CHAPTER 1. GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND DATA, AND THEORY OF OPERATION
GENERAL INFORMATION
PREPARATION FOR STORAGE OR SHIPMENT
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
THEORY OF OPERATION
Table 2. M915A3 Front Suspension Kit (Part Number: 57K4955)
Table 3. M915A4 Front Suspension Kit (Part Number: 57K4956)
CHAPTER 2. OPERATOR INSTRUCTIONS
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED
OPERATION UNDER USUAL CONDITIONS
OPERATION UNDER USUAL CONDITIONS - CONTINUED
ESCAPE HATCH OPERATION
OPERATION IN EXTREME TEMPERATURES
STOWAGE AND DECAL/DATA PLATE GUIDE
CHAPTER 3. OPERATOR MAINTENANCE INSTRUCTIONS
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL PMCS PROCEDURES - CONTINUED
GENERAL PMCS PROCEDURES - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
CLEANING BALLISTIC GLASS
CHAPTER 4. UNIT MAINTENANCE INSTRUCTIONS
GENERAL MAINTENANCE INSTRUCTIONS
GENERAL INFORMATION
GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED
PAINTING INSTRUCTIONS
USE OF SEALANT
DOOR ASSEMBLY REPLACEMENT
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR HANDLE REPLACEMENT
DOOR HANDLE REPLACEMENT - CONTINUED
DOOR HANDLE REPLACEMENT - CONTINUED
DOOR LATCH REPLACEMENT
DOOR LATCH REPLACEMENT - CONTINUED
DOOR LATCH REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR LATCH ADJUSTMENT
DOOR LATCH ADJUSTMENT - CONTINUED
CAB SUPPORT REINFORCEMENT REPLACEMENT
CAB SUPPORT REINFORCEMENT REPLACEMENT - CONTINUED
CAB SUPPORT REINFORCEMENT REPLACEMENT - CONTINUED
WHEEL ZONE DEFLECTOR REPLACEMENT
WHEEL ZONE DEFLECTOR REPLACEMENT - CONTINUED
WHEEL ZONE DEFLECTOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
RIGHT SIDE ARMOR REPLACEMENT
RIGHT SIDE ARMOR REPLACEMENT - CONTINUED
RIGHT SIDE ARMOR REPLACEMENT - CONTINUED
RIGHT SIDE ARMOR REPLACEMENT - CONTINUED
RIGHT SIDE ARMOR REPLACEMENT - CONTINUED
RIGHT SIDE ARMOR REPLACEMENT - CONTINUED
LEFT SIDE ARMOR REPLACEMENT
LEFT SIDE ARMOR REPLACEMENT - CONTINUED
LEFT SIDE ARMOR REPLACEMENT - CONTINUED
LEFT SIDE ARMOR REPLACEMENT - CONTINUED
LEFT SIDE ARMOR REPLACEMENT - CONTINUED
LEFT SIDE ARMOR REPLACEMENT - CONTINUED
A-PILLAR ARMOR REPLACEMENT
A-PILLAR ARMOR REPLACEMENT - CONTINUED
A-PILLAR ARMOR REPLACEMENT - CONTINUED
REAR ARMOR REPLACEMENT
REAR ARMOR REPLACEMENT - CONTINUED
REAR ARMOR REPLACEMENT - CONTINUED
REAR ARMOR REPLACEMENT - CONTINUED
REAR ARMOR REPLACEMENT - CONTINUED
REAR ARMOR REPLACEMENT - CONTINUED
REAR ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
FIREWALL ARMOR REPLACEMENT
FIREWALL ARMOR REPLACEMENT - CONTINUED
FIREWALL ARMOR REPLACEMENT - CONTINUED
FIREWALL ARMOR REPLACEMENT - CONTINUED
FIREWALL ARMOR REPLACEMENT - CONTINUED
FIREWALL ARMOR REPLACEMENT - CONTINUED
ESCAPE HATCH REPLACEMENT
ESCAPE HATCH REPLACEMENT - CONTINUED
COWL ARMOR REPLACEMENT
COWL ARMOR REPLACEMENT - CONTINUED
FRONT ARMOR REPLACEMENT
FRONT ARMOR REPLACEMENT - CONTINUED
FRONT ARMOR REPLACEMENT - CONTINUED
FRONT ARMOR REPLACEMENT - CONTINUED
FRONT ARMOR REPLACEMENT - CONTINUED
FRONT ARMOR REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
CHAPTER 5. SUPPORTING INFORMATION
REFERENCES
REFERENCES - CONTINUED
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
MAINTENANCE FUNCTIONS
EXPLANATION OF COLUMNS IN THE MAC, TABLE 1- CONTINUED
Table 1. MAC for the Crew Protection Kit
Table 1. MAC for the Crew Protection Kit - Continued.
