ARMY TM P AIR FORCE T.O. 36A12-1B *SUPERSEDES COPY DATED JUNE 1998

Transcription

1 ARMY TM P AIR FORCE T.O. 36A12-1B *SUPERSEDES COPY DATED JUNE 1998 UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST FOR M1078 SERIES, 2-1/2-TON, 4X4, LIGHT MEDIUM TACTICAL VEHICLE (LMTV) MODEL NSN EIC TRK, CAR., LMTV, M1078 W/WN BHH W/O WN BHD TRK, VAN, LMTV, M1079 W/WN BHG W/O WN BHE TRK, CHAS, LMTV, M BHC TRK, CAR., LMTV, AIRDROP, M1081 W/WN BHJ W/O WN BHF DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENTS OF THE ARMY AND THE AIR FORCE 31 JULY 2001

2 TECHNICAL MANUAL NO P ARMY TM P AIR FORCE T.O. 36A12-1B HEADQUARTERS DEPARTMENTS OF THE ARMY AND THE AIR FORCE TECHNICAL ORDER Washington, DC 31 July 2001 NO. 36A12-1B UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST FOR M1078 SERIES, 2-1/2-TON, 4X4 LIGHT MEDIUM TACTICAL VEHICLE (LMTV) MODEL NSN EIC Trk, Car., LMTV, M1078 W/WN BHH W/O WN BHD TRK, VAN, LMTV, M1079 W/WN BHG W/O WN BHE Trk, Chas, LMTV, M BHC Trk, Car., LMTV, AIRDROP, M1081 W/WN BHJ W/O WN BHF REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know a way to improve the procedures, please let us know. 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 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 your letter or DA Form 2028 direct to: AMSTA- LC-CI/TECH PUBS, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL The address is The fax number is DSN or Commercial (309) DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. *This publication supercedes TM p DATED 17 June i/(ii Blank)

3 TM P TABLE OF CONTENTS Page Illus./ Figure Section I. INTRODUCTION Section II. REPAIR PARTS LIST Group 01 Engine 0100 Dressed Engine with Container Engine Mounts Engine Brackets Cylinder Head with Valves and Gasket Cylinder Block Crankshaft Pulley and Damper Flywheel, Housing and Flex Plates Piston and Push Rods Idler Gear Camshaft Front and Side Housing Covers and Cam Followers Valve Cover and Gasket Rocker Arms Push Rods, Valves, Valve Springs Oil Cooler Oil Pan and Oil Pump Oil Hoses and Tubes Engine Oil Sampling Valve Engine Oil Filter and Filter Base Engine Oil Dipstick and Filler Tube Crankcase Breather Inlet Manifold, Gasket and Cover Exhaust Manifold Group 03 Fuel System 0301 Fuel Injector Air Cleaner Turbocharger Charge Air Cooler, Pipes, Brackets and Hoses Fuel Regulating Valve, Tubes, Fittings and Hoses Fuel Tank, Clamps and Brackets Governor and Fuel Transfer Fuel Control Linkage Fuel Filter Fuel/Water Separator Ether Starting Aid Accelerator, Hand Throttle and Linkage Group 04 Exhaust System 0401 Exhaust Pipe Heat Shield Exhaust Pipes, Brackets and Clamps Muffler, Ejector, Clamps and Brackets Muffler Heat Shield, Clamps and Resilient Mounts Group 05 Cooling System 0501 Radiator, Overflow Tank, Hoses and Fittings iii

