TM &P-1 TECHNICAL MANUAL

Transcription

1 TM &P-1 TECHNICAL MANUAL OPERATOR S, ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL [INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST] FOR TRUCK, FIREFIGHTING, DRY CHEMICAL AFFF NSN VOLUME I This copy is a reprint which includes current pages from Change 1. HEADQUARTERS, DEPARTMENT OF THE ARMY 14 APRIL 1986

2 TABLE OF CONTENTS SECTION PAGE(S) PARTS CATALOG - S-SERIES MODEL INTERNATIONAL HARVESTER GROUP INDEX A. GENERAL INFORMATION B. FRAME Bumper, Front Crossmember, Intermediate Sidemember, Chart C. FRONT AXLE Axle, Front, Driving, Dana FA lb Spring, Front, Mounting, Dana FA lb Flanges Light, Warning, Installation D. ENGINE Light, Warning, Installation E. CHASSIS SPRINGS Shock Absorber, Installation F. BRAKES Compressor, Piping, Air and Governor Mounting Compressor, Mounting and Piping, Air Strainer, Air Compressor Compressor, Air Midland Ross EL Governor, Air Compressor Valve, Parking Brake Control Valve, Brake Pedal and Control Compressor, Mounting and Hosing Air Midland Ross EL Shield Heat Valve, Double Check Switch, Stoplight Schematic System Diagram Bracket, Manifold Block, Button Plug, Chart Chamber, Air Brake MGM 30 in. - Emergency Valve, Check Chart, Connections, Elbows and Fittings Tank, Mounting and Hosing, Air Hoses, Tubes, Clamps, Chart Adjuster, Auto-Slack Repair Kits - Rear Axle Chamber, Air Brake, MGM 30 in. - Service Valve, Safety Valve, Quick Release Dryer, Mounting and Hosing, Air-Breakmaster Model i

3 TABLE OF CONTENTS SECTION PAGE(S) F. BRAKES - CONTINUED Dryer, Air-Breakmaster Model Brake Mounting, Rear Brake, Rear Gauge, Switch Valve Chart G. STEERING GEAR Chart, Hoses and Fittings Column, Steering and Wheel - Standard Gear, Steering and Drag Link Installation Pump, Power Steering Installation Pump, Power Steering 2050 psi - Eaton Link, Drag Gear, Steering - Ross HFB H. PROPELLER SHAFTS J. EXHAUST SYSTEM Muffler, Tail Pipe, Exhaust and Mounting K. ELECTRICAL SYSTEM Terminals, Solderless - Standard Terminals, Solderless and Butt Splices - Standard Connector Bodies and Terminals - Standard Clips, Extensions and Straps - Standard Switches - Standard Wiring Harness, Battery Cables and Miscellaneous Clamps, Extension Clips - Standard Lamps, Bulbs, Indicators - Standard Horns, Buzzers, Warning Harness and Cables - Standard Light, Instrument Panel, Product Graphic Panel, Instrument Cluster with Speedometer Tachometer, Gauges and Bezels Flasher, Fuses and Circuit Breakers Harness, Turn Signal Light and Horn Hi-Note Harness, Automatic Transmission Wiring, Oil Temperature Gauge, Switches, Back-Up Light, Neutral Safety Harness, Stop, Tail, Turn and Back-Up Light Light, Turn Signal and Parking Light, Head with Bezel Cable and Mounting, Tachometer Motor, Starting 12V Delco Harness, Engine Wiring for D9.OL Engine with 12V Start ii

4 TABLE OF CONTENTS SECTION PAGE(S) K. ELECTRICAL SYSTEM - CONTINUED Light, Stop, Tail, Turn Light, License Plate Battery Cable and Mounting with Frame Mounted Batteries Light, Clearance, Roof Mounting Light, Dome Switch, Turn Signal Pulley, Belt, Alternator and Mounting for D9.OL Engine Horn, Mounting, Dual Air Harness, Headlights, Turn Signals, Horns L. FRONT SHEET METAL Hood and Grille Guard, Splash Step Fender Extension and Hood Bumper Installation Deflector, Stone Fender, Rubber Extension Cable, Hood M. SPEEDOMETER Product Graphic and Miscellaneous Graphics Cable, Speedometer Drive N. ENGINE Radiator, Collar and Stay Rod Mounting Crossmember, Engine Mounting Front - Standard Accelerator, Control Throttle Bracket, Engine Mounting Rear Cover, Oil Pan Insulator Tank, Deaeration Mounting Vent, Crankcase Gasket Sets, Engine Injector, Fuel Nozzle and Nozzle Holder Pump, Fuel Injection Filter, Fuel Mounting Head, Cylinder and Related Parts Piping, Fuel Injector Pump, Fuel Injection and Mounting Crankcase and Related Parts Governor, Fuel Injection Pump Pump, Water Outlet and Thermostat Cooler, Oil Filter Pump, Oil iii

