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 36-1-191S-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 INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. LIST OF EFFECTIVE 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.....15December 2004 Change ........1........1July 2005 TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 322 CONSISTING OF THE FOLLOWING: Page *Change Page *Change Page *Change No. No. No. No. No. No. Title ..................... 1 A....................... 1 i - ii.....................0 iii....................... 1 iv- vii................... 0 viii- ix...................1 x Blank ................... 0 xi....................... 0 xii Blank .................. 0 xiii ...................... 0 xiv Blank.................. 0 1-1 - 1-16................. 0 2-1 - 2-59................. 0 2-60 Blank................. 0 3-1- 3-6..................0 3-7.......................1 3-8...................... 1 3-8.1 Added ................ 1 3-8.2 Blank ................ 1 3-9 - 3-12................. 0 3-13 ......................1 3-14 ..................... 1 3-14.1 Added ............... 1 3-14.2 Blank................ 1 3-15 - 3-23 ................ 0 3-24 Blank................. 0 4-1 - 4-40................. 0 5-1- 5-8..................0 6-1 - 6-54................. 0 7-1 - 7-19................. 0 7-20 Blank................. 0 8-1 - 8-65................. 0 8-66 Blank................. 0 9-1- 9-4..................0 A-1 - A-10 ................ 0 * Zero in this column indicates an original page. A Change 1 USAF TO 36-1-191 TABLE OF CONTENTS Chapter Page Chapter Page LIST OF ILLUSTRATIONS ........... viii 2.9 OTHER SPECIAL PURPOSE VE- HICLES AND VEHICULAR LIST OF TABLES .................. EQUIPMENT ............. 2-2 ix 2.10 AMBULANCES ............. 2-2 2.11 OSI VEHICLES ............. 2-3 FOREWORD ..................... xi 2.12 RECRUITING SERVICE ....... 2-3 2.13 PAINTING OF VEHICLE TOPS SAFETY SUMMARY ............... xiii WHITE ................. 2-3 2.14 EXCESSIVE GLARE .......... 2-3 1 SERVICEABILITY STANDARDS ....... 1-1 2.15 INTERIORS ................ 2-3 2.16 CAMOUFLAGE PATTERN PAINT- 1.1 PURPOSE ................. 1-1 ING.................... 2-3 1.2 SCOPE .................... 1-1 2.17 THERMAL SPRAY EQUIPMENT . 2-3 1.3 DEFINITIONS .............. 1-1 2.18 SAFETY PRECAUTIONS ...... 2-4 1.4 GENERAL INSPECTION POLI- 2.19 PREPARATION FOR PAINTING . 2-5 CIES ................... 1-1 2.20 SPECIALTY COATINGS ....... 2-6 1.5 LIMITED TECHNICAL INSPEC- 2.20.3 Ceramic-Loaded Coatings ....... 2-6 TION ................... 1-1 2.20.4 Spray-In Bed Liners ........... 2-6 1.5.2 Disposition Inspections ......... 1-1 2.21 PRIME COATS .............. 2-7 1.5.3 Receiving/Acceptance Inspections . 1-2 2.22 FINISH COATS .............. 2-7 1.5.4 Used Vehicles (Receiving Inspec- 2.22.1 Finish Coats ................ 2-7 tion) .................... 1-2 2.22.5 Chemical Agent Resistant Coating 1.5.5 New Vehicles (Acceptance Inspec- (CARC) Paints ............ 2-8 tion) .................... 