Maintenance and Repair procedures. The information in this manual applies to M16 series rifles and
M4 series carbines. However, the M16A1 rifle is illustrated in this technical manual.

GENERAL

There are several things you need to know to use this manual efficiently.

1. All references in the manual are to pages only. Reference to maintenance procedures is to the page where
the respective initial setup appears.

2. Illustrations for the maintenance procedures show only those parts affected by the operation being
performed.

3. Whenever the male gender is mentioned in the manual (i.e., crewman, repairman), it also pertains to
females.

Change 4 iii
ARMY TM 9-1010-221-23&P

4. When the term evacuate to support maintenance is used, the entire weapon must be evacuated.

5. When a procedure is common between the M203, M203A1, and M203A2 grenade launchers, ONLY
the M203 configuration will be depicted. If a procedure is not common to both weapons, the procedure will be
incorporated. Not all paragraph headers were changed to address both weapons; however, the procedures apply
to both M203, M203A1, and M203A2 grenade launchers.

INDEXES

This manual is organized to help you find the information you need quickly. There are several useful
indexes.

1. Front Cover Index. Is a tabbed index of sections, keyed to boxed entries in table of contents
and tabbed pages in this manual.

2. Table of Contents. Lists in order all chapters, sections, and appendixes. Gives page
references.

3. Nomenclature Cross-References List.

4. Symptom Index. Located just before the troubleshooting table in each maintenance chapter.
Lists, in order of appearance in the troubleshooting table, parts of the weapon with possible
malfunctions. References pages of the troubleshooting table.

5. Alphabetical Index. Located at the end of the manual. An extensive subject index for
everything in the manual. Gives page references.

MAINTENANCE PROCEDURES

There are two maintenance chapters:

Army and Navy personnel use chapter two for unit maintenance procedures and chapter three for direct
support maintenance procedures.

Air Force personnel: Only Air Force Specialty Code 3POXB Combat Arms Training and Maintenance
(CATM) specialists, technicians, and gunsmiths are authorized to perform maintenance procedures
contained in this manual.

Marine Corps personnel use chapter two for 2
nd
echelon maintenance procedures and chapter three for
3
rd
echelon maintenance procedures.

Each maintenance task has an initial setup containing a list of the following things you will need in order
to do your maintenance task.

1. Tools and Special Tools. For standard and special tools, see appendixes B and C. Army and
Marine Corps users are to use the Tools Set, Gage Set, and/or Tool Kit listed in the initial setup.

iv Change 4

INTENTIONALLY LEFT BLANK

ARMY TM 9-1010-221-23&P
AIR FORCE TO 11W 3-9-4-2

1010-221-23&P

1-0 Change 4

1-0 Change 4
M203A2 W/E
M203A1 W/E
M203 W/E
2-0 ARMY TM 9-1010-221-23&P

CHAPTER 1
INTRODUCTION

Section I. GENERAL INFORMATION

1-1. SCOPE

a. Type of Manual. Uni t and Di rect Support Mai ntenance, i ncl udi ng the Repai r Parts and
Speci al Tool s Li st.

b. Model Number and Equipment Name. M203, 40MM Grenade Launcher W/E, i s attached to
the M16 seri es ri fl es and M203A1, 40MM Grenade Launcher, attached to the M4 seri es carbi nes.
M203A2, 40MM Grenade Launcher W/E, i s attached to the M16A4 ri fl es equi pped wi th the M5
Adapter Rai l System (ARS), and to the M4/M4A1 carbi nes equi pped wi th the M4 Adapter Rai l
System (ARS). Refer to TM 9-1005-249-23&P for M16 and M16A1 Ri fl e i nstructi ons. Refer to TM
9-1005-319-23&P for M16A2 Ri fl e and M4/M4A1 Carbi ne i nstructi ons.

c. Purpose of Equipment. Provi des 40MM grenade fi re power to ground forces equi pped wi th
M16 Seri es Ri fles and M4 Seri es Carbi nes.

1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS. Department of the Army forms and
procedures used for equipment maintenance will be those prescribed by DA PAM 738-750, The Army
Maintenance Management System (TAMMS).

Air Force users refer to TO 11W-1-10 for applicable forms and records.

Marine Corps users refer to TM 4700-15/1 (Equipment Record Procedures).

Navy users refer to applicable preventive maintenance system instructions.

1-3. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE. See TM 750-244-7.

1-4. PREPARATION FOR STORAGE OR SHIPMENT.

Air Force users refer to Special Package Instruction (SPI) 00-856-6885.

Marine Corps users refer to MCO P4450.7.

1-5. OFFICIAL NOMENCLATURE, NAMES, AND DESIGNATIONS.

NOMENCLATURE CROSS-REFERENCE LIST

Common Name Official Nomenclature

Barrel stop ...................................................................................................... Pawl
Cartridge locator spring .................................................................................. Helical compression spring
Handgrip assembly......................................................................................... Grenade launcher grip
Hand guard assembly..................................................................................... Grenade hand guard

Change 4 1-1

ARMY TM 9-1010-221-23&P

1-5. OFFICIAL NOMENCLATURE, NAMES, AND DESIGNATIONS (CONT).

NOMENCLATURE CROSS-REFERENCE LISTS (CONT)

Common Name Official Nomenclature

Locking wire.................................................................................................... Nonelectrical wire
Mounting bolt .................................................................................................. Shoulder bolt
Quadrant sight assembly................................................................................ Rifle grenade launcher sight
Quadrant sight clamp...................................................................................... Rim clenching clamp
Safety detent................................................................................................... Detent plunger
Sight aperture retainer .................................................................................... Spring tension clip
Sight leaf mount.............................................................................................. Mounting bracket
Sight pivot screw............................................................................................. Shoulder screw
Sight post ........................................................................................................ Front sight
Swivel locking bar ........................................................................................... Rim clenching clamp
Trigger pin....................................................................................................... Headed straight pin

1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR). If your grenade
launcher needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what
you dont like about your equipment. Let us know why you dont like the design.

Army users submit Standard Form (SF) 368 (Quality Deficiency Report (QDR)) to: AMSTA-AR-QAW-C, TACOM-
ARDEC, 1 Rock Island Arsenal, Rock Island, IL 61299-7300. The preferred method for submitting QDRs is
through the Army Electronics Product Support (AEPS) website under the Electronic Deficiency Reporting System
(EDRS). The web address is: https://aeps.ria.army.mil. This is a secured site requiring a password which can be
applied for on the front page of the website.

Air Force users submit Quality Deficiency Report (QDR) in accordance with Technical Order 00-35D-54,
Technical Manual, USAF, Materiel Deficiency Reporting and Investigating System, to: WR-ALC/LKCB, Robins
AFB, GA 31098-1640.

USMC users are encouraged to submit SF 368 in accordance with MCO 4855.10 (Quality Deficiency Report
(QDR)) to Commander, Marine Corps Logistics Base, Code 808, Albany, GA 31704-5000.

Navy users submit Quality Deficiency Report (QDR) to: Commander, Code 4081 Bldg 2521, NAVSURF
WARCENDIV, 300 Hwy 361, Crane, IN 47522-5001.

A reply will be sent to you.

1-7. CORROSION PREVENTION AND CONTROL (CPC). CPC of Army materiel is a continuing concern.
It is important that any corrosion problems with this item be reported so that the problem can be corrected and
improvements can be made to prevent the problem in future items.

While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials
such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a
corrosion problem.

If a corrosion problem is identified, it can be reported using SF 368, Quality Deficiency Report. Use of key words
such as corrosion, rust, deterioration, or cracking will ensure that the information is identified as a CPC
problem.

1-2 Change 4
ARMY TM 9-1010-221-23&P

Army users submit Quality Deficiency Report (QDR) (SF 368) to:

ATTN: AMSTA-AR-QAW-C
TACOM-ARDEC
1 Rock Island Arsenal
Rock Island, IL 61299-7300

Air Force users submit Quality Deficiency Report (QDR) in accordance with Technical Order 00-35D-54,
Technical Manual, USAF, Materiel Deficiency Reporting and Investigating System to:

WR-ALC/LKCB
Robins AFB, GA 31098-1640

Marine Corps users submit SF 368 in accordance with MCO 4855.10 (Quality Deficiency Report (QDR)) to:

Commander
Marine Corps Logistics Bases
Code 808
Albany, GA 31704-5000

Navy users submit Quality Deficiency Report (QDR) to:

Commander, Code 4081, Bldg 2521
NAVSURF WARCENDIV, 300 Hwy 361
Crane, IN 47522-5001

Section II. EQUIPMENT DESCRIPTION AND DATA

1-8. GENERAL. This section covers equipment description and data for unit and direct support maintenance.
Refer to TM 9-1010-221-10, operators manual, for lower level equipment description and data.

1-9. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES.

a. The grenade l auncher i s a breech-l oadi ng, pump-acti on, si ngl e-shot, manual l y operated
weapon.

b. It can fi re a vari ety of 40mm ammuni ti on.

c. The secondary sear (sear by nomencl ature i n accordance wi th i tem 13, page C-5-1)
prevents acci dental fi ri ng i f the tri gger i s hel d down duri ng cocki ng and l oadi ng operati ons. When
the tri gger i s forward, the fi ri ng pi n i s hel d to the rear by the sear porti on of the tri gger, not the
sear.

Change 4 1-3

ARMY TM 9-1010-221-23&P

1-9. EQUIPMENT CHARACTERISTIC, CAPABILITIES, AND FEATURES (CONT).
d. Two separate ai mi ng systems are avai l abl e to the operator.

(1) The fol di ng l eaf si ght assembl y on top of the hand guard assembl y i s for short-range
fi ri ng.

(2) The quadrant si ght assembl y i s mounted on the carryi ng handl e of the M16 seri es ri fl es,
the M4 seri es carbi nes and i s used for l ong-range fi ri ng.

1-10. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.

A HAND GUARD ASSEMBLY. The molded plastic hand guard assembly fits over the barrel of the M16 series
rifle.

B QUADRANT SIGHT ASSEMBLY. The quadrant sight assembly is attached to the carrying handle of the
M16 series rifles and M4 series carbines. It provides range selection from 50 to 400 meters in 25 meter
increments.

C RECEIVER ASSEMBLY. The aluminum frame mounts to the underside of the M16 series rifles and M4
series carbines. The receiver assembly houses a firing mechanism and an ejection system, and supports
the barrel assembly.

D BARREL ASSEMBLY. The barrel assembly consists of a specially treated aluminum barrel and a plastic
handgrip assembly. The 12 inch long barrel with six narrow lands is chambered for special 40mm grenade
launcher ammunition. The barrel assembly slides forward and backward under the receiver assembly in
sliding tracks.

E LEAF SIGHT ASSEMBLY. The folding leaf sight assembly, located on top of the hand guard assembly,
provides range selection from 50 to 250 meters in 50 meter increments.

GRENADELAUNCHER
40 MM, M203
S/N 158615
USA
SAFE
M16
CAL 5.56 MM
SEMI
A E
B
D
C

GRENADE LAUNCHER
40 MM, M203
S/N 158616
USA
SAFE
M16A2
CAL 5.56 MM SEMI
E
A
B
D
C

1-4 Change 1
ARMY TM 9-1010-221-23&P

1-11. DIFFERENCES BETWEEN MODELS.

NOTE
The M203 attaches to the M16 series rifles and the M203A1 attaches to the M4 series carbines.
The M203A2 attaches to M16A4 rifles and M4/M4A1 carbines equipped with either the M5 or M4 Adapter
Rail System.

There are remaining old style receivers which require the old style trigger pin. All configurations
require the new firing pin.

There is a new front mounting bracket for the M203A1. The new mounting bracket assembly has
a bracket clamp assembly and the tang has been removed.

There is a quick release bracket used to attach the M203A2. This bracket is a semi-permanent
installation to the M203A2.

1-12. EQUIPMENT DATA.

US CUSTOMARY METRIC

Barrel length .................................................................................. 12 inches 30.5 centimeters

Weight............................................................................................ 3 pounds 1.4 kilograms

Rifling data:
Length of rifling......................................................................... 10 inches 25.4 centimeters

Number of lands ............................................................................ 6

Change 4 1-5

ARMY TM 9-1010-221-23&P

1-13. STORAGE OF GRENADE LAUNCHER M203.

a. M12 Rack. Bui l t for the M16 seri es ri fl e and the M203 grenade l auncher. Store the l auncher
i n the M12 rack wi th the si ght i n the 300-400 meter posi ti on so that when you cl ose the l ocki ng bar
of the rack, the bar mi sses the si ght. The si ght has to be above the 300-meter posi ti on to avoi d
damage from the bar of the rack. For the correct way of stori ng the l auncher i n the M12 rack, see
the i l l ustrati on bel ow.

b. Modified M11 Rack. Stores most M203 grenade l aunchers wi th the si ght set i n the 175-
through 200-meter setti ng. See the i l l ustrati on bel ow. Check the rack to see whi ch setti ng i s
best. The 175-meter setti ng i s good for some l aunchers; others need up to 200 meters. Because
of the di fferent posi ti ons of the bars, the si ght on your l auncher may not cl ear the bar at al l . In thi s
case, remove the si ght and store i t separatel y i n the arms room.

NOTE
Keep obj ects off stored si ghts and cushi on si ghts between l ayers.

MODIFIED M11 RACK

M12 RACK MODIFIED M11 RACK

1-6 Change 4
ARMY TM 9-1010-221-23&P
Section III. PRINCIPLES OF OPERATION
1-14. TECHNICAL PRINCIPLES OF OPERATION. The M203 grenade launcher is light-
weight and compact and must be attached to M16 series rifles.
The M203A1 grenade launcher is
light-weight and compact and must be attached to M4 series carbines.
a. Open the launcher, insert a round, and close the launcher.
b. Place on SAFE.
c. Place the launcher to your shoulder. Keep muzzle pointed at target and move the safety from the SAFE to
the FIRE position.
d. Align the front and rear of the quadrant sight assembly with the target and squeeze the trigger.
e. Squeezing the trigger releases the firing pin and allows it to impact the primer on the round.
f. The primer ignites the propellant in the round.
g. Gas from the burning propellant pushes the projectile along the barrel of the launcher.
h. The rifling in the barrel causes the projectile to rotate, which provides stability during flight to the target.
Change 1 1-7/(1-8 blank)
ARMY TM 9-1010-221-23&P
CHAPTER 2
UNIT MAINTENANCE PROCEDURES
Section I. LUBRICATION INSTRUCTIONS
2-1. LUBRICATION INSTRUCTIONS. Wherever the term Cleaner, Lubricant, and Preservative (CLP) or
the words Lubricant, Lube, LSA, or LAW are cited in this TM, it is to be interpreted to mean CLP, LSA, or
LAW can be utilized as applicable. The following constraints must be adhered to:
a. Under all but the coldest arctic conditions, LSA (item 13, app D) or CLP (item 5, app D) are
the lubricants to use on your weapon. Either may be used at -10F and above. However, do not
use both on the same weapon at the same time.
b. LAW (item 12, app D) is the lubricant to use during cold arctic conditions, +10F and below.
c. Any of the lubricants may be used from -10F to +10F.
NOTE
Do not mix lubricants on the same weapon.
d. The weapon must be thoroughly cleaned during change from one lubricant to another. Dry
Cleaning Solvent (SD) (item 9, app D) is recommended for cleaning during change from one
lubricant to another.
e. Rifle Bore Cleaner (RBC) (item 7, app D) may be used to remove carbon buildup in the bore
and other portions of the weapon.
Section II. REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST,
MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE);
AND SUPPORT EQUIPMENT
2-2. COMMON TOOLS AND EQUIPMENT. For authorized common tools and equipment, refer to the
Modified Table of Organization and Equipment (MTOE), CTA 50-970 or CTA 8-100, as applicable to your unit.
2-3. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT. Special tools, TMDE, and support
equipment are listed in appendixes B and C of this manual.
2-4. REPAIR PARTS. Repair parts are listed and illustrated in appendix C of this manual.
2-1
ARMY TM 9-1010-221-23&P
Section Ill. SERVICE UPON RECEIPT
2-5. SERVICE UPON RECEIPT OF MATERIEL. Refer to the table below.
SERVICE UPON RECEIPT-40MM GRENADE LAUNCHER M203/M203A1
NOTE
The initial gaging procedures for Active Army, Army Reserve, and Army National Guard are required
one year from receipt of the weapons.
ACTION REMARKS
a. Remove grenade launcher and components from
packaging.
b. Remove protective wrappings.
c. Inspect the equipment for damage incurred during
shipment.
The grenade launcher, swivel mount, hand guard
assembly, quadrant sight assembly, and mounting
hardware are packaged in a protective wrapping
and shipped as a unit, two to a carton.
If the equipment has been damaged, report the
damage on SF 364, Report of Discrepancy (ROD).
d. Check the equipment against the packing slip to
see if the shipment is complete.
Report all discrepancies in accordance with the
instructions of DA PAM 738-750.
Air Force users submit MDR and Product Quality
Deficiency Report to WR-ALC/LZBS, Robins AFB,
GA 31098-5609.
Marine Corps users report discrepancies in
accordance with MCO P4610.19, Transportation
and Travel Record of Transportation
Discrepancies.
Navy users submit Quality Deficiency Report to:
Commander, Code 4081 Bldg 2521, NAVSURF
WARCENDIV, 300 Hwy 361, Crane, IN 47522-
5001.
e. Check to see whether equipment has been
modified.
Check DA PAM 25-30 for current MWOs.
f. Send M203 grenade launcher and 5.56mm M16
series rifles to direct support maintenance for
initial installation.
g. Send M203A1 grenade launcher and 5.56mm M4
series carbines to direct support maintenance for
initial installation.
2-2 Change 1
ARMY TM 9-1010-221-23&P

Section IV. UNIT PREVENTIVE MAINTENANCE CHECKS
AND SERVICES (PMCS)

2-6. GENERAL. This section contains the procedures and instructions necessary to perform unit preventive
maintenance checks and services. These services are to be performed by unit maintenance personnel with the
assistance of the operator where practical.

2-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES.

WARNING
Clear the weapon before starting an inspection. Do not squeeze the trigger until
the weapon has been cleared. Inspect the chamber to be sure it is empty. Avoid
having live ammunition where maintenance is performed.

NOTE
All active Army M203/M203A1/M203A2 grenade launchers must be inspected and gaged at least
annually for safety. All Army Reserve and Army National Guard M203/M203A1/M203A2 grenade
launchers must be inspected and gaged at least once every two years, after the initial
inspection/gaging procedures have been accomplished. The initial gaging procedures for Active
Army, Army Reserve, and Army National Guard are required one year from receipt of the
weapons. This two-year interval may be maintained unless PMCS or other physical evidence
indicates that an individual units M203/M203A1/M203A2 grenade launchers require inspections
at a more frequent interval. If it is determined that a yearly inspection is necessary for an
individual unit, only that unit will be affected. This will not affect other units in regard to the
interval of inspection.

a. General. The PMCS procedures are contai ned i n the fol l owi ng tabl e. They are arranged i n
l ogi cal sequence requi ri ng a mi ni mum amount of ti me and moti on on the part of the persons
performi ng them and are arranged so that there wi l l be a mi ni mum i nterference between persons
performi ng checks si mul taneousl y on the same end i tem.

b. Item No. Column. Checks and servi ces are numbered i n di sassembl y sequence. Thi s
col umn shal l be used as a source of i tem numbers for the TM Number col umn on DA Form 2404,
Equi pment Inspecti on and Mai ntenance Worksheet, i n recordi ng resul ts of PMCS.

c. Interval Column. Thi s col umn gi ves the desi gnated i nterval when each check i s to be
performed.

d. Item To Be Checked Or Serviced Column. Thi s col umn l i sts the i tems to be checked or
servi ced.

e. Procedure Column. Thi s col umn contai ns a bri ef descri pti on of the procedure by whi ch the
check i s to be performed. It contai ns al l the i nformati on requi red to accompl i sh the checks and
servi ces. Informati on marked SH i ndi cates a speci fi c equi pment shortcomi ng and the procedure
needed to correct the shortcomi ng. Ai r Force Speci al ty Code 3POXB Combat Arms Trai ni ng and
Mai ntenance (CATM) Speci al i sts, Techni ci ans, and Gunsmiths wi l l conduct the PMCS semi-
annual l y on i n-use weapons.

f. Not Fully Mission Capable If: Column. Thi s col umn contai ns a bri ef statement of the
condi ti on (e.g., mal functi on, defi ci ency (D)) that woul d cause the covered equi pment to be l ess
than ful l y ready to perform i ts assi gned mi ssi on.

Change 4 2-3
ARMY TM 9-1010-221-23&P
2-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT).
UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR 40MM GRENADE LAUNCHER,
M203/M203A1/M203A2

Item
No.

Interval

Item To Be Checked
Or Serviced

Procedure

Not Fully
Mission Capable
If:

WARNING
Clear weapon before
starting inspection.

1 Quarterly Grenade launcher with or
without M16 series rifles
or M4 series carbines
a. Check weapon for cleanliness,
sufficient lubrication, and proper
assembly.

Weapon not
properly assembled.

WARNING
Using the old style firing pin
can cause injury to
personnel and damage to
equipment when firing a live
round.
b. Check for any missing or damaged
parts, and for old style firing pin,
part number 8448327. Whenever
the old pin is identified, evacuate
to direct support maintenance.

Parts missing,
damaged or old
style firing pin is
installed.

c. Check grenade launcher for dents
and worn/shiny surfaces.

Grenade launcher is
dented, or has
worn/shiny surfaces.
(See note on p 2-
6.1.)
d. Check for positive retention to
rifle/carbine (p 2-27).
Grenade launcher is
not positively retain-
ed on rifle/carbine.
(See p 3-6, 7c.)
WARNING
The grenade launcher could fire
without squeezing the trigger if the
sear does not function properly.

e. Check grenade launcher for
proper function. Make sure the
grenade launcher is cleared.
Cock the launcher and squeeze
the trigger. Firing pin should
release. Hold trigger to rear and
cock the launcher. Release
trigger and listen for an audible
click, then squeeze the trigger.
Firing pin should release. If firing
pin releases before squeezing the
trigger, evacuate to support
maintenance.
Grenade launcher
does not function
properly.
f. Check locking wire
(p 2-27).

2-4 Change 4
ARMY TM 9-1010-221-23&P
AlR FORCE TO 11W3-9-4-2
M203/M203A1 (CONT)
I t em
No.
1
Interval
Quarterly
(cont)
2 Quarterly
3 Quarterly
Item To Be Checked
Or Serviced
Grenade launcher with
or without M16 series
rifle or M4 series carbine
(cont)
Annual direct support
safety and serviceability
inspection and gaging
Hand guard assembly
and leaf sight assembly
Barrel assembly
Procedure
h.
a.
b.
a.
b.
g. Thoroughly clean areas that
are to be touched up using dry
cleaning solvent (item 9, app
D). Touch up shiny exterior
surfaces with solid film
lubricant (item 11, app D).
Check to ensure annual direct
support safety and
serviceability inspection and
gaging has been done, and
that the next gaging and
inspection is scheduled. If
annual gaging has not been
performed within the last year,
notify direct support
maintenance.
Check hand guard assembly
for cracks.
Check leaf sight assembly for
bent, broken, or missing parts.
Check that markings are
legible. Check screws for
tightness. If damaged,
evacuate to direct support
maintenance.
Visually inspect barrel
assembly for bulges, dents, or
cracks. Barrel assembly
should be cylindrical in shape.
Check handgrip assembly for
damage and positive retention
to barrel. If damaged or no
positive retention, evacuate to
direct support maintenance.
Not Fully
Mission Capable
If:
Annual gaging has not
been performed within
the last year.
Cracks exceed 1 inch
(2.54 cm) and/or if chips
are on back lip of hand
guard assembly.
Barrel has bulges, dents,
or cracks or is oval in
shape.
Handgrip assembly is
damaged or is not
positively retained on
barrel.
Change 1 2-5
ARMY TM 9-1010-221-23&P
M203/M203A1 (CONT)
Item
No. Interval
3
Quarterly
(cont)
4
Quarterly
Change 1 2-6
Item To Be Checked
Or Serviced
Barrel assembly
(cont)
Receiver assembly WARNING
Procedure
c. Check the barrel extension for
tightness to the barrel. This will
be accomplished by moving the
barrel extension up and down,
side to side, and front to rear with
the thumb and index finger, while
visually examining it. If obvious
play/movement occurs, evacuate
to direct support maintenance.
d.
Check for defective cartridge
locator spring. Push the
cartridge locator toward the
barrel, and then release. The
cartridge locator must move
forward and back under spring
pressure.
Using the old style firing pin,
part number 8448327, can
cause injury to personnel
and damage to equipment
when firing a live round. The
old firing pin must be
replaced by the new firing
pin, part number 12002970,
whenever the old pin is
identified in the weapon.
Not Fully
Mission Capable
If:
Barrel extension is
loose, bent, or
cracked.
Cartridge locator
does not move
under spring
pressure.
ARMY TM 9-1010-221-23&P
M203/M203A1 (CONT)
Item
No.
4
Interval
Item To Be Checked
Or Serviced
Quarterly Receiver assembly
(cont) (cont)
Procedure
Not Fully
Mission Capable
If:
a. Inspect for burrs, nicks, wear, or
other damage.
Burred, nicked,
worn, or
damaged.
b. Inspect for missing finish on weapon.
Apply solid film lubricant to shiny
surfaces.
NOTE
Solid Film Lubricant (SFL) is the authorized touchup for the M203/M203A1 Grenade Launcher
and may be used on up to one third of the exterior finish of the weapon.
FOR CONUS USE ONLY: Solid Film Lubricant (item 11, app D) may be used as a touchup
without limitation on the receiver assembly. This is to say that units which DO NOT fall under the
category of Divisional Combat Units or rapid deployment type units may have up to 100 percent
of the exterior surface of the receiver assembly protected with SFL. Prior to application of SFL,
the surface must be thoroughly cleaned and inspected for corrosion and/or damage. If corroded
or damaged, the part must be repaired or replaced prior to application of SFL. Continued use
under combat conditions would result in an unprotected surface when the SFL wears off. This
would result in a large light reflecting surface and accelerated deterioration of the unprotected
surface. Therefore, Divisional Combat Units and units which fall under the definition of Rapid
Deployment type must adhere to the limitation of NOT over one third of their exterior surface
covered by SFL.
If M203/M203A1 Grenade Launcher RECEIVER ASSEMBLY is missing one third or more of its
exterior protective finish, resulting in an unprotected/light reflecting surface, it is a candidate for
overhaul. This missing finish will be considered a shortcoming. This shortcoming requires
action to obtain a replacement weapon. Once a replacement has been received, evacuate the
original weapon to depot for overhaul.
Once the missing exterior protective finish of the receiver assembly has exceeded one third of its
total surface, the probability of reclaiming the receiver assembly during overhaul diminishes
rapidly. In order to extend the life of the receiver assembly, which is the serial numbered item, it
is necessary to evacuate the weapon to depot once the missing finish reaches one third of the
total surface of the receiver assembly.
Change 1 2-6.1/(2-6.2 blank)
ARMY TM 9-1010-221-23&P

M203/M203A1 (CONT)

Item
No.

