TM P CARRIER, CARGO, TRACKED, 6-TON M548A1 ( ) CARRIER, CARGO, TRACKED, 6-TON M548A3 ( )

Transcription

1 UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST (INCLUDING DEPOT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST) FOR CARRIER, CARGO, TRACKED, 6-TON M548A1 ( ) CARRIER, CARGO, TRACKED, 6-TON M548A3 ( ) This publication supersedes, dated 15 August DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENT OF THE ARMY i March 2003

2 HEADQUARTERS TECHNICAL MANUAL DEPARTMENT OF THE ARMY NO P Washington D.C., 30 March 2003 UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST (INCLUDING DEPOT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST) FOR CARRIER, CARGO, TRACKED, 6-TON M548A1 ( ) CARRIER, CARGO, TRACKED, 6-TON M548A3 ( ) CURRENT AS OF JUNE 2002 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. Submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms), 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, DA Form 2028 direct to: AMSTA-LC-CI/TECH PUBS, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL The address is TACOM-TECH-PUBS@ria.army.mil. The fax number is DSN or Commercial (309) DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. This publication supersedes, dated 15 August i

3 TABLE OF CONTENTS PAGE ILLUS FIGURE SECTION I INTRODUCTION... 1 SECTION II REPAIR PARTS LIST Group 01 ENGINE 0100 Engine and Shipping Container Engine Front Mounting Engine Assembly Attaching Parts Power Plant Rear Mounting Air Box Drain and Related Parts Cylinder Head Assembly and Lifting Brackets Drive Pulley and Hardware Drive Plate, Flywheel and Housing Rocker Arm Covers Rocker Arm Covers Deleted Oil Pan and Oil Gage Assembly Oil Pan and Oil Gage Assembly Oil Filter Assembly and Adaptor Oil Filter Assembly, Adaptor, and Related Parts Engine Oil Gage Rod Engine Oil Filler Neck Engine Oil Filter Mounting and Hoses Engine Oil Hoses and Fittings Engine Lubrication System Exhaust Manifold Group 03 FUEL SYSTEM 0302 Fuel Pump Assembly and Drive Fuel Lines and Fittings Fuel Lines and Fittings Air Cleaner Filter Air Cleaner Filter Indicator, Hoses and Fittings Air Cleaner Installation and Ducts Air Cleaner Assembly Air Cleaner Hoses and Fittings Turbocharger and Related Parts Deleted Fuel Lines and Fittings Fuel Lines and Fittings Primary Fuel Filter Air Separator Tubes and Fittings Air Separator and Tube Fittings Fuel Filler Neck and Tank Fittings Secondary Fuel Filter Hoses and Fittings Engine Fuel Filter Lines Fuel Filter and Strainer Assemblies Air Box Heater Related Parts Air Box Heater Related Parts Air Box Heater Assembly Air Pump, Ignition Coil, and Related Parts Throttle and Fuel Controls Throttle and Fuel Cutoff Controls Accelerator Pedal and Linkage ii

4 TABLE OF CONTENTS (cont) PAGE ILLUS FIGURE 0312 Accelerator Pedal Fuel Control Linkage Fuel Control Linkage Group 04 EXHAUST SYSTEM 0401 Muffler and Exhaust Pipes Exhaust System Installation Group 05 COOLING SYSTEM 0501 Radiator and Mounting Radiator Thermostat, Housing, Lines, and Fittings Radiator Hoses, Lines and Fittings Radiator Hoses, Lines and Fittings Cooler Pump Assembly, Idler Pulley and Belt Set Fan and Fan Drive Fan and Fan Drive Installation Fan Belt Idler Fan Belt Idler Vaneaxial Fan Assembly Fan Ventilating Right Angle Drive, Cooling Fan Group 06 ELECTRICAL SYSTEM 0601 Generator Mounting and Belt Set 100 AMP Generator Mounting and Belt Set 200 AMP Generator and Mounting Hardware AMP Generator Regulator and Mounting Bracket Regulator and Mounting Hardware Starter and Mounting Hardware Starter Lead Starter Motor Relay and Leads Instrument Panel and Attaching Parts Instrument Panel and Attaching Parts Instrument Panel Indicators Instrument Panel Switches Instrument Panel Lights and Switches Instrument Panel Lights and Switches Circuit Breakers Circuit Breakers Master Switch and Electrical Leads Beam Selector, Stoplight and Hand Brake Switches Blackout Headlight Assembly Service and Infrared Headlight Assembly Stoplight and Taillight Assembly, Left Stoplight and Taillight Assembly, Right Dome Light Blackout Marker Light Engine Sending Units and Warning Switches Engine Sending Units and Warning Switches Horn Assembly and Ground Lead iii

