TM-9-2320-211-20-3-2
TM 9-2320-211-20-3-2
T.O.
36A12-1C-422-1-3
TECHNICAL MANUAL
VOLUME 3 OF 3
PART 2 OF 2
MAINTENANCE
ORGANIZATIONAL
LEVEL
5-TON, 6X6, M39 SERIES TRUCKS
(MULTIFUEL)
TRUCK,
CHASSIS:
M40A2C,
M61A2, M63A2; TRUCK, CARGO:
M54A2,
M54A2C,
M55A2;
TRUCK,
DUMP: M51A2; TRUCK, TRACTOR:
M52A2;
TRUCK,
WRECKER,
MEDIUM:
M543A2
NOTE:
THE
STYLE
EXPERIMENTAL.
B Y
T H E
A
OF
IT
A R M Y
LIMITED
THIS
IS
TM
IS
BEING
O N L Y
T R I E D
O N
BASIS
DEPARTMENTS OF THE ARMY AND THE AIR FORCE
DECEMBER 1980
WARNING
EXHAUST GASES CAN BE DEADLY
Exposure to exhaust gases produces symptoms of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death can
result from severe exposure.
Carbon monoxide occurs in the exhaust fumes of fuel burning heaters and internal
combustion engines, and becomes dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to insure the safety
of personnel whenever fuel burning heater(s) or engine of any vehicle is operated for
maintenance purposes or tactical use.
Do not operate heater or engine of vehicle in an enclosed area unless it is adequately
ventilated.
Do not idle engine for long periods wit bout maintaining adequate ventilation in personnel compartments.
Do not drive any vehicle with inspection plates or cover plates removed unless necessary for maintenance purposes.
Be alert at all times during vehicle operation for exhaust odors and exposure symptoms.
If either are present, immediately ventilate personnel compartments. If symptoms persist, remove affected personnel from vehicle and treat as follows: expose to fresh air;
keep warm; do not permit physical exercise; if necessary, administer artificial
respiration.
If exposed, seek prompt medical attention for possible delayed onset of acute lung
congestion. Administer oxygen if available.
The best defense against exhaust gas poisoning is adequate ventilation.
WARNING
Serious or fatal injury to personnel may result
if the following instructions are not complied with.
Do not use a wire brush or compressed air to clean face and brake drum. There may
be asbestos dust on the drum which can be dangerous to your health if you breathe
it in.
Dry cleaning solvent is flammable. Do not use near an open flame. Keep a, fire extinguisher nearby when solvent is used. Use only in well-ventilated places. Failure
to do this may result in injury to personnel and damage to equipment.
Eye shields must be worn when using compressed air. Eye injury can occur if eye
shields are not used.
Do not dry wheel bearings with compressed air.
cause serious injury to personnel.
Spinning bearings may explode and
Do not work on tire until all the air is out of it.
injury if the ring should fly off.
Stand clear of retaining ring to avoid
a
WARNING - Cont
Be careful when inflating tires. Remounted tires should always be inflated in a
safety cage. If a safety cage is not available, turn tire and rim over with outer hubside down.
Leave transmission jack in place under mounting bracket for support. Failure to do
this may let mounting bracket fall, causing injury to personnel and damage to
equipment.
Keep hands away from wheels when jacking up truck. Wheels may turn as they clear
the ground. Personnel can be injured.
Always wear protective gloves when handling winch cable. Do not let winch cable
slip through hands. Rusty or broken wires can cause serious injury.
Unlock cab door assembly carefully. It has been freed and may fall, causing injury
to personnel.
Always use hand THROTTLE to control engine speed when operating winch. Avoid
sudden changes in speed or high speed. Rough, jerky operation may cause broken
shear pins and snapped cables, damage to truck or injury to personnel may result.
Rear winch assembly is heavy. Rig hoist chain on rear winch assembly so that it does
not slide. Sliding of rear winch assembly could cause serious injury to personnel and
damage to equipment.
Do not work on hot hydraulic system.
Hot hydraulic oil can burn personnel.
Never work under a raised dump body unless safety hoist braces are in position.
Dump body could drop down, causing death or injury to personnel working under it.
Hold lower boom roller assembly when taking out cap screws. Boom roller assembly is
heavy. Dropping it could result in injury to personnel and damage to equipment.
Smoking, sparks or open flame are not allowed within 50 feet of work area when
working on fuel system components.
Do not let tool touch battery and truck. This will cause a direct short, arcing, tool
will heat to red hot, and battery may explode. This can cause serious injury to
personnel and damage to equipment.
b
*TM
9-2320-211-20-3-2
T.O.
TECHNICAL MANUAL
NO. 9-2320-211-20-3-2
TECHNICAL ORDER
NO. 36A12-1C-422-1-3
36A12-1C-422-1-3
DEPARTMENTS OF THE ARMY
AND
THE AIR FORCE
WASHINGTON, DC, 10 December 1980
TECHNICAL MANUAL
VOLUME 3 OF 3
PART 2 OF 2
MAINTENANCE
ORGANIZATIONAL LEVEL
5-TON, 6X6, M39 SERIES TRUCKS
(MULTIFUEL)
Model
NSN without Winch
NSN with Winch
M40A2C
M61A2
M63A2
2320-00-969-4114
2320-00-055-9264
2320-00-226-6251
2320-00-965-0321
2320-00-285-3757
Truck, Cargo
M54A2
M54A2C
M55A2
2320-00-055-9266
2320-00-926-0874
2320-00-073-8476
2320-00-055-9265
2320-00-926-0874
2320-00-055-9259
Truck, Dump
M51A2
2320-00-055-9262
2320-00-055-9263
Truck, Tractor
M52A2
2320-00-055-9260
2320-00-055-9261
Truck, Wrecker,
Medium
M543A2
Chassis
2320-00-055-9258
Current as of 25 Jul 80.
*This manual together with TM 9-2320-211-20-1, 10 December 1980; TM 9-2320-211-20-2-1, 10 December 1980;
TM 9-2320-211-20-2-2, 10 December 1980 and TM 9-2320-211-20-3-1, 10 December 1980 supersedes so much of
TM 9-2320-211-20, 1 June 1973 as pertains to multifuel vehicles including all changes.
TM 9-2320-211-20-3-2
REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes or if you know of a way to improve
the procedure, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to
Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual direct to:
Commander, US Army Tank-Automotive Command, ATTN: DRSTA-MB, Warren,
Michigan 48090. A reply will be furnished to you.
TABLE OF CONTENTS
Part 2 of 2
CHAPTER 13. WHEEL SYSTEM GROUP MAINTENANCE
Section 1. S c o p e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Items Covered . . . . . . . . . . . . . .
Equipment Items Not Covered. . . . . . . . . . .
Section II. Front Wheel Assembly . . . . . . . . . . . . . . . .
Front Wheel and Brake Drum Assembly
Removal and Replacement . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . .
Replacement . . . . . . . . . .
Front Hub and Brake Drum
Assembly Removal and Replacement . . . .
Preliminary Procedure . . . . . . .
Removal . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . .
Replacement. . . . . . . . . . . .
Front and Rear Hub and Brake Drum
Assembly Repair . . . . . . . . . . .
Preliminary Procedure . . . . . . . .
Front Hub and Brake Drum . . . . .
Rear Hub and Brake Drum. . . . . . .
Front Wheel Bearing Cones and Seal
Removal and Replacement for Service . .
Preliminary Procedure. . . . . . . . . . . . . . .
Removal. . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . .
Front Inner and Outer Wheel Bearings
and Seal Removal and Replacement . . . . .
Preliminary Procedure. . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . .
Lubrication. . . . . . . . . . . . . . . .
ii
Paragraph
Page
13-1
13-2
13-1
13-1
13-1
13-1
13-3
13-3a
13-3b
13-3c
13-1
13-1
13-2
13-5
13-4
13-4a
13-4b
13-4c
13-4d
13-10
13-10
13-10
13-12
13-12
13-5
13-5a
13-5b
13-5c
13-15
13-15
13-15
13-23
13-6
13-6a
13-6b
13-6c
13-6d
13-6e
13-6f
13-31
13-31
13-31
13-32
13-33
13-34
13-35
13-7
13-7a
13-7b
13-7c
13-7d
13-7e
13-36
13-36
13-36
13-38
13-39
13-40
TM 9-2320- 211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Studs Removal and Replacement . .
Preliminary Procedure. . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Section III. Rear Wheel Assembly. . . . . . . . . . . . . . . . . . . . .
Rear Wheels and Brake Drum
Assembly Removal and Replacement . . . .
Preliminary Procedure. . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . . . . . . . . . . . .
Rear Hub and Brake Drum Assembly
Removal and Replacement. . . . . . . . . . . . .
Preliminary Procedure. . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection. . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Bearing Cones and Seals
Removal and Replacement for
S e r v i c e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure. . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . .
I n s p e c t i o n. . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Rear Inner and Outer Wheel Bearings
and Seals Removal and Replacement . . .
Preliminary Procedure. . . . . . . . . . . . . . .
R e m o v a l. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Section IV. Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pneumatic Tire and Tube Removal
and Replacement . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure. . . . . . . . . . . . . . .
R e m o v a l. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 14. STEERING SYSTEM GROUP MAINTENANCE
Section I. S c o p e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Items Covered. . . . . . . . . . . . . .
Equipment Items Not Covered. . . . . . . . . .
Page
13-7f
13-8
13-8a
13-8b
13-8c
13-41
13-43
13-43
13-43
13-44
13-45
13-9
13-9a
13-9b
13-9c
13-45
13-45
13-45
13-48
13-10
13-10a
13-10b
13-10c
13-10d
13-53
13-53
13-53
13-56
13-56
13-11
13-11a
13-11b
13-11c
13-11d
13-11e
13-11f
13-60
13-60
13-60
13-61
13-62
13-63
13-64
13-12
13-12a
13-12b
13-12c
13-12d
13-12e
13-12f
13-65
13-65
13-65
13-67
13-68
13-69
13-71
13-73
13-13
13-13a
13-13b
13-13c
13-73
13-73
13-73
13-78
14-1
14-2
14-1
14-1
14-1
iii
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Section II.
Section III.
iv
Mechanical Steering Gear Assembly . . . . . . .
Front Wheel Alinement . . . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . .
Toe-In Check and Adjustment . . . . . . . .
Pitman Arm Removal and Replacement...
Preliminary Procedures . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . . . . . . . . . . . .
Steering Tie Rod Assembly and Tie
Rod End Removal and Replacement . . . .
Removal of Tie Rod Assembly . . . . . . . .
Removal of Tie Rod End. . . . . . . . . . .
Replacement of Tie Rod End . . . . . . . . .
Replacement of Tie Rod Assembly . . . .
Upper and Lower Drag Links Removal
Replacement, Check, and Adjustment. .
Preliminary Procedure . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . . . . . . . . . . . .
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .
Drag Link Relay Lever Removal
and Replacement. . . . . . . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Assembly Removal
and Replacement. . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R e p l a c e m e n t. . . . . . . . . . . . . . . . . . . . . . .
Steering Knuckle Arm Check and
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Mechanism Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . . . . . . . . . . .
Steering Hoses, Lines, and Fittings . . . . . .
Power Steering Hoses, Lines, and
Fittings Removal and Replacement . . . . .
Preliminary Procedures . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Page
14-3
14-3a
14-3b
14-4
14-4a
14-4b
14-4c
14-1
14-1
14-1
14-2
14-8
14-8
14-8
14-10
14-5
14-5a
14-5b
14-5c
14-5d
14-11
14-11
14-12
14-13
14-14
14-6
14-6a
14-6b
14-6c
14-6d
14-6e
14-15
14-15
14-15
14-18
14-20
14-21
14-7
14-7a
14-7b
14-22
14-22
14-23
14-8
14-8a
14-8b
14-8c
14-24
14-24
14-24
14-26
14-9
19-27
14-10
14-10a
14-10b
14-10c
14-28
14-28
14-29
14-35
14-41
14-11
14-11a
14-11b
14-11c
14-41
14-41
14-43
14-45
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Steering Reservoir. . . . . . . . . . . . . . . . . . . . . .
Hydraulic Steering Oil Reservoir
Removal and Replacement. . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 15. FRAME AND TOWING ATTACHMENTS
GROUP MAINTENANCE
Section I. Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Items Covered . . . . . . . . . . . . . .
Equipment Items Not Covered. . . . . . . . .
Section II. Frame Components. . . . . . . . . . . . . . . . . . . . . .
Bumpers Removal and Replacement
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Section III. Pintles and Towing Attachments. . . . . . . . . .
Towing Pintle Assembly Removal
and Replacement . . . . . . . . . . . . . . . . . . . . .
R e m o v a l. . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Towing Pintle Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Front Lifting Shackle Bracket
Removal and Replacement . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . .
Rear Lifting Shackle Removal
and Replacement . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure. . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Section IV. Spare Wheel Carrier . . . . . . . . . . . . . . . . . . .
Spare Wheel Carrier Removal,
Repair, and Replacement (Truck
M51A2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . .
Spare Wheel Carrier Removal,
Repair, and Replacement (Trucks
M54A2 with Winch and M55A2 with
W i n c h ). . . . . . . . . . . . . . . . . . . . . . . .
Page
14-47
Section IV.
14-12
14-12a
14-12b
14-12c
15-1
15-2
15-3
15-3a
15-3b
14-47
14-47
14-48
14-51
15-1
15-1
15-1
15-1
15-1
15-2
15-5
15-9
15-4
15-4a
15-4b
15-9
15-9
15-14
15-5
15-5a
15-5b
15-19
15-19
15-20
15-6
15-6a
15-6b
15-21
15-21
15-23
15-7
15-7a
15-7b
15-7c
15-7d
15-25
15-25
15-26
15-27
15-28
15-29
15-8
15-8a
15-8b
15-8c
15-29
15-29
15-33
15-33
15-9
15-39
v
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Section V.
CHAPTER 16.
Section I.
Section II.
vi
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning, Inspection, and Repair. . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare Wheel Carrier Removal and
Replacement (Trucks M54A2 and
M54A2C without Winch and Truck
M54A2C with Winch) . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . .
Spare Wheel Carrier Removal, . . . . . . . . . . .
Repair, and Replacement (Truck
M52A2 without Winch) . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . .. . . . .
Cleaning, Inspection, and Repair
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Fifth Wheel Assembly . . . . . . . . . . .
Fifth Wheel Assembly Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
SPRINGS AND SHOCK ABSORBERS GROUP
MAINTENANCE
Scope . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Items Covered . . . . . . . . . . . . . . .
Equipment Items Not Covered . . . . . . . . . . .
Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Axle Spring Assembly Removal
and Replacement . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Leaf Spring Assembly
Removal and Replacement . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Spring Seat Removal,
Replacement, and Adjustment . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement and Adjustment . . . . . . . . . .
Paragraph
15-9a
15-9b
15-9c
15-9d
15-9e
Page
15-39
15-41
15-42
15-42
15-43
15-10
15-10a
15-10b
15-46
15-46
15-47
15-11
15-11a
15-11b
15-11c
15-11d
15-48
15-48
15-49
15-51
15-52
15-54
15-12
15-12a
15-12b
15-54
15-54
15-55
16-1
16-2
16-1
16-1
16-1
16-1
16-3
16-3a
16-3b
16-3c
16-1
16-1
16-2
16-6
16-4
16-4a
16-4b
16-4c
16-11
16-11
16-11
16-14
16-5
16-5a
16-5b
16-5c
16-18
16-18
16-19
16-24
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Section III.
CHAPTER 17.
Section I.
Section II.
Section III.
Section IV.
Shock Absorbers . . . . . . . . . . . . . . . . . . . . . . . . .
Front Axle Shock Absorber
Removal and Replacement. . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
BODY, CAB, HOOD, AND HULL GROUP
MAINTENANCE
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Items Covered . . . . . . . . . . . . . .
Equipment Items Not Covered . . . . . . . . . . .
Body And Cab Components
Brush Guard Assembly Removal
and Replacement . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Door Assembly Removal
and Replacement . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Tunnel Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Windshield Assembly Removal
and Replacement . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driver’s Seat Assembly Removal
and Replacement . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Companion Seat Assembly
Removal and Replacement . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Crane Operator’s Seat Removal
and Replacement (Truck M543A2) . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Crane Operator’s Back Rest
Removal and Replacement (Truck
M543A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Page
16-32
16-6
16-6a
16-6b
16-32
16-32
16-33
17-1
17-2
17-1
17-1
17-1
17-1
17-3
17-3a
17-3b
17-3c
17-1
17-1
17-2
17-3
17-4
17-4a
17-4b
17-4c
17-4
17-4
17-4
17-7
17-5
17-5a
17-5b
17-10
17-10
17-11
17-12
17-6
17-6a
17-6b
17-6c
17-12
17-12
17-12
17-13
17-14
17-7
17-7a
17-7b
17-14
17-14
17-16
17-8
17-8a
17-8b
17-18
17-18
17-19
17-9
17-9a
17-9b
17-20
17-20
17-21
17-10
17-10a
17-10b
17-22
17-22
17-23
vii
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Section V.
Section VI.
CHAPTER 18.
Section 1.
Section II.
Viii
Stowage and Tool Boxes . . . . . . . . . . . . . . . . . .
Left Tool Box Assembly Removal
and Replacement. . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Pioneer Stowage Tool Box Assembly
Removal and Replacement (Truck
M52A2 without Winch and Truck
M543A2 with Winch) . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . .
Pioneer Tool Set Bracket Assembly and
Pioneer Tool Bracket Removal, Repair
and Replacement (Trucks M51A2,
M52A2, M54A2, M54A2C, and M55A2). . .
Preliminary Procedure. . . . . . . .
R e m o v a l. . . . . . . . . . . . . . . . . . . .
Cleaning. . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . .
Cargo Body Components . . . . . . . . . . . . .
Tailgage Control Linkage Adjustment
(Truck M51A2) . . . . . . . . . . . . . . .
Troop Seat Rack Assembly Repair . . . . . .
Preliminary Procedure. . . . . . . . . .
Disassembly of Rack and Seat
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly of Rack Assembly . . . . . . . .
Disassembly of Seat Assembly. . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . .
Inspection and Repair. . . . . . . .
Assembly of Seat Assembly . . . . .
Assembly of Rack Assembly . . . . .
Assembly of Rack and Seat Assembly. .
WINCH, HOIST, AND CRANE ASSEMBLIES
GROUP MAINTENANCE
S c o p e. . . . . . . . . . . . . . . . . . . . . . .
Equipment Items Covered. . . . . .
Equipment Items Not Covered . . . . . .
Winch, Hoist, and Crane Assemblies . . . . . .
Front Winch and Rear Winch Brake
Tests and Adjustments. . . . . . . . .
Preliminary Procedure. . . . . . .
Drag Brake Test and Adjustment . . . . .
Automatic Brake Test and
Adjustment. . . . . . . . . . . .
Page
17-24
17-11
17-11a
17-11b
17-24
17-25
17-26
17-12
17-12a
17-12b
17-12c
17-27
17-27
17-28
17-29
17-13
17-13a
17-13b
17-13c
17-13d
17-13e
17-30
17-30
17-30
17-34
17-34
17-35
17-39
17-14
17-15
17-15a
17-39
17-40
17-40
17-15b
17-15c
17-15d
17-15e
17-15f
17-15g
17-15h
17-15i
17-40
17-41
17-42
17-44
17-44
17-45
17-48
17-50
18-1
18-2
18-1
18-1
18-1
18-1
18-3
18-3a
18-3b
18-1
18-1
18-2
18-3c
18-4
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Front Winch Cable Removal and
Replacement (All Trucks Except
M543A2). . . . . . . . . . . . . . . .
Preliminary Procedure. . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Front Winch Cable Removal and
Replacement (Truck M543A2). . . . . . . . . .
Preliminary Procedure . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . .
Front Winch Tension Sheave
Assembly Removal and Replacement
(Truck M543A2) . . . . . . . . . . . . . . .
R e m o v a l. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . .
Front Winch and Roller Assembly
Removal, Replacement, Test, and
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .
R e m o v a l. . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . .
Test and Adjustment. . . . . . . . .
Rear Winch Drive Chain Removal,
Replacement, and Adjustment
(Truck M543A2). . . . . . . . . . . . . . . .
Preliminary Procedure. . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Winch Cable Tensioner
Assembly Checkout and Adjustment
(Truck M543A2). . . . . . . . . . . . . .
Preliminary Procedures. . . . . . . . . . . . . .
Checkout . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Winch Propeller Shaft Pillow
Block Removal and Replacement . . . . . . . .
Preliminary
Procedures.
.
.
.
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Rear Winch to Power Divider Controls
and Linkage Adjustment (Truck
M543A2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Winch Assembly Removal and
Replacement (Truck M543A2). . . . . . . .
Preliminary Procedures. . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . .
Page
18-4
18-4a
18-4b
18-4c
18-14
18-14
18-14
18-15
18-5
18-5a
18-5b
18-5c
18-16
18-16
18-16
18-17
18-6
18-6a
18-6b
18-18
18-18
18-20
18-7
18-7a
18-7b
18-7c
18-22
18-22
18-23
18-24
18-8
18-8a
18-8b
18-8c
18-8d
18-36
18-36
18-36
18-38
18-41
18-9
18-9a
18-9b
18-9c
18-44
18-44
18-45
18-46
18-10
18-10a
18-10b
18-10c
18-47
18-47
18-47
18-48
18-11
18-49
18-12
18-12a
18-12b
18-12c
18-54
18-54
18-55
18-60
ix
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Dump Truck Body Hoist Pump
Assembly Removal and
Replacement . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . .
Control Valve Assembly Removal
and Replacement (Truck M51A2). . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . .
Dump Body Hydraulic Lines Removal
and Replacement (Truck M51A2). . .
Preliminary Procedures. . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement
. . . . . . . . . . .
Dump Body Hoist Brace Locking
and Unlocking (Truck M51A2). . .
Locking. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unlocking. . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist Control Linkage Check and
Adjustment (Truck M51A2). . . . . .
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Hoses Removal and
Replacement (Truck M543A2) . . . . . . .
Preliminary Procedure. . . . . .
Lift Cylinder-to-Boom Support
Crossover Tube Hoses . . . .
Boom Support Crossover-toSnubber Valve Hose. . . . . .
Valve Bank-to-Swing Motor Hoses . . . .
Pump-to-Valve Bank Hose and
T u b e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Bank-to-Hoist Motor Tubes . . . . .
Valve Bank-to-Hoist Motor Hoses . . . . .
Valve Bank-to-Extension
Cylinder Hoses. . . . . . . . . . . . . . . . . . . . .
Boom Support Crossover Tube-toValve Bank Tube. . . . . . . . . .
Flow Regulator. . . . . . . . . . .
Crossover Tube Tee Fitting . . . . . .
Boom Support Crossover-toReservoir Hose. . . . . . . . . . . .
Oil Filter-to-Pump Hose . . .
Lift Cylinder Packing Assembly
Adjustment (Truck M543A2) . . . . .
x
Page
18-13
18-13a
18-13b
18-13c
18-65
18-65
18-65
18-66
18-14
18-14a
18-14b
18-67
18-67
18-71
18-15
18-15a
18-15b
18-15c
18-75
18-75
18-75
18-76
18-16
18-16a
18-16b
18-77
18-77
18-78
18-17
18-17a
18-17b
18-79
18-79
18-80
18-18
18-18a
18-83
18-83
18-18b
18-84
18-18c
18-18d
18-86
18-88
18-18e
18-18f
18-18g
18-94
18-98
18-104
18-18h
18-112
18-18i
18-18j
18-18k
18-120
18-124
18-126
18-18l
18-18m
18-128
18-130
18-19
18-134
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Hydraulic System Pressure Test
and Adjustment . . . . . . . . . . .
Preliminary Procedures. . . . . . . .
Test and Adjustment. . . . . . .
Valve Bank Relief Valve Test and
Adjustment (Truck M543A2). . . . . . . . .
Preliminary Procedure . . . . . . . .
Test and Adjustment . . . . . . . .
Control Valve Bank Cover Removal
and Replacement (Truck M543A2) . . . . . .
Preliminary Procedure . . . . . . . . .
R e m o v a l. . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . .
Control Valve Bank Assembly Removal
and Replacement (Truck M543A2). . . .
Preliminary
Procedures.
.
.
Removal . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . .
Hydraulic Oil Filter Element
Removal and Replacement (Truck
M543A2) . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . .
Cleaning, Inspection, and Repair . . . . .
A s s e m b l y. . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . .
Hydraulic Oil Tank Assembly Removal
and Replacement (Truck M543A2). . . . . .
Preliminary Procedure . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . .
Slipring Contact Brushes Removal and
Replacement (Truck M543A2) . . . . .
Removal . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . . .
Hoist Automatic Brake Band Removal,
Replacement, and Adjustment (Truck
M543A2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . .
Replacement and Adjustment . . . . . . . . . . . .
Rotochamber Adjustment (Truck
M543A2) . . . . . . . . . . . . . . . . . .
Hoist Winch Cable Removal and
Replacement (Truck M543A2) . . . .
Preliminary Procedure . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . .
Page
18-20
18-20a
18-20b
18-135
18-135
18-135
18-21
18-21a
18-21b
18-140
18-140
18-140
18-22
18-22a
18-22b
18-22c
18-144
18-144
18-144
18-145
18-23
18-23a
18-23b
18-23c
18-146
18-146
18-146
18-149
18-24
18-24a
18-24b
18-24c
18-24d
18-24e
18-24f
18-152
18-152
18-152
18-153
18-155
18-156
18-158
18-25
18-25a
18-25b
18-25c
18-159
18-159
18-159
18-163
18-26
18-26a
18-26b
18-167
18-167
18-168
18-27
18-27a
18-27b
18-169
18-169
18-172
18-28
18-175
18-29
18-29a
18-29b
18-29c
18-176
18-176
18-176
18-179
xi
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Crane Boom and Shipper Cable
Rollers Removal and Replacement
(Truck M543A2). . . . . . . . . . . . . . . . .
Preliminary Procedures. . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . .
Crane Inner Boom Roller Assembly
Adjustment
(Truck
M543A2).
.
Preliminary Procedures . . . . .
Vertical Adjustment . . . . . . .
Lateral Adjustment
. . . .
Crane Snatch Block Removal and
Replacement (Truck M543A2) . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . .
Removal of One-Part Line . . . . . . . . . . . . .
Removal of Two-Part Line . . . . . . . . . . . .
Removal of Three-Part Line . . . . . . . . . .
Replacement of One-Part Line . . . . . . . .
Replacement of Two-Part Line . . . . . . . .
Replacement of Three-Part Line . . . . .
Operator Guard Removal and
Replacement (Truck M543A2) . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 19. BODY ACCESSORY ITEMS GROUP
MAINTENANCE
Section I. S c o p e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Items Covered . . . . . . . . . . . . . .
Equipment Items Not Covered . . . . . . . . . . .
Section II. Canvas Items and Related Parts . . . . . . . . . .
End Curtains Removal and
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Long Cargo Body Top Cover Removal
and Replacement . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Bow Assembly Repair... . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Cover Removal and Replacement . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
xii
Page
18-30
18-30a
18-30b
18-30c
18-182
18-182
18-183
18-184
18-31
18-31a
18-31b
18-31c
18-185
18-185
18-185
18-191
18-32
18-32a
18-32b
18-32c
18-32d
18-32e
18-32f
18-32g
18-196
18-196
18-197
18-198
19-199
18-200
18-201
18-202
18-33
18-33a
18-33b
18-204
18-204
18-205
19-1
19-2
19-1
19-1
19-1
19-1
19-3
19-3a
19-3b
19-3c
19-1
19-1
19-2
19-3
19-4
19-4a
19-4b
19-5
19-5a
19-5b
19-5c
19-5d
19-6
19-6a
19-6b
19-5
19-5
19-7
19-8
19-8
19-8
19-9
19-9
19-10
19-10
19-14
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Lashing Hook Removal and
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Accessory
Items. . . . . . . . . . . . . . . . . . . . . . . . . .
Section III.
Windshield Wiper Motor Removal
and Replacement . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . .
Windshield Wiper Blade Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . . . . .
Windshield Wiper Arms Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . .
Windshield Washer Kit Removal, Repair
and Replacement . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R e p a i r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . . . .
Rear View Mirror Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . .
Rear View Mirror Arm Assembly
Removal and Replacement . . . . . .
Preliminary Procedure . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . . . .
Section IV. Data Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Data Plates Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal (Screw-on Type). . . . . . .
Replacement (Screw-on Type) . . . . .
Removal (Drive Screw Type). . . . . . . . . .
Replacement (Drive Screw Type). . . .
Removal (Solid Rivets Type) . . . . . .
Replacement (Solid Rivets Type). . . . .
Removal (Adhesive Type). . . . . . . .
Replacement (Adhesive Type) . . . . . .
CHAPTER 20. NONELECTRICAL GAGES GROUP
MAINTENANCE
S
cope. . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1.
Equipment Items Covered . . . . . . . . . . . . . .
Equipment Items Not Covered . . . . . . . . . .
Page
19-7
19-7a
19-7b
19-19
19-19
19-20
19-21
19-8
19-8a
19-8b
19-21
19-21
19-23
19-9
19-9a
19-9b
19-25
19-25
19-26
19-10
19-10a
19-10b
19-27
19-27
19-28
19-11
19-11a
19-11b
19-11c
19-11d
19-29
19-29
19-29
19-32
19-32
19-12
19-12a
19-12b
19-36
19-36
19-37
19-13
19-13a
19-13b
19-13c
19-38
19-38
19-38
19-42
19-46
19-14
19-14a
19-14b
19-14c
19-14d
19-14e
19-14f
19-14g
19-14h
19-46
19-47
19-48
19-49
19-50
19-51
19-52
19-53
19-54
20-1
20-2
20-1
20-1
20-1
xiii
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Section II.
xiv
Nonelectrical Gages. . .
Tachometer an-d Speedometer Removal
and Replacement. . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . . . . . . . . . . . . .
Tachometer Drive Unit Removal
and Replacement . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Tachometer Flexible Shaft Assembly
Removal and Replacement . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . . . . . . . . . . . . .
Tachometer Drive Adapter
Removal, Rapair, and Replacement. . . . .
Preliminary Procedure . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning, Inspection, and Repair . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Flexible Shaft and
Core Assembly Removal and
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedures. . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Shaft Adapter Assembly
Removal and Replacement . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Drive Joint Assembly
Removal and Replacement . . . . . . . . . . . . .
R e m o v a l. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Tachograph (Late Model Trucks) . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Tachograph Adjustment . . . . . . . . . . . . . .
Tachograph Chart . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading of Chart . . . . . . . . . . . . . . . . . . . .
Analyzing the Chart . . . . . . . . . . . . . . . . .
Falsification and Irregularities . . . . . . .
Page
20-1
20-3
20-3a
20-3b
20-3c
20-1
20-1
20-2
20-4
20-4
20-4a
20-4b
20-4c
20-7
20-7
20-7
20-8
20-5
20-5a
20-5b
20-5c
20-9
20-9
20-9
20-13
20-6
20-6a
20-6b
20-6c
20-6d
20-16
20-16
20-16
20-17
20-18
20-7
20-7a
20-7b
20-7c
29-19
20-19
20-19
20-25
20-8
20-8a
20-8b
20-32
20-32
20-35
20-9
20-9a
20-9b
20-10
20-10a
20-10b
20-10c
20-10d
20-11
20-11a
20-11b
20-11c
20-11d
20-11e
20-38
20-38
20-39
20-40
20-40
20-41
20-49
20-59
20-62
20-62
20-64
20-66
20-70
20-79
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Tachograph Drive Shafts Removal
and Replacement . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 21. MAINTENANCE OF MATERIAL USED IN
CONJUNCTION WITH MAJOR ITEMS
Section 1. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Items Covered . . . . . . . . . . . . . .
Equipment Items Not Covered . . . . . . . . . .
Section II. Winterization Kits . . . . . . . . . . . . . . . . . . . . . . .
Personnel Heater Electric Fuel Pump
Removal, Replacement, and Test . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Water Personnel Heater
Inspection and Functional Test . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Circuit Breaker Removal,
Replacement, and Test . . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Emergency Switch
Removal, Test, and Replacement. . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Control Valve Resistor Assembly
Removal, Test, and Replacement
(Model 8460-C24) . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Hot Water Personnel Heater Control
Cables Removal and Replacement . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Control Box Assembly Removal
and Replacement . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Control Box Repair and Test . . . .
Preliminary Procedure . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .
Page
20-12
20-85
21-1
21-2
21-1
21-1
21-1
21-1
21-3
21-3a
21-3b
21-3c
21-3d
21-1
21-1
21-2
21-4
21-6
21-4
21-4a
21-4b
21-4c
21-7
21-7
21-7
21-7
21-5
21-5a
21-5b
21-5c
21-5d
21-11
21-11
21-12
21-13
21-15
21-6
21-6a
21-6b
21-6c
21-17
21-17
21-19
21-20
21-7
21-7a
21-7b
21-7c
21-7d
21-22
21-22
21-22
21-24
21-25
21-8
21-8a
21-8b
21-27
21-27
21-29
21-9
21- 9a
21- 9b
21-10
21-10a
21-10b
21-33
21-33
21-34
21-35
21-35
21-35
xv
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Test . . . . . . . . . . . . . . . . . . . . . .
Hot Water Personnel Water Heater
Hoses Removal and Replacement. . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Powerplant Heater Fuel Filter Removal
and Replacement . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedures . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Powerplant Heater Fuel Lines and
Fittings Removal and Replacement. . . . .
Powerplant Heater Control Box Removal,
Repair and Replacement . . . . . . . . . . . . . .
Battery Box Heater Kit Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedures. . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Hood Cover Assembly Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . . . . . .
Radiator Cover Assembly Removal
and Replacement . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . . . . . .
Gearshift Lever Cover Assembly
Removal and Replacement . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Lever Cover Assembly
Removal and Replacement . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . .
Alcohol Evaporator Kit Removal,
Inspection and Replacement . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection. . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . .
xvi
Page
21-10c
21-10d
21-10e
21-38
21-38
21-41
21-11
21-11a
21-11b
21-11C
21-42
21-42
21-42
21-43
21-12
21-12a
21-12b
21-12c
21-44
21-44
21-44
21-45
21-13
21-46
21-14
21-46
21-15
21-15a
21-15b
21-15c
21-47
21-47
21-47
21-53
21-16
21-16a
21-16b
21-16c
21-61
21-61
21-61
21-63
21-17
21-17a
21-17b
21-65
21-65
21-66
21-18
21-18a
21-18b
21-67
21-67
21-68
21-19
21-19a
21-19b
21-69
21-69
21-70
21-20
21-20a
21-20b
21-20c
21-20d
21-20e
21-20f
21-71
21-71
21-71
21-72
21-73
21-73
21-74
TM 9-2320-211-20-3-2
TABLE OF CONTENTS-CONT
Paragraph
Evaporator Tube Assembly Removal
and Replacement . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Slave Receptacle Assembly
Removal, Repair, Test, and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Section III. Deep Water Fording Kit . . . . . . . . . . . . . . . . . .
Deep Water Fording Relief Valve
Removal and Replacement . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . .
Section IV. Special Purpose Kits
Decontamination Apparatus Mounting . . . .
Bracket Removal and Replacement. . . . . . .
Preliminary Procedure . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement. . . . . . . . . . . . . .
Troop Seat Kit Removal, Repair and
Replacement . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . .
Replacement . . . . . . . . . . . . .
APPENDIX A. REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
21-21
21-21a
21-21b
21-21c
21-75
21-75
21-75
21-76
21-22
21-22a
21-22b
21-22c
21-22d
21-22e
21-77
21-77
21-77
21-81
21-81
21-82
21-86
21-23
21-23a
21-23b
21-86
21-86
21-87
21-24
21-24a
21-24b
21-24c
21-88
21-88
21-88
21-88
21-89
21-25
21-25a
21-25b
21-25c
21-25d
21-25e
21-90
21-90
21-94
21-98
21-99
21-104
A-1
Index 1
xvii
TM 9-2320-211-20-3-2
LIST OF ILLUSTRATIONS
Figure
14-1
20-1
20-2
20-3
20-4
20-5
20-6
20-7
20-8
20-9
20-10
20-11
20-12
20-13
20-14
20-15
20-16
20-17
20-18
20-19
20-20
20-21
20-22
20-23
20-24
xviii
Title
Power Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front and Back View of Tachograph Chart . . . . . . . . . . . . . . .
...........................
Tachograph Chart Divisions
Vehicle Speed Recordings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop and Go Recordings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distance Traveled Recordings . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine RPM Recordings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Good Driving Speed Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bad Driving Speed Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Good and Bad Driving Over Short Distances . . . . . . . . . . . . .
Driving Downhill without Gear Engaged . . . . . . . . . . . . . . . . . .
Driving Uphill in Wrong Gear . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving Uphill in Correct Gear . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving Downhill in Wrong Gear . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Run at Excessively High RPM . . . . . . . . . . . . . . . . . . . .
Excessive Engine Idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Poor Cold Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Good Cold Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Stylus Bent to Simulate Lower Speeds . . . . . . . . . . . . .
No Deflection of Speed and Distance Styluses . . . . . . . . . . . .
All Recordings on Front Side of Chart Interrupted . . . . . . .
Trip Made Between Removal of Used Chart and
Insertion of New Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Superimposed Recordings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Recording Runs for Unusually Long Period at
a Uniform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All Styluses Give Vertical Recordings Due to Stoppage . . .
Page
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TM 9-2320-211-20-3-2
CHAPTER 13
WHEEL SYSTEM GROUP MAINTENANCE
Section I. SCOPE
13-1. EQUIPMENT ITEMS COVERED. This chapter gives equipment maintenance procedures for front wheel assembly, rear wheel assembly, and tires for which there are
authorized corrective maintenance tasks at the organizational maintenance level.
13-2. EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective
maintenance is authorized at the organizational maintenance level are covered in this
chapter.
Section II.
FRONT
WHEEL
ASSEMBLY
13-3. FRONT WHEEL AND BRAKE DRUM ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS:
Wheel bearing nut wrench,
pn 7076869
3/4-inch socket wrench
10-inch socket handle
Torque wrench, 150 pound-feet
capacity
SUPPLIES:
PERSONNEL:
EQUIPMENT
a.
Portable bearing lubricator,
NSN 4930-00-704-1852
Hand grease gun,
NSN 4930-00-253-2478
Wheel lift truck
Hub and brake drum drive flange gasket
Artillery and automotive grease, type GAA MIL-G-10924
Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
One
CONDITION:
Truck parked on level ground, engine off, handbrake
set.
Preliminary Procedure. Jack up front wheel. Refer to part 1, para 10-3.
13-1
TM 9-2320-211-20-3-2
b.
1.
Removal.
Using 10-inch socket handle with 3/4-inch socket wrench, unscrew and take
off 10 capscrews and lockwashers (1), flange (2), and gasket (3). Throw
away gasket.
GO TO FRAME 2
13-2
TM 9-2320-211-20-3-2
FRAME 2
1.
Using wheel bearing nut wrench with socket handle, unscrew and take off
locknut (1). Take off adjusting nut lockwasher (2).
2. Using wheel bearing nut wrench with socket handle, unscrew and take off
adjusting nut (3).
GO TO FRAME 3
13-3
TM 9-2320-211-20-3-2
FRAME 3
Put wheel lift truck under front tire (1) as shown.
Jack up wheel lift truck until lift arms just touch tire (1).
Shake top of tire (1) until outer wheel bearing cone (2) moves out of hub (3).
Take off outer wheel bearing cone.
4. Level lift arms on wheel lift truck until wheel and brake drum assembly (4) can
be pulled straight off spindle (5).
5. Pull wheel lift truck and wheel and brake drum assembly (4) away from truck.
END OF TASK
1.
2.
3.
13-4
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
CAUTION
Do not slide lip of seal over threaded spindle. Seal
can be damaged.
1. Push wheel lift truck and wheel and brake drum assembly (1) toward truck so
that hub (2) goes on spindle (3) as shown.
GO TO FRAME 2
13-5
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
Using portable bearing lubricator and hand grease gun, grease outer wheel
bearing cone (1).
Put outer wheel bearing cone (1) in hub (2) as shown.
Using wheel bearing nut wrench and socket handle, screw on adjusting nut (3).
Lower wheel lift truck and take it away from truck.
GO TO FRAME 3
13-6
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
Check brake adjustment. Refer to Part 1, para 12-8.
While turning wheel (1) and using wheel bearing nut wrench with socket
handle, tighten adjusting nut (2) until wheel binds. Then back off adjusting
nut 1/8-turn.
3. Put one hand on bottom and one hand on top of wheel (1). Push with one hand
and pull with the other hand. If wheel bearing cone (3) is adjusted right,
there will be very little wobble.
GO TO FRAME 4
13-7
TM 9-2320-211-20-3-2
FRAME 4
1.
Put adjusting nut lockwasher (1) on spindle (2) so that tab on lockwasher fits
in keyway in spindle.
2. Using wheel bearing nut wrench with socket handle, screw on and tighten locknut (3).
GO TO FRAME 5
13-8
TM 9-2320-211-20-3-2
FRAME 5
Hold flange (1) and gasket (2) in place. Using 3/4-inch socket wrench and
socket handle, screw in 10 lockwashers and capscrews (3).
2. Using torque wrench, tighten capscrews (3) to 81 to 104 pound-feet.
NOTE
Follow-on Maintenance Action Required:
Jack down truck. Refer to Part 1, para 10-3.
END OF TASK
1.
13-9
TM 9-2320-211-20-3-2
13-4. FRONT HUB AND BRAKE DRUM ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS : 3/4-inch socket wrench
Portable bearing lubricator,
Breaker bar
NSN 4930-00-704-1852
Wheel bearing nut wrench,
Hand grease gun,
pn 7076869
NSN 4930-00-253-2478
Torque wrench,
150 pound-feet capacity
SUPPLIES : Hub and drum drive flange gasket
Grease, solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
Artillery and automotive grease, type GAA, MIL-G-10924
PERSONNEL: Two
EQUIPMENT CONDITION : Truck parked on level ground, engine off, handbrake
set.
a. Preliminary Procedure. Jack up truck and remove front wheel. Refer to
TM 9-2320-211-10.
b. Removal.
FRAME
1.
1
Using 3/4-inch wrench, and breaker bar, unscrew and take off 10 cap screws
and 10 lockwashers (1). Hold flange (2) and gasket (3) to keep them from
falling.
2. Take off flange (2) and gasket ( 3). Throw gasket away.
GO TO FRAME 2
13-10
TM 9-2320-211-20-3-2
FRAME 2
1.
Using wheel bearing nut wrench, unscrew and take off locknut (1)
and washer (2).
2. Using wheel bearing nut wrench, unscrew and take off adjusting
nut (3).
3. Take outer bearing cone (4) out of hub and brake drum assembly
(5).
Soldiers 4. Take off hub and brake drum assembly (5).
A and B
END OF TASK
13-11
TM 9-2320-211-20-3-2
c. Cleaning and Inspection. Clean and inspect wheel bearing cones and cups.
Refer to Part 1, para 1-3.
d. Replacement.
FRAME
1
CAUTION
Do not let seal slide on threads as this can damage seal.
Soldiers 1. Put hub and brake drum assembly (1) on spindle (2).
A and B
GO TO FRAME 2
13-12
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
GO
Using portable bearing lubricator and hand grease gun, grease outer bearing
cone (1).
Put outer bearing cone (1) in hub and drum assembly (2).
Using wheel bearing nut wrench, screw on adjusting nut (3).
Replace front wheel but do not jack down truck. Refer to TM 9-2320-211-10.
While turning wheel (4), using wheel bearing nut wrench, tighten adjusting
nut (3) until wheel binds.
Using wheel bearing nut wrench, back off adjusting nut (3) 1/8 turn.
Put one hand on bottom and one hand on top of wheel (4). Push with one hand
and pull with other hand.
NOTE
If bearings are adjusted correctly, there will be hardly
any play or wobble.
Put on washer (5) so that tab on washer fits in keyway in spindle (6).
Using wheel bearing nut wrench, screw on and tighten locknut (7).
TO FRAME 3
13-13
TM 9-2320-211-20-3-2
FRAME 3
Hold flange (1) and gasket (2) in place. Using 3/4-inch wrench, screw on 10
lockwashers and 10 cap screws (3).
2. Using jack, lower wheels to ground.
3. Using torque wrench and 3/4-inch socket wrench, tighten cap screws (3) to 81
to 104 pound-feet.
NOTE
Follow-on Maintenance Action Required:
Check brake adjustment. Refer to Part 1, para 12-8 and 12-9.
END OF TASK
1.
13-14
TM 9-2320-211-20-3-2
13-5. FRONT AND REAR HUB AND BRAKE DRUM ASSEMBLY REPAIR.
Arbor press
TOOLS : 11/16-inch wrench
Ballpeen hammer
Brass Hammer
Brass drift
Wood block, 4 X 4 X 18
Stiff brush
inches (2)
SUPPLIES : None
PERSONNEL : Two
EQUIPMENT CONDITION : Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove hub and brake drum assembly. For front hub
and brake drum assembly, refer to para 13-4. For rear hub and brake drum assembly,
refer to para 13-10.
b. Front Hub and Brake Drum.
(1) Disassembly.
FRAME 1
Soldiers 1.
A and B
2.
3.
GO TO FRAME 2
Put drum (1) on top of two wood blocks (2) as shown.
Using 11/16-inch wrench, unscrew and take off 10 nuts (3) and
washers (4). Take off inspection cover (5).
Using brass hammer, tap hub assembly (6) out of drum (1).
13-15
TM 9-2320-211-20-3-2
FRAME 2
1.
Soldiers
A and B
2.
3.
GO TO FRAME 3
13-16
Using hammer and brass drift, drive out and throw away 10 wheel
studs (1).
Take hub (2) out of hub adapter (3) .
Using hammer and brass drift, drive out and throw away 10 studs
(4).
TM 9-2320-211-20-3-2
FRAME 3
1.
Working through front of hub (1) and using hammer and brass drift, tap out
seal (2) and wheel bearing cone (3).
END OF TASK
13-17
TM 9-2320-211-20-3-2
(2) Cleaning, inspection and repair.
FRAME 1
WARNING
Do not use a wire brush or compressed air to clean face
(1) and brake drum (2). There may be asbestos dust on
the drum which can be dangerous to your health if you
breathe it in.
Clean dirt or mud from brake drum (2) using a brush and water.
1.
2. Check that drum (2) is not cracked. If drum is cracked, throw it away and
get a new one.
3. Check that face (1) of drum (2) is not scored as shown. If drum is scored,
tell direct support maintenance.
GO TO FRAME 2
13-18
TM 9-2320-211-20-3-2
FRAME 2
WARNING
Dry cleaning solvent is flammable. Do not use near an open
flame. Keep a fire extinguisher nearby when solvent is used.
Use only in well-ventilated places. Failure to do this may
result in injury to personnel and damage to equipment.
1. Clean hub (1) with solvent and let it dry.
2. Check that hub (1) is not cracked. If hub is cracked, throw it away and get
a new one.
3. Check that inner and outer wheel bearing cups (2) are tight inside hub (1) . If
cups are loose, remove inner and outer wheel bearing cups. Refer to para
13-7. Throw away hub and get a new one,
4. Check that adapter (3) is not cracked or warped. If adapter is damaged, throw
it away and get a new one.
5. Check bearing cone (4) and seal (5). Refer to front wheel bearing cones and
seal inspection and lubrication, para 13-6.
END OF TASK
13-19
TM 9-2320-211-20-3-2
(3) Assembly.
FRAME
1.
1
If new hub (1) is used, replace inner and outer wheel bearing cups. Refer to
para 13-7.
2. Put wheel bearing cone (2) and seal (3) in rear of hub (1). Using hammer and
brass drift, tap seal in place.
GO TO FRAME 2
13-20
TM 9-2320-211-20-3-2
FRAME 2
1.
Using hammer and brass drift, drive 10 studs (1) into outside row
of holes of hub adapter (2).
Aline holes in hub adapter (2) with holes in hub (3).
Soldiers 2.
A and B
3. Using hammer and brass drift, drive in 10 wheel studs (4).
GO TO FRAME 3
13-21
TM 9-2320-211-20-3-2
FRAME 3
Aline 10 shorter studs on hub (1) with holes in drum (2). Put hub
into drum.
Put inspection cover (3) on stud next to inspection hole in drum (2)
so hole is covered.
3. Using 11/16-inch wrench , screw on and evenly tighten 10 washers
(4) and nuts (5).
NOTE
Follow-on Maintenance Action Required:
Replace front hub and brake drum assembly. Refer to
para 13-4.
END OF TASK
Soldiers 1.
A and B
2.
13-22
TM 9-2320-211-20-3-2
c.
Rear Hub and Brake Drum.
(1) Disassembly.
FRAME 1
Soldiers 1.
A and B
2.
Put drum (1) on top of two wood blocks (2) as shown.
Using 11/16-inch wrench, unscrew and take off 10 nuts (3) and
washers (4). Take off inspection cover (5) .
3. Using brass hammer, tap hub assembly (6) out of drum (1).
GO TO FRAME 2
13-23
TM 9-2320-211-20-3-2
FRAME 2
Soldiers 1.