Interval

Item To Be Checked
Or Serviced

Procedure

Not Fully
Mission Capable
If:

4

Quarterly
(cont)

Receiver assembly
(cont)

c. Check self-locking screw in
back plate for tightness (p 2-
32).

d. Check the breech insert visually.
It should not be above the
surface of the breech face.
Evacuate to direct support
maintenance.

Self-locking screw is not
tight.

Breech insert protrudes
above the breech face.

5 Quarterly Barrel stop With barrel assembly installed on
the receiver assembly, move barrel
assembly forward to barrel stop.
Barrel stop must prevent the barrel
assembly from being removed from
the tracks in the receiver assembly.
Barrel stop does not
prevent the barrel
assembly from being
removed from the
receiver assembly.

Verify barrel stop pin is staked on
both sides.

6

Quarterly

Barrel latch

Pull barrel assembly rearward to
close. Barrel latch must lock the
barrel assembly fully closed.

Barrel latch does not lock
barrel assembly fully
closed.

7 Quarterly Cartridge extractor Check for broken or missing
cartridge extractor, spring pin, or
spring.

Cartridge extractor,
spring pin, or spring is
broken or missing.

8 Quarterly Cartridge ejector Visually inspect cartridge ejector for
cracks. Push cartridge ejector into
breech. Cartridge ejector should
move and return under spring
pressure.
Cartridge ejector is
cracked or not moving
and returning under
spring pressure.

Change 1 2-7
ARMY TM 9-1010-221-23&P


M203/M203A1 (CONT)

Item
No.

Interval

Item To Be Checked
Or Serviced

Procedure

Not Fully
Mission Capable
If:

9

Quarterly

Quadrant sight
assembly

a. Check for cracked, broken, or
missing teeth (p 2-39).

b. If damaged, repair or replace
the quadrant assembly. Refer
to page 2-39.

c. In order to prevent the
quadrant sight assembly from
being damaged, refer to page
1-6.

10 Quarterly Annual DS safety and
serviceability inspection
and gaging
Check to ensure annual DS safety
and serviceability inspection and
gaging has been done and that the
next gaging and inspection is
scheduled. If annual gaging has
not been performed within the last
year, notify direct support
maintenance.

Annual gaging has
not been
performed.

Section V. UNIT TROUBLESHOOTING

2-8. GENERAL

a. This section contains troubleshooting information for locating and correcting most of the operating troubles
which may develop in the 40mm grenade launcher M203. Each malfunction for the individual part or assembly is
followed by a list of tests or inspections which will help you to determine the corrective actions to take. Perform
the tests/inspections and corrective actions in the order listed.

b. This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions.
If a malfunction is not listed or is not corrected by listed corrective actions, see individual repair sections for
maintenance instructions on each major assembly.

2-9. TROUBLESHOOTING PROCEDURES. Refer to troubleshooting table for malfunctions, tests, and
corrective actions. The symptom index is provided for a quick reference of the malfunctions covered in the table.

2-8 Change 3
ARMY TM 9-1010-221-23&P
SYMPTOM INDEX
Troubleshooting
Procedures
Page
Failure to fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Failure to cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Failure to close or latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Failure to extract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Failure to lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 13
Failure of the leaf sight assembly to remain at the selected range . . . . . . . . . . . . 2-13
Failure of quadrant sight assembly to stay in selected position . . . . . . . . . . . . . . 2- 14
UNIT TROUBLESHOOTING
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
WARNING
Clear the weapon before starting an inspection.
1. FAILURE TO FIRE.
Step 1. Check for dirt in firing pin recess (1).
Clean firing pin recess with CLP (item 5, app D) or RBC (item 7,
app D) (see TM 9-1010-221-10).
2-9
ARMY TM 9-1010-221-23&P
2-9. TROUBLESHOOTING PROCEDURES (CONT).
UNIT TROUBLESHOOTING (CONT)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Step 2. Check for dirt in cartridge locator slot (2).
Clean cartridge locator slot with CLP (item 5, app D) or RBC (item
7, app D) (see TM 9-1010-221-10).
NOTE
Barrel must be closed to function the firing mechanism.
Step 3. Check for water or oil in firing pin recess (1),
Point muzzle up and handfunction barrel and firing mechanism (3).
2-10
ARMY TM 9-1010-221-23&P
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Step 4. Check for broken or improperly assembled parts of firing mechanism (3).
Evacuate to direct support maintenance if firing mechanism is
broken or improperly assembled.
Step 5. Check for defective cartridge locator spring (4):
a. Using cleaning rod section, push cartridge locator toward muz-
zle, and then release.
b. Cartridge locator must move forward and back under spring
pressure.
c. If cartridge locator does not function, evacuate to direct sup-
port maintenance.
2-11
ARMY TM 9-1010-221-23&P
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. FAILURE TO COCK.
Check for proper installation of follower guide assembly.
Reassemble (p 2-32).
3. FAILURE TO CLOSE OR LATCH.
Check for proper installation of follower guide assembly.
Reassemble (p 2-32).
4. FAILURE TO EXTRACT.
Step 1. Check for broken or missing cartridge extractor (1), spring pin (2), or
spring (3).
If cartridge extractor, spring pin, or spring is broken or missing,
evacuate to direct support maintenance.
Step 2. Check for residue
Clean and
buildup in barrel and chamber area.
lubricate barrel and chamber area.
2- 12
ARMY TM 9-1010-221-23&P
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. FAILURE TO LOCK.
Check for dirty follower guide assembly or receiver cavity.
a. Remove back plate and follower guide assembly (p 2-32).
b. Clean and lubricate back plate and follower guide assembly (p 2-33).
c. Clean and lubricate trigger housing (p 2-34).
6. FAILURE OF THE LEAF SIGHT ASSEMBLY TO REMAIN AT THE SELECTED RANGE.
Step 1. Check for loose machine screw (1) on front folding sight leaf (2). Tighten machine screw.
Step 2. Check for loose machine screws (3) on sight leaf vase (4). Tighten machine screws.
2-13
ARMY TM 9-1010-221-23&P
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
7. FAILURE OF QUADRANT SIGHT ASSEMBLY TO STAY IN SELECTED POSITION.
Check quadrant sight assembly for damaged, missing, or dirty parts.
Repair (p 2-38).
Section VI. UNIT MAINTENANCE PROCEDURES
2-10. GENERAL.
a. This section contains procedures for removing or installing the 40mm grenade launcher M203/M203A1
from the M16 series rifle and M4 series carbine. Unit maintenance is authorized to remove and install the M203
grenade launcher after initial installation. The M203 grenade launcher must be installed on the same weapon
from which it was removed. The M203A1 may be removed but not reinstalled by the unit armorer. AIR FORCE
PERSONNEL ONLY: The grenade launcher should be installed on the same rifle from which it was removed.
However, there may be situations where this may not be possible.
b. Direct support maintenance will make the initial installation of both the M203 and M203A1 grenade
Launchers. Since there is a torque requirement to the bracket clamp assembly screw of the M203A1, direct
support must always perform installation of the M203A1. There is no maintenance requirement to put the
M203A1 back on the same weapon.
2-14 Change 1
ARMY TM 9-1010-221-23&P

2-11. 40MM GRENADE LAUNCHER M203/M203A1 W/E - MAINTENANCE INSTRUCTIONS

This task covers:

a. Removal of M203 Grenade Launcher From M16 Seri es Ri fl e and M203A1 Grenade
Launcher From M4 Seri es Carbi ne
b. Inspecti on/Repai r
c. Instal l ati on of M203 Grenade Launcher to M16 Seri es Ri fl e and M203A1 Grenade
Launcher to M4 Series Carbine

INITIAL SETUP
Tool s and Speci al Tool s
(Army) Smal l Arms Repai rman Tool Ki t (i tem 5, app B)
(MC) Smal l Arms Repai rman Tool Ki t (i tem 5, app B)
Materials/Parts

Locking wire (MS20995C32) (9505-00-293-4208)
Ri vet (8448697) (from TM 9-1005-249-23&P, TM 9-1005-319-23&P, or TM 05538C-23&P/2A
(Mari ne Corps onl y) (Used to return grenade l auncher to the M16 seri es confi gurati on onl y.)
References
TM 9-1005-249-10, TM 9-1005-319-10, or TM 05538C-10/1A (Mari ne Corps onl y)
TM 9-1005-249-23&P
TM 9-1005-319-23&P or TM 05538C-23&P/2A (Mari ne Corps onl y)
Equipment Condition

Grenade launcher installed on M16 series rifle/M4 series carbine.

REMOVAL OF M203/M203A1 GRENADE LAUNCHER FROM M16 SERIES RIFLE/M4 SERIES CARBINE

WARNING

Clear both weapons before disassembly and ensure bolt of the rifle/carbine is forward.
NOTE
The M203 must be reinstalled on the same rifle from which it was removed.

The M203A1 may be switched to a different carbine by direct support.

The M203A2 may be switched to a different rifle or carbine equipped with the M5 or M4 Adapter
Rail System. The rifle or carbine MUST be re-zeroed to re-establish weapon accuracy.

When mounting an M203A1 or M203A2 grenade launcher, ensure side sling swivel is mounted
on the right side of the carbine. If not, remove side sling swivel (TM 9-1005-319-23&P, para 2-
16, steps 5A thru 5C and reassemble, steps 4B thru 4D.

AIR FORCE ONLY: The grenade l auncher shoul d be i nstal l ed on the same ri fl e
from whi ch i t was removed. However, there may be si tuati ons where thi s may not
be possi bl e.

MARINE CORPS ONLY: Also see pages 3-4 thru 3-10.

Change 4 2-15

ARMY TM 9-1010-221-23&P

2-11. 40MM GRENADE LAUNCHER M203/M203A1 W/E - MAINTENANCE INSTRUC-
TIONS (CONT).

REMOVAL OF M203/M203A1 GRENADE LAUNCHER FROM M16 SERIES RIFLE/M4 SERIES
CARBINE (CONT)

1. Using a screwdriver, remove the quadrant sight
assembly (1) (if used) by loosening the mounting
bolt (2) on the right side of the weapon.

1
2

2. Remove sling (3) from front swivel (4).

4
3

CAUTION
Do not use a screwdriver or any other tool
when removing the hand guard assembly,
doing so may damage the hand guard
assembly and/or slip ring.

3. Pull back slip ring (5). Lift up on hand guard
assembly (6) and pull to rear to remove.

NOTE
If you have difficulty removing the hand
guard assembly, use the buddy system.
See step 4.

6
5

2-16 Change 1
ARMY TM 9-1010-221-23&P
4. Stand the weapon on the buttstock (7
Grip the stock with one hand and the
lower end of hand guard assembly (6)
with the other hand. Have your buddy
press down with both hands on the slip
ring (5). Pull hand guard assembly (6)
free.
6.
5. Press barrel latch (8) and move barrel
assembly (9) forward to barrel stop
(10).
Using a screwdriver, press barrel stop
(10) and slide barrel assembly (9) from
receiver assembly (11).
2- 17
ARMY TM 9-1010-221-23&P
2-11. 40MM GRENADE LAUNCHER M203 W/EMAINTENANCE INSTRUCTIONS
(CONT).
REMOVAL OF M203 GRENADE LAUNCHER FROM M16 SERIES RIFLE (CONT)
7. Cut locking wire ( 12) at head of two
machine screws ( 13) at points shown.
Use pliers to remove locking wire.
8. Remove two machi ne screws (13).
9. Pull front of receiver assembly (11)
away from rifle. Then lift it up and out
of the rifle slip ring (5).
NOTE
A bushing half may fall out.
2-18
ARMY TM 9-1010-221-23&P

NOTE
Mounting bracket is hand fit at direct support
maintenance. Be sure to reinstall on the same
weapon from which it was removed.

If the grenade launcher is to be mounted on a
different rifle, a new mounting bracket may be
required.

10. Remove mounting bracket (14).

11. Remove two bushing halves (15).

14
15
14

REMOVAL OF M203A1 FROM M4 SERIES CARBINE

NOTE - DELETED

M203A1 ONLY

11.1. Cut locking wire at head of two socket
head screws (15.1). Use pliers to remove
locking wire.

11.2. Cut wire on bracket clamp assembly
screw (15.2) and remove wire. Loosen
bracket clamp assembly screw and
remove bracket clamp assembly.

1 5. 1
1 5. 2

Change 3 2-18.1
ARMY TM 9-1010-221-23&P

2-11. 40MM GRENADE LAUNCHER M203/M203A1 W/E MAINTENANCE INSTRUC-
TIONS (CONT).

REMOVAL OF M203A1 FROM M4 SERIES CARBINE

15.1
15.1

15.3
15.4

M203A1 ONLY

11.3 Remove two socket head screws (15.1) and
washers.
M203A1 ONLY
11.4. Pull front of receiver assembly (15.3) away
from carbine. Then lift it up and out of the
carbine slip ring (15.4).

15.5
15.6
15.5

M203A1 ONLY
11.5. Remove mounting bracket (15.5) and two bushing halves (15.6).

2-18.2 Change 1
ARMY TM 9-1010-221-23&P
REMOVAL OF M203/M203A1 GRENADE LAUNCHER FROM M16 SERIES RIFLE/M4 SERIES
CARBINE (CONT)
NOTE
FOR M203: Perform steps 12 thru 19 if weapon is being returned to the M16 series configuration.
Skip steps 12 thru 16 and start with step 17 if the M203 grenade launcher is to be sent to direct
support for maintenance.
FOR M203A1: Perform steps 17 thru 19 if weapon is being returned to the M4 series configuration.
12. Remove two spring pins (16).
Change 1 2- 19
ARMY TM9-1010-221-23&P
2-11. 40MM GRENADE LAUNCHER M203/M203A1 W/E-MAINTENANCE INSTRUC-
TIONS (CONT).
REMOVAL OF M203 GRENADE LAUNCHER FROM M16 SERIES RIFLE (CONT)
13. Lift swivel locking bar (17) up and out of swivel
mount (18).
15. Remove rivet (19). Separate front swivel (4)
from swivel mount (18).
14. Remove swivel mount (18).
NOTE
Requisition new rivet from TM 9-1005-249-
23&P, TM 9-1005-319-23&P, or TM 05538C-
23&P/2A (Marine Corps only).
16. Install front swivel (4) with new rivet (19) on
bottom of front sight. Flare rivet with punch and
hammer.
2-20
ARMY TM 9-1010-221-23&P
(CONT)
NOTE
Refer to operator manuals for the buddy
system procedure on installing hand guards.
17. Install hand guard (20) in tube cap (21).
Push down on slip ring (5). Push hand guard in
place and release slip ring (5).
18. Install other hand guard (22) in tube cap (21).
Push down on slip ring (5). Push hand guard in
place and release slip ring (5).
2-21
ARMY TM 9-1010-221-23&P
2-11. 40MM GRENADE LAUNCHER M203/M203A1 W/E - MAINTENANCE INSTRUCTIONS
(CONT).
(CONT).
19. Install sling (3) in front swivel (4) or side swivel
mount.
20. M4 series carbine must be re-zeroed after removal
of M203A1 since removal changes the zero.
INSPECTION/REPAIR
1. Inspect rifle (1). Refer to TM 9-1005-249-23&P, TM 9-1005-319-23&P, or TM 05538C-23&P/2A (Marine
Corps only).
2. Inspect mounting bracket (2) for bends or
damage. If damaged, evacuate to direct
support maintenance. Inspect two machine
screws (3). If damaged, replace machine
screws. MARINE CORPS ONLY: Refer to
page 3-4.
2-22 Change 1
ARMY TM 9-1010-221-23&P
3. Inspect bushing halves (4) for chips or wear. If damaged,
replace bushing halves.
4. Inspect heat shield for tightness on hand guards. If loose
enough to rattle, evacuate grenade launcher to direct
support maintenance.
INSTALLATION OF M203 GRENADE LAUNCHER TO M16 SERIES RIFLE
NOTE
The M203 grenade launcher must be reinstalled on
the same rifle from which it was removed.
The M203A1 grenade launcher may be switched to
a different carbine by direct support.
When mounting an M203A1 grenade launcher,
ensure side sling swivel is mounted on the right side
of the carbine. If not, remove side sling swivel (TM
9-1005-319-23&P, para 2-16, steps 5A thru 5C and
reinstall, steps 4B thru 4D.
1. Remove sling (1) from front swivel (2).
CAUTION
Do not use a screwdriver or any other tool when
removing the hand guard, doing so may damage
the hand guard and/or slip ring.
NOTE
Refer to TM 9-1005-249-10 for the buddy system
procedure on installing hand guards. Keep both
hand guards at unit maintenance to convert M16
series rifle back to original configuration.
2. Push down on the slip ring (3) and pull out and down
on the hand guard (4).
Change 1 2-23
ARMY TM 9-1010-221-23&P
2-11. 40MM GRENADE LAUNCHER M203/M203A1W/E - MAINTENANCE INSTRUCTIONS
(CONT).
INSTALLATION OF M203 GRENADE LAUNCHER TO M16 SERIES RIFLE (CONT)
3. Push down on the slip ring (3) and lift the hand
guard (5) up and out.
5. Install front swivel (6) to swivel mount (8) with
new rivet (7).
4. Remove front swivel (6) from bottom of front
sight by driving out rivet (7).
6. Install swivel mount (8).
2-24 Change 1
ARMY TM 9-1010-221-23&P
7. Place swivel locking bar (9) in swivel
mount (8).
9. Remove barrel assembly (11) from
receiver assembly (12) if assembled.
See page 2-17.
8. Install two spring pins (10).
10. Install bushing half (13) in mounting
bracket (14).
11. Position mounting bracket (14) over
rifle barrel with the tip (15) pointing
forward. Install other bushing half
(13).
2- 25
ARMY TM 9-1010-221-23&P
2-11. 40MM GRENADE LAUNCHER M203 W/EMAINTENANCE INSTRUCTIONS
(CONT).
12. Whi l e hol di ng mounti ng bracket (14)
forward, position receiver assembly
(12) over rifle barrel. Align spring pin
(16) with notch in barrel nut (17). Be
sure spring pin is fully seated in notch
of barrel nut.
NOTE
For proper alignment, ensure the
receiver assembly is centered under
the barrel of the rifle.
13. Seat receiver assembly (12) firmly in
rifle.
2- 26
ARMY TM 9-1010-221-23&P
14. Align screw holes in receiver assembly and mount-
ing bracket and install two machine screws (18).
Fully tighten machine screws (18).
15. Check installation of receiver assembly as follows:
a. The movement from side to side should not
exceed 1/8 inch (0.32 cm) left or right of center.
Total movement cannot exceed 1/4 inch (0.64
cm).
b. If excess side to side movement exists, replace
the bushing halves.
c. There must be no up and down movement
between the receiver assembly (M203) and the
rifle barrel.
16. Use cleaning rod section to engage trigger guard
(19).
17. Install locking wire (20) as follows:
a. Install an 8 inch (20.32 cm) length of locking
wire (20); it may be started at either machine
screw (18).
b. Insert locking wire (20) approximately halfway
through hole in head of machine screw (18).
Change 1 2-27
ARMY TM 9-1010-221-23&P
2-11. 40MM GRENADE LAUNCHER M203/M203A1 W/E-MAINTENANCE INSTRUC-
TIONS (CONT).
c. Wrap the half of the wire farthest from the front
of the receiver assembly around the head of
the mounting screw in a clockwise direction.
d. Twist wire strands together in either right-
hand or left-hand direction. Begin at the screw
head until the twisted wire is approximately 1-
1/4 inches (3.175 cm) long.
e. Wrap the twisted wire around the front of
receiver assembly (12). Insert one strand of
wire through machine screw (18) and pull wire
tight.
f. Untwist the wire if twisted segments of the wire
prevent it from being drawn tightly across the
front of receiver assembly. Replace wire if
untwisted, because wire will not be tight.
g. Wrap loose strand of wire around head of
machine screw (18) in a counterclockwise
direction.
16. Twist wire strands together, beginning at the
screw head, until the twisted wire is
approximately 1/2 inch (1.27 cm) long.
2-28
ARMY TM 9-1010-221-23&P

19. Cut off excess wire strands and bend twisted
section out of the way.

20. Insert tracks on barrel assembly (11) into tracks in receiver assembly (12) and compress barrel stop
(21). Pull barrel assembly (11) rearward and barrel stop (21) will snap in place.

21. Pull barrel assembly (11) rearward to close. Barrel latch (22) must lock barrel assembly (11) fully
closed.

2-29
ARMY TM 9-1010-221-23&P
2-11. 40MM GRENADE LAUNCHER M203 W/E - MAINTENANCE INSTRUCTIONS
(CONT).


22. Stand the weapon on the buttstock (23). Grip
the stock with one hand and the lower end of the
hand guard assembly (24) with the other hand.
Have your buddy press down with both hands on
the slip ring (3). Install hand guard assembly
(24) in tube cap (25). Push hand guard
assembly in place and release slip ring (3).

23. Install sling (1) in front swivel (6).

24. Install quadrant sight assembly (26); pull it
gently to rear until it becomes snug; and using a
screwdriver, tighten mounting bolt (27) on right
side.

NOTE
When used on the M16A4 rifle, the leaf sight and rail grabber assembly will be attached to slot
T38 on the M5 Adapter Rail System.

When used on the M4 or M4A1 carbine, the leaf sight and rail grabber assembly will be
attached to slot T24 on the M4 Adapter Rail System.

25. Turn the torque knob of the assembly counterclockwise until it stops turning. Place the assembly on the
upper rail and insure the recoil lug is seated in the correct slot. The torque knob should be to the left of
the carbine or rifle. Turn the torque knob clockwise until you hear two clicks.

2-30 Change 4

ARMY TM 9-1010-221-23&P
2-12. RECEIVER ASSEMBLY-MAINTENANCE INSTRUCTIONS.
This task covers:
a. Removal d. I nspect i on/ Repai r
b. Di sassembl y e. Lubrication/Reassembly
c. Cl eani ng f. I nst al l at i on
INITIAL SETUP
Tools and Special Tools
(Army) Small Arms Repairman Tool Kit (item 5, app B)
(MC) Small Arms Repairman Tool Kit (item 5, app B)
Materials/Parts
Cleaner, lubricant, and preservative (CLP) (item 5, app D)
Dry cleaning solvent (item 9, app D)
Rubber gloves (item 10, app D)
Self-locking screw (MS21262-5)
Wiping rag (item 17, app D)
References
TM 9-1010-221-10
Equipment Condition
Grenade launcher installed on M16 series rifle.
Sling and hand guard assembly removed.
Clear both weapons before starting
an inspection and ensure the bolt of
the rifle is forward.
Disengage trigger guard. Push receiver
takedown pin (1) and receiver pivot pin
out and remove lower receiver.
2-31
ARMY TM 9-1010-221-23&P
2-12. RECEIVER ASSEMBLY - MAINTENANCE INSTRUCTIONS (CONT).
DISASSEMBLY
NOTE
The current configuration of the back plate and follower guide assembly is
depicted above. The previous configuration follower guide assembly contained a
captured spring and detent; therefore, it did not require a screw. The old-type back
plate and follower guide assembly only need to be replaced if defective. If the old
configuration of either the back plate or the follower guide assembly requires
replacement, both parts must be replaced, as the old to new configurations are not
compati bl e.
1. Cock the grenade launcher. Slide the barrel assembly (1) forward. Using allen wrench,
remove and discard self-locking screw (2).
WARNING
To avoid injury to your eyes, use care when removing and installing spring-loaded
parts.
2. Slide back plate (3) out of receiver assembly (4). Slide barrel assembly rearward and
remove follower guide assembly (5).
2- 32
ARMY TM 9-1010-221-23&P
CLEANING
1. Clean back plate (1) and follower guide assembly (2)
using wiping rag (item 17, app D) and CLP (item 5,
app D).
WARNING
Dry cleaning solvent is FLAMMABLE and
TOXIC and must be kept away from open
flames and used in a well-ventilated area.
Use of rubber gloves is necessary to protect
the skin when washing grenade launcher
parts.
Appropriate eye protection is recommended when
cleaning your weapon and/or its parts.
2. Wash receiver assembly (3) thoroughly in dry
cleaning solvent (item 9, app D) to remove oil, dirt,
and sand. Wipe with wiping rag (item 17, app D) and
allow to air dry. Clean barrel assembly (4) using
wiping rag (item 17, app D) and CLP (item 5, app D).
INSPECTION/REPAIR
1. Make sure that follower guide assembly (1) does not
have broken springs or bent rods.
2. Inspect back plate (2) and follower guide assembly
(1) for serviceability.
3. Inspect barrel assembly (3) for cracks or dents.
inspect hand grip assembly for cracks and chipped
away material. If damaged, evacuate grenade
launcher to direct support maintenance.
4. Replace all unserviceable authorized parts in the
Change 1 2-33
ARMY TM 9-1010-221-23&P
2-12. RECEIVER ASSEMBLY-MAINTENANCE INSTRUCTIONS (CONT).
LUBRICATION/REASSEMBLY
1. Lubricate the sides of the cocking lever (1) trigger,
top of sear (2) and spring (3) with CLP (item 5,
app D).
NOTE
Be sure the beveled side of the back plate is
down and to the rear of the receiver assembly
before placing back plate in slot of receiver
assembly.
Be sure follower guide assembly is installed
as illustrated.
2. Install follower guide assembly (4) in receiver
assembly (5). While holding follower guide
assembly (4) in place, slide back plate (6) in slot of
2-34
2-35
ARMY TM 9-1010-221-23&P
LUBRICATION/REASSEMBLY (CONT)
3. Align screw hole in back plate (6) with
threaded hole in follower guide
assembly. Install new self-locking
screw (7) and tighten securely using
allen wrench.
4. Insert a 3/32-inch drive pin punch
through the firing pin hole. Push the fir-
ing pin (8) into the receiver assembly
(5) until it clicks.
ARMY TM 9-1010-221-23&P
2-12. RECEIVER ASSEMBLYMAINTENANCE INSTRUCTIONS (CONT).
LUBRICATION/REASSEMBLY (CONT)
5.
6.
7.
Install and close barrel assembly (9) on
the receiver assembly (5) (p 2-29).
Open barrel assembly and place one or
two drops of CLP (item 5, app D) on
ejector (10). With a punch, press and
release ejector several times to spread
lubricant.
Place one or two drops of CLP (item 5,
app D) in firing pin hole (11).
NOTE
The weapon must be cocked in
order for safety lever to operate.
8. Cock grenade launcher. Turn grenade
launcher upside down putting safety
(12) in safe position. Oil safety detent
(13) using one or two drops of CLP
(item 5, app D). Operate the safety
several times to work in the oil.
2- 36
ARMY TM 9-1010-221-23&P

9. Lubricate the barrel assembly track (14) and
bore (15) using CLP (item 5, app D). Close barrel
assembly.

10. Wipe all exposed surfaces of the receiver
assembly with wiping rag (item 17, app D) with a small
amount of CLP (item 5, app D) applied.