4 TM P Illus./ Page Figure Group 05 Cooling System (continued) 0502 Radiator Fan Shroud Thermostat and Cooling Tubes Water Pump and Drive Engine Fan and Clutch Assembly Group 06 Electrical System AMP Alternator, Brackets and Belt AMP Voltage Regulator M MD Starter and Solenoid M ME Starter and Solenoid Auxiliary Starter Solenoid Fuel Shutoff Solenoid Instrument Panel Auxiliary Panel and Switches WTEC II Dashboard Cable Assembly and Power Distribution Panel WTEC III Dashboard Cable Assembly and Power Distribution Panel Turn Signal Control Flasher Unit Solenoid Valve Assembly CTIS Electronic Control Unit, ECU Dimmer Module, and Frequency ECU A Reverse Polarity Relay and Starter Shunt Headlamp Assembly Composite Taillight Assembly Cab and Door Clearance and Marker Lights Chassis Clearance and Marker Lights Backup Light Blackout Drive Light Composite Front Light Assembly Sensors, Switches and Transducers Air Brakes Pneumatic Switch Horn Batteries, Box, Guard and Cables Engine Cable Routing Clamps and Insulators Engine Control Cable Assembly STE/ICE Cable Assembly Pin Intervehicle Cable Transmission Wiring Harness Transmission Harness WTEC III Transmission Wiring Harness Windshield Washer Pump/EMI Cable Pin Intervehicle Cable Assembly Cab Cable Routing Clamps and Brackets Warning Light Cable Assembly Door and Cab Marker Light Cable Assembly Air Drop Cab Clearance and Marker Lights Lower Cable Assembly 0613 Air Drop Cab Clearance and Marker Lights Upper Cable Assembly 0613 Winch Control Cable Assembly Rear Lights Cable Assembly iv

5 TM P Illus./ Page Figure Group 06 Electrical System (continued) 0613 Front Lights Cable Assembly Start and Charge Cable Assembly PTO Cable Assembly Door Ajar, Marker and Blackout Control Cable Assembly Windshield Wiper EMI Cable Assembly Chemical Kit Cable Assembly Starter Ground Cable Assembly V Reverse Polarity Relay Cable Assembly V Alternator Cable Assembly V Power Distribution Panel Cable Assembly V Power Distribution Panel Cable Assembly Power Distribution Panel Ground Cable Assembly Starter Power Cable Assembly Battery Ground Cable Assembly V Alternator Cable Assembly V Reverse Polarity Relay Cable Assembly Clearance Light Cable Assembly Starter to Chassis Ground Cable and Clamps CTIS Cable Assembly Auxillary Panel Cable Assembly Group 07 Transmission 0705 WTEC II Transmission Electronic Control Unit WTEC II Vehicle Interface Module WTEC III Transmission Electronic Control Unit WTEC III Transmission Gear Selector Torque Converter Module Transmission with Container Transmission Mounts Transmission Dipstick Front Support Assembly P1 Planetary Carrier P2 Planetary Carrier P3 Planetary Carrier Converter Housing Module Mainshaft Module Adapter Housing Module C3, C4 and C5 Clutch Rotating Clutch Module Control Valve Module Transmission Oil Filler Tube, Cooler, Hoses, Bracket and Clamps Transmission Oil Filters Scavenge Pump, Hose and Fittings Transmission Oil Sampling Valve Group 08 Transfer and Final Drive Assembly 0801 Transfer Case Module Group 09 Propeller Shafts/Universal Joints Assembly 0900 M1078, M1079,M1081 Driveshafts Group 10 Front Axles 1000 Front Axle and Wheel End Assembly v