5 TABLE OF CONTENTS SECTION PAGE(S) N. ENGINE - CONTINUED Manifold, Intake and Crossover Fan, Clutch Drive Mounting Hosing, Radiator and Deaeration Tank Mounting Cleaner, Air Mounting and Piping Engine Shutdown Radiator, Mounting Piping, Air Compressor and Governor Pulley, Idler Belt and Mounting O. TRANSMISSION Transfer Case - Rockwell - Standard Product Graphics, Shifting Valve, Air Shift Selector Control, Auto, Transmission Mounting Control, Transfer Case Lever Valve, Transfer Case Control Angle, Transfer Case Mounting Adapter, Transmission to Engine Hosing, Oil Filter Filter, Oil Products Graphic, Shifting Diagram Gauge, Temperature Sender Flanges Valve, Chart Gauge, Oil Level AT545 Transmission Pictorial Index Kit, Service Torque Converter and Oil Pump Forward Clutch and Turbine Shaft Fourth Clutch Third Clutch, Center Support and Second Clutch Gear Unit and Output Shaft First Clutch Transmission Case, Governor and Vacuum Modulator Control Valve Body Assembly Oil Pan, Oil Filter, Governor and Speedometer Drive Gears Supplemental Parts Information Transmission Vent Assembly and Breather Shroud Front Support MY'79 Metric Converter Fourth Clutch Housing Assembly Fourth Clutch Trim in Reverse Control Valve Body Rework iv

6 TABLE OF CONTENTS SECTION PAGE(S) O. TRANSMISSION - CONTINUED Control Valve Body and Separator Plate Reference Stator Shaft Bushing Replacement Consolidation of Control Valve Body P. REAR AXLE Crossmember, Rear Spring and Mounting Axle, Rear, IH/Dana Q. FUEL TANK Tank, Fuel, 30 Gallon Pump, Submerged Fuel Tank, Fuel, 30 Gallon with Step Chart, Clamp, Cable Strap, Union, Plug, Fittings, Grommet, Connectors, Nipple, Adapter, Tee, Elbow, Hose, Tube and Conduit R. CAB AND BODY Fittings, Clamps, Hoses, Conduit, Cable Straps, Shut-Off Valves, Button Plugs, Grommets and O-Rings Mat, Floor Handle, Grab Emblem, Model Designation Panel, Roof and Cowl Panel, Back and Underbody Panel, Underbody Panel, Side Panel, Roof, Inner Mounting, Cab, Low Door, Cab Trim, Interior and Window Installation Panel, Instrument Wiper, Electric Visor, Sun Mirror, Rear View, Beach - Standard Plate, Master Cylinder Mounting Heater Seat, Driver and Passenger Belt, Seat Duct, Heater Washer, W/S S. WHEELS Rim, Tubeless, Tires Wheels, Drum or Rotor v

7 TABLE OF CONTENTS SECTION PAGE(S) ROCKWOOD TWIN AGENT 1500/250 DRY CHEMICAL AFFF UNIT Section I - Twin Agent Unit Self Contained Dry Chemical System Self Contained AFFF System Dry Chemical/AFFF System Schematic Section II - Data Sheets for Components Supplied Section III - Discharge Devices Twin Agent Handline Remote Manual Twin Agent Turret Shaper - AFFF Dry Chemical Nozzle Hose Reel TWIN AGENT SKID SYSTEM SCHEMATICS AMP LEECE-NEVILLE ALTERNATOR DYNAMOTE INVERTER HURST JAWS OF LIFE HURST POWER UNIT SIGNAL MODEL PA300* ELECTRONIC SIREN RESCUE CRASH TOOL KIT PARTNER SAW AND ATTACHMENTS BODY SCHEMATIC BRUSH GUARD ELECTRONIC SCHEMATIC SKID UNIT AIR CHARGING SYSTEM LAMP, QUARTZ WITH TELESCOPING POLE SPOTLIGHT LAMP, QUARTZ, 500 WATT HYDRAULIC RESCUE KIT, 10 TON INDEX vi