11. Perform function check on receiver assembly in
accordance with TM 9-1010-221-10.

14
15

INSTALLATION

2
1

3

1. Install upper receiver and barrel assembly to lower receiver and extension assembly and secure with
receiver pivot pin (1) and takedown pin (2).
2. Use cleaning rod section to engage trigger guard (3) back in place.

2-37
ARMY TM 9-1010-221-23&P
2-13. QUADRANT SIGHT ASSEMBLY - MAINTENANCE INSTRUCTIONS.

This task covers:

a. Disassembly c. Reassembly
b. Inspection/Repair

INITIAL SETUP

(Army) Small Arms Repair man Tool Kit (item 5, app B)

Equipment Condition
Quadrant sight assembly removed from host weapon
carrying handle.
DISASSEMBLY

1. Unscrew mounting bolt (1) and
remove quadrant sight clamp (2).

2. Unscrew sight pivot screw (3) and
separate sightarm assembly (4) from
range assembly quadrant (5) or (5.1).

3. Slide latch assembly (6) to the notch
in the sightarm assembly (4) and
remove latch assembly (6) and helical
compression spring (7).

4. Unscrew sight post (8).

CAUTION
Sightarm assembly (4) is made
of light plastic. Take care
when driving out spring pin (9)
or breakage may occur.

5. Drive out spring pin (9) and remove
sight aperture retainer (10) and sight
aperture (11) by pushing down on
sight aperture retainer (10).

NOTE
Refer to pages 2-40 thru 2-45 for
further breakdown of items 4, 5,
and 6.

2-38 Change 4
NOTE
When replacing Item 2 below for the
first time, also replace Item 3, Page 2-
40. These are new parts (see Figures
C-6 and C-7) and are not compatible
with the parts they replace.
ARMY TM 9-1010-221-23&P
INSPECTION/REPAIR

Inspect for worn or damaged parts. Replace authorized unserviceable components.

REASSEMBLY

CAUTION
Sight aperture arm (2.1) is made of light plastic. Take care when driving in spring pin (2), or breakage may occur.

1. Place sight aperture (3) and sight aperture retainer (4) in place on sightarm assembly (1) and drive in spring
pin (2).

2. Install sight post (5).

3. Place helical compression spring (6) in latch assembly (7). Insert latch assembly (7) in notch of sightarm
assembly (1) and slide to the right.

4. Align the screw holes in sightarm assembly (1) and range assembly quadrant (8) or (8.1); install and
tighten sight pivot screw (9).

5. Align screw holes in quadrant sight clamp (10) and range assembly quadrant (8) or (8.1); install mounting
bolt (11).

Change 4 2-39

ARMY TM 9-1010-221-23&P
2-14. RANGE ASSEMBLY QUADRANT -- MAINTENANCE INSTRUCTIONS.

This task covers:


INITIAL SETUP


Equipment Condition
Range assembly quadrant removed from quadrant sight assembly.
Refer to page 2-38.

DISASSEMBLY

NOTE
Disassemble only to replace unserviceable components.

Remove two machine screws (1) and separate fire control quadrant (2) from bracket assembly (3). This
configuration is for use with M16A1/M16A2/M16A3 rifles.

Remove two machine screws (1.1) and separate fire control quadrant (2) from spacer (2.1) and
bracket assembly (3). This configuration is for use with M16A4 rifles and M4/M4A1 carbines.

2-40 Change 3

NOTE
When replacing Item 3 below for the
first time, also replace Item 2, Page
2-38. These are new parts (see
Figures C-6 and C-7) and are not
compatible with the parts they
replace.
ARMY TM 9-1010-221-23&P

INSPECTION/REPAIR

Inspect for worn or damaged parts. Replace authorized unserviceable components.

REASSEMBLY

2
1
3
1 . 1
1
2
3. 1
USE THI S CONFIGURATI ON WITH
M1 6A4 RIFLES AND M4/M4A1
CARBINES.
USE THI S CONFIGURATI ON WITH
M1 6A1 /M1 6A2/M1 6A3 RIFLES.

Position fire control quadrant (1) on bracket assembly (2) or on spacer (1.1) then on bracket assembly (2) and
secure with two machine screws (3) or (3.1).

Change 3 2-41
ARMY TM 9-1010-221-23&P

2-15. LATCH ASSEMBLY -- MAINTENANCE INSTRUCTIONS.

This task covers:


INITIAL SETUP


Equipment Condition
Latch assembly removed from quadrant sight assembly. Refer to page 2-38.

DISASSEMBLY

NOTE
Disassemble only to replace unserviceable
components.

Remove headless straight pin (1) from sight latch (2).

2
1

INSPECTION/REPAIR

1. Inspect for worn or damaged parts.

2. Replace authorized unserviceable components.

2-42
ARMY TM 9-1010-221-23&P
REASSEMBLY
Drive headless straight pin (1) into sight
latch (2).
2-16. SIGHTARM ASSEMBLYMAINTENANCE INSTRUCTIONS.
This task covers:
b. I nspect i on/ Repai r
INITIAL SETUP
Materials/Parts
Rivet (1 2002884) (two)
Equipment Condition
Sightarm assembly removed from quadrant sight assembly. Refer to page 2-38.
2- 43
ARMY TM 9-1010-221-23&P
2-16. SIGHTARM ASSEMBLYMAINTENANCE INSTRUCTIONS (CONT).
NOTE
Disassemble only to replace unserviceable components.
File the peened end from rivets (1) or drive rivets (1) from quadrant sightarm (2) with punch
and hammer. Discard rivets. Remove sight post arm (3) and sight aperture arm (4).
INSPECTION/REPAIR
1. Inspect for worn or damaged parts.
2. Replace authorized unserviceable components.
2- 44
ARMY TM 9-1010-221-23&P

REASSEMBLY

Position sight post arm (1) and sight aperture arm (2) in quadrant sightarm (3). Drive new rivets (4)
through quadrant sightarm (3), sight post arm (1), and sight aperture arm (2). Peen the rivets.

Change 4 2-45

ARMY TM 9-1010-221-23&P

2-17. MAINTENANCE OF QUICK RELEASE BRACKET.

This task covers:

a. Installation d. Disassembly/Reassembly
b. Removal e. Mounting To M4/M4A1 Carbine Equipped with M4 ARS
c. Inspection/Repair f. Mounting To M16A4 Rifle Equipped with M5 ARS

INITIAL SETUP

Tools
(ARMY) Small Arms Repairman Tool Kit
(item 5, app B)

NOTE

References to the Retaining Spring, PN 12973125, apply only to the original version of the Quick Release
Bracket. The newest version does not require the Retaining Spring to prevent the accidental depression of the
Detent Plunger, PN 12973126. PN 12999211 has replaced the old style Detent Plunger. Depress the plunger
in the UNLOCK position to open the bracket, then in the LOCK position after the bracket is open to remove or
insert the five position shim plate (see illustration below). If the Retaining Spring is lost or broken, order the
new Detent Plunger and PN 12999210, Helical Compression Spring, which replaces PN 12973144. All other
instructions concerning the installation and operation of the Quick Release Bracket are common to both the old
and new versions.

CAUTION

Before the quick release mount is installed on the M203 receiver, both ends of the hole for the
M203 barrel stop pin must be staked to prevent loss of the headless pin (figure C-5, item 31).

2-46 Change 4

ARMY TM 9-1010-221-23&P

a. INSTALLATION

WARNING

CONFIRM GRENADE LAUNCHER AND HOST WEAPON ARE UNLOADED AND SAFE.

1. Remove the M203 grenade launcher from its host weapon (if it is attached).

2. Remove the original factory mount from the M203 or M203A1 grenade launcher (if it is attached).

3. Thoroughly clean the front mount receiving area of the receiver, and particularly the screw holes and
their threads, with degreaser such as dry cleaning solvent (app D, item 9).

4. Compare the illustration below with the quick release bracket parts for familiarization:

LEFT BRACKET ASSEMBLY
RIGHT HALF BASE
FIVE POSITION
SHIM PLATE
2 SOCKET HEAD
CAP SCREWS

Change 4 2-47
ARMY TM 9-1010-221-23&P
2-17. MAINTENANCE OF QUICK RELEASE BRACKET (CONT).
a. INSTALLATION (CONT).

5. As illustrated below, hold the retaining spring (1) away from the plunger (2). Fully depress the plunger and
rotate the latch lever (3) fully upward. Lift the latch arm (4) away from the hook (5). It may be necessary to
depress the plunger to allow the latch lever to lock. Rotate the latch arm up and out of the way to its fully open
position. Depress the plunger and remove the five-position shim plate (6). Remove the right half base (7) by
sliding it off the left bracket assembly (8) dovetail.

4
2
5
6
7
8
3
1

6. Thoroughly clean the 2 socket head cap screws, the right half base, and the left bracket assembly with a
degreaser such as dry cleaning solvent (app D, item 9).

7. Slide the right half base onto the left bracket assembly dovetail. Depress the plunger and reinsert the shim
plate into the bracket.

2-48 Change 4
ARMY TM 9-1010-221-23&P

8. Slide the quick release bracket onto the forward mount area of the receiver as illustrated. Make sure the
quick release bracket is perpendicular to the receiver during this procedure.

9. The purpose of this procedure is to determine if spring washers will be required. In most cases,
spring washers will not be required because the five-position shim plate will be retained within the
bracket by the plunger, but can be pulled from the groove using finger pressure while the plunger is
fully depressed. Do not use spring washers (10) at this time.

Assemble the bracket to the receiver as follows:

a. Start each screw (9) as illustrated below and tighten with a 5/32 hexagonal wrench until each screw
head is just below flush.

b. Continue to tighten each screw until there is no play or movement between the bracket and the receiver

c. If you are unable to remove the shim plate, some minor loosening of the screws is allowable in this
procedure as long as there is no play or movement between the bracket and the receiver.

NOTE
If you are unable to tighten the screws enough to completely eliminate play or movement between the
bracket and the receiver, the threaded inserts in the receiver might be damaged. Contact Direct Support to
correct this condition.

d. If minor loosening of the screws does not result in both the retention of the shim plate, and the ability to
remove the shim plate while the plunger is depressed, install one spring washer between the receiver
and the right half base. Be sure the screw passes through the hole in the washer to prevent breakage
of the washer. If you are still unable to remove the shim plate with your fingers while depressing the
plunger, install the second spring washer between the receiver and the left bracket assembly. If you are
unable to remove the shim plate with your fingers after installing both washers, the receiver may be
undersized and require replacement. Contact Direct Support.
NOTE
Do not use more than two spring washers. This may result in loss of the shim plate. Loss of the shim plate
makes the M203A2 non-mission capable. If loss occurs, the shim plate should be replaced as quickly as
possible.
9
10
9
10

Change 4 2-49

ARMY TM 9-1010-221-23&P

a. INSTALLATION (CONT).

NOTE
A new set of socket head cap screws (and spring washers if needed) must be used each time the
quick release bracket is installed on the M203A2.

10. Referring to step 5 on page 4-3, re-install the five-position adjustment shim plate while noting the dot pattern
on the front face of the shim plate. The dot pattern should face the muzzle, and the side with 2 dots
should be inserted down. (This is illustrated in the figure below). Close and lock the bracket and latch
lever. It may be necessary to depress the plunger to allow the latch to lock. This should keep the shim plate
from falling free of the assembly.

2-50 Change 4
ARMY TM 9-1010-221-23&P

11. Instal l ati on of the qui ck rel ease bracket to the recei ver i s now compl ete as i l l ustrated
di rectl y bel ow:

NOTE
THE DOT PATTERN ON THE FIVE-POSITION SHIM PLATE SHOWN ON THE RIGHT.
THIS SIDE SHOULD FACE THE MUZZLE WHEN INITIALLY INSTALLED ON THE
M203. ALSO NOTE THAT THE CURVED SIDE WITH 2 DOTS IS INSERTED DOWN.

b. REMOVAL

Usi ng a 5/32" hexagonal wrench from the standard smal l arms repai rman tool ki t, remove each
socket head cap screw as i l l ustrated bel ow.

c. INSPECTION/REPAIR

1. Vi sual l y i nspect the qui ck rel ease bracket for broken, corroded, or missi ng parts.

2. Repai r the qui ck rel ease bracket by repl aci ng any broken, corroded, or mi ssi ng parts.

Change 4 2-51
ARMY TM 9-1010-221-23&P

d. DISASSEMBLY/REASSEMBLY

1. Remove the M203A2 from the M16A4 ri fl e or the M4 carbi ne by performi ng the
fol l owi ng steps:

(a) Hol d the retai ni ng spri ng (1) away from the pl unger (2).

(b) Depress the pl unger.

(c) Rotate the l atch l ever (3) upward.

(d) Li ft the l atch arm (4) away from the hook (5).

(e) Press the l atch l ever ful l y
downward to engage the pl unger.
It wi l l be necessary to depress the
pl unger to al l ow the l atch l ever to
engage the pl unger. There wi l l be
an audi bl e cl i ck when the l atch
l ever has engaged the pl unger and
the pl unger wi l l snap forward
toward the muzzl e.

(f) Rotate the l atch arm up and out of
the way to i ts ful l y open posi ti on.
When performi ng thi s step on the
ri fl e, careful l y pul l the l atch arm
from between the gas tube and
barrel .

(g) Di sengage the tri gger guard from
the magazi ne wel l .

4
2
5
1
3
SECURE ON
RIFLE/CARBINE
M203A2 W/QUICK
RELEASE BRACKET
REMOVED
FROM
RIFLE/CARBINE

(h) Pi vot the M203A2 downward from the host weapon, di sengagi ng the tri gger guard and the
rear of the recei ver from the host weapon.

2-52 Change 4
ARMY TM 9-1010-221-23&P

2. Remove the qui ck rel ease bracket from the M203A2
(see removal , page 4-6).

3. Remove the fi ve-posi ti on shi m pl ate (6).

6

4. Remove the ri ght hal f base (7) by sl i di ng i t off the
l eft bracket assembl y (8) dovetai l .

7
8

5. Secure the l eft bracket assembl y i n a vi se as
i l l ustrated.

6. Remove the retai ni ng spri ng (1) from the l eft
bracket assembl y (8).

8
4
3
1

Change 4 2-53

ARMY TM 9-1010-221-23&P
d. DISASSEMBLY/REASSEMBLY (CONT).

NOTE
The pl unger i s under spri ng pressure. Make
sure the pl unger i s faci ng away from you.

7. Use a 1/16" punch to remove the spri ng pi n (9)
whi ch retai ns the pl unger (10) wi thi n the l eft
bracket assembl y (8). Remove the pl unger
and the compressi on spri ng from the l eft
bracket assembl y.

8. Use a 3/32 punch to remove the spri ng pi n
(11) onl y when repl aci ng i t.

10
8
9
11

9. Thoroughl y cl ean the qui ck rel ease bracket, payi ng speci al attenti on to the pi vot poi nts of the
l atch arm and l atch l ever. Thi s wi l l i nsure the qui ck rel ease bracket operates correctl y.

10. Li ghtl y l ubri cate the qui ck rel ease bracket surface areas. Generousl y l ubri cate the l atch
arm, l atch l ever, pl unger, and the fi ve-posi ti on shi m pl ate. Be sure to generousl y l ubri cate
al l pi vot poi nts on the l atch arm and l atch l ever.
NOTE
Before inserting spring pin (9), make sure the plunger (10) is fully depressed.

11. To reassembl e, reverse steps 3-8. Be sure to use a new spring pin. To remount the
M203 w/qui ck rel ease bracket to the host weapon, reverse step 1.

e. MOUNTING TO THE M4 CARBINE
PRINCIPLE OF THE FIVE-POSITION SHIM PLATE
The basi c overal l l ength between the barrel nut rol l pi n at the rear of the recei ver, and the
starti ng posi ti on shi m pl ate cutout surface at the front, i s approxi matel y 11 i nches. As noted i n
step 5, some sl i di ng moti on may be detectabl e between the carbi ne barrel shoul der and the
front of the fi ve-posi ti on shi m pl ate at the starti ng, or mi ni mum, overal l l ength cutout posi ti on.
Subsequent re-i nserti on of the fi ve-posi ti on shi m pl ate to i ts #2, #3, #4, or maxi mum (fi fth)
l ength posi ti on (refer to step 2, page 4-10) wi l l sl i ghtl y i ncrease the overal l l ength of the
assembl y beyond the basi c 11 i nches, and therefore tend to mi ni mi ze or el i mi nate any sl i di ng
moti on between the barrel shoul der and the fi ve-posi ti on shi m pl ate.
At some poi nt, the uni t armorer wi l l note that the shi m pl ate wi l l not fi t i nto the cutout of the
carbi ne barrel shoul der (as i ndi cated as INCORRECT i n step 5). At thi s poi nt, go back to the
next l owest posi ti on and secure, cl ose, and l ock the bracket around the carbi ne.
The fol l owi ng steps descri be checki ng for sl i di ng moti on wi th the next or #2 notch up, and
agai nst the carbi ne barrel shoul der. If the #2 posi ti on does not mi ni mi ze the sl i di ng moti on,
repeat the procedure wi th the #3 notch up and so on. If the fi fth or maxi mum posi ti on i s
desi red, note that the back or smooth face of the shi m pl ate i s ori ented towards the muzzl e.
Do not be concerned i f onl y a smal l amount of sl i di ng moti on i s sti l l detectabl e wi th the shi m
pl ate i n i ts apparentl y opti mum setti ng, because the l atch arm wi l l compensate for thi s when i t i s
cl osed and l ocked.
2-54 Change 4
ARMY TM 9-1010-221-23&P

1. Fol l ow the steps as descri bed i n para a. Installation to attach the qui ck rel ease bracket to
the M203.

2. Compare the i l l ustrati on bel ow wi th the qui ck rel ease bracket (1) for the purpose of
fami l i ari zati on wi th al l posi ti ons of the fi ve-posi ti on shi m pl ate (2):
1
2
STARTING POSITION
(ALL DOTS FACING MUZZLE
2 DOT CURVED SIDE DOWN)
FIFTH OR MAXIMUM
POSITION (BACK
FACING MUZZLE)
FRONT
(MUZZLE)
VIEW
FULLY DEPRESS PLUNGER
TO INSTALL/REMOVE
THE SHIM PLATE
FRONT SIDE BACK
# 2 POSITION # 3 POSITION # 4 POSITION

3. Set the fi ve-positi on shi m pl ate i n the bracket to the mi ni mum posi ti on as i l l ustrated, wi th the
2 dots down and faci ng the muzzl e.

LEFT SIDE
VIEW
FRONT
VIEW
FRONT
(MUZZLE)
VIEW

Change 4 2-55

ARMY TM 9-1010-221-23&P

e. MOUNTING TO THE M4 CARBINE (CONT)

4. If present, remove the l ower rai l of the M4 adapter rai l system from the M4 carbi ne. Move
the rear of the M203A2 recei ver i nto posi ti on around the carbi ne barrel . Confi rm that the
l atch arm (3) of the bracket i s ful l y open. Rotate the muzzl e end of the M203A2 towards the
carbi ne barrel whi l e sl i di ng the M203A2 fi rml y to the rear. Confirm that the roll pin in the
rear of the M203A2 receiver engages the carbine barrel nut at the six oclock position
notch.

3
3

5. Fi rml y hol d the M203A2 i n posi ti on/back
agai nst the barrel nut of the carbi ne, whi l e
al so hol di ng the muzzl e end of the M203A2
agai nst the carbi ne s barrel . Inspect the
fi ve-posi ti on shi m pl ate, l ooki ng from the top
of the carbi ne barrel , and al so from the front,
as i l l ustrated bel ow. The i nner notch of the
shi m pl ate shoul d rest behi nd the shoul der of
the barrel . Now, try to sl i de the M203A2
back and forth i f possi bl e, and note the
di stance of any sl i di ng moti on. Some moti on
wi l l be detectabl e wi th most carbi ne barrel s
wi th the shi m pl ate i n i ts starti ng posi ti on. If
during this step the cutout in the shim
plate does not fit behind the barrel
shoulder, it is most probably inserted at
its maximum thickness (no dots facing the
muzzle), or position #2, #3, or #4 (refer to
step 2 on page 4-10).

NOTE
Endurance testi ng i ndi cated that i t may be
necessary to swi tch to another shi m pl ate
(2) posi ti on after several thousand rounds
have been fi red. The uni t armorer shoul d
check for excessi ve sl i di ng moti on each
ti me the shi m pl ate i s removed for
cl eani ng/l ubri cati on and the M203A2 re-
mounted to the carbi ne.

BARREL SHOULDER
BARREL DIAMETER
FORWARD OF
SHOULDER
SHIM
PLATE
BARREL SHOULDER FITS
INTO CUTOUT IN SHIM
PLATE
CORRECT
BARREL DIAMETER
REAR OF SHOULDER
INCORRECT
BARREL SHOULDER
DOES NOT FIT INTO
CUTOUT IN SHIM
PLATE
M
P

5
.
5
6

N
A
T
O

1
/
7

2-56 Change 4

ARMY TM 9-1010-221-23&P

6. Remove the M203A2 from the carbi ne. Depress the pl unger (4), wi thdraw the shi m
pl ate and re-i nsert i t i n the #2 posi ti on (refer to step 2, page 4-10). Note that the #2
position is indicated by a single dot stamped on its shim plate cutout, and that this
side of the shim plate faces the muzzle.
7. Re-mount the M203A2 to the carbi ne' s barrel nut and barrel shoul der. Attempt to sl i de
the M203A2 from front to rear.
8. If forward and back moti on i s detected, repeat step 7 wi th the shi m pl ate i n the #3 posi ti on.
If the assembl y i s now too l ong (i t wi l l not engage behi nd the barrel shoul der, but ri des up
onto the barrel ' s maj or di ameter), go back to the l ast posi ti on tri ed wi th the shi m pl ate, and
compl ete the M203A2 attachment.

When the opti mum posi ti on of the shi m pl ate i s establ i shed:
a. If necessary, hol d the retai ni ng spri ng out of the way and depress the pl unger (4) to
unl ock the l atch l ever (5).

b. Rotate the l atch arm (3) over the carbi ne barrel .
c. Catch the hook (6) i n the hol e of the l atch arm.
d. Rotate the l atch l ever (5) down.
e. Depress the pl unger (4). Make sure the retai ni ng spri ng does not engage the pl unger
duri ng thi s step.
f. Squeeze the l atch l ever ful l y cl osed (whi ch al l ows the pl unger to be rel eased and snap
forward). Thi s wi l l hol d the l atch l ever i n the ful l y cl osed/l ocked posi ti on.
NOTE
In its final motion, the latch lever may require very firm pressure against the bracket to
allow the plunger to snap back into place, locking the latch lever closed. If necessary,
use the buddy system. DO NOT use a vise or other mechanical device. Doing so may
cause damage to the quick release bracket.
g. Rotate the M203A2 tri gger guard (7) to engage the l i p of the magazi ne wel l .

2-57 Change 4
ARMY TM 9-1010-221-23&P

e. MOUNTING TO THE M4 CARBINE (CONT)

9. If forward and back moti on i s
detected wi th the shi m pl ate set to i ts
#3 notch, remove the M203A2 from
the carbi ne. Remove and re-i nsert
the shi m pl ate i n i ts #4 posi ti on. Note
that the #4 position is indicated by
three dots stamped adjacent to its
shim plate cutout, and that this
side of the shim plate faces the
muzzle.

# 4 POSITION
FRONT
(MUZZLE)
VIEW
DEPRESS PLUNGER TO
REMOVE/INSTALL THE
5-POSITION ADJUSTMENT
SHIM PLATE

10. If the #5 or maxi mum posi ti on i s requi red, i nsert the shi m pl ate as i l l ustrated bel ow.

# 5 POSITION
(BACKSIDE OF ADJUSTMENT)
SHIM PLATE FACES THE MUZZLE
FRONT
(MUZZLE)
VIEW
DEPRESS PLUNGER TO
REMOVE/INSTALL THE
SHIM PLATE

CAUTION
When detachi ng the M203A2 for cl eani ng, i nspecti on, or l ubri cati on, check and note
the posi ti on of the shi m pl ate for ease of re-attachment.

2-58 Change 4

ARMY TM 9-1010-221-23&P
f. MOUNTING TO THE M16A4 RIFLE

PRINCIPLE OF THE FIVE-POSITION SHIM PLATE
The basi c overal l l ength between the barrel nut rol l pi n at the rear of the recei ver, and the
starti ng posi ti on shi m pl ate cutout surface at the front, i s approxi matel y 11 i nches. As noted i n
step 5, some sl i di ng moti on may be detectabl e between the ri fl e barrel stop and the front of the
fi ve-posi ti on shi m pl ate at the starti ng, or mi ni mum, overal l l ength cutout posi ti on.

Subsequent re-i nserti on of the fi ve-posi ti on shi m pl ate to i ts #2, #3, #4, or maxi mum (fi fth) l ength
posi ti on (refer to step 2, page 4-14) wi l l sl i ghtl y i ncrease the overal l l ength of the assembl y
beyond the basi c 11 i nches, and therefore tend to mi ni mi ze or el i mi nate any sl i di ng moti on
between the barrel stop and the fi ve-posi ti on shi m pl ate.

The fol l owi ng steps descri be checki ng for sli di ng moti on wi th the next or #2 notch up, and agai nst
the ri fl e barrel stop. If the #2 posi ti on does not mi ni mi ze the sl i di ng moti on, repeat the procedure
wi th the #3 notch up and so on. If the fi fth or maxi mum posi ti on i s desi red, note that the back
or smooth face of the shi m pl ate i s ori ented towards the muzzl e. Do not be concerned i f onl y a
smal l amount of sl i di ng moti on i s sti l l detectabl e wi th the shi m pl ate i n i ts apparentl y opti mum
setti ng, because the l atch arm wi l l compensate for thi s when i t i s cl osed and l ocked.
NOTE
Endurance testing indicated that it may be necessary to switch to another shim plate
position after several thousand rounds have been fired. The unit armorer should check
for excessive sliding motion each time the shim plate is removed for cleaning/lubrication
and the M203A2 re-mounted to the rifle.

