TM 9-2320-273-20

TECHNICAL MANUAL

ORGANIZATIONAL MAINTENANCE

TRUCK TRACTOR, LINE HAUL,

50,000 GVWR, 6 X 4, M915 (NSN 2320-01-028-4395)

TRUCK TRACTOR, LIGHT EQUIPMENT TRANSPORTER

(LET), 56,000 GVWR, 6 X 6, W/WINCH

M916 (NSN 2320-01-028-4396)

TRUCK TRACTOR, MEDIUM EQUIPMENT TRANSPORTER

(MET), 75,000 GVWR, 8 X 6, W/WINCH

M920 (NSN 2320-01-028-4397)

TRUCK CHASSIS, 75,000 GVWR, 8 X 6,

FOR 20-TON DUMP TRUCK,

M917 (NSN 3805-01-028-4389)

TRUCK CHASSIS, 56,000 GVWR, 6 X 6,

FOR BITUMINOUS DISTRIBUTOR TRUCK,

M918 (NSN 3895-01-028-4390)

TRUCK CHASSIS, 75,000 GVWR, 8 X 6,

FOR CONCRETE-MOBILE@ MIXER TRUCK,

M919 (NSN 3895-01-028-4391)

AM GENERAL CORPORATION TA 075632

HEADQUARTERS, DEPARTMENT OF THE ARMY

This copy is a reprint which includes current

NOVEMBER 1980

pages from Changes 1 through 4.

TM 9-2320-273-20

C4

CHANGE

No. 4

HEADQUARTERS

DEPARTMENT OF THE ARMY

WASHINGTON, D. C., 20 April 1993

ORGANIZATIONAL MAINTENANCE

TRUCK TRACTOR, LINE HAUL,

50,000 GVWR, 6X4, M915 (NSN 2320-01-028-4395)

TRUCK TRACTOR, LIGHT EQUIPMENT TRANSPORTER

(LET), 56,000 GVWR, 6X6, W/WINCH

M916 (NSN 2320-01-028-4396)

TRUCK TRACTOR, MEDIUM EQUIPMENT TRANSPORTER

(MET), 75,000 GVWR, 8X6, W/WINCH

M920 (NSN 2320-01-028-4397)

TRUCK CHASSIS, 75,000 GVWR, 8X6

FOR 30 TON DUMP TRUCK

M917 (NSN 3805-01-028-4389)

TRUCK CHASSIS, 56,000 GVWR, 6X6

FOR BITUMINOUS DISTRIBUTOR TRUCK,

M918 (NSN 3895-01-028-4390)

TRUCK CHASSIS, 75,000 GVWR, 6X6

FOR CONCRETE MOBILE MIXER TRUCK,

M919 (NSN 3895-01-028-4391)

TM 9-2320-273-20, 28 November 1980, is changed as follows:

1. Remove old pages and insert new pages as indicated below.

2. The Preventive Maintenance Checks and Services have been completely replaced; no change bars or

pointing hands will appear on pages 3-3 through 3-10.30.

Remove Pages Insert Pages

3-3 through 3-10 3-3 through 3-10.30

3. File this change sheet in the front of the publication for information purposes.

By Order of the Secretary of the Army:

GORDON R. SULLIVAN

General, United States Army

Official:

MILTON H. HAMILTON

Administrative Assistant to the

Secretary of the Army

Chief of Staff

Distribution:

To be distributed in accordance with DA Form 12-38-E, Block 0298, requirements for

TM 9-2320-273-20.

Approved for public release; distribution is unlimited.

TM 9-2320-273-20

CHANGE

No. 3

HEADQUARTERS

DEPARTMENT OF THE ARMY

Washington D.C., 26 June 1992

ORGANIZATIONAL MAINTENANCE

TRUCK TRACTOR, LINE HAUL,

50,000 GVWR, 6 X 4, M915 (NSN 2320-01-028-4395)

TRUCK TRACTOR, LIGHT EQUIPMENT TRANSPORTER

(LET), 56,000 GVWR, 6 X 6, W/WINCH

M916 (NSN 2320-01-028-4396)

TRUCK TRACTOR, MEDIUM EQUIPMENT TRANSPORTER

(MET), 75,000 GVWR, 8 X 6, W/WINCH

M920 (NSN 2320-01-028-4397)

TRUCK CHASSIS, 75,000 GVWR, 8 X 6

FOR 30 TON DUMP TRUCK,

M917 (NSN 3805-01-028-4389)

TRUCK CHASSIS, 56,000 GVWR, 6 X 6

FOR BITUMINOUS DISTRIBUTOR TRUCK,

M918 (NSN 3895-01-028-4390)

TRUCK CHASSIS, 75,000 GVWR, 6 X 6

FOR CONCRETE MOBILE MIXER TRUCK,

M919 (NSN 3895-01-028-4391)

TM 9-2320-273-20,28 November 1980 is changed as follows:

1.

2.

3.

4.

Remove old pages and insert new pages as indicated below.

New or changed material is indicated by a vertical bar in the margin of the page.

Added or revised illustrations are indicated by a vertical bar adjacent to the illustration.

Remove Pages Insert Pages

3-3 and 3-4 3-3 and 3-4

10-85 and 10-86 10-84.1 thru 10-86

Index 11 and Index 12 Index 11 thru Index 12.1/(index 12.2

blank)

File this change sheet in front of the publication for reference purposes.

By Order of the Secretary of the Army:

MILTON H. HAMILTON

Administrative Assistant to the

Secretary of the Army

01981

GORDON R. SULLIVAN

General, United States Army

Chief of Staff

Distribution:

To be distributed in accordance with DA Form 12-38-E (Block 0298) Unit Maintenance requirements for

TM9-2320-273-20.

Approved for public release; distribution is uniimited.

Official:

TM 9-2320-273-20

C2

CHANGE

NO. 2

HEADQUARTERS

DEPARTMENT OF THE ARMY

Washington, DC, 18 June 1987

ORGANIZATIONAL MAINTENANCE MANUAL

TRUCK TRACTOR, LINE HAUL,

50,000 GVWR, 6 X 4, M915 (NSN 2320-01-028-4395)

TRUCK TRACTOR, LIGHT EQUIPMENT TRANSPORTER

(LET), 56,000 GVWR, 6 X 6, W/WINCH

M916 (NSN 2320-01-028-4396)

TRUCK TRACTOR, MEDIUM EQUIPMENT TRANSPORTER

(MET), 75,000 GVWR, 8 X 6, W/WINCH

M920 (NSN 2320-01-028-4397)

TRUCK CHASSIS, 75,000 GVWR, 8 X 6,

FOR 20-TON DUMP TRUCK,

M917 (NSN 3805-01-028-4389)

TRUCK CHASSIS, 56,000 GVWR, 6 X 6,

FOR BITUMINOUS DISTRIBUTOR TRUCK,

M918 (NSN 3895-01-028-4390)

TRUCK CHASSIS, 75,000 GVWR, 8 X 6,

FOR CONCRETE MOBILE MIXER TRUCK,

M919 (NSN 3895-01-028-4391)

TM 9-2320-273-20, 28 November 1980 is changed as follows:

1. Remove old pages and insert new pages as indicated below.

2. New or changed material is indicated by a vertical bar in the margin of the page.

3. Added or revised illustrations are indicated by a vertical bar adjacent to the illustration identification number

Remove Pages Insert Pages Remove Pages Insert Pages

c and d

1-15 and 1-16

2-5/2-6 (blank)

2-23 and 2-24

2-65 thru 2-68

2-75 thru 2-82

3-1 thru 3-10

4-7 and 4-8

4-25 and 4-26

5-31 thru 5-34

5-91 and 5-92

6-11 and 6-12

9-5 and 9-6

9-11 thru 9-18

c and d

1-15 and 1-16

2-5/2-6 (blank)

2-23 and 2-24

2-65 thru 2-68

2-75 thru 2-82

3-1 thru 3-10

4-7 and 4-8

4-25 thru 4-26.2

5-31 thru 5-34

5-91 thru 5-92.4

6-11 thru 6-12.2

9-5 and 9-6

9-11 thru 9-18

9-28 thru 9-34

9-53 and 9-54

9-175 thru 9-178

10-39 thru 10 66

11-27 thru 11-32

12-49/12-50 (blank)

A-1 and A-2

B-13 and B-14

B-17 and B-18

B-21 and B-22

C-3 and C-4

Index-1 thru Index-6

Index-9 and Index-10

Index-13 thru Index-15/16 (blank)

9-28 thru 9-34.8

9-53 thru 9-54.4

9-175 thru 9-178

10-39 thru 10 66

11-27 thru 11-32

12-49 thru 12-52

A-1 and A-2

B-13 and B-14

B-17 and B-18

B-21 and B-22

C-3 and C4

Index-1 thru Index-6

Index-9 and Index-10

Index-13 thru Index-15/16 (blank)

FO-2 thru FO-15

4. File this change sheet in front of the publication for reference purposes.

FO-2 thru FO-15

Approved for Public Release; Distribution is Unlimited.
By Order of the Secretary of the Army:

TM 9-2320-273-20

C2

JOHN A. WICKHAM, JR.

General, United States Army

Chief of Staff

Official:

R.L. DILWORTH

Brigadier General, United States Army

The Adjutant General

Distribution:

To be distributed in accordance with DA Form 12-38, Organizational Maintenance requirements for

M915, M916, M920 Trucks and Truck chassis for M917, M918, and M919.
TM 9-2320-273-20

CHANGE

NO. 1

C1

HEADQUARTERS

DEPARTMENT OF THE ARMY

Washington, DC. 18 February 1983

ORGANIZATIONAL MAINTENANCE MANUAL

TRUCK TRACTOR, LINE HAUL,

50,000 GVWR, 6 X 4, M915 (NSN 2320-01-028-4395)

TRUCK TRACTOR, LIGHT EQUIPMENT TRANSPORTER

(LET), 56,000 GVWR, 6 X 6, W/WINCH

M916 (NSN 2320-01-028-4396)

TRUCK TRACTOR, MEDIUM EQUIPMENT TRANSPORTER

(MET), 75,000 GVWR, 8 X 6, W/WINCH

M920 (NSN 2320-01-028-4397)

TRUCK CHASSIS, 75,000 GVWR, 8 X 6,

FOR 20-TON DUMP TRUCK,

M917 (NSN 3805-01-028-4389)

TRUCK CHASSIS, 56,000 GVWR, 6 X 6,

FOR BITUMINOUS DISTRIBUTOR TRUCK,

M918 (NSN 3895-01-028-4390)

TRUCK CHASSIS, 75,000 GVWR, 8 X 6,

FOR CONCRETE MOBILE MIXER TRUCK,

M919 (NSN 3895-01-028-4391)

TM 9-2320-273-20, 28 November 1980 is changed as follows:

1. Remove old pages and insert new Pages as indicated below. Now or changed material

is indicated by a vertical bar in the margin of the page. Added or revised illustrations

are indicated by a vertical bar adjacent to the identification number.

Remove Pages Insert Pages Remove Pages Insert Pages

i i 9-135 and 9-136 9-135 and 9-136

3-3 through 3-10 3-3 through 3-10 9-165 and 9-166 9-165 and 9-166

4-141 through 4-146 4-141 through 4-146 10-3 and 10-4 10-3 and 10-4

5-157 through 5-160 5-157 through 5-160 10-9 and 10-10 10-9 and 10-10

6-13 through 6-16 6-13 through 6-14.2, 11-89 through 11-94 11-89 through 11-94

6-15 and 6-16 B-11 and B-12 B-11 and B-12, B-12.1

2. File this change sheet in front of the publication for reference purposes.
TM 9-2320-273-20

C1

By Order of the Secretary of the Army:

E.C. MEYER

General, United States Army

Chief of Staff

Official:

ROBERT M. JOYCE

Major General, United States Army

The Adjutant General

Distribution:

To be distributed in accordance with DA Form 12-38, organizational maintenance requirements for M915, M916,

M920 trucks and truck chassis for M917, M918, and M919.
TM 9-2320-273-20

This manual may include copyrighted technical data of one or more of the following subcontractors

of AM General Corporation:

© 1975

© 1973, 1978

© 1971

© 1976

© 1965, 1967, 1973, 1977

© 1971, 1972, 1974, 1975

© 1970

© 1977, 1978, 1979

© 1977

© 1976

© 1973

© 1976

© 1975, 1975, 1977

© 1975

© 1972, 1973, 1976

© 1960

© 1976

© 1977

© 1976

© 1970, 1975, 1976, 1977,

© 1978, 1979

© 1976, 1977

© 1978

Alinabal, Division of MPB Corporation

Anchorlock, Division of Royal Industries

Bostrom, Division of Universal Oil

Products Company

The Budd Company

Cole-Hersee Company

Chelsea Power Equipment, Division of

Dana Corporation

Cross Manufacturing, Incorporated

Cummins Engine Company, Incorporated

Dayco Corporation

Eberhard Manufacturing Company,

Division of the Eastern Company

Firestone Steel Products Company,

Division of the Firestone Tire and

Rubber Company

Grote Manufacturing Company

Owatonna Tool Company, Tools and

Equipment Division

Holland Hitch Company

Long Manufacturing, Division of

Borg-Warner Corporation

Mercury Metal Products

Nelson Muffler, Division of Nelson

Industries, Incorporated

Phillips, Division of Budd

Parker-Hannifin Corporation

RockwelI International

Ross Gear, Division of TRW, Incorporated

Snap-On Tools Corporation

AM General has written permission from any and all such subcontractors holding copyrights to grant

the United States Government a royalty free, nonexclusive and irrevocable license throughout the

world for Governmental purposes to publish, translate, reproduce, deliver, perform, dispose of, and

to authorize others so to do, alI tecnnical data now or hereafter covered by copyright. Any use other

than that authorized above must be made with the express permission of AM General or the subcontractor whose copyrighted material is being used. This notice must be reproduced on alI copies

or portions thereof.

a/(b (blank))

TM 9-2320-273-20

CARBON MONOXIDE POISONING CAN BE DEADLY

Carbon monoxide is a colorless, odorless, poisonous gas, which, when breathed, deprives the body of

oxygen and causes suffocation. Exposure to air contaminated with carbon monoxide produces symptoms

of headache, dizziness, loss of muscular control, apparent drowsiness, or coma. Permanent brain damage

or death can result from severe exposure.

Carbon monoxide occurs in the exhaust fumes of fuel-burning internal combustion engines and can

become dangerous under conditions of inadequate ventilation. The following precautions must be

observed to insure the safety of personnel:

A. DO NOT operate the engine of a vehicle in an enclosed area unless it is ADEQUATELY

VENTILATED.

B. DO NOT idle the engine for long periods without maintaining ADEQUATE VENTILATION

in the personnel compartments.

C. DO NOT drive any vehicle with inspection plates, cover plates, or engine compartment

doors removed unless it is necessary for maintenance purposes.

D. BE ALERT at all times during vehicle operation for exhaust odors, and exposure symptoms.

If either are present, IMMEDIATELY VENTILATE the personnel compartments. If symptoms persist, remove affected personnel from the vehicle and treat as follows:

(1) Exposure to fresh air.

(2) Keep warm.

(3) DO NOT PERMIT EXERCISE.

(4) If necessary, administer artificial respiration (see FM 21-11).

THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS ADEQUATE VENTILATION.

COMPRESSED AIR

Compressed air used for cleaning purposes will not exceed 30 psi. Use only with effective chip guarding

and personal protective equipment (goggles/shield, gloves, etc.).

WINCH HYDRAULIC RESERVOIR (M916 AND M920)

Do not remove fill cap when hydraulic fluid is hot. The hydraulic tank is pressurized to 5 psi. Remove

the fill cap slowly.

c
TM 9-2320-273-20

COOLING FAN

When working in the engine compartment with the engine running, stay clear of the cooling fan. The

fan may engage automatically at any time and could cause serious injury.

PUSHER AXLE (M917, M919, AND M920)

When the pusher axle is in the up position it freewheels. DO NOT USE THE PUSHER AXLE AS A

STEP. You can fall and be injured. Always lower the pusher axle when the vehicle is parked.

FILLING THE RADIATOR

Let the radiator cool before removing cap. Remove radiator cap in two steps. First, place a thick cloth

over the cap and slowIy rotate cap left to its first stop; pause, and let pressure escape from cooling

system. Then rotate cap farther left until you can remove it. Failure to follow this procedure can result in serious burns.

LIFTING THE TRUCK

Improper use of lifting equipment and attachment of cables to the truck can result in serious personnel injury and equipment damage. OBSERVE ALL STANDARD RULES OF SAFETY.

HOOD SAFETY LATCH

After raising hood, insert the S-shaped safety hook through two matching holes in the prop channels

to prevent the hood from falling accidentally.

EXHAUST PIPE AND MUFFLER

During normal operation the exhaust pipe and muffler can become very hot. Be careful not to touch

these components with your bare hands. Do not allow your body to come in contact with the pipe

or muffler. Exhaust system components may be hot enough to cause serious burns.

d Change 2
This manual contains copyright material. * TM 9-2320-273-20

Technical Manual HEADQUARTERS

DEPARTMENT OF THE ARMY

No. 9-2320-273-20 Washington, DC, 28 November 1980

ORGANIZATIONAL MAINTENANCE MANUAL

TRUCK TRACTOR, LINE HAUL,

50,000 GVWR, 6 X 4, M915 (NSN 2320-01-028-4395)

TRUCK TRACTOR, LIGHT EQUIPMENT TRANSPORTER

(LET), 56,000 GVWR, 6 X 6, W/WINCH

M916 (NSN 2320-01-028-4396)

TRUCK TRACTOR, MEDIUM EQUIPMENT TRANSPORTER

(MET), 75,000 GVWR, 8 X 6, W/WINCH

M920 (NSN 2320-01-028-4397)

TRUCK CHASSIS, 75,000 GVWR, 8 X 6,

FOR 20-TON DUMP TRUCK,

M917 (NSN 3805-01-028-4389)

TRUCK CHASSIS, 56,000 GVWR, 6 X 6,

FOR BITUMINOUS DISTRIBUTOR TRUCK,

M918 (NSN 3895-01-028-4390)

TRUCK CHASSIS, 75,000 GVWR, 8 X 6,

FOR CONCRETE MOBILE MIXER TRUCK,

M919 (NSN 3895-01-028-4391)

REPORTING OF ERRORS

You can help improve this publication. If you find any mistakes, or if

you know of a way to improve the procedures, please let us know. Mail

your letter, DA Form 2028 (Recommended Changes to Publication and

blank forms), or DA Form 2028-2 located in back of this Publication

direct to: US Army Tank-Automotive Command, ATTN: DRSTAMBP, Warren MI 48090. A reply will be furnished to you.

Page

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Section I General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

II Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

*This manual supersedes DRAFT TM 9-2320-273-20, 30 August 1979.

Change 1 i
TM 9-2320-273-20

CHAPTER 2

Section I

II

Ill

IV

V

VI

V l l

Vll l

lX

X

Xl

XII

XIII

X lV

XV

XVl

XVII

XVll l

XIX

XX

XXl

XXl l

XXIII

XXIV

XXV

XXVI

XXVII

XXVll l

CHAPTER 3

Section I

II

Ill

IV

V

CHAPTER 4

Section I

II

Ill

TABLE OF CONTENTS (Continued)

PRINCIPLES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Truck/Tractor Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Transfer Case and Rear Axle Differential Lockup. . . . . . . . . . . . . .

Pusher Axle and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Axle and Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel and Air lntake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relays, Circuit Breakers, and Wire Identification . . . . . . . . . . . . . . . . . . .

Starting and Starting Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ether Quick-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries and Power Generating System . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blackout Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Heating and Ventilating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressed Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Air-Powered Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Takeoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Winterization Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTERGRATED SYSTEMS MAINTENANCE . . . . . . . . . . . . . . . . . . . .

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts, Special Tools, TMDE, and Support Equipment . . . . . . . . . .

Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventive Maintenance Checks and Services. . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE AND ENGINE SYSTEMS MAINTENANCE . . . . . . . . . . . . .

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts, Special Tools, TMDE, and Support Equipment . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

2-1

2-1

2-2

2-4

2-7

2-10

2-12

2-14

2-15

2-17

2-19

2-23

2-27

2-30

2-33

2-37

2-40

2-42

2-44

2-58

2-60

2-61

2-62

2-66

2-68

2-82

2-86

2-89

2-90

2-92

3-1

3-1

3-1

3-1

3-3

3-11

3-17

4-1

4-1

4-1

4-1

4-7

ii
TM 9-2320-273-20

TABLE OF CONTENTS (Continued)

Page

CHAPTER 5 ELECTRICAL AND

INSTRUMENTATION SYSTEMS MAINTENANCE . . . . . . . . . . . . . . . 5-1

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts, Special Tools, TMDE, and Support Equipment . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

5-1

5-2

5-65

Section I

II

Ill

CHAPTER 6 TRANSMISSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts,Special Tools, TMDE, and Support Equipment . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6-1

6-2

6-7

Section I

II

Ill

CHAPTER 7 POWER TRANSFER CASE MAINTENANCE . . . . . . . . . . . . . . . . . . . 7-1

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts, Special Tools, TMDE, and Support Equipment . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

7-1

7-1

7-5

Section I

II

Ill

CHAPTER 8 PROPEL LERSHAFTS AND AXLE MAINTENANCE . . . . . . . . . . . . . 8-1

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts, Special Tools, TMDE, and Support Equipment . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1

8-1

8-2

8-5

Section I

II

Il l

CHAPTER 9 COMPRESSED AIR AND BRAKE SYSTEMS . . . . . . . . . . . . . . . . . . . 9-1

9-1

9-1

9-2

9-17

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts, Special Tools, TMDE, and Support Equipment . . . . . . . . . .

Troublesh-ooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section I

II

Ill

CHAPTER 10 WHEELS, STEERING,

AND SUSPENSION SYSTEMS MAINTENANCE . . . . . . . . . . . . . . . . . 10-1

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts, Special Tools, TMDE and Support Equipment. . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1

10-1

10-2

10-12

Section I

II

Ill

iii
TM 9-2320-273-20

CHAPTER 11

Section I

II

Ill

CHAPTER 12

Section I

II

Ill

APPENDIX A

APPENDIX B

Section I

II

Il l

APPENDIX C

Section I

II

APPENDIX D

Section I

APPENDIX E

Secton I

II

TABLE OF CONTENTS (Continued)

Page

FRAME, BODY AND CAB MAINTENANCE . . . . . . . . . . . . . . . . . . . . 11-1

Chapter Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Repair Parts, Special Tools, TMDE and Support Equipment. . . . . . . . . . . 11-1

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

WINCH AND POWER TAKEOFF LINKAGE MAINTENANCE . . . . . . . 12-1

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Repair Parts, Special Tools, TMDE and Support Maintenance. . . . . . . . . . 12-1

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . . . . . . B-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Maintenance Allocation Chart for Truck, Tractor, M915,

M916, and M920 and Chassis for M917, M918, and M919 . . . . . . . . . . . . B-4

Tool and Test Equipment Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPENDABLE SUPPLIES AND MATERIALS LIST . . . . . . . . . . . . . . C-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Expendable Supplies and Materials List . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

ILLUSTRATED LIST OF MANUFACTURED ITEMS . . . . . . . . . . . . . . . . E-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Illustrated Manufacturing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

iv

B-20
TM 9-2320-273-20

HOW TO USE THIS MANUAL

This manual contains the following information to help you understand how the truck/tractor works,

how to service it, and how to make authorized repairs.

WHAT THIS MANUAL CONTAINS

This manual is divided into chapters which provide the following information:

CHAPTER 1 – INTRODUCTION

This chapter contains general information on different truck/tractor models covered in this manual.

Included are illustrations showing the inside and outside of the vehicle.

CHAPTER 2 – PRINCIPALS OF OPERATION

This chapter contains information on how the vehicle works. It is divided into sections by function:

fuel system, oil system, etc. (see Table of Contents for complete listing).

CHAPTER 3 – TRUCK/TRACTOR MAINTENANCE

This is the integrated maintenance chapter. It includes information that applies to all the maintenance

chapters that follow (chapter 4 thru 11), including the following important information:

a. When to inspect, test, and service the vehicle. (Preventive Maintenance Checks and

Services.)

b. How to find the best troubleshooting procedures for a specific problem. (Troubleshooting

Symptom Index.)

CHAPTERS 4 THRU 12 - INDIVIDUAL MAINTENANCE CHAPTERS (See Table of Contents).

These chapters give you the following information:

a. How to find out what’s causing a problem. (Troubleshooting Procedures.)

b. A list of authorized maintenance procedures. (Maintenance Task Summaries.)

c. Detailed procedures for replacing and servicing component parts (Task Procedures).

Procedures include a list of special tools that you’ll need (if any), materials required and

references to other manuals, if needed.

v
TM 9-2320-273-20

This listing includes the nomenclature cross reference list and the list of abbreviations used in this manual.

A. NOMENCLATURE CROSS REFERENCE LIST

Common Name Official Nomenclature

Air Cooler, Intercooler

Drive Shaft

Power Steering Cylinder

Dual Control Valve, Treadle Valve

Crankcase Breather

Antifreeze, Ethylene Glycol Mixture

Power Transfer/Differential Lockup Control

Cold Start System

Tail Pipe

Float Switch

Power Steering Pump, Power Steering Reservoir

Ratio Valve

Differential Lockout Engaged Switch

Splash Shields

Intermediate Pipe

Brake Control Valve

PTO Propeller Shaft U-Joint

Jacobs Brake Cover, Valve Cover,

Cylinder Head Cover

Stowage Box

Cross Tube

Hand Control Valve for Trailer

Exhaust Pipe

Aftercooler

Propeller Shaft

Auxiliary Assist Cylinder

Dual Brake Valve

Breather Tube

Coolant

Differential Lockup Control

Ether Quick-Start System

Exhaust Stack

Fuel Level Sending Unit

Hydraulic Pump and Reservoir Assembly

Limiting Valve

Lockout Switch

Mud Flaps

Muffler Inlet Pipe

Park Brake Valve

PTO-to-Pump Coupling

Rocker Arm Housing Cover

Seat Risers and Tool Box

Tie Rod

Trailer Brake Valve

Turbo Outlet Pipe

vi
TM 9-2320-273-20

B. LIST OF ABBREVIATIONS

amp

approx

attn

cm

cu ft

cu m

cu yd

DA

dia

desc

fig

GVWR

gnd

in.

Kg

kph

m

Ml

mph

MTOE

No.

NSN

para

PMCS

P/N

psi

PTO

qt

ref

TM

TMDE

vert

ampere

approximate

attention

centimeter

cubic foot/cubic feet

cubic meter

cubic yard

Department of the Army

diameter

description

figure

gross vehicle weight rating

ground

inch

kilogram

kilometers per hour

meter

Michigan

miles per hour

Modified Table of Organization & Equipment

number

National Stock Number

paragraph

Preventive Maintenance Checks & Services

part number

pounds per square inch

Power Takeoff

quart

reference

technical manual

Test, Measurement & Diagnostic Equipment

vertical

vii
TM 9-2320-273-20

Reporting Equipment Improvement Recommendations (ElR’s).

ElR’s can and must be submitted by anyone who is aware of an unsatisfactory condition with the

equipment design or use. It is not necessary to show a new design or list a better way to perform a

procedure, just simply tell why the design is unfavorable or why a procedure is difficult. See TM 38-

750. Mail ElR’s directly to Commander, U.S. Army Tank Automotive Materiel Readiness Command,

ATTN: DRSTA-MTC, Warren, Michigan, 48090. A reply will be furnished to you.

Equipment Improvement Report and Maintenance Digest (ElR MD) and Equipment Improvement

Report and Maintenance Summary (EIR MS).

The quarterly Equipment Improvement Report and Maintenance Digest, TB 43-0001-39 series, contains valuable field information on the equipment covered in this manual. The information in the

TB 43-0001-39 series is compiled from some of the Equipment Improvement Reports that you prepared on the vehicles covered in this manual. Many of these articles result from comments, suggestions,

and improvement recommendations that you submitted to the ElR program. The TB 43-0001-39 series

contains information on equipment improvements, minor alterations, proposed Modification Work

Orders (MWO’S), warranties (if applicable), actions taken on some of your DA Form 2028’s (Recommended Changes to Publications), and advance information on proposed changes that may affect this

manual. In addition, the more maintenance significant articles, including minor alterations, field-fixes,

etc., that have a more permanent and continuing need in the field are republished in the Equipment

Improvement Report and Maintenance Summary (EIR MS) for TARCOM Equipment (TM 43-0143).

Refer to both of these publications (TB 43-0001-39 series and TM 43-0143) periodically, especially

the TB 43-0001-39 series, for the most current and authoritative information on your equipment.

The information will help you in doing your job better and will help in keeping you advised of the

latest changes to this manual. Also refer to DA Pam 310-4, Index of Technical Publications, and

Appendix A, References, of this manual.

viii
TM 9-2320-273-20

This page intentionally left blank.

ix
TM 9-2320-273-20

Figure 1-1. M915 Series Vehicles

1-0
TM 9-2320-273-20

CHAPTER 1

INTRODUCTION

1-1. OVERVIEW.

This chapter provides you with the following information:

a. Forms and record data required for maintenance.

b. Physical description of each truck model and major equipment components.

Section I GENERAL INFORMATION

1-2. SCOPE.

Type of Manual: Organizational Maintenance.

Model Numbers and Equipment Names (fig. 1-1):

a. M915 Line Haul Truck Tractor

b. M916 Light Equipment Transporter Truck Tractor

c. M917 20-Ton Dump Truck

d. M918 Bituminous Distributor Truck

e. M919 Concrete Mobile Mixer Truck

f. M920 Medium Equipment Transporter Truck Tractor

Chassis Designations:

a. Type I – Model M915

b. Type II – Models M916 and M918

c. Type Ill – Models M917, M919, and M920

1-3. MAINTENANCE FORMS, RECORDS, AND REPORTS.

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by TM 38-250, The Army Maintenance Management System.

1-4. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE.

Requirements and procedures for destruction of Army materiel to prevent enemy use are given in

TM 750-244-6.

1-1
TM 9-2320-273-20

1-5. ADMINISTRATIVE STORAGE.

Storage information is given in TM 740-90-1, Administrative Storage.

Section II EQUIPMENT DESCRIPTION AND DATA

1-6. PURPOSE OF EQUIPMENT.

Model M915.

Model M916.

Model M917.

Model M918.

Model M919.

Model M920.

Used for on-road line hauling of loads up to a gross vehicle weight rating of 50,000 Ibs

(22,680 Kg), 30,000 Ibs (13,608 Kg) on fifth wheel.

Used for transporting light equipment, both on and off the road, up to a gross vehicle

weight rating of 56,000 Ibs (25,402 Kg), 28,000 Ibs (12,700 Kg) on fifth wheel.

A heavy-duty, 20-ton dump truck used to haul aggregate and similar materials. Capable

of operating both on and off the road, up to a gross vehicle weight rating of 75,000 Ibs.

Hauls 15.2 cu yds (11.62 cu m) heaped, and 19.6 cu yds (14.98 cu m) with 12 inch

sideboards.

Used with a mounted bituminous distributor to spread 375 gallons (1,419.52 liters) of

bitumen per minute at a road speed of 1.5 miles per hour (2.41 K/H).

Used with a mounted concrete mixer to mix and spread concrete at a maximum rate

of 40 cu ft per minute. Can transport sufficient cement, sand, coarse aggregate and

water to mix 8 cu yds (6.12 cu m) on-site.

Used to transport medium equipment both on and off the road, up to a gross vehicle

rating of 75,000 Ibs (34,020 Kg), 40,000 Ibs (18,144 Kg) on fifth wheel.

1-7. CAPABILITIES AND FEATURES.

a. Interchangeable frame components (Exception: Frames for Types II and III chassis have

an added 3/8-inch outer channel.)

b. Commercial-type replacement parts for entire vehicle, available through national network of dealers and vendors.

c. Commercial operating components that require no special maintenance procedures and

a minimum of special tools:

(1)

(2)

(3)

(4)

(5)

(6)

(7)

Six-cylinder, in-line, four-stroke, four-cycle turbocharged diesel engine.

Semi-automatic, centrifugal clutch transmission with 16 forward and 2 reverse

speeds.

Transfer case for front wheel drive (M916 thru M920).

Pusher axle for weight distribution (M917, M919, and M920).

Rear tandem axle.

Power Takeoff (PTO) for power to drive accessories (M916 thru M920).

Winch (M916 and M920).

1-2
TM 9-2320-273-20

1-8. LOCATION OF MAJOR EXTERIOR COMPONENTS.

The illustration below identifies the major exterior components located on one or more models of

M915 thru M920 vehicles. See table 1-1, Differences Between Models for model configuration

differences and a reference to detailed information. Also see the Operator’s Manual TM 9-2320-273-10.

1-3
TM 9-2320-273-20

1-9. LOCATION OF MAJOR INTERIOR COMPONENTS.

The illustration below identifies the major interior components located on the M915 thru M920

vehicles. No identification plates, instruction plates, warranty plates, modification plates or stencils

are applicable to organizational maintenance.

1-10. DIFFERENCES BETWEEN MODELS.

The major equipment and functional differences between models are given in table 1-1. For illustrations and descriptions, refer to the following:

a. Illustration of each model (fig. 1-1).

b. Purpose of each model (para 1-6).

c. Differences between models (table 1-1).

1-4
TM 9-2320-273-20

Table 1-1. Differences Between Models.

EQUIPMENT/FUNCTION

Type I Chassis.

Type I I Chassis.

Type III Chassis.

Transfer Case.

Pusher Axle.

Driving Front Axle.

Spare Tire and Wheel

Assembly.

Hoist for Spare.

Towing Pintle.

Fifth Wheel.

Spacer Kit for Fifth

Wheel.

Winch.

Work Lamps – Stationary.

Work Lamps – Portable.

Power Takeoff (PTO).

Hose Tender and Cable

Support.

Backup Alarm.

Double Rail Frame.

Front Shock Absorbers.

No-Spin Differential (1)

(2)

Tires:

Highway.

On/Off Road.

Special Bodies:

Dump Body.

Bituminous Distributor.

Concrete-Mobile ®Mixer.

Auxiliary Power Steering

Cylinder.

Sliding Rear Window.

Front and Rear Air

Connections.

Tail Roller.

24V Receptacle.

VEHICLE MODEL

M915 M916

(PARA)

X 1-2

X X 1-2

X X X 1-2

X X X X X 2-14

X X X 2-16

X X X X X 2-19

X X 10-11,10-12

X X X –

X X X X –

X X X 11-13

X X

X X 2-80

X X 2-48

X X X 5-54

X X X X X 2-78

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

X X X X

1-5

M917 M918 M919 M920 DESC/REF
TM 9-2320-273-20

1-11. EQUIPMENT DATA.

MODEL M915 TRUCK TRACTOR

OVERALL CHARACTERISTICS:

National Stock Number:

Curb Weight:

Axle Loads (Empty):

Front Axle:

Rear Axle:

Axle Loads (with 30,000 Ibs (13,608 Kg) 5th Wheel Load):

Front Axle:

Rear Tandem:

Gross Vehicle Weight:

Gross Axle Weight Rating:

Front Axle:

Rear Tandem:

Gross Vehicle Weight Rating:

Towed Load (M872 Trailer – 30,000 lb (13,608 Kg ) on the King Pin):

Gross Combination Weight Rating:

DIMENSIONAL DATA:

Overall Length (Less Pintle Hook and Litting Shackle):

Overall Width (Body):

Height (Over Horns – Empty):

Overall Height (Over Stack-Empty):

Cab to Axle:

Bumper to Back of Cab:

Bumper to Front Axle:

Wheel Base:

Shipping Cube, Minimum:

Tandem Axle Spacing:

Tread Width:

Front:

Rear:

Dual Tire Spacing:

Fifth Wheel to Rear Tandem:

Overall Length with M-872 Trailer:

Angle of Approach (Loaded):

Minimum Turning diameter, Curb to Curb:

Minimum Ground Clearance (Under Rear Walking Beam Bracket, Empty):

Fording Depth, Maximum:

PERFORMANCE:

Maximum Speed Forward (At 2,100 rpm – 16th Gear):

Speed on 3.9% Grade:

Maximum Grade (At GCWR):

Minimum Sustained Speed (At 1,300 rpm):

Maximum Drawbar Pull @ 0.7 Coefficient:

Maximum Side Slope (W/Adequate Tractive Surface):

ENGLISH

2320-01-028-4395

19,630 Ibs

9,920 lbs

9,710 Ibs

11,055 Ibs

37,660 Ibs

48,715 Ibs

12,000 Ibs

38,000 Ibs

55,000 Ibs

86,170 Ibs

105,000 Ibs

268.50 in.

96.75 in.

114.63 in.

134.63 in.

86 in.

119 in.

37.5 in.

168.25 in.

1,674 cu ft

52 in.

78.40 in.

71.57 in.

13.75 in.

8 in.

54.92 ft

38°

53.50 ft

10.25 in.

20 in.

66.60 mph

25 mph

17%

2.31 mph

25,028 Ibs

10%

METRIC

8781 Kg

4,500 Kg

4,405 Kg

5,015 Kg

17,083 Kg

22,097 Kg

5,443 Kg

17,236 Kg

24,941 Kg

39,121 Kg

47,627 Kg

6.82 m

2.46 m

2.91 m

3.42 m

2.18 m

3.02 m

.95 m

4.30 m

47.40 cu m

1.32 m

1.99 m

1.82 m

.35 m

.20 m

16.74 m

38°

16.31 m

.26 m

.51 m

107.16 kph

40.22 kph

17%

3.72 kph

11,262 Kg

10%

1-6
TM 9-2320-273-20

1-11. EQUIPMENT DATA (Continued).

MODEL M916 TRUCK TRACTOR

OVERALL CHARACTERISTICS: ENGLISH METRIC

National Stock Number: 2320-01028-4396

Curb Weight: 27,500 Ibs 12,474 Kg

Axle Loads (Empty):

Front Axle : 13,370 Ibs 6,065 Kg

Rear Axle: 14,130 Ibs 6,409 Kg

Axle Loads (with 25,588 Ibs (11,606 Kg) 5th Wheel Load):

Front Axle: 14,570 Ibs 6,609 Kg

Rear Tandem: 40,930 Ibs 18,566 Kg

Gross Vehicle Weight: 55,500 Ibs 25,174 Kg

Gross Axle Weight Rating:

Front Axle: 14,860 Ibs 6,740 Kg

Rear Tandem: 52,160 Ibs 23,659 Kg

Gross Vehicle Weight Rating: 56,000 Ibs 25,402 Kg

Towed Load (M172A1 Trailer – 25,588 Ibs (11,606 Kg) on the King Pin): 78,500 Ibs 35,639 Kg

Gross Combination Weight Rating: 106,000 Ibs 48,082 Kg

DIMENSIONAL DATA:

Overall Length (Less Pintle Hook and Lifting Shackle): 294.30 in. 7.48 m

Overall Width (Body): 96.75 in. 2.46 m

Height (Over Horns – Empty): 128.00 in. 3.25 m

Overall Height (Over Stack – Empty): 142.00 in. 3.61 m

Cab to Axle: 105 in. 2.67 m

Bumper to Back of Cab: 124 in. 3.15 m

Bumper to Front Axle: 43 in. 1.09 m

Wheel Base: 186 in. 4.72 m

Shipping Cube, Minimum: 2,212 cu ft 62.64 cu m

Tandem Axle Spacing: 56 in. 1.42 m

Tread Width:

Front: 77.90 in. 1.98 m

Rear: 72.70 in. 1.85 m

Dual Tire Spacing:

Fifth Wheel to Rear Tandem:

13.75 in. .349 m

8 in. .20 m

Overall Length with M172A1 Trailer: 58.66 ft 17.88 m

Angle of Approach (Loaded): 42° 42°

Minimum Turning Diameter, Curb to Curb: 80 ft 24.40 m

Minimum Ground Clearance (Under Rear Walking Beam Bracket, Empty): 11.62 in. .29 m

Fording Depth, Maximum: 20 in. .51 m

PERFORMANCE:

Maximum Speed (Forward (At 2100 rpm – 16th Gear): 59 mph

Speed on 3.9% Grade:

94.93 kph

25 mph 40.22 kph

Maximum Grade (At GCWR): 25% 25%

Minimum Sustained Speed (At 1300 rpm): 2.23 mph 3.59 kph

Maximum Drawbar Pull @ 0.7 Coefficient: 47,725 Ibs 20,576 Kg

Maximum Side Slope (W/Adequate Tractive Surfaces): 10% 10%

1-7
TM 9-2320-273-20

1-11. EQUIPMENT DATA (Continued).

OVERALL CHARACTERISTICS:

MODEL M917 DUMP TRUCK CHASSIS

National Stock Number:

Curb Weight:

Axle Loads (Empty):

Front Axle:

Rear Axle:

Axle Loads (with 40,000 Ibs (18,144 kg) Payload):

Front Axle:

Rear Tandam:

Pusher Axle:

Gross Vehicle Weight:

Gross Axle Weight Rating:

Front Axle:

Rear Tandem:

Pusher:

Gross Vehicle Weight Rating:

DIMENSIONAL DATA:

Overall Length (Less Pintle Hook and Lifting Shackle):

Dverall Width (Body):,

Overall Height (Over Cab Protector):

Cab to Axle:

Bumper to Back of Cab:

Bumper to Front Axle:

Wheel Base:

Shipping Cube, Minimum:

Tandem Axle Spacing:

Tread Width:

Front:

Pusher:

Rear:

Pusher Axle to Rear Tandem Forward Axle:

Dual Tire Spacing (6.88 in. (.17 m) between each dual):

Angle of Approach (Loaded):

Minimum Turning Diameter, Curb to Curb:

Minimum Ground Clearance (Under Rear Walking Beam Bracket, Empty):

Fording Depth, Maximum:

PERFORMANCE:

Maximum Speed Forward (At 2100 rpm – 16th Gear):

Speed on 3.9% Grade:

Maximum Grade (At GCWR):

Minimum Sustained Speed (At 1300 rpm):

Maximum Side Slope (W/Adequate Tractive Surface):

ENGLISH

3805-01-028-4389

34,080 Ibs

18,670 Ibs

15,360 Ibs

10,980 Ibs

44,200 Ibs

20,000 Ibs

74,980 Ibs

14,860 Ibs

52,160 Ibs

20,000 Ibs

75,000 Ibs

350.60 in.

96.75 in.

141 in.

130 in.

124 in.

43 in.

211 in.

2,804 cu ft

56 in.

77.90 in.

72.70 in.

72.70 in.

54 in.

13.75 in.

42°

89.50 ft

12 in.

20 in.

59 mph

25 mph

25%

2.23 mph

10%

METRIC

15,459 Kg

8,469 Kg

6,967 Kg

4,890 Kg

20,049 Kg

9,072 Kg

34,011 Kg

6,740 Kg

23,659 Kg

9,072 Kg

34,019 Kg

8.90 m

2.46 m

3.60 m

3.30 m

3.15 m

1.09 m

5.36 m

79.40 cu m

1.42 m

1.98 m

1.95 m

1.85 m

1.37 m

.35 m

42°

27.30 m

.30 m

.51 m

94.93 kph

40.22 kph

25%

3.59 kph

10%

1-8
TM 9-2320-273-20

1-11. EQUIPMENT DATA (Continued).

MODEL M918 BITUMINOUS DISTRIBUTOR TRUCK CHASSIS

OVERALL CHARACTERISTICS: ENGLISH METRIC

National Stock Number: 3895-01-028-4390

Curb Weight: 30,280 Ibs 13,735 Kg

Axle Loads (Empty):

Front Axle: 11,9801 bs

Rear Axle:

5,434 Kg

19,300 Ibs 8,754 Kg

Axle Loads (with 13,483 Ibs (6,116 Kg) Payload):

Front Axle: 12,520 Ibs 5,679 Kg

Rear Tandem: 30,760 Ibs

Gross Vehicle Weight:

13,953 Kg

43,280 Ibs 19,632 Kg

Gross Axle Weight Rating:

Front Axle: 14,860 Ibs

Rear Tandam:

6,740 Kg

52,160 Ibs 23,659 Kg

Gross Vehicle Weight Rating: 56,000 Ibs 25,402 Kg

DIMENSIONAL DATA:

Overall Length: 350.60 in. 8.90 m

Overall Width (Body): 96.75 in. 2.46 m

Height (Over Horns – Empty): 128 in. 3.25 m

Overall Height (Over Stack – Empty): 142.0 in. 3.61 m

Cab to Axle: 105 in. 2.67 m

Bumper to Back of Cab: 124 in. 3.15 m

Bumper to Front Axle: 43 in. 1.09 m

Wheel Base: 186 in. 4.72 m

Shipping Cube, Minimum: 2,544 cu ft 72.04 cu m

Tandem Axle Spacing: 56 in. 1.42 m

Thread Width:

Front: 77.90 in. 1.98 m

Rear: 72.70 in. 1.85 m

Dual Tire Spacing: 13.75 in. .35 m

Angle of Approach (Loaded): 42° 42°

Minimum Turning Diameter, Curb to Curb: 80 ft 24.40 m

Minimum Ground Clearance (Under Rear Walking Beam Bracket, Empty): 11.62 in. .29 m

Fording Depth, Maximum: 20 in. .51 m

PERFORMANCE:

Maximum Speed Forward (At 2100 rpm – 16th Gear):

Speed on 3.9% Grade:

94.93 kph

40.22 kph

Maximum Grade (At GCWR) 25%

Minimum Sustained Speed (At 1300 rpm): 3.59 kph

Maximum Side Slope (W/Adequate Tractive Surface): 10%

59 mph

25 mph

25%

2.23 mph

10%

1-9
TM 9-2320-273-20

1-11. EQUIPMENT DATA (Continued).

MODEL M919 CONCRETE MOBILE MIXER TRUCK CHASSIS

OVERALL CHARACTERISTICS: ENGLISH METRIC

National Stock Number: 3895-01-028-4391

Curb Weight: 37,540 Ibs 17,028 Kg

Axle Loads (Empty):

Front Axle: 14,280 Ibs 6,477 Kg

Rear Axle: 23,260 Ibs 10,551 Kg

Axle Loads (with 36,500 Ibs (16,556 Kg) Payload):

Front Axle: 9,210 Ibs 4,178 Kg

Rear Tandem: 43,880 Ibs 19,904 Kg

Pusher Axle: 20,000 Ibs

Gross Vehicle Weight:

9,072 Kg

73,090 Ibs 33,154 Kg

Gross Axle Weight Rating:

Front Axle: 14,860 Ibs 6,740 Kg

Rear Tandem: 52,160 Ibs 23,659 Kg

Pusher: 20,000 Ibs 9,072 Kg

Gross Vehicle Weight Rating: 75,000 Ibs 34,019 Kg

DIMENSIONAL DATA:

Overall Length: 374.40 in. 9.51 m

Overall width (Body): 96.75 in. 2.46 m

Height (Over Horns – Empty): 128 in. 3.25 m

Overall Height (Over Stack – Empty): 142.0 in.

Cab to Axle:

3.61 m

130 in. 3.30 m

Bumper to Back of Cab: 124 in. 3.15 m

Bumper to Front Axle: 43 in. 1.09 m

Wheel Base: 211 in. 5.36 m

Shipping Cube, Minimum: 2,716 cu ft 76.91 cu m

Tandem Axle Spacing: 56 in. 1.42 m

Tread Width:

Front: 77.90 in. 1.98 m

Pusher: 72.70 in. 1.85 m

Rear: 72.70 in. 1.85 m

Pusher Axle to Rear Tandem Forward Axle: 54 in. 1.37 m

Dual Tire Spacking (6.88 in. (.17 m) between each dual): 13.75 in. .35 m

Angle of Approach (Loaded): 42° 42°

Minimum Turning Diameter, Curb to Curb: 89.50 ft 27.30 m

Minimum Ground Clearance (Under Rear Walking Beam Bracket, Empty): 12 in. .30 m

Fording Depth, Maximum: 20 in. .51 m

PERFORMANCE:

Maximum Speed Forward (At 2100 rpm – 16th Gear): 59 mph 94.93 kph

Speed of 3.9% Grade: 25 mph 40.22 kph

Maximum Grade (At GCWR): 25% 25%

Minimum Sustained Speed (At 1300 rpm): 2.23 mph 3.59 kph

Maximum Side Slope (W/Adequate Tractive Surface): 10% 10%

1-10
TM 9-2320-273-20

1-11. EQUIPMENT DATA (Continued).

MODEL M920 TRUCK TRACTOR

OVERALL CHARACTERISTICS: ENGLISH METRIC

National Stock Number: 2320-01-028-4397

Curb Weight: 30,270 Ibs 13,730 Kg

Axle Loads (Empty):

Front Axle: 14,700 Ibs 6,668 Kg

Rear Axle: 15,570 Ibs 7,063 Kg

Axle Loads (with 40,000 lbs (18,144 Kg) 5th Wheel Load):

Front Axle: 8,870 Ibs 4,023 Kg

Rear Tandem: 46,010 lbs 20,870 Kg

Pusher Axle: 30,000 Ibs

Gross Vehicle Weight:

9,072 Kg

74,880 Ibs 33,965 Kg

Gross Axle Weight Rating:

Front Axle: 14,860 Ibs 6,740 Kg

Rear Tandem: 52,160 Ibs 23,659 Kg

Pusher: 20,000 Ibs 9,072 Kg

Gross Vehicle Weight Rating: 75,000 Ibs 34,019 Kg

Towed Load (M-870 Trailer – 40,000 Ibs (18,144 Kg) on the King Pin): 99,730 Ibs 45,277 Kg

Gross Combination Weight Rating: 130,000 Ibs 58,968 Kg

DIMENSIONAL DATA:

Overall Length: 319,30 in. 8.11 m

Overall Width (Body): 96.75 in. 2.46 m

Height (Over Horns – Empty): 128 in. 3.25 m

Overall Height (Over Stack – Empty): 142 in. 3.61 m

Cab to Axle: 130 in. 3.30 m

Bumper to Back of Cab: 124 in. 3.15 m

Bumper to Front Axle: 43 in. 1.09 m

Wheel Base: 211 in. 5.36 m

Shipping Cube, Minimum: 2,317 cu ft 65.61 cu m

Tandem Axle Spacing: 56 in.

Tread Width:

1.42 m

Front: 77.90 in. 1.98 m

Pusher: 72.70 in. 1.85 m

Rear: 72.70 in. 1.85 m

Pusher Axle to Rear Tandem Forward Axle: 54 in. 1.37 m

Dual Tire Spacing (6.88 in. (.17 m) Between each Dual):

Fifth Wheel to Rear Tandem:

13.75 in. .35 m

8 in. .20 m

Overall Length with M-870 Trailer: 60.75 ft 18.52 m

Angle of Approach (Loaded): 42° 42°

Minimum Turning Diameter, Curb to Curb: 89.50 ft 27.30 m

Minimum Ground Clearance (Under Rear Walking Beam Bracket, Empty): 11.62 in. .29 m

Fording Depth, Maximum: 20 in. .51 m

PERFORMANCE:

Maximum Speed Forward (At 2100 rpm – 16th Gear): 59 mph 94.93 kph

Maximum Speed on 3.9% Grade: 25 mph 40.22 kph

Maximum Grade (At GCWR): 25% 25%

Minimum Sustained Speed (At 1300 rpm): 2.23 mph 3.59 kph

Maximum Drawbar Pull @ 0.7 Coefficient: 47,403 Ibs 21,501 Kg

Maximum Side Slope (W/Adequate Tractive Surface): 10% 10%

1-11
TM 9-2320-273-20

1-11 EQUIPMENT DATA (Continued).

CAB (ALL MODELS)

Make: AM General.

Type: 2-passenger, all-steel with butterfly hood.

ENGINE (ALL MODELS)

Make/Model/Type: Cummins Diesel/NTC-400/6 -cylinder, 4 cycle.

Displacement: 855 cu in. (14 liters).

Compression Ratio: 13.5:1.

Horsepower – Gross: 400 @ 2100 rpm (298 Kw @ 2100 RPM).

Torque - Gross: 1150 lb-ft @ 1500 RPM (1559 N•m @ 1500 RPM).

Lube Capacity: 46 qts (43.5 liters).

Coolant Capacity: 17.25 gal (65.3 liters).

Governed Speed: 2100 rpm.

Retarder (Integral with Engine):

Make/Model: Jacobs/130

TRANSMISSION (ALL MODELS)

Make/Model/Type: Caterpillar/D7155/Semi-Automatic

Number of Gears: 16 Forward, 2 Reverse.

Ratios: 1st 14.77

2nd 12.21

3rd 10.07

4th 8.33

5th 6.89

6th 5.70

7th 4.70

8th 3.89

9th 3.14

10th 2.60

11th 2.14

12th 1.77

13th 1.47

14th 1.21

15th 1.00

16th .83

Reverse 14.77

Reverse 8.33

Shift: Remote – Air Control – Power Shift

Lube Capacity: 5.5 gal (20.8 liters).

Weight, Net Dry (Approx) Including Control: 1,090 Ibs (494.86 Kg).

1-12
TM 9-2320-273-20

1-11. EQUIPMENT DATA (Continued).

TRANSFER CASE (MODELS M916 THROUGH M920)

Make/Model:

Ratio:

Torque Capacity:

Torque Proportioning – Front/Rear:

Lock-Up – Front Axle:

Lube Capacity:

Oshkosh/1,800 series F-U29.

1:1.

15,155 Ib-ft (20,550 NŽm).

1:1 When Engaged.

Air Operated.

5 qts (4.48 liters).

AXLES (MODEL M915)

Front:

Make/Model/Type:

Rated Capacity:

Steer Angle:

Rear Tandem:

Make/Model:

Ratio:

Rated Capacity (Tandem):

Inter-Axle Differential:

Lock-Up:

Axle Differential – Forward/Rear Make/Type:

Rear/Rear Make/Type:

Lubrication:

Lube Capacity – Forward/Rear:

Rockwell/F-F931/l-Beam.

12,000 Ibs (5448 Kg).

32°.

Rockwell/SQHP.

4.44:1.

38,000 Ibs (17,252 Kg).

Bevel Gear.

Air Control.

Detroit Automotive/No-Spin.

Rockwell/Bevel Gear.

Pressure.

40/36 pts (19/17 liters).

AXLES (MODELS M916 AND M918)

Front:

Make/Model/Type:

Ratio:

Rated Capacity:

Steer Angle:

Rear Tandem:

Make/Type:

Ratio:

Rated Capacity (Tandem):

Inter-Axle Differential:

Lock-Up:

Axle Differential Make/Type:

Lubrication:

Lube Capacity – Forward/Rear:

Rockwell/FDS/1807/Hypoid.

6.17:1.

20,000 Ibs (9,080 Kg).

28°.

Rockwell/SUHD

6.17:1.

58,000 Ibs (26,332 Kg).

Bevel Gear.

Air Operated.

Detroit Automotive/No-Spin.

Pressure.

34/28 pts (16/13.2 liters).

1-13
TM 9-2320-273-20

1-11. EQUIPMENT DATA (Continued).

AXLES (MODELS M917, M919, AND M920)

Front:

Make/Type/Model: Rockwell/Hypoid FDS-1807.

Ratio: 6.17:1.

Rated Capacity: 20,000 Ibs (9,080 Kg).

Steer Angle: 28 degrees.

Pusher: Type: Rockwell/Granning.

Rated Capacity: 20,000 Ibs (9,080 Kg).

Singles/Duals: Duals.

Rear Tandem:

Make/Model: Rockwell/SUHD.

Ratio: 6.17:1.

Rated Capacity (Tandem): 58,000 Ibs (26,332 Kg).

Inter-Axle Differential: Bevel Gear.

Lock-Up: Air Operated.

Axle Differential Make/Type: Detroit Automotive/No-Spin.

Lubrication: Pressure.

Lube Capacity – Forward/Rear: 34/28 pts (16.08/13.25 liters).

SUSPENSION (MODEL M915)

Front:

Make/Type: Rockwell/Asymmetrical Leaf Pin & Shackle.

Rate: 1,861 Ibs/in. (332.3 Kg/cm).

Static Deflection: 2.73 in. (6.93 cm).

Rear Tandem:

Make/Model/Type: Hendrickson/RTE 380/Walking Beam-Steel Leaf.

Static Deflection: .97 in. (2.46 cm).

SUSPENSION (MODEL M916)

Front:

Make/Type: Rockwell/Asymmetrical Leaf Pin & Shackle.

Rate: 3,245 lbs/in. (580 Kg/cm).

Static Deflection: 1.94 in. (4.93 cm).

Rear Tandem:

Make/Model/Type: Hendrickson/RT 450/Walking Beam-Steel Leaf.

Static Deflection: 2.85 in. (7.24 cm).

1-14
TM 9-2320-273-20

1-11. EQUIPMENT DATA (Continued).

SUSPENSION (MODEL M917)

Front:

Make/Type:

Rate:

Static Deflection:

Pusher:

Make/Model/Type:

Raising System:

Rear Tandem:

Make/Model/Type:

Static Deflection:

Rockwell/Asymmetrical Leaf Pin & Shackle.

3,245 lbs/in. (580 Kg/cm).

2.11 in. (5.36 cm).

Granning/T-500 AP/Trailing Arm Non-Linear

(503 lbs/in.) (85.2 Kg/cm).

External Positive Pneumatic.

Hendrickson/RT 450/Walking Beam-Steel Leaf.

2.38 in. (6.04 cm).

SUSPENSION (MODEL M918)

Front:

Make/Type:

Rata:

Static Deflection:

Rear Tandem:

Make/Model/Type:

Static Deflection:

Front:

Make/Type:

Rate:

Static Deflection:

Pusher:

Make/Model/Type:

Raising System:

Rear Tandem:

Make/Model/Type:

Static Deflection:

Rockwell/Asymmetrical Leaf Pin & Shackle.

3,245 Ibs/in. (580 Kg/cm).

2.26 in. (5.74 cm).

Hendrickson/RT 450/Walking Beam-Steal Leaf.

4.6 in. (11.68 cm).

SUSPENSION (MODELS M919 AND M920)

Rockwell/Asymmetrical Leaf Pin & Shackle.

3,245 lbs/in. (980 Kg/cm).

2.11 in. (5.36 cm).

Granning/T-500 AP/Trailing Arm Non-Linear

(503 lbs/in.) (85.2 Kg/cm).

External Positive Pneumatic.

Hendrickson/RT 450/Walking Beam-Steal Leaf.

2.00 in. (5.08 cm).

WHEELS (MODEL M915)

All Positions - Make/Model:

Size – Dia x Rim Width:

Number of Studs/Bolt Circle:

Budd/47890-3.

20.00 x 8 in. (508 x 203 mm).

10/11.25 in. (10/28.6 cm).

Stud Size: 1.125 in. Grade 8 (2.86 cm).

Offset/Dual Spacing: 6.88/13.75 in. (17.5/35 cm).

Rated Capacity: 7,280 Ibs (3,305 Kg).

1-15
TM 9-2320-273-20

1-11. EQUIPMENT DATA (Continued).

WHEELS (MODELS M916 AND M918)

All Positions - Make/Model: Budd/R49210.

Size - Dia x Rim Width: 24.00 x 8 in. (610 x 203 mm).

Number of Studs/Bolt Circle: 10/11.25 in. (10/28.6 cm).

Stud Size: 1.125 in. Grade 8 (2.86 cm).

Offset/Dual Spacing: 6.88/13.75 in. (17.5/35 cm).

Rated Capacity: 7,430 Ibs (3.373 Kg).

WHEELS (MODELS M917, M919 AND M920)

All Positions - Make/Model:

Size - Dia x Rim Width:

Number of Studs/Bolt Circle:

Stud Size:

Offset/Dual Spacing:

Rated Capacity:

Budd/R49210.

24.00 x 8 in. (610 x 203 mm).

10/11.25 in. (10/28.6 cm).

1.125 in. Grade 8 (2.86 cm).

6.88/13.75 in. (17.5/35 cm).

7,430 Ibs (3.373 Kg).

TIRES (MODEL M915)

All Positions – Make/Model:

Size:

Type:

Load Range/Ply Rating:

Static Loaded Radius:

Rated Capacity – Single/Dual:

10.00 x 20 in. (254 x 508 mm).

Bias Ply - On-Highway.

G/14.

19.6 in. (49.8 cm).

6,040/5,300 Ibs (2742/2406 Kg).

TIRES (MODELS M916 THROUGH M920)

All Positions – Make/Model:

Size: 11.00 x 24 in. (279 x 610 cm).

Type: Bias Ply – On/Off Highway.

Load Range/Ply Rating: G/14.

Static Loaded Radius: 22.5 in. (57.1 cm).

Rated Capacity – Single/Dual: 7,430/6,520 Ibs (3,373/2,9360 Kg).

1-16 Change 2
TM 9-2320-273-20

1-11. EQUIPMENT DATA (Continued).

BRAKES (MODELS M917, M918, AND M920)

Service: Rockwell – Air Actuated

Front Axle: 16 sq in. (Actuator) – Wedge

Dia x Width: 17 x 6 in. (48.18 x 15.24 cm).

Pusher Axle: 36 sq in. (Actuator) – “S” Cam

Dia x Width: 16.5 x 7 in. (47.72 x 17.78 cm).

Rear Tandem: 30 sq in. (Actuator) – “S” Cam

Dia x Width:

Parking:

16.5 x 7 in. (41.91 x 17.78 cm)

Type: Spring Chamber

Location: Rear Tandems

Actuation: Air Exhaust

FIFTH WHEEL (MODEL M915)

Make/Model: Holland/3600-102-LH

Type: 36 in. (91.4 cm) Dia – Single Oscillating

Rated Capacity: 40,000 Ibs (18,160 Kg) Vert

150,000 Ibs (68,100 Kg) Drawbar

King Pin Size: 2.0 in. (5.08 cm)

Pitch – Forward/Aft: 15/10°

FIFTH WHEEL (MODELS M916 AND M920)

Make/Model: Holland/FW-70-0-15

Type: 36 in. (91.4 cm) Dia – Single Oscillating

Rated Capacity: 70,000 Ibs (31,780 Kg) Vert

200,000 Ibs (90,800 Kg) Drawbar

King Pin Size: 3.5 in. (8.9 cm)

Pitch – Forward/Aft: 15/19°

PINTLE (MODELS M915, M916, M917 AND M920)

Make/Type: Holland/NO. 760

Rated Capacity: 30 ton (27.2 metric ton)

1-17
TM 9-2320-273-20

1-11. EQUIPMENT DATA (Continued)

STEERING (MODELS M915 THROUGH M920)

Gear – Make/Type:

Model:

Ratio:

Auxiliary Cylinder Make/Model:

Piston Diameter:

Wheel:

Diameter:

Pump Make/Type:

Model:

Flow Rates:

Ross/Integral Power

HFB-70033

23.4:1

Ross/C44538

2.80 in. (7.1 1 cm)

Sheller Globe

20 in. (50.8 cm)

Eaton/Gear Driven

ERS-15867-1

3.35 GPM (12.68 liters min) @ 600 RPM + 1200 psi

7.0/8.0 GPM (26.49/30.28 liters) @ 3000 RPM

+ 50 psi

BRAKES (MODEL M915)

Make/Type:

Service:

Front Axle:

Dia x Width:

Rear Tandem:

Dia x Width:

Parking:

Make/Type:

Location:

Actuation:

Rockwell – Air Actuated

9 sq in. (Actuator) – Wedge

15 x 5 in. (38.1 x 12.7 cm)

30 sq in. (Actuator) - “S” Cam

16.5 x 7 in. (41.9 x 17.8 cm)

Anchorlock – Spring Chamber

Rear Tandems

Air Exhaust

BRAKES (MODELS M916 AND M918)

Service:

Front Axle:

Dia x Width:

Rear Tandem:

Dia x Width:

Parking:

Make/Model:

Location:

Actuation:

Rockwell – Air Actuated

16 sq in. (Actuator) – Wedge

17 x 6 in. (43.2 x 15.2 cm)

30 sq in. (Actuator) – “S” Cam

16.5 x 7 in. (41.9 x 17.8 cm)

Anchorlock Spring Chamber

Rear Tandems

Air Exhaust

1-18
TM 9-2320-273-20

1-11. EQUIPMENT DATA (Continued).

FRAME (MODEL M915)

Type: Steel-Heat Treat-Bolted110,000 psi (758,450 kPa)

Channel Section: 10,625 in. x 3.25 in. x .38 in.

(28.99 cm x 8.25 cm x .7 cm)

Section Modulus: 17.7 cu in. (290 cm3

)

Overall Width: 34 in. (86.4 cm)

FRAME (MODELS M916 THROUGH M920)

Type: Steel-Heat Treated-Bolted110,000 psi (758,450 kPa)

Channel Section: 10.625 in. x 3.25 in, x .38 in.

(28.99 cm x 8.25 cm x .7 cm)

Auxiliary Section (Wrapper): 11.50 in. x 3.625 in. x .38 in.

Section Modulus: 38.04 cu in. (623.36 cm3

)

Overall Width: 34 in. (86.4 cm)

WINCH (MODELS M916 AND M920)

Make/Model: DPMFG/4045

Type: Hydraulic Planetary

Capacity: 45,000 Ibs (20411.64 Kg)

ELECTRICAL SYSTEM (ALL MODELS)

Type: Basic 12V-w/24V Starting

Batteries Make/Model/Type: Delco Remy/1200 Series/

Maintenance Free

Number/Volts: 4/12V

Alternator Make/Model: Leece-Neville/2500JB

Volts/Amps: 12/24V/85 Amps

Starter:

Make/Model: Leece-Neville/7406 MA Series

Volts: 24V

1-19/1-20 (Blank)

TM 9-2320-273-20

CHAPTER 2

PRINCIPLES OF OPERATION

2-1. OVERVIEW.

This chapter explains the functioning of chassis components you will be maintaining at the Organizational level, and how these components relate to each other. The explanation is broken down into the

following sections:

a.

b.

c.

d.

e.

f.

g.

h.

i.

j.

k.

l.

m.

n.

o.

p.

q.

r.

s.

t.

u.

v.

w.

x.

y.

z.

aa.

bb.

Truck/Tractor Chassis (para 2-2 thru 2-5).

Engine (para 2-6, 2-7).

Engine Controls (para 2-8 thru 2-10).

Transmission and Controls (para 2-11, 2-12).

Power Transfer Case and Rear Axle Differential Lockup (para 2-13, 2-14).

Pusher Axle and Controls (para 2-15, 2-16).

Front Axle and Suspension (para 2-17 thru 2-19).

Rear Axle (para 2-20 thru 2-22).

Fuel and Air Intake System (para 2-23 thru 2-25).

Engine Oil System (para 2-26 thru 2-28).

Exhaust System (para 2-29, 2-30).

Cooling System (para 2-31 thru 2-33).

Relays, Circuit Breakers, and Wire Identification (para 2-34 thru 2-36).

Starting and Starting Control System (para 2-37, 2-38).

Ether Quick-Start (para 2-39, 2-40).

Batteries and Power Generating System (para 2-41, 2-42).

Service Lighting System (para 2-43 thru 2-49).

Blackout Lighting System (para 2-50, 2-51).

Instrumentation (para 2-52).

Electric Horn (para 2-53, 2-54).

Cab Heating and Ventilating Systems (para 2-55 thru 2-58).

Compressed Air System (para 2-59, 2-60).

Brake System (para 2-61 thru 2-70).

Auxiliary Air-Powered Systems (para 2-71 thru 2-74).

Steering System (para 2-75, 2-76).

Power Takeoff (para 2-77, 2-78).

Winch (para 2-79, 2-80).

Winterization Kit (para 2-81, 2-82).

2-1
TM 9-2320-273-20

2-1. OVERVIEW (Continued).

You can find other basic information about the M915, M916, and M920 Truck Tractors and Chassis

for the M917, M918, and M919 in:

a. Chapter 5, section II (Circuit Descriptions).

b. Appendix D (Schematic Diagrams).

c. TM 9-2320-273-10 (Operating Instructions for the M915, M916, and M920 Truck

Tractors and Chassis for the M917, M918, and M919).

Section I TRUCK/TRACTOR CHASSIS

Following is a description of the basic chassis and cab and illustrations of the power train. You will

find detailed descriptions of the major components shown in subsequent sections in this chapter.

2-3. BASIC CHASSIS AND CAB.

The basic chassis and cab for all M915 thru M920 vehicles is the Crane Carrier Corporation Centaur

Model T3824. Three frame types are used, each designated by its corresponding chassis.

a.

b.

c.

d.

e.

f.

Type I for ModeI M915 (6 x 4 tractor).

Type II for Model M916 (6 x 6 tractor).

Type II for Model M918 (6 x 6 bituminous distributor).

Type Ill for Model M917 (8 x 6 dump truck).

Type Ill for Model M919 (8 x 6 Concrete-Mobile® mixer).

Type III for Model M920 (8 x 6 tractor).

The same basic frame is used for each type design. Type II and Type III frames differ from Type I

frame by the addition of a 3/8-inch outer channel. The designations given above (6 x 4, 6 x 6 and

8 x 6) refer to the number of wheel positions on the vehicle (first digit) and number of drive wheel

positions (second digit). For example: 6 x 4 indicates six wheel positions (inside wheels on rear

axles are not counted), and four driving wheel positions.

2-2

2-2. INTRODUCTION.
TM 9-2320-273-20

2-4. POWER TRAIN M915.

2-5. POWER TRAIN – M916 thru M920.

NOTE

Pusher Axle (not shown) on Models M917,

M919, and M920 is non-driving unit.

2-3
TM 9-2320-273-20

Section II ENGINE

2-6. INTRODUCTION.

The Cummins NTC-400 Engine is used on all M915 thru M920 vehicles. It is an inline, six-cylinder,

four-stroke, four-cycle, turbocharged diesel engine. The engine is common to other production truck

diesel engines, without special operating or maintenance requirements. This section provides you with

illustrations that identify major exterior components. See one of the following associated engine systems in this chapter for details:

a. Engine Controls (section IIl).

b. Fuel and Air Intake System (section IX).

c. Engine Oil System (section X).

d. Exhaust System (section Xl).

e. Cooling System (section XlI).

f. Starting and Starting Control System (section XlV).

g. Ether Quick-Start System (section XV).

h. Batteries and Power Generating System (section XVI).

2-4
TM 9-2320-273-20

2-7. ENGINE EXTERIOR COMPONENTS.

Change 2 2-5/2-6 (blank)

TM 9-2320-273-20

Section III ENGINE CONTROLS

2.8. INTRODUCTION.

Cab engine controls for all M915 thru M920 vehicles are identical. Special body engine speed controls

for models M917, M918, and M919 are described in the following manuals:

a. M917 Dump Truck – TM 5-3805-274-24 & P.

b. M918 Bituminous Distributor – TM 5-3895-371-24 & P.

c. M919 Concrete - Mobil®Mixer – TM 5-3895-372-20.

2-9. ENGINE SPEED CONTROLS.

1.

2.

3.

4.

5.

6.

7.

8.

HAND THROTTLE. Allows manual control of engine rpm. Throttle motion is transferred

by cable to engine mounted pivot lever (6).

THROTTLE CABLE. Flex cable from hand throttle to engine mounted pivot lever (6).

ACCELERATOR PEDAL. Connected by mechanical linkage to under cab pivot lever (4).

PIVOT LEVER. Mechanical linkage that connects accelerator pedal to accelerator rod.

ACCELERATOR ROD. Connects accelerator pedal and throttle linkage to accelerator lever

on fuel pump.

ENGINE MOUNTED PIVOT LEVER. This lever connects the under dash hand throttle

cable (ALL) and the winch throttle cable (M916 and M920) to the accelerator rod.

ACCELERATOR LEVER. This lever controls the flow of fuel through the fuel pump thus

setting engine speed.

FUEL CONTROL RETURN SPRING. Return accelerator lever to normal position when

hand throttle and accelerator pedal are not engaged.

2-7
TM 9-2320-273-20

2-10. ENGINE RETARDER BRAKE CONTROLS.

NOTE

In reading the following descriptions

make sure that the throttle switch is in

its normally-closed position.

1. ENGINE RUN SWITCH. Energizes the 12-volt electrical system, including engine retarder

brake circuit.

2. ENGINE RETARDER SWITCH. Three-position switch allows driver to select engine braking

for two cylinders (LOW), four cylinders (MED), or six cylinders (HIGH). Depressing foot

pedal actuated switch completes 12-volt power circuit to energize one, two, or three solenoids.

2-8
TM9-2320-273-20

2-10. ENGINE RETARDER BRAKE CONTROLS (Continued).

3.

4.

5.

6.

ClRCUIT BREAKER (CB-6). Protects electrical components of engine retarder brake circuit

by opening when load exceeds 20 amps. Automatically recycles until the overload is

removed.

FLOOR PEDAL SWITCH. Allows driver to activate engine brake circuit with his left foot.

When depressed, switch supplies 12-volt power through CB-6, throttle switch, engine retarder

switch, to energize the selected solenoid valve.

THROTTLE SWITCH. Open switch prevents activation of engine retarder brake if hand

throttle is pulled out or accelerator pedal is pressed down. Activating arm on fuel pump lever

closes switch when hand throttle and accelerator are both disengaged.

SOLENOID VALVES. When valves are activated, they operate engine braking mechanism.

2-9
TM 9-2320-273-20

Section IV TRANSMISSION AND CONTROLS

2-11. INTRODUCTION.

The Caterpillar D7155 transmission is used on all M915 thru M920 trucks. It is a mechanical drive

unit with 16 forward speeds and 2 reverse speeds. The transmission is bolted directly to engine flywheel housing.

2-12. TRANSMISSION AND CONTROLS.

1. ENGINE RUN SWITCH. Energizes the 12-volt electrical system, including the transmission

oil temperature gage circuit.

2. TRANSMISSION OIL TEMPERATURE GAGE. Signal from sending unit actuates pointer

gage showing transmission oil temperature.

3. ClRCUIT BREAKER (CB-6). Protects electrical components of transmission oil temperature

circuit when load exceeds 20 amps. Automatically recycles until the overload is removed.

4, RATlO SELECTOR UNIT. Floor-mounted, houses transmission controls.

5. GEAR SELECTOR. Allows operator to select desired gear.

6. TRANSMISSION AlR CHARGING VALVE. Used to charge control line when starting up.

7. CONTROL LINE. Carries pneumatic pressure which controls pressure from supply line.

Normal air pressure is 90-120 psi (transmission is disengaged if air pressure drops below 60 psi).

8. BREATHERS. Prevent air pressure buildup in case.

9. SUPPLY LINE. Pneumatic pressure, controlled by line from ratio selector and sets transmission to selected gear. Normal air pressure is 90-120 psi (transmission is disengaged if air

pressure drops below 60 psi).

10. SPEEDOMETER CABLE. Provides engine speed input to tachograph.

11. TRANSMISSION OIL COOLER. Two hydraulic lines carry warm oil from the transmission

to an oil cooler mounted in front of radiator. Once cooled, the oil is returned to the

transmission.

12. DIPSTICK AND OIL FILL PORT. Used to inspect and replenish oil supply. Normal

capacity: at oil change 5.5 gallons (21 liters) of engine oil.

13. DRAIN PLUG. Provides access for draining oil. Has magnetic base to attract foreign particles in the oil and warn of unusual wear of the internal parts.

14. SUPPLY RESERVOIR. Provides air supply line. Normal air pressure is 90-120 psi (transmission is disengaged if air pressure drops below 60 psi).

15. ACCESS PLATE. Provides opening for access to oil pump suction line screen, There is an

identical plate on the opposite side of the transmission.

16. TRANSMISSION OIL TEMPERATURE SENDING UNIT. Provides electrical signal to temperature gage for indicating transmission oil temperature.

2-10
TM 9-2320-273-20

2-12. TRANSMISSION AND CONTROLS (Continued).

2-11
TM 9-2320-273-20

Section V POWER TRANSFER CASE AND REAR AXLE

DIFFERENTIAL LOCKUP

2-13. INTRODUCTION.

The power transfer cases on M916 thru M920 trucks provide a means of engaging or disengaging front

wheel drive. The instrument panel control for this feature also allows the driver to lock up the rear

inter-axle differential so that all differentials on rear axle tandem turn the same speed. (The instrument panel control engages or disengages the front propeller shaft to the front driving axle (M916 thru

M920) and the inter-axle differential located in all the forward rear tandem axles.) On M916 and

M920 models only, an oil cooler is used to keep the transfer case lubricant within the proper temperature range during warm weather operation. It is disconnected in cold weather to prevent cooler damage (see para 7-9).

The M915 is a 6 x 4, activating the differential lockout control locks the inter-axle differential thereby connecting the transmission to front tandem and rear tandem axles solidly together.

The forward rear tandem axle is equipped with a no-spin differential which automatically locks, eliminating differential action independent of the manual control, at least three wheels on the rear tandem

must turn when the inter-axle differential lock is engaged.

2-14. POWER TRANSFER CASE.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

ENGINE RUN SWITCH. Energizes 12-volt electrical system, including differential lockup

indicator circuit,

LOCKUP INDICATOR. Illuminates when lockup switch is closed.

ClRCUIT BREAKER (CB-6). Protects electrical components of differential lockup circuit by

opening when load exceeds 20 amps, Automatically recycles until overload is removed.

AIR MANIFOLD. Routes air from reservoir to control valve.

CONTROL VALVE. Provides control to engage or disengage front wheel drive on M916 thru

M920. When front wheel drive is engaged, air pressure is applied to lockup rear axle differential. When front wheel drive is disengaged, air pressure is vented through lockup valve. On

M915, this control locks up the rear differential only.

OIL COOLER LINE. Carries cooled oil to top of power transfer case. (M916 and M920 only).

OIL COOLER. By means of fresh air flow thru fins and tubing, cools warm oil from power

transfer case (M916 and M920 only); suspended under winch platform.

OIL COOLER LINE. Brings warm oil from power transfer case to oil cooler (M916 and M920

only).

OIL PUMP. Driven from upper shaft of power transfer case, draws warm oil from bottom of

case, pumps thru cooler, and returns to top of case (M916 and M920 only).

OIL PUMP LINE. Carries warm oil from bottom of case to pump (M916 and M920 only).

TEE. Replaces drain plug (plug is reinserted in end of tee; provides connection for line (10).

(M916 and M920 only).

2-12
TM 9-2320-273-20

2-14. POWER TRANSFER CASE (Continued).

12. LOCKUP CHAMBER. When air pressure is applied to the chamber, it mechanically locks the

rear axle differential in place so that drive is applied to both rear axles. Without air pressure,

the differential applies drive to the axle that offers the least resistance.

13. DRAIN PLUGS. Allow draining oil during service intervals. Has magnetic base to attract

foreign particles and warn of unusual wear of internal parts.

14. FILLER PLUGS. Provide means of checking and replenishing oil supply.

15. LOCKUP SWITCH. Normally open; closed by 60 psi air pressure to activate lockup indicator

circuit.

2-13
TM 9-2320-273-20

Section VI PUSHER AXLE AND CONTROLS

2-15. INTRODUCTION.

A pusher axle is provided on M917, M919, and M920 vehicles.

2-16. PUSHER AXLE.

1. PRESSURE REGULATOR VALVE. Allows operators to regulate air pressure to air bags.

2. PRESSURE GAGE. Air-actuated gage indicates pressure in lines to air bags.

3. UP-DOWN SELECTOR VALVE. In DOWN position, directs air pressure to air bags which

lower axle. In UP position, directs pressure to air cylinders which raise axle.

4. AlR CYLINDERS. Provide force to raise axle to stowed position.

5. SHOCK ABSORBERS. Stabilize fluctuations in air bags caused by road surface variations.

6. AlR BAGS. Provide force to lower axle to road position.

2-14
TM 9-2320-273-20

Section Vll FRONT AXLE AND SUSPENSION

2-17. INTRODUCTION.

The Model M915 is equipped with a non-driving front axle; the Models M916 thru M920 have a driving

front axle. (See power train illustrations in paragraphs 2-4 and 2-5.) Shock absorbers are used only on

the Model M915.

2-18. NON-DRIVING FRONT AXLE (M915).

1. KNUCKLE AND KINGPIN ASSEMBLY (Shown with drum removed). Movable joint between

the wheel and axle l-beam.

2. STEERING ARM. Connects to power steering drag link (see para 2-76).

3. DRUM. Houses the wheel brakes. Serves as mount for front wheels.

4. TIE ROD ASSEMBLY. Connects left and right knuckles for synchronized movement of both

wheels.

5. SHOCK ABSORBERS (M915). Supplement spring and stabilize spring fluctuations caused

by road surface variations.

6. LEAF SPRINGS. Absorb and minimize the amount of road shock transmitted to the vehicle

frame.

7. SHACKLE. Swinging support that permits the leaf spring to vary in length as it is deflected.

8. BRAKE Al R CHAMBER. When pressure is supplied to the chambers from the air system,

they mechanically activate the brake mechanism.

2-15
TM 9-2320-273-20

2-19. DRIVING FRONT AXLE (M916 THRU M920).

NOTE

1.

2.

3.

4.

5.

See illustration in para 2-18 for identification and description of common

components.

BREATHER. Allows fumes from hot oil to escape.

CARRIER. Houses differential drive and driven gears.

PINION YOKE. Attaches to transfer case propeller shaft universal. (See illustration in

para 2-5.)

DRAIN PLUG. Allows draining oil at service intervals.

FILLER PLUG. Provides access for checking oil level and replenishing oil supply.

2-16
TM 9-2320-273-20

Section Vlll REAR AXLE

2-20. INTRODUCTION.

Two similar rear axle assemblies are used in the M915 thru M920 vehicles. The Model M915 uses one

type; the Models M916 thru M920 use a different assembly. (Specifications for both axles are given

in para 1-11.)

2-21. REAR AXLE (M915).

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

HUB AND DRUM ASSEMBLY. Serves as mount for rear wheels. Houses the brake shoe

assemblies which can be mechanically forced against it to slow or stop the vehicle.

AXLE SHAFT. Transmits power from the differential gear assembly to the hub assembly

inside of axle housing.

INTER-AXLE PROPELLER SHAFT. Transmits power to rear axle.

DIFFERENTIAL LOCKUP CHAMBER. Air actuated by lockup switch located in cab

interior. (Refer to para 2-14 for description.)

BRAKE AIR CHAMBER. (Refer to para 2-64 for description.)

PINION YOKE. Connects to propeller shaft from transmission.

OIL FILTER. Oil filter (under cover) removes impurities from oil in forward rear axle. Filter

is replaceable, automobile-type unit (Refer to LO 9-2320-273-12.)

DRAIN PLUG. Allows draining oil at service intervals.

FILLER PLUG. Used to inspect oil level and replenish oil supply.

BREATHER. Allows fumes from hot oil to escape.

2-17
TM 9-2320-273-20

2-22. REAR AXLE (M916 THRU M920).

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

NOTE

See illustration in paragraph 2-21 for

identification and description of common

components. For organizational maintenance purposes, the basic difference between

the axles shown in paragraphs 2-21 and 2-22

is that the axle shown below does not have

an oil filter. Quantity and placement of fill

and drain plugs also differ from one configuration to the other.

AXLE SHAFT. Transmits power from the differential gear assembly to the hub assembly inside

of axle housing.

HUB AND DRUM ASSEMBLY. Serves as mount for rear wheels. Houses the brake shoe assemblies which can be mechanically forced against it to slow or stop the vehicle.

FILLER PLUG. A plug used to gain access for inspecting oil level and replenishing oil supply.

INTER-AXLE PROPELLER SHAFT. Transmits power for forward-rear to rear-rear axle.

DIFFERENTIAL LOCKUP CHAMBER. Air actuated by lockup switch located in cab interior.

(Refer to para 2-14 for description.)

BRAKE AIR CHAMBER. (Refer to para 2-64 for description.)

PINION YOKE. Connects to propeller shaft from power transfer case.

DIFFERENTIAL INTERNAL LUBRICATION PUMP. Circulates gear lubricant under pressure

thru differential gears.

DRAIN PLUG. A magnetic plug which allows draining oil at service intervals. Also, draws metallic particles from the oil.

BREATHER. Allows fumes from hot oil to escape.

2-18
TM 9-2320-273-20

Section IX FUEL AND AIR INTAKE SYSTEM

2-23. INTRODUCTION.

This system is comprised of two basic subsystems: fuel delivery and air intake. The systems are identical in all M915 thru M920 vehicles.

2-19
TM 9-2320-273-20

2-24. FUEL DELlVERY.

1. FUEL GAGE. Needle actuated by electrical signal from sending unit which shows level of

fuel in tank.

2. ENGINE RUN SWITCH. Energizes 12-volt electrical system, including circuits to solenoid

shutoff valve and fuel level sending unit.

3. ClRCUIT BREAKER (CB-6). Protects electrical components of fuel system by opening circuit when load exceeds 20 amps. Automatically recycles until overload is removed.

4. PUSH TUBE. Transmits motion from cam follower to rocker arm assembly.

5. INJECTOR. Cam timed to meter and inject fuel into each cylinder.

6. ROCKER ARM. Transmits directional movement from push tube to injector.

7. FUEL DELlVERY LINE. Carries fuel under pressure from fuel pump to fuel manifold.

8. BYPASS LINE. Carries excess fuel from manifold back to tank.

9. CAMSHAFT. Determines valve and injector timing.

10. TANK. 118-gallon (446.63 liters) capacity (110-gallon (416.35 liters) draw).

11. FUEL LEVEL SENDING UNIT. Provides electrical signal to fuel gage for indicating fuel

quantity in tank.

12. CAM FOLLOWER. Mechanical lever transmits cam lobe movement from cam shaft to push

tube.

13. FILTER. Throwaway filter removes impurities from fuel. Petcock in bottom allows operator

to drain off water filtered from fuel.

14. SOLENOID SHUTOFF VALVE. Normally closed, shutting off fuel supply to engine. Open

when engine run switch is ON.

15. SCREEN FILTER. Located in fuel pump. Provides additional filtration for fuel prior to

entering engine.

16. MANUAL OVERRIDE FOR FUEL SHUTOFF SOLENOID. Normally closed, can be screwed

open to allow operation of engine when solenoid is not working.

17. FUEL PUMP. Gear driven from compressor drive. Built-in governor meters fuel through

screen filter, solenoid shutoff valve, and into injectors. Excess fuel from pump is returned

to the tank, The tachometer drive is located on the pump housing.

18. AlR ACTUATING LINE. Carries pressurized air from intake manifold to fuel pump. Pressure from line opens valve in pump and allows full fuel flow.

2-20
TM 9-2320-273-20

2-24. FUEL DELIVERY (Continued).

2-21
TM 9-2320-273-20

2-25. AIR INTAKE.

1. AlR RESTRICTION INDICATOR. Mounted on instrument panel. A red signal shows on

indicator housing when air cleaner needs servicing. A tube connects the indicator to the air

cleaner outlet. When air flow through the cleaner is restricted, the red signal becomes visible.

The unit is factory set to signal at a specific filter restriction. Resetting is accomplished by

pushing a button which is recessed in the bottom.

2. CROSSOVER TUBE. Directs compressed air from turbocharger, through aftercooler, to

intake manifold.

3. AFTER COOLER. Cools air entering intake manifold from turbocharger. Water flow from

engine cooling system absorbs heat. (See illustration of cooling system in paragraph 2-32.)

4. ENGINE INTAKE MANIFOLD. Directs compressed air charge to each cylinder after it has

been cooled by aftercooler.

5. PLENUM. Directs outside air to the air intake tube.

6. AIR INTAKE TUBE. Draws outside air through grille mounted plenum and into air cleaner.

7. lNLET TUBE. Directs air from air cleaner to turbocharger.

8. TURBOCHARGER. Driven by exhaust gases (para 2-30). Compresses air in the intake manifold to increase engine power.

9. AIR CLEANER. Mounted on fire wall. Removes impurities from air entering turbocharger.

Has replaceable dry, two-stage element.

2-22
TM 9-2320-273-20

Section X ENGINE OIL SYSTEM

2-20. INTRODUCTION.

The engine oil system is identical on all M915 thru M920 vehicles. The system provides lubricating

oil for moving internal engine parts and the turbocharger. In addition, engine oil is used by the

Jacobs® brake (engine retarder).

2-23
TM 9-2320-273-20

2-27. COMPONENTS AND PIPING ARRANGEMENT.

1. OIL BYPASS FILTER. Provides additional filtration, allowing a longer period between

oil changes. Oil from pump circulates through the filter, then to the sump.

2. OIL PUMP. Circulates oil through engine to provide cooling and lubrication.

3. DRAINCOCK. Provide passage for draining oil.

4. FLATWASHER. Provides seal between draincock and oiI bypass filter.

2-24 Change 2
TM 9-2320-273-20

2-27. COMPONENTS AND PIPING ARRANGEMENT (Continued).

3.

4.

5.

6.

7.

8.

9.

10.

BREATHER TUBE. Allow fumes from hot oil to escape.

OIL FILLER. Located in engine cover. Used for replenishing engine oil supply.

OIL COOLER. Coolant circulates through internal tubes of oil cooler and carries away

heat from engine oil.

PRIMARY OIL FILTER. Throwaway filter removes dirt and foreign particles from oil.

DIPSTICK. Engine oil level indicator.

DRAIN PLUG. Located in bottom of engine oil pan, Used to drain oil from engine.

OIL RETURN LINE. Carries return oil from turbocharger to engine block.

OIL SUPPLY LINE. Carries oil under pressure to cool and lubricate turbocharger.

2-25
TM 9-2320-273-20

2-28. OIL MONITORING SYSTEM.

1. ENGINE RUN SWITCH. Energizes 12-volt electrical system, including oil pressure gage

and warning light circuits.

2. OIL PRESSURE GAGE. Needle activated by electrical signal from oil pressure sending unit

indicates engine oil pressure.

3. OIL WARNING LIGHT. Indicator light is activated by 12-volt power from pressure switch

when engine oil pressure drops below 5 psi (34 kPa).

4. ClRCUIT BREAKER (CB-6). Protects electrical components of oil system by opening circuit

when load exceeds 20 amps. Automatically recycles until overload is removed.

5. PRESSURE SWITCH. Closes when oil pressure drops below 5 psi (34 kPa) and supplies

12-volt power to oil warning indicator.

6. OIL PRESSURE SENDING UNIT. Provides electrical signal to oil pressure gage to indicate

oil pressure.

2-26
TM 9-2320-273-20

Section Xl EXHAUST SYSTEM

2-29. INTRODUCTION.

The exhaust system is identical in all M915 thru M920 vehicles, except for minor variations in

arrangement.

2-27
TM 9-2320-273-20

2-30. EXHAUST SYSTEM.

1. RAIN CAP. Prevents entry of rain and dirt into exhaust pipes when engine is not in use.

2. EXHAUST MANIFOLD. Bolted to exhaust ports on cylinder heads. Collects exhaust

from ports and directs it to turbocharger.

3. TURBOCHARGER. See illustration and description in paragraph 2-25.

4. TURBO OUTLET PIPE. Carries hot exhaust away from turbocharger.

5. FLEX PIPE(S). Connect turbo outlet pipe, muffler inlet pipe, and muffler. Pipes are

flexible to allow for vibrations and expansion in system.

6. MUFFLER INLET PIPE. Connects flex pipes.

7. MUFFLER. Directs exhaust through baffles to deaden noise.

8. EXHAUST STACK. Directs exhaust from muffler.

2-28
TM 9-2320-273-20

2-30. EXHAUST SYSTEM (Continued).

2-29
TM 9-2320-273-20

Section XII COOLING SYSTEM

2-31. INTRODUCTION.

The cooling system is identical in all M915 thru M920 vehicles, The system provides coolant

for the engine block, oil cooler, aftercooler, fuel injectors, and air compressor.

2-32. COMPONENTS AND PIPING ARRANGEMENT.

1. THERMOSTAT DEAERATION LINE. Escape route for air trapped in radiator top or

thermostat housing.

2. RADIATOR IN LET HOSE. Channels hot coolant into radiator when thermostat is open.

3. ENGINE SHUNT LINE. Allow air bubbles from coolant in pump to escape into radiator,

to prevent pump cavitation.

4. RADIATOR CAP. Closes off filler opening and keeps system under pressure up to a

maximum of 10 psi.

5. RADIATOR. Coolant is circulated through a series of fins and baffles so that outside

air flow can dissipate heat.

6. OIL COOLER. Engine coolant circulates through internal tubes of cooler and carries

away heat from engine.

7. AFTERCOOLER. Coolant flowing through core cools hot air entering intake manifold

ports from turbocharger.

8. WATER LINE. Carries water under pressure from block to aftercooler.

9. WATER LINE. Carries hot water from air compressor to thermostat housing.

10. WATER LINE. Carries coolant from water pump to air compressor.

11. ACCESSORY DRIVE. Powers the fan and water pump.

12. FAN. Forces air through radiator to control coolant temperature.

13. FAN CLUTCH. Air pressure from actuator engages fan when coolant temperature rises

above 190°F (88°C).

14. THERMOSTAT. Shuts off coolant flow to radiator until temperature reaches 185°F

(85°C). Coolant is then directed through radiator inlet hose to the radiator.

15. FAN CLUTCH ACTUATOR. When coolant temperature rises above 190°F (88°C),

actuator directs compressed air into fan clutch causing fan to engage.

16. WATER MANIFOLD. Collects coolant from cylinder heads and directs it to thermostat

housing.

2-30
TM 9-2320-273-20

2-32. COMPONENTS AND PIPING ARRANGEMENT (Continued).

2-31
TM 9-2320-273-20

2-33. COOLANT TEMPERATURE MONITORING SYSTEM.

1.

2.

3.

4.

5.

6.

WATER TEMPERATURE GAGE. Shows coolant temperature actuated by electrical

signal from water temperature sending unit.

ENGINE RUN SWITCH. Energizes 12-volt electrical system, including temperature

gage and temperature indicator light circuits.

ENGINE COOLANT TEMPERATURE WARNING LIGHT. Activated by 12-volt

power from water temperature switch when engine temperature exceeds 225°F

(107°C).

ClRCUIT BREAKER (CB-6). Protects electrical components and wiring of coolant

system by opening circuit when load exceeds 20 amps. Automatically recycles until

overload is removed.

WATER TEMPERATURE SWITCH. Normally open, closes to activate indicator light

when coolant temperature exceeds 225°F (107°C).

WATER TEMPERATURE SENDING UNIT. Provides electrical signal to temperature

gage.

2-32
TM 9-2320-273-20

Section XIII RELAYS, CIRCUIT BREAKERS, AND WIRE IDENTIFICATION

2-34. INTRODUCTION.

a. The electrical relays are identical in all M915 thru M920 vehicles, except for minor

variations in arrangement. The M917, M918, and M919 use two relays, the M915

use seven relays; while the M916 and M920 use eight.

b. The circuit breakers are identical in the M915 thru M920 vehicles, except for minor

variations in arrangement. The M917, M918, and M919 use six circuit breakers to

protect their electrical systems, the M915 uses eight; while the M916 and M920 use

nine. These circuit breakers are rated at 20 amps continuous load. If an overload

does occur, the circuit breaker automatically recycles (opens and closes) until the

overload is removed.

2-33
TM 9-2320-273-20

2-35. RELAYS AND CIRCUIT BREAKERS.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

RELAY (K1). (M915 thru M920) Normally open contacts: Provides 12-volt power to

the electric horn when energized.

RELAY (K2). (M915, M916, and M920) Normally open contacts: Provides 24-volt power

to trailer left turn signal light when energized.

RELAY (K2). (M918 and M919) Normally closed contacts: Provides 12-volt power to

the backup alarm when energized.

RELAY (K2). (M917) Normally closed contacts: Disconnects 12-volt power from

tractor backup lights when the Operation switch is in BLACKOUT position,

RELAY (K3). (M915, M916, and M920) Normally open contacts: Provides 24-volt

power to trailer right turn signal light when energized.

RELAY (K4). (M915, M916, and M920) Normally open contacts: Provides 24-volt

power to trailer blackout stop lights when energized.

RELAY (K5). (M915, M916, and M920) Normally open contacts: Provides 24-volt

power to trailer blackout tail lights when energized.

RELAY (K6). (M915, M916, and M920) Normally open contacts: Provides 24-volt

power to trailer marker and tail lights when energized.

RELAY (K7). (M915, M916, and M920) Normally closed contacts: Disconnects

12-volt power from tractor backup lights when operation switch is in BLACKOUT

position.

RELAY (K8). (M916 and M920) Normally closed contacts: Provides 12-volt

power to work lamps when WORK LAMPS switch is ON.

ENGINE TEMPERATURE DIODE. Provides a circuit to illuminate engine temperature

indicator when engine is cranking, and prevents engagement of the starter by feedback

voltage in the event the water temperature switch closes.

CIRCUIT BREAKER (CB-9). Protects the 12-volt work lamps circuit in the M916 and

M920 vehicles.

ClRCUIT BREAKER (CB-8). Protects the 24-volt blackout stop, marker, and tail light

circuits for trailers used with the M915, M916, and M920 vehicles.

ClRCUIT BREAKER (CB-7). Protects the 24-volt left and right turn signals and

blackout tail light circuits for trailers used with the M915, M916, and M920 vehicles.

ClRCUIT BREAKER (CB-6). Protects the 12-volt engine retarder brake, instrument

gages, low air, park brake, and differential lockout circuits in the M915 thru M920

vehicles.

CIRCUIT BREAKER (CB-5). Protects the 12-volt backup lights and ether start circuits

in the M915 thru M920 vehicles.

CIRCUIT BREAKER (CB4). Protects the 12-volt heater fan motor circuit in the M915

thru M920 vehicles.

CIRCUIT BREAKER (CB-3). Protects the 12-volt cigar Iighter and dome light circuits

in the M915 thru M920 vehicles.

CIRCUIT BREAKER (CB-3). Protects the 12-volt utility outlets on the M915, M916,

and M920 vehicles.

2-34
TM 9-2320-273-20

2-35. RELAYS AND CIRCUIT BREAKERS (Continued).

17. ClRCUIT BREAKER (CB-2). Protects the 12-volt electric horn and turn signal flasher

circuits in the M915 thru M920 vehicles.

18. ClRCUIT BREAKER (CB-1). Protects the 12-volt stop light, operation switch, turn

signal, and instrument lighting circuits in the M915 thru M920 vehicles.

2-35
TM 9-2320-273-20

2-36. WIRE IDENTIFICATION.

The electrical wiring on the M915 thru M920 vehicles is contained in braided or loomed harness

assemblies. The wires are permanently hot-stamped with individual circuit numbers. The circuit

numbers appear two inches from each termination end and every six inches throughout the length.

Refer to Appendix D for wiring harness drawings and electrical system diagrams, for circuit

numbers and terminations.

2-36
TM 9-2320-273-20

Section XIV STARTING AND STARTING CONTROL SYSTEM

2-37. INTRODUCTION.

The starting and starting control system is identical in all M915 thru M920 vehicles.

2-37
TM 9-2320-273-20

2-38. STARTING AND STARTING CONTROL SYSTEM.

1. ENGINE RUN SWITCH. Directly controls fuel solenoid shutoff valve and allows

remainder of starting circuit to be placed into operation when the start button is

depressed.

2. ENGINE START BUTTON. Activates starting circuit by energizing the starter

relay.

3. STARTER RELAY. With ENGINE RUN switch on, transmission ratio selector lever

in neutral, and ENGINE START button depressed, the relay energizes and closes the

starter solenoid circuit.

4. NEUTRAL SAFETY SWITCH. Switch is normally open. Starting circuit cannot be

activated when ratio selector lever is in any position other than neutral.

5. STARTER SOLENOID. 12-volt power is applied to the starter solenoid when

starter relay is energized. The solenoid closes and supplies 24-volt power, which

energizes the starter motor.

6. STARTER MOTOR. When energized, the motor engages the flywheel to start the

engine.

7. FUEL SOLENOID SHUTOFF VALVE. When the ENGINE RUN switch is turned

on, valve is energized and opens to allow fuel to pass to the injectors. (See paragraph

2-24 for description of fuel system.)

2-38
TM 9-2320-273-20

2-38. STARTING AND STARTING CONTROL SYSTEM (Continued).

2-39
TM 9-2320-273-20

Section XV ETHER QUICK-START

2-39. INTRODUCTION.

The quick-start system is identical in all M915 thru M920 vehicles.

2-40. ETHER QUICK-START.

1.

2.

3.

4.

5.

6.

7.

8.

ENGINE RUN SWITCH. Energizes 12-volt electrical system, including quick-start

solenoid valve circuit.

ETHER BUTTON. Activates solenoid valve. Will not work if thermal switch is open.

ClRCUIT BREAKER (CB-5). Protects electrical components and wiring of quickstart system by opening circuit when load exceeds 20 amps. Automatically recycles

until overload is removed.

THERMAL SWITCH. Opens when coolant temperature is above 50°F (10°C), and

prevents solenoid valve from activating.

ETHER CYLINDER. Replaceable 18-02 (710 cc) ether container.

ETHER TUBE. Carries ether from solenoid valve thru atomizer to engine air intake

manifold.

ATOMIZER. Sprays fine ether mist into intake manifold.

SOLENOID VALVE. Controls release of ether from cylinder. When solenoid is

energized, ether flows to atomizer.

2-40
TM 9-2320-273-20

2-40. ETHER QUICK-START (Continued).

2-41
TM 9-2320-273-20

Section XVI BATTERIES AND POWER GENERATING SYSTEM

2-41. INTRODUCTION.

The battery and generating system provides 12- and 24-volt power to electrical

M920 vehicles. The power generating system is identical for all vehicles.

2-42. BATTERIES AND POWER GENERATING SYSTEM.

1.

2.

3.

4.

5.

systems in M915 thru

ENGINE RUN SWITCH. Supplies 12-volt power from batteries through switch, circuit

breaker, to voltmeter.

VOLTMETER. 10- to 16-volt gage indicates voltage provided by battery pack, and

alternator.

ClRCUIT BREAKER (CB-6). Protects electrical components of volt meter circuit by

opening when load exceeds 20 amps. Automatically recycles until overload is removed.

BATTERY PACK. Comprised of four 12-volt, maintenance-free batteries. Two batteries

wired in paralIel in each set. Each set connected in series for 24-volt output. Battery

pack is used for both 1.2- and 24-volt output.

AC GENERATOR (ALTERNATOR). Generates voltage for recharging battery pack.

Has external 24-volt transformer rectifier.

2-42
TM 9-2320-273-20

2-42. BATTERIES AND POWER GENERATING SYSTEM (Continued).

2-43
TM 9-2320-273-20

Section XVII SERVICE LIGHTING SYSTEM

2-43. INTRODUCTION.

The service lighting system provides illumination required while operating the vehicles. This system

is comprised of the following subsystems:

a. Headlamps and Tail Lamps (para 2-44).

b. Marker and Clearance Lamps (para 2-45),

c. Turn Signals and Hazard Warning Lamps (para 2-46).

d. Backup Lamps (para 2-47).

e. Work Lamps (para 2-48).

f. Instrument and Cab Dome Lamps (para 2-49).

g. Stop Lamps (See brake switches and indicators (para 2-63)).

Individual circuit descriptions, except stop lamps, follow in this section. You can find a complete

electrical schematic diagram and wiring harness diagrams in Appendix D.

2-44. HEADLAMPS AND TAIL LAMPS.

When headlamp switch is on, and operation lamp switch is in NORMAL, battery power is supplied

to illuminate the headlamps and tail lamps as well as the trailer tail lamps on the M915, M916, M917,

and M920. The traiIer tail lamps are powered through tractor chassis receptacles.

1. HEADLAMPS. Each assembly has two filaments in a sealed unit, a high beam and a low

beam. Selection of high or low beam is controlled by the dimmer switch.

2. RELAY (K6). Normally open contacts; energized by 12-volt power from operation lamp

switch when in NORMAL and headlamp switch is in on position. When relay is closed,

24-volt power is applied to trailer tail lamps, through circuit breaker and tractor receptacles.

3. ClRCUIT BREAKER (CB-8). Protects electrical components of 24-volt relay circuit by

opening when load exceeds 20 amps. Automatically recycles until overload is removed.

4. OPERATION LAMP SWITCH. Two-position safety switch for NORMAL and BLACKOUT

modes of operation. To select mode, switch is pulled out and placed to either position.

Set to NORMAL, 12-volt power from the lamp switch passes through operation lamp switch

contacts to energize; tail lamps, headlamps (through dimmer switch), and coil of relay.

Set to BLACKOUT, 12-volt power is removed from regular service lamps, electric horn,

and backup alarm, while 12-volt power from the lamp switch is supplied through the switch

to blackout tail lamps, marker lamps, and headlamp.

5. TAIL LAMPS. Each assembly contains two bulbs: A double-element bulb provides tail

lamp, turn signal lamp, and stop lamp. A separate bulb is used for the backup lamp. The

tail lamp circuit is energized through the operation lamp switch when headlamp switch is

in either ON position. (The circuits for turn signals, stop lamps, and backup lamps are

described in paragraph 2-46 and 2-47).

2-44
TM 9-2320-273-20

2-44. HEADLAMPS AND TAIL LAMPS (Continued).

2-45
TM 9-2320-273-20

2-44. HEADLAMPS AND TAIL LAMPS (Continued).

6. 24-VOLT TRAILER RECEPTACLE (M915, M916, M917, and M920). Tractor chassis

mounted 12-pin connector to provide power to Iunette-towed vehicles. (This receptacle

is 12-volts on the M917).

7. HIGH-BEAM INDICATOR. When power is supplied to each high-beam filament in the

headlamps, the high-beam indicator is illuminated via the same circuit.

8. DIMMER SWITCH. Two-position, floor-mounted switch. The switch is always closed in

one of two positions to energize either the low-beam or high-beam filament.

9. HEADLAMP SWITCH. Three-position with one OFF position and two ON positions,

When the switch is pulled out to the second detented ON position, 12-volt power is

supplied to the lighting systems through operation lamp switch. (The first detented position

on the switch energizes the circuit for tail lamps, but not the headlamps.) The switch has an

integral circuit breaker that opens to protect the complete circuit in the event of a “short”

or faulty wiring. The circuit breaker is a recycling type; that is, it opens when the circuit

is overloaded and cycles until the fault is removed.

10. 24-VOLT TRAILER RECEPTACLE (M915, M916, and M920). Tractor chassis mounted

12-pin connector, provides 24 volts to trailer for lighting and tail lamps.

11. 12-VOLT TRAILER RECEPTACLE (M915, M916, and M920. Tractor mounted sevenpin connector provides 12 volts to trailer for lighting.

2-46
TM 9-2320-273-20

2-44. HEADLAMPS AND TAIL LAMPS (Continued).

2-47
TM 9-2320-273-20

2-45. MARKER AND CLEARANCE LAMPS.

When headlamp switch is in either ON position, the operation lamp switch is in NORMAL position,

12-volt power is supplied to illuminate clearance lamps and front marker lamps as well as the trailer

marker lamps on M915, M916, M917, and M920 vehicles. The trailer marker lamps receive power

through receptacles mounted on the tractor chassis.

1. MARKER LAMP ASSEMBLY. Each assembly has two bulbs that illuminate whenever

headlamp switch is ON and operation lamp switch is in NORMAL. One bulb is used as a

marker lamp, and the other is for turn signals (para 2-46).

2. RELAY (K6). Normally open contacts; 12-volt power energizes relay when operation

light switch is in NORMAL and headlamp switch is ON. When contacts of relay close, 24

volts from circuit breaker CB-8 is supplied to tractor chassis receptacles.

3. ClRCUIT BREAKER (CB-8). Protects electrical components for 24-volt tractor receptacle

circuits by opening when load exceeds 20 amps, Automatically recycles until overload is

removed.

4. 24-VOLT TRAILER RECEPTACLE (M915, M916, M917, and M920). 12-pin connector

for 24-volt power used for Iunette-towed vehicles. (This receptacle is 12-volts on the M917).

5. OPERATION LAMP SWITCH. With the switch set to NORMAL and the headlamp switch

ON, 12-volt power is supplied to marker lamps, clearance lamps, and 12-volt tractor receptacle.

6. CLEARANCE LAMP SWITCH. Provides the capability of flashing the clearance lamps on

the cab and the 12 volt supplied to the tractor receptacle, when switch is depressed and

released. 12-volt power is supplied to the switch when headlamp switch is ON and operation switch is in NORMAL.

7. HEAD LAMP SWITCH. Supplies 12-volt power, when in either ON position, through

operation lamp switch in NORMAL, to clearance lamps, marker lamps, and 12-volt tractor

receptacle.

8. 24-VOLT TRAILER RECEPTACLE (M915, M916, and M920). 12-pin connector containing 24-volt circuit for trailer marker lamps.

9. 12-VOLT TRAILER RECEPTACLE (M915, M916, and M920). Seven-pin connector containing 12-volt circuit for trailer clearance and marker lamps.

10. CLEARANCE LAMPS. Each unit has a replaceable single-element bulb that illuminates

when headlight switch is in either ON position, and operation lamp switch is in NORMAL.

The clearance lamps will flash when clearance lamp switch is depressed and released.

2-48
TM 9-2320-273-20

2-45. MARKER AND CLEARANCE LAMPS (Continued).

2-49
TM 9-2320-273-20

2-46. TURN SIGNAL AND HAZARD WARNING LAMPS.

When the operation lamp switch is in NORMAL position, battery power is applied to the turn signal

control to illuminate right or left: front turn signals, rear turn signals as well as trailer turn signals

on M915, M916, M917, and M920 vehicles through tractor-mounted receptacles. Also, the turn

signal control contains a hazard warning switch, that allows the operator to flash all lamps in the

turn signal system simuItaneously.

1. MARKER AND TURN SIGNAL LAMP ASSEMBLY. Each assembly has a replaceable

single filament bulb that flashes when turn signal control or hazard warning switch is on.

2. RELAY (K2). Normally open contacts; closed by 12 volts from left turn signal control or

hazard warning switch. When relay is energized, 24 volts is applied to tractor mounted

receptacles for trailer left turn signals.

3. RELAY (K3). Normally open contacts; closed by 12 volts from right turn signal control or

hazard warning switch. When relay is energized, 24 volts are applied to tractor mounted

receptacles for trailer right turn signals.

4. ClRCUIT BREAKER (CB-2). Protects electrical components of flasher, turn signal control,

and hazard warning switch circuits by opening when load exceeds 20 amps. Automatically

recycles until overload is removed.

5. ClRCUIT BREAKER (CB-7). Protects electrical components of 24-volt relay and circuits

by opening when load exceeds 20 amps. Automatically recycles until overload is removed.

6. OPERATION LAMP SWITCH. Two-position switch for normal and blackout modes of

operation. When set to NORMAL, 12-volt battery power from circuit breaker (CB-2)

passes through switch contacts to turn signal control, flasher unit, and hazard warning switch.

7. REAR TAIL LAMPS. Each assembly contains two bulbs; the tail lamp turn signal and

stop lamp circuits all use the same bulb. When either the turn signal control or hazard

warning switch are on, the turn signal and stop lamp filaments flash. When the turn signal

control is activated, only the bulb on the side selected flashes. If the brakes are engaged at

the same time that the hazard warning switch is on, both bulbs flash. When the brakes are

engaged and the turn signal control is activated, one bulb will flash and the other bulbs will

remain on constantly.

8. 24-VOLT TRAILER RECEPTACLE (M915, M916, M917, and M920). Tractor mounted

12-pin connector provides 24 volts power to Iunette-towed vehicles. This receptacle is

12-volts on the M917.

9. FLASHER UNIT. This unit receives 12-volt power from operation lamp switch in NORMAL

position and supplies this power alternately on and off to turn signal control or hazard

warning switch when either one is engaged.

10. HAZARD WARNING SWITCH. When this switch is engaged, it receives 12-volt power from

the operation lamp switch and energizes all components in the turn signal circuits simultaneously.

11. TURN SIGNAL CONTROL. When this control is engaged, it receives 12-volt power from

flasher unit. (The flasher unit receives 12-volt power through operation lamp switch and

circuit breaker CB-2.) Power is then supplied to:

a. Front left or right turn signals.

b. Rear left or right turn signals.

c. 12-volt Trailer Receptacle.

d. Relays K2 and K3 (To energize relay and supply power to both tractor mounted

24-volt receptacles for trailer turn signals.)

2-50
TM 9-2320-273-20

2-46. TURN SIGNAL AND HAZARD WARNING LAMPS (Continued).

12. INDICATOR LAMPS. Three bulbs to indicate left turn (green), right turn (green), or hazard

(red). The bulbs are energized, by selection, with 12-volt power from the flasher unit.

13. 12-VOLT TRAILER RECEPTACLE (M915, M916, and M920). Tractor mounted seven-pin

connector provides 12-volt power to the trailer turn signal lamps.

14. 24-VOLT TRAILER Receptacle (M915, M916, and M920). Tractor mounted 12-pin

connector provides 24-volts power to the trailer turn signal lamps.

2-51
TM 9-2320-273-20

2-47. BACKUP LAMPS.

When the operator places the gear ratio selector lever in reverse position (R1 or R2), air pressure

within the transmission closes backup switch. When operation lamp switch in NORMAL position and

engine run switch ON, the circuit is energized to illuminate each backup bulb in tail lamp assembly.

1. BACKUP SWITCH. The switch is normally open. When closed, it receives 12-volt battery

power through circuit breaker CB-5 and supplies power through normally closed contacts of

relay K7 to energize backup lamps in tail lamp assemblies.

2. RELAY (K7). The relay is normally closed. When the operation lamp switch is placed to

BLACKOUT position, 12-volt power is supplied to coil of K7, energizing the relay, and opens

the contacts. This prevents the backup lamps from coming on whenever the operation lamp

switch is in BLACKOUT mode.

3. ClRCUIT BREAKER (CB-5). Protects electrical components of backup switch circuit by

opening when load exceeds 20 amps. Automatically recycles until overload is removed.

4. ClRCUIT BRAKER (CB-2). Protects electrical components of relay K7 circuits by opening

when load exceeds 20 amps. Automatically recycles until overload is removed.

5. TAIL LAMP. Each assembly contains two bulbs: A tail, turn signal, and stop lamp bulb

which contain two filaments and backup bulb which contains one filament. When the backup

switch closes, the backup lamp illuminates.

6. OPERATION LAMP SWITCH. Two-position switch for NORMAL AND BLACKOUT modes

of operation. In this circuit, the switch is used to prevent operation of the backup lamp. In

BLACKOUT position, 12-volt power from circuit breaker CB-2 passes through the switch and

energizes coil of relay K7, thus preventing the backup lamps from possibly coming on.

7. ENGINE RUN SWITCH. This switch controls 12-volt power to the backup switch through

circuit breaker CB-5. When the switch is off the backup lamp circuit is de-energized.

2-52
TM 9-2320-273-20

2-47. BACKUP LAMPS (Continued).

2-53
TM 9-2320-273-20

2-48. WORK LAMPS (M916 AND M920).

When the operation switch is in NORMAL position, and the operator places the work lamps switch to

ON, 12-volt power is supplied to the work lamps on the M916 and M920 vehicles.

1. WORK LAMPS. Each assembly contains a single filament sealed beam unit. When the operation switch is in NORMAL and the work lamps switch is ON, the work lamps come on.

2. WORK LAMPS SWITCH. Two-position switch for ON and OFF mode of operation. When

the switch is ON, 12-volt power is supplied through CB-2, normally closed contacts of relay

K8, to the work lamps.

3. RELAY (K8). The relay is normally closed. When the operation switch is placed to BLACKOUT, 12-volt power is supplied to coil of K8, energizing the relay, and opens the contacts.

This prevents the work lamps from coming on whenever the operation switch is in the

BLACKOUT mode.

4. ClRCUIT BREAKER (CB-9), Protects electrical components of work lamps circuit by opening when load exceeds 20 amps. Automatically recycles until overload is removed.

5. ClRCUIT BREAKER (CB-2). Protects electrical components of relay K8 circuits by opening

when load exceeds 20 amps. Automatically recycles until overload is removed.

6. OPERATION SWITCH. Two-position switch for NORMAL and BLACKOUT modes of

operation. In this circuit, the switch is used to prevent operation of the work lamps. In

BLACKOUT position, 12-volt power from circuit breaker CB-2 passes through the switch

and energizes coil of relay K8, thus preventing the work lamps from being turned on.

2-54
TM 9-2320-273-20

This page intentionally Ieft blank.

2-55
TM 9-2320-273-20

2-49. INSTRUMENT AND CAB DOME LAMPS.

a. With the headlamp switch in either ON position, the instrument lamps illuminate. The

dome lamp illuminates whenever the dome lamp switch is ON.

b. The low air pressure warning lamp on left-hand cluster, clearance lamp on center cluster

and six indicator lamps on the right-hand cluster are described with their respective

circuits in this chapter, That is, the high engine temperature warning indicator is described with the cooling system; low oil pressure warning indicator with the oil system,

etc., (see table of contents).

1. LEFT HAND INSTRUMENT CLUSTER, The instrument gage lamps on this panel receive

12-volt power from headlamp switch when it is in either ON position, Each gage contains

its own illumination bulb.

2. CENTER INSTRUMENT CLUSTER. The center cluster contains the tachograph which is

illuminated when the headlamp switch is in either ON position.

3. HEADLAMP SWITCH. Three-position switch with one OFF position and two ON positions,

In either ON position, 12-volt battery power passes through the switch to energize the following lamp in this circuit:

a. Instrument lamps on left-hand instrument cluster.

b. Clearance switch and tachograph illumination lamps on center cluster.

c. Switch and functional indicators on right-hand instrument cluster.

d. Illumination lamps on heater panel.

e. Illumination lamps on ratio selector.

The headlamp switch has a variable rheostat that allows the operator to adjust the brightness of all

lamps in this circuit by turning the switch knob.

4. RIGHT-HAND INSTRUMENT CLUSTER. The instrument lamps on this cluster receive

12-volt power from the headlamp switch and illuminate the windshield wiper, and windshield washer indicator.

5. ClRCUIT BREAKER (CB-3). Protects electrical components of dome lamp circuit by opening when load exceeds 20 amps. Automatically recycles until overload is removed.

6. DOME LAMP AND SWITCH ASSEMBLY. When the assembly integral switch is ON, the

lamp is energized by 12-volt battery power through circuit breaker (CB-3).

7. HEATER PANEL LAMPS. When the headlamp switch is in either ON position, the lamps

are energized by 12-volt battery power and illuminates the heater control panel.

8. GEAR RATIO SELECTOR LAMP. When the headlamp switch is in either ON position,

the lamp is energized by 12-volt battery power and illuminates the gear ratio selector.

2-56
TM 9-2320-273-20

2-49. INSTRUMENT AND CAB DOME LAMPS (Continued).

2-57
TM 9-2320-273-20

Section XVIII BLACKOUT LIGHTING SYSTEM

2-50. INTRODUCTION.

The blackout lighting system prevents operation of the horn, backup alarm, and all service lighting

(para 2-43), except instrument lamps, and dome lamp. The system provides the following intensity

lighting for blackout operation on all M915 series vehicles:

a. One headlamp.

b. Two front marker lamps.

c. Two tail and stop lamps.

d. Trailer tail, stop, and marker lamps on M915, M916, M917, and M920 at the 12-pin

trailer receptacles.

2-51. BLACKOUT LIGHTING SYSTEM.

NOTE

In reading the following component description you should remember that the

OPERATION switch is in BLACKOUT

position.

1. BLACKOUT HEADLAMP. The lamp consists of a single, replaceable sealed beam unit. With

the headlamp switch in the ON position, the blackout headlamp is energized by a 12-volt

battery power.

2. BLACKOUT MARKER LAMPS. Each lamp consists of a replaceable bulb which is energized

by 12-volt battery power when the headlamp switch is in either ON position.

3. ClRCUIT BREAKER (CB-8). Protects electrical components for 24-volt blackout stop lamp

relay circuit by opening when load exceeds 20 amps. Automatically recycles until overload

is removed.

4. RELAY (K5). Normanlly open contacts: Closed by 12-volt power when the operation switch

is in BLACKOUT. When relay is energized, 24-volt power is supplied from circuit breaker

CB-7 through 24-volt trailer receptacle for blackout tail lamps.

5. ClRCUIT BREAKER (C B-7). Protects electrical components for 24-volt blackout tail lamp

relay circuit by opening when load exceeds 20 amps. Automatically recycles until overload

is removed.

6. RELAY (K4). Normanlly open contacts: Closed by 12-volt power when the operation switch

is in BLACKOUT. When relay is energized, 24-volt power is supplied from circuit breaker

CB-8 through 24-volt trailer receptacle.

7. ClRCUIT BREAKER (CB-1). Protects electrical components for stop switch circuit by opening when load exceeds 20 amps. Automatically recycles until overload is removed.

8. 24-VOLT TRAILER RECEPTACLE (M915, M916, M917, and M920). Tractor mounted 12-

pin connector to provide 24-volt battery power to Iunette - towed trailers for blackout tail

and stop lamps. This receptacle is 12-volts on M917.

2-58
TM 9-2320-273-20

2-51. BLACKOUT LIGHTING SYSTEM (Continued).

9. REAR BLACKOUT LAMPS. Contains the bulbs for blackout tail and stop lamps. The blackout tail lamp is energized when the operation switch is in BLACKOUT and the headlamp

switch is in either ON position. The stop lamps are energized when the stop lamp switch is

actuated.

10. OPERATION LAMP SWITCH. Two-position switch for NORMAL and BLACKOUT modes

of operation. With this switch in the BLACKOUT position, 12-volt battery power is available from the headlamp switch to energize: blackout headlamp, marker lamps, tail lamps,

and relay K4 and K5.

11. HEADLAMP SWITCH, Three-position switch with one OFF position and two ON positions.

The switch supplies 12-volt battery power to the OPERATION lamp switch.

12. 24-VOLT TRAILER RECEPTACLE (M915, M916, and M920). Tractor mounted 12-pin

connector to provide 24-volt battery power to trailer blackout tail and stop lamps.

13. STOP LAMP SWITCH. The stop lamp switch is part of the brake system and is shown and

described in paragraph 2-63. In this circuit, the switch receives 12-volt battery power from

circuit breaker CB-1. When the brakes are engaged, the switch closes and supplies 12-volt

power through the operation lamp switch to energize relay K4. With this relay closed, 24-

volt battery power is supplied through circuit breaker CB-8 to the 24-volt tractor mounted

trailer receptacles.

2-59
TM 9-2320-273-20

Section XIX INSTRUMENTATION

2-52. INTRODUCTION.

Table 2-1 lists the instruments and major input connections for all M915 thru M920 vehicles. Connections for instrument gage lamps have been omitted. (See wiring diagram in Appendix D.) You

will find an illustration or schematic diagram for each listed instrument by using the Reference/

Illustration column of the table.

Table 2-1. Instruments.

2-60
TM 9-2320-273-20

Section XX ELECTRIC HORN

2-53. INTRODUCTION.

The electric horn circuit is identical on all M915 thru M920 vehicles.

2-54. ELECTRIC HORN

1. ELECTRIC HORN. The horn is energized by 12-volt battery power when horn button is

depressed and operation lamp switch is in NORMAL position.

2. RELAY (K1). When horn button is depressed, coil of relay is energized by 12-volt battery

power from circuit breaker. With relay de-energized, 12 volts are supplied from a second lead

from circuit breaker, through operation lamp switch, through contacts of relay to horn.

3. ClRCUIT BREAKER (CB-2) Protects electrical components of horn circuit by opening when

load exceeds 20 amps. Automatically recycles until overload is removed.

4. HORN BUTTON. Pushing this button activates the horn circuit and energizes the horn.

5. OPERATION LAMP SWITCH. Two-position switch for normal and blackout modes of operation. With switch set to NORMAL and horn button depressed, 12-volt battery power from

circuit breaker passes through switch contacts to relay.

2-61
TM 9-2320-273-20

Section XXI CAB HEATING AND VENTILATING SYSTEMS

2-55. INTRODUCTION.

The cab heating and ventilating system are identical in all M915 thru M920 vehicles. This system is

comprised of:

a. Heater Electrical Control

b. Heater Water Controls

c. VentiIating System

2-56. HEATER ELECTRICAL CONTROLS.

1.

2.

3.

4.

ENGINE RUN SWITCH. Controls 12-volt battery power to heater fan switch. When switch is

OFF, fan cannot be actuated.

ClRCUIT BREAKER (CB-4). Protects electrical components of heater fan switch by opening

when load exceeds 20 amps. Automatically recycles until overload is removed.

FAN SWITCH. Four-position switch with three ON positions. Supplies 12-volt battery power

through circuit breaker (CB-4) to motor. Current flow increases as switch is moved from LOW

to MEDIUM to HIGH.

MOTOR. Powers heater fan. Actuated by current from heater fan switch.

2-62
TM 9-2320-273-20

2-57. HEATER WATER CONTROLS.

1. HEATER KNOB. Allows operator to regulate flow of coolant through control valve.

2. CONTROL VALVE. Controls heater temperature by regulating flow of hot water to heater

core. Cable from heater knob in cab opens valve as knob is pulled out. Valve is spring-loaded

to close as knob is pushed in. Some water passes through this valve even when it is fully closed.

3. HEATER SHUTOFF VALVE. Supplies coolant to control valve. Manual shutoff handle

allows complete cutoff of coolant flow to heater.

4. HEATER RETURN TUBE. Carries coolant from heater to water pump.

5. HEATER SUPPLY TUBE. Carries coolant from control valve to heater.

2-63
TM 9-2320-273-20

2-58. VENTILATING SYSTEM.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

NOTE

The driver’s fresh air vent is a manually

operated unit mounted in the lower cowl

side of the cab. It is not serviced at the

organizational level.

HEAT CONTROL KNOB. Allows driver to heat cab, Connected by cable to water control

valve.

FAN CONTROL SWITCH. Allows driver to control amount of heat in cab. Connected

by electrical wires to heater motor.

DRIVER HEAT KNOB. Allows driver to open or close heat vent for his side of cab.

Connected by cable to heat control lever.

PASSENGER HEAT KNOB. Allows passenger to open or close heat vent for his side

of cab. Connected by cable to heat control lever.

FRESH VENT CONTROL KNOB. Allows driver to control fresh air vent on passenger

side. Connected by cable to vent control lever.

RECIRCULATION VENT CONTROL KNOB. Allows driver to recirculate cab air

through heater. Connected by cable to recirculation control lever.

WATER CONTROL VALVE. Allows flow of water through heater core. Actuated

by cable from heat control knob.

HEATER MOTOR. Drives fan for distributing heat. Actuated by fan control

switch.

HEAT CONTROL LEVER. Actuates flap at heat vent for passenger. Connected by

cable to passenger pull knob.

HEAT CONTROL LEVER. Actuates flap at heat vent for driver. Connected by cable

to driver pull knob.

RECIRCULATION CONTROL LEVER. Actuates shutter inside heater. Connected by

cable to recirculation vent control knob.

FRESH VENT CONTROL LEVER. Actuates shutters at fresh air vent. Connected by

cable to fresh vent control knob.

2-64
TM 9-2320-273-20

2-58. VENTILATING SYSTEM (Continued).

2-65
TM 9-2320-273-20

Section XXII COMPRESSED AIR SYSTEM

2-59. INTRODUCTION.

The compressed air supply system is the same in all M915 thru M920 vehicles.

2-60. COMPRESSED AIR SYSTEM.

1. SAFETY VALVE. Vents air when pressure in supply tank rises above 150 psi (1,034 kPa).

2. TRANSMISSION CONTROL LINE. Air supply to ratio selector valve in cab.

(see para 2-12).

3. CHECK VALVE. One-way valve prevents air from flowing out of supply air reservoir back

to compressor.

4. EXTERNAL AIR COUPLINGS. Tractor to trailer couplings are provided on M915, M916,

and M920 models. All models are equipped with front external air couplings for brake

use when the vehicle must be towed, Rear external air couplings are provided on M915,

M916, M917 and M920 for brake actuation of a disabled vehicle being towed.

5. PRIMARY RESERVOIR LINE. Carries air from primary tank to supply reservoir.

6. TIRE INFLATION AIR HOSE FITTING. Used in conjunction with the tire inflation

air hose and chuck.

7. ACCESSORY DRIVE. Provides power to operate compressor.

8. COMPRESSOR. Draws air from cleaner, compresses it, and directs it to supply air reservoir.

9. COMPRESSOR GOVERNOR. Opens unloading valve to vent air before compression

when pressure in supply tank is above 105-125 psi (724-826 kPa).

10. AlR DRYER. Air from compressor is dried and contaminants are removed before entering

the system.

11. SUPPLY AlR RESERVOIR. Receives compressed air from compressor.

2-66 Change 2
TM 9-2320-273-20

2-60. COMPRESSED AIR SYSTEM (Continued).

Change 2 2-67
TM 9-2320-273-20

Section XXIII BRAKE SYSTEM

2-61. INTRODUCTION.

The brakes on all M915 thru M920 vehicles are actuated by the compressed air system

(para 2-60).

The system is comprised basically of valves and controls for dual air brakes (service and emergency).

“S’’- type cam brakes with two air chambers are used in the rear on all models and on the pusher

axle (Models M917, M919 and M920). Wedge-type brakes with one air chamber (M916 thru M920)

or two air chambers (M915 only), are used in the front. (See illustration and description of each

type of brake in paragraphs 2-65 thru 2-70).

(Refer to section XXIV for description of auxiliary air powered systems.)

This section is divided into three parts: controls, switches and indicators, and system components.

Since the number of air reservoirs and the arrangement of valves and lines differs with each vehicle

model, a separate arrangement drawing is provided for each in paragraphs 2-65 thru 2-70. (See

Appendix D for a piping schematic diagram of each vehicle model.)

2-68
TM 9-2320-273-20

2-62. CONTROLS.

1.

2.

3.

4.

5.

6.

7.

REAR AlR PRESSURE GAGE. Direct pressure gage indicates air pressure in rear

service reservoir.

FRONT AIR PRESSURE GAGE. Direct pressure gage indicates air pressure in

front service reservoir.

TRAILER EMERGENCY BRAKE VALVE. In applied position, supplies pressure

to trailer service and emergency air lines.

PARKING BRAKE VALVE. Normally supplies pressure holding spring brakes

in compressed position. When knob is pulled out, valve exhausts air pressure,

allowing spring brakes to apply.

DUAL BRAKE VALVE. Applies front and rear service brakes at the same time

when brake pedal is pushed.

TRAILER BRAKE HAND CONTROL (M915, M916 and M920). Applies trailer brakes

only. Opens connection between air supply reservoir and trailer service brake lines as it

is turned clockwise.

LOW AIR PRESSURE WARNING INDICATOR (12-volt). Circuit normally held open,

by air pressure. Closes to activate control panel indicator when pressure drops below

70 psi.

2-69
TM 9-2320-273-20

2-63. BRAKE SWITCHES AND INDICATORS.

1. STOP LAMP SWITCH. Normally open air actuated switch, which closes when brakes are

actuated. The switch receives 12-volt battery power from circuit breaker CB-1 and supplies

this power through the operation switch in NORMAL position, turn signal control to the

tractor tail stop lamps. Also, with switch closed, 12-volt battery power is routed through

the operation switch to the 12-volt trailer receptacle.

2. PARK BRAKE INDICATOR. Illuminates when the park brakes are applied. Indicator receives 12-volt battery power through engine run switch in ON position, circuit breaker

CB-6, and actuated parking brake switch.