8 LIST OF ILLUSTRATIONS TITLE IDENTIFICATION PAGES(S) ILLUSTRATION PARTS CATALOG S-SERIES MODEL, INTERNATIONAL HARVESTER GROUP INDEX FRAME Bumper, Front Crossmember, Intermediate Sidemember, Chart FRONT AXLE Axle, Front, Driving, Dana FA lbs Axle, Front, Driving, Dana FA lbs Spring, Front and Mounting Dana FA lbs Light, Warning Installation Light, Warning Installation CHASSIS SPRINGS Shock Absorber, Installation IH FA BRAKES Compressor, Piping, Air and Governor Mounting Compressor, Mounting and Piping, Air Strainer, Air Compressor Compressor, Air Midland Ross EL Governor, Air Compressor Valve, Parking Brake Control Valve, Brake Pedal and Control Compressor, Mounting and Hosing, Air Midland Ross EL Shield, Heat Valve, Double Check Switch, Stoplight Schematic - System Diagram Bracket, Manifold Block, Button Plug, Chart Chamber, Air Brake MGM 30 in. Emergency Valve, Check Chart, Connections, Elbows and Fittings vii

9 LIST OF ILLUSTRATIONS TITLE IDENTIFICATION PAGES(S) ILLUSTRATION BRAKES - CONTINUED Chart, Connections, Elbows and Fittings Tank, Mounting and Hosing, Air Hoses, Tubes, Clamps, Chart Adjuster, Auto-Slack Repair Kits - Rear Axle Chamber, Air Brake, MGM 30 in. Service Valve, Safety Valve, Quick Release Dryer, Mounting and Hosing Air-Breakmaster Model Dryer, Air-Breakmaster Brake Mounting, Rear Brake, Rear Gauge, Switch, Valve Chart STEERING GEAR Chart, Hoses and Fitting Column, Steering and Wheel Standard Gear, Steering and Drag Link Installation Pump, Power Steering Installation Pump, Power Steering 2050 psi Eaton Link, Drag Gear, Steering, Ross HFB EXHAUST SYSTEM Muffler, Tail Pipe, Exhaust and Mounting ELECTRICAL SYSTEM Terminals, Solderless - Standard Terminals, Solderless and Butt Splices - Standard Connector Bodies and Terminals - Standard Clips, Extensions and Straps - Standard Switches - Standard Wiring Harness, Battery Cables and Miscellaneous viii

10 LIST OF ILLUSTRATIONS TITLE IDENTIFICATION PAGES(S) ILLUSTRATION ELECTRICAL SYSTEM - CONTINUED Clamps, Extension Clips - Standard Light, Instrument Panel Product Graphic Panel, Instrument Cluster with Speedometer, Tachometer, Gauges and Bezels Flasher, Fuses and Circuit Breakers Harness, Turn Signal Light and Horn Hi-Note Harness, Automatic Transmission Wiring, Oil Temperature, Gauge, Switches, Back-Up Light, Neutral Safety Harness, Stop, Tail, Turn and Back-Up Light Light, Turn Signal and Parking Light, Head with Bezel Cable and Mounting, Tachometer Motor, Starting 12V Delco Harness, Engine Wiring for D9.OL Engine with 12V Start Light, Stop, Tail, Turn, Back-Up Light, License Plate at Frame Battery Cable and Mounting with Frame Mounted Batteries Light, Clearance, Roof Light, Dome Switch, Turn Signal Pulley, Belt, Alternator and Mounting Horn, Mounting Horn, Relay and Back-Up Harness, Headlights, Turn Signals, Horns FRONT SHEET METAL Hood and Grille Guard, Splash Step Fender Extension and Hood Bumper Installation ix

11 LIST OF ILLUSTRATIONS TITLE IDENTIFICATION PAGES(S) ILLUSTRATION FRONT SHEET METAL - CONTINUED Deflector, Stone Fender, Rubber Extension Cable, Hood SPEEDOMETER Product Graphic and Miscellaneous Graphics Cable, Speedometer Drive ENGINE Radiator, Collar and Stay Rod Mounting Crossmember, Engine Mounting Front - Standard Accelerator, Control Throttle Bracket, Engine Mounting Rear Cover, Oil Pan Insulator Tank, Deaeration Mounting Vent, Crankcase Injector, Fuel Nozzle and Nozzle Holder Pump, Fuel Injection Filter, Fuel Mounting Head, Cylinder and Related Parts Piping, Fuel Injector Pump, Fuel Injection Drive and Mounting Crankcase, and Related Parts Governor, Fuel Injection Pump Pump, Water Outlet and Thermostat Cooler, Oil Filter Pump, Oil Manifold, Intake and Crossover Fan, Clutch Drive Mounting Hosing, Radiator and Deaeration Tank Mounting Cleaner, Air Mounting and Piping Engine Shutdown Radiator, Mounting Piping, Air Compressor and Governor Pulley, Idler Belt and Mounting x