1. Fol l ow the steps as descri bed i n para a. Instal l ati on to attach the qui ck rel ease bracket (1) to
the M203A2.

2. Compare the i l l ustrati on bel ow wi th the qui ck rel ease bracket for the purpose of
fami l i ari zati on wi th al l posi ti ons of the fi ve-posi ti on shi m pl ate (2):
2
1
STARTING POSITION
(ALL DOTS FACING MUZZLE
2 DOT CURVED SIDE DOWN)
FIFTH OR MAXIMUM
POSITION (BACK
FACING MUZZLE)
FRONT SIDE BACK
# 2 POSITION # 3 POSITION
# 4 POSITION
FULLY DEPRESS PLUNGER
TO INSTALL/REMOVE
THE SHIM PLATE
FRONT
(MUZZLE)
VIEW

Change 4 2-59
ARMY TM 9-1010-221-23&P


f. MOUNTING TO THE M16A4 RIFLE (CONT)

3. Set the fi ve-posi ti on shi m pl ate i n the bracket to the mi ni mum posi ti on as i l l ustrated, wi th the
2 dots down and faci ng the muzzl e.

LEFT SIDE
VIEW
FRONT
VIEW
FRONT
(MUZZLE)
VIEW

4. If present, remove the l ower rai l of the M5 adapter rai l system from the M16A4 ri fl e. Confi rm
that the barrel stop i s i nstal l ed i nsi de the handguard cap. Move the rear of the recei ver i nto
posi ti on around the ri fl e barrel . Confi rm that the l atch arm (3) of the bracket i s ful l y open.
Rotate the muzzl e end of the M203A2 towards the ri fl e barrel whi l e sl i di ng the M203A2 fi rml y
to the rear. Confirm that the roll pin in the rear of the M203A2 receiver engages the rifle
barrel nut at the six o' clock position notch.

3
3

5. Fi rml y hol d the M203A2 i n posi ti on/back agai nst the barrel nut of the ri fl e, whi l e al so hol di ng
the muzzl e end of the M203A2 agai nst the ri fl e' s barrel stop. Now, try to sl i de the M203A2
back and forth i f possi bl e, and note the di stance of any sl i di ng moti on. Some moti on may be
detectabl e wi th the shi m pl ate i n i ts starti ng posi ti on.

2-60 Change 4
ARMY TM 9-1010-221-23&P

6. Remove the M203A2 from the ri fl e. Depress the pl unger (4), wi thdraw the shi m
pl ate and re-i nsert i t i n the #2 posi ti on (refer to step 2, page 4-14). Note that the #2
position is indicated by a single dot stamped on its shim plate cutout, and that this
side of the shim plate faces the muzzle.
7. Re-mount the M203A2 to the ri fl e' s barrel nut and barrel stop. Attempt to sl i de the
M203A2 from front to rear.

8. If forward and back moti on i s detected, repeat step 7 wi th the #3 notch agai nst the ri fl e
barrel stop. If the assembl y i s now too l ong (i t wi l l not engage behi nd the barrel stop), go
back to the l ast posi ti on tri ed wi th the shi m pl ate, and compl ete the M203A2 attachment
process as descri bed next.

When the opti mum posi ti on of the shi m pl ate i s establ i shed:

a. Careful l y work the l atch arm (3) between the ri fl e barrel and the gas tube.
b. Hol d the retai ni ng spri ng away from the pl unger (4) and depress the pl unger to unl ock the
l atch l ever (5).
c. Catch the hook (6) i n the hol e of the l atch arm.
d. Rotate the l atch l ever (5) down.
e. Depress the pl unger (4). Make sure the retai ni ng spri ng does not engage the pl unger
duri ng thi s step.
f. Squeeze the l atch l ever ful l y cl osed (whi ch al l ows the pl unger to be rel eased and snap
forward). Thi s wi l l hol d the l atch l ever i n the ful l y cl osed/l ocked posi ti on.
NOTE
In i ts fi nal moti on, the l atch l ever may requi re very fi rm pressure agai nst the bracket to
al l ow the pl unger to snap back i nto pl ace, l ocki ng the l atch l ever cl osed. If necessary, use
the buddy system. DO NOT use a vi se or other mechani cal devi ce. Doi ng so may cause
damage to the qui ck rel ease bracket.
g. Rotate the M203A2 tri gger guard (7) to engage the l i p of the magazi ne wel l .

FRONT
MUZZLE
VIEWS
SIDE VIEW
4
5
6
7
3

Change 4 2-61
ARMY TM 9-1010-221-23&P

f. MOUNTING TO THE M16A4 RIFLE (CONT)

9. If forward and back moti on i s detected wi th the shi m pl ate set to i ts #3 notch, remove the
M203A2 from the ri fl e. Remove and re-i nsert the shi m pl ate i n i ts #4 posi ti on. Note that the
#4 position is indicated by three dots stamped adjacent to its shim plate cutout, and
that this side of the shim plate faces the muzzle.
# 4 POSITION
FRONT
(MUZZLE)
VIEW
DEPRESS PLUNGER TO
REMOVE/INSTALL THE
SHIM PLATE

10. If the #5 maxi mum posi ti on i s requi red, i nsert the shi m pl ate as i l l ustrated bel ow.

# 5 POSITION
FRONT
(MUZZLE)
VIEW
DEPRESS PLUNGER TO
REMOVE/INSTALL THE
SHIM PLATE

CAUTION
When detachi ng the M203A2 for cl eani ng, i nspecti on, or l ubri cati on, check and note the posi ti on
of the shi m pl ate for ease of re-attachment.

2-62 Change 4
ARMY TM 9-1010-221-23&P
CHAPTER 3
DIRECT SUPPORT MAINTENANCE PROCEDURES
Section I. REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST,
MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE); AND
SUPPORT EQUIPMENT
3-1. COMMON TOOLS AND EQUIPMENT. For authori zed common tool s and equi pment,
refer to the Modified Table of Organization and Equipment (MTOE), CTA 50-970 or CTA 8-100,
as applicable to your unit.
3-2. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT. Special tools, TMDE, and sup-
port equipment are listed in appendixes B and C of this manual.
3-3. REPAIR PARTS. Repair parts are listed and illustrated in appendix C of this manual.
Section II. DIRECT SUPPORT TROUBLESHOOTING
3- 4. GENERAL.
a. This section contains troubleshooting information for locating and correcting most of the
operating troubles which may develop in the 40mm grenade launcher M203. Each malfunction
for the individual part or assembly is followed by a list of tests or inspections which will help
you to determine the corrective actions to take. Perform the tests/inspections and corrective ac-
tions in the order listed.
b. This manual cannot list all malfunctions that may occur, nor all tests or inspections and
corrective actions. If a malfunction is not listed or is not corrected by listed corrective actions,
see individual repair sections for maintenance instructions on each major assembly.
3-5. TROUBLESHOOTI NG PROCEDURES. Refer to troubleshooting table for malfunctions,
tests, and corrective actions. The symptom index is provided for a quick reference of the
malfunctions covered in the table.
SYMPTOM INDEX
Troubleshooting
Procedures
Page
Failure to Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Failure to Cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Failure to Extract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Failure of Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Failure to Close or Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Failure to Eject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-1
ARMY TM 9-1010-221-23&P
DIRECT SUPPORT TROUBLESHOOTING
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. FAILURE TO FIRE.
Step 1. Check for broken firing
Replace broken
pin.
firing pin (p 3-21).
Step 2. Check for weak or broken compression helical spring.
Replace weak or broken compression helical spring
Step 3. Check for burred firing pin or trigger notch.
Remove burrs on firing pin or trigger notch.
2. FAILURE TO COCK.
Step 1. Check for worn or broken sear.
Replace worn or broken sear (p 3-20).
Step 2. Check that cocking lever is correctly assembled.
Reassemble cocking lever (p 3-21).
Step 3. Check for broken or bent spring pin.
Replace broken or bent spring pin (p 3-21).
Step 4. Check for proper assembly of follower guide assembly.
Reinstall follower guide assembly (p 3-31).
3. FAILURE TO EXTRACT,
Check for broken cartridge extractor or compression helical spring.
Replace broken cartridge extractor or compression
(p 3-21).
(p 3-20).
helical spring
3- 2
ARMY TM 9-1010-221-23&P

DIRECT SUPPORT TROUBLESHOOTING (CONT)

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

4. FAILURE OF SAFETY.

Step 1. Check for worn coil compress helical spring.

Replace worn coil compression helical spring (p 3-22).

Step 2. Check for broken grenade launcher safety.

Replace broken grenade launcher safety (p 3-22).

Step 3. Check for broken or missing spring pin.

Replace broken or missing spring pin (p 3-22).

5. FAILURE TO CLOSE OR LATCH.

Step 1. Check for worn barrel extension or barrel assembly.

Replace worn barrel extension (p 3-22).

6. FAILURE TO EJ ECT.

Check for worn, broken, or missing cartridge ejector, spring, or retainer.

Replace worn, broken, or missing parts (p 3-21).

3-3
ARMY TM 9-1010-221-23&P

Sect i on III. DIRECT SUPPORT MAINTENANCE PROCEDURES

3-6. 40MM GRENADE LAUNCHER M203/M203A1 W/E MAINTENANCE INSTRUCTIONS

This task covers:

Initial installation of the M203 grenade launcher on an M16 series rifle.

INITIAL SETUP


Materials/Parts
Locking wire (MS20995C32) (9505-00-293-4208)
Rivet (8448697) (from TM 9-1005-249-23&P, TM 9-1005-319-23&P, or TM 05538C-23&P/2A (Marine
Corps only)) (used to return grenade launcher to the M16 series configuration only)
Spring pin (MS39086-41)
Swivel locking bar (12598618)

Equipment Condition
Sling and hand guards removed from M16 series rifle (p 2-23).

INSTALLATION OF M203

1. Remove rivet (1) and front swivel (2). Discard rivet (1).

2
1

3-4 Change 3
ARMY TM 9-1010-221-23&P

NOTE
The M16/M16A1 rifle uses the old type
swivel mount and swivel locking bar. When
one or both parts must be replaced, order
new type swivel mount (PN 12598617) and
swivel locking bar (PN 12012059). M16A2
can only use the new configuration.
M4/M4A1 carbines use swivel locking bar
(PN 12991254).

2. Install front swivel (2) and new rivet (3) in swivel
mount (4). Flare the rivet (3) with a punch and
hammer.

4
2
3
4
2
3
OLD

3. Refer to page 2-23 and perform steps 1 thru 14
and return here.

CAUTION
The mounting bracket tang has been lengthened
and will require filing for proper fit. Remove only
the minimum amount of metal from tip to make
sure mounting holes are properly aligned.

5

4. If screw holes in receiver assembly and mounting bracket (5) cannot be aligned, remove the mounting
bracket and file the tip as required.

5. Install bushing half and repeat steps 12 thru 14 on page 2-26.

Change 3 3-5
ARMY TM 9-1010-221-23&P

3-6. 40MM GRENADE LAUNCHER M203/M203A1 W/E MAINTENANCE INSTRUC-
TIONS (CONT).

INSTALLATION OF M203 (CONT).

6. Install two machine screws (6). Fully tighten one
machine screw first, and then the other.

6
6

7. Check installation of receiver assembly as follows:

a. While holding rifle in a vertical position with the
muzzle up, attempt to move the receiver
assembly up and down and from side to side.

b. There must be no up and down movement
between the receiver assembly (M203) and the
rifle barrel.

c. The movement from side to side should not
exceed 1/8 inch (0.32 cm) left or right of center.
Total movement cannot exceed inch (0.64
cm).

d. If excess side to side movement exists, replace
the bushing halves.

e. If excess up and down movement exists, obtain
a new mounting bracket and repeat steps 3 thru
6.

8. Refer to page 2-27 and complete assembly.

RECEIVER
ASSEMBLY
FIRMLY
SEATED

3-6 Change 1
ARMY TM 9-1010-221-23&P
INSPECTION/REPAIR
1. Inspect carbine (1). Refer to TM 9-1005-249-23&P, TM 9-1005-319-23&P, or TM 05538C-23&P/2A
(Marine Corps only).
2. Inspect mounting bracket assembly (2) for bends or
damage. If damaged, replace/repair. Inspect two
socket head screws (3) and washers (4). If damaged,
replace.
3. Inspect bushing halves (5) for chips or wear. If damaged, replace
bushing halves.
4. Inspect heat shield for tightness on hand guard. If loose enough to rattle,
replace as necessary.
INSTALLATION OF M203A1
1. Disassemble quadrant sight (see para 2-13, steps 1 and 2).
2. Disassemble range quadrant (see para 2-14). Dispose/turn-in two excess machine screws.
Change 1 3-6.1
ARMY TM 9-1010-221-23&P
INSTALLATION OF M203A1 (CONT)
3. Install quadrant sight spacer between range
quadrant and bracket assembly.
4. Reassemble range assembly quadrant using 2
new machine screws.
5. Reassemble quadrant sight assembly (see
para 2-13, steps 4 and 5).
6. Remove sling from front swivel (see para 2-11, step 2).
NOTE
Side swivel mount has to be on the right side of the M4/M4A1 when mounting the M203A1
Grenade Launcher.
7. Ensure side swivel mount has the sling swivel located on the right side of the M4/M4A1. If not, disassemble
side swivel mount (see para 2-16, step 5A thru 5C).
8. Reassemble side swivel mount (see para 2-16, steps 4B thru 4D).
9. Install M203A1 to the M4/M4A1.
a. Remove handguard.
NOTE
The following step is performed without the mounting
bracket.
b. Align spring pin (1) with notch in barrel nut (2). Be sure
spring pin is fully seated in notch of barrel nut. Seat receiver
assembly (3) firmly in carbine.
NOTE
For proper alignment, ensure the receiver assembly is
centered under the barrel of the carbine.
3-6.2 Change 1
ARMY TM 9-1010-221-23&P
c. Depress the barrel stop (4) on the M203A1 receiver
and ensure it operates through its full range of motion.
If the barrel stop operates through its full range of
motion, proceed to step 10.
d. If barrel stop is prevented from operating through its
full range of motion by making contact with the bayonet
lug on the M4/M4A1 carbine, remove the M203A1
receiver from the M4/M4A1 carbine.
e. Disassemble the barrel stop from the M203A1 receiver
(see para 3-10, step 1).
stop as shown in illustration.
(2) File burrs and sharp edges from barrel
stop.
f. Modify barrel stop, as follows:
(1) Grind or file excess material from barrel
(3) Touch up area of bare metal with solid
film lubricant (appendix D, item 11).
g. Reassemble barrel stop in M203A1 receiver
(see para 3-10, step 14).
10. Install bushing half into mounting bracket assembly.
Change 1 3-6.3
ARMY TM 9-1010-221-23&P
INSTALLATION OF M203A1 CONT)
11. Stake once on each side of barrel stop pin hole (5).
11.1. Position mounting bracket over carbine barrel in step down area between muzzle and front sight with
the flanges toward the muzzle.
12. Rotate mounting bracket upward/side ways and insert other bushing half between M203A1 receiver and
M4/M4A1 carbine barrel.
13. Insert bracket clamp assembly (6) into mounting bracket (7) behind the mounting bracket flange, with the
rounded portion of bracket clamp assembly toward carbine barrel, and slide the bracket clamp assembly in
until the bracket clamp assembly tabs hook underneath the mounting bracket flange.
14. Lift up on bracket clamp assembly to avoid binding and align screw holes in receiver assembly and
mounting bracket. Install two washers, two socket head screws and tighten snug by hand.
15. Screw in the bracket clamp assembly screw (8) until the bracket clamp (6) is snug against the mounting
bracket flange, then tighten the bracket clamp assembly screw an additional turn. DO NOT OVER
TIGHTEN.
16. Fully tighten the two screws on the side of the receiver.
3-6.4 Change 2
Change 1 3-6.5/(3-6.6 blank)
ARMY TM 9-1010-221-23&P
17. Check installation of the M203A1 receiver assembly as follows.
a. The movement from side to side should not exceed 1/8 inch left or right of center. Total movement
cannot exceed inch.
b. If excess side to side movement exist, replace the bushing halves.
c. Check forward and rearward movement of M203A1 receiver. No forward or backward movement is
allowed.
18. Engage trigger guard (para 2-11, step 16).
19. Install locking wire:
a. Install an 8 inch (20.32 cm) length of locking wire; it may be started at either socket head screw.
b. Insert locking wire approximately halfway through hole in head of socket head screw.
c. Wrap the half of the wire farthest from the front of the receiver assembly around the head of the
mounting screw in a clockwise direction.
d. Twist wire strands together in either right-hand or left-hand direction. Begin at the socket head screw
until the twisted wire reaches an appropriate hole in the bracket clamp assembly screw. Insert locking
wire through one of the bracket clamp assembly screw holes.
e. Twist wire in same direction used in step a until one strand of wire can be inserted through socket
head screw on other side of receiver and pull wire tight.
f. Wrap loose strand of wire around head of socket head screw in a counter clock wise direction.
g. Twist wire strands together, beginning at the screw head, until the twisted wire is approximately 1/2
inch (1.27 cm) long.
h. Cut off excess wire strands and bend twisted section out of the way.
20. Install M203 barrel (see para 2-11, steps 20 and 21).
21. Install new handguard and sight assembly (see para 2-11, step 22).
22. Install sling in front swivel (see para 2-11, step 23).
23. Install quadrant sight assembly (see para 2-11, step 24).
24. Function check M203A1, using function checks for the M203 in TM 9-1010-221-10, (page 3-13).
25. Re-zero M4/M4A1 carbine because installation of the M203A1 changes the zero of the M4 carbines.

ARMY TM 9-1010-221-23&P
3-7. 40MM GRENADE LAUNCHER M203/M203A1MAINTENANCE INSTRUCTIONS.

This task covers:


INITIAL SETUP

(ARMY) Small Arms Repairman Tool Kit (item 5, app B)

Materials/Parts
Sealing compound (item 19, app D)

Equipment Condition
a. Hand guard assembly removed from M16 series rifle. Refer to page 2-16.
b. Leaf Sight and Rail Grabber Assembly removal from M5 or M4 Adapter Rail System

DISASSEMBLY

NOTE
Disassemble only to replace
unserviceable components.

1. Remove two machine screws (1) from leaf
sight assembly (2).

1.1 Remove two socket head screws (4) and two
hex nuts (5) from leaf sight and rail grabber
assembly.

2. Remove leaf sight assembly (2) from hand
guard assembly (3).

3. Remove leaf sight assembly (2.1) from rail
grabber assembly (6).

2
3
1

4 4
6
5 5
2.1

Change 4 3-7
ARMY TM 9-1010-221-23&P

3-7. 40MM GRENADE LAUNCHER M203/M203A1MAINTENANCE INSTRUCTIONS
(CONT).

INSPECTION/REPAIR

1. Inspect hand guard assembl y for cracks or di storti on. Cracks shoul d not exceed 1 i nch
(2.54 cm) i n l ength.

2. Inspect heat shi el d for ti ghtness on hand guard. If heat shi el d i s l oose enough to rattl e,
the hand guard assembl y must be repl aced.

3. Inspect al l parts for servi ceabi l i ty.

4. Repl ace al l authori zed unservi ceabl e parts.

NOTE
For further breakdown of l eaf si ght assembl y, see page 3-9.

5. Cl ean hand guard assembl y.

6. If the rai l grabber assembl y i s damaged, i t must be repl aced.

REASSEMBLY

1. Align holes in base of leaf sight assembly (1)
with holes in hand guard assembly (2). Apply
sealing compound (item 19, app D) to two
machine screws (3). Install and fully tighten
two machine screws (3).

2. Install hand guard assembly (2) on M16 series
rifle (p 2-30).

3. Align holes in base of leaf sight assembly
(1.1) with holes in rail grabber assembly (4).
Apply sealing compound (item 19, app D) to
two socket head screws (3.1) and assemble
with two hex nuts (5).

2
3
1

3.1
4
5 5
1.1
3.1

3-8 Change 4
ARMY TM 9-1010-221-23&P

3-8. LEAF SIGHT ASSEMBLYMAINTENANCE INSTRUCTIONS.

Thi s task covers:

a. Di sassembl y c. Reassembl y/Lubri cati on
b. Cl eani ng/Inspecti on/Repai r

INITIAL SETUP

(ARMY) Smal l Arms Repai rman Tool Ki t (i tem 5, app B)

Materi al s/Parts
Cl eaner, l ubri cant, and preservati ve (i tem 5, app D)
Dry cl eani ng sol vent (i tem 9, app D)
Rubber gl oves (i tem 10, app D)
Spri ng pi n (MS39086-66)
Wi pi ng rag (i tem 17, app D)

Equi pment Condi ti on
a. Leaf si ght assembl y removed from hand guard (page 3-7).
b. Leaf si ght assembl y removed from rai l grabber assembl y (page 3-7).

DISASSEMBLY

NOTE
Disassemble only to
replace unserviceable
components.

1. Remove machine screw (1), lockwasher (2),
and front folding sight leaf (3, 3.1).

2. Remove spring pin (4) and flat washer (5)
from sight windage screw (6). Discard
spring pin (4).

3. Unscrew sight windage screw (6) from
sight leaf mount (7) and sight leaf base (8)
or (8.1).

Change 4 3-9
ARMY TM 9-1010-221-23&P

3-8. LEAF SIGHT ASSEMBLY - MAINTENANCE INSTRUCTIONS (CONT).

CLEANING/INSPECTION/REPAIR

WARNING
Dry cleaning solvent is FLAMMABLE and TOXIC and must be kept away from
open flames and used in a well-ventilated area. Use of rubber gloves is
necessary to protect the skin when washing grenade launcher parts.


1. Cl ean front fol di ng si ght l eaf wi th dry cl eani ng sol vent (i tem 9, app D) and wi pi ng rag (i tem
17, app D).

2. Inspect al l parts for servi ceabi l i ty.

3. Repl ace al l authori zed unservi ceabl e parts.

REASSEMBLY/LUBRICATION

1. Lubricate all parts with CLP (item 5, app D).

2. Place sight leaf mount (1) in sight leaf base (2)
or (2.1) and align holes as illustrated.

3. Insert and screw in sight windage screw (3)
through holes in sight leaf base and sight leaf
mount. Secure sight windage screw (3) with
flat washer (4) and new spring pin (5).

4. Line up hole in front folding sight leaf (6, 6.1)
with hole in sight leaf mount (1). Secure with
lockwasher (7) and machine screw (8).

3-10 Change 4
ARMY TM 9-1010-221-23&P

3-9. BARREL ASSEMBLY - MAINTENANCE INSTRUCTIONS

Thi s task covers:

a. Di sassembl y c. Inspecti on/Repai r
b. Cl eani ng d. Reassembl y/Lubri cati on

INITIAL SETUP

Barrel extensi on staki ng support tool (fi g. E-3, app E)
Bore constri cti on check tool (fi g. E-1, app E)
(ARMY) Smal l Arms Repai rman Tool Ki t (i tem 3, app B)

Materi al s/Parts
Adhesi ve (i tem 1, app D)
Bore brush (7790631)
Cl eaner, l ubri cant, and preservati ve (CLP) (i tem 5, app D)
Dry cl eani ng sol vent (i tem 9, app D)
Penetrant ki t (i tem 15, app D)
Rubber gl oves (i tem 10, app D)
Wi pi ng rag (i tem 17, app D)

Reference
TM 9-1010-221-10

Equi pment Condi ti on
Barrel assembl y removed from grenade l auncher (page 2-17).

Change 3 3-11
ARMY TM 9-1010-221-23&P

3-9. BARREL ASSEMBLY - MAINTENANCE INSTRUCTIONS

DISASSEMBLY

WARNING
To avoid injury to your eyes, use care
when removing and installing spring-
loaded parts.

NOTE
Disassemble only to replace unserviceable
components.

Cartridge locator and/or compression helical
spring may have to be replaced if there is
no spring tension when the cartridge locator
is de-pressed.

A file may have to be used to remove
staked metal. Prying of the barrel extension
may be required.

4
3
2
1

1. Check to see if barrel extension has previously been restaked. If it has been restaked previously, a new
barrel extension is necessary.

2. Disassemble staked barrel extension (1), cartridge locator (2), and compression helical spring (3) from
barrel (4).

CLEANING

WARNING
Dry cleaning solvent is FLAMMABLE and TOXIC and must be kept away from
open flames and used in a well-ventilated area. Use of rubber gloves is
necessary to protect the skin when washing grenade launcher parts.


1. Cl ean components thoroughl y of al l grease, oi l , water and any excessi ve adhesi ve usi ng dry
cl eani ng sol vent (i tem 9, app D). After cl eani ng, dry al l parts wi th a wi pi ng rag (i tem 17,
app D).

2. Cl ean bore and chamber wi th bore brush (see TM 9-1010-221-10).

3-12 Change 4
ARMY TM 9-1010-221-23&P

INSPECTION/REPAIR

1
2
3
4

1. Inspect the bore of the barrel (1) for pitting and erosion. Fine pits are allowed. If pits are wider than the
lands or grooves and are over 0.38 inch (0.97 cm) in length, replace barrel.

2. Use bore constriction check tool (2) (fig. E-1, app E) to detect dents and minor damage that would interfere
with forward progress of fired projectile. Tool must pass freely through entire barrel bore. If it does not
pass freely, the barrel is unserviceable and must be replaced.

3. Inspect compression helical spring (3) for breaks and distortion. Replace if necessary.

4. Visually inspect cartridge locator (4) for burrs, pits, and cracks. Replace if necessary.

5

5. Inspect barrel extension (5) for burrs, pits, and cracks using penetrant kit (item 15, app D) as follows:

WARNING
Dry cleaning solvent is FLAMMABLE and TOXIC and must be kept away from open flames and used
in a well-ventilated area. Use of rubber gloves is necessary to protect the skin when washing grenade
launcher parts.


a. Make sure area to be inspected is clean, free of oil, etc. by using dry cleaning solvent (item 9, app D).
Spray a small amount of remover in penetrant kit on the area to be inspected, let it dry, and wipe with a
wiping rag (item 17, app D).

Change 1 3-13
ARMY TM 9-1010-221-23&P

3-9. BARREL ASSEMBLY MAINTENANCE INSTRUCTIONS (CONT).

INSPECTION/REPAIR (CONT).

b. Spray penetrant to wet component to be inspected.

c. Spray developer over penetrant and let it work. Wherever there is a crack, there will be
a change in color. If there are cracks, the component is unserviceable.

d. If no cracks are indicated, spray remover on area. Let dry, and wipe with a wiping rag
(item 17, app D).

NOTE
Replace handgrip assembly if it is cracked or has broken cartridge retainers. Repair handgrip
assembly if it is loose from the barrel.

6. Remove defective handgrip assembly as follows:

a. With barrel assembly laying so barrel extension is facing up, set external retaining ring pliers between
edges of handgrip assembly where it contacts barrel, and spread.

b. Do this in several locations up and down the length of handgrip assembly until handgrip adhesive and
barrel separate.

c. With pliers approximately at midpoint, spread handgrip assembly and carefully tap barrel out with
rubber/plastic hammer.