1-3 2.23 NON-SLIP MATERIALS ....... 2-8 1.5.6 Shipping Inspections ........... 1-3 2.24 HVLP SPRAY GUN PROCE- 1.5.7 Military Assistance Program ..... 1-4 DURES ................. 2-8 1.5.8 Depot Repair/Rebuild Request .... 1-4 2.25 MARKINGS ................ 2-9 1.6 GENERAL INSPECTION STAN- 2.26 ACTIVITY MARKINGS ........ 2-10 DARDS ................. 1-5 2.27 ADDITIONS OR DEVIATIONS . 2-10 1.6.1 Appearance ................. 1-5 2.28 REQUIREMENTS ............ 2-10 1.6.2 Tools ..................... 1-5 2.29 CAMOUFLAGE ............. 2-11 1.6.4 Seals, Oil And Grease .......... 1-6 2.30 SPECIFICATIONS ............ 2-11 1.6.5 Bearings, Anti-Friction Ball And 2.31 SEMI-GLOSS DARK GREEN .... 2-11 Roller ................... 1-6 2.32 MARKING REQUIREMENTS FOR 1.6.6 Operational Test .............. 1-6 VEHICLES USED ON LAND- 1.6.7 Vacuum Tests ............... 1-6 ING AREAS .............. 2-11 1.6.8 Pollution/Emissions Control De- 2.33 IDENTIFICATION MARKINGS . 2-12 vices ................... 1-6 2.34 NATIONAL SYMBOL AND IN- 1.7 MINIMUM SERVICEABILITY TERNATIONAL MARKINGS . 2-12 STANDARDS ............. 1-6 2.34.1 National Symbol ............. 2-12 2.34.2 International Markings ......... 2-12 2 PAINTING, MARKING, AND LIGHTING . 2-1 2.35 TACTICAL MARKINGS ....... 2-12 2.36 CONCEALED MARKINGS ..... 2-12 2.1 PURPOSE ................. 2-1 2.37 DECALCOMANIA ........... 2-12 2.2 REQUIREMENT FOR PAINTING . 2-1 2.38 SPECIAL MARKINGS ......... 2-12 2.3 AUTHORIZED COLORS ....... 2-1 2.39 SIZE OF MARKINGS ......... 2-12 2.4 GENERAL ADMIN USE VE- 2.40 LOCATION OF VEHICLE IDENTI- HICLES ................. 2-2 FICATION MARKINGS ...... 2-12 2.5 FIRE TRUCKS .............. 2-2 2.41 NATIONAL SYMBOL ......... 2-13 2.6 AIRCRAFT REFUELING VE- 2.42 AIR NATIONAL GUARD (ANG) HICLES ................. 2-2 VEHICLES ............... 2-13 2.7 LIQUID OXYGEN/NITROGEN 2.43 RESERVE OFFICERS’ TRAINING TRANSPORTING .......... 2-2 CORPS VEHICLES ......... 2-13 2.8 LAW ENFORCEMENT SEDANS . 2-2 2.44 DECALCOMANIAS .......... 2-13 i TO 36-1-191 TABLE OF CONTENTS - CONTINUED Chapter Page Chapter Page 2.44.1 Decal-KPH to MPH ........... 2-13 2.73 MARKING SECURITY FORCE 2.44.4 Additional Decals ............. 2-14 VEHICLES ............... 2-23 2.45 SPECIAL MARKINGS ......... 2-14 2.74 ALERT, REFLEX, BASE OPS, 2.46 VEHICLES USED IN TRANS- AND BASE CIVIL ENGINEER PORTING SICK AND IN- (FIRE MARSHAL) ......... 2-23 JURED .................. 2-14 2.75 FOLLOW ME VEHICLES ...... 2-23 2.47 AUTOMOBILE, AMBULANCE 2.76 LOW VISIBILITY MARKING. (METROPOLITAN) ......... 2-14 SNOW REMOVAL EQUIP- 2.48 AMBULANCE (VAN/MODULAR MENT .................. 2-23 TYPE COMMERCIAL, 4 × 2 2.77 MARKING EXPLOSIVE ORDI- AND 4 × 4 PAINTED WHITE) . 2-15 NANCE DISPOSAL VE- 2.49 AMBULANCE (VAN/MODULAR) HICLES ................. 2-23 4 × 2 AND 4 × 4 PAINTED 2.78 MARKING VEHICLES EQUIPPED SEMI-GLOSS GREEN ....... 2-15 WITH MS51335 SERIES 2.50 BUS, 44 PASSENGER, CONVERT- PINTLE HOOKS ........... 2-23 IBLE (MULTILITTER) ....... 