A and B
2.
Using hammer and brass drift, drive out and throw away 10 studs
(1). Take off deflector (2).
Using 11/16-inch wrench, unscrew and take out eight cap screws
(3) and lockwashers (4).
3. Take off backing plate (5).
4. Using hammer and brass drift, drive out and throw away 10 wheel
studs (6) .
GO TO FRAME 3
13-24
TM 9-2320-211-20-3-2
FRAME 3
1. Working through front of hub (1) and using hammer and brass drift, tap out
wiper (2), seal (3), and wheel bearing cone (4).
END OF TASK
13-25
TM 9-2320-211-20-3-2
(2) Cleaning, inspection and repair.
FRAME 1
WARNING
1.
2.
3.
GO
13-26
Do not use a wire brush or compressed air to clean face
(1) or brake drum (2). There may be asbestos dust on
the drum which can be dangerous to your health if you
breathe it in.
Clean dirt or mud from brake drum (2) using a brush and water.
Check that drum (2) is not cracked. If drum is cracked, throw it away and
get a new one.
Check that face (1) of drum (2) is not scored as shown. If drum is scored,
tell direct support maintenance.
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME
2
WARNING
Dry cleaning solvent is flammable. Do not use near an
open flame. Keep a fire extinguisher nearby when solvent is used. Use only in well-ventilated places. Failure to do this may result in injury to personnel and
damage to equipment.
1. Clean hub (1) with solvent and let it dry.
2. Check that hub (1) is not cracked. If hub is cracked, throw it away and get
a new one.
3. Check that inner and outer wheel bearing cups (2) are tight inside hub (1).
If cups are loose, remove inner and outer wheel bearing cups. Refer to para
13-12. Throw away hub and get a new one.
4. Check that backing plate (3) , and deflector (4) are not cracked or warped. If
parts are damaged, throw them away and get new ones.
5. Check bearing cone (5) , seal (6) and wiper (7). Refer to rear wheel bearing
cones and seals inspection and lubrication, para 13–11.
END OF TASK
13-27
TM 9-2320-211-20-3-2
(3) Assembly.
FRAME 1
1.
If new hub (1) is used, replace inner and outer wheel bearing cups. Refer to
para 13-12.
2. Put wheel bearing cone (2), seal (3), and wiper (4) in rear of hub (1). Using
hammer and brass drift, tap seal in place.
GO TO FRAME 2
13-28
TM 9-320-211-20-3-2
FRAME 2
1.
Soldiers 2.
A and B
3.
Using hammer and brass drift, drive in 10 wheel studs (1).
Aline inside row of holes in backing plate (2) with threaded holes
in hub (3).
Using 11/16-inch wrench, screw in and tighten eight washers (4)
and capscrews (5).
4. Aline holes in deflector (6) with holes in backing plate (2).
5. Using hammer and brass drift, drive in 10 studs (7).
GO TO FRAME 3
13-29
TM 9-2320-211-20-3-2
FRAME 3
Soldiers 1.
A and B
2.
Aline 10 shorter studs on hub (1) with 10 holes in drum (2) . Put
hub into drum.
Put inspection cover (3) on stud next to inspection hole in drum
(2) so hole is covered.
3. Using 11/16-inch wrench, screw on and evenly tighten 10 washers
(4) and nuts (5).
NOTE
Follow-on Maintenance Action Required:
Replace rear hub and brake drum assembly. Refer to
para 13-10.
END OF TASK
13-30
TM 9-2320-211-20-3-2
13-6.
FRONT WHEEL BEARING CONES AND SEAL REMOVAL AND REPLACEMENT
FOR SERVICE.
TOOLS : Portable bearing lubricator, NSN 4930-00-704-1852
Hand grease gun, NSN 4930-00-253-2478
Medium ballpeen hammer
3/4 x 10-inch brass drift
SUPPLIES : Artillery and automotive grease, type GAA, MIL-G-10924
Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
Clean rags
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked on level ground, engine off, handbrake
set.
a. Preliminary Procedure. Remove front wheel and brake drum assembly. Refer
to para 13-3.
b. Removal.
FRAME 1
NOTE
Outer wheel bearing cone is taken out during removal
of front wheel and drum assembly.
1. Working through front of hub (1) and using hammer and brass drift, tap out
inner wheel bearing cone (2) and seal (3) from hub (4).
END OF TASK
13-31
TM 9-2320-211-20-3-2
c.
Cleaning.
NOTE
This task is for both inner and outer wheel
bearing cones.
FRAME 1
WARNING
Dry cleaning solvent is flammable. Do not use near
an open flame. Keep a fire extinguisher nearby when
solvent is used. Use only in well-ventilated places.
Failure to do this may result in injury to personnel
and damage to equipment.
CAUTION
1.
2.
Do not spin bearings at any time. Spinning will
seriously damage bearings.
After cleaning, keep bearings clean and dry. Dirt
and moisture can damage bearings.
NOTE
All old lubricant must be taken off bearings during
cleaning. Do soaking and rapping steps over as
necessary to take off all old lubricant.
Using degreaser and solvent, soak bearing cone (1) to loosen lubricant.
If lubricant is left on bearing cone (1) after soaking, clap bearing against
heel of hand to loosen lubricant.
WARNING
Do not dry wheel bearing with compressed air. Spinning bearings may explode and cause serious injury
to personnel.
3. Let bearing cone (1) dry.
4. Using clean rags, wipe all old grease from hub (2).
END OF TASK
13-32
TM 9-2320-211-20-3-2
d.
Inspection.
FRAME 1
1.
2.
3.
4.
NOTE
Inner and outer wheel bearing cups are inside of hub.
If wheel bearing cone (1) or cup (2) needs replacing,
do wheel bearing cones and seals removal and replacement. Refer to para 13-7.
Hold wheel bearing cone (1) and turn it slowly to check all sides of bearing
cone.
Check that bearing cone (1) has not overheated. Bearing cone will turn blue
where it has overheated. Throw away overheated bearing cone.
Check that cups (2) are not brinelled (dented or scored). Throw away
brinelled bearing cup.
Check that cups (2) and bearing rollers (3) are not spalled (chipped or
pitted). Throw away spalled bearing cones or cups.
END OF TASK
13-33
TM 9-2320-211-20-3-2
e.
Lubrication.
FRAME 1
Put wheel bearing cone (1) into portable bearing lubricator as shown.
Using hand grease gun, grease wheel bearing cone (1) until grease comes out of sides
of bearing.
END OF TASK
1.
2.
13-34
TM 9-2320-211-20-3-2
f.
Replacement.
FRAME 1
1.
2.
3.
Put in inner wheel bearing cone (1).
Using brass drift and hammer, tap in seal (2).
Using clean rag, wipe all grease from seal (2) and hub (3) .
NOTE
Follow-on Maintenance Action Required:
Replace front wheel and brake drum assembly. Refer
to para 13-3.
END OF TASK
13-35
TM 9-2320-211-20-3-2
13-7.
FRONT INNER AND OUTER WHEEL BEARINGS AND SEAL REMOVAL AND
REPLACEMENT.
TOOLS : 18-inch brass drift
Hammer
Portable bearing lubricator, NSN 4930-00-704-1852
Hand grease gun, NSN 4930-00-253-2478
Drop light
SUPPLIES: Artillery and automotive grease, type GAA, MIL-G-10924
Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
Clean rags
Inner wheel bearing seal
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked on level ground, engine off, handbrake
set.
a. Preliminary Procedure. Remove front hub and brake drum assembly. Refer
to para 13-3.
b. Removal.
NOTE
Outer wheel bearing cone is taken out during front
hub and brake drum assembly removal.
FRAME 1
1.
Working through inside of hub (1) using hammer and brass drift, tap outer
edges of bearing cup (2) until bearing cup comes out.
2. Turn over hub and brake drum assembly (1).
GO TO FRAME 2
13-36
TM 9-2320-211-20-3-2
FRAME 2
1. Using hammer and seal remover and replacer, tap out seal (1).
2. Take out inner wheel bearing cone (2).
3. Using bearing cup puller, take out inner wheel bearing cup (3).
END OF TASK
13-37
TM 9-2320-211-20-3-2
c.
Cleaning.
NOTE
This task is for both inner and outer wheel
bearing cones.
FRAME 1
WARNING
1.
2.
Dry cleaning solvent is flammable. Do not use near an
open flame. Keep a fire extinguisher nearby when solvent is used. Use only in well-ventilated places. Failure to do this may result in injury to personnel and
damage to equipment.
NOTE
All old lubricant must be taken off bearing cones (1)
during cleaning. Soak bearing cones as long as needed
to take off all old lubricant.
Soak bearing cone (1) in solvent.
Rinse bearing cone (1) in clean solvent.
WARNING
Do not dry bearing with compressed air. Spinning
bearings may explode and cause serious injury to
personnel.
3. Let bearing cone (1) dry.
4. Using clean rags, wipe all old grease from inside hub (2).
END OF TASK
13-38
TM 9-2320-211-20-3-2
d.
Inspection.
FRAME 1
Place drop light behind bearing assembly.
Hold wheel bearing cone (1) and turn inner race (2) slowly.
Check that bearing rollers (3) and wheel bearing cone (1) have no cracks,
flaking, pitting or long or deep scratches.
4. Check that wheel bearing cone (1) has not overheated. Wheel bearing cone will
turn blue where it has overheated.
5. Check that bearing cups (4) have no dents or small depressions.
NOTE
If bearing rollers (3) are damaged, throw away bearing
cone (1) and get a new one.
6. Check that bearing cups (4) and bearing rollers (3) are not splintered or
chipped.
7. Throw away damaged parts and get new ones.
END OF TASK
1.
2.
3.
13-39
TM 9-2320-211-20-3-2
e. Lubrication.
FRAME 1
Put wheel bearing cone (1) into portable bearing lubricator as shown.
Using hand grease gun, grease wheel bearing cone (1) until the grease
comes out of sides of bearing.
END OF TASK
1.
2.
13-40
TM 9-2320-211-20-3-2
f.
Replacement.
FRAME 1
Put wheel bearing cup (1) into hub (2) as shown.
Using hammer and brass drift, lay brass drift on top of wheel bearing cup (1)
as shown. Tap brass drift until wheel bearing cup is in hub (2).
3. Using hammer and brass drift, tap sides of wheel bearing cup (1) evenly all
around until it is seated inside hub (2).
4. Turn over hub and brake drum assembly (3) and do steps 1 through 3 again
for outer wheel bearing cup (4).
GO TO FRAME 2
1.
2.
13-41
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
Turn over hub and brake drum assembly (1) as shown.
Put inner wheel bearing cone (2) in hub (3).
Put seal (4) into hub (3) as shown.
Using hammer and brass drift, lay brass drift on top of seal (4) as shown. Tap
brass drift until seal is in hub (3).
5. Using hammer and brass drift, tap sides of seal (4) evenly all around until it
is seated inside hub (3).
6. Using clean rag, wipe off all grease around hub (3) and top of seal ( 4).
NOTE
Follow-on Maintenance Action Required:
Replace front hub and brake drum. Refer to para 13-3.
END OF TASK
13-42
TM 9-2320-211-20-3-2
13-8. WHEEL STUDS REMOVAL AND REPLACEMENT.
TOOLS : Heavy ballpeen hammer
3/4 x 10-inch punch
2 x 4 x 8-inch wood block (2)
SUPPLIES: Lubricating oil, ICE, OE/HDO 10, MIL-L-2104
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove hub and brake drum assembly. For front
hub and brake drum assembly, refer to para 13-3. For rear hub and brake drum
assembly, refer to para 13-10.
b. Removal.
Put hub and brake drum assembly (1) on floor and using hammer, drive out
10 studs (2).
END OF TASK
1.
13-43
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
2.
Place very light film of oil on 10 studs (1).
Put hub and brake drum assembly (2) on wood blocks and using hammer and
punch, drive studs (1) into hub (3).
NOTE
Follow-on Maintenance Action Required:
Replace hub and brake drum assembly. For front hub and
brake drum assembly, refer to para 13-3. For rear hub
and brake drum assembly, refer to para 13-10.
END OF TASK
13-44
TM 9-2320-211-20-3-2
Section III. REAR WHEEL ASSEMBLY
13-9. REAR WHEELS AND BRAKE DRUM ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS : Wheel bearing nut wrench.
3/4-inch socket wrench
Torque wrench, 150 pound-feet capacity
10-inch socket handle
Portable bearing lubricator.
Hand grease gun.
Wheel lift truck
SUPPLIES : Rear axle shaft gasket
Artillery and automotive grease, type GAA, MIL-G-10924
Solvent, dry cleaning, type II (SD-2) , Fed. Spec P-D-680
PERSONNEL: One
EQUIPMENT CONDITION : Truck parked on level ground, engine off, handbrake
set.
a. Preliminary Procedure. Jack up rear wheel. Refer to Part 1, para 10-3.
b. Removal.
1.
Using 3/4-inch socket wrench with socket handle, unscrew and take out 10 capscrews and lockwashers (1).
2. Take out flange and shaft assembly (2) and gasket (3). Throw away gasket.
GO TO FRAME 2
13-45
TM 9-2320-211-20-3-2
FRAME 2
1.
Using wheel bearing nut wrench with socket handle, unscrew and take off
locknut (1) and lockwasher (2).
2. Using wheel bearing nut wrench with socket handle, unscrew and take off
adjusting nut (3).
GO TO FRAME 3
13-46
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
Put wheel lift truck under rear wheels and brake drum assembly (1) as shown.
Jack up wheel lift truck until lift arms just touch tires (2).
Shake top of tires (2) until outer wheel bearing cone (3) and outer seal (4)
move out of hub (5).
4. Take off outer wheel bearing cone (3) and outer seal (4).
5. Level lift arms on wheel lift truck until rear wheels and brake drum assembly
(1) can be pulled straight off spindle (6).
6. Pull wheel lift truck and rear wheels and drum assembly (1) away from truck.
END OF TASK
13-47
TM 9-2320-211-20-3-2
c.
Replacement.
CAUTION
Do not slide lip of seal over threaded end of
spindle. Seal can be damaged.
1.
Push wheel lift truck and wheels and drum assembly (1) toward truck so that
hub (2) goes on spindle (3) as shown.
GO TO FRAME 2
13-48
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
GO
Using portable bearing lubricator and hand grease gun, grease outer wheel
bearing cone (1).
Put outer wheel bearing cone (1) and outer seal (2) in hub (3) as shown.
Using wheel bearing nut wrench and socket handle, screw on adjusting nut (4).
Lower wheel lift truck and take it away from truck.
TO FRAME 3
13-49
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
Check brake adjustment. Refer to Part 1, para 12-8 and 12-9.
While turning rear wheels (1) and using wheel bearing nut wrench with socket
handle, tighten adjusting nut (2) until wheels bind. Then back off adjusting
nut 1/8 turn.
3. Put one hand on bottom and one hand on top of wheels (1). Push with one
hand and pull with the other hand. If wheel bearing (3) is adjusted correctly,
there will be very little wobble.
GO TO FRAME 4
13-50
TM 9-2320-211-20-3-2
FRAME
4
1.
Put lockwasher (1) on spindle (2) so that tab on washer fits in keyway in
spindle.
2. Using wheel bearing nut wrench with torque wrench, screw on locknut (3) and
tighten it to 50 pound-feet.
3. Jack down rear wheels. Refer to Part 1, para 10-3.
GO TO FRAME 5
13-51
TM 9-2320-211-20-3-2
FRAME
1.
5
Put gasket (1) and flange and shaft assembly (2) in hub and brake drum
assembly (3) as shown.
2. Using 3/4-inch wrench, screw in 10 lockwashers and cap screws (4).
3. Using torque wrench with 3/4-inch socket wrench, tighten capscrews (4) to
81 to 104 pound-feet.
END OF TASK
13-52
TM 9-2320-211-20-3-2
13-10. REAR HUB AND BRAKE ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS :
3/4-inch wrench
Wheel bearing nut wrench, pn 7076869
Torque wrench, 150 pound-feet capacity
Portable bearing lubricator, NSN 4930-00-704-1852
Hand grease gun, NSN 4930-00-253-2478
SUPPLIES : Rear axle shaft gasket
Artillery and automotive grease, type GAA, MIL-G-10924
Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
PERSONNEL: Two
EQUIPMENT CONDITION : Truck parked on level ground, engine off, handbrake set.
Preliminary Procedures. Remove outer and inner rear wheels. Refer to
TM 9-2320-211-10.
b.
Removal.
1.
Using 3/4-inch wrench, unscrew and take off 10 screws and lockwashers
(1).
2.
Take out flange and shaft assembly (2) and gasket (3). Throw gasket
away.
GO TO FRAME 2
13-53
TM 9-2320-211-20-3-2
FRAME 2
1. Using wheel bearing nut wrench, unscrew and takeoff locknut (1) and washer (2).
2. Using wheel bearing nut wrench, unscrew and takeoff adjusting nut (3).
GO TO FRAME 3
13-54
TM 9-2320-211-20-3-2
1.
2.
Soldiers 3.
A and B
END OF TASK
Take out outer seal (1).
Take out outer bearing cone (2).
Take hub and brake drum assembly (3) off of spindle (4).
13-55
TM 9-2320-211-20-3-2
c.
Cleaning and Inspection.
cups . Refer to para 13-12.
d.
Replacement.
Clean and inspect wheel bearing cones and
CAUTION
Soldiers 1.
A and B
GO TO FRAME 2
13-56
Do not let seal slide on spindle threads as this
can damage inner seal lip,
Put hub and drum assembly (1) on spindle (2).
TM 9-2320-211-20-3-2
FRAME 2
1.
Using portable bearing lubricator and hand grease gun, grease outer
bearing cone (1).
2.
Put outer bearing cone (1) in hub and brake drum assembly (2).
3.
Put outer seal (3) in place.
GO TO FRAME 3
13-57
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
4.
5.
6.
7.
GO
13-58
Using wheel bearing nut wrench, screw on adjusting nut (l).
Replace inner and outer rear wheels. Refer to TM 9-2320-211-10.
While turning wheel (2), using wheel bearing nut wrench, tighten adjusting
nut (1) until wheel binds.
Using wheel bearing nut wrench, back off adjusting nut (1) 1/8 turn.
Put one hand on bottom and one hand on top of wheel (2). Push with one
hand and pull with other hand to check bearing adjustment.
NOTE
If bearings are adjusted correctly, there will be
hardly any play or wobble.
Put on washer (3) so that tab on washer fits in keyway in spindle (4).
Using wheel bearing nut wrench, screw on and tighten locknut (5).
TO FRAME 4
TM 9-2320-211-20-3-2
FRAME
4
1.
2.
3.
Jack down wheels. Refer to TM 9-2320-211-10.
Check brake adjustment. Refer to Part 1, para 12-8 and 12-9.
Put gasket (1) and flange and shaft assembly (2) in hub and brake drum
assembly (3).
4.
Using 3/4-inch wrench, screw on 10 lockwashers and 10 screws (4). Using
torque wrench, tighten screws to 81 to 104 pound-feet.
END OF TASK
13-59
TM 9-2320-211-20-3-2
13-11. REAR WHEEL BEARING CONES AND SEALS REMOVAL AND REPLACEMENT
FOR SERVICE.
Portable bearing lubricator, NSN 4930-00-704-1852
TOOLS:
Hand grease gun, NSN 4930-00-253-2478
3/4 x 10-inch brass drift pin
Medium ballpeen hammer
SUPPLIES : Artillery and automotive grease, type GAA, MIL-G-10924
Solvent, dry cleaning, type II (SD–2), Fed. Spec P-D-680
Clean rags
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked on level ground, engine off, handbrake set.
Preliminary Procedure. Remove rear wheels and brake drum assembly.
a.
Refer to para 13-9.
b.
Removal.
FRAME 1
NOTE
Outer wheel bearing cone and seal are taken out
during rear wheels and brake drum assembly removal.
1.
Working through front of hub (1) and using hammer and brass drift, tap out
wiper (2), seal (3), and inner wheel bearing cone (4).
END OF TASK
13-60
TM 9-2320-211-20-3-2
c.
Cleaning.
NOTE
This task is for both inner and outer wheel
bearing cones.
FRAME 1
WARNING
Dry cleaning solvent is flammable. Do not use
near an open flame. Keep a fire extinguisher
nearby when solvent is used. Use only in wellventilated places. Failure to do this may result
in injury to personnel and damage to equipment.
CAUTION
1.
2.
Do not spin bearings at anytime. Spinning will
seriously damage bearings. After cleaning, keep
bearings clean and dry. Dirt and moisture can
damage bearings.
NOTE
All old lubricant must be taken off bearings during
cleaning. Do soaking and rapping steps over as
necessary to take off all old lubricant.
Using degreaser and solvent, soak bearing cone (1) to loosen lubricant.
If lubricant is left on bearing cone (1) after soaking, rap bearing cone
against heel of hand to loosen lubricant.
WARNING
Do not dry wheel bearing with compressed air.
Spinning bearings may explode and cause serious
injury to personnel.
3.
Let wheel bearing cone (1) dry.
4.
Using clean rags, wipe all old grease from hub (2).
END OF TASK
13-61
TM 9-2320-211-20-3-2
d.
FRAME
Inspection.
1
NOTE
Inner and outer wheel bearing cups are inside
hub . If wheel bearing cone (1) or cup (4) needs
replacing, do wheel bearing cones and seals removal and replacement. Refer to para 13-12.
1.
Place drop light behind bearing assembly.
2.
Hold wheel bearing cone (1) and turn inner race (2) slowly.
Check that bearing rollers (3) and wheel bearing cone (1) have no cracks,
3.
flaking, pitting or long or deep scratches.
Check that wheel bearing cone (1) has not overheated. Wheel bearing cone
4.
will turn blue where it has overheated.
5.
Check that bearing cups (4) have no dents on small depressions.
NOTE
If bearing rollers (3) are damaged, throw away
bearing cone (1) and get a new one.
Check that bearing cups (4) and bearing rollers (3) are not splintered or
6.
chipped.
Throw away damaged parts and get new ones.
7.
END OF TASK
13-62
TM 9-2320-211-20-3-2
e.
Lubrication.
FRAME 1
1.
2.
Put wheel bearing cone (1) into portable bearing lubricator as shown.
Using hand grease gun, grease wheel bearing cone (1) until grease comes out
of sides of bearing.
END OF TASK
13-63
TM 9-2320-211-20-3-2
f.
FRAME
1.
2.
3.
Replacement.
1
Put inner wheel bearing cone (1) in hub (2).
Using hammer and brass drift pin, tap in seal (3) and wiper (4).
Using clean rag, wipe all grease from seal (3) and hub (2).
NOTE
Follow-on Maintenance Action Required:
Replace rear wheels and drum assembly. Refer to para 13-9.
END OF TASK
13-64
TM 9-2320-211-20-3-2
13-12.
REAR INNER AND OUTER WHEEL BEARINGS AND SEALS REMOVAL AND
REPLACEMENT.
Brass drift
Portable bearing lubricator,
TOOLS:
Bearing cup puller
NSN 4930-00-704-1852
Seal remover and replacer
Hand grease gun,
Hammer
NSN 4930-00-253-2478
Clean rags
SUPPLIES:
Artillery and automotive grease, type GAA, MIL-G-10924
Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked on level ground, engine off, handbrake set.
a.
Preliminary Procedure. Remove rear hub and brake drum assembly.
Refer to para 13-10.
NOTE
Outer wheel bearing and seal are taken out
during rear hub and drum assembly removal.
Removal.
b.
FRAME 1
1.
Using bearing cup puller, take out outer bearing cup (1).
2.
Turn over hub and brake drum assembly (2).
GO TO FRAME 2
13-65
TM 9-2320-211-20-3-2
1.
Using hammer and seal remover and replacer, tap out wiper (1) and inner
seal (2). Throw away seal.
2.
Take out inner wheel bearing cone (3).
3.
Using bearing cup puller, take out inner wheel bearing cup (4).
END OF TASK
13-66
TM 9-2320-211-20-3-2
c.
Cleaning.
NOTE
This task is for both inner and outer
wheel bearing cones.
FRAME 1
WARNING
Dry cleaning solvent is flammable. Do not use
near an open flame. Keep a fire extinguisher
nearby when solvent is used. Use only in wellventilated places. Failure to do this may result
in injury to personnel and damage to equipment.
CAUTION
1.
2.
Do not spin bearings at any time. Spinning will
seriously damage bearings.
After cleaning, keep bearings clean and dry. Dirt
and moisture can damage bearings.
NOTE
All old lubricant must be taken off bearings during
cleaning. Do soaking and clapping steps over as
necessary to take off all old lubricant.
Using degreaser and solvent, soak bearing cone (1) to loosen lubricant.