5 TABLE OF CONTENTS (cont) PAGE ILLUS FIGURE 0612 Batteries and Mounting Parts Batteries and Mounting Parts Electrical Leads, Battery Battery Leads Instrument Panel and Fuel Pump Wiring Harness Attaching Parts Wiring Harness Attaching Hardware Main Wiring Harness Attaching Parts Wiring Harness Attaching Parts Main Wiring Harness Main Wiring Harness Instrument Panel Wiring Harness Instrument Panel Wiring Harness Generator to Regulator Wiring Harness Generator Wiring Harness, Branched Wiring Harness, Branched Wiring Harness, Attaching Hardware Transmission Controller Wiring Harness Bilge Pump Lead, Electrical Personnel Heater Wiring Harness and Attaching Hardware Radio and Heater Control Box Wiring Harness Heater Control Box Wiring Harness Power Plant Wiring Harness Attaching Hardware Power Plant Wiring Harness Transmission Wiring Harness Attaching Hardware Regulator to Hull Wiring Harness Engine Ground Lead Trailer Light Wiring Harness Left Taillight Wiring Harness Fuel Pump Wiring Harness Fuel Pump Wiring Harness Differential Oil Temperature Lead Group 07 TRANSMISSION 0700 Transmission with Shipping Container Transmission Assembly and Associated Parts Transmission Filler Neck and Level Gage Transmission Attaching Hardware Power Train Mounts Installation Shift Tower Installation Tow Start Installation Right Hand Cover and Center Housing Output Driven Gear and Steer Shaft Drive Gear Left Hand Cover Top Cover Input Housing Center Housing and Hydrostatic Pump and Motor Deleted Right Hand End Cover and Brake Apply Cam Shaft Transmission Range Selector and Linkage Transmission Range Selector and Switch Transmission Oil Filler Neck Oil Pan and Output Shaft iv

6 TABLE OF CONTENTS (cont) PAGE ILLUS FIGURE 0714 Deleted G2 Backup, Priority Valve and Oil Transfer Plate Filter Cover Assembly and Filter Element Transmission Oil Valve and Attaching Parts Transmission Oil Cooler Hoses and Fittings Transmission Oil Cooler Lines and Fittings Oil Pumps and Filter Group 08 TRANSFER AND FINAL DRIVE ASSEMBLIES 0801 Transfer Gearcase and Mounting Parts Transfer Gearcase Final Drive Assembly Final Drive Assembly Engine Disconnect Lever and Support Engine/Transfer Case Quick Disconnect Transfer Gearcase Oil Filler and Drain Group 09 PROPELLER, PROPELLER SHAFT, UNIVERSAL JOINTS COUPLER AND CLAMP ASSEMBLY 0900 Propeller Shafts and Component Parts, 7C and 6C U-Joints Propeller Shafts Group 11 REAR AXLE 1124 Final Drive and Filler Differential and Mounting Parts Differential Oil Filter Lines and Fittings Differential Oil Filter Assembly Differential Steering Control Differential Steering Control Right Angle Gear Box, Differential Group 12 BRAKES 1206 Linkage Control, Brakes Lever, Brake Control Group 13 WHEELS AND TRACKS 1301 Torsion Bar and Anchors Roadwheel Support Arm Idler Arm Assembly Track Tension Adjuster Assembly Track Tension Adjuster Idler Wheels Track Drive Sprockets Track Shoe Assembly Roadwheel and Mounting Parts Group 14 STEERING 1401 Steering Components Steering Connecting Links Differential Steering Levers and Linkage Differential Steering and Linkage Pivot Steer, Brake Lines and Fittings v