6 TM P Illus./ Page Figure Group 10 Front axles (continued) 1002 Front Axle Differential Carrier Group 11 Rear Axles 1100 Rear Axle and Wheel End Assembly Rear Axle Differential Carrier Group 12 Brakes 1202 Brake Assembly Air Brake Chambers and Cage Bolts Front Gladhands, Hoses and Fittings Rear Gladhands, Hoses and Fittings Front Brake Valve, Hoses and Fittings Air Tanks, Clamps, Hoses and Fittings CTIS Quick Relief Valves, Hoses and Fittings Load Sensing Valve, Hoses and Fittings Air Brake Protection Valve, Hoses and Fittings Anti-Compound Relay Valve, Hoses, and Fittings Air Relay Valve, Hoses and Fittings Two Way Check Valve, Hoses and Fittings Inversion Valve, Hoses and Fittings Rear Brake Hoses and Fittings Rear Brake Hose Clamps and Brackets Pneumatic Hose Routing Loop Clamps and Brackets Brake Pedal, Foot Control Valve, Hoses and Fittings Park and Trailer Air Supply Valves, Hoses and Fittings Low Pressure Transmitter, Two Way Check Valves, Hoses and Fittings Park Control, Emergency/Service Two Way Check Valve, Hoses and Fittings Manifold Valve, Hoses and Fittings Air Compressor Group 13 Wheels 1311 Wheel Assembly and CTIS Valve Tire Group 14 Steering 1401 Tie Rod and Tie Rod Ends Steering Wheel and Column Steering Gear, Pitman Arm and Drag Link Power Steering Pump Power Steering Hoses Power Steering Reservoir Group 15 Frame M1078, M1079, M1080 Frame Assembly M1081 Frame Assembly Rear Light Carrier Air Drop Extraction Assembly Air Drop Extraction Assembly Brackets Airdrop Parachute Suspension Assembly Front Bumper and Gravel Deflector Front Lift Beam Pintle Hook Spare Tire Retainer vi

7 TM P Page Illus./ Figure Group 16 Springs and Shocks 1601 Front Leaf Spring Suspension Front Resilient Mount and Angle Brackets Rear Leaf Springs Rear Resilient Mount and Mechanical Stop Front Shocks Rear Shocks Rear Stabilizer Bar Group 18 Body and Cab 1801 Standard Cab Assembly, Doors, and Hinges Air Drop Cab Assembly, Doors, and Hinges Dashboard Roof Hatch and Front Grille Engine Splash Guards Cab Door Fittings Door Locks and Handles Air Drop Davit Boom Assembly Front Cab Supports Rear Cab Support, Leveling Valve, Latch, Air Spring, Hoses and Fittings Cab Fenders Van Splash Shields Standard Cab Windows Air Drop Cab Windows Cab Door Windows and Fittings Rear Fenders and Splash Guards Cab Steps Cab Drain Plugs Cab Floor Coverings and Door Seals Standard Cab Liners, Boarding Handles and Sun Visors Air Drop Panels, Visors and Boarding Handles Center Seat and Seat Belt Passenger Seat and Seat Belt Driver Seat and Seat Belt Tool Box Cab Storage Box Assembly M1078 Cargo Bed, Dropside Assembly and Ladder M1081 Cargo Bed, Dropside Assembly and Ladder Cargo Bed Dropside Assembly M1078 and M1081 Cargo Bed Sub-Assembly Load Spreader Rear Lift Beam Bow Stowage Door, Hinge and Latch Van Body Upper Subframe Van Lifting Arm Assembly Van Pod Assembly Van Spreader Bar Van Body Panels, Fittings and Hardware vii

8 TM P Page Illus./ Figure Group 18 Body and Cab (continued) 1812 Van Steps Van Door Catch Striker and Fittings Van Right Hand Door Van Right Hand Door, Window and Blackout Shield Van Left Hand Door Van Door Check Left and Right Van Large Window Assembly Van Small Window, Screen and Cover Van Tapping Plates Van Electrical Boxes, Switches and Fittings Van Electrical Conduits Van Blackout Switches Van Blackout and Emergency Lights Van Fluorescent Lights Van Clearance Lights Van Relay Box Assembly Van Breaker Box Assembly Van Exhaust Fan Assembly Van 110/208V Power Panel Van 12/24V Power Panel Van Data and Identification Plates Group 20 Hoist, Winch, Power Control Unit and Power Take-Off K Self Recovery Winch Assembly K Self Recovery Winch Cable, Guides, Rollers and Brackets Power Take-Off Assembly Group 22 Body Chassis and Accessories 2202 Rear Reflectors Windshield Washer Reservoir Windshield Wiper and Motor Cab Mirrors Front Reflectors Personnel Heater Assembly Data and Identification Plates Group 24 Body Hydraulic Lift Components 2401 Air/Hydraulic Power Unit, Hoses and Fittings Back-up Hydraulic Pump, Hoses and Fittings Hydraulic Manifold Hoses and Fittings Hydraulic Manifold Assembly Hydraulic Manifold Assembly Spare Tire Retainer Lift Cylinder, Hoses and Fittings Cab Hydraulic Cylinder, Hoses and Fittings Hydraulic Rotary Pump, Winch Control Valve, Hoses and Fittings Suspension Cylinder, Hoses and Fittings Hydraulic Reservoir and Filter Group 33 Special Purpose Kits 3301 Engine Container viii