NOTE
Early production barrels do not contain the locating rivet in the handgrip assembly or the locating
recess in the barrel. If you have this type of barrel, discard it. Do not repair. The hand grip
assembly has a locating rivet positioned in about the center on the right side. The head of this
rivet, on the inside of the handgrip assembly, enters into a small recess on the right side of the
barrel.

7. Spread handgrip assembly away from the barrel sufficiently to release rivets from recess in barrel. Once
released from rivet recesses, handgrip assembly should slide off under hand pressure.

8. Clean all the old adhesive from the barrel and dry thoroughly.

3-14 Change 3

ARMY TM 9-1010-221-23&P
REASSEMBLY/LUBRICATION
1. Assemble handgrip assembly to barrel as follows:
NOTE
Take care not to dent or bend the barrel during the repair/reassembly process.
a. Apply adhesive (item 1, app D) to the inside of the new handgrip assembly and work
it onto the barrel from the rear, Make sure to get the locating rivet head into the
barrel locating recess.
b. Clean all excessive adhesive from the assembled components.
c. Lightly clamp the handgrip assembly in position and allow the adhesive to set for ap-
proximately 24 hours.
d. Remove clamps. Assembly is now ready for use.
2. Wipe inside of barrel with wiping rag (item 17, app D) containing a small amount of CLP
(item 5, app D).
3. Apply light film of CLP (item 5, app D) to bore and outside of barrel.
4. Reassemble compression helical spring (1) and cartridge locator (2) on barrel (3).
3- 15
ARMY TM 9-1010-221-23&P
3-9. BARREL ASSEMBLYMAINTENANCE INSTRUCTIONS (CONT).
REASSEMBLY/LUBRICATION (CONT)
5. For support, place barrel extension (4) on barrel extension staking tool (fig. E-3, app E).
Clamp and secure in a vise. Slide barrel (3) chamber on barrel extension staking tool.
CAUTION
Do not stake over original staking.
NOTE
Only one time restaking.
6. Using a center punch, securely stake barrel extension (4) to barrel (3) four times on each
side, between original stake marks.
7. Use bore constriction check tool (fig. E-1, app E) to ensure barrel has not been dented.
3-16
ARMY TM 9-1010-221-23&P
3-10. RECEIVER ASSEMBLY-MAINTENANCE INSTRUCTIONS
This task covers:
a. Disassembly c. Inspection/Repair
b. Cleaning d. Reassembly/Lubrication
e. Annual Gaging/Inspection
INITIAL SETUP
Test Equipment
Firing pin protrusion gage (item 2, app B)
Shop Set, Small Arms: Field Maintenance, Basic Less Power (item 3, app B)
Bore brush (TM 9-1005-249-10, TM 9-1005-319-10, or TM 05538C-10/1A (Marine Corps only))
Chamber cleaning brush 8432358 (TM 9-1005-249-10, TM 9-1005-319-10, or TM 05538C-10/1A (Marine
Corps only))
Field Maintenance Shop Set (item 3, app B)
(ARMY) Small Arms Repairman Tool Kit (item 5, app B)
Slave pin (fig. E-2, app E)
Torque wrench adapter (item 1, app B)
Materials/Parts
Cleaner, lubricant, and preservative (CLP) (item 5, app D)
Dry cleaning solvent (item 9, app D)
Penetrant kit (item 15, app D)
Pipe cleaner (item 6, app D)
Rubber gloves (item 10, app D)
Sealing compound, Devcon F (item 18, app D)
Self-locking screw (MS21262-5)
Solid film lubricant (item 11, app D)
Surface primer (item 16, app D)
Wiping rag (item 17, app D)
References
TM 9-1005-249-10
TM 9-1005-319-10 or TM 05538C-10/1A (Marine Corps Only)
TM 9-1010-221-10
Equipment Conditions
Make sure grenade launcher is cleared and cocked before starting disassembly procedures.
Grenade launcher removed from M16 series rifle (p 2-15 thru 2-19).
Change 1 3-17
ARMY TM 9-1010-221-23&P
3-10. RECEIVER ASSEMBLY--MAINTENANCE INSTRUCTIONS (CONT).
DISASSEMBLY
NOTE
Solid Film Lubricant (SFL) is the authorized touchup for the M203/M203A1 Grenade
Launcher and may be used on up to one third of the exterior finish of the weapon.
FOR CONUS USE ONLY: Solid Film Lubricant (item 11, app D) may be used as a
touchup without limitation on the receiver assembly. This is to say that units which
DO NOT fall under the category of Divisional Combat Units or rapid deployment type
units may have up to 100 percent of the exterior surface of the receiver assembly
protected with SFL. Prior to application of SFL, the surface must be thoroughly
cleaned and inspected for corrosion and/or damage. If corroded or damaged, the part
must be repaired or replaced prior to application of SFL. Continued use under combat
conditions would result in an unprotected surface when the SFL wears off. This would
result in a large light reflecting surface and accelerated deterioration of the
unprotected surface. Therefore, Divisional Combat Units and units which fall under
the definition of Rapid Deployment type must adhere to the limitation of NOT over one
third of their exterior surface covered by SFL.
If a M203/M203A1 Grenade Launcher RECEIVER Assembly is missing one third or
more of its exterior protective finish, resulting in an unprotected/light reflecting
surface, it is a candidate for overhaul. This missing finish will be considered a
shortcoming. This shortcoming requires action to obtain a replacement weapon. Once
a replacement has been received, evacuate the original weapon to depot for overhaul.
Once the missing exterior protective finish of the receiver assembly has exceeded one
third of its total surface, the probability of reclaiming the receiver assembly during
overhaul diminishes rapidly. In order to extend the life of the receiver assembly,
which is the serial numbered item, it is necessary to evacuate the weapon to depot
once the missing finish reaches one third of the total surface of the receiver assembly.
CAUTION
Except for disassembly of the cartridge extractor and trigger guard, disassemble in the
following order. Not following this order may result in damage to components.
NOTE
Make sure that grenade launcher is cleared and cocked before starting disassembly
procedures. Remove screw thread insert when required for repair.
3-18 Change 1
ARMY TM 9-1010-221-23&P
1. Remove headless straight pin (1) to release
torsion helical spring (2) and barrel stop (3).
M203A1 requires removal of peening.
NOTE
Remove headless straight pin only when
barrel latch or compression helical spring
requires replacement.
2. Remove headless straight pin (4) to release
barrel latch (5) and compression helical spring
(6).
WARNING
3. Remove and discard self-locking screw (7) from back plate (8). Remove back plate (8) and follower
guide assembly (9) from receiver.
NOTE
The old part number for the back plate (8) is 8448314, and the old part number for the follower guide
assembly (9) is 8448387.. The current configuration of the back plate and follower guide assembly is
shown. The previous configuration follower guide assembly contained a captured spring and detent,
therefore, it did not require a screw. The old type back plate and follower guide assembly only need to
be replaced if defective. If the old configuration or either the back plate or the follower guide assembly
requires replacement, both parts must be replaced, as old to new configurations are not compatible.
Change 1 3-19
ARMY TM 9-1010-221-23&P
DISASSEMBLY (CONT)
4. Remove spring pin (10) to release trigger
guard (11).
WARNING
NOTE
The new trigger pin, part number 12002921, for the receiver assembly is illustrated above. When the
new trigger pin is removed, the trigger separates into three parts: the trigger, sear, and compression
helical spring.. The old trigger pin is also illustrated above and is a repair part for the old trigger
assembly. When the old trigger pin is removed, the trigger assembly remains intact by the sleeve
bushing.
5. Remove spring pin (12), trigger pin (13), and trigger (14). If old trigger pin, remove sleeve bushing (15)
from trigger(14). Remove sear (16) and compression helical spring (17) from trigger (14). Remove
compression helical spring (18) from receiver assembly.
3-20
ARMY TM 9-1010-221-23&P

WARNING
Using the old style firing pin, part number
8448327, can cause injury to personnel
and equipment when firing a live round.
The old firing pin must be replaced by the
new firing pin, part number 12002970,
whenever the old pin is identified in the
weapon.

6. Remove spring pin (19), cocking lever (20),
and firing pin (21).

19
20
21
NEW OLD

22
25
24
25.1
23

26
27
28

WARNING
To avoid injury to your eyes, use care when
removing and installing spring-loaded parts.

NOTE
Remove spring pin (25.1) only when damaged.

7. Remove spring pin (22) to release ejector
retainer (23), compression helical spring (24),
8. Remove spring pin (26) to release cartridge
extractor (27). Remove compression helical
spring (28).

cartridge ejector (25), and spring pin (25.1).

Change 4 3-21

ARMY TM 9-1010-221-23&P


DISASSEMBLY (CONT)

WARNING
To avoid injury to your eyes, use care
when removing and installing spring-
loaded parts.

9. Remove spring pin (29) to release grenade
launcher safety (30), safety detent (31), and
compression helical spring (32).

29
32
30
31

CLEANING

WARNING
Dry cleaning solvent is FLAMMABLE and TOXIC and must be kept away from open flames and
used in a well-ventilated area. Use of rubber gloves is necessary to protect the skin when
washing grenade launcher parts.


Clean parts of all grease, oil, water, and dirt using dry cleaning solvent (item 9, app D). After cleaning,
dry all parts with a wiping rag (item 17, app D) and lubricate with CLP (item 5, app D).

INSPECTION/REPAIR

1. Check al l parts for damage. Repl ace al l aut hori zed unservi ceabl e parts.

2. Check al l spri ngs for breaks, di storti on, and cracks. Repl ace i f faul ty.

3. Inspect al l remai ni ng parts for burrs or deformati on. Remove burrs and mi nor deformati ons
wi th a fi ne stone.

4. Check that fi ri ng pi n, saf ety, extractor, and extractor pi n are not broken. Repl ace i f broken.

3-22 Change 1
ARMY TM 9-1010-221-23&P
5. Inspect the trigger and sear for damage and/or wear. If excessively worn, the trigger pull can be affected.
See page 3-34 for trigger pull test. If old trigger assembly is unserviceable, replace it with trigger, sear, and
compression helical spring. The new trigger pin and spring pin will also be required.
6. Inspect barrel latch. Use penetrant kit (item 15, app D) to check for cracks as follows.
WARNING
launcher parts.
a. Make sure area to be inspected is clean and free of oil, etc., by using dry cleaning solvent (item 9, app
D). Spray a small amount of remover on the area to be inspected, let it dry, and wipe off with a wiping
rag (item 17, app D).
b. Spray penetrant to wet component to be inspected.
c. Spray developer over penetrant and let it work. Wherever there is a crack, there will be a change in
color. If there are cracks, the component is unserviceable.
d. If no cracks are indicated, spray remover on area, let it dry, and wipe it off with a wiping rag (item 17,
app D).
CAUTION
Do not remove breech insert unless damaged or loose.
NOTE
For M203 receiver assemblies with serial numbers 39700 and above, go to step 7.
For M203 receiver assemblies with serial numbers 39700 and below, refer to step 8.
Change 1 3-23
ARMY TM 9-1010-221-23&P
INSPECTION/REPAIR (CONT)
7. Visually inspect the face of the breech insert (1)
for damage. Inspect the breech insert; it should
not protrude above the breech face and should not
be more than 0.007 inches (0.018 cm) below the
breech face. If the weapon fails any part of the
above inspection, skip to step 9 for repair. If the
weapon passes all of the above inspections, skip
to page 3-27 for reassembly.
NOTE
There is no reverse torque requirement on receiver assemblies with serial numbers
39700 and above.
Before inspecting an M203 with serial number 39700 and below, check records to see if
it has previously had its breech insert repaired. If it has been repaired, inspect in
accordance with step 7 above.
8. Use torque wrench adapter and torque wrench and apply 60 in.-lb (6.78 N-m) of reverse
torque to the breech insert (1). If insert indicates no movement and meets the acceptable
criteria cited in step 7 above, it is acceptable; skip to page 3-28 for reassembly. If it does not
meet this criteria, continue with repair procedures in step 9.
NOTE
A breech insert that has been repaired on receiver assemblies 39700 and below will no
longer require a reverse check. Therefore, a record should be maintained to prevent a
duplication of effort.
9. Use torque wrench adapter and remove breech insert (1). Discard the breech insert if
damaged. Examine the breech insert threads in the receiver assembly for damage. If the
threads in the receiver assembly are not damaged, install the breech insert using the
procedures on page 3-25. If the threads in the receiver assembly are damaged, install the
breech insert using the procedures on page 3-26.
3-24
ARMY TM 9-1010-221-23&P
10. Install breech insert (1) in receiver assemblies
with no thread damage as follows:
a. Clean all sealing compound residue in the
receiver assembly using an M16A1/M16A2 rifle
chamber cleaning brush (see TM 9-1005-249-
10, TM 9-1005-319-10, or TM 05538C10/1A
(Marine Corps only)). Insert brush into the
threaded hole and rotate several times.
b. Clean the threads of the new breech insert (1)
thoroughly, using the chamber cleaning brush
(see TM 9-1005-249-10, TM 9-1005-319-10, or
TM 05538C10/1A (Marine Corps only)).
c. Remove all traces of oil and grease so the
sealing compound will adhere properly.
d. Use surface primer (item 16, app D) to remove oil and grease and to leave a clean, dry
surface. Apply surface primer on the threads in the receiver assembly and on the breech
insert (1). Allow primer to dry completely.
CAUTION
Do not stake the breech insert.
e. Apply sealing compound (item 19, app D) to coat both the threads of the receiver assembly
and the threads of the breech insert (1). Install the breech insert in the receiver assembly.
Tighten the breech insert (using torque wrench adapter and torque wrench) to 50 5 in.-lb
(5.7 0.6 N-m). Check the breech insert to make sure it is flush to 0.007 inch (0.018 cm)
below the surface of the breech face. Turn the breech insert in as unserviceable if it
protrudes above breech face or if it is more than 0.007 inch (0.018 cm) below the breech
face.
f. Allow the repaired grenade launcher to stand for 24 hours before using to permit the
sealing compound to cure.
3-25
ARMY TM 9-1010-221-23&P
INSPECTION/REPAIR (CONT)
11. Install breech insert (1) in receiver assemblies with damaged threads as follows:
WARNING
launcher parts.
a. Remove the breech insert from the receiver assembly. Clean thoroughly using dry cleaning solvent
(item 9, app D). The threads must be free of all residue, including oils.
b. Clean the stripped hole in receiver assembly using a bore brush (TM 9-1005-249-10, TM 9-1005-319-
10, or TM 05538C10/1A (Marine Corps only)) to remove or loosen debris. Clean with dry cleaning
solvent (item 9, app D) to remove debris and oils.
c. Apply surface primer (item 16, app D) to the breech insert (1) threads and shoulder area as well as to
the receiver assembly hole that has the stripped threads. The primer should be applied to the shoulder
area of the hole as well. Allow the primer to dry completely.
3-26 Change 1
ARMY TM 9-1010-221-23&P

1

d. Apply a coat of sealing compound, DEVCON F (item 18, app D), to the breech insert (1) and the hole area
in the receiver assembly. Install the breech insert as if being threaded. When the breech insert is in the
final assembled position, flush to 0.007 inch (0.018 cm) below the breech surface of the receiver assembly,
remove all excess sealing compound from the breech insert face, including the notches in the breech insert
for the torque wrench adapter. Be sure all excess sealing compound is removed from the firing pin hole in
the breech insert, including the rear area where the firing pin makes contact with the breech insert. Insert a
pipe cleaner (item 6, app D) from the rear of the grenade launcher and through the firing pin hole.

e. Reassemble the back plate to the receiver assembly and place a C-clamp against the breech insert (1) and
the back plate. Tighten the C-clamp only enough to hold the breech insert in a tight position to the receiver
assembly. Do not bend back plate inward. Let the sealing compound cure for 24 hours.

f. To be sure the repair is satisfactory, remove C-clamp. Use the torque wrench adapter and torque wrench
and apply 55 in.-lb (6.22 N-m) reverse torque to the breech insert (1). The breech insert should not move or
loosen. If the breech insert loosens, turn the grenade launcher in as unserviceable.

3-27

ARMY TM 9-1010-221-23&P


REASSEMBLY

1. Install spring pin (1), helical compression
spring (2), safety detent (3), flat end first, and
grenade launcher safety (4), and secure with
spring pin (5). Spring pin should be equal
distance to both sides.

1
5
4
2
3

2. Seat compression helical spring (5) in hole in
receiver. Install cartridge extractor (6) and
secure with spring pin (7). Check that spring
pin (7) is equally positioned on both sides.

7
6
5

3-28 Change 4
ARMY TM 9-1010-221-23&P
3. Place compression helical spring (8) on
cartridge
ejector (9). Install cartridge ejector in
middle hole of receiver as shown. Position
ejector retainer (10) on compression helical
spring (8). Press on ejector retainer (10) to
compress compression helical spring (8) and
secure with spring pin (11). If removed,
install spring pin (11.1).
WARNING
Using the old style firing pin, part
number 8448327, can cause injury to
personnel and damage to equipment
when firing a live round. The old
firing pin must be replaced by the new
firing pin, part number 12002970,
whenever the old firing pin is
identified in the weapon.
NOTE
Install firing pin with flat side up. The
cocking lever goes in slot in receiver.
4. Seat cocking lever (12) on firing pin (13) as
shown.
Install cocking lever (12) and firing pin (13),
and secure with spring pin (14).
Change 1 3-29
ARMY TM 9-1010-221-23&P
REASSEMBLY (CONT)
NOTE
The new trigger pin for the receiver assembly is illustrated in this procedure. The old trigger pin is also
illustrated here. When old trigger pin is unserviceable, replace with new old style trigger pin.
5. Install compression helical spring (15) into the back of the firing pin receiver.
WARNING
6. Install new trigger pin as follows:
NOTE
A fabricated slave pin (item E-2, app E) may be used to hold items (16), (17), and (18) together.
a. Place compression helical spring (16) on trigger (17).
b. Position sear (18) on compression helical spring (16) and align trigger pin holes in trigger (17) and sear
(18).
c. Install the trigger (17) and secure with trigger pin (19) and spring pin (20). Check that head of trigger
pin (19) is located on right side of receiver.
7. Install old trigger pin as follows:
a. Place compression helical spring (16) and sear (18) on trigger (17).
b. Install trigger (17) and secure with trigger pin (19) and sleeve bushing (21).
8. For firing pin protrusion test procedures, refer to page 3-35.
3-30 Change 1
3-31
ARMY TM 9-1010-221-23&P
ARMY TM 9-1010-221-23&P
REASSEMBLY (CONT)
12. Install compression helical spring (27)
and barrel latch (28). Secure with
headless straight pin (29) by installing
headless straight pin flush to 0.030
in. (0.076 cm) slightly below the tip
of the receiver. The headless straight
pin must not be flush with or extend
below the bottom surface.
13. Stake headless straight pin in place as follows:.
a. Stake pin in place at top and bottom, 180 degrees opposed; do not allow punch to
extend or slide into pinhole during staking.
b. Receiver staking shall be limited to four, placed 90 degrees apart at 3, 6, 9, and 12
o cl ock.
c. Inspect staked area for cracked or separated material. Replace receivers that have
cracked or separated material.
3- 32
ARMY TM 9-1010-221-23&P
14. Place torsion helical spring (30) on barrel stop (31)
and secure with headless straight pin (32).
M203A1 ONLY Handguard assembly does not
cover barrel stop pin holes (32.1) therefore one
stake each side of receiver is required to retain
barrel stop pin.
15. Insert tracks on barrel assembly (33) into tracks in receiver assembly (34). Lift up on barrel assembly (33)
and compress barrel stop (31). Pull barrel assembly (33) rearward and barrel stop (31) will snap in place.
16. Perform function checks in accordance with TM 9-1010-221-10.
Change 1 3-33
ARMY TM 9-1010-221-23&P
ANNUAL GAGlNG/INSPECTlON
1. Test trigger pull as follows:
a. Cock grenade launcher.
c. Place grenade launcher on edge of table,
barrel
end up. Support grenade launcher firmly with
hand.
b. Place safety in FIRE position.
d. Place rod on trigger and let it hang freely.
e. Begin adding weights to the rod until trigger
releases firing pin. Record the weight.
NOTE
Minimum trigger pull is 5 pounds (2.27 kg);
maximum trigger pull is 11 pounds (4.99
kg).
Trigger pull measuring fixture is found in SC
4933-95-CL-A11.
3-34 Change 1
2. Test firing pin protrusion as follows:
WARNING
To avoid injury to your eyes, use care when
removing and installing spring-loaded parts.
a. Cock the grenade launcher.
b. Move barrel to forward position.
c. Remove self-locking screw (1), back plate (2),
and follower guide assembly (3). Discard self-
locking screw (1).
ARMY TM 9-1010-221-23&P
d. Squeeze the trigger and measure firing pin
protrusion using firing pin protrusion gage. If
firing pin exceeds maximum limit, or if it does
not meet the minimum limit, replace it and
regage.
e. Install follower guide assembly (3) in receiver.
Install and secure back plate (2) with new self-
locking screw (1).
3. Each weapon must be hand-functioned to check for
unusual binding, positive cocking action, and
general operation. Dummy ammunition must be
used to be sure of positive chambering, extraction,
and ejection action. Dummy rounds can be
acquired through local TAS-C.
4. Check for bore constriction (p 3-13).
5. Inspect the weapon for missing finish and touch up
with SFL as per instructions (pg 3-18).
Change 1 3-35
ARMY TM 9-1010-221-23&P
Section IV. PREEMBARKATION INSPECTION OF MATERIEL IN UNITS
ALERTED FOR OVERSEAS MOVEMENT
3-11. PREEMBARKATION INSPECTION OF MATERIEL IN UNITS ALERTED FOR
OVERSEAS MOVEMENT.
a. General. This inspection is conducted on materiel in alerted units scheduled for overseas
duty to be sure that such materiel will not become unserviceable in a relatively short time. It
prescribes a higher percentage of remaining usable life in serviceable materiel to meet a specific
need beyond minimum serviceability.
b. Preinspection Points.
WARNING
Clear the weapon before starting inspection. Do not squeeze the trigger until the
weapon has been cleared. Inspect the bore and chamber to be sure they are empty
and free from obstructions.
(1) Before inspection, clean the grenade launcher thoroughly of all grease, dirt, or other
foreign matter that might keep it from functioning properly or get in the way of gages and tools
during inspection.
(2) Grenade launchers must be free of burrs, rust, or corrosion on functional surfaces.
(3) Parts must not be cracked, bent, distorted, or damaged and must not be excessively
worn or loose.
(4) Minor defects in metal components do not normally affect their acceptability. For
example, scratches and tool marks are ordinarily of no importance.
(5) Inspect finish of metal surfaces. Satisfactory metal surfaces for weapons range from
black to light gray. A shiny metal surface is objectionable only when it is capable of reflecting
light. No weapon will be rejected unless exterior parts have a shine.
c. Inspection Points.
(1) Springs must not be distorted or broken. Springs must have enough tension to perform
their function.
(2) Inspect the barrel for the following:
(a) Barrel must be clean and free of corrosion caused by moisture and powder fouling.
(b) Barrel must pass bore constriction check (p 3-13).
(c) Pits in the chamber are allowable if they do not get in the way of extraction.
(d) Scattered or uniformly fine pits, or fine pits in a densely pitted area, are allowable.
3-36 Change 1
ARMY TM 9-1010-221-23&P
(e) Tool marks are acceptable, regardless of length. They may appear as lines running
along the grooves or spiraling across the tops of lands.
(3) The sear and cocking notches must be in good condition. Chipped engaging corners will
be cause for rejection. Slight wear on functional surfaces, including engaging corners, shall be
acceptable, providing the minimum trigger pull requirements are met.
(4) Chips, flat spots, or bent striker points on firing pin will be cause for rejection.
(5) The cartridge engaging surfaces on extractors must not be chipped or deformed.
(6) Safety must positively position in both SAFE and FIRE positions. When in the SAFE
position, the weapon must not fire when the trigger is squeezed; when in the FIRE position, the
weapon must fire when the trigger is squeezed.
(7) Each weapon must be hand-functioned to check for unusual binding, positive cocking
action, and general operation. Dummy ammunition must be used to be sure of positive chamber-
ing, extraction, and ejection action. Dummy rounds can be acquired through local TAS-C.
(8) Rivets and spring pins must be tight.
(9) All markings must be legible.
d. Specific Standards. Refer to the following table:
STANDARDS FOR PREEMBARKATION INSPECTION OF 40MM GRENADE
LAUNCHER M203 IN UNITS ALERTED FOR OVERSEAS MOVEMENT
Item Standard
General Clear grenade launcher of any ammunition and inspect in
accordance with para 3-11. Grenade launcher must pass all testing
in paragraph 3-10.
Hand guard assembly Hand guard assembly must not be damaged so as to prevent
positive retention to M16 series rifles.
Barrel assembly Origin of rifling must not advance to a point more than 3.9 inches
(9.91 cm) from breech end of barrel assembly. Barrel assembly
must pass bore constriction check as cited on page 3-13. Cartridge
locator must function properly under spring tension.
Receiver assembly
Trigger pull
Trigger and sear must not have rounded or damaged surfaces.
Minimum 5 pounds (2.27 kg). Maximum 11 pounds (4.99 kg). Use
trigger pull measuring fixture as cited on page 3-34.
Change 1 3-37
ARMY TM 9-1010-221-23&P
3-11. PREEMBARKATION INSPECTION OF MATERIEL IN UNITS ALERTED FOR
OVERSEAS MOVEMENT (CONT).
STANDARDS FOR PREEMBARKATION INSPECTION OF 40MM GRENADE
LAUNCHER M203 IN UNITS ALERTED FOR OVERSEAS MOVEMENT (CONT)
Item Standard
Firing pin protrusion Must pass firing pin protrusion test as cited on page 3-35. Grenade launcher
must have latest configuration firing pin (PN 12002970) as cited on page 3-21.
M203 grenade launcher Perform function checks in accordance with operators manual.
3-38
ARMY TM 9-1010-221-23&P

APPENDIX A

REFERENCES

A-1. SCOPE. This appendix lists all technical manuals and field manuals referenced in this manual.