7 TABLE OF CONTENTS (cont) PAGE ILLUS FIGURE 1403 Pivot Steer, Brake Assembly Steering Brakes, Master Brake Cylinder Brake, Single Disk, Pivot Group 15 FRAME, TOWING ATTACHMENTS, AND DRAWBARS 1503 Towing Pintle Vehicle Towing and Tie Down Eyes Group 16 SPRINGS AND SHOCK ABSORBERS 1604 Shock Absorber Assembly Group 18 BODY, CAB, HOOD AND HULL 1801 Lifting Eyes Brake System Mounting Provision Air Cleaner Mounting Provision Steering System Mounting Provision Screw Thread Inserts Track Covers Compartment Doors Compartment Windows Heater Duct and Exhaust Hold Covers Engine Access Panel and Beams Support Beams and Engine Grilles Cab Cover Windshield Assembly Floor Plates and Covers Floor Plates Personnel Seats Personnel Seats Driver's Seat and Mount Stowage Pads and Straps Cargo Compartment Door Tailgate and Mounting Parts Group 20 HOIST, WINCH, CAPSTAN, WINDLASS, POWER CONTROL UNIT AND POWER TAKE OFF 2001 Winch Installation Winch Drum and Clutch Winch Gears Gearcase and Shafts Winch Transfer Gearcase Power Take-Off and Mounting Hardware Group 22 BODY CHASSIS OR HULL AND ACCESSORY ITEMS Canvas Cover and Bows Canvas Cover and Straps Windshield Wiper and Motor Forward Bilge Pump and Tubes Vehicle Compartment Heater and Covers Vehicle Compartment Heater Components vi

8 TABLE OF CONTENTS (cont) PAGE ILLUS FIGURE 2207 Vehicle Compartment Heater Ducts and Hoses Vehicle Compartment Heater Fuel Lines Attaching Parts Fuel Filter/Separator Data Plates and Markers Data Plates Stowage Markers Decals Decals Group 26 TOOLS AND TEST EQUIPMENT (REPAIR PARTS) 2604 Sling, Beam Type Rheostat, Portable Wiring Harness, Accessory Kit Group 33 SPECIAL PURPOSE KITS 3303 Personnel Cab Heater Kit, Lines and Fittings Personnel Cab Heater Kit, Fan Assembly Heater Kit Wiring Harness Personnel Cab Heater, Ducts and Fittings Personnel Cab Heater, Insulated Cover Personnel Heater Kit Cab Cover Cab Insulation Kit Cab Insulation Kit Cargo Area Heater Lines and Fittings (Primary) Cargo Area Heater Assembly Heater Control Box Assembly Cargo Area Heater Wiring Harness Cargo Area Heater Wiring Harness Cargo Area Cover (Secondary) Cargo Area Covers (Secondary) Cargo Area Cover Cargo Area Cover Engine Coolant Heater Hoses and Fittings Engine Coolant Heater Assembly Pump, Heater and Attaching Hardware Engine Coolant Heater Hoses and Fittings Hoses and Fittings Engine Coolant Heater Wiring Harness Control Box and Attaching Hardware Hoist and Beam Material Handling Kit Material Handling Kit, Cushions, Racks and Straps Air Compressor and Drive Belts Air Tank, Hoses and Fittings Air Brake Treadle Valve, Hoses and Fittings Air Brake Pedal Air Brake Hose Front Directional Signal Light Kit Rear Directional Signal Light Kit Front Turn Signal Light Assembly Front Turn Signal Wiring Harness Right Stop and Taillight Assembly Right Rear Stop Light vii