9 TM P Page Illus./ Figure Group 33 Special Purpose Kits (continued) 3301 Transmission Container Van Heater Kit EMI Shielded Pump Assembly Van Air Conditioner Kit Options Panel Kit M1078 and M1081 Troopseat Kit M1078 AND M1081 Soft Top Cover Kit (Steel) Amber Warning Light Flywheel Housing Vent Kit A Polarity Protection Device, Terminal, Block, Cables and Brackets A Alternator and Regulator Light Material Handling Crane Kit Light Material Handling Crane Winch Assembly Light Material Handling Crane Hoist Assembly Light Material Handling Crane Mast and Swing Assembly Light Material Handling Crane Handle Assembly Light Material Handling Crane Boom Assembly Light Material Handling Crane Cable Extension Light Material Handling Crane Plug and Circuit Breaker Shelter Tiedown Kit S280 Shelter Ladder Adapter Kit Crane Adapter Kit Group 34 Armaments, Sighting and Fire Control Material 3402 Machine Gun Mounting Kit Small Arms Mount Air Dryer, Hoses and Fittings Wet Air Tank, Clamps, Hoses and Fittings Group 47 Measuring Gages 4705 Air Filter Warning Indicator Group 94 Repair Kits Repair Kits... Kits-1 Group 95 Hardware Supplies and Bulk Material, Common Bulk Items... Bulk-1 Section III.SPECIAL TOOLS LIST Group 26 Tools and Test Equipment 2604 Unit Maintenance Special Tools Direct Support Maintenance Special Tools General Support Maintenance Special Tools Section IV. CROSS REFERENCE INDEX Part Number Index... I-1 National Stock Number Index... I-122 Figure and Item Number Index... I-172 ix/(x Blank)

10 TM P UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST SECTION I. INTRODUCTION 1.Scope. This RPSTL lists and authorizes spares and repair parts; special tools; special test, measurement, diagnostic equipment (TMDE); and other special support equipment required for performance of unit, direct support, and general support maintenance of the M1078 Series LMTV. It authorizes the requisitioning, issue, and disposition of spares, repair parts and special tools as indicated by the source, maintenance and recoverability (SMR) codes. 2.General. In addition to Section I, 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 lists also includes parts which must be removed for replacement of 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 are listed separately in their own functional group within Section II. Repair parts for repairable special tools are also listed in this section. b.section III. Special Tools List. A list of special tools, special TDME, and other special support equipment authorized by this RPSTL (as indicated by Basis of Issue (BOI) information in DESCRIPTION AND USABLE ON CODE column) for the performance of maintenance. c.section IV. Cross-Reference Index. 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 numbers in alphanumeric sequence and cross-references NSN, CAGEC and part numbers. 1

11 Section II. REPAIR PARTS LIST

12 SECTION II TM P FIGURE 1. DRESSED ENGINE WITH CONTAINER

13 SECTION II TM P (1) (2) (3) (4) (5) (6) ITEM SMR PART DESCRIPTION AND NO CODE FSCM NUMBER USABLE ON CODE (UOC) QTY GROUP 0100: ENGINE ASSEMBLY FIG.1 DRESSED ENGINE WITH CONTAINER 1 PAFHH 0FW ENGINE AND CONTAINER... 1 END OF FIGURE 1-1