If lubricant is left on bearing cone (1) after soaking, clap bearing cone
against heel of hand to loosen lubricant.
WARNING
Do not dry wheel bearing with compressed air.
Spinning bearings may explode and cause serious
injury to personnel.
Let wheel bearing cone (1) dry.
3.
Using clean rags, wipe all old grease from hub (2).
4.
END OF TASK
13-67
TM 9-2320-211-20-3-2
d.
Inspection.
FRAME 1
1.
2.
3.
Place drop light behind bearing assembly.
Hold wheel bearing cone (1) and turn inner race (2) slowly.
Check that bearing rollers (3) and wheel bearing cone (1) have no cracks,
flaking, pitting or long or deep scratches.
Wheel bearing cone
Check that wheel bearing cone (1) has not overheated.
4.
will turn blue where it has overheated.
Check that bearing cups (4) have no dents or small depressions.
5.
NOTE
If bearing rollers (3) are damaged, throw away
bearing cone (1) and get a new one.
Check that bearing cups (4) and bearing rollers (3) are not splintered or
6.
chipped.
Throw away damaged parts and get new ones.
7.
END OF TASK
13-68
TM 9-2320-211-20-3-2
e.
Lubrication.
FRAME 1
‘
Put wheel bearing cone (1) into portable bearing lubricator as shown.
Using hand grease gun, grease wheel bearing cone (1) until grease comes
out of sides of bearing.
GO TO FRAME 2
1.
2.
13-69
TM 9-2320-211-20-3-2
FRAME 2
1.
Using clean rag, clean all old grease from inside of hub (1).
CAUTION
Do not get any grease on face of brake drum (2). Grease
on brake drum will cause brakes to pull or grab.
END OF TASK
13-70
TM 9-2320-211-20-3-2
f.
Replacement.
FRAME 1
1.
Put wheel bearing cone (1) into inner wheel bearing cup (2). Put wheel
bearing cup into hub (3) as shown. Take wheel bearing cone out of wheel
bearing cup.
2.
Using hammer and brass drift, lay brass drift on top of wheel bearing cup
(2) as shown. Tap brass drift until wheel bearing cup is in hub (3).
Using hammer and brass drift, tap sides of wheel bearing cup (2) evenly
3.
all around until it is seated all the way down inside hub (3).
Turn over hub and brake drum assembly (4) and do steps 1 through 3
4.
again for outer wheel bearing cup (5).
GO TO FRAME 2
13-71
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
Turn over hub and brake drum assembly (1) as shown.
Put inner wheel bearing cone (2) in hub (3).
Using seal remover and replacer and hammer, tap in seal (4) and wiper (5).
NOTE
Follow-on Maintenance Action Required:
Replace rear hub and brake drum assembly. Refer to
para 13-10.
END OF TASK
13-72
TM 9-2320-211-20-3-2
Section IV. TIRES
13-13. PNEUMATIC TIRE AND TUBE REMOVAL AND REPLACEMENT.
TOOLS:
Curve spoon tire iron
Locking ring tire iron
Tire demounter
3-pound mallet
2 x 4 x 12-inch wood block (3)
SUPPLIES: None
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove wheel from truck. Refer to TM 9-2320-211-10.
b. Removal.
FRAME 1
1.
2.
Unscrew tire valve cap (1) from valve stem (2).
Using tire valve cap (1) as tool, unscrew valve core (3) out of valve stem (2).
Air will come out of tire.
GO TO FRAME 2
13-73
TM 9-2320-211-20-3-2
FRAME 2
WARNING
Do not work on tire until all the air is out of it. Stand
clear of retaining ring to avoid injury if the ring should
fly off.
NOTE
Put soap and water solution on tire bead to help in the
removal of the tire (1) from rim (2).
Soldiers 1. When all of the air is out of tire (1), put tire and rim (2) on deA and B
mounter base (3).
GO TO FRAME 3
13-74
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
4.
Soldiers 5.
A and B
6.
GO TO FRAME
Put demounter (1) in place on tire and rim assembly (2).
Slide four bead breaker feet (3) into position on cross arms (4) and
seat bead breaker feet on tire bead (5) against retaining ring (6).
Screw in handle (7) until tire bead (5) breaks away from rim (8).
Unscrew handle (7) until tire bead (5) breaks away from rim (8).
Turn tire and rim assembly (2) over on demounter base (9). Do
steps 1 through 4 again on other side of tire and rim assembly.
Take tire and rim assembly (2) off demounter base (9).
4
13-75
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
3.
4.
Put tire (1) and rim (2) on a hard flat surface.
Using foot, push tire (1) down from retaining ring (3) at joining ends (4).
Put one tire iron between joining ends (4) and other tire iron into notch (5).
Using both tire irons, pry retaining ring (3) open and out of rim (2) by sliding
one tire iron after the other as shown.
GO TO FRAME 5
13-76
TM 9-2320-211-20-3-2
FRAME 5
1.
2.
3.
4.
END
Push valve stem (1) through rim (2) so it stays inside tire (3).
Put tire (3) on wood blocks. Using foot, push rim (2) down and out of tire.
Lift tire (3) off blocks and rim (2).
Take tire liner (4) and tube (5) out of tire (3) .
OF TASK
13-77
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
Using valve cap (1) as tool, screw valve core (2) into valve stem (3).
Put tube (4) into tire (5).
Put just enough air in tube (4) so tube holds shape. Refer to
TM 9-2320-211-10 for tire inflation procedures.
Put tire liner (6) over valve stem (3) and into tire (5). Make sure tube
4.
(4) and tire liner are straight and not pinched.
GO TO FRAME 2
1.
2.
3.
13-78
TM 9-2320-211-20-3-2
FRAME 2
1. Put tire (1) onto rim (2) so that valve stem (3) will point to high part of rim
(2). Valve stem must line up with hole in rim.
2. Put valve stem (3) through hole in rim (2).
3. Seat tire (1) firmly onto rim (2).
GO TO FRAME 3
13-79
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
4.
Put end (1) of retaining ring (2) into rim groove (3) of rim (4). Check that
the end is caught in the rim groove.
Using locking ring tire iron, put it in slot (5) in retaining ring (2). Pry iron
toward out side of rim (4) forcing retaining ring into rim groove (3).
Using foot, walk retaining ring (2) into rim groove (3) until it is seated fully
all the way around rim (4).
Using mallet, hammer all the way around on retaining ring (2) to make sure
that it is fully caught in rim groove (3).
WARNING
Be careful when inflating tire. Remounted tires should
always be inflated in a safety cage. If a safety cage is
not available, turn tire and rim over with outer hub-side
down.
5. Put air in tire. Refer to TM 9-2320-211-10. Screw on valve cap (6) after inflating tire.
NOTE
Follow-on Maintenance Action Required:
Replace tire on truck. Refer to TM 9-2320-211-10.
END OF TASK
13-80
TM 9-2320-211-20-3-2
CHAPTER 14
STEERING SYSTEM GROUP MAINTENANCE
Section I. SCOPE
14-1. EQUIPMENT ITEMS COVERED. This chapter gives equipment maintenance
procedures for the mechanical steering gear assembly, steering hoses, lines, and
fittings, and steering reservoir for which there are authorized corrective maintenance
tasks at the organizational maintenance level.
14-2. EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective
maintenance is authorized at the organizational maintenance level are covered in this
chapter.
Section II.
MECHANICAL
STEERING
GEAR
ASSEMBLY
14-3. FRONT WHEEL ALINEMENT.
TOOLS: Toe-in gage
15/16-inch wrench (2)
10-inch pipe wrench
SUPPLIES: None
PERSONNEL:
EQUIPMENT
a.
Two
CONDITION:
Truck parked on smooth level ground, wheels in
straight ahead position, engine off, handbrake set.
Preliminary Procedures.
(1) Put air in front tires to correct pressure. Refer to TM 9-2320-211-10.
(2) Check wheel bearing adjustment. Refer to para 13-4.
14-1
TM 9-2320-211-20-3-2
b.
Toe-in Check and Adjustment.
FRAME 1
1.
Place toe-in gage (1) between front wheels at middle of tire as far in front of
axle (2) as possible.
2. Move toe-in gage (1) up and down until chains (3) just touch the ground.
GO TO FRAME 2
14-2
TM 9-2320-211-20-3-2
FRAME 2
1. Move scale (1) so that pointer (2) reads zero.
GO TO FRAME 3
14-3
TM 9-2320-211-20-3-2
Soldier A 1.
2.
Start engine. Refer to TM 9-2320-211-10.
With toe-in gage (1) in place, move truck forward so that toe-in
gage is in back of axle (2) and chains (3) just touch the ground.
Soldier B 3. Tell soldier A when chains (3) just touch the ground.
Soldier A 4. Stop engine. Refer to TM 9-2320-211-10.
GO TO FRAME 4
14-4
TM 9-2320-211-20-3-2
FRAME 4
1.
Read position of pointer (1) on scale (2). Pointer should read -1/6 to -3/16
inch TOE IN.
IF READING IS NOT WITHIN GIVEN LIMITS, LEAVE TOE-IN GAGE IN PLACE AND
GO TO FRAME 5.
IF READING IS WITHIN GIVEN LIMITS, GO TO FRAME 6
14-5
TM 9-2320-211-20-3-2
1.
2.
Using wrenches, loosen two nuts (1) at each end of tie rod (2).
Using pipe wrench, turn tie rod (2) until pointer (3) reads -1/16 to -3/16
inch TOE IN on scale (4).
3. Using wrenches, tighten two nuts (1) at each end of tie rod (2).
GO TO FRAME 6
14-6
TM 9-2320-211-20-3-2
1. Take off toe-in gage (1).
END OF TASK
14-7
TM 9-2320-211-20-3-2
14-4. PITMAN ARM REMOVAL AND REPLACEMENT.
TOOLS: 1 13/16-inch wrench
7/8-inch wrench
Hammer
Puller
Torque wrench, 600 pound-feet capacity
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove upper drag link from pitman arm. Refer
to para 14-6.
b. Removal.
FRAME 1
1. Using 1 13/16-inch wrench, unscrew and take off nut (1).
2. Take off lockwasher (2).
GO TO FRAME 2
14-8
TM 9-2320-211-20-3-2
FRAME 2
1. Put puller (1) on pitman arm (2).
2. Using 7/8-inch wrench, screw in bolt (3). If pitman arm does not come off,
tap bolt with hammer and screw bolt in again.
3. Do step 2 again until pitman arm (2) is loose.
4. Take off puller (1) and pitman arm (2).
END OF TASK
14-9
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
Turn steering wheel all the way to the right. Counting the turns, turn
steering wheel all the way to the left.
2. Turn steering wheel to the right one half the number of turns counted.
The steering wheel is now centered.
3. Put pitman arm (1) in place on splined shaft (2) with pitman arm pointed
straight up and ball socket facing in toward truck.
4. Using hammer, tap pitman arm (1) near splined shaft (2) until threaded
end of splined shaft comes through pitman arm. Be careful not to hit
splined shaft.
5. Put lockwasher (3) on splined shaft (2). Using 1 13/16-inch wrench,
screw on and tighten nut (4).
6. Using torque wrench, tighten nut (4) to 400 pounds-feet.
NOTE
Follow-on Maintenance Action Required:
Replace upper drag link. Refer to para 14-6.
END OF TASK
1.
14-10
TM 9-2320-211-20-3-2
14-5. STEERING TIE ROD ASSEMBLY AND TIE ROD END REMOVAL AND
REPLACEMENT.
Pipe wrench
TOOLS: Pliers
15/16-inch wrench (2)
1 5/16-inch socket wrench
Ratchet handle
Tie rod end puller
Small hammer
Puller kit
Chisel
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked on level surface, engine off, handbrake
set.
a. Removal of Tie Rod Assembly.
FRAME 1
Jack up and support front axle housing. Refer to Part 1, para 10-3.
Using pliers, take out cotter pin (1).
Using 1 5/16-inch socket wrench with ratchet handle, unscrew and take
off nut (2).
4. Using puller, take tie rod end (3) out of steering knuckle (4). If necessary,
using hammer, hit steering knuckle to loosen tie rod end. Do not drop loose
parts on tie rod end.
5. Screw nut (2) onto ball stud (5).
6. Do steps 2 through 5 again for other end of tie rod assembly (6).
7. Take out tie rod assembly (6).
END OF TASK
1.
2.
3.
14-11
TM 9-2320-211-20-3-2
b. Removal of Tie Rod End.
FRAME 1
NOTE
This task is the same for both tie rod ends (4) except
that on left side of truck, tie rod end has left hand
threads. On right side of truck, tie rod end has
right hand threads.
1. If there is a tack weld (1) as shown, using hammer and chisel, carefully
break tack weld. Do not damage threads.
2. Using 15/16-inch wrenches, loosen two nuts (2) on two screws (3).
3. Using pipe wrench, unscrew and take off tie rod end (4). Note number of
turns needed to take off tie rod end.
4. Do steps 1 through 3 again for other end of tie rod assembly (5).
END OF TASK
14-12
TM 9-2320-211-20-3-2
c.
Replacement of Tie Rod End.
FRAME 1
NOTE
This task is the same for both tie rod ends (1) except
that on left side of truck, tie rod end has left hand
threads. On right side of truck, tie rod end has right
hand threads.
1. Using pipe wrench, screw tie rod end (1) onto tie rod (2), using number of
turns noted.
2. Using pipe wrench, screw tie rod end (3) onto tie rod (2), using number of
turns noted.
3. Using 15/16-inch wrenches, tighten four nuts (4) on four screws (5).
END OF TASK
14-13
TM 9-2320-211-20-3-2
d.
Replacement of Tie Rod Assembly.
FRAME 1
Put tie rod assembly (1) under truck. Make sure that tie rod end (2) with
left hand threads is on left side of truck.
2. Unscrew and take off nut (3).
3. Put tie rod end (2) into steering knuckle (4) and hold it in place.
4. Using 15/16-inch socket wrench with ratchet handle, screw on and tighten
nut (3).
5. Put cotter pin (5) through nut (3) and ball stud (6).
6. Using pliers, bend ends of cotter pin (5) around nut (3).
7. Do steps 2 through 6 again for other end of tie rod assembly (1).
8. Remove supports and lower front axle housing. Refer to Part 1, para 10-3.
NOTE
Follow-on Maintenance Action Required:
1. Adjust toe-in. Refer to para 14-3.
2. Lubricate tie rod assembly. Refer to
LO 9-2320-211-12.
END OF TASK
1.
14-14
TM 9-2320-211-20-3-2
14-6. UPPER AND LOWER DRAG LINKS REMOVAL, REPLACEMENT, CHECK, AND
ADJUSTMENT.
NOTE
This task is the same for upper and lower drag links.
This task is shown for the lower drag link.
TOOLS: 1/2-inch drive ratchet handle
1/2-inch drive screwdriver bit
6-inch pliers
SUPPLIES: Cotter pin (2)
Clean rag
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Park truck with front wheels pointing straight ahead.
Refer to TM 9-2320-211-10.
b. Removal.
FRAME 1
1.
2.
3.
4.
GO
Using pliers, take out two cotter pins (1), one from each end of drag link (2).
Throw away cotter pins.
Using pliers, unhook two dust shields (3), one from each end of drag link (2).
Using screwdriver bit, unscrew two plugs (4) at ends of drag link so that
1 inch of thread shows.
Using clean rag, wipe off grease from drag link (2).
TO FRAME 2
14-15
TM 9-2320-211-20-3-2
FRAME 2
1. Turn steering wheel (1) in both directions to loosen drag link ends.
GO TO FRAME 3
14-16
TM 9-2320-211-20-3-2
FRAME 3
1. Working under trUck, take off drag link (1) from ball studs (2).
2. Take off two dust shields (3) and two felt pads (4) from two ball studs (2).
END OF TASK
14-17
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
NOTE
The front end of the drag link assembly (1) is the end
with the greatest distance between ball stud opening
(2) and threaded end of drag link (3).
1. Put two dust shields (4) and two felt pads (5) on two ball studs (6) as
shown.
2. Put drag link (1) on two ball studs (6) as shown. Hold drag link in place.
GO TO FRAME 2
14-18
TM 9-2320-211-20-3-2
FRAME 2
1.
Using screwdriver bit, screw in and tighten front plug (1) and rear plug (2).
Back off plugs until screw slot in plugs aline with cotter pin holes in drag
link (3).
2. Using pliers, put cotter pin (4) in each end of drag link (3) and bend open
ends of cotter pins.
3. Put two tabs on each dust shield (5) in slots on other end of dust shield.
Using pliers, pull tabs and bend them back as shown.
NOTE
Follow-On Maintenance Action Required:
Do drag link check and adjustment. Refer to para 14-6d.
END OF TASK
14-19
TM 9-2320-211-20-3-2
d.
Check.
FRAME 1
Soldier A 1.
Soldier B 2.
3.
4.
END OF TASK
14-20
Turn steering wheel (1) back and forth just enough to feel free
play, about 2 inches each way.
Check that two ball studs (2) do not move back and forth inside
drag link (3).
If there is movement inside drag link (3), do drag link adjustment.
Refer to paragraph 14-6e. If the drag link adjustment is good,
do step 4.
Lubricate drag link. Refer to LO 9-2320-211-12.
TM 9-2320-211-20-3-2
e. Adjustment.
FRAME 1
1. Using pliers, take out cotter pin (l).
2. Using screwdriver bit, tighten plug (2), then loosen until slot in plug alines
with cotter pin holes (3) in end of drag link (4).
3. Using pliers, put in cotter pin (1) and bend open ends.
4. Do steps 1 through 3 again for other end of drag link (4).
5. Lubricate drag link. Refer to LO 9-2320-211-12.
END OF TASK
14-21
TM 9-2320-211-20-3-2
14-7. DRAG LINK RELAY LEVER REMOVAL AND REPLACEMENT .
TOOLS: Pliers
7/16-inch wrench
1/2-inch drive ratchet
1/2-inch drive screwdriver bit
3/4-inch wrench (2)
Hammer
Brass drift
SUPPLIES : Dust shield (2)
PERSONNEL: One
EQUIPMENT CONDITION : Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
Using pliers, pull out cotter pin (1) from upper drag link (2) and lower drag
link (3). Throw away cotter pins.
2. Using pliers, unhook dust shield with felt pad (4) from upper and lower drag
links (2 and 3).
3. Using screwdriver bit, unscrew plug (5) at end of upper and lower drag links
(2 and 3) until one inch of thread shows.
4. Pull two drag links (2 and 3) away from relay lever (6).
5. Take off two dust shields with felt pads (4) and throw them away.
6. Using 7/16-inch wrench, unscrew and take out grease fitting (7).
7. Using 3/4-inch wrenches, unscrew nut (8) and take out bolt (9).
8. Using hammer and brass drift, drive out pin (10) at point (11) and take
off lever (6).
END OF TASK
14-22
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1.
2.
3.
4.
5.
6.
7.
8.
9.
Put relay lever (1) in place as shown.
Using hammer and brass drift pin, tap shaft (2) through relay lever (1).
Put screw (3) in place.
Using 3/4-inch wrenches, tighten nut (4).
Using 7/16-inch wrench, screw in and tighten grease fitting (5).
Put dust shield with felt pad (6) on each of two ball studs (7).
Press upper drag link (8) onto one ball stud (7) and lower drag link (9) onto
other ball stud on relay lever (1).
Using screwdriver bit, screw in and tighten two plugs (10) into two drag
links (8 and 9). Back plugs off until slot alines with holes for cotter pins
(11).
Using pliers, put cotter pin (11) through each drag link (8 and 9) and plug
(10). Bend open ends of cotter pins.
Snap dust shield with felt pads (6) around each drag link (8 and 9).
NOTE
Follow-on Maintenance Action Required:
1. Lubricate drag links. Refer to LO 9-2320-211-12.
2. Adjust drag links. Refer to para 14-6.
END OF TASK
14-23
TM 9-2320-211-20-3-2
14-8. STEERING WHEEL ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS: 1 1/8-inch socket wrench
1 1/4-inch socket wrench
Torque wrench, 150 pound-feet capacity
Steering wheel puller
SUPPLIES: None
PERSONNEL: TWO
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove horn button assembly. Refer to Part 1, para 7-38.
b. Removal.
FRAME 1
Hold steering wheel (1).
Using 1 1/4-inch wrench, unscrew nut (2) until it is level with
top of shaft (3).
GO TO FRAME 2
Soldier A 1.
Soldier B 2.
14-24
TM 9-2320-211-20-3-2
FRAME 2
1.
Turn steering wheel (1) to the drive straight ahead position. Refer to
TM 9-2320-211-10.
2. Put adapter (2) in center of steering wheel nut (3).
3. Put adapter (4) over steering column.
4. Put puller (5) over adapters (2 and 4) as shown.
5. Using 1 1/8-inch wrench, screw in puller screw (6) until steering wheel (1)
pops loose.
6. Take off puller (5) and adapters (2 and 4).
7. Using 1 1/4-inch wrench, unscrew and take off nut (3).
8. Take off steering wheel (1).
END OF TASK
14-25
TM 9-2320-211-20-3-2
c. Replacement.
FRAME 1
Soldier A
Soldier B
NOTE
Steering wheel (1) must be put on steering column (2)
so that spokes form a Y when looked at from driver’s
seat and front wheels must point straight ahead.
1. Put steering wheel (1) on steering column (2). Mesh splines on
wheel with splines on column.
2. Hold steering wheel (1).
3. Using 1 1/4-inch wrench, screw on nut (3). Using torque wrench,
tighten nut to 55 to 65 pound-feet.
NOTE
Follow-on Maintenance Action Required:
Replace horn button assembly. Refer to Part 1, para 7-38.
END OF TASK
14-26
TM 9-2320-211-20-3-2
14-9. STEERING KNUCKLE ARM CHECK AND ADJUSTMENT.
TOOLS: Torque wrench, 600 pound-feet capacity
SUPPLIES: None
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
FRAME
1
Soldier A 1.
Soldier B 2.
3.
Soldiers 4.
A and B
Turn steering wheel (1) about 2 inches to right and left several
times.
Check that there is no play between steering knuckle arm (2) and
steering knuckle (3).
If there is any play between these parts, using torque wrench,
tighten four nuts (4) to 155 to 200 pound-feet.
Do steps 1 through 3 again. If there is still play between steering
knuckle arm (2) and steering knuckle (3), tell direct support
maintenance.
END OF TASK
14-27
TM 9-2320-211-20-3-2
14-10. STEERING MECHANISM REMOVAL AND REPLACEMENT.
NOTE
This task is the same for both sides of front axle
assembly except where noted.
TOOLS : 7/16-inch wrench
9/16-inch wrench
7/8-inch wrench
15/16-inch wrench
l-inch wrench
1 1/2-inch wrench
Torque wrench, 600 pound-feet capacity
6-inch pliers
Bearing remover, pn 7950127
Bearing remover and replacer, pn 7950130
Bearing replacer, pn 7950129
8-ounce hammer
Stud remover and replacer
SUPPLIES: Axle shaft seal (2)
Axle shaft seal assembly (2)
Trunnion bearing spacer set
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedures.
(1)
front axle.
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
14-28
Jack up front of truck and put safety jacks under frame rails behind
Refer to Part 1, para 10-4.
Remove front tires and wheels. Refer to TM 9-2320-211-10.
Remove front hub and brake drum assembly. Refer to para 13-4.
Tell direct support to remove backing plate assembly.
Remove tie rod assembly. Refer to para 14-5.
Remove drag link. Refer to para 14-6.
Remove front moisture seal and dust boots. Refer to Part 1, para 11-4.
Tell direct support to remove steering control power cylinder.
Drain front axle. Refer to LO 9-2320-211-12.
TM 9-2320-211-20-3-2
b.
Removal.
FRAME 1
1. Using hammer, tap spindle (1) to loosen it.
2. Take off spindle (1).
3. Take washer (2) off axle shaft (3).
4. Using bearing remover, take spindle bearing sleeve (4) out of spindle (l).
GO TO FRAME 2
14-29
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3,
FOR
FOR
14-30
Pull out axle shaft (l).
Takeout axle shaft seal assembly (2) with axle shaft seal (3) and washer (4).
Take axle shaft seal (3) off axle shaft seal assembly (2). Throw away seal.
LEFT SIDE OF AXLE, GO TO FRAME 3.
RIGHT SIDE OF AXLE, GO TO FRAME 4
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
4.
5.
6.
7.
GO
Using l-inch wrench, unscrew and take off four nuts (1) and lockwashers (2).
Using hammer, tap steering arm (3) lightly.
Take off steering arm (3) and four split dowels (4).
Using 7/16-inch wrench, take out grease fitting (5).
Using pliers, pull out and throw away cotter pin (6).
Using 1 l/2-inch wrench, unscrew and take off nut (7).