Table 2. Tools and Test Equipment Requirements for the Crew Protection Kit.
EXPENDABLE AND DURABLE ITEMS LIST
EXPENDABLE AND DURABLE ITEMS LIST - CONTINUED
EXPENDABLE AND DURABLE ITEMS LIST - CONTINUED
TORQUE LIMITS
Table 1. Torque Limits - SAE Standard Fasteners.
Table 2. Torque Limits - Metric Fasteners.
CREW PROTECTION KIT INSTALLATION INSTRUCTIONS
EQUIPMENT INSTALLATION INSTRUCTIONS AND PARTS LIST
REVISIONS
Installation Instructions
List of Updates (Effective Pages)
PREFACE
Table of Contents
List of Figures
List of Figures - Continued
List of Figures - Continued
List of Tables
GENERAL INFORMATION
OVERVIEW AND GENERAL INSTALLATION GUIDELINES
PREPARATION
Figure 2-1. Cabin Preparations - Cutting the External Mirror's Electrical Wiring.
Figure 2-3. Cabin Preparations - Installing Drilling-Pattern #999 and Drilling One 8-mm (5/16") Hole
Table 3-1. Kit Inventory - Ballistic Items
Table 3-1. Kit Inventory - Ballistic Items - Continued
Table 3-2. Kit Inventory - Non-Ballistic Items
Table 3-2. Kit Inventory - Non-Ballistic Items - Continued
Off-the-Shelf Items
Fasteners
Fasteners - Continued
Kit Installation Checklist
Figure 4-1. General View before Kit Installation.
Supplemental Cab Support Kit Installation
Parts, Fasteners, Special Tools, and Materials
Figure 5-3. Supplemental Cab Support Kit Installation Rubber Bumper (#179) Removal / Installation
Parts, Fasteners, Special Tools, and Materials
Installation Instructions
Figure 5-6. Installing the RH Wheel Housing Placing the RH Wheel Housing Support Arm
Figure 5-6a. Installing the RH Wheel Housing RH Wheel Housing Fasteners.
Parts, Fasteners, Special Tools, and Materials
Installation Instructions
Figure 5-9. Installing the LH Wheel Housing - Placing the LH Wheel Housing Support Arm.
Parts, Fasteners, Special Tools, and Materials
Figure 5-12. LH (Driver's) Floor Kit Installation
Figure 5-14. Floor Kit Installation (3 of 4).
Figure 5-16. RH Kit Installation - Final View.
Installation Instructions
Figure 5-18. RH Kit Installation (1 of 3).
Figure 5-21. LH Kit Installation - Final View.
Figure 5-23. LH Kit Installation (1 of 3).
Figure 5-25. LH Kit Installation (3 of 3).
Figure 5-27. Backside Kit Installation Parts.
Installation Instructions
Figure 5-28. Backside Kit Installation (1 of 3).
Figure 5-32. Roof Kit Installation Parts.
Installation Instructions
Figure 5-34. Roof Kit Installation- LH Corner (2 of 10).
Figure 5-35. Roof Kit Installation Right Rear (3 of 10).
Figure 5-39. Roof Kit Installation - Left Rear Corner (7 of 10).
Figure 5-41. Roof Kit Installation - RT Top A-Pillar (9 of 10).
Figure 5-44. Windscreen Bars and Brackets Installation - Parts.
Figure 5-45. Windscreen Bars and Brackets Installation - Right Side (1 of 4).
Figure 5-47. Windscreen Bars and Brackets Installation - Left Side (3 of 4).
Figure 5-49. Firewall Kit Installation - Final View.
Figure 5-51. Firewall Kit Installation (1 of 4).
Figure 5-53. Firewall Kit Installation (3 of 4).