A-2. TECHNICAL MANUALS/TECHNICAL ORDERS

TM 9-1005-249-10............... Operator s Manual : M16A1 Ri fl e

TM 9-1005-249-23&P........... Uni t and Di rect Support Mai ntenance Manual (i ncl udi ng Repai r
Parts and Speci al Tool s Li st) Ri fl e, 5.56MM, M16 (1005-00-856-
6885) Ri fl e, 5.56MM, M16A1 (1005-00-073-9421)

TM 9-1005-319-10............... Operator s Manual w/Components Li st for Ri fl e, 5.56MM, M16A2
and M4/M4A1 Carbi ne W/E

TM 9-1005-319-23&P........... Uni t and Di rect Support Mai ntenance Manual (i ncl udi ng Repai r
Parts and Speci al Tool s Li st) for Ri fl e, 5.56MM, M16A2 and
M4/M4A1 Carbi ne W/E

TM 9-1010-221-10............... Operator s Manual : 40MM Grenade Launcher M203/M203A1/
M203A2

TM 9-1300-206.................... Ammuni ti on Expl osi ve Standards

TM 750-244-7 ..................... Procedures for Destructi on of Equi pment i n Federal Supply
Cl assi fi cati ons 1000, 1005, 1010, 1015, 1020, 1025, 1030, 1055,
1090, and 1095 to Prevent Enemy Use

TM 4700-15/1...................... Equi pment Record Procedures

TM 05538C-10/1A ............... Operator s Manual w/Components Li st for Ri fl e, 5.56MM, M16A2
W/E

TO 00-35D-54 ..................... Materi el Defi ci ency Reporti ng and Investi gati ng System

TO 11W-1-10 ...................... Hi stori cal Data Recordi ng of Inspecti on, Mai ntenance, and Fi ri ng
Data for Ground Weapons

TO 33K-1-100 ..................... (TMDE) Interval Cal i brati on and Repai r Reference Gui de and
Work Uni t Code Manual

SL 3-00607A....................... Mari ne Corps Tool Ki t, Smal l Arms Repai rman

Change 4 A-1

ARMY TM 9-1010-221-23&P

A-3. FIELD MANUALS.

FM 4-25.11 ......................... Fi rst Ai d for Sol di ers

FM 3-22.31 ......................... 40MM Grenade Launchers M203 and M79

A-4. FORMS.

AFTO Form 22..................... Techni cal Order System Publ i cati ons Improvement Report

DA Form 2028 ..................... Recommended Changes to Publ i cati ons and Bl ank Forms

DA Form 2028-2 .................. Recommended Changes to Equi pment Techni cal Manual s

DA Form 2404 ..................... Equi pment Inspecti on and Mai ntenance Worksheet

NAVMC 10772 ..................... Recommended Changes to Techni cal Publ i cati ons

SF 364................................ Report of Di screpancy (ROD)

SF 368................................ Product Qual i ty Defi ci ency Report

A-5. DA PAMS.

DA PAM 738-750 ................. The Army Mai ntenance Management System (TAMMS)

DA PAM 25-30..................... Consol i dated Index of Army Publ i cati ons and Bl ank Forms

A-6. MISCELLANEOUS PUBLICATIONS.

CTA 8-100 .......................... Army Medi cal Department Expendabl e/Durabl e Items

CTA 50-970......................... Expendabl e/Durabl e Items (Except Medi cal , Cl ass V, Repai r
Parts, and Heral di c Items)

DOD 4160.21-M-1................ Defense Demi l i tari zati on Manual

MCO P4450.7 ...................... Mari ne Corps Warehousi ng Manual

MCO P4610.19 .................... Transportati on and Travel Record of Transportati on
Di screpanci es

MCO 4855.10 ...................... Qual i ty Defi ci ency Report

SPI 00-856-6885 ................. Speci al Packagi ng Instructi ons for M16 Ri fl e

A-2 Change 4
ARMY TM 9-1010-221-23&P
APPENDIX B
MAINTENANCE ALLOCATION CHART (MAC)
Section I. INTRODUCTION
B-1. THE ARMY MAINTENANCE SYSTEM MAC.
a. This introduction (section I) provides a general explanation of all maintenance and repair
functions authorized at various maintenance levels under the standard Army Maintenance
System concept.
b. The Maintenance Allocation Chart (MAC) in section II designates overall authority and
responsibility for the performance of maintenance functions on the identified end item or compo-
nent. The application of the maintenance functions to the end item or component will be consis-
tent 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 an H subcolumn.
Depot-includes a D subcolumn.
c . Section Ill lists the tools and test equipment (both special tools and com-
mon tool sets) required for each maintenance function as referenced from section Il.
d. Section IV contains supplemental instructions and explanatory notes for a particular
maintenance function.
B-2. MAINTENANCE FUNCTIONS. Maintenance functions are limited to and defined as
follows: (except for ammunition MAC
1
) .
a. 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).
b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or elec-
trical characteristics of an item and comparing those characteristics with prescribed standards.
c. 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, lubricants, chemical fluids, or gases.
1
Exception is authorized for ammunition MACs to permit use of maintenance function headings
that better describe or identify ammunition peculiar maintenance functions. The headings used
and their definitions shall be included in the appropriate ammunition technical manual(s).
B-1
ARMY TM 9-1010-221-23&P
B-2. MAINTENANCE FUNCTIONS (CONT).
d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position,
or by setting the operating characteristics to specified parameters.
e. Align. To adjust specified variable elements of an item to bring about optimum or desired
performance.
NOTE
Air Force Precision Measurement Equipment Laboratory (PMEL) personnel will
calibrate small arms inspection gages in accordance with TO 33K-1-100.
f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments
or test, measuring, and diagnostic equipment used in precision measurement. Consists of com-
parisons of two instruments, one of which is a certified standard of known accuracy, to detect
and adjust any discrepancy in the accuracy of the instrument being compared.
g.
Remove/Install. To remove and install the same item when required to perform service or
other maintenance functions. Install may be the act of emplacing, seating, or fixing into position
a spare, repair part, or module (component or assembly) in a manner to allow the proper func-
tioning of an equipment or system.
h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place.
"Replace" is authorized by the MAC and assigned maintenance level is shown as the 3rd posi-
tion code of the SMR code.
i. Repair. The application of maintenance services
2
including fault location/troubleshooting
3
,
removal/installation, and disassembly/assembly
4
procedures, and maintenance actions
5
to identify
troubles and restore serviceability to an item by correcting specific damage, fault, malfunction,
or failure in a part, subassembly, module (component or assembly), end item, or system.
j. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a com-
pletely serviceable/operational condition as required by maintenance standards in appropriate
technical publications (i. e., DMWR). Overhaul is normally the highest degree of maintenance per-
formed by the Army. Overhaul does not normally return an item to like new condition.
2
Services-inspect, test, service, adjust, align, calibrate, and/or replace.
3
Fault location/troubleshooting-The process of investigating and detecting the cause of equip-
ment malfunctioning; the act of isolating a fault within a system or unit under test (UUT).
4
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).
5
Actions-Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing.
B-2
ARMY TM 9-1010-221-23&P
k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable
equipment to a like new condition in accordance with original manufacturing standards. Rebuild
is the highest degree of materiel maintenance applied to Army equipment, The rebuild operation
includes the act of returning to zero those age measurements (e.g., hours/miles) considered in
classifying Army equipment/components.
B-3. EXPLANATION OF COLUMNS IN THE MAC, SECTION II (NOT FOR M.C. USE).
a. Column 1, Group Number. Column 1 lists functional group code numbers, the purpose of
which is to identify maintenance significant components, assemblies, subassemblies, and
modules with the next higher assembly.
b. Column 2, Component/Assembly. Column 2 contains the item names of components,
assemblies, subassemblies, 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, see paragraph B-2.)
d. Column 4, Maintenance Level. Column 4 specifies each level of maintenance authorized to
perform each function listed in Column 3, by indicating work time required (expressed as
manhours in whole hours or decimals) in the appropriate subcolumn. 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
vary at different maintenance levels, appropriate work-time figures are to 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 func-
tions authorized in the maintenance allocation chart, 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)
6
H . . . . . . . . . . . . . General support maintenance
D . . . . . . . . . . . . . . . Depot maintenance
e. Column 5, Tools and Test Equipment Reference Code. Column 5 specifies, by code, those
common tool sets (not individual tools), common TMDE, special tools, special TMDE, and special
support equipment required to perform the designated function. Codes are keyed to tools and
test equipment in section Ill.
6
This maintenance level is not included in Section II, column (4) of the Maintenance Allocation
Chart. Functions to this level of maintenance are identified by a work-time figure in the "H" col-
umn of Section II, column (4), and an associated reference code is used in the Remarks column
(6). This code is keyed to Section IV, Remarks, and the SRA complete repair application is ex-
plained there.
B-3
ARMY TM 9-1010-221-23&P
f. Column 6, Remarks Code. When applicable, this column contains a letter code, in
alphabetical order, which is keyed to the remarks contained in Section IV.
B-4. EXPLANATI ON OF COLUMNS I N TOOL AND TEST EQUI PMENT REQUI REMENTS,
SECTION Ill.
a. Column 1, Reference Code. The tool and test equipment reference code correlates with a
code used in the MAC, Section II, Column 5.
b. Column 2, Maintenance Level. The lowest level of maintenance authorized to use the tool
or test equipment.
c. Column 3, Nomenclature. Name or identification of the tool or test equipment.
d. Column 4, National Stock Number. The National Stock Number of the tool or test
equipment.
e. Column 5, Tool Number. The manufacturers part number, model number, or type number,
B-5. EXPLANATI ON OF COLUMNS I N REMARKS, SECTI ON I V.
a. Column 1, Remarks Code. The code recorded in column 6, Section Il.
b. Column 2, Remarks Code. This column lists information pertinent to the maintenance
function being performed as indicated in the MAC, Section Il.
B-4
ARMY TM 9-1010-221-23&P

Section II. MAINTENANCE ALLOCATION CHART

FOR

40MM GRENADE LAUNCHER M203/M203A1/M203A2 W/E

(1)

(2)

(3)

(4)
Maintenance Level

(5)
Tools

(6)

Group

Component/

Maintenance

Unit

DS

GS

Depot
and
Test Eqpt

Remarks

Number Assembly Function C O F H D Ref Code Code

00 LAUNCHER, GRENADE,
40MM, M203/M203A1/
M203A2 W/E
Inspect
Service
Install
Repair
0.2
0.2
0.2

0.5
0.2

0.3
1.0

5
5

A

01 LAUNCHER, GRENADE,
40MM, M203/M203A1/
M203A2
Inspect
Service
Install
Repair
0.1
0.1
0.1

0.2
0.5
0.2

0.3
1.0

5
5

B
A

0101 MOUNTING BRACKET
ASSEMBLY

Inspect
Repair
Replace
0.1 0.1 0.1
0.2
0.2

3,5
3,5

02 QUICK RELEASE
BRACKET
Install
Remove
Inspect
Repair
Disassemble
Reassemble
0.1
0.1
0.1
0.1
0.1
0.1
5
5

5
B
B

A

0201

LEFT BRACKET
ASSEMBLY

Inspect
Repair
Disassemble
Reassemble

0.1
0.1
0.1
0.1

5

A

03 LEAF SIGHT AND RAIL
GRABBER ASSEMBLY
Disassemble
Reassemble
0.1
0.1
5

04 LEAF SIGHT ASSEMBLY Inspect
Service
Repair
Replace
0.1
0.1
0.1

0.2

5

05 BARREL ASSEMBLY Inspect
Service
Replace
Repair
0.1
0.1

0.1

0.2

0.1
0.5

5
5

C

Change 4 B-5
ARMY TM 9-1010-221-23&P
MAINTENANCE ALLOCATION CHART (CONT)

(1)

(2)

(3)

(4)
Maintenance Level

(5)
Tools

(6)

Group

Component/

Maintenance

Unit

DS

GS

Depot
and
Test Eqpt

Remarks

Number Assembly Function C O F H D Ref Code Code

06 RECEIVER ASSEMBLY Inspect
Test
Service
Repair
0.1

0.2
0.1

0.2

0.2
0.1

1.0

2,3

1,3,5

07 QUADRANT SIGHT
ASSEMBLY
Inspect
Service
Remove/Install
Repair
0.1
0.1
0.1
0.1

0.4

5

B

0701 QUADRANT, RANGE
ASSEMBLY
Inspect
Repair

0.1
0.1

5

0702 LATCH ASSEMBLY Inspect
Repair
0.1
0.1

5

0703 SIGHTARM
ASSEMBLY
Inspect
Repair
0.1
0.1

Section III. TOOL AND TEST EQUIPMENT
FOR
40MM GRENADE LAUNCHER M203/M203A1 W/E

Tool or
Test
Equipment
Ref Code

Maintenance
Level

Nomenclature

National
Stock Number

Tool Number

1

F

Adapter, Torque
Wrench

5120-01-047-3294

12003033
2 F Gage, Firing Pin
Protrusion

5220-00-348-8434 12002976
3 (ARMY
ONLY)
F Shop Set, Small
Arms: Field Main-
tenance, Basic
Less Power

4933-00-754-0664 SC 4933-95-
A11
4 DELETED

5 (ARMY
AND MC
ONLY)
O Tool Kit, Small
Arms Repairman
5180-01-462-4254
MC 5180-00-357-7770
(ARMY) SC
5180-95-B71
(MC) SL 3-
00607A

B-6 Change 4
ARMY TM 9-1010-221-23&P

MAINTENANCE OF SMALL ARMS GAGES

Smal l arms gages are preci si on tool s used to qui ckl y and economi cal l y i nspect di mensi ons and
i nterface poi nts on smal l arms weaponry. They are made of tool steel and machi ned to extremel y
ti ght tol erances. Wi th few excepti ons, each smal l arms weapon system has gages used at Di rect
Support and Depot mai ntenance l evel s.

Gages are suscepti bl e to corrosi on. To decrease the frequency and severi ty of corrosi on, smal l
arms gages shoul d be peri odi cal l y degreased wi th MIL-PRF-680 Type II, al l owed to dry, and then
gi ven a l i ght coati ng of CLP or si mi l ar preservati ve oi l . Wi pe the preservati ve off each gage wi th a
soft cl oth before use.

When usi ng smal l arms gages, careful l y fol l ow the i nstructi ons gi ven i n the appropri ate techni cal
manual . Never force a gage! Thi s wi l l cause excessi ve wear and decrease the servi ceabl e l i fe of
the gage.

Smal l arms gages are suscepti bl e to materi al di spl acement as a resul t of i mpact. For exampl e, a
gage dropped onto a concrete fl oor may appear perfectl y fi ne to the naked eye, but because i t i s
machi ned to extremel y ti ght tol erances, materi al di spl acement may have occurred. Thi s resul ts i n
the gage bei ng out of tol erance. To prevent thi s, perform gagi ng on tabl es or workbenches that
are padded or covered wi th vi nyl or rubber, whenever possi bl e.

Perhaps the most cruci al thi ng you can do to i nsure your gages are servi ceabl e i s to make sure to
have them cal i brated every 360 days as requi red by TB 43-180, Cal i brati on and Repai r
Requi rements for the Mai ntenance of Army Materi el . Di rect Support i s authori zed 2 of each smal l
arms gage; submi t gages for cal i brati on on a staggered schedul e so one wi l l al ways be avai l abl e.
Onl y the Test, Mai ntenance, and Di agnosti c Equi pment Laboratori es l i sted i n TB 43-180 are
authori zed and equi pped to perform thi s cal i brati on.

Section IV. REMARKS
FOR
40MM GRENADE LAUNCHER M203/M203A1 W/E

REMARKS
CODE
REMARKS

A

Repair and replacement of parts performed by unit maintenance is limited to authorized items
listed in Appendix C of this manual, except for swivel (8448571) and tubular rivet (8448697)
listed in TM 9-1005-249-23&P or TM 9-1005-319-23&P or TM 05538C-23&P/2A (Marine Corps
only).

B Unit maintenance is authorized to install and remove the Quick Release Bracket to the M203A2.
All levels of maintenance are authorized to mount and dismount the M203A2 W/Quick Release
Bracket to and from host weapon. Crew maintenance is authorized M203A2 to remove/
i nstal l the quadrant si ght assembl y.

C

Bore constri cti on check tool , manufactured from NSN 9510-00-813-5335.

Change 4 B-7/(B-8 blank)

ARMY TM 9-1010-221-23&P
APPENDIX C
UNIT AND DIRECT SUPPORT MAINTENANCE
C-1. SCOPE.
This RPSTL lists and authorizes spares and repair parts; special tools; special test, measurement,
and diagnostic equipment (TMDE); and other special support equipment required for performance
of unit and direct support maintenance of the grenade launcher. It authorizes the requisitioning,
issue, and disposition of spares, repair parts, and special tools as indicated by the Source,
Maintenance and Recoverability (SMR) codes.
C-2. GENERAL.
In addition to Section 1, Introduction, this Repair Parts and Special Tools List is divided into the
following sections:
a. Section II. Repair Parts List. A list of spares and repair parts authorized by this RPSTL for
use in the performance of maintenance. The list also includes parts which must be removed for
replacement of the authorized parts. Parts lists are composed of functional groups in ascending
alphanumeric sequence, with the parts in each group listed in ascending figure and item number
sequence. Bulk materials are listed by item name in FIG BULK at the end of the section. Repair
parts kits or sets are listed separately in their own functional group within section Il. Repair
parts for repairable special tools are also listed in this section.
b. Section Ill. Special Tools List. A list of special tools, special TMDE, and other special sup-
port equipment authorized by this RPSTL (as indicated by Basis of Issue (BOI) information in
DESCRIPTION AND USABLE ON CODE (UOC) column) for the performance of maintenance.
c. Section IV. Cross-Reference Indexes. A list, in National item identification number (NIIN)
sequence, of all National stock numbered items appearing in the listings, followed by a list in
alphanumeric sequence of all part numbers appearing in the listings. National stock numbers and
part numbers are cross-referenced to each illustration figure and item number appearance. The
figure and item number index lists figure and item number in alphanumeric sequence and cross-
-references NSN, CAGEC, and part number.
C-3. EXPLANATION OF COLUMNS (SECTIONS II AND Ill).
a. ITEM NO. (Column (1)). Indicates the number used to identify items called out in the
illustration.
C-1
ARMY TM 9-1010-221-23&P
C-3. EXPLANATION OF COLUMNS (SECTIONS II AND Ill) (CONT).
b. SMR CODE (Column (2)). The Source, Maintenance, and Recoverability (SMR) code is a
5-position code containing supply/requisitioning information, maintenance level authorization
criteria, and disposition instruction, as shown in the following breakout:
Source Maintenance Recoverability
Code Code Code
How you get an item 3rd position 4th position Who determines
disposition action
Who can install, Who can do on an unservice-
replace, or use complete repair able item
item on the item
*Complete Repair: Maintenance capacity, capability, and authority to perform all corrective
maintenance tasks of the Repair function in a use/user environment in order to restore ser-
viceability to a failed item.
(1) Source Code. The source code tells you how you get an item needed for maintenance,
repair, or overhaul of an end item/equipment. Explanations of source codes follow:
Explanation
Stocked items; use the applicable NSN to request/requisition
items with these source codes. They are authorized to the
level indicated by the code entered in the 3rd position of
the SMR code.
**NOTE: Items coded PC are subject to deterioration.
Items with these codes are not to be requested/requisitioned
individually. They are part of a kit which is authorized to
the maintenance level indicated in the 3rd position of the SMR
code. The complete kit must be requisitioned and applied.
individually. They must be made from bulk material which is
identified by the part number in the DESCRIPTION AND USABLE
ON CODE (UOC) column and listed in the Bulk Material group in the
repair parts list in this RPSTL. If the item is authorized to you by
the 3rd position code of the SMR code, but the source code
indicates it is made at a higher level, order the item from the
higher level of maintenance.
C-2
ARMY TM 9-1010-221-23&P
Code Explanation
individually. The parts that make up the assembled item must
be requisitioned or fabricated and assembled at the level of
maintenance indicated by the source code. If the 3rd posi-
tion code of the SMR code authorizes you to replace the item,
but the source code indicates the item is assembled at a higher
level, order the item from the higher level of maintenance.
XA- DO not requisition an "XA" -coded item. Order its next higher assembly. (Also, refer to the
NOTE below.)
XB- If an "XB" item is not available from salvage, order it using the CAGEC and part number
given.
XC- Installation drawing, diagram, instruction sheet, field service drawing, that is identified by
manufacturers part number.
XD- Item is not stocked. Order an "XD"-coded item through normal supply channels using the
CAGEC and part number given, if no NSN is available.
NOTE
Cannibalization or controlled exchange, when authorized, may be used as a source
of supply for items with the above source codes, except for those source coded
"XA" or those aircraft support items restricted by requirements of AR 750-1.
(2) Maintenance Code. Maintenance codes tell you the level(s) of maintenance authorized
to USE and REPAIR support items. The maintenance codes are entered in the third and fourth
positions of the SMR code as follows:
(a) The maintenance code entered in the third position tells you the lowest maintenance
level authorized to remove, replace, and use an item. The maintenance code entered in the third
position will indicate authorization to one of the following levels of maintenance:
Code Applic ation/Explanation
C -Crew or operator maintenance done within unit or aviation unit
maintenance.
O -Unit or aviation unit level can remove, replace, and use the item.
F -Direct support or aviation intermediate level can remove, replace,
and use the item.
H -General support level can remove, replace, and use the item.
C-3
ARMY TM 9-1010-221-23&P
C-3. EXPLANATION OF COLUMNS (SECTIONS II AND III) (CONT).
Code Application/Explanation
L -Specialized repair activity can remove, replace, and use the item.
D -Depot level can remove, replace, and use the item.
(b) The maintenance code entered in the fourth position tells you whether or not the
item is to be repaired and identifies the lowest maintenance level with the capability to do com-
plete repair (i.e., perform all authorized repair functions). (NOTE: Some limited repair may be
done on the item at a lower level of maintenance, if authorized by the Maintenance Allocation
Chart (MAC) and SMR codes.) This position will contain one of the following maintenance
codes:
Code Application/Explanation
o -Unit or aviation unit is the lowest level that can do complete repair
of the item.
F -Direct support or aviation intermediate is the lowest level that can
do complete repair of the item.
H -General support is the lowest level that can do complete repair of
the item.
L -Specialized repair activity (designate the specialized repair activity)
is the lowest level that can do complete repair of the item.
D -Depot is the lowest level that can do complete repair of the item.
Z -Nonreparable. No repair is authorized.
B -No repair is authorized. (No parts or special tools are authorized for
the maintenance of a B coded item. ) However, the item may be
reconditioned by adjusting, lubricating, etc., at the user level.
(3) Recoverability Code. Recoverability codes are assigned to items to indicate the disposi-
tion action on unserviceable items. The recoverability code is entered in the fifth position of the
SMR code as follows:
Recoverability
Codes Application/Explanation
Z -Nonreparable item. When unserviceable, condemn and dispose of
the item at the level of maintenance shown in 3rd position of SMR
Code.
O -Reparable item. When uneconomically reparable, condemn and
dispose of the item at unit or aviation unit level.
C-4
ARMY TM 9-1010-221-23&P
Recoverability
Codes
F
H
D
L
A
Application/Explanation
-Reparable item. When uneconomically reparable, condemn and
dispose of the item at the direct support or aviation intermediate level.
-Reparable item. When uneconomically reparable, condemn and
dispose of the item at the general support level.
-Reparable item. When beyond lower level repair capability, return to
depot. Condemnation and disposal of item not authorized below depot
level.
-Reparable item. Condemnation and disposal not authorized below
specialized repair activity (SRA).
-Item requires special handling or condemnation procedures because
of specific reasons (e.g., precious metal content, high dollar value,
critical material, or hazardous material). Refer to appropriate
manuals/directives for specific instructions.
c. NSN (Column (3)). Indicates the National stock number (NSN) assigned to the item and
which will be used for requisitioning.
d. CAGEC (Column (4)). The Contractor and Government Entity Code (CAGEC) is a 5-digit
numeric code which is used to identify the manufacturer, distributor, or Government agency, etc.,
that supplies the item.
e. PART NUMBER (Column (5)). Indicates the primary number used by the manufacturer
(individual, company, firm, corporation, or Government activity), which controls the design and
characteristics of the item by means of its engineering drawings, specifications standards, and
inspection requirements to identify an item or range of items.
NOTE
When you use an NSN to requisition an item, the item you receive may have a different
part number from the part ordered.
f. DESCRIPTION AND USABLE ON CODE (UOC) (Column (6)). This column includes the
following information:
(1) The Federal item name and, when required, a minimum description to identify the item.
(2) The physical security classification of the item is indicated by the parenthetical entry
which is a physical security classification abbreviation, e.g., Phy Sec C1 ( ) -Confidential, Phy
Sec C1 (S) -Secret, Phy Sec C1 (T) -Top Secret.
(3) Items that are included in kits and sets are listed below the name of the kit or set.
(4) Spare/repair parts that make up an assembled item are listed immediately following the
assembled item line entry.
(5) Part numbers for bulk materials are referenced in this column in the line item entry for
the item to be manufactured/fabricated.
Change 1 C-5
ARMY TM 9-1010-221-23&P
C-3. EXPLANATION OF COLUMNS (SECTIONS II AND Ill) (CONT).
(6) When the item is not used with all serial numbers of the same model, the effective serial
numbers are shown on the last line(s) of the description (before UOC).
(7) The usable on code, when applicable (see paragraph 5, Special Information).
(8) In the Special Tools List section, the basis of issue (BOI) appears as the last line(s) in
the entry for each special tool, special TMDE, and other special support equipment. When density
of equipment supported exceeds density spread indicated in the basis of issue, the total
authorization is increased proportionately.
(9) The statement END OF FIGURE appears just below the last item description in Column
5 for a given figure in both Section II and Section Ill.
g. QTY (Column (7)). The QTY (quantity per figure column) indicates the quantity of the item
used in the breakout shown on the illustration figure, which is prepared for a functional group,
subfunctional group, or an assembly. A V appearing in this column in lieu of a quantify indicates
that the quantity is variable and the quantity may vary from application to application.
C-4. EXPLANATION OF COLUMNS (SECTION IV).
a. NATIONAL STOCK NUMBER (NSN) INDEX.
(1) STOCK NUMBER column. This column lists the NSN by National item identification
number (NIIN) sequence. The NIIN consists of the last nine digits of
NSN
the NSN (i.e., 5305-01-674-1467). When using this column to locate an item,
NIIN
ignore the first 4 digits of the NSN. However, the complete NSN should be used when ordering
items by stock number.
(2) FIG. column. This column lists the number of the figure where the item is identified/
located. The figures are in numerical order in section II and section III.
(3) ITEM column. The item number identifies the item associated with the figure listed in
the adjacent FIG. column. This item is also identified by the NSN listed on the same line.
b. PART NUMBER INDEX. Part numbers in this index are listed by part number in ascending
alphanumeric sequence (i.e., vertical arrangement of letter and number combination which places
the first letter or digit of each group in order A through Z, followed by the numbers 0 through 9 and
each following letter or digit in like order).
(1) CAGEC column. The Contractor and Government Entity Code (CAGEC) is a 5-digit
numeric code used to identify the manufacturer, distributor, or Government agency, etc., that
supplies the item.
(2) PART NUMBER column. Indicates the primary number used by the manufacturer
(individual, firm, corporation, or Government activity), which controls the design and
characteristics of the item by means of its engineering drawings, specifications standards, and
inspection requirements to identify an item, or range of items.
C-6 Change 1
ARMY TM 9-1010-221-23&P

(3) STOCK NUMBER column. This column lists the NSN for the associated part number and manu-
facturer identified in the PART NUMBER and CAGEC columns to the left.