Take out ball and stud assembly (8).
TO FRAME 4
14-31
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
3.
4.
GO
14-32
Using 1-inch wrench, unscrew and takeoff four nuts (1) and lockwashers (2).
Using hammer, tap sleeve plate (3) lightly.
Take off sleeve plate (3) and four split dowels (4).
Using 7/16-inch wrench, unscrew and take out grease fitting (5).
TO FRAME 5
TM 9-2320-211-20-3-2
FRAME 5
1.
2.
3.
4.
5.
Takeout spacer (l).
Takeoff sleeve (2) with bearing (3).
Using bearing remover and replacer, take bearing (3) out of sleeve (2).
Using 7/16-inch wrench, unscrew and take out grease fitting (4).
Using 15/16-inch wrench, unscrew and take out two screws (5) and lockwashers (6).
6. Take off sleeve plate (7) and sleeve (8) with bearing ( 9).
7. Using bearing remover and replacer, take bearing (9) out of sleeve (8).
GO TO FRAME 6
14-33
TM 9-2320-211-20-3-2
FRAME 6
1.
Takeoff steering knuckle (1).
NOTE
Do not take out studs unless they are damaged.
2. Using stud remover and replacer, unscrew and take out four studs (2) and
ten studs (3).
3. Using hammer, knock welds off screw (4) and nuts (5).
4. Using 7/8-inch and l-inch wrenches, unscrew and take out screw (4) and
nut (5).
END OF TASK
14-34
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1. Using 7/8-inch wrench, screw nut (1) on screw (2).
2. Using l-inch wrench, screw in screw (2).
3. Using stud remover and replacer, screw in ten studs (3) and four studs (4).
4. Put steering knuckle (5) in place on axle housing (6).
GO TO FRAME 2
14-35
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
5.
6.
7.
8.
FOR
FOR
14-36
Using bearing remover and replacer, put bearing (1) in sleeve (2).
Put sleeve (2) in place.
Put sleeve plate (3) in place.
Using 15/16-inch wrench, screw in two screws (4) and lockwashers (5).
Using 7/16-inch wrench, screw in grease fitting (6).
Using bearing remover and replacer, put bearing (7) in sleeve (8).
Put sleeve (8) in place.
Put spacer (9) in place.
LEFT SIDE OF FRONT AXLE, GO TO FRAME 3.
RIGHT SIDE OF FRONT AXLE, GO TO FRAME 4
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
4.
5.
6.
GO
Put ball and stud assembly (1) in place.
Using 1 1/2-inch wrench, screw on and tighten nut (2), alining holes
for cotter pin (3).
Using pliers, put in cotter pin (3) and bend open ends.
Using 7/16-inch wrench, screw in and tighten grease fitting (4).
Put steering arm (5) and four split dowels (6) in place.
Using l-inch wrench, and torque wrench, screw on and tighten four nuts
(7) and lockwashers (8) to 155 to 200 pound-feet.
TO FRAME 4
14-37
TM 9-2320-211-20-3-2
FRAME 4
Using 7/16-inch wrench, screw in and tighten grease fitting (1) in sleeve
plate (2).
2. Put sleeve plate (2) and four split dowels (3) in place.
3. Using l–inch wrench, and torque wrench, screw on and tighten four nuts (4)
and lockwashers (5) to 155 to 200 pound-feet.
GO TO FRAME 5
1.
14-38
TM 9-2320-211-20-3-2
FRAME 5
1.
2.
3.
4.
GO
Put axle shaft seal (1) on axle shaft seal assembly (2).
Put washer (3) on axle shaft seals (l).
Put washer (3), seal (1), and seal assembly (2) in axle housing (4).
Put in axle shaft (5).
TO FRAME 6
14-39
TM 9-2320-211-20-3-2
FRAME 6
1.
2.
3.
Using bearing replacer, put spindle bearing sleeve (1) in place in spindle (2).
Put washer (3) in place on axle shaft (4).
Put spindle (2) in place.
NOTE
Follow-on Maintenance Action Required:
1. Replace moisture seal and dust boot. Refer to Part 1,
para 11-4.
2. Tell direct support to replace steering control power
cylinder.
3. Replace drag link. Refer to para 14-6.
4. Replace tie rod assembly. Refer to para 14-5.
5. Replace backing plate assembly. Tell direct support
maintenance.
6. Replace front hub and brake drum assembly. Refer
to para 13-4.
7. Replace front wheels and tires. Refer to
TM-9-2320-211-10.
8. Grease front axle assembly. Refer to
LO 9-2320-211-12.
9. Take out safety jacks and lower truck. Refer to Part 1,
para 10-4.
10. Fill front axle. Refer to LO 9-2320-211-12.
11. Do wheel alinement. Refer to para 14-3.
END OF TASK
14-40
TM 9-2320-211-20-3-2
Section III. STEERING HOSES, LINES, AND FITTINGS
POWER STEERING HOSES, LINES, AND FITTINGS REMOVAL AND
REPLACEMENT.
NOTE
This procedure is typical and is the same for all types
of hoses, lines, and fittings used on the power steering
system. Refer to figure 14-1, used as a support diagram
for troubleshooting each system.
TOOLS: l-gallon container
1 1/4-inch wrench
1 1/2-inch wrench
1 3/8-inch wrench
SUPPLIES: Rags
Tags
Caps
Thread tape, MIL-T-27730A
Lubricating oil, ICE, OE/HDO IO, MIL-L-2104
PERSONNEL: One
EQUIPMENT CONDITION : Truck parked, engine off, handbrake set.
a. Preliminary Procedures.
(1) Open hood. Refer to TM 9-2320-211-10.
(2) Drain power steering reservoir. Refer to LO 9-2320-211-12.
14-11.
14-41
TM 9-2320-211-20-3-2
Figure 14-1. Power Steering System
14-42
TM 9-2320-211-20-3-2
b.
Removal.
FRAME 1
1.
2.
Turn three fasteners (1) to the left to unlock them.
Take off power steering access panel (2) from inside of left front fender
housing (3).
GO TO FRAME 2
14-43
TM 9-2320-211-20-3-2
FRAME 2
NOTE
Before taking off hydraulic line, tag both sides of connection to be sure line is put back in the same place.
Cap all open hydraulic lines and plug all open ports
to keep dirt out of system.
1. Place container under truck below power steering pump.
2. Using 1 1/2-inch wrench, unscrew nut (1).
3. Using 1 1/4-inch wrench, unscrew nut (2) and take off hose (3).
4. Using 1 3/8-inch wrench, unscrew and take out reducer (4).
5. Using 1 1/4-inch wrench, unscrew elbow (5).
END OF TASK
14-44
TM 9-2320-211-20-3-2
c. Replacement.
FRAME 1
1.
2.
3.
4.
5.
GO
NOTE
Wrap threads of fittings with thread tape.
Take caps and plug off hydraulic line and port.
Using 1 1/4-inch wrench, screw in and tighten elbow (1).
Using 1 3/8-inch wrench, screw in and tighten reducer (2).
Using 1 3/8-inch wrench, put hose (3) in place and tighten nut (4).
Using 1 1/2-inch wrench, screw on and tighten nut (5).
TO FRAME 2
14-45
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Put power steering access panel (1) in place inside of left front fender
housing (2).
Turn three fasteners (3) to right to lock them.
NOTE
Follow-on Maintenance Action Required:
1. Fill power steering reservoir. Refer to
LO 9-2320-211-12.
2. Close hood. Refer to TM 9-2320-211-10.
END OF TASK
14-46
TM 9-2320-211-20-3-2
Section IV. STEERING RESERVOIR
14-12. HYDRAULIC STEERING OIL RESERVOIR REMOVAL AND REPLACEMENT.
1-inch wrench
TOOLS:
15/16-inch wrench
1 1/2-inch wrench (2)
9/16-inch wrench
11/16-inch wrench
1-gallon container
7/16-inch wrench (2)
SUPPLIES: Lubricating oil, ICE, OE/HDO 10, MIL-L-2104
Tags
Dust caps
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedures.
(1) Open hood and left side panel. Refer to TM 9-2320-211-10.
(2) Drain hydraulic steering oil reservoir. Refer to LO 9-2320-211-12.
14-47
TM 9-2320-211-20-3-2
b. Removal.
FRAME 1
1.
2.
3.
4.
5.
GO
14-48
NOTE
Before taking off hydraulic lines, tag both sides of
connection to be sure lines are put back in the same
place. Cap all open hydraulic lines and plug all open
hydraulic lines and open ports to keep dirt out of
system.
Using 11/16-inch wrench, unscrew sleeve nut (1) on hydraulic line (2).
Move hydraulic line away.
Using 7/16-inch wrenches, take off nut (3).
Using l-inch wrench, unscrew sleeve nut (4) from steering gear (5).
Using 15/16-inch wrench, unscrew hose (6) from reservoir (7).
Using 1 1/2-inch wrenches, unscrew sleeve nut (8) from reservoir (7).
Move hydraulic lines (6 and 9) away.
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME 2
Soldier A 1.
Working in engine compartment and using 9/16-inch wrench,
hold screw (1). Tell soldier B when ready.
Soldier B 2. Working under left front frame and using 9/16-inch wrench,
unscrew and take off safety nut (2).
Soldier A 3. Take off screw (1), washer (3), and cushion (4).
GO TO FRAME 3
14-49
TM 9-2320-211-20-3-2
FRAME 3
Soldier A 1.
Soldier B 2.
Soldier A 3.
Soldiers 4.
A and B
Soldier A 5.
END OF TASK
14-50
Working in engine compartment and using 9/16-inch wrench,
hold nut (1). At the same time, hold reservoir (2). Tell
soldier B when ready.
Working under left front fender, and using 9/16-inch wrench,
unscrew and take off screw (3).
Take off nut (1) and two washers (4).
Do steps 1 through 3 again for nut (5), two washers (6),
and screw (7) at other side of reservoir (2).
Lift reservoir (2) off truck and take out cushion (8) and spacer
(9).
TM 9-2320-211-20-3-2
c. Replacement.
FRAME 1
Soldier A
1.
Soldier B
2.
Soldier A
3.
Soldiers
4.
A and B
GO TO FRAME
Put reservoir (1) into place on left side of engine compartment.
Aline mounting holes and hold reservoir in position.
Working under left front fender, put screw (2) through mounting
hole as shown. Using 9/16-inch wrench, hold screw in place.
Tell soldier A when ready.
Using 9/16-inch wrench, screw on and tighten two washers (3)
and nut (4).
Do steps 2 and 3 again for screw (5), two washers (6), and nut
(7) at other side of reservoir (1).
2
14-51
TM 9-2320-211-20-3-2
FRAME 2
Soldier A 1.
Working in engine compartment, put screw (1) through washer
(2), mounting cushion (3), and hole in mounting bracket (4).
Put another cushion (3) on screw and slide spacer (5) over screw
into cushions.
2. Put screw (1) through frame (6) and tell soldier B when ready.
Soldier B 3. Working under left front frame, and using 9/16-inch wrench,
screw on and tighten safety nut (7).
GO TO FRAME 3
14-52
TM 9-2320-211-20-3-2
FRAME 3
1.
Put on hydraulic line (1). Using 11/16-inch wrench, screw on sleeve
nut (2).
2. Put on hydraulic line (3). Using 1 1/2-inch wrenches, screw sleeve nut
(4) onto reservoir (5).
3. Using 15/16-inch wrench, screw hose (6) onto reservoir (5).
4. Using l-inch wrench, screw sleeve nut (7) onto steering gear (8).
5. Using 7/16-inch wrenches, screw on and tighten nut (9).
NOTE
Follow-on Maintenance Action Required:
1. Fill hydraulic steering oil reservoir. Refer to
LO 9-2320-211-12.
2. Close hood and left side panel. Refer to
TM 9-2320-211-10.
END OF TASK
14-53/(14-54 blank)
TM 9-2320-211-20-3-2
CHAPTER 15
FRAME AND TOWING ATTACHMENTS GROUP MAINTENANCE
Section I. SCOPE
15-1. EQUIPMENT ITEMS COVERED. This chapter gives equipment maintenance
procedures for frame components, pintles and towing attachments, spare wheel
carrier, and fifth wheel assembly for which there are authorized corrective maintenance tasks at the organizational maintenance level.
15-2. EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective
maintenance is authorized at the organizational maintenance level are covered in this
chapter.
Section II.
FRAME
COMPONENTS
15-3. BUMPERS REMOVAL AND REPLACEMENT.
TOOLS:
3/4-inch wrench (2)
15/16-inch wrench (2)
SUPPLIES: None
PERSONNEL:
EQUIPMENT
One
CONDITION:
Truck parked, engine off, handbrake set.
15-1
TM 9-2320-211-20-3-2
a.
Removal.
(1) Front bumper.
FRAME 1
Using 3/4-inch wrenches, unscrew and takeoff three screws (1) and nuts (2).
One of the screws is inside frame member (3).
2. Using 15/16-inch wrenches, unscrew and take off two screws (4) and nuts (5).
One of the screws is inside frame member (3).
3. Do steps 1 and 2 again on other side of bumper (6).
GO TO FRAME 2
1.
15-2
TM 9-2320-211-20-3-2
FRAME 2
1. Using 3/4-inch wrenches, unscrew and take off two screws (1) and nuts (2).
2. Using 15/16-inch wrenches, unscrew and take off two screws (3), nut (4),
and nut (5) inside of frame member (6).
3. Using 15/16-inch wrenches, loosen bolt (7).
4. Do steps 1 through 3 again on other side of bumper (8).
5. Pull bumper (8) forward and take it off.
END OF TASK
15-3
TM 9-2320-211-20-3-2
(2) Rear bumperettes.
FRAME 1
1.
2.
Using 3/4-inch wrenches, unscrew and take off four screws (1) and nuts (2).
Using 3/4-inch wrenches, unscrew and take off two screws (3) and nuts (4).
Takeoff bumperette (5).
3. Do steps 1 and 2 again for other bumperette (6).
END OF TASK
15-4
TM 9-2320-211-20-3-2
b.
Replacement.
(1) Front bumper.
FRAME 1
Move lifting shackle (1) up out of the way.
Pull up on shackle bracket (2) and hold it. Slide upper lip of bumper (3)
into place between shackle bracket and upper bumper bracket (4). Do again
for other side of bumper.
3. Push bottom lip of bumper (3) into place under lower bumper bracket (5).
Do again for other side of bumper.
4. Aline holes in bumper (3) with holes in shackle bracket (2), upper bumper
bracket (4), and lower bumper bracket (5) on both sides of bumper.
GO TO FRAME 2
1.
2.
15-5
TM 9-2320-211-20-3-2
FRAME 2
Using 3/4-inch wrenches, screw in and tighten two screws (1) and nuts ( 2).
Using 15/16-inch wrenches, screw in and tighten two screws (3), nuts (4),
and nut (5) on inside of frame member (6).
3. Using 15/16-inch wrench, tighten bolt (7).
4. Do steps 1 through 3 again for other side of bumper (8).
GO TO FRAME 3
1.
2.
15-6
TM 9-2320-211-20-3-2
FRAME 3
1. Using 3/4-inch wrenches, screw in and tighten three screws (1) and nuts (2).
One of the screws is inside frame member (3).
2. Using 15/16-inch wrenches, screw in and tighten two screws (4) and nuts (5).
One of the screws is inside frame member (3).
3. Do steps 1 and 2 again for other side of bumper (6).
END OF TASK
15-7
TM 9-2320-211-20-3-2
(2) Rear bumperettes.
FRAME 1
Put bumperette (1) in place on frame (2), aline holes and hold it. Put four
screws (3) through outside holes.
2. Using 3/4-inch wrenches, screw in and tighten four screws (3) and nuts (4).
3. Using 3/4-inch wrenches, screw in and tighten two screws (5) and nuts (6).
4. Do steps 1 through 3 again for other bumperette (7).
END OF TASK
1.
15-8
TM 9-2320-211-20-3-2
Section III. PINTLES AND TOWING ATTACHMENTS
15-4. TOWING PINTLE ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS: 9/32-inch wrench
1 1/8-inch wrench
7/16-inch wrench
Transmission jack
3/4-inch wrench
Pliers
15/16-inch wrench
SUPPLIES: None
PERSONNEL: TWO
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
Removal.
FRAME
1
Soldier A 1.
Soldier B 2.
Hold bolts (1) with 7/16-inch wrench.
Working inside of frame of truck and using 7/16-inch wrench,
unscrew and take off four nuts (2) and lockwashers (3).
Soldier A 3. Take out four bolts (1) and cover (4). Take off retainer plate
(5). Pull out connector (6) and unscrew coupling (7). Take
off connector (6).
GO TO FRAME 2
15-9
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
GO
Using pliers, take out cotter pin (1). Take off nut and washer (2).
Takeout pintle hook (3).
Using 1 1/8-inch wrenches, unscrew and take off four nuts (4). Take out
four bolts (5).
Using 9/32-inch wrench, unscrew and takeout lubrication fitting (6).
Place transmission jack under mounting bracket (7) for support.
TO FRAME 3
15-10
TM 9-2320-211-20-3-2
FRAME 3
Soldier A
Soldier B
1.
2.
Hold bolts (1) with 1 1/8-inch wrench.
Working inside of frame of truck and using 1 1/8-inch wrench,
unscrew and take off four nuts (2).
WARNING
Do not take out bolts (1) while soldier A is under truck.
Pintle and mounting bracket (3), may fall, causing injury
to personnel and damage to equipment.
Soldier A 3. Hold mounting bracket (3) steady.
Soldier B 4. Take out four bolts (1).
5. Using transmission jack, slowly lower pintle and mounting
bracket (3) to floor.
GO TO FRAME 4
15-11
TM 9-2320-211-20-3-2
FRAME 4
Soldier A 1.
Soldier B 2.
Soldier A 3.
Soldier B 4.
Working inside frame of truck and using 15/16-inch wrench,
hold four bolts (1).
Working under truck and using 15/16-inch wrench, unscrew and
take out four nuts (2).
Take out four bolts (1).
Using 3/4-inch wrench and reaching in through hand hole (3),
hold two nuts (4).
Using 3/4-inch wrench, unscrew and take out two bolts (5).
Do steps 4 and 5 again for other side of reinforcement (6).
Soldier A 5.
Soldiers 6.
A and B
GO TO FRAME 5
15-12
TM 9-2320-211-20-3-2
FRAME 5
Soldier A 1.
Soldier B 2.
Soldier A 3.
Soldiers 4.
A and B
END OF TASK
Working inside frame of truck and using 3/4-inch wrench,
hold five nuts (1) and hold brace (2).
Working on side of truck and using 3/4-inch wrench, unscrew
and take out five bolts (3).
Take out brace (2).
Do steps 1 through 3 on other side of truck.
15-13
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME
1
Soldier A 1.
Soldier B 2.
Working inside frame of truck, put on brace (1) and aline holes
with holes in frame.
Working on side of truck, put in five bolts (2). Using 3/4-inch
wrench, hold five bolts (2).
Using 3/4-inch wrench, screw on and tighten five nuts (3).
Do steps 1 through 3 on other side of truck.
Soldier A 3.
Soldiers 4.
A and B
GO TO FRAME 2
15-14
TM 9-2320-211-20-3-2
FRAME 2
Soldiers 1.
A and B
Soldier A 2.
Soldier B 3.
Working inside frame of truck, put on reinforcement (1). Line
up bolt holes.
Put in two bolts (2). Using 3/4-inch wrench, hold bolts (2).
Working under truck, reach through hand hole (3) and using
3/4-inch wrench, screw on and tighten two nuts (4).
Do steps 2 and 3 again on other side of reinforcement (1).
Soldiers 4.
A and B
Soldier A 5. Put in four bolts (5). Using 15/16-inch wrench, hold bolts (5).
Soldier B 6. Using 15/16-inch wrench, screw on and tighten four nuts (6).
GO TO FRAME 3
15-15
TM 9-2320-211-20-3-2
FRAME 3
Soldier A
Soldier B
1.
2.
Soldier A
3.
Hold mounting bracket (1) steady on transmission jack.
Using transmission jack, lift mounting bracket (1) up to frame
(2).
Aline bolt holes and put in four bolts (3). Using 1 1/8-inch
wrench, hold bolts (3).
WARNING
Leave transmission jack in place under mounting bracket
(1) for support. Failure to do this may let mounting
bracket fall, causing injury to personnel and damage
to equipment.
Soldier B 4. Working inside frame of truck, and using 1 1/8-inch wrench,
screw on and tighten four nuts (4). Take out transmission jack.
GO TO FRAME 4
15-16
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
3.
4.
5.
GO
Using 9/32-inch wrench, screw in and tighten lubrication fitting (1) into
mounting bracket (2).
Put in four bolts (3). Using 1 1/8-inch wrenches, screw on and tighten
four nuts (4).
Put pintle hook (5) in mounting bracket (2).
Put on washer (6). Screw on nut (7) only tight enough so pintle hook (5)
can still turn easily.
Line up a slot on nut (7) with hole in pintle hook (5) and put in cotter
pin (8). Using pliers, bend over ends of cotter pin.
TO FRAME 5
15-17
TM 9-2320-211-20-3-2
FRAME
5
Soldier A 1.
2.
Soldier B 3.
END OF TASK
15-18
Screw coupling (1) into connector (2). Put on retainer plate (3),
connector (2) and mounting bracket (4), and aline bolt holes of
connector.
Put on cover (5). Put in four bolts (6). Hold bolts with 7/16-inch
wrench.
Working inside of frame of truck, put on lockwashers (7). Using
7/16-inch wrench, screw on and tighten four nuts (8).
TM 9-2320-211-20-3-2
15-5. TOWING PINTLE REMOVAL AND REPLACEMENT.
TOOLS: Pliers
12-inch adjustable automatic wrench
0.010-inch feeler gage
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME
1.
2.
3.
END
1
Using pliers, take out cotter pin (1) and throw it away.
Using wrench, unscrew and take off slotted nut (2) and thrust washer (3).
Take out towing pintle assembly (4).
OF TASK
15-19
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
Push towing pintle assembly (1) through hole in bracket (2).
Put on thrust washer (3). Using wrench, screw on slotted nut (4).
Place feeler gage (5) between thrust washer (3) and bracket (2).
Using wrench, tighten slotted nut (4) until feeler gage (5) barely slides in
and out.
NOTE
Towing pintle assembly (1) should turn freely with no side
motion.
5. Using pliers, push cotter pin (6) through holes in slotted nut (4) and towing
pintle assembly (1). Bend open ends of cotter pin.
NOTE
Follow-on Maintenance Action Required:
Lubricate towing pintle assembly. Refer to
LO 9-2320-211-12.
END OF TASK
1.
2.
3.
4.
15-20
TM 9-2320-211-20-3-2
15-6. FRONT LIFTING SHACKLE BRACKET REMOVAL AND REPLACEMENT.
NOTE
This task is the same for both right and left
front lifting shackle brackets. This task is
shown for right front lifting shackle bracket.
TOOLS: 15/16-inch wrench (2)
15/16-inch socket with breaker bar
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal
FRAME 1
1. Unhook and pull out clip (1) . Pull out pin (2) and take off shackle (3).
GO TO FRAME 2
15-21
TM 9-2320-211-20-3-2
FRAME 2
1.
Using 15/16-inch wrench and socket with breaker bar, unscrew and take
off two nuts (1) and two screws (2).
2.
Using 15/16-inch wrench and socket with breaker bar, unscrew and take
off nut (3) and screw (4). Take out spacer (5 and 6) and bracket (7).
END OF TASK
15-22
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1.
Put bracket (1) in place on bumper (2), alining holes. Push two screws (3)
through holes in bracket.
2. Using 15/16-inch wrenches, screw on and tighten two nuts (4).
3. Put spacers (5 and 6) in place and push screw (7) through spacers. Using
15/16-inch wrenches, screw on and tighten nut (8).
GO TO FRAME 2
15-23
TM 9-2320-211-20-3-2
FRAME 2
Put shackle (1) in place on bracket (2), alining holes.
Push pin (3) through holes in shackle (1) and bracket (2). Push clip (4)
through hole in pin and close clip.
END OF TASK
1.
2.
15-24
TM 9-2320-211-20-3-2
15-7. REAR LIFTING SHACKLE REMOVAL AND REPLACEMENT.
TOOLS: 3/4-inch wrench (2)
15/16-inch wrench (2)
SUPPLIES : Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set,
a. Preliminary Procedure. Remove air coupling and bracket. Refer to
Part 1, para 12-21.
15-25
TM 9-2320-211-20-3-2
b.
Removal.
FRAME 1
NOTE
Bumperette (4) may not be on all models.
1. Using 3/4-inch wrenches, unscrew and take out four nuts (1).
2. Using 3/4-inch wrenches, unscrew and take out two nuts (2). Take out
six screws (3) with bumperette (4).
3. Pull out pin (5). Take out pin (6) and shackle (7).
4. Using 15/16-inch wrenches, unscrew and take out three nuts (8). Take out
three screws (9) and bracket (10).
5. Repeat steps (1, 2, 3, and 4) for other side.
END OF TASK
15-26
TM 9-2320-211-20-3-2
c.
Cleaning.
WARNING
Dry cleaning solvent is flammable. Do not use
near an open flame. Keep a fire extinguisher
nearby when solvent is used. Use only in wellventilated places. Failure to do this may result
in injury to personnel and damage to equipment.
NOTE
Clean all parts before inspection, after repair,
and before assembly.
(1) Clean inner and outer surfaces of metallic parts and all areas that might
get oil or grease with dry cleaning solvent.
(2) Remove sludge and gum deposits with a stiff brush.
(3) Steam cleaning may be used to take off grease and dirt after dry
cleaning solvent has been used.
(4) Dry with clean rags.
(5) Rust must be taken off using a wire brush.
(6) Refer to Part 1, para 1-3 for more cleaning steps.
15-27
TM 9-2320-211-20-3-2
d.
Replacement.
FRAME 1
Put bracket (1) against truck. Put in three screws (2).
Using 15/16-inch wrenches, screw on three nuts (3).
Put shackle (4) over bracket (1). Put in pin (5). Put in pin (6) and
close.
4. Hold bumperette (7) against truck. Put in six screws (8).
5. Using 3/4-inch wrenches, screw on two nuts (9).
6. Using 3/4-inch wrenches, screw on four nuts (10).
7. Do steps (1, 2, 3, 4, and 5) again for other side.
NOTE
Follow-on Maintenance Action Required:
Replace air coupling and bracket. Refer to Part 1, para 12-21.
END OF TASK
1.
2.
3.
15-28
TM 9-2320-211-20-3-2
Section IV. SPARE WHEEL CARRIER
15-8. SPARE WHEEL CARRIER REMOVAL, REPAIR, AND REPLACEMENT (TRUCK
M51A2).
TOOLS: General mechanic’s tool kit
SUPPLIES: Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
Using wrench, unscrew and take off nut (1). Drop down J-bolt
(2).
Lift off support clamp (3).
Roll out spare tire and wheel assembly (4).
2.
Soldiers 3.
A and B
GO TO FRAME 2
15-29
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
5.
GO
15-30
Open toolbox door (1).
Using wrenches, unscrew and take off four nuts (2).
Take out four screws (3) and lift off bracket (4).
Using 5/8-inch wrenches, unscrew and take off four nuts (5).
Take out four screws (6) and take off two brackets (7).
TO FRAME 3
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
4.
GO
Using wrenches, unscrew and take off six nuts (1).
Take out six screws (2) with washers (3) and lift off tool box (4).
Using 5/8-inch wrenches, unscrew and take off four nuts (5).
Take out four screws (6) and take off two braces (7).
TO FRAME 4
15-31
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
3.
4.
END
15-32
Using 5/8-inch wrenches, unscrew and take off two nuts (1).
Take out two screws (2) and lift off support bracket (3).
Using 13/16-inch wrenches, unscrew and take off four nuts (4).
Take out four screws (5) and lift off tire and tool box base (6).
OF TASK
TM 9-2320-211-20-3-2
b.
Repair.
WARNING
Dry cleaning solvent is flammable. Do not use
near an open flame. Keep a fire extinguisher
nearby when solvent is used. Use only in wellventilated places. Failure to do this may result
in injury to personnel and damage to equipment.
(1) Using solvent, clean grease and dirt from all parts.
(2) Check that all parts have no cracks, breaks or bending.
(3) If parts are damaged, get new ones in their place.
c. Replacement.
FRAME 1
Aline holes in tire and tool box base (1) with holes in brackets (2).
Push four screws (3) through holes in tire and tool box base (1).
Using 13/16-inch wrenches, screw on and tighten four nuts (4).
Aline holes in bottom of support bracket (5) with holes in sides of tire and
tool box base (1).
5. Push two screws (6) through holes in sides of tire and tool box base (1).
6. Screw on and hand tighten two nuts (7).
GO TO FRAME 2
1.
2.
3.
4.
15-33
TM 9-2320-211-20-3-2
FRAME 2
1.
Aline holes in braces (1) with holes in sides of tire and tool box base (2)
and support bracket (3).
2. Push four screws (4) through holes in braces (1).
3. Screw on and hand tighten four nuts (5).
GO TO FRAME 3
15-34
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
GO
Aline holes in bottom of toolbox (1) with holes in tire and toolbox base (2).
Push six screws (3) with washers (4) through holes in bottom of tool box (1).
Using wrenches, screw on and tighten six nuts (5).
TO FRAME 4
15-35
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
3.
GO
15-36
Aline holes in brackets (1) with holes in tool box (2) and support bracket (3).
Push four screws (4) through holes in brackets (1).
Screw on and hand tighten four nuts (5).
TO FRAME 5
TM 9-2320-211-20-3-2
FRAME 5
1.
2.
3.
4.
5.
GO
Aline holes in bracket (1) with holes in tool box (2) and support bracket (3).
Push four screws (4) through holes in bracket (1), tool box (2), and support
bracket (3).
Using wrenches, screw on and tighten four nuts (5).
Using 5/8-inch wrenches, tighten ten nuts (6, 7, and 8).
Close tool box door (9).
TO FRAME 6
15-37
TM 9-2320-211-20-3-2
FRAME 6
1.
2.
3.
Lift spare tire and wheel assembly (1) onto tire and tool box base (2).
Hook support clamp (3) onto tire and tool box base (2).
Hook one end of J–bolt (4) onto tire and tool box base (2) and push other
end through hole in support clamp (3).
4. Using wrench, screw on and tighten nut (5).
END OF TASK
15-38
TM 9-2320-211-20-3-2
15-9. SPARE WHEEL CARRIER REMOVAL, REPAIR, AND REPLACEMENT (TRUCKS
M54A2 WITH WINCH AND M55A2 WITH WINCH).
TOOLS: Wheel stud nut wrench
9/16-inch wrench (2)
3/4-inch wrench (2)
SUPPLIES: Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
Using stud nut wrench, unscrew and take off two nuts (1) with
two washers (2) and spring (3).
Lift out two J-bolts (4).
Slide out spare tire and wheel assembly (5).
2.
Soldiers 3.
A and B
GO TO FRAME 2
15-39
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
END
15-40
Using 3/4-inch wrenches, unscrew and take off four nuts (1).
Take out four screws (2).
Using 3/4-inch wrenches, unscrew and take off four nuts (3).
Take out four screws (4) and drop down carrier (5).
OF TASK
TM 9-2320-211-20-3-2
b.
Disassembly.
FRAME 1
1.
2.
Using 9/16-inch wrenches, unscrew and take off two nuts (1).
Take out two screws (2) with washers (3) and take off bracket (4) and
carrier plate (5).
3. Using 3/4-inch wrenches, unscrew and take off two nuts (6).
4. Take out two screws (7) and take off bracket (8).
END OF TASK
15-41
TM 9-2320-211-20-3-2
WARNING
Dry cleaning solvent is flammable. Do not use
near an open flame. Keep a fire extinguisher
nearby when solvent is used. Use only in well–
ventilated places. Failure to do this may result
in injury to personnel and damage to equipment.
c. Cleaning, Inspection, and Repair.
(1) Using solvent, clean dirt and grease from all parts.
(2) Check that all parts have no cracks, breaks or dents.
(3) If parts are damaged, get new ones in their place.
d. Assembly.
FRAME 1
1. Aline holes in bracket (1) with holes in plate assembly (2).
2. Push two screws (3) through holes in plate assembly (2).
3. Using 3/4-inch wrenches, screw on and tighten two nuts (4).
4. Aline holes in bracket (5), plate assembly (2), and carrier plate (6).
5. Push two screws (7) through holes in bracket (5). Put on washers (8).
6. Using 9/16-inch wrenches, screw on and tighten two nuts (9).
END OF TASK
15-42
TM 9-2320-211-20-3-2
e.
Replacement.
FRAME 1
1.
2.
3.
4.
5.
6.
GO
Aline holes in carrier plate (1) with holes in frame (2).
Push four screws (3) through holes in carrier plate (1).
Using 3/4-inch wrenches, screw on and tighten four nuts (4).
Aline holes in bracket (5) with holes in frame (2).
Push four screws (6) through holes in frame (2).
Using 3/4-inch wrenches, screw on and tighten four nuts (7).
TO FRAME 2
15-43
TM 9-2320-211-20-3-2
FRAME 2
Soldiers 1.
A and B
2.
Lift spare tire and wheel assembly (1) and place it on carrier
plate (2).
Push one J-bolt (3) through hole in bracket (4) and one J-bolt
(5) through hole in plate assembly (6). Hook both J-bolts
onto spare tire and wheel assembly (1).
GO TO FRAME 3
15-44
TM 9-2320-211- 20-3-2
FRAME 3
1.
Using wheel stud nut wrench, screw on and tighten nut (1) with washer (2)
onto free end of J-bolt (3).
2. Using wheel stud nut wrench, screw on and tighten nut (4) with spring (5)
and washer (6) onto free end of J-bolt (7).
END OF TASK
15-45
TM 9-2320-211-20-3-2
15-10. SPARE WHEEL CARRIER REMOVAL AND REPLACEMENT (TRUCKS M54A2
AND M54A2C WITHOUT WINCH AND TRUCK M54A2C WITH WINCH).
TOOLS: Pliers
Wheel stud nut wrench
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
2.
3.
4.
END
15-46
Using wrench, unscrew and take off two nuts (1).
Take off spare tire and wheel assembly (2).
Using pliers, take out two cotter pins (3) and throw them away.
Take out two stud pins (4) and two studs (5).
OF TASK
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1.
2.
3.
Aline holes in studs (1) with holes in mounting bracket (2).
Push two stud pins (3) through holes in mounting bracket (2).
Using pliers, push two cotter pins (4) through holes in two stud pins (3)
and bend open ends of cotter pins.
4. Place ends of studs (1) through holes in spare tire and wheel assembly (5).
5. Using wrench, screw on and tighten two nuts (6).
END OF TASK
15-47
TM 9-2320-211-20-3-2
15-11. SPARE WHEEL CARRIER REMOVAL, REPAIR, AND REPLACEMENT (TRUCK
M52A2 WITHOUT WINCH).
TOOLS: 7/16-inch wrench (2)
3/4-inch wrench (2)
9/16-inch wrench (2)
SUPPLIES: Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
PERSONNEL: TWO
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedures.
(1) Remove spare wheel from spare wheel carrier. Refer to
TM 9-2320-211-10.
(2) Disassemble wiring harness receptacle connector. Refer to Part 1, para
7-45.
(3) Remove air cutoff valves and air hose assembly. Refer to
Part 1, para 12-32.
(4) Remove tool box. Refer to para 17-12.
15-48
TM 9-2320-211-20-3-2
b.
Removal.
FRAME 1
Soldier A
1.
Soldier B
2.
Soldier A
Soldiers
A and B
3.
4.
5.
GO TO FRAME
Hold left fuel tank protector (1) so it does not fall when soldier B
takes out screws (2) and locknuts (3).
Using 9/16-inch wrenches, unscrew and take out four capscrews (2)
and locknuts (3).
Take off left fuel tank protector (1).
Do steps 1 through 3 again to take off right fuel tank protector (4).
Using 3/4-inch wrenches, unscrew and take out four capscrews
(5), washers (6) and locknuts (7).
2
15-49
TM 9-2320-211-20-3-2
FRAME 2
Soldiers 1. Takeoff spare wheel and tool box carrier base assembly (1)
A and B
from chassis rails (2).
END OF TASK
15-50
TM 9-2320-211-20-3-2
c. Cleaning, Inspection, and Repair.
FRAME 1
WARNING
Dry cleaning solvent is flammable. Do not use near
an open flame. Keep a fire extinguisher nearby when
solvent is used. Use only in well-ventilated places.
Failure to do this may result in injury to personnel and
damage to equipment.
1. Clean all parts with solvent.
2. Check that 12 cap screws (1) and locknuts (2) have no stripped threads.
3. Check that J-bolt (3) has no damaged threads or bends.
4. Check that spare tire clamp (4) has no cracks, bends or dents.
5. Check that all other parts have no cracks, bends or dents. If parts are
damaged, tell direct support maintenance.
6. If parts (1 through 4) are damaged, get new ones in their place.
END OF TASK
15-51
TM 9-2320-211-20-3-2
d.
Replacement.
FRAME 1
Soldiers 1.
A and B
Put spare wheel and tool box carrier base assembly (1) on chassis
rails (2) and aline screw holes in tool box assembly with holes in
chassis rails.
GO TO FRAME 2
15-52
TM 9-2320-211-20-3-2
FRAME 2
Soldier A
1.
Using 3/4-inch wrenches, screw in and tighten four capscrews
(1), washers (2), and locknuts (3).
Hold left fuel tank protector (4) in place as shown while soldier B
puts in screws (5) and locknuts (6).
Using 9/16-inch wrenches, screw in and tighten four capscrews
(5) and locknuts (6).
Do steps 1 and 2 again to put on right fuel tank protector (7).
2.
Soldier B
3.
Soldiers
A and B
4.
NOTE
Follow-on Maintenance Action Required:
1.
2.
3.
4.
Replace air cutoff valves and air hose support
assembly. Refer to Part 1, para 12-32.
Assemble wiring harness receptacle connector.
Refer to Part 1, para 7-45.
Replace spare wheel. Refer to TM 9-2320-211-10.
Replace tool box. Refer to para 17-12.
END OF TASK
15-53
TM 9-2320-211-20-3-2
Section V. FIFTH WHEEL ASSEMBLY
15-12. FIFTH WHEEL ASSEMBLY REMOVAL, REPLACEMENT AND ADJUSTMENT.
TOOLS: General mechanic toolkit, NSN 5180-00-209-6225
Hoisting equipment
SUPPLIES: None
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
2.
Soldier A 3.
Soldier B 4.
END OF TASK
15-54
Put hoisting equipment on fifth wheel assembly (1).
Using wrench, unscrew and takeoff five screws (2) and lockwashers (3) on left and right sides of fifth wheel assembly (1).
Using hoisting equipment, lift fifth wheel assembly (1) off truck.
Guide fifth wheel assembly (1) up and away from truck so it
does not hit anything.
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
Soldier A 1.
Soldier B 2.
3.
4.
END OF TASK
Using hoist, lower fifth wheel assembly (1) on truck.
Guide fifth wheel assembly (1) while it is being lowered into
position shown.
Using wrench, screw in and tighten five screws (2) and lockwashers (3) on left and right sides of fifth wheel assembly (1).
Adjust fifth wheel assembly. Refer to TM 9-2320-211-10.
15-55/(15-56 blank)
TM 9-2320-211-20-3-2
CHAPTER 16
SPRINGS AND SHOCK ABSORBERS GROUP MAINTENANCE
Section 1. SCOPE
16-1. EQUIPMENT ITEMS COVERED . This chapter gives equipment maintenance procedures for springs and shock absorbers for which there are authorized corrective
maintenance tasks at the organizational maintenance level.
16-2. EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective
maintenance is authorized at the organizational maintenance level are covered in this
chapter.
Section II. SPRINGS
16-3. FRONT AXLE SPRING ASSEMBLY REMOVAL AND REPLACEMENT .
NOTE
This task is the same for the left and right
front springs. This task is shown for the
left front spring.
TOOLS :
1 5/16-inch wrench
3/4-inch wrench (2)
7/16-inch wrench
1 5/16-inch socket wrench
Hydraulic floor jack
Motor vehicle trestle
Torque wrench, 600 poundfeet capacity
Wood block, 12 x 12 x 24-inches
Screwdriver bit
SUPPLIES :
Medium ballpeen hammer
Brass drift
Pry bar
6-inch pliers
(4)
None
PERSONNEL : Two
EQUIPMENT
a.
CONDITION:
Truck parked, engine off, handbrake set, rear
wheels chocked.
Preliminary Procedures.
(1) Remove shock absorber. Refer to para 16-6.
(2) Remove drag link. Refer to para 14-6.
16-1
TM 9-2320-211-20-3-2
b.
Removal.
FRAME
1.
1
Put hydraulic jack (1) under axle housing (2) as shown.
WARNING
2.
3.
4.
5.
GO
16-2
Keep hands away from wheels when jacking up truck. Wheels
may turn as they clear the ground. Personnel can be injured.
Using hydraulic jack (1), jack up truck until front wheels (3) are off ground about
6 inches.
Put motor vehicle trestle (4) on top of two wood blocks (5) and set trestle under
frame as shown.
Do step 3 again on other side of truck.
Using hydraulic jack (1), jack truck down onto two trestles (4).
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME
1.
2.
3.
4.
GO
2
Using hydraulic jack, jack up axle housing (1) just enough so weight of axle housing
is on jack.
Using 7/16-inch wrench, unscrew and take out two grease fittings (2).
Using 3/4-inch wrenches, hold two capscrews (3) and unscrew and take off two nuts
(4). Take out two capscrews.
Using hammer and brass drift, drive out two pins (5 and 6).
TO FRAME 3
16-3
TM 9-2320-211-20-3-2
FRAME
1.
3
Using 1 5/16-inch wrench, unscrew and take off four nuts (1) and washers (2).
Take off clamp plate (3).
GO TO FRAME 4
16-4
TM 9-2320-211-20-3-2
FRAME 4
1.
Using hydraulic jack, slowly lower axle housing (l).
NOTE
If spring eye (2) is stuck in bracket (3), jack up axle housing
(1) and using pry bar, pry out spring eye from bracket. Then
lower axle housing.
Soldiers
A and B
2.
Take off two U-bolts (4) and upper spring seat (5).
3.
Lift spring (6) off lower spring seat (7) and take spring out of truck.
Take off lower spring seat.
END OF TASK
16-5
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
Place lower seat (1) on axle housing (2) as shown.
Place spring (3) on lower seat (1) so that end of bolt (4) is in center hole of
seat.
3. Place upper seat (5) on top of spring (3).
4. Place two U-bolts (6) over upper seat (5) with ends through holes in lower
seat (1).
GO TO FRAME 2
1.
2.
16-6
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Put clamp plate (1) over two U-bolts (2) as shown.
Put four washers (3) on two U-bolts (2) and using 1 5/16-inch wrench, screw on four
nuts (4).
GO TO FRAME 3
16-7
TM 9-2320-211-20-3-2
FRAME 3
1.
Using hydraulic jack, jack up axle housing (1) until spring eye (2) goes into
shackle (3).
2. Using hammer and brass drift, drive in pin (4).
3. Put capscrew (5) through clamp (6).
4. Using 3/4-inch wrenches, hold capscrew (5) and screw on and tighten nut (7).
5. Using 7/16-inch wrench, screw in and tighten grease fitting (8).
GO TO FRAME 4
16-8
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
3.
4.
5.
6.
GO
Using hydraulic jack, raise or lower axle housing (1) as needed to aline front
spring eye (2) with hole in bracket (3).
Using hammer and brass drift, drive in pin (4).
Put capscrew (5) through clamp (6).
Using 3/4-inch wrenches, hold capscrew (5) and screw on and tighten nut (7).
Using 7/16-inch wrench, screw in and tighten grease fitting (8).
Using torque wrench with 1 5/16-inch socket wrench, tighten four nuts (9) to
350 to 400 pound-feet.
TO FRAME 5
16-9
TM 9-2320-211-20-3-2
FRAME 5
1.
2.
3.
Using hydraulic jack (1), jack up truck until truck is off two trestles (2).
Takeout two trestles (2) and four wood blocks (3).
Using hydraulic jack (1), lower truck onto ground. Take away hydraulic jack.
NOTE
Follow-on Maintenance Action Required:
1. Lubricate shackle pins. Refer to LO 9-2320-211-12.
2. Replace shock absorber. Refer to para 16-6.
3. Replace drag link. Refer to para 14-6.
END OF TASK
16-10
TM 9-2320-211-20-3-2
16-4. REAR AXLE LEAF SPRING ASSEMBLY REMOVAL AND REPLACEMENT.
NOTE
This task is the same for the left and right rear
axle leaf spring assemblies. This task is shown
for the left rear axle leaf spring assembly.
1 1/2-inch wrench
TOOLS: 1 13/16-inch wrench (2)
3/4-inch drive socket set
1 5/16-inch wrench
Safety jack
Torque wrench, 600 poundfeet capacity
SUPPLIES: None
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedures.
(1) Take off wheels next to spring to be taken off. Refer to
TM 9-2320-211-10.
(2) Raise frame to take weight from spring to be taken off and support
both rear axles with safety jacks. Refer to Part 1, para 10-3.
b.
Removal.
FRAME 1
1.
Using 1 13/16-inch wrench, unscrew and take off two clamp screws (1)
from rear of seat (2). Take washers (3) off screws.
2.
Using 1 1/2-inch wrench, unscrew and take off four nuts (4). Take off
four washers (5) and two U-bolts (6).
NOTE
On trucks M543A2, saddle (7) is a stabilizer bar (8).
3. Take off saddle (7).
GO TO FRAME 2
16-11
TM 9-2320-211-20-3-2
FRAME 2
Place jack under torque rod (1).
Using 1 5/16-inch wrenches, unscrew and take off four nuts (2).
Take out four washers (3) and screws (4).
Lift bracket (5) slightly up off locator pin.
Slide bracket (5) off spring (6). Be careful not to bend brake line
bracket (7).
NOTE
If spring pressure does not let bracket (5) come out,
change height of jack under frame.
GO TO FRAME 3
1.
2.
3.
4.
5.
16-12
TM 9-2320-211-20-3-2
FRAME 3
Soldiers 1.
A and B
END OF TASK
Slide spring (1) out of bracket (2). Lift spring (1) from truck.
16-13
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
Soldiers 1.
A and B
2.
Lift spring (1) and slide it into bracket (2).
Place spring (1) onto seat (3) with end of bolt (4) in center hole
of seat (3).
GO TO FRAME 2
16-14
TM 9-2320-211-20-3-2
FRAME 2
1.
Place bracket (1) with wear plate over end of spring (2) and onto locator
pin on axle (3).
Push four screws (4) through two brake line brackets (5), bracket (1),
2.
and torque rod bracket (6). Put washer (7) on each screw.
Using 1 5/16-inch wrenches, screw on and tighten four nuts (8).
3.
GO TO FRAME 3
16-15
TM 9-2320-211-20-3-2
FRAME 3
1.
Place saddle (1) over spring (2) with center bolt (3) through hole in saddle.
NOTE
On truck M543A2, saddle (1) is a stabilizer bar (4).
2.
Place two U-bolts (5) over saddle (1) and through seat (6).
GO TO FRAME 4
16-16
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
3.
4.
5.
Place four washers (1) on two U-bolts (2).
Using 1 1/2-inch wrench, screw on four nuts (3).
Using torque wrench, tighten nuts (3) to 350 to 450 pound-feet.
Place washers (4) on two screws (5).
Using 1 13/16-inch wrench, screw in and tighten screws (5) into spring
seat (6).
NOTE
Follow-on Maintenance Action Required:
1. Put back rear wheels. Refer to TM 9-2320-211-10.
2. Take out all jacks and blocks. Refer to Part 1, para 10-3.
END OF TASK
16-17
TM 9-2320-211-20-3-2
16-5. REAR SPRING SEAT REMOVAL, REPLACEMENT, AND ADJUSTMENT.
NOTE
This task is the same for the left and right
rear spring seats. This task is shown for the
left rear spring seat.
Wheel bearing wrench, pn 7076869
TOOLS: Jack
Brass drift punch
Portable bearing lubricator,
Hammer
NSN 4930-00-704-1852
Spring scale, 0 to 50 pounds
Hand grease gun,
Tire iron
NSN 4930-00-253-2478
Wood blocks (2)
1 7/8-inch wrench
1/2-inch wrench
1 1/2-inch wrench
Torque wrench, 600 poundfeet capacity
SUPPLIES: Bearing cap gasket
Artillery and-automotive grease, type GAA, MIL-G-10924
Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
Rags
Tags
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove outer and inner rear wheels next to spring
seat to be taken off. Refer to TM 9-2320-211-10.
16-18
TM 9-2320-211-20-3-2
b. Removal.
FRAME 1
1.
Place jack (1) under crosstube bracket (2). Lift it high enough to take tube
load off spring (3).
2. Using 1 7/8-inch wrench, unscrew and takeout two screws with washers (4).
3. Using 1 1/2-inch wrench, unscrew and take off four nuts (5). Take off four washers
(6), two U-bolts (7), and saddle (8).