12 LIST OF ILLUSTRATIONS TITLE IDENTIFICATION PAGES(S) ILLUSTRATION TRANSMISSION Transfer Case - Rockwell Standard Product Graphics, Shifting Valve, Air Shift Selector Control Automatic Transmission Mounting Control, Transfer Case Lever Valve, Transfer Case Control Control, Transfer Case and Mounting Adapter, Transmission to Engine Hosing, Oil Filter Filter, Oil Products Graphics, Shifting Diagram Gauge, Temperature Sender Valve, Chart Gauge, Oil Level AT545 Transmission Pictorial Index Torque Converter and Oil Pump... Figure Forward Clutch and Turbine Shaft... Figure Fourth Clutch Figure Third Clutch, Center Support and Second Clutch... Figure Gear Unit and Output Shaft... Figure First Clutch... Figure Transmission Case, Governor and Vacuum Modulator... Figure Control Valve Body Assembly... Figure Pan, Oil Filter, Governor and Speedometer Drive Gears... Figure Model AT545 Transmission Cross Section F.O TRANSMISSION SUPPLEMENTAL PARTS INFORMATION Transmission Vent Assembly... Figure Breather Shroud... Figure Front Support... Figure MY'79 Metric Converter... Figure Fourth Clutch Housing Assembly... Figure xi

13 LIST OF ILLUSTRATIONS TITLE IDENTIFICATION PAGES(S) ILLUSTRATION TRANSMISSION SUPPLEMENTAL PARTS INFORMATION - CONTINUED Tanged vs. Tangless Pistons... Figure Fourth Clutch Trim in Reverse Figure Control Valve Body Rework Area... Figure Typical Control Valve Body Rework Figure Control Valve Body and Separator Plate Reference... Figure Stator Shaft Bushing Replacement... Figure REAR AXLE Crossmember, Rear Spring and Mounting Axle, Rear, IH/Dana FUEL TANK Tank, Fuel 30 Gallon Pump, Submerged Fuel Tank, Fuel 30 Gallon with Step Chart, Clamp, Cable Strap, Union, Plug, Fitting, Grommet, Connector Nipple, Adapter, Tee, Elbow, Hose and Conduit CAB AND BODY Fittings, Clamps, Hoses, Conduit, Cable Straps, Shut-Off Valves, Button Plugs, Grommets and O-Rings Mat, Floor Grab, Handle Emblem, Model Designation Panel, Roof and Cowl Panel, Back and Underbody Panel, Underbody Panel, Side Panel, Roof, Inner Mounting, Cab, Low Door, Cab Trim, Interior and Window Installation Panel, Instrument Wiper, Electric, American Bosh Visor, Sun xii

14 LIST OF ILLUSTRATIONS TITLE IDENTIFICATION PAGES(S) ILLUSTRATION CAB AND BODY - CONTINUED Mirror, Rear View, Beach - Standard Plate, Master Cylinder Mounting Heater, Control Heater Seat, Driver and Passenger Belt, Seat Duct, Heater Washer, W/S WHEELS Rim, Tubeless Tires Wheels, Drum or Rotor ROCKWOOD TWIN AGENT 1500/250 DRY CHEMICAL/AFFF UNIT Schematic Ball Type Check Valve Liquid Pressure Relief Valve M-Series Valve M-Series Parts List DT Valve DT Valve Parts List Nitrogen Regulator ½ Inch M-Series Ball Valve with Air Actuator Dual Agent Hand Line Foam/ Dry Powder Turret Remote Manual Twin Agent Remote Manual Turret Shaper - AFFF Dry Chemical Nozzle Hose Reel Twin Agent System Schematics AMP LEECE-NEVILLE ALTERNATOR Schematic DYNAMOTE INVERTER Schematic Wiring Diagram Unit - Schematic xiii

15 LIST OF ILLUSTRATIONS TITLE IDENTIFICATION PAGES(S) ILLUSTRATION HURST JAWS OF LIFE Rescue Tool Accessories HURST POWER UNIT 4 Cycle Unit SIGNAL MODEL PA300* ELECTRONIC SIREN Chassis Removal Figure Internal View Figure Component Location Diagram... Figure Schematic Diagram... Figure MISCELLANEOUS EQUIPMENT FIRE BODY Figure BRUSH GUARD... Figure ELECTRICAL SCHEMATICS Figure SKID UNIT AIR CHARGING SYSTEM Figure LAMP, QUARTZ WITH TELESCOPING POLE Figure SPOTLIGHT Figure LAMP, QUARTZ, 500 WATT Figure HYDRAULIC RESCUE KIT, 10 TON Figure xiv