(4) FIG. column. This column lists the number of the figure where the item is identified/located in sections
II and III.

(5) ITEM column. The item number is that number assigned to the item as it appears in the figure
referenced in the adjacent figure number column.

C-5. SPECIAL INFORMATION.

a. ASSEMBLY INSTRUCTION. Detailed assembly instructions for items source coded to be assembled
from component spare/repair parts are found in chapters 2 and 3. Items that make up the assembly are listed
immediately following the assembly item entry or reference is made to an applicable figure.

b. ASSOCIATED PUBLICATIONS. The publication listed below pertains to the grenade launcher and its
components:

Publication Short Title
TM 9-1010-221-10 Grenade Launcher M203/M203A1/M203A2

c. USABLE ON CODE. The usable on code appears in the lower left corner of the DESCRIPTION column
heading, Usable on codes are shown as UOC in DESCRIPTION column (justified left) on the first line
applicable item description/nomenclature. Uncoded items are applicable to all models. Identification of the
usable on codes used in the RPSTL are:

Code Used On
401 M203 Grenade Launcher
BC7 M203A1 Grenade Launcher
BJ9 M203A2 Grenade Launcher

C-6. HOW TO LOCATE REPAIR PARTS.

a. When National Stock Number or Part Number is Not Known.

(1) First. Using the table of contents, determine the assembly group or subassembly group to which
the item belongs. This is necessary since figures are prepared for assembly groups and subassembly groups,
and listings are divided into the same groups.

(2) Second. Find the figure covering the assembly group or subassembly group to which the item
belongs.

Change 4 C-7
ARMY TM 9-1010-221-23&P

C-6. HOW TO LOCATE REPAIR PARTS (CONT).

(3) Third. Identify the item on the figure and note the item number.

(4) Fourth. Refer to the Repair Parts List for the figure to find the part number for the item number noted
on the figure.

(5) Fifth. Refer to the Part Number Index to find the NSN, if assigned.

b. When National Stock Number or Part Number is Known:

(1) First. Using the Index of National Stock Numbers and Part Numbers, find the pertinent National stock
number or part number. The NSN index is in National Item Identification Number (NIIN) sequence. (See C-
4.a.(1). The part numbers in the Part Number Index are listed in ascending alphanumeric sequence. (See C-
4.b.). Both indexes cross-reference you to the illustration figure and item number of the item you are looking for.

(2) Second. After the figure and item number, verify that the item is the one youre looking for, then locate
the item number in the repair parts list for the figure.

C-7. ABBREVIATIONS.

Not applicable.

C-8

SECTION II ARMY TM 9-1010-221-23&P
NAVY SW 370- AE-MMI-010

SECTION II. REPAIR PARTS LIST

GRENADE LAUNCHER
40 MM, M203
S/N 158615
USA
SAFE M16
CAL 5.56 MM
SEMI
GRENADELAUNCHER
40 MM, M203
S/N158616
USA
SAFE
M16A2
CAL 5.56 MM
SEMI
M203
2
1
1A
2
M203A1
1B
2
M203A2

Fi gure C-1. 40MM Grenade Launcher M203 W/E 11838703, M203A1 W/E
12597125 and M203A2 W/E 12999553
(1)
Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

Description and Usable On Code (UOC)
(7)

Qty

1

1

1A

1B

2

XAFFA

XAOFA

XAFFA

XAFFA

PAOOO

1010-01-442-2313

19204

19204

19200

19200

19200

8448300

8448300

12982965

12999552

12598114

GROUP 00 40MM GRENADE LAUNCHER
M203 W/E 11838703, M203A1 W/E
12597125 AND M203A2 W/E 12999553
FIG. C-1 40MM GRENADE LAUNCHER
M203, M203A1 AND M203A2

LAUNCHER (M203)
UOC:401
LAUNCHER (MARINE CORPS ONLY)
UOC:401
LAUNCHER (M203A1)
UOC:BC7
LAUNCHER (M203A2)
UOC:BJ9
SIGHT ASSEMBLY, QUADRANT

END OF FIGURE

1

1

1

1

1

C-1-1 Change 4


3A
1 2
2
3
4
5
4
6
7
7
8
9
10
10
12
11
*
*
5E
M203 Grenade Launcher
5B
5D
5C
* NOT COMPONENT PARTS OF LAUNCHER.
REQUISITION RIVET AND SWIVEL, AS
REQUIRED, FROM TM 9-1005-319-23&P.
12
10
11
8A
10
9A 7
7
M203A1 Grenade Launcher
*
*
6
4A
4B
5A
4B
4A
1A
2
2
3
8B
8B

Figure C-2. 40MM Grenade Launcher M203 8448300, M203A1 12982965 and
M203A2 12999552

Change 4

(1)
Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

(7)

Qty

1

1

1A

2

2

3
3

3A

4

4A

4B

5

5

5A

5B

5C

5D

5E

6

7

8

8

8A

8B

PAFZZ

PAOZZ

PAFZZ

PAFZZ

PAOZZ

AFFFF
AFOFF

AFFFF

PAOZZ

PAOZZ

PAOZZ

PAFZZ

PAOZZ

PAOFF

XAOZZ

PAOZZ

PAOZZ

PAOOO

PAOZZ

PAOZZ

XAFFA

XAOFA

XAFFA

XAFFA

1010-00-438-7431

1010-00-438-7431

1010-01-470-7105

5305-00-182-9265

5305-00-182-9265

5305-00-150-9212

5305-01-442-0157

5310-00-160-9817

5340-01-376-0876

5340-01-376-0876

5340-01-442-0165

1010-01-442-0156

5305-01-442-0157

1005-01-452-3528

9505-00-293-4208

3120-00-438-7332

19204

19204

19200

96906

96906

19204
19204

19200

88044

19200

80205

19200

19200

19200

19200

19200

19200

19200

80205

19204

19204

19204

19200

19200

8448377

8448377

12990563

MS51957-43B

MS51957-43B

8448330
8448330

12598117

AN502-10-8

12957129

NAS1149C0363B

12011998

12011998

12957126

12957127

12957128

12957129

12973116

NASM20995C32

8448320

8448380-1

8448380-1

8448380-2

8448380-3

GROUP 01 40MM GRENADE LAUNCHER
M203 8448300, M203A1 12982965
AND M203A2 12999552 AND 0101
MOUNTING BRACKET ASSEMBLY
FIG. C-2 40MM GRENADE LAUNCHER
M203, M203A1 AND M203A2

GUARD,HAND,GRENADE (HAND
GUARD ASSEMBLY UOC:401
GUARD,HAND,GRENADE (MARINE
CORPS ONLY) UOC:401
HANDGUARD AND BUSHING ASSEM-
BLY (M203A1) UOC:BC7
SCREW, MACHINE
UOC:BC7,401
SCREW, MACHINE (MARINE CORPS
ONLY) UOC:401
LEAF SIGHT ASSEMBLY
LEAF SIGHT ASSEMBLY (MARINE
CORPS ONLY) UOC:401
ASSEMBLY, LEAF SIGHT AND RAIL
GRABBER UOC:BJ9
SCREW, MACHINE
UOC: 401
SCREW, CAP SOCKET HEAD
UOC:BC7
WASHERS
UOC:BC7
BRACKET, MOUNTING
UOC:401
BRACKET, MOUNTING (MARINE
CORPS ONLY) UOC:401
BRACKET, MOUNTING ASSEMBLY
(M203A1) UOC:BC7
BRACKET, MOUNTING
UOC: BC7
BRACKET CLAMP ASSEMBLY
UOC: BC7
UOC: BC7
QUICK RELEASE BRACKET
UOC:BJ9
WIRE, NONELECTRICAL
UOC:BC7,401
BUSHING HALF, SLEEVE
UOC:BC7,401
RECEIVER ASSEMBLY
UOC:401
RECEIVER ASSEMBLY (MARINE
CORPS ONLY) UOC:401
RECEIVER ASSEMBLY (M203A1)
UOC:BC7
RECEIVER ASSEMBLY (M203A2)
UOC:BJ9

1

1

1

2

2

1
1

1

2

2

2

1

1

1

1

1

1

1

V

2

1

1

1

1

C-2-1
Change 4


(1)
Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

(7)

Qty

9

9A

10

11

12

12

PAOZZ

PAOZZ

PAOZZ

PAOZZ

PAFFF

PAOZZ

5340-01-440-7610

5340-01-474-2845

5315-00-690-0544

1010-01-264-6517

1010-01-376-3342

1010-01-376-3342

19200

19200

96906

19200

19200

19200

12012059

12991254

MS39086-93

12598617

12012005

12012005

BAR, LOCKING
UOC: 401,BJ9
BAR, LOCKING
UOC: BC7,BJ9
PIN, SPRING
UOC:BC7,401,BJ9
MOUNT, SWIVEL
UOC:BC7,401,BJ9
BARREL ASSEMBLY, GRENADE
UOC:BC7,401,BJ9
BARREL ASSEMBLY (MARINE
CORPS ONLY) UOC:401

END OF FIGURE

1

1

2

1

1

1

C-2-2
Change 4


4
2
5
3
1

Figure C-2A. Quick Release Bracket 12973116

(1)
Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

(7)

Qty

1

2

3

4

5

XAOOO

PAOZZ

PAOZZ

PAOZZ

PAOZZ

5310-01-452-9635

1005-01-453-1634

5305-01-452-9639

5365-01-453-9287

19200

19200

19200

19200

19200

12973117

12973140

12973127

12973130

12973129
GROUP 02 QUICK RELEASE
BRACKET 12973116
FIG. C-2A. QUICK RELEASE
BRACKET

ASSEMBLY, LEFT BRACKET
UOC:BJ9
WASHER, SPRING
UOC: BJ9
BASE, RIGHT HALF
UOC:BJ9
UOC:BJ9
SHIM, PLATE
UOC:BJ9

END OF FIGURE

1

2

1

2

1

C-2A-1
Change 4

4
2
5
6
7
8
3
1
8
7
6

Figure C-2B. Left Bracket Assembly 12973117
(1)

Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

(7)

Qty

1

2

3

4

5

6

7

8

PAOZZ

PAOZZ

PAOZZ

PAOZZ

XAOZZ

XAOZZ

XAOZZ

XAOZZ

5315-00-823-8743

5340-01-502-5471

5315-00-847-3735

5360-01-502-5468

80205

19200

80205

19200

19200

19200

19200

19200

MS16562-219

12999211

MS16562-190

12999210

12973124

12973120

12973121

12973118
GROUP 0201 LEFT BRACKET
ASSEMBLY 12973117
FIG. C-2B. LEFT BRACKET
ASSEMBLY

PIN, SPRING
UOC:BJ9
PLUNGER, DETENT
UOC:BJ9
PIN, SPRING
UOC:BJ9
SPRING, COMPRESSION
UOC:BJ9
RIVET
UOC:BJ9
LATCH LEVER
UOC:BJ9
LATCH ARM
UOC:BJ9
LEFT HALF BASE
UOC:BJ9

END OF FIGURE

1

1

1

1

2

1

1

1

C-2B-1
Change 4


Figure C-2C. Leaf Sight and Rail Grabber Assembly 12598117

(1)

Item
No.
(2)

SMR
Code
(3)

NSN
(4)

CAGEC
(5)

Part
Number
(6)

Description and Usable On Code
(UOC)
(7)

Qty

1

AFFFF

19200

12598115

GROUP 03 LEAF SIGHT AND
RAIL GRABBER ASSEMBLY
12598117
FIG. C-2C. LEAF SIGHT AND
RAIL GRABBER ASSEMBLY

ASSEMBLY, LEAF SIGHT (SEE
FIGURES C-3 AND C-3-1 FOR
DOWN PARTS)
UOC:BJ9

1

2 PAFZZ 5305-01-463-3305 96906 MS24671-13B SCREW, CAP, SOCKET HEAD 2

3

PAFZZ

5340-01-466-7727

19200

12598130
UOC:BJ9
ASSEMBLY, RAIL GRABBER
UOC:BJ9

1

4 PAFZZ 5310-00-420-0737 96906 MS35649-284B NUT, PLAIN HEX 2
UOC:BJ9

END OF FIGURE

C-2C-1
Change 4


1
2
3
4
5
6A
8
7
6
3A

Figure C-3. Leaf Sight Assembly M203 and M203A1 8448330, M203A2 12598115

(1)
Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

(7)

Qty

1
1

2
2

3
3

3A
4

4

5
5

6
6

6A

7
7

8
8

PAFZZ
PAOZZ

PAFZZ
PAOZZ

PAFZZ
PAOZZ

PAFZZ
PAFZZ

PAOZZ

PAFZZ
PAOZZ

PRFZZ
PAOZZ

PAFZZ

PAFZZ
PAOZZ

PAFZZ
PAOZZ

5305-00-182-9241
5305-00-182-9241

5310-00-176-6362
5310-00-176-6362

1010-00-438-7343
1010-00-438-7343

1005-01-454-5541
5340-00-438-7337

5340-00-438-7337

5305-00-492-8196
5305-00-492-8196

1010-00-438-7347
1010-00-438-7347

1010-01-441-5507

5310-01-396-2208
5310-01-396-2208

5315-01-475-3483
5315-01-475-3483

19204
19204

19204
19204

19204
19204

19200
19200

19204

19200
19200

19204
19204

19200

80205
80205

80205
80205

8448331
8448331

8448328
8448328

8448322
8448322

12598129
8448321

8448321

8448340
8448340

8448323
8448323

12012037

NAS1149CN632B
NAS1149CN632B

MS39086-66
MS39086-66

GROUP 04 LEAF SIGHT ASSEMBLY
M203 AND M203A1 8448330,
M203A2 12598115
FIG. C-3 LEAF SIGHT ASSEMBLY

SCREW, MACHINE UOC:BC7,401,BJ9
SCREW, MACHINE (MARINE CORPS
ONLY) UOC:401
WASHER, LOCK UOC:BC7,401,BJ9
WASHER, LOCK (MARINE CORPS
ONLY) UOC:401
LEAF, SIGHT UOC:BC7,401
LEAF, SIGHT (MARINE CORPS ONLY)
UOC:401
LEAF, SIGHT UOC:BJ9
BRACKET, MOUNTING
UOC:BC7,401,BJ9
BRACKET, MOUNTING (MARINE
CORPS ONLY) UOC:401
SCREW, WINDAGE UOC:BC7,401,BJ9
SCREW, WINDAGE (MARINE CORPS
ONLY) UOC:401
BASE, SIGHT LEAF UOC:401
BASE, SIGHT LEAF (MARINE CORPS
ONLY ) UOC:401
BASE, SIGHT LEAF (M203/M203A1)
UOC:BC7,401,BJ9
WASHER, FLAT UOC:BC7,401,BJ9
WASHER, FLAT (MARINE CORPS
ONLY ) UOC:401
PIN, SPRING UOC:BC7,401,BJ9
PIN, SPRING (MARINE CORPS ONLY)
UOC:401
END OF FIGURE

1
1

1
1

1
1

1
1

1

1
1

1
1

1

1
1

1
1

Change 4 C-3-1


1
3
2
4
5

Figure C-4. Barrel Assembly 12012005

(1)
Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

(7)

Qty

1

2

3

4

5

PAFZZ

PAFZZ

PAFZZ

XAFZZ

PAFZZ

3040-00-438-7321

1010-00-438-7274

5360-00-177-4220

1010-01-384-3618

19204

19204

19204

19200

19200

8448315

8448312

8448306

12012006

12012007
GROUP 05 BARREL ASSEMBLY
12012005
FIG. C-4 BARREL ASSEMBLY

BARREL, EXTENSION
UOC:BC7,401,BJ9
LOCATOR, CARTRIDGE
UOC:BC7,401,BJ9
SPRING, HELICAL, COMPRESSION
UOC:BC7,401,BJ9
BARREL
UOC:BC7,401,BJ9
GRIP, GRENADE LAUNCHER
UOC:BC7,401,BJ9
END OF FIGURE

1

1

1

1

1
C-4-1
Change 4


Figure C-5. Receiver Assembly M203 8448380-1, M203A1 8448380-2 and M203A2 8448380-3

Change 4


(1)
Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

(7)

Qty

1

2

3

4

4A

4B

5

6

7

7A

8

9

10

11

12

13

14

15

16

17

18

19

20

21

PAFZZ

PAFZZ

PAFZZ

XAFDA

XAFDA

XAFDA

PAOZZ

PAOZZ

PAFZZ

PAFZZ

PAFZZ

PAOZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

3040-00-438-7375

5360-00-182-4798

5315-00-176-6387

1010-00-888-1078

5305-01-213-9942

5315-00-103-7099

5315-00-903-7200

5315-00-237-1896

1010-00-888-1077

1010-00-438-7271

5360-01-113-6247

5340-00-438-7292

1010-00-181-3413

5360-00-177-4219

1010-00-439-1773

5360-00-007-4866

1010-00-438-7358

1010-00-348-8433

1055-00-888-1072

5340-00-438-7356

5360-01-037-6448

19204

19204

19204

19200

19200

19200

19204

81348

19204

96906

19204

19204

19204

19204

19200

19204

19200

19204

19204

19200

19204

19204

19200

96906

8448348

8448326

8448350

8448338-1

8448338-2

8448338-3

8448776

MS16997-18L

8448781

MS39086-163

12002921

8448775

8448302

12006355

8448313

8448342

8448305

8448341

8448777

8448332

12002970

8448773

8448324

AS24585-1025

GROUP 06 RECEIVER ASSEMBLY
M203 8448380-1, M203A1 8448380-2,
AND M203A2 8448380-3
FIG. C-5 RECEIVER ASSEMBLY

PAWL
UOC:BC7,401,BJ9
SPRING, HELICAL, TORSION
UOC:BC7,401,BJ9
PIN, STRAIGHT, HEADLESS
UOC:BC7,401,BJ9
RECEIVER, CARTRIDGE UOC:401

RECEIVER UOC:BC7

RECEIVER UOC:BJ9

PLATE, BACK
UOC:BC7,401,BJ9
SCREW, SELF-LOCKING
UOC:BC7,401,BJ9
PIN, SPRING
UOC:BC7,401,BJ9
PIN, SPRING (BARREL NUT)
UOC:BC7,401,BJ9
PIN, STRAIGHT, HEADED (TRIGGER
PIN) UOC:BC7,401,BJ9
FOLLOWER GUIDE ASSEMBLY
UOC:BC7,401,BJ9
EJECTOR, CARTRIDGE
UOC:BC7,401,BJ9
SPRING, HELICAL COMPRESSION
UOC:BC7,401,BJ9
DISK, SOLID, PLAIN
UOC:BC7,401,BJ9
SEAR
UOC:BC7,401,BJ9
UOC:BC7,401,BJ9
TRIGGER
UOC:BC7,401,BJ9
UOC:BC7,401,BJ9
LEVER, COCKING
UOC:BC7,401,BJ9
PIN, FIRING
UOC:BC7,401,BJ9
SAFETY, GRENADE LAUNCHER
UOC:BC7,401,BJ9
PLUNGER, DETENT
UOC:BC7,401,BJ9
UOC:BC7,401,BJ9

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

C-5-1
Change 4


(1)
Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

(7)

Qty

21A

22

23

24

25

26

27

28

29

30

31

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

PAFZZ

5315-00-176-6551

1010-00-439-1788

1010-00-618-1483

5360-00-177-4230

5315-00-282-3642

5315-00-843-7986

5315-00-616-4261

1010-00-438-7272

5340-00-438-7376

5360-00-177-4217

5315-00-844-5599

96906

19204

19204

19204

80205

80205

80205

19200

19200

19204

96906

MS39086-39

8448375

8448386

8448308

MS16562-96

MS16562-33

MS16562-28

8448303

8448349

8448304

MS16555-632

PIN, SPRING
UOC:BC7,401,BJ9
GUARD, TRIGGER
UOC:BC7,401,BJ9
EXTRACTOR, CARTRIDGE
UOC:BC7,401,BJ9
SPRING. HELICAL, COMPRESSION
UOC:BC7,401,BJ9
PIN, SPRING
UOC:BC7,401,BJ9
PIN, SPRING
UOC:BC7,401,BJ9
PIN, SPRING
UOC:BC7,401,BJ9
INSERT, BREECH
UOC:BC7,401,BJ9
LEVER, LOCK-RELEASE
UOC:BC7,401,BJ9
UOC:BC7,401,BJ9
UOC:BC7,401,BJ9

END OF FIGURE

1

1

1

1

1

2

1

1

1

1

1

C-5-2
Change 4


Figure C-6. Quadrant Sight Assembly M203, M203A1 and M203A2 12598114

Change 4


(1)
Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

(UOC)
(7)

Qty

1

2

3

3A

4

5

6

7

8

9

10

11

PAOZZ

PAOZZ

AOOOO

AOOOO

PAOOO

PAOZZ

PAOZZ

PAOZZ

PAOZZ

PAOOO

PAOZZ

PAOZZ

5306-00-185-8016

5340-01-475-4291

1010-01-285-1016

5315-01-013-2553

5305-01-135-9500

5340-01-122-9409

1010-01-122-9679

1010-01-441-1621

5360-01-135-3710

1010-00-438-7385

19200

19200

19200

19200

19204

96906

19204

19200

19200

19200

19204

19200

12002880

12991504

9346305

12598116

12002885

MS39086-4

12002875

12002876

12002878

9346306

12002874

8448360

GROUP 07 QUADRANT SIGHT ASSEMBLY
M203, M203A1 AND M203A2 12598114
FIG. C-6 QUADRANT SIGHT ASSEMBLY
M203, M203A1 AND M203A2

BOLT, SHOULDER (MOUNTING)
UOC:BC7,401,BJ9
CLAMP, RIM CLENCHING
UOC:BC7,401,BJ9
QUADRANT, RANGE
UOC:401
QUADRANT, RANGE ASSEMBLY
(M203A1) UOC:BC7,BJ9
SIGHTARM ASSEMBLY
UOC:BC7,401,BJ9
PIN, SPRING
UOC:BC7,401,BJ9
SCREW, SHOULDER
UOC:BC7,401,BJ9
CLIP, SPRING TENSION
UOC:BC7,401,BJ9
APERTURE, SIGHT
UOC:BC7,401,BJ9
LATCH ASSEMBLY
UOC:BC7,401,BJ9
UOC:BC7,401,BJ9
SIGHT, FRONT
UOC:BC7,401,BJ9

END OF FIGURE

1

1

1

1

1

1

1

1

1

1

1

1

C-6-1
Change 4


Figure C-7. Quadrant, Range Assembly M203 9346305 and M203A1/M203A2 12598116

(1)
Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

(7)

Qty

1

2

3

4

5

PAOZZ

PAOZZ

PAOZZ

PAOZZ

PAOZZ

5340-01-474-9020

1290-01-124-5213

5305-00-455-2550

5365-01-441-7384

5305-00-417-5264

19200

19200

96906

19200

96906

12991510

9346309

MS51959-28B

12598113

MS51959-34B

GROUP 0701 QUADRANT, RANGE
ASSEMBLY M203 9346305 AND
M203A1/M203A2 12598116
FIG. C-7 QUADRANT, RANGE
ASSEMBLY

BRACKET ASSEMBLY
UOC:BC7,401,BJ9
QUADRANT, FIRE CONTROL
UOC:BC7,401,BJ9
SCREW, MACHINE
UOC:401
SPACER, QUADRANT SIGHT
UOC:BC7,401,BJ9
SCREW, MACHINE
UOC:BC7,401,BJ9

END OF FIGURE

1

1

2

1

2

C-7-1
Change 4


1
2

Figure C-8. Latch Assembly 9346306

(1)
Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

(7)

Qty

1

2

XAOZZ

PAOZZ

5315-01-137-7188

19200

19204

9346307

9346311

GROUP 0702 LATCH ASSEMBLY
9346306
FIG. C-8 LATCH ASSEMBLY

LATCH, SIGHT
UOC:BC7,401
UOC:BC7,401

END OF FIGURE

1

1

C-8-1
Change 4


Figure C-9. Sightarm Assembly 12002885

(1)
Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

(7)

Qty

1

2

3

4

PAOZZ

XAOZZ

PAOZZ

PAOZZ

5320-01-136-7161

1010-01-122-9410

1010-01-122-9408

19204

19200

19200

19200

12002884

12002881

12002877

12002873

GROUP 0703 SIGHTARM ASSEMBLY
12002885
FIG. C-9 SIGHTARM ASSEMBLY

RIVET, TUBULAR
UOC:BC7,401,BJ9
ARM, QUADRANT SIGHT
UOC:BC7,401,BJ9
ARM, SIGHT APERTURE
UOC:BC7,401,BJ9
ARM, SIGHT POST
UOC:BC7,401,BJ9

END OF FIGURE

2

1

1

1

C-9-1
Change 4

SECTION III ARMY TM 9-1010-221-23&P

Section III. SPECIAL TOOLS LIST

Figure C-10. Special Tools

(1)
Item
No.
(2)
SMR
Code
(3)

NSN
(4)

CAGEC
(5)
Part
Number
(6)

(UOC)
(7)

Qty

1

2

PAFZZ

PAFZZ

5120-01-047-3294

5220-00-348-8434

19204

19204

12003033

12002976

GROUP 9500 SPECIAL TOOLS

FIG. C-10 SPECIAL TOOLS

ADAPTER, TORQUE WRENCH

GAGE, FIRING PIN PROTRUSION
(2 per DS/GS)

END OF FIGURE

1

2

C-10-1
Change 4

Intentionally Left Blank

SECTION IV ARMY TM 9-1010-221-23&P
CROSS-REFERENCE INDEXES
NATIONAL STOCK NUMBER INDEX
STOCK NUMBER FIG. ITEM STOCK NUMBER FIG. ITEM
5360-00-007-4866
5315-00-103-7099
5305-00-150-9212
5310-00-160-9817
5310-00-176-6362
5315-00-176-6387
5315-00-176-6551
5360-00-177-4217
5360-00-177-4219
5360-00-177-4220
5360-00-177-4230
1010-00-181-3413
5360-00-182-4798
5305-00-182-9241
5305-00-182-9265
5306-00-185-8016
5315-00-237-1896
5315-00-282-3642
9505-00-293-4208
1010-00-348-8433
5220-00-348-8434
5305-00-417-5264
5310-00-420-0737
1010-00-438-7271
1010-00-438-7272
1010-00-438-7274
5340-00-438-7292
3040-00-438-7321
3120-00-438-7332
5340-00-438-7337
1010-00-438-7343
1010-00-438-7347
5340-00-438-7356
1010-00-438-7358
3040-00-438-7375
5340-00-438-7376
1010-00-438-7385
1010-00-438-7431
1010-00-439-1773
1010-00-439-1788
5305-00-455-2550
5305-00-492-8196
5315-00-616-4261
1010-00-618-1483
5315-00-690-0544
5315-00-823-8743
5315-00-843-7986
5315-00-844-5599
5315-00-847-3735
1055-00-888-1072