Figure 5-55. Emergency Exit Kit Installation - Final View.
Installation Instructions
Figure 5-57. Emergency Exit Kit Installation (1 of 4).
igure 5-59. Emergency Exit Kit Installation (4 of 4).
Figure 5-61. Front Cowl Kit Installation - Parts.
Figure 5-62. Front Cowl Kit Installation (1 of 1).
Figure 5-64. RH Cowl Kit Installation Parts.
Installation Instructions
Figure 5-65a. RH Cowl Kit Installation - Door Step Preparation (1 of 3)
Figure 5-65b. RH Cowl Kit Installation (2 of 3).
Figure 5-68. LH Cowl Kit Installation Parts.
Installation Instructions
Figure 5-69a. LH Cowl Kit Installation - Door Step Preparation (1 of 3).
Figure 5-69b. LH Cowl Kit Installation
Figure 5-72. Front Cover Kit Installation - Parts.
Figure 5-73. Front Cover Kit Installation
Figure 5-75. Front Cover Kit Installation (3 of 5).
Figure 5-79. Windscreen Kit Installation Parts.
Installation Instructions
Figure 5-80. Windscreen Kit Installation (1 of 7).
Figure 5-82. Windscreen Kit Installation (3 of 7).
Figure 5-86. Windscreen Kit Installation (7 of 7).
Figure 5-87. Seats Installation - Final View.
Figure 5-89. Seats Installation - Seats Base Installation (1 of 1).
Figure 5-91. RH Armored Door Installation Parts
Parts, Fasteners, Special Tools, and Materials
Installation Instructions
Figure 5-92. RH Armored Door Installation
Installation Instructions
Figure 5-96. RH Door Accessories Assembly - Parts Removed from the OEM Door.
Figure 5-99. RH Door Accessories Assembly (3 of 6).
Figure 5-104. LH Armored Door Installation Parts.
Installation Instructions
Figure 5-107. LH Armored Door Installation - Lower Hinge, Door Detent (3 of 4).
Installation Instructions
Figure 5-109. LH Door Accessories Assembly - Parts Removed from the OEM Door.
Figure 5-113. LH Door Accessories Assembly - Assembly of external Door Handle (4 of 6).
Figure 5-116. Insulation Installation - Final View.
Installation Instructions
Figure 5-120. Insulation Installation - Roof Insulation (4 of 7).
Kit Installation Completion
Figure 5-124. Re-installation of Interior Components.
Table 6-1. Recommended Maximum Torque Values
Figure 6-1. Fasteners Map - Cab Support Reinforcement.
Figure 6-2. Fasteners Map - RH and LH Wheels Housing.
Figure 6-3. Fasteners Map - Floor and Firewall.
Figure 6-4. Fasteners Map - RH and LH sides.
Figure 6-5. Fasteners Map Backside.
Figure 6-6. Fasteners Map Roof.
Figure 6-7. Fasteners Map - Windscreen and Front Cover (1 of 2).
Figure 6-8. Fasteners Map - Windscreen and Front Cover (2 of 2).
Figure 6-9. Fasteners Map - RH and LH Doors.
Prep work for Cab Support installation (M916-A1 Only)
Installation Instructions
Figure 7-1. Elbow Adjustment.
Figure 7-3. Hose Wrap Location.
Parts, Fasteners, Special Tools, and Materials
Parts, Fasteners, Special Tools, and Materials
Figure 7-6. #659 Installation (#658 RH).
Installation Instructions
Figure 7-8. Wheel Housing.
Parts, Fasteners, Special Tools, and Materials
Parts, Fasteners, Special Tools, and Materials
Figure 7-10. Shift Tower Installation.
Shift Tower Installation (M916-A1 Only)
Figure 7-11. Shift Tower Installation (M916-A1).
Rear Wall Mounting Plate (M915-A2 and M916-A1)
Figure 7-12. Mounting Plate Installation.
