hmmwv-manuals

Appendix A References

A-1. Scope

This appendix lists all forms, field manuals, technical manuals, and other publications required for use with this manual.

A-2. Publications Index

The following index should be consulted frequently for latest changes or revisions and for new publications relating to materiel covered in this manual.

Consolidated Index of Army Publications and Blank Forms . . . . . . . . . . . . . DA PAM 25-30

A-3. Forms

1. Remove antiskid strip (4) from cargo floor (3).
2. Clean remaining adhesive from cargo floor (3).
3. Inspect plugs (1) in cargo floor (3) and right wheelhouse (2), and replace plugs (1) if damaged.
b. Installation
1. 2. Ensure surface of cargo floor (3) is free of dirt and oil. Peel paper backing (5) from antiskid strip (4) and press antiskid strip (4) firmly onto cargo floor (3).
A-4. FIELD MANUALS
NBC Protection
NBC Decontamination
Operation and Maintenance of Ordnance Materiel in Cold Weather (0° to -65°F) FM 9-207
First Aid for Soldiers
Manual for the Wheeled Vehicle Driver
Browning Machinegun Caliber .50 HB, M2 FM 23-65
Machinegun 7.62-MM, M60 FM 23-67
Basic Cold Weather Manual
Northern Operations
Army Motor Transport Units and Operations
Mountain Operations
General Fabric Repair !!!
Inspection, Care and Maintenance of Antifriction Bearings . . TM 9-214
Materials Used for Cleaning, Preserving, Abrading, and Cementing Ordnance
Materiel and Related Materials (Including Chemicals) TM 9-247
Operator's Manual for Machinegun, Caliber .50 Browning, M2 . TM 9-1005-213-10
Operator's Manual for M60, 7.62-MM Machinegun . . TM 9-1005-224-10

A-4. Field Manuals A-5. Technical Manuals A-5. Technical Manuals (Cont'D)

REFERENCES
A-1. SCOPE
This appendix lists all forms, field manuals, technical manuals, and other publications required for use
with this manual.
A-2. PUBLICATIONS INDEX
The following index should be consulted frequently for latest changes or revisions and for new publications
relating to materiel covered in this manual.
Consolidated Index of Army Publications and Blank Forms DA PAM 25-30
A-3. FORMS
Recommended Changes to Publications and Blank Forms DA Form 2028
Recommended Changes to Equipment Technical Publications DA Form 2028-2
Hand Receipt/Annex Number DA Form 2062
Exchange Tag DA Form 2402
Equipment Inspection and Maintenance Worksheet DA Form 2404
The Army Maintenance Management System (TAMMS) DA PAM 738-750
Preventive Maintenance Schedule and Record DD Form 314
Processing and Deprocessing Record for Shipping, Storage,
and Issue of Vehicles and Spare Engines DD Form 1397
Quality Deficiency Report Standard Form 368
A-4. FIELD MANUALS
NBC Decontamination FM 3-5
Operation and Maintenance of Ordnance Materiel in Cold Weather (0° to -65°F) FM 9-207
First Aid for Soldiers FM 21-11
Machinegun 7.62-MM, M60 FM 23-67
Basic Cold Weather Manual FM 31-70
Northern Operations FM 31-71
Army Motor Transport Units and Operations FM 55-30
Mountain Operations FM 90-6
General Fabric Repair FM 10-16
A-5. TECHNICAL MANUALS
Inspection, Care and Maintenance of Antifriction Bearings TM 9-214
Materials Used for Cleaning, Preserving, Abrading, and Cementing Ordnance
Materiel and Related Materials (Including Chemicals) TM 9-247
Operator's Manual for Machinegun, Caliber .50 Browning, M2 TM 9-1005-213-10
Operator's Manual for M60, 7.62-MM Machinegun TM 9-1005-224-10

A-6. Technical Bulletins A-7. Army Regulations A-8. Other Publications

Appendix B Maintenance Allocation Chart

Section I. INTRODUCTION

B-1. The Army Maintenance System (Mac)

a. This section 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 component. The application of the maintenance functions to the end item or component will be consistent 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 III lists the tools and test equipment (both special tools and common tool sets) required for each maintenance function as referenced from section II.

d. Section IV contains supplemental instructions and explanatory notes for a particular maintenance function.

B-2. Maintenance Functions

Maintenance functions will be limited to and defined as follows: 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 electrical characteristics of an item and comparing those characteristics with prescribed standards.

c. Service. Operations required periodically to keep an item in proper operating condition, i.e., to clean (includes decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids, or gases.

d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper or exact 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.

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 comparisons 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 functioning 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 is shown as the 3d position code of the SMR code.

i. Repair. The application of maintenance services, including fault location/troubleshooting, removal/installation, and disassembly/assembly procedures, and maintenance actions 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 completely serviceable/operational condition as required by maintenance standards in appropriate technical publications (i.e., DMWR). Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an item to like-new condition.

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 (hours/ miles, etc.) considered in classifying Army equipment/components.

B-3. Explanation Of Columns In The Mac, Section Ii

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 names of components, assemblies, subassemblies, and modules for which maintenance is authorized.

c. 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 para. B-2.) d. Column (4)-Maintenance Category. Column 4 specifies, by the listing of a work time figure in the appropriate subcolumn(s), the category of maintenance authorized to perform the function listed in Column 3. This figure represents the active time required to perform that maintenance function at the indicated category of maintenance. If the number of complexity of the tasks within the listed maintenance function vary at different maintenance categories, appropriate work time figures will be shown for each category. 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/quality control time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the maintenance allocation chart. The symbol designations for the various maintenance categories are as follows: NOTE When a complete replace or repair task performed at higher level maintenance includes lower level maintenance tasks (equipment condition/follow-on tasks), the lower level work time figures in the MAC must be added to the higher level work time shown in the MAC to determine the total time to accomplish that maintenance function.

Policy for Safeguarding and Controlling Comsec Material AR 380-40
Prevention of Motor Vehicle Accidents AR 385-55
Packaging of Material AR 700-15
Army Material Maintenance Policy and Retail Maintenance Operation AR 750-1

e. Column (5)-Tools and Equipment. Column 5 specifies, by code, those common tool sets (not individual tools) and special tools, TMDE, and support equipment required to perform the designated function.

f. Column (6)-Remarks. This column shall, when applicable, contain a letter code, in alphabetic order, which shall be keyed to the remarks contained in Section IV.

B-4. Explanation Of Columns In Tool And Test Equipment Requirements, Section Iii

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 Category. The lowest category 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 manufacturer's part number.

B-5. Explanation Of Columns In Remarks, Section Iv

a. Column (1)-Remarks Code. The code recorded in column 6, Section II. b. Column (2)-Remarks. This column lists information pertinent to the maintenance function being performed as indicated in the MAC, Section II.

TM 9-2320-280-20-3

i. Repair. The application of maintenance services, including fault location/troubleshooting,
removal/installation, and disassembly/assembly procedures, and maintenance actions 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 completely
serviceable/operational condition as required by maintenance standards in appropriate technical
publications (i.e., DMWR). Overhaul is normally the highest degree of maintenance performed by the
Army. Overhaul does not normally return an item to like-new condition.
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 (hours/ miles, etc.) considered in classifying Army equipment/components.
B-3. EXPLANATION OF COLUMNS IN THE MAC, SECTION II
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 names of components, assemblies,
subassemblies, and modules for which maintenance is authorized.
c. 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 para. B-2.)
d. Column (4)-Maintenance Category. Column 4 specifies, by the listing of a work time figure in
the appropriate subcolumn(s), the category of maintenance authorized to perform the function listed in
Column 3. This figure represents the active time required to perform that maintenance function at the
indicated category of maintenance. If the number of complexity of the tasks within the listed maintenance
function vary at different maintenance categories, appropriate work time figures will be shown for each
category. 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/quality control time in addition to the time
required to perform the specific tasks identified for the maintenance functions authorized in the
maintenance allocation chart. The symbol designations for the various maintenance categories are as
follows:
NOTE
When a complete replace or repair task performed at higher
level maintenance includes lower level maintenance tasks
(equipment condition/follow-on tasks), the lower level work
time figures in the MAC must be added to the higher level
work time shown in the MAC to determine the total time to
accomplish that maintenance function.
C Operator or crew
O Unit maintenance
F Direct Support maintenance
H General Support maintenance
D Depot maintenance
e. Column (5)-Tools and Equipment. Column 5 specifies, by code, those common tool sets (not
individual tools) and special tools, TMDE, and support equipment required to perform the designated
function.
f. Column (6)-Remarks. This column shall, when applicable, contain a letter code, in alphabetic

Section II. MAINTENANCE ALLOCATION CHART (Cont'd) Section II. MAINTENANCE ALLOCATION CHART (Cont'd)

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function Ref Code Code
C O F H D
01 ENGINE
0100 Engine Assembly Inspect 0.2 0.7
Test 1.0 1,20,21,22,26 G
Service 0.5 1,2
Adjust 1.0 41,42
Replace 32.7 25,145
Repair 16.0 1,7,10,43-45
Mount, Engine Inspect 0.1 2,144,145
Replace 1.6 1,2,144-
146,149
0101 Cylinder Head Replace 3.0 1,6
Repair 5.0 1,6,8,12-18
Block, Cylinder Repair 10.0 1,6-8,12-18
0102 Crankshaft Replace 4.0 1
Pulley, Crankshaft Replace 0.5 1,6
Damper, Vibration Replace 0.5 1,6
Bearings, Crankshaft Replace 4.0 1
Oil Seals, Crankshaft, Front Replace 2.0 1
Oil Seals, Crankshaft, Rear Replace 2.0 1,6,46
0103 Flywheel Replace 3.5 1,6
0104 Pistons, Connecting Rods
Rods, Connecting Replace 8.0 1,6
Bearings, Connecting Rod Replace 2.0 1,6
Pistons Replace 8.0 1,6
Rings, Piston Replace 7.0 1,6,10
0105 Valves, Camshaft, and Timing
System
Cover, Rocker Arm Replace 1.0 1,6
Valves, Intake and Exhaust Replace 3.0 6
Repair 3.0 6,8
Rocker Arm Assembly Replace 2.1 1,6
Springs, Valve Test 0.5 1,8
Replace 2.3 1,6
Rods, Push Replace 3.0 1
Lifters Replace 6.0 1

TM 9-2320-280-20-3

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function C O F H D Ref Code Code
Gears and Chain, Timing Replace 4.0 1,6,10
Camshaft Replace 4.0 1,6,10
Bearings, Camshaft Replace 4.0 1,6,45,47
0106 Engine Lubrication System
Pan, Oil Replace 2.0 1,2
Pump, Oil Replace 2.5 1,6
Filter, Oil Replace 0.5 1,2
Dipstick and Tube Replace 0.2 1,2,156
Oil Cooler Assembly Inspect 0.1
Replace 0.5 1,2
Repair 1.0 1
Lines, Oil Cooler Inspect 0.2
Replace 1.8 1
Valve, Crankcase Depression Inspect 0.1
Regulator Test 0.3 L
Service 0.3 1
Replace 0.3 1,2
0108 Manifold, Intake Replace 3.0 1,6
Manifold, Exhaust Replace 3.0 1,146,
150,156
03 FUEL SYSTEM
0301 Injector Nozzle, Fuel Test 0.5 1,9
Replace 0.7 1,6,49,134,
146,153
0302 Lines, Injection Pump Inspect 0.1
Replace 2.0 1,147,148
Pump, Injection Inspect 0.1
Calibrate A 1,9,59-65 A
Replace 4.0 1,147
Repair 0.6 5.0 1,9,50-57, O
158-161
Fuel Pump Test 0.3 1,2
Replace 1.0 1,2
0304 Cleaner Assembly, Air Inspect 0.2
Service 0.2 0.5 1
Replace 0.2 1
Horn, Air Induction Inspect 0.1
Replace 0.3 1,2
0306 Lines and Fittings, Fuel Inspect 0.2
Replace 3.2 1
Tank, Fuel Inspect 0.1
Replace 2.6 1,2

Section II. MAINTENANCE ALLOCATION CHART (Cont'd)

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function Ref Code Code
C O F H D
0309 Filter Assembly, Fuel Inspect 0.1
Service 0.1 0.5 1 B
Replace 0.5 2
0311 Glow Plugs Test 0.3 2
Replace 0.7 1,2,48,155
0312 Accelerator Linkage Inspect 0.2
Adjust 0.2 1
Replace 0.8 1,2
Hand Throttle Inspect 0.1 0.1
Adjust 0.2 1
Replace 0.5 1,2
04 EXHAUST SYSTEM
0401 Muffler Inspect 0.2
Replace 1.9 1,2
Crossover Pipe Inspect 0.2
Replace 1.2 1,2,145,
150
Tailpipe Inspect 0.2
Replace 0.5 1,2
05 COOLING SYSTEM
0501 Radiator Inspect 0.1 0.2
Test 0.5 2,66
Replace 4.3 1
Repair 3.0 1
Surge Tank Inspect 0.1
Service 0.1 0.5 1,2 C
Replace 0.6 1
0502 Shroud, Fan Inspect 0.1
Replace 4.4 1
Repair F F,M
0503 Hoses, Lines, and Clamps Inspect 0.1 0.1
Replace 2.5 1
Thermostat Test 0.2
Replace 0.3 1,2
0504 Pump, Water Replace 3.5 1,6
0505 Fan Inspect 0.1 0.1
Replace 1.0 1,2,161
Fan Drive Repair 4.7 1,6
Pulley, Water Pump Replace 4.8 1,157

Section II. MAINTENANCE ALLOCATION CHART (Cont'd) TM 9-2320-280-20-3

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function C O F H D Ref Code Code
Belts, Drive Inspect 0.1
Adjust 0.5 1,2,67
Replace 1.0 1,2,67
06 ELECTRICAL SYSTEM
0601 Alternator (60 Ampere) Inspect 0.1
Test 0.3 2,166
Adjust 0.3 1,163
Replace 1.0 1,2
Pulley, Alternator Replace 1.2 1,2,67
0603 Starter Inspect 0.2
Test 0.3 2
Replace 1.9 1,2,145,
146,149
Repair 8.3 1,9
0607 Instrument Panel
Switches Replace 0.3 1
Instruments, Gages Inspect 0.1
Replace 0.5 1
Circuit Breakers Replace 0.5 1
0608 Control, Directional Signal Inspect 0.1
Replace 0.3 1
Protective Control Box Inspect 0.1
Replace 0.3 1
0609 Headlight Inspect 0.1
Adjust 0.2 1,2
Replace 0.5 1
Lights, Composite, Front Inspect 0.1
and Rear Replace 0.1 1
0610 Sending Units and Warning Test 0.1 2
Switches Replace 0.1 1
0611 Horn Assembly Inspect 0.1
Test 0.2 2
Replace 0.3 1
Switch, Horn Test 0.2 2
Replace 0.2 1
0612 Battery Inspect 0.1
Test 0.5 2
Service 0.2 1
Replace 1.6 1
Cables, Battery Inspect 0.2
Replace 0.8 1
Repair 0.5 1,2

Section II. MAINTENANCE ALLOCATION CHART (Cont'd)

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function Ref Code Code
C O F H D
0613 Wiring Harnesses
Wiring Harness, Engine Inspect 0.3
Replace 4.5 1,6
Repair 0.5 1,2
Wiring Harness, STE/ICE-R Inspect 0.3
Replace 3.7 1,6
Repair 0.5 1,2
Wiring Harness, Body Inspect 0.4
Replace 3.5 1,6
Repair 0.5 1,2
Wiring Harness, Hood Inspect 0.2
Replace 1.0 1
Repair 0.5 2
0615 Ambulance Electrical
System
Spotlight and Ceiling Inspect 0.1
Light Bulbs Replace 0.1 1
Spotlight and Ceiling Inspect 0.1
Light Assemblies Replace 0.2 1
Blackout Light Switches Inspect 0.1
Replace 0.2 1
Backup Lights Replace 0.3 1
Control Box Inspect 0.1
Replace 2.5 1
Control Box Relays, Replace 0.3 1
Switches, Fuse Blocks
Heat/Vent Control Replace 0.3 1
Panel (M996)
Heat, Vent, and Replace 10.0 1
A/C Control Box (M997)
Heat, Vent, and Replace 0.3 1
A/C Switches and Relays
200 Ampere Alternator Inspect 0.2
Test 0.3 2,166
Replace 1.1 1
Adjust 0.3
Repair 4.0
Lighting Wiring Harness Replace 3.5 1
NBC Control Box and Replace 4.3
Wiring Harness

Section II. MAINTENANCE ALLOCATION CHART (Cont'd) TM 9-2320-280-20-3

(4) (1) (2) (3) (5) (6) Maintenance Level
Tools and Group Maintenance Remarks Direct General Unit Equipment Depot Support Support
Number Component/Assembly Function Code Ref Code F H C O D
07 TRANSMISSION (3L80) 0705 Shift Control and Linkage Inspect 0.1 0.2
Adjust 0.5 1 Replace 1.5 1,2
Repair 1.0 6 Modulator, Mechanical Adjust 0.1 2
Replace 0.6 2 Switch Neutral Start Replace 0.5 1
Detent Solenoid Replace 1.7 1,2 0708 Torque Converter Replace 3.3 1,2
0710 Transmission Assembly Inspect 0.1 D Test 0.5 2,6,145
Service 0.2 1,2 Replace 5.8 1,6,144
Repair 4.0 1,6,70,80 Transmission Mount Inspect 0.2
Replace 1.0 1,6 Gear Unit Replace 1.5 1,6,70-73
Repair 1.3 1,6,72-75 0713 Forward Clutch Replace 2.0 1,6,70-73
Repair 0.6 1,6,76,77 Direct Clutch Replace 2.0 1,6,70-73,79
Repair 0.8 1,6,76,77 Intermediate Clutch Replace 2.0 1,6,70-73
Repair 0.8 1,6,74,75,79 0714 Rear Servo Replace 1.0 1,6,78
Repair 0.3 1,6,78 Front Servo Replace 1.0 1,6
Repair 1.0 1,6 Band, Front and Rear Replace 2.5 1,6,70-73,79
Governor Inspect 0.2 Replace 0.5 1,6
Control Valve Replace 1.3 1,6 Repair 1.0 1,6,10
0721 Oil Pump, Transmission Replace 1.0 1,6,70,71,73,80 Repair 1.6 1,6,73-75
Seal, Oil Pump Replace 0.3 1,6,80 Oil Filter, Transmission Replace 1.5 1,2
Oil Cooler Lines Inspect 0.2 Replace 1.0 1

Section II. MAINTENANCE ALLOCATION CHART (Cont'd) Section II. MAINTENANCE ALLOCATION CHART (Cont'd)

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct General Depot Equipment Remarks
Number Component/Assembly Function Support Support Ref Code Code
C O F H D
TRANSMISSION (4L80-E)
0705 Shift Control and Linkage Inspect 0.1 0.2
Adjust 0.5 1
Replace 1.5 1,2
Repair 1.0 1,2
Throttle Position Sensor Adjust 0.1 1,63,166,173
Replace 0.6 1,63,166,173
Switch, Neutral Start Replace 0.5 1
0708 Torque Converter Replace 3.3 1,2
0710 Transmission Assembly Inspect 0.1 D
Test 0.5 1,2,6,
93.1,93.2,
145,166,173
Service 0.2 1,2
Replace Repair 5.8 4.0 1,2,6,144 1,6,70,71,81
Overhaul 13.5 1,6,70-73,
79,81-84,
92,93,95,172
Transmission Mount Inspect 0.2
Replace 1.0 1,2
Gear Unit Replace 1.5 1,6,84
Repair 1.3 1,6,84
0713 Forward Clutch Replace 2.0 1,6,85,
87,88,172
Repair 0.6 1,6,85-88,
172
Direct Clutch Replace 2.0 1,6,79,
87,88,
172
Repair 0.8 1,6,79,
86-88
Intermediate Clutch Replace 2.0 1,6,84
Repair 0.8 1,6,79,84
Fourth Clutch Replace 2.0 1,6,86-88
Repair 0.8 1,6,87-89
Turbine Shaft and Replace 2.0 1,6
Overdrive Carrier Repair 0.8 1,6,79,86,90
0714 Rear Servo Replace 1.0 1,6
Repair 0.3 1,6
Front Servo Replace 1.0 1,6
Repair 1.0 1,6
Band, Front and Rear Replace 2.5 1,6,92,93
Governor Inspect 0.2
Replace 0.5 1,6
Control Valve Replace 1.3 1,6
Repair 1.0 1,6,10

TM 9-2320-280-20-3

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function Ref Code Code
C O F H D
0721 Oil Pump, Transmission Replace 1.0 1,6,83
Repair 1.6 1,6,83,91
Seal, Oil Pump Replace 0.3 1,6,80
Oil Filter, Transmission Replace 1.5 1,2
Lines, Oil Cooler Inspect 0.2
Replace 1.0 1,2
08 TRANSFER
0801 Transfer Case Inspect 0.1
Service 0.5 2
Replace 5.2 1,6,144
Repair 5.7 1,6,75,94-106 P
Overhaul 10.0 1,6,10,75
94,106,144
Seal, Oil, Input and Output Replace 1.3 1,2,94
Shaft
Yokes, Front and Rear Replace 1.2 1,2
Bearings, Output Shaft Replace 3.0 1,2,75,95-100
Gear, Speedometer Driven Replace 0.5 1,2,107
0803 Shift Control and Linkage Inspect 0.1 0.2 D
Adjust 0.5 1
Replace 1.0 1,2
Repair 1.0 1,2
09 PROPELLER SHAFTS
0900 Shafts, Propeller, Front Service 0.2 1,2
Replace 1.0 1,2
Repair 0.5 1.2 1,2,6 E
Shaft, Propeller, Rear Service 0.2 1,2
Replace 1.0 1,2
Repair 1.2 1,2
Joints, Universal Inspect 0.1
Service 0.3 2
Replace 1.5 1,2
10 FRONT AXLE
1000 Halfshaft Inspect 0.2
Replace 2.2 1,2
Repair 1.0 1,2

Section II. MAINTENANCE ALLOCATION CHART (Cont'd)

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function Ref Code Code
C O F H D
1002 Differential Assembly Inspect 0.1
Service 0.5 1,2
Replace 5.0 1,2
Repair 10.2 1,7,75,94,
117-124
Seal, Output Shaft, Differential Replace 1.0 1,6,117
Seal, Pinion, Differential Replace 0.3 1,6,94
Differential Cover Replace 0.5 1,2 H
1004 Knuckle and Geared Hub Inspect 0.1
Service 0.5 1,2
Replace 2.0 1,2,167
Repair 1.2 1,2,6,75, K
126-128,129
Bearing, Spindle, Geared Hub Adjust 0.9 1,2,127
Seal, Input, Geared Hub Replace 2.0 1,2,75,126
Seal, Spindle, Geared Hub Replace 1.0 1,2,75,127,128 I
Steering Stop Adjust 0.5 2
Replace 0.3 2
Upper Control Arm Inspect 0.1
Replace 1.0 1,2
Repair 1.0 1,2
Lower Control Arm Inspect 0.1
Replace 2.6 1,2
Repair 1.0 1,2
Ball Joint, Upper and Lower Replace 0.6 1,2,129,146,
151
11 REAR AXLE
1100 Halfshaft Inspect 0.2
Replace 1.8 1,2
Repair 1.0 1,2
1102 Differential Assembly Inspect 0.1
Service 0.5 1,2
Replace 5.0 1,2
Repair 10.0 1,7,75,94,
117-124
Seal, Output Shaft, Differential Replace 1.0 1,6,117
Seal, Pinion, Differential Replace 0.3 1,6,94