9 TABLE OF CONTENTS (cont) PAGE ILLUS FIGURE 3307 Right Turn Signal Wiring Harness Trailer Light Wiring Harness Right Stop Light Extension Lead Turn Signal Control Assembly ODS Straps and Covers Group 47 GAGES, WEIGHING AND MEASURING DEVICES 4701 Speedometer Shaft Assembly and Mounting Speedometer Drive Shaft Tachometer Shaft Assembly and Mounting Tachometer Drive Shaft Group 76 FIRE FIGHTING EQUIPMENT COMPONENTS 7639 Fire Extinguisher Group 91 CHEMICAL, BIOLOGICAL, AND RADIOLOGICAL (CBR) EQUIPMENT 9111 NBC Installation NBC Installation NBC Installation Air Purifier/Precleaner Assembly Group 94 REPAIR KITS 9401 Repair Kits... KITS Group 95 BULK MATERIALS 9501 Bulk Material...Bulk-1 Bulk SECTION III SPECIAL TOOLS LIST Group 26 TOOLS AND TEST EQUIPMENT 2604 Unit Maintenance Special Tools Unit Maintenance Special Tools Direct Support Special Tools General Support Special Tools Engine Special Tools Engine Special Tools Transmission Special Tools SECTION IV CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX...I-1 PART NUMBER INDEX...I-37 viii

10 SECTION I UNIT, DIRECT SUPPORT ANDGENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST (INCLUDING DEPOT 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, and Diagnostic Equipment (TMDE); and other special support equipment required for performance of Unit Maintenance, Direct Support and General Support Maintenance of the M548A1 and M548A3 vehicles. This RPSTL 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 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 in item name sequence. Repair kits are listed separately in their own functional group within Section II. Repair parts for repairable special tools are also listed in this section. Items listed are shown on the associated illustration(s)/figure(s). b. Section III. Special Tools List. A list of special tools, special TMDE and other special support equipment authorized by this RPSTL (as indicated by Basis of Issue (BOI) information in DESCRIPTION AND USABLE ON CODE columns) 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 listing, 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-reference NSN, CAGE and part number. 1

11 SECTION II Figure 1. Engine and Shipping Container

12 SECTION II (1) (2) (3) (4) (5) (6) (7) ITEM SMR NSN PART DESCRIPTION AND NO CAGE NUMBER USABLE ON CODE (UOC) QTY GROUP 01 ENGINE GROUP 0100 ENGINE ASSEMBLY FIG. 1 ENGINE AND SHIPPING CONTAINER 1 PAFHD ENGINE WITH CONTAIN... 1 UOC:V96, 1 PAFHD ENGINE,W CONTAINER XAFHD ENGINE,DIESEL REFER TO 1 TM P FOR COMPONENTS... 2 XAFHD ENGINE,DIESEL DETROIT DIESEL 1 DIVISION GMC SERIES 6V53 REFER TOTM P FOR COMPONNET PARTS... UOC:V96, 3 PAHHH CONTAINER SHIPPING REFER TO 1 TM P FOR COMPONENTS... 3 PAFHH SHIPPING AND STORAG REFER TO 1 TM P FOR COMPONENT PARTS UOC:V96, END OF FIGURE 1-1

13 SECTION II Figure 2. Engine Front Mounting (M548A1)

14 SECTION II (1) (2) (3) (4) (5) (6) (7) ITEM SMR NSN PART DESCRIPTION AND NO CAGE NUMBER USABLE ON CODE (UOC) QTY GROUP 0100 ENGINE ASSEMBLY CONTINUED FIG. 2 ENGINE FRONT MOUNTING (M548A1) 1 PAOOO SUPPORT,ENGINE,FRON... 1 UOC:V96, 2 PAOZZ MS SCREW,CAP,HEXAGON H... 2 UOC:V96, 3 PAOZZ WASHER,KEY... 2 UOC:V96, 4 PAOZZ MS SCREW,CAP,HEXAGON H... 2 UOC:V96, 5 PAOZZ MS WASHER,FLAT... 2 UOC:V96, END OF FIGURE 2-1