16 GROUP INDEX INDEX DESCRIPTION INDEX 1001 FRAME 1026 MT145 GROUP INDEX MT-145 /ENGINE WARNING 1031 FRONT AXLE /LIGHT 1041 INSTALLATION CHASSIS SPRINGS 1042 PARTS CATALOG S - SERIES MODELS BRAKES 1043 STEERING GEAR 1085 PROPELLER SHAFTS 1099 EXHAUST 1114 STANDARD HORNS ELECTRICAL STANDARD WIRING 1117 COMPONENTS FRONT SHEET METAL 1170 SPEEDOMETER 1180 ENGINE 1184 TRANSMISSION 1226 REAR AXLE 1302 INTERNATIONAL TRUCKS FUEL TANKS 1308 CAB & BODY 1316 WHEELS 1352 APRIL

17 GENERAL INFORMATION A BRIEF GUIDE TO USING THIS MASTER PARTS CATALOG Page I. VEHICLE AND ITS SPECIFICATIONS A. Where to Locate Specific Information... 2 o Line Setting Ticket (LST) Loose Copy in Vehicle - Copy Sent to Selling Location - Copy Sent to Selling Location Parts Department - Copy Available through IH Printing and Distribution Service - Westmont o Service Unit Record - A record of Vehicle Identification and Specifications for all IH trucks built each year. Available on microfiche only B. What Specific information is Available on Line Set Ticket o Vehicle Model Number... 4 o Vehicle Identification Number o Component Codes or Unit/Division o Chassis Build Data...6 C. How Does This Relate to the Catalog... II. IDENTIFYING SPECIFICATIONS WITH OR WITHOUT LINE SET TICKET A. Determine the Appropriate Group With or Without Line Set Ticket o Alphabetical Parts Index Guide... 7 o Unit/Division Identification o Group Indexes Alphabetical Figure Title Index - Vendor Model Index - Unit/Division Index B. Identify Group Without Line Set Ticket o Individual Group Information o Supplier When Applicable o Supplier Model and Serial Number o Numerical Parts Index o Alphabetical Parts List PAGE

18 GENERAL INFORMATION III. General A. Identifying Parts With a Figure o Illustration and Parts List o Attaching Parts o Kits o Bulk Material o Build Date for Design Changes o Special Equipment o Vendor Part Number o Ordering by Description Page B. Support Publications o Index of Part Numbers o Vendors Cross Reference Parts List o Supersedence Parts List o Accessories for International Trucks o Fast Moving Truck Parts o Expandable Catalog Binder C. List of Abbreviations D. List of General Descriptions and Group Location NOTE: Current catalogs are generated from production bills of material. If a part or group of parts (unit or division) has been revised and/or added to production within 60 days of publication, this information will be included in the next catalog revision. If critical items or service information is omitted due to the time lapse, we often provide special reports through timely releases of Parts Information Letters (PIL) and Advanced Information to District Servicemen (AIDS). I. VEHICLE AND ITS SPECIFICATIONS A. WHERE TO LOCATE SPECIFIC INFORMATION o LINE SETTING TICKET For trucks built prior to 1973, the Line Setting Ticket (LST) must be used to determine needed information. The LST is the document required to determine which components are ordered and used to build a truck. Copies are made available in several places. PAGE

19 GENERAL INFORMATION -- Loose copy in vehicle - Every vehicle leaves the plant with a full size LST copy included in the papers in the vehicle. This is very important and the customer should be encouraged to use it for parts ordering and retain it in the vehicle. -- Copy sent to selling location - A copy is printed on the back of the Customer Service Record Card-BH-894-sent to the dealer selling the truck. -- Copy sent to Parts Department - A copy is sent to the selling locations Parts Department for their records. -- Copy Available through IH Printing and Distribution Service- Copies of LST's can be purchased through IH Printing and Distribution Service-Westmont. o SERVICE UNIT RECORD To determine the Model Number, Vehicle Identification Number and Component Codes for any IH truck manufactured in 1973 or later, the Service Unit Record should be used. This record covers every truck manufactured in each model year and is available in microfiche. You can order your own copy of this record. Availability through Westmont order Form. The example shows all information available and the layout of service unit records by chassis serial number. Example: CGA24869VIN24947CGA24869, NAME OF COF-4070A,WB 152,ENG NTC ,TRANS RTO , RA 4.10 R/S SQHD 14333, SUSP DAY 4 SPRG 14625, FA IH 12000# WIDE TRD 02139,STG M , TANK DUAL SIDE AL 15532, TIRES 11.00X SE SE SE SE PAGE