3. OPERATION LAMP SWITCH. Two-position switch for NORMAL and BLACKOUT modes

of operation. With the switch set to NORMAL, 12-volt battery power is received from

closed stop lamp switch, and circuit breaker CB-1. This 12-volt power is supplied through

the turn signal control to the tractor tail stop lamp. 12-volt power is also supplied to the

12-volt trailer receptacle.

4. PARK BRAKE SWITCH. Normally open, air actuated switch on parking brake (para 2-62).

Closes to energize park brake indicator when parking brakes are actuated.

5. ClRCUIT BREAKER (CB-6). Protects electrical components of parking brake circuit by

opening when load exceeds 20 amps. Automatically recycles until overload is removed.

6. ClRCUIT BREAKER (CB-1), Protects electrical components of stop lamp circuit by opening when load exceeds 20 amps. Automatically recycles until overload is removed.

7. STOP TAIL LAMPS. Unit contains two bulbs, a single-filament bulb for backup, and a

two-filament bulb for tail, turn signal, and stop lamps. The stop lamps receive 12-volt

power through circuit breaker CB-1, closed stop lamp switch, closed contacts of operation

switch, and the turn signal control.

8. ClRCUIT BREAKER (CB-6). Protects electrical components of parking brake circuit by

opening when load exceeds 20 amps. Automatically recycles until overload is removed.

9. 12-VOLT TRAILER RECEPTACLE. When the stop lamp switch is closed and the operation

switch is in NORMAL, 12-volt battery power is supplied to the tractor mounted receptacle

for trailer stop lamps.

2-70
TM 9-2320-273-20

2-63. BRAKE SWITCHES AND INDICATORS (Continued).

2-71
TM 9-2320-273-20

2-64. SYSTEM COMPONENTS.

This paragraph describes and illustrates the major components that comprise the brake system in the

M915 series vehicles.

a.

b.

c.

d.

e.

f.

g.

h.

Wedge Brakes.

“S’’- Type Cam Brake.

Air Chambers.

Reserve Air Reservoir. (Supply reservoir is described in compressed air system,

para 2-60).

Relay Valve.

Double-Check Valve.

Quick-Release Valve.

Limiting Valve.

A. WEDGE BRAKES. Used on front wheels of all six vehicle models.

2-72
TM 9-2320-273-20

2-64. SYSTEM COMPONENTS (Continued).

B.

C.

“S’’- TYPE CAM BRAKE. Used on rear tandem axle inside wheels on all six models and

pusher axle wheel on M917, M919 and M920.

AIR CHAMBER. Two used on each rear tandem axle of all vehicle models. Spring loaded

brake applies when air pressure drops due to:

1. compressed air system failure.

2. engine shutdown.

3. application of park brakes.

2-73
TM 9-2320-273-20

2-64. SYSTEM COMPONENTS (Continued).

D. RESERVE AIR RESERVOIR. Two reserve air reservoirs are used on M915, M916, and

M918; three on M917, M919, and M920. (See illustrations in para 2-65 thru 2-70.)

E. RELAY VALVE. Pressure from cab brake valves control flow of air from brake reservoirs

to rear axle brake chambers. Applies rear brakes faster and more firmly than if they were

actuated directly by air pressure in control lines from cab.

2-74
TM 9-2320-273-20

2-64. SYSTEM COMPONENTS (Continued).

F. DOUBLE-CHECK VALVE. Directs air flow from either of two inlet lines into a single

outlet line.

G. QUICK-RELEASE VALVE. Vents air from rear brake system when operator releases brake.

H. LIMITING VALVE. Directs air pressure from a single incoming line to brakes on both

sides of truck.

2-75
TM 9-2320-273-20

2-65. AIR SYSTEM ARRANGEMENT (M915).

NOTE

The components shown below are described in paragraph 2-64.

2-76 Change 2
TM 9-2320-273-20

2-66. AIR SYSTEM ARRANGEMENT (M916).

Change 2 2-77
TM 9-2320-273-20

2-67. AIR SYSTEM ARRANGEMENT (M917).

2-78 Change 2
TM 9-2320-273-20

2-68. AIR SYSTEM ARRANGEMENT (M918).

Change 2 2-79
TM 9-2320-273-20

2-69. AIR SYSTEM ARRANGEMENT (M919).

2-80 Change 2
TM 9-2320-273-20

2-70. AIR SYSTEM ARRANGEMENT (M920).

Change 2 2-81
TM 9-2320-273-20

Section XXIV AUXILIARY AIR-POWERED SYSTEMS

2-71. INTRODUCTION.

Air pressure from the compressed air system is used for the following: (Brakes are covered in section

XXIII.)

a. Transmission and Controls (para 2-12).

b. Power Transfer Case (para 2-14).

c. Pusher Axle (para 2-16).

d. Windshield Wipers (para 2-72).

e. Air Horn (para 2-73).

f. Fan Clutch Control (para 2-74).

2-72. WINDSHIELD WIPERS AND WASHERS.

1. WIPER CONTROL KNOB. In OFF position, knob directs air from supply line to park line.

When pulled out, it diverts air to wiper line. By turning clockwise (LOW) or counterclockwise

(HIGH), desired speed is selected. Return to center and push in to park wipers.

2. WASHER BUTTON. When button is pushed, air flows from manifold to reservoir.

3. WlPER KNOB SUPPLY LINE. Carries air for wiper system from manifold to control knob.

4. WASHER AlR SUPPLY LINE. Carries air from manifold to control button.

5. COMPRESSED AIR SUPPLY MANIFOLD. Supplies compressed air to washer and wiper

through supply lines.

6. WIPER ARM. Connect wiper blade to linkage blade. Moved by motor.

7. WIPER BLADE. Replaceable blade wipes windshield.

8. RESERVOIR FILLER CAP. Filter underneath cap prevents dirt from entering system. Cap

closes firmly to maintain pressure in system.

9. WASHER FLUID RESERVOIR. Holds supply of washer fluid.

10. RESERVOIR AlR LINE. Carries pressurized air from button to reservoir where pressure

forces fluid into washer hose,

11. WASHER FLUID HOSE. Carries washer fluid from reservoir onto windshield

12. PARK AlR LINE. When knob is pushed into PARK position, air flows through park line to

motor causing wiper blades to move down to REST position.

13. WIPER MOTOR. Air-powered motor turns wipers back and forth when air comes from wiper

line or moves them down windshield to PARK position when air comes through park line.

14. WIPER AIR LINE. When knob is in WIPE position, air flows through wiper line to motor

which starts wiper blades in motion.

15. WIPER LINKAGE. Linkage from motor actuates two wiper arms.

2-82
TM 9-2320-273-20

2-72. WINDSHIELD WIPERS AND WASHERS (Continued).

2-83
TM 9-2320-273-20

2-73. AIR HORNS.

1. AIR HORNS. Air-powered signaling devices.

2. CONTROL VALVE. Allows compressed air to flow to horns when lever is pulled downward.

3. LEVER. Actuates control valve when pulled downward by chain in cab.

2-84
TM 9-2320-273-20

2-74. FAN CLUTCH CONTROLS.

1. FAN CLUTCH. When actuator opens, compressed air from supply reservoir engages clutch to

actuate fan.

2. FAN CLUTCH ACTUATOR. Opens air connection between supply reservoir and fan clutch

when coolant temperature rises above 190°F (88°C).

3. PRIMARY RESERVOIR. Supplies air pressure to engage clutch and rotate fan when actuator

opens air connection.

2-85
TM 9-2320-273-20

Section XXV STEERING SYSTEM

2-75. INTRODUCTION.

Two power steering systems are used for the M915 thru M920 vehicles: one for the M915 and one

for the M916 thru M920. The systems are identical, except for the following:

Auxiliary power cylinder and associated hydraulic lines - used on the M916 thru M920

only.

2-76. STEERING SYSTEM.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

AUXILIARY ASSIST CYLINDER. Piston moved back and forth by pressure from lines.

Connects to right wheel steering arm through auxiliary drag link. (M916 thru M920 ONLY.)

POWER STEERING GEAR. Hydraulically multiplies input torque from steering column and

transmits it to Pitman arm.

UNIVERSAL. Changes angle of torque from steering wheel and applies it to input shaft of

power steering gear.

STEERING WHEEL. Provides rotational torque to steering shaft, actuating steering system.

UNIVERSAL. Changes angle of steering torque.

HYDRAULIC PUMP AND RESERVOIR. Pump supplies hydraulic pressure to power steering

system. Reservoir provides a supply of oil to assure complete filling of hydraulic system.

STEERING GEAR RETURN LINE. Carries hydraulic fluid from steering gear back to

reservoir.

STEERING GEAR SUPPLY LINE. Carries hydraulic fluid under pressure from pump to

steering gear.

STEERING ARM. Transmits fore and aft movement from drag link to knuckle assembly.

DRAG LINK. Transfers motion of Pitman arm to steering arm and tie rod.

TIE ROD ASSEMBLY. Connects steering arms so that wheels turn together.

PITMAN ARM. Transfers steering torque (boosted by power steering gear to drag link).

AUXILIARY CYLINDER HYDRAULIC LINES. Carry fluid under pressure from the

steering gear to operate auxiliary cylinder.

POWER STEERING COOLER. Cools power steering fluid by means of finned unit on

vehicle grille, exposed to outside air. After the fluid is cooled, it is returned to the power

steering system.

2-86
TM 9-2320-273-20

2-76. STEERING SYSTEM (Continued).

2-87/2-88 Blank

TM 9-2320-273-20

Section XXVI POWER TAKEOFF

2-77. INTRODUCTION.

The power takeoff is installed on M916 thru M920. It supplies power from the engine to auxiliary

equipment.

2-78. POWER TAKEOFF.

1. PTO ADAPTER. Mounts on transmission and mates to transmission drive gear.

2. PTO. Gear driven from adapter. Provides drive for:

a. Winch hydraulic pump on the M916 and M920 (para 2-80).

b. Hoist cylinder hydraulic pump on the M917 (TM 5-3805-274-24 & P).

c. Hydraulic power pump on the M918 (TM 5-3895-371-24 & P).

d. Power train jack screw for conveyor drive on the M919 (TM 5-3895-372-20).

3. CONTROL LEVER. Engages or disengages PTO. Actuated by pulling control knob in cab.

4. PTO CONTROL KNOB. Allows movement of control lever from cab. Pulling knob out

engages PTO. Pushing knob in disengages PTO.

2-89
TM 9-2320-273-20

Section XXVII WINCH

2-79. INTRODUCTION.

The winch is installed on M916 and M920. The assembly is located behind the cab with all operating

controls.

2-80. WINCH.

1. INLINE RETURN FILTER. Throwaway filter removes water and dirt from oil returning

to reservoir.

2. WINCH CABLE. 7/8 inch (22.2 mm) diameter wire rope, 150 feet (46 m) long. Rated at

75,000 Ibs (33,600 N) minimum breaking strength.

3. CONTROL VALVE. Detented “up” position supplies pressure to outlet for auxiliary

hydraulic system. Down position provides high speed winch operation.

4. AUXILIARY THROTTLE. Adjusts power input to PTO by altering engine speed.

5. DIRECTIONAL CONTROL VALVE. Controls winch direction. Spring-loaded valve returns

to middle position when released, causing winch brakes to apply.

6. HYDRAULIC MOTOR. Turns winch to pay out or haul in cable. Powered by oil under

pressure from pump.

7. DUAL PUMP. 22 gpm/gear; total of 44 gpm @ 2200 engine rpm gear type pump powered

by PTO supplies 2350 psi (14,800 kPa) hydraulic pressure to motor through hydraulic

valves.

8. POWER TAKEOFF. Drives dual pump. (See paragraph 2-78 for functional description.)

9. INLET STRAINER. Removes large particles from oil going to dual pump.

10. HYDRAULIC RESERVOIR. Supplies oil to dual pump and receives oil returning from

system.

11. COVE R PLATE. When removed allows access to interior of reservoir to service interal

strainer and for general clean out.

2-90
TM 9-2320-273-20

2-80. WINCH (Continued).

2-91
TM 9-2320-273-20

Section XXVIII WINTERIZATION KIT

2-81. INTRODUCTION.

The Winterization Kit is an available option on all M915 thru M920 vehicles. This kit facilitates

vehicle start-up at temperatures down to -50°F (-46°C.). The components of this kit are described

below.

2-82. WINTERIZATION KIT.

1.

2.

3.

4.

5.

6.

110 VAC POWER CORD. This twenty-five foot power cord is used to connect a suitable

110/115 V exterior power supply to the power receptacle mounted on top of the vehicle

circuit breaker box.

CIRCUIT BREAKER BOX. Mounted to the vehicle right side behind the front fender and

in front of the battery box, this control center channels incoming 110 VAC electrical

power to any of four separate heaters. Each of the heaters is controlled and protected by

an individual circuit breaker.

TRANSMISSION OIL HEATER. Located on the forward, lower, left side of the transmission, this immersion heater supplies 375 watts. No thermostat is used due to the

relatively low wattage. When the 110 VAC power cord is plugged in, this heater can be

operated by the circuit breaker so marked. The breaker is a 15 ampere.

ENGINE OIL HEATER. Also an immersion type heater, the unit is mounted thru the

aft, lower, left side of the engine oil pan with a capacity of 750 watts, which is controlled

by a thermostat set at 170°F. The thermostat mounts to a plate outside the oil pan and

is protected by an insulated waterproof cover. When the 110 VAC power cord is plugged

in, this heater can be operated by the circuit breaker so marked. The breaker is a 15

ampere.

ENGINE COOLANT HEATER. This thermo-syplon type requires no circulating pump

and has a capacity of 2700 to 2800 watts. The heating unit integral with a thermostat

set at 190° F, is mounted to the main right hand frame rail below the turbocharger. The

heated coolant is piped to the top of the engine into the rear water manifold. The hot

coolant flows down thru the engine as the cold coolant returns to the heater. When the

110 VAC power cord is plugged in, this heater can be operated by the circuit breaker so

marked. The breaker is a 30 ampere.

BATTERY BOX HEATER. The battery box is insulated and heated by a coil, under the

battery support, with a capacity of 550 watts. A thermostat mounted on the inside back

wall of the box closes at +35°F and opens at +55°F. When the 110 VAC power cord is

plugged in, this heater can be operated by the circuit breaker so marked. The breaker is

a 15 ampere.

2-92
TM 9-2320-273-20

2-82. WINTERIZATION KIT (Continued).

2-93/2-94 {Blank)

TM 9-2320-273-20

CHAPTER 3

INTEGRATED SYSTEMS MAINTENANCE

3-1. OVERVIEW.

This chapter provides you with the following information related to overall truck tractor/truck

chassis maintenance:

a. Tools and Equipment.

b. Service Upon Receipt.

c. Preventive Maintenance Checks and Services (PMCS).

d. Composite Troubleshooting Index.

Section I REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

3-2. COMMON TOOLS AND EQUIPMENT.

For authorized common tools and equipment, refer to the Modified Table of Organization and

Equipment (MTOE) applicable to your unit.

3-3. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.

There are no special tools, TM DE and support equipment required for the procedures in this chapter.

3-4. SPARES AND REPAIR PARTS.

Spares and repair parts are listed and illustrated in the Repair Parts and Special Tools List covering

Organizational Maintenance for this equipment (TM 9-2320-273-20P).

Section II SERVICE UPON RECEIPT

3-5. CHECKING UNPACKED EQUIPMENT.

a. Inspect the equipment for damage incurred during shipment. If the equipment has been

damaged, report the damage on SF Form 364, Report of Discrepancy (ROD).

b. Check the equipment against the packing slip to see if the shipment is complete. Report

all discrepancies in accordance with the instructions of DA PAM 738-750.

Change 2 3-1
TM 9-2320-273-20

3-6. SERVICE UPON RECEIPT CHECKLIST M915 THRU M920 VEHICLES.

LOCATION/lTEM ACTION REMARKS

1. Protective wrappings. Remove.

2. Engine, tires, glass Check for missing parts

panels, instruments. or shipping damage.

3. Separately packaged kits. Inspect for damage.

4. Brakes and brake shoes. Check to be sure brake shoes See para 2-64 thru 2-70

do not stick to brake drums. for locations.

5. Breather tube, air intake, Remove all tape and wrapping. See paras 2-12, 2-25,2-27,

exhaust stack, transmission, 2-30, 2-42, and 2-64 thru

alternator, brakes. 2-70 for locations.

6. Water pump and alter- Check tension and adjust See para 4-51 and 4-53.

nator belts. if necessary.

7. Cooling system, fuel Check fluid levels. TM 9-2320-273-10.

system, transmission,

and differentials.

Do not allow SD-2 dry cleaning solvents

to come in contact with seals or flexible

hoses. These cleaners cause leather,

rubber, and synthetic materials to dry

out, rot, and lose pliability

8. Machined surfaces Remove wrappings. Clean

with SD-2 dry cleaning solvent.

9. a. Key switch, engine Make sure all electrical See TM 9-2320-273-10

retarder switch, switches are OFF. for locations.

worklamps, clearance

lamps, headlamp switch,

cigar lighter.

b. Battery cables. Connect. See para 5-37.

10. Oil system. If truck is due for an oil See para 4-14.

change, drain crankcase,

replace filters, and refill to

operating level.

11. Entire vehicle. a. Lubricate. See LO 9-2320-273-12.

b. Inspect for:

1. Leaks.

2. Loose or broken

hoses and lines.

3. Other damage.

3-2
TM 9-2320-273-20

Section Ill. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

3-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION. This section

contains Unit PMCS requirements for the M915 vehicle. The PMCS tables contain checks and services necessary to ensure the vehicle is ready for operation. Using the PMCS tables, perform maintenance at the specified intervals. Preventive Maintenance Checks and Services in TM 9-2320-273-10 must be completed before

doing Unit preventive maintenance.

3-8. MAINTENANCE FORMS AND RECORDS. Every mission begins and ends with paperwork. There is

not much of it, but it must be kept up. The filled out forms and records have several uses. They area record of

the services, repairs, and modifications made on the vehicle; they are reports to unit maintenance and to the

Commander; and they serve as a checklist to find out what is wrong with the vehicle after its last use, and

whether those faults have been fixed. For information needed on forms and records, see DA PAM 738-750.

3-9. GENERAL MAINTENANCE PROCEDURES.

WARNING

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors,

and are harmful to 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.

a. CLEANLINESS. Dirt, grease, oil and debris only get in the way and may cover up a serious problem. Use

dry cleaning solvent on metal surfaces and soapy water on rubber.

b. BOLTS, NUTS, AND SCREWS. Check bolts, nuts, and screws for obvious looseness, missing, bent, or

broken condition and tighten or replace as necessary. They cannot all be checked with a tool, of course, but

look for chipped paint, bare metal, or rust around bolt heads.

c. WELDS. Look for loose or chipped paint, rust, or gaps where parts are welded together. If a bad weld is

found, have it repaired.

d. ELECTRIC WIRES AND CONNECTORS. Look for cracked or broken insulation, bare wires, and loose or

broken connectors. Tighten loose connectors and make sure the wires are in good shape.

e. HYDRAULIC LINES AND FlTTINGS. Look for wear, damage, leaks, and make sure clamps and fittings

are tight. Wet spots show leaks, of course, but a stain around a fitting or connector may indicate a leak. If a

connector or fitting is loose, tighten it. If something is broken or worn out, repair or replace per applicable procedure.

3-10. FLUID LEAKAGE. It is necessary to know how fluid leakage affects the status of fuel, oil, coolant, and

the hydraulic systems. The following are definitions of types/classes of leakage necessary to know in order to

determine the status of the vehicle.

CAUTION

Equipment operation is allowable with minor leakages (Class I or II). Of course, consideration must be given to the field capacity in the item/system being checked/inspected. When in

doubt, notify the supervisor. When operating with Class I or II leaks, continue to check fluid

levels as required in the PMCS. Class Ill leaks should be repaired per applicable procedure.

a. Class 1. Seepage or fluid as indicated by wetness or discoloration not great enough to form drops.

Change 4 3-3
TM 9-2320-273-20

b. Class Il. Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being

checked/inspected.

c. Class Ill. Leakage of fluid great enough to form drops that fall from the item being checked/inspected.

3-11. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) TABLES.

a. Do the (S) PREVENTIVE MAINTENANCE once every six months and/or every 3000 miles (4,827 KM)

whichever comes first.

b. Do the (A) PREVENTIVE MAINTENANCE once each year and/or every 6,000 miles (9,654 KM) whichever

comes first.

c. Do the (B) PREVENTIVE MAINTENANCE once each year and/or every 12,000 miles (19,308 KM) whichever comes first.

d. Always do the PREVENTIVE MAINTENANCE in the same order until it gets to be a habit. Once practiced,

it will be easy to spot anything wrong in a hurry.

e. If something does not work, troubleshoot with instructions in Chapter 2.

f. If anything looks wrong and is not fixed, write a DA Form 2404.

g. When doing preventive maintenance, take along the tools and supplies needed to make all the checks.

Always take a clean cloth or two.

3-4 Change 4
TM 9-2320-273-20

Item

No.

1

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Interval

SemiAnnual

Item To Be

Inspected

PreService

Checks

Procedure

PRIOR TO ROAD TEST

Ensure Operator/Crew has performed

-10 PMCS listed in TM 9-2320-273-10.

ROAD TEST

Maintenance personnel will be with vehicle operator to assist in performing -10

PMCS checks and verify pre-service

checks.

NOTE

The following will be performed during

the road test. These inspections must

be performed before any -20 level

PMCS regardless of interval.

For road test, vehicle will be driven at

least five miles over different ground to

give enough time to detect any malfunctions.

a. Notice if starter engages smoothly

and turns the engine at normal cranking speed.

b. Listen for unusual engine noise at

idle, at operating speeds, and under

acceleration. Be alert for excessive vibration and the smell of oil, fuel and exhaust.

Not Mission

Capable If:

a. Starter inoperative or makes excessive grinding sound.

b. Engine knocks,

rattles or smokes excessively.

Change 4 3-5
TM 9-2320-273-20

Item

No.

1

Interval

SemiAnnual

Item To Be

Inspected

PreService

Checks

Continued

Procedure

c. Check for transmission response to

shifting and for smoothness of operation in all speed ranges. Be alert for unusual noises and difficulty in shifting in

any speed range.

d. Check for transfer response to

shifting and for smoothness of operation in all gear ranges. Be alert for unusual noises and difficulty in shifting in

any gear range.

e. Test for response to accelerator

feed. Observe for sticking pedal.

f. With vehicle speed approximately 5

mph (8 kph) turn steering wheel to left,

then right, to detect steering backlash,

shimmy or freeplay is more than 1-1/2

inches (38 mm) if either direction. Vehicle should respond instantly. With

vehicle moving on straight, level terrain, lightly hold steering wheel to

check for pull and wandering.

g. Apply brake pedal with steady

force. Vehicle should slow down and

stop without pulling to one side or jerking. Release brake pedal. The brakes

should release immediately and without difficulty.

h. Observe vehicle response to road

shocks, side sway or continuous

bouncing indicates a malfunction.

Not Mission

Capable If:

c. Transmission

shifts improperly,

does not shift or

makes excessive

noises.

d. Transfer jumps

out of gear or makes

excessive noises.

e. Pedal sticking or

binding.

f. Steering binds,

grabs, wanders or

freeplay is more than

1-1/2 inch (38 mm) in

either direction.

g. Brakes chatter,

pull to one side or inoperative. Brakes will

not release.

h. Handling is unstable.

3-6 Change 4

Table 3-1. Unit Level Preventive Maintenance Checks And Services M915-M920
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Item

No.

1

2

Interval

SemiAnnual

SemiAnnual

Item To Be

Inspected

PreService

Checks

Continued

Fuel System

Procedure

AFTER ROAD TEST

a. Make sure the vehicle has been

cleaned of mud, gravel, etc., from the

underbody, outside and crew compartment area.

CAUTION

Do not hold steering wheel at full left or

right position for longer than 10 seconds. Oil overheating and pump damage can result.

b. With vehicle stopped, turn steering

wheel to extreme left, then to the extreme right to check for hard steering.

c. Check engine operation at all

speeds. Insure that engine does not go

over engine governed speed -

600-2100 rpm.

WARNING

Adhesives, solvents, and sealing compounds can burn easily, can give off

harmful vapors, and are harmful to skin

and clothing. To avoid injury or death,

keep away from fire and use in wellventilated area. If adhesive, solvents,

or sealing compound get on skin or

clothing, wash immediately with soap

and water.

a. Clean fuel transfer pump screen by

soaking in a carbon dissolving agent, or

clean the screen in fuel oil and dry with

compressed air. Visually inspect screen

for holes or embedded metal particles in

mesh.

Not Mission

Capable If:

b. Hard steering is

evident.

c. Engine governed

speed - no load is below 600 rpm or exceeds 2100 rpm.

a. Screen is worn or

damaged.

Change 4 3-7
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks And Services M915-M920

Item Interval Item To Be Procedure Not Mission

No. Inspected Capable If:

2 Semi- Fuel b. Purge and clean fuel tank (TB

Annual System 43-0212), if required.

Continued c. Inspect fuel injection pump, nozzle c. Rubber cap missIines, and fittings for leaks and damage. ing or torn on return

line. Any nozzle

loose or damaged.

d. Inspect all fuel lines for loose connec- d. Any Class III leak.

tions, splits, cracks, and kinks that could

leak.

3 Semi- Engine Ac- a. Check for missing, broken, cracked a. Any drivebelt is

Annual cessory and frayed drivebelts. Check alternator missing or broken.

Drive Belt and fan belts 1/2 inch or less adjustment Belt fiber has more

for looseness, dry rot, excessive fraying than one crack (1/8

and cracks. inch in depth or 50%

of belt thickness) or

has frays more than 2

inches long.

b. Check fan belt (paragraph 4-45D) and b. Belts are loose.

alternator belt (paragraph 4-55C) for adjustment.

3-8 Change 4
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Item Interval Item To Be Procedure Not Mission

No. Inspected Capable If:

4 Semi- Fan, Alter- a. Inspect the pulleys for alignment.

Annual nator, and

Water b. Inspect the water pump for leaks and

Pump fan shrouds to see if they are securely

mounted.

5 Semi- Alternator a. Check for loose wiring connections or a. Loose connecAnnual Wiring and worn insulation. tions or worn insulaEngine tion.

Mount

b. Inspect for cracked or loose engine b. Cracked or loose

mounts. engine mounts.

6 Semi- Air Intake a. Inspect air cleaner, hoses, and tubing

Annual System for proper installation, cracks, breaks, or

loose connections that could let unfiltered air get into air intake system.

WARNING

Compressed air used for cleaning purposes will not exceed 30 psi. Use only

with effective chip guarding and personal

protective equipment (goggles/shield,

gloves, etc.).

NOTE

Outside element can be washed up to

five times or blown clean with air an indefinite number of times. This 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.

b. Remove air filters and service (para- b. Air filters have

graph 4-24 B). After servicing, reinstall holes or damaged

(paragraph 4-24C). seal.

Change 4 3-9
TM 9-2320-273-20

Item

No.

7

Table 3-1. Unit Level Preventive Maintenance Checks And Services M915-M920

Interval

SemiAnnual

Item To Be

Inspected

Engine

Crankcase

Procedure

NOTE

COLD TEMPERATURE OPERATION

For operation of equipment in expected

continuous temperatures below 0° F

(-18° C), remove lubricants prescribed in

the key for temperature above 0° F (-18°

C). Re-lubricate with lubricant specified

in the key for temperatures 0° F to -50° F

(-18° C to -46° C).

NOTE

Engine Oil Filter. After installing new filter

element, fill crankcase, operate engine 5

minutes, and check housing for leaks.

Shut down engine, check crankcase oil

level and bring to full mark.

NOTE

If AOAP laboratory is not available, drain

and refill engine crankcase with OE/HDO

every 3,000 miles (4,800 km) or semi-annually, whichever comes first.

a. Drain and refill crankcase with OE/

HDO.

b. Replace engine oil filter.

c. Check and clean crankcase breather

and attaching hoses.

d. Check all oil lines and hoses for

cracks and wear that could cause leaks.

e. Check oil filter housing and oil pan

drain plug for looseness. Make sure all

oil pan bolts are tight.

f. Check rocker housing covers for evidence of leaks.

Not Mission

Capable If:

“Do not operate” received from AOAP

laboratory.

b. Oil filter has

Class Ill leak.

d. Cracks, frays,

leaks, and wear are

evident.

e. Drain plugs and

oil pan bolts are

loose.

f. Class Ill leaks evident.

3-10 Change 4
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Item

No.

8

9

10

Interval

SemiAnnual

SemiAnnual

SemiAnnual

Item To Be

Inspected

Cab, En

gine,

Front/

Rear Light

Wiring

Harness

Alternator

and En

gine

Mount

Battery

Electrical

System

Procedure

Check all wiring harnesses for frays, splits,

missing insulation or poor connections.

Replace any worn wiring.

Inspect alternator mounting for looseness.

Inspect bracket and attaching hardware for

cracks, bends, and loose mounting.

NOTE

Refer to TM 9-61 40-200-14for more specific details on battery maintenance.

a. Inspect battery box for corrosion and

debris.

b. Clean slave receptacle and coat with

corrosion preventive compound.

c. Check and record specific gravity of

each cell.

d. Inspect battery cables for frays, splits,

and looseness.

Not Mission

Capable If:

Insulation missing.

Frays, splits, poor

connections evident.

Loose mounting,

cracks, or bends evident.

a. Corrosion that

has made holes in

metal battery box.

b. Terminals corroded.

c. If cell is below

1.225 specific gravity.

d. Cables frayed,

split, or loose.

Change 4 3-10.1
TM 9-2320-273-20

Item

No.

11

12

Table 3-1. Unit Level Preventive Maintenance Checks And Services M915-M920

Interval

SemiAnnual

SemiAnnual

Item To Be

Inspected

Power

Steering

Pump and

Filter

Compressed

Air System

Procedure

a. Inspect power steering pump for

leaks, cracks, and damage.

b. Check steering stops for proper adjustment (paragraph 10-21.2).

c. Check steering gear poppet valve for

proper adjustment (paragraph 10-21.3).

d. Change filter when fluid is contaminated.

NOTE

In areas where more than approximately

30° range of temperature is common,

small amounts of water can accumulate

in the air brake system due to condensation. The presence of small amounts of

water due to condensation is normal.

a. Drain air tanks. If any moisture is

forced out, inspect air dryer and replace

filter (paragraph 9-10). If moisture is

milky, blue or green, serious internal malfunctions are indicated.

b. Inspect air reservoirs, attaching

valves, lines and connections for mounting looseness, bends, dents, and cracks

that could cause leaks.

Not Mission

Capable If:

a. Cracks, damage,

or Class Ill leaks.

b. Steering stops

out of adjustment.

c. Steering gear

poppet valve is out

of adjustment.

d. Fluid is contaminated.

a. Moisture is milky,

blue or green.

b. Bends, dents,

cracks, loose air

lines or air leaks evident.

3-10.2 Change 4
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Change 4 3-10.3
TM 9-2320-273-20

Item

No.

15

Table

Interval

SemiAnnual

3-1. Unit Level Preventive Maintenance Checks And Services

Auxiliary

Throttle

(All models

in cat

M916 and

M920 on

Hydraulic

Winch)

NOTE

Do not oil control wire. The wire case has

teflon paste in it for wire lubrication.

Oil the body of the assembly with OE/HDO

and place a drop of oil (OE/HDO) under the

plunger cap.

M915-M920

Not Mission

Capable If:

3-10.4 Change 4

Item To Be

Inspected

Procedur e
TM 9-2320-273-20

Item

No.

16

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Interval

SemiAnnual

Item To Be

Inspected

Cooling

System

Procedure

WARNING

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) and MlL-A-11755 in temperatures below 0° F (-18° C).

a. Check coolant condition. Test coolant

to see if draining is necessary (TB

750-651).

b. Check all hoses for looseness, splits,

wear, and cracks that would cause leaks.

c. Inspect hose clamps for wear and

serviceability.

Not Mission

Capable If:

a. Coolant condition/testing shows

draining is required.

b. Class Ill leakage

evident. Hoses are

loose or have splits

or cracks.

c. Hose clamps are

worn or unserviceable.

Change 4 3-10.5
TM 9-2320-273-20

Item

No.

17

18

19

20

Table

Interval

SemiAnnual

SemiAnnual

SemiAnnual

SemiAnnual

3-1. Unit L

Item To Be

Inspected

Tires

Wheel

Alignment

Parking

Brake

Transmission

evel Preventive Maintenance Checks And Service

Procedure

CAUTION

Do not mix radial and bias tires on the

same vehicle. Make sure tires are cold

when you check pressure.

a. Inspect tires for unusual wear, penetrating objects, and improper matching.

b. Make sure all wheel Iugnuts are installed and tightened to correct torque

value 450 lb-ft (610 N.m).

Check toe-in and adjust as necessary.

Toe-in should be 1/8 inch (3.2 mm).

Inspect spring brake

and double air brake

and damaged fittings.

control valve, lines

chambers for leaks

a. Check transmission to bellhousing bolts

for gaps and torques.

b. If any bolt shows a gap or is loose, remove bolt and apply Ioctite; reinstall bolt

with flat washer and torque to 55 Ib-ft + or

-5 Ib-ft (74.6 N.m + or -6.8 Nm); then proceed to check all the remaining bolts as follows: Torque each bolt to 50 Ib-ft (67.8

N.m). If bolt turns or has a gap, remove

and’ apply Ioctite, reinstall

washer and torque 55 Ib-ft

(74.6 N.m + or -6.8 N.m).

bolt and flat

+ or - 5 Ib-ft

M915-M920

Not Mission

Capable If:

a. Tires improperly

match.

b. Any Iugnut missing and/or improperly torqued.

Toe-in out of adjustment.

Air leaks or damaged fittings.

3-10.6 Change 4
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Item Interval Item To Be Procedure Not Mission

No. Inspected Capable If:

20 Semi- Trans- C. Check transmission for cracks, loose c. Cracks, loose

Annual mission bolts, leaks, and obvious damage. bolts, or Class Ill

leaks evident.

Continued

d. Inspect transmission output shaft seal d. Damage or Class

for damage and leaks. Ill leaks evident.

e. Drain and refill transmission oil every e. “Do not operate”

6,000 miles (9,654 km) or annually, received from AOAP

whichever comes first. lab.

f. Replace transmission filter.

21 Semi- Exhaust WARNING

Annual System

The exhaust pipe and muffler can become very hot during vehicle operation.

Be careful not to touch these parts with

bare hands, or allow body to come in contact with pipe or muffler. Exhaust system

parts can become hot enough to cause

serious burns.

a. Inspect exhaust manifold, exhaust a. Evidence of corpipes, muffler, and tailpipe for corrosion, rosion or carbon decarbon deposits which may indicate posits evident.

leaks.

b. Inspect for damaged pipes, loose b. Pipes damaged,

clamps and leaking gaskets or seals. clamps loose, gaskets or seals leaking.

c. Inspect raincap to make sure it oper- C. Raincap does not

ates freely. operate freely, does

not close when engine is off, or missing.

Change 4 3-10.7
TM 9-2320-273-20

Item

No.

22

Table 3-1. Unit Level Preventive Maintenance Checks And Services M915-M920

Interval

SemiAnnual

Item To BE

Inspected

Rear Axles

Rear Axle

Spring and

Walking

Beam

Axle Differentials

(M916/M

920)

Front

Driving

and all

Rear

Axle Hous

ing Vent

Plug

Procedure

NOTE

COLD TEMPERATURE OPERATION

For operation of equipment in expected

continuous temperatures below 0° F (-18°

C), remove lubricants prescribed in the key

for temperatures above 0° F (-18° C). Relubricate with lubricants specified in the

key for temperatures 0° F to -50° F (-18° C

to -46° C).

NOTE

Pressure gun should be held on fittings

until new grease appears. This will assure that all the old contaminated grease

has been forced out. Take weight off suspension walking beam during lubrication

to ensure uniform application of grease

into the trunnion bushing.

a. Lubricate with GAA the Axle Spring

and Walking Beam.

b. Check and refill all axle differential

with GO as required.

WARNING

Adhesives, solvents, and sealing compounds can burn easily, can give off

harmful vapors, and are harmful to 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. Remove vent plug from axle housing.

Wash vent plug in solvent and allow to air

dry.

d. Coat threads with pipe thread sealing

compound and install axle housing

breather.

Not Mission

Capable If:

a. Fitting will not

purge old lubricant

out of component.

c. Axle vent plug

missing or cannot be

cleaned.

3-10.8 Change 4
TM 9-2320-273-20

Item

No.

23

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Interval

SemiAnnual

Item To Be

Inspected

Front

Axles

Drag Link,

Front Axle

Spring

Steering

Shaft Universals

Procedure

NOTE

COLD TEMPERATURE OPERATION

For operation of equipment in expected

continuous temperatures below 0° F (-18°

C), remove lubricants prescribed in the key

for temperatures above 0° F (-18° C). Relubricate with lubricants specified in the

key for temperatures 0° F to -50° F (-18° C

to -46° C).

NOTE

Pressure gun should be held on fittings

until new grease appears. This will assure that all the old contaminated grease

has been forced out. Take weight off suspension walking beam during lubrication

to ensure uniform application of grease

into the trunnion bushing.

a. Lubricate with GAA the Drag link, front

axle spring.

b. Inspect suspension/spring hanger

brackets and pins for wear or damage.

Inspect steering shaft for looseness and lubricate with GAA.

Not Mission

Capable If:

a. Fitting will not

purge old lubricant

out of component.

b. Spring hanger

brackets bent or broken.

Fitting will not purge

old lubricant out of

component.

Change 4 3-10.9
TM 9-2320-273-20

Item

No

23

Table

Interval

SemiAnnual

1-1. Unit Level Preventive Maintenance Checks And Service

Item To Be

Inspected

Front

Axles

Continued

Drive Line

Universal

Joint, Slip

Yokes and

Splines

Procedure

NOTE

Apply grease until purging takes place at

the air hole in the end slip yoke.

a. Lubricate drive line universal joint with

GAA and check for looseness or side

play.

b. Lubricate slip yokes and spline with

GAA and check for looseness or side

play.

M915-M920

Not Mission

Capable If:

a. Fitting will not

purge old lubricant

out of component,

loose or side play.

b. Fitting will not

purge old lubricant

out of component,

loose or side play.

3-10.10 Change 4
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Itern Interval Item To Be Procedure Not Mission

No. Inspected Capable If:

24 Semi- M916 and NOTE

Annual M920 COLD TEMPERATURE OPERATION

Front Axle

Only For operating of equipment in expected

continuous temperatures above 0° F (-18°

C), remove lubricants prescribed in the key

for temperatures above 0° F (-18° C).

Relubricate with lubricants specified in the

key for temperatures 0° F to -50° F (- 18° C

to -46° C).

NOTE

Change lubricant in new or rebuilt axles

within 1000 miles (1600 km) but no

sooner than 500 miles (800 km). Following initial drain, change lubricant every

24,000 miles (18,000 km) or 2 years of

service, whichever comes first. During all

lubricant changes, remove metal particles from magnetic drain and filler plugs.

NOTE

Fill front differential to bottom of CHECK

and FILL plug hole.

a. Check lubricant level of axle differential. Fill as necessary with GO.

Change 4 3-10.11
TM 9-2320-273-20

Item

No.

25

26

Table 3-1. Unit Level Preventive Maintenance Checks And Service

Interval

SemiAnnual

Item To Be

Inspected

Auxiliary

Power

Steering

Cylinder

Procedure

NOTE

Pressure gun should be held on fittings

until new grease appears. This will assure that all the old contaminated grease

has been forced out.

Lubricate the auxiliary power steering cylinder with GAA.

M915-M920

Not Mission

Capable If:

Fitting will not purge

old lubricant out of

component.

SemiAnnual

Pusher Axle Lift Linkage (M920

Only)

NOTE

Pressure gun should be held on fittings

until new grease appears. This will assure that all the old contaminated grease

has been forced out.

Lubricate the pusher axle linkage with

GAA.

Fitting will not purge

old lubricant out of

component.

3-10.12 Change 4
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Change 4 3-10.13
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks And Services M915-M920

Item Interval Item To Be Procedure Not Mission

No. Inspected Capable If:

29 Semi- Frame a. Inspect frame side rails for cracks, a. Cracks, bends,

Annual and breaks, bends, wear deterioration and or breaks in frame.

Cross- missing and loose fasteners. Any loose or missing

fasteners.

members

b. Inspect crossmembers for cracks, b. Cracks, bends,

breaks, bends, wear deterioration and or breaks in

missing and loose fasteners. crossmembers. Any

loose or missing fasteners.

30 Semi- Torque a. Check torque rods for damage. a. Damage is eviAnnual Rods dent.

b. Check mounting brackets for cracks, b. Cracks, breaks,

breaks, rust, and loose mounting hard- or loose mounting

ware on frame. hardware.

WARNING

Do not start engine or move vehicle when

anyone is under vehicle. Severe injury or

death could result.

NOTE

31 Semi- Propeller When using a grease gun, apply lubricant

Annual Shafts to the fitting until clean lubricant

and Uni- squeezes out of the part being lubricated.

versal

Joints NOTE

Use the proper lubricant to purge all four

bearing seals of each universal joint.

This flushes abrasive contaminates from

each bearing and assures all four bearings are filled properly.

NOTE

When vehicle is operating under severe

conditions, lubricate propeller shafts and

universal joints every 500 hours.

a. Lubricate using GAA all axle propeller a. Fitting will not

shafts and universal joints. purge old lubricant

out of component.

3-10.14 Change 4
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Item

No.

31

32

Interval

SemiAnnual

SemiAnnual

Item To Be Procedure

Inspected

Propeller b. Lubricate using GAA transmission to

Shafts transfer case propeller shaft and univerand Uni- sal joints.

versal

Joints

Continued 

M916/

M920 Tie

Rod

Not Mission

Capable If:

a. Damage is evident.

b. Cracks, breaks,

or loose mounting

hardware.

c. Inspect all propeller shafts for bends

and cracks.

d. Inspect U-joints for wear, play, broken

or missing lubrication fittings and secure.

There should be no free play at U-joint.

NOTE

Pressure gun should be held on fittings

until new grease appears. This will assure that all the old contaminated grease

has been forced out. Take weight off suspension walking beam during lubrication

to ensure uniform application of grease

into the trunnion bushing.

a.

b.

Lubricate tie rod ends with GAA.

Check tie rod drag links for proper

torque. Tighten nuts-to 120 lb-ft (163

N.m).

c. Bends or cracks

evident.

d. Lubrication fittings or screws are

broken or missing.

Wear and play evident.

a. Fitting will not

purge old lubricant

out of component,

loose or side play.

b. Improper torque

value.

Change 4 3-10.15
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks And Services M915-M920

Item Interval Item To Be Procedure Not Mission

No. inspected Capable If:

33 Semi- Winch a. Check for damage and proper opera- a. Improper control

Annual (M916 tion of winch assembly. response.

and M920

only) b. Check and fill gearbox with OE/HDO b. Class Ill leak evito proper level. dent.

c. Check for proper braking.

d. Inspect winch cables for damage,

kinks, frayed strands, and excessive

wear.

34 Semi- Winch a. Check control panel cylinders and

Annual Control hoses for hydraulic leaks.

Panel

b. Check and fill hydraulic fluid reservoir

with OE/HDO to proper level.

35 Semi- 5th Wheel Inspect and test the operation of the lockAnnual Assem- ing mechanism. Adjust as necessary

blies (paragraph 11-13).

36 Semi- Winteriza- NOTE

Annual tion Kit Never operate a heater without fluid in

the oil pan, transmission, or engine cooling system.

a. Plug in 110 VAC power cord to power

source and to receptacle on vehicle circuit breaker box with vehicle exposed to

+35° F (+1.6° C) or lower.

b. Turn on all four circuit breakers to the

“ON” position.

NOTE

Allow at least 15 minutes, then check for

appropriate heating level.

c. Engine coolant +190° F.

d. Engine oil to +170° F.

e. Transmission oil to +55° F.

f. Battery Box to +55° F.

3-10.16 Change 4
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Item

No.

Interval Item To Be

Inspected

Procedure

FINAL ROAD TEST

After all services and inspections have

been completed, take vehicle on a short

road test to make sure all corrections have

been accomplished. Correct any defects or

malfunctions that occur during this test.

During road test:

1. Listen for any noises.

2. Check steering operation.

3. Check operation of brakes.

4. Check transmission operation; all

ranges.

5. Check engine retarder (JACOBS

ENGINE BRAKE) operation (TM

9-2320-273-10).

6. Note any loss of power or rough running engine.

7. Check driveline lockup system operation (TM 9-2320-273-10).

Not Mission

Capable If:

Change 4 3-10.17
TM 9-2320-273-20

Item

No.

37

38

39

Table

Interval

Annual

Annual

Annual

or On

Condition

1-1. Unit Level Preventive Maintenance Checks And Service

Item To B

Inspected

Engine

Throttle

Lever

Headlights

Hydraulic

System

(M916

and

M920)

Procedure

Lubricate with GAA the engine throttle

lever pivot.

Check headlight adjustment. Adjust headlights (paragraph 5-25.1).

NOTE

If AOAP laboratory is not available, drain

and refill hydraulic reservoir every 6,000

miles (9,654 km) or annually, whichever

comes first.

a. Replace hydraulic fluid filters (all models paragraph 12-9).

NOTE

To drain hydraulic reservoir, remove bottom drain plug.

b. Drain reservoir using drain plug.

c. Refill hydraulic reservoir using OE/

HDO.

d. Inspect PTO Hydraulic pump for leaks

or obvious damage.

M915-M920

Not Mission

Capable If:

Fitting will not purge

old lubricant out of

component.

“Do not operate” received from AOAP

laboratory.

b. AOAP indicates

changes required.

3-10.18 Change 4
TM 9-2320-273-20

Item

No.

40

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Interval

Annual

tern To Be

Inspected

Tires

Procedure

NOTE

Rotate tires (refer

9-2610-200-14, paragraph

WARNING

to TM

2-9).

 Changing tire pressure or wheel alinement, out of the recommended specifications, may adversely affect the vehicle’s

handling characteristics. Loss of vehicle

control may result in serious injury or

death and damage to equipment.

 Never mix radial tires and bias ply tires on

the same axle. If radial tires are used in

combination with bias ply tires on a vehicle, the radial tires must be placed on the

rear axle only. Failure to do this may

cause damage to equipment or injury to

personnel.

NOTE

Vehicle must be up on jack stands for the

following checks.

a. Inspect tires for uneven wear and balance.

NOTE

If vehicle is new, and has been driven

less than 3,000 miles (4,800 km), it is not

necessary to aline wheels unless abnormal handling is reported.

b. Check alinement of front and rear

wheels (see TM 9-2320-280-20-1, paragraph(s) 8-7 and 8-8).

Not Mission

Capable If:

a. Tires exhibit excessive or uneven

wear or balance.

b. Front or rear

wheel are out of

alinement.

Change 4 3-10.19
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks And Services M915-M920

Item Interval Item To Be Procedure Not Mission

No. Inspected Capable If:

41 Annual Front NOTE

Wheel Do not remove wheels from hubs. Use

Bearings truck wheel lift to remove wheels and hub

as an assembly.

NOTE

M915 0nly See paragraph 10-13 for bearing removal and installation.

NOTE

M916/ See paragraph 10-14 for bearing reM920 moval and installation.

a. Remove, clean and re-pack with GAA

front wheel bearings.

b. Check wheel bearings for looseness, b. Loose, damaged

damage or wear (paragraph 10-13 b). or worn is evident.

c. Clean hub and brake shoe assemblies

with brake cleaning solvent.

NOTE

If hub has one gouge or grooves, turn hub

into Direct Support for resurfacing.

d. Check brake drums for obvious d. Deep grooves or

grooves and uneven wear. uneven wear is evident.

e. Check that brake shoe linings are not e. Brake shoe linworn less than 1/4 inch. ings worn less than

1/4 inch.

42 Annual Axle Brake NOTE

Cam-Shaft When using a grease gun, apply lubricant

and Slack to the fitting until clean lubricant

Adjuster squeezes out of the part being lubricated.

Lubricate GAA No.1 -4 axle brake cam- Fitting will not purge

shafts and slack adjusters. old lubricant out of

component.

3-10.20 Change 4
TM 9-2320-273-20

Item

No.

43

44

45

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M92O

Interval

Annual

Annual

Annual

tern To Be

Inspected

Rear Axles

Forward

Rear Axle

Oil Filter

Starter

Procedure

a. Inspect each input and output shaft

seal for damage and leaks.

NOTE

Do not remove wheels from hubs. Use

truck wheel lift to remove wheels and hub

as an assembly.

b. Remove, clean, and check wheel

bearings for damage or wear (paragraph

10-15).

c. Clean hub and brake shoe assemblies

with brake cleaning solvent.

NOTE

If hub has one gouge or grove, turn hub

into Direct Support for resurfacing.

d. Check brake drums for obvious

grooves and uneven wear.

Change forward rear axle oil filter (paragraph 8-13).

a. Remove starter (paragraph 5-32).

b. Remove three socket head screws

and add three to five drops of OE/HDO to

each reservoir.

Not Mission

Capable If:

b. Wheel bearings

loose, damaged, or

worn.

d. Deep grooves or

uneven wear is evident.

Change 4 3-10.21
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks And Services M915-M920

Item

No.

45

46

47

Interval

Annual

Annual

Annual

tern To Be

Inspected

Starter

Continued

Speedometer

Pusher

Axle

Wheel

Bearing

(M920)

Procedure

WARNING

Adhesives, solvents, and sealing compounds can burn easily, can give off

harmful vapors, and are harmful to skin

and clothing. To avoid injury or death,

keep away from fire and use in well-ventilated area. If adhesive, solvents, or sealing compund get on skin or clothing,

wash immediately with soap and water.

c. Clean drive and drive spline and apply

a thin coat of grease (GAA).

Lubricate speedometer with GAA.

NOTE

Do not remove wheels from hubs. Use

truck wheel lift to remove wheels and hub

as an assembly.

NOTE

See paragraph 10-16

moval and installation.

for bearing rea. Remove, clean, and repack with GAA

the pusher axle wheel bearing.

Not Mission

Capable If:

3-10.22 Change 4
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks and Sewices M915-M920

Item Interval Item To Be Procedure Not Mission

No. Inspected Capable If:

47 Annual Pusher b. Check wheel bearings for looseness,

Axle damage, or wear (paragraph 10-16b).

Wheel

Bearing c. Clean hub and brake shoe assemblies

(M920) with brake cleaning solvent.

Continued NOTE

If hub has one gouge or groove, turn hub

into Direct Support for resurfacing.

d. Check brake drums for obvious

grooves and uneven wear.

e. Check that brake shoe linings are not

worn less than 1/4 inch.

48 Annual Front Stop- NOTE

master Off-Highway (M916/M920 as applicaWedge ble). Change grease whenever seals are

Brakes replaced or when brakes are relined.

and Chambers M916/ Lubricate stopmaster wedge brake chamM920 bers annually or whenever seals are replaced or brakes are relined with GAA.

Change 4 3-10.23
TM 9-2320-273-20

Table 3-1 Unit Level Preventive Maintenance Checks And Services M915-M920

3-10.24 Change 4
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Item Interval Item To Be Procedure Not Mission

No. Inspected Capable If:

FINAL ROAD TEST

After all services and inspections have

been completed, take vehicle on a short

road test to make sure all corrections have

been accomplished. Correct any defects or

malfunctions that occur during this test.

During road test:

1. Listen for any noises.

2. Check steering operation.

3. Check brake operation.

4. Check transmission operation; all

ranges.

5. Check engine retarder (JACOBS

ENGINE BRAKE) operation (TM

9-2320-273-10).

6. Note any loss of power or rough running engine.

7. Check driveline lockup system operation (TM 9-2320-273-10).

Change 4 3-10.25
TM 9-2320-273-20

Item

No.

51

52

53

Table

Interval

Biennially

Biennially

Biennially

3-1. Unit L

Item To Be

Inspected

Transfer

Case

(M916 and

M920

Only)

Tie Rod

Ends

(M915

Only)

Front Stopmaster

Wedge

Brakes

and Chambers

M916/

M920

evel Preventive Maintenance Checks And Service

Procedure

Drain oil from transfer case at drain plug.

Refill with OE/HDO at fill plug.

DRAINS

Inspect tie rod for looseness.

NOTE

On-Highway (M916/M920 as applicable). Change grease whenever seals are

replaced, or when brakes are relined.

Lubricate stopmaster wedge brake chambers annually or whenever seals are replaced or brakes are relined with GAA.

M915-M920

Not Mission

Capable If:

Any looseness is

evident.

3-10.26 Change 4
TM 9-2320-273-20

Table 3-1. Unit Level Preventive Maintenance Checks and Services M915-M920

Item Interval Item To Be Procedure Not Mission

No. Inspected Capable If:

54 Biennially Rear Axles NOTE

Change lubricant in new or rebuilt axles

within 1000 miles (1600 km) but no

sooner than 500 miles (800 km). Following initial drain, change lubricant every

12,000 miles (19,300 km) or 2 years of

service, whichever comes first. During all

lubricant changes, remove metal particles from magnetic drain and filler plugs.

Drain and refill all axle differentials with Differentials have

GO. not been drained

within specified interval.

55 Biennially Front NOTE

Axles Change lubricant in new or rebuilt axles

M916/ within 1000 miles (1600 km) but no

M920 sooner than 500 miles (800 km). Following initial drain, change lubricant every

12,000 miles (19,300 km) or 2 years of

service, whichever comes first. During all

lubricant changes, remove metal particles from magnetic drain and filler plugs.

Drain and refill front axle differential with Differentials have

GO. not been drained

within specified interval.

Change 4 3-10.27
TM 9-2320-273-20

M915 THROUGH M920 SERIES TRUCK (CHASSIS)

PMCS PARTS LIST

ITEM PART STOCK NOMENCLATURE REMARKS

NO NUMBER NUMBER

______________________________________________________________________________

Semi-Annual (6,000 Miles)

1 286718 2940-01-081-1391 DESSICANT PACK 1

2 LF6070 2940-01-019-4513 ENG-FF-OIL-FTR 1

3 C175AP 2940-00-316-1413 ENG-BP-OIL-FTR 1

______________________________________________________________________________

Annual (12,000 Miles)

1 286718 2940-01-081-1391 DESSICANT PACK 1

2 LF6070 2940-01-019-4513 ENG-FF-OIL-FTR 1

3 C175AP 2940-00-316-1413 ENG-BP-OIL-FTR 1

4 FS1212 2910-01-146-1099 FUEL FILTER 1

5 250C127S 2940-01-065-8396 INT-AIR-FILTER 1 DON’T REUSE

6 250C128S 2940-01-066-1327 EXT-AIR-FILTER 1 CLEAN 5X ONLY

7 3280-V-5040 2940-00-221-3470 F-RR-AXLE FTR 1 M915 ONLY

8 WF2071 4330-00-274-4712 ENG-WTR-FILTER 1 KIT OPTION

______________________________________________________________________________

1

2

3

4

5

6

7

8

9

10

11

12

13

286718

LF6070

C175AP

FS1212

250C127S

250C128S

3280-V-5040

WF2071

ERS27549

S58

A-1205-L-1338

2208-M-819

839495

3-10.28 Change 4

Biennial (24,000 Miles)

2940-01-081-1391 DESSICANT PACK

2940-01-019-4513 ENG-FF-OIL-FTR

2940-00-316-1413 ENG-BP-OIL-FTR

2910-01-146-1099 FUEL FILTER

2940-01-065-8396 INT-AIR-FILTER

2940-01-066-1327 EXT-AIR-FILTER

2940-00-221-3470 F-RR AXLE FTR

4330-00-274-4712 ENG-WTR-FILTER

2530-00-445-4420 P/S PUMP FTR

2910-00-545-1350 WINCH-HYD-FTR

5330-01-082-7965 SEAL, WHL BRNG

5330-01-082-8595 HUB GASKET

5330-00-409-5771 SEAL, IN BRNG

1

1

1

1

1 DON’T REUSE

1 CLEAN 5X ONLY

1 M9150NLY

1 KIT OPTION

1 AS REQUIRED

1 M916/M9200NLY

2 M915FRONT AXLE

2 M915FRONT AXLE

4 915 TANDEM AXLE
TM 9-2320-273-20

Biennial (24,000 Miles) - Continued

ITEM PART STOCK NOMENCLATURE QTY REMARKS

NO NUMBE R NUMBER

14 A-1205-N-612

15 1229-X-518

16 2208-X-440

17 *2499 (78500)

*A-1205-Y-1533

 1199-T-3166

 A-1205-T-774

 A-1205-U-619

 1244U879

 2208-W-413

5330-00-807-8123

5310-00-800-0695

5330-00-580-6567

5330-01-330-5412

5330-01-088-9142

5330-01-090-2106

2540-00-938-8160

5330-01-076-2886

5330-01-075-0790

5330-00-255-0310

(*Part of kit identified above with **)

SEAL, OUT BRNG

STAR WASHERS

GASKET, HUB

SEALS, WH BRNG

SEAL, WHL BRNG

SEAL, WHL BRNG

SEAL, IN BRNG

SEAL, OUT BRNG

SEAL, WHL BRNG

HUB GASKET

18 1205-P-1212 5330-01-090-2107 SEAL, IN BRNG

19 2208-P-796 5330-01-273-9944 HUB GASKET

4

16

4

4

2

2

4

4

4

2

915 TANDEM AXLE

915 TANDEM AXLE

915 TANDEM AXLE

915 TANDEM AXLE

M916-M920 F. AX

M916-M920 F. AX

M916-M920 T. AX

M916-M920 T. AX

M916-M920 T. AX

M916-M920 T. AX

2 PUSHER AXLE

2 PUSHER AXLE

Change 4 3-10.29
TM 9-2320-273-20

LUBRICATION TABLE

REFILL EXPECTED TEMPERATURES

LUBRICANTS CAPACITY

(SEE NOTE 20) (APPR.) Above +32°F +40°F to -15°F

(See Note 19) O°F to-65°F

OE/HDO, AND OEA (ARCTIC GRADE)-OIL

ENGINE

11 GAL WITH OE/HDO 30 OE/HDO 10 OEA

BOTH FILTERS

OE/HDO-10, AND OEA

ARCTIC GRADE)-OIL 32 QUARTS

DEXRON* ATF PREFERRED) WITH EXTERNAL OE/HDO 10 OE/HDO 10 OEA

SEE NOTE 11 E)

TRANSMISSION

GO LUBRICANT,

MULTIPURPOSE SEE NOTE 7C GO 85/140 GO 80/90 GO 75

(-40°F LIMIT)

(EP 75W-90,SHC 75W-90, (-40°F to-65°F)

OR P.A.O. 75W 140 PER

MIL-L-2105C)

DIFFERENTIALS

OE/HDO-10, AND OEA

(ARTIC GRADE)-OIL

(DEXRON* ATF PREFERRED) 2 QUARTS ALL TEMPERATURES

(SEE NOTE 4B)

POWER STEERING D - Daily

GAA-GREASE W - Weekly, as required dependAUTOMOTIVE & AS REQUIRED ing upon use

ARTILLERY

CWII-LUBR, CHAIN EX- 1-1,000 Miles or 1

POSED GEAR AND WIRE AS REQUIRED month, whichever occurs first

ROPE 3-3,000 Miles or 3 months,

whichever occurs first

12-12,000 Miles or 12 months,

whichever occurs first

24-24,000 Miles or 24 months,

whichever occurs first

FOR ARTIC OPERATION REFER TO FM 9-207

TOTAL MAN-HOURS

INTERVAL D W 1 3 6 12 24

MAN-HOURS .3 .1 .7 .4 .6 .4 3.2

NOTE: The man-hours shown above have been established on an individual vehicle basis and hence

are not applicable at maintenance facilities where production line methods are employed.

3-10.30 Change 4
TM 9-2320-273-20

Section lV TROUBLESHOOTING SYMPTOM INDEX

3-8. INTRODUCTION.

Detailed troubleshooting procedures are provided in chapters 4 thru 12 of this manual. The procedures are arranged by subsystem categories under Malfunction Symptoms. The following composite

Malfunction Symptom Index provides a cross reference to the troubleshooting procedures contained

in the other chapters.

Table 3-2. Composite Troubleshooting Symptom Index

Troubleshooting Procedures

Malfunction

Table Number

BACKUP LAMPS.

Backup lamp(s) inoperative. 5-12 1

 BATTERY SYSTEM.

All electrical systems are weak. 5-1 1

Engine fails to crank or cranks slowly. 5-1 2

Batteries do not hold a charge. 5-1 3

BLACKOUT LIGHTING SYSTEM.

All blackout lamps inoperative. 5-13 1

One blackout marker, headlamp, tail lamp, or

stop lamp inoperative. 5-13 2

Trailer blackout lamps inoperative. 5-13 3

CHARGINGCIRCUIT.

Batteries are being undercharged or overcharged. 5-5 1

COMPRESSED AIR AND BRAKE SYSTEMS.

Insufficient air pressure. 9-1 1

Excessive system pressure indicated. 9-1 2

Park brakes will not release. 9-1 3

Trailer brakes will not release. 9-1 4

Service brakes will not release (one wheel only). 9-1 5

Service brakes will not apply. 9-1 6

3-11
TM 9-2320-273-20

Table 3-2. Composite Troubleshooting Symptom Index (Continued).

Troubleshooting Procedures

Malfunction

Table Number

COMPRESSED AIR AND BRAKE SYSTEMS (Continued).

No service brakes on trailer only. 9-1 7

Trailer hand control unit will not apply trailer

service braes. 9-1 8

Park brakes will not apply. 9-1 9

Service brakes are weak or slow responding

(all wheels). 9-1 10

Front service brakes are weak or slow responding. 9-1 11

Rear service brakes are uneven or erratic. 9-1 12

Service brakes are uneven or erratic on one or

more wheels. 9-1 13

Brakes overheat. 9-1 14

Stop lamps do not operate, brakes function normally. 9-1 15

Pressure gage(s) not indicating or not accurate,

brakes normal. 9-1 16

Air horn does not operate. 9-1 17

Windshield wipers are inoperative. 9-1 18

Interaxle differential lockup inoperative. 9-1 19

Engine will not crank. 4-1 1

Engine will crank but not start. 4-1 2

Engine stops, not seized. 4-1 3

Engine stops, seized. 4-1 4

High oil consumption. 4-1 5

Intermittent loss of power. 4-1 6

Sudden loss of power. 4-1 7

Gradual loss of power, no smoke. 4-1 8

Slow deceleration, engine “floats”. 4-1 9

3-12
TM 9-2320-273-20

Table 3-2. Composite Troubleshooting Symptop Index (Continued).

Troubleshooting lProcedures

Malfunction

Table Number

ENGINE (Continued).

Erratic idle speed. 4-1 10

Excessive exhaust smoke during acceleration. 4-1 11

Excessive exhaust smoke throughout speed range. 4-1 12

High fuel consumption. 4-1 13

Low oil pressure. 4-1 14

No cab heat. 4-1 15

Excessive exhaust noise. 4-1 16

Exhaust fumes in cab. 4-1 17

Engine overheats 4-1 18

ENGINE RETARDER CONTROLS.

No retarding action. 5-4 1

Retard inoperative in one or two selector position. 5-4 2

ETHER QUICK-START CONTROLS.

Solenoid cannot be heard to click when ether

button is pushed. 5-3 1

Towing pintle does not pivot or latch,

or jaw is stuck. 11-1 1

Excessive jerking of towed trailer. 11-1 2

Excessive noise or popping sounds from fifth

wheel when turning. 11-1 3

Both headlamps blink on and off. 5-8 1

One headlamp inoperative. 5-8 2

Both headlamps inoperative. 5-8 3

High beam indicator inoperative. 5-8 4

3-13
TM 9-2320-273-20

Table 3-2. Composite Troubleshooting Symptom Index (Continued).

Troubleshooting Procedures

Malfunction

Table Number

INSTRUMENTS AND INDICATORS.

Differential lockup lamp inoperative. 5-7 1

Park brake lamp inoperative. 5-7 2

Instrument panel gages inoperative. 5-7 3

Tachograph clock is inoperative. 5-7 4

Indicator/illumination lamp out. 5-7 5

MARKER LAMPS.

Front marker lamps inoperative. 5-9 1

Intermediate marker lamps inoperative. 5-9 2

Rear marker lamps inoperative. 5-9 3

All marker lamps inoperative. 5-9 4

MISCELLANEOUS ELECTRICAL.

Electric horn inoperative. 5-14 1

Personnel heater fan inoperative. 5-14 2

Dome lamp inoperative. 5-14 3

Work lamps inoperative. 5-14 4 & 5

Cigar lighter inoperative. 5-14 6

Winterization kit malfunctioning. 5-14 7

[PARKING AND TAIL LAMPS.

Single lamp inoperative. 5-10 1

Front lamps inoperative. 5-10 2

Rear lamps inoperative. 5-10 3

POWER TAKEOFF.

PTO wilI not engage. 12-2 1

PTO is excessively noisy. 12-2 2

POWER TRANSFER CASE..

Power transfer case does not turn front axle

propeller shaft. 7-1 1

Excessive heat buildup. 7-1 2

3-14
TM 9-2320-273-20

Table 3-2. Composite Troubleshooting Symptom Index (Continued).

Troubleshooting Procedures

Malfunction

Table Number

POWER TRANSFER CASE (Continued).

Lubricant leaking. 7-1 3

Transfer case noisy (oil level okay). 7-1 4

PROPELLER SHAFTS AND AXLES.

Excessive shaft noise or vibration. 8-1 1

Excessive backlash. 8-2 1

Continuous axle or wheel noise. 8-2 2

Lubricant leaking. 8-2 3

Excessive or uneven tire wear. 8-2 4

STARTER SYSTEM.

Starter fails to crank or cranks too slowly. 5-2 1

Starting motor is noisy and engagement is erratic 5-2 2

Front tires wearing unevenly. 10-2 1

Hard steering. 10-2 2

Vehicle wanders or pulls to one side. 10-2 3

Lost motion or excessive play in steering wheel. 10-2 4

Temporary increase in effort when turning

steering wheel. 10-2 5

Vehicle does not fully steer from stop to stop. 10-2 6

STOP AND TURN SIGNAL LAMPS.

Turn signals inoperative. 5-11 1

Stop lamps inoperative. 5-11 2

SUSPENSION.

Vehicle wanders or shimmies. 10-3 1

Pusher axle will not raise or lower. 10-3 2

Rear axle assembly not tracking properly. 10-3 3

3-15
TM 9-2320-273-20

Table 3-2. Composite Troubleshooting Symptom Index (Continued).

Troubleshooting Procedures

Malfunction

Table Number

TRANSMISSION. 

Selector lever cannot be moved from NEUTRAL

position. 6-1 1

Engine does not turn driveshaft in any speed,

forward or reverse. 6-1 2

Engine turns driveshaft in some gears, but not others. 6-1 3

Engine does not turn power takeoff in NEUTRAL. 6-1 4

Truck moves when engine is at low idle and transmission

in gear. 6-1 5

Transmission housing breather shows an air leak

after the shift is complete. 6-1 6

Transmission feels like it is engaged, then not engaged,

then engaged again – Transmission is also noisy. 6-1 7

Transmission has a decrease in oil level with an

increase in oil in the engine. 6-1 8

Transmission gears make noise during a shift, 6-1 9

WARNING LAMPS AND ALARMS.

Engine temperature warning lamp inoperative. 5-6 1

Engine oil pressure low warning lamp inoperative. 5-6 2

Low air pressure warning lamp and/or buzzer

inoperative. 5-6 3

Backup alarm is inoperative. 5-6 4

WHEELS AND TIRES.

Tires wearing unevenly. 10-1 1

Noisy or bumping sound while traveling on the road. 10-1 2

Winch operates in one direction only. 12-1 1

Winch does not operate in either direction. 12-1 2

Winch operates at one speed only. 12-1 3

Winch will not hold suspended load. 12-1 4

3-16
TM 9-2320-273-20

Section V TORQUE INSTRUCTIONS

3-9. Use these guidelines when tightening bolts and capscrews:

a. If the text gives a specific torque value, use it.

b. Never torque engine capscrew beyond the values given for grade 5 in table 3-3.

c. If no torque is specified, refer to table 3-3 for torque value.

Never torque an engine capscrew beyond

the value given for grade 5, even if it is

marked as grade 6, 7 or 8.

3-17
TM 9-2320-273-20

Table 3-3. Standard Capscrew Markings and Torque.

Current Useage Much Used Much Used Used at Times Used at Times

Minimum Tensile To 1/2-69,000 (476) TO 3/4-120,000 (827) To 5/8-140,000 (965) 150,000 (1034)

Strength PSI To 3/4-64,000 (421) To 1-115,000 (793) To 3/4-133,000 (917)

MPa To 1-55,000 (379)

Quality of Material Indeterminate Minimum Commercial Medium Commercial Best Commercial

SAE Grade Number 1 or 2 5 6 or 7 8

Capscrew Head Markings

Manufacturer’s marks

may vary

These are all SAE

Grade 5 (3 line)

Capscrew Body Size Torque Torque Torque Torque

(Inches) - (Thread) Lb-Ft (N-m) Lb-Ft (N•m) Lb-Ft (N•m) Lb-Ft (N•m)

1/4 – 20 5(7) 8(11) 10(14) 12(16)

-28 6(8) 10(14) 14(19)

5/16-18 11(15) 17(23) 19(26) 24(33)

-24 13(18) 19(26) 27(37)

3/8 – 16 18(24) 31(42) 34(46) 44(60)

-24 20(27) 35(47) 49(66)

7/16 – 14 28(38) 49(66) 55(75) 70(95)

- 20 30(41) 55(75) 78(106)

1/2 – 13 39(53) 75(102] 85(115) 105(142)

– 20 41(56) 85(115) 120(163)

9/16 – 12 51(69) 110(149) 120(163) 155(210)

– 18 55(75) 120(163) 170(231)

5/8 – 11 83(113) 150(203) 167(226) 210(285)

– 18 95(129) 170(231) 240(325)

3/4 – 10 105(142) 270(366) 280(380) 375(508)

– 16 115(156) 295(400) 420(569)

7/8 – 9 160(217) 395(536) 440(597) 605(820)

– 14 175(237) 435(590) 675(915)

1 – 8 2351319.) 590(800) 660(895) 910(1234)

– 14 250(339) 660(895) 990(1342)

1.

2.

3.

4.

Always use the torque values listed above when definite specifications are not available.

Note: Do not use standard values in place of those specified in other sections of this manual; special attention should

be observed when using SAE Grade 6, 7 and 8 capscrews.

The above is based on use of clean and dry threads.

Reduce torque by IO% when engine oil is used as a Iubricant.

Reduce torque by 20% if new plated capscrews are used.

Caution: Capscrews threaded into aluminum may require reductions in torque of 30% or more, unless inserts are used. TA 074608

3-18
TM 9-2320-273-20

CHAPTER 4

ENGINE AND ENGINE SYSTEMS MAINTENANCE

4-1. OVERVIEW.

This chapter provides you with the following information related to engine maintenance:

a. All required special tools and equipment

b. Other technical manuals

c. Troubleshooting procedures

d. Maintenance procedures

Section I REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

4-2. COMMON TOOLS AND EQUIPMENT.

For authorized common tools and equipment, refer to the Modified Table of Organization and

Equipment (MTOE) applicable to your unit.

 4-3. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.

The special tools, TM DE, and support equipment required for the engine maintenance procedures

described in this chapter are limited to the oil filter strap wrench. (Refer to Organizational Maintenance RPSTL, TM 9-2320-273-20P for tool description and illustration.)

 4-4. SPARES AND REPAIR PARTS.

Spares and repair parts are listed and illustrated in the Repair Parts and Special Tools List covering

Organizational Maintenance for this equipment (TM 9-2320-273-20P).

Section II TROUBLESHOOTING

4-5. INTRODUCTION.

Procedures for troubleshooting the engine and engine systems are given in table 4-1. These procedures are limited to isolation of faulty components that can be repaired or replaced at the Organizational Maintenance level. (For repair and replacement, see section III in this chapter.) A complaint

by the operator may have a variety of causes, singly or in combination. For example, in cases where

internal engine parts have failed, the true cause can usually be found in one or more of the fluid

systems and less frequently in the internal parts themselves. Therefore, a thorough repair would

include the investigation and discovery of the faulty system.

4-1
TM 9-2320-273-20

Table 4-1. Engine and Engine Systems Troubleshooting.

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

1. ENGINE WILL NOT CRANK:

Step 1. Check battery condition.

Test, charge, or replace as indicated by hydrometer (para 5-7).

Step 2. Check battery cables and terminals for loose or dirty connections.

Clean and tighten connections.

Step 3. Check electrical starting system.

a. Troubleshoot starting system (para 5-8).

b. Notify Direct Support Maintenance.

2. ENGINE WILL CRANK BUT NOT START:

Step 1. Check fuel level in tank.

Add fuel, if required.

Step 2. Check fuel solenoid shutoff valve.

Repair, if required (para 4-16).

Step 3. Check for leaking fuel lines.

Tighten connections or replace fuel lines as required (para 4-20).

Step 4. Check for air cleaner element restriction.

Service air cleaner element (para 4-24).

Step 5. Check for white exhaust smoke.

Use cold weather starting aid (Refer to TM 9-2320-273-10).

Step 6. Check for dirty fuel filter.

Service fuel filter (para 4-18).

Step 7. Check for congealed fuel (cold weather).

Check fuel specifications (Refer to TM 9-2320-273-10).

3. ENGINE STOPS, NOT SEIZED:

Step 1. Refer to steps 1 thru 7 of Malfunction 2 above.

Step 2. Check for obstructed air vent in fuel tank.

Remove air vent (para 4-23), then clean.

4. ENGINE STOPS, SEIZED:

Refer problem to Direct Support Maintenance.

4-2
TM 9-2320-273-20

Table 4-1. Engine and Engine Systems Troubleshooting (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

5. HIGH OIL CONSUMPTION:

Step 1. Check for overfilling.

a. Check oil level.

b. Determine that you have proper dipstick by matching against known

proper configuration.

Step 2. Check service records to determine that proper viscosity of oil is in use. (Refer to

LO 9-2320-273-12.)

Step 3. Check engine for external oil leaks with engine running.

Refer to Direct Support Maintenance for repair of oil leaks.

6. INTERMITTENT LOSS OF POWER:

Step 1. Refer to steps 1, 3 and 4 of Malfunction 2.

Step 2. Check fuel tank air vent.

Remove air vent (refer to para 4-23); then clean.

Step 3. Refer to step 6 of Malfunction 2.

Refer to Direct Support Maintenance.

7. SUDDEN LOSS OF POWER:

Step 1. Check fuel level in tank.

Step 2. Check for exhaust restriction.

a. Check for loose baffles. Replace muffler if damaged (para 4-37).

b. Check for damaged exhaust stack. Replace.

Step 3. Check for dirty fuel filter.

Service fuel filter (para 4-18).

Step 4. Check for leaking fuel lines.

Tighten connections or replace fuel lines as required (para 4-20).

Step 5. Check for air cleaner element restriction.

Service air cleaner element as necessary (para 4-24).

Step 6. Check for congealed fuel (cold weather).

Check fuel specification (refer to TM 9-2320-273-10).

4 -3
TM 9-2320-273-20

Table 4-1. Engine and Engine Systems Troubleshooting (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

8. GRADUAL LOSS OF POWER, NO SMOKE:

Step 1. Check for leaking fuel lines.

Tighten connections or replace fuel lines as required (para 4-20).

Step 2. Check for air intake restriction.

Service air intake as necessary (para 4-25).

Step 3. Check for worn accelerator rod linkage.

Adjust and replace worn parts (para 4-21).

Step 4. Check for congealed fuel (cold weather).

Check fuel specification (refer to TM 9-2320-273-10).

9. SLOW DECELERATION, ENGINE “FLOATS”:

Check for air leaks in fuel pump supply lines.

Service supply lines as necessary (para 4-20).

10. ERRATIC IDLE SPEED:

Check for air leaks in fuel pump supply lines.

Service supply lines as necessary (para 4-20).

11. EXCESSIVE EXHAUST SMOKE DURING ACCELERATION:

Step 1. Check for dirty fuel filter.

Service fuel filter (para 4-18).

Step 2. Check for air crossover tube leaks (para 4-28).

a. Repair air crossover tube leaks (para 4-28).

b. Refer to Direct Support Maintenance.

12. EXCESSIVE EXHAUST SMOKE THROUGHOUT SPEED RANGE:

Step 1. Check for dirty air cleaner element.

Clean or replace element (para 4-24).

Step 2. Check for poor quality fuel.

a. Check fuel specification. (Refer to TM 9-2320-273-10).

b. Refer to Direct Support Maintenance.

13. HIGH FUEL CONSUMPTION:

Step 1. Check for poor quality fuel.

a. Check fuel specification trefer to TM 9-2320-273-10).

b. Notify Direct Support Maintenance.

4-4
TM 9-2320-273-20

Table 4-1. Engine and Engine Systems Troubleshooting (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

14. LOW OIL PRESSURE:

Step 1. Check oil level.

Fill to proper level (Refer to Lubrication Order LO 9-2320-273-12).

Step 2. Check filter.

Replace filter (para 4-14).

Step 3. Check for defective oil pressure gage.

Test pressure with a gage that is known to be good (para 5-59). If test gage

indicates correct pressure, replace gage. If low or no pressure is indicated,

notify Direct Support Maintenance.

15. NO CAB HEAT:

Step 1. Check for closed heater water control valve.

Open valve (para 4-50).

Step 2. Check for air in heater.

Bleed air from heater (para 4-50).

Step 3. Check for low coolant level.

Fill to proper level and check for leaks (para 4-42).

Step 4. Check thermostat and thermal control (engine running cold).

Replace thermostat (para 4-43).

16. EXCESSIVE EXHAUST NOISE:

Step 1. Check for defective exhaust pipe or gasket(s).

Replace defective item (para 4-34 thru 4-38, as applicable).

Step 2. Check for defective muffler.

Replace muffler (para 4-37).

17. EXHAUST FUMES IN CAB:

Check for loose or defective manifold or leaks in pipes.

Replace pipe (para 4-34 thru 4-38, as applicable) or refer to Direct Support

Maintenance if manifold is defective.

18. ENGINE OVERHEATS:

Step 1. Check coolant level.

Add coolant until sight glass is full.

4-5
TM 9-2320-273-20

Table 4-1. Engine and Engine Systems Troubleshooting (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

18. ENGINE OVERHEATS (Continued):

Step 2. Check for loose or broken fan belts.

Tighten or replace belts (para 4-45).

Step 3. Check thermostat.

Replace thermostat (para 4-43).

Step 4. With engine running and radiator cap removed, check for proper coolant flow.

a. Check for clogged radiator hose. Clean or replace hoses (para 4-39).

b. Replace water pump (para 4-53).

Step 5. Check fan clutch actuator.

a. Check actuator tubes. Replace if necessary (para 4-48 or 4-49).

b. Replace actuator (para 4-46 or 4-47).

c. Replace fan clutch (para 4-45).

d. Refer problem to Direct Support Maintenance.

4-6
TM 9-2320-273-20

Section Ill MAINTENANCE PROCEDURES

4-6. INTRODUCTION

This section provides Organizational Level maintenance procedures for the engine and engine systems.

To find a specific maintenance procedure, see one of the following lists of task summaries:

a.

b.

c.

d.

e.

f.

g..

Engine Oil System Maintenance (para 4-7.

Fuel and Air Intake System Maintenance (para 4-8).

Engine Retarder Brake Maintenance (para 4-9).

Ether Quick-Start System Maintenance (para 4-10).

Exhaust System Maintenance (para 4-11).

Cooling System Maintenance (para 4-12).

Alternator Drive System Maintenance (para 4-13).

4-7
TM 9-2320-273-20

4-7. ENGINE OIL SYSTEM MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT

APPLICABLE CONFIGURATIONS CONDITION PARA. CONDITION DESCRIPTION

All. 11-14A or C. Left Front Fender Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Oil, 40 qts (Refer to Appendix C).

Containers, Five Gallon (3).

Rags.

Bypass Filter Element, 2122 (37099).

Cover Gasket, 4311 (37099).

Primary Filter Element, 299670 (15434).

Tape, Antiseizing Item 14, Appendix C.

PERSONNEL REWIRED

One (MOS-63B20).

REFERENCES (TM)

M9-2320-273-20P. SPECIAL ENVIRONMENTAL CONDITIONS

TM9-2320-273-10.

LO 9-2320-273-12 Vehicle parked on level ground.

REFERENCES (TROUBLESHOOTING)

Table 4-1.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1. Engine Oil Service: 4-14 4-1

A. Draining oil. 4-14A

B. Removal of primary filter. 4-14B

C. Inspection of fiIter adapter. 4-14C

D. Installation of primary filter. 4-14D

E. Removal of bypass filter. 4-14E

F. Bypass filter inspection. 4-14F

G. Inspection/replacement of oil lines 4-14G

4-8 Change 2
TM 9-2320-273-20

4-7. ENGINE OIL SYSTEM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TAS K TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1. Engine Oil Service (Continued):

H. Installation of bypass filter element. 4-14H

I. Replenishing oil. 4-14I

J. Checking for leaks. 4- 14J

2. Breather Tube Maintenance: 4-15

A. Removal. 4-15A

B. Cleaning. 4-15B

C. Inspection. 4-15C

D. Installation. 4-15D

4-9
TM 9-2320-273-20

4-8. FUEL AND AIR INTAKE SYSTEM MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT

APPLICABLE CONFIGURATIONS CONDITION PARA CONDITION DESCRIPTION

All. 5-37A._ Batteries Disconnected.

11-14 A or C. Left Front Fender Removed.

TEST EQUIPMENT 4-22A. Hand Throttle Cable Disconnected

None. 12-12A. at Throttle Mounting Bracket.

Winch Throttle Cable Disconnected

SPECIAL TOOLS at Throttle Mounting Bracket

None. (M916 and M920).

MATERIALS/PARTS (P/N)

Shield (2910-00-064-7787). Outer Filter Element V250C128,

O-Ring (5330-00-081-9299). Inner Filter Element V250C127.

Masking Tape. Container(s) (AR for fuel).

Marking Pencil. Liquid Teflon (Appendix C).

Fuel Filter (2910-00-174-5822). Soap Solution.

O-Ring, 213079 (15434). Dry Cleaning Solvent SD-2 (Appendix C).

Container (1 qt. Gasket (5330-00-951-3538).

Tachometer RPM Drive Cable Cap Seal Ring (5330-00-961-9470).

MA280J20000 (34623). Cotter Pin (3), 103362 (24617).

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

One, two or three (MOS-63B20). Vehicle parked on level ground.

Work in well ventilated area.

REFERENCES (TM) Darkened area for filter check.

Work area must be clean as dirt in the air

TM 9-2320-273-20P. passages can damage the turbocharger and

TM 9-2320-273-10. engine.

REFERENCES (TROUBLESHOOTING) GENERAL SAFETY INSTRUCTIONS

Table 4-1. Engine off.

Transmission in Neutral.

Park brake set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1. Fuel Solenold Shutoff Valve Maintenance: 4-16 4-1

A. Removal. 4-16A

B. Installation. 4-16B

C. Operational Check. 4-16C

2. Fuel Pump Screen Maintenance: 4-17

A. Removal. 4-17A

B. Cleaning. 4-17B

4-10
TM 9-2320-273-20

4-8. FUEL AND AIR INTAKE SYSTEM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK

NO.

2.

3.

4.

5.

6.

7.

8.

TASK

Fuel Pump Screen Maintenance (Continued):

C. Installation.

D. Checking for leaks.

Fuel Filter Maintenance:

A. Removal.

B. Installation.

C. Checking for leaks.

Tachograph RPM Cable Maintenance:

A. Removal.

B. Installation.

C. Operational check.

Lines, Hoses, and Fittings Maintenance

Accelerator Pedal and Rod Maintenance:

A. Removal.

B. Installation.

C. Checking idle speed.

Hand Throttle Linkage Maintenance:

A. Removal.

B. Cleaning and inspection.

C. Installation.

D. Checking idle speed.

Fuel Tank Maintenance:

A. Removal.

B. Installation.

C. Checking for leaks.

TASK

REF

4-17C

4-17D

4-18

4-18A

4-18B

4- 18C

4-19

4-19A

4-19B

4-19C

4-20

4-21

4-21A

4-21B

4-21C

4-22

4-22A

4-22B

4-22C

4-22D

4-23

4-23A

4-23B

4-23C

TROUBLESHOOTING

REF (TABLE)

4-1

4-1

4-1

4-1

4-11
TM 9-2320-273-20

4-8. FUEL AND AlR INTAKE SYSTEM MAINTENANCE TASK SUMMARY (Continued

LIST OF TASKS

TASK

NO.

9.

10.

11.

12.

TASK

Air Cleaner Element Maintenance:

A. Removal.

B. Cleaning.

C. Installation

Air Cleaner Assembly Maintenance:

A. Removal of filter assembly.

B. Removal of brackets & fittings.

C. installation of brackets & fittings.

D. Installation of filter assembly.

Air Cleaner Restriction Indicator Maintenance:

A. Removal of indicator.

B. Installation of indicator.

C. Removal of tube and filter.

D. Installation of tube and filter.

Turbo Air Inlet Maintenance:

A. Removal.

B. Inspection.

C. Installation.

D. Checking for leaks.

TASK

REF

4-24

4-24A

4-24B

4-24C

4-25

4-25A

4-25B

4-25C

4-25D

4-26

4-26A

4-26B

4-26C

4-26D

4-27

4-27A

4-27B

4-27C

4-27D

TROUBLESHOOTING

REF (TABLE)

4-1

4-1

4-12
TM 9-2320-273-20

4-9. ENGINE RETARDER BRAKE MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT

APPLICABLE CONFIGURATIONS CONDITION PARA CONDITION DESCRIPTION

All. 4-15A. Breather tube removed.

TEST EQUIPMENT 4-27A. Turbo air inlet removed.

None.

4-28A&B. Rocker arm housing covers

removed.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Dry cleaning solvent (Refer to Appendix C).

Crossover tube gasket (center cover only) (216487).

Gasket, rocker arm housing (3009999).

PERSONNEL REQUIRED

One, or two (MOS-63B20).

REFERENCES (TM)

TM9-2320-273-10.

TM9-2320-273-20P. SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Work area must be clean, as dirt in the

Table 5-4. turbocharger and engine can cause damage.

Vehicle parked on level ground.

GENERAL SAFETY INSTRUCTIONS

Engine off; transmission in neutral.

Park brake set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1. Rocker Arm Housing Covers Maintenance: 4-28 5-4

A. Removal of crossover tube. 428 A

B. Removal of cover. 4-28B

C. Cleaning. 4-28C

D. Installation of cover. 4-28D

E. InstalIation of crossover tube. 4-28E

2. Engine Retarder Brake Maintenance: 4-29 5-4

Inspection. 4-29

4-13
TM 9-2320-273-20

4-10. ETHER QUICK-START SYSTEM MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT

APPLICABLE CONFIGURATIONS CONDITION PARA CONDITION DESCRIPTION

All. 4-30A. Ether Cylinder Removed.

TEST EQUIPMENT 911A. Alcohol Evaporator Removed.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Ether cylinder (2910-01-072-1783).

Solenoid valve, 913032-04 (06991).

Atomizer, 91302406 (06991).

PERSONNEL REQUIRED

TWO (MOS-63B20)

REFERENCES (TM) SPECIAL ENVIRONMENTAL CONDITIONS

TM9-2320-273-10. Work in well ventilated area.

TM9-2320-273-20P. Vehicle parked on level ground.

REFERENCES (TROUBLESHOOTING) Coolant temperature must be below 50°F

or ether button wiII not function.

Table 5-3. GENERAL SAFETY INSTRUCTIONS

Ether is highly explosive, dispose of

cylinder properly. Be alert for the strong odor

of spilled ether. Guard against flame or sparks

in work area. Engine off; transmission in

neutral. Park brake set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1. Ether Cylinder Maintenance: 4-30 5-3

A. Removal. 4-30A

B. Installation. 4-30B

C. Operational check. 4-30C

2. Solenoid Valve Maintenance: 4-31 5-3

A. Removal. 4-31 A

B. InstalIation. 4-31 B

4-14
TM 9-2320-273-20

5-3

4-10. ETHER QUICK-START SYSTEM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

3. Atomizer Maintenance: 4-32 5-3

A. Removal. 4-32A

B. Installation and operational check. 4-32B

4. Ether Tube Maintenance: 4-33

A. Removal. 4-33A

B. Inspection. 4-33B

C. Installation, 4-33C

D. Operational check. 4-33D

4-15
TM 9-2320-273-20

4-11. EXHAUST SYSTEM MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT

APPLICABLE CONFIGURATIONS CONDITION PARA CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Locknut (M916/M920) M 1219B-20002 (34623).

Couplings (5) 5.0-1236 BJ (76700).

(3) 5.0-1256 LJ [76700).

5.0-1259 LJ (76700).

PERSONNEL REQUIRED

One or two (MOS-63B20).

REFERENCES (TM)

TM9-2320-273-10.

TM9-2320-273-20P. SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Vehicle parked on level ground.

Table 4-1.

GENERAL SAFETY INSTRUCTIONS

Wait until exhaust components are cool.

Engine off; transmission in neutral.

Park brake set.

TASK

NO.

1.

2.

LIST OF TASKS

TASK

Turbo Outlet Pipe Maintenance:

A. Removal.

B. Inspection of mating

C. Installation.

D. Checking for leaks.

Flex Pipes Maintenance:

A. Removal.

flanges.

B. Inspection of mating fIanges.

4-16

TASK

REF

4-34

4-34A

4-34B

4-34C

4-34D

4-35

4-35A

4-35B

TROUBLESHOOTING

REF (TABLE)

4-1

4-1
TM 9-2320-273-20

4-1

4-11. EXHAUST SYSTEM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

2. Flex Tubes Maintenance (Continued):

C. Installation. 4-35C

D. Checking for leaks. 4-35D

3, Muffler Inlet Pipe Maintenance: 4-36 4-1

A. Removal. 4-36A

B. Inspection of mating flanges. 4-36B

C. Installation. 4-36C

D. Checking for leaks. 4-36D

4. Muffler Maintenance: 4-37

A. Removal. 4-37A

B. Inspection of mating flanges. 4-37B

C. Installation. 4-37C

D. Checking for leaks. 4-37D

5. Exhaust Stack Maintenance: 4-38

A. Removal. 4-38

B. Inspection of mating flanges and rain 4-38B

cap.

C. Installation. 4-38C

D. Checking for leaks. 4-38D

4-17
TM 9-2320-273-20

4-12. COOLING SYSTEM MAINTENANCE TASK SUMMARY.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All.

TEST EQUIPMENT

Belt tension gage.

SPECIAL TOOLS

Thermostat mandrel No. 139.

MATERIALS/PARTS (P/N)

Insulators (2) CBA24-500 (76005)

Liquid teflon (refer to appendix C).

Container (60 qt min).

Gasket (6620-00-047-281 1).

Rubber seal (5330-00-864-5422).

O-Rings (4) (5330-00-506-4874).

Sealing rings (6) (5330-00-143-8369).

Gasket, 210859 (15434).

Soap solution.

Gasket, 3011931 (15434).

Gasket, 208132 (15434).

Gasket, water pump to engine block

(5330-01 -066-5350) .

Gasket, water pump to heater manifold

208132 (15434).

EQUIPMENT

CONDITION PARA CONDITION DESCRIPTION

4-41A. Upper fan shroud removed.

4-42A. Coolant drained.

4-49A, 4-51A. 4-47A. Water pump belt removed.

4-46A.

4-25A.

4-41A.

4-44A.

4-45A.

6-10A.

5-73A.

4-27A.

11-29A, 11-32A.

11-16E.

11-16A.

10-22A.

Fan clutch “actuator removed.

Air cleaner removed.

Upper shroud & fan removed.

Fan removed.

Fan belts removed.

Transmission oil cooler hoses removed.

Water temperature switch wire removed.

Turbo air inlet removed

Hood removed

Brush guard removed (M916/M920).

Grille removed.

Steering pump cooler hoses removed.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle parked on level ground.

GENERAL SAFETY INSTRUCTIONS

Engine off; transmission in neutral.

Park brake set.

PERSONNEL REQUIRED

One or two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

REFERENCES (TROUBLESHOOTING)

Table 4-1.

4-18
TM 9-2320-273-20

4-12. COOLING SYSTEM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1. Radiator Hoses Maintenance: 4-39 4-1

A. Inspection. 4-39A

B. Removal. 4-39B

C. Installation. 4-39C

2. Radiator Maintenance: 4-40 4-1

A. Removal. 4-40A

B. Installation. 4-40B

3. Fan Shrouds Maintenance: 4-41

A. Removal. 4-41A

B. Installation. 4-41B

4. Coolant System Maintenance: 4-42 4-1

A. Drain. 4-42A

B. Inspection/installation of draincocks 4-42B

C. Replenishing coolant, 4-42C

D. Checking for leaks. 4-42D

5. Thermostat and Housing Maintenance: ‘ 4-43 4-1

A. Removal. 4-43A

B. Testing. 4-43B

C. Installation. 4-43C

D. Operational check. 4-43D

6. Fan Maintenance: 4-44 4-1

A. Removal. 4-44A

B. Installation. 4-44B

C. Operational check. 4-44C

4-19
TM 9-2320-273-20

4-12. COOLING SYSTEM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

7. Fan Clutch and Belts Maintenance: 4-45

A. Removal. 4-45A

B. Inspection. 4-45B

C. Installation. 4-45C

D. Adjustment. 4-45D

8. Fan Clutch Actuator Maintenance (M915, M916,

M917, M918, and M920): 4-46 4-1

A. Removal. 4-46A

B. Inspection of air tubes. 4-46B

C. Installation. 4-46C

D. Operational check. 4-46 D

9. Fan Clutch Actuator and Valve

Maintenance (M919): 4-47 4-1

A. Removal. 4-47A

B. Inspection of air tubes. 4-47B

C. Installation. 4-47C

D. Operational check. 4-47 D

10. Fan Clutch Actuator Tubes Maintenance

(M915, M916, M917, M918, and M920): 4-48 4-1

A. Removal. 4-48A

B. Installation. 4-48B

C. Checking for leaks. 4-48C

11. Fan Clutch Actuator Tubes Maintenance (M919): 4-49 4-1

A. Removal. 4-49A

B. Inspection. 4-49B

C. Installation. 4-49C

D. Checking for leaks. 4-49D

4-20
TM 9-2320-273-20

4-12. COOLING SYSTEM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

12. Heater Shutoff Valve Maintenance: 4-50 4-1

A. Removal. 4-50A

B. Installation. 4-50B

C. Bleeding heater. 4-50C

13. Water Pump Belt Maintenance: 4-51

A. Removal. 4-51 A

B. Installation. 4-51 B

C. Adjustment. 4-51C

14. Water Manifold Maintenance: 4-52

A. Removal. 4-52A

B. Inspection. 4-52B

C. Installation. 4-52C

15. Water Pump Maintenance: 4-53

A. Removal. 4-53A

B. Installation. 4-53B

16. ‘Water Pump Idler Pulley Maintenance: 4-54

A. Removal. 4-54A

B. Installation. 4-54B

C. Operational check. 4-54C

NOTE

Maintenance procedures for the

water temperature switch and

transmitter are given in Chapter 5,

section III.

4-1

4-21
TM 9-2320-273-20

4-13. ALTERNATOR DRIVE SYSTEM MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT

APPLICABLE CONFIGURATIONS CONDITION PARA CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

Belt tension gage.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20)

REFERENCES (TM)

TM9-2320-273-10

SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING)

Table 4-1.

Vehicle parked on level ground.

GENERAL SAFETY INSTRUCTIONS

Engine off; transmission in neutral.

Park brake set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1 Alternator Belts Maintenance: 4-55

A. Removal. 4-55A

B. Installation. 4-55B

C. Adjustment 4-55C

4-22
TM 9-2320-273-20

This page intentionally left blank.

4-23
TM 9-2320-273-20

OIL SYSTEM

4-14. ENGINE OIL SERVICE.

MIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Draining Oil. (15) g. Inspection/Replacement of Oil Lines. (10)

 b . Removal of Primary Filter. (10) h. Installation of Bypass Filter. (15)

c. Inspection of Filter Adapter. ( 5) i. Replenishing Oil. (15)

d. Installation of Primary Filter, (10) j. Checking for Leaks. (10)

Removal of Bypass Filter. (10)

Bypass Filter Inspection. ( 5) 105 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All, 11-14 A or C. Left Fender Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Oil, 40 Qts (Refer to Appendix C).

Containers (Three 5-gal buckets).

Rag, Wiping.

Bypass Filter Element, 2122 (37099).

Cover Gasket, 4311 (37099).

Primary Oil Filter, 299670 (15434).

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-20P.

LO 9-2320-273-12.

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 4.1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-24
TM 9-2320-273-20

OIL SYSTEM

4-14. ENGINE OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

A. DRAINING OIL.

1. Vent plug

washer (3).

2) and

2. Drain plug (31).

NOTE

Place container under crankcase drain plug (31)

to catch oil.

Unscrew and remove. Allow sufficient time for

a.

b.

c.

d.

oil to drain from bypass

filter to crankcase.

Unscrew and remove. Oil should be drained

Allow all oil to drain out. from a warm engine.

Inspect magnet for foreign

particles and wipe clean. Stop flow by reinserting

Screw in and tighten plug to change containers.

4-25
TM 9-2320-273-20

4-26 Change 2
TM 9-2320-273-20

OIL SYSTEM

4-14. ENGINE OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

A.1. OIL SAMPLE FOR ANALYSIS.

NOTE

Before beginning this task check engine

oil level according to Operator’s manual

(TM 9-2320-273-10).

Start engine (see TM 9-2320-273-10),

warm vehicle to normal operating range

and stop engine.

1. Draincock (16). a. Unscrew and loosen. When taking a sample, first

use a container to drain a

small amount of oil to clean

the valve assembly.

b. When completed with

task 1., use the proper

bottle and take oil sample

from the oil bypass filter

drain valve as shown in

illustration on page 4-26,

item 16.

c. Check oil level to insure

proper level after sampling.

B. REMOVAL OF PRIMARY FILTER.

NOTE

Place container under primary filter (30)

to catch oil.

3. Primary filter (30). Unscrew using filter wrench.

Throw filter away.

C. INSPECTION OF FILTER ADAPTER.

4. Filter adapter (29). Inspect for: If adapter is defective, notify

a. Cracks. Direct Support.

b. Nicks.

c. Damaged threads.

Change 2 4-26.1
TM 9-2320-273-20

OIL SYSTEM

4-14. ENGINE OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

D. INSTALLATION OF PRIMARY FILTER.

5. New primary filter (30). a. Apply lube to seal. Do not use filter wrench,

b. Screw into filter adapter

(29) and tighten by hand,

E. REMOVAL OF BYPASS FILTER.

NOTE

Place container under bypass filter draincock

(16) to catch oil,

6. Bypass filter draincock (16) a. Remove and allow oil to

and washer (17). drain out.

b. Screw in and tighten.

7. Two clamping bolts (7). Unscrew and remove.

8. Clamping ring (6). Remove.

9. Cover (4) and cover gasket (5). Remove. Discard cover gasket (5).

10. Pack hold down assembly (28). Unscrew and remove.

11. Bypass filter element (8). Remove and discard.

12. Filter to pump line (20) and Unscrew and remove

filter to sump line (21). from two elbows (22).

13. Eight bolts (12), Iockwashers Unscrew and remove.

(13) and nuts (11).

4-26.2 Change 2
TM 9-2320-273-20

OIL SYSTEM

4-14. ENGINE OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

4-27
TM 9-2320-273-20

OIL SYSTEM

4-14. ENGINE OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

E. REMOVAL OF BYPASS FILTER {Continued).

14. Two mounting bracket Lift off and remove canister

clamps (24). (23).

15. Two elbows (22). Unscrew from canister (23).

16. Eight nuts (15) and lock- Unscrew and remove two

washers (14). mounting brackets (10) from

eight mounting studs (9) at

firewall.

F. BYPASS FILTER INSPECTION.

17. Orifice (26) and bleeder Holes should not be blocked.

hole (27). Clean out with a piece of wire

if necessary.

18. Mounting brackets (10), Inspect for:

clamps (24), canister (23) a. Damage,

and elbows (22). b. Looseness,

c. Stains from leaks.

d. Crossed threads.

Replace any damaged

components if necessary.

19. Filter to pump line (20)

and filter to sump line (24).

20. Two connectors (18) and 19).

21. Filter to pump line (20) and

filter to sump line (21).

a. Unscrew from two

connectors (18).

b. Inspect for:

1. Cracks.

2. Stains from leaks.

3. Kinks.

4. End fitting damage.

a. Unscrew from oiI pump

and oil sump.

b. Coat threads with liquid

teflon.

c. Screw into oil pump and

oil sump.

Screw onto connectors (18)

and (19).

Replace if threads are

damaged.

4-28
TM 9-2320-273-20

OIL SYSTEM

4-14. ENGINE OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

4-29
TM 9-2320-273-20

OIL SYSTEM

4-14. ENGINE OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

H. INSTALLATION OF BYPASS FILTER.

22. Two mounting brackets (10). a. Position over eight mounting

studs (9).

b. Secure with eight Iockwashers

(14) and nuts (15).

23. Two elbows (22). a. Coat threads with liquid teflon.

b. Screw into canister (23).

24. Canister (23). Secure to two mounting brackets

(10) with two clamps (24), eight

bolts (12). Iockwashers (13), and

nuts(11).

25. Filter to pump line (20) and Screw onto two elbows (22).

and filter to sump line (21).

26. Bypass filter element (8). Place into canister (23).

27. Pack hold down assembly a. Place thru center of bypass

(28). filter element (8) in canister

(23).

b. Screw all the way down to the

stop.

28. Cover (4) and new cover Set in place on canister flange (25).

gasket (5).

29. Clamping ring (6). a. Position over cover (4) and

canister flange (25).

b. Secure with two clamping bolts

(7); draw up bolts until they

stop against shoulder.

30. Vent plug (2) and washer (3). Install at cover (4) and tighten.

l. REPLENISHING OIL.

31. Filler cap (1). a. Remove.

b. Pour oil thru filler cap opening. See LO 9-2320-273-12.

c. Tighten filler cap. OEA IF SUB-ZERO.

J. CHECKING FOR LEAKS.

32. Engine. a. Start up. See TM 9-2320-273-10.

b. Run 3-5 minutes, shut

off and let set 8-10 minutes.

4-30
TM 9-2320-273-20

OIL SYSTEM

4-31
TM 9-2320-273-20

OIL SYSTEM

4-14. ENGINE OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

J. CHECKING FOR LEAKS (Continued).

33. Dipstick (32). Pull out and check oil level. If oil level is far above or

Should be near “H” mark. below mark, check to be

sure you have the correct

dipstick for the NTC 400

engine.

34. Primary filter (30), drain plug Check for leaks. Tighten as necessary.

(31), connectors (18) and (19),

two elbows (22), drain cock (16),

cover (4), filter to pump line

(20) and filter to sump line (21).

4-32
TM 9-2320-273-20

OIL SYSTEM

4-33
TM 9-2320-273-20

OIL SYSTEM

4-15. BREATHER TUBE MAINTENANCE.

HIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

 b. Cleaning. (15)

c. Inspection. ( 5)

 d. Installation. ( 5)

30 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

None.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-34
TM 9-2320-273-20

OIL SYSTEM

4-15. BREATHER TUBE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Two clamps (2), and line (1). Remove from breather cup (3).

2. Tube (6). Remove by loosening capscrews (5).

and pulling tube (6) out of loop

clamp (4).

4-35
TM 9-2320-273-20

OIL SYSTEM

4-15. BREATHER TUBE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. CLEANING

3. Tube (6). immerse and flush in solvent.

C. INSPECTION.

4. Tube (6). Check for: a. Cracks. If tube (6) is defective,

b. Nicks. replace.

c. Dents.

5. Line (1). Check for cracks. If line (1) is defective,

replace.

D. lNSTALLATION.

6. Line (1).

7. Clamps (2).

8. Tube (6).

9. Clamps (2).

Attach to breather tube cap (3).

Put on line (1).

Push into line (1) and loop clamp (4).

Tighten capscrew (5).

Put into place.

4-36
TM 9-2320-273-20

OIL SYSTEM

4-15. BREATHER TUBE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-37
TM 92320-273-20

FUEL AND AIR INTAKE

4-16. FUEL SOLENOID SHUTOFF VALVE MAINTENANCE.

THIS TASK COVERS: (Approximate TIME REQUIRED FOLLOWS TASK Description.)

a. Removal. (10)

b. Installation. (10)

c. Operational Check. ( 5)

25 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 11-14 A or C. Left Fender Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Shield (2910-00-084-7787).

O-Ring (5330-00-081-9299).

Gasket (5330-00-951-3538).

Masking Tape.

Marking Pencil.

PERSONNEL REQUIRED

TWO (MOS-63B20). (2nd mechanic turns

engine run switch in part C.).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Work in Well Ventilated Area.

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-38
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM

4-16. FUEL SOLENOID SHUTOFF VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Two nuts (11) and Unscrew and remove. Hold rear nut with wrench

washers (10). as front nut is being loosened.

2. Two wires (9). Remove from terminals (14). Mark wires for installation

reference, using masking

tape and marking pencil.

3. Four screws (12) and washers (13). Unscrew and remove.

4-39
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM

4-16. FUEL SOLENOID SHUTOFF VALVE MAINTENANCE (Continued).

LOCATlON/lTEM ACTION REMARKS

A. REMOVAL (Continued).

4. Coil assembly (8), shield (7),

O-ring (6), spring washer (5),

and valve (4).

5. Two screws (1), and

two washers (2 and 3).

6. Valve (16), and gasket (15).

 B. INSTALLATION.

7.

8.

9.

10.

11,

Gasket (15), valve (16),

two washers (2 and 3), and

two screws (1).

Coil assembly (8), shield (7),

O-ring (6), spring washer (5),

and valve (4).

Four mounting screws (12),

and washers (13).

Two wires (9).

Nuts (11), and washers (10).

 C. OPERATIONAL CHECK.

a. Remove.

b. Throw away shield (7),

and O-ring (6).

Unscrew and remove.

a. Remove valve.

b. Throw away gasket.

a. Hold gasket (15) and

valve (16), in place and

insert two screws (1)

and washers (2 and 3).

b. Tighten screws (1).

Hold in place. Insert four

screws (12), and washers (13).

Tighten.

Attach to terminals (14).

Install on terminals and tighten.

12. INSTRUMENT PANEL/

engine run switch.

13. Coil assembly (8).

14. Engine.

15. Coil assembly (8).

Turn ON, and OFF again. 2nd mechanic.

Listen for “click” when 1st mechanic.

run switch is turned ON

or OFF.

Start up (see TM 9-2320- Engine will not start unless

273-10). solenoid is working.

Check valve for leaks.

4-40
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM

4-16. FUEL SOLENOID SHUTOFF VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-41
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM

1-17. FUEL PUMP SCREEN MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Cleaning. (10)

c. Installation. (10)

d. Checking for Leaks. ( 5)

35 Minutes Total,

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 11-14 A or C. Left Fender Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Cap Seal Ring (5330-00-961-9470).

PERSONNEL REQUIRED

One (MOS-63B20).

SPECIAL ENVIRONMENTAL CONDITIONS

Work in Well Ventilated Area.

Vehicle Parked on Level Ground.

REFERENCES (TM)

GENERAL SAFETY INSTRUCTIONS

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

None.

Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-42
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

1-17. FUEL PUMP SCREEN MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Filter screen cap (1).

2. Cap seal ring (2), filter

spring (3), and fuel filter

screen assembly (4).

Unscrew and remove.

a. Take out.

b. Throw away cap seal ring (2).

B. CLEANING.

3. Fuel filter screen assembly (4). Clean.

4-43
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-17. FUEL PUMP SCREEN MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION.

4. Fuel filter screen assembly (4). Drop into place. Opening must be down.

5. Filter spring (3) and new cap Set into place.

seal ring (2).

6. Filter screen cap (1). Screw in.

D. CHECKING FOR LEAKS.

7. Engine. Start up (see TM 9-2320-273-10).

8. Filter screen cap (1). Look for leaking around edges.

NOTE

Follow-on maintenance required. Install

left fender; refer to para 11-14.

4-44
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-17. FUEL PUMP SCREEN MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-45
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-18. FUEL FILTER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Installation. (10)

c. Checking for leaks. ( 5)

20 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 11-14 A or C. Left Fender Removal.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIAL/PARTS (P/N)

Fuel Filter (2910-00-174-5822).

O-Ring, 213079 (15434).

Container (1qt).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM9-2320-273-20P.

TM9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

Work in Well Ventilated Area.

GENERAL SAFETY INSTRUCTIONS

Engine Off; Transmission in Neutral.

Park Brake Set.

4-46
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-18. FUEL FILTER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL .

1. Fuel filter (4). a. Open draincock (3) and Unscrew draincock for use in

drain fuel into suitable new replacement filter.

container.

b. Unscrew and remove.

2. O-ring (2). Remove and throw away.

B. INSTALLATION.

3. New fuel filter (4). a. Install draincock (3).

b. Fill with clean fuel.

Install new O-ring (2).

d. Screw in until seal just Do not tighten with wrench.

touches filter head (1).

e. Screw in one-half turn

to three-fourths turn

more.

4-47

c .
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-18. FUEL FILTER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. CHECKING FOR LEAKS.

4. Engine.

5. Fuel filter (4).

Start up (see TM 9-2320-273-10).

Check for leaks.

NOTE

Follow-on maintenance action required:

Install left fender; refer to para 11-14.

4-4 8
TM 9-2320-273-20

This page intentionally left blank ,

4-49
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-19. TACHOGRAPH RPM CABLE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 4)

b. Installation. ( 6)

c. Operational Check. ( 2)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Disconnect Batteries.

TEST EQUIPMENT 11-14 A or C. Left Fender Removed.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Tachometer RPM Cable, MA280J20000 (34623).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM9-2320-273-10.

TM9-2320-273-20P.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off; Transmission in Neutral.

Park Brake Set.

4-50
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-19. TACHOGRAPH RPM CABLE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Do not work behind dash panel until batteries

are disconnected.

1. Two quarter-turn screws Loosen. Lower panel. Closest cable to the

(1). lowered panel.

2. Tachograph RPM cable (3). a. Disconnect from RPM Tachograph RPM cable

port (2) of tachograph. may be tied to the heater

b. Remove capscrew and water control valve cable;

clamp (5). if so remove tie.

N

4-51
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-19. TACHOGRAPH RPM CABLE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

c. Unscrew from tachograph

drive (4) on fuel pump.

d. Pull through firewall and

remove.

B. lNSTALLATION.

3. Tachograph RPM cable (3). a. Screw into tachograph Avoid bending the cable

drive (4) on fuel pump. sharply. For proper operab. Thread free end through tion, cable should be as

firewall. straight as possible.

c. Install capscrew and

clamp (5).

d. Connect to “RPM” port

(2) of tachograph.

e. Replace cable tie.

4. Two quarter-turn screws (1). Close panel; tighten screws.

C. OPERATIONAL CHECK.

5. Engine.

6. Tachometer.

7. Engine.

Start up (see TM9-2320-273-

10).

Check for appropriate

reading (580-620 rpm if

engine is idling normally)

and responsiveness to

changes in engine speed.

Shut down (see TM 9-2320-273-10).

NOTE

Follow-on maintenance action required:

a. Connect batteries; refer to para 5-37B.

b. Install left fender; refer to para 11-14.

4-52
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-19. TACHOGRAPH RPM CABLE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-53 
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-20. LINES, HOSES AND FITTINGS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (see Appendix C).

Soap Solution.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM9-2320-273-10.

TM9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Work in Well Ventilated Area.

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off; Transmission in Neutral.

Park Brake Set.

4-54
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-20. LINES, HOSES, AND FITTINGS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

The illustration below identifies all

exterior lines and hoses of the fuel system. No special instructions or tools

are needed if you follow standard shop

practice techniques. During installation,

observe the following:

1.

2.

3.

4.

Line-to-block fittings. Coat pipes with liquid teflon

before insertion.

Line-to-line fittings. Screw together.

Air line. Check for leakage with soap

solution.

Hose-to-line fittings. Clamp securely.

After installation, start up engine (see

TM9-2320-273-10) and check for leaks.

4-55
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-21. ACCELERATOR PEDAL AND ROD MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Installation. (15)

c. Checking Idle Speed. ( 3)

33 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-22A. Hand Throttle Cable Disconnected

TEST EQUIPMENT at Throttle Mounting Bracket.

12-12A,

None.

Winch Throttle Cable Disconnected

at Throttle Mounting Bracket

SPECIAL TOOLS (M916 and M920)_.

None.

MATERIALS/PARTS (P/N)

Cotter pin (3), 103362 (24617).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle-Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 4-1.

4-66
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-57
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-21. ACCELERATOR PEDAL AND ROD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

2. Two bolts (5), Iockwashers Unscrew and remove bracket

and nuts (18). (6).

3. TWO bolts (8), Iockwashers Unscrew and remove pedal stop

(12), and nuts (13). bracket (11 ),

4. Bolt (9) and two nuts (10). Unscrew and remove from Count number of threads

pedal stop bracket (11 ). before disassembly.

5. Three screws (50). Unscrew and remove seal

retainer (48) and accelerator

seal (47).

6. Cotter pin (39). Remove and pull out clevis pin Discard cotter pin (39).

(38); lift out rod (49).

7. Locknut (16) and flat Unscrew and remove pivot

washer (17). lever (40), flanged bearing

(41 ), and flanged bearing (43).

8. Four bolts (44), flat washers Unscrew and remove bellcrank

(45) and nuts (46). bracket (42).

9. Spring (19). Unhook from lever (20) and

attachment point to cab at

other end of spring,

10. Nut (21 ) and washer (22). Unscrew and remove lever (20).

11. Nut (29) and washer (30). Unscrew from ball stud (27). Remove items (23 thru

(27) as an assembly.

Count number of threads

before disassembly to

maintain idle speed setting.

12. Ball stud (23) and (27) Unscrew from bellcrank rod

along with nuts (24) and (26). (25).

13. Spring (28). Unhook from bracket (3)

located at fuel pump lever

(32), and from throttle

mounting bracket (34).

4-58
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-59
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM

4-21. ACCELERATOR PEDAL AND ROD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

14. Locknut ( 15) and flatwasher

(14).

15. Two bolts (36) and Iockwashers

(35).

Unscrew and remove fork (37)

and nylon flanged bushing

(33).

Unscrew and remove throttle

mounting bracket (34).

B. INSTALLATION.

16. Throttle mounting bracket (34).

17. Nylon flanged bushing (33) and

fork (37).

18. Spring (28).

19. Nuts (24) and (26) along

with ball stud (23) and (27),

20. Ball stud (27).

21. Ball stud (23).

22. Bellcrank bracket (42).

23. Flanged bearing (41 ) and

(43).

24. Pivot lever (40).

Position against side of engine

and install with two bolts (36)

and Iockwashers (35).

Attach to throttle mounting

bracket (34) with flat washer

(14) and locknut (15).

Hook to bracket (31), located

at fuel pump lever (32), and

to throttle mounting bracket (34).

Screw onto bellcrank rod (25). Screw on the same number of threads you

counted in step A 11.

a. Insert threaded end thru

bracket (31 ).

b. Attach with washer (30) and

nut (29).

a. Insert threaded end thru

lever (20).

b. Attach with washer (22)

and nut (21 ).

Attach to cab with four bolts

(44), flat washers (45) and nuts

(46).

Position in either end of guide

tube in bellcrank bracket (42).

a. Insert threaded end thru

flanged bearing (41 ), bellcrank bracket (42), flanged

bearing (43) and lever (20).

b. Secure with flat washer (17)

and locknut (16).

4-60
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-21. ACCELERATOR PEDAL AND ROD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

25. Spring (19). Hook to lever (20) and cab

attachment point.

26. Rod (49). a. Insert up thru cab floor From underneath cab

opening until mounting floor.

hole alines with that in

pivot lever (40).

b. Insert clevis pin (38).

c. Secure with new cotter

LEGEND:

pin (39).

1. COTTER PIN 34. THROTTLE MOUNTING

2. PEDAL BRACKET

3. CLEVIS PIN 35. LOCKWASHER (2)

4. COTTER PIN 36. BOLT (2)

5. BOLT (2) 37. FORK

6. BRACKET 38. CLEVIS PIN

7. STRAlGHT PIN 39. COTTER PIN

8. BOLT (2) 40. PIVOT LEVER

9. BOLT 41. FLANGED

10. NUT (2) BEARING

11. PEDAL STOP 42. BELLCRANK

BRACKET BRACKET

12. LOCKWASHER (2) 43. FLANGED

13. NUT (2) BEARING

14. FLAT WASHER 44. BOLT (4)

15. LOCKNUT 45. FLAT WASHER (4)

16. LOCKNUT 46. NUT (4)

17. FLAT WASHER 47. ACCELERATOR

18. LOCKWASHER SEAL

AND NUT (2) 48. SEAL RETAINER

19. SPRING 49. ROD

20. LEVER 50. SCREW (3)

21. NUT

22. WASHER

23. BALL STUD

24. NUT

25. BELLCRANK

ROD

26. NUT

27. BALL STUD

28. SPRING

29. NUT

30. WASHER

31. BRACKET

32. FUEL PUMP

LEVER

33. NYLON FLANGED

BUSHING TA 075637

4-61
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-21. ACCELERATOR PEDAL AND ROD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

27. Accelerator seal (47) and

and seal retainer (48).

28. Bolt (9) and two nuts (10).

29. Pedal stop bracket (11).

30. Bracket (6).

31. Pedal (2).

C. CHECKING IDLE SPEED.

32. Engine.

33. Nut (29), washer (30)

and bracket (31).

34. Ball stud (27).

Slide over rod (49) and secure to

cab floor with three screws (50).

Install thru pedal stop bracket

(11).

Attach to cab floor with two

bolts (8), Iockwashers (12) and

nuts (13).

Install to cab floor with two

bolts (5), Iockwashers and

nuts (18).

a.

b.

a.

b.

c.

Install to bracket (6) with

straight pin (7) and new

cotter pin (4).

Install to rod (49) with clevis

pin (3) and new cotter pin (1).

Start up (see TM 9-2320-273-

20).

With engine warmed to normal

operating temperature, check to

see that tachometer reads 580-

620 rpm with your foot off

the accelerator pedal.

Shut down.

Unscrew from ball stud (27).

a. Loosen nut (26).

b. Turn counterclockwise to

increase idle speed or clockwise to decrease idle speed.

c. Lock in position with nut

(26).

d. Reconnect to bracket (31)

with washer (30) and nut

(29).

From inside cab.

Screw nuts (10) onto

bolt (9) the same number of threads you

counted in step A. 4.

If idle speed was below

580 rpm or above 620

rpm proceed to step 33.

4-62
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-21. ACCELERATOR PEDAL AND ROD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. CHECKING IDLE SPEED (Continued).

35. Engine. a. Start up (see TM 9-2320-273-

10).

b. Verify that idle speed is Readjust as necessary.

within the correct rpm range.

Follow on maintenance required:

a. Reconnect hand throttle cable

at throttle mounting bracket;

refer to para 4-22C.

b. Reconnect winch throttle

cable at throttle mounting

LEGEND: bracket; refer to para 12-12C.

(M916 and M920 only).

1. COTTER PIN 33. NYLON FLANGED 2. PEDAL BUSHING 3. CLEVIS PIN

4. COTTER PIN 34. THROTTLE MOUNTING

BRACKET 5. BOLT (2)

6. BRACKET 35. LOCKWASHER (2)

7. STRAIGHT PIN 36. BOLT (2)

37. FORK 8. BOLT (2) 38. CLEVIS PIN 9. BOLT

10. NUT (2) 39. COTTER PIN

11. PEDAL STOP 40. PIVOT LEVER

BRACKET 41. FLANGED

12. LOCKWASHER (2) BEARING

13. NUT (2) 42. BELLCRANK

14. BRACKET FLAT WASHER

15. LOCKNUT 43. FLANGED

16. LOCKNUT BEARING

17. FLAT WASHER 44. BOLT (4)

18. LOCKWASHER 45. FLAT WASHER (4)

AND NUT (2) 46. NUT (4)

19. SPRING 47. ACCELERATOR

20. LEVER SEAL

21. NUT 48. SEAL RETAINER

49. ROD 22. WASHER

23. BALL STUD 50. SCREW (3)

24. NUT

25. BELLCRANK

ROD

26. NUT

27. BALL STUD

28. SPRING

29. NUT

30. WASHER

31. BRACKET

32. FUEL PUMP

LEVER

4-63
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-22. HAND THROTTLE LINKAGE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a.. Removal. (20)

b. Cleaning and lnspection.( 5)

c. Installation. (30)

d. Checking Idle Speed. ( 2)

57 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off; Transmission in Neutral.

Park Brake Set.

4-64
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-22. HAND THROTTLE LINKAGE MAINTENANCE (Continued).

I

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1.

2.

3.

4.

Setscrew (6).

Two locknuts (8) and washers (9).

Hand throttle cable (3).

Two screws (12).

Unscrew and remove from

pivot lever (5).

Unscrew and remove.

Pull through bracket (4).

a. Remove from heater Screws are located on

control panel (13). each end.

b. Remove back of heater

control panel (13).

LEGEND:

1. THROTTLE KNOB

2. LOCKNUT

3. HAND THROTTLE

CABLE

4. BRACKET

5. PIVOT LEVER

6. SET SCREW

7. CABLE WIRE

8. LOCKNUT (2)

9. WASHER (2)

10. STAR WASHER

11. LOCKNUT

12. SCREW (2)

13. HEATER CONTROL

PANEL

TA 074625

4-65
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-22. HAND THROTTLE LINKAGE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

5. Locknut (11) and starwasher

(10).

6. Hand throttle cable (3).

7. Locknut (2).

B. CLEANING AND INSPECTION.

8. Hand throttle cable (3).

C. INSTALLATION.

9.

10.

11.

12.

13.

14.

15.

16.

Locknut (2).

Hand throttle cable (3).

Locknut (11) and starwasher

( 1 0

Hand throttle cable (3).

Heater control panel (13).

Two locknuts (8) and

washers (9).

Setscrew (6).

Throttle knob (1).

Unscrew and remove from

hand throttle cable (3).

PuII from firewalI and heater

control panel (13).

Unscrew and remove from

hand throttle cable (3).

Wipe clean and inspect for:

a.Kinked cable.

b. Cable end crossed or

burred threads.

Screw onto hand throttle

cable (3).

Install thru front of heater

control panel (13).

Screw onto hand throttle

cable (3).

Insert end thru firewall

and bracket.

a.

b.

a.

b.

Install back of panel.

Install two screws (12)

and tighten.

Install and tighten.

It may be necessary to

either loosen or tighten

the locknut (8) on the

outer bracket face.

Install and tighten to lock

cable wire (7).

Remove and lubricate hand

throttle cable (3) per LO 9-

2320-273-12.

Replace as necessary.

4-66
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-22. HAND THROTTLE LINKAGE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

D. CHECKING IDLE SPEED.

17. Engine. a. Start up (see TM 9-2320-

273-10).

b. With engine warmed up

check that:

(1) Engine idles at 580.

620 rpm when throttle

knob (1) is pushed

completely in.

(2) Idle speed increases as

soon as you begin to

pull out on throttle

knob (1). (Turning knob

counterclockwise will

also increase rpm.)

LEGEND:

1. THROTTLE KNOB

2. LOCKNUT

3. HAND THROTTLE

CABLE

4. BRACKET

5. PIVOT LEVER

6. SET SCREW

7. CABLE WIRE

8. LOCKNUT (2)

9. WASHER (2)

10. STAR WASHER

11. LOCKNUT

12. SCREW (2)

13. HEATER CONTROL

PANEL

TA 074626

4-67
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-23. FUEL TANK MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (35)

b. Installation. (40)

c. Checking for Leaks. ( 5)

80 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

SD-2 Dry Cleaning Solvent (Refer to Appendix C).

Containers for Fuel (AR).

Masking Tape.

Marking Pencil.

PERSONNEL REQUIRED

Three (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Work in Well Ventilated Area.

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off; Transmission in Neutral.

Park Brake Set.

4-68
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-23. FUEL TANK MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Be sure that tank is supported so that it

will not fall when straps (26) are removed.

A. REMOVAL.

NOTE

Place container under drain plug (28) to

catch fuel.

TA 074627

4-69
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-23. FUEL TANK MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

1. Drain Plug (28). a. Remove and allow fuel to

drain into container.

b. Screw back into tank.

2. Two fuel lines (33). Unscrew from two elbows (24). Mark locations for reassembly.

3. Two elbows (24). Unscrew and remove from fuel

tank (27).

4. Phillips head screw (19), slot- Unscrew and remove two ter- Mark wire locations for

ted head screw (20) and four minals (17). reassembly.

washers (18).

5. Six nuts (3) and Iockwashers Unscrew and remove three

(4). straps (26).

6. Fuel tank (27). Lower from vehicle to ground.

7. Two bolts (10), washers (7), Unscrew and remove two hose Slide hose clamps (9) off

and nuts (8). clamps (9) from two brackets two fuel lines (33).

(11).

8. Two bolts (12), washers (13), Unscrew and remove two

washers (5), and nuts (6). brackets (11).

9. Twelve bolts (2) and nuts (1). Unscrew and remove three

J-brackets (32).

10. Air vent (31). Unscrew from fuel tank (27). Run wire thru vent hole

to ensure free air flow.

11. Three insulators (29). Remove from three straps (26). Replace if rubber is cracked or deteriorated.

12. Fuel cap (15). Unscrew and pull out to point

where fuel cap retainer (23)

catches on fuel fiIter screen

inside tank.

13. Fuel cap gasket (21) and Inspect for damage. Replace as necessary by

fuel cap chain (22). unhooking chain from inside of fuel cap (15) and

replacing, use needle

nose pliers to open chain

link.

14. Fuel sender flange (16) with Remove; refer to para 5-79A.

fuel sender attached.

4-70
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-23. FUEL TANK MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-71
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-23. FUEL TANK MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

15. Fuel sender flange (16) with Install; refer to para 5-79B.

fuel sender attached.

16. Fuel cap {15) with fuel cap Position on fuel fill neck (25)

gasket (21), fuel cap chain (22), and screw fuel cap (15) on.

and fuel cap retainer (23).

17. Three insulators (29). Install on three straps (26).

18. Air vent (31). Screw into fuel tank (27).

19. Three J-brackets (32). Aline mounting holes to frame

and install with twelve bolts

(2) and nuts (1).

20. Two brackets (11). Install to two J-brackets (32) Install to the two forward

with two bolts (12), washers most J-brackets.

(13), washers (5), and nuts

(6).

21. Two hose clamps (9). a. Slide over two fuel lines (33).

b. Secure to two brackets (11)

with two bolts (10), washers

(7) and nuts (8).

22. Fuel tank (27). Raise into position against three

J-brackets (26).

23. Three strap (26) with three a. Insert three lower T-bolts

insulators (29). (30) thru bottom of three

J-brackets (32) and secure

with three Iockwashers (4)

and nuts (3).

b. Insert three upper T-bolts

(14) thru top center hole of

three J-brackets (32) and

secure with three lockwashers (4) and nuts (3).

24. Two terminals (17). Position on fuel sender flange Install as you marked at

(16) and install with phillips disassembly.

head screw (19), slotted head

screw (20) and four washers

(18).

25. Two elbows (24). a. Apply liquid teflon to

threads.

b. Screw into fuel tank (27).

4-72
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-23. FUEL TANK MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

TA 075639

4-73
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-23. FUEL TANK MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

26. Two fuel lines (33). Screw onto two elbows (24). Install as you marked at

disassembly.

C. CHECKING FOR LEAKS.

27. Fuel fill neck (25). Remove fuel cap (15) from Be sure drain plug (28)

fuel fill neck (25). Fill tank is tightened.

with fuel (see TM 9-2320-

273-10).

28. Fuel cap (15). Put on and tighten to fuel

fill neck (25).

29. Engine. Start up (see TM 9-2320-

273-10).

30. Fuel tank (27), two fuel Check for leaks. Retighten as necessary.

lines (33), and two elbows

(24).

31. Engine. Shut down (see TM 9-2320-

273-10).

NOTE

For other fuel line locations refer to para 4-20.

4-74
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-23. FUEL TANK MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

TA 075640

4-75
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-24. AIR CLEANER ELEMENT MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.

a. Removal. (10)

b. Cleaning. (15)

c. Installation. (15)

40 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

MATERIALS/PARTS (P/N)

Inner Filter Element (If Outside Filter Has

Been Cleaned Five Times.) (250C127).

Outer Filter Element (250C128).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-20P.

SPECIAL ENVIRONMENTAL CONDITIONS

Darkened Area for Element Check.

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off; Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 4-1.

4-76

None.
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-24. AIR CLEANER ELEMENT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Handle (1) and retainer bar (2). Unscrew handle, slide bar out

of slots and remove.

2. Outer filter element (3). Grasp bands on face and pull

out of canister (7).

Do not clean inner element. Do not remove

unless to replace with a new element. This

should be done after the outside filter has

been cleaned five times.

3. Inner filter element (6). Remove if necessary, by un- Rubber seal at opposite end

screwing wing nut (4) and may stick making removal

removing rubber backed difficult. Grasp end and work

washer (5). back and forth to free.

LEGEND:

1. HANDLE

2. RETAINER BAR

3. OUTER FILTER

ELEMENT

4. WING NUT

5. RUBBER BACKED

WASHER

6. INNER FILTER

ELEMENT

7. CANISTER

8. BOOT

TA 074629

4-77
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-24. AIR CLEANER ELEMENT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Compressed air used for cleaning purposes will not

exceed 30 psi. Use only with effective chip guarding and personal protective equipment (goggles/

shield, gloves, etc.).

4. Outer filter element (3). a. Tap element to shake dust

loose.

b. Insert compressor air nozzle Pressure should not exceed

into element to blow out 30 psi.

dust.

c. Wash in water with mild Skip this step if filter seems

non-sudsing detergent. clean and after steps a and b.

Rinse gently with clean

water and allow to air dry.

(Replace after five

washings.)

d. Shine light inside element. If element is damaged,

Watch outside for light replace.

shining through leaks.

5. Canister (7). a. Squeeze boot (8) together

to release trapped dust.

b. Wipe inside of canister (7)

clean.

C. INSTALLATION.

6. Inner filter element (6). If removed, install new element

by positioning rubber backed

washer (5) over stud and screw

on wing nut (4).

7. Outer filter element (3). Place in canister (7).

8. Retainer bar (2), and handle Slide through slots and

(1). tighten.

4-78

B. CLEANING.
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-24. AIR CLEANER ELEMENT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

1.

2.

3.

4.

5.

6.

7.

8.

HANDLE

RETAINER BAR

OUTER FILTER

ELEMENT

WING NUT

RUBBER BACKED

WASHER

INNER FILTER

ELEMENT

CANISTER

BOOT

TA 074630

4-79
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM

4-25. AIR CLEANER ASSEMBLY MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal of Filter Assembly. (5)

b. Removal of Brackets and Fittings. (5)

c. Installation of Brackets and Fittings. (5)

d. Installation of Filter Assembly. (5)

20 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

TWO (MOS-63820).