Relocate Engine Check Connector (M915-A2 and M916-A1)
FIELD MAINTENANCE (UNIT AND DIRECT SUPPORT MAINTENANCE) REPAIR PARTS AND SPECIAL TOOLS LISTS (RPSTL) INTRODUCTION
EXPLANATION OF COLUMNS IN THE REPAIR PARTS LISTS
Maintenance Code
Recoverability Code
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGE FORMAT AND COLUMNS
HOW TO LOCATE REPAIR PARTS
Figure 1. Cab Support Reinforcement Kit
Figure 1. Cab Support Reinforcement Kit - Continued
Figure 2. Wheel Housing Armor Kit
Figure 2. Wheel Housing Armor Kit - Continued
Figure 3. Interior Protection Armor Kit (Sheet 1 of 3)
Figure 3. Interior Protection Armor Kit (Sheet 2 of 3)
Figure 3. Interior Protection Armor Kit (Sheet 3 of 3)
Figure 3. Interior Protection Armor Kit - Continued
Figure 3. Interior Protection Armor Kit - Continued
Figure 4. Side Protection Armor Kit (Sheet 1 of 2)
Figure 4. Side Protection Armor Kit (Sheet 2 of 2)
Figure 4. Side Protection Armor Kit - Continued
Figure 4. Side Protection Armor Kit - Continued
Figure 5. Rear Protection Armor Kit
Figure 5. Rear Protection Armor Kit - Continued
Figure 6. Front Cowl Protection Armor Kit (Sheet 1 of 2)
Figure 6. Front Cowl Protection Armor Kit (Sheet 2 of 2)
Figure 6. Front Cowl Protection Armor Kit - Continued
Figure 6. Front Cowl Protection Armor Kit - Continued
Figure 7. Windscreen Protection Armor Kit (Sheet 1 of 2)
Figure 7. Windscreen Protection Armor Kit (Sheet 2 of 2)
Figure 7. Windscreen Protection Armor Kit - Continued
Figure 8. Roof Protection Armor Kit
Figure 8. Roof Protection Armor Kit - Continued
Figure 9. Foam Insulation Kit
Figure 9. Foam Insulation Kit - Continued
GROUP 94 REPAIR KITS
GROUP 94 REPAIR KITS - Continued
NATIONAL STOCK NUMBER INDEX
NATIONAL STOCK NUMBER INDEX - Continued
PART NUMBER INDEX
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
GENERAL INFORMATION
PREPARATION FOR STORAGE OR SHIPMENT
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
THEORY OF OPERATION
Table 2. M915A3 Front Suspension Kit (Part Number: 57K4955)
Table 3. M915A4 Front Suspension Kit (Part Number: 57K4956)
CHAPTER 2. OPERATOR INSTRUCTIONS
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - CONTINUED
OPERATION UNDER USUAL CONDITIONS
OPERATION UNDER USUAL CONDITIONS - CONTINUED
ESCAPE HATCH OPERATION
OPERATION IN EXTREME TEMPERATURES
STOWAGE AND DECAL/DATA PLATE GUIDE
CHAPTER 3. OPERATOR MAINTENANCE INSTRUCTIONS
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL PMCS PROCEDURES - CONTINUED
GENERAL PMCS PROCEDURES - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
CLEANING BALLISTIC GLASS
CHAPTER 4. UNIT MAINTENANCE INSTRUCTIONS
GENERAL MAINTENANCE INSTRUCTIONS
GENERAL INFORMATION
GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED
PAINTING INSTRUCTIONS
USE OF SEALANT
DOOR ASSEMBLY REPLACEMENT
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR HANDLE REPLACEMENT
DOOR HANDLE REPLACEMENT - CONTINUED
DOOR HANDLE REPLACEMENT - CONTINUED
DOOR LATCH REPLACEMENT
DOOR LATCH REPLACEMENT - CONTINUED
DOOR LATCH REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR LATCH ADJUSTMENT
DOOR LATCH ADJUSTMENT - CONTINUED
CAB SUPPORT REINFORCEMENT REPLACEMENT
CAB SUPPORT REINFORCEMENT REPLACEMENT - CONTINUED