Section II. MAINTENANCE ALLOCATION CHART (Cont'd) TM 9-2320-280-20-3

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function Ref Code Code
C O F H D
1104 Knuckle and Geared Hub Inspect 0.1
Service 0.5
Replace 2.0 2,167
Repair 1.2 1,2,75,126,
128,129 K
Bearing, Spindle, Geared Hub Adjust 0.9 1,2,127
Seal, Input, Geared Hub Replace 2.0 1,2,75,126
Seal, Spindle, Geared Hub Replace 1.0 1,2,75,127,
128
Upper Control Arm Inspect 0.1
Replace 1.0 1,2
Repair 1.0 1,2
Lower Control Arm Inspect 0.1
Replace 2.6 1,2
Repair 1.0 1,2
Ball Joint, Upper and Lower Replace 0.6 1,2,129,146,
151
12 BRAKES
1201 Parking Brake Lever Adjust 0.3
Replace 1.0 1,2
Parking Brake Cable Adjust 0.5 1,2
Replace 1.0 1,2
Parking Disc Brake Pad Inspect 0.2
Replace 1.0 1,2
Dual Service/Parking Adjust 0.5 1,2
Brake Cable, Right Rear Replace 0.7 1,2
Dual Service/Parking Adjust 0.5 1,2
Brake Cable, Left Rear Replace 0.5 1,2
Dual Service/Parking Inspect 0.1
Calipers, Rear Replace 1.0 1,2,162
Dual Service/Parking Inspect 0.2
Pads, Rear Replace 1.0 1,2
1202 Service Brakes Test 0.1
Calipers, Front and Rear Replace 1.0 1,2,152,162
Repair 0.5 1,6
Pads, Front and Rear Inspect 0.2
Replace 1.0 1,2,152
Rotor, Front and Rear Inspect 0.1 1
Replace 1.2 1,2
Repair 1.5 1,6

Section II. MAINTENANCE ALLOCATION CHART (Cont'd)

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function Ref Code Code
C O F H D
1204 Master Cylinder Inspect 0.1
Service 0.2 2
Replace 0.5 1,2
Brake Lines Inspect 0.2
Replace 1.5 1
Proportioning Valve Replace 0.6 1,2
1205 Hydro-Boost Replace 1.3 1,2
1206 Pedal, Brake Replace 1.0 1,2,146,153
13 WHEELS AND TIRES
1301 Front Wheel Toe-In Align 0.5 1
Rear Wheel Toe-Out Align 0.5 1
1311 Wheel and Tire Assembly Inspect 0.1 0.1
Service 0.2
Replace 0.4 0.1 1,2 N
Repair 0.5 1,2,130
Runflat Assembly Replace 2.2 1,2,4,144,
154,131 J
14 STEERING
1401 Mechanical Steering
Wheel, Steering Replace 0.7 1,2
Column, Steering Inspect 0.1
Replace 1.8 1,2
Intermediate Shaft, Steering Service 0.2 1,2
Replace 0.5 1,2
Tie Rod Assembly Inspect 0.1
Service 0.2 1,2
Adjust 0.5 1,2,167
Replace 0.5 1,2,129
Center Link Inspect 0.1 1,2
Replace 0.3 1,2,167
Pitman Arm Inspect 0.1
Replace 1.0 1,2,129
Idler Arm Inspect 0.1
Replace 0.3 1,2,129
Camber/castor Adjustment 2.2 1,138.1
1407 Gear, Power Steering Inspect 0.2
Replace 0.5 1,2
Repair 3.7 1,6,132,
133,135

Section II. MAINTENANCE ALLOCATION CHART (Cont'd) TM 9-2320-280-20-3

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function Ref Code Code
C O F H D
1410 Pump, Power Steering Inspect 0.1 0.1
Test 0.5 1,2,
136-138
Service 0.2 1,2
Replace 1.0 1,2
Repair 1.0 1,2
Pulley, Power Steering Pump Replace 0.5 1,2,137
1411 Hoses, Lines, and Fittings Inspect 0.2
Power Steering Replace 1.0 1
15 FRAME
1501 Frame Assembly Inspect 0.5
Repair F 1,5 F
Crossmember, Transmission Replace 2.0 1
Crossmember, Suspension, Inspect 0.2
Front, Brackets, and Replace 4.5 1,6
Supports Repair 2.0 1,5
Crossmember, Rear Replace 2.0 1,2
Bumpers Replace 0.5 1,2
1503 Pintle, Towing Inspect 0.1
Service 0.1 1
Replace 1.0 1,2
Repair 0.2 1,2
16 SPRINGS AND SHOCK ABSORBERS
1601 Springs Inspect 0.1
Replace 1.0 1,2
1604 Absorbers, Shock Inspect 0.1 0.1
Replace 0.8 1,2
1605 Rod, Stabilizer Replace 1.5 1,2
Rod, Radius Inspect 0.1
Replace 1.0 1,2
Repair 0.5 1,2
18 BODY AND HOOD
1801 Body Inspect 0.1
Service 1.0 1
Replace F 1,6 F
Repair F 1,2,139,140 F
Hood Inspect 0.1
Replace 1.3 1,2
Repair F 1,6 F

Section II. MAINTENANCE ALLOCATION CHART (Cont'd)

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function Ref Code Code
C O F H D
Doors, Rear Inspect 0.1
Replace 0.2 1
Repair F 1,5,139 F
Cover, Engine Access Inspect 0.1
Replace 0.1 1
Repair F 1,5,139 F
1802 Windshield Assembly, Folding Inspect 0.1
Replace 2.0 1,2
Repair F 1,5,139 F
Windshield Assembly, Fixed Inspect 0.1
Replace 2.0 1,6
Repair F 1,5,139 F
Windshield Glass Inspect 0.1
Replace 1.0
1806 Seats Inspect 0.1
Replace 1.0 1,2
Repair 1.0 1,2
Seatbelts Inspect 0.1
Replace 0.8 1,2
1808 Stowage Racks, Boxes, Inspect 0.1
and Straps Replace F 1,2 F
Repair F 1,2 F
Tailgate Inspect 0.1
Replace 0.4 1,2
Repair 1.0 1,5,139
1812 TOW Carrier and Armament
Carrier (M966, M966A1,
M1025, M1025A1, M1025A2,
M1026, M1026A1, M1036,
M1043, M1043A1, M1043A2,
M1044, M1044A1, M1045,
M1045A1, M1045A2, M1046,
M1046A1, M1121)
Doors, Crew Inspect 0.1
Adjust 0.3 1,2
Replace 0.2 1
Repair F 1,5,139 F
Door, Cargo Shell Inspect 0.1
Adjust 0.3 1,2
Replace 2.5 1,2
Repair F 1,2,139 F
Glass, Door Inspect 0.1
Replace 1.0 1
Weapon Station Inspect 0.1
Replace 1.5 1,6
Gunners Platform Inspect 0.1
Replace 0.5 1

Section II. MAINTENANCE ALLOCATION CHART (Cont'd) TM 9-2320-280-20-3

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function C O F H D Ref Code Code
S250 Shelter Carrier
(M1037, M1042)
Support, Shelter Inspect 0.1
Replace 2.0 1,2
Sling, Tiedown Inspect 0.1
Replace 0.3 1
Soft Top Ambulance
(M1035, M1035A1)
Rack, Litter Inspect 0.1
Replace 1.5 1,2,
Ambulance - 2-Litter
(M996, M996A1),
4-Litter (M997, M997A1
M997A2)
Door, Rear Inspect 0.1
Adjust 0.4 1,2
Replace 0.3 1,2
Door Latch and Handles, Inspect 0.1
Rear Replace 0.5
Steps, Rear Inspect 0.1
Replace 0.5 1,2
Repair 0.6 1,2
Litter Rack, Upper Inspect 0.1
Replace 1.5 1,2
Doors, Stowage Inspect 0.1
Replace 1.0 1,2,139
Doors, Bulkhead Inspect 0.1
Replace 2.0 1,2,139
Extension Rails, Litter Repair 1.2 1,2
NBC Heaters and Brackets Inspect 0.1
Replace 0.8 1,2
NBC Filters and Brackets Inspect 0.1
Replace 0.7 1,2
Ambulatory Patient Seat Inspect 0.1
Replace 0.6 1,2
Heat/Vent Panel (M996,
M996A1) Replace 0.3 1,2
Heater (M996, M996A1) Adjust 1.5 1,6
Replace 0.8 1,2
Repair 3.5 1,6
Heater (M997, M997A1, Adjust 1.5 1,6
M997A2) Replace 0.8 1,2
Repair 3.5 1,6

Section II. MAINTENANCE ALLOCATION CHART (Cont'd)

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function F H Ref Code Code
C O D
20 WINCH
2001 Winch Assembly Service 0.2
Replace 0.6 1,2
Repair 4.0 1,9,159
Cable, Winch Inspect 0.5
Service 0.5 1
Replace 0.4 1,2
Control Assembly, Winch Inspect 0.1
Replace 0.1 1,2
22 BODY ACCESSORY ITEMS
2201 Bows Inspect 0.1
Service 0.5
Replace 1.0 1
Repair 0.5 1
Cover, 2-Door Cab Inspect 0.1 1
Service 0.5
Replace 0.5 1
Repair F 1,7 F
Cover, 4-Door Cab Inspect 0.1 1
Service 0.5
Replace 1.5 1
Repair F 1,7 F
Cover, 2-Door Cargo Inspect 0.1
Service 0.5
Replace 1.0 1
Repair F 1,7 F
Cover, 4-Door Cargo Inspect 0.1
Service 0.5
Replace 1.0 1
Repair F 1,7 F
Door, Front Inspect 0.1
Service 0.1
Adjust 0.4 1,2
Replace 0.2 1 F
Repair F 1,7 F
Cover, Rear Door Inspect 0.1
Service 0.1
Replace 0.2 1
Repair F 1,7 F
Curtain, Body Cover Inspect 0.1
Service 0.5
Replace 1.0 1
Repair F 1,7 F

Section II. MAINTENANCE ALLOCATION CHART (Cont'd) TM 9-2320-280-20-3

(1) (2) (3) (4) (5) (6)
Maintenance Level Tools and
Group Maintenance Unit Direct Support General Support Depot Equipment Remarks
Number Component/Assembly Function Ref Code Code
C O F H D
2202 Motor, Windshield Wiper Test 0.3 2
Replace 0.5 1,2
Arm Assembly, Wiper Inspect 0.1
Replace 0.2 1,2
Linkage, Wiper Replace 0.5 1
Motor and Reservoir Test 0.2 2
Assembly, Washer Service 0.2 1
Replace 0.1 1,2
Nozzle, Washer Replace 0.5 1
Mirror, Rearview Inspect 0.1
Adjust 0.1
Replace 0.2 1,2
Reflectors Replace 0.2 1
Steering Wheel Lock Replace 1.0 1,139
2207 Ducting, Defroster and Heater Replace 1.0 1
Controls, Defroster and Heater Replace 1.0 1
Heater Assembly Replace 1.4 1,2
2210 Data Plates Replace 0.5 1,139
33 SPECIAL PURPOSE KITS
3303 Arctic Winterization Kit Install 8.0 6,139-142
Arctic Heater Kit Install 8.0 6,139-142
Pump and Lines, Fuel Inspect 0.1 0.2
Replace 1.0 1,2
Heater Inspect 0.1
Replace 0.2 1
Control, Heater Replace 0.5 1
Repair 1.0 1
2-Man Crew Top Kit Install 2.0 139
Cover, 2-Door Cab Inspect 0.1
Replace 0.5 1
Repair F 7 F
Curtain, Body Cover Inspect 0.1
Replace 0.5 1
Repair F 7 F
3305 Deep Water Fording Kit Install 4.0 1,2
Snorkel, Intake and Exhaust Inspect 0.2 0.2
Install 2.0
Replace 1.5 2
Venting Inspect 0.1 0.1
Replace 1.0 1

Section II. MAINTENANCE ALLOCATION CHART (Cont'd)

(1) (2) (3) (5) (6)
Group Maintenance Maintenance Level Direct General Tools and Remarks
Number Component/Assembly Function Unit Support Support Depot Equipment Ref Code Code
C O F H D
3307 100 AMP Alternator Kit Inspect 0.2
Test 0.3 4
Install 2.5 2
Replace 1.0 2
Repair 1.0 9
Troop Seat Kit Inspect 0.1
Install 2.0 1,2
Replace 0.8 2
Repair 1.0 4
Communications Kit Install 3.0 1,2
Replace F 1 F
47 GAGES (NON-ELECTRICAL)
4701 Speedometer Replace 0.2 1
Cable and Housing Replace 0.5 1
4702 Gage, Air Restriction Inspect 0.1
Replace 0.1 1
52 AIR CONDITIONER
Ambulance (M997, M997A1,
M997A2)
5203 Compressor, A/C Replace 1.5 1,2,19,19.1
Repair 3.0 1,2,143
Bracket Mounting, Replace 0.4 1
Compressor
5205 Service Valve, A/C Replace 0.6 2,19,19.1
5217 A/C Lines and Fittings Inspect 0.1
Replace 1.5 1,6,19,19.1
Air Conditioner Inspect 0.1
Test 0.3
Service 1.6 2,19,19.1,143
5230 Coil, Condensor Replace 1.6 2,19
5241 Coil, Evaporator Replace 2.0 2,19
Repair 0.4 2
5243 Blower Motor, Condenser Replace 0.8 1
Blower Motor, Evaporator Replace 1.0 1
Repair 0.6
5246 Bottle, Dryer Replace 0.3 1

Section Iii. Tool And Test Equipment Requirements

(1) Reference Code (2) Maintenance Category (3) Nomenclature (4) National/NATO Stock Number (5) Tool Number
1 O Tool Kit, General Mechanic's 5180-00-177-7033 SC5180-90-CL-N26
Automotive
2 O Shop Equipment, Automotive Maintenance and Repair: 4910-00-754-0654 SC4910-95-CLA74
Organizational Maintenance,
Common #1, Less Power
3 O Shop Equipment, Automotive 4910-00-754-0653 SC4910-95-CLA73
Maintenance and Repair:
Organizational Maintenance,
Supplemental #1, Less Power
4 O Shop Equipment, Automotive 4910-00-754-0650 SC4910-95-CLA72
Maintenance and Repair:
Organizational Maintenance,
Common #2, Less Power
5 O Tool Kit, Body and Fender 5180-00-754-0643 SC5180-90-N34
6 F Shop Equipment, Automotive 4910-00-754-0705 SC4910-95-CLA31
Maintenance and Repair: Field
Maintenance, Basic, Less Power
7 F Shop Equipment, Automotive 4910-00-754-0706 SC4910-95-CLA62
Maintenance and Repair: Field
Maintenance, Supplemental #1,
Less Power
8 F Shop Equipment, Automotive Maintenance and Repair: Field 4910-00-754-0707 SC4910-95-CLA63
Maintenance, Supplemental #2,
Less Power
9 F Shop Equipment, Fuel and Electrical 4940-00-754-0714 SC4910-95-CLA01
System Engine: Field Maintenance,
Basic, Less Power
10 F Shop Equipment, Automotive 4910-00-348-7696 SC4910-95-CLA02
Maintenance and Repair: Field
Maintenance, Wheeled Vehicles, Post,
Camp and Station, Set A
11 O Special Tool Kit, Organizational 5180-01-387-5455 57K0267
11.1 O Special Tool Kit, Organizational, 5180-01-410-8467 57K3219
Supplemental ("A2" series only)
12 F Special Tool Kit, Direct Support 5180-01-389-7560 57K0268
13 H Special Tool Kit, General Support 5180-01-389-7561 57K0266
13.1 H Special Tool Kit, General Support, 5180-01-408-7050 57K3218
Supplemental ("A2" series only)
13.2 H Special Tool Kit, General Support, 5180-01-357-9692 57K0236
Supplemental Transmission

Section Iii. Tool And Test Equipment Requirements

(1) Reference (2) Maintenance (3) (4) National/NATO (5) Tool
Code Category Nomenclature Stock Number Number
NOTE
The optional metric tool sets listed below are required for maintenance of this
vehicle.
14 O Metric Wrench Set, 10-32 mm, 5120-01-119-0010 OEXM719K
Open End/Box End
15 O Metric Socket Set, 6-26 mm, Std., 6 pt., 5120-01-117-3876 221FSMY
3/8 in. Drive
16 F Metric Socket Set, Std., 6 pt., 5120-01-112-9543 B107.5
3/8 in. Drive, Deep Reach
17 F Metric Allen Wrench Kit 5120-01-046-5079 B18.3.2M
18 F Metric Tap and Die Kit 5136-01-119-0005 TDM99117
19 F Tool Kit, Service Refrigeration Unit 5180-00-596-1474 SC5180-90-CL-N18
19.1 F Parts Kit, FR-12 Refrigerant 4130-01-452-8773 57K3534
01 ENGINE
20 F Adapter, Compression Gage 4910-01-238-2551 J 26999-30
21 F Quick Disconnect 4730-01-842-5266 J 25209
22 F 90° Elbow 4730-00-985-4804 MS51815-4P
23 F Remover, Hydraulic Valve Lifter 5120-01-209-6870 J 29834
24 DELETED
25 F Engine Lifting Sling 4910-01-193-7808 J 33139
26 F Tester, Engine Compression 4910-00-785-6437 J 6692A
27 DELETED
28 DELETED
29 DELETED
30 DELETED
31 DELETED
32 DELETED
33 DELETED
34 DELETED
35 DELETED
36 DELETED
37 DELETED

Section Iii. Tool And Test Equipment Requirements

(1) Reference Code (2) Maintenance Category (3) Nomenclature (4) National/NATO Stock Number (5) Tool Number
38 DELETED
39 DELETED
40 DELETED
41 F Gauge, Timing 6620-01-231-3671 MT95
42 F Meter, Dynamic Timing 5180-01-186-3114 J 33127
43 DELETED
44 H Stand - Engine Repair 4910-00-506-0037 1725A
45 DELETED
46 H Installer, Crankshaft Rear Oil Seal (6.2L) 5120-01-210-8792 J 33153
H Installer, Crankshaft Rear Oil Seal (6.5L) 5120-01-422-0334 J 39084
47 H Remover and Installer, Camshaft Bearings 5120-01-206-3818 J 35178
48 O Pliers, Needle Nose, 90° 5120-01-174-4496 497ACP
03 FUEL SYSTEM
49 F Remover, Fuel Injection Nozzle 5120-01-171-5233 J 29873
50 H Installer, Drive Shaft Bearing 5120-01-208-7771 23805
51 H Installer, Drive Shaft Seal 5120-01-208-7752 22727
52 H Kit, Throttle and Shutoff Shaft Bushing 5180-01-189-0448 18411
53 H Socket, Torx Drive, T27 5120-01-367-3534 FTX27A
54 H Support, Governor Weight 5120-01-197-0236 16313
55 H Wrench, End Cap 5120-01-207-5563 20548
56 H Roller to Roller Setting Tool 5120-01-200-4526 19969
57 H Fixture, Holding 5120-01-208-7753 23615
58 H Mandrel, Pilot Tube 5120-01-208-1767 16314
59 H Extractor, Delivery Valve Test Set 5120-00-816-7059 26081
60 DELETED
61 H Linkage Gap Tool 5210-01-249-0370 23080
62 H Indicator, Automatic Advance 5210-01-249-0368 23745
63 O Block, Throttle Lever Gauge 4820-01-179-4869 J 33043
64 H Protractor 6675-01-247-2286 22089

Section Iii. Tool And Test Equipment Requirements Section Iii. Tool And Test Equipment Requirements

Reference (2) Maintenance (3) (4) National/NATO (5) Tool
Code Category Nomenclature Stock Number Number
H Gage, Air Timing 5220-01-247-0361 23715
05 COOLING SYSTEM
66 O Tester, Radiator 4910-00-728-8227 ST255A
O Gage, Belt Tension 6635-01-093-3710 J 23600B
06 ELECTRICAL SYSTEM
F Socket, Torx 5120-01-227-3159 TLE60
O Starter Pinion Core Shaft Nut Driver 9530-00-236-7723 MS14267C001
07 TRANSMISSION (3L80)
H Fixture, Transmission Holding 5120-01-198-7583 J 8763-02
71 H Base, Transmission Holding Fixture 5120-01-144-4484 J 3289-20
H Holding Tool, Transmission Gear Unit Assembly 4910-01-178-8865 J 21795-02
73 H Adapter, Slide Hammer, 3/8-16 5120-01-130-8865 J 6471-2
74 H Bushing Service Set 5180-01-195-9777 J 21465-01
O Driver Handle 5120-00-677-2259 J8092
H Compressor, Clutch Spring 5120-01-210-8793 J 4670-01
H Adapter, Clutch Spring Compressor 4910-01-210-1318 J 21664
78 H Gage, Band Apply Selector 4910-01-178-0722 J 21370
H Alignment Tool, Intermediate Clutch Pack 4910-01-209-0729 J 24396
F Installer, Oil Pump Seal 5120-01-176-1845 J 21359A
07 TRANSMISSION (4L80-E)
H Adapter, Holding Tool, Use W/J 8763-02 5120-01-422-1326 J 38655
H Adapter, Torque, 3/8 5120-01-367-3536 FTX40A
83 H Removal/Installer Tool, Oil Pump 5120-01-422-1308 J 37789-A
H Installer/Remover, Gear Unit 5120-01-422-1300 J 38868-A
H Adapter, Clutch Compressor Spring , Use W/J 23327 5120-01-422-1329 J 38734
(1) 65 67 68 69 70 72 75 76 77 79 80 81 82 84 85
(1) Reference Code (2) Maintenance Category (3) Nomenclature (4) National/NATO Stock Number (5) Tool Number
86 H Seal Protectors, Forward Clutch Piston, Kit Includes J 38732-1 and J 21362-1 5120-01-422-1301 J 38732
87 H Compressor, Clutch Spring 4910-01-178-0724 J 23327
88 H Adapter, Compressor, Clutch Spring, Use W/J 23327 5120-01-410-8216 J 25018-A
89 H Seal Piston and Housing, Fourth Clutch, Includes J38731-1, J38731-2, J38731-3 5180-01-422-0138 J 38731
90 H Installer/Sizer/Pusher, Turbine Shaft Seal, Includes J38736-1, J38736-2, J38736-3, J38736-4, J38736-5, J38736-6 5120-01-422-7051 J 38736
91 H Installer/Sizer/Pusher, Oil Pump Seal Ring J 38739-1, J 38739-2, J 38739-3 5180-01-422-1294 J 38739
92 H Gauge Pin, Band Apply, Use W/J 38737 5120-01-422-0032 J 21370-10
93 H Tool Pin Checking, Band Apply 5120-01-422-1313 J 38737
93.1 O Jumper, Throttle Position Sensor Adjustment 6150-01-412-7774 12460120
93.2 O Case, Transmission Diagnostic Cable 5120-01-408-8173 12460136
93.3 O Diagnostic Switch Cable 6150-01-410-8215 12460137
08 TRANSFER (218)
94 O Installer, Yoke Seal 4910-01-179-5530 J 29162
95 H Adapter, Slide Hammer 5120-01-391-5131 J 6471-8
96 H Installer, Front Output Shaft Rear Bearing 5120-01-195-2721 J 29163
97 H Installer, Rear Output Shaft Bearing 5120-01-196-0084 J 29166
98 H Installer, Front Output Shaft Front Bearing 5120-01-170-3278 J 29167
99 H Remover, Front Output Shaft Front Bearing 5120-01169-4876 J 29168
100 H Remover, Universal Bearing and Bushing 5120-01-201-7857 J 29369
101 H Remover, Input Gear Bearing 5120-01-195-4551 J 29170
102 H Installer, Input Gear Bearing 5120-01-185-7955 J 29169

Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS

Section Iii. Tool And Test Equipment Requirements

(1) (2) (3) (4) (5)
Reference Code Maintenance Category Nomenclature National/NATO Stock Number Tool Number
103 H Installer, Rear Retainer Bearing 5120-01-185-8024 J 7818
104 H Installer, Main Shaft Bearing 5120-01-265-4872 J 36307
105 H Remover, Annulus Gear Bushing 5120-01-185-7956 J 29185
106 H Installer, Annulus Gear Bushing 5120-01-247-6629 J 29185-2
107 O Mirror, Inspection 5120-00-618-6902 J 35219
08 TRANSFER (242)
108 H Installer, Bushing Remover/Bearing 5120-01-357-3633 J 33826
109 H Installer, Mainshaft Pilot Bearing 5120-01-389-9992 J 39636
110 H Installer, Input Gear Seal 5120-01-357-3632 J 33831
111 H Installer, Output Shaft Front Bearing 5120-01-357-3630 J 33833
112 H Installer, Output Shaft Seal 5120-01-227-1680 J 22661
113 H Remover, Extension Housing Bushing 5120-01-357-3631 J 33839
114 H Bearing Tool 5120-01-357-9123 J 9276-3
115 H Installer, Extension Housing Seal 5120-01-361-3101 J 33843
116 H Installer, Bearing and Bushing 5120-01-185-7960 J 29174
116.1 O Installer, Inserter 5120-01-144-1849 J 38869
116.2 O Installer, Seal 5120-01-437-0480 6888
116.3 O Handle, Drive 5120-01-026-1666 C-4171
116.4 H Installer, Output Shaft, Rear Bearing 5120-01-477-6860 J 33832 or
5742628
10 AND 11 FRONT AND REAR AXLE
117 F Installer, Axle Shaft and Seal 5120-01-187-3659 J 33142
118 H Adapters, Axle Holding Fixture 5120-01-218-8235 J 33149-A
119 H Spreader, Differential Housing 4910-00-105-2823 W129
120 H Remover, Pinion Rear Bearing Cup 5120-01-185-7957 J 21786
121 H Remover, Pinion Front Bearing Cup 5120-01-187-3660 J21787
122 H Installer, Pinion Rear Bearing Cup 5120-01-185-7962 J 8608
123 H Installer, Pinion Front Bearing Cup 5120-01-185-7964 J 8611-01
124 H Set, Pinion Setting Gage 5180-01-216-8643 J 35199
125 H Set, Pinion Setting Gauge 5180-01-363-8079 J 39524
126 O Installer, Geared Hub Input Seal 5120-01-187-3607 J 33143
(1) Reference Code (2) Maintenance Category (3) Nomenclature (4) National/NATO Stock Number (5) Tool Number
127 O Wrench, Geared Hub Locknut 5120-01-185-7963 J 33144
128 O Installer, Geared Hub Spindle Seal 5120-01-229-0842 J 35184
129 O Pickle Fork 5120-00-880-4268 11595179
13 WHEELS AND TIRES
130 O Bubble Balancer 4910-01-093-0167 MIL-B-45989
131 O Runflat Compressor 5120-01-335-5847 J 39250 or
528236
14 STEERING SYSTEM
132 F Remover and Installer, Adjuster Plug Bearing 5120-01-185-7965 J 6221
133 F Remover and Installer, Pitman Shaft Bearing 5120-01-082-6447 J 6278
134 F Wrench, Spanner 5120-01-082-6436 J 7624
135 F Arbor, Rack Piston 5120-01-179-1032 J 21552
136 O Analyzer, Power Steering 4910-01-185-7966 12342943
137 O Installer, Power Steering Pump Pulley 4910-01-179-2517 J 25033-B
138 O Adapter 5120-01-231-1709 J 33141
138.1 H Equipment, Alignment 4910-01-154-1820 DFP 134
18 BODY AND HOOD
139 O Tool Kit, Riveter 5180-01-201-4978 D-100-MIL-1
140 F Puller, Head, Right Angle 5130-01-044-7196 H763-456
141 F Puller, Head, Offset 5130-01-329-0509 H781-456
142 F Puller, Head, Straight 5130-01-104-5370 H749A-456
52 AIR CONDITIONER
143 F Tool Kit, Compressor 5180-01-267-2907 J 29642-C
MULTIPURPOSE TOOLS
144 O Adapter, Torque, 9/16 in. 5120-01-367-3582 SRES 18

Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS

Section Iv. Remarks

(1) (2) (3) (4) (5)
Reference Maintenance National/NATO Tool
Code Category Nomenclature Stock Number Number
145 O Adapter, Torque, 3/4 in. 5120-01-367-3585 SRES 24
146 O Adapter, Socket, 3/8 in. to 1/2 in. Drive 5120-00-240-8702 11655788-2
147 F Crowfoot, 3/8 in. Drive, 16 mm 5120-01-242-8165 J 35159
148 F Crowfoot, 1/2 in. Drive, 19 mm 5120-01-230-9421 J 35160
149 O Crowfoot, 3/8 in. Drive, 5/8 in. 5120-00-184-8398 FC20
150 O Crowfoot, 3/8 in. Drive, 9/16 in. 5120-01-335-1094 FC 18A
151 O Crowfoot, 3/8 in. Drive, 15/16 in. 5120-01-335-1100 FC-30A
152 O Crowfoot, 3/8 in. Drive, 14 mm 5120-01-079-8023 FCOM14
153 O Crowfoot, 3/8 in. Drive, 7/8 in. 5120-01-335-1099 FC-28A
154 O Crowfoot, 3/8 in. Drive, 11/16 in. 5120-01-335-1096 FC-22A
155 O Socket, Deep Well, 12 pt., 3/8 in. 5120-00-277-1463 FVS121
156 O Driver, Hex-Head, 8 mm 5120-01-053-4159 FAM8A
157 O Driver, Hex-Head, 6 mm 5120-01-055-1308 FAM6A
158 O Driver, Hex-Head, 1/8 in. 5120-01-016-9202 J 35171
159 F Driver, Hex-Head, 5/32 in. 5120-01-367-3456 FA5A
160 O Driver, Hex-Head, 1/4 in. 5120-00-596-8508 FA8A
161 O Driver, Hex-Head, 5/16 in. 5120-00-683-8602 FA10B
162 O Driver, Hex-Head, 7 mm 5120-01-437-3658 FAM 7
163 O Driver, Hex-Head, 3/16 in. 5120-00-683-8597 FA6A
164 O "C" Clamp 5120-01-180-0908 A-A-429
165 O Connector Repair Kit 5180-00-876-9336 7550526
166 O Multimeter 6625-01-139-2512 AN/PSM-45

Appendix C Expendable/Durable Supplies And Materials List

SECTION I. INTRODUCTION

C-1. Scope

This appendix lists expendable/durable supplies and materials you will need to maintain the M998 series vehicles. These items are authorized to you by CTA 50-970, Expendable Items (Except Medical, Class V, Repair Parts, and Heraldic Items).

C-2. Explanation Of Columns

a. Column (1)-Item Number. This number is assigned to each entry in the listing and is referenced in "Initial Setup" of applicable tasks under the heading of "Materials/Parts." b. Column (2)-Level. This column identifies the lowest level of maintenance that requires the listed item.

C - Operator/Crew O - Unit 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 listing indicates the Commercial and Government Entity Code (CAGEC) in parentheses followed by the part number. e. Column (5) - Unit of Measure (U/M). Indicates the measure used in performing the actual maintenance function. This measure is expressed by an alphabetical abbreviation (QT, GAL.). If the unit of measure differs from the unit of issue, requisition the lowest unit of issue that will satisfy your requirements.

(1) REMARKS (2)
CODE REMARKS
A Calibration time will be established when support equipment requirements are identified.
B Operator drains water from fuel filter assembly. All other service is performed at unit level.
C Operator replenishes coolant. All other service is performed at unit level. D Operator inspects shift lever. All other inspections are performed at unit level.
E Direct support maintenance repairs coupling shaft by replacing center bearing. All other repair is performed at unit level.
F In this category, no specific times can be established. Time required for repair will depend on the extent of repair required for damaged components.
G Simplified test equipment/internal combustion engine (STE/ICE-R) testing times may vary depending on the type of tests being performed.
H For vehicles with new brake adapters, P/N 10453002. I It is authorized to remove spindle to replace the seal. All other repair is performed
at direct support level. J Runflat compressor to be used with rubber runflat.
K If the puller kit is not available at unit level, it can be found in the GSA catalogue, Blind Hole Puller Set, NSN 5120-00-140-3557.
L This tool can be found in the MCRL or GSA catalogue, Manometer, U-Tube, NSN 6685-00-857-4895.
M Fan shroud repair is limited to repairs that can be made using fiberglass repair kit (Appendix C, Item 50). Only these repairs that can be made while the shroud is
installed on the vehicle are authorized. N Operator can remove and replace wheel assembly, but must notify unit maintenance
to tighten lug nuts to proper torque as soon as possible. O Direct support replaces fuel injection pump governor cover gasket, shut-off solenoid,
and cold advance solenoid. P Direct support can reseal transfer case and rear transfer case housing with silicone
sealant (RTV), NSN 6850-01-159-4844.

Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST

Section Ii. Expendable/Durable Supplies And Materials List (Cont'D)

(1) (2) (3) (4) (5)
ITEM NATIONAL STOCK
NUMBER LEVEL NUMBER DESCRIPTION U/M
1 O ADHESIVE: plastic cement
(04963) 1099
8040-01-126-1422 1 Quart Can QT
2 O ADHESIVE: ethyl-2-cyanoacrylate, low viscosity
(81349) MIL-A-46050C
8040-00-826-3535 1 Ounce Bottle OZ
2.1 O ADHESIVE: sealant, gray, Uniroyal
(89619) SILAPRENE M6325-11
8030-01-347-0964 11 Ounce Cartridge OZ
3 O ADHESIVE: silicone, black
(01139) RTV-103
8040-00-865-8991 12 Ounce Cartridge OZ
4 O ADHESIVE: synthetic, rubber
(GA100AJ1)
8040-00-165-8614 1 Quart Can QT
5 O ADHESIVE: silicone, RTV
(81349) MIL-A-46164
8040-00-938-1535 12 Ounce Cartridge OZ
6 O ADHESIVE: plumbing, solvent cement
(81349) MIL-A-22010
8040-00-573-1502 1 Pint Container PT
7 O ADHESIVE: type II, class II
(80244) MIL-A-46050-C
8040-01-167-2613 5 Ounce Tube OZ
8040-01-090-9320 1 Pint PT
8 O ADHESIVE: general trim, spray
(04963) 051135 08080
8040-01-215-3426 24 Ounce Can OZ
9 O ADHESIVE SEALANT: RTV silicone rubber, clear
(71984) SILASTIC 737 RTV
N/A 3 Ounce Tube OZ
N/A 10.3 Ounce Cartridge OZ
N/A 5.5 Gallon Pail GAL.
9.1 O ADHESIVE:
(71984) 732 RTV
8040-00-078-9774 6 Ounce Cartridge OZ
(1) (2) (3) (4) (5)
ITEM NATIONAL STOCK
NUMBER LEVEL NUMBER DESCRIPTION U/M
10 O ADHESIVE-SEALANT: silicone, RTV, general purpose
8040-00-833-9563 (80244) MIL-A-46106, type I 5 Ounce Tube OZ
11 C ANTIFREEZE: arctic-type
(81349) MIL-A-11755
6850-00-174-1806 55 Gallon Drum GAL.
12 C ANTIFREEZE: ethylene glycol, inhibited heavy-duty, single package
(81349) MIL-A-46153
6850-00-181-7929 1 Gallon Container GAL.
6850-00-181-7933 5 Gallon Container GAL.
13 O ANTISEIZE COMPOUND: conductive (81349) MIL-A-907
8030-00-059-2761 1 Pound Can LB
14 C BRAKE FLUID: silicone, automotive, all weather, operational and preservative
(81349) MIL-B-46176
9150-01-102-9455 1 Gallon Can GAL.
9150-01-123-3152 5 Gallon Can GAL.
15 CHALK, MARKING: (81348) SS-C-255
7510-00-223-6701 1 Gross GR.
16 O CLEANING AND LUBRICATING COMPOUND: electrical (81349) MIL-C-83360
6850-00-003-5295 16 Ounce Can OZ
17 C DETERGENT: general purpose, liquid (81349) MIL-D-16791
7930-00-282-9699 1 Gallon Container GAL.
17.1 C DETERGENT: laundry (81348) PD-245
7930-00-985-6904 20 oz. box OZ
18 C DRYCLEANING SOLVENT: (81348) P-D-680, type II
6850-00-110-4498 1 Pint Can PT
6850-00-274-5421 5 Gallon Drum GAL.
6850-00-285-8011 55 Gallon Drum GAL.
6850-00-637-6135 Bulk GAL.

Section Ii. Expendable/Durable Supplies And Materials List (Cont'D)

Section Ii. Expendable/Durable Supplies And Materials List (Cont'D)

(1) (2) (3) (4) (5)
ITEM NUMBER LEVEL NATIONAL STOCK NUMBER DESCRIPTION U/M
19 C FUEL OIL: diesel, regular, DF-2 (81348) VV-F-800
9140-00-286-5295 5 Gallon Can GAL.
9140-00-286-5296 55 Gallon Drum GAL.
20 C FUEL OIL: diesel, winter, DF-1 (81348) VV-F-800
9140-00-286-5287 5 Gallon Drum GAL.
9140-00-286-5288 55 Gallon Drum GAL.
21 C FUEL OIL: diesel, arctic, DF-A (81348) VV-F-800
9140-00-286-5282 5 Gallon Can GAL.
9140-00-286-5284 55 Gallon Drum GAL.
22 C GREASE: automotive and artillery (81349) MIL-G-10924
9150-00-935-1017 14 Ounce Cartridge OZ
9150-00-190-0904 1-3/4 Pound Can LB
9150-00-190-0905 6-1/2 Pound Can LB
23 O GREASE: ball and roller bearing (73219) 18901
9150-01-095-5512 Case, 24/14 Ounce Cans OZ
24 O GREASE: dielectric colloid (72872) 112X
N/A 1 Gallon Container GAL.
25 O GREASE: lithium base w/molybdenum disulfide (60218) LS2267
9150-01-015-1542 14.5 Ounce Cartridge OZ
26 C HYDRAULIC FLUID: transmission (24617) Dexron® II
9150-00-698-2382 1 Quart Can QT
9150-00-657-4959 5 Gallon Can GAL.
27 C HYDRAULIC FLUID: transmission (24617) Dexron® III
9150-01-353-4799 1 Quart Can QT
1950-01-114-9968 55 Gallon Drum GAL.
27.1 O LUBRICANT: run flat (62161) 12460308-1 55 Gallon Drum GAL.

Change 1 C-5

Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (Cont'd)
(1) (2) (3) (4) (5)
ITEM NATIONAL STOCK
NUMBER LEVEL NUMBER DESCRIPTION U/M
28 C LUBRICATING OIL: gear, multipurpose, GO 75
(81349) MIL-L-2105
9150-01-035-5390 1 Quart Can QT
9150-01-035-5391 5 Gallon Drum GAL.
29 C LUBRICATING OIL: gear, multipurpose, GO 80/90
(81349) MIL-L-2105
9150-01-035-5392 1 Quart Can QT
9150-01-035-5393 5 Gallon Drum GAL.
30 C LUBRICATING OIL: internal combustion
engine, arctic, OEA
(81349) MIL-L-46167
9150-00-402-4478 1 Quart Can QT
9150-00-402-2372 5 Gallon Drum GAL.
9150-00-491-7197 55 Gallon Drum GAL.
31 C LUBRICATING OIL: internal combustion
engine, tactical service, OE/HDO 10
(81349) MIL-L-2104
9150-00-189-6727 1 Quart Can QT
9150-00-186-6668 5 Gallon Can GAL.
9150-00-191-2772 55 Gallon Drum GAL.
32 C LUBRICATING OIL: internal combustion
engine, tactical service, OE/HDO 30
(81349) MIL-L-2104
9150-00-186-6681 1 Quart Can QT
9150-00-188-9858 5 Gallon Drum GAL.
9150-00-189-6729 55 Gallon Drum GAL.
33 O LUBRICATING OIL: general purpose,
corrosion resistant and oxidation resistant
(92895) PQRUSTPREVENTIVENO172
9150-00-273-2389 4 Ounce Can OZ
34 C LUBRICATING OIL: internal combustion
engine, tactical service, OE/HDO 15/40
(81349) MIL-L-2104
9150-01-152-4117 1 Quart Can QT
9150-01-152-4118 5 Gallon Drum GAL.
9150-01-152-4119 55 Gallon Drum GAL.

Section Ii. Expendable/Durable Supplies And Materials List (Cont'D)

(1) (2) (3) (4) (5)
ITEM NATIONAL STOCK
NUMBER LEVEL NUMBER DESCRIPTION U/M
35 C PRIMER, ADHESIVE: spray
(81349) MIL-A-46050C
8010-01-826-3535 15 Ounce Can OZ
36 C RAG: wiping, cotton and
cotton-synthetic
(58536) A-A-531
7920-00-205-1711 50 Pound Bale LB
37 O REPAIR KIT, Glass Reinforcement
Plastic Laminate
(81349) MIL-R-19907D
2090-00-372-6064 1 Kit KT
38 O SEALANT: silicone, RTV
(11862) 1052734
6850-01-159-4844 8-1/2 Ounce Tube OZ
39 O SEALING COMPOUND
(05972) 51831
8030-01-374-3504 50 Milliliter Tube ML
8030-01-374-2338 300 Milliliter Cartridge ML
40 O SEALING COMPOUND: adhesive, elastomeric
(00333) M6325-11OZ
8030-01-347-0964 11 Ounce Cartridge OZ
41 O SEALING COMPOUND: anaerobic, adhesive/sealant
(05972) 272-40
8030-01-171-7628 50 CC Bottle CC
42 O SEALING COMPOUND: canvas
(81349) MIL-A-46106
8040-01-010-8758 1 Quart QT
43 O SEALING COMPOUND: corrosion-resistant
(81349) MIL-S-81733, type II
8030-00-009-5023 Kit EA
44 O SEALING COMPOUND: pipe,
anaerobic, with teflon
(05972) 59231
8030-01-054-0740 50 Milliliter Tube ML
45 O SEALING COMPOUND:
thread-locking, high strength
(80244) MIL-S-46163, type I, grade K
8030-00-148-9833 10 CC Bottle CC

Appendix D Illustrated List Of Manufactured Items

Section I. Introduction D - 1 . S C O P E

This appendix includes complete instructions for making items authorized to be manufactured or fabricated at unit maintenance.

D - 2 . G E N E R A L

a . A part number index in alphanumeric order is provided for cross-referencing the part number of the item to be manufactured to the figure which covers fabrication criteria.

b . All bulk materials needed for manufacture of an item are listed by part number or specification number in a tabular list on the illustration.

Table D-1. Manufactured Items Part Number Index.

48 O SILICONE COMPOUND: dielectric colloid,
non-melting, heat stable, NATO code no. S-736 (81349) MIL-S-8660
6850-00-880-7616 8 Ounce Tube OZ
6850-00-295-7685 10 Pound Can LB
49 O SODIUM BICARBONATE:
technical (baking soda)
(81348) O-S-576
6810-00-264-6618 1 Pound Box LB
6810-00-290-5574 100 Pound Bag LB
50 O TAPE: pressure-sensitive adhesive,
polyester film, transparent, 1 in. wide, 2 mil thick
(80063) SMA597833-3
7510-00-149-0732 72 Yard Roll YD
51 O TAPE: pressure-sensitive adhesive,
masking, flat, 1 in. width
(19203) 8790710
7510-00-283-0612 60 Yard Roll YD
52 O TAPE: hook and pile material
(81349) MIL-F-211840
8315-01-115-7617 YD
53 O TWINE: fibrous, cotton
(string) 16-ply
(81348) T-T-871
4020-00-291-5901 375 Yard Spool YD
APPENDIX D
ILLUSTRATED LIST OF MANUFACTURED ITEMS
Section I. INTRODUCTION
D - 1 . S C O P E
This appendix includes complete instructions for making items authorized to be manufactured or fabricated
at unit maintenance.
D - 2 . G E N E R A L
a . A part number index in alphanumeric order is provided for cross-referencing the part number of the
item to be manufactured to the figure which covers fabrication criteria.
b . All bulk materials needed for manufacture of an item are listed by part number or specification number
in a tabular list on the illustration.
Table D-1. Manufactured Items Part Number Index.
PART NO. FIGURE NO. PART NO. FIGURE NO. PART NO. FIGURE NO.
MS51331-1 D-88 5573534 D-35 5584373 D-37
MT161A D-90 5574986 D-21 5584383 D-15
M23053/1-204-0 D-61 5575468 D-24 5584707 D-21
M23053/7-204-2 D-61 5577552 D-35 5584813 D-22
M23053/4-303-0 D-1 5578874 D-39 5584836 D-22
M23053/4-303-2 D-1 5578875 D-39 5584892 D-39
M232053/4-304-2 D-2 5578876 D-39 5584893 D-39
RR-C-271 D-15.1 5578877 D-39 5588617-7.5 D-33
RR-C-271-6 D-3 5578878 D-39 5588618-13 D-32
SF5575898 D-7 5578887 D-9 5588698 D-8
SF5585243 D-16 5578910 D-10 5588767 D-11
SF5585245 D-16 5578911 D-11 5589086 D-29
SF5585258 D-16 5578940 D-30 5589275 D-31
SF5589035 D-4 5578999 D-12 5590023 D-14
SF5589036 D-4 5579007 D-11 5590024 D-14
SF5589037 D-5 5579008 D-10 5590025 D-14
SF5590706 D-26 5579997 D-13 5591157 D-37
SF5591372 D-6 5581213 D-27 5591158 D-37
SF5591612 D-25 5581366 D-34 5591159 D-37
SF5592748 D-4 5582451 D-62 5591161 D-37
12338591-1 D-94 5582479 D-14 5591168 D-37
12342947 D-94 5582641 D-37 5591180 D-15
12446730 D-95 5582642 D-37 5591210 D-36
12446770 D-86 5582643 D-37 5591253 D-37
12446771 D-87 5582645 D-37 5591482 D-37
12446821 D-62.1 5582646 D-37 5591483 D-37
14066306 D-18 5582648 D-15 5591681 D-15
15667 D-91 5582649 D-15 5591707 D-37
15847 D-38 5583183 D-14 5591937 D-14
15848 D-38 5583855 D-15 5591938 D-14
1775-826 D-17 5584173 D-37 5592085 D-58
23500024 D-11 5584188 D-28 5594083 D-36
23500084 D-19 5584372 D-15 5594278 D-23

Table D-1. Manufactured Items Part Number Index (Cont'd).

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.470 IN. INSULATION SLEEVING. MIL-I-23053
INSIDE DIAMETER HEAT SHRINK
HEAT SHRINK INSULATION SLEEVING
INSULATION CUT MANUFACTURED FROM
PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
M23053/4-303-0 1.5 M23053/4-303-0 (81349)
M23053/4-303-2 1.5 M23053/4-303-2 (81349)

Section Ii. Illustrated Manufacturing Instructions

HEAT SHRINK INSULATION SLEEVING
INSULATION CUT MANUFACTURED FROM
PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
M23053/4-304-2 2.0 M23053/4-304-2 (81349)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.940 IN. INSULATION SLEEVING. MIL-I-23053
INSIDE DIAMETER HEAT SHRINK

Figure D-1. Heat Shrink Insulation Sleeving INSTRUCTIONS: Cut insulation to length shown.

Figure D-2. Heat Shrink Insulation Sleeving INSTRUCTIONS: Cut insulation to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

TOWING PINTLE LOCK CHAIN
CHAIN CUT MANUFACTURED
PART NUMBER LENGTH FROM NSN
RR-C-271-6 6 LINKS 4010-00-129-3321
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
10 LINKS CHAIN, WELDLESS RR-C-271. TYPE II. CLASS 2
DEFROSTER FLEX DUCTING
ITEM DUCTING CUT MANUFACTURED FROM
NO. PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
SF5589035 37 FLX4001-16057600 (16632)
N SF5589036 7 FLX4001-16057600 (16632)
8 SF5592748 19 FLX4001-16057600 (16632)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
20 IN. INSIDE DIAMETER DUCT. FLEX ASTM D 1149

Figure D-3. Towing Pintle Lock Chain INSTRUCTIONS: Cut chain to length shown.

Figure D-4. Defroster Flex Ducting

Instructions:

Determine ducting part number needed from RPSTL and cut ducting to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

DEFROSTER FLEX DUCTING
DUCTING CUT MANUFACTURED FROM
PART NUMBER TENGTH PART NUMBER (CAGEC)
(INCHES)
SF5589037 33-1/2 FLX4001-12057600 (16632)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.50 IN. INSIDE DIAMETER DUCT. FLEX ASTM D1149
----------------- --------
DEFROSTER FLEX DUCTING
DUCTING CUT MANUFACTURED FROM
PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
SF5591372 8.50 FLX4001-24057600 (16632)
MATERIAL BLOCK
STOCK SIZE CONSULER COLLECTION COLLECTION COLLEGION COLLEGION COLLEGION COLLEGION COLLEGION COLLEGION COLLEGION COLLEGION COLLEGION COLLEGION COLLEGION COLLECTION CONTRACT COLLECTION CO DESCRIPTION SPECIFICATION
3.00 IN. INSIDE DIAMETER DUCT FLEX ASTM D1149

Figure D-5. Defroster Flex Ducting INSTRUCTIONS: Cut duct to length shown.

Figure D-6. Defroster Flex Ducting INSTRUCTIONS: Cut duct to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

BATTERY CABLE EDGE PROTECTOR
EDGE PROTECTOR CUT MANUFACTURED
PART NUMBER LENGTH FROM NSN
(INCHES)
SF5575898 3-7/8 5325-00-074-3301
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.200 IN. HEIGHT GROMMET, NONMETALLIC ASTM D-4066
0.162 IN. WIDTH
0.085 IN. OPENING

Figure D-7. Battery Cable Edge Protector

ARCTIC/AMBULANCE HEATER FUEL SUPPLY HOSE
HOSE CUT MANUFACTURED FROM:
PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
5588698 2-13/16 9438306 (11862)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.312 IN. ± 0.016 IN. INSIDE DIAMETER HOSE GM-6165-M
0.562 IN. ± 0.023 IN. OUTSIDE DIAMETER

Instructions:

Cut edge protector to length shown.