REFERENCES (TM)

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off; Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 4-1.

4-80
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-25. AIR CLEANER ASSEMBLY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL OF FILTER ASSEMBLY.

1. Turbo air inlet pipe (7). Loosen clamp (6). at filter discharge and remove inlet pipe.

2. Restriction indicator tube (3). Disconnect flare nut (4) from

elbow (5).

3. Air intake pipe (15). Loosen clamps (17) and slide

boot (16) off air intake pipe (15).

4. Four nuts (11) and four Remove from three studs (8)

Iockwashers (10). and bolt (9).

5. Filter assembly (1). Remove.

B. REMOVAL OF BRACKETS AND FITTINGS (REPLACEMENT OF UNIT ONLY).

6. Two capscrews (12) and two Remove.

nuts and Iockwashers (13).

7. Two brackets (14). Spread and remove.

8. Nipple filter (2). Remove with elbow (5) attached.

LEGEND:

1. FILTER ASSEMBLY

2. NIPPLE FILTER

3. RESTRICTION

INDICATOR TUBE

4. FLARE NUT

ELBOW

5.CLAMP (2)

7. TURBO AIR INLET

PIPE

8. STUD (3)

9. BOLT

10. LOCKWASHER (4)

11. NUT (4)

12. CAPSCREW (2)

13. NUT AND

LOCKWASHER (2)

14. BRACKET (2)

15. AIR INTAKE PIPE

16. BOOT

17. CLAMP (2)

TA 074631

4-81
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-25. AIR CLEANER ASSEMBLY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION OF BRACKETS AND FITTINGS (IF REMOVED).

9.

10.

11.

Nipple filter (2). Install with elbow (5) attached.

Two brackets (14). Spread and position on air

filter assembly (1).

Two capscrews (12) and two Install finger tight.

nuts and Iockwashers (13).

D. INSTALLATION OF FILTER ASSEMBLY.

12.

13.

14.

15.

Filter assembly (1). Place on three studs (8), and

bolt (9), install four lockwashers (10) and nuts (11).

Air intake pipe (15). Slide boot (16) over air intake

pipe (15) position and tighten

two clamps (17).

Restriction indicator Connect flare nut (4) to elbow

tube (3). (5) and tighten.

Turbo air inlet pipe (7). Install over filter discharge.

Position and tighten clamps (6).

If brackets are removed it

may be necessary to reposition them to fit over studs.

Tighten nuts at this time.

4-82
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-25. AIR CLEANER ASSEMBLYIWAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

1. FILTER ASSEMBLY

2. NIPPLE FILTER

3. RESTRICTION

INDICATOR TUBE

4. FLARE NUT

5. ELBOW

6. CLAMP (2)

7. TURBO AIR INLET

PIPE

8. STUD (3)

9.

10.

11.

12.

13.

14.

15.

16.

17.

BOLT

LOCKWASHER (4)

NUT (4)

CAPSCREW (2)

NUT AND

LOCKWASHER (2)

BRACKET (2)

AIR INTAKE PIPE

BOOT

CLAMP (2)

TA 074632

4-83
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-26. AIR CLEANER RESTRICTION INDICATOR MAINTENANCE.

THlS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal of Indicator. (2)

b. Installation of Indicator. (2)

c. Removal of Tube and Filter. (5)

d. Installation of Tube and Filter. (6)

15 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

None.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off; Transmission in Neutral

Park Brake Set.

4-84
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM

4-26. AIR CLEANER RESTRICTION INDICATOR MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

A. INDICATOR REMOVAL.

1. Flare nut (4). Reach behind bracket and unscrew nut from compression

adapter (3). Disconnect tube (5).

2. Two screws (1) and Unscrew and remove.

starwashers (11).

3. Restriction indicator (2). Remove. If replacing indicator remove

compression adapter (3).

TA 074633

4-85
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

Position on bracket.

Screw in and tighten.

4-26. AIR CLEANER RESTRICTION INDICATOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INDICATOR INSTALLATION.

4. Restriction indicator (2).

5. Two screws (1) and If new indicator is being

starwashers (11). installed screw in and tighten

compression adapter (3),

into restriction indicator (2).

NOTE

If you plan to remove tube (5) and nipple

filter (10), go directly to step 7, if not do

step 6.

6. Flare nut (4). Screw onto compression

adapter (3) and tighten.

C. TUBE AND FILTER REMOVAL.

7. Flare nut (7). Unscrew. Disconnect tube

(5).

8. Nipple filter (10). Unscrew and remove from air

cleaner with elbow (9) and

fitting (8).

9. Tube (5) and grommet (6). Remove from firewall.

4-86
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-26. AIR CLEANER RESTRICTION INDICATOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

D. TUBE AND FILTER INSTALLATION.

10. Nipple filter (10), elbow Screw onto air cleaner.

(9) and fitting (8).

11. Flare nut (7). Screw onto connector (8).

12. Tube (5) and grommet (6). Install grommet. Insert tube

through firewall.

13. Flare nut (4). Screw onto adapter (3). Reach behind bracket.

TA 074634

4-87
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM

4-27. TURBO AIR INLET MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (4)

b. Inspection. (5)

c. Installation. (6)

d. Checking for Leaks. (2)

17 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Work Area Must be Clean as Dirt in the Air Passages

Can Damage the Turbocharger and Engine.

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-88
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

Loosen.

Loosen and remove.

Remove.

LOCATION/lTEM ACTION REMARKS

Dirt in the air passages can severely damage

the turbocharger and engine. Be sure your

work area is clean. Clean parts before

installation. Cover openings to keep out dust

while you are working.

A. REMOVAL.

1. Six clamps (6).

2. Clamp (4), hose (3).

3. Three elbow pipes (2), (7),

and (9); three straight pipes

(5), (8) and (9), and two

boots (10) and (13).

B. INSPECTION.

4. Three elbow pipes (2), (7), Inspect for Replace, if necessary.

and (9); three straight pipes

(5), (8) and (9), and two

a. cracks

b. leaks

boots (10) and (13). c. blockage

LEGEND:

1. AIR CLEANER

2. ELBOW PIPE

3. HOSE

4. CLAMP

5. STRAIGHT PIPE

6. CLAMP (6)

7. ELBOW PIPE

8. STRAIGHT PIPE

9. STRAIGHT PIPE

10. BOOT

11. ELBOW PIPE

12. TURBOCHARGER

13. BOOT

TA 074635

4-89

4-27 TURBO AIR INLET MAINTENANCE (Continued).
TM 9-2320-273-20

FUEL AND AIR INTAKE SYSTEM.

4-27. TURBO AIR INLET MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION.

5. Two straight pipes Insert into elbow pipes

(5) and (8). (2), (7) and (11).

6. Straight pipe (9). Insert into two boots (10)

and (13).

7. Two elbow pipes (2) and (11). Attach to turbocharger (12)

and air cleaner (1).

8. Six clamps (6). Tighten to 32-36 lb-in

(3.6-4.1 N•m).

D. CHECKING FOR LEAKS.

9. Engine. Start up (see TM 9-2320-273-10).

During normal operation, the turbocharger

and outlet pipe can become very hot. Be

careful not to touch these components with

your bare hands. These components may

be hot enough to cause severe burns.

LEGEND:

1. AIR CLEANER

2. ELBOW PIPE

3. HOSE

4. CLAMP

5. STRAIGHT PIPE

6. CLAMP (6)

7. ELBOW PIPE

8. STRAIGHT PIPE

9. STRAIGHT PIPE

10. BOOT

11. ELBOW PIPE

12. TURBOCHARGER

13. BOOT

TA 074636

4-90
TM 9-2320-273-20

This page intentionally left blank.

4-91
TM 9-2320-273-20

ENGINE RETARDER BRAKE

4-28. ROCKER ARM HOUSING COVERS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

Removal of Crossover Tube. (5)

Removal of Cover. ( 5)

Cleaning. (20)

Installation of Cover. ( 5)

Installation of Crossover Tube( 5)

40 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-15A. Breather Tube Removed

TEST EQUIPMENT 4-27A. (For Center Cover Only).

Turbo Air Inlet Removed.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Dry Cleaning Solvent (Refer to Appendix C).

Gasket for Crossover Tube

(Center Cover Only.) (216487).

Gasket for Rocker Arm Housing

(3009999).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 5-4.

SPECIAL ENVIRONMENTAL CONDITIONS

Work Area Must be Clean as Dirt in the Turbocharger

and Engine Can Cause Damage.

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-92
TM 9-2320-273-20

ENGINE RETARDER BRAKE.

4-28. ROCKER ARM HOUSING COVERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Do not allow SD-2 dry cleaning solvents to

come in contact with seals on flexible

hoses. These cleaners may damage leather,

rubber, and synthetic materials.

A. REMOVAL OF CROSSOVER TUBE (FOR CENTER COVER, ONLY).

1. Ether atomizer line (1). Unscrew and remove.

2. Four capscrews (2), washers Unscrew and remove. At this time tachograph

(3), and gasket (4). Throw away gasket (4). cable and hose are free

enough to move out of

way.

4-93
TM 9-2320-273-20

ENGINE RETARDER BRAKE.

If rubber connector

is damaged, replace.

4-28. ROCKER ARM HOUSING COVERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL OF CROSSOVER TUBE (Continued).

3. Upper clamp (5). Loosen.

4. Crossover tube (6). Remove.

B. REMOVAL OF COVER.

5. Five capscrews (7), Unscrew and remove.

and washers (8).

6. Rocker arm housing cover (9). Lift off.

7. Gasket (10). Take off and throw away.

C. CLEANING.

8. Rocker arm housing cover (9). Clean with dry cleaning solvent.

9. Engine retarder housing (11). Wipe grease from rim where

gasket (10) rests.

D. INSTALLATION OF COVER.

10. New gasket (10). Set in place on engine retarder

housing (11).

11. Rocker arm housing cover (9). Set onto gasket (10).

12. Capscrews (7) and washers (8). Tighten to 15 Ib-ft (20 N•m)

with torque wrench.

E. INSTALLATION OF CROSSOVER TUBE (CENTER COVER ONLY).

13. Crossover tube (6) and new Hold in place and attach Clamp down tachograph

crossover tube gasket (4). with capscrews (2) and cable and hose at this

washers (3). time.

14. Upper clamp (5). Tighten.

15. Crossover tube capscrews (2). Tighten.

16. Ether atomizer line (1). Connect and tighten.

4-94
TM 9-2320-273-20

ENGINE RETARDER BRAKE.

LOCATION/lTEM ACTION REMARKS

NOTE

Follow-on maintenance action required

if center cover was removed:

a. Install breather tube; refer to para 4-15D.

b. Install turbo air inlet; refer to para 4-27C.

TA 074638

4-95

4-28. ROCKER ARM HOUSING COVERS MAINTENANCE (Continued).
TM 9-2320-273-20

ENGINE RETARDER BRAKE

4-29. ENGINE RETARDER BRAKE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

Inspection, (20)

20 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-28A. Remove Crossover Tube.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 5-4.

4-28B. Rocker Arm Housing

Covers.

SPECIAL ENVIRONMENTAL CONDITIONS

Work Area Must be Clean as Dirt in the Turbocharger

and Engine can Cause Damage.

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-96
TM 9-2320-273-20

ENGINE RETARDER BRAKE

4-29. ENGINE RETARDER BRAKE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

During normal operation the turbocharger

and outlet pipe can become very hot. Be

careful not to touch these components

with your bare hands. These components

may be hot enough to cause serious burns.

You will be operating the engine with

cover removed. Be absolutely certain that

work area is clean and dust-free. Do not

allow dirt, tools, or engine parts to fall

into engine.

LEGEND:

1. ENGINE

2. ENGINE

3. ENGINE

RETARDER ARMATURES

RETARDER PEDAL

RETARDER SWITCH

TA 074639

4-97
TM 9-2320-273-20

ENGINE RETARDER BRAKE.

4-29. ENGINE RETARDER BRAKE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

INSPECTION.

1. Engine. Start up (see TM 9-2320-273-

10) (1st mechanic).

2. Six engine retarder armatures Bleed brakes by pressing each

(1). engine retarder armature five

or six times in a row. (2nd

mechanic).

3. Cab/Engine Retarder a. Keep engine retarder pedal

Switch (3). (2) pressed down to actuate engine retarder switch

(3).

b. Start with dash selector Refer to TM 9-2320-273-10.

switch at LOW.

c. Move to MED.

d. Move to HIGH. (1st

mechanic).

4. Engine retarder armatures (1). Observe that: If brake does not work

a. When dash selector switch properly, refer problem to

is at LOW center arma- Direct Support Maintenance.

ture remains down.

b. When dash selector switch

is moved to MED, center

armature comes up, armature on ends go down.

c. When dash selector switch

is on HIGH, all armatures

go down.

NOTE

Follow-on maintenance action required:

a. Install rocker arm housing covers, and

crossover tube, para 4-28D and E.

4-98
TM 9-2320-273-20

ENGINE RETARDER BRAKE.

4-29. ENGINE RETARDER BRAKE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

1. ENGINE RETARDER ARMATURES

2. ENGINE RETARDER PEDAL

3. ENGINE RETARDER SWITCH

4-99

TA 074640
TM 9-2320-273-20

ETHER QUICK-START SYSTEM

4-30. ETHER CYLINDER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Installation.

c. Check Operation. ( 5)

20 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Ether Cylinder (2910-01-072-1783).

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

Two (MOS-63B20).

(2nd Mechanic Operates

1. Coolant Temperature Must be Below 50°F or Ether

Cab Control in Part C). Solenoid Valve Will Not Function.

REFERENCES (TM) 2. Work in a Well Ventilated Area Away From Sparks or

TM 9-2320-273-20P. Flame.

3. Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Ether is Highly Explosive.

TROUBLESHOOTING REFERENCES Be Alert for the Strong Odor of Spilled Ether.

Guard Against Flame or Sparks in Work Area.

Table 5-3. Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-100

(10)
TM 9-2320-273-20

ETHER QUICK-START SYSTEM.

4-30. ETHER CYLINDER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Ether is highly explosive. Dispose of cylinder

properly. Be alert for the strong odor of

spilled ether. Guard against flame or sparks

in work area.

A. REMOVAL.

1. Clamp (4). Loosen.

2. Ether cylinder (1). Unscrew from fitting (5) It may be necessary to

and lift out. hold fitting (5) with

open-end wrench.

NOTE

Check neck of cylinder for dirt or

lint prior to installation.

B. INSTALLATION.

3. Ether cylinder (1). Screw into fitting (5).

4. Clamp (4). Tighten.

TA 074641

LEGEND:

1. ETHER CYLINDER

2. CROSSOVER TUBE

3. ATOMIZER LINE

4. CLAMP

5. FITTING

4-101
TM 9-2320-273-20

ETHER QUICK-START SYSTEM.

4-30. ETHER CYLINDER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. OPERATIONAL CHECK.

5.

6.

7.

8.

9.

10.

Atomizer Line (3).

INSTRUMENT PANEL/

Engine run switch.

INSTRUMENT PANEL/

Ether button

Atomizer Line (3)

INSTRUMENT PANEL/

Engine run switch.

Atomizer Line (3).

NOTE

Coolant temperature must be below 50°F

or solenoid valve will not function.

Unscrew from crossover

tube (2).

Turn On.

Push and release.

Observe ether mist.

After check, turn OFF.

Screw into crossover

tube (2).

Refer TM 9-2320-273-10

2nd Mechanic.

If mist is not observed,

check ether temperature

switch (para 5-74), solenoid

valve (para 4-31), ether tube

(para 4-33), and atomizer

(para 4-32).

2nd Mechanic.

4-102
TM 9-2320-273-20

ETHER QUICK-START SYSTEM.

4-30. ETHER CYLINDER MAINTENANCE (Continued).

ACTION REMARKS

LEGEND:

1. ETHER CYLINDER

2. CROSSOVER TUBE

3. ATOMIZER LINE

4. CLAMP

5. FITTING

4-103

LOCATION/ITE M

TA 074642
TM 9-2320-273-20

ETHER QUICK START SYSTEM

4-31. SOLENOID VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Installation. (25)

45 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-30A. Ether Cylinder Removed.

9-11A.

TEST EQUIPMENT

Remove Alcohol Evaporator.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS {P/N)

Solenoid Valve, 913032-04 (06991).

PERSONNEL REQUIRED

TWO (MOS-63B20).

(2nd Mechanic Operates

Cab Control in Part C of Para 4-30.)

REFERENCES (TM)

TM 9-2320-273-20P

TROUBLESHOOTING REFERENCES

Table 5-3.

SPECIAL ENVIRONMENTAL CONDITIONS

Coolant Temperature Must be Below 50°F or Ether

Solenoid Valve Will Not Function.

Work in a Well Ventilated Area Away From Sparks or Flame.

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Ether is Highly Explosive.

Be Alert for the Strong Odor of Spilled Ether.

Guard Against Flame or Sparks in Work Area.

Engine OFF; Transmission in Neutral.

Park Brake Set.

4-104
TM 9-2320-273-20

ETHER QUICK-START SYSTEM

4-31. SOLENOID VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Ether is highly explosive. Be alert for

the strong odor of spilled ether. Guard

against flames or sparks in work area.

A. REMOVAL.

1. Two wires (10). Unplug from quick-disconnect (9).

2. Ether tube (7). Unscrew from solenoid valve (8).

4-105
TM 9-2320-273-20

ETHER QUICK-START SYSTEM.

4-31. SOLENOID VALVE MAINTENANCE {Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Two bolts (6), washers (5), Unscrew and remove.

and spacers (3).

4. Bolt (11) and nut (2). Unscrew and remove bracket (4)

with solenoid valve (8) attached

from mounting bracket (1).

B. INSTALLATION.

5. Bracket (4) with solenoid Mount to engine with two bolts

valve (8) attached. (6), washers (5), and spacers

(3).

6. Bolt (11) and nut (2). Mount thru bracket (4) and

mounting bracket (1) and tighten.

7. Ether tube (7). Screw onto solenoid valve (8).

8. Quick disconnect (9). Plug in two wires (10).

NOTE

Follow-on maintenance required:

Install ether cylinder and check operation;

see para 4-30 B and C.

4-106
TM 9-2320-273-20

ETHER QUICK-START SYSTEM.

4-31. SOLENOID VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

MOUNTING BRACKET

NUT

SPACER (2)

BRACKET

WASHER (2)

BOLT (2)

ETHER TUBE

SOLENOID VALVE

QUICK DISCONNECT

WIRE (2)

BOLT

TA 074644

4-107
TM 9-2320-273-20

ETHER QUICK-START SYSTEM

4-32. ATOMIZER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (2)

b. Installation and Operational Check. (3)

5 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Atomizer, 91302406 (06991)

PERSONNEL REQUIRED

Two (MOS-63B20).

(2nd Mechanic Operates Cab

Controls in Part B.)

REFERENCES (TM)

None.

TROUBLESHOOTING REFERENCES

Table 5-3.

SPECIAL ENVIRONMENTAL CONDITIONS

Coolant Temperature Must Be Below 50°F or Ether

Solenoid Valve Will Not Function.

Work in a Well Ventilated Area Away from Sparks or Flame.

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Ether is Highly Explosive.

Be Alert for the Strong Odor of Spilled Ether.

Guard Against Flame or Sparks in Work Area.

Engine OFF: Transmission in Neutral.

Park Brake Set.

4-108
TM 9-2320-273-20

ETHER QUICK-START SYSTEM.

4-32. ATOMIZER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Atomizer (2). a. Unscrew ether tube (3)

and remove.

b. Unscrew from crossover

tube (1).

LEGEND:

1. CROSSOVER TUBE

2. ATOMIZER

3. ETHER TUBE

TA 074645

4-109
TM 9-2320-273-20

ETHER QUICK-START SYSTEM.

4-32. ATOMIZER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Coolant temperature must be below 50°F

or solenoid valve will not function.

 B. INSTALLATION AND OPERATIONAL CHECK.

2. Ether tube (3).

lNSTRUMENT PANEL/

3. Ether button.

4. Atomizer (2).

INSTRUMENT PANEL/

5. Engine run switch.

6. Atomizer (2).

7. Ether tube (3).

Screw on atomizer (2).

Push (2nd mechanic). Engine run switch must be ON

Observe ether mist from If mist is not observed, check

atomizer (2) (2nd mechanic). ether temperature switch

(para 5-74), ether cylinder

(para 4-30), solenoid valve

(para 4-31), and ether tube

(para 4-33).

Engine run switch OFF

(2nd mechanic).

a. Remove from ether tube

(3).

b. Screw into crossover tube

(1).

Screw into atomizer (2).

4-110
TM 9-2320-273-20

ETHER QUICK-START SYSTEM.

4-32. ATOMIZER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

1. CROSSOVER TUBE

2. ATOMIZER

3. ETHER TUBE

TA 074646

4-111
TM 9-2320-273-20

ETHER QUICK-START MAINTENANCE.

4-33. ETHER TUBE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Inspection. ( 5)

c. Installation. (10)

d. Operational Check. ( 5)

30 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All.

TEST EQUIPMENT

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

None. None.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

Two (MOS-63B20). Coolant Temperature Must be Below 50°F

(2nd Mechanic Operates Cab or Ether Solenoid Valve Will Not Function.

Controls in Part D.) Work in a Well Ventilated Area Away From Sparks or Flame.

REFERENCES (TM) Vehicle Parked on Level Ground.

None. GENERAL SAFETY INSTRUCTIONS

Ether is Highly Explosive. Be Alert for the Strong Odor of

Spilled Ether. Guard Against Flame or Sparks in Work Area.

Engine OFF.

Transmission in Neutral.

TROUBLESHOOTING REFERENCES Park Brake Set.

Table 5-3.

4-112
TM 9-2320-273-20

ETHER QUICK-START SYSTEM.

4-33. ETHER TUBE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Ether tube (3).

2. Atomizer (2).

a. Unscrew from atomizer (2).

b. Unscrew from solenoid valve

(4).

Unscrew from crossover tube (1).

LEGEND:

1. CROSSOVER TUBE

2. ATOMIZER

3. ETHER TUBE

4. SOLENOID VALVE

TA 074647

4-113
TM 9-2320-273-20

ETHER QUICK-START SYSTEM.

4-33. ETHER TUBE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSPECTION.

3. Ether tube (3), solenoid Look for:

valve (4), atomizer (2). a. Cracks.

b. Leaks.

c. Kinks.

d. Damaged fittings.

C. INSTALLATION.

4. Ether tube (3). a. Screw onto solenoid valve

(4).

b. Screw onto atomizer (2).

NOTE

Coolant temperature must be below 50°F

or solenoid valve will not function.

D. OPERATIONAL CHECK.

5. INSTRUMENT PANEL/ Engine run switch must be ON.

Ether button.

6. Atomizer (2). If mist is not observed, check

ether temperature switch

(para 5-74) ether cylinder

(para 4-30), so!enoid valve

(para 4-31), and atomizer

(para 4-32).

7. lNSTRUMENT/PANEL.

Engine run switch.

8. Atomizer (2).

9. Ether tube (3).

Push (2nd mechanic).

Observe ether mist

(1st mechanic).

Turn OFF (2nd mechanic).

a. Unscrew from ether

tube (3).

b. Screw into crossover

tube (1).

Screw onto atomizer (2).

Replace, if necessary.

4-114
TM 9-2320-273-20

ETHER QUICK-START SYSTEM.

4-33. ETHER TUBE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

1. CROSSOVER TUBE

2. ATOMIZER

3. ETHER TUBE

4. SOLENOID VALVE

TA 074648

4-115
TM 9-2320-273-20

EXHAUST SYSTEM.

4-34. TURBO OUTLET PIPE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a Removal. ( 5)

b. Inspection of Mating Flanges. ( 5)

c. Installation. (10)

d. Checking for Leaks. ( 5)

25 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Coupling, 5-0-1259LJ(76700).

Coupling (3), 5-0-1236BJ (76700).

Locknut (M916/M920) M/219 B-20002 (34623).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 92320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Wait Until Exhaust Components are Cool.

Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-116
TM 9-2320-273-20

EXHAUST SYSTEM.

4-34. TURBO OUTLET PIPE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

During normal operation, the exhaust pipes

and muffler can become very hot. Be careful

not to touch these components with your

bare hands. Do not allow your body to come

in contact with the hot pipes or muffler. Exhaust system components may be hot enough

to cause serious burns.

4-117
TM 9-2320-273-20

A. REMOVA L

EXHAUST SYSTEM.

4-34. TURBO OUTLET PIPE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Locknut (10) and bolt (11). Unscrew and remove clamp Replace locknut (10).

(8).

2. Two coupling nuts (12). Loosen.

3. Two clamp nuts (5) and Unscrew and remove U-clamp

washers (4). (13) and spacer (3) from

bracket (6).

4. Turbocharger outlet pipe Remove.

(7).

5. Coupling (2). Remove and discard.

B. INSPECTION OF MATING FLANGES.

6. End of turbocharger outlet Check for: Replace (1) and (7) if neces-

(9), turbocharger outlet pipe a. Burrs.

(7), and flex pipe (1).

sary, or refer to Direct

b. Cracks. Support for (9).

c. Distortion.

C. INSTALLATION.

7. Turbocharger outlet pipe (7), Position at bracket (6) and Do not tighten clamp nuts

U-clamp (13), spacer (3). install with two washers (4) (5) yet.

and clamp nuts (5).

8. Turbocharger outlet (9). a. Aline with turbocharger

outlet pipe (7).

b. Secure with clamp (8), bolt

(11), and locknut (10).

9. New coupling (2). a. Position at connection of

flex pipe (1) and turbocharger outlet pipe (7).

b. Secure with two new coup- Use torque wrench and

Iing nuts (12). tighten to 45 Ib-ft (61 N·m).

10. Two clamp nuts (5). Tighten.

D. CHECKING FOR LEAKS

11. Engine. Start up (see TM 9-2320-

273-10).

4-118
TM 9-2320-273-20

EXHAUST SYSTEM.

4-34. TURBO OUTLET PIPE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

D. CHECKING FOR LEAKS (Continued).

12. Coupling (2) and clamp (8). Listen for leaks. Tighten two coupling nuts

(12) or locknut (10) as

necessary.

13. Engine. Shut down (see TM 9-2320-

273-10).

4-119
TM 9-2320-273-20

EXHAUST SYSTEM.

4-35. FLEX PIPES MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Inspection of Mating Flanges. ( 5)

c.Installation. (10)

d.Checking for Leaks. ( 5)

25 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All . None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Couplings (3), 5.0-1236BJ (76700).

Coupling, 5.0-1259LJ (76700).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Wait Until Exhaust Components are Cool.

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 4-1.

4-120
TM 9-2320-273-20

EXHAUST SYSTEM.

4-35. FLEX PIPES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

WARNING

During normal operation, the exhaust pipes

and muffler can become very hot. Be careful not to touch these components with your

bare hands. Do not allow your body to come

in contact with the hot pipes or muffler.

Exhaust system components may be hot

enough to cause serious burns.

4-121
TM 9-2320-273-20

EXHAUST SYSTEM.

4-35. FLEX PIPES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Eight coupling nuts (2). Loosen and slide three couplings (4) and coupling (8) onto

flex pipes (3) and (6).

2. Flex pipes (3) and (6). Remove.

3. Three couplings (4) and Remove and discard.

coupling (8).

B. INSPECTION OF MATING FLANGES.

4. Turbocharger outlet pipe (7), Inspect pipes and pipe ends Replace if necessary.

muffler inlet pipe (5), for:

muffler (1), and flex pipes a. Cracks.

(3) and (6). b. Distortion.

c. Burring.

C. INSTALLATION.

5. Three new couplings (4) Slide onto flex pipes

and coupling (8). (3) and (6).

6. Flex pipes (3) and (6). Put in place.

7. Three new couplings (4) Slide into position over

and coupling (8). connections.

8. Eight coupling nuts (2). Tighten to 45 Ib-ft

(61 N·m) with torque

wrench.

D. CHECKING FOR LEAKS.

9. Engine. Start up (see TM 9-2320-

273-10).

10. Flex pipes (3) and (6); Listen for leaks Retighten coupling nuts

three couplings (4) and (2) as necessary.

coupling (8).

11. Engine. Shut down (see TM 9-2320-

273-10).

4-122
TM 9-2320-273-20

EXHAUST SYSTEM,

4-35. FLEX TUBES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-123
TM 9-2320-273-20

EXHAUST SYSTEM.

4-36. MUFFLER INLET PIPE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 6)

b. Inspection of Mating FIanges. ( 5)

c.Installation. (10)

d. Checking for Leaks. ( 5)

26 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N}

Coupling (2), 5.0-1236BJ (76700).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Wait Until Exhaust Components are Cool.

Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-124
TM 9-2320-273-20

EXHAUST SYSTEM.

4-36. MUFFLER INLET PIPE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

WARNIN G

During normal operation, the exhaust

pipes and muffler can become very hot.

Be careful not to touch these components with your bare hands. Do not

allow your body to come in contact

with the hot pipes or muffler. Exhaust

system components may be hot enough

to cause serious burns.

4-125
TM 9-2320-273-20

EXHAUST SYSTEM.

4-36. MUFFLER INLET PIPE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1.

2.

3.

4.

5.

6.

7.

Two U-clamp nuts (7).

Two bracket bolts (3) and

two bracket nuts (2).

Two U-clamp nuts (13).

Two bracket bolts (16) and

two bracket nuts (15).

Four coupling nuts (18).

Muffler inlet pipe (10).

Couplings (6) and (17).

Unscrew and remove spacer

(8) and U-clamp (9).

Unscrew and remove bracket

(4).

Unscrew and remove spacer

(12) and U-clamp (11).

Unscrew and remove bracket

(14).

Loosen and slide couplings

(6) and (17) onto muffler

inlet pipe (10).

Remove.

Slide from muffler inlet pipe

(10).

B. INSPECTION OF MATING FLANGES.

8. Flex pipes (1) and (5) and Inspect pipes for:

muffler inlet pipe (10). a. Burrs,

C. INSTALLATION.

9. Two new couplings

and (17).

b. Cracks.

c. Distortion.

(6) Slide onto muffler inlet

pipe (10).

10. Muffler inlet pipe (10). Set in position and slide

couplings (6) and (17)

over ends of flex pipes

(1) and (5).

11. Bracket (14). Install to vehicle with two

bracket bolts (16) and

bracket nuts (15).

12. U-clamp (11) and spacer (12). Position around muffler

inlet pipe (10) and secure

to bracket (14) with two

U-clamp nuts (13).

Discard couplings.

Replace as necessary,

4-126
TM 9-2320-273-20

EXHAUST SYSTEM.

4-36. MUFFLER INLET PIPE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-127
TM 9-2320-273-20

EXHAUST SYSTEM.

Install to vehicle with two

bracket bolts (3) and

bracket nuts (2).

Position around muffler

inlet pipe (10) and secure

to bracket (4) with two

U-clamp nuts (7).

Tighten to 45 Ib-ft (61

N·m) with torque wrench.

4-36. MUFFLER INLET PIPE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

13. Bracket (4).

14. U-clamp (9) and spacer (8).

15. Four coupling nuts (18).

D. CHECKING FOR LEAKS.

16. Engine.

17. Muffler inlet pipe (10).

18. Engine.

Start up (see TM 9-2320-273-

10).

Listen for leaks.

Shut down (see TM 9-2320-

273-10).

4-128
TM 9-2320-273-20

EXHAUST SYSTEM.

4-36. MUFFLER INLET PIPE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-129
TM 9-2320-273-20

EXHAUST SYSTEM

4-37. MUFFLER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a.Removal. (10)

b.Inspection of Mating Flanges. ( 5)

c.Installation. (10)

d. Checking for Leaks. ( 5)

30 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Coupling, 5.0-1259LJ (76700).

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Wait Until Exhaust Components Are Cool.

Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-130
TM 9-2320-273-20

EXHAUST SYSTEM.

4-37. MUFFLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

WARIN G

During normal operation the exhaust pipes

and muffler can become very hot. Be careful not to touch these components with your

bare hands, Do not allow your body to come

in contact with the hot pipes or muffler. Exhaust system components may be hot enough

to cause serious burns.

A. REMOVAL.

1. Two coupling nuts (17). Loosen and slide coupling (16)

down over flex pipe (15).

2. Two U-clamp nuts (5) and Unscrew and remove U-clamp

U-clamp washers (4). (2) and spacer (11 ).

4-131
TM 9-2320-273-20

EXHAUST SYSTEM.

4-37. MUFFLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Four bracket bolts (7), bracket Unscrew and remove Uwashers (8) and insulators (9). clamp bracket (6).

4. Two U-clamp nuts (20) and Unscrew and remove UU-clamp washers (14). clamp (18) and spacer (19).

5. Muffler (10) and exhaust Remove from flex pipe (15). If muffler (10) is to be restack (13). placed, pull exhaust stack

(13) from muffler.

6. Four bracket bolts (1), bracket Unscrew and remove Uwashers (21), and insulators (2). clamp bracket (3).

7. Coupling (16). Slide off of flex tube (15). Discard coupling (16).

B. INSPECTION OF MATING FLANGES.

8. Flex pipe (15), muffler (10), Inspect pipe ends for: Replace as necessary.

and exhaust stack (13). a. Burrs.

b. Cracks.

c. Distortion.

C. INSTALLATION.

9. Four insulators (2) and U- a. Position to cab.

clamp bracket (3). b. Install with four bracket

bolts (1) and bracket

washers (21).

10. Four insulators (9) and a. Position to cab.

U-clamp bracket (6). b. Install with four bracket

bolts (7) and bracket

washers (8),

11. New coupling (16). Slide over flex pipe (15).

12. Exhaust stack (13). Slide into top of muffler (10). If removed.

13. Muffler (10) and exhaust Slide into flex pipe (15).

stack (13).

14. Coupling (16). Slide up over connection of

muffler (10) and flex pipe (15).

15. Two coupling nuts (17). Tighten to 45 Ib-ft (61 N·m)

with torque wrench.

16. U-clamp (18) and spacer (19). Position around muffler (10)

at U-clamp bracket (3).

4-132
TM 9-2320-273-20

EXHAUST SYSTEM.

4-37. MUFFLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-133
TM 9-2320-273-20

EXHAUST SYSTEM.

4-37. MUFFLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

17. Two-U-clamp washers (14) Screw onto U-clamp (18)

and U-clamp nuts (20). and tighten.

18. U-clamp (12) and spacer (11). Position around muffler (10)

and exhaust stack (13) at

U-clamp bracket (6).

19. Two U-clamp washers (4) Screw onto U-clamp (12)

and U-clamp nuts (5). and tighten.

D. CHECKING FOR LEAKS.

20. Engine.

21. Muffler (10).

22. Engine.

Start up (see TM 9-2320-

273-10).

If muffler is leaking, you Tighten connections as

will hear a hissing sound. necessary.

Shut down (see TM 9-2320-

273-10).

4-134
TM 9-2320-273-20

EXHAUST SYSTEM

4-37. MUFFLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-135
TM 9-2320-273-20

EXHAUST SYSTEM.

4-38. EXHAUST STACK MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REWIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Inspection of Mating Flanges and Rain Cap. (5)

c. Installation. (5)

d. Checking for Leaks. (5)

20 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIAL/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Wait Until Exhaust Components are Cool.

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 4-1.

4-136
TM 9-2320-273-20

EXHAUST SYSTEM.

Loosen.

Lift up out of U-clamp and

muffler (3).

4-38. EXHAUST STACK MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

WARIN G

During normal operation, the exhaust pipes

and muffler can become very hot. Be careful

not to touch these components with your

bare hands. Do not allow your body to come

in contact with the hot pipes or muffler.

Exhaust system components may be hot

enough to cause serious burns.

A. REMOVAL.

1. Two U-clamp nuts (4).

2. Exhaust stack (5).

4-137
TM 9-2320-273-20

EXHAUST SYSTEM.

4-38. EXHAUST STACK MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Nut (2). Unscrew and remove rain cap

4. Exhaust stack (5) and

muffler (3).

5. Rain cap (1).

C. INSTALLATION.

6. Rain cap (1).

7. Exhaust stack (5).

8. Two U-clamp nuts (4).

D. CHECKING FOR LEAKS.

9. Engine.

10. Exhaust stack (5).

11. Engine.

Inspect ends for:

a. Burrs.

b. Cracks.

c. Distortions.

Check for free movement

and a good seal to top of

exhaust stack (5).

Position on exhaust stack

(5) and tighten nut (2).

Slide into muffler (3).

Tighten.

Start up (see TM 9-2320-

273-10).

Listen for leaks, and

tighten U-clamp nuts (4)

as necessary.

Shut down (see TM 9-2320-

273-10).

Replace if necessary.

Replace if necessary.

4-138

(1).
TM 9-2320-273-20

EXHAUST SYSTEM.

4-38. EXHAUST STACK MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

4-139
TM 9-2320-273-20

COOLING SYSTEM.

4-39. RADIATOR HOSES MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a.Inspection. (10)

b. Removal. (15)

c. Installation. (20)

45 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-42A. Coolant Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20),

REFERENCES (TM)

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

None.

TROUBLESHOOTING REFERENCES

Table 4-1.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-140
TM 9-2320-273-20

COOLING SYSTEM.

4-39. RADIATOR HOSES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. Inspection.

1. Radiator inlet hose (3), water Check for: If hoses or tube are leaking

pump aeration hose (5), over- a, Cracks. or damaged, replace.

flow hose (8), two radiator b. Kinks.

outlet hoses (13), radiator c. Stains (may indicate leaks).

outlet tube (14) and radiator

aeration hose (18).

LEGEND:

1. INLET ELBOW 11. LOCKWASHER (2)

2. HOSE CLAMP (6) 12. CAPSCREW (2)

3. RADIATOR INLET HOSE 13. RADIATOR OUTLET HOSE (2)

4. HOSE CLAMP 14. RADIATOR OUTLET TUBE

5. WATER PUMP AERATION HOSE 15. FRONT WATER MANIFOLD

6. RADIATOR 16. REDUCER (2)

7. HOSE CLAMP 17. CONNECTOR (2)

B. OVERFLOW HOSE 18. RADIATOR AERATION HOSE

9. HOSE RETAINER (2) 19. OUTLET FITTING

10. FLAT WASHER (2) 20. OUTLET HOUSING TA211959

Change 1 4-141
TM 9-2320-273-20

COOLING SYSTEM.

4-39. RADIATOR HOSES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. REMOVAL.

2. Two hose clamps (2). Unscrew and remove radiator

inlet hose (3).

3. Hose clamp (4) and hose Unscrew and remove water

clamp (7). pump aeration hose (5).

4. Two connectors (17). Unscrew and remove radiator

aeration hose (18).

5. Two reducers (16). Unscrew from radiator (6)

and front water manifold

(15).

6. Four hose clamps (2). Unscrew and remove two

radiator outlet hoses (13)

and radiator outlet tube

(14).

7. Two capscrews (12), Unscrew and remove two

Iockwashers (11), and hose retainers (9).

flat washers (10).

8. Overflow hose (8). Remove by twisting and

pulling from barb fitting.

C. INSTALLATION.

9. Overflow hose (8).

10. Two hose retainers (9).

Turn and push onto barb

fitting on side of radiator

fill neck.

Position around overflow

hose (8) and secure to

side of radiator (6) with

two capscrews (12), lockwashers (11), and fIat

washers (10).

4-142 Change 1
TM 9-2320-273-20

COOLING SYSTEM.

4-39. RADIATOR HOSES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

1. INLET ELBOW 11. LOCKWASHER (2}

2. HOSE CLAMP (6) 12. CAPSCREW (2)

3. RADIATOR INLET HOSE 13. RADIATOR OUTLET HOSE (2)

4. HOSE CLAMP 14. RADIATOR OUTLET TUBE

5. WATER PUMP AERATION HOSE 15. FRONT WATER MANIFOLD

6. RADIATOR 16. REDUCER (2)

7. HOSE CLAMP 17. CONNECTOR (2)

8. OVERFLOW HOSE 18. RADIATOR AERATION HOSE

9. HOSE RETAINER (2) 19. OUTLET FITTING

10. FLAT WASHER (2) 20. OUTLET HOUSING

TA211960

Change 1 4-143
TM 9-2320-273-20

COOLING SYSTEM.

4-39. RADIATOR HOSES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

11. Two radiator outlet hoses a. Slide radiator outlet hose

(13), radiator outlet tube (14), (13) over ends of radiator

and four hose clamps (2). outlet tube (14).

b. Slide four hose clamps

(2) over radiator outlet

hoses (13).

c. Slide one radiator outlet

hose (13) over outlet fitting (19) and secure with

two hose clamps (2).

d. Slide other radiator out.

let hose (13) over outlet

of radiator (6) and secure

with two hose clamps (2).

12. Two reducers (16). a. Apply liquid teflon to threads.

b. Screw into top of radiator (6)

and front water manifold (15).

13. Radiator aeration hose (18) Screw connectors (17) into two

with two connectors (17). reducers (16).

14. Water pump aeration hose (5), a. Slide hose clamps (4) and (7)

hose clamp (4), and hose over water pump aeration

clamp (7). hose (5).

b. Secure water pump aeration

hose (5) to top of radiator (6)

and top of outlet housing (20)

with hose clamps (4) and (7).

15. Radiator inlet hose (3) and a. Slide hose clamps (2) over

two hose clamps (2). radiator inlet hose (3).

b. Secure radiator inlet hose (3)

to top of radiator (6) and

inlet elbow (1) with two hose

clamps (2).

NOTE

Follow-on maintenance required:

Install draincock, fill with coolant, and check

for leaks; refer to para 4-429, C, and D.

Fill with Arctic Anti-Freeze if sub-zero

conditions are anticipated.

4-144 Change 1
TM 9-2320-273-20

COOLING SYSTEM.

4-39. RADIATOR HOSES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

TA211961

Change 1 4-145
TM 9-2320-273-20

COOLING SYSTEM.

4-40. RADIATOR MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.

a. Removal. (25)

b. Installation. (30)

55 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All,

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

EQUIPMENT CONDITION

PARAGRAPH

4-42A.

11-32A.

11-16E.

11-16A.

10-22A.

6-10A.

MATERIALS/PARTS (P/N)

Insulators (2) CBA 24-500 (76005).

Liquid Teflon (refer to appendix C).

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-20P.

CONDITION DESCRIPTION

Drain Coolant.

Hood Removed,

Brush Guard Removed

(M916 thru M920).

Grille Removed.

Steering Pump Cooler Hoses

Removed.

Transmission Oil Cooler

Hoses Removed.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 4-1.

4-146
TM 9-2320-273-20

COOLING SYSTEM.

4-40. RADIATOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Radiator aeration hose (9). Unscrew fitting from connector in radiator top tank.

2. Three hose clamps (1), (2), Loosen and remove inlet hose

and (16). (3), pump aeration hose (18)

and outlet hose (17) from

radiator (15).

3. Two clamps (19). Loosen. Slide boot (20) onto If desired, loosen forward

air filter inlet tube (21). clamp at opposite end of

tube and remove tube.

4. Two nuts (8) and washers (7). Loosen and remove.

5. Two nuts (10) and Loosen and remove.

washers (11).

LEGEND:

1. HOSE CLAMP

2. HOSE CLAMP

3. INLET HOSE

4. ROD ARM (2)

5. FAN

6. CAPSCREW (6)

7. WASHER (2)

8. NUT (2)

9. RADIATOR AERATION

HOSE

10. NUT 1,2)

11. WASHER (2)

12. SUPPORT

13. INSULATOR (2)

14. MOUNTING STUD (2)

15. RADIATOR

16. HOSE CLAMP

17. OUTLET HOSE

18. PUMP AERATION HOSE

19. CLAMP (2)

20. BOOT

21. AIR FILTER INLET TUBE

22. CLAMP (2)

23. CLAMP BOLT (2)

24. NUT (2)

TA 074661

4-147
TM 9-2320-273-20

COOLING SYSTEM.

4-40. RADIATOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

6. Two rod arms (4). a. Remove two nuts (8) and washers

(7).

b. Remove two rod arms and attached ball studs from radiator.

c. If required, separate rods by removing two nuts (24), clamp

bolts (23) and clamps (22) from

center of rod arms (4).

7. Radiator (15). a. Tilt forward and support.

b. Remove six capscrews (6)

from fan (5) and remove

fan.

c. Lift radiator (15) enough to If lifting device is availclear insulators (13) and able, install lifting eyes

remove. in rod arm holes.

8. Two insulators (13). a. Remove.

b. Throw away.

NOTE

To remove shrouds from radiator assembly

refer to paragraph 4-41. Fan Shrouds

Maintenance.

B. INSTALLATION.

9. Two new insulators (13). Position on mounting studs You may use tape to

(14). hold the insulators in

place.

10. Radiator (15). a. Aline mounting studs (14) with

support (12). Set in place.

b. Tilt forward and support.

Install six capscrews (6)

into fan (5). Torque to 25-32

Ib-ft (33.9 to 43.4 N•m).

11. Two rod arms (4). a. If separated, install two nuts

(24), clamp bolts (23), and

clamps (22) thru center of

rod arms (4) and tighten.

b. Insert in top support bracket.

c. Install two washers (7) and

nuts (8). Tighten.

4-148
TM 9-2320-273-20

COOLING SYSTEM.

4-40. RADIATOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

TA 074662

4-149
TM 9-2320-273-20

COOLING SYSTEM.

4-40. RADIATOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

12. Two washers (11) and Install and tighten.

nuts (10).

13. Air filter inlet tube (21). a. If removed, reinsert at

filter end and tighten

forward clamp,

b. Slide boot (20) onto air

inlet and tighten two

clamps (19).

14. Three hose clamps Reinstall inlet hose (3)

(1), (2) and (16). pump aeration hose (18)

and outlet hose (17) to

radiator. Position clamps

and tighten.

15. Radiator aeration Apply liquid teflon to

hose (9). fitting and screw into

connector.

NOTE

Follow-on maintenance actions required:

a. Install steering pump cooler hoses, para 10-22.

b. Install transmission cooler hoses, para 6-10C.

c. Install grille, para 11-16.

d. Install brush guard (M916/M920), para 11-16.

e. Fill cooling system, para 4-42C; use Artic Anti Freeze if sub zero.

f. Install hood, para 11-32C.

4-150
TM 9-2320-273-20

COOLING SYSTEM.

4-40. RADIATOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

HOSE CLAMP

HOSE CLAMP

INLET HOSE

ROD ARM (2)

FAN

CAPSCREW (6)

WASHER (2)

NUT (2)

RADIATOR AERATION

HOSE

NUT (2)

WASHER (2)

SUPPORT

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

INSULATOR (2)

MOUNTING STUD (2)

RADIATOR

HOSE CLAMP

OUTLET HOSE

PUMP AERATION HOSE

CLAMP (2)

BOOT

AIR FILTER INLET TUBE

CLAMP (2)

CLAMP BOLT (2)

NUT (2)

TA 075643

4-151
TM 9-2320-273-20

COOLING SYSTEM.

4-41. FAN SHROUDS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Installation. (30)

50 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCE (TM)

None.

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

None. None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

None.

4-152
TM 9-2320-273-20

COOLING SYSTEM.

4-41. FAN SHROUDS MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

A. REMOVAL.

1. Six capscrews (12), Unscrew and remove.

nuts (6), and twelve

washers (7) and (11).

2. Four capscrews (8), Unscrew and remove.

flat washers (10), and

lock washers (9).

4-153
TM 9-2320-273-20

COOLING SYSTEM.

4-41. FAN SHROUDS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Upper fan shroud (1). a. Remove.

b. Remove fan (refer to

para 4-4A).

4. Four capscrews (5), lock- Unscrew and remove.

washers (4) and fiat washers

(3).

5. Lower fan shroud (2). Remove.

B. INSTALLATION.

6. Lower fan shroud (2). a. Set in place and attach

with four capscrews (5),

Iockwashers (4), and

flat washers (3).

b. Install fan (refer to

para 4-4B).

7. Upper fan shroud (1). Set in place and attach with

four capscrews (8), flat

washers (10), and lockwashers (9).

8. Six capscrews (12), Screw on and tighten.

nuts (6), and twelve

washers (7) and (11).

9. Eight capscrews (5) and (8), Tighten.

Iockwashers (4) and (9), and

flat washers (3) and (10).

4--154
TM 9-2320-273-20

COOLING SYSTEM

4-41. FAN SHROUDS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-155
TM 9-2320-273-20

COOLING SYSTEM.

4-42. COOLANT SYSTEM MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Drain. (21)

b. Inspection/Installation of Draincocks. ( 1)

c. Replenishing Coolant. (10)

d. Checking for Leaks. ( 5)

37 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Container(s) (60 qt min).

Liquid Teflon (refer to appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCE (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 4-1.

4-156
TM 9-2320-273-20

COOLING SYSTEM

4-42. COOLANT SYSTEM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Before opening each drain cock, place

container underneath to catch coolant.

A. DRAIN .

1. Radiator cap (2). Remove.

2. Radiator draincock (4). Open and let coolant drain out.

3. Thermostat petcock (7). Open.

4. Oil cooler draincock (5). a. Open.

b. Let coolant drain out.

c. Close.

5. Ether quick-start sending

unit (6). a. Disconnect wire.

b. Remove ether quick-start

sending unit and clean threads.

c. Allow coolant to drain out.

d. Apply liquid teflon to threads

and install ether quick-start

sending unit.

LEGEND:

1. SIGHT GLASS

2. RADIATOR CAP

3. RADIATOR FILL

NECK

4. RADIATOR

DRAINCOCK

5. OIL COOLER

DRAINCOCK

6. ETHER QUICK-START

SENDING UNIT

7. THERMOSTAT

PETCOCK

TA 074665

4-157
TM 9-2320-273-20

COOLING SYSTEM

NOTE

Fill with Artic Anti Freeze if sub-zero

Add coolant until thermostat petcock (7) overflows.

Close.

Continue adding coolant

until sight glass (1) is

filled.

4-42. COOLANT SYSTEM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSPECTION/INSTALLATION OF DRAINCOCKS.

6. Radiator draincock

(4), oil cooler draina. Remove as required.

b. Inspect for damage.

cock (5) and thermo- C. Coat threads with

stat petcock (7). liquid teflon.

d. Screw into place and

close.

C. REPLENISHING COOLANT.

7. Radiator fill neck

(3).

8. Thermostat petcock

(7).

9. Radiator fill neck

(3).

D. CHECKING FOR LEAKS.

10. Engine. Start up (see TM 9-2320-273-10).

11. Coolant system. a. Check for leaks.

b. Make sure coolant level Add more if needed.

is to the top of sight

glass (1).

12. Radiator cap, (2). Install.

4-158
TM 9-2320-273-20

COOLING SYSTEM

4-42. COOLANT SYSTEM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-159
TM 9-2320-273-20

COOLING SYSTEM.

4-43. THERMOSTAT AND HOUSING MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Testing. (10)

c. Installation. (30)

d. Operational Check. (15)

75 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-42A. Cooling System

Drained Below

TEST EQUIPMENT Thermostat Housing.

None,

SPECIAL TOOLS

Thermostat Seal Mandrel, ST-1225 (15434).

MATERIALS/PARTS (P/N)

Gasket (6620-00-047-2811).

Rubber Seal (5330-00-864-5422).

Gasket, 210859 (15434).

Container(s) for Coolant.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCE (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-160
TM 9-2320-273-20

COOLING SYSTEM

4-43. THERMOSTAT AND HOUSING MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL .

1. Bypass hose clamp (4), Loosen and remove hoses.

radiator inlet hose clamp (10),

and hose (9).

2. Compressor coolant line Unscrew from fitting (8).

(15).

LEGEND:

1. WASHER

2. CAPSCREW

3. ELBOW

4. BYPASS HOSE

CLAMP

5. GASKET

6. WASHER (4)

7. CAPSCREW (4)

8. FITTING

9. HOSE

10. RADIATOR INLET

HOSE CLAMP

11. THERMOSTAT

HOUSING

12. RUBBER SEAL

13. THERMOSTAT

14. GASKET

15. COMPRESSOR

COOLANT LINE

TA 074667

4-161
TM 9-2320-273-20

COOLING SYSTEM.

4-43. THERMOSTAT AND HOUSING MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3.

4.

5.

6.

7.

Two capscrews (2), and

washers (1).

Elbow (3) and gasket (5).

Four capscrews (7) and

washers (6).

Thermostat housing (11).

Gasket (14), thermostat (13),

and rubber seal (12).

Unscrew and remove.

a. Remove.

b. Check elbow for

cracks.

Unscrew and remove.

a. Tap with soft head

hammer and remove.

b. Check housing for:

1. Cracks.

2. Damaged fittings.

3. Stains from leaks.

Remove.

Replace if necessary.

B. TESTING.

8. Thermostat (13). a.

b.

 C. INSTALLATION.

9. Thermostat (13), gasket (14),

and rubber seal (12).

10. Gasket (5), elbow (3),

washer (1), and capscrew (2).

11. Compressor coolant line (15).

Check that at room temperature thermostat is

closed.

Put thermostat in hot

water. When temperature reaches 185°F (85°C)

thermostat should open.

Install rubber seal (12)

in thermostat housing (11)

using thermostat seal

mandrel.

Install thermostat (13), new

gasket (14), and secure with

four capscrews (7), and

washers (6).

Secure new gasket (5),

and elbow (3), with two

capscrews (2), and washers

(1).

Screw to fitting (8).

If thermostat does not

work, replace it.

Seal must be installed

with part number or metal

flange of seal toward

mandrel to ensure proper

sealing.

4-162
TM 9-2320-273-20

COOLING SYSTEM

4-43. THERMOSTAT AND HOUSING MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-163
TM 9-2320-273-20

COOLING SYSTEM.

Start up (see TM 9-2320-

273-10).

a. Check for leaks at thermostat

housing.

b. Make sure coolant is to the top

of the radiator sight glass.

4-43. THERMOSTAT AND HOUSING MAINTENANCE (Continued).

LOCATION ITEM ACTION REMARK S

C. INSTALLATION (Continued).

12. Bypass hose clamp (4), Install hoses to thermoradiator inlet hose clamp stat housing (11).

(10) and hose (9).

13. Fill cooling system. Refer to para 4-42C.

D. OPERATIONAL CHECK.

14. Engine.

15. Cooling system.

4-164
TM 9-2320-273-20

COOLING SYSTEM.

4-43. THERMOSTAT AND HOUSING MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-165
TM 9-2320-273-20

COOLING SYSTEM.

4-44. FAN MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Installation. (15)

c. Operational Check. ( 2)

32 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-41A. Upper Fan Shroud Removed.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCE (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Trasmission in Neutral.

Park Brake Set.

Fan Clutch May Engage at any

Time When Engine is Running.

4-166
TM 9-2320-273-20

COOLING SYSTEM

Unscrew and remove.

Remove from fan clutch

(3) and lay in lower fan

shroud.

Remove

Remove from lower fan

shroud.

Refer to para 4-45A.

4-44. FAN MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVA L

1. Six machine bolts (1) and

Iockwashers (2).

2. Fan (4).

3. Fan clutch (3).

4. Fan (4).

4-167
TM 9-2320-273-20

COOLING SYSTEM.

4-44. FAN MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

5. Fan (4). Set in lower fan shroud.

6. Fan clutch (3). Install. Refer to para 4-45 C & D.

7 Fan (4), six machine bolts

(1), and Iockwashers (2).

a. Mount on fan clutch (3). Numbers on fan blade

b. Tighten machine bolts must face radiator.

to 25-31 Ib-ft (34-42

N•m).

8. Upper fan shroud. Reinstall. Refer to para 4-41 B.

C. OPERATIONAL CHECK.

9. Engine. Start up (see TM 9-2320-273-10).

10. Fan (4). With engine running, make sure

that fan draws air from radiator.

11. Engine. Shut down (see TM 9-2320-273-

10).

4-168
TM 9-2320-273-20

This page intentionally left blank.

4-169
TM 9-2320-273-20 

COOLING SYSTEM.

4-45. FAN CLUTCH AND BELTS MAINTENANCE.

a. Removal. (10)

b. Inspection. ( 5)

c. Installation. ( 5)

d. Adjustment. (15)

35 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-41A. Upper Fan Shroud

Removed.

TEST EQUIPMENT

Belt Tension Gage.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCE (TM)

None.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

Fan Clutch May engage at any

Time Engine is Running.

4-170
TM 9-2320-273-20

COOLING SYSTEM.

4-45. FAN CLUTCH AND BELTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Fan. Remove from fan clutch (8) Refer to para 4-44 A.

and set in lower fan shroud.

2. Three machine bolts (1). Loosen.

3. Two fan belts (6). Remove by loosening locknut (5) and adjusting screw (4).

4. Actuator outlet line (3). Loosen and remove from

fan clutch (8).

5. Three machine bolts (1), three Remove. Flat washers (9) are used

Iockwashers (2), two flat with the two lower machwashers (9), and fan clutch (8). ine bolts (1).

4-171
TM 9-2320-273-20

COOLING SYSTEM.

Install; hand tighten

machine bolts (1).

Install over fan clutch

(8) and accessory drive

pulley (7).

CAUTION

4-45. FAN CLUTCH AND BELTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSPECTION.

6. Actuator outlet line (3). Check for: Replace if necessary.

a. Leaks.

b. Kinks.

c. Cracks.

d. Damaged threads.

7. Two fan belts (6). Check for: Replace if necessary.

a. Cuts. Belts must be replaced

b. Wear. as a matched set.

C. INSTALLATION.

8. Fan clutch (8), three Be sure fan lockup screw

machine bolts (1), three

Iockwashers (2), and two

(10) is backed out. Flat

washers (9) are used with

flat washers (9). the two lower machine

bolts (1).

9. Two fan belts (6). Rotate fan clutch (8)

toward accessory drive

pulley (7) for ease of

installation.

Fan lockup screw (10) should not be used

unless clutch stops functioning and engine

begins to overheat.

4-172
TM 9-2320-273-20

COOLING SYSTEM

4-45. FAN CLUTCH AND BELTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-173
TM 9-2320-273-20

COOLING SYSTEM.

4-45. FAN CLUTCH AND BELTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

D. ADJUSTMENT.

NOTE

Use belt tension gage to check tension.

It should be 120 Ib-ft (162 N•m) for

new belts or 100 Ib-ft (136 N•m) for

used belts. Used belts have more than

one thousand miles of use.

10. Adjusting screw (4), Loosen locknut (5) and

locknut (5) and fan belts adjust tension as necessary

(6). with adjusting screw (4).

11. Three machine bolts (1). Tighten to 70-85 Ib-ft

(95-115 NŽm).

12. Two fan belts (6). Check that tension is the

same as described in step 9.

13. Locknut (5). Tighten securely.

14. Actuator outlet line (3). Install on fan clutch (8).

15. Fan. Lift from lower fan shroud Refer to para 4-44 B.

and install to fan clutch (8).

NOTE

Follow-on maintenance action required:

Install upper fan shroud; refer to para 4-41 B.

4-174
TM 9-2320-273-20

COOLING SYSTEM.

4-45. FAN CLUTCH AND BELTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-175
TM 9-2320-273-20

COOLING SYSTEM.

1-46. FAN CLUTCH ACTUATOR MAINTENANCE (M915, M916, M917 AND M920).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Inspect Air Lines. ( 5)

c. Installation. (15)

d. Operational Check. (10)

40 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915,’M916, M917, M918, M920. 4-42A. Coolant Drained Below

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (refer to appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCE (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 4-1.

Fan Clutch Actuator.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

Fan Clutch May Engage at Any

Time Engine is Running.

4-176
TM 9-2320-273-20

COOLING SYSTEM.

4-46. FAN CLUTCH ACTUATOR MAINTENANCE (M915, M916, M917, M918 AND M920)

(Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVA L

1. Air inlet line (4). Disconnect connector (1) and

remove air inlet line (4) from

fan clutch actuator (5).

2. Air outlet line (6). Disconnect connector (2) and

remove air outlet line (6) from

fan clutch actuator (5).

3. Fan clutch actuator (5). Unscrew and remove. Use crows foot wrench,

if necessary.

4. Elbows (3) and (7). Unscrew and remove.

4-177
TM 9-2320-273-20

COOLING SYSTEM.

4-46. FAN CLUTCH ACTUATOR MAINTENANCE (M915, M916, M917, M918 & M920) (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSPECT AIR LINES.

5. Air inlet (4) and outlet

(6) lines.

C. INSTALLATION.

a. Inspect lines for:

1. Cracks.

2. Kinks.

b. Inspect elbows and

connectors for:

1. Cracks.

2. Bends.

Replace, if

Replace, if

6. Fan clutch actuator (5).

7. Elbows (3) and (7).

8. Air outlet line (6).

9. Air inlet line (4).

Coat threads with liquid

teflon, screw in.

Coat threads with liquid

teflon, screw in.

Screw connector (2) into

side marked OUTLET.

Screw connector (1) into

side marked INLET.

NOTE

Follow-on maintenance required before

operational check:

Refill radiator; refer to para 4-42C.

D. OPERATIONAL CHECK.

10. Engine. Start up (see TM 9-2320-273-

11. Fan. Observe that fan begins to

operate when engine water

temperature (gage on instrument panel in cab) rises above

190°F, (88°C).

necessary.

necessary.

12. Engine. Shut down (see TM 9-2320-

273-10).

4-178

10.
TM 9-2320-273-20

COOLING SYSTEM

4-46. FAN CLUTCH ACTUATOR MAINTENANCE (M915, M916, M917, M918 & M920) (Continued)

LOCATION/lTEM ACTION REMARKS

4-179
TM 9-2320-273-20

COOLING SYSTEM.

4-47. FAN CLUTCH ACTUATOR AND VALVE MAINTENANCE (M919).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Insection of Air Tubes. ( 5)

c. Installation. (15)

d. Operational Check. (10)

40 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M919. 4-42A. Coolant Drained Below Fan

Clutch Actuator Level.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (refer to appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCE (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

Fan Clutch May Engage at Any Time Engine

is Running.

4-180
TM 9-2320-273-20

COOLING SYSTEM.

4-47. FAN CLUTCH ACTUATOR AND VALVE MAINTENANCE (M919) (Continued).

4-181
TM 9-2320-273-20

COOLING SYSTEM.

4-47. FAN CLUTCH ACTUATOR AND VALVE MAINTENANCE (M919) (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Two tube assemblies (3).

2. Two tube assemblies (13)

and (14).

3. Fan clutch actuator (12).

4. Hex nut (2).

5. Wire (1)

6. Two hex screws (5) and

Iockwashers (4).

7. Fan clutch valve (11).

8. Two hex screws (9), hex nuts

(6), Iockwashers (7), and

flat washers (8).

9. Bracket (10).

B. INSPECTION OF AIR TUBES. !

10. Four tube assemblies (3),

(13), and (14).

Disconnect at fan

actuator (12) and

clutch valve (11).

Disconnect at fan

actuator (12).

clutch

fan

clutch

Unscrew and remove.

Remove.

Remove.

Remove.

Remove.

Remove.

Remove.

a. Inspect tubes for:

1. Cracks.

2. Kinks.

b. Inspect fittings for:

1. Cracks.

2. Bends.

NOTE

Tag for location.

Tag for location.

Use crows foot wrench

if necessary.

Replace if necessary.

Replace if necessary.

If a new fan clutch actuator or fan clutch

valve is being installed, transfer fittings

from defective valve or actuator to the new

one. Use liquid teflon on threaded connections.

11. Bracket (10). Set in place and secure

with two hex screws (9)

hex nuts (6), Iockwashers

(7), and flat washers (8).

Tighten securely.

4-182
TM 9-2320-273-20

COOLING SYSTEM.

4-47. FAN CLUTCH ACTUATOR AND VALVE MAINTENANCE (M919) (Continued).

4-183
TM 9-2320-273-20

COOLING SYSTEM.

4-47. FAN CLUTCH ACTUATOR AND VALVE MAINTENANCE (M919) (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

12. Fan clutch valve (11). Set in place and secure with

two hex screws (5) and

Iockwashers (4).

13. Wire (1). Install over terminal and

secure with hex nuts (2).

14. Fan clutch actuator (12). Coat threads with liquid Tighten securely with crows

teflon and screw in. foot wrench.

15. Two tube assemblies (13) Connect at fan clutch Note identification tagged

and (14). actuator (12). for ease of installation.

16. Two tube assemblies (3). Connect at fan clutch Note identification tagged

actuator (12) and fan for ease of installation.

clutch valve (11).

D. OPERATIONAL CHECK.

17. Engine. Start up (see TM 9-2320-

273-10).

18. Fan. Observe that fan begins to

operate when engine water

temperature (gage on instrument panel in cab) rises

above 190°F (88°C) and/

or when fan clutch valve

switch is manually operated

(see TM 9-2320-273-10).

19. Engine. Shut down (see TM 9-2320-

273-10).

4-184
TM 9-2320-273-20

COOLING SYSTEM.

4-47. FAN CLUTCH ACTUATOR AND VALVE MAINTENANCE (M919) (Continued).

4-185
TM 9-2320-273-20

COOLING SYSTEM.

4-48 FAN CLUTCH ACTUATOR TUBES MAINTENANCE (M915, M916, M917, M918 & M92O).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (5)

c. Checking for Leaks. (2)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915, M916, M917, M918, M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Soap Solution.

Liquid Teflon (refer to appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCE (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 4-1.

4-186
TM 9-2320-273-20

COOLING SYSTEM.

4-48. FAN CLUTCH ACTUATOR TUBES MAINTENANCE (M915, M916, M917, M918 AND

M920) (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL .

1. Four fittings (1). Unscrew from fan clutch Replace if necessary.

(7), actuator (3) and tee

(5) located on compressor

governor (6).

2. Two elbows (2). Unscrew from fan clutch Replace if necessary.

actuator (3).

3. Inlet tube (4) and outlet a. Remove.

tube (8). b. Inspect for:

1. Cracks.

2. Leaks.

3. Damaged fittings.

c. Blow gently through

tubes to see that air

flow is not blocked.

4-187
TM 9-2320-273-20

COOLING SYSTEM.

Start up (see TM 9-2320-

273-10).

WARNIN G

Be sure to stay completely clear of fan

blades. Do not reach into fan clutch

area while engine is operating.

Use soap solution to check

for leaks.

Shut down (see TM 9-2320-

273-10).

4-48. FAN CLUTCH ACTUATOR TUBES MAINTENANCE (M915, M916, M917, M918 AND

M920) (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

4. Two elbows (2). Coat threads with liquid

teflon. Screw into fan

clutch actuator.

5. Two tubes (4) and (8). a. Coat threads with liquid

teflon.

b. Screw four fittings (1) on

fan clutch (7), actuator

(3), and tee fitting (5)

located on compressor

governor (6).

c. Tighten.

C. CHECKING FOR LEAKS.

6. Engine.

7. Tubes (4) and (8).

8. Engine.

4-188
TM 9-2320-273-20

COOLING SYSTEM

4-48. FAN CLUTCH ACTUATOR TUBES MAINTENANCE (M915, M916, M917, M918 & M920}

(Continued).

LOCATION/lTEM ACTION REMARKS

4-189
TM 9-2320-273-20

COOLING SYSTEM.

4-49. FAN CLUTCH ACTUATOR TUBES MAINTENANCE (M919).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Inspection. ( 5)

c. Installation. (10)

d. Checking for Leaks. ( 5)

30 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M919. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Soap Solution.

Liquid Teflon (refer to appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 4-1

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

4-190
TM 9-2320-273-20

COOLING SYSTEM.

4-49. FAN CLUTCH ACTUATOR TUBES MAINTENANCE (M919) (Continued).

LOCATION/lTEM ACTION REMARKS

4-191
TM 9-2320-273-20

COOLING SYSTEM.

4-49. FAN CLUTCH ACTUATOR TUBES MAINTENANCE (M919).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL .

1. Tube (1).

2. Tube (2).

3. Tee (3).

4. Tube (5).

5. Tube (8).

6. Connector (9).

7. Four elbows (11).

Disconnect at fan clutch

valve (10) and fan clutch

actuator (12).

Tag for location.

Disconnect at fan clutch

actuator (12) and at

governor (4).

Tag for location.

Remove at governor (4).

Disconnect from connector Tag for location.

(7) located on fan clutch

and at fan clutch actuator

(12).

Disconnect at fan clutch Tag for location.

valve (10) and at fan clutch

actuator (12).

Remove.

Remove one elbow (11) at

fan clutch valve (10) and

three elbows (11) at the

fan clutch actuator (12).

4-192
TM 9-2320-273-20

COOLING SYSTEM.

4-49. FAN CLUTCH ACTUATOR TUBES MAINTENANCE (M919) (Continued).

LOCATION/lTEM ACTION REMARKS

4-193
TM 9-2320-273-20

COOLING SYSTEM.

4-49. FAN CLUTCH ACTUATOR TUBES MAINTENANCE (M919) (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSPECTION.

8. Tubes and fittings. Inspect all components for Replace if necessary.

cracks and defects.

C. INSTALLATION.

9. Four elbows (11). Install one elbow (11) at Coat threads with liquid

fan clutch valve (10) and tefIon.

three elbows (11) at the

fan clutch actuator (12).

10. Connector (9). Install in fan clutch valve Coat threads with liquid

(10). teflon.

11. Tube (8). Connect at fan clutch Coat threads with liquid

valve (10) and at fan clutch teflon.

actuator (12).

12. Tube (5). Connect tube (5) to con- Coat threads with liquid

nector (7) located on fan teflon.

clutch (6) and at fan

clutch actuator (12).

13. Tee (3). Install tee into governor Coat threads with liquid

(4). teflon.

4-194
TM 9-2320-273-20

COOLING SYSTEM.

4-49. FAN CLUTCH ACTUATOR TUBES MAINTENANCE (M919) (Continued).

LOCATION/lTEM ACTION REMARKS

4-195
TM 9-2320-273-20

COOLING SYSTEM.

4-49. FAN CLUTCH ACTUATOR TUBES MAINTENANCE (M919) (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

14. Tube (2). Connect at fan clutch Coat threads with liquid

actuator (12) and at tee teflon.

(3).

15. Tube. Connect at fan clutch Coat threads with liquid

actuator (12) and at fan teflon.

clutch valve (10).

D. CHECKING FOR LEAKS.

16.

17.

18.

Engine.

Tubes, fittings, and

connections.

Engine.

Start up (see TM 9-2320-

273-10).

WARNIN G

Be sure to stay completely clear of fan blades.

Do not reach into fan clutch area while engine

is operating.

Use soap solution to check

for leaks.

Shut down (see TM 9-2320-

273-10).

4-196
TM 9-2320-273-20

COOLING SYSTEM

4-49. FAN CLUTCH ACTUATOR TUBES MAINTENANCE (M919) (Continued).

LOCATION/lTEM ACTION REMARKS

4-197
TM 9-2320-273-20

COOLING SYSTEM.

4-50. HEATER SHUTOFF VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Installation. (15)

c. Bleeding Heater. (5)

30 Minutes Total. 

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-42A. Coolant Drained below

Level of Valve.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Container(s).

Liquid Teflon (refer to appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCE (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

4-198
TM 9-2320-273-20

COOLING SYSTEM.

4-50. HEATER CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Two clamps (5).

2. Heater tube (3) and

rubber hose (4).

3. Valve (6).

Loosen.

Remove from valve (6).

Unscrew and remove from

manifold (7).

If necessary you may

remove clamp (2) by

unscrewing capscrew

(1).

4-199
TM 9-2320-273-20

COOLING SYSTEM.

4-50. HEATER CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

4. Valve (6).

5. Heater tube (3) and

rubber hose (4).

a.

b.

a.

b.

Coat threads with

liquid teflon.

Screw into adapter

manifold (7).

Connect to valve (6).

Tighten clamps (5),

If you removed clamp

(1), put it back on and

tighten capscrew (2).

C. BLEEDING HEATER.

6.

7.

8.

9.

Cab/heater outlet hose.

Engine.

Cab/heater knob,

heater outlet hose.

Valve (6).

NOTE

Before removing outlet hose, place clean

container under heater openings to catch

coolant.

Loosen clamp and disconnect hose (para 11-27).

Start up (see TM 9-2320-

273-10).

a. Pull knob (see TM 9-

2320-273-10).

b. When coolant flows from

heater, push knob back in.

c. Immediately connect hose

to heater. Tighten clamp.

d. Pull knob out again.

a. With engine running, check

for leaks.

4-200
TM 9-2320-273-20

COOLING SYSTEM.

4-50. HEATER CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-201
TM 9-2320-273-20

COOLING SYSTEM.

4-51. WATER PUMP BELT MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (5)

c. Adjustment. (1)

11 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-44A. Fan Removed.

4-45A. Fan Belts Removed.

TEST EQUIPMENT

Belt Tension Gage.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCE (TM)

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

None.

4-202
TM 9-2320-273-20

COOLING SYSTEM.

Loosen.

Loosen.

Take off. Fan belts and fan must

be removed first.

4-51. WATER PUMP BELT MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

 A. REMOVAL.

1. Idler pulley locknut

(2) and washer (3).

2. Idler belt adjusting

screw (1).

3. Idler belt (4).

4-203
TM 9-2320-273-20

COOLING SYSTEM.

4-51. WATER PUMP BELT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

4. Idler belt (4). Put on over idler pulley Do not force belt on with

(7), water pump pulley (6), screwdriver.

and accessory drive (5).

C. ADJUSTMENT.

5. Idler belt adjust- Adjust until belt tension

ing screw (1). is 90/100 on belt tension

gage.

6. Idler pulley locknut Tighten 50 Ib-ft (68 N-m)

(2). with torque wrench.

N OTE

Follow-on maintenance action required:

Install and adjust fan belts; refer to

4-45B and C.

Install fan; refer to para 4-44B and C.

4-204
TM 9-2320-273-20

COOLING SYSTEM

4-51. WATER PUMP BELT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-205
TM 9-2320-273-20

COOLING SYSTEM.

4-52. WATER MANIFOLD MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (25)

b. Inspection.

c. Installaticm.

( 5)

(30)

60 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All.

TEST EQUIPMENT

SPECIAL TOOLS

None.

MATERlALS/PARTS (P/N)

O-Rings (4) (5330-00-506-4874).

Sealing Rings (6) (5330-00-143-8369).

Gasket (3011931) (15434).

Gasket (208132) (15434).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCE (TM)

TM9-2320-273-20P.

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

4-42A. Coolant Drained below

Manifold Level.

4-46A. Fan Clutch Actuator

Removed.

5-73A. Water Temperature Switch

Wire Removed.

4-25A. Air Cleaner Assembly

Removed.

4-27A. Turbo Air Inlet Removed.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

None.

4-206
TM 9-2320-273-20

COOLING SYSTEM.

4-52. WATER MANIFOLD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 A. REMOVAL.

1. Return hose (3) and a. Loosen clamp.

radiator hose (5). b. Disconnect hose.

4-207
TM 9-2320-273-20

COOLING SYSTEM.

4-52. WATER MANIFOLD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

2. Transfer tube (9). a. Remove capscrew (1).

b. Remove tube (9).

3. Deaeration line (4) heater Remove from front manihose (2), air compressor fold (10).

line (7), and hose (8).

4. Four capscrews (25) Unscrew and remove

and washers (26). thermostat housing (6).

5. Rear manifold (32), a. Unscrew and remove Examine O-rings and sealtwo O-rings (29), coupling capscrews and washers.

(30), two sealing rings (28),

ing rings as you remove

b. Remove rear manifold them. Leaks may sometimes

four capscrews (12),and and coupling. be repaired by replacing

washers (11). c. Throw away sealing broken or damaged rings.

rings and O-rings.

6. Cencer manifold (31), a. Unscrew and remove Examine O-rings and sealcoupling (30), two O-rings capscrews and washers.

(29), sealing rings (28),

ing rings as you remove

b. Remove center manifold them. Leaks may sometimes

four capscrews (12),and and coupling, be repaired by replacing

washers (11). c. Throw away O-rings broken or damaged rings.

and sealing rings.

7. Front manifold (10), a. Unscrew and remove Examine sealing rings as

gasket (27), two sealing capscrews and washers. you remove them. Leaks

(18), four capscrews (12), b. Remove front manifold. may sometimes be repaired

and washers (11). c. Throw away gasket and by replacing broken or

sealing rings. damaged rings.

8. Hose nipple (17) and Unscrew and remove.

connector (16).

9. Two capscrews (13), two Unscrew and remove.

capscrews (15), and four

washers (14).

10. Two capscrews (20) and Unscrew and remove Discard gasket (19)and (24).

capscrews (22). water transfer connection

(18), gasket (19), bracket

(21), water inlet connection

(23), and gasket (24).

4-208
TM 9-2320-273-20

COOLING SYSTEM.

4-52. WATER MANIFOLD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-209
TM 9-2320-273-20

COOLING SYSTEM.

4-52. WATER MANIFOLD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS r

B. INSPECTION.

11. Front manifold (10), center

manifold (31), rear manifold

(32), two couplings (30),

thermostat housing (6),

engine block (33), water

transfer connection (18), and

water inlet connection (23).

 C. INSTALLATION.

12. Hose nipple (17) and

connector (16).

13. New gasket (19) and water

transfer connection (18).

14. New gasket (24), water

inlet connection (23), and

bracket (21).

a. Inspect mating surfaces

for:

1. Burrs.

2. Cracks.

3. Distortion.

b. Inspect manifolds and

couplings for:

1. Cracks.

2. Leaks.

3. Discoloration.

Screw into water transfer

connection (18).

Install to water pump with

two capscrews (13), two

capscrews (15), and four

washers (14).

Mount to water transfer

connection (18) as shown

and to side of engine with

two capscrews (20) and

one capscrew (22).

Replace as necessary.

4-210
TM 9-2320-273-20

COOLING SYSTEM.

4-52. WATER MAN I FOLD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

)

4-211
TM 9-2320-273-20

COOLING SYSTEM.

4-52. WATER MANIFOLD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

Front manifold (10), and

two new sealing rings (28).

Four capscrews (12)

and washers (11).

Coupling (30), two new 0-

rings (29), center manifold

(31) and two new sealing

rings (28).

Four capscrews (12) and

washers (11).

Rear manifold (32), two new

O-rings (29), coupling (30),

and two new sealing rings (28)

Four capscrews (12) and

washers (11).

Twelve capscrews (12).

New gasket (27) and thermostat housing (6).

Four capscrews (25) and

washers (26).

Deaeration line (4) and

heater hose (2).

Air compressor line (7).

Return hose (3), radiator

hose (5) and hose (8).

Transfer tube (9).

Place in position on engine

block (33).

Screw on finger tight.

Place in position against

front manifold (10) and

engine block (33).

Screw on finger tight.

Place in position on

engine block (33) against

center manifold (31).

Screw on finger tight.

Tighten to 35 Ib-ft (47

N-m) with torque wrench.

Set in place.

Install and tighten.

Screw into front manifold

(10).

Install and tighten.

Attach to front manifold

(10) and tighten clamps.

Install to front manifold

(10) with capscrew (1).

Alternate to tighten down

evenly.

4-212
TM 9-2320-273-20

COOLING SYSTEM.

4-52. WATER MANIFOLD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Follow on maintenance required:

Install water temperature switch wire; refer

to paragraph 5-73B.

Install fan clutch actuator; refer to paragraph 4-46C.

Install air cleaner and turbocharger air intake;

refer to paragraph 4-25D & 4-27C.

Refill cooling system and check for leaks;

refer to paragraph 4-42C & D.

4-213
TM 9-2320-273-20

COOLING SYSTEM.

4-53. WATER PUMP MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Installation. (15)

30 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-44A. Fan Removed.

TEST EQUIPMENT 4-45A. Fan Clutch and Belts

None. Removed.

4-51A. Water Pump Belts Removed.

SPECIAL TOOLS 4-42A. Coolant Drained.

None.

MATERIALS/PARTS (P/N)

Gasket, Water Pump to

Engine Block (5330-01-066-5350).

Gasket, Water Pump to

Heater Manifold, 208132 (15434).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 4-1.

4-214
TM9-2320-273-20

COOLING SYSTEM.

4-53. WATER PUMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-215
TM 9-2320-273-20

COOLING SYSTEM.

4-53. WATER PUMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1.

2.

3.

4.

5.

6.

7.

8.

Adjusting screw (4).

Idler pulley (7).

Two capscrews (1) and

washers (2).

Four capscrews and

washers (3).

Two capscrews and

washers (9).

Capscrew (14). Iockwasher

(13), and clamp (12).

Four capscrews and

washers (10).

Water pump (8) and gaskets.

 B. INSTALLATION.

Remove.

Remove hex nut (5) and lockwasher (6) and remove idler

pulley from water pump (8).

Loosen and remove.

Loosen and remove.

Loosen and remove.

Unscrew and remove.

Unscrew and remove.

a. Remove from engine

bypass tube (11 ).

b. Throw away gaskets.

and

9.

10.

11.

12.

13.

14.

Water pump (8) and new

gaskets.

Four capscrews and

washers, (10).

Capscrew (14). Iockwasher

(13), and clamp (12).

Two capscrews and washer_,

four capscrews and washers (3).

Two capscrews (1) and

washers (2).

Idler pulley (7).

Put in position on bypass

tube (11) and engine.

Install and tighten to 35

Ib-ft (47 N-m).

Install and tighten securely,

Install and tighten to 35

Ib-ft (47 N-m).

Install and tighten securely.

Install in water pump (8)

and secure with hex nut

(5) and Iockwasher (6).

Do not tighten.

4-216

A. REMOVAL .
TM 9-2320-273-20

COOLING SYSTEM.

4-53. WATER PUMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

15. Adjusting screw (4). Install. No specific adjustment

needed at this time.

NOTE

Follow-on maintenance action required:

install water pump belt; refer to para 4-51 B and C.

Adjust water pump belt; refer to para 4-51C.

Install fan clutch; refer to para 4-45C.

Install fan belt; refer to para 4-45C.

Install fan; refer to para 4-44B.

Replenish coolant and check for leaks, refer

to para 4-42C and D. Fill with arctic anti

freeze if sub zero.

4-217
TM 92320273-20

COOLING SYSTEM.

-54. WATER PUMP IDLER PULLEY MAINTENANCE.

HIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

Removal. (10)

Installation. (10)

Operational Check. ( 5)

25 Minutes Total.

NIlTIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

None.

GENERAL SAFETY INSTRUCTIONS

None.

4-218
TM9-2320-273-20

COOLING SYSTEM.

Loosen and remove.

Remove.

Remove.

4-54. WATER PUMP IDLER PULLEY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 A. REMOVAL.

1. Nut (3) and washer

(2).

2. Idler belt adjusting

screw (l).

3. Idler pulley (4).

4-219
TM 9-2320-273-20

COOLING SYSTEM.

4-54. WATER PUMP IDLER PULLEY MAINTENANCE (Continued}.

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

4.

5.

6.

7.

Idler pulley (4).

Idler belt adjusting screw (1).

Washer (2) and nut (3).

Belt (5).

C. OPERATIONAL CHECK.

8. Engine.

9. Idler pulley (4).

10, Engine.

Set into place.

Install.

Screw on finger tight.

a.

b.

Adjust belt tension with

adjusting screw (1 ) until

belt tension gage reads

90/100.

Tighten locknut (3) to

50 Ib-ft (68 N-m) with

a torque wrench.

Start up (see TM 9-2320-

273-10).

Be sure to stay completely clear of fan blades.

Do not reach into fan area while engine is

operating.

Check that belt rides

smoothly on pulley and

that pulley is not slipping.

Shut down (see TM 9-2320-

273-10).

4-220
TM9-2320-273-20

COOLING SYSTEM.

4-54. WATER PUMP IDLER PULLEY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4-221
TM9-2320-273-20

ALTERNATOR DRIVE SYSTEM.

4-55. ALTERNATOR BELTS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (5)

c. Adjustment. (1)

11 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

Belt Tension Gage.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

None.

4-222
TM9-2320-273-20

ALTERNATOR DRIVE SYSTEM.

4-55. ALTERNATOR BELTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Alternator capscrews Loosen.

(6) and (9).

2. Adjusting nut (3). Loosen.

3. Adjusting nut (2). ‘ Loosen to allow alternator

(8) to slide towards engine

along adjusting rod (11),

enough to remove alternator

belts (5).

4. Two alternator belts (5). Take off. The belts are a

matched set.

4-223
TM9-2320-273-20

ALTERNATOR DRIVE SYSTEM.

4-55. ALTERNATOR BELTS MAINTENANCE (Continued),

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

5. Alternator belts (5). a. Put onto alternator Do not pry on with

pulley (7) and vibra- screwdriver. Always

tion damper (4), replace belts as a set.

b. Push alternator Never put on just one

away from engine new belt.

until belts stop the

travel of alternator.

C. ADJUSTMENT.

6. Adjusting nut (2). Tighten against adjusting A used belt is one

rod collar (10) until belt that has been on the

tension is 110 Ibs for new truck more than a

belts, or 80 Ibs for used thousand miles.

belts.

7. Jam nut (1) Tighten against collar (10).

8. Adjusting nut (3). Tighten against adjusting

nut (2).

9. Alternator capsrews Torque to 30 Ib-ft (41 N-m).

(6) and (9).

4-224
TM 9-2320-273-20

CHAPTER 5

ELECTRICAL AND INSTRUMENTATION SYSTEMS MAINTENANCE

5-1. OVERVIEW.

This chapter provides you with the following information related to electrical and instrumentation

systems maintenance:

a. All required special tools and equipment,

b. Other technical manuals.

c. Troubleshooting procedures.

d. Maintenance procedures.

Section I REPAIR PARTS, SPECIAL TOOLS, TMDE AND SUPPORT EQUIPMENT

5-2. COMMON TOOLS AND EQUIPMENT .

For authorized common tools and equipment, refer to the Modified Table of Organization and

Equipment (MTOE) applicable to your unit.

5-3. SPECIAL TOOLS, TMDE, SUPPORT EQUIPMENT.

The special tools, TMDE and support equipment required for the electrical and instrumentation

maintenance procedures described in this chapter are limited to the test meters shown in para 5-6.

5-4. SPARES AND REPAIR PARTS.

Spares and repair parts are listed and illustrated in the Repair Parts and Special Tools List

covering Organizational Maintenance for this equipment (TM 9-2320-273-20P).

5-1
TM 9-2320-273-20 

Section II TROUBLESHOOTING

5-5. INTRODUCTION.

a. Scope. This section contains detailed troubleshooting information for locating and

correcting malfunctions in the electrical system. Each of the functional subsystems is treated

separately by means of:

(1) A physical and functional description.

(2) A circuit schematic.

(3) A brief overall subsystem check.

(4) Step-by-step test to diagnose problems using authorized test equipment,

b. Subsystem Circuits. The functional subsystem circuits covered in this section are

in the followlng sequence:

presented

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(1o)

(11)

(12)

(13)

(14)

Battery (table 5-1 ).

Starting (table 5-2).

Ether Quick-Start Control (table 5-3).

Engine Retarder Control (table 5-4).

Battery Charging (table 5-5).

Warning Lamps and Alarms (table 5-6).

Instruments and Indicators (table 5-7).

Headlamps (table 5-8).

Marker Lamps (table 5-9).

Parking and Tail Lamps (table 5-10).

Stop and Turn Signal Lamps (table 5-11).

Backup Lamps (table 5-12).

Blackout Lighting System (table 5-13).

Miscellaneous Electrical (table 5-14).

c. General Troubleshooting Procedures. The following procedures are general “in nature and

should be applied as appropriate during any electrical troubleshooting.

(1) Research the problem. Before you start detail troubleshooting procedures, review

the wiring diagram and schematic (Appendix D) to thoroughly familiarize yourself with the circuit(s)

involved. Analyze the symptoms and conditions and use common sense and logic to determine the

most likely cause for the problem, then troubleshoot that circuit first. The more information you

have concerning the problem, the easier it will be to troubleshoot.

—/

5-2
TM 9-2320-273-20

5-5. INTRODUCTION (Continued).

(2) Genera/ Approach. First, isolate to the subsystem level (in cases where more than

one subsystem IS involved); next, isolate the problem to a single circuit within the subsystem; then

isolate the problem to the faulty component. An example of-an exception to this rule would be in

cases where a lamp is out; the first step would be to check the bulb.

(3) Wiring. Frayed, broken, loose, or corroded wiring is a common source of problems

in any electrical circuit. Always make a visual inspection before starting detail troubleshooting.

-- Observe in particular, contacts to ground. Components with case grounds are especially troublesome.

(4) Circuit Breakers.

Never jumper a cycling circuit breaker unless specifically instructed to do

so in the troubleshooting procedure. The overload could cause serious

damage to equipment and result in a fire.

The circuit breakers in these circuits are the automatic recycling type. If an overload exists, the

circuit breaker will open and shut off all circuits being fed by that particular circuit breaker. After

cooling, the circuit breaker will close. If the problem still exists the circuit breaker will again open.

This cycle will continue until the problem is corrected. When a circuit breaker is cycling, it will

feel warm to the touch and you can hear a clicking sound.

(5) Re/ays. A relay is basically a two-element device – a coil and a set of contacts in a

common housing. When voltage is applied to the coil, the contacts close (normally open relay) or

open (normally closed relay). The relay provides a path of supply voltage to a circuit or component

which draws a heavy current load. In troubleshooting, first be sure the coil is functioning. Connect

a multi meter between frame ground and the hot side of the coil and check for 12 volts dc nominal.

If voltage is present, disconnect the multi meter and measure voltage across any set of contacts with

the coil voltage present. The meter should indicate either 12 or 24 volts dc nominal depending on

the circuit involved. Sometimes it is advantageous to simply jumper across the relay contacts and

if the inoperative circuit being checked works, a bad relay or voltage supply wiring is indicated.

5-3
TM 9-2320-273-20

5-6, TEST EQUIPMENT. 

a. /introduction. I n automotive troubleshooting, the Simpson 160, the TS-352B/U, and the

AN/URM-105 will do the same job. Therefore, your automotive shop sets may contain any one of

these multi meters (fig. 5-1). Any of these three multi meters can be used to troubleshoot the

electrical system.

5-4
TM 9-2320-273-20

5-6. TEST EQUIPMENT (Continued).

b. Using the Ohms Seale. The Ohms Scale (fig. 5-2 thru fig, 5-4) is used to make tests for

continuity, shorts, and resistance. The multi meter must be set up and “zeroed” before making

these tests. Do the following steps that match the multi meter you have:

Figure 5-2. Using the Ohms Scale and “Zeroing” Multimeter AN/URM-105

NOTE

If needle will not “zero,” replace the batteries.

If the needle still will not “zero” after replacing the batteries, turn the meter in for repair.

TA 074691

5-5
TM 9-2320-273-20

5-6. TEST EQUIPMENT (Continued).

Figure 5-3. Using Ohms Scale and “Zeroing” Multimeter TS-352 B/U

NOTE

If needle will not “zero”, replace the batteries. If the needle will not

“zero” after replacing the batteries, turn the meter in for repair.

TA 074692

5-6
TM 9-2320-273-20

5-6. TEST EQUIPMENT (Continued).

SIMPSON 160

(1)

(2)

(3)

until needle is

Set selector switch on “RX1”.

Put black probe in “COM-” jack.

Put red probe in “+” jack.

Now “zero” the meter. While touching the probes together, turn “ADJ” knob

over the “0” on the top scale.

Figure 5-4. Using Ohms Scale and “Zeroing” Multimeter Simpson

NOTE

160

If the needle will not “zero”, replace the batteries, If the needle still will

not “zero” after replacing the batteries, turn the meter in for repair.

TA 074693

5-7

(4)
TM 9-2320-273-20

5-6. TEST EQUIPMENT (Continued).

c. Continuity Tests. Continuity tests are made to check for breaks in a circuit (such as the

switch, light bulb, or electrical cable illustrated). To make a continuity check (’Fig. 5-5), do the

following steps:

Failure to perform the following step can damage the multimeter.

(1) Disconnect the circuit being tested. To be safe, disconnect the battery ground strap.

(2) Set up and “zero” the multimeter.

(3) Connect the meter probes to both terminals of the circuit being tested. (The

TS-352B/U is illustrated below, but the probes are connected to the circuit the same way with each

of the three multi meters.)

Figure 5-5. Making a Continuity Check

(4) Look at the meter needle.

(a) If the needle swings to the far right over the “O” on the top scale (on all

three multimeters), the circuit has continuity.

(b) If the needle doesn’t move, the circuit is open (broken).

(c) If the needle jumps or flickers, there is a loose connection in the circuit being

tested,

TA 074694

5-8
TM 9-2320-273-20

5-6. TEST EQUIPMENT (Continued).

d. Testing for Shorts. A short (or short circuit) occurs when two circuits that should not be connected have metal-to-metal contact with each other. A short also occurs when a circuit that should not

touch ground has metal-to-metal contact with ground. To check for shorts, do the following steps:

Failure to do the following step can damage the multimeter.

(1) Disconnect the circuit being tested. TO be safe, disconnect the battery ground cable.

(2) Set UP and “zero” the multimeter (para b.).

(3) Wiith any of the three multimeters, connect one probe to one circuit and the other

probe to the other circuit or ground (if checking for a short to ground). Figure 5-6 shows a check

to see if wire “A” is shorted to wire “B” in the wiring harness.

Figure 5-6. Testing for Shorts

(4) Look at the needle.

(a) If the needle swings to the far right over the “O” on the top scale (on all three

multi meters), the circuits are shorted.

(b) If the needle doesn’t mover the circuits are not shorted.

(c) If needle jumps or flickers, the circuits are occasionally shorted.

e. Testing Resistance. To measure resistance in a circuit do the following steps.

Failure to do the following step can damage the multimeter.

TA 074695

5-9
TM9-2320-273-20

 5-6. TEST EQUIPMENT (continued). 

(1) Disconnect the circuit being tested. To be safe, disconnect the battery ground cable.

(2) Set up and “zero” the multimeter (para b).

(3) If the test in this manual calls for an “Ohms Range” different than “RX” or “Xl,”

set the selector switch to that range (like “RX10” or “X10”).

NOTE

“ZERO” the meter whenever you change ranges.

(4) With any of the three multimeters, connect the probes across the circuit or item to

be measured. Figure 5-7 below shows measuring the resistance of a temperature sending unit:

(5) Read the meter. If the meter switch is on the “RX1” or “X1” range, the reading is

taken directly from the top scale. If the meter switch is on a different range, (fig. 5-8), multiply

the reading on the scale according to the table below.

OHMS SWITCH

SETTING. YOU DO!

X1 or RX1. READ NUMBER ON SCALE.

X10 OR RX10 MULTIPLY READING BY 10.

X100 OR RX 100. MULTIPLY READING BY 100.

X1K OR RX1K. MULTIPLY READING BY 1000.

X10K OR RX10K. MULTIPLY READING BY 10,000.

(REMEMBER: K = 1000)

Figure 5-8. Ohms Switch Settings

TA 074696

5-10
 5-6. TEST EQUIPMENT (Continued). 

For example, the meters in

TM 9-2320-273-20

fig, 5-9 below show the following readings:

OHMS SWITCH READING.

SETTING.

X1 OR RX1. 4 OHMS.

X10 OR RX10. 40 OHMS.

X100 OR RX100. 400 OHMS.

Figure 5-9. OHMS Switch Settings

f. Using the DC Volts Sea/e. The dc volts scale is used to measure all voltages in the electrical

system.

Before using the multi meter to measure dc voltage, do the following steps that match the multimeter you have (fig. 5-10 thru fig. 5-1 2).

(7) AN/URM-105

Set meter switch to dc volts range given in TM.. (To measure 24 volts dc, set switch

on “100 DC VOLTS” range. )

Figure 5-10. Using the DC Volts Scale AN/URM-105 TA 074697

5-11
TM 9-2320-273-20

 5-6. TEST EQUIPMENT (Continued).

(2) TS-352 B/U

(a) Set FUNCTION switch (1) to DIRECT (range switch can be at any position).

(b) Put black lead in “DC/* AC/OHMS” jack (2).

(c) To measure 24 volts dc, plug red lead into “50V” jack on left side of meter (3).

(If measuring less than 10 volts dc, use “10V” jack, If measuring less than 2.5

volts dc, use “2.5V” jack.)

Figure 5-11. Setting the Function Switch TS-352 B/U

(3) SIMPSON 160

(a) Connect black lead to COM- jack.

(b) Connect red lead to+ jack.

(c) TO measure 24 volts dc, set selector switch to V/DC 50 position. (If measuring

less than 10 volts dc, set selector switch to V/DC 10 position. If measuring less

than 2.5 volts dc, set selector switch to V/DC 2.5 position. )

Figure 5-12. Setting the Function Switch Simpson 160 TA 074698

5-12
TM 9-2320-273-20

5-6. TEST EQUIPMENT (Continued).

will protect the meter.

g. Measuring DC Voltage. To measure dc volts (fig. 5-13), do the following steps:

(1) Set up multimeter (see para f).

NOTE

If you are not sure of the voltage to be measured on the vehicle, always

start on the highest range shown in para f. This will protect the meter,

(2) With any of the three multimeters, connect the red probe to the positive (+) side of

the circuit and the black probe to the negative (-) side. The example below shows 24 volts dc being

measured across the batteries.

Figure 5-13. Measuring DC Voltage

(3) Read the meter. (Figures 5-14 thru 5-16 show how to read all three multi meters.)

If the needle tries to move off scale to the left, reverse the probes on the circuit.

TA 074699

5-13
TM 9-2320-273-20

5-6. TEST EQUIPMENT (Continued).

(a) AN/URM-105

Read the upper, black, straight-lined portion of the AC and DC VOLTS scale

for the range the selector switch is set at:

SWITCH SETTING. SCALE.

1000 DC VOLTS. 0.10 (AND MULTIPLY BY 100).

100 DC VOLTS. 0.10 (AND MULTIPLY BY 10).

10 DC VOLTS. 0.10.

1 DC VOLT. 0.10 (AND MULTIPLY BY 10).

Thus the meter iIIustrated is showing

SWITCH SETTING. READING.

100 DC VOLTS. 20 VOLTS DC.

10 DC VOLTS. 2 VOLTS DC.

1 DC VOLT. .2 VOLTS DC.

the following readings:

Figure 5-14. Reading DC Volts Scale AN/URM-105

TA 074700

5-14
TM 9-2320-273-20

5-6. TEST EQUIPMENT (Continued).

(b) TS-352 B/U.

Read the DC volts scale for the range the red lead is plugged in at:

RANGE. SCALE.

50V. 0.5 (AND MULTIPLY BY 10).

10V. 0.10.

2.5V. 0.2.5.

Thus the meter illustrated is showing the following readings:

I

RANGE. READING.

I

50V. 20 VOLTS DC.

10V. 4 VOLTS DC.

2.5V. 1 VOLT DC.

Figure 5-15. Reading DC Volts Scale- TS-352 B/U

(c) SIMPSON 160

Read the “DC VOLTS” scale for the range the selector switch is set at:

SWITCH SETTING. SCALE.

V/DC 50. 0.50.

V/DC 10. 0.10.

V/DC 2.5. 0.25 (AND DIVIDE BY 10).

Thus the meter illustrated

SWITCH SETTING. READING.

V/DC 50. 20 VOLTS DC.

V/DC 10, 4 VOLTS DC.

V/DC 2.5. 1 VOLT DC.

is showing the following readings:

Figure 5-16. Reading DC Volts Scale - Simpson 160 TA 074701

5-15
TM 9-2320-273-20

5-7. BATTERY SYSTEM.

a Description. Four 12-volt, heavy-duty, maintenance-free batteries, (fig. 5-1 7) are located

in an enclosure in the right-hand frame rail under the cab. The batteries are connected in a seriesparallel combination to provide 24 volts for engine starting plus trailer lighting, and 12 volts for

operation of all of the electrical equipment on the vehicle. Water never needs to be added to the

maintenance-free batteries. There are no vent plugs in the cover. The batteries are completely

sealed except for a small vent hole in the side. The test indicator in the cover can be used to

determine if the battery is charged to the proper level for testing.

-

Figure 5-17. Battery System

TA 074702 

5-16
TM 9-2320-273-20

5-7. BATTERY SYSTEM (Continued).

b. Test Indicator. The test indicator is a built-in hydrometer in one cell which provides

visual information for battery testing only. The test indicator will give correct indications

only when the battery is relatively level and the top is clean. Under normal conditions, the

indicator displays either green or dark to indicate readiness of battery for testing.

(1) Green dot visible. Any green appearance is interpreted as a green dot,

which means the battery is ready for testing. On rare occasions following prolonged

cranking, the green dot may still be visible. If this should occur, the battery needs

charging.

(2) Dark green (dot not visible). The battery needs to be charged prior to testing. On rare occasions the test indicator may turn light yellow. In this case, the battery must

be replaced and the vehicle charging system should be checked out.

Do not charge, test, or jump start a battery when a light yellow color

appears in the test indicator as the battery may explode, squirt electrolyte from the vent hole, and/or damage the charging system of this

vehicle.

c. The negative terminals of the battery combination (fig. 5-18) are connected to the ground

connector of the starting motor and from there to the engine, tractor frame, and cab (ground).

The 24-volt cable of the battery combination is connected to the starting solenoid relay. When

the relay contacts are closed, 24-volt power is routed to the starter motor. The 12-volt cable

is connected to the alternator and to two circuit breakers for 12-volt distribution.

5-17
TM 9-2320-273-20

Table 5-1 Battery System Troubleshooting.

F

L E

A T

M S INSTRUCTION INDICATION YES NO REMARKS

1 ALL ELECTRICAL

SYSTEMS ARE

WEAK.

1 Inspect battery ter- a. Loose. Tighten.

minals.

b. Corroded or dirty. Clean. Go to

Step 2.

2 Inspect battery cases. a. Cracked or broken. Replace Go to

(para 5-38). Step 3.

‘3 Inspect cables. a. Frayed or broken. Replace

(para 5-39).

b. Corroded. Clean Go to

Step 4.

4 Check battery test a. Green. Test

indicators. (Malf 2,

Step 2).

b. Dark. Charge

(para 5-38).

c. Yellow Replace Troubleshoot

(para 5-38). charging system

(table 5-5).

NOTE

A defective battery in the series par:

allel configuration will adversely

affect the charge of the other

batteries.

2 ENGINE FAILS TO CRANK OR CRANKS SLOWLY.

1 Check battery test a. Green. Test

indicators. (para 5-38).

b. Dark. Charge

(para 5-38).

c. Yellow. Replace Troubleshoot

(para 5-38). charging system

(table 5-5).

2 Test batteries under

load.

a. Disconnect connector on fuel

shutoff valve.

5-18

P
TM 9-2320-273-20

2

3

P

E

T- S—

2

1

Table 5-1. Battery System Troubleshooting (Continued).

INSTRUCTION INDICATION YES NO

ENGINE FAILS TO CRANK OR CRANKS SLOWLY (Continued).

Test batteries under

load (Continued).

b. Crank engine for

approximately 15

seconds to remove

battery surface

charge.

c. Connect a multimeter as shown in

Figure 5-18.

d. Have an assistant

crank the engine

for 15 seconds.

e. Observe voltmeter.

f. Disconnect the

battery cables and

jumper to a known

good source, such

as another vehicle.

g. Connect the multimeter as before,

except on the

jumper batteries.

h. Have an assistant

crank the engine

for 15 seconds.

i. Observe voltmeter.

24 volts DC nominal. Troubleshoot starting circuit

table 5-2).

NOTE

f the engine will not crank, perform the

Remove

and test

each battery (para

5-38).

following steps,

24 volts DC nominal.

BATTERIES DO NOT HOLD A CHARGE.

Check vehicle lights. On.

Troubleshoot starting circuit

(table 5-2).

Turn Off.

Remove

and test

each battery (para

5-38).

Go to step

REMARKS

5-19
TM 9-2320-273-20

Table 5-1. Battery System Troubleshooting (Continued).

INSTRUCTION INDICATION YES

BATTERIES DO NOT HOLD A CHARGE (Continued).

Check for shorts to

ground as follows:

a.

b.

c.

d.

e.

f.

9.

Disconnect battery

ground cable at

battery.

Set multimeter to

at least 30 volts

DC.

Turn off all electrical systems.

Connect red test

lead to disconnected ground

cable and black

test lead to the

battery negative

terminal.

Observe meter.

Disconnect connector to each circuit breaker, one

at a time, until

meter drops to

o volt.

Disconnect devices

on that circuit one

at a time until

meter drops below

4 volts.

Any voltage indication

0 voltage indication.

0 voltage.

Go to Step

Check wire

connection.

Replace

defective

component.

Go to Step

g.

5-20

NO REMARKS

f .
TM 9-2320-273-20

Table 5-1. Battery System Troubleshooting (Continued).

Figure 5-18. DC Voltage Tests

5-21
TM 9-2320-273-20

5-8. STARTING SYSTEM CIRCUIT.

a. Description (fig. 5- 79). The starting system consists of two sets of 12-volt batteries

(connected in series/parallel to provide 24 volts for starting), a starter motor and solenoid, a starter

relay, a neutral safety switch, a key switch (ENGINE RUN), and a start button. When the ENGINE

RUN switch is turned ON, the fuel solenoid valve is opened and power is applied to one side of the

ENGINE START switch. When the transmission ratio selector is in neutral (N) (closing the neutral

safety switch), the starter relay is energized and 24 volts dc is applied to the starter solenoid coil.

Starter solenoid contacts then close and apply 24 volts to the starter motor. When the engine starts,

an overrunning clutch in the starter motor allows the motor to run free until the ENGINE RUN

switch is released, thus removing 24-volt power from the starter motor.

b. Troubleshooting the Starting System Circuits. When you suspect a starting system circuit

problem, perform the steps in table 5-2.

Figure 5-19. Starting System Circuit (Simplified Schematic)

5-22
TM 9-2320-273-20

1

2

3

4

5

Table 5-2. Starter System Circuit Troubleshooting.

INSTRUCTION INDICATION YES NO REMARKS

STARTER FAILS TO CRANK OR CRANKS TOO SLOWLY.

Turn on ignition key Normal reading. Go to Step 2. Troubleswitch and check shoot batvoltmeter tery charg-

(TM 9-2320-273-1 O). ing circuit

(para 5-11).

Push engine run Thump. GO to Step 4. Check

button and have an wiring to

assistant listen for starter

heavy thump of the relay. Go to

solenoid switch on Step 3.

the starting motor.

Push engine run Click. Go to Step 4.

button and have an

assistant listen for a

click of the starter

relay located behind

the center of the

instrument panel.

Feel all battery,

starter, and starter

relay terminals.

Check starting solenoid switch with

multi meter as shown

(figure 5-20), while

cranking engine.

Excessive heat.

24 volts (nominal).

Repair or replace cables

or connectors.

Replace

motor and/

or solenoid

switch

(para 5-32).

Check

wiring to

START

switch. Go

to Step 4.

Go to Step

5.

Go to Step

6.

5-23
TM 9-2320-273-20

Table 5-2. Starter System Circuit Troubleshooting (Continued).

Figure 5-20. Starting Solenoid Switch Checks

5-24
TM 9-2320-273-20

Table 5-2. Starter System Circuit Troubleshooting (Continued).

5-25
TM 9-2320-273-20

Table 5-2. Starter System Circuit Troubleshooting (Continued).

5-26
TM 9-2320-273-20

Table 5-2. Starter System Circuit Troubleshooting (Continued).

INSTRUCTION INDICATION YES NO REMARKS

STARTER FAILS TO CRANK OR CRANKS TOO SLOWLY (Continued).

a. Check operation of

the ENGINE RUN

switch with multimeter as shown in

(figure 5-23). Check

for 12 volts nominal

on the side of the

switch that is wired

to the starter relay

while pushing the

button.

b. Check wiring.

Refer to wiring

diagram and

schematic in

Appendix D.

12 volts nominal. Go to

Step 9.

Check wirin

g starter

relay. Go to

Step 9.

Replace

ENGINE

RUN switch

(para 5-35).

Figure 5-23. ENGINE START Switch Checks

TA 074708

5-27

8
TM 9-2320-273-20

Table 5-2. Starter System Circuit Troubleshooting (Continued).

INSTRUCTION INDICATION YES NO REMARKS

I

STARTER FAILS TO CRANK OR CRANKS TOO SLOWLY (Continued).

Check ENGINE RUN

as

a.

b.

follows:

Remove connector

from back of

ENGINE RUN

switch.

Install jumper wire

as shown in figure

5-24.

Starter motor cranks. Replace

ENGINE

RUN switch

(para 5-35).

Go to

Step 10.

Figure 5-24. ENGINE RUN Switch Checks.

TA 074709

5-28
TM 9-2320-273-20

Table 5-2. Starter System Circuit Troubleshooting (Continued).

INSTRUCTION INDICATION YES NO REMARKS

1 STARTER FAILS TO CRANK OR CRANKS TOO SLOWLY (Continued).

10 Check for loose con- Loose. Tighten.

nections between

batteries and the

ENGINE RUN Defective. Repair or

switch (circuits shown replace.

in figure 5-25).

Figure 5-25. Starting Circuit to ENGINE RUN switch.

2 STARTING MOTOR IS NOISY AND ENGAGEMENT IS ERRATIC.

1 Replace motor and

solenoid switch

assembly (para 5-32).

TA 074710

5-29
TM 9-2320-273-20

5-9. ETHER QUICK-START CONTROLS. 

a. Description (fig. 5-26). The ether injection solenoid valve is opened to allow ether to flow

from the storage canister into the intake manifold when the ETHER button is pushed and released and

the ether temperature switch is closed (engine coolant temperature is less than 50°F (10°C).

b. Troubleshooting Perform the steps in table 5-3 to isolate faulty components of the ether

quick-start controls.

Figure 5-26. Ether Quick-Start Electrical Circuit

5-30
TM 9-2320-273-20

1

2

3

4

5

6

Table 5-3. Ether Quick Start Control Circuit Troubleshooting.

INSTRUCTION INDICATION YES NO REMARKS

SOLENOID CANNOT

Check engine coolant

temperature gage.

Check for voltage at

circuit 51 terminal of

ETHER switch.

Check for voltage at

circuit 51A terminal

of ETHER switch.

Check for voltage at

circuit 51B terminal

of solenoid.

Check for voltage at

circuit 51C terminal

of solenoid.

Check for voltage at

terminal of ETHER

temperature switch.

BE HEARD TO CLICK WHEN ETHER BUTTON IS PUSHED.

Below 50°F (10°C). Go to Step

2.

NOTE

The ETHER button must be pushed and

released when performing the following checks.

12 voltage nominal.

12 volts dc nominal.

12 volts dc nominal.

12 volts dc nominal.

12 volts dc nominal.

Go to Step

3.

Go to Step

4.

Go to Step

5.

Go to Step

6.

Replace

witch (para

5-74).

Check circuit breaker

(para 5-5)

and wiring.

Replace

witch

(para 5-74).

Repair

wiring or

connections

Replace

solenoid.

Repair

wiring or

connections

Solenoid is not supposed to work when

coolant is above 50°F

5-31
TM 9-2320-273-20

 5-10. ENGINE RETARDER CONTROLS. 

a. Description. The engine retarder solenoid valves are applied by the foot switch as selected

by the three-position ENGINE RETARDER switch (fig. 5-27). The operator must let up on the foot

throttle to close the throttle position sensing switch.

b. Troubleshooting the Engine Retarder Control. Perform the steps in table 5-4 to isolate

faulty components of the engine retarder circuit.

Figure 5-27. Engine Retarder Control Circuit

5-32 Change 2
TM 9-2320-273-20

Table 5-4. Engine Retarder Control Circuit Troubleshoot ting.

1

2

3

4

5

6

7

INSTRUCTION INDICATION

NO RETARDING ACTION.

With ENGINE RUN 12 volts dc nominal.

switch on, check for

voltage to retarder

foot switch (circuit

52A).

Check for voltage at

circuit 52B terminal

of foot retarder

switch.

Check for voltage at

circuit 52C terminal

of transmission pressure switch.

Check for voltage at

circuit 52D terminal

of transmission pressure switch.

Check for voltage at

circuit 52E terminal

of throttle position

sensing switch.

Check for voltage at

circuit 52F terminal

of throttle position

sensing switch.

Check for voltage at

circuit 52G terminal

of panel ENGINE

RETARDER switch.

YES NO REMARKS

Go to Step 2. Check for

faulty circuit breaker

(para 5-5 C),

NOTE

Before making the voltage checks described in steps 2 through 8, do the

following:

Apply parking brake.

Check system air pressure.

Activate transmission control group.

Put transmission in gear.

Press and hold engine retarder foot pedal

during voltage checks.

12 volts dc nominal.

12 volts dc nominal.

12 volts dc nominal.

12 volts dc nominal.

12 volts dc nominal.

12 volts dc nominal.

Go to Step 3

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 7

GO to Step 8

Replace

switch.

Repair wiring between

52B and

52C.

Drain system air

pressure

and replace

switch.

Repair wiring (52D,

52E) or

connection!

Replace

switch.

Repair wiring (52F,

52G) or

connection:

Change 2 5-33
TM 9-2320-273-20

Table 5-4. Engine Retarder Control Circuit Troubleshooting (Continued).

INSTRUCTION INDICATION YES NO REMARKS

1 NO RETARDING ACTION (Continued).

8 Check for voltage at 12 volts dc nominal. Go to Step 9. Replace

circuit 52H and 52K switch.

terminals of panel

ENGINE RETARDER

switch with switch in

HIGH position,

9 Check for voltage at 12 volts dc nominal. Refer to Di- Repair wireach solenoid valve, rect Support ing (52J,

circuits 52J, 52L Maintenance, 52L, 52M)

and 52M. or connections.

5-34 Change 2
TM 9-2320-273-20

5-11. BATTERY CHARGING CIRCUIT. 

a. Description. Charging of the batteries is accomplished by a 14-volt, 85-ampere, self-load

limiting alternator with an integral transformer rectifier providing 24 volts for the cranking batteries

and 12 volts for other vehicle electrical loads. This system uses two sets of 12-volt batteries in series

to provide 24 volts for cranking. The cranking batteries are charged by the transformer rectifier unit,

and as the load demand on these batteries is cranking only, the 15 amperes available from the transformer rectifier’ is more than sufficient for this application. As the cranking batteries become charged,

the output current gradually drops to approximately one ampere when the terminal voltage of the

battery reaches 13.8 volts (adjustable). The charging circuit is shown in figure 5-28.

Figure 5-28. Battery Charging Circuit

5-35
TM 9-2320-273-20

Table 5-5. Battery Charging Circuit Troubleshooting.

INSTRUCTION INDICATION YES NO REMARKS

BATTERIES ARE BEING UNDERCHARGED OR OVERCHARGED.

1 Check batteries

(table 5-1, malfunction 2, step 2).

2 Check the alternator a. Loose. Tighten Go to Step

drive belts for proper (para 5-43). 3.

tension (para 4-55). b. Damaged. Replace Go to Step

(para 5-43). 3.

3 Check all charging a. Loose. Tighten.

circuit wiring and b. Defective Repair or

connections. replace.

4 Refer to Direct Support Maintenance.

5-36
TM9-2320-273-20

5-12. WARNING LAMPS AND ALARMS .

a. Description. The following warning lamps and alarms are employed in this vehicle series:

(1) ENGINE TEMPERATURE warning lamp.

(2) ENGINE OIL LOW warning lamp.

(3) LOW AIR PRESSURE warning lamp.

(4) BACKUP ALARM (M916 THRU M9ZO).

The ENGINE TEMPERATURE warning lamp is actuated when the water temperature sensing switch

closes (at 225° F, 95°C) if the ignition switch is ON. The ENGINE 0IL LOW warning lamp is actuated

when the engine oil pressure sensing switch closes (at 5 psi, 100 kPa) if the ignition switch is ON. The

LOW Al R PRESSURE warning lamp and buzzer are actuated when the low air switch closes (between

64 and 76 psi) if the ignition switch is ON. The backup alarm goes off when the backup switch is closed

and the ignition switch is ON unless the manual backup alarm override switch is open. The circuits for

these devices are shown in figure 5-29. Wire connection points and wire identification numbers are

indicated.

Figure 5-29. Warning Lamp and Alarm Circuits

5-37
TM 9-2320-273-20

Table 5-6. Warning Lamps and Alarms Circuit Troubleshooting.

INSTRUCTION INDICATION YES NO REMARKS

1 ENGINE TEMPERATURE WARNING LAMP INOPERATIVE.

1 Press START switch. Lamp lights. Replace Replace the

water tem- bulb.

perature

switch (para

5-73).

2 Attach test lead be- Lamp lights. Replace Go to Step

tween the ground side water tem- 3.

of the bulb (circuit perature

6A) and ground and switch (para

turn on the ENGINE 5-73).

RUN switch.

3 Check the ENGINE Lamp lights. Double Check wirlamp when the check the ing to cirENGINE RUN temperature cuit breaker.

switch is ON. switch.

4 Check for faulty cir- 12 volts dc nominal. Repair wir- Replace circuit breaker No. 6 ing (circuits cuit breaker.

with multi meter. 44, 44H,

44J).

2 ENGINE OIL PRESSURE LOW WARNING LAMP INOPERATIVE.

1 Attach test lead be- Lamp lights. Replace the Replace the

tween the ground side switch (para bulb.

of the bulb (circuit 5-71).

54A) and ground and

turn on the ENGINE

RUN switch.

2 Troubleshoot wiring.

LOW AIR PRESSURE’ WARNING LAMP AND/OR BUZZER INOPERATIVE.

NOTE

The air pressure must be below 60 psi to

perform the following check.

Attach a test lead a. Lamp and buzzer Replace the

across both terminals operate. pressure

on the LOW AIR switch (para

PRESSURE switch 5-81).

(located on the fire- b. Lamp only works. Replace the

wall inside cab at

center).

buzzer (para

5-80).

5-38

3
TM 9-2320-273-20

Table 5-6. Warning Lamps and Alarms Circuit Troubleshooting (Continued).

INSTRUCTION INDICATION YES NO REMARKS

3 LOW AIR PRESSURE WARNING LAMP AND/OR BUZZER INOPERATIVE (Continued).

c. Buzzer only works. Replace the

bulb (para

5-61).

d. Neither lamp nor Troublebuzzer operates. shoot wiring

(refer to

schematic in

Appendix D).

4 BACKUP ALARM IS INOPERATIVE.

NOTE

The compressed air system must be within

normal operating pressures to actuate the

backup switch.

1 Verify the backup

alarm override switch

is OFF, and the ENGINE RUN switch is

ON. Place the ratio

selector in one of the

reverse gears.

2 Check for voltage at 12 dc volts nominal. Go to Step Go to Step

the alarm with a 3. 4.

multi meter.

3 Check ground at Bad ground. Repair Replace the

alarm for loose or ground. alarm (para

dirty ground. 5-78).

4 Attach a test lead Alarm operates. Replace Go to Step

across the terminals backup 5.

on the backup switch. switch (para

5-77). /

5‘ Attach a test lead Alarm operates. Replace Go to Step

across the terminals switch. 6.

on the override

switch,

6 Troubleshoot wiring

through circuit

breaker. Refer to

schematic in

Appendix D.

5-39
TM 9-2320-273-20

5-13. INSTRUMENTS AND INDICATORS.]

a. Description. Electrically operated gages and indicators in the cab provide information for

operation as follows:

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

PARK BRAKE lamp.

DIFFERENTIAL LOCKUP lamp.

FUEL LEVEL gage.

POWER TAKEOFF lamp.

WATER TEMP gage.

TRANS OIL TEMP gage.

OIL PRESSURE gage.

VOLTS meter.

TACHOGRAPH (clock).

LAMPS.

The circuits for these items are shown in figure 5-30. Wire connection points and wire identification

numbers are indicated.

.

—

5-40
TM 9-2320-273-20

Figure 5-30. Instrument and lndicator Circuits

5-41
TM 9-2320-273-20

Table 5-7. Instruments and Indicators Circuit Troubleshooting.

1

2

3

1

2

3

INSTRUCTION INDICATION YES

DIFFERENTIAL LOCKUP LAMP INOPERATIVE.

With differential lockup control set to

LOCK, and ENGINE

RUN switch ON

check for voltage to

the lamp using a

multi meter.

Attach test lead

across the differential

lockup control

terminals.

Troubleshoot wiring.

Refer to wire diagram

and schematic in

Appendix D.

PARK BRAKE LAMP

With park brake applied and ENGINE

RUN switch set to

ON, use a multimeter

to check voItage to

the lamp.

Attach test lead

across park brake

switch terminals

(located in instrument

panel near circuit

breaker).

Troubleshoot wiring.

Refer to wiring diagram and schematic

in Appendix D.

12 volts dc nominal.

Lamp lights.

INOPERATIVE.

12 volts dc nominal.

Lamp lights.

Check for

good ground

at bulb.

(Replace

bulb)

(para 5-63).

Replace

differential

lockup control (para

5-83).

Check for a

good ground

at the bulb.

(Replace the

bulb) (para

5-63).

Replace

park brake

switch (para

5-82).

NO

Go to

Step 2.

Go to

Step 3.

Go to

Step 2.

Go to

Step 3.

5-42

REMARKS
TM 9-2320-273-20

3

Table 5-7. Instruments and Indicators Circuit Troubleshooting (Continued).

INSTRUCTION INDICATION YES

INSTRUMENT PANEL GAGES INOPERATIVE.

Check the following

gages: Trans oil temp,

water temp, oil press,

fuel.

a. Using a multi meter

check for voltage at

the gage terminals.

b. Attach jumper

across terminals of

sending unit.

c. Troubleshoot wiring.

Refer to wire diagram and schematic

in Appendix D.

Check volts gage:

a. Using a multi meter

check voltage at

gage terminals.

b. Troubleshoot wiring.

Refer to wire diagram and schematic

in Appendix D.

12 volts dc nominal.

Gage operates.

12 volts dc nominal.

Replace

gage.

Replace

sending unit

Replace

gage.

NO

Go to Step

b.

Go to

Step c.

Go to

Step b.

REMARKS

5-43
TM 9-2320-273-20

4

5

Table 5-7. Instruments and Indicators Circuit Troubleshooting (Continued).

INSTRUCTION INDICATION

TACHOGRAPH CLOCK IS INOPERATIVE.

Check circuit 59 using 12 volts dc nominal.

a multi meter.

Check wiring. Refer to

diagram and schematic

in Appendix D.

lNDICATOR/lLLUMINATION LAMP OUT.

Pull headlamp switch

out.

Check for voltage at

the headlamp switch

using a multimeter.

Check wiring to headlamp switch. Refer to

wire diagram and

schematic in Appendix

D.

For individual lamps

that are out, replace

bulb. Turn on headlamp switch.

Check wiring. Refer to

wire diagram and schematic in Appendix D.

All lamps come on with

headlamp switch at

full out or half way

position.

12 volts dc nominal.

Lamp comes on.

YES

Replace

tachograph

para 5-66)

Go to Step 4

Replace

headlamp

switch

para 5-62).

NO

Go to

Step 2.

Go to

Step 2.

Go to

Step 3.

5-44

REMARKS
TM 9-2320-273-20

5-14. HEADLAMPS.

a. Description (fig. 5-31). The headlamp system uses two sealed-beam lamps which provide

separate and distinct high and low beams. A foot-operated dimmer switch controls the use of the

high or low beam. The headlamp switch on the instrument panel turns the headlamps ON and OFF,

A recycling type circuit breaker in the headlamp switch protects the circuit without a total loss of

the headlamps in case of a short.

b. Troubleshooting the Headlamp Circuit. Perform the steps in table 5-8 to isolate faulty

components of the headlamp circuit.

Figure 5-31. Headlamp Circuit

5-45
TM 9-2320-273-20

1

2

3

1

2

3

4

5

6

Table 5-8. Headlamp Circuit Troubleshooting

INSTRUCTION INDICATION YES NO

BOTH HEADLAMPS BLINK ON AND OFF

NOTE

A short in the headlamp circuit is causing

the circuit breaker to

ONE HEADLAMP IS INOPERATIVE.

Remove the lamp and 12 volts dc nominal.

check for voltage at

the lamp socket with

multimeter.

BOTH HEADLAMPS ARE INOPERATIVE.

Check blackout lamp

switch position.

Check for voltage at

dimmer switch terminal (circuit 26B)

using multimeter.

Check for voltage at

lamp switch (circuit

26) terminal.

Check for voltage at

lamp switch (circuit

10D) terminal.

Troubleshoot wiring.

Check circuit breaker

in headlamp switch.

12 volts dc nominal.

Fig. 5-32.

12 volts dc nominal.

12 volts dc nominal.

Continuity.

cycle.

Replace

lamp

(para 5-44).

Replace

(para 5-57).

Check circuit 26

wiring.

Replace

switch

(para 5-62).

Troubleshoot wiring

Repair

ground

connection

at lamp.

Go to

Step 3.

Go to

Step 4.

Go to

Step 5.

Replace

headlamp

switch.

REMARKS

5-46
TM 9-2320-273-20

Table 5-8. Headlamp Circuit Troubleshooting (Continued).

INSTRUCTION INDICATION

Figure 5-32. Dimmer Switch Checks

I

4 HIGH BEAM INDICATOR IS INOPERATIVE.

I

Check for voltage at

lamp and terminal 2

with multi meter.

12 volts dc nominal. Replace bulb Check wire

(para 5-63), numbers

or switch 24, 25, 26,

(para 5-57). 10, 27 and

28B from

dimmer selector switch

at terminals

1, 2, and 3.

5-47

YES NO REMARK S
TM 9-2320-273-20

a. Description. All vehicles in the series have five front marker lamps. The concrete mixer

also has two intermediate side marker lamps. The dump, bituminous distributor, and the concrete mixer also have five rear marker lamps. Wiring to 24 V dc and 12 V dc trailer connectors is also provided. The lamps are turned on by the headlamp switch when the blackout

switch is in the normal position. A momentary contact CLEARANCE LAMP switch allows the

driver to flash the lamps.

b. Troubleshooting. The marker lamps circuit is straightforward and troubleshooting can,

for the most part, be based on observation of the lamp(s) not working and reference to the

circuit schematic, figure 5-33. The checks in table 5-9 can be used to isolate a problem.

Figure 5-33. Marker Lamps Circuit

5-48

5-15. MARKER LAMPS.
TM 9-2320-273-20

Table 5-9. Marker Lamps Circuit Troubleshooting.

INSTRUCTION INDICATION I YES I NO I REMARKS

1

2

3

4

Tighten.

Repair.

FRONT MARKER LAMPS INOPERATIVE.

If none of the front Loose connection. Tighten.

marker lamps operates Broken wire. Repair.

check wiring from the

switch.

INTERMEDIATE MARKER LAMPS INOPERATIVE.

If neither of the side Loose connection. Tighten.

marker lamps operate, Broken wire. Repair.

check wiring from the

switch.

REAR MARKER LAMPS INOPERATIVE.

If none of the rear Loose Connection.

marker lamps oper- Broken wire.

ates, check wiring

from the switch.

ALL MARKER LAMPS INOPERATIVE.

Check for voltage at 12 volts dc nominal. Troubleboth switch terminals shoot wiring.

using multi meter.

Replace any

single lamp

that is inoperative.

Replace

bulb.

Replace

bulb.

Replace

switch.

5-49
TM 9-2320-273-20

5-16. PARKING AND TAIL LAMPS.

a. Description. The (front) parking and (rear) tail lamps are combination lamps which also

provide stop and turn functions. The parking and tail lamp functions are actuated by the headlamp

switch when it is pulled either halfway or all the way out (fig. 5-34).

b. Troubleshooting. Troubleshooting is indicated directIy as the result of the observed

malfunction as described in table 5-10.

Figure 5-34. Parking and Tail Lamp Circuit

5-50
TM 9-2320-273-20

Table 5-10. Parking and Tail Lamps Circuit Troubleshooting.

INSTRUCTION INDICATION YES NO REMARKS

1 SINGLE LAMP INOPERATIVE.

Replace bulb. Lamp lights. Check

wiring.

2 FRONT LAMPS ARE INOPERATIVE.

Check circuits 30C,

30D, 30E, and 30F

wiring and connection

points, using a multimeter.

3 REAR LAMPS ARE INOPERATIVE.

Check circuits 30L,

and 30M wiring and

connection points,

using a multimeter.

5-51
TM 9-2320-273-20

5-17. STOP AND TURN SIGNAL LAMPS.

a. Description. The turn signal and stop lamps (fig. 5-35) are combination lamps which also

provide the parking and tail lamp functions. Referring to figure 5-35, you will see that circuits

35B and 36C provide the right turn directional flashing when the control handle is raised. Circuits

37 and 37F provide the left turn directional flashing when the control lever is lowered. The hazard

lamps use those same circuits simultaneously to provide flashing of all four lamps. The stop lamp

switch completes circuit 25 to actuate circuits 36C and 37F which provide the stop lamp function.

The flashing functions override the stop and park functions. The flashing lamps on the control

operate in conjunction with the flashing circuits (refer to table 5-11).

Figure 5-35. Stop and Turn Signal Lamp Circuit.

5-52
TM 9-2320-273-20

1

2

1

2

3

4

1

2

Table 5-11. Stop and Turn Signal Lamps Circuit Troubleshooting.

INSTRUCTION INDICATION YES NO

NOTE

If any single lamp does not operate, try replacing

the lamp bulb first. Likewise, if lamps in different

circuits fail, replace the lamp bulbs first. When

replacing any lamp bulb, clean the socket contacts

and check for a good ground. If a lamp bulb is not

the problem, proceed as follows. Be sure the

ignition key switch is ON when checking the stop

or park functions.

TURN SIGNALS INOPERATIVE.

Jumper across the

terminals of the flasher (P to L).

Check circuit wiring

and circuit breaker,

using multimeter.

Check for voltage at

turn signal control

connector.

If the stop lamps work

but the rear directionals do not, replace the

directionals control.

Lamp lights.

12 volts dc nominal.

12 volts dc nominal.

STOPLAMPS ARE INOPERATIVE.

If the turn signals work

but the stop lamps do

not, check for voltage

on both terminals of

the stoplamp switch

while the brake pedal

is being depressed.

Check circuit 25

wiring.

Replace

flasher.

Go to Step

3.

Replace

control

(para 5-58).

Go to

Step 2.

Repair/

replace.

Repair

wiring.

NOTE

Air pressure must be normal for the stoplamps

to operate.

12 volts dc nominal. Go to Checking

Step 2. wiring to

switch, then

replace

switch

(para 5-85).

REMARKS

5-53
TM 9-2320-273-20

 5-18. BACKUP LAMPS.

a. Description (fig. 5-36). When the ratio selector is placed in either reverse speed, the airactuated backup switch (located on the transmission) will close and light up the backup lamps if

the ENGINE RUN switch is turned on and the blackout switch is in the normal position.

(Reference Table 5-12.)

NOTE

The compressed air system must be charged

within the normal operating range in order

to shift the transmission and actuate the

backup switch.

Figure 5-36. Backup Lamp Circuit.

5-54
TM 9-2320-273-20

Table 5-12. Backup Lamps Circuit Troubleshooting.

INSTRUCTION INDICATION YES NO REMARKS

1 BACKUP LAMP(S) INOPERATIVE.

1 Check for voltage at 12 volts dc nominal. Check Go to

inoperative lamp using ground, re- Step 2.

multimeter. place bulb

(para 5-46).

2 Check for voltage at 12 volts dc nominal. Go to Check circircuit 38B terminal Step 3. cuit 38B

of backup switch. wiring.

3 Check for voltage at 12 volts dc nominal. Replace Check circircuit 38A terminal switch cuit 38A

of backup switch. (para 5-77). wiring and

circuit

breaker.

5-55
TM 9-2320-273-20

5-19. BLACKOUT LIGHTING SYSTEM.

a. The blackout lighting system is shown and pictorially described in paragraphs 2-50 and

2-51. See iIllustration in paragraph 2-51 for location of the major components in this system.

b. To aid in troubleshooting, a schematic diagram (fig. 5-37) is provided below that isolates

the blackout lighting system from the complete vehicle electrical system. You will find the vehicle

electrical schematic diagram in Appendix D, along with the vehicle wiring harness drawings.

Figure 5-37. Blackout Lighting System Circuit

5-56
TM 9-2320-273-20

Table 5-13. Blackout Lighting System Circuit Troubleshooting.

INSTRUCTION INDICATION YES NO REMARKS

NOTE

The following procedures assume that:

a. Normal service lighting system functions

properly (if not; refer to para 5-14).

b. OPERATION switch is in BLACKOUT

position.

1 ALL BLACKOUT LAMPS INOPERATIVE.

Replace OPERATION

switch.

2 ONE BLACKOUT MARKER, HEADLAMP, TAIL LAMP OR STOP LAMP INOPERATIVE.

1 Replace bulb. Lamp goes on, Go to

Step 2.

2 Check for voltage at 12V nominal available Inspect

lamp connector; then at one test point; not wiring bework back to OPERA- available at preceding tween points

TION switch checking test point. checked;

for voltage at each then replace

wire connector. defective

wire(s).

3 TRAILER BLACKOUT LAMPS INOPERATIVE.

1 Check for voltage at 24V nominal available Inspect Go to

trailer applicable at one test point; not wiring be- Step 2.

connector pin (A or available at preceding tween points

F); then work back to test point. checked;

output of relay (K4 then replace

or K5) checking for defective

voltage at each wire wire(s).

connection.

2 Check for voltage at 12V nominal. Go to Go to If power is available,

input of relay coil Step 3. Step 4.

(K4 or K5).

problem is in relay

or 24V circuit from

starter solenoid. If

power is not available, problem is in

relay or 12V circuit

from OPERATIONS

switch. Check relay

as described in para.

5-5C.

5-57
TM 9-2320-273-20

Table 5-13. Blackout Lighting System Circuit Troubleshooting (Continued).

3

3

4

INSTRUCTION

TRAILER BLACKOUT

Check for voltage at

relay contact terminal

then work back to

starter solenoid.

Check for voltage at

each wire contact

from relay to

OPERATION switch.

INDICATION

LAMPS INOPERATIVE

24V nominal available

at one test point; not

available at preceding

test point.

12V nominal available

at one test point; not

available at preceding

test point.

YES

(Continued)

Inspect

wiring between points

checked;

then replace

defective

wire(s).

Inspect

wiring between point

checked;

then replace

defective

wire(s).

NO REMARKS

5-58
TM 9-2320-273-20

5-20. MISCELLANEOUS ELECTRICAL.

The items covered in this paragraph are:

a.

b.

c.

d.

e.

f.

g.

Electric horn.

Heater fan.

Dome lamp in the cab.

Fixed work lamps (M916 and M920 only).

Portable work lamp receptacles.

Cigar lighter.

Winterization kit.

5-59
TM 9-2320-273-20

Table 5-14. Miscellaneous Electrical Circuit Troubleshooting.

INSTRUCTION INDICATION YES NO REMARKS

1 ELECTRICAL HORN IS INOPERATIVE

1 Check horn for a good Clean and tighten. Go to Repair.

ground. Step 2.

2 Check for voltage at 12 volts dc nominal. Replace Go to

horn using multimeter horn Step 3.

while pressing horn (para 5-68).

button.

3 Check for voltage at 12 volts dc nominal. Check cir- Go to

terminal 3 (fig. 5-38) cuit 41 Step 4.

on horn relay while wiring.

pressing horn button.

4 Check for voltage at 12 volts dc nominal. Go to

terminal 1 on horn Step 5.

relay while pressing

horn button.

5 Jumper terminal 2 on Horn operates. Go to Replace

horn relay to ground. Step 6. horn relay

(para 5-67).

6 Check horn button Wiring and ground Replace Repair.

switch ground and okay. button

wiring to horn relay. switch

(para 5-67).

Figure 5-38. Electric Horn Circuit

I I 1 1

TA 074723

5-60
TM 9-2320-273-20

Table 5-14. Miscellaneous Electrical Circuit Troubleshooting (Continued).

INSTRUCTION INDICATION YES NO REMARKS

2 PERSONNEL HEATER FAN INOPERATIVE.

1 Turn Engine Run 12 volts dc nominal. Replace Go to

switch ON and check switch Step 3.

for voltage at termin- (para 5-69).

al B on heater switch,

fig. 5-39 using a

multi meter.

2 If any speed is work- Detective switch. Repair. Replace

ing check wiring switch

between switch and (para 5-69).

fan motor.

3 Troubleshoot wiring

(circuits 33 and 34).

Figure 5-39. Heater Fan Circuit

I

3 DOME LAMP INOPERATIVE.

1 Replace the bulb. Lamp lights. Go to

Step 2.

2 Using a multimeter 12 volts dc nominal. Replace Go to

check for voltage at switch Step 3.

dome lamp switch (para 5-56).

terminals (fig. 5-40).

3 Troubleshoot wiring.

TA 074724

5-61
TM 9-2320-273-20

Table 5-14. Miscellaneous Electrical Circuit Troubleshooting (Continued).

INSTRUCTION INDICATION YES NO REMARKS

Figure 5-40. Dome Lamp, Work Lamps, and Cigar Lighter Circuits.

4 WORK LAMPS INOPERATIVE (FIXED, M916 AND M920 ONLY).

1 Replace bulb. Lamp lights. Go to

Step 2.

2 Check wiring between 12 volts dc nominal. Replace Go to

lamps and switch. switch Step 3.

Check for voltage at (para 5-62A).

terminal on switch.

3 Troubleshoot

wiring.

5 WORK LAMPS INOPERATIVE (PORTABLE RECEPTACLES).

1 Replace bulb. Lamp lights. Go to

Step 2.

2 Check wiring between 12 volts dc nominal. Replace Go to

lamps and switch. switch Step 3.

Check for voltage at (para 5-62A).

terminal on switch.

3 Troubleshoot wiring.

6 CIGAR LIGHTER INOPERATIVE.

1 Replace the lighter Lighter works. Go to

element. Step 2.

2 Check for voltage at 12 volts dc nominal. Replace Go to

lighter receptacle, receptacle Step 3.

using a multimeter. (para 5-60A).

3 Troubleshoot wiring.

TA 074725

5-62
TM 9-2320-273-20

7

1

2

3

4

Table 5-14. Miscellaneous Electrical Circuit Troubleshooting (Continued).

INSTRUCTION INDICATION YES NO REMARKS

Check 110 VAC

power source.

Check power cord,

receptacle, and all

wiring for breaks.

Replace circuit

breaker.

Replace engine oil

heater thermostat.

I

Figure 5-41. Winterization Kit

WINTERIZATION KIT MALFUNCTIONING.

Heaters functions.

Heaters functions.

Heater functions.

Heater functions.

Go to

Step 2.

Go to

Step 3.

Go to

step 4,

5, 6, or 7.

Refer to

DS/GS for

heater

replacement.

TA 074726

5-63
TM 9-2320-273-20

Table 5-14. Miscellaneous Electrical Circuit Troubleshooting (Continued).

INSTRUCTION INDICATION YES NO REMARKS

I

WINTERIZATION KIT MALFUNCTIONING (Continued).

Replace engine

coolant heater &

thermostat.

Replace transmission oil heater.

Replace battery

box heater and

thermostat.

Figure 5-41. Winterization Kit

Heater functions.

Heater functions.

Heater functions.

TA 074727

5-64
TM 9-2320-273-20

Section Ill MAINTENANCE PROCEDURES

5-21. INTRODUCTION.

This section provides you with Organizational Level maintenance procedures for the electrical

and instrumentation systems. To find a specific maintenance procedure, see one of the

following task summaries.

a. Circuit Breakers and Wiring (para 5-22).

b. Starting and Starting Control (para 5-23).

c. Batteries and Alternator (para 5-24).

d. Exterior Lighting (para 5-25).

e. Cab Interior Lighting and Switches (para 5-26).

f. Panel-Mounted Instruments (para 5-27).

g. Electric Horn and Cab Heater Control (para 5-28).

h. Sending Units, Switching Devices and Winterization Kit (para 5-29).

5-65
TM 9-2320-273-20

5-22. CIRCUIT BREAKERS AND WIRING MAINTENANCE TASK SUMMARY.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All-Circuit Breakers.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

REFERENCES (TROUBLESHOOTING)

None.

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

5-37A. Batteries Disconnected.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TASK

NO.

1

2

3

LIST OF TASKS

TASK

Circuit Breaker Maintenance:

(M915, M916 and M920):

A. Removal.

B. Installation.

C. Operational Check

Circuit Breaker Maintenance

(M917, M918 and M919):

A. Removal.

B. Installation.

C. Operational Check.

Wiring Harness Maintenance:

TASK

REF

5-30

5-30A

5-30B

5-30C

5-30.1

5-30.1 A

5-30.1 B

5-30.1 C

5-31

TROUBLESHOOTING

REF (TABLE)

None

None

None

5-66
TM 9-2320-273-20

5-23. STARTING AND STARTING CONTROL MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Battery Disconnected.

11-14A or C. Left Fender Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

Small Flat Tip Punch.

MATERIALS/PARTS (P/N)

Gasket (5330-00-143-7737).

Nylon Rope (10 feet).

Gasket (5330-00-252-3274).

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20 P. SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Vehicle on Level Ground.

Table 5-2,4-1, 5-3.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1 Starter Motor Maintenance: 5-32 4-1

A. Removal. 5-32A 5-2

B. Installation. 5-32B

C. Operational Check. 5-32C

2 Starter Relay Maintenance: 5-33

A. Removal. 5-33A

B. Installation. 5-33B

C. Operational Check. 5-33C

5-2

5-67
TM 9-2320-273-20

5-23. STARTING AND STARTING CONTROL MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TIM K TROUBLESHOOTING

NO. TASK REF REF (TABLE)

3 Starter Button Maintenance: 5-34 5-2

A. Removal. 5-34A

B. Installation. 5-34B

C. Operational Check. 5-34C

4 Engine Run Switch Maintenance: 5-35

A. Removal. 5-35A

B. Installation. 5-35B

C. Operational Check. 5-35C

5 Ether Button Maintenance: 5-36

A. Removal. 5-36A

B. Installation. 5-36B

C. Operational Check. 5-36C

4-1

5-3

5-68
TM 9-2320-273-20

5-24. BATTERIES AND ALTERNATOR MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 11-14 A&C. Right Front Fender Removed.

TEST EQUIPMENT

Battery Charger.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REWIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Vehicle Parked on Level Ground.

Table 5-1, 5-5.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Park Brake Set.

Transmission in Neutral.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1 Disconnect Batteries: 5-37 5-1

A. Removal. 5-37A

B. Installation. 5-37B

C. Operational Check. 5-37C

5-69
TM 9-2320-273-20

5-24. BATTERIES AND ALTERNATOR MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

2 Battery Maintenance: 5-38 5-1

A. Removal. 5-38A

B. Cleaning. 5-38B

C. Inspection. 5-38C

D. Charging. 5-38D

E. Installation. 5-38E

3 Battery Cables Maintenance: 5-39 5-1

A. Removal. 5-39A

B. Installation. 5-39B

C. Operational Check. 5-39C

4 Battery Box Latch Maintenance: 5-40

A. Removal. 5-40A

B. Installation. 5-40B

C. Operational Check. 5-40C

5 Battery Box Cover Maintenance: 5-41

A. Removal. 5-41A

B. Installation. 5-41B

C. Checking Fit. 5-41C

6 Battery Box Maintenance: 5-42

A. Removal. 5-42A

B. Installation. 5-42B

7 Alternator Maintenance: 5-43 5-5

A. Removal. 5-43A

B. Installation. 5-43B

C. Operational Check. 5-43C

5-70
TM 9-2320-273-20

5-25. EXTERIOR LIGHTING MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Battery Disconnected.

5-44A. Headlamp Removed if Wire (3)

TEST EQUIPMENT is to be Removed.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

1. 35 W-12V Bulb GE 4419 (or equal).

2. Non Flammable Cleaning Solvent,

(Refer to Appendix C).

3. Bearing Grease (Refer to Appendix C).

4. Tape.

5. Marking Pen.

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-20P. LO 9-2320-273-12.

TM 9-2320-273-10. SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Vehicle Parked on Level Ground.

Table 5-8, 5-9, 5-10, 5-11, 5-13, 5-14.

GENERAL SAFETY INSTRUCTIONS

Park Brake Set.

Engine Off.

Transmisison in Neutral.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1 Headlamps Maintenance: 5-44 5-8

A. Removal. 5-44A

B. Installation. 5-44B

C. Operational Check. 5-44C

2 Front Turn and Marker Lamps Maintenance: 5-45

A. Removal. 5-45A

B. Installation. 5-45B

C. Operational Check. 5-45C

5-9

5-11

5-71
TM 9-2320-273-20

5-25. EXTERIOR LIGHTING MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

3 Rear Lamp Assembly Maintenance: 5-46 5-10

A. Removal. 5-46A

B. Installation. 5-46B

C. Operational Check. 5-46C

4 Clearance Lamps Maintenance: 5-47

A. Removal. 5-47A

B. Installation. 5-47B

C. Operational Check. 5-47C

5 Blackout Headlamp Maintenance: 5-48

A. Removal. 5-48A

B. Installation. 5-48B

C. Operational Check. 5-48C

6 Blackout Marker Lamps Maintenance: 5-49

A. Removal. 5-49A

B. Installation. 5-49B

C. Operational Check. 5-49C

7 Blackout Tail and Stop Lamps Maintenance: 5-50

A. Removal. 5-50A

B. Installation. 5-50B

C. Operational Check. 5-50C

8 Stationary Work lamp Bulb Replacement: 5-51

A. Removal. 5-51A

B. Installation. 5-51 B

C. Operational Check. 5-51C

9 Stationary Worklamp Replacement: 5-52

A. Removal. 5-52A

B. Installation. 5-52B

C. Operational Check. 5-52C

5-14

5-9

5-13

5-13

5-13

5-14

5-72
TM 9-2320-273-20

5-25. EXTERIOR LIGHTING MAINTENANCE TASK SUMMARY (Continued).

TASK

NO.

10

11

12

LIST OF TASKS

TASK

Portable Work Lamp Bulb Replacement:

A. Removal.

B. Installation.

C. Operational Check.

Portable Work Lamp Maintenance:

A. Disassembly.

B. Assembly.

C. Operational Check.

Trailer Lamp Connector Maintenance (12 and

24 Volt):

A. Removal (24 Volt Connector).

B. Removal (12 Volt Connector).

C. Inspection (24 Volt and 12 Volt).

D. Installation (24 Volt Connector).

E. Installation (12 Volt Connector).

F. Test 24 Volt and 12 Volt).

TASK

REF

5-53

5-53A

5-53B

5-53C

5-54

5-54A

5-54B

5-54C

5-55

5-55A

5-55B

5-55C

5-55D

5-55E

5-55F

TROUBLESHOOTING

REF (TABLE)

5-14

5-14

5-10

5-73
TM 9-2320-273-20

5-26. CAB INTERIOR LIGHTING AND SWITCH MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Vehicle Parked on Level Ground.

Table 5-8, 5-11, 5-14.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1 Dome Lamp Maintenance: 5-56 5-14

A. Removal. 5-56A

B. Installation. 5-56B

C. Operational Check. 5-56C

2 Headlamp Dimmer Switch Maintenance: 5-57

A. Removal. 5-57A

B. Installation. 5-57B

C. Operational Check. 5-57C

5-74
TM 9-2320-273-20

5-26. CAB INTERIOR LIGHTING AND SWITCH MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

3 Turn Signal Control Maintenance: 5-58 5-11

A. Removal. 5-58A

B. Installation. 5-58B

C. Operational Check. 5-58C

5-75
TM 9-2320-273-20

5-27. PANEL-MOUNTED INSTRUMENTS MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Battery Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Seven Day Disk Pack (7530-01-060-1628).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10

SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Vehicle Parked on Level Ground.

Table 5-6, 5-7, 5-9, 5-14.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1 Electrical Instruments Maintenance (LH Cluster): 5-59 5-7

A. Removal. 5-59A

B. Installation. 5-59B

C. Operational Check. 5-59C

2 Cigar Lighter Maintenance: 5-60

A. Removal. 5-60A

B. Installation. 5-60B

C. Operational Check. 5-60C

5-14

5-76
TM 9-2320-273-20

5-27. PANEL-MOUNTED INSTRUMENTS MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

3. Low Air Pressure Indicator Lamp Maintenance: 5-61 5-6

A. Removal. 5-61A

B. Installation. 5-61B

C. Operational Check. 5-61C

4. Electrical Switches Maintenance (R H Cluster): 5-62 5-6

A. Removal. 5-62A

B. Installation. 5-62B

C. Operational check. 5-62C

5. Indicator Lamps Maintenance (R H Cluster): 5-63 5-7

A. Removal. 5-63A

B. Installation. 5-63B

C. Operational Check. 5-63C

6. Clearance Lamps Switch Maintenance 5-64 5-9

A. Removal. 5-64A

B. Installation. 5-64B

C. Operational Check. 5-64C

7. Clearance Indicator Lamp Maintenance: 5-65 5-9

A. Removal. 5-65A

B. Installation. 5-65B

C. Operational Check. 5-65C

8. Tachograph Maintenance: 5-66 5-7

A. Reading Tachograph Disk. 5-66A

B. Disk Pack Removal. 5-66B

C. Disk Pack Installation. 5-66C

D. Tachograph Removal. 5-66D

E. Tachograph Installation. 5-66E

F. Operational Check. 5-66F

5-77
TM 9-2320-273-20

5-28. ELECTRIC HORN AND CAB HEATER CONTROL MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Vehicle Parked on Level Ground.

Table 5-14.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

LIST OF TASKS

TASK

NO. TASK

1

2

Horn Button Maintenance:

A. Removal.

B. Installation.

C. Operational Check.

Horn Maintenance:

A. Removal.

B. Installation.

C. Operational Check.

TASK

REF

5-67

5-67A

5-67B

5-67C

5-68

5-68A

5-68B

5-68C

TROUBLESHOOTING

REF (TABLE)

5-14

5-14

5-78
TM 9-2320-273-20

5-28. ELECTRIC HORN AND CAB HEATER CONTROL MAlNTENANCE TASK SUMMARY

(Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

3 Heater Fan Switch Maintenance: 5-69 5-14

A. Removal. 5-69A

B. Installation. 5-69B

C. Operational Check. 5-69C

5-79
TM 9-2320-273-20

5-29. SENDING UNITS, SWITCHING DEVICES AND WINTERIZATION KIT

MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-42A. Radiator Drained Below Actuator

Level.

TEST EQUIPMENT 5-37A. Batteries Disconnected.

None. 6-9A. Transmission Oil Drained.

SPECIAL TOOLS 6-9C. Cab Floor Inspection Plate Removed.

None. 9-13A. Air Reservoir Drained.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Gasket, Fuel Level Sending Unit (2013).

Container (Approx. 2 gal).

30 Amp Circuit Breaker.

15 Amp Circuit Breaker (3).

Gasket (1020803).

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P. SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Vehicle Parked on Level Ground.

Table 6-1, 5-6, 5-12, 5-7, 12-2, 5-3, 5-11, 5-14.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1 Oil Pressure Sending Unit Maintenance: 5-70 5-7

A. Removal. 5-70A

B. InstalIation. 5-70B

C. Operational Check. 5-70C

2 Oil Pressure Switch Maintenance: 5-71 5-6

A. Removal. 5-71A

B. Installation 5-71B

C. Operational Check. 5-71C

5-80
TM 9-2320-273-20

5-29. SENDING UNITS, SWITCHlNG DEVICES AND WINTERIZATION KlT MAlNTENANCE

TASK SUMMARY (Continued).

LIST OF TASKS

TASK

NO.

3.

4.

5.

6.

7.

8.

9.

TASK

Water Temperature Sending Unit Maintenance:

A. Removal.

B. Installation.

C. Operational Check.

Water Temperature Switch Maintenance:

A. Removal.

B. Installation.

C. Operational Check.

Ether Temperature Switch Maintenance:

A. Removal.

B. Installation.

C. Operational Check.

Neutral Safety Switch Maintenance:

A. Removal.

B. Installation.

C. Operational Check.

Transmission Oil Temperature Sending Unit

Maintenance:

A. Removal.

B. Installation.

C. Operational Check.

Backup Switch and Clutch Disengagement Sensor

Maintenance:

A. Removal.

B. Installation.

C. Operational Check.

Backup Alarm Maintenance:

A. Removal.

B. Installation.

C. Operational Check.

TASK

REF

5-72

5-72A

5-72B

5-72C

5-73

5-73A

5-73B

5-73C

5-74

5-74A

5-74B

5-74C

5-75

5-75A

5-75B

5-75C

5-76

5-76A

5-76B

5-76C

5-77

5-77A

5-77B

5-77C

5-78

5-78A

5-78B

5-78C

TROUBLESHOOTING

REF (TABLE)

5-7

5-7

5-3

6-1

5-7

5-12

5-6

5-81
TM 9-2320-273-20

5-29. SENDING UNITS, SWITCHING DEVICES AND WINTERIZATION KIT

MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

10 Fuel Level Sending Unit Maintenance: 5-79 5-7

A. Removal. 5-79A

B. Installation. 5-79B

C. Operational Check. 5-79C

11 Low Air Pressure Buzzer Maintenance: 5-80 5-6

A. Removal. 5-80A

B. InstalIation. 5-80B

C. Operational Check. 5-80C

12 Low Air Pressure Switch Maintenance: 5-81 5-6

A. Removal. 5-81A

B. InstalIation. 5-81B

C. Operational Check. 5-81C

13 Park Brake Switch Maintenance: 5-82 5-7

A. Removal. 5-82A

B. Installation. 5-82B

C. Operational Check. 5-82C

14 Differential Lock-Up Switch Maintenance: 5-83 5-7

A. Removal. 5-83A

B. Installation. 5-83B

C. Operational Check. 5-83C

15 Power Takeoff (PTO) Switch Maintenance: 5-84 12-2

A. Removal. 5-84A

B. Installation. 5-84B

C. Operational Check. 5-84C

16 Stop Lamp Switch Maintenance: 5-85 5-11

A. Removal. 5-85A

B. Installation. 5-85B

C. Operational Check. 5-85C

5-82
TM 9-2320-273-20

5-29. SENDING UNITS, SWITCHING DEVICES AND WINTERIZATION KIT

MAINTENANCE TASK SUMMARY (Continued).

TASK

NO.

17

18

19

20

21

22

LIST OF TASKS

TASK

Instrument Relay Maintenance:

A. Removal.

B. Installation.

C. Operational Check.

Winterization Kit Circuit Breakers, Box,

and Receptacle Maintenance:

A. Removal of Circuit Breakers.

B. Installation of Circuit Breakers.

C. Operational Check.

D. Removal of Circuit Breaker Box

and Receptacle.

E. Installation of Circuit Breaker Box

and Receptacle.

F. Operational Check.

Winterization Kit Transmission Oil Heater

Maintenance:

A. Removal of Heater.

B. Installation of Heater.

C. Operational Check.

Winterization Kit Engine Oil Heater Thermostat

Maintenance:

A. Removal of Thermostat.

B. Installation of Thermostat.

C. Operational Check.

Winterization Kit Engine Coolant Heater

Maintenance:

A. Removal of Heater.

B. Installation of Heater.

C. Operational Check.

Winterization Kit Battery BOX Heater

Maintenance:

A. Removal of Heater.

B. Installation of Heater.

C. Operational Check.

TASK

REF

5-86

5-86A

5-86B

5-86C

5-87

5-87A

5-87B

5-87C

5-87D

5-87E

5-87F

5-88

5-88A

5-88B

5-88C

5-89

5-89A

5-89B

5-89C

5-90

5-90A

5-90B

5-90C

5-91

5-91A

5-91B

5-91C

TROUBLESHOOTING

REF (TABLE)

None

5-14

5-14

5-14

5-14

5-14

5-83
TM 9-2320-273-20

5-29. SENDING UNITS, SWITCHING DEVICES AND WINTERIZATION KIT MAINTENANCE

TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

23 Winterization Kit Battery Box Thermostat

and Terminal Strip Maintenance: 5-92 5-14

A. Removal. 5-92A

B. Installation. 5-92B

C. Operational Check. 5-92C

24 Winterization Kit Battery Box Insulation

Maintenance: 5-93 None

A. Removal. 5-93A

B. Cleaning. 5-93B

C. Installation. 5-93C

5-84
TM 9-2320-273-20

This page intentionally left blank.

5-85
TM 9-2320-273-20

CIRCUIT BREAKERS AND WIRING.

5-30. CIRCUIT BREAKER MAINTENANCE. (M915, M916, and M920)

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (4)

b. Installation. (4)

c. Operational Check. (2)

10 Minutes Total.

INITIALSETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915, M916, and M920 – (9) Circuit Breakers 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

None.

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission on Neutral.

Park Brake Set.

Always disconnect batteries to prevent electrical shorts

when working in the circuit breaker area. An electrical

short or arc can cause damage to wiring and other electrical components.

5-86

SPECIAL ENVIRONMENTAL CONDITIONS
TM 9-2320-273-20

CIRCUIT BREAKERS AND WIRING.

5-30. CIRCUIT BREAKER MAINTENANCE (M915, M916, and M920) (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL. I

To prevent electrical shorts and damage to wiring or other components,

always: use one flat washer and two locknuts on the top row of terminal

studs (copper), except no flat washer is used where a bus bar is present.

Use one flat washer and one locknut on the bottom row of terminal studs

(silver).

Connect wire terminals to the correct circuit breaker or diode and to the

correct color terminal stud as illustrated.

NOTE

Circled numbers in the illustration are wire numbers, while uncircled

numbers are legend items.

Wire number 15D used on M916 and M920 only.

5-87
TM 9-2320-273-20

CIRCUIT BREAKERS AND WIRING.

5-30. CIRCUIT BREAKER MAINTENANCE (M915, M916, AND M920) (CONTINUED).

LOCATION/lTEM ACTlON REMARKS

A. REMOVAL (Continued).

1. Three quarter turn screws (1). Loosen.

2. Circuit Panel cover (2). Lower.

3. Two screws (7). Remove from circuit breaker

bracket (3).

4. Three locknuts (9) and two a. Unscrew from diode (4) or Only one flat washer (8) is

fIat washers (8). circuit breaker (6). used when a bus bar (5) is

b. Remove wire terminals. present.

c. Remove diode (4) or Also remove bus bar (5)

circuit breaker (6). if used.

B. INSTALLATION.

5. Diode (4) or circuit breaker a. Install in circuit breaker Install per illustration, assuring

(6). bracket (3). the copper terminal stud is on

b. Position bus bar (5) if used. top and the silver is on the

c. Install wire terminals. bottom.

Ensure wire terminals are

connected to the correct circuit

breaker or diode and to the

correct color terminal stud.

d. Secure with two flat Only one flat washer (8) used

washers (8) and three when a bus bar (5) is present.

locknuts (9); torque each

locknut to 18-22 lb-in.

(2.0-2.5 N•m).

6. Circuit breaker bracket (3). a. Aline mounting holes.

b. Secure with two screws (7).

7. Circuit panel cover (2). Raise into position.

8. Three quarter turn screws (1). Tighten.

9. Batteries. Connect per paragraph 5-37B.

 C. OPERATIONAL CHECK.

10. Circuit breaker (6) or

diode (4).

Refer to paragraph 2-34 and

2-35; check the operation of

the circuit breaker or diode

replaced.

5-88
TM 9-2320-273-20

CIRCUIT BREAKERS AND WIRING.

5-30. CIRCUIT BREAKER MAINTENANCE (M915, M916, and M920) (Continued).

LOCATION/ITEM ACTION REMARKS

LEGEND:

1. QUARTER TURN SCREW (3)

2. CIRCUIT PANEL COVER

3. CIRCUIT BREAKER BRACKET

4. DIODE

5. BUS BAR (2)

6. CIRCUIT BREAKER (9)

7. SCREW (2)

8. FLAT WASHER (16)

9. LOCKNUT (30)

TA 074729

5-89
TM 9-2320-273-20

CIRCUIT BREAKERS AND WIRING.

5-30.1 CIRCUIT BREAKER MAINTENANCE. (M917, M918, AND M919)

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a.Removal. (4)

b.Installation. (4)

c. Operational Check. (2)

10 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M917, M918, M919 – (7) Circuit Breakers. 5-37A . Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None

PERSONNEL REQUIRED

One (MOS-63B20).

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

REFERENCES (TM)

TM 9-2320-273-10. GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission on Neutral.

Park Brake Set.

Always disconnect batteries to prevent electrical shorts

TROUBLESHOOTING REFERENCES when working in the circuit breaker area. An electrical

None. short or arc can cause damage to wiring and other electrical components.

5-90
TM 9-2320-273-20

CIRCUIT BREAKERS AND WIRING.

5-30.1 CIRCUIT BREAKER MAINTENANCE (M917, M918, AND M919) (Continued).

LOCATION/ITEM ACTION REMARKS

 A. REMOVAL.

To prevent electrical shorts and damage to wiring or other components,

always: use one flat washer and two locknuts on the top row of terminal

studs (copper), except no flat washer is used where a bus bar is present.

Use one flat washer and one locknut on the bottom row of terminal studs

(silver).

Connect wire terminals to the correct circuit breaker or diode and to the

correct color terminal stud as illustrated.

NOTE

Circled numbers in the illustration are wire numbers, while uncircled

numbers are legend items.

5-90.1
TM 9-2320-273-20

CIRCUIT BREAKERS AND WIRING.

5-30.1 CIRCUIT BREAKER MAINTENANCE (M917, M918, AND M919) (CONTINUED).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

1. Three quarter turn screws (1). Loosen.

2. Circuit Panel cover (2). Lower.

3. Two screws (7). Remove from circuit breaker

bracket (3).

4. Three locknuts (9) and two a. Unscrew from diode (4) or Only one flat washer (8) is

flat washers (8). circuit breaker (6). used when a bus bar (5) is

b. Remove wire terminals. present.

c. Remove diode (4) or Also remove bus bar (5)

circuit breaker (6). if used.

B. INSTALLATION.

5. Diode (4) or circuit breaker a. Install in circuit breaker Install per illustration, assuring

(6). bracket (3). the copper terminal stud is on

b. Position bus bar (5) if used. top and the silver is on the

c. Install wire terminals. bottom.

Ensure wire terminals are

connected to the correct circuit

breaker or diode and to the

correct color terminal stud.

d. Secure with two flat Only one flat washer (8) used

washers (8) and three when a bus bar (5) is present.

locknuts (9); torque each

locknut to 18-22 lb-in.

(2.0-2.5 N•m).

6. Circuit breaker bracket (3). a. Aline mounting holes.

b. Secure with two screws (7).

7. Circuit panel cover (2). Raise into position.

8. Three quarter turn screws (1). Tighten.

9. Batteries. Connect per paragraph 5-37 B.

 C. OPERATIONAL CHECK.

10. Circuit breaker (6) or

diode (4).

Refer to paragraph 2-34 and

2-35; check the operation of

the circuit breaker or diode

replaced.

5-90.2
TM 9-2320-273-20

CIRCUIT BREAKERS AND WIRING.

5-30.1 CIRCUIT BREAKER MAINTENANCE (M917, M918, AND M919) (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

1. QUARTER TURN SCREW (3)

2. CIRCUIT PANEL COVER

3. CIRCUIT BREAKER BRACKET

4. DIODE

5. BUS BAR

6. CIRCUIT BREAKER (7)

7. SCREW (2)

8. FLAT WASHER (14)

9. LOCKNUT (29) TA 076535

5-90.3
TM 9-2320-273-20

CIRCUIT BREAKERS AND WIRING.

5-31. WIRING HARNESS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

See Appendix D for Harness Routing and Location.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission In Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

None.

5-90 4
TM 9-2320-273-20

CIRCUIT BREAKERS AND WIRING.

5-31. WIRING HARNESS MAINTENANCE (Continued).

LOCATlON/lTEM ACTION REMARKS

NOTE

For removal and installation of vehicle

wiring harness, refer to Appendix D for

harness routing and location. Illustrated

below are typical connectors and terminals

used on the vehicle wiring harness. Use

standard shop maintenance procedures in

removing all harness clamps and cable ties.

5-91
TM 9-2320-273-20

ELECTRICAL SYSTEM.

5-31.1. WIRING HARNESS REPAIR.

LOCATION/lTEM ACTION REMARKS

LEGEND:

1.

2.

3.

4.

5.

6.

CONNECTOR PLUG 7.

CONNECTOR RECEPTACLE 8.

CRIMPING TOOL 9.

CONTACT REMOVAL TOOL (SIZE #12) 10.

CONTACT REMOVAL TOOL (SIZE #16) 11.

HEXAGON NUT 12.

LOCKWASHER

BRACKET

TERMINAL (AS REQUIRED)

WIRE (AS REQUIRED)

WIRE (AS REQUIRED)

TERMINAL PIN (AS REQUIRED)

TA 237221

5-92 Change 2
TM 9-2320-273-20

ELECTRICAL SYSTEM.

5-31.1. WIRING HARNESS REPAIR (Continued).

LOCATION/ITEM ACTION REMARKS

 A. CIRCULAR CONNECTOR PLUG REPAIR.

1. Connector plug (1).

2. Terminal pin (12).

3. All parts.

4. Terminal pin (12).

5. New terminal pin (12).

6. Terminal pin (12).

7. Connector plug (1).

NOTE

Use this procedure to repair any one

of the connector plugs.

Unscrew and remove from

connector receptacle (2).

Using contact removal tool

(4) or (5), pull out from rear

side of connector plug ( 1).

Clean and inspect.

Remove from wire (11) and

discard.

Using crimping tool (3),

install onto wire (11).

Push into rear end of connector plug (1) until it snaps

into place.

Line up slots with pins on

connector receptacle (2) and

screw in until it clicks into

place.

If connector plug (1) is being

replaced, repeat this step

until all terminal pins (12)

have been removed. Be

sure to tag wires (11).

If any terminal pins (12) are

damaged, perform steps (4)

and (5).

Be careful not to damage

terminal pin (12) during

this step.

If connector plug (1) is new,

repeat this step until all

terminal pins (12) have been

installed. Check the mating

side of connector plug (1)

to make sure all connector

receptacles (2) are on the

same level.

Change 2 5-92.1
TM 9-2320-273-20

ELECTRICAL SYSTEM.

.

5-31.1. WIRING HARNESS REPAIR (Continued).

LOCATION/lTEM ACTION REMARKS

B. CIRCULAR CONNECTOR RECEPTACLE REPAIR.

NOTE

Use this procedure to repair any one

of the connector receptacles.

1. Connector plug (1). Unscrew and remove from

connector receptacle (2).

2. Hexagon nut (6) and Unscrew and remove from

Iockwasher (7). connector receptacle (2).

3. Connector receptacle (2). Remove from bracket (8).

4. Terminal (9). Using contact removal tool (4) If connector receptacle (2) is

or (5), pull out from rear side being replaced, repeat this step

of connector receptacle (2). until all terminals (9) have

been removed. Be sure to tag

wires (10).

5. All parts. Clean and inspect. If any terminals (9) are damaged, do steps 6 and 7.

6. Terminal (9). Remove from wire ( 10) and

discard.

7. New terminal (9). Using crimping tool (3), install Be careful not to damage teronto wire (10). minal (9) during this step.

8. Terminal (9). Push into rear end of con- If connector receptacle (2) is

nector receptacle (2) until new, repeat this step until all

it snaps into place. terminals (9) have been installed. Check the mating

side of connector receptacle

(2) to make sure all terminals

(9) are on the same level.

9. Connector receptacle (2). a. Position on bracket (8).

b. Secure with hexagon nut

(6) and Iockwasher (7).

10. Connector plug (1). Line up slots with pins on connector receptacle (2) and screw

on until it clicks into place.

5-92.2 Change 2

TM 9-2320-273-20

STARTING AND STARTING CONTROL.

5-32. STARTER MOTOR MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (30)

b. Installation. (30)

c. Operational Check. (2)

62 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

11-14A&C. Left Fender Removed.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

1. Gasket (5330-00-143-7737).

2. Nylon Rope (10 Feet).

3. Gasket (5330-00-252-3274).

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10,

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 4-1, 5-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Park Brake Set.

Transmission In Neutral.

5-92.3 (blank) /5-92.4
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

Remove.

Remove.

5-32. STARTER MOTOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Disconnect battery cables before removing

starter.

 A. REMOVAL.

1.

2.

5-93

Two hex nuts (9)

and washers (8).

Five wires (10) and

ground strap (7).
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

Discard gaskets (3)

and (5).

5-32. STARTER MOTOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

NOTE

Wrap rope around starter motor and first

mechanic holds rope while second mechanic performs steps 3, 4, 7, and 8.

3. Three bolts (1) Remove.

and washers (2).

4. Starter motor (6). Remove.

5. Gasket (3), spacer (4), Remove.

and gasket (5).

B. INSTALLATION.

6. New gasket (3), spacer (4), Aline and install

and new gasket (5). on starter motor (6).

7. Starter motor (6). Aline and install.

8. Three washers (2) and Install and tighten.

bolts (1) .

9. Five wires (10) and InstalI on starter

ground strap (7). motor (6) according to

figure.

10. Two washers (8) and Install and tighten.

hex nuts (9).

11. Batteries. Connect per paragraph 5-37B.

C. OPERATIONAL CHECK.

12. Engine. Start up (see TM 9-2320-273-10).

Verify that starter motor (6)

engages.

NOTE

Follow-on maintenance action required:

Install left fender, para 11-14B or D.

5-94
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

5-32. STARTER MOTOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Follow-on maintenance action required:

Replace fender, para 11-14.

5-95
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

5-33. STARTER RELAY MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REWIRED FOLLOWS TASK DESCRIPTION.)

a. Removal.

b. Installation. (5)

c. Operational Check. (2)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-2.

5-96

(5)
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

5-33. STARTER RELAY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Three quarter-turn Loosen.

screws (1).

2. Circuit panel cover Lower hinged panel.

(2).

3. Four hex nuts (6) Remove.

and washers (7).

5-97
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

5-33. STARTER RELAY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

4. Five wires (8). Remove.

5. Two bolts (5), washers Remove.

(4), and hex nuts (3).

6. Starter relay (9). Remove.

B. INSTALLATION.

7. Starter relay (9). Set relay in place and aline

mounting holes.

8. Two bolts (5), washers Install and tighten.

(4), and hex nuts (3).

9. Five wires (8). Connect wires according

to figure.

10. Four washers (7) and Replace and tighten.

hex nuts (6).

11. Circuit panel cover (2). Raise into place.

12. Three quarter-turn Tighten.

screws (1).

13. Batteries. Connect per paragraph 5-37B.

5-98
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

5-33. STARTER RELAY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. OPERATIONAL CHECK.

14. ENGINE RUN switch (11). Turn ON.

15. ENGINE START button (10). Depress momentarily and observe

that the starter motor engages.

LEGEND:

1. QUARTER TURN SCREW (3)

2. CIRCUIT PANEL COVER

3. HEX NUT (2)

4. WASHER (2)

5. BOLT (2)

6. HEX NUT (4)

7. WASHER (4)

8. WIRE (5)

9. STARTER RELAY

10. ENGINE START BUTTON

11. ENGINE RUN SWITCH

TA 074734

5-99
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

5-34. ENGINE START BUTTON MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (5)

c. Operational Check. (2)

12 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

5-37A. Batteries Disconnected.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-2.

5-100
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

5-34. ENGINE START BUTTON MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

A. REMOVAL.

1. Four quarter-turn

screws (1).

2. Hinged instrument

panel (2).

Loosen.

Lower.

LEGEND:

1.

2.

3.

4.

5.

6.

7.

8.

9.

QUARTER TURN SCREW (4)

HINGED INSTRUMENT PANEL

SCREW (2)

WASHER (2)

WIRE (4)

STARTER BUTTON

ADJUSTING HEX NUT

KNURLED NUT

ENGINE RUN SWITCH

TA 074735

5-101
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

5-34. ENGINE START BUTTON MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Two screws (3) and Remove.

washers (4).

4. Four wires (5). Remove.

5. Knurled nut (8). Remove,

6. Starter button (6). Remove.

7. Adjusting hex nut (7). Remove.

B. INSTALLATION.

8. Adjusting hex nut (7). Adjust to proper depth on

starter switch to allow

installation of knurled nut (8).

9. Starter button (6). Replace in panel.

10. Knurled nut (8). Install and tighten.

11. Four wires (5), two InstalI according to figure and

washers (4) and screws (3). tighten.

12. Hinged instrument Raise into place.

panel (2).

13. Four quarter-turn Tighten.

screws (1).

5-102
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

5-34. ENGINE START BUTTON MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Follow-on maintenance:

a. Hook up batteries; refer to para. 5-37B.

C. OPERATIONAL CHECK.

14. ENGINE RUN switch (9). Turn ON.

15. ENGINE START button Depress momentarily and observe

(6). that the starter motor engages.

TA 074736

LEGEND:

1. QUARTER TURN SCREW (4)

2. HINGED INSTRUMENT PANEL

3. SCREW (2)

4. WASHER (2)

5. WIRE (4)

6. STARTER BUTTON

7. ADJUSTING HEX NUT

8. KNURLED NUT

9. ENGINE RUN SWITCH

5-103
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

5-35. ENGINE RUN SWITCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (5)

c. Operational Check. (2)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A . Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

Small Flat Tip Punch.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

5-104
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

5-35. ENGINE RUN SWITCH MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

A. REMOVAL.

1. Four quarter-turn screws (1). Loosen.

2. Hinged instrument panel (2). Lower.

3. Wire connector (4) and two wires (3). Remove.

4. Hex nut (8). Remove.

5. ENGINE RUN switch (5). Remove from instrument

panel.

6. Lock cylinder (7). Place switch in ON

position. Insert flat

tip punch in cylinder

extraction hole (6) and

remove lock cylinder (7).

I

5-105
TM 9-2320-273-20

STARTING AND STARTING CONTROL.

Aline lock cylinder (7)

and press into switch.

Aline and insert in

instrument panel.

Install and tighten.

Install on switch.

Raise into place.

Tighten.

Connect per paragraph 37B.

5-35. ENGINE RUN SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

7. ENGINE RUN switch (5).

8. ENGINE RUN switch (5).

9. Hex nut (8).

10. Wire connector (4) and

wires (3).

11. Hinged instrument panel (2).

12. Four quarter-turn screws (1).

13. Batteries.

C. OPERATIONAL CHECK.

14. Engine Start up (see TM 9-2320-273-10). Verify that

all circuits are operational.

5-106
TM 9-2320-273-20

This page intentionally left blank.

5-107
TM 9-2320-273-20

STARTING AND STARTING CONTROL .

5-36. ETHER BUTTON MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (5)

c. Operational Check. (5)

15 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (M OS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

5-37A . Batteries Disconnected.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Sat.

TROUBLESHOOTING REFERENCES

Table 5-3.

5-108
TM 9-2320-273-20

STARTING AND STARTING CONTROL .

5-36. ETHER BUTTON MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Four quarter turn screws (1). Loosen.

2. Hinged instrument panel (2). Lower hinged panel.

3. Knurled nut (8). Remove.

4. ETHER button (6). Remove.

5. Hex nut (7). Remove.

6. Two screws (3) Remove.

and washers (4).

7. Two wires (5). Remove.

5-109
TM 9-2320-273-20

STARTING AND STARTING CONTROL

5-36. ETHER BUTTON MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

8. Two wires (5). Place on ETHER button (6).

9. Two washers (4) Install and tighten.

and screws (3).

10. Hex nut (7). Install and adjust to proper depth

on ETHER button (6) to allow

installation of knurled nut (8).

11. ETHER button (6). Install in instrument panel.

12. Knurled nut (8). Install and tighten.

13. Hinged instrument panel(2). Raise into place.

14. Four quarter turn screws (1). Tighten.

15. Batteries. Connect per paragraph 5-37B.

C. OPERATIONAL CHECK.

16. Engine. Start up using cold start procedure (see TM 9-2320-273-10).

5-110
TM 9-2320-273-20

This page intentionally left blank.

5-111
TM 9-2320-273-20

BATTERIES AND ALTERNATOR MAINTENANCE.

5-37. DISCONNECT BATTERIES.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

c. Operational Check. (2)

b. Installation. (5)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-1.

5-112
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-37. DISCONNECT BATTERIES (Continued).

LOCATION/lTEM ACTION REMARKS

Do not place edge of cover on cables.

A. REMOVAL,

1. Two battery box cover Unfasten to slide off

latches (1). battery box cover (2).

2. Hex nut (4). Remove.

3. Cable (3). Remove from terminals (5).

Replace hex nut (4) on

terminal (5).

4. Hex nut (7). Remove.

5. Cable (6). Remove from terminal (8).

Replace hex nut (7) on

terminal (8).

6. Hex nut (10). Remove.

5-113
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-37. DISCONNECT BATTERIES (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

7. Cable(11). Remove from terminal (9).

Replace hex nut (10) on

terminal (9).

B. INSTALLATION.

8. Hex nut (10). Remove from terminal (9).

9. Cable(11). Connect to terminal (9).

10. Hex nut (10). Install and tighten.

11. Hex nut (7). Remove from terminal (8).

12. Cable (6). Connect to terminal (8).

13. Hex nut (7). Install and tighten.

14. Hex nut (4). Remove from terminal (5).

15. Cable (3). Connect to terminal (5).

16. Hex nut (4). Install and tighten.

NOTE

Check cables at terminal connections for

tightness; then, cover terminals with light

coat of lubricant.

17. Battery box cover (2). Install.

18. Two battery box Fasten to battery box

cover latches (1). cover (2).

C. OPERATIONAL CHECK.

19. Engine. Start up (see TM 9-2320-273-10).

If system fails to operate, check

connections for proper location

and tighteners.

20. Engine. Shut down (see TM 9-2320-273-10).

5-114
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-37. DISCONNECT BATTERIES (Continued).

LOCATION/lTEM ACTION REMARKS

5-115
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-38. BATTERY MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Cleaning. ( 10)

c. Inspection. ( 5)

d. Charging. (120)

e. Installation. ( 20)

175 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

A l l None. None.

TEST EQUIPMENT

Battery Charger.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-1.

5-116
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-38. BATTERY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Two battery box cover Unfasten to remove battery Pull up and out to remove.

latches (3). box cover (1).

2. Eight hex nuts (4). Remove.

3. Ten cables (8) and (9). Remove.

5-117
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

6-38. BATTERY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

4. Five bolts (13), washers Remove.

(14), and hex nuts (15).

5. Battery bracket (7). Remove.

6. Four batteries (10). Remove from battery box (2).

B. CLEANING.

7. Cable connectors and Use baking soda, water, and

terminals (5), and

battery top.

a wire brush to clean the

parts. Cover connections with

grease after instalIation.

C. INSPECTION.

8. Battery cases. Make sure that none is leaking

or cracked.

9. Four test indicators (6). Make sure that a GREEN DOT If indicator is completely

appears in the indicator dark the battery needs to

window. be charged. If indicator

shows yellow, the battery

needs to be replaced.

D. CHARGING.

Always turn off charger before connecting or

disconnecting to a battery to prevent sparks or

arcing which might cause explosion or ignition.

Do Not Charge a Battery if the Green Dot is

Visible.

Do Not Charge a Battery if the Test Indicator

is Light Yellow.

5-118
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-38. BATTERY MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

D. CHARGING (Continued).

10. Eight hex nuts (4). Install and tighten to positive and

negative terminals.

11. Two battery charger Connect to hex nuts (4) and lead

leads (11). pad (12) on positive and negative

terminals. Charge battery according

to table 5-15.

5-119
TM 9-2320-273-20

Table 5-15. Battery Charging Rates.

BATTERY MODEL SLOW CHARGING RATE FAST CHARGING RATE

20A at 3-3/4 hours

30A at 2-1/2 hours

1200 5A at 15 hours 40A at 2 hours

10A at 7-1/2 hours 50A at 1-1/2 hours

5-120
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-38. BATTERY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

D. CHARGING (Continued).

TO AVOID DAMAGE turn off charger

and remove leads if:

a. Battery case feels hot (125°F) (51.7°C).

b. Violent gassing or spewing of

electrolyte occurs.

12. Eight hex nuts (4). Remove.

5-121
TM 9-2320-273-20

BATTERIES AND ALTERNATOR

5-38. BATTERY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

E. INSTALLATION.

13. Four batteries (10). Set batteries in box as shown.

14. Battery bracket (7). Set in place.

15. Five bolts (13), washers Install and tighten.

(14), and hex nuts (15).

16. Ten cables (8) and (9).

17. Eight hex nuts (4).

18. Battery box cover

latches (3).

Always check to make sure that the

batteries are connected as shown in the

illustration (series-parallel). Failure to

connect batteries correctly can result

in severe damage to the truck’s electrical

system.

Connect to batteries as shown.

Replace and tighten.

Install cover (1) and fasten latches.

NOTE

Follow-on maintenance action required:

a. Check operation; refer to TM 9-2320-273-10.

5-122
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-38. BATTERY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-123
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-39. BATTERY CABLES MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (6)

b. Installation. (6)

c. Operational Check. (2)

14 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Sat.

TROUBLESHOOTING REFERENCES

Table 5-1.

5-124
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-39. BATTERY CABLES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Two battery box cover Unfasten to slide and remove

latches (23). battery box cover (1).

2. Two bolts (2), washers Remove.

(12), and nuts (13).

3. Two cable clamps (3). Remove,

4. Hex nut (22). Remove from terminal (21).

LEGEND:

1. COVER

2. BOLT (2)

3. CLAMP (2)

4. CABLE

5. TERMINAL

6. WASHER

7. NUT

8. TERMINAL

9. WASHER

10. NUT

11. CABLE

12. WASHER (2)

13. NUT (2)

14. NUT (4)

15. RUBBER GASKET

16. SCREW (2)

17. WASHER (2)

18. SLAVE RECEPTACLE

19. WASHER (8)

20. SCREW (4)

21. TERMINAL

22. HEX NUT

23. COVER LATCH (2)

24. CABLE

25. TERMINAL

26. CABLE

27. NUT

5-125
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-39. BATTERY CABLES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

5. Cable (4). Remove from terminal (21).

6. Nut (7) and washer (6). Remove from terminal (5).

7. Cable (4). Lift from terminal (5) and remove.

8. Nut (10) and washer (9). Remove from terminal (8).

9. Cable (11).

10. Nut (27).

11. Cable(11).

12. Cables (24) and (26).

13. Slave receptacle (18).

B. INSTALLATION.

14. Slave receptacle (18),

and gasket (15).

15. Cables (24) and (26).

16. Cable (11).

17. Nut (27).

Remove from terminal (8).

Remove from terminal (25).

Lift from terminal (25) and remove.

Remove two screws (16) and

washers (17); lift cables

from slave receptacle (18).

a. Remove four screws (20),

eight washers (19) and four

nuts (14).

b. Remove slave receptacle (18)

with rubber gasket (15).

Install to battery box with four

screws (20), eight washers

(19) and four nuts (14).

Install to slave receptacle (18)

with two screws (16) and

washers (17).

NOTE

After installation of cables, cover terminals

and nuts with light coat of lubrication.

Connect to terminal (25).

Install on terminal (25) and tighten.

Remove from battery

terminals as shown,

if required.

Replace if damaged.

Reconnect to battery

terminals as shown.

5-126
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-39. BATTERY CABLES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

1. COVER

2. BOLT (2)

3. CLAMP (2)

4. CABLE

5. TERMINAL

6. WASHER

7. NUT

8. TERMINAL

9. WASHER

10. NUT

11. CABLE

12. WASHER (2)

13. NUT (2)

14. NUT (4)

15. RUBBER GASKET

16. SCREW (2)

17. WASHER (2)

18. SLAVE RECEPTACLE

19. WASHER (8)

20. SCREW (4)

21. TERMINAL

22. HEX NUT

23. COVER LATCH (2)

24. CABLE

25. TERMINAL

26. CABLE

27. NUT

5-127
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-39. BATTERY CABLES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

18. Cable (11).

19. Nut (10) and washer (9).

20. Cable (4).

21. Nut (7) and washer (6).

22. Cable (4).

23. Nut (22).

24. Two cable clamps (3).

25. Bolts (2), washers (12),

and nuts (13).

Connect to terminal (8).

Install on terminal (8) and tighten.

Connect to terminal (5).

Install on terminal (5) and tighten.

Connect to terminal (21).

Install on terminal (21) and tighten.

Install on cables (4) and (11).

Install and tighten.

C. OPERATIONAL CHECK.

26. Cables (11) and (4).

27. Engine.

28. Engine.

Check connections at batteries,

solenoid switch, and starter

motor to verify tightness.

Start up (see TM 9-2320-273-

1 0.

Shut down (see TM 9-2320-

273-10).

5-128
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-39. BATTERY CABLES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

1. COVER

2. BOLT (2)

3. CLAMP (2)

4. CABLE

5. TERMINAL

6. WASHER

7. NUT

8. TERMINAL

9. WASHER

10. NUT

11. CABLE

12. WASHER (2)

13. NUT (2)

14. NUT (4)

15. RUBBER GASKET

16. SCREW (2)

17. WASHER (2)

18. SLAVE RECEPTACLE

19. WASHER (8)

20. SCREW (4)

21. TERMINAL

22. HEX NUT

23. COVER LATCH (2)

24. CABLE

25. TERMINAL

26. CABLE

27. NUT

TA 075701

5-129
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-40. BATTERY BOX LATCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (6)

b. installation. (6)

c. Operational Check. (1)

13 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

5-41A. Battery Box Cover Removed.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

None.

5-130
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-40. BATTERY BOX LATCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1.

2.

3.

4.

5.

6.

Two nuts (4), washers Remove.

(3) and screws (1).

Bracket (2). Remove.

Cotter pin (8) and pin (7). Remove.

Battery box cover hook (6). Remove.

Hex nut (11), washer (10) Remove.

and bolt (5).

Anchor bracket (9). Remove.

LEGEND:

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

SCREW (2)

BRACKET

WASHER (2)

NUT (2)

BOLT

HOOK

PIN

COTTER PIN

ANCHOR BRACKET

WASHER

HEX NUT

TA 074749

5-131
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-40. BATTERY BOX LATCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

7.

8.

9.

Bracket (2), two screws

(1), washers (3) and nuts (4).

Anchor bracket (9), bolt

(5), washer (10), and nut (11)

Battery box cover hook (6),

pin (7) and cotter pin (8).

Install and tighten.

Install and tighten.

Install

C. OPERATIONAL CHECK.

10. Battery box cover.

11. Battery box hook .

Install per paragraph 5-91 B.

5-132

Check that battery box cover hook

(6) engages bracket (2) and is under

tension when released.
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

LEGEND:

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

SCREW (2)

BRACKET

WASHER (2)

NUT (2)

BOLT

HOOK

PIN

COTTER PIN

ANCHOR BRACKET

WASHER

HEX NUT

5-133

5-40. BATTERY BOX LATCH MAINTENANCE (Continued).
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-41. BATTERY BOX COVER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (2.0)

b. Installation. (2.0)

c. Checking Fit. (0.5)

4.5 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral

Park Brake Set.

5-134
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-41. BATTERY BOX COVER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Two rubber hooks (3).

2. Battery box cover

3. Battery box cover

(2).

(2).

4. Two rubber hooks (3).

5. Battery box.

Unlatch.

Remove.

a. Pull forward.

b. Lift up.

Install.

a. Position to aline pins (1)

with mounting holes.

b. Slide back, then lower.

Fasten to battery box cover.

Check fit of cover (1) over battery box;

make sure hooks (3) latch tight on

the bracket.

5-135
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

 5-42. BATTERY BOX MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

 a. Removal. (10)

b. Installation. (10)

20 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-38A. Batteries Removed.

TEST EQUIPMENT 9-16A. Air Reservoir Above

None. Battery Box Removed.

SPECIAL TOOLS

None.

MATERIALS/PARTS (PIN)

None.

PERSONNEL REQUIRED

T WO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

None.

5-136
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-42. BATTERY BOX MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Spacer (5). Remove.

2. Eight nuts (1), washers (2) Remove.

and bolts (3).

3. Battery box (4). Remove.

4. Battery box (4). Position and hold.

5. Eight bolts (3), washers Install and tighten.

(2) and nuts (1).

6. Spacer (5). Set in place.

NOTE

Follow-on maintenance action requ i red:

a. Install batteries, refer to para 5-38E.

b. Install air reservoir; refer to para 9-16B.

5-137
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-43. ALTERNATOR MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQURED RED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Installation. (20)

c. Operational Check. ( 5)

40 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All . 5-37A. Batteries Disconnected.

TEST EQUIPMENT 11-14A&C. Right Front Fender

None. Removed.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF .

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-5.

5-138
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-43. ALTERNATOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Three nuts (14)

and washers (13).

2. Three wires (12).

3. Adjusting nuts (2).

4. Bolt (4), washer (3)

and nut (15).

5. Adjustment rod (1).

6. Two nuts(11).

7. Alternator (9).

8. Two nuts (11), washers

(10) and bolts (8).

9. Alternator (9).

LEGEND:

1. ROD

2. NUT (2)

3. WASHER

4. BOLT

5. KEY

6. NUT

7. PULLEY

8. BOLT (2)

9. ALTERNATOR

10. WASHER (2)

11. NUT (2)

12. WIRE (3)

13. WASHER (3)

14. NUT (3)

15. N U T

16. BELT (2)

Remove.

Remove.

Unscrew to release tension

on alternator (9).

Remove.

Raise out of way.

Loosen, but do not remove.

Move towards engine and

remove two belts ( 16).

Remove slowly while holding

alternator (9) in place.

Remove.

5-139
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-43. ALTERNATOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

10. Nut (6), key (5), and Remove from alternator

pulley (7). shaft.

11. Pulley (7), key (5), and Install on alternator shaft. Transfer parts if not

nut (6). damaged.

12. Alternator (9). Aline and hold in place.

13. Two bolts (8), washers Install, but do not tighten.

(10) and nuts (11).

14. Adjustment rod (1). Lower and aline with mounting

hole on alternator (9).

15. Bolt (4), washer (3) Install but do not tighten.

and nut (15).

16. Alternator (9). Push towards engine and

replace two belts ( 16).

17. Adjusting nuts (2). Tighten until proper tension

is applied to belts (16)

(Refer to para 4-55).

18. Bolt (4) and nut (15). Tighten.

19. Two nuts (11 ) and bolts (8). Tighten.

20. Three wires (12). Install according to figure.

21. Three washers (13) Install and tighten.

and nuts (14).

22. Batteries. Connect per paragraph 5-37B.

23. Engine Start up (see TM 9-2320-273-10).

Verify voltmeter indicates normal.

 NOTE

Follow-on maintenance action required:

Replace fender paragraph 11-14B or D.

5-140
TM 9-2320-273-20

BATTERIES AND ALTERNATOR.

5-43. ALTERNATOR MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

LEGEND:

1. ROD

2. NUT (2)

3. WASHER

4. BOL T

5. KEY

6. NUT

7. PULLEY

8. BOLT (2)

9. ALTERNATOR

10. WASHER (2)

11. NUT (2)

12. WIRE (3)

13. WASHER (3)

14. NUT (3)

15. NUT

16. BELT (2)

5-141
TM 9-2320-273-20

EXTERIOR LIGHTING MAINTENANCE.

5-44. HEADLAMPS MAINTENANCE.

THIS TASK COVERS: APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Installation. (10)

c. Operational Check. ( 2)

22 Minutes Total

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

None. None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-8.

5-142
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-44. HEADLAMPS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Screw (15). Remove.

2. Rim cover (14). Remove by pushing up and

pulling outward to release

spring clip.

NOTE

Do not remove spring and two screws

which hold inner and outer bases together as headlight re-alinement will

be necessary.

5-143
TM 9-2320-273-20

EXTERIOR LIGHTING

5-44. HEADLAMPS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

3. Three short screws (13). a. Remove

b. Remove headlamp retainer (12).

4. Headlamp (11). Disconnect wire connector

(10) and remove.

5. Six screws (9). Remove

6. Headlamp base (8). Remove.

7. Two nuts (5), one bolt (6) Remove three headlamp wires (7)

and three washers (4). from terminal board (3).

8. Three wires (7). Install on terminal board (3).

9. Three washers (4) and two Install and tighten on

nuts (5), and one bolt (6). terminal board (3).

10. Headlamp base (8). Install with six screws (9) and

aline.

11. Wire connector (10). Connect to headlamp (11)

and insert headlamp into

base (8).

12. Headlamp retainer (12). Install with three short screws

(13).

13. Rim cover (14). Install with screw (15).

14. OPERATION switch (2). Set to NORMAL.

15. LAMP switch (1). Pull ON to second position.

16. HEADLAMP (11). Observe that headlamp comes ON.

17. DIMMER switch (16). Press and verify that HIGH beam

comes ON. Press again and verify

that LOW beam comes ON.

5-144
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-44. HEADLAMPS MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

5-145
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-45. FRONT TURN AND MARKER LAMPS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (6)

b. Installation. (6)

c. Operational Check, (1)

13 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-9, 5-11.

5-146
TM 9-2320-273-20

EXTERIOR LIGHTING.

Remove.

Remove.

Remove.

Remove.

5-45. FRONT TURN AND MARKER LAMPS MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

1. Four screws (12).

2. Lens (11).

3. Gasket ( 10).

4. Bulb (14).

5-147
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-45. FRONT TURN AND MARKER LAMPS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5. Two screws (4). Remove.

6. Lens (3). Remove.

7. Bulb (5). Remove.

8. Two nuts (7), washers Remove.

(6) and wire clamp (13).

9. Wire connector (8). Remove from front turn

and marker lamp (9).

10. Front turn and marker Remove.

lamp (9).

11. Front turn and marker Aline in mounting holes.

lamp (9).

12. Two washers (6), nuts Install and tighten.

(7) and wire clamp (13).

13. Wire connector (8). Connect to front turn and

marker lamp (9).

14. Bulb (5). Insert and turn to tighten.

15. Lens (3). Replace and aline.

16. Two screws (4). Install and tighten.

17. Bulb (14). Insert and turn to tighten.

18. Gasket (10). Replace and aline.

19. Lens(11). Replace and aline.

20. Four screws ( 12). Install and tighten.

21. OPERATION switch (2). Set to NORMAL.

22. LAMP switch (1). Pull out to first notch and

verify that marker lamps (9)

come ON.

5-148
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-45. FRONT TURN AND MARKER LAMPS MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

23. Turn signal control (15). Push lever down. Verify

that left turn lamp flashes.

24. Turn signal control (15). Push lever up. Verify that

right turn lamp flashes.

5-149
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-46. REAR LAMP ASSEMBLY MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

c. Operational Check. (2)

b. Installation.

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

1. Non-Flammable Cleaning Solvent (Refer to Appendix C)

2. Bearing Grease; GAA (Refer to Appendix C).

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 5-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

5-150

(5)
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-46. REAR LAMP ASSEMBLY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-151
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-46. REAR LAMP ASSEMBLY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Four screws (15). Remove

2. Lens (14). Remove.

3. Gasket (13}. Remove. Discard if cracking or tears

4. Bulb (12). Remove.

are evident.

5. Bulb (3). Remove.

6. Four screws (10). Remove.

7. Terminal cover (9). Remove.

NOTE

Remove grease from wire connections

with cleaning solvent before proceeding

to next step.

8. Three screws (6) and Remove.

washers (7).

9. Three wires (8). Remove.

10. Two nuts (4) and Remove.

washers (5).

11. Rear lamp assembly (11). Remove.

12. Rear lamp assembly (11). Aline mounting studs and

install.

13. Two washers (5) and Install and tighten.

nuts (4).

14. Three wires (8). Replace on rear lamp assembly according to figure.

15. Three washers (7) and Install and tighten.

screws (6).

16. Terminal cover (9). Fill with bearing grease;

then, aline and install.

5-152
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-46. REAR LAMP ASSEMBLY MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

5-153
TM 9-2320-273-20

EXTERIOR LIGHTING.

Install and tighten.

Insert and twist to tighten.

Insert and twist to tighten.

Install if it was removed.

Aline and install.

Install and tighten.

5-46. REAR LAMP ASSEMBLY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

17. Four screws (10).

18. Bulb (3).

19. Bulb (12).

20. Gasket (13).

21. Lens (14).

22. Four screws (15).

23. OPERATION switch (2). Set to NORMAL. First mechanic.

24. LAMP switch (1). Pull ON. First mechanic.

25. Rear lamp assembly (11). Verify that lights go ON. Second mechanic.

26. Brake pedal (16). Press down. First mechanic.

27. Rear lamp assembly (11). Verify that brake lights go Second mechanic.

ON.

28. Turn signal control (17). Press lever down. First mechanic.

29. Left rear lamp assembly (11). Verify that left turn signal Second mechanic.

lamp flashes.

30. Turn signal control (17). Push lever up. First mechanic.

31. Right rear lamp assembly (11). Verify that right turn signal Second mechanic.

lamp flashes.

5-154
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-46. REAR LAMP ASSEMBLY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-155
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-47. CLEARANCE LAMPS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (2)

b. Installation. (2)

c. Operational Check. (1)

5 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-9.

5-156
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-47. CLEARANCE LAMPS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Screw (3) and seal (4). Remove.

2. Lens (5) and gasket (6). Remove.

3. Bulb (7). Remove.

4. Two screws (8) and Remove.

ground washers (9).

Change 1 5-157
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-47. CLEARANCE LAMPS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5. Lamp base (10). Remove.

6. Gasket (11). Remove. Discard if cracking or tears

are evident

7. Wire connector (12). Disconnect.

8. Wire connector ( 12). Connect.

9. Gasket (11). Install.

10. Lamp base (10). Aline mounting holes.

11. Two screws (8) and Install and tighten.

ground washers (9).

12. Bulb (7). Install.

13. Gasket (6) and lens (5). Replace.

14. Screw (3) and seal (4). Install and tighten.

15. OPERATION switch (2). Set to NORMAL.

16. LAMP switch (1). Pull ON; verify that

clearance lamps come on.

17. CLEARANCE button (13). Press and verify that

clearance lamps go OFF.

NOTE

Upon completion of this task, apply a

suitable windshield sealant over screws

(8) to prevent water entry.

5-158 Change 1
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-47. CLEARANCE LAMPS MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

Change 1 5-159
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-48. BLACKOUT HEADLAMP MAINTENANCE.

THIS TASK COVERS (APPROXIMATE TIME REQURIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

c. Operational Check. (2)

12 Minutas Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-44A. Headlamp Removed if Wire

TEST EQUIPMENT (3) is To Be Removed.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-232O.273-10.

TROUBLESHOOTING REFERENCES

Table 5-13.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

5-180

b. Installation. (5 )
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-48. BLACKOUT HEADLAMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Three retaining screws Remove.

(10).

2. Lens cover (11). Remove.

5-161
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-48. BLACKOUT HEADLAMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

3. Gasket (9). Remove. Discard if cracking or tears are

evident.

4. Bulb (13). Remove.

5. Nut (6) and washer (5). Remove from terminal (4).

6. Wire (3). Remove from terminal (4).

7. Nut (7) and washer (8). Remove.

8. Blackout headlamp Remove.

assembly (12).

NOTE

To gain access to terminal block (4) refer

to para. 5-44.

9. Blackout headlamp Aline mounting stud and

assembly (12). install.

10. Washer (8) and nut (7). Install and tighten.

11. Wire (3). Connect to terminal (4).

12. Washer (5) and nut (6). Install and tighten.

13. Bulb (13). Install and twist to tighten.

14. Gasket (9). Install.

15. Lens cover (11). Aline and install.

16. Three retaining Tighten.

screws (10).

17. Headlamp. Install per paragraph 5-45.

18. OPERATION switch (2). Set to BLACKOUT.

19. LAMPswitch (1). Pull ON. Verify that blackout headlamp comes ON.

5-162
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-48. BLACKOUT HEADLAMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-163
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-49. BLACKOUT MARKER LAMPS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (5)

c. Operational Check. (2)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-44A. Headlamp Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-13.

5-164
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-49. BLACKOUT MARKER LAMPS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-165
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-49. BLACKOUT MARKER LAMPS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Two screws (13). Remove.

2. Lens cover (12). Remove.

3. Gasket (11). Remove. Discard if cracking or tears are

evident.

4. Bulb (14). Remove.

5. Wire connector (3). Remove.

6. Nut (9) and washer (8). Remove.

7. Blackout marker lamp (10). Remove.

8. Nut (7) and washer (6). Remove from terminal (5).

9. Wire (4). Remove from terminal (5).

B. INSTALLATION.

10. Wire (4). Install on terminal (5).

11. Washer (6) and nut (7). Install and tighten.

12. Blackout marker lamp (10). Aline mounting stud and

install.

13. Washer (8) and nut (9). Install and tighten.

14. Wire connector (3). Install in blackout marker

(10).

15. Bulb (14). Install and twist to tighten.

16. Gasket (11). Install.

17. Lens cover (12). Aline and install.

18. Two screws (13). Install and tighten.

19. Headlamp. Install per paragraph 5-44.

C. OPERATIONAL CHECK.

20. OPERATION switch (2). Set to BLACKOUT.

5-166
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-49. BLACKOUT MARKER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. OPERATIONAL CHECK (Continued).

21. LAMP switch (1). Pull On to first position and

verify that blackout marker

lamp comes ON.

5-167
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-50. BLACKOUT TAIL AND STOPLAMPS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

c. Operational Check. (2)

b. Installation (5)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

TwO (MOS-63B20).

REFERENCES (TM)

TM 92320273-10.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission In Neutral.

Park Brake Set.

Table 5-13.

5-168
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-50. BLACKOUT TAIL AND STOPLAMPS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Six screws (9). Loosen from blackout tail Screws (9) cannot be

and stop lamp assembly (12). removed from lens

cover (10).

2. Lens cover (10). Remove.

3. Gasket (8). Remove. Discard if cracking or tears are

evident.

4. Bulbs (7) and (11). Remove.

5-169
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-50. BLACKOUT TAIL AND STOPLAMPS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

5. Two wire connectors (6). Disconnect.

6. Two bolts (3), washers (4), Remove.

and star washers (5).

7. Blackout tail and stoplamp Remove.

assembly (12).

B. INSTALLATION.

8. Blackout tail and stoplamp Aline with mounting holes.

assembly (12).

9. Two star washers (5), washers Install and tighten.

(4) and bolts (3).

10. Two wire connectors (6). Reconnect.

11. Bulbs (7) and (11). Install and twist to tighten.

12. Gasket (8). Install.

13. Lens cover (10). Aline and install.

14. Six screws (9). Install and tighten.

C. OPERATIONAL CHECK.

15. OPERATION switch (2). Set to BLACKOUT. First mechanic.

16. LAMP switch (1). Pull ON. First mechanic.

17. Blackout tail and Verify that both tail Second mechanic.

stoplamp assembly (12). lights (7) come ON.

18. Brake pedal (13). Press down. First mechanic.

19. Blackout tail and Verify that both brake Second mechanic.

stoplamp assembly (12). lamps (11) come ON.

5-170
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-50. BLACKOUT TAIL AND STOPLAMPS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-171
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-51. STATIONARY WORK LAMP BULB REPLACEMENT.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION)

a. Removal. (5)

c. Operational (2)

b. Installation. (5)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 and M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

35W 12V GE4419

(or equal) Bulb.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-201P

TROUBLESHOOTING REFERENCES

Table 5-14,

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

5-172
TM 9-23202-73-20

EXTERIOR LIGHTING.

5-51. STATIONARY WORK LAMP BULB REPLACEMENT (Continued).

LOCATION/ITEM ACTION REMARKS

5-173
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-51. STATIONARY WORK LAMP BULB REPLACEMENT (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Prior to the removal of the bulb make certain that the work lamp switch is in the

OFF position.

1.

2.

3.

4.

Machine screw (2) and hex

nut (3).

Retainer ring (1).

Two screws (4).

Bulb (5).

Remove.

Remove.

Loosen and remove wires

(6).

Remove.

B. INSTALLATION.

5.

6.

7.

8.

Bulb (5).

Two screws (4).

Retainer ring (1).

Machine screw (2) and hex

nut.(3).

C. OPERATIONAL CHECK.

9. Work lamp switch.

Hold in position and

install wires (6).

Tighten.

Install.

Install and tighten.

Place switch in ON

position.

Check to see that lamp is lit.

5-174
TM 9-2320-273-20

EXTERIOR LIGHTING

5-51. STATIONARY WORK LAMP BULB REPLACEMENT (Continued).

LOCATION/lTEM ACTION REMARKS

5-17 5
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-52. STATIONARY WORK LAMP REPLACEMENT.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Installation. (15)

c. Operational Check. ( 2)

27 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916, and M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-14.

5-176
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-52. STATIONARY WORK LAMP REPLACEMENT (Continued).

LOCATION/ITEM ACTION REMARKS

1. Wire (2). Cut and remove connectors.

2. Hex nut (5) and Remove.

Iockwasher (4).

3. Cone spacer (3). Remove.

4. Lamp assembly (1). Remove.

B. INSTALLATION.

5. Lamp assembly (1). Install.

6. Cone spacer (3), hex nut (5) Install. Tighten nut.

and Iockwasher (4).

7. Wire (2). Reconnect, using suitable

electrical connectors.

C. OPERATIONAL CHECK.

8. WORK LAMP switch. Place switch in Check to see that

ON position. lamp is lit.

5-177
TM 9-2320273-20

EXTERIOR LIGHTING.

5-53. PORTABLE WORK LAMP BULB REPLACEMENT.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

c. Operational Check. (2)

b. Installation. (5)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

35W12VGE4419

(or equal) Bulb.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 5-14.

None. None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

5-178
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-53. PORTABLE WORK LAMP BULB REPLACEMENT (Continued).

LOCATION/lTEM ACTION REMARKS

1. Machine screw (6) and Remove.

hex nut (7).

2. Retainer (1). Remove from housing (5),

3. Two screws (3). Loosen and remove two wires (4).

4. Bulb (2). Remove.

5-179
TM 9-2320-273-20

EXTERIOR LIGHTING

Hold in place and install

wires (4).

Tighten.

Install in housing (5).

Install on housing (5).

Install and tighten.

5-53. PORTABLE WORK LAMP BULB REPLACEMENT (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

5. Bulb (2).

6. Two screws (3).

7. Bulb (2).

8. Retainer ring (1).

9. Machine screw (6)

and hex nut (7).

C. OPERATIONAL CHECK.

10. Lamp. Plug into outside cab Lamp should now be lit.

receptacle and flip switch

to ON position.

5-180
TM 9-2320-273-20

This page intentionally left blank.

5-181
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-54. PORTABLE WORK LAMP MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Disassembly. (10)

b. Assembly. (10)

c. Operational Check. (10)

30 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

 APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 553A. Bulb Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERiALS/PARTS (P/N)

None.

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

One (MOS63B20).

REFERENCES (TM)

TM 9-2320-273-10.

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-14.

5-182
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-54. PORTABLE WORK LAMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. DISASSEMBLY.

1. Wire nut (17).

2. Lock nut (1)

3. Switch (2).

4. Hex nut (16) and

Iockwasher (15).

Remove.

Remove.

Remove.

Remove.

5-183
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-54 PORTABLE WORK LAMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. DISASSEMBLY (Continued).

5. Hex bolt (7), plastic

washer (6) and spacer

(14).

6. Hex nut (9) and

Iockwasher (8).

7. Bracket (5), plastic

washer (4) and flat

washer (3).

8. Screw (13).

9. Lever (10).

10. Rubber suction cup

(11).

 B. ASSEMBLY.

11. Rubber suction cup

(11).

12. Lever (10).

13. Screw (13).

14. Plastic washer (4)

and flat washer (3).

15. Bracket (5).

16. Lockwasher (8) and

hex nut (9).

17. Hex bolt (7), spacer

(14) and plastic

washer (6).

18. Hex nut (16) and

Iockwasher (15).

19. Switch (2).

20. Locknut (1).

Remove.

Remove.

Remwe,

Remove.

Remwe.

Remove from housing (12).

Install in housing (12).

Insert through housing (12)

and suction cup (11).

Install and tighten.

Install.

Install.

Install and tighten.

Install.

Install and tighten.

Install.

Install and tighten.

5-184
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-54. PORTABLE WORK LAMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. ASSEMBLY (Continued).

21. Wire nut (17). Twist one wire from switch

and one wire from supply

used together and install.

22. Bulb (18). Install Refer to para

5-53.

C. OPERATIONAL CHECK.

23. Lamp Assembly Plug into outside cab Lamp should now be lit.

receptacle and flip switch

to ON position.

5-185
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-55. TRAILER LAMP CONNECTOR MAINTENANCE (12 AND 24 VOLT).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal (24 Volt Connector). (10) f. Test (24 Volt and 12 Volt). ( 5)

b. Removal (12 Volt Connector). (10)

c. Inspection (12 Volt and 24 Volt Connector). (10) 55 Minutes Total.

d. Installation (24 Volt Connector). (10)

e. Installation (12 Volt Connector). (10)

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915, M916, M917, and M920. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Tape.

Marking Pen.

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 5-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

5-186
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-55. TRAILER LAMP CONNECTOR MAINTENANCE (12 VOLT AND 24 VOLT) (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

If wires are to be cut, mark each with

tape and pen.

A. REMOVAL (24 VOLT CONNECTOR).

1. Connector assembly (8). Unscrew from back of connector assembly (8) and pull free.

2. Four bolts (1) and Remove.

nuts (2).

5-187
TM 9-2320-273-20

CAB INTERIOR LIGHTING AND SWITCHES.

5-56. DOME LAMP MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

c. Operational Check. (1)

b. Installation.

11 Minutes Total.

INTIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-14.

5-190

(5)
TM 9-2320-273-20

CAB INTERIOR LIGHTING AND SWITCHES.

5-56. DOME LAMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Three screws (6).

2. Lens (5).

3. Bulb (4).

4. Two screws (3) and

trim washers (7).

5. Dome lamp assembly (8).

6. Wire connector (1).

Remove.

Remove.

Remove.

Remove.

Remove.

Disconnect.

5-191
TM 9-2320-273-20

CAB INTERIOR LIGHTING AND SWITCHES.

5-56. DOME LAMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

7. Wire connector (1) Reconnect.

8. Dome lamp assembly Aline and install.

(8).

9. Two trim washers (7) Install and tighten.

and screws (3).

10. Bulb (4). Install and twist to tighten.

11. Lens (5) Aline and install.

12. Three screws (6). Install and tighten.

C. OPERATIONAL CHECK.

13. DOME LAMP switch (2). Press ON and OFF. Verify

that lamp comes ON and goes

OFF.

5-192
TM 9-2320-273-20

CAB INTERIOR LIGHTING AND SWITCHES.

5-56. DOME LAMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-193
TM 9-2320-273-20

CAB INTERIOR LIGHTING AND SWITCHES

5-57. HEADLAMP DIMMER SWITCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Installation. (10)

c. Operational Check. (2)

22 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (PIN)

None.

PERSONNEL REQUIRED

One MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-8.

5-194
TM 9-2320-273-20

CAB INTERIOR LIGHTING AND SWITCHES.

Lift from dimmer switch (3).

Remove.

Remove from under cab

floor board.

Remove.

Remove.

5-57. HEADLAMP DIMMER SWITCH MAINTENANCE (Continued).

LOCATlON/lTEM ACTION REMARKS

A. REMOVAL.

1. Floor mat.

2. Two screws (4) and

washers (5).

3. Headlamp dimmer

switch (3).

4. Three screws (7)

and washers (6).

5. Four wires (8).

5-195
TM 9-2320-273-20

CAB INTERIOR LIGHTING AND SWITCHES.

5-57. HEADLAMP DIMMER SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

6. Four wires (8). Install on dimmer switch (3)

according to figure.

7. Three washers (6) and Install and tighten.

screws (7).

8. Headlamps dimmer switch (3). Install into cab floor board.

9. Two washers (5) and screws (4). Install and tighten.

10. Floor mat. Replace.

C. OPERATIONAL CHECK.

11. LAMP switch (1). Pull ON.

12. HEADLAMP DIMMER switch (3). Press down. Verify that high

beam indicator lamp (2) comes ON.

Press down on headlamp dimmer

switch (3) again and verify that high

beam indicator lamp (2) goes OUT.

5-196
TM 9-2320-273-20

CAB INTERIOR LIGHTING AND SWITCHES

5-57. HEADLAMP DIMMER SWITCH MAINTENANCE (Continued).

LOCATlON/lTEM ACTION REMARKS

5-197
TM 9-2320-273-20

CAB INTERIOR LIGHTING AND SWITCHES.

5-58. TURN SIGNAL CONTROL MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (7)

b. Installation. (7)

c. Operational Check. (1)

15 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-11.

5-198
TM 9-2320-273-20

CAB INTERIOR LIGHTING AND SWITCHES.

5-58. TURN SIGNAL CONTROL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Two screws (11) and Remove.

strap (6).

2. Two screws (2). Remove.

3. Cover (3). Remove.

4. Handle (13) with Remove.

bulb (4).

5. Flare tab (12). Remove.

6. Connector (10). Disconnect.

5-199
TM 9-2320-273-20

CAB INTERIOR LIGHTINGAND SWITCHES.

5-58. TURN SIGNAL CONTROL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

7. Bolt (9) and Remove from cable

washer (8). clamp (7).

8. Turn signal control (5). Remove from steering

column (14).

B. INSTALLATION.

9. Flare tab (12). Place over pin and press down.

10. Handle (13) with bulb (4). Install and twist to tighten.

11. Cover (3). Install.

12. Two screws (2). Install and tighten.

13. Turn signal control (5). Aline and install on steering

column (14).

14. Strap (6) and two screws Replace and tighten.

(11).

15. Connector (10). Reconnect.

16. Cable clamp (7). Aline.

17. Washer (8) and bolt (9). Install and tighten.

C. OPERATIONAL CHECK.

18. OPERATION switch (1). Set to Normal.

19. Directional signal Place in down position and

handle (13). observe that left green lamp

flashes.

Place handle in up position

and observe that right green

lamp flashes.

20. Flare tab (12). Pull tab and observe that red

lamp flashes.

5-200
TM 9-2320-273-20

CAB INTERIOR LIGHTING AND SWITCHES.

5-58. TURN SIGNAL CONTROL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-201
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS

5-59. ELECTRICAL INSTRUMENTS MAINTENANCE (LH CLUSTER).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (5)

c. Operational Check. (5)

15 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EOUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Park Brake Set.

Transmission In Neutral.

TROUBLESHOOTING REFERENCES

Table 5-7.

5-202
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-59. ELECTRICAL INSTRUMENTS MAINTENANCE (LH CLUSTER) (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVA L

1. Four quarter-turn

screws (1).

2. Hinged instrument

panel (2).

NOTE

The gages covered in the following procedures are identical as far as removal and

installation; therefore, only one is covered

the FUEL gage.

Loosen.

Lower.

5-203
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-59. ELECTRICAL INSTRUMENTS MAINTENANCE (LH CLUSTER) (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Illuminating bulb (10).

4. Two nuts (5) and

washers (6).

5. Three wires (7).

6. Two nuts (3) and

washers (4).

7. Bracket (9).

8. FUEL gage (8).

 B. INSTALLATION.

9.

10.

11.

12.

1 3.

1 4.

15.

16.

17.

FUEL gage (8).

Bracket (9).

Two washers (4)

and nuts (3).

Three wires (7).

Two washers (6)

and nuts (5).

Illuminating bulb (10).

Hinged instrument panel (2).

Four quarter-turn

screws (1).

Batteries.

C. OPERATIONAL CHECK.

18. Engine.

19. Gages.

Remove.

Remove.

Remove.

Remove.

Remove.

Remove from instrument

panel.

Aline and insert in panel.

Install on back of FUEL

gage (8).

Install and tighten.

Install according to

figure.

Install and tighten.

Install.

Raise into place.

Tighten.

Connect per paragraph 5-37B.

Start up (see TM 9-2320-273-10).

Observe gage replaced and verify

operation.

5-204
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-59. ELECTRICAL INSTRUMENTS MAINTENANCE (LH CLUSTER) (Continued).

LOCATION/lTEM ACTION REMARKS

5-205
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-60. CIGAR LIGHTER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation, (5)

c. Operational Check. (1)

11 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS {P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

TM 9-2320-273-10.

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-14.

5-206
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-60. CIGAR LIGHTER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Four quarter-turn

screws (1).

2. Hinged instrument panel (2).

3. Wire cap connector (6).

Loosen.

Lower.

Remove.

5-207
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-60. CIGAR LIGHTER MAINTENANCE (Continued).

LOCATlON/lTEM ACTION REMARKS

A. REMOVAL (Continued).

4. Heating unit and Remove.

button assembly (4).

5. Cigar lighter casing (5). Unscrew from cigar

lighter unit (3).

6. Cigar lighter unit (3). Remove from instrument

panel.

B. INSTALLATION.

7. Cigar lighter unit (3).

8. Cigar lighter casing (5).

9. Wire cap connector (6).

10. Hinged instrument panel (2).

11. Four quarter-turn

screws (1).

12. Batteries.

C. OPERATIONAL CHECK

13. Heating unit and button

assembly (4).

Insert and press. Verify

that element gets hot.

Install in instrument

panel.

Install on cigar lighter

unit (3) and tighten.

Install on cigar lighter

unit (3).

Raise into place.

Tighten.

Connect per paragraph 5-37B.

5-208
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-60. CIGAR LIGHTER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-209
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-61. LOW AIR PRESSURE INDICATOR LAMP MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOW TASK DESCRIPTION.)

a. Removal. (1)

b. Installation

3 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 5-6.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in NEUTRAL.

Park Brake Set.

5-210

c. Operational Check.

(1)

(1)
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-61. LOW AIR PRESSURE INDICATOR LAMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Four quarter-turn

screws (1).

2. Hinged instrument panel

(2).

3. Two wires (3)

4. LOW AIR PRESSURE

indicator lamp unit

(4).

Loosen.

Lower.

Remove.

Remove from instrument panel.

5-211
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-61. LOW AIR PRESSURE INDICATOR LAMP MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

B. INSTALLATION.

5. LOW AIR PRESSURE Aline and press into

indicator lamp unit (4). instrument panel.

6. Two wires (3). Connect to LOW Al R

PRESSURE indicator

lamp unit (4).

7. Hinged instrument panel (2). Raise into place.

8. Four quarter-turn Tighten.

screws (1).

9. Batteries. Connect per paragraph 5-37B.

C. OPERATIONAL CHECK.

10. Air pressure supply Bleed off air pressure

reservoir. (see TM 9-2320-273-10).

11. ENGINE RUN switch (5). Turn on. Verify that LOW

AIR PRESSURE lamp comes

ON.

5-212
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-61. LOW AIR PRESSURE INDICATOR LAMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-213
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-62. ELECTRICAL SWITCHES MAINTENANCE (RH CLUSTER).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (30)

b. Installation. (30)

c. Operational Check. ( 5)

65 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

1. OPERATION Switch-All. 5-37A. Batteries Disconnected.

2. ENGINE RETARDER Switch-All.

3. LAMP Switch-All.

4. BACKUP ALARM Switch -

M916 Thru M920.

5. WORK LAMPS Switch -

M916 and M920.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERlALS/PARTS (P/N)

Masking tape.

Marking pen.

Tie Wrap, MS-3367-2-0 (96906).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 5-4, 5-6, 5-14.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

5-214
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-62. ELECTRICAL SWITCHES MAINTENANCE (RH CLUSTER) (Continued).

LOCATION/lTEM ACTION REMARKS

5-215
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-62. ELECTRICAL SWITCHES MAINTENANCE (RH CLUSTER) (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Tag all wires prior to disconnecting for ease of correct

installation.

A. REMOVA L

1. Two quarter-turn Loosen.

screws (21).

2. Hinged instrument panel Lower.

(6).

3. Hex Nut (7). Remove from ENGINE RETARDER

switch (8).

4. Three wires (9). Disconnect and remove ENGINE

RETARDER Switch (8).

5. Hex nut (20). Remove from WORK LAMPS M916 and M920

switch (12). only.

6. Two screws (10) Unscrew and remove WORK LAMPS M916 and M920

and wires (11). switch (12). only.

7. Hex Nut (19). Remove from BACKUP ALARM M916 thru M920.

switch (14).

8. Two screws (13) Unscrew and remove BACKUP M916 thru M920.

and wires (15). ALARM switch (14).

9. Hex Nut (18). Remove from OPERATION

switch (16).

10. Twelve wires (17). Disconnect and remove OPERATION

switch (16).

11. Knob and shaft Remove by pressing release button (3)

assembly (1). on top of LAMP switch (2).

12. Knurled nut (22). Remove from LAMP switch (2).

13. Tie wrap (4). Cut and remove from around LAMP If used.

switch (2) and LAMP switch connector (5).

14. Lamp switch a. Disconnect by pulling outward

connector (5). slightly on two molded clips (23).

b. Remove LAMP switch (2).

5-216
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-62. ELECTRICAL SWITCHES MAINTENANCE (RH CLUSTER) (Continued).

LOCATION/lTEM ACTION REMARKS

5-217
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-62. ELECTRICAL SWITCHES MAINTENANCE (RH CLUSTER) (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Install all wires as you marked at removal.

B. INSTALLATION.

15. LAMP switch con- Push on to LAMP switch (2). Ensure two molded clips

nector (5). (23) are snapped over

two tabs (24).

16. New tie wrap (4). Install around LAMP switch (2) If one was present

and LAMP switch connector (5). at removal.

17. LAMP switch (2). a. Position in hinged instrument

panel (6).

b. Secure with knurled nut (22).

18. Knob and shaft Insert shaft into LAMP switch Push in firmly until

assembly (1). (2). locked in position.

19. Twelve wires (17). Connect to OPERATION

switch (16).

20. OPERATION switch (16). a. Position in hinged instrument

panel (6).

b. Secure with hex nut (18).

21. Two wires (15). Secure to BACKUP ALARM M916 thru M920.

switch (14) with two screws

(13).

22. BACKUP ALARM a. Position in hinged instrument M916 thru M920.

switch (14). panel (6).

b. Secure with hex nut (19).

23. Two wires (11). Connect to WORK LAMPS M916 and M920

switch (12) with two screws (10). only.

24. WORK LAMPS a. Position in hinged instrument M916 and M920

switch (12). panel (6). only.

b. Secure with hex nut (20).

25. Three wires (9). Connect to ENGINE RETARDER

switch (8).

26. ENGINE RETARDER a. Position in hinged instrument

switch (8). panel (6).

b. Secure with hex nut (7).

27. Hinged instrument Raise into position and secure

panel (6). with two quarter-turn screws (21).

28. Batteries. Connect (refer to para. 5-37B).

C . OPERATIONAL CHECK.

29. Switch (as required). Check operation.

5-218
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-62. ELECTRICAL SWITCHES MAINTENANCE (RH CLUSTER) (Continued).

LOCATION/ITEM ACTION REMARKS

5-219
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-63. INDICATOR LAMPS MAINTENANCE (RH CLUSTER).

THIS TASK COVERS: (APPROXIMATE: TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (3)

b. Installation. (3)

c. Operational Check. (3)

9 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

1. M916 Thru M920-ALL.

2. M915 ALL(Except PTO).

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 5-7.

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

None. None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

5-220
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-63. INDICATOR LAMPS MAINTENANCE (RH CLUSTER) (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Two quarter-turn

screws (1).

2. Hinged instrument

panel (2).

3. HIGH BEAM bulb (3).

Loosen.

Lower hinged panel.

Remove.

5-221
TM 9-2320-273-20

PANEL MOUNTED lNSTRUMENTS

Insert in holder.

Insert in holder.

Insert in holder.

Insert in holder.

Insert in holder.

Insert in holder.

Raise into place.

Tighten.

5-63. lNDICATOR LAMPS MAINTENANCE (RH CLUSTER) (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

4. PARK BRAKE bulb (4). Remove.

5. PTO bulb (5). Remove.

6. DIFF LOCK bulb (6). Remove.

7. ENG TEMP bulb (7). Remove.

8. ENG OIL bulb (8). Remove.

B. INSTALLATION.

9. ENG OIL bulb (8).

10. ENG TEMP bulb (7).

11. DIFF LOCK bulb (6).

12. PTO bulb (5).

13. PARK BRAKE bulb (4).

14. HIGH BEAM bulb (3).

15. Hinged instrument

panel (2).

16. Two quarter-turn

Screws (1).

C. OPERATIONAL CHECK.

17. Switch (as required). Turn on and verify

operation of new buIb.

5-222
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-63. INDICATOR LAMPS MAINTENANCE (RH CLUSTER) (Continued).

LOCATION/lTEM ACTION REMARKS

5-223
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-64. CLEARANCE LAMPS SWITCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

c. Operational Check.

b. Installation

11 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

ALL. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-9.

5-224

(5)

(1)
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-64. CLEARANCE LAMPS SWITCH MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

5-225
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-64. CLEARANCE LAMPS SWITCH MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

A. REMOVAL .

1. Knurled nut (8). Remove.

2. Clearance lamps Remove from instrument

switch (6). panel.

3. Hex nut (7). Remove.

4. Two screws (3) and Remove.

washers (4).

5. Four wires (5). Remove

B. INSTALLATION.

6. Four wires (5), two Install and tighten on

washers (4), and clearance lamps switch (6).

screws (3).

7. Hex nut (7). Install and adjust to proper

depth on switch (6) to al low

installation of knurled nut (8).

8. Clearance lamps Install in instrument panel.

switch (6).

9. Knurled nut (8). Install and tighten.

10. Batteries. Connect per paragraph 5-37B.

C. OPERATIONAL CHECK.

11. LAMP switch (1). Pull ON.

12. OPERATION switch (2). Set to Normal.

13. CLEARANCE LAMPS Press and release. First mechanic.

switch (6).

14. Clearance lamps. Verify that lamps go Second mechanic.

OFF and ON.

5-226
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-64. CLEARANCE LAMPS SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-227
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-65. CLEARANCE INDICATOR LAMP MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (1)

b. Installation. (1)

c. Operational Check. (1)

3 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (PIN)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

None.

5-228
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS .

5-65. CLEARANCE INDICATOR LAMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 A. REMOVAL.

1. Three wires (3).

2. Clearance indicator

lamp unit (2).

Remove from underneath panel.

Remove from instrument panel

by pushing outward from behind

panel.

5-229
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-65. CLEARANCE INDICATOR LAMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 B. INSTALLATION.

3. Clearance indicator

lamp unit (2).

4. Three wires (3).

5. Batteries.

 C. OPERATIONAL CHECK.

Aline and press into

instrument panel.

Connect to clearance

indicator lamp unit

(2).

Connect per paragraph 5-38.

6. LAMP switch (1). Pull ON. Verify that CLEARANCE

LAMPS indicator (2) comes ON.

5-230
TM 9-2320-273-20

This page intentionally left blank.

5-231
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-66. TACHOGRAPH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Reading Tachograph Disk. (AR)

b. Disk Pack Removal. ( 2)

c. Disk Pack Installation. ( 2)

d. Tachograph Removal. ( 7)

e. Tachograph Installation. ( 7)

f. Operational Check. ( 5)

23 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Seven Day Disk Pack (7530-01-060-1628).

PERSONNEL REQUIRED

One MOS-63B20).

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

REFERENCES (TM]

GENERAL SAFETY INSTRUCTIONS

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 5-7.

Engine OFF.

Transmission in Neutral.

Park Brake Set.

5-232
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-66. TACHOGRAPH MAINTENANCE (Continued).

A. READING TACHOGRAPH DISK.

TIME The outer ring of the disk has markings for 24 hours. Any events shown on the disk by

markings happened at the time shown on the outer ring of the disk. Also, each time the

tachograph is opened, a small tic mark is put onto the disk by each stylus. (There is a

stylus for vehicle speed, engine speed, and distance).

SPEED Next to the outer marks for time there is a band about 3/4” wide. The stylus moving in

this area records vehicle speed at any moment. You can see at a glance if an operator has

been speeding.

RPM After the speed band, there is a narrower band (about 1/2”). Another stylus moves in

this area recording engine RPM. You can see if the engine has been overrevved. You can

also determine whether the driver warmed up the engine before moving out. To see this,

compare RPM reading with vehicle speed. The disk should record the RPM for the proper

number of minutes before vehicle speed is recorded.

DISTANCE A third stylus moves in the narrowest band, closest to the disk’s center. This stylus moves

away from the center for 5 miles and then toward the center for 5 miles.

In the disk shown, the vehicle did not move fro midnight to about 5:37 AM. Then the engine was

started, rewed momentarily to about 1800 RPM, then idled at 600 RPM for six or seven minutes, rewed

to 2100 RPM momentarily, then shut down at about 5:46. At 7:10 AM the engine was started again,

idled for 22 minutes. At 7:32 it moved out, attaining a speed of about 28 mph, then stopped and idled

for eight minutes. Then it moved out, accelerated to about 45 mph and did stop-and-go driving for about

32 minutes, accelerating from 0 to about 45 mph three times and traveling about 15 miles, At 8:11 it

stopped, having traveled about 15 miles, it idled for about 48 minutes and then was shut down at about

9 AM.

5-233
TM 9-2320-273-20

PANEL MOUTED INSTRUMENTS.

5-66. TACHOGRAPH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. DISK PACK REMOVAL.

CAUTION

The disk pack must be changed before the end

of the seventh day to prevent stylus damage.

1. Key (6). Unlock tachograph (3) with

key (6) and swing open.

2. Retainer (1). a. Turn to the left and remove.

b. Lift out used disk pack (2).

NOTE

If pack is not properly instaIled, instruments

and dials may not function.

C. DISK PACK INSTALLATION. ]

3. New disk pack (2). a. Enter date, driver’s name, Enter in center field on disk

vehicle number and mile- number one.

age.

b. Ensure pack is under separating knife (7) and under

tachometer lever (4).

c. Aline time at installation

with red dot (5) on disk.

d. With disk pack in position

on center hub, place retainer (1) in place and turn

to the right.

4. Tachograph (3). Swing up into closed position

and lock with key (6).

5-234
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-66. TACHOGRAPH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-235
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-66. TACHOGRAPH MAlNTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

D. TACHOGRAPH REMOVAL.

5.

6.

7.

8.

9.

10.

11.

12.

Two quarter turn screws (1).

Hinged instrument panel (2).

RPM cable (7).

MPH cable (9).

Wire connector (6).

Two knurled nuts (3) and

washers (4).

Two brackets (5).

Tachograph (8).

E. TACHOGRAPH INSTALLATION.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Tachograph (8).

Two brackets (5).

Two washers (4) and knurled

nuts (3).

Wire connector (6).

MPH cable (9).

RPM cable (7).

Hinged instrument panel (2).

Two quarter-turn screws (1).

Batteries.

F. OPERATIONAL CHECK.

22. Engine.

23. Tachograph (8).

24. Engine.

Remove.

Lower hinged panel.

Disconnect.

Disconnect.

Disconnect.

Remove.

Remove.

Remove.

Insert into panel.

Install on tachograph (8).

Install and tighten.

Reconnect.

Reconnect.

Reconnect.

Raise into place.

Tighten.

Connect per paragraph 5-37B.

Start (Refer to TM 9-2320-

273-10).

Check operation.

Shut down (Refer to TM 9-2320-

273-10).

5-236
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-55. TRAILER LIGHTS CONNECTOR MAINTENANCE (12 AND 24 VOLT) (Continued).

LOCATION/ITEM ACTION REMARKS

E. INSTALLATION (12 VOLT CONNECTOR) (Continued).

13. Rubber boot (7). Slide into position over terminal connections.

F. TEST (24 VOLT AND 12 VOLT).

14. Connector assemblies a. Hook up suitable

(9) and (10). trailer.

b. Activate cab controls. 1st mechanic.

c. Check for proper 2nd mechanic.

functioning of all

trailer lights.

5-189
TM 9-2320-273-20

EXTERIOR LIGHTING.

5-55. TRAILER LIGHTS CONNECTOR MAINTENANCE (12 AND 24 VOLT) (Continued).

LOCATION/lTEM ACTION REMARKS

 A. REMOVAL (24 VOLT CONNECTOR) (Continued).

3. Connector assembly Remove from mounting

(9). plate (11).

B. REMOVAL (12 VOLT CONNECTOR).

4. Rubber boot (7). Twist and pull from back Replace if cracked.

of connector assembly (8).

5. Seven terminal Unscrew and remove wires. Mark wires to facilitate

screws (6). installation.

6. TwO bolts (5), Remove.

washers (3), and

nuts (4).

7. Connector assembly Remove from mounting

(10). plate (11).

C. INSPECTION (24 VOLT AND 12 VOLT).

8. Connectors assemblies Inspect pin receptacles Replace as necessary.

(9) and (10). (24V) and pins (12V) for

corrosion.

D. INSTALLATION (24 VOLT CONNECTOR).

9. Connector assembly Mount into plate (11)

(9). with four bolts (1) and

nuts (2). Tighten.

10. Connector assembly (8). Push into back of connector

assembly (9) and screw on

ring.

E. INSTALLATION (12 VOLT CONNECTOR).

11. Connector assembly Mount into mounting plate

(10). (11) with two bolts (5), washers (3}, and nuts (4). Tighten.

12. Seven terminal Insert seven wires as marked

screws (6). at removal and fasten with

screws (6). Tighten.

5-188
TM 9-2320-273-20

PANEL MOUNTED INSTRUMENTS.

5-66. TACHOGRAPH MAINTENANCE, {Continued).

LOCATION/lTEM ACTION REMARKS

5-237
TM 9-2320-273-20

ELECTRICAL HORN AND CAB HEATER CONTROL.

5-67. HORN BUTTON MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (2.0)

b. Installation. (2.0)

c. Operational Check. (0.5)

4.5 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

ALL. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 5-14.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission In Neutral.

Park Brake Set.

5-238
TM 9-2320-273-20

ELECTRIC HORN AND CAB HEATER CONTROL.

Loosen.

Lower.

Remove.

Push down and twist counterclockwise, and remove.

Remove.

Remove.

5-67. HORN BUTTON MAINTENANCE (Continued),

LOCATION/lTEM ACTION REMARKS

1. Three quarter turn screws (9).

2. Hinged panel (8).

3. Horn relay (7).

4. Horn button (1).

5. Retainer (2), and spring (3).

6. Brass cup (4).

5-239
TM 9-2320-273-20

ELECTRIC HORN AND CAB HEATER CONTROL.

5-67. HORN BUTTON MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

7. Three screws (6). I

8. Base plate (5). I

Loosen and remove.

Remove.

B. INSTALLATION.

9.

10.

11.

12.

13.

14.

15.

16.

17.

Base plate (5).

Three screws (6).

Brass cup (4).

Spring (3) and retainer

(2).

Horn button (1).

Horn relay (7).

Hinged panel (8).

Three quarter turn

screws (9).

Batteries.

C. OPERATIONAL CHECK.]

18. Horn button (1).

Place in steering wheel.

Screw in and tighten.

Install.

Install over brass cup.

Install.

Install.

Raise into position.

Tighten.

Connect (refer to para 5-37 B).

Press. Verify that horn

operates.

Push down and turn clockwise.

5-240
TM 9-2320-273-20

ELECTRIC HORN AND CAB HEATER CONTROL.

5-67. HORN BUTTON MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-241
TM 9-2320-273-20

ELECTRIC HORN AND CAB HEATER CONTROL.

5-68. HORN MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

c. Operational Check. ( 1)

b. Installation. ( 5)

11 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 5-14.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission In Neutral.

Park Brake Set.

5-242
TM 9-2320-273-20

ELECTRIC HORN AND CAB HEATER CONTROL.

Disconnect.

Remove.

Remove.

5-68. HORN MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Wire connector (1).

2. Bolt (2), washer (5)

and nut (6).

3. Horn assembly (4).

5-243
TM 9-2320-273-20

ELECTRIC HORN AND CAB HEATER CONTROL.

5-68. HORN MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 B. INSTALLATION.

4. Horn assembly (4).

5. Bolt (2), washer (5)

and nut (6).

6. Wire connector (1).

7. Batteries

C. OPERATIONAL CHECK.

Replace and aline mounting

hole.

Replace and tighten.

Reconnect.

Connect (refer to para 5-37 B).

8. Horn button (7).

9. Horn adjusting screw (3).

Press and verify the horn

works.

Adjust for maximum loudness.

5-244
TM 9-2320-273-20

ELECTRIC HORN AND CAB HEATER CONTROL.

5-68. HORN MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-245
TM 9-2320-273-20

ELECTRIC HORN AND CAB HEATER CONTROL.

5-69. HEATER FAN SWITCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Installation. ( 5)

c. Operational Check. ( 1)

11 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 537A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 92320273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission In Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-14.

5-246
TM 9-2320-273-20

ELECTRIC HORN AND CAB HEATER CONTROL.

Remove.

Slide back over cables.

Pull off.

Remove.

Remove from lower control panel.

Remove.

5-69. HEATER FAN SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Two screws (2).

2. Back panel cover (7).

3. Heater knob (6).

4. Hex nut (5).

5. Heater fan switch (4).

6. Four wires (3). Tag for proper location.

5-247
TM 9-2320-273-20

ELECTRIC HORN AND CAB HEATER CONTROL.

5-69. HEATER FAN SWITCH MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

B. INSTALLATION.

7. Four wires (3). Install on heater fan

switch (4).

8. Heater fan switch (4). Aline and install in

lower control panel.

9. Hex nut (5). Install and tighten.

10. Heater knob (6). Install.

11. Back panel cover (7). Slide over cables and

press on back of lower

control panel.

12. Two screws (2). Install and tighten.

13. Batteries. Connect per paragraph

5-37B.

C. OPERATIONAL CHECK.

14. ENGINE RUN switch (1).

15. HEATER FAN switch (4).

Turn left to accessory.

Rotate heater knob (6)

through all positions (Lo,

Medium, Hi) and verify

the heater fan increases

and decreases accordingly. Verify that fan motor

shuts off with heater knob

(6) set to OFF.

5-248
TM 9-2320-273-20

ELECTRIC HORN AND CAB HEATER CONTROL.

5-69. HEATER FAN SWITCH MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

5-249
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-70. OIL PRESSURE SENDING UNIT MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REWIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

c. Operational Check ( 2)

b. Installation. ( 5)

.

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 92320273-10.

TM 9-2320-273-20F?

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission In Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-7.

5-250
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

Remove.

Remove.

5-70. OIL PRESSURE SENDING UNIT MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

1. Nut (5) and washer (4).

2. Wire (3).

3. Oil pressure sending

unit (2).

Remove.

5-251
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-70. OIL PRESSURE SENDING UNIT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 B. INSTALLATION.

4. Oil pressure sending

unit (2).

5. Wire (3).

6. Washer (4) and nut (5).

 C. OPERATIONAL CHECK.

7. Engine.

8. Oil pressure gage (1).

Coat threads with Iiquid

teflon. Install and tighten.

Place on oil pressure sending

unit (2).

Install and tighten.

Start up (see TM 9-2320-273-10).

Observe that gage indicates a

pressure reading.

5-252
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-70. OIL PRESSURE SENDING UNIT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-253
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-71. OIL PRESSURE SWITCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

c. Operational Check. ( 1)

b. Installation. ( 5)

11 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 92320273-10.

TM 92320273-20P.

TROUBLESHOOTING REFERENCES

Table 5-6.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission In Neutral.

Park Brake Set.

5-254
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

Remove.

Remove.

Remove.

5-71. OIL PRESSURE SWITCH MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

1. Screw (2) and washer (3). I

2. Wire (4). I

3. Oil pressure switch (1). I

5-255
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-71. OIL PRESSURE SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

4. Oil pressure switch (1).

5. Wire (4).

6. Washer (3) and

screw (2).

Coat threads with liquid

teflon. Install and tighten.

Place on oil pressure

switch (1).

Install and tighten.

 C. OPERATIONAL CHECK.

7. Engine Run switch (6). Turn ON. Verify that Low

Oil indicator (5) lamp goes ON.

5-256
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-71. OIL PRESSURE SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-257
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-72. WATER TEMPERATURE SENDING UNIT MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Installation. ( 5)

c. Operational Check. (10)

20 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-42A. Radiator Drained Below

TEST EQUIPMENT

Sending Unit Level.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission In Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-7.

5-258
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-72. WATER TEMPERATURE SENDING UNIT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-259
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-72. WATER TEMPERATURE SENDING UNIT MAINTENANCE (Continued).

LOCATION/ITEM - ACTION REMARKS

 A. REMOVAL.

1.

2.

3.

Nut (5) and

washer (4).

Wire (3).

Water temperature

sending unit (1).

B. INSTALLATION.

4.

5.

6.

—

Remove.

Remove from terminal (2).

Remove.

Water temperature

sending unit (1).

Wire (3).

Washer (4) and

nut (5).

Coat threads with liquid

teflon. Install and tighten.

Place on terminal (2).

Install and tighten.

 C. OPERATIONAL CHECK.

7. Engine

8. Water temperature

gage (6).

Start up (see TM 9-2320-273-10).

Observe that temperature

increases as truck engine

warms up.

NOTE

Follow on maintenance required:

Fill radiator per paragraph 4-42.

5-260
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-72. WATER TEMPERATURE SENDING UNIT MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

5-261
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-73. WATER TEMPERATURE SWITCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Installation. ( 5)

c. Operational Check. (20)

30 Minutes Total .

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-42A. Radiator Drained Below

Switch Level.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320- 273-20P.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission In Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-7.

5-262
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-73. WATER TEMPERATURE SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 A. REMOVAL.

1. Nut (1) and

Iockwasher (2).

2. Wire (3).

Remove.

Remove from terminal (4).

5-263
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-73. WATER TEMPERATURE SWITCH MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

A. REMOVAL (Continued).

3. Water temperature Remove.

switch (5).

B. INSTALLATION.

4. Water temperature

switch (5).

5. Wire (3).

6. Lockwasher (2) and

nut (1).

Coat threads with Iiquid

teflon. Install and

tighten.

Place on terminal (4).

Install on terminal

(4) and tighten.

C. OPERATIONAL CHECK.

7. Engine. Start (refer to TM 9-2320-273-10).

Monitor WATER TEMP gage, switch

shouId close and activate indicator

lamp when coolant reaches 225°F

(107°C) .

Let radiator cool before removing cap. Remove

radiator cap in two steps. First, place a thick

cloth over the cap and slowly rotate cap left to

its first stop; pause, and let pressure escape from

the cooling system. Then rotate cap farther left

until you can remove it. Failure to follow this procedure can result in serious burns.

NOTE

Follow-on maintenance required: Fill radiator per

paragraph 4-42.

5-264
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-73. WATER TEMPERATURE SWITCH MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

5-265
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATIQN KIT.

5-74. ETHER TEMPERATURE SWITCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REWIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (2)

b. Installation. (2)

c. Operational Check. (2)

6 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-42A. Radiator Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Container (Approx 2 gal).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

Coolant Temperature Below 50°F.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission In Neutral.

Park Brake Set.

Table 5-3.

5-266
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-74. ETHER TEMPERATURE SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 A. REMOVAL.

1. Wire connector (1).

2. Ether temperature

switch (2).

Remove.

Remove. Place container to

catch coolant

draining from block.

5-267
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-74. ETHER TEMPERATURE SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

3. Ether temperature

switch (2).

4. Wire connector (1).

Coat threads with liquid

teflon. Install and tighten.

Reconnect.

 C. OPERATIONAL CHECK.

NOTE

Follow-on maintenance required:

Fill radiator per paragraph 4-42.

5. Engine. Start using cold start procedure

(refer to TM 9-2320-273-10).

5-268
TM 9-2320-273-20

This page intentionally left blank.

5-269
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-75. NEUTRAL SAFETY SWITCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a.. Removal. ( 5)

c. Operational Check. ( 2)

b. Installation ( 5)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

None. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 6-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission In Neutral.

Park Brake Set.

5-270
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-75. NEUTRAL SAFETY SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 A. REMOVAL.

1. Nine screws (2). Remove.

2. Ratio selector Remove.

side cover (1).

3. Two screws (5) and Remove.

washers (4).

5-271
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-75. NEUTRAL SAFETY SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

4. Two wires (3). Remove.

5. Two screws (7), Remove.

washers (8) and

nuts (9).

6. Neutral safety Remove.

switch (6).

B. INSTALLATION.

7. Neutral safety

switch (6).

8. Two screws (7),

washers (8) and nuts (9).

9. Two wires (3), washers

(4) and screws (5).

10. Ratio selector

side cover (1).

11. Nine screws (2).

c. OPERATIONAL CHECK.

12. Ratio selector

lever (10).

13. Engine.

Aline and install.

Install and tighten.

Install and tighten on

neutral safety switch (6).

Aline and install.

Install and tighten.

Set to N.

Start up (see TM 9-2320-273-10).

Install per

illustration.

5-272
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-75. NEUTRAL SAFETY SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-273
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-76. TRANSMISSION OIL TEMPERATURE SENDING UNIT MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 2)

b. Installation. ( 2)

c. Operational Check. (20)

24 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 6-9A. Transmission Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIAL/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

LO 9-2320-273-12.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 5-7.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

5-274
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-76. TRANSMISSION OIL TEMPERATURE SENDING UNIT MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

1. Hex nut (5) and washer (4). Remove.

2. Wire (3). Remove from terminal (2).

3. Transmission oil tempera- Remove.

ture sending unit (1).

5-275
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-76. TRANSMISSION-OIL TEMPERATURE SENDING UNIT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

4. Transmisison oil tempera- Coat threads with liquid

ture sending unit (1). teflon. Install and tighten.

5. Wire (3). Replace on terminal (2).

6. Washer (4) and hex nut (5). Replace on terminal (2),

and tighten.

NOTE

Follow on maintenance required:

Fill transmission per paragraph

6-9.

5-276
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-76. TRANSMISSION OIL TEMPERATURE SENDING UNIT MAINTENANCE (Continued).

LOCATlON/lTEM ACTION REMARKS

C. OPERATIONAL CHECK.

7. Engine. Start-up (refer to TM 9-2320-273-10).

Check TRANS OIL TEMP gage to be

certain temperature readings go up as

the oil warms.

5-277
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-77. BACKUP SWITCH AND CLUTCH DISENGAGEMENT SENSOR MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

c. Operational Check. ( 2)

b. Installatlon. ( 5)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 6-9C. Cab Floor Inspection

TEST EQUIPMENT

None.

SPECIAL TOOLS

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 5-12.

9-13A.

Plate Removed.

Air Reservoirs Drained.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

5-278
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-77. BACKUP SWITCH AND CLUTCH DISENGAGEMENT SENSOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

On M915 model only, access can be gained

outside truck by reaching through under cab

floor.

1. Wire Connector (2). Disconnect.

2. Backup switch (1). Remove.

3. Two screws (7) Unscrew and remove

and washers (6). two wires (5).

4. Clutch disengagement Unscrew and remove.

sensor (4).

Mark for

identification.

5-279
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES. AND WINTERIZATION KIT.

5-77. BACKUP SWITCH AND CLUTCH DISENGAGEMENT SENSOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

5. Backup switch (1). Coat threads with liquid Teflon. Install and tighten.

6. Wire connector (2). Connect to backup switch (1).

7. Clutch disengagement Apply liquid Teflon

sensor (4). to threads and screw

into valve body.

8. Two wires (5). Fasten to terminals

with two washers (6)

and screws (7).

9. Cab floor inspection Replace per paragraph 6-9.

plate. (M916 thru M920 only).

C. OPERATIONAL CHECK.

10. Engine. Start up (see TM 9-2320-273-

10).

11. Ratio selector lever (3). Set to R1 or R2 First mechanic.

Verify that backup lamps Second mechanic.

come ON.

12. Vehicle. Test drive. Check operation Disengagernent sensor

of engine retarder (see shouId override engine

TM 9-2320-273-10). retarder when rpm

drops below 700.

5-280
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-77. BACKUP SWITCH AND CLUTCH DISENGAGEMENT SENSOR MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

5-281
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-78. BACKUP ALARM MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

c. Operational Check. ( 2)

b. Installation. ( 5)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 thru M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-6.

5-282
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-78. BACKUP ALARM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Wire (4). Disconnect.

2. Four bolts (5), washers Remove.

(6), and nuts (7).

3. Backup alarm (8). Remove.

5-283
TM 9-2320-273-20

SENDING UNITS. SWITCHING DEVICES. AND WINTERIZATION KIT.

Aline mounting holes.

Install and tighten.

Reconnect.

5-78. BACKUP ALARM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

4. Backup alarm (8).

5. Four bolts (5), washers

(6), and nuts (7).

6. Wire (4).

C. OPERATIONAL CHECK.

7. Engine.

8. BACKUP ALARM

switch (1).

9. PARKING BRAKE

control (2).

10. Ratio selector (3).

11. Backup alarm (8).

Start up (see TM 9-2320-273-

10).

Set to NORMAL.

Pull ON.

Set to R1 or R2.

Verify that alarm operates.

5-284
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WlNTERIZATION KIT.

5-78. BACKUP ALARM MAINTENANCE (Continued).

LOCATlON/lTEM ACTION REMARKS

5-285
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-79. FUEL LEVEL SENDlNG UNIT MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Installation. ( 5)

c. Operational Check. ( 1)

11 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Sending Unit Gasket (2013).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 5-7.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

5-286
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-79. FUEL LEVEL SENDING UNIT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-287

Do not smoke or handle flammable materials

while performing this task. Flame or explosion will cause physical injury.
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-79. FUEL LEVEL SENDING UNIT MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

A. REMOVAL.

1.

2.

3.

4.

5.

Screw (1) and washers (2)

and (4).

Wire (3).

Five screws (10).

Wire (9).

Flange (5). gasket (6).

and fuel Ievel sending

unit (8).

B. INSTALLATION.

Remove.

Remove.

Remove.

Remove

Remove from tank {7).

6. Fuel level sending unit (8),

gasket (6), and flange (5).

7. Wire (9) and five screws (10).

8. Wire (3), washers (2) and (4),

and screw (1).

Aline and insert into

tank (7).

Install and tighten.

Install and tighten.

 C. OPERATIONAL CHECK.

9. ENGINE RUN switch (11). Turn ON. Verify that FUEL

gage (12) indicates fuel level.

Discard gasket (6).

5-288

TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-80. LOW AIR PRESSURE BUZZER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REWIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 8)

b. Installation. ( 5)

c. Operational Check. ( 3)

16 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT 9-13A. Air Reservoirs Drained.

None.

SPECIAL TOOLS

None.

MATERIAL/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

Table 5-6.

5-290
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-80. LOW AIR PRESSURE BUZZER MAINTENANCE. (Continued).

LOCATlON/lTEM ACTION REMARKS

A. REMOVAL .

1. Three quarter-turn screws (1). Loosen.

2. Circuit panel cover (2). Lower.

5-291
TM 9-2320-273-20

SENDING UNITS. SWITCHING DEVICES, AND WINTERIZATION KIT.

5-80. LOW AIR PRESSURE BUZZER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Two screws (5) washers (4). Remove.

4. Two wires (3). Remove.

5. Two bolts (7) washers (8) Remove.

and nuts (9).

6. Low air pressure buzzer (6). Remove.

B. INSTALLATION.

7. Low air pressure buzzer (6). Aline mounting holes.

8. Two bolts (7), washers (8), Install and tighten.

and nuts (9).

9. Two wires (3). Place on low air pressure

buzzer (6) according to

figure.

10. Two washers (4) and screws (5). Install and tighten.

11. Circuit panel cover (2).

12. Three quarter-turn screws (1).

13. Batteries.

C. OPERATIONAL CHECK

14.

15.

Engine.

Two AIR PRESSURE GAGES

(10), LOW AIR PRESSURE

INDICATOR (11), LOW AIR

PRESSURE BUZZER (6).

Raise into place.

Tighten.

Connect per paragraph 5-37B.

Start up (see TM 9-2320-273-

10).

Verify that gages indicate LOW

PRESSURE. indicator lamp

comes ON, and buzzer is

ACTIVATED.

5-292
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-80. LOW AIR PRESSURE BUZZER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-293
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-81. LOW AIR PRESSURE SWITCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 9)

c. Operational Check, ( 6)

b. Installation,

25 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

9-13A. Air Reservoirs Drained.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

Table 5-6.

5-294

(10)
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-81. LOW AIR PRESSURE SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Switch is located on firewall.

A. REMOVAL.

1. Two screws (3), washers (4) Remove.

and four wires (5).

2. Two screws (2). Remove.

3. Low air pressure switch (6). Remove.

4. Low air pressure switch Remove.

base (7).

5-295
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-81. LOW AIR PRESSURE SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

5.

6.

7.

8.

9.

C. OPERATIONAL CHECK,

10. Engine.

11. LOW AIR PRESSURE gages

(8), LOW AIR PRESSURE

indicator (9) and low air

pressure buzzer (1).

Low air pressure switch

base (7).

Low air pressure

switch (6).

Two screws (2).

Four wires (5), two washers

(4) and screws (3).

Batteries.

Coat threads with liquid teflon.

Install and tighten.

Aline and install on

Install and tighten.

Install and tighten.

base (7).

Connect per paragraph 5-37B.

Start up (see TM 9-2320-273-

10).

Verify that gages indicate low

pressure, indicator lamp comes

ON, and buzzer is activated.

5-296
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-81. LOW AIR PRESSURE SWITCH MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

5-297
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-82. PARK BRAKE SWITCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 3)

b. Installation. ( 3)

c. Operational Check. ( 5)

11 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT 9-13A. Air Reservoirs Drained.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 5-7.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

5-298
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-82. PARK BRAKE SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Three quarter-turn screws (1). Loosen.

2. Circuit panel cover (2). Lower.

5-299
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES ANB WINTERIZATION KIT.

5-82. PARK BRAKE SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Two screws (7) and washers Remove.

(6).

4. Three wires (3). Remove.

5. Park brake switch (4). Remove from adapter (5).

B. INSTALLATION.

6. Park brake switch (4). Coat threads with liquid tefIon. Install and tighten into

adapter (5).

7. Three wires (3), two washers Install and tighten,

(6) and screws (7).

8. Circuit panel cover (2). Raise into place.

9. Three quarter-turn screws (1). Tighten.

10. Batteries. Connect per paragraph 5-37B.

C. OPERATIONAL CHECK

11. Engine. Start up (see TM 9-2320-273-

10).

12. PARKING BRAKE control Pull ON.

(8).

13. PARK BRAKE indicator (9). Observe that indicator lamp

comes ON.

5-300
TM 9-2320-273-20

SENDING UNITS. SWITCHING DEVICES, AND WINTERIZATION KIT.

582. PARK BRAKE SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-301
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-83. DIFFERENTIAL LOCK-UP SWITCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

Removal. (3)

Installation. (3)

Operational Check. (2)

8 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT 9-13A. Air Reservoirs Drained.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-23202-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 5-7.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground,

GENERAL SAFETY INSTRUCTIONS

Engine OFF

Transmission in Neutral

Park Brake Set.

5-302
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-83. DIFFERENTIAL LOCK-UP SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Three quarter-turn screws (1). Loosen.

2. Circuit panel cover (2). Lower .

3. Two screws (7) and Remove.

washers (6).

4. Two wires (3). Remove.

5. Differential lock-up switch (4). Remove.

6. Hex nut (5). Remove.

5-303
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-83. DIFFERENTIAL L LOCK-UP SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

7. Hex nut (5). Install on differential lock-up

switch (4).

8. Differential lock-up switch (4). Coat threads with liquid

teflon. Install and tighten.

9. Hex nut (5). Tighten.

10. Two wires (3), washers (6) Install and tighten.

screws (7).

11. Circuit panel cover (2). Raise into place.

12. Three quarter-turn Tighten.

screws (1).

13. Batteries. Connect per paragraph 5-37B.

C. OPERATIONAL CHECK.

14. Engine. Start up (see TM 9-2320-273-10).

15. DIFFERENTIAL LOCK-UP Set to LOCK.

control (8).

16. DIFFERENTIAL LOCK-UP Observe that indicator

indicator (9). lamp comes on.

5-304
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-83. DIFFERENTIAL LOCK-UP SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-305
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-84. POWER TAKEOFF(PTO) SWITCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 Thru M920. None. None

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 12-2.

5-306

b. Installation. (5)

c. Operational Check. (2)
TM 9-2320-273-20

SENDING UNITS. SWITCHING DEVICES AND WINTERIZATlON KIT.

Remove.

Remove with two

wires (3).

5-84. POWER TAKEOFF (PTO) SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Nutcap (7) and

Iockwasher (6).

2. Two screws (9),

grounding washer (8)

and wire clamp (10).

5-307
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-84. POWER TAKEOFF (PTO) SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

3. PTO switch (4). Remove from bracket (5).

4. PTO switch (4).

5. Lockwasher (6) and nutcap

(7).

6. Two wires (3).

7. Two screws (9), grounding

washer (8) and wire clamp

(10).

8. Engine.

9. PTO control knob (2).

10. PTO indicator (1).

Install on bracket (5).

Install and tighten.

Install on PTO switch (4).

Install to PTO.

Start up (see TM 9-2320-

273-10).

Pull to engage.

Observe that indicator

lamp comes ON.

5-308
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-84. POWER TAKEOFF (PTO) SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-309
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-85. STOPLAMP SWITCH MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (2)

c. Operational Check. (1)

b. Installation

5 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

Two (MOS-63B20).

References (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-11.

5-310

(2)
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-85. STOPLAMP SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Two nuts (2) and washers (3). Remove.

2. Two wires (4). Remove.

3. Two screws (5). Remove.

4. Stoplamp switch (6). Remove.

5-311
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-85. STOPLAMP SWITCH MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

B. INSTALLATION.

5. Stoplamp switch (6).

6. Two screws (5).

7. Two wires (4),

washers (3) and

nuts (2).

C. OPERATIONAL CHECK.

8. Engine.

9. OPERATION switch (1).

10. BRAKE pedal (7).

11. BRAKE lamps.

Aline and install.

Install and tighten.

Install and tighten.

Start up (see

TM 9-2320-273-10).

Set to NORMAL.

Press DOWN. First mechanic.

Verify that brake Second mechanic.

lamps come ON.

5-312
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-85. STOPLAMP SWITCH MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-313
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-86. INSTRUMENT RELAY MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (2)

b. Installation, (2)

c. Operational Check. (1)

5 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATlONS PARAGRAPH CONDITION DESCRIPTION

1. M917, M918, M919 – Two Relays.

2. M915 – Seven Relays. None. None.

3. M916 and M920 – Eight Relays.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

None.

5-314
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-86. INSTRUMENT RELAY MAINTENANCE

LOCATION/lTEM ACTION REMARKS

1. Three quarter-turn screws (1). Loosen.

2. Circuit panel cover (2). Lower.

3. Relay (4). Remove from relay bracket (3).

4. Relay (4). Aline and press into relay bracket (3).

5-315
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-86. INSTRUMENT RELAY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5. Circuit panel cover (2). Raise into place.

6. Three quarter-turn screws (1). Tighten.

7. Relay. Refer to paragraph 2-34 and

check the operation of the

relay replaced.

5-316
TM 9-2320-273-20

This page intentionally left blank.

5-317
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-87. WINTERIZATION KIT CIRCUIT BREAKERS, BOX, AND RECEPTACLE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION. )

a. Removal of Circuit Breaker (es). (15) d. Removal of Circuit Breaker Box and Receptacle, (60)

b. Installation of Circuit Breaker (es). (15) e. Installation of Circuit Breaker Box and Receptacle. (60)

c. Operational Check. (15) f. Operational Check (30)

195 Minutes

Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

30 Amp Circuit Breaker (1).

15 Amp Circuit Breaker (3).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 5-14.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

110 VAC Cable Disconnected From

Power Source and Receptacle.

All Breakers Set to OFF.

5-318
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-87. WINTERIZATION KIT CIRCUIT BREAKERS, BOX, AND RECEPTACLE

MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Four screws (7) and Remove and lift out inner Open outer cover to

washers (8). panel (6). gain access to (6),

(7), and (8).

2. Two screws (1) or (4). Remove and lift off wires. Screws (1) if 15 amp

breaker; screws (4) if

 30 amp breaker. Mark

wires for location.

3. Circuit breaker (2) Remove by pulling out. Circuit breakers are the

or (3). plug in type. Item (2)

15 amp; Item (3) 30

amp.

4. Circuit breaker Install by pushing into Be sure breaker is

(2) or (3). position. securely snapped in.

5. Two screws (1) or (4). Place wires into position Be sure to reattach

on circuit breaker and wires as marked in step 2.

secure with screws.

6. Inner panel (6). Set into position in box

(5) and attach with four

screws (7) and washers (8).

5-319
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-87. WINTERIZATION KIT CIRCUIT BREAKERS, BOX, AND RECEPTACLE

MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. OPERATIONAL CHECK.

7. Receptacle (18).

8. Circuit breaker (2)

Plug in 110 VAC power cord,

or (3). Flip replaced breaker to ON

and verify that appropriate

heater is functional.

D. REMOVAL OF CIRCUIT BREAKER BOX AND RECEPTACLE.

9.

10.

11.

12.

13.

14.

15.

Breaker box (5).

Four cable to receptacle

box connectors (15).

Six screws (1) and two

screws (4).

Three bolts (9) with washers

(10) and nuts (11).

Receptacle (18).

Three wires (19).

Four bolts (14), washers

(13) and nuts (12).

Open outer cover, remove four

washers (8) and screws (7) and

inner panel (6) to gain access to

box attaching hardware.

Unscrew.

Unscrew and remove eight

wires (17).

Unscrew and remove circuit

breaker t/ox (5) with receptacle

box (16) attached.

Remove retaining screws.

Disconnect from receptacle

(18) and remove receptacle.

Unscrew and remove receptacle

box (16) from circuit breaker

box (5).

E. INSTALLATION OF CIRCUIT BREAKER BOX AND RECEPTACLE.

16.

17.

18.

19.

After verifying proper

heater functions, flip all

breakers to OF F and disconnect power cord.

Mark each wire and pull

wire out of receptacle box.

Mark position before

disconnecting.

Receptacle box (16). Attach to circuit box (5) with

Three wires..

Circuit breaker box

Eight wires (17).

four bolts (14), washers (13)

and nuts (12).

Connect to receptacle (18) and

install receptacle to box (16).

(5). Mount to vehicle with three bolts

(9), washers (10) and nuts (11 ).

Push thru either side of receptacle

box and fasten to circuit breakers

as marked, with six screws (1)

and two screws (4).

5-320
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-87. WINTERIZATION KIT CIRCUIT BREAKERS. BOX, AND RECEPTACLE

MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

20. Four cable connectors (15), Screw onto receptacle box (16).

21. Inner panel (6). Fasten to box (5) with four

screws (7) and washers (8).

Insure all breakers are OFF.

22. Receptacle (18).

23. Four circuit breakers

(2) and (3).

24. Four circuit breakers

(2) and (3).

Plug in 110 VAC power cord.

Flip to ON and verify that all

four heaters are functioning.

Flip to OFF, disconnect power

cord and close outer cover on

circuit breaker box (5).

NOTE

Follow-on maintenance action required:

Connect 12 VDC vehicle batteries per

para 5-37B.

5-321
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-88. WINTERIZATION KIT TRANSMISSION OIL HEATER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal of Transmission Oil Heater, (30)

b. Installation of Transmission Oil Heater. (30)

c. Operational Check. (15)

75 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 6-9A. Transmission Oil Drained.

5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

One (MOS-63B20). Vehicle Parked on Level Ground.

REFERENCES (TM) GENERAL SAFETY INSTRUCTIONS

TM 9-2320-273-10. Engine OFF.

TM 9-2320-273-20P. Transmission in Neutral.

Park Brake Set.

110 VAC Cable Disconnected From Power Source

and Receptacle.

All Breakers Set to OFF.

TROUBLESHOOTING REFERENCES

Table 5-14.

5-322
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-88. WINTERIZATION KIT TRANSMISSION OIL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL OF HEATER.

1. Heater cover (7). a, Remove two bolts (5) and

Iockwashers (6).

b. Remove heater cover (7) from

heater mounting plate (2).

2. Wire assembly (11). Remove from heater mounting

plate (2).

5-323
 TM 9-2320-273-20

SENDING UNITS. SWITCHING DEVICES, AND WINTERIZATION KIT.

5-88. WINTERIZATION KIT TRANSMISSION OIL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL OF HEATER (Continued).

3. Cable grip (10).

4. Heater mounting plate (2)

and heater (1).

B. INSTALLATION OF HEATER.

5. Heater (1) and heater

mounting plate (2).

6. Cable grip (10).

7. Wire assembly (11).

8. Heater cover (7).

C. OPERATIONAL CHECK.

9. Refill transmission.

10. 110 VAC power cord.

11. Heater (1).

12. Vehicle batteries.

a. Remove nut (8) and washer (9).

b. Remove cable grip (10) from

heater cover (7).

a. Remove two screws (4) and

Iockwashers (3).

b. Remove heater mounting plate

(2) and heater (1) from transmission.

a. Install in transmission.

b. Secure with two screws (4)

and Iockwashers (3).

a. Install in heater cover (7).

b. Secure with nut (8) and

washer (9).

Connect to heater mounting plate

(2).

a. Install on heater mounting

plate (2).

b. Secure with two bolts (5)

and Iockwashers (6).

Refer to para 6-9E.

Plug into source and vehicle

receptacle, flip transmission

heater circuit breaker to ON.

Verify that heater is functioning,

Reconnect per para 5-37B.

Flip circuit breaker OFF

and disconnect power

cord after check.

5-324
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES. AND WINTERIZATION KIT.

5-88. WINTERIZATION KIT TRANSMISSION OIL HEATER MAINTENANCE (Continued).

5-325
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-89. WINTERIZATION KIT ENGINE OIL HEATER THERMOSTAT MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal of Thermostat. (30)

b. Installation of Thermostat. (30)

c. Operational Check. (15)

75 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-14A. Engine Oil Drained.

5-37A. Batteries Disconnected.

TEST EQUIPMENT

None,

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Gasket (1020803).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 5-14.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

110 VAC Cable Disconnected From Power

Source and Receptacle.

All Breakers Set to Off.

5-326
TM 9-2320-273-20

SENDING UNITS. SWITCHING DEVICES, AND WINTERIZATION KIT.

Mark locations.

5-89. WINTERIZATION KIT ENGINE OIL HEATER THERMOSTAT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL OF THERMOSTAT.

1. Two screws (6) and Unscrew and remove

washers (7). cover (5).

2. Wire assembly (4). Disconnect from terminals

on plate (8).

5-327
TM 9-2320-273-20

SENDING UNITS. SWITCHING DEVICES, AND WINTERIZATION KIT.

5-89. WINTERIZATION KIT ENGINE OIL HEATER THERMOSTAT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL OF THERMOSTAT (Continued).

3. Clamp (3) Remove from transmission front Remove if wire assembly

by taking out one screw. is to be disconnected at

circuit breaker box.

4. Two screws (2) with Remove and lift off plate (8) with

washers. thermostat and coil (9) attached.

5. Two screws (12) and Unscrew to remove retainer (10). Lift out thermostat and

washers (11). coil (9). Replace as necessary.

6. Gasket (1). Remove. Discard.

B. INSTALLATION OF THERMOSTAT.

7. New gasket (1). Install to side of oil pan.

8. Thermostat and coil (9). Install to plate (8) with retainer

(10), two washers (11) and

two screws (12).

9. Plate (8) with coil and Mount over gasket with two

thermostat (9) attached. screws (2) and washers.

10. Clamp (3). Install over wire assembly If removed.

(4) at transmission front.

11. Wire assembly (4). Connect to heater terminals Install as marked.

on plate (8).

12. Cover (5). Install on plate (8) with two

screws (2) and washers.

C. OPERATIONAL CHECK.

13. Refill engine oil pan. Refer to para 4-14.

14. 110 VAC power cord. Plug into source and vehicle re- Flip breaker to OFF and

ceptacle, flip engine oil circuit remove power cord after

breaker ON and verify that check.

heater is functioning properly.

5-328
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES. AND WINTERIZATION KIT.

5-89. WINTERIZATION KIT ENGINE OIL HEATER THERMOSTAT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-329
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES AND WINTERIZATION KIT.

5-89. WINTERIZATION KIT ENGINE OIL HEATER THERMOSTAT MAINTENANCE (Continued)

LOCATION/lTEM ACTION REMARKS

C. OPERATIONAL CHECK (continued).

NOTE

If after thermostat maintenance the heater

does not function properly, refer to DS/GS

as the oil pan will have to be removed for

service of the heater,

Follow-on maintenance required:

Reconnect vehicle batteries per para 5-37B.

5-330
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-89. WINTERIZATION KIT ENGINE OIL HEATER THERMOSTAT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-331
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-90. WINTERIZATION KIT ENGINE COOLANT HEATER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal of Heater (60)

b. Installation of Heater. (60)

c. Operational Check . (15)

135 Minutes Total

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-42A. Engine Cooling System Drained.

4-25A/4-27A. Engine Air Filter and

TEST EQUIPMENT Ducts Removed.

None. 4-37A. Batteries Disconnected.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (See App C) .

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 5-14.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

110 VAC Cable Disconnected

From Power Source and Receptacle.

All Breakers Set to OFF.

5-332
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION-KIT.

5-90. WINTERIZATION KIT ENGINE COOLANT HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-333
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-90. WINTERIZATION KIT ENGINE COOLANT HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Two hose clamps (5).

Tee (2) and nipple (1).

Two hose clamps (5).

Bushing (19).

Two hose clamps (5).

Two nipples (41) and

valve (36).

Elbow (28), two nipples

(24) and (27), tee (26),

and draincock (25).

Wire assembly (22), cable

grip (15), washer (16) and

locknut (17).

Three harness clamps (13),

(14), and (39).

Wire assembly (22).

Two screws (29), nuts (34)

and Iockwashers (33).

Bracket (10).

Loosen and remove hose (6).

Unscrew and remove from water

manifold. Remove draincock (3)

and adapter (4).

Loosen and remove hose (6)

from pipe (7), adapter (4),

and clamp (14).

Unscrew and remove from rear

port of heater (23).

Loosen and remove hose (6)

from two adapters (30) and (35).

Unscrew and remove from

engine block with elbow (42)

and adapter (35).

Unscrew and remove from forward port on bottom of heater

(23).

Remove from thermostat (18).

a.

b.

a.

b.

Remove two nuts (12), bolts

(32) and Iockwashers (11)

and remove harness clamps

(13) and (14).

Remove nut (37), bolt (40)

and Iockwasher (38) and remove harness clamp (39).

Pull thru to circuit breaker

if service is required.

Replace terminals (20) or

splice connectors (21) as

required.

Unscrew and remove heater

(23) and thermostat (18).

Separate from support (31)

by removing bolt (32), lockwasher (9), and nut (8).

5-334
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-90. WINTERIZATION KIT ENGINE COOLANT HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-335
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-90. WINTERIZATION KIT ENGINE COOLANT HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

The thermostat (18) cannot be replaced

separate of the heater.

13. Bracket (10). Assemble to support (31) and

secure with bolt (32), lockwasher (9) and nut (8).

14. Heater (23) and thermo- Mount to support (31) with

stat (12). two screws (29), nuts (34)

and Iockwashers (33).

15. Wire assembly (22). Reroute, if removed.

16. Three harness clamps a. Install harness clamps (13)

(13), (14), and (39). and (14) and secure with

two nuts (12), bolts (32)

and Iockwashers (11).

b. Install harness clamp (39)

and secure with nut (37),

bolt (40) and Iockwasher

(38).

17. Wire assembly (22), cable Install on thermostat (18).

grip (15), washer (16) and

locknut (17).

18. Elbow (28), two nipples

(24) and (27), tee (26),

a. Coat threads with liquid teflon.

b. Install on forward port on

and draincock (25). bottom of heater (23).

19. Two nipples (41), valve

(36), elbow (42), and

a. Coat threads with liquid teflon.

b. Install on engine block.

adapter (35).

29. Hose (6). a. Install two hose clamps (5).

b. Fit ends on adapters (30)

and (35).

c. Tighten hose clamps (5).

21. Bushing (19). a. Coat threads with liquid teflon.

b. Install in rear port of heater

(23).

5-336
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT

5-337
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-90. WINTERIZATION KIT ENGINE COOLANT HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

22. Hose (6). a. Insert thru harness clamp (14).

b. Install two hose clamps (5).

c. Fit ends on adapter (4) and

pipe (7).

d. Tighten hose clamps (5).

23. Nipple (1) and tee (2). a. Coat threads with liquid teflon.

b. Install nipple (1) into water

manifold,

c. Install draincock (3) and

adapter (4).

24. Hose (6). a. Install two hose clamps (5).

b. Fit ends on adapter (4) and

pipe (7).

c. Tighten hose clamps (5).

C. OPERATIONAL CHECK.

25. Engine coolant system. Refill, refer to para 4-42C.

26. Engine air cleaner. Install, refer to para 4-25D.

27. Engine turbo air inlet. Install, refer to para 4-27C.

28. 110 VAC power cord. Plug into curcuit breaker box

receptacle and power source.

29. Engine coolant heater Flip to ON and verify that After check, flip circuit

circuit breaker. heater (23) functions properly. breaker to OFF and disconnect power cord.

30. Vehicle batteries. Reconnect, per para 5-37B.

31. Engine. Start up (refer to TM 9-2320-

273-10) and check for leaks.

32. Engine. Shut down, refer to TM 9-

2320-273-10.

5-338
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-339
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-91. WINTERIZATION KIT BATTERY BOX HEATER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (60)

b.Installation. (60)

c. Operational Check. (15)

135 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAP H CONDITION DESCRIPTION

All. 5-38A. Batteries Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 5-14.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level ground.

Battery Thermostat Must be Below 35°F

for Actuation of Heater.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

110 VAC Cable Disconnected From

Power Source and Receptacle.

All Breakers Set to OFF.

5-340
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-91. WINTERIZATION KIT BATTERY BOX HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL

1. Cover assembly (1). a. Mark and disconnect terminals Refer to para 5-92.

(2) from terminal strip,

b. Remove six screws (15) and

Iockwashers (16).

c. Remove cover assembly from

bottom of battery box.

2. Heater (3) and loom (6). a. Remove four capscrews (14),

washers (8), and nuts (7).

b. Remove heater (3) and loom

(6) from bottom cover (13).

3. Four brackets (9) and tube a. Remove four screws (5), lockclips (4). washers (10) and nuts (11).

b. Remove four brackets (9)

and tube clips (4).

4. Cover (17), insulation (19), a. Remove.

and seals (20) and (21). b. Clean surface with Milsolv (18). Milsolv (18) supplied

with kit.

5-341
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-91. WINTERIZATION KIT BATTERY BOX HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

5. Insulation (12) and bottom a. Remove.

cover (13). b. Clean surface with Milsolv

(18).

B. INSTALLATION

6. Insulation (12) and bottom a. Apply adhesive (22) to Adhesive (22) supplied

cover (13). bottom cover (13). with kit.

7. Insulation (19) and cover (17). a. Install insulation (19)

in place.

b. Install cover (17).

8. Four seals (20) and (21). a. Apply adhesive (22) to

seals.

b. Stick in place.

9. Heater (3) and loom (6). a. Install four brackets (9)

and tube clips (4).

b. Secure with four screws Do not tighten nuts (11)

(5), Iockwashers (10), at this time.

and nuts (11).

c. Position heater (3) and

loom (6) on bottom cover

(13) and aline four mounting holes.

d. Install four capscrews (14),

washers (8) and nuts (7)

and tighten.

e. Tighten four nuts (11),

Iockwashers (10) and

screws (5).

10. Cover assembly (1). Install to bottom of battery Position loom (6) so it is

box. accessible after installation of cover assembly (1).

11. Two terminals (2). Connect to terminal strip. Refer to para 5-92.

5-342
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-91. WINTERIZATION KIT BATTERY BOX HEATER MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

C. OPERATIONAL CHECK.

2. 110 VAC power cord. Plug into power source and

vehicle receptacle. Flip battery

heater circuit ON.

13. Heater (3). Verify that heater (3) functions Thermostat closes at

properly. 350F (1.7°C) and opens

at 55°F ( 12.8°C).

NOTE

Follow-on maintenance action required:

Install and connect batteries per para 5-38E.

5-343
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERZATION KIT.

5-92. WINTERIZATION KIT BATTERY BOX THERMOSTAT AND TERMINAL

STRIP MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (45)

b. Installation. (45)

c. Operational Check. (15)

105 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-38A. Batteries Removal.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERlALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 5-14.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

Battery Thermostat Must be Below 35°F

for Actuation of Heater.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

110 VAC Cable Disconnected From

Power Source and Receptacle.

All Breakers Set to OFF.

5-344
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-92. WINTERIZATION KIT BATTERY BOX THERMOSTAT AND TERMINAL STRIP

MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL

1. Rear cover assembly (1). a. Remove seven capscrews

(17), seven Iockwashers

Hex nuts (19) are only

(18) and four hex nuts (19).

used on sides of rear cover

(16).

b. Remove rear cover (16).

2. Cover (7). Remove two screws (11), four

teflon washers (3), two bushings

(30) and hex nuts (29).

3. Thermostat assembly (6). a. Remove two screws (31),

Iockwashers (5), and hex

nuts (4).

b. Remove thermostat assembly

(6) from cover (7).

5-345
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-92. WINTERIZATION KIT BATTERY BOX THERMOSTAT AND TERMINAL STRIP

MAINTENANANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

4. Cover (21). Remove two hex nuts (23), lockwashers (22), and screws (14).

5. Terminal strip (20). a. Remove wire assembly (2). Tag terminals to aid in

b. Remove two hex nuts (24), reassembly.

Iockwashers (25) and screws

(13).

6. Two cable grips (9) and (10). Remove two conduit nuts (26).

and reducing washers (27).

7. Two grommets (15). Remove.

8. Insulation (28). Remove with sharp tool or Milsolv (8) supplied

putty knife and clean off with kit.

adhesive with Milsolv (8).

B. INSTALLATION

9. Insulation (28). a. Install adhesive (32) to Adhesive (32) supplied

rear cover (16). with kit.

b. Put insulation (28) in place.

10. Two grommets (15). Install.

11. Two cable grips (9) and (10). Install into rear cover and

secure with two reducing

washers (27) and conduit

nuts (26).

12. Terminal strip (20). a. Install and secure with two

screws (13), Iockwashers

(25) and screws (13).

b. Install wire assembly (2).

13. Cover (21). Install and secure with two

hex nuts (23), Iockwashers

(22), and screws (14).

5-346
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-92. WINTERIZATION KIT BATTERY BOX THERMOSTAT AND TERMINAL

STRIP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-347
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES. AND WINTERIZATION KIT.

5-92. WINTERIZATION KIT BATTERY BOX THERMOSTAT AND TERMINAL STRIP

MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

14. Thermostat assembly (6). Install in cover (7) and secure

with two screws (31), lockwashers (5), and hex nuts (4).

15. Cover (7). Install and secure with two

screws (11), four teflon washers

(3), two bushings (30), and hex

nuts (29).

16. Rear cover assembly (1). Install and secure with seven Hex nuts (19) are only

capscrews, seven Iockwashers

(18), and four hex nuts (19).

used on sides of rear cover

(16).

C. OPERATIONAL CHECK.

17. 110 VAC power cord. Plug into power source and

vehicle receptacle. Flip battery

heater circuit ON.

18. Thermostat assembly (6). Verify operation. Thermostat closes at 35°F

(1.7°C) and opens at 55°F

(12.8°C).

NOTE

Follow-on maintenance action required:

Install and connect batteries per para 5-38E.

5-348
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-93. WINTERIZATION KIT BATTERY BOX THERMOSTAT AND TERMINAL

STRIP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-349
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-93. WINTERIZATION KIT BATTERY BOX INSULATION MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (30)

b. Cleaning. (45)

c. Installation. (15)

90 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION 

All. 5-38A. Batteries Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (PIN)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

Battery Thermostat Must be Below 35°F

for Actuation of Heater.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

110 VAC Cable Disconnected From

Power Source and Receptacle.

All Breakers Set to OFF.

5-350
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-93. WINTERIZATION KIT BATTERY BOX INSULATION MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARK S

A. REMOVAL

1. Insulation (1), (3), (4), (5), If insulation is damaged or needs Milsolv (19) supplied

and (15), and seal (2). replacement scrape off with sharp with kit.

tool or putty knife and clean off

adhesive with Milsolv (19).

5-351
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-93. WINTERIZATION KIT BATTERY BOX INSULATION MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

2. Four capscrews (18), lock- Remove and lift out four

washers (17), nuts (16), retainers (8), and transite (6).

and screws (7).

3. Four screws (10), and two Remove.

retainers (9),

4. Two screws (12), lock- Remove and scrape off inwashers (13), and brackets sulation (11) with sharp tool

(14). or putty knife.

B. CLEANING

5. Battery compartment. Wash out with high pressure

water or steam and clean off

adhesive with Milsolv (19).

C. INSTALLATION

6. Adhesive (20), insulation

(1), (3), (4), (5), (11),

Apply adhesive (20) to all Adhesive (20) supplied

insulation panels and apply with kit.

and (15), and seal (2). to their respective places.

7. Two brackets (14), lock- Install.

washers (13), and screws (1 2).

8. Four screws (10), and two Install.

retainers (9).

9. Four capscrews (18), eight Install four retainers (8) and

Iockwashers (1 7), and nuts

(16), four retainers (8), four

transite (6) and secure with

four capscrews (8) and screws

transites (6), and screws (7). (7).

5-352
TM 9-2320-273-20

SENDING UNITS, SWITCHING DEVICES, AND WINTERIZATION KIT.

5-93. WINTERIZATION KIT BATTERY BOX INSULATION MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5-353 /5-354 (Blank)

TM 9-2320-273-20

CHAPTER 6

TRANSMISSION MAINTENANCE

6-1. OVERVIEW.

This chapter provides you with the following information related to transmission maintenance:

a. All required special tools and equipment.

b. Other technical manuals.

c. Troubleshooting procedures.

d. Maintenance procedures.

Section I REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

6-2. COMMON TOOLS AND EQUIPMENT.

For authorized common tools and equipment, refer to the Modified Table of Organization and

Equipment (MTOE) applicable to your unit.

6-3. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.

The special tools, TMDE and support equipment required for the transmission maintenance

procedures described in this chapter are as follows: 0-150 psi (0-1-34 kPa) air pressure gage

(refer to Organizational Maintenance RPSTL, TM 9-2320-273-20P for tool description and

illustration).

6-4. SPARES AND REPAIR PARTS.

Spares and repair parts are listed and illustrated in the repair parts and special tools list covering

Organizational Maintenance for this equipment (TM 9-2320-273-20P).

6-1
TM 9-2320-273-20

Section II TROUBLESHOOTING

6-5. INTRODUCTION.

Troubleshooting procedures (table 6-1) are limited to those on-vehicle checks for which corrective actions are within the scope of Organizational Maintenance. Prior to starting any troubleshooting, the malfunction should be verified after the transmission has been warmed up to

over 1OO° F (37.8°C) since a cold transmission can give faulty indications. To warm the transmission, run the engine for approximately 10 minutes with the transmission in NEUTRAL.

The transmission will feel warm to the touch.

6-6. TEST EQUIPMENT.

An air pressure gage with a range of 0-150 psi (0-1034 kPa) is required to check for proper

air pressure.

6-2
TM 9-2320-273-20

Table 6-1. Transmission Troubleshooting Procedures.

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

1.

2.

SELECTOR LEVER CANNOT BE MOVED:

Step 1.

Step 2.

Step 3.

Step 4.

Inhibitor plate jammed with dirt.

Remove cover, clean, and lubricate (Seg LO 9-2320-273-12).

Inhibitor centering piston assembly out of alinement or damaged.

Replace (Refer to Direct Support).

Bolts holding air control line to ratio selector too long or incorrectly torqued.

Tighten to 9 Ib-ft ( 12 N•m), replace damaged components, or use shorter bolts.

Bolts incorrectly installed when ratio selector assembled.

Check to see that bolts are not run in at an angle.

ENGINE DOES NOT TURN DRIVESHAFT IN ANY SPEED FORWARD OR REVERSE:

Step 1.

Step 2.

Step 3.

Step 4.

Check oil level in transmission.

Add oil to correct level (see LO 9-2320-273-12).

Check to see that air hand control valve on ratio selector is pushed in.

Push in hand valve.

Check to see that air pressure supply is available and adequate to transmission;

60-120 psi (414-827 kPa).

Troubleshoot compressed air system (para 9-5).

Inspect air control line and connectors between ratio selector and transmission.

Tighten to 18 Ib-ft (24 N•m) or replace damaged components.

6-3
TM 9-2320-273-20

Table 6-1. Transmission Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

2. ENGINE DOES NOT TURN DRIVESHAFT IN ANY SPEED FORWARD OR REVERSE

(Continued):

Step 5. Check to see that air pressure is available at ratio selector from truck

compressed air system.

a. Troubleshoot compressed air system ( para 9-5).

b. Refer to Direct Support Maintenance for troubleshooting.

3. ENGINE TURNS DRIVE SHAFT IN SOME GEARS BUT NOT OTHERS:

Step 1. Check to see that adequate compressed air is available from truck.

Troubleshoot compressed air system (para 9-5).

Step 2. Check air control line and connections between ratio selector and

transmission for tight connections, damage and leaks.

a. Tighten to 18 Ib-ft (24 N•m) or replace damaged

components.

b. Refer to Direct Support Maintenance for troubleshooting.

4. ENGINE DOES NOT TURN POWER TAKEOFF IN NEUTRAL :

Perform same steps as in Malfunction 2.

5. TRUCK MOVES WHEN ENGINE IS AT LOW IDLE AND TRANSMISSION IN GEAR :

Step 1. Check engine low idle rpm (should be 580-620 rpm).

Refer to Direct Support Maintenance for adjustment.

Step 2. Check transmission operating temperature.

Allow transmission temperature to reach 10O°F (37.8°C)

before putting truck in gear.

Step 3. Put selector lever in NEUTRAL and check engine rpm at low idle.

Put selector lever in 4th gear and check engine rpm.

a. If engine rpm does not change, the problem is corrected.

b. If engine rpm decreases, the input clutch may be warped.

Refer to Direct Support Maintenance for repairs.

6-4
TM 9-2320-273-20

Table 6-1. Transmission Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

6. TRANSMISSION HOUSING BREATHERS SHOW AN AIR LEAK AFTER THE SHIFT

IS COMPLETE :

Refer to Direct Support Maintenance for troubleshooting.

7. TRANSMISSION FEELS LIKE IT IS ENGAGED, THEN NOT ENGAGED, THEN

ENGAGED AGAIN – TRANSMISSION IS ALSO NOISY:

Refer to Direct Support Maintenance for troubleshooting.

8. TRANSMISSION HAS A DECREASE IN OIL LEVEL WITH AN INCREASE IN

OIL IN THE ENGINE :

Step 1. Check for inoperative breathers.

Replace the breathers (para 6-9C and 6-9 D).

Step 2. Check engine crankshaft seal.

Refer to Direct Support Maintenance.

9. TRANSMISSION GEARS MAKE NOISE DURING A SHIFT:

Step 1. Check for correct oil level.

Add oil to correct level (refer to LO 9-2320-273-12).

Step 2. Check for oil leaks.

Refer problem to Direct Support Maintenance.

Step 3. Check for clogged oil pump suction screen.

Clean screen (para 6-9B).

6-5
TM 9-2320-273-20

Table 6-1. Transmission Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

10. TRANSMISSION TEMPERATURE GAGE READINGS ABNORMALLY HIGH :

Step 1. Check for correct oil level.

Add or remove oil to correct level (refer to LO 9-2320-273-12).

Step 2. Check for oil leaks.

Refer problem to Direct Support Maintenance.

Step 3. Check for clogged oil pump suction screen.

Clean screen (para 6-9 B).

Step 4. Check oil cooler fins for obstructions.

Clean cooling fins.

6-6
TM 9-2320-273-20

Section Ill MAINTENANCE PROCEDURES

6-7. INTRODUCTION.

This section provides you with Organizational Level maintenance procedures for the transmission. The scope of maintenance is limited to the work listed in the following summary

of task procedures.

6-7
TM 9-2320-273-20

6-8. TRANSMISSION MAINTENANCE TASK SUMMARY.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Dry Cleaning Solvent SD-2 (Refer to Appendix C).

Oil – 5.5 Gallons (Refer to Appendix C).

Case Breathers (12), (2520-01-077-2803).

Oil Funnel.

Container, 6 Gal Min.

Gaskets (2), 9N4010 (11083).

 O-Ring, 3D2824 (11083).

Soap Solution.

Gaskets (2), 9N1507 (11083).

Loctite (242).

Masking Tape.

Marking Pen.

Cable Ties (8) SST4S (06383).

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS (63B20).

References (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

REFERENCES (TROUBLESHOOTING)

Table 6-1, 5-7, 9-1.

EQUIPMENT CONDITION

PARAGRAPH

9-13A.

11-16A.

11-16E.

4-23A.

4-30A.

5-37A.

6-11A.

9-16A.

CONDITION DESCRIPTION

Air Reservoirs Drained.

Front Radiator Shell and

Screen Removed.

Brush Guard Removed

(916 thru 920).

Fuel Tank Removed.

Ether Cylinder Removed.

Batteries Disconnected.

Floor Access Plate Removed.

Supply Air Reservoir Removal (M916 thru M920

Only).

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Park Brake Set.

Transmission in Neutral.

6-8
TM 9-2320-273-20

6-8. TRANSMISSION MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1. Oil Service : 6-9 6-1

A. Draining Oil. 6-9A

B. Cleaning or Replacement of Pump Screen. 6-9B

C. Removal of Case Breather. 6-9C

D. Installation of New Case Breather. 6-9D

E. Replenishing Oil Supply. 6-9E

F. Checking for Leaks. 6-9F

2. Oil Cooler Maintenance: 6-10

A. Removal. 6- 10A

B. Cleaning and Inspection. 6-10B

c. Installation. 6- 10C

3. Pneumatic Control Line Maintenance: 6-11

A. Removal. 6-11A

B. Inspection. 6-11B

c. InstalIation. 6-11C

b. Checking for Leaks. 6-11D

4. Ratio Selector and Air Charging Valve 6-12

Maintenance:

A. Removal. 6-12A

B. Inspection of Lines and Fittings. 6-12B

C. Lubrication of Ratio Selector. 6-1 2C

D. Installation. 6-12D

E. Operational Check. 6-12E

5. Speedometer Cable Maintenance: 6-13

A. Removal. 6-13A

B. installation. 6-13B

C. Operational Check. 6-13C

6. Transmission Control Heater Maintenance: 6-14

A. Removal. 6- 14A

B. Installation. 6-14B

c. Operational Check. 6-14C

6-1

9-1

9-1

5-7

6-9
TM 9-2320273-20

TRANSMISSION.

6-9. OIL SERVICE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Draining Oil. (10)

b. Cleaning or Replacement of Pump Screen. (15)

c. Removal of Case Breather. ( 5 )

d. Installation of New Case Breather. ( 5 )

e. Replenishing Oil Supply. (10)

f. Checking for Leaks. (10)

55 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All . None. None.

TEST EQUIPMENT

None

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Nonflammable Cleaning Solvent SD-2 (Refer to Appendix C).

Oil, 5.5 gallons (21 Liters) (Refer to Appendix C);

OEA if Sub-Zero Use.

Case Breathers (12) (2520-01-077-2803).

Oil Funnel.

Container, 6 gal min.

Loctite (242).

Gaskets (2), 9N1507 (11083).

O-Ring, 3D2824 (11083).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

LO 9-2320-273-12.

TM 9-2320-273-20P.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 6-1.

6-10
TM 9-2320-273-20

TRANSMISSION .

6-9. OIL SERVICE (Continued).

LOCATION/lTE M ACTION REMARKS

NOTE

Transmission should be warm for this task.

Park the truck on level ground.

 A. DRAINING OIL.

Place container

oil.

NOTE

under drain plug to catch

Change 2 6-11
TM 9-2320-273-20

TRANSMISSION.

6-9. OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

A. DRAINING OIL (Continued).

1. Dipstick (4). Remove.

2. Drain plug (6) and a. Unscrew and remove.

O-ring (7).

b. Throw away O-ring.

c. Allow oil to drain out.

d. Inspect magnetic base of If there are large metal particles

plug. notify Direct Support Maintenance.

e. Install new O-ring (7) on

drain plug (6).

f. Screw in plug and tighten,

A-1. TAKING OIL SAMPLE FOR ANALYSIS

NOTE

Before beginning this task check transmission oil level according to operator’s

manual (TM 9-2320-273-10).

Start engine (see TM 9-2320-273-10),

warm vehicle to normal operating

range and stop engine.

1. Draincock (16) a. Unscrew and loosen. When taking a sample, first use a

container to drain a small amount

of oil to clean the valve assembly.

b. When completed with task

1., use the proper bottle

and take oil sample from

the transmission drain valve

(see TB 43-0210).

c. Check oil level to insure

proper level after sampling.

6-12 Change 2
TM 9-2320-273-20

TRANSMISSION.

6-9. OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

B. CLEANING OR REPLACEMENT OF PUMP SCREEN.

3. Eight capscrews (11) and Unscrew and remove.

washers ( 10).

4. Access cover (9) and a. Remove. On the M916 thru M920 the left

gasket (8).

b. Discard gasket (8).

side access cover is blocked by the

PTO, so you will have to use the

right side cover.

CAUTION

Exercise care that when the pump

screen is replaced, that it is properly

latched. If not the screen will fall

into the housing and may damage

internal transmission parts.

5. Pump screen (12). a.

b.

c.

d.

Slide off of suction tube (13)

by grasping metal spring tab

and pushing down slightly

while pulling out.

Inspect magnets. If there are large metal

particles, notify Direct Support

Maintenance.

Clean with dry cleaning

solvent.

Dry with compressed air.

Change 2 6-12.1/6-12.2 (blank)

TM 9-2320-273-20

TRANSMISSION.

6-9. OIL SERVICE (Continued).

LOCATION/ITEM ACTION REMARKS

B. CLEANING OR REPLACEMENT OF PUMP SCREEN (Continued).

e. Inspect. If screen or magnets are

damaged, replace assembly.

f. Slide onto suction tube Be sure spring clip latches

base, pushing down screen in place. A distinct

slightly on clip while click will be heard. Check for

sliding in. proper engagement by pulling

out with slight pressure and not

pushing down on clip.

6. New gasket (8). a. Put in place.

access cover (9),

eight capscrews (11), b. Tighten capscrews (11 ) to

and washers (10). 31 Ib-ft (42 N•m)

with torque wrench.

6-13
TM 9-2320-273-20

TRANSMISSION.

6-9. OIL SERVICE (Continued).

LOCATION/ITEM ACTION REMARKS

C. REMOVAL OF CASE BREATHER.

7. Floor mat. Pull back at seam to expose

access plate (2).

8. Eleven screw (1). Remove.

9. Access plate (2). Remove from cab floor.

10. One case breather Unscrew, remove and throw

(3). away.

10.1.lf required, Unscrew, remove and throw

change vents (14). away.

D. INSTALLATION OF NEW CASE BREATHER.

11. One new case breather Apply Ioctite on threads,

(3). screw in and tighten carefully with pliers. Do not

clamp too tightly, othewise

the plastic cap may crack.

11.1. Eleven new breather Apply Ioctite on threads,

vents (14). screw in and tighten carefully with pliers. Do not

clamp too tightly, otherwise

the plastic cap may crack.

12. Access plate (2) and Position and secure with

control cable grommet twelve screws (1).

and plate.

13. Floor mat. Reinstall over cover plate.

E. REPLENISHING OIL SUPPLY.

14. Dipstick tube (5). a. Insert tip of funnel.

b. Pour in 5.5 gal (20.8 liters)

transmission oil.

c. Put dipstick (4) in place.

6-14 Change 1
TM 9-2320-273-20

TRANSMISSION .

6-9. OIL SERVICE (Continued).

ACTION REMARKS

F. CHECKING FOR LEAKS.

15. Engine.

16. Transmission.

17. Dipstick (4).

18. Engine.

Start up (see TM 9-2320-273-10).

Check for fluid and air leaks while

engine is at low idle.

Check oil level. Add more if needed.

Shut down (see TM 9-2320-273-10).

Change 1 6-14.1 /(6-14.2 blank)

LOCATION/ITE M

TM 9-2320-273-20

TRANSMISSION.

6-9. OIL SERVICE (Continued).

LOCATION/ITEM ACTION REMARKS

Do not allow SD-2 dry cleaning solvents to

come in contact with seals or flexible hoses.

These cleaners may damage leather, rubber,

and synthetic materials.

Change 1 6-15
TM 9-2320-273-20

TRANSMISSION.

6-10. OIL COOLER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Cleaning and Inspection. (15)

c. Installation. (15)

45 Minutes Total

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 11-16A. Front Radiator Shell and

TEST EQUIPMENT

None.

Screen Removed.

11-16E. Brush Guard Removed

(M916 thru M920)

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 6-1.

6-16
TM 9-2320-273-20

TRANSMISSION.

6-10. OIL COOLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Hydraulic hoses (4) Remove from two trans- Remove by unscrewing

and (10). mission mounted elbows barb fitting from elbow.

(9).

2. Three bolts (5), star- Unscrew and remove three Retainers are located along

washers (6), and rubber coated hose top of frame rail.

nuts (7). retainers (8).

3. Hydraulic hoses (4) a. Remove from two oil Remove by unscrewing

and (10). cooler mounted elbows barb fitting from elbow.

(1) and (3).

b. Pull hydraulic hoses (4) and

(10) out of vehicle.

4. Four bolts (1 1), lock- Unscrew and remove oil

washers ( 12), and cooler (2).

washers (13).

6-17
TM 9-2320-273-20

TRANSMISSION.

6-10. OIL COOLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B . CLEANING AND INSPECTION.

5. Hydraulic hoses (4) Inspect for cracking Replace as necessary.

and (10). and leaks.

6. Oil cooler (2). Clean cooling fins, in- Replace as necessary.

spect for bent fins and

leaks.

C. INSTALLATION.

7. Oil cooler (2). Install with four bolts

(11), lockwashers (12),

and washers (13).

8. Hydraulic hose (4) a. Install to oil cooler

and (10). mounted elbows (1)

and (3).

b. Install to transmission

mounted elbows (9).

Three hose retainers Install with three bolts Install hoses per

 (8) . (5), star washers (6), illustration.

and nuts (7) and tighten.

6-18

9 .
TM 9-2320-273-20

TRANSMISSION.

6-10. OIL COOLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Follow-on maintenance required:

a. Install front radiator shell and screen;

refer to paragraph 11-16D.

b. Install Brush Guard; refer to paragraph

11-16F (M916 thru M920).

6-19
TM 9-2320-273-20

TRANSMISSION.

6-11. PNEUMATIC CONTROL LINE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Inspection. ( 5 )

c. Installation. (15)

d. Checking for Leaks. (25)

60 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Soap Solution.

Gaskets (Two), 9N4010 (11083).

PERSONNEL REQUIRED

One (MOS-63B20)

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

6-20
TM 9-2320-273-20

TRANSMISSION .

6-11. PNEUMATIC CONTROL LINE MAINTENANCE (Continued).

LOCATION/lTE M ACTION REMARK S

Do not begin work on air lines until pressure in

air system has dropped completely.

NOTE

Pull back floor mat to expose access plate.

6-21
TM 9-2320-273-20

TRANSMISSION.

6-11. PNEUMATIC CONTROL LINE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Two screws (5) and washers (6). Loosen and remove.

2. Retainer (7). Remove.

3. Ten screws (13). Loosen and remove.

4. Access plate (12). Remove.

5. Grommet (9). Remove,

6. Three bolts (11). Loosen and remove.

7. Three bolts (1) and Loosen and remove.

washers (2).

8. Control line (8) and Remove Discard two gaskets (3).

two gaskets (3).

B. INSPECTION.

9. Control line (8). a. Inspect for:

1. Cracks.

2. Leaks.

3. Kinks.

b. Blow air through to see

that line is not clogged.

C. INSTALLATION.

10. Control line (8) and a. Attach to ratio selector

two new gaskets (3). (4) using three bolts (1)

and washers (2).

b. Attach to transmission (10)

using three bolts (11).

11. Six bolts (1) and (11). Tighten to 18 Ib-ft (24 N•m)

using torque wrench.

12. Grommet (9). Install.

13. Access plate (12). Install.

14. Ten screws (13). Install and tighten.

15. Retainer (7). Install.

16. Two screws (5) and Install and tighten.

washers (6).

Replace if necessary.

6-22
TM 9-2320-273-20

TRANSMISSION.

6-11. PNEUMATIC CONTROL LINE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Follow on maintenance action required:

Close drain valve on air reservoir; (refer to

para 9-13 D).

D. CHECKING FOR LEAKS.

17. Engine. Start up (See TM9-2320-273-10).

18. CAB/Air charging valve. Push in and charge until When system reaches 65

system reaches 65 psi psi, valve will stay in

(448 kPa). without being held.

6-23
TM 9-2320-273-20

TRANSMISSION.

6-11. PNEUMATIC CONTROL LINE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

D. CHECKING FOR LEAKS (Continued).

19. Control line (8). Check for leaks, using

soap solution.

6-24
TM 9-2320-273-20

This page intentionally left blank.

6-25
TM 9-2320-273-20

TRANSMISSION.

6-12. RATIO SELECTOR AND AIR CHARGING VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED RED FOLLOWS TASK DESCRIPTION.)

a. Removal. (8)

b. Inspection of Lines and Fittings. (2)

c. Lubrication of, Ratio Selecton. (5)

d. Installation. (8)

e. Operational Check. (5)

28 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.’

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

6-26
TM 9-2320-273-20

TRANSMISSION.

6-12. RATIO SELECTOR AND AIR CHARGING VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

6-27
TM 9-2320-273-20

TRANSMISSION.

6-12. RATIO SELECTOR AND AIR CHARGING VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Knob (1) and indicator (2). Unscrew and remove.

2. Four screws (4). Unscrew and remove.

3. Housing (3). Remove and lay on side.

4. Pin (14). Remove with hammer and punch.

5. Knob (15). Remove.

6. Airlines(n) and (12). Unscrew from valve (10),

tag and remove.

7. Nut (13). Loosen and remove.

8. Valve (10). Remove.

B. INSPECTION OF LINES AND FITTINGS.

9. Air lines (11) and (12). Inspect for: Also check threads on

a. Cracks. valve (10) for damage.

b. Leaks. Replace as necessary.

c. Damaged threads.

C. LUBRICATION OF RATIO SELECTOR.

10. Inhibitor plate (7), retainer Spray surfaces between See LO 9-2320-273-12.

(9), base (8), guide (6) these items any time

and plunger (5). sticking becomes evident.

6-28
TM 9-2320-273-20

TRANSMISSION.

6-12. RATIO SELECTOR AND AIR CHARGING VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

6-29
TM9-2320-273-20

TRANSMISSION.

Put in place.

Screw on and tighten.

a. Place on valve (10).

b. Attach with pin (14).

Screw onto fittings.

a. Attach with four screws (4).

b. Tighten screws (4).

Screw in and tighten.

6-12. RATlO SELECTOR AND AIR CHARGING VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 D. INSTALLATION.

11. Valve (10).

12. Nut (13).

13. Knob (15).

14. Air lines (11) and (12).

15. Housing (3).

16. Knob (1) and indicator (2).

E. OPERATIONAL CHECK.

17. Engine. Start up (see TM 9-2320-273-10).

18. Air charging valve knob (15). a. Push knob in with air pressure

below 65 psi (448 kPa). It

should pop out when released.

b. Push knob in with air pressure

above 65 psi (448 kPa). It

should stay in and the sound

of the transmission engaging

should be evident.

c. Test drive vehicle. Shifts

should be smooth with no

evidence of sticking.

6-30
TM 9-2320-273-20

TRANSMISSION.

6-12. AIR CHARGING - VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

6-31
TM 9-2320-273-20

TRANSMISSION.

6-13. SPEEDOMETER CABLE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (10)

c. Operational check. (5)

Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 5-7.

6-32
TM 9-2320-273-20

TRANSMISSION.

6-13. SPEEDOMETER CABLE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL. 

1. Two quarter-turn screws (1). Loosen and lower panel.

2. Speedometer cable (4). a. Disconnect from km/h

MPH connection (2) on

back of tachograph (8).

b. Unscrew connector (6) M916/M920 – Unscrew from

from speedometer drive adapter (7) at speedometer

(5) at transmission. drive (5).

c. Pull thru grommet (3)

on firewall.

6-33
TM 9-2320-273-20

TRANSMSSION.

Unscrew and remove from (M916/M920 only).

speedometer drive (5).

6-13. SPEEDOMETER CABLE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Adapter (7).

B. INSTALLATION.

4. Adapter (7). Install on speedometer drive (M916/M920 only).

(5).

5. Speedometer cable (4). a. Plug into speedometer

drive (5) or adapter (7).

Tighten connector (6).

b. Thread free end through

grommet (3) on firewall.

c. Connect to MPH port (2)

on back of tachograph

(8).

6. Two quarter-turn screws (1). Close panel and tighten screws.

C. OPERATIONAL CHECK.

7. Vehicle. Road test. Check tachograph

(8) for appropriate road speed

indication and responsiveness

to changes in speed.

6-34
TM 9-2320-273-20

TRANSMISSION.

6-35

6-13. SPEEDMETER CABLE MAINTENANCE (Continued).

LOCATION/ITEM ACTIO N REMARKS
TM 9-2320-273-20

TRANSMISSION.

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (60)

b. Installation. (60)

c. Operational Check. (30)

150 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATION

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

All. 4-23A. Fuel Tank Removed.

4-30A. Ether Cylinder Removed.

TEST EQUIPMENT 5-37A. Batteries Disconnected.

6-11A. Floor Access Plate Removed.

None. 9-16A. Supply Air Resevoir Removed

(M916 thru M920 0nly).

SPECIAL TOOLS

Non.

MATERIALS/PARTS (P/N)

Masking Tape.

Marking Pen.

Cable Ties (8), SST4S (06383).

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

None

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

Temperature of Transmission

Control 0°F (-17.8°C) or Less for Testing.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

6-36
TM 9-2320-273-20

TRANSMISSION.

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued),

LOCATION/lTEM ACTION REMARKS

1. Four nuts (1) and washers (2). Unscrew and remove two

heater covers (3) and insulation strips (4).

6-37
TM 9-2320-273-20

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

2. Four nuts (15) and Unscrew and remove four Wires are contained in harness

washers (16). wires from two heaters (7). (17). Tag for reassembly.

3. Two nuts (5) and Unscrew and remove bottom Remove only the bottom heatwashers (6). heater (7) and two washers

(10) from two rods (14).

er at this time.

4. Top heater (7), two nuts Remove as an assembly from

(5), washers (6), rods (14),

After assembly has been retransmission. moved, disassemble nuts,

washers (10), and four washers, and heater from rods.

nuts (11).

5. Harness (17). Unplug from switch (13). Tag for reassembly. One

terminal from harness (17)

will still be connected to

switch (13).

6. Two bolts (8) and Unscrew and remove harness Tag one terminal from harness

washers (9). (17), plate (12), and switch (17) for reassembly.

(13) from transmission.

7. Four cable ties (18). Cut and remove from harness Discard.

(17).

6-38

TRANSMISSION.
TM 9-2320-273-20

TRANSMISSION

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

6-39
TM 9-2320-273-20

TRANSMISSION.

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

8. Harness (17). Unplug from harness (21). Inside cab by driver’s seat

at ratio selector support (M915),

or at PTO console (M916 thru

M920). Tag for assembly.

9. Harness (21). Pull down to remove from This step required to replace

bracket (23). lamp.

10. Lens (19). Push up from bottom to

remove from bracket (23).

11. Two bolts (25), washers Unscrew and remove bracket

(24), and nuts (26). (23) with decal (22) attached.

6-40
TM 9-2320-273-20

TRANSMISSION.

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

6-41
TM 9-2320-273-20

TRANSMISSION.

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

12. Four cable ties (18). Cut and remove. Discard.

13. Screw (39). Unscrew from sending unit Near starter. Wire is contained

(40) and remove one wire. in harness (17). Tag for assembly.

14. Two nuts (38), washers Unscrew and remove four At ether quick-start bracket.

(37), nuts (37), and wires from switch (34). Four wires are contained in

washers (35). harness (17). Tag for assembly.

15. Two bolts (30), washers Unscrew and remove switch

(31) and nuts (32). (34) from bracket (33).

16. Two bolts (29), washers Unscrew and remove bracket

(28), and nuts (27). (33).

17, Nut (45) and washer (44). Unscrew and remove one wire. At fuel pump. Wire is contained in harness (17). Tag for

assembly.

18. Two screws (41). Unscrew and remove two Near power steering pump.

wires from sending unit (42). Wires are contained in harness

(17). Tag for assembly.

19. Sending unit (42). Unscrew from elbow (43).

20. Elbow (43). Unscrew from engine block.

21. Nut (46), and washer (47). Unscrew and remove one wire. On positive post of alternator.

Wire is contained in harness

(17) which is now completely

removed from vehicle. Tag for

assembly.

6-42
TM 9-2320-273-20

TRANSMISSION.

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

6-43
TM 9-2320-273-20

TRANSMISSION

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

22. Two nuts (11). Screw one nut (11) onto Nut must be exactly 1 7/8

each of two rods (14). inches from end of rod for

proper installation clearance

(see exploded view).

23. Two washers (10) and Slide onto two rods (14). At same end of rods you

one heater (7). installed nuts (11) on in

step (22).

24. Two nuts (5) and washers Install on two rods (14) Check for 1 7/8 inch measure-

(6). and adjust down to con- ment again from nuts (11) to

tact heater (7). end of rods (14). Adjust if

necessary.

25. Assembled heater (7), Position on top edge of

two nuts (11), nuts (5), transmission.

washers (6), washers (10),

and rods (14).

Do not over tighten nuts (5) or (11).

Adjust to retain heaters (7) snugly

against transmission control. Over

tightening will cause heaters to distort

and pull away from control block on

transmission.

26. Second-heater (7), two a, Install at bottom of two

nuts (11), washers (10), rods (14).

washers (6), and nuts (5). b. Tighten two bottom nuts If heater(s) start to bow, loosen

(11) and two bottom nuts nuts (11) until heater(s) are

(5) to snug two heaters straight, then lock in place with

to transmission. nuts(11).

6-44
TM 9-2320-273-20

TRANSMISSION.

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

6-45
TM 9-2320-273-20

TRANSMISSION.

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

27. Switch (13) and plate a. Put switch (13) thru center

(12). of plate (12).

b. Position plate (12) on

transmission as shown.

c. Install one bolt (8) and

washer (9), but do not

tighten.

28. Harness (17). a. Position one wire from harness Install as tagged during

and one wire from switch (13). disassembly.

b. Install second bolt (8) and

washer (9).

c. Tighten two bolts (8) to 32

Ib-ft (43 N-m).

d. Plug harness (17) into switch

(13).

e. Install four harness wires, two Install as tagged during

to each heater (7) and secure disassembly.

with four washers (16) and

nuts (15).

Do not over tighten nuts (1) as this will cause

bowing of heaters (7) and heater covers (3).

29. Two insulation strips (4) Position as shown and secure Set insulation strips inside

and heater covers (3). with washers (2) and nuts (1). heater covers. Slide heater

covers onto two rods (14).

30. Four new cable ties (18). Install around harness (17) to At transmission air line and

prevent slack. at engine or chassis harness.

6-46
TM 9-2320-273-20

TRANSMISSION.

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

6-47
TM 9-2320-273-20

TRANSMISSION.

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

31.

32.

33.

34.

Bracket (23).

Lens (19).

Lamp (20).

Harness (21).

Install to PTO console (M916

thru M920) or to ratio selector

support (M915) with two bolts

(25), washers (24), and nuts

(26).

Press down into bracket (23).

a. Plug into harness (21).

b. Press into lens (19).

Plug into harness (17). Install as tagged at disassembly.

6-48
TM 9-2320-273-20

TRANSMISSION,

1-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

6-49
TM 9-2320-273-20

TRANSMISSION.

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

35. Harness (17). a. Route along engine and

secure with four new

cable ties (18).

b. Install one wire to sending

unit (40) with screws

(39) .

36. Bracket (33). Position at ether quick-start

37. Switch (34).

38. Harness (17).

bracket and instalI with two

bolts (29}, washers (28) and

nuts (27).

Install to bracket (33) with

two bolts (30), washers (31),

and nuts (32).

a. Install four wires to four

terminals on switch (34)

with two nuts (38), washers (37), nuts (36), and

washers (35).

b. Install one wire to fuel

pump and secure with

nut (45) and washer (44).

Left side. Install as needed to

prevent slack.

Near starter. Install as tagged

at disassembly.

Install as tagged at disassembly.

Install as tagged at disassembly.

6-50
TM 9-2320-273-20

TRANSMISSION

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

6-51
TM 9-2320-273-20

TRANSMISSION.

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 B. INSTALLATION (Continued).

39. Elbow (43). a. Coat threads with liquid

tefIon.

b. Screw into engine block. Near power steering pump.

40. Sending unit (42). Screw onto elbow (43).

41. Harness (17). a. Install two wires to send- Install as tagged at disassembl y.

ing unit (42) with two

screws (41).

b. Install one wire to alternator positive post with

washer (47) and nut (46).

NOTE

Follow-on maintenance action required:

a. Install fuel tank; refer to para 4-23B and C.

b. Install supply air reservoir (M916 thru M920

only); refer to para 9-166 and C.

c. Connect batteries; refer to para 5-37B.

d. Install floor access plate; refer to para 6-11C.

e. Install ether cylinder; refer to para 4-30B

and C.

 C. OPERATIONAL CHECK.

42. Engine. Start up (see TM 9-2320-

273-10).

43. Lamp (20). Should light and remain on See decal (22) for further

until control temperature is instructions.

in excess of 0°F (-17.8°C).

44. Engine. Shut down (see TM 9-2320-

273-10).

6-52
TM 9-2320-273-20

TRANSMISSION.

6-14. TRANSMISSION CONTROL HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

6-53/6-54 (Blank)

TM 9-2320-273-20

CHAPTER 7

POWER TRANSFER CASE MAINTENANCE

7-1. OVERVIEW.

This chapter provides you with the following information related to power transfer case maintenance:

a. All required special tools and equipment.

b. Other technical manuals.

c. Troubleshooting procedures.

d. Maintenance procedures.

Section I REPAIR PARTS, SPECIAL TOOLS, TMDE,

AND SUPPORT EQUIPMENT

7-2. COMMON TOOLS AND EQUIPMENT.

For authorized common tools and equipment, refer to the Modified Table of Organization and

Equipment (MTOE) applicable to your unit.

7-3. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.

No special tools, TMDE and support equipment are required for the power transfer case maintenance procedures described in this chapter.

7-4. SPARES AND REPAIR PARTS.

Spares and repair parts are listed and illustrated in the Repair Parts and Special Tools List

covering Organizational Maintenance for this equipment (TM 9-2320-273-20P).

Section II TROUBLESHOOTING

7-5. INTRODUCTION.

Troubleshooting procedures (table 7-1) are limited to those on-vehicle checks for which corrective

actions are within the scope of Organizational Maintenance.

7-1
TM 9-2320-273-20

Table 7-1. Power Transfer Case Troubleshooting Procedures.

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

1.

2.

3.

4.

POWER TRANSFER CASE DOES NOT TURN FRONT AXLE PROPELLER SHAFT:

Disconnect control air supply line at power transfer case air chamber and check for air

supply with differential lockup control valve switch in LOCK position.

a. Replace defective control valve (para 9-44).

b. Troubleshoot truck compressed air system (para 9-5).

c. If air control system is good, refer problem to Direct Support

Maintenance.

EXCESSIVE HEAT BUILDUP:

Step 1. Check oil level in both the main case and the clutch housing for proper level.

Fill to proper level (para 7-8).

Step 2. Check oil cooler system for proper functioning.

Tighten fittings, clean cooling fins, replace pump (para 7-9).

LUBRICANT LEAKING:

Step 1. Check drain plugs for tightness.

Tighten drain plugs.

Step 2. Check for clogged or damaged breathers on clutch housing.

Replace breathers.

Step 3. Check for damaged gaskets or seals.

Refer problem to Direct Support Maintenance.

TRANSFER CASE NOISY (OIL LEVEL OKAY):

Refer problem to Direct Support Maintenance.

7-2
TM 9-2320-273-20

7-6. POWER TRANSFER CASE MAINTENANCE TASK SUMMARY.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

M916 thru M920.

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

7-8A. Power Transfer Case Oil

Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Oil, 5 Qts (4.7 Liters) (Refer to Appendix C);

OEA if Sub-zero Use.

Oil Funnel.

Container, 1.5 Gal (5.68 Liters).

Gaskets -2 18108F (34632).

Plugs.

Liquid Teflon (Refer to Appendix C).

Cable Ties -2 5963577-A (06383).

Masking Tape.

Marking Pen.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

REFERENCES (TROUBLESHOOTING)

Table 7-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral

Park Brake Set.

7-3
TM 9-2320-273-20

7-6. POWER TRANSFER CASE MAINTENANCE TASK SUMMARY (Continued),

TASK

NO.

1.

2.

LIST OF TASKS

TASK

Oil Service:

A. Draining Oil.

B. Replenishing Oil Supply.

C. Checking for Leaks.

Cooler System Maintenance:

A. Removal.

B. Cleaning and Inspection.

c. Installation.

D. Operational Check.

TASK

REF

7-8

7-8A

7-8B

7-8C

7-9

7-9A

7-9B

7-9C

7-9D

TROUBLESHOOTING

REF (TABLE)

7-1

7-1

7-4
TM9-2320-273-20

Section Ill MAINTENANCE PROCEDURES

7-7. INTRODUCTION.

This section provides you with Organizational Level maintenance procedures for the power transfer

case. The scope of work is limited to oil service and cooler system maintenance.

NOTE

Maintenance procedures for the differential

lockup control valve are given in Chapter 9,

Section III, paragraph 9-44.

7-5
TM 9-2320-273-20

POWER TRANSFER CASE.

7-8. OIL SERVICE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Draining Oil. (15)

b. Replenishing Oil Supply. (15)

c. Checking for Leaks. (15)

45 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 thru M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Oil Funnel.

Oil, 5 Qts (4.7 Liters) (Refer to Appendix C);

OEA if Sub-zero Use.

Container, 1.5 Gal (5.68 Liters).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

Table 7-1.

7-6
TM9-2320-273-20

POWER TRANSFER CASE.

7-8. OIL SERVICE (Continued).

LOCATION/ITEM ACTION REMARKS

A. DRAINING OIL..

 1. Oil level plugs (1) and (2). Unscrew and remove.

NOTE

Before unscrewing drain plugs, place container underneath to catch oil.

7-7
TM 9-2320-273-20

POWER TRANSFER CASE.

7-8. OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

A. DRAINING OIL (Continued).

2. Drain plugs (3) and (4). a. Unscrew and remove.

b. Allow oil to drain out.

c. Wipe plugs and openings

with clean, dry rag.

d. Screw in drain plugs (3)

and (4) tightly.

B. REPLENISHING OIL SUPPLY.

3. Oil level plug (1).

4. Oil level plug (2).

C. CHECKING FOR LEAKS.

a. Pour in two quarts of oil.

b. Screw in oil level plug (1)

tightly.

a. Add oil until visible in fill

hole of transfer case.

b. Screw in oil level plug (2)

tightly.

c. Clean off spilled oil.

5. Two oil level plugs (1) and

(2), and two drain plugs (3)

and (4).

Road test vehicle, then check

for leaks.

Use funnel.

Use funnel

Retighten plugs as necessary.

7-8
TM 9-2320-273-20

POWER TRANSFER CASE.

7-8. OIL SERVICE (Continued).

LOCATION/ITEM ACTION REMARKS

7-9
POWER TRANSFER CASE.

7-9. COOLER SYSTEM MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Cleaning and Inspection. (15)

c. Installation. (20)

d. Operational Check. (10)

65 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

M916 and M920.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Gaskets 2, MA128-20004 (34623).

Plugs.

Liquid Teflon (Refer to Appendix C)

Masking Tape.

Marking Pen.

Cable Ties 2, SST4S (06383).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 7-1.

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

7-8A. Povver Transfer Case Oil

Drained.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground,

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

7-10
TM 9-2320-273-20

POWER TRANSFER CASE.

7-9. COOLER SYSTEM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Two bolts (32), six washers Unscrew and remove grille

(20), and two nuts (21). (31).

2. Lines (1) and (16). Remove from three adapters Plug openings; mark location

(28). for reassembly.

7-11
TM 9-2320-273-20

POWER TRANSFER CASE.

7-9. COOLER SYSTEM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Two elbows (17) and one Unscrew from cooler (33) Remove adapters (28) from

elbow (2). and transfer case (3). elbows (17) and (2) if necessary.

4. Four bolts (5), washers (18), a. Unscrew and remove two

and nuts (19). retainers (6), and four

mounting plugs (7).

b. Lower cooler (33) from If support angles (8) are to be

two support angles (8). removed from winch platform

brace (9), remove four bolts

(34), washers (18), and nuts

(14).

5. Two cable ties (10). Remove. Discard.

6. Bolt (15), washer (12), Unscrew and remove two

and nut (11). adapters (28).

7. Lines (16) and (26). Disconnect from two Plug openings; mark location

adapters (28). for reassembly.

8. Two elbows (27). Unscrew and remove from Remove adapters (28) from

pump (22). elbows (27) if necessary.

9. Four bolts (25). Unscrew and remove pump Discard gaskets (23).

(22), spacer (24), and two

gaskets (23).

10. Line (26). Disconnect from adapter (28). Plug opening, mark location

for reassembly.

11. Clamp (13). Unscrew existing nuts and

remove.

12. Adapter (28). Unscrew from tee (29).

13. Tee (29). Unscrew from bottom of

transfer case (3).

14. Plug (30). Unscrew from tee (29).

B. CLEANING AND INSPECTION.

15. Cooler (33). a. Spray with water to

clean off debris.

b. Check fins and tubes Replace as necessary.

for damage.

7-12
TM 9-2320-273-20

POWER TRANSFER CASE.

7-9. COOLER SYSTEM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

7-13
TM 9-2320-273-20

POWER TRANSFER CASE.

7-9. COOLER SYSTEM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. CLEANING AND INSPECTION (Continued). ]

16. Lines (1), (16), and a. Wipe clean.

(26). b. Inspect for cracks. Replace as necessary.

17. Fasteners and fittings; all. Inspect for damaged threads. Replace as necessary.

C. INSTALLATION.

NOTE

Remove plugs and apply liquid tefion to

all oil carrying connection threads as re18. Plug (30).

19. Adapter (28).

20. Tee (29).

21. Line (26).

22. Clamp (13).

23. Two new qaskets (23),

assembled.

Screw into tee (29).

Screw into tee (29).

Screw into bottom of

transfer case (3).

Screw onto adapter (28).

Install around line (26) and

fasten to transfer case with

existing nut.

a. Aline with shaft (4) and

spacer (24) and pump” (22). four mounting holes.

b. Install with four bolts

(25); torque to 14 Ib-ft

24. Two elbows (27) Screw into pump (22).

25. Lines (16) and (26). Screw onto two adapters

(28).

26. Elbow (2). Screw into top of transfer

case (3).

27. Line (1). Screw onto adapter (28).

28. Two support angles (8). If removed, fasten to winchplatform brace (9) with four

bolts (34), washers (18), and

nuts (14).

Install as marked.

Assemble per illustration for

either warm or cold weather

operation.

Install adapters (28) to elbows

if removed.

Install as marked.

Install adapter (28) to elbow,

if removed.

Torque to 14 Ib-ft (19 N.m).

7-14

(19 N•m).
TM 9-2320-273-20

POWER TRANSFER CASE.

7-9. COOLER SYSTEM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

7-15
TM 9-2320-273-20

POWER TRANSFER CASE.

7-9. COOLER SYSTEM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

29. Cooler (33).

30. Two elbows (17).

31. Lines (1) and (16.

32. Grille (31).

D. OPERATIONAL CHECK.

33. Transfer case (3).

34. Engine.

35. Cooler system.

36. Engine.

Aline with mounting holes

on two support angles (8)

and secure with four bolts

(5), two retainers (6), four

mounting plugs (7), four

washers (18), and four nuts

(19).

Screw into cooler (33).

a.

b.

c.

Screw onto adapters (28).

Fasten together with two

new cable ties (10).

Fasten to winch platform

with two clamps (13), one

bolt (13), one bolt (15),

washer (12), and nut (11).

Fasten to cooler (33) with

two bolts (32), six washers

(20) and two nuts (21).

Refill with oil; para 7-8B.

Start up (refer to TM 9-

2320-273-10).

Check for leakage at all

connection points to transfer case (3) and cooler (33).

Shut down (refer to TM 9-

2320-273-10).

Torque to 14 Ib-ft (19 N•m).

Install adapters (28) to elbows

if removed.

Route along LH frame rail.

Torque to 9 Ib-ft (12 N•m).

Torque to 14 Ib-ft (19 N•m).

Tighten as necessary.

7-16
TM 9-2320-273-20

POWER TRANSFER CASE.

7-9. COOLER SYSTEM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

7-17/7-18 (Blank)

TM 9-2320-273-20

CHAPTER 8

PROPELLER SHAFTS AND AXLE MAINTENANCE

 8-1. OVERVIEW.

This chapter provides you with the following information related to propeller shaft and axle

maintenance:

a. All required special tools and equipment.

b. Other technical manuals.

c. Troubleshooting procedures,

cl. Maintenance procedures.

Section I REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

 8-2. COMMON TOOLS AND EQUIPMENT.

For authorized common tools and equipment, refer to the Modified Table of Organization and

Equipment (MTOE) applicable to your unit.

 8-3. SPECIAL TOOLS, TMDE AND SUPPORT EQUIPMENT.

The special tools, TMDE and support equipment required for the propeller shaft and axle procedures

described in this chapter are as follows. (Refer to Organizational Maintenance RPSTL, TM 9-2320-

273-20P for tool description and illustration.)

Oil filter strap wrench.

8-4. SPARES AND REPAIR PARTS.

Spares and repair parts are listed and illustrated in the Repair Parts and Special Tools List covering

Organizational Maintenance for this equipment (TM 9-2320-273-20P).

8-1
TM 9-2320-273-20

Section II TROUBLESHOOTING

8-5. INTRODUCTION.

Tables 8-1 and 8-2 contain instructions for troubleshooting the propeller shafts and axles. The corrective actions describe how to fix the problem or refer to a procedure for fixing the problem. The

tables are arranged by malfunctions in the following order:

PROPELLER SHAFTS (table 8-1). Excessive shaft noise or vibration.

AXLES (table 8-2).

a. Excessive backlash.

b. Continuous axle or wheel noise.

c. Lubricant leaking,

d. Excessive or uneven tire wear.

If you cannot locate a problem using these procedures, refer to the troubleshooting procedures for

wheels, steering, and suspension (para 10-5).

8-2
TM 9-2320-273-20

Table 8-1. Propeller- Shafts Troubleshooting Procedures.

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

1. EXCESSIVE SHAFT NOISE OR VIBRATION:

Step 1. Check torque of yoke bolts at universal joints.

Torque bolts to 300 Ib-ft (407 N•m).

Step 2. Check torque of capscrews.

Torque capscrews to 100 Ib-ft (136 N•m).

Step 3. Inspect propeller shafts and universal joints for evidence of damage or excessive wear.

Replace worn or damaged components (para 8-11).

Step 4. Check universal joints for adequate lubrication.

Lubricate (para 8-11).

Step 5. Check for proper shaft alinement, propeller shafts are properly phased when the cross

and bearing in the yokes at each end of shaft are in the same place.

Disassemble and aline as necessary (para 8-11).

NOTE

Look for arrow marks on the propeller

shaft and slip yoke. The arrows will

point toward each other. if marks are

not discernible, punch mark each member insuring reassembly in the same

relative position.

Step 6. Remove propeller shaft from vehicle. Check freedom of motion of splines by moving

shaft from fully retracted to fuIIy extended. If excessive force is required to retract or

extend shaft, or it does not reach full travel, separate shaft halves and inspect splines for

wear, damage, and lubrication.

Replace shaft assembly if required (para 8-11).

8-3
TM 9-2320-273-20

Table 8-2. Axles Troubleshooting Procedures.

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

1. EXCESSIVE BACKLASH:

Step 1. Check all universal joints.

Lubricate and replace as necessary (para 8-11).

Step 2. Check drive axle capscrews on universal joints for tightness.

Torque to 100-110 Ib-ft (136-149 N•m) (para 8-11D). If the problem persists,

notify Direct Maintenance Personnel.

2. CONTINUOUS AXLE OR WHEEL NOISE:

Step 1. Check lube level in axle housing.

Fill axle housing to proper level (para 8-12 for front axle or 8-13 for rear axle).

Step 2. Check lube pump cover (forward rear axle) for visible damage. Remove and check for

clogged filter (M915 only).

a. Replace filter as required (para 8-13).

b. Refer problem to Direct Support Maintenance if internal pump damage is

evident.

Step 3. Check that brake shoes are not dragging. Check for overheating of brake drum. Jack

wheel clear of ground. Use tanker bar to pry up under wheel to check for loose

bearings. Any movement of wheels indicates loose bearings. With brakes released

spin wheels to check for overly tight bearings. Wheel should spin freely and smoothly.

Remove hub and drum to check condition of bearings.

Adjust dragging brakes and clean, repack, or replace bearings as necessary (para

10-13 or 10-14, for front wheels, para 10-15 for rear wheels).

Step 4. Visually inspect tires.

Inflate tires to proper pressure or replace if necessary (refer to TM 9-2320-273-10).

Step 5. Check wheel balance.

Balance wheels, if necessary.

3. LUBRICANT LEAKING:

Step 1. Check all cover plate bolts for tightness.

8-4
TM 9-2320-273-20

Table 8-2. Axles Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

LUBRICANT LEAKING (Continued):

Tighten bolts or notify direct support personnel to reseal.

Step 2. Check breathers (driving axles) for obstruction or damage.

Clean or replace as necessary.

4. EXCESSIVE OR UNEVEN TIRE WEAR:

Step 1. Check wheel alinement (para 10-10 for front wheels).

Adjust alinement.

Step 2. Check brake adjustment.

Adjust brake if required (para 9-31 (M915), 9-32 (M916-M920) for front wheels

or 9-33 (M915), 9-34 (M916-M920) for rear wheels).

Step 3. Check cold tire pressure.

Inflate to proper pressure (Refer to TM 9-2320-273-10).

Section Ill MAINTENANCE PROCEDURES

8-6. INTRODUCTION.

This section provides you with Organizational Level maintenance procedures for the propeller shafts

and axles. To find a specific maintenance procedure, see one of the following task summaries.

a. Propeller Shafts (para 8-7).

b. Front Axle (para 8-8).

c. Rear Axle (para 8-9).

d. Pusher Axle (para 8-10).

8-5
TM 9-2320-273-20

8-7. PROPELLER SHAFTS MAINTENANCE TASK SUMMARY.

INITIAL SETUP

APPLICABLE CONFIGURATIONS EQUIPMENT CONDITION

All. PARAGRAPH _ CONDITION DESCRIPTION

None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None. 

MATERIALS/PARTS (P/N)

GAA ( Refer to Appendix C).

Blocks.

Nonflammable Dry Cleaning Solvent SD-2 (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12. SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Vehicle Parked on Level Ground.

Table 8-1, 8-2.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

Propeller Shafts: 8-11 8-1, 8-2

A. Removal. 8-11A

B. Cleaning and Lubrication. 8-11 B

C. Inspection of Universals. 8-11C

D. Installation. 8-11D

E. Checking for Vibration. 8-11E

8-6
TM 9-2320-273-20

8-8. FRONT AXLE MAINTENANCE TASK SUMMARY.

lNlTIAL SETUP

APPLICABLE CONFIGURATIONS EQUIPMENT CONDITION

M916 thru M920. PARAGRAPH CONDITION DESCRIPTION

None. Axle Oil Warm (Perform Oil Service

TEST EQUIPMENT immediately after truck has been

None. driven).

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

GO (27 Pints, 12.7 Liters) (Refer to Appendix C).

GOS Gear Oil if Sub-Zero Use (Refer to Appendix C).

Chassis Grease (Refer to Appendix C).

Liquid Teflon (Refer to Appendix C).

Container (3 Gallon).

Nonflammable Cleaning Solvent SD-2 (Refer to Appendix C).

Grease Gun.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12. SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Vehicle Parked on Level Ground.

None.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

Oil Service (M916 thru M920) : 8-12 None

A. Draining Oil. 8-12A

B. Replenishing Oil Supply. 8-12B

C. Operational Check. 8-12C

8-7
TM 9-2320-273-20

8-9. REAR AXLE MAINTENANCE TASK SUMMARY.

INITIAL SETUP

APPLICABLE CONFIGURATIONS EQUIPMENT CONDITION

All. PARAGRAPH CONDITION DESCRIPTION

None. Axle Oil Warm. (Perform

TEST EQUIPMENT Oil Service Immediately

None. After Truck Has Been

SPECIAL TOOLS

Driven. )

None.

MATERIALS/PARTS (P/N)

Container, 10 Gals (38 Liters).

Gear Oil, GOS if Sub-Zero Use (Refer to Appendix C).

M915 M916 Thru M920.

76 Pints (36 Liters). 62 Pints (29 Liters).

Oil Filter Element (M915), 3280-V-5040 (78500).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12. SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Vehicle Parked on Level Ground.

Table 8-2.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Park Brake Set.

Transmission in Neutral.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

Oil Service: 8-13 8-2

A. Draining Oil. 8-13A

B. Replacing Oil Filter (M915 Only). 8-13B

C. Replenishing Oil. 8-13C

D. Checking for Leaks. 8-13D

8-8
TM 9-2320-273-20

8-10. PUSHER AXLE MAINTENANCE TASK SUMMARY.

INITIAL SETUP

APPLICABLE CONFIGURATIONS EQUIPMENT CONDITION

M917, M919, and M920. PARAGRAPH CONDITION DESCRIPTION

TM 9-2320-273-10. Pusher Axle Down.

TEST EQUIPMENT 9-13A. Air Reservoirs Bled.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P. SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Vehicle Parked on Level Ground.

Table 9-1,

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1. Pusher Axle Air Bags (M917, M919, and M920): 8-14 9-1

A. Removal. 8-14A

B. Installation. 8-14B

C. Operational Check. 8-14C

2. Pusher Axle Lift Cylinders: 8-15

A. Removal. 8-15A

B. Installation. 8-15B

C. Operational Check. 8-15C

9-1

8-9
TM 9-2320-273-20

8-10. PUSHER AXLE MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK

NO. TASK

TROUBLESHOOTING

REF REF (TABLE)

3. Pusher Axle Pressure Gage : 8-16 9-1

A. Removal. 8-16A

B. Installation. 8-16B

C. Operational Check. 8-16C

4. Pusher Axle Pressure Regulator Valve : 8-17

A. Removal. 8-17A

B. InstalIation. 8-17B

C. Operational Check. 8-17C

5. Pusher Axle Up-Down Selector Valve : 8-18

A. Removal. 8-18A

B. Installation. 8-18B

C. Operational Check. 8-18C

9-1

9-1

8-10
TM 9-2320-273-20

This page intentionally left blank.

8-11
TM 9-2320-273-20

PROPELLER SHAFTS AND UNIVERSAL JOINTS.

8-11. PROPELLER SHAFTS AND UNIVERSAL JOINTS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (25)

b. Cleaning and Lubrication. (10)

c. Inspection of Universals. (10)

d. Installation. (25)

e. Checking for Vibration. (15)

85 Minutes Total .

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

GAA (Refer to Appendix C).

Blocks.

Nonflammable Cleaning Solvent SD-2 (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS63B20).

REFERENCES (TM)

TM 9-2320-273-10.

LO 9-2320-273-12.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 8-1, 8-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

8-12
TM 9-2320-273-20

PROPELLER SHAFTS AND UNIVERSAL JOINTS.

8-11. PROPELLER SHAFTS AND UNIVERSAL JOINTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

The M915 has two propeller shafts

while the M916 thru M920 have

four. Two styles of yokes and

two universal joints are used

throughout the model series as

illustrated below.

8-13
TM 9-2320-273-20

PROPELLER SHAFTS AND UNIVERSAL JOINTS.

8-11. PROPELLER SHAFTS AND UNIVERSAL JOINTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

APPLICATION

Model Quantity Style Location

M915 1 A Prop shaft from transmission to forward rear axle.

1 B Prop shaft from forward rear axle to rear rear axle.

M916, M917 1 B Prop shaft from transmission to top of transfer case.

M918, M919 1 B Prop shaft from bottom of transfer case to front axle.

M920 1 B Prop shaft from bottom rear of transfer case to forward rear axle.

1 A Prop shaft from forward rear axle to rear rear axle.

NOTE

Before disassembly of any prop shafts and

U-joints, punch mark each shaft and joint

to insure proper assembly alinement. If already punch marked, do not make new marks,

but use existing ones.

NOTE

Before disassembly, use a suitable jack or

sling to support shaft. It may be necessary

to jack up rear differential with Park Brake

OFF to release torque pressure on prop

shaft/joint connections.

STYLE A

1. Four Iockplates (2). Bend down tabs as needed.

2. Eight capscrews (1). Unscrew and remove.

3. Four Iockplates (2). Remove from bearing cups (3).

4. Bearing cups (3). Remove.

5. Yokes (6) and cross (4). a. Disengage cross from yokes.

b. Remove cross (4).

c. Swing shaft yoke free of axle

or transmission.

d. Unscrew grease fitting (5).

8-14
TM 9-2320-273-20

PROPELLER SHAFTS AND UNIVERSAL JOINTS.

8-15
TM 9-2320-273-20

PROPELLER SHAFTS AND (UNIVERSAL JOINTS

8-Il. PROPELLER SHAFTS AND UNIVERSAL JOINTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

STYLES A AND B

8. Yoke (6) and propeller a. Pull yoke (6) out of Inspect dust seal (8) and replace

shaft (7). propeller shaft (7). as necessary.

b. Screw on dust seal (8)

and slide yoke (6) and

propeller shaft (7) back

together.

B. CLEANING AND LUBRICATION.

Do not allow SD-2 dry cleaning solvent to

come in contact with seals or flexible hoses.

These cleaners may damage leather, rubber,

and synthetic materials.

STYLE A

9. Yoke (6), cross (4), a. Soak in dry cleaning

four Iockplates (2), solvent to loosen grease

eight capscrews (1), and and foreign matter.

grease fitting (5). b. Clean thoroughly and

refer to 8-11C for inspection prior to

lubrication.

NOTE

Do not disassemble bearing assembly inside bearing cups.

10. Four bearing cups (3). a. Clean with a short stiff

brush being careful not

to dislodge needle bearings.

b. Coat lightly with GAA.

11. Grease fitting (5). Screw into cross (4) and apply

grease liberally thru grease

fitting (refer to LO 9-2320-

273-12) and on all mating

surfaces.

8-16
TM 9-2320-273-20

PROPELLER SHAFTS AND UNIVERSAL JOINTS.

8-11. PROPELLER SHAFTS AND UNIVERSAL JOINTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

8-17
TM 9-2320-273-20

PROPELLER SHAFTS AND UNIVERSAL JOINTS.

Replace as necessary.

8-11. PROPELLER SHAFTS AND UNIVERSAL JOINTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS 

B. CLEANING AND LUBRICATION (Continued).

STYLE B

12. Universal joint (9), yoke a. Clean with dry cleaning

(15), grease fittings (5), solvent being careful not

(10), and (14). to contact seals. Refer to

8-11C for inspection

prior to lubrication.

b. Screw grease fittings into

yokes and joints and apply

grease liberally through all

grease fittings (5), (10),

and (14) (refer LO 9-2320-

273-12) and on all mating

surfaces.

C. INSPECTION OF UNIVERSALS.

STYLE A

13. Universal joint yokes (6), Inspect for:

crosses (4) and bearing a. Excess wear.

cups (3). b. Damaged grease seals.

14. Propeller shaft (7). Slide shaft sections and in- Replace as necessary.

spect for excess spline wear

and binding.

15. Grease fitting (5). Inspect for: Replace as necessary.

a. Damaged threads.

b. Damaged tip.

STYLE B

16. Universal joint (9). Inspect for damaged grease Replace as necessary.

seals.

17. Grease fittings (10) and (14). Inspect for damaged threads Replace as necessary.

or tip.

Style A bearing cups (3) and cross (4)

should be replaced as a set. Do not use an

old cross with new cups or old cups with

a new cross. Style B universal joints must

be replaced as an assembly if excessive wear

or grease leakage is evident. Repair parts

are available only in kits.

8-18
TM 9-2320-273-20

PROPELLER SHAFTS AND UNIVERSAL JOINTS .

8-19
TM 9-2320-273-20

PROPELLER SHAFTS AND UNIVERSAL JOINTS.

8-11. PROPELLER SHAFTS AND UNIVERSAL JOINTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

D. INSTALLATION.

STYLE A

18. Yoke (6) and cross (5).

19. Two bearing cups (3).

20. Two Iockplates (2).

21. Yoke (6) and cross (4).

22. Two bearing cups (3).

23. Two Iockplates (2).

STYLE B

24. Universal joint (9).

25. Universal joint (9)

attached to shaft

flange.

Install cross in one yoke.

Press into yoke to secure cross.

a. Install one on each bearing cup.

b. Attach with capscrews (1).

Install other yoke.

Press into yoke to secure cross.

a. Install one on each bearing cup.

b. Attach with capscrews (1).

c. Bend up tabs on Iockplates (2).

Aline mounting holes to propeller

shaft flange, install hexhead bolts

(11) and Iockwashers (12). Tighten

to 100-110 Ib-ft (136-149 N•m).

Raise into alinement with yoke

mounting holes, install hexhead

bolts (11) and Iockwashers (12).

Tighten to 100-110 Ib-ft (136-

149 N•m). Install locknuts (13),

if so equipped.

NOTE

Follow-on maintenance required:

Lubricate all grease fittings (5),

(10), and (14) (see LO 9-2320-

273-12).

8-20
TM 9-2320-273-20

PROPELLER SHAFTS AND UNIVERSAL JOINTS.

8-21
TM 9-2320-273-20

FRONT AXLE.

8-12. OIL SERVICE (M916 Thru M920).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Draining Oil. (15)

b. Replenishing Oil Supply. (20)

c. Operational Check. (30)

65 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 thru M920. None. Axle Oil Warm (Perform

TEST EQUIPMENT

Oil Service Immediately

After Truck Has Been

None. Driven.)

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

CW, 27 Pt (12.7 Liters) (Refer to Appendix C).

GOS Gear Oil if Sub-Zero Use (Refer to Appendix C).

Chassis Grease, GAA (Refer to Appendix C).

Liquid Teflon (Refer to Appendix C).

Container (3 Gal).

Non-Flammable Cleaning Solvent SD-2 (Refer to Appendix C).

Grease Gun.

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

One, (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

None.

8-22
TM 9-2320-273-20

NOTE

Before removing drain plug (2), place

container underneath to catch oil.

Remove and allow oil to

drain out.

a. Remove, inspect, and

clean with solvent.

b. Install; threads coated

with Teflon.

a. Wipe plug and openings

clean.

b. Screw in and tighten.

8-12. OIL SERVICE (M916 Thru M920).

LOCATION/lTEM ACTION REMARKS

A. DRAINING OIL.

1. Filler plug (1) and

drain plug (2).

2. Vent plug (4).

3. Drain plug (2).

8-23

FRONT AXLE
TM 9-2320-273-20

FRONT AXLE.

8-12. OIL SERVICE (M916 Thru M920) (Continued).

LOCATION/lTEM ACTION REMARKS

B. REPLENISHING OIL SUPPLY.

4. Opening at filler plug (1). a. Add 27 pts (12.7 liters) If sub-zero useage add GOS

of GO. gear oil.

b. Wipe filler plug (1) and

opening clean.

c. Screw in filler plug (1)

and tighten.

5. Six grease fittings (3). Lubricate with chassis grease,

using grease gun.

C. OPERATIONAL CHECK.

6. Vehicle. Road test. Check for unusual If excessively noisy, refer

noise. problem to Direct Support

Maintenance.

7. Front driving axle. After road test, check for Retighten plugs as necessary.

leaks.

8-24
TM 9-2320-273-20

FRONT AXLE.

8-12. OIL SERVICE (M916 THRU M920) (Continued).

8-25
TM 9-2320-273-20

REAR AXLE.

8-13. OIL SERVICE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Draining Oil. (15)

b. Replacing Oil Filter (M915). ( 5)

c. Replenishing Oil. (10)

d. Checking for Leaks. (20)

50 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. Axle Oil Warm. (Perform

TEST EQUIPMENT

Oil Service Immediately

After Truck Has Been

None. Driven.)

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Container. 10 Gals (38 Liters).

Gear Oil , GOS if Sub-Zero Use (Refer to Appendix C).

M915 M916 Thru M920.

76 Pints (36 Liters). 62 Pints (29 Liters).

Oil Filter Element (M915), 3280-V-5040 (78500).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 8-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

8-26
TM 9-2320-273-20

REAR AXLE.

8-13. OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

A. DRAINING OIL.

1. Filler plugs (1) and (10) Unscrew and remove.

or (7) and (12).

NOTE

Before removing a drain plug, place container underneath to catch oil. Drain

plugs are magnetic and any metal particles

should be completely removed. If excessive,

refer to Direct Support.

8-27
TM 9-2320-273-20

REAR AXLE.

8-13. OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

A. DRAINING OIL (Continued).

2. Magnetic drain plugs (9) and a. Remove.

(11) or (6) and (8). b. Allow oil to drain.

c. Wipe magnetic plugs and

axle housing.

d. Screw in plugs.

B. REPLACING OIL FILTER (M915 ONLY).

3. Two filter cover locknuts (5). Remove. Replace studs (4) if damaged.

4. Filter cover (3). Slide off filter.

5. Filter (2). Unscrew and throw away. You will need to use a strap

wrench.

6. New filter (2). a. Moisten gasket with oil.

b. Screw on until gasket

contacts adapter.

c. Tighten one more full turn.

7. Filter cover (3). a. Slide over new filter (2) and

studs (4).

b. Secure with two locknuts (5).

C. REPLENISHING OIL.

8. Front filler plug (10) a. Pour in GO. Fill with GOS if sub-zero useage.

(1) M95 -40 Pts (19

(2) M916 thru M920 -

34 pts (16 liters).

b. Screw in filler plug.

9. Rear filler plug(s) (1) a. Pour in GO.

or (12). (1) M915 -36pts(17 One plug.

(2) M916 thru M920- Two plugs.

28 pts (13 liters).

b. Screw in filler plug(s).

8-28
TM 9-2320-273-20

REAR AXLE.

8-13. OIL SERVICE (Continued).

LOCATION/lTEM ACTION REMARKS

D. CHECKING FOR LEAKS.

10. Vehicle. Road test.

11. Filler plugs(1) and (10) a. Check for leaks.

or (7) and (12); drain plugs b. Check oil level.

(9) and (11) or (6) and (8),

filter (2) (M915 only).

Add more oil if necessary.

8-29
TM 9-2320-273-20

PUSHER AXLE.

8-14. PUSHER AXLE AIR BAGS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Installation. (20)

c. Operational Check. (10)

50 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M917, M919, M920. TM 9-2320-273-10. Pusher Axle Down.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P,

TROUBLESHOOTING REFERENCES

Table 9-1.

9-13A. Air Reservoirs Drained.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

8-30
TM 9-2320-273-20

PUSHER AXLE.

8-14. PUSHER AXLE AIR BAGS MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

NOTE

Air bags should be replaced as a pair.

A. REMOVAL.

1. Two air lines (9). a. Unscrew and remove. Replace if necessary.

b. Inspect for: Located on top plate (4)

(1) Leaks. toward inside of chassis rails.

(2) Cracks.

(3) Damaged fittings.

2. Two air line fittings (1). Unscrew from studs (inner). Located on top plates (4).

3. Two nuts (2). Unscrew from studs (inner). Located on top plates (4).

4. Two nuts (3). Unscrew from studs (outer). Located on top plates (4).

8-31
TM 9-2320-273-20

PUSHER AXLE.

8-14. PUSHER AXLE AIR BAGS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

5. Eight bolts (7) and Remove from bottom

Iockwashers (6). plates (8).

6. Two air bags (5). a. Slide out.

b. Inspect for: Replace if cracked or leaking.

(1) Deterioration. Replace as a set of two air bags.

(2) Cracks.

7. Two air bags (5). Slide into position between

top plates (4) and bottom

plates (8); aline holes.

8. Eight bolts (7) and Install through bottom

Iockwashers (6). plates (8) and tighten.

9. Two nuts (3). Install and tighten on outer

top plate stud.

10. Two nuts (2). Install and tighten on upper

inner air line studs.

11. Two air line fittings (1). Apply liquid teflon to threads

and screw onto upper inner air

stud above nuts (2).

12. Two air lines (9). Apply liquid teflon and install

on air line fittings (1).

C. OPERATIONAL CHECK.

13. Engine. Start up (see TM 9-2320-273-

10).

14. Pusher axle. Raise and lower (see TM 9-2320-

273-10). Check for proper inflation and deflation of both air

bags.

15. Engine. Shut down (see TM 9-2320-

273-10).

8-32
TM 9-2320-273-20

PUSHER AXLE.

8-14. PUSHER AXLE AIR BAGS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

8-3 3
TM 9-2320-273-20

PUSHER AXLE.

8-15. PUSHER AXLE LIFT CYLINDERS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Installation. (20)

Operational Check. (10)

50 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M917, M919, M920. TM 9-2320-273-10. Pusher Axle Down.

TEST EQUIPMENT 9-13A. Air Reservoirs Drained.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

8-34
TM 9-2320-273-20

PUSHER AXLE.

8-15. PUSHER AXLE LIFT CYLINDERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Lift cylinders should be replaced as a pair.

A. REMOVAL.

1. Two air lines (8) and a. Unscrew and remove. One on each side of truck.

elbows (9). b. Inspect for: Replace if necessary.

(1) Cracks.

(2) Leaks.

(3) Damaged fittings.

2. Four capscrews (3), and Unscrew and remove.

washers (2).

3. Two nuts (7). Unscrew and remove.

4. Two nuts (6). Unscrew and remove. Remove

two lift cylinders (5).

8-35
TM 9-2320-273-20

PUSHER AXLE.

8-15. PUSHER AXLE LIFT CYLINDERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

5. Two lift cylinders (5). Place in position, Aline bolt

holes. Push studs through

brackets (1).

6. Four capscrews (3) with Screw in and tighten.

washers (2).

7. Two nuts (7). Screw on and tighten.

8. Two nuts (6). Screw on and tighten.

9. Two elbows (9) and a. Put liquid teflon on

air lines (8). threads of elbows (9).

b. Screw on air lines (8)

and tighten.

C. OPERATIONAL CHECK.

10. Engine. Start up (see TM 9-2320-273-

10).

11. Pusher axle. Raise and lower (see TM 9-

2320-273-10). Check for

proper inflation and deflation

of both lift cylinders.

12. Engine. Shut down (see TM 9-2320-273-

10).

8-36
TM 9-2320-273-20

8-15. PUSHER AXLE LIFT CYLINDERS MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

8-37

PUSHER AXLE.
TM 9-2320-273-20

PUSHER AXLE.

8-16. PUSHER AXLE PRESSURE GAGE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Installation. (10)

c. Operational Check. (10)

30 Minutes Total .

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M917, M919, M920. TM9-2320-273-10. Pusher Axle Down.

TEST EQUIPMENT 9-13A . Air Reservoirs Bled

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

Table 9-1.

8-3 8
TM 9-2320-273-20

PUSHER AXLE.

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Four screws (2). Loosen and remove. Remove

panel (3).

2. Bulb/lamp assembly (4). Disconnect.

3. Air lines (5) and (6). a.

b.

4. Air line fitting block (7). a.

Unscrew and remove from

fitting block (7) and elbow

(8).

Inspect for:

(1) Cracks.

(2) Leaks.

(3) Damaged fittings.

Unscrew from back of gage

(1).

Inspect for damaged

threads.

b.

Replace if necessary.

Replace if necessary.

8-39
TM 9-2320-273-20

PUSHER AXLE.

Unscrew and remove.

Remove.

Remove.

Place in panel (3).

8-16. PUSHER AXLE PRESSURE GAGE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

5. Two nuts (9).

6. Two brackets (10).

7. Gage (1).

8. Gage (1).

9. Two brackets (10).

10. Two nuts (9).

11. Fitting block (7).

12. Air lines (5) and (6).

13. Bulb/lamp assembly (4).

14. Panel (3).

C. OPERATIONAL CHECK.

15. Engine.

16. Pressure gage.

17. Engine.

Put in place. Screw in and

tighten four screws (2).

Start up (see TM 9-2320-

273-10).

Check readings as regulator

valve is actuated (see TM 9-

2320-273-10).

Shut down (see TM 9-2320-

273-10).

Place in position over

gage studs.

Screw on and tighten.

Apply liquid teflon to threads

and screw into the rear of gage

(1).

Screw on and tighten.

Connect.

8-40
TM 9-2320-273-20

8-16. PUSHER AXLE PRESSURE GAGE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

PUSHER AXLE

8-41
TM 9-2320-273-20

PUSHER AXLE.

8-17. PUSHER AXLE REGULATOR VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (3.5)

b. Installation. (3.5)

c. Operational Check. (2.0)

9.0 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CON FIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M917, M919, M920. TM9-2320-273-10 . Pusher Axle Down.

TEST EQUIPMENT

9-13A. Air Reservoirs Drained.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

8-42
TM 9-2320-273-20

PUSHER AXLE.

8-17. PUSHER AXLE REGULATOR VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Four screws (1).

2. Two air lines (3).

3. Elbows (6).

4. Lockring (5).

Unscrew and remove.

panel (2).

a. Unscrew and remove

from elbows (6).

b. Inspect for:

(1) Cracks.

(2) Leaks.

(3) Damaged fittings.

Unscrew from valve (4).

Unscrew and remove from

panel front. Remove valve

(4).

Replace if necessary.

8-43
TM 9-2320-273-20

PUSHER AXLE.

8-17. PUSHER AXLE REGULATOR VALVE MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

 B . INSTALLATION. 

5. Elbows (6). Apply liquid teflon to threads

and screw into valve (4).

6. Valve (4). a. Insert in panel (2).

b. Screw on and tighten lockring (5).

7. Two air lines (3). Screw onto fittings (6) and

tighten.

8. Panel (2). Set in place. Screw in and

tighten four screws (1).

C. OPERATIONAL CHECK.

9. Engine. Start up (see TM 9-2320-273-10).

10. Pressure regulator valve. Check for increases and decreases

in pressure readings on gage when

valve is operated (see TM 9-2320-

273-10).

11. Engine. Shut down (see TM 9-2320-

273-10).

8-44
TM 9-2320-273-20

PUSHER AXLE.

8-17. PUSHER AXLE REGULATOR VALVE MAINTENANCE (Continued.

LOCATION/lTEM ACTION REMARKS

8-45
TM 9-2320-273-20

PUSHER AXLE.

8-18. PUSHER AXLE UP-DOWN SELECTOR VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Installation. (15)

c. Operational Check. (10)

35 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M917, M919, M920. TM 9-2320-273-10. Pusher Axle Down.

TEST EQUIPMENT

9-13A. Air Reservoirs Drained.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS [P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

8-46
TM 9-2320-273-20

PUSHER AXLE.

Unscrew and remove.

Unscrew and remove

panel (5).

a. Unscrew and remove from

two elbows (3) and straight

fitting (9).

b. Inspect for:

(1) Cracks.

(2) Leaks.

(3) Damaged fittings.

Unscrew from valve (4).

Unscrew and remove valve

(4).

Replace if necessary.

8-18. PUSHER AXLE UP-DOWN SELECTOR VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL. 

1. Screw (7) and lever (6).

2. Four screws (1).

3. Three air lines (2).

4. Two elbows (3) and

straight fitting (9).

5. Four screws (8).

8-47
TM 9-2320-273-20

Set in place. Screw in and

tighten four screws (1).

Attach to valve (4) and

tighten screw (7).

PUSHER AXLE.

8-18. PUSHER AXLE UP-DOWN SELECTOR VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

6. Two elbows (3) and Coat threads with liquid teflon

straight fitting (9). and screw into valve (4).

7. Valve (4). Attach to panel (5) with four

screws (8). Tighten screws.

8. Three air lines (2). Screw into two elbows (3) Supply line goes to center of

and straight fitting (9). valve, air bag line goes to top

of valve, and lift cylinder line

goes to bottom of valve.

9. Panel (5).

10. Lever (6).

C. OPERATIONAL CHECK.

11. Engine. Start up (see TM 9-2320-

273-10).

12. Pusher axle. Check for proper raising and

lowering (see TM 9-2320-

273-10).

13. Engine. Shut down (see TM 9-2320-

273-10).

8-48
TM 9-2320-273-20

PUSHER AXLE.

8-49/8-50 (Blank)

TM 9-2320-273-20

CHAPTER 9

COMPRESSED AIR AND BRAKE SYSTEMS

9-1. OVERVIEW.

This chapter provides you with the following information

maintenance:

a. All required special tools and equipment.

b. Other technical manuals.

c. Troubleshooting procedures.

d. Maintenance procedures.

related to compressed air and brake

Section I REPAIR PARTS, SPECIAL TOOLS, TMDE AND SUPPORT EQUIPMENT

9-2. COMMON TOOLS AND EQUIPMENT.

For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE) applicable to your unit.

9-3. SPECIAL TOOLS, TMDE, SUPPORT EQUIPMENT.

The special tools, TMDE and support equipment required for the compressed air and

nance procedures described in this chapter are limited to the following items. (Refer

Maintenance RPSTL, TM 9-2320-273-20P for tool description and illustration.)

a. Air Pressure Gage (0-200 psi min).

b. Brake spring pliers.

c. Wheel dolly jacks, and blocks.

d. Oil filter strap wrench.

9-4. SPARES AND REPAlR PARTS.

brake mainteto Organizational

Spares and repair parts are listed and illustrated in the Repair Parts and Special Tools Iist covering

Organizational Maintenance for this equipment (TM 9-2320-273-20P).

9-1
TM 9-2320-273-20

Section ll TROUBLESHOOTING

9-5. INTRODUCTION.

a. General. The primary use of the compressed air system is to operate the service and park/

emergency vehicle brakes. Other uses of compressed air are for transmission shifting control, air horn

operation, windshield wiper and washer operation, the differential lockout, and on some vehicles,

pusher axle controls, and front wheel drive. Air system component location illustrations for each

truck model are contained in paragraphs 9-5e thru 9-5j. These same illustrations are contained in paragraphs 2-65 thru 2-70 and the components are further described in paragraph 2-64.

b. Scope. This section contains troubleshooting instructions based on observed malfunctions

starting with generalized pressure problems and continuing to more specific malfunctions of components and compressed air functions.

c. Test Equipment: Air pressure gage (0-200 psi min].

d. Troubleshooting. Troubleshooting procedures are given in table 9-1. The procedures are

grouped under the malfunctions listed below. Perform only those steps in a procedure required to

remedy the malfunction.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

Insufficient air pressure (Malfunction No. 1).

Excessive system pressure indicated (Malfunction No. 2).

Park brakes will not release (Malfunction No. 3).

Trailer or towed vehicle brakes will not release (Malfunction No. 4).

Service brake will not release (one wheel only) (Malfunction No. 5).

Service brakes will not apply (Malfunction No. 6).

No service brakes on trailer or towed vehicle only (Malfunction No. 7).

Trailer hand control will not apply trailer service brakes (Malfunction No. 8).

Park brakes will not apply (Malfunction No. 9).

Service brakes are weak or slow responding (all wheels) (Malfunction No. 10).

Front service brakes are weak or slow responding (Malfunction No. 11).

Rear service brakes are uneven or erratic (Malfunction No. 12).

Service brakes are uneven or erratic on one or more wheels (Malfunction No. 13).

Brakes overheat (Malfunction No. 14).

Stop lamps do not operate, brakes function normally (Malfunction No. 15).

Pressure gage(s) not indicating or is not accurate, brakes normal (Malfunction No. 16.

Air horn does not operate (Malfunction No. 17).

Windshield wipers or washers are inoperative (Malfunction No. 18).

Interaxle differential lockup inoperative (Malfunction No. 19).

9-2
TM 9-2320-273-20

Table 9-1. Compressed Air and Brake System Troubleshooting Procedures.

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

1. INSUFFICIENT AIR PRESSURE:

Step 1. Check for air exhausting through open or damaged air reservoir drain valves.

a. Close or replace manual drain valve (para 9-13).

b. Replace automatic drain valve on supply reservoir (para 9-12).

Step 2. Check for loose air connections between the compressor, governor, and air reservoirs.

Tighten any loose air connections and replace damaged components.

Step 3. Check governor for proper operation and adjustment. Should be set to control pressure in supply reservoir at 105-125 psi (724-862 kPa).

Refer problem to Direct Support Maintenance.

Step 4. With the engine not running, loosen the compressor output line at the compressor and

listen for escaping air.

a. If air escapes continuously, replace the check valve in that line at the supply

reservoir (para 9-15).

b. If the check valve is okay, refer problem to Direct Support Maintenance.

Step 5. Check air Iine connections for tightness and air lines for cracks or breaks.

Tighten or replace connections and lines as necessary.

2. EXCESSIVE SYSTEM PRESSURE INDICATED:

Step 1. Check for inoperative pressure safety relief valve on the supply reservoir.

Replace the safety release valve (para 9-14) only if reservoir exceeds 150 psi.

Step 2. Check governor for proper operation.

Refer problem to Direct Support Maintenance.

3. PARK BRAKES WILL NOT RELEASE:

Step 1. Check reservoir pressure gage and verify LOW PRESSURE warning lamp is out.

See Malfunction 1.

Step 2. Verify PARK BRAKE manual valve is closed.

Close valve; if valve will not close, refer to para 9-19.

Step 3. Check air lines for leakage or damage. Use a soap solution to check for leakage at

connections and watch for bubbles.

Replace damaged lines and tighten loose connections (para 9-36).

9-3
TM 9-2320-273-20

Table 9-1. Compressed Air and Brake System Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

3. PARK BRAKES WILL NOT RELEASE (Continued):

Step 4. (M915, M916 and M920 only). Inspect intervehicle air hoses for proper connections.

Connect hoses properly.

Step 5. Check the air line between the two rear quick-release valves for damage or leaks using

a soap solution.

a. Replace the line if damaged and tighten connections.

b. Replace the park brake quick-release valve (para 9-22).

4. TRAILER OR TOWED VEHICLE BRAKES WILL NOT RELEASE:

Step 1. Check intervehicle air hoses for proper connections. Close the trailer supply valve and

disconnect the hoses.

Reconnect the hoses and open the supply valve.

Step 2. Check for trailer air leaks or defective brakes.

Troubleshoot trailer.

5. SERVICE BRAKES WILL NOT RELEASE (ONE WHEEL ONLY) :

Troubleshoot brake.

Refer to brake malfunctions 3 and 4, above.

6. SERVICE BRAKES WILL NOT APPLY:

Step 1. Check the pressure gages in the cab.

Operate the engine to build up proper pressure.

Step 2. Check position of park brake and trailer supply valves.

Position correctly.

Step 3. (M915, M916 and M920 only). Check intervehicle connections.

Connect air hoses correctly and open trailer supply valve.

9-4
TM 9-2320-273-20

Table 9-1. Compressed Air and Brake System Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

6. SERVICE BRAKES WILL NOT APPLY (Continued):

Step 4. Check for leakage at the brake pedal valve using a soap solution.

Tighten connections or replace defective brake pedal valve (para 9-21).

Step 5. Check brakes for proper adjustment and worn linings.

Adjust brakes (para 9-31, 9-32, 9-33, 9-34).

7. NO SERVICE BRAKES ON TRAILER OR TOWED VEHICLE ONLY:

Step 1. Check service air hose connection and position of trailer supply valve.

Reconnect hose properly and open trailer supply valve.

Step 2. Check trailer supply valve for damage or leakage using a soap solution.

Replace defective valve (para 9-17).

Step 3. Check the double-check valve(s) for damage or leakage using a soap solution.

Replace defective valve (para 9-27).

Step 4. Check tractor protection valve for damage or corrosion.

If valve is defective, replace defective valve.

8. TRAILER HAND CONTROL WILL NOT APPLY TRAILER SERVICE BRAKES:

Step 1. Check air lines between trailer hand control and double check valve for leakage using

a soap solution.

Repair leaks.

Step 2. Check tractor protection valve for damage or leaks using a soap solution.

Tighten connections or replace valve (para 9-26).

Step 3. Check the double-check valve for damage or leaks using a soap solution.

Tighten connections or replace valve (para 9-27).

9. PARK BRAKES WILL NOT APPLY:

Step 1. Inspect vent on the park brake valve for damage or clogging.

Clean vent or replace valve (para 9-19).

Change 2 9-5
TM 9-2320-273-20

Table 9-1. Compressed Air and Brake System Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

9. PARK BRAKES WILL NOT APPLY (Continued):

Step 2. Check air chambers for proper position of caging bolt.

Adjust caging bolt (Para 9-37).

10. SERVICE BRAKES ARE WEAK OR SLOW RESPONDING (ALL WHEELS):

Step 1. Check for low reservoir pressure. Pressure should not be below 80 Ibs. (Buzzer

sounds at 80 Ibs).

See Malfunction 1.

Step 2. Check service air lines for damage and leakage using a soap solution.

Tighten loose connections and replace damaged lines.

Step 3. Check brake linings and adjustment (para 9-31, 9-32, 9-33, 9-34, 9-35).

Replace brake linings and/or adjust as necessary.

11. FRONT SERVICE BRAKES ARE WEAK OR SLOW RESPONDING:

Step 1. Check air lines between brake pedal valve and front brake chambers for damage and

leakage using a soap solution.

Tighten loose connections and replace damaged lines.

Step 2. Check the limiting valve for damage and leakage using a soap solution.

Replace defective limiting valve (para 9-25).

Step 3. Check the brake pedal valve for damage and leakage using a soap solution.

Replace defective valve (para 9-21).

Step 4. Check front brakes for worn linings (shoes) and proper adjustment.

Adjust brakes and replace linings if necessary (para 9-31, 9-32).

12. REAR SERVICE BRAKES ARE UNEVEN OR ERRATIC:

Step 1. Check for leakage in air lines between service brake relay valve and wheel air chambers

using a soap solution.

Tighten loose connections or replace defective components.

9-6
TM 9-2320-273-20

Table 9-1. Compressed Air and Brake System Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

12. REAR SERVICE BRAKES ARE UNEVEN OR ERRATIC (Continued):

Step 2. Check for air leakage between the air reservoir and the rear service brake relay valve.

Tighten loose connections or replace damaged line.

Step 3. Leak test rear brake part of the brake pedal valve.

Tighten loose connections or replace pedal valve (para 9-21).

Step 4. Check brake shoes for proper adjustment.

Adjust brake shoes (para 9-39).

13. SERVICE BRAKES ARE UNEVEN OR ERRATIC ON ONE OR MORE WHEELS:

Step 1. Have an assistant press and hold the brake pedal valve down and perform leakage

test on air lines at affected wheels using a soap solution.

Tighten loose connections, repair or replace damaged air lines or hoses.

Step 2. Loosen line fitting at affected wheel air chamber and have an assistant lightly depress

the treadle valve, Listen for air exhausting from line. No air indicates a clogged line.

Replace damaged or clogged line.

Step 3. Check brake adjustment (para 9-31,9-32, 9-39):

a. Adjust brake and schedule for maintenance as soon as possible.

b. If manual adjustment does not correct the problem, refer problem to

Direct Support Maintenance.

Step 4. Press brake pedal down and listen for air leakage around wheel air chamber clamp.

Tighten clamp or replace ruptured chamber diaphragm (para 9-36 for front

brakes, para 9-37 for rear brakes).

Step 5. Remove hub and drum assembly to inspect plunger and adjuster mechanism and brake

return springs (para 9-31 and 9-32 for front brakes, para 9-33 and 9-34 for rear brakes).

Clean, repair or replace defective components.

Step 6. Check the brake linings for grease, glazing and proper installation (para 9-31 and 9-32

for front brakes, para 9-33 and 9-34 for rear brakes).

Clean, replace, or reinstall as required.

9-7
TM 9-2320-273-20

Table 9-1. Compressed Air and Brake System Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

14. BRAKES OVERHEAT:

Step 1. Check for low reservoir pressure.

If below 80 psi, see Malfunction 1.

Step 2. Check for damaged or leaking front limiting valve or rear relay valves.

Tighten loose connections or replace defective valve (para 9-24 or 9-25, as

applicable).

Step 3. Pull hub and drum assembly (para 10-13 through 10-15 as applicable) and inspect

brake assembly. Apply brakes lightly and observe shoe movement for smooth

operation.

a. Replace weak or broken return springs (para 9-31 and 9-32 for front

brakes, 9-33 and 9-34 for rear brakes).

b. Clean, service, and assemble brake mechanism.

Step 4. Check for insufficient lining to drum clearance (para 9-31 and 9-32 for front brakes,

para 9-33 and 9-34 for rear brakes).

a. Adjust.

b. If adjusting fails, refer problem to Direct Support Maintenance.

Step 5. Inspect wheel bearings for damage and proper lubrication.

Adjust, lube, or replace bearings (para 10-13 through para 10-15 as applicable).

15. STOP LAMPS DO NOT OPERATE, BRAKES FUNCTION NORMALLY:

Step 1. Have an assistant step on the brake pedal (with ignition key switch on) and check for

approximately 12 volts dc at both electrical connections on the stoplamp switch.

If voltage is not present on both terminals, replace the double-check valve/stop

lamp switch (para 9-28 or 9-29),

Step 2. Check for defective wiring or electrical connectors.

Troubleshoot the electrical system (para 5-17).

9-8
TM 9-2320-273-20

Table 9-1. Compressed Air and Brake System Troubleshooting Procedures (Continued).

MALFUNCTION .

TEST OR INSPECTION .

CORRECTIVE ACTION .

16. PRESSURE GAGE(S) NOT INDICATING OR IS NOT ACCURATE, BRAKES NORMAL:

Step 1. Disconnect affected air line(s) at gage(s) and press the brake pedal. If no air exhausts,

the line is clogged or broken.

Replace defective line or gage (para 9-20).

17. AIR HORN DOES NOT OPERATE:

Step 1. Check for air LOW PRESSURE.

If air pressure is below 20 Ibs , operate engine until air pressure is back to 120 Ibs.

See Malfunction 1.

Step 2. Inspect air lines for damage or clogging.

a. Replace damaged or clogged lines.

b. Replace defective manually-operated horn valve (para 9-45).

18. WINDSHIELD WIPERS OR WASHERS ARE INOPERATIVE:

Step 1.

Step 2.

Step 3.

Check for air leakage in lines to the wiper or washer control valve using a soap solution.

Tighten loose connections and replace damaged lines.

Check to see if the wiper mechanical linkage is binding or broken.

Replace defective linkage (para 9-42).

Loosen air line at the wiper motor and turn control to the run position. Air should

exhaust from the line.

a. If no air exhausts, replace the control valve (para 9-43).

b. If air exhausts, replace the motor (para 9-42).

9-9
TM 9-2320-273-20

Table 9-1. Compressed Air and Brake System Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

19. INTERAXLE DIFFERENTIAL LOCKUP INOPERATIVE:

Disconnect air lines at rear axle; then engage lockup control valve on instrument panel. Check for

air pressure at rear axle. No air indicates clogged lines or defective control valve.

a. Replace clogged lines.

b. Replace defective control valve (para 9-44).

c. If air controls are working normally, refer problem to Direct Support

Maintenance.

9-10
TM 9-2320-273-20

BRAKE SYSTEM

9-5e. AIR SYSTEM ARRANGEMENT (M915).

NOTE

The components shown below are described in paragraph 2-64.

Change 2 9-11
TM 9-2320-273-20

BRAKE SYSTEM

9-5f. AIR SYSTEM ARRANGEMENT (M916).

LEGEND:

19. CHECK VALVE

1. WEDGE BRAKE AIR CHAMBER 20. TRACTOR PROTECTION VALVE

2. PARKING BRAKE VALVE 21. AIR HOSE COUPLING

3. PLUG 22. 90°ELBOW

4. DRAIN COCK 23. DRAIN COCK

5. SECONDARY RESERVOIR 24. SUPPLY RESERVOIR

6. DOUBLE CHECK VALVE 25. SAFETY VALVE

7. 90°CHECK VALVE 26. ADAPTER

8. 90°ELBOW 27. CHECK VALVE

9. PRIMARY RESERVOIR 28. SPRING BRAKE CONTROL VALVE

10. SPRING AND SERVICE BRAKE 29. DOUBLE CHECK VALVE

CHAMBER/SLACK ADJUSTER (2) 30. DUAL BRAKE VALVE

11. QUICK RELEASE VALVE (2) 31. WEDGE BRAKE AIR CHAMBER

12. SPRING AND SERVICE BRAKE 32. LIMITING VALVE

CHAMBER/SLACK ADJUSTER (2) 33. AIR COMPRESSOR/GOVERNOR

13. RELAY VALVE 34. CHECK VALVE

14. QUICK RELEASE AND DOUBLE 35.

CHECK VALVE

AIR DRYER

36. DOUBLE CHECK AND STOPLAMP

15. DRAIN COCK VALVE

16. 90°ELBOW 37. TRAILER SUPPLY VALVE

17. PLUG 38. TRAILER HAND CONTROL BRAKE

18. ADAPTER (2) VALVE

9-12 Change 2
TM 9-2320-273-20

BRAKE SYSTEM

9-5g. AIR SYSTEM ARRANGEMENT (M917).

LEGEND: 22. PRIMARY RESERVOIR

23. CHECK VALVE

1. WEDGE BRAKE AIR CHAMBER 24. 90° ELBOW (2)

2. PARKING BRAKE VALVE 25. EXHAUST VALVE

3. PLUG (2) 26. QUICK RELEASE VALVE

4. DRAIN COCK 27. TRACTOR PROTECTION VALVE

5. SECONDARY RESERVOIR 28. DRAIN COCK

6. DOUBLE CHECK VALVE 29. 90° ELBOW

7. 90° CHECK VALVE 30. AIR HOSE COUPLING

8. 90° ELBOW 31. SUPPLY RESERVOIR

9. AIR BRAKE CHAMBER/SLACK 32. CHECK VALVE

ADJUSTER (2) 33. ADAPTER

10. PLUG (3) 34. SAFETY VALVE

11. PRIMARY RESERVOIR 35. SPRING BRAKE CONTROL VALVE

12. 45° ELBOW (2) 36. DOUBLE CHECK VALVE

13. DRAIN COCK 37. DUAL BRAKE VALVE

14. SPRING AND SERVICE BRAKE 38. DOUBLE CHECK AND STOPLAMP

CHAMBER/SLACK ADJUSTER (2) VALVE

15. RELAY VALVE 39. WEDGE BRAKE AIR CHAMBER

16. SPRING AND SERVICE BRAKE 40. LIMITING VALVE

CHAMBER/SLACK ADJUSTER (2) 41. AIR COMPRESSOR/GOVERNOR

17. QUICK RELEASE VALVE (3) 42. CHECK VALVE

18. QUICK RELEASE AND 43. TRAILER SUPPLY VALVE

DOUBLE CHECK VALVE 44. TRAILER HAND CONTROL BRAKE

19. DRAIN COCK’ VALVE

20. PLUG 45. PRESSURE PROTECTION VALVE

21. 45° ELBOW 46. AIR DRYER

Change 2 9-13
TM 9-2320-273-20

BRAKE SYSTEM

9-5h. AIR SYSTEM ARRANGEMENT (M918).

9-14 Change 2
TM 9-2320-273-20

BRAKE SYSTEM

9-5i. AIR SYSTEM ARRANGEMENT (M919).

LEGEND: 21. DRAIN COCK

22. 90° ELBOW

1. WEDGE BRAKE AIR CHAMBER 23. PLUG

2. PARKING BRAKE VALVE 24. PRIMARY RESERVOIR

3. PLUG (2) 25. 90° ELBOW (2)

4. DRAIN COCK 26. CHECK VALVE

5. SECONDARY RESERVOIR 27. QUICK RELEASE VALVE

6. 90° ELBOW 28. EXHAUST VALVE

7. 90° CHECK VALVE 29. 90° ELBOW

8. DOUBLE CHECK VALVE 30. AIR HOSE COUPLING

9. AIR BRAKE CHAMBER/SLACK 31, DRAIN COCK

ADJUSTER (2) 32. SUPPLY RESERVOIR

10. PLUG (2) 33. ADAPTER

11. VALVE 34. SAFETY VALVE

12. PRIMARY RESERVOIR 35. CHECK VALVE

13. DRAIN COCK 36. SPRING BRAKE CONTROL VALVE

14. 90° ELBOW 37. DOUBLE CHECK AND STOPLAMP

15. 45° ELBOW VALVE

16. SPRING AND SERVICE BRAKE 38. AIR DRYER

AIR CHAMBER/SLACK ADJUSTER (2) 39. CHECK VALVE

17. RELAY VALVE 40. WEDGE BRAKE AIR CHAMBER

18. SPRING AND SERVICE BRAKE 41. AIR COMPRESSOR/GOVERNOR

AIR CHAMBER/SLACK ADJUSTER (2) 42. LIMITING VALVE

19. QUICK RELEASE VALVE (3) 43. PRESSURE PROTECTION

20. QUICK RELEASE AND DOUBLE VALVE

CHECK VALVE 44. DUAL BRAKE VALVE

Change 2 9-15
TM 9-2320-273-20

BRAKE SYSTEM

9-5j. AIR SYSTEM ARRANGEMENT (M920).

LEGEND:

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

WEDGE BRAKE AIR CHAMBER (2)

PARKING BRAKE VALVE

PLUG (2)

DRAIN COCK

SECONDARY RESERVOIR

90° CHECK VALVE

DOUBLE CHECK VALVE

90° ELBOW

QUICK RELEASE VALVE

AIR BRAKE CHAMBER/SLACK

ADJUSTER

PLUG (3)

PRIMARY RESERVOIR

45° ELBOW

90° ELBOW

DRAIN COCK

SPRING AND SERVICE BRAKE

CHAMBER/SLACK ADJUSTER (2)

RELAY VALVE

SPRING AND SERVICE BRAKE

CHAMBER/SLACK ADJUSTER (2)

QUICK RELEASE VALVE (3)

90° ELBOW

PLUG

DRAIN COCK

QUICK RELEASE AND DOUBLE

CHECK VALVE

PRIMARY RESERVOIR

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

90° ELBOW {2)

CHECK VALVE

AIR BRAKE CHAMBER/SLACK

ADJUSTER

EXHAUST VALVE

TRACTOR PROTECTION VALVE

DRAIN COCK

90° ELBOW

AIR HOSE COUPLING

SUPPLY RESERVOIR

DOUBLE CHECK VALVE

PLUG

SAFETY VALVE

CHECK VALVE

SPRING BRAKE CONTROL

VALVE

DOUBLE CHECK VALVE

DOUBLE CHECK AND STOPLAMP

VALVE

AIR DRYER

LIMITING VALVE

AIR COMPRESSOR/GOVERNOR

CHECK VALVE

TRAILER SUPPLY VALVE

PRESSURE PROTECTION VALVE

HAND CONTROL TRAILER

BRAKE VALVE

DUAL BRAKE VALVE

9-16 Change 2
TM 9-2320-273-20

Section Ill MAINTENANCE PROCEDURES

9-8. INTRODUCTION.

This section provides you with Organizational Level maintenance procedures for the compressed air

and brake systems. To find a specific maintenance procedure, see one of the following task summaries.

a. Compressed Air System (para 9-7).

b. Brake System (para 9-8).

c. Auxiliary Air-Powered Component Systems (para 9-9).

9-17
TM 9-2320-273-20

9-7. COMPRESSED AIR SYSTEM MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

MATERIALS/PARTS (P/N) SPECIAL ENVIRONMENTAL CONDITIONS

Gasket (5330-00-755-71 91). Vehicle Parked on Level Ground.

Soap Solution. Work in Well Ventilated Area Away From

Silicone Sealant (Refer to Appendix C). Sparks and Flames.

Controllable Shop Air Supply.

Non Flammable Cleaning Solvent SD-2 (Refer to Appendix C). GENERAL SAFETY INSTRUCTIONS

Tape, Antiseizing Item 14, Appendix C.

Check Valve, 275756 (06853). Engine Off.

Air Pressure Gage. Transmission in Neutral.

Marking Pen.

Park Brake Set.

Masking Tape.

REFERENCES (TM)

TM 9-2320-273-10.

TM 9.2320-273-20P.

LO 9-2320-273-12.

REFERENCES (TROUBLESHOOTING)

Table 9-1.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1. Air Dryer Dehydrate Cartridge Replacement: 9-10

9- 10A

2. Air Dryer Replacement: 9-11

a. Removal. 9-11A

b. Installation. 9-11B

c. Checking for Leaks. 9-11C

2.1 Air Dryer Repair. 9- 11.1

9-18 Change 2
TM 9-2320-273-20

9-7. COMPRESSED AIR SYSTEM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

3. Supply Reservoir Automatic Drain Valve

and Air Hose Coupling: 9-12 9-1

a. Removal. 9-12A

b. Installation. 9-12B

c. Checking for Leaks. 9-12C

4. Secondary Reservoir Manual Drain Valve

Maintenance: 9-13

a. Bleeding Reservoirs. 9-13A

b. Removal. 9-13B

c. Installation. 9-13C

d. Checking for Leaks. 9-13D

5. Safety Release Valve Maintenance: 9-14

a. Removal. 9- 14A

b. Testing. 9-14B

c. Installation. 9-14C

d. Operational Check. 9-14D

6. Supply Reservoir Check Valve Maintenance: 9-15 9-1

a. Removal. 9-15A

b. Testing. 9-15B

c. Installation. 9-15C

d. Operational Check. 9-15D

7. Reservoirs and Air Lines Maintenance: 9-16 9-1

a. Removal. 9-16A

b. Installation. 9-16B

c. Checking for Leaks. 9-16C

9-1

9-1

9-19
TM 9-2320-273-20

9-8. BRAKE SYSTEM MAINTENANCE TASK SUMMARY.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All.

TEST EQUIPMENT

EQUIPMENT CONDITION

PARAGRAPH

9-13A.

5-37A.

9-27A and 9-28A.

10-13A.

None,

10-14A.

SPECIAL TOOLS

Snap Ring Pliers.

Brake Spring Pliers.

(See TM 9-2320-273-10).

CONDITION DESCRIPTION

Air Reservoirs Drained.

Batteries Disconnected.

Double Check Valve Removed.

Hub and Drum Assembly

Removed (M915).

Hub and Drum Assembly

Removed (M916 Thru M920).

Wheel Raised OFF Ground;

Park Brake Should Be

Released and Wheels Blocked.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Masking Tape.

Marking Pen.

Soap and Water Solution.

Seal, 1205-E-1409 (78500).

GAA (Refer to Appendix C).

Cotter Pin, K-227 (78500).

Cotter Pin, 210490 (06853).

Cotter Pin, 210492 (06853).

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

TWO (MOS-63B20). Vehicle Parked on Level Ground.

REFERENCES (TM) GENERAL SAFETY INSTRUCTIONS

TM 9-2320-273-10. Engine Off.

LO 9-2320-273-12. Transmission in Neutral.

TM 9-2320-273-20P. Park Brake Set.

Wheels Blocked.

REFERENCES (TROUBLESHOOTING)

Table 9-1.

TASK

NO.

1.

2.

LIST OF TASKS

TASK

Trailer Supply Brake Valve:

a. Removal.

b. Inspection of Lines and Fittings.

c. Installation.

d. Operational Check.

Trailer Hand Brake Valve:

a. Removal.

TASK

REF

9-17

9-17A

9-17B

9-17C

9-17D

9-18

9-18A

TROUBLESHOOTING

REF (TABLE)

9-1

9-1

3-20
TM 9-2320-273-20

9-1

9-8. BRAKE SYSTEM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

2. Trailer Hand Brake Valve (Continued):

b. Inspection of Air Lines and Fittings. 9-18B

c. Installation. 9-18C

d. Operational Check. 9-18D

3. Parking Brake Valve: 9-19

a. Removal. 9-19A

b. Inspection of Lines and Fittings. 9-19B

c. Installation. 9-19C

d. Operational Check. 9-19D

4. Air Pressure Gages Maintenance: 9-20

a. Removal. 9-20A

b. Installation. 9-20B

c. Operational Check. 9-20C

5. Brake Pedal and Valve Maintenance: 9-21

a. Pedal Removal. 9-21A

b. Valve Removal. 9-21B

c. Valve Installation, 9-21C

d. Pedal Installation. 9-21D

e. Operational Check. 9-21E

6. Service Brakes Quick Release Valve: 9-22

a. Removal. 9-22A

b. Installation 9-22B

c. Operational Check. 9-22C

7. Quick-Releasel/Double-Check Valve Maintenance“ 9-23 9-1

a. Removal. 9-23A

b. Installation. 9-23B

c. Operational Check. 9-23C

9-1

9-1

9-1

9-21
TM 9-2320-273-20

9-8. BRAKE SYSTEM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

No. TASK REF REF (TABLE

8. Relay Valve Maintenance : 9-24 9-1

a. Removal. 9-24A

b. Installation. 9-24B

c. Checking for Leaks. 9-24C

9. Limiting Valve Maintenance : 9-25 9-1

a. Removal, 9-25A

b. Installation. 9-25B

c. Operational Check. 9-25C

10. Tractor Protection Valve Maintenance: 9-26 9-1

a. Removal. 9-26A

b. Installation. 9-26B

c. Operational Check. 9-26C

11. Double Check Valve Maintenance : 9-27 9-1

a. Removal. 9-27A

b. Installation, 9-27B

c. Checking for Leaks. 9-27C

12. Double Check and Stoplamp Valve Maintenance 9-28 9-1

(M918 and M919):

a. Removal. 9-28A

b. Installation. 9-28B

c. Operational Check. 9-28C

13. Double Check and Stoplamp Valve Maintenance 9-29 9-1

(M915, M916, M917, M920) :

a. Removal.

b. Installation. 9-29A

Operational Check.

9-29B

c. 9-29C

9-22
TM 9-2320-273-20

9-1

9-8. BRAKE SYSTEM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

14. External Air Couplings Maintenance: 9-30 9-1

a. Removal. 9-30A

b. Installation. 9-30B

15. Front Brake Shoes Maintenance (M915): 9-31

a. Removal. 9-31A

b. Inspection. 9-31 B

c. Installation. 9-31 c

d. Adjustment. 9-31 D

16. Front Brake Shoes Maintenance

(M916 Thru M920): 9-32

a. Removal. 9-32A

b. Inspection. 9-32B

c. Installation. 9-32C

d. Adjustment. 9-32D

17. Rear Brake Shoes Maintenance (M915): 9-33

a. Removal. 9-33A

b. Inspection. 9-33B

c. Installation. 9-33C

18. Rear Brake Shoes Maintenance (M916 thru

M920). 9-34

a. Removal. 9-34A

b. Inspection. 9-34B

c. Installation. 9-34C

9-1

9-1

9-1

9-23
TM 9-2320-273-20

9-8. BRAKE SYSTEM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

19. Pusher Axle Brake Shoes Maintenance: 9-35 9-1

a. Removal. 9-35A

b. Inspection. 9-35B

c. Installation. 9-35C

d. Adjustment. 9-35D

20. Front Brake Air Chamber Maintenance: 9-36 9-1

a. Removal. 9-36A

b. Disassembly. 9-36B

c. Reassembly. 9-36C

d. Installation. 9-36D

e. Operational Check. 9-36E

21. Rear Brake Air Chamber Maintenance: 9-37 9-1

a. Caging Power Spring. 9-37A

b. Removal. 9-37B

c. Installation. 9-37C

d. Uncaging Power Spring. 9-37D

e. Operational Check. 9-37E

22. Pusher Axle Brake Air Chamber Maintenance: 9-38 9-1

a. Removal. 9-38A

b. Disassembly. 9-38B

c. Assembly. 9-38C

d. Installation. 9-38D

23. Slack Adjusters Maintenance: 9-39 9-1

a. Adjustment – Slack Adjuster

(Forward Rear Tandem). 9-39A

b. Adjustment – Push Rod

(Rear Rear Tandem). 9-39B

9-24
TM 9-2320-273-20

This page intentionally left blank.

9-25
TM 9-2320-273-20

9-9. AUXILIARY AlR-POWERED COMPONENT SYSTEMS MAINTENANCE TASK SUMMARY.

INITIAL SETUP

APPLICABLE CONFIGURATIONS EQUIPMENT CONDITION CONDITION DESCRIPTION

All. PARAGRAPH Batteries Disconnected.

5-37A. Air Reservoirs Drained.

TEST EQUIPMENT 9-13A. Differential Lock-up Switch

None. 5-83A. Removed.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Masking Tape.

Marking Pen

Soap and Water Solution.

Gasket (4730-01-055-4013).

PERSONNEL REQUIRED

One or Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P. SPECIAL ENVIRONMENTAL CONDITIONS

REFERENCES (TROUBLESHOOTING) Vehicle Parked on Level Ground.

Table 9-1.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1. Windshield Washers Maintenance : 9-40 9-1

a. Removal. 9-40A

b. Installation. 9-40B

c. Operational Check. 9-40C

2. Windshield Washer Control Maintenance: 9-41

a. Removal. 9-41 A

b. Inspection of Air Lines 9-41 B

9-1

9-26
TM 9-2320-273-20

9-9. AUXILIARY AIR-POWERED COMPONENT SYSTEMS MAINTENANCE TASK SUMMARY

(Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

2. Windshield Washer Control Maintenance

(Continued):

c. Installation. 9-41 C

d. Operational Check. 9-41 D

3. Windshield Wiper Motor Maintenance: 9-42 9-1

a. Removal. 9-42A

b. Installation. 9-42B

c. Operational Check. 9-42C

4. Windshield Wiper Control Maintenance: 9-43 9-1

a. Removal. 9-43A

b. Inspection of Air Lines. 9-43B

c. Installation. 9-43C

d. Operational Check. 9-43D

5. Differential Lockup Control Valve Maintenance: 9-44 9-1

a. Removal. 9-44A

b. Installation. 9-44B

c. Checking for Leaks. 9-44C

6. Air Horn and Control Valve Maintenance: 9-45 9-1

a. Removal. 9-45A

b. Installation. 9-45B

c. Operational Check. 9-45C

9-27
TM 9-2320-273-20

BRAKE SYSTEM.

9-10. AIR DRYER DEHYDRATE CARTRIDGE REPLACEMENT.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (0.4)

b. Cleaning and Inspection. (0.3)

c. Installation. (0.6)

1.3 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All.

TEST EOUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Grease, Silicone, Lubrication Item, Appendix B.

Dehydrate Cartridge Assembly (06853) 286968.

Tape, Antiseizing Item 14, Appendix C.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

None.

TM 9-2320-273-10. Air System Draincocks

Opened.

SPECIAL ENVIRONMENTAL CONDITIONS

Work Area Clean and Away from Blowing Dirt and Dust.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Vehicle on Level Ground.

Wheels Blocked.

9-28 Change 2
TM 9-2320-273-20

BRAKE SYSTEM.

9-10. AIR DRYER DEHYDRATE CARTRIDGE REPLACEMENT (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Air dryer does not have to be removed from

vehicle for this operation.

A. REMOVAL.

1. Electrical terminal (14). a. Remove insulating boot (8),

nut (13) and electrical

wire (7).

b. Disconnect hose assembly (6)

from connector (12).

2. End cover assembly (5). Loosen three screws (10) and

turn three retaining clips (11)

inward so they do not touch air

dryer housing (1).

NOTE

Make alinement marks on the end cover

assembly and air dryer housing. This will

help you aline them during reassembly.

3. End cover assembly (5). While pressing up on end cover

assembly (5) pry out retaining

ring (9) using flat tip screwdriver.

4. Air dryer housing (1). Remove end cover assembly (5).

5. Using 3/4 inch socket wrench

unscrew and remove dehydrate

cartridge (3).

Discard O-ring (4).

Discard cartridge.

 B. CLEANING AND INSPECTION.

CAUTION

Do not put end cover assembly into cleaning

solvent. This could damage the heating

element or thermostat.

NOTE

Make sure all cleaning solvent residue has

been removed before reassembly.

Change 2 9-28.1
TM 9-2320-273-20

 BRAKE SYSTEM.

9-10. AIR DRYER DEHYDRATE CARTRIDGE REPLACEMENT (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION.

6. Air dryer housing (1). a. Lubricate O-ring (2) with Torque to 32 Ib-ft.

silicone grease.

b. Using 3/4 inch socket wrench

screw in and tighten new

dehydrate cartridge (3).

7. Lubricate O-ring (4) with silicone grease and install in

groove.

NOTE

Assistant may be required for this step.

8. a. Join alinement marks and

press end cover assembly (5)

up as far as it will go.

b. Secure with retaining ring (9).

9. Three retaining clips (11). Turn outward and over the edge

of air dryer housing (1) and

tighten three screws (10).

10. Electrical terminal (14). Install electrical wire (7), nut

(13) and insulating boot (8).

11. End cover assembly (5). Apply antiseizing tape and

connect hose assembly (6) to

connector (12).

NOTE

Follow-on maintenance action required:

Pressurize air system and check for leaks

and proper operation.

9-28.2 Change 2
TM 9-2320-273-20

BRAKE SYSTEM,

9-10. AIR DRYER DEHYDRATE CARTRIDGE REPLACEMENT (Continued).

LOCATION/lTEM ACTION REMARKS

Change 2 9-29
TM 9-2320-273-20

9-11. AIR DRYER REPLACEMENT.

THIS TASK COVERS {APPROXIMATE TIME REOUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (1.0)

b. Cleaning and Inspection. (0.2)

c. Installation. (1.0)

d. Operational Check. (0.3)

2.5 Minutes Total.

INITIAL SETUP EOUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. TM 9-2320.273-10. Air System Draincocks Opened.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Tape, Antiseizing Item 14, Appendix C.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Work Area Clean and Away from Blowing Dirt

and Dust.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Vehicle on Level Ground.

Wheels Blocked.

TROUBLESHOOTING REFERENCES

None.

9-30 Change 2

BRAKE SYSTEM.
TM 9-2320-273-20

BRAKE SYSTEM.

9-11. AIR DRYER REPLACEMENT (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Air dryer assembly (1). Unscrew and remove hoses

(3) and (11) and tubing (2).

2. Electrical terminal (17). Remove terminal protector

(14), boot (13), nut (15) and

wire (12).

NOTE

For the M916 thru M920 only, disconnect

tube (23) from top of air dryer assembly (1).

3. Mounting brackets (21). Remove four hexagon nuts

(8), four lock washers (9),

four flat washers (10) and

(19), four capscrews (20) and

dryer assembly (1).

4. Frame bracket (7). Remove four screws (6), four

nuts (4), four washers (5) and

two air dryer mounting

brackets (21).

5. Purge tank reservoir (25). Unscrew and remove

tubing (23).

6. Four nuts (26) and four Unscrew and remove U-bolts

lock washers (27). (24) and purge tank

reservoir (25).

B. CLEANING AND INSPECTION.

7. Clean and inspect all parts.

C. INSTALLATION.

8. Air dryer brackets (21), Secure with four screws (6),

frame bracket (7). four washers (5) and four

nuts (4).

NOTE

There should be 1/2 inch minimum clearance between fuel tank and mounting brackets (21), This may require moving the fuel

tank rearward.

Change 2 9-31
TM 9-2320-273-20

BRAKE SYSTEM.

9-11. AIR DRYER REPLACEMENT (Continued).

LOCATION/ITEM ACTION REMARKS

 C. INSTALLATION (Continued).

9. Air dryer assembly (1). Secure to mounting brackets

(21) with four capscrews

(20), four flat washers (19)

and (10), four lock washers

(9) and four hexagon nuts (8).

10. Air dryer head assembly Install wire (12), secure with

(22), electrical terminal (17). nut (15). Install boot (13)

and terminal protector (14).

11. Air dryer assembly (1). Apply antiseizing tape,

install tubing (2), hoses (3)

and (11).

NOTE

For the M916 thru M920 only, apply antiseizing tape and install tube (23) on air dryer

assembly (1).

12. Cab mounting bracket (28), Secure with U-bolts (24), four

purge tank reservoir (25). lock washers (27), and four

nuts (26).

13. Tubing (23). Apply antiseizing tape and connect to purge tank reservoir (25).

D. OPERATIONAL CHECK.

WARNING

Make sure wheels are blocked and transmission is in neutral. Failure to do this could

cause injury or death to persons working in

and around vehicle.

14. Air system. Close draincocks.

15. Engine. a. Start up (see

TM 9-2320-273-10).

b. Charge air system to 100 psi.

16. Air dryer assembly (1). Check for air leakage at exhaust cover (18), or any air line

connections.

9-32 Change 2
TM 9-2320-273-20

BRAKE SYSTEM.

1-11. AIR DRYER REPLACEMENT (Continued).

LOCATION/lTEM ACTION REMARKS

D. OPERATIONAL CHECK (Continued).

17.

18. Air dryer assembly (1).

Allow system to reach operating pressure, a sharp burst of

air should escape from exhaust

cover (18).

NOTE

Step number 18 must be done in temperatures below 50° F (9.9°C).

Run engine for a minimum of

five minutes, end cover (22)

should be warm if not replace

the heating element.

NOTE

No follow-on maintenance is required.

Change 2 9-32.1
TM 9-2320-273-20

BRAKE SYSTEM.

9-11. AIR DRYER REPLACEMENT (Continued).

LOCATION/lTEM ACTION REMARKS

9-32.2 Change 2
TM 9-2320-273-20

BRAKE SYSTEM.

9-11. AIR DRYER REPLACEMENT (Continued).

LOCATION/lTEM ACTION REMARKS

Change 2 9-33
TM 9-2320-273-20

BRAKE SYSTEM.

9-11.1. AIR DRYER REPAIR.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Disassembly. (1.0)

b. Cleaning, (0.3)

c. Inspection and Repair. (0.4)

d. Assembly. (1.0)

2.7 Minutes Total.

INITIAL SETUP EOUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-11. Air Dryer Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Grease, Silicone, Lubrication Item, Appendix C.

Tape, Antiseizing Item 14, Appendix C.

Kit, Check Valve Repair (06853) 287298.

Kit, Seal (06853) 287053.

Dehydrate Cartridge Assembly (06853) 286968.

PERSONNEL REQUIRED

One (MOS-63820).

REFERENCES (TM)

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Work Area Clean and Away from Blowing Dirt

and Dust.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Vehicle on Level Ground.

Wheels Blocked.

9-34 Change 2
TM 9-2320-273-20

BRAKE SYSTEM.

9-11.1. AIR DRYER REPAIR (Continued).

LOCATION/lTEM ACTION REMARKS

1. End cover housing (35).

2. End cover assembly (17).

3. End cover housing (35),

O-ring (16).

4. End cover housing (35),

connector (36).

5. Exhaust cover (28).

6. Purge valve assembly (18).

7. Air dryer end cover

housing (35).

8. Purge valve housing (24).

9. Dehydrate cartridge (15).

10. Safety valve (13), and

connector (11).

11. Air dryer housing (2).

Remove three screws (38) and

three retaining clips (37).

While pressing inward remove

retaining ring (39) with a flat

tip screwdriver.

Unscrew and remove, discard

O-ring.

Unscrew and remove.

Remove screw (30), recessed

washer (31) and exhaust

diaphragm (32).

Remove 3 screws (29) and

exhaust cover (28).

Remove purge valve assembly

(18), by unscrewing purge

valve housing (24).

Remove screw (27), purge

valve piston (20), spring (21),

purge valve (25), lock washer

(26) and O-ring (19). Discard

O-ring, spring and purge valve.

Unscrew and remove from air

dryer housing (2) using a

3/4-inch socket wrench.

Unscrew and remove from air

dryer housing (2).

Unscrew and remove check

valve (3). Remove O-ring (9).

Discard O-rings (22

A. DISASSEMBLY.

NOTE

Add Iocation marks between end cover housing (35) and air dryer housing (2) prior to

disassembly. This will help you aline them

correctly during reassembly.

and (23).

Discard dehydrate cartridge.

Discard O-ring (9).

Change 2 9-34.1
TM 9-2320-273-20

BRAKE SYSTEM.

9-11.1. AIR DRYER REPAIR (Continued).

LOCATION/ITEM ACTION REMARKS

A. DISASSEMBLY (Continued).

12. Unscrew and remove valve Discard ball, spring and

body (10) {rem end cap (4). sealing washer.

Remove ball, (5), spring (6),

spring guide (7) and sealing

washer (8).

13. Remove two pipe plugs (1)

and nipple (12).

NOTE

Mark the positions of the air dryer assembly

mounting brackets (40) on the air dryer

housing (2), The position of these mounting brackets is important when installing the

air dryer to the vehicle.

14. Two nuts (41). Loosen and remove.

15. Two lock washers (42). Remove.

16. Two screws (43). Remove.

17. Two mounting brackets (40). Remove from air dryer

housing (2).

NOTE

For M916 thru M920 only, remove elbow

(45) and reducer (46) from air dryer

housing (2).

B. CLEANING.

CAUTION

Do not immerse (soak) end cover housing in

cleaning solution. The end cover housing

contains a thermostat and heating element

which could be damaged.

18. Clean all parts.

9-34.2 Change 2
TM 9-2320-273-20

BRAKE SYSTEM.

9-11.1. AIR DRYER REPAIR (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSPECTION AND REPAIR.

NOTE

All repair consists of replacing defective

parts discovered during inspection and replacing discarded parts with new items

provided.

19. Inspect all parts for damage

and serviceability.

20. End cover assembly (17). a. Connect a 12VDC source to

end cover housing (35). Connect a positive lead to electrical terminal (34), and a

negative lead to the outer

shell of the head assembly.

b. Expose end cover housing

(35) to temperatures below

50°F (9.9° C). If the heating element is working

properly the outer shell

should become warmer

within a few minutes. If the

outer shell does not become

warmer, the end cover

housing must be replaced.

D. ASSEMBLY.

NOTE

When installing two mounting brackets (40),

aline them with the marks on the air dryer

housing (2).

21. Air dryer housing (2), two a. Install two screws (43).

mounting brackets (40). b. Install and tighten two lockwashers (42) and two

nuts (41).

22. Air dryer housing (2). Apply antiseizing tape and

install nipple (12) and two pipe

plugs (1).

Change 2 9-34.3
TM 9-2320-273-20

BRAKE SYSTEM.

9-11.1. AIR DRYER REPAIR (Continued).

LOCATION/lTEM ACTION REMARKS

D. ASSEMBLY (Continued).

23. Valve body (10).

24.

25. Air dryer housing (2).

26. Valve body (10).

NOTE

For the M916 thru M920 only, apply antiseizing tape and install reducer (46) and

elbow (45) in air dryer housing (2).

Install new sealing washer (8),

spring guide (7) with rounded

bottom first in valve body.

InstalI new spring (6) in groove

of spring guide (7) and place

new ball (5) on spring.

a.

b.

Lubricate end cap (4) with

silicone grease. Screw in and

torque to 200 - 225 lb-in

(280 - 315 N•m).

Lubricate new O-ring (9)

with silicone grease, and

install.

Screw in and tighten check

valve (3).

Apply antiseizing tape.

Screw in and tighten connector (11).

CAUTION

27. Air dryer housing (2).

28.

Make sure exhaust hole in safety valve points

downward when in place.

a. Apply antiseizing tape to

safety valve (13).

b. Screw in and tighten.

a. Lubricate O-ring (14) on dehydrate cartridge (15) with

siIicone grease.

b. Screw in dehydrate cartridge

(15), tighten using a 3/4-in.

socket wrench. Torque to

32 Ib-ft (43.3 N•m).

9-34.4 Change 2
TM 9-2320-273-20

BRAKE SYSTEM.

9-11.1. AIR DRYER REPAIR (Continued).

LOCATION/lTEM ACTION REMARKS

D. ASSEMBLY (Continued).

29. End cover housing (35),

connector (36).

30.

31.

32.

33.

34.

35.

36.

37.

New O-ring (19).

Purge valve housing (24).

New O-rings (22) and (23).

Purge valve assembly (18).

Exhaust diaphragm (32),

diaphragm washer (31)

and screw (30).

Exhaust cover (28).

New O-ring (16).

End cover assembly (17).

Apply antiseizing tape, screw

in and tighten.

Lubricate with silicone grease

and install on purge valve

piston (20).

a. Lubricate purge valve piston

(20) with silicone grease.

b. Install purge valve piston

(20), new spring (21), new

purge valve (25) (rubber end

goes in first), new lockwasher (26) and screw (27).

Torque screw to 50 lb-in

(67,8 N•m).

Lubricate with silicone grease

and install on purge valve

housing (24).

Lubricate with siIicone grease,

screw into end cover housing (35).

Install into new exhaust The rounded end of diaphragm

cover (28). washer should be facing the

exhaust diaphragm.

Install on purge valve assembly

(18) using three screws (29).

Lubricate with silicone grease

and install into groove on

air dryer housing (2).

NOTE

Assistant may be required for this step.

Lubricate with silicone grease,

press into air dryer housing

(2) as far as it will go. Install

retaining ring (39) and secure

with three retaining clips (37)

and three screws (38).

Change 2 9-34.5
TM 9-2320-273-20

BRAKE SYSTEM.

9-11.1. AIR DRYER REPAIR (Continued).

LOCATION/lTEM ACTION REMARKS

D. ASSEMBLY (Continued).

38. Boot (33). Place in plastic bag and tape

to air dryer assembly for use

during installation.

NOTE

Follow-on maintenance action required:

Install air dryer (para 9-11c).

9-34.6 Change 2
TM 9-2320-273-20

BRAKE SYSTEM.

9-11.1. AIR DRYER REPAIR (Continued).

LOCATION/lTEM ACTION REMARKS

Change 2 9-34.7
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-12. SUPPLY RESERVOIR AUTOMATIC DRAIN VALVE AND AIR HOSE COUPLING.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (5)

c. Checking for Leaks. (5)

15 Minutes Total .

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Primary Air Reservoirs

TEST EQUIPMENT Drained.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Soap Solution.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

Table 9-1.

9-34.8

TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-12. SUPPLY RESERVOIR AUTOMATIC DRAIN VALVE AND AIR HOSE COUPLING (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

4. Drain valve (3). a. Coat threads with liquid

teflon.

b. Screw into supply reservoir

(1) and tighten.

5. Elbow (2) and air hose a. Coat threads with liquid

coupling (6). teflon.

b. Screw elbow (2) into

supply reservoir (1).

c. Screw air hose coupling (6)

into elbow (2).

C. CHECKING FOR LEAKS.

6. Engine. Start up (see TM 9-2320-273-

10). Allow system to reach

operating pressure of 90-120

psi (621-827 kPa).

7. Drain valve (3), supply

reservoir (1), elbow (2),

and air hose coupling (6). Use soap solution to check for

leaks.

8. Engine. Shut down (see TM 9-2320-

273-10).

9-36
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-12. SUPPLY RESERVOIR AUTOMATIC DRAIN VALVE AND AIR HOSE COUPLING (Continued).

LOCATION/lTEM ACTION REMARKS

9-37
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-13. SECONDARY RESERVOIR MANUAL DRAIN VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Bleeding Reservoirs. (2)

b. Removal. (1)

c. Installation. (2)

d. Checking for Leaks. (5)

10 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Soap Solution.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-38
TM 9-2320-273-20

COMPRESSED AlR SYSTEM.

Before removing drain valve, bleed the

secondary reservoir. There is one on all

models located under passenger door.

Turn handle and allow air to

exhaust.

9-13. SECONDARY RESERVOIR MANUAL DRAIN VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

For location, refer to locator illustration

(para 9-5 e. thru 9-5 j.).

A. BLEEDING RESERVOIRS.

1. Drain valve (2).

B. REMOVAL.

2. Drain valve (2). Unscrew and remove from

reservoir (1).

9-39
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-13. SECONDARY RESERVOIR MANUAL DRAIN VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION.

3. Drain valve (2).

D. CHECKING FOR LEAKS.

4. Drain valve (2).

5. Engine.

6. Drain valve (2).

7. Engine.

a. Coat threads with liquid

tefIon.

b. Screw into reservoir (1) and

tighten.

Turn handle to close valve, Be sure valves are closed

al I service reservoirs.

Start up (see TM 9-2320-

273-10). Allow system to

reach operating pressure of

90-120 psi (621-827 kPa).

Use soap solution to check Tighten as necessary.

for leaks.

Shut down (see TM 9-2320-

273-10).

on

9-40
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-13. SECONDARY RESERVOIR MANUAL DRAIN VALVE MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

9-41
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-14. SAFETY RELEASE VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 2)

b. Testing. (10)

c. Installation. ( 3)

d. Operational Check ( 5)

20 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT (M915 Primary

M916 Thru M920-

None. Secondary).

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Soap Solution.

Controllable Shop Air Supply.

Air Pressure Gage.

PERSONNEL REQUIRED

One (MOS-63B20).

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

REFERENCES (TM)

GENERAL SAFETY INSTRUCTIONS

TM 9-2320-273-10.

TM 9-2320-273-20P. Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 9-1.

9-42
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-14. SAFETY RELEASE VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

For location refer to locator illustration

(para 9-5 e. thru 9-5 j.).

Do not remove safety release valve until

reservoir pressure is fulIy exhausted.

1. Safety release valve (2). Unscrew and remove from reservoir (1).

2. Check safety release a. Connect to adjustable

valve (2), pressure supply with

pressure gage between

valve and supply.

9-43
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-14. SAFETY RELEASE VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. TESTING (Continued).

b. Gradually increase pres- If valve does not work

sure, Valve should ex- properly, replace it.

haust air when pressure

reaches 145-155 psi

(1000-1069 kPa).

C. INSTALLATION.

3. Safety release valve (2). a. Coat threads with liquid

teflon.

b. Screw into reservoir (1)

and tighten.

D. OPERATIONAL CHECK.

4. Engine. a. Start up (see TM 9-2320-273-10).

b. Allow system to reach operating

pressure of 105-120 psi (724-827 kPa).

5. Safety release valve (2). Use soap solution to check for leaks. Tighten as necessary.

6. Engine. Shut down (see TM 9-2320-273-10).

9-44
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-14. SAFETY RELEASE VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

1. RESERVOIR

2. SAFETY RELEASE

VALVE

TA 074903

9-45
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-15. SUPPLY RESERVOIR CHECK VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (4)

b. Testing. (2)

c. Installation. (4)

d. Operational Check. (4)

14 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Primary Air Reservoirs

TEST EQUIPMENT Drained.

None.

SPECIAL TOOLS

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Controllable Shop Air Supply.

Air Pressure Gage.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

9-46
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-15. SUPPLY RESERVOIR CHECK VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

Do not remove check valve untiI reservoir pressure is fully exhausted.

1. Air line (2). Unscrew and remove.

2. Elbow (4). Unscrew and remove.

3. Check valve (1). Unscrew and remove from

reservoir (3) (M915) or from

elbow (5) (M916 thru M920).

TA 074904

9-47

M916 thru M920
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-15. SUPPLY RESERVOIR CHECK VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. TESTING.

4. Check valve (1). a. Connect to adjustable

pressure supply with

pressure gage between

valve and supply.

b. Gradually increase pressure. If valve does not work properly,

Valve should begin exhaust- replace it.

ing air when pressure reaches

145-155 psi (1000-1069

kPa).

C. INSTALLATION.

5. Check valve (1). a. Coat threads with liquid

teflon.

b. Screw into reservoir (3) M915.

and tighten.

c. Screw into elbow (5). M916 thru M920.

6. Elbow (4). Screw into check valve (1). M916 thru M920.

7. Air line (2). Install and tighten.

D. OPERATIONAL CHECK.

8. Engine. a. Start up (see TM 9-2320-

273-10).

b. Allow system to reach operating pressure of 105-120

psi (724-827 kPa).

9. Check valve (1). Use soap solution to check for Tighten as necessary.

leaks.

10. Engine. Shut down (see TM 9-2320-

273-10).

9-48
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-15. SUPPLY RESERVOIR CHECK VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

TA 074905

9-49
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-16. RESERVOIRS AND AIR LINES MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Installation. (10)

c. Checking for Leaks. ( 5)

25 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Soap Solution.

Marking Pen.

Masking Tape.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-50
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-16. RESERVOIRS AND AIR LINES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

For locations of reservoirs see para 9-5 e.

thru 9-5 j. of this manual.

Do not remove any reservoir or air line until

pressure is fully exhausted from all supply

and service reservoirs.

NOTE

The illustrations below show a typical air

reservoir and associated air lines and fittings

of the M915 thru M920 truck tractors and

chassis. No special instructions or tools are

needed if you follow standard shop practice

techniques.

LEGEND:

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

NUT (2)

BOLT (2)

RESERVOIR

PLUG(S)

REDUCER(S)

VALVE(S)

STRAP (4)

ELBOW(S)

CONNECTOR(S)

AIR LINE(S)

9-51
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-16. RESERVOIRS AND AIR LINES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

NOTE

As you remove each component, tag

for reassembly.

1. Air line(s) (10). Disconnect.

2. Two nuts (1). Loosen and remove.

3. Two bolts (2). Remove.

4. Reservoir (3). Slide forward or aft through

two sets of straps (7) and

remove.

5. All fittings on reservoir; Unscrew and remove.

(plug{s) (4), reducer(s) (5),

valve(s) (6), elbow(s) (8),

connector(s) (9).

B. INSTALLATION.

NOTE

Check all lines and fittings for leaks,

cracks, and damaged threads. Replace,

if necessary. Be sure hoses are connected to the proper reservoir or valve ports

as you tagged at removal.

6. Plug(s) (4), reducer(s) (5), Coat threads with liquid

valve(s) (6), elbow(s) (8) teflon and install.

and connector(s) (9).

7. Reservoir (3). Slide back into place through

two sets of straps (7).

8. TWO bolts (2). Install one through each set

of straps (7).

9. Two nuts (1). Install and tighten.

10. Air line(s) (10). Reconnect.

9-52
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-16. RESERVOIRS AND AIR LINES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. CHECKING FOR LEAKS.

11. Engine. a. Start up (see TM 9-2320-

273-10).

b. Allow system to reach operating pressure of 105-120

psi (724-827 kPa).

c. Check for leaks using soap Retighten as necessary.

solution, then shut down

engine.

LEGEND:

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

NUT (2)

BOLT (2)

RESERVOIR

PLUG(S)

REDUCER(S)

VALVE(S)

STRAP (4)

ELBOW(S)

CONNECTOR(S)

AIR LINE(S)

TA 074907

9-53
TM 9-2320-273-20

COMPRESSED AIR SYSTEM

9-16.1. AIR DRYER TUBING AND HOSE REPLACEMENT.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (1.0)

b. Inspection and Installation. (0.4)

c. Operational Check. (0.3)

1.7 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. TM 9-2320-273-10. Air System Draincocks Open.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIAL/PARTS (P/N)

Tape, Antiseizing Item 14, Appendix C.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Work Area Clean and Away from Blowing Dirt

and Dust.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Vehicle on Level Ground.

Wheels Blocked.

TROUBLESHOOTING REFERENCES

None.

Change 2 9-54
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-16.1. AIR DRYER TUBING AND HOSE REPLACEMENT.

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Air dryer. Disconnect damaged hoses Tag each component for

(1), lines (2), tubes (3), reassembly. Note the

or fittings (4). routing of the hoses, lines

and tubes when removing

them.

B. INSPECTION AND INSTALLATION.

2. Air dryer. Check all hoses (1), lines Replace if necessary.

(2), tubes (3), or fittings

(4) for leaks, cracks and

damage.

3. Install new hoses (1), lines

(2), tubes (3) in the same

location as the old ones.

CAUTION

Make sure that all support clamps (5) are

used when replacing lines or tubes. Do not

let tubing touch any hot surface such as

compressor discharge line (6), or oil lines.

4. Hoses (1), lines (2), tubes

(3) or fittings (4).

C. OPERATIONAL CHECK.

5. Air system.

Apply antiseizing tape on

all threads and reconnect as

tagged during removal.

Close draincocks and start

engine to charge the air

system.

NOTE

No Follow-on maintenance required,

Charge air system until it

reaches 120 psi (827.4 kPa)

and check for air leaks.

9-54.1 Change 2
TM 9-2320-273-20

COMPRESSED AIR SYSTEM.

9-16.1. AIR DRYER TUBING AND HOSE REPLACEMENT.

LOCATION/lTEM ACTION REMARKS

Change 2 9-54.2

TM 9-2320-273-20

BRAKE SYSTEM.

9s-17. TRAILER SUPPLY BRAKE VALVE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Inspection of Lines and Fittings. ( 5)

c. Installation. (15)

d. Operational Check. (15)

45 Minutes Total.

INlTIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915, M916, M917, and M920. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT 5-37A. Batteries Disconnected.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Masking Tape.

Marking Pen.

Soap and Water Solution.

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Park Brake Set.

Transmission in Neutral.

9-54.3(blank)/9-54.4
TM 9-2320-273-20

BRAKE SYSTEM.

9-17. TRAILER SUPPLY BRAKE VALVE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

For location, refer to locator illustration

para 9-5 e. thru 9-5 j.

Disconnect battery before doing any work

behind dash panel.

A. REMOVAL.

1. Two quarter-turn screws (1). Loosen.

2. Hinged panel (2). Lower.

3. Roll pin (3). Push out.

4. Control Knob (4). Remove.

5. Locknut (5). Unscrew and remove.

9-55
TM 9-2320-273-20

BRAKE SYSTEM.

9-17. TRAILER SUPPLY BRAKE VALVE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

Do not remove any air lines until pressure is fully exhausted from all reservoirs.

6. Air line (6). a. Label using masking tape

and marker pencil.

b. Unscrew and remove from valve (7).

7. Air line (8). a. Label using masking tape

and marker pencil.

b. Unscrew and remove from valve (7).

8. Valve (7). Remove from dash panel.

B. INSPECTION OF LINES AND FITTINGS.

9. Air lines (6) and (8). Inspect for: Replace, if necessary.

a. Cracks.

b. Leaks.

c. Kinks.

d. Damaged threads.

C. INSTALLATION.

10. Valve (7).

11. Two air lines (6) and (8).

12. Locknut (5).

13. Control knob (4).

14. Roll pin (3).

15. Hinged panel (2).

16. Two quarter-turn

screws (1).

D. OPERATIONAL CHECK.

17. Engine. Start up (see TM 9-2320-273-10).

Allow pressure to reach 105-120

psi (724-827 kPa).

Install behind dash panel.

a. Coat threads on valve (7)

with liquid teflon.

b. Screw into valve (7) and

tighten.

Screw into valve (7) and

tighten.

Install by alining hole in knob

with hole in valve handle.

Push in.

Raise into position.

Tighten.

9-56
TM 9-2320-273-20

BRAKE SYSTEM.

9-17. TRAILER SUPPLY BRAKE VALVE (Continued).

LOCATION/lTEM ACTION REMARKS

D. OPERATIONAL CHECK (Continued).

18. Control knob (4). Push in. 2nd mechanic.

19. CAB/Park brake control a. Apply and release 2nd mechanic.

and brake pedal. parking brakes.

b. Press and release

brake pedal.

20. Trailer brakes. Check that brakes apply

when:

a. Park brake is applied.

b. Brake pedal is pressed.

c. Trailer emergency brake

knob is pulled out.

1st mechanic.

21. Engine. Shut down (see TM 9-2320-273-10).

9-57
TM 9-2320-273-20

BRAKE SYSTEM.

9-18. TRAILER HAND BRAKE VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Inspection of Air Lines and Fittings. ( 5)

c. Installation. (10)

d. Operational Check. (15)

35 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915, M916, M917, M920. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Masking Tape.

Marking Pen.

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 9-1.

9-58
TM 9-2320-273-20

BRAKE SYSTEM.

Knob is not threaded.

9-18. TRAILER HAND BRAKE VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

For location, refer to locator illustration

(para 9-5 e. thru 9-5 j.).

A. REMOVAL.

1. Air supply line (6) and air a. Use tape and marker pencil

delivery line (7). to label lines.

b. Unscrew from adapters

(4) and remove.

2. Two capscrews (2) and Unscrew and remove.

Iockwashers (1).

3. Valve (8) and retaining Remove.

strap (3).

4. Two adapters (4), Unscrew and remove from

valve (8).

5. Knob (9). Remove by twisting and

pulling.

9-59
TM 9-2320-273-20

BRAKE SYSTEM.

9-18. TRAILER HAND BRAKE VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSPECTION OF AIR LINES AND FITTINGS.

6. Air supply line (6), air Inspect for: Replace as necessary.

delivery line (7), two a. Cracks.

adapters (4), and valve (8). b. Leaks.

c. Damaged threads.

C. INSTALLATION.

7. Knob (9). Push onto valve handle.

8. Two adapters (4). Screw into valve (8).

9. Valve (8). Position on steering column (5).

10. Two capscrews (2) and Screw in and tighten to

Iockwashers (1). secure retaining strap (3)

to valve (8).

11. Air supply line (6) and Screw air lines onto Be sure to attach each Iine to

air delivery line (7). adapters (4) and tighten. the correct fitting as you marked.

D. OPERATIONAL CHECK.

12. Engine. Start up (See TM 9-2320-273-

10). Allow pressure to reach 105-

120 psi (724-827 kPa).

13. Knob (9). a. Pull down slowly. 1st mechanic.

b. Check for leaks at air 1st mechanic.

supply line (6) and air

delivery line (7).

c. Check for air pressure 2nd mechanic.

at gladhand connection

or trailer.

d. Return handle to normal 1st mechanic.

position.

14. Engine. Shut down (see TM 9-2320-

273-10).

9-60
TM 9-2320-273-20

BRAKE SYSTEM.

9-18. TRAILER HAND BRAKE VALVE MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

LEGEND:

1.

2.

3.

4.

5.

6.

7.

8.

9.

LOCKWASHER (2)

CAPSCREW (2)

RETAINING STRAP

ADAPTER (2)

STEERING COLUMN

AIR SUPPLY LINE

AIR DE LlVERY

LINE

VALVE

KNOB

TA 074911 I

9-61
TM 9-2320-273-20

BRAKE SYSTEM.

9-19. PARKING BRAKE VALVE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Inspection of Lines and Fittings. ( 5)

c. Installation. (20)

d. Operational Check. (15)

55 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (refer to appendix C).

Masking Tape.

Marking Pen.

Soap and Water Solution.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 9-1.

9-62
TM 9-2320-273-20

BRAKE SYSTEM.

9-19. PARKING BRAKE VALVE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

For location, refer to locator illustration

(para 9-5 e. thru 9-5 j.).

Disconnect battery before doing any work

behind dash panel.

9-63
TM 9-2320-273-20

BRAKE SYSTEM.

9-19. PARKING BRAKE VALVE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL .

1. Three quarter-turn screws (1). Loosen.

2. Hinged panel (2). Lower.

3. Roll pin (10). Push out.

4. Control knob (11). Remove.

5. Locknut (12). Unscrew and remove.

6. Two wires (6). Mark and disconnect

from sending unit (5).

Do not remove any air lines until pressure

is fully exhausted from all reservoirs.

7. Three air lines (14) a. Label using masking tape

and marker pencil.

b. Unscrew and remove.

8. Valve (9). Remove from dash panel.

B. INSPECTION OF LINES AND FITTINGS.

9. Air lines (14). Inspect for:

a. Cracks.

b. Leaks.

c. Kinks.

d. Damaged threads.

C. INSTALLATION.

10. Fittings. Lay new valve beside old valve

and remove fittings (13), (8)

and assembly (4) from old valve,

coat threads with Iiquid teflon

and install in new valve.

Replace if necessary.

9-64
TM 9-2320-273-20

BRAKE SYSTEM.

9-19. PARKING BRAKE VALVE (Continued).

LOCATION/ITEM ACTION REMARKS

C. INSTALLATION (Continued).

NOTE

Install fittings to same angle as removed.

11. Valve (9). Install behind dash panel.

12. Three air lines (14). Screw onto valve (9) and

tighten.

9-65
TM 9-2320-273-20

BRAKE SYSTEM.

9-19. PARKING BRAKE VALVE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

13. Two wires (6). Fasten to sending unit (5).

14. Locknut (12). Screw onto valve (9) and

tighten.

15. Control knob (11). Install by alining hole in knob

with hole in valve handle.

16. Roll pin (10). Push in.

17. Hinged panel (2) Raise into position.

18. Three quarter-turn Tighten.

screws (1).

D. OPERATIONAL CHECK.

19. Engine Start up (see

TM 9-2320-273-10).

20. Control knob (11). a. When valve is pushed in, Brakes will not release until

parking brakes should be system reaches 65 psi.

released.

b. When valve is pulled out,

parking brakes should

apply.

c. Apply soapy solution to

the fittings and check for

bubbles. If bubbles

appear, tighten fittings.

21. Engine. Shut down (see

TM 9-2320-273-10).

9-66
TM 9-2320-273-20

BRAKE SYSTEM.

9-19. PARKING BRAKE VALVE (Continued).

LOCATION/lTEM ACTION REMARKS

9-67
TM 9-2320-273-20

BRAKE SYSTEM.

9-20. AIR PRESSURE GAGES MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Installation. (10)

c. Operational Check. (10)

30 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Park Brake Set.

Transmission in Neutral.

9-68
TM 9-2320-273-20

BRAKE SYSTEM.

9-20. AIR PRESSURE GAGES MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

NOTE

The procedure below may be used to

replace either of the two air gages on the

left-hand instrument panel.

A. REMOVAL .

1. Four quarter-turn screws (1). Loosen. Lower hinged panel (2).

2. Air line (5). a. Unscrew and remove. Replace, if necessary.

b. Inspect for:

1. Leaks.

2. Cracks.

3. Damaged fittings.

9-69
TM 9-2320~273-20

BRAKE SYSTEM.

9-20. AIR PRESSURE GAGES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Socket and bulb (3). Remove by pulling on socket.

4. Two nuts (8) and Remove.

washers (7).

5. Bracket (6). Remove.

6. Gage (4). Remove gage.

NOTE

If you are pulling rear air gage do the same

as above.

B. INSTALLATION.

7. Gage (4). Place in panel (2) with studs If a new gage is being installed,

pushed through bracket (6). transfer alI components and use

liquid teflon on threads.

8. Two nuts (8) and Install and tighten.

washers (7).

9. Socket and bulb (3). Press in until socket is

flush with gage (4).

10. Air line (5). Screw into gage (4).

11. Hinged panel (2). Close. Tighten four quarterturn screws (1).

NOTE

If you removed rear air gage do the same

as above.

C. OPERATIONAL CHECK.

12, Engine. Start up (see TM 9-2320-273-

10).

13. Gage (4). Observe that pressure build up

is registered on gage and that

both front and rear show approximately the same pressure.

14. Engine. Shut down (see TM 9-2320-273-

10).

9-70
TM 9-2320-273-20

BRAKE SYSTEM.

9-20. AlR PRESSURE GAGES MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

LEGEND:

1.

2.

3.

4.

5.

6.

7.

8.

QUARTER-TURN

SCREW (4)

HINGED PANEL

SOCKET AND

BULB

GAGE

AIR LINE

BRACKET

WASHER (2)

NUT (2)

TA 074916

9-71
TM 9-2320-273-20

BRAKE SYSTEM.

9-21. BRAKE PEDAL AND VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Pedal Removal. ( 5)

b. Valve Removal. (20)

c. Valve Installation. (20)

d. Pedal Installation. (10)

e. Operational Check. ( 2)

57 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained,

9-27A and 9-28A. Double Check Valve

TEST EQUIPMENT Removed.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Soap and Water Solution.

Masking Tape.

Marking Pen,

Cotter Pin, 210490 (06853).

Cotter Pin, 210492 (06853).

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Park Brake Set.

Transmission in Neutral.

9-72
TM 9-2320-273-20

BRAKE SYSTEM.

9-21. BRAKE PEDAL AND VALVE MAINTENANCE (Continued).

LOCTION/lTEM ACTION REMARKS

9-73

A. PEDAL REMOVAL.

1. Cotter pin (11).
TM 9-2320-273-20

BRAKE SYSTEM.

9-21. BRAKE PEDAL AND VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. PEDAL REMOVAL (Continued).

When brake pedal is removed, piston wiII

drop from brake valve.

2. Roller pin (13). Remove.

3. Cotter pin (10). Remove.

4. Fulcrum pin (14). Push out and remove pedal (12),

along with two spacers (19).

B. VALVE REMOVAL.

Do not remove brake valve untiI pressure

is fully exhausted from all reservoirs.

5. Two air lines (8). a. Unscrew and remove. Replace if necessary.

b. Tape and mark each line

as an aid when installing

line.

c. Inspect for:

1. Leaks.

2. Cracks.

3. Damaged fittings.

6. Two air lines (1). a. Unscrew and remove. Replace if necessary.

b. Tape and mark each line M918 and M919 only.

as an aid when installing

line.

c. Inspect for:

1. Leaks.

2. Cracks.

3. Damaged fittings.

7. Five engine compartment a, Unscrew and remove. Replace if necessary.

air lines (20)< b. Tape and mark each line

as an aid when installing line.

c. Inspect for:

1. Leaks.

2. Cracks.

3. Damaged fittings.

8. Check valve (21). Remove.

9-74
TM 9-2320-273-20

BRAKE SYSTEM.

9-21. BRAKE PEDAL AND VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-75
TM 9-2320-273-20

BRAKE SYSTEM.

9-21. BRAKE PEDAL AND VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. VALVE REMOVAL (Continued).

9. Three elbows (22). a. Unscrew and remove.

b. Tape and mark each fitting

as an aid when installing.

10. Three bolts (6), Iockwashers

(5) and washers (4).

a. Unscrew and remove.

b. Remove valve (15).

11. Two elbows (7). a. Unscrew and remove.

b. Tape and mark as an aid

when installing.

12. Two plugs (9). a. Unscrew and remove.

b. Tape and mark as an aid

when installing.

13. Connector (16). a. Unscrew and remove. M916 thru M920.

b. Tape and mark as an aid

when installing.

14. Plug (17). a. Unscrew and remove. M915 only.

b. Tape and mark as an aid

when installing.

15. TWO plugs (18). a. Unscrew and remove.

b. Tape and mark as an aid

when installing.

16. Reducer (3). a. Unscrew and remove M918 and M919 only.

with tee (2) attached.

b. Tape and mark as an aid

when installing.

C. VALVE INSTALLATION.

17. Reducer (3) with tee a. Coat threads with liquid M918 and M919 only.

(2) attached. tefIon.

b. Install, noting position of

tee and reducer when

removed.

18. TWO plugs (18). a. Coat threads with liquid

tefIon.

b. Installr noting positions

of plugs when removed.

9-76
TM 9-2320-273-20

BRAKE SYSTEM.

9-21. BRAKE PEDAL AND VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-77
TM 9-2320-273-20

BRAKE SYSTEM.

9-21. BRAKE PEDAL AND VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. VALVE INSTALLATION (Continued).

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

Plug (17).

Connector (16).

Two plugs (9).

Two elbows (7).

Valve (15).

Three elbows (22).

Check valve (21).

Five engine compartment

air lines (20).

Two air lines (1).

Two air lines (8).

a. Coat threads with liquid

tefIon.

b. Install, noting position of

plug when removed.

a. Coat threads with liquid

teflon.

b. Install, noting position of

connector when removed.

a. Coat threads with liquid

teflon.

b. Install, noting position of

plugs when removed.

a. Coat threads with liquid

teflon.

b. Install, noting position of

elbows when removed.

a. Aline with mounting holes

on firewall in cab.

b. Install with three bolts (6),

Iockwashers (5), and washers

(4).

a. Coat threads with liquid

tefIon.

b. Install, noting position of

elbows when removed.

a. Coat threads with liquid

tefIon.

b. Install, noting position of

check valve when removed.

Install, noting positions of air

lines when removed.

Install, noting positions of air

lines when removed.

Install, noting positions of air

lines when removed.

M915 only.

M916 thru M920.

M918 and M919 only.

9-78
TM 9-2320-273-20

BRAKE SYSTEM.

9-21. BRAKE PEDAL AND VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-79
TM 9-2320-273-20

BRAKE SYSTEM.

9-21. BRAKE PEDAL AND VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

D. PEDAL INSTALLATION.

NOTE

Install piston into brake valve before

installing pedal.

29. Pedal (12). a. Aline with mounting holes

on valve (15).

b. Install fulcrum pin (14) and

two spacers (19).

30. Cotter pin (10). Install thru fulcrum pin (14).

31. Roller pin (13). Install thru pedal (12).

32. Cotter pin (11). Install thru roller pin (13).

NOTE

Follow on maintenance action required:

Install double check valve; refer to para 9-27B

and 9-28B.

E. OPERATIONAL CHECK.

33. Engine. Start up (see TM 9-2320-273-

10). Allow system to reach

operating pressure of 105-120

psi (724-827 kPa).

34. Pedal (12). Press down, then release. Second mechanic.

35. All brakes. Check to see that all brakes First mechanic.

are actuated when pedal is

pressed, and that they are

released when pedal is released.

36. Valves (15) and (21). Use soap solution to check for Retighten as necessary.

leaks.

37. Engine. Shut down (see TM 9-2320-

273-10).

9-80
TM 9-2320-273-20

BRAKE SYSTEM.

9-21. BRAKE PEDAL AND VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-81
TM 9-2320-273-20

BRAKE SYSTEM.

9-22. SERVICE BRAKES QUICK RELEASE VALVE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Installation. (10)

c. Operational Check. (10)

25 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915, M916, M918 – 2 Valves Total. 1 each Axle. 9-13A.

M917, M919, M920 – 3 Valves Total.

Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (PIN)

Liquid Teflon (Refer to Appendix C).

Soap and Water Solution.

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-82
TM 9-2320-273-20

BRAKE SYSTEM.

9-22. SERVICE BRAKES QUICK RELEASE VALVE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

For location, refer to locator illustration

(para 9-5 e thru 9-5 j).

Do not remove quick-release valve until

pressure is fully exhausted from all

reservoirs.

TA 074920

9-83
TM 9-2320-273-20

BRAKE SYSTEM.

9-22. SERVICE BRAKES QUICK RELEASE VALVE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL .

1. Three air lines (2).

2. Two bolts (6), washers (5),

and nuts (4).

3. Valve (3).

B. INSTALLATION.

4. Valve (3).

5. Valve

6. TW O

3).

washers (5) and nuts (4).

7. Three air lines (2).

C. OPERATIONAL CHECK.

8. Engine.

9. CAB/Brake pedal.

10. Valve (3).

11. Engine.

a. Unscrew and remove.

b. Inspect for:

1. Leaks.

2. Cracks.

3. Damaged threads.

Unscrew and remove.

Remove from bracket (1).

Transfer all components

(elbows, adapters, etc.) to

new valve. Use liquid teflon

on threaded joints.

a. Coat threads with liquid

teflon.

b. Set onto bracket (7) and

install two bolts (6).

Install on bolts (6) and tighten.

Screw on and tighten.

Start up (see TM 9-2320-

273-10). Allow system to

reach operating pressure of

105-120 psi (724-827 kPa).

Press down and release.

a. Check that air exhausts

from valve when brake

pedal is released.

b. Use soap solution to check

for leaks.

Shut down (see

TM 9-2320-273-10).

Replace if necessary.

Second mechanic.

9-84
TM 9-2320-273-20

BRAKE SYSTEM.

9-22. SERVICE BRAKES QUICK RELEASE VALVE (Continued,

LOCATION/lTEM ACTION REMARKS

9-85
TM 9-2320-273-20

BRAKE SYSTEM.

9-23. QUICK RELEASE/DOUBLE-CHECK VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (5)

c. Operational Check. (2)

12 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Drain Primary Air Reservoirs

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (refer to appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 9-1.

9-86
TM 9-2320-273-20

BRAKE SYSTEM.

9-23. QUICK RELEASE/DOUBLE-CHECK VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

For location, refer to locator illustration

(para 9-5 e. thru 9-5 j.).

Do not remove quick-release/double-check

valve until pressure is fully exhausted from

all reservoirs.

TA 074922

9-87
TM 9-2320-273-20

BRAKE SYSTEM.

9-23. QUICK RELEASE/DOUBLE-CHECK VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

On the M915, the valve is located forward

of the fifth wheel on the right frame rail.

On the M916 thru M920 it is on the left

frame rail.

A. REMOVAL .

1. Four air lines(1).

(M916 thru M920 have

five air lines.)

2. Two nuts (3), washers (2),

and bolts (5).

B. INSTALLATION.

3. New valve (4).

4. Valve (4).

5. Four air lines (1).

C. OPERATIONAL CHECK.

6. Engine. Start up (see TM 9-2320-273-

10). Allow system to reach

operating pressure of 105-120

psi (724-827 kPa).

7. CAB/Brake pedal. Press and release. Second mechanic.

a. Unscrew and remove.

b. Inspect for:

1. Cracks.

2. Damaged fittings.

Unscrew and remove. Remove valve (4).

Transfer all components

(elbows, adapters, etc.) to

new valve. Use liquid teflon

on threads.

Attach to frame rail with two

nuts (3), washers (2), and

bolts (5). Tighten nuts and

bolts.

a. Coat fittings with liquid

teflon.

b. Screw on and tighten.

Tag lines for ease of

installation.

Replace, if necessary.

9-88
TM 9-2320-273-20

BRAKE SYSTEM.

9-23. QUICK RELEASE/DOUBLE-CHECK VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. OPERATIONAL CHECK (Continued).

8. Valve (4). a. Check to see that air First mechanic.

exhausts from-valve when

brakes are released.

b. Use soap solution to check

for leaks.

9. Engine. Shut down (see

TM 9-2320-273-10).

TA 074923

9-89
TM 9-2320-273-20

BRAKE SYSTEM.

1-24. RELAY VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Installation. (20)

c. Checking for Leaks. (10)

45 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Soap and Water Solution.

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

SPECIAL ENVIRONMENTAL CONDITIONS

9-90
TM 9-2320-273-20

BRAKE SYSTEM.

a. Unscrew and remove.

b. Inspect for:

1. Cracks.

2. Damaged fittings.

Replace if necessary.

9-24. RELAY VALVE MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

Do not remove relay valve until pressure

is fully exhausted from all reservoirs.

A. REMOVAL .

1. Pilot line (6), two brake

chamber lines (7) and (8),

and supply line (9).

9-91
TM 9-2320-273-20

BRAKE SYSTEM.

9-24. RELAY VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

2. Two nuts (1), washers (2), a. Unscrew and remove.

and bolts (4). b. Remove valve (5).

B. INSTALLATION.

3. Valve (5). Transfer alI components

(elbows, adapters, etc.) to

new valve before installation.

Use liquid teflon on joints.

4. Valve (5), two nuts (1), a. Position against frame

washers (2), and bolts (4). crossmember (3).

b. Tighten nuts.

5. Pilot line (6), two brake a. Coat threads with liquid

chamber lines (7) and (8), teflon.

and supply line (9). b. Screw into valve (5) and

tighten.

C. CHECKING FOR LEAKS.

6. Engine.

7. Valve (5).

8. Engine.

Start up (see TM 9-2320-273-

10). Allow system to reach

Qperating pressure of 105-120

psi (724-827 kPa).

Apply service brakes and

check for leaks using soap

solution.

Shut down (see

TM 9-2320-273-10) .

9-92
TM 9-2320-273-20

BRAKE SYSTEM.

9-24. RELAY VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-93
TM 92320273-20

BRAKE SYSTEM.

3-25. LIMITING VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Installation. (10)

c. Operational Check. ( 5)

20 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT—

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (refer to appendix C)

Soap and Water Solution.

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES—

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-94
TM 9-2320-273-20

BRAKE SYSTEM.

9-25. LIMITING VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Do not remove limiting valve until pressure

is fully exhausted from all reservoirs.

NOTE

For location, refer to locator illustration

(para 9-5 e. thru 9-5 j.).

 9-95
TM 9-2320-273-20

BRAKE SYSTEM.

9-25. LIMITING VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 A. REMOVAL.

1. Three air lines (l).

2. Two capscrews (5), two

washers (4) and two nuts (3).

a.

b.

a.

b.

Unscrew and remove.

Inspect for:

1. Cracks.

2. Damaged fittings.

Unscrew and remove.

Remove valve (2).

Replace, if necessary.

B. INSTALLATION .

3. Valve (2).

4. Three air lines 1).

C. OPERATIONAL CHECK.

5. Engine.

6. CAB/Brake pedal,

7. Valve (2).

8. Vehicle.

Attach to bracket (6) with

two capscrews (5), two

washers (4) and two nuts (3).

a. Coat threads with liquid

teflon.

b. Screw in and tighten.

Start up (see

TM 9-2320-273-10).

Press down.

Use soap solution to check

for leaks.

Road test. Check for even

If a new valve is installed transfer all components (elbows,

adapters, etc. ) to new valve. Use

liquid teflon on threaded joints.

Second mechanic.

First mechanic. Perform

this step while brake pedal

is pressed down.

application of front brakes.

9-96
TM 9-2320-273-20

BRAKE SYSTEM.

9-25. LIMITING VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-97
TM 92320273-20

BRAKE SYSTEM.

3-26. TRACTOR PROTECTION VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REWIRED FOLLOWS TASK DESCRIPTION.)

a . Removal. (15)

b . Installation. (10)

c . Operational Check. (10)

35 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915, M916, M917, M920. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIAL/PARTS (PIN)

Liquid Teflon (Refer to Appendix C).

Marking Pen.

Masking Tape.

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-98
TM 9-2320-273-20

BRAKE SYSTEM.

9-26. TRACTOR PROTECTION VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

For location, refer to locator illustration

(para 9-5 e. thru 9-5 j.).

Do not remove tractor protection valve

until pressure is fully exhausted from all

reservoirs.

9-99
TM 9-2320-273-20

BRAKE SYSTEM.

9-26. TRACTOR PROTECTION VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Airlines (1), (2), (3), and

2. Two nuts, Iockwashers, and

bolts (5).

3. Spacer clip (6).

4. Valve (7), M916, M917, M920

or valve (6), M915.

5. Valve (7), M916, M917, M920

or valve (6), M915.

B. INSTALLATION.

6.

7.

8.

9.

Valve (7), M916, M917, M920

or valve (6), M915.

Spacer clip (6).

Two nuts, Iockwashers, and

bolts (5).

Air lines (1), (2), (3), and

(4).

C. OPERATIONAL CHECK.

10. Engine.

11. Valve (7), M916, M917, M920

or valve (6), M915.

Remove.

Remove.

Remove.

Remove.

Transfer all components (elbows, fittings, adapters, etc. )

to new valve. Coat threaded

joints with liquid teflon,

Install in vehicle.

Install

Install and tighten.

Install and tighten.

Start up (see TM 9-2320-

273-10). Allow system to

reach operating pressure of

105-120 psi (724-827 kPa).

Apply trailer supply valve

and brake pedal valve. Use

soap solution to check for

leaks.

Tag lines for ease of

location at installation.

(M916, M917, and M920

only, )

If installing new valve,

(M916, M917, and M920

only. )

Replace any damaged

lines and/or fittings.

Second mechanic

9-100

(4)
TM 9-2320-273-20

BRAKE SYSTEM.

926. TRACTOR PROTECTOR VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. OPERATIONAL CHECK (Continued):

NOTE

If leaks are detected, re-tighten all fittings.

If leaks persist, remove hoses and fittings

and examine for cracks, and damaged fittings. Replace if necessary.

9-101
TM 9-2320-273-20

-. . BRAKE SYSTEM.

9-27. DOUBLE-CHECK VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Installation. (10)

c. Checking for Leaks. (10)

25 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (refer to appendix C).

Masking Tape.

Marking Pencil.

Soap and Water Solution.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-102
TM 9-2320-273-20

BRAKE SYSTEM.

9-27, DOUBLE-CHECK VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Do not remove double-check valve until pressure

is fully exhausted from all reservoirs.

NOTE

For location, refer to locator illustration (para

9-5 e. thru 9-5 j,). Double-check valves are attached

to the rear of the secondary air reservoir and to the

engine side of the brake pedal valve on all models.

There is a double-check valve on the driver’s side of

the brake pedal valve on all models except the M918

and M919. All models use a double check valve with

stoplamp switch attached to the engine side of the

firewaIl near the brake pedal valve. The procedure

below is general and may be used to service any of

these double-check valves.

9-103
T M 9-2320-273-20

BRAKE SYSTEM.

9-27. DOUBLE-CHECK VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL. ]

NOTE

Before removing air lines, use masking tape

and marking pencil to identify air lines for

installation in their proper location.

1. Wires (1), air lines (3), Remove from double-check Replace -

and tee (8). valve with stoplamp switch

(2).

2. Double-check valve with Unscrew and remove.

stoplamp switch (2).

damaged.

3. Air lines (3) and elbows (4). Unscrew from double-check Replace if damaged.

valve (5).

4. Double-check valve (5). Unscrew and remove.

B. INSTALLATION.

5.

6.

7.

8.

NOTE

Apply liquid teflon to threads of valves,

elbows, and tee as you assemble per the

locations you marked at disassembly.

Double-check valve with Screw in and tighten to firestoplamp switch (2) wall, brake pedal valve (6), or

or double-check valve secondary air reservoir (7).

(5).

Elbows (4) and tee (8). Screw into double-check

valve with stoplamp switch

(2) or double-check valve [5).

Air lines (3). Install at double-check valve

with stoplamp switch (2) or

double-check valve (5).

Wires (1). Connect to terminals of doublecheck valve with stoplamp switch

(2).

9-104
TM 9-2320-273-20

BRAKE SYSTEM.

9-27. DOUBLE-CHECK VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. CHECKING FOR LEAKS.

9.

10.

11.

Engine. Start up (see TM 9-2320-273-

10). Allow system to reach

operating pressure of 105-120

psi (724-827 kPa).

Double-check valve with Use soap solution to check for

stoplamp switch (2), leaks.

double-check valve (5), air

lines (3), elbows (4), and

tee (8).

Engine. Shut down

273-10).

(see TM 9-2320-

Tighten as necessary.

J

9-105
TM 9-2320-273-20

BRAKE SYSTEM.

9-28a DOUBLE-CHECK AND STOPLAMP VALVE MAINTENANCE (M918 AND M919).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

 a. Removal. (10)

 b. Installation. (10)

 c. Operational Check. (10)

30 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M918 and M919. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (refer to appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

Table 9-1.

9-106
TM 9-2320-273-20

BRAKE SYSTEM,

9-28. DOUBLE-CHECK AND STOPLAMP VALVE MAINTENANCE (M918 AND M919) (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Fittings (1) and (8). Unscrew and remove two Mark location for reassembly.

air lines.

2. Tee (2). Unscrew and remove.

9-107
TM 9-2320-273-20

BRAKE SYSTEM.

9-28. DOUBLE-CHECK AND STOPLAMP VALVE-MAINTENANCE (M918 AND M919) (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Two terminal nuts (4). Unscrew and remove two Mark location for reassembly.

wires (3).

4. Double-check and stop- Unscrew from bulkhead

lamp valve (6). fitting (5).

5. Elbow (7). Unscrew and remove from

tee (2).

B. INSTALLATION.

6. Elbow (7). a. Coat threads with liquid

tefIon.

b. Screw into tee (2).

7. Double-check and stop- a. Coat threads with liquid

lamp valve (6). teflon.

b. Screw into bulkhead

fitting (5).

8. Tee (2). a. Coat threads with liquid

teflon.

b. Screw into double-check

and stoplamp valve (6).

9. Fittings (1) and (8). a. Coat threads with liquid

teflon.

b. Screw into tee (2) and Install as previously marked.

elbow (7).

10. Two wires (3). Install over terminals and Install as previously marked.

secure with two terminal

nuts (4).

9-108
TM 9-2320-273-20

BRAKE SYSTEM.

Road test. Check operation

of:

a.

b.

c.

d.

Service brakes.

Park brakes.

Trailer brakes.

Stoplamps.

9-28. DOUBLE-CHECK AND STOPLIGHT VALVE MAINTENANCE (M918 AND M919) (Continued).

LOCATION/lTEM ACTION REMARKS

C. OPERATIONAL CHECK.

11. Vehicle. Tighten fittings as necessary

to stop any detected air

leaks.

9-109
TM 9-2320-273-20

BRAKE SYSTEM.

1.29. DOUBLE-CHECK AND STOPLAMP VALVE MAINTENANCE (M915, M916, M917C M920)

rHls TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

Removal. (15)

Installation. (15)

Operational Check. (10)

40 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915, M916, M917, M920. 9-13A. Secondary Air

TEST EQUIPMENT Reservoirs Drained.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (refer to appendix C).

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY lNSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-110
TM 9-2320-273-20

BRAKE SYSTEM.

Remove.

Remove from stoplamp Tag for location.

switch terminals.

Remove. Tag for location.

Remove. In cab.

9-29. DOUBLE-CHECK AND STOPLAMP VALVE MAINTENANCE (M915, M916, M917, M920)

(Continued).

LOCATION/ITEM ACTION REMARKS

1. Two nuts and washers (2).

2. Two wires (1).

3. Three air lines (4).

4. Air line (7).

9-111
TM 9-2320-273-20

BRAKE SYSTEM.

9-29. DOUBLE-CHECK AND STOPLAMP VALVE MAINTENANCE (M915, M916, M917, M920)

(Continued).

LOCATlON/ITEM ACTION REMARKS

A. REMOVAL (Continued).

5. Adapter (6). Remove. In cab.

6. Nut (5). Remove. In cab, 2nd mechanic

to hold valve to keep

from twisting while

nut removed.

7. Valve (3). Remove from vehicle.

8. Valve (3). Remove elbows, adapters,

tee’s from valve.

B. INSTALLATION.

9. Valve (3). InstalI elbows, tee’s, Coat threads with

adapters in valve. liquid teflon.

10. Valve (3). Install in vehicle.

11. Nut (5). Install on valve. 2nd mechanic to hold

valve from turning

during tightening.

12. Adapter (6). Install. Coat threads with

liquid teflon.

13. Air line (7). Install.

14. Three air lines (4). Install.

15. Two wires (1). Install on terminals.

16. Two nuts and washers (2). Install.

—

9-112
TM 9-2320-273-20

BRAKE SYSTEM.

9-29. DOUBLE-CHECK AND STOPLAMP VALVE MAINTENANCE (M915, M916, M917, M920)

(Continued).

LOCATION/lTEM ACTION REMARKS

C. OPERATIONAL CHECK.

17. Vehicle Road test check operation

of:

a. Service brakes.

b. Park brakes.

c. Trailer brakes.

d. Stoplamps.

9-113
TM 9-2320-273-20

BRAKE SYSTEM.

9-30. EXTERNAL AIR COUPLINGS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Installation. (10)

15 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTlON

M915, M916, M920. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (refer to appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-114
TM 9-2320-273-20

BRAKE SYSTEM.

9-30. EXTERNAL AIR COUPLINGS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Do not remove couplings until pressure is

fully exhausted from all reservoirs.

9-115
TM 9-2320-273-20

BRAKE SYSTEM.

9-30. EXTERNAL AIR COUPLINGS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL .

1. Couplings (1) and Unscrew and remove from Tractor to trailer

couplings adapter (2). hoses (3). connections.

2. Shutoff valve (4). Unscrew from coupling (1), Front and rear connections.

coupling adapter (2), hose

(3) and bracket (5).

3. Hose (3) and shut-off Inspect for: Replace if necessary.

valve (4). a. Leaks.

b. Cracks.

c. Damaged fittings.

d. Smooth valve handle

operation.

 B. INSTALLATION.

4. Couplings (1) and

couplings adapter (2).

5. Shutoff valve (4).

a. Apply liquid teflon Tractor to trailer

to threads, connections.

b. Screw on hoses (3).

a. Apply liquid teflon Front and rear

to threads. connections.

b. Install thru bracket(s) to

coupling (1), coupling adapter (2), and hose (3).

9-116
TM 9-2320-273-20

BRAKE SYSTEM.

9-30. EXTERNAL AIR COUPLINGS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-117
TM 9-2320-273-20

BRAKE SYSTEM.

9-31. FRONT BRAKE SHOES MAINTENANCE (M915).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Inspection. ( 5)

c. Installation. (15)

d. Adjustment. (15)

50 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 10-13A. Hub and Drum Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERlALS/PARTS (P/N)

GAA (Refer to Appendix C).

Cotter Pin, K-227 (78500).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 9-1

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-118
TM 9-2320-273-20

BRAKE SYSTEM.

9-31. FRONT BRAKE SHOES MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

9-119
TM 9-2320-273-20

BRAKE SYSTEM.

9-31. FRONT BRAKE SHOES MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

1. Two brake springs (2). Remove with brake spring Place notched tip of pliers

pliers. against hood on spring, unnotched tip against inner

ridge of brake shoe (1), squeezing pliers to stretch spring and

remove it from the notch.

2. Two brake shoes (1). Remove from clip (18) and

lift off shoes.

3. Two clips (18), two nuts Loosen nut (19) and remove Remove only if damaged or

(19), two Iockwashers (20), capscrew (21), Iockwasher broken.

and two capscrews (21). (20) and clip (18).

4. Two anchor guides (6) and Remove. Remove only if service on

two Iockwashers (7). actuator is needed.

5. Capscrew (12), Iockwasher Remove. Remove only if service on

(11), spring (10), and pawl actuator is needed.

(9).

6. Two seal assemblies (4), Remove. Clean, inspect, and replace

plunger (5), two plungers

(13), two actuators (14),

as necessary.

two seal assemblies (15),

and two adjusting bolts (16).

7. Two wedges (8). Remove and clean. Replace if damaged.

8. Dust shield (22), four Unscrew capscrews (23). Remove only if replacement

capscrews (23), and four is needed,

washers (24).

9. Two brake springs (2), brake Inspect for: Clean and replace as necessary.

shoes (1), seal assemblies (4) a. Dirt.

and (15) and all hardware. b. Wear.

c. Damage.

9-120
TM 9-2320-273-20

BRAKE SYSTEM.

9-31. FRONT BRAKE SHOES MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

9-121
TM 9-2320-273-20

BRAKE SYSTEM.

9-31. FRONT BRAKE SHOES MAINTENANCE (M915) (Continued).

LOCATION/ITEM ACTION REMARKS

C. INSTALLATION.

10.

11.

12.

13.

14.

15.

Dust shield (22), four

capscrews (23), and

four washers (24).

Two wedges (8).

Plunger (5), two seal

assemblies (4), two

plungers (13), two

actuators (14), two seal

assemblies (15), two

adjusting bolts (16), two

anchor guides (6), and

two Iockwashers (7).

Two clips (18), two nuts

(19), two Iockwashers (20),

and two capscrews (21).

Install dust shield (22)

and secure with capscrews

(23) and washers (24).

Install into spider (17).

Install into spider (17)

and secure with anchor

guide (6), Iockwasher (7),

capscrew (12), Iockwasher

(11), spring (10), and pawl

(9).

Install clips (18) and Install new if previously

secure with capscrews (21), removed.

Iockwashers (20), and nuts

(19).

If you replace any brake shoe, replace all the

Two brake shoes (1).

Two springs (2).

shoes on ‘that axle. A combination of new

and old shoes on the same axle will cause

uneven braking. Make sure that the brake shoes

are clean before you install them. Be careful

not to get grease or oil on the linings as you

assemble them.

a. Apply a thin film of Do NOT get any grease on

grease to plunger (5) the braking surfaces.

slots for adjusting bolt

(16) and shoe rest pads.

b. Position shoes on assembly with pads resting in

slots for adjusting bolt (16).

c. Double-check to be sure

that arrows on shoes point

in the direction that wheel

wiII rotate.

a. Turn to latch shoes in

position.

b. Install with brake spring

pliers. Curved part of each

spring must be towards

adjacent brake cylinder.

9-122
TM 9-2320-273-20

BRAKE SYSTEM,

9-31. FRONT BRAKE SHOES MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

9-123
TM 9-2320-273-20

BRAKE SYSTEM.

9-31. FRONT BRAKE SHOES MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

NOTE

Follow-on maintenance action required

before adjustment:

Para 10-12B and C.

D. ADJUSTMENT.

16. Wheel.

17. TwO dust plugs (3).

If jack is used, support truck with blocks

so that it will not fall if jack slips.

Jack or hoist free of

ground.

a. Remove dust plugs (3).

b. Insert adjusting spoon,

c. Turn starwheel bolt

(inside slot) until

brakes drag heavily

on drums.

d. Back off starwheel just

until wheels turn freely.

e. Replace dust plugs (3).

9-124
TM 9-2320-273-20

BRAKE SYSTEM.

9-31. FRONT BRAKE SHOES Maintenance (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

9-125
TM 9-2320-273-20

BRAKE SYSTEM.

9-32. FRONT BRAKE SHOES MAINTENANCE (M916 thru M920).

THIS TASK COVERS: (APPROXIMATE TIME REOUlRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Inspection. ( 5)

c. Installation. (15)

d. Adjustment. (15)

50 Minutes Total,

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 thru M920 10-14A. Hub and Drum Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

GAA (Refer to Appendix C).

Cotter Pin (2), K227 (78500).

Seal, 1205-E-1409 (78500).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-126
TM 9-2320-273-20

BRAKE SYSTEM.

9-32. FRONT BRAKE SHOES MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

9-127
TM 9-2320-273-20

BRAKE SYSTEM.

9-32. FRONT BRAKE SHOES MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Two brake springs (7).

Two cotter pins (4).

Two nuts (2) and washers

(3).

Two springs (5).

Two plates (6).

Two pins (1).

Two brake shoes (8).

Guide (24), and (22), cap

(23), pawl (21), two guides

(25), and two lock plates

(26).

Two retainers (9), two springs

(10) and (11), two adjusting

bolts (12), two anchors (13),

two plungers (14), two

retainers (15), two seals (16),

and two plungers (17).

Remove with brake spring

pliers.

Remove and discard.

Remove.

Remove.

Remove.

Remove.

Remove.

Remove to provide access

to wedge cylinder parts.

Remove and clean; discard

seals (16).

Snap ring (18) and wedge (19). Remove for inspection.

Place notched tip of pliers

against hood on spring, unnotched tip against inner ridge

of brake shoe (8), squeezing

pliers to stretch spring and

remove it from the notch.

Remove for inspection, not

normally needed unless trouble

is indicated.

Replace if damaged.

11. Brake springs (7), shoes (8), Inspect for:

and all hardware. a. Dirt.

b. Wear.

c. Damage.

Replace as necessary.

9-128
TM 9-2320-273-20

BRAKE SYSTEM.

9-32. FRONT BRAKE SHOES MAINTENANCE (M916 thru M920) (Continued).

LOCATION/lTEM ACTION REMARKS

9-129
TM 9-2320-273-20

BRAKE SYSTEM.

9-32. FRONT BRAKE SHOES MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION.

If you replace any brake shoe, replace all the

shoes on that axle. A combination of new

and old shoes on the same axle will cause

uneven braking. Make sure that the brake shoes

are clean before you install them. Be careful

not to get grease or oil on the linings as you

assemble them.

12. Wedge (19) and snap Install into spider (20).

ring (18).

13. Two plungers (17), two Install as shown.

new seals (16), two retainers

(15), two plungers (14),

two anchors (13), two

adjusting bolts (12), two

springs (10) and (11) and

two retainers (9).

14. Guides (24) and (22), cap Install pawl (21) with

(23), pawl (21), two guides

(25), and two Iockplates

guides (24) and (22),

and cap (23).

(26).

15. Two brake shoes (8). Install.

16. Two pins (1), two plates Install pins (1) and plates

(6), two springs (5), two (6) with springs (5),

washers (3), two nuts (2), washers (3), nuts (2),

and two new cotter pins and new cotter pins (4).

(4).

17. Two springs (7). Install with brake spring

pliers.

NOTE

Follow-on maintenance action required

before adjustment:

Install hub and drum; refer to para

10-14B and C.

9-130
TM 9-2320-273-20

BRAKE SYSTEM.

9-32. FRONT BRAKE SHOES MAINTENANCE (M916 thru M920) (Continued).

LOCATION/lTEM ACTION REMARKS

9-131
TM 9-2320-273-20

BRAKE SYSTEM.

9-32. FRONT BRAKE SHOES MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

D. ADJUSTMENT.]

18. Wheel.

19. Two dust covers (27)

If jack is used, support truck with blocks

so that it will not fall if jack slips.

Jack or hoist free of

ground.

a.

b.

c.

d.

e.

Remove.

Insert adjusting tool.

Turn starwheel bolt (inside

slot) until brakes drag

heavily on drums.

Back off starwheel just

until wheels turn freely.

Replace dust covers (27).

9-132
TM 9-2320-273-20

BRAKE SYSTEM,

9-32. FRONT BRAKE SHOES MAINTENANCE (M916 thru M920) (Continued).

LOCATION/lTEM ACTION REMARKS

9-133
TM 9-2320-273-20

BRAKE SYSTEM.

9-33. REAR BRAKE SHOES MAINTENANCE (M915).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.) —

Removal. (15)

Inspection. (15)

Installation . (20)

50 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915. 10-15A. Hub and Drum removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral

Park Brake Set.

TROUBLESHOOTING REFERENCES

9-1.

9-134
TM 9-2320-273-20

BRAKE SYSTEM.

9-33. REAR BRAKE SHOES MAINTENANCE (M915) (Continued).

LOCATION/ITEM ACTION REMARKS

9-135
TM 9-2320-273-20

BRAKE SYSTEM.

9-33. REAR BRAKE SHOES MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

1. RH and LH camshafts Back off on slack adjuster

(28) and (29). until camshafts (28) and

(29) are in fully released

position.

2. Two shoe assemblies (20) With a pry bar, pry upon

and two rollers (26). shoe assemblies (20) and

pull out rollers (26).

3. Spring (30) and two Remove,

pins (25).

4. Two springs (14). Tilt shoe assemblies (20)

out 180 degrees to release

springs (14) and remove.

5. Two lock screws (15) Cut lock wire and loosen

and two anchor pins (13). lock screw (15) to remove

anchor pin (13) and shoe

assemblies (20).

B. INSPECTION.

6. Camshafts (28) and (29), Inspect for excessive wear

bearings (17) and (8), and and looseness in bearings

two bushings (18). (17), bushing (18), and

bearing (8).

7. Two shoe assemblies (20). Inspect for wear or damage If linings (22) and (23) are to

and replace as necessary. be serviced separately, refer

to Direct Support Maintenance

as rivets (24) will have to be

drilled out of linings and shoes

(21).

NOTE

Perform steps 8 thru 14 only if excessive

wear has been found.

8. Retaining ring (12) and Remove,

washer (11).

9. Slack adjuster. Remove (refer to para

9-39A and B).

9-136 Change 1
TM 9-2320-273-20

BRAKE SYSTEM.

9-33. REAR BRAKE SHOES MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

9-137
TM 9-2320-273-20

BRAKE SYSTEM.

9-33. REAR BRAKE SHOES MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSPECTION (Continued). ‘

10. Camshafts (28) and (29), Remove by tapping gently

two washers (10), and from rear.

washer (27).

11. Bracket assemblies (4) Remove by unscrewing

and (5) and gasket (1). four capscrews (3) with

four Iockwashers (2).

12. Bearing (8) and seal (9). Remove from brackets (6)

and (7).

13. Two bushings (18), seal Remove from spider (19).

(16), and bearing (17).

14. Four capscrews (31) and Remove from spider (19). Remove only if damaged or

dust shield (32). replacing spider.

C. INSTALLATION.

15. Two bushings (18), seal Push into spider (19).

(16), and bearing (17).

16, Bearing (8) and seal (9). Insert into brackets (6)

and (7),

17. Bracket assemblies (4) and Install and secure with

and (5) and gasket (1). four capscrews (3) and

Iockwashers (2).

18. Camshafts (28) and (29) Install through bearings

and washer (27). (17) and (8).

19. Two shoe assemblies (20) a. Install to spider (19)

and two anchor pins (13). thru two bushings (18).

b. Tighten lock screw (15)

and install new lock wire.

9-138
TM 9-2320-273-20

BRAKE SYSTEM.

9-33. REAR BRAKE SHOES MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

9-139
TM 9-2320-273-20

BRAKE SYSTEM.

9-33. REAR BRAKE SHOES MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

20. Two springs (14). Hook up springs (14) to shoe

assemblies (20).

21. Two pins (25) and spring Insert pins (25) into two

shoe assemblies (20) and

hook spring (30) in position.

22. Two rollers (26). With a long handled screw- Repeat for opposite shoe to

driver, pry shoe assemblies

(20) away from camshafts

install rollers.

(28) and (29) and install

rollers (26).

23. Dust shield (32) and Install dust shield and secure

four capscrews (31). with capscrews (31) to spider

(19).

24. Two washers (10) and (11), Install and adjust slack

and retainer ring (12). adjuster (refer to para 9-36A

and B).

NOTE

Follow-on maintenance action required:

Install hub and drum (refer to para 10-15C).

9-140

(30).
TM 9-2320-273-20

BRAKE SYSTEM.

9-33. REAR BRAKE SHOES MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

9-141
TM 9-2320-273-20

BRAKE SYSTEM.

9-34. REAR BRAKE SHOES MAINTENANCE (M916 THRU M920).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Inspection, (15)

c. Installation. (20)

50 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 Thru M920. 10-14A. Hub and Drum Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

Snap Ring Pliers.

Brake Spring Pliers.

MATERIAL/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 9-1.

9-142
TM 9-2320-273-20

BRAKE SYSTEM.

LOCATION/lTEM ACTION REMARKS

9-34. REAR BRAKE SHOES MAINTENANCE (M916 THRU M920) (Continued).

9-143
TM 9-2320-273-20

BRAKE SYSTEM.

Use brake spring pliers.

9-34. REAR BRAKE SHOES MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Camshafts (36) and (37). Back off on slack adjuster See para 9-39A and B.

until camshafts are in the

released position.

2. Two brake shoe assemblies With a long handle screw-

(26) and two rollers (28). driver pry brake shoe

assemblies (26) away from

camshafts (36) and (37),

then remove rollers (28).

3. Spring (34) and two pins Remove.

4. Two retainer rings (14), Remove from rear using

two retainers (13), and snapring pliers on retainer

two felt rings (12). rings (14).

5. TWO Iockbolts (22), two a. Cut lock wire and remove.

anchor pins (23), two b. Loosen lock bolts (22)

retainer rings (14), two and pull anchor pins (23)

retainers (13), and two out of retainer rings (14),

felt rings (12). retainers (13) and felt

rings (12) from front.

6. Two shoe assemblies (26) Remove.

and bushings (33).

7. Two bushings (20). Remove. Inspect for wear.

8. Retaining ring (11), two Remove. Remove only if excessive loosewashers (10), washer (9), ness is evident.

and camshafts (36) and (37)

and washer (35).

9. Four capscrews (2), four Remove with gasket (39).

washers (1), and brackets

(3) and (4).

10. Two bushings (7) and Remove from brackets

seals (8). (5) and (6).

11. Seal assembly (18), Remove. Replace only if excessive wear

bushing (19), and seal (21). is evident.

12. Six capscrews (24). Unscrew and remove dust

shields (25) and (38).

13. Spider (17). Replace only if broken or

damaged.

9-144

(27).
TM 9-2320-273-20

BRAKE SYSTEM.

9-34. REAR BRAKE SHOES MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

9-145
TM 9-2320-273-20

BRAKE SYSTEM.

9-34. REAR BRAKE SHOES MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSPECTION.

14. Gasket (39), seals (8),

(18), and (21), bushings

(7), (19), (20) and (23),

and camshafts (36) and

(37), and shoe assemblies

(26).

C. INSTALLATION.

15.

16.

17.

18.

19.

a. Inspect for wear and

replace as needed.

b. If linings (29) and (31)

are to be serviced separately, refer to Direct Support

Maintenance as rivets (30)

will have to be drilled out

and replaced with new.

Bushing (19), seal

assembly (18), and

seal (21).

Brackets (5) and (6),

bushing (7) and seal (8).

Brackets (3) and (4),

and gasket (39).

If you replace any brake shoe, replace all

the shoes on that axle. A combination of

new and old shoes on the same axle will

cause uneven braking. Make sure that the

brake shoes are clean before you install

them. Be careful not to get grease or oil

on the linings as you assemble them.

Camshafts (36) and (37)

and washer (36).

Two anchor pins (23)

two bushings (20).

and

Push seal (21) in place then

bushing. (19), and seal

assembly (18).

Push bushing (7) into place

then install seal (8).

Install one gasket (39) into

brackets (3) and (4) and

secure with four capscrews

(2) and washers (1).

a.

b.

c.

a.

b.

c.

Install one washer (35) on

on each camshaft and

install through bushings (19)

and (7).

Install washers (9) and (10)

then retaining ring (11).

Position two shoe assemblies

(26).

Install anchor pins (23)

through shoe assemblies (26).

Install bushings (20) into

spider (17).

Tighten lock bolt (22) and

install Iockwire.

9-146
TM 9-2320-273-20

BRAKE SYSTEM.

9-34. REAR BRAKE SHOES MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

9-147
TM 9-2320-273-20

BRAKE SYSTEM.

9-34. REAR BRAKE SHOES MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

20. Two felt rings (12), two Slide onto anchor pins

retainers (13), and two (23) from rear.

retainer rings (14).

21. Two felt rings (12), Install on anchor pin (23) Use snap ring pliers on retainer

two retainers (13), and from front side and secure. rings (14).

two retainer rings (14).

22. Two pins (27), and spring Install pins (27) and hook

on spring (34) with brake

spring pliers.

23. Two shoe assemblies (26) With long screwdriver pry Repeat operation for opposite

and two rollers (28). up on shoe assembly (26) shoe.

and install roller (28).

24. Dust shields (25) and (38). Install with six capscrews

(24).

25. Slack adjusters. Adjust (see para 9-39A

and B).

NOTE

Follow-on maintenance action required:

Install hub and drum; refer to para 10-14C.

9-148

(34).
TM 9-2320-273-20

BRAKE SYSTEM.

9-34. REAR BRAKE SHOES MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

9-149
TM 9-2320-273-20

BRAKE SYSTEM.

9-35. PUSHER AXLE BRAKE SHOES MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Inspection. ( 5)

c. Installation. (15)

d. Adjustment. (15)

50 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

M917, M919, M920.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

GAA (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 9-1.

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

10-16A. Hub and Drum Removed.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-150
TM 9-2320-273-20

BRAKE SYSTEM.

9-35. PUSHER AXLE BRAKE SHOES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-151
TM 9-2320-273-20

BRAKE SYSTEM.

9-35. PUSHER AXLE BRAKE SHOES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Two brake shoe With a long handle screwassemblies (27). driver lift brake shoe assemblies

and remove two rollers (25) and

retainers (24).

2. Spring (26) and two Remove.

pins (23).

3. Four snap rings (1), four From rear side remove snap

washers (2) and two pins ring (1) and washer (2), then

(5). pull out pin (5).

4. Two brake shoe Lift off.

assemblies (27).

5. Two bushings (3) and Remove.

grease fittings (4).

6. Snap ring (6), two washers Remove and pull camshaft

(7), two seaIs (8), O-ring (14) out of spider.

(9), and O-ring (13).

7. Bushing (10), bushing Remove.

(11), and grease fitting (12).

8. Dust shield (18) and (19), Remove. Remove only if damaged and

six capscrews (15), replacement is needed.

six Iockwashers (16), and

six washers (17).

B. INSPECTION.

9. Brake spring (26), shoe Inspect for:

assemblies (27), O-ring a. Dirt.

(9), O-ring (13) and all b. Wear.

hardware. c. Damage

NOTE

If lining (22) is to be replaced separately,

rivets (21) will have to be drilled out and

replaced with new. Refer to Direct Support

Maintenance.

Replace as necessary.

9-152
TM 9-2320-273-20

BRAKE SYSTEM.

9-35. PUSHER AXLE BRAKE SHOES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-153
TM 9-2320-273-20

BRAKE SYSTEM.

9-35. PUSHER AXLE BRAKE SHOES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

If you replace any brake shoe, replace all the

shoes on that axle. A combination of new

and old shoes on the same axle wiII cause

uneven braking. Make sure that the brake shoes

are clean before you install them. Be careful

not to get grease or oil on the linings as you

assemble them.

10.

11.

12.

13.

14.

15.

16.

17.

O-ring (13), seal (8),

washer (7), and camshaft

(14).

O-ring (9), seal (8),

washer (7), snap ring (6),

and grease fitting (12).

Two bushings (3) and

grease fitting (4).

Two brake shoe assemblies

(27).

TWO pins (5), two washers

(2) and two snap rings (1).

Two washers (2) and two

snap rings (1).

Spring (26) and two pins (23).

Two rollers (25) and two

retainers (24).

Install bushings (10) and

(11), O-ring (13), seal (8),

washer (7), and then install

camshaft (14) thru bushings

(10)and(11).

Install.

Install into spider.

Place on spider.

Install snap ring (1) on pin

(5) with washer (2) and push

through brake shoe assembly

(27) and bushing (3).

Install washer (2) on back side

of pin (5) and install snap ring

Install pins (23) and hook UP

spring (26).

With long handle screwdriver

raise brake shoe to allow

room to install roller (25)

and retainer (24).

(1).

Repeat operation for opposite

shoe.

9-154
TM 9-2320-273-20

BRAKE SYSTEM.

9-35. PUSHER AXLE BRAKE SHOES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-155
TM 9-2320-273-20

BRAKE SYSTEM.

9-35. PUSHER AXLE BRAKE SHOES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

18. Dust shields (18) and (19). Install and secure with six If previously removed.

capscrews (15), Iockwashers

(16), and washers (17).

NOTE

Follow-on maintenance action required:

Install hub and drum; refer to para 10-16C.

9-156

19. Adjust slack adjuster. See para 9-39.
TM 9-2320-273-20

BRAKE SYSTEM.

9-35. PUSHER AXLE BRAKE SHOES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-157
TM 9-2320-273-20

BRAKE SYSTEM.

9-36. FRONT BRAKE AIR CHAMBER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

Removal. (15)

Disassembly. (15)

Reassembly. (15)

 Installation. (15)

Operational Check.

70 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Soap and Water Solution.

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-158

a.

b.

c .

d .

e (10)
TM 9-2320-273-20

BRAKE SYSTEM.

9-36. FRONT BRAKE AIR CHAMBER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Do not remove brake chamber until pressure

is fully exhausted from all reservoirs.

NOTE

The M915 has two front brake air chambers

per wheel, while the M916 thru M920 have one.

9-159
TM 9-2320-273-20

BRAKE SYSTEM.

M916 thru M920.

9-36. FRONT BRAKE AIR CHAMBER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Air line (1). a. Unscrew and remove.

b. Inspect for: Replace if necessary.

1. Cracks.

2. Leaks.

3. Damaged fittings.

2. Collet nut (2). Loosen. M915 only.

3. Fitting (16). Remove.

4. Brake chamber assembly Unscrew and remove the Be careful not to lose wedge

(4) and identification ring (3). brake chamber; the identi- guide (5).

fication ring can also be

removed now.

5. Brake plug (14). Remove.

6. Clamp bolt (15) and clamp Unscrew and remove

clamp ring (12).

7. Pressure housing (11) and Pull apart for access to

non-pressure housing (6). boot (7), retainer (8),

push rod (9), and

diaphragm (10).

8. Boot (7), retainer (8), Assemble within non- Be sure to assemble as illustrated.

push rod (9), and diaphragm pressure housing (6) and

(10). pressure housing (11).

9. Clamp ring (12). Secure to housings (6) and

(11) with clamp bolt (14)

and clamp nut (13).

10. Brake plug (14). Install into pressure hous- M916 thru M920.

ing (11).

11. Wedge guide (5). Insert into non-pressure

housing (6).

9-160
TM 9-2320-273-20

BRAKE SYSTEM.

9-36. FRONT BRAKE AIR CHAMBER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-161
BRAKE SYSTEM.

9-36. FRONT BRAKE AIR CHAMBER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

12. Brake chamber assembly

(4) and identification

a. Slip identification ring (3)

onto neck of brake chamber

ring (3). assembly (4).

b. Screw on collet nut (2) and

tighten.

c. Screw brake chamber assembly (4) into wheel backing

plate.

13. Fitting (16). a. Coat threads with liquid

tef Ion.

b. Screw into brake chamber

assembly (4) and tighten.

14. Airline (1). a. Coat threads with liquid

teflon.

b. Screw into fitting (16) and

tighten.

15. Engine. Start up (see TM 9-2320-273-

10). Allow system to reach

operating pressure of 105-120

psi (725-827 kPa).

16. Cab/brake pedal. Press down. 2nd mechanic.

17. Front brake air chamber a. Check that brakes apply 1st mechanic.

assembly (4). when pedal is pressed.

b. Use soap solution to check

for leaks.

18. Vehicle. Road test. Check for proper

braking.

19. Engine. Shut down (see TM 9-2320-

273-10).

9-162
TM 9-2320-273-20

BRAKE SYSTEM.

9-32. FRONT BRAKE AIR CHAMBER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-163
TM 9-2320-273-20

BRAKE SYSTEM.

9-32. REAR BRAKE AIR CHAMBER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Caging Power Spring. ( 5)

b. Removal. (20)

c. Installation (25)

d. Uncaging Power Spring. (10)

e. Operational check. ( 2)

62 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Soap and Water Solution.

PERSONNEL REQUIRED

TWO ( MOS-63B20) .

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Wheels Blocked.

Transmission in Neutral.

9-164
TM 9-2320-273-20

BRAKE SYSTEM.

9-37. REAR BRAKE AIR CHAMBER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Block the truck wheels before you cage the

power spring, since caging the spring

releases the parking brakes.

The spring brake chamber contains a powerful spring. Do not remove the clamp rings

or disassemble the chambers even with the

compression spring caged. Refer to DS/GS

Maintenance if internal service is required.

Change 1 9-165
TM 9-2320-273-20

BRAKE SYSTEM.

9-37. REAR BRAKE AIR CHAMBER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Do not use an impact wrench with a

torque setting higher than 30 Ib-ft

(41 N·m) to cage power spring.

1. Wheels Block.

2. CAB/Park brake control (1). Push to release park brakes.

3. Cap(15). Pull out from access hole (14).

4. Release nut (3) and Unscrew from release stud (13).

washer (16). Remove stud from its holder.

5. Release stud (13). a. Insert stud through access

hole (14) and turn 1/4 turn

to secure cross pin into

pressure plate.

b. Screw on nut (3) and washer

(16).

c. Turn release stud assembly

with wrench until compression spring is fully caged.

6. Manual drain valves (2). a. Turn to drain air pressure.

Exhaust pressure from both

service reservoirs on the

M915, M916, and M918 and

all three service reservoirs on

the M917, M919 and M920.

b. Close drain valves.

7. Two air lines (4). a. Use tape to mark air lines. This will help you connect

them properly during

installation.

b. Unscrew and remove Replace if necessary.

c. Inspect for:

1. Cracks.

2. Leaks.

3. Damaged fittings.

8. Cotter key (10) and pin (11). Remove.

9. Yoke (8). Disconnect from slack adjuster (9).

10. TWO nuts (7), Iockwashers Unscrew and remove. Remove

(6), and flat washers (5). air chamber (12).

9-166
TM 9-2320-273-20

BRAKE SYSTEM.

9-37. REAR BRAKE AIR CHAMBER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

11. Air chamber (12). Position on mounting bracket. Exhaust check valve

should point down.

12. Two nuts (7), Iockwashers a. Screw on.

(6) and flat washers (5). b. Tighten nuts to 100 Ib-ft

(136 N·m) with torque

wrench.

NOTE

Upper nut on both chambers cannot be

torqued unless a 15/16 crowfoot is used.

13. Yoke (8) Attach to slack adjuster (9).

14. Pin (11) and cotter key (10). Install in yoke (8).

9-167
TM 9-2320-273-20

BRAKE SYSTEM.

9-37. REAR BRAKE AIR CHAMBER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

15. Two air lines (4).

16. Manual drain valves (2).

17 Engine.

18. CAB/Park brake control (1).

19. Release stud (13).

20. Cap (15).

a. Coat threads with liquid

tefIon.

b. Screw in and tighten.

Ensure they are closed.

Start up (see TM 9-2320-273-

10). Allow system to reach

operating pressure of 105-120

psi (724-827 kPa).

Push in.

a. Turn nut (3) with washer

(16) to release spring.

b. Remove nut (3) and washer

(16) from stud (13).

c. Turn stud (13) 1/4 turn

counterclockwise (Ieft)

and remove from access

hole (14).

d. Insert stud (13) into holder

and secure with washer (16)

and nut (3).

Press into access hole (14).

Be sure to connect each

line to the correct port.

NOTE

Operational check requires system pressure of at least 100 psi (690 kPa). Run

engine until this pressure is reached.

21. Engine. Shut down.

22. CAB/Park brake control (1). a. Push in. Second mechanic.

b. pull out.

23. Air chamber (12). a. Should actuate when valve First mechanic.

is pulled out, and release

when valve is pushed in.

9-168
TM 9-2320-273-20

BRAKE SYSTEM.

9-37. REAR BRAKE AIR CHAMBER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

b. Use soap solution to check

for leaks.

24. CAB/Brake pedal. a. Press down. Second mechanic.

b. Release.

25. Air chamber (12). Should apply when pedal is

pressed, and release when

pedal is released.

9-169
TM 9-2320-273-20

BRAKE SYSTEM.

9-38. PUSHER AXLE BRAKE AIR CHAMBER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Disassembly. (15)

c. Assembly. (15)

d. Installation. (10)

50 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Tape.

Marking Pen.

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Wheels Blocked.

Table 9-1.

9-170
TM 9-2320-273-20

BRAKE SYSTEM.

9-38. PUSHER AXLE BRAKE AIR CHAMBER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Air line (3). Unscrew and remove from

fitting (2).

2. Fitting (2). Remove from housing (4).

3. Cotter key (13) and pin (14). Remove and disassemble

yoke (12) on push rod (9)

9-171

from slack adjuster (15)
TM 9-2320-273-20

BRAKE SYSTEM.

9-38. PUSHER AXLE BRAKE AIR CHAMBER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4. Two nuts (16) and

washers (17).

5. Push rod (9).

6. Assembled housings

(4) and (11).

7. Two nuts (8).

8. Clamp ring (6).

9. Diaphragm (5).

10. Clamp ring (6).

11. Push rod (9).

12. Housing (11) with

assembled air chamber.

13. Slack adjuster (15) and

yoke (12) on push rod (9).

Unscrew and remove housing

(11) with assembled air chamber (1) from mounting bracket

on vehicle.

a. Wrap with tape.

b. Apply suitable pressure

with vice grips to retain

spring (10) in position.

Using marker pencil, draw a

line from one end to the

other.

Unscrew and remove clamp

bolts (7).

Pull apart and separate housings (4) and (11) for access

to diaphragm (5).

Position between housings

(4) and (11).

Position over housings joint

and secure with two clamp

bolts (7), and nuts (8).

a. Remove vise grips.

b. Remove tape.

Position housing studs thru

vehicle mounting bracket and

secure with two washers (17)

and nuts (16).

Aline holes, slide pin (14) in

position and secure with new

cotter key (13).

Clamp vise grips onto rod close

to housing (11).

You will use this line to

aline parts during reassembly.

Replace diaphragm if necessary.

Use the line you drew in step

6 to aline housings.

9-172
TM 9-2320-273-20

BRAKE SYSTEM.

9-38. PUSHER AXLE BRAKE AIR CHAMBER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

14. Fitting (2). a. Apply liquid teflon to

threads.

b. Screw into housing (4)

and tighten.

15. Air line (3). a. Apply liquid teflon to hose

9-173

fitting threads

b. Screw into fitting (2) and 

tighten.
TM 9-2320-273-20

BRAKE SYSTEM.

9-39. SLACK ADJUSTERS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Adjustment – Slack Adjuster (15)

(Forward Rear Tandem).

b. Adjustment – Push Rod (30)

(Rear Rear Tandem).

45 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

TWO (MOS63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

None.

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

(See TM 9-2320-273-10). Wheel Raised OFF

Ground; Park Brake

Should Be Released And

Wheels Blocked.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission In Neutral.

9-174
TM 9-2320-273-20

BRAKE SYSTEM.

9-39. SLACK ADJUSTERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

The procedure in this paragraph is limited to

adjustment; it should be performed with

wheel off of ground and parking brake

released.

1. Adjusting screw (2). a. While turning wheel rotate

adjusting screw (2) until

brakeshoes are tight

against brakedrum.

b. Back off adjusting screw (2)

approximately one turn or

until wheel does not drag.

2. CAB/Brake pedal. Push completely down. Second mechanic.

3. Slack adjuster (3) and a. If brake chamber push rod

push rod (6). (6) travel is less than 3/4

inch (1.9 cm) or more than

1 inch (2.54 cm) go to

part B.

b. If brake chamber push rod

(6) travel is 3/4 to 1 inch

(1.9 cm to 2.54 cm), adjustment is satisfactory.

c. If angle between slack

adjuster (3) and push rod

(6) is less than 90°, go to

part B.

d. If angle between slack

adjuster (3) and push rod

(6) is more than 90°,

adjustment is satisfactory.

Do this procedure carefully. The slack adjuster may be turned toward the brake chamber and might snap back.

Change 2 9-175
 TM 9-2320-273-20

BRAKE SYSTEM.

9-39. SLACK ADJUSTERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

4. Slack adjuster (3). If push rod travel does not fall

between 3/4 to 1 inch (1.9 cm

to 2.54 cm), tighten adjusting

screw to decrease travel or

loosen to increase travel.

5. Cotter key (4) and clevis a. Remove.

pin (5). b. Disconnect slack adjuster

(3) from push rod (6).

6. Push rod locknut (7). a. Loosen.

b. Turn push rod (7) to

shorten.

7. Clevis pin (5). Insert into slack adjuster (3).

8. CAB/Brake pedal. Push completely down. Second mechanic.

9. Slack adjuster (3) and If angle between slack ad- First mechanic.

push rod (6). juster (3) and push rod (6)

is at least 90°, go to

step 10.

10. Locknut (7). Tighten.

11. Cotter key (4) Push into clevis pin (5).

NOTE

If adjustment to the push rod/slack adjuster

angle is necessary, the push rod travel must

be rechecked.

9-176 Change 2
TM 9-2320-273-20

BRAKE SYSTEM.

9-39. SLACK ADJUSTERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Change 2 9-177
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-40. WINDSHIELD WASHER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (5)

c. Operational Check. (2)

 12 Minutas Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 8-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehcile Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Sat.

9-178
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-40. WINDSHIELD WASHER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Two small hoses (2). Disconnect from wiper Remove heater duct to

pivot assemblies (4). gain access to hose (2) on

right side.

2. Air line (5) and waterline (8). Disconnect from reservoir

(6).

9-179
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-40. WINDSHIELD WASHER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

3. Reservoir (6).

4. Two small hoses (2),

T-connection (1), and

water line (8).

5. Reservoir (6).

6. Air line (5) and

waterline (8).

7. Two small hoses (2).

Lift out of bracket (7).

Inspect for:

a. Leaks.

b. Cracks.

Set into bracket (7).

Connect to reservoir (6).

Connect to wiper pivot

assemblies (4).

8. INSTRUMENT PANEL/

Washer button.

Push. Check that washer

fluid is squirted onto windshield. Adjust nozzles (3)

if necessary. Check for leaks.

Replace if necessary.

Reconnect heater duct.

If air pressure is low, you

may need to start engine

before washers will work.

9-180
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-40. WINDSHIELD WASHERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-181
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEM.

9-41. WINDSHIELD WASHER CONTROL MAINTENANCE.

a. Removal. (7)

b. Inspection of Air Lines. (7)

c. Installation. (1)

d. Operational Check. (5)

20 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-37A. Batteries Disconnected.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (refer to appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 9-1.

9-182

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEM.

9-41. WINDSHIELD WASHER CONTROL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1.

2.

3.

4.

5.

6.

7.

Two quarter-turn screws (1). Loosen so that instrument

Supply line fitting

Allen screw (2).

Control knob (3).

Nut (4).

Valve body (7).

Outlet hose (5).

(6).

panel can be lowered.

Unscrew from valve body (7).

Remove.

Remove.

Loosen and remove.

Remove from back side of

panel.

Pull off of valve body (7).

9-183
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEM.

9-41. WINDSHIELD WASHER CONTROL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

8. Air supply line, and fitting Inspect for:

(6), air outlet hose (5).

Replace if necessary.

a. Cracks.

b. Leaks.

c. Brittleness.

d. Damaged fittings.

9. Outlet hose (5). Push onto arm of valve

body (7).

10. Valve body (7). a. Put through hole in instrument panel.

b. Screw on and tighten

nut (4).

c. Install control knob (3)

and tighten AlIen screw

(2).

11. Supply line fitting (6). Screw into valve body (7).

12. Two quarter-turn screws (1). Tighten to fasten instrument

panel in position.

NOTE

Follow-on maintenance required:

Reconnect batteries per para 5-37B.

13. Engine RUN switch.

14. Washer control knob (3). I If washer does not work, lower

dash panel and check for leakage at air line connections. If

there is no leakage, troubleshoot

the rest of the washer system

(para 9-5).

15. Engine RUN switch. Turn OFF (see TM 9-2320-

273-10).

Turn ON (see TM 9-2320-

273-10).

Push.

9-184
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEM.

9-41. WINDSHIELD WASHER CONTROL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-185
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEM.

9-42. WINDSHIELD WIPER MOTOR MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (30)

b. Installation. (30)

c. Operational Check. (11)

71 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Masking Tape.

Marking Pen.

Gasket (4730-01-055-4013).

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-186
TM 9-2320-273-20

Remove.

Remove from motor shaft.

AUXILIARY AIR-POWERED COMPONENT SYSTEM.

9-42. WINDSHIELD WIPER MOTOR MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

1. Clip (3).

2. Drive lever (2).

9-187
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEM.

9-42. WINDSHIELD WIPER MOTOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

3.

4.

Two air lines (1).

Four capscrews (6), washers

(5) and nuts (4).

5. New gasket (8) and motor (7)

6. Four capscrews (6), washers

(5) and nuts (4).

7. Two air lines (1).

8. Drive lever (2).

9. Clip (3).

10. Engine.

11. Windshield wipers.

12. Engine.

a. Use masking tape to mark

PARK and RUN air lines.

b. Unscrew and remove.

Unscrew and remove motor Discard gasket.

(7) and gasket (8).

Position against firewall.

Screw in and tighten.

Screw into ports marked

PARK and RUN. Tighten.

Slide onto motor shaft.

Clip onto shaft.

Start up (see TM 9-2320-273-

10). Allow system to reach

operating pressure of 105-120

psi (724-827 kPa).

Check operation at high and

low speeds.

273-10 

9-188

Shut down (see TM 9-2320-
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEM.

9-42. WINDSHIELD WIPER MOTOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-189
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-43. WINDSHIELD WIPER CONTROL MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 7)

b. Inspection of Air Lines ( 2)

c. Installation. (11)

d. Operational Check. ( 1)

21 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (PIN)

Masking Tape.

Marking Pen.

Liquid Teflon (refer to appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

5-37A. Batteries Disconnected.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-190
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-43. WINDSHIELD WIPER CONTROL MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

1. Allen screw (3). a. Loosen with Allen wrench.

b. Remove knob (2).

2. Two quarter-turn screws (1). Loosen so that instrument

panel can be lowered.

3. Supply line (8), wiper park a. Use tape and marker pen

line (7), and wiper run to identify each line.

line (6). b. Unscrew fittings from

valve body (9).

4. Nut (4) and washer (5). a. Unscrew and remove.

b. Remove valve body (9)

from back side of panel.

9-191
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-43. WINDSHIELD WIPER CONTROL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

5. Supply line (8), wiper park Inspect for: Replace if necessary.

line (7), and wiper run a. Cracks.

line (6). b. Leaks.

c. Damaged fittings.

6. Supply line (8), wiper park Screw into valve body (9).

line (7), and wiper run Be sure that each line is

line (6). screwed into the proper

opening.

7. Valve body (9). a. Push forward through

hole in rear of instrument

panel.

b. Screw on and tighten

washer (5) and nut (4).

8. Two quarter-turn screws (1). Tighten to fasten instrument

panel cover.

9. Knob (2). a. Push onto valve body and

twist until Allen setscrew

(3) is seated properly on

stem of valve body.

b. Tighten with Allen wrench.

10. Batteries. Connect (see para 5-37 B).

10. Engine RUN switch. Turn ON (see TM 9-2320-273-10).

11. Wiper knob. Pull out. Check to see that If wipers do not work, open

wipers operate properly on panel and check for air leaks

Hl, LOW, and PARK. at fittings. If no leaks are

present troubleshoot the rest

of the wiper system (see

para 9-5).

12. Engine RUN switch. Turn OFF (see TM 9-2320-273-10).

9-192
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-43. WINDSHIELD WIPER CONTROL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-193
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-44. DIFFERENTIAL LOCKUP CONTROL VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (6)

c. Checking for Leaks. (2)

13 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

5-83A. Differential Lockup

TEST EQUIPMENT Switch Removed.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (refer to appendix C).

Soap and Water Solution.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Differential Lockup Engaged.

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-194
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-44. DIFFERENTIAL LOCKUP CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Do not remove differential lockup

control valve until pressure is completely

exhausted from alI reservoirs.

1. Two screws ( 1). Loosen and remove

valve (2).

NOTE

The figure below shows M915 valve. M916

through M920 valves have three air line connections.

9-195
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-44. DIFFERENTIAL LOCKUP CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

2. Air lines (3) and (4).

3. Air lines (3) and (4).

4. Valve (2).

5. Engine.

6. Valve (2).

7. Engine.

a. Unscrew and remove.

b. Inspect for:

1. Cracks.

2. Leaks.

3. Damaged fittings.

Screw into valve (2) and

tighten.

Remount in instrument

panel and install two

screws (1).

Start up (see TM 9-2320-273-10).

Allow system to reach operating pressure of 105-120 psi

(724-827 kPa).

Engage, use soap solution to

check for leaks.

Shut down (see TM 9-2320-

Replace if necessary.

273-10).

NOTE

Follow-on maintenance action required:

Install differential lockup switch; refer

to para 5-83B.

9-196
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-44. DIFFERENTIAL LOCKUP CONTROL VALVE MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

NOTE

The figure below shows M915 valve, M916 through M920

valves have three air line connections.

9-197
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-45. AIR HORN AND CONTROL VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.) —

a. Removal. (18)

b. Installation. (22)

c. Operational Check. ( 5)

45 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 9-13A. Air Reservoirs Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (Refer to Appendix C).

Soap and Water Solution.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 9-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

9-198
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-45. AIR HORN AND CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-199
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-45. AIR HORN AND CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Do not remove valve (14) until pressure is

fully exhausted from all reservoirs.

NOTE

For access to horns and valve remove headliner screws and pull down headliner as

necessary.

1. Screw (10) and washer (11). Unscrew and remove one

end of chain (12).

2. Chain (12). Disconnect from handle on Use pliers to open S-hook.

valve (14) by slightly opening S-hook (13).

3. Supply line (18). Unscrew from fitting (15).

4. Fitting (15). Unscrew from valve (14).

5. Valve (14). Unscrew from horn inlet (8).

6. Horn inlet (8). Unscrew from tee (4).

7. Line (6). Unscrew from connector (5)

and elbow (7).

8. Connector (5). Unscrew from tee (4).

9. Plug (9). Unscrew from tee (4).

10. Tee (4). Unscrew from left hand

horn (24).

11. Elbow (7). Unscrew from right hand

horn (24).

12. Six screws (22), Unscrew and remove two M917 has only one horn located

washers (17), and horns (24), pedestals (20), on left hand side.

nuts (16). gaskets (23), gaskets (19),

and rubber liners (21 ).

13. Four screws (1) and Unscrew and remove two M917 only.

nuts (3). plate covers (2), washers

(25), and washer (26).

M917 only.

-

9-200
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-45. AIR HORN AND CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-201
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-45. AIR HORN AND CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Coat all threaded connections with liquid

teflon as you assemble.

14. Two gaskets (19), Position on cab roof M917 has only one horn.

gaskets (23), pedestals and install with six screws

(20), rubber liners (21 ), (22), washers (17), and

and horns (24). and nuts (16).

15. Elbow (7). Screw into horn (24) on

right hand side.

NOTE

Follow step 16. For M917 only.

16. Two cover plates (2), Position on right hand cab

washers (25), and roof and install with four

washers (26). screws (1) and nuts (3).

17. Tee (4). Screw into horn (24) on

left hand side.

18. Connector (5). Screw into tee (4).

19. Plug (9). Screw into tee (4).

20. Line (6). Screw onto connector

(5) and elbow (7).

21. Horn inlet (8). Screw into bottom of

tee (4).

22. Fitting (15). Screw into valve (14).

23. Valve (14). Screw onto horn inlet (8).

24. Supply line (18). Screw onto fitting (15).

25. S-hook (13). a. Hook thru hole in handle

of valve (14) and one end

of chain (12).

b. Clamp S-hook closed with

pliers.

M917 only.

9-202
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-45. AIR HORN AND CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

9-203
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-45. AIR HORN AND CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

26. Chain (12).

27. Engine.

28. Chain (12).

29. Valve (14).

30. Engine.

Secure other end to cab roof

with screw (10) and washer

(11).

Start up (see TM 9-2320-

273-10). Allow system to reach

operating pressure of 105-120

psi (724-827 kPa).

a. Pull.

b. Release.

Check for leaks with soap

and water solution.

Shut down (see TM 9-2320-

273-10).

Horn should

Horn should

Retighten as

NOTE

Reposition headliner, if lowered, and secure

with screws and trim washers.

blow.

stop blowing.

necessary.

9-204
TM 9-2320-273-20

AUXILIARY AIR-POWERED COMPONENT SYSTEMS.

9-45. AIR HORN AND CONTROL VALVE MAINTENANCE (Continued),

LOCATION/lTEM ACTION REMARKS

9-205/9-206(Blank)

TM 9-2320-273-20

CHAPTER 10

WHEELS, STEERING, AND SUSPENSION SYSTEMS MAINTENANCE

This chapter provides you with the following information related to wheels, steering, and suspension

systems maintenance.

a. All required special tools and equipment.

b. Other technical manuals.

c. Troubleshooting procedures.

d. Maintenance procedures.

Section l REPAIR PARTS, SPECIAL TOOLS, TMDE AND SUPPORT EQUIPMENT

For authorized common tools and equipment, refer to the Modified Table of Organization and

Equipment (MTOE) applicable to your unit.

The special tools, TMDE and support equipment required for the wheels, steering, and suspension

systems maintenance procedures described in this chapter are limited to the following items: (Refer

to Organizational Maintenance RPSTL, TM 9-2320-273-20P for tool description and illustration.)

a.

b.

c.

d.

e.

f

g.

h.

i.

j.

k.

l.

m.

Toe-in gage.

Valve core removing tool.

Gooseneck tool.

Rim tool.

Safety cage.

4-inch, 6-point wheel bearing nut wrench.

Wheel bearing packing tool.

Wheel dolly.

Tie rod end puller.

Pitman arm removing tool.

Pitman arm spacer.

Spacer removing tool.

Ball joint puller.

10-1
TM 9-2320-273-20

Spares and repair parts are listed and illustrated in the Repair Parts and Special Tools List covering

organizational maintenance for this equipment (TM 9-2320-273-20P).

Section II TROUBLESHOOTING

Tables 10-1 thru 10-3 contain instructions for troubleshooting the wheels, steering, and vehicle

suspension. The correction actions describe how to fix the problem or refer to a procedure for

fixing the problem. The troubleshooting tables are arranged by malfunctions in the following order.

WHEELS AND TIRES (table 10-1):

a.

b.

STEERING

a.

b.

c.

d.

e.

f.

Tires wearing unevenly,

Noisy or bumpy sound while traveling down the road.

(table 10-2):

Front tires wearing unevenly.

Hard steering.

Vehicle wanders or pulls to one side.

Lost motion or excessive play in steering wheel.

Temporary increase in effort when turning steering wheel.

Vehicle does not fully steer from stop to stop.

SUSPENSION (table 10-3):

a. Vehicle wanders or shimmies.

b. Pusher axle will not raise or lower.

c. Rear axle assembly not tracking properly.

10-2
TM 9-2320-273-20

Table 10-1. Wheel and Tire Troubleshooting Procedures.

MALFUNCTION .

TEST OR INSPECTION.

CORRECTIVE ACTION.

1. TIRES WEARING UNEVENLY:

Step 1. Check wheel alinement if problem is on front wheels.

Aline front wheels (para 10-10).

Step. 2. Check rear brakes for proper adjustment. (Front brakes are self -adjusting.)

Adjust brakes ( para 9-33, 9-34, 939).

Step 3. Check wheel bearing for adjustment, lubrication, and damage.

Adjust, lubricate, or replace (para 10-13, 10-14, 10-15 or 10-16, as

applicable).

2. NOISY OR BUMPING SOUND WHILE TRAVELING ON THE ROAD:

Step 1. Check lug wheel stud cap nuts for proper torque.

Tighten lug nuts to 450 Ib-ft (610 N.m).

Step 2. Inspect U-bolts for tightness.

Tighten U-bolts (125-165 Ib-ft (170-224 N.m) for M915,

200-270 Ib-ft (271-366 N.m) for M916 thru M920).

Step 3. Inspect spring shackle pins for looseness using a pry bar. No noticeable movement

is allowable.

Refer to Direct Support Maintenance.

Step 4. Check wheel bearings for vertical looseness using a prying bar beneath the tire.

Check for proper lubrication and damage.

Adjust, lubricate, or replace bearing (para 10-13, 10-14, 10-15 or 10-16, as

applicable).

Step 5. Inspect rear axle shaft for damage by jacking up both wheels. Turn wheels to one

extreme and rotate one wheel by hand while listening for a rumbling or grinding

sound within the axle. Repeat on other wheel.

Replace axle shaft (para 10-15),

Step 6. Check pusher axle for damaged components or leaking air lines.

Replace components as necessary (para 9-38, 10 16) or contact Direct

Support Maintenance.

Change 1 10-3
TM 9-2320-273-20

Table 10-1. Wheel and Tire Troubleshotting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

2. NOISY OR BUMPING SOUND WHILE TRAVELING ON THE ROAD (Continued):

Step 7. Inspect front driving axle (M916 thru M920) as in Step 5.

Refer to paragraph 10-14 or Direct Support Maintenance.

10-4
TM 9-2320-273-20

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

1. FRONT TIRES WEARING UNEVENLY:

Step 1. Inspect U-bolts for tightness.

Tighten U-bolts (125-165 Ib-ft (170-224 N-m) for M915;

200-270 Ib-ft (271-366 N-m for M916 thru M920.

Step 2. Inspect spring shackle pins for looseness using a pry bar. No noticeable movement

is allowable.

Refer to Direct Support Maintenance.

Step 3. Check wheel bearings for vertical looseness using a pry bar beneath the tire. Check

for proper lubrication and damage,

Adjust, lubricate, or replace bearing (para 10-13 or 10-14, as applicable).

Step 4. Check for proper toe-in (0 to 1/8-inch).

Adjust toe-in (para 10-10).

Step 5. Check brakes for proper adjustment.

Adjust brakes (para 9-31 and 9-32).

2. HARD STEERING:

Step 1. Check oil level in power steering pump.

Fill to proper level (LO 9-2320-273-12).

Step 2. Check all steering linkage for proper lubrication.

Lubricate (LO 9-2320-273-12).

Step 3. Check U-bolts for tightness.

Tighten U-bolts (125-165 Ib-ft (170-224 N-m) for M915;

200-270 Ib-ft (271-366 N-m) for M916 thru M920).

Step 4. Inspect all hydraulic lines and fittings for leakage or damage.

Tighten or replace lines or fittings (para 10-22 and 10-23).

Step 5. Check tie rod for damage or loose ends. No play is allowable.

Tighten or replace (para 10-20).

10-5

Table 10-2. Steering Troubleshooting Procedures.
TM 9-2320-273-20

Table 10-2. Steering Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

2. HARD STEERING (Continued):

Step 6. Inspect drag link for damage.

Replace drag link (para 10-19).

Step 7. Check steering gear for proper adjustment.

Refer to Direct Support Maintenance.

Step 8. Inspect axle shaft for damage (M916 thru M920).

Refer problem to Direct Support Maintenance.

3. VEHICLE WANDERS OR PULLS TO ONE SIDE:

Step 1. Check U-bolts for tightness.

Tighten U-bolts (125-165 Ib-ft (170-224 N.m) for M915,

200-270 Ib-ft (271-336 N-m) for M916 thru M920).

Step 2. Check front spring pin for damage by using a pry bar. No noticeable play is

allowed.

Refer to Direct Support Maintenance.

Step 3. Check auxiliary cylinder for damage (M916 thru M920).

Replace cylinder (para 10-23).

Step 4. Check drag link for damage.

Replace drag link (para 10-19).

Step 5. Check tie rod for looseness or damage.

Adjust or replace tie rod assembly (para 10-20).

Step 6. Check for dragging brake by jacking vehicle and spinning wheel by hand.

Adjust brake (para 9-31 and 9-32).

Step 7. Check hub and drum for damage.

Replace (para 10-13 or 10-14, as applicable).

10-6
TM 9-2320-273-20

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

3. VEHICLE WANDERS OR PULLS TO ONE SIDE (Continued):

Step 8. Check wheel bearing adjustment by using a pry bar. No noticeable play is

allowable. Check for proper lubrication or damage.

Adjust, lubricate, or replace bearing (para 10-13 or 10-14, as applicable).

4. LOST MOTION OR EXCESSIVE PLAY IN STEERING WHEEL:

Step 1. Check free play. Tape a piece of stiff wire or weld rod to the instrument panel so

that one end is near the rim of the steering wheel. Turn the wheel to one extreme

of free travel (wheels do not move) and mark the wheel at the wire. Turn the

wheel the other way to the end of the free play and mark the wire position on the

wheel. Measure the free play around the circumference of the steering wheel.

Maximum free play with engine running is 2-1/2 inches.

Refer to Direct Support Maintenance.

Step 2. Check drag link for looseness or damage.

Replace drag link (para 10-19).

Step 3. Check tie rod for damage or loose end. No free play is allowable in tie rod end.

Adjust or replace tie rod (para 10-20).

Step 4. Check pitman arm for damage.

Replace pitman arm (para 10-21).

Step 5. Check pump reservoir for damage.

Replace reservoir (para 10-22).

Step 6. Check auxiliary cylinder for damage. (M916 thru M920).

Replace cylinder (para 10-23).

5. TEMPORARY INCREASE IN EFFORT WHEN TURNING STEERING WHEEL.

Step 1. Check all steering linkage for proper lubrication.

Lubricate (LO 9-2320-273-12).

Step 2. Check hydraulic reservoir for damage and leakage.

Replace reservoir (para 10-22).

10-7

Table 10-2. Steering Troubleshooting Procedures (Continued).
TM 9-2320-273-20

Table 10-2. Steering Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

5.

6.

TEMPORARY INCREASE IN EFFORT WHEN TURNING STEERING WHEEL (Continued):

Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

Step 8.

Check steering gear mounting bolts for tightness.

Tighten to 180 Ib-ft (244 N-m).

Check steering gear adjustment.

Refer to Direct Support Maintenance.

Check auxiliary cylinder for damage or leakage (M916 thru M920).

Replace cylinder (para 10-23).

Inspect drag link for damage.

Replace drag link (para 10-19).

Inspect tie rod for damage or loose end. No play is allowable.

Replace tie rod end (para 10-20).

(All models except M915). Inspect axle shaft for damage by jacking up both wheels,

turning wheels to one extreme, and rotating one wheel by hand. Listen for rumbling

or grinding sound within the axle. Repeat on other wheel.

Refer to Direct Support Maintenance.

VEHICLE DOES NOT FULLY STEER FROM STOP TO STOP:

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Check all steering linkage for proper lubrication.

Lubricate (LO 9-2320-273-12).

Check pitman arm for damage.

Replace pitman arm (para 10-21).

Check drag link for damage or looseness. No play is allowable.

Replace drag link (para 10-19).

Check the tie rod for damage or loose end. No play is allowable.

Replace tie rod end if loose (para 10-20).

Check steering gear mounting bolts for tightness,

a. Tighten bolts to 180 Ib-ft (244 N.m).

b. Refer to Direct Support Maintenance.

10-8
TM 9-2320-273-20

Table 10-3. Suspension Troubleshooting Procedures

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

1. VEHICLE WANDERS OR SHIMMIES:

Step 1. Check for insufficient lubrication.

Lubricate (LO 9-2320-273-12).

Step 2. Check for loose wheel stud cap nuts.

Tighten nuts to 450 Ib-ft (610 N-m).

Step 3. Check for loose spring U-bolts.

Tighten nuts on U-bolts (125-165 Ib-ft (170-224 N-m) for M915, 200-270

Ib-ft (271-366 N-m) for M916 thru M920).

Step 4. Check wheel bearings for play using a pry bar.

Adjust or replace bearing (para 10-13 or 10-14, as applicable).

Step 5. Inspect tie rod for damage and ends for looseness. No play is allowable.

Replace tie rod end if loose (para 10-20).

Step 6. Inspect drag link for damage.

Replace drag link (para 10-19).

Step 7. Check propeller shafts and universal joints for wear and damage. Wear is

indicated by any movement between the shaft and the joint in any direction.

Replace (para 8-11).

Step 8. Check spring pins for wear using a pry bar, No noticeable movement is allowed.

Refer to Direct Support Maintenance.

Step 9. (N/A M915). Check front axle shaft for damage by jacking up both wheels,

turning wheels to one extreme and rotating one wheel by hand. Listen for a

rumbling or grinding sound within the axle. Repeat on other wheel.

Refer to Direct Support Maintenance.

Change 1 10-9
TM 9-2320-273-20

Table 10-3. Suspension Troubleshooting Procedures (Continued)

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

2. PUSHER AXLE WILL NOT RAISE OR LOWER:

Step 1. Check air bags for damage and leakage by listening for a hissing sound or using a

soap solution and watching for bubbles.

Replace air bags (para 8-14).

Step 2. Check air lines for leakage using a soap solution.

Replace lines (para 8-14 and 8-15).

Step 3. Check lifting bags for damage.

Replace defective bags (para 8-15).

Step 4. Inspect all brackets and connecting arms for bends or other damage.

Refer to Direct Support Maintenance.

Step 5. Check control valves for damage and leakage using a soap solution with valve under

pressure. A 1-inch bubble in 5 seconds is permissible.

Tighten connections and/or replace the control valves (para 8-17 pusher axle

pressure regulator valve, or para 8-18 pusher axle up-down selector valve).

Step 6. Check shock absorbers for damage and tight mounting.

Tighten or replace (para 10-25).

3. REAR AXLE ASSEMBLY NOT TRACKING PROPERLY:

Step 1. (M915, M916, M920). Check fifth wheel for secure mounting. This step applies only

if a trailer is attached.

Tighten, refer to torque table, para 3-9.

Step 2. Check torque rod for security and damage.

Tighten (105 Ib-ft (142 N-m) for the M915, 180 Ib-ft (244 N-m) for the M916 thru

M920), or replace (para 10-26).

Step 3. Check for dragging brake by jacking vehicle and rotating wheels by hand.

Adjust or replace (para 9-33, 9-34). Refer to Direct Support Maintenance.

10-10
TM 9-2320-273-20

Table 10-3. Suspension Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

3. REAR AXLE ASSEMBLY NOT TRACKING PROPERLY (Continued):

Step 4. Check wheel bearing adjustment using a pry bar. No noticeable movement is

allowable. Check for damage and proper lubrication.

Adjust, lubricate, or replace (para 10-15 or 10-16).

Step 5. Check hubs and drums for damage.

Replace (para 10-15 or 10-16).

10-11
TM 9-2320-273-20

Section Ill MAINTENANCE PROCEDURES

This section provides you with Organizational Level maintenance procedures for the wheels,

steering, and suspension systems. To find a specific maintenance procedure, see one of the

following task summaries:

a. Wheels and Tires (para 10-7).

b. Steering Mechanism (para 10-8).

c. Suspension System (para 10-9).

10-12
TM 9-2320-273-20

This page intentionally left blank.

10-13
TM 9-2320-273-20

10-7. WHEEL AND TIRE MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT

APPLICABLE CONFIGURATIONS CONDITION PARAGRAPH CONDITION DESCRIPTION

All. (See TM 9-2320-273-10.) Wheel and Tire Assembly Removed.

(See TM 9-2320-273-10.) Axle Jacked Up.

TEST EQUIPMENT

None.

SPECIAL TOOLS

Toe-in Gage.

Ball Joint Puller.

MATERIALS/PARTS (P/N)

Soap Solution, Hub Cap Gasket, 2208-P-796 (78500).

Hub Gasket, 2208-M-819 (78500). Oil Seal, A-1205-Y-1533 (78500).

Bearing Seal, A-1205-L-1338 (78500). Inner Bearing Seal M915, A-1205-T-696 (78500).

GAA (Refer to Appendix C). M916/M920, A-1 205-T-774

Nonflammable Cleaning Solvent SD-2 (Refer to Appendix C). (78500).

Seal Installer. Outer Bearing Seal M915, A1205-N-612 (78500).

Wheel Bearing Packing Tool. M916/M920, A-1 205-U-619

Wheel Dolly. (78500).

Wheel Bearing Nut Wrench, Star Washers (16), 1229-X-518 (78500).

Permatex (Refer to Appendix C). Gasket (2) M915, 2208-X-440 (78500).

Silicone (RTV) Gasket Material (Refer to Appendix C). M916/M920, 2208-W-41 3 (78500).

Cotter Pin (2) K-2616 (78500). Brass Drift.

Inner Bearing Seal, 1205-P-1212 (78500).

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

One or Two (MOS-63B20). Vehicle Parked on Level Ground.

REFERENCES (TM) GENERAL SAFETY INSTRUCTIONS

TM 9-2320-273-10.

TM 9-2320-273-20P. Wheels Blocked.

LO 9-2320-273-12. Engine OFF.

Transmission in Neutral.

REFERENCES (TROUBLESHOOTING) Park Brake Set

Table 10-1, 10-2, 10-3.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1. Front Wheels Maintenance: 10-10 10-1

A. Checking Alinement. 10-10A

B. Adjustment of Alinement (M915). 10-10B

C. Adjustment of Alinement (M916 thru M920). 10-10C

2. Tire and Tube Maintenance (M915): 10-11 10-1

A. Removal. 10-11A

B. Inspection. 10-11B

C. Installation. 10-11C

10-14
TM 9-2320-273-20

10-7. WHEEL AND TIRE MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

Tire and Tube Maintenance (M916 thru M920): 10-12 10-1

A. Removal. 10-12A

B. Inspection. 10-12B

C. Installation. 10-12C

Front Wheel Bearings and Seals

Maintenance (M915): 10-13 10-2

A. Removal. 10-13A

B. Inspection. 10-13B

C. Packing and Installation of Bearings. 10-13C

Front Wheel Bearings and Seals

Maintenance (M916 thru M920): 10-11 10-2

A. Removal. 10-14A

B. Inspection. 10-14B

c . Packing and Installation of Bearings. 10-14C

Rear Wheel Bearings, Shafts, and Seals

Maintenance: 10-15 10-3

A. Removal. 10-15A

B. Inspection. 10-15B

c . Packing and Installation of Bearings. 10-15C

Pusher Axle Bearings and Seals: 10-16 10-3

A. Removal. 10-16A

B. Inspection. 10-16B

C. Packing and Installation of Bearings. 10-16C

10-15
TM 9-2320-273-20

INITIAL SETUP EQUIPMENT

APPLICABLE CONFIGURATIONS CONDITION PARAGRAPH CONDITION DESCRIPTION

All. 5-67A. Horn Button Assembly Removed.

11-14A or C. Front Fenders Removed.

TEST EQUIPMENT 11-16A. Grille Removed.

None. 5-37A. Batteries Disconnected.

4-18A. Fuel Filter and Adapter Removed.

SPECIAL TOOLS (M916 thru M920).

None.

MATERIALS/PARTS (P/N)

GAA (Refer to Appendix C). Balljoint Puller.

Nonflammable Cleaning Solvent SD-2 (Refer to Appendix C). Jack Stands.

Cotter Pin, 103415 (24617). Power Steering Fluid (Refer to Appendix C).

Cotter Pin, 103389 (24617). Liquid Teflon (Refer to Appendix C).

Snapring, 100475 (15434). Clean Container (Quart).

Gasket, Oil Pump to Adapter (5330-01-071-5727). Grease Gun.

O-Ring, 008771-026 (19954). Plugs.

Wheel Puller. Cable Tie, PLT4H-MO (06383).

Silicone RTV Sealant (Refer to Appendix C). Cable Tie, MS-3367-2-O (96906).

Cotter Pin (2), K-2616 (78500).

PERSONNEL REQUIRED

One or Two MOS-63B20).

REFERENCES (TM) SPECIAL ENVIRONMENTAL CONDITIONS

TM 9-2320-273-10. Vehicle Parked on Level Ground.

LO 9-2320-273-12.

TM 9-2320-273-20P. GENERAL SAFETY INSTRUCTIONS

REFERENCES (TROUBLESHOOTING) Engine OFF.

Table 10-2. Transmission in Neutral.

Park Brake Set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1. Steering Wheel Maintenance: 10-17 10-2

A. Removal. 10-17A

B. Installation. 10-17B

C. Operational Check. 10-17C

2. Lower Steering Shaft Maintenance: 10-18 10-2

A. Removal. 10-18A

B. Disassembly. 10-18B

C. Assembly. 10-18C

10-16

10-8. STEERING MECHANISM MAINTENANCE TASK SUMMARY.
TM 9-2320-273-20

10-8. STEERING MECHANISM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

2. Lower Steering Shaft Maintenance (Continued):

D. Installation. 10-18D

E. Operational Check, 10-18E

3. Drag Link Maintenance: 10-19 10-2

A. Removal. 10-19A

B. Inspection of Mating Connections. 10-19B

C. Installation. 10-19C

D. Operational Check. 10-19D

4. Tie Rod Maintenance: 10-20 10-2

A. Removal. 10-20A

B. Inspection. 10-20B

C. Installation. 10-20C

5. Pitman Arm Maintenance: 10-21 10-2

A. Removal. 10-21A

B. Inspection of Mating Surfaces. 10-21B

C. Installation. 10-21C

6. Hydraulic Power Steering Pump and

Cooler Maintenance: 10-22 10-2

A, Removal. 10-22A

B. Inspection of Lines, Fittings, and Cooler. 10-22B

C. Installation. 10-22C

D. Filling and Bleeding System. 10-22D

E. Operational Check. 10-22E

10-17
TM 9-2320-273-20

10-8. STEERING MECHANISM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

7. Auxiliary Cylinder (M916 Thru M920): 10-23 10-2

A. Removal. 10-23A

B. Inspection. 10-23B

C. Installation. 10-23C

D. Operational Check. 10-23D

10-18
TM 9-2320-273-20

10-9. SUSPENSION SYSTEM MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

TOOLS

None.

MATERIALS/PARTS (P/N)

GAA (Refer to Appendix C).

Shock Absorbers (2) (2540-00-740-961 7).

Rubber Bushings (8) (6365-00-740-9618).

Nonflammable Cleaning Solvent SD-2 (Refer to Appendix C).

Shock Absorbers (2) (2540-01-011-0614).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P. SPECIAL ENVIRONMENTAL CONDITIONS

LO 9-2320-273-12. Vehicle Parked on Level Ground.

REFERENCES (TROUBLESHOOTING)

Table 10-3.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

N O. TASK REF REF (TABLE)

1. Front Axle Shock Absorbers Maintenance

(M91 5): 10-24 10-3

A. Removal. 10-24A

B. Cleaning and Inspection. 10-24B

C. Installation. 10-24C

10-19
TM 9-2320-273-20

10-3

10-9. SUSPENSION SYSTEM MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

2. Pusher Axle Shock Absorbers Maintenance: 10-25 10-3

A. Removal. 10-25A

B. Cleaning and Inspection. 10-25B

C. Installation. 10-25C

3. Torque Rods Maintenance: 10-26

A. Removal (M915). 10-26A

B. Removal (M916 Thru M920). 10-26B

C. Cleaning and Inspection (All). 10-26C

D. Installation (M915). 10-26D

E. Installation (M916 Thru M920). 10-26E

10-20
TM 9-2320-273-20

This page intentionally left blank.

10-21
TM 9-2320-273-20

WHEELS AND TIRES.

10-10. FRONT WHEELS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Checking Alinement. (10)

b. Adjustment of Alinement (M915).

c. Adjustment of Alinement

(M916 thru M920). (25)

35 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

Toe-In Gage.

Ball Joint Puller.

MATERIALS/PARTS (P/N)

Cotter Pin (2) K-2616 (78500).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTiNG REFERENCES

Table 10-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

10-22
TM 9-2320-273-20

WHEELS AND TIRES.

10-10. FRONT WHEELS MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

NOTE

Before checking or adjusting toe-in, be

sure tires are properly inflated (see

TM 9-2320-273-10), Truck should be

parked in a level area, When parking

truck, straighten wheels and pull straight

forward for final fifteen feet.

1. Front wheels - front side. a. Place toe-in gage ( 1 ) See illustration below.

between wheels on front

side. Chain should just

touch ground.

10-23
TM 9-2320-273-20

WHEELS AND TIRES.

10-10. FRONT WHEEL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

b. Set gage pointer (2) See illustration below.

2. Front wheels - back side.

c.

a.

b.

to zero.

Remove gage.

Place gage between

front wheels on back

side. Chains should

just touch ground.

Gage should read 0-1/8

inch (0-3.175 mm).

Adjust toe-in (step 8)

if necessary.

10-24
TM 9-2320-273-20

WHEELS AND TIRES.

10-10. FRONT WHEEL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

3. Two bolts ( 1), Iockwashers Loosen.

(2), and clamp nuts (3).

4. Tie rod (4). Screw further onto ball joint

(5) to decrease toe-in. Unscrew

to increase toe-in.

5. Front wheels. a. Check toe-in (para A).

b. Repeat adjustment procedure

until toe-in is 1/16 1/16

inch (1.6 1.6 mm).

6. Two bolts (1), Iockwashers Tighten clamp nut to

(2), and clamp nuts (3). 40-55 Ib-ft (54-68 N-m).

10-25
TM 9-2320-273-20

WHEELS AND TIRES.

10-10. FRONT WHEEL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

7.

8.

9.

10.

11.

I 2.

13.

NOTE

Do one end at a time because you have

to drop the tie rod to adjust.

Bolt (2), Iockwasher (8) Loosen from clamp (5),

and clamp locknut (4).

Cotter pin (1) and Remove from top stud of balI

castellated nut (9). joint (6).

Ball joint (6). a.

b.

c.

Use ball joint puller and

remove from steering knuckle

(7), or tap with rawhide hammer.

Screw ball joint in to tie rod (3)

to decrease toe-in and out to

increase toe-in.

Repeat adjustment procedure

until toe-in is 1/16 + 1/16 inch

(1.6 +1.6 mm).

Bolt (2), Iockwasher (8) Torque to 40-55 Ib-ft (54-68 N-m).

and clamp locknut (4).

Ball joint (6). Install back into steering knuckle (7).

Castellated nut (9). a. Install on top stud of ball joint (6).

b. Torque to 110-125 Ib-ft (149-169

N-m).

Cotter pin (1). Insert new cotter pin through nut (9)

and top ball joint stud; then bend

ends over.

10-26
TM 9-2320-273-20

WHEELS AND TIRES.

10-10. FRONT WHEEL MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

10-27
TM 9-2320-273-20

WHEELS AND TIRES.

10-11. TIRE AND TUBE MAINTENANCE (M915).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Inspection. (10)

c. Installation. (30)

60 Minutes Total,

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915. (See TM 9-2320-273 -10.) Wheel and Tire Assembly

TEST EQUIPMENT Removed.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Soap Solution.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 10-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

Wheels Blocked.

10-28
TM 9-2320-273-20

WHEELS AND TIRES.

10-11. TIRE AND TUBE MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

Always remove the valve core and exhaust

all air from a single tire and from both

tires of a dual assembly prior to removing

any rim components, or any wheel components, such as nuts and rim clamps.

Check the valve stem by running a piece of

wire through the stem to make sure it is

not plugged.

10-29
TM 9-2320-273-20

WHEELS AND TIRES.

10-11. TIRE AND TUBE MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

1. Valve cap (7). Remove. Cap can also be used to

remove core.

2. Valve stem (6). Remove core with valve core

removing tool or valve cap.

3. Tire (1). Use gooseneck tool to free A heavy soft headed mallet

tire bead from Iockring (3) may be helpful in breaking

all around tire. tire loose from Iockring.

4. Lockring (3). Use rim tool to pry Iockring

(3) free from rim (2).

5. Tire (1) and rim (2) a. Turn over.

assembly. b. Use gooseneck tool to

separate second tire bead

from rim.

c. Remove tire (1), inner

liner (4) and tube (5).

6. Tube (5) and inner Remove from tire (1).

liner (4).

7. Tire (1), tube (5) Inspect for: Replace, if necessary, or

and inner liner (4). a. Excessive wear. repair.

b. Uneven wear.

c. Cracks. See TM 9-2610-200-20 for

d. Leaks. information on pneumatic

tires and tubes.

8. Rim (2). Inspect for: Replace, if necessary.

a. Rust streaks.

b. Corrosion. For rust streaks or corrosion,

c. Cracked rims. wire brush and repaint.

d. Damaged threads on studs.

e. Wheel cracks.

10-30
TM 9-2320-273-20

WHEELS AND TIRES.

10-11. TIRE AND TUBE MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

Mismatched tires will make truck handle

poorly and may cause accidents. All tires

on an axle should have the same diameter,

 1/8 inch (3.2 mm). When replacing a

tire, measure it and the other tires on the

axle to be sure that the distances from top

to bottom do not vary by more than 1/4

inch (6.4 mm). Use a depth gage to

measure tires.

10-31
TM 9-2320-273-20

WHEELS AND TIRES.

10-11. TIRE AND TUBE MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

9. Tire (1), tube (5), rim

(2) and inner liner (4).

a.

b.

c.

d.

Place tube in tire.

Place liner over tube.

Lubricate both beads of

tire with soap solution

and, using gooseneck tool,

work both tire beads onto

rim.

Place valve stem (6)

through hole in rim.

10. Lockring (3). Set in place.

Heavy hammer blows will damage rim.

bead into rim gently.

11. Lockring (3). a.

b.

c.

d.

Insert one end into rim (2).

Walk along ring to push it

into place.

Tap final few inches into

rim with hammer.

Check to be sure that ring

is securely seated all the

way around.

Rim should be laying with

outer side on top.

Tap

10-32
TM 9-2320-273-20

WHEELS AND TIRES.

10-11. TIRE AND TUBE MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

When inflating tires (wheel removed from

vehicle) always use safety cage to prevent

injury if ring should fly off.

12. Tire and wheel a. Place in safety cage and

assembly. inflate.

b. Install valve cap.

c. Mount on truck (see

TM-9-2320-273-10).

10-33
TM 9-2320-273-20

WHEELS AND TIRES.

10-12. TIRE AND TUBE MAINTENANCE (M916 THRU M920)

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Inspection. (10)

c. Installation. (30)

60 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 thru M920. (See TM 9-2370-273-10). Wheel and Tire Assembly

TEST EQUIPMENT Removed.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (PIN)

Soap Solution.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

Wheels Blocked.

TROUBLESHOOTING REFERENCES

Table 10-1.

10-34
TM 9-2320-273-20

WHEELS AND TIRES.

10-12. TIRE AND TUBE MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

Always remove the valve core and exhaust all

air from a single tire and from both tires of a

dual assembly prior to removing any rim

components, or any wheel components, such

as nuts and rim clamps.

Check the valve stem by running a piece of

wire through the stem to make sure it is not

plugged.

1. Valve cap (8). Remove. Cap can also be used to

remove core.

2. Valve stem (7). Remove core with valve core

removing tool, or valve cap.

10-35
TM 9-2320-273-20

10-12. TIRE AND TUBE MAINTENANCE (M916 THRU M920) (Continua).

LOCATION/ITEM ACTION REMARKS

3. Tire (1). Use gooseneck tool to free A heavy soft headed mallet

tire bead from side ring may be used in breaking tire

all around tire. loose from ring.

4. Lockring (4) and a. Use rim tool to pry side

side ring {3). ring (3) free from rim (2).

b. Remove both rings.

5. Tire (1) and rim (2). a. Turn over.

b. Use gooseneck tool to

separate second tire bead

from rim.

c. Remove tire (1), inner

liner (5) and tube (6).

6. Tube (6) and inner liner (5). Remove from tire (1).

7. Tire (1) tube (6) and Inspect for: Replace, if necessary, or

inner liner (5). a. Excessive wear. repair.

b. Uneven wear. See TM 9-2610-200-20

c. Cracks. for information on pneumatic

d. Leaks. tires and tubes.

8. Rim (2). Inspect for: Replace, if necessary.

a. Rust streaks.

b. Corrosion.

For rust streaks or corrosion,

wire brush and repaint.

c. Cracked rims.

d. Damaged threads on studs.

e. Wheel cracks.

10-36

WHEELS AND TIRES
TM 9-2320-273-20

WHEELS AND TIRES

10-12. TIRE AND TUBE MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION.

Mismatched tires will make truck handle poorly and

may cause accidents. All tires on an axle should have

the same diameter, ± 1/8 inch (3.2 mm) when replacing a tire, measure it and the other tires on the axle to

be sure that the distances from top to bottom do not

vary by more than 1/4 inch (6.4 mm). Use a depth

gage to measure tires.

9. Tire (1), tube (6), a. Place tube in tire.

rim (2), and inner

liner (5). b. Place liner over tube.

c. Lubricate both beads of

tire with soap solution.

d. Place valve stem (7) Rim should be laying

through hole in rim. with outer side on top.

10-37
TM 9-2320-273-20

WHEELS AND TIRES.

D-12. TIRE AND TUBE MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

Heavy hammer blows will damage rim. Tap

bead into rim gently.

10. Lockring (4).

11. Tire and wheel

assembly.

a.

b.

c.

d.

e.

Insert one end into rim (2).

Walk along ring to push it

into place.

Tap final few inches into

gutter with hammer.

Check to be sure that ring

is securely seated all the

way around.

Install side ring (3).

When inflating tires (wheel removed from

vehicle) always use a safety cage to prevent

injury if ring should fly off.

a. Place in safety cage and

inflate.

b. Install valve cap.

c. Mount on truck (see

TM 9-2320-273-10).

10-38
TM 9-2320-273-20

WHEELS AND TIRES.

10-12. TIRE AND TUBE MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

10-39
TM 9-2320-273-20

WHEELS AND TIRES.

10-13. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M915).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Inspection. ( 5 )

c. Packing and Installation of Bearings. (30)

45 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915. (See TM 9-2320-273-10). Axle Jacked-Up.

TEST EQUIPMENT

(See TM 9-2320-273-10). Wheel and Tire Assembly

Removed.

None.

SPECIAL TOOLS

Outside Wheel Bearing Nut Wrench, P/N 1920 (45152)

NSN 5120-01-089-9068.

Inside Wheel Bearing Nut Wrench, P/N 1922 (45152)

NSN 5120-01-112-0593.

MATERIALS/PARTS (P/N)

Seal Installer.

Wheel Bearing Packing Tool.

Hub Gasket, 2208-M-819 (78500).

Bearing Seal, A-1 205-L-1338 (78500).

GAA (Refer to Appendix C).

Washer.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 10-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

Wheel Blocked.

10-40 Change 2
TM 9-2320-273-20

WHEELS AND TIRES.

10-13. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

1. Drum (7).

2. Six capscrews (6)

and washers (5)

3. Hub cap (8) and

gasket (9)

4. Nut (10), washer (11),

and Iockring (12).

5. Nut (13).

6. Outer Bearing (14).

7. Hub (1).

Remove. It may be necessary to tap

with hammer to break drum

loose.

Unscrew and remove.

a. Remove.

b. Throw gasket away.

Remove. Install new washer (11).

Remove.

Remove.

a. Remove.

b. Damaged wheel studs (16)

can be removed with an

arbor press and a new stud

pressed in.

Change 2 10-41
TM 9-2320-273-20

WHEELS AND TIRES

10-13. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M1915) (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

8. Seal (4) and inner Remove and throw Tap out from inside of

bearing (3). seal away. hub (1) using hammer

and wood block.

9. Cup (2). Remove.

10. Cup (15). Remove.

NOTE

Clean all component parts with SD-2 solvent.

Do not use compressed air to clean bearings.

B. INSPECTION.

11. Inner bearing (3) and Inspect for: Replace as necessary.

outer bearing (14). a. Flat spots or chips in

bearing rollers.

b. Cracks.

c. Breaks.

d. Smooth operation.

e.Discoloration.

12. Cups (2) and (15). Inspect for:

a. Flat spots.

b. Cracks.

c. Gouges.

d. Discoloration.

13. Axle spindle. Inspect for:

a. Grooves.

b. Gouges.

c. Abnormal wear.

d. Discoloration.

NOTE

All component parts must be clean and

free of all dirt and foreign matter.

Replace as necessary.

Notify Direct Support

Maintenance.

10-42
TM 9-2320-273-20

WHEELS AND TIRES.

10-13. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M915) (Continued).

LOCATION/lTE M ACTION REMARKS

C. PACKING AND INSTALLATION OF BEARINGS.

14. Inner bearing (3) and

outer bearing (14).

15. Cup (2).

16. Inner bearing (3).

17. Seal (4).

18. Cup (15).

19. Hub (1).

20. Outer bearing (14).

Use bearing packing tool

and pack bearings. If

packing tool is not available, bearings may be

hand packed.

Place in hub (1).

Place in cup (2).

Tap new seal in hub (1), Lettering on seal should

using a seal installer. face truck.

Place in hub (1).

Place in axle spindle.

Place in cup (15).

Change 2 10-43
TM 9-2320-273-20

WHEELS AND TIRES.

10-13. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

21. Preload nut (13). a. Install the preload nut Alining pin must face out.

using wheel bearing nut

wrench.

b. If reusing the same bearings, torque to 50 Ib-ft

(68 N•m) while rotating

wheel in both directions.

c. If new bearings have been

installed, torque to 100

Ib-ft (136 N•m) while

rotating wheel in both

directions, back off to

0 Ib-ft. Torque to 50

Ib-ft {68 N•m).

d. Back off preload nut

no more than 1/4 turn

counterclockwise to

install cotter pin.

10-44 Change 2
TM 9-2320-273-20

WHEELS AND TIRES.

10-13. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARKS

22. Lockring (12). Install.

23. Washer (11). Slide over axle.

24. Locknut (10). a. Install.

b. Torque to 125 Ib-ft

(169.5 N•m).

25. Washer (11). Bend tabs over nut (10).

26. Deleted.

27. Gasket (9) and hubcap (8). Align with hub (1).

28. Six capscrews (6) and

washers (5

29. Drum (7).

a. Install.

b. Torque to 9-12 Ib-ft

(12-16 N•m).

Place over hub (1) and seat

into position by installing

two nuts equally spaced, then

remove nuts and install tire

and wheel assembly. Reinstall lug nuts and torque

lug nuts to 450 Ib-ft (610

N•m) (see TM 9-2320-273-10).

30. Remove jack. Road test vehicle.

NOTE

Follow-on maintenance action required:

Install wheel and tire, road test vehicle,

refer to TM 9-2320-273-10.

Adjust nut (13) to slip into

nearest hole in Iockring (12).

See inset for sequence.

Lug nuts on left side of vehicle

are left-handed threads.

Change 2 10-44.1/10-44.2 (blank)

TM 9-2320-273-20

WHEELS AND TIRES.

10-13. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M915) (Continued).

LOCATION/lTEM ACTION REMARK S

Change 2 10-45
TM 9-2320-273-20

WHEELS AND TIRES.

10-14. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M916 THRU M920).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (25)

b. Inspection of Bearings. ( 5 )

c. Packing and Installation of Bearings. (30)

60 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 Thru M920. (see TM 9-2320-273-10). Front Axle Jacked Up.

TEST EQUIPMENT (see TM 9-2320-273-10). Wheel Removed.

None.

SPECIAL TOOLS

Wheel Bearing Nut Wrench, PN 1919 (45152)

Part of Wrench Set, NSN 5120-00-169-4586.

MATERIALS/PARTS (P/N)

Wheel Dolly.

Wheel Bearing Nut Wrench.

Permatex (Refer to Appendix C).

Silicone (RTV) Gasket Material (Refer to Appendix C).

Oil Seal, A-1205-Y-1533 (78500).

GAA (Refer to Appendix C).

PERSONNEL REWIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 10-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

Wheels Blocked.

10-46 Change 2
TM 9-2320-273-20

WHEELS AND TIRES.

10-14. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

Block rear wheels of truck to keep it

from rolling. Block up axle so that

truck will not fall if jacks give way.

Eight capscrews (13)

and washers (12).

2. Drive flange (11).

Unscrew and remove.

a. Remove.

b. Drive out expansion plug

(14) with hammer and

punch.

Several blows with a hammer may

be needed to loosen drive flange.

Do not hit studs.

Replace expansion plug (14)

only if damaged.

Change 2 10-47
TM 9-2320-273-20

WHEELS AND TIRES.

10-14. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

3. Jam Nut (10), retainer (9), Use wheel bearing nut wrench

and bearing adjusting nut (8). to remove.

NOTE

Outer bearing cone (7) is loose and will

will drop out when hub is removed and shook.

4. Hub and drum assembly (5). Remove.

5. Oil seal (2), and inner bearing a. Remove.

cone (3). b. Throw away oil seal (2).

6. Inner and outer bearing cups a. Clean and inspect these items.

(4) and (6). If discoloration or pitting is

noted, refer problem to DS/GS,

as inner and outer bearings cups

(4) and (6) must be pressed out

and in.

b. Damaged wheel studs (15) can Wheel studs ( 15) on

be pressed out and installed left side of vehicle will

with an arbor press. have LH threads and

RH threads on right

side of vehicle.

7. Inner and outer bearing a. Inspect for:

cones (3) and (7). 1. Missing rollers. Replace if necessary.

2. Flat, chipped, or pitted

surfaces.

3. Secure fit.

b. If bearings are to be reused: See TM 9-214 fpr infor1. Remove surface oil and

mation on maintenance

of bearings.

gum deposits.

2. Soak in hot oil (140°F, 60°C)

to loosen hardened oil and

grease.

3. Wipe dry. Do not use

compressed air.

4. Coat with a light film of oil.

Wrap bearings in paper until

you are ready to install.

10-48 Change 2
TM 9-2320-273-20

WHEELS AND TIRES.

10-14. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/ITEM ACTION REMARKS

C. PACKING AND INSTALLATION OF BEARINGS.

8. Inner bearing cone (3). a. Use bearing packing tool

to pack with grease, or

pack by hand.

b. Place in hub and drum assembly

(5) so that smaller end will

point away from truck.

9. New oil seal (2). Place in hub and drum assembly (5).

Do not use excessive pressure to install

seal. Do not tap seal after it has bottomed. These actions will crush the set

sleeve and damage the seal.

Change 2 10-49
TM 9-2320-273-20

WHEELS AND TIRES.

10-14. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M916 THRU M920) (Continued.

LOCATION/lTEM ACTION REMARKS

C. PACKING AND INSTALLATION OF BEARINGS (Continued).

Be careful not to damage oil seal

(2) as you install the hub and

drum assembly.

10. Hub and drum assembly (5). a. Mount assembly on

spindle (1).

b. Press hub until inner bearing

cone (3) is seated flush on

spindle.

11. Outer bearing cone (7). a. Use wheel bearing packing

tool to pack with grease, or

pack by hand.

b. Place on spindle (1) against

outer bearing cup (6). Small

end of bearing shoud point

towards truck.

10-50
TM 9-2320-273-20

WHEELS AND TIRES.

10-14. FRONT WHEELS BEARINGS AND SEALS MAINTENANCE (M916 THRU M920 (Continued.

LOCATION/lTEM ACTION REMARKS

Change 2 10-51
TM 9-2320-273-20

WHEELS AND TIRES.

10-14. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

C. PACKING AND INSTALLATION OF BEARINGS (Continued).

12. Preload nut (8).

13. Retainer (9) and locknut (10).

a.

b.

c.

d.

a.

b.

Install the preload nut

using wheel bearing nut

wrench.

If reusing the same bearings,

torque to 50 Ib-ft (68 N•m)

while rotating wheel in both

directions.

If new bearings have been

installed, torque to 100 lb-ft

(136 N•m). While rotating

wheel in both directions,

back off to 0 Ib-ft. Torque

to 50 Ib-ft (68 N•m).

Back off preload nut no

more than 1/4 turn

counterclockwise to instalI cotter pin.

Screw onto spindle (1).

Tighten locknut (10) to

250 to 400 Ib-ft, (340-

544 N•m).

10-52 Change 2
TM 9-2320-273-20

WHEELS AND TIRES.

10-14. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

C. PACKING AND INSTALLATION OF BEARINGS (Continued).

14.

15.

16.

Drive flange (11). a. Coat inside surface with

silicone (RTV) gasket material.

b. Attach to hub with eight capscrews (13) and washers (12).

c. Install expansion plug (14),

if removed.

Eight capscrews (13) Tighten to 175-205 Ib-ft (237-

and washers (12). 282 N•m) with torque wrench.

Tighten as shown.

Tire and wheel assembly Install (refer to TM 9-2320-273-10).

Tighten wheel stud nuts (15) with

torque wrench to 450 Ib-ft (610 N•m),

in sequence shown.

Change 2 10-52.1/10-52.2 (blank)

TM 9-2320-273-20

WHEELS AND TIRES.

10-14. FRONT WHEEL BEARINGS AND SEALS MAINTENANCE (M916 THRU M920) (Continued).

LOCATION\lTEM ACTION REMARKS

Change 2 10-53
TM 9-2320-273-20

WHEELS AND TIRES.

10-15. REAR WHEEL BEARINGS, SHAFTS, AND SEALS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REWIRED FOLLOWS TASK DESCRIPTION.)

a. Removal.

(25)

b. Inspection of Bearings.

( 5)

c. Packing and Installation of Bearings. (30)

60 Minutes Total

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

Wheel Bearing Nut Wrench, PN 1914 (45152)

Part of Wrench Set, NSN 5120-00-169-4586.

MATERIALS/PARTS (P/N)

Non-Flammable Cleaning Solvent SD-2 (Refer to Appendix C).

Inner Bearing Seal M915 (A1205-T-696) M916 Thru M920 (A1205-T-774) (78500).

Outer Beering Seal M915 (A1205-N-612) M916 Thru M920 (A1205-4-619) (78500).

Star Washers (16) (1229-X-518) (78500).

Gasket (2) M915 (2208-X-440) M916 Thru M920 (2208-W-413) (78500).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 10-3.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

Wheels Blocked.

10-54 Change 2
TM 9-2320-273-20

WHEELS AND TIRES.

10-15. REAR WHEEL BEARINGS, SHAFTS, AND SEALS MAINTENANCE.

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Eight nuts (6) and a. Remove.

star washers (5). b. Throw away star washers (5).

Do not pry between flange of axle shaft (3)

and mating surface of hub. Do not hit studs (13).

Change 2 10-55
TM 9-2320-273-20

WHEELS AND TIRES.

10-15. REAR WHEEL BEARINGS, SHAFTS, AND SEALS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

2. Axle shaft (3) and eight a. Use slidge hammer to Do not hit studs (13).

tapered spacers (4). pound until tapered

spacers (4) loosen.

b. Remove.

3. Two gaskets (1), bearing a. Remove. Replace outer oil seal wiper

seal (2), and outer oil seal (8), if damaged.

wiper (8).

b. Throw away bearing seal

(2) and two gaskets (1).

4. Locknut (9), keyed Remove with wheel nut wrench.

spacer (10), and

preload nut (11).

5. Outer wheel bearing (12). Pull out.

Do not depend on jacks to support truck.

Block it securely so that it will not fall if

jack gives way.

6. Rear wheels Jack up (see TM 9-2320-273-10).

7. Wheel, hub, and drum Remove.

assembly (7).

8. (M915 Only) Oil Slinger Remove.

(14), five washers (15)

and capscrews (16).

9. Inner bearing seal (18), a. Remove. a. YOU should now be reachinner wheel bearing (17), ing into the side of the hub

and inner oil seal wiper (19). that was facing the truck.

b. Throw away inner bearing b. Replace inner oil seal wiper

seal (18). (18), if damaged.

10-56 Change 2
TM 9-2320-273-20

WHEELS AND TIRES.

10-15. REAR WHEEL BEARINGS. SHAFTS, AND SEALS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

10. Outer wheel bearing (12) and Replace, if necessary.

a. Inspect for:

1. Missing rollers.

2. Flat, chipped, or

pitted surfaces.

3. Discoloration.

4. Secure fit.

Change 2 10-57

inner wheel bearing (17).
TM 9-2320-273-20

WHEELS AND TIRES.

10-15. REAR WHEEL BEARINGS, SHAFTS, AND SEALS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

10. Outer wheel bearing (12) b. If bearings are to be reused:

and inner wheel bearing 1. Remove surface oil and

(17) (continued). gum deposits.

2. Clean with solvent.

3. Wipe dry, Do not use See TM 9-214 for information

compressed air. on maintenance.

4. Coat with a light film of

oil. Wrap bearings in paper

until you are ready to

install them.

11. (M915 only) Oil slinger Install.

(14), five washers (15)

and capscrews (16).

12. Inner wheel bearing (17). a. Use bearing packing tool

to pack with grease.

b. Place in wheel/hub/drum

assembly (7) so that smaller

end will point away from

truck.

13. New inner bearing seal (18) Place over inner wheel bearing

and inner oil seal wiper (19). (17) in wheel/hub/drum assembly (7). Lettering should face

truck when wheel is mounted.

14. Wheel/hub/drum assembly Place in position over brake

(7). (20), using wheel dolly.

15. Outer wheel bearing (12). a. Use bearing packing tool

to pack with grease.

b. Place on hub with small

end towards truck.

10-58 Change 2
TM 9-2320-273-20

WHEELS AND TIRES.

10-15. REAR WHEEL BEARINGS, SHAFTS, AND SEALS MAINTENANCE (Continued).

LOCATION/lTEM ACTIO N REMARKS

C. PACKING AND INSTALLATION OF BEARINGS.

16. Preload nut (11).

17. Keyed spacer (10) and

locknut (9).

a. Install preload nut using

wheel bearing nut wrench.

b. If reusing the same bearings, torque to 50 Ib-ft

(68 N•m) while rotating

wheel in both directions,

c. If new bearings have been

installed, torque to 100 Ib-ft

(136 N•m) while rotating

wheel in both directions,

back off to 0 Ib-ft. Torque

to 50 Ib-ft.

d. Back off preload nut no

more than 1/4 turn

counterclockwise.

a. Install with wheel bearing

nut wrench.

b. Torque locknut (9) to

250-400 Ib-ft (340-

544 N•m).

Change 2 10-58.1/10-58.2 (blank)

TM 9-2320-273-20

WHEELS AND TIRES.

10-15. REAR WHEEL BEARINGS, SHAFTS, AND SEALS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. PACKING AND INSTALLATION OF BEARINGS (Continued)

18. New bearing seal (2), two Put in place over studs (13).

new flange gaskets (1), and

outer oil seal wiper (8).

19. Axle shaft (3). Set in place.

20. Eight tapered spacers (4), star Screw on. Tighten to 175 Ib-ft

washers (5), and nuts (6). (237 N•m) with torque wrench.

Tighten in this order:

NOTE

Follow-on maintenance action required:

After road testing vehicle, check for oil leaks.

Change 2 10-59
TM 9-2320-273-20

WHEELS AND TIRES.

10-16. PUSHER AXLE BEARINGS AND SEALS.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (30)

b. Inspection. (10)

c. Packing and Installation of Bearings. (30)

70 minutes Total.

INITIAL SETU P EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M917, M919, M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

Outside Wheel Bearing Nut Wrench, PN 1909, Part of Set NSN 5120-00-169-4586.

Inside Wheel Bearing Nut Wrench, PN 1927, Part of Set NSN 5120-00-169-4586.

MATERIALS/PARTS (P/N)

Seal Installer.

Brass Drift.

GAA (Refer to Appendix C).

Non-Flammable Cleaning Solvent SD-2 (Refer to Appendix C).

Inner Bearing Seal, 1205-P-1212 (78500).

Hub Cap Gasket, 2208-P-796 (78500).

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 10-3.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Sat.

Wheels Blocked.

10-60 Change 2
TM 9-2320-273-20

WHEELS AND TIRES.

10-16. PUSHER AXLE BEARINGS AND SEALS (Continued).

LOCATION/lTEM ACTION REMARKS

1.

2.

3.

4.

5.

6.

7.

8.

Axle.

Tire/hub assembly (5).

Six capscrews (14)

and washers (15).

Hub cap (13) and

gasket (12).

Allen head setscrew

(10).

Outer locknut (11).

Lockring (9).

Preload nut (8).

Jack up.

Place on wheel dolly.

Remove.

Remove.

Remove.

Remove.

Remove.

Remove.

Discard gasket.

Change 2 10-6
TM 9-2320-273-20

WHEELS AND TIRES.

10-16. PUSHER AXLE BEARINGS AND SEALS (Continued).

LOCATION/lTEM ACTION REMARKS

 A. REMOVAL (Continued).

9. Outer bearing (7). Remove.

10. Tire/hub assembly (5). Slide off axle shaft (1).

11. Inner bearing (3) Remove. Use hammer and brass drift.

and seal (2). Tap out bearing and seal.

Discard seal (2).

NOTE

Clean all parts with cleaning solvent SD-2.

Do not use compressed air to clean bearings.

12. Inner bearing (3) and Inspect for: Replace as necessary.

outer bearing (7). a. Cracks. Refer to TM 9-2320-273-20P.

b. Chips.

c. Breaks.

d. Flat spots on rollers.

e. Smooth operation.

f. Discoloration (straw

colored or bluish tint).

13. Cups (4) and (6). Inspect for: Refer to Direct Support

a. Flat Spots. Maintenance. If replacement

b. Roughness. is needed, cups must be

c. Cracks. pressed out and in.

d. Gouges.

e. Wear.

f. Discoloration (straw

colored or bluish tint).

14. Axle Shaft (1). Inspect for: Refer to Direct Support

a. Grooves. Maintenance. If replacement

b. Gouges. is needed, cups must be

c. Abnormal wear. pressed out and in.

d. Discoloration.

10-62
TM 9-2320-273-20

WHEELS AND TIRES.

Use hammer and seal

installer.

10-16. PUSHER AXLE BEARING AND SEALS (Continued).

LOCATION/lTEM ACTION REMARKS

C. PACKING AND INSTALLATION OF BEARINGS.

15. Inner bearings (3). a. Use bearing packing tool

to pack with grease or

pack by hand.

b. Place in cup (4) inside

of hub (5).

16. New seal (2). Tap in place.

17. Tire/hub assembly (5). Slide over axle shaft (1),

using wheel dolly.

18. Outer bearing (7). a. Use bearing packing

tool to pack with grease

or pack by hand.

b. Insert in cup (6) inside

of hub (5).

Change 2 10-63
TM 9-2320-273-20

WHEELS AND TIRES.

10-16. PUSHER AXLE BEARINGS AND SEALS (Continued).

LOCATION/lTEM ACTION REMARKS

C. PACKING AND INSTALLATION OF BEARINGS (Continued).

19. Preload nut (8).

20. Lockring (9).

21. Outer locknuts (11).

a. Install preload nut using

wheel bearing nut wrench.

b. If reusing the same bearings, torque to 50 Ib-ft

(68 N•m) while rotating

wheel in both directions.

c. If new bearings have been

installed, torque to 100

Ib-ft (136 N•m) while rotating wheel in both directions, back off to 0 Ib-ft.

Torque to 50 Ib-ft (68 N•m).

d. Back off preload nut no

more than 1/4 turn counterclockwise to install cotter

pin.

Install.

a.

b.

Install.

Torque to 250-300 Ib-ft

(339-406.8 N•m).

Alining pin (16) must face

toward Iockring (9).

Adjust preload nut (8) so that

alining pin (16) slips into nearest

hole in Iockring (9).

10-64 Change 2
TM 9-2320-273-20

WHEELS AND TIRES.

10-16. PUSHER AXLE BEARINGS AND SEALS (Continued).

LOCATION/lTEM ACTION REMARKS

C. PACKING AND INSTALLATION OF BEARINGS (Continued).

22. Setscrew (10). Install in one of four

tappings.

23. Gasket (12) hub Line up holes.

cap (13).

24. Capscrews (14) and Tighten to 25–31

washers (15). Ib-ft (33.90–42.04 N•m)

in sequence shown.

25. Jack. Remove from axle.

Change 2 10-65
TM 9-2320-273-20

STEERING MECHANISM.

10-17. STEERING WHEEL MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (7)

b. Installation. (7)

c. Operational Check. (1)

15 Minutes Total.

INITIAL SETU P EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-67A. Horn Button Assembly

TEST EQUIPMENT

Removed.

5-37A. Batteries Disconnected.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Wheel Puller.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P:

TROUBLESHOOTING REFERENCES

Table 10-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

10-66
TM 9-2320-273-20

STEERING MECHANISM.

10-17. STEERING WHEEL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Nut(1). Unscrew and remove.

2. Steering wheel (2). Remove using suitable wheel

puller.

B. INSTALLATION.

3. Steering wheel (2). Place on steering column.

Turn gently to seat splines.

4. Nut (1). Screw onto shaft (3)

and tighten.

C. OPERATIONAL CHECK.

5. Engine. Start up (see TM 9-2320-273-10).

6. Steering wheel (2). Turn both directions.

Check that front wheels turn.

Follow on Maintenance.

a. Install horn button assembly

(para 5-67B).

b. Connect batteries (para 5-37B).

10-67
TM 9-2320-273-20

STEERING MECHANISM.

10-18. LOWER STEERINGSHAFT MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Disassembly. (18)

c. Assembly.

d. Installation. (18)

(30)

e. Operational Check. (2)

78 Minutes Total.

INITIAL SETU P EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

GAA (Refer to Appendix C).

Non-Flammable Dry Cleaning Solvent SD-2 (Refer to Appendix C).

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 10-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

10-68
TM 9-2320-273-20

STEERING MECHANISM

10-18. LOWER STEERING SHAFT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Turn wheels to left for better access.

1. Nut (1), washer (8), Unscrew and remove.

and capscrew (12).

2. Yoke (11). Remove from steering gear (6).

3. Nut (7), washer (2), Unscrew and remove.

and capscrew (5).

4. Universal joint yoke Slide off of upper

(3). steering shaft (4).

10-69
TM 9-2320-273-20

STEERING MECHANISM

10-18. LOWER STEERING SHAFT MAINTENANCE (Continued).

LOCATION/lTEM ACTIO N REMARKS

A. REMOVAL (Continued).

5. Lower steering shaft (10). Remove through firewall U-Joints and yokes will still

from under hood. be attached.

B. DISASSEMBLY.

Tap bearings only hard enough to break

them away from snap rings.

6. Four snap rings (14). Remove.

7. Four bearings (15). Remove. You can push out the first

bearing of each yoke by pressing gently on the opposite

bearings. Press cross end to

push out second bearing.

8. Three grease fittings (17). Remove from two crosses Check for thread or ball tip

(16) and lower steering damage and replace as

shaft (10). necessary.

9. Two crosses (16) and four Separate.

yokes (9), (11), and (3).

10. Lower steering shaft (10). Slide splined sections apart.

11. Dust cap (13). Inspect. If damage is evident, remove

by prying up tabs and install

new dust cap by staking tabs

with a center punch.

COMPRESSED AIR USED FOR CLEANING

PURPOSES WILL NOT EXCEED 30 PSI.

USE ONLY WITH EFFECTIVE CHIP

GUARDING AND PERSONAL PROTECTIVE

EQUIPMENT (GOGGLES/SHIELD, GLOVES,

ETC).

10-70
TM 9-2320-273-20

STEERING MECHANISM

10-18. LOWER STEERING SHAFT MAINTENANCE (Continued).

LOCATlON/ITEM ACTION REMARKS

12.

Do not allow SD-2 dry cleaning solvents to come in

contact with seals or flexible hoses. These cleaners

may damage leather, rubber, and synthetic materials.

Four yokes (3), (9), (11), a. Clean with SD-2 dry cleaning

two crosses (16), and solvent and dry with comeight bearings (15). pressed air.

b. Inspect for cracks, wear, Use Fine stone to remove Iight

nicks, burrs, and scratches. marks. Replace as necessary

as a set.

10-71
TM 9-2320-273-20

STEERING MECHANISM

10-18. LOWER STEERING SHAFT MAINTENANCE (Continued).

LOCATION/lTE M ACTION REMARKS

NOTE

Bearings and cross should be replaced as a set.

If the cross or any bearing is damaged, replace

the set.

 C. ASSEMBLY.

13. Lower steering shaft (10).

14. Three grease fittings (17).

15. Two crosses (16).

16. Eight bearings (15).

17. Eight snap rings (14).

D. INSTALLATION.

18.

19.

20.

21.

22.

23.

Lower steering shaft (10).

U-joint yoke (3).

Yoke (11).

Capscrew (12), washer (8),

and nut (7).

Capscrew (5), washer (2),

and nut (1).

Three grease fittings (17).

Slide splined sections

together at dust cap (13).

Install in two crosses (16) and

lower steering shaft (10).

a.

b.

a.

b.

Place between four yokes

(3), (9), and (11).

Lubricate assembly with

GAA.

Lubricate with GAA.

Use soft hammer to carefully tap bearings into

yokes.

Seat in yoke grooves.

From under hood, insert

through hole in firewall.

Push onto splined shaft of

upper steering shaft (4).

Push onto splined shaft of

steering gear (6).

Screw in and tighten.

Screw on and tighten.

Use grease gun and apply

GAA.

Upper and lower U-joints

and yokes are attached to

shaft at this time.

10-72
STEERING MECHANISM.

10-18. LOWER STEERING SHAFT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARK S

E. OPERATIONAL CHECK.

24. Engine. Start up (see TM 9-2320-273-10).

25. Steering wheel. Turn. Check that front wheels

turn freely.

10-73
TM 9-2320-273-20

STEERING MECHANISM.

10-19. DRAG LINK MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Inspection of Mating Connections. ( 5 )

c. Installation. (20)

d. Operational Check. (15)

60 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Cotter Pin (2), K-2616 (78500).

Grease Gun

GAA (refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 10-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

10-74
TM 9-2320-273-20

STEERING MECHANISM.

10-19. DRAG LINK MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Turn wheel left or right for easy

accessibility in performing task.

 A. REMOVAL. 

1. Cotter pins (2)

and (5).

2. Castle nuts (3)

and (6).

Remove with pliers and

throw away.

a. Back off nuts until they

are flush with threaded

portion of shaft.

b. Using a sledge hammer

hit this area until drag

link unseats.

c. Unscrew and remove.

If pins stick, tighten or loosen

castle nuts (3) and (6) slightly

to aline slot.

10-75
TM 9-2320-273-20

STEERING MECHANISM.

10-19. DRAG LINK MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Drag link (4). Remove.

4. Two lubrication fittings (8). Unscrew and remove.

 B. INSPECTlON OF MATING CONNECTIONS.

5. Drag link (4), steering

6.

arm (1), and pitman arm

(7).

Two lubrication fittings (8).

C. INSTALLATION.

7. Two lubrication fittings (8).

8. Drag link (4).

9. Castle nuts (3) and (6).

10. New cotter pins (2)

and (5).

11. Two lubrication fittings (8).

D. OPERATIONAL CHECK.

12. Engine.

13. Steering wheel.

14. Engine.

Inspect mating surfaces for:

a. Scoring.

b. Gouging.

c. Excess or uneven wear.

Inspect for:

a. Damaged ball end seal.

b. Damaged threads.

Install at either end of drag

link.

a. Place one end in steering

arm (1).

b. Place the other end in

pitman arm (7).

Screw on and tighten to 120

Ib-ft (163 N•m) with

torque wrench.

Insert cotter pins (2)

and (5) with pliers

and bend ends over.

Grease with GAA until

grease is visible at either

end connection.

Replace if necessary,

If connections are damaged,

troubleshoot steering system

(para 10-5).

Replace as necessary.

It may be necessary to

tighten castle nuts (3) and

(6) further in order to

aline slots with hole.

Use grease gun.

Start up (see TM 9-2320-273-10).

Check to see that wheels turn

freely.

Shut down (see TM 9-2320-273-10).

10-76
TM 9-2320-273-20

STEERING MECHANISM.

10-19. DRAG LINK MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

10-77
TM 9-2320-273-20

STEERING MECHANISM.

10-20. TIE ROD MAINTENANCE.

THIS TASk COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Inspection of End Assemblies. ( 5 )

c. Installation. (25)

50 Minutes Total.

INITIAL SETU P EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 11-14A or C. Front Fenders Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Ball joint Puller.

Jack Stands.

Cotter Key (2), K-2616 (78500).

PERSONNEL REQUIRED

Two (MOS-63820).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 10-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

10-78
TM 9-2320-273-20

STEERING MECHANISM.

10-20. TIE ROD MAINTENANCE (Continued).

LOCATION/lTEM ACTIO N REMARKS

1. Tie downs (9) and Tie a suitable rope between

tie rod (4). these two points, on either

side, to support weight of

tie rod ends when

disconnected.

10-79
TM 9-2320-273-20

STEERING MECHANISM.

10-20. TIE ROD MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

A. REMOVAL (Continued).

2. Two cotter keys (2) and Remove from ball joints

nuts (1). (7) on each side.

3. Two ball joints (7). a. Using ball joint puller or

tapping with mallet remove

from steering arms (8) on

each side (M915). Remove

from knuckles (10) (M916

thru M920).

b. Lower and remove tie rod

(4) with ball joints (7) by

unfastening and lowering

rope sling on either side.

4. Two bolts (3), washers Loosen.

(5), and nuts (6).

5. Two ball joints (7). a. Counting the number of turns,

unscrew from tie rod (4).

b. Slide off clamp (11) from

tie rod (4).

B. INSPECTION OF END ASSEMBLIES.

6. Two ball joints (7). Holding tie rod connection If there is any looseness,

in one hand and steering arm replace assembly.

connection in other hand,

check for any play or

looseness.

C. INSTALLATION.

7. Two ball joints (7). a. Slide one clamp (11) onto

either end of tie rod (4).

b. Screw onto tie rod (4),

using same number of turns

as you counted in step 5.

8. Two bolts (3), washers Install thru two clamps (11) and

(5), and nuts (6). torque to 40-55 Ib-ft (54-74 N•m).

9. Two ball joints (7). Fasten ropes to tie downs (9) and

tie rods (4) and hoist up into

steering arms (8) (M915) or

knuckles (10) (M916 thru M920).

Tie rope sling securely.

10-80
TM 9-2320-273-20

STEERING MECHANISM.

10-20. TIE ROD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

10. Two nuts (1). a. Torque to 110-125 Ib-ft

(149-169 NŽm).

b. Secure with new cotter key

(2) at each end.

NOTE

Follow-on maintenance action required:

Check wheel alinement; refer to paragraph

10-10A. Install front fenders; refer to

paragraph 11-14 B or D.

10-81
TM 9-2320-273-20

STEERING MECHANISM.

10-21. PITMAN ARM MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUI RED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Inspection of Mating Surfaces. (5)

c. Installation. (20)

40 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Cotter Pin, K-2616 (78500).

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

One (MOS-63B20). Vehicle Parked on Level Ground.

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 10-2.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

10-82
TM 9-2320-273-20

STEERING MECHANISM.

10-21. PITMAN ARM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Check for alinement marks (1) and (3) on pitman arm (7) and steering gear shaft (9). If none

are found, put scribe lines on at this time.

1. Cotter pin (5), nut Remove. Discard cotter pin (5).

(6), and drag link (4).

2. Nut (2) and bolt (8). Unscrew and remove.

Be careful not to damage shaft when

removing pitman arm.

3. Pitman arm (7). Remove.

LEGEND:

1. ALINEMENT

MARK

2. NUT

3. ALINEMENT

MARK

4. DRAG LINK

5. COTTER PIN

6. NUT

7. PITMAN ARM

8. BOLT

9. STEERING

GEAR SHAFT

10-83
TM 9-2320-273-20

STEERING MECHANISM.

10-21. PITMAN ARM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSPECTION OF MATING SURFACES.

4. Pitman arm (7) and steering Inspect mating surfaces If pitman arm is damaged,

gear shaft (9). for: replace. If shaft is damaged,

a. Burrs. replace steering gear or refer

b. Gouges. problem to Direct Support

c. Uneven or excess Maintenance.

wear.

C. INSTALLATION.

5. Pitman arm (7) and

steering gear shaft (9).

6. Nut (2) and bolt (8).

7. Drag link (4), nut (6),

and new cotter pin (5).

a. Aline marks (1) and (3).

b. Insert wedge to open arm

slightly.

c. Drive on with mallet.

d. Check that marks are still

alined.

Screw on. Tighten to 400 Ib-ft

(542 NŽm) with torque wrench.

a. Install.

b. Torque nut to 120 Ib-ft

(163 N•m).

10-84
TM 9-2320-273-20

STEERING MECHANISM.

10-21. PITMAN ARM MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

LEGEND:

1. ALINEMENT

MARK

2. NUT

3. ALINEMENT

MAR K

4. DRAG LINK

5. COTTER PIN

6. NUT

7. PITMAN ARM

8. BOLT

9. STEERING

GEAR SHAFT

Change 3 10-84.1/(10-84.2 blank)

TM 9-2320-273-20

10-21.1. STEERING ARM MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Preparation c. Cleaning/Inspection

b. Disassembly d. Assembly

2 Hours Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH

M915 None None

Analyzer, Power Steering, NSN 4910-01-160-3618

P/N J26487 (33287)

SPECIAL TOOLS

Pushrod Driver (fabricate IAW Section 10-21.4, page 10-85)

P/N DTA177323 (19207)

Puller, NSN 5120-00-595-9305

P/N GGG-P-781 (81348)

Torque Wrench, NSN 5120-00-221-7983

P/N SW130-301 (10001)

Multiplier, Torque Wrench NSN 5120-01-142-6941

P/N 392 (87641)

Steering Stop Template (fabricate IAW Section 10-21.4, page 10-85)

MATERIALS/PARTS (P/N)

Steering Arm Kit, 2MPS-3993 (78500)

Includes:

Cotter Pin, (MS24665-498 (96906)

Key, 16X202 (78500)

Nut, Drag Link/Steering Arm, MS35692-69 (96906)

Nut, Knuckle/Steering Arm, MS35692-1824 (96906)

Boot, Grease, 415172C1 (89346)

Steering Arm, 3133-G-6663 (78500)

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

One (MOS-63S) Vehicle Parked on Level Ground.

TM 9-2320-273-10 Engine OFF.

TM 9-2320-273-24&P Transmission in Neutral.

TM 9-2320-273-34 Parking Brake Set.

Rear Wheels Chocked.

TROUBLESHOOTING REFERENCES

Table 10-2.

Change 3 10-84.3

STEERING MECHANISM.

TEST EQUIPMENT

CONDITION DESCRIPTION

REFERENCES (TM) GENERAL SAFETY INSTURCTIONS
TM 9-2320-273-20

STEERING MECHANISM.

10-21.1. STEERING ARM MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

1. Perform front axle toe-in/toe-out check. (See paragraph 10-1 0).

2. Chock rear wheels.

3. Set parking brakes and break loose both front wheel

lug nuts.

4. Lift front of vehicle off ground and secure with floor jacks.

5. Remove both front wheels. IAW TM 9-2320-273-10.

6. Turn steering wheel fully left.

1. Brake line (1), left front brake chamber (2) Disconnect

and fitting (5). and remove.

2. Three bolts (4), bracket and king pin cover Remove. Do not discard. Move

plate (3). bracket and brake line to

one side. Cover exposed

fitting hole.

10-84.4 Change 3
TM 9-2320-273-20

STEERING MECHANISM.

10-21.1. STEERING ARM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. DISASSEMBLY (Continued)

3. Cotter pin (6), castle nut (7) and Discard cotter pin and

drag link (8). castle nut.

4. Steering arm boss (10), drag link (8), Remove using Discard dust boot (12).

steering arm (11), and dust boot (12). puller tool (9).

Change 3 10-84.5

Remove.
TM 9-2320-273-20

STEERING MECHANISM.

Remove.

10-21.1. STEERING ARM MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. DISASSEMBLY (Continued)

5. Cotter pin (13), castle nut (14), and Discard cotter pin and

steering arm (11). castle nut.

NOTE

If push rod driver (15) does not align with steering arm (11), perform step (6) first,

to permit more steering travel and alignment of tool.

6. Push rod driver (15), steering arm (11), Thread pushrod Drive steering arm out of

and knuckle housing (16). driver (15) squarely knuckle housing.

onto end of steering

arm.

7. Key (17) Remove. Discard.

8. Steering arm (11). Remove. Destroy. (Not for reuse)

9. Jam nut (18) and stop bolt (19). Loosen nut and

Remove bolt.

10-84.6 Change 3
TM 9-2320-273-20

STEERING MECHANISM.

10-21.1. STEERING ARM MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

Knuckle assembly bore (20). Clean off rust, Inspect for obvious damburrs, and foreign age.

material.

NOTE

Before performing step 1 verify that a new key (17) is in place

on the tapered end of the steering arm (11).

1. Steering arm (11) Clean and install onto

knuckle assembly (16).

2. Castle nut (14) and steering arm (11). Install castle nut (14) Place nut on threaded end

of steering arm (11), and

finger tighten. If dust boot

(12) was removed during

disassembly, install dust

boot onto drag link (8) and

insert into steering arm

CAUTION boss (10). Secure with

castle nut (7) and finger

tighten.

Do not exceed 785 Ib-ft (1064 N-m). Do not back off

castle nut (14) during this step.

Do not exceed 230 Ib-ft (312 N-m). Do not back off castle

nut (7) during this step.

3. Castle nut (14), steering arm cotter pin Torque castle nut. Torque to minimum

hole (14). of 560 Ib-ft (759 N-m).

Align with steering arm

cotter pin hole.

4. Cotter pin (13) Install and secure.

5. Castle nut (7) and drag link cotter Torque to minimum of

pin hole (22). 165 Ib-ft (224 N-m), align

and secure.

Change 3 10-84.7
TM 9-2320-273-20

STEERING MECHANISM.

10-21.2. STEERING STOP INSPECTION AND ADJUSTMENT PROCEDURES.

THlS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Inspection

b. Adjustment

1/2 Hour Total.

EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH

M915 None None

Analyzer, Power Steering, NSN 4910-01-160-3618

P/N J26487 (33287)

SPECIAL TOOLS

Pushrod Driver (fabricate IAW Section 10-21.1 G, page 10-85)

P/N DTA177323 (19207)

Puller, NSN 5120-00-595-9305

P/N GGG-P-781 (81348)

Torque Wrench, NSN 5120-00-221-7983

P/N SW130-301 (10001)

Multiplier, Torque Wrench NSN 5120-01-142-6941

P/N 392 (87641)

Steering Stop Template (fabricate lAW Section 10-21.1 G, page 10-85)

MATERIALS/PARTS(P/N)

Steering Arm Kit, 2MPS-3993 (78500)

Includes:

Cotter Pin, (MS24656-498 (96906)

Key, 16X202 (78500)

Nut, Drag Link/Steering Arm, MS35692-69 (96906)

Nut, Knuckle/Steering Arm, MS35692-1824 (96906)

Boot, Grease, 415172C1 (89346)

Steering Arm, 3133-G-6663 (78500)

One (MOS-63S)

TM 9-2320-273-10

TM 9-2320-273-24&P

TM 9-2320-273-34

Table 10-2.

SPECIAL EVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Parking Brake Set.

Rear Wheels Chocked.

10-84.8 Change 3

INITIAL SETUP

TEST EQUIPMENT

CONDITION DESCRIPTION

PERSONNEL REQUIRED

REFERENCES (TM)

TROUBLESHOOTING REFERENCES
Mark lines.

10-21.2. STEERING STOP INSPECTION AND ADJUSTMENT PROCEDURES (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Check that alignment marks on the pitman arm steering gear sector shaft

are in alignment before performing the steering stop adjustment procedure.

1. Template (23), steering knuckle housing (16), Install. Put template on top of

and three cover bolts (4). housing, and partially install bolts to position template.

2. Front brake drums (24). Center and Make two measurements,

measure. the first at the forward side

of the brake drum, measuring the distance “d” from

the frame to the back of

the brake drum. Then

make the same measurement at the rear of the

brake drum. Adjust as

necessary to make the

measurements equal.

3. Template (23). Put straight edge on zero

degree reference line (25)

and mark a line (26)

across the king pin. Line

(26) should be perpendicular to the line of travel (27).

NOTE

A 1/8-inch spacer must be used when adjusting the steering stops in order

to acquire the correct steer angle.

4. 1/8-inch spacer (28), steering stop bolt (19), Position, adjust, Put spacer between

steering stop boss (29), brake drum (24), and tighten. steering stop bolt and

king pin line (26), 32 degree reference steering stop boss, turn

line (30), template (23), and jam nut (18). brake drum full left

until king pin line aligns

with 32 degree reference

line on template. If the 32

degree reference line

does not line up with the

king pin line, adjust steering stop bolt. Tighten jam

nut and remove spacer.

Change 3 10-84.9

STEERING MECHANISM.

TM 9-2320-273-20
TM 9-2320-273-20

STEERING MECHANISM.

10-21.2. STEERING STOP INSPECTION AND ADJUSTMENT PROCEDURES (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Brake drum must be turned full right before performing step 6.

6. Template (23). Remove. Perform same procedure

(steps 1 thru 5) for the

right side steering stop

adjustment.

7. Fitting threads (5) and left front brake Coat and install. Coat threads using

chamber (2). teflon sealant.

8. King pin cover plate and bracket (3), Install and secure

bolts (4) and fitting (5). onto knuckle assembly.

9. Paint new steering arm and

touch Up IAW TB 43-0209.

10. Grease the steering

knuckle and drag link IAW

LO 9-2320-273-12.

11. Wheels and tires. Torque lug nuts IAW para

3-9.

Install.

10-84.10 Change 3
STEERING MECHANISM.

10-21.3. STEERING GEAR POPPET ADJUSTMENT.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Analyze

b. Adjustment

1/2 Hour Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH

M915 None None

TEST EQUIPMENT

Analyzer, Power Steering, NSN 4910-01-160-3618

P/N J26487 (33287)

SPECIAL TOOLS

Pushrod Driver (fabricate IAW Section 10-21.1 G, page 10-85)

P/N DTA177323 (19207)

Puller, NSN 5120-00-595-9305

P/N GGG-P-781 (81348)

Torque Wrench, NSN 5120-00-221-7983

P/N SW130-301 (10001)

Multiplier, Torque Wrench NSN 5120-01-142-6941

P/N 392 (87641)

Steering Stop Template (fabricate IAWSection 10-21.1 G, page 10-85)

Steering Arm Kit, 2MPS-3993 (78500)

Includes:

Cotter Pin, (MS24656-498 (96906)

Key, 16X202 (78500)

Nut, Drag Link/Steering Arm, MS35692-69 (96906)

Nut, Knuckle/Steering Arm, MS35692-1824 (96906)

Boot, Grease, 415172C1 (89346)

Steering Arm, 3133-G-6663 (78500)

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

One (MOS-63S) Vehicle Parked on Level Ground.

TM 9-2320-273-10 Engine OFF.

TM 9-2320-273-24&P Transmission in Neutral.

TM 9-2320-273-34 Parking Brake Set.

Rear Wheels Chocked.

TROUBLESHOOTING REFERENCES

Table 10-2.

Change 3 10-84.11

TM 9-2320-273-20

CONDITION DESCRIPTION

MATERIAL/PARTS (P/N)

REFERENCE (TM) GENERAL SAFETY INSTRUCTIONS
TM 9-2320-273-20

STEERING MECHANISM

10-21.3. STEERING GEAR POPPET ADJUSTMENT (Continued).

LOCATION/ITEM ACTION REMARKS

NOTE

The following procedure sets the steering gear poppet adjusting screws

so that power steering system pressure is reduced before the steering

stop bolts contact the axle beam boss.

1. Discharge line (31) on power steering Remove line at pump

pump (32). side only.

2. Power steering analyzer (33) and valve (34). Install and fully open

valve on analyzer.

3. Analyzer (33). Start engine. Run at idle (600 rpm).

Cycle steering wheel full

left and right 3-4 times to

purge all air from analyzer

and warm fluid. Shut off

engine. Check power

steering fluid level and

adjust as necessary. Re10-84.12 Change 3

start engine.
TM 9-2320-273-20

STEERING MECHANISM.

10-21.3. STEERING GEAR POPPET ADJUSTMENT (Continued).

LOCATION/ITEM ACTION REMARKS

When setting poppets, do not hold steering in full lock position for

more than 15 seconds. If full lock position Is held for more than 15

seconds, excessive heat will build up in system and extensive damage may occur.

NOTE

Poppet adjusting screws are adjusted to relieve pressure at 32 degree

steering angle. Make sure 1/8-inch (3mm) spacer is between steering

knuckle stop screw and axle beam boss when adjusting poppet adjusting

screws.

NOTE

The power steering pump has an internal system relief valve to limit maximum pump pressure to 1850-2050 psi (12756-14135 kPa). Observed

operating pressure is variable and dependent on the resistance within the

steering system (e.g. tire inflation, floor surface). Typically, system pressure will be approximately 1100-1500 psi (7585-10343 kPa) with properly

inflated tires on concrete floor.

4. Rear poppet adjusting screw (35), Adjust, lock and Note system operating

and locknut (36). tighten. pressure on analyzer as

you turn wheel from

straight ahead to full left.

Pressure should be above

900 psi (6205 kPa) until

the steering stop contacts

the l/8-inch spacer and

steering stop boss, then

drops to 400-900 psi

(2758-6205 kPa). If observed operating pressure

does not hold until the

stop makes contact, back

out the left side rear

poppet adjusting screw.

Change 3 10-84.13
TM 9-2320-273-20

STEERING MECHANISM.

10-21.3. STEERING GEAR POPPET ADJUSTMENT (Continued).

LOCATION/lTEM ACTION REMARKS

4. Rear poppet adjusting screw (35), Adjust, lock and If system pressure does

and locknut (36) (Continued). tighten. not relieve as the stop

makes contact, turn poppet adjusting screw in.

Leek poppet adjusting

screw in this position by

tightening nut. Torque to

12-18 Ib-ft (16-23 N-m)

and remove spacer.

5. Right turn poppet adjusting Repeat step 4 for the right

screw (37) side poppet adjusting

screw.

6. Engine Shut Off.

7. Power steering analyzer (33). Remove.

8. Discharge line (31). Install onto power Cycle system and recheck

steering pump. fluid level.

10-84.14 Change 3
TM 9-2320-273-20

STEERING MECHANISM.

10-21.4. FABRICATION OF PUSHROD DRIVER AND STEERING STOP TEMPLATE.

LOCATION/lTEM ACTION REMARKS

THlS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Fabrication

1 Hour Total.

NOTES:

1. APPLICABLE STANDARDS:

A. DOD-STD-0010D (AR)

B. ANSI-Y14.5M-1982

2. MATERIAL: STEEL, CARBON, 1010-1025

SPEC ASTM A108 OR ASTM A576

3. ALL EDGES SHALL BE FREE FROM BURRS AND BROKEN .005-.030

4. WELD PER MlL-STD-1261 CLASS 1

5. APPLY PROTECTIVE FINISH PER DTA 175782.

NOTES:

1. APPLICABLE STANDARDS:

A. DOD-STD-00100D (AR)

B. ANSI-Y14.5M-1982

2. MATERIAL: ALUMINUM ALLOY SHEET 6061 -T6

SPEC QQ-A-250/11

.125 THICK

3. ALL EDGES SHALL BE FREE FROM BURRS AND BROKEN .005-.030

Change 3 10-85
TM 9-2320-273-20

STEERING MECHANISM.

10-22. HYDRAULIC POWER STEERING PUMP AND COOLER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a.Removal. (20)

b.Inspection of Lines, Fittings, and Cooler. ( 5)

c.Installation. (20)

d. Filling and Bleeding System. (10)

e. Steering Operational Check. ( 5)

60 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 11-14A or C. Left Front Fender Removed.

TEST EQUIPMENT 11-16A. Grille Removed.

4-18A. Fuel Filter and

None. Adapter Removed

(M916 Thru M920 Only).

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Plugs.

Gasket, Adapter to Oil Pump (5330-01-071-5727).

Silicone RTV Sealant (Refer to Appendix C).

Power Steering Fluid (Refer to Appendix C).

Snapring, 100475(15434).

O-Ring, 008771-026 (19954).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10

TM 9-2320-273-20P

LO 9-2320-273-12

TROUBLESHOOTING REFERENCES

Table 10-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

10-86
TM 9-2320-273-20

STEERING AND ALINEMENT.

Remove.

10-22. HYDRAULIC POWER STEERING PUMP AND OIL COOLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

CAUTION

Dirt may severely damage the power

steering system. Make sure your work

area is clean. Cover openings in the pump

to keep dust out.

A. REMOVAL .

1. Two capscrews (6) Push engine retarder

and washers (5). switch (4) aside.

10-87
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-22. HYDRAULIC POWER STEERING PUMP AND COOLER MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

A. REMOVAL (Continued).

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Hydraulic pump and Wipe away surface dirt and

reservoir assembly (3). grease.

NOTE

Plug openings as soon as you disconnect Iines.

Two hose clamps (22).

Bolt (15), Iockwasher (16) and

flat washer (17).

Hose clamp (1).

Hose (14).

Two fittings (13)

and one (11).

Four bolts and

Iockwashers (20),

Capscrew (10) and

washer (9).

Two locknuts (26).

Remove.

Unscrew and remove hose

retainer (19).

Remove.

Remove from upper rear

connection on hydraulic pump

and reservoir assembly (3) and

lower fitting on cooler (23).

Unscrew and remove two

hoses (12),

Unscrew from four nuts and

washers (18); remove cooler

(23).

a. Unscrew and remove from

hose strap (8).

b. Push oil line (7) out of way.

a. Unscrew and remove.

b. Pull hydraulic pump and

reservoir assembly (3) free

from adapter (31),

c. Throw away O-ring (27).

NOTE

Mark location for reassembly.

Mark locations for reassembly.

Remove from bottom

through frame rail notch

(M915).

Remove from top over

frame rail (M916 thru

M920).

Coupling (24) may fall out when adapter (31)

is removed. Do not lose it.

Snapring (25). Remove from coupling (24); Throw away snapring.

slide coupling from shaft.

10-88
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-22. HYDRAULIC POWER STEERING PUMP AND COOLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

12. Two capscrews (29) and a. Unscrew and remove. You may need to tap

washers (30). b. Remove adapter (31) from adapter (31) loose with

oil pump (21), a brass drift.

c. Throw away gasket (32).

13. TWO studs (28). Unscrew from hydraulic pump

and reservoir assembly (3).

B. INSPECTION OF LINES, FITTINGS, AND COOLER.

14. Two hoses (12) and Inspect for: Replace as necessary.

one hose (14). a. Cracks.

b. Discoloration/staining.

c. Damaged fittings.

10-89
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-22. HYDRAULIC POWER STEERING PUMP AND COOLER MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

B. INSPECTION OF LINES, FITTINGS AND COOLER (Continued).

15. Oil cooler (23). Inspect for: Clean or replace as

a. Bent or broken cooling necessary.

fins and tubing,

b. Debris lodged between

fins.

C. INSTALLATION.

16. TWO studs (28), Screw into hydraulic pump

and reservoir assembly (3).

17. Adapter (31). a. Coat oil pump side with

silicone RTV sealant.

b. Put new gasket (32) on

oil pump side.

c. Attach to oil pump (21)

with two capscrews (29)

and washers (30).

18. Coupling (24). Slide on and install new

snapring (25).

19. Adapter (31). a. Coat power steering pump

side with silicone RTV

sealant.

b. Put new O-ring (27) in

position.

NOTE

Before installing pump, be sure oil line (7)

is pushed out of way.

20. Hydraulic pump and a. Hold with fill cap (2) on On M916 thru M920,

reservoir assembly (3). top and shaft pointed away lift pump over frame

from engine. Push up rail and into position.

between frame and engine

until shaft catches on frame

(M915).

b. Turn fill cap towards cab. Pump shaft may have to be

Tilt shaft upwards. Lift turned slightly to aline

into position. splines in coupling (24).

21. Two locknuts (26). Screw onto two studs (28)

and tighten.

10-90
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-22. HYDRAULIC POWER STEERING PUMP AND COOLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

22. Cooler (23). a. Aline flange holes with

those on front metal.

b. Attach with four bolts and

Iockwashers (20), and four

nuts and washers (18).

23. Two hoses (12) and a. Unplug openings. Install in locations

one hose (14). b. Fasten with two hose marked upon removal.

clamps (22), and one

hose clamp (1) as shown.

c. Screw in two hose fittings

(13) and one fitting (11)

as shown.

10-91
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-22. HYDRAULIC POWER STEERING PUMP AND COOLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 C. INSTALLATION (Continued).

24. Engine retarder switch Attach to fuel pump with two

(4). capscrews (6) and washers (5).

25. Oil line (7). Attach with capscrew (10),

washer (9), and hose strap

(8); tighten capscrew to

18 Ib-ft (24 N·m).

26. Hose retainer (19). Install over hoses (12) and

(14) to front metal with bolt

(15), Iockwasher (16), and

flatwasher (17).

D. FILLING AND BLEEDING SYSTEM.

27. Fill cap (2). a. Remove.

b. Add fluid if needed.

Fluid should be checked

when warm with engine

off.

Be prepared to add fluid to the system as

soon as pump begins operating.

28. Engine. Start up (see TM 9-2320-273-10).

29. Filler cap (2). a. Watch fluid level. If it

drops, add more fluid

immediately. Continue

until fluid stabilizes.

b. Replace cap.

c. Check for oil leaks.

E. STEERING OPERATIONAL CHECK.

30. Steering wheel. Turn in both directions.

Wheel should turn easily

with no jogging,

31. Engine. Shut down (see TM 9-2320-273-10).

10-92
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-22. HYDRAULIC POWER STEERING PUMP AND COOLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Follow-on maintenance required:

Install fender; refer to paragraph 11-14B OR D.

Install grille; refer to paragraph 11-16D.

Install fuel filter and adapter; refer to

paragraph 4-18B (M916 thru M920).

10-93
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-22. HYDRAULIC POWER STEERING PUMP AND COOLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

At temperatures at or below 0°F, the

cooler must be disconnected from the

power steering fluid system. Failure to

do so may cause the cooler tubing to

rupture. The proper procedure is to disconnect one hose (12) which runs from

the steering gear to the cooler (20) and

reconnect same to the hydraulic pump

and reservoir assembly (3). Then, the

hose from the cooler to the reservoir

should be taken off and reconnected to

the cooler input per illustration below.

10-94
TM 9-2320-273-20

This page intentionally left blank.
TM 9-2320-273-20

STEERING MECHANISM.

10-23. AUXILIARY CYLINDER (M916 THRU M920).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (22)

b. Inspection. ( 5)

c. Installation. (30)

d. Operational Check. ( 5)

62 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 Thru M920. 11-14C. Right Front Fender

TEST EQUIPMENT Removed.

None.

SPECIAL TOOLS

None.

MATERIAL/PARTS (P/N)

Container, 1 Pint.

Liquid Teflon (Refer to Appendix C).

Power Steering Fluid (Refer to Appendix C).

Cotter Pin, 103415 (24617).

Cotter Pin, 103389 (24617).

GAA (Refer to Appendix C).

Cable Tie, PLT44-MO (06383).

Cable Tie, MS-3367-2-0 (96906).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 10-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

10-96
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-23. AUXILIARY CYLINDER (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

If lines (6) and (13) are to be removed entirely

from vehicle, unscrew from bottom of

steering gear.

A. REMOVAL .

1. Line (6). Disconnect from elbow (14) Approximately 1/2 pint.

and drain oil.

2. Line (13). Disconnect from elbow (14) Approximately 1/2 pint.

and drain oil.

3. Bolt (8), Iockwasher (10) Unscrew and remove two hose

and nut (12). retainers (7) from bracket (9).

4. Two cable ties (11). Snip off. Discard. Lines (6) and (13)

may now be removed from

vehicle, if needed.

10-97
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-23. AUXILIARY CYLINDER (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

5. Two fittings (14). Unscrew and remove.

6. Cotter pin (22). Remove and throw away.

7. Nut (23). Remove.

8. Ball joint (1). Remove from steering arm (24), Tap out with hammer.

9. Rubber boot (25). Lift out of steering arm (24).

10. Cotter pin (18). Remove and throw away.

11. End cap (15), spring (16), Unscrew end cap (15) and

and outer ball cup (17). remove cap, spring, and outer

ball cup.

12. Cylinder (5). Line up ball portion of slot

with head of ball joint (19)

and remove from ball. Set

cylinder (5) with ball joint

(1) and clamp (3) on bench.

13. Inner ball cup (17). Remove from cylinder (5).

14. Nut (21) and washer Remove from back side of

(20). ball joint (19) stud.

15. Ball joint (19). Remove from frame mounting

plate.

16. Clamp nut (2). See NOTE below, then unscrew

from clamp bolt (4) and remove

clamp (3).

NOTE

Before proceeding with step (17), count number

of threads showing between ball joint (1) and

cylinder (5) on cylinder shaft for installation.

17. Ball joint (1). Unscrew from shaft on cylinder

(5).

B. INSPECTION.

18. Ball joint (1). Inspect for wear. Replace as necessary.

19. Ball joint (19). Inspect for wear. Replace as necessary.

20. Steering arm (24). Inspect for wear. Replace as necessary.

10-98
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-23. AUXILIARY CYLINDER (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSPECTION (Continued).

21. Cylinder (5). Hole worn (out of round). Replace as necessary.

Inspect for:

a. Wear.

b. Dents

c. Cracks.

22. Spring (16). Inspect for coil breaks. Replace as necessary.

23. Two ball cups (17). Inspect for wear or scoring. Replace as necessary.

24. Rubber boot (25). Inspect for tears or cracking. Replace as necessary.

10-99
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-23. AUXILIARY CYLINDER (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION.

25. Ball joint (1). Screw onto shaft of cylinder Screw on shaft until same

(5). number of threads that were

showing on disassembly are

showing now.

26. Clamp (3). Slide over ball joint arm and

secure with clamp bolt (4) and

clamp nut (2).

27. Ball joint (19). SIide joint stud through the

frame mounting plate. Use

mallet if necessary.

28. Nut (21) and washer (20). a. Screw onto stud of ball joint

(19) and tighten.

b. Apply GAA to ball.

29. Inner ball cup (17). a. Apply GAA to cup surface.

b. Slide into cylinder end until

seated with cup surface

facing out.

30. Cylinder (5). Line up ball portion of slot

and slide over ball joint (19).

31. Rubber boot (25). Place in steering arm (24). Small end down.

32. Ball joint (1). Insert in steering arm (24).

33. Nut (23). Screw on until tight, then

advance nut for cotter pin

hole alinement.

34. New cotter pin (22). Insert through hole in stud of

ball joint (1) and bend tabs

over.

35. Outer ball cup (17), a. Apply GAA to ball face of

spring (16) and end cup (17) outer.

cap (15). b. insert outer cup into cylinder with cup face inward

toward ball (19).

c. Slide Spring (16) into cylinder

and seat against outer cup

flat face.

d. Screw in cap (15) until flush.

e. Aline cap slot with next

cotter pin hole in cylinder.

10-100
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-23. AUXILIARY CYLINDER (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

36. New cotter pin (18). Install through cylinder

end and bend over tabs.

37. Two fittings (14). Apply liquid teflon to threads;

insert in cylinder and tighten;

advance so that line end faces up.

38. Line (6). Install to one elbow (14) and

tighten in position shown.

39. Line (13). Install to one elbow (14) and

tighten in position shown.

NOTE

If lines (6) and (13) were removed from vehicle,

install to bottom of steering gear in positions

shown.

10-101
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-23. AUXILIARY CYLINDER (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

40. Two hose retainers (7). Place over lines (6) and (13)

and secure to bracket (9) with

bolt (8), Iockwasher (10), and

nut (12).

41. Two new cable ties (11). Install around two lines (6) and

(13) and front cross frame tube.

42. Cylinder (5). Lubricate with GAA at two ball

joint grease fittings as shown.

43. Power steering fluid level. Check (refer to LO 9-2320-273-12).

NOTE

Follow on maintenance action required: Install

fender; refer to paragraph 11- 14D.

 D. OPERATIONAL CHECK.

44. Engine. Start up. Refer to TM 9-2320-273-10.

45. Wheels. Turn all the way to left and to

right.

46. Cylinder (5), line (6) Check for leaks. Tighten as necessary.

and line (13).

47. Engine. Shut down. Refer to TM 9-2320-273-10.

10-102
TM 9-2320-273-20

STEERING AND ALINEMENT.

10-23. AUXILIARY CYLINDER (M916 THRU M920) (Continued).

LOCATION/lTEM ACTION REMARKS

10-103
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-24. FRONT AXLE SHOCK ABSORBERS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a.Removal. (10)

b.Cleaning and inspection. (10)

c.Installation. (10)

30 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

GAA (Refer to Appendix C).

Shock Absorbers (2) (2540-00-740-961 7).

Rubber Bushings (8) (6365-00-740-9618).

Nonflammable Cleaning Solvent SD-2 (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 10-3.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

10-104
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-24. FRONT AXLE SHOCK ABSORBERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

a.

b.

c.

NOTE

Shock absorbers should be replaced in pairs.

Perform the following procedure twice, once

on each side of the truck.

Shock absorbers should be replaced if:

1. Spring action is not dampened, indicating

worn shock absorbers.

2. Fluid leakage is noted on outer shock

absorber surfaces; bottom section.

Procedure is written based upon need for

new shock absorbers.

10-105
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-24. FRONT AXLE SHOCK ABSORBERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Two nuts (3). Unscrew and remove from

axle and two shafts (5).

2. Two washers (2), four Remove.

bushings (1), and shock

absorbers (4).

B. CLEANING AND INSPECTION.

3. Clean and inspect a. Clean in solvent and Replace shafts if threads are

shaft thread (5) and blow dry. worn or damaged.

nuts (3). b. Apply GAA to threads. a. Replace upper shaft (5) by

removing four bolts, nuts

and washers.

C. INSTALLATION. b. Notify Direct Support

Maintenance for replace4. Two new inner bushings Place on axle and two ment of lower shaft (5).

(1). shafts (5) with large

ends toward truck.

5. New shock absorber Place against bushings on

(4). shafts (5).

6. Two new outer bushings Place on axle and two

(1). shafts (5) with small

ends toward shock absorber.

7. Two washers (2) a. Screw on to shafts (5).

and nuts (3). b. Tighten nuts to 125-165

Ib-ft (170-224 N·m).

10-106
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-24. FRONT AXLE SHOCK ABSORBERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

10-107
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-25. PUSHER AXLE SHOCK ABSORBERS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a.Removal. (10)

b.Cleaning and Inspection. (10)

c.Installation. (10)

30 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M917, M919, M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Shock Absorbers (2) (2540-01 -011-061 4).

Rubber Bushings (8) (6365-00-740-961 8).

Nonflammable Cleaning Solvent SD-2 (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 10-3.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

10-108
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-25. PUSHER AXLE SHOCK ABSORBERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Shock absorbers should be replaced in pairs.

Perform the following procedures twice, once

on each side of the truck. Shock absorbers

should be replaced if spring action is not

dampened or if fluid leakage is noted on outer

shock absorber surfaces, bottom section. This

procedure is based upon need for new shock

absorbers.

10-109
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-25. PUSHER AXLE SHOCK ABSORBERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Two nuts (1). Unscrew and remove.

2. Four bushings (2), Pull bolt (6) out to disassemble

two spacers (5), two spacers (4), bushings (2) and

bolts (6), two sleeves sleeves (4).

(4) and shock absorber

(3).

 B. CLEANING AND INSPECTION.

3. Bolts (6) and nuts (1). a. Soak in non-flammable

4.

5.

6.

7.

Two new bushings (2)

and sleeve (4).

New shock absorber (3)

and spacer (5).

Two new bushings (2)

and sleeve (4).

New shock absorber (3)

and spacer (5).

solvent and wipe dry.

b. Inspect threads for wear,

chips, and crossed threads.

Place in top end of shock

absorber (3).

Attach to top bracket with

nut (1) and bolt (6) in order

illustrated.

Place in bottom end of shock

absorber (3).

Attach to bottom bracket

(7) with nut (1) and bolt (6)

in order illustrated.

Replace as necessary.

Small ends of bushings should

face shock absorber.

Small ends of bushings should

face shock absorber.

10-110
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-25. PUSHER AXLE SHOCK ABSORBERS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

10-111
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-26. TORQUE RODS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal (M915). ( 5)

b. Removal (M916 Thru M920). (10)

c. Cleaning and Inspection (All). (10)

d. Installation (M915). (10)

e. Installation (M916 Thru M920). (15)

50 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Nonflammable Cleaning Solvent SD-2 (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

Table 10-3.

10-112
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-26. TORQUE RODS MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

A. REMOVAL (M915).

1. Four washer base nuts Unscrew and remove from

(1) and four washer two axle brackets (2) and

base bolts (3). torque rods (4) and (8).

2. Two hex head bolts (7), Unscrew and remove from Shim sets (5) may drop from

two flat washers (6), and center torque rod connec- cross-member (9) when torque

two washer base nuts (1). tions at shim sets (5). rods are removed.

3. Torque rods (4) and (8). Remove.

10-113
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-26. TORQUE RODS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. REMOVAL (M916 THRU M920).

4. Four hex nuts (1), Unscrew and remove from

flatwashers (2), and two axle brackets (3) and

bolts (4). torque rods (5) and (8).

5. Two hex nuts (13), Unscrew and remove from Shim sets (6) may drop from

flatwashers (12), and center torque rod connec- cross-member (7) and crossbolts (10). tions at shim sets (6). member plates (11) when

6. Hex nut (13), Unscrew and remove from

torque rods are removed.

flatwasher (12),

Plates (11) are welded to crosscenter torque rod connecand bolt (9). member (7).

tions at shim sets (6).

7. Torque rods (5) and (8). Remove.

C. CLEANING AND INSPECTION (ALL).

8. Fasteners (1), (2), and Clean in solvent and wipe

(4) plus shim block sets

(5) (M915) or (6) (M916

dry.

Inspect for:

thru M920). a. Crossed threads.

b. Burrs.

c. Egg shaped holes (5)

or (6).

9. Torque rod rubber Wipe clean and inspect

bushings (14). for:

a. Egg shaped bushing

b. Deterioration and

cracking.

D. INSTALLATION (M915).

10. Torque rods (4) and (8), Aline mounting holes with

shim block sets (5). those in cross member (9).

11. Two hex head bolts (7), Install bolts through torque

flat washer base nuts rods (4) and (8), shim block

(1). sets (5) and cross-member

(9), washers and nuts as

illustrated. Torque to 105

Ib-ft (142 N·m).

Replace as necessary.

10-114
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-26. TORQUE RODS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

D. lNSTALLATION (M915) (Continued).

12. Torque rod (4) and (8), Aline mounting holes.

axle brackets (2).

13. Four washer base bolts Install bolts through

(3) and washer base nuts outer torque rod ends

(1). and fasten to axle

brackets (2) with nuts

(1). Torque to 105

Ib-ft (142 N·m).

10-115
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-26. TORQUE RODS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

E. INSTALLATION (M916 THRU M920).

14.

15.

16.

Torque rods (5) and (8), Aline mounting holes with

shim block sets (6). those in cross member (7)

and cross member plates

(11).

Three bolts (9) and (10), Install bolts through torque

flatwashers (12) and rods (5) and (8), shim block

hex nuts (13). sets (6), cross member plates

(11) and cross member (7) as

illustrated. Install washers

and nuts. Torque to 180 Ib-ft

(244 N·m).

Torque rods (5) and (8), Aline mounting holes.

axle brackets (3).

17. Four bolts (4), flat Install bolts through outer

washers (2), and hex torque rod ends and fasten

nuts (1). to axle brackets (3) with

washers (2) and nuts (1).

Torque to 180 Ib-ft

(142 N·m).

10-116
TM 9-2320-273-20

SUSPENSION SYSTEM.

10-26. TORQUE RODS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

10-117/10-118 (Blank)

TM 9-2320-273-20

CHAPTER 11

FRAME, BODY AND CAB MAINTENANCE

11-1. OVERVIEW.

This chapter provides you with the following information related to frame, body and cab

maintenance:

a. All required special tools and equipment.

b. Other technical manuals.

c. Troubleshooting procedures.

d. Maintenance procedures.

a. Do not drill holes in frame flanges.

b. Do not weld frame.

Section I REPAIR PARTS, SPECIAL TOOLS, TMDE AND SUPPORT EQUIPMENT

11-2. COMMON TOOLS AND EQUIPMENT.

For authorized common tools and equipment, refer to the Modified Table of Organization and

Equipment (MTOE) applicable to your unit.

11-3. SPECIAL TOOLS, TMDE, SUPPORT EQUIPMENT.

The special tools, TMDE and support equipment required for the frame, body and cab maintenance

procedures described in this chapter are limited to the 1000-lb hoist and lift hook. (Refer to

Organizational Maintenance RPSTL, TM 9-2320-273-20P for tool description and illustrations.)

11-4. SPARES AND REPAIR PARTS.

Spares and repair parts are listed and illustrated in the Repair Parts and Special Tools List covering

Organizational Maintenance for this equipment (TM 9-2320-273-20P).

11-1
TM 9-2320-273-20

Section ll TROUBLESHOOTING

11-5. INTRODUCTION.

Table 11-1 contains instructions for troubleshooting the frame components. The corrective actions

describe how to fix a problem or refer to a procedure for fixing the problem. The Troubleshooting

table is arranged by malfunctions in the following order:

FRAME :

a.

b.

c.

Towing pintle does not pivot or latch, or jaw is stuck (Malfunction No. 1).

Excessive jerking of towed trailer (Malfunction No. 2).

Excessive noise or popping sounds from fifth wheel when turning (Malfunction No. 3).

11-2
TM 9-2320-273-20

Table 11-1. Frame Troubleshooting Procedures.

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

1. TOWING PINTLE DOES NOT PIVOT OR LATCH, OR JAW IS STUCK:

Step 1. Check for proper lubrication.

Lubricate (LO 9-2320-273-12).

Step 2. Check lock for damage.

Replace (para 11-10).

2. EXCESSIVE JERKING OF TOWED TRAILER:

Step 1. Check for proper lubrication of fifth wheel.

Lubricate (LO 9-2320-273-12).

Step 2. Check bolts and bracket on fifth wheel for tightness.

Tighten, refer to torque table (para 3-9).

Step 3. Inspect coupler jaw and locks for damage.

Replace fifth wheel (para 11-13).

3. EXCESSIVE NOISE OR POPPING SOUNDS FROM FIFTH WHEEL WHEN TURNING:

Step 1. Check for proper lubrication of fifth wheel.

Lubricate (LO 9-2320-273-12).

Step 2. Check all mounting bolts on fifth wheel for tightness.

Tighten, refer to torque table (para 3-9).

Step 3. Inspect locks for damage.

Replace fifth wheel (para 11-13).

11-3/11-4(Blank)

TM 9-2320-273-20

Section III MAINTENANCE PROCEDURES

11-6. INTRODUCTION.

This section provides you with Organizational Level Maintenance procedures for the frame, body,

and cab. To find a specific maintenance procedure, see one of the following task summaries.

a. Frame (para 11-7).

b. Body and Cab (para 11-8).

11-5
TM 9-2320-273-20

11-7. FRAME MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH

All. (See TM 9-2320-273-10).

11-16E.

TEST EQUIPMENT

None.

TOOLS

CONDITION DESCRIPTION

Spare Wheel/Tire Removed.

Brush Guard Removed (M916

Thru M920).

1,000 lb Hoist.

Lift Hook.

M916 and M920 5th Wheel Adjustment Tool (CT447ALX2).

MATERIALS/PARTS (P/N)

Lithium (Chassis) Grease (Refer to Appendix C). Sleeve (M915), 188-4-VM (97706).

Cotter Pin, 108656 (24617).

GAA (Refer to Appendix C).

Cotter Pin, 773 (74410).

PERSONNEL REQUIRED

One MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

LO 9-2320-273-12

TM 9-2320-273-20P.

REFERENCES (TROUBLESHOOTING)

Table 11-1.

TASK

NO.

1.

2.

Sleeve (M916), S409-1SB (75535).

Cable (M915), 1/8 x 15/7 x 19 (75535).

Cable (M916), 1/8 x 15 ft/7 x 19 (75535).

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TASK

Bumper and Towing Eyes Maintenance:

A. Removal.

B. Installation.

Pintle Maintenance (M915 thru M917 and

M920) :

A.

B.

C.

D.

Removal.

Cleaning and Inspection.

Installation.

Lubrication and Adjustment.

TASK

REF

11-9

11-9A

11-9B

11-10

11-10A

11-10B

11-10C

11-10D

TROUBLESHOOTING

REF (TABLE)

11-1

11-1

11-6

LIST OF TASKS
TM 9-2320-273-20

11-7. FRAME MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

3. Spare Tire Hoist Cable (M915 and M916): 11-11 11-1

A. Removal. 11-11A

B. InstalIation. 11-11B

4. Spare Tire Hoist Maintenance (M915 and M916) 11-12 11-1

A. Removal. 11-12A

B. Installation. 11-12B

5. Fifth Wheel Maintenance: 11-13 11-1

A. Removal. 11-13A

B. Lubrication. 11-13B

C. Adjustment. 11-13C

D. Installation. 11-13D

11-7
TM 9-2320-273-20

11-8. BODY AND CAB MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 11-26A. Heater Removed.

11-14A or C. Fenders Removed.

TEST EQUIPMENT 11-20A and 11-21A. Seats Removed.

None. 4-25A. Air Cleaner Removed.

4-42A. Coolant Drained.

TOOLS 5-44A. Headlamp Assembly

None. Removed.

11-16E. Brush Guard Removed

MATERIALS/PARTS (P/N) (M916 Thru M920)

Lubriplate (Refer to Appendix C). 11-16A. Grille Removed.

GAA (Refer to Appendix C). 11-32A. Hood Removed.

Non Flammable Cleaning Solvent (SD-2) 11-19A. Mud Flaps Removed.

(Refer to Appendix C). 11-9A. Tow Eyes Removed,

Cotter Pin, 137155 (24617) 5-50A. Blackout Taillamps

Rivet (10), SSLQ-66 (05693). Removed.

Rivet (30), SSLQ-64 (05693).

Grease Gun.

Electrical Tape.

Clean Container.

Hose Tie (3), PLT 4H-MO (06363).

Hoist.

Jack Stands.

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

Two (MOS-63B20). Vehicle Parked on Level Ground.

REFERENCES (TM GENERAL SAFETY INSTRUCTIONS

TM 9-2320-273-10. Engine OFF.

LO 9-2320-273-12. Transmission in Neutral.

TM 9-2320-273-20P. Park Brake Set.

REFERENCES (TROUBLESHOOTING)

Table 4-1.

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

1. Fender Maintenance: 11-14

A. Removal of Front Fender (M915). 11-14A

B. Installation of Front Fender (M915). 11-14B

C. Removal of Front Fender (M916

thru M920). 11-14C

D. Installation of Front Fender (M916

thru M920). 11-14D

E. Removal of Rear Fender. 11-14E

F. Installation of Rear Fender. 11-14F

11-8
TM 9-2320-273-20

11-8. BODY AND CAB MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

2. Ventilator Maintenance: 11-15

A. Removal. 11-15A

B. Installation. 11-15B

3. Grille Maintenance: 11-16

A. Removal. 11-16A

B. Disassembly. 11-16B

C. Assembly. 11-16C

D. Installation. 11-16D

E. Brush Guard Removal. 11-16E

F. Brush Guard Installation. 11-16F

4. Optional Winter Front Maintenance: 11-17

A. Original Installation. 11-17A

B. Removal. 11-17B

C. Installation 11-17C

5. Grille Support Brackets Maintenance: 11-18

A. Removal. 11-18A

B. Installation. 11-18B

6. Mud Flaps Maintenance: 11-19

A. Removal. 11-19A

B. Installation. 11-19B

7. Driver’s Seat Maintenance: 11-20

A. Removal. 11-20A

B. Cleaning and Lubricating of Hardware. 11-20B

C. Installation. 11-20C

8. Passenger’s Seat Maintenance: 11-21

A. Removal. 11-21A

B. Cleaning and Lubricating Adjusting 11-21B

Mechanism.

C. Installation. 11-21C

9. Seat Riser and Tool Box Maintenance: 11-22

A. Removal. 11-22A

B. Installation. 11-22B

11-9
TM 9-2320-273-20

11-8. BODY AND CAB MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

10. Windshield Wiper and Blade Assembly 11-23

Maintenance:

A. Removal. 11-23A

B. Installation. 11-23B

C. Operational Check. 11-23C

11. Windshield Wiper Arms Maintenance: 11-24

A. Removal. 11-24A

B. Installation. 11-24B

C. Operational Check. 11-24C

12. Rear View Mirror Maintenance: 11-25

A. Removal. 11-25A

B. Disassembly, 11-25B

C. Assembly. 11-25C

D. Installation. 11-25D

E. Adjustment. 11-25E

13. Heater Maintenance: 11-26 4-1

A. Removal. 11-26A

B. Installation. 11-26B

14. Heater Hose Maintenance: 11-27 4-1

15. Heater Control Panel Maintenance: 11-28 4-1

A. Removal of Knob and Cable. 11-28A

B. Installation of Knob and Cable. 11-28B

C. Operational Check. 11-28C

16. Heater Control Valve Maintenance: 11-29 4-1

A. Removal. 11-29A

B. Installation. 11-29B

11-10
TM 9-2320-273-20

11-8. BODY AND CAB MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK TASK TROUBLESHOOTING

NO. TASK REF REF (TABLE)

17. Heater Air Ducts Maintenance: 11-30 4-1

A. Removal. 11 -30A

B. Installation. 11-30B

C. Checking for Leaks. 11-30C

18. Data and Instruction Plates Maintenance: 11-31

19. Hood Maintenance: 11-32

A. Removal. 11-32A

B. Installation. 11-32B

20. Tail Roller Maintenance: 11-33

A. Removal. 11-33A

B. Installation. 11-33B

11-11
TM 9-2320-273-20

FRAME.

11-9. BUMPER AND TOWING EYES MAINTENANCE.

THIS TASK COVERS: (Approximate TIME REQUIRED FOLLOWS TASK Description.)

a. Removal. (15)

b. Installation. (15)

30 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 11-16E Brush Guard Removed

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Cotter Pin, 108656 (24617).

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

(M916 Thru M920).

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 11-1.

11-12
TM 9-2320-273-20

FRAME.

11-9. BUMPER AND TOWING EYES MAINTENANCE.

LOCATION/lTEM ACTION REMARKS

1. Two cotter pins (5). Remove and throw away.

2. Clevis (6) and pin (7). Slide pin (7) out and remove

clevis (6).

3. Four screws (9), washers Unscrew and remove classifi- M915 thru M920.

(11), and nuts (12). cation sign (10) and bracket (13).

4. Two screws (9), washers (11), Unscrew and remove bracket (14). M916 thru M920.

and nuts (12).

NOTE

Before removing capscrews (8) support

bumper to keep it from falling.

5. Eight capscrews (8) Unscrew and remove. If you want to change a

and nuts (2). single towing eye, remove

only the four capscrews

on that side.

11-13
TM 9-2320-273-20

FRAME.

11-9. BUMPER AND TOWING EYES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

6. Bumper (1) and two a. Remove.

towing eyes (4). b. Inspect for rust or Replace if necessary.

damage.

B. INSTALLATION.

7. Bumper (1). Put in place against front

extension (3).

8. Two towing eyes (4) Put eyes in place and insert

and eight capscrews (8). capscrews.

9. Eight nuts (2). Put on; tighten capscrews

(8) and nuts (2).

10. Clevis (6). Position, slide in pin (7), and

secure with new cotter pin (5).

11. Bracket (14). Install to bumper (1) with M916 thru M920.

two screws (9), washers (11)

and nuts (12).

12. Bracket (13). a. Install to bracket (14) with M916 thru M920.

two screws (9), washers (11),

and nuts (12).

b. Install to bumper (1) with M915.

two screws (9), washers (11),

and nuts (12).

13. Classification sign (10). Install to bracket (13) with M915 thru M920.

two screws (9), washers (11),

and nuts (12).

Follow-on maintenance action required:

Install brush guard (M916 thru M920 only);

refer to para 11-16F.

11-14
TM 9-2320-273-20

FRAME.

11-9. BUMPER AND TOWING EYES MAINTENANCE (Continued).

ACTION REMARKS LOCATION/ITEM

11-15
TM 9-2320-273-20

FRAME.

11-10. PINTLE MAINTENANCE (M915 THRU M917 AND M920).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Cleaning and Inspection. (15)

c. Installation. (20)

d. Lubrication and Adjustment. (15)

65 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915 Thru M917 and M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Lithium (Chassis) Grease (Refer to Appendix C).

Cotter Pin, 773 (74410).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 11-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

11-16
TM 9-2320-273-20

FRAME.

Remove and discard.

a. Unscrew and remove.

b. Remove hook assembly (5).

NOTE

If you do not need to remove brackets

(9) go directly to step 6.

11-10. PINTLE MAINTENANCE (M915 THRU M917 AND M920) (Continued).

LOCATION/lTEM ACTION REMARKS

1. Cotter Pin (1).

2. Slotted nut (2) and

spacer (3).

11-17
TM 9-2320-273-20

FRAME.

11-10. PINTLE MAINTENANCE (M915 THRU M917 AND M920) (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Two capscrews (8), a. Unscrew and remove.

washers (10), nuts (11). b. Remove two brackets (9).

B. CLEANING AND INSPECTION.

4. Cotter pin (6). Remove from hook assembly Check that chain (7) is

(5) and spread jaws. securely riveted to hook

assembly (5) and that links

are not damaged.

5. All parts. Clean and lubricate with

diesel fuel or suitable light

oil. inspect for signs of

damage or wear and replace

as necessary.

C. INSTALLATION.

6. Two brackets (9). Hold in position.

7. Two capscrews (8), Screw in loosely. Insure grease fittings face

washers (10) and nuts (11). down.

8. Hook assembly (5). Push through bracket (9)

from back end.

9. Spacer (3) and slotted Screw on loosely.

nut (2).

10. Two capscrews (8) and Tighten.

nuts(11).

D. LUBRICATION AND ADJUSTMENT.

11. Cotter pin (6) Install in hook assembly (5).

12. Four grease fittings (4). Apply grease with grease gun.

13. Slotted nut (2). a. Tighten until pintle hook

binds when turned.

b. Loosen just until hook

turns with some resistance.

14. New cotter pin (1). a. Insert to hold slotted nut

(2) in place.

b. Spread ends.

11-18
TM 9-2320-273-20

FRAME.

11-10. PINTLE MAINTENANCE (M915 THRU M917 AND M920) (Continued).

LOCATION/lTEM ACTION REMARKS

11-19
TM 9-2320-273-20

FRAME.

11-11. SPARE TIRE HOIST CABLE (M915 AND M916).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Installation. (10)

15 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915 and M916. (See TM 9-2320-273-10). Spare Wheel and

Tire Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Sleeve (M915), 188-4-VN (97706).

Sleeve (M916), S409-1SB (75535).

Cable (M915), 1/8 x 15/7 x 19 (75535).

Cable (M916), 1/8 x 15 ft/7 x 19 (75535).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 11-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

11-20
TM 9-2320-273-20

FRAME.

11-11. SPARE TIRE HOIST CABLE (M915 AND M916) (Continued).

LOCATION/lTEM ACTION REMARKS

1. Two nuts (5). Loosen.

2. Cable (3). Unwind. Pull cable end out

from under clamp (1) and

remove.

3. Hook (4). Remove by cutting old cable (3).

4. New cable (3). Install sleeve (2), pass thru hook

(4), place end of cable thru other

side of sleeve (2) and secure with

suitable crimping tool.

5. Cable (3). Insert under clamp (1).

6. Two nuts (5). Tighten.

11-21
TM 9-2320-273-20

FRAME.

11-12. SPARE TIRE HOIST MAINTENANCE (M915 and M916).

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal (30)

b. Installation. (35)

65 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915 and M916. (See TM 9-2320-273-10). Spare Wheel and

TEST EQUIPMENT

Tire Removed.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 11-1.

11-22
TM 9-2320-273-20

FRAME.

11-12. SPARE TIRE HOIST MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Four screws (17), washers Unscrew and remove frame

(22), and nuts (21). (10) with assembled hoist

from pedestal (26).

2. Retaining ring(1). Remove.

3. Spring (2), handle (3), Remove. NOTE

and disk (4). If M916 pedestal is to be serviced,

11-23

remove one bolt and nut attaching

thru frame rail.
TM 9-2320-273-20

FRAME.

11-12. SPARE TIRE HOIST MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

4. Screw (23) and locknut (20). Unscrew and remove frame

spacer (19) and drum assembly (18).

5. Retaining ring (8). Remove, slide pinion shaft

assembly (7) to side and

remove brake face (6), and

ratchet gear (5).

6. Ratchet bolt (16) and Unscrew and remove ratchet

locknut (12). spring (13), ratchet spacer

(14), and ratchet pawl (15).

7. Bushings (9), and (11). Remove.

8. Cotter pin (30) and Remove and unscrew Discard cotter pin.

clevis pin (31). clevis (36) from tension

rod (37).

9. Three nuts (38) and (39). Unscrew and remove tension Nut (38) attaches to clevis

rod (37) from tension rod (36) and two nuts (39) attach

support assy (40) and clevis at either side of tension rod

(36). support assy (40).

10. Tie down (25) and two Unscrew and remove pedestal

pedestal mounting nuts (24). (26).

11, Two bolts (32), washers Unscrew and remove two

(34), and nuts (35). cable rollers (33).

12. Two bolts (28) and nuts Unscrew and remove carrier

(27). (29).

B. INSTALLATION.

13. Carrier (29), Install with two bolts (28)

and nuts (27).

14. Two cable rollers (33). Install to pedestal (26) with

two bolts (32), washers (34),

and nuts (35).

15. Pedestal (26). Install with tie down (25) and

two pedestal mounting nuts (24).

16. Tension Rod (37). Install with three nuts (38) and Nut (38) attaches to clevis

(39) to tension rod support (36) and two nuts (39) attach

assy (40) and clevis (36). at either side of tension rod

support assy (40).

17. Clevis (36). Screw onto tension rod (37) and

fasten to pedestal with clevis pin

(31) and new cotter pin (30).

18. Bushings (9) and (11). Install in frame (10).

11-24
TM 9-2320-273-20

FRAME.

11-12. SPARE TIRE HOIST MAINTENANCE (M915 and M916) (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

19. Ratchet spring (13), ratchet Install to frame (10) with ratchet

spacer (14), and ratchet pawl bolt (16) and locknut (12).

(15).

20. Ratchet gear (5), brake Install on pinion shaft (7), slide

face (6). shaft (7) into frame (10), and

fasten with retaining ring (8).

21. Spacer (19) and drum (18). Install to frame (10) with

screw (23) and nut (20).

22. Disk (4), handle (3), and Install on pinion shaft (7) and

spring (2). fasten with retaining ring (1).

23. Frame (10) with assembled Install to pedestal (26) with four

hoist. screws (1 7), washers (22), and

nuts (21).

NOTE

Follow on maintenance required:

Install spare tire and wheel (see TM 9-2320-273-10).

11-25
TM 9-2320-273-20

FRAME.

11-13. FIFTH WHEEL MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Lubrication. (10)

c. Adjustment. (10)

d. Installation. (25)

60 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915, M916, M920 None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

1,000 Lb Hoist.

Lift Hook.

M916 and M920 Fifth Wheel Adjustment

TOOI (CT447ALX2).

MATERIALS/PARTS (P/N)

GAA (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 11-1.

11-26
TM 9-2320-273-20

FRAME.

11-13. FIFTH WHEEL MAINTENANCE.

LOCATION/lTEM ACTION REMARKS

A. ADJUSTMENT (M915 ONLY).

NOTE

Clean 5th wheel thoroughly before making adjustment.

Use tool TLN 1000 in the following

procedure.

Change 2 11-27
TM 9-2320-273-20

FRAME.

11-13. FIFTH WHEEL MAINTENANCE (Continued).

ACTION REMARKS

A. ADJUSTMENT (M915 ONLY) (Continued).

NOTE

To install the fifth wheel lock tester, the

fifth wheel lock jaws must be open. Do step

1 to open lock jaws, if necessary.

1. Secondary lock handle (10) a.

release handle (9), and

lock jaws (6).

2. 5th wheel lock tester (1).

3. Nut (11).

4. Fifth wheel lock tester (1).

b.

a.

b.

c.

d.

e.

a.

b.

a.

b.

Pull out secondary lock handle (10) until it catches on the

5th wheel plate assembly (7).

Pull out release handle and

pry open lock jaws (6).

Grasp handle of king pin

plate (4) and place king pin

(3) into lock jaws (6).

Place lever (2) over front of

5th wheel plate assembly (7).

While pushing down on king

pin plate (4), rotate lever

(2), away from 5th wheel

plate assembly (7) until

king pin (3) is locked in

lock jaws (6).

Position bar (5) over edge

of cross tie (8).

Pry forward with lever (2)

and rearward with bar (5)

to check for play (1/8”

(.31 cm) or less).

Turn nut counter-clockwise

to allow for yoke (13) to

slide down and reposition

on the lock jaws (6).

Tighten nut (11) until

rubber block (12) fits

snugly against the 5th

wheel plate assembly, but

stiII can be turned by hand.

Rotate lever (2) towards

5th wheel plate assembly (7).

Position bar (5) on edge of

cross tie (8), using leverage

remove king pin (3) from

lock jaws (6).

Be sure king pin plate (4)

is flat against 5th wheel

plate assembly (7) during

this operation.

Do step 3 to adjust lock

jaws (6), if necessary.

If there is still play after

adjusting lock jaws (6), refer

to Direct Support and General Support Maintenance.

11-28 Change 2

LOCATION/ITEM
TM 9-2320-273-20

11-13. FIFTH WHEEL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. ADJUSTMENT (M915 ONLY) (Continued).

NOTE

Repeat this procedure to verify proper adjustment of fifth wheel.

Follow-on maintenance action required:

Re-lubricate as per LO 9-2320-273-12.

B. ADJUSTMENT (M916 and M920 ONLY).

NOTE

Clean 5th wheel thoroughly before making adjustment.

Use tool TLN 1500 in the following

procedure.

Change 2 11-29

FRAME.
TM 9-2320-273-20

FRAME.

11-13. FIFTH WHEEL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. ADJUSTMENT (M916 and M920 ONLY) (Continued).

11-30 Change 2
TM 9-2320-273-20

FRAME.

11-13. FIFTH WHEEL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. ADJUSTMENT (M916 and M920 ONLY) (Continued).

NOTE

To install the fifth wheel lock tester, the

fifth wheel lock jaws must be open. Do step

1 to open lock jaws, if necessary.

1. Secondary lock handle (10), a. PulI out secondary lock

release handle (9) and lock handle (10), until it

jaws (6). catches on 5th wheel plate

assembly (7).

b. Pull out release handle (9),

and pry open lock jaws (6).

2. Fifth wheel lock tester (1). a. Grasp handle of king pin

plate (4) and place king pin

(3) into lock jaws (6).

b. Place lever (2) over front of

5th wheel plate assembly.

c. While pushing down on Be sure king pin plate (4)

king pin plate (4), rotate is flat against the 5th wheel

lever (2) away from 5th plate assembly (7) during

wheel plate assembly (7) this operation.

until king pin (3) is locked

in lock jaws (6).

d. Position bar (5) over edge

of cross tie (8).

e. Pry forward with lever (2) Do step 3 to adjust lock jaws

and rearward with bar (5) (6), if necessary.

to check for play (1/8”

(.31 cm) or less).

3. Hexagon head nut (11). Tighten or loosen to obtain If there is still play after

a snug fit against 5th wheel adjusting lock jaws (6) refer

plate assembly (7). to Direct Support and General Support Maintenance.

4. Fifth wheel lock tester (1). a. Rotate lever (2) towards

5th wheel plate

assembly (7).

b. Position bar (5) on edge

of cross tie (8), using leverage remove king pin (3)

from lock jaws (6).

Change 2 11-31
TM 9-2320-273-20

FRAME.

11-13. FIFTH WHEEL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. ADJUSTMENT (M916 and M920 ONLY) (Continued).

NOTE

Repeat this procedure to verify proper

adjustment of fifth wheel.

Follow-on maintenance action required:

Re-lubricate as per LO 9-2320-273-12.

11-32 Change 2
TM 9-2320-273-20

FRAME.

11-13. FIFTH WHEEL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

11-33
TM 9-2320-273-20

BODY AND CAB.

11-14. FENDER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal of Front Fender (M915). (10)

b. Installation of Front Fender (M915). (10)

c. Removal of Front Fender (M916 Thru M920). (15)

d. Installation of Front Fender (M916 Thru M920). (15)

e. Removal of Rear Fender. ( 5)

f. Installation of Rear Fender. ( 5)

60 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 5-44A If damaged Front Fenders

TEST EQUIPMENT are to be Removed:

Headlamp Assembly

None. Removed.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

11-16E Brush guard removed

(M916 thru M920).

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Park Brake Set.

Transmission in Neutral.

TROUBLESHOOTING REFERENCES

None.

11-34
TM 9-2320-273-20

BODY AND CAB.

11-14. FENDER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL OF FRONT FENDER (M915).

1. Unlatch hood. Refer to TM 9-2320-273-10.

2. Cannon connector. Twist and remove from firewall

connector.

3. Ten bolts (22), washer (21), Remove. Fender to bumper brace

nineteen washers (25) and (20) and fender to cab

ten nuts (26). support brace (31) may

be removed from vehicle

by unscrewing one existing nut.

4. Front fender (33), two inner Remove from fender supports (3) Second mechanic to

stiffeners (27), one outer and (38). assist.

stiffener (24), mud flap (30),

and two anti-sail braces (32).

11-35
TM 9-2320-273-20

BODY AND CAB.

11-14. FENDER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL OF FRONT FENDER (M915) (Continued).

5. Eight bolts (5), sixteen washers Unscrew and remove top filler

(6), and eight nuts (29). panel (7).

6. Six bolts (36), twelve washers Unscrew and remove forward

(35), and six nuts (28). filler panel (12) and rear filler

panel (34).

7. Three bolts (37) and nuts (1). Unscrew and remove fender

support (38).

8. Three bolts (4) and nuts (2). Unscrew and remove fender

support (3).

B. INSTALLATION OF FRONT FENDER (M915).

9. Fender support (3). install to frame rail with three

bolts (4) and nuts (2).

10. Fender support (38). Install to frame rail with three

bolts (37) and nuts (1).

11. Forward filler panel (12) and a. Aline with mounting holes on

rear filler panel (34). fender (33).

b. Attach with six bolts (36),

twelve washers (35), and six

nuts (28).

12. Top filler panel (7). a. Aline with mounting holes on

fender (33), forward filler

panel (12), and rear filler panel

(34).

b. Attach with eight bolts (5),

sixteen washers (6), and eight

nuts (29).

13. Front fender (33), two inner a. Aline with mounting holes on If braces (20) or (31)

stiffeners (27), one outer fender supports (3) and (38). were removed from

stiffener (24), mud flap (30), b. Attach with ten bolts (22), vehicle, reinstall with

two anti-sail braces (32), fender washer (21), nineteen washers one existing nut.

to bumper brace (20) and (25) and ten nuts (26).

fender to cab support brace (31).

14. Cannon connector. Twist onto firewall connector.

15. Latch hood. Refer to TM 9-2320-273-10.

C. REMOVAL OF FRONT FENDER (M916 thru M920).

16. Unlatch hood. Refer to TM 9-2320-273-10.

17. Cannon connector. Twist and remove from firewall

connector.

11-36
TM 9-2320-273-20

BODY AND CAB.

11-14. FENDER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

11-37
TM 9-2320-273-20

BODY AND CAB.

11-14. FENDER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. REMOVAL OF FRONT FENDER (M916 thru M920) (Continued).

18.

19.

20.

21.

22.

23.

24.

25.

Two nuts (11 ), washers (10),

washers (13), and bolts (14).

Bolt (15), two washers (16)

and nut (17).

Ten bolts (22), washer (21),

nineteen washers (25) and

ten nuts (26).

Front fender (33), two inner

stiffeners (27), one outer

stiffener (24), mud flap (30),

and two anti-sail braces (32).

Eight bolts (5), sixteen washers

(6), and eight nuts (29).

Six bolts (36), twelve washers

(35), and six nuts (28).

Three bolts (37) and nuts (1).

Three bolts (4) and nuts (2).

Unscrew and remove.

Unscrew and remove with brush

guard support (18).

Remove.

Remove from fender supports (3).

and (38).

Unscrew and remove top filler panel

(7).

Unscrew and remove forward filler

panel (12) and rear filler panel (34).

Unscrew and remove fender support

(38).

Unscrew and remove fender support

(3).

D. INSTALLATION OF FRONT FENDER (M916 thru M920).

26.

27.

28.

29.

30.

Fender support (3). Install to frame rail with three bolts

(4) and nuts (2).

Fender support (38). Install to frame rail with three bolts

(37) and nuts (1).

Forward filler panel, (12) and a.

rear filler panel (34).

b.

Top filler panel (7). a.

b.

Front fender (33), two inner a.

stiffeners (27), one outer

stiffener (24), mud flap (30), b.

two anti-sail braces (32), fender

to bumper brace (20) and

fender to cab support brace (31).

Aline with mounting holes on

fender (33).

Attach with six bolts (36), twelve

washers (35), and six nuts (28).

Aline with mounting holes on

fender (33), forward filIer panel

(12), and rear filler panel (34).

Attach with eight bolts (5), sixteen

washers (6), and eight nuts (29).

Aline with mounting holes on

fender supports (3) and (38),

Attach with ten bolts (22),

washer (21), nineteen washers

(25) and ten nuts (26).

Fender to bumper brace

(20) and fender to cab

support brace (31) may

be removed from vehicle

by unscrewing one existing nut.

Second mechanic to

assist.

If braces (20) or (31)

were removed from

vehicle, reinstall with one

existing nut.

11-38
TM 9-2320-273-20

BODY AND CAB.

11-14. FENDER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

11-39
TM 9-2320-273-20

BODY AND CAB.

11-14. FENDER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

D. INSTALLATION OF FRONT FENDER (M916 thru M920) (Continued).

31. Brush guard support (18). a. Aline mounting holes.

b. Install to fender with two bolts

(14), washers (10), washers (13),

and nuts (11).

c. Install to brush guard with bolt

(15), two washers (16) and nut

(17).

32. Cannon connector. Twist onto firewall connector.

33. Latch hood. Refer to TM 9-2320-273-10.

11-40
TM 9-2320-273-20

BODY AND CAB.

11-14. FENDER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

11-41
TM 9-2320-273-20

BODY AND CAB.

11-14. FENDER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

E. REMOVAL OF REAR FENDER.

34. Bolt (12) and nut (14). a. Unscrew, loosen clamp (13), and Mounting pin (6) used on

slide mounting tube (15) with M916, M917, M920;

fender (19) attached, from mounting pin plate (10)

mounting pin (6) or mounting used on M915.

pin plate (10).

b. Slide clamp (13) off mounting

tube (15).

35. Three bolts (16) and nuts (18). Unscrew and remove mounting tube

(15).

36. Three bolts (5) and nuts (20). Unscrew and remove with three

supports (17).

37. Six bolts (3), washers (2), and Unscrew and remove mud guard (4).

nuts (1).

38. Bolt (7) and nut (6). Unscrew from frame rail and M916, M917, and M920

remove mounting pin (6). only.

39. Four bolts (11) and nuts (9). Unscrew from frame rail and M915 only.

remove mounting pin plate (10).

F. INSTALLATION OF REAR FENDER.

40. Mounting pin plate (10). a. Aline with frame rail holes. M915 only.

b. Attach with four bolts (11)

and nuts (9).

41. Mounting pin (6). a. Aline with frame rail hole. M916, M917, and M920

b. Attach with bolt (7) and nut (8). only.

42. Mud guard (4). a. Aline with mounting at top of

rear quarter fender (19).

b. Attach with six bolts (3), washers

(2), and nuts (1).

43. Three supports (17). a. Aline with mounting holes on

rear quarter fender (19).

b. Attach with three bolts (5) and

nuts (20) at upper fender

curvature.

44. Mounting tube (15). a. Aline with lower mounting holes

on three supports (17) and rear

quarter fender (19).

b. Attach with three bolts (16) and

nuts (18).

45. Clamp (13). Slide over mounting tube (15).

11-42
TM 9-2320-273-20

BODY AND CAB.

11-14. FENDER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

F. INSTALLATION OF REAR FENDER (Continued).

46. Mounting tube (15). a. Slide over mounting pin (6)

(M916, M917, and M920), or

mounting pin plate (10) (M915).

b. Secure with bolt (12) and nut

(14) thru clamp (13).

M916, M917, M920

11-43
TM 9-2320-273-20

BODY AND CAB.

1-15. VENTILATOR MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Installation. (10)

20 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 11-26A. Heater Removed.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES TM

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

None.

11-44
TM 9-2320-273-20

BODY AND CAB.

Loosen, Remove two cable

wires (2) from clips.

Slide off of two pins (3).

11-15. VENTILATOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

The driver’s side ventilator is riveted into

the side of the cab. It is not maintained

at the Organizational level.

1. Two clips (1).

2. Two wire ends (7). If necessary, tag for location.

11-45
TM 9-2320-273-20

BODY AND CAB.

11-15. VENTILATOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Four screws (6) Unscrew and remove.

4. Ventilator (5). Remove.

5. Seal (4). a. Inspect seal for deterioration.

If necessary, remove using a

suitable tool.

b. If seal is being replaced, cut

seal to desired length and

remove adhesive backing.

Install seal on ventilator

applying firm and even

pressure.

B. INSTALLATION.

6. Ventilator (5).

7. Four screws (6).

8. Two wire ends (7).

9. Two clips (1).

Set in place.

Screw in and tighten.

Slide onto two pins (3).

Fasten over cable wires (2).

NOTE

Follow-on maintenance action required:

Install heater; refer to paragraph 11-24B.

11-46
TM 9-2320-273-20

BODY AND CAB.

11-15. VENTILATOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

11-47
TM 9-2320-273-20

BODY AND CAB.

11-16. GRILLE AND BRUSH GUARD MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Disassembly. ( 5)

c. Assembly. (10)

d. Installation.

e. Brush Guard Removal. (10)

f. Brush Guard Installation. (10)

55 Minutes Total

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES TM

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

11-48

(10)
TM 9-2320-273-20

BODY AND CAB.

11-16. GRILLE AND BRUSH GUARD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

NOTE

On M916 thru M920, remove brush guard;

refer to para 11-16E.

1. Sixteen capscrews (24), Unscrew and remove grille (4).

Iockwashers (25) and

washers (26).

2. Two bolts (14), washers Unscrew and remove screen (21).

(13), nuts (11), and brackets

(12).

Top of grille will need to

be tipped forward to

remove bolts (M916 thru

M920).

11-49
TM 9-2320-273-20

BODY AND CAB.

11-16. GRILLE AND BRUSH GUARD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 B. DISASSEMBLY.

3.

4.

5.

Rail (1) two fillers (2),

two fillers (9), and two

rails (10).

Twenty-three capscrews (6)

and plates (7).

Two tap screws (22) and

plate (23).

C. ASSEMBLY.

6. Plate (23).

7. Screen (5).

8. Rail (l), two fillers (2), two

fillers (9), and two rails (10).

D. INSTALLATION.

9. Grille (4).

10. Screen (21).

11. Grille (4).

12. Install brush guard.

Drill out rivets (3) and remove.

Unscrew and remove screen

Unscrew and remove.

5).

Fasten to grille (4) with two tap

screws (22).

Aline with grille (4) and attach

with twenty-three capscrews (6)

and plates (7).

Install to grille (4) with new

rivets (3).

Position on truck.

Install with two bolts (14), washers

(13), brackets (12), and nuts (11).

Install with sixteen capscrews (24),

Iockwashers (25) and washers (26).

Refer to para 11-16F.

E. BRUSH GUARD REMOVAL (M916 thru M920 only).

13. Eight screws (1 5), washers

(16), and nuts (17).

Unscrew and remove two brackets

(18) and braces (19).

14, Eight screws (15), washers Unscrew and remove brush guard

(16), and nuts (17). (20) from front bumper.

F. BRUSH GUARD INSTALLATION (M916 thru M920 only).

15. Brush guard (20). Aline with mounting holes on top

of bumper and secure with eight

screws (15), washers (16), and

nuts (17).

16. Two braces (19) and Aline with mounting holes at

brackets (18). front fenders and brush guard

(20) and secure with eight screws

(15), washers (16), and nuts (17).

It is not necessary to

remove steel spring nuts

(8) unless they are broken.

Replace any broken steel

spring nuts (8) as needed.

Top of grille must be

tipped forward to install

bolts (M916 thru M920).

M916 thru M920 only.

11-50
TM 9-2320-273-20

BODY AND CAB.

11-16. GRILLE AND BRUSH GUARD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

11-51
TM 9-2320-273-20

BODY AND CAB

11-17. OPTIONAL WINTER FRONT MAINTENANCE.

THIS TASK COVERS: (Approximate TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Original Installation. (30)

b. Removal. (15)

c. Installation (15)

30 minutes total.*

*Not including original installation.

INITIAL SETU P EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 11-16A. Grille Removed.

11-16E. Brush Guard Removed

(M916 thru M920).

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

Two (MOS-63B20).

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

REFERENCES (TM)

TM 9-2320-273-10. GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

None.

11-52

TROUBLESHOOTING REFERENCES
TM 9-2320-273-20

BODY AND CAB.

11-17. OPTIONAL WINTER FRONT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. ORIGINAL INSTALLATION.

1. Installation drawing (12) Follow the instructions contained An installation drawing

and template (13). within the installation drawing and and drill template is supuse the template for proper drill plied with each Winter

locations on the grille. Front Kit.

11-53
TM 9-2320-273-20

BODY AND CAB.

11-17. OPTIONAL WINTER FRONT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 B. REMOVAL.

2. Three screws (5), Iockwashers Unscrew and remove top bar

(10), flat washers (9), and nuts assembly (3) along with three

(8). strap and buckle assemblies (2).

3. Twenty-one twist locks (7) a. Turn to unlock and remove

and Iockwashers (6). winter front (1).

b. Unscrew from two side bar

assemblies (4) and bottom

bar assembly (11).

4. Twelve screws (5), lock- Unscrew and remove two side

washers (10), fIat washers bars (4) and bottom bar (11).

(9) and nuts (8).

 C. INSTALLATION.

5. Two side bars (4) and Attach to grille with twelve Twist locks (7) and lockbottom bar (11). screws (5), Iockwashers (10), washers (6) are replaced

flat washers (9), and nuts (8). only with bottom bar (11)

and side bars (4).

6. Winter front (1), three Fasten to grille with three

strap and buckle assemblies screws (5), Iockwashers (10),

(2), and top bar (3). flat washers (9) and nuts (8).

7. Winter front (1). Adjust grille coverage for

weather conditions with strap

and buckle assemblies (2) and

twist locks (7).

Follow on Maintenance Action required:

a. Install grille; refer to para 11-16D.

b. Install brush guard (M916 thru M920);

refer to para 11-16F.

11-54
TM 9-2320-273-20

BODY AND CAB.

11-17. OPTIONAL WINTER FRONT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

11-55
TM 9-2320-273-20

BODY AND CAB.

11-18. GRILLE SUPPORT BRACKETS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Installation. (15)

30 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

All.

TEST EQUIPMENT

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

11-16E. Brush Guard Removed

(M916 thru M920).

None. 11-16A. Grille Removed.

SPECIAL TOOLS 11-29A. Hood Removed.

None.

MATERIALS/PARTS (P/N)

Rivet (10) SSLQ-66 (05693).

Rivet (30) SSLQ-64 (05693).

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

None.

11-66
TM 9-2320-273-20

BODY AND CAB.

11-18. GRILLE SUPPORT BRACKETS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1.

2.

3.

Thirty rivets (9) and seal (10). Drill out rivets (9) and remove

seal (10).

Bolt (15), six capscrews (3), Remove bracket (8) from bracket

Iockwashers (2) and washers (4).

(1).

Three rivets (9). Drill out and remove baffle (13)

and seal (14).

11-57
TM 9-2320-273-20

BODY AND CAB.

11-18. GRILLE SUPPORT BRACKETS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

4. Six capscrews (3), lockwashers (2) and washers (1).

5. Five rivets (7), retainer (6),

and shield (5).

6. Bracket (11).

Unscrew and remove bracket (4).

Drill out rivets (7) to remove

shield (5) and retainer (6).

Repeat steps (2), (3), (4), and (5)

on opposite side and remove

bracket (11).

B. INSTALLATION.

7.

8.

9.

10.

11.

12.

Bracket (4), shield (5),

retainer (6), and five new

rivets (7).

Six capscrews (3), washers

(1) and Iockwasher (2).

Bracket (8), bolt (16),

bracket (11), six capscrews

(3), washer (1), and

Iockwasher (2).

Three new rivets (9), baffle

(13) and seal (14).

Brackets (4) and (5).

Thirty-seven new rivets

Install onto bracket (4) with new

rivets (7).

Install bracket (4) to radiator

support.

Install.

Install and secure with rivets (9).

Repeat steps (7), (8), (9) and (10)

for opposite side.

Install rivets to secure seal (10).

(9) and seal (10).

Follow on Maintenance Action required:

a. Install grille; refer to para 11-16D.

b. Install brush guard (M916 thru M920);

refer to para 11-16F.

c. Install hood; refer to para 11-29B.

11-58
TM 9-2320-273-20

BODY AND CAB.

11-18. GRILLE SUPPORT BRACKETS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

11-59
TM 9-2320-273-20

BODY AND CAB.

11-19. MUD FLAPS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5 )

b. Installation. (10)

15 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M915, M916, M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

None.

11-60
TM 9-2320-273-20

BODY AND CAP.

11-19. MUD FLAPS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Procedure is same for removal of either flap.

A. REMOVAL

1. Spring pin (11) (M915) or Remove from spring bracket (2).

cotter pin (7) (M916, and

M920).

2. Spring bracket (2). Lift out of mounting bracket (8).

3. Mud flap (5). Remove from spring bracket (2)

by removing four bolts (3), washers

(4) and four nuts (6).

4. Two bolts (9) and washers Unscrew and remove mounting

(10). bracket (8).

5. Two bolts (12) and nuts (1). Unscrew and remove stowage

bracket (13). M915 only.

B. INSTALLATION.

6. Stowage bracket (13). Attach to RH frame rail with two M915 only.

bolts (12) and nuts (1).

7. Mounting bracket (8). Attach to rear frame with two

washers (10) and bolts (9).

8. Mud flap (5) Install mud flap onto spring bracket

(2) and secure with four bolts (3),

washers (4) and four nuts (6).

9. Spring bracket (2). Insert into mounting bracket (8) and

install spring pin (11) (M915) or

cotter pin (7) (M916 and M920).

11-61
TM 9-2320-273-20

BODY AND CAB.

11-20. DRIVERS SEAT MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 4)

b. Cleaning and Lubricating Hardware. ( 5)

c. Installation. ( 6 )

15 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Grease Gun.

GAA (Refer to Appendix C).

Lubriplate (Refer to Appendix C).

Non-Flammable Dry Cleaning Solvent SD-2 (Refer to Appendix C).

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

11-62
TM 9-2320-273-20

BODY AND CAB.

11-20. DRIVERS SEAT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL

1. Four nuts (6), washers (11), Unscrew and remove.

and bolts (12).

2. Seat (1). Lift out and remove from seat Two mechanics.

base (5).

3. Two bolts (10), Iockwashers Unscrew and remove seat belt

(9), and nuts (8). assembly (7).

11-63
TM 9-2320-273-20

BODY AND CAB.

11-20. DRIVERS SEAT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. CLEANING AND LUBRICATING HARDWARE.

CAUTION

Do not allow dry cleaning solvents to

come in contact with non-metal materials, These cleaners may damage

leather, rubber, and synthetics.

4.

5.

6.

Slide rails (14)

metal parts.

Grease fittings

and other

(2).

Two torsion bar ends (4),

three adjusting mechanisms

(3), (13), and (15), and

slide rails (14).

C. INSTALLATION.

7.

8.

9.

10.

Adjusting mechanisms (3),

(13), and (15).

Seat (1).

Four washers (11), bolts (12),

and nuts (6).

Seat belt assembly (7).

Clean with SD-2 dry cleaning

solvent.

Lubricate, using grease gun.

Lubricate liberally with

Lubriplate.

Move to center positions.

Set in place and aline mounting

holes.

Screw on and tighten to secure

seat (1) to seat base (5).

a.

b.

Aline mounting holes.

Install with two bolts (10),

Iockwashers (9), and nuts (8).

See LO 9-2320-273-12.

11-64
TM 9-2320-273-20

BODY AND CAB.

11-20. DRIVERS SEAT MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

11-65
TM 9-2320-273-20

BODY AND CAB.

11-21. PASSENGER’S SEAT MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REWIRED FOLLWS TASK DESCRIPTION.)

a. Removal. (5)

b. Cleaning and Lubricating Adjusting Mechanism. (5)

c. Installation. (7)

17 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Lubriplate (Refer to Appendix C).

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

One (MOS-63B20). Vehicle Parked On Level Ground.

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

None.

11-66
TM 9-2320-273-20

BODY AND CAB.

11-21. PASSENGER’S SEAT MAINTENANCE (Continued).

LOCATION/lTEM ACTIO N REMARKS

A. REMOVAL

1. Tool box door (5). Open for access to nuts (3) Remove tools if necessary.

and washers (4).

2. Four nuts (3) and washers (4). Unscrew and remove.

3. Seat (1). Lift out and remove.

B. CLEANING AND LUBRICATING ADJUSTING MECHANISM.

4. Adjusting rack and tooth a. Clean with soap and water.

mechanism (2). Dry thoroughly.

b. Apply Lubriplate to both

sides.

C. INSTALLATION

5. Seat (1). a. Place back in position.

b. Set in place with studs (6)

in holes.

6. Four washers (4) and nuts (3). Screw on and tighten.

7. Tool box door (5). Close. Put tools back in if you took

11-67
TM 9-2320-27320

CAB AND BODY.

11-22. SEAT RISER AND TOOL BOX MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REWIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (45)

b. Installation. (45)

90 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 11-20A. Drivers Seat Removed (for

Seat Riser Removal).

TEST EQUIPMENT 11-21A. Passenger’s Seat Removed

None. ( For Tool Box Removal).

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

Two (MOS-63B20).

REFERENCES (TM)

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground

TM 9-2320-273-10 GENERAL SAFETY INSTRUCTIONS

Engine Off.

Park Brake Set.

Transmission In Neutral.

TROUBLESHOOTING REFERENCES

None.

11-68
TM 9-2320-273-20

CAB AND BODY.

11-22. SEAT RISER AND TOOL BOX MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Instructions for repairing metal tool box

and seat riser may be found in FM 43-2.

A. REMOVAL

1. Three bolts (2) and Unscrew and remove fire

nuts (4). extinguisher bracket (3).

2. Four bolts (10), nuts (5), Unscrew and remove two

and eight washers (11). piece ratio selector brace (6).

3. Thirty-six bolts (8), Unscrew and remove. Total fasteners for both

washers (9). riser and tool box.

4. Seat riser (7) and tool Remove

box (1).

11-69
TM 9-2320-273-20

CAB AND BODY.

11-22. SEAT RISER AND TOOL BOX MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION

5. Seat riser (7) and Place in cab. Aline with

tool box (1). bolt holes in cab floor.

6. Thirty-six bolts (8) Screw in and tighten.

and washers (9).

7. Ratio selector brace (6). Install with four bolts (10),

nuts (5), and eight washers (11).

8. Fire extinguisher bracket (3). Install with three bolts (2) and

nuts (4).

Follow-on maintenance actions required.

a. Install driver’s seat; refer to para

11-20 C.

b. Install passenger’s seat; refer to

para 11-21 C.

11-70
TM 9-2320-273-20

This page intentionally left blank.

11-71
TM 9-2320-273-20

BODY AND CAB.

11-23. WINDSHIELD WIPER BLADE AND ASSEMBLY MAINTENANCE.

11-23. WINDSHIELD WIPER BLADE AND ASSEMBLY MAINTENANCE.

a. Removal. (4)

c. Operational Check. (1)

b. Installation.

8 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

None.

11-72

(3)
TM 9-2320-273-20

BODY AND CAB.

Unscrew and remove.

Remove from arm (1).

Pry up.

Slide out of metal case (3).

11-23. WINDSHIELD WIPER BLADE AND ASSEMBLY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL

1. Screw (6) and nut (2).

2. Wiper blade assembly (7).

3. Locking tab (4)

4. Rubber blade (5).

11-73
TM 9-2320-273-20

BODY AND CAB.

11-23. WINDSHIELD WIPER BLADE AND ASSEMBLY MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION.

5. Rubber blade (5).

6. Locking tab (4).

7. Blade assembly (7).

8. Screw (6) and nut (2).

Slide into metal case (3).

Push down over rubber blade

(5).

Aline with arm (1).

a. Put screw through arm (1)

and blade assembly (7).

b. Screw nut on and tighten.

 C. OPERATIONAL CHECK.

9. Wiper knob.

10. Wiper blade (5).

Pull out.

Check to see that blade

moves across windshield

with good contact.

Squirting windshield with

washer fluid will make it

easy to tell if wiper blade

is operating properly.

11-74
TM 9-2320-273-20

This page intentionally left blank.

11-75
TM 9-2320-273-20

BODY AND CAB.

11-24. WINDSHIELD WIPER ARMS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESRIPTION.)

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 9-1.

11-76

a. Removal.

b. Installation.

c. Operational Check.

( 4)

(3)

( 1)

8 Minutes Total.
TM 9-2320-273-20

BODY AND CAB.

11-24. WINDSHIELD WIPER ARMS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Nut (1) and Iockwasher

(2).

Unscrew and remove.

2. Wiper arm (3).

3. Spring (5). If spring is stretched so that

it does not hold arm tightly,

replace.

Lift off of knurled driver

(4).

Unhook and remove.

NOTE

Procedures for removing and installing blade

are given in para 11-23.

11-77
TM 9-2320-273-20

BODY AND CAB.

Seat firmly on knurled

driver (4).

Screw on and tighten.

11-24. WINDSHIELD WIPER ARMS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION

4. Spring (5). Lock into place. Arm should be in same

position as when you removed

it.

5. Arm (3).

6. Lockwasher (2) and

nut(1).

C. OPERATIONAL CHECK.

NOTE

Operate wipers to see that they move normally.

Squirt windshield with washer fluid and check

that it is removed without streaking. Park wipers.

If wipers do not operate correctly, troubleshoot

wiper system as described in Table 9-1.

11-78
TM 9-2320-273-20

BODY AND CAB.

11-24. WINDSHIELD WIPER ARMS MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

11-79
TM 9-2320-273-20

BODY AND CAB.

11-25. REAR VIEW MIRROR MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Disassembly. (15)

c. Assembly. (15)

d. Installation. (10)

e. Adjustment. (10)

60 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGUTATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

11-80
TM 9-2320-273-20

BODY AND CAB.

11-25. REAR VIEW MIRROR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Procedure shown is for right side mirror.

Identical procedure is used for left side mirror.

A. REMOVAL

1. Six bolts (1) and Loosen and remove.

Iockwashers (2).

2. Mirror assembly (5). Remove.

11-81
TM 9-2320-273-20

BODY AND CAB.

11-25. REAR VIEW MIRROR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. DISASSEMBLY.

3.

4.

5.

6.

7.

8.

9.

Two acorn nuts (13).

Two tube clamps (16),

two Iockwashers (20) and

spacers (21).

Mirror assembly (23).

Capscrew (12), acorn nut

(17) and Iockwasher (18).

Two acorn nuts (6).

Loop detent assembly (14).

bracket (upper) (3), bracket

(lower) (4) and two

compression springs (7).

Cross brace bracket (9) and

loop cross brace (11).

 C. ASSEMBLY.

10.

11.

12.

13.

14.

15.

16.

Cross brace bracket (9) and

loop cross brace (11).

Two compression springs

(7), loop detent assembly

(14), bracket (upper) (3)

and bracket (lower) (4).

Two acorn nuts (6).

Capscrew (12), acorn nut

(17), and Iockwasher (18).

Two tube clamps (16),

Two acorn nuts (13).

Mirror assembly (23).

 D. INSTALLATION.

Loosen and remove.

Remove.

Pull free from face of mirror

head assembly (15).

Loosen and remove.

Loosen and remove.

Remove from pivot rod (8).

Remove by unthreading two

outer jam nuts (10) and removing from pivot rod (8).

Install on pivot rod (8) and

secure with jam nuts (10).

Install on pivot rod (8).

Install and tighten.

Install to fasten loop cross

brace (1 1) to tube clamp

(19) and tighten.

Position mirror head assembly

(15) and pivot tube clamps

over screws (22) to secure.

Install and tighten.

Stick onto face of mirror head

assembly (15).

17. Mirror assembly (5).

18. Six bolts (1) and lockwashers (2).

Position on door and aline

mounting holes.

Install and tighten.

If damaged.

If removed.

11-82
TM 9-2320-273-20

BODY AND CAB.

11-25. REAR VIEW MIRROR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

E . ADJUSTMENT

19. Mirror head assembly (15). Adjust for best view.

NOTE

If hauling extra wide loads, loosen two

nuts on loop detent assembly (14).

Mirrors can be telescoped an additional

five inches.

11-83
TM 9-2320-273-20

BODY AND CAB.

11-26. HEATER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (27)

b. Installation. (55)

82 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. 4-25A. Air Cleaner Cannister

TEST EQUIPMENT Removed.

None. 4-42A. Radiator Drained.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Electrical Tape.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

11-84
TM 9-2320-273-20

BODY AND CAB.

11-26. HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. ENGINE COMPARTMENT/ a. Loosen two clamps (10).

Heater hoses (8) and (9). b. Disconnect hoses. Keep hose ends raised to

prevent coolant from running out.

2. ENGINE COMPARTMENT/ Loosen and remove.

Four nuts (7) and washers (6).

11-85
TM 9-2320-273-20

BODY AND CAB.

11-26 HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. CAB/Three wires (2). Remove electrical tape and

disconnect wires.

4. CAB/Two air ducts (1). a. Loosen clamps (3).

b. Remove ducts.

5. CAB/Two cable clips (5). a. Loosen.

b. Remove cables.

6. CAB/Heater (4). a. Remove eight screws from

runner and slide floor mat

out of way of heater.

b. Remove.

7. Two insulators (12). Remove from four heater

mounting studs (11).

B. INSTALLATION.

8. Two insulators (12). Install over four heater

mounting studs (11).

9. CAB/Heater (4). Set in place.

10. CAB/Two cable clips (5). a. Attach cables. PASSENGER cable goes to

b. Tighten clips. bottom, DRIVER cable

goes to top.

11. CAB/Two air ducts (1). Attach and tighten clamps (3).

12. CAB/Three wires (2). a. Connect. Wires are color-coded to

b. Wrap connections with help you match them up.

electrical tape.

13. Floor mat. Install eight screws to secure

runner over floor mat.

14. ENGINE COMPARTMENT/ Install and tighten.

four nuts (7) and washers (6).

15. ENGINE COMPARTMENT/ a. Install hoses.

Heater hoses (8) and (9). b. Secure with two clamps (10).

11-86
TM 9-2320-273-20

BODY AND CAB.