GO TO FRAME 2
16-19
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
GO
16-20
Using 1/2-inch wrench, unscrew and take out six screws with washers (1). Take off
bearing cap (2) and gasket (3). Throw gasket away.
Lower jack (4) enough for spring seat (5) to clear spring (6).
Using wheel bearing wrench, unscrew and take off outer nut (7). Take off washer (8).
Using wheel bearing wrench, unscrew and take off inner nut (9).
TO FRAME 3
TM 9-2320-211-20-3-2
FRAME 3
NOTE
Outer bearing (1) will fall out when spring seat (2) is taken
off crosstube (3).
1. Slide spring seat (2) off crosstube (3).
2. Tag outer bearing (1).
Go TO FRAME 4
16-21
TM 9-2320-211-20-3-2
FRAME 4
1.
Using hammer and tire iron, pry and tap side to side and take washer (1), two dust
seals (2) and wiper (3) off crosstube (4).
CAUTION
Put spring seat (5) on wood blocks when taking out bearing
(6) and seal (7) so that they are not damaged.
2. Using hammer and drift punch, tap around inside of inner bearing (6) and take out
seal (7) and inner bearing. Tag inner bearing.
GO TO FRAME 5
16-22
TM 9-2320-211-20-3-2
FRAME 5
WARNING
Dry cleaning solvent is flammable. Do not use near an open
flame. Keep a fire extinguisher nearby when solvent is used.
Use only in well-ventilated places. Failure to do this may
result in injury to personnel and damage to equipment.
1. Using rag, wipe all grease from spring seat (1), two bearings (2), and two cups (3).
Clean with solvent and let dry thoroughly. Do not use compressed air.
2. Check that bearings (2) and cups (3) have no wear or defects.
3. If bearings (2) or cups (3) are damaged, using drift punch and hammer, drive cups out
of spring seat (1). Throw away cups and bearings.
END OF TASK
16-23
TM 9-2320-211-20-3-2
c. Replacement and Adjustment.
FRAME 1
1.
If bearing cups (1) have been taken out, place new cup into each end of spring seat
(2) with thin edge out.
2. Using drift punch and hammer, tap two cups (1) into place. Make sure that cups
are fully seated.
GO TO FRAME 2
16-24
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Put thin coating of grease on inside of spring seat (1).
Using bearing packer, pack inner bearing (2) with grease. Make sure that grease
fills all spaces.
3. Place inner bearing (2) in spring seat (1) with small end in. Take off tag.
4. Using drift punch and hammer, tap seal (3) into spring seat (1) with seal lip into
bearing (2).
GO TO FRAME 3
16-25
TM 9-2320-211-20-3-2
FRAME 3
1. Put washer (1), two seals (2), and wiper (3) on crosstube shaft (4).
2. Using drift punch and hammer, tap wiper (3) onto seat (5).
GO TO FRAME 4
16-26
TM 9-2320-211-20-3-2
FRAME
4
1.
2.
Place spring seat (1) on crosstube (2) with empty end facing out.
Using bearing packer, pack outer bearing (3) with grease. Make sure that grease
fills all spaces.
3. Place outer bearing (3) in spring seat (1) with small end in. Take off tag.
4. Screw on inner adjusting nut (4) with bump facing out as shown, but do not tighten
at this time.
GO TO FRAME 5
16-27
TM 9-2320-211-20-3-2
FRAME 5
1.
2.
3.
4.
5.
6.
GO
16-28
Hook end of scale (1) in hole in spring seat (2) as shown.
Using wheel bearing wrench, tighten inner adjusting nut (3).
Pull down on scale (1) until spring seat (2) just starts to turn and read scale.
Scale must read between 24 and 32 pounds. (This is equal to 12 to 15 pounds
preload on bearings.)
If reading is more than 32 pounds, loosen inner adjusting nut (3) and do step 3 again.
If reading is less than 24 pounds, tighten inner adjusting nut (3) and do step 3 again.
Do steps 4 and 5 again until reading on scale (1) is between 24 and 32 pounds.
TO FRAME 6
TM 9-2320-211-20-3-2
FRAME 6
1.
2.
Put washer (1) on crosstube (2) with tab (3) in keyway (4).
Bump on nut (5) should aline with a hole on washer (1). If it does not, using wheel
bearing wrench, turn nut to right. Line up bump with next hole.
3. Using wheel bearing wrench, screw on and tighten nut (6).
4. Pull down on scale until spring seat just starts to turn and read scale. If reading is
not between 24 and 32 pounds, unscrew nut (6), take off washer (1) and do frame 5
again.
GO TO FRAME 7
16-29
TM 9-2320-211-20-3-2
FRAME
1.
7
Place gasket (1) and cap (2) on seat (3), alining holes. Using 1/2-inch wrench,
screw in and tighten six screws with washers (4).
2. Raise jack (5) under crosstube bracket (6) until spring (7) rests on seat (3).
GO TO FRAME 8
16-30
TM 9-2320-211-20-3-2
FRAME 8
Place two U-bolts (1) over saddle (2) and through seat (3).
Put four washers (4) on ends of two U-bolts (1) and using 1 1/2-inch wrench, screw
on four nuts (5). Using torque wrench, tighten nuts to 300 to 400 pound-feet.
3. Using 1 7/8-inch wrench, screw on and tighten two screws with washers (6)
through seat (3).
4. Lower jack (7) and take it out.
NOTE
Follow-on Maintenance Action Required:
Replace inner and outer rear wheels. Refer to TM 9-2320-211-10.
END OF TASK
1.
2.
16-31
TM 9-2320-211-20-3-2
Section III. SHOCK ABSORBERS
FRONT AXLE SHOCK ABSORBER REMOVAL AND REPLACEMENT.
NOTE
This task is the same for the right and left front
axle shock absorbers. This task is shown for the
right front axle shock absorber.
TOOLS: 1 1/8-inch wrench
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
16-6.
FRAME 1
1.
At each end of shock absorber (1), using wrench, unscrew and take off nut
(2). Take off washer (3).
2. Pull off shock absorber (1) with two rubber bushings (4) at each end.
END OF TASK
16-32
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1. Place one rubber bushing (1) with narrow end out on each mounting stud (2).
2. Place shock absorber (3) on two studs (2) with larger end on upper stud as shown.
3. Place one rubber bushing (4) with wide end out on each stud (2).
4. Put washer (5) on each stud (2) and using wrench, screw on and tighten two nuts (6).
END OF TASK
16-33/(16-34 blank)
TM 9-2320-211-20-3-2
CHAPTER 17
BODY, CAB, HOOD, AND HULL GROUP MAINTENANCE
Section I. SCOPE
17-1. EQUIPMENT ITEMS COVERED. This chapter gives equipment maintenance
procedures for body and cab components, windshield, seats, stowage and tool boxes,
and cargo body components for which there are authorized corrective maintenance
tasks at the organizational maintenance level.
17-2. EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective
maintenance is authorized at the organizational maintenance level are covered in this
chapter.
Section II. BODY AND CAB COMPONENTS
17-3. BRUSH GUARD ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS : 3/4-inch wrench (2)
SUPPLIES : None
PERSONNEL: One
EQUIPMENT CONDITION : Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Open hood. Refer to TM 9-2320-211-10.
17-1
TM 9-2320-211-20-3-2
b.
Removal.
FRAME 1
1.
2.
Using 3/4-inch wrenches, unscrew and loosen two brace nuts (1) and bolts (2).
Using 3/4-inch wrenches, unscrew and loosen two mounting nuts (3) and
bolts (4).
3. Pull top of brush guard (5) forward and lift if off truck.
END OF TASK
17-2
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
2.
3.
Position brush guard (1) on front of truck as shown.
Using 3/4-inch wrenches, screw in and tighten two mounting nuts (2) and
bolts (3).
Using 3/4-inch wrenches, screw in and tighten two brace nuts (4) and bolts
(5).
NOTE
Follow-on Maintenance Action Required:
Close hood. Refer to TM 9-2320-211-10.
END OF TASK
17-3
TM 9-2320-211-20-3-2
17-4. CAB DOOR ASSEMBLY REMOVAL AND REPLACEMENT.
NOTE
This task is the same for the right and left cab
door assemblies. This task is shown for the right
assembly.
TOOLS: Cross-tip screwdriver (Phillips type)
1/2-inch wrench
Hammer
7/16-inch wrench (2)
1/8-inch pin punch
Pliers
SUPPLIES:
None
PERSONNEL: TWO
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove rear view mirror. Refer to para 19-12.
b. Removal.
FRAME 1
1.
2.
Open cab door (1).
Using pliers, take out cotter pin (2) and throw it away. Reach through vent
door (3) and take out door stop (4).
3. Close door (1) to first catch.
GO TO FRAME 2
17-4
TM 9-2320-211-20-3-2
FRAME 2
Soldier A 1.
Soldier B 2.
Soldier A 3.
Using 7/16-inch wrenches , unscrew and take off nut (1) and
screw (2). Hold mirror brace assembly (3).
Using 1/2-inch and 7/16-inch wrenches, unscrew and take off two
nuts (4). Using hammer and punch, drive out screw (5) and then
screw (6).
Take off mirror brace assembly (3).
WARNING
Unlock cab door assembly (8) carefully. It has been
freed and may fall, causing injury to personnel.
Soldier B 4. Turn door handle (7) to unlock door (8). Take off door.
GO TO FRAME 3
17-5
TM 9-2320-211-20-3-2
1.
Using phillips screwdriver, unscrew and take out eight screws (1). Take off
two hinge parts (2).
2. Put two hinge parts (2) in place on door (3), alining holes for two screws (4).
Put screws in place. Screw on and finger tighten two nuts (5).
END OF TASK
17-6
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
Using 1/2-inch and 7/16-inch wrenches, unscrew and take off two nuts (1) and
screws (2). Take off two hinge parts (3).
2. Put two hinge parts (3) in place on truck, alining holes for eight screws (4).
Using screwdriver, screw in and tighten eight screws.
GO TO FRAME 2
17-7
TM 9-2320-211-20-3-2
FRAME 2
Soldier A 1.
Soldier B 2.
Soldier A 3.
Soldier B 4.
Soldier A 5.
GO TO FRAME
17-8
Put door (1) in place on cab. Push door closed to first catch. Hold
door in place.
Put punch up through top hinge (2) to hold door (1) in place.
Put mirror brace assembly (3) in place, alining holes for two
screws (4).
Put two screws (4) in place. Punch will fall out of top hinge (2).
Using 1/2-inch and 7/16-inch wrenches, screw on and tighten two
nuts (5).
Put mirror brace assembly (3) on bracket (6), alining holes for
screw (7). Put screw in place. Using 7/16-inch wrench, screw on
and tighten nut (8).
3
TM 9-2320-211-20-3-2
FRAME 3
1.
Open door (1). Working through vent door (2), put door stop (3) in place,
alining holes for cotter pin (4). Put cotter pin in place and using pliers, bend
open ends of cotter pin.
NOTE
Follow-on Maintenance Action Required:
Replace rear view mirror. Refer to para 19-12.
END OF TASK
17-9
TM 9-2320-211-20-3-2
17-5. CAB TUNNEL REMOVAL AND REPLACEMENT.
TOOLS: 7/16-inch wrench
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME
1.
2.
1
Lift up companion seat (1).
Using 7/16-inch wrench, unscrew and take out 12 screws (2) with lockwashers
(3) on front tunnel (4).
NOTE
If front tunnel has a boot put in, shift knob may have to
be taken out to lift tunnel off over shift lever.
3. Lift up and slide off front tunnel (4).
4. Using 7/16-inch wrench, unscrew and take out 11 screws (5) with lockwashers
(6) on toe board (7). Take off toe board.
5. Using 7/16-inch wrench, unscrew and take out six screws (8) with lockwashers
(9). Lift up and slide off rear tunnel (10).
END OF TASK
17-10
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
Put toe board (1) in place and aline holes. Using 7/16-inch wrench, screw in
and tighten 11 screws (2) with lockwashers (3).
2. Slide rear tunnel (4) down into place and aline holes.
3. Using 7/16–inch wrench, screw in and tighten six screws (5) with lockwashers
(6).
4. Slide front tunnel (7) down over shift lever (8).
5. Aline holes in front tunnel (7) with holes in cab floor, toe board (1), and rear
tunnel (4).
6. Using 7/16-inch wrench, screw in and tighten 12 screws (9) with lockwashers
(10).
7. Put down companion seat (11).
END OF TASK
1.
17-11
TM 9-2320-211-20-3-2
Section III. WINDSHIELD
17-6. CAB WINDSHIELD ASSEMBLY REMOVAL AND REPLACEMENT.
NOTE
This task is the same for the right and left side
windshield assemblies. This task is shown for
the right side assembly.
TOOLS: 3/8-inch wrench
7/16-inch wrench
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove windshield wiper motor. Refer to para 19-8.
b. Removal.
FRAME 1
1.
2.
3.
Lift up windshield lock handle (1).
Loosen two windshield adjusting arm thumbscrews (2).
Push forward on windshield lock handle (1) and open windshield assembly
(3). Tighten two screws (2).
4. Using 7/16-inch wrench, unscrew and take out two screws (4).
5. Using 3/8-inch wrench, unscrew and take out seven screws (5) while holding
windshield assembly (3). Take out windshield assembly.
END OF TASK
17-12
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
Put windshield assembly (1) in place as shown.
Using 3/8-inch wrench, screw in and tighten seven screws (2).
Aline hole in each of two adjusting arms (3) with hole in each of two
tabs (4) on side of windshield assembly (1).
4. Using 7/16-inch wrench, screw in and tighten two screws (5).
5. Loosen two windshield adjusting arm thumbscrews (6) and using windshield
lock handle (7), pull windshield closed. Push windshield lock handle down.
NOTE
Follow-on Maintenance Action Required:
Replace windshield wiper motor. Refer to para 19-8.
END OF TASK
1.
2.
3.
17-13
TM 9-2320-211-20-3-2
Section IV. SEATS
17-7. DRIVER’S SEAT ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS: 1/2-inch socket
1/2-inch wrench (2)
4-inch extension
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
2.
3.
4.
GO
17-14
Using 1/2-inch wrenches, unscrew and takeoff screw (1) and nut (2).
Do step 1 again on other side of seat cushion (3).
Pullout seat cushion (3).
Pull off backrest cushion (4).
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME 2
1.
Using 1/2-inch socket with 4-inch extension, unscrew and take off four
nuts (1).
2. Lift up handle (2) and hold it.
3. While holding handle (2) in up position, pull up and take off seat frame (3).
4. Take off four flat washers (4).
END OF TASK
17-15
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
Put four flat washers (1) in place on base (2). While holding handle (3) in up
position, put seat frame (4) on seat base (2) as shown.
2. Using 1/2-inch socket with 4-inch extension, screw in and tighten four nuts
(5).
3. Push handle down as shown.
GO TO FRAME 2
1.
17-16
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
Put backrest cushion (1) into frame (2) as shown.
Put seat cushion (3) into frame (2) as shown.
Using 1/2-inch wrenches, screw in and tighten screw (4) and nut (5) on both sides
of frame (2).
END OF TASK
17-17
TM 9-2320-211-20-3-2
17-8. COMPANION SEAT ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS: 1/2-inch wrench (2)
9/16-inch wrench
SUPPLIES: None
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a.
Removal.
FRAME 1
1.
2.
3.
4.
5.
6.
Soldiers 7.
A and B
END OF TASK
17-18
Raise seat cushion (1) to lean against back rest cushion (2)
as shown.
Using 9/16-inch wrench, unscrew and take out screw (3).
Using 9/16-inch wrench, unscrew and take out screw (4).
Using 1/2-inch wrenches, unscrew and take off four screws (5)
and nuts (6).
Move seat cushion (1) down.
Using 1/2-inch wrench, loosen screw (7). Push backrest
cushion (2) down to lean against seat cushion (1).
Lift up companion seat assembly and take it out of cab.
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
Soldiers
A and B
1.
Put companion seat assembly into cab.
2.
3.
4.
Raise backrest cushion (1) into position as shown.
Using 1/2-inch wrench, tighten screw (2).
Raise seat cushion (3) to lean against backrest cushion (1)
as shown.
Using 1/2-inch wrenches , screw in and tighten four screws (4)
and nuts (5).
Using 9/16-inch wrench, screw in and tighten screw (6).
Using 9/16-inch wrench, screw in and tighten screw (7).
Pull front of seat cushion (3) forward and down.
5.
6.
7.
8.
END OF TASK
17-19
TM 9-2320-211-20-3-2
17-9. CRANE OPERATOR’S SEAT REMOVAL AND REPLACEMENT (TRUCK M543A2).
TOOLS: 9/16-inch wrench
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
Using 9/16-inch wrench, unscrew and takeout capscrew (1) and lockwasher
(2) from under seat (3).
2. Using 9/16-inch wrench, unscrew and take out cap screw (4) and lock washer
(5) from under gondola (6).
3. Take out seat (3).
END OF TASK
1.
17-20
TM 9-2320-211-20-3-2
b. Replacement.
FRAME 1
1.
2.
Put seat (1) in place and aline two screw holes.
Using 9/16-inch wrench, screw in and tighten capscrew (2) and lockwasher
(3) under seat (1).
3. Using 9/16-inch wrench, screw in and tighten capscrew (4) and lockwasher
(5) under gondola (6).
END OF TASK
17-21
TM 9-2320-211-20-3-2
17-10. CRANE OPERATOR’S BACK REST REMOVAL AND REPLACEMENT (TRUCK
M543A2).
TOOLS: 9/16-inch wrench
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
Using 9/16-inch wrench, unscrew and takeout two capscrews (1) and lockwashers (2).
2. Takeout backrest (3).
END OF TASK
17-22
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1.
2.
Put back rest (1) in place and aline two screw holes.
Using 9/16-inch wrench, screw in and tighten two capscrews (2) and lockwashers (3).
END OF TASK
17-23
TM 9-2320-211-20-3-2
Section V. STOWAGE AND TOOL BOXES
17-11. LEFT TOOLBOX ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS: 7/16-inch wrench (2)
1/2-inch socket (2)
Ratchet
SUPPLIES: None
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
17-24
TM 9-2320-211-20-3-2
a.
Removal.
FRAME 1
1.
2.
3.
4.
Soldiers 5.
A and B
6.
END OF TASK
Open tool box door (1).
Using 7/16-inch wrenches, unscrew and take off eight screws (2)
and eight nuts (3). Take off drum bracket (4).
Using 7/16-inch wrenches, hold three nuts (5) and unscrew and
take out three screws (6). Take out three nuts.
Using 1/2-inch wrenches, hold nut (7) and unscrew and take out
screw (8). Take off nut.
Do steps 2 and 3 again for other side of tool box (9). Soldier B
holds nuts (5) while soldier A takes out screws (6).
Lift off tool box (9).
17-25
TM 9-2320-211-20-3-2
b.
Replacement
FRAME 1
1.
2.
3.
Soldiers 4.
A and B
5.
6.
END OF TASK
17-26
Put tool box (1) into place and aline screw holes.
Using 1/2-inch wrenches, hold nut (2) and screw in and tighten
screw (3).
Using 7/16-inch wrenches, hold three nuts (4) and screw in and
tighten three screws (5).
Do steps 2 and 3 again for other side of tool box (1). Soldier B
holds nuts (2) while soldier A screws in and tightens screws (3).
Put drum bracket (7) in place. Using 7/16-inch wrenches, hold
eight nuts (8) and screw in and tighten eight screws (9).
Close tool box door (6).
TM 9-2320-211-20-3-2
17-12. PIONEER STOWAGE TOOLBOX ASSEMBLY REMOVAL AND REPLACEMENT
(TRUCK M52A2 WITHOUT WINCH AND TRUCK M543A2 WITH WINCH).
TOOLS: 9/16-inch wrench (2)
7/16-inch wrench
9/16-inch socket wrench
7/16-inch socket wrench
Cross-tip screwdriver (Phillips type)
SUPPLIES: Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove pioneer tools.
17-27
TM 9-2320-211-20-3-2
b.
Removal.
FRAME 1
Soldier A 1.
Soldier B 2.
3.
4.
5.
Soldiers 6.
A and B
END OF TASK
17-28
Using 9/16-inch wrench, hold six self-locking nuts (1).
Open toolbox door (2).
Working inside toolbox and using 9/16-inch wrench, unscrew and
take off six capscrews (3) and six flat washers (4).
Take off self-locking nuts (1).
Using 9/16-inch wrenches, unscrew and take off capscrew (5)
and self-locking nut (6).
Liftoff toolbox (7).
TM 9-2320-211-20-3-2
c.
FRAME
Replacement.
1
Soldiers 1.
A and B
Soldier A 2.
3.
Soldier B 4.
5.
Lift tool box (1) into place, alining holes.
Using 9/16-inch wrenches, screw in and tighten capscrew (2)
and self-locking nut (3).
Working inside tool box, put in six capscrews (4) and six flat
washers (5). Using 9/16-inch wrench, hold six capscrews (4).
Using 9/16-inch wrench, screw on and tighten six self-locking
nuts (6).
Close tool box door (7).
NOTE
Follow-on Maintenance Action Required:
Replace pioneer tools in pioneer tool bracket.
END OF TASK
17-29
TM 9-2320-211-20-3-2
PIONEER TOOL SET BRACKET ASSEMBLY AND PIONEER TOOL BRACKET
REMOVAL, REPAIR, AND REPLACEMENT (TRUCKS M51A2, M52A2, M54A2.
M54A2C, and M55A2).
TOOLS: 9/16-inch wrench (2)
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove pioneer tools from bracket.
b. Removal.
(1) Cargo trucks (M54A2, M54A2C, and M55A2).
17-13.
FRAME 1
1. Open toolbox door (1).
2. Using 9/16-inch wrenches, unscrew and take out four screws (2), nuts (3), and
washers (4).
3. Takeoff pioneer tool bracket (5).
END OF TASK
17-30
TM 9-2320-211-20-3-2
(2) Dump body truck (M51A2).
FRAME 1
1.
Using 9/16-inch wrenches, unscrew and take off four nuts (1) and four lockwashers (2). Take out four screws (3).
2. Take off pioneer tool rack (4).
GO TO FRAME 2
17-31
TM 9-2320-211-20-3-2
FRAME 2
1.
Using 9/16-inch wrenches, unscrew and takeoff two nuts (1). Take out two
screws (2) and two lockwashers (3).
2. Take off rear bracket (4).
3. Do steps 1 and 2 again for front bracket (5).
END OF TASK
17-32
TM 9-2320-211-20-3-2
(3) Tractor truck (M52A2).
FRAME
1
Using 9/16-inch wrenches, unscrew and take out four screws (1) and
locknuts (2).
Take off pioneer tool bracket (3).
2.
END OF TASK
1.
17-33
TM 9-2320-211-20-3-2
WARNING
Dry cleaning solvent is flammable. Do not use near
an open flame. Keep a fire extinguisher nearby when
solvent is used. Use only in well-ventilated places.
Failure to do this may result in injury to personnel
and damage to equipment.
c. Cleaning. Clean pioneer tool bracket with solvent.
d. Inspection and Repair. Check that pioneer tool bracket has no bends, dents,
cracks or welding defects. Repair by welding or straightening. Refer to TM 9-237
and FM 43-2.
17-34
TM 9-2320-211-20-3-2
e.
Replacement.
(1) Cargo trucks (M54A2, M54A2C, and M55A2).
FRAME 1
1.
2.
Put pioneer tool bracket (1) in place.
Using 9/16-inch wrenches, screw in and tighten four screws (2), nuts (3),
and washers (4).
3. Close tool box door (5).
NOTE
Follow-on Maintenance Action Required:
Put pioneer tools back in pioneer tool bracket.
END OF TASK
17-35
TM 9-2320-211-20-3-2
(2) Dump body truck (M51A2).
FRAME 1
1.
2.
3.
4.
5.
From inside of dump body, put two screws (1) in place.
Put two braces (2) on screws (1).
Using 9/16-inch wrenches, screw on and tighten lockwashers (3) and nuts (4).
Put two screws (5) through holes in bottom of braces (2).
Using 9/16-inch wrenches, screw on and tighten two lockwashers (6) and
nuts (7).
GO TO FRAME 2
17-36
TM 9-2320-211-20-3-2
FRAME 2
1. Hold pioneer rack (1) in place against brackets (2).
2. Put four screws (3) through holes in rack (1) and brackets (2).
3. Put four lockwashers (4) on screws (3).
4. Using 9/16-inch wrenches, screw on and tighten four nuts (5).
END OF TASK
17-37
TM 9-2320-211-20-3-2
(3) Tractor truck (M52A2).
FRAME 1
1.
2.
Put pioneer tool bracket (1) in place.
Using 9/16-inch wrenches, screw in and tighten four screws (2) and nuts (3).
