PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INSTRUCTIONS
TM 9-2815-225-34&P · Work Package 0006 00
INTERVALS
An overhauled engine must receive periodic maintenance to ensure it remains reliable and meets its expected service life. To meet these in-service expectations, PMCS service items and intervals included in this in this Work Package (WP) are to be followed. These instruction apply only to vehicles in normal operation. Engines must be serviced more frequently to compensate for abnormal or extreme conditions, such as high or low temperatures, immersions in water, or exposure to sand or dust. Intervals for changing filters (fuel, oil, air, etc.) are the same. Lubricants that have become contaminated must be changed regardless of scheduled intervals. Intervals for items under warranty must follow manufacturer recommendations until after the warranty has expired. Points requiring lubrication at 1000 or 2000 miles on vehicles not accumulating that amount in a six-month period will be lubricated semi-annually. Points requiring lubrication at 10,000, 24,000, or 50,000 miles on vehicles not accumulating that amount in a twelve-month period will be lubricated annually. When practicable, lubrication services will coincide with vehicle organizational PMCS.
TM page 0006 00-2
FUEL PUMP SCREEN AND FUEL FILTER
WARNING Compressed air used for cleaning purposes must not exceed 30 psi. Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).
Fuel Pump Screen—Soak screen in a carbon dissolving agent, then flush it in a sonic cleaner unit, or clean screen in fuel oil and dry with compressed air. Visually inspect screen for holes or embedded metal particles in mesh. Discard screen if damaged or worn and replace with new part. Fuel Filter (spin-on type)—Change fuel filter at 10,000-mile intervals. Open petcock and drain fuel into a suitable container. Remove element with a filter wrench and transfer petcock from old filter to new.
CRANKCASE
Check oil level daily and change oil hot full flow bypass filter elements at 10,000 miles or six months, which ever occurs first. To check engine oil level, wait at least 1 minute after stopping to allow oil to drain into crankcase. Safe operating level is between ADD and FULL mark on dipstick. Engine capacity is 11.5 gallons with both filters. Check and clean crankcase breather and attaching hoses whenever oil is changed.
STARTER
NOTE Do not lubricate alternator and starter wiring.
Remove starter every 100,000 miles for lubrication. Refer to TM 9-2320-273-20. Remove three socket head screws, add three to five drops of SAE oil to each reservoir, and lubricate drive and drive spline. Clean with solvent, then apply a thin coat of grease (GAA) so the pinion will move freely.
ALTERNATOR
Inspect alternator at 100,000-mile intervals. No lubrication is required. Bearings are sealed for life.
AIR FILTER
WARNING Compressed air used for cleaning purposes must not exceed 30 psi. Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).
Service air filter when red shows in window of restriction indicator or at 2000 miles, which ever comes first. Refer to TM 9-2320-273-10 for location and function of indicator Outside element can be washed up to five times or blown clean with air an indefinite number of times. Outside element is costly and should be reused. Handle and clean carefully. Inside safety filter should not be washed or blown clean and should be replaced every 10,000 miles. Clean the outside element by tapping the element, reverse flow cleaning with compressed air, or washing in water with a mild non-sudsing detergent.
TEMPERATURE RISE
If ambient temperature rises to +70º F for no more than one week, use of OE/HDO 10 lubricating oil is permissible. If ambient temperature rises to +32º F for no more than one week, use of OEA lubricating oil is permissible.
TM page 0006 00-3
UNIT LEVEL PMCS
Table 1. Unit Level PMCS Instructions.
ITEM MAN ITEM TO EQUIPMENT NOT READY/
INTERVAL PROCEDURE
NO. HOURS CHECK/SERVICE AVAILABLE IF:
1 Semi-annual 0.5 Pre-service a. Notice if starter engages a. Starter inoperative or
smoothly and turns engine makes excessive grinding at normal cranking speed. noise.
b. Listen for unusual engine b. Engine knocks, rattles, noise at idle, at operating or smokes excessively. speeds, and under acceleration. Be alert for excessive vibration and the smell of oil, fuel, and exhaust.
c. Check engine operation at c. Engine governed speed all speeds. Ensure that at no-load is below engine does not go above, 600 rpm or exceeds or below, engine governed 2100 rpm. speed (600–2100 rpm)
2 Semi-annual 2.0 Fuel system a. Inspect fuel filter/water a. Any Class III leak. separator assembly for dents and cracks that could cause leaks.
b. Replace filter element b. Fuel filter clogged. every 3,000 miles (4,827 km) or semiannually, whichever occurs first.
WARNING Adhesives, solvents, and sealing compounds can burn easily, give off harmful vapors, and damage skin and clothing. To avoid injury or death, keep away from fire and use in well-ventilated area. If adhesive, solvents, or sealing compound get on skin or clothing, wash immediately with soap and water. c. Clean screen by soaking in c. Screen is worn or a carbon dissolving agent, damaged. then flush in a sonic cleaner unit, or clean screen in fuel oil and dry with compressed air. Visually inspect screen for holes or embedded metal particles in mesh.
TM page 0006 00-4
Table 1. Unit Level PMCS Instructions (Contd).
ITEM MAN ITEM TO EQUIPMENT NOT READY/
INTERVAL PROCEDURE
NO. HOURS CHECK/SERVICE AVAILABLE IF:
2 4.8 d. Purge and clean fuel tank
(Contd) (TB 43-0212), if required.
e. Inspect fuel injection e. Rubber cap missing or
pump, nozzle lines, and torn on return line.
fittings for leaks and
damage.
f. Inspect all fuel lines for f. Any Class III leak.
loose connections, splits,
cracks, and kinks that
could leak.
3 Semi-annual 2.0 Aftercooler Inspect aftercooler for leaks Class III leaks or loose
and loose hardware. hardware.
4 Semi-annual 0.5 Engine Inspect for missing, broken, Any drivebelt is missing or
accessory cracked, and frayed broken; belt fiber has more
drive drivebelts; dry rot; excessive than one crack (50% of belt
fraying; and cracks. thickness) or has frays
more than 2 in. (5.08 cm)
long.