11-26 HEATER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

Follow-on Maintenance Action required:

a. Fill cooling system; refer to para 4-42C

and D.

b. Install air cleaner cannister; refer to

para 4-25D.

c. Bleed heater; refer to para 4-50C.

11-87
TM 9-2320-273-20

BODY AND CAB.

11-27. HEATER HOSE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

A l l 4-42a. Radiator Drained.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING

Table 4-1.

Engine Off.

Park Brake Set.

Transmission In Neutral.

11-88
TM 9-2320-273-20

BODY AND CAB.

11.27. HEATER HOSE MAINTENANCE (Continued).

NOTE

All heater hoses and clamps are maintained

using standard shop practices and techniques,

Replace hoses that are cracked or deteriorated

and any defective clamps.

Follow on maintenance action required:

a. Fill cooling system; refer to para 4-42 C and D.

b. Bleed heater; refer to para 4-50C.

c. Check for leaks.

11-89
TM 9-2320-273-20

BODY AND CAB.

11-28. HEATER CONTROL PANEL MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal of Knob and Cable. ( 5 )

b. Installation of Knob and Cable. (10)

c. Operational Check. ( 6 )

20 Minutes Totel.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Cable tie, MS-3367-1-9 (96906)

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Park Brake Set.

Transmission In Neutral.

11-90 Change 1
TM 9-2320-273-20

BODY AND CAB.

11-28 HEATER CONTROL PANEL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

CAUTION

This procedure tells you how to remove and install

the passenger heat control knob and cable. Follow

the same steps to replace controls for driver heat,

fresh vent, recirculation vent, and heater. Be sure

to secure a new cable tie around cables after task

completion to prevent contact and possible

electrical short against air pressure warning switch

located on the firewall.

Change 1 11-91
TM 9-2320-273-20

BODY AND CAB.

11-28. HEATER CONTROL PANEL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 A. REMOVAL OF KNOB AND CABLE.

1. Clip (6). Loosen. Remove cable (1) from

clip.

2. Cable end (8). Slide off of pin (7).

3. Setscrew (9). Loosen. Remove knob (5).

4. Two screws (3). Remove rear cover (2) from front

cover (4).

5. Nut (11). Unscrew from collar (10).

6. Cable tie (12) Cut and remove from cable

(1) and four other cables.

7. Cable (1). Remove through rear cover (2),

nut (11), and front cover (4).

B. INSTALLATION OF KNOB AND CABLE.

8. Cable (1). Thread cable end (8) through front

cover (4), nut (11), and rear cover

(2).

9. Cable tie (12) Install around cable (1) and

four other cables.

10. Nut(n). Screw onto collar (10) and tighten.

11. Rear cover (2). SIide onto front cover (4) and

secure with two screws (3).

12. Knob (5). a. Place onto cable (1).

b. Tighten setscrew (9).

13, Cable end (8). Slide onto pin (7).

14. Cable (1). Fasten with clip (6).

C . OPERATIONAL CHECK.

15. Knob (5). Pull out and push in. Check that Check for binding in

pin (7) swings as you move the cable (1), if pin (7) fails to

knob. swing.

11-92 Change 1
TM 9-2320-273-20

BODY AND CAB.

11-28. HEATER CONTROL PANEL MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Change 1 11-93
TM 9-2320-273-20

BODY AND CAB.

11-29. HEATER CONTROL VALVE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REWIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Installation. (15)

30 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Clean Container.

PERSONNEL REWIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY lNSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

11-94
TM 9-2320-273-20

BODY AND CAB.

11-29. HEATER CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL

1. Shutoff valve (7).

NOTE

Control knob and cable replacement

procedures are given in paragraph 11-28.

Close (turn handle clockwise).

11-95
TM 9-2320-273-20

BODY AND CAB.

11-29. HEATER CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

2. Screw (2).

3. Cable end (4).

4. Two clamps (9).

5. Control valve (8).

B . INSTALLATION. 

Loosen. Remove cable (1) from

clip (3).

Slide off of pin (5).

NOTE

Before removing control valve (8), place

clean container underneath to catch

spilled coolant.

Loosen.

Remove from two rubber

connectors (6).

6. Control valve (8).

7. Two clamps (9).

8. Cable (1).

9. Cable end (4).

Push into two rubber connectors

(6).

Tighten.

Place in clip (3) and tighten screw

(2).

Slide onto pin (5).

NOTE

Follow-on maintenance action required:

Bleed heater and adjust shutoff valve;

refer to paragraph 4-50C.

11-96
TM 9-2320-273-20

BODY AND CAB.

11-29. HEATER CONTROL VALVE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

11-97
TM 9-2320-273-20

BODY AND CAB.

11-30. HEATER AIR DUCTS MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REWIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (7)

b. Installation. (8)

c. Checking for Leaks. (5)

20 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Hose Tie (3), PLT4A-MO (06383).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 4-1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

11-98
TM 9-2320-273-20

BODY AND CAB.

11-30. HEATER AIR DUCTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 A. REMOVAL.

1.

2.

3.

Clamps (2), (3), and Loosen.

(4).

Three hose ties (7) Cut and

Air ducts (1) and (8). Remove.

remove.

11-99
TM 9-2320-273-20

BODY AND CAB.

11-30. HEATER AIR DUCTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

4. Three screws (6). Remove.

and three brackets (5).

B. INSTALLATION.

5. Three screws (6) and Install.

brackets (5).

6. Air ducts (1) and (8). Set in place.

7. Clamps (2), (3), and (4). Tighten.

8. Three new hose ties (7). Install thru brackets (5) and

around air ducts (1) and (8).

C. CHECKING FOR LEAKS.

9. Engine. Start up (see TM 9-2320-273-10).

10. INSTRUMENT PANEL/ Turn on heater and fan.

heater controls.

11. Air ducts (1) and (8). Check for leaks. Tighten clamps

(2), (3) or (4) as necessary.

12. Engine. Shut down (see TM 9-2320-273-10).

11-100
TM 9-2320-273-20

BODY AND CAB.

11-30. HEATER AIR DUCTS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

11-101
TM 9-2320-273-20

BODY AND CAB.

1-31. DATA AND INSTRUCTION PLATES MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

11-102
TM 9-2320-273-20

BODY AND CAB.

11-31. DATA AND INSTRUCTION PLATES MAINTENANCE.

LOCATION/lTEM ACTION REMARKS

All data and instruction plates are identified

in TM 9-2320-273-10. Maintenance is limited to

cleaning and replacement. To clean, use a

shop rag and dry cleaning solvent. Replace by

removing existing means of attachment; then

instalI new plate and fasten with identical

attaching parts.

11-103
TM 9-2320-273-20

BODY AND CAB.

11-32. HOOD MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Installation. (25)

45 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

All. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Cotter Pin, 137155 (24617).

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

None.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked On Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine Off.

Transmission In Neutral.

Park Brake Set.

11-104
TM 9-2320-273-20

BODY AND CAB.

11-32. HOOD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

The following procedure is applicable to

both the left or right hood top and side

panels.

1. Cotter pin (12). a. Remove and discard.

b. Remove pin (11) and

two washers (10).

2. Four capscrews (3), Unscrew and remove handle (2).

washers (4) and nuts

(5).

3. Four capscrews (6), Unscrew and remove two hook

washers (8) and brackets (7).

nuts (9).

LEGEND:

1. HOOD TOP PANEL

2. HANDLE

3. CAPSCREW (4)

4. WASHER (4)

5. NUT (4)

6. CAPSCREW (4)

7. HOOK BRACKET (2)

8. WASHER (4)

9. NUT (4)

10. WASHER (2)

11. PIN

12. COTTER PIN

13. HOOD SIDE PANEL

14. CAPSCREW (14)

15. WASHER (14)

16. NUT (14)

17. NUT (14)

18. WASHER (28)

19. CAPSCREW (14)

20. CAPSCREW, WASHER,

AND NUT (4)

21. FRONT BRACKET

22. PIN PLATE

23. HOOD CENTER PANEL

11-105
TM 9-2320-273-20

BODY AND CAB.

11-32. HOOD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

4.

5.

6,

7.

Fourteen capscrews Unscrew and remove hood side

(14), washers (15) panel (13).

and nuts (16).

Fourteen capscrews (19), Unscrew and remove hood top

twenty-eight washers (18), panel (1).

and fourteen nuts (17).

Four capscrews, washers, a. Remove from pin plate (22).

and nuts (20). b. Slide pin plate (22) from front

bracket (21).

Hood center panel (23). Remove from rear bracket (21)

on firewall.

NOTE

Inspect hood prop safety chains, S-hooks,

and rubber grommets for damage. Replace

as necessary.

B. lNSTALLATION.

8. Hood center panel (23). Insert pin into rear bracket (21)

on firewall.

9. Four capscrews, washers, a. Insert pin plate (22) into front

and nuts (20). bracket (21).

b. Install pin plate (22) to center

panel (23).

10. Hood top panel (1). Position and secure with fourteen

capscrews (19), twenty-eight washers

(18) and fourteen nuts (17).

11. Hood side panel (13). Position and secure with

fourteen capscrews (14),

washers (15) and nuts (16).

12. Hood brackets (7). Position on hood side panel

(13) and secure with four

capscrews (6), washers (8)

and nuts (9).

13. Handle (2). Position and secure with

four capscrews (3), washers

(4) and nuts (5).

11-106
TM 9-2320-273-20

BODY AND CAB.

11-32. HOOD MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

14. Two washers (10) Insert and secure with cotter

and pin (11). pin (12).

LEGEND:

1. HOOD TOP PANEL

2. HANDLE

3. CAPSCREW (4)

4. WASHER (4)

5. NUT(4)

6. CAPSCREW (4)

7. HOOK BRACKET (2)

8. WASHER (4)

9. NUT (4)

10. WASHER (2)

11. PIN

12. COTTER PIN

13. HOOD SIDE PANEL

14. CAPSCREW (14)

15. WASHER (14)

16. NUT (14)

17. NUT (14)

18. WASHER (28)

19. CAPSCREW (14)

20. CAPSCREW, WASHER, AND NUT (4)

21. FRONT BRACKET

22. PIN PLATE

23. HOOD CENTER PANEL

TA 075304

11-107
TM 9-2320-273-20

BODY AND CAB.

 11-33. TAIL ROLLER MAINTENANCE.

THIS TASK COVERS: (APPROXlMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Installation. (20)

40 Minutes Total.

INITIAL SETUP

APPLICABLE CONFIGURATIONS

M916 and M920.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Hoist.

Jack Stands.

PERSONNEL REQUIRED

TWO (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

REFERENCES (TROUBLESHOOTING)

None.

EQUIPMENT CONDITION

PARAGRAPH CONDITION DESCRIPTION

11-19A. Mud Flaps Removed.

11-9A. Tow Eyes Removed.

5-50A. Blackout Tail Lamps

Removed.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

Use Suitable Jack Stands and Hoist to Support

Tail Roller Assembly; it is Very Heavy.

11-108
TM 9-2320-273-20

BODY AND CAB.

11-33. TAIL ROLLER MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

The Tail Roller is very heavy. Use

extreme caution when raising or

lowering to prevent injury if it

should fall.

1. One roller mounting Support with suitable jack stand. Choose the roller mountbracket (5). ing bracket on the side

where bolt (3) and nut (6)

are used.

2. Tail roller (2). Support with suitable hoist.

3. Four washer base bolts (7) Remove from roller mounting

and washer base nuts (2). bracket (5) and the frame rail (8).

4. Tail roller (2) with assembled a. Move tail roller in the direction Second mechanic guides

roller mounting bracket (5). of the roller mounting bracket assembly to the ground.

without bolts. The tail roller’s

axle shaft will be pulled out of

the other roller mounting

bracket.

b. Slowly lower jackstand and

hoist.

LEGEND:

1. WASHER BASE NUT (8)

2. TAIL ROLLER

3. BOLT

4. LUBRICATION FITTING (2)

5. ROLLER MOUNTING BRACKET (2)

6, NUT

7. WASHER BASE BOLT (8)

8. FRAME RAIL (2)

TA 076699

11-109
TM 9-2320-273-20

BODY AND CAB.

11-33. TAIL ROLLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

5. One bolt (3), one nut (6), Remove.

and the roller mounting

bracket (5).

6. Roller mounting bracket Pull tail roller’s axle shaft out of

(5) and tail roller (2). roller mounting bracket.

7. Four washer base nuts (1) Unscrew and remove second Removal is necessary only

and washer base bolts (7). roller mounting bracket (4). if replacement is needed

due to wear or damage.

NOTE

If bearings inside tail roller or axle

shaft are to be serviced, refer to

Direct Support Maintenance.

B. INSTALLATION.

8. One roller mounting bracket Aline with holes in frame rail (8) Make sure you use correct

(5). and install with four washer base holes in roller mounting

bolts (7) and washer base nuts bracket. M916 uses two

(1). top rows; M920 uses

bottom two rows.

9. Second roller mounting Slide over axle shaft of tail roller

bracket (5). (2) and secure with bolt (3) and

nut (6).

10. Tail roller (2) with assembled a. Lift into position with hoist and First mechanic operates

roller mounting bracket (5). aline mounting holes with those hoist while second guides

in frame rails (8) and tail roller assembly.

axle into first roller mounting

bracket already installed.

b. Block in position with axle

stands.

11. Four washer base bolts (7) Install thru second roller mounting Make sure you use correct

and washer base nuts (1). bracket (5) and frame rail (8). bolt holes in roller mounting bracket. M916 uses

two top rows; M920 uses

bottom two rows.

11-110
TM 9-2320-273-20

BODY AND CAB.

LEGEND:

1.

2.

3.

4.

5.

6.

7.

8.

WASHER BASE NUT (8)

TAIL ROLLER

B0LT

LUBRICATION

FITTING (2)

ROLLER MOUNTING

BRACKET (2)

NUT

WASHER BASE

BOLT (8)

FRAME RAIL (2)

11-33. TAIL ROLLER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

12. Two lubrication fittings (4). Clean, inspect and lubricate using Refer to Direct Support

grease gun (see LO 9-2320-273-12). Maintenance if replacement is necessary.

Follow-on maintenance action required:

a. Install blackout tail lamps (para 5-50B).

b. Install tow eyes (para 11-9B).

c. Install mud flaps (para 11-19B).

TA 075700

11-111/11-112(Blank)

TM 9-2320-273-20

CHAPTER 12

WINCH AND PTO LINKAGE MAINTENANCE

12-1. OVERVIEW.

This chapter provides you with the following information related to winch and power takeoff

maintenance:

a. All required special tools and equipment.

b. Other technical manuals.

c. Troubleshooting procedures.

d. Maintenance procedures.

Section I REPAIR PARTS, SPECIAL TOOLS, TMDE AND SUPPORT EQUIPMENT

 12-2. COMMON TOOLS AND EQUIPMENT.

For authorized common tools and equipment, refer to the Modified Table of Organization and

Equipment (MTOE) applicable to your unit.

 12-3. SPECIAL TOOLS, TMDE, SUPPORT EQUIPMENT.

The special tools, TMDE and support equipment required for the winch and power takeoff

maintenance procedures described in this chapter are limited to the oil filter strap wrench.

(Refer to Organizational Maintenance RPSTL, TM 9-2320-273-20P for tool description and

illustration.) -

12-4. SPARES AND REPAIR PARTS.

Spares and repair parts are listed and illustrated in the Repair Parts and Special

covering Organizational Maintenance for this equipment (TM 9-2320-273-20P).

Tools List

Section II TROUBLESHOOTING

12-5. INTRODUCTION.

Tables 12-1 and 12-2 contain instructions for troubleshooting the winch and the power

takeoff, which are driven by the transmission. The corrective actions tell you how to fix the

12-1
TM 9-2320-273-20

 12-5. INTRODUCTION (Continued).

problem or refer you to a procedure that will fix the problem. The Troubleshooting tables are

arranged by malfunctions in the following order:

WINCH (M916 and M920) (Table 12-1)

a. Winch operates in one direction only.

b. Winch does not operate in either direction.

c. Winch operates at one speed only.

d. Winch will not hold suspended load.

POWER TAKEOFF (PTO) (M916 thru M920) (Table 12-2).

a. PTO will not engage.

b. PTO is excessively noisy.

Section III MAINTENANCE PROCEDURES

 12-6. INTRODUCTION.

This section provides you with Organizational Level maintenance procedures for the winch. The

scope of maintenance is limited to the work listed in the following summary of task procedures.

12-2
TM 9-2320-273-20

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

1. WINCH OPERATES IN ONE DIRECTION ONLY:

Step 1. Inspect all oil lines for damage and leakage.

Replace lines (para 12-13).

Step 2. Inspect directional control valve for leakage.

Tighten connections or replace valve (para 12-11).

Step 3. Check winch motor for leakage and visible signs of overheating.

Replace winch motor (para 12-14).

Step 4. Check to see if pilot orifice in winch brake valve is plugged.

Clean orifice.

2. WINCH DOES NOT OPERATE IN EITHER DIRECTION:

Step 1. Check all oil lines for damage and leakage.

Tighten loose connections and replace defective components.

Step 2. Check pump inlet strainer and in line filter for clogging.

Replace filter element (para 12-9 and 12-10).

Step 3. Check reservoir for proper oil level.

Fill to proper level (LO 9-2320-273-12).

Step 4. Check pump for leakage and visible signs of overheating.

Replace pump (para 12-15).

Step 5. Connect a pressure gage in line between each control valve and winch motor

(one at a time) and attempt to operate.

If pressure is normal (2350 psi maximum), refer winch to Direct

Support Maintenance for replacement.

12-3

Table 12-1. Winch Troubleshooting Procedures.
TM 9-2320-273-20

Table 12-1. Winch Troubleshooting Procedures (Continued).

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

3. WINCH OPERATES AT ONE SPEED ONLY:

Check the auxiliary control valve for damage and leakage.

a. Tighten or repair leaking connections or lines.

b. Replace valve (para 12-11).

c. Check rear gear section of dual pump (refer to Direct Support).

4. WINCH WILL NOT HOLD SUSPENDED LOAD:

Step 1. Check failsafe brake disk to see if it is oil soaked.

Replace brake assembly.

Step 2. Check failsafe brake disks for wear.

Replace brake.

12-4
TM 9-2320-273-20

Table 12-2. Power Takeoff (PTO) Troubleshooting Procedures.

MALFUNCTION.

TEST OR INSPECTION.

CORRECTIVE ACTION.

1.

2.

PTO WILL NOT ENGAGE:

Have an assistant attempt to engage the PTO (TM 9-2320-273-10) and visualIy check the

shift rod (lever) on the PTO for movement.

a. If shift does not move, replace PTO linkage (para 12-16).

b. If the shift rod moves, refer the problem to Direct Support Maintenance for

PTO replacement.

PTO IS EXCESSIVELY NOISY:

Notify Direct Support Maintenance.

12-5
TM 9-2320-273-20

2-7. WINCH MAINTENANCE TASK SUMMARY.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 and M920. None. None.

TEST EQUIPMENT

None.

TOOLS

None.

MATERIALS/PARTS (P/N)

Clean Container.

Marking Pen.

Filter Element, 74011 (34623).

Oil (1 qt).

Gasket (9995).

Gasket (2), 11027 (34623).

Pin Kit, 1V1701 (34623).

Non-flammable Dry Cleaning Solvent SD-2 (Refer to Appendix C).

Liquid Teflon (Refer to Appendix C).

Masking Tape.

Plugs.

Gasket, Hydraulic Motor to Failsafe Brake, 28426 (34625).

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

TWO MOS-63B20) Vehicle Parked Level.

REFERENCES (TM) GENERAL SAFETY INSTRUCTIONS

TM 9-2320-273-10 Engine OFF.

TM 9-2320-273-20P Transmission in Neutral.

LO 9-2320-273-12 Park Brake Set.

REFERENCES (TROUBLESHOOTING)

Table 12-1, 12-2.

12-6
TM 9-2320-273-20

12-7. WINCH MAINTENANCE TASK SUMMARY (Continued).

LIST OF TASKS

TASK

NO.

1.

2.

3.

4.

5.

6.

TASK

Winch Cable Maintenance:

A. Removal.

B. Installation.

Inline Filter Maintenance:

A. Removal.

B. Installation.

C. Checking for Leaks.

Reservoir Screen and Strainer Maintenance:

A. Removal.

B. Cleaning.

C. Installation.

Control Valves Maintenance:

A. Removal.

B. Installation.

C. Operational Check.

Throttle Maintenance:

A. Removal.

B. Cleaning and Inspection.

C. Installation.

D. Operational Check.

Hydraulic Lines and Fittings Maintenance:

A. Removal.

B. Installation.

C. Checking for Leaks.

TASK

REF

12-8

12-8A

12-8B

12-9

12-9A

12-9B

12-9C

12-10

12-10A

12-10B

12-10C

12-11

12-11A

12-11B

12-11C.

12-12

12-12A

12-12B

12-12C

12-12D

12-13

12-13A

12-13B

12-13C

TROUBLESHOOTING

REF (TABLE)

12-1

12-2

12-1

12-2

12-1

12-2

12-1

12-2

12-1

12-2

12-1

12-2

12-7
TM 9-2320-273-20

12-7. WINCH MAINTENANCE TASK SUMMARY (Continued).

TASK

NO.

7.

8.

9.

LIST OF TASKS

TASK

Hydraulic Motor Maintenance:

A. Removal.

B. Cleaning and Inspection.

C. Installation and Operational Check.

Hydraulic Pump Maintenance:

A. Removal.

B. Installation.

C. Operational Check.

PTO Linkage Maintenance:

A. Removal.

B. Installation.

C. Operational Check.

TASK

REF

12-14

12-14A

12-14B

12-14C

12-15

12-15A

12-15B

12-15C

12-16

12-16A

12-16B

12-16C

TROUBLESHOOTING

REF (TABLE)

12-1

12-2

12-1

12-2

12-1

12-2

12-8
TM 9-2320-273-20

This page intentionally left blank.

12-9
TM 9-2320-273-20

WINCH.

2-8. WINCH CABLE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Installation. (20)

35 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 and M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

Two (MOS-63B20) .

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 12-1, 12-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Park ad on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

12-10
TM 9-2320-273-20

WINCH.

12-8. WINCH CABLE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS -

1. Cable (1). Unreel from drum (2). Refer to TM 9-2320-273-10.

2. Nuts (3). Remove.

3. U-bolt (4). Remove.

B. INSTALLATION.

4. U-bolt (4). Install through holes on

side of drum.

5. Nuts (3). Screw onto U-bolt (4). Do not

tighten at this time.

6. Cable (1). Slide unswaged end of cable

between U-bolt (4) and drum

(2). Cable should protrude

approximately 1.00 inch.

7. Nuts (3). Tighten.

8. Cable (1). Rewind on drum (2). Refer to TM 9-2320-273-10.

TA 075306

12-11
TM 9-2320-273-20

WINCH.

12-9. INLINE FILTER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (5)

b. Installation. (5)

c. Checking for Leaks. (5)

15 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 and M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Filter Element, 74011 (34623).

Oil, 1 qt (1 liter) (refer to appendix C).

Container.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

Table 12-1, 12-2.

12-12
TM 9-2320-273-20

WINCH.

12-9. INLINE FILTER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Winch system retains some pressure even

when not in use. Before you begin

maintenance, vent pressure by carefully

removing fill cap (1).

TA 076307

12-13
TM 9-2320-273-20

12-9. INLINE FILTER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Filter (4). Using wrench, unscrew and Place container

throw away. under filter.

2. Gasket (5). Inspect. Replace if necessary.

B. INSTALLATION .

Do not use strap wrench to install filter.

3. Filter (4). a. POur in 1 qt (1 liter)

b. Install gasket (5).

c. Screw on until filter top

just touches mounting plate (3).

d. Tighten 1/4 turn more.

4. Sight glass (2). Check that oil is visible in top Add oil if necessary.

sight glass.

5. Fill cap (1). Screw on and tighten.

C. CHECKING FOR LEAKS.

6. Engine.

7. PTO.

8. Filter (4).

9. Engine. I

Start up (see

TM 9-2320-273-10).

Engage (see

TM 9-2320-273-10).

Check for oil leaks.

Shut down (see TM 9-2320-

273-10).

Tighten as necessary.

12-14

WINCH .
TM 9-2320-273-20

WINCH.

12-9. INLINE FILTER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

The reservoir screen and strainer should be

cleaned or replaced each time you service

the inline filter. See para 12-10.

12-15
TM 9-2320-273-20

WINCH.

12-10. RESERVOIR SCREEN AND STRAINER MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. ( 5)

b. Cleaning. (10)

c. Installation. ( 5)

20 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 and M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Non-flammable Cleaning Solvent SD-2 (refer to appendix C).

Clean Container.

Gasket (2), 11027 (34623).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 12-1, 12-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

12-16
TM 9-2320-273-20

WINCH.

12-10. RESERVOIR SCREEN AND STRAINER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Winch system retains some pressure

even when not in use. Remove fill

cap (1) slowly.

12-17
TM 9-2320-273-20

WINCH.

12-10. RESERVOIR SCREEN AND STRAINER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

1. Fill cap with chain (1). Unscrew.

2. Drain plug (6). Unscrew and drain fluid into

clean container.

3. Nut (11). a. Loosen. Slide upper cover (10), two

b. Remove nut (11) with gaskets (9) and lower cover,

other hand. with stud (8) to the side with

one hand.

4. Upper cover (10), two Lift out of reservoir (5). Discard gaskets (9).

gaskets (9), and lower

cover with stud (8).

5. Pump inlet strainer (7). Unscrew and remove.

6. Six screws (12). Remove and lift out retainer Inspect gaskets (3). If damaged,

(2), two gaskets (3), and make from stock using old

flange and screen (4). gasket for a template.

B. CLEANING.

Do not allow dry cleaning solvent SD-2 to

come in contact with seals or flexible hoses.

Such cleaners may damage leather, rubber,

and synthetic materials.

7. Flange and screen (4) a. Clean with dry cleaning If damaged, replace.

and pump inlet strainer (7). solvent.

b. Allow to dry.

C. INSTALLATION.

8. Flange and screen (4), two Place in reservoir fill opening

gaskets (3) and retainer (2). and secure with six screws (12).

9. Pump inlet strainer (7). Insert thru access hole and

screw onto pipe.

10. Lower cover with stud (8), a. Hold in position with one

two new gaskets (9), and hand at access hole in

upper cover (10). reservoir (5).

b. Install nut (11) and tighten. To keep parts in proper position

first turn nut (11) by hand while

pulling up. Once snug, tighten

with wrench.

12-18
TM 9-2320-273-20

WINCH.

See LO 9-2320-273-12.

12-10. RESERVOIR SCREEN AND STRAINER MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION (Continued).

11. Drain plug (6). Screw into reservoir bottom.

12. Resemoir (5). Fill.

13. Fill cap with chain (1). Screw on.

TA 075310

12-1 9
TM 9-2320-273-20

WINCH.

12-11. CONTROL VALVES MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (10)

b. Installation. (15)

c. Operational Check. (10)

35 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 and M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Liquid Teflon (refer to appendix C).

Plugs.

Masking Tape.

Marking Pen.

Pin Kit, IV1701 (34623).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 12-1, 12-2.

12-20
TM 9-2320-273-20

12-11. CONTROL VALVES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Winch system retains some pressure even

when not in use. Before you begin

maintenance, vent pressure by carefully

removing fill cap (1).

12-21

WINCH .
TM 9-2320-273-20

WINCH.

12-11. CONTROL VALVES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

The following procedure describes removal

and installation of the directional control

valve. Follow the same steps to remove

and install the auxiliary control valve.

A. REMOVAL.

1. Six screws (2). Unscrew and remove cover (3).

2. Pin kit (5) and handle (4). a. Remove three cotter pins. Discard pin kit (5).

b. Remove three straight pins.

c. Remove one plate.

d. Lift off handle (4).

NOTE

Plug each line as soon as you have disconnected it. This wiII prevent loss of

fluid from the system.

3. Two pressure lines (7). a. Disconnect at valve (8) Tag and mark where each line

and plug. connects.

b. Inspect for: Replace if necessary.

1. Leaks.

2. Cracks.

3. Discoloration.

4. Damaged fittings.

4. Three bolts (6). Unscrew and remove valve (8).

B. INSTALLATION.

5. Valve (8). a. Set in place.

b. Screw on and tighten three

bolts (6).

6. Two pressure lines (7). Unplug and connect to valve (8).

7. Handle (4). Attach to valve (8) with new pin

8. Fill cap (1). Screw on, and tighten.

C. OPERATIONAL CHECK.

9. Engine. Start up (see TM 9-2320-273-

10). Engage PTO.

12-22

kit (5).
TM 9-2320-273-20

WINCH.

12-11. CONTROL VALVES MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. OPERATIONAL CHECK (Continued).

10. Control valve (8). Operate winch and check for:

a. Leakage. Tighten connections as necessary.

b. Proper operation.

11. Cover (3). Aline with mounting holes in

winch control panel and install

with six screws (2).

12-23
TM 9-2320-273-20

WINCH.

2-12. THROTTLE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REWIRED FOLLOWS TASK DESCRIPTION.)

 a. Removal. (10)

b. Cleaning and Inspection. (10)

c. Installation. (10)

 d. Operational Check. ( 5 )

35 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 and M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

TROUBLESHOOTING REFERENCES

Table 12-1, 12-2.

12-24
TM 9-2320-273-20

WINCH.

12-12. THROTTLE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL

1. Setscrew (3). Loosen from throttle arm

(8) on left side of engine.

2. Nut (5) and washer (4). Unscrew nut from winch

throttle cable threaded end

(11).

12-25
TM 9-2320-273-20

WINCH.

12-12. THROTTLE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

3. Cable wire (6). a. Pull free from throttle arm

(8) and bracket (7).

b. Feed cable wire (6) down

underneath chassis.

4. Six screws (1). a. Remove.

b. Remove winch panel cover

(2).

5. Nut (10), and star- Remove from winch throttle

washer (9). cable threaded end (11).

6. Winch throttle control Pull up and out to remove Feed cable from under chassis

(13). cable (12). up through winch control panel

carefully so as not to damage

cable.

B. CLEANING AND INSPECTION.

7. Cable (12). Wipe cable and threaded

ends clean and inspect for:

a. Cracks in cable exterior. Replace as necessary.

b. Kinks which will cause

binding.

c. Crossed or burred threads.

C. INSTALLATION.

8. Winch throttle cable Install with starwasher (9)

threaded end (11). and nut (10). Tighten.

9. Cable (12). Feed down under chassis

over cross frame brace, and

up into engine compartment.

10. Cable wire (6). Insert through bracket (7)

and into throttle arm (8).

11. Setscrew (3). Tighten into cable wire (6).

12. Winch paneI cover (2). Install with six screws (1).

12-26
TM 9-2320-273-20

WINCH.

12-12. THROTTLE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

D. OPERATIONAL CHECK.

12. Engine. Start up and engage PTO

(see TM 9-2320-273-10).

13. Winch throttle control Operate and check that engine

(13). rpm rises and falls accordingly.

14. Engine. Shut down (see TM 9-2320-

273-10).

12-27
TM 9-2320-273-20

WINCH.

12-13. HYDRAULIC LINES AND FITTINGS MAINTENANCE.

THIS TASK COVERS (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Installation. (15)

c. Checking for Leaks. (10)

40 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 and M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Plugs.

Liquid Teflon (refer to appendix C).

Masking Tape.

Marking Pencil.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

Table 12-1, 12-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Park Brake Set.

Transmission in Neutral.

12-28
TM 9-2320-273-20

WINCH.

12-13. HYDRAULIC LINES AND FITTINGS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

Winch system retains some pressure even

when not in use. Before you begin

maintenance, vent pressure by carefully

removing fill cap (1).

12-29
TM 9-2320-273-20

WINCH.

,

12-13. HYDRAULIC LINES AND FITTINGS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

NOTE

The illustration at right shows major lines and

fittings of the winch hydraulic system. The

procedure describes removal and installation

of the directional control valve-to-motor line,

but the same steps may be used to remove and

install any of the lines.

A. REMOVAL

1. Six capscrews (2). Unscrew and remove Skip this step if you

cover (3). are changing a line

outside the winch panel.

NOTE

As soon as you disconnect a line, plug

the port and the line. Tag and mark

all lines.

2. Upper fitting (4). Unscrew. Plug port

and line.

3. Lower fitting (6). Unscrew. Plug port

and line.

4. Line (5). Remove and inspect for: Replace if necessary.

a. Cracks.

b. Leaks.

c. Discoloration.

d. Damaged fittings.

NOTE

If line contains a large amount of

fluid, drain the fluid from the line

and pour it into reservoir fill neck.

12-30
TM 9-2320-273-20

WINCH.

NOTE

Be sure that you install line between the

proper ports. Use the illustration below

as a reference.

12-13. HYDRAULIC LINES AND FITTINGS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

 B. INSTALLATION.

12-31
TM 9-2320-273-20

WINCH.

12-13. HYDRAULIC LINES AND FITTINGS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B . INSTALLATION (Continued).

5. Lower fitting (6). a. Coat threads with

liquid teflon.

b. Unplug port and line.

Screw together and

tighten.

6. Upper fitting (4). a. Coat threads with

liquid teflon.

b. Unplug port and line.

Screw together and

tighten.

7. Fill cap (1). Screw on and tighten.

 C. CHECKING FOR LEAKS

8. Engine. Start up (see

TM 9-2320-273-10).

Engage PTO.

9. Line (5). a. Wipe away dirt and

oil.

b. Check for leaks. Retighten as necessary.

NOTE

After checking for leaks, use sight glasses

to check winch oil level. Add oil if necessary (refer to LO 9-2320-273-12).

10. Engine. Disengage PTO and shut

down (see TM 9-2320-

273-10).

11. Cover (3). Set in place. Screw in

and tighten six capscrews (2).

12-32
TM 9-2320-273-20

2-13. HYDRAULIC LINES AND FITTINGS MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

12-33

WINCH .
TM 9-2320-273-20

WINCH.

2-14. HYDRAULIC MOTOR MAINTENANCE

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (15)

b. Cleaning and Inspection. (15)

c. Installation and Operational Check. (15)

45 Minutes Total.

INlTIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 and M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Clean Container.

Gasket, Hydraulic Motor to Failsafe Brake, 26426 (34625).

Hydraulic Oil ( Refer to Appendix C).

Silastic Gasket Sealer (Refer to Appendix C).

Plugs.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 12-1, 12-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

12-34
TM 9-2320-273-20

WINCH.

12-14. HYDRAULIC MOTOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

12-35
TM 9-2320-273-20

WINCH.

12-14. HYDRAULIC MOTOR MAINTENANCE. (Continued).

LOCATION/ITEM ACTION REMARKS

Winch system retains some pressure even

when not in use. Before you begin

maintenance, vent pressure by carefully

removing reservoir fill cap.

A. REMOVAL.

1. Six screws (3) and Unscrew and remove winch

Iockwashers (2). front cover (1).

2. Four screws {9) and Unscrew and remove winch

Iockwashers (10). rear cover (8).

3. Five hydraulic line Unscrew from hydraulic motor

connections: (4), (5), (6), (16) and plug connections.

(7), and (17).

4. Two screws (18) and Unscrew and pull hydraulic

hex nuts (11). motor (16) straight out from

failsafe brake.

5. Gasket (13). Discard.

B. CLEANING AND INSPECTION.

6. Hose fittings at Wipe clean and inspect for Replace fitting

connections (4), (5), (6), crossed threads, burrs, as necessary.

(7), and (17). and cracked hoses.

7. Motor spline shaft (12). Wipe clean and inspect for Refer to Direct Support/

gouges, chips, and broken General Support Maintensplines. ance if shaft splines or

spline sleeve on failsafe

brake are damaged.

C. INSTALLATION AND OPERATIONAL CHECK

8 New gasket (13). Coat both sides with silastic

gasket sealer and place on

flange of hydraulic motor (16).

9. Two screws (18). Position in flange slots of

hydraulic motor (16).

12-36
TM 9-2320-273-20

WINCH

12-14. HYDRAULIC MOTOR MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

12-37
TM 9-2320-273-20

WINCH.

12-14. HYDRAULIC MOTOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

C. INSTALLATION AND OPERATIONAL CHECK (Continued).

10. Hydraulio motor (16). Aline capscrews (18) and spline

shaft (12); push into position

against failsafe brake.

11. Two hex nuts (11). Screw on to screws (18) and

tighten.

12. Five hydraulic line a. Remove plugs.

connections: (4), (5), b. Coat threads with liquid

(6), (7), and (17). teflon.

c. Install and tighten as illustrated.

13. Winch rear cover (8). Install with four screws (9)

and Iockwashers (10).

14. Engine. Start up and engage PTO

(see TM 9-2320-273-10).

15. Winch. Engage (see TM 9-2320-273-

10).

a. Check for leaks.

b. Disconnect PTO and shut

down engine (see TM 9-

2320-273-10).

16. Winch front cover (1). Install with six Iockwashers

(2) and screws (3).

Tighten fittings as necessary.

12-38
TM 9-2320-273-20

12-14. HYDRAULIC MOTOR MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

12-39

WINCH.
TM 9-2320-273-20

2-15. HYDRAULIC PUMP MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REWIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Installation. (20)

c. Operational Check. ( 5)

45 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 and M920. None. None.

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Clean Container.

Plugs.

Liquid Teflon (Refer to Appendix C).

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TM 9-2320-273-20P.

LO 9-2320-273-12.

TROUBLESHOOTING REFERENCES

Table 12.1.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

12-40

WINCH.

TEST EQUIPMENT
TM 9-2320-273-20

WINCH.

12-15. HYDRAULIC PUMP MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

Winch system retains some pressure even

when not in use. Before you begin maintenance, vent pressure by carefully

removing fill cap (1).

12-41

TA 075321
TM 9-2320-273-20

WINCH.

12-15. HYDRAULIC PUMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

NOTE

Plug each line as soon as you have disconnected

it. This will prevent loss of fluid from system.

As an alternate the reservoir may be drained.

1. Four clamps (8). a. Unscrew and remove two Plug lines as removed.

reservoir lines (7).

b. Inspect for:

1. Cracks. Replace if necessary.

2. Leaks.

3. Discoloration.

4. Damaged fittings.

NOTE

Before you unscrew motor lines, place clean

container underneath to catch oil draining

from pump.

2. Two fittings (9). a. Unscrew and remove two Plug lines as removed.

motor lines (2).

b. Inspect for: Replace if necessary.

1. Cracks.

2. Leaks.

3. Discoloration.

4. Damaged fittings.

3. Two capscrews (3) Unscrew and remove.

and washers (4).

4. Pump (5). Remove from PTO (6).

B. INSTALLATION.

5. Pump (5). Position against PTO (6).

6. Two capscrews (3). Screw in and tighten.

and washers (4).

12-42
TM 9-2320-273-20

WINCH.

12-15. HYDRAULIC PUMP MAINTENANCE (Continued).

LOCATION/ITEM ACTION REMARKS

TA 075322

12-43
TM 9-2320-273-20

WINCH.

12-15. HYDRAULIC PUMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

B. INSTALLATION (Continued).

NOTE

Be sure you connect each hose to the

proper port.

7. Two fittings (9) with two a. Coat threads with liquid

motor lines (2) attached. tefIon.

b. Unplug, screw in, and

tighten.

8. Pump (5). Using funnel, pour oil from

container into top ports.

9. Two reservoir lines (7). Attach with four clamps (8).

10. Fill cap (1). Screw on and tighten.

C. OPERATIONAL CHECK.

11. Engine. Start up (see TM 9-2320-273-

10). Engage PTO.

12. Winch. Check operation.

13. Pump (5). Check for leaks. Retighten connections as

necessary.

14. Engine. Disengage PTO and shut down

(see TM 9-2320-273-10).

NOTE

Use sight glasses to check oil level in

reservoir. Add oiI if necessary (refer

to LO 9-2320-273-12).

12-44
TM 9-2320-273-20

WINCH.

12-15. HYDRAULIC PUMP MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

TA 075323

12-45
TM 9-2320-273-20

WINCH.

12-16. PTO LINKAGE MAINTENANCE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (20)

b. Installation. (25)

c. Operational Check. ( 5)

50 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

M916 Thru M920. None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

None.

PERSONNEL REQUIRED

One (MOS-63B20).

REFERENCES (TM)

TM 9-2320-273-10.

TROUBLESHOOTING REFERENCES

Table 12-1, 12-2.

SPECIAL ENVIRONMENTAL CONDITIONS

Vehicle Parked on Level Ground.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Park Brake Set.

12-46
TM 9-2320-273-20

WINCH.

Loosen.

Remove.

Remove.

12-16. PTO LINKAGE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL .

1. Screw (9) and

retaining nut (8).

2. Capscrew (11).

3. Bracket (12).

TA 075324

12-47
TM 9-2320-273-20

WINCH.

12-16. PTO LINKAGE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

A. REMOVAL (Continued).

4. Capscrew (7) and nut (5). Remove.

5. Clamp (6). Remove.

6. Knob (1). Remove.

7. Locknut (2) and (3). Remove.

8. Cable (4). Remove and inspect for

kinks or breaks.

B. INSTALLATION.

9. Cable (4).

10. Knob (1).

11. Clamp (6).

12. Cable (4).

13. Bracket (12).

C. OPERATIONAL CHECK.

14. Start engine.

15. Check PTO operation.

Secure with locknuts (2),

and (3).

Install.

Secure with capscrew (7)

and nut (5).

Secure at PTO arm (10) by

running thru hole in retaining nut (8) and tightening

screw (9).

Secure with capscrew (11).

(Refer to TM 9-2320-273-10.)

(Refer to TM 9-2320-273-10.)

12-48
TM 9-2320-273-20

WINCH.

12-16. PTO LINKAGE MAINTENANCE (Continued).

LOCATION/lTEM ACTION REMARKS

LEGEND:

1. KNOB

2. LOCKNUT

3. LOCKNUT

4. CABLE

5. NUT

6. CLAMP

7. CAPSCREW

8. RETAINING NUT

9. SCREW

10. PTO ARM

11. CAPSCREW

12. BRACKET

12-49
TM 9-2320-273-20

WINCH.

12-17. TAKING HYDRAULIC SYSTEM OIL SAMPLE.

THIS TASK COVERS: (APPROXIMATE TIME REQUIRED FOLLOWS TASK DESCRIPTION.)

a. Removal. (0.4)

b. Installation. (0.4)

c. Operational Check. (0.2)

1.0 Minutes Total.

INITIAL SETUP EQUIPMENT CONDITION

APPLICABLE CONFIGURATIONS PARAGRAPH CONDITION DESCRIPTION

AlI None. None.

TEST EQUIPMENT

None.

SPECIAL TOOLS

None.

MATERIALS/PARTS (P/N)

Bushing, MS51847-1 (96906).

Bushing, MS51847-9 (96906).

Drain Cock, 7-2177-4 (86768).

Tape, Antiseizing Item 14, Appendix C.

PERSONNEL REQUIRED SPECIAL ENVIRONMENTAL CONDITIONS

One (MOS-63B20). Work Area Clean and Away from Blowing Dirt and Dust.

REFERENCES (TM)

TM 9-2320-273-20P.

TROUBLESHOOTING REFERENCES

None.

GENERAL SAFETY INSTRUCTIONS

Engine OFF.

Transmission in Neutral.

Vehicle on Level Ground.

Wheels Blocked.

12-50 Change 2
TM 9-2320-273-20

WINCH.

Place drain pan under

plug (1).

Remove and discard

plug (1).

Allow oil to drain.

12-17. TAKING HYDRAULIC SYSTEM OIL SAMPLE.

LOCATION/lTEM ACTION REMARKS

A. REMOVAL.

1. Winch Console (5).

2.

B. INSTALLATION.

NOTE

Apply antiseizing tape to all threaded

connections.

3. Winch Console (5). Install bushing (2).

4. Install bushing (3) into

bushing (2).

5. Install drain cock (4) into

bushing (3).

6. Winch reservoir. Refill to proper level.

C. OPERATIONAL CHECK.

NOTE

Start engine (see TM 9-2320-273-10).

7. Winch Console (5). Operate winch. Check bushings (2) and (3) and

drain cock (4) for leaks.

Change 2 12-51
TM 9-2320-273-20

WINCH.

12-17. TAKING HYDRAULIC SYSTEM OIL SAMPLE.

LOCATION/lTEM ACTION REMARKS

LEGEND:

1. PLUG

2. BUSHING

3. BUSHING

4. DRAIN COCK

5. WINCH CONSOLE

12-52 Change 2
TM 9-2320-273-20

APPENDIX A

REFERENCES

A-1. PUBLICATION INDEXES.

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

Index of Army Motion Pictures and Related Audio-Visual Aids . . . . . . . . . . . . . . . . . DA PAM 108-1

Consolidated Index of Army Publications and Blank Forms. . . . . . . . . . . . . . . . . . . . DA PAM 310-1

A-2. FORMS.

The following forms pertain to this material. (Refer to DA Pamphlet 310-2 for index of blank forms.)

Standard Form 46, U.S. Government Motor Vehicle Operator’s Identification Card.

Standard Form 91, Operator’s Report of Motor Vehicle Accident.

DA Form 2028, Recommended Changes to Publications and Blank Forms.

Refer to DA PAM 738-750, The Army Maintenance Management Systems (TAMMS), for instructions on

the use of maintenance forms pertaining to this material.

 A-3. OTHER PUBLICATIONS.

The following publications contain information pertinent to the major item materiel and associated

equipment.

a. Operating Vehicle

Operator’s Manual for M915, M916, and M920 Truck Tractors and

Chassis for M917, M918, and M919. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. TM 9-2320-273-10

Change 2 A-1
TM 9-2320-273-20

A-3. OTHER PUBLICATIONS (Continued).

b.

Army Motor Transport: Units and Operations. . . . . . . . . . . . . . . . . . . . . . . . FM 55-30

Manual for the Wheeled Vehicle Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-305

Prevention of Motor Vehicle Accidents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 385-55

Accident Reporting and Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 385-40

Maintenance and Repair

Organizational Maintenance for M915, M916, and M920 Truck

Tractors and Chassis for M917, M918, and M919. . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-273-20

Organizational Maintenance Repair Parts and Special Tools

List for M915, M916, and M920 Truck Tractors and Chassis

for M917, M918, and M919 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-273-20P

Lubrication Order for M915, M916, and M920 Truck Tractors

and Chassis for M917, M918, and M919 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LO 9-2320-273-12

Direct Support and General Support Repair Parts and Special

Tools List for M915, M916, and M920 Truck Tractors and

Chassis for M917, M918, and M919 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-273-34P

Organizational Care, Maintenance and Repair of Pneumatic

Tires and lnner Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2610~200~24

Description, Use, Bonding Techniques, and Properties of

Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB ORD 1032

Materiels Used for Cleaning, Preserving, Abrading, and Cementing

Ordnance Materiel and Related Materials Including Chemicals. . . . . . . . . . . . . TM 9-247

Metal Body Repair and Related Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 43-2

Welding Theory and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. TM 9-237

Painting instructions for Field Use.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. TM 43-0139

Inspection, Care, and Maintenance of Anti-friction Bearings. . . . . . . . . . . . . . . TM 9-214

Use of Antifreeze Solutions and Cleaning Compounds in Engine

Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 750-651

A-2 Change 2
TM 9-2320-273-20

A-3. OTHER PUBLICATIONS (Continued).

Cooling Systems: Tactical Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 50-254

Functional Grouping Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 750-93-1

c. Cold Weather Operation and Maintenance

Basic Cold Weather Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-70

Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 31-71

Operation and Maintenance of Ordnance Materiel in Extreme Cold

Weather (0°F to -65°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 9-207

Winterization Kits for Army Tank-Automotive Materiel . . . . . . . . . . . . . . . . . . . SB 9-16

d. Decontamination

Chemical, Biological, and Radiological (CBR) Decontamination. . . . . . . . . . . . . TM 3-220

Chemical, Biological, Radiological, and Nuclear Defense. . . . . . . . . . . . . . . . . . . FM 21-40

e. Truck Bodies

Organizational, Direct Support and General Support

Maintenance Manual for M917 Dump Truck Body . . . . . . . . . . . . . . . . . . . . . . TM 5-3805-274-24&P

Organizational, Direct Support and General Support

Maintenance Manual for M918 Bituminous Distributor

Truck Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 5-3895-371-24&P

Organizational Maintenance Manual for M919 ConcreteMobile? Mixer Truck Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 5-3895-372-20

Direct Support and General Support Maintenance Manual

For M919 Concrete-Mobile Mixer Truck Body . . . . . . . . . . . . . . . . . . . . . . . . . . TM 5-3895-372-34

f. General

Principles of Automotive Vehicles.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-8000

Camouflage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 5-20

Procedures for Destruction of Tank-Automotive Equipment to

Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-244-6

Administrative Storage of Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 740-90-1

Color, Marking and Camouflage Painting of Military Vehicles. . . . . . . . . . . . . . . TB 43-0209

Preservation, Packaging, and Packing of Military Supplies TM 38-230-1 &

and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. TM 38-230-2

Shipment and Limited Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. MI L-V-62038

Storage Serviceability Standard:

Tracked Vehicles, Wheeled Vehicles, and Component parts. . . . . . . . . . . . . . . SB 740-98-1

g. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-2300-295-15/17

A-3/A-4 (Blank)

TM 9-2320-273-20

APPENDIX B

MAINTENANCE ALLOCATION CHART

Section I INTRODUCTION

B-1. GENERAL.

a. This section provides a general explanation of all maintenance and repair functions authorized at various maintenance levels.

b. The Maintenance Allocation Chart (MAC) in section II designates overall responsibility for

the performance of maintenance functions on the identified end item or component. The implementation of the maintenance functions upon the end item or component will be consistent with the

assigned maintenance functions.

c. Section III lists the special tools and test equipment required for each maintenance function

as referenced from section II.

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

B-2. MAINTENANCE FUNCTIONS.

a. /nspect. To determine the serviceability of an item by comparing its physical, mechanical,

and/or electrical characteristics with established standards through examination.

b. Test. To verify serviceability and detect incipient failure by measuring the mechanical or

electrical characteristics of an item and comparing those characteristics with prescribed standards.

c. Service. Operations required periodicalIy to keep an item in proper operating condition;

i.e., to clean (decontaminate), to preserve, to drain, to paint, or to replenish fuel, lubricants, hydraulic fluids, or compressed air supplies.

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

setting the operating characteristics to specified parameters.

e. Aline. To adjust specified variable elements of an item to bring about optimum or desired

performance.

f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or

test measuring and diagnostic equipments used in precision measurement. Consists of comparisons of

two instruments, one of which is a certified standard of known accuracy to detect and adjust any discrepancy in the accuracy of the instrument being compared.

g. Install. The act of emplacing, seating, or fixing into position an item, part, or module (component or assembly) in a manner to allow the proper functioning of an equipment or system.

h. Replace. The act of substituting a serviceable like type part, subassembly y or module (component or assembly) for an unserviceable counterpart.

B-1
TM 9-2320-273-20

B-2. MAINTENANCE FUNCTIONS (Continued).

i. Repair. The application of maintenance services1 or other maintenance actions2 to repair serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly), and item, or system.

j. Overhaul. That maintenance effort (services/actions) necessary to restore an item to a completely

serviceable/operational condition as prescribed by maintenance standards (i.e., DMWR) in appropriate

technical publications. Overhaul is normally the highest degree of maintenance performed by the Army.

Overhaul does not normally return an item to like new condition.

k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturing standards. Rebuild is the highest

degree of material maintenance applied to Army equipment. The rebuild operation includes the act of

returning to zero those age measurements (hours/miles, etc.) considered in classifying Army equipments/

components.

B-3. COLUMN ENTRIES USED IN THE MAC.

a. Column 1, Group Number. Column 1 lists group numbers, the purpose of which is to identify

components, assemblies, subassemblies, and modules with the next higher assembly.

b. Column 2, Component/Assernbly. Column 2 contains the names of components, assemblies, subassemblies, and modules for which maintenance is authorized.

c. Column 3, Maintenance Functions. Column 3 lists the functions to be performed on the item

listed in column 2. (For detailed explanation of these functions, see paragraph B-2.)

d. Column 4, Maintenance Level. Column 4 specifies, by the listing of a “work time” figure in the

appropriate sub-column(s), the lowest level of maintenance authorized to perform the function listed in

column 3. This figure represents the active time required to perform the maintenance function at the

indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance

function varies at different maintenance levels, appropriate “work time” figures will be shown for each

level. The number of manhours specified by 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, troubleshooting time,

and quality assurance/quality control time in addition to the time required to perform the specific tasks

identified for the maintenance functions authorized in the maintenance allocation chart. The symbol

designations -

C –

O

F –

H –

D –

for the various maintenance levels are as follows:

Operator or crew

Organizational maintenance

Direct Support maintenance

General Support maintenance

Depot maintenance

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

1Services – Inspect, test, service, adjust, a line, calibrate, or replace.

2Action – Welding, grinding, riveting, straightening, facing, remachining, or resurfacing.

B-2
TM 9-2320-273-20

B-3. COLUMN ENTRIES USED IN THE MAC (Continued).

f. Colurnn 6, Remarks. This column shall contain a letter code in alphabetical order which shall be

keyed to the remarks contained in section IV.

B-4. COLUMN ENTRIES USED IN TOOL AND TEST EQUIPMENT REQUIREMENTS.

a. Column 1, Tool or Test Equipment Reference Code. The tool and test equipment reference code

correlates with a maintenance function on the identified end item or component.

b. Column 2, Maintenance Level. The lowest level of maintenance authorized to use the tool or test

equipment.

c. Column 3, Nomenclature. Name or identification of the tool or test equipment.

d. Column 4, National/NATO Stock Number. The National or NATO stock number of the tool or

test equipment.

e. Column 5, Tool Number. The manufacturer’s part number.

B-5. EXPLANATION OF COLUMNS IN SECTION IV.

a. Reference Code. The code scheme recorded in column 6, section II.

b. Remarks. This column lists information pertinent to the maintenance function being performed

as indicated on the MAC, section II.

B-3
TM 9-2320-273-20

Section II MAINTENANCE ALLOCATiON CHART FOR TRUCK, TRACTOR,

M915, M916, AND M920 AND CHASSIS FOR M917, M918, AND M919.

(1) (2) (3) (4) (5) (6)

MAINTENANCE

GROUP COMPONENT/ASSEMBLY MAINTENANCE CATEGORY

NUMBER EQUIPMENT REMARKS

C O F H D

01 ENGINE Repair 19.2 2-3-4

Adjust 3.8

Test 0.4

0100 Engine (Diesel) Service 2.0

Replace 11.0

Repair 65.0 1 thru 77-81 -

Engine Mount Inspect 0.2 84-85-97

Replace 0.4 99 thru 180-

0101 Cylinder Head Inspect 1.0 189 thru 221

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 Sleeve Assembly Inspect 0.5

Replace 18.0 99 thru 101-

0102 Crankshaft & Main Bearings Inspect 0.5 128

Replace 17.3 117 thru 119

Main Seals Inspect 0.1

Replace 20.0 120 thru 127-

Vibration Damper Inspect 0.5 194-195

Replace 1.0

0103 Flywheel Assembly Replace 13.0 45

0104 Connecting Rods, Bearings Inspect 0.3

and Pistons Assembly Replace 27.0 207 thru 215-

Repair 8.0 221

0105 Valves Inspect 0.8

Adjust 1.8 71 thru 77

Replace 14.0 2

Cam Shaft and Bearing Inspect

Replace 27.0 197 thru 206

Cam Follower Housing Inspect 0.2

Replace 12.0 46 thru 49-

Cam Follower Inspect 0.2 51 thru 54-81

Replace 14.0

Push Tubes (Valve) Inspect 0.1

Replace 8.0

B-4

FUNCTION

TOOLS AND
TM 9-2320-273-20

Section ll MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(1) (2)

GROUP

NUMBER COMPONENT/ASSEMBLY

01 ENGINE (Continued)

Timing Gear

Rocker Arm Assembly

Valve Cover and Gasket

0106 Oil Pump

Oil Filter

Oil Filter Adapter

Bypass Oil Filter

Oil Pan

External Lines

Oil Breather

Oil Cooler

Oil Pressure Regulator

Level Gage (dipstick)

0108 Aftercooler

Exhaust Manifold

0109 Accessory Drive

(3)

Inspect

Replace

Inspect

Replace

Inspect

Replace

Inspect

Replace

Repair

Service

Replace

Replace

Service

Replace

Inspect

Replace

Repair

Inspect

Replace

Inspect

Service

Replace

Inspect

Replace

Inspect

Test

Replace

Replace

Inspect

Repair

Replace

Inspect

Replace

Inspect

Repair

Replace

(4)

MAINTENANCE

MAINTENANCE CATEGORY

FUNCTION

C O F H

0.6

24.0

0.6

2.5

0.1

0.5

2.5

3.0

0.6

0.2

10.8

0.6

0.6

0.1

2.0

1.3

0.1

1.0

0.1

0.2

0.2

0.1

3.0

0.1

0.8

0.2

0.1

0.1

2.0

2.5

0.1

2.8

0.5

2.0

4.5

(5)

TOOLS AND

EQUIPMENT

130 thru 132

143

55

56 thru 65

B-5

(6)

REMARKS

1.5

D
TM 9-2320-273-20

Section II MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(1) (2) (3) (4) (5) (6)

MAINTENANCE

GROUP COMPONENT/ASSEMBLY CATEGORY

NUMBER REMARKS

C O F H D

01 ENGINE (Continued)

0112 Engine Retarder Inspect 0.5

Repair 6.0 81

Replace 3.0

Adjust 1.5

03 FUEL SYSTEM

0301 Fuel Injector Assembly Test 0.8

Adjust 4.0 71 thru 77-

Replace 4.0 84

Calibrate 1.0 3 thru 12-84-

Repair 1.8 152

0302 Fuel Pump Assembly Inspect 0.5 151 thru 154-

Service of Filter& Screw Service 0.2 166 thru 171-

Test 4.8 188

Replace 2.0 144 thru 150

196

Calibrate 3.5 159

160

166 thru 171

174

192

Repair 8.9 155-156

158

161 thru 164

165-172-173

177 thru 179

189 thru 191

193

216 thru 220

0302 Engine Fuel Lines and Inspect 0.5

Fittings Replace 1.5

B-6

MAINTENANCE

FUNCTION

TOOLS AND

EQUIPMENT
TM 9-2320-273-20

Section ll MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(1)

GROUP

NUMBER

03

0304

0305

0306

0309

0311

0312

04

(2)

COMPONENT/ASSEMBLY

FUEL SYSTEM (Continued)

Air Cleaner Assembly

Air Cleaner Restriction

Indicator

Turbocharger

Turbocharger Air Inlet

Fuel Tank

Fuel Filter

Ether Quick-Start Kit

Accelerator Pedal and

Linkage

Throttle Control and

Linkage

EXHAUST SYSTEM

Muffler

Exhaust Pipe

Flex Tube

(3)

MAINTENANCE

FUNCTION

Inspect

Service

Replace

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

Inspect

Service

Repair

Replace

Inspect

Service

Replace!

Inspect

Service

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Adjust

Inspect

Replace

Inspect

Replace

Inspect

Replace

(4)

MAINTENANCE

CATEGORY

C O F H D

0.1 0.2

0.5

0.1

0.2

0.1

1.8

3.0

0.1

0.3

0.1

0.2

1.5

2.0

0.1

0.3

0.3

0.1

0.3

0.5

0.5

0.1

0.8

0.5

1.0

0.3

0.2

0.1

0.5

0.1

0.4

3.1

0.4

(5)

TOOLS AND

EQUIPMENT

175-176-

219

B-7

(6)

REMARKS
TM 9-2320-273-20

Section ll MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(1) (2) (3) (4) (5) (6)

MAINTENANCE

GROUP COMPONENT/ASSEMBLY CATEGORY

NUMBER REMARKS

C O F H D

04 EXHAUST SYSTEM

(Continued)

Extension Tube Inspect 0.1

Replace 0.4

Tailpipe Inspect 0.1

Replace 0.2

05 COOLING SYSTEM

0501 Draincock Inspect 0.1

Replace 0.2

Radiator Assembly Inspect 0.2

Service 0.2

Replace 3.0

Repair 2.0

Test 0.3

0502 Fan Shrouds Inspect 0.1

Replace 1.5

0503 Lines, Fittings, Hoses Inspect 0.1

Replace 2.5

Thermostat Replace 1.0

97

Thermostat Housing Replace 1,0

Water Manifold Replace 2.0

Repair 2.0

Water Control Valve Inspect

Replace 0.4

0504 Water Pump 0.1

Replace

Repair 3.0 2.0 56 thru 70

0505 Fan Inspect 0.1

Replace 0.5

Fan Clutch Inspect 0.1

Replace 1.5

Water Pump Idler Pulley Replace 0.5

Crankshaft Pulley Replace 0.1

Accessory Drive Belts Inspect 0.2

Adjust 0.2

Replace 1.0

B-8

MAINTENANCE

FUNCTION

TOOLS AND

EQUIPMENT

Inspect

0.2
TM 9-2320-273-20

Section ll MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(1)

GROUP

NUMBER

(2)

COMPONENT/ASSEMBLY

05

0507

06

0601

0603

0607

0608

0609

COOLING SYSTEM

(Continued)

Fan Clutch Actuator

Fan Clutch Actuator Hoses

ELECTRICAL SYSTEM

Alternator & Regulator

(Internal)

Alternator Drive Belts

Starter Motor/Solenoid

Starter Magnetic Switch

Instruments – LH Cluster

Engine Run Switch

Start Switch

Ether Quick-Start Button

Clearance Lamp

Headlight

Blackout Switch

Engine Retarder Selector Switch

Engine Retarder Foot Switch

Turn Signal Control

Backup Alarm Override

Work Lamp Switch

Heater Fan Switch

Dimmer Switch

Service Head Lamps

(3)

MAINTENANCE

FUNCTION

C

Inspect 0.2

Replace

Inspect 0.1

Replace

Inspect

Replace

Adjust

Test

Repair

Inspect

Adjust

Replace

Replace

Repair

Inspect

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

0.2

0.1

0.1

(4)

MAINTENANCE

CATEGORY

O F H

0.5

0.5

1.0

0.5

0.5

2.0

0.1

0.3

0.9

1.8

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.6

(5)

TOOLS AND

EQUIPMENT

78-79

80

(6)

REMARKS

916/920

B-9

D
TM 9-2320-273-20

Section II MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(1) (2) (3) (4) (5) (6)

MAINTENANCE

GROUP COMPONENT/ASSEMBLY CATEGORY TOOLS AND

NUMBER EQUIPMENT

C O F H D

06 ELECTRICAL SYSTEM

(Continued)

Marker & Turn Signal Lamps Replace 0.3

Clearance Lamps Replace 0.3

Tail, Brake, Turn Signal, Replace 0.3

Stop, and Backup Lamps

Work Lamps Replace 0.3 916 & 920

Blackout Head Lamp Replace 0.3

Blackout Tail & Stop Lamps Replace 0.3

Dome Lamp & Switch Replace 0.3

Instrument Illumination Replace 0.3

Lamps

0610 Sending Units

Fuel Level Replace 0.4

Water Temperature Replace 0.2

Oil Pressure Replace 0.2

Transmission Oil Temperature Replace 0.2

Switches and Relays

High Engine Water Replace 0.2

Temperature

Low Engine Oil Pressure Replace 0.2

Low Brake Air Pressure Replace 0.2

Backup Replace 0.2 916-920

0610 Park Brake Engaged Replace 0.2

Turn Signal Flasher Replace 0.2

PTO Engaged Replace 0.2 916-920

Neutral Safety Switch Replace 0.2

Differential Lockout Engaged Replace 0.2

Instrument Panel Circuit Replace 0.2

Breakers

instrument Panel Relays Replace 0.2

0611 Horn Replace 0.4

Horn Button Replace 0.5

B-10

MAINTENANCE

FUNCTION
TM 9-2320-273-20

Section II MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(1)

GROUP

NUMBER

06

0612

0613

0617

07

0706

0710

(2)

COMPONENT/ASSEMBLY

ELECTRICAL SYSTEM

(Continued)

Low Air Buzzer

Backup Alarm

Batteries, Box & Cables

Batteries

Battery Box

Battery Cable

Chassis Wiring Harnesses

Trailer Coupling (Electric)

TRANSMISSION

Ratio Selector

Air Control Line

Control Group

Pump, Oil

Oil Cooler

(3)

MAINTENANCE

FUNCTION

Replace

Replace

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Inspect

Adjust

Replace

Test

Repair

Replace

Inspect

Adjust

Replace

Test

Repair

Inspect

Service

Replace

Repair

Inspect

Inspect

Replace

(4)

MAINTENANCE

CATEGORY

C

0.5

0.2

0.2

0.2

0.2

0.1

0.3

0.1

O

0.2

0.2

0.6

1.5

1.0

0.5

0.3

3.5

1.0

0.2

0.3

0.6

0.5

2.0

0.2

0.1

F

2.3

8.0

4.0

0.2

H

0.7

2.0

0.5

1.0

2.5

22.0

D

(5)

TOOLS AND

EQUIPMENT

183 thru 185

(6)

REMARKS

Includes

Strainer

Change 1 B-11

Transmission
TM 9-2320-273-20

Section ll MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(1) (2) (3) (4) (5) (6)

MAINTENANCE

GROUP COMPONENT/ASSEMBLY

CATEGORY

NUMBER

REMARKS

C O F H D

08 POWER TRANSFER

0801 Transfer Assembly Inspect 0.1

Service 0.5

Replace 4.0

Repair 3.0

0803 Power Transfer/Diff. Replace 0.5

Lockout Control

09 PROPELLER SHAFTS &

UNIVERSAL JOINTS

Universal Joints Inspect 0.3

Service 0.2

Replace 1.4

Propeller Shafts Inspect 0.3

Service 0.2

Replace 1.0

10 FRONT AXLE

1000 Driving Axle Assembly Inspect 0.2

Service 1.0 M916 thru

Replace 6.0 M920

Repair 40.0

Non-Driving Axle Assembly Inspect 0.1

Service 0.3

Repair

M915 only

6.0

Replace 4.0

Bearings, Axle Shaft and Inspect 0.1

Flanges Replace 4.0 10.0 98

1002 Differential Assembly Replace 4.5 M916 thru

Repair 8.0

Overhaul

M920

17.5

1004 Front Axle End Assembly Inspect 0.5 M915 only

Replace 2.0

B-12 Change 1

MAINTENANCE

FUNCTION

TOOLS AND

EQUIPMENT
TM 9-2320-273-20

Section II MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(1)

GROUP

NUMBER

11

1100

(2)

COMPONENT/ASSEMBLY

REAR AXLE

Rear Bogie Axle

Rear Axle Housing

(3)

MAINTENANCE

FUNCTION

Inspect

Service

Replace

Repair

Overhaul

Inspect

Replace

C

0.1

0.1

(4)

MAINTENANCE

CATEGORY

O

0.7

F

4.0

4.0

10.0

H

17.5

D

(5)

TOOLS AND

EQUIPMENT

(6)

REMARKS

M915 only

(Include

filter)

M916 thru

M920

Change 1 B-12.1/(B-12.2blank)

TM 9-2320-273-20

Section II MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(2)

COMPONENT/ASSEMBLY

REAR AXLE (Continued)

Differential and Carrier

Filter

Flange, Companion Drive

Pinion

Seal, Oil, Drive Pinion

Bearing

Rear Axle Shaft, Right or

Left

Differential Lockout Air

Chamber

Pusher Axle

Air Bags

Lift Cylinders

BRAKES

Park Brake Assembly

Foundation Brakes

Brake Shoe Assemblies

Slack Adjuster

S-Cam Mechanism

(3)

MAINTENANCE

FUNCTION

Replace

Repair

Overhaul

Inspect

Replace

Inspect

Replace

Inspect

Replace

Replace

Repair

Replace

Inspect

Service

Replace

Repair

Replace

Replace

Inspect

Adjust

Repair

Replace

Inspect

Adjust

Repair

Replace

Replace

Replace

(4)

MAINTENANCE

CATEGORY

C O F H D

9.8

9.8

11.8

0.1

0.2

0.1

1.0

0.1

1.5

3.5

1.0

1.0

0.1

2.0

6.0

6.0

1.0

1.0

0.1

0.5

0.8

1.4

1.0

0.5

3.5

3.0

0.3

3.0

(5)

TOOLS AND

EQUIPMENT

87-88-90

thru 95-186-

187

(6)

REMARKS

M917,

M919 &

M920

Rear Only

Includes

Shoe Spring

Rear Only

Rear Only

B-13

( 1)

GROUP

NUMBER
TM 9-2320-273-20

Section II MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(1)

GROUP

NUMBER

12

1208

1208

1208

1208

1211

(2)

COMPONENT/ASSEMBLY

BRAKES (Continued)

Air Lines and Fittings

(Truck Tractor)

Air Reservoirs

Automatic Drain

Air Brake Chambers

Double Brake Chambers

Wedge and Actuator Housing

Assemblies

Trailer Hand Brake

Dual Brake Volvo and Pedal

Trailer Protection Valve

Relay Valve

Ouick Release

Limiting Valve

Double Check Valves

Air Compressor

Air Compressor Governor

Air Dryer

Trailer Connector Brake

Lines and Couplings

(3)

MAINTENANCE

FUNCTION

Inspect

Replace

Inspect

Service

Replace

Replace

Adjust

Replace

Repair

Adjust

Replace

Repair

Replace

Inspect

Replace

Repair

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Repair

Adjust

Replace

Inspect

Service

Replace

Inspect

Replace

Repair

(4)

MAINTENANCE

CATEGORY

O F H D

2.2

1.1

0.2

0.2

2.0

2.2

0.2

2.0

2.2

2.0

1.8

1.5

1.5

1.5

1.5

1.5

1.5

1.5

4.0

2.0

0.5

1.5

0.8

1.0

1.3

(5) (6)

TOOLS AND

EQUIPMENT REMARKS

85-177 thru

180-219

Individual

Lines

Supply

Reservoir

Only

Spring Brake

Chamber

Only

Front and

Pusher Axle

Only

Spring Brake

Chamber only

B-14 Change 2

C

1.0
TM 9-2320-273-20

Section II MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(1) (2) (3) (4) (5) (6)

MAINTENANCE

GROUP COMPONENT/ASSEMBLY CATEGORY

NUMBER

REMARKS

C O F H D

13 WHEELS

1300 Wheel Alinement Inspect 0.8

Adjust 0.5

1311 Hub Assemblies Replace 0.5

Drums Replace 1.5

Repair 1.5

Bearings and Seals Service 1.5 Inner and

Replace 1.5 82-83-96-98 Outer Bearings and

Seals

Wheel Assembly Inspect 0.1 Include

Replace 0.5 Tire

Service 0.1

1313 Tire and Tube Assembly Replace 2.1

Repair 1.3

14 STEERING

1401 Steering Wheel Inspect 0.1

Replace 0.5

Upper Steering Column Replace 3.0

Repair 3.5

Lower Steering Column Replace 1.0

Repair 0.5

Drag Links Inspect 0.1

Adjust 0.3

Replace 1.0

Repair 1.5

Pitman Arm Replace 0.8

Tie Rod Inspect 0.1

Adjust 1.0

Replace 1.5

Repair 1.0

1410 Steering Gear Adjust 0.2

Replace 1.5

Repair 2.0

B-15

MAINTENANCE

FUNCTION

TOOLS AND

EQUIPMENT
TM 9-2320-273-20

Section II

(1)

GROUP

NUMBER

14

1411

15

1501

1503

1503

1504

1506

16

1601

MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(2)

COMPONENT/ASSEMBLY

STEERING (Continued)

Hydraulic Steering Pump and

Reservoir Assembly

Power Steering Cylinder

FRAME ASSEMBLY

Frame

Bumper

Pintle Hook Assembly

Towing Eyes

Spare Wheel Carrier

Fifth Wheel

Fifth Wheel Assembly

SPRINGS, SHOCK ABSORBERS, AND TORQUE RODS

Springs

Front Spring Pins

(3)

MAINTENANCE

FUNCTION

Inspect

Service

Replace

Repair

lnspect

Replace

Repair

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

Replace

Inspect

Adjust

Service

Repair

Replace

Inspect

Service

Replace

Repair

Replace

C

0.1

0.2

0.1

0.5

0.1

0.1

0.5

0.1

(4)

MAINTENANCE

CATEGORY

O

1.0

2.0

1.0

0.6

0.2

0.5

1.0

0.5

4.0

0.2

0.1

F

1.5

1.5

4.0

6.0

H

2.0

3.0

D

(5)

TOOLS AND

EQUIPMENT

181

182

(6)

REMARKS

916-920

M915,

M916 and

M920

B-16
TM 9-2320-273-20

Section II MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued)

GROUP

NUMBER

16

1604

1605

18

1801

1601

1602

(2)

COMPONENT/ASSEMBLY

SPRINGS, SHOCK ABSORBERS, AND TORQUE RODS

(Continued)

Shock Absorbers

Torque Rods

CAB AND BODY

Cab Mounts

Cab

Doors

Steps

Hood Panels and Crossbar

support

Ventilators & Control

Grille

Splash Shields

Fenders

Windshield

(3)

MAINTENANCE

FUNCTION

Inspect

Replace

Replace

Inspect

Replace

Inspect

Inspect

Replace

Repair

Inspect

Repair

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Inspect

Replace

Repair

Inspect

Replace

C

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

(4)

MAINTENANCE

CATEGORY

O

1.0

1.0

0.2

0.5

0.5

0.5

0.3

1.0

1.5

F

1.0

2.0

1.0

1.0

.5

1.2

D

(5)

TOOLS AND

EQUIPMENT

89

(6)

REMARKS

Non-Driving

Front Axle

(M915) and

Pusher Axle

(M917,

M919 and

M920)

Change 2 B-17

H
TM 9-2320-273-20

Section II

(1)

GROUP

NUMBER

18

1808

2001

2004

MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

COMPONENT/ASSEMBLY

CAB AND BODY

[Continued)

Seats

Stowage Box

WINCH AND POWER

TAKEOFF

Winch

Cable Assemblies

Controls, Valves

Hydraulic Lines & Fittings

Hydraulic Motor

Hydraulic Pump

Reservoir, In-Line Filter,

and Screen

Power Takeoff

Power Takeoff Adapter

Power Takeoff Linkage

Power Takeoff Coupling

(3)

MAINTENANCE

FUNCTION

Inspect

Replace

Repair

inspect

Replace

Repair

Inspect

Service

Replace

Repair

Inspect

Service

Replace

Replace

Replace

Repair

Inspect

Replace

Repair

Inspect

Replace

Repair

Replace

Service

Inspect

Replace

Repair

Replace

Replace

Replace

(4)

MAINTENANCE

CATEGORY

C

0.1

0.1

0.3

0.3

0.2

0.2

0.1

0.2

O

0.5

1.0

1.0

0.4

1.0

1.5

0.5

2.0

3.0

3.0

4.0

1.0

0.8

1.5

F

0.5

4.0

8.0

2.0

1.5

1.0

1.0

2.0

1.0

H

(5)

TOOLS AND

EQUIPMENT

86

(6)

REMARKS

M916 and

M920

M916 thru

M920

B-18
TM 9-2320-273-20

Section II MAINTENANCE ALLOCATION CHART FOR TRUCK, TRACTOR, M915,

(1)

GROUP

NUMBER

22

2207

2210

47

4701

4702

M916, AND M920 AND CHASSIS FOR M917, M918, AND M919 (Continued).

(2)

COMPONENT/ASSEMBLY

ACCESSORY ITEMS

Windshield Wiper Motors

Windshield Wiper Controls

Arm and Wiper Blades

Mirrors

Windshield Washer

Windshield Washer Control

Air Horn and Control Valve

Personnel Heater

Air Ducts

Heater Control Valve and

Cable

Heater Control Panel

Data and Instruction Plates

GAGES NON-ELECTRIC

Tachograph

Speedometer Cable

Tachometer Cable

Pressure Gages

Gages

(3)

MAINTENANCE

FUNCTION

Replace

Replace

Inspect

Replace

Inspect

Replace

Inspect

Service

Replace

Replace

Replace

Inspect

Replace

Repair

Inspect

Replace

Adjust

Replace

Replace

Repair

Inspect

Replace

Service

Replace

Replace

Replace

Inspect

Replace

Inspect

Replace

(4)

MAINTENANCE

CATEGORY

C

0.1

0.1

0.1

0.2

0.1

0.1

0.1

0.1

0.1

O

0.8

0.3

0.2

0.3

0.5

0.3

0.3

2.0

0.8

0.2

0.5

1.0

0.5

0.2

0.3

0.4

0.4

0.5

0.5

F

1.0

1.0

H D

(5)

TOOLS AND

EQUIPMENT

(6)

REMARKS

B-19
TM 9-2320-273-20

Section Ill TOOL & TEST EQUIPMENT REQUIREMENTS.

Tool or Test

Equipment

Number Maintenance National/Nato

Reference Code Category Nomenclature Stock Number Tool

1 F H Checking Tool, Blow-By 3375150

2 F H Reamer, Valve Guide 5110-00-980-7347 ST-646

3 F H Cutting Tool, Bead 5110-00-932-2089 ST-788

4 F H Expander, Tube, Roller 3441-00-922-6699 ST-880

5 F H Cage ST-880-1

6 F H Roll ST-880-2

7 F H Nut, Thrust ST-880-6

8 F H Mandrel ST-880-7

9 F H Cutter, Injector Sleeve 4910-00-981-3105 ST-884

10 F H Holder ST-884-1

11 F H Cutter ST-884-3

12 F H Pilot ST-884-6

13 F H Tool, Cylinder Head 4910-00-999-1499 ST-913

14 F H Lockscrew ST-913-1

15 F H Bearing ST-913-7

16 F H Plug, Locking ST-913-11

17 F H Insert, Fiber ST-913-18

18 F H Screw Assembly, Adjusting ST-913-23

19 F H Tool Holder ST-913-14

20 F H Tool Bit ST-913-17

21 F H Tool, Grooving 5120-00-178-0948 ST-1100

22 F H Body (5-1/2 In. Bore) ST-1100-10

23 F H Nut, Adjusting (1 1/4-20 Thread) ST-1100-7

24 F H Capscrew (1/4-28x 3/16 In.) ST-1100-6

25 F H Sleeve, Rod ST-1100-8

26 F H Rod, Tool Adjusting ST-1100-11

27 F H Spring, Rod ST-1100-9

28 F H Cap, Tool Setting ST-1100-14

29 F H Cutting Tool ST-1100-13

30 F H Spring, Tool ST-1100-12

31 F H Sleeve Injector 4910-00-150-5858 ST-1140

32 F H Holding Tool, Injector Sleeve 5120-00-104-1795 ST-1179

33 F H Driver, Injector Sleeve 5120-00-981-3108 ST-1227

34 F H Puller, Injector Sleeve 5120-00-113-5271 ST-1244

35 F H Tip, Extractor ST-1244-7

36 F H Rod ST-1244-2

B-20
TM 9-2320-273-20

Section Ill TOOL & TEST EQUIPMENT REQUIREMENTS (Continued).

Tool or Test

Equipment

Number Maintenance National/Nato

Reference Code Category Nomenclature Stock Number Tool

37 F H Collar, Forming ST-1244-6

38 F H Spacer ST-1244-9

39 F H Bridge, Support ST-1244-1

40 F H Washer, Thrust ST-1244-5

41 F H Nut (l-8 Thread) ST-1244-4

42 F H Nut (9/16-12 Thread) ST-1244-3

43 F H Driver ST-1244-8

44 F H Driver, Valve Guide 3375282

45 F H Attachment, Dial Gage ST-1325

46 F H Bushing, Block and Mandrel, Lever 5180-00-916-1813 ST-249

47 F H Mandrel ST-249-1

48 F H Mandrel ST-249-2

49 F H Sleeve ST-249-3

50 F H Spacer, Crosshead Guide 4910-00-150-3797 ST-633

51 F H Mandrel Set, Machine 3460-00-499-1210 ST-691

52 F H Mandrel ST-691-1

53 F H Block ST-691-2

54 F H Mandrel ST-691-3

55 F H Mandrel, “O” Ring, Lubricating Oil Cooler ST-1218

56 F H Pulley Assembly, Tool 5180-00-944-0374 ST-386

57 F H Arbor ST-386-2

58 F H Nut ST-386-3

59 F H Adapter, Ball, Thrust Bearing ST-386-11

60 F H Spacer ST-386-5

61 F H Adapter 3375205

62 F H Adapter (2-1/4 In. X 7/8 in. Dia.) ST-386-10

63 F H Adapter (2-1/4 in. X 1 In. Dia.) ST-386-9

64 F H Adapter (2-1/4 In. X 1 In. Dia.) ST-386-8

65 F H Adapter (1-7/8 In. X 1 In. Dia.) ST-386-6

66 F H Mandrel, Water Pump Seal ST-658

67 F H Mandrel, Water Pump Seal 5120-00-159-8916 ST-659

68 F H Fixture, Bearing Disassembly ST-1114

69 F H Water Pump Seal Driver ST-1159

70 F H Driver, Water Pump Drive Shaft Oil Seal 3375180

71 F H Adapter, Torque Wrench 5120-00-103-4687 ST-669

72 F H Driver, 3/8 In., Plastic Handle F-40A

B-21
TM 9-2320-273-20

Section III TOOL & TEST EQUIPMENT REQUIREMENTS (Continued).

TooI or Test

Equipment

Number Maintenance National/Nato

Reference Code Category Nomenclature Stock Number Tool

73 F H Handle ST-699-1

74 F H Blade, Screwdriver 1/2 In. X 0.062 In. M-1302 A-5

75 F H Blade, Screwdriver 1/4 In. X 0.032 In. TM-82

76 F H Socket, 3/4 In. Deep Double Hex M-1302B-24

77 F H Socket, 9/1 6 In. Deep Double Hex M-1302B-18

78 F H Rod, Expanding CG-40-4

79 F H Collet 43/64 to 52/64 CG-40-11

80 F H Socket 1/4 In. 12 Point, 1/4 In. Drive STMD-8

81 F H Socket, Jacobs Brake B1465A

82 OF H Installing Tool, Seal RD259A

83 O F H Handle, Seal Installing Tool RD263

84 F H Fixture, Injector Timing 4910-00-712-0537 ST-593

85 F H Wrench, Air Compressor 5120-01-072-2952 3375159

86 F H Bar, Bearing Puller 11074

87 F H Yoke Installer J-26422-10

88 F H Wrench, Differential Adjusting Nut J-972

89 F H Tool, Remove-Replace Windshield Moulding 5120-00-279-8422 CPR109701

90 F H Tool, Yoke Installer 4120-01-014-0017 J-26422

91 F H Shaft, 1 1/4-12 Thread J-26422-2

92 F H Nut J-26422-3

93 F H Shaft 1 1/4-12 J-26422-4

94 F H Sleeve J-26422-1

95 F H Wear Sleeve Installation Tool J-26424

96 OF H Socket, Pusher Axle 3 3/16 In. J-7757-2

97 OF H Thermostat Seal Mandrel ST-1225

98 OF H 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

B-22 Change 2
TM 9-2320-273-20

Section Ill TOOL & TEST EQUIPMENT REQUIREMENTS (Continued).

Tool or Test

Equipment

Number Maintenance National/Nato

Reference Code Category Nomenclature Stock Number Tool

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 Pump 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

B-23
TM 9-2320-273-20

Tool or Test

Equipment

Number

Reference Code

150

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165

166

167

168

169

170

171

172

173

174

175

176

177

178

179

180

181

182

183

184

185

186

Section Ill TOOL & TEST EQUIPMENT REQUIREMENTS (Continued).

Maintenance

Category

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

H

Nomenclature

Torque Tool, Injector

Fixture, Top Stop Injector Setting

Tool, Adjusting

Crowsfoot, 1-3/8 In., Locknut Wrench

Wrench, Inch Pound Torque

Block, Weight Carrier

Puller, Tachometer Drive

Collar

Collet

Adapter Plate, Fuel Filter

Gasket

Front Cover, Main Shaft Assembly

Driver, Front Cover

Driver, Main Shaft Seal

Installation Tool, Main Shaft & Bearing

Installation Tool, Throttle Shaft Ball

Adjust Kit, AFC Fuel Pump

Installation Tool, No Air Screw “O” Ring

Tool, AFC No Air Adjusting

Installation Tool, Glyd Ring

Forming Tool, Glyd Ring

Tool, AFC Adjusting

Installation Tool, Cast Governor Weight Carrier

Mandrel, Tachometer Drive Cup Plug

Throttle Travel Template

Turbo Support Block

Socket, Wrench

Puller Assembly

Screw

Puller

Holder

Lock Tester 2 In.

Lock Tester 3 In.

Step Plate, Mechanic

Bracket

Installer

Staking Tool, Pinion Bearing

National/Nato

Stock Number

5120-01-074-0020

5120-00-116-7625

5120-00-065-1031

5120-00-923-0856

5120-00-473-6921

Tool

ST-1145

3375160

3375165

3375166

3375232

ST-1231

ST-1326

ST-1326-2

ST-1326-1

3375014

3375015

3375175

3375174

3375173

3375172

3375204

3375189

3375148

3375140

3375146

3375147

3375137

3375230

3375271

3375355

ST-608

ST-1095

ST-544

ST-544-2

ST-544-1

ST-851

TLN-1000

ITL42

8B7560

FT901

2P8260

26883

B-24
TM 9-2320-273-20

Section III TOOL & TEST EQUIPMENT REQUIREMENTS (Continued).

Tool or Test

Equipment

Number Maintenance National/Nato

Reference Code Category Nomenclature Stock Number Tool

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 Bearing 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 Gage, Groove Wear 5210-00-999-1209 ST-560

B-25/B-26 (Blank)

TM 9-2320-273-20

APPENDIX C

EXPENDABLE SUPPLIES AND MATERIALS LIST

Section I INTRODUCTION.

C-1. SCOPE.

This appendix lists expendable supplies and materials you will need to operate and maintain the M915,

M916, M920 Truck Tractors and Chassis for M917, M918, and M919.

These items are authorized to you by CTA 50-970, Expendable Items (Except Medical, Class V, Repair

Parts, and Heraldic Items).

C-2. EXPLANATION OF COLUMNS.

a. Column 1 – Item Number. This number is assigned to the entry in the listing and is referenced in

the narrative instructions to identify the material (e.g., “Use cleaning compound, item 5, App. D“).

b. Column 2 – Level. This column identifies the lowest level of maintenance that requires the

listed item.

C –

O –

F –

H –

Operator/Crew.

Organizational Maintenance.

Direct Support Maintenance.

General Support Maintenance.

c. Column 3 – National Stock Number. This is the National stock number assigned to the item; use

it to request or requisition the item.

d. Column 4 – Description. Indicates the Federal item name and, if required, a description to

identify the item. The last line for each item indicates the part number followed by the Federal Supply

Code for Manufacturer (BSCM) in parentheses, if applicable.

e. Column 5 — Unit of Measure (U/M). Indicates the measure used in performing the actual maintenance function. This measure is expressed by a two-character alphabetical abbreviation (e.g., ea, in, pr).

If the unit of measure differes from the unit of issue, requisition the lowest unit of issue that will satisfy

your requirements.

C-1
TM 9-2320-273-20

(1)

ITEM

NUMBER

1

2

3

4

5

Section II EXPENDABLE SUPPLIES AND MATERIALS LIST.

(2)

LEVEL

O

C

C

(3)

NATIONAL

STOCK

NUMBER

9150-00-065-0029

9150-00-935-1017

9150-00-190-0904

9150-00-190-0905

9150-00-190-0907

9150-00-234-5197

9150-00-261-7891

9150-00-261-7904

9150-00-257-5440

9150-00-257-5443

9150-00-265-9425

9150-00-265-8428

9150-00-265-9429

9150-00-265-9430

9150-00-265-9433

9150-00-265-9435

9150-00-265-9436

9150-00-265-9437

(4)

DESCRIPTION

Grease, Automotive

and Artillery GAA

(MIL-G-10924C)

2-1/4-oz tube

14-oz cartridge

1-lb can

5-lb can

35-lb can

Oil, Lubricating, Exposed Gear, CW

(VV-L-751C)

5-lb can

35-lb pail

Oil, Lubricating, Gear

Subzero, GOS

(MIL-L-10324)

1-qt can

5-gal drum

55-gal drum

Oil, Lubricating

OE/HDO 10

(MIL-L-2104C)

1-qt can

5-gal drum

55-gal drum, 16 gage

55-gal drum, 18 gage

Oil, Lubricating,

OE/HDO 30

(MIL-L-2104C)

1-qt can

5-gal drum

55-gal drum, 16 gage

55-gal drum, 18 gage

(5)

U/M

oz

oz

lb

lb

lb

lb

lb

qt

gal

gal

qt

gal

gal

gal

qt

gal

gal

gal

C-2
TM 9-2320-273-20

Section II EXPENDABLE SUPPLIES AND MATERIALS LIST (Continued).

(1)

ITEM

NUMBER

6

7

8

9

10

11

12

(2)

LEVEL

C

O

0

0

C

C

C

(3)

NATIONAL

STOCK

NUMBER

9150-00-265-9440

9150-00-265-9442

9150-00-265-9441

9140-00-286-5286

9140-00-286-5287

9140-00-286-5288

9140-40-286-5289

9140-00-286-5294

9140-40-286-5295

9140-00-286-5296

9140-00-286-5297

6850-00-664-5685

6850-00-281-1985

(4)

DESCRIPTION

Oil, Lubricating,

OE/HDO 50

(MIL-L-2104C)

1 -qt can

5-gal drum

55-gal drum, 16 gage

Oil, Lubricating, OHT,

(Ml L-H-60830)

Oil, Lubricating, OEA,

ICE, Subzero,

(MIL-L-46167)

Lubricant, Gear, Universal,

(MIL-L-2106)

Oil, Fuelr Diesel DF-1

Winter

(VV-F-800)

Bulk

5-gal can

55-gal drum, 16 gage

55-gal drum, 18 gage

Oil, Fuel, Diesel DF-2

Regular

(VV-F-800)

Bulk

5-gal can

55-gal drum, 16 gage

55-gal drum, 18 gage

MISCELLANEOUS

Solvent, Dry Cleaning,

SD-2 (P-D-680)

1-qt can

1-gal can

(5)

U/M

qt

gal

gal

gal

gal

gal

gal

gal

gal

gal

gal

qt

gal

C-3
TM 9-2320-273-20

Section II EXPENDABLE SUPPLIES AND MATERIALS LIST (Continued).

(1) (2) (3)

ITEM NATIONAL

NUMBER LEVEL STOCK

NUMBER

13 c 6850-00-243-1992

14 o 8030-00-889-3535

15 0

16 0

17 0 8030-00-252-3391

(4)

DESCRIPTION

Antifreeze, Permanent,

Glycol, Inhibited

(MIL-A-46153)

Tape, Antiseizing

Soap Solution

Lubriplate

Silicone Sealant

(5)

U/M

1 gal

C-4 Change 2
TM 9-2320-273-20

APPENDIX D

SCHEMATIC DIAGRAMS

Section I INTRODUCTION.

This appendix provides you with electrical system and compressed air system schematic diagrams.

NOTE

Fold out diagrams are located at the

end of this technical manual.

D-2. ELECTRICAL DIAGRAMS.

Figure FO-1.

Figure FO-2.

Figure FO-3.

Figure FO-4.

Figure FO-5.

Figure FO-6.

Figure FO-7.

Figure FO-8.

Figure FO-9.

Figure FO-10.

Figure FO-11.

Figure FO-12.

Figure FO-13.

Figure FO-14.

Figure FO-15.

Left and Right Hand Front Signal Lamp Harness Assemblies (M915 thru M920).

Left and Right Hand Fender Harness Assemblies (M915 thru M920).

Engine Harness Assembly (M915 thru M920).

Cab Marker Lamp Harness Assembly (M91681 M920).

Cab Front and Underbody Harness Assembly (M915 thru M920).

Chassis Harness Assembly (M915, M916 & M920).

Chassis Harness Assembly (M917).

Chassis Harness Assembly (M918 & M919).

Instrument Panel Harness Assembly (M915).

Instrument Panel Harness Assembly (M916 and M920).

Instrument Panel Harness Assembly (M917, M918 and M919).

M915, Line Haul Truck Tractor Electrical Diagram.

M916 Light Equipment and M920 Medium Equipment Transporter Truck Tractor

Electrical Diagram.

M917, 20-Ton Dump Truck Chassis Electrical Diagram.

M918 Bituminous Distributor and M919 Concrete-Mobile* Mixer Truck Chassis

Electrical Diagram.

D-3. COMPRESSED AIR.

Figure FO-16. M915 Tractor Schematic Diagram.

Figure FO-17. M916 Tractor Schematic Diagram.

Figure FO-18. M917 Dump Truck Connecting Schematic Diagram.

Figure FO-19. M918 Bituminous Distributor Connecting Schematic Diagram.

Figure FO-20. M919 Concrete-Mobile@ Mixer Connecting Schematic Diagram.

Figure FO-21. M920 Tractor Schematic Diagram.

D-1/D-2(Blank)
The fold-outs in this technical 

publication are not available.

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NOT DIGITIZED
TM9-2320-273-20

APPENDIX E

ILLUSTRATED LIST OF MANUFACTURED ITEMS

Section l INTRODUCTION.

a. This appendix includes complete instructions for making items authorized to be manufactured

or fabricated at organizational level.

b. A part number index in alphanumeric order is provided for cross-referencing the part number of

the item to be manufactured to the figure which covers fabrication criteria.

c. All bulk materials needed for manufacture of an item are listed by part number or specification

number in a tabular list on the illustration.

E-2. MANUFACTURED ITEM PART NUMBER INDEX.

PART NO.

M/145-20027

M/145-20028

M/145-20049

M/357-20001

M/357-20002

M/357-20005

M/357-20006

M/357-20008

M/357-20009

M/357-20012

M/357-20052

M/357-20053

M/357-20057

M/357-20059

M/357-20060

M/357-20061

M/357-20062

M/357-20063

M/357-20064

M/357-20066

M/357-20067

M/357-20068

M/357-20069

M/357-20070

FIGURE NO.

E-5

E-5

E-5

E-1

E-2

E-3

E-3

E-4

E-4

E-4

E-4

E-4

E-3

E-1

E-1

E-2

E-1

E-1

E-2

E-1

E-1

E-2

E-2

E-2

PART NO.

M/357-20071

M/357-20072

M/357-20073

M/357-20074

M/357-20075

M/357-20076

M/357-20077

M/357-20078

M/357-20080

M/357-20046

M/357-20087

M/357-20088

M/357-20089

M/357-20090

M/357-20091

M/357-20092

M/357-20093

M/357-20094

M/357-20095

M/357-20096

M/357-20097

M/357-20098

M/357-20089

M/357-20100

FIGURE NO.

E-1

E-1

E-1

E-3

E-3

E-3

E-3

E-1

E-4

E-3

E-3

E-3

E-3

E-3

E-2

E-2

E-2

E-2

E-2

E-1

E-1

E-1

E-1

E-1

PART NO.

M/357-20101

M/357-20102

M/357-20103

M/357-20112

M/357-20113

M/357-20114

M/357-20115

M/357-20116

M/357-20117

M/357-20118

M/357-20119

M/357-20120

M/357-20126

M/357-20127

M/357-20128

M/357-20129

M/357-20130

M/357-20131

M/357-20132

M/357-20133

M/357-20134

M/357-20135

MA145-20001

MB147-20001

FIGURE NO.

E-1

E-1

E-4

E-3

E-3

E-3

E-3

E -3

E-3

E-1

E-1

E-1

E-3

E-2

E-2

E-2

E-2

E-2

E-2

E-2

E-2

E-2

E-5

E-6

E-1
TM9-2320-273-20

Section ll ILLUSTRATED MANUFACTURING INSTRUCTIONS.

MATERIAL BLOCK

STOCK SIZE DESCRIPTION SPECIFICATION

1/4” (6.35 mm) OUTER DIA. TUBE, NONMETALLIC SAEJ844, TYPE 3A

Figure E-1. 1/4” (6.35mm) O.D. Nonmetallic Tubing and Fittings,

Fabricate Tube From NSN 4720-01-058-7213

INSTRUCTIONS:

1. Determine tube part number needed from RPSTL and cut squarely to correct length as shown above.

2. Select proper end fittings based upon tube part number.

3. Insert tube into fitting and tighten nut with wrench until one thread remains visible on the fitting

body.

E-2
TM9-2320-273-20

MATERIAL BLOCK

STOCK SIZE DESCRIPTION SPECIFICATION

3/8” (9.52 mm) OUTER DIA. TUBE, NONMETALLIC SAEJ844, TYPE 3B

Figure E-2. 3/8” (9.52mm) O. D. Nonmetallic Tubing and Fittings,

Fabricate Tube From NSN 4720-01-040-0591

INSTRUCTIONS:

1. Determine tube part number needed from RPSTL and cut squarely to correct length as shown above.

2. Select proper end fittings based upon tube part number.

3. Insert tuba into fitting and tighten nut with wrench until one thread remains visible on the fitting

body.

E-3
TM9-2320-273-20

MATERIAL BLOCK

STOCK SIZE DESCRIPTION SPECIFICATION

1/2” (12.7 mm) OUTER DIA. TUBE, NONMETALLIC SAEJ844, TYPE 3B

Figure E-3. 1/2” (12.7mm) O.D. Nonmetallic Tubing and Fittings,

Fabricate Tube From NSN 4720-01-040-0592

INSTRUCTIONS:

1. Determine tube part number needed from RPSTL and cut squarely to correct length as shown above.

2. Select proper end fittings based upon the part number.

3. Insert tube into fitting and tighten nut with wrench until one thread remains visible on the fitting

body.

E-4
TM9-2320-273-20

MATERIAL BLOCK

STOCK SIZE DESCRIPTION SPECIFICATION

5/8” (17.14 mm) OUTER DIA. TUBE, NONMETALLIC SAEJ844, TYPE 3B

Figure E-4. 5/8” (17.14mm) O.D. Nonmetallic Tubing and

Fabricate Tube From NSN 4720-01-009-9058

INSTRUCTIONS:

1. Determine tube part number needed from RPSTL and cut squarely to correct length as shown above.

2. Select proper end fittings based upon tube part number.

3. Insert tube into fitting and tighten nut with wrench until one thread remains visible on the fitting

body.

E-5

TM 9-2320-273-20

Subject, Para

Accelerator

Description, 2-9

Pedal, 4-21

Rod ( Linkage), 4-21

Troubleshooting, 4-5

Accessory Drive

Description, 2-32

A

Accessory Drive Belts

(See Fan Belts and Water Pump Belt)

Adapter, Oil Filter

(See Oil Filter Adapter)

Aftercooler

Description, 2-25

Air Bags (Pusher Axle)

Description, 2-16

Maintenance, 8-14

Air Brakes Chambers

(See Air Chambers)

Air Chambers

Description, 2-18

Front Brake, 9-36

Lines and Fittings, 9-17

Pusher Axle Brake, 9-38

Rear Brake, 9-37

Air Charging Valve

Description, 2-12

Maintenance, 6-12

Air Cleaner

Assembly Maintenance, 4-25

Description, 2-25

Servicing Element, 4-24

ALPHABETICAL INDEX

Subject, Para

Air Cleaner Restriction Indicator

Description, 2-25

Maintenance, 4-26

Air Compressor Governor

(See Compressor Governor)

Air Cooler/Intake Manifold

(See Aftercooler)

Air Dryer

Description, 2-60

Air Horn

Control Valve, 9-45

Description, 2-73

Maintenance, 9-45

Troubleshooting, 9-5

Air Intake System

Air Cleaner Assembly, 4-25

Air Cleaner Element, 4-24

Air Cleaner, Restriction Indicator, 4-26

Description, 2-25

Troubleshooting, 4-5

Turbo Air Inlet, 4-27

Turbocharger, 2-25

Air Lines and Fittings, 9-17

Air Pressure Gages

Description, 2-52, 2-62

Maintenance, 9-20

Air Reservoirs

Automatic Drain Valve, 9-12

Description, 2-60

Lines and Fittings, 9-17

Maintenance, 9-16

Manual Drain Valve, 9-13

Change 2 Index 1
TM 9-2320-273-20

ALPHABETICAL INDEX (Continued)

Subject, Para Subject, Para

Alinement, Front Wheels, 10-10

Alternator and Rectifier

Description, 2-42

Drive Belts, 4-55

Maintenance, 5-43

 Analysis, Oil Sample, 4-14

Atomizer (Quick-Start System)

Description, 2-40

Maintenance, 4-32

Auxiliary Cylinder, Power Steering

(M916 thru M920)

Description, 2-76

Maintenancer 10-23

B

Backup Alarm

Maintenance, 5-78

Backup Alarm Switch, 5-62

Backup Lamps

(See Rear Light Assembly)

Backup Switch

Description, 2-47

Maintenance, 5-77

Batteries

Description, 2-42

Disconnection, 5-37

Maintenance, 5-38

Battery Box

Heater, 5-91

Latch, 5-40

Cover,5-41

Maintenance, 5-42

Battery Cables

Maintenance, 5-39

Bearings and Seals

(See Wheel Bearings and Seals)

Belts

Alternator, 4-55

Fan, 4-45

Water Pump, 4-51

Blackout Lamps

Blackout Headlamp, 5-48

Blackout Marker Lamps, 5-49

Blackout Tail and Stop Lamps, 5-50

Description, 2-51

Troubleshooting, 5-19

Blackout Lamp Operation Switch

Description, 2-51

Maintenance, 5-50

Bogey Axle

(See Rear Axle)

Brake Control Valve

(See Park Brake Valve)

Brake Lamps

(See Rear Lamp Assembly)

Brake Pedal and Valve

Description, 2-62

Maintenance, 9-21

Brake Reservoirs

(See Air Reservoirs)

Index-2 Change 2
TM 9-2320-273-20

ALPHABETICAL INDEX (Continued)

Subject, Para

Brake Shoe Assemblies

Description, 2-64 thru 2-70

Front (M915), 9-31

Front (M916 thru M920), 9-32

Pusher Axle, 9-35

Rear (M915), 9-33

Rear (M916 thru M920), 9-34

Brake System, Air

Air Chambers, Front, 9-36

Air Chambers, Rear, 9-37

Air Dryer Dehydrate Cartridge

Replacement, 9-10

Air Dryer Repair, 9-11.1

Air Dryer Replacement, 9-11

Air Pressure Gages, 9-20

Brake Drums, Front (M915), 10-13

Brake Drums, Front (M916 thru M920), 10-14

Brake Drums, Rear, 10-15

Brake Shoes, Front, 9-31, 9-32

Brake Shoes, Pusher Axle, 9-35

Brake Shoes, Rear, 9-33, 9-34

Description, 2-61 thru 2-70

Lines and Fittings, 9-17

Pusher Axle Brake Air Chamber, 9-38

Slack Adjusters, 9-39

Troubleshooting, 9-5

Valves (See Brake Valves)

Brake Valves

Air Lines and Fittings, 9-17

Brake Pedal Valve, 9-21

Description, 2-62

Double-Check Valve, 9-27

Limiting Valve, 9-25

Park Brake Valve, 9-19

Quick-Release/Double-Check Valve, 9-24

Relay Valve, 9-24

Service Brakes Quick-Release Valve, 9-22

Tractor Protection Valve, 9-26

Tractor/Trailer Brake Valve, 9-18

Trailer Supply Valve, 9-17

Breathers

Crankcase, 4-15

Transmission, 6-9

Breather Tube, 4-15

Brush Guard, 11-16

Bumper, 11-9

Bypass Filter

Description, 2-27

Subject, Para

Maintenance, 4-14

Bypass Oil Filter

(See Bypass Filter)

C

Cable Assembly, Winch

Description, 2-80

Maintenance, 12-8

Cables, Battery

(See Battery Cables)

Chassis Wiring Harness, 5-31

Cigar Lighter, 5-60

Circuit Breakers

Description, 2-35

Maintenance, 5-30, 5-30.1, 5-87.

Clearance Lamps

Description, 2-45

Maintenance, 5-47

Clearance Lamp Switch

Description, 2-45

Maintenance, 5-64

Cold Start System

(See Ether Quick-Start System)

Compressed Air System

Air Pressure Gages, 9-20

Air Dryer Tubing and Hose Replacement, 9-16.1

Automatic Drain Valve, 9-12

Description, 2-60

Manual Drain Valve, 9-13

Reservoirs, 9-16

Safety Release Valve, 9-14

Trailer Supply Valve, 9-17

Troubleshooting, 9-5

(See Also, Brake System and Brake Valves)

Compressor Governor

Description, 2-60

Control Valves, Winch

Description, 2-80

Maintenance, 12-11

Change 2 Index-3
TM 9-2320-273-20

ALPHABETICAL INDEX (Continued)

Subject, Para Subject, Para

Coolant

Draining, 4-42

Heater, 5-90

Replenishing, 4-42

Cooler, Oil

Description, 2-27,2-32

Inspection, 3-7

Cooling System

Description, 2-31 thru 2-33

Drain Cock, 4-42

Draining and Filling, 4-42

Fan, 4-44

Fan Belts, 4-45

Fan Clutch, 4-45

Fan Clutch Actuator

(M915, M916, M917, M918 & M920), 4-46

Fan Clutch Actuator (M919), 4-47

Fan Clutch Actuator Tubes

(M915, M916, M917, M918 & M920), 4-48

Fan Clutch Actuator Tubes (M919), 4-49

Fan Shrouds, 4-41

Heater Control Valve, 4-50, 11-26

Heater Shutoff Valve, 4-50

Radiator, 4-40

Radiator Hoses, 4-39

Thermostat and Housing, 4-43

Troubleshooting, 4-5, 5-13

Water Manifold, 4-52

Water Pump, 4-53

Water Pump Belts, 4-51

Water Pump Idler Pulley, 4-54

Water Temperature Sending Unit, 5-72

Water Temperature Switch, 5-73

Crossover Tube

Description, 2-25

Maintenance, 4-28

Cross Tube

(See Tie Rod)

Cylinder Head Cover

(See Rocker Arm Housing Cover)

D

Differential Lockup Engaged

(See Lockup Switch)

Differential Lockup Control Valve

Description, 2-14

Maintenance, 9-44

Dimmer Switch

Description, 2-44

Maintenance, 5-57

Directional Control Valve, Winch

Description, 2-80

Maintenance, 12-11

Dome Lamp and Switch Assembly

Description, 2-49

Maintenance, 5-56

Double-Check Valve

Description, 2-64

Maintenance, 9-27

Drag Link

Description, 2-76

Maintenance, 10-19

Drain Cock, Radiator, 4-42

Driver’s Seat, 11-20

Driving Axle Assembly

(See Front Axle (M916 thru M920)

and Rear Axle)

Drums, Brake

Description, 2-18,2-21

Front (M915), 10-13

Front (M916 thru M920), 10-14

Rear, 10-15

Dual Brake Valve and Pedal

(See Brake pedal and Valve)

Dual Control Valve

(See Brake Pedal and Valve)

Data and Instruction Plates, 11-31

Index-4
TM 9-2320-273-20

Subject, Para

E

ALPHABETICAL INDEX (Continued)

Subject, Para

Electrical System

Wiring Harness Repair, 5-31.1

Circular Connector Plug Repair, 5-31.1

Circular Connector Receptacle Repair, 5-31.1

End Assembly

Front Axle (M915), 10-13

Front Axle (M916 thru M920), 10-14

Pusher Axle, 10-16

Rear Axle, 10-15

Tie Rod, 10-20

Engine

Description, Exterior Components, 2-7

Troubleshooting, 4-5

Engine Coolant Heater, 5-90

Engine Fuel Lines and Fittings

Description, 2-24

Maintenance, 4-20

Engine Mount, 3-7

Engine Oil Heater Thermostat, 5-89

Engine Retarder Brake

Cover, 4-28

Description, 2-10

Foot Switch, 4-29

Inspection, 4-29

Selector Switch, 5-62

Engine Run Switch

Description, 2-38

Maintenance, 5-35

Engine Temperature Indicator Lamp

Description, 2-33

Maintenance, 5-63

Ether Cylinder

Description, 2-40

Maintenance, 4-30

Ether Quick-Start Button

Description, 2-40

Maintenance, 5-36

Ether Quick-Start Kit

Atomizer, 4-32

Description, 2-40

Ether Button, 5-36

Ether Cylinder, 4-30

Ether Tube, 4-33

Solenoid Valve, 4-31

Temperature Switch, 5-74

Troubleshooting, 5-9

Ether Tube

Description, 2-40

Maintenance, 4-33

Exhaust Manifold

Description, 2-30

Exhaust Pipe

(See Turbo Outlet Pipe)

Exhaust Stack

Description, 2-30

Maintenance, 4-38

Exhaust System

Description, 2-29, 2-30

Exhaust Stack, 4-38

Flex Pipes, 4-35

Muffler, 4-37

Muffler Inlet Pipe, 4-36

Troubleshooting, 4-5

Turbo Outlet Pipe, 4-34

Extension Tube

(See Muffler Inlet Pipe)

External Lines, Oil, 4-14

F

Fan

Description, 2-32

Maintenance, 4-44

Fan Belts, 4-45

Fan Clutch

Description, 2-32, 2-74

Maintenance, 4-45

Fan Clutch Actuator

Description, 2-32, 2-74

Change 2 Index-5
TM 9-2320-273-20

ALPHABETICAL

Subject, Para

Maintenance (M915, M916,

M917, M918 & M920), 4-46

Maintenance (M919), 4-47

Fan Clutch Actuator Tubes

(M915, M916, M917, M918 & M920), 448

Fan Clutch Actuator Tubes

(M919), 4-49

Fan Shrouds, 4-41

Fan Switch

(See Heater Switch)

Fenders, 11-14

 Fifth Wheel Maintenance, 11-13

Filter Adapter, Oil

(See Oil Filter Adapter)

Filters

Air Cleaner, 4-24

Fuel, 4-18

Fuel Pump Screen, 4-17

Inline, Winch, 12-9

Oil, 4-14

Rear Axle (M915), 8-13

Reservoir Screen& Strainer,Winch, 12-10

Transmission Pump Screen, 6-9

Flasher Unit

Description, 2-46

Flex Pipes

Description, 2-30

Maintenance, 4-35

Foot Switch. Engine Retarder Brake

Description, 2-10

Maintenance, 4-29

Forms, Maintenance, 1-3

Frame

Bumper, 11-9

Fifth Wheel, 11-13

Pintle, 11-10

Spare Tire Hoist (M915 & M916), 11-12

Spare Tire Hoist Cable (M915 & M916), 11-11

INDEX (Continued)

Subject, Para

Towing Eyes, 11-9

Troubleshooting, 11-5

Front Axle, (M915)

Description, 2-18

Drag Link, 10-19

End Assembly, 10-13

Shock Absorbers, 10-24

Tie Rod, 10-20

Troubleshooting, 10-5

Front Axle (M916 thru M920)

Bearings and Seals, 10-14

Description, 2-19

Oil Semite, 8-12

Troubleshooting, 8-5, 10-5

Front Wheels

Alinement, 10-10

Bearings and Seals (M915), 10-13

Bearings and Seals (M916 thru M920), 10-14

Hubs (M915), 10-13

Hubs (M916 thru M920), 10-14

Tires and Tubes, 10-11

Troubleshooting, 10-5

Fuel Filter

Description, 2-24

Maintenance, 4-18

Fuel Gage

Description, 2-24

Maintenance, 5-59

Fuel Level Sending Unit

Description, 2-24

Maintenance, 5-79

Fuel Lines, Hoses, and Fittings

Description, 2-24

Maintenance, 4-20

Fuel Pump Assembly

Description, 2-24

Filter, 4-18

Lines, Hoses, and Fittings, 4-20

Pump Screen, 4-17

Solenoid Shutoff Valve, 4-16

Tachometer Cable, 4-19

Index-6 Change 2
TM 9-2320-273-20

ALPHABETICAL INDEX (Continued)

Subject, Para Subject, Para

Fuel Pump Screen

Description, 2-24

Maintenance, 4-17

Fuel Solenoid

(See Solenoid Shutoff Valve)

Fuel System

Description, 2-24

Fuel Filter, 4-18

Fuel Gage, 5-59

Fuel Level Sending Unit, 5-79

Fuel Pump Screen, 4-17

Hand Throttle and Linkage, 4-22

Lines, Hoses, and Fittings, 4-20

Solenoid Shutoff Valve, 4-16

Tachometer Cable, 4-19

Tank, 4-23

Troubleshooting, 4-5

Fuel Tank

Description, 4-23

Maintenance, 4-23

G

Gages

Air Pressure, 9-20

Fuel, 5-59

Oil Pressure, 5-59

Pusher Axle Air Pressure, 8-16

Tachograph, 5-66

Transmission Oil Temperature, 5-59

Troubleshooting, 5-13, 9-5

Voltmeter, 5-59

Water Temperature, 5-59

Grille, 11-16

Grille Support Brackets, 11-18

H

Hand Control Valve

(See Trailer Brake Valve)

Hand Throttle and Linkage

Description, 2-9

Maintenance, 4-22

Troubleshooting, 4-5

Hazard Warning Switch

Description, 2-46

Maintenance, 5-58

Headlamps

Description, 2-44

Dimmer Switch, 5-57

Lamps, 5-44

Switch, 5-62

Heater

Air Ducts, 11-30

Control Panel, 11-28

Control Valve, 11-29

Description, 2-56, 2-57

Fan Switch, 5-69

Hoses, 11-27

Motor, 11-24

Shutoff Valve, 4-48

High-Beam Indicator

Description, 2-44

Maintenance, 5-63

High Engine Water Temperature Switch

(See Water Temperature Switch)

Hood, 11-32

Horn, Air

(See Air Horn)

Horn, Electric

Button and Cable, 5-67

Description, 2-54

Maintenance, 5-68

Horn Switch

(See Horn, Electric)

Hub Assemblies and Drums

Front (M915), 10-13

Front (M916 thru M920), 10-14

Rear, 10-15

Hydraulic Pump and Reservoir Assembly,

Power Assembly

Description, 2-76

Maintenance, 10-22

Index-7
TM 9-2320-273-20

ALPHABETICAL INDEX (Continued)

Subject, Para Subject, Para

Hydraulic Steering Pump Intake Manifold

(See Hydraulic Pump and Reservoir Assembly) (See Aftercooler)

Hydraulic System, Winch Intercooler

Description, 2-80 (See Aftercooler)

Inline Filter, 12-9

Lines and Fittings, 12-13 Intermediate Pipe

Motor, 12-14 (See Muffler Inlet Pipe)

Pump, 12-15

Reservoir Screen & Strainer, 12-10 J

Valves, 12-11

Jacobs Brake

I (See Engine Retarder Brake)

Idler Pulley, 4-52

Inline Filter (Winch)

Description, 2-80

Maintenance, 12-9

Jake Brake

(See Engine Retarder Brake)

K

L

Instruction Plates, 11-31

Instrument Panel Circuit Breakers

Description, 2-35

Maintenance, 5-30

Instrument Panel Relays, 5-86

(See Individual Systems)

Instruments

Description, 2-52

Front Wheel Brake Air Pressure Gage, 9-20

Fuel Gage, 5-59

Oil Pressure Gage, 5-59

Pusher Axle Air Pressure Gage, 8-16

Tachograph, 5-66

Transmission Oil Temperature, 5-59

Troubleshooting, 5-12, 5-13,5-20

Voltmeter, 5-59

Water Temperature Gage, 5-59

Instruments – L.H. Cluster

Air Pressure Gages, 9-20

Description, 2-52

Fuel Gage, 5-59

Oil Pressure Gage, 5-59

Transmission Oil Temperature Gage, 5-59

Voltmeter, 5-59

Water Temperature Gage, 5-59

Limiting Valve, 9-25

Lines, Fittings, and Hoses (Cooling System)

Description, 2-32

Maintenance, 4-42,4-39

Linkage, Accelerator

(See Accelerator)

Lockup Switch, 5-83

Low Air Pressure Warning Indicator

Description, 2-62

Maintenance, 5-61

Low Air Buzzer, 5-80

Low Air Pressure Switch

Maintenance, 5-81

Low Brake Air Pressure Switch

(See Low Air Pressure Switch)

Index-8
TM 9-2320-273-20

ALPHABETICAL INDEX (Continued)

Subject, Para

Low Engine Oil Pressure

(See Oil Pressure Switch)

Lower Steering Column

Maintenance, 10-18

M

Maintenance, Forms, 1-3

Manifold, Water, 4-52

Manual Drain Valve

Maintenance, 9-13

Marker and Turn Signal Lamps

Description, 2-45,2-46

Maintenance, 5-45

Mud Flaps, 11-19

Muffler

Description, 2-30

Maintenance, 4-37

Muffler Inlet Pipe

Description, 2-30

Maintenance, 4-36

N

Neutral Safety Switch

Description, 2-38

Maintenance, 5-75

Non-Driving Axle Assembly

(See Front Axle, M915)

O

Oil System

Breather Tube, 4-16

Cooler, 3-7

Description, 2-26, 2-27, 2-28

Filter, 4-14

Filter Adapter, 4-14

Oil Lines, 4-14

Oil Pressure Gage, 5-59

Oil Pressure Switch, 5-71

Oil Sample for Analysis, 4-14

Subject, Para

Oil Service, 4-14

Rocker Arm Housing Cover, 4-28

Troubleshooting, 4-5

P

Park Brake

Control Valve, 9-19

Description, 2-62, 2-63

Indicator, 5-63

Relay Valve, 9-24

Switch, 5-82

Park Brake Engaged Switch

(See Park Brake)

Park Brake Valve

Description, 2-62

Maintenance, 9-19

Passenger’s Seat, 11-21

Pedal, Accelerator

(See Accelerator)

Pedal, Brake

(See Brake Pedal and Valve)

Personnel Heater

(See Heater)

Pintle, 11-10

Pitman Arm

Description, 2-76

Maintenance, 10-21

Pivot Lever, Accelerator

Description, 2-9

Maintenance, 4-21

Pneumatic Control Lines (Transmission)

Description, 2-12

Maintenance, 6-11

Power Steering Cylinder

(See Auxiliary Cylinder)

Power Steering Gear

(See Steering Gear)

Change 2 Index-9
TM 9-2320-273-20

ALPHABETICAL INDEX (Continued)

Subject, Para Subject, Para

Power Steering Pump

(See Hydraulic Pump and Reservoir Assembly)

Power Steering Reservoir

(See Hydraulic pump and Reservoir Assembly)

Power Steering System

(See Steering System)

Power Takeoff

(See PTO)

Power Train

Description (M915), 2-4

Description (M916 thru M920), 2-5

Maintenance (See Individual Components)

Power Transfer Case

Cooler Maintenance, 7-9

Description, 2-14

Oil Semite, 7-8

Troubleshooting, 7-5

Power Transfer/Differential Lockout Control

(See Differential Lockup Control Valve)

Pressure Gages, Air

Front Brake Air, 9-20

Pusher Axle, 8-16

Rear Brake Air, 9-20

Pressure Regulator Valve, Pusher Axle

Description, 2-16

Maintenance, 8-17

Propeller Shafts

Description, 2-4,2-5,2-21,2-22

Shaft Maintenance, 8-11

Troubleshooting, 8-5

Universal, 8-11

PTO

Description, 2-78

Linkage, 12-16

Switch, 5-84

Troubleshooting, 7-5, 12-5

Pulleys

Accessory Drive, 2-32

idler, 4-54

Water Pump, 4-51,4-54

Pusher Axle (M917, M918, & M920)

Air Bags, 8-14

Description, 2-16

Lift Cylinders, 8-15

Pressure Gage, 8-16

Pressure Regulator Valve, 8-17

Shock Absorbers, 10-25

Troubleshooting, 8-5

Up-Down Selector Valve, 8-18

Wheel Bearings and Seals, 10-16

Q

Quick-Release Valves

Quick-Release/Double-Check, 9-23

Service Brakes, 9-22

R

Radiator

Description, 2-32

Drain and Fill, 4-42

Drain Cock, 4-42

Fan Shrouds, 4-41

Lines and Hoses, 4-39

Remove and Install ,4-40

Ratio Selector

Description

Description, 2-12

Maintenance, 6-12

Ratio Valve

(See Limiting Valve)

Rear Axle

Bearing and Seals, 10-15

Description, 2-21,2-22

Oil Service, 8-13

Torque Rods, 10-26

Troubleshooting, 8-5, 10-5

PTO Engaged Switch

(See PTO)

Index-10
TM 9-2320-273-20

ALPHABETICAL INDEX (Continued)

Subject, Para

Rear Bogey Axle

(See Rear Axle)

Rear Lamp Assembly

Description, 2-46, 2-47

Maintenance, 5-46

Rear View Mirror, 11-25

Relays

Description, 2-35

Maintenance, 5-86

(See Individual Systems)

Relay Valves, 9-24

Reservoirs, Air

Automatic Drain Valve, 9-12

Description, 2-60

Maintenance, 9-16

Manual Drain Valve, 9-13

Safety Release Valve, 9-14

Troubleshooting, 9-5

Reservoir, Winch

Description, 2-80

Inline Filter, 12-9

Screen and Strainer, 12-10

Rocker Arm Housing Cover, 4-28

Roller, Tail, 11-33

S

Safety Release Valve

Description, 2-60

Maintenance, 9-14

Safety Valve

(See Safety Release Valve)

S-Cam Mechanism, 9-34

Screens

Fuel Pump, 4-17

Fuel Tank, 4-23

Transmission, 6-9

Winch Reservoir, 12-10

Subject, Para

Seat Risers, 11-22

Seats

Driver’s, 11-20

Passenger’s, 11-21

Selector Switch, Engine Retarder Brake

Description, 2-10

Maintenance, 5-62

Service Brakes

{See Brake System)

Service Head Lamps

(See Headlamps)

Shock Absorbers

Description, 2-16,2-18

Front Axle, 10-24

Pusher Axle, 10-25

Slack Adjusters

Adjust, 9-39

Remove and Install, 9-39

Solenoid Shutoff Valve (Fuel)

Description, 2-24

Maintenance, 4-16

Solenoid Valve, Quick-Start

Description, 2-40

Maintenance, 4-31

Solenoid Valves, Engine Retarder Brake

Description, 2-10

Inspection, 4-29

Spare Wheel Mount

Hoist Cable, 11-11

Hoist, 11-12

Speedometer Cable

Description, 2-52

Maintenance, 6-13

Splash Shields

(See Mud Flaps)

Starter

Description, 2-38

Index-11
TM 9-2320-273-20

ALPHABETICAL INDEX (Continued)

Subject, Para

Motor, 5-32

Relay, 5-33

Switch, 5-34

Troubleshooting, 5-8

Starter Magnetic Switch

(See Starter)

Starter Solenoid

(See Starter, Motor)

Steering Arm Maintenance, 10-84.3

Assembly, 10-84.7

Cleaning and Inspection, 10-84.7

Disassembly, 10-84.4

Fabrication of Pushrod Driver and

Steering Stop Template, 10-85

Preparation, 10-84.4

Steering Column, 10-18

Steering Gear

Description, 2-76

 Steering Gear Poppet Adjustment, 10-84.11

Steering System

Auxiliary Cylinder, 10-23

Description, 2-76

Drag Link, 10-19

Hydraulic Pump and Reservoir Assembly,

10-22

Lower Steering Column, 10-18

Pitman Arm, 10-21

Steering Wheel, 10-17

Tie Rod, 10-20

Troubleshooting, 10-5

U-Joints, 10-18

Steering Stop Inspection and Adjustment

Procedures, 10-84.8

Steering Wheel

Description, 2-76

Maintenance, 10-17

Stop Lamps

(See Rear Lamp Assembly)

Subject, Para

Stop Switches

Description, 2-76

Maintenance, 5-85

Stowage Box

(See Seat Risers)

Supply Rervoir

Automatic Drain Valve, 9-12

Description, 2-60

Maintenance, 9-16

Suspension System

Front Axle Shock Absorbers, 10-24

Pusher Axle Shock Absorbers, 10-25

Rear Axle Torque Rods, 10-26

Troubleshooting, 10-5

Switches and Relays

(See Specific Items)

T

Tachograph Assembly

Description, 2-52

Maintenance, 5-66

Speedometer Cable, 6-13

Tachometer Cable, 4-19

Tail Lamps

(See Rear Lamp Assembly)

Tail Pipe

(See Exhaust Stack)

Tail Roller, 11-33

Thermal Switch, Quick-Start

(See Ether Quick-Start Kit)

Thermostat Control and Linkage

Description, 2-9

Maintenance, 4-22

Troubleshooting, 4-5

Throttle, Winch

Description, 2-80

Maintenance, 12-12

Index-12 Change 3
TM 9-2320-273-20

ALPHABETICAL INDEX (Continued)

Subject, Para

Tie Rod

Adjust, 10-10

Description, 2-18,2-76

Remove and Install, 10-20

Tires and Tubes, 10-11

Tool BOX, 11-22

Change 3 Index-12.1/(Index 12.2 blank)

TM 9-2320-273-20

ALPHABETICAL INDEX (Continued)

Subject, Para Subject, Para

Torque Rods, 10-26

Torque Table, 3-9

Towing Eyes, 11-9

Tractor Protection Valve, 9-26

Trailer Brake Valve

Description, 2-62

Maintenance, 9-18

Trailer Connector Brake Lines and Couplings

(See Brake System )

Trailer Couplings, Electric, 5-55

Trailer Hand Brake Valve

(See Trailer Brake Valve)

Trailer Hand Control Valve

(See Trailer Brake Valve)

Trailer Supply Valve

Description, 2-62

Maintenance, 9-17

Transmission

Air Charging Valve, 6-12

Breather, 6-9

Control Heater, 6-14

Control Lines, 6-11

Description, 2-12

Neutral Safety Switch, 5-75

Oil Heater, 5-88

Oil Temperature Gage, 5-59

Oil Temperature Sending Unit, 5-76

Oil Service, 6-9

Ratio Selector, 6-12

Screen Filter, 6-9

Troubleshooting, 6-5, 6-6

Troubleshooting

Axles, 8-5

Backup Lamps, 5-18

Battery Charging, 5-11

Battery System, 5-7

Blackout Lighting System, 5-19

Brakes, 9-5

Compressed Air System, 9-5

Engine, 4-5

Engine Retarder, 5-10

Ether Quick-Start, 5-9

Frame, 11-5

Gages, and Sending Units, 5-13

Headlamps, 5-14

Marker Lamps, 5-15

Miscellaneous Electrical, 5-20

Parking and Tail Lamps, 5-16

Power Transfer Case, 7-5

Propeller Shafts, 8-5

Starting System, 5-8

Steering System, 10-5

Stop and Turn Signal Lamps, 5-17

Suspension, 10-5

Symptom Index, 3-8

Transmission, 6-5, 6-6

Warning Lamps and Alarms, 5-12

Wheels, 10-5

Winch, 12-5

Turbo Air Inlet

Description, 2-25

Maintenance, 4-27

Turbocharger

Description, 2-25

Turbocharger Air Inlet

(See Turbo Air Inlet)

Turbo Outlet Pipe

Description, 2-30

Maintenance, 4-34

Turn Signals

Control, 5-58

Description, 2-46

Lamps, Front, 5-45

Lamps, Rear, 5-46

Troubleshooting, 5-17

Turn Signal Switch (Control)

(See Turn Signals)

U

Universal Joints (Drive Train)

Inspect, 8-11

Maintenance. 8-11

Index-13
TM 9-2320-273-20

ALPHABETICAL INDEX (Continued)

Subject, Para Subject, Para

Universal Joints (Steering Column)

Description, 2-76

Maintenance, 10-18

Up-Down Selector Valve

Description, 2-80

Maintenance, 8-18

V

Valve Cover

(See Rocker Arm Housing Cover)

Valves

Air Charging, 6-11

Air Horn Control, 9-43

Atomizer, 4-32

Automatic Drain, 9-12

Brake Pedal, 9-21

Differential Lockup Control, 9-42

Double-Check, 9-28,9-29

Fuel Solenoid Shutoff, 4-16

Heater Shutoff, 4-50

Heater Water Control, 11-26

Limiting, 9-25

Manual Drain, 9-13

Park Brake, 9-19

Pusher Axle Pressure Regulator, 8-17

Pusher Axle Up-Down Selector, 8-18

Quick-Release/Double-Check, 9-23

Quick-Start Solenoid, 4-31

Relay, 9-24

Safety Release, 9-14

Service Brakes Quick-Release, 9-22

Tractor Protection, 9-26

Tractor/Trailer Brake, 9-18

Trailer Supply, 9-17

Winch Control, 12-11

Ventilator

Description, 2-58

Maintenance, 11-15

Voltmeter

Description, 2-52

Maintenance, 5-59

W

Water Manifold

Description, 2-32

Maintenance, 4-52

Water Pump

Belt, 4-51

Description, 2-32

Idler Pulley, 4-54

Maintenance, 4-53

Water Temperature Gage

Description, 2-33

Maintenance, 5-59

Water Temperature Sending Unit

Description, 2-33

Maintenance, 5-72

Water Temperature Switch

Description, 2-33

Maintenance, 5-73

Wheels

Alinement, 10-10

Drums: Covered w/Wheel Bearings and Seals

Front Wheel Bearings and Seals (M915), 10-13

Front Wheel Bearings and Seals

(M916 thru M920), 10-14

Hubs: Covered w/Wheel Bearings and Seals

Pusher Axle Wheel Bearings and Seals, 10-16

Rear Wheel Bearings and Seals, 10-15

Tires and Tubes, 10-11

Troubleshooting, 10-5

Winch

Cables, 12-8

Control Valves, 12-11

Description, 2-80

Hydraulic Lines and Fittings, 12-13

Hydraulic Motor, 12-14

Hydraulic Pump, 12-15

Inline Filter, 12-9

PTO Linkage, 12-16

Reservoir Screen & Strainer, 12-10

Taking Hydraulic System Oil Sample, 12-17

Throttle, 12-12

Wiring Harness Repair, 5-31.1

Circular Connector Plug Repair, 5-31.1

Circular Connector Receptacle Repair, 5-31.1

Index- 14 Change 2
TM 9-2320-273-20

Subject, Para

ALPHABETICAL INDEX (Continued)

Subject, Para

Troubleshooting, 12-5

Windshield Washers

Control Button, 9-41

Description, 2-72

Maintenance, 9-40

Windshield Wipers

Arms, 11-24

Blades, 11-23

Control, 9-43

Description, 2-72

Motor, 9-42

Troubleshooting, 95

Winter Front, 11-17

Winterization Kit

Battery Box Heater, 5-91

Circuit Breaker Box, 5-87

Circuit Breakersr 5-87

Description, 2-81, 2-82

Engine Coolant Heater, 5-90

Engine Oil Heater Thermostat, 5-89

Receptacle, 5-87

Transmission Oil Heater, 5-88

Wire Identification, 2-36

Work Lamps (M916 & M920)

Description, 2-48

Lamps, 5-54

Switch, 5-62

X Y Z

Index-15/16(blank)

TM 9-2320-273-20

By Order of the Secretary of the Amy

Official:

E. C. MEYER

General, United States Army

Chief of Staff

J. C. PENNINGTON

Major General, United States Army

The Adjutant General

Distribution:

To be distributed in accordance with DA Form 12-38, organizational maintenance

requirements for M915, M916, M920 trucks and truck chassis for M917, M918, and M919,

*U.S. GOVERNMENT PRINTING OFFICE : 19940- 300-421 (03051)















TM 9-2320-273-20
PIN: 047617-000