CAB SUPPORT REINFORCEMENT REPLACEMENT - CONTINUED
WHEEL ZONE DEFLECTOR REPLACEMENT
WHEEL ZONE DEFLECTOR REPLACEMENT - CONTINUED
WHEEL ZONE DEFLECTOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
FLOOR ARMOR REPLACEMENT - CONTINUED
RIGHT SIDE ARMOR REPLACEMENT
RIGHT SIDE ARMOR REPLACEMENT - CONTINUED
RIGHT SIDE ARMOR REPLACEMENT - CONTINUED
RIGHT SIDE ARMOR REPLACEMENT - CONTINUED
RIGHT SIDE ARMOR REPLACEMENT - CONTINUED
RIGHT SIDE ARMOR REPLACEMENT - CONTINUED
LEFT SIDE ARMOR REPLACEMENT
LEFT SIDE ARMOR REPLACEMENT - CONTINUED
LEFT SIDE ARMOR REPLACEMENT - CONTINUED
LEFT SIDE ARMOR REPLACEMENT - CONTINUED
LEFT SIDE ARMOR REPLACEMENT - CONTINUED
LEFT SIDE ARMOR REPLACEMENT - CONTINUED
A-PILLAR ARMOR REPLACEMENT
A-PILLAR ARMOR REPLACEMENT - CONTINUED
A-PILLAR ARMOR REPLACEMENT - CONTINUED
REAR ARMOR REPLACEMENT
REAR ARMOR REPLACEMENT - CONTINUED
REAR ARMOR REPLACEMENT - CONTINUED
REAR ARMOR REPLACEMENT - CONTINUED
REAR ARMOR REPLACEMENT - CONTINUED
REAR ARMOR REPLACEMENT - CONTINUED
REAR ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
FIREWALL ARMOR REPLACEMENT
FIREWALL ARMOR REPLACEMENT - CONTINUED
FIREWALL ARMOR REPLACEMENT - CONTINUED
FIREWALL ARMOR REPLACEMENT - CONTINUED
FIREWALL ARMOR REPLACEMENT - CONTINUED
FIREWALL ARMOR REPLACEMENT - CONTINUED
ESCAPE HATCH REPLACEMENT
ESCAPE HATCH REPLACEMENT - CONTINUED
COWL ARMOR REPLACEMENT
COWL ARMOR REPLACEMENT - CONTINUED
FRONT ARMOR REPLACEMENT
FRONT ARMOR REPLACEMENT - CONTINUED
FRONT ARMOR REPLACEMENT - CONTINUED
FRONT ARMOR REPLACEMENT - CONTINUED
FRONT ARMOR REPLACEMENT - CONTINUED
FRONT ARMOR REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
FOAM INSULATION REPLACEMENT - CONTINUED
CHAPTER 5. SUPPORTING INFORMATION
REFERENCES
REFERENCES - CONTINUED
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
MAINTENANCE FUNCTIONS
EXPLANATION OF COLUMNS IN THE MAC, TABLE 1- CONTINUED
Table 1. MAC for the Crew Protection Kit
Table 1. MAC for the Crew Protection Kit - Continued.
Table 2. Tools and Test Equipment Requirements for the Crew Protection Kit.
EXPENDABLE AND DURABLE ITEMS LIST
EXPENDABLE AND DURABLE ITEMS LIST - CONTINUED
EXPENDABLE AND DURABLE ITEMS LIST - CONTINUED
TORQUE LIMITS
Table 1. Torque Limits - SAE Standard Fasteners.
Table 2. Torque Limits - Metric Fasteners.
CREW PROTECTION KIT INSTALLATION INSTRUCTIONS
EQUIPMENT INSTALLATION INSTRUCTIONS AND PARTS LIST
REVISIONS
Installation Instructions
List of Updates (Effective Pages)
PREFACE
Table of Contents
List of Figures
List of Figures - Continued
List of Figures - Continued
List of Tables
GENERAL INFORMATION
OVERVIEW AND GENERAL INSTALLATION GUIDELINES
PREPARATION
Figure 2-1. Cabin Preparations - Cutting the External Mirror's Electrical Wiring.
Figure 2-3. Cabin Preparations - Installing Drilling-Pattern #999 and Drilling One 8-mm (5/16") Hole
Table 3-1. Kit Inventory - Ballistic Items
Table 3-1. Kit Inventory - Ballistic Items - Continued
Table 3-2. Kit Inventory - Non-Ballistic Items
Table 3-2. Kit Inventory - Non-Ballistic Items - Continued
Off-the-Shelf Items
Fasteners
Fasteners - Continued
Kit Installation Checklist
Figure 4-1. General View before Kit Installation.