5 Semi-annual 0.5 Water pump a. Inspect pulley for
alignment.
b. Inspect belt for proper b. Any drivebelt is missing
tension (1/2–3/4 in. or broken; belt fiber has
(1.2–1.9 cm)) deflection more than one crack
when you press down (50% of belt thickness) or
firmly. has frays more than 2 in.
(5.08 cm) long.
c. Inspect water pump for
leaks and inspect fan
shrouds for secure
mounting.
6 Semi-annual 0.5 Thermostat Inspect thermostat housing
housing and and water manifold for leaks.
front, center,
and rear
water
manifolds
7 Semi-annual 0.5 Alternator a. Inspect for loose wiring a. Loose connections or
wiring and connections or worn worn insulation.
engine mount insulation.
b. Inspect for cracked or b. Cracked or loose engine
loose engine mounts. mounts.
TM page 0006 00-5
Table 1. Unit Level PMCS Instructions (Contd).
ITEM MAN ITEM TO EQUIPMENT NOT READY/
INTERVAL PROCEDURE
NO. HOURS CHECK/SERVICE AVAILABLE IF:
8 Semi-annual 1.0 Cooling WARNING
system If vehicle has been operating, use extreme care to avoid being burned when removing cooling system radiator cap. Use heavy rags or gloves to protect hands. Turn radiator cap only one-half turn counterclockwise and allow pressure to be relieved before fully removing cap.
NOTE Coolant level is correct when sight glass is full (TM 9-2320-273-10). Use MIL-A-46153 in temperatures above 0° F (-18° C). a. Inspect coolant condition. a. Coolant condition/testing Test coolant to see if shows draining is draining is required required. (TB 750-651). b. Inspect all hoses for b. Class III leakage evident. looseness, splits, wear, Hoses are loose or have and cracks that would splits or cracks. cause leaks. c. Inspect hose clamps for c. Hose clamps are worn or wear and serviceability. unserviceable.
9 Semi-annual Engine NOTE crankcase For operation of equipment in expected continuous temperatures below 0° F (-18° C), remove lubricants prescribed for temperatures above 0° F (-18° C). Relubricate with lubrication specified for temperatures 0° F to -50° F (-18° C to -460° C).
NOTE If AOAP laboratory is not “Do not operate” received available, drain and refill from AOAP lab. engine crankcase with OE/HDO every 6,000 miles (9,654 km) or semiannually, whichever comes first. Lubricate fan clutch with GAA.
TM page 0006 00-6
Table 1. Unit Level PMCS Instructions (Contd).
ITEM MAN ITEM TO EQUIPMENT NOT READY/
INTERVAL PROCEDURE
NO. HOURS CHECK/SERVICE AVAILABLE IF:
10 Semi-annual 1.0 Engine a. Drain and refill crankcase
crankcase with OE/HDO lubricating
oil.
b. Replace engine oil filter b. Oil filter has Class III
and bypass oil filter. leak.
c. Inspect all oil lines and c. Cracks, frays, leaks, and
hoses for cracks and wear wear are evident.
that could cause leaks.
d. Inspect oil filter housing d. Drain plugs and oil pan
and oil pan drain plug for bolts are loose.
looseness. Ensure oil pan
bolts are tight.
11 Semi-annual 0.4 Rocker cover Inspect rocker cover gasket Crack, frays, leaks, and
gaskets for oil leaks. If necessary, wear are evident.
tighten bolts and/or replace
gaskets.
12 Semi-annual 0.5 Oil cooler Inspect oil cooler for leaks, Crack, frays, leaks, and
and lines loose hardware, and wear are evident.
damaged fittings.
TM page 0006 00-7
MAINTENANCE ALLOCATION CHART
The Maintenance Allocation Charts (MACs), tables 2 and 3, designate overall authority and responsibility for the performance of maintenance functions on the identified end item or component. The application of the maintenance functions to the end item or component will be consistent with the capacities and capabilities of the designated maintenance categories.
EXPLANATION OF MAINTENANCE ALLOCATION CHART
Column 1, Group Number—Column 1 lists code numbers, which identify maintenance significant components, assemblies, subassemblies, and modules with the higher assembly. Column 2, Component/Assembly—Column 2 contains the names of components, assemblies, subassemblies, and modules for which maintenance is authorized. Column 3, Maintenance Function—Column 3 lists the functions to be performed on the item listed in Column 2. Column 4, Maintenance Category—Column 4 specifies the category of maintenance authorized to perform each maintenance function at the indicated category of maintenance. If the number or complexity of the tasks within the listed maintenance function varies at different maintenance categories, appropriate “work time” figures will be shown for each category. The “work time” figure represents the average time required to restore an item (assembly, subassembly, component, module, end item, or system) to a serviceable condition under typical field operating conditions. This time includes preparation time (including any necessary disassembly/assembly time), troubleshooting/fault location time, and quality assurance/quality control time in addition to the time required to perform each specific task. The symbol designations for the various maintenance categories are as follows: F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Support Maintenance H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Support Maintenance Column 5, Tools and Equipment—Column 5 specifies, by code, those common tool sets (not individual tools) and special tools, TMDE, and support equipment required to perform the designated function.
TM page 0006 00-8
Table 2. Maintenance Allocation Chart for M915–M920.
(1) (2) (3) (4) (5)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE TOOLS AND
NO. ASSEMBLY FUNCTION CATEGORY EQUIPMENT
F H
01 ENGINE Repair 19.2 2-3-4
Adjust 3.8
Test 0.4
0100 Engine (Diesel) Service
Replace 11.0
Repair 65.0 1 thru 77, 81, 84,
85, 97
Engine Mount Inspect 0.4 99 thru 180, 189
Replace thru 221
0101 Cylinder Head Inspect 1.0
Replace 7.0
Repair 10.4 2 thru 44, 50
Engine Block Inspect 2.0 8
Repair 40.0 99 thru 116
128, 129
Cylinder and Inspect 0.5
Sleeve Assembly Replace 18.0 99 thru 101
128
0102 Crankshaft and Inspect 0.5
Main Bearings Replace 17.3 117 thru 119
Main Seals Inspect 0.1
Replace 20.0 120 thru 127
194, 195
Vibration Damper Inspect 0.5
Replace 1.0
0103 Flywheel Replace 13.0 45
Assembly
0104 Connecting Rods, Inspect 0.3 207 thru 215
Bearings and Replace 27.0 221
Pistons Assembly Repair 8.0
TM page 0006 00-9
Table 2. Maintenance Allocation Chart for M915–M920 (Contd).
