TECHNICAL MANUAL UNIT MAINTENANCE, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS

Transcription

1 TECHNICAL MANUAL UNIT MAINTENANCE, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS TRUCK TRACTOR, LINE HAUL, 50,000 GVWR, 6 X 4, M915A1 NSN This manual supersedes TM P DATED 31 JANUARY, 1984 AND TM P DATED 31 JANUARY, 1984 AND ALL CHANGES. Approved for Public Release; Distribution is Unlimited HEADQUARTERS, DEPARTMENT OF THE ARMY NOVEMBER 1990

2 TECHNICAL MANUAL HEADQUARTERS DEPARTMENT OF THE ARMY * Washington DC., 30 November 1990 UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS TRUCK TRACTOR, LINE HAUL, 50,000 GVWR, 6 X 4, M915A1 NSN Current as of 2 May, 1990 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028,(Recommended Changes to Publications and Blank Forms), or DA Form located in back of this manual direct to: U. S. Army Tank-Automotive Command, ATTN: AMSTA-MB Warren, Ml A reply will be furnished to you. Approved for public release; distribution is unlimited. SECTION I. INTRODUCTION 1 SECTION II. REPAIR PARTS LIST 1-1 GROUP 01 ENGINE 0100-ENGINE ASSEMBLY ENGINE MOUNTS ENGINE ASSEMBLY RELATED PARTS VALVES, CAMSHAFTS AND TIMING SYSTEMS ROCKER COVERS ENGINELUBRICATION SYSTEM OIL FILTER AND RELATED PARTS OIL PAN, DIPSTICK AND RELATED PARTS MANIFOLDS AIR AFTERCOOLER RELATED PARTS ACCESSORY DRIVING MECHANISMS FAN SUPPORT BRACKET AND RELATED PARTS ENGINE BRAKE ENGINE RETARDER COMPRESSOR ASSEMBLY AIR COMPRESSOR LINES AND FITTINGS *SUPERSEDES TM P DATED 31 JANUARY 1984 AND TM P DATED 31 JANUARY i

3 TABLE OF CONTENTS PAGE ILLUS FIG GROUP 03 FUEL SYSTEM 0302-FUEL PUMPS FUEL LINES AND FITTINGS FUEL PUMP MAIN HOUSING FILTER AIR CLEANER AIR CLEANER ASSEMBLY TURBOCHARGER AIR INTAKE MANIFOLD TANKS, LINES, FITTINGS, HEADERS SOLENOID VALVE FUELTANKASSEMBLY FUEL HEATER, LINES AND FITTINGS FUEL FILTERS WATER SEPARATOR FILTER ENGINE STARTING AIDS ETHER QUICK START KIT ACCELERATOR, THROTTLE OR CHOKE CONTROLS FUEL CONTROL LEVER ACCELERATOR PEDAL AND LINKAGE GROUP 04 EXHAUST SYSTEM 0401-MUFFLER AND PIPES EXHAUST SYSTEM GROUP 05 COOLING SYSTEM 0501-RADIATOR RADIATOR ASSEMBLY RADIATOR ASSEMBLY-EXPLODED VIEW SHROUDS RADIATOR SHROUDS WATER MANIFOLDS, HEADERS, THERMOSTATS AND HOUSING GASKET THERMOSTAT HOUSING, WATER MANIFOLD AND WATER FILTER RADIATOR LINES AND FITTINGS WATER PUMP WATER PUMP AND IDLER FAN ASSEMBLY FAN, FAN CLUTCH AND ACTUATOR GROUP 06 ELECTRICAL SYSTEM 0601-GENERATOR, ALTERNATOR ALTERNATOR ASSEMBLY ALTERNATOR ASSEMBLY-EXPLODED VIEW ALTERNATOR ASSEMBLY ATTACHING HARDWARE STARTING MOTOR STARTER ASSEMBLY STARTING MOTOR-EXPLODED VIEW INSTRUMENT OR ENGINE CONTROL PANEL GAGES, SWITCHES AND INSTRUMENT PP. NEL LIGHTS DIRECTIONAL CONTROL ASSEMBLY AND CONTROL PEDAL REMOTE CONTROL LEVER AND PUSH SWITCH LIGHTS HEADLIGHT AND RELATED PARTS ii