2-15 2.79 SLOW MOVING VEHICLE EM- 2.51 AUTOMOBILE, STATION BLEM .................. 2-23 WAGON ................. 2-15 2.80 STRIKE HAZARD MARKINGS . 2-23 2.52 MOBILE MEDICAL VANS ..... 2-16 2.81 CENTER OF BALANCE MARK- 2.53 RECRUITING VEHICLES ...... 2-16 INGS ................... 2-23 2.54 COMMUNICATIONS AND 2.82 NOISE HAZARD MARKING .... 2-24 GROUND CONTROL AP- 2.83 MARKING CAMOUFLAGE PAT- PROACH VEHICLES ....... 2-16 TERN PAINTED VEHICLES . 2-24 2.55 TRACTORS AND FORKLIFTS . 2-16 2.84 MARKING LAW ENFORCEMENT 2.56 TIRE SIZE/TYPE AND INFLA- SEDANS ................ 2-24 TION PRESSURE .......... 2-16 2.85 MARKING 41-PASSENGER IN- 2.57 SCHOOL BUS SAFETY MARK- TERCITY BUSES USED FOR INGS ................... 2-16 SUPPORT OF BANDS. ...... 2-25 2.58 D.O.T. MOTOR CARRIER 2.86 WRM MARKINGS ........... 2-25 SAFETY REGULATION MARK- 2.87 INSTALLATION OF REFLECTOR- INGS ................... 2-17 IZED TAPE .............. 2-25 2.59 FUEL DISPENSING AND AIR- 2.88 REMOVAL OF REFLECTORIZED CRAFT SERVICING VE- TAPE................... 2-25 HICLES ................. 2-17 2.89 REQUISITIONING OF MARK- 2.60 NO SMOKING WITHIN FIFTY INGS ................... 2-26 FEET ................... 2-17 2.90 FIGURES .................. 2-26 2.61 PRODUCT IDENTIFICATION . 2-17 2.91 LIGHTING REQUIREMENTS . 2-58 2.61.5 Demineralized Water Trucks ..... 2-18 2.92 SPECIAL DATA ............. 2-58 2.61.6 Potable Water Trucks: .......... 2-18 2.92.1 Directional Signaling Devices .... 2-58 2.62 PUMPING DURING COLD TEM- 2.92.2 Reflectors .................. 2-58 PERATURES ............. 2-18 2.93 TRAILER LIGHTING CABLES . 2-58 2.63 MANHOLE COVER AND 2.94 SPOT LIGHTS .............. 2-59 NOZZLE MARKINGS ....... 2-18 2.95 SUPPLY DATA .............. 2-59 2.63.1 Jet Fuel Dispensing Units ....... 2-18 2.96 WARNING OR INDICATING 2.63.2 Avgas Dispensing Units ........ 2-18 LIGHTS ................. 2-59 2.64 HYDRANT FUELING TRUCKS . 2-18 2.65 PURGING FLUID VEHICLES . 2-20 3 MOTOR VEHICLE AND BASE SUPPORT 2.66 WASTE FUEL VEHICLES ...... 2-20 EQUIPMENT INSPECTION ......... 3-1 2.67 RECLAIMED FUEL VEHICLES . 2-20 2.68 GASEOUS SERVICING TRAIL- 3.1 PURPOSE ................. 3-1 ERS.................... 2-20 3.2 RECOMMENDED CHANGES . 3-1 2.69 PROPELLANT SEMITRAILERS . 2-21 3.3 APPLICABLE PUBLICATIONS . 3-1 2.70 FIRE FIGHTING VEHICLES .... 2-21 3.4 GENERAL ................. 3-1 2.71 OPERATING INSTRUCTIONS . 2-22 3.5 OPERATOR DAILY/WEEKLY IN- 2.72 CONTINENTAL OR LYCOMING SPECTION REQUIREMENTS . 3-2 AIR-COOLED ENGINES ..... 2-22 ii 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 4.2.9 Air Pressure (Tire) ............ 4-1 3.6.1 Operator Compartment ......... 3-2 4.3 GENERAL ................. 4-1 3.6.2 Hydraulic Systems ............ 3-2 4.4 PURPOSE ................. 4-1 3.6.3 Check Coolant System, Heater and 4.5 SCOPE .................... 4-1 Air Conditioning ........... 3-2 4.6 OTHER DOCUMENTS ........ 4-1 3.6.6 Fuel System ................ 3-2 4.7 SELECTION OF TIRES ........ 4-1 3.6.9 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 ...............