Figure D-8. Arctic/Ambulance Heater Fuel Supply Hose INSTRUCTIONS: Cut hose to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

FUEL CAN DRAIN HOSE
HOSE CUT MANUFACTURED FROM
PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
5578887 10-1/2 9436581 (11862)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.500 IN. INSIDE DIAMETER 0.750 IN. OUTSIDE DIAMETER HOSE, NONMETALLIC GM06147-M

Figure D-9 Fuel Can Drain Hose

FUEL SUPPLY HOSE
ITEM NO. HOSE PART NUMBER CUT LENGTH MANUFACTURED FROM NSN
(INCHES)
5578910 6-1/2 4720-01-159-5796
ટ 5579008 2-13/16 4720-01-159-5796
3 5740702 10 4720-01-185-9473
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.375 IN. ± 0.016 IN. INSIDE DIAMETER 0.625 IN. ± 0.023 IN. OUTSIDE DIAMETER HOSE. NONMETALLIC GM-6165-M

INSTRUCTIONS: Cut hose to length shown.

Figure D-10. Fuel Supply Hose

Instructions:

Determine hose part number needed from RPSTL and cut hose to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

FUEL HOSE
ITEM NO. HOSE PART NUMBER CUT LENGTH (INCHES) MANUFACTURED FROM HSN
1 23500024 হ্ন 4720-01-155-7784
2 5578911 9 4720-01-155-7784
3 5579007 2-13/16 4720-01-155-7784
র্ব 5588767 26 4720-01-155-7784
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0250 IN. ± 0.016 IN. INSIDE DIAMETER HOSE, NONMETALLIC GM-6165-M
0.500 IN. + 0.023 IN. 0141SIDE DIAMETER

Figure D-11. Fuel Hose

OVERFLOW HOSE
HOSE CUT MANUFACTURED
PART NUMBER LENGTH EROW HSN
(INCHES)
5578999 18-5/16 4720-01-185-6673
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.290 IN. ± 0.040 IN. INSIDE DIAMETER HOSE, NONMETALLIC ASTM D2000

Instructions:

Determine hose part number needed from RPSTL and cut hose to length shown.

Figure D-12. Overflow Hose

Instructions:

Cut hose to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

HEATER HOSE
HOSE CUT MANUFACTURED
PART NUMBER LENGTH FROM NSN
(INCHES)
5579997 2-1/2 4720-00-241-4435
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.62 IN. INSIDE DIAMETER 0.94 IN. OUTSIDE DIAMETER HOSE, NONMETALLIC SAE 20R3, CLASS D-1
CONNECTOR HOSES
IIIEM NO. HOSE PART NUMBER CUT LENGTH (INCHES) MANUFACTURED FROM NSN
5582479 3 4720-01-186-2358
5583183 19 4720-01-186-2358
5590023 23 4720-01-186-2358
5590024 41 4720-01-297-0255
5 5590025 27 4720-01-271-6955
6 5591937 7-1/4 4720-01-186-2358
7 5591938 10 4720-01-186-2358
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.367 IN. ± 0.023 IN. INSIDE DIAMETER 0.656 IN. ± 0.031 IN. OUTSIDE DIAMETER HOSE, NONMETALLIC GM-6210-M

Figure D-13. Heater Hose INSTRUCTIONS: Cut hose to length shown.

Figure D-14. Transmission Cooling Lines Connector Hoses and Steering Hydraulic System Hoses

Instructions:

Determine hose part number needed from RPSTL and cut hose to length shown.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

5597223 D-60 5598034 D-59 5598828 D-65
5597224 D-60 5598035 D-59 5598829 D-66
5597225 D-60 5598036 D-59 5598830 D-67
5597226 D-60 5598061 D-59 5598832 D-68
5597227 D-60 5598062 D-59 5598833 D-69
5597228 D-60 5598063 D-59 5598834 D-70
5597229 D-60 5598064 D-59 5598835 D-71
5597230 D-60 5598065 D-59 5598836 D-72
5597231 D-60 5598132 D-60 5598837 D-73
5597232 D-60 5598133 D-60 5598838 D-74
5597722 D-60 5598134 D-60 5598839 D-75
5597723 D-60 5598236 D-44 5598840 D-76
5597724 D-60 5598237 D-43 5598841 D-77
5597725 D-60 5598238 D-40 5598842 D-78
5595995 D-23 5597995 D-59 5598815 D-54
5597214 D-60 5597997 D-59 5598816 D-45
5597215 D-60 5597998 D-59 5598817 D-46
5597216 D-60 5597999 D-59 5598818 D-48
5597217 D-60 5598000 D-59 5598819 D-41
5597218 D-60 5598029 D-59 5598820 D-47

Figure D-15. Vent Line Hose.

FUEL CAP CHAIN
PART NUMBER CUT MANUFACTURED
LENGTH (INCHES) FROM NSN
RR-C-271 8 4010-00-958-0633
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
BULK CHAIN, WELDLESS RR-C-271, TYPE II, CLASS 7-16 |

Instructions:

Determine hose part number needed from RPSTL and cut hose to length shown.

Figure D-15.1. Fuel Cap Chain.

INSTRUCTIONS: Cut chain to length shown.

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.190 IN. INSIDE DIAMETER HOSE, NONMETALLIC ASTM D1149
WINDSHIELD WASHER HOSE
ITEM NO. HOSE PART NUMBER CUT LENGTH MANUFACTURED FROM PART NUMBER (CAGEC)
(INCHES)
SF5585243 16 846-50 (11288)
2 SF5585245 36 846-50 (11288)
3 SF5585258 27 846-50 (11288)

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

Figure D-16. Windshield Washer Hose

AIR RESTRICTION HOSE
HOSE CUT MANUFACTURED
PART NUMBER LENGTH FROM NSN
(INCHES)
1775-826 84 4720-01-188-3190
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.125 IN. INSIDE DIAMETER 0.25 IN. INSIDE DIAMETER HOSE, NONMETALLIC N/A

Instructions:

Determine hose part number needed from RPSTL and cut hose to length shown.

Figure D-17. Air Restriction Hose INSTRUCTIONS: Cut hose to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

FUEL DRAIN BACK HOSE
HORE CUT MANUFACTURED
PART NUMBER ITENGTH FROM NSN
(INCHES)
14066306 4720-01-184-0432
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.156 IN. INSIDE DIAMETER 0.281 IN. OUTSIDE DIAMETER HOSE, NONMETALLIC N/A
THERMOSTAT BYPASS HOSE
HOSE CUT MANUFACTURED
PART NUMBER LENGTH FROM NSM
(INCHES)
23500084 4720-01-845-9211
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.750 IN. INSIDE DIAMETER 1.00 IN. OUTSIDE DIAMETER HOSE. NONMETALLIC N/A

Figure D-18. Fuel Drain Back Hose INSTRUCTIONS: Cut hose to length shown.

Figure D-19. Thermostat Bypass Hose INSTRUCTIONS: Cut hose to length shown.

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.25 IN. INSIDE DIAMETER 0.50 IN. OUTSIDE DIAMETER HOSE. NONMETALLIC GM-6163-M
FUEL DRAIN BACK HOSE
HOSE CUT MANUFACTURED
PART NUMBER LENGTH FROM NSN
(INCHES)
9439363 4720-01-163-7833

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

Figure D-20. Fuel Drain Back Hose

EDGE PROTECTOR
ITEM EDGE PROTECTOR CUT MANUFACTURED
NO. PART NUMBER LENGTH FROM NSN
(INCHES)
5574986 5-11/16 2590-01-196-7281
5584707 8-7/8 2590-01-196-7281
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.280 IN. WIDTH 0.370 IN. HEIGHT PAD, CUSHIONING N/A

INSTRUCTIONS: Cut hose to length shown.

Figure D-21. Handle Edge Protector

Instructions:

Determine edge protector part number needed from RPSTL and cut edge protector to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

FIXED DOOR SEAL
ITEM SEAL CUT MANUFACTURED FROM
NO. PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
5584813 49-7/16 R-421-N (82942)
5584836 21-15/16 R-421-N (82942)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.75 IN. ± 0.09 IN. SQUARE RUBBER, NEOPRENE N/A

Figure D-22. Fixed Door Seal

EDGE PROTECTOR
ITEM EDGE PROTECTOR CUT MANUFACTURED FROM
NO. PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
5594278 6-1/2
5595995 8-1/2 ZX-4295 (76385)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.56 IN. WIDTH CHANNEL NONMETALLIC N/A
1.00 IN. HEIGHT

Instructions:

Determine seal part number needed from RPSTL and cut seal to length shown.

Figure D-23. Handle Edge Protector

Instructions:

Determine edge protector part number needed from RPSTL and cut edge protector to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

ANTI-NOISE PAD
PAD PART NUMBER CUT MANUFACTURED
(INCHES) FROM NSN
5575468 1-1/2 X 1-3/16 5330-01-198-3521
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.10 IN. THICK RUBBER STRIP N/A

Figure D-24. Anti-Noise Pad

WINDSHIELD LOWER SEAL
SEAL CUT MANUFACTURED FROM
PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
SF5591612 83-1/2 68-412121-2 (82942)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.250 IN. THICK SEAL ASTM D 1056
0.50 IN. WIDTH ASTM D-903

INSTRUCTIONS: Cut pad to size shown.

Figure D-25. Windshield Lower Seal INSTRUCTIONS: Cut seal to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

WINDSHIELD LOWER SEAL
SEAL PART NUMBER CUT LENGTH MANUFACTURED FROM PART NUMBER (CAGEC)
(INCHES)
SF5590706 80-1/2 68-412121-1 (82942)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.188 IN. THICK SEAL ASTM D-1056
0.50 IN. WIDTH ASTM D-903
RUBBER LOWER SEAL
SEAL CUT MANUFACTURED
PART NUMBER LENGTH FROM NSN
(INCHES)
5581213 17-1/4 5330-01-288-7822
MATERIAL BLOCK
SIOCK SIZE DESCRIPTION SPECIFICATION
N/A SEAL RUBBER N/A

Figure D-26. Windshield Lower Seal INSTRUCTIONS: Cut seal to length shown.

Figure D-27. Rubber Lower Seal

Instructions:

Determine seal part number needed from RPSTL and cut seal to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

TRAY ASSEMBLY SEAL
SEAL CUT MANUFACTURED
PART NUMBER LENGTH FROM NSN
(INCHES)
5584188 100 5330-01-202-8360
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.520 IN. THICK 1.136 IN. WIDTH SEAL, NONMETALLIC ASTM D 1056
ARCTIC CURTAIN SEAL
SEAL CUT MANUFACTURED FROM
PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
5589086 30 1C-100-01 (55674)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 IN. THICK 1.75 IN. WIDTH SEAL, RUBBER MIL-I-14511B

Figure D-28. Tray Assembly Seal INSTRUCTIONS: Cut seal to length shown.

Figure D-29. Arctic Curtain Seal INSTRUCTIONS: Cut seal to length shown.

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)

SPIRAL WRAP CHAFE GUARD
GUARD CUT MANUFACTURED FROM
PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
5578940 25FT2661-16P-120.00 (98441)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.50 IN. INSIDE DIAMETER CHAFE GUARD, SPIRAL WRAP N/A
FOAM INSULATION STRIP
INSULATION CUT MANUFACTURED FROM
PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
5589275 12 1C-025-02 (55674)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.25 IN. THICK STRIP FOAM, INSULATION MIL-I-14511B
0.50 IN. WIDTH

Figure D-30. Spiral Wrap Chafe Guard INSTRUCTIONS: Cut chafe guard to length shown.

Figure D-31. Foam Insulation Strip INSTRUCTIONS: Cut insulation to length shown.

RUN FLAT LUBE PACKAGE TAPE
TAPE CUT MANUFACTURED FROM
PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
5588618-13 13 Y-9485 (04963)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
3.0 IN. WIDTH TAPE, ADHESIVE N/

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd) Figure D-32. Run Flat Lube Package Tape INSTRUCTIONS: Cut tape to length shown.

FILAMENT TAPE
TAPE CUT MANUFACTURED
PART NUMBER TENGTH FROM NSN
(INCHES)
5588617-7.5 7.5 7510-00-802-8311
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.75 IN. WIDE TAPE FILAMENT N/A

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS [Cont'd)

FOAM TAPE
TAPE CUT MANUFACTURED
PART NUMBER LENGTH FROM NSN
(INCHES)
5581366 81-1/2 9320-01-155-2369
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.75 IN. WIDTH TAPE, FOAM N/A
0.045 IN. THICK

Figure D-33. Filament Tape INSTRUCTIONS: Cut tape to length shown, Figure D-34. Foam Tape INSTRUCTIONS: Cut tape to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

FUEL SYSTEM VENT LINE
ITEM VENT LINE CUT MANUFACTURED
NO. PART NUMBER LENGTH FROM NSN
(INCHES)
5573534 27 4720-01-003-6706
5577552 43 4720-01-003-6706
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.375 IN. INSIDE DIAMETER 0.50 IN. OUTSIDE DIAMETER TUBING. NONMETALLIC SAE J844

Figure D-35. Fuel System Vent Line

FUEL SYSTEM VENT LINE
ITEM VENT LINE CUT MANUFACTURED FROM
NO. PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
5591210 11 PFT-6B (87373)
5594083 91 PFT-6B (87373)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.312 IN. INSIDE DIAMETER 0.375 IN. OUTSIDE DIAMETER TUBING, NONMETALLIC SAE J844

Instructions:

Determine vent line part number needed from RPSTL and cut vent line to length shown.

Figure D-36. Fuel Tank Vent Line INSTRUCTIONS: Cut vent line to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

VENT LINE TUBE
ITEM NO. TUBE PART NUMBER CUT LENGTH (INCHES) MANUFACTURED FROM NSN
1 5582641 4 4720-01-071-4042
2 5582642 11 4720-01-071-4042
3 5582643 15 4720-01-071-4042
4 5582645 তৰ 4720-01-071-4042
5 5582646 32 4710-01-347-6368
6 5584173 8 4720-01-071-4042
7 5584373 26 4720-01-071-4042
8 5591157 40 4720-01-071-4042
9 5591158 35-1/2 4720-01-071-4042
10 5591159 7 4720-01-071-4042
11 5591161 10 4720-01-071-4042
12 5591168 ୧୬ 4720-01-071-4042
13 5591253 41 4720-01-071-4042
14 5591482 12 4720-01-071-4042
15 5591483 14 4720-01-071-4042
16 5591707 70 4120-01-071-4042
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.180 IN. INSIDE DIAMETER TUBING. NONMETALLIC SAE J844. TYPE A
0.250 IN. OUTSIDE DIAMETER

Figure D-37. Vent Line Tube

Instructions:

Determine tube part number needed from RPSTL and cut tube to length shown.

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
4 IN. GAGE, TYPE 1, CLASS A WIRE, ELECTRICAL MIL-C-13486
WINCH BATTERY CABLE
ITEM CABLE PART CUT LENGTH MANUFACTURED END TERMINALS END INSULATOR
NO. NUMBER (INCHES) FROM NSW મરેશ
15847 74 6145-00-538-8219 5940-00-520-2447 M23053/03-0
5940-00-197-3664 (81349)
2 15848 87-1/2 6145-00-538-8219 5940-00-520-2447 M23053/03-0
5940-00-197-3664 (81349)

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

993_image_0.png

Figure D-38. Winch Battery Cable

Instructions:

  1. Determine cable number needed from RPSTL and cut cable 6145-00-538-8219 to length as shown. 2. Select and solder proper end terminals to cable ends as shown. (Refer to TC 9-237 for soldering instructions.)

  2. Install insulator as shown. 4. Cut 14 inches of spiral wrap from bulk 25 FT 2661-8P (98441) and install as shown. Spiral wrap is held in position with black tape at both ends.

  3. Mark and install identification band using old cable as reference.

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)

BATTERY CABLE ASSEMBLY
TEM CABLE PART CUT LENGTH MANUFACTURED END TERMINALS END INSULATORS
NO. NUMBER (INCHES) FROM NSN મરેશ NSN
1 5578874 21 6145-00-705-6674 5940-00-705-6732 5970-01-174-9449
5940-00-705-6732 5970-01-174-9449
2 5578875 25 6145-00-705-6674 5940-00-735-5520 5970-01-174-9449
5940-00-705-6732 5970-01-174-9449
3 5578876 13 6145-00-705-6674 5940-00-705-6732 5970-01-174-9449
5940-00-705-6732 5970-01-174-9449
4 5578877 રે રેણ 6145-00-705-6674 5940-00-735-5520 5970-01-174-9449
5940-00-705-6732 5970-01-174-9449
5 5578878 32 6145-00-705-6674 5940-00-705-6732 5970-01-174-9449
5940-00-705-6732 5970-01-174-9449
6 5584892 31 6145-00-705-6674 5940-00-735-5520 5970-01-174-9449
5940-00-735-5520 5975-01-208-9618
7 5584893 31 6145-00-705-6674 5940-00-735-5520 5970-01-174-9449
5940-00-705-6732 5970-01-174-9449
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
"0" GAGE WIRE ELECTRICAL MIL-C-13486

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

995_image_0.png

Figure D-39. Battery Cable Assembly

Instructions:

  1. Determine cable number needed from RPSTL and cut wire 6154-00-705-6674 to length as shown.

NOTE

  1. Select and solder proper end terminals to cable ends as shown. (Refer to TC 9-237 for soldering instructions.)

Insulator boot 5582481 is installed on 30° bent terminal end of item 6.

  1. Select and install proper insulators as shown. 4. Mark and install circuit number identification band and part number identification band using old cable as reference.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598238 13 X 10.55 C 540 B H52 (28818)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1

996_image_0.png

Figure D-40. A/C Compartment Side Front Insulation INSTRUCTIONS: Cut insulation to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598819 21.80 X 29.50 C 540 B H52 (28818)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1

997_image_0.png

SHOWN WITH

ADHESIVE SIDE UP Figure D-41. A/C Compartment Passenger Side Ceiling Insulation

INSTRUCTIONS: Cut insulation to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598813 24.55 X 13.50 C 540 B H52 (28818)
MATERIAL BLOCK
રાંભર્સ રાટિં DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1

998_image_0.png

SHOWN WITH ADHESIVE SIDE UP Figure D-42. A/C Compartment Bulkhead Outboard Insulation INSTRUCTIONS: Cut insulation to dimensions shown.

MATERIAL BLOCK
RIOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1
AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598237 28.90 X 12.00 C 540 B H52 (28818)

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

999_image_0.png

SHOWN WITH ADHESIVE SIDE UP Figure D-43. A/C Compartment Side Rear Insulation

INSTRUCTIONS: Cut insulation to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598236 28.50 X 22.00 C 540 B H52 (28818)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1

1000_image_0.png

SHOWN WITH ADHESIVE SIDE UP

Figure D-44. A/C Compartment Roof Insulation

INSTRUCTIONS: Cut insulation to dimensions shown.

MATERIAL BLOCK
DESCRIPTION SPECIFICATION STOCK SIZE
FOAM. ACOUSTIC ASTM D-903 1.00 THICK UL 94 HF-1
AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598816 12.80 X 10.75 C 540 B H52 (28818)

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598817 23.70 X 18.50 C 540 B H52 (28818)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1

Figure D-45. A/C Compartment Front Closeout Insulation INSTRUCTIONS: Cut insulation to dimensions shown.

Figure D-46. A/C Compartment Front Ceiling Insulation INSTRUCTIONS: Cut insulation to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598820 9.40 X 33.70 C 540 B H52 (28818)
MATERIAL BLOCK
SLOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903 UL 94 HF-1

Figure D-47. A/C Compartment Driver Compartment Above Door Insulation INSTRUCTIONS: Cut insulation to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598818 32.90 X 24.80 C 540 B H52 (28818)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1

1003_image_0.png

SHOWN WITH ADHESIVE SIDE UP Figure D-48. A/C Compartment Driver Side Ceiling Insulation

INSTRUCTIONS: Cut insulation to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUI MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598241 14.75 X 4.20 C 540 B H52 (28818)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM. ACOUSTIC ASTM D-903
UL 94 HF-1

1004_image_0.png

SHOWN WITH ADHESIVE SIDE UP Figure D-49. A/C Compartment Condenser Top Outer Insulation INSTRUCTIONS: Cut insulation to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598242 12.50 X 19.80 C 540 B H52 (28818)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903 UL 94 HF-1

1005_image_0.png

Figure D-50. A/C Compartment Condenser Top Inner Insulation

INSTRUCTIONS: Cut insulation to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598814 10.00 X 13.50 C 540 B H52 (28818)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1

SHOWN WITH ADHESIVE SIDE UP

1006_image_0.png

Figure D-51. A/C Compartment Bulkhead Upper Inboard Insulation INSTRUCTIONS: Cut insulation to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598245 22.62 X 26.20 C 540 B H52 (28818)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1

1007_image_0.png

SHOWN WITH ADHESIVE SIDE UP Figure D-52. A/C Compartment Access Door Insulation

INSTRUCTIONS: Cut insulation to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598821 7.80 X 5.60 C 540 B H52 (28818)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1

Figure D-53. A/C Compartment Access Door Insulation INSTRUCTIONS: Cut insulation to dimensions shown.

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598815 5.70 X 12.30 C 540 B H52 (28818)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1

1009_image_0.png

SHOWN WITH ADHESIVE SIDE UP Figure D-54. A/C Compartment Condenser Side Inner Insulation INSTRUCTIONS: Cut insulation to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D) Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUI MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598240 6.50 X 12.10 C 540 B H52 (28818)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1

1010_image_0.png

SHOWN WITH ADHESIVE SIDE UP Figure D-55. A/C Compartment Condenser Side Insulation INSTRUCTIONS: Cut insulation to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598243 8.75 X 11.25 C 540 B H52 (28818)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1

1011_image_0.png

SHOWN WITH ADHESIVE SIDE UP Figure D-56. A/C Compartment Condenser Closeout Panel Insulation

INSTRUCTIONS: Cut insulation to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

AIR CONDITIONING COMPARTMENT INSULATION
INSULATION CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER (CAGEC)
5598239 11 X 10.50 C 540 B H52 (28818)
MATERIAL BLOCK
SIOCK SIZE DESCRIPTION SPECIFICATION
1.00 THICK FOAM, ACOUSTIC ASTM D-903
UL 94 HF-1

1012_image_0.png

SHOWN WITH ADHESIVE SIDE UP

Figure D-57. A/C Compartment Condenser Side Insulation

INSTRUCTIONS: Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)

LITTER STOWAGE DOOR SEAL
INSULATION CUT MANUFACTURED FROM
PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
5592085 48 ZX-2004 (76385)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.38 THICK WEATHERSEAL MIL-STD-1180
0.42 WIDE

Figure D-58. Litter Stowage Door Seal INSTRUCTIONS:

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)

NBC DOOR AND ACCESS PANEL SEALS
TTEM SEAL CUT MANUFACTURED FROM
NO. PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
1 5597994 14.70 R-495-T (79101)
2 5597995 16.98 R-495-T (79101)
3 5597997 33.56 R-495-T (79101)
4 5597998 4.72 R-495-T (79101)
5 5597999 31.28 R-495-T (79101)
6 5598000 11.56 R-495-T (79101)
7 5598029 10.62 R-495-T (79101)
8 5598030 18.92 R-495-T (79101)
9 5598031 16.66 R-495-T (79101)
10 5598032 13.76 R-495-T (79101)
11 5598033 4.38 R-495-T (79101)
12 5598034 29.86 R-495-T (79101)
13 5598035 29.42 R-495-T (79101)
14 5598036 24.50 R-495-T (79101)
15 5598061 5.56 R-495-T (79101)
16 5598062 7.56 R-495-T (79101)
17 5598063 3.28 R-495-T (79101)
18 5598064 2.50 R-495-T (79101)
19 5598065 3.72 R-495-T (79101)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.060 THICK SEAL, RUBBER ASTM D 1056
0.50 WIDE MIL-STD-1180

Figure D-59. NBC Door and Access Panel Seals INSTRUCTIONS:

Determine seal part number needed from RPSTL and cut seal to length shown. Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)

NBC SYSTEM PVC TUBING
ITEM TUBING CUT MANUFACTURED FROM
NO. PART NUMBER LENGTH મિટીન
(INCHES)
1 5597214 1.62 4710-00-112-8626
2 5597215 1.81 4710-00-112-8626
3 5597216 2.00 4710-00-112-8626
4 5597217 2.12 4710-00-112-8626
5 5597218 2.38 4710-00-112-8626
6 5597219 3.75 4710-00-112-8626
7 5597220 3.25 4710-00-112-8626
8 5597221 4.62 4710-00-112-8626
9 5597222 4.25 4710-00-112-8626
10 5597223 4.38 4710-00-112-8626
11 5597224 4.75 4710-00-112-8626
12 5597225 5.25 4710-00-112-8626
13 5597226 6.87 4710-00-112-8626
14 5597227 10.62 4710-00-112-8626
15 5597228 15.31 4710-00-112-8626
16 5597229 15.88 4710-00-112-8626
17 5597230 30.12 4710-00-112-8626
18 5597231 31.38 4710-00-112-8626
19 5597232 6.81 4710-00-112-8626
20 5597722 1.31 4710-00-112-8626
21 5597723 8.75 4710-00-112-8626
22 5597724 5.80 4710-00-112-8626
23 5597725 1.38 4710-00-112-8626
মৰ্ব 5597726 1.75 4710-00-112-8626
25 5597727 4.65 4710-00-112-8626
26 5597728 7.45 4710-00-112-8626
27 5597730 6.12 4710-00-112-8626
28 5597957 2.70 4710-00-112-8626
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.75 INSIDE DIAMETER TUBING. PVC ASTM 1784
ASTM D 2846
FMVSS-302

Figure D-60. NBC System PVC Tubing

NBC SYSTEM PVC TUBING (Cont'd)
IIIEM NO. TUBING PART NUMBER CUT LENGTH (INCHES) MANUFACTURED FROM NSN
29 5597958 7.50 4710-00-112-8626
30 5597970 14.12 4710-00-112-8626
31 5598132 10.28 4710-00-112-8626
32 5598133 2.88 4710-00-112-8626
33 5598134 3.03 4710-00-112-8626

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

Figure D-60. NBC System PVC Tubing (Cont'd) INSTRUCTIONS: NOTE

HEAT SHRINK INSULATION SLEEVING
INSULATION CUT MANUFACTURED FROM
PART NUMBER LENGTH PART NUMBER (CAGEC)
(INCHES)
M23053/1-204-0 2.0 M23053/1-204-0 (81349)
M23053/1-204-2 2.0 M23053/1-204-2 (81349)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.625 IN. INSULATION SLEEVING. MIL-I-23053
INSIDE DIAMETER HEAT SHRINK

Make sure tubing is cut square at ends, and ends are free of nicks, burrs, and cracks.