15 SECTION II Figure 3. Engine Assembly Attaching Parts (M548A3)

16 SECTION II (1) (2) (3) (4) (5) (6) (7) ITEM SMR NSN PART DESCRIPTION AND NO CAGE NUMBER USABLE ON CODE (UOC) QTY GROUP 0100 ENGINE ASSEMBLY CONTINUED FIG. 3 ENGINE ASSEMBLY ATTACHING PARTS (M548A3) 1 PAOZZ MS21044N8 NUT,SELF-LOCKING,HE PAOZZ MS WASHER,FLAT PAOZZ MS FITTING,LUBRICATION PAOZZ LEVER,REMOTE CONTRO PAOZZ B1821BH050F450N SCREW,CAP,HEXAGON H... 1 END OF FIGURE 3-1

17 SECTION II Figure 4. Power Plant Rear Mounting (M548A3)

18 SECTION II (1) (2) (3) (4) (5) (6) (7) ITEM SMR NSN PART DESCRIPTION AND NO CAGE NUMBER USABLE ON CODE (UOC) QTY GROUP 0100 ENGINE ASSEMBLY CONTINUED FIG. 4 POWER PLANT REAR MOUNTING (M548A3) 1 PAOZZ B1821BH063C550N SCREW,CAP,HEXAGON H PAOZZ MS WASHER,FLAT PAOZZ WASHER,FLAT PAOZZ MOUNT,RESILIENT PAOZZ BRACKET,MOUNTING PAOZZ MS R COUPLING,CLAMP,GROO PAOZZ WASHER,CONVEX PAOZZ MS NUT,SELF-LOCKING,HE... 2 END OF FIGURE 4-1

19 SECTION II Figure 5. Air Box Drain and Related Parts

20 SECTION II (1) (2) (3) (4) (5) (6) (7) ITEM SMR NSN PART DESCRIPTION AND NO CAGE NUMBER USABLE ON CODE (UOC) QTY GROUP 0101 CRANKCASE, BLOCK, CYLINDER HEAD FIG. 5 AIR BOX DRAIN AND RELATED PARTS 1 PAOZZ TUBE ASSEMBLY,METAL... 2 UOC:V96, 2 PAOZZ ELBOW,PIPE TO TUBE... 2 UOC:V96, 2 PAOZZ ELBOW,PIPE TO TUBE CYL BLK TO 1 AIRBOX DRAIN TUBE RBK... 3 PAOZZ VALVE,CHECK PAOZZ X4X4 ELBOW,PIPE TO TUBE PAOZZ MS ELBOW,PIPE CYL BLK LBK PAOZZ TUBE ASSEMBLY,METAL AIRBOX DRAIN LB 1 UOC:AP4 7 PAOZZ ADAPTER,STRAIGHT,PI MOOZZ HOSE,NONMETALLIC MAKE FROM HOSE, 1 P/N , AIRBOX DRAIN LB... UOC:AP4 9 PAOZZ FITTING,CYLINDER HE... 1 UOC:AP4 10 PAOZZ ELBOW,HOSE OIL PAN,LBK PAOZZ CLIP,SPRING TENSION PAOZZ TUBE ASSEMBLY,METAL RIGHT BANK PAOZZ ELBOW,PIPE TO TUBE CHECK VALVE 1 INLET,RBK PAOZZ MS WASHER,LOCK PAOZZ SPACER,TRUCK ADVERS PAOZZ ADAPTER OIL GAGE RIGHT BANK PAOZZ WASHER,FLAT RIGHT BANK PAOZZ B1821BH031C075N BOLT,MACHINE 5/16-18UNC-2AX3/R GR PAOZZ TUBE ASSEMBLY,METAL CHECK VALVE 1 OUTLET,RBK PAOZZ CLAMP,LOOP PAOZZ B1821BH031C100N BOLT,MACHINE 5/16-18UNC-2AX1 GR END OF FIGURE 5-1