C-5 16
C-5 7
C-2 4
C-2 4B
C-3 2
C-5 3
C-5 21A
C-5 30
C-5 14
C-4 3
C-5 24
C-5 13
C-5 2
C-3 1
C-2 2
C-6 1
C-5 8
C-5 25
C-2 6
C-5 18
C-10 2
C-7 5
C-2C 4
C-5 10
C-5 28
C-4 2
C-5 12
C-4 1
C-2 7
C-3 4
C-3 3
C-3 6
C-5 20
C-5 17
C-5 1
C-5 29
C-6 11
C-2 1
C-5 15
C-5 22
C-7 3
C-3 5
C-5 27
C-5 23
C-2 10
C-2B 1
C-5 26
C-5 31
C-2B 3
C-5 19

I-1

1010-00-888-1077
1010-00-888-1078
5315-00-903-7200
5315-01-013-2553
5360-01-037-6448
5360-01-113-6247
1010-01-122-9408
5340-01-122-9409
1010-01-122-9410
1010-01-122-9679
1290-01-124-5213
5360-01-135-3710
5305-01-135-9500
5320-01-136-7161
5315-01-137-7188
5305-01-213-9942
1010-01-264-6517
1010-01-285-1016
5340-01-376-0876
1010-01-376-3342
1010-01-384-3618
5310-01-396-2208
5340-01-440-7610
1010-01-441-1621
1010-01-441-5507
5365-01-441-7384
1010-01-442-0156
5305-01-442-0157
5305-01-442-0157
5340-01-442-0165
1010-01-442-2313
1005-01-452-3528
5310-01-452-9635
5305-01-452-9639
1005-01-453-1634
5365-01-453-9287
1005-01-454-5541
5305-01-463-3305
5340-01-466-7727
1010-01-470-7105
5120-01-047-3294
5340-01-474-2845
5340-01-474-9020
5315-01-475-3483
5340-01-475-4291
5360-01-502-5468
5340-01-502-5471

C-5 9
C-5 5
C-5 7A
C-6 5
C-5 21
C-5 11
C-9 4
C-6 7
C-9 3
C-6 8
C-7 2
C-6 10
C-6 6
C-9 1
C-8 2
C-5 6
C-2 11
C-6 4
C-2 5
C-2 12
C-4 5
C-3 7
C-2 9
C-6 9
C-3 6A
C-7 4
C-2 5C
C-2 4A
C-2 5D
C-2 5A
C-1 2
C-2 5E
C-2A 2
C-2A 4
C-2A 3
C-2A 5
C-3 3A
C-2C 2
C-2C 3
C-2 1A
C-10 1
C-2 9A
C-7 1
C-3 8
C-6 2
C-2B 4
C-2B 2

Change 4

PART NUMBER INDEX
CAGEC PART NUMBER STOCK NUMBER FIG. ITEM

88044
96906
80205
80205
80205
96906
80205
80205
81348
96906
96906
96906
96906
96906
80205
96906
96906
96906
96906
80205
80205
80205
19200
19204
19204
19200
19200
19200
19200
19200
19204
19204
19204
19204
19204
19204
19204
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
AN502-10-8
AS24585-1025
MS16562-190
MS16562-28
MS16562-96
MS16555-632
MS16562-219
MS16562-33
MS16997-18L
MS24671-13B
MS35649-284B
MS39086-39
MS39086-163
MS39086-4
MS39086-66
MS39086-93
MS51957-43B
MS51959-28B
MS51959-34B
NASM20995C32
NAS1149CN632B
NAS1149C0363B
12002873
12002874
12002875
12002876
12002877
12002878
12002880
12002881
12002884
12002885
12002921
12002970
12002976
12003033
12006355
12011998
12012005
12012006
12012007
12012037
12012059
12598113
12598114
12598115
12598116
12598117
12598129
12598130
12598617
5305-00-150-9212
5360-01-037-6448
5315-00-847-3735
5315-00-616-4261
5315-00-282-3642
5315-00-844-5599
5315-00-823-8743
5315-00-843-7986
5305-01-213-9942
5305-01-463-3305
5310-00-420-0737
5315-00-176-6551
5315-00-903-7200
5315-01-013-2553
5315-01-475-3483
5315-00-690-0544
5305-00-182-9265
5305-00-455-2550
5305-00-417-5264
9505-00-293-4208
5310-01-396-2208
5310-00-160-9817
1010-01-122-9408
5360-01-135-3710
5305-01-135-9500
5340-01-122-9409
1010-01-122-9410
1010-01-122-9679
5306-00-185-8016

5320-01-136-7161
1010-01-285-1016
5315-00-237-1896
1010-00-348-8433
5220-00-348-8434
5120-01-047-3294
5360-01-113-6247
5340-01-376-0876
1010-01-376-3342

1010-01-384-3618
1010-01-441-5507
5340-01-440-7610
5365-01-441-7384
1010-01-442-2313

1005-01-454-5541
5340-01-466-7727
1010-01-264-6517
C-2
C-5
C-2B
C-5
C-5
C-5
C-2B
C-5
C-5
C-2C
C-2C
C-5
C-5
C-6
C-3
C-2
C-2
C-7
C-7
C-2
C-3
C-2
C-9
C-6
C-6
C-6
C-9
C-6
C-6
C-9
C-9
C-6
C-5
C-5
C-10
C-10
C-5
C-2
C-2
C-4
C-4
C-3
C-2
C-7
C-1
C-2C
C-6
C-2
C-3
C-2C
C-2
4
21
3
27
25
31
1
26
6
2
4
21A
7A
5
8
10
2
3
5
6
7
4B
4
10
6
7
3
8
1
2
1
4
8
18
2
1
11
5
12
4
5
6A
9
4
2
1
3A
3A
3A
3
11

Change 4 I-2
PART NUMBER INDEX

19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19200
19204
19204
19200
19204
19200
19204
19204
19204
19200
19204
19204
19200
19204
19204
19200
19204
19204
19204
19204
19200
19200
19200
19200
19200
19204
19204

12597126
12597127
12597128
12597129
12597129
12973116
12973117
12973118
12973120
12973121
12973124
12973127
12973129
12973130
12973140
12982965
12990563
12991254
12991504
12991510
12999210
12999211
12999552
8448300
8448302
8448303
8448304
8448305
8448306
8448308
8448312
8448313
8448315
8448320
8448321
8448322
8448323
8448324
8448326
8448328
8448330
8448331
8448332
8448338-1
8448338-2
8448338-3
8448340
8448341
8448342

5340-01-442-0165

1010-01-442-0156
5305-01-442-0157
5305-01-442-0157
1005-01-452-3528

1005-01-453-1634
5365-01-453-9287
5305-01-452-9639
5310-01-452-9635

1010-01-470-7105
5340-01-474-2845
5340-01-475-4291
5340-01-474-9020
5360-01-502-5468
5340-01-502-5471

1010-00-438-7271
1010-00-438-7272
5360-00-177-4217
5360-00-177-4219
5360-00-177-4220
5360-00-177-4230
1010-00-438-7274
5340-00-438-7292
3040-00-438-7321
3120-00-438-7332
5340-00-438-7337
1010-00-438-7343
1010-00-438-7347
5340-00-438-7356
5360-00-182-4798
5310-00-176-6362

5305-00-182-9241
1010-00-438-7358

5305-00-492-8196
1010-00-439-1773
1010-00-181-3413

I-3 Change 4

C-2
C-2
C-2
C-2
C-2
C-2
C-2A
C-2B
C-2B
C-2B
C-2B
C-2A
C-2A
C-2A
C-2A
C-1
C-2
C-2
C-6
C-7
C-2B
C-2B
C-1
C-1
C-5
C-5
C-5
C-5
C-4
C-5
C-4
C-5
C-4
C-2
C-3
C-3
C-3
C-5
C-5
C-3
C-2
C-3
C-5
C-5
C-5
C-5
C-3
C-5
C-5

5A
5B
5C
4A
5D
5E
1
8
6
7
5
3
5
4
2
1A
1A
9A
2
1
4
2
1B
1
10
28
30
14
3
24
2
12
1
7
4
3
6
20
2
2
3
1
17
4
4A
4B
5
15
13

PART NUMBER INDEX
19204
19200
19204
19200
19204
19204
19204
19200
19200
19204
19204
19204
19204
19204
19204
19200
19200
19200
19200
19204
8448348
8448349
8448350
8448360
8448375
8448377
8448380-1
8448380-2
8448380-3
8448386
8448773
8448775
8448776
8448777
8448781
9346305
9346306
9346307
9346309
9346311
3040-00-438-7375
5340-00-438-7376
5315-00-176-6387
1010-00-438-7385
1010-00-439-1788
1010-00-438-7431

1010-00-618-1483
1055-00-888-1072
1010-00-888-1077
1010-00-888-1078
5360-00-007-4866
5315-00-103-7099

1010-01-441-1621

1290-01-124-5213
5315-01-137-7188
C-5
C-5
C-5
C-6
C-5
C-2
C-2
C-2
C-2
C-5
C-5
C-5
C-5
C-5
C-5
C-6
C-6
C-8
C-7
C-8
1
29
3
11
22
1
8
8A
8B
23
19
9
5
16
7
3
9
1
2
2

I-4
Change 4

ARMY TM 9-1010-221-23&P

APPENDIX D

EXPENDABLE AND DURABLE ITEMS LIST


D-1. SCOPE.

This appendix lists expendable and durable items you will need to maintain the grenade launcher. This listing is
for informational purposes only and is not authority to requisition the listed items. These items are authorized to
you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items).

D-2. EXPLANATION OF COLUMNS.

a. Column (1) Item Number. This number is assigned to the entry in the listing for referencing when
required.

b. Column (2) Level. This column identifies the lowest level of maintenance that requires the listed
item.

C Operator/Crew
O Unit Maintenance
F Direct Support Maintenance

c. Column (3) National Stock Number. This is the National Stock Number assigned to the item;
use it to request or requisition the item.

d. Column (4) Description. Indicates the Federal item name and, if required, a description to identify
the item. The last line for each item indicates the Contractor and Government Entity Code (CAGEC) in
parentheses followed by the part number.

e. Column (5) Unit of Measure (U/M)/Unit of Issue (U/I). This measure is expressed by a two-
character alphabetical abbreviation (e.g., ea., in., pr.). If the unit of measure differs from the unit of issue as
shown in the Army Master Data File (AMDF), requisition the lowest unit of issue that will satisfy your
requirements.

D-1
ARMY TM 9-1010-221-23&P
Section II. EXPENDABLE AND DURABLE ITEMS LIST

(1)

Item
Number

(2)

Level

(3)
National
Stock
Number

(4)

Description

(5)

(U/M)

1 F

8040-00-043-1717
8040-00-680-1080
8040-00-266-7429

8040-01-486-1862
ADHESIVE:
(73842) PLIOBOND20
2 oz tube
3.75 oz tube
8 oz can

(04963) SCOTCHGRIP 1099
5 oz tube

TU

CN

TU

2 C 1005-00-242-5687 BOTTLE, ASSEMBLY CYLINDRICAL:
(19204) 8448444

EA
3 O 8020-00-244-0153 BRUSH, ARTISTS:
(81348) H-B-241

EA
4 O 7920-00-205-2401 BRUSH, CLEANING, TOOLS
AND PARTS:
(81349) MIL-S-43871

EA
5

C

O
O

9150-01-102-1473

9150-01-054-6453
9150-01-053-6688

CLEANER, LUBRICANT, AND PRESERVATIVE:
(81349) MIL-L-63460
1/2 oz (14.79 ml) bottle
(27412) CLP-5, CLP-7
1 pt (0.48 l) can
1 gal. (3.78 l) container

OZ

OZ
GL
6 O 9920-00-292-9946 CLEANER, TOBACCO PIPE:
(89855) DILLS PIPE CLEANER

EA
7 C

6850-00-224-6656
6850-00-224-6657
CLEANING COMPOUND, RIFLE BORE:
small arms bore cleaning solution (RBC)
(81349) MIL-PRF-372
2 fl oz (59.15 ml) bottle
8 oz (236.6 ml) can

OZ
OZ
8 O 5350-00-221-0872 CLOTH, ABRASIVE:
(81348) PC-458

SH
9 O

6850-01-474-2319
6850-01-474-2317
6850-01-474-2316
DRY CLEANING SOLVENT: type II
(81349) MIL-PRF-680
1 gal. (3.78 l)
5 gal (18.93 l)
55 gal (208.18 l)

GL
GL
GL

10 O

8415-00-823-7458
8415-00-823-7459
8415-00-823-7460
GLOVES, RUBBER:
(81349) MIL-DTL-32066
Size 9
Size 10
Size 11

PR
PR
PR

D-2 Change 4

ARMY TM 9-1010-221-23&P

EXPENDABLE AND DURABLE ITEMS LIST (CONT)

(1)

Item
Number

(2)

Level

(3)
National
Stock
Number

(4)

Description

(5)

(U/M)/
(U/I)

11 O 9150-01-260-2534 LUBRICANT, SOLID FILM:
16 oz (0.45 kg) spray can
(81349) MIL-L-23398

OZ
12 C 9150-00-292-9689 LUBRICATING OIL, WEAPONS:
(LAW)
1 qt (0.95 l) can
(81349) MILL14107

QT
13

C
C

9150-00-935-6597
9150-00-889-3522
LUBRICATING OIL, WEAPONS:
(LSA), semifluid
(81349) MILL46000
2 fl oz (59.15 ml) plastic bottle
4 fl oz (118.30 ml) bottle

OZ
OZ
14 DELETED

15 F 6850-00-826-0981 PENETRANT KIT:
(81349) MIL-I-25135

KT
16 F 8030-00-181-8372 PRIMER SEALING COMPOUND:
6 oz (170 g) can
(81349) MIL-S-22473

CN
17 C 7920-00-205-1711 RAG, WIPING:
50 lb (22.68 kg) bale
(58536) A-A-531

LB
18 F 8030-00-051-4011 SEALING COMPOUND:
1 lb (454 gm)
(16059) DEVCON F

KT
19 F 8030-00-081-2335 SEALING COMPOUND: locktite, locking
torque 3/8 bolt 70/175, viscosity
100-200, yellow
10 cc bottle
(81349) MIL-S-22473

CC
20 O 9505-00-293-4208 WIRE, NONELECTRICAL
0.032 in.
(19204) MS20995C32

LB

Change 4 D-3/(D-4 blank)

ARMY TM 9-1010-221-23&P
NAVY SW 370-AE-MM1-010
APPENDIX E
ILLUSTRATED LIST OF MANUFACTURED ITEMS
E-1.
a.
tured
b.
INTRODUCTION.
This appendix includes complete instructions for making items authorized to be manufac-
or fabricated at unit and/or direct support levels.
All bulk materials needed for manufacture of an item are listed by part number or
specification number in a tabular list on the illustration.
Figure E-1. Fabrication of bore constriction check tool
NOTES:
1. MATERIAL: MILD STEEL (1018) BAR STOCK, 1-3/4 IN. DIA, NSN 9510-00-813-5335,
UNIT OF ISSUE: FOOT, QQ-S-634 OR EQUIVALENT.
2. PURPOSE OF TOOL: TO DETECT DENTS AND OR MINOR DAMAGE SUFFICIENT TO lM-
PEDE FORWARD PROGRESS OF FIRED PROJECTILE.
3. USE HANDLE SECTION OF SMALL ARMS CLEANING ROD (SMALL ARMS REPAIRMAN
TOOL KIT).
4. TOOL MUST PASS FREELY THROUGH ENTIRE BARREL BORE,
E-1
ARMY TM 9-1010-221-23&P
Figure E-2. Slave pin
NOTES:
1. FABRICATE SLAVE PIN FROM MATERIAL BLOCK, WIRE, STEEL ALLOY, GRADE 4140,
ASTM-A547 OR EQUIVALENT.
2. PURPOSE OF TOOL: TO HOLD TRIGGER PARTS ASSEMBLED DURING INSTALLATION.
3. ALL DIMENSIONS SHOWN ARE IN INCHES WITH THE METRIC CONVERSION TO CEN-
TIMETERS IN PARENTHESES.
Figure E-3. Barrel extension staking support tool
1. FABRICATE FROM MATERIAL BLOCK, ALUMINUM OR MILD STEEL BAR STOCK, AS
AVAILABLE.
2. PURPOSE OF TOOL: FOR SUPPORT DURING STAKING OF BARREL EXTENSION.
3. ALL DIMENSIONS SHOWN ARE IN INCHES WITH THE METRIC CONVERSION TO CEN-
TIMETERS IN PARENTHESES
E-2

ARMY TM 9-1010-221-23&P

ALPHABETICAL INDEX

Subject Page
O* F**
B

Barrel Assembly - Maintenance Instructions......................................................................... 3-11
Cleaning.......................................................................................................................... 3-12
Disassembly ................................................................................................................... 3-12
Inspection/Repair............................................................................................................ 3-13
Reassembly/Lubrication ................................................................................................. 3-15

C

Common Tools and Equipment ............................................................................................ 2-1 3-1
Corrosion Prevention and Control (CPC).............................................................................. 1-2 1-2

D

Destruction of Army Materiel to Prevent Enemy Use ........................................................... 1-1 1-1
Differences Between Models ................................................................................................ 1-5 1-5

E

Equipment Characteristics, Capabilities, and Features ........................................................ 1-3 1-3
Equipment Data .................................................................................................................... 1-5 1-5
Expendable and Durable Items List ...................................................................................... D-1 D-1

G

40MM Grenade Launcher M203/M203A1 - Maintenance Instructions ................................. 3-7
Disassembly.. 3-7
Inspection/Repair .............................................................................................................. 3-8
Reassembly ...................................................................................................................... 3-8

40MM Grenade Launcher M203/M203A1 W/E - Maintenance Instructions ......................... 2-15 3-4
Removal of M203/M203A1 Grenade Launcher from M16 Series Rifle/M4 Series Carbine 2-15
Inspection/Repair .............................................................................................................. 2-22
Installation of M203........................................................................................................... 3-4
Installation of M203 Grenade Launcher to M16 Series Rifle ............................................ 2-23

I

Illustrated List of Manufactured Items................................................................................... E-1 E-1

* Unit maintenance
** Direct support maintenance

Change 4 Index 1

ARMY TM 9-1010-221-23&P

Subject Page
O* F**
L

Latch Assembly - Maintenance Instructions ......................................................................... 2-42
Disassembly ................................................................................................................... 2-42
Reassembly.................................................................................................................... 2-43
Leaf Sight Assembly - Maintenance Instructions.................................................................. 3-9
Cleaning/Inspection/Repair ............................................................................................ 3-10
Disassembly ................................................................................................................... 3-9
Reassembly/Lubrication ................................................................................................. 3-10
Location and Description of Major Components................................................................... 1-4 1-4
Lubrication Instructions ......................................................................................................... 2-1

M

Maintenance Allocation Chart (MAC).................................................................................... B-1 B-1
Maintenance Forms, Records, and Reports ......................................................................... 1-1 1-1

O

Official Nomenclature, Names, and Designations ................................................................ 1-1 1-1

P

Preembarkation Inspection of Materiel in Units Alerted for
Overseas Movement ......................................................................................................... 3-36
Preventive Maintenance Checks and Services..................................................................... 2-3
Principles of Operation.......................................................................................................... 1-7 1-7

Q

Quadrant Sight Assembly - Maintenance Instructions.......................................................... 2-38
Disassembly ................................................................................................................... 2-38
Reassembly .................................................................................................................... 2-39

R

Range Assembly Quadrant - Maintenance Instructions ....................................................... 2-40
Disassembly..................................................................................................................... 2-40
Inspection/Repair ............................................................................................................. 2-41
Reassembly ..................................................................................................................... 2-41

* Unit maintenance

Index 2 Change 4

ARMY TM 9-1010-221-23&P

Subject Page
O* F**
R (Cont)

Receiver Assembly - Maintenance Instructions.................................................................... 2-31 3-17
Cleaning.......................................................................................................................... 2-33 3-22
Disassembly ................................................................................................................... 2-32 3-18
Inspection/Repair............................................................................................................ 2-33 3-22
Installation ....................................................................................................................... 2-37
Lubrication/Reassembly ................................................................................................. 2-34
Reassembly.................................................................................................................... 3-28
Removal.......................................................................................................................... 2-31
Annual Gaging/Inspection............................................................................................... 3-34
References............................................................................................................................ A-1 A-1
Repair Parts .......................................................................................................................... 2-1 3-1
Repair Parts and Special Tools List ...................................................................................... C-1 C-1
Reporting Equipment Improvement Recommendations (EIR).............................................. 1-2 1-2

S

Scope .................................................................................................................................... 1-1 1-1
Service Upon Receipt of Materiel ......................................................................................... 2-2
Special Tools, TMDE, and Support Equipment .................................................................... 2-1 3-1
Sightarm Assembly - Maintenance Instructions.................................................................... 2-43
Disassembly..................................................................................................................... 2-44
Inspection/Repair ............................................................................................................. 2-44
Reassembly ..................................................................................................................... 2-45
Storage of Grenade Launcher M203 .................................................................................... 1-6 1-6

T

Technical Principles Of Operation ........................................................................................ 1-7 1-7
Troubleshooting Procedures................................................................................................. 2-8 3-1

* Unit maintenance

Change 1 Index 3/(Index 4 blank)

By Order of the Secretary Of the Army and the Air Force:
GORDON R. SULLIVAN
Chief of Staff
Official:
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
03249
MERRILL A. McPEAK
G e n e r a l
r United States Air Force
Official :
Chief of Staff
RONALD W . YATES
General,
United States Air Force
Commander, Air Force Materiel Command
DISTRIBUTION :
To be distributed in accordance with DA Form 12-40-E, Block 0545,
requirements for TM 9101022123&P.
frU.S.GOVERNMENT PRINTINGOFFICE: 19S3746-045/7011 3

RECOMMENDED CHANGES TO
PUBLICATIONS
AND BLANK FORMS
For use of this form, see AR 25-30; the proponent agency is ODISC4.
Use Part II (reverse) for Repair Parts and
Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
DATE
Date you filled out
this form.
TO: (Forward to proponent of publication or form) (Include ZIP Code)
AMSTA-LC-CI / TECH PUBS, TACOM-RI
FROM: (Activity and location) (Include ZIP Code)

Your mailing address
PART I ALL PUBLICATIONS (EXCEPT RPSTL ANDSC/SM) ANDBLANK FORMS
PUBLICATION/FORM NUMBER
TM 9-1010-221-23&P
DATE

TITLE
Unit and Direct Support Maintenance Manual Including Repair
Parts and Special Tools List For Launcher, Grenade, 40MM,
M203, W/E (1010-00-179-6447) (EIC:4QB) and Launcher,
Grenade, 40MM, M203A1, W/E (1010-01-434-9028)
(EIC:4QH)

ITEM
NO.
PAGE
NO.
PARA-
GRAPH
LINE
NO. *
FIGURE
NO.
TABLE
NO.
RECOMMENDED CHANGES AND REASON
(Provide exact wording of recommended changes, if possible).

7

C-2-1

C-2

NSN should be 3120-00-438-7332.

*Reference to line numbers within the paragraph or subparagraph.
TYPED NAME, GRADE OR TITLE

Your Name
TELEPHONE EXCHANGE/AUTOVON, PLUS
EXTENSION

SIGNATURE

Your Signature
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00

TO: (Forward direct to addressee listed in publication)
Your address
DATE
Date you filled out this
form
PART II REPAIR PARTS ANDSPECIAL TOOL LISTS ANDSUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER
TM 9-1010-221-23&P

DATE

TITLE
Unit and Direct Support Maintenance Manual
Including Repair Parts and Special Tools List For
Launcher, Grenade, 40MM, M203, W/E (1010-00-
179-6447) (EIC:4QB) and Launcher, Grenade,
40MM, M203A1, W/E (1010-01-434-9028)
(EIC:4QH)

PAGE
NO.

COLM
NO.

LINE
NO.

NATIONAL STOCK
NUMBER

REFERENCE
NO.

FIGURE
NO.

ITEM
NO.
TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED

RECOMMENDED ACTION

PART III REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)


Your Name

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

Your Signature
UASPPC V3.00

PUBLICATIONS
AND BLANK FORMS
DATE


TM 9-1010-221-23&P
DATE

TITLE
Grenade, 40MM, M203A1, W/E (1010-01-434-9028)
(EIC:4QH)

ITEM
NO.
PAGE
NO.
PARA-
GRAPH
LINE
NO. *
FIGURE
NO.
TABLE
NO.


EXTENSION

SIGNATURE



DATE

PUBLICATION NUMBER
TM 9-1010-221-23&P

DATE

TITLE
40MM, M203A1, W/E (1010-01-434-9028)
(EIC:4QH)

PAGE
NO.

COLM
NO.

LINE
NO.

NATIONAL STOCK
NUMBER

REFERENCE
NO.

FIGURE
NO.

ITEM
NO.
TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED

RECOMMENDED ACTION




SIGNATURE

UASPPC V3.00

PUBLICATIONS
AND BLANK FORMS
DATE


TM 9-1010-221-23&P
DATE

TITLE
Grenade, 40MM, M203A1, W/E (1010-01-434-9028)
(EIC:4QH)

ITEM
NO.
PAGE
NO.
PARA-
GRAPH
LINE
NO. *
FIGURE
NO.
TABLE
NO.


EXTENSION

SIGNATURE



DATE

PUBLICATION NUMBER
TM 9-1010-221-23&P

DATE

TITLE
40MM, M203A1, W/E (1010-01-434-9028)
(EIC:4QH)

PAGE
NO.

COLM
NO.

LINE
NO.

NATIONAL STOCK
NUMBER

REFERENCE
NO.

FIGURE
NO.

ITEM
NO.
TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED

RECOMMENDED ACTION




SIGNATURE

UASPPC V3.00

PUBLICATIONS
AND BLANK FORMS
DATE


TM 9-1010-221-23&P
DATE

TITLE
Grenade, 40MM, M203A1, W/E (1010-01-434-9028)
(EIC:4QH)

ITEM
NO.
PAGE
NO.
PARA-
GRAPH
LINE
NO. *
FIGURE
NO.
TABLE
NO.


EXTENSION

SIGNATURE



DATE

PUBLICATION NUMBER
TM 9-1010-221-23&P

DATE

TITLE
40MM, M203A1, W/E (1010-01-434-9028)
(EIC:4QH)

PAGE
NO.

COLM
NO.

LINE
NO.

NATIONAL STOCK
NUMBER

REFERENCE
NO.

FIGURE
NO.

ITEM
NO.
TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED

RECOMMENDED ACTION




SIGNATURE

UASPPC V3.00

070835-003
PIN: 070835-000

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