Determine tubing part number needed from RPSTL and cut tube to length shown.

Figure D-61. Heat Shrink Insulation Sleeving INSTRUCTIONS: Cut insulation to length shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

200 AMP ALTERNATOR CABLE ASSEMBLY
CABLE CUT LENGTH MANUFACTURED END TERMINAL END INSULATOR
PART NUMBER (INCHES) FROM NSN Nav તિર્થ
5582451 58 6145-00-705-6674 5940-00-735-5520 5970-00-174-9449
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
"O" GAGE WIRE, ELECTRICAL MIL-C-13486

1017_image_0.png

Figure D-62. 200 Amp Alternator Cable Assembly.

Instructions:

  1. Cut cable to length as shown. 2. Cut 14 inches of spiral wrap from bulk and install as shown. Secure spiral wrap in position with black tape at both ends.

  2. Select and solder proper end terminals to cable ends as shown. (Refer to TC 9-237 for soldering instructions.)

  3. Install insulator and insulator boot to cable ends as shown. 5. Mark and install identification bands using old cable as reference.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

Figure D-5. Defroster Flex Ducting
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
"O" GAGE WIRE, ELECTRICAL MIL-C-13486

1018_image_0.png

Figure D-62.1. 12 Volt Alternator Cable Assembly.

Instructions:

  1. Cut cable to length as shown. 2. Cut of 92.50 inches spiral wrap from bulk and install as shown. Secure spiral wrap in position with tape at both ends.

  2. Select and solder proper end terminals to cable ends as shown. (Refer to TC 9-237 for soldering instructions.)

  3. Install insulator and insulator boot to cable ends as shown. 5. Mark and install identification bands using old cable as reference.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

Figure D-7. Battery Cable Edge Protector
MATERIAL BLOCK
STOCK SIZE DESCRIbLION SPECIFICATION
0.250-IN. DIAMETER TUBE, METALLIC MIL-T-6845
0.250-IN. (NOM)
INSIDE DIAMETER HOSE, NONMETALLIC MIL-H-13444
0.438-IN. (NOM)
OUTSIDE DIAMETER

1019_image_0.png

Figure D-63. Fuel Filter Bleeder Tool.

Instructions:

  1. Cut steel tube, NSN 4710-00-825-5894, to length as shown. 2. Thread one end of the tube 5/8 inch. 3. Install nut, NSN 5310-00-997-1888, and O-ring, NSN 5330-00-966-8657, on threaded end of tube. 4. Install 24-inch rubber hose, NSN 4720-00-542-3304, to the other end of the tube.
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
1. .125 IN. THICK FLAT STEEL N/A
2. .375 IN. DIAMETER ROUND STEEL N/A
Figure D-9 Fuel Can Drain Hose

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

1020_image_0.png

Figure D-63.1. Glow Plug Tool Assembly.

Instructions:

  1. Cut steel to lengths as shown. 2. Weld flat steel and round steel together at angle as shown. 3. Forked end (dimension F) must fit behind hex-head of glow plug. Thickness may have to be ground down from .125 inch to .0625 inch to insure proper fit.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

PLASTIC SHEET
PLASTIC SHEET PART NUMBER CUT LENGTH MANUFACTURED FROM NSN
(INCHES)
5598827 AS REQUIRED 9330-00-618-7214
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.002-IN. (NOM) THICK 26-IN. (NOM) WIDTH PLASTIC SHEET, PRESS N/A

Figure D-64. Plastic Sheet

Instructions:

Cut two pieces of plastic large enough to cover small hole or crack with enough to overlap about 1/4 in.

around damaged area of window.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
12 x 4-FT SHEET ALUMINUM ALLOY ASTM B 209-90
0.060 THICK TEMPER T-4

1022_image_0.png

Figure D-65. Protective Shield

Instructions:

  1. Cut aluminum sheet metal to size as shown.

Locate, mark, and drill two 0.193-in. diameter holes in protective shield (1).

Locate, mark, and drill three 0.203-in. diameter holes in protective shield (1).

Make two 0.50-in. relief cuts in sides of protective shield (1).

  2. Bend edges (90° bend along dotted lines) on protective shield (1).

Remove all burrs and sharp edges.

Paint protective shield (1) as required. Refer to TM 43-0139.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

PROTECTIVE ENGINE COVER
COVER PART NUMBER CUT (INCHES) MANUFACTURED FROM PART NUMBER NSN
5598829 34 X 60 N/A
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.750-IN. THICK PLYWOOD, 4 X 8 FT. SHEET MIL-STD-731A

1023_image_0.png

Figure D-66. Protective Engine Cover

Instructions:

  1. Cut plywood to dimensions shown. If necessary, modify plywood for proper fit.

  2. Paint cover and outline with yellow safety boarder, 4-inches wide on outside edges.

  3. Stencil "NO STEP AREA" caution on outside edges.

  4. Prior to installing protective engine cover, remove both plate covers and seals from airlift brackets. 5. Store flat or hang on wall to prevent warpage.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

PROTECTIVE ENGINE COVER
COVER CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER NSN
5598830 40.0 x 46.5 N/A
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.750-IN. THICK PLYWOOD, 4 X 8 FT. SHEET MIL-STD-731A

1024_image_0.png

Figure D-67. Cooler Fin Protective Cover

Instructions:

  1. Cut plywood to dimensions shown. If necessary, modify plywood for proper fit.

  2. Never use cover with engine running; engine damage will occur.

  3. Stencil "NO STEP" caution to top of cover.

  4. Prior to installing cooler fin protective cover, remove both plate covers and seals from airlift bracket.

  5. Store flat or hang on wall to prevent warpage.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

MATERIAL BLOCK
SPECIFICATION DESCRIPTION STOCK SIZE
STEEL. CARBON ASTM A569 .1196-IN. THICK HR. CQ. P&O

1025_image_0.png

Figure D-68. Siren Mounting Bracket

Instructions:

  1. Fabricate siren mounting bracket according to dimensions shown. 2. Remove all burrs and sharp edges.

  2. Clean per SPEC TT-C-490. Treat per SPEC Type I or II, or SPEC TT-C-490. 4. Prime per SPEC MIL-P-52192, MIL-P-53022, or MIL-P-53030. 5. Finish-paint per SPEC MIL-C-46168.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

SHEET
PART NUMBER CUT LENGTH MANUFACTURED FROM NSN
(INCHES)
5598833 AS SHOWN N/A
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
.1196-IN. THICK STEEL, CARBON ASTM A569
HR, CQ, P&O

1026_image_0.png

Instructions:

  1. Fabricate warning light mounting bracket according to dimensions shown.

  2. Weld sizes are minimum. Weld per SPEC MIL-STD-1261.

  3. Remove all burrs and sharp edges.

  4. Clean per SPEC TT-C-490. Treat per SPEC Type I or II, or SPEC TT-C-490.

  5. Prime per SPEC MIL-P-52192, MIL-P-53022, or MIL-P-53030. 6. Finish-paint per SPEC MIL-C-46168.

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
12 AWG WIRE, ELECTRICAL MIL-C-13486
WIRE "D"
WIRE PART NUMBER CUT LENGTH (INCHES) MANUFACTURED FROM NSN
5598834 5.0 2. 6145-00-705-6678
ટમદાા પરંત TERMINAL INSULATOR મરત WASHER NSN
1. 2590-00-695-9076 (2 EACH) (2 EACH) (2 EACH) 4. 5940-00-399-6676 3. 5310-00-298-8903
WIRE "F"
WIRE PART NUMBER CUT LENGTH MANUFACTURED
(INCHES) FROM NSN
5598835 123.0 4. 6145-00-705-6678
SHELL NSN TERMINAL INSULATOR મરેન WASHER NSN
1. 5935-00-695-9077 3. 5999-00-925-6495 2. 5310-00-595-7044
5. 2590-00-695-9076 7. 5940-00-399-6676 6. 5310-00-298-8903
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
12 AWG WIRE, ELECTRICAL MIL-C-13486

Figure D-70. Wire "D" - Adapter "A" to Adapter Connector "B"

1027_image_0.png

2

1027_image_1.png

Figure D-71. Wire "F" - Passenger Side Siren Switch to Adapter Connector "B"

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
12 AWG WIRE, ELECTRICAL MIL-C-13486
WIRE "G"
WIRE PART NUMBER CUT LENGTH MANUFACTURED
(INCHES) FROM NSN
2598836 117.0 4. 6145-00-705-6678
SHELL NSN TERMINAL INSULATOR WASHER NSN
મરાત
1. 5935-00-695-9077 3. 5999-00-925-6495 2. 5310-00-595-7044
5. 2590-00-695-9076 7. 5940-00-399-6676 6. 5310-00-298-8903

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)

1028_image_0.png

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
12 AWG WIRE, ELECTRICAL MIL-C-13486
WIRE "L"
WIRE PART NUMBER CUT LENGTH MANUFACTURED
(INCHES) FROM NSN
5598837 113.0 4. 6145-00-705-6678
SHELL NSW TERMINAL INSULATOR WASHER NSN
NSN
1. 5935-00-695-9077 3. 5999-00-925-6495 2. 5310-00-595-7044
5. 2590-00-695-9076 7. 5940-00-399-6676 6. 5310-00-298-8903

Figure D-72. Wire "G" - Passenger Side Siren Switch Adapter Connector "E"

1028_image_1.png

Figure D-73. Wire "L" - Relay Lead "C" to Circuit Breaker in Battery Box

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
12 AWG WIRE, ELECTRICAL MIL-C-13486
WIRE "K"
WIRE PART NUMBER CUT LENGTH MANUFACTURED
(INCHES) FROM NSN
2598838 104.0 2. 6145-00-705-6678
TERMINAL INSULATOR
મર્સ
1. 5940-00-682-2445
3. 5940-00-113-8183

1029_image_0.png

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
12 AWG WIRE, ELECTRICAL MIL-C-13486
WIRE "I"
WIRE PART NUMBER CUT LENGTH MANUFACTURED
(INCHES) EBOW HSH
5598839 127.0 2. 6145-00-705-6678
TERMINAL INSULATOR
મરેમ
1. 5940-00-113-8183
(2 EACH)

Figure D-74. Wire "K" - Battery Ground Stud by Relay Mounting Ground

1029_image_1.png

Figure D-75. Wire "I" - Siren Assembly Mount to Relay Mounting Ground

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
12 AWG WIRE, ELECTRICAL MIL-C-13486
WIRE "N"
WIRE PART NUMBER CUT LENGTH (INCHES) MANUFACTURED FROM NSN
5598840 22.0 2. 6145-00-705-6678
રમદાા પરંત TERMINAL INSULATOR પરંત WASHER NSN
3. 2590-00-695-9076 1. 5940-00-682-2445 5. 5940-00-399-6676 4. 5310-00-298-8903
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
14 AWG WIRE, ELECTRICAL MIL-C-13486
WIRE "H"
WIRE PART NUMBER CUT LENGTH MANUFACTURED
(INCHES) FROM NSN
5598841 120.0 4. 6145-00-152-6499
SHELL NSW TERMINAL INSULATOR SLEEVE/WASHER NSN
મરાર
1. 5970-00-906-0159 3. 5995-00-057-2929 2. 5310-00-833-8567
5. 5935-00-833-8561 7. 1015-00-798-2997 6. 5970-00-833-8562

Figure D-76. Wire "N" - Circuit Breaker to Battery Stud (Positive)

1030_image_0.png

Figure D-77. Wire "H" - Siren Hot Side to Adapter Connector "E" .

1030_image_1.png

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)

MATERIAL BLOCK
ટાOCK ટાટદ DESCRIPTION SPECIFICATION
14 AWG WIRE, ELECTRICAL MIL-C-13486
WIRE "J"
WIRE PART NUMBER CUT LENGTH MANUFACTURED
(INCHES) FROM ASN
5598842 57.0 4. 6145-00-152-6499
રમદાા પરંત TERMINAL INSULATOR મર્ટેશ WASHER NSN
1. 5970-00-906-0159 5. 5940-00-283-5281 2. 5310-00-833-8567
3. 5995-00-057-2929

1031_image_0.png

5

MATERIAL BLOCK
રાંભરત રાટેદ DESCRIPTION SPECIFICATION
14 AWG WIRE, ELECTRICAL MIL-C-13486
WIRE "A"
WIRE PART NUMBER CUT LENGTH MANUFACTURED
(INCHES) FROM NSN
5598843 6.75 1. 6145-00-152-6499
ટેનિટા પરંત TERMINAL INSULATOR ટાદિશ્ર્ટ મિટેન
મરાર
2. 5933-00-833-8561 4. 1015-00-748-2997 3. 5970-00-833-8562
(2 EACH) (2 EACH) (2 EACH)

Figure D-78. Wire "J" - Warning Light Black Lead to Relay Mounting Ground

1031_image_1.png

Figure D-79. Wire "A" - Light Toggle Switch to Adapter Connector "D" Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
14 AWG WIRE, ELECTRICAL MIL-C-13486
WIRE "B"
WIRE PART NUMBER CUT LENGTH MANUFACTURED
(INCHES) FROM NSN
5598844 9.50 1. 6145-00-152-6499
ટેમદાર પરિત TERMINAL INSULATOR ટાદEAE HSM
NSN
2. 5933-00-833-8561 4. 1015-00-748-2997 3. 5970-00-833-8562
(2 EACH) (2 EACH) (2 EACH)

1032_image_0.png

WIRE "M"
WIRE PART NUMBER CUT LENGTH MANUFACTURED
(INCHES) FROM ASN
5598845 47.0 1. 6145-00-152-6499
SHEIT HSN TERMINAL INSULATOR STEEAE HSM
NSN
2. 5933-00-833-8561 4. 1015-00-748-2997 3. 5970-00-833-8562
(2 EACH) (2 EACH) (2 EACH)
MATEDIAI I BLOCK
-- a desires of the call and a comments of the color of the color of the control of the control of the consistence of the consistence of the consistences and FOR AND A BRIDGE OF CONSULTION OF ANNUAL A SHORE AND AT CHARLE AN LE LE SELL AN --
STOCK SIZE RIPTION SPECIFICATION
14 AWG -- WIRR ELECTRICAL MIL -C-13486
A STATUS AND AND AND AND AND AND AND OF COLLECTION OF CLASS OF HOUSE OR HE I S MARALLA LE LE MARK OF Children & Children Children Children Children Children Children Children Children Children Children Children Children Children Children Children Charles Acres of the controllers of the control of ------------------ -- A proper a control and control of LEASE LEASE CONSULER COLLECTION COLLECTION COLLECTION COLLECTION COLLECTION COLLECTION OF

Figure D-80. Wire "B" - Light Toggle Switch Adapter Connector "A"

Figure D-81. Wire "M" - Warning Light Red Lead to Adapter Connector "D"

1032_image_1.png

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
A=14 AWG. B=12 AWG WIRE, ELECTRICAL MIL-C-13486
RELAY CONNECTOR
WIRE PART NUMBER CUT LENGTH (INCHES) MANUFACTURED FROM NSN
5598846 5. A 17.0 6. B 15.0. AND 10.0 6. 6145-00-705-6678 5. 6145-00-152-6499
SHELL ASSEMBLY/SHELL NSN TERMINAL INSULATOR મરાત SLEEVE/WASHER NSN
1. 5935-00-686-2609 9. 1015-00-798-2997 8. 5970-00-833-8562
7. 5935-00-833-8561 10. 5940-00-399-6676 (2 EACH) 11. 5310-00-298-8903 (2 EACH)
12. 2590-00-695-9076 (2 EACH)
NUT NSN GROMMET
3. 5310-00-655-9860 4. 5935-00-335-9414 2. 5365-00-752-7633

1033_image_0.png

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)

GRAB LOOP
GRAB LOOP CUT LENGTH MANUFACTURED
PART NUMBER (INCHES) FROM NSN
5598847 12 in. 8315-00-634-3304
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
STRAP WEBBING N/A
N/A THREAD N/A

Instructions:

  1. Remove cargo shell door strap from vehicle. Refer to para. 11-22.

  2. Position grab loop one-third of the way down strap. Fold strap into thirds and mark top fold. 3. Secure grab loop to strap with thread using box stitch and string. Refer to FM 10-16. 4. Install cargo shell door strap on vehicle with grab loop facing the rear. Refer to para. 11-22.

1034_image_0.png

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICIATION
100 FT. FELT, MECHANICAL MILG20241

NOTE: ALL DIMENSIONS ARE IN INCHES

1035_image_0.png

Figure D-84. Felt Sheet INSTRUCTIONS: Cut felt to dimensions shown.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICIATION
0.63 THICK HEAT SHIELD N/A

1036_image_0.png

NOTE:

All dimensions are in inches.

Figure D-85. Heat Shield Extension INSTRUCTIONS: All inside bend radius to 6.12 unless otherwise specified.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

LEFT SPLASH SHIELD ACCESS COVER
ACCESS COVER CUT TO SIZE MANUFACTURED FROM
PART NUMBER (INCHES) મરા
12446770 AS SHOWN 9530-01-071-2140
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICIATION
10 X 12-FT SHEET. ALUMINUM ALLOY IAW QQ-A-225/8
0.08 IN. THICK 6061-T6

1037_image_0.png

Figure D-86. Left Splash Shield Access Cover.

Instructions:

  1. Cut aluminum sheet metal to size as shown. 2. Locate, mark, and drill two .313-.375-in. diameter holes in left splash shield access cover as shown. 3. Locate, mark, and drill one .406-.466-in. diameter hole in left splash shield access cover as shown. 4. Remove all burrs and sharp edges. 5. Paint left splash shield access cover as required. (Refer to TM 43-0139.)

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

1038_Image_0.png

LEFT SPLASH SHIELD
SPLASH SHIELD CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER
12446771 AS SHOWN 12340361

Figure D-87. Left Splash Shield.

Instructions:

  1. Remove left splash shield. (Refer to para. 10-17.) 2. Cut hole (2) in left splash shield (1) as shown. 3. Using fabricated access cover (6) as a template, locate, mark, and drill a 0.312-inch diameter hole (5) through left splash shield (1) as shown.

Existing mounting hardware is used to secure bottom right-hand hole.

  1. Secure top two holes of access cover (6) to left splash shield (1) with two NSN 5306-00-225-8499 washers (4), NSN 5306-00-225-8499 screws (7), NSN 5310-00-087-7493 washers (4), and NSN 5310-00-814-0673 nuts (3) as shown.

  2. Install modified left splash shield. (Refer to para. 10-17.)

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

VEHICULAR SPLASH GUARD NSN | CAPSCREWS NSN WASHERS NSN
1. 2540-00-843-7043 (2 EACH) 6. 5305-00-269-3241 (4 EACH) 3. 5310-00-087-7493 (4 EACH)
LOCKNUTS NSN 90° ANGLE BRACKET NSN
4. 5310-00-959-1488 (4 EACH) 5. 9540-00-140-2417 (2 EACH)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICIATION
0.125 IN. THICK ALUMINUM ALLOY TEMPER 6061 QQ-A-250/11

1039_image_0.png

1039_image_1.png

Instructions:

  1. Cut aluminum sheet metal to size as shown.

  2. Locate, mark, and drill two .75 X .40 in. slots in mud flap plate.

  3. Locate, mark, and drill two .40 in. diameter holes in mud flap plate.

  4. Remove all burrs and sharp edges. 5. Locate, mark, and drill eight holes in angle bracket (5) as shown. 6. Paint as required. Refer to TM 43-0139.

  5. Install mud flap (1) between mounting bracket (2) and angle bracket plate (5) with four washers (3), capscrews (6), washers (3), and locknuts (4).

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

REINFORCEMENT BRACKET
PART NUMBER CUT TO SIZE MANUFACTURED EROW NSN
(INCHES)
N/A AS SHOWN 9535-00-541-7194
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.0500 IN. THICK ALUMINUM ALLOY TEMPER QQ-A-250/11

1040_image_0.png

Figure D-89. "C" Pillar Reinforcement Bracket.

Instructions:

  1. Cut two pieces of aluminum sheet metal to size as shown.

  2. Locate, mark, and drill four 0.125-inch diameter holes in reinforcement brackets (1).

  3. Bend left reinforcement bracket (1). 4. Bend right reinforcement bracket (1) in opposite direction.

-- Book and Company of Children and Company of the in Annual Access of Children Company BALL BOOK COLLEGION COLLEGION COLLECTION COLLECTION COLLECTION COLLECTION COLLEGION COLLECTION COLLEGION COLLECTION COLLEGION COLL A SEEN AND L I
ALATPRIAL BLACK
---------------- Market I A conce a LAND RESERVED OF COLLECTION OF COLLECTION OF COLLECTION OF COLLECTION OF COLLECTION OF COLLECTION OF COLLECTION OF COLLECTION OF COLLECTION OF COLLECTION OF CONSULTION OF CON
would need and the dr. and a subs on anywood and
--------------------------- -- ---- . -- --------------------
1
STATISTICS OF CONSUL -- AN AND REAL PARK RESERVED LE IN -------------- . Married All Property of Children ANNUAL BOOK OF CHILIP OF No. of course a consider of -- MONE RESERVEN A LINE IN RESEARCE A R . L I STATUTE AND LEASE OF CHARGE
TURRET BEARING SEAL
SEAT CUT MANUFACTURED
PART NUMBER LENGTH (FEE)) FROM NSN
MT161A 22 5330-01-282-2213

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd) 11 FT Figure D-90. Turret Bearing Seal.

INSTRUCTIONS:

MATERIAL BLOCK
STOCK SIZE 0.250 IN. INSIDE DIAMETER DESCRIPTION HOSE, NONMETALLIC SPECIFICATION N/A
0.500 IN. OUTSIDE DIAMETER

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

1042_image_0.png

Figure D-91, Winch Wire Rope Assembly

Instructions:

  1. (a) Properly seize wire rope end before cutting. To seize wire rope end, follow these instructions.

(1) Wrap the seizing wire around the wire rope as tight as possible. (2) Twist the ends of the seizing together by hand counterclockwise so that the twist is near the middle of the seizing.

NOTE Do not try to tighten the seizing by twisting.

(3) Tighten the twist just enough to take up the slack. (4) Tighten the seizing by prying the twist away from the axis of the wire rope. (5) Tighten the twist again as described in step (3). (6) Repeat the process until the seizing can not be pryed away from the axis of the wire rope. (7) Cut off wire ends and pound the twist into contact with the seizing.

(b) Cut wire rope to length as shown and install part of clamp with nut on wire rope.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

  1. Position rope after seizing in a suitable fixture to make a loop, leaving enough rope to wrap around thimble and enclose in clamp.

  2. Insert thimble and close jaws of fixture to enable rope to conform to groove of thimble. 4. Place one half of clamp in position and adjust rope accordingly. The seized portion of the wire rope should equal one rope diameter and protrude entirely beyond the threaded end of the clamp half.

  3. Install clamp nut. Holding both threaded halves in position, push the nut into both halves through the first two threads. Ensure proper alignment of both threaded halves, and that there is no crossthreading.

  4. Remove rope, clamp and thimble while still connected. 7. Hold opposing flats of clamp halves in suitable fixture and properly lubricate exposed threads with high-viscosity lubricating oil.

  5. Using a permanent marker, mark one flat nut to ensure the same opposing flats are checked before and after tightening the clamp.

  6. Using calipers, measure 1/8 inch across the flat nut from the bottom and note measurement.

  7. Check to make sure clamp halves are properly secured in fixture, and tighten with appropriate wrench.

  8. Using calipers, again take measurement of the same flat nuts as was done before tightening of the nut. If the increment dilation is between 0.004 and 0.007 inches, clamp is tight.

1043_image_0.png

Change 2 D-71

MATERIAL BLOCK
SIOCK SIZE DESCRIPTION SPECIFICATION
.050 X 36 IN. THICK ALUMINUM ALLOY 6061-T6 QQ-A-250/11
RETAINER
SEAL CUT MANUFACTURED
PART NUMBER LENGTH FROM NSN
(FEED)
N/A 9535-00-250-6503

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

.53 R

1044_image_0.png

1044_image_1.png

1044_image_2.png

Figure D-92. Ambulance Bulkhead Door Retainer.

INSTRUCTIONS:

  1. Cut retainer to length shown.

  2. Remove all burrs and sharp edges.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

1045_Image_0.png

Figure D-93. Parking Brake Lever.

INSTRUCTIONS:

Caution

When drilling through the transmission cowl, be careful not to drill into the transmission housing.

The location of the mounting hole will vary depending on vehicle configuration. Locate the hole in a suitable place, near the driver's seat 1.

5 Drill a 1/4-in. hole in the transmission cowl (7), near the driver's seat (10).

Cut chain (4) to desired length and install the clamp (1) on chain (4) with capscrew (5), lockwasher (2), and nut (3). Install chain (4) on transmission cowl (7) with capscrew (6), lockwasher (9), and nut (8). With the parking brake applied, slip clamp (1) over lever (11) to lock it in place. When not in use, stow the chain lock out of the way.

Paint chain lock red for easy identification.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

Instructions:

Disconnect battery ground cable (Refer to para. 4-73).

NOTE Have container availabe to catch fluid drainage from hydraulic hoses.

Remove clamp (4) and hydraulic hose (5) from elbow fitting (2).

Disconnect fan drive hydraulic hose (11) from fitting (12). Remove elbow fitting (2) from adapter bushing (9). Remove nut (3), washer (6), and washer (8) securing adapter bushing (9) to fan shroud (7).

Remove fan drive hydraulic hose (11) from elbow fitting (10).

Remove fitting (12) from fan drive (1).

Apply sealing compound (appendix C, item 44) to all pipe threads during installation.

Install hose (13) on elbow fitting (10).

Install quick-disconnect (14) on fitting (15).

Install fan drive hydraulic hose (13) in quick-disconnect (14).

Install fitting (15) in fan drive (1).

Install adapter bushing (9) and washer (8) in fan shroud (7) with washer (6) and nut (3). Install elbow fitting (2) in adapter bushing (9). Install hydraulic hose (5) on elbow fitting (2) with clamp (4). Connect battery ground cable (para. 4-73). Bleed power steering system (para. 8-29).

1047_image_0.png

Figure D-94. Fan Drive Quick-Disconnect.

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

Lnstructlons:

  1. Using existing turret handle (1) as a template, scribe two reference lines (2) on weapon station (4). 2. Locate and mark the center of six spot welds (3) on turret handle (1).

Ensure drill does not penetrate weapon station.

  1. Using 0.313-inch diameter drill bit, drill out six spot welds (3) in turret handle (1).

  2. Using chisel, remove turret handle (1) from weapon station (4).

NOTE When grinding weapon station, ensure that the two reference lines are not removed.

  1. Grind off any remaining spot weld (3) material flush with weapon station (4). 6. Using two reference lines (2) marked in step 1, position turret handle (5) on weapon station (4). 7. Using turret handle (5) as a template, drill four 0.344-inch diameter holes (6) in weapon station (4). 8. Spot paint weapon station (4) (refer to TM 43-0139). 9. Install turret handle (5) on weapon station (4) with four washers (8), capscrews (7), washers (8), and locknuts (9).

  2. Spot paint capscrews (7) and locknuts (9) (refer to TM 43-0139).

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

1049_image_0.png

Figure D-95. Turret Handle Replacement.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

ITEM MATERIALS
NO. REQ'D DESCRIPTION NSN/PART NUMBER
8 Insulation Sleeving: 2 in. 5970-01-815-1295
เง 8 Electrical Wire: 48 in. 6145-00-152-6499
8 Wire Marker 46F5981
4 5 5 Tiedown Strap 5975-00-074-2072
1 Receptacle 5935-00-738-8328

1050_image_0.png

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
14 AWG WIRE, ELECTRICAL MIL-C-13486
N/A INSULATION SLEEVING MIL-I-23053/2

Figure D-96. Body Harness Receptacle Fabrication.

Instructions: Note

When connecting electrical wire to connector pins on engine harness plug connector, use NSN 3439-00-133-1108 solder. (Refer to TB SIG-222 for soldering.)

  1. Cut eight sections of wire (2) to length as shown. 2. Cut eight sections of insulation sleeving (1) as shown. 3. Position eight sections of insulation sleeving (1) on wires (2). 4. Connect eight sections of wire (2) to receptacle pins marked A, B, C, D, E, F, G, and H on receptacle (5). Place insulation sleeving (1) over wires (2) and receptacle pins and into position as shown.

  2. Apply sealant NSN 8040-00-225-4918 to receptacle pins, wires, and sleeving. 6. Use wire markers (3) on eight sections of wire (2) to locate and mark wires. Secure eight sections of wire (2) with five tiedown straps (4).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

Figure D-24. Anti-Noise Pad

1051_image_0.png

Figure D-97. Body Harness Connector Fabrication.

INSTRUCTIONS:

When connecting electrical wires to connector pins on body harness connector, use NSN 3439-00-133-1108 solder. (Refer to TB SIG-222 for soldering.)

  1. Cut eight sections of wire (2) to length as shown. 2. Place grommet retaining nut (5) over eight sections of wire (2). 3. Position eight sections of wire (2) in grommet (1). 4. Place coupling nut (6) over plug shell assembly (7). 5. Connect eight sections of wire (2) to receptacle pins marked A, B, C, D, E, F, G, and H on plug shell assembly (7).

  2. Position grommet (1) in plug shell assembly (7) and secure with grommet retaining nut (5). 7. Use wire markers (3) on eight sections of wire (2) to locate and mark wires. Secure eight sections of wire (2) with five tiedown straps (4).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

Figure D-26. Windshield Lower Seal

1052_image_0.png

Figure D-98. Engine Harness Plug Connector Fabrication.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

Instructions: Note

When connecting electrical wire to connector pins on engine harness plug connector, use NSN 3439-00-133-1108 solder. (Refer to TB SIG-222 for soldering.) 14. Using plug connector (1) and wire markers (3), locate and mark nine wires. Secure nine wires with six tiedown straps (4).

  1. Cut three sections of electrical wire (6) to length as shown. 2. Remove 3-in. (76.2 mm) section of electrical insulation from electrical wire (6). 3. Cut three sections of insulation sleeving (7) to length as shown. 4. Position three sections of insulation sleeving (7) over wires (6). 5. Using plug connector (1), disassemble shell, coupling nut (5), ferrule, and grommet. 6. Place coupling nut (5) and ferrule over three wires (6). 7. Place three wires (6) in holes marked D, E, and F in grommet. 8. Connect three wires (6) to receptacle pins marked D, E, and F on shell. 9. Cut six sections of electrical wire (2) to length as shown.

  2. Place six wires (2) in coupling nut (5), ferrule, and holes marked A, B, C, G, H, and I on grommet.

  3. Connect six wires (2) to receptacle pins marked A, B, C, G, H, and I on shell.

  4. Position grommet and ferrule in shell and secure with coupling nut (5). Using three wires (6) with insulation, heat-shrink sleeving (7) in position.

  5. Apply sealant NSN 8040-00-225-4918 to three wires (6) and insulation sleeving (7) on plug connector (1).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

Figure D-28. Tray Assembly Seal
INSTRUCTIONS: Cut seal to length shown.
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
14 AWG WIRE, ELECTRICAL MIL-C-13486
14 AWG WIRE, ELECTRICAL MIL-C-13486/1
N/A INSULATION SLEEVING MIL-I-23053/2
N/A INSULATION SLEEVING MIL-I-23053/5

1054_image_0.png

Figure D-99. Engine Harness Receptacle Fabrication.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

Instructions: Not E

When connecting electrical wire to connector pins on engine harness receptacle, use NSN 3439-00-133-1108 solder. (Refer to TB SIG-222 for soldering.)

  1. Cut three sections of electrical wire (2) to length as shown. 2. Cut three sections insulation sleeving (1) to length as shown. 3. Position three sections of insulation sleeving (1) on wires (2). 4. Connect three wires (2) to receptacle pins marked D, E, and F on receptacle connector (7). Place insulation sleeving (1) over wires (2) and receptacle pins and heat-shrink insulation sleeving (1) into position.

  2. Apply sealant NSN 8040-00-225-4918 to three wires (2) and insulation sleeving (1) on receptacle connector (7).

  3. Cut six sections of electrical wire (5) to length as shown. 7. Cut six sections of insulation sleeving (6) to length as shown. 8. Position six sections of insulation sleeving (6) on wires (5). 9. Connect six wires (5) to receptacle pins marked A, B, C, G, H, and I on receptacle connector (7).

Place electrical insulating sleeving (6) over wires (5) and receptacle pins and heat-shrink insulation sleeving (6) into position.

  1. Use wire markers (3) on nine sections of wire to locate and mark wires. Secure wires with six tiedown straps (4).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

ITEM MATERIALS
NO. REQ'D DESCRIPTION NSN/PART NUMBER
4 1 Mini-box (bottom section) 5999-00-971-8848
7 6 Screw 5305-00-958-4353
8 6 Washer 5310-00-880-5976
9 6 Non-metallic Bumper 5340-01-219-6733
10 6 Nut 5310-00-934-9753

1056_image_0.png

Figure D-100. Mini-box Bottom Section Drill Procedure.

1057_image_0.png

Figure D-100. Mini-box Bottom Section Drill Procedure (Cont'd).

Instructions:

  1. Locate, mark, and drill 0.138-in. diameter hole (1) in mini-box bottom section (4) as shown. 2. Locate, mark, and drill two 1.250-in. diameter holes (2) in mini-box bottom section (4) as shown. 3. Locate, mark, and drill four 0.190-in. diameter holes (3) in mini-box bottom section (4) as shown. 4. Locate, mark, and drill fourteen 0.138-in. diameter holes (5) in mini-box bottom section (4) as shown. 5. Locate, mark, and drill two 0.750-in. diameter holes (6) in mini-box bottom section (4) as shown. 6. Install six non-metallic bumpers (9) on mount holes on mini-box bottom section (4) with washers (8), screws (7), and nuts (10) as shown.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

PRE-PUNCHED CHANNEL
CHANNEL CUT LENGTH MANUFACTURED
PART NUMBER FROM NSN
67 AS SHOWN N/A
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
3 ft CHANNEL N/A

1058_image_0.png

Figure D-101. Pre-punched Channel.

INSTRUCTIONS: Cut two channels to length shown.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

ITEM MATERIALS
NO. REQ'D DESCRIPTION PART NUMBER
ل 1 Channel, Pre-punched: 7 in. 67
6 2 3 Terminal Block 0621
3 Terminal Block 0624
4 1 End Section 0630
5 2 Channel Clamp ୧୫

1059_image_0.png

Figure D-102. Channel, 7.00-in. and Terminal Block Assembly.

Instructions:

Install three terminal blocks (2), terminal blocks (3), terminal blocks (2), and end section (4) on channel (1) with two channel clamps (5).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

MATERIALS ITEM DESCRIPTION NO. REQ'D PART NUMBER
ພ
1 Channel, Pre-punched: 6 in. 67 8 Terminal Block 0621
1 End Section 0630 4 2 Channel Clamp ୧୫

1060_image_0.png

Figure D-103. Channel, 6.00-in. and Terminal Block Assembly.

INSTRUCTIONS: Install eight terminal blocks (2) and end section (3) on channel (1) with two channel clamps (4).

ITEM MATERIALS
NO. REQ'D DESCRIPTION NSN/PART NUMBER
1 2 Grommet, Non-metallic 5325-00-270-8890
2 র্ব Cable Tie Holder MB4A
3 8 Screw 5305-00-958-4353
4 র্ব Screw 5305-00-984-6210
5 1 Mini-box (bottom section) 5999-00-971-8848
6 2 Grommet, Non-metallic 5325-00-309-7164
7 1 Wire Marker 46F5981
8 র্ব Nut 5310-00-934-9758
9 4 Washer 5310-00-883-9384
10 8 Washer 5310-00-880-5976
11 8 Nut 5310-00-934-9753

1061_image_0.png

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

Figure D-104. Terminal Block Assemblies and Cable Tie Holder Installation.

Instructions:

  1. Using wire marker (7) and 6-in. and 7-in. terminal block assemblies, locate and mark sections as shown.

  2. Install 6-in.and 7-in. terminal block assemblies in mini-box bottom section (5) with four screws (4), washers (9), and nuts (8).

  3. Install four cable tie holders (2) in mini-box bottom section (5) with eight screws (3), washers (10), and nuts (11).

  4. Install two non-metallic grommets (1) in holes A on mini-box bottom section (5). 5. Install two non-metallic grommets (6) in holes B on mini-box bottom section (5).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

WINCH BATTERY CABLE
CABLE CUT
ITEM PART LENGTH MANUFACTURED END TERMINALS END INSULATOR
NO. NUMBER (INCHES) FROM NSN NSN
1 15847 74 6145-00-538-8219 5940-00-520-2447 M23053/03-0
5940-00-197-3664 (81349)
2 15848 87-1/2 6145-00-538-8219 5940-00-520-2447 M23053/03-0
5940-00-197-3664 (81349)
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
4 IN. GAGE, TYPE 1, CLASS A WIRE, ELECTRICAL MIL-C-13486

1062_image_0.png

Figure D-105. Receptacle Plug and Pin Assemblies.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

1063_Image_0.png

Figure D-105. Receptacle Plug and Pin Assemblies (Cont'd).

Instructions:

  1. Cut fourteen sections of electrical wire (2) to length as shown. 2. Install fourteen receptacle pins (1) on wires (2) as shown. 3. Using fourteen wire markers, mark wires (2) with numbers 1 through 13 and 16 as shown. 4. Install eleven terminal lugs (4) on wires (2) marked 2, 3, 4, 5, 6, 7, 9, 10, 12, 13, and 16 as shown. 5. Install two receptacle pins (1) (without wires) in slotted positions marked 14 and 15 on receptacle plug (5).

  2. Install fourteen receptacle pins (1) (with wires connected) in slotted positions marked 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, and 16 on receptacle plug (5).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

ITEM MATERIALS
NO. REQ'D DESCRIPTION NSN
ਤੋਂ 28 Terminal Lug 5940-00-283-5280

Instructions: Note

  1. Route wires (5) from body harness receptacle (6) through grommet (7). 2. Install eight terminal lugs (3) on wires (5) from body harness receptacle (6). 3. Install wires (5) marked A, B, C, D, E, F, G, and H on body harness receptacle (6) to matching letters on terminal block assembly (4).

  2. Route wires (10) from body harness connector (8) through grommet (9). 5. Install eight terminal lugs (3) on wires (10) from body harness connector (8). 6. Install wires (10) marked A, B, C, D, E, F, G, and H on body harness connector (8) to matching letters on terminal block assembly (4).

  3. Route wires (13) on engine harness connector (14) through grommet (15). 8. Connect three wires (12) marked D, E, and F on engine harness connector (14) to matching letters on terminal block assembly (11). Do not tighten screws.

  4. Install six terminal lugs (3) on wires (13) from engine harness connector (14)

  5. Install wires (13) marked A, B, C, G, H, and I on engine harness connector (14) to matching letters on terminal block assembly (11).

  6. Route wires (2) on engine harness receptacle (1) through grommet (16).

  7. Connect three wires (12) marked D, E, and F on engine harness receptacle (1) to matching letters on terminal block assembly (11).

  8. Install six terminal lugs (3) on wires (2) from engine harness receptacle (1). 14. Install wires (2) marked A, B, C, G, H, and I on engine harness receptacle (1) to matching letters on terminal block assembly (11).

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

1065_image_0.png

Figure D-106. Body, Engine Harness Connector, and Receptacle Installation.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

1066_Image_0.png

Figure D-107. Receptacle Plug Installation.

INSTRUCTIONS:

  1. Connect wires (3) marked 2, 3, 4, 6, 7, and 16 on receptacle plug (4) to terminal strip (2) marked H, F, G, C, D, and B.

  2. Connect wire (3) marked 13 on receptacle plug (4) to terminal strip (2) marked E. 3. Connect wires (5) marked 1, 8, 11 on receptacle plug (4) to terminal strip (1) marked E, F, D. 4. Connect wires (3) marked 5, 9, 10, and 12 on receptacle plug (4) to terminal strip (1) marked A, H, I, and G.

ITEM MATERIALS
NO. REQ'D DESCRIPTION NSN/PART NUMBER
3 র্ব Screw 5305-00-984-6210
4 2 Loop Clamp 5340-00-057-2904
5 2 Conduit Insulation: 48 in. 68240
દ AR Tape 7510-00-802-8311
8 র্ব Washer 5310-00-883-9384
9 র্ব Nut 5310-00-934-9758
11 র্ব Tiedown Strap 5975-00-074-2072
12 2 Loop Clamp 5434-00-724-7038
13 2 Conduit Insulation: 54 in. 68243

1067_image_0.png

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

Figure D-108. Terminal Strip Installation.

Instructions:

  1. Install four tiedown straps (11) in cable tie holders (10) and secure wires (2) to cable tie holders (10) with tiedown straps (11).

  2. Install two loop clamps (4) on wires (2) of body harness connector and receptacle with screws (3), washers (8), and nuts (9).

  3. Install two loop clamps (12) on wires (2) of engine harness connector and receptacle with screws (3), washers (8), and nuts (9).

  4. Cut two 48-in. (1,219.2 mm) sections of conduit insulation (5). 5. Remove ten tiedown straps (7) from wires (2) of body harness connector and receptacle. 6. Position two sections of conduit insulation (5) over wires (2) of body harness connector and receptacle and secure with tape (6).

  5. Cut two 54-in. (1,371.6 mm) sections of conduit insulation (13). 8. Remove twelve tiedown straps (7) from wires on engine harness connector and receptacle. 9. Position sections of conduit insulation (13) over wires (2) on engine harness connector and receptacle and secure with tape (6).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

ITEM MATERIALS
NO. REQ'D DESCRIPTION NSN
I 5 Electrical Wire: 12 in. 6145-00-152-6499
2 5 Tip Jack 5935-00-683-7651
:3 5 Insulation Sleeving: 1 in. 5970-00-815-1295
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
14 AWG WIRE, ELECTRICAL MIL-C-13486/1
N/A INSULATION SLEEVING MIL-I-23053/5

1068_image_0.png

Figure D-109. Tip Jack Lead Assembly.

INSTRUCTIONS:

Not E

When connecting electrical wire to receptacle pins on tip jacks, use NSN 3493-00-133-1108 solder. (Refer to TB SIG-222 for soldering.)

  1. Cut wire (1) into five 12-in. sections as shown. 2. Cut insulation sleeving (3) into five 1-in. sections as shown. 3. Connect five wires (1) to receptacle pins on tip jacks (2). 4. Place insulation sleeving (3) over wires (1) and receptacle pins and heat-shrink insulation sleeving (3) into position.

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

1069_image_0.png

Figure D-110. Mini-box Top Section Drill Procedure.

Instructions:

Locate, mark, and drill thirteen 0.156-in. diameter holes (1) in mini-box top section (4).

Locate, mark, and drill six 0.205-in. diameter holes (3) in mini-box top section (4).

Locate, mark, and drill four 0.138-in. diameter holes (2) in mini-box top section (4).

ITEM MATERIALS
NO. REQ'D DESCRIPTION મરા
1 Data Mark Set 7510-01-040-7110
1 Data Mark Set 7510-01-158-1037
2 13 Led 5980-01-288-0188
3 1 Mini-Box (top section) 5999-00-971-8848
র্ব 5 Tip Jack (assembled in figure D-109) 5935-00-683-7651
7 5 Terminal Lug 5940-00-283-5280
10 1 Tip Jack 5935-00-683-7651
13 25 Insulation Sleeving: 1 in. 5970-00-812-2974

1070_image_0.png

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

Figure D-110. Mini-box Top Section Drill Procedure (Cont'd).

Instructions (Cont'D):

  1. Using data mark set, mark location of thirteen holes (1) on mini-box top section (3). 5. Using data mark set, mark location of six holes (9) on mini-box top section (3). 6. Install tip jack (10) and nut (8) in hole (9) marked 2 on mini-box top section (3). 7. Install five tip jacks (4) with wires (5) and nuts (6) in holes (9) marked 1, 3, 4, 5, and 6 on mini-box top section (3).

  2. Install five terminal lugs (7) to wires (5) on tip jacks (4). 9. Install thirteen LEDs (2) in holes (1) marked 1 through 13 on mini-box top section (3).

  3. Cut electrical insulation sleeving (13) into twenty-five sections as shown.

  4. Place twelve sections of electrical insulation sleeving (13) over red (+) wires (11) marked 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, and 13 on LEDs (2).

  5. Place thirteen sections of electrical insulation sleeving (13) over black (–) wires (12) marked 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, and 13 on LEDs (2).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

ITEM MATERIALS
NO. REQ'D DESCRIPTION NSN/PART NUMBER
Punch Board: 2 x 3 in. 64P44EP
2 31 Electrical Wire: 5 in. 6145-00-808-4849
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
N/A WIRE, ELECTRICAL MIL-W-16878/4
N/A PUNCH BOARD 64P44EP

1071_image_0.png

Figure D-111. Punch Board and Electrical Wire.

Instructions:

  1. Cut punch board (1) to size as shown. 2. Locate, mark, and drill four 0.375-in. diameter holes in punch board (1) as shown. 3. Cut thirty-one 5-in. sections of electrical wire (2) as shown.
ITEM MATERIALS
NO. REQ'D DESCRIPTION NSN/PART NUMBER
1 1 Plug Connector 5935-01-230-9304
2 1 Punch Board (fabricated in figure D-99) 64P44EP
3 1 Isolated Resistor Network 13F170
4-6 3 Diode ECG125
7 1 Bussed Resistor Network 13F171
31 Wire (cut in figure D-99)

1072_image_0.png

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

Figure D-112. Punch Board Assembly.

Instructions:

5 . Install bussed resistor network (7) on punch board (2). 6 . Install eleven wires to pins (8) marked 1, 2, 3, 4, 5, 8, 9, 10, 11, 12, and 14 on bussed resistor network (7).

7 . Install diodes (4), (5), and (6) on punch board (2).

  1. Install plug connector (1) on punch board (2). 2. Install fourteen wires to pins (8) marked 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, and 16 on plug connector (1).

  2. Install insulated resistor network (3) on punch board (2). 4. Install six wires to pins (8) marked 1, 4, 7, 8, 11, and 14 on isolated resistor network (3).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

1073_Image_0.png

Figure D-113. Test Module Assembly.