(1) (2) (3) (4) (5)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE TOOLS AND
NO. ASSEMBLY FUNCTION CATEGORY EQUIPMENT
F H
0105 Valves Inspect 0.8 71 thru 77
Adjust 1.8 2
Replace 14.0
Chamshaft and Inspect 27.0 197 thru 206
Bearing Adjust
Replace
Cam Follower Inspect
Housing Replace 0.2 46 thru 49
12.0 51 thru 54, 81
Cam Follower Inspect
Replace 0.2
14.0
Push Tubes Inspect
(Valve) Replace 0.1
8.0
Timing Gear Inspect
Replace 0.6
24.0
Rocker Arm Inspect 0.6
Assembly Replace 2.5
Valve Cover and Inspect
Gasket Replace
TM page 0006 00-10
Table 2. Maintenance Allocation Chart for M915–M920 (Contd).
(1) (2) (3) (4) (5)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE TOOLS AND
NO. ASSEMBLY FUNCTION CATEGORY EQUIPMENT
F H
0106 Oil Pump Inspect 1.5 65.0 130 thru 132
Replace 2.5
Repair
Oil Filter Service 10.8 143
Replace
Oil Filter Adapter Replace
Bypass Oil Filter
Service
Oil Pan Replace
Inspect
Replace 2.0
External Lines Repair 1.3
Inspect
Oil Breather Replace
Inspect
Service
Oil Cooler Replace
Inspect
Oil Pressure Replace 3.0 55
Regulator
Inspect 0.1
Test 0.8
Level Gauge Replace 0.2
(dipstick)
Replace
0108 Aftercooler Inspect 2.0
Repair 2.5
Replace
Exhaust Manifold Inspect
Replace 2.8
109 Accessory Drive Inspect 0.5 56 thru 65
Repair 2.0
Replace 4.5
0112 Engine Retarder Inspect 6.0 81
Repair 3.0
Replace 1.5
Adjust
TM page 0006 00-11
Table 2. Maintenance Allocation Chart for M915–M920 (Contd).
(1) (2) (3) (4) (5)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE TOOLS AND
NO. ASSEMBLY FUNCTION CATEGORY EQUIPMENT
F H
03 FUEL SYSTEM
0301 Fuel Injector Test 0.8
Assembly Adjust 4.0 71 thru 77, 84
Replace 4.0
Calibrate 1.0 3 thru 12-84
152
Repair 1.8
0302 Fuel Pump Inspect 4.8 159
Assembly 2.0 160
Service of Filter Service 166 thru 171
and Screw 174
Test 192
Replace
Calibrate 3.5 155, 156,
158
Repair 8.9 161 thru 164
Engine Fuel Lines 165, 172, 173
and Fittings Inspect 177 thru 179
Replace 189 thru 191, 193,
216 thru 220
TM page 0006 00-12
Table 3. Maintenance Allocation Chart for M915A1.
(1) (2) (3) (4) (5)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE TOOLS AND
NO. ASSEMBLY FUNCTION CATEGORY EQUIPMENT
F H
01 ENGINE
0100 Engine (Diesel) Service
Replace 16.0 83
Repair 65.0 143
Engine Mount Inspect
Replace 0.4
0101 Cylinder Head Inspect 1.0
Replace 7.0
Repair 10.4 84, 86, 87,
88, 90, 91,
95 thru 95
2.0 103, 104,
10.0 109, 110,
112, 114,
121 thru
124, 126,
141, 168
Engine Block Inspect
Repair 144, 145,
158, 170,
171
Cylinder and Inspect 0.5
Sleeve Assembly Replace 18.0 166
0102 Crankshaft and Inspect 0.5
Main Bearings Replace 17.3 143
Main Seals Inspect 0.1
Replace 20.0 100, 172
Vibration Damper Inspect 0.5
Replace 1.0
0103 Disk & Gear Replace 13.0
Assembly
0104 Connecting Rods, Inspect 0.3 135,138,
Bearings and Replace 7.0 161,154,
Pistons Assembly Repair 8.0 133,134,147
TM page 0006 00-13
Table 3. Maintenance Allocation Chart for M915A1 (Contd).
(1) (2) (3) (4) (5)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE TOOLS AND
NO. ASSEMBLY FUNCTION CATEGORY EQUIPMENT
F H
0105 Valves Inspect 0.8 71 thru 77
Adjust 1.8 2
Replace 14.0
Chamshaft and Inspect 0.8 197 thru 206
Bearing Replace 27.0
Cam Follower Inspect 0.2 46 thru 49
Housing Replace 12.0 51 thru 54, 81
Cam Follower Inspect 0.2
Replace 14.0
Push Tubes Inspect 0.1
(Valve) Replace 8.0
Timing Gear Inspect 0.6 106, 113, 117
Replace 24.0
Rocker Arm Inspect 0.6 93
Assembly Replace 2.5
Valve Cover and Inspect
Gasket Replace
TM page 0006 00-14
Table 3. Maintenance Allocation Chart for M915A1 (Contd).