4 TABLE OF CONTENTS PAGE ILLUS FIG CLEARANCE MARKER LIGHT, DIRECTIONAL LIGHTS AND RELATED PARTS BLACKOUT LIGHT,HEADLIGHT AND RELATED PARTS BLACKOUT STOPLIGHT, TAILLIGHT AND RELATED PARTS MAP LIGHT, DOME LIGHTS AND RELATED PARTS SENDING UNITS AND WARNING SWITCHES ENGINE AND TRANSMISSION TEMPERATURE TRANSMITTERS AND RELATED PARTS SENDING UNITS AND WARNING SWITCHES CONTROL PANEL SENDING UINTS AND RELATED PARTS HORN, SIREN HORN AND HORN BUTTON BATTERIES, STORAGE BATTERY BOX AND COVER BATTERY BOX RELATED PARTS BATTERY AND RELATED PARTS CHASSIS WIRING HARNESS WIRING HARNESSES (FIREWALL TO FENDERS) WIRING HARNESSES (SIGNAL LAMPS AND MARKER LIGHTS) WIRING HARNESSES (CAB TO FRAME, ENGINE TO FRAME, BLACKOUT MARKER LAMP, BLACKOUT HEADLAMP) CHASSIS WIRING HARNESS CAB FRONT AND UNDERBODY WIRING HARNESS ENGINE WIRING HARNESS INSTRUMENT PANEL WIRING HARNESS WIRING HARNESS ATTACHING HARDWARE GROUP 07 TRANSMISSION 0700-TRANSMISSION ASSEMBLY TRANSMISSION MOUNTS GEAR SHIFT, VACUUM BOOSTER AND CONTROLS TRANSMISSION CONTROLS TORQUE CONVERTER TORQUE CONVERTER TRANSMISSION ASSEMBLY TRANSMISSION ASSEMBLY CONVERTER HOUSING FRONT SUPPORT INPUT SHAFT MAIN GEAR UNIT TRANSMISSION HOUSING REAR HOUSING INTERMEDIATE CLUTCH FOURTH CLUTCH THIRD AND SECOND CLUTCH FIRST AND REVERSE CLUTCH LOW CLUTCH SERVO UNIT CONTROLVALVE TRIMMER VALVES COOLERS, PUMPS, MOTORS OIL CHARGING PUMP COOLER AND FILTER LINES AND FITTINGS iii

5 TABLE OF CONTENTS PAGE ILLUS FIG GROUP 09 PROPELLER AND PROPELLER SHAFTS 0900-PROPELLER SHAFTS PROPELLER SHAFTS GROUP 10 FRONTAXLE 1000-FRONT AXLE ASSEMBLY FRONT STEERING AXLE STEERING AND LEANING WHEEL MECHANISM STEERING MECHANISM FRONT AXLE GROUP 11 REAR AXLE 1100-REAR AXLE ASSEMBLY REAR TANDEM HOUSING REAR AXLE HOUSING DIFFERENTIAL FORWARD REAR DIFFERENTIAL REAR REAR DIFFERENTIAL GROUP 12 BRAKES 1202-SERVICE BRAKES SLACK ADJUSTER BRAKE ASSEMBLY, FRONT BRAKE ASSEMBLY, REAR AIR BRAKE SYSTEM AIR LINES AND FITTINGS AIR LINE BRACKET AND TIES BRAKE TREADLE VALVE BRAKE VALVE-EXPLODED VIEW BRAKE CHAMBER, FRONT BRAKE CHAMBER, FORWARD REAR BRAKE CHAMBER, REAR REAR AIR RESERVOIRS AIR DRYER ASSEMBLY AIR COMPRESSOR ASSEMBLY AIR COMPRESSOR GOVERNOR TRAILER BRAKE CONNECTIONS AND CONTROLS TRAILER HAND BRAKE VALVE GROUP 13 WHEELS AND TRACKS WHEEL ASSEMBLY WHEEL ASSEMBLY HUB AND DRUM, FRONT HUB AND DRUM, REAR TIRES TIRE GROUP 14 STEERING 1401-MECHANICAL STEERING GEAR ASSEMBLY STEERING COLUMN, UPPER STEERING COLUMN, LOWER STEERING LINKAGE POWER STEERING GEAR ASSEMBLY STEERING GEAR MOUNTING iv

6 TABLE OF CONTENTS PAGE ILLUS FIG STEERING GEAR ASSEMBLY HYDRAULIC PUMP OR FLUID MOTOR ASSEMBLY POWER STEERING PUMP HOSES, LINES, FITTINGS POWER STEERING COOLER LINES AND FITTINGS GROUP 15 FRAME, TOWING ATTACHMENTS AND DRAWBARS 1501-FRAME ASSEMBLY FRAME ASSEMBLY, FRONT FRAME ASSEMBLY, CENTER FRAME ASSEMBLY, REAR BUMPER AND BRUSH GUARD PINTLES AND TOWING ATTACHMENTS PINTLE HOOK AND TOW EYE SPARE WHEEL CARRIER AND TIRE LOCK SPARE TIRE CARRIER AND DECK PLATES SPARE TIRE HOIST FIFTH WHEEL FIFTH WHEEL ASSEMBLY AND RAMPS FIFTH WHEEL PLATE ATTACHING HARDWARE GROUP 16 SPRINGS AND SHOCK ABSORBERS 1601-SPRINGS FRONT SUSPENSION ASSEMBLY FRONT LEAF SPRING ASSEMBLY TANDEM AXLE SUSPENSION BEAM ASSEMBLY EQUALIZER AND BEAM END ADAPTER ASSEMBLY SHOCK ABSORBING EQUIPMENT SHOCK ABSORBER TORQUE, RADIUS AND STABILIZER RODS TORQUE ROD ASSEMBLY GROUP 18 BODY, CAB, HOOD AND HULL 1801-BODY, CAB, HOOD AND HULL ASSEMBLIES CAB ASSEMBLY, HULL INTERIOR CAB ASSEMBLY COMPONENTS DOOR ASSEMBLY COMPONENTS DOOR ASSEMBLY AND RELATED PARTS RADIATOR GRILLE HOOD FENDERS, WINDSHIELD, GLASS FENDER ASSEMBLY WINDSHIELD, DOOR GLASS AND SLIDING REAR WINDOW SLIDING REAR WINDOW-EXPLODED VIEW UPHOLSTERY, SEATS AND CARPETS FLOOR MATS AND CAB TRIM SUN VISOR DRIVER S SEAT COMPANION SEAT STOWAGE RACKS, BOXES, STRAPS, CARRYING CASES, CABLE REELS, HOSE REELS SEAT RISER AND TOOL BOX v

7 TABLE OF CONTENTS PAGE ILLUS FIG GROUP 22 BODY, CHASSIS OR HULL ACCESSORY ITEMS 2202-ACCESSORY ITEMS SIDE MIRRORS MIRRORS, SPOTTER AIR HORN WINDSHIELD WASHER AND WIPERS HEATER AND DEFROSTER LINES AND FITTINGS HEATER ASSEMBLY AIR DIFFUSER ASSEMBLY HEATER CONTROL PANEL DEFROSTER FANS DATA PLATES AND INSTRUCTION HOLDERS EXTERIOR DATA PLATES INTERIOR DATA PLATES GROUP 47 GAGES (NONELECTRICAL),WEIGHING AND MEASURING DEVICES 4701-INSTRUMENTS (SPEED AND DISTANCE) TACHOGRAPHS AND CABLES GAGES, MOUNTINGS,LINES AND FITTINGS AIR PRESSURE GAGES GROUP 67 PRECISION INSTRUMENTS AND SYSTEMS 6715-SPECIAL ELECTRONIC TEST EQUIPMENT, MOUNTED OR PORTABLE SIMPLIFIED TEST EQUIPMENT- INTERNAL COMBUSTIBLE ENGINE (STE/ICE) GROUP 95 REPAIR KITS 9501-REPAIR KITS...KIT-1 KIT...KIT-1 KIT GROUP 95 GENERAL USE STANDARIZED PARTS 9501-BULK MATERIEL...BULK-1 BULK....BULK-1 BULK SECTION III SPECIAL TOOLS LIST GROUP 26 TOOLS AND TEST EQUIPMENT 2604-SPECIAL TOOLS UNIT TOOL LIST DIRECT SUPPORT TOOL LIST GENERAL SUPPORT TOOL LIST SECTION IV. CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX I-1 PART NUMBER INDEX I-31 FIGURE AND ITEM NUMBER INDEX I-99 vi

8 SECTION I UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS (INCLUDING DEPOT MAINTENANCE PARTS) SECTION 1. 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, Direct Support and General Support Maintenance of the Truck, Tractor, Line Haul, M915A1. 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: 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. b. SMR CODE (Column (2)). The Source, Maintenance, and Recoverability (SMR) code is a 5- position code containing supply/requisitioning information, maintenance category authorization criteria and disposition instructions, as shown in the following breakout: 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 the 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 column) for the performance of maintenance. c. 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-references NSN, CAGE and part numbers. *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 serviceability to a failed item. 1

9 SECTION II TA FIGURE 1. ENGINE MOUNTS.

10 SECTION II (1) (2) (3) (4) (5) (6) ITEM SMR PART NO CODE CAGEC NUMBER DESCRIPTION AND USABLE ON CODES (UOC) QTY GROUP: 01 ENGINE GROUP: 0100 ENGINE ASSEMBLY FIGURE 1. ENGINE MOUNTS. 1 PAFZZ MS SCREW,CAP,HEXAGON PFFZZ MD32K BRACKET,EYE. NONROTA REAR MOUNT PAFZZ M/ BRACKET,ANGLE PAFZZ WASHER,FLAT PAFZZ MS SCREW,CAP,HEXAGON PAFZZ M/ WASHER,FLAT POFZZ OB GROMMET REAR PAFZZ M/ WASHER,FLAT PAFZZ NUT,SELF-LOCKING,CO PAFZZ M/ WASHER,FLAT. * POFZZ M/ BUSHING,RUBBER FRONT... 2 END OF FIGURE 1-1

11 SECTION II TA FIGURE 2. ENGINE ASSEMBLY RELATED PARTS.

12 SECTION II (1) (2) (3) (4) (5) (6) ITEM SMR PART NO CODE CAGEC NUMBER DESCRIPTION AND USABLE ON CODES (UOC) QTY GROUP: 01OD ENGINE ASSEMBLY FIGURE 2. ENGINE ASSEMELY RELATED PARTS. 1 PAODZZ NUTIPLAIN,CONE SEAT... V 2 PAOZZ MS WASHE4RLOCK PAOZZ SPACER,SLEEVE... V 4 PAOZZ BRACKET, ENGINE LIFT PAOZZ PLATE,IDENTIFICATIO PAOZZ S-2286 SCREW... 5 END OF FIGURE 2-1

13 SECTION II TA FIGURE 3. ROCKER COVERS.

14 SECTION II (1) (2) (3) (4) (5) (6) ITEM SMR PART NO CODE CAGEC NUMBER DESCRIPTION AND USABLE ON CODES (UOC) QTY GROUP:0105 VALVEST CAMSHAFTS AND TIMING SYSTEM FIGURE 3. ROCKER COVERS. 1 PAOZZ CAR,FILLER OPENING PAOZZ SCREW,CAP,HEXAGON PAOZZ COVER,ROCKER FRONT PAOZZ COVER,ENGINE POPPET CENTER PAOZZ COVER,ENGINE POPPET P0OZZ GASKET... 3 END OF FIGURE 3-1

15 SECTION II TA FIGURE 4. OIL FILTER AND RELATED PARTS.

16 SECTION II (1) (2) (3) (4) (5) (6) ITEM SMR PART NO CODE CAGEC NUMBER DESCRIPTION AND USABLE ON CODES (UOC) QTY GROUP: 0106 ENGINE LUBRICATION SYSTEM FIGURE 4. OIL FILTER AND RELATED PARTS. 1 PAOZZ ADAPTER,FILTER HEAD PAOZZ SCREW,CAP,HEXAGONE PAOZZ SWITCH,PRESSURE PAOZZ PACKING,PREFORMED PAOZZ ADAPTER,FILTER HEAD PAOZZ FILTER ELEMENT,FLUI PAOZZ FILTER ELEMENT,FLUI PAOZZ COCK,DRAIN... 1 END OF FIGURE 4-1