Instructions:

1 . Connect wire marked 6 on plug connector to banded end of diode R1. 2 . Connect wire marked 14 on isolated resistor network to bandless end of diode R1. 3 . Connect wire marked 7 on plug connector and wire marked 14 on bussed resistor network to banded end of diode R2.

4 . Connect wire marked 13 on plug connector to bandless end of diode R3. 5 . Connect wire marked 11 on isolated resistor network to bandless end of diode R2. 6 . Connect wire marked 8 on isolated resistor network bandless end of diode R3. 7. Connect wire marked 1 on isolated resistor network to black (-) wire marked 6 on LED on mini-box top section.

  1. Connect wire marked 4 on isolated resistor network to black (-) wire marked 7 on LED. 9. Connect wire marked 7 on isolated resistor network to black (-) wire marked 13 on LED.

1074_image_0.png

Section Ii. Illustrated Manufacturing Instructions (Cont'D)

Figure D-113. Test Module Assembly (Cont'd).

Instructions (Cont'D):

Connect wire marked 16 on plug connector to red (+) wire marked 13 on LED.

Connect wire marked 1 on plug connector to three red (+) wires marked 1, 6, and 7 on LED.

Connect wire marked 2 on plug connector to red (+) wire marked 2 on LED.

Connect wire marked 3 on plug connector to red (+) wire marked 3 on LED.

Connect wire marked 4 on plug connector to red (+) wire marked 4 on LED.

Connect wire marked 5 on plug connector to red (+) wire marked 5 on LED.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

1075_Image_0.png

Figure D-113. Test Module Assembly (Cont'd).

Instructions (Cont'D):

  1. Connect wire marked 8 on plug connector to red (+) wire marked 8 on LED. 17. Connect wire marked 9 on plug connector to red (+) wire marked 9 on LED. 18. Connect wire marked 10 on plug connector to red (+) wire marked 10 on LED. 19. Connect wire marked 11 on plug connector to red (+) wire marked 11 on LED. 20. Connect wire marked 12 on plug connector to red (+) wire marked 12 on LED.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

1076_Image_0.png

Figure D-113. Test Module Assembly (Cont'd).

Instructions (Cont'D):

  1. Connect wire marked 9 on bussed resistor network to black (–) wire marked 9 on LED. 28. Connect wire marked 10 on bussed resistor network to black (–) wire marked 10 on LED. 29. Connect wire marked 11 on bussed resistor network to black (–) wire marked 11 on LED. 30. Connect wire marked 12 on bussed resistor network to black (–) wire marked 12 on LED.

  2. Connect wire marked 1 on bussed resistor network to black (–) wire marked 1 on LED. 22. Connect wire marked 2 on bussed resistor network to black (–) wire marked 2 on LED. 23. Connect wire marked 3 on bussed resistor network to black (–) wire marked 3 on LED. 24. Connect wire marked 4 on bussed resistor network to black (–) wire marked 4 on LED. 25. Connect wire marked 5 on bussed resistor network to black (–) wire marked 5 on LED. 26. Connect wire marked 8 on bussed resistor network to black (–) wire marked 8 on LED.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

ITEM MATERIALS
NO. REQ'D DESCRIPTION NSN/PART NUMBER
2 ব Spacer 313-1437-024
3 25 Insulation Sleeving (install in figure D-110) 5970-00-812-2974
ব র্ব Screw 5305-00-928-9021
8 র্ব Washer 5310-00-880-5976
9 র্ব Nut 5310-00-934-9753

1077_image_0.png

Figure D-113. Test Module Assembly (Cont'd).

Instructions (Cont'D):

  1. Place electrical insulation sleeving (3) over wire (10) marked 1 on plug connector. 32. Place twenty-four sections of insulation sleeving (3) over connected wires (6) and (11) on LEDs (5) and heat-shrink into position.

  2. Install four screws (4) in mount holes (12) on mini-box top section (1) and position four spacers (2) and punch board (7) on screws (4) and secure with four washers (8) and nuts (9).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
14 AWG WIRE ELECTRICAL MIL-C-13486/1
ITEM MATERIALS
NO. REQ'D DESCRIPTION NSN
1 2 Terminal Lug 5940-00-577-3807
1 Electrical Wire: 12 in. 6145-00-808-4849
-1 1 Screw 5305-00-984-6210
8 1 Nut 5310-00-934-9758
11 1 Washer 5310-00-883-9384

1078_image_0.png

Figure D-113. Test Module Assembly (Cont'd).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

1079_Image_0.png

Figure D-113. Test Module Assembly (Cont'd).

Instructions (Cont'D):

  1. Cut electrical wire (2) to length as shown. 35. Connect two terminal lugs (1) on wire (2). 36. Install wire (2) and tip jack lead (3) marked 5 on mount hole (10) on mini-box bottom section (9) with washer (11), screw (7), and nut (8).

  2. Connect wire (2) to terminal strip (4) marked D with screw (5). 38. Connect tip jack lead (3) marked 1 to terminal strip (6) marked H with screw (5). 39. Connect tip jack lead (3) marked 3 to terminal strip (6) marked B with screw (5). 40. Connect tip jack lead (3) marked 4 to terminal strip (6) marked C with screw (5). 41. Connect tip jack lead (3) marked 6 to terminal strip (6) marked A with screw (5). 42. Using existing drive pin, punch out four screw mount holes (14) in mini-box top section (12). 43. Install plug (16) and connector (15) as shown. 44. Install mini-box top (12) on bottom section (9) with four existing screws (13).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

GREEN RUBBER CANVAS
PART CUT MANUFACTURED
NO. LENGTH FROM NSN
(INCHES)
8434398 2 at 3X12 8305-00-616-0022
4 at 4X15
2 at 36X6
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
39.00 IN. MINIMUM CLOTH,COATED PLASTIC, VINYL BOTH SIDES 11 TYPE AND 2 CLASS

1080_image_0.png

Figure D-114. Green Rubber Canvas Straps.

Instructions:

  1. Cut canvas, NSN 8305-00-616-0022, into eight reinforcement straps for lengths shown. 2. Secure six grommets, NSN 5325-00-281-8643, and six stud turn buttons, NSN 5325-00-930-7607, to canvas straps using twelve clinch plate turn buttons, NSN 5325-00-371-8108.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

HEX WRENCH
PART CUT MANUFACTURED
NO. LENGTH FROM NSN
(INCHES)
N/A as shown 9515-00-814-7316
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.188 IN. THICK STRIP, METAL ASTM-A569

1081_image_0.png

Figure D-115. Hex Wrench.

Instructions:

  1. Cut piece of steel sheet metal to size as shown. 2. Remove all burrs and sharp edges.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.125 IN. THICK 0.188 IN. THICK STRIP, METAL ASTM-A569
OPEN END WRENCHS
PART CUT MANUFACTURED
NO. LENGTH FROM NSN
(INCHES)
N/A as shown 9515-00-814-7316
9515-00-596-2044

1082_image_0.png

Figure D-116. Open End Wrench.

Instructions:

  1. Cut piece of 0.188 in. steel sheet metal to make handle (2) as shown. 2. Cut two 0.125 in. pieces of sheet metal to make two jaws (1) as shown. 3. Weld two jaws (1) to handle (2). 4. Remove all burrs and sharp edges.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

SHEET
PART CUT MANUFACTURED
NO. LENGTH FROM NSN
(INCHES)
N/A as shown 9530-00-226-0380
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.700 IN. THICK ALUMINUM ALLOY N/A

1083_image_0.png

1083_image_1.png

Figure D-117. Fixture Fabrication.

Instructions:

  1. Fabricate fixture according to dimensions as shown. 2. Remove all burrs and sharp edges.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

SHEET
PART CUT MANUFACTURED
NO. LENGTH FROM NSN
(INCHES)
N/A as shown 9510-00-229-4822
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
N/A BAR, METAL ASTM A108

1084_image_0.png

Figure D-118. Bushing Fabrication.

Instructions:

  1. Using NSN 9510-00-229-4822 metal bar, fabricate bushing (1) as shown. 2. Remove all burrs and sharp edges. 3. Press bushing (1) into fixture hole (2) (fixture fabricated in figure D-117).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

Figure D-53. A/C Compartment Access Door Insulation
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.375 IN. INSIDE DIAMETER 0.625 IN. OUTSIDE DIAMETER HOSE, WIRE BRAIDED N/A

1085_image_0.png

Figure D-119. Hose.

INSTRUCTIONS:

Not E

Do not apply sealing compound to first two threads of straight a d a p t e r.

  1. Connect clamp (3), straight adapter (2), and straight swivel adapter (1) to hose (4). Tighten clamp (3). 2. Connect clamp (3), straight adapter (5), pipe coupling (6), and pipe nipple (7) to hose (4). Tighten clamp (3).

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.125 X 2.57 X 3.50 IN. ALUMINUM FLAT SHEET IAW ASTM B 209
0.125 X 0.75 X 24.0 IN. ALUMINUM RECTANGLE IAW ASTM B 211

1086_image_0.png

Figure D-120. Pulley Alignment Tool Fabrication.

INSTRUCTIONS:

Not E

  1. Cut aluminum sheet (1) to size as shown. 2. Position aluminum rectangle (2) on top of aluminum sheet (1) as shown in figure D-130.

NOT E Check all measurements before welding, riveting, or bolting pulley alignment tool together.

  1. Assemble pulley alignment tool as shown in figure D-130.

Section Ii. I L L U S T R Ated Manufacturing Instructions (Cont'D)

1087_image_0.png

Figure D-120. Pulley Alignment Tool Fabrication (Cont'd).

ITEM MATERIALS
NO. DESCRIPTION REQ'D NSN/PART NUMBER
Terminal Lug 5940-00-113-8184
2 Terminal Lug 5940-00-504-4703
3 Electrical Wire: 9.7 in. 6145-00-570-0516
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
18 AWG WIRE, ELECTRICAL (WITH INSULATION) MIL-C-13486

1088_image_0.png

Figure D-121. Grounding Jumper Wire.

Instructions:

  1. Cut a electrical wire (3) to length as shown. 2. Install terminal lugs (1) and (2) as shown.

Appendix E Torque Limits

E-1. General

This section provides general torque limits for screws used on the M998 series vehicles. Special torque limits are indicated in the maintenance procedures for applicable components. The general torque limits given in this appendix shall be used when specific torque limits are not indicated in the maintenance procedure.

Unless otherwise specified, standard torque tolerance shall be ± 10%. These general torque limits cannot be applied to screws that retain rubber components. The rubber components will be damaged before the correct torque limit is reached. If a special torque limit is not given in the maintenance instructions, tighten the screw or nut until it touches the metal bracket, then tighten it one more turn.

E-2. Torque Limits

Table E-1 lists dry torque limits. Dry torque limits are used on screws that do not have lubricants applied to the threads. Table E-2 lists wet torque limits. Wet torque limits are used on screws that have high pressure lubricants applied to the threads.

E-3. How To Use Torque Table

1089_Image_0.png

a. Measure the diameter of the screw

1089_image_2.png

you are installing.

b. Count the number of threads per inch.

c. Under the heading SIZE, look down the left-hand column until you find the diameter of the screw you are installing (there will usually be two lines beginning with the same size).

d. In the second column under SIZE, find the number of threads per inch that matches the number of threads you counted in step b.

CAPSCREW HEAD MARKINGS Manufacturer's marks may vary.

These are all SAE Grade 5 (3-line).

e.

f.

To find the grade screw you are installing, match

1089_image_1.png the markings on the head to the correct picture of CAPSCREW HEAD MARKINGS on the torque table.

Look down the column under the picture you found in step e. until you find the torque limit (in lb-ft or NŽm) for the diameter and threads per inch of the screw you are installing.

Table E-1. Torque Limits for Dry Fasteners

1090_image_0.png

CAPSCREW HEAD MARKINGS

TORQUE
ડાટદ SAE GRADE NO. 1 or 2 SAE GRADE NO. 5 SAE GRADE NO. 6 or 7 SAE GRADE NO. 8
DIA. INCHES THREADS PER INCH MILUMETERS POUND FEET NEWTON METERS POUND FEET NEWTON METERS POUND FEET NEWTON METERS POUND FEET NEWTON METERS
1/4 20 6.35 5 6.78 8 10.85 10 13.56 12 16.27
1/4 28 6.35 6 8.14 10 13.56 ー 一 14 18.98
5/16 18 7.94 11 14.92 17 23.05 19 25.76 ર્ડવે 32.52
5/16 তৰ্ 7.94 13 17.63 19 25.76 l l 27 36.61
3/8 16 9.53 18 24.41 31 42.04 34 46.10 イダ 59.66
3/8 24 9.53 20 27.12 35 47.46 l l 49 66.44
7/16 14 11.11 28 37.97 ਕੰਰੇ 66.44 રેર 74.58 70 94.92
7/16 20 l 30 40.68 55 74.58 ー l 78 105.77
1/2 I 3 12.70 39 52.88 75 101.70 8 ર 115.26 105 142.38
1/2 20 一 イ1 55.60 85 115.26 ー ﺴ 120 162.72
9/16 12 14.29 २ । 69.16 110 149.16 120 162.72 155 210.18
9/16 18 l ર્ફ 74.58 120 162.72 - ー 170 230.52
રાજ 11 15.88 63 85.43 150 203.40 167 226.45 210 284.76
5/8 18 - તેર 128.82 170 230.52 ー l 240 325.44
3/4 10 19.05 105 142.38 270 366.12 280 379.68 375 508.50
3/4 16 l 112 155.94 295 400.02 - | 420 569.52
7/8 9 22.23 160 216.96 રૂત્રેસ 535.62 440 596.64 605 820.38
7/8 14 一 175 237.30 435 589.86 -- - 675 915.30
1 8 25.40 235 318.66 590 800.04 ୧୧୦ 894.96 910 1233.96
1 14 一 250 339.00 660 894.96 ー ー 990 1342.44
1-1/8 ー 25.58 ー 1 800- 1084.8- l - 1280- 1735.7-
880 1193.3 1440 1952.8
1-1/4 ー 31.75 - l - l ー 一 1820- 2467.9-
1-3/8 1460- 1979.8 - 2000 2380- 2712.0 3227.3-
ー 34.93 - - 1680 2278.1 - 2720 3688.3
1-1/2 ー 38.10 - | 1940- 2630.6- ー - 3160- 4285.0-
2200 2983.2 3560 4827.4

Table E-2. Torque Limits for Wet Fasteners

1091_image_0.png

CAPSCREW HEAD MARKINGS

SAE GRADE TORQUE SAE GRADE
SIZE SAE GRADE SAE GRADE
NO. 1 or 2 NO. 5 NO. 6 or 7 NO. 8
DIA. THREADS MILUMETERS POUND NEWTON POUND NEWTON POUND NEWTON POUND NEWTON
INCHES PER INCH FEET METERS FEET METERS FEET METERS FEET METERS
1/4 20 6.35 4.5 6.10 7.2 9.76 9.0 12.20 10.8 14.64
1/4 28 6.35 5.4 7.33 9.0 12.20 - l 12.6 17.08
5/16 18 7.94 9.9 13.43 15.3 20.75 17.1 23.18 21.6 29.27
5/16 24 7.94 11.7 15.87 17.1 23.18 - ー 24.3 32.95
3/8 16 9.53 16.2 21.97 27.9 37.84 30.6 41.49 39.6 53.69
3/8 24 9.53 18.0 24.41 31.5 42.71 - l 44.1 59.80
7/16 14 11.11 25.2 34.17 44.1 59.80 49.5 67.12 63.0 85.42
7/16 20 - 27.0 36.61 49.5 67.12 - l 70.2 95.19
1/2 13 12.70 35.1 47.59 67.5 91.53 76.5 103.73 94.5 128.14
1/2 20 - 36.9 50.04 76.5 103.73 - l 108.0 146.45
8/16 12 14.29 45.9 62.24 99.0 134.24 108.0 146.45 139.5 189.16
9/16 18 | 49.5 67.12 108.0 146.45 - l 153.0 207.47
5/8 11 15.88 56.7 76.89 135.0 183.06 150.3 203.80 189.0 256.28
5/8 18 - 85.5 115.94 153.0 207.47 l 一 216.0 296.90
3/4 10 19.05 94.5 128.14 243.0 329.51 252.0 341.71 337.5 457.65
3/4 16 - 103.5 140.35 265.5 360.02 - - 378.0 536.87
7/8 9 22.23 144.0 195.26 355.5 482.06 396.0 536.98 544.5 738.34
7/8 14 - 157.5 213.57 391.5 530.87 l l 607.5 823.77
I 8 25.40 211.5 286.79 531.0 720.04 594.0 805.46 819.0 1110.56
1 14 l 225.0 305.10 594.0 805.46 - l 891.0 1208.20
1-18 ー 25.58 l l 720.0- 976.32- - - 1152.0- 1562.13-
792.0 1073.97 1296.0 1757.52
1-1/4 - 31.75 - - l - - - 1638- 2221.11-
1800 2440.80
1-3/8 一 34.93 - ー 1314.0- 1781.82- l - 2142.0- 2904.57-
1512.0 2050.29 2448.0 3319.47
1-1/2 一 38.10 - - 1746.0- 2367.54- - 一 2844.0 3856.5-
1980.0 2684.88 3204.0 4344.66

Appendix E (Cont'D)

E-5. Conversion Formula

Corrected ll 19 lb-ft (25.8 N-m)
reading
Corrected = 19 lb-ft (25.8 N.m) +
reading
Corrected 19 lb-ft (25.8 N.m) +
reading
Corrected 17 lb-ft (23.1 N.m)
reading

Corrected dial or scale readings are determined by the use of the following formula:

Corrected Required Length of torque wrench + Length of adapter
reading torque value Length of Torque Wrench

The length of the torque wrench is measured from the center of the handle to the center of the drive. The length of the adapter is measured from the center of the drive to the center of the winch.

Example:

1.14

1092_image_0.png

In this example, the torque wrench measures 22 in. (55.9 cm) and the adapter is 3 in. (7.6 cm). The required torque is 19 lb-ft (25.8 NŽm).

22 in. (55.9 cm) + 3 in. (7.6 cm)
+ 22 in. (55.9 cm)
25 in. (63.5 cm)
22 in. (55.9 cm)

Appendix F Wiring Diagrams And Schemat I C

F-1. General

This appendix contains wiring diagrams of special vehicle equipment and an overall vehicle electrical system schematic you will need to maintain M998 series vehicles.

FIGURE TITLES PAGE
NO. NO.
F-1 Winch Wiring Diagram F-2
F-2 Arctic Winterization Kit Wiring Diagram F-3
F-3 AN/GRC-160 Communications Kit Wiring Diagram F-4
F-4 Slave Receptacle and TOW Harness Wiring Diagram F-5
F-5 M1097, "A1", and "A2" Series Vehicles, Switch and F-6
Lamp Transfer Case Low Lock Indicator Wiring Diagram
F-6 M1097, "A1", and "A2" Series Vehicles, Auxiliary Power Supply Wiring Diagram F-7
F-7 Siren and Warning Light Wiring Diagram F-8
F-8 Glow Plug Control Functional Logic Diagram F-9
F-9 Protective Control Box ("A2" Series Vehicles) F-10
F-10 Buss Bar and 12 Volt Transmission Power ("A2" Series Vehicles) F-11
FO-1 Electrical System Wiring Diagram FP-1
FO-2 Electrical System Wiring Diagram (M996 and M996A1) FP-3
FO-3 Electrical System Wiring Diagram (M997 and M997A1) FP-7
FO-4 Electrical System Wiring Diagram (M1025A2, M1035A2, M1043A2, and M1045A2) FP-11
FO-5 Electrical System Wiring Diagram (M1097A2) FP-13
FO-6 Electrical System Wiring Diagram (M997A2) FP-15

F-2. Wiring Diagram And Schematic Index

1094_image_0.png

1095_image_0.png

1096_image_0.png

Figure 3. AN/GRC-160 Communications Kit Wiring Diagram.

The following applies to vehicles with serial number 100,000 and above and vehicles with kits 5705623 and 5705624 installed.

1097_image_0.png

Figure 4. Slave Receptacle and TOW Harness Wiring Diagram.

1098_image_0.png

Figure F-5. M1097, "A1", and "A2" Series Vehicles, Switch and Lamp Transfer Case Low Lock Indicator Wiring Diagram.

1099_image_0.png

Figure F-6. M1097, "A1", and "A2" Series Vehicles, Auxiliary Power Supply Wiring Diagram.

1100_image_0.png

SIREN ASSEMBLY

Figure F-7. Siren and Warning Light Wiring Diagram.

1101_image_0.png

Figure F-8. Glow Plug Control Functional Logic Diagram.

1102_image_0.png

Figure F-9. Protective Control Box ("A2" Series Vehicles).

1103_image_0.png

Figure F-10. Buss Bar & 12 Volt Transmission Power ("A2" Series Vehicles).

Figure FO-1. Electrical System Wiring Diagram (Located at Back of Manual).

Appendix G Mandatory Replacement Parts

Section I. INTRODUCTION

G-1. Scope

This appendix lists mandatory replacement parts you will need to maintain M998 series vehicles.

G-2. Explanation Of Columns

a. Column (1) - Item Number. This number is assigned to each entry in the listing and is referenced in the "Initial Setup" of applicable tasks under the heading of "Materials/Parts".

b. Column (2) - Nomenclature. Name or identification of the part. c. Column (3) - Part Number. The manufacturer's part number.

d. Column (4) - National Stock Number. The national stock number of the part.

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd) Figure D-57. A/C Compartment Condenser Side Insulation
Figure D-58. Litter Stowage Door Seal
INSTRUCTIONS: Cut seal to length shown.

Section II. MANDATORY REPLACEMENT PARTS

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd) Figure D-59. NBC Door and Access Panel Seals Determine seal part number needed from RPSTL and cut seal to length shown.
Figure D-60. NBC System PVC Tubing

Section II. MANDATORY REPLACEMENT PARTS (Cont'd)

Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)
Figure D-60. NBC System PVC Tubing (Cont'd)
NOTE
Make sure tubing is cut square at ends, and ends are free of nicks, burrs, and cracks.
Determine tubing part number needed from RPSTL and cut tube to length shown.
Figure D-61. Heat Shrink Insulation Sleeving
MATERIAL BLOCK STOCK SIZE DESCRIPTION SPECIFICATION
"O" GAGE WIRE, ELECTRICAL MIL-C-13486
200 AMP ALTERNATOR CABLE ASSEMBLY CABLE CUT LENGTH MANUFACTURED END TERMINAL END INSULATOR
PART NUMBER (INCHES) FROM NSN NSN NSN 5582451 58 6145-00-705-6674 5940-00-735-5520 5970-00-174-9449
Figure D-62. 200 Amp Alternator Cable Assembly.
1. Cut cable to length as shown. 2. Cut 14 inches of spiral wrap from bulk and install as shown. Secure spiral wrap in position with
black tape at both ends. 3. Select and solder proper end terminals to cable ends as shown. (Refer to TC 9-237 for soldering
instructions.) 4. Install insulator and insulator boot to cable ends as shown.
5. Mark and install identification bands using old cable as reference.

Section II. MANDATORY REPLACEMENT PARTS (Cont'd)

MATERIAL BLOCK STOCK SIZE DESCRIPTION SPECIFICATION
"O" GAGE WIRE, ELECTRICAL MIL-C-13486
12 VOLT ALTERNATOR CABLE ASSEMBLY CABLE CUT LENGTH MANUFACTURED END TERMINAL END INSULATOR
PART NUMBER (INCHES) FROM P/N PART NUMBER PART NUMBER 12446821 102 M13486/1-9 MS20659-108 12460417
Figure D-62.1. 12 Volt Alternator Cable Assembly.
1. Cut cable to length as shown. 2. Cut of 92.50 inches spiral wrap from bulk and install as shown. Secure spiral wrap in position with
tape at both ends. 3. Select and solder proper end terminals to cable ends as shown. (Refer to TC 9-237 for soldering
instructions.) 4. Install insulator and insulator boot to cable ends as shown.
5. Mark and install identification bands using old cable as reference.