Supplemental Cab Support Kit Installation
Parts, Fasteners, Special Tools, and Materials
Figure 5-3. Supplemental Cab Support Kit Installation Rubber Bumper (#179) Removal / Installation
Parts, Fasteners, Special Tools, and Materials
Installation Instructions
Figure 5-6. Installing the RH Wheel Housing Placing the RH Wheel Housing Support Arm
Figure 5-6a. Installing the RH Wheel Housing RH Wheel Housing Fasteners.
Parts, Fasteners, Special Tools, and Materials
Installation Instructions
Figure 5-9. Installing the LH Wheel Housing - Placing the LH Wheel Housing Support Arm.
Parts, Fasteners, Special Tools, and Materials
Figure 5-12. LH (Driver's) Floor Kit Installation
Figure 5-14. Floor Kit Installation (3 of 4).
Figure 5-16. RH Kit Installation - Final View.
Installation Instructions
Figure 5-18. RH Kit Installation (1 of 3).
Figure 5-21. LH Kit Installation - Final View.
Figure 5-23. LH Kit Installation (1 of 3).
Figure 5-25. LH Kit Installation (3 of 3).
Figure 5-27. Backside Kit Installation Parts.
Installation Instructions
Figure 5-28. Backside Kit Installation (1 of 3).
Figure 5-32. Roof Kit Installation Parts.
Installation Instructions
Figure 5-34. Roof Kit Installation- LH Corner (2 of 10).
Figure 5-35. Roof Kit Installation Right Rear (3 of 10).
Figure 5-39. Roof Kit Installation - Left Rear Corner (7 of 10).
Figure 5-41. Roof Kit Installation - RT Top A-Pillar (9 of 10).
Figure 5-44. Windscreen Bars and Brackets Installation - Parts.
Figure 5-45. Windscreen Bars and Brackets Installation - Right Side (1 of 4).
Figure 5-47. Windscreen Bars and Brackets Installation - Left Side (3 of 4).
Figure 5-49. Firewall Kit Installation - Final View.
Figure 5-51. Firewall Kit Installation (1 of 4).
Figure 5-53. Firewall Kit Installation (3 of 4).
Figure 5-55. Emergency Exit Kit Installation - Final View.
Installation Instructions
Figure 5-57. Emergency Exit Kit Installation (1 of 4).
igure 5-59. Emergency Exit Kit Installation (4 of 4).
Figure 5-61. Front Cowl Kit Installation - Parts.
Figure 5-62. Front Cowl Kit Installation (1 of 1).
Figure 5-64. RH Cowl Kit Installation Parts.
Installation Instructions
Figure 5-65a. RH Cowl Kit Installation - Door Step Preparation (1 of 3)
Figure 5-65b. RH Cowl Kit Installation (2 of 3).
Figure 5-68. LH Cowl Kit Installation Parts.
Installation Instructions
Figure 5-69a. LH Cowl Kit Installation - Door Step Preparation (1 of 3).
Figure 5-69b. LH Cowl Kit Installation
Figure 5-72. Front Cover Kit Installation - Parts.
Figure 5-73. Front Cover Kit Installation
Figure 5-75. Front Cover Kit Installation (3 of 5).
Figure 5-79. Windscreen Kit Installation Parts.
Installation Instructions
Figure 5-80. Windscreen Kit Installation (1 of 7).
Figure 5-82. Windscreen Kit Installation (3 of 7).
Figure 5-86. Windscreen Kit Installation (7 of 7).
Figure 5-87. Seats Installation - Final View.
Figure 5-89. Seats Installation - Seats Base Installation (1 of 1).
Figure 5-91. RH Armored Door Installation Parts
Parts, Fasteners, Special Tools, and Materials
Installation Instructions
Figure 5-92. RH Armored Door Installation
Installation Instructions
Figure 5-96. RH Door Accessories Assembly - Parts Removed from the OEM Door.
Figure 5-99. RH Door Accessories Assembly (3 of 6).
Figure 5-104. LH Armored Door Installation Parts.
Installation Instructions
Figure 5-107. LH Armored Door Installation - Lower Hinge, Door Detent (3 of 4).
Installation Instructions
Figure 5-109. LH Door Accessories Assembly - Parts Removed from the OEM Door.