(1) (2) (3) (4) (5)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE TOOLS AND
NO. ASSEMBLY FUNCTION CATEGORY EQUIPMENT
F H
0106 Oil Pump Inspect 1.5
Replace 2.5
Repair 3.0 142.165
Oil Filter Service 82
Replace
Oil Filter Adapter
Replace
Oil Pan
Inspect
Replace 2.0
Repair 1.3
External Lines
Inspect
Replace
Oil Breather
Inspect
Service
Replace
Oil Cooler
Inspect
Replace 3.0
Repair 2.0
Oil Pressure
Regulator Inspect 0.1
Test 0.8
Replace 0.2
Level Gauge
(dipstick) Replace
0108 Aftercooler Inspect 2.0
Repair 2.5
Replace
Exhaust Manifold Inspect
Replace 2.8
0109 Accessory Drive Inspect 0.5 111, 129
Repair 2.0 129
Replace 4.5
0112 Engine Retarder Inspect 6.0 121, 130
Repair 3.0
Replace 1.5
Adjust
0121 Engine Repair 4.0 117
Replace 2.0 34, 43, 40, 94, 101
TM page 0006 00-15
TOOL AND TEST EQUIPMENT REQUIREMENTS
Column 1—Reference Code. The tool and test equipment reference code correlates with a code used in tables 2 and 3, Column 5. Column 2—Maintenance Category. The lowest category of maintenance authorized to use the tool or test equipment. Column 3—Nomenclature. Name or identification of the tool or test equipment. Column 4—National Stock Number. The national stock number of the tool or test equipment. Column 5—Tool Number. The manufacturer’s part number.
TM page 0006 00-16
Table 4. Tool and Test Equipment Requirements for M915–M920.
REF MAINTENANCE
NOMENCLATURE NATIONAL STOCK NO. TOOL NUMBER
CODE CATEGORY
1 FH Checking Tool, Blow-By 3375150
2 FH Reamer, Valve Guide 5110-00-980-7347 ST-646
3 FH Cutting Tool, Bead 5110-00-932-2089 ST-788
4 FH Expander, Tube, Roller 3441-00-922-6699 ST-880
5 FH Cage ST-880-1
6 FH Roll ST-880-2
7 FH Nut, Thrust ST-880-6
8 FH Mandrel ST-880-7
9 FH Cutter, Injector Sleeve 4910-00-981-3105 ST-884
10 FH Holder ST-884-1
11 FH Cutter ST-884-3
12 FH Pilot ST-884-6
13 FH Tool, Cylinder Head 4910-00-999-1499 ST-913
14 FH Lockscrew ST-913-1
15 FH Bearing ST-913-7
16 FH Plug, Locking ST-913-11
17 FH Insert, Fiber ST-913-18
18 FH Screw Assembly, Adjusting ST-913-23
19 FH Tool Holder ST-913-14
20 FH Tool Bit ST-913-17
21 FH Tool, Grooving 5120-00-178-0948 ST-1100
22 FH Body (5-1/2 In. Bore) ST-1100-10
23 FH Nut, Adjusting (1-1/4-20 Thread) ST-1100-7
24 FH Capscrew (1/4-28 x 3/16 In.) ST-1100-6
25 FH Sleeve, Rod ST-1100-8
26 FH Rod, Tool Adjusting ST-1100-11
27 FH Spring, Rod ST-1100-9
28 FH Cap, Tool Setting ST-1100-14
29 FH Cutting Tool ST-1100-13
30 FH Spring, Tool ST-1100-12
31 FH Sleeve Injector 4910-00-150-5858 ST-1140
32 FH Holding Tool, Injector Sleeve 5120-00-104-1795 ST-1179
33 FH Driver, Injector Sleeve 5120-00-981-3108 ST-1227
34 FH Puller, Injector Sleeve 5120-00-113-5271 ST-1244
35 FH Tip, Extractor ST-1244-7
36 FH Rod ST-1244-2
TM page 0006 00-17
Table 4. Tool and Test Equipment Requirements for M915–M920 (Contd).
REF MAINTENANCE
NOMENCLATURE NATIONAL STOCK NO. TOOL NUMBER
CODE CATEGORY
37 FH Collar, Forming ST-1244
38 FH Spacer ST-1244
39 FH Bridge, Support ST-1244
40 FH Washer, Thrust ST-1244-5
41 FH Nut (l-8 Thread) ST-1244
42 FH Nut (9/16-12 Thread) ST-1244
43 FH Driver ST-1244
44 FH Driver, Valve Guide 3375282
45 FH Attachment, Dial Gauge ST-1325
46 FH Bushing, Block and Mandrel, Lever 5180-00-916-1813 ST-249
47 FH Mandrel ST-249-1
48 FH Mandrel ST-249-2
49 FH Sleeve ST-249-3
50 FH Spacer, Crosshead Guide 4910-00-150-3797 ST-633
51 FH Mandrel Set, Machine 3460-00-499-1210 ST-691
52 FH Mandrel ST-691-1
53 FH Block ST-691-2
54 FH Mandrel ST-691-3
55 FH Mandrel, O-Ring, Lubricating Oil Cooler ST-1218
56 FH Pulley Assembly, Tool 5180-00-944-0374 ST-386
57 FH Arbor ST-386-2
58 FH Nut ST-386-3
59 FH Adapter, Ball, Thrust Bearing ST-386-11
60 FH Spacer ST-386-5
61 FH Adapter 3375205
62 FH Adapter (2-1/4 In. x 7/8 In. Dia.) ST-386-10
63 FH Adapter (2-1/4 In. x 1 In. Dia.) ST-386-9
64 FH Adapter (2-1/4 In. x 1 In. Dia.) ST-386-8
65 FH Adapter (1-7/8 In. x 1 In. Dia.) ST-386-6
66 FH Mandrel, Water Pump Seal ST-658
67 FH Mandrel, Water Pump Seal 5120-00-159-8916 ST-659
68 FH Fixture, Bearing Disassembly ST-1114
69 FH Water Pump Seal Driver ST-1159
70 FH Driver, Water Pump Drive Shaft Oil Seal 3375180
71 FH Adapter, Torque Wrench 5120-00-103-4687 ST-669
72 FH Driver, 3/8 In., Plastic Handle F-40A
TM page 0006 00-18
Table 4. Tool and Test Equipment Requirements for M915–M920 (Contd).
REF MAINTENANCE
NOMENCLATURE NATIONAL STOCK NO. TOOL NUMBER
CODE CATEGORY
73 FH Handle ST-699-1
74 FH Blade, Screwdriver 1/2 In. x 0.062 In. M-1302 A-5
75 FH Blade, Screwdriver 1/4 In. x 0.032 In. TM-82
76 FH Socket, 3/4 In. Deep Double Hex M-1302B-24
77 FH Socket, 9/16 In. Deep Double Hex M-1302B-18
78 FH Rod, Expanding CG-40-4
79 FH Collet 43/64 to 52/64 CG-40-11
80 FH Socket 1/4 In. 12 Point, 1/4 In. Drive STMD-8
81 FH Socket, Jacobs Brake B1465A
82 OFH Installing Tool, Seal RD259A
83 OFH Handle, Seal Installing Tool RD263
84 FH Fixture, Injector Timing 4910-00-712-0537 ST-593
85 FH Wrench, Air Compressor 5120-01-072-2952 3375159
86 FH Bar, Bearing Puller 11074
87 FH Yoke Installer J-26422-10
88 FH Wrench, Differential Adjusting Nut J-972
89 FH Tool, Remove-Replace Windshield Moulding 5120-00-279-8422 CPR109701
90 FH Tool, Yoke Installer 4120-01-014-0017 J-26422
91 FH Shaft, 1-1/4-12 Thread J-26422-2
92 FH Nut J-26422-3
93 FH Shaft 1-1/4-12 J-26422-4
94 FH Sleeve J-26422-1
95 FH Wear Sleeve Installation Tool J-26424
96 OFH Socket, Pusher Axle 3-3/16 In. J-7757-2
97 OFH Thermostat Seal Mandrel ST-1225
98 OFH Socket, Wheel Bearing 1902
99 H Tool, Counterbore 5120-00-150-7488 ST-1295
100 H Holder, Tool 5120-00-150-7489 ST-1065
101 H Tool Bit, Counterbore ST-1059-17
102 H Boring Tool, Liner Counterbore ST-1168
103 H Bearing, Drive ST-1168-4
104 H Screw, Drive ST-1168-6
105 H Shaft, Drive ST-1168-3
106 H Sprocket, Drive ST-1168-5
107 H Chain, Drive ST-1168-7
108 H Sprocket, Drive ST-1168-10
109 H Tool Bit ST-1168-19
110 H Ring, Snap, Drive Shaft ST-1168-8
TM page 0006 00-19
Table 4. Tool and Test Equipment Requirements for M915–M920 (Contd).
REF MAINTENANCE
NOMENCLATURE NATIONAL STOCK NO. TOOL NUMBER
CODE CATEGORY
111 H Ring, Snap, Drive Bearing ST-1168-9
112 H Counterbore Tool Liner ST-1255
113 H Chamfer Tool, Lower Bore Sleeve ST-1318
114 H Tool Bit ST-1318-23
115 H Bore Tool, Lower Liner ST-1287
116 H Tool Bit ST-1287-10
117 H Puller, Shoulder Bolt, Gear Crank 3375081
118 H Puller, Gear, Crank Bridge Assembly 3375075
119 H Puller, Jaw, Crankshaft Gear 3375077
120 H Puller-installer, Oil Seal ST-1259
121 H Spacer Ring (1-7/16 In.) ST-1259-4
122 H Plate, Top ST-1259-1
123 H Spacer Ring (3/16 In.) ST-1259-2
124 H Screw, Allen Head (1/4-20 x 1/2 In.) ST-1259-3
125 H Screw, Main Puller (1/2-13 x 2 In.) ST-1259-7
126 H Screw, Allen Head (1/4-20 x 1-3/4 In.) ST-1259-5
127 H Screw, Seal Puller ST-1259-6
128 H Clamp, Cylinder Liner 5120-00-104-1816 ST-1184
129 H Driver 3375153
130 H Gear & Spacer Mandrel, Lubricating Oil ST-1157
131 H Bushing Mandrel, Lubricating Pump ST-1158
132 H Bushing Tool, Lubrication Pump Body Cover 3375206
133 H Bushing, Guide 3375223
134 H Adapter, Drive 3375229
135 H Housing, Main Bore 3375220
136 H Knob, Plastic 3375228
137 H Dial Indicator 3375227
138 H Tool Bit 3375226
139 H Tool Bit 3375225
140 H Tool Bit 3375207
141 H Knob, Cutter Adjusting 3375224
142 H Bushing, Guide 3375221
143 H Bushing, Guide 3375222
144 H Orifice Torque 5120-01-072-2955 ST-1090
145 H Driver, Torque Wrench ST-1090-1
146 H Screwdriver ST-1090-2
147 H Screw, Set ST-1090-4
148 H Wrench, Allen, 5/64 In. ST-1090-3
149 H Checking Tool, Injector Protrusion ST-981
TM page 0006 00-20
Table 4. Tool and Test Equipment Requirements for M915–M920 (Contd).
REF MAINTENANCE
NOMENCLATURE NATIONAL STOCK NO. TOOL NUMBER
CODE CATEGORY
150 H Torque Tool, Injector ST-1145
151 H Fixture, Top Stop Injector Setting 3375160
152 H Tool, Adjusting 3375165
153 H Crowsfoot, 1-3/8 In., Locknut Wrench 3375166
154 H Wrench, Inch Pound Torque 3375232
155 H Block, Weight Carrier ST-1231
156 H Puller, Tachometer Drive ST-1326
157 H Collar ST-1326-2
158 H Collet ST-1326-1
159 H Adapter Plate, Fuel Filter 3375014
160 H Gasket 3375015
161 H Front Cover, Main Shaft Assembly 3375175
162 H Driver, Front Cover 3375174
163 H Driver, Main Shaft Seal 3375173
164 H Installation Tool, Main Shaft & Bearing 3375172
165 H Installation Tool, Throttle Shaft Ball 3375204
166 H Adjust Kit, AFC Fuel Pump 3375189
167 H Installation Tool, No Air Screw O-Ring 3375148
168 H Tool, AFC No Air Adjusting 3375140
169 H Installation Tool, Glyd Ring 3375146
170 H Forming Tool, Glyd Ring 3375147
171 H Tool, AFC Adjusting 3375137
172 H Installation Tool, Cast Governor Weight 3375230
173 H Mandrel, Tachometer Drive Cup Plug 3375271
174 H Throttle Travel Template 5120-01-074-0020 3375355
175 H Turbo Support Block ST-608
176 H Socket, Wrench 5120-00-116-7625 ST-1095
177 H Puller Assembly 5120-00-065-1031 ST-544
178 H Screw ST-544-2
179 H Puller ST-544-1
180 H Holder 5120-00-923-0856 ST-851
181 H Lock Tester, 2 In. TLN-1000
182 H Lock Tester, 3 In. ITL42
183 H Step Plate, Mechanic 5120-00-473-6921 8B7560
184 H Bracket FT901
185 H Installer 2P8260
186 H Staking Tool, Pinion Bearing 26883
TM page 0006 00-21
Table 4. Tool and Test Equipment Requirements for M915–M920 (Contd).
REF MAINTENANCE
NOMENCLATURE NATIONAL STOCK NO. TOOL NUMBER
CODE CATEGORY
187 H Carrier Stand J-3409-1
188 H Adapter Pot, Injector 3375086
189 H Assembly Tool, O-Ring 5120-00-396-8089 ST-422
190 H Assembly Tool, Tube 5120-00-999-1505 ST-835
191 H Driver, Governor Cylinder 4910-00-150-5801 ST-853
192 H Adjusting Tool 4910-00-150-5805 ST-984
193 H Assembly Tool, Tachometer 5120-00-896-8087 ST-1032
194 H Driver, Seal, Crankshaft 4910-00-150-5810 ST-997
195 H Pins ST-997-6
196 H Wrench, Injector 5120-00-150-7492 ST-995
197 H Mandrel, Camshaft Bushing 5120-00-055-4013 ST-1228
198 H Shank, Mandrel ST-1228-3
199 H Driver ST-1228-9
200 H Puller Assembly ST-1228-13
201 H Guide ST-1228-5
202 H Guide (2-1/2 In.) 3375154
203 H Shaft Assembly ST-1228-4
204 H Roll Pin ST-1228-14
205 H Rod ST-1228-2
206 H Slide Hammer ST-1228-1
207 H Bushing Driver 4910-00-150-5802 ST-1242
208 H Block ST-1242-3
209 H Cup ST-1242-2
210 H Pin, Cotter ST-1242-6
211 H Driver (Tapered) ST-1242-4
212 H Knock-Out Ring (Tapered) ST-1242-5
213 H Knock-Out Ring (Straight) ST-1242-7
214 H Driver, Straight ST-1242-8
215 H Mandrel ST-1242-1
216 H Fixture, Ream, Fuel Pump Front Main 5110-00-981-3107 ST-490
217 H Puller, Mechanical 5120-00-999-1504 ST-709
218 H Puller, Bushing 3375108
219 H Vise, Ball Joint 4910-00-999-5106 ST-302
220 H Front Seal Assembly 5120-00-896-8097 ST-419
221 H Gauge, Groove Wear 5210-00-999-1209 ST-560
TM page 0006 00-22
Table 5. Tool and Test Equipment Requirements for M915A1.
REF MAINTENANCE
NOMENCLATURE NATIONAL STOCK NO. TOOL NUMBER
CODE CATEGORY
Chassis Tools and Test Equipment
1 0 Pin, Oil Pan Guide 5315-01-151-1106 J 3387-2
2 0 Indicator Set, Dial 5120-00-402-9619 J 7872
3 0 Driver, Bushing 5120-01-159-1841 700291
4 0 Wrench, Hexagon Locknut,
4-1/8 Inch 5120-01-145-5793 1915
5 0 Wrench, Hexagon Locknut,
2-1/4 Inch 5120-01-089-9068 1920
6 0 Analyzer, Power Steering J 26487
7 0 Bar, Holding, Pinion Yoke
and Flange J 3453
8 0 Handle 450237
9 0 Adapter 427
10 0 Plug, Bearing 706
11 0 Adapter 446
12 0 Plug, Bearing 715
13 0 Removal Tool, Contact 5120-01-158-4707 114010
14 0 Removal Tool, Contact 5120-01-158-4708 0411-204-
1605
15 0 Crimping Tool 5120-00-251-3990 5417
16 0 Crimping Tool MS3191A
17 00 Locator, Socket Contact 5120-01-131-0138 600092
18 0 Insertion Tool, Contact 5120-01-131-0140 CIT-F80-16
19 0 Extraction Tool, Contact 5120-01-131-0139 CET-F80-16
20 0 Tester, Lock Fifth Wheel,
2 Inches 5120-01-097-0170 TLN-1000
21 F Remover, Seal and Dust Shield 5120-01-048-2153 J 24171
22 F Installer, Output Shaft Seal 5120-01-159-1852 J 24202-1A
23 F Handle, Driver 5120-01-054-4048 J 24202-4
24 F Jack, Transmission 4910-00-585-3622 49
25 F Tool, Spanner 294514
26 F Service Set, Torque Rod Bushing 4910-01-159-1734 Y-820
27 F Service Set, Equalizing 5180-01-084-6010 Y-850-A
28 F Tube, Receiving 4910-01-159-1735 Y-860
29 F Adapter, Removing 5120-01-159-1843 Y-861
30 F Adapter, Installing 5120-01-159-1845 Y-862
31 F Remover and Installer,
Windshield C-4009-B
32 H Handle, Driver 5120-00-677-2259 J 8092
33 H Gauge, Clearance Clutch Pack,
0.080–0.120 Inch 5210-01-048-2161 J 24192
34 H Gauge, Clearance, Clutch Pack,
0.060–0.120 Inch 5210-01-048-2162 J 24193
TM page 0006 00-23
Table 5. Tool and Test Equipment Requirements for M915A1 (Contd).
REF MAINTENANCE
NOMENCLATURE NATIONAL STOCK NO. TOOL NUMBER
CODE CATEGORY
35 H Gauge, Clearance, Clutch Pack,
0.095–0.145 Inch 5210-01-048-5283 J 24194
36 H Bracket, Lifting, Center Support 5210-01-116-6048 J 24195
37 H Bracket, Lifting, Mainshaft 5210-01-115-1157 J 24196
38 H Installer, Bearing, Front
Support Hub 5120-01-115-1160 J 24197
39 H Installer, Oil Seal, Oil Pump 5120-01-054-4049 J 24198
40 H Installer and Staking Set,
Collector Ring 5120-01-048-3124 J 24200
41 1 Installer, Bushing, Output Shaft 5120-01-115-9174 J 24203
42 H Compressor, Clutch Spring 5120-01-048-3129 J 24204
43 H Installer and Remover,
Speedometer Bushing 5120-01-116-5017 J 24205-A
44 H Installer, Sleeve, Front
Planetary Bushing 4910-01-158-3989 J 24207
45 H Compressor Set, Center Support 5120-01-116-5016 J 24208-C
46 H Fixture, Lifting, Fourth Clutch 5120-01-115-1159 J 24209
47 H Protector, Inner Seal, Clutch
Piston 5120-01-048-2156 J 24210
48 H Protector, Seal, Forward Clutch 5120-01-048-2157 J 24216-01
49 H Installer Mainshaft Orifice 5120-01-115-1162 J 24217
50 H Ring Retainer, Stator Camspring
and Roller 5120-01-115-1158 J 24218-2
51 H Compressor, Spring 5120-01-048-2160 J 24219
52 H Fixture, Alignement, Fourth
Clutch 5120-01-115-1156 J 24221
53 H Fixture, Holding, Transmission 5120-01-115-1165 J 24310
54 H Pin Set, Guide 5120-01-115-1163 J 24315
55 H Lifting Tool, Flywheel 5120-01-116-6049 J 24365
56 H Installer, Bushing, Rear
Planetary Carrier 5120-01-159-1844 J 24368
57 H Installer, Orifice Plug 5120-01-054-4053 J 24369
58 H Puller, Universal 5120-00-999-4053 J 24420
59 H Installer, Bearing, Rear 5120-01-054-4054 J 24447
60 H Installer, Retaining Ring 5120-01-054-4050 J 24453
61 H Remover, Rear Bearing, 5120-01-054-0188 J 24534
In-Vehicle
62 H Installer, Seal, Shift Lever 5120-01-115-1161 J 26282
63 H Remover, Seal, Shift Lever 5120-01-118-6264 J 26401
64 H Remover and Installer, Snapring,
Pump J 26598-A
65 H Staking Tool, Bushing, Sun Gear J 26997-A
66 H Reamer Set, Bushing, Sun Gear 5110-01-150-9755 J 28489
67 H Installer and Staking Set,
Bushing, Center Support 4910-01-158-3971 J 28525
TM page 0006 00-24
Table 5. Tool and Test Equipment Requirements for M915A1 (Contd).
REF MAINTENANCE
NOMENCLATURE NATIONAL STOCK NO. TOOL NUMBER
CODE CATEGORY
68 H Installer, Bearing 5120-01-159-1842 J 28646-A
69 H Installer, Pin, Governor Support 5120-01-122-1179 J 28684
70 H Gauge, Ring, Center and Front
Support Seal 5210-01-133-6888 J 29198-3
71 H Lifter, Clutch Assembly 4910-01-159-1736 J 33079
72 H Remover and Installer, Driven
Gear Shaft J 33080
73 H Scale, Tension 4910-00-779-6832 J 8129
74 H Staking Tool J 26883
75 H Stand, Repair, Differential 4910-01-085-7729 J 3409-01
76 H Compressor, Spring, Slider TLN-2500
77 H Driver Bushing 4910-01-158-3986 J 24201
78 H Adjusting Tool, Valve Ring J 24314
79 H Fixture Set, Gear Removing J 26899
Engine Tools and Test Equipment
80 O Gauge, Manifold Pressure 6220-01-147-9954 ST-1273
81 O Mandrel, Thermostat Seal 4910-01-097-6948 ST-1225
82 O Wrench, Oil and Fuel Filter,
Spin-On 5120-01-160-8863 3375049
83 F Fixture, Engine Lifting 2815-00-362-2042 ST-125
84 F Tool, Valve Seat Insert 4910-00-345-3708 ST-257
85 F Vise, Ball Joint 4910-00-999-1506 ST-302
86 F Compressor, Valve Spring 5120-01-145-7293 ST-448
87 F Fixture, Head Holding 4920-00-711-9307 ST-583
88 F Spacer, Crosshead Guide 4910-00-150-5797 ST-633
89 F Mandrel, Water Pump Bearing 4910-00-097-6986 ST-658
90 F Cutter, Valve Seat Insert 5133-00-999-1208 ST-662
91 F Arbor, Valve Guide 3640-00-999-1173 ST-663
92 F Adapter, Torque Wrench 5120-00-103-4687 ST-669
93 F Block and Mandrel, Rocker Lever 3460-00-999-1210 ST-691
94 F Plate, Air Compressor Mounting 4910-01-159-8701 ST-749
95 F Tool, Bead Cutting 5110-00-932-2089 ST-788
96 F Tool, Injector Seat Cutting 4910-00-925-0755 ST-824
97 F Brush, Fuel Passage Cleaning 7920-00-168-3244 ST-876
98 F Expander, Injector Sleeve 3441-00-922-6699 ST-880
99 F Cutter, Injector Seat 4910-00-981-3105 ST-884
100 F Driver, Crankshaft Oil Seal 4910-00-150-5810 ST-997
101 F Mandrel, Air Compressor Bushing ST-1105
102 F Fixture, Bearing Disassembly 4910-01-097-6987 ST-1114
103 F Driver, Valve Seat Insert
Staking Tool 4910-00-150-5843 ST-1122
104 F Pilot, Valve Seat Insert
Staking Tool 4910-00-150-5844 ST-1124
TM page 0006 00-25
Table 5. Tool and Test Equipment Requirements for M915A1 (Contd).
REF MAINTENANCE
NOMENCLATURE NATIONAL STOCK NO. TOOL NUMBER
CODE CATEGORY
105 F Mandrel, Seal Wear Sleeve 4910-01-097-6988 ST-1159
106 F Mandrel, Seal 4910-01-161-2115 ST-1173
107 F Tool, Injector Sleeve Holding 5120-00-104-1795 ST-1179
108 F Driver, Oil Seal 5120-01-160-8867 ST-1191
109 F Driver, Injector Sleeve 5120-00-981-3108 ST-1227
110 F Puller, Injector Sleeve 5120-00-113-5271 ST-1244
111 F Puller 5120-01-128-2678 3376663
112 F Tester, Valve Vacuum 4910-01-128-2691 ST-1257-A
113 F Installer, Oil Seal 4910-01-106-0492 ST-1259
114 F Extractor, Valve Seat ST-1279
115 F Attachment, Dial Gauge 5120-01-128-2679 ST-1325
116 F Tool, Blowby Checking 3375150
117 F Expander, Oil Seal 4910-01-097-6972 3375151
118 F Wrench, Air Compressor 4910-01-085-9211 3375159
119 F Puller, Injector 5120-01-072-2952 3375161
120 F Pilot, Oil Seal 4910-01-097-6989 3375180
121 F Tester, Spring 4910-01-142-4929 3375182
122 F Driver, Expansion Plug, 3/4" 4910-01-143-3336 3375190
123 F Driver, Expansion Plug, 1" 4910-01-143-3337 3375191
124 F Driver, Expansion Plug, 1-1/4" 4910-01-143-2023 3375192
125 F Puller 5120-01-155-3795 3375257
126 F Driver, Valve Guide 4910-01-097-6971 3375282
127 F Mandrel, Water Pump Seal 5120-01-128-2675 3375448
128 F Dial Indicator and Sleeve
Assembly 5120-01-157-2291 3376050
129 F Assembly Tool, Pulley
Installation 5120-01-156-4183 3376326
130 F Wrench, Solenoid Valve 011494
131 F Socket, Special, 5/8" X 1/2"
Drive SINL-200
132 H Fixture, Ream 5110-00-981-3107 ST-490
133 H Gauge, Piston Ring Groove 5210-00-999-1209 ST-560
134 H Fixture, Connecting Rod
Checking 4910-00-977-7507 ST-561
135 H Mandrel, Connecting Rod
Locating 4910-01-146-7130 ST-563
136 H Tool, Burnishing 4910-00-999-1503 ST-708
137 H Puller, Governor Weight 5120-00-999-1504 ST-709
138 H Expander, Piston Ring 5120-00-150-7486 ST-763
139 H Wrench, Injector Cup 5120-00-150-7492 ST-995
140 H Extension, Plunger 4910-00-150-5819 ST-1089
141 H Extractor, Dowel Pin 4910-00-150-5848 ST-1134
142 H Mandrel, Spacer 4910-01-097-6913 ST-1157
143 H Puller, Main Bearing Cap 5120-01-141-5777 ST-1178
TM page 0006 00-26
Table 5. Tool and Test Equipment Requirements for M915A1 (Contd).
REF MAINTENANCE
NOMENCLATURE NATIONAL STOCK NO. TOOL NUMBER
CODE CATEGORY
144 H Clamp, Cylinder Liner 5120-00-104-1816 ST-1184
145 H Driver, Liner 5120-00-999-1206 ST-1229
146 H Tool, Plunger Protrusion
Checking 4910-01-141-8388 ST-1241
147 H Driver, Connecting Rod Bushing 4910-01-098-1914 ST-1242
148 H Conversion Kit 4910-01-147-7896 ST-1261
149 H Injector, Master K 4910-01-154-6406 ST-1262
150 H Stand, Injector 4910-01-082-1346 ST-1298
151 H Pot, Injector Adapter 4910-00-185-8508 3375086
152 H Plate, Fuel Pump Mounting 4910-01-128-2685 3375133
153 H Fixture, Setting, Top Stop
Injector 4910-01-097-6926 3375160
154 H Compressor, Piston Ring 5120-01-128-2758 3375162
155 H Tool Kit, AFC Fuel Pump
Adjusting, Tool 5180-01-102-8418 3375189
156 H Tool, Installing, Throttle Shaft
Ball 4910-01-118-3747 3375204
157 H Kit, Crack Detection 6850-00-145-0255 3375432
158 H Tool, Cylinder Block Counterbore 4910-01-150-9713 3375455
159 H Fixture, Injection Timing 4910-00-999-1269 3375522
160 H Puller, AFC Barrel 5120-01-128-2688 3375599
161 H Pin, Connecting Rod Guide 3375601
162 H Indicator, Level & Angle 4910-01-074-0020 3375855
163 H Driver, Pressurizing Valve 4910-01-143-2034 3375959
164 H Tool, Adjusting, Fuel Pump Idle 4910-00-150-5805 3375981
165 H Fixture, AFC Pressure Valve 4910-01-152-2743 3376011
166 H Puller, Cylinder Liner,
Universal 5120-01-143-2032 3376015
167 H Driver, Lock Cup 4910-00-150-5801 3376136
168 H Block, Gauge 5210-01-157-3091 3376220
169 H Wrench, Torque, Inch-Pound 4910-01-097-6929 3376592
170 H Kit, Camshaft Bushing Driver 5120-01-146-7131 3376633
171 H Driver, Camshaft Bushing 5120-01-156-6186 3376637
172 H Oil Seal Assembly Tool 5120-00-896-8097 ST-419
173 H Front Cover and Mainshaft Assembly
Tool 3375175
174 H Tester, Injector Leakage ST-990
175 H Stand, Injector Test ST-790
176 H Tester, Injector Cup Spray 5120-01-029-6861 ST-668
177 H Link 4910-01-128-9810 ST790-362
178 H Orifice 4910-00-999-1501 ST790-363
179 H Injector Adapter Pot ST-1254
180 H Kit, K-Cam J 33113
END OF WORK PACKAGE
TM page 0007 00-1