Section II. MANDATORY REPLACEMENT PARTS

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.250-IN. DIAMETER TUBE, METALLIC MIL-T-6845
0.250-IN. (NOM)
INSIDE DIAMETER HOSE, NONMETALLIC MIL-H-13444
0.438-IN. (NOM)
OUTSIDE DIAMETER
FUEL FILTER BLEEDER TOOL
CUT
ITEM TOOL MANUFACTURED LENGTH
NO. PART NUMBER FROM NSN (INCHES)
1 5598825 1-1/2 4710-00-825-5894
2 5598826 24 4720-00-542-3304
1. 2. 3. 4. Figure D-63. Fuel Filter Bleeder Tool. INSTRUCTIONS: Cut steel tube, NSN 4710-00-825-5894, to length as shown. Thread one end of the tube 5/8 inch. Install nut, NSN 5310-00-997-1888, and O-ring, NSN 5330-00-966-8657, on threaded end of tube. Install 24-inch rubber hose, NSN 4720-00-542-3304, to the other end of the tube.

Section II. MANDATORY REPLACEMENT PARTS

MATERIAL BLOCK STOCK SIZE DESCRIPTION SPECIFICATION
1. .125 IN. THICK FLAT STEEL N/A 2. .375 IN. DIAMETER ROUND STEEL N/A
GLOW PLUG TOOL ITEM CUT MANUFACTURED FROM
NO. LENGTH PART NUMBER (FSCM) (INCHES)
1 as shown 9515-00-204-3994 2 as shown 9510-00-189-0652
DIMENSIONS: A. 7-1/2" F. 11/32"
B. 5-1/2" G. 45° C. 2" H. 1/8" Flat Steel
D. 1/2" I. 3/8" Rod E. 3/4"
Figure D-63.1. Glow Plug Tool Assembly.
1. Cut steel to lengths as shown. 2. Weld flat steel and round steel together at angle as shown.
3. Forked end (dimension F) must fit behind hex-head of glow plug. Thickness may have to be ground down from .125 inch to .0625 inch to insure proper fit.

Section II. MANDATORY REPLACEMENT PARTS

Figure D-64. Plastic Sheet
INSTRUCTIONS: Cut two pieces of plastic large enough to cover small hole or crack with enough to overlap about 1/4 in.
around damaged area of window.

Section II. MANDATORY REPLACEMENT PARTS

Figure D-65. Protective Shield
Cut aluminum sheet metal to size as shown. Locate, mark, and drill two 0.193-in. diameter holes in protective shield (1).
Locate, mark, and drill three 0.203-in. diameter holes in protective shield (1). Make two 0.50-in. relief cuts in sides of protective shield (1).
5. Bend edges (90° bend along dotted lines) on protective shield (1). Remove all burrs and sharp edges.
Paint protective shield (1) as required. Refer to TM 43-0139.

INDEX VOLUME III

Figure D-66. Protective Engine Cover
INSTRUCTIONS: 1. Cut plywood to dimensions shown. If necessary, modify plywood for proper fit.
2. Paint cover and outline with yellow safety boarder, 4-inches wide on outside edges. 3. Stencil "NO STEP AREA" caution on outside edges.
4. Prior to installing protective engine cover, remove both plate covers and seals from airlift brackets. 5. Store flat or hang on wall to prevent warpage.

INDEX (Cont'd)

Figure D-67. Cooler Fin Protective Cover
INSTRUCTIONS: 1. Cut plywood to dimensions shown. If necessary, modify plywood for proper fit.
2. Never use cover with engine running; engine damage will occur. 3. Stencil "NO STEP" caution to top of cover.
4. Prior to installing cooler fin protective cover, remove both plate covers and seals from airlift bracket. 5. Store flat or hang on wall to prevent warpage.

INDEX (Cont'd)

Figure D-68. Siren Mounting Bracket
INSTRUCTIONS:
Fabricate siren mounting bracket according to dimensions shown. 1. 2. Remove all burrs and sharp edges.
Clean per SPEC TT-C-490. Treat per SPEC Type I or II, or SPEC TT-C-490. 3. Prime per SPEC MIL-P-52192, MIL-P-53022, or MIL-P-53030. 4.
Finish-paint per SPEC MIL-C-46168. 5.

INDEX (Cont'd)

Figure D-69. Warning Light Mounting Bracket
INSTRUCTIONS: 1. Fabricate warning light mounting bracket according to dimensions shown.
2. Weld sizes are minimum. Weld per SPEC MIL-STD-1261. 3. Remove all burrs and sharp edges.
4. Clean per SPEC TT-C-490. Treat per SPEC Type I or II, or SPEC TT-C-490. 5. Prime per SPEC MIL-P-52192, MIL-P-53022, or MIL-P-53030.
6. Finish-paint per SPEC MIL-C-46168.

INDEX (Cont'd)

Figure D-70. Wire "D" - Adapter "A" to Adapter Connector "B"

INDEX (Cont'd)

Figure D-72. Wire "G" - Passenger Side Siren Switch Adapter Connector "E"

INDEX (Cont'd)

Figure D-74. Wire "K" - Battery Ground Stud by Relay Mounting Ground

INDEX (Cont'd)

Figure D-76. Wire "N" - Circuit Breaker to Battery Stud (Positive)

INDEX (Cont'd)

Figure D-78. Wire "J" - Warning Light Black Lead to Relay Mounting Ground

INDEX (Cont'd)

Figure D-80. Wire "B" - Light Toggle Switch Adapter Connector "A"

INDEX (Cont'd)

Figure D-82. - Relay Connector

INDEX (Cont'd)

1. Remove cargo shell door strap from vehicle. Refer to para. 11-22. 2. Position grab loop one-third of the way down strap. Fold strap into thirds and mark top fold.
3. Secure grab loop to strap with thread using box stitch and string. Refer to FM 10-16. 4. Install cargo shell door strap on vehicle with grab loop facing the rear. Refer to para. 11-22.
Figure D-83. Grab Loop

INDEX (Cont'd)

Figure D-84. Felt Sheet
INSTRUCTIONS: Cut felt to dimensions shown.

INDEX (Cont'd)

Figure D-85. Heat Shield Extension All inside bend radius to 6.12 unless otherwise specified.

INDEX (Cont'd)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICIATION
10 X 12-FT SHEET. ALUMINUM ALLOY IAW QQ-A-225/8
0.08 IN. THICK 6061-T6
LEFT SPLASH SHIELD ACCESS COVER
ACCESS COVER CUT TO SIZE MANUFACTURED FROM
PART NUMBER (INCHES) NSN
12446770 AS SHOWN 9530-01-071-2140
Figure D-86. Left Splash Shield Access Cover. INSTRUCTIONS:
1. Cut aluminum sheet metal to size as shown.
2. Locate, mark, and drill two .313-.375-in. diameter holes in left splash shield access cover as shown.
3. Locate, mark, and drill one .406-.466-in. diameter hole in left splash shield access cover as shown.
4. Remove all burrs and sharp edges.
5. Paint left splash shield access cover as required. (Refer to TM 43-0139.)

INDEX (Cont'd)

LEFT SPLASH SHIELD
SPLASH SHIELD CUT MANUFACTURED FROM PART NUMBER (INCHES) PART NUMBER
12446771 AS SHOWN 12340361
Figure D-87. Left Splash Shield.
INSTRUCTIONS: 1. Remove left splash shield. (Refer to para. 10-17.)
2. Cut hole (2) in left splash shield (1) as shown. 3. Using fabricated access cover (6) as a template, locate, mark, and drill a 0.312-inch diameter hole (5)
through left splash shield (1) as shown. NOTE
Existing mounting hardware is used to secure bottom right-hand hole. 4. Secure top two holes of access cover (6) to left splash shield (1) with two NSN 5306-00-225-8499
washers (4), NSN 5306-00-225-8499 screws (7), NSN 5310-00-087-7493 washers (4), and NSN 5310-00-814-0673 nuts (3) as shown.
5. Install modified left splash shield. (Refer to para. 10-17.)

INDEX (Cont'd)

Figure D-88. Mud Flap.
INSTRUCTIONS: Cut aluminum sheet metal to size as shown. 1.
2. Locate, mark, and drill two .75 X .40 in. slots in mud flap plate. Locate, mark, and drill two .40 in. diameter holes in mud flap plate. 3.
4. Remove all burrs and sharp edges. 5. Locate, mark, and drill eight holes in angle bracket (5) as shown.
6. Paint as required. Refer to TM 43-0139. Install mud flap (1) between mounting bracket (2) and angle bracket plate (5) with four washers (3), 7.
capscrews (6), washers (3), and locknuts (4).

INDEX (Cont'd)

Figure D-89. "C" Pillar Reinforcement Bracket.
1. Cut two pieces of aluminum sheet metal to size as shown. 2. Locate, mark, and drill four 0.125-inch diameter holes in reinforcement brackets (1).
3. Bend left reinforcement bracket (1). 4. Bend right reinforcement bracket (1) in opposite direction.

INDEX (Cont'd)

Figure D-90. Turret Bearing Seal.
INSTRUCTIONS: 1. Cut seal to length shown.

INDEX (Cont'd)

WINCH WIRE ROPE ASSEMBLY
ASSEMBLY CUT MANUFACTURED TERMINAL CLAMP THIMBLE
PART LENGTH FROM PART NUMBER PART NUMBER PART NUMBER
NUMBER (INCHES) PART NUMBER (CAGEC) (CAGEC) (CAGEC)
(CAGEC)
15667 1200.0 21451 (27647) 16464 (27647) MS16843-5 (96906) G-408-3/8 (75535)
4.0 INCH WIRE TERMINAL LOOP CLAMP ROPE Figure D-91, Winch Wire Rope Assembly
INSTRUCTIONS:
1. (a) Properly seize wire rope end before cutting. To seize wire rope end, follow these instructions.
NOTE
- Ensure each wrap is tight to the preceding wrap.
- Ensure the length of the seizing is not less than the diameter
of the wire rope.
(1) Wrap the seizing wire around the wire rope as tight as possible.
(2) Twist the ends of the seizing together by hand counterclockwise so that the twist is near the
middle of the seizing.
NOTE
Do not try to tighten the seizing by twisting.
(3) Tighten the twist just enough to take up the slack.
(4) Tighten the seizing by prying the twist away from the axis of the wire rope.
(5) Tighten the twist again as described in step (3).
(6) Repeat the process until the seizing can not be pryed away from the axis of the wire rope.
(7) Cut off wire ends and pound the twist into contact with the seizing.
(b) Cut wire rope to length as shown and install part of clamp with nut on wire rope.

INDEX (Cont'd)

Figure D-92. Ambulance Bulkhead Door Retainer.
lNSTRUCTIONS: 1. Cut retainer to length shown.

INDEX (Cont'd)

Figure D-93. Parking Brake Lever. INSTRUCTIONS:
CAUTION When drilling through the transmission cowl, be careful not to drill
into the transmission housing. NOTE
The location of the mounting hole will vary depending on vehicle configuration. Locate the hole in a suitable place, near the driver's
seat
Drill a 1/4-in. hole in the transmission cowl (7), near the driver's seat (10). 1. Cut chain (4) to desired length and install the clamp (1) on chain (4) with capscrew (5), lockwasher (2), 2.
and nut (3). Install chain (4) on transmission cowl (7) with capscrew (6), lockwasher (9), and nut (8). 3.
4. With the parking brake applied, slip clamp (1) over lever (11) to lock it in place. When not in use, stow the chain lock out of the way.
Paint chain lock red for easy identification. 5

INDEX (Cont'd)

Disconnect battery ground cable (Refer to para. 4-73). 1. NOTE
Have container availabe to catch fluid drainage from hydraulic hoses.
Remove clamp (4) and hydraulic hose (5) from elbow fitting (2). 2. Disconnect fan drive hydraulic hose (11) from fitting (12). 3.
Remove elbow fitting (2) from adapter bushing (9). 4. Remove nut (3), washer (6), and washer (8) securing adapter bushing (9) to fan shroud (7). 5.
Remove fan drive hydraulic hose (11) from elbow fitting (10). 6. 7. Remove fitting (12) from fan drive (1).
NOTE Apply sealing compound (appendix C, item 44) to all pipe threads
during installation.
8. Install hose (13) on elbow fitting (10). Install quick-disconnect (14) on fitting (15). 9.
Install fan drive hydraulic hose (13) in quick-disconnect (14). Install fitting (15) in fan drive (1).
Install adapter bushing (9) and washer (8) in fan shroud (7) with washer (6) and nut (3). Install elbow fitting (2) in adapter bushing (9).
Install hydraulic hose (5) on elbow fitting (2) with clamp (4). Connect battery ground cable (para. 4-73).
Bleed power steering system (para. 8-29).

INDEX (Cont'd)

lNSTRUCTlONS: 1. Using existing turret handle (1) as a template, scribe two reference lines (2) on weapon station (4).
2. Locate and mark the center of six spot welds (3) on turret handle (1). NOTE
Ensure drill does not penetrate weapon station.
3. Using 0.313-inch diameter drill bit, drill out six spot welds (3) in turret handle (1). 4. Using chisel, remove turret handle (1) from weapon station (4).
NOTE When grinding weapon station, ensure that the two reference lines
are not removed.
5. Grind off any remaining spot weld (3) material flush with weapon station (4). 6. Using two reference lines (2) marked in step 1, position turret handle (5) on weapon station (4).
7. Using turret handle (5) as a template, drill four 0.344-inch diameter holes (6) in weapon station (4). 8. Spot paint weapon station (4) (refer to TM 43-0139).
9. Install turret handle (5) on weapon station (4) with four washers (8), capscrews (7), washers (8), and locknuts (9).
10. Spot paint capscrews (7) and locknuts (9) (refer to TM 43-0139).

INDEX (Cont'd)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
14 AWG WIRE, ELECTRICAL MIL-C-13486
M AT E R I A L S I T E M
R E Q ' D D E S C R I P T I O N N S N / PA RT NUMBER N O .
1 8 Insulation Sleeving: 2 in. 5970-01-815-1295
2 8 Electrical Wire: 48 in. 6145-00-152-6499
NOTE When connecting electrical wire to connector pins on engine harness plug connector, use NSN 3439-00-133-1108 solder. (Refer to TB SIG-222 for soldering.) Cut eight sections of wire (2) to length as shown. Cut eight sections of insulation sleeving (1) as shown. Position eight sections of insulation sleeving (1) on wires (2). Connect eight sections of wire (2) to receptacle pins marked A, B, C, D, E, F, G, and H on recep tacle (5). Place insulation sleeving (1) over wires (2) and receptacle pins and into position as shown. 1. 2. 3. 4.
4 5 Tiedown Strap 5975-00-074-2072
5 1 Receptacle 5935-00-738-8328
Apply sealant NSN 8040-00-225-4918 to receptacle pins, wires, and sleeving. 5.
Use wire markers (3) on eight sections of wire (2) to locate and mark wires. Secure eight sections of 6.
wire (2) with five tiedown straps (4).
Figure D-96. Body Harness Receptacle Fabrication. INSTRUCTIONS:
3 8 Wire Marker 46F5981
N/A INSULATION SLEEVING MIL-I-23053/2

INDEX (Cont'd)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
14 AWG WIRE, ELECTRICAL MIL-C-13486
I T E M M AT E R I A L S
N O . R E Q ' D D E S C R I P T I O N N S N / PA RT NUMBER
1 1 Grommet 5365-00-772-2322
2 8 Electrical Wire: 48 in. 6145-00-152-6499
3 8 Wire Marker 46F5981
4 5 Tiedown Strap 5975-00-074-2072
5 1 Grommet Retaining Nut 5935-00-333-9414
6 1 Coupling Nut 5310-00-655-9860
7 1 Plug Shell Assembly 5935-00-686-2608
INSTRUCTIONS: 1. 2. 3. 4. Figure D-97. Body Harness Connector Fabrication. NOTE When connecting electrical wires to connector pins on body harness connector, use NSN 3439-00-133-1108 solder. (Refer to TB SIG-222 for soldering.) Cut eight sections of wire (2) to length as shown. Place grommet retaining nut (5) over eight sections of wire (2). Position eight sections of wire (2) in grommet (1). Place coupling nut (6) over plug shell assembly (7).
5. Connect eight sections of wire (2) to receptacle pins marked A, B, C, D, E, F, G, and H on plug shell
assembly (7).
6. Position grommet (1) in plug shell assembly (7) and secure with grommet retaining nut (5).
7. Use wire markers (3) on eight sections of wire (2) to locate and mark wires. Secure eight sections of

INDEX (Cont'd)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
14 AWG WIRE, ELECTRICAL MIL-C-13486
8 AWG WIRE, ELECTRICAL MIL-C-13486/1
N/A INSULATION SLEEVING MIL-I-23053/2
I T E M M AT E R I A L S
N O . R E Q ' D D E S C R I P T I O N N S N / PA RT NUMBER
1 1 Plug Connector 5935-01-173-7654
2 6 Electrical Wire: 60 in. 6145-00-538-8222
3 9 Wire Marker 46F5981
4 6 Tiedown Strap 5975-00-074-2072
5 1 Coupling Nut 5310-00-655-9860
6 3 Electrical Wire: 60 in. 6145-00-152-6499
7 3 Insulation Sleeving: 3 in. 5970-00-812-2967
Figure D-98. Engine Harness Plug Connector Fabrication.

INDEX (Cont'd)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
14 AWG WIRE, ELECTRICAL MIL-C-13486
14 AWG WIRE, ELECTRICAL MIL-C-13486/1
N/A INSULATION SLEEVING MIL-I-23053/2
N/A INSULATION SLEEVING MIL-I-23053/5
I T E M M AT E R I A L S
N O . R E Q ' D D E S C R I P T I O N N S N / PA RT NUMBER
1 3 Insulation Sleeving: 1-1/2 in. (38.1 mm) 5970-00-812-2967
2 3 Electrical Wire: 60 in. (1,524 mm) 6145-00-538-8222
3 9 Wire Marker 46F5981
4 6 Tiedown Strap 5975-00-074-2072
5 6 Electrical Wire: 60 in. (1,524 mm) 6145-00-152-6499
6 6 7 1 Insulation Sleeving: 1-1/2 in. (38.1 mm) Receptacle Connector 5970-00-815-1295 5935-01-149-5163
Figure D-99. Engine Harness Receptacle Fabrication.

INDEX 28 Change 2 INDEX (Cont'd)

M AT E R I A L S I T E M N O . R E Q ' D D E S C R I P T I O N N S N / PA RT NUMBER
4 1 Mini-box (bottom section) 5999-00-971-8848 7 6 Screw 5305-00-958-4353
8 6 Washer 5310-00-880-5976 9 6 Non-metallic Bumper 5340-01-219-6733
10 6 Nut 5310-00-934-9753
Figure D-100. Mini-box Bottom Section Drill Procedure.

INDEX (Cont'd)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
3 ft CHANNEL N/A
PRE-PUNCHED CHANNEL
CHANNEL CUT LENGTH MANUFACTURED
PART NUMBER 67 AS SHOWN FROM NSN N/A
Figure D-101. Pre-punched Channel.
INSTRUCTIONS: Cut two channels to length shown.

INDEX (Cont'd)

I T E M M AT E R I A L S
N O . R E Q ' D D E S C R I P T I O N PA RT NUMBER
1 1 Channel, Pre-punched: 7 in. 67
4 1 End Section 0630
Figure D-102. Channel, 7.00-in. and Terminal Block Assembly.
2 6 3 3 Terminal Block Terminal Block 0621 0624
5 2 Channel Clamp 68
INSTRUCTIONS: Install three terminal blocks (2), terminal blocks (3), terminal blocks (2), and end section (4) on

INDEX (Cont'd)

I T E M M AT E R I A L S
N O . R E Q ' D D E S C R I P T I O N PA RT NUMBER
1 1 Channel, Pre-punched: 6 in. 67
2 8 Terminal Block 0621
3 1 End Section 0630
4 2 Channel Clamp 68
Figure D-103. Channel, 6.00-in. and Terminal Block Assembly.
INSTRUCTIONS: Install eight terminal blocks (2) and end section (3) on channel (1) with two channel clamps (4).

INDEX (Cont'd) Para Page Para Page

M AT E R I A L S I T E M N O . R E Q ' D D E S C R I P T I O N N S N / PA RT NUMBER
1 2 Grommet, Non-metallic 5325-00-270-8890 2 4 Cable Tie Holder MB4A
3 8 Screw 5305-00-958-4353 4 4 Screw 5305-00-984-6210
5 1 Mini-box (bottom section) 5999-00-971-8848 6 2 Grommet, Non-metallic 5325-00-309-7164
7 1 Wire Marker 46F5981 8 4 Nut 5310-00-934-9758
9 4 Washer 5310-00-883-9384 10 8 Washer 5310-00-880-5976
11 8 Nut 5310-00-934-9753
Figure D-104. Terminal Block Assemblies and Cable Tie Holder Installation.
INSTRUCTIONS: 1. Using wire marker (7) and 6-in. and 7-in. terminal block assemblies, locate and mark sections as
shown. 2. Install 6-in.and 7-in. terminal block assemblies in mini-box bottom section (5) with four screws (4),
washers (9), and nuts (8). 3. Install four cable tie holders (2) in mini-box bottom section (5) with eight screws (3), washers (10), and
nuts (11). 4. Install two non-metallic grommets (1) in holes A on mini-box bottom section (5).
5. Install two non-metallic grommets (6) in holes B on mini-box bottom section (5).

INDEX (Cont'd)

MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION 14 AWG WIRE, ELECTRICAL MIL-C-13486/1
M AT E R I A L S I T E M N O . R E Q ' D D E S C R I P T I O N N S N / PA RT NUMBER
1 16 Receptacle Pin 1-87756-6 2 14 Electrical Wire: 12 in. 6145-00-808-4849
3 14 Wire Marker 46F5981 4 11 Terminal Lug 5940-00-577-3807
5 1 Receptacle Plug 103308-8

INDEX

M AT E R I A L S I T E M
INSTRUCTIONS:
and receptacle harness assemblies.
on terminal block assembly (4).
letters on terminal block assembly (4).
on terminal block assembly (11). Do not tighten screws.
on terminal block assembly (11).
terminal block assembly (11).
terminal block assembly (11).

By Order of the Secretary of the Army: DENNIS J. REIMER General, United States Army Chief of Staff Official: m. 8 YVONNE M. HARRISON Administrative Assistant to the Secretary of the Army 01702 By Order of the Secretary of the Air Force: RONALD R. FOGLEMAN General, United States Air Force Chief of Staff Official: HENRY VICCELLIO, JR.

General, United States Air Force Commander, Air Force Materiel Command By Order of the Marine Corps: D. R. BLOOMER Colonel, USMC Director, Program Support Marine Corps Systems Command DISTRIUBTION: To be distributed in accordance with DA Form 12-38-E, block 0900, requirements for TM 9-2320-280-20-3.

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DA FORM 2028, FEB 74 TO: (Forward direct to addressee listed in publication)

FROM: (Activity and location)
(include ZIP code)

DATE: AMSTA-LC-CI Tech Pubs, TACOM-RI 1 Rock Island Arsenal

Rock Island, IL 61299-7630

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TYPED NAME, GRADE, OR TITLE TELEPHONE EXCHANGE/AUTOVON,

SIGNATURE

PLUS EXTENSION

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TM 9-2320-280-20-3

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PO-4. Electrical System Wiring Diagram (M 1025A2, M 1035A2, M 1043A2, M 1045A2).

FP-1 1/(FP-12 blank)

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FO-6. Electrical System Wiring Diagram (M997A2) (Cont'd).

The Metric System And Equivalents

Linear Measure

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Meter = 100 Centimeters = 1,000 Millimeters = 39.37 Inches 1 Kilometer = 1,000 Meters = 0.621 Miles SQUARE MEASURE 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Miles

Cubic Measure

1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet LIQUID MEASURE 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1,000 Milliliters = 33.82 Fluid Ounces TEMPERATURE Degrees Fahrenheit (F) = °C - 9 ÷ 5 + 32 Degrees Celsius (C) = F° - 32 - 5 ÷ 9 212° Fahrenheit is equivalent to 100° Celsius 90° Fahrenheit is equivalent to 32.2° Celsius 32° Fahrenheit is equivalent to 0° Celsius WEIGHTS 1 Gram = 0.001 Kilograms = 1,000 Milligrams = 0.035 Ounces 1 Kilogram = 1,000 Grams = 2.2 Lb 1 Metric Ton = 1,000 Kilograms = 1 Megagram = 1.1 Short Tons

13 2 Conduit Insulation: 54 in. 68243
Figure D-108. Terminal Strip Installation.
INSTRUCTIONS:
with tiedown straps (11).
washers (8), and nuts (9).
washers (8), and nuts (9).
4. Cut two 48-in. (1,219.2 mm) sections of conduit insulation (5).
and secure with tape (6).
7. Cut two 54-in. (1,371.6 mm) sections of conduit insulation (13).
and secure with tape (6).

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Approximate Conversion Factors

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