Figure 5-113. LH Door Accessories Assembly - Assembly of external Door Handle (4 of 6).
Figure 5-116. Insulation Installation - Final View.
Installation Instructions
Figure 5-120. Insulation Installation - Roof Insulation (4 of 7).
Kit Installation Completion
Figure 5-124. Re-installation of Interior Components.
Table 6-1. Recommended Maximum Torque Values
Figure 6-1. Fasteners Map - Cab Support Reinforcement.
Figure 6-2. Fasteners Map - RH and LH Wheels Housing.
Figure 6-3. Fasteners Map - Floor and Firewall.
Figure 6-4. Fasteners Map - RH and LH sides.
Figure 6-5. Fasteners Map Backside.
Figure 6-6. Fasteners Map Roof.
Figure 6-7. Fasteners Map - Windscreen and Front Cover (1 of 2).
Figure 6-8. Fasteners Map - Windscreen and Front Cover (2 of 2).
Figure 6-9. Fasteners Map - RH and LH Doors.
Prep work for Cab Support installation (M916-A1 Only)
Installation Instructions
Figure 7-1. Elbow Adjustment.
Figure 7-3. Hose Wrap Location.
Parts, Fasteners, Special Tools, and Materials
Parts, Fasteners, Special Tools, and Materials
Figure 7-6. #659 Installation (#658 RH).
Installation Instructions
Figure 7-8. Wheel Housing.
Parts, Fasteners, Special Tools, and Materials
Parts, Fasteners, Special Tools, and Materials
Figure 7-10. Shift Tower Installation.
Shift Tower Installation (M916-A1 Only)
Figure 7-11. Shift Tower Installation (M916-A1).
Rear Wall Mounting Plate (M915-A2 and M916-A1)
Figure 7-12. Mounting Plate Installation.
Relocate Engine Check Connector (M915-A2 and M916-A1)
FIELD MAINTENANCE (UNIT AND DIRECT SUPPORT MAINTENANCE) REPAIR PARTS AND SPECIAL TOOLS LISTS (RPSTL) INTRODUCTION
EXPLANATION OF COLUMNS IN THE REPAIR PARTS LISTS
Maintenance Code
Recoverability Code
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGE FORMAT AND COLUMNS
HOW TO LOCATE REPAIR PARTS
Figure 1. Cab Support Reinforcement Kit
Figure 1. Cab Support Reinforcement Kit - Continued
Figure 2. Wheel Housing Armor Kit
Figure 2. Wheel Housing Armor Kit - Continued
Figure 3. Interior Protection Armor Kit (Sheet 1 of 3)
Figure 3. Interior Protection Armor Kit (Sheet 2 of 3)
Figure 3. Interior Protection Armor Kit (Sheet 3 of 3)
Figure 3. Interior Protection Armor Kit - Continued
Figure 3. Interior Protection Armor Kit - Continued
Figure 4. Side Protection Armor Kit (Sheet 1 of 2)
Figure 4. Side Protection Armor Kit (Sheet 2 of 2)
Figure 4. Side Protection Armor Kit - Continued
Figure 4. Side Protection Armor Kit - Continued
Figure 5. Rear Protection Armor Kit
Figure 5. Rear Protection Armor Kit - Continued
Figure 6. Front Cowl Protection Armor Kit (Sheet 1 of 2)
Figure 6. Front Cowl Protection Armor Kit (Sheet 2 of 2)
Figure 6. Front Cowl Protection Armor Kit - Continued
Figure 6. Front Cowl Protection Armor Kit - Continued
Figure 7. Windscreen Protection Armor Kit (Sheet 1 of 2)
Figure 7. Windscreen Protection Armor Kit (Sheet 2 of 2)
Figure 7. Windscreen Protection Armor Kit - Continued
Figure 8. Roof Protection Armor Kit
Figure 8. Roof Protection Armor Kit - Continued
Figure 9. Foam Insulation Kit
Figure 9. Foam Insulation Kit - Continued
GROUP 94 REPAIR KITS
GROUP 94 REPAIR KITS - Continued
NATIONAL STOCK NUMBER INDEX
NATIONAL STOCK NUMBER INDEX - Continued
PART NUMBER INDEX
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued