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USAF TO 36-1-191

1. le hi Al ANCE cA F09603 005 Figure 2 2 Modular Ambulance 2 27 TO 36 1 191 EIL E a AMBULANCE 6 IN CONTINUOUS STRIPE COLOR OMAHA ORANGE O M o 6 IN CONTINUOUS STRIPE n COLOR OMAHA ORANGE EF AMBULANCE E or F09603 006 Figure 2 3 Van Ambulance 2 28 TO 36 1 191 27227 Sy X OR B OO QQ amp O LJ F09603 007 a Figure 2 4 Truck Ambulance 2 29 TO 36 1 191 2 30 POLICE 2 OR EMERGENCY 911 4 INCH LETTERS WHITE LETTERS POLICE 7 INCH LETTERS US AIR FORCE REGISTRATION p 74 222 NUMBER FOR OFFICIAL USE ONLY STRATA BLUE STRIPES 4 INCHES WIDE TWO INCHES APART POLICE 7 INCH LETTERS US AIR FORCE REGISTRATION NUMBER F09603 008 FOR OFFICIAL USE ONLY Figure 2 5 Law Enforcement Sedan BOTH SIDES OF VEHICLE CAUTION BEFORE TOWING LATCH PI
2. RETAIL SELLER S NAME ADDRESS CITY STATE ZIP NAME AND ADDRESS OF RETAIL BUYER FIRST SECOND INITIAL INITIAL LAST NAME ONLY STREET ADDRESS CITY OR TOWN STATE ZIP CODE RETAIL BUYER S SIGNATURE This section of the form is to be used to notify Ford Motor Company of a delayed warranty start date WARRANTY START REASON FOR DELAY OF WARRANTY START DATE DATE REQUESTED e Please attach copies of documents to support warranty start date example new vehicle sales invoice or state registration MONTH DAY YEAR MILEAGE AT TIME OF DELIVERY TO RETAIL SELLER NO TENTHS MILEAGE AT TIME OF RETAIL SALE NOTE When this section of the form is completed submit IMMEDIATELY to Ford Motor Company with supporting documentation attached This section of the form is to be used to notify Ford Motor Company of an In transit mileage accumulation MILEAGE AT TIME OF REASON FOR IN TRANSIT MILEAGE ACCUMULATION DELIVERY RETAIL SELLER Please attach documents to support accumulated mileage NO TENTHS MILEAGE AT TIME OF RETAIL SALE NO TE
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4. 1 NNW QN CA CLA Chapter 2 9 2 10 2 11 2 12 2 13 2 14 2 15 2 16 2 17 2 18 2 19 2 20 2 20 3 2 20 4 2 21 2 22 2 22 1 2 22 5 2 23 2 24 2 25 2 26 2 27 2 28 2 29 2 30 2 31 2 32 2 33 2 34 2 34 1 2 34 2 2 35 2 36 2 37 2 38 2 39 2 40 241 242 2 43 2 44 OTHER SPECIAL PURPOSE VE HICLES AND VEHICULAR EQUIPMENT AMBULANCES OSI VEHICLES RECRUITING SERVICE PAINTING OF VEHICLE TOPS WHITE 244 vse sere EXCESSIVE GLARE INTERIORS ee ee in CAMOUFLAGE PATTERN PAINT ING acai we be eG eee ee ds THERMAL SPRAY EQUIPMENT SAFETY PRECAUTIONS PREPARATION FOR PAINTING SPECIALTY COATINGS Ceramic Loaded Coatings Spray In Bed Liners PRIME COATS FINISH COATS Finish Coats Chemical Agent Resistant Coating CARC Paints NON SLIP MATERIALS HVLP SPRAY GUN PROCE DURES MARKINGS ACTIVITY MARKINGS ADDITIONS OR DEVIATIONS REQUIREMENTS CAMOUFLAGE SPECIFICATIONS SEMI GLOSS DARK GREEN MARKING REQUIREMENTS FOR VEHICLES USED ON LAND ING AREAS IDENTIFICATION MARKINGS NATIONAL SYMBOL AND IN TERNATIONAL MARKINGS National Symbol Internati
5. 5 1 4 381 Regulator 4 32 54 RESPONSIBILITIES 5 1 4 38 2 Pressure Gauges 4 32 2 9 REMS OLVIMS INTERFACE 5 1 4 39 VEHICLES EQUIPPED WITH 5 6 EXCEPTIONS 5 1 DISC BRAKES 4 32 5 7 CHANGES 5 2 4 40 STORAGE OF TIRES 4 33 5 8 MAJOR COMMAND SUPPLE 4 41 USE OF FOREIGN OBJECT DAM MENTS gaus 5 2 FOD TIRES 4 33 5 9 MAXIMUM ONE TIME REPAIR 4 41 1 Necessity 4 33 ALLOWANCE 5 2 4 41 2 4 33 5 10 AGE ouis Giles EAS 5 2 4 42 SOLID AND SEMI PNEUMATIC 5 11 STANDARD PRICE 5 2 TIRES 2223632 ks 4 33 5 12 REPAIR ESTIMATE 5 2 4 43 TIRES doe a 4 33 5 13 DIRECT LABOR 5 2 4 43 1 Standard Solid Rubber Tires 4 33 5 14 DIRECT MATERIAL 5 2 4 43 2 Cushion Rubber Tires 4 33 5 15 INDIRECT EXPENSES 5 3 4 44 TYPE OF MOUNTINGS 4 33 5 16 OTHER CHARGES 5 3 444 Pres 4 33 5 17 HOURLY LABOR RATE 5 3 4 442 Bolt On 4 33 5 18 EXCLUSIONS 5 3 4 443 Integral Type 4 33 5 19 DEPOT LEVEL REPAIR 5 3 4 44 4 Solid Lug Base 4 33 5 20 ACCIDENT REPAIR ESTI 4 44 5 Semi Pneumatic Lug Base Type 4 33 MATES ou ek yer ise 5 3 4 45 TREAD
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7. RIDGES F09603 059 Figure 4 17 Tubeless Tire Construction 4 28 1 3 valve stem Deflate tire by removing the valve core from 4 28 1 4 Use liberal amount of approved rubber lubricant on the tire beads 4 28 1 5 Actual demounting must be done carefully Never attempt to force bead into drop center well at one spot Inch it off a little at a time working around the tire to prevent damage to the beaded area 4 28 1 6 For preparation of the rim check the rim to be sure it is in good condition and free of rust Remove any rust or other accumulation of foreign material with a wire brush 4 28 1 7 It is important to carefully inspect the valve Worn valves should not be reused Install valve Use valve designated by vehicle manufacturer since valves vary as to length and diameter 4 28 1 8 Lubricate tire beads and rim flanges and bead ledge area with a liberal amount of approved rubber lubricant Properly lubricated beads will seat themselves quickly and easily with minimum air pressure 4 29 TUBE TYPE TIRES Inspect tires for nails glass or other injurious Particles in tread see Figure 4 16 Inspect for tread wear cuts in fabric TO 36 1 191 fabric breaks or damaged beads and do not install tires unless satisfactory for service Remove any dirt and foreign material from inside of tire 4 30 INNER TUBES Check tubes for punctures pinches cuts and cracks see Figure 4 18 Inspect valves for proper ben
8. juouroSeueuir y Aq pesn oq 5 uonoedsut 10 s9Jnpo20Jd 1SI 429u2 pue woy uonoedsuj 956 Semi Trailer Inspection Form and Checklist Procedures Figure 3 1 3 17 TO 36 1 191 Table 3 5 Semi Trailer Structural Inspection Checklist If A Crack Is Found Enter Y In The Corresponding Block Otherwise Enter A N DISCREPANCY EXISTS GOOSENECK FRONT Y N Inspect welds of the forward bulkhead to the surrounding structure Inspect all front gooseneck components for cracks in the parent material as ee A B Cc ANCY E C DISCREP XISTS GOOSENECK BOTTOM Y N Inspect welds of the fifth wheel king pin supporting structure Inspect welds of the upper coupler plate to the main beams fifth wheel supporting X X structure X ___ Inspect welds of the toolbox bottom to both main beam flanges as applicable X Inspect welds on the gooseneck splice plates on the main beam lower flanges forward X X of landing gear Inspect welds of all main beam web stiffeners on inner and outer sides of main beam Lp webs Inspect welds of the gooseneck extension at all cross member and bulkhead connec X X ions where 1o 1e side Inspect welds of the gooseneck extension at all cross member and bulkhead connec X X ey comes tw be man ens Inspect all bottom gooseneck co
9. New Tire Dimensions Tire Markings Tire Rotation sc 244 02 or ae Rotation Patterns for Tires Static Out of Balance Dynamic Out of Balance Stages of Tire Inflation An Example of Tire Abuse Inspecting A Tire For Casing Damage Using the Extension Hose to Inflate a MAME Se ese Ota IO E De ee Change 1 Page 2 27 2 27 2 28 2 29 2 30 2 30 2 31 2 31 2 32 2 32 2 33 2 34 2 34 2 35 2 35 2 36 2 36 2 36 2 37 2 37 2 38 2 39 2 40 2 40 2 41 2 41 2 42 2 43 2 44 2 44 Figure 4 15 4 16 4 17 4 18 4 19 4 20 4 21 4 22 4 23 4 24 4 25 5 1 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 6 10 6 11 6 12 6 13 6 14 6 15 6 16 6 17 7 1 172 7 3 7 4 7 5 7 6 Title Effects of Rim Design on Proper Mounting Position Points of Inspection for Tires and Tubes eo vole oue aad ee Tubeless Tire Construction Tire Mounting and Demounting Operation Manually Demounting Tire Drop Center RIM ES Manually Mounting Tire Drop Center Rin cxx eae es cae as Trajectory Warning Tire Inflator Cage with proper Inflation Equipment Shown Pressure Gauge Test Record Pressure Gauge Test Assembly Tire Inventory Control Record One Time Repair Computation Worksheet Commercial General Purp
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11. product marking WASTE FUEL shall be stenciled in 6 inch black letters color number 17038 on both sides and rear of the tank 2 66 2 product marking WASTE FUEL shall be stenciled in 1 inch black letters color number 17038 adja cent to the manhole covers 2 66 3 Ared X in 2 inch wide stripes shall be applied on hose reel compartment doors using red paint color number 11105 2 67 RECLAIMED FUEL VEHICLES 2 67 1 vehicles used for handling recoverable or reclaimed fuel shall be marked as follows F09603 003 EXHIBIT B NOZZLE MARKINGS 2 67 2 The product marking RECLAIMED FUEL shall be stenciled in 6 inch red letters lusterless color number 31136 2 20 2 67 3 The product marking RECLAIMED FUEL shall be stenciled in l inch red letters lusterless color number 31136 adjacent to the manhole covers 2 68 GASEOUS SERVICING TRAILERS The following special markings will be applied to all gaseous oxygen or nitrogen trailers classified as vehicles in FSC 2330 Not applicable to MH 1 MH 2 and AF M32A17 tube bank semitrailers 2 68 1 Material Identification For the purpose of this instruction gaseous servicing trailers are divided into two categories One employs an enclosure around the compressed gas cylinders such as E 3 and the E 2 The other has no enclosure and all cylinders are exposed to plain view of the servicing personnel On those trailers which employ an enclosure the word OXY
12. Vehicles may be required to bear all markings described in this Technical Order or only a portion of those described depending upon the type of vehicle its mission and the safety factors involved Where required by civil law major command or theater commanders may make additions to or deviations from the markings prescribed herein The extent of such additions or deviations will be held to an absolute minimum and will be consistent with safe practice 2 228 REQUIREMENTS Markings will be clearly maintained on all vehicles at all times except as follows 2 28 1 transfer within the USAF all organization markings shall be removed 2 28 2 Upon permanent transfer to DRMS all Air Force markings including USAF registration numbers shall be obliterated or removed Data plates showing chassis and engine serial numbers shall not be removed 2 28 3 Upon transfer to Military Assistance Program MAP all Air Force markings shall be removed 2 29 CAMOUFLAGE When the requirements for camouflage or concealment out weigh the requirement for identification the markings pre scribed herein may by direction of the major command concerned be obliterated with some readily available re moval substance NOTE This guidance takes precedence over TO s 36 1 161 or 36 1 171 2 30 SPECIFICATIONS Markings for all vehicles except those in Paragraph 2 10 will be accomplished by applying reverse or direct silk screened r
13. and valve core 4 35 2 3 After tire has been completely deflated install cap to prevent damage to threads of valve stem Loosen beads from rim flanges Figure 4 19 A PRINCIPLE OF DROP CENTER RIM D REMOVING INSIDE BEAD TO 36 1 191 B LOOSENING BEAD FROM RIM FLANGE F09603 061 Figure 4 19 Manually Demounting Tire Drop Center Rim Do not dislodge tire beads lock rings or split flange rings until absolutely certain that no air pressure remains in tire 4 35 2 4 Insert two tire irons about 6 inches apart between upper bead and rim near valve Kneel on tire 180 from valve to force upper bead into well 4 35 2 5 Pry outer bead over flange near valve 4 35 2 6 Work irons progressively around tire bead lifting tire bead over flange Figure 4 19 4 35 2 7 Remove tube from tire Do not pull on valve 4 35 2 8 Push inner bead into tube well on one side Some passenger cars and light trucks use drop center rims known as safety rims Figure 4 19 These have a hump in base of bead ledge to hold beads in place Sets of manual type iron are used to force beads off bead seats Wheel must be demounted before removal of tires After beads are forced off the seats proceed as discussed to remove tire in same manner as above 4 35 3 Mount tires as follows 4 35 3 1 Inspect tire tube and rim Remove valve cap Inflate tube slightly and insert in tire placing valve at balance mark Lay wheel fl
14. 3 2 4 7 SELECTION OF TIRES 4 1 3 669 Air Brakes 3 3 4 8 TIRE CONSTRUCTION MATE 3 6 10 Wheels and Tires 3 3 RIAL 4 2 3 6 11 Vehicle Lighting 3 8 1 4 8 1 Rayon Fiber 4 2 3 6 14 3 8 1 4 8 2 Polyester Fiber 4 2 3 6 15 Hydraulic System Special Purpose 483 Nylon Fiber 4 2 Assemblies 3 8 1 4 8 4 Fiberglass 4 2 3 616 Drive Line 2 28 e renn xe Er 3 9 ASS MEER 4 2 3 6 17 Warning Devices And Decals 3 9 4 9 LOAD RANGE 4 2 3 7 FUEL SERVICING EQUIPMENT 4 10 TIRE CONSTRUCTION 4 2 INSPECTION 3 9 4 10 1 Conventional Bias Ply 4 2 3 8 SPECIAL LUBRICATION IN 4 10 2 4 2 STRUCTIONS AND PRODUCT 410 3 Radial RE 4 2 SPECIFICATIONS 3 9 4 10 4 Special Use Tires 4 2 3 8 1 Special Instructions D 3 9 4 11 HANDLING CHARACTERIS 3 8 7 Technical Data and Product Specifi TICS 4 2 Canon qeu M 412 TIRE SIZE RATING 4 3 3 9 ANNUAL TUNE UP EMISSION 412 1 Bias 4 3 OPERATION CHECKS Ge ANOS Melle oxy ees ress ik 4 3 3 9 1 Engines eae aoe p E E 3 12 4 13 TIRE MARKINGS 4 3 3 92 Emission Systems 3 12 General 4 3 310 SPECIAL INSPECTION 3 12 4132
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16. 7 27 2 3 3 Unsatisfactory design Vehicles that do not meet user needs 7 27 2 3 4 Unsatisfactory depot repair or remanufacture 7 27 2 3 5 Other conditions as deemed appropriate by the VFM 7 28 PROCESSING MDR S The format illustrated in Figure 7 1 shall be used for processing Vehicle Unsatisfactory Reports for vehicles equip ment The instructions for completion are cited in the format illustration and are mandatory for submitting 7 29 PROCESSING UNSATISFACTORY REPORTS 7 29 1 VM amp A will ensure that DR exhibits are marked or tagged with DD Form 2332 Materiel Deficiency Exhibit see Table 7 1 Figure 7 3 Initially the DD Form 2332 must have all blocks except 7 11 and 12 completed see Table 7 1 for instruc tions If size allows the exhibit shall be moved from the Vehicle management area to a secure minimum access area designated as a DR holding area When directed the exhibit will be shipped to the action point If instructions to ship hold or process the exhibit have not been received within 30 calendar days of the report date the exhibit holding activity shall process the exhibit for repair disposition according to its condition 7 29 2 When releasing or shipping the exhibit the activity shall 7 29 2 1 Complete Blocks 7 11 and 12 of DD Form 2332 attached to the exhibit along with a copy of the DR 7 29 2 2 Attach a second completed DD Form 2332 on the outside of the package
17. 8 21 1 4 Cooling systems shall be checked to ensure that they are filled to operating level with the coolant required Antifreeze shall be checked for strength with a hydrometer or refractometer for extended life coolants When inspection reveals that coolant is unserviceable the system shall be drained flushed and refilled 8 21 1 5 Necessary lubrication shall be performed in accordance with Chapter 3 or the manufacturer s lubrication guide Manufacturer s guide takes precedence 8 21 1 6 Batteries Wet batteries received with vehicles may be used until completion of first exercise They shall then be moved to a battery room and maintained in a charged condition until shipped or until a dry battery replacement is obtained Wet batteries being maintained may be used for exercise where such use does not compromise the operational ready requirements Batteries received charged and dry may be stored in the vehicle battery carrier however it is recommended that inside storage be provided Vent holes in the filler caps of dry batteries shall be plugged or sealed until the battery is activated for vehicle outshipment Cable termi nals shall be coated with grease conforming of Specification MIL PRF 10924B and secured to the vehicle with tape conforming to Specification SAE AMS T 2208 The respon sible storage officer shall see that sufficient electrolyte is on hand to activate all dry batteries No dry battery shall be activated until a ch
18. 8 4 3 Determination of corrosion center to be used Re quest for routine shipment instructions should also contain a request for the vehicle to be processed through a corrosion treatment facility 8 5 LEVELS OF PRESERVATION The levels of preservation provided herein are as follows 8 5 1 Level A the requirements specified for this level are intended to provide adequate protection to vehicles and 8 1 TO 36 1 191 components from corrosion deterioration and physical dam age during shipment handling and varying periods of storage in excess of 90 days from date of preservation 8 5 2 Level B the requirements specified for this level are intended to provide adequate protection for domestic or oversea shipment open deck loading excluded and which may involve outside storage for a combined total of approxi mately 90 days 8 5 3 Level C the requirements specified for this level are intended to provide adequate protection during domestic shipments to immediate use locations and for vehicles Non Mission Capable Supply for less than 90 days 8 5 4 Live Storage and Air Shipments see Paragraph 8 12 through Paragraph 8 23 8 5 5 PACAF and ACC CENTAF have deviated from conventional storage methods with concurrence and approval of USAF ILGM and adopted the vapor phase corrosion inhibiting VpCI method of storage for WRM assets Refer ence PACAFHAN 24 3 available electronically at https www hqpacaf af mil sc im Publicatio
19. PARE 6850 01 470 3304 to remove salt de posit Dr 55 Gl 6850 01 470 3312 NSL NOTE Corroseal CHLOR RID DTS Appropriate rustproofing grade required is denoted in the Application figures Refer to Paragraph 6 7 and Figure 6 1 and 6 2 and TO 36 1 131 2 ZC 010 may be used as a preferred material for MIL C 81309 type 2 ZC 010 may be obtained from Zip Chem 400 Jarvis Drive Morgan Hill CA 95307 3 CORTEC VCI 369 may be used for coating exterior and interior recesses and radiators Materials may be obtained through GSA or CORTEC Corporation 4119 White Bear Parkway St Paul MN 55110 4 Cor Ban 35 may be used as the preferred materials for MIL PRF 16173 Grade 2 Cor Ban 35 may be obtained through GSA or Zip Chem Products 400 Jarvis Drive Morgan Hill CA 95307 5 Dinol TK5941 Rock kote may be used as an optional method for coating chipping protection on Air Force Vehicles It can be applied over primer used as a topcoat over paint or can be applied to bare metal and then painted with standard vehicle paint 6 Material identified by this asterisk may be used as a preferred material for application on electrical connectors and or contact points 6 8 Material Unit of Issue TO 36 1 191 NSN Additional corrosion and cleaning related consumable materials can be found in TO 1 1 691 Appendix A Application 6 11 PREPARATION FOR TREATMENT 6 11 1 The instructions outlined herein are inte
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21. 1 7 2 13 Axle Intermediate Axle housings or tubes shall not be bent cracked or twisted Spring seats and torque rod mounts shall be tight and be free from cracked welds Axle shaft flange shall show no signs of lubricant leaks Axle vent caps shall be free of mud and other foreign debris Cap shall turn freely 1 7 2 14 Axle Rear Same as intermediate axle 1 7 2 15 Axle Steerable Rear Live Same as Front Axle 1 7 2 16 Battery Battery Box Battery Clamps battery shall be of proper size type and capacity and without external cracks in case or cover Connectors or sealing compound shall show no signs of leaking electrolyte Dry charged batteries with correct amount of electrolyte in separate containers will normally be used for overseas shipments When exceptions are authorized to ship wet batteries the electrolyte shall be at proper level 3 8 inch over plates and have a specific gravity reading of not less than 1 265 corrected to 26 6 C 80 F Terminals and terminal posts shall be firmly anchored clean and shall show no 1 7 TO 36 1 191 corrosion or deterioration The voltage reading of each cell shall be at least two volts Nickel iron alkaline type batteries shall be fully charged and the electrolyte level and specific gravity reading shall be correct for the particular battery concerned Battery box shall be clean and show no signs of corrosion Battery clamps shall be clean with no cracks
22. 2 2 2 Vehicle Staff or equivalent may autho rize refinishing of vehicles in colors other than those specified in this TO when required to meet security or operational requirements Initial authorization may be verbal for imme diate mission requirements followed by written approval as soon as mission requirements allow A copy of the written approval will be sent to WR ALC LESV 2 2 3 Spot painting in lieu of complete refinishing will be accomplished to the greatest extent practical The use of premixed aerosol paint cans shall be kept to the minimum necessary to refinish small areas less than 1 soft total Spot painting or panel repair painting shall be accomplished using environmentally approved application equipment such as high volume low pressure spray equipment or touch up spray guns The use of small paint brushes SEMPEN applicator tips and rollers are also encouraged Use the same type of primer coatings and topcoat finishes for touchup as is applied to the surrounding areas 2 2 4 Bare surfaces or sections of bodies and sheet metal which have become exposed by deterioration of paint or by accident will immediately be spot painted to prevent dete rioration of the sheet metal 2 3 AUTHORIZED COLORS 2 3 1 For camouflage purposes theater commanders in overseas areas are authorized to deviate from the colors prescribed herein Current policy will be published in MAJ COM supplements if applicable 2 3 2
23. 4 47 1 Inspect tires for uneven wear and separation 4 47 2 Check for oil or grease leaks that could or have contaminated the rubber tires 4 47 3 Check tires for wear and replace when necessary 4 47 4 Inspect tires for tread cracks base separation and slippage of rim on wheel 4 47 5 Check solid and semi pneumatic lug base type tires for looseness or slipping on wheel 4 47 6 Solid rubber tires should be replaced on vehicles using the same tread on drive wheels NOTE Solid rubber type tires and track components not covered in this technical order will be repaired replaced as prescribed by the technical order pertaining to applicable equipment 4 48 GENERAL The following guidelines will be used for removal of pneu matic tires from a vehicle being processed for disposal Solid rubber and semi pneumatic tires will not be removed from vehicles being processed for disposal 4 48 1 The determination as to whether tires will be removed is a responsibility of vehicle management in coor dination with Distribution Flight and DRMS Distribution 4 34 Flight involvement is only necessary if the local base supply function stocks issues and manages vehicle tires Many Distribution Flights have divested themselves of this func tion 4 48 2 Whenever possible any tire that is removed will be replaced with an unserviceable but inflatable tire 4 48 3 Vehicles except those which have been wrecked will have tires in
24. 4940 00 836 4215 Air Powered liquid pressure cleaning pump un 4940 00 076 8200 derbody and fenders Blast Cleaning Machine for removing rust and 4940 00 253 9515 foreign deposits Goggles safety pase O Formit CPC applicator wands __ O Formit 36 360 PN 009131 Formit 48 STD FOG PN 009133 Formit 48 360 PN 009132 Formit 48 90 FOG PN 009134 6 3 TO 36 1 191 Table 6 1 Item Required Equipment And Materials Continued NSN Formit spray wands are described with the middle number being the length of the spray can wand The second des ignator is the type of spray pattern issuing from the wand such as 360 is a full circle F is a fan and FOG is a fine mist STD FOG signifies the fogging spray comes from the center of the spray comes from the center of the sprayhead The 90 FOG signifies the spray comes from the side of the spray head Formit applicators may be ob tained from Zip Chem Products 1860 Dobbin Drive San Jose CA 95133 1 800 648 2661 Respirators listed here are for reference only The base bioenvironmental engineers prior to the commencement of maintenance requiring the respiratory protection devices will approve all respirators utilized in vehicle man agement shop for the appropriate use AS 457 should reflect all items listed above except those prefixed by an asterisk Application Cleaning Compound MIL PRF 87937D Type I Type II Type III Type IV Cleaning Co
25. 5 144 Tires are charged according to Chapter 4 The following information is provided for your convenience check Chapter 4 for more detailed guidelines 5 14 4 1 New tires will be charged to the vehicle at the full stock fund price 5 14 4 2 New retreaded tires will be charged to the vehicle at the current retreading cost as computed in OLVIMS 5 14 4 3 Used tires will not be charged to the vehicle 5 15 INDIRECT EXPENSES Figure the total indirect expenses by multiplying the esti mated direct labor hours by the total indirect expense rate Get the indirect expense rate from the Employee Master List PCN SB004 029 when available If your activity does not have OLVIMS PCN SB004 029 refer to AFI 24 302 5 16 OTHER CHARGES Other charges to be included in the repair estimate are 5 16 1 Contract services and costs which can be identified to the repair job 5 16 2 Cost of preparing the vehicle or part for shipment if it cannot be fixed on site 5 16 3 Cost of transportation from overseas to the CONUS and return Note that transportation within the CONUS is excluded from the repair estimate 5 16 4 Cost of repairs to modified equipment winteriza tion items and follow on corrosion control treatment Note that the initial costs for buying and installing these items are excluded from the estimate 5 16 5 other costs which can be identified to the specific repair job 5 17 HOURLY LABOR RATE The lo
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27. Crash fire and rescue structural and ramp fire fighting Fire Chief and Assistant Fire Chief When fire fighting vehicles require complete repaint for corrosion control or accident damage upper portions of the cab from window belt line up shall be painted white color number 17875 and lower portions will be painted solid red color number 11136 of Federal Standard 595 other administrative use motor vehicles used to support fire fighting vehicles will remain the color specified in purchase requests They may be equipped with distinctive identification markings sirens and rotating beacons as required for emergency use provided that these items are affixed to a removable roof mounted rack The rack may be marked to identify a particular fire fighting function NOTE Fire trucks returning from DEPOT that are not painted red white as specified will not be re painted solely to meet the requirements of this chapter 2 6 AIRCRAFT REFUELING VEHICLES Aircraft refueling vehicles shall be painted full gloss dark green color number 14052 of Federal Standard 595 2 7 LIQUID OXYGEN NITROGEN TRANSPORTING Liquid oxygen nitrogen transporting equipment compressed gas semi trailers and propellant semitrailers shall be painted as specified below 2 7 1 Liquid oxygen nitrogen transporting equipment shall be painted strata blue color number 15045 of Federal Standard 595 except the top three fourths of the tank which shall be p
28. J Silver Red 1 1 2 in 2 in x 1 4 in 3613142 Letter Silver Red 1 1 2 in 2 in x 1 4 in NOTE The following are supplied in ten identical characters per package 3613143 Letter L Silver Red 1 1 2 in 2 in x 1 4 in 3613144 Letter M Silver Red 1 1 2 in 2 in x 1 4 in 3613145 Letter Silver Red 1 1 2 in 2 in x 1 4 in 3613146 Letter O Silver Red 1 1 2 in 2 in x 1 4 in 3613147 Letter P Silver Red 1 1 2 in 2 in x 1 4 in 3613148 Letter Q Silver Red 1 1 2 in 2 in x 1 4 in 3613149 Letter R Silver Red 1 1 2 in 2 in x 1 4 in 3613150 Letter S Silver Red 1 1 2 in 2 in x 1 4 in 3613151 Letter T Silver Red 1 1 2 in 2 in x 1 4 in 3613152 Letter U Silver Red 1 1 2 in 2 in x 1 4 in 3613153 Letter V Silver Red 1 1 2 in 2 in x 1 4 in 2 51 TO 36 1 191 Part No Legend Or Symbol Colors Letter Or No Emblem Size ii 3613154 Letter W Silver Red 1 1 2 in 2inxl4in 3613155 Letter Silver Red 1 1 2 in 2 in x 1 4 in 3613156 Letter Y Silver Red 1 1 2 in 2 in x 1 4 in 3613157 Letter Z Silver Red 1 1 2 in 2 in x 1 4 in 3613158 Letter A die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613159 Letter B die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613160 Letter C die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613161 Letter D die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613162 Letter E die cut pre spaced Ye
29. Location Very Severe Severe Moderate Mild Wash vehicle Ev Wash vehicle every Wash vehicle Every Wash vehicle ery 5 days Every 45 days Capital Municipal Apt Springfield X IL ANG Channel Island Port Hueneme NAS X CA ANG Charleston AFB SC X Charleston Kanawha Apt WV X ANG Charlotte Douglas Municipal Apt NC X Cheyenne Apt WY ANG X Clear AFS AK Columbus AFB MS AETC Comiso AS IT Danelly Fld Montgomery AL X ANG Davis Monthan AFB Tucson AZ X Decimo Mannu AB SP X Des Moines IAP IA ANG X Dhahran SA X Diego Garcia Indian Ocean X Dobbins AFRB Marietta GA X AFRC Dover AFB DE X Duluth IAP MN ANG X Dyess AFB Abilene TX X Eareckson Shemya AFB Aleutian X Is AK East WV Reg Apt Martinsburg X WV ANG Ebbing ANG AR X Edwards AFB Rosamond CA X Eglin AFB FL X Eielson AFB AK X Ellington Fld Houston TX ANG X Ellsworth AFB Rapid City SD X Elmendorf AFB Anchorage AK X FAA Tech Center NJ X Fairchild AFB Spokane WA X Falcon AFB CO Florennes AB FRG Forbes Fld KS ANG Fort Smith Mun Apt AR ANG X Fort Wayne Apt IN ANG X Francis E Warren AFB Cheyenne X WY ANG Fresno Air Term CA ANG X Galena Arpt AK X v X 6 46 TO 36 1 191 Table 6 2 Corrosion Severity Zones and Minimum Wash Interval Continued Location Geilenkhirchen GE Gen Mitchell IAP Milwaukee WI ANG Gibbsboro AFS NJ Glenn L Martin SAP MD
30. cINOE pombe Suissoooud ON q QOIAIOS pU JOU soop asvo JULIN d0sso1duroo 01 esouy uoyganos eqni 8 0 5208 yey 9509 8 Aq jejur 1 Avids LE c 8 ALL 108 V pombe Suissoooud Suissoooud ON sSn d ure1p pue JO 20 Zc G 91314 TI SE E TN9E OL 995 V OT 7 7 198 pue 1245 5 AYL 9497 OL Jed ainssaid oun ysnf py 7 8 ALL 198 17 6 uones CE CJN9 OL Jed ainssaid oun jsnfpe pue Surdde1 7 9 109 sjuauroumbos uonen3guooos V saunuy JO SOATRA sp ogrueur y ured jou 9 1e1deuo TI SE E CINDE OL 91 IJA L surojs amp g LIJ SINL dnyonoy pue jureq ON sxreurow puy uornonisu PAT 19peo T 031e 09 UUNI T 8 ALL y fqns ON A 3 TO 36 1 191 V S oureg uoreururjuoo uiojs s Jredoz oq jsnur Surjeoo mq Sune d puojxo p
31. 1 Silver Red 1 1 2 in 2 in x 1 3 in 3613351 Number 2 Silver Red 1 1 2 in 2 in x 1 3 in 3613352 Number 3 Silver Red 1 1 2 in 2 in x 1 3 in 3613353 Number 4 Silver Red 1 1 2 in 2 in x 1 3 in 3613354 Number 5 Silver Red 1 1 2 in 2 in x 1 3 in 3613355 Number 6 Silver Red 1 1 2 in 2 in x 1 3 in 3613356 Number 7 Silver Red 1 1 2 in 2 in x 1 3 in 3613357 Number 8 Silver Red 1 1 2 in 2 in x 1 3 in 3613358 Number 9 Silver Red 1 1 2 in 2 in x 1 3 in 3613359 Number 0 Silver Red 1 1 2 in 2 in x 1 3 in 3613360 Number 1 Silver Red 3 in 4 in x 2 6 in 3613361 Number 2 Silver Red 3 in 4 in 2 6 in 3613362 Number 3 Silver Red 3 in 4 in x 2 6 in 3613363 Number 4 Silver Red 3 in 4 in x 2 6 in 3613364 Number 5 Silver Red 3 in 4 in x 2 6 in 3613365 Number 6 Silver Red 3 in 4 in x 2 6 in 3613366 Number 7 Silver Red 3 in 4 in x 2 6 in 3613367 Number 8 Silver Red 3 in 4 in x 2 6 in 3613368 Number 9 Silver Red 3 in 4 in x 2 6 in 3613369 Number 0 Silver Red 3 in 4 in x 2 6 in 3613370 Number 1 Silver Red 4 in 6 in x 3 3 in 3613371 Number 2 Silver Red 4 in 6 in x 3 3 in 3613372 Number 3 Silver Red 4 in 6 in x 3 3 in 3613373 Number 4 Silver Red 4 in 6 in x 3 3 in 3613374 Number 5 Silver Red 4 in 6 in x 3 3 in 3613376 Number 6 Silver Red 4 in 6 in x 3 3 in 3613376 Number 7 Silver Red 4 in 6 in x 3 3 in 3613377 Number
32. 7 29 2 3 In the remarks block of the release shipping document enter Deficiency Report Exhibit Also add the DR report control number and the Materiel Improvement Project number MIP 7 29 2 4 Ship the exhibit by priority methods and notify the action point by message The message should contain the MIP number DR exhibit stock number if available exhibit part number nomenclature transportation control number TCN and method of shipment 7 29 2 5 Ship DR exhibit within 48 hours after receipt of exhibit disposition instructions 7 29 2 6 Ensure that exhibits are properly packed and identified according to the requirements of this publication Assure that shipping information is entered on exhibit docu ments How to Complete a DD Form 2332 In Block 1 Report Control Number Date N establishing the DR Originating Activity NSN Part No Serial No Remarks MO C The number in Item 3 of the associated Deficiency Report DR The date from the DR submission date This will be the date of the message The name and address of the originating activity s screening point The national stock number from Item 5 of the DR The manufacturer s part number of the failed item from Item 8 of the DR The serial number of the failed item from Item 9 of the DR Information such as the MIP number that was not included in the other blocks and that will assist in identifying the exhibits If the item is a mis
33. 9 1 9 2 93 9 4 9 5 PURPOSE end e tmd SCOPE RECOMMENDED CHANGES DEPOT MAINTENANCE MAINTENANCE CRITERIA AND PRODUCTION CYCLES Page 8 56 8 56 8 57 8 57 8 57 8 57 8 58 8 58 8 59 8 59 8 59 8 59 8 62 8 63 8 63 8 63 Chapter 9 6 ESTIMATED COMPLETION DATES 2 5 bs bo ae 9 7 AUTOMATED AIR FORCE TECH NICAL ORDER AFTO FORM 9 REQUIREMENT 9 8 VEHICLE INSPECTION ACCEP TANCE 9 9 WARRANTY DISCREPANCY PORTING 5222x293 eee 910 WR ALC LE 9 11 VEHICLES AND COMPONENTS NOT ELIGIBLE FOR DEPOT MAINTENANCE 9 12 VEHICLE COMPONENTS ELI GIBLE FOR DEPOT MAINTE NANCE Doe 9 13 AUTHORIZED DEPOT VE HICLES 9 14 MAINTENANCE ASSISTANCE 9 15 WRALCILE 9 16 VEHICLE REQUIREMENTS 9 17 ADDITIVE REQUIREMENTS 9 18 REQUEST FOR DEPOT OVER HAUL 9 19 VEHICLE REPAIR SCHEDUL JC 920 ATTACHMENTS 9 21 APPROVAL been 9 22 CONTRACTORS APPENDIX TUNNER 60K Aircraft Cargo Loader 9 1 9 1 9 2 9 2 P N D N TET D NO SO 0 0 Nel 9 SO SO KAR RO gt vii TO 36 1 191 Figure NN e e e 2 24 2 25 2 26 2 27 2 28 2 29 2
34. Continued COLUMN COLUMN COLUMN II III IV Component Level Type of Vehicle Tires A AM Tools Tracks A SE B SE Trailers In verted Transfer Case Assemblies Transmissions A AV COLUMN V Processing Required Unless otherwise specified no preservatives or Mounted preservative coatings shall be applied to tires a Shipment Road tires mounted shall be inflated to 10 pounds above the pressure recommended for maximum load Spare tires shall be inflated to 2 3 of the pressure recommended for maxi mum load levels A amp B b Storage Pressure in all tires of vehicles blocked clear of ground reduced to approximately 2596 of the normal operating pressure c Enclose the tires and wheel assemblies in black polyethylene material NSN 8135 00 579 6487 Secure with twine or pressure sensitive tape Punch holes through bottom of the enclosure to permit drainage of condensation a Maintain prescribed operating pressure b Shipment Inflate to 10 pounds above operating pressure Tires destined for long term storage may be preserved with preservative conforming to MIL P 11520 if determined cost effective See Item 83 OVE Coat metal components of rubber tracks and the entire surface of metal tracks with Type P 1 preservative Dunnage shall be placed beneath tracks of stored crawler vehicles to provide ad equate drainage No processing required See Item 69 See Item 46 Differentials a Standard Drive Transmission sha
35. Figure 6 1 6 14 QUARTER PANELS AND REAR FENDER WELLS INCLUDING ALL BOXED IN AND DOUBLE PANEL SECTIONS UP TO AND INCLUDING 16 INCHES FROM BOTTOM ACCESS TO THIS AREA MAY BE THROUGH AN INSPECTION PLUG NEAR THE BOTTOM OF THE PANEL THIS MAY BE AN OPEN PANEL AND CARE MUST BE TAKEN TO AVOID EXCESSIVE SPRAYING WHICH COULD RESULT IN MATERIAL PENETRATING THE TRUNK AREA ON SOME VEHICLES THIS AREA MAY BE TREATED FROM INSIDE THE TRUNK IN SOME CASES 1 2 INCH HOLES MAY NEED TO BE DRILLED IN THE REAR DOOR PILLAR HIGH ENOUGH TO CLEAR THE INNER WHEEL HOUSING THIS HOLE SHOULD BE LOCATED WHERE THE TWO PANELS DIVERGE ENOUGH TO PROVIDE ROOM TO INSERT THE SHORT CURVED WAND PLUG HOLES WHEN COMPLETED USE GRADE 1 F09603 076 Commercial General Purpose Vehicles Areas of Application Sheet 4 TO 36 1 191 APPLICATION ALL FRONT AND REAR LIGHT WELLS AND PANELS IF REAR LIGHTS ARE NOT ACCESSIBLE FROM UNDERNEATH THEY MAY BE REACHED THROUGH THE TRUNK WHEN VEHICLE IS ON THE FLOOR OR GROUND TYPICAL PARKING LAMP GRADE 4 GRADE 4 GRADE 4 REAR TRUNK FLOOR AND PANEL ASSEMBLY ALL BOXED IN OR DOUBLE PANELED AREAS AND SEAMS INCLUDING AREA OF DECK LID PLUS REAR GRAVEL SHIELD FENDER SKIRT WELLS UNDERSIDE OF FENDER SOME VEHICLES MAY HAVE A SPARE TIRE MOUNTED IN THIS AREA BE SURE TO REMOVE TIRE BEFORE TREATING THIS AREA TREAT THE REAR FENDERS IN THE SAME MANNER AS THE FRONT ACCESS TO PART OF
36. ing this area 2 55 TRACTORS AND FORKLIFTS 2 55 1 Tractors other than truck tractors and aircraft towing tractors will be marked using Figure 2 6 and Figure 2 9 as a guide 2 55 2 guide Forklifts will be marked using Figure 2 30 as a 2 56 TIRE SIZE TYPE AND INFLATION PRESSURE 2 56 1 manufacturer s recommended operating tire size and ply and or rating in addition to the recommended operating tire pressure will be stenciled in the area of the left door on adjacent to either the front or rear door pillar post of vehicles so equipped This instruction will not be applied to those vehicles equipped with a label on which the manufac turer s recommended operating tire size and ply and or rating and operating tire pressure is embossed 2 56 2 On other type vehicles the operating tire size and ply and or rating in addition to the recommended operating tire pressure will be stenciled on the shield panel or frame immediately adjacent to the left front tire If rear tires have a different manufacturer s recommended operating tire size and ply and or rating and or pressure this will be stenciled adjacent to left rear tire 2 56 3 Size of letters and numbers will be 1 2 inch high and they will be of a contrasting color If there is a tone down requirement the color will be black lusterless NOTE The tire pressure embossed on a label or stenciled on the vehicle represents normal usage pressures for which the vehicle
37. 1 5 6 15 7 1 5 8 1 6 1 6 1 1 6 2 1 6 4 1 6 5 1 6 6 1 6 7 1 6 8 1 7 2 PAINTING MARKING AND LIGHTING 2 1 2 2 2 3 2 4 29 2 6 27 2 8 36 1 191 TABLE OF CONTENTS PURPOSE eter x REESE SCOPE ts fens ee 5515 9 3 DEFINITIONS GENERAL INSPECTION POLI CIES n esas LIMITED TECHNICAL INSPEC TION Os dial ees Disposition Inspections Receiving Acceptance Inspections Used Vehicles Receiving Inspec HOD a ch ak rex Soe Sond gs New Vehicles Acceptance Inspec HO a as ide dore Hid ta ews Shipping Inspections Military Assistance Program Depot Repair Rebuild Request GENERAL INSPECTION STAN DARDS Appearance 2 5 cw baa TOOlS RUSSES P SEES Seals Oil And Grease Bearings Anti Friction Ball And ROMET Sites v Operational Test Vacuum Tests Pollution Emissions Control De VICES sor deis e RN ats MINIMUM SERVICEABILITY STANDARDS PURPOSE RERO REQUIREMENT FOR PAINTING AUTHORIZED COLORS GENERAL ADMIN USE VE HICLES eee we US FIRE TRUCKS AIRCRAFT REFUELING VE HICLES n xn LIQUID OXYGEN NITROGEN TRANSPORTING LAW ENFORCEMENT SEDANS Page viii RRR Re t 1 1 gt
38. 1 7 2 133 1 Certified Welder A person who has com pleted a welder s training course and possesses one or more of the following a Certification from American Welding Society b Certification for Aircraft Welders in accordance with TO 00 25 252 c Certification from a third party that weld samples have been destructively inspected and found acceptable 1 7 2 133 2 Qualified Welder A task qualified welder TO 36 1 191 CHAPTER 2 PAINTING MARKING AND LIGHTING 2 1 PURPOSE The purpose of this chapter is to provide standard painting and marking requirements and instructions as well as mini mum lighting requirements for USAF owned leased or rented vehicles Wing Group commanders will not authorize deviation from painting marking and lighting standards prescribed within this Technical Order without approval from MAJCOM unless deviation authority is specified herein MAJCOMs will determine if additional approval is necessary beyond their level WR ALC LE 2 1 1 These provisions apply to all vehicles owned leased or rented to the USAF including the Air National Guard identified in Federal Supply Groups 23 24 38 39 and 58 and those in Federal Supply Classes 1740 and 4210 2 1 2 The provisions of TO 35 1 3 apply to equipment designated as USAF Ground Support Equipment GSE 2 1 3 The term vehicle includes wheeled tracked and combined wheel and track laying vehicles and chassis powered by self co
39. 1887 TO 36 1 191 1 5 8 10 Functional testing may also be accomplished at any other time there is a reasonable doubt as to condition of equipment involved 1 6 GENERAL INSPECTION STANDARDS 1 6 1 Appearance The equipment internally and ex ternally shall be clean dry and free from mud and other debris No organizational insignia or other nonstandard mark ings shall be left on vehicles being shipped from using organizations Vehicle s finish will be in such condition as to afford adequate protection against rust or corrosion in accordance with Chapter 2 1 6 2 Tools Specialized tools are usually not required on general purpose and material handling vehicles Special ized tools on all other vehicles will be provided in accordance with the directive applicable to that item of equipment 1 6 3 Inspections shall be performed to ensure that such items as supporting attaching or connecting members are in good condition that stowed or assembled items are secure adequately lubricated and not excessively worn or leaking 1 6 3 1 Inspect for good condition This means parts and components which are not bent twisted chafed burned broken cracked bare frayed collapsed torn cut or deterio rated 1 6 3 2 Excessively worn is construed to mean subject to early parts failure Excessive wear of mating parts or linkage connections is usually evidenced by too much play lash or lost motion It also includes ille
40. 2 17 7 Follow the thermal spray equipment manufactur ers preparation and application instructions The metalized coating shall be applied to a minimum thickness of 6 mils and maximum of 8 mils NOTE The use of a multi metal dry film thickness DFT gauge such as the Positector 6000 series or equivalent is required to accurately measure the applied MWAS coating thickness 2 17 8 surface which shows visible moisture rust scale or other contamination shall be re blasted or otherwise mechanically cleaned to the proper surface finish prior to metalizing The surface must be completely coated to the specified thickness within six hours of completion of abrasive blasting Abrasive blast only the area that will be metalized within the given workday 2 17 9 metalized coating shall be inspected for thickness by using a multimetal dry film thickness Gauge to ensure correct surface thickness is achieved surfaces that have not received the optimal coating thickness of 6 8 mils or other uncoated areas must be immediately roughened with a mechanical grinder with a minimum of a 25 grit disc Manually apply a cross hatch grinding pattern to the substrate with only enough pressure to roughen the surface that will be coated Immediately apply the thermal spray coating to reach the proper coating thickness 2 17 10 Properly applied metalized coating provides ex cellent long term corrosion protection Unless a color is r
41. 3 USE GRADE 2 COAT ALL AREAS AROUND WINDOW SEAMS HINGES AND MIRROR BRACKETS COAT ALL EXTERNAL METAL TO METAL JOINTS AND ENTIRE OUTER SURFACE IF FILM COATING APPEARS TO BE TOO HEAVY WIPE OR POLISH WITH A CLEAN CLOTH 4 USE GRADE 2 COAT ALL WHEELS BOTH SIDES LUGS AND RIMS 5 USE GRADE 4 FOR ALL ELECTRICAL SYSTEMS DASH PANEL LIGHT SOCKETS SPARK PLUGS DISTRIBUTOR GENERATOR ETC 6 USE GRADE FOR RADIATOR ELECTROLYSIS CONTROL APPLY FIRST COAT OF GRADE 3 TO BOTH EXTERNAL SURFACES OF RADIATOR CORE FOLLOW THE SAME PROCEDURE WITH THE SECOND COAT OF GRADE 3 REFERENCE NUMERICAL LEGEND F09603 083 Figure 6 1 Commercial General Purpose Vehicles Areas of Application Sheet 11 6 21 TO 36 1 191 APPLICATION MISCELLANEOUS ANY AREA WHICH HAS NOT BEEN SPECIFICALLY MENTIONED ABOVE BUT IS DISCOVERED TO BE PART OF AN AREA REQUIRING TREATMENT 15 TO BE ADEQUATELY COVERED OVERSPRAY CLEAN UP CLEANING MATERIALS MAY BE TOXIC TO EYES SKIN AND RESPIRATORY TRACT EYE AND SKIN PROTECTION REQUIRED USE ONLY IN AWELL VENTILATED AREA F09603 084 Figure 6 1 Commercial General Purpose Vehicles Areas of Application Sheet 12 6 22 TO 36 1 191 AREAS TO BE RUST PROOFED PLATFORM AND RAMP CONVEYORS RADIATOR EXTERIOR WINCH CAB AREA DOORS HINGES FLOOR BOTH SIDES BATTERY BOX PLATFORM UNDERSIDE INCLUDING CHAINS LAMPS LADDER ELECTRICAL CONNECTIONS WHEEL RIMS SUSPENSION PLATFORM AND CH
42. 4 36 8 Ordering Information The National Highway Traffic Safety Administration has prepared safety information charts as part of a continuing campaign to alert truck and bus service personnel to the risk involved when working with multi piece truck and bus wheels Individuals who service such wheels may obtain a copy of each chart without cost by writing to General Services Division Distribution National Highway Traffic Safety Administration 400 Seventh Street SW Washington DC 20590 4 36 8 1 Reprints of the above mentioned charts are available through the Occupational Safety and Health Admin istration OSHA area offices The address and telephone number of the nearest OSHA area office can be obtained by looking in the local telephone directory under U S Govern ment U S Department of Labor Occupational Safety and Health Administrative Single copies are available without charge 4 36 8 2 Available from Rubber Manufacturers Associa tion are numerous demounting and mounting procedure charts for all special and general purpose vehicles Also available are booklets on safety and servicing and multi piece rim wheels and a training for a minor fee Write for the catalog from Rubber Manufacturers Association 1901 Penn sylvania Ave NW Washington DC 20060 4 31 TO 36 1 191 4 36 8 3 Tire and Rim Association Inc Year Book specify the year may be ordered from Tire and Rim Association Inc 175 Montrose W Ave Sui
43. 8 Silver Red 4 in 6 in x 3 3 in 3613378 Number 9 Silver Red 4 in 6 in x 3 3 in 3613379 Number 0 Silver Red 4 in 6 in x 3 3 in 3613380 Number 1 Silver Red 6 in 8 in x 5 2 in 3613381 Number 2 Silver Red 6 in 8 in x 5 2 in 3613382 Number 3 Silver Red 6 in 8 in x 5 2 in 3613383 Number 4 Silver Red 6 in 8 in x 5 2 in 3613384 Number 5 Silver Red 6 in 8 in x 5 2 in 3613385 Number 6 Silver Red 6 in 8 in x 5 2 in 3613386 Number 7 Silver Red 6 in 8 in x 5 2 in 3613387 Number 8 Silver Red 6 in 8 in x 5 2 in 3613388 Number 9 Silver Red 6 in 8 in x 5 2 in 3613389 Number 0 Silver Red 6 in 8 in x 5 2 in 3613393 100 130 Silver Purple 4 in 5 in x 30 in 3613394 100 130 Silver Purple 6 in 7 in x 42 in 2 55 TO 36 1 191 Part No Legend Or Symbol Colors Letter Or No Emblem Size BKGND 3613395 115 145 Silver Purple 4 in 5 in x 30 in 3613396 115 145 Silver Purple 6 in 7 in x 42 in 3613397 AVGAS Silver Purple 4 in 5 in x 24 in 3613398 AVGAS Silver Purple 6in 7 in x 32 in 3613399 Silver Purple 4 in 6in x 33 in 3613400 F Silver Purple 6 in 8 in x 5 6 in 3613401 2 Silver Purple 4 in 6 in X 33 in 3613402 E Silver Purple 6in 8 in x 5 6 in 3613403 eps Silver Purple 4 in 6inx 33 in 3613404 qe Silver Purple 6in 8 in x 5 6 in 3613405 8 Silver Purple 4 in 6inx 33 in 3613406 8 Silver Purple 6in 8 in x 5 6 in 9275871 01 Number 0 die cut pre spaced Blue No
44. 9150 01 053 6688 6850 01 328 3617 TO 36 1 191 Application For outdoor protection this material can only be used for a limited time where temperature is not extreme Grade 3 may be used on radiator exteriors Thin transparent tack free protective film for protection of metal surfaces against corrosion during indoor stor age and limited outdoor preservation Use on control cables fasterners bare metal areas or anywhere temporary 30 days or less protection is needed Temporary repair of small paint damage areas from chips scratches or cracks Intended for use on nonmoving parts not requiring a lubricated surface such as fasterners seams access pan els joints unpainted metal etc Water displacing CPC which may be applied by dipping spraying brush ing or from pressurized containers Suitable for use on any metal surface for indoor and short term outdoor protection where surfaces can be re coated when required Water displacing CPC for use on avi onic equipment electrical connector plugs and contact points Lubrication and short term preservation of aircraft hinges and small and large caliber weapons NOTE Do not use MIL PRF 63460 on rubber or other elastomeric materials Use only in areas from which solvents can evapo rate Water displacing CPC for use on elec tronic connectors and components electrical motors relays and termi nals light fixtures storage batteries all mechanical close tol
45. A B gate Chassis A B Chrome A B COLUMN Level Type of Vehicle AV SP SP GP AV CP COLUMN V Processing Required See Items 46 and 118 Remove drain plugs from wing boom chain hous ing and check for entrapped water if inspection reveals water content drain and flush with type I Grade 10 oil Specification MIL L 21260 and fill with lubricant specified in applicable lubrica tion chart Clean surfaces adjacent to upper and lower swing boom housing cover openings with barrier material conforming to MIL B 131 and seal with tape conforming to MIL T 43115 level B and MIL T 22085 level A Exposed gears non precision drive chains sprock ets and adjusting mechanisms shall be coated with V V L 800 Type P 9 or MIL C 16173 P 3 preservative oil to assure penetration to inner surfaces of rollers pins and bushings Excess Type P 9 or P 3 preservative shall be allowed to drain then entire area shall be coated with MIL C 16173 Type P 1 preservative Wire rope chains shall be coated with oil con forming to VV L 7510 Coat uncovered chains with MIL C 16173 Type P 1 preservative Coat unpainted metal surfaces of fifth wheel plates sheaves track idler wheels side plates axles frames springs propeller shafts including splines slip joints and univer sal joints and steering assemblies with MIL C 62218 Avoid coating rubber or surfaces of fric tion brakes If inadvertently applied cl
46. Disk abrasive closed coating 24 grit 7 in diam eter 7 8 in arbor hole Disk abrasive closed coating 36 grit 7 in diam eter 7 8 in arbor hole Disk abrasive open coating grade 0 7 in diam eter without arbor hole Enamel Black full gloss color no 17038 Enamel Black lusterless color no 37038 Enamel Gray color no 16081 full gloss type I Enamel Green semi gloss color no 24633 Enamel Orange Yellow full gloss color no 13538 Enamel Red color no 11105 full gloss Type I Enamel Red lusterless color no 31136 Enamel Strata Blue color no 15046 Fed Std No 595 Enamel Yellow full gloss color no 13538 6850 00 551 9577 NSL 2540 00 409 8878 NSN 6850 01 381 4408 55 Gallon Drum NSN 6850 01 381 3300 5 Gallon Can NSN 6850 01 381 5088 55 Gallon Drum NSN 6850 01 381 5139 5 Gallon Can 8305 00 205 3495 8030 00 290 5141 8030 00 165 8577 6850 00 559 2836 6850 00 559 2835 6850 00 256 0157 8010 00 297 0586 8010 00 297 0560 5345 00 558 5929 5345 00 558 5928 5345 00 196 1692 5345 00 186 8248 8010 00 527 2050 8010 00 297 0547 8010 00 616 7496 8010 00 527 3197 8010 00 680 0200 8010 00 616 7487 8010 00 472 5512 8010 00 298 2287 8010 00 527 2045 LP DLA GSA GSA GSA GSA GSA GSA AF Stock GSA GSA GSA GSA GSA GSA GSA GSA DOD GSA GSA GSA GSA GSA GSA GSA DOD GSA 2 45 TO 36 1 191 Table 2 2 Supply Information Co
47. Floor deck platform shall be firm and shall not be deteriorated to point that it will not hold sustain a load satisfactorily Wood platform planking shall not be dry rotted or cracked to the point it will impair its strength Metal decks shall not be loose or have rust holes in them welds and attached hardware shall not be cracked or broken There shall be no loose missing or broken bolts nuts or washers 1 7 2 60 Foam Meter Crash Fire Equipment Foam tanks filler vent and gauge shall be in good condition and operational Foam metering valve shall be set and operate properly 1 7 2 61 Frame The frame shall not be bent cracked or twisted Cross members shall not be loose at point of attachment to side rails Frames that have been repaired by welding will not be considered serviceable if welds are cracked or a good fusion of metals has not been obtained Welder areas that extend 1 3 or more across a frame section will be reinforced with channel or angle iron over the welded area There shall be no missing or broken bolts or rivets Refer to TO 36A12 1A 3052 2 and TB 9 2300 247 40 for 1 11 TO 36 1 191 inspection and repair procedures for tactical vehicle frames TB 9 2300 247 40 is available via the Warner Robins web site under the tactical vehicles link 1 7 2 62 Fuel Pump Fuel Filter Pump shall be free of oil and fuel leaks Pump s filter or sediment bow shall be free of dirt or water The pump shall be
48. Inspect welds of toolbox cross members at the main beam flanges and webs x a Inspect welds of the fifth wheel king pin and king pin supporting structure bulkheads X X cross members etc Inspect welds of the toolbox bottom at both main beam flanges O XxX xXx Inspect welds of the front bulkhead located at the rear of the gooseneck X X Inspect welds of the gooseneck extension at all cross member and bulkhead connec X X wies he man Gawain eee Inspect welds of the gooseneck extension at all cross member and bulkhead connec X X Pine wers they connect e Gul peu 3 20 TO 36 1 191 TVOIdAL NC 39NV I3 NV38 Figure 3 3 Typical Beam Construction 3 22 TO 36 1 191 F09603 042 SPLICE PLATE TYPICAL KING PIN SUPPORTING STRUCTURE OR UPPER COUPLER ASSEMBLY Figure 3 4 King Pin Mounting Area 3 23 3 24 blank TO 36 1 191 CHAPTER 4 TIRES 41 SAFETY SUMMARY The following are general safety precautions that are not related to any specific procedures and therefore do not appear elsewhere in this publication These are recommended pre cautions that personnel must understand and apply during many phases of operations and maintenance Personnel must at all times observe all safety regulations Some equipment and
49. Inspection personnel must be familiar with the inspection system set forth in AFI 24 302 Vehicle Fleet Management and Chapter 3 covering maintenance inspection and recording thereof as well as with the requirements of this technical order Chapter 3 specifically excludes vehicles in storage from the operational inspection intervals prescribed therein therefore maintenance inspection intervals as well as storage inspection intervals are prescribed below For purposes of practicality and economy both inspections shall be scheduled concurrently when possible 8 8 3 Responsibility Earlier portions of this technical order establish responsibility for processing Responsibility for conduct of inspection will be delegated to vehicle man agement activity Management will insure that qualified inspectors are available to accomplish required inspections and report discrepancies noted 8 9 PRE STORAGE PREPARATIONS 8 9 1 Cleaning Remove all debris from cabs crew compartments bodies tool compartments equipment storage areas and other places as required Remove rust and scale from corroded areas Remove or cover any item subject to damage during washing Wash vehicle thoroughly and re move stones from tires wheels tracks or suspension When steam cleaning is necessary insure that equipment subject to damage is removed or adequately shielded and that personnel are instructed never to direct cleaning jets at critical areas Drain
50. Letter F Letter G Letter Letter I Letter J Letter Letter L Letter Letter Letter O Letter Colors BKGND Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver None None None None None None None Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Letter Or No Size 1 1 2 in 1 1 2 in 1 1 2 in 1 1 2 in 1 1 2 in 1 1 2 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 3 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in TO 36 1 191 Emblem Size 2 in x 1 4 in 2 in x 1 4 in 2 in x 1 4 in 2 in x 1 4 in 2 in x 1 4 in 2 in x 1 4 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 i
51. Level A storage shall be given complete storage inspections as follows 8 12 3 1 Inspect at rate of per cent of total stored except that at least one unit shall be inspected from each group of like vehicles each 180 day period to determine if the preservation and processing measures applied are effectively preventing corrosion and deterioration 8 12 3 2 Where quantities permit no vehicle shall be selected for inspection which has been operated subsequent to the last processing and samples shall be selected at random to avoid repeated inspection of the same unit vehicle 8 12 3 3 If this inspection reveals defects in preservation an additional 10 percent shall be inspected and a report of conditions with recommendations for corrective action sub mitted to the responsible storage officer 8 12 3 4 To enable detailed observation assemblies shall be depreserved and disassembled sufficiently to permit assur ance that no corrosion or deterioration has occurred Visual inspection will be sufficient in depth and scope to reduce the requirement for extensive disassembly 8 12 4 Storage Site 8 12 4 1 A requirement may exist for vehicles to be maintained in either inside or outside storage At no time will vehicles be stored so as to permit contact between tires and a surface soaked with oil or grease Vehicles stored on a surface which is not level will have the wheels or tracks securely chocked to prevent movement 8 12 5 Outs
52. Operators shall report defects detected during exercise to storage facility inspectors to ensure proper condition tagging of units found other than serviceable A serviceability inspection shall be accomplished on each unit 180 days from the date of receiving inspection and every 180 days thereafter except that this inspection shall be adjusted to coincide with the next scheduled exercise programmed after its due date 8 20 3 Shipping As the vehicles are maintained in serviceable status and immediate availability for delivery is mandatory shipping inspection requirements shall be held to a minimum The following inspections are required 8 20 3 1 Insure that vehicle is complete and serviced that OVE records publications batteries etc are with the unit 8 20 3 2 Check to insure that the shipment complies with applicable traffic and carrier tariff regulations 8 20 3 3 If vehicles are to be offered for military airlift ensure that the requirements of AFMAN 24 204 1 are met including necessary certification 8 20 3 4 Check shipping documents 8 20 4 Other Inspections Additional inspection ac tions shall be initiated as required by the responsible storage officer A routine daily inspection to visually check tire inflation accumulation of water in vehicle bodies evidence of pilferage or theft unusual leakage and other easily observable defects is required Special surveillance tours shall be made immediately following
53. TIRE AND Rim Association Yearbook should be used in conjunction with vehicle manufacturer s information as a reference for rims and tire match up 47 SELECTION OF TIRES Vehicle Fleet Managers are tasked with the job of obtaining correct replacement tires for their vehicle fleet Replacement tires must be selected to match the use application of each vehicle This section is intended to provide necessary basic information on tire construction and industry ratings so that logical tire selections can be made Under no circumstances will replacement tire s be of a lesser ply rating load range than recommended by the manufacturer Under no circum stances will working air pressure exceed the capacity of the 4 1 TO 36 1 191 rim Rims requiring replacement will meet or exceed Original Equipment Manager OEM specifications for the vehicle When replacing tires with a higher load range due to local availability do not exceed rim capacities OEM vehicle load capacities and gross vehicle weight will not change 4 8 TIRE CONSTRUCTION MATERIAL The term means a manufactured product made of rubber chemicals fabric and steel or other materials which when mounted on a suitable wheel provides traction and or sustains the load The most important tire materials are those used for cord body These materials determine the strength and maintain the inflated configuration of the tire 4 8 1 Rayon Fiber Rayon fiber is used
54. TO 35 1 3 Cleaning Corrosion Prevention Painting and Marking of USAF Support Equip ment TO 36 1 Corrosion Prevention and Control Vehicle 131 Management Index File VMIF formerly 43 0213 TO 36A 1 1301 This publication is only available at the WR ALC LE web site Use the following web link to ac cess and download the most current pub lication https sevpgm robins af mil vehicle VMIF 6 4 DEFINITIONS 6 4 1 Corrosion Premature deterioration of metals or metallic components resulting from the action of service environment oxidation upon vehicle and vehicular compo nents Rate of deterioration is accelerated by infrequent improper vehicle cleaning corrosion removal and subjecting vehicle components to ice control compounds 6 4 2 Rust Ferrous oxides resulting from chemical oxida tion process acting on iron steel subjected to water or moist air 6 4 3 Rustproofing Protective coating applied to vehicles vehicle components and vehicle equipment for the express purpose of retarding and or preventing the corrosion process 6 4 4 Tropical Corrosion Control Same as rustproofing with additional applications to other areas for more complete protection under highly corrosive climates conditions 6 4 5 Factory Corrosion Control Any all measures taken by manufacturer to ensure the finished product is protected from corroding Actions taken may include rustproofing zinc coating dipping and the use of plastics and
55. TRUCK PANELS INNER SEPARATING THE CARGO COMPARTMENT FROM THE OUTSIDE OF THE TRUCK IF THE INNER PANELS DO NOT EXTEND TO THE FULL HEIGHT OF THE BODY THE COMPOUND CAN BE SPRAYED FROM THE TOP EDGE DOWNWARD IN SOME CASES 1 2 INCH HOLES WILL NEED TO BE DRILLED SIX TO EIGHT INCHES FROM THE BOTTOM IN THE INNER PANEL BETWEEN ALL THE VERTICAL BRACES INSERT A SHORT CURVED WAND AND SPRAY THE LOWER PORTION OF THIS AREA RIVET HEADS OUTLINE CLOSED AREAS BETWEEN INNER AND OUTER PANELS TRUCK BODIES ALL ENCLOSED BOXED IN AND DOUBLE PANELED AREAS INCLUDING DOORS GATES AND BODY FLOOR TRUCK BODY SKIRTS Figure 6 1 SPRAY THIS AREA FROM UNDERNEATH EXAMINE THIS AREA FOR HOLLOW SECTIONS WHICH NEED TO BE COATED INSIDE IN CASE OF VEHICLES HAVING THE SPARE TIRE MOUNTED IN THIS AREA BE SURE TO REMOVE TIRE BEFORE SPRAYING THE AREA REMOVE ANY COMPOUND THAT MAY COME IN CONTACT WITH THE TIRE F09603 080 Commercial General Purpose Vehicles Areas of Application Sheet 8 TO 36 1 191 APPLICATION COMPLETE FRAME INCLUDING INSIDE ALL OF BOXED IN AND EXPOSED EXTERIOR SURFACES SPRINGS BRACKETS RUNNING GEAR AND WHEEL RIMS SPRAY FRAME WHEEL RIMS LUGS AND RUNNING GEAR WITH GRADE 1 SPRAY ALL METAL UNDERNEATH WITH GRADE 1 SPRAY WEST COAST MIRRORS WITH GRADE 3 SPRAY ALL BOXED IN AREAS WITH GRADE 1 DRILL 1 2 IN HOLES WHERE ENTRANCE IS NECESSARY AND USE FLEX HOSE EXTENSION WHERE DEEP CAVITY PRO
56. V eAu 3198 ON sjuourarmbos uomneunSguooow sxreurow puy uornonisu PAT T 8 AQL joefqng ON 19peo T 09 T V 7 TO 36 1 191 Ares 29110 UOISOIIOO pue aunjsrour so1nso ouo yoodsur pue 80 9A 6 5 8 uonoog ZI CE 21496 OL Jed 159 pue 31015 pesut Se YOO 089 Jod juoA os uA pue WA pue jsneuxo Jed ong K onoos 5 pue spy Je uo3uan pue 25015 uedo are Kan ains 0 uwap Jo 394528 gui eos pombas jr pue joedsur pue senso out 12edsur Suissoooud 66 8 NOLLOHS TI SE E CIN9 OL FAS ASN 4404 dd ANVIL TANA NV IO CNV LSOVHXY ANV LH INI Hd VIL HAOINGL 1 15 eY 1 19W 0 39 8 UTEM YNY 680CC L TIN Jed ade pno jsneuxo 0OO SI 1o V 089 Jed 1ueAqos ysny pue pue soqnj ong ye pue ong 81 5 Srp Jor Tong Jo jno 19jeou uny oui ong joe
57. When recommended by the Manufacturer s Guidance tire pressure should be temporarily increased without exceeding maximum side wall pressure while operating with heavy loads or for sustained highway opera tion Stenciled tire pressure shall not be changed when tire pressure is temporarily increased but will be changed if the vehicle is primarily operated under heavy load conditions 4 23 1 5 When the correct tire pressure is not available through all other sources use the applicable table of the Tire and Rim Association Yearbook 4 11 TO 36 1 191 4 23 2 Maintenance Inspection See Figure 4 16 When a vehicle is in for a scheduled inspection or a mounted tire is brought in for repair visually inspect and replace if any of the following are present 4 23 2 1 A break or cut exposing the body cords 4 23 2 2 bump or bulge 4 23 2 3 Tire tread or side walls cracked or deeply weather checked exposing cords or endangering vehicle safety Tires made of nylon polyester cord need not be replaced if weather checked 4 23 2 4 Tread is worn to 2 32 inch Military tread tires will be removed when tread design is worn smooth in the center 4 23 2 5 Abnormal wear Rotate abnormally worn tire and correct cause of abnormal wear 4 23 3 Tire Shop Inspection 4 23 3 1 tires in for repair will be inspected along with tube or tubeless tire valve stem and wheel prior to mounting 4 23 3 2 Prior to mounting all tires
58. cal order and are identified by type of inspection as follows 3 4 1 1 Operator Inspection 3 4 1 2 Preventative Maintenance and Inspection PM amp I 3 4 1 8 Annual Inspection 3 4 1 4 Special Inspection 3 4 1 5 Technical Inspection 3 4 1 6 Acceptance or Receipt Inspection 3 4 2 General inspection and service requirements appli cable to most vehicle equipment are specified in the follow ing paragraphs by type of inspection service and special inspections tests are contained in Table 3 1 and Table 3 2 of this technical order for easy reference Specialized require ments peculiar to certain equipment and exceptions to general requirements and or intervals are contained under Paragraph 3 8 titled Special Lubrication Instructions and Product Specifications 3 4 3 Except for operator inspections and the Vehicle Emissions Test inspection work cards may be prepared and used locally for guidance in performing inspections 3 4 4 Except for operator inspections Annual and PM amp T s will be performed by the vehicle management activity with assistance from using organizations when specified All actions will be recorded on the work order To minimize vehicle Non Mission Capable time and excessive workload the intervals indicated in Table 3 1 and Table 3 2 are sequenced where possible to accommodate concurrent ac complishments of Annual and PM amp l s service or test re quirements Specified mile hour for Annual and PM a
59. continuing operations Refuelers will grounded to an approved ground as per TO 00 25 172 Personnel must be thoroughly famil iar with the operating procedures and safety precautions outlined in the operation technical manual for the specific refueler to be exercised 8 21 3 2 When storage experience or special conditions require more frequent exercising the local commander or VFM is authorized to vary the exercise interval to ensure adequate protection When this document is specified con tractually permission to increase frequency must be obtained from the contracting officer or his authorized representative 8 21 3 3 Vehicle in long term level A storage shall be exercised bi yearly as a minimum 8 58 8 21 3 4 Exercise Period vehicles shall be oper ated for one half hour unless otherwise specified This time may include the warm up period Accessory and mounted equipment shall be operated for a period sufficient to exercise and lubricate all moving parts but not to exceed one half hour Vehicles will be driven a minimum of ten minutes during this interval 8 21 3 5 Requirements Prior To Exercise 8 21 3 5 1 Check for evidence of leakage of oil fuel or coolant Ensure that engine and power train component lubricant levels are proper 8 21 3 5 2 Check tire inflation Tires shall be inflated to five pounds in excess of specified operating pressures 8 21 3 5 3 Remove temporary protective exhaust stack covers 8
60. eAneAJosoud ydeis Sursn 1 8 ALL 198 8 sxreurow puy uornonisu oS e 09 UUNI SS ec ulojs S 1sneuxq ed T Ary s1ougo dry ond psaq yoolqng QEL ON el A 6 TO 36 1 191 qeu ojeur pue sjuouoduioo yoop 301d 1equnj pesn oov d poxoo 591 Adwa XIS 680CC L TIIN Jod ainoas pue vos pue sse o 9 71 d edej pue 1orueq uir sSuruedo 1 000295 JO 9AUOO I9AOO pue SIO OI II S cIN9 OL Jed tuwo 19400 shen osn RJS Jo O1 der 11 7 uonoeg II 3r jr pue pomsyuoser GE E C N9 OL 199 dund sjuouoduioo SUISN 51591 8 Sursn xoop ISTRY 511 0 ATULIY pop qv 91 TOA POA Ig IA sse JO c T 01 Joao 1snfpy qv 253 JOYSeM p 9rqgspurA ST Suissooo1d ON q poseurep oq Sj 9q pue uoneinaguoo 31 JO 8 Yop este snu peup sey jured 51194 ponad Sune1odo uoju3n o1 3dooxo y 949 uorsuo qoq JOYO 9 Wary 0 8 ALL 198
61. faces When cooling systems is thermostatically controlled engine shall be operated until a tem perature has been reached that causes thermostat to open assuring complete mixing and even distribution of the antifreeze solution ve hicles with antifreeze installed by the proce dures outlined herein will be marked using the following format This marking should be lo cated as close as possible to the cooling system fill neck It must also be located if possible so as not to detract from vehicle appearance and yet be readily visible to personnel checking and or servicing the system ANTIFRZ 5 97 The above format will be cut in 1 2 inch letters and applied with white paint Line number one containing the phrase ANTIFRZ will be stan dard in all applications The information con tained in line number two will vary The first letter will be either A or C depending on the type antifreeze used The remainder of that line will contain in numerical code the month and year in which the system was serviced For ex ample A 5 97 in the above format means Arctic antifreeze was installed in May 1997 C 5 92 means antifreeze CID A A 52624 was installed in May 1992 b Antifreeze compound procedure For shipment and storage in areas where the temperature drops below 40 F cooling system shall be filled with antifreeze compound conforming to Specification CID A A 52624 The compound shall be used without dilution 8 26 4
62. i cede avg 9 1 LIST OF TABLES Table Title Page Table Title 2 1 Required Markings for Common 4 2 Measuring Procedure for New Tires Substances 9 Ges bbe See 2 26 4 3 Tire Size Conversion Chart 2 2 Supply Information 2 45 4 4 Tire Size Conversion Chart European 3 Vehicle and Equipment Inspection and Metric Tire Size Service Intervals 3 4 4 5 Tire Size Conversion Charts 3 2 Special Preventative Inspection Tests 3 7 6 1 Required Equipment And Materials 3 3 Preventative Maintenance Interval 6 2 Corrosion Severity Zones and Minimum Conversion Table Miles to Kilometers 3 8 Wash Interval 3 4 Definition of Terms 3 15 6 3 Galvanic Series of Metals and Alloys 3 5 Semi Trailer Structural Inspection 7 1 How to Complete a DD Form 2332 Checklist 222248 xS 3 18 7 2 VIWG Members 3 6 Semi Trailer Structural Inspection 8 1 Materials Required for Processing SU 3 18 8 2 Processing Procedures 3 7 Semi Trailer Structural Inspection 9 Depot Eligible Vehicles Checklist EE 3 19 9 9 Command Abbreviations 3 8 Semi Trailer Structural Inspection A Tunner 60 Aircraft Cargo Loader Checklist ea MESS 3 19 4 Tolerance In Matching Dual Tires 4 10 Change 1 Page Page
63. in open position Windshield wiper arms and blades shall be removed and together with keys placed in a waterproof bag conforming to type optional Class B of Specification MIL DTL 117H then stowed in dash compartment or securely attached to steering column Windows shall be opened 1 2 inch for ventilation and cab air vents left in open position 8 21 TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN COLUMN I II Item Component Level Type of Vehicle Processing Required 29 Cabs Soft Top A AV Except when removal of top is required for ship and Open ment cab shall be processed in accordance with Type Items 7 and 12 When removed top shall be thoroughly dried folded or rolled in a manner to avoid creasing of plastic windows packaged in accordance with Method IC 5 of Specifica tion MIL DTL 117H and packed in a nailed wood box conforming to specification PPP B 621 Box shall be identified and stowed with other OVE Windshield wiper arms and blades shall be removed and together with keys stowed in dash compartment and windshield secured in folded down position When dash compartment is not provided wiper arms and blades together with keys shall be placed in a bag conforming to type optional Class B of Specification MIL DTL 117H and securely at tached to steering column Seat backs and cush ions shall be removed and fabric surfaces cov ered with barrier material Barri
64. passenger car truck bus industrial etc as identified in the description Select the type tread ply rating and type of construction bias or radial required keeping in mind the information discussed in Paragraph 4 8 through Paragraph 4 10 NOTE Effective tire management requires matching the tire of the vehicle to its mission Initial cost should be a secondary consideration to maximum safety maintenance and economy energy efficiency 4 18 1 Steel Belted Radial Tires For general purpose use steel belted radial tires will yield maximum life cycle safety economy 4 18 2 Non Radial Tires Non radial tires should be replaced by steel radials on an attrition basis unless vehicle and tire manufacturer recommend other constructions for special purpose use 419 TIRE REPLACEMENT 4 19 1 Purchase new radial tires in complete sets for use on one vehicle where possible 4 19 2 Avoid purchasing new tires of non radial design for general purpose use Use existing non radials by cross switching between vehicles similarly equipped 4 19 3 Use radials and belted 60 70 and 78 series in complete sets 4 19 4 Do not mix tire sizes on the same vehicle unless so directed by manufacturer s recommendation or operational necessity Snow tires should be of the same size and con struction as those on the non drive axle 4 19 5 The may approve the use of either light truck or passenger car tires for commercial pickup tru
65. presence of ions 6 16 2 3 lons Atomsor groups of atoms bound together that is either positively or negatively charged An electrical current occurs when ions are forced to move through water solutions Ions cannot move through metal conductors 6 16 2 4 Electrolyte liquid solution usually water containing ions Salt water is an electrolyte an aqueous 1 water solution of sodium ions and chloride ions 6 16 3 Theory of Corrosion When a metal corrodes the metal atoms lose electrons and become metal ions in an electrolyte solution The positively charged metal ions can combine with negatively charged ions to form corrosion products such as metallic chlorides oxides hydroxides and sulfides Four conditions must exist before this type of corrosion can occur 6 16 3 1 A metal must be present that has a tendency to corrode The corroding metal is known as the anode 6 16 3 2 A dissimilar conductive material the cathode that has less of a tendency to corrode than the anode must be present Examples include a different metal a protected part of the same metal or conductive composites 6 16 3 3 A conductive liquid electrolyte must connect the anode and cathode so that ions can carry electrical current between them Electrolyte FRESH OR SALT WATER ACIDS GASES ETC Figure 6 3 Diagram of a Simplified Corrosion Cell 6 16 3 4 Electrical contact between the anode and cathode usually in the form of met
66. since requirements are based on local conditions and available types of vehicles cannot be predetermined 2 96 WARNING OR INDICATING LIGHTS Emergency Vehicles i e fire trucks flight safety air field management and base disaster mobile command post ve hicles shall use the revolving flasher type light of aviation red 2 96 1 The color of the revolving light used on Security Police Vehicles will conform to the color specified for police vehicles in the traffic code of the state in which the installa tion is located 2 96 2 Metropolitan and van type ambulances shall use a revolving flasher light with a clear lens incorporating 4 bulbs alternating lens colors two red and two white Station wagon and field type ambulances designated for general ambulance service will continue to use the red revolving flasher light Those station wagon and field ambulances designated as EMERGENCY USE may be equipped with the same revolving flasher light as authorized for van type and metro politan ambulances 2 96 3 Other vehicles which are authorized to operate on the apron taxiways and runways i e maintenance vehicles and alert reflex trucks will be equipped with the hazard warning lights four way flashers as required by the Depart ment of Transportation or a revolving pulsating type light of TO 36 1 191 aviation yellow The pulsating yellow light is optional on those vehicles that are equipped with the four way flashing hazar
67. trucks and black on tone down trucks TO 36 1 191 2 70 1 3 For P 2 P 4 P 8 P 12 P 15 P 18 P 19 P 21 P 22 P 23 P 24 P 26 and P 28 a 10 inch pattern 1 inch stripe l inch body color 6 inch stripe 1 inch body color inch stripe 1 6 1 2 70 1 4 For P 10 P 13 P 20 and P 27 a 7 inch pattern 1 inch stripe 1 inch body color 3 inch stripe 1 inch body color 1 inch stripe 1 3 1 This shield will be provided and paid for by CE 2 70 1 5 Location Perimeter horizontal striping to be located below the body centerline covering at least 1 2 of the length or as space permits of each facing surface length or width 2 70 1 6 For other fire protection equipment command foam trailer hazmat trailer stripes may be added when authorized by respective major command 2 70 1 7 Funding for all striping shall be provided by base CE 2 70 2 Vehicles will have the letters UNITED STATES and AIR FORCE as follows 2 70 2 1 Synthetic or encapsulated gold leaf with outline and black shadow Other colors with outline and black shadow Other colors with outline and shadow are permitted to allow for sufficient contrast between lettering and vehicle paint color 2 70 2 2 Left and right sides in long radius elliptical arches above and below lettering center line 2 70 2 3 No lettering on tone down trucks 2 70 2 4 Size of lettering to be minimum of 2 5 inches to a maximum of 6 inches 2 70 2 5 Location of
68. 1 2 in 1 1 2 in 1 1 2 in 1 1 2 in 1 1 2 in 1 1 2 in 1 1 2 in 1 1 2 in 1 1 2 in 1 1 2 in 1 1 2 in Emblem Size 6 in x 33 in 6 in x 33 in 6 in x 33 in 6 in x 33 in 6 in x 33 in 6 in x 3 3 in 6 in x 33 in 6in x 33 in 6 in x 33 in 6 in x 3 3 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 8 in x 5 6 in 2 in x 1 3 in 2 in x 13 in 2 in x 1 3 in 2 in x 13 in 2 in x 1 3 in 2 in x 13 in 2 in x 1 3 in 2 in x 13 in 2 in x 1 3 in 2 in x 13 in 2 in x 1 3 in 2 in x 13 in TO 36 1 191 Part No Legend Or Symbol Colors Letter Or No Emblem Size 3613343 Number 4 die cut pre spaced Yellow None 1 1 2 in 2 in X 1 3 in 3613344 Number 5 die cut pre spaced Yellow None 1 1 2 in 2 in X 1 3 in 3613345 Number 6 die cut pre spaced Yellow None 1 1 2 in 2 in x 1 3 in 3613346 Number 7 die cut pre spaced Yellow None 1 1 2 in 2 in X 1 3 in 3613347 Number 8 die cut pre spaced Yellow None 1 1 2 in 2 in X 1 3 in 3613348 Number 9 die cut pre spaced Yellow None 1 1 2 in 2 in X 1 3 in 3613349 Number 0 die cut pre spaced Yellow None 1 1 2 in 2 in X 1 3 in 3613350 Number
69. 11 HANDLING CHARACTERISTICS Each of the basic tire construction designs have different handling characteristics Figure 4 3 Handling is also af fected by tire size width tread design inflation pressure and rim width Bias belted and radial tires may produce over steer while increasing traction When compared to conventional tires they will also accentuate any steering and suspension problems that may exist Figure 4 4 They should only be used in complete wheel sets and never mixed with different types unless originally equipped by the vehicle equipment manufacturer reference Paragraph 4 19 4 12 TIRE SIZE RATING 4 12 1 Bias Tire sizes are expressed in terms of inflated tire cross section width and rim diameter i e 6 00x13 6 00 or 6 equals the tire cross section width and 13 equals rim diameter 4 12 2 Metric Most small tire sizes are now expressed with a metric designation such as P205 75R14 The P designates a passenger car tire 205 is the cross section width in millimeters 75 is the aspect ratio R is the radial designa tor and 15 expresses the rim size in inches 413 TIRE MARKINGS 4 131 General Much is being done toward regulating the quality and the application of pneumatic tires most of LOAD RANGE PLY RATING LOAD RANGE Figure 4 1 BIAS PLY BIAS BELT TO 36 1 191 which will apply to passenger type vehicles Federal Tire Safety Regulations specify that th
70. 15 8 14 1 Introduction 8 56 1 271 General aah Set te 7 16 8142 Scope ev 8 56 7 27 2 Method Of Reporting 7 16 8 15 STORAGE AREA 8 56 7 28 PROCESSING MDR S 7 16 8 16 USE OF STORED VEHICLES 8 56 7 29 PROCESSING UNSATISFACTORY 8 17 OPERATING PERSONNEL 8 56 REPORTS 7 16 8 18 TETOS tk ex Rs 8 56 7 30 VIWG duos eder d 7 17 8 19 REPAIR 8 56 vi Chapter 8 20 8 20 2 8 20 3 8 20 4 8 21 8 21 1 8 21 2 8 21 3 8 22 8 22 1 8 22 2 8 22 3 8 22 4 8 22 5 8 22 6 8 23 8 24 8 24 1 TO 36 1 191 TABLE OF CONTENTS CONTINUED INSPECTION During Storage Shipping c m eee m m Other Inspections DETAILED PROCEDURES Preparation For Storage Exercise Intervals o segues es GENERAL 2222 bend es Purpose And Scope Instructions Specific Instructions Oil Purge on os55 8564404 24 85 Steam Purge Segregators 2 FOLLOW ON PROCEDURES PREPARATION FOR AIRLIFT OF FUEL SERVICING VEHICLES UNDER FIELD CONDITIONS APPLICABLE TO ACC AF SOC AND ANG UNITS ONLY Safety Precautions 8 24 13 Off Fog Purging 8 24 17 Equipment Required 9 INTERMEDIATE AND DEPOT REPAIR OF VEHICLES AND COMPONENTS
71. 16 oz aerosol can Plate Air Force License part no AF 1 Color White Part no AF 2 Color Olive Drab Part no AF 3 Color Desert Sand Polyurethane coating dark Green 24052 part no PWC 218 Pacific West UNICOR Amerimac LTD 33W480 Fabyan Parkway Suite 105 West Chicago IL 60185 Telephone Number 630 444 1111 Chemical U 12 ea 13 oz spray cans Corp 337 Summit Dr 2 46 8010 00 108 5912 9140 00 242 6751 7220 00 823 7423 7220 00 823 7421 6220 00 985 3152 6220 00 985 3153 8010 01 131 9194 6220 00 947 7535 6220 00 947 7570 6220 00 958 7897 6220 00 947 7572 6220 00 947 7621 8010 01 078 9281 8010 00 181 8292 8010 00 839 5663 7220 00 823 7422 7720 00 823 7419 7220 00 823 7420 8030 00 290 5141 8010 00 965 2500 8010 00 988 1458 GSA AF Stock GSA GSA DLA S9G DLA S9G GSA DLA S9G DLA S9G DLA S9G DLA S9G DLA S9C GSA GSA GSA GSA GSA GSA GSA GSA GSA Table 2 2 Supply Information Continued Nomenclature P O Box 183 Corte Madera CA 94925 0183 Phone 415 922 4560 Polyurethane Coating green color no 24052 Fed Spec MIL PRF 85285 Polyurethane Coating dark green color no 14052 Fed Spec MIL PRF 85285 2 quart kit Polyurethane Coating dark green color no 14052 Fed Spec MIL PRF 85285 2 gallon kit Primer synthetic refinishing Spec TT P 636b 5 gallon pail Remover paint and varnish alkali type powder form Spec MIL R 2
72. 2 grade and class optional se cured with tape conforming to Specification MIL T 22085 b Nozzles within waterproof compartments Coat with Type P 9 preservative seal openings with tape conforming to Specification MIL T 22085 and secure in place c When the measures outlined above are not prac tical nozzles will be preserved in accordance with a above and packed with the OVE No processing required 8 41 TO 36 1 191 COLUMN I Item 83 84 85 86 8 42 COLUMN II Component On Vehicle Equipment Padlocks Painting Panels and In struments Table 8 2 Processing Procedures Continued COLUMN A B gt III Level COLUMN IV Type of Vehicle AV AV AV a e COLUMN V Processing Required Unless otherwise specified OVE shall be pre served packaged packed and marked in accor dance with the Level A requirements of Specifi cation MIL P 12841 Where treatment of a specific item is covered elsewhere in this TO and conflicts with that prescribed in MIL P 12841 the provisions herein will control Storage OVE may be removed for inside stor age when determined necessary by the respon sible storage officer If so the equipment for each vehicle shall be segregated and the vehicle shall be tagged OVE INCOMPLETE RE PLACE PRIOR TO OUTSHIPMENT When OVE is left in or on the vehicle it shall be stored in a protected location if available When storag
73. 2 10 Automatic Fire Extinguisher System extinguisher system tanks and valves shall be secure with no leaks Tanks shall be fully charged Lines and nozzles shall be secure Nozzles shall be clean and properly aimed at points most likely to catch fire 1 7 2 11 Auxiliary Fire Extinguishers Brackets tinguishers shall be fully charged and securely mounted Nozzle shall be free from corrosion and not damaged or plugged Wire safety seals will be intact Inspection and test record shall be affixed legible and current Brackets shall be of proper type and size Latches shall not be cracked or bent which prevent the fire extinguisher from being held securely Brackets shall be securely mounted to vehicle or equipment 1 7 2 12 Axle Front 1 7 2 12 1 Rigid Type Axle Axle beam shall not be cracked or bent Steering knuckle tie rod drag link bearings or spindle bushing shall show no sign of excess play or movement Camber and caster shall be in accordance with manufacturer s specifications Wheel bearings shall be prop erly adjusted 1 7 2 12 2 Live Axle Axle housing or tube shall not be bent or cracked and shall be free of leaks Outer machined surfaces of steering knuckle joints on axles which house constant velocity universal joints shall be free of rust or other damage Steering knuckle boot or guard shall not be bent torn or otherwise defective Steering knuckle bearings shall be properly adjusted
74. 21 3 5 4 Install canvas covers to protect exposed equip ment or items stored in open areas such as vehicle beds 8 21 3 5 5 Install standby batteries Check battery water level if battery received with vehicle is being used for initial exercise 8 21 3 5 6 Check lights reflectors wipers and horns 8 21 3 6 Conduct Of Exercise Start vehicle and run until normal operating temperature has been reached Operate vehicle in all gear ratios except that crawler mounted cranes need only be driven forward and backward for one complete revolution of the tracks Operate auxiliary mounted equip ment and accessories exercising all controls at least one time An adequate truck tractor or towing unit shall be provided for semi trailers and towed equipment The mover shall be equipped to permit testing of trailer lights brakes and other equipment requiring a power source 8 21 3 7 Check During Exercise cising will ensure that 8 21 3 7 1 Engines operate without abnormal noise vibra tion overheating or other evidence of malfunction Checks during exer 8 21 3 7 2 Brakes function properly Upon completion of exercise drain air reservoirs of air brake systems 8 21 3 7 3 Power train components function smoothly without grinding or other unusual noise 8 21 3 7 4 Steering mechanisms function smoothly with no evidence of binding or shimmy 8 21 3 7 5 Hydraulic and pneumatic systems function smoothly with no evidence of unusual
75. 2104 Cushions and Seat See Items 11 14 and 29 Seat Back Dash Panel See Item 29 Including Defroster Vents Differentials Fill to operating level with applicable grade of lubricant conforming to Specification MIL L 2105 and operate at sufficient speed to assure lubricant coverage of all interior parts and sur faces See items 7 28 and 29 See Item 52 See Item 20 50 51 COLUMN COLUMN I II Item Component Drums Cable TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN B Engines Diesel A B Level Type of Vehicle SP AV COLUMN COLUMN V Processing Required Preservative oil VV L 800 15 toxic to skin eyes and respiratory tract Avoid skin and eye contact Good general ven tilation normally adequate Coat all exposed unpainted metal surfaces of cable drums with Type P 1 preservative oil Wire cable not previously coated shall be unreeled and coated with Type P 1 preservative oil Al low to dry rewind and secure Where addi tional protection is considered essential cover the rewound cable with waterproofed wrapping paper conforming to Specification PPP B 1055 scaled to adjacent outer surface of drum flange with tape MIL T 43115 for level B and MIL T 22085 for level A Leave a 2 inch gap under neath the drum for drainage Engine fuel intake line shall be disconnected at the most easily accessible point nearest the fuel tank and a line f
76. 22 3 6 1 Select level area 100 feet from any building source of ignition or sewer system Position fuel servicing vehicle fuel tank so that sump pump is at the lowest position possible 8 22 3 6 2 Static ground tank s to an approved earth ground If ground point is unavailable drive steel rod into earth in accordance with TO 00 25 172 Paragraph 6 11 Ensure all metal drain containers are grounded to fuel tank and common ground point Con nections shall be made to clean unpainted surfaces e Dispose of full containers in accordance with AFMAN 23 110 8 22 3 6 3 Locate at least two 2 fire extinguishers upwind and maintained by qualified individuals NOTE Have sufficient containers available to position one at each drain point e Dispose of drained fuel in accordance with AFMAN 23 110 as containers become full 8 22 3 6 4 Completely drain each fuel tank compartment including associated piping pumps filters and segregators Open all valves and all fuel from tank pumping system using all available low point drains tank sump filter separator manual drain pump drain line strainer and bottom loading manifold Remove all accessory items such as gauges and floats which might entrap fuel 8 22 3 6 5 Close seal all drains or openings it may be necessary to fabricate covers from some types of openings 8 22 3 6 6 Fill fuel tank and overflow with cold water for a minute or 5 minutes Drain tank completely 8
77. 3 Water Temperature Hot water washing breaks the bond between the grease oil and the vehicle flushing away the grease and oil Additionally hot water washers reduce quantities of cleaning compounds consumed Hot water shall be used when feasible for equipment cleaning operations 6 15 8 4 At deployed remote sites raw water can signifi cantly impact the metals content of washwater Raw water could dissolve metals from building and washwater plumbing systems including copper from copper pipe zinc and lead from galvanized pipe etc To assist units in deployed loca tions the required water quality standards for equipment wash stations are listed below Unless an emergency exists orga nizations should have the nearest DOD civil engineer or other 6 37 TO 36 1 191 qualified laboratory service assess the water quality standards at the deployed locations prior to the commencement of washing operations Do not clean electrical equipment with the power on There are hazards of personnel being shocked or electrocuted Disconnect batteries prior to cleaning electrical generator sets as shorting of switches may cause power to be applied to system Any solvent must be used with extreme care on insulation and insulated wires particularly in electric equipment as the solvents may deterio rate the insulation 6 15 8 5 Removal Of Fungus From Electrical Con nectors Pins male contacts and receiver holes female contacts whic
78. 30 3 1 4 7 4 9 4 10 4 11 4 12 4 13 4 14 viii LIST OF ILLUSTRATIONS Title License Plate Modular Ambulance Van Ambulance Truck Ambulance Law Enforcement Sedan Warehouse Tug Highlighting Marking Aircraft Cargo Handling Truck Harness Required Area Highlighted Markings Age Towing vacuo Be e RE Fuel Trailer Two Wheel Fuel Oil Servicing Trucks Refueling Truck Waste Fuel Vehicle Rescue Fire Truck P 18 Water Tanker Fire Truck 19 Fire Trick uk d RR P 20 Ramp Fire Truck P 23 Ramp Fire Truck P 24 Ramp Fire Truck Manual Release Pintle Hooks Hydrant Fueling Truck Strike Hazard Marking Highlighting Marking Refueling Vehicles Res Demineralized Water Truck UDMH Hydrazine Semi Trailer N204 Semi Trailer Liquid Oxygen Unit Liquid Nitrogen Trailers and Trucks Highlighted Trailers and Tractors Forklift TCK ius ew ee RR Semi Trailer Inspection Form and Checklist Procedures Typical Lowbed Trailer Structure Full Width Gooseneck Shown Typical Beam Construction King Pin Mounting Area Load Ranges Tire Construction Handling Characteristics Cornering Characteristics
79. 30 7 Age Life expectancy years have been reached or exceeded 5 30 8 J Miles Kilometers Hours Life expectancy miles kilometers hours have been reached or exceeded 5 30 9 Age and Miles Kilometers Hours Within One Year Life expectancy years and miles kilometers hours will be reached within one year 5 7 TO 36 1 191 5 30 10 L Age Within One Year Life expectancy years will be reached within one year 5 30 11 Miles Kilometers Hours Within One Year Life expectancy miles kilometers hours will be reached within one year 5 30 12 N Age and Miles Kilometers Hours Within Two Years Life expectancy years and miles kilometers hours will be reached within two years 5 30 13 P Age Within Two Years Life expectancy years will be reached within two years 5 30 14 Miles Kilometers Hours Within Two Years Life expectancy miles kilometers hours will be reached within two years 5 30 15 Mid cycle Vehicle has reached or exceeded half of its programmed life expectancy in years OLVIMS will automatically enter this code using the age criteria in the vehicle master file Lower replacement codes A Q based on utilization will take precedence over code R 5 30 16 S Depot Repaired Vehicles Assign to depot repaired vehicles See Paragraph 5 31 2 for special instruc tions 5 30 17 T Other Will be assigned when replacement codes A through S and U do not apply 5 30 18 U Warranty New Remanufac
80. 4 27 2 5 Buffing Buff cleaned area thoroughly to a smooth velvet surface taking care not to gouge liner or expose casing fabric Remove dust from buffing with an approved method 4 27 3 Repair Procedures After completing basic preparation finish repair by selecting one of the following three repair methods 4 27 3 4 Chemical Vulcanizing Repairs 4 27 3 1 1 Fill Injury The injury must be filled with contour conforming material following manufacturer s in structions Cut off material flush with inner liner 4 27 3 1 2 Cementing Vulcanizing cement is flammable and toxic to skin eyes and respiratory tract Skin and eye protection is required Avoid repeated or pro longed contact Good general ventilation is nor mally adequate Avoid all sources of ignition Always use self vulcanizing cement recommended by the patch manufacturer Apply a thin coating of chemical vulca nizing cement to the prepared and buffed surface Allow to dry thoroughly Keep dirt and other impurities from contami nating the cement remaining in the can 4 27 3 1 3 Patch Application Remove backing from non reinforced patch and center over injury Stitch patch down thoroughly with stitching tool working from center out 4 27 3 2 Hot Vulcanizing Repairs 4 27 3 2 1 Fill Injury The injury must be filled with contour conforming material following manufacturer s in structions Cut off material flush with inner liner 4 27 3 2 2 Cemen
81. 4 29 TO 36 1 191 NSN of Gauge Tested Date Tested PSI Variance Date Master Tester With Master Gauge Cali Gauge brated AFLC FORM 192 GENERAL PURPOSE DATA SHEET PREVIOUS EDITIONS OF THIS SEP 63 FORM WILL BE USED F09603 065 Figure 4 23 Pressure Gauge Test Record 4 30 TO 36 1 191 NSN 6685 00 067 5259 F09603 066 Figure 4 24 Pressure Gauge Test Assembly 4 36 7 5 Whenever a tire is in a restraining device the employee shall not rest or lean any part of his body or equipment on or against the restraining device 4 36 7 6 After tire inflation the tire rim and rings shall be inspected while within the restraining device or make sure that they are properly seated and locked If further adjustment to the tire rim or rings is necessary the tire shall be deflated by removal of the valve core before adjustment is made 4 36 7 7 No attempt shall be made to correct the seating of side and lock rings by hammering striking or forcing the components while the tire is pressurized 4 36 7 8 Cracked broken bent or otherwise damaged rim components shall not be reworked welded braced or other wise heated 4 36 7 9 Whenever multi piece rim wheels are being handled employees shall stay out of the trajectory unless the employer can demonstrate that performance of the servicing makes the employee s presence in the trajectory necessary
82. 6 Tire Markings 4 5 TO 36 1 191 LF RF LF RF FOUR TIRE FIVE TIRE LR RR NOTE WHEN SNOW TIRES ARE INSTALLED THE REGULAR TREAD TIRES ON THE REAR SHOULD BE MOVED TO THE FRONT AND THE FRONT TIRES STORED WHEN SNOW TIRES ARE REMOVED INSTALL STORED TIRES ON THE REAR Figure 4 7 Tire Rotation 4 6 TO 36 1 191 A 4X4 ST 4X2 ST B 4X4 DT 4X2 DT TRUCKS TRUCKS AND CARS C 6X6 ST D 6X4 DT INCLUDE SPARE IN ROTATION PROCESS IN ACCORDANCE WITH ESTABLISHED MEASUREMENTS F09603 050 Figure 4 8 Rotation Patterns for Tires A WHEEL OUT OF BALANCE WHEN STATIONARY CAUSES VIBRATION OF THE CAR DUE TO THE TENDENCY OF THE HEAVIER PART OF THE WHEEL ASSEMBLY TO REMAIN AT THE LOWEST POINT ON THE WHEEL VIBRATION AT THIS POINT CAUSES TRAMP OF BOUNCE RESULTING IN ROUGH RIDE AND VIBRATION OF MOVING PARTS m Figure 4 9 Static Out of Balance 4 7 TO 36 1 191 A WHEEL OUT OF BALANCE WHEN ROTATING OR WHEN THE TWO HALVES OF AWHEEL ACT IN OPPOSING DIRECTIONS ALONG DIFFERENT PLANES TENDS TO TURN INWARD AND OUTWARDS EVERY ONE HALF REVOLUTION TIRE AND CAR DAMAGING SHIMMY IS CREATED F09603 052 Figure 4 10 Dynamic Out of Balance 4 13 1 9 Radial if applicable 4 13 1 10 Tire tread must be molded to include a tread wear indicator 2 32 in tread depth 4 13 2 Branding of tires is prohibited Tire Branding 4 14 TIRE ROTATION To realize full tire life potenti
83. 83 For shipment Remove parts as required to effect desired reduction in shipping cube The packed parts shall be placed in a protected location on the vehicle and secured in a manner to prevent movement and damage during shipment and storage Removed bolts and nuts screws pins and washers shall be placed in one of the mating parts and secured to prevent their loss 8 9 5 Matchmarking Parts removed shall be match marked when necessary to facilitate reassembly Match mark ing information shall be on cloth shipping tags or on metal tags Cloth tags shall be waterproof in accordance with standard MIL STD 129P 8 9 6 Historical Records Historical records shall be maintained current and complete packaged in an envelope conforming to Type II Class b of Specification MIL DTL 117H and placed in dash compartment lubrication order holder or securely attached in a conspicuous location near the identification or data plate 8 9 7 Marking In addition to specified special marking vehicles shall be marked in accordance with the applicable requirements of Standard MIL STD 129P 8 10 PRE STORAGE ACTIONS Storage and preservation of vehicles temporarily removed from service due to Non Mission Capable Supplies NMCS awaiting repair disposition etc will be the responsibility of the vehicle fleet manager VFM A general condition inspec tion with particular emphasis on security and preservation shall be accomplished when vehicle i
84. A B COLUMN Type of Vehicle AV AV AV AV COLUMN V Processing Required b Exposed control panels or instruments shall be afforded adequate physical protection as re quired Where panels or instruments project so as to present a breakage in transit problem a protective housing or framework shall be fabri cated of lumber or plywood Each control knob dial face or Gauge shall be cushioned as re quired See USAF Specification Bulletin 56 for selection of available cushioning agents The panel or instrument shall be covered with a shroud fabricated from waterproofed Kraft wrapping paper conforming to Specification PPP B 1055 or other waterproof barrier listed in USAF Specification Bulletin 56 c For extended storage it is recommended that water vapor proof barriers and tapes be used and that the sealed housings or shrouds be pro vided with humidity indicators and MIL B 3464 desiccant as specified for Method II of Specifi cation MIL P 116 Lubricate and coat exposed unpainted surfaces with Type P 1 preservatives Data plates in exposed locations on instrument panels bodies engines accessories etc shall be covered with a thin coat of varnish conform ing to Specification MIL I 24092 See Item 46 Differentials a Publications shall be assembled and packaged in accordance with Method IC 3 of Specifica tion MIL P 116 and stored in OVE containers Applicable technical orders or technical manu als will a
85. AFB OH 45433 5006 HQ AFSOC LGTM 100 Bartley Street Suite 210 Hurlburt Fld FL 32544 5273 HQ AFSPC LGTV 150 Vandenberg St Suite 1105 Peterson AFB CO 80914 4435 HQ AMC LGTV 402 Scott Drive Room 217 Scott AFB IL 62225 5308 HQ PACAF LGRTV 25 E Street Suite 1326 Hickam AFB HI 96853 5427 SSG LGTR 201 East Moore Dr Maxwell AFG Gunter Annex AL 36114 3005 HQ AFRC LGTV 155 2nd Street Robins AFB GA 31098 1635 ANGRC LGTV 3500 Fetchet Avenue Andrews AFB MD 20331 5157 USAF Academy LGTV 8122 Edgerton Dr Suite 101 USAF Academy CO 80840 2450 WR ALC LE 225 Okmulgee Ct Robins AFB GA 31098 1647 AFLMA LGT 502 Ward St Maxwell AFG Gunter Annex AL 36114 3236 Det 1 345 TRS CC 1370 Selfridge Ave Lackland AFB TX 78236 1030 HQ USAF ILGM 1030 Air Force Pentagon Washington DC 20330 1030 HQ AFCESA CEOM 139 Barnes Dr Tyndall AFB FL 32403 5319 11 TRNS LGTO 361 Thomas Rd STE 100 Bolling AFB DC 20332 0303 HQ USAF ILSR 1030 Air Force Pentagon Washington DC 20330 1030 HQ AFOSI LGTX BLDG 626 Room 1000 Bolling AFB DC 20330 6001 TO 36 1 191 Table 7 2 VIWG Members Continued HQ AETC LGRTV HQ AIA LGSP 555 E Street East 102 Hall Blvd STE 258 Randolph AFB TX 78150 4440 San Antonio TX 78243 5000 HQ USAFE LGTV AF Element VEMSO Unit 3050 Box 105 54 Willow Street Wing B Ramstein AB GE APO AE 09094 0105 Langley AFB VA 23665 1996 VEHICLE CONFERENCE VEHICLE IMPROVEMENT WORKING GROUP VIWG ACTION ITEMS IN
86. AV ment other than water Batteries cables and electrolytes except elec tric powered MHE COLUMN COLUMN COLUMN COLUMN I II Item Component Level Type of Vehicle h i Remove batteries from vehicles in VDP status COLUMN V Processing Required Sealing and coating compound and Polyurethane paint are flammable and toxic to eyes skin and respiratory tract Avoid skin and eye contact Good gen eral ventilation is normally adequate Keep away from open flames or other sources of ignition Use special acid and alkali resistant coating in the battery compartment to resist sulfuric acid and potassium hydroxide used in storage batteries The surface to receive coating must be thoroughly clean dry and free from any contamination Apply one coat MIL PRF 81733D Type sealing and coating compound corrosion inhibitive and one coat MIL PRF 85285D poly urethane paint to battery box supports and retainers Application shall be in accordance with the manufacturer s instructions Battery Compartment Finish only when climatic conditions or security con cerns warrant such action If batteries are re moved ensure they are identified with the ve hicle registration number and are stored in an appropriate location Clean as per Item 3 a above Disconnect cables from battery removing the batteries cables ground cable ends away from battery posts and electrolytes Cover battery posts wi
87. Air Force In making this determination consideration will be given to the transporta tion costs of shipping a vehicle to and from an overhaul facility the overall Air Force asset requirement position turn around time the cost of new procurement as opposed to depot level overhaul and the local capability to obtain repair through contract maintenance or interservice support 9 21 2 WR ALC LE will provide commands with neces sary statements of work work specification etc as may be needed to assist local VFM in administration of local contract maintenance or interservice support agreements for depot level overhaul 9 22 CONTRACTORS Commercial concerns and Department of Defense Interser vice Support Agents performing depot overhaul services for the Air Force will use AFTO Form 439 Overhaul Contractor End Item Report Serialized Control Copies of this report will be forwarded to major command headquarters monthly AFTO Form 439 is located on WRALC website Table 9 2 Command Abbreviations Command Abbreviation Air Combat Command Air Education Training Command Air Force Materiel Command Air Force Reserve Command Air Force Special Operations Command Air Force Space Command Air Mobility Command Pacific Air Forces United States Air Forces in Europe NOTE Field Operating Agencies and Direct Reporting Units are not listed TO 36 1 191 APPENDIX A TUNNER 60K AIRCRAFT CARGO LOADER GENERAL INFORMAT
88. Apt Sioux City IA ANG Sky Harbor Apt Phoenix AZ ANG Spangdahlem AB GE Springfield Bleckley Mun Apt OH ANG Standiford Fld Lvle IAP Louisville KY ANG Suffolk Co Apt NY ANG Suwon AB KO Tabuk SA Taegu AB KO Thule AB GRE Tinker AFB Oklahoma City OK Toledo Exp Apt Swanton OH ANG Tonapah AFS NV Torrejon AB SP Travis AFB Fairfield CA Truax Fld Dane City Reg Apt Madison WI ANG Tucson IAP AZ ANG Tulsa IAP OK ANG Tyndall AFB Panama City FL Vance AFB Enid OK AETC Vandenberg AFB Lompoc CA Volk Fld Apt WI Wake Island Westover AFB Chicopee MA AFRC Wheeler AFB HI Whiteman AFB Knobnoster MO Very Severe Wash vehicle Ev ery 5 days Severe Moderate TO 36 1 191 Mild Wash vehicle every Wash vehicle Every Wash vehicle Every 45 X days 6 49 TO 36 1 191 Table 6 2 Corrosion Severity Zones and Minimum Wash Interval Continued Location Very Severe Severe Moderate Mild Wash vehicle Ev Wash vehicle every Wash vehicle Every Wash vehicle ery 5 days Every 45 days Will Rogers IAP Oklahoma City OK ANG Willow Grove ARS Philadelphia PA AFRC ANG Wright Patterson AFB Dayton OH Yeager Apt Charleston WV ANG Yokota AB Japan Youngstown Warren Reg Apt ARS OH AFRC Zaragoza AB SP Table 6 3 Galvanic Series of Metals and Alloys Table 6 3 Galvanic Series of Metals and
89. Areas without humidity control may be sources of condensed moisture 6 17 9 Microorganisms Microbial induced corrosion is a result of the action of bacteria fungi or molds Microor ganisms are nearly everywhere and outnumber all other types of living organisms Organisms that cause the most corrosion problems are bacteria and fungi Damage from microbial growth can result from a The tendency of the growth to hold moisture that causes corrosion b Digestion of substrates as food for the microorganism c Corrosion of the surface beneath the growth by secreted corrosive fluids 6 17 9 1 Microbial attack can be prevented by applying moisture proofing coatings to nutrient materials or by drying the interiors of compartments with desiccants However some moisture proofing coatings are attacked by microorgan isms especially if they are used on contaminated surfaces When dry some microorganisms can survive in spore form for long periods and can become active when moisture is available 6 17 9 2 When desiccants become saturated and unable to absorb the moisture passing into the affected area microor ganisms can begin to grow Dirt dust and other airborne contaminants are the least recognized contributors to micro bial attack Unnoticed small amounts of airborne debris may be sufficient to promote fungal growth Slimes molds fungi and other living organisms some microscopic can grow on damp surfaces and submerged surfac
90. Association Standard 1904 for detailed inspection and documentation procedures 3 10 7 Natural Gas Cylinder Tank Inspection base maintaining Natural Gas Vehicles will accomplish pre ventive maintenance and inspections in accordance with Compressed Gas Association Pamphlet C 6 4 Methods for External Visual Inspection of Natural Gas Vehicle Fuel containers and Their Installations The pamphlet can be purchased from the Compressed Gas Association s website at www cganet com 3 11 TECHNICAL INSPECTION AFTO FORM 91 LIM ITED TECHNICAL INSPECTION LTI MOTOR VE HICLE The AFTO Form 91 will be used for technical inspection on all USAF vehicles as prescribed herein except those having a standard price or local purchase price of less than 10 000 AFTO Form 91 will be processed to the appropriate agency under the following condition 3 11 1 Disposition Instructions When it has been deter mined by the Logistics Readiness Squadron commander or equivalent may be delegated to the Vehicle Fleet Manager as appropriate that it is not cost effective to repair a vehicle in accordance with Chapter 5 an AFTO Form 91 Limited Technical Inspection LTD will be prepared in accordance with command policy If vehicle management is a contracted TO 36 1 191 service the LRS QAP or LRS Commander will make the determination on vehicle cost effectiveness Requests for disposition of uneconomical repairable excess veh
91. Cleaning Compound Aero space Equipment Types I II IIT IV 6 15 6 4 1 I is for general use on exterior surfaces and is effective for removing heavy oils greases and carbon deposits Type I should not be used in poorly ventilated areas Do not heat above 115 F Type I is biodegradable in many waste treatment facilities However before using this material verify that this cleaner can be treated by local facilities Type I will separate out oily waste allowing the waste to be removed and disposed of while the remainder of the cleaning solution is sent to a waste treatment facility 6 15 6 4 2 is for general use on exterior surfaces and for removing medium to light oils and greases Type II is biodegradable in many waste treatment facilities however before using verify that this cleaner can be treated by local facilities Type II will separate out oily waste allowing the waste to be removed and disposed of while the remainder of the cleaning solution is sent to a waste treatment facility 6 15 6 4 3 Type III is a gel cleaner and is effective for cleaning medium to light oils Since it is a gel it will adhere to vertical surfaces for more effective cleaning Type III will separate out oily waste however the oil cleaner separation is difficult to determine unless the solution sits for several hours Type III is biodegradable in many waste treatment facilities However before using this material verify that this
92. Concerns Corrosion Preventive Compounds CPC Types And Applications Sealers and Sealant Usage Page 5 4 5 4 DO DO PO P2 wy DADD DOW DDADD ooo EM Chapter 6 16 CORROSION THEORY CAUSE AND EFFECTS 22 d 6 16 1 Definitions of Corrosion 6 16 2 Corrosion Related Chemical Defini HONS sek EGG D eee eh 4s 6 16 3 Theory of Corrosion 6 16 4 Development of Corrosion 6 16 5 Metals Affected By Corrosion 6 16 6 Types of Corrosion 6 17 FACTORS INFLUENCING COR ROSION occ RR 6171 Moisture 6 17 2 Condensed Moisture 6 17 3 Open Cell Foam 6 17 4 Salt Atmospheres 6 17 5 Industrial Pollutants 6 17 6 Sand Dust and Volcanic Ash 6 577 Climate 6 47 8 Manufacturing 6 47 9 Microorganisms 6 17 10 Mechanical Stress 6 17 11 Welded Areas 6 17 12 Dme sss ks 6 17 13 Preventive Maintenance PM 7 WARRANTIES 7 1 PURPOSE rannas 7 2 SCOPE 3 34 sus uer 7 3 CHAPTER ORGANIZATION 7 4 INTRODUCTION 7 9 DEFICIENCY REPORTING SCOPE oo 05 cured XA A 7 6 DEFINITIONS oe 7 6 0 Originating Point 7 6 3 Screening Point 7 64 Contact Point 7 605 AF Ac
93. Decals Any additional informational or instructional type decals deemed necessary i e booster battery cable hookup DIESEL FUEL UNLEADED FUEL identification may be applied at the discretion of the Logistics Readiness Squadron Commander or equivalent NOTE Decals installed inside vehicles may be removed if written approval is obtained from the base Level Safety Office and Wing Commander Writ ten approval for decal removal will be maintained in vehicle operations for reference purposes 2 45 SPECIAL MARKINGS Special markings prescribed herein are in addition to vehicle markings described in the preceding paragraphs unless oth erwise specified NOTE The sizes of the letters and numbers will comply with the specifications given in the remaining paragraphs of this chapter 2 46 VEHICLES USED IN TRANSPORTING SICK AND INJURED Vehicles used in transporting sick and injured will be marked according to Paragraph 2 48 through 2 52 and as illustrated in Figure 2 2 through 2 4 red and orange cross emblems will be premasked with a low tack translucent carrier tape NOTE Where theater commanders are aware that the orange red crosses are offensive to the populace in which these ambulances must operate they may elect not to use the crosses Instead these commanders shall require the use of markings appropriate to the country where they are used 2 47 AUTOMOBILE AMBULANCE METROPOLI TAN 2 47 1 premasked
94. Die cut pre spaced Black None 1 1 2 in 2 in xX 1 4 in 3613421 Letter G Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613422 Letter H Die cut pre spaced Black None 1 1 2 in 2 in X 1 4 in 3613423 Letter Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613424 Letter J Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613425 Letter K Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613426 Letter L Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613427 Letter M Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613428 Letter N Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613429 Letter O Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613430 Letter P Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613431 Letter Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613432 Letter Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613433 Letter S Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613434 Letter Die cut pre spaced Black None 1 1 2 in 2 in X 1 4 in 3613435 Letter U Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613436 Letter V Die cut pre spaced Black None 1 1 2 in 2 in X 1 4 in 3613437 Letter W Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613438 Letter X Die cut pre spaced Black None 1 1 2 in 2 in xX 1 4 in 3613439 Letter Y Die cut pre spaced
95. Economic Factors 4 12 42 Resuscitation 4 1 424 Restricti h fR ded 422 Warnings 4 1 EP Restichons on the Use ofReireade 423 Buffing Operations 4 1 4 13 n EUN TNR ees 4 24 4 Procedures for Obtaining Retread 4 24 Compressed Air 4 1 435 Vulcanizing C t 4 1 SerVICeS Be wes 4 13 bs eM 7 425 REGROOVING TIRES 4 13 4 2 6 Sharp Or Pointed Tools 4 1 435 1 Technical Criteria 4 13 427 Tire Mounting 4 1 uu ME M clfc Change 1 iii TO 36 1 191 TABLE OF CONTENTS CONTINUED Chapter Page Chapter Page 4 25 2 Restriction on the Use of Regrooved 4 45 3 Diamond Tread 4 33 THES oe eee 4 13 445 4 Rib Tread 5 3 5 2 xr 4 33 4 26 SERVICING RADIAL TIRES 4 14 4 46 PREVENTIVE MAINTENANCE 4 34 4 26 4 Mounting 4 14 4 47 INSPECTION 4 34 4 26 2 Lubrication 4 14 4 48 GENERAL 4 34 4 263 Balancing 4 14 4 49 CRITERIA FOR REMOVAL OF 4 26 4 Inflation 4 14 TIRES hace ead aoe Rat 4 34 4 27 REPAIR PROCEDURES FOR 4 50 TIRES CONSIDERED UNSER TIRES 224294664 eh 4 15 VICEABLE ON EQUIPMENT 4 27 Punctures 4 15 BEING PROCESSED FOR DIS 4 27 2 Evaluation and Preparation 4 15 54 4 75 4 34 4 27 3 Repair Procedures 4 16 4 51 CONTRO
96. Goodfellow AFB TX Gowen Field Boise Air Term ID ANG Grand Forks AFB Emarado ND Great Falls IAP MT ANG Greater Peoria Apt IL ANG Greater Pittsburgh Apt PA Griffiss AFB Rome NY Grissom ARB Peru IN AFRC Gulfport Biloxi RAP MS Gunter AFS AL Hancock IAP Syracuse NY ANG Hanscom AFB Bedford MA Harrisburg IAP PA ANG Hector IAP Fargo ND ANG Hellenikon AB GR Hickam AFB Honolulu HI Hill AFB Ogden UT Holloman AFB Alamogordo NM Homestead ARB FL AFRC Howard AB Panama Hulman Reg Apt IN ANG Hurlburt Fld Fort Walton Beach FL Incirlik AB Turkey Indian Springs AFAF NV Iraklion AS GR Istres AB France Izmir AS TUR Jacksonville IAP FL ANG Jeddah SA Joe Foss Fld Sioux Falls SD ANG Kadena AB Japan Kanawha Apt WV Keesler AFB Biloxi MS Keflavic NAS IC Key Fld Meridian MS ANG Khamis Mushay SA Kim Hae AB KO King Khalid SA Very Severe Wash vehicle Ev ery 5 days Severe Moderate Mild Wash vehicle every Wash vehicle Every Wash vehicle Every 45 days X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 6 47 TO 36 1 191 Table 6 2 Corrosion Severity Zones and Minimum Wash Interval Continued Location Very Severe Severe Moderate Mild Wash vehicle Ev Wash vehicle every Wash vehicle Every Wash vehicle ery 5 days Every 45 days King Solom
97. I II IV V Item Component Level Type of Vehicle Processing Required 58 Forks B MH Remove and secure to vehicle using minimum flat steel strapping conforming to Specification QQ 8 781 to reduce shipping cube Coat unpainted surfaces with Type P 1 preservative 59 Fuel Tanks A B SP See Item 10 Refueler body 60 Fuel Tanks A AV Process by either of the following methods ve hicular applicable a Fuel tanks shall be completely drained of fuel filled with P 10 Type I Grade 30 preservative oil and again drained Tank shall be allowed to stand with drain plug removed until oil flow ceases Plug shall be coated with the P 10 Type I Grade 30 preservative oil and reinstalled Drained preservative oil may be reused for pro cessing of other gasoline fuel tanks provided not more than 10 percent of the resultant fluid is gasoline b Fuel tanks shall be completely drained of fuel and atomized sprayed with Type I Grade 30 preservative oil using atomizing equipment with an extension nozzle which will assure complete coverage of all interior surfaces Tank shall be allowed to stand with drain plug removed until oil flow ceases Plug shall be coated with the P 10 grade preservative oil and reinstalled Un less draining of tanks is specified residual fuel may remain in the tank 61 Gears Exposed See Item 33 62 Gear Boxes See Items on differentials and power trains and transmissions 63 Grills Outside Storage and
98. IN SOME CASES ACCESS HOLES MAY BE PRESENT OR IT MAY BE NECESSARY TO REMOVE THE HEADLIGHT A SHORT CURVED WAND MAY BE USED TO GAIN ADVANTAGE IN THE APPLICATION FRONT FENDER FRONT FENDER HEADLIGHT 2 SPRAYING HEADLIGHT AREA AHEAD _ OF FENDER BAFFLE USE GRADE 1 Ws A E GRADE 4 _ SPRAYING RUST AREA AROUND HEAD Nos LIGHTS WHERE FENDER BAFFLE IS me NOT USED USE GRADE 1 ad USE GRADE 1 GRADE 2 GRADE 4 t gt GRADE4 e GRADE 4 GRADE 4 TYPICAL HEADLAMP GRADE 2 FRONT AREA OF HOOD INSIDE OF BOXED IN OR SUPPORT SECTIONS UNDERSIDE BATTERY BOX AND VENTS GRADE 1 GRADE 1 n F09603 074 Figure 6 1 Commercial General Purpose Vehicles Areas of Application Sheet 2 TO 36 1 191 APPLICATION COWL PILLAR AND HINGE BOX SECTION INCLUDING ALL BOXED IN SUPPORT SECTIONS AND DOUBLE PANELED SECTIONS INSIDE AREA COWL AND ROOF OF ROOF AND INSIDE OF ROOF PANELS IT MAY BE NECESSARY TO DRILL A 1 2 INCH HOLE IN THE POST NOT MORE THAN 8 IN UP FROM THE ROCKER PANEL IF DOOR POST IS CONCEALED WHEN THE DOORS ARE CLOSED THE HOLE MAY BE MADE FROM THE BACK SIDE TO PREVENT IT FROM SHOWING INSERT SHORT CURVED WAND IN A DOWNWARD DIRECTION AND SPRAY SPRAY WITH GRADE 1 TREATMENT OF THE FRONT DOOR PILLAR MAY BE POSSIBLE THROUGH THE DOOR HINGE OPENING IF NOT DRILL A 1 2 INCH HOLE APPROX IMATELY EIGHT INCHES FROM THE BOTTOM O
99. NOTE All other functional and safety markings for above vehicles will be accomplished as required in preceding portions of this technical order 2 59 2 60 blank TO 36 1 191 CHAPTER 3 MOTOR VEHICLE AND BASE SUPPORT EQUIPMENT INSPECTION 3 1 PURPOSE This chapter prescribes inspections and services required for Air Force motor vehicles and vehicular equipment inspections service maintenance will be documented in ac cordance with AFI 24 302 This technical order applies to all Air Force activities including Air National Guard respon sible for operating and maintaining vehicles and vehicular equipment 3 2 RECOMMENDED CHANGES Submit proposed changes on AFTO Form 22 and forward through command channels to WR ALC TILT in accordance with TO 00 5 1 Major commands will make sure that change requests contain adequate justification and that the suggested changes are required from a command viewpoint MAJCOMs have the authority to waive the inspection intervals contained in this TO where warranted MAJCOMs will have authority to supplement this tech order to meet mission requirements Any deviations must be on file at the MAJCOMs 3 3 APPLICABLE PUBLICATIONS See AFI24 302 3 4 GENERAL 3 4 1 Preventative maintenance inspections tests and ser vices for USAF owned vehicles vehicular base support equipment and powered Support Equipment SE maintained by the vehicle management shops are defined in this techni
100. PATTERNS 4 33 521 REPAIR ESTIMATES FOR CON 4 45 Smooth Tread 4 33 TRACTOR MAINTAINED VE 445 2 Grooved Tread 4 33 HICLES 5 3 Chapter 5 22 5 23 5 24 5 25 5 26 2 27 5 28 5 29 5 30 5 31 36 1 191 TABLE OF CONTENTS CONTINUED AUTHORIZATION FOR REPAIR REPAIR AUTHORITY FOR MINI MUM ESSENTIAL REPAIRS REPAIR AUTHORITY FOR MA JOR REPAIRS SUBMISSION OF REPAIR RE QUESTS FOR MAJOR REPAIR APPROVAL CRITERIA FOR APPROVAL OF MAJOR REPAIRS DISPOSITION OF VEHICLES REPLACEMENT CODES CODE ASSIGNMENT EXPLANATION OF CODES SPECIAL INSTRUCTIONS 6 CORROSION PREVENTION AND CON TROL FOR AIR FORCE VEHICLES 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 7 1 6 7 2 6 7 3 6 7 4 6 8 GENERAL SCOPE eh Gawd woe REFERENCE PUBLICATIONS DEFINITIONS AIR FORCE POLICY RESPONSIBILITIES CORROSION CONTROL LEV ELS INITIAL CORROSION CON TROL Acceptance Inspection FOLLOW ON CORROSION CON TROL Responsibility EQUIPMENT AND MATERIALS REQUIRED PREPARATION FOR TREAT MENT i253 amp Gtez c RR RE Inspection enes uai Cleanin RUSTPROOFING APPLICATION FOLLOW ON APPLICATION TABLES OF APPLICATION VEHICLE CLEANING AND COR ROSION PROTECTION Types Of Cleaners Use of Cleaners Solvent Cleaning and the Use of Salt Water Washdown Additives General Cleaning and Material Pro cess
101. Safety Office and should be used for inflating vehicle tires Figure 4 22 Tire cages carrying any of the following NSNs are not bolted to the floor to allow the cage to flex properly during a tire wheel explosion Cages from other manufacturers and carrying 4 32 other NSNs than those listed here will be bolted to the floor if specified by the manufacturer If in doubt consult the manufacturer 4910 00 025 0623 Air Force drawing part No 64E330077 4910 01 034 6188 Wright Tool Co and Hennes sey Ind 4910 01 333 3504 AHCON Industries 4910 01 421 0985 Air Force Spec A A 58048 4 38 1 Regulator The tire inflator cage is equipped with an automated electronic inflation control Air pressure re quirements are preset allowing the operator to pursue other task while the tire is being filled When using tire cage NSN 4910 00 025 0623 part No 64E33077 a regulator gauge calibrated through PMEL shut off valve service hose and lock on type chuck will be used to control the air when inflating Also a bleed valve will be used to relieve pressure in hose when tire is filled 4 38 2 Pressure Gauges Tire pressure gauges in the tire shop area will be checked quarterly with a precision type gauge for accuracy When testing these gauges if they are found to be inaccurate in excess of plus or minus 2 psi they will be replaced Materiel control will remove the gauge from service and obtain a replacement as soon as possible AF Form 3
102. This authorization can also be applied to vehicle marking procedures such as the use of lusterless black enamel for marking a vehicle painted olive drab OD An example reflecting overseas command exercise of this author ity is Project Tone Down as authorized by USAFER 400 16 It is not necessary that overseas command deviations to color marking procedures provided in Paragraph 2 3 be published in this Technical Order nor will prior approval by WR ALC on an individual basis be required 2 3 8 Within CONUS lease conservative colored vehicles when dark blue is not available 2 3 3 1 GSA lease vehicles will be treated the same as government owned vehicles and marked in accordance with Chapter 2 of TO 36 1 191 In accordance with Federal Management Regulation 101 38 203 the only additional markings authorized on leased vehicles are for security and law enforcement vehicles Any other markings must be authorized in writing by the HQ GSA Fleet Manager 1 the MOU between the AF and GSA for marking GSA vehicles with white tops In all cases additional markings that cause 2 1 TO 36 1 191 damage or discoloration of the paint will be filled back to the user by GSA upon vehicle rotation or replacement 2 4 GENERAL ADMIN USE VEHICLES Air Force general administrative use vehicles including sedans station wagons school buses truck tractors etc shall be manufacturers dark blue or conservative color 2 5 FIRE TRUCKS
103. Tire Branding 4 8 D n ARGUS 3 13 414 TIRE ROTATION 4 8 xA don qua pecial Purpose TE 4153 4 8 3 105 Cranes Crane Shovels High Reach 416 WHEBL NUT TORQUE 55 ES HE 4 17 SAFETY ECONOMY AND SER Trucks Line Maintenance Derrick VICE 4 8 Trucks dees Vs 3 10 7 Natural Gas Cylinder Tank Inspec mus a On ENE 4 8 ori PR 3 14 3 11 TECHNICAL INSPECTION AFTO 4 18 1 Steel Belted Radial TES tal a 4 9 FORM 91 LIMITED TECHNI 4 18 2 Non Radial Tires 4 9 CAL INSPECTION LTD 4 19 TIRE REPLACEMENT 4 9 MOTOR VEHICLE 3 14 1 4 20 BREAK IN 4 9 3 11 2 Transfer Vehicle Being Transferred 4 21 TIRE MANAGEMENT serus QE dus 4 9 to Another Installation 3 14 1 4 21 5 Valve Positioning and Capping 4 9 3 12 ACCEPTANCE INSPECTION 3 15 4 22 INSPECTION AND SERVICING 4 10 3 13 SEMI TRAILER INSPECTIONS 3 15 423 IN USE INSPECTION 4 10 3 13 2 Annual Inspection 3 15 4 23 1 Operator Inspection 4 10 4 23 2 Maintenance Inspection 4 12 4 TIRES 4 1 4 23 3 Tire Shop Inspection 4 12 4 23 4 Base Storage Supply Inspection 4 12 41 SAFETY SUMMARY nq TIRES etus ees je 42 SAFETY PRECAUTIONS 4 1 4 24 1 Technical 22mm 4 12 tat 4 24 2
104. _____ J X X Inspect welds of main deck cross members at the main beam webs X X Inspect welds of main deck cross members at the side rails xXx J X Inspect welds of side rails at the forward bulkhead cross member Xx X Inspect welds of metal decking at supporting structure as applicable X X Inspect surfaces of main beam flanges webs for cracks in the parent material X X TO 36 1 191 Table 3 6 Semi Trailer Structural Inspection Checklist Continued If A Crack Is Found Enter Y In The Corresponding Block Otherwise Enter A Inspect welds of center cross members at the main beam webs flanges as applicable Inspect welds of main beam web stiffeners at all locations as applicable Inspect welds of undercarriage attachment points at the main beam flanges dercarriage 1 air tank etc Inspect all main deck understructure components for cracks in the parent material DISCREPANCY EXISTS MAIN LEFT AND RIGHT SIDE Y N Inspect welds of D rings tie downs and associated gussets at the side rails Inspect welds of side rails at the rear cross member and forward bulkhead gussets as X applicable NENRN Inspect welds of the outrigger arm attachments at the side rails Inspect all main deck left and right side components for cracks in the parent material Table 3 7 Semi Trailer Stru
105. able to furnish guidance on specific questions 8 22 2 2 Military Airlift Vehicles are usually offered for airlift in drive away condition to facilitate loading operations vehicles which are self propelled or which include internal combustion engines or motors are classified as harzardous materials in AFMAN 24 204 1 Preparing Haz ardous Materials for Military Air Shipment The require ments of this manual must be met and necessary certifications to this effect accomplished see AFMAN 24 2040 Before offering any vehicle for air shipment the following checks must be made 8 22 2 2 1 Analyze the vehicle and its contents including all OVE to ascertain the hazardous cargo included checking against AFMAN 24 204 to determine the classification of the hazard 8 22 2 2 2 Ensure that the requirements of AFMAN 24 204 are met that the shipper s certificates are accomplished and when applicable authorizations for operational necessity secured 8 22 2 2 3 Ensure that OVE and all mounted equipment is adequately secured to prevent shifting during air transit Harzardous materials are not to be stripped for airlift or included in consolidation containers 8 22 3 Specific Instructions 8 22 3 1 Fuel Tanks Vehicle fuel tanks will contain no more fuel than necessary to meet operational requirements during deployments or to facilitate aircraft loading unloading operations Ensure that all transmissions transfer cases gear
106. activities shall contact their MAJCOM counterparts for immediate resolution of the conflict 4 RESPONSIBILITY FOR CHANGES TO THIS MANUAL Recommended changes corrections or deletions activi ties using this manual are invited to submit recommended modifications additions or deletions All suggestions are collected by each MAJCOM vehicle staff and submitted during the next Block Cycle Update BCU The BCU cutoff date for this publication is May 30 each year Each MAJCOM will submit their consolidated changes to HQ AFELM VEMSO who will consolidate and coordinate changes amongst the other Final review and coordination will be accomplished at the Annual Vehicle Maintenance Advisory Group normally held in June each year Any urgent or immediate changes to this manual are pro cessed as defined in TO 00 5 1 5 SUPPLEMENTS MAJCOM supplements to this manual must be coordinated with and approved by HQ USAF ILGM and WR ALC LESV prior to publication and dissemination xi xii blank TO 36 1 191 SAFETY SUMMARY 1 GENERAL The following are general safety precautions not related to any specific procedure and therefore do not appear elsewhere in this publication These are recommended precautions and instructions that personnel must understand and apply during many phases of operation and maintenance to ensure personal safety and health 2 PROTECTIVE CLOTHING Wear protective clothing
107. and zinc Figure 6 11 Filiform Corrosion 6 44 LOOSE JOINT RELATIVE MOVEMENT t CORROSION PRODUCTS 5 WEAR AND CORROSION BEFORE AFTER EXPOSED OXIDE lt gt METAL LAYERS OXIDE PARTICLES F09603 116 Figure 6 12 Diagram of Fretting Corrosion 6 16 6 11 Fretting corrosion see Figure 6 12 is a special form of concentration cell corrosion that occurs in combina tion with surface wear The corrosion products increase the wear of the surface and the wear exposes more bare metal surface to be corroded The overall effect is greater than the single effects of corrosion and wear added together It has the general appearance of galling in which chunks of metal are torn from the surface with corrosion at the torn areas or ragged pits This type of corrosion occurs on faying surfaces of close tolerance and on parts under high pressure in a corrosive environment when there is slight relative movement of parts such as that caused by vibration Fretting corrosion is most commonly found in heavily loaded joints that are subject to vibration such as press fitted ball bearing races bolted flanges fayed surfaces electrical connections and riveted areas Fretting corrosion can be very destructive in that it loosens mated parts and close tolerance fittings that in turn lead to stress or fatigue failures In the case of i
108. appropriate charges as prescribed in Paragraph 5 12 of this chapter 5 22 1 1 Prepare written repair estimates for major repairs repairs that may cause the onetime repair limit to be exceeded and repairs for accident damage Document these estimates in accordance with AFI 24 302 5 22 1 2 It is not necessary to prepare written repair estimates for minor repairs except accident repairs 5 22 2 Determine age of the vehicle See Paragraph 5 10 5 22 3 Determine total accumulated miles kilometers or hours as applicable This can be done by reading the odom eter or the hour meter Use the vehicle master list to estimate utilization if the odometer or hour meter is not working 5 22 4 Determine the vehicle one time repair allowance 5 22 4 1 the one time repair allowance from the latest master list 5 22 4 2 Use Figure 5 1 One Time Repair Computation Worksheet when manual computations are necessary 5 22 4 3 The OLVIMS repair allowances and the manual One Time Repair Allowance are based on the following formulas Age Computation Repl Price x 1 0 9 x Age in months Life Expectancy in months Utilization Computations Repl Price x 1 0 9 x Utilization Utilization Life Exp n utilization computations use miles kilometers or hours as indicated in the vehicles MHUK Code Reference https sevpgm robins af mil mil vehicle vmif section2 asp Use the age or utilization computation which result
109. barrier material con forming to Specification MIL B 121 sealed with pressure sensitive tape conforming to Specifica tion MIL T 43115 for level B and MIL T 22085 for level A Where climatic conditions require further protection cover this wrap with a waterproof shroud fabricated from material conforming to Specification PPP B 1055 Seats Seat A B AM See Items 11 14 and 29 Backs and Cushions Screens Line A SE a Remove clean coat with P 10 preservative oil and replace b Screens handling drinking water will be pro cessed as above using Type P 14 preservative B SE No processing required Segregators A SE a Coat all internal surfaces with P 10 Type I Grade 10 preservative oil and reassemble Se cure cover with sufficient bolts uniformly spaced and tightened Bolts not used shall be coated with the preservative wrapped in greaseproof barrier Specification MIL B 121 placed in a cloth bag and fastened to the segre gator COLUMN I Item 100 101 102 103 104 105 106 107 COLUMN II Component Sheaves Soft Tops Splines Springs Sprockets Starter Drive Steering Sys tems Hy draulic Straps Leather TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN III Level COLUMN COLUMN IV V Type of Vehicle Processing Required b Shipment Place a suitable soft wood block be neath segregator floats to relieve weight of float assembly on needle valve A war
110. by the vehicle manufacturer They shall be free of cuts fabric breaks or other damage that would cause early failure Tires of different construction design belted bias radial and bias shall not be intermixed on the same vehicle TO 36 1 191 Tires of different tread design or tread diameter shall not be mixed on the same axle Tires on vehicles being shipped shall have 50 percent of tread intact Retreaded tires will not be used on ambulances law enforcement sedans the front wheels of buses or for any other reasons cited in Chapter 4 1 7 2 120 Thermostat And Shutters Thermostats shall operate properly and shall be of the correct temperature range prescribed by manufacturer The shutters control mechanism shall operate freely without binding and shall not have excessively worn components Shutter control devices shall be clean and free of leaks Shutter vents shall not be bent broken or missing 1 7 2 121 Tilt And Lift Control Mechanism Lever and or control mechanism shall operate freely without binding or dragging and shall not have excessive worn components 1 7 2 122 Transmissions Transfers Cases And Power Takeoffs 1 7 2 122 1 Transmissions Conventional transmis sions shall shift into the selected gear smoothly and without unusual noise Synchro clutches and shaft bearings shall not be excessively worn and operate properly without unusual noise Automatic transmissions shall shift into proper gear at specified s
111. can be obtained by local purchase or from the manufacturer if not provided with the vehicle equipment Product Name Specification Engine Oil MIL PRF 2104G 15W40 MIL PRF 2104G 15W40 MIL PRF 2104G Re Refined Oil 10W30 SAE J2362 Re Refined Oil 10W30 SAE J2362 Re Refined Oil 10W30 SAE J2362 Re Refined Oil 15W40 MIL PFR 2104G Re Refined Oil 15W40 MIL PFR 2104G Re Refined Oil 15W40 MIL PFR 2104G 3 8 7 1 3 Extract lubrication charts applicable to assigned equipment from above publications 3 8 7 2 The vehicle management activity shall assemble and maintain within the lubrication work center a reference library for each model of equipment in sequence according to the third digit of the registration number as follows 3 8 7 2 1 3 8 7 2 2 Commercial special purpose 3 8 7 2 3 nance Commercial general purpose D Commercial Construction Base Mainte 3 8 7 2 4 E Materials handling equipment 3 8 7 2 5 Military general purpose 3 8 7 2 6 L Military special purpose 3 8 7 27 Military Construction Base Maintenance 3 8 7 2 8 W Vehicular type AGE 3 8 7 2 X Nonreportable 3 8 7 2 10 other 3 8 7 3 Product Specifications The following lubri cant oil products are listed by common name and referenced to the existing military specification These products will normally be used by the vehicle activities except as modified under Special Instructions Paragr
112. capable of providing prescribed pressure and quantity in accordance with the manufacturer s specifications 1 7 2 63 Fuel Tank And Lines Fuel tank shall be securely mounted to prevent shifting or movement during operation of vehicle Tank seams filler neck and connections shall be properly aligned with no leaks or cracks Lines shall be secure and anchored in a manner to prevent failure due to vibration 1 7 2 64 Gauges And Sending Units All instruments and or gauges shall operate properly and be securely mounted Pressure sending units shall be free of leaks Dials and lenses shall be clear and free of cracks Indicator needles and numerals shall be legible See Meters Paragraph 1 7 2 89 1 7 2 65 Gantry A Frame And Revolving Base Gantry A frame and revolving base shall be properly aligned and shall have no breaks cracks or excessive wear of pinholes and brackets All bolts shall be in place and tight 1 7 2 66 Generators Alternators Auxiliary Chargers Etc Generator alternators and charging devices shall operate without undue heating and will indicate proper charging during operation Commutators will not be burned or scored to the extent that early failures will occur Brushes shall have at least one half usable length intact and be free from binding Brush holders and brush springs shall provide proper pressure for contact with commutator or slip rings Generator alternator shall show no evidence of rough be
113. chemicals have inherent hazards that cannot be mechani cally safeguarded Personnel must perform these functions with caution 4 2 SAFETY PRECAUTIONS 4 2 1 Resuscitation Personnel working with or near highly toxic chemicals should be familiar with modern methods of resuscitation Such information may be obtained from base medical services 4 2 2 Warnings The following warnings appear in the text of this technical order and are repeated here for empha sis 4 2 3 Buffing Operations Buffing solvent is flammable and toxic to the skin eyes and respiratory tract Eye and skin protection is required Avoid prolonged or repeated contact Good general ventilation is normally adequate Watch out for ignition sources 4 2 4 Compressed Air Compressed air used for clean ing can create airborne particles that may enter the eyes Pressure will not exceed 30 psi Eye protection is required 4 2 5 Vulcanizing Cement Vulcanizing cement can be flammable and toxic to the skin eyes and respiratory tract Eye and skin protection is required Avoid repeated or prolonged contact Good general ventilation is normally adequate Watch out for ignition sources NOTE Not all Vulcanizing cement is flammable NSN 2640 00 138 8320 is not flammable It contains trichloroethylene so it still must be used in a well ventilated area 4 2 0 Sharp Or Pointed Tools prevent injury to personnel exercise caution when using sharp or pointed to
114. clear 4 27 3 4 7 Never exceed 40 psi TO 36 1 191 4 27 3 4 8 If beads do not seat remove valve core re lubricate re position and re inflate 4 27 3 4 9 Check repair for leakage with water or soap solution and adjust air pressure to recommended levels 4 28 MOUNTING AND DEMOUNTING TUBELESS TIRES See Figure 4 15 4 281 Demounting 4 28 1 1 Remove tire and wheel assembly from car 4 28 1 2 Place tire and rim on machine or floor with a narrow bead ledge of the rim up See Figure 4 20 views A and B 4 17 TO 36 1 191 4 18 IMPORTANT PROPER PROCEDURES FOR DEMOUNTING AND MOUNTING TUBELESS PASSENGER CAR TIRES o VIEW 1 RIM WITH NO HUMP AND WITH VALVE HOLE ON WEDGE LEDGE SIDE MOUNT AND DEMOUNT WITH VALVE HOLE DOWN E VIEW 2 RIM WITH HUMP ON EACH SIDE AND VALVE HOLE ON NARROW LEDGE SIDE MOUNT AND DEMOUNT WITH VALVE HOLE UP D VIEW 3 RIM WITH HUMP AND VALVE HOLE ON NARROW LEDGE SIDE SIMILAR RIMS WITHOUT HUMP ALSO IN USE MOUNT AND DEMOUNT WITH VALVE HOLE UP VIEW 4 PROPER POSITION OF RIM WITH NARROW LEDGE UP VALVE ON NARROW LEDGE SIDE VIEW 5 PROPER POSITION OF RIM WITH NARROW LEDGE UP VALVE ON WIDE WEDGE SIDE IMPORTANT IN BOTH MOUNTING AND DEMOUNTING ALWAYS START WITH THE NARROW BEAD F09603 057 Figure 4 15 Effects of Rim Design on Proper Mounting Position E CHECKING TIRE F CHECKING TUBE F09603 058 Figure 4 16 Points of Inspection for Tires and Tubes anum
115. concentration cell corrosion or crevice corrosion that occurs on metal surfaces having an organic coating system It is recognizable by its characteristic wormlike trace of corrosion products beneath the paint film see Figure 6 11 Filiform occurs when the relative humidity of the air is between 78 percent and 90 percent and when the surface is slightly acidic It starts at breaks in the coating system such as scratches and cracks around fasteners and seams and proceeds underneath the coating because of the diffusion of water vapor and oxygen from the air through the coating Filiform corrosion can attack steel magnesium and aluminum surfaces and may lead to more serious corrosion in some locations Filiform corrosion can be prevented by storing equipment in an environment with a relative humidity below 70 percent using coating systems with a low rate of diffusion for oxygen and water vapors maintaining coatings in good conditions and washing equipment to remove acidic contaminants from the surface such as those created by air pollutants Filiform corrosion is an unusual type of attack since it does not weaken or destroy the metal but only affects the surface appearance Filiform corrosion most often occurs in humid environments Once the humidity drops below 65 percent Filiform corrosion stops When the humidity rises above 95 percent blisters form rather than filaments Filiform corro sion forms mostly on steel aluminum magnesium
116. develop around packing gland do not tighten gland nut until packing has a chance to soak up with oil Cracking or breaking of the packing may occur and require replace ment of the packing 2 System with oil returns Drain system and re fill with P 10 Type 1 Grade 10 preservative oil Operate to Insure coating of all surfaces Con nect temporary line from high pressure outlet of control valve to lower connection of the oil re turn line tube Remove one Allen head screw or air bleed screw at top of hoist and with engine at idle slowly move control valve lever to up position allowing oil from reservoir to flow through oil return line and completely fill the lift cylinder above the piston Replace the screw remove the temporary line and connect the high pressure line and oil return line in their proper positions Mark machine in a conspicu ous location with a waterproof tag reading as follows 8 37 TO 36 1 191 COLUMN COLUMN COLUMN COLUMN 8 38 Table 8 2 Processing Procedures Continued I II IH Item Component Level Type of Vehicle COLUMN V Processing Required The hydraulic system of this equipment is filled with preservative oil conform ing to Type P 10 Grade 1 of Specifica tion MIL P 116 Drain oil from upper part of lift cylinder by slowly raising the upright assembly so that the cylinder piston is in the topmost position This will allow the oil to return to the oil reservoir by the oil return line
117. exceed 12 inches in height and width Badge markings will be installed with non permanent material i e 3M type film 2 70 5 Vehicles which have controls and or equipment concealed in closed compartment may have the appropriate title marked in a centrally located place on the outside of the compartment doors using legible black letters Local base fire chief may authorize the use of optional markings for com partment content 2 71 OPERATING INSTRUCTIONS 2 71 1 aid in the operation and to prevent potential damage to equipment and injury to personnel vehicles without adequate operational instructions or plates in the driver s or operator s compartment may have the name of or duty performed by the lever switch valve or pedal etc marked on or near each and the use or direction of movement if deemed necessary These markings will be of the smallest readable size Understandable abbreviations may be used On equipment where it is determined that marking instructions will not obtain the desired results because of appearance inadequate space or other reasons an operating instruction plate will be fabricated and fastened securely to the equip ment within easy and full vision of the operator or driver 2 71 2 Cranes high reach maintenance and telephone line maintenance construction vehicles that are not insulated and not designed for working in close proximity of electrical power lines shall be equipped with a metal s
118. free of cracks and securely mounted Manifolds and gaskets shall be free of leaks There shall be no missing mounting studs nuts or bolts Heat riser and choke valves shall operate freely 1 7 2 89 Meters Meters shall operate properly and shall be calibrated in accordance with Chapter 3 1 7 2 90 Mirrors Mirror heads shall be clear not dis colored and free cracks and chips Mounting brackets shall be free of bent or deformed members in such a manner as to impair strength Mounting bolts shall be properly secured Adjustment controls will operate properly 1 7 2 91 Moldboard Moldboard circle pins pivots balls and sockets shall have no excessive wear and be properly lubricated Mounting bolts pin keepers and adjust ment shims shall be properly mounted 1 7 2 92 Mowers Sickle Guards And Pitman Pit man arm and shaft shall be properly aligned There shall be no excessive wear in attaching or reciprocating parts TO 36 1 191 1 7 2 93 Filter And Coolers Oil filters coolers external oil lines shall have no internal or external leaks 1 7 2 94 Oil Pans And Covers Engine oil pan and valve covers shall not be damaged to the point that would impair the proper seal of the gaskets Pan and covers shall be securely tightened and be free of leaks 1 7 2 95 Oil Pumps And Relief Valves Oil pump and relief valves with engine at operating temperature shall be free of leaks and shall be able to produce a
119. go unnoticed causing significant mainte nance repair or equipment condemnation 2 20 4 1 There are numerous commercial vendors apply ing spray in bed liner materials under various trade brand names The preferred material for application to USAF trucks is aliphatic polyurea 2 20 4 1 1 Aliphatic Polyurea is a two component material that provides a very durable non fading barrier coating Specialized heated plural component application equipment may be required to apply this material Organizations are authorized to have this material applied commercially 2 20 4 1 1 1 Authorized aliphatic polyurea spray in bed liner material specifications should at a minimum have the following properties as found on the specific material data sheets a Shore A Hardness 92 2 This property determines the hardness of the material b Tensile Strength 1800 psi minimum This property is the ability of the material to withstand being pulled apart c Percent Elongation 200 percent minimum This is the ability of the product to stretch without disbonding from the surface that it is applied to d Water Moisture Absorption 1 6 percent This is the ability of the product not to absorb or allow moisture to permeate through the coating to the surface that it is applied Aromatic polyurea is not a suitable substitute for aliphatic polyurea Aromatic polyurea is less resistant to sunlight and will fade and chalk over a period of continued ex
120. have different activities even though they may be part of the same metal and corrosion occurs inside the crevice This form of corrosion often occurs between faying surfaces or when a surface is covered by a foreign material such as dirt or under gaskets rubber or plastic tape The mechanisms involved in crevice corrosion are very similar to pitting corrosion Crevice corrosion most often occurs where there are stagnant solutions electrolytes in holes gasket surfaces lap joints under surface deposits TO 36 1 191 sand dirt corrosion products etc and in crevices under bolt and rivet heads To become a site for corrosion a crevice must be wide enough progresses at ever increasing rates due to various electrochemical factors Crevice corrosion is also most intense in solutions containing chlorides saltwater Metals susceptible to pitting stainless steel aluminum magnesium are also susceptible to crevice corrosion How ever not all metals that are susceptible to crevice corrosion will be susceptible to pitting Three general types of crevice corrosion are Metal ion concentration cells Oxygen concen tration cells Active passive cells 6 16 6 7 Stress corrosion cracking SCC is the Inter granular cracking of a metal caused by the combined effects of constant tensile stress internal or applied and corrosion Internal or residual stresses are produced by cold working forming and heat treatment operations during man
121. in accordance with TO 36A 1 6 1 7 2 106 Segregators Segregators shall meet stan dard established in TO 37A 1 101 1 7 2 107 Shock Absorbers Shock absorbers shall not have leaks excessively worn bushings and be securely mounted Shock absorbers shall be recommended type and size according to vehicle manufacturer and shall effectively control rebound 1 7 2 108 Sling Mechanism And Controls Mecha nism shall operate free y and shall be free of excessive loose motion Positive limit stops on both sides shall be in place and securely attached 1 7 2 109 Solid Tires Solid tires shall be of the size and type specified for the vehicle Tires shall exceed minimum serviceable standards established in Chapter 4 For overseas shipment at least 50 percent of the usable thickness of the tires shall be intact Twenty five percent of the usable thickness is sufficient for domestic shipment 1 7 2 110 Spark Plugs Spark plugs shall be of proper type and heat range recommended by manufacturer Insula tors shall be clean and free of cracks Spark plugs shall be gapped and torqued in accordance with manufacturer s speci fications 1 7 2 111 Speedometer Tachometer or Hour Meter Speedometer tachometer or hour meter shall be mounted securely and operate without any apparent defects such as noise or fluctuations of indicating hands or pointers The lens shall not be cracked or clouded to the extent that visibility of instrument dial
122. is placed in service flush the boiler system with live steam until all oil is removed No processing required Pump down the refrigeration system prior to stor age or shipment by removing protective plug from the pressure Gauge port and attaching a suction Gauge range 30 inches mercury vacuum to 100 psi pressure Close the receiver outlet service valves tightly and operate the tank pressure switch so that the compressor will run and pump the refrigerant from the suction side to the receiver When the suction pressure is at 10 inches vacuum switch off the compres sor switch If pressure rise is above 4 psi repeat the operation Then close discharge valve bleed pressure on high side of compressor to 0 psi If pressure rise is indicated repeat bleeding on high side of compressor until 0 psi reading is indicated Adequately tag the refrigeration sys tem to indicate pumped down condition See Items 10 and 13 See Items 10 and 13 Except when otherwise specified tarpaulins and other loose canvas items shall be thoroughly dried folded or rolled in a manner to avoid creasing of plastic windows packaged in accor dance with method IC 5 of Specification MIL P 116 and packed in a nailed wood box con forming to Specification PPP B 621 Box shall be identified and stowed in a protected location on the vehicle 8 49 TO 36 1 191 COLUMN I Item 113 114 115 116 117 118 8 50 Table 8 2 Processing Procedures
123. is used for general shop and warehouse vehicles that require maximum surface contact to support maximum unit loading 4 45 2 Grooved Tread Grooved tread is used for large vehicles with extra heavy loads The tread has good heat dissipation qualities 4 45 3 Diamond Tread Diamond tread provides good traction on ramps and wet surfaces It combines good skid reducing characteristics and maximum heat dissipation quali ties with minimum wear under heavy load and low speed conditions 4 45 4 Rib Tread Rib tread provides for maximum steady pull in either direction and is especially adapted to snow slippery roads sand and other extreme surface condi tions 4 33 TO 36 1 191 4 46 PREVENTIVE MAINTENANCE Vehicle management responsibilities are as follows 4 46 1 Proper wheel bearing adjustment and lubrication will reduce drag thus reducing tire wear Lubricate wheel bearings in accordance with pertinent technical manual or Chapter 3 NOTE Do not over lubricate either wheel bearings or chassis since grease and oil will work out and deteriorate rubber 4 46 2 Improper steering linkage adjustment or axle align ment results in fast irregular tread wear flange wear and chewed rubber At the first sign of irregular wear check for mechanical faults and correct according to the pertinent technical manual 4 47 INSPECTION Vehicle management responsibilities performed during scheduled inspections servicing are as follows
124. on trickle in battery shop if quantities to be stored do not exceed room capabilities 8 11 MAINTENANCE Except for intervals of inspection which shall be as detailed below and unless otherwise specified the requirements of AFI 24 302 and Chapter 1 of this TO will apply Conduct of inspection minimum serviceability standards forms and posting of vehicle records shall be as prescribed by those requirements 8 11 1 During Storage 81111 major inspection shall be accomplished every 12 months and inspection forms revised accordingly 8 11 1 2 Whenever storage inspection reveals damage through a failure in preservation or any other cause a serviceability inspection shall be performed using AFTO Form 91 Vehicles previously listed as serviceable will be scheduled into the vehicle management activity for repair and return to a serviceable condition 8 11 1 3 When these reports indicate a possibility of general failure of a specific preservation application or a processing deficiency common to a certain type of vehicle the responsible VFM shall direct inspection of a representative sample of like equipment in storage and initiate further inspections as indicated by the results of such sampling to ensure that the equipment in storage is serviceable 8 11 2 Outshipment Immediately prior to shipment a serviceability inspection for condition and completeness in accordance with Chapter 1 shall be performed to ensure that the v
125. or dust may be unnoticed by operating personnel they may be sufficient to initiate and accelerate corrosion Larger amounts of chloride or carbonate laden sand combined with moisture causes excessive corrosion see Figure 6 15 6 17 7 Climate Warm moist air typically found in tropical climates tends to accelerate corrosion Conversely dry cool air typically found in northern tier climates tends to slow corrosion rates Corrosion does not occur in very dry conditions For this reason desiccants are placed in shipping containers to create very dry local environments The pro posed operational and maintenance environments and estab lished corrosion prevention and control processes shall be considered in military vehicle design and procurement 6 17 8 Manufacturing During the manufacture assem bly or repair of vehicles many factors can cause the introduction of corrosion Use of unsuitable materials and improper materials processing can cause corrosion Shearing or hole punching operations on some metal alloys especially on high strength aluminum may create stresses that will lead to corrosion or provide a slight lip to inhibit complete drainage from an area Raised edges of the hole punching operations may cause incomplete drainage of electrolytes once the panels are installed Assembly of parts in areas contaminated by fumes or vapors from adjacent operations may entrap fumes in the equipment which might lead to future corrosion
126. or point is restricted Dial and odometer numerals shall be legible Hour meters shall not continue to operate in excess of 3 minutes after engine has been stopped 1 7 2 112 Spray Bars Piping And Connections Spray bars shall have no leaks I bends or broken parts Joints and couplings shall operate properly with nozzles in place Spray bar support rods shall be properly adjusted 1 7 2 113 Springs Springs shall not have cracked or broken leaves Springs shall be correctly assembled with rebound clips and center bolt properly torqued Spring leaves shall not have an indication of excessive deflection or reverse curvature Reverse curvature acceptable on 4x4 models with front axle leaf springs Both springs shall have approxi mately the same deflection with vehicle parked on level surfaces Spring shackle bolts and bushing shall not be excessively worn Spring U bolts shall be of proper size and length and be torqued in accordance with manufacturer s specifications 1 7 2 114 Starter Solenoid Starter solenoids shall en gage and operate starter properly The solenoid shall be clean and securely mounted Wire connections shall be clean and tight Starter crushes shall have 1 2 length remaining and brush holders springs free to maintain sufficient brush pres sure 1 7 2 115 Static Ground Static ground cables shall be replaced if more than one third of the cable strands are broken or if electrical continuity is suspect Clips
127. pans shall be cleaned dried and coated with preservative oil specification MIL L 21260E Type 1 Grade 30 8 28 FOLLOW ON PROCEDURES 8 23 1 Leave the refueler in a covered and ventilated area with the manhole s open until such time as the refueler is to be loaded aboard an aircraft 8 23 2 maintain a safe vehicle the tank shall be checked using the combustible gas indicator every 12 hours until the vehicle is loaded for shipment If the reading is above the safe limit of 20 percent LEL the tank must be repurged 8 63 TO 36 1 191 8 23 3 Explosive vapor level of the vehicle will be taken one half hour before loading and the reading recorded on the AF Form 1492 attached to the operating control panel 8 24 PREPARATION FOR AIRLIFT OF FUEL SERVIC ING VEHICLES UNDER FIELD CONDITIONS APPLI CABLE TO ACC AFSOC AND ANG UNITS ONLY 8 24 1 Safety Precautions personnel involved in these operations must strictly adhere to the following safety precautions 8 24 1 1 all times The buddy two person system must be used at 8 24 2 Remove all static collecting spark producing cloth ing jewelry and equipment prior to starting work 8 24 3 personnel performing these operation will wear safety shoes 8 24 4 Smoking materials lighters and matches must be excluded from the work area 8 24 5 Personnel will mount the fuel servicing vehicle from the upwind side only 8 24 6 The fuel servicing
128. prescribed in Paragraph 2 41 2 34 2 International Markings Where required by NATO SEATO CENTO etc agreements Air Force ve hicles will contain the markings prescribed in those standards that have been ratified by the US Commands having juris diction over military activities in the NATO SEATO CENTO etc Areas will ensure compliance with the provi sions of the international agreements unless otherwise in structed by Headquarters USAF 2 35 TACTICAL MARKINGS Tactical markings are authorized only on vehicles assigned to tactical units and shall be removed when vehicles are trans ferred from jurisdiction of the commander prescribing their use Tactical vehicle markings are prescribed in Military Standard 642 2 12 2 36 CONCEALED MARKINGS All US Air Force and US Government identification markings shall be concealed in unmarked OSI vehicles The vehicle nomenclature data plate may be mounted inside glove boxes that can be locked or inside the trunk compartment If the vehicle registration number and serial number are not re flected on the data plate they will be stenciled inside the trunk lid 2 37 DECALCOMANIA Decalcomanias used to reflect conversion of miles per hour to kilometers per hour tower signals for control of airdrome traffic non reflectorized red cross decals and all other non reflectorized markings will be manufactured from mate rial conforming to MIL M 43719 Type II Class I 2 8
129. punctures nail holes or cuts up to 1 4 inch must be repaired from the inside of the tire The repair material used must seal the inner liner and fill the injury to be considered a permanent repair Industry approved repair methods include a combination of plug and patch chemical or hot vulcanizing patches and head type plugs all applied from inside the tire If a tire continues to lose air or has lost all or most of its air pressure it must be removed from the wheel for complete internal inspection to be sure it is not damaged NOTE There are several compounds available that can be introduced into a tire to automatically seal a puncture and prevent a flat tire In areas where punctures are prevalent range operations etc use of one of these materials should be considered 4 27 1 1 Never repair tires worn below 2 32 inch tread depth 4 27 1 2 Never try to repair tires with tread punctures larger than 1 4 inch in house Repair of side walls bead sectioning and large cuts will normally be available through the local recapping agency efforts will be made to effect repairs and recap damaged tires Reduction of recyclable wastes and conservation of funds will be the determining factors Off road tires are more adaptable to these type repairs than auto truck tires NOTE Puncture repairs should be restricted to tread area 4 27 2 Evaluation and Preparation 4 27 2 1 Inspection Before repairing remove nail or othe
130. reflectorized decal with a 3 inch Omaha orange cross on a 2 inch square white field shall be applied 1 inch above the left and right corners of the windshield 2 47 2 premasked reflectorized decal with a 6 inch Omaha orange cross on an 8 inch square white field shall be applied on the center of the rear door panel directly below the 6 inch orange stripe The legend AMBULANCE in 3 inch black reflective letters shall be applied immediately below the cross If space is not adequate two reflective decals with 3 inch Omaha orange crosses on a 2 inch square white field may be applied on each side of the door above the window The legend AMBULANCE in 3 inch black reflective letters shall be centered between the two crosses 2 47 3 A premasked reflectorized decal with a 6 inch Omaha orange cross will be applied on the rear side window on each side of the vehicle The word AMBULANCE in 3 inch black reflective letters shall be applied directly below the cross 2 47 4 A premasked reflectorized decal with an 18 inch Omaha orange cross on a 22 inch square white field shall be applied on the roof in a central location 2 47 5 The legend AMBULANCE in mirror reversed image shall be centered approximately 1 inch windshield using 1 1 2 inch reflective letters 2 47 6 An orange stripe not less than 6 inches nor more than 14 inches wide shall encircle the entire ambulance body at the belt line below the bottom edge of cab windows b
131. requests payment pay the bill and obtain reim bursement later from the manufacturer This method how ever should be a last resort because of the collection effort involved NOTE requests for reimbursements submitted to a manufacturer must accurately identify the activ ity to which the remittance is to be made payable Contact the Accounting and Finance officer for this designation 7 23 2 If the manufacturer or his representative is not receptive to a problem which is believed to be the manufac turer s responsibility an Action Warranty Report AWR will be submitted in accordance with this technical order Action Warranty Reports on deficiencies not satisfactorily corrected by the dealer or district representative will contain besides the normal information the following 7 23 2 1 Date of delivery of the vehicle 7 23 2 2 Contract number on which the vehicle was procured 7 23 2 3 Manufacturer s vehicle identification number year model and mileage 7 23 2 4 Name and address of manufacturer s representa tive refusing warranty include dealer and district represen tative 7 23 2 5 Reason for refusing warranty 7 23 2 6 Define exactly what parts are required 7 24 PARTS EXHIBITS In cases where a complaint is submitted documenting war ranty problems defective parts will be retained for at least 30 days unless otherwise advised by WR ALC 7 25 WARRANTY REPORTING Information only Warranty Re
132. resistant CARC aliphatic polyurethane coat ing system that may be used on CARC coated equipment as an alternative to the solvent borne CARC coatings MIL C 46168D and MIL C 53039 2 22 5 3 3 This coating provides outstanding corrosion protection and maintains the required spectral and color reflectance required of all approved CARC coatings 2 22 5 8 4 MIL DTL 64159 is supplied in colors Green 34094 Aircraft Green 34031 Brown 30051 Tan 33446 Black 37030 Gray 36300 The coating is not currently stock listed Organization wishing to requisition this material will find manufacturer s part numbers and authorized manufactur er s listed on Qualified Product List QPL QPL 64159 The current QPL may be found at the following website http assist 1 daps dla mil quicksearch 2 22 5 3 5 MIL DTL 64159 may have an extended curing time in humid areas Additionally specialized application equipment may be required As the coating application requirements may vary between manufacturers contact the appropriate MIL DTL 64159 vendor customer service repre sentative listed in the QPL for application details for their specific coating application requirements 2 22 5 4 When CARC paint is used as a vehicle finish stencil the letters in close proximity of the vehicle s data plate CARC will be applied in accordance with TO 36 1 161 and TO 36 1 171 2 223 NON SLIP MATERIALS Non slip fabric or walkway compound may be appli
133. sary sonsuojoedeuo Sur pueu juo19gIp ong pexooeuo oq s 1o1njoejnugut 59215 pue soouvieo o suorsuauip or SOSULI PROT ur soouar9grp sour juo eA bo 107 o qtrssod semje jou st 8 oourg ALON STMOL SSTd STMOLISH7d _ 8145 6604 ST 8LAT STMOL SETd STOLE _ 9451 84 SI SLUL ___ SLO HH STNSL SCCd ST 8LAH eroa STASIS Td ST 8LAD ___ STNSL SOCd ST 8LAA _ saws sroda ______ STNSL S6Id STMOL SLId TWOS SOd _____ STUSLISLId 5108 5914 ST 8LAE Ooo e 1 8 STAOS S6Zd STWO9 GLCd STOAT POLITE PSL IS Td vI 8 8D STAOS SLZd STWO9 CCCd _____ SI 004H 1 00 61 PSL SOC vI 8 83 sTuos socd STWO9 Crcd lt 10940 vINOL SOCd OL vINSZ S6Id v LSU vINOC COcd vIWOS cVCd _____ vl 09HD OL _______ ____ vINOS Svcd vINO9 Stcd sp T 09N PIMOL S6l 6 _____ vLOLHO TB aooaa ood PINOL CSI PIWOL CSId vrIWSL SLId 18248 ETAOS SEZA tlWO9 SIcd ET 09NO 0 80 ETMOL S6Td ET OLAO ETAO8 SSTId ETSL 6 l 0oNH tIWOL SGId __
134. show damage abuse or missing equip ment on arrival obtain proof of the discrepancies from the carrier and arrange for immediate repair of such vehicle s at the nearest manufacturer s authorized dealer or such place as authorized by the manufacturer s zone district or regional office or factory branch The damage abuse or missing equipment must be noted on all copies of the waybill or shipping document signed by the carrier and a copy given to the dealer If warranty repair cannot be arranged with the dealer the discrepancies should be reported to the Traffic Management Office and processed in accordance with DOD 4500 9R Part 2 or DFASREG 7 21 SPECIAL WARRANTY PROCEDURES WITHIN THE 50 STATES OF THE UNITED STATES AND THE DISTRICT OF COLUNBIA Generally warranty correction within the 50 states of the U S and the District of Columbia is performed at the local manufacturer s or dealer facility Some remote geographic locations and emergency situations require special handling as follows TO 36 1 191 7 21 1 Air Force Warranty Corrections With Reim bursement 7 21 1 1 In locations which are quite distant from fran chised dealer shops the manufacturer may agree to reimburse the government for corrections made under warranty provi sions Proper approval must be obtained from the manufac turer before such corrections are made WR ALC LE Robins AFB GA 31908 5365 upon request will assist in establishing such agre
135. shown in Table 6 2 are based upon the corrosion severity zones listed in TO 1 1 691 and the wash cycles established in TO 36 1 131 Organizations may wash assigned equipment more often if necessary but not less Should vehicles be temporarily assigned to very severe or severe corrosion prone locations where cleaning is not practical or was deferred the affected vehicles shall be cleaned inspected and lubricated within 15 days of returning to home station 6 15 3 Cleaning is a broad term covering methods and materials needed to remove soils from a surface Selection of an appropriate cleaning method in any given case depends on three important factors 1 type and amount of soil 2 base material composition and surface condition and 3 degree of cleanliness required 6 15 4 As it relates to equipment cleaning the types of soils and the types of coatings on vehicles dictate the required effective cleaning compounds Soils that collect on a surface may be placed in three classes a Oily Soils Examples hydraulic oil lubricating oil light oil and oil base rust preventives When present as a thin film or small residue and when not very viscous in nature these soils may be removed by alkaline cleaners On more stubborn areas cleaning solvent MIL PRF 680 Type II or III may be used Usually the longer a soil remains and the higher the temperature the more difficult the soil is to remove b Semi Solid Soils Examples thi
136. the absence of guidance from the vehicle TO refer to AFOSH STD 91 46 Paragraph 9 4 1 For nuclear certified cranes In addition to above listed requirements lift hooks will receive annual non destructive inspection NDI testing and accomplishment of testing will be documented by Vehicle Management Refer to AFOSH STD 91 46 Paragraph 9 4 1 3 10 5 2 High Reach Trucks A fully qualified operator from the using organi zation must operate crane during this test Hoist and leveling cables will be completely inspected on all high reach trucks at least every three years or more often as determined by the VFM VMS The VFM VMS will deter mine whether complete overhaul is necessary to make sure the equipment is in a safe and trouble free condition If 3 14 Change 1 overhaul is necessary the cost of these repairs must be funded locally and forecast in budget estimates 3 10 5 2 1 Dielectric Voltage Breakdown Test The dielectric voltage breakdown tests are to be performed on cranes and high reach vehicles equipped with insulated booms lift platforms etc concurrently with a visual inspec tion of all weldments and a boom weight test Specific testing and inspection procedures are contained in the applicable technical orders and TO 36C 1 4 Dielectric Testing of Insulated Manlift Devices The following general guidelines are provided 3 10 5 2 2 Dielectric test is the responsibility of the local Base Civil Engineer or
137. the con troller box using moisture proof tape Specification MIL T 22085 Cover exposed ends of electrical cable or harnesses plug openings sockets terminals circuit breaker junction boxes etc with the tape specified above Spray all wiring with insulating varnish Specification MIL V 13811 d S a NOTE MIL V 1137 may be substituted for MIL V 13811 in applications suggested above No processing required a Thoroughly clean bitumen from pumping sys tem Disconnect suction and discharge hoses at pump and fill pump and adjacent piping with P 10 Type I Grade 30 preservative Rotate pump and thoroughly coat internal parts with oil Drain and seal all openings with tape Specification MIL T 22085 COLUMN COLUMN COLUMN I II Item Component B 110 Systems Re A B frigeration 111 Tanks 112 Tarpaulins A B TO 36 1 191 Table 8 2 Processing Procedures Continued Type of Vehicle COLUMN V Processing Required b Drain and assure that the boiler and tubes are thoroughly dry Fill boiler system with preserva tive oil P 10 Type I Grade 30 drain oil into clean container for re use Store with drain plug removed Allow a vent in the top of the system to remain open Protect the vent to allow only air circulation Attach caution tag to unit The following information will be stamped or typed thereon This system treated with oil Specifica tion MIL L 21260 Type I Grade 30 Before equipment
138. the eyes Eye protection is required Abrasive blasting operations involve airborne particles which may be hazardous to the body and eyes A hood that will cover the head neck and shoulders safety glasses hearing protection leather gloves with gauntlets and other personal protective equip ment is required as mandated by local Bioenvi ronmental Engineer and Ground Safety Office 4 32 3 Thoroughly remove rust dirt and other foreign materials from all surfaces Hand brushes electric wire brushes or sand blasting may be used 4 20 4 32 3 1 Gutters of rim bases should be cleared of rust and other materials obstructing safe positive seating of rings 4 32 3 2 Bead seat areas of rim should be free of rust and rubber deposits This is especially important for drop center rims because the bead seat is the air sealing element 4 32 3 3 Rings should be cleaned with wire brush Pay particular attention to seating surfaces and bead particular seat areas Metal Primer is toxic to skin eyes and respira tory tract Avoid skin and eye contact Good general ventilation adequate 4 32 3 4 Paint rims by brush or spray with a fast drying metal primer Surfaces should be clean and dry prior to painting Ensure that base metal areas on outside of tire side of rim are covered This is especially important on drop center tubeless rims because warm and sometimes moist air is in constant contact with the metal surface on the tire side of the
139. thoroughly and dry Insure that drain holes in body and compartment areas are open 8 9 2 Painting After cleaning removal of rust and drying of surfaces requiring painting use passivator filters sealers primers and repaint as required Refer to Chapter 2 Painting and Marking of USAF Vehicles Spot painting will be accomplished in lieu of complete repainting when ever practical 8 9 3 General Processing general application tech nical order of this type cannot provide specific guidance for every item When the detailed requirements do not provide guidance refer to Specification MIL STD 2073 1D Meth ods of Preservatives Application Criteria and Preservation Methods References below to P Type preservatives are to those of Specification MIL STD 2073 1D 8 9 3 1 Exposed Machined Surfaces Unless other wise specified coat with Grade I P 1 or Grade II P 2 Preservative and wrap with waterproofed grease proofed barrier material conforming to Specification PRF 121G grade c secured with pressure sensitive tape 8 9 3 2 Unpainted Non critical Exterior Metal Sur faces Unless otherwise specified coat with Grade I P 1 preservative This is a cold application hard film preservative and should not be applied in any instance where removal prior to use is required 8 9 4 Disassembly Items subject to damage and pilfer age shall be removed and packaged and stored as specified for TO 36 1 191 OVE see item
140. to eliminate potential aircraft engine or aircraft tire damage 4 41 2 Acquisition When the base FOD control officer determines that a special tire tread design is necessary for specific vehicles a tire will be selected from available sources which offers the most protection from FOD This will normally be a diamond or cross bar type tread or any tread without narrow groves or ribs The selected tire will be approved by the responsible VFM to ensure that the vehicle s design or operational capability is not reduced When the need is validated conventional tires may also be retreaded with military tread to support FOD tire requirements provid ing the required service is available for the size needed 4 42 SOLID AND SEMI PNEUMATIC TIRES Solid and semi pneumatic tires will be used only on slow moving industrial type materials handling equipment Solid or semi pneumatic tires provide much less cushioning than pneumatic tires but are used where required loading is far beyond the capacity of comparable sized pneumatic tires 4 43 TYPE OF TIRES 4 43 1 Standard Solid Rubber Tires Standard solid rubber tires have a relatively thin and hard section This type of tire has greater load capacity than a comparative sized cushion type Rolling resistance and cushioning of this con ventional type is less than the cushion rubber tire 4 43 2 Cushion Rubber Tires The cushion rubber tire has a relatively thick and soft section This ty
141. to personnel 4 36 4 2 Each restraining device shall have the capacity to withstand the maximum force that would be transferred to it during an explosive wheel separation occurring at 150 per cent of maximum tire specification pressure for the wheels being serviced TO 36 1 191 4 36 4 3 Restraining device shall be capable of preventing rim components from being thrown outside or beyond the frame of the device for any wheel position within the device 4 36 4 4 Restraining devices shall be inspected prior to each day s use and after any explosive separation of wheel components and any restraining devices exhibiting any of the following defects shall be immediately removed from ser vice 4 36 4 4 1 4 36 4 4 2 Cracked or broken components Cracks at welds 4 36 4 4 3 Bent or sprung components caused by mishan dling abuse or wheel separation 4 36 4 4 4 Pitting of components due to excessive corro sion 4 36 4 5 Restraining devices removed from service in accordance with Paragraph 4 36 4 4 shall not be returned to service until they are inspected repaired if necessary and are certified either by the manufacturer or by a Registered Professional Engineer as meeting the strength requirements of Paragraph 4 36 4 2 and Paragraph 4 36 4 3 4 36 5 Aclip on chuck with a sufficient length of hose to permit the employee to stand clear of the potential trajectory of the wheel components in an in line valve with gauge or a press
142. tributors Components shall be correctly aligned securely mounted and shall have no leaks The gear box shall contain no excessive foreign matter and be free of cracks The gear box shall be serviced with proper lubrication and to proper level There shall be proper clearance between face of tamper and edge of screen Drive chains will exhibit proper tensions 1 7 2 2 AirAnd Hydraulic Motors Motors shall operate freely without excessive vibrations or without binding cor rectly aligned Fittings and connections shall be free of leaks 1 7 2 3 Air Cleaner And Pre Cleaner Gaskets seals clamps hoses tubes elements baffles and body shall be secure and shall not be damaged as to prevent it from operating properly Dry type elements shall be clean Wet type shall be clean and contain the proper amount and type oil 1 7 2 4 Air Compressor Compressor shall be capable of delivering a maximum of compressed air to the system without unusual noise or leaks Unloader valve s cut in and cut out pressure shall be at the prescribed pressure setting of the governor 1 7 2 5 Air Hydraulic Cylinder Cylinder shall be ca pable of producing braking action comparable with variable pedal pressures applied There shall be no leaks at gaskets lines or seals 1 7 2 6 Governor Air governor and lines shall be securely mounted with no leaks Cut in and cut out pressure shall be within limits established by applicable publication m
143. uniformly applied to like assets When a vehicle is removed from WRM status the triangle must be removed 2 87 INSTALLATION OF REFLECTORIZED TAPE 2 87 1 Clean surface of vehicle prior to applying marking 2 87 2 Remove liner film down 2 87 3 Position emblem on clean surface Tack in position with thumb pressure 2 87 4 Start in center using hard overlapping strokes of low friction plastic squeeze 2 87 5 Re squeeze the edges using very firm strokes 2 87 6 Apply clean sealer to the edges of the tape 2 87 7 Repairs to damaged areas can be made without stripping original tape Clean damaged area and apply new tape over affected area 2 88 REMOVAL OF REFLECTORIZED TAPE Lacquer thinner kylol and isopropyl alcohol are flammable and toxic Good general ventilation is normally adequate Skin and eye protection is required Avoid all sources of ignition 2 88 1 Pressure sensitive tape may be removed by soften ing with heat heat lamp heat gun steam etc and adhesive residue can be softened with rags soaked with wipe solvent P W 2891 or isopropyl alcohol and scraped away with plastic scraper or putty knife 2 88 2 When tape has been applied for several years it may be more easily removed by masking off the area around the tape and then brushing with paint remover TT R 2918 Type I over the tape Several applications of remover may be required at shortly spaced intervals tape residue should be removed with plastic s
144. used are peculiar to vehicle management operation or an unwarranted duplication of processing facilities would result NOTE Reference to intra organizational responsibility is included for orientation and information only It is not intended to vary or supplement any direc tives as to placement of basic responsibilities 8 3 4 Deprocessing Inspection deprocessing and preparation for service are the responsibility of the base vehicle management activity except where drive away ship ments or other special instructions are involved 8 4 WATER EXPORT OVERSEAS 8 4 1 Newly acquired vehicles whether destined for over seas or CONUS locations shall have received manufacturer s standard rustproofing Local base commanders shall deter mine need for additional corrosion treatment and or process ing as required All newly procured vehicles destined for water export to highly corrosive environments or subject to frequent deployment to those areas should be considered for added rustproofing Severe to very severe corrosive locations are depicted in Table 6 2 8 4 2 Vehicles in use and destined for overseas shipment as a result of command levies will be processed at local base or off base facilities as determined by the owning command The local commander is the lowest level officer who may authorize processing or treatment at a specific center or facility Transfer of ownership and responsibility occurs at the overseas port destination
145. vehicle will be parked in a well ventilated area as remote as possible and down wind from the nearest buildings vehicles fixed equipment 8 24 7 Ground the vehicle 8 24 8 Place a 50 pound or larger fire extinguisher 50 feet upwind of the fuel servicing vehicle being purged 8 24 9 Ensure proper respiratory protection is provided Contact local Bioenvironmental Engineer for type of respi ratory protection required Personnel must grasp the static ground to dis charge body static before approaching the fuel servicing vehicle 8 24 10 Drain the fuel servicing vehicle tank and plumb ing Leave drain valves and vents open 8 24 11 Open vehicle tank accesses and soak up fuel puddles with non static collecting non spark producing cloth rags wrapped on a wooden stick 8 64 8 24 12 Purge system IAW 8 24 13 or 8 24 14 8 24 13 Off Fog Purging 8 24 13 1 Close all valves which serve to isolate the fuel pump and plumbing which cannot be drained 8 24 13 2 Remove caps and plugs to gain maximum access to other plumbing 8 24 13 3 Spray coat all inside surfaces of the fuel servicing tank and accessible plumbing with 10 weight motor oil using a paint sprayer equipped with a fogging nozzle 8 24 13 4 8 24 15 After one half hour proceed to Paragraph 8 24 14 Pump Purging with Automotive Diesel Fuel This procedure may be used in lieu of oil fog purging where the supply disposal of automotive diesel fuel does not present a
146. vehicles will have an LTI in their records from the shipping unit Incoming vehicle deficiencies disclosed on a receipt inspection for vehicles received from another Air Force activity will be indicated on AFTO Form 91 If it is determined that the vehicle does not meet the standards established herein the AFTO Form 91 will be forwarded to the losing command through normal command channels for their information and necessary action The letter of trans mittal will identify the activity responsible for the deficien cies and include date the vehicle was received as well as date inspected An information copy of this letter will be for warded to WR ALC LE when the Item Manager has directed vehicle shipment Transmittal letter will cite specific mini mum action required to bring vehicle to a serviceable condition Upon concurrence by WR ALC LE that the asset was transferred in an unserviceable condition the shipping activity will take whatever action necessary i e provide fund cite for parts contract labor etc to place vehicle in service able condition within 30 days from date of WR ALC LE notification For all discrepancies noted on AFTO Form 91 which do not necessarily place vehicle in an unserviceable status it shall be the responsibility of the shipping activity to provide any items considered replaceable or provide funded obligation authority It shall be the responsibility of the receiving activity to install items provided and or repa
147. was primarily designed If vehicle is to be used for loads other than the normal the correct operating tire pressure must be established using guidelines contained in Chapter 4 Abbreviate the words Tire Pressure Example T P 70 2 56 4 Nitrogen filled tires Stencil Nitrogen filled tires do not service to each fender well and each inner rim near the valve stem on vehicles equipped with nitrogen filled tires 2 57 SCHOOL BUS SAFETY MARKINGS The variation in state law requirements for special markings for special types of vehicles prohibits the establishment of uniform instructions for this class of markings in detailed form Safety markings for school buses will be applied to conform to local state regulations Distinctive colors may be applied to the complete vehicle when required by state regulation When state laws do not prescribe school bus safety markings the provisions of this section will be considered minimum requirements 2 58 D O T MOTOR CARRIER SAFETY REGULA TION MARKINGS Vehicles transporting explosives or other dangerous material off base will be marked in accordance with D O T Regula tions 49 CFR 172 504 The variation in safety and or special marking requirements of foreign nations prohibits the estab lishment of uniform instructions in detail form Therefore safety markings as required and conforming with local laws of the host country and the provisions of any international agreement w
148. water rinse cycles has shown that the approved additive materials can provide enhanced corrosion protection to ve hicles stored and operating in close proximity to salt contamination 6 15 7 2 MIL PRF 680 Types II and MIL PRF 680 Types II and IIL also known as Stoddard s Solvent or Dry Cleaning Solvent can be used to clean a variety of soils particularly oils greases and hydraulic fluids Type II has a flash point of less than 140 F Type III has a flash point of over 200 F 6 15 7 2 1 Both types of MIL PRF 680 will leave a slight oily residue This is desirable if flash rusting protection is needed If the part cleaned with MIL PRF 680 is to be painted or surface bonding is to occur wiping the affected surfaces with a clean cloth dampened with non petroleum based cleaning compound or solvent cleaner such as Isopro pyl Alcohol 1 735 or Acetone O A 51 is necessary 6 15 7 3 Saltwater Wash down Additives 6 15 7 3 1 Saltwater wash down additives may be used for equipment based or operating in locations where salt water TO 36 1 191 regularly contaminates the equipment surfaces The additives are designed to assist in the removal of dried salt deposits The removal of the salt deposits on a regular basis will significantly reduce the occurrences and severity of corrosion on support equipment The saltwater wash down additives are most effective if used in a regular two week rinsing cycle for areas where equipment
149. will be serviceable and securely attached Reels shall be mounted securely and should rewind without binding 1 7 2 116 Steering Gear And Components 1 7 2 116 1 The steering gear shall afford positive control of the vehicle and shall not indicate undue wear incorrect adjustment worn bearings or loose connections The steering gear box and mast jacket shall be securely mounted and in proper alignment Steering gear shall be properly lubricated and be free of leaks 1 7 2 116 2 Steering linkage shall be properly lubricated and be adjusted in accordance with the manufacturer s specifications Linkage connection shall be securely fastened and locking devices shall not be missing or broken Worm shaft shall not have appreciable end play or radial movement at mast jacket bushing bearing 1 7 2 116 3 Steering wheel shall not be broken or cracked to the point it will impair its strength or reliability The steering wheel shall be properly centered 1 7 2 117 Switches Switches shall operate properly in all positions and shall not indicate overheating when used for extended periods A suitable control knob or lever shall be properly installed 1 7 2 118 Tanks Tanks shall be clean and free of leaks Tank baffles and fittings shall be securely mounted and free of cracked welds Fuel and oil tanks interior coating shall be in accordance with the provisions of TO 36Y31 1 1 1 7 2 119 Tires Tires shall be of the size and type specified
150. 1 42 43 COLUMN I Item TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN II IV Component Level Type of Vehicle Covers and Curtains Cargo Soft Top Vehicles Covers Man hole Crankcase En A AN gine B SP COLUMN V Processing Required c Water and corrosion inhibitor procedure For shipment and storage within the bounds of 30 degrees north latitude and 30 degrees south lati tude except continental United States cooling system shall be preserved as follows Prior to or concurrently with other preservation required engine operation cooling system shall be filled with clear water up to but not including the radiator upper tank A corrosion inhibitor con forming to Specification O I 490 shall be added in the proportion of 5 ounces of the inhibitor for each 10 quarts of water The inhibitor shall be dissolved in 2 quarts of warm water and poured into the radiator while the engine is idling More water shall be added if necessary to fill the radiator to operating level A warning tag bearing the information COOLING SYSTEM DOES NOT CONTAIN ANTIFREEZE FILLED WITH WATER AND INHIBITOR shall be securely attached to radiator filler neck d Preservative and drain procedure Cooling sys tem shall be filled with Type P 3 preservative prior to engine preservation After engine pres ervation cooling systems shall be drained and drain cocks left in open position
151. 1 152 4117 15W 40 Strapping Flat Steel 135 00 281 4069 9 ls w on CA MIL PRF 2105E Lubricant Non EP Enclosed Gear 9150 01 035 5394 Grade 80 90 140 250 a a o gt 4 E oo lt lt zZ gt Tiju T N Q m T J Oo lt 7 ne gt es he TNO Nii ouo ers t lt lt lle NI Sle ceI ER QT 5 GL 9150 01 152 4118 55 GL 9150 01 152 4119 8 3 TO 36 1 191 Table 8 1 Materials Required for Processing Continued Specification Material Item NSN Federal MIL PRF 2105E Lube Gear Universal GD 80W 90 GD 80W 90 10 deg F to 120 deg F QT 9150 01 035 5392 GD 75W 50 deg F to 55 deg F QT 9150 01 035 5390 GD 85W 140 10 deg F to 120 F QT 9150 01 048 459 1 MIL PRF 3150D 2 MIL D 3464D Absorbent Moisture Desiccant Type DR 6850 00 935 9794 NAS847 5340 00 240 9228 MIL P 14105D 59295 Corrosion Preventative P1 Cd SS G 659A Coating Elastomerie MIL G 21164D MIL PRF 9000H MIL C 10382 Preventative Corrosion Petrolatum Spray 5 GL 8030 00 25 1 5049 For Potable Water amp Food Handling Machinery Equip ment PI 4 Engine cooling systems P11 MIL PRF 10924G Lubricant Grease Corrosion Preventative 9150 01 197 7688 9150 01 197 7693 9150 01 197 7690 9150 01 197 7689 9150 01 197 7692 9150 01 197 7691 Material Waterproof Ba
152. 1055 and paper secured except at bottom with tape conforming to Specification MIL T 43115 for Level B and MIL T 22085 for Level A Horn button shall be covered with the same class paper of a size to completely cover opening around horn button and paper shall be secured in the same manner as specified for dash panel When required for reduction in cube top end curtains and wind shield wiper arms and blades shall be removed and packaged in accordance with Level A above except that seat backs and cushions dash panel including defroster vents and horn button shall not be preserved COLUMN I Item 12 13 TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN II III Component Level Type of Vehicle Bodies Van A B SE Ambulance Panel Utility and Mainte nance Ve hicles Bodies Water A B SP Tank TR ST COLUMN V Processing Required Body drains and ventilators shall be opened to provide all possible ventilation See item 5 Door hinges latches and operating mechanisms shall be lubricated with MIL PRF 32033 Type P 9 preservative oil Special equipment fur nished with the body shall be preserved in ac cordance with requirements of applicable techni cal orders or process specifications listed on USAF Specification Bulletin 56 Level A or B domestic as applicable Requests for special instructions will be directed as specified in Sec tion I Paragraph 1 5 Doors shall be se
153. 126 or equivalent with identical heading as per Figure 4 23 will be annotated each time the gauges are checked Items used to assemble test 4 38 2 1 Test Apparatus apparatus are as follows 4 38 2 2 Bourdon type gauge 125 psi 0 250 of one percent accuracy calibrated in one half pound increments will be used as a master gauge 4 38 23 Air pressure regulator necessary ties reducers valve core stems and nipples are required for assembly Complete assembly is shown in Figure 4 24 4 39 VEHICLES EQUIPPED WITH DISC BRAKES Correct wheel mounting and bolt tightening procedures are critical on vehicles equipped with disc brakes The bolts must be tightened in an opposite pattern and to the proper torque values To minimize possible rotor damage do not use an impact wrench 4 40 STORAGE OF TIRES Tires on vehicles being processed for level A storage will be prepared in accordance with Chapter 8 of this TO 4 44 USE OF FOREIGN OBJECT DAMAGE FOD TIRES Routine use of FOD tires has been discontinued Results of an Air Force Maintenance Evaluation Program project and all major command survey concluded that the use of FOD tires is not justifiable 4 411 Necessity Reported needs for FOD tires should be critically reviewed on a case by case basis Future use of FOD tires will be predicated on factual data compiled and validated by the base FOD control officer Validation will affirm that such a program is necessary
154. 15 5 3 Solvent Emulsion Cleaners This type of cleaner removes a soil by emulsifying the oil constituent of the soil and holding it in suspension in water 6 15 6 Use of Cleaners 6 15 6 1 Material composition and surface condition affect the methods and materials to be used in cleaning Certain nonferrous metals such as zinc and aluminum present special problems because heavy duty alkaline or strong acid cleaners attack the metal Roughness of surface tends to hold a soil thereby making it harder to remove The use of unauthorized cleaning compounds or the use of authorized cleaning compounds that are not properly mixed may result in damage to the coating system or initiation of corrosion 6 15 6 2 There are a number of authorized and tested cleaning compounds Selection and use of unapproved clean ing compounds may cause damage to the components or painted surfaces Each cleaner has specific uses and must be carefully applied to prevent personal injury or damage to equipment Only use authorized cleaners that are listed on the qualified products listing QPL for a specific specification A listing of the most current QPL for an authorized cleaning compound can be found on the Air Force Corrosion Preven tion and Control office website https afcpco robins af mil 6 36 6 15 6 3 MIL PRF 85570 Cleaning Compound Aircraft Exterior Types I IA II IIL IV and V 6 15 6 3 1 Type I is for general use on exterior surface
155. 191 NOTE For diesel fuel purge see Paragraph 8 24 14 omit items 8 24 14 1 8 24 14 2 and 8 24 14 3 and add sufficient automotive diesel fuel for vehicle in question 25 gallons for MIB trailer 40 gallons for M99 vehicle 8 65 8 66 blank TO 36 1 191 CHAPTER 9 INTERMEDIATE AND DEPOT REPAIR OF VEHICLES AND COMPONENTS 9 1 PURPOSE To implement the Air Force policy for depot overhaul of vehicles as cited in AFI 24 302 and to prescribe the procedures for obtaining this class of maintenance support 9 2 SCOPE This publication applies to all Air Force activities including Air National Guard units operating and maintaining vehicles and vehicular equipment 9 3 RECOMMENDED CHANGES Request for changes with specific justification will be sub mitted on AFTO Form 22 as outlined in TO 00 5 1 Forms should be forwarded to WR ALC TILT Robins AFB GA 31098 5345 9 4 DEPOT MAINTENANCE 9 4 1 Refer to AFI 24 302 for overhaul policy and proce dures as applied to depot maintenance of vehicles and vehicle components 9 4 2 Maintenance can be accomplished by replacement of unserviceable assemblies local contract or evacuation to a repair site or depot The Production Manager shall determine the most practical and economical method of obtaining maintenance support In no case will a complete vehicle be evacuated to a repair facility when the vehicle can be returned to service by replacement of components eith
156. 200 Letter Q die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613201 Letter R die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613202 Letter 5 die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 2 52 Part No 3613203 3613204 3613205 3613206 3613207 3613208 3613209 3613210 3613211 3613212 3613213 3613214 3613215 3613216 3613217 3613218 3613219 3613220 3613221 3613222 3613223 3613224 3613225 3613226 3613227 3613228 3613229 3613230 3613231 3613232 3613233 3613234 3613235 3613236 3613237 3613238 3613239 3613240 3613241 3613242 3613243 3613244 3613245 3613246 3613247 3613248 3613249 3613250 3613251 Legend Or Symbol Letter die cut pre spaced Letter U die cut pre spaced Letter die cut pre spaced Letter W die cut pre spaced Letter X die cut pre spaced Letter die cut pre spaced Letter Z die cut pre spaced Letter Letter B Letter C Letter Letter E Letter F Letter G Letter Letter I Letter J Letter K Letter L Letter Letter N Letter O Letter Letter Letter R Letter S Letter T Letter U Letter V Letter W Letter X Letter Y Letter Z Letter Letter B Letter C Letter D Letter E
157. 2085 Bodies will be tilted as neces sary to drain any accumulated water Prior to shipment all access doors to compartment equipment lockers and control panels will be secured to prevent pilferage When design does not include a locking device flat steel strapping conforming to Specification ASTM D3953 may be banded over doors and mounted equipment such as ladders spare tires etc Comers or pro jections susceptible to damage by banding will be properly cushioned or protected by inserting 1 in X 4 in wood strips beneath the bond where necessary COLUMN COLUMN I II Item Component Bodies Cargo and Com mand Type of Vehicle TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN V Processing Required 59295 preservative is flam mable and toxic to eyes skin and respi ratory tract Avoid skin and eye contact Good general ventilation is normally adequate Keep away from open flames or other sources of ignition Cover shall be removed leather straps coated with Neat s foot Oil and cover includ ing end curtains shall be thoroughly dried folded or rolled packaged in accordance with Method IC 5 of Specification STD 2073 1 and packed in a nailed wood box conforming to Specification PPP B 621 Box shall be identified to indicate contents Top bows shall be re moved Unpainted metal surfaces of bows stake pockets and removed hardware shall be coated with CID A A 59295 Type P 1 preserv
158. 22 3 6 7 Close or seal drains and openings once more Mix one part detergent MIL D 81956 to 10 12 gallons of water warm to hot preferred Spray solution over interior surface of fuel tank Slush contents to ensure complete interior coverage and allow mixture to stand 20 to 30 minutes Open drain and flush with hot water Prior to welding or cutting of any tank ensure the operation has been reviewed as required by AFOSH STD 91 5 by the Bioenviromental En gineer Fire Department and Base Safety Office 8 22 3 6 8 Check empty tank with vapor explosion level meter ELM NSN 6665 01 038 3006 or 6665 01 089 1910 A reading of less than 20 percent of the LEL is considered safe to ship 6 percent to weld A second reading at least 4 hours from first safe indication must be taken prior to TO 36 1 191 shipment or storage to ensure vapor fumes have not built back up to a unsafe level Repeat neutralizing procedures until a safe level is observed via a minimum of two concurrent readings 4 hours apart 8 22 3 6 9 Affix tag to fuel cap in a conspicuous location which states Fuel has been drained and vapors chemically neutralized to safe explosive level reading 8 22 3 7 Forced Air Purge Blower air supply to be used with these procedures shall be an explosion proof blower of the type MA 1 or type HDU 13M If these blowers are not available the local ground safety unit may authorize the use of another type blower 8 22 3 7 1 Se
159. 332 Materiel Deficiency Exhibit Tag 7 30 VIWG The VIWG is a working group consisting of MAJCOM vehicle representatives that review reported vehicle equip ment deficiencies and establish priorities for resolution 7 30 1 VIWG will be chaired by the Vehicle System Program Office WR ALC LE and meet annually or on an as required basis at WR ALC WR ALC LE will ensure the following are accomplished 7 30 1 1 Collect and perform trend analysis on unsatisfac tory reports URs 7 30 1 2 Prepare agenda and forward it to VIWG members at least 15 days prior to the VIWG 7 30 1 3 Prepare minutes and specify action items in accordance with Figure 7 7 7 17 TO 36 1 191 7 30 1 4 Provide Semi Annual status follow ups on action items 7 30 2 MAJCOMS are responsible to 7 30 2 1 Collect and monitor VURs and warranty reports 7 30 2 2 Monitor DRs 7 30 2 3 action Coordinate with applicable ALC for corrective 7 30 2 4 Submit prioritized proposed action items for VIWG conference Table 7 2 7 30 2 5 Fund and support VIWG meetings as scheduled by WR ALC LE Program funds for one five day meeting per year 7 31 REPORTING Action items not identified in the WR ALC LE agenda will be reported to WR ALC LE following the format in Figure 7 7 7 32 VIWG MEMBERS Listed below VIWG Members HQ ACC LGTV 130 Douglas St Ste 301 Langley AFB VA 23665 2096 HQ AFMC LGRV 4375 Chidlaw Rd Ste 6 Wright Petterson
160. 4 11 4 38 T 4 39 4 39 E 6 3 25 6 45 6 50 7 16 7 18 24 8 3 F 8 5 9 2 a 9 4 A 2 ix x blank TO 36 1 191 FOREWORD 1 PURPOSE The purpose of this manual is to provide vehicle fleet managers VFM supervisors VMS and technicians a single publication encompassing technical and managerial guidance related to the maintenance and upkeep of their respective vehicle and vehicular equipment fleets 2 SCOPE This technical manual specifies procedures materials and guidance for the Vehicle Fleet Manager VFM It addresses the minimum vehicle serviceability standards for appropriate painting marking requirements vehicle inspection require ments and vehicle repair allowances Further it prescribes procedures for corrosion control storage and shipment warranties and depot overhaul and repair and applies to all Active Duty AF Reserve Air National Guard vehicle man agement units All guidance listed is mandatory unless exceptions are authorized elsewhere with this manual 3 USAGE Use this manual in conjunction with and in support of the appropriate Army Technical Manuals TMs Technical Bul letins TBs Air Force Instructions Air Force Manuals and Air Force Technical Orders TOs Where this manual con flicts with Army and Air Force vehicle specific technical manuals technical orders the vehicle specific guidance shall take precedence over this manual However vehicle manage ment
161. 4 21 2 Never operate vehicles with tires under inflated Abnormal heat buildup and tread edge wear can result from under inflation Tread print can serve as an indication of proper tread contact for a given tire and load See Figure 4 4 4 21 3 When tires of a different make or tires of different tread wear are used either the diameter or circumference should be measured after mounting and inflation Never overinflate or under inflate a tire to compensate for tire measurement variations See Table 4 1 for measuring proce dures 4 21 4 When dual tires have a permissible difference in measurements the larger size tire should be mounted outside Insure dual mounted tires do not make physical contact with each other when mounted A minimum of inch separation is required This will prevent unnecessary heat buildup and possible tire failure NOTE Users shall follow procedures for measuring new tires as shown in the Tire and Rim Association Yearbook 4 21 5 Valve Positioning and Capping 4 21 5 1 Valves should be properly centered in valve holes and slots to prevent scraping against brake drums 4 21 5 2 Valves should be placed so they extend through the wheel 4 21 5 3 Valves on inside duals should point away from the vehicle and valves on outside duals should point toward the vehicle 4 21 5 4 Each valve stem will be equipped with an approved valve stem cap to prevent dirt from entering the valve mechanism and to reduce the
162. 4 36 2 10 Service Area that part of an employer s premises used for the servicing of multi piece rim wheels or any other place where an employee services multi piece rim wheels 4 36 2 11 Trajectory any potential path or route that a lock ring side ring rim base and or tire may travel during an explosive rim separation and includes paths which may deviate from that perpendicular to the assembled position of the components on the rim base at the time of separation See Figure 4 21 Trajectory warning for examples 4 36 2 12 Wheel an assemblage of tire tube and multi piece rim components 4 36 3 Employee Training 4 36 3 1 The employer shall provide a training program to train and instruct all employees on hazards involved in servicing multi piece rims and the safety procedures to be followed 4 36 3 1 1 The employer shall ensure that no employee services a multi piece rim wheel unless the employee has been trained and instructed on correct procedures of mount ing demounting and all related services activities and correct safety precautions for the rim type being serviced and the safe operating procedures described later in this chapter 4 36 3 2 Information to be used in the training program shall include at a minimum data contained on the charts and contents of this technical order 4 36 3 3 Where an employer knows or has reason to believe that any of his employees is unable to read and understand the charts
163. 4 36 2 2 Installing a Wheel the transfer and attachment of an assembled wheel onto a vehicle axle hub 4 36 2 3 Removing the opposite of installing 4 36 2 4 Mounting a Tire the assembly or putting together of rim components tube liner flap and tire to form a wheel including inflation 4 36 2 5 Demounting the opposite of mounting 4 36 2 6 Multi Piece Rim a vehicle wheel rim consisting of two or more parts one of which is a side or locking ring designed to hold the tire on the rim by interlocking compo nents when the tube is inflated regardless of the sizes of the component parts 4 36 2 7 Restraining Device a mechanical apparatus such as a safety cage rack or safety bar arrangement or other machinery or equipment specifically designed for this pur pose that will constrain all multi piece rim wheel compo nents following their release during an explosive separation of the wheel components See Figure 4 22 4 36 2 8 Rim Manual a publication containing instruc tions from the manufacturer or other qualified organization for correct mounting demounting maintenance and safety precautions peculiar to the multi piece rim being serviced 4 36 2 9 Service or Servicing the mounting and de mounting of multi piece rim wheels activity such as inflat ing deflating installing removing maintaining handling or storing of multi piece rim wheels including inflating and deflating of wheels installed on vehicles
164. 464 Number 3 die cut pre spaced Blue None l in 3613465 Number 4 die cut pre spaced Blue None l in 3613466 Number 5 die cut pre spaced Blue None l in 3613467 Number 6 die cut pre spaced Blue None l in 2 49 TO 36 1 191 Part No Legend Or Symbol Colors Letter Or No Emblem Size _ 5 3613468 Number 7 die cut pre spaced Blue None lin 3613469 Number 8 die cut pre spaced Blue None lin 3613470 Number 9 die cut pre spaced Blue None lin 3613471 Number 0 die cut pre spaced Blue None l in 3613472 BADGE SECURITY POLICE reflector Blue None 1 in ized 3613017 WATER ALCOHOL NATO SYMBOL Black Silver 1 2 in 2 in x 9 1 2 in 8738 2 lines of copy as shown 3613018 OPEN MANHOLE COVERS WHEN Silver Red 2in 10 in x 36 in PUMPING FUEL OIL OR WATER AT TEMPERATURES BELOW 25 F 4 lines of copy 3613019 OIL ACFT ENG Silver Red 3 in 4 in x 36 in 3613020 OIL ACFT ENG Silver Red 4 in 5 in x 48 in 3613021 KEROSENE Silver Red 4 in 5 in x 30 in 3613022 KEROSENE Silver Red 6 in 7 in x 48 in 3613025 DIESEL FUEL Silver Red 3 in 4 in x 36 in 3613026 DIESEL FUEL Silver Red 4 in 5inx 42 in 3613027 MOGAS Silver Red 3 in 4in x 18 in 3613028 MOGAS Silver Red 4 in 5 in x 24 in 3613029 CLASS A POISON 2 lines of copy Blue Silver 6 in 14 in x 72 in as shown 3613030 UDMH HYDRAZINE CORROSIVE Blue Silver 6 in 14 in x 72 in LIQUID 2 lines of copy as shown 3613031 DEMINERALIZED WATER S
165. 5 8 21 3 9 Records The records received with each ve hicle shall be maintained as required by applicable directives and technical orders In addition the vehicle management activity shall initiate records showing the condition status of each vehicle stored its location and all processing performed The condition record shall be posted daily to show these units in operationally ready status This record shall explain the non operational ready status of vehicles so marked and indicate the target date for return to ready status 8 22 GENERAL 8 22 1 Purpose And Scope The information contained in this section is furnished to familiarize personnel respon sible for preparing vehicles for airlift with the administrative and processing problems commonly encountered It is advi sory only and not intended to conflict with or supersede any other regulations manuals technical orders or special in structions While special instructions on fuel servicing ve hicles are included coverage is general in nature Requests for assistance on specific problems should be directed to the prime agency responsible for the end item 8 22 2 Instructions 8 22 2 1 Commercial Airlift Vehicles being offered for commercial air shipment must comply with applicable carrier TO 36 1 191 rules and tariffs In general these are similar to the regulations governing military airlift Your local Hazardous Materiel Certifier formally Base Supply should be
166. 5 5555 8010 01 362 3877 8010 01 362 3876 8010 00 161 5718 8010 00 515 2258 4240 00 022 2524 NSL NSL 7690 00 78 1 2496 7690 00 78 1 2497 9515 00 640 4201 7510 00 266 6712 7510 00 079 7906 9390 00 949 8045 9390 00 945 8046 9390 00 949 8047 9390 00 057 4543 9390 00 753 3208 9390 00 949 7588 9390 00 949 7598 N A 8010 01 441 5940 6810 00 551 1487 GSA GSA GSA DOD AF Stock LP LP GSA GSA AF Stock GSA GSA GSA GSA GSA GSA GSA GSA GSA LP GSA GSA TO 36 1 191 Source 2 47 TO 36 1 191 Table 2 2 Supply Information Continued Nomenclature Stock Number Source Walkway Compond non slip rough type black grit 8010 00 641 0427 AF Stock as an integral part of the coating Spec MIL W 5044 type II 1 gal 2 90 2 The following markings are required for compli ance with this technical order Markings will be requisitioned from DAPS Sacramento 5015 Arnold Ave Bldg 29 McClellan CA 95652 916 643 4952 Using the part number and complete description that fol lows Part No Legend Or Symbol Colors Letter Or No Emblem Size 3613001 NO SMOKING WITHIN 50 FEET 2 Silver Red 4in 10 in x 42 in lines of copy as shown 3613002 NO SMOKING WITHIN 50 FEET 1 line Silver Red 4in 5 in 72 in of copy as shown 3613003 NO SMOKING WITHIN 50 FEET 1 line Silver Red 3 in 4 in x 60 in of copy as shown 3613004 FLAMMAB
167. 5 Lights 1 7 2 85 1 Clearance and Marker Lights shall be securely mounted and operate properly Light output shall be sufficient to be visible in normal shaded daylight Lens shall not be cracked or broken so as to allow water to enter housing or be discolored Color and number shall be mounted in accordance with Chapter 2 1 7 2 85 2 Headlights and Parking Directional Headlights shall be securely mounted and properly adjusted Sealed beam units shall be securely installed to reflect correct beam pattern on road surface Lens shall not be cracked broken or discolored Filters used in blackout tail lights M series vehicles shall not be cracked and shall be properly installed and conform to standards set forth in Chapter 2 or applicable technical manual 1 7 2 85 3 Tail Brake Directional and Backup lights brake directional and backup lights shall be securely mounted and operate properly Light output shall be sufficient to be visible in normal shaded daylight Lens shall not be cracked or broken so as to allow water to enter housing or discolored 1 7 2 86 Line Strainers Baskets Line strainers con dition and mounting shall be in accordance with TO 37A 1 101 1 7 2 87 Manhole Vents Manhole filler cover hinges and front and rear air vent valves shall be clean and function properly Gaskets shall be in good condition and in proper placement 1 7 2 88 Manifolds Intake And Exhaust Manifolds shall be
168. 5134 Respirator paint spray Sealer non reflective marking edge 8 oz can Sealer reflective marking edge 8 oz can Star symbol white lusterless pressure sensitive adhesive backing code no 654L USPSW 6 in Star symbol white lusterless pressure sensitive ad hesive backing code no 655 USPSW 10 in Steel sheet carbon hot rolled annealed 0 063 in thick Fed Spec QQ S 636 Tape masking scotch manila creped 1 in wide 60 yd roll Type I Tape pressure sensitive adhesive 2 in wide oil and water resistant 60 yd Roll Tape reflective pressure sensitive adhesive back ing 2 in 5 yd Roll 3270 silver Tape reflective pressure sensitive adhesive back ing 3 in x 50 yd Roll 3270 silver Tape reflective pressure sensitive adhesive back ing 4 in x 50 yd Roll 3270 silver Tape reflective pressure sensitive adhesive back ing 4 in x 50 yd Roll 3271 yellow Tape reflective pressure sensitive adhesive back ing 1 in x 50 yd Roll 3271 yellow or 3272 red PN 137 165 Tape reflective pressure sensitive adhesive back ing 2 in x 50 yd Roll 3271 yellow or 3272 red PN 137 166 Tape reflective pressure sensitive adhesive back ing 3 in x 50 yd Roll 3272 red PN 137 167 Tape reflective pressure sensitive 3M adhesive back color blue 4 in wide x 50 yd Removable 3M PN 690 75 St Paul MN Thinner Synthetic resin enamel Spec TT T 306 Type III Trichloroethane technical 55 gal drum Stock Number 8010 01 30
169. 63 2 Avgas Dispensing Units Manhole cover and nozzle markings on AVGAS dispensing units shall be applied using a purple background with silver letters and numbers as illustrated in exhibit A amp B 1 TYPE PRODUCT 4JP 5 JP8 AVGAS 115 145 etc 2 PRODUCT SYMBOLS A filled four pointed silver star on a red background represents Jet Fuel A filled four pointed silver star on a purple background represents AVGAS A filled four pointed black star and a filled black crescent represents rocket fuel A filled black square represents lubricating oil 2 63 8 NATO symbol Refer to MIL STD 161F for these symbols Examples JP 4 fuel is F 40 and AVGAS 100 130 is F 18 2 63 4 PERMIT REQUIRED CONFINED SPACE EN TRY manhole covers or employee accessible not bolted closed entry points on vehicles or trailers must be marked by decal or stencil DANGER CONFINED SPACE ENTER BY PERMIT ONLY 2 64 HYDRANT FUELING TRUCKS 2 64 1 The following markings shall be displayed on both sides of the Hydrant Fueling Trucks Markings may be decals or stencils using red paint color number 31136 FLAMMABLE 4 inch silver letters on a red background NO SMOKING WITHIN 50 FT 3 inch silver letters JET FUEL 7 8 F43 3 inch silver letters on red background CARGO FIRE AVOID WATER 2 inch red let ters silver background 2 64 2 The above markings will be applied on a panel locally fabrica
170. 8 Intergranular Corrosion Cell 6 16 6 4 Intergranular corrosion see Figure 6 8 is an attack on the grain boundaries of the metal A highly magnified cross section of any commercial alloy shows the granular structure of the metal This consists of quantities of individual grains each having a clearly defined boundary that chemically differ from the metal within the grain The grain boundaries are frequently anodic 1 tend to corrode more easily to the metal within the grain When in contact with an electrolyte rapid corrosion occurs at the grain boundaries Figure 6 9 Exfoliation Corrosion 6 16 6 5 Exfoliation corrosion see Figure 6 9 is an advanced form of Intergranular corrosion and occurs when the surface grains of a metal are lifted up by the force of expanding corrosion products occurring at the metal grain boundaries The lifting up or swelling is visible evidence of exfoliation corrosion Exfoliation occurs on extruded rolled wrought and forged high strength aluminum and magnesium parts Figure 6 10 Concentration Crevice Corrosion 6 16 6 6 Concentration Crevice corrosion see Figure 6 10 occurs when the electrolyte in a crevice has a different concentration than the area adjacent to the crevice This type of corrosion is also known as concentration cell corrosion Electrolyte inside the crevice contains less oxygen and more metal ions than electrolyte just outside the crevice As a result the metal surfaces
171. 8 22 3 5 5 Allow the refueling unit to set undisturbed for 24 hours Redrain all low pints tank sump filter separator manual drain line strainer and bottom loading manifold 8 60 8 22 3 5 6 No more than 12 gallons of product will remain in the refueling vehicle following the final drain 8 22 3 5 7 manual drains not equipped with spring loaded closing devises will be safety wired shut prior to shipment 8 22 3 5 8 Secure tag AF Form 980 Caution Tag on the refueler operating control panel with inscription as follows This refueling unit has been drained of combus tible product in accordance with TO 36 1 191 This vehicle was last in service carrying insert type of fuel it last held 8 22 3 6 Chemical Neutralization Chemical neutral ization is the primary method for vehicles last carrying flammable products flashpoint below 100 F Oil steam and forced air purges are included as alternate methods and should be used only when facilities or equipment are not available to accomplish the chemical neutralization Personnel engaged in neutralization or purging operations shall Not wear wool nylon silk rayon or other clothing fabric possessing ten dency to generate static electricity Wear clean cotton clothing with no metal buttons zippers or fittings Remove all con tents from pockets Use cotton cloths for cleaning clean up pur poses Other fabrics could generate static electricity 8
172. 8 SPECIAL MARKINGS Special markings i e no smoking signs fluid identification will be applied as specified beginning in Paragraph 2 45 2 89 SIZE OF MARKINGS The size of the letters and numerals to be used in accom plishing vehicle markings are as follows 2 39 1 US AIR FORCE 1 1 2 inch 2 39 2 Registration Number 1 1 2 inch 2 39 8 FOR OFFICIAL USE ONLY 3 4 inch 2 39 4 The size of all other markings is included in the paragraph pertaining to the specific marking involved NOTE Present stocks of reflective marking material will be used prior to ordering new sizes 2 40 LOCATION OF VEHICLE IDENTIFICATION MARKINGS 2 40 1 2 25 When AF license plates are used refer to Paragraph 2 40 2 When AF license plates are not used the following procedures will be adhered to 2 40 2 1 Vehicle identification on the sides and the rear of vehicles will consist of US AIR FORCE and registration number and are placed as follows 2 40 2 2 On most vehicles center the identification mark ings on each front door or in a comparable position in relation to the operator s seat on vehicles without doors 2 40 2 3 trailers and semi trailers the identification markings will be centered vertically on each side of the front quarter of the vehicle 2 40 2 4 The location of identification on the rear of the vehicle is not prescribed due to the various types of design characteristics involved The loc
173. 930 00 985 6750 N A Dressing Leather Mildew Preventative ____________ 8030 00 221 0665 Pp OI Nea sfot 8030 00244 103 9150 00 250 0926 CID A A 52518 6810 00 270 9988 MIL A 53009A 1 6850 01 160 3868 Neutralizer Soda Ash Sodium Carbonate lt T N o D Q Q s No Type I Light 6810 00 237 2906 Type Medium 6810 00 233 1715 Type IIL Dense 6810 00 262 8567 Box Wooden Nailed Lock Comer 8115 00 685 5171 Primer Synthetic Rust Inhibiting 8010 00 161 7275 Solvent Dry Cleaning Type II 850 00 285 8011 gt zo a 5 ses m 2 Dr e gt Q gt gt Fo UA gt 9140 00 286 5284 MIL PRF 32033 9150 00 281 2060 CLB1 8135 00 171 1559 8135 00 292 9789 9130 00 148 7104 pL MILITARY DEPARTMENT OF DEFENSE MIL STD 2073 1D 1 MIL E 6060D Supl Packaging Envelopes 8 x 12 8105 00 264 5525 10 14 8105 00 726 7387 22 28 8105 00 235 2686 Material Flex Grease Proof Barrier Paper Laminated 36 x 24 Type II 8135 00 680 2777 Material Water Vapor Proof Barrier 36 x 200 Yds For Weights of 10 or under 8135 00 541 2453 Support Items Accessories and Kit Packaging Military Marking for Shipment and Storage Packaging and Packing Support Requirements For Special Mechanical Components and Repair Parts LS Heat Sealable __ _______ Oil Lube Internal Combusted Engine QT 915 0
174. A warning tag bearing the information CLOSE DRAIN COCKS AND FILL COOLING SYSTEM BE FORE OPERATING ENGINE shall be se curely attached in a conspicuous location within driver s compartment e Cooling systems exhibiting obvious leaks shall be repaired Minor leaks may be eliminated by adding leak preventive compound conforming to Specification O L 460 See Items 8 11 and 29 Close and seal Protect against tampering with wire type railroad car seal prior to shipment Engine crankcase shall contain MIL L 21260 Type P 10 preservative oil Type I Grade 10 30 or 50 as applicable filled to operating level 8 27 TO 36 1 191 COLUMN I Item 44 45 46 47 48 49 8 28 Table 8 2 Processing Procedures Continued Transfer as semblies and power take Off assem blies and other gear driven units except those lubricated by the units to which they are attached Doors Drives Gear Chain Drums Brake A Interior Sur face COLUMN COLUMN COLUMN COLUMN II V Component Level Type of Vehicle Processing Required B Engine crankcase shall contain lubricating oil con forming to requirements of applicable drawing specification or lubrication order filled to oper ating level When crankcase contain Type P 10 preservative oil Type I Grade 10 or 30 as ap plicable operating level shall be attained by addition of the same grade oil or lubricating oil conforming to Specification MIL L
175. ALTY COATINGS 2 20 1 In addition to the metallizing materials and the standard automotive primers and paint topcoats there are several specialty coating systems that are particularly effec tive for military vehicle applications 2 20 2 Zinc rich primers offer superior corrosion protec tion when applied over properly prepared carbon steel The primer typically contains 60 80 percent by weight of zinc metal dust that provides the corrosion protection to steel surfaces on which it is applied If the topcoat is applied relatively thin the zinc particles often are not totally covered by the topcoat As a result small particles of the zinc dust may be exposed to the air As the zinc reacts with the environment the zinc particles may turn white and show up as white specks in the topcoat 2 20 2 1 resolve this issue a two part primer system has been approved for use on abrasive blasted or other properly prepared carbon steel surfaces This is the preferred primer coating material only if the steel base metal surface is properly prepared The system consists of the wet to wet application of zinc rich primer and an intermediate primer over the zinc rich primer NOTE Follow the primer coating manufacturer s di rections on paint spray gun and fluid cup type and the selection of the paint gun fluid tip fluid needle and air cap Failure to follow the coating manufacturer s guidance on equip ment selection and use may result in th
176. ASSIS LINKAGE CONNECTING POINTS BEHIND INSTRUMENT PANEL 1 USE GRADE 1 COAT ALL METAL UNDERNEATH OF VEHICLE RUNNING GEAR FRAME SPRINGS BRAKE RODS STEERING MECHANISM ETC 2 USE GRADE 1 COAT EXTERIOR OF ROOF CAB CAB CORNERS AND BEHIND SEAT AREAS LIFT FLOOR MAT AND COAT ENTIRE FLOOR AREA REMOVE PANEL AND COAT ENTIRE INSIDE OF DOOR INCLUDING DOOR MECHANISM COAT HINGE BOXES 3 USE GRADE 1 COAT BATTERY BOX AND TERMINALS ALL AREAS AROUND MOTOR 4 USE GRADE 2 COAT ALL SEAMS AROUND WINDOW AREAS HINGES AND ALL EXTERIOR METAL TO METAL JOINTS LADDER PIPE RAIL WELDS ETC SPRAY LIGHT COAT OVER ENTIRE EXTERIOR VEHICLE IF FILM THICKNESS IS TOO HEAVY AND SUBJECTED TO PERSONAL CONTACT REMOVE EXCESS BY RUBBING AND OR POLISHING WITH A CLEAN CLOTH 5 USE GRADE 2 SPRAY BOTH SIDES OF WHEELS RIMS AND LUGS 6 USE GRADE 4 SPRAY ENTIRE ELECTRICAL SYSTEMS INSTRUMENT PANEL LIGHT SOCKETS GENERATOR ETC 7 USE GRADE 3 SPRAY EXTERIOR CORE BOTH SIDES FIRST COAT WITH GRADE 3 REPEAT SCHEDULE WITH SECOND COAT OF GRADE 3 REFERENCE NUMERICAL LEGEND F09603 085 Figure 6 2 Special Purpose Vehicles Full Tracked Tractors Sheet 1 of 13 6 23 TO 36 1 191 1 USE GRADE 1 SPRAY ALL METAL AREAS UNDERNEATH MIXER AND SPRAY ALL CLOSED IN AREAS 2 USE GRADE 2 SPRAY ALL EXTERIOR METAL PULLEYS CABLES EXTERIOR RUNNING GEAR ETC WIPE OFF EXCESS MATERIAL WITH CLEAN CLOTH IF NECESSARY SPRAY BOTH SIDES OF WHEELS RIMS AN
177. AT TERN PAINTED VEHICLES 2 84 MARKING LAW ENFORCEMENT SEDANS x cz 2 85 MARKING 41 PASSENGER IN TERCITY BUSES USED FOR SUPPORT OF BANDS 2 86 WRM MARKINGS 2 87 INSTALLATION OF REFLECTOR IZED TAPE 5 2 cevi 2 88 REMOVAL OF REFLECTORIZED TAPE 2 89 REQUISITIONING OF MARK INGS usu sh 2 90 FIGURES 4 5 25556 5 5465 RO 2 91 LIGHTING REQUIREMENTS 2 92 SPECIAL DATA 2 92 1 Directional Signaling Devices 2922 2 93 TRAILER LIGHTING CABLES 2 94 SPOT LIGHTS 455434444 256 2 95 SUPPLY DATA 2 2 3x3 2 96 WARNING OR INDICATING LIGHTS 3 MOTOR VEHICLE AND BASE SUPPORT EQUIPMENT INSPECTION 3 1 PURPOSE 454 3 2 RECOMMENDED CHANGES 3 APPLICABLE PUBLICATIONS 3 4 GENERAL ES ERE 3 5 OPERATOR DAILY WEEKLY IN SPECTION REQUIREMENTS 2 25 2 25 TO 36 1 191 TABLE OF CONTENTS CONTINUED Chapter Page Chapter Page 3 6 PREVENTATIVE MAINTENANCE 4 2 8 Injury Prevention 4 1 AND INSPECTION 3 2 4 29 Air Pressure Tire 4 1 3 6 Operator Compartment 3 2 4 3 GENERAL 22e 4 1 3 62 Hydraulic Systems 3 2 4 4 PURPOSE 3 2655 244 e604 errs 4 1 3 6 3 Check Coolant System Heater and 4 5 SCOPE Zu 4 1 Air Conditioning 3 2 4 6 OTHER DOCUMENTS 4i 3 6 6 Fuel System
178. Alloys Continued ANODIC High Corrosion Potential Magnesium Alloys Zinc plate Beryllium Cadmium plate Uranium depleted Aluminum Alloys Indium Tin plate Stainless Steel 430 active Lead 1010 Steel Cast iron Stainless Steel 410 active Copper plate Nickel plate AM 350 active Chromium plate Stainless Steels 350 310 301 304 active Stainless Steels 430 410 passive Stainless Steels 13 8 17 7 pH active Brass yellow Naval a y Factors that influence metal corrosion and the rate at which it Stainless Steel 316L active occurs are outlined in this section Both natural and man Bronze 220 made environments cause corrosion of vehicles Natural Copper conditions that affect the corrosion process are moisture Stainless Steel 347 active temperature salt atmospheres ozone sand dust solar radia Copper Nickel 715 tion insects and birds and microorganisms Man made conditions that affect the corrosion process are industrial Stainless Steel 202 active Monel 400 pollution manufacturing operations storage conditions and shipment By understanding these conditions maintenance Stainless Steel 201 active Stainless Steels 321 316 active Carbon Graphite CATHODIC Low Corrosion Potential 6 17 FACTORS INFLUENCING CORROSION 6 50 personnel will be better able to prevent corrosion from initially occurring or minimize the impact of corrosion afte
179. BLES 2 93 1 Lighting connectors are not generally furnished with vehicles of the 1 2 to 1 1 2 ton capacity Since compara tively few of these vehicles ever tow trailers off base or trailers which require lights it is not considered to be economically sound Installation of lighting connectors on these vehicles may be accomplished by the using activity 2 93 2 The new SAE ATA seven circuit cables plugs and sockets are coded by either numbers or colors The SAE ATA wiring code which follows should be used when installing the new components Conductor Wire No Color Circuit 1 White Ground 2 Black Clearance Lights 3 Yellow Left Turn Light 4 Red Stop Lights 5 Green Right Turn Light 6 Brown Tail Light Blue Auxiliary Circuit 7 Blue Auxiliary Circuit Since many semi trailers are equipped with compartment lights spot lights etc the number 7 or blue auxiliary circuit should be used for this purpose 2 94 SPOT LIGHTS If required by operating officials spot lights can be installed on vehicles to meet local operational conditions or to comply with existing regulatory requirements When installed it must be mounted on the vehicle centerline directly over the windshield head section with an inside control readily acces sible to the driver 2 95 SUPPLY DATA Parts necessary for lighting and reflector requirements for off base operation not available in local supply will be requisi tioned through regular supply channels
180. Black None 1 1 2 in 2 in x lin 3613440 Letter Z Die cut pre spaced Black None 1 1 2 in 2 in X 1 3 in 3613441 Number 1 Die cut pre spaced Black None 1 1 2 in 2in xX lin 3613442 Number 2 Die cut pre spaced Black None 1 1 2 in 2 in X 1 3 in 3613443 Number 3 Die cut pre spaced Black None 1 1 2 in 2 in X 1 3 in 3613444 Number 4 Die cut pre spaced Black None 1 1 2 in 2 in X 1 3 in 3613445 Number 5 Die cut pre spaced Black None 1 1 2 in 2 in X 1 3 in 3613446 Number 6 Die cut pre spaced Black None 1 1 2 in 2 in X 1 3 in 3613447 Number 7 Die cut pre spaced Black None 1 1 2 in 2 in x 1 3 in 3613448 Number 8 Die cut pre spaced Black None 1 1 2 in 2 in X 1 3 in 3613449 Number 9 Die cut pre spaced Black None 1 1 2 in 2 in 1 3 in 3613450 Number 0 Die cut pre spaced Black None 1 1 2 in 2 in 1 3 in 3613451 FOR OFFICIAL USE ONLY Die cut Black None 3 4 in None pre spaced 3613456 AMBULANCE Mirror Image Die cut Black None 3 in None pre spaced 3613457 AMBULANCE Mirror Image Reflec Silver None 1 1 2 in tive Die cut pre spaced 3613458 POLICE die cut pre spaced Blue None 7 in 3613459 POLICE die cut pre spaced Blue None 4 in 3613460 FOR OFFICIAL USE ONLY die cut pre Blue None 1 in spaced 3613461 Letter B die cut pre spaced Blue None l in 3613462 Number 1 die cut pre spaced Blue None l in 3613463 Number 2 die cut pre spaced Blue None l in 3613
181. C LOADED RADIUS DISTANCE FROM THE CENTER OF THE AXLE TO THE GROUND UNDER THE SPECIFIED LOAD AND INFLATION PRESSURE RIM DIAMETER DIAMETER OF THE RIM FROM BEAD SEAT TO BEAD SEAT OVERALL DIAMETER DIAMETER OF THE TIRE FROM TREAD SURFACE TO TREAD SURFACE WHILE INFLATED BUT UNLOADED OVERALL SECTION WIDTH DISTANCE BETWEEN THE OUTER SIDEWALLS OF AN INFLATED TIRE RIM WIDTH DISTANCE BETWEEN THE INSIDE OF THE RIM FLANGES SECTION HEIGHT DISTANCE FROM THE BEAD SEAT TO THE OUTER TREAD SURFACE OF THE INFLATED TIRE SECTION WIDTH DISTANCE BETWEEN THE OUTER SIDE WALLS OF AN INFLATEDTIRE LESS ANY ORNAMENTATION OR CURB RIBS TREAD WIDTH THE WIDTH OF THE TREAD SURFACE DESIGNED FOR CONTACT WITH THE ROAD F09603 047 Figure 4 5 New Tire Dimensions DIAMETER OF WHEEL IN INCHES LOAD INDEX AND SPEED SYMBOL U S DOT SAFETY STANDARD CODE RATIO OF HEIGHT TO RADIAL WIDTH ASPECT RATIO WIDTH OF TIRE IN MILLIMETERS PASSENGER CAR TIRE 4 Mag avo Masc 2 02 yyyyt INFLATION AND gt 4 LOAD LIMIT 2 01 oz wi TREADWEAR TRACTION TIRE PLY COMPOSITION AND TEMPERATURE GRADES AND MATERIALS USED THE TIRE SIZE SHOWN BELOW IS 215 65R16 THE 215 REPRESENT ITS SECTION WIDTH TIRE WIDTH IN MM 65 IS THE TIRES ASPECT RATIO THE RADIO OF THE SIDEWALL HEIGHT TO THE TREAD WIDTH THE R REPRESENTS TIRE CONSTRUCTION IN THIS CASE RADIAL AND THE LAST ITEM IS THE 15 WHICH REPRESENTS THE RIM WHEEL SIZE F09603 048 Figure 4
182. Clellan CA 95652 916 643 4952 2 56 TO 36 1 191 Legend Or Symbol Emblem Size 3613505 3613506 toned down 3613510 NHTSA Airdrome Traffic Signals MPH to KPH CAUTION BEFORE TOWING LATCH PINTLE CLOSE TRIPLOCK INSTALL LOCK PIN WARNING DO NOT EXCEED 100 PSI IN HALON SUPPLY CYLINDER DURING TRANSFER OPERATION OVER PRESSURIZATION OF SUPPLY CYLINDER MAY CAUSE FAILURE OF TANK RESULTING IN INJURY OR DEATH Air Force A Great Way of Life CAUTION BEFORE TOWING LATCH PINTLE CLOSE TRIPLOCK INSTALL LOCK PIN 15 Passenger Van 2 90 4 The following Modular Ambulance s Decals can be obtained from Wheeled Coach 2778 Coach N Forsyth Road Winter Park FL 32792 407 677 7777 2 3 4 in x 3 in 2 in x 3 in 3 1 2 in x 4 1 2 in 5 1 2 in x 3 1 2 in 7 ft 6 in x 6 in 3 1 2 in x 4 1 2 in AS 71212 AS 71208 AS 71211 AS 71003 AS 71006 AS 71001 AS 71205 AS 71210 AS 71009 COMPARTMENT BODY TOP COMPARTMENT BODY SIDE REAR OF VEHICLE COMPARTMENT BODY SIDE REAR OF VEHICLE FRONT HOOD ABOVE GRILLE COMPARTMENT BODY SIDE REAR OF VEHICLE FRONT HOOD ABOVE GRILLE RED CROSS RED CROSS RED CROSS STAR OF LIFE STAR OF LIFE STAR OF LIFE AMBULANCE AMBULANCE AMBULANCE MIR ROR IMAGE 2 57 TO 36 1 191 2 91 LIGHTING REQUIREMENTS The lighting and signaling devices prescribed in this technical order provide the minimum electrical directional signalin
183. Commands will obtain from the bases LTI s for vehicles requiring overhaul in the upcoming fiscal year Any vehicles 9 3 TO 36 1 191 previously scheduled for depot overhaul which upon physi cal inspection do not meet the criteria for depot overhaul will be rescheduled to an appropriate out year Deletions changes will be updated in the appropriate data system LTI s will be consolidated by the command and forwarded by cover letter to be received by WR ALC LE not later than 15 Aug of each year Desired quarter of input for overhaul should be annotated on the LTI and in the appropriate data system WR ALC LE will schedule programmed require ments as close as possible to the requested induction sched ule LTI will be used to determine if overhaul is required and to rank vehicle overhaul priority by overall condition 9 20 ATTACHMENTS Missing accessories removed by owning activity will not be replaced by depot i e crane attachments servicing hose dozer blades fire fighting equipment etc There shall be no substitution for vehicles scheduled for depot overhaul unless specifically authorized by WR ALC LE 9 24 APPROVAL If depot overhaul of a vehicle is approved by WR ALC LE instructions for shipment to an overhaul facility will be issued at the appropriate time by WR ALC LE 9 211 WR ALC LE will make necessary evaluation on a case by case basis to determine what level of maintenance best serves the needs of the
184. D LUGS 3 USE GRADE 4 SPRAY COMPLETE ELECTRICAL SYSTEM SPARK PLUGS COIL DISTRIBUTOR GENERATOR IGNITION SYSTEM ETC 4 USE GRADE 3 CONTROL RADIATOR ELECTROLYSIS SPRAY EXTERIOR SURFACE BOTH SIDES OF RADIATOR CORE WITH A FIRST COAT OF GRADE 3 REPEAT SCHEDULE AND SPRAY SECOND COAT WITH GRADE 3 REFERENCE NUMERICAL LEGEND F09603 086 Figure 6 2 Special Purpose Vehicles Full Tracked Tractors Sheet 2 6 24 TO 36 1 191 P stant s ab INED ie 9 U 1 USE GRADE 1 SPRAY ALL METAL UNDERNEATH CRANE RUNNING GEARS SPRINGS UNDERNEATH FENDERS AND ALL BOXED IN AREAS 2 USE GRADE 1 SPRAY INTERIOR OF DOORS HINGES AND HINGE BOXES INSIDE OF CAB ROOF LIFT MAT AND SPRAY CAB FLOOR SPRAY ALL INSIDE AREAS OF MOTOR HOOD AND ALL SURROUNDING AREAS AROUND MOTOR SPRAY BATTERY BOX AND TERMINALS 3 USE GRADE 2 SPRAY AROUND ALL WINDOW SEAMS SPRAY ALL CABLES PULLEYS SPRAY ALL EXTERIOR METAL SURFACES IF FILM THICKNESS IS TOO HEAVY IN UNDESIRED AREAS WIPE OR POLISH EXCESS MATERIAL WITH A CLEAN CLOTH SPRAY ALL PIANO HINGES AND DOOR CATCHES SPRAY ALL INNER COMPARTMENTS 4 USE GRADE 2 SPRAY BOTH SIDES OF ALL WHEELS RIMS AND LUGS 5 USE GRADE 4 SPRAY COMPLETE ELECTRICAL SYSTEM LIGHT SOCKETS SPARK PLUGS DISTRIBUTER COIL GENERATOR IGNITION ETC 6 USE GRADE 3 TO CONTROL RADIATOR ELECTROLYSIS SPRAY BOTH EXTERIOR SIDES OF RADIATOR CORE SPRAY FIRST COAT WITH GRADE 3 REPEAT SCHEDULE AND SPRA
185. D MOTOR SPRAY BATTERY BOX AND TERMINALS COAT INNER AREA COMPARTMENT OF OPERATOR S SEAT 2 USE GRADE 2 SPRAY ALL EXTERIOR SURFACES METAL TO METAL JOINTS ETC IF FILM THICKNESS IS TOO HEAVY SUBJECTED TO PERSONAL CONTACT EXCESS CAN BE WIPED OR POLISHED WITH A CLEAN CLOTH SPRAY ALL EXTERIOR RUNNING GEAR AND OPERATOR S DECK 3 USE GRADE 4 SPRAY COMPLETE ELECTRICAL SYSTEM SPARK PLUGS DISTRIBUTOR GENERATOR COIL IGNITION INSTRUMENT PANEL ETC 4 USE GRADE 3 TO CONTROL RADIATOR ELECTROLYSIS SPRAY BOTH SIDES OF EXTERIOR RADIATOR CORE WITH A FIRST COAT OF GRADE 3 REPEAT SCHEDULE WITH SECOND COAT OF GRADE 3 REFERENCE NUMERICAL LEGEND F09603 097 Figure 6 2 Special Purpose Vehicles Full Tracked Tractors Sheet 13 6 15 VEHICLE CLEANING AND CORROSION PRO TECTION 6 15 1 A well developed corrosion prevention and control program includes a scheduled cleaning program utilizing approved cleaning materials and processes as a key element in reducing the impact of corrosion Use of untested or unauthorized cleaning materials may cause premature coating system failure and or accelerated corrosion 6 15 2 operating locations fall in specific corrosion severity zones The Air Force Corrosion Prevention and Control Office AFRL MLS OLR has established the cor rosion severity zones based on a number of factors including the available water quality air quality nearness to salt water etc The minimum wash cycles
186. DURES OUTSIDE THE LIMITS OF THE 50 UNITED STATES AND THE DIS TRICT OF COLUMBIA Generally warranty corrections outside of the 50 United States and the District Columbia overseas areas includes furnishing of new parts and assemblies to replace those defective ones returned to the contractor by the Air Force However in some areas many dealers or representatives of U S manufacturers will honor warranties in the same manner as in CONUS If warranty action is needed contact the local dealer distributor or the manufacturer s regional office for procedures prior to using the following MILITARY SHIPMENT LABEL TO 36 1 191 Form Approved Formatted Table No 0704 01 1 TRANSPORTATION CONTROL NUMBER FB5294 4273 x001xxx 2 POSTAGE DATA 5 SHIPPED TO POE TRAFFIC MANAGEMENT OFFICE 436 MAW DOVER AFB DE 19902 PACAF SUU TRAFFIC MANAGEMENT OFFICE 60 MAWILGS TRAVIS AFB CA 94535 5350 4 TYPE SERVICE 6 TRANS PRIORITY 7T POD 8 PROJECT 9 ULTIMATE CONSIGNEE OR MARK FOR FE5294 51 TRANS LGTM UNIT 2069 APO AE 96278 2069 ATTN VEHICLE FLEET MANAGER DSN 784 5486 DD FORM 1387 NOV 86 10 WT This Piece 29 OCT 94 12 CUBE This Piece 14 DATE SHIPPED 16 PIECE NUMBER 13 CHARGES 15 FMS CASE NUMBER 17 TOTAL PIECES Previous editions are obsolete F09603 103 Figure 7 5 Military Shipment Label sample 7 13 TO 36 1 191 7 22 1 Ina situation where d
187. Distri bution flight to be filed in the suspense file and to aid in reconciling the DIFM listing 4 55 4 Upon return of retreaded tires from contract main tenance they will be turned into the Distribution Flight utilizing DIFM turn in documents 4 56 SEASONAL TIRE STOCKS Seasonal tires may be used when required Seasonal tires will be maintained in the supply point during the winter season and turned in to the Distribution Flight for storage until required for next season s use An excess exception code on the basic item record in the Distribution Flight will be used to retain these tires for seasonal use This procedure also applies to conventional tires replaced with seasonal tires Codes to be used to control these tires will be determined by the Distri bution Flight Non studded seasonal mud and snow tires for other than passenger vehicles will normally be kept on the vehicle year round The VFM should review the Distribution Flight stocks of seasonal tires 90 days prior to the use period to determine if stocks and levels are adequate 4 57 STORAGE OF TIRES Tires in storage will deteriorate from elements such as light heat oil dust dirt smoke and water Air in motion acts as the carrier and the catalyst Protection against these factors must be considered when storing pneumatic tires Mainte nance of tires on vehicles in storage is outlined in Chapter 8 4 58 TIRE COSTING Tire costing within the base vehicle ma
188. ELS RIMS AND LUGS 5 USE GRADE 4 SPRAY COMPLETE ELECTRICAL SYSTEM LIGHT SOCKETS SPARK PLUGS DISTRIBUTOR GENERATOR COILS LOCKS ETC 6 USE GRADE 3 FOR VEHICLE RADIATOR ELECTROLYSIS CONTROL SPRAY BOTH EXTERNAL SIDES OF RADIATOR CORE WITH FIRST COAT OF GRADE 3 REPEAT THIS SCHEDULE WITH SECOND COAT OF GRADE 3 REFERENCE NUMERICAL LEGEND F09603 094 Figure 6 2 Special Purpose Vehicles Full Tracked Tractors Sheet 10 6 32 TO 36 1 191 6 2 IAM 1 USE GRADE 1 SPRAY ALL METAL UNDERNEATH SWEEPER UNDER ALL FENDERS SPRAY INTO ALL BOXED IN AREAS 2 USE GRADE 1 SPRAY INSIDE DOORS AND CAB CORNERS HINGES AND HINGE BOXES SPRAY INSIDE ALL CAB ROOF AREAS SPRAY UNDER HOOD AND ALL AREA AROUND MOTOR SPRAY BATTERY BOX AND TERMINALS 3 USE GRADE 2 SPRAY ALL EXTERIOR SURFACE METAL TO METAL JOINTS SPRAY AROUND ALL WINDOW SEAMS SPRAY ALL AREAS AND GEARS ON AND AROUND ROTATING BRUSHES SPRAY INTERIOR OF ALL COMPARTMENTS AND CAB FLOORS 4 USE GRADE 2 SPRAY BOTH SIDES OF ALL WHEELS RIMS AND LUGS 5 USE GRADE 4 SPRAY COMPLETE ELECTRICAL SYSTEM LIGHT SOCKETS SPARK PLUGS COILS GENERATOR DISTRIBUTOR INSTRUMENT PANEL ETC 6 USE GRADE 3 FOR VEHICLE RADIATOR ELECTROLYSIS CONTROL SPRAY BOTH EXTERIOR SIDES OF RADIATOR CORE WITH A FIRST COAT OF GRADE 3 REPEAT THIS SCHEDULE WITH A SECOND COAT OF GRADE 3 REFERENCE NUMERICAL LEGEND F09603 095 Figure 6 2 Special Purpose Vehicles Full
189. ER in 3 inch silver reflective letters red back ground will be centered vertically and horizontally on each side and rear of the tank 2 62 PUMPING DURING COLD TEMPERATURES 2 62 1 The marking OPEN MANHOLE COVER WHEN PUMPING FUEL OIL OR WATER AT TEMPERATURES BELOW 25 DEGREES F will be placed on all fuel oil and water dispensing units except Refuelers with power operated vents and an interlock system that prevents fuel from being pumped out of the pumping system tank unless the vent is open such as the R 11 Refueler Marking will be placed in an area as near as possible to the pump compartment Marking will be 2 inch silver letters on a reflective red background 2 62 2 On two wheel trailers the marking as indicated in the preceding paragraph will be centered on the lower half of tank 2 68 MANHOLE COVER AND NOZZLE MARKINGS Application and size of manhole cover and nozzle markings These markings shall be applied to all manhole covers and nozzles on aviation and rocket fuel and oil dispensing units Oil dispensing units may be marked by stenciling with black paint color number 17038 or using reflectorized markings Exhibit A amp B Jet fuel and AVGAS dispensing units will be marked as follows 2 63 1 Jet Fuel Dispensing Units Manhole cover and nozzle markings on jet fuel dispensing units shall be applied using decals or stencils with red paint number 31136 as illustrated in exhibits A amp B 2
190. F Recruiting Service 2 53 3 Recruiting decalcomanias will be centrally pro cured by Headquarters USAF Recruiting Service Randolph Air Force Base Texas 2 54 COMMUNICATIONS AND GROUND CONTROL APPROACH VEHICLES Bodies of van type vehicles and those vehicular types which are components of AGE sets systems containing communi cations and ground control approach equipment and located or operated on landing areas runways or taxiways will be painted with the Conventional checkerboard markings on alternate blocks of Aviation orange and white The size of the checkerboard blocks will be such that there will be not less than four nor more than six longitudinal rows This pattern of marking will be applied to the antenna housing roof sides rear and frontal area which is unobstructed by the vehicular cab Chassis and cabs will be painted yellow color number 13538 van type radar and flight control sets having rotating search antennas mounted on the hood will have a circular 3 inch wide strip of red reflectorized tape conform ing to specification LS 300 applied just outside the area covered by the antenna during rotation The following state ment will be stenciled using a contrasting color enamel just outside this area in such a position that it can be read by personnel approaching the area from the mounted ladder 2 16 Search reflector scan area Insure that safety switch S 134045 is in safe position before enter
191. F THE PILLAR INSERT SHORT CURVED WAND IN A DOWNWARD DIRECTION IN SOME CASES THIS OPENING WILL PROVIDE ACCESS TO THE AREA BEHIND THE FRONT FENDER AND BAFFLE SPRAY WITH GRADE 1 IF THIS AREA IS NOT ACCESSIBLE FROM THE TRUNK DRILL A 1 2 INCH HOLE IN A NON CRITICAL STRUCTURAL AREA OF THE POST THE HOLE SHOULD BE LOCATED WHERE THE TWO PANELS DIVERGE ENOUGH TO PROVIDE ROOM TO INSERT THE CURVED WAND IN A DOWNWARD DIRECTION POSITION OF HOLE TO SPRAY INSIDE REAR DOOR PILLAR F09603 075 Figure 6 1 Commercial General Purpose Vehicles Areas of Application Sheet 3 6 13 TO 36 1 191 APPLICATION SAG INSIDE A PX SPRAYING WINDOWS SHOULD BE IN RAISED POSITION ON SOME VEHICLES PLUGGED INSPECTION HOLES CAN BE USED IF NONE ARE AVAILABLE 1 2 INCH HOLES MUST BE DRILLED CHECK DRAIN HOLES IN BOTTOM EDGE OF DOOR TO BE SURE WATER HAS DRAINED FROM DOOR HOLE SHOULD LOCATED IN EACH DOOR END PANEL APPROXIMATELY SIX TO EIGHT INCHES FROM THE BOTTOM INSERT LONG STRAIGHT WAND TO TREAT THE LOWER DOOR PANEL AREA DIRECT SPRAY DOWNWARD TO PREVENT COMPOUND FROM REACHING WINDOW REGULATOR AND TO INSURE COMPLETE COVERAGE OF THE CRITICAL AREAS INSIDE THE DOOR PLUG ALL HOLES CHECK DRAIN HOLES TO BE SURE THE ARE OPEN USE GRADE 1 DOG LEGS AND BOXED IN SECTION USE GRADE 1 FROM INSIDE TRUNK SPRAYING BETWEEN WHEELHOUSE AND REAR FENDER QUARTER PANELS TYPICAL RUST AREA BOLT ON FENDER
192. F09603 020 Figure 2 17 20 Ramp Fire Truck 24 IN NUMBERS F09603 021 Figure 2 18 23 Ramp Fire Truck TO 36 1 191 OPTIONAL SIZE NUMBER 14 IN NUMBERS SS IN LETTERS Erano Figure 2 19 24 Ramp Fire Truck BEFORE TOWING LATCH PINTLE CLOSE TRIP LOCK INSTALL LOCK PIN F09603 023 Figure 2 20 Manual Release Pintle Hooks 2 37 TO 36 1 191 F09603 024 Hydrant Fueling Truck Sheet 1 of 2 Figure 2 21 2 38 TO 36 1 191 Te AY Dus per he F09603 025 Hydrant Fueling Truck Sheet 2 Figure 2 21 F09603 026 Figure 2 22 Strike Hazard Marking 2 39 TO 36 1 191 US AIR FORCE 92L00525 FLAMMABLE NO SMOKING WITHIN 50 FT FLAMMABLE NO SMOKING WITHIN 50 FT CARGO FIRE AVOID WATER TAPE F09603 027 Figure 2 23 Highlighting Marking Refueling Vehicles DE MINERALIZED WATER DS AIR FORCE CAUTION WATER NOT FIT FOR DRINKING BTL 805 1 CAUTION WATER NOT FIT FOR DRINKING fj U S AIR FORCE BTL 805 W F09603 028 Figure 2 24 Demineralized Water Truck 2 40 TO 36 1 191 Figure 2 25 UDMH Hydrazine Semi Trailer F09603 030 Figure 2 26 N204 Semi Trailer 2 41 TO 36 1 191 22 LIQUID OXYGEN M Y d NO SMOKING WITHIN F09603 031 Figure 2 27 Liquid Oxygen Unit 2 42 eu LIQUID NITROGEN 1 F09603 032 Figure 2 28 Liquid Nitrogen Trailers and
193. GEN or NITROGEN as applicable will be applied in 3 inch high letters on the control panel immediately below or adjacent to the pressure regulator assembly In addition the word OXYGEN or NITROGEN as applicable will be applied in 3 inch letters on the control panel immediately below or adjacent to the pressure regula tor assembly In addition the word OXYGEN or NITRO GEN as applicable will be applied in 3 inch high letters on each side and near the top of the cylinder enclosure On trailers which have no enclosure all cylinders will be painted according to TO 42B5 1 2 for the material contained within the cylinders Cylinders will be identified as indicated in TO 42B5 1 2 so that each cylinder will have the name of the gas contained within stenciled parallel to the longitudinal axis and on diametrically opposite sides in letters 1 3 4 to 2 inches high White enamel will be used on both oxygen and nitrogen cylinders Due to space limitations no attempt will be made to mark control panel on this type trailer 2 68 2 Service Point Markings Service point markings as prescribed by MIL STD 101B for oxygen and nitrogen will be applied by stencil to all delivery line nozzles using full gloss black paint color number 17038 or by use of decals Two horizontally filled rectangles represent oxygen A filled square with a quarter arc removed from each corner repre sents nitrogen NATO CODES have not been assigned for oxygen or nitrogen and ther
194. IDE DOOR HINGES INNER COMPARTMENTS AND ALL METAL TO METAL JOINTS SPRAY LIGHT COATING OVER ENTIRE EXTERIOR SURFACE IF FILM IS TOO HEAVY WIPE OR POLISH WITH CLEAN CLOTH 3 USE GRADE 2 SPRAY ALL WHEELS BOTH SIDES RIMS LUGS 4 USE GRADE 4 SPRAY COMPLETE ELECTRICAL SYSTEM DASH PANEL LIGHT SOCKETS SWITCHES SPARK PLUGS DISTRIBUTOR GENERATOR ELECTRIC MOTORS ETC 5 USE GRADE 3 FOR VEHICLE RADIATOR ELECTROLYSIS CONTROL SPRAY BOTH SIDES OF EXTERIOR RADIATOR CORE WITH 1 COAT GRADE 3 THEN FOLLOW SAME PROCEDURE WITH SECOND COAT OF GRADE 3 REFERENCE NUMERICAL LEGEND F09603 089 Figure 6 2 Special Purpose Vehicles Full Tracked Tractors Sheet 5 6 27 TO 36 1 191 1 USE GRADE 1 IN ALL AREAS UNDERNEATH OF FORKLIFT ALL CLOSED IN AND BOXED IN AREAS SPRAY BATTERY BOX AND TERMINALS 2 USE GRADE 2 ON HOIST CHAIN SPROCKETS AND MAST ROLLERS HOSE REELS AND ON ALL SURFACE METAL TO METAL JOINTS SPRAY LIGHT FILM OVER ENTIRE EXTERIOR SURFACE IF FILM THICKNESS IS TOO HEAVY WIPE OR POLISH WITH A CLEAN CLOTH SPRAY BOTH SIDES OF ALL WHEELS RIMS AND LUGS SPRAY EXTERIOR SURFACE OF FLOOR PLATES 3 USE GRADE 4 SPRAY ON COMPLETE ELECTRICAL SYSTEM LIGHT SOCKETS IGNITION SWITCHES ETC 4 USE GRADE 3 TO CONTROL RADIATOR ELECTROLYSIS SPRAY FIRST COAT WITH GRADE 3 ON BOTH EXTERNAL SIDES OF RADIATOR CORE REPEAT SCHEDULE FOR SECOND COAT USING GRADE 3 REFERENCE NUMERICAL LEGEND F09603 090 Figure 6 2 Speci
195. ION This Appendix includes the instructions for Level A and Level B long term storage of the TUNNER 60 K Aircraft Cargo Loader Table A 1 includes the steps required to preserve the TUNNER in the recommended sequence Spe cial considerations required to remove the TUNNER form long term storage are included in the right hand column and should be performed in reverse order unless otherwise speci fied Operation of the TUNNER requires special knowledge and procedures that operators of other vehicles are not familiar with For this reason copies of TO 36M2 3 35 11 and TO 36M2 3 35 12 should be used by the personnel performing the specified operational and maintenance tasks For level A long term storage of the TUNNER in one location the TUNNER will be in the normal configuration not reconfigured for air transport The chassis will be lowered until the suspension is almost fully contracted with the chassis resting on four 6 inch blocks or beams relieving pressure from the suspension system The deck will be lowered fully until it is firmly on the chassis Other configu rations may be required for various modes of transportation for Level A and B storage and are described in TO 36M2 3 35 1 but after transport when parked for storage it shall be lowered to the position described above and in Table 1 under Chassis for Level A For reduction of the cube the cab may be moved inboard using procedures in TO 36M2 3 35 11 Paragraph
196. ISPOSITION OF VEHICLES Vehicular equipment maintained in AFEMS and reported in the VMIF at https sevpgm robins af mil vehicle vmif section2 asp are coded as to criticality Those that are considered critical in accordance with AFMAN 23 110 are coded and those that are non critical are coded N Based on criticality disposition requests are processed as follows 5 27 1 Disposition request for vehicles coded which are obsolete exceed their age or utilization miles hours or kilometers life expectancy or are uneconomically reparable will be forwarded to the squadron commander or operations officer Upon approval of the squadron commander or opera tions officer the vehicle will be processed directly to the disposal activity 5 27 2 Vehicles coded which are serviceable or are economically reparable and those coded regardless of condition when declared excess to the need of the major command will be reported to WR ALC LE for disposition or redistribution action 5 27 3 AFTO Form 91 Limited Technical Inspection Motor Vehicle will be prepared by the responsible vehicle management activity and forwarded with each vehicle dispo sition request to the MAJCOM LGTV 5 28 REPLACEMENT CODES Vehicle replacement codes identify the status of the fleet for replacement programming These codes generated in OLVIMS denote eligibility for immediate replacement or signal the need for pr
197. L OF TIRES 4 35 4 28 MOUNTING AND DEMOUNTING 4 52 SUPPLY POINT 4 35 TUBELESS TIRES 4 17 4 53 RESPONSIBILITIES 4 35 4 28 1 Demounting 4 17 4 54 TURN IN PROCEDURES FOR 4 29 TUBE TYPE TIRES 4 19 UNSERVICEABLE TIRES 4 35 4 30 INNER TUBES 4 19 4 55 PROCEDURES FOR REPAIR 431 TIRE FLAPS 4 19 ABLE RETREADABLE TIRES 4 35 439 RIMS 4 19 456 SEASONAL TIRE STOCKS 4 36 433 4 21 457 STORAGE OF TIRES 4 36 4 34 DETACHABLE RIMS 4 22 4 58 TIRE COSTING 4 36 4 35 DROP CENTER RIMS 4 22 4 59 TIRE WARRANTIES 4 36 4 36 SERVICING MULTI PIECE RIM 4 60 INVENTORY CONTROL 4 36 WHEELS oo sists net deea 4 24 4 61 THE TIRE AND RIM ASSOCIA ABOI BAG KE 4 24 TION YEARBOOK 4 37 4 36 2 Definitions 4 24 4 62 CONVERSION TABLES 4 37 4 36 3 Employee Training 4 24 4 36 4 Tire Servicing Equipment 4 25 5 REPAIR ALLOWANCES AND REPLACE 4 36 6 Wheel Component Acceptability 4 25 MENT CODES 1x2 eere seen news 5 1 4 36 7 Safe Operating Procedure 4 26 4 36 8 Ordering Information 4 31 5 1 PURPOSE 4 6 08 BARES DSSS 5 1 4 37 USE OF STUDS IN TIRES 4 32 2 2 GENERAL 5 1 4 38 TIRE INFLATION 4 32 5 3 SCOPE is
198. LE Red Silver 6 in 7 in X 54 in 3613005 FLAMMABLE Red Silver 4 in 5inx36in 3613006 FLAMMABLE ARC Red Silver 4 in 10 in x 66 in 3613007 NO SMOKING WITHIN 100 FEET 2 Silver Red 6 in 14 1 2 in x 84 in lines of copy as shown 3613008 JET FUEL JP4 Silver Red 6 in 7 in x 55 in 3613009 FUEL Silver Red 4 in 5in x 40 in 3613012 91 96 Silver Red 4 in 5inx 30 in 3613013 91 96 Silver Red 6 in 7 in 42 in 3613016 WATER ALCOHOL Silver Red 6 in 7 in 66 in 3613453 UDMH Die cut pre spaced Blue Silver 4 in None 3613455 Black None 1 1 2 in 3613452 AMBULANCE Die cut pre spaced Black None 3 in None 3613411 RED CROSS SYMBOL Reflective Pre Omaha Orange 3inx3in 4inx4 in masked White 3613412 RED CROSS SYMBOL Reflective Pre Omaha Orange 6inx6in 8 in x 8 in masked White 3613413 RED CROSS SYMBOL Reflective Pre Omaha Orange 18 in x 18 in 24 in x 24 in masked White 3613414 US AIR FORCE Die cut Pre spaced Black None 1 1 2 in None 3613415 Letter A Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613416 Letter B Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613417 Letter C Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613418 Letter D Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 2 48 TO 36 1 191 Part No Legend Or Symbol Colors Letter Or No Emblem Size size 3613419 Letter E Die cut pre spaced Black None 1 1 2 in 2 in x 1 4 in 3613420 Letter F
199. MN COLUMN II IV V Component Level Type of Vehicle Processing Required Gasoline is flammable and toxic to eyes skin and respiratory tract Avoid skin and eye contact Good general ventila tion is normally adequate Keep away from open flames or other sources of ignition Engines Gaso A B AM Engine fuel intake line shall be disconnected at line the most easily engine For injector type en gine injector fuel return line shall be discon nected at the quick disconnect coupling A line shall be connected to the injector fuel return quick disconnect coupling to permit draining into a recovery container Recovered fuel oil mixture shall not be used for preserving other engines Engine shall be started and operated at fast idle until running smoothly then accelerate to 3 4 speed without load at the same time fuel supply shall be switched to VV L 800 Type P 9 preservative oil The instant the engine begins to misfire turn off ignition and disconnect line from portable container engine and vehicle fuel line reconnected Prior to continuation of preser vation engine shall be cooled to a cylinder head temperature of not more than 100 F Cooling may be accelerated by use of induced air currents Spark plugs shall be removed exer cising maximum care in handling to avoid dam age to threads and electrodes during preserva tion While engine is being cranked with starting motor two ounces of P 10 Type I Grade 30 preservative
200. NTHS NOTE When this section of the form is completed DO NOT submit to Ford Motor Company unless a repair is required beyond warranty but within the mileage extension period MAIL TO FORD CUSTOMER SERVICE DIVISION FCS 900 11 98 PREVIOUS EDITIONS MAY NOT BE USED P O BOX 1597 DEARBORN MI 48121 F09603 099 Figure 7 2 Delayed Delivery Form Ford Motor Company 7 8 TO 36 1 191 GENERAL MOTORS DELAYED WARRANTY START General Motors Vehicle Information Vehicle Identification Number GM VIN ALL 17 CHARACTERS 6 7 8 8 10 11 12 13 14 15 16 17 Vehicle Date __ Odometer Reading ________ X NOTONS Check if Isometers Vehicle Application RV Political Subdivision Commercial Coach CIRCLE ONLY ONE Date odometer reading at first retail sale updated special body equipment recreational commercial or coach vehicle Date odometer reading when vehicle is placed in service by a GM authorized seat or political subdivision Customer Information Customer Name Business Political Subdivision Address STREET STATE ZIP PROVINCE POSTAL CODE Phone Customer Signature Sales Information GM Dealer Retailer Code Retail Outlet Address STREET STATE ZIP PROVINCE POSTAL CODE Phone AREA Retail Outlet Dealer Signature 7 7 _ Reason for Delayed Warranty Start This for
201. NTLE CLOSE TRIPLOCK INSTALL LOCK PIN F09603 009 Figure 2 6 Warehouse Tug TO 36 1 191 yy v BLACKENED OUT AREAS REPRESENT HIGHLIGHT MARKINGS SILVER TAPE REFLECTORIZED STRIPE Hi 4 ag FINT NUN ET E sr CORN F09603 010 Figure 2 7 Highlighting Marking Aircraft Cargo Handling Truck WATCH STEP HARNESS REQUIRED F09603 01 1 Figure 2 8 Harness Required Area 2 31 TO 36 1 191 TAPE F09603 012 Figure 2 9 Highlighted Markings Age Towing Tractor U S AIR FORCE 87L 502 FLAMMABLE E etas MOGAS 91 98 FLAMMABLE F09603 013 Figure 2 10 Fuel Trailer Two Wheel 2 32 TO 36 1 191 F09603 014 vaL 0 8 3ouo4 SN H3JVM GIOAV 3uld M0139 09 NIH LIM SNIMOWS ON H31VM 110 ONIdWNd N3HM AdALLAOV Su3AOO 3 IOHNVIN N3dO Fuel or Oil Servicing Trucks Figure 2 11 2 33 TO 36 1 191 F09603 015 F09603 016 Figure 2 13 Waste Fuel Vehicle 2 34 TO 36 1 191 F09603 017 2o A qe RO 07 AE A s Nis te 1 IN 6 IN 1 IN STRIPING F09603 018 Figure 2 15 18 Water Tanker Fire Truck 2 35 TO 36 1 191 2 36 TOP 24 IN NUMBERS 3 5 IN LETTERS 16 IN NUMBERS 1 IN 6 IN 1 IN STRIPING F09603 019 Figure 2 16 19 Fire Truck 1 IN 3 IN 1 IN STRIPING 2 5 IN LETTERS 10 IN NUMBERS
202. Nozzles Fuel A SP Servicing and Crash Fire B SP COLUMN V Processing Required Disconnect air line to each air motor at the con nection Atomize spray interior of motor with grade 1 P 10 preservative oil No processing required a Seal all openings to electric windings with tape Specification MIL T 43115 level B MIL T 22085 Affix a warning tag REMOVE PACK AGING TAPE PRIOR TO OPERATION Openings of explosion proof spray tight totally enclosed and watertight fan cooled motors where cooling air does not flow over the wind ings need not be taped b Apply Type P 1 preservative to unpainted exter nal metal surfaces Do not permit preservative on any rotat ing part from which it may be thrown on the windings Insulating varnish Specification MIL V 24092 shall be applied to such parts c Shafts and rigid couplings shall be coated with Type P 1 preservative Flexible couplings shall be coated with grease Specification MIL G 10924 See Item 55 a Installed turret bumper underbody etc nozzles not requiring removal to reduce cubage or prevent breakage or pilferage in transit shall be coated with Type P 3 preservative and wrapped and cushioned with barrier material Specification MIL B 121 grade A Protective covers provided shall be secured in place When no such cover is provided the nozzle preserved as above shall be over wrapped with barrier material conforming to Specification MIL B 13239 Type B
203. OLISH OR WASH WITH DETERGENTS BEFORE enter date WASH AS OFTEN AS NECESSARY WITH WATER ONLY The time element will coincide with the paint manufacturer s recommendation 2 22 4 The painted finish of garnish moldings and instru ment panels of the interiors of sedans will not be painted if the finish is serviceable and if restoration to original condition can be accomplished by cleaning and applying wax com pound 2 22 5 Chemical Agent Resistant Coating CARC Paints 2 22 5 1 CARC finish is not generally required and will not be specified for the majority of Air Force acquisitions Where CARC is essential to a user s mission CARC will be specified MAJCOM or WR ALC may challenge a user s stated need for CARC and where validated will then approve its use 2 22 5 2 Air Force will accept CARC painted vehicles procured through TACOM when it would add cost to the Air Force procurement to deviate from CARC finishing regard less of user s need 2 22 5 8 Owning units will maintain the CARC finish for vehicles where CARC need has been validated For all others units may either maintain the CARC finish or refinish with non CARC polyurethane or enamel paint when refinishing becomes necessary 2 22 5 3 1 CARC has been validated the preferred replacement material is Chemical Agent Resistant Aliphatic Polyurethane Water Dispersible MIL DTL 64159 2 22 5 3 2 This specification covers water dispersible chemical agent
204. R ALC LE 7 17 1 Basic Warranty Coverage The contractor shall warrant the vehicle and furnished equipment against parts failure or malfunction due to design construction or instal lation errors defective workmanship and missing or incor rect parts exceptions see Paragraph 7 18 for a minimum period of 12 months and 15 months for vehicles outside the contiguous 48 United States from date of acceptance or 12 000 miles of operation exclusive of any accumulated drive away mileage whichever occurs first Warranty cover age shall include any defects or shortcomings under Para graph 7 17 The warranty begins when the Government accepts the vehicle from the contractor FOB point of origin destination 7 17 2 Extended Coverage In addition to the basic coverage the contractor shall provide chassis manufacturer s commercial powertrain component warranty This coverage shall be for at least three years from date of acceptance or 50 000 miles exclusive of accumulated drive away mileage whichever occurs first This coverage applies only to domes tic use General Motors Ford and Chrysler have agreed to extended coverage for parts only for those vehicles procured by WR ALC that are used outside the 50 states of the United States TO 36 1 191 7 17 3 Corrosion Coverage contractor shall pro vide the chassis manufacturer s commercial corrosion cover age This coverage shall be for at least 5 years 100 000 miles General Motor
205. RE SIZE TYPE AND INFLA TION PRESSURE SCHOOL BUS SAFETY MARK INGS uS D O T MOTOR CARRIER SAFETY REGULATION MARK INGS 2 gsc bee aoe Rex FUEL DISPENSING AND AIR CRAFT SERVICING VE HICLES NO SMOKING WITHIN FIFTY FEET og Se vende ae NE qoa PRODUCT IDENTIFICATION Demineralized Water Trucks Potable Water Trucks PUMPING DURING COLD TEM PERATURES MANHOLE COVER AND NOZZLE MARKINGS Jet Fuel Dispensing Units Avgas Dispensing Units HYDRANT FUELING TRUCKS PURGING FLUID VEHICLES WASTE FUEL VEHICLES RECLAIMED FUEL VEHICLES GASEOUS SERVICING TRAIL ERS EE Yd xS PROPELLANT SEMITRAILERS FIRE FIGHTING VEHICLES OPERATING INSTRUCTIONS CONTINENTAL OR LYCOMING AIR COOLED ENGINES Page 2 13 2 14 2 14 2 18 2 18 2 18 2 18 2 20 2 20 2 20 2 20 2 21 2 21 2 22 2 22 Chapter 2 73 MARKING SECURITY FORCE VEHICLES 5 5 sa 2 74 ALERT REFLEX BASE OPS AND BASE CIVIL ENGINEER FIRE MARSHAL 2 75 FOLLOW ME VEHICLES 2 16 LOW VISIBILITY MARKING SNOW REMOVAL EQUIP MENT beat 2771 MARKING EXPLOSIVE ORDI NANCE DISPOSAL VE HICLES 2 78 MARKING VEHICLES EQUIPPED WITH MS51335 SERIES PINTLE HOOKS 2 79 SLOW MOVING VEHICLE EM BLEEM x xke ES 2 80 STRIKE HAZARD MARKINGS 2 81 CENTER OF BALANCE MARK INGS n ai edt eh og Peete ege 2 82 NOISE HAZARD MARKING 2 83 MARKING CAMOUFLAGE P
206. ROCESSING 8 1 d i a s e ewan oe 8 3 3 Intra Organizational Responsibility 8 1 asic Warranty Coverage 7 8 3 4 Deprocessing 8 1 D ripe dc ID d 84 WATER EXPORT OVERSEAS 8 1 17 orrosion Coverage 8 8 5 LEVELS OF PRESERVATION 8 1 7 17 4 Emission Control System 7 3 8 6 PROCESSING PROCEDURES 8 2 7 17 5 Domestic saccus 7 3 87 EXPLANATION OF COLUMNS 8 2 i 8 8 PRELIMINARY ACTIONS 8 52 17 arranty Extensions 8 8 1 Administrative 8 52 7 17 9 Warranty For Trailers 7 6 O82 8 52 7 18 WARRANTY EXCEPTIONS 7 6 8 8 3 Responsibility 8 53 7 18 1 Tires and Batteries 7 6 8 9 PRE STORAGE PREPARATIONS 8 53 7 18 3 Nonwarranty Period Adjustments TI 8 9 1 Cleaning 8 53 7 18 4 Tactical Vehicle Warranty 7 7 8 9 2 Painting 8 53 7 19 SERVICES AND 741 8 9 3 General Processing 8 53 7 8 9 4 Disassembly 8 53 7 20 DELIVERY CONDITION 7 11 8 9 5 Marinas OCT 8 53 7 21 SPECIAL WARRANTY PROCE 8 9 6 Historical Records 8 53 E UU MIN 89 7 Marking 8 53 STATES AND THE DISTRICT 8 10 PRE STORAGE ACTIONS 8 53 OF COLUMBIA 7 11 8 11 MAINTENANCE 8 54 erani RED 8 11 2 Outshipment 8 54 7 21 1 Air Force Warranty Correcti
207. ROVAL The base VFM after determining that major repair is justified see Paragraph 5 22 will request a repair decision using the following procedures 5 25 1 Prepare a limited technical inspection AFTO Form 91 listing only those major and minor repairs necessary to return the vehicle to a safe and serviceable condition 5 25 2 Furnish a complete written evaluation of the vehicle s overall condition 5 25 3 Forward AFTO Form 91 and evaluation via cover letter to Logistics Readiness Squadron Commander or equivalent may be delegated as appropriate for approval or disapproval F09603 068 One Time Repair Computation Worksheet 5 25 4 Refer to Chapter 9 for guidance on submitting requests for depot level repair NOTE Preserve the vehicle as required by Chapter 8 to prevent further deterioration while waiting for a repair decision 5 26 CRITERIA FOR APPROVAL OF MAJOR RE PAIRS Logistics Readiness Squadron Commander or equivalent may be delegated as appropriate may authorize major repairs to uneconomically reparable vehicles when 5 26 1 Vehicle is not obsolete 5 26 2 Vehicle is not excess to base authorization 5 26 3 Vehicle is essential to base mission 5 26 4 Replacement cannot be effected by redistribution of a serviceable like item 5 26 5 Suitable substitute is not available from base onhand inventory 5 26 6 New procurement replacement vehicle will not be available within 90 days 5 27 D
208. Rodent Control Insect and rodent control are the responsibilities of the Installations Engineer ing Office 8 13 LOADING 8 13 1 Rail Shipment Loading of vehicles on open top cars for shipment by rail shall be in accordance with the applicable requirements of the rules issued by the Association of American Railroads 8 13 2 Highway Shipment Loading of vehicles for shipment by highway and rules for shipment by haul away drive away or tow away shall be in accordance with U S 8 55 TO 36 1 191 Department of Transportation Federal Highway Administra tion Motor Carrier Safety Regulations and applicable Mili tary Regulations 8 13 3 Guidance in particular cases may be obtained from local LRS Vehicle Management Flight 8 14 GENERAL DEPROCESSING 8 14 1 Introduction This provides minimum dures to maintain Air Force vehicles in operating condition ready for immediate use with minimum deprocessing during storage for indefinite periods These procedures will be implemented only when the requirement for immediate operational readiness will not permit the delays incident to standard processing and deprocessing for storage and ship ment Authority to implement must be obtained from WR ALC LE When this technical order is specified contractually use of these procedures is not authorized unless special provision implementing this section is effected 8 14 2 Scope These procedures are minimum mea sures It
209. Shimmy symptoms a static or dynamic balance is required 4 8 4 15 2 1 Static out of balance See Figure 4 9 4 15 2 2 Dynamic out of balance See Figure 4 10 4 16 WHEEL NUT TORQUE Tire shop personnel will obtain wheel nut torque values from manufacturer s service manuals and formulate a chart or quick reference list to be used by personnel mounting tires This reference will be readily available to the tire shop 4 17 SAFETY ECONOMY AND SERVICE Tires are being offered in increasing numbers of sizes and constructions to provide added safety improved economy and special service capabilities EPA findings indicate that up to a 10 percent fuel savings can be obtained by using radial tires of the largest practical size and by keeping them inflated to upper inflation limits Users must however avoid inter mixing belted bias radial and bias ply tires on one vehicle Each type of construction reacts differently under the same load a mixture may cause sideslip wandering fishtailing etc 4 18 SELECTION OF PNEUMATIC TIRES Carcasses from tires requiring replacement must accompany replacement requisitions on a one to one basis Replacement tires will be selected from base supplies of recapped tires federal supply lists GSA schedules or commercial dealer stock in that order Refer to Paragraph 4 24 of this technical order tor directives relative to recapped tires Tire type will be determined by application i e
210. Shipment Grilles louvers around and over engine and control compart ments which allow entry of water will be cov ered with waterproofed paper conforming to Specification PPP B 1055 secured with tape Specification MIL T 43115 for level B MIL T 22085 for level A On vertical panels where ventilation is desired the tape will not be ap plied at bottom edge 64 Hardware A B AM Lubricate and coat unpainted machined surfaces Hinges etc with Type P 9 preservative oil 65 Horn Button A AV See Items 11 and 29 B AV No processing required 8 35 TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN COLUMN I II Item Component Level Type of Vehicle Processing Required 66 Hose Gasoline A SP a Disconnect hose and drain clean and dry with and Fire Ex dry oil free compressed air or other acceptable cept oxidizer means Replace gaskets as necessary and recon transfer or nect propellant b For storage within compartments cover dis system ser charge end of hose and coupling with barrier vicing conforming to Grade A Class 2 of Specification MIL B 121 secured with tape conforming to Specification MIL T 22085 Where the hose may be exposed to the weather discharge ends and couplings prepared as above shall be over wrapped with barrier conforming to MIL B 131 Class 1 sealed with tape con forming to Specification MIL T 22085 Exposed reels or storage compartments not provided
211. TECTION IS DESIRABLE SPECIAL TRUCKS AND TRUCK AS REQUIRED IN ACCORDANCE WITH THE FOLLOWING INDIVIDUAL MOUNTED EQUIPMENT INSTRUCTION SHEETS F09603 081 Figure 6 1 Commercial General Purpose Vehicles Areas of Application Sheet 9 6 19 TO 36 1 191 EXTERIOR LIGHT LOAD OF GRADE 2 MAYBE SPRAYED ON COMPLETE EXTERIOR SURFACES OF VEHICLE WIPE OFF EXCESS IF FILM THICKNESS TOO HEAVY FOR PERSONNEL CONTACT AREAS QUARTER PANEL ROOF PANEL CENTER SECTION DOOR PANEL TAIL LIGHT FRONT FORWARD PANELS SECTION FORWARD HEADLIGHT PANELS FRONT FENDER SECTION REAR GRADE 5 DOOR PANELS amp TOP REAR DOORS amp WINDSHIELD INNER HEADLIGHT PANELS di ROCKER PANELS REAR FENDERS REAR RENDER FRONT FENDER WELLS WELLS INTERIOR F09603 082 Figure 6 1 Commercial General Purpose Vehicles Areas of Application Sheet 10 6 20 TO 36 1 191 1 USE GRADE 1 COAT ALL METAL UNDERNEATH VEHICLE SPRINGS RUNNING GEARS FENDER WELLS AND ALL BOXED IN AREAS IF INNER PANELS CAN T BE REACHED FROM UNDERSIDE OF VEHICLE REMOVE PANELS FROM INSIDE OR DRILL 1 2 IN HOLES FOR SPRAY NOZZLE INSERTION 2 USE GRADE 1 COAT ENTIRE INSIDE ROOF AREA REMOVE HEADLINER OR DRILL 1 2 IN HOLES IF NECESSARY TO REACH THESE AREAS COAT INSIDE ALL DOORS UNDERNEATH HOOD AND HOOD EDGE ALL AREA SURROUNDING MOTOR BATTERY BOX AND TERMINALS RAISE FLOOR MAT AND SPRAY ALL FLOOR AREA
212. THE REAR FENDERS MAY BE POSSIBLE THROUGH THE TRUNK WHEN THE VEHICLE IS ON THE FLOOR BE SURE TO COAT THE FENDER BEAD USE GRADE 1 REAR TRUNK AND 5 FENDER AREA Au USE GRADE 1 FO9603 077 Figure 6 1 Commercial General Purpose Vehicles Areas of Application Sheet 5 6 15 TO 36 1 191 APPLICATION ALL JOINTS SEAMS AND MOULDINGS AROUND WINDOWS AND WINDOW TRIM USE GRADE 2 USE GRADE2 BODY JOINTS SEAMS AND CHROME MOULDINGS ALL INNER AREAS AND BOXED IN SECTIONS COMPLETE SOME VEHICLES WILL HAVE ACCESS HOLES AT EACH END REMOVE PLUGS AND INSERT LONG STRAIGHT WAND AS FAR AS IT WILL GO SPRAY CONTINUOUSLY AS WAND IS WITHDRAWN REPLACE PLUGS FOR VEHICLES WITH OPENINGS IN THE BOTTOM OF ROCKER PANELS ENLARGE THE OPENING WITH A DRIFT INSERT SHORT CURVED WAND AND SPRAY IN THE SAME MANNER IF ACCESS CANNOT BE GAINED BY EITHER OF THE ABOVE METHODS A 1 2 INCH HOLE SHOULD BE DRILLED IN THE BOTTOM OF THE PANELS AND THE AREA TREATED WITH A SHORT CURVED WAND CENTER PUNCH BEFORE USING ELECTRIC DRILL CHECK DRAIN HOLES WHEN COMPLETED TO BE SURE THEY ARE OPEN ALL UNDERSIDE BODY FLOOR SUPPORTS ENCLOSED AND BOXED IN SECTIONS AS WELL AS EXPOSED AREAS USE GRADE INSERT GUN INTO BOXED CHANNELS UNDER FLO FRAME ALL EXTERIOR EXPOSED AREAS ON UNITIZED CONSTRUCTION ALL BOXED IN AND INTERIOR SECTIONS AS WELL USE GRADE 1 F09603 078 Figure 6 1 Commercial General Purpose Vehicles Areas of Ap
213. TO 36 1 191 TECHNICAL MANUAL TECHNICAL AND MANAGERIAL REFERENCE FOR MOTOR VEHICLE MAINTENANCE F09603 89 D 3074 BASIC AND ALL CHANGES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION This publication supersedes TO 36 1 1915 1 dated 13 July 2005 DISTRIBUTION STATEMENT Approved for public release distribution is unlimited WR ALC PA Cert No 05 07418 Other requests for this document should be referred to 542 MSUG GBMUDE Robins AFB GA 31098 Questions concerning technical content should be referred to 542 SEVSG GBZVS Robins AFB GA 31098 Published Under Authority of the Secretary of the Air Force 15 DECEMBER 2004 CHANGE 1 1 JULY 2005 TO 36 1 191 LIST OF EFFECTIVE PAGES INSERT LATEST CHANGED PAGES DESTROY SUPERSEDED PAGES NOTE The portion of the text affected by the changes is indicated by a vertical line in the outer margin of the page Changes to illustrations are indicated by shaded or screened areas or by miniature pointing hands Dates of issue for original and changed pages are Original 0 15 December 2004 1 July 2005 TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 322 CONSISTING OF THE FOLLOWING Change Page Change Page No No Zero in this column indicates an original page A Change 1 USAF Chapter LIST OF ILLUSTRATIONS LIST OF TABLES FOREWORD SAFETY SUMMARY 1 SERVICEABILITY STANDARDS 1 1 1 2 1 3 1 4 1 5 1 5 2 1 5 3 1 5 4
214. Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN COLUMN I II Item Component Level Type of Vehicle Processing Required Insecticides are toxic to eyes skin and respiratory tract They shall only be ap plied by certified Pest Control personnel 14 Bodies Passen S GP Protect cloth upholstery by spraying with insecti ger Car cide Remove drain plugs from deck of trunk Protect opening with suitable mesh screen to prevent entrance of insects Drain plugs shall be coated with MIL PRF 46002C 1 preservative oil except rubber plugs packaged in accor dance with 33 of Specification MIL STD 2073 1 and secured in trunk compartment Re quirements of Item 27 cabs hard top apply 15 Bodies Trailer B GP No special processing required and Truck with Wood Floor A AV Clean upper and lower surfaces of wood floors of foreign matter Apply a coat of Specification Wood Floor CID A A 59295 to lower surfaces of floors if unpainted Top surfaces of unpainted wood floors shall be rubbed down with raw lin seed oil Wood Floor CID A A 59295 Repeat application each six months or more often if necessary same as Level A requirement above if necessary 16 Boom Assem B AV Same as Level A requirement above if necessary bly A B SP Shipment Place block of wood on Wrecker rear frame cross member lower boom to rest on block of wood Loosen cables and rewind on drums secure cable to sheave asse
215. Tracked Tractors Sheet 11 6 33 TO 36 1 191 AREA APPLICATION 1 USE GRADE 1 SPRAY ALL METAL UNDERNEATH VEHICLE ALL RUNNING GEAR SPRINGS CLOSED AND BOXED IN AREAS UNDER FENDERS 2 USE GRADE 1 SPRAY INSIDE DOORS HINGES HINGE BOXES AND UNDERSIDE CAB ROOF 3 USE GRADE 1 SPRAY UNDER HOOD AND ALL AREAS AROUND MOTOR AND GRILL SPRAY BATTERY BOX AND TERMINALS 4 USE GRADE 2 SPRAY AROUND ALL WINDOW SEAMS AND EXTERIOR METAL TO METAL JOINTS SPRAY ALL EXTERIOR METAL SURFACES IF FILM THICKNESS IS TOO HEAVY AND SUBJECTED TO PERSONAL CONTACT WIPE OR POLISH EXCESS MATERIAL WITH A CLEAN CLOTH SPRAY INSIDE OF CAB FLOOR IF METAL IS EXPOSED 5 USE GRADE 2 SPRAY BOTH SIDES OF ALL WHEELS RIMS AND LUGS 6 USE GRADE 4 SPRAY COMPLETE ELECTRICAL SYSTEM LIGHT SOCKETS IGNITION DISTRIBUTOR GENERATOR SPARK PLUGS ETC 7 USE GRADE 3 TO CONTROL RADIATOR ELECTROLYSIS SPRAY BOTH EXTERIOR SIDES OF RADIATOR CORE SPRAY FIRST COAT WITH GRADE 3 REPEAT SCHEDULE AND SPRAY SECOND COAT WITH GRADE 3 REFERENCE NUMERICAL LEGEND F09603 096 Figure 6 2 Special Purpose Vehicles Full Tracked Tractors Sheet 12 6 34 ar Mio AN oa i reis afa c Be ide E sppL sist TO 36 1 191 E 1 USE GRADE 1 SPRAY ALL METAL UNDERNEATH TRACTOR SPRINGS RUNNING GEAR ETC SPRAY ALL ROLLERS ON TRACTOR CLEATS SPRAY UNDER SURFACE OF MOTOR HOOD AND ALL AREAS AROUN
216. Trailers And Semitrailers Except Rocket Fuel And Missile Propellant And Oxidizer Transporting Equip ment 8 22 3 4 1 These procedures are to be performed in addition to requirements specified in preceding paragraphs 8 22 3 4 2 operations and processes involving the cleaning preservation packaging and packing requirements specified herein should be coordinated with local LRS vehicle management flight Distribution Flight medical and safety personnel as appropriate in accordance with AFMAN 24 204 8 22 3 5 Main Fuel Tank The following procedures for preparation of fuel tanks for air shipment only 8 22 3 5 1 To prepare vehicles last designated for carrying combustible products flashpoint above 100 F use the fol lowing procedures 8 22 3 5 2 Static ground vehicle to an approved ground according to TO 00 25 172 8 22 3 5 3 Have appropriate fire extinguishers available 8 22 3 5 4 Completely dump and drain each fuel tank compartment including associated piping pumps filters and segregators Open all valves to remove fuel from tank pumping system using all available low point drains tank sump filter separator manual drain pump drain line strainer and bottom loading manifold Ensure all metal drain containers are grounded to fuel tank and common ground point Connections shall be made to clean unpainted surfaces Dis pose of full containers in accordance with AF MAN 23 110 and TO 42B 1 23
217. Trucks TO 36 1 191 2 43 TO 36 1 191 SEE DETAIL SEE DETAIL DETAIL A N LIFT HERE BLACK LETTERS LIFT HERE TIE DOWN TIE DOWN p E 3 S REAR VIEW CAPACITY RED FIG 2 IN BLACK LETTERS al TIRE PRESSURE TIRE PRESSURE SIDE VIEW F09603 034 Figure 2 30 Forklift Truck 2 44 2 90 1 The following materials are required for compli ance with this technical order Refer to Table 2 2 Table 2 2 Supply Information TO 36 1 191 Stock Number Acid Phosphoric metal conditioner 30 gallon drum Activator press sensitive adhesive 1 pint can Bar roof mounting Replacement for MEK and Lacquer Thinner Substitute for toluene xylene and MEK Cloth cotton cheesecloth unshrunk white Con struction II 50 yd bolt 36 in wide Fed Spec CCC C 440 Coating Compound Bituminous solvent black acid proof paint with asphalt base Spec MIL C 4501 medium solids Brushing and spraying con sistency type II 1 gallon Coating Compound Metal pretreatment acid resin Spec MIL C 15328A 5 gallon can Compound Grease cleaning type I nonphenolic 55 gallon drum Compound Grease cleaning type II phenolic 55 gallon drum Compound high pressure steam cleaning alkaline powder for metal surfaces 125 Ib drum Enamel Green Semi Gloss color no 34087 Enamel Green Olive Drab Disk abrasive closed coating grit 7 in diameter 7 8 in arbor hole
218. USE NSN TO 361 1 1301 NOMENCLATURE MFG MODEL ACTION ITEM NUMBER ALC USE ONLY SUBMITTED BY a b NAME RANK ORGANIZATION c d OFFICE SYMBOL TELEPHONE NUMBER SUBJECT PROBLEM RECOMMENDED SOLUTION CONF ACTION COMMENT 10 ACTION OPR 11 COMPLETION DATE 12 STATUS 13 BACK UPs AND WARRANTY REPORTS F09603 105 o RON Figure 7 7 VIWG Action Items 7 19 7 20 blank TO 36 1 191 CHAPTER 8 STORAGE AND SHIPMENT 8 1 PURPOSE The purpose of this chapter is to assist concerned personnel in the protection of Air Force vehicles by use of long and short term storage procedures Information contained herein will serve as a guide for preparing serviceable and economically reparable vehicles for storage and shipment In addition inspecting and servicing requirements for vehicles in storage awaiting shipment are provided 8 1 1 Vehicles which have been processed for storage in accordance with locally issued instructions should be repro cessed to the extent necessary for adequate preservation to comply with this publication 8 2 SCOPE Processing instructions outlined within this publication per tain to all serviceable and reparable Air Force vehicles excluding transport and transfer vehicles for missile systems oxidizers propellants and pressurizing gases Requests for specific instructions in preparing these special purpose ve hicles for storage should be forwarded to the prime agency
219. Under normal conditions this oil may be used in the operation of the equipment 3 Systems without oil return Hydraulic systems equipped with multiple lift cylinders triple cyl inders or completely sealed single cylinders without oil return lines Drain hydraulic fluid and replace with P 10 Type 1 Grade 10 preser vative oil Operate system to insure coating of inner surfaces Mark the machine in a conspicu ous location with a waterproof tag as follows The hydraulic system of this equipment is filled with preservative oil conform ing to Type P 10 Grade 3 of Specifica tion MIL P 116 Under normal condi tions this oil may be used in the operation of the equipment Upright masts and booms Extend full length and coat sliding contact areas with automotive and artillery grease Specification MIL G 10924 Close to shortest length and secure Coat all exposed unpainted surfaces with Type P 1 pre servative 69 70 71 COLUMN I Item TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN II IV V Component Level Type of Vehicle Processing Required Inverted Trail A B TR ers ST Jacks Outrigger A SP B SP Keys A B AV Hydraulic fluid MIL H 83282 is toxic to skin eyes and respiratory tract Avoid skin and eye contact Good gen eral ventilation normally adequate Fill to operational level with MIL H 83282 hydraulic fluid and operate to insure coating
220. WR This report is required on all vehicles equipment when the contractor re fuses to make corrections under warranty refer to Paragraph 7 25 1 2 for reporting procedures 7 8 4 nfo Only Warranty Satisfactory Report IWR This report is required for all vehicles equipment when the manufacturer contractor satisfactorily corrects the deficiency in a timely manner and value of the repairs exceeds 1000 00 or when three or more vehicles have the same deficiency satisfactorily corrected regardless of cost refer to Paragraph 7 25 1 1 for reporting procedures 7 9 GENERAL 7 9 1 Certifying Official VFM VMS certify the accu racy of and release most reports for transmission 7 9 2 Materiel Improvement Project AMIPisa planned effort to investigate and resolve deficiencies or to evaluate proposed enhancements 7 9 3 Exhibit material or products Items of hardware or samples of 7 9 4 MDR Exhibit Holding Activity The unit holding the MDR exhibit pending disposition instructions 7 9 5 Warranty Items Items which are guaranteed by the manufacturer or rebuilder 7 10 GENERAL PROCEDURES 7 101 MDR reports will be transmitted within 72 hours of identification 7 10 2 All other reports will be transmitted within 15 days of identification 7 11 METHOD OF REPORTING reports will be submitted using the deficiency reporting and mail system DREAMS MDR s and AWR s will be subm
221. XTREME TIRE FLEXING AND BUILD UP EXTREME HEAT RUNNING THE RISK OF FAILURE IT CAUSES RAPID WEAR ON THE OUTER EDGE OF THE TREAD Figure 4 11 4 23 1 4 Vehicles all types general and special purpose tires and spares if applicable will be gauged adjusted and recorded monthly by the operator on the Operator s Inspec tion Guide and Trouble Report form as required by AFI 24 302 Vehicle operators may check pressure of nitrogen filled tires if they have a pressure gauge suitable for nitrogen valve stems but they will not add nitrogen Vehicle manage ment technicians will service nitrogen filled tires Tires will be gauged cold and side wall pressure will not be exceeded Use the pressure for the size type tire and load as specified in the Manufacturer s Guidance If this information is not provided on the data plate or if there is a conflict between the data plate the stenciled tire pressure and or Manufacturer s Guidance report the discrepancy to vehicle management to TREAD CONTACT WITH ROAD OVER INFLATION CAUSES TIRE TO RIDE HARD AND SUBJECT TO IMPACT DAMAGE AND WEAKENING OF THE CARCASS IT ALSO CAUSES EXCESSIVE WEAR IN THE CENTER OF THE TREAD TREAD CONTACT WITH ROAD PROPER INFLATION THE CORRECT PROFILE FOR FULL CONTACT WITH THE TREAD F09603 053 Stages of Tire Inflation ensure the correct pressure is stenciled on the vehicle accord ing to Chapter 2 Vehicle management will correct all erroneous data
222. Y BATTERY BOX AND TERMINALS SPRAY UNDERSIDE CAB ROOF 2 USE GRADE 2 SPRAY HUBS AND INSIDE OF WHEELS SPRAY ALL EXTERIOR METAL SURFACES AND CAB FLOOR IF FILM THICKNESS IS TOO HEAVY SUBJECT TO PERSONAL CONTACT WIPE OR POLISH EXCESS MATERIAL WITH CLEAN CLOTH 3 USE GRADE 4 SPRAY COMPLETE ELECTRICAL SYSTEM SPARK PLUGS DISTRIBUTOR GENERATOR COIL IGNITION SYSTEM ETC 4 USE GRADE 3 FOR CONTROL OF RADIATOR ELECTROLYSIS SPRAY BOTH SIDES OF EXTERIOR RADIATOR CORE WITH A FIRST COAT OF GRADE 3 REPEAT SCHEDULE WITH A SECOND COAT OF GRADE 3 REFERENCE NUMERICAL LEGEND F09603 093 Figure 6 2 Special Purpose Vehicles Full Tracked Tractors Sheet 9 6 31 TO 36 1 191 1 USE GRADE 1 SPRAY ALL METAL UNDERNEATH VEHICLE UNDER FENDERS RUNNING GEAR SPRINGS AND ALL BOXED IN AREAS 2 USE GRADE 1 SPRAY INSIDE DOORS HINGES HINGE BOXES REMOVE HEADLINER AND SPRAY INSIDE ROOF AREA LIFT FLOOR MAT AND SPRAY COMPLETE FLOOR SPRAY INSIDE HOOD AND ALL AREA AROUND MOTOR AND GRILL BATTERY BOX AND TERMINALS 3 USE GRADE 2 SPRAY ALL EXTERIOR SURFACE METAL TO METAL JOINTS AROUND ALL WINDOW SEAMS BEHIND ALL CHROME AND SIDE MIRROR AREAS SPRAY INSIDE ALL COMPARTMENTS AND PIANO HINGES SPRAY FILM OVER ENTIRE EXTERIOR METAL SURFACE IF FILM THICKNESS IS TOO HEAVY IN AREAS OF DIRECT PERSONAL CONTACT WIPE OR POLISH WITH A CLEAN CLOTH SPRAY ALL EXTERIOR ROTATING GEARS 4 USE GRADE 2 SPRAY BOTH SIDES OF ALL WHE
223. Y SECOND COAT WITH GRADE 3 REFERENCE NUMERICAL LEGEND F09603 087 Figure 6 2 Special Purpose Vehicles Full Tracked Tractors Sheet 3 6 25 TO 36 1 191 1 USE GRADE 1 SPRAY ALL METAL UNDERNEATH INCLUDING FRAME RUNNING GEAR CHASSIS SPRINGS UNDER FENDERS AND BOXED IN AREAS 2 USE GRADE 1 SPRAY CAB INSIDE CAB DOORS HINGES AND HINGE BOXES CAB ROOF AND ALL AREAS AROUND AND UNDERNEATH REVOLVING CAB SPRAY ALL AREAS AROUND MOTOR BATTERY BOX AND TERMINALS 3 USE GRADE 2 SPRAY ALL METAL TO METAL SURFACE JOINTS CABLE PULLEYS ALL SEAMS AROUND WINDOWS CAB FLOOR AND AREA AROUND GEAR MECHANISM IN CRANE CAB SPRAY LIGHT FILM OVER ENTIRE EXTERIOR IF FILM THICKNESS IS TOO HEAVY WIPE OR POLISH EXCESS OFF WITH A CLEAN CLOTH SPRAY ALL INNER COMPARTMENTS 4 USE GRADE 2 SPRAY BOTH SIDES OF ALL WHEELS LUGS AND RIMS 5 USE GRADE 4 SPRAY COMPLETE ELECTRICAL SYSTEM LIGHT SOCKETS SPARK PLUGS DISTRIBUTOR COIL GENERATOR INSTRUMENT PANEL ETC 6 USE GRADE 3 VEHICLE RADIATOR ELECTROLYSIS CONTROL SPRAY BOTH EXTERIOR SIDES OF RADIATOR WITH A FIRST COAT OF GRADE 3 REPEAT THIS SCHEDULE WITH A SECOND COAT OF GRADE 3 REFERENCE NUMERICAL LEGEND F09603 088 Figure 6 2 Special Purpose Vehicles Full Tracked Tractors Sheet 4 6 26 TO 36 1 191 1 USE GRADE 1 SPRAY UNDERNEATH OF VEHICLE ALL METAL RUNNING GEAR SPRINGS ALL BOXED IN AREAS 2 USE GRADE 2 SPRAY ALL AREAS AROUND WINDOW SEAMS S
224. __ 21048 _ ETASL S8Id TWOS S Id ET 82 ETAOS SIZA tIWO9 S6Id 1 09 ETAOL SST TWOZ S81d 1 0 ETASL SLId PWOS SO d ET 8LAY IZIS p AQEL 4 38 TO 36 1 191 Table 4 4 Tire Size Conversion Chart European Metric Tire Size Pi Vehicle Tire Placard Specifies A European Metric Tire Size 175R15 P185 75R15 Table 4 5 Tire Size Conversion Charts ie Tite Parl Specifies A European Mere Tre Sie _ Acceptable Substitute Size Substitute Size P195 80R15 P205 75R15 P215 70R15 GR78 15 GR70 15 4 39 TO 36 1 191 Table 4 5 Tire Size Conversion Charts Continued If Vehicle Tire Placard Specifies A European Metric Tire Size P255 70R15 P305 50R15 4 40 TO 36 1 191 CHAPTER 5 REPAIR ALLOWANCES AND REPLACEMENT CODES 5 1 PURPOSE Set up procedures for making vehicle repair decisions writing repair estimates assigning replacement codes and preparing the annual vehicle buy lists The intent is to develop an orderly vehicle repair and replacement program avoiding costly repairs when it would be cheaper to replace the vehicle or lease commercial equipment 5 2 GENERAL Repair policy and replacement programming procedures of this manual were developed from guidance contained in AFI 24 302 Vehicle Management 5 3 SCOPE Applies to all USAF and Air National Guard activities that operate and or maintain USAF vehicles The term v
225. a tion normally provided by DD250s is being received via other means when DD250s are not available The consensus is whenever DD250s are available they will be ordered as part of the procurement package When they are not avail able the information will be required via some form of invoice receiving document 5 11 STANDARD PRICE The standard price is usually based on a weighted average of the last year s procurement cost or in some cases the last 5 2 time the asset was purchased The standard price of the I amp S master stock number shall be used in making repair decisions since it represents the best estimate of the cost to buy a replacement vehicle Prices are reviewed continuously and updated through the supply systems Questions about stan dard pricing should be referred to the local AFEMS manager If the standard price is not available locally contact the item manager at WR ALC LE Refer to https sevpgm robin s af mil vehicle vmif section3 asp to identify the office sym bol and contact information of the item manager NOTE During repair disposal decisions major com mands will consider factors not included in the I amp S master NSN price e g overseas transporta tion costs foreign buy costs and so forth 5 12 REPAIR ESTIMATE The repair estimate will show the expected cost to make the vehicle safe and serviceable Do not try to keep vehicles in a like new condition In figuring an estimate consi
226. above the stripe The basic weight of the vehicle will be applied adjacent to the stripe to indicate basic weight of the vehicle EXAMPLE CB 2430 LBS 2 81 2 The above marking may be applied using reflective paint of a contrasting color or the reflective tape listed in the supply information table at the end of this chapter 2 82 NOISE HAZARD MARKING Noise hazard marking shall be displayed in the vehicle cab in a readily visible location or adjacent to the access door on all vehicles determined to exceed noise level requirements The size of marking shall be approximately 3 3 4 inch x 2 1 2 inch and shall be applied by stenciling in a contrasting color as follows HAZARD Hazardous noise area ear protection required 2 83 MARKING CAMOUFLAGE PATTERN PAINTED VEHICLES Camouflage pattern painted vehicles shall be marked as follows 2 83 1 Unit identification shall be applied in black luster less paint When National Symbol STAR is used it shall be applied in accordance with Paragraph 2 41 using lusterless black paint camouflage 2 83 2 Safety and Instructional markings such as tire pressure fuel type and fill level may be retained in black lusterless letters no larger than 1 inch Markings directly related to personnel safety must be evaluated by responsible safety personnel NOTE This guidance takes precedence over TO 36 1 161 or 36 1 171 2 24 2 84 MARKING LAW ENFORCEMENT SEDANS Law enforcement sed
227. ack of this form 4 61 THETIRE AND RIM ASSOCIATION YEARBOOK The Tire and Rim Association Yearbook will be purchased to supplement this chapter This yearbook is updated as needed by the Tire and Rim Association This yearbook gives technical specification based on engineering principles and approved practices Information in this yearbook covers tire sizes and load ranges for all vehicles rim specifications tire pressure and valve stem criteria The Tire and Rim Associa tion Yearbook can be ordered from 175 Montrose West Ave TO 36 1 191 Suite 150 Copley Ohio 44321 An order form can be downloaded from the Tire and Rim Association website http www us tra org traMain htm 4 62 CONVERSION TABLES Table 4 3 through Table 4 5 contain tire size conversion charts NOTE Refer to manufacturer s specification listed in MOD the vehicle TO or the owners manual for wheel nut torque values TIRE INVENTORY CONTROL RECORD RECEIVED ISSUED TURN IN B C D BALANCE BACK ORDER ACTION BY E F G STOCK NUMBER SIZE TYPE PLY F09603 067 Figure 4 25 Tire Inventory Control Record 4 37 TO 36 1 191 e xe oures uo sited ur Jr ATUO poyruued so soJr SITIOS pue 09 JO 9520 UT owes uo soin oq JOU
228. age ment of the supply point is the responsibility of the Distri bution Flight 4 54 TURN N PROCEDURES FOR UNSERVICE ABLE TIRES Unserviceable tires repairable or condemned regardless of source will be turned into the Distribution Flight 4 55 PROCEDURES FOR REPAIRABLE RETREAD ABLE TIRES When sufficient quantities of retreadable tires have been accumulated vehicle management personnel will process a DIFM status update form coded CTR to the Distribution Flight reference AFMAN 23 110 This status request will result in a notice from the Distribution Flight to either repair or transfer to disposal As a result vehicle management personnel will process the tires for retreading or turn in to the Distribution Flight repair unit 4 55 1 Before processing tires to contract maintenance for retreading vehicle management personnel will determine the types of tread and the size of tires that local contractors can process for retreading If the original tread is available a determination must be made whether a requirement exists to have these tires retreaded with a different tread 4 55 2 process retreadable tires to contract mainte nance supply point personnel will prepare AF Form 9 Request for Purchase The organization code of the vehicle management activity will be entered on the AF Form 9 4 35 TO 36 1 191 4 55 3 One signed copy of the form will be returned to vehicle management and then forwarded to the LRS
229. ainted full gloss white color number 17875 Interior of compartments shall be painted semi gloss green color number 24533 of Federal Standard 595 NOTE When storage compartments and trim prohibit painting the top threefourths of the tank white 1 A M32R 6 the tank will be painted white down to the top of the storage compartments 2 7 2 Compressed gas cylinder semi trailers shall be painted full gloss green color number 14052 except the cylinders cylinders shall be painted full gloss white color number 17875 2 7 3 A M32R 16 and A M32R 17 propellant semi trailers will be painted dark green full gloss green color number 14052 except the top threefourths of the tank shall be painted full gloss white color number 17875 of Federal Standard 595 Interior of compartments shall be painted strata blue color number 15045 2 8 LAW ENFORCEMENT SEDANS Law enforcement sedans shall be painted full gloss white color number 17875 2 9 OTHER SPECIAL PURPOSE VEHICLES AND VE HICULAR EQUIPMENT other vehicles and vehicular equipment not specifically addressed elsewhere in this TO will be procured with the OEM standard color The rationale for this policy is based on manufacturer s standard practice of charging an extra pre mium per vehicle for alternate color choices Constrained vehicle buy budgets warrant procurement of these assets in the manufacture s standard colors Each MAJCOM is autho rized to procure v
230. al tires should be inspected and rotated in accordance with the recommendations in the operators manual if available or at 5 000 to 10 000 mile intervals The first such rotation is the most important one in setting the stage for long even tread wear In some instances if irregular wear begins to develop rotation will be advisable before the recommended mileage interval Before rotating determine the cause of wear and correct any misalignment balance or other mechanical problem Earlier and more frequent rotation may also be desirable due to differences in tread wear between front and rear tires After rotation adjustment of individual tire air pressure to acceptable car or tire manufacturer s recommendation is required in accor dance with the tire s new location on the car See Figure 4 7 and Figure 4 8 415 TIRE BALANCE Shaky shimmying wheels are caused by all or part of the rotating assembly being out of balance An assembly one ounce out of balance at the tread will develop a sledgeham mer pounding at 50 MPH 4 15 1 There are two main symptoms of out of balance and they are as follows 4 15 1 1 or road shock usually occurs at higher speeds and is felt through the steering wheel as vibration that increases with speed See Figure 4 9 4 15 1 2 Shimmy is a rapid side movement of front wheels which usually is apparent in sidewise vibration of the front end See Figure 4 10 4 15 2 To correct the Tramp or
231. al Purpose Vehicles Full Tracked Tractors Sheet 6 6 28 TO 36 1 191 1 USE GRADE 1 SPRAY ALL METAL UNDERNEATH TRAILER AND FENDERS SPRAY SPRINGS 2 USE GRADE 2 SPRAY SURFACE AREAS AND WIPE OFF EXCESS IF NEEDED WITH A CLEAN CLOTH COAT BOTH SIDES OF WHEELS RIMS LUGS 3 USE GRADE 4 SPRAY ALL GAUGES REFERENCE NUMERICAL LEGEND F09603 091 Figure 6 2 Special Purpose Vehicles Full Tracked Tractors Sheet 7 6 29 TO 36 1 191 1 USE GRADE 1 SPRAY ALL METAL UNDERNEATH GRADER UNDERNEATH BEAM AND MOTOR HOOD SPRAY BATTERY BOX AND TERMINALS ALL AREAS AROUND MOTOR 2 USE GRADE 2 SPRAY BOTH SIDES OF WHEELS RIMS LUGS SPRAY ALL SURFACE METAL IF FILM THICKNESS IS TOO HEAVY IN AREAS SUBJECTED TO PERSONAL CONTACT WIPE OR POLISH EXCESS MATERIAL WITH A CLEAN CLOTH SPRAY CAB FLOORS AND ALL EXPOSED WORKING GEARS 3 USE GRADE 4 SPRAY COMPLETE ELECTRICAL SYSTEM IGNITION INSTRUMENT PANEL SPARK PLUGS DISTRIBUTOR COIL GENERATOR ETC 4 USE GRADE 3 TO CONTROL RADIATOR ELECTROLYSIS IN EQUIPMENT SPRAY BOTH EXTERNAL SIDES OF RADIATOR CORE WITH FIRST COAT OF GRADE 3 REPEAT SCHEDULE WITH SECOND COAT OF GRADE 3 REFERENCE NUMERICAL LEGEND F09603 092 Figure 6 2 Special Purpose Vehicles Full Tracked Tractors Sheet 8 6 30 TO 36 1 191 AREA APPLICATION 1 USE GRADE 1 SPRAY ALL METAL UNDERNEATH ROLLER SPRAY ALL AREAS INSIDE MOTOR HOOD COMPARTMENT AND ALL AREAS AROUND MOTOR SPRA
232. al to metal contact must exist so that electrons can move from the anode where they are released to the cathode Eliminating any one of these four conditions illustrated in the corrosion cell diagram shown at Figure 6 3 will stop corrosion For example an effective primer and paint film on a metal surface will prevent the conducting liquid electrolyte from conducting the anode and cathode thereby stopping the electric current Figure 6 4 Example of Raised Corrosion Product TO 36 1 191 DIESEL Figure 6 5 Aluminum Fuel Tank Exhibiting Uni form Etch 6 16 4 Development of Corrosion corrosive at tacks begin on the surface of metals The word surface should not be construed as corrosion only occurring on the top of a piece of metal The surface of a piece of metal may be the interior wall of a hollow tube or the secondary structure of a vehicle the top sides or bottom of a panel etc If allowed to progress corrosion can penetrate into and through the metal When corrosion products form they often precipitate onto the corroding surface as a powdery or scaled deposit as shown in Figure 6 4 6 16 5 Metals Affected By Corrosion The metals most commonly used in vehicle construction are aluminum steel and to some extent magnesium Cadmium nickel chromium and silver are sometimes used as protective plating Metals have a wide range of corrosion resistance The most active metals i e those that tend to lose elec
233. all be cranked with starting motor un til intake or exhaust valve into each cylinder is open Without cranking two ounces of P 10 Type I Grade 30 preservative oil shall be atom ized sprayed into open port each cylinder Com pression release shall be freed and manifolds reinstalled A warning tag bearing the informa tion ENGINE PRESERVED DO NOT CRANK shall be securely attached in a con spicuous location within driver s compartment d Two cycle diesel engines Diesel throttle shall be completely closed Air box cover s shall be removed from side of engine opposite the blower Engine shall be cranked with starting motor until piston in cylinder to be sprayed is below intake ports Procedure shall be repeated for each cylinder Engine shall be cranked with the starting motor for at least three complete revolutions after spraying the last cylinder Complete cycle of spraying into cylinders shall be repeated except that engine shall be cranked with the starting motor for not more than one complete revolution after spraying the last cylin der Interior surfaces of air box cover s shall be coated with the same type and grade preserva tive oil and reinstalled A warning tag bearing the information ENGINE PRESERVED DO NOT CRANK shall be securely attached in a conspicuous location within driver s compart ment 8 32 52 COLUMN I Item TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLU
234. ance public safety 3 10 2 5 2 4 R 9s are not permitted for use on public highways due to not meeting current tank standards and therefore are unable to be certified M49s are considered tactical vehicles and are exempt from certification require ments outlined in 49 CFR Part 180 401 417 3 10 3 Hydraulic Systems Special Purpose Assem blies Change hydraulic filters and hydraulic fluid every three years or 3600 hours Record filter fluid analysis action on vehicle historical records 3 10 4 Truck tractor fifth wheel plate and semitrailer king pin will be thoroughly cleaned of all grease and foreign material and components carefully inspected to determine condition Worn or damaged components visually determined to be in doubtful condition will be cause for disassembly and repair or replacement Standard fifth wheel locking jaws will be adjusted to fit a 2 005 inch round rod stud Locking jaws in the locked position that are worn 1 8 inch beyond all available adjustment will be replaced Semi trailer king pin worn 1 8 inch maximum when measured in front to rear direction will be replaced Maximum combination wear of locking jaws in the locked position and king pin will not exceed 1 4 inch Upon completion of inspection repair lubri cate fifth wheel plate and trailer king pin Change 1 3 13 TO 36 1 191 3 10 5 Cranes Crane Shovels High Reach Trucks Line Maintenance Derrick Trucks 3 10 5 1 Mobile Crane Load Tests Ve
235. and gaskets will not leak or show evidence of deterioration Hoses may exhibit minor superficial weather cracks 1 7 2 24 9 Riveted brake linings shall have not less than 1 32 inch of the lining material remaining above rivet heads at thinnest point Bonded lining and disc brake pads shall have not less than 1 32 inch of original material thickness remaining at thinnest point 1 7 2 24 10 Brake drums and rotors shall be free of cracks hub lubricant and brake fluid Disc brake rotors shall meet specifications for lateral runout parallelism and thick ness in accordance with applicable technical manual 1 7 2 24 11 Brake combination valve and warning system shall be operational 1 7 2 24 12 Brake pedal pads shall not be worn to where metal shows beneath the pads 1 7 2 25 Brakes Steering For friction type steering brakes as used on crawler type tractors and similar equip ment which operate independently or are connected with operation of steering clutches Riveted linings shall have not less than 50 percent of material above rivet heads remaining at thinnest point Bonded linings shall have not less than 50 percent of original material thickness remaining at the thin nest point Brakes shall operate effectively 1 7 2 26 Brush Guard And Grille Bush guards shall be securely installed and properly aligned Original contours of metal members will be maintained Welds shall not be cracked or have rusted areas Grilles shall be s
236. and valve seats shall be in good condition so as to prevent undue loss of TO 36 1 191 compression Piston rings shall not be excessively worn as to cause excessive oil consumption or plug fouling Compres sion test reading shall meet or exceed requirements pre scribed in Paragraph 1 6 6 3 1 7 2 125 Voltage Regulator Voltage regulator shall operate properly at controlled rate of voltage output Voltage regulators shall be securely mounted and their connections shall be clean 1 7 2 126 Warning Devices Backup Warning de vices shall be securely mounted and shall emit a loud clear warning signal when actuated by placing transmission in reverse Wiring connections shall be clean and tight Relays shall be securely mounted and operate properly Wire instal lation shall not be chaffed or worn through 1 7 2 127 Water Foam Tank Water and foam tanks shall be in serviceable condition and securely mounted Tank filler cover or manhole gasket and fastening device shall be serviceable Tank valves and piping shall be securely mounted and shall have no leaks 1 7 2 128 Water Lock Valve Ballast and operation shall be in accordance with TO 37A 1 101 1 7 2 129 Wheels Sprockets And Tracks 1 7 2 129 1 Wheels Wheels shall be of proper size and type in accordance with vehicle manufacturer Wheels shall not be cracked or damaged so as to impair sealing of tire to rim Lock rings or wheel grooves shall not be bent rus
237. ans shall be marked as follows NOTE Due to differences in vehicles i e size of fend ers doors and other panels letter size and location size of security forces shields may vary if the intended location does not allow enough space for application 2 84 1 POLICE in 7 inch reflective strata blue letters color number 15045 shall be centered on a rearward facing vertical portion of the trunk lid as illustrated in Figure 2 5 NOTE Use of 4 inch letters permitted for the vehicles designs that prevent the esthetic application of 7 inch letters 2 84 2 POLICE in 2 or 4 inch reflective strata blue letter color number 15045 shall be applied to the top vertical side of both front fenders as illustrated in Figure 2 5 2 84 8 security police badge shall be centered on both front doors as illustrated in Figure 2 5 2 84 4 Vehicle registration number in 1 1 2 inch reflective strata blue letters will be applied and centered on the license plate between the legend US AIR FORCE and FOR OFFI CIAL USE ONLY A single license plate will be placed on the rear of vehicle illustrated in Figure 2 5 unless otherwise directed by MAJCOM or local law 2 84 5 When authorized by major command dual 4 inch strata blue stripes 2 inches apart may be applied to each side of the vehicle as illustrated in Figure 2 5 Stripes may be applied with reflectorized tape 3M part number 690 75 or may be painted using the following procedure Apply a compara
238. anufacturer s specifications 1 7 2 7 Air Tanks Lines And Valves Air reservoir tanks shall be securely mounted and free from dents or other external damage Air dryers and or moisture rejector shall function properly Air hoses lines and their connections shall be tight and free of leaks Safety valves shall not leak after manual operation and air pressure returned within normal operating limits 1 7 2 8 Antifreeze Protection Antifreeze type and strength shall be sufficient to protect the lowest expected ambient temperature An approved antifreeze coolant shall be used year round to provide cooling system protection The optimum coolant water solution shall be 50 50 or the vehicle manufacturer s specifications Use of OEM recommended extended life coolant is recommended throughout the ve hicles warranty period After the warranty expires revert to use of antifreeze meeting CID A A 52624 NOTE Under no circumstances will water be added to coolant system to top off Only the proper antifreeze type and solution shall be used to replace lost coolant 1 7 2 9 Apron And Tail Gate Apron and tail gate shall close properly without binding Guide rollers shall maintain proper apron or gate alignment Tail gate hinges and latches TO 36 1 191 shall function properly and hold gate in proper alignment Apron and tailgate shall have no cracked or bent members Cables or chains and sheaves shall not be excessively worn 1 7
239. aph 3 8 and as may be specified by manufacturers for subsequently procured new equipment Quantity 9150 01 152 4117 9150 01 152 4118 9150 01 152 4119 9150 01 413 6897 9150 01 413 6892 9150 01 413 6990 9150 01 421 1427 9150 01 421 1424 9150 01 421 1432 Product Name Specification Quantity Chassis Lubricant PRF 10924G 9150 01 197 7688 MIL PRF 10924G 9150 01 197 7689 on Petroleum base fire resistant Hydraulic Oil PRF 83282D 9150 00 149 7431 QT MIL PRF 83282D 9150 00 149 7432 GL Nonpetroleum Base Hydraulic Brake Fluid SAE J1703 9150 01 052 6762 QT SAE J1703 9150 00 231 9071 GL Automatic Transmission Fluid Dextron III 9150 00 698 2382 QT Automatic Transmission Fluid Ford Type F 9150 00 843 1636 GL Oil Lube General Purpose Silicone Spray MIL PRF 173315 9150 00 823 7860 CN Product Name Penetrating Oil Grease Wheel Bearing Antifreeze Water Pump Lube to 55 0 F Fuel Motor Gasoline MOGAS Winter Grade Diesel Summer Grade Diesel Brake Fluid Silicone Specification A A 50493B MIL G 25013 CID A A 52624A ASTM D48 14 CID A A 52557A CID A A 52557A MIL PRF 46176B MIL PRF 46176B MIL PRF 46176B TO 36 1 191 NSN Quantity 9150 00 26 1 7899 9150 01 306 9202 6850 0 1 441 3223 9130 00 148 7104 9150 01 102 9455 9150 01 123 3152 9150 01 072 8379 Ice Classifications Former Classifications Military Equivalent Specifica Gasoline Engines Service SA Utility Gas Diesel Service SB Min
240. ar ings or bearing play Mountings shall be secure and free from oil and foreign material 1 7 2 67 Grapnel And Hooks Grapnels and hooks shall be clean and free of cracks and broken welds 1 7 2 68 Hammers Jaw Linings Plates And Rolls These items shall not be excessively worn where damage to mounting base may occur On gyratory type crushers mantle and concaves shall show no signs of looseness or excessive wear 1 7 2 69 Heaters Defrosters Heaters shall be securely mounted and operate properly Heater blower motors shall operate at proper speed and shall be free of unusual noise Heater core and hose connections shall be free of leaks Heater hoses shall not be cracked brittle or mushy Gasoline burning heaters shall ignite and operate within time limits specified by the manufacturer Heater control systems shall operate and maintain all operating circuits in accordance with manufacturer s specifications Defroster hoses shall not be torn and shall be connected properly Heater defroster control cables and linkage shall be securely mounted and operate without binding 1 7 2 70 Heater Exchanger And Evaporator Heat exchanger bonnets and core assembly shall have no leakage nor damaged or defective parts Evaporator shall have no leaks rust or corrosion 1 7 2 71 Heater Flues And Stacks Distributors Heater flues and stacks shall have no leaks or broken connectors or straps 1 7 2 72 Heater Tubes And Flue
241. at with valve hole up Screw a valve fishing tool on the valve stem Start to mount tire with valve pointing toward valve hole pulling handle of fishing tool through valve hole in rim Place inside bead in rim well near valve hole Figure 4 20 4 23 TO 36 1 191 4 35 3 2 Holding inside bead in well force remainder of inside bead over flange with a tire tool or rubber raced hammer Spread tire and pull stem through hole in rim Figure 4 20 4 35 3 3 Place outside bead in well opposite valve and pry on rim with tire tool with rubber faced hammer being careful not to damage beads on rim Keep as much of bead as possible in rim well Figure 4 20 4 35 3 4 Check position of valve shifting tire in order to center valve in hole with aid of fishing tool Pull very gently with fishing tool in order not to tear tube at base of valve 4 35 3 5 Center tire around rim and inflate to about 10 psi Apply air chuck to that part of fishing tool that serves as a valve stem extension In this operation valve stem maybe held by fishing tool If bead fails to seat properly against rim flanges at this pressure either the tube is pinched or part of bead is still in well in which case deflate and make appropriate corrections Occasionally beads will fail to seat in rim flange due to friction between beads and rim espe cially if rim has not been sufficiently or properly lubricated with solution This can be corrected by holding tire and rim infl
242. ate properly Control levers will function without sticking or binding 1 7 2 100 Rectifier Rectifier shall show no evidence of damage due to heat broken terminals bent blades plates or excessive dust accumulation Blowers shall operate properly Fan blades shall have no bent blades Transformer shall have no heat damage 1 7 2 101 Refrigeration And Air Conditioners pressors shall operate properly without unusual noise Con denser evaporator and hoses lines fittings shall be clean and free of leaks Compressor belts shall conform to the standard established in belts Paragraph 1 7 2 17 Thermostat control units shall operate properly 1 14 1 7 2 102 Rotors And Paddles Rotors and paddles shall be securely mounted and properly aligned 1 7 2 103 Scarifier Scarifier shall be securely mounted Teeth shall not be excessively worn Lift mechanism shall be properly aligned and operate without binding 1 7 2 104 Seats Seats shall be securely mounted Seats should not have loose springs or missing padding Adjusting devices shall operate properly Seat covers shall not be torn frayed nor be taped as a repair 1 7 2 105 Seat Belts Restraint Device All devices shall be securely mounted and retractors and centrifugal clutches shall operate freely Webbing will not be cut melted or frayed Buckles will open freely Belt buckles shall latch and release properly without binding Number and type seat belt Installed shall be
243. ated 10 to 15 psi upright and bouncing it on ground If bead is properly seated remove fishing tool inflate to full pressure then remove valve core and deflate tire to smooth out wrinkles in tube Install valve core and again inflate to recommended pressure Check valve for leaks and install valve cap Beads of tires mounted on safety rims used on some passenger cars and light trucks snap over the bump into place after approximately 20 psi is applied A snapping noise can be heard as beads snap into place Inflate sufficiently to force beads against rim flanges then deflate completely and again inflate to prescribed air pressure Do not continue to inflate tire beyond 40 psi if beads are not in position There is danger that beads may strike flange with enough force to break and jump the flange 4 36 SERVICING MULTI PIECE RIM WHEELS 4 36 1 Scope This paragraph applies to the servicing of vehicle wheels which tube type tires mounted on multi piece rims have defined below 4 36 2 Definitions 4 36 2 1 Charts the United States Department of Trans portation National Highway Traffic Safety Administration NHTSA publications entitled Safety Precautions for Mounting and Demounting Tube type Truck Bus Tires or any other publications containing at a minimum the same instructions safety precautions and other information con tained on those charts that are applicable to the types of multi piece rim wheels being serviced 4 24
244. ates with the registration number preprinted or purchasing blank plates and applying the registration number as specified in this Technical Order regardless of which method units use to purchase the plates all license plates will be appropriately controlled and kept secured when awaiting installation NOTE Due to printing processes the preprinted plates may have larger lettering 2 25 1 5 Vehicle fleet managers will publish an Operating Instruction OI to ensure procedures are in place to control TO 36 1 191 the plates throughout the order process order receipt installation reuse and removal destruction of plates on DRMS bound vehicles The OI must also include procedures for notifying local authorities SF and OSI when plates are lost or stolen it must also provide procedures for keeping a record of lost and stolen plates Reused plates must have the registration number removed when the plate is taken from its original vehicle before storing for future use When a vehicle is shipped or transferred to another base or deployed location the license plate will be removed and placed inside the vehicle record jacket inside a sealed envelope A placard or protected paper with the registration number printed in large numbers will be posted secured inside the vehicle window windshield When shipping a vehicle to a depot contractor for rebuild remove the license plate and place it in the vehicle historical file for reinstallation up
245. ation and arrangement of identification however will be such that it will not be exposed to excessive abrasive action under normal operation and so that the vehicle may be easily identified from the rear If space does not permit the agency identification will be omitted Markings will be uniform on like type vehicles 2 40 2 5 Due to the various types of materials handling equipment the exact location for identification is not speci fied These markings will be applied using Figure 2 6 2 40 2 6 Identification markings on tractors will be ap plied as follows 2 40 2 6 1 On industrial and agricultural tractors US AIR FORCE and the registration number on both sides of the hood 2 40 2 6 2 On crawler tractors excavators and the like US AIR FORCE and the registration number on two lines on sides and rear of seat leaving 1 inch between lines 2 40 2 6 3 On crawler tractors place US AIR FORCE and the registration number on two lines on sides and rear of seat 1 inch between lines If space does not permit markings on the seat sides place USAF and the registration number on one line on both sides of the hood 2 40 2 6 4 Location of all other markings is included in the paragraph pertaining to the specific marking involved 2 41 NATIONAL SYMBOL 2 41 1 A white five pointed star is prescribed as the national symbol This symbol will be applied on vehicles assigned to units in overseas operations when dir
246. ative and hardware when dry shall be reinstalled into one of the mating parts Bows shall be banded to gether with strapping conforming to Class A or B of Specification ASTM D3953 and secured to floor of cargo compartment Openings afforded by removal of bows and stake pockets that are not provided with drain holes to permit drain ing shall be covered with tape conforming to Specification SAE AMS T 22085 When re quired for reduction in cube troop seats and side racks shall be removed banded together with the same class strapping and secured to floor of cargo compartment Boxed cover shall be stowed and secured with other OVE Body drains shall be opened to prevent accumulation of water Cargo and command bodies When required for reduction of cube cover bows troop seats and side racks shall be removed and packaged in accordance with Level A above All exposed unpainted machined surfaces of the hydraulic ram when the dump body is fully retracted shall be coated with MIL C 10578 P 1 preservative Release tailgate to prevent ac cumulation of water in body 8 13 TO 36 1 191 COLUMN I Item Table 8 2 Processing Procedures Continued COLUMN II Component Bodies Dump A COLUMN III Level COLUMN IV Type of Vehicle GP GP COLUMN V Processing Required Dump body Unpainted metal surfaces of body roller arms and ramps uncovered tailgate chains locking devices control levers and re
247. ay be encoun tered Interval conflicts between 1 TOs and AF Form 1807 15 not cause to submit AFTO Form 22 TO System Publication Improvement Report and Reply The form is used by the refueler vehicle operator to document refueler vehicle operability and serviceability inspections 3 6 PREVENTATIVE MAINTENANCE AND INSPEC TION The Preventative Maintenance and Inspection intervals are reflected in Table 3 1 and Table 3 2 In addition to these requirements any safety related inspections adjustments and services recommended by the manufacturer and outlined in the applicable technical orders will be performed As a minimum the following systems and their components are inspected to ensure proper configuration functionality ser viceability and compliance i e manuals technical data TCTO safety recall service campaigns or service bulletins during PM amp I and Annual inspections 3 2 3 6 1 Operator Compartment Gauges accessories clutch free travel parking and service brake operation transmission control lever and operation of engine and accessories Also check seat belts for operation cleanliness or frayed deteriorated condition 3 6 2 Hydraulic Systems 3 6 2 1 Brake system for fluid levels and leaks 3 6 2 2 Power steering and or hydraulic systems for fluid level and leaks 3 6 2 3 General condition on all lines and fittings to include chaffing and abnormal wear 3 6 3 Check Coolant System Heater and Air C
248. be placed The markings illustrated are furnished as a guide to indicate the location of the markings in respect to the space available Markings of vehicles not illustrated herein will be applied in a manner as nearly as possible to that illustrated for compa rable vehicles Required Markings for Common Substances Oxygen Refrigerated Liquid UN1073 Nonflammable gas Oxidizer Compressed Oxygen UN1072 Nonflammable gas Oxidizer Compressed Nitrogen UN1066 Nonflammable gas Liquid Hydrogen UN1966 Flammable gas Compressed Hydrogen UN1049 Flammable gas Compressed Helium UN1046 Nonflammable gas UN1223 Flammable Liquid Liquid Helium UN1963 Nonflammable gas Diesel Fuel NA1993 Required Labels Liquid Petroleum Gas UN1075 Flammable gas LPG Propane UN1978 Flammable gas Dinitrogen Tetrozide UN1067 Poison Gas Oxidizer Corrosive UN2929 Poison Flammable Liquid Nitrogen Refrigerated Liquid UN1977 Nonflammable gas Labels can be found in 49 CFR 172 519 The required markings were obtained from The Hazardous Materials Table in 49 CFR 172 101 2 26 Fuel Aviation Turbine Engine UN1863 Flammable Liquid TO 36 1 191 U S AIR FORCE FOR OFFICIAL USE ONLY F09603 004 Figure 2 1 License Plate hh Cis
249. because of low cost resilience and the fact that it provides a soft ride However it is not as strong as most of the other materials and loses strength when subjected to heat Rayon will absorb moisture but it does not have flat spot tendencies 4 8 2 Polyester Fiber Polyester fiber is a synthetic fiber stronger than rayon but equally resilient It is more heat resistant and less expensive than rayon 4 8 3 Nylon Fiber Nylon fiber is a synthetic fiber which is probably the widest used of all cord fibers It has high heat resistance excellent impact resistance minimum flex and will not absorb water It gives a harsher ride and will tend toward flat spotting 4 8 4 Fiberglass Fiberglass is the newer of tire cord body materials and is used only as a belt or buffer material It provides excellent cord strength resists flexing and provides cooler running tire and one that provides long wear 4 8 5 Steel Steel wire is being used as a radial cord as a belt cord and as an armor material Steel shavings are imbedded in the underbody as a buffer material The steel wire cord is used in radial tires both truck and passenger Steel wire makes a very strong belt It provides excellent traction and gives maximum wear for a given thickness of tread 4 9 LOAD RANGE Load range defines the type of service as well as the load carrying capacity based on the category of tire Under no circumstances will replacement tire s be of lesser
250. bility of space 2 59 2 SMOKING WITHIN 50 FEET 4 or 6 inch letters depending on availability of space TO 36 1 191 2 59 3 CARGO FIRE AVOID WATER 2 inch letters 2 59 4 JET FUEL PRODUCT 4 or 6 inch letters depending on availability of space 2 59 5 EMERGENCY TANK SHUTOFF 2 inch letters 2 60 NO SMOKING WITHIN FIFTY FEET For vehicles described below which store transport flam mable materials Markings may be decals or stencils using red paint color number 31136 2 60 1 SMOKING WITHIN 50 in 2 inch letters shall be applied Refer to Figure 2 27 2 60 2 fuel or oil servicing trucks NO SMOKING WITHIN 50 FT in 2 inch silver letters Refer to Figure 2 1 2 60 8 Two wheeled trailers will be marked on each side of the tank with SMOKING WITHIN 50 FT in 3 inch letters 2 61 PRODUCT IDENTIFICATION 2 61 1 Place the word AVGAS JET FUEL OIL ACFT ENG DIESEL FUEL KEROSENE MOGAS whichever is applicable on the rear and both sides of tank Markings may be decals or stencils using red paint color number 31136 AVGAS 115 145 F22 will be applied in silver reflective letters with a purple background JET FUEL or and all other markings will be applied using decals or stencils using red paint color number 31136 Use 6 inch letters on all semitrailers and trucks with a capacity of 1 500 gal
251. ble blue metallic acrylic enamel Dupont Bonzai blue formula number B9134 or equivalent Paint over cover coat with blue pearl Paint and tape shall be locally procured 2 84 6 The base chief of security police may authorize the use of the following optional markings 2 84 6 1 Emergency dial 911 Use white letters and locate on the rear portion of the uppermost blue stripe on each side of the vehicle as illustrated in Figure 2 5 Vehicle without strip use 1 1 2 inch strata blue letters in approximately the same area 2 84 6 2 Crime stop dial XXXXXXX as described in Paragraph 2 84 6 1 above 2 84 6 3 Such items as crime stop programs bumper stickers dare program stickers etc may be applied to the bumpers light bars or located on the rear windows such that the sticker does not affect rearward vision nor should it cover the center mounted stop light 2 84 6 4 When authorized by MAJCOM military working dog magnetic stenciling may be applied Magnetic reflective stencils will mark Security Forces vehicles used for trans porting military working dogs Magnetic signs will be applied to the rear side doors of the vehicle using red letters on a reflective white background Lettering is to be a minimum of 3 inches in height Exact markings will be CAUTION MILITARY WORKING DOG The word caution must be centered above the blue stripe if so equipped military working dog will be stenciled below Markings for vehicles other than four d
252. boom light cable Remove two boom attaching pins from boom mast using a fork lift truck for support of boom Start trac tor and shift into reverse gear and back tractor from boom Lower boom on a suitable support Touch up paint if required Surfaces not requir ing paint and subject to corrosion will be coated with grade I corrosion preventive compound Specification CID A A 59295 Stencil USAF registration number and package number on boom See Item 8 Exterior unpainted or threaded surfaces such as cable clevises and linkage of service and park ing brakes shall be coated with CID A 59295 Type P 1 preservative Place a block on foot and hand brakes to ensure brake cannot be activated 8 19 TO 36 1 191 COLUMN I Item 20 21 22 23 8 20 COLUMN II Component Brake Systems Air Brake Systems Air Hydraulic Brake Systems Electric Brake Systems Hydraulic Table 8 2 Processing Procedures Continued COLUMN A A B III Level AV AV AV AV AV AV AV COLUMN Type of Vehicle COLUMN IV V Processing Required Air compressor shall be processed as specified in Item 37 Air reservoirs shall be drained of all condensation and interior surfaces sprayed with atomized MIL PRF 21260E P 10 Type 1 Grade 30 preservative oil Drain plugs and threaded openings shall be coated with Type P 10 Type 1 Grade 30 preservative oil and plugs rein stalled Drain valves shall be left in open pos
253. c will not be outlined in reflectorized tape 2 32 2 6 HARNESS REQUIRED AREA A 3 inch wide yellow line painted on both catwalks of the loaders is required Lines will be painted at the following locations 25K AT THE LAST PALLET LOCK NGSL AT THE SECOND TO LAST PALLET LOCK 40K AT THE SECOND TO LAST PALLET LOCK 60K AT THE LAST PALLET LOCK 2 11 TO 36 1 191 a Stencil the words HARNESS REQUIRED AREA next to the yellow line on the side nearest the end of the loader catwalk using 1 3 4 inch high yellow block letters b Identify the following loader tie down rings as a fall restraint attaching point by painting them yellow 25K SECOND TO LAST T D RING ON THE GUIDE RAIL 25K NGSL SECOND TO LAST T D RING ON THE GUIDE RAIL drivers side THIRD TO LAST T D RING ON THE GUIDE RAIL non drivers side 40K SECOND TO LAST T D RING ON THE GUIDE RAIL 60K SECOND TO LAST T D RING ON THE GUIDE RAIL c Paint the inside of both front and rear emergency pallet stops on the 25K 40K NGSL and 60K yellow 2 33 IDENTIFICATION MARKINGS The term identification includes the following 2 33 1 Agency Identification US AIR FORCE 2 33 2 USAF Registration Number 2 33 3 Official Use Only 2 34 NATIONAL SYMBOL AND MARKINGS INTERNATIONAL 2 34 1 National Symbol The national symbol may be applied to all vehicles operated by the USAF in overseas theaters by direction of the Theater Commander concerned Size and location are
254. cal contact in the presence of an electrolyte Figure 6 6 illustrates the principal of galvanic corrosion by having a steel hinge bolted to an aluminum skinned door Galvanic corrosion is usually recognizable by a buildup of corrosion at the joint between the metals If the dissimilar metal groups listed in Table 6 3 are widely separated and are in direct electrical contact galvanic corrosion is probably occurring The less corrosion resistant metal the higher metal in Table 6 3 becomes the anode and the more corrosion resistant metal the lower metal in Table 6 3 becomes the cathode As stated earlier the anode will corrode The farther apart the metals are in Table 6 3 the more severe will be the corrosion of the anodic metal if the metals are joined electrically and placed in an electrolyte In most cases the galvanic series listed in Table 6 3 is a good predictor of how metals will corrode in a galvanic couple A major factor in galvanic corrosion is the size of the anode and cathode A small anode in contact with a large cathode will corrode much more severely than a large anode in contact with a small cathode 6 16 6 3 The most common corrosion on aluminum and magnesium alloys is called pitting corrosion see Figure 6 7 It is first noticeable as a white or gray powdery deposit similar to dust that blotches the surface When the deposits are cleaned away tiny pits or holes can be seen in the surface Pitting corrosion may also occur
255. cal shop hourly rate will be computed in OLVIMS PCN N310029 according to AFCSM 24 1 Use the military labor rate in overseas areas where the indigenous or contract labor rate is lower than the military labor rate 5 18 EXCLUSIONS When the repair estimate is to be used to decide whether repair is feasible exclude the cost for maintenance overhaul TO 36 1 191 and replacement of items which are not included in the stock list description of the vehicle Therefore charges for check ing and replenishing fluid levels and charges for installing and maintaining special mounted components or accessories shall be excluded from the repair estimate Accordingly the following items except for accident repair estimates will be excluded 5 18 1 agents Fuel oil antifreeze and other fluids or servicing 5 18 2 Two way radios fire extinguishers tool kits sirens f lashing lights tire chains and so forth 5 18 3 The cost of modification kits and the initial installation 5 18 4 Cost of winterization kit and initial installation 5 18 5 Initial cost of corrosion control treatment 5 18 6 Transportation costs except for overseas to CO NUS 5 18 7 Charges for purchase installation and maintenance of special attachments which are base funded and not part of the basic vehicle 5 19 DEPOT LEVEL REPAIR Send depot repair requirements to WR ALC LE in accor dance with AFI 24 302 and Chapter 9 Do not reset hour meters or od
256. cases crankcases hydraulic systems and cooling systems are securely closed that drain plugs are tight and that seals and gaskets are sound Leakage of flammable liquids from ve hicles or engines shipped separately is a matter of continuing concern to air transportation units When engines or motors internal combustion are shipped separately or as a part of other apparatus the engine and shipping container shall be marked in a clearly visible area with the words FUEL DRAINED When vehicles are shipped boxed or crated all flammable liquids should be similarly drained and the same marking applied Boxed vehicles are prepared for shipment as specified in Standard MIL STD 3003A 8 22 3 2 Batteries Vehicles may be transported by military aircraft with wet battery installed provided that the battery is completely protected against short circuits remove cables and secure ends away from the terminals and secured so that leakage of acid will not occur see AFM 24 204 Wet batteries shipped as part of the OVE should be packed as specified in AFMAN 24 204 Dry batteries offer no special hazard and may be installed in the vehicles battery carrier or placed with OVE 8 59 TO 36 1 191 8 22 3 3 Battery Acid Electrolyte Electrolyte shall be packed in accordance with paragraphs 8 9 and 8 14 or 8 9 and 8 27 of AFMAN 24 204 and attached to vehicle under hood for air or sea shipment 8 22 3 4 Air Shipment Of Fuel Servicing Trucks
257. cases the corrosion process occurs at the same rate no matter how long the metal has been exposed to the environment In other cases corrosion can decrease with time because of the barrier formed by corrosion products or increase if a barrier to corrosion is being broken down 6 17 13 Preventive Maintenance PM is prob ably one of the easiest most effective and least expensive means of preventing corrosion and is the process organization maintenance personnel can control 6 17 13 1 earlier that corrosion is detected and treated will determine the effectiveness of a corrosion PM program When corrosion is detected a specific and immediate pro gram for corrective treatment is required 6 17 13 2 Each type of corrosion has its own peculiarities and will require special treatment Complete treatment in volves thorough inspection of all corroded areas evaluation of the corrosion damage paint and corrosion removal appli cation of chemical surface treatments sealing and applica tion of protective finishes 6 17 13 3 Normally aluminum steel and magnesium alloys found in vehicle equipment will begin to corrode if salt deposits corrosive fluids or other electrolytes are allowed to accumulate and remain on the metal surface In order to effectively prevent corrosion an established frequent cycle of cleaning inspection preservation and lubrication must be followed 6 17 13 3 1 Corrosion can be minimized by fr
258. cated in the preceding paragraph may be installed to meet local conditions and state regulations NOTE Head lamp units incorporating left way shift characteristics shall be installed on vehicles to satisfy local condition requirements in areas where a left hand traffic pattern prevails 2 58 2 92 SPECIAL DATA 2 92 1 Directional Signaling Devices Electric direc tional signaling devices should be mounted on the front rear and rear of the vehicle or combination of vehicles near the extreme and outermost corners They should be mounted not less than 24 inches and not more than 60 inches above ground level Color of devices will be yellow or amber on the front and red or amber on the rear Location and color of direc tional signaling devices which have been factory installed on new vehicles will not be changed to comply with this technical order however it all cases local state regulations will be adhered to 2 92 2 Reflectors reflectors will be in accordance with Ordnance drawing number B161059 Reflector installa tion on vehicles will not exceed a height of 60 inches and should not be less than 24 inches above the ground on which the vehicle stands On vehicles which are so constructed as to make compliance with the 24 inch requirement impractical lower mountings may be used NOTE devices should be illuminated and should be visible both day and night at a distance of 100 feet 2 93 TRAILER LIGHTING CA
259. ccompany the vehicle when shipped b Vehicle historical record and other applicable forms will be packaged Method IC 3 and at tached to vehicle FM TO 8 43 TO 36 1 191 COLUMN COLUMN I II Item Component 91 Pumping Sys tem Fuel except cryo genic liquids 8 44 Table 8 2 Processing Procedures Continued COLUMN III Level COLUMN IV Type of Vehicle SE SE COLUMN V Processing Required a interior surfaces of fuel transfer pump shall be sprayed with P 10 Type 1 Grade 30 preser vative oil Manifold valves shall be placed in open position Pump and sump drain plugs shall be removed coated with P 10 Type I Grade 30 preservative oil and placed in a bag conforming to Type II Class C of Specification MIL B 117 and identified A warning tag bearing the infor mation PUMP AND SUMP DRAIN PLUGS REMOVED REPLACE BEFORE OPERAT ING ENGINE AND PUMP shall be securely attached together with bag in a conspicuous location on the pump With the engine cooled to a temperature of not more than 100 F the fol lowing shall be accomplished 1 Engine crankcase shall contain P 10 Type I Grade 10 or 30 preservative oil as applicable filled to operating level 2 Spark plugs shall be removed exercising maximum care in handling to avoid damage to threads and electrodes during preservation 3 While engine is being cranked manually two ounces of P 10 Type I Grade 30 preservative oil shall be at
260. cedures for loading these data in the master record 5 30 EXPLANATION OF CODES 5 30 1 A Age Miles Kilometers Hours and One Time Repair Life expectancy years and miles kilometers hours have been reached or exceeded the vehicle requires repairs which would exceed the one time repair allowance and the repair approval authority has decided that only minimum essential repairs shall be made 5 30 2 Age and One Time Repair Life expectancy years have been reached or exceeded the vehicle requires repairs which would exceed the one time repair allowance and the repair approval authority has decided that only minimum essential repairs shall be made 5 30 3 C Miles Kilometers Hours and One Time Repair Life expectancy miles kilometers hours have been reached or exceeded the vehicle requires repairs which would exceed the one time repair allowance and the repair approval au thority has decided that only minimum essential repairs shall be made 5 30 4 One Time Repair Repair estimate exceeds the one time repair allowance and the repair approval authority has decided that only minimum essential repairs shall be made 5 30 5 Obsolete Assign when the item manager declares the vehicle obsolete The vehicle maintenance activ ity will manually enter this code in OLVIMS upon notifica tion 5 30 6 Age and Miles Kilometers Hours Life expect ancy years and miles kilometers hours have been reached or exceeded 5
261. chance of leakage Coordinate this requirement with the base FOD officer concerning flightline vehicles 4 21 5 5 The use of metal valve stem caps is not autho rized Metal caps will be disposed of and replaced with plastic caps 4 9 TO 36 1 191 NOTE Types of tread designs are defined as regular highway mud and snow lug diamond ribbed etc Different retreaders or manufacturers tread design of the specific type may be intermixed on the same axle of vehicles Different types of tread designs may be intermixed on the same axle of slow moving non self propelled equipment 4 22 INSPECTION AND SERVICING Tire inspections and servicing are essential in obtaining maximum tire use The guidelines furnished below are those that will ensure economic and safe tire utilization These procedures should be locally altered when it is beneficial to the Air Force However the altering of these procedures should never result in a potential injury to personnel or impede equipment mission accomplishment or safety 4 22 1 Nitrogen filled tires Some new commercially manufactured base maintenance vehicles are equipped with nitrogen filled tires The advantages of nitrogen are a longer service life for the tire and lower fire explosion potential during hot weather high heat conditions These tires can be serviced with standard nitrogen servicing equipment such as that used to service accumulators on 463L equipment Only trained vehicle mana
262. cial Phone Number Flight Commander i444 Safety Official Phone Number if Reported to local Safety Office i446 Leave Blank i472 Leave Blank i474 Leave Blank i476 Leave Blank i478 Country 1380 USA Bad Actor Choose N i950 Enter N A i1335 Details Problem Summary i340 Include the following as a minimum a chronological account of events leading up to the deficiency b description and cause of the deficiency if known c action taken or recommended and d applicable TO Figure and Index of the failed component 1590 Additional Information i1590 Include registration number M H K and results of inspections performed on similar items or vehicles Note Use the Forward DR button to automatically open your e mail program and forward this DR for local editing and approval Use the Submit DR button to submit this DR to the applicable ALC after local coordination and approval It may appear that nothing happens after clicking the Submit DR button This is normal and the DR has been sent lo the ALC unless you receive an error notice You should receive confirmation from the Dreams Server in a few hours Use the Forward DR button again to send a courtesy copy of this DR to the applicable POC after submission to the ALC Figure 7 1 7 17 6 Foreign Use When vehicles are used outside the 50 states of the United States the District of Columbia and when applicable Puer
263. ck oils grease and heavy rust preventives These soils are usually removed with alkaline cleaners Heavy deposits of this type are 6 35 TO 36 1 191 usually best removed by using a solvent first and then applying an alkaline cleaner c Soils Containing Solids Examples mud carbonized oils and corrosion products scale These soils are usually the most difficult to remove Removal of these soils usually takes a combination of solvent soaking alkaline pressure spray and scrubbing mechanical agi tation and in case of corrosion products acid pickling or abrasive blasting As mentioned before aged soils increase difficulty of removal 6 15 5 Types Of Cleaners Cleaners that are used in this technical manual may be placed in three types as follows 6 15 5 1 Alkaline Cleaners This type of cleaner re moves a soil by displacement from the surface rather than by direct solution in the cleaner After displacement the soil may be carried in the body of the cleaner as a suspension it may separate or in the case of fatty soils it may react partially or completely with the cleaner to form water soluble soap Cleaners of this type usually have components that aid in lifting from a surface 6 15 5 2 Solvent Cleaners This type of cleaner re moves a soil by dissolving the soil and usually leaves a thin film or residue of an oily nature Removal of this oily film or residue is accomplished by using an alkaline cleaner 6
264. cks according to vehicle mission and projected gross vehicle weight as long as load range is equal to or higher than the type listed in the OEM Operations User s Manual In the event OEM or WR ALC deviates from this guidance through service bul letins IMCs TCTOs etc WR ALC s new guidance takes precedence 4 19 6 Tires on tactical vehicles M Series will normally be replaced with original equipment tread design NDMS or NDCC If these vehicles are not used in tactical support missions the VFM may approve the use of commercial mud snow or highway tread design NOTE Changes in these general rules can be made in response to manufacturer s recommendations for special vehicles loads missions 4 20 BREAK IN New tires should have a break in period Limit speed to 55 MPH for first 50 miles Avoid rapid acceleration or hard braking 4 24 TIRE MANAGEMENT Inflate radial tires to the maximum pressure recommended by the manufacturer for the specific vehicle tire and mission TO 36 1 191 Use inspection methods of Paragraph 4 23 to determine proper tire pressure maintenance Adhere strictly to the fol lowing guidelines 4 21 1 Never exceed maximum pressure shown on the tire sidewall or capacity of rim unless directed by the manufac turer s service guidance In the event OEM or WR ALC deviates from this guidance through service bulletins IMC TCTO WR ALC s new guidance takes precedence See Figure 4 6
265. cleaner can be treated by local facilities 6 15 6 4 4 Type IV is heavy duty cleaner effective for cleaning heavy oils and greases This material differs from Type I in that it has no flash point Type IV is biodegradable in many waste treatment facilities however before using verify that this cleaner can be treated by local facilities Type IV will separate out oily waste allowing the waste to be removed and disposed of while the remainder of the cleaning solution is sent to a waste treatment facility 6 15 6 4 5 Type I and IV cleaners may be used dip tanks They may not be used in vapor degreasing tanks NOTE Use only authorized cleaning materials and fol low the manufacturer s guidance on dilution agitation and rinsing Damage to the surfaces being cleaned coating deterioration or prema ture corrosion may occur 6 15 7 Solvent Cleaning and the Use of Salt Water Washdown Additives 6 15 7 1 Solvent based cleaners are typically used to clean oily or very stubborn soils and stains They must be used carefully to avoid damage to equipment and personnel Additionally many of these solvents are targeted by environ mental regulations that may limit their use or place extreme restrictions on disposal techniques Judicious use will get the job done while minimizing the amounts of cleaners that have to be disposed of The regular use of saltwater washdown additives applied to vehicles during regular wash and clear
266. conjunction with catalytic converters shall be properly in stalled Catalytic converters will meet federal emission re quirements straight up exhaust stacks shall have a raincap installed 1 7 2 55 Fairleads Cranes Bushings sheaves pins and mountings shall have no excessive wear See Cables Paragraph 1 7 2 28 1 7 2 56 Fifth Wheel Fifth wheel and rocker pins shall be properly lubricated and not show signs of excessive wear Locking jaws in the locked position shall not have more than 1 8 inch wear Locking components shall operate properly and be free of excessive wear See King Pin and Fifth Wheel Plate Paragraph 1 7 2 83 1 7 2 57 Filter Differential And Pumping Pressure Micronic filters and filter separators shall have correct differ ential pressure and filter flow rate when operated at normal pumping pressure Condition of filter elements or separators shall be determined by differential pressure readings quantity of fuel pumped through filter assemblies or date of installa tion in accordance with TO 37A 1 101 1 7 2 58 Floodlight And Spotlights fuel required for testing purposes shall be removed from unit prior to shipment Flood and or spotlights shall operate properly and be securely mounted Directing components shall be securely mounted and operate properly Lenses shall be properly installed and shall not be chipped or cracked to the point which allows dirt or water to enter 1 7 2 59 Floors
267. contain lubricating oil conforming to re quirements of applicable drawing specification or lubrication order filled to operating level When air cleaner contains P 10 preservative oil grade as applicable operating level shall be at tained by addition of the same grade oil or lu bricating oil conforming to Specification MIL PRF 2104G Clean batteries cable and battery boxes as re quired with a solution consisting of one half pound of soda ash CID A A 59563 per gallon of water Disconnect cables removing the ground cable first and secure to battery support with tape con forming to Specification SAE AMS T 22085 Inspect filter element to ensure it Type is clean COLUMN COLUMN COLUMN COLUMN I II Item Component Level Type of Vehicle B AV a b Air Cleaners A B AV Air Type Batteries A AV a cables and electrolyte with no holes or slits Clean all dirt and par ticles from filter housing Ensure filter seats proper Do not coat element with preservative Tape all openings with tape conforming to SAE AMS T 22085 When working around batteries always wear eye protection face shield acid resistant rubber apron and gloves Clean batteries cable and battery boxes as re quired with a solution consisting of one half pound of soda ash Specification O S 571 per gallon of water Disconnect cables removing the ground cable first and secure to battery support with tape con f
268. corrosion prone locations as listed in the appropriate column of Table 6 2 6 6 2 Local vehicle managers shall be responsible for assuring that local Commander s standards imposed are met preserved Any Materiel Deficiency Reports MDRs attributed to corrosion are to be documented in vehicle historical records Decision as to using in house capabilities or contracting out shall rest with local managers and bioen vironmental engineers In house capabilities will be used to the maximum extent possible 6 6 2 1 The impact of corrosion is normally slow and is dependent on many factors such as time operating location preventive maintenance etc 6 6 2 2 Local Vehicle Fleet Managers and technicians should be familiar with the different types of corrosion as shown in Paragraph 6 16 the types of preventive materials and processes listed in this technical order and those refer enced in Paragraph 6 3 6 2 6 6 2 3 Utilizing MDR system to elevate the early identification of corrosion problems to the MAJCOM vehicle manager depot program manager and equipment specialist will greatly assist Air Force efforts in corrosion awareness in equipment design and corrosion preventive process develop ment 6 7 CORROSION CONTROL LEVELS Four levels of corrosion prevention are used 6 7 1 TypeA Factory Rustproofing Protective coatings applied by the vehicle manufacturer as the standard protec tion provided for all their commercial vehicl
269. cover open 8 22 3 7 16 Secure tag AF Form 1492 on refueler operating control panel with inscription OPEN MAIN TANK SHUTOFF VALVE BEFORE ENGAGING PUMP 8 22 4 Oil Purge This method is authorized as an alternate procedure where capabilities exist The preferred fluids for this purge are specification MIL PRF 38299C or 8 62 100 percent JP 5 Where time operational commitments or material constraints do not allow use of these the following fluids are also authorized Jet fuels Grades Jet A Jet A 1 and JP 8 Diesel fuels Diesel Fuel Marine MIL F 16884 and Diesel Fuel Regular CID A A 52557A Grades DFA DFW DF 1 and DF 2 No other purge fluids are authorized 8 22 4 1 Static ground the tank to an approved ground reference Technical Order 00 25 172 8 22 4 2 Place containers under drains Open all valves and drain all fuel from the tank and pumping system using all available low point drains tank sump filter separator manual drain pump drain line strainer and bottom loading manifold 8 22 4 3 Dispose of drained fuel in accordance with Technical Order 42B 1 23 or AFM 23 110 8 22 4 4 Close all valves and drains 8 22 4 5 Fill refueler cargo tank with purge fluid NOTE Purge fluid shall be of the highest flash point available but in no case less than 100 ASTM Standard D93 and Technical Order 1 1 3 prior to being pumped into the refueler cargo tank Allow fluid to remain in tank for a minimum of 20 min
270. craper or bevel edge putty knife between applications The paint remover may damage the paint beneath the tape requiring cleaning and touchup painting in that area 2 88 3 A proven alternative to the above procedure is use of a 4 or 6 inch stripe molding and decal remover disk 3M that removes pressure sensitive tape without damaging the underlying paint finish Disks are available under NSN 5130 01 390 9503 4 inch and NSN 5130 01 390 9504 6 2 25 TO 36 1 191 inch and an adapter for using the disks with a drill is available under NSN 5130 01 391 2095 NOTE The above solvents are flammable and toxic therefore all safety precautions shall be taken 2 89 REQUISITIONING OF MARKINGS All markings listed in this chapter source coded WR ALC will be requisitioned in accordance with AFI 37 162 Request will be submitted on DD Form 843 to DAPS Sacramento 5015 Arnold Ave Bldg 29 McClellan CA 95652 916 643 4952 Completed Form 843 may be faxed to 916 643 4768 NOTE If decals are not available upon immediate req uisition and equipment involved hampers mission capability or presents a safety hazard in an unmarked condition appropriate markings may be stenciled on vehicles or equipment prior to receipt of decals Table 2 1 2 90 FIGURES The following figures are representative of the various types of bumpers cabs and bodies upon which the vehicle mark ings specified in this technical order are to
271. ctural Inspection Checklist If A Crack Is Found Enter Y In The Corresponding Block Otherwise Enter A N DISCREPANCY EXISTS REAR CROSS MEMBER Y N Inspect welds of rear cross member to under ride protection Inspect welds of D ring tie downs and associated gussets at the rear bumper Inspect welds of rear cross member at side rails Inspect cross member for cracks in the parent material Inspect welds of both main beams at the rear cross member DISCREPANCY EXISTS MAIN DECK TOP Y N Inspect welds of side rails at the forward bulkhead cross member Inspect welds of metal decking to the surrounding structure as applicable X Inspect top surface of main beam flanges for cracks in the parent material Inspect welds of both main beams at the forward bulkhead cross member Inspect welds of both gussets in the transition from the gooseneck to the main deck forward bulkhead cross member If A Crack Is Found Enter Y In The Corresponding Block Otherwise Enter DISCREPANCY EXISTS GOOSENECK TOP Y N Note Remove fixed covers as applicable Be sure to inspect welds inside of tool X X X boxes 3 19 TO 36 1 191 Table 3 8 Semi Trailer Structural Inspection Checklist Continued If A Crack Is Found Enter Y In The Corresponding Block Otherwise Enter A Inspect welds of main beam flanges at the main beam webs i me Inspect welds of toolbox covers and hinges ieee
272. cured to prevent pilferage and theft Water tank body Water tank body shall be cleaned in accordance with Method C 14 using a non toxic cleaning compound and dried IAW STD 2073 1D After cleaning drains and lower out lets shall be left in open position and openings covered with filter paper or fine mesh aluminum or plastic screen secured in place with tape conforming to Specification SAE AMS T 22085 for Level A and B Removed drain plugs shall be coated with Type P 14 preservative and placed in a bag conforming to Type II Class C of Specification MIL DTL 117H Bag will be identified sealed and securely attached to one of the faucets or in a conspicuous location within equipment compartments Valves faucets and forward outlet shall be coated with Type P 14 preservative Rubber seals of hatches and top openings shall be coated with talc conform ing to Type IV Class C of Specification CID A A 52518 and forward outlet hatches and top openings shall be closed and secured Equip ment compartment drains shall be secured in open position and compartment doors closed and secured to prevent pilferage or damage For steel tanks other than stainless or precoated all interior tank surfaces shall be coated with CID A A 52518 Type P 14 preservative NOTE Water storage and foam tanks on fire fighting equipment will be cleaned by any applicable method Coating will conform to Specification MIL C 18480 8 17 TO 36 1 191
273. d Assure this opera tion has been reviewed by the local bioenvi ronmental engineer Chromate SAE AMS C 81769 is toxic to skin eyes and respiratory tract Avoid skin and eye contact Good general ventilation is normally adequate e Airless spray guns use very high pressure prevent injury hands will not be used to check the output 2 19 3 1 Surfaces for all vehicular equipment except and E vans shelters shall be prepared in accordance with TO 1 1 8 MIL HDBK 808 Air Force change drawing number 98752 7737593 2 19 3 2 The surfaces of communications and electronic vans shelters may be prepared with either PR 1432GV polysulfide primer or MIL PRF 23377 epoxy primer The major command owning the vehicle may specify an alterna tive primer to be used Refer to TO 1 1 8 and the manufac tures instructions for the mixing and application of epoxy primer MIL PRF 23377 and polysulfide primer PR 1432GV In the event of instructional conflict the primer manufacturer application instructions shall take precedence Pre treat all bare aluminum with a non chromate conversion coating such as Henkle Alodine 5700 or equivalent prior to application of polysulifide primer Apply two coats of polysulifide primer preferable with an airless spray gun Each coat should 2 5 TO 36 1 191 provide a dry film thickness of 1 0 to 1 5 mils 0 025 to 0 038 mm Allow manufacturer s recommended drying time be tween each coating 2 20 SPECI
274. d 542945 euoneded uuoj1oq Sepoui Joy suononujsut 10 I 6 CINO9 OL 995 sepour pouinboi 10 ore suoneinsyuoo spotted 10 1dooxo umop 329p 14819 OAR pS 0j 155200 YI eui 3snf sisseuo 8 PUY Od SHATVA NOLLV IOSI NOISNHd SNS ASOD LON OQ 118 soid uorsuedsns 1 1940 T UOIS uadsng Sune1odo onunuoo SXoo q YM 303002 19V enprarpur 0 suoneooj sisseuo Jopun pasn oq ouv d j10d dns SururoJ 42019 HOW C p y uonoos TI SE cIN9 OL spuvis xoef 10 payloads suonisod SISSeqo pouon Isod eq reus 5209 Jo y 209 suo 01 Suyos suon Ipuoo JO pezis 10 dns 10 sxoo q qour 9 0j uo ore suoneinsyuoo spon d 10 1dooxq aqny sjurod Joaid pue saurmoq oqn TO 36 1 191 ON sjuauroumnbos uonenSguooos sxreurow puy 1 8 ILL joefqng ON Jopeo 8 jje3oury 09 UUN T V A 2 TO 36 1 191 sonpoooi1d ooueuojureur Inoy 067 Jo OT p p uonoes z Cc e cIN9 OL Jed 9S0 175 6 uones 6
275. d and condition of inside and outside treads New tubes may not have valves with proper bends Replace any leaking cores Install valve caps and tighten valve stem nuts especially on new tubes If installing or replacing tubes in radial tires ensure radial designated tubes are used 4 31 TIRE FLAPS Flaps should be of proper size and type for the tire Check flaps for cracks folds tears and cleanliness Ensure radial designated tube protection flaps are used with radial tires 4 32 RIMS Check rims for cracks dents dirt and rust especially in the gutter Figure 4 18 Be sure that rim lock ring is of proper size and type for the rim used and is not sprung or bent Inspect wheels for worn or out of round stud holes and cracked disks Side rings and locking rings are not inter changeable if they are of different manufacture Wheel rims for tubeless tires must be free of rust gummy rubber deposits nicks and gouges in the rim bead seat surface so as to provide an airtight seal with tire bead 4 32 1 and wheel maintenance during tire inspec tions 4 32 1 1 Check all metal surfaces thoroughly while mak ing tire inspections including areas between duals and on inboard side of wheel Watch for e Excessive rust or corrosion buildup cracks in metal e Bent flanges resulting from road obstructions e Deep rim tool marks on rings or in gutter areas e Loose missing or damaged nuts or clamps e Bent or stripped studs
276. d to the responsible VFM for corrective action When this document is specified contractually the authority to repair and the extent of repair to be contractually accomplished if any shall be as specified by the procuring agency This document shall not be interpreted as authorizing repair by the contractor Notify WR ALC LE if any unusual problems are encountered or vehicles are unserviceable for an extended period of time 8 20 INSPECTION 8 20 1 Receiving Each vehicle received shall be inspected for serviceability in accordance with Chapter 1 This inspec tion shall include accomplishment of a listing of depreserva tion actions required to place the equipment in operational ready status Those parts of the serviceability inspection which require equipment operation may be conducted at the time of initial exercise The depreservation check list shall indicate whether the vehicle is equipped with a wet battery or with a dry battery and electrolyte It shall also include information as to the status of preservation of On Vehicle Equipment OVE for storage The responsible VFM will ensure that proper discrepancy reports are prepared on vehicles received in incomplete or damaged condition When receiving inspection indicates that carrier liability and claim action may be involved the damaged unit should be held as is if practical pending notification to the carrier and correc tive action under applicable regulations 8 20 2 During Storage
277. d warning lights 2 96 4 General purpose vehicles which rarely operate on the apron and taxiway areas at night i e staff cars buses and station wagons may be equipped with aviation yellow magnetic based caution lights at the discretion of the local commander 2 96 5 Snowplows and Emergency Arresting Barrier Ve hicles shall use the revolving flasher type light with amber yellow or blue globe Light must be capable of emitting no less than 40 nor more than 400 candle power Rotation will be such as to emit at least 90 flashes per minute and be visible through a 360 degree radius 2 96 6 Lighting equipment over and above that indicated in the preceding paragraphs may be installed to meet local conditions and state local regulations NOTE Warning lights will not be permanently affixed to Security Police alert reflex fire chief EOD ve hicles etc Detachable mounting brackets will be used to facilitate vehicle rotation 2 96 7 requirements for non revolving pulsating yel low lights should be filled when possible by removing the non revolving pulsating light from vehicle which have both the non revolving pulsating light and the hazard warning lights 2 96 8 Red revolving flasher lights presently installed on metropolitan ambulances will not be replaced solely to comply with this TO but will be replaced if required by local or host country law The lights on these ambulances will be replaced on an as required basis
278. damage NOTE Requirements for fuel pumping systems filters and segregators are covered un der applicable items 8 15 TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN COLUMN I II Item Component Level Type of Vehicle Processing Required 11 Bodies Soft A B GP Top shall be removed thoroughly dried folded or Top Vehicles rolled in a manner to avoid creasing of plastic windows packaged in accordance with Method IC 5 of Specification MIL P 116 and packed in a nailed wood box conforming to Specification PPP B 621 Box shall be identified and stowed with other OVE Windshield wiper arms and blades shall be removed and together with keys stowed in dash compartment and wind shield secured in folded down position When dash compartment is not provided wiper arms and blades together with key shall be placed in a bag conforming to type optional Class b of Specification MIL B 117 and securely attached to steering column Seat backs and cushions shall be removed and fabric surfaces covered with barrier material conforming to Type CW 1 Class 2 or Type B 2 Class 2 grade A of Speci fication MIL B 13239 Barrier material shall be secured with tape conforming to Specification MIL T 43115 for Level B and MIL T 22085 for Level A and seat backs and cushions reinstalled Dash panel including defroster vents shall be covered with waterproof paper conforming to Specification PPP B
279. de the CONUS in which case the contractor will pay shipping costs to the port of embarkation designated by the government In the event it is necessary to return defective parts components to the contractor for inspection shipping costs will be borne by the activity requesting warranty Commercial chassis on which special purpose equipment is mounted will have the same warranty as previously outlined for commercial ve hicles 7 17 9 Warranty For Trailers Due to the wide latitude in warranty coverage furnished by various commercial trailer manufacturers blanket instructions cannot be developed Normally trailer components such as landing gears suspen sion systems and brake systems are covered by warranty for 90 days and will be reported direct to individual component manufacturers or local dealers Failures and or problems encountered on basic trailers are normally covered by a one year warranty against faulty material and or workman ship Problems of this type will be reported to the local dealer or manufacturer s office when dealers are not available If assistance is required contact WR ALC LE 7 18 WARRANTY EXCEPTIONS 7 18 1 Tires and Batteries The basic vehicle warranty does not cover tires and batteries These items are warranted by the tire and battery manufacturers under their own warranty provisions Warranty provisions are largely depen dent upon method of procurement The following information is provided to ass
280. der where the vehicle will be repaired 1 by the base vehicle manage ment activity a nearby government installation contract maintenance or a depot repair activity When preparing the repair estimate to decide whether or not the estimated cost of repair will exceed the one time repair allowance include the expenses listed below Exception Refer to Paragraph 5 21 when developing repair estimates for contractor maintained vehicles 5 12 1 Direct labor 5 12 2 Direct material 5 12 3 Indirect expenses 5 12 4 Other charges as may apply 5 13 DIRECT LABOR Work which can be identified to a specific repair job is direct labor Use the shop hourly labor rate when figuring the cost of direct labor 5 14 DIRECT MATERIAL Material or supplies which can be identified to a specific repair job are direct material 5 14 1 Determine the cost of all direct material which will he used to fix the vehicle 5 14 2 Consumable items obtained from the normal supply system will be charged at the standard inventory price Local purchase and COPARS consumable items will be priced at the invoice cost including any transportation charges which you can identify Items made locally will be charged at the actual cost 5 14 3 Components and assemblies used in the repair process will be costed at the exchange price For exchange able parts obtained from the normal supply channels a price of 50 percent of the stock list price will be used
281. e Vc soSurg SIOO T PUR SMODUIAA drys 19M So q9 jueuidmqs 19 EM 10 So q souiopeg ON PAT C8 PL i ofqng ON 19peo T 031e 09 T V A 9 TO 36 1 191 uoreoo ewou pue yoedun uorjeoo ewou oj pue yoedun uoroo oj pue xoedu e qeo i dde jr uontsod preoqjno 0 JENU II Ieq pue Surpueq sjuauroumbos uonen83guooos suon onusur uoneinaguoood 917 IF 01 pI 6 cIN9 OL pu c C cIN9 OL TI SE E CINDE OL 9pn our progs suoneor qnd 29 v 9497 06 7 8 ALL 198 5 V 9197 7 9 ALL 108 9 9 98 0 8 ALL Jed 5 VAT 7 9 ALL 108 18 1ed Suruedo 0 qe pueg uwap 100p 8 woyoq SutA 9 C80cC L TIN 19d y m eos pue I SSUP TET q TIIA 198 peno IoLIIeQ JO soprs pue do 19407 G80CC L Jed IQP 19407 2ejuoo So qeo pue sasoy 129 01d n o c T op c TI SE ZINDE OL 199 preoqur epi s oonper
282. e ing made by the tire shop during mounting or repair 4 24 RETREADING TIRES USAF policy requires the use of retread tires to the maximum extent possible Buy new tires only when original tire carcasses are too worn to retread retreads are not available or retreads will not meet the minimum performance or quality standard for their intended function 4 24 1 Technical Criteria 4 24 1 1 Physically inspect tires to ensure that they meet the condition criteria for retreading THIS TIRE WAS DRIVEN A SHORT DISTANCE WHILE FLAT DAMAGE WAS NOT VISIBLE FROM THE OUTSIDE F09603 054 Figure 4 12 An Example of Tire Abuse 4 24 1 2 The same tire may be retreaded any number of times if the carcass is free of defects which render it unacceptable for retreading NOTE It is not necessary to insert inner tubes in properly retreaded tubeless tires 4 24 2 Economic Factors 4 24 2 1 Limit the unit cost for retreading to 100 percent of the acquisition cost of a new replacement tire Include transportation charges in the cost analysis when those costs are documented and will drive the cost of the tire above the new tire cost 4 24 2 1 1 the projected or actual cost of retreading exceeds the 100 percent limitation ask the contracting officer to consider alternative sources for retreading service 4 24 2 1 2 is authorized to waive the 100 percent limitation when the benefits from retreading will equal o
283. e Assem blies 3 6 15 1 Check cylinders lines seals and reservoirs for general condition and possible contamination particles and water Change fluid every 3600 operating hours or three years whichever comes first Document change on AF Form 1828 Change 1 3 8 1 3 8 2 blank 3 6 15 2 Change filters in accordance with applicable TO NOTE Sonic filters can be removed cleaned and rein stalled in lieu of replacement 3 6 16 Drive Line Carefully inspect drive line to keep the vehicle operating smoothly Check boots for leaks cracks weathering and security of placement Replace as required 3 6 17 Warning Devices And Decals Inspect all ve hicle warning devices lights and buzzers for proper opera tion Ensure all warning and caution decals are in good repair and easily read 3 7 FUEL SERVICING EQUIPMENT INSPECTION The following inspections tests and services will be per formed in accordance with TO 37A 1 101 Gauge and meter calibration line and basket strainer inspection hoses used for hot ICT refueling and fuel dispensing pressure regulators Dry break couplers will be inspected in accordance with TO 37A4 3 3 These services are in addition to scheduled items listed in Paragraph 3 10 NOTE Hydrostatic hose testing is normally only re quired when new fuel hoses are installed or immediately after abnormal use i e crushing or kinking and after coupler s have been replaced installed or wh
284. e Matched rim parts 4 32 1 2 Dispose of damaged rims or wheels Excessively corroded or cracked rims of rings can be dangerous Deflate tires prior to the removal of rims or wheels from the vehicle 4 32 1 2 1 Mark damaged or hazardous areas with chalk so that part will be removed from service 4 32 1 2 2 Replace damaged parts Ensure that replace ments are made with proper sizes and types of rims and rings 4 32 1 2 3 Inflate tires only to recommended air pressure 4 19 TO 36 1 191 4 32 2 Rim and wheel maintenance during tire changes 4 32 2 1 Check all metal surfaces A more thorough check may be made however after the tire been demounted 4 32 2 1 1 Cracks in the rim base in the back flange and gutter areas are caused by deep rim tool marks overloading over inflating tires and using larger than recommended tire sizes 4 32 2 2 Cracks through side ring spreading laterally through the entire section are caused by improper mounting and demounting techniques impact with road obstructions and excessive clamping torques 4 32 2 3 Cracks in the wheel disc between stud holes or hand holes are caused by loose wheel nuts improper installation procedures and use of incorrect sizes types of attaching parts 4 32 2 4 Erosion and chipping of bead seat of lock ring resulting from excessive corrosion may occur with this part as well as others if protective measures are not taken Wire brush operations are hazardous to
285. e at sustained highway speeds This decision however must be supportable through fully documented failure history Failures of retreaded tires will be reported to the contracting officer High failure rates should be reported to the contract administrator 4 24 3 5 Tenant vehicles will be required to use retreaded tires on the same basis as host base vehicles Exceptions will require a request from the major command headquarters for the tenant concerned TO 36 1 191 4 24 3 6 Check federal state and local laws before using retreaded tires Some states restrict the use of retreads based on wheel or tire type 4 24 4 Procedures for Obtaining Retread Services 4 24 4 1 Overseas Through Interservice Support Agree ment or contract maintenance Federal Specification ZZ T 0041 or other equal standards will be used 4 24 42 CONUS Through contract maintenance using Federal Supply Schedule FSG 26 as a guide These sched ules are negotiated yearly by GSA region however this does not restrict the VFM from utilizing local businesses that are economically competitive and within a reasonable distance Normally vehicle management will process tires to contract maintenance The VFM will be the determining authority on which source will be used 4 2443 All efforts will be made to ensure original carcasses are returned This will aid in the recapping effort 4 25 REGROOVING TIRES Regrooving of tires is optional as a means to cut o
286. e cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613182 Letter Y die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613183 Letter Z die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613184 Letter A die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613185 Letter B die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613186 Letter C die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613187 Letter D die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613188 Letter E die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613189 Letter F die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613190 Letter G die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613191 Letter H die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613192 Letter die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613193 Letter J die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613194 Letter die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613195 Letter L die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613196 Letter M die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613197 Letter N die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613198 Letter O die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613199 Letter P die cut pre spaced Silver None 1 1 2 in 2 in x 1 4 in 3613
287. e following markings must be included on tires manufactured for highway use Figure 4 6 4 13 1 1 Size 4 13 1 2 Maximum permissible inflation pressure 4 13 1 3 Maximum load rating 4 13 1 4 Manufacturer s identification by name or by brand name and a specified numeric code marking 4 13 1 5 Ply cord material 4 13 1 6 Number of plies in the sidewall and number of plies in the tread if different 4 13 1 7 Tubeless or tube type 4 13 1 8 Note that tire conforms to Federal Motor Vehicle Safety Standards PLY RATING LOAD RANGE PLY RATING F09603 043 Load Ranges RADIAL PLY F09603 044 Figure 4 2 Tire Construction 4 3 TO 36 1 191 CONVENTIONAL RADIAL SQUIRM NO SQUIRM SQUEEZE NO SQUEEZE F09603 045 Figure 4 3 Handling Characteristics RADIAL PLY DEFORMED NARROW CONTACT AREA FULL FLAT CONTACT AREA DIAGRAMS SHOW DIFFERENCES IN CONVENTIONAL BIAS PLY TIRES AND RADIAL PLY TIRES WHEN CORNERING STIFF SIDEWALL OF CONVENTIONAL TIRE LIFTS PART OF THREAD OF THE PAVEMENT WHEN RADIAL IS PROPERLY INFLATED IT RESISTS SUCH DEFORMATION DUE TO ALL OF TREAD AREA AND SIDEWALL WHICH FLEXES MORE EASILY F09603 046 Figure 4 4 Cornering Characteristics 4 4 TO 36 1 191 OVERALL SECTION 4 WIDTH SECTION WIDTH MM SECTION HEIGHT RIM gt WIDTH OVERALL DIAMETER RIM INCHES DIAMETER STATIC LOADED RADIUS DEFLECTION LL TREAD WIDTH STATI
288. e space inside closed cabs or bodies or within waterproof compartments is used the requirements for waterproofing of the exterior container covers is waived provided the OVE can remain as stored throughout shipment When exposed storage of OVE boxes is neces sary cleats or skids will be placed beneath the boxes to protect against contact with accumu lated moisture Shipment OVE boxes shall be secured to pre vent shifting during loading transit and unload ing operations Every effort will be exerted to so position the boxes that shipping cubage is held at an absolute minimum Boxes containing elec trolyte batteries or other dangerous items shall be located to facilitate inspection or removal if necessary It is recommended that strapping be applied to boxes only at time of out shipment See Item 75 See Chapter 6 a Treatment of dash panels is covered under Bod ies Control and instrument panels which are housed in cabinets or in compartments with ac cess doors shall have controls or instrument faces protected with adequate cushioning and the openings around the door or cover sealed with pressure sensitive tape conforming to Specification MIL T 43115 level B MIL T 22085 level A 87 88 89 90 COLUMN I Item TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN II Component Level Pintles A B Plates Identifi A B cation Power Take Off A B Assembly Publications
289. e zinc rich primer clogging the paint spray gun Do not use zinc rich primer as an intercoat adhesion promoter for topcoat touchup Zinc rich primer is designed to be applied only over properly prepared bare steel 2 20 2 2 Two Part Zinc Rich Primer Coating Sys tem two part coating system consists of one coat of zinc rich primer conforming to MIL PRF 26915 Type II and a wet to wet application of one coat of MIL P 53030 a water reducible chrome and lead free intermediate primer The wet to wet application means immediately after applying one coat of the zinc rich primer clean the spray gun and apply the second coat of primer using MIL P 53030 The wet to wet application ensures bonding between the two primers The MIL P 53030 provides a smoother primer coating and covers any zinc particles that may later cause white specks through the topcoat The smoother the primer coating the smoother the appearance of the topcoat 2 20 8 Ceramic Loaded Coatings The loaded coatings are epoxy coatings filled with ceramic particles that provide long term erosion wear and corrosion protection Ceramic loaded coatings manufactured by Free com Inc Big Spring TX or equivalent are for optional use only in high wear areas where chalking and fading is not an aesthetic concern Units desiring to use this material should contact WR ALC LE for approval prior to use NOTE Epoxy coatings will fade and present a chalk
290. ean immediately Clean and apply a coat of MIL C 62218 Do not polish 8 23 TO 36 1 191 COLUMN COLUMN I II Item Component 36 Clutch 37 Compressor Air 8 24 Table 8 2 Processing Procedures Continued COLUMN COLUMN Level Type of Vehicle COLUMN V Processing Required A AV Clutch pedal with gear shift in NEUTRAL posi tion shall be depressed a distance sufficient to remove free play and then depressed 1 to 1 1 2 inches more Pedal shall be secured in depressed position by wiring to floor board plates or by wiring a wood block to pedal shaft beneath floor board Flywheel housing drain plug shall be removed and coated with Type P 1 preserva tive Drain plug together with a warning tag bearing the information FLYWHEEL HOUS ING DRAIN PLUG REMOVED REINSTALL BEFORE PLACING VEHICLE IN SERVICE shall be securely attached in a conspicuous loca tion within driver s compartment When a threaded boss is provided in flywheel housing adjacent to drain hole removed drain plug shall be installed in threaded boss A warning tag bearing the information FLYWHEEL HOUS ING DRAIN PLUG REMOVED AND IN STALLED ADJACENT TO DRAIN HOLE REINSTALL IN DRAIN HOLE BEFORE PLACING VEHICLE IN SERVICE shall be securely attached in a conspicuous location within driver s compartment Do not block two way tractor clutches after placing in neutral po sition Do not completely depress clutch pedals as
291. eck has been made to ascertain if a serviceable wet battery is available Every effort will be made to reduce battery room operations to a minimum 8 21 1 7 Fuel Tanks The vehicle s fuel tank shall be filled in accordance with AFMAN 24 20400 NOTE Depending on mode of shipment fuel tanks may require draining and purging prior to shipment in accordance with AFMAN 24 204 1 and Paragraph 8 22 of this manual If lengthy storage results gasoline fuel sys tems may show evidence of gumming In this event the following alternative procedure is authorized The fuel tanks shall be drained and coated with preservative conforming to Speci fication MIL PRF 21260E The fuel line shall be disconnected on the tank side of the fuel pump Exercising or operation will be con ducted using a portable fuel supply 8 21 1 8 Special Precautions Personnel assigned to depreservation shall be furnished specific instructions regard ing such special purpose vehicles as liquid oxygen gaseous cryogenic tube tank trailers and related equipment Many of these units are pressurized with nitrogen contain components 8 57 TO 36 1 191 which have been preserved under special cleanliness criteria that must be maintained until actual use may contain dangerous materials or are insulated by the drawing of vacuums on annular spaces No depreservation shall be accomplished or controls moved except by properly trained personnel The exercise method i
292. ected by the Theater Commander 2 41 2 The size of the national symbol will vary consid erably depending on the type vehicle concerned It should be large enough to take full advantage of the surface on which it appears and should use the largest clearly visible space 2 41 3 When used the national symbol will be applied to the hood and on both sides of vehicles using lusterless white paint Color number 37875 or nonreflective decals On horizontal surfaces the star will be placed so that one of the five points is directed toward the rear of the vehicle On vertical or nearly vertical surfaces one of the five points is directed up 2 41 4 The national symbol will not be used on vehicles operated in the continental United States TO 36 1 191 2 42 AIR NATIONAL GUARD ANG VEHICLES Additional marking for ANG vehicles may consist of using a plate same size as a license plate to identified unit s vehicles Units can put an additional front plate on the vehicle which will not replace the requirement for two license plates on the vehicle if state law requires it or MAJCOM The plate may consist of these elements Minuteman Decal or Unit Decal along with these lines 1 ANG 2 Unit Identifier 105AW 3 City and State Stewart N Y Which translates to ANG 105AW Stewart NY 2 43 RESERVE OFFICERS TRAINING CORPS VE HICLES Markings for vehicles assigned to the Air Force ROTC consist of two groups 1 i
293. ection The purpose of this section is to 6 40 provide maintenance personnel with the knowledge necessary to understand the causes of corrosion and in turn help minimize corrosion damage through prevention and early detection and treatment 6 16 1 Definitions of Corrosion Corrosion is the elec trochemical deterioration of a metal because of its chemical reaction with the surrounding environment This reaction occurs because of the tendency of metals to return to their naturally occurring states usually oxide or sulfide ores For example iron in the presence of moisture and air will return to its natural state iron oxide or rust Aluminum and magnesium form corrosion products that are white oxides or hydroxides When corrosion occurs water is usually present in some form e g humidity moisture condensation rain salt spray etc acting as an electrolyte and reacting chemi cally with metal surfaces 6 16 2 Corrosion Related Chemical Definitions 6 16 2 1 Atom The smallest unit of an element There are more than 100 elements including metals such as aluminum magnesium iron nickel titanium cadmium chromium copper and carbon and non metals such as hydrogen oxygen sulfur and chlorine 6 16 2 2 Electron negatively charged particle much smaller than an atom An electrical current occurs when electrons are forced to move through metal conductors Electrons also flow through water solutions but only in the
294. ector Pump 1 7 2 31 1 Carburetor Carburetors shall be securely mounted with all attachments installed Carburetor s circuits shall operate properly Fuel mixture screw caps EPA limit stops shall not be removed and shall have full control of air fuel mixture from rich to lean at idle Gaskets and diaphragms shall be in good condition and not leak 1 7 2 31 2 Fuellnjector Fuelinjectors shall be securely mounted and shall show no signs of leaking Fuel injection pumps and fuel injectors shall operate in accordance with applicable technical manuals 1 7 2 31 3 Governors Governor shall control engine within 5 percent of maximum rated RPMs but shall not exceed maximum rated RPMs Governor shall have no surge at maximum RPMs 1 7 2 32 Carriage Lift Forks And Mast Assembly Cargo rest shall be securely installed and properly aligned Welds shall not be cracked The horizontal position of both forks shall be the same plane and be free of cracks Forks locks shall be in place and function properly Mast assembly shall be free of cracks and will be properly aligned Chain sprockets and rollers shall be free from binding and cracks Load chains shall be properly adjusted and securely an chored All bolts and locking pins shall not show signs of wear and be secured Backrest shall be secure 1 7 2 33 Or Gidgeon Revolving Shovel Crane Deicer Manlift Or Work Platform Type Ass ests All components will be securely mount
295. ecurely mounted and properly aligned Grilles shall not have large areas broken out or main structure members cracked or broken Medallions and chrome strips if applicable shall be securely fastened 1 7 2 27 Bumpers And Push Plate Bumpers and push plates shall have the original contour of metal and shall not be cracked or have rusted areas All welds and mounting bolts shall be secured Rubber pads shall be secured and not show signs of excessive deterioration 1 7 2 28 Cables Boom hoist and winch cables shall be of properly rated capacity as prescribed by manufacturer The TO 36 1 191 cable will be free of kinks excessive wear flat spots frayed or broken strands and properly lubricated All mounts and U bolt clips will be properly torqued 1 7 2 29 System Dry Chemical Halon System Etc Fire Extinguisher Equipment Containers shall conform to appropriate technical order and or manufacturer specifications Desiccant tanks containers shall be recharged prior to storage shipment or placing in service Tanks shall be charged to appropriate pressures Hoses shall exhibit no deterioration Hose connections couplings piping and tanks will display no evidence of corrosion or leakage systems and components shall be securely mounted 1 7 2 80 Canvas Canvas shall not be torn or mildewed and shall have no missing grommets ropes or straps 1 7 2 31 Carburetor Fuel Injector Governor And In j
296. ed properly adjusted and will indicate no excessive wear Lock will operate effectively all adjustments shall be in accordance with applicable equipment manual Centerpin flange mount ing bolts or cap screws shall be secure 1 7 2 34 Chains Chains shall not be excessively worn pitted or have broken rollers Half master link shall be of 1 9 TO 36 1 191 proper size and locking device shall be secure Tension adjustment shall be in accordance with applicable technical manual 1 7 2 35 Clutch Clutch disc shall not bind or drag when disengaged and shall engage without grabbing or chattering Clutch adjusting device shall have at least 50 percent of the adjustment range left Clutch pedal free travel floor board clearance shall be in accordance with applicable technical manual Clutch release bearing shall be properly lubricated and operate without unusual noise Hydraulic clutch master and slave cylinder shall be free of all leaks Clutch adjust ments and operational characteristics will be in accordance with manufacturer s specification 1 7 2 36 Coil And Supressors Coil wiring and shielding shall be in good condition secure clean and connections tight Coil shall be capable of producing mini mum voltage required by manufacturer s specifications Sup pressers shall be in good condition and effectively eliminate interference 1 7 2 37 Commutator And Slip Rings Armature bear ings and lubricant seals shall i
297. ed discrepancies unless accomplished within last 90 days 3 13 1 1 Structural inspection per this table Any cracks annotated in Column A of the Semi Trailer Structural Inspec tion Checklist shall be corrected prior to releasing the vehicle from the vehicle management activity Repairs of deficiencies annotated in Column B of the checklist may be delayed up to 15 days at the VEM s discretion however every effort should be made to repair these discrepancies while the vehicle is in the vehicle management complex Repair of cracks identified in Column C of the checklist may be delayed until the next annual inspection 3 13 1 2 Check wiring system for broken or frayed sec tions 3 13 1 3 Check the suspension for broken or worn parts 3 13 1 4 Visually inspect brake operating parts for exces sive wear or damage Check slack adjusters for proper adjustment and operation TO 36 1 191 3 13 2 Annual Inspection 3 13 2 1 Perform structural inspection per this table and correct all weld cracks or other structural abnormalities 3 13 2 2 Every third annual inspection clean inspect replace as required and repack wheel bearings NOTE Wheel bearings lubricated by oil shall be cleaned and inspected replaced as required whenever the brake shoes are replaced anytime wheel bearings serviceability is a question or annually if regularly submerged in water ie boat trailers 3 13 2 3 Tighten all U or spring bolts as necessar
298. ed position If removed they will be strapped together and secured in the cargo compartment of the vehicle B AV No processing required Radiators A B AV See Item 40 Cooling Systems Registers Fuel A B ST a No processing required on sealed type registers SE 8 45 TO 36 1 191 COLUMN I Item 96 97 98 99 8 46 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN II Component Level Type of Vehicle Processing Required b Remove clean and coat operating mechanism with Type P 9 preservative oil Reinstall in original position on the vehicle and seal any openings with moisture proof pressure sensitive tape conforming to Specification MIL T 43115 for level B and MIL T 22085 for level A Rod Piston A B MH Coat machined surfaces of piston rod with Ford Truck SE P 10 Type 1 Grade 30 preservative oil Disconnect return oil line at hose connection and raise hoist to full height Insert cylinder oil return line in container filled with two quarts of oil from reservoir Lower hoist as in normal operation until oil is drawn into cylinder Raise hoist stopping elevation when oil starts to flow from the return line opening Fog interior with P 10 Type I Grade 30 preservative oil through the return line opening while lowering the hoist to bottom position Connect return line Coat top of piston rod with grease conforming to Specification MIL G 10924 and wrap with water proof grease proof
299. ed to stepping standing and walking surfaces of vehicles to eliminate potential safety hazards 2 24 HVLP SPRAY GUN PROCEDURES 2 241 High Volume Low Pressure HVLP paint spray guns shall be used as a means of keeping paint overspray to a minimum and to conform to federal state and local environmental requirements Refer to TO 1 1 8 Chapter 4 for more complete guidance on the operations and mainte nance of HVLP paint spray equipment 2 24 2 obtain the best results when spray painting the gun should be held perpendicular to the work at all times and approximately 6 to 10 inches from the surface The proper stroke is made with a free arm motion keeping the face of the air cap parallel with the surface at all points on the stroke The ends of the stream are feathered out by beginning the stroke before pulling the trigger of the gun and releasing the trigger just before ending the stroke Avoid arcing the gun during the stroke to prevent uneven application and excessive overspray at the end of the stroke in accordance with TO 1 1 8 Chapter 4 2 24 3 Adjust gun to operate at maximum speed consistent with material rate of flow surface and individual skill 2 25 MARKINGS The policy governing authorization of identification markings or exemption thereto are contained in AFI 24 302 2 25 1 Vehicles procured for Air Force use will be re ceived from the manufacturer without official markings 1 US Air Force For Of
300. ed vehicles 2 25 3 3 Part number AF 3 a desert sand plate with black numbers letters for use on all desert sand colored vehicles 2 25 3 4 The vehicle registration number will be affixed if not ordered preprinted centered on the license die cut letters and numbers will be Highway Gothic 1 1 2 inch Units also have the option to purchase the die cut letters and numbers from UNICOR Units will use one rear license plate or may use two license plates if directed by the MAJCOM or local law Existing license plates will be replaced with the new style plates only if they are damaged AF vehicles will either have an approved AF license plate or will be marked in accordance with Paragraph 2 40 2 2 25 35 Commands units will not place logos on em blems on the license plate 2 25 3 6 Force vehicles in the inventory prior to January 1992 with markings displayed on the side and rear of the vehicles will retain those markings as specified in this technical order until the vehicle is removed from the Air Force inventory Vehicles that require complete repainting or returned from depot will be marked with license plates when appropriate All other applicable markings will be applied as specified in this technical order For vehicles without appro priate mounting brackets brackets must be manufactured or procured locally 2 26 ACTIVITY MARKINGS The markings prescribed in this Technical Order provide a uniform method of ide
301. eduled maintenance intervals than those defined in this chapter is delegated to the VFM VMS in order to prevent premature engine component failure The following documentation will be available 3 4 8 1 Documented engine component problems prema ture failure evidence of impending failure excessive sludge accumulations etc 3 4 8 2 Cost analysis to include estimated cost of oil filters waste oil disposal and additional labor hours Analysis must address specific vehicles by registration number or management code and be maintained in each vehicle record jacket 3 4 9 VFM may establish a local policy allowing utilization of manufacturer guidelines for the replacement of fuel filters in lieu of TO 36 1 91 requirements Ensure correct replacement intervals in accordance with manufac turer s guidelines are loaded in OLVIMS 3 5 OPERATOR DAILY WEEKLY INSPECTION RE QUIREMENTS Daily weekly inspections and servicing will be performed by vehicle equipment operators using the appropriate Operators Inspection Guide and Trouble Report Form Applicable Form 1800 Series Refer to 24 302 for guidance on use of inspection guide forms NOTE The AF Form 1807 Operator s Inspection Guide and Trouble Report Fuel Servicing is applicable to a variety of refueler vehicles and equipment Since it is a multi use form some minor conflict with a dash one technical order 1 TO for a specific type or set of refuelers m
302. efective part s that will be replaced under warranty will place a vehicle in Non Mission Capable Supply status and an Air Force purchased replace ment part s can be made available the Air Force part s will be used to return the vehicle to service In this case the part s later replaced by the manufacturer will be used to replenish supply stocks 7 22 2 Return Of Defective Parts In overseas areas the user should exercise the vehicle warranty in one of the following ways 7 22 2 1 Submit a claim letter with an info copy to WR ALC LE to the appropriate contractor s representative Furnish contractor with a military shipment label DD Form 1387 as illustrated in Figure 7 5 Include in the claim an offer to return the parts which failed and the following essential information NOTE Manufacturer s are not equipped to receive teletype messages 7 22 2 1 1 Complete description of the failure Photos must be furnished on all driveline components engines transmissions drive shafts and differentials 7 22 2 1 2 Vehicle model MFG and Contract No 7 22 2 1 3 Date vehicle was accepted by the procuring agency date on DD Form 250 7 22 2 1 4 Vehicle identification number VIN 7 22 2 1 5 Mileage hours when failure occurred 7 22 2 1 6 Listing of required replacement repair parts by part number and nomenclature 7 22 21 7 Transportation Control Number TCN for replacement parts 7 22 2 1 8 Include a cover letter w
303. eflectorized tape and die cut prespaced letters and numbers conforming to ASTM D4956 Sheets Class 3 Type 1 using the following colors 2 30 1 Reflective red background with reflective silver letters on red yellow white or gray surfaces conforming to ASTM D4956 Sheets Class 3 Type 1 color J 2 30 2 Die cut prespaced reflective black letters and numbers on white surfaces for metropolitan van and modular type emergency ambulances only shall conform ASTN D4956 Sheets Class 1 color black with Type VI candle power CP or less NOTE die cut prespaced letters and numbers will comply with Gothic style Bureau of Public Roads Standards Series C 2 30 3 Reflective red background with reflective silver letters on red yellow white or grey surfaces conforming to Federal Specification LS 300 Type 1 Class 3 Reflectivity 1 color J 2 30 4 Die cut prespaced reflective black letters and numbers on white surfaces for metropolitan van and modular type emergency ambulances only shall conform to Federal Specification LS 300 Type 1 Class 1 color black with Reflectivity 10 candle power CP or less NOTE die cut prespaced letters and numbers will comply with Gothic style Bureau of Public Roads Standards Series C 2 31 SEMI GLOSS DARK GREEN Vehicles dark green color number 24052 will be stenciled using paint black lusterless color number 37038 Danger markings may be applied using paint red lusterless colo
304. efore are not applicable to these trailers In addition to the filling point symbols the word OXYGEN or NITROGEN as applicable will be stenciled with white enamel or applied with reflectorized tape on the hose immediately upstream of the servicing nozzle Letters and symbols will be the largest size that the hose and nozzle will accommodate 2 68 3 No Smoking The words NO SMOKING WITHIN 50 in silver reflective letters on red reflective background will be applied in 2 inch letters on each side of oxygen trailers having an enclosure around cylinders Mark ings to oxygen trailers that do not have an enclosure will be at the discretion of the using command using a locally fabricated plate marked as described above Nitrogen trailers do not require NO SMOKING marking since nitrogen is an inert material 2 69 PROPELLANT SEMITRAILERS Semitrailer tankers A M32R 16 and A M32R 17 will be marked as follows 2 69 1 The type of material being transported CLASS A POISON or UDMH HYDRAZINE CORROSIVE LIQUID will be applied to each side of the trailer Marking shall consist of 6 inch high blue letters on a white back ground 2 692 SMOKING WITHIN 100 FEET in 6 inch silver reflective letters on a 12 inch wide red reflective background will be applied to each side of the tank 2 69 3 N5O transporters shall display the marking OXI DIZERS in 2 inch yellow letters on a black background on the front and rear of the t
305. ehicle as used in this manual refers to any equipment assigned a vehicle registration number as required by AFI 24 302 This includes motor vehicle chassis used as components of other end items and vehicular equipment managed as Support Equipment SE All provisions of this chapter apply for AFEMS reportable vehicles listed in the VMIF at https sevpgm robins af mil vehicle vmif section2 asp If the equip ment is not AFEMS reportable do not use this manual for making repair decisions and do not include such equipment in the Vehicle Buy Program Contact the equipment item manager if in doubt 5 4 RESPONSIBILITIES Vehicle Fleet Managers will set up local procedures to ensure that this manual except for the Vehicle Buy Program is complied with Vehicle Management amp Analysis Registered Equipment Management System REMS Vehicle Opera tions RED HORSE Squadrons and tenant organizations participate in the Vehicle Buy Program as directed by the parent MAJCOM 5 5 REMS OLVIMS INTERFACE There will be a monthly exchange of selected information between the On Line Vehicle Interactive Management Sys tem OLVIMS and the Registered Equipment Management System REMS at base level Each month the Standard Base Supply System will prepare a record for each vehicle in the REMS file These records are then input into OLVIMS and checked against the OLVIMS vehicle master file This inter face will point out inventory errors in both
306. ehicle and all accessories attachments mounted equip ment and OVE are serviceable and complete 8 12 STORAGE STATUS OF PRESERVATION AND PROCESSING INSPECTIONS FOR VEHICLES PRE SERVED FOR LEVEL A 8 12 1 Visual Inspection Vehicles and their attach ments and OVE shall be given a visual inspection each 90 day storage period or more frequently contingent upon climatic conditions and determination by the vehicle fleet manager 8 54 The inspections shall be recorded on general purpose data sheet AFLC Form 192 This inspection shall be visual and normally requires no removal of preservation or component disassembly beyond removal of cover and access plates hatches etc This inspection shall include the following 8 12 1 1 Condition of painted surfaces 8 12 1 2 Effectiveness of preservation applied to external surfaces 8 12 1 3 Check of air pressure in tires Where quantity of vehicles in storage justifies the VFM may perform this check on a sampling basis 8 12 1 4 Leakage of lubricants or preservative oils from assemblies such as power train components pumps tanks etc 8 12 1 5 Leakage of cooling system or evidence of dete rioration of coolant lines and hoses 8 12 1 6 Deterioration of packing on OVE or accessories 8 12 1 7 OVE Completeness of accessories attachments and 8 12 1 8 Accumulation of water in body areas including interior of door panels 8 12 1 9 Condition of shrouds tar
307. ehicles and vehicular equipment with any color required based on operational mission and security requirements 2 10 AMBULANCES Ambulances shall be painted as specified below 2 10 1 Metropolitan van type and modular emergency ambulances shall be painted full gloss white color number 17875 of Federal Standard 595 A 6 inch wide continuous stripe of full gloss orange color number 12473 shall be painted immediately below the windows the entire length of both sides and rear of the vehicle 2 10 2 Tactical military design M series vehicles mobile tactical communications systems equipment vehicle mobility coded vehicles shall be painted in accordance with MAJCOM operational requirements NOTE Field type ambulances currently painted strata blue will not be repainted until the paint has deteriorated or been damaged to a point where repainting is deemed necessary 2 11 OSI VEHICLES Painting of the Office of Special Investigation OSI and intelligence operation vehicles Vehicles used by the Office of Security Investigation OSI and vehicles used by Air Force Special Activities Center AFSAC for intelligence operations purposes may be painted a color other than specified herein 2 12 RECRUITING SERVICE Recruiting service van used in advertising and publicity are exempt from the painting requirements of this technical order The colors painting schemes designs for these vans will be as directed by the Commander USAF Recr
308. emblies and or subassemblies of the same It outlines responsibilities and procedures for reporting vehicle deficiencies through the USAF Materiel Deficiency Reporting and Investigating Sys tem refer to TO 00 35D 54 for system operation 7 2 SCOPE These procedures and requirements apply to all USAF vehicle management activities 7 3 CHAPTER ORGANIZATION 7 3 1 Introduction Addresses purpose scope and orga nization of this technical order 7 3 2 Deficiency Reporting Procedures Addresses report classifications definitions submitting activity responsibili ties report routing and time frames 7 3 8 Warranty Procedures Addresses warranty coverage exceptions communications report classifications defini tions submitting activity responsibilities and report routing 7 3 4 Materiel Deficiency Report MDR Addresses warranty report classification submission criteria reporting procedure and routing for MDRs only 7 3 5 Vehicle Unsatisfactory Report VUR Addresses report classification submission criteria reporting procedure and routing for VURs only 7 3 6 Materiel Deficiency Exhibit Addresses responsi bilities time frames forms documentation and procedures for holding disposing of a deficient part 7 3 7 Vehicle Improvement Working Group Addresses responsibilities composition purpose and proce dures of the working group 7 4 INTRODUCTION This chapter establishes procedures f
309. ements 7 21 1 2 Typical statements of provisions under which such an agreement might be made are as follow 7 21 1 2 1 A labor rate is established between the govern ment shop and the vehicle manufacturer s representative 7 21 1 2 2 Time allowances for each repair is based upon the vehicle manufacturer s flat rate manual for the particular make model and year 7 21 1 2 3 Reimbursement segment for parts is based on current factory list prices less discounts quoted in the manu facturer s price lists NOTE The manufacturer may prefer to evaluate each case 7 21 2 Independent Non Dealer Garage Warranty Corrections 7 21 2 1 Prior approval must be obtained from the manu facturer s zone district or regional service manager for corrections made by independent garages Reimbursement of warranty expenses incurred at non dealer garages will be considered by the manufacturer in the following instances 7 21 2 1 1 Emergency repairs are necessary in a location where the manufacturer is not represented 7 21 2 1 2 Emergency repairs are necessary during peri ods other than dealer s normal business hours 7 21 2 2 The manufacturer s reimbursement to the gov ernment will be based on the following 7 21 2 2 1 7 21 2 2 2 labor rate charged at the nearest franchised dealer for that make vehicle The manufacturer s flat rate time schedule 7 21 2 2 3 parts and major assemblies in the manu facturer s price
310. en there is a suspected deteriora tion of the hose See exceptions in frequencies of inspections noted in TO 37A 1 101 Table 5 1 Hydrostatic test new hose s only if certification of hydrostatic testing of the hose cannot be obtained from the vendor Hose s on new R 11s R 12s have been hydrostatically tested prior to delivery to the user 3 8 SPECIAL LUBRICATION INSTRUCTIONS AND PRODUCT SPECIFICATIONS 3 8 1 Special Instructions Table 3 1 of this technical order establishes the intervals for preventative maintenance and inspection as part of the scheduled inspection When the technical orders commercial manuals or manufacturer s specifications establish a mandatory interval significantly different from Table 3 1 based on design features and deviations would cause damage and or void the manufactur er s warranty the manufacturer s recommended intervals will be used NOTE Units that implement a MAJCOM oil analysis program may extend oil life in vehicles according to the program guidelines TO 36 1 191 3 8 1 1 When warranty expires Table 3 1 will be fol lowed 3 8 1 2 The VFM may recommend for major command approval adjusted lubrication oil and filter change intervals when justified based on local operating and environmental conditions Changes in assignment of vehicles with adjusted intervals will require change to appropriate static data Major commands are authorized to approve justified changes to service
311. enance Interval Conversion Table Miles to Kilometers 45000 46600 48200 49800 51400 53000 54700 56300 57900 59500 61100 62700 64300 65900 67500 69100 70700 72400 74000 75600 77200 78800 80400 82000 83600 85200 86800 88400 90100 91700 93300 94900 96500 98100 99700 101300 102900 3 6 11 Vehicle Lighting Check all lights i e head lights turn signals warning lights mounted signals spot flood lights for general condition and operation 3 6 12 Check pintle hooks and towing attachments Make sure of proper mounting and proper locking safety pin installation and caution decal is affixed in accordance with TO 36 1 121 3 6 13 Check battery for proper solution level Clean and service terminals and battery box as necessary 65000 66000 67000 68000 69000 770000 71000 72000 73000 74000 75000 76000 77000 78000 79000 80000 81000 82000 83000 84000 85000 86000 87000 88000 89000 90000 91000 92000 93000 94000 95000 96000 97000 98000 99000 100000 104500 106100 107800 109400 111000 112600 114200 115800 117400 119000 120600 122200 123800 125500 127100 128700 130300 131900 133500 135100 136700 138300 139900 141500 143200 144800 146400 148000 149600 151200 152800 154400 156000 157600 159200 160900 3 6 14 Corrosion Inspect all areas of vehicle for corro sion and treat as required in accordance with Chapter 6 3 6 15 Hydraulic System Special Purpos
312. enter in the vehicle master record the year and month of depot repair 5 31 2 1 When the vehicle is repaired locally on obligation authority OA citing depot maintenance funds the item manager will tell the using activity whether or not to assign code S 5 31 2 2 Upon assignment to code S the vehicle will remain in this code for 60 months from the date of repair loaded in the master record except where the one time repair allowance would be exceeded and the decision is made not to repair the vehicle 5 31 2 3 OLVIMS will release the vehicle from code S after 60 months and reassign a replacement code based on data loaded in the vehicle master record The vehicle man agement activity will monitor code S reassignments and make corrections using the following criteria 5 31 2 4 If OLVIMS assigns codes A thru L change the vehicle s age criteria so that OLVIMS will assign replace ment code P 5 31 2 5 No change is required when OLVIMS assigns codes P thru T unless the one time repair allowance would be exceeded and the decision is made not to repair the vehicle 5 31 2 6 Do not use code U for vehicles under depot repair warranty The vehicle management activity will monitor depot repair warranty period manually using the vehicle historical record TO 36 1 191 CHAPTER 6 CORROSION PREVENTION AND CONTROL FOR AIR FORCE VEHICLES 6 1 GENERAL 6 2 SCOPE This chapter establishes policies and procedures for control ling ma
313. ention and Control Program shall be to enhance safety and extend equipment service life Concurrent with that aim reduced costs repair man hours and system equipment downtime will be of paramount concern in pre ventive measures incorporated 6 5 2 newly procured commercial vehicles will be furnished with manufacturer s standard factory Type A rust proofing The only exceptions are those vehicles procured for Foreign Military Sales FMS and Tactical applications No additional treatment will be imposed unless documented Vehicle Historical Records dictate the need to revise this policy 6 5 3 O amp M funds shall be used for any added treatment required to comply with this policy War Reserve Materiel WRM destined for long term storage shall be preserved and treated in accordance with Chapter 6 and Chapter 8 6 6 RESPONSIBILITIES 6 6 1 Local Installation Commanders shall exercise final responsibility for current procedures or modifications on all vehicles under their command as they deem necessary in light of safety mission adequacy and or lifecycle maintenance economies Commanders shall coordinate any change to levels of prevention and control imposed through the MAJ COM vehicle managers Air Force Support Equipment and Vehicle Management Directorate WR ALC LE and the Air Force Corrosion Prevention and Control Office AFRL MLS OLR Added treatment is considered necessary for vehicles operating in very severe and severe
314. ents with a completed current LTI and cover letter to WR ALC LEM The cover letter shall certify that the vehicles submitted meet the criteria for depot overhaul as contained in this technical order that the required repair is beyond command capabilities and that the funds are will be available to cover the requested additions If the necessary funds are not available MAJCOM must determine if the substitution of a previously scheduled approved vehicle of the same NSN is required These instances must be kept to an absolute minimum There shall be NO substitution for vehicles scheduled for depot overhaul unless specifically authorized by WR ALC LEM 918 REQUEST FOR DEPOT OVERHAUL Wing level vehicle managers will forward a completed LTI with full justification for overhaul to the appropriate major command headquarters Ensure the LTI shows not only currently unserviceable components but also those reason ably expected to deteriorate to an unserviceable state over the next 5 years Major commands will consolidate overhaul requirements and forward with cover letter to WR ALC LE in accordance with schedule as defined in Paragraph 9 19 The cover memorandum shall certify that the vehicles sub mitted meet the criteria for depot overhaul as contained in this chapter and the required repair is beyond base command capabilities Requests received without these certifications will be returned without action 919 VEHICLE REPAIR SCHEDULING
315. equent washing because in many cases the severity of corrosion depends on the length of time electrolytes are in contact with metals If a Qualified Product Listed QPL cleaning com pound and additives are used frequently cleaning a surface will reduce the likelihood of corrosion Prompt detection and removal of corrosion will limit the extent of damage to the vehicle or vehicle components 6 17 13 4 Atypical PM program should include personnel trained in corrosion identification prevention effective re moval chemical treatment paint removal sealing and re painting An effective PM program also includes 6 53 TO 36 1 191 6 54 Proper vehicle washing and cleaning cycle based on the corrosion severity zone the equipment operates in Daily cleaning or wiping down of all exposed unpainted surfaces such as actuating rods of hydraulic cylinders Keeping all drains open and low lying areas dry Initial use inspection and reapplication of CPCs fol lowing vehicle washing repairs and component re placement Early detection and repair of corrosion and damaged protective coatings and sealants Sealing gaps seams and holes to prevent moisture entry This is especially important around spot welded areas Application reapplication of sealants following vehicle repairs and component replacements Awareness of corrosion during regular maintenance activities while performing daily repairs and mainte nance tasks alway
316. equired by AFOSH STD 91 5 by the Bioenvironmental Engineer Fire Depart ment and Base Safety Office MIL PRF 32033 1 Preservative Oil is toxic to skin eyes and respiratory tract Avoid skin and eye contact Good general ven tilation is normally adequate Bodies Fuel A SP The tank shall be purged as per Paragraph 8 24 Tanks ST After purging the interior of the tank will be TR visually inspected When inspection discloses that the tank requires cleaning or that protective coating is not satisfactory the tank will be pro cessed to the extent necessary to fulfill the re quirements of TO 36Y31 1 1 interior sur faces of fuel compartments on vehicles equipped with uncoated steel tanks except stainless steel including unpainted metal sur faces of underside of hatches shall be coated with P 10 Type I Grade 30 preservative oil and tank drains left in open position Drain openings shall be screened to prevent entry of insects and rodents Rubber seals of hatches shall be coated with talc conforming to Type IV Class C of Specification CID A A 52518 and hatches shall be closed and secured Exterior unpainted metal surfaces of hose couplings valves and pump shall be coated with CID A A 59295 Type P 1 preservative Equipment com partment drains shall be secured in open posi tion Door hinges and latches will be lubricated with MIL PRF 32033 1 Type P 9 preservative oil and doors closed and secured to prevent pilferage or
317. equired on thermal sprayed coating for operational purposes MAJCOMs may elect to leave any completely metalized equipment unpainted 2 18 SAFETY PRECAUTIONS The safety precautions contained in TO 1 1 8 Paragraph 5 1 which are applicable to the operation of vehicle paint shops and spray painting of vehicles shall be adhered to during cleaning and repainting of vehicles and ground servicing and powered ground equipment The following specific safety precautions will be taken to ensure the safety of personnel and to prevent accidental damage to equipment 2 18 1 Paint spray respirators meeting National Institute of Occupational Safety and Health NIOSH requirements will be worn by painters during spray operations Contact the local bioenvironmental engineer BEE to schedule respirator training and respirator fit test prior to assigning a technician to paint tasks The BEE is the only authority to determine the appropriate respirator for all given painting operations 2 18 2 indoor spray painting shall be accomplished in a vehicular paint spray room having a minimum face air velocity of 125 fpm 2 18 3 Smoking or open flame devices are prohibited in the paint shop The mist that comes from a spray gun is highly flammable and a spark or flame of any type will cause it to flash or explode 2 18 4 To eliminate fire hazards it is essential to keep the paint shop clean Walls and floors of paint spray booths should be covered with a
318. equirements when such a need arises 1 5 8 5 Reinspections of new or used items which were previously inspected and classified as acceptable may be made in accordance with the following policy 1 5 8 6 Subsequent inspections prior to issue shipment or placing of equipment into service will be made if item has been in storage for more than 90 days or if there is a reasonable doubt as to equipment s condition 1 5 8 7 Any equipment which has been improperly stored or preserved shall be functionally tested if there is a reason to believe that deterioration may have resulted or that the effectiveness of preservation may have been impaired 1 5 8 8 equipment involved in an accident or subject to potential damage from some other cause during shipment shall be functionally tested Damage or discrepancies noted will be reported on Supply Discrepancy Report SDR SF 364 in accordance with AFJMAN 23 215 An information copy of the SF 364 will be forwarded to WRALC LE Robins AFB GA 31098 1887 1 5 8 9 Vehicles or equipment which have been given preservation processing intended to provide protection for a specified period of time may be functionally tested at the expiration of the specified period and prior to subsequent preservation processing Where inspection reveals preserva tion to have been improper SDR will be prepared and submitted in accordance with AFJMAN 23 215 with an information copy to WR ALC LE Robins AFB GA 31098
319. er Corporation 7 10 7 19 POST DELIVERY SERVICES AND TIONS INSPEC Vehicle warranties do not provide for 1 000 mile or other post delivery inspections Government vehicles are procured in a ready to run status and all necessary predelivery inspections are required to be made at the contractor s plant prior to shipment Any vehicle received which is not in a ready to run condition should be reported to WR ALC LE and warranty repairs pursued 7 20 DELIVERY CONDITION In transporting delivering the vehicle some systems may not be filled to capacity additions of OEM recommended cool ants and oil usually will be necessary Normally the vehicle will be ready to operate however Air Force agencies are required to perform an acceptance inspection to identify safety and mechanical defects prior to placing the vehicle in service i e chaffing hoses belts and lines and hoses against the exhaust systems Minor adjustments when required should be accomplished by the base vehicle management activity however if serious discrepancies are detected such as incorrect tire size incorrect missing or malfunctioning components or body leaks arrangements should be made for prompt correction by the local dealer To secure reimburse ment from the appropriate manufacturer the dealer will need the contract number USAF registration number serial num ber and mileage NOTE When new vehicle s is are delivered to destina tion and
320. er by the intermediate maintenance activity or local contract 9 5 MAINTENANCE CRITERIA AND PRODUCTION CYCLES Overhaul of AF vehicles approved herein for Depot Mainte nance will be accomplished in accordance with WR ALC LE TYPE DEPOT TYPE VEHICLE AGREEMENT FACILITY prepared work specifications and Technical Orders applicable to the vehicle s undergoing overhaul Overhaul cycles are specified in applicable contractual documents or Depot Main tenance Interservice Agreements DMISA Excluded is tran sit time to and from the maintenance facility Type mainte nance required production cycles vehicle types type agreement and type facility is shown in Table 9 1 9 6 ESTIMATED COMPLETION DATES Arrival dates and estimated completion dates are posted on the contractors monthly production report that can be ob tained from the Warner Robins depot web page https sevpgm robins af mil Depot program default asp 9 7 AUTOMATED AIR FORCE TECHNICAL ORDER AFTO FORM 91 1 REQUIREMENT A copy of the original AFTO Form 91 Limited Technical Inspection LTD updated to include any change in condition of the vehicle shall be included with the vehicle when shipped to a Depot Overhaul Facility Overhaul activities shall be accomplished in strict accordance with WR ALC Work Specification and applicable Technical Orders 9 8 VEHICLE INSPECTION ACCEPTANCE In accordance with contract the sole responsibility for i
321. er material shall be secured with tape conforming to SAE AMS 1 22085 and seat backs with waterproof paper conforming to Specification PPP B 1055 and paper secured except at bottom with tape con forming to Specification SAE AMS T 22085 Horn button shall be covered with the same type paper of a size to completely cover open ing around horn button and paper shall be se cured in the same manner as specified for dash panel Floor mat shall be removed rolled tied and stowed on the vehicle Doors including hinges latches seals locks operating mecha nisms access plates and interior surfaces of door accessible through inspection openings shall be processed in accordance with applicable requirements of Item 28 Door glass shall be rolled down to maximum extent and door glass slit sealed with tape conforming to SAE AMS 1 22085 When top is removed from vehicles equipped with automatic transmissions only gear shift lever shall be placed in neutral posi tion and exposed machined surfaces shall be coated with grease conforming to Specification MIL PRF 0924G Openings in top of shift tow ers shall be covered with tape conforming to SAE AMS T 22085 8 22 30 31 32 33 34 35 COLUMN I Item TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN II Component Cases A B Transmis sion Differ ential and Transfer Case Swinger B Gear Chains Drive A and Exposed Gears Chains Tail
322. erance compo nents such as piano hinges on all in terior or exterior metal surfaces 6 7 TO 36 1 191 Material Corrosion Preventive Spray On Sound Heat Insulation Unit of Issue Dr 55 GI NSN 8030 00 709 3327 Application Vehicle undercoating underside of chassis hood Do not mix the prepaint corrosion removing compounds with or allow the prepaint corrosion removing com pounds to come in contact with other acids or acid solutions Not for use on aluminum or magnesium type metals Corrosion Remover Qt 6850 00 656 1291 Water soluble dissolver surface rust and MP7 Prepaint oxidation on metal surfaces prior to painting Plugs Cap Protective Ea 5340 00 240 9228 Rustproofing drain hole plugs Dust Sealing Compound Tu 8030 00 29 1 8380 For low adhesion fillet and faying sur Low Adhesion Cor A 1 2 face sealing of removable structures rosion Inhibiting Tu 8030 00 584 4399 such as panel doors floor panels and A 2 6 oz plates Tu 8030 01 127 8281 A 2 12 oz Ea 8030 00 152 0062 The number next to the letter signifies A 2 2 5 02 the working life of the mixed sealant in hours Sealing Compound Ea 6850 01 406 2060 Provides corrosion protection for multi non hardening Zip metal components and parts enclosed Chem s ZC 027L in non ventilated control boxes cabi nets or tool boxes up to 5 cubic feet in volume Wash Down Additives for use on steel Gl 6850 01 470 3319 Saltbuster amp
323. erations 8 22 5 3 Have appropriate fire extinguishers available and manned 8 22 5 4 Insure that personnel wear only cotton clothing non static generating 8 22 5 5 Open all valves and drain all product from the tank and pumping system using all available low point drains to include the tank sump filter separator manual drain and pump drain plug bottom loading manifold 8 22 5 6 Remove the tank to pump line strainer and plug the forward end of the strainer to prevent carryover of moisture during tank purging or remove the entire strainer assembly Precautionary measures should be taken to insure steam does not come in contact with electrical wiring and components 8 22 5 7 Steam clean tank by introducing steam through the manhole and baffle Plate opening into each tank compart ment in sufficient volume to raise and maintain a temperature within the tank of not less than 207 degrees F and not more than 212 degrees Close manhole cover to the extent steam line will permit Steam the tank for at least three hours 8 22 5 8 Measure explosive vapor level using combustible gas indicator LEL readings should be 20 percent or less If explosive level is greater than 20 percent of LEL repeat steam cleaning for one hour Continue steam cleaning until an explosive vapor level is obtained below 20 percent of LEL 8 22 5 9 Remove plug from tank to pump suction line replace strainer basket and close all pumping system valves Inc
324. eriod 7 15 1 2 Submit warranty reports in accordance with AFI 24 302 and this chapter to document warranty actions in excess of 1000 00 or when three or more vehicles have the same deficiency satisfactorily corrected regardless of cost 7 15 1 3 File all warranty transaction documentation in the temporary portion of the historical record jacket Dispose of them in accordance with AFI 37 138 7 15 2 WR ALC LE will 7 15 2 1 as single Air Force agency for vehicle warranty management 7 15 2 2 services Assist installation VFM in obtaining warranty 7 15 2 3 Perform actions required in connection with the Department of Transportation Manufacturer Defect Recall Program This will include user notification 7 16 COMMUNICATION Direct contact by the with the manufacturer s branch dealer or designated representative is authorized for correc tion of warranty deficiencies If problems are encountered follow the procedures outlined in Paragraph 7 21 To locate the dealer or manufacturers refer to the owner s manual 1 technical order or contact WR ALC LE by message or telephone 7 17 WARRANTY COVERAGE Vehicles are procured from various manufacturers under contracts which may include different warranty clauses which are subject to change from year to year Written warranties are provided with each vehicle either in booklet form or decal displayed on the vehicle If warranty provisions are unclear contact W
325. ersonnel and is applicable to all vehicles Inspections shall be accomplished in such detail as necessary to determine condition of equip ment and accuracy of entries of the inspection forms 1 5 1 3 When parts are replaced they will be replaced with items equal to or better than new original equipment items MAJCOMs may waive these standards for intra command shipments when urgent mission requirements exist On the other hand both gaining and losing MAJCOMs must agree before standards are waived for inter command ship ments 1 5 2 Disposition Inspections 1 5 2 1 When it has been determined by the Chief Vehicle Management Flight Vehicle Fleet Manager that it is not cost effective to repair a vehicle in accordance with Chapter 5 an AFTO 91 computer generated version preferred Limited Technical Inspection LTD will be prepared in accordance with command policy This statement will include sufficient information necessary for determination of 1 5 2 2 When inspections are performed on economically reparable special purpose base maintenance vehicle equip 1 1 TO 36 1 191 ment 463L MHE or general purpose vehicles declared ex cess a narrative statement will accompany applicable AFTO Form 91 This statement will include sufficient information necessary for determination of 1 5 2 2 1 ment item The general condition of the vehicle or equip 1 5 2 2 2 The estimated calendar days required to accom plish listed re
326. es 6 7 2 Type B Mild Rustproofing Protective coatings applied only to those areas visually exposed on the vehicle undercarriage Types A amp B are authorized at installations designated in Table 6 2 as subject to mild or moderate corrosion susceptibility 6 7 3 Type C Design Corrosion Control Protective coatings methods as defined in TO 36 1 131 and manufac turer s standards Coatings are not to be applied above vehicle wheel wells Type C is authorized for vehicles designated as tactical WRM M series SWA and FMS 6 7 4 Type D Tropical Corrosion Control Consist of complete treatment of all body surfaces and boxed in internal structures as specified in Figure 6 1 and Figure 6 2 and for tactical vehicle and trailers listed in TO 36 1 131 Type D is authorized for installations designated in Table 6 2 under severe or very severe corrosion susceptibility 6 8 INITIAL CORROSION CONTROL All new Air Force commercial vehicles will be shipped directly to AF users with only factory rustproofing applied Based on local conditions VFMs must determine to what extent each newly assigned vehicle is to be treated 6 8 1 Acceptance Inspection Inspection will 6 8 1 1 Determine the type corrosion prevention or control that has been applied 6 8 1 2 Compare vehicle status with corrosion control standards set by local commanders this publication and manufacturer s best commercial practices as applicable 6 8 1 3 Ascertain
327. es Their presence can cause the areas they occupy to have different oxygen and electrolyte concentrations Additionally the organisms may secrete corrosive wastes causing actual perforations of the metal surfaces see Figure 6 16 Figure 6 16 View of Microbial Induced Corrosion 6 17 10 Mechanical Stress Manufacturing processes such as machining forming welding or heat treatment can leave stresses in vehicle parts Almost all alloys in vehicle construction are sensitive to a form of corrosion known as stress corrosion cracking This residual stress causes corro sion to proceed more rapidly in structurally important regions of the part until failure occurs Figure 6 17 Corrosion on Weldments TO 36 1 191 6 17 11 Welded Areas Welded areas are naturally corrosion prone locations see Figure 6 17 The welding process modifies the surrounding metal surfaces exposing bare edges of metal to welding fluxes and other contaminants The immediate weldment areas contain a mixture of different SAIC metals and alloys The combination of the modified parent metal structure and the welding fluxes require the welded bead area to be properly prepared before coating Abrasive blasting is the preferred method of cleaning weld nugget beads At a minimum the weld nuggets beads should be thoroughly cleaned with a stiff wire brush to remove any surface contaminants 6 17 12 Time As time goes on metals naturally tend to corrode In some
328. etion or treatment of bare metal surfaces Allow it to dry thoroughly then sand lightly TO 36 1 191 2 21 2 Apply one or two coats as required of surface sealer MIL HDBK 1223AC to wood surfaces of vehicle bodies allowing a minimum of one hour drying time between coats 2 21 3 Apply a medium coat of bituminous paint MIL C 450 to undersurfaces of wood floor decking 2 21 4 When it becomes necessary to replace wooden floors of trucks and trailers use hardwood material wood metal and plastic decking treat using guidance from MIL HDBK 1223 and obtain a suitable pretreated hardwood material from local commercial market The pretreated hard wood material obtained commercially shall be material that is normally used in commercial industry for flooring trailers trucks and all other vehicular equipment NOTE To preserve nuclear certifications replacing wooden floors on trucks or trailers with Rum ber is not authorized without prior written ap proval from WR ALC LEVS 2 21 5 coating for the MIL PRF 85285 Type coating system will be applied in accordance with TO 1 1 8 and the coating manufacturer s instructions For equipment located in or operating in severe corrosion prone locations the two part primer system conforming to MIL PRF 26915 and MIL P 53030 All spray painting will be accomplished in an exhaust ventilated booth meeting requirements of OSHA 1910 107 Respiratory protective devices wil
329. extreme heat is prevalent which remain in a stationary position with personnel remaining in the cabs for operation of the equipment may have the tops painted white 2 14 EXCESSIVE GLARE Painting of vehicles to eliminate excessive glare may be accomplished in the following instances Instrument panel tops may be repainted with a lusterless paint to eliminate excessive glare Relocation of data plates and decals is also permitted to eliminate glare TO 36 1 191 215 INTERIORS The original manufacturers color of Interiors will be retained 216 CAMOUFLAGE PATTERN PAINTING Camouflage pattern painting will be accomplished in accor dance with TO s 36 1 161 Section VI and 36 1 171 Chapters 1 5 217 THERMAL SPRAY EQUIPMENT 2 17 1 Thermal Spray Coatings provide very durable long term corrosion protection to high wear areas on equip ment and or vehicles 2 17 2 For the purposes of this technical order Thermal Spray Coatings are considered a metalization process and are addressed as metal wire arc spray MWAS coatings 2 17 3 There are several methods of thermally spraying metal alloys For coating large sections and components the most commonly used equipment in the Air Force is dual metal wire electric arc spray The types of equipment listed in this manual are recommended for field depot level and OEM production levels Organizations may use the Thermion 500 and the Thermion Bridgemaster or equivalent systems for
330. ference Repeat this process if bead has not seated A radial tire with all improperly seated bead will cause vibration 4 26 3 Balancing Balance tires referring to balancing procedure in service manual for vehicle being serviced 4 26 4 Inflation 4 26 4 1 Always follow model year recommended tire pressure ratings NOTE Under inflation can lead to tire bead chafing thereby causing a slow leak A slow leak condi tion is aggravated by use of wide rims and cold weather F09603 055 Figure 4 13 Inspecting A Tire For Casing Damage TO 36 1 191 TIRE MOUNTING WARNING FAILURE TO COMPLY WITH THESE PROCEDURES MAY RESULT IN FAULTY POSITIONING OF THE TIRE AND OR RIM PARTS AND CAUSE THE ASSEMBLY TO BURST WITH EXPLOSIVE FORCE SUFFICIENT TO CAUSE SERIOUS PHYSICAL INJURY OR DEATH NEVER MOUNT OR USE DAMAGED TIRES OR RIMS HOLD DOWN MECHANISM F09603 056 Figure 4 14 Using the Extension Hose to Inflate a Tire 4 26 4 2 All passenger car tires will be air gauge checked at least once a month 4 26 4 2 1 4 26 4 2 2 Check pressures when tires are cool 4 26 4 2 3 Check pressure more often in cold weather which may cause dangerously low pressure drops Use an accurate calibrated air gauge 4 26 4 2 4 For sustained highway driving increase infla tion 4 psi above the recommended pressure but do not exceed the maximum inflation stamped on the tire side wall 4 27 REPAIR PROCEDURES FOR TIRES 4 27 1 Punctures Tread
331. ficial Use Only and registration num ber Air Force vehicle management shops will mark vehicles using standard AF license plates Figure 2 1 on the rear of each vehicle where a license plate s installation is practical Two license plates front and rear are authorized if required by MAJCOM or local law 2 25 1 1 Plates are available through UNICOR Federal prison industries in three colors and will contain necessary information as outlined in this Technical Order 2 25 1 2 To accommodate the Federal Fleet FEDFLEET Council s more stringent security measures UNICOR is prohibited from selling license plates to anyone by name not on an approved to purchase list however the FEDFLEET Council will allow Air Force units an exemption by allowing AF units to order plates under the unit s designation with an official mailing address 2 25 1 8 UNICOR AMERIMAC will not accept orders by non AF designated units UNICOR AMERIMAC will pro vide HQ USAF Element VEMSO an e mail copy of all orders placed Additionally VEMSO will periodically review and provide a list of all registered buyers to the respective MAJCOMs Each MAJCOM must validate all of their registered units Additionally new registrations or changes to registrations must be processed through each respective MAJCOM for validation and forwarding for VEMSO ap proval Only then will the registration be forwarded to UNICOR AMERIMAC 2 25 1 4 Units will have the option of ordering pl
332. for resolving the deficiency 7 DEFICIENCY TYPES 7 7 1 Design Deficiency A condition that limits or prevents the use of the vehicle for the purpose intended These conditions cannot be corrected except through a design change 7 7 2 Maintenance Deficiency condition which re sults in excessive maintenance man hour expenditures 7 7 3 Materiel Deficiency failure of a major assem bly subassembly or component that if uncorrected may cause death injury or severe occupational illness or would cause loss or damage to a vehicle 7 7 4 Quality Deficiency Errors in workmanship non conformance to specifications or other technical require ments Failures or malfunctions which cannot be attributed to errors in workmanship will not be reported as quality defects 7 1 TO 36 1 191 7 8 REPORT CATEGORIES 7 8 1 Materiel Deficiency Report This report is required when conditions occur which may cause death severe injury or occupational illness would cause loss or damage to a vehicle or directly restrict the combat readiness capability of the using organization 7 8 2 Vehicle Unsatisfactory Report This re port is required when a vehicle does not meet the user needs a vehicle s design depot repair or remanufacture is unsatis factory or premature materiel failure or equipment malfunc tion occurs that does not meet the criteria for a MDR 7 8 3 Action Warranty Report A
333. function satisfactorily Fenders hood running boards steps and other sheet metal items shall not be damaged or broken Vehicle bodies fenders trunks and hood with small dents and scratches shall be acceptable if there is no evidence of tearing or creased metal Holes in sheet metal other than drain or access holes shall not be greater than 1 2 inch in diameter All body and cab bolts will be intact and tight Body or cargo stakes and cover bows shall be free of cracks and connecting devices shall work properly 1 7 2 21 Bogies Suspension Trunnions Torque Rods Bushings Bogies suspension components shall not be bent cracked or twisted Trunnion rollers shall rotate smoothly free of any binding Rubber bushing bearings or seals and shafts shall not be excessively worn or show signs of deterioration leaks Torque rods shall be correctly as sembled and securely mounted metal bushings shall not be excessively worn 1 7 2 22 Boom Crane And Wrecking Equipment Mast Assembly And Insulated Booms The boom assembly shall not be bent or deformed in such a manner as to impair strength or efficiency All welds of major elements shall be sound Telescopic extensions mechanisms will operate smoothly without binding or drag Manual cranks shall be present serviceable and securely mounted Pulleys and sheaves shall have no excessive wear or broken flanges that might damage cable All mounts and hinge bushing shall show no evidence
334. g devices and requirements for vehicles Reflective markings for trailers trailer conspicuity 2 91 1 electrical devices shall conform to State and Federal Highway Administration Motor Carrier Safety Regu lations When local state or foreign country regulations conflict with this technical order those pertinent regulations prevailing will take precedence These requirements apply to vehicles operated on and off base trailers having overall width of 80 inches or more and a gross weight rating of more than 10 000 pounds will be marked with a minimum of 2 inch red and white prismatic 980 reflective sheeting Federal Specifications ASTM D4956 Type IV Class 1 Figure 2 29 Current standards for trailer vans and trailers can be found in 49 CFR parts 393 13 and 571 108 2 91 2 off base operated vehicles included in the OLVIMS management code table will be equipped with the electrical directional signaling lighting and reflector devices prescribed by this technical order 2 91 3 The following legends represent the lights reflec tors and markers which may be required on all types of vehicular equipment 2 91 3 1 Head Lamp 2 91 3 2 Red Tail Light 2 91 3 3 Red or Amber Stop Light 2 91 3 4 Red Clearance Lamp 2 91 3 5 Amber Clearance Light 2 91 3 6 Red Side Marker 2 91 3 7 Amber Side Marker 2 91 3 8 Red Reflector 2 91 3 9 Amber Reflector 2 91 4 Lighting and reflector equipment over and above that indi
335. gement personnel will accomplish this Vehicle operators may check tire pressure if they have a pressure gauge suitable for nitrogen valve stems but they will not add nitrogen to the tires Vehicle Management technicians will stencil Nitrogen filled tires do not service to each fender well and each inner rim near the valve stem Table 4 1 4 23 IN USE INSPECTION 4 23 1 Operator Inspection Primary responsibility of detecting and reporting defects in the vehicle tires is placed upon the operator and or the using organization These inspections are 4 23 1 1 Presence of valve caps evidence of breaks deep cuts imbedded glass or nails bulges or other potentially hazardous conditions 4 23 1 2 Tread wear as indicated by visible wear indica tors across the tire tread or measured by a depth gauge in a major tread groove Minimum tread depth is 2 32 inch The front tires of trucks 10 000 GVW and greater operated primarily off base at speeds greater than 35 MPH shall have at least 4 32 inch tread depth NOTE Major tread is defined as any portion of a tire that is grooved and designed to make contact with the road surface Any part of the tire that is subject to wear by rubbing against the pavement or ground 4 23 1 3 Daily inspection for adequate inflation will be determined by a visual inspection unless otherwise stated in equipment manual Tires on equipment with duals will be pounded with a hammer or tool to determine if ai
336. gibility as applied to mark ings data and caution plates and other printed matter 1 6 8 3 Wooden components of equipment should be in such condition so as not to compromise their structural strength Cracks running with the grain that do not affect strength need not be replaced Wood may crack from natural causes without necessarily having its strength impaired Bruises and dents do not render wooden components unac ceptable 1 6 3 4 Scratches tool marks compression and or stress marks which do not impair structural integrity or components are ordinarily of no significance and do not render an item unacceptable 1 6 8 5 castings will be without cracks securely bolted and free from excessive lubricant leaks at all joints Obvious imperfections such as external blow holes slag and sand inclusions and improperly dimensioned sections due to imperfect molding will be cause for rejection of assemblies 1 6 8 6 welds of major elements must be sound Minor welds involving attachments only may be imperfect pro 1 5 TO 36 1 191 vided sufficient connecting metal remains to retain attach ment through normal shipment handling and operation without further breakage or loss Overlapping welds etc 1 6 8 7 Components of equipment permanently attached by means of rivets or welds must be firmly attached so that loss through vibration or normal operation will not occur 1 6 3 8 Indications of corrosion around rivet
337. gloves apron etc approved for the materials and tools being used 3 SAFETY EQUIPMENT When cleaners and primers are being applied approved equipment shall be used Make sure fire fighting equipment is readily available and in working order Maintain minimum quantities required to accomplish tasks Solvents will be contained in approved containers 4 ELECTRICAL CIRCUITS Operating personnel must think safety at all times Do not replace components or make adjustments inside of equipment with the electrical power supply turned on To avoid injuries always remove power from discharge and ground a circuit before touching it If a test connection to energized equipment is required make the test equipment ground connection before probing the voltage or signal to be tested Do not attempt internal service or adjustment of equipment unless another person capable of rendering aid and resuscitation is present 5 WARNINGS CAUTIONS AND NOTES Calls attention to an essential operating or main tenance procedure practice condition statement etc which if not strictly observed could result in injury to or death of personnel or long term health hazards Calls attention to an essential operating or main tenance procedure practice condition statement etc which if not strictly observed could result in damage or destruction of equipment or loss of mission effectiveness NOTE An essential or unusual procedure cond
338. gs st sso un porred JAIO e e Aq aq isnt IMIS 03 aq pinous uorjedsur Surinp soq 92IAI8S UI yun uonoedsur asn uodn Jo Agrep Surmp Aq punoj st 12 1 J s amp ep cq UOP g e Aq aq asnu 9orAJos 03 HUN 8 s329Jop Jo soe MAI S V NAXWL 38 OL NOILOV NINNTO9 511544 NOILO3dSNI ayy Jo 3uoJj y uo suonoedsur 8 y UQ saoeng se se xpouesooS pasn oq 3sippotp oy SUPP pa32adsurt aq few sjurof wuoj uonoedsur Jo angeu omus ay o qnog pue woy uonoedsug y Sursn Aq ssoooe 03 suepiuuoo juounS ueul osje a 99 se 10 suopo dsu jpenuue Surinp
339. gure 6 1 apply to all commercial general purpose vehicles whether passenger car small or large truck station wagons or similar equipment Figure 6 2 lists special purpose vehicles having distinct features requir ing application data not explicitly covered by general appli cation requirements of Figure 6 1 TO 31 1 131 provides the requirements for rustproofing military series equipment TO 36 1 191 APPLICATION P arc MEN CRITICAL RUST AREAS ON A TYPICAL SEDAN RADIATOR SHIELD AND GRILLE PANEL ASSEMBLY PLUS GRAVEL SHIELD OR PANEL RADIATOR Figure 6 1 EXTERIOR FRONT AND BACK SIDES SPRAY EXTERIOR SURFACE RADIATOR CORE NEXT TO MOTOR FAN WITH FIRST COAT OF GRADE 3 START MOTOR TO RUN A LITTLE ABOVE IDLE THEN SPRAY FRONT AREA OF RADIA TOR CORE AND LET FAN SUCTION DRAW IN THE MATERIAL FOR COMPLETE COVERAGE REPEAT THIS SCHEDULE WITH SECOND COAT USING GRADE 3 Commercial General Purpose Vehicles Areas of Application Sheet 1 of 12 F09603 073 TO 36 1 191 AREA APPLICATION BEHIND GRILLE AND HEADLIGHTS LIGHT WELLS EYEBROWS UNDER SIDE OF FENDER ALL ENCLOSED BOXED IN AND SUPPORT SECTIONS TREAT THE SURFACE OF THE FENDER WELL FENDER BEAD AND HEAVY SPLASH AREA BAFFLES AND SUPPORTING MEMBERS THE SHORT CURVED WAND MAY BE USED TO SPRAY FENDER BEADS SOME VEHICLES MAY BE SO CONSTRUCTED THAT ACCESS TO HEADLIGHT AREA WILL BE EASIER FROM ABOVE WHEN THE VEHICLE IN ON THE FLOOR
340. h are contaminated by fungus growth can be cleaned by wiping with 1 735 Isopropyl Alcohol A clean lint free cloth moistened with the solvent should be used to wipe the pins and a toothpick or pipe cleaner saturated with the solvent should be used to wipe out the holes Flint abrasive paper shall be used instead of aluminum oxide emery abrasive paper or cloth to clean contact points commutators or slip rings of generators and motors Since aluminum oxide and emery are conductors of electricity the de tached grains will short circuit the commutator and the dislodged grains could lodge under the brush where they could cut deep scratches in the soft copper commutator Do not vapor clean or spray clean assembled motors 6 15 8 6 Contact Points Use of solvents to clean electrical contact points may result in an oil film which will interfere with operation of the point Use only flint abrasive 6 38 paper Do not use aluminum oxide or emory abrasive paper or cloth to clean electrical contact points The contact points shall be dusted or vacuum cleaned thoroughly after cleaning with abrasive Care must be taken so that no abrasive particles enter functional parts 6 15 8 7 Electronic Components Wipe the external areas of the component with dry cloth Carefully vacuum any loose dust or metal particles from the interior of the compo nent or compartment Use a soft non metallic bristle brush to aid in cleaning After cleaning app
341. h red cross on a 10 3 4 inch square white field will be applied to the center of each rear side door 2 51 2 A premasked reflectorized decal with a 6 inch red cross on an 8 inch square white field will be applied on the center of the tailgate If space is inadequate for the single large decal two reflectorized decals with a 8 inch red cross 2 15 TO 36 1 191 on 2 inch square field will be applied to the upper corners of the tailgate immediately below the rear window of the vehicle 2 52 MOBILE MEDICAL VANS Special purpose semi trailers used as mobile dispensaries dental clinics and other primary medical functions will be marked as follows 2 52 1 premasked reflectorized decal with a 36 inch red cross on a 48 inch square white field will be applied on the right and left front and rear external panels in a central position 2 52 2 Apremasked non reflectorized decal with a 36 inch red cross on a 48 inch square white field will be applied to the roof in a central location 2 53 RECRUITING VEHICLES Markings for Air Force vehicles assigned to recruiting service are as follows 2 53 1 Emblem will be reflectorized decalcomania 12 inches in diameter 2 53 2 The emblem will be centered horizontally 6 inches below the top of the front door panel Emblems that cannot be placed as described above due to varying body styles will be applied to vehicles as determined by instructions issued by the Commander of the USA
342. hap exhibit enter the word MISHAP and the Mishap control number in this block Exhibits subject to warranty correction will include the word WAR in this block When exhibit is requested by action point or sup port point include Ship To instruction Table 7 1 In Block 8 Item Description 9 Name 10 Phone 11 Date Exhibit Release 12 Exhibit Released to TO 36 1 191 How to Complete a DD Form 2332 Continued Enter The nomenclature of the failed item from Item 6 of the DR Name of the screening point representative The DSN and commercial including area code telephone numbers of the screening point The date the exhibit was released to the action or support point The name address and telephone number of the person at the action point or support point to whom the exhibit was released MATERIAL DEFICIENCY EXHIBIT 1 REPORT CONTROL NUMBER FJ2379 850938 2 DATE 13 Jul 83 3 ORIGINATING ACTIVITY 4250 TWAMO Wright Patterson AFB OK 4 NSN 2620 06 8803 5 PART NO 6 SERIAL NO 703123920 7 REMARKS Continue on reverse if necessary DD Form 2332 04 May 8 NAME 10 PHONE 8 ITEM DESCRIPTION Engine ASSY FRONT MATERIAL DEFICIENCY EXHIBIT 11 DATE EXHIBIT RELEASED 12 EXHIBIT RELEASED TO 7 REMARKS Continued DD Form 2332 Reverse 04 May BACK F09603 104 Figure 7 6 DD Form 2
343. he vehicle is to be salvaged consider the disposition of special mounted equipment independently It may be economical to remove the special equipment before disposing of the vehicle Supply policy published in AFMAN 23 110 and instructions issued by the item manager for the special equipment involved will govern the disposition 5 6 4 Vehicles which have been declared obsolete by the item manager may be replaced even though the projected life expectancy in years or miles has not been reached The item manager will decide whether or not vehicles are obsolete and will notify the major commands furnishing the stock number a brief nomenclature and registration number Major com mands will notify their subordinate REMS activities 5 6 4 1 REMS will notify VM amp A when a vehicle has been declared obsolete This notification will be in writing and will identify the registration numbers of the vehicles affected 5 6 4 2 Obsolete vehicles may be operated until repair parts no longer can be obtained unless otherwise directed by the item manager or the major command 5 1 TO 36 1 191 5 6 4 3 Refer to AFMAN 23 110 for guidance on process ing obsolete vehicles to DRMS 5 7 CHANGES Send recommended changes to this Technical Order to WR ALC LE using guidelines of TO 00 5 1 5 8 MAJOR COMMAND SUPPLEMENTS Major commands may supplement this chapter see Para graph 1 5 e of TO 00 5 1 to delegate repair approval authority to set u
344. hey are exposed to acid paint removers plating solutions and other acidic and more alkaline materials This occurs when a cathodic reaction on the high strength metal surface produces hydrogen which diffuses into the bulk metal accumulates at grain boundaries and weakens the structure If the part is under load or contains residual manufacturing stresses sudden catastrophic failure occurs when the part can no longer sustain the internal and or applied stresses Hydrogen embrittlement has been known to occur in parts stressed to only 15 percent of nominal tensile strength 6 16 6 9 Corrosion fatigue is the cracking of metals caused by the combined effects of cyclic stress and corrosion and is very similar to stress corrosion cracking If it is in a corrosive environment no metal is immune to some reduc 6 43 TO 36 1 191 tion in resistance to cyclic stressing In simplified terms corrosion fatigue is mechanical fatigue aggravated by a corrosive environment In corrosion fatigue the corrosive environment causes a lowering or reduction of the fatigue limit the ability of a metal to resist fatigue cracking of a metal as it undergoes cycles of stress In the absence of a corrosive environment this same metal would be able to withstand significantly more cycles of stress before cracking Corrosion fatigue seems to be most prevalent in environments that cause pitting corrosion 6 16 6 10 Filiform corrosion is a special form of oxygen
345. hicle Management will ensure using organizations accomplish load testing to 110 percent of capacity for any extensively repaired modified cranes This requirement also applies to high reach trucks auger derricks or any other boom equipped vehicle with a personnel basket File the manufacturer s load test certifica tion for new cranes in the vehicle historical record If a new crane is received without the load test certificate contact the manufacturer to obtain the certificate If this is not possible load testing will be required NOTE For nuclear certified hydraulic mobile cranes perform an annual load test of 100 percent of the rated capacity Upon completion of the test the weight load test date will be stenciled on the lower boom assembly Records of all tests will be filed with the maintaining and using organiza tions Refer to AFOSH STD 91 46 paragraph 8 2 4 6 Upon completion of test stencil in 1 inch letters on the lower boom assembly 3 10 5 1 1 Mobile Crane Hook Inspections Annually Vehicle Management will inspect lift hooks on cranes for cracks chemical damage hook attachment and security lubrication of swivel joint excessive clearance in the hook opening in excess of 15 percent of the original gap and evidence of twisting in excess of 10 degrees from normal configuration If any of these conditions exist the hook must be replaced Inspect crane hook and lifting hardware in accordance with the vehicles TO In
346. i tion and a warning tag bearing the information AIR RESERVOIR DRAIN VALVES OPEN CLOSE BEFORE OPERATING VEHICLE shall be securely attached in a conspicuous loca tion within driver s compartment For other than self propelled vehicles tag shall be securely attached in a conspicuous location near identifi cation or data plate Exposed ends of service air lines and dummy couplings shall be covered with tape conforming to Specification SAE AMS T 22085 Air reservoirs shall be drained of all condensation and interior surfaces sprayed with atomized MIL SAE AMS T 21260E P 10 TYPE 1 Grade 30 preservative oil Exhaust ports of relay emergency quick release and relay valves not equipped with exhaust check valves shall be closed by inserting pipe plugs or sealed with pressure sensitive tape A warn ing tag bearing the information EXHAUST PORTS CLOSED REMOVE PLUGS AND TAPE BEFORE OPERATING VEHICLE shall be securely attached in a conspicuous location within driver s compartment No preservation required Air hydraulic vacuum and vacuum hydraulic brakes shall be processed in accordance with the applicable requirements of Items 21 and 23 Brake system shall be filled with operational hy draulic brake fluid Openings and vents of electrical items shall be sealed with tape conforming to Specification SAE AMS T 22085 A warning tag bearing the information OPENINGS AND VENTS SEALED REMOVE TAPE BEFORE OPERAT ING VEHICLE sha
347. ial Pollutants Airborne pollutants that contribute to the deterioration of non metallic materials and severe corrosion of metals are carbon from internal com bustion engine exhausts nitrates from agricultural fertiliz ers ozone from electrical motors and welding operations sulfur dioxide from engine exhaust and industrial and ship smoke stacks and sulfates from automobile exhaust 6 51 TO 36 1 191 Figure 6 14 Open Cell Foam and Resulting Corro sion Figure 6 15 Corrosion Resulting from Long Term Exposure to Sand 6 17 6 Sand Dust and Volcanic Ash Sand dust and volcanic ash are present in many areas but particularly in industrial areas where they often contain a number of tar products ashes and soot Dust is also found in tropical zones with plentiful rainfall and arid zones where there is little or no rainfall Sand and dust are extreme problems in deserts because the wind carries dry powdery sand and dust During 6 52 sandstorms sand and dust can penetrate sealed equipment and many internal areas of vehicles Sand dust and volcanic ash are hygroscopic and can absorb and hold moisture when present on internal or external surfaces of vehicles or elec tronic parts Dust from volcanic areas contains chlorides and sulfates Dust from desert areas may contain chlorides carbonates and sulfates These materials are extremely cor rosive in the presence of moisture Although small amounts of sand
348. iately forwarded to the local Air Force Procurement Officer TO 36 1 191 7 18 3 Nonwarranty Period Adjustments manu facturer s warranty adjustment policies are not necessarily confined to the warranty period Malfunction or parts failure discovered at some point beyond the warranty period attrib uted to a manufacturing defect may be corrected at no cost or on a cost sharing basis depending upon the individual case 7 18 4 Tactical Vehicle Warranty Tactical vehicles of military design M series are often procured through TACOM without a normal commerical warranty The absence of an overall commercial vehicle warranty however does not negate claims for correction of material deficiencies or defective workmanship When premature defect can be at tributed to a manufacturing defect submit a Vehicle Unsat isfactory Report VUR in accordance with provisions of this technical order NOTE CUCVs carry a special warranty To obtain war repair CUCV vehicles refer to TO 36A12 1A 2081 1 for procedures 7 7 TO 36 1 191 DATE NOTIFICATION OF DELAYED DELIVERY DATE OR IN TRANSIT MILEAGE ACCUMULATION This form is to be used to notity Ford Motor Company of a delayed warranty start date or to report an in transit mileage accumulation on a vehicle driven not transported from the assembly plant to the receiving location VEHICLE IDENTIFICATION NUMBER NAME AND ADDRESS OF RETAIL SELLER
349. icles will be submitted in accordance with AFMAN 23 110 3 11 2 Transfer Vehicle Being Transferred to Another Installation 3 11 2 1 Prior to shipping vehicles between Air Force activities a technical inspection will be performed to deter mine that vehicles are serviceable from an operational stand point as specified in Chapter 1 Transferred vehicles must be in a condition that will permit utilization by the receiving activity without additional repairs Prepare the LTI form in duplicate A copy will be included in the vehicle records for use by the receiving organization 3 11 2 2 The technical inspection of vehicles designated for the Military Assistance Program will indicate specifically the condition of the equipment in relation to its original life expectancy and appearance The eligibility of these vehicles is not affected by the repair allowance A copy will be included in the vehicle records for use by the receiving organization Change 1 3 14 1 3 14 2 blank 3 11 2 3 Acceptance For used vehicles use the LTI prepared by the transferring organization AFTO Form 91 will be accomplished on the new vehicles if necessary 3 11 2 4 Depot Repair Request Input Refer to Chapter 1 312 ACCEPTANCE INSPECTION See Chapter 1 3 13 SEMI TRAILER INSPECTIONS 3 13 1 Corrective Action Inspection The following in spection should be performed on semi trailers when they are reported to vehicle management with annotat
350. ide Storage For outside storage the most suitable hard standing or natural ground surface will be selected When natural surface is selected it shall have good drainage and must maintain its texture under normal climatic conditions so as to be free from soft spots To eliminate fire hazards during dry weather care will be taken to prevent accumulation of grass and weeds in the storage site and the areas immediately surrounding it Vehicles shall be stored with one end slightly elevated so that the maximum amount of accumulated water will drain from the hull or body Storage under trees will be avoided 8 12 6 Inside Storage Inside storage will be used wherever available Fork lift trucks fire trucks and vehicles containing electronic equipment or other types of equipment TO 36 1 191 as determined by the commander or VFM concerned will be stored inside buildings or provided equal protection from weather conditions 8 12 7 Spacing And Arrangement Vehicles will be spaced so as to permit ready access for inspection and servicing during storage Fire lanes will be provided at appropriate intervals Vehicles will be arranged by types and positioned to facilitate removal in accordance with prevailing issue policy Normally vehicles which were received first will be the first ones shipped General guidance on storage is contained in AFMAN 23 110 Storage and Materials Han dling 8 12 8 Nesting Or Stacking For Storage Small t
351. if follow on controls methods are re quired and to what extent necessary The VFM shall deter mine level and means Specifications for local contracts shall be tailored from requirements contained in this publication 6 8 1 4 Ensure all tactical vehicles have been rustproof in accordance with TO 36 1 131 6 9 FOLLOW ON CORROSION CONTROL 6 9 1 Responsibility VFM is responsible for 6 9 1 1 Upgrading corrosion prevention to meet those standards set by the local Commander 6 9 1 2 Inspecting all assigned vehicles during annual inspection for assurance that preventive standards are met 6 9 1 3 Ensuring vehicles are restored to a condition designed to prevent significant vehicle deterioration under existing usage environments Table 6 1 TO 36 1 191 6 9 2 The local Installation Commander is responsible to establish and adjust standards to assure an effective program of corrosion control and prevention by employing the most cost effective measures Objective is to assure each vehicle attains a nominal vehicle life cycle as defined in VMIF The VMIF is available using a military computer by accessing the WR ALC LE website at the following address https sevpgm robins af mil vehicle vmif 610 EQUIPMENT AND MATERIALS REQUIRED Refer to Table 6 1 Required Equipment And Materials Automotive Vehicle Hydraulic Lift 4910 01 065 9540 Drum Pump Airless Spray 2 1 ratio includes hose gun extension and tip
352. ifications 1 7 2 48 Drawbar Tow Bar Draw or tow bars shall not bent in such a manner as to impair strength of efficiency All welds shall be sound and not cracked safety chains shall be of proper length and size See Pintle Hook Lock Pin Paragraph 1 7 2 97 1 7 2 49 Drive Propeller Shafts And U Joints 1 7 2 49 1 Drive shafts shall be straight and balanced AII welds shall be sound and without cracks Drive shaft splines shall not be worn more than 15 percent of the original splines width 1 7 2 49 2 Universal joint trunnion bearings shall indicate no excessive rotary lost motion U joint bearings shall be properly lubricated 1 7 2 49 3 Pillow block and or center support bearing shall not allow any radial motion and be properly lubricated 1 7 2 49 4 Propeller shaft end yokes will be in plane when propeller shaft is assembled with splined yoke alignment markings matched 1 7 2 50 Drums Elevators And Discharge Chutes Drums elevators and discharge chutes shall be properly mounted with no indication of excessive wear and shall function in accordance with applicable equipment manual 1 7 2 51 Eccentric Shaft Or Sleeve Eccentric shafts used on jaw crushers and sleevetype eccentric used on rotary crushers shall have no excessive wear and shall be properly aligned and lubricated 1 7 2 52 Electric Motors The commutator surface shall have a smooth polish and shall be free of copper beads and grease I
353. ign approxi mately 8 by 10 inches The sign shall be affixed to the upper center of the cab panel directly in front of the operators knees On other applicable vehicles sign shall be affixed to the operators ground control panel and basket control panel This sign shall have a white background with DANGER in 2 inch red letters DO NOT OPERATE BOOM OR DERRICK WITHIN 10 FEET OF ELECTRIC LINES in 1 2 inch black letters In addition a metal plate 3 x 4 inches affixed to the right hand side of the above referenced DANGER sign 2 22 having a red background with DO NOT OPERATE BOOM ABOVE 80 DEGREES FROM THE HORIZONTAL PLANE in 5 16 inch white letters 2 71 3 All forklifts shall have RIDERS in 2 inch black letters stenciled vertically on both uprights of the fork frame facing the operator Figure 2 30 2 714 Aircraft towing tractors and tugs used for towing aircraft shall be equipped with a metal sign approximately 3 x 4 inches red background with MAXIMUM SPEED 10 MPH AIRCRAFT TOWING SPEED 5 MPH in 5 16 inch silver letters This sign shall be attached to a panel directly in front of the operator 2 71 5 special purpose and engineer equipment having speedometers and or tachometers shall have the maximum safe operating speed and or revolutions per minute indicated by a red line painted on the glass covering the dial 2 71 6 Mobile cranes and street sweepers shall have instructional metal placard of the larges
354. ility Support As we move to a more expeditionary Air Force it is very likely we will deploy vehicles to extremely austere forward operating locations with little if any logistical support Vehicles sourced to deploy must be the best available These vehicles are expected to perform the mission with little to no support for the first 30 60 days Therefore it is imperative that all vehicle leadership ensures squadron group and wing commanders endorse deploying the best and newest vehicles Additionally history has shown Desert Storm Operation Noble Eagle Operation Iraqi Free dom etc that major deployments of US forces around the globe are more successful if the arriving vehicle support is in a higher than average state of readiness historically dubbed 36 1 191 Plus The 36 1 191 Plus vehicle certification includes as a minimum 1 5 641 Reviewing historical record and work order history data to ensure nothing disqualifies the vehicle from performing as expected 1 5 6 4 2 There is no indication that the vehicle has hangar queen tendencies or trends of repetitive mainte nance 1 5 6 4 3 NMCS experience is inordinate when compared with peer vehicles 1 5 6 4 4 The vehicle is not immediately scheduled for depot level input 1 5 6 4 5 There are no outstanding TCTOs that can be accomplished 1 5 6 4 6 Attending to the physical conditioning of the vehicle by certifying that 1 5 6 4 7 new f
355. ill apply Trailers with an overall width of 2032 mm 80 inches or more and a gross vehicle weight of 4436 kg 10 001 pounds or more will be marked in accordance with DOT code of federal regulation 49 CFR 393 13 The requirement for bilingual stenciling of safety markings will be at the discretion of the major command 2 58 1 chart in Table 2 1 gives examples of the DOT marking requirements for some common substances See Figure 2 28 for an example of the marking of a liquid nitrogen trailer Local and or state laws may also be appli cable therefore local authorities should be contacted about requirements for transporting hazardous materials NOTE The requirements of federal state or local laws are not superseded by any requirement of this TO unless covered by an exemption 2 59 FUEL DISPENSING AND AIRCRAFT SERVIC ING VEHICLES Refer to Figure 2 11 Figure 2 12 and Figure 2 23 for marking and highlighting of R 9 11 aircraft refuelers and fuel servicing vehicles i e C 300 1 Markings may be decals or stencils using red paint color number 31136 Aircraft refuelers shall be marked in accordance with 49 CFR 172 302 National Fire Protection Association NFPA stan dard 407 as referenced below Local and or state laws may also be applicable therefore local authorities shall be con tacted about requirements for transporting hazardous materi als 2 59 1 FLAMMABLE 4 or 6 inch letters depending on availa
356. ilters are installed where possible filters will be long life premium quality 1 5 6 4 8 Power and drive belts are absolutely crack free and check free 1 5 6 4 9 Cooling system is clean with antifreeze mixed to 50 percent antifreeze 50 percent water 1 5 6 4 10 Water pump shows no sign of fatigue or leakage if in doubt replace it 1 5 6 4 11 All water hoses are crack free with no bulging sponginess 1 5 6 4 12 Dust boots crack free properly positioned and securely fastened 1 5 6 4 13 Hydraulic cylinder ram shaft wiping seals wipe the shaft as dry as factory manufacturer tolerance allows to include power steering rams 1 4 1 5 6 4 14 Every system or major component for which an on vehicle fault isolation test or operability assessment is developed per tech data was analyzed and load tested and found to be completely within specs 1 alternators batter les starter motors fuel injector pumps etc Document results and retain data in permanent vehicle records jacket until vehicle is returned or dropped from VAL 1 5 6 4 15 thorough quality control inspection of work will be done during prep for shipment 1 5 6 4 16 Since the DOD single battlefield fuel is 1 8 does the deploying vehicle need any components beefed up prior to deploying fuel pump 1 5 7 Military Assistance Program Maximum repair allowances do not restrict vehicles shipped under the Military Assistance Progra
357. ilver Red 6 in 7 in x 72 in 3613032 WARNING TRANSFER FROM LINE Black Silver 1 8 in 2in x 5 OR CONTAINER IDENTIFIED BY NAME OF ALCOHOL REQUIRED REFER TO TECHNICAL ORDERS 2 1 14 AND 36A9 3 12 1 FOR WATER ALCOHOL MIXING AND TESTING DATA 5 lines of copy as shown 3613041 EXPLOSIVES A Red Silver 6 in 8 in x 60 in 3613042 EXPLOSIVES B Red Silver 6 in 8 in x 60 in 3613043 POISON Blue Silver 4 in 6 in x 30 in 3613044 OXIDIZERS Yellow Black 4 in 6 in x 34 in 3613045 V Water Alcohol Chevron Black Silver 3 4 in x 5inx 7 6inx 8 in in 3613046 COMPRESSED GAS 2 lines of copy Green Silver 4 in 11 in x 36 in 3013047 CORROSIVES Blue Silver 4 in 6 in x 36 in 3613048 RADIOACTIVE black Yellow 4 in 6 in x 36 in 3613049 DANGEROUS Red Silver 4 in 6 in x 36 in 3613050 CARGO FIRE AVOID WATER Red Silver 2 in 6 in x 36 in 3613051 SECURITY POLICE 1 line of copy as Blue Silver 2in 4 in 24 in shown 3613053 RED CROSS SYMBOL Reflect pre Red White 3inx3in 4inx4in masked 3613054 RED CROSS SYMBOL Reflect pre Red White 6inx6in 8 in x 8 in masked 2 50 TO 36 1 191 Part No Legend Or Symbol Colors Letter Or No Emblem Size 3613055 RED CROSS SYMBOL Reflect pre Red White 8 in X 8 in 10 3 4 in x 10 masked 3 4 in 3613056 RED CROSS SYMBOL Reflect pre Red White 18 in x 18 in 24 in x 24 in masked 3613057 RED CROSS SYMBOL Non Reflect pre Red White 36 in x 36 in 48 in x 48 in masked 3616058 RED CROSS SYMBOL Reflective pre Red White 36 i
358. imum Duty Service SC Service SD Service SE Leaded Service SF Unleaded Diesel Engines Service CA Service CB Service CC Service CD Combinations Service CC SE Service CD SE MS 764 67 MS 768 71 MS 771 80 C80 present None None MIL PRF 2104G None SAE J2362 MILPRF 2104G MIL L 2104 MIL PRF 210G4 MIL L 2104 MIL PRF 210G4 SAE J2362 MIL PRF 2104G Oils meeting SE classification will be used in 1971 and newer commercial G P vehicles SA through SD oils may be used in older models according to age and usage SF to be used in all other vehicles unless environment opera tional conditions dictate special lube requirements 3 11 TO 36 1 191 NOTE e 15W40 oil meets crankcase requirements for most gasoline and diesel engines Hot environment where the winter 10th per centile minimum temperatures do not go be low 0 Fahrenheit 18 centigrade grade 15W40 can be used year round Extra preheat warm up is necessary when temperatures oc casionally drops below 0 Fahrenheit Grade 15W40 can be used in all hot weather envi ronments except Detroit Diesel Series 53 71 92 engines which are limited to 100 Fahr enheit while under warranty Product Name Specification Engine Oil MIL L 46167 Re refined MIL SPEC motor oil Executive Order 12873 and the Resource Conservation and Recovery Act require federal agencies to purchase products containing recycled materi als Units required to use v
359. in other types of alloys The combination of small active anodes to large passive cathodes causes severe pitting Pitting starts as an advanced form of 6 42 uniform etch If left untreated it can deteriorate into very severe corrosion that results in localized and relatively deep holes in the metal Pits are isolated holes that can vary in shape and size and usually take several months to a year before they become visible Pitting is an extremely destruc tive and insidious form of corrosion It causes equipment to fail because of perforation with very little weight or material loss on the entire structure It is also difficult to detect because the pits are often covered with corrosion products Pitting usually initiates at anodic points on a metal surface such as breaks in protective coatings or films scratches and irregu larities that are exposed to an aggressive electrolyte Pits usually grow in the direction of gravity and will develop and grow downward from a horizontal surface Even though a pit is slow to initiate once started it will progress at an ever increasing rate and will tend to undercut the surface as it grows Figure 6 7 Pitting Corrosion CORROSION CORROSION 4 5 RUST ALUMINUM BLISTER LAYER BLISTER CLADDING CAPILLARY VOI 7 7 INTERGRANULAR ROLLED ALUMINUM ALLOY ATTACK ELONGATED GRAINS Poe lt gt INQUE Ree Sirs CADMIUM PLATED STEEL FASTENER CATHODE F09603 112 Figure 6
360. intenance local contract or interservice agreement with other DoD agencies 9 15 WR ALC LE WR ALC LE will provide organizational and intermediate maintenance assistance to the requiring command in accor dance with the provisions of TO 00 25 107 9 16 VEHICLE REQUIREMENTS WR ALC LE will send to each command by 15 May a printout of Current Vehicle Requirements and Vehicle Repair Projections Each CONUS and overseas base will submit current year revalidation and five outyears projected require ments to their respective major command by 15 July of each year Major commands will consolidate and validate depot maintenance requirements and input these requirements to WR ALC LE via the appropriate data system This data will be used by WR ALC LE to prepare the MAJCOM s Logistics Support Review Brochure MAJCOM s are provided an advance copy of this brochure upon publication and prior to the Logistics Support Review NOTE Host base will consolidate repair requirements for tenant organizations and submit in accordance with above instructions Information copy shall be forwarded to tenant organization s respective commands Tunner 9 17 ADDITIVE REQUIREMENTS Overhaul requirements which generate after the initial sub mission of annual requirements or cancellation of items included in the initial submission will be submitted by bases to the appropriate major command shall submit out of cycle requirem
361. intervals based on the considerations listed below however blanket type interval and adjustments to satisfy ease of scheduling will not be permitted The following should be considered when adjusting Annual and PM amp I intervals 3 8 1 3 Operational environment e g dust high humidity cold weather corrosion 3 8 1 4 Operational utilization e g flight line multi shift poor terrain 3 8 1 5 Operational speed e g high way usage normal base extensive idling 3 8 1 6 Intervals that enhance the safety and continued operation of the equipment e g direct support mission essential vehicles NOTE Care should be exercised in reducing intervals for lubrication to prevent unnecessary work loads from being imposed on the vehicle management activity and unnecessary waste of resources Some newer vehicles specify the use of syn thetic oils Authority is granted to comply with OEM specifications throughout the warranty period Upon the next service where the fluids need changing after the warranty has expired lubrication products will meet the specifica tions listed herein 3 8 2 Fuel lubrication oil and battery additives will not be used in Air Force vehicles or equipment except those listed in TO 36 1 7 3 8 3 Requirements for products not identified to a military specification will be justification for local purchase 3 8 4 Certain late model vehicles are factory equipped with components that normally will
362. inventory control record AFTO Form 70 Figure 4 25 reproduced locally will be used 4 60 4 AFTO Form 70 Tire Inventory Control Record Figure 4 25 Optional This form will contain the following entries 4 60 41 Column A DATE Enter the day and month 4 60 4 2 Column B RECEIVED Enter the quantity of tires received from The Distribution Flight maintenance removed from equipment retreadable reparable and con demnation 4 60 4 3 Column C ISSUED Enter the quantity issued for installation on a vehicle or to the vehicle management activity 4 60 4 4 Column D TURN IN Enter the quantity turned in to the Distribution Flight as excess retreading or processing to DRMS 4 60 4 5 Column E BALANCE Enter the balance after adding the quantity received to the previous balance and deducting the quantities issued and turned in to the Distribu tion Flight 4 60 4 6 Column F BACK ORDER Enter the total quantity on back order 4 60 4 7 Column G ACTION BY The person making the tire transaction will enter his last name in this column 4 60 4 8 Block 1 STOCK NUMBER Enter the stock number 4 60 4 9 Block 2 SIZE TYPE PLY Enter the tire size type ply rating and tread design 4 60 4 10 Block 3 COST Enter the cost of tire 4 60 4 11 Block 4 LEVEL Enter the authorized 15 day operating stock level as determined by the in coordi nation with the LRS distribution flight officer List the applicable vehicles on the b
363. ir items not necessary to replace However man hours devoted to installation repair in excess of normal maintenance which must be contracted shall be funded by the shipping activity 1 5 4 4 Serial Numbers Vehicle Identification Num ber or VIN NOTE Replacement eligible vehicles may only be shipped within CONUS in an as is status upon prior agreement between shipping and receiving activities except when shipping mission essential vehicles Vehicle chassis and engine serial number will be checked and recorded on the receiving inspection Engine serial numbers if applicable will be maintained current Before transfer of vehicles to another organization or disposal the vehicles will be inspected to assure serial numbers are recorded 15411 The manufacturer normally assigns serial num bers to vehicle chassis and or engines in accordance with standard practices Chassis serial numbers are stamped on various locations i e frame cross members data plates on door post or the firewall VIN numbers are found in the lower left corner of the windshield on the dashboard of most commercially manufactured vehicles 1 5 4 1 2 substitute serial number will be used in instances where research fails to reveal a manufacturer s serial number The substitute numbers will be recorded on the Vehicle Historical Record 1 5 4 1 3 Installation procedures for lost identification plates A locally manufactured data plate will be in
364. ir replace only those parts assemblies necessary to ensure engine performance in accor dance with manufacturer s specifications 3 9 2 Emission Systems Exhaust emission system will be serviced and maintained as follows 3 9 2 1 Compare vehicle performance against manufactur er s specifications i e cylinder balance c o and hydrocar bons Accomplish performance testing by using an infrared emission tester or opacity meter 3 9 2 2 Ensure proper choke operation 3 9 2 3 Inspect clean or replace emission control devices hoses PCV valves etc 3 9 2 4 Where applicable the infrared emission tester opacity meter will be used to certify emission tests on gasoline diesel engines for vehicles assigned maintained on DoD installations Printouts readings will be attached or annotated on closed work order and retained in records jacket as proof of testing being accomplished If host country state or local laws require more stringent standards these will take precedence over recommended manufacturer s specifications 3 9 3 Maintain a copy of engine analyzer emissions tester technical data printout in the records if required by host country state or local requirements 3 10 SPECIAL INSPECTION For reasons of safety and to ensure operational reliability numerous special inspections and operational test require ments are imposed by the technical directives referenced in Paragraph 3 8 Many of these requirements are listed i
365. irgin oil must submit a waiver request with justification to their MAJCOM for approval Cold environments where summer average daily highs seldom exceed 60 degrees Fahren heit and the number of days with a maximum temperature between 90 and 100 Fahrenheit are very limited MIL PRF 2104G can be used year round If continuous daily high tempera tures exceed 90 Fahrenheit oil should be changed to 15W40 MIL PRF 2104G Product Name Specification Engine Oil SAE 12362 Product Name Specification Engine Oil SAE J2362 other environments where temperatures are 15 to 100 Fahrenheit use grade 10W30 where temperatures are 0 to 2 125 Fahrenheit use grade 15W40 Product Name Specification NSN Universal Gear Lubricant MIL PRF 2105E 80W90 9150 01 035 5392 10 to 120 Fahrenheit 75W 9150 01 035 5390 50 to 55 Fahrenheit 85W140 9150 01 048 4591 10 to 120 Fahrenheit Re refined MIL SPEC motor oil Executive Order 12873 and the Resource Conservation and Recovery Act require federal agencies to purchase products containing recycled materi als Units required to use virgin oil must submit a waiver request with justification to their MAJCOM for approval 3 9 ANNUAL TUNE UP EMISSION OPERATION CHECKS The tune up emission system operation checks specified below will be accomplished at intervals established in Table 3 1 3 9 1 Engines Perform an engine diagnostic test using available test equipment Repa
366. is realized that such general application instructions will not provide coverage for all vehicles under the diverse climatic conditions encountered worldwide Therefore local commanders or their authorized responsible officers are expected to implement further essential protective measures as required When these procedures are specified contractu ally the implementation of such additional protective mea sures shall be effected only with the approval of the contract ing officer or his authorized representative 8 15 STORAGE AREA The earlier requirements stated in this chapter are applicable except that vehicles shall not be stored in stacks or blocked up Since operationally ready vehicles are especially subject to theft and pilferage special attention to security measures is essential Containers of foam and fire crash trucks loaded with foam should not suffer prolonged exposure to tempera tures lower than 32 F Vehicles operationally exercised dur ing freezing weather must use the vehicle s winterization equipment If space permits fuel servicing vehicles shall be spaced so that the bimonthly fuel cycling exercise specified can be safely conducted without requiring moving of the vehicle If such space is not available these vehicles must be removed to a sufficiently isolated area for this operation Adequate fire protection shall be provided during this pro cessing 8 16 USE OF STORED VEHICLES Vehicles being stored under
367. is stored or operates in the immediate vicinity of saltwater environments less than 2 5 miles 6 15 7 3 2 For equipment deploying or returning from deployment in desert environments where the sand contains high chloride and carbonate concentrations and where wash capabilities are limited the wash down additives should be applied before and after deployment operations and whenever the equipment is completely washed during deployment Follow the manufacturers mixing and application instruc tions 6 15 8 General Cleaning and Material Process Con cerns 6 15 8 1 Cleaning compounds facilitate oils grease and soil removal However cleaning compounds can damage certain material surfaces and parts if they are improperly diluted and applied TO 1 1 691 identifies additional ap proved cleaning compounds and dilution rates for washing operations Using cleaning solutions more concentrated than the manufacturer s dilution rates is not acceptable This action may actually hamper washing operations because concentrated soap solutions tend to make surfaces slippery and can impede washing pads from loosening the soils In addition concentrated solutions require more rinse water to remove excess cleaner and may cause paint deterioration or corrosion 6 15 8 2 Cleaning compounds may impart Biochemical Oxygen Demand BOD to the washwater and increase the pH Therefore use of excessive amounts of cleaning com pounds should be avoided 6 15 8
368. ist vehicle management managers in han dling warranty adjustments when applicable 7 18 1 1 Original Tires Batteries Provided With New Vehicles The normal commercial warranty commercial fleet industrial provisions if separately stated is furnished on tires and batteries procured with new vehicles Whenever possible and practical tires and batteries should remain on original vehicle until replacement is required If warranty action is indicated and if the tire battery has remained on the original vehicle process a warranty claim through the Con tract Repair Service Activity for warranty adjustments from the nearest local dealer manufacturer of defective tires bat teries An AF Form 9 citing estimated funds for prorated exchange price should accompany the property 7 18 1 2 Normally replacement tires obtained through U S Army Tank automotive and Armaments Command TACOM contain no provisions for warranties unless spe cifically advised of and no specific records are required 7 18 1 3 Locally Procured Tires Batteries and Retreading Service Warranty adjustments should be processed per terms of contract Normally the standard commercial warranty will apply 7 18 2 Maintenance Not Covered By Warranty Unless caused by defective material or workmanship the manufac turer will not perform warranty corrections for the following regardless of vehicle age and mileage 7 18 2 1 Repair requirements resulting from manufacture
369. ith DD Form 1387 informing the contractor where and how to ship the part Inform the contractor to place adhere the label on the package Also to place a copy of shipment label inside of package 7 22 2 1 9 Mailing address of the person to be contacted concerning the claim 7 22 2 2 The contractor may respond with repair parts request that the failed parts be returned to CONUS for evaluation or deny the claim 7 22 2 3 When the contractor requests exhibits the above information must accompany the exhibit Airmail or air freight modes should be used for transportation of exhibits from overseas 7 22 2 4 Refer to local installation s Transportation Traffic Management Office TMO for assistance in filling out the Military Shipment Label DD Form 1387 as described below 7 22 2 4 1 Block 1 TRANSPORTATION CONTROL NUMBER Assigned by local TMO 7 22 2 4 2 Blocks 2 4 LEAVE BLANK 7 22 2 4 3 Block 5 SHIPPED TO POE The Port of Embarkation POE which will accept the shipment from the contractor and forward it to the user It will vary dependent upon the overseas location required priority and mode of shipment Obtain from TMO 7 22 2 4 4 Block 6 TRANS PRIORITY Required priority of which the shipment will be processed from the POE to the user will often reflect the mode of shipment determined at the POE Obtain from TMO 7 22 2 4 5 Blocks 7 8 LEAVE BLANK 7 22 2 4 6 Block 9 ULTIMATE CONSIGNEE OR MARK FOR Provide u
370. ition or statement which will be highlighted WARNINGs and CAUTION statements have been strategi cally placed throughout this text prior to operating or main tenance procedures practices or conditions considered es sential to the protection of personnel WARNING or equipment and property CAUTION or when essential to highlight a practice A WARNING and a CAUTION or NOTE will apply each time the step to which it refers is repeated Prior to starting any task the WARNINGS CAU TIONS and NOTES for the task will be reviewed and understood xiii xiv blank TO 36 1 191 CHAPTER 1 SERVICEABILITY STANDARDS 1 14 PURPOSE The purpose of this chapter is to provide minimum service ability standards for USAF vehicles that must be met or surpassed before a vehicle can be placed into or accepted from a transit status These standards are established to ensure safe daily operation mission needs and to prevent shifting of workload 1 2 SCOPE The instructions prescribed herein are intended to provide uniform inspections and standards for USAF vehicles in operation or transit The uniform inspection method for determining the condition of vehicles is the Limited Techni cal Inspection which is performed with the AFTO Form 91 References to AFTO Form 91 apply equally to the Automated LTI module in OLVIMS The standards which must be met are defined in this chapter These standards shall be applied to vehicle components to determi
371. itted directly to the GO21 database with an informa 7 2 tional copy to the appropriate MAJCOM Information war ranty reports will be e mailed to the MAJCOM with an informational copy to WR ALC The MAJCOM s will pro vide a specific e mail address to their bases for these reports The WR ALC addresses can be found on their web page at http 137 244 43 130 phone phone htm See Figure 7 1 for a sample dreams document 712 CONTROL AND COMMUNICATION 7 12 1 VM amp A will establish a file in accordance with AFMAN 37 123 This file will be used to store all correspon dence pictures and back up data for each open MIP being tracked by their activity 713 PURPOSE This chapter provides general warranty information and outlines responsibilities and procedures for obtaining war ranty adjustments It has been coordinated with government fleet managers and applicable automotive manufacturers 714 GENERAL WARRANTIES 7 14 1 The Air Force normally purchases new vehicles with a manufacturer s warranty for correction of deficiencies during the initial use period Warranties have been paid for and must be used where economically feasible The will exercise options of this technical order to prevent excessive Non Mission Capable times on low cost warranty repairs 715 RESPONSIBILITIES 7 15 1 The installation vehicle fleet manager will 7 15 1 1 Initiate action for correction of deficiencies occurring during the warranty p
372. ke manifold vacuum will be reduced 1 inch for each 1 000 feet if test location is above sea level 1 6 8 Pollution Emissions Control Devices All com ponents of any of these systems shall be properly mounted and operating as prescribed in applicable technical publica tions All systems shall meet or exceed the most stringent of requirements set forth by vehicle manufacturer local state federal or host country agencies 1 7 MINIMUM SERVICEABILITY STANDARDS 1 7 1 These standards are intended as guidelines Always reference the manufacturer s technical manuals for specifics These standards shall be applied to vehicle components in determination of vehicle classification under conditions out lined in Paragraph 1 3 through 1 5 1 7 1 1 Configuration Control Vehicle repairs to oper ating systems will maintain the manufacturer s original con figuration for example levers that pull to raise the dump bed will not be changed to a push action The operation of all controls shall be clearly labeled configured and operate in the same manner as intended by the original manufacturer s design and technical guidance Any wavier from this guid ance shall be routed through the MAJCOM Vehicle Staff and to WRALC LES for approval 1 7 2 In the following numbered subparagraphs and listed in alphabetical order the vehicle components and the mini mum serviceability standards are 1 7 2 1 Agitator Bituminous Mixers and Asphalt Dis
373. kings shall be applied with stencil or other suitable method Size and color scheme will match manual release pintle hook markings specified in this para graph NOTE Vehicles using pintle hooks where the pin is inserted automatically upon closing of the trip lock the above decal is not required 2 79 SLOW MOVING VEHICLE EMBLEM A slow moving vehicle emblem will be applied on the rear of all slow moving vehicles in a readily visible location NOTE Due to the various makes models and vehicle designs involved no specific mounting instruc tions will be specified It will be the responsibility of local operating officials to determine which vehicles will require the slow moving vehicle emblem based on local operational requirements 2 80 STRIKE HAZARD MARKINGS Strike hazard markings shall be applied on crane and derrick cabs or portions that extend outward over the chassis when being stowed in 4 to 6 inch alternating bands of black and yellow as illustrated in Figure 2 22 2 81 CENTER OF BALANCE MARKINGS The center of balance CB and basic weight marking may be applied to those vehicles that are susceptible to air deploy ment as follows 2 81 1 The center of balance CB marking will be applied on each side of the vehicle in a 1 inch wide stripe not less 2 23 TO 36 1 191 than 3 inches long The stripe will be located at the lowest visible point of the vehicle The letters CB will be applied directly
374. l be used when required by local safety office and medical services Bioenvironmental Engineer 2 22 FINISH COATS 2 22 4 Finish Coats Enamel and polyurethane paints are flammable and toxic Good general ventilation is normally adequate Skin and eye protection is required Avoid all sources of ignition There are several types of finish coats applied at both the OEM and field levels such as acrylic enamel and polyure thane high solid polyurethane two and three part clear coat 2 7 TO 36 1 191 systems etc Where possible organizations shall use the same type of coating system for touchup and repaint appli cations as was applied by the OEM If the finish system is totally removed and the OEM coating system is not feasible for field applications or operational needs dictate coating changes WRALC LESV in coordination with the MAJCOM vehicle manager shall provide finish system requirements 2 22 2 Simonizing waxing or polishing of USAF vehicles by commercial contract is authorized only when in house cost exceeds cost of obtaining like service through commercial resources The waxing and polishing of USAF vehicles in accordance with good commercial practice will be left to the discretion of the Installation Commander This work will be closely monitored to insure that proper material and or procedures are utilized 2 22 3 Repainted vehicles shall bear a temporary notice affixed to the dash panel reflecting DO NOT P
375. lated linkage shall be coated with MIL C 10578 P preservative Hydraulic system shall be filled to operating level with operational hydraulic fluid When furnished cab protector rack ex cept when welded shall be removed and se cured within body Removed hardwood and un painted surfaces exposed by disassembly shall be coated with A A 59295 P 1 preservative and hardware reinstalled into one of the mating parts All exposed unpainted machined surfaces of the hydraulic ram when the dump body is fully retracted shall be coated with MIL C 16273 P 1 preservative Release tailgate to pre vent accumulation of water in body Removed hardware and unpainted surfaces exposed by disassembly shall be coated with CID A A 59295 1 preservative and hardware reinstalled into one of the mating parts Dump body Hydraulic system shall be filled to operating level with operational hydraulic fluid When required for reduction in cube cab pro tector rack except when welded shall be re moved and secured within body Removed hard ware and unpainted surfaces exposed by disassembly shall be coated with MIL C 16173 P 1 preservative and hardware reinstalled into one of the mating parts 10 COLUMN I Item TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN II IV V Component Level Type of Vehicle Processing Required Prior to welding or cutting of any tank ensure the operation has been reviewed as r
376. leakage at seals or tendency to bind 8 21 3 8 Requirements Prior To Re Storage 8 21 3 8 1 The water foam systems of fire crash and rescue trucks shall be operated The compressed gas auxiliary systems should be pressure checked and inspected but do not require operations After delivery of foam line hoses and nozzles must be thoroughly flushed in accordance with the procedures specified in applicable operation and service handbooks 8 21 3 8 2 Tires shall be marked before vehicle operation to indicate the segment in contact with the ground When the vehicle is returned to storage after exercise tires shall be inspected to insure that the vehicle rests on another segment of the tires 8 21 3 8 3 Visually inspect vehicle for evidence of mal function such as oil or coolant leaks Report these and any other defects detected during exercise 8 21 3 8 4 Refill fuel tanks to capacity Except for bodies of fuel servicing vehicles which shall contain only enough fuel for the 15 day exercise 8 21 3 8 5 Replace covers on vertical exhaust stacks 8 21 3 8 6 Lubricate as required 8 21 3 8 7 Take all possible measures to prevent accumu lation of water in vehicle bodies such as ensuring that drain holes are open tilting bodies and loosening tailgates and use of temporary tarpaulins fabricated from waterproofed Kraft wrapping paper conforming to Specification PPP B 1055 secured with tape conforming to Specification SAE AMS T 2208
377. lect a level area 100 feet from any building source of ignition or sewer system Position fuel servicing vehicle so that the tank sump is in the lowest position possible 8 22 3 7 2 Static ground the vehicle to an approved earth ground If not available drive a steel rod into the ground until resistance between the rod and ground is in accordance with TO 0025 172 Paragraph 6 11 8 22 3 7 3 Have sufficient fire extinguishers available placed 50 feet upwind manned by qualified individuals Ensure all metal drain containers are grounded to fuel tank and common ground point Connections shall be made to clean unpainted surfaces Dis pose of full containers in accordance with AF MAN 23 110 NOTE Have sufficient containers available to position one at each drain point Dispose of drained fuel in accordance with AFMAN 23 110 as containers become full 8 22 3 7 4 Place conductive metal or galvanized contain ers under drain points Ground containers to tank and to tank s common ground Grounding connections shall be made to clean unpainted surfaces Open all valves and drain all fuel from the tank pumping system using all available low point drains tank sump filter separator manual drain pump drain line strainer and bottom loading manifold 8 22 3 7 5 Leave all drains open with a container to catch fuel during the purging operation This is to facilitate maximum air circulation 8 61 TO 36 1 191 Start blower air s
378. lettering to be on unobstructed vertical panel such as main body cab door or pump com partment Refer to Figure 2 14 to Figure 2 19 for examples 2 70 2 6 Funding for letters shall be provided by the base CE 2 70 3 ARFF trucks and flight line support trucks will have the radio call numbers marked on each side and top Details follow 2 70 3 1 As space permits the side numbers shall be a minimum of 16 inches 2 70 3 2 As space permits top numbers shall be a mini mum of 24 inches in height and affixed with their base toward the front of the vehicle 2 21 TO 36 1 191 2 70 3 3 Color for call numbers shall be in sharp contrast to the vehicle color 2 70 4 Fire chief and assistant fire chief vehicles will be marked CHIEF 1 and CHIEF 2 or FIRE CHIEF and ASSISTANT CHIEF respectively using reflective tape An exception is allowed for those installations that are members of state or county fire organizations and use district or regional call signs In this case the vehicles may be marked in the same manner as above using the call sign assigned to the fire chief and assistant chief vehicles by the fire organi zation If the regional call sign is used CHIEF 1 CHIEF 2 FIRE CHIEF and ASSISTANT CHIEF will not be placed in any other location on the vehicle Base fire department shield may be applied to CHIEF 1 and 2 only The shield must fit within the UNITED STATES and AIR FORCE and not
379. lists 7 11 TO 36 1 191 NOTE If the non dealer shop s invoice is less than the combination of Paragraph 7 21 2 1 1 and graph 7 21 2 1 2 the manufacturer will reimburse the lesser amount 7 21 3 Conditional Warranty Corrections manu facturer will authorize warranty corrections at the nearest independent garage when it is determined that the nearest authorized dealer is located at a point too distant to economi cally transport the vehicle s to and from such facility land is not in the best interest of the government The authorization by the manufacturer will be based on the following condi tions 7 21 3 1 Prior approval for the warranty corrections has been granted by the manufacturer 7 21 3 2 The manufacturer designates the independent garages if used 7 21 4 Air Force Repair of Warranty Covered Ve hicles Without Reimbursement If special handling as outlined in Paragraph 7 17 1 through Paragraph 7 17 3 above cannot be used the VFM may elect to repair a vehicle covered by warranty in an Air Force shop if the cost of the repairs is less than the cost of transporting the Vehicle to and from the warranty facility 7 21 5 Air Force Emergency Repair of Warranty Cov ered Vehicles VFM may repair a vehicle covered by warranty in an Air Force shop if the time needed for correction of the defect by the contractor under warranty would result in mission impairment 7 22 WARRANTY PROCE
380. livery tube and spray head If the can still does not spray remove and clean the plastic spray head then spray again to clear the delivery tube AMLGUARD buildup is difficult to remove especially after prolonged exposure to direct sunlight As increasing CPC buildup may affect the functionality of the parts to which the CPC is applied previously applied coatings should be re moved before reapplication 6 15 94 16173 is a non water displacing CPC that may be used on dried surfaces or on surfaces that have been first treated with a water displacing CPC It is a very effective soft film non drying CPC that is easily removed As a soft film CPC care must be taken to ensure contami nants do not collect on the soft CPC surface for extended periods of time MIL PRF 16173 covers five different grades of CPCs that can be applied by brushing or dipping Grades l 2 and 4 do not displace water and must be applied to dried surfaces or to surfaces that have been treated with MIL C 81309 a Grade 1 thick hard black CPC that is difficult to remove However it offers the most corrosion protection of all the CPCs indoors and outdoors and may be used at temperatures down to b Grade 2 A thick soft grease like brown CPC that remains tacky and can be removed with mineral spirits or dry cleaning solvent It protects under relatively severe conditions and given adequate maintenance touch up as necessary can be used for mo
381. ll be outlined to indicate height length and width using silver reflective tape conform ing to ASTM D4956 Type II Class 3 Type 1 color 2 77 MARKING EXPLOSIVE ORDINANCE DIS POSAL VEHICLES These vehicles may be equipped with rotating warning lights as well as sirens When warning lights and sirens are used they will be installed on a removable mounting bar NSN 2540 00 409 8878 The abbreviated legend E O D will be applied to a metal backing plate in 2 inch silver reflective letters on a red background and affixed to the front and rear of the mounting bar The type of lights and color of lenses will be in accordance with local or state laws regarding TO 36 1 191 operation of emergency vehicles or in cases of overseas operation in compliance with status of forces or host nation agreements NOTE This guidance takes precedence over TO 36 1 161 or 36 1 171 2 78 MARKING VEHICLES EQUIPPED WITH MS51335 SERIES PINTLE HOOKS All vehicles except toned down equipped with a manual release pintle hook CID A A 52550 series will be marked as illustrated in Figure 2 20 using amp 1 2 inch silver reflective letters on a red background Toned down vehicles will be marked utilizing a non reflective decal with amp 1 2 inch black letters color number 37038 on green background color number 24052 Mark vehicles with towing capacity IAW TO 36 1 121 Standardization of Lunette and Pintle Hook Tow ing Attachments Mar
382. ll be securely attached in a conspicuous location within driver s compart ment No preservation required Brake system shall be filled with operational hy draulic brake fluid in accordance with the appli cable lubrication instruction for level B Use MIL PRF 46176B for level A 24 25 26 27 28 COLUMN I Item TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN II Component Level Burners Heater A B Gas Fired Cables Battery Cables Hoist A Cables interve A hicular jumper Cabs Hard Top A wW w w COLUMN Type of Vehicle SE AV SP AV AV AV COLUMN V Processing Required Preserve interior surfaces of burners by spraying P 10 Type I Grade 30 preservative oil into air intake while the blower is in operation See Items 3 and 4 See Item 120 Secure to vehicle with tape Specification SAE AMS T 22085 Door hinges latches and operating mechanisms shall be lubricated with Type P 9 preservative oil Locks shall be lubricated with molybdenum disulfide conforming to Specification SAE AMS M 7866 Inspection access plates shall be removed and all interior surfaces of doors in cluding inner surfaces of access plates if un painted shall be coated with CID A A 59295 preservative and access plates reinstalled Be sure that door drain holes remain open Win dows shall be opened 1 2 inch for ventilation and when applicable cab air vents shall be left
383. ll contain ap plicable grade of lubricant conforming to Speci fication MIL L 2105 filled to operating level and shall be operated through all ranges for a minimum of minute at a sufficient engine speed to assure lubricant coverage of all interior parts and surfaces b Automatic Drive COLUMN 119 I Item TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN II IV V Component Level Type of Vehicle Processing Required 1 Long term storage Transmission shall contain P 10 preservative oil Type I Grade 10 or 30 as applicable filled to operating level and shall be operated as specified above Transmissions pre served with P 10 preservative oil that do not operate on lubricating oil conforming to Specifi cation MIL L 2104 shall have a warning tag bearing the information Vehicle TRANSMIS SION FILLED WITH P 10 PRESERVATIVE OIL DO NOT DRIVE VEHICLE MORE THAN 10 MILES BEFORE DRAINING AND REFILLING WITH PRESCRIBED OPERA TIONAL LUBRICANT securely attached to the shift selector 2 Shipment Transmission shall be filled to oper ating level with prescribed operational lubricant and operated as specified under a above Standard Drive As specified for Level A above b Automatic Drive Transmission shall contain lubricant conforming to requirements of appli cable drawing specification or lubrication or der filled to operating level When transmission contains P 10 pre
384. llow None 1 1 2 in 2 in x 1 4 in 3613163 Letter F die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613164 Letter G die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613165 Letter H die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613166 Letter die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613167 Letter J die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613168 Letter die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613169 Letter L die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613170 Letter M die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613171 Letter N die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613172 Letter die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613173 Letter P die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613174 Letter Q die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613175 Letter R die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613176 Letter 5 die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613177 Letter T die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613178 Letter U die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613179 Letter V die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613180 Letter W die cut pre spaced Yellow None 1 1 2 in 2 in x 1 4 in 3613181 Letter X di
385. locks then deflate in all cases to relieve unnatural strain free creases or wrinkles Finally install valve core and again inflate to recommended operating pressures 4 34 DETACHABLE RIMS To demount detachable rims on duals remove the lug then force off outer rims the space band and inner rim Reverse 4 22 procedures in mounting When mounting be sure lugs fit in their proper place against the rim Before lowering wheel to ground rotate wheel and check to make sure assembly does not wobble 4 35 DROP CENTER RIMS This type of rim has a well in the center which permits mounting and demounting Figure 4 19 and Figure 4 20 shows how the well in the rim makes these operations possible with lower part of bead in its seat The upper part would have to be stretched or broken to free it but with the lower part of the bead pushed into rim well it is not necessary to stretch the upper part to slip it over the flange 4 35 1 Tires may be removed from a drop center rim except from a safety type rim without removing the wheel especially on small size tires Considerable skill is required to mount and demount tires on this rim when wheel is on the vehicle For this reason the instructions in Figure 4 19 are procedures when the wheel is removed 4 35 2 Demount tires as follows 4 35 2 1 Determine which rim flange is nearer to the drop center well and position short side upward 4 35 2 2 Deflate tire by removing valve
386. lons or more 2 inch letters on trucks with less than 1 500 gallons capacity and 3 inch letters on two wheel trailers 2 61 2 Numerals identifying the grade of gasoline or type of oil will be added immediately after the word AVGAS or OIL in sizes prescribed for letters in the preceding paragraph Example AVGAS115 145 Oil Type MIL L 22851 or JET FUEL JP4 2 61 3 When converting a unit from one type product to a different type product all markings will be changed to correspond with the product to be dispensed 2 61 4 The appropriate NATO symbol as outlined in TO 42B1 1 15 will be applied to each side of aviation fuel and oil servicing vehicles immediately below the product identi fication The appropriate NATO symbol shall also be applied to the rear of aviation fuel and oil servicing vehicles where 2 17 TO 36 1 191 space permits Symbols will be the same size and color as product identification markings 2 61 5 Demineralized Water Trucks The words DEMINERALIZED WATER in 6 inch black letters will be centered vertically and horizontally on the left and right sides of the tank and on the rear centered approximately 8 inches from the top of the tank The words CAUTION WATER NOT FIT FOR DRINKING in 2 inch block type letters will be stenciled using black paint color number 1703B directly below the words DEMINERALIZED WATER at all three locations 2 61 6 Potable Water Trucks The words POTABLE WAT
387. ls shall be positioned for gasoline operation and diesel throttle completely closed While engine is being cranked with starting mo tor one ounce of P 10 Type I Grade 30 preser vative oil shall be atomized sprayed into each cylinder through spark plug openings Injectors and pre combustion cups when necessary shall be removed Engine controls shall be posi tioned for diesel operation While engine is be ing cranked with starting motor two ounces of the same type and grade preservative oil shall be atomized sprayed into each cylinder through the injector opening Engine shall be cranked with starting motor for at least five complete revolutions after spraying the last cylinder Without cranking two additional ounces of P 10 Type I Grade 30 preservative oil shall be atomized sprayed into each cylinder through spark plug opening Threaded ends of spark plugs injectors and pre combustion chambers shall be coated with the same type and grade preservative oil and plugs injectors and pre combustion chambers reinstalled Engine con trols shall then be positioned for diesel opera tion A warning tag bearing the information ENGINE PRESERVED DO NOT CRANK shall be securely attached in a conspicuous loca tion within driver s compartment 8 30 TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN I II IV Item Component Level Type of Vehicle COLUMN V Processing Required b Fou
388. luding main tank shutoff valve 8 22 5 10 On vehicles equipped with uncoated steel tanks except stainless steel spray each tank compartment with TO 36 1 191 preservative oil specification MIL PRF 21260E Type 1 Grade 30 Install tag AF Form 1492 on refueler operating control panel with inscription as follows This refueler has been drained of fuel and preserved with lubricating oil conforming to MIL PRF 21260E Prior to servicing aircraft the unit shall be purged with fuel to be dispensed by circulating through the system for approximately 10 minutes This fuel should be disposed of in accordance with local disposal procedures Install new filter or separator elements before placing the vehicle in service 8 22 5 11 Leave manhole s open 8 22 5 12 Secure tag AF Form 1492 on refueler operat ing control panel with inscription OPEN MAIN TANK SHUTOFF VALVE BEFORE ENGAGING PUMP 8 22 6 Segregators 8 22 6 1 Asuitable soft wood block will be placed beneath segregator floats to relieve weight of float assembly on needle valve the cover will then be replaced and attached with only a sufficient number of bolts to retain cover in place When installing care will be exercised to insure that float assembly will not be compressed against wood block 8 22 6 2 Other bolts nuts and washers will be placed in a shipping bag and attached to the segregator NOTE If the unit is purged by the steam method all internal
389. ly a light film of MIL L 87177 Grade B on the inside of the connector and the electrical contact points 6 15 9 Corrosion Preventive Compounds CPC Types And Applications are used for temporary protection of painted and unpainted surfaces and where paint has been damaged or removed CPCs function by preventing corrosive materials from contacting and corroding bare metal surfaces Some of the compounds have the capability of displacing moisture in seams joints and panels that overlap each other Some CPCs also provide lubrication as well as corrosion protection Generally CPCs are mixtures of special additives in petroleum derivatives special oils or greases CPCs range in appearance and consistency from the thick black types such as MIL PRF 16173 Grade 1 to light electronic grade spray material such as MIL L 87177 Grade B Several specialty CPCs contain vapor phase corrosion inhibitors that provide additional corrosion protection in enclosed areas The thicker CPCs provide the best corrosion protection are longer lasting and more difficult to remove The thinner materials provide some lubrication and do not crack chip or peel but must be removed and replaced The protection provided is temporary so the compound must be reapplied periodically after removal by washing or contact with solvents or fuel 6 15 9 1 The recommended maximum frequency of CPC application is based on the corrosion severity of the opera tional en
390. ly assigns serial numbers to vehicle chassis and or engines in accordance with standard practices Chassis serial numbers are stamped on various locations i e frame cross members data plates on door post or the firewall VIN numbers are found in the lower left corner of the windshield on the dashboard of most commer cially manufactured vehicles TO 36 1 191 1 5 5 3 serial number will be obtained from the manu facturer if the data plate cannot be found 1 5 5 4 Installation procedures for lost identification plates A locally manufactured data plate will be installed on vehicles that do not have the original manufacturer s data plate This plate may be manufactured from available mate rials and the size determined by the individual application Information from the manufacturer shall be recorded on the data plate 1 5 6 Shipping Inspections 1 5 6 1 Transfer Vehicle Being Transferred to An other Installation 1 5 6 2 Conus Shipment Prior to shipping vehicles between Air Force activities a technical inspection will be performed to determine that vehicles are acceptable Trans ferred vehicles must be in a condition that will permit use by the receiving activity without additional repairs Prepare the LTI form in duplicate A copy will be included in the vehicle records for use by the receiving organization NOTE Every effort should be made to ship only those assets with at least 50 percent of their life e
391. m MAP This applies to vehicles being shipped from Zone of Interior or from overseas A copy of the LTI will be included in the vehicle records for use by the receiving organization 1 5 7 1 In addition to inspection requirements of this technical order the following standards shall be used in determining eligibility of vehicles for MAP requirements 1 5 7 2 Vehicle appearance shall be above average and spot painting will be kept to a bare minimum When spot painting five percent or more of painted surface the vehicle shall be completely refinished 1 5 7 3 Vehicle will be complete with all components assemblies and parts TCTOs will be completed unless waived by receiving MAJCOM liaison 1 5 7 4 Excessively cracked or missing glass windows windshields light lenses etc will be replaced 1 5 7 5 X Vehicle components assemblies and accessories shall be in serviceable condition and in proper adjustment with remaining anticipated life expectancy of 50 percent 1 5 7 6 EXAMPLE Brake linings will have 50 percent of original usable thickness remaining 1 5 7 7 inspection on vehicles designated for the Military Assistance Program will indicate specifically the condition of equipment in relation to its original life expect ancy and appearance 1 5 8 Depot Repair Rebuild Request 1 5 8 1 1715 may be sent electronically to MAJCOM or WR ALC If hard copy forms are used the LTI will be prepared in triplicate when
392. m is to be completed signed and mailed to GM DELAYED WARRANTY START P O BOX 51850 LIVONIA MI 45750 Send one copy to PO BOX above provide one copy to customer place one copy in your file March 97 209603 101 Figure 7 3 Delayed Delivery Form General Motors Company TO 36 1 191 U S GOVERNMENT VEHICLE MICRO CHRYSLER NO MOTORS LIMITED WARRANTY REGISTRATION CARD This form is to be used to establish the correct delivery warranty start date Chrysler s Limited Warranty is included with each vehicle unless otherwise specified Complete this form accurately and legibly when vehicle is received mail 42 copy as addressed When requesting service from an authorized Chrysler Dealer the 1 copy is to be presented for verification of the service date CHRYSLER VEHICLE IDENTIFICATION NUMBER VIN DELIVERY DATE Month Day Year CONTRACT NUMBER NAME AND ADDRESS OF GOVERNMENT AGENCY MILEAGE AT DELIVERY STREET ADDRESS ITEM NO CITY STATE PROV Exclude 10ts U S ARMY REGISTRATION NO NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 9941 DETROIT POSTAGE WILL BE PAID BY ADDRESSEE CHRYSLER CORPORATION WARRANTY REGISTRATION DEPT 423 17 02 P O BOX 242 DETROIT MI 48288 F09603 102 Figure 7 4 Delayed Delivery Form Chrysl
393. mbly guide with wire Remove boom swinger case by re moving boom king pin Remove topping pivot and stow in OVE box Stencil USAF registration number and package number on boom Booms will be removed on all overseas shipments if practical On ZI ship ments only where requirement exists for re duced cubage will booms be removed Surfaces not requiring paint and subject to cor rosion will be treated with corrosion preventive compound Military Specification CID A A 59295 e 17 18 19 COLUMN I Item COLUMN II Component Boom Crane Bows Brake Systems Table 8 2 Processing Procedures Continued TO 36 1 191 COLUMN COLUMN COLUMN IV V Level Type of Vehicle Processing Required B SP a Shipment Engage the swing lock and lower boom to rest on front cowling frame Secure by using necessary blocking and band with not less than 1 1 4 inch banding If possible re move front section of boom to reduce cubage and secure to rear section of boom with not less than 1 1 4 inch banding Paint or touch up boom as required with applicable service color Prior to removing boom place boards 2 inch 6 inch length required between crane table and truck bed in sufficient quantity to prevent damage to center bearing Drop boom to full extent using Tractor steel drum and block of wood at boom tip for mounted support Discon nect boom and hook cables and rewind cables on drum Disconnect
394. mentalize a trailer and or to protect against damage caused by shifting cargo 3 15 TO 36 1 191 Table 3 4 Definition of Terms Continued Terminology Meaning Parent Material base material Structural shapes or plates which are welded to create the chassis Chassis The structural framework comprising the load carrying elements on all trailers Gooseneck On a drop frame trailer that portion of the trailer which extends upward and forward from the front of the loading deck to and including the upper coupler and front cross member Gooseneck Full Width A gooseneck the same width as the trailer neck King Pin A specially machined stub shaft which extends vertically from the lower surface of the upper coupler assembly which locks into a fifth wheel Outrigger side bracket Structural load carrying members attached to and extending outward from the side beams TO 36 1 191 ysea y Poeno jqe d v e punoj pue pa32edsur 1 vaey s jdwes uoreorgae 2 25 5 00 OL MYI SIJ9pJ9AA HEDY Joy URLIO q K3eroog Surp oAA ueorrouny e SUIMOT OJ Jo ouo sassassod pue asinoo 8 e pojo duroo seu oym y SNOILINI33G Jop 2A perpenb Aq saredog ppjoAA do
395. metalizing operations Thermion equipment may be procured from Thermion Metalizing System Ltd P O Box 2136 Silverdale WA 98383 2136 Table 2 1 page 3 lists currently authorized metalization materials and various sources of supply NOTE Prior to utilizing any thermal spray process on vehicles obtain approval from WRALC LE Fol low all manufacturers guidance on the thermal spray equipment surface preparation and appli cation processes 2 17 4 In the MWAS process two electrically isolated wires of the selected coating material are given opposite DC polarity using an arc welder power supply The wires are simultaneously fed to an application gun where they are brought into close proximity to initiate an electric arc The arc between the two impinging wires results in a local region of high temperature plasma and molten metal A jet of com pressed air directed through the arc region from behind disperses and projects the molten metal to the surface being coated The metal droplets impinge on the substrate solidify and bond to form a continuous barrier sacrificial coating for cathodic protection of the metal structure The application gun remains 8 12 inches from the metal surface and negli gible heat is imparted to the substrate even during extended coating activities 2 3 TO 36 1 191 2 17 5 Proper application of these metalized coatings requires that the substrate be prepared with a minimum near white abrasive blas
396. moved as opposed to method 2 involving removal of manifolds 1 Diesel throttle shall be completely closed In jectors or injectors and pre combustion cham bers as applicable shall be removed and coated with P 10 Type I Grade 30 preservative oil exercising maximum care in handling to avoid damage to injectors and pre combustion cham bers during preservation While engine is being cranked with starting motor two ounces of P 10 Type 1 Grade 30 preservative oil shall be atomized sprayed into each cylinder through the openings Injectors or injectors and precombus tion chambers as applicable shall be rein stalled A warning tag bearing the information ENGINE PRESERVED DO NOT CRANK shall be securely attached in a conspicuous loca tion within driver s compartment 8 31 TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN COLUMN I II Item Component Level Type of Vehicle Processing Required 2 As an alternative when method 1 is found to be impractical the following shall be accom plished Diesel throttle shall be completely closed Intake or exhaust manifold or both shall be removed and when applicable compression release secured in release position While engine is being cranked with starting motor two ounces of P 10 Type I Grade 30 preservative oil shall be atomized sprayed into each cylinder through intake valve at the time valve opens Engine sh
397. mp T s are considered adequate for Air Force vehicles When mandatory warranty intervals are more restrictive than Table 3 1 and Table 3 2 the manufacturer s intervals will be used Upon expiration of the warranty revert to intervals directed by this manual When accomplished concurrently each of the in spection services or tests listed in Table 3 1 and Table 3 2 will require a separate entry on the work order NOTE Annual and PM amp I s will always be one transac tion and will be performed concurrently and recorded on the work order as well as Vehicle Historical Record Those inspections services or tests which are not tracked in OLVIMS will be accomplished concurrently with PM amp I or Annual Inspection 3 4 5 Due to their design limitations vehicles equipment that cannot be practically transported to the vehicle manage ment shop for inspection or services will be serviced by the mobile maintenance team When the required service exceeds the team capability the responsible will determine the alternate course of action 3 4 6 Vehicles used solely for stationary training purposes are exempt from any scheduled services 3 4 7 Vehicles in storage will be inspected and serviced in accordance with Chapter 8 The may waive scheduled maintenance inspections service reflected in Table 3 1 Table 3 2 and manufacturer s tech order for these vehicles 3 1 TO 36 1 191 3 4 8 Authority to implement more frequent sch
398. mponents for cracks in the parent material x x p __ os C Eo e e o e o o T sk JL Bop DISCREPANCY EXISTS GOOSENECK LEFT AND RIGHT SIDE YN Inspect welds of all main beam stiffeners attached to the main beam webs and main X X beam flanges Inspect welds of both main beams to the forward and rear bulkheads X X Inspect welds of all landing gear support brackets at the main beam main deck attach X X ment points Inspect welds of all landing gear support brackets at the landing pear X Inspect all left and right side gooseneck components for cracks in the parent material lated Table 3 6 Semi Trailer Structural Inspection Checklist If A Crack Is Found Enter In The Corresponding Block Otherwise Enter A DISCREPANCY EXISTS MAIN DECK UNDERSTRUCTRE Y N nspect welds of both main beams at rear bumper nspect welds of main beam flanges at the main beam webs nspect welds of main deck cross members at the main beam webs nspect welds of main deck cross members at the side rails nspect welds of side rails at the forward bulkhead cross member nspect welds of metal decking at supporting structure as applicable nspect surfaces of main beam flanges webs for cracks in the parent material Inspect welds of main beams at the forward bulkhead cross member Inspect welds of both main beams at rear bumper _______ _ X Inspect welds of main beam flanges a the main beam webs
399. mpound MIL PRF 85570 Type I GI 1 GI Cn 5 GI Dr 55 Gl Bulk GI 1 Gl Cn 5 Gl Dr 55 Gl Bulk GI 1 GI Dr 55 GI Bulk GI 1 GI Dr 55 GI Cn 5 Gl Dr 15 Gl Dr 55 Gl 850 01 390 7808 6850 01 390 7811 6850 01 390 7816 6850 01 390 7821 6850 01 390 7827 6850 01 339 5227 6850 01 339 5228 6850 01 390 7828 6850 01 390 9530 6850 01 390 9453 6850 01 390 9558 6850 01 429 2368 6850 01 429 2371 6850 01 237 7482 6850 01 237 8003 6850 01 237 8004 Terpene based solvent emulsion water diluteable cleaning compound Best used on heavily soiled areas on painted and unpainted surfaces where sufficient ventilation is available De pending on dilution ratio may be used for general vehicle cleaning Suitable for use on high gloss or tac tical paint systems Water diluteable cleaning compound Best used for general vehicle cleaning on painted or unpainted surfaces Suitable for use on high gloss or tac tical paint systems Gel type thixotropic viscous cleaning compound Best suited for use on heavily soiled surfaces painted or unpainted where additional dwell time is desired 1 Should be used in areas that can tolerate high volume water rinsing Heavy duty water diluteable cleaning compound Equally suited for clean ing both heavily soiled areas and gen eral surfaces may be used on painted or unpainted surfaces Suitable for use on high gloss or tactical pai
400. n 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 4 in x 2 8 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 6 in x 3 3 in 2 53 TO 36 1 191 Part No 3613252 3613253 3613254 3613255 3613256 3613257 3613258 3613259 3613260 3613261 3613262 3613263 3613264 3613265 3613266 3613267 3613268 3613269 3613270 3613271 3613272 3613273 3613274 3613275 3613276 3613277 3613278 3613279 3613280 3613281 3613282 3613283 3613284 3613285 3613286 3613287 3613330 3613331 3613332 3613333 3613334 3613335 3613336 3613337 3613338 3613339 3613340 3613341 3613342 2 54 Legend Or Symbol Letter Q Letter Letter S Letter Letter U Letter Letter W Letter X Letter Y Letter 7 Letter Letter Letter Letter D Letter E Letter F Letter Letter Letter T Letter J Letter Letter Letter Letter Letter Letter P Letter Q Letter Letter S Letter Letter U Lette
401. n excellent way to minimize corrosion Sealers can also be used to separate two conductive metal surfaces preventing gal vanic or crevice corrosion 6 15 10 2 Sealers are normally resins with or without fillers which are compounded to dry to a hard surface or to remain soft and pliable They can be formed in place applied by spray gun or paste Room Temperature Vulcanizing RTV Adhesive Sealant MIL A 46106 emits acetic acid during its curing process and can cause corrosion when used in confined spaces Unless otherwise di rected by the OEM or other official guidance only non acetic acid emitting RTV shall be used Refer to TO 1 1 691 for sealant materials appli cations and processes 6 15 10 3 There are sealants in the Air Force inventory that can damage vehicle parts and structures if used improp erly For example Room Temperature Vulcanizing RTV Adhesive Sealant MIL A 46106 is not authorized when sealing metal parts in enclosed areas 6 16 CORROSION THEORY CAUSE AND EFFECTS To help prevent corrosion vehicle technicians first need to understand corrosion causes and effects and be able to recognize that there are several types of corrosion with different preventive measures This section is an introduction to corrosion theory the causes of corrosion and the factors that influence its development The various forms of corro sion and the effect of corrosive environments on vehicles are also described in this s
402. n 18 inch red cross on a 22 inch square white field centered on the rear doors and the word AMBU LANCE in 3 inch reflectorized letters centered under the red cross 2 49 5 The roof markings shall consist of a reflectorized decal with an 18 inch red cross on a 22 inch square white field centrally located on the roof panel 2 50 BUS 44 PASSENGER CONVERTIBLE MULTI LITTER 2 50 1 The marking AMBULANCE 3 inch high direct prespaced silver reflective letters will be centered in the routing view box above the windshield 2 50 2 A premasked reflectorized decal with a 36 inch red cross on a 48 inch square white field will be applied on each side of the vehicle below the windows in a central location NOTE Decals that cannot be applied as described above due to body style uneven or ribbed surfaces etc may be applied to an appropriate sized aluminum plate and affixed to the vehicle with aluminum or stainless steel bolts Permission must be obtained from GSA before any modification to one of their vehicles can be made 2 50 3 A premasked reflectorized decal with an 18 inch red cross on a 22 inch square white field will be applied on the rear of the bus in a central location 2 51 AUTOMOBILE STATION WAGON Station wagons which have been converted for use in lieu of metropolitan ambulances by installation of wheel litter at tachments will be marked as follows 2 51 1 A premasked reflectorized decal with an 8 inc
403. n Table 3 1 and Table 3 2 Every effort should be made to perform the inspections tests concurrently with the Annual or PM amp I When not accomplished as a part of the regularly scheduled Annual or PM amp I these inspections tests will be separately tracked and accomplished at intervals specified by the pre scribing directive or technical order Applicable directives must be consulted for detailed procedures when accomplish ing these inspections Each special inspection test will be recorded on the Vehicle Historical Record 3 10 1 Clean inspect replace as required and repack wheel bearings Every 36 000 miles 2400 hours or more frequently if local laws or operating conditions require When brakes are replaced brake shoes wheel cylinders calipers rotors drums etc should be checked at this interval Trailers and semi trailer wheel bearings will be repacked every three years NOTE Wheel bearings lubricated by oil shall be cleaned and inspected replace as required whenever the brake shoes are replaced anytime wheel bearing serviceability is in question or annually if regu larly submerged in water i e boat trailers 3 10 2 Refuelers following refueling test services will be accomplished at intervals outlined in Table 3 2 3 10 2 1 Filter Separator Element Change Change filter separator elements in accordance with TO 37A 1 101 If replacement filter packages or elements show evidence of damage elements will no
404. n alkaline batteries consists of a solution of potassium and lithium hydroxide in water The electro lyte will be packaged as specified and identified to this type battery b Electrolyte accompanying the vehicles when required shall be packaged in accordance with Specification PPP B 140C Wrap the contact plug with neutral paper con forming to Specification MIL P 17667D over wrap with water vapor proof barrier material conforming to Specification MIL B 131 sealed with pressure sensitive tape conforming to Specification PRF 131J Connector cables re moved shall be preserved and packaged in ac cordance with Method IAW or Specification MIL STD 2073 1D 1 and secured within the battery compartment or stored with the removed battery as applicable COLUMN I Item COLUMN II Component Belts Drive Type of Vehicle TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN V Processing Required d Cover tops of batteries secured in place in the vehicle battery carrier with a protective shroud of waterproofed paper conforming to Specifica tion PPP B 1055 B extending down sides and ends a minimum of 6 inches and secured with pressure sensitive adhesive tape conforming to Specification SAE AMS T 22085 Unless otherwise specified batteries will be stored and shipped in the vehicle battery carrier Cables and contact plugs shall be preserved as specified for Level A above No special protec tive meas
405. n height shall be centered between the red crosses on the rear doors 2 48 6 The roof marking shall consist of a premasked 36 x 36 inch red cross on a 42 x 42 inch white field centrally located on the roof panel NOTE Decals will not be replaced solely to comply with this TO Compliance with this TO will be accom plished as decals require replacement 2 48 7 An orange stripe not less than 6 inches nor more than 14 inches wide shall encircle the entire ambulance body at the belt line below the bottom edge of cab windows but may exclude the front of the hood panel The material for striping shall be reflectorized to ASTM D4956 Sheets Class 1 or 3 Type 1 Then follow on with the NOTE about the decals 2 49 AMBULANCE VAN MODULAR 4 x 2 AND 4 x 4 PAINTED SEMI GLOSS GREEN 2 49 1 The legend AMBULANCE in mirror image in 3 inch reflectorized black letters shall be applied on the front center of the hood TO 36 1 191 2 49 2 Two reflectorized decals with a 3 inch red cross on a 2 inch square white field will be placed one on each side of the word AMBULANCE approximately 6 inches from the first and last letters 2 49 3 The side markings shall consist of the word AMBULANCE in 3 inch black reflectorized letters cen tered on the side of the body underneath the centered reflectorized decal with an 18 inch red cross on a 22 inch square white field 2 49 4 The rear markings shall consist of a reflectorized decal with a
406. n of the USAF Management List in the Federal Supply Catalogs are not eligible for depot maintenance 9 12 VEHICLE COMPONENTS ELIGIBLE FOR DE POT MAINTENANCE Vehicle components coded T in the repair column of the USAF Management List in the Federal Supply Catalogs are eligible for depot maintenance and will be processed for overhaul in accordance with AFMAN 23 110 913 AUTHORIZED DEPOT VEHICLES Those vehicles on which depot level maintenance is autho rized are listed in Table 9 1 Depot Eligible Vehicles NOMENCLATURE TYPE A S32P 19 A S32P 22 A S32P 23 and A S32P 24 Fire Fighting Equipment Table 9 1 NOMENCLATURE Truck Refueler Truck Hydrant Hose Runway Vacuum Sweeper Aircraft Towing Tractor TO 36 1 191 Depot Eligible Vehicles Continued TYPE A S32R 9 1980 model and later and A S32R 11 R 12 BETA R 12 Tri State HSV A S32M 3 MB 2 and U 30 25K Truck A C Cargo Loading Unloading 463L A S32H 5 and A S32H 5A 40K Truck A C Cargo Loading Unloading 463L A S32H 6 and A S32H 6A 60K Loader A C Cargo Loading Unloading 463L 9 14 MAINTENANCE ASSISTANCE Requests for maintenance assistance on vehicles will be processed through the major command headquarters to WR ALC LE in accordance with TO 00 25 107 The major command involved must certify the assistance required is essential to the mission and beyond the practical limitations of the using command s resources intermediate ma
407. n placing tubes in tires on wheels be sure that 4 33 3 1 Valves point in correct direction 4 33 3 2 Valves that are offset in tubes are placed to match the offset valve hole in rim 4 21 TO 36 1 191 4 33 3 3 Angle valves are pointed toward the removable flanges of rim 4 33 3 4 Be careful not to damage beads with tire tools or hammer Bead wires are easily damaged if gouged with steel tools If proper directions are followed severe use of tools is not necessary When difficulties are met check methods 4 33 3 5 Synthetic tubes and flaps require special care and precautions must be observed in mounting to ensure maxi mum service Before placing a small size tube in tire the tube should be inflated to about three quarters full or to point where it starts to round out Large tubes should not be rounded out until after being placed in tires Inspect tire and repair all damage Lubricate entire surface of tube with tire lubricant 4 33 3 6 Flaps must be dusted or lubricated on both sides in addition to tube Natural rubber flaps used with synthetic tubes need only be dusted or lubricated on side that comes in contact with tube 4 33 3 7 After properly preparing the tube tire and rim place tube in tire and mount in usual manner Next inflate sufficiently to force tire beads to seat properly against rim flange of drop center and semi drop center rims Allow flaps to center properly between beads of flat base rims and bead
408. n shall be securely mounted within easy reach of vehicle operator and its contacts shall wear in front and rear direction Fifth wheel plate s welds shall be sound and not cracked be protected from water and dirt Relays shall be securely mounted and operate properly 1 7 2 77 Hoses Nozzles And Pumps Fuel Servicing Types Hoses shall show no evidence of deterioration other than small weather cracks that will not impair service ability and shall be free of leaks Nozzles shall operate properly and shall show no evidence of leakage Pumps shall be free of leaks and shall operate properly at the required pressure as indicated in applicable technical publications 1 7 2 78 Hose Reel System Fuel And Fire Units Hose reel swing joint and hose connection shall have no leaks under operating pressure Hose reel swing lock shall operate satisfactorily with hose reel in travel or operating position Hose reel charging valve shall open without excessive pull on charging cable and pulleys when actuated Hand line nozzles shall operate properly under maximum pumping pressure 1 7 2 79 Hydraulic System Hydraulic pumps and re lief valves shall maintain operating pressure as prescribed by the manufacturer Pumps shall operate smoothly without unusual noise Reservoirs shall be in good condition and securely mounted Reservoirs shall be serviced with proper lubricant and be free of water Lines hoses and their connections shall be tight a
409. n which vehicles are placed in service User should fill out all appropriate information and return form to address listed at the bottom of the form See Figure 7 2 thru Figure 7 3 for delayed delivery forms for the big three manufacturers Mailing address are as follows General Motors Address GM Delayed Warranty Start PO Box 51850 Livonia MI 48150 Ford Motor Company Ford Customer Service Division PO Box 43392 13th Floor 300 Renaissance Center Detroit MI 48243 Chrysler Corporation Warranty Registration Dept 423 17 02 PO Box 242 Detroit MI 44288 Ford Motor Company Chrysler Corporation 7 17 7 Warranty Extensions If the contractor receives from any supplier or subcontractor additional warranty cov erage on the whole or any component of the vehicle in the form of time and or mileage including any pro rata arrange ments or the contractor generally extends to his commercial customers a greater or extended warranty cover age includ ing anti corrosion the government shall receive correspond ing warranty benefits 7 17 8 Special purpose vehicles procured under Air Force specifications by the Air Force and or Defense Construction Supply Center are warranted for 12 months from date of acceptance Defective parts or assemblies determined to be covered by warranty will be replaced at no cost to the government Shipping costs for replacement items will be the responsibility of the contractor except to bases outsi
410. n x 36 in 48 in x 48 in masked 3613060 FOR OFFICIAL USE ONLY Silver Red 3 4 in 1 1 4 in x 15 in 3613061 U S AIR FORCE Silver Red 1 1 2 in 3 in X 21 in 3613065 U S AIR FORCE Silver Red 1 1 2 in None 3613062 U S AIR FORCE Die cut pre spaced Yellow None 1 1 2 in None 3613063 ALERT FORCE Blue Yellow 2 1 2 in 3 1 2 in x 26 in 3613066 FOR OFFICIAL USE ONLY Die cut Silver None 3 4 in None pre spaced 3613064 FOR OFFICIAL USE ONLY Die cut Yellow None 3 4 in None 3613080 OXYGEN Yellow Black 3 in 5 in 22 in 3613067 LIQUID OXYGEN Yellow Black 4 in 6 in x 36 in 3613081 NITROGEN Green Silver 3in 5 in x 24 in 3613068 LIQUID NITROGEN Green Silver 4 in 6 in x 40 in 3613069 CAUTION Silver Red 4 in 6 in x 22 in 3613082 FLAMMABLE GAS 2 lines of copy Red Silver 4 in 11 in x 36 in shown 3613103 AMBULANCE Reflective die cut pre Silver None 3 in None spaced NOTE The following are supplied in ten identical characters per package 3613132 Letter A Silver Red 1 1 2 in 2 in x 1 4 in 3613133 Letter H Silver Red 1 1 2 in 2 in x 1 4 in 3613134 Letter C Silver Red 1 1 2 in 2 in x 1 4 in 3613135 Letter D Silver Red 1 1 2 in 2 in x 1 4 in 3613136 Letter E Silver Red 1 1 2 in 2 in x 1 4 in 3613137 Letter F Silver Red 1 1 2 in 2 in x 1 4 in 3613138 Letter G Silver Red 1 1 2 in 2 in x 1 4 in 3613139 Letter H Silver Red 1 1 2 in 2 in x 1 4 in 3613140 Letter Silver Red 1 1 2 in 2 in x 1 4 in 3613141 Letter
411. nagement activity will be in accordance with AFI 24 302 4 59 TIRE WARRANTIES Tire warranties new and retreaded are based on tread wear Warranties will be used when economical 1 when value gained exceeds the cost of using the warranty to include handling and transportation 4 60 INVENTORY CONTROL On an required basis the Distribution Flight will produce a supply point listing which reflects authorized quantities and on hand assets 4 60 1 The DIFM listing depicts those tires on hand in the tire shop awaiting turn in or repair and the tires that have been processed for repair retread 4 36 4 60 2 DIFM reports can be used to reconcile inventories Using these products on a frequent basis should eliminate the need for maintenance of an inventory record When these reports are used for inventory control inventory reconcilia tion must be accomplished at least monthly 4 60 3 Custodial control of tires within the tire shop is the responsibility of shop supervisor The Distribution Flight has primary responsibility and accountability for tires in the supply point until issued Commands may direct that tire inventory be controlled by individual transaction if detailed control is essential Normally this requirement will arise where security is a documented problem or difficulties are being experienced in reconciling the reports with the inven tory If individual transaction control is necessary the tire
412. nd approve or disapprove all requests for vehicle depot overhaul according to WR ALC Form 2117 and the following criteria 9 10 1 Vehicles coded S in the repair column of the USAF Management List in Federal Catalogs are eligible for depot overhaul when the following conditions are met 9 10 1 1 The owning command s inventory of the vehicle and suitable substitutes on which overhaul is requested is within approved authorizations and the command certifies vehicle is essential to the command mission 9 10 1 2 Replacement cannot be supplied within one year and scope of the repairs listed on the LTI as being required are beyond the practical repair limitation of the using activity and justify evacuation of the vehicle to a depot overhaul facility Commands will certify that repairs are beyond base and intermediate level capability 9 10 1 3 The cost of repairs estimated on the LTI do not exceed 75 percent of the cost of the replacement item and transportation to repair facility 9 10 1 4 Depot overhaul will not normally be accom plished when 9 10 1 4 1 The using command s inventory of the autho rized item and suitable substitute exceeds their authorization 9 10 1 4 2 The vehicle on which depot overhaul is re quested is being applied as an unsuitable substitute for another 9 10 1 4 3 Vehicles designated by type and model by the WR ALC LE Equipment and Vehicle Management Director Table 9 1 ate as being unworthy of conti
413. nd free of leaks 1 7 2 80 Ignition Wires Secondary Secondary wires shall be clean and free of weather cracks chaffing and burn spots Secondary wires shall be of proper type and length Spark plug and distributor cap terminal boots shall be clean and form a tight seal Sealed water proofed type secondary wires shall be clean and the connecting end shall be secured properly 1 7 2 81 Inter Cooler And After Cooler Inter cooler and after cooler shall be securely mounted and connections shall not leak Air passages shall be clean and not damaged Relief valve assembly shall function properly 1 7 2 82 Interior Trim Panels headliner and floor cov erings shall be clean complete properly mounted anchored and free of major tears Molding and metal plastic trim shall not be rusted cracked excessively or broken nor have missing screws mounting clips 1 7 2 83 King Pin And Fifth Wheel Plate Semi trailer king pin and fifth wheel plate shall be properly lubricated and shall not have more than 1 8 inch wear in front and rear direction Fifth wheel plate s welds shall be sound and not cracked 1 7 2 84 Landing Gear Landing gear shall operate smoothly without binding or dragging and be securely mounted Cranks shall be present serviceable and securely mounted Mounting flanges frames shall have no cracks loose bolts or loose rivets Landing pads wheels shall not be bent cracked or broken TO 36 1 191 1 7 2 8
414. nd maintain the required pressure as prescribed by the manufacturer NOTE Condition of engine shall be considered when observing oil pump pressure indications 1 7 2 96 Painting And Marking Painting and markings shall be in accordance with Chapter 2 and shall afford adequate protection to the metal 1 7 2 97 Pintle Hook And Trailer Type Connection Pintle hooks shall be securely mounted with properly hard ened bolts and lubricated properly No excessive wear shall be found in the jaw pins and in the locking device Safety lock pins shall be of proper size in length and be attached with a chain in accordance with TO 36 1 121 Other type connection shall be properly mounted and free of cracked welds or excessive wear 1 7 2 98 Power Controls And Winches Power control units and or winches shall be securely mounted and properly aligned Housing drums seals and gaskets shall be free of leaks and cracks Drum bushings bearings shall not be excessively worn Clutch and or brake bands shall be prop erly adjusted and not be excessively worn Cables shall be properly reeled on drums and be lubricated Sheaves shall not be broken or worn to the point where cable damage might result 1 7 2 99 Pumps Fire Fire pumps shall be free of leaks and shall be able to produce and maintain the required pressure as prescribed by the manufacturer Pump casings and or housings shall not be cracked or broken Pump primer equipment will oper
415. nd servicing is mandatory for radial tires as improper mounting and under inflation can severely reduce tire life Radial tires have an inherent bulge making it impossible to visually judge air pressure The only sure way to determine if a tire is properly inflated is to check it with a gauge Regular air pressure checks are absolutely essential to ensure maximum service life from any tire 4 26 1 Mounting Inspect wheel after wire brushing inside wheel flange All bead seats must be free of dirt and rust 4 26 11 Remove all wheel weights 4 26 1 2 If evidence of distortion or impact damage exists measure wheel for runout 4 26 1 3 If wheel flange is bent replace the wheel 4 26 1 4 valve stems cores and caps shall be installed before new tires are fitted to wheel Only plastic stem caps will be used on any government owned or leased vehicle 4 26 2 Lubrication Lubricate tire beads with liberal amount of approval rubber lubricant Beads must be lubri cated in mounting and demounting to prevent bead damage Ensure the portion of bead opposite the tire tool is inside the wheel flange prior to mounting then mount in the usual manner DO NOT ALLOW the tire to hang up on the tire tool Relubricate bead if necessary Without valve core inflate tire to 40 psi Deflate Install valve core and inflate to recom mended tire pressure Carefully check bead to rim seat Tire bead to rim clearance should be the same around the circum
416. nded for all makes and models of AF vehicles new or used The illustra tions in Figure 6 1 and Figure 6 2 are for concept only Personnel assigned to accomplish this treatment will exercise good judgment in performing the task efficiently and ensure all corrosion prone areas are treated Particular attention must be given to those sections of a vehicle that are most susceptible to corrosion when operating in tropical subtropi cal and coastal regions and in areas where salt solutions are used for snow and ice removal 6 11 2 Inspection Vehicles received shall be inspected to determine compliance with standards set by the local Installation Commander Each vehicle will be inspected at least annually to determine the areas requiring reprocessing This inspection should be performed in conjunction with the annual inspection Results shall be entered on AF Forms 1823 and 1828 6 11 3 Cleaning 6 11 3 1 Cleaning of the vehicle will require placing it on a lift and raising it to proper working level The recom mended procedure is to begin at the front and work toward the rear as follows Front splash panel headlight area front fenders panels and supporting members fender beads floor pan rocker panels quarter panels fuel tank tail and back up light area and rear splash panel Remove heavy deposits of rust loose undercoating mud gravel and foreign material by using wire brush putty knife screw driver rubber hammer or improvised to
417. nder head and block shall be free of cracks or indications of oil water or compression leaks around studs bolts and or gaskets Core plugs shall have no leaks or signs of deterio ration 1 7 2 45 Differential Final Drive Differential carrier shall be free of cracks or leaks around mount gasket and pinion seal Carriers shall have no mounting studs nuts or bolts missing Ring and pinion gear adjustment shall be in accordance with manufacturer s specification Carrier bear ings shall be properly lubricated and adjusted and operate free of unusual noise lubricant leakage 1 7 2 46 Dipper Clamshell Dragline Back Hoe And Hook Block There shall be no excessive wear missing teeth cracks loose or missing bolts or rivets Sheaves shall have no excessive wear broken flanges worn bushings pins or pin retainers Shovel dipper and dragline bucket shall be properly adjusted to assure satisfactory operation 1 7 2 47 Distributor And Ignition Systems Caps and rotors shall not be cracked corroded or damaged Breaker points shall not have burned pitted or misaligned contact surfaces Point opening shall be adjusted in accordance with manufacturer s specifications Pick up coil magnetized field core and module in HEI distributors shall be free of dust and dirt Advance timing device shall work properly with no worn or broken parts evident Due to numerous and varied ignition systems operating consult manufacturer s spec
418. ndicate no wear or leaks Armature and circulating air passages shall be free of excess dust oil and grease Slip rings or commutator and brushes shall be in good condition and properly fitted and brush holders secure 1 7 2 38 Controller Contractor And Accelerator Re sistor Controller shall be free of all dust and grit and shall operate freely There shall be no broken springs and shunts connections shall be clean and tight Contacts shall be clean and not excessively worn or rough Contacts shall have at least 1 2 of their usable thickness intact Contactor shall be free of all dust and grit Contacts shall have no burned or scorched tips and will have at least 1 2 of their usable thickness Intact Cable and shunt connections shall be clean and tight Accelerating resistor shall be free of all dust and grit and connections shall be tight Resistor ribbon and porcelain insulator surface shall have no defects 1 7 2 89 Cooling System The cooling system shall be free of leaks and capable of maintaining proper temperature range during normal engine operation Pressurized cooling systems shall be capable of withstanding and holding recom mended test pressures Cooling systems shall be serviced with an approved antifreeze coolant solution at the 50 50 ratio or as specified by the vehicle manufacturers The radiator shall be clean and properly mounted Radiator caps shall be of prescribed pressure recommended by the manu factu
419. ne 1 1 2 in 9275871 03 Number 1 die cut pre spaced Blue None 1 2 in 9275871 05 Number 2 die cut pre spaced Blue None 1 2 in 9276871 07 Number 3 die cut pre spaced Blue None 1 2 in 9275871 11 Number 4 die cut pre spaced Blue None 1 2 in 9276871 13 Number 5 die cut pre spaced Blue None 1 2 in 9276871 16 Number 6 die cut pre spaced Blue None 1 2 in 9275871 17 Number 7 die cut pre spaced Blue None 1 2 in 9275871 21 Number 8 die cut pre spaced Blue None 1 2 in 9275871 23 Number 9 die cut pre spaced Blue None 1 2 in 9275871 25 Letter die cut pre spaced Blue None 1 2 in 9275871 27 Letter die cut pre spaced Blue None 1 1 2 in NOTE The following Manhole Cover Markings are available in 2 in x 6 in identical legends with symbols 3613407 AVGAS 115 145 F 22 Silver Purple 3613408 AVGAS 100 130F 18 Silver Purple 3613409 JP 4 F 40 Silver Red 3613410 JP 5 F 44 Silver Red 3613070 AVOIL D 1100 0 128 Black Silver 3613071 AVOIL D 1055 0 123 Black Silver 3613037 AVOIL 1100 0 117 Black Silver 3613038 AVOIL 1065 0 113 Black Silver 3613039 AVOIL 10100 132 Black Silver 3613040 AVOIL 1005 0 132 Black Silver 93104808 JP 8 F 34 Black Red 2 90 3 The following decals are requisition for compliance with this technical order Requisition decals from DAPS Sacramento 5015 Amold Ave Bldg 29 Mc
420. ne vehicle acceptability Fail ure to meet these standards shall be cause for rejecting a vehicle or component Inspections will be accomplished at completion of repairs and prior to release of vehicle from the maintenance activity for subsequent shipment Although the majority of vehicles will meet this standard throughout their life local conditions may require deviations from some of these requirements Adherence to these requirements is man datory only when a vehicle is placed into or received from a transit status Other uses of this technical order are left to the discretion of the 1 3 DEFINITIONS The term vehicle will normally be considered to include all self propelled equipment trailers semitrailers and some towed equipment The term acceptable means the vehicle fully meets the requirements of this chapter as revealed during the Limited Technical Inspection 1 4 GENERAL INSPECTION POLICIES vehicles destined for transfer within the Air Force will be inspected prior to shipment to ensure that they meet or surpass the minimum serviceability standards established in this chapter The vehicle condition will be established only after all systems and components have been service tested Qualified vehicle maintenance personnel when performing these inspections must stress sufficiency and adequacy and not perfection For further determination of worn parts refer to the general inspection guide of this technical
421. new used or retreaded shall be inspected for bead damage cracks cord damage ply or tread separation sectional repairs and quality or workman ship 4 23 3 3 New and retreaded tires found defective will be returned to the source of supply for adjustment replacement 4 23 3 4 Inspect the inside and outside of retreaded tires for defects or substandard quality prior to mounting retreaded tire will not be mounted on a wheel if any of the aforementioned defects are prevalent 4 23 3 5 4 23 3 5 1 No tire except as indicated below will be submitted for retreading when a break cut or other defect would require repair or sectioning prior to retreading Inspection of carcass prior to retreading 4 23 3 5 2 Earth mover tires having more than three radial cracks must be rejected unless they can be cured with sectional repair 4 23 3 5 3 Circumferential cracks found in the inner band ply of the bead or in the shoulder area will render a tire unsuitable for retreading 4 23 3 5 4 tire which is so worn that the cords will be exposed during the buffing operation will not be retreaded 4 23 4 Base Storage Supply Inspection 4 23 41 shelf life assigned to NSN s by source manager will not be imposed at base user level 4 12 4 23 4 2 the extent possible older stock will be used first 4 23 4 3 Base supply receiving inspectors will tag tires serviceable unserviceable with final acceptance rejection b
422. ng ON 19peo T 031e 09 A 5 TO 36 1 191 sauruodo 58 58 58 u09 pug uonesuop uoo usng Snyd 3 uwap uou pue ong Jo e19jog 8v guru mA MOWY ue ong 8 uni pue 3135 uonenSguooos 19197 SS c g 1984 Suruedo 1 ode V 949 WA 8 e qur Suruodo ode pue 19197 c 7 8 AL 198 y 9 9 c 7 8 ALL 198 100151591 001501102 SI yur jou 9 exn8y pT cc e cIN9 OL AK quiesse JOTI oqnj avue o qrssoo oe ur0joq Snyd Suisn eug pue jong Jo 1 no Suruoud Is yur ong Sp 91 6L SOY 0j UMJI pue 99 21 5 8 6L WA esoq Ajddns 12900 1 em314 cI C cIN9 OL 01 IJOY 8 AP D p qns pue Jony
423. nimum essential re pairs Major repairs which exceed the one time repair limit will be processed in accordance with current procedures TO 36 1 191 5 24 REPAIR AUTHORITY FOR MAJOR REPAIRS When a decision on major repairs is determined in accor dance with Paragraph 5 26 the Logistics Readiness Squadron Commander or equivalent may be delegated as appropriate is the approval authority Approval authorities will ensure that the following considerations are addressed 5 24 1 Can the base mission be done if repair is not approved and vehicle is retired from service 5 24 2 the base mission be done by reassigning another vehicle from a lower priority unit pending receipt of a replacement 5 24 3 Is joint utilization of a vehicle by two or more units possible pending receipt of a replacement 5 24 4 Which is more economical repair of the vehicle or rental of another until replacement is received 5 24 5 If this repair is made how much use can be expected and will the additional vehicle utilization equal or exceed the value of the repair costs 5 24 6 Is the repair absolutely necessary Example An engine has low compression and uses a quart of oil in approximately 500 miles 800 kilometers but has no audible knocks exhaust doesn t contain unreasonable smoking and otherwise operates satisfactorily Replacement or repair of the engine is unnecessary Or another example valves are burned causing loss of power then
424. ning tag bear ing the information REMOVE SOFT WOOD BLOCKS IN SEGREGATOR PRIOR TO PLACING IN SERVICE will be securely at tached to the segregator SE No processing required except that for shipment segregator floats will be blocked specified as above SE Lubricate sheave bearings with grease automotive and artillery conforming to Specification MIL G 10924 Coat sheave cable track with Type P 1 preservative See Item 29 AV Coat exposed machined surfaces of splines with Type P 1 preservative a When nesting stacking or when individual ve hicle design results in excessive weight being placed on the springs of vehicles in storage a suitable block shall be placed between the axle and frame to eliminate this stress b Shipment Applicable loading rules or special instructions may require blocking of springs as above to dampen vertical vibration and shock in transit Check with Traffic Management nel when special guidance is required AV Coat exposed unpainted sprockets with Type P 1 preservative When there is evidence of rust or corrosion clean and coat with a thin film of primer conforming to Specification TT P 664 AV Fill hydraulic reservoir with the prescribed opera tion lubricant Do not mix various hydraulic fluids No processing required AM Coat with Neat s foot Oil Specification C N 200 or leather dressing mildew preventive Specifi cation O L 164 AV No processing req
425. nitials and 2 abbrevia tion of the institution to which the vehicle is assigned EXAMPLE ROTC USC USAF Reserve Officers Training Corps University of Southern California 2 44 DECALCOMANIAS 2 44 1 Decal KPH to MPH A decal for converting kilometers per hour to miles per hour will be used on military vehicles operating out of the United States when this conver sion is not shown on the speedometer Place the decal on the instrument panel in easy view of the operator SAMPLE KPH MPH KPH MPH 20 12 70 44 30 19 80 50 40 25 90 56 50 31 100 62 60 37 110 68 2 44 2 DECAL Tower signals or control of airdrome traffic A decal sample copy below shall be applied to the dash panel or header above the windshield in easy view of the operator in both GSA and GOV vehicles that travel on the flightline SAMPLE TOWER SIGNAL FOR CONTROL OF AIR DROME TRAFFIC STEADY GREEN CLEARED TO CROSS 2 13 TO 36 1 191 STEADY RED STOP FLASHING RED CLEAR THE ACTIVE RUNWAY FLASHING WHITE RETURN TO STARTING POINT RED AND GREEN GENERAL EXERCISE EX TREME CAUTION 2 44 3 DECAL NHTSA warning label for 15 passenger vans National Highway Traffic Safety Administration has issued increased roll over risk for 15 passen ger vans with 10 or more occupants have three times the rollover ratio than those with fewer than 10 occupants Sudden vehicle maneuvers could increase the propensity to roll over 2 44 4 Additional
426. noncombustible product that can be removed when dirty 2 18 5 Dirty rags and paper refuse shall be kept in separate metal containers with self closing lids and appropriate mark ings The contents shall be removed and disposed of at the end of each operating shift 2 18 6 electrical installations and equipment used in painting areas shall comply with the requirements of NFPA STANDARD NO 33 Spray Application Using Flammable Materials and National Electric Code Number 70 2 18 7 supplies of paint thinner etc authorized within the paint rooms shall be kept in OSHA and NFPA Code 30 approved grounded metal cabinets ventilated by vent holes to prevent accumulation of vapors Thinners solvents and other highly volatile flammable agents autho rized for use at the work site shall be kept in OSHA and Code 30 approved grounded metal safety cans 2 18 8 paint spraying equipment shall be kept thor oughly clean and shall be inspected frequently to insure that it is in serviceable condition 2 18 9 Frequent inspections shall be made of electrical equipment by qualified electricians to insure proper operation and to eliminate fire hazards due to short circuits defective electric switches or improper maintenance 2 18 10 paint spray room or paint spray booths shall be protected by an adequate amount of the proper type fire extinguishers and install water sprinklers 2 18 11 personnel engaged in acid
427. not require lubrication for a period up to 30 000 miles 48200 kilometers of opera tion Specialized lubricants may be used in lieu of specifica tion PRF 10924G Grease for servicing these components 3 8 5 Some Ford Automatic Transmissions use type F automatic transmission fluid NSN 9150 00 843 1636 con 3 9 TO 36 1 191 forming to Ford Specification M2C33 Internal damage could occur if the wrong fluid is used Fluids of different types should not be mixed NOTE Manufacturers fluid recommendations should be checked prior to adding or changing automatic transmission lubricant 3 8 8 Commercial products may be locally purchased for cleaning and servicing battery terminals boxes and cable ends 3 8 7 Technical Data and Product Specification 3 8 7 1 Adequate technical data reference material on lubrication oils and accessories suitable for the various types of vehicles equipment must be available and accessible to maintenance personnel as a guide for servicing components Lubrication data can be obtained from the following sources 3 8 7 1 1 For commercial design vehicles Order lubrica tion instructions from GSA Federal Supply Schedule NSN 7610 00 660 0271 and 7610 00 660 0272 or refer to Mitch ell ON Demand 3 8 7 1 2 Other commercial design equipment military design general and special purpose equipment Obtain appli cable technical orders TO through publication distribution channels Commercial manuals
428. ns 4 36 7 1 1 When the tire has been driven under inflated at 80 percent or less of its recommended pressure 4 36 7 1 2 When there is obvious or suspected damage to the tire or wheel components 4 36 7 2 Rubber lubricant shall be applied to bead and rim mating surfaces during assembly of the wheel and inflation of the tire 4 26 4 36 7 3 Tires shall be inflated only when contained by a restraining device except that when the wheel assembly is on a vehicle Tires that are under inflated but have more than 80 percent of the recommended pressure may be inflated while the wheel is on the vehicle if remote control inflation equipment is used and no employees are in the trajectory and except as provided in Paragraph 4 36 7 5 4 36 7 4 When a tire is being partially inflated without restraining device for the purpose of seating the lock ring or to round out the tube such inflation shall not exceed 3 psi 0 21 kg cm TO 36 1 191 A PLACING INSIDE BEAD IN WELL B LIFTING INSIDE BEAD OVER RIM C PLACING OUTSIDE BEAD IN WELL F09603 062 Figure 4 20 Manually Mounting Tire Drop Center Rim 4 27 TO 36 1 191 TRAJECTORY STAY OUT OF TRAJECTORY AREA AS INDICATED BY HIGHLIGHTED MARKINGS UNDER SOME CIRCUMSTANCES THE TRAJECTORY MAY BE DIFFERENT THAN EXPECTED F09603 063 Figure 4 21 Trajectory Warning 4 28 TO 36 1 191 Figure 4 22 Tire Inflator Cage with proper Inflation Equipment Shown
429. ns 7 26 2 1 Death injury or illness will result if not corrected 7 26 2 2 Damage or loss of a motor vehicle major assembly system or subsystem will result if not corrected 7 26 2 3 The deficiency is known or suspected to be the cause of an Air Force mishap prepare and forward in accordance with AFI 91 204 7 26 2 4 agreement between a system program man ager and a using MAJCOM has been made for tracking a deficiency 7 26 2 5 The combat readiness capabilities of the using organization are severely restricted 7 26 2 6 unsafe condition exists a nuclear certified vehicle 7 27 PROCESSING DR S The format illustrated in Figure 7 1 shall be used for processing materiel deficiency reports MDRs for vehicles 7 15 TO 36 1 191 equipment The instructions for completion are cited m the format illustration and are mandatory for submitting MDRs 7 27 1 General Reporting of UR s unsatisfactory con ditions for vehicles equipment is mandatory All reports will be submitted as outlined in Paragraph 7 11 7 27 2 Method Of Reporting 7 27 21 Reports will be prepared using the format con tained in Figure 7 1 7 27 2 2 Reports will be processed using DREAMS as shown in Figure 7 1 7 27 2 3 Vehicle Unsatisfactory Reports will be submitted for the following conditions 7 27 2 3 1 7 27 2 3 2 Premature materiel failure or equipment mal function occurs that does not meet the criteria for a MDR
430. ns Pages BasicPub s htm 24 and USCENTAFAFI 24 101 for detailed procedures for VpCI storage methods The two types of VpCI storage are 8 5 5 1 Active Storage Active storage provides a level of VpCI protection sufficient for vehicles that are periodically exercised or utilized during exercises and surges Actively stored vehicles are maintained in a ready to use configura tion PACAFHAN 24 3 Chapter 6 and USCENTAFI24 101 Chapter 6 details procedures for preparing vehicles for active storage 8 5 5 2 Inactive Storage Inactive storage provides a level of VpCI protection sufficient for periods of inactivity for up to three years Inactively stored vehicles are not main tained in any way during periods of inactivity with exceptions for accomplishment of urgent action time compliance tech nical orders etc PACAFHAN 24 3 Chapter 5 USCENTAFI24 101 Chapter 5 details procedures for pre paring vehicles for inactive storage 8 6 PROCESSING PROCEDURES 8 6 1 8 1 Materials required for processing are listed in Table 8 7 EXPLANATION OF COLUMNS Column explanations of Table 8 2 are as follows 8 7 1 Column I indicates the item number 8 7 2 Column lists the component part accessory or system to be processed These are in alphabetical order to facilitate reference 8 7 3 Column III indicates the level A or B of processing described NOTE No detailed requirements are specified for Level C which i
431. nspection shall exceed minimum serviceability standards established in TO 44B 1 102 1 6 6 Operational Test 1 6 6 1 Power Vehicle engine will be capable of effec tively delivering the motive power for which it was designed 1 6 6 2 Unusual Noises components of equipment will operate without unusual noises An unusual noise is a sound which by its nature indicates a malfunction of the component or a probability that the component will if continued in use cause further damage 1 6 6 3 Compression The compression pressure devel oped in a cylinder of internal combustion engines shall not differ by more than the variance specified by the manufac turer Vehicles exhibiting compression variances of more than 10 between cylinders shall be acceptable if vehicle is capable of attaining maximum allowable speed runs smoothly at low speed and shows no signs of excessive oil consumption NOTE When available chassis dynamometer check may be used in lieu of compression test When using the dynamometer the vehicle being checked will meet or exceed local performance standards es tablished through implementation of Chapter 3 1 6 7 Vacuum Tests internal combustion engines except diesel engines shall be capable of producing a steady intake manifold vacuum of 18 inches or more at idling speed and at approximately 75 percent maximum allowable engine speed when engine is at normal operating temperature Required inta
432. nspection and acceptance of overhauled vehicles remains with the Defense Contract Administration Services personnel NOTE User commands may dispatch or may be re quested to dispatch personnel to a depot main tenance facility to witness or to assist with inspection testing and acceptance of their ve hicle s However approval to dispatch personnel must be granted by WR ALC LE on an indi vidual basis prior to dispatch AVG PRODUCTION CYCLE OVERHAUL AF CONTRACT CONTRACTOR ALL Figure 9 1 90 20 DAYS OVERHAUL 09603 106 Maintenance Criteria and Production Cycles 9 1 TO 36 1 191 9 9 WARRANTY DISCREPANCY REPORTING The Depot Maintenance Facility is required to provide an overhauled vehicle capable of performing its intended pur pose and function With the exception of tires and problems attributed to operator abuse transportation damage or neg ligence failures occurring during the warranty period are considered to be the responsibility of the overhaul facility and are subject to the provisions of the DMISA or contract Direct contact by the vehicle and the overhaul contractor or designated representative is authorized to correct warranty deficiencies If problems are encountered contact WR ALC LE by message or telephone for assistance in resolving warranty problems The overhaul vehicle warranty period is in accordance with the specific contract 9 10 WR ALC LE WR ALC LE will evaluate a
433. ntained power unit trailers and semi trailers 2 1 4 For environmental and bio environmental reasons the automotive industry does not normally use paint contain ing lead For that same reason lead based paints must not be used when repainting Air Force vehicles Any deviation from this policy requires a waiver from WR ALC LE 2 1 5 Coating systems include all primers and topcoat components Coating systems selected for use on USAF vehicles shall meet all volatile organic compound VOC requirements and other environmental requirements for the area where the equipment is based 2 2 REQUIREMENT FOR PAINTING 2 2 1 1 1 8 Guide for painting Repainting of vehicu lar equipment is authorized when adequate protection must be afforded against corrosion and the cost of repainting is less costly than spot painting Repainting of surfaces which have been repaired following an accident is also authorized However equipment will not be repainted merely to change the color gloss characteristics or to improve the appearance except as indicated in 2 2 2 below Frequent washing and appropriate maintenance of painted surfaces by operators will maintain the desired vehicle appearance Normal deteriora tion of painted surfaces such as chips scratches and minor corrosion is to be expected and shall not be cause for complete repainting of a vehicle Equipment programmed for replacement and removal from the inventory will not be repainted
434. nted sys tems General purpose solvent based Clean ing of painted and unpainted surfaces Check for regulatory compliance be fore using Type I because it contains aromatic solvents Material Type II Type III Type IV Type V Coating Polyurethane Gloss Advanced Performance Coating Extended Life Top coat Coating Polyurethane Gloss Touchup Brush SEMPEN Coating Polyurethane MIL PRF 85285 Type I Semi Gloss Advanced Performance Coating Extended Life Top coat Preval Spray Power Pack Spray System Unit of Issue 1 GI Cn 5 Gl Dr 15 Gl Dr 55 Gl Cn 5 Gl Cn 5 GI Dr 15 Gl Dr 55 Gl Cn 5 GI Dr 15 Gl Dr 55 Gl Ea NSN 6850 01 239 0571 6850 01 235 0872 6850 01 248 9828 6850 01 236 0128 6850 01 232 9164 6850 01 235 0873 6850 01 248 9829 6850 01 248 9830 6850 01 234 0219 6850 01 248 9831 6850 01 235 7458 NSL 8010 01 501 5573 NSL NSL 8080 01 501 5574 8010 01 501 5575 8010 01 501 5576 8010 01 441 6017 8010 01 441 6018 8010 01 441 6019 8010 01 441 6003 8010 01 441 6004 8010 01 441 6005 8010 01 441 6020 8010 01 441 6026 8010 01 441 6029 NSL NSL NSL TO 36 1 191 Application General purpose non solvent based Cleaning of painted and unpainted surfaces Water based formula may be used on both high gloss and camou flage paint systems Gloss paint cleaner Abrasive spot cleaner for high gloss paint surfaces where the Type II cleane
435. nterior of motor shall have no charred or broken insulation or other damage Connections shall be clean tight and painted with proper grade of armature varnish Bearings shall show no evidence of excessive wear or end play Brushes shall move freely in the holders and shall be free of dirt and other foreign matter The brush pressure arms shall be free from bending in the bodies and shall have approximately the same pressure on each brush Brushes shall have at least 1 2 of their usable length intact Motors shall be capable of performing their specific operation without excessive noise arcing or overheating 1 7 2 53 Engine Air Liquid Cooled Engine shall be free of oil leaks securely mounted and all accessories shrouds and attachments shall be properly installed Engine s cylinder compression shall be within manufacturer s specifi cations or allowed standards listed in Paragraph 1 6 6 3 Compression Standards Governor shall maintain steady op eration within 25 RPM of maximum rating at full throttle operation 1 7 2 54 Exhaust System Exhaust pipes catalytic converters mufflers flame arresters and rain caps shall not be excessively rusted as to result in early failure and shall be free of obvious leaks Exhaust system s hangers and clamps shall not be broken and be securely mounted Muffler s condensation drain holes shall be in the proper position to prevent early failure Heat shields and shrouds used in TO 36 1 191
436. ntifying vehicles as property of the 2 10 USAF and serve to associate such property with the organi zation to which it is assigned MARKINGS WILL NOT BE PLACED ON VEHICLES EXCEPT AS AUTHORIZED BY THIS TECHNICAL ORDER 2 26 1 Special activity markings and radio call signs may be used on certain flight line vehicles which have not been otherwise specified in this TO when such markings are deemed mission essential by the installation commander Any such markings should be simple to apply and easy to remove without damaging the vehicle exterior surfaces and finish 2 26 2 activity identification markings for all other vehicles may be applied by use of a locally fabricated plate approximately 6 x 12 inches to be attached to the front license plate holder activity markings or insignias will be designed furnished and installed by the using organization and must be readily removable to facilitate rotation of vehicles between using activities Changing to new markings will be performed when replacement is required due to damage or deterioration 2 26 3 Marking contaminated vehicles in accordance with Counter Chemical Biological Warfare CONOPS Due to the hazards embedded in nuclear biological or chemically con taminated vehicles all vehicle operators and maintainers must conspicuously identify and mark contaminated assets in accordance with AFMAN 10 2602 NBCC Defense Opera tions and Standards 2 27 ADDITIONS OR DEVIATIONS
437. ntinued Nomenclature Stock Number Source Enamel Strata Blue color no 15045 Fed Spec MIL D 46141 Kerosene 55 gallon drum 18 Gauge type II Non slip fabric pressure sensitive adhesive back ing amp 3 4 in x 24 in 50 pieces per box black green red or silver Non slip fabric pressure sensitive adhesive back ing 5 amp gt in x 5 amp 1 2 in 50 pieces per box black green red or silver Light warning vehicular yellow pulsating 24 volt Light warning vehicular yellow pulsating 12 volt Enamel Alkyd Semi gloss color no 24052 Light warning vehicular amber rotating 14 volts MS5137 4 Light warning vehicular amber rotating 28 volts Lights warning vehicular red rotating 28 volts MS51317 1 Light warning vehicular blue rotating 15 volts MS51317 6 Light warning vehicular blue rotating 28 volts MS51317 5 Enamel gray color no 16081 Fed Spec MIL C 83286 Enamel yellow color no 13538 Fed Spec MIL C 83286 Enamel blue color no 15045 Fed Spec MIL C 83286 Non slip fabric pressure sensitive adhesive back ing 6 in x 24 in 50 pieces per box black green red or silver Non slip fabric pressure sensitive adhesive back ing 6 in x 60 ft roll black green red or silver Non slip fabric pressure sensitive adhesive back ing 24 in x 60 ft roll black green red or silver Paint Bituminous coal tar pitch base Spec MIL C 450a Paint reflective white 12 lb can Paint Strata blue
438. nued depot overhaul due to age or obsolescence of major components 9 10 1 4 4 The LTI indicates the vehicle has reached a state of deterioration so that further repairs would be imprac tical regardless of the owning command s asset position practically all major systems require rebuild major accident damage major components missing etc 9 10 1 4 5 The LTI indicates that the repairs required are clearly within the intermediate maintenance capability e g minor repair or repair or replacement of only one or two major components etc 9 10 1 4 6 The vehicle is assigned to the requesting command on a Code ASC 048 For Retention Only 9 10 1 4 7 The cost of overhaul plus the cost of one way transportation from assigned base to over haul site exceeds 75 percent of the replacement cost of a new vehicle This must be tempered by judgment In some cases it may be essential to accomplish the overhaul but in all cases the commands will be challenged as to the impact non overhaul would have on the command mission 9 10 1 4 8 serviceable replacement vehicle can be supplied from any source in lieu of overhaul 9 10 1 4 9 replacement is scheduled for delivery from new procurement within one year and the command alloca tion is sufficient to allow replacement in lieu of overhaul 911 VEHICLES AND COMPONENTS NOT ELIGIBLE FOR DEPOT MAINTENANCE Vehicles coded U and vehicle components coded X P or N in the repair colum
439. of excessive wear or deterioration Insu lated boom sections shall be free of all dirt oil grease or other foreign matter Dielectric voltage breakdown test must be current in accordance with TO 36C 1 4 1 7 2 23 Brake System Parking Hand Control handle or foot pedal shall have at least 1 3 of its full travel in reserve when fully applied and holding vehicle Control cables rods and linkage shall operate freely Anchor adjust ments on external band type parking or hand brakes shall be properly adjusted and safety wired Parking hand brake will be checked as follows 1 7 2 231 With parking hand brake fully applied place vehicles equipped with standard transmission in the highest forward gear For those equipped with automatic transmis sion place in drive 1 7 2 23 2 Accelerate engine gently 1 7 2 23 3 On those equipped with standard transmission gradually engage clutch If this tends to stall engine or hold vehicle in stopped position the brakes can be considered satisfactory 1 7 2 23 4 When equipped with an automatic transmis sion vehicle should not move appreciably or break free from restraint 1 7 2 24 Brake System Serivce 1 7 2 24 1 Service brakes will be capable of stopping vehicle effectively When applied service brakes will indicate no appreciable side pull unusual noises or excessive pedal travel and will not indicate a lack of pull back spring action Brake pedal shall have 50 percent of t
440. of inner surfaces a When cargo or other trailers are to be inverted for shipment filler plug and vent assembly shall be removed from hydraulic brake master cylin der and solid plug installed using two compres sion type copper gaskets to prevent loss of brake fluid Filler plug and vent assembly shall be coated with P 10 Type I Grade 30 preserva tive oil packaged in accordance with Method IC 1 of Specification MIL P 116 and secured to master cylinder A warning tag bearing the in formation MASTER CYLINDER FILLER PLUG AND VENT ASSEMBLY SECURED TO MASTER CYLINDER REINSTALL BEFORE PLACING VEHICLE IN SERVICE shall be securely attached to trailer to vehicle brake line connection Exposed ends of airplane type shock absorbers shall be covered with tape conforming to Specification MIL T 43115 for level B MIL T 22085 for level A When required for ship ment wheels of inverted trailer shall be re moved and secured to trailer bed When removed racks shall be stowed and secured in a manner that will not increase cubage b Insure that drain holes are provided where nec essary to prevent accumulation of water i e fenders Coat screw surfaces with Type P 9 preservative oil Remove outriggers and coat internal un painted surfaces of tubes and unpainted surfaces of outrigger beams with Type P 1 preservative No preservative required Unless otherwise specified keys may be stowed in dash compartment When no dash compartmen
441. of rim manual the employer shall assure that the employee is instructed concerning the contents of the charts and rim manual in a manner which the employee is able to understand 4 36 3 4 employer shall assure that each employee demonstrates and maintains an ability to service multi piece rims safely including performance of the following tasks 4 36 3 4 1 4 36 3 4 2 4 36 3 4 3 Mounting of tires including inflation within a restraining device Demounting of tires including deflation Inspection of wheel components 4 36 3 4 4 Use of the restraining device 4 36 3 4 5 Handling of wheels 4 36 3 4 6 Inflation of tires when a wheel is mounted on the vehicles 4 36 3 4 7 Installation and removal of wheels 4 36 3 5 The employer shall evaluate each employee s ability to perform these tasks and to service multi piece rim wheels safely and shall provide additional training as neces sary to assure that each employee maintains proficiency 4 36 4 Tire Servicing Equipment 4 36 4 1 The employer shall furnish and shall assure that employees use a restraining device in servicing multi piece rim wheels NOTE When operating in a contingency situation where a restraining device is not available chains may be used to restrain the lock ring If a forklift is available the forks should be used in conjunction with chains to secure the lock ring Ensure that every precaution available has been taken to prevent injury
442. of tires a supply point normally will be established by Distribution Flight in or adjacent to the tire shop It is usually a 15 day operating stock At large installations the supply point may be manned by LRS distribution personnel A portion of the operating stock may be built up wheel tire assemblies as determined by experi ence need and availability of wheels Built up assemblies should be stored in tire shop under custody of shop supervisor with the supply point retaining accountability until installed 4 53 RESPONSIBILITIES The VFM will TO 36 1 191 4 53 1 Provide space within the vehicle management activity for the storage of tires 4 53 2 In coordination with LRS Distribution officer establish and adjust the operating and or supply point levels for tires 4 53 3 Insure that excesses are returned to LRS LGRD 4 53 4 Review with Distribution Flight the repair cycle time item required for repair and return for tires and adjust levels accordingly 4 53 5 Furnish status of tires under custody of the main tenance activity when required by the Distribution Flight 4 53 6 In coordination with the LRS Distribution officer develop instructions to cover exact issue and turn in proce dures and other operating procedures for effective manage ment of tires The Distribution Flight officer is responsible for the maintenance including delivery to control and record keeping associated with the supply point operation Man
443. official Air Force license plates 2 25 3 required by the Federal Acquisition Regulation FAR the only approved license plate for use on AF vehicles is produced at UNICOR Amerimac Ltd 33W480 Fabyan Parkway Suite 105 West Chicago IL 60185 Telephone Number 630 444 1111 Fax Number 630 444 1118 E mail info 9 amerimac net 2 9 TO 36 1 191 These plates will be mandatory for all AF owned vehicles as specified below Appropriate control measures are required to prevent theft or pilferage of uninstalled plates Report all instances of lost or stolen license plates whether installed or from stock to local security forces investigations sec tion Units will be required to identify themselves to UNICOR when placing orders by their unit designation base and location 1 90th TRANS LGTM FE Warren AFB WY 99999 These plates will not be installed on contract owned or Non Appropriated Fund NAF vehicles Com mercial vehicles leased longer than 60 days other than GSA leased vehicles are authorized the AF license plate with MAJCOM concurrence 2 25 3 1 Part number AF 1 a white plate with blue numbers letters for use on all blue vehicles law enforcement sedans van modular type ambulances painted white red fire fighting vehicles and commercial colored vehicles 2 25 3 2 Part number AF 2 an olive drab plate with black numbers letters for use on all olive drab camouflage yellow green and lime yellow color
444. ogramming of funds to permit retire ment of vehicles as they become eligible Replacement codes are key factors in determining and justifying vehicle replace ment requirements Vehicle Fleet Managers shall ensure that the replacement coding criteria published in the at https sevpgm robins af mil vehicle vmif section2 aspare applied correctly and that these codes identify the true status of the vehicle fleet 5 29 CODE ASSIGNMENT 5 29 1 Codes A through U as applicable may be assigned when both age and utilization miles kilometers hours ser vice life criteria have been assigned The complete range of replacement codes generally is applied to general purpose vehicles but may be appropriate for other categories as well 5 29 2 Codes B D H L P R S T and U will apply when service life 15 based on age alone a rule these the only codes which will be assigned to special purpose TO 36 1 191 construction and base maintenance and nonmotorized equip ment Check https sevpgm robins af mil vehicle vmif section2 asp for exceptions 5 29 3 Replacement codes normally are assigned by OLVIMS based on service life and other criteria loaded in the vehicle master record The vehicle management activity shall monitor the assignment of codes and make corrections when appropriate Refer to the VMIF at https sevpgm rob ins af mil vehicle vmif section2 asp for service life criteria and use current OLVIMS pro
445. oil shall be atomized sprayed into each cylinder through spark plug openings Without cranking two additional ounces of the P 10 Type I Grade 30 preserva tive oil shall be atomized sprayed into each cyl inder threaded ends of spark plugs shall be coated with the same type and grade preserva tive oil and plugs reinstalled A warning tag bearing the information ENGINE PRE SERVED DO NOT CRANK shall be securely attached in a conspicuous location within the driver s compartment 8 33 TO 36 1 191 COLUMN I Item 53 54 55 56 57 8 34 COLUMN II Component engines Dis mounted or Boxed Equipment Equipment Exhaust Sys tem Extinguishing Fire Fifth Wheels Table 8 2 Processing Procedures Continued Level Type of Vehicle COLUMN IH B A B AV A AV B AV A B AV A B GP SP COLUMN COLUMN V Processing Required Generally vehicles in storage for 90 days or less should not require extreme measures of protec tion It is recommended that the fuel be drained to approximately five 5 gallons or drained completely Before storage an additive of type P 9 preservative oil or MIL L 46152 heavy duty engine oil will be added to the fuel approxi mately two quarts per five gallons fuel Start engine and run at fast idle until engine starts to misfire or heavy smoke comes from the exhaust The ignition switch shall be immediately turned off Upon returning vehicle to service fill fuel tank to red
446. ols 4 2 7 Tire Mounting prevent injury to personnel or damage to equipment observe the following mounting pre cautions 4 2 8 Injury Prevention prevent injury to personnel or damage to equipment always lubricate beads and never exceed 40 lbs of air pressure until the bead is seated See Paragraph 4 26 2 4 2 9 Air Pressure Tire Do not dislodge tire beads lock rings or split flange rings until absolutely certain that no air pressure remains in the tire 4 3 GENERAL Motor vehicles depend on pneumatic semi pneumatic or solid rubber tires for mobility Tire technology is expanding rapidly and has reached a point where much more than a cursory glance and candid opinions are necessary to devise a satisfactory tire management program within the Air Force The constantly changing tire manufacturing processes and their products dictate an up to date reference source for tire management 4 4 PURPOSE This chapter provides information and direction for the selection inspection service and control of motor vehicles tires This chapter reflects policies and guidelines consistent with Presidential Executive Orders and Environmental Pro tection Agency policies of national interest 4 5 SCOPE This chapter is divided into sections pertinent to major phases of tire management This chapter applies to all Air Force activities involved in tire maintenance for Air Force motor vehicles 4 6 OTHER DOCUMENTS
447. ols paying particular attention to seam welds and corners Removal of heavy deposits creates airborne par ticles which may be hazardous to eyes Eye protection is required 6 11 3 2 For an extremely dirty underbody it may be advisable to PRESSURE clean the area first before steam method Warm water and mild detergent solution should suffice The coating materials listed have excellent adhesions to moist or wet surfaces and will displace water permitting immediate application of the coating compounds soon after surfaces have been washed Drilling creates airborne particles which may be hazardous to eyes Eye protection is required 6 11 3 3 Examine vehicle for inspection type openings before drilling any special holes Holes drilled for the purpose of applying material should not exceed 1 2 inch diameter Such holes are to be blocked or capped with plastic or rubber seal type caps after completion of rustproofing in the area There are a number of manufacturers marketing plastic plugs for closing holes Use care to avoid getting rustproofing materials on upholstery soft trim and seat belt retractor mechanism which are located behind trim panels or inside door posts 612 RUSTPROOFING APPLICATION With airless spray equipment the compound is discharged from the nozzle at extremely high pressure and could easily penetrate the skin A protective shield is required between person spraying and object being sprayed To avoid seri
448. ometers on vehicles repaired at this level of maintenance 5 20 ACCIDENT REPAIR ESTIMATES 5 20 1 When preparing accident repair estimates use standard material costs i e prices obtained from the flat rate and parts manuals or from local vendor price lists If the material item has exchange value use the exchange price Include in the estimate all direct and indirect costs associated with accident repairs 5 20 2 When pecuniary liability has been established as a result of an accident vehicles will be depreciated in accor dance with AFMAN 23 220 5 21 REPAIR ESTIMATES FOR CONTRACTOR MAINTAINED VEHICLES The repair estimate will be the total cost of contract services and expenditures which can be identified to the repair job For the purposes of contract repairs all labor and material charges are to be considered direct costs Labor costs will be computed using the contractor s line item labor rate listed in 5 3 TO 36 1 191 the repair contract Vehicles are beyond economical repair when the total contract costs exceed the OLVIMS computed repair allowance 5 22 AUTHORIZATION FOR REPAIR Each time a vehicle comes to the shop for repair the vehicle management activity will estimate how much the repairs will cost and then decide whether or not the vehicle should be fixed Vehicle Management and Analysis will 5 22 1 Estimate the repair cost including direct labor direct material indirect expenses and other
449. omized sprayed into each cylinder through spark plug opening 4 Without cranking one additional ounce of P 10 Type I Grade 30 preservative oil shall be atomized sprayed into cylinders threaded ends of spark plugs shall be coated with the same grade preservative oil and plugs reinstalled 5 A warning tag bearing the information EN GINE PRESERVED DO NOT CRANK DO NOT OPERATE ENGINE AND PUMP WITH OUT FLUID IN PUMPING SYSTEM shall be securely attached in a conspicuous location on pumping system 6 Sediment bowl and fuel line of engine fuel tank shall be completely drained of fuel 7 Fuel tank shall be preserved in accordance with the applicable requirements of Item 60 b Fuel pumping system shall be preserved in ac cordance with a above except that engine crankcase shall contain lubricating oil conform ing to requirements of applicable drawing specification or lubrication order filled to oper ating level When crankcase contains P 10 pre servative oil Type I Grade 10 or 30 as appli cable operating level shall be attained by addition of the same grade oil or lubricating oil conforming to Specification MIL L 2104 92 93 94 95 COLUMN I Item TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN II IV V Component Level Type of Vehicle Processing Required Pumping Sys B SE Interior surfaces of centrifugal reciprocating wa tems ter and rotary pumps incl
450. ompressor crankcase shall contain lubricating oil conforming to requirements of applicable drawing specification or lubrication order filled to operating level When crankcase contains Type P 10 preservative oil operating level shall be attained by addition the same type oil or lubricating oil conforming to Specification MIL L 2104 Containers A AV Drain clean thoroughly and flush with Type I Spare Fuel Grade 30 P 10 preservative oil Install cap and tighten securely Control Cable B AV No preservation required A AV Wipe choke and throttle control cables with cloth saturated with Type P 9 preservative oil Cooling Sys AV Cooling systems shall be protected in accordance tems with paragraph a below unless otherwise di rected by the responsible officer or as necessary to comply with requirements of shipping direc tives 8 25 TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN COLUMN I II Item Component Level Type of Vehicle Processing Required Ethylene glycol is toxic to skin eyes and respiratory tract Avoid skin and eye contact Good general ventilation is nor mally adequate a Water and antifreeze procedure Cooling sys tems shall contain a clean solution consisting of equal parts by volume of antifreeze ethylene glycol conforming to CID A A 52624 and wa ter filled to capacity Engine shall be operated to assure coverage of all interior parts and sur
451. on Arpt AK X Kingsley Fld Klamoth Falls IAP X OR ANG Kirtland AFB NM Albuquerque X NM Kulis ANG AK X Kunsan AB S Korea X Kwangju AB KO X Lackland AFB TX X Lajes Fld Azores Portugal X Lambert Field St Louis IAP MO X ANG Langley AFB Hampton VA X Larnaka International Apt Cyprus X Laughlin AFB Del Rio TX X Lincoln Mun Apt NE ANG Point Arena AFS CA Pope AFB Fayetteville NC Port Austin AFS MI NO RECORDS Portland IAP OR ANG X Prince Sultan AB Kharj SA X Quonset St Apt Providence RI X ANG RAF Akrotiri Cyprus RAF Croughton UK RAF Fairford RAF Lakenheath UK RAF Mildenhall UK RAF Molesworth UK Ramstein AB GE X Randolph AFB San Antonio TX X AETC Reese AFB Lubbock TX AETC X Reno Tahoe IAP NV ANG X Rhein Main AB GE X Richards Gebauer AFRB MO X AFRC Rickenbacker IAP Columbus OH X ANG Riyadh SA X Robins AFB Warner Robins GA X Rosecrans Mem Apt St Joseph X MO ANG Salt Lake City IAP UT ANG X San Vito AS IT X x 6 48 Table 6 2 Corrosion Severity Zones and Minimum Wash Interval Continued Location Savannah IAP Travis Fld Savannah GA ANG Savannah Municipal Apt GA Schenectady Co Apt NY ANG Scott AFB Belleville IL Selfridge ANGB Mount Clemens MI ANG Seymour Johnson AFB Goldsboro NC Shaw AFB Sumter SC Sheppard AFB Wichita Falls TX AETC Sioux Gateway
452. on of the vehicle e g a lighting system mirrors windshield wipers carbure tor fuel pump filter elements muffler fan belts alternator distributor generator voltage regulator starter water pump components of brake system and cooling system or radiator may be done as minimum essential repairs The cost of minimum essential repair shall not exceed the one time repair allowance 5 23 1 2 Appearance repairs may be approved as mini mum essential repairs when 5 23 1 2 1 The repair is within the one time repair allow ance 5 23 1 2 2 The vehicle will be retained in service long enough to justify the repair and 5 23 1 2 3 approving official considers the vehicle s appearance prejudicial to the USAF image Appearance or cosmetic repairs not affecting the safety or seviceability of the vehicle that exceed the one time repair allowance must be approved by the Chief Vehicle management Flight or equivalent 5 23 2 Major repairs which involve extensive rework of major components or assembles may not be authorized as minimum essential repairs Refer to Chief Vehicle Manage ment Flight or equivalent NOTE Preparation of AFTO Form 91 is not required when a major repair is needed and the repair cost does not exceed the one time repair limit for the vehicle The Chief Vehicle Management Flight or equivalent is the approval authority Approval for these repairs lies with the base level VFM VMS along with other mi
453. on the vehicles return A placard or protected paper with the registration number printed in large numbers will be posted secured inside the vehicle window windshield When shipping or transferring a vehicle to a sister service or through the Military Assistance Program MAP the plates will be removed from the vehicle and reused or destroyed A placard or protected paper with the registration number printed in large numbers will be posted secured inside the vehicle window windshield 2 25 2 Major Commands have the option for the use of license plates on vehicles with D registration numbers graders front end loaders etc and registration num bers K loaders forklifts etc Commands not choosing to use license plates must mark these vehicles using die cut letters numbers or by stenciling using specification and place ment requirements contained in this technical order Stan dardized license plates will be used on all other classes of Air Force vehicles 2 25 2 1 The new license plates will only be used on Air Force vehicles and equipment maintained and tracked by vehicle management and government furnished equipment owned by the Air Force and managed under property clause of the FAR by a contractor Non Appropriated vehicles will be marked according to their own functional area s guidance and will be visually distinct to preclude confusion with AF Appropriated vehicles LSVs not maintained by Vehicle Management will not use
454. onal Markings TACTICAL MARKINGS CONCEALED MARKINGS DECALCOMANIA SPECIAL MARKINGS SIZE OF MARKINGS LOCATION OF VEHICLE IDENTI FICATION MARKINGS NATIONAL SYMBOL AIR NATIONAL GUARD ANG VEHICLES RESERVE OFFICERS TRAINING CORPS VEHICLES DECALCOMANIAS Page 2 2 2 2 2 3 2 3 2 3 2 5 2 6 2 6 2 6 2 7 2 7 2 7 2 9 2 10 2 10 2 10 2 11 2 11 2 11 PY b2 b2 b2 TO 36 1 191 Chapter 2 44 1 2 44 4 2 45 2 46 2 47 2 48 2 49 2 50 2 51 2 52 2 53 2 54 2 55 2 56 2 57 2 58 2 59 2 60 2 61 2 61 5 2 61 6 2 62 2 63 2 63 1 2 63 2 2 64 2 65 2 66 2 67 2 68 2 69 2 70 2 71 2 72 TABLE OF CONTENTS CONTINUED Decal KPH to MPH Additional Decals SPECIAL MARKINGS VEHICLES USED IN TRANS PORTING SICK AND IN IURED iewewe RES AUTOMOBILE AMBULANCE METROPOLITAN AMBULANCE VAN MODULAR TYPE COMMERCIAL 4 x 2 AND 4 x 4 PAINTED WHITE AMBULANCE VAN MODULAR 4 x 2 AND 4 x 4 PAINTED SEMI GLOSS GREEN BUS 44 PASSENGER CONVERT IBLE MULTILITTER AUTOMOBILE STATION WAGON MOBILE MEDICAL VANS RECRUITING VEHICLES COMMUNICATIONS AND GROUND CONTROL AP PROACH VEHICLES TRACTORS AND FORKLIFTS TI
455. ondi tioning Check hoses and radiator for leaks proper fluid level and general condition Take specific gravity reading Wash and clean off radiator fins coils as applicable Test coolant and reserve alkalinity using testing kit NSN 6630 01 011 5039 or comparable equipment NOTE Vehicles will have a minimum 50 percent anti freeze mixture at all times or arctic antifreeze 25 of protection 3 6 4 Check prime and auxiliary engines for mounted components general condition and leaks 3 6 5 drive belts for proper tension Replace if exces sive wear fraying or damage is evident 3 6 6 Fuel System 3 6 6 1 Check for proper operation or leaks 3 6 6 2 Ensure fuel tank sump is drained on vehicles so equipped 3 6 6 3 Check and drain filter bowls as required AII fuel filters shall be changed per manufacturers suggested intervals or every 2 years 24 000 miles whichever is earlier 3 6 6 4 Inspect service replace air filter as required 3 6 6 5 Inspect exhaust system to include catalytic con verters tail pipes and spark arrestors for damage and leaks Repair or replace all unserviceable items NOTE Vehicles requiring spark arrestors or purifiers are specified in TO 38 1 23 3 6 6 6 Inspect service replace passenger compartment air filter as required on vehicles so equipped 3 6 7 Inspect and service spark arrestors purifiers and mufflers as follows 3 6 7 1 Check spark arresting muffler every 12 m
456. only valve and seat recondition ing should be done 5 5 TO 36 1 191 STEP ONE TIME REPAIR ALLOWANCE WORKSHEET SAMPLE LIFE EXP 6 YRS AND 100 00 MILES REPL PRICE 60 000 CURRENT AGE 48 MONTHS YOUR ANSWER CURRENT MILEAGE 40000 48 1 DIVIDE AGE IN MONTHS BY LIFE IN MONTHS 72 0 6667 DIVIDE MILES OR HOURS OR KILOMETERS OPERATED BY LIFE 40000 MILES 1B EXPECTANCY IN MILES HOURS OR KILOMETERS DATA MUST 100000 MILES 0 4000 BE COMPATIBLE DON T DIVIDE HOURS BY MILES E G 1C ENTER THE LARGER OF STEP 1A OR 1B 0 667 2 MULTIPLY 1C BY 0 9 0 6667 X 0 9 0 6000 3 SUBTRACT STEP 2 FROM 1 0 1 0 6000 0 4000 4 IF ANSWER IN STEP 3 IS LESS THAN 0 15 CHANGE IT TO 0 15 AND ENTER ANSWER IN STEP 4 OTHERWISE JUST COPY STEP 3 ANSWER IN STEP 4 MULTIPLY STEP 4 BY THE I amp S MASTER NSN PRICE THIS GIVES YOU THE ONE TIME REPAIR ALLOWANCE 0 400 0 4000 X 60 000 24 000 Figure 5 1 5 24 7 low utilization vehicle which is nearing its life expectancy in age may enter the shop for repair the cost of which is within but on the borderline of that authorized In this instance the VFM shall make a complete evaluation of the overall condition of the vehicle If major repair will be required before the vehicle reaches its life expectancy and the repair cannot be depreciated totally consider retiring the vehicle in lieu of repair 5 25 SUBMISSION OF REPAIR REQUESTS FOR MA JOR REPAIR APP
457. ons With Reimbursement 7 11 8 12 STORAGE STATUS OF PRESER VATION AND PROCESSING 7 11 INSPECTIONS FOR VEHICLES PRESERVED FOR LEVEL A 7 21 2 Independent Non Dealer Garage Warranty Corrections 7 21 3 Conditional Warranty Corrections 7 21 4 Air Force Repair of Warranty Cov ee 7 12 8 123 Complete Storage Inspection 8 12 4 Storage Site 8 12 1 Visual Inspection 8 12 2 Functional Inspection 7 21 5 Air Force Emergency Repair of War 8 54 8 54 8 54 8 55 8 55 ranty Covered Vehicles 7 12 8 12 5 Outside Storage 8 55 7 22 WARRANTY PROCEDURES OUT 8 12 6 Inside cp esq PEEL 8 55 SIDE THE LIMITS OF THE 50 8 12 7 Spacing And Arrangement 8 55 UNITED STATES AND THE 8 12 8 Nesting Or Stacking For Storage 8 55 DISTRICT OF COLUMBIA 7 12 8 12 9 Blocking And Fire Precautions 8 55 7 22 2 Return Of Defective Parts 7 14 8 12 10 Security And Fire Precautions 8 55 7 23 WARRANTY PROBLEMS 7 14 8 12 11 Insect And Rodent Control 8 55 7 24 PARTS EXHIBITS 7 15 8 13 LOADING 65 4544 8 55 7 25 WARRANTY REPORTING 7 15 8 13 1 Rail Shipment 8 55 7 25 2 Warranty Report Processing 7 15 8 43 2 Highway Shipment 8 55 7 26 GENERAL 7 15 8 14 GENERAL DEPROCESSING 8 56 7 27 PROCESSING DR S 7
458. onths in accordance with TO 38 1 23 3 6 7 2 Vehicle Fleet Managers shall initiate more frequent maintenance as necessary where inspections reveal excessive carbon buildup 3 6 8 Check front suspension and rear springs shackles and shock absorbers struts for leaks ball joints king pins for TO 36 1 191 excessive wear upper lower control arms for excessive wear and damage steering for loose connections free play and excessive wear 3 6 9 Brakes Check air and brake hoses valves and air tanks for leaks and tight connections Adjust slack adjusters as required Drain moisture from air tanks Check air system for leaks 3 6 10 Wheels and Tires Check for visible damage abnormal wear and pressure specified by Chapter 4 3 3 TO 36 1 191 SIJU OT 00 6T Seprut QOO CT sinog QOZI 20 Tenuuy ydess OTA 00 6T Seprut QOO CT sinoy QOZI 20 Tenuuy SIJU OT 00 6T Seprut QOO CT sinog QOZI 20 enuuy Q0 6T 0000 10 enuuy 6 6 NOLLOHdSNI TVONNV c IO sINOY or 293 Iwo A 008p serut 0005 Jr enuue wood ourguo xne sopn our sinoy op 10 5 0096 S9 0009 onp sypuow c IO sINOY or S193 Iwo 008p serut 0005 Jr enuue wood
459. oor sedans and trucks will be marked in a similar fashion centered on the front portion of the rear quarter panel 2 88 MARKING 41 PASSENGER INTERCITY BUSES USED FOR SUPPORT OF BANDS 2 85 1 The band s number followed by AIR FORCE BAND may be centered on the blue background below the windows on each side of the bus when approved by the Major Command EXAMPLE 701 AIR FORCE BAND 2 85 2 The marking shall be applied in 12 inch high letters and numbers using white paint to match the color of the bus top 2 85 3 All other markings shall be standardized in accor dance with this Technical Order NOTE When authorized by the MAJCOM CONUS only buses may display the slogan Air Force A Great Way of Life The slogan will be on a pressure sensitive decal applied to both sides of the bus directly below the windows between the fender well and front door driver s window on left side 2 85 4 Buses previously marked with band names shall not be remarked until routine repainting is required 2 80 WRM MARKINGS Vehicles will be marked with a triangle to indicate their status as WRM assets The WRM triangle will be a black solid colored equilateral triangle standing upright The triangle will TO 36 1 191 be applied to the front and rear bumpers of a vehicle or in a conspicuous location on the front and rear of vehicles not having bumpers The size of the triangle will not exceed six inches in size and should be
460. or corrosion evident and firmly anchored 1 7 2 17 Belts V And Serpentine belts shall be of proper groove width and length They shall have no visible cracks or signs of fraying shall not bottom in pulleys except ribbed serpentine belts and shall be properly adjusted for tension Friction surfaces of belt shall be capable of driving accessories without noticeable slippage Belt tensioner shall be serviceable in accordance with applicable technical orders See manufacturer s recommendations on serviceability of ribbed serpentine belts 1 7 2 18 Bits Augers Drills And Attachments items shall be in generally good working condition and secured Cutting edges shall be clean and free from nicks or burrs that would affect operation 1 7 2 19 Blowers Oilers And Burners 1 7 2 19 1 Blowers shall operate satisfactorily and shall be adequately lubricated and clean 1 7 2 19 2 Boilers shall be free from cracks leaks and securely mounted Cleaning shall be in accordance with applicable equipment manual 1 7 2 19 3 Burners shall operate satisfactorily Burner tips shall be in good condition with a correct flame pattern All accessories shall be securely mounted Cleaner elements shall be in satisfactory condition Fuel strainer air supply and stack dampers shall be in satisfactory condition to insure efficient combustion 1 7 2 20 Body And Cab Doors hood ventilators trunks and other operating items shall
461. or caustic cleaning operations shall wear rubber gloves aprons boots goggles and respiratory protection equipment approved by Base Medical Services and Ground Safety 2 18 12 acid or other oxidizing agents shall be permitted in the paint room or stored where they may come in contact with painting materials at any time 2 19 PREPARATION FOR PAINTING 2 19 1 Fuel oil servicing trucks and trailer tanks shall be drained of all fuel and oil prior to painting and the tanks will be completely filled with water or the vapors will be removed with steam in accordance with TO 36Y31 1 1 TO 36 1 191 NOTE The steam hose shall be of conductive rubber and shall be grounded to the truck trailer the truck trailer shall also be grounded before beginning steaming operations 2 19 2 instances where the chrome finish is deteriorated on body hardware exterior trim moldings or bumper bars and replating is considered economically feasible restoration to original finish may be made When facilities and or funds are unavailable for replating these parts may be painted with applicable color coat when they are rusted or damaged excessively 2 19 3 Preparation of surfaces for application of polyure thane paint MIL PRF 85285 type I in accordance with TO 1 1 8 Chapter 3 Chromic Acid SAE AMS2470 is highly toxic to the skin eyes and respiratory tract Avoid all contact Skin and eye protection and vapor control are require
462. or composites and are intended to provide adequate protection in order to comply with manufacturer s stated warranty provisions 6 4 6 Design Corrosion Control Rustproofing treatments performed prior to delivery of vehicles to AF using facilities Primarily applies to Tactical Vehicles receiving treatment in accordance with TO 36 1 131 procedures and general pur pose GP vehicles treated in accordance with manufacturer s standards 6 4 7 Initial Corrosion Control Inspections conducted by AF organizations upon initial receipt of vehicle Inspection to determine what treatment has been applied the treatment sufficiency and any additional treatments that are required 6 4 8 Follow On Corrosion Control Method efforts taken or employed by AF using activities to assure effective treatment of vehicles under local authority include those actions taken to maintain service life as defined in the VMIF and the necessary pursuit of warranty claims 6 4 9 Undercoating The application of coating com pounds to vehicle chassis and underbodies for the purpose of sound and or heat insulation Undercoating is not a substitute for effective rustproofing 6 1 TO 36 1 191 6 4 10 Vehicle Any wheeled or tracked commercial special purpose construction or materiel handling type conveyance for which vehicle management has responsibil ity 6 5 AIR FORCE POLICY 6 5 1 The objective of vehicle rustproofing under the Air Force Corrosion Prev
463. or identifying reporting and tracking deficiencies on Air Force motor vehicles equip ment the components major assemblies and or subassem blies of the same Additionally it establishes and defines the responsibilities for initiation submission certification and other management actions 7 5 DEFICIENCY REPORTING SCOPE The deficiency reporting procedures in this chapter apply to all USAF vehicle management activities and affiliated agen cies for which USAF has support responsibility 7 6 DEFINITIONS 7 6 1 Deficiency Report DR A generic term for all Deficiency Reports MDR VUR AWR IWR 7 6 2 Originating Point An individual or section within a Vehicle Management activity that identifies a deficiency and prepares the draft report Customer Service Center CSC personnel or section supervisors are normally the Originating Point 7 6 8 Screening Point individual within Vehicle Management and Analysis who performs all administrative actions tracking and necessary follow up and finalizes the report for the certifying official The screening point will use the deficiency reporting and mail system DREAMS to perform these functions 7 6 4 Contact Point The ALC office which receives reports assigns Materiel Improvement Projects MIPs and monitors the appropriate action WR ALC LZBS SA ALC LPRO OO ALC PMDAQ OC ALC LIMQ SM ALC TILE 7 6 5 AF Action Point The AF AFLC action point responsible
464. orage on suitable wood bases with solid floor using two or more skids A standard pallet may be used provided the load does not exceed 2500 pounds When the vehicle is stored under adequate cover the battery shall be stored in place in the vehicle battery carrier a Wet batteries 8 9 TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN COLUMN I II Item Component Level Type of Vehicle Processing Required 1 Lead acid type Lead acid type wet charged batteries shall not be placed in long term stor age They shall be removed and reported to the appropriate property class as excess requesting disposition instructions Batteries removed shall be maintained in a charged condition while awaiting disposition instructions NOTE Batteries may remain in vehicle for lev els B and C conditions Also when stored outside under level A conditions batteries may remain in vehicle for ex ercise purposes until no longer capable of recharging 2 Nickel iron alkaline Make certain that the electrolyte is at the recommended level and that filler caps are in a closed position Discharge batteries at normal rate to 0 5 volts per cell Short circuit each tray leaving wires connected during the storage period NOTE These batteries may be received dis charged dumped of electrolyte and short circuited Unless otherwise speci fied they need not be filled The elec trolyte for nickel iro
465. order and applicable manufacturer s specifications where close toler ance factors are present Activities scheduled to receive vehicles will requisition the applicable technical orders in accordance with TO 00 5 1 When shipping a one of a kind vehicle all TOs will accompany the vehicle 1 5 LIMITED TECHNICAL INSPECTION This inspection is used to determine the condition of a vehicle or piece of equipment It consists of complete functional testing of the item and all components using a Limited Technical Inspection Motor Vehicle AFTO Form 91 and applicable equipment handbooks The requirement for com plete functional testing does not extend to equipment or components on which it is obviously impractical to perform such tests A rock crushing plant is an example of such equipment fuel servicing semitrailer vehicle on the other hand would require complete functional testing 1 5 1 Inspection will be required to determine if a vehicle is acceptable repairable or should be processed for disposal 1 5 1 1 In general this inspection will reveal the accept able condition of a vehicle while accomplishing a check for completeness of records estimate of repair costs and condi tion classification If the vehicle has special tools delivered with the vehicle the inspection shall include an accounting of those tools 1 5 1 2 The use of AFTO Form 91 as an inspection form is restricted to qualified vehicle maintenance p
466. orming to Specification MIL T 43115 Wet batteries except nickel iron alkaline see item 3 MHE shall be removed from vehicles and reported to the appropriate property class as excess requesting disposition instructions Bat teries so removed shall be maintained in a charged condition while awaiting disposition instructions COLUMN I Item TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN II IV V Component Level Type of Vehicle Processing Required d Dry batteries shall be space packaged and packed in accordance with the overseas require ments of Specification PPP B 140C The vent holes in the filler caps of dry batteries shall be plugged or sealed Electrolyte is highly toxic to the skin eyes and respiratory tract Avoid all con tact Skin amp eye protection amp vapor control are required Assure this opera tion has been reviewed by local Bioen vironmental Engineer e Electrolyte shall be packaged and packed in accordance with the requirements of Specifica tion O S 801F Packaged batteries and electrolyte shall be stowed with other OVE Electrolyte shall be stowed in a manner permitting easy removal at ports when special stowing is required by mari time regulations Battery posts shall be covered with plastic caps or tape conforming to Specification SAE AMS T 22085 rh ge 8 7 TO 36 1 191 Table 8 2 Processing Procedures Continued Storage ship B
467. ose Vehicles Areas of Application Special Purpose Vehicles Full Tracked TfactOtS xim Diagram of Simplified Corrosion Cell pA RR RE Example of Raised Corrosion Product Aluminum Fuel Tank Exhibiting Uniform Etch Galvanic Corrosion Steel Hinge Bolted To An Aluminum Door Pitting Corrosion Intergranular Corrosion Cell Exfoliation Corrosion Concentration Crevice Corrosion Filiform Corrosion Diagram of Fretting Corrosion Corrosion Accelerated By Condensed Moisture oc see Rr Rs Open Cell Foam and Resulting CoITOSIOH sss n eom Corrosion Resulting from Long Term Exposure to Sand View of Microbial Induced Corrosion Corrosion on Weldments Deficiency Report Delayed Delivery Form Ford Motor Company Y Delayed Delivery Form General Motors Company Delayed Delivery Form Chrysler Corporation Military Shipment Label sample DD Form 2332 Materiel Deficiency Exhibit Tag Page 4 18 4 19 4 19 4 21 4 23 4 27 4 28 4 29 4 30 4 31 4 37 5 6 6 11 6 23 6 41 6 41 6 41 6 42 6 42 6 42 6 43 6 43 6 44 6 44 6 51 6 52 6 52 6 53 6 53 74 TO 36 1 191 LIST OF ILLUSTRATIONS CONTINUED Figure Title Page Figure Title 7 7 VIWG Action Items 7 19 9 1 Maintenance Criteria and Production Cycles
468. otal brake pedal travel in reserve when brakes are fully applied with vehicle station ary Anti lock brake systems shall operate in accordance with manufacturer s specifications 1 7 2 24 2 Brake pedal on air over hydraulic and vacuum assist brake systems shall have 50 percent of total brake pedal travel in reserve when brakes are fully applied with vehicle stationary 1 7 2 24 3 Power assist service brake pedal travel shall be in accordance with manufacturers specifications 1 7 2 24 4 Hydraulic brake lines and fittings shall be free of leaks Master and wheel cylinders and or calipers shall function properly without leaks Reconditioned cylinder bores shall not exceed 0 003 inch oversize Master cylinder fluid level shall be within 1 2 inch of top of cylinder reservoir Cylinder mounting bolts shall be secure 1 7 2 24 5 Air brake system with pressure above governor cut in point shall not bleed down more than 3 psi per minute with the service brakes in fully applied or fully release position 1 7 2 24 6 Air brake diaphragm pushrod travel shall be within limits established in applicable equipment handbook Diaphragm shall not leak through or around its outer edge should diaphragm leak complete set must be replaced 1 7 2 24 7 Hydrovac brake booster shall display no visible interior exterior leaks from booster when operationally checked in accordance with applicable equipment handbook 1 7 2 24 8 Hoses hose coupling and or gl
469. other owning organization with assistance from Vehicle Management as required Where personnel and or test equipment are not available test will be conducted by local contract Normally local power or tele phone companies can provide this service 3 10 5 2 3 Visual inspection of welded areas is the re sponsibility of vehicle management welded areas on the boom and boom attachments will be thoroughly cleaned Any cracks or damage visible to the naked eye will be cause for repair replacement action NOTE Low medium profile trucks used only to set poles install antennas and other telecommunica tions equipment on poles that have no live volt age must have the following warning stenciled on the operator s console and basket This equipment will not be used on joint use poles or within 10 feet of electrical power lines without being dielectrically tested and certified according to TO 36C 1 4 by qualified personnel 3 10 6 Certification Test Firefighting Aerial Ladders and Elevating Platforms shall be tested at least annually after major repairs or overhaul following the use of the aerial ladder when it may have been subjected to unusual operating conditions of stress or load or when there is reason to believe that usage has exceeded the manufacturer s recom mended operating procedure This test is the responsibility of Base Fire Department with assistance from Vehicle Mainte nance Refer to National Fire Protection
470. ound any damage to applied pre servative coating shall be remedied by applica tion of additional Type P 1 preservative to dam aged areas All exposed unpainted metal surfaces of cable drums sheaves snatch blocks boom block A frame crane or derrick boom controls and linkage shall be coated with Type P 1 preservative All moving mating parts shall be coated with grease conforming to Specifica tion MIL G 10924 Hydraulic system shall con tain operational hydraulic fluid filled to operat ing level When operating surfaces of hydraulic piston are exposed piston shall be coated with grease conforming to Specification MIL G 10924 and over wrapped with barrier material conforming to Type IL grade A Class 2 of Specification MIL B 121 secured with tape conforming to Specification MIL T 43115 for level B and MIL T 22085 for level A When hydraulic piston is retracted exposed surfaces of piston shall be coated with Type P 1 preserva tive Hydraulic controls shall be secured in neu tral position Wire rope chains shall be coated with preservative lubricant conforming to VV L 751 Specification See applicable provisions under Items 7 11 28 29 No processing required unless otherwise specified See applicable provisions under Items 11 28 Blades and Arms 29 8 8 2 Scope Inspection operations incident to storage and shipment include both maintenance inspections and inspection of the status of preservation and processing
471. ous injury keep fingers away from spray nozzle Gloves and face shield or goggles shall be worn while operating the spray equipment If accomplished at in house facilities proper venti lation equipment and trained personnel shall be utilized 6 121 36 1 131 TB 43 0213 provides guidance for the proper placement of rustproofing access holes and meth ods of rustproofing application Follow the procedures in TO 36 1 131 TB 43 0213 unless they conflict with those pro vided in this manual In the case of procedural conflict the requirements in this TO take precedence 6 12 2 Spraying is quick and effective and is the best means of coating hard to reach areas The majority of appli 6 9 TO 36 1 191 cations will require an airless type spray pump and an airless spray tip of 0 031 orifice diameter with a 100 mesh screen It may be necessary to use flexible tip extensions Use product manufacturer s recommendation for air pressure when apply ing Grade 1 material It is extremely important that the spray equipment be adjusted to spray the particular area Test the spray gun pattern to insure that inside or hidden body panels will have complete coverage without using excessive amounts of compound With airless spray equipment the compound is discharged from the nozzle at extremely high pressure and could easily penetrate the skin A protective shield is required between person spraying and the object being sprayed To avoid seri
472. ous injury keep fingers away from spray nozzle Gloves and face shield or goggles shall be worn while operating the spray equipment If accomplished at in house facilities proper venti lation equipment and trained personnel shall be utilized 6 12 3 Work must be accomplished in a well ventilated area such as a lubrication bay Masking of vehicle prior to application of these corrosion preventive materials is not required neither is removal of components However wheels may be removed to improve accessibility to wheel well area 6 12 4 Material should be applied in layers of equal thickness not to exceed 1 16 inch Coatings of greater thickness wastes material 6 12 5 When any excess rustproofing material appears on exterior surfaces due to overspray drips or runs in seams smudged surfaces of windows and upholstery it shall be removed A mixture consisting of equal parts of mineral spirits and water is recommended for removal of such residue Care should be exercised to prevent excessive solvent solutions from removing rustproofing compounds from treated areas 6 12 6 It is imperative that drain and vent holes do not become clogged After applying rustproofing materials all drain holes or passages must be checked to ascertain that excess material has not accumulated in the drain area restricting use of the drain hole 6 12 7 Processing of the vehicle must not leave it with smudged windows or inadvertently cause interference wi
473. p command standard reporting procedures and to provide guidance to subordinate organizations Supple ments however shall not conflict with the basic policy Send an information copy to HQ USAF ILGM HQ USAF ILSP and WR ALC LES 5 9 MAXIMUM ONE TIME REPAIR ALLOWANCE The one time repair allowance is the maximum amount of money which can be spent for repair of a vehicle at any one time This allowance is based on two separate factors miles kilometers hours accumulated and age The factor which allows the smaller dollar value determines the repair allowance 5 10 AGE Age starts from the date of acceptance embossed on the data plate attached to the vehicle If missing from the data plate the date of acceptance shown on the DD Form 250 will be used If historical records for an older model vehicle are lost and the acceptance date is not shown on the data plate and all other sources for this information have been exhausted use 1 Jan and the year indicated in the vehicle registration number as the acceptance date For new vehicles contact the item manager if the acceptance date cannot be determined locally NOTE On the light duty passenger carrying IPT DD250s are no longer required because many of the manufacturers no longer provide them The responses throughout the branch for the other IPTs were that DD250s are sporadically received as a result of the same experience that not all manufacturers will provide them The inform
474. pairs including time required to obtain neces sary parts and supplies 1 5 2 2 8 The capability and or feasibility of accomplish ing required repairs at intermediate maintenance level 1 5 2 2 4 most efficient means of accomplishing required repairs to ensure vehicle is being shipped in an acceptable condition 1 5 2 2 5 The ability of vehicle or equipment to satisfy proposed mission requirement 1 5 2 2 6 Requirement for IM Depot Level maintenance support in accordance with AFI 24 302 Except for excess general purpose vehicles 1 5 2 2 7 Whether any vehicle systems or components deviate from original manufacturer configuration exception approved TCTOs service bulletins or safety recalls pub lished by the manufacturer or WR ALC 1 5 3 Receiving Acceptance Inspections new and used vehicles and equipment will be inspected by the Air Force activity which receives them within 60 days of receipt Equipment processed or prepared for storage or shipment may be de processed on a sampling basis to determine condition 1 5 8 1 Records Inspection Upon receipt of a new or used vehicle or equipment item VM amp A and vehicle manage ment personnel will jointly perform an inspection of the records file to determine completeness of records and vehicle equipment condition as reflected by the records VM amp A will take custody of the active Vehicle Historical Record and the shipping LTI If applicable review work o
475. paulins canvas covers and other protective coverings 8 12 1 10 Any visual indication of defect or deterioration affecting unit serviceability shall be noted and reported to the responsible storage officer 8 12 2 Functional Inspection Every 180 days or more frequently as determined by the VFM and concurrent with alternate inspections conducted in accordance with the pre ceding paragraph each vehicle shall be exercised in place to effect distribution of lubricants and preservatives using vehi cle s own power system or an external power source as necessary Suggested procedures follow 8 12 2 1 Be sure clutch is disengaged 8 12 2 2 Place shifting lever in high gear 8 12 2 3 Engage transfer case if so equipped 8 12 2 4 Lock one rear wheel Rotate other wheel in forward direction at sufficient speed to insure that portion of gears above oil level are thoroughly lubricated For vehicles with front wheel drive limited slip and traction differentials rotate both drive wheels simultaneously 8 12 2 5 Vehicles equipped with steering clutches inspect for evidence of water and corrosion If evident operate vehicle to ensure free movement of clutches and reprocess as required 8 12 2 6 Perform any preservation required as a result of operation While vehicle power train assemblies are being exercised check for grinding or other unusual noise and or evidence of binding 8 12 3 Complete Storage Inspection Vehicles
476. pe tire offers greater cushioning and rolling resistance than a comparative TO 36 1 191 sized conventional solid rubber tire Required replacements will be selected from Federal Supply Catalog 2630 40IL 4 44 TYPE OF MOUNTINGS 4 441 Press On Press on type tire is bonded to a steel band and the complete unit is pressed on to the outside rim of the wheel When the tire requires replacement the band is pressed off and a new one pressed on 4 442 Bolt On Bolt on type tire is bonded to a flanged rim provided with holes for bolting to a drive flange 4 44 3 Integral Type Integral type tire is bonded di rectly to the metal wheel When the tire requires replacement a new tire may be cured on provided the wheel is not deformed cracked or chipped beyond repair 4 44 4 Solid Lug Base Type Solid lug base type tire is used for light and medium loads When loaded near rated capacity it provides cushioning nearly equal to pneumatic tires The tire is constructed of resilient rubber on base lugs which prevent creeping on the wheels The wheels are of two piece construction for mounting and demounting 4 44 5 Semi Pneumatic Lug Base Type Semi pneumatic lug base type tire is similar to the solid lug base except for a hollow center without tube or valve Its carrying capacity is lower but it has better cushioning characteristics than the solid lug base type 4 45 TREAD PATTERNS 4 45 1 Smooth Tread Smooth tread
477. peed without hesitation or clutch slippage Trans mission case pan and attached covers shall be securely mounted and be free of leaks Transmissions shall be serviced with the proper lubricants at prescribed levels Operational linkage shall be properly adjusted and operate without binding 1 7 2 122 2 Transfer Case Transfer case shall shift into the selected gear range smoothly and without unusual noise Sprague units and shift bearings shall not be exces sively worn and be properly adjusted Transfer case and attached covers shall be securely mounted and free of leaks Transfer cases shall be serviced with the proper lubricant at prescribed levels Shift linkage shall be properly adjusted and not be excessively worn 1 7 2 122 3 Power Takeoffs Power takeoff units shall be properly secured and free of leaks Controls shall be properly adjusted and not be excessively worn 1 7 2 123 Turret System Crash Fire Turret opera tion shall be smooth and accurate with positive reaction from turret controls Hydraulic cylinders control lines hoses and swivels shall be installed properly and free of leaks Turret shall be capable of operating under full operating pressures and flow rate during water and foam operation 1 7 2 124 Valves And Piston Rings Valves and lifters shall not have excessive lash or clearance Valve stems and guides shall not be worn to the point that excessive oil consumption or plug fouling is present Valve faces
478. perational cost Check federal state host nation and local laws before using regrooved tires Some state and countries restrict the use of regrooved tires 4 25 1 Technical Criteria a Vehicle management activities will ensure tire regroov ing is in compliance with the Code of Federal Regula tions CFR Title 49 Transporation Chapter V National Highway Traffic Safety Administration NHTSA De partment of Transportation Part 569 Regrooved Tires b Develops an Operating Instruction that addresses tire regrooving policy tracking procedures training and qualifications and equipment use inspection and care Failure of regrooved tires will be reported to the VFM VMS immediately c Physically inspect tires to ensure that they meet the condition criteria for regrooving d The tires may only be regrooved once and will be evaluated for retreading once the regrooved tire is worn NOTE It is not necessary to insert inner tubes in properly regrooved tubeless tires 4 25 2 Restriction on the Use of Regrooved Tires a Regrooved tires will not be used on ambulances law enforcement sedans or fire fighting vehicles 4 13 TO 36 1 191 b Regrooved tires will not be used on front wheels of buses c Regrooved tires or any combination thereof will not be used on any vehicle when their use would seriously impair mission support or create a safety hazard 4 26 SERVICING RADIAL TIRES Proper tire maintenance a
479. plant branch dealer or with the contractor s approval T To correct the supplies itself or II to have them corrected by a commercial garage facility the cost of the labor involved in the replacement of the failed or malfunctioned parts or assemblies shall be borne by the contractor 7 3 TO 36 1 191 Dreams VM input Form Version 2 02 File Number 1 Report Control Number i80 Select GO21 and applicable ALC Include DODAAC and Unit Designator See Dreams Manual to automate this feature Status 5 Deficiency Report Type MDR VUR AWR IWR and Brief Description of Vehicle Type and NEW Failed Component 120 Example P23 Wheel Hub Assembly Originator Base Installation 150 Originator Name Phone Number Date Submitted i52 Originator Street Address i49 Originator City State Zip 151 Originator Organization Office Symbol i55 Drafter s E mail Address amp Phone Number i57 Report Category i60 2 Operational Impact to User s Mission i61 Mishap HAP Control Number if assigned by local Safety Office i90 Hazard Severity Code See TO 00 35D Enter N A i95 54 192 NSN of Deficient Component 1100 Nomenclature of Deficient Component i110 Date Deficiency Discovered i120 Enter N A i135 Deficient Component s Manufacturer i140 Name of Depot or Contractor if Overhauled i145 Manufacturer s CAGE Code i150 De
480. plication Sheet 6 TO 36 1 191 AREA APPLICATION STATION WAGON TAIL GATES INSIDE OF OUTER AND BOTTOM PANEL AT LEAST UP TO AND INCLUDING 16 INCHES FROM BOTTOM IF HOLES ARE NOT AVAILABLE DRILL A 1 2 INCH HOLE IN EACH SIDE OF TAIL GATE SIX TO EIGHT INCHES FROM BOTTOM REMOVE INSIDE PANEL A OR DRILL 1 2 IN SIDE HOLES AND SPRAY REMOVE WEATHERSTRIP AND SPRAY THIS AREA SPRAY HINGES USE GRADE 1 STATION WAGONS HINGES DRILL 1 2 IN HOLE TYP EACH SIDE FLOOR OF CAB KICK PAD AREA CORNER AREA BEHIND SEATS CAVITY AREA THROUGH DOOR HINGE HOLES OR DRILL 1 2 INCH HOLE FROM UNDERNEATH INTERIOR OF ROOF UNLESS COATING IS NOT DESIRABLE BECAUSE OF FELT OR PLASTIC LINING F09603 079 Figure 6 1 Commercial General Purpose Vehicles Areas of Application Sheet 7 6 17 TO 36 1 191 APPLICATION TRUCK DOORS MANY WILL HAVE A REMOVABLE METAL ACCESS PLATE IN THE INNER PANEL VEHICLE CORROSION PREVENTIVE CAN BE SPRAYED INSIDE THE DOOR AND NO HOLES NEED TO BE DRILLED BE SURE THE METAL ACCESS PLATE IS SEALED WHEN REINSTALLED TO PREVENT RAIN FROM LEAKING THROUGH THE DOOR COMPOUND SHALL BE SPRAYED INTO THE LOWER PORTION OF REAR DOORS IF HOLES ARE NOT AVAILABLE DRILL A 1 2 INCH HOLE IN EACH VERTICAL EDGE OF THE DOOR AND COAT THE LOWER PORTION BE 4 2 USE GRADE 1 n fre zip desc ue HOLES
481. ply rating load range than recommended by the manufacturer in the OEM Operators User s Manual In the event OEM or WR ALC Deviates from this guidance through service bulletins IMCs TCTOs etc WR ALC s new guidance takes prece dence Refer to Figure 4 1 for a load range ply rating conversion 4 10 TIRE CONSTRUCTION 4 10 1 Conventional Bias Ply Figure 4 2 The bias tire is the conventional tire which has been in use since the 1920s The cords in the plies or layers which make up the body of the bias tire crisscross at an angle called the bias angle usually about 30 40 degrees to the center line Cords may be arranged in two or more even number plies depending in general on the strength desired in the finished tire This design provides rigidity in both side wall and tread but bias tires squirm more and tend to run hotter than belted bias or radial 4 10 2 Bias Belted Figure 4 2 In a belted tire the cords in the body are also arranged in a crisscross pattern but in addition it has two or more layers of fabric or belt under the tread The cords in the belt also run at an angle about 25 degrees to the center line This construction provides a side wall stiffness similar to the bias tire with increased strength and stiffness in the tread Body cords are made of rayon nylon or polyester belt cords are made of fiberglass rayon or steel The belted bias tire squirms less than the bias tire runs cooler and gi
482. port IWR and Action War ranty Report shall be submitted according to the procedures outlined in the following paragraphs TO 36 1 191 7 25 1 Conditions for submitting warranty report 7 25 1 1 Information Only Warranty Satisfactory Reports IWR will be submitted for all vehicles to document satis factorily corrected repairs in excess of 1000 00 or when three or more vehicles equipment have the same discrepancy satisfactorily corrected The IWR will be forwarded to the MAJCOM with an information copy to WR ALC LE 7 25 1 2 Action Warranty Reports AWR will be submit ted for all vehicles equipment when the contractor refuses to make corrections under warranty The action warranty report will be addressed to WR ALC LE for action with information copy to MAJCOM 7 25 2 Warranty Report Processing Warranty Re ports will be submitted using the format illustrated in Figure 7 1 The illustrated format is mandatory and information required for each entry is contained in the format 7 25 3 warranty deficiencies whether repaired or not that meet criteria for reporting as a materiel deficiency will be reported in accordance with this chapter 7 26 GENERAL Reporting of materiel deficiencies is mandatory reports will be submitted as outlined in Paragraph 7 11 7 26 1 will be processed using DREAMS as shown in Figure 7 1 7 26 2 Materiel deficiency reports will be submitted for the following conditio
483. posite edge or through both laminations shall be rejected Star bull s eye or com bination cracks successfully repaired in accordance with approved maintenance practices shall be considered service able 1 7 2 130 2 Plexi glass shall not be used for windshields Plexi glass installed on doors shall not have major scratches and or abrasions Plexi glass which exhibits minor discolor ing or abrasions that affect operator s vision which cannot be removed by polishing shall be replaced 1 7 2 131 Wiper Motor Blades And Washers All components shall be securely mounted and shall operate properly Wiper blade edges will be pliable and will maintain full contact with glass Wiper arms will have adequate tension to ensure effective wiper action Arm or blades will not strike frames or division bars when operated Hoses shall show no evidence of leaks or signs of deterioration Washer spray pattern and quantity shall be sufficient to cover wiped area of window 1 7 2 132 Wiring And Connections wiring shall be of proper gauge and be securely attached mounted to prevent damage connections shall be clean and secured Wiring insulation will be free of significant weather checks and shall not be frayed chaffed so as to expose internal conductor Wiring harnesses shall be secured in such a manner that they will not interfere with other components or be subject to potential damages 1 7 2 133 Certified vs Qualified Welder
484. posure to sunlight 2 20 4 1 1 1 1 Apply the aliphatic polyurea to clean dry sound surfaces free of any loose particles or foreign matter Scuff the surface with a minimum of 100 grit abrasive paper Repair any defects in the surface being painted prior to top coating with polyurea Apply the polyurea in a manner to have a minimum 0 25 inch dry film thickness 2 20 4 2 alternative to the polyurea is a sprayable polyurethane truck bed liner type coating Morton Paint Company PN 1440 2 or equivalent on high wear areas and storage compartment interiors Colors shall be black or consistent with the existing color utilized on the equipment 2 20 4 2 1 Polyurethane spray in bed liner materials are commercially available vinyl polymers This material will provide better protection than drop in bed liners but it is not as durable as the aliphatic polyurea spray in bed liners 2 20 4 2 2 The polyurethane spray in bed liner material will require coating maintenance touchup when it is damaged to prevent corrosion Prepare and apply this material per the coating manufacturer s instructions 2 20 5 Prior to coating any new galvanized steel remove any surface grease Flux or oil with a commercial prepaint wax and grease remover Apply one wet coat of a waterborne wash prime primer Sherwin Williams P60G2 primer R7K44 catalyst or equivalent 2 21 PRIME COATS 2 21 1 The first coat of primer will be applied within 24 hours after compl
485. pot CAGE Code if Overhauled i155 Enter N A i165 Deficient Component s Part Number i170 Deficient Component s Serial Lot Batch Number i180 Enter N A i190 Enter N A i195 Enter N A i200 Enter N A i205 Item New Repaired i210 Date Manufactured Repaired Overhauled i220 Enter N A i225 Item s M H K Operating Time at Failure i230 Enter N A i235 N A M H K Since New Overhaul i240 M H K Since Installation i250 Current Vehicle M H K i260 Quantities i266 i268 i270 i272 Received Inspected Deficient In Stock Enter N A i280 Leave Blank i282 Enter N A 1284 Vehicle Registration Number i290 Vehicle Mngt Code Make Model amp Contract i295 Next Higher Assembly NHA Nomenclature i302 NHA NSN i300 NHA Part Number i304 F09603 098 Figure 7 1 Deficiency Report Sheet 1 of 2 TO 36 1 191 NHA NSN i300 NHA Serial Number i306 Unit Cost i310 Item Under Warranty i320 NHA Part Number i304 Estimated Repair Cost i315 Warranty Expiration Date i1440 OLVIMS System Code i330 Std Reporting Designator SRD i360 Enter N A i365 MAJCOM Activity Code See TO 00 35D 54 Table 7 1 i370 Exhibit Submitter Holding Status see TO 00 35D 54 appendix A i430 Address of Unit holding Exhibit i440 Cognizant Technical Expert Official Phone Number i442 Certifying Offi
486. pound Grade 1 A A 59295 Corrosion Preventive Compound Solvent Cutback Cold Application MIL PRF 16173 Class II Grade 1 Hard Film Class I Grade 2 Soft film Unit of Issue Ea Ea Ea Dr 16 Gl 16 oz aerosol Pt GI 1 Gl 5 Gl Dr 55 Gl Cn Aerosol Qt Gl 1 GI Cn 5 Gl Dr 55 Gl NSN 8010 01 441 6006 8030 01 282 5626 8030 01 103 2868 8010 01 495 8652 8010 01 441 5888 8010 01 441 6032 8010 01 441 6008 8010 01 441 6009 8010 01 441 6010 8010 01 441 6021 8010 01 441 6028 8010 01 441 6016 5610 00 641 0426 5610 00 141 7842 5610 00 641 0427 8030 01 127 3684 8030 01 134 6513 8030 00 146 9701 8030 00 935 7158 8030 01 396 5731 8030 01 396 5732 8030 01 347 0970 8030 01 396 5237 8030 00 118 0666 8030 01 149 1731 8030 01 244 1297 8030 01 244 1298 8030 00 244 1295 Application Color 24052 Semi Gloss Forest Green Vehicle tops vinyl spray upholstery tires bottles leather and plastic 02Y040 2TU 31136 Red 33538 Yellow 35044 Dark Blue 36118 Gray 37038 Black 37875 White Dark Gray 36231 Light Gray 36440 Black 37038 Inside doors rocker panels door posts and inside trunk lids Long term protection of metal surfaces against corrosion with or without cov erings indoors or outdoors Thick grease like consistency for pro tecting metal surfaces against corro sion during rework or storage In cludes extended indoor protection of interior or exterior
487. problem 8 24 14 1 Add automotive diesel fuel to the fuel servicing tank Use 25 gallons for ME 1 trailers or 40 gallons for M99 vehicle 8 24 14 2 Circulate the diesel fuel by pumping for 10 to 20 minutes while directing the flow from the dispensing nozzle to wash down all wall surfaces of the tank 8 24 14 3 Soak up fuel puddles with non static collecting non sparking cloth rags wrapped on a wooden stick 8 24 14 4 Pump diesel fuel into available diesel vehicle fuel tank s 8 24 14 5 8 24 15 After one half hour proceed to Paragraph 8 24 15 Take meter reading of the lower explosive level LEL and repeat purge procedures if required until a LEL of 20 percent or less has been achieved 8 24 16 When safe limits have been obtained close fuel caps lids install all plumbing caps plugs securely reinstall M99 filters as applicable and seal all plumbing caps plugs and filter cap lid with pickling tape 8 24 17 Equipment Required 8 24 17 1 nozzle One each spray gun paint with fogging 8 24 17 2 One each hose air length in excess of 60 feet 8 24 17 3 Two quarts 10 weight motor oil 8 24 17 4 Rags of sufficient quantity non static collecting non spark producing 8 24 17 5 One each 50 pound or larger fire extinguisher for use with Class B and C fires 8 24 17 6 One each roll of pickling tape 8 24 17 7 Time required to perform this task approxi mately two hours with three persons TO 36 1
488. prolonged compression of clutch springs may cause a permanent set Be sure gear shift levers are in neutral position Where storage experi ence indicates a need for additional measures the following options may be specified by the responsible AF storage or Vehicle Fleet Man ager Clutch may be disassembled If disassembled metal surfaces of operating parts including clutch collars linkage pins flywheel ring gear and starter drive shall be coated with a thin film primer Specification TTP 664 Remove clutch cover plates and with the clutch engaged spray a thin film of primer TTP 664 on all accessible metal surfaces within the hous ing B AV No preservation required 38 39 40 COLUMN I Item TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN II IV V Component Level Type of Vehicle Processing Required A AX Where the lubricating system is separate from the associated power unit air compressor crankcase shall contain MIL L 21260 P 10 perseverative oil only grade 10 or 30 as applicable filled to operating level Compressor air cleaner shall be removed and air intake and outlet disconnected While engine is being operated during preserva tion P 10 Type I Grade 30 preservation oil shall be sprayed into compressor air intake and outlet shall be reconnected Compressor air cleaner oil bath type shall be preserved as specified in Item 1 and reinstalled B AX Air c
489. r Letter W Letter X Letter Y Letter 7 Number 1 die cut pre spaced Number 2 die cut pre spaced Number 3 die cut pre spaced Number 4 die cut pre spaced Number 5 die cut pre spaced Number 6 die cut pre spaced Number 7 die cut pre spaced Number 8 die cut pre spaced Number 9 die cut pre spaced Number 0 die cut pre spaced Number 1 die cut pre spaced Number 2 die cut pre spaced Number 3 die cut pre spaced Colors BKOND Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Silver Yellow Yellow Yellow Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red None None None None None None None None None None None None None Letter Or No Size 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 4 in 1 1 2 in 1 1 2 in 1
490. r it occurs 6 17 1 Moisture Moisture is present in air as a gas water vapor or as finely divided droplets of liquid mist or fog and often contains contaminants such as chlorides sulfates and nitrates that increase its corrosive effects Moisture will enter all areas of vehicles that air can enter AII enclosed areas that are not hermetically sealed allow air to enter and leave as the difference in pressure between the inside and outside the equipment changes These pressure differences occur when atmospheric pressure changes and when the air temperature inside an enclosed area changes As the surrounding surfaces are heated moisture laden air is drawn into the enclosed area or absorbed in open cell foam As the air around the equipment cools moisture will con dense in the enclosed areas and settle in the lowest area of the part 6 17 2 Condensed Moisture Condensed moisture will usually evaporate as the surrounding air warms but will leave behind its contaminants residues including salts This can result in the build up of soils and salt contamination Con densed moisture and its contaminants can also be trapped in close fitting wettable joints such as faying surfaces Some gasket and packing materials will absorb several times their weight in water and when heated can transmit this retained moisture into the sealed area Moisture can accumulate in such areas through successive cycles of warming and cooling and cause corro
491. r number 31136 TO 36 1 191 2 32 MARKING REQUIREMENTS FOR VEHICLES USED ON LANDING AREAS 2 32 1 Vehicles which operate primarily on the apron and taxiways painted dark green or olive drab i e fire trucks fuel servicing trucks A S32A 2 water truck 463L and ground support equipment GSE will be marked with silver reflectorized tape This vehicular equipment will be high lighted to indicate length width and height using silver reflective tape conforming ASTM D4956 Rolls Class 3 Type 1 color The tape will be applied in 2 inch wide strips 8 to 12 inches long as illustrated in Figure 2 7 Figure 2 23 and Figure 2 29 NOTE Use Figure 2 7 Figure 2 23 and Figure 2 29 as a guide for marking all vehicles where highlight ing is required 2 32 2 other vehicles operating primarily on the apron and taxiways excluding general purpose vehicles will be marked as follows 2 32 2 1 Reflective tape markings 2 32 2 2 Clearance lights 2 32 2 3 Hazard warning lights four way flashers as required by the Department of Transportation 2 32 2 4 Non revolving pulsating type light of aviation yellow as specified in SAE AS25050 2 32 2 5 Revolving flasher type light of aviation red or blue as specified in SAE AS25050 NOTE Prescribed lighting requirements begin in Para graph 2 93 of this technical order General pur pose vehicles i e sedans station wagons mul tistep panels pickup trucks buses et
492. r puncturing objects from tire With tire inflated apply soap solution to damaged area to determine if air loss is from one or more punctures Deflate the tire unseat the beads and apply approved bead lubricant Then remove tire from wheel carefully to avoid further damage to the tire particularly to the bead and place on spreader 4 27 2 2 Probing Probe puncture with blunt smooth surface awl or other hand probing tool to determine size and direction of injury making sure no foreign material is left in the injury 4 15 TO 36 1 191 4 27 2 3 Internal Examination Bulge tire on spreader marking the puncture with tire crayon Inspect for evidence of other damage e g in the bead area Care should be used not to enlarge the injury 4 27 2 4 Cleaning Bung solvent is flammable and toxic to the skin eyes and respiratory tract Eye and skin protec tion is required Avoid repeated or prolonged contact Good general ventilation is normally adequate Avoid all sources of ignition Clean punctured area thoroughly with chemical buffer cleaner covering a slightly larger area than required for patch Make certain that no loose or frayed wire ends protrude through the liner Buffing operations create airborne particles Eye protection consisting of safety goggles is re quired Compressed air used for cleaning can create airborne particles that may enter the eyes Pressure will not exceed 30 psi Eye protection is required
493. r approved parts not being used except in emer gency cases approved by the manufacturer 7 18 2 2 Abuse negligence or alteration of original parts or adjustments 7 18 2 3 Engine tune up or related cleaning or adjusting operations including maintenance to comply with govern ment emission control standards 7 18 2 4 Service and parking brake adjustments lining replacements 7 18 2 5 General tightening 7 18 2 6 Headlight adjustments 7 18 2 7 Wheel aligning or tire balancing 7 18 2 8 Materials required in servicing or repairing such as oil grease brake fluid antifreeze filter elements or drive belts 7 18 2 9 Labor for installation of accessories not ordered on vehicles 7 18 2 10 Miscellaneous expense such as gasoline tow ing telephone rental vehicle lodging loss of personal property or sales tax NOTE The manufacturer s dealer may bill the Air Force for nonwarranty materials or adjustments used in conjunction with warranty repair To avoid such charge a clear understanding documented on the repair ticket if necessary should be achieved with the dealer to prohibit adjustments or use of materials not covered by warranty The Air Force should provide oil grease brake fluid antifreeze etc not covered by warranty that are required in completing the warranty repair If unforeseen nonwarranty repairs are accomplished in con junction with warranty repair the billing and an explanation should be immed
494. r cycle straight diesel engines with open e ings other than fuel injectors and valves into combustion chambers and cylinders Diesel throttle shall be completely closed Covers plugs or flanges over openings shall be re moved and while engine is being cranked with starting motor two ounces of P 10 Type I Grade 30 preservative oil shall be atomized sprayed into each cylinder through the opening Without cranking two additional ounces of P 10 Type 1 Grade 30 preservative oil shall be atomized sprayed into each cylinder through the openings Interior surfaces of covers shall be coated with the same type and grade preserva tive oil and covers reinstalled A warning tag bearing the information ENGINE PRE SERVED DO NOT CRANK shall be securely attached in a conspicuous location within driv er s compartment Four cycle straight diesel engines without openings other than fuel injectors and valves into combustion chambers and cylinders Preser vation shall be accomplished by one of the fol lowing two methods The practicability of method 1 will depend on the ease with which injectors can be removed and on the size of openings in the pre combustion chambers If these openings are too small to effectively admit and distribute the preservative oil the precom bustion chambers will require removal and the practicability of this procedure will then depend on the ease with which the precombustion chambers can be re
495. r exceed that of a new tire or if new replacement tires are not available when needed 4 24 2 2 Specify that contractors use the cold process retread method when possible and economically advanta geous considering transportation cost Tests have shown that cold process retreads are generally less costly per mile allow repeated retreading have a higher life expectancy and are normally readily available 4 24 2 3 Do not retread tires for which there is no foreseeable requirement Base supply is responsible for tire inventory management using DIFM procedures Vehicle Fleet Managers must be closely involved in the base tire management program 4 24 3 Restrictions on the Use of Retreaded Tires 4 24 3 1 Retreaded tires will not be used on ambulances 4 24 3 2 Retreaded tires will not be used on Law Enforce ment Sedans NOTE Law enforcement sedans are received from manufactures equipped with high pursuit radial tires When these tires require replacement they will be replaced with standard radial tires of a comparable size 4 24 3 3 tires will not be used on front wheels of buses 4 24 3 4 Retreaded tires will not be used on any vehicle when their use would seriously impair mission support or create a safety hazard Organizations experiencing serious operational difficulties or safety hazards attributable to re treaded tires may use tires on passenger and cargo vehicles if they operate regularly off bas
496. r is not ef fective Flat paint cleaner Use on low gloss tactical paint scheme coatings to re move stubborn contaminants such as boot marks and smudges as well as gun blast and exhaust tack soil Gel type cleaner Thixotropic cleaner for vertical and overhead areas where complete rinsing with water can be tolerated clings to vertical or over head Preval Spray Power Pack Spray System 11136 Red Gloss PN 99R020 1TU 12197 International Orange 13538 Yel low PN 990R003 1TU 15044 Dark Blue 99Y014 1TU 16473 Light Gray PN 99BL013 17038 Black PN 99GY029 17925 White 99W035 Clear 11136 Red Gloss 12197 Orange 13538 Yellow 15044 Dark Blue 15050 Dark Blue 16473 Light Gray 17038 Black 17925 White 23538 Yellow PN 99Y013 24052 Forest Green 999GN001 27038 Black 99BK005 6 5 TO 36 1 191 1 m Material Coating Polyurethane MIL PRF 85285 Type I Semi Gloss Touchup Brush SEMPEN Coating Preservative Rubber A A 52408 Coating Preservative Rubber Protection Coating Primer Epoxy Polyamide Yellow MIL PRF 23377 Preval Spray Power Pack Spray System Coating Primer Epoxy Polyamide Touchup Yellow MIL PRF 23377 Type I Coating Primer Water borne Epoxy Yellow MIL PRF 85582 Type I Class C2 SEMPEN Coating Touchup MIL PRF 85285 Type I Coating Polyure thane Flat Touchup SEMPEN Brush Coating Walkway Compound Non slip A A 59166 Corrosion Preventive Com
497. r pressure is present Check tire inflation pressures when tires are cold In addition to the visual inspection radial tire pressure will be checked with a gauge if handling problems are experience Tolerance In Matching Dual Tires p Permissible Difference Outside Diameter of Tire Under 30 inches From 30 to 40 inches From 40 to 50 inches Over 50 inches Type 3 4 inch 1 1 8 inch 1 1 2 inch 1 3 4 inch TO 36 1 191 Table 4 2 Measuring Procedure for New Tires FOR PASSENGER CAR EX CEPT P TYPE Before measuring tires shall be mounted and inflated to 24 psi for Load Range B to 28 psi for Load Range C and to 32 psi for Load Range D and allowed to stand 24 hours minimum at normal room temperature and inflation pressure readjusted to 24 psi Load Range B 28 psi Load Range C and 32 psi Load Range D Before measuring tires shall be mounted and inflated to 26 psi for Standard Load and 32 psi for Extra Load allowed to stand 24 hours minimum at normal room temperature and inflation pressure readjusted to 26 psi for Standard Load and 32 psi for Extra Load Before measuring tire shall be mounted and inflated to the pressure for the maximum load for duals if listed allowed to stand for 24 hours mini mum at normal room temperature and inflation pressure readjusted to the pressure for the maximum load FOR PASSENGER CAR TIRES FOR OTHER PASSENGER CAR TREAD CONTACT WITH ROAD UNDER INFLATION CAUSES E
498. railer and directly below the marking 2 69 4 N O transporters shall also have DOTSP 3121 applied to the right side of the tank near the front in 2 inch high letters and numbers on a contrasting background 2 69 5 N50 transporters shall be marked INHALATION HAZARD in 3 1 2 inch letters on a contrasting background on all four sides near the flammable placard 2 69 6 Unsymmetrical Dimethylhydrazine UDMH trans porters shall display the markings UDMH on the front and rear and CORROSIVES on the front 2 69 7 The marking FLAMMABLE in 2 inch red letters on a silver background will be applied directly above the marking specified in Paragraph 2 82 e 2 69 8 UDMH transporters shall also have the marking DOT SP 2828 applied to the right side of the tank near the front in 2 inch high letters and numbers on a contrasting background 2 70 FIRE FIGHTING VEHICLES 2 701 Reflective striping may be applied to any previ ously non striped fire fighting vehicle using non permanent 3M type material Details follow 2 70 1 1 Striping materials shall be in accordance with ASTM D4956 Type III Class 1 or 3 Previously striped trucks shall not be upgraded before complete repaint is required The installation of these markings will be of a non permanent type material 1 e 3M type film to facilitate easy removal and prevent damage to painted exterior of vehicles 2 70 1 2 Colors white on red trucks red on lime yellow
499. rders AFTO Form 9 prepared by transferring unit and other related records to determine maintenance status of the item Upon completion of the records inspection VM amp A will schedule and initiate work order s to accomplish the acceptance inspections outlined below and other maintenance actions necessary to complete the acceptance For vehicles equipment received by transfer the AFTO Form 91 accomplished by the transferring unit will be attached to the work order for reference by vehicle management personnel during the acceptance inspec tion 1 5 8 2 Inspection The acceptance inspection will be accomplished on new and used vehicles equipment upon receipt and assignment to the LRS Vehicle Management activity for preparation for service The inspection consists of as a minimum 1 5 3 2 1 The visual inspection portion of the scheduled inspection Lubrication oil and filter change will be per formed if necessary 1 5 3 2 2 functionality check of all major components on the vehicle If the inspection reveals unsatisfactory con dition the may direct a technical inspection AFTO Form 91 or work order repair estimate to support warranty action new vehicle or other follow up action on used vehicles equipment received by transfer from another instal lation If the AFTO Form 91 is used it will be attached to the work order and filed according to local approved procedures 1 5 4 Used Vehicles Receiving Inspection Used
500. requested by the MAJCOM to support the annual depot overhaul requirements Forward LTI to the major command transportation function 1 5 8 2 When instructions have been received to ship specific vehicle to a depot overhaul facility a new LTI will be prepared to accompany the vehicle This LTI will reflect all missing components Labor and material costs need not be computed on this LTI Vehicles arriving at depot repair facilities are inspected to ensure accompanying LTI identifies missing components if any All vehicles and components are overhauled repaired in accordance with WR ALC s work specifications Upon receipt of vehicles from depot an acceptance LTI should be performed Reference Chapter 9 for warranty actions 1 5 8 8 Vehicles Placed on Loan to Other DoD Agen cies or Other Authorized Agencies When instructions have been received to loan lease a vehicle to a Government contractor another DoD agency or other authorized agencies an LTI will be prepared in duplicate reflecting the current condition of the vehicle One copy of the LTI will remain on file until the vehicle is returned and used as a receiving checklist The other copy accompanies the loaned vehicle 1 5 8 4 Vehicles Placed on Special Projects or Appli cation Special projects and or application may require an LTI to be prepared Appropriate authority will make the determination and provide instructions on processing filing number of copies and other r
501. rer Hoses shall be of proper size and shall show no signs of deterioration Water pump shaft and bearings shall not be excessively worn and will operate without unusual noise 1 7 2 40 Coolant System Pumps Crashfire Trucks Hand pump shall turn freely without binding or leaking Electric pumps shall operate satisfactorily from instrument panel control Hose connections shall be tight with no leaks 1 10 1 7 2 41 Conveyors Applicable To Loaders Graders Ditchers Etc All components shall be securely mounted and in good operating condition Conveyor belts shall ride correctly and rollers shall turn freely All belt splices shall be in good condition Belt tension adjustment shall be in accordance with manufacturer specifications Frame and roller bolts shall be secured and free of cracks 1 7 2 42 Cutting Edges Scrapers Runners Shoes And End Bits Applicable To Dozers Graders Rooters Drag Lines Etc There shall be no excessively worn loose cracked or broken parts There shall be no missing or broken parts Wear shall not exceed 50 percent NOTE Replacement parts are the responsibility of the owning organization in accordance with AFI 24 302 1 7 2 43 Cylinders Hydraulic Cylinder packing glands or seals shall show no evidence of oil leaks Piston rod ram shall be free of nicks burrs or scratches that may cause damage to packing gland or oil seals 1 7 2 44 Cylinder Head And Engine Block Cyli
502. responsible for the end item Each organization commander shall stress safety instructions when receiving and initially handling such vehicles Residues of explosive toxic and chemical agents may cause bodily harm 8 8 RESPONSIBILITY FOR PROCESSING AND DEPROCESSING 8 3 1 Owning Air Force organizations and installations are responsible for processing serviceable and economically reparable vehicles The vehicle management activity which falls under that specific owning group shall be responsible for processing deprocessing reparable vehicles The require ments of this technical order do not apply to vehicles which are awaiting disposal however they may be used for guid ance when minimum measures are needed to protect item s sales value redistribution assets or to achieve optimum environmental safety 8 3 2 The processing activity is also responsible for prevention of vehicle deterioration while vehicle is awaiting processing 8 3 8 Intra Organizational Responsibility Processing for storage conduct of storage and processing for shipment are the responsibility of the base vehicle management activ ity However considerations or expedience economy and practicality may lead local commanders to designate that base vehicle management shops perform part or all of these tasks This will usually be the case where the quantity of vehicles processed is small work intermittent special skills are required and facilities to be
503. rim 4 32 3 5 Lubricate tire side of rim base just prior to mounting tire Avoid the use of any lubricant which contains water or solvent that is injurious to rubber A combination lubricant and rust preventive compound is preferable This protective measure is of particular importance with drop center tubeless rims as the air in the tire is contained by the tire side rim surface TO 36 1 191 APPLYING SOAP SOLUTION C FOLDING LARGE SIZED TUBE D USE OF SAFETY BLOCKING F09603 060 Figure 4 18 Tire Mounting and Demounting Operation 4 33 PREPARATION 4 33 1 Use lubricant solution on tire beads to make mounting and demounting easier particularly when mounting and demounting tires on drop center or semi drop center rims Do not use oil or grease because petroleum products cause rapid deterioration of rubber Do not use any lubricant which does not dry for it may cause the bead to slip Apply lubricant solution with a brush or swab taking care not to allow excess solution to enter tire 4 33 2 Large size tubes should be folded before insertion in tire 4 33 2 1 Deflate the tube completely 4 33 2 2 Install valve cap 4 33 2 3 With tube in circular position fold quarter of tube to left of valve inward 4 33 2 4 Likewise fold two quarters opposite valve in ward 4 33 2 5 Insert pointed end with valve into tire then insert other pointed end into tire and unfold tube into tire see Figure 4 18 4 33 3 Whe
504. rom a portable container of diesel fuel conforming to Specification V V F 800 shall be connected to the line leading to engine Injector fuel return line shall be discon nected at the quick disconnect coupling A line shall be provided and connected to the injector fuel return quick disconnect coupling to permit draining into a recovery container Recovered fuel oil mixture shall not be used for preserving other engines Engine shall be started and oper ated at fast idle without load until thoroughly warm Engine shall be accelerated to 3 4 speed at the same time fuel supply shall be switched to VV L 800 Type P 9 preservative oil Engine shall be operated until entire fuel system and internal operating surfaces are coated with the preservative oil Engine shall be stopped and fuel lines reconnected Prior to continuation of preservation engine shall be cooled to a maxi mum cylinder head temperature of 100 F Cooling may be accelerated by use of induced air currents Preservation shall then be continued in accordance with one of the following meth ods as applicable 8 29 TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN COLUMN I II V Item Component Level Type of Vehicle Processing Required a Four cycle gasoline starting diesel engine Spark plugs shall be removed exercising maxi mum care in handling to avoid damage to threads and electrodes during preservation En gine contro
505. ron alloys brown to red iron oxide will issue from the area or interface experiencing fretting corrosion On aluminum alloys a black corrosion product is evident Table 6 2 Corrosion Severity Zones and Minimum Wash Interval TO 36 1 191 Air Force Academy Colorado Springs CO Aj Taif SA A Jouf SA Albrook AFS PAN Allen C Thompson Fld Jackson MS ANG Altus AFB OK AETC Anchorage IAP AK ANG Andersen AFB GU Andrews AFB MD Wash DC Ankara AS TUR Annville PA ANG Antiqua West Indies Arnold AFB TN As Sulayyil SA Ascension Island UK Atlantic City NJ ANG Aviano AB IT Bagram AB Afganistan Bahrain Bangor IAP ME ANG Barksdale AFB Shreveport LA Barnes M Apt Westfield MA ANG Battle Creek MI ANG Beale AFB Marysville CA Bellows AFS HI Birmingham International Apt AL ANG Bolling AFB DC Bradley IAP Windsor Locks CT ANG Brindisi Casale AB IT Brooks City Base TX Buckley ANGB Denver CO ANG Burlington IAP VT ANG Byrd Fld Richmond VA ANG Calumet AFS MI Camp New Amsterdam NE Cannon AFB Clovis NM Cannon IAP NV Cape Canaveral AFS FL Cape Cod AFS MA Wash vehicle Ev ery 5 days Wash vehicle every Wash vehicle Every Wash vehicle Every 45 X X X X X X X X X X X X X X X X X X X X X X X X X X days 6 45 TO 36 1 191 Table 6 2 Corrosion Severity Zones and Minimum Wash Interval Continued
506. rrier CLI CL II MIL V 13811 Varnish Waterproof Electrical Ignition QT 8010 00 298 3870 CID A A 59295 Compound Corrosion Preventative P1 GD I For Cooling system and Pumps 55 GL 8030 00 244 1300 GD II P2 5 GL 8030 00 244 1298 GD III P3 55 GL 8030 00 244 1294 GD V P21 55 GL 8030 00 2526 1604 MIL P 10578 Compound Corrosion Preventative GD I PI 5 GL 6850 00 854 7952 6 MIL P 17667 Paper Chemical Neutral Wrapping 33 X 600 Type 1 8135 00 558 1242 MIL C 18480 Coating Preservative 5 GL 8030 00 275 8121 MIL PRF 21260E Preservative Lube Oil GD 10 55 GL 9150 00 111 0208 Type 1 Air Cleaners Spark amp Compression P10 GD 30 9150 00 111 0201 Type 1 Ignited Engines Fuel Tonics 50 Type I 9150 00 111 0214 Preservative Aluminum Alloys Ferrous Metals P18 Primer Epoxy Polymide TO 36 1 191 Table 8 1 Materials Required for Processing Continued Specification Material Item NSN Federal MIL L 23398D SAE AMS T 22085 Tape Pressure Sensitive Type II 5G MIL 1 24092D DOD PRF 24574 MIL PRF 38299 Fluid CID A A 59441 1 Inhibitor Corrosion Control I Aluminum Ferrous Metal Closed Systems P20 MIL PRF 46147C Lubricant Solid Film Air Cured Corrosion 1207 CN 9150 01 500 2795 Inhibitor 8 L CID A A 52624 Anitfreeze Ethylene Glycol HD To 55 F 55 GL Also used for arctic Hydraulic Fluid MIL PRF 46170C MIL PRF 46176B Fluid Brake Silicone Master Brake Cylinder GL 9150 01 102 9455 M
507. s and is effective for use on heavy soils and grease Type I contains solvents and should not be used in poorly ventilated areas or on lacquer painted surfaces 6 15 6 3 2 Type IA is an aerosol used for spot cleaning on exterior surfaces Do not use on lacquer surfaces plastics or composite surfaces 6 15 6 3 3 is for general use on exterior and interior surfaces It is effective on light oils and hydraulic fluids Type II contains less solvents and can be used in areas of reduced ventilation 6 15 6 3 4 is for use on high gloss surfaces only It contains abrasives that remove soils by wearing away the surface that holds the soil This cleaner will raise the sheen of gloss semi gloss or flat topcoats Type III is used to spot clean and clean engine exhaust areas on gloss finishes 6 15 6 3 5 Type IV is a rubberized spot cleaner for use on semi gloss and flat camouflage finishes It effectively cleans exhaust tracks smudges boot marks or other embedded soils Type IV is a cleaner with suspended rubber particles When the rubber particles are rubbed on a soiled surface the particles act like tiny erasers and remove the soil This cleaner will not alter the gloss of a camouflage coating 6 15 6 3 6 Type V is a gelled cleaner which can be used to replace solvent cleaning where water rinsing can be allowed and can be used to clean vertical surfaces where thin cleaners will run off 6 15 6 4 MIL PRF 87937
508. s ueds 0 50990 309 pue JIM 6 510189119 8 sei quiessy esodung eroedgs surojsAS oi neQpAH L pojeroosse pue xoou urooq YLI usrpp ouei 9 suuope d 33 surooq so orqoA qovor pue uo 159 INPI Sseue1o pue yonn 10 801159 IFM p pue s10jo s1edipe sropurA PPIM 59045 JOD PM oedos pue se oov dor yoodsut weap uonoedsur yue 2 sjuouro o ooepdos 81038591895 sjuourounbos AYA 8 JONA SIiopre1 xueg ong sorueSo r Suysay eruuonburn 1 1591 81591 z 3 7 1 TO 36 1 191 859330 5309 oje d ogen 12edsug 10815 PALI sour oov do1 pue jseo SOUT 11 Jo uonoedsur pensita oouo19Jos suononasu eroedg speA1o3u ponunuo sjsopyuonoodsug er odg SununoJA ISPLUILD SOULL WIPO r jse uonoedsu Ct AQEL Change 1 3 8 TO 36 1 191 Table 3 3 Preventative Maint
509. s Ford and Chrysler have agreed to extended coverage for parts only for those vehicles procured by WR ALC that are used outside the 50 states of the United States 7 17 4 Emission Control System contractor shall provide a warranty in conformance with applicable regula tions of the Federal Environmental Protection Agency and the California Air Resources Board that covers emission control related parts which will be replaced repaired or adjusted if there is a defect in a covered part that causes the vehicle to fail to conform to regulations for five years or 50 000 miles whichever occurs first Some components such as distribu tor sparks plugs ignition wiring and manifolds are ex cluded if over 24 months or 24 000 miles and their primary purpose is not to reduce vehicle emissions Some items may require scheduled replacement and are only warranted up to the first replacement interval This coverage applies only to domestic use 717 5 Domestic Use When vehicles are used within the 50 states of the United States the District of Columbia and when applicable Puerto Rico and the Virgin Islands the warranty shall include the furnishing without cost to the Government FOB contractor s nearest dealer or branch to vehicles location or station new parts and assemblies to replace any that failed or malfunctioned within the warranty period In addition when the Government elects to have the work performed at the contractor s
510. s Oil Servicing Units Burners shall not be operated if a trace of asphalt is leaking into the flues Heater tubes and flues shall be securely mounted and shall not leak 1 7 2 73 Hinges And Latches Alignment of hinges and latches shall allow opening closing and removal of panels without difficulty Hinges and latches shall be properly lubricated and securely mounted Hinges for personnel doors shall be properly aligned so as to not allow door to drop or hang up when door is opened 1 7 2 74 Hoisting Control Units Levers pedals and control cables shall show no evidence of excessive wear lost motion or rust and they shall have excessive wear and sheaves bearings shall not have excessive wear and be properly adjusted Brakes shall be capable of holding a capacity load and bands shall have 50 percent original lining thickness remaining Operating clutches shall not slip or drag under load and bands shall have 50 percent of their original lining thickness remaining 1 7 2 75 Hoisting And Topping Winch Controls Con trols shall operate smoothly without unusual noise Drum clutches shall have no drag but at the same time they shall have ample movement for operation and proper travel on the screw for shifting the drum to the clutch Lever and linkage shall have no excessive lost motion 1 7 2 76 Horn Horn shall be securely mounted and shall produce a loud clear signal when actuated by the horn button The horn butto
511. s bolts joints or welds will be cleaned and inspected to determine extent of damage It will then be repaired and or treated to prevent further deterioration 1 6 4 Seals Oil And Grease 1 6 4 1 Seals used for retaining hydraulic and gear oils on revolving or reciprocating shaft applications may show slight seepage and still be considered acceptable If seepage is sufficient to form flow tracks and drip from housing or shaft or forms wet accumulations on adjacent members or panels from thrown lubricant the seal shall be rejected 1 6 4 2 Seals used for retaining grease in rotating assem blies such as wheel hubs shall show no evidence of leakage Presence of a slight oily film on the exterior and areas adjacent to the oil seal may be caused by the capillary action of light oils present in most greases and is not cause for replacement of seal 1 6 4 3 Wiping surfaces of synthetic type seals shall be smooth and maintain pressure contact with intended sealing surface throughout the radial or thrust surfaces of the seal 1 6 4 4 Leather seals that have hardened shall be rejected Sealing edges that are worn to a sharp or ragged edge are not acceptable 1 6 4 5 Bellows type seals steering knuckle CV joints gear case shifter shafts shall not be cut slit or cracked Mounting clamps or devices shall be secure and properly installed 1 6 5 Bearings Anti Friction Ball And Roller Bearings removed for lubrication service or i
512. s 2 16 1 2 Hoses and cables must be protected from contact with the ground Lowering the suspension and the deck all the way minimizes the exposure of the critical rod surfaces of hydraulic cylinders to the environment and minimizes the degree of preservation tasks required It also provides maximum protection for all loader components from the weather Resting the chassis on blocks at a low height takes loading off the suspension hydraulic components and eliminates the risks of hydraulic leakage which could cause suspension drop and result in excessive uneven loads on TUNNER components For these reasons the TUNNER should not be left unmonitored for extended periods of time in the air transport configuration Suspension isolation valves should NOT be closed during storage as this would make system relief valves ineffective and could allow excessive loads and pressures from thermal changes and leakage Specific steps for preparation for long term storage and removal from storage have been simplified by requiring the standard Operational Checks and the 250 hour maintenance procedures be performed upon removal from storage This assures proper operation and clean filters etc using standard Technical Order procedures A 1 9 7 uonoS TI SE E TW9E OL Jod 542945 euonedoed uuoj1oq 9 p AQEL p uonoos c Ce CIN9 OL seunpoooud ooueu ojureur STZ pue 9 uonoes C C IN9 OL Jo
513. s IAW Table 3 2 of this technical order Inspections will be loaded tracked in OLVIMS as concurrent or special inspections Refer to the applicable end item manual for specific inspection criteria i e Oshkosh R 11 IAW TO 36A12 13 17 82 TO 36 1 191 NOTE Definition of In Commerce as it pertains to the guidance in this TO The transport and sale transfer of POL products to or from a non DoD agency On or off base operations or any combi nation thereof has no impact on determining In Commerce status 3 10 2 5 2 Pressure Leakage tests and tank certification are required if vehicles are used in commerce Pressure leakage tests will be conducted and tank marking will be applied IAW 49 CFR Part 180 401 417 prior to use Person nel performing pressure leakage test must meet requirements outlined in 49 CFR Part 180 409 3 10 2 5 2 1 Military or contracted operations using Air Force assets in commerce require tank certification in accor dance with 49 CFR Part 180 401 417 3 10 2 5 2 2 Contracted operations using contracted com mercial assets in commerce require tank certification IAW 49 CFR Part 180 401 417 If a contractor operates Air Force assets utilizing Air Force fuel they are not in commerce 3 10 2 5 2 3 Units required to operate refueling vehicles on public highways not in commerce on a recurring basis may elect to have assets certified IAW 49 CFR Part 180 401 417 This is provided as possible option to enh
514. s in the lower repair allowance Repair allowance shall not be less than 15 of the standard price of the re placement vehicle 5 22 5 Compare the repair estimate with the one time repair allowance 5 22 5 1 If the one time repair allowance will not be exceeded and the vehicle has not reached its age or utilization life expectancy proceed with the repair However vehicles which exceed any one of the life expectancy criteria 1 one time repair allowance age miles kilometers or hours are considered uneconomically reparable and repair approval must be obtained before work can be started 5 22 5 2 Officials responsible for approving repairs must exercise good judgement when evaluating requests for repair Consider mission impact the length of time the vehicle is anticipated to remain in service the projected date a replace ment vehicle will be available and amortization of the repair cost Uneconomically reparable vehicles which are excess or nonessential to the base mission shall be reported for dispo sition in lieu of performing the repairs 5 22 5 3 See Paragraph 5 23 and Paragraph 5 24 for level of repair approval 5 23 REPAIR AUTHORITY FOR MINIMUM ESSEN TIAL REPAIRS Base level VFM VMS may approve minimum essential repairs to uneconomically reparable vehicles 5 23 1 Minimum essential repair is explained below 5 23 1 1 Repair or replacement of minor components affecting driver visibility safety or operati
515. s intended to provide adequate protec tion at minimum cost for immediate use domestic shipments The preparing activity is expected to preserve package and pack to insure safe receipt at first destination and must comply with appli cable carrier rules and regulations In every case care must be exercised to ensure that cooling systems are adequately protected that body drains and ventilators are open that hatches doors and compartment covers are secured against pilferage and that accompanying acces sories and OVE On Vehicle Equipment are properly stowed When the vehicle is shipped Level C to a port for transit overseas the OVE shall be packaged in accordance with require ments for Level A or B unless otherwise specified 8 7 4 Column IV contains the symbol for the type of vehicles affected by the entry Symbols used are as follows vehicles vehicles except trailers and semi trailers GP General purpose vehicles MH Materials handling vehicles SE Special equipment vehicles SP Special purpose vehicles ST Semitrailers TR Trailers The Tunner 60K aircraft loader is covered separately in Appendix A 8 7 5 Column V prescribes the minimum required process ing or equal In addition general cross references are made to a process described elsewhere TO 36 1 191 Table 8 1 Materials Required for Processing Federal Ef __________ _______________ Automobile Pase ________________ 7
516. s look for signs of corrosion or corrosion damage Track causes of initial corrosion to the source and eliminate the source 6 17 13 5 Vehicle cleaning is the first step in preventing corrosion by removing salt deposits corrosive fluids mate rials that collect and hold moisture and other electrolytes As mentioned earlier vehicle should be washed based on the corrosion severity zone the equipment operates in 6 17 13 6 In some situations cleaning and washing should be done immediately Immediate cleaning is required when a Spilled electrolytes or other corrosive deposits are found around batteries battery terminals or the battery com partment The vehicle or any components are exposed to corrosive fire extinguishing agents Salt deposits or other corrosive contaminants are found Of special concern would be the lowest level of the equipment where salt laden water or condensation will drain to This area is usually the last area to dry Unless regularly rinsed with clean potable water the salt and other contaminants will achieve a greater concentration and be more corrosive The vehicle is exposed to significant amounts of salt water Fungus or other organism growth is apparent TO 36 1 191 CHAPTER 7 WARRANTIES 7 1 PURPOSE This chapter establishes procedures for identifying reporting and tracking deficiencies and warranties on Air Force motor vehicles equipment and the components major ass
517. s not applicable to such units 8 21 1 9 In areas where freezing weather is expected special attention to adequate sealing around windshields is recommended to prevent damage from ice accumulation 8 21 2 Exercise Intervals Unless otherwise specified each vehicle shall be exercised immediately after initial receiving operations and once every 30 days thereafter 8 21 3 Exceptions 8 21 3 1 The pumping system of fuel servicing trucks and semi trailers shall be operated every 30 days to ensure that seals and gaskets of pumps and couplings do not deteriorate A sufficient quantity of fuel shall be maintained in the tanks to permit a cycling operation pumping from and return to the tank Care shall be exercised that pumps are not run dry A check of the differential pressure shall be made every 30 days If the difference between inlet and outlet pressure exceeds 15 psi the filters require replacement Fuel used in cycling operations shall be replaced every 12 months or upon evidence of breakdown Cycling operations require the utmost caution on the part of all personnel Gasoline and most other fuels are extremely flammable and easily ignited Fuel vapors can be lighted by static or friction sparks hot exhaust pipes lighted cigarettes elec trical devices and similar ignition sources Fire guard personnel must be maintained during cy cling operation to watch for fires fuel leaks and any other emergency which could warrant dis
518. s placed in storage and again at least once each 90 days thereafter Parts will not be stored on soft easily marred trim or upholstery Tires will be kept inflated Battery cables shall only be disconnected on those vehicles on NMCS status for electrical problems and where a possibility exists for electrical shorts or excessive battery voltage drop current drainage Batteries shall be removed from vehicles on NMCS status which are subject to climatic extremes or subfreezing temperatures which are projected to exceed 72 hours duration Batteries shall be stored under protective cover in normal room ambient tem perature and kept on trickle charge All other vehicles not on status shall receive upon receipt and prior to process ing a complete serviceability inspection of the entire vehicle and its mounted equipment Use AFTO Form 91 Limited Technical Inspection Motor Vehicles to ensure all On Vehicle Equipment OVE is in accordance with standards Maintain proper storage status on each vehicle 8 53 TO 36 1 191 NOTE Status may be maintained on status lists boards or placement of a locally fabricated placard on vehicle with the following minimum information Vehicle registration number NMCS Disposition date work order number major component part required reason for storage date of last inspec tion Tagged batteries removed from vehicle shall be stored in normal room temperature ambient under protective cover and left
519. s will be on a white or olive drab background depending on vehicle color and local require ments Rear side panel markings for pickup trucks will read SECURITY FORCES and be applied on both side panels flush with the top of the bed rails Markings must be uniform height of six inches have dark blue or olive drab background with 4 inch lettering in white or black depending on vehicle color No additional markings will be applied to the rear of the truck Sedans are marked according to Paragraph 2 88 AII markings for security forces pickup trucks and other un marked vehicles will be applied with a temporary material magnetic or other non permanent adhesive to facilitate easy removal without damaging painted surfaces NOTE Due to differences in vehicles 1 e size of fend ers doors and other panels letter size and location size of security forces shields may vary if the intended location does not allow enough space for application 2 4 ALERT REFLEX BASE OPS AND BASE CIVIL ENGINEER FIRE MARSHAL Marking of these and other vehicles requiring specific iden tification will be accomplished by use of a detachable device The mounting bar NSN 2540 00 409 8878 may be used when approved by the Major Command concerned 2 5 FOLLOW ME VEHICLES The FOLLOW sign will be painted white reflective FSN 8010 965 2500 2 76 LOW VISIBILITY MARKING SNOW REMOVAL EQUIPMENT All snow removal equipment wi
520. ser s complete military shipping address 7 22 2 4 7 Block 10 LEAVE BLANK 7 22 2 4 8 RDD Required Delivery Date Latest date parts are required Required entry for priority shipments 7 22 2 4 9 Blocks 12 17 LEAVE BLANK 7 22 25 If the user feels that the contractor has not fulfilled warranty provisions the user should request assis tance from WR ALC LE 7 22 3 Shipment Warranty claims and exhibits when required must be mailed or shipped to the manufacturer of the equipment subject to the claim 7 23 WARRANTY PROBLEMS Should the dealer refuse to make corrections under the warranty proceed as follows 7 23 1 Contact the zone district or regional service office see OWNER manual or 1 technical order and furnish a full explanation of the difficulty 7 23 1 1 If prompt correction is necessary and the zone district or regional service representative is not readily available proceed with one of the following 7 23 1 2 Instruct the dealer to make the necessary correc tions bill the Air Force activity on open account and hold any replaced parts or assemblies for examination by the manufacturer s representative NOTE Prior to obligating the Air Force for payment advance coordination with Base Contracting of fice is necessary 7 23 1 3 Refer the dealer s invoice to the manufacturer s representative for payment direct to the dealer 7 23 1 4 In Isolated cases where the dealer objects to open billing or
521. servative oil Type I Grade 10 or 30 as applicable operating level shall be attained by addition of the same grade oil Transmission shall be operated through all ranges for a minimum of one minute at a suffi cient engine speed to assure lubricant coverage of all interior parts and surfaces Universal B AV Coat exposed machined surfaces with Type P 1 Joints preservative w 2 5 8 51 TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN COLUMN I II Item Component Level Type of Vehicle Processing Required Winch and other Gear Driven As semblies Windows Windshields Windshield Wiper 8 8 PRELIMINARY ACTIONS 8 8 1 Administrative Ensure that proper inspections have been performed and that any unit involved in carrier claims or manufacturer s warranty action has been cleared for processing Check that reporting actions have been taken as indicated For example Report of Damaged or Improper Shipment Report of Survey or Unsatisfactory Report Check status of maintenance actions such as repair painting or accomplishment of time compliance technical orders 8 52 Winch gear case and other gear driven units and Derrick Assemblies shall contain gear lubricant conforming to requirements of applicable lubri cation order filled to operating level Wire cable shall be unreeled and all surfaces shall be coated with Type P 1 preservative While cable is being Rew
522. sion on the interior of the part resulting in premature structural failure as shown in Figure 6 13 Figure 6 13 Corrosion Accelerated By Condensed Moisture TO 36 1 191 6 17 3 Open Cell Foam Open cell foam see Figure 6 14 acts as a sponge like material used mainly for sound suppression and insulation Humidity condensation rainfall cleaning wash water etc is absorbed into the foam and ultimately migrates to the mating metal surface to which it is attached The absorbed moisture is very slow in drying out and provides the moisture electrolyte against the metal sur faces When possible open cell foam should not be used Closed cell types of foam may be suitable substitutes for this material and will not absorb moisture If open cell foam is the only material suitable for your needs prior to installation in the vehicles seal all open cell surfaces with a polysulfide type sealant such as MIL PRF 81733 Also seal the sides of any perforations in the foam to prevent moisture absorption 6 17 4 Salt Atmospheres When dissolved in water salt particles form electrolytes The ocean which is 3 5 percent to 3 9 percent salt is the world s primary source of salt Normal sea winds carry from 10 to 100 lbs of sea salt per cubic mile of air Because dissolved salts are strong electro lytes it is easy to understand why coastal environments are listed in the moderate to very severe corrosion prone catego ries 6 17 5 Industr
523. st maximum protection requirements It may be used at temperatures as low as 40 F c Grade 3 A thin soft film CPC Use MIL C 81309 Type III as a substitute d Grade 4 A thin relatively dry semitransparent film through which identification can be read It may be used at temperatures as low as 40 F e Grade 5 A soft film low pressure steam removable CPC 6 15 9 5 MIL PRF 63460 is a thin water displacing protective penetrating lubricant used for cleaning lubrication and preservation of components This material has good lubricating properties between 65 and 105 F 54 and 41 C It may be applied by brushing dipping or spraying 6 15 9 6 MIL L 87177 Lubricants Water Displacing Synthetic is a water displacing electronics grade CPC with 6 39 TO 36 1 191 vapor corrosion inhibitors VCI This material is specifically formulated for electrical electronic equipment and compo nents This material does not alter the electrical resis tance or magnetic properties of metal substrates The approved material can be safely applied to protect low voltage circuits or relays without causing any changes in conductivity It can be safely used with most plastics elastomers and other nonmetallics 6 15 10 Sealers and Sealant Usage 6 15 10 1 Many sections of the vehicles contain joints and flanges The use of an appropriate sealer to prevent the entry of water and contaminants into crevices and joints is a
524. stalled on vehicles that do not have the original manufacturer s data plate This plate may be manufactured from available mate rials and the size determined by individual application Information to be recorded on data plate is as follows a Manufacturer s serial number e g 00513 b USAF vehicle number e g 87L03431 if serial number or VIN is unknown Since chassis and or engine serial number is essential data required by most states for obtaining certification of title disposal officers are required to enter the serial number on the Standard Form 97 Certification of Release of a Motor Vehicle prior to sale Therefore serial numbers will not be removed from vehicles or engines unless directed by specific authority 1 5 5 New Vehicles Acceptance Inspection All new vehicles received from a manufacturer will be inspected by the first Air Force activity which receives it An AFTO Form 91 will be accomplished New items found to be unacceptable as the result of manufacturing defects will be processed as outlined in Chapter 7 1 5 5 1 Serial Numbers Vehicle Identification Num beror VIN Vehicle chassis and engine serial number will be checked and recorded on the acceptance inspection Engine serial numbers if applicable will be maintained Before transfer of vehicles to another organization or dis posal the vehicles will be inspected to assure serial numbers are recorded 1 5 5 2 The manufacturer normal
525. stalled when turned in for disposal If a tire is removed and not replaced an appropriate entry will be made in block 122 of the AFTO Form 91 If the tire and wheel are removed as a unit a like size replacement wheel will be installed on the vehicle 4 48 4 When serviceable tires are not removed due to absence of the situations listed in Paragraph 4 50 an appro priate explanation will be made in block 122 of AFTO Form 91 4 49 CRITERIA FOR REMOVAL OF TIRES At least one of the following situations must prevail before serviceable tires are removed from a vehicle 4 49 1 The stock of like size tires in the supply point of the vehicle management activity is below established operating level and or the stock in Distribution Flight is below retention level and there are no tires due in to fulfill this requirement 4 49 2 Vehicles in the local fleet are equipped with like size tires that will soon need to be replaced 4 49 3 Distribution Flight has unfilled requisitions for like size tires 4 50 TIRES CONSIDERED UNSERVICEABLE ON EQUIPMENT BEING PROCESSED FOR DISPOSAL A tire having any one of the conditions listed below as detected by visual inspection will not be removed from a vehicle being processed for disposal 4 50 1 Less than one half the original or retreaded tread remaining applicable up to and including 16 inch size tires 4 50 2 Less than one quarter of the original or retreaded tread remaining applicable
526. such severe climatic conditions as hail lashing rain heavy snow etc 8 24 DETAILED PROCEDURES 8 211 Preparation For Storage 8 21 1 1 Cleaning Following initial receiving inspection and removal of any processing materials such as tape strippable coatings and other preservatives the vehicle shall be thoroughly washed Subsequent cleaning shall be accom plished only as necessary in support of inspection and exercise operations Care shall be taken to prevent damaging of critical components such as electrical units control panels and similar items NOTE If storage is located in areas where a highly saline atmosphere exists a periodic fresh water wash down of all equipment is recommended If paint on the vehicle shows excessive oxidation wax per P W 120 should be applied at discretion of the 8 21 1 2 Depreservation Any depreservation required to place the vehicle in operational status shall be accomplished OVE not essential to operational readiness may be stored in processed condition If OVE is removed for inside storage the equipment for each vehicle shall be segregated and adequately identified to expedite reloading upon call The vehicle shall be tagged to require replacement of OVE prior to shipment TO 36 1 191 8 21 1 3 Assemblies such as crankcase differentials gear cases and transmissions shall as required be drained flushed and filled to operating level with the prescribed lubricant
527. surfaces without the use of barrier materials Exterior surfaces Seams joints behind mold ing strip window trim and other hard to reach areas 4 2 3 6 Material Class 1 Grade 3 Class IL Grade 4 Transparent non tacky soft film Corrosion Preventive Compound Water Displacing Clear AMLGUARD MIL DTL 85054 Type I Aerosol Type II Bulk form Corrosion Preventive Compound Water Displacing Ultra Thin Film MIL C 81309 Type II Soft film Class 1 Non pressurized Class 2 aerosol con tainer Type III Soft film avionic grade Class 1 Non aerosol Class 2 aerosol Lubricant Cleaner and Preservative for Weapons and Weap ons Systems CLP MIL PRF 63460D Corrosion Preventive Compound Electron ics Grade with VCI Unit of Issue Qt Qt Pt GI 1 GI Cn 5 Gl Dr 55 Gl Cn 12 oz Cn 16 oz Bt 32 oz Qt Cn 5 Gl GI 1 Gl Cn 5 Gl Dr 55 Gl Cn 16 oz GI 1 GI Cn 16 oz BT 4 OZ Squeeze PT 16 OZ Sprayer QT 32 OZ Sprayer GL 1 GAL Cn NSN 8030 00 935 7163 8030 00 926 2280 8030 01 396 5738 8030 01 396 5743 8030 01 347 0972 8030 01 396 5736 8030 01 066 3971 8030 01 041 1596 8030 01 347 0983 8030 01 347 0981 8030 01 347 0982 8030 00 213 3279 8030 00 262 7358 8030 00 524 9487 8030 00 938 1947 8030 01 347 0978 8030 00 546 8637 9150 01 079 6124 9150 01 054 6453 9150 01 327 9631
528. systems and will automatically exchange selected data OLVIMS will prepare an FCI record for each replacement code change The records will be melded with REMS for input into the Standard Base Supply System which will update the REMS file 5 6 EXCEPTIONS Separate procedures govern Air Education and Training Command training vehicles vehicles withdrawn from dis posal obsolete vehicles and special mounted equipment 5 6 1 Air Education and Training Command AETC training vehicles will be assigned replacement code T and will remain in this code until AETC decides that replacements are needed The decision to replace these vehicles will be based on overall condition When required select an appli cable replacement code from this chapter to identify the vehicle lead time away from replacement 5 6 2 Do not assign replacement codes to vehicles with drawn from the Defense Reutilization and Marketing Service DRMS and issued as training mockups 5 6 3 Special mounted equipment is defined as equipment which is not an integral part of the vehicle and is not included in the basic stocklist description for the vehicle Examples are test equipment radar equipment communications equip ment photographic equipment generator sets and repair equipment mounted in or on general purpose trucks trailers semi trailers or vans 5 6 3 1 When figuring repair cost estimates exclude the cost of repairs to special equipment 5 6 3 2 When t
529. t is provided keys shall be placed a waterproof bag conforming to MIL B 13239 Type B 2 material The bag shall be securely attached to the steering column 8 39 TO 36 1 191 COLUMN I Item 72 73 74 75 76 77 78 8 40 COLUMN II Component Lamps Lights and Reflector Lenses Landing Gear Levers Gear Lights Locks Including Padlocks Latches Mats Floor Mirrors Rear View Table 8 2 Processing Procedures Continued COLUMN A B A B A B A B III Level COLUMN IV Type of Vehicle AV ST AX AX AV AV AV AV AX COLUMN V Processing Required S For rail shipment only exterior lamps lights and reflector lenses shall be completely covered with Kraft paper The paper shall be covered and secured with tape conforming to Specifica tion MIL T 43115 level B MIL T 22085 level A b Lamps lights and reflector lenses removed from the vehicle shall be preserved in accor dance with Method IC 5 of Specification MIL P 116 Coat all exposed unpainted machined metal sur faces and threaded surfaces requiring occasional turning in operation of the unit with grease con forming to Specification MIL G 10924 Exposed unpainted non critical surfaces shall be coated with Type P 1 preservative Place lever in disengaged position To prevent water from entering transmissions through un protected openings seal openings with water proof tape conforming
530. t be used 3 10 2 2 Inspection Testing and Servicing Water Seg regators Clean and service every three years or when filter elements are changed Water drain valves and water block valves will be serviced as outlined in applicable equipment technical manuals at intervals prescribed above NOTE Vehicle Management will inform the fueler con trol center any time the pumping system is open Name of person notified date and time will be annotated on the AF Form 1807 3 10 2 3 Perform spark check for aircraft servicing and other vehicles equipment designated for concurrent refueling operations in accordance with TO 00 25 172 3 10 2 4 Quinquennial Testing Cryogenic Fuel Trailer Tube Bank Trailers 3 10 2 4 1 This test will be performed at five year inter vals 3 10 2 4 2 Normally facilities do not exist at Air Force bases for quinquennial testing of cryogenics fuel trailers Base vehicle management coordinating with base fuels will program their requirements in accordance with Chapter 9 Intermediate and Depot Repair of USAF vehicles and vehicle components Advanced planning is required to insure tests are completed as scheduled 3 10 2 5 Tank Inspections Tank inspections will be conducted IAW Table 3 2 of this technical order Title 49 Code of Federal Regulations Part 180 401 through Part 180 417 and or end item technical manuals 3 10 2 5 1 Vehicles not in commerce only require internal external inspection
531. t practical size affixed to read white background with red letters SOUND HORN WAIT FOR SIGNAL FROM OPERATOR BEFORE PASSING 2 1 7 Rollerized vehicle beds K Loaders and flatbed trailers will have the legend WATCH STEP applied on the walkway at each end of the rollerized beds The legend will be stenciled in 3 inch letters at one foot intervals beginning at each end of the rollerized bed and extending inward for 4 feet The legend will be applied using yellow paint on black and green surfaces and black paint on yellow surfaces 2 2 CONTINENTAL OR LYCOMING AIR COOLED ENGINES vehicles equipped with Continental or Lycoming air cooled engines will have the auxiliary engine oil which is specified in the applicable technical order either stenciled or taped on a body panel near the engine or on the access door to the engine using 1 2 inch letters When applying this information by stenciling use white paint on red surfaces and black paint on yellow surfaces When using tape apply red tape with silver numbers EXAMPLE Auxiliary Engine Oil Specifications Grade 2 3 MARKING SECURITY FORCE VEHICLES Security Forces pickup trucks and unmarked vehicles used for security duties shall be marked as follows Security force badge decal will be centered on both front doors using a temporary adhesive type material example magnetic or 3M vinyl easily removable without damaging painted surfaces Security force badge
532. te 150 Copely OH 44321 4 37 USE OF STUDS IN TIRES Tire studs may be used when state laws permit and when their use is required to maintain operational capability on ice and snow Their use shall be determined jointly by the vehicle operations and VFMs with the coordination of FOD safety officers and civil engineering where applicable The follow ing instructions apply 4 37 1 Studs should be applied to all drive wheels 4 37 2 Studs are not recommended for military mud and snow tread 4 37 3 When installing studs consider the cost involved in removing such tires and storing them during summer months Studded tires will not be used during summer months 4 37 4 Casings will not be submitted for retreading if studs are or have previously been installed 4 37 5 Do not stud used pre drilled tires Experience has shown that small rocks become embedded in the holes and the stud may push the rock through the casing 4 37 6 Studded tires will not be run on the chassis dynamometer as the studs will severely damage the rollers The pre mold designed tire treads are best suited for studding However any tire is suitable if it meets the tolerances provided in the stud instal lation instruction data This data with the neces sary tools is furnished in a kit The required studs will be local purchased as needed 4 38 TIRE INFLATION Tire inflator cage NSN 4910 01 333 3504 part No SP88 is authorized and certified by the AF
533. ted or pitted to the extent proper fit is impaired Wheel lug bolt holes shall not show evidence exceeding 1 8 inch out of roundness condition Lug bolts nuts shall all be present and have proper torque 1 7 2 129 2 Drive Sprockets Drive sprocket shall not be worn more than 1 16 inch on driving face The throat or track guiding surfaces of sprocket flanges shall not be worn more than 1 8 inch deep at any point Idler flanges shall not be worn more than 3 16 inch deep at any point on track guiding surfaces Bogie top rollers shall rotate freely and will be free of flat spots on the cylindrical surfaces Idler shackles shall swing freely on the idler post 1 7 2 129 3 Tracks Rubber or steel tracks shall have at least 1 2 of their original usable treads thickness intact and shall be free of cuts grooves cracks or other damage likely to cause early failure The usable thickness of these treads is approximately 1 4 inch The track blocks shall not vary more than 1 8 inch in thickness Road Pads if installed will have a minimum of 50 percent of pad life remaining 1 7 2 130 Windshield And Windows 1 7 2 130 1 Windshield and windows shall not be clouded or have foggy areas extending more than 2 inches from edge of glass The glasses shall not have cracks with a radius of 25 percent of the length or width of glass or in accordance with local laws manufacturers manuals guidelines whichever are more stringent Cracks extending to op
534. ted from noncorrosive material 36 inches long by 13 inches wide For Beta Systems R 12 the panel will be mounted on the outside sheet metal of the chain guard of the hose reels Two locally manufactured flat stock brackets for outer support will be required For the Kovatch R 12 the panel will be mounted to the top of the hose reel frames One locally manufactured support bracket will be required for the left side TO 36 1 191 FO9603 122 FO9603 123 NOTE Markings presently applied to the Hydrant Fuel ing Trucks will not be changed until they are damaged or deteriorated to the point that replace ment is necessary F09603 002 EXHIBIT A MANHOLE COVER MARKINGS 2 19 TO 36 1 191 2 65 PURGING FLUID VEHICLES Vehicles used for handling purging fluid shall be marked as follows 2 65 1 The product marking PURGING FLUID shall be stenciled on both sides and rear of the tank in 6 inch black letters color number 17048 2 65 2 The product marking PURGING FLUID shall be stenciled adjacent to the manhole covers in l inch black letters color number 17038 2 65 3 The following statement shall be stenciled in 1 inch black letters color number 17038 on both sides of the tank immediately below the product marking Do not use for any purpose other than purging fuel tanks 2 66 WASTE FUEL VEHICLES vehicles used for handling waste fuel shall be marked as follows 2 66 1
535. terials processes and levels of protection to be incorporated in or performed upon Air Force AF vehicles or equipment for corrosion prevention and control Paragraph 6 1 through 6 13 contain general information pertaining to the scope of this publication reference publications definitions AF policy responsibilities and levels of corrosion preven tion Figure 6 1 Commercial General Purpose Vehicles and Figure 6 2 Special Purpose Vehicles depict proper areas to apply corrosion preventive materials Refer to the figures in this chapter for the application of preventive materials on military type vehicles Table 6 2 rates AF installations as to the corrosive susceptibility of vehicles at or within close proximity to the installation This table also includes the minimum effective wash cycle for the specified corrosion severity zone the equipment is assigned to or operating from Paragraph 6 15 provides the local installation commanders and vehicle fleet managers with the knowledge based tools to establish an effective corrosion prevention and control pro gram 6 3 REFERENCE PUBLICATIONS AFI 24 302 Procedures for Vehicle Maintenance Man agement AFI 121 105 Air and Space Equipment Structural Main tenance TO 00 USAF Deficiency Reporting and Investiga 35D 54 tion System TO 1 1 8 Application and Removal of Organic Coat ings Aerospace and Non Aerospace Equipment TO 1 1 691 Aircraft Weapon Systems Cleaning and Corrosion Control
536. th any mechanical or electrical functioning of the vehicle 6 12 8 Inadequate coating of inner surfaces in corrosive environments will quickly result in internal destruction of parts or assemblies beginning in the hidden or inside areas and working outward Therefore the corrosion preventive measures that must be considered are twofold 1 provisions for protection of exposed surfaces and 2 provisions for protection of inner surfaces which are often completely bare metal without any prior protective coatings Some rocker panels brackets braces hood areas and center posts may have hidden baffles Probing with applicator wand will locate these potential blockages and determine need for hole drilling and treatment Both sides of such baffles should be coated 6 13 FOLLOW ON APPLICATION 6 13 1 Spot rustproofing is required to protect an area of the vehicle that has had the corrosion preventive material removed due to accident or damage or where corrosion is evident 6 13 2 Clean affected area by method described in Para graph 6 11 3 6 13 3 Rustproofing materials and CPCs will deteriorate over time and will require occasional reapplication Most corrosion preventive compounds can be effectively used over previously applied rustproofing if these old coatings are still tightly adhered to the vehicle 6 13 4 Apply corrosion prevention compounds per graph 6 12 6 14 TABLES OF APPLICATION Areas described in Fi
537. th plastic caps or with tape except electric tape conforming to Specification pow ered MHE SAE AMS T 22085 Wet batteries Batteries shall be Secured in place in vehicle battery carrier Maintain batter ies fully charged COLUMN I Item TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN II IV V Component Level Type of Vehicle Processing Required d Dry batteries Batteries shall be secured in place in vehicle battery carriers The vent holes in the filler cap shall be plugged or sealed The electrolyte shall be packed in accordance with O S 801F and stowed as specified under Level A requirements above NOTE When a unit has been in Level B stor age for the maximum 90 day period and determination is made to reprocess Level B it is recommended that wet type batteries be removed from closed type cabs or bodies and maintained un der protective storage in a fully charged condition or replaced with dry charged batteries as determined by the respon sible storage officer Wet type batteries becoming excess under this procedure will be reported as prescribed under Level A above Batteries and A MH Electric powered materials should be placed in cables elec inside storage when such space is available tric powered When the materiel handling equipment cannot materials be placed in inside storage the battery will be handling removed pending shipment and placed in pro equipment tected st
538. these procedures may be used to supplement the storage facility complement of vehicles provided that such use is compatible with the readiness requirement Use must be sufficient to meet the periodic exercise requirement and vehicles so used shall be rotated with like models in storage so that such usage is maintained at a minimum If use does not include exercise of mounted accessories and auxiliary equipment the requirement for 8 56 periodic exercise of these components shall be accomplished When this document is used contractually permission to use stored equipment must be obtained from the contracting officer or his authorized representative 8 17 OPERATING PERSONNEL Drivers and operators assigned to exercise equipment must be adequately skilled and experienced No operator shall be assigned to exercise any item of special purpose equipment who is not familiar with that particular vehicle and its accessories When this document is specified contractually the contractor shall furnish a certificate of competency for each driver and operator including a listing of the equipment covered by this certificate 818 TCTO S Accomplishment of time compliance technical orders TC TO s is required TCTO action shall be posted to vehicle records Vehicles in long term storage in flexible storage containers will have TCTO s installed during next major inspection 819 REPAIR Vehicles requiring repair will be immediately reporte
539. ting Always use the cement recom mended by the patch manufacturer Apply thin coat of recommended cement to the prepared and buffed surface Allow to dry thoroughly 4 27 3 2 3 Patch Application Apply hot vulcanizing patch and cure according to manufacturer s recommenda tions 4 27 3 8 Head Type Plug Repairs 4 27 3 31 Cementing Always use the cement recom mended by the plug manufacturer Apply a thin coat of chemical vulcanizing cement to the prepared and buffed surface Allow to dry thoroughly 4 27 3 3 2 Plug Insertion Remove backing from stem and plughead Pull through according to manufacturer s recommendations 4 27 3 3 3 Stitching To prevent injury to personnel exercise caution when using sharp or pointed tools Stitch plughead down firmly with stitching tool working from center out 4 27 3 4 Finished Repair There are a number of satis factory methods of repair Regardless of type of repair used finished repair should seal the inner liner and fill the injury After inflating check finished repair with water or soap solution to assure complete seal Observe tire mounting precautions in Paragraph 4 27 3 4 1 through 4 27 3 4 9 below 4 27 3 4 1 Clean rim 4 27 3 4 2 Lubricate both tire beads with approved lubri cant 4 27 3 4 3 Lubricate bead ledges and flanges of rim 4 27 3 4 4 Center tire on rim 4 27 3 4 5 Use extension hose with gauge and clip on chuck See Figure 4 14 4 27 3 4 6 Stand
540. ting condition with a 2 mil anchor profile Industry specifications for zinc metalized coatings typically call for a 46 mil thick coating For aluminum a 10 mil coating is required due to the differing protection mechanisms provided by the two metal coatings The metalizing process produces medium to high local noise levels metal oxide fumes and ultra violet radiation emissions from the arc region of the spray unit During initial metalizing process planning consult your local bioenvironmental engineer for the proper hearing protection respi ratory and other personal protective equipment PPE approvals 2 17 6 The porous nature of metalized coatings allow deep penetration of a liquid sealer or coating and result in a dry to the touch condition in less than 20 minutes under high humidity ambient conditions even without the benefit of baking 2 17 6 1 The liquid sealer or coatings are not required but do provide additional corrosion protection or colorization NOTE If left unsealed un top coated the 85 15 percent zinc aluminum alloy sprayed surfaces will age to a dark gun metal gray color The unsealed uncoated 100 percent aluminum will retain its silver color 2 17 6 2 high temperature components metalized with aluminum organizations may use METCOSEAL SA silicone aluminum sealer to prevent any rust staining that may occur This sealer is available from METCO INC 1101 Prospect Avenue Westbury N Y 11590
541. tion Point 7 7 DEFICIENCY TYPES 2 455284 771 Design Deficiency 7 1 Maintenance Deficiency 7 1 3 Materiel Deficiency 7 74 Quality Deficiency 7 8 REPORT CATEGORIES 7 8 1 Materiel Deficiency Report MDR 7 8 2 Vehicle Unsatisfactory Report 7 8 3 Action Warranty Report AWR 7 8 4 Info Only Warranty Satisfactory Report IWR 7 9 GENERAL RR GC 7 91 Certifying Official 7 9 2 Materiel Improvement Project MIP soe hee Reb E 793 7 94 Exhibit Holding Activity Page 6 40 6 40 6 40 6 40 6 41 6 41 6 41 6 50 6 51 6 51 6 51 6 51 6 51 6 52 6 52 6 52 6 52 6 53 6 53 6 53 6 53 E aaua ooo oou ood oco 1 N N eee uo NN 7 2 7 2 7 2 7 2 7 2 7 2 TO 36 1 191 TABLE OF CONTENTS CONTINUED Chapter Page Chapter Page 7 9 5 Warranty Items 7 2 7 31 REPORTING 4 24 2 65 235 46 ge 8 7 18 7 10 GENERAL PROCEDURES 7 2 7 32 VIWG MEMBERS 7 18 7 11 METHOD OF REPORTING 7 2 7 12 M ocu AND COMMUNICA d5 8 STORAGE AND SHIPMENT 8 1 713 PURPOSE T 7 14 GENERAL WARRANTIES 72 8 1 7 15 RESPONSIBILITIES Pu EE 7 2 8 3 RESPONSIBILITY FOR PROCESS 7 16 COMMUNICATION 7 3 ING AND DEP
542. to Rico and the Virgin Islands the warranty shall include the furnishing of new parts or assem blies to replace any returned to the contractor by the Gov ernment which failed or malfunctioned within the warranty period The replacement parts or assemblies shall be deliv ered by the contractor to the port of embarkation in the United States designated by the Government Required port of embarkation and priority are identified to the contractor by means of the claim letter and Military Shipment Label DD 09603 099 Deficiency Report Sheet 2 Form 1387 as specified in Paragraph 7 22 2 4 In addition to warranty parts identified by the user contractors often iden tify deficiencies through factory recall or service bulletin programs Contractors will often request an address for shipping the parts to an overseas location VFMs are re minded of possible problems with delayed shipments due to customs restrictions Providing the contractor with a Military Shipment Label DD Form 1387 may be necessary should priority shipment be required The contractor shall not be required to bear the cost of the labor involved in correcting defects in vehicles operated in foreign countries 7 5 TO 36 1 191 7 17 6 1 Delayed Delivery Warranties To provide additional extended warranty based on the in service date for vehicles being shipped overseas Delayed delivery forms may be used by the user to annotate the actual delivery in service date i
543. to Specification MIL T 22085 Openings too large to tape may be shrouded with waterproof paper conforming to MIL B 13239 grade B sealed to the shift lever and secured over the tower using the same type tape as above b Lubricate operating parts with grease conform ing to Specification MIL G 10924 Coat un painted metal surfaces of hand grips handles and levers with Type P 1 preservative See Item 72 See 71 Locks and padlocks shall be lubricated with lybdenum disulfide conforming to Specification MIL M 7866 Latches shall be lubricated with VV L 800 Type P 9 preservative oil Unpainted metal exterior surfaces shall be coated with Type P 1 preservative Floor mat shall be removed from soft top or open cab vehicles rolled tied and packed and stowed as prescribed for OVE No processing required Mirrors need not be removed for storage For rail or surface water shipment removal of mirrors is recommended to prevent breakage of pilferage Removed mirrors will be properly cushioned packaged in fiberboard boxes and stowed in the driver s or passenger s compartment of hard top vehicles or packed and stowed for soft top ve hicles with other boxed material TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN I II III IV Item Component Level Type of Vehicle 79 Motors Air A SE except windshield SE 80 Motors Elec B SE tric 81 Mufflers 82
544. to tires above the 16 inch size tire 4 50 3 Less than 1 16 inch of the original or retreaded tread remaining applicable to special and high cost tires 4 50 4 A break or cut in the tread or sidewalls 4 50 5 A bump bulge or knot caused by separation or failure of tire structure 4 50 6 Circumferential cracks within the tread 4 50 7 Radial cracks 4 50 8 Damaged by excessive heat 4 50 9 Evidence of separation between tire carcass and retreaded tread 4 50 10 Not suitable for retreading 4 50 11 Sectional repaired 4 50 12 Tread and side walls deteriorated with the tire structure hard and brittle 4 50 13 Evidence of other conditions prevailing which through the determination of the VFMs make the tires unsuitable for use 4 51 CONTROL OF TIRES Issue turn in and control of tires sourced through SBSS will be accomplished in accordance with DIFM control proce dures Tires codes XF are subject to repair cycle asset control The DIFM control system is basically a positive system which requires a return of a tire same size serviceable or unserviceable for every tire issued NOTE Excess tires will not be turned in to FB 2065 or FD 2060 account If inspection reveals that cost and or condition of tire s are such that further use is anticipated they will be reported to Army Tank Automotive Command DRSTAFOGA source AKZ for disposition instructions 4 52 SUPPLY POINT In order to provide a stock
545. trons easily such as magnesium and aluminum corrode easily and are listed at the top of Table 6 3 The most noble metals 1 those that do not lose electrons easily such as gold and silver do not corrode easily and are listed at the bottom of Table 6 3 6 16 6 Types of Corrosion Corrosion is cataloged and classified in many ways and the treatment of the corroded area may differ based on the metal substrate and type of corrosion Occasionally different names are used for the same type of corrosion Common types of corrosion are described below 6 41 TO 36 1 191 6 16 6 1 Uniform etch corrosion see Figure 6 5 results from a direct chemical attack on a metal surface and involves only the metal surface On a polished surface this type of corrosion is first seen as a general dulling or etching of the surface and if the attack continues the surface becomes rough and possibly frosted in appearance This type of corrosion appears uniform because the anodes and cathodes are very small and constantly shift from one area of the surface to another An example is the etching of metals by acids The discoloration or general dulling of metal created by exposure to elevated temperatures is not considered to be uniform etch corrosion el Figure 6 6 Galvanic Corrosion Steel Hinge Bolted To An Aluminum Door 6 16 6 2 Galvanic corrosion is usually described as corro sion between two or more dissimilar metals that are in electri
546. tured Vehicles Assign while vehicle is under new vehicle or remanufacture warranty 5 31 SPECIAL INSTRUCTIONS 5 31 1 Codes A thru D 5 31 1 1 Assign codes A thru D only when the vehicle in addition to meeting other criteria for replacement except Code D requires repairs which would exceed the one time repair allowance AND the repair approval authority has ruled that the repairs need not be made In making this determina tion the approval authority will ensure that the repair estimate includes only those costs which are chargeable against the one time repair allowance 5 31 1 2 After the vehicle is coded A thru D it may remain in service if its condition does not present a safety hazard to personnel or equipment or until the vehicle is not longer operable 5 31 1 3 When approved by the appropriate authority as outlined in Paragraph 5 23 minimum essential repairs may be made to keep the vehicle operable 5 31 1 4 Place work order showing the major repair requirements used to establish codes A thru D in the vehicle record jacket If a later decision is made to accomplish the major repairs the vehicle management activity must ensure that the repair is recorded 5 31 1 5 OLVIMS bases will document delayed mainte nance according to AFI 24 302 5 31 1 6 Non OLVIMS bases will flag the vehicle historical record for vehicles assigned codes A thru D and code S 5 31 2 Upon receipt of a vehicle from depot rebuild
547. types both of which can be applied by dipping spraying brushing or an aerosol container They provide temporary protection from corrosion and are easily removable with a solvent The two types primarily used for vehicles are Types II and III a Type Type is soft thin CPC film for general use It is particularly useful on moving or sliding parts where some lubrication is needed such as hinges or bomb racks It may be washed away by rain or wash proce dures Type II shall be used to protect areas which cannot be properly drained or contain recesses that are particularly difficult to reach b Type Type III is an ultra thin soft film CPC primarily used on avionics and electronic equipment Although this coating is nonconductive it will allow electrical contact because it is soft and very thin Do not use MIL PRF 16173 Grade 3 as a substitute 6 15 93 MIL DTL 85054 Corrosion Preventive Com pound AMLGUARD is a water displacing CPC that forms a clear dry flexible film It is intended for use as a protective coating until painting is practical Because of its paint like TO 36 1 191 characteristics it does not provide lubrication It can be applied by dipping brushing spraying or from aerosol containers After each use of an aerosol can invert the can and spray until spray tip nozzle is clear of entrapped material If an aerosol can does not spray invert and depress the spray tip several times to clear the de
548. uce lubrication and return vehicle to service Process in accordance with TO 38 1 5 See Item 83 On Vehicle Equipment Unpainted surfaces of exhaust system except manifold shall be coated with Type P 1 preser vative or enamel conforming to Specification MIL 5557 When required for reduction in cube upper section of vertical tailpipe shall be removed coated with Type P 1 preservative and stowed with other OVE Opening of vertical tailpipes unless protected by a rain cap or opening left by disassembly shall be sealed with tape conforming to Specification 22085 When required for reduction in cube upper sec tion of vertical tailpipe shall be removed coated with Type P 1 preservative and stowed with other OVE Opening of vertical tailpipes unless protected by a rain cap or opening left by disas sembly shall be sealed with tape conforming to Specification MIL T 43115 portable hand type fire extinguishers shall be packaged in accordance with Method IC 5 of MIL P 116 and packed in OVE boxes except those mounted in equipment compartments ad equately protected against pilferage during tran sit and storage Boxes shall be clearly marked to indicate contents and date of last cylinder test Coat unpainted surfaces of fifth wheels and upper fifth wheel plates and king pins with Type P 1 preservative TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN COLUMN
549. uding impellers ro tors rotor shafts pistons piston rods air cham bers vanes vane slots valves valve rods thrust pins cylinder walls oil air steam or water pas sages and gears shall be sprayed with MIL C 18382 Type P 14 preservative When applicable spraying shall be accomplished while slowly actuating pump Top or end casing of two stage or larger pumps with horizontally or vertically split casings shall be removed and coated with Type P 14 preservative Pump shall be allowed to stand with drain plug removed until preserva tive flow ceases Plug shall be coated with the Type P 14 preservative and reinstalled Other openings leading to interior pump shall be closed with threaded cap plugs or tape con forming to Specification MIL T 43115 level B MIL T 22085 level A Preservative oil P 10 Type 1 Grade 30 may be used to process inte rior surfaces of water pumps where potability is not a consideration NOTE The water foam systems of fire crash and rescue trucks must be thoroughly flushed with water at all levels of stor age VDP etc in accordance with di rectives and or the procedures specified in applicable operation and service handbooks If inspections show this had not been accomplished this action will be accomplished immediately Racks A AV Where the racks do not increase the shipment cube or present an obstacle to slinging where overseas shipment is anticipated they may be left in the install
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551. ufacture of a part and remain concealed in the part unless stress relief operations are used Other hidden stresses are induced in parts when press or shrink fits are used and when slightly mismatched parts are clamped together with rivets and bolts All these stresses add to those caused by applying normal loads to parts in operation Metals have threshold stresses below which stress corrosion cracking will not occur This threshold stress varies from metal to metal depending on the characteristics of the applied stress The following conditions must be present for SCC to occur The component or structure must be under a tensile stress This tensile stress may be provided by an externally applied service load or a residual stress resulting from manufacturing procedures such as roll ing punching deep drawing or welding The material must also be exposed to an environment that causes SCC Whereas all metals will form stress corrosion cracks in some environ ment under the proper conditions there is no one environ ment that causes SCC in all metals SCC is most prevalent and of the most concern in high strength steels stainless steels mostly in the austenitic group high strength alumi num alloys 2000 and 7000 series copper based alloys and titanium alloys 6 16 6 8 Hydrogen embrittlement is the weakening of materials such as high strength steel typically 180 Ksi and above some high strength aluminum and some stainless steels when t
552. uired 8 47 TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN I II Item Component Level Type of Vehicle 108 Systems Elec A AV trical B AV 109 Systems A SE Heating and Pumping Asphalt 8 48 COLUMN V Processing Required These systems are normally resistant to corrosion therefore the procedures below are suggested and are to be implemented at the discretion of the responsible storage officer as required by local climatic conditions length of storage and type of storage afforded When equipped with lubricating points lubri cate generator starter distributor or magneto with a few drops of P 10 Type I Grade 30 pre servative oil Remove cover and rotor from the distributor or magneto Wipe interior with a clean soft cloth saturated with petrolatum Specification VV P 236 avoiding contact points Where there is evidence of corrosion in starters or generators disassemble clean and coat inte rior of housing with insulating varnish Specifi cation MIL V 13811 avoiding current carrying contact areas Tape all openings with MIL T 22085 tape and spray assembly with the varnish prescribed above Electric Material Handling Equipment Coat all exposed contact points with MIL L 3150 P 7 preservative oil or MIL C 81309 Spray panels and wiring with insulating varnish MIL V 13811 taking care to avoid coating contact sur faces Tape opening around cover on
553. uiting Service The identification markings required by Section III of this Tech nical Order are mandatory 213 PAINTING OF VEHICLE TOPS WHITE 2 13 1 MAJCOMs have the option to approve painting tops white on sedans No approvals will be granted for use below the Wing Base Commander or equivalent level In agreement between HQ USAF ILGM and HQ GSA Fleet the only authorized White Top on Wing Commander s GSA leased vehicle is 3M Controlac Plus Graphic Film or other approved equivalent The using organization is responsible for all application and removal costs including vehicle appearance damage or paint mismatch caused by the process 2 13 2 The tops of ambulances and convertible buses may be painted white in areas where extreme heat is prevalent and vehicles must remain stationary for extended periods of time with patients remaining on board When authorized by the MAJCOM the LRS Vehicle Fleet Manager may approve painting bus tops white providing the paint used is base coat white polyurethane clear coat The painted portion should extend to but no lower than the side windows 2 13 3 With MAJCOM approval vans and semitrailer vans used for communications photographic repair shops etc in which assigned personnel perform duties and are located in areas where extreme heat is prevalent may have the tops painted white 2 134 With MAJCOM approval special purpose con struction and base maintenance vehicles used in areas where
554. upply before inserting duct into manhole opening This is to prevent fuel vapors from entering duct and into blower 8 22 3 7 6 Place blower air supply 50 feet upwind of fuel servicing vehicle Ground the blower to the static ground 8 22 3 7 7 Connect duct to outlet side of blower air supply 8 22 3 7 8 Start blower air supply 8 22 3 7 9 Ground duct to the vehicle 8 22 3 7 10 Insert duct in manhole secure with tape or tie to vehicle Remove duct from manhole opening before shut ting off air supply when taking combustible gas readings Allow 10 minutes after removing duct before taking reading 8 22 3 7 11 Purge tank for two hours NOTE During purging operation observe that air is being expelled at all drain openings Trapped fuel may prevent air from being circulated through all drains In the event air is not coming out of a drain temporarily close all other drains and observe if trapped fuel is expelled Reopen drains 8 22 3 7 12 Measure explosive vapor level of tank using combustible gas indicator LEL readings should be 20 percent or less Make readings in several areas of the tank If reading is above 20 percent of the LEL resume purging operation step 8 8 22 3 7 13 obtained Purge for one hour after safe reading is 8 22 3 7 14 Remove duct from manhole opening before shutting off blower air supply 8 22 3 7 15 Close all valves including main tank shutoff valve and low point drains Leave manhole
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556. ure regulator preset to a desired valve shall be furnished by the employer and used to inflate tires 4 36 5 1 area Current charts shall be available in the service 4 36 5 2 current rim manual containing instructions for the type of rims being serviced shall be available in the service area 4 36 5 3 The employer shall assure that only tools recom mended in the rim manual for the type wheel being serviced are used to service multi piece rim wheels 4 36 6 Wheel Component Acceptability 4 36 6 1 Wheel components shall not be interchanged except as provided in the charts or in the applicable rim manual 4 36 6 2 Wheel components shall be inspected prior to assembly Rim bases side rings or lock rings which are bent out of shape pitted from corrosion broken or cracked shall not be used and shall be rendered unusable or discarded 4 36 6 3 Mating surfaces of the rim gutter rings and tires shall be free of any dirt surface rust scale or rubber buildup prior to mounting and inflation 4 25 TO 36 1 191 4 36 7 Safe Operating Procedure The employer shall establish a safe operating procedure for servicing multipiece rim wheels and shall assure that employees are instructed in and follow that procedure The procedure shall include at least the following elements 4 36 7 1 Tires shall be completely deflated by removing the valve core before a wheel is removed from the axle in either of the following situatio
557. ures are required for nickel iron alkaline batteries Wet charged lead acid batter ies shall be maintained in charged condition awaiting shipment or use Shrouding shall be optional at the discretion of the responsible of ficer Electrolyte shall be packaged as specified for Level A above Tension of all drive belts shall be released Coat unpainted surfaces of pulley grooves with primer conforming to Specification TT P 664 A warning tag bearing the information TEN SION RELEASED ON ALL DRIVE BELTS ADJUST BEFORE USE shall be securely at tached in a conspicuous location near driver s or operator s controls 8 11 TO 36 1 191 COLUMN I Item Table 8 2 Processing Procedures Continued COLUMN COLUMN II Component Level Bodies Gen B eral cabs are A B covered un der appli cable items below COLUMN IV Type of Vehicle AV AV COLUMN V Processing Required No processing required Except as otherwise specified bodies will be suffi ciently ventilated to permit free movement of air by opening drain valves or plugs and placing 1 4 to 3 8 inch spacers between inspection plates and floor of vehicle or access doors where design permits Openings for ventilation will be protected from entry of casual water and driving rain or snow by draping with water proofed Kraft paper conforming to Specification PPP B 1055B secured in place with pressure sensitive tape conforming to Specification SAE AMS T 2
558. ust Be Tagged to Read Use MIL B 46176 Only Lubricant Solid Film Phosphoric Acid Bonded ASTM D6107 Compound Anti Leak Cooling System 850 00 849 4035 e EM 9130 01 355 2393 MIL A 53009A Additive Anti Freeze Extender QT 6850 01 160 3868 Sealer Weld Through For Overlapping Surfaces rel Additive Diesel Stabilizing Storage 5 GL 6850 01 246 6544 Commercial Product STA BIL or equal Additive MOGAS Anti Gumming Storage 4oz BIT 6850 00 274 5 193 Commercial Product STA BIL or equal A Compound Corrosion Preventive 1607 8030 01 134 6513 MIL C 81309E Compound Corrosion Preventive Electrical Contacts 8030 00 546 8637 1602 CID A A59295 Compound Corrosion Preventative 8030 01 041 1596 Touch Up Across 1602 Of Exposed Meter 1 QT 8030 01 045 4780 PI 1 QT MIL L 46152 T n Fo B 1 Q gt gt Ne UA Table 8 2 Processing Procedures COLUMN COLUMN COLUMN COLUMN COLUMN I II IV V Item Component Level Type of Vehicle Processing Required Air Cleaners Shall contain P 10 Type 1 Grade 30 preservative Oil Bath oil filled to operating level Unpainted surfaces Type above operating level shall be coated with the same type and grade preservative oil 8 5 TO 36 1 191 Table 8 2 Processing Procedures Continued except elec tric powered materials handling equipment for water shipment COLUMN V Processing Required Shall
559. ut may exclude the front of the hood panel The material for striping shall be reflectorized to ASTM D4956 Sheets Class 1 or 3 Type 1 NOTE Decals will not be replaced solely to comply with this TO Compliance with this TO will be accom plished as decals require replacement 2 48 AMBULANCE VAN MODULAR TYPE COM MERCIAL 4 x 2 AND 4 x 4 PAINTED WHITE 2 48 1 The legend AMBULANCE in block blue letters not less than 4 inches high shall be mirror image centered above the grill on the orange or white background 2 48 2 Block type blue STAR OF LIFE not less than 3 inches on a 4 inch white field located both to the right and left of the legend AMBULANCE mirror image above the grill 2 48 3 The legend AMBULANCE in block blue letters on a white field not less than 6 inches in height shall be centered between STAR OF LIFE and Red Cross on each side of vehicle 2 48 4 A block type blue STAR OF LIFE not less than 16 inches shall be on the right and left side panels A block type blue STAR OF LIFE not less than 12 inches shall be centered between upper and lower windows of each rear door 2 48 5 red cross on a white field not less than 16 inches shall be on the right and left side panels A premasked 6 inch red cross on an 8 inch white field shall be on the lower portion of each rear door The legend AMBU LANCE in block type blue letters on a white field not less than 4 inches i
560. utes 8 22 4 6 Circulate 1 000 gallons of purge fluid through the under wing hose and bottom loading connection into the cargo tank Circulate 500 gallons of purge fluid through the overwing hose back into the cargo tank Empty the cargo tank and drain in accordance with Table 8 2 8 22 4 7 Measure explosive vapor level of tank using combustible gas indicator LEL readings should be 20 percent or less If explosive level is greater than 20 percent of the LEL repurge Continue purging until safe vapor lever is obtained This refueling unit has been drained of fuel and oil purged in accordance with TO 36 1 191 Prior to servicing aircraft the unit shall be purged with not less than 500 gallons of fuel to be dispensed by circulating through the system for approxi mately 10 minutes This fuel shall be disposed of in accordance with local disposal procedures 8 22 4 8 Secure tag AF Form 1492 on refueler operating control panel with inscription as follows 8 22 5 Steam Purge This method is authorized as an alternate procedure when capabilities to perform chemical neutralization forced air or oil purge does not exist 8 22 5 1 Select an area at least 100 feet from any building source of ignition or sewer system Slope of land must be away from inhabited or operational facilities 8 22 5 2 Static ground the tank to low resistance ground reference TO 00 25 172 bond the tank to metal water supply plumbing to be used in rinsing op
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562. ves more mileage 4 10 3 Radial Figure 4 2 The radial tire carries a letter number which has an R in it such as P205 75R14 The cords in the body run at right angles to the center line and may be arranged in one to three plies Over this radial section is added a belt made of up to four plies whose cords run at an angle of about 15 degrees to the center line The result is a tire with flexible side walls that even when fully inflated looks as though it needs air has great stiffness and strength in the tread area In some radials the belts are made of steel in others fiberglass or rayon The radial tire like the belted bias has minimum squirm runs cool and provides long wear 4 10 4 Special Use Tires There are many other types of special use tires on the market Basic construction will fall into one of the above categories but size cord materials compounding ingredients and tread designs i e diamond and mud and snow tread will vary with the purpose for which they are to be used Various types of blow out and puncture resistant tires are on the market Some have a steel safety belt underneath the tread Some have an inner tire separated from the main body of the tire by an air space Some others are difficult to balance satisfactorily Foam filled puncture proof battle damage tires have been used success fully on slow moving construction and 463L vehicles Their use has proven essential in some combat situations 4
563. vironment The frequency of application can be set to coincide with wash cycles but should not be extended These compounds should not be considered an alternative for proper painting however CPCs do provide temporary protection until proper corrosion removal and repainting can take place The CPCs should not be applied at temperatures above 95 F or below 50 F Refer to TO 1 1 691 for CPC recommended replacement frequency CPCs shall not be used on or adjacent to Oxygen lines fittings or equipment The com pound shall not be used on surfaces where temperatures will exceed 300 F Failure to com ply may result in fire hazard CPCs have a flash point above 100 F but may contain flammable solvents The compounds should be handled stored and applied with the same safety precautions as paint type finishes containing flammable solvents Failure to comply could result in a fire NOTE Use only corrosion preventive compounds autho rized by WR ALC LEEV or the Air Force Cor rosion Prevention and Control Office AFRL MLS OLR 6 15 9 2 MIL C 81309 Corrosion Preventive Compound Water Displacing Ultra Thin Film is a general purpose corrosion preventive compound that can be used whenever a CPC or a water displacing compound is called for but no specification is referenced MIL C 81309 materials are excel lent water displacing compounds that provide an ultra thin soft protective film 0 5 mil or less The specification covers two
564. with waterproof covers shall be protected with shrouds fabricated from barrier material con forming to or 4 of Specification PPP B e 1055 B SP Hose exposed to the weather will be processed in TR accordance with Level A subparagraph c above ST 67 Hose Oxidizer A B SP Request information from prime agency for end Transfer or item TR Propellant System Ser ST Hoses A B SP Loose air lines shall be secured near to compo Air Braided nents and connected with tape conforming to and Nylon MIL T 43115 or placed within vehicle if too TR long or weighty Hose bend radius shall not ex ceed one foot Tape ends shall have dummy ST connectors inserted and taped with MIL T 43115 for level B MIL T 22085 for level A 68 Hydraulic Sys A MH a Process in accordance with tems Materi 1 When the hydraulic system is filled to operat als Handling ing level with MIL H 46170 hydraulic oil the Equipment system shall be operated to ensure coating of inner surfaces waterproof tag shall be secured to the vehicle in a conspicuous location The tag shall read as follows 8 36 TO 36 1 191 Table 8 2 Processing Procedures Continued COLUMN COLUMN COLUMN COLUMN COLUMN I II IV V Item Component Level Type of Vehicle Processing Required The hydraulic system of this equipment is filled with MIL H 46170 and need not be drained before operation When placing in operation and refilling hy draulic system if leaks
565. xpectancy age miles kilometers remaining as reflected in the Vehicle Management Index File VMIF at https sevpgm robins af mil vehicle vmif section2 asp However Item Managers or MAJCOMs may direct shipment of assets with less than 50 percent life expectancy remaining to satisfy mission requirements For shipment be tween MAJCOMs the gaining command must concur with the shipment of any asset in as is condition or with less than 50 percent life expectancy 1 5 6 3 Overseas Shipment Air Force Installations Equipment to be shipped overseas except those vehicles being shipped under the Military Assistance Program MAP must be in safe and serviceable condition and have at least 75 percent of their anticipated life remaining The percentage of remaining service life will be computed using life expectancy years and or mileage as reflected in the Vehicle Management Index File VMIF at https sevpgm robins af mil vehicle vmif section2 asp Equipment requiring repairs which would exceed the one time repair allowance is considered uneco nomically reparable and will not be considered for shipment overseas 1 3 TO 36 1 191 NOTE Only standard interchangeable and when autho rized by prime depot substitute items of equip ment will be shipped overseas When authorized obsolete equipment may be used within the confines of the continental limits of the United States 1 5 6 4 Overseas Shipment For Contingency And Mob
566. y 3 13 2 4 Inspect all brake parts i e linings drums etc for wear and damage Check slack adjusters for proper adjustment and operation Repair adjust as required 3 13 2 5 Check axle spindles for alignment 3 13 2 6 Check air system for leaks or deteriorated parts 3 13 2 7 Check wiring harness for broken parts frayed wires damaged connectors conduit etc 3 13 2 8 Lubricate trailer per vehicle TO Table 3 4 Definition of Terms Terminology Main Beam one of a pair Undercarriage running gear bogie blies Upper coupler plate upper fifth wheel plate Rear Cross Member A main structural member of a lowbed platform or chassis trailer usually A structural sub frame complete with suspension and axle wheel assem The flat plate on the underside of the upper coupler through which the king pin protrudes and which rests directly on the tractor fifth wheel A transverse member at the extreme rear of a trailer to which the bumper is normally mounted and on which stop tail and turn lights are often installed Cross Member Upper Coupler Assembly A transverse member in a trailer chassis or under frame The structural element at the front of a trailer which includes the kingpin which receives and transfers the load from the forward portion of the trailer s load carrying elements to the tractor s fifth wheel Bulkhead A structure fixed or removable installed across the width of a trailer to compart
567. y appearance if exposed to sunlight for long peri ods of time 2 20 31 Ceramic laden epoxy coating material is used for application to high erosion and high wear areas such as inside of street sweeper debris hoppers The application surface must have all corrosion removed and have a 2 mil surface profile for the material to properly adhere 2 20 3 2 For high wear areas ceramicladen epoxy coat ings such as CeRam Kote SPG or equivalent should be procured in contrasting colors One color of ceramicladen coating should be applied to a dry film thickness DFT of 15 mils After 3 hours the contrasting color should then be applied directly over the top of the base color for a minimum total DFT of 36 mils Applying multi colored applications will provide a method of determining when the debris wear paths require recoating before bare metal is evident When the base coat color first becomes visible through the secondary topcoat the vehicle should be scheduled for drop in mainte nance as soon as practical The ceramic laden topcoat should then be reapplied to bring the total DFT back to the appropriate thickness 2 20 4 Spray In Bed Liners bed liners pro vide corrosion protection to cargo vans pickup trucks trailer beds etc The spray in bed liner if properly applied is far superior to plastic drop in liners Drop in liners allow fluids and water condensation to collect under the liner resulting in corrosion that may
568. ype vehicles such as compact pickups may be placed inside larger type vehicle bodies where sufficient space is adequate for performing the maintenance services required during storage period Where vehicles are stored in stacks arrangement should make it possible to remove a vehicle from the stack without disturbing more than one other stack 8 12 9 Blocking And Fire Precautions Vehicles shall be blocked off the ground using blocks suitable to support the weight of the vehicle s so that rubber tires are off the ground When nesting stacking or loading if individual vehicle design results in excessive weight being placed on the springs a suitable block shall be placed between the axle and frame to eliminate this stress Track laying vehicles shall be stored on long dunnage 8 12 10 Security And Fire Precautions Adequate se curity measures will be effected to prevent theft and pilferage Fire prevention equipment and procedures at Air Force activities are responsibilities of the Installations Engineering Office in accordance with AFI 32 2001 Storage personnel will ensure that changes in storage areas are immediately reported so that proper precautions can be implemented Commercial contractors operating storage areas will effect fire and damage control procedures as required by the Contracting Officer or his authorized representative and in accordance with applicable state county or municipal regu lation 8 12 11 Insect And

USAF TO 36-1-191

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