14 SECTION II TM P FIGURE 2. ENGINE MOUNTS

15 SECTION II TM P (1) (2) (3) (4) (5) (6) ITEM SMR PART DESCRIPTION AND NO CODE FSCM NUMBER USABLE ON CODE (UOC) QTY GROUP 0100: ENGINE ASSEMBLY FIG.2 ENGINE MOUNTS 1 PAFZZ BRACKET,ENGINE MOUN PAFZZ SCREW,CAP,HEXAGON H M14 X 2 X PAFZZ 0FW BRACKET,ANGLE PAFZZ SCREW,CAP,HEXAGON H M20 X 2.5 X PAFZZ BRACKET,ENGINE MOUN PAFZZ MOUNT,RESILIENT PAFZZ SPACER,SLEEVE PAFZZ WASHER,FLAT 1/ PAFZZ NUT,SELF-LOCKING,EX M12 X PAFZZ BOLT,MACHINE M8 X 1.25 X PAFZZ BOLT,MACHINE M12 X 1.5 X PAFZZ NUT,SELF-LOCKING,EX M8 X PAFZZ SPACER,PLATE PAFZZ BOLT,MACHINE M12 X 1.5 X PAFZZ BOLT,MACHINE M12 X 1.5 X PAFZZ BRACKET,ENGINE MOUN... 1 END OF FIGURE 2-1

16 SECTION II TM P FIGURE 3. ENGINE BRACKETS

17 SECTION II TM P (1) (2) (3) (4) (5) (6) ITEM SMR PART DESCRIPTION AND NO CODE FSCM NUMBER USABLE ON CODE (UOC) QTY GROUP 0100: ENGINE ASSEMBLY FIG.3 ENGINE BRACKETS 1 PAOZZ T4136 BOLT,MACHINE M10 X 1.5 X PAOZZ T4121 WASHER,FLAT M PAOZZ R9234 PLATE,MOUNTING PAOZZ BRACKET,ANGLE PAOZZ SCREW,CAP,HEXAGON H M14 X 2 X PAOZZ BRACKET,ENGINE MOUN PAOZZ R9233 BRACKET,ANGLE PAOZZ BRACKET,VEHICULAR C PAOZZ SCREW,CAP,HEXAGON H M14 X 2 X PAOZZ 0FW BRACKET,MOUNTING PAOZZ SCREW,CAP,HEXAGON H M6 X 1 X PAOZZ WASHER,FLAT M PAOZZ MS CLAMP,LOOP 1 IN PAOZZ DIN 934 ST M6 NUT,PLAIN,HEXAGON M6 X PAOZZ DIN933-M10X20-8. BOLT,MACHINE M10 X 1.5 X A4C 16 PAOZZ BRACKET,ENGINE MOUN... 1 END OF FIGURE 3-1

18 SECTION II TM P FIGURE 4. CYLINDER HEAD WITH VALVES AND GASKET

19 SECTION II TM P (1) (2) (3) (4) (5) (6) ITEM SMR PART DESCRIPTION AND NO CODE FSCM NUMBER USABLE ON CODE (UOC) QTY GROUP 0101: CRANKCASE, BLOCK, CYLINDER HEAD FIG.4 CYLINDER HEAD WITH VALVES AND GASKET 1 PAFZZ T3282 SPACER,RING PAFZZ T0657 SCREW,CAP,HEXAGON H M20 X 2.5 X PAFZZ T5030 SCREW,CAP,HEXAGON H M10 X 1.5 X PAFZZ J9671 PACKING,PREFORMED PART OF KIT P/N 3 9X PAFZZ S8003 PLUG,MACHINE THREAD PAFZZ M6471 PLUG,EXPANSION AHHHH CYLINDER HEAD,DIESE PAHHH CYLINDER HEAD,DIESE (WITH GUIDES, 1 INSERTS AND SLEEVES)... 9 PAFZZ P6930 GASKET PART OF KIT P/N 9X END OF FIGURE 4-1

20 SECTION II TM P FIGURE 5. CYLINDER BLOCK