NOTE
Follow-on Maintenance Action Required:
Put pioneer tools back in pioneer tool bracket.
END OF TASK
17-38
TM 9-2320-211-20-3-2
Section VI. CARGO BODY COMPONENTS
17-14. TAILGATE CONTROL LINKAGE ADJUSTMENT (TRUCK M51A2).
TOOLS: 15/16-inch combination box and open end wrench
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
NOTE
To raise and lower dump body, and open and
close tailgate, refer to TM 9-2320-211–10.
FRAME 1
1.
Using wrench, loosen central rod nuts (1) and two control rods (2), one on
each side of body.
2. Using wrench, screw in adjusting nut (3) until latch (4) locks tailgate (5)
tightly closed.
3. Using wrench, tighten control rod nut (1).
4. Do steps 2 and 3 for other side of truck.
5. Raise dump body (6) and open tailgate control handle (7) to make sure two
latches (4) let go of tailgate (5).
6. Lower dump body (6) and lock control handle (7).
END OF TASK
17-39
TM 9-2320-211-20-3-2
17-15. TROOP SEAT RACK ASSEMBLY REPAIR.
NOTE
This task is the same for the right and left side
troop seat rack assemblies. This task is shown
for the right side troop seat rack assembly.
9/16-inch wrench
TOOLS: Pliers
Scrubbing
brush
Cross-tip screwdriver
Mallet
(Phillips type)
1/2-inch wrench
Strong soap
SUPPLIES:
Rags
Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove rack and seat assembly from truck. Refer
to TM 9-2320-211-10.
b. Disassembly of Rack and Seat Assembly.
NOTE
This task is shown for six legs on side troop seat
rack assembly. This task is the same for side
troop seat rack assemblies with five legs.
FRAME 1
1. Lift up and hold legs (1) away from pins (2) in six places.
2. Using pliers, take out and throw away six cotter pins (3).
3. Take out six pins (2).
4. Take seat assembly (4) off rack assembly (5).
END OF TASK
17-40
TM 9-2320-211-20-3-2
c.
Disassembly of Rack Assembly.
NOTE
If carriage bolts turn when taking off nuts,
wood is unserviceable. Split wood away from
bolt. Using 1/2-inch open end wrench, hold
bolt.
FRAME 1
Using screwdriver and 1/2-inch wrench, unscrew and take out two screws (1).
Take off two washers (2), clamps (3), and nuts (4) on each end.
2. Using 1/2-inch wrench, unscrew and take off two nuts (5) from each end
bow pocket assembly (6).
3. Using 1/2-inch wrench, unscrew and take off four nuts (7) from each of
center four bow pocket assemblies (8).
4. Take off boards (9).
5. Using mallet, hammer 20 square neck screws (10) out of boards (9).
END OF TASK
1.
17-41
TM 9-2320-211-20-3-2
d.
Disassembly of Seat Assembly.
FRAME 1
1.
Using 9/16-inch wrench, hold screw (1) at each of six channels (2). Using
9/16-inch wrench, unscrew and take off six self-locking nuts (3). Takeout
screws and six legs (4).
GO TO FRAME 2
17-42
TM 9-2320-211-20-3-2
FRAME 2
1.
Using 1/2-inch wrench, unscrew and take off 27 nuts (1). Take out one
screw (2).
2. Take off six hinges (3) and angle iron (4).
3. Take off six channels (5).
4. Using mallet, tap 27 screws (6) out of each side board (7).
5. Using mallet, tap six screws (8) out of each inside board (9).
END OF TASK
17-43
TM 9-2320-211-20-3-2
WARNING
Dry cleaning solvent is flammable. Do not use
near an open flame. Keep a fire extinguisher
nearby when solvent is used. Use only in well–
ventilated places. Failure to do this may result
in injury to personnel and damage to equipment.
e. Cleaning.
(1) Using solvent, clean all metal parts.
(2) Dry all metal parts.
(3) Using strong soap and cold water, scrub all wood parts.
(4) Using cold water, rinse all wood parts.
f. Inspection and Repair.
(1) Check all metal parts. Throw away any bent, broken or damaged parts.
Get new parts in their place.
(2) Check all wood parts. Throw away any cracked, splintered or warped
parts. Get new parts in their place.
17-44
TM 9-2320-211-20-3-2
g.
Assembly of Seat Assembly.
FRAME 1
1.
2.
3.
4.
5.
6.
GO
Put seven square neck screws (1) through holes in board (2) from top side
of board as shown. Using mallet, tap screws in so heads are flush with
board.
Put angle iron (3) on one screw (1) and put six channels (4) on other six
screws.
Using 1/2-inch wrench, screw on and tighten seven nuts (5).
Do step 1 again for board (6).
Put board (6) in place so six screws go through bottom holes in channels (4)
and one screw goes through bottom hole in angle iron (3).
Put six hinges (7) in place as shown. Using 1/2-inch wrench, screw on and
tighten seven nuts (8).
TO FRAME 2
17-45
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
GO
17-46
Find top part of inside boards (1). Using mallet, tap 12 square neck
screws (2) through holes in each inside board so screw heads are flush with
board.
Put square neck screws (2) through holes in channels (3) and angle iron (4)
as shown. Screw on and finger tighten nuts (5) on square neck screws. If
screws do not come through enough to screw on nuts, using mallet, hammer
screws in.
Push screw (6) through hole in channel (3) as shown.
Screw on and finger tighten nut (7). Using 1/2-inch wrench, tighten 27
nuts (5 and 7).
TO FRAME 3
TM 9-2320-211-20-3-2
FRAME 3
1.
Put legs (1) on six channels (2), lining up screw holes for machine screw (3).
Put machine screw through holes in channels and legs and using 9/16-inch
wrench, hold it.
2. Using 9/16-inch wrench, screw on six self-locking nuts (4). Make sure they
are just snug and do not keep legs (1) from moving easily.
END OF TASK
17-47
TM 9-2320-211-20-3-2
h.
Assembly of Rack Assembly.
FRAME 1
1.
2.
3.
4.
GO
17-48
Find front of board (1). Put ten square neck screws (2) through holes in
board so screw heads are on front side.
Put square neck screws (2) through end bow pocket assemblies (3) and bow
pocket assemblies (4). Using 1/2-inch wrench, screw on and tighten nuts (5)
on square neck screws. If screws do not come through enough to screw on
nuts, then using mallet, hammer screws in.
Find front of board (6). Put ten square neck screws (7) through holes in
board so screw heads are on front side.
Put square neck screws (7) through end bow pocket assemblies (3) and bow
pocket assemblies (4). Using 1/2-inch wrench, screw on and tighten nuts (8)
on square neck screws. If screws do not come through enough to screw on
nuts, then using mallet, hammer screws in.
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME 2
Put screw (1) washer (2) and clamp (3) together as shown. Put screw, washer
and clamp through hole in board (4).
2. Using 1/2–inch wrench and screwdriver, screw on and tighten nut (5).
3. Do steps 1 and 2 again on other end of board (4).
END OF TASK
1.
17-49
TM 9-2320-211-20-3-2
Assembly of Rack and Seat Assembly.
i.
FRAME 1
1.
2.
Put seat assembly (1) into rack assembly (2) so hinge parts (3) join together.
Put clevis pin (4) through hinge parts (3) in six places. Put cotter pin (5)
through hole in pin. Using pliers, bend open ends of cotter pin.
NOTE
Follow-on Maintenance Action Required:
Replace rack and seat assembly in truck.
Refer to TM 9-2320-211-10.
END OF TASK
17-50
TM 9-2320-211-20-3-2
CHAPTER 18
WINCH, HOIST, AND CRANE ASSEMBLIES GROUP MAINTENANCE
Section I. SCOPE
18-1. EQUIPMENT ITEMS COVERED. This chapter gives equipment maintenance
procedures for winch, hoist, and crane assemblies for which there are authorized
corrective maintenance tasks at the organizational maintenance level.
18-2. EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective
maintenance is authorized at the organizational maintenance level are covered in this
chapter.
Section II.
WINCH, HOIST, AND CRANE ASSEMBLIES
18-3. FRONT WINCH AND REAR WINCH BRAKE TESTS AND ADJUSTMENTS.
NOTE
This task is the same for the front winch and
rear winch on all trucks. This task is shown
for the front winch. There is no drag brake
adjustment for rear winch.
TOOLS :
9/16-inch wrench
Offset screwdriver
Leather gloves
SUPPLIES :
PERSONNEL :
None
Three
EQUIPMENT CONDITION :
a.
Preliminary Procedure.
Truck parked, engine off, handbrake set.
Release drum lock knob.
Refer to TM 9-2320-211-10.
18-1
TM 9-2320-211-20-3-2
b.
FRAME
Drag Brake Test and Adjustment.
(1) Test.
1
WARNING
Always wear protective gloves when handling winch
cable. Do not let winch cable slip through hands.
Rusty or broken wires can cause serious injury.
1. Grab winch cable (1) and pull out about six feet of cable, then let go of
cable quickly. If drum (2) keeps turning, do drag brake adjustment,
para 18-3 (2). If drum (2) stops turning when cable (1) is let go, adjustment is correct.
END OF TASK
18-2
TM 9-2320-211-20-3-2
(2) Adjustment.
FRAME 1
1. Using offset screwdriver, screw in adjusting screw (1) 1/2 turn.
2. Do test again. Refer to para 18-3b (1).
END OF TASK
18-3
TM 9-2320-211-20-3-2
c.
Automatic Brake Test and Adjustment.
FRAME 1
Soldier A 1.
Park truck (1) with winch to be tested at top of steep grade as
shown. Refer to TM 9-2320-211-10. Sit in cab with engine
running throughout this task.
GO TO FRAME 2
18-4
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
5.
6.
GO
Pull handbrake (1) up to brake on position.
Press clutch pedal (2) all the way down.
Place FRONT TRANSMISSION gearshift lever (3) in N (neutral) position.
Let clutch pedal (2) up.
Turn front winch cover lever hinge lock (4) to unlock position.
Keep front WINCH CONTROL lever (5) in upper N (neutral) position.
TO FRAME 3
18-5
TM 9-2320-211-20-3-2
FRAME 3
Soldier B 1. Pull out front drum lock knob (1). Turn it 1/4 turn and let it
go into unlocked position.
GO TO FRAME 4
18-6
TM 9-2320-211-20-3-2
FRAME 4
Soldier C
1.
2.
Park second truck (1) at bottom of steep grade in a direct line
with winch (2) on first truck (3) as shown. Refer to
TM 9-2320-211-10.
Sit in cab with engine running during this task.
WARNING
Always wear protective gloves when handling winch
cable. Do not let winch cable slip through hands. Rusty
or broken wires can cause serious injury.
CAUTION
Do not operate winch with less than four turns of cable
on drum. End of cable may pull free of drum.
NOTE
Do not kink winch cable.
Soldier B 3. Pull winch cable (4) from winch (2) to reach second truck (1).
4. Hook winch cable (4) on second truck (1).
GO TO FRAME 5
18-7
TM 9-2320-211-20-3-2
FRAME 5
Move front winch drum clutch lever (1) on upper truck as far
as it will go from drum (2) (engage position). Stand clear
of trucks and cable (3).
GO TO FRAME 6
Soldier B 1.
18-8
TM 9-2320-211-20-3-2
FRAME 6
Soldier C
1.
Soldier A
2.
Sit in cab of lower truck, ready to step on brake pedal (1) to
stop truck if it starts to roll down grade. Tell soldier A when
ready.
Sitting in cab of upper truck with engine running, leave FRONT
TRANSMISSION gearshift lever (2) in N (neutral) position.
WARNING
Always use hand THROTTLE (3) to control engine speed
when operating winch. Avoid sudden changes in speed
or high speed. Rough, jerky operation may cause broken
shear pins and snapped cables, damage to truck or injury
to personnel.
3. Press down on clutch pedal (4).
4. Move front WINCH CONTROL lever (5) to L (low) position.
GO TO FRAME 7
18-9
TM 9-2320-211-20-3-2
FRAME 7
Soldier A 1.
Sitting in cab of upper truck (1), let clutch pedal (2) come up
slowly.
2.
Wind in winch cable (3) to take up slack.
3.
Use hand THROTTLE (4) to control speed and continue smooth
operation. Pull lower truck (5) three-quarters of the way up
grade.
GO TO FRAME 8
18-10
TM 9-2320-211-20-3-2
FRAME 8
Soldier A 1.
Sitting in cab of upper truck (1), press clutch pedal (2) all
the way down.
2. Place front WINCH CONTROL lever (3) in upper N (neutral)
position.
3. Let up on clutch pedal (2) slowly.
IF TRUCK (4) ROLLS DOWN GRADE, GO TO FRAME 9.
IF TRUCK (4) DOES NOT ROLL DOWN GRADE, GO TO FRAME 10
18-11
TM 9-2320-211-20-3-2
FRAME 9
Push down brake pedal (1). Pull up handbrake (2) to brake on
position and let go of brake pedal. Tell soldier B when ready.
2. Using 9/16-inch wrench, turn screw (3) one-half turn to right.
NOTE
When correctly adjusted, the brake will become warm, but
should not be too hot to hold brake cover with hand.
3. Push handbrake (2) down to off position.
ROLLS DOWN GRADE, DO FRAME 9 AGAIN.
DOES NOT ROLL DOWN GRADE, GO TO FRAME 10
Soldier C 1.
Soldier B
Soldier C
IF TRUCK
IF TRUCK
18-12
TM 9-2320-211-20-3-2
FRAME 10
Soldier C
1.
Pull handbrake (1) to brake on position. Tell soldier A when
ready.
Soldier A 2. Press clutch pedal (2) all the way down.
3. Place front WINCH CONTROL lever (3) in R (reverse) position.
4. Let up clutch pedal (2) slowly until there is enough slack in
cable (4) to unhook it from truck (5).
5. Press clutch pedal (2) all the way down.
6. Place front WINCH CONTROL lever (3) in N (neutral) position.
7. Let up clutch pedal (2).
Soldier B 8. Unhook winch cable (4) from truck (5).
Soldier A 9. Rewind winch cable (4). Refer to TM 9-2320-211-10.
10. Disengage winch drum clutch lever. Refer to TM 9-2320-211-10.
NOTE
Follow-on Maintenance Action Required:
Lock drum lock knob. Refer to TM 9-2320-211-10.
END OF TASK
18-13
TM 9-2320-211-20-3-2
18-4. FRONT WINCH CABLE REMOVAL AND REPLACEMENT (ALL TRUCKS EXCEPT
M543A2).
WARNING
Always wear leather gloves when handling winch
cable. Never allow cable to run through hands.
Broken or rusty wires can cause painful injuries
to personnel.
TOOLS: 3/8-inch sockethead screw key (Allen wrench or equivalent)
Leather gloves
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Operate winch and unwind all cable from winch
drum. Refer to TM 9-2320-211-10.
b. Removal.
FRAME 1
Using allen wrench, unscrew and take out setscrew (1). Pull cable (2)
from hole in drum ( 3).
END OF TASK
1.
18-14
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
Put cable (1) through hole in drum (2). Cable should just come through drum.
Using allen wrench, screw in and tighten setscrew (3).
NOTE
Follow-on Maintenance Action Required:
Operate winch and wind cable onto drum. Refer to
TM 9-2320-211-10.
END OF TASK
18-15
TM 9-2320-211-20-3-2
18-5. FRONT AND REAR WINCH CABLE REMOVAL AND REPLACEMENT
(TRUCK M543A2).
WARNING
Always wear leather gloves when handling winch
cable. Never allow cable to run through hands.
Broken or rusty wires can cause painful injuries
to personnel.
3/8-inch sockethead screw key (Allen wrench or equivalent)
TOOLS:
Leather gloves
None
SUPPLIES:
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
Preliminary Procedure. Operate winch and unwind all cable from winch
a.
drum. Refer to TM 9-2320-211-10.
Removal.
b.
FRAME 1
1.
2.
3.
END
18-16
Using allen wrench, unscrew and take out setscrew (1).
Pull cable (2) from hole in drum (3).
Take cable out of swivel sheave (4) and cable tensioner (5).
OF TASK
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
Put end of cable (1) through cable tensioner (2), over swivel sheave (3),
and into hole in drum (4), until cable comes just through drum.
2.
Using allen wrench, screw in and tighten setscrew (5).
NOTE
Follow-on Maintenance Action Required:
Operate drum and wind cable onto drum. Refer to
TM 9-2320-211-10.
END OF TASK
18-17
TM 9-2320-211-20-3-2
18-6. FRONT WINCH TENSION SHEAVE ASSEMBLY REMOVAL AND
REPLACEMENT (TRUCK M543A2).
18-inch hinged handle
TOOLS: Hoisting equipment
Breaker bar
Chain sling
3/4-inch wrench (2)
Offset screwdriver
SUPPLIES: None
PERSONNEL: None
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
2.
3.
4.
5.
GO
18-18
Put chain sling and hoist onto front winch and roller assembly (1) as shown.
Using hoist, take slack out of chain and cable.
Take off propeller shaft front universal joint from yoke on winch driveshaft.
Refer to Part 1, para 10-11.
Using 3/4-inch wrenches, unscrew and take off three screws and lockwashers (2) and three nuts (3) on both sides of front winch and roller
assembly (1).
Using 3/4-inch wrenches, unscrew and take off three screws, lockwashers,
and flat washers (4) on both sides of front winch and roller assembly (1).
Using hoist, lift front winch and roller assembly (1) to clear front bumper
(5). Take off front winch and roller assembly (1).
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME 2
1.
Using 3/4-inch wrench, unscrew and take out two capscrews (1) with
washers (2).
2.
Do step 1 again on other side.
Take out tension sheave assembly (3).
3.
4.
Take out two shims (4).
END OF TASK
18-19
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1.
Put tension sheave assembly (1) on front of winch assembly (2).
Put in two shims (3).
2.
Using 3/4-inch wrench, screw in two capscrews (4) with washers (5).
3.
Do step 3 again on other side.
4.
GO TO FRAME 2
18-20
TM 9-2320-211-20-3-2
Using hoist, lift front winch and roller assembly (1) to clear front bumper
(2).
2.
Using 3/4-inch wrenches, screw in and tighten three screws, flat washers,
and lockwashers (3) on both sides of front winch and roller assembly (1).
3.
Using 3/4-inch wrenches, screw in and tighten three screws with flat
washers (4) and three locknuts (5) on both sides of front winch and
roller assembly (1).
4.
Put propeller shaft front universal joint on yoke on winch driveshaft.
Refer to Part 1, para 10-11.
5.
Take off chain sling and hoist. Move hoist away.
END OF TASK
1.
18-21
TM 9-2320-211-20-3-2
18-7. FRONT WINCH AND ROLLER ASSEMBLY REMOVAL, REPLACEMENT,
TEST, AND ADJUSTMENT.
TOOLS: Hoisting equipment
Chain sling
Offset screwdriver
3/4-inch wrench (2)
18-inch hinged handle breaker bar
3/4-inch socket
SUPPLIES: None
PERSONNEL: Three
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
Put chain sling hoist onto front winch and roller assembly (1) as shown.
Using hoist, take slack out of chain and cable.
2. Take off propeller shaft front universal joint from yoke on winch driveshaft.
Refer to Part 1, para 10-11.
3. Using 3/4-inch wrenches, unscrew and take off three screws and lockwashers
(2) and three nuts (3) on both sides of front winch and roller assembly (1).
4. Using 3/4-inch wrench, unscrew and take off three screws, lockwashers,
and flat washers (4) on both sides of front winch and roller assembly (1).
5. Using hoist, lift front winch and roller assembly (1) to clear front bumper
(5). Take off front winch and roller assembly.
END OF TASK
1.
18-22
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1.
Using hoist, lift front winch and roller assembly (1) to clear front bumper (2)
and lower it into place as shown, alining screw holes.
2. Using 3/4-inch wrench, screw in and tighten three screws, flat washers, and
lockwashers (3) on both sides of front winch and roller assembly (1).
3. Using 3/4-inch wrenches, screw in and tighten three screws with flat washers
(4) and three locknuts (5) on both sides of front winch and roller assembly (1).
4. Put propeller shaft front universal joint on yoke on winch drive shaft. Refer
to Part 1, para 10-11.
5. Take off chain sling and hoist. Move hoist away.
END OF TASK
18-23
TM 9-2320-211-20-3-2
c.
Test and Adjustment.
(1) Drag brake.
FRAME 1
1.
2.
3.
IF
IF
18-24
Set up for unwinding winch cable (1). Refer to TM 9-2320-211-10.
Pull winch cable (1) out five feet and quickly stop pulling.
Rewind winch cable (1). Refer to TM 9-2320-211-10.
WINCH DRUM TURNED AFTER PULLING STOPPED, GO TO FRAME 2.
WINCH DRUM STOPPED TURNING WHEN PULLING STOPPED, END OF TASK
TM 9-2320-211-20-3-2
FRAME 2
1.
Using offset screwdriver, turn drag brake adjusting screw (1) 1/8 turn in
direction of arrow.
GO BACK TO FRAME 1
18-25
TM 9-2320-211-20-3-2
(2) Automatic brake.
(a) Preliminary procedure. Drive truck with winch to be tested to top
of steep grade and park it facing grade. Refer to TM 9-2320-211-10.
(b) Test and adjustment.
FRAME 1
Soldier A 1.
2.
3.
4.
5.
6.
7.
GO TO FRAME
18-26
Pull up handbrake (1) to on position.
On wreckers, set electric brake:
(a) Press down on service foot brake (2).
(b) Press electric BRAKE LOCK button (3).
(c) Let up on service foot brake (2).
(d) Let up on electric BRAKE LOCK button (3).
Press clutch pedal (4) all the way down.
Place TRANSMISSION gearshift lever (5) in N (neutral) position.
Let up on clutch pedal (4).
Turn front winch control lever hinge lock (6) to unlock position.
Keep front WINCH CONTROL lever (7) in upper N position as
shown on data plate (8).
2
TM 9-2320-211-20-3-2
FRAME 2
Soldier B 1.
Pull front winch drum lock knob (1) out of deep slot, turn it
90°, and let it go into shallow slot (unlock position).
GO TO FRAME 3
18-27
TM 9-2320-211-20-3-2
FRAME 3
On trucks with level wind device:
(a) Pull front winch level wind lock knob (1) out of deep slot,
turn it 90°, and let it go into shallow slot (unlock position).
(b) Pull out front winch cable tension control lever latch (2),
turn it 90°, and let it go into shallow slot (unlock position).
(c) Move front winch cable tension control lever (3) all the way
to left side of truck to take tension off cable (4).
(d) Pull out front winch cable tension control lever latch (2),
turn it 90°, and let it go into deep slot. Move cable tension
control lever (3) until plunger slips into hole, locking lever
in off position.
GO TO FRAME 4
Soldier B 1.
18-28
TM 9-2320-211-20-3-2
FRAME 4
Soldier C
1.
Park truck (1) at bottom of steep grade in a direct line with winch
(2) as shown. Refer to TM 9-2320-211-10. Standing in cab
throughout this test and adjustment task, keep engine running.
WARNING
Always wear protective gloves when handling winch cable.
Do not let winch cable slip through hands. Rusty or
broken wires can cause serious injury.
CAUTION
Do not operate winch with less than four turns of cable
on drum.
NOTE
Do not kink winch cable.
Soldier B 2. Pull winch cable (3) from winch (2) to reach truck (1).
3. Put winch cable (3) onto truck (1) .
GO TO FRAME 5
18-29
TM 9-2320-211-20-3-2
FRAME 5
Move front winch drum clutch lever (1) all the way away from
drum (engage position). Stand clear of trucks and cable.
GO TO FRAME 6
Soldier B 1.
18-30
TM 9-2320-211-20-3-2
FRAME 6
Soldier C
1.
Soldier A
2.
Stand in cab to step on brake pedal (1) to stop truck if truck
starts to roll downgrade. Tell soldier A when ready.
With engine running, leave TRANSMISSION gearshift lever (2) in
N (neutral) position.
WARNING
Always use hand THROTTLE to control engine speed
when operating winch. Avoid sudden changes in speed
or high speed.
Rough, jerky operation may cause broken shear pins and
snapped cables, damage to vehicle or injury to personnel.
Soldier A 3. Press down on clutch pedal (3).
4. Move front WINCH CONTROL lever (4) to L (low) position.
GO TO FRAME 7
18-31
TM 9-2320-211-20-3-2
FRAME 7
Let clutch pedal (1) come up slowly.
Wind in winch cable to take up slack.
Use hand THROTTLE (2) to control speed and continue smooth
operation. Pull truck (3) three-quarters of the way up the grade.
GO TO FRAME 8
Soldier A 1.
2.
3.
18-32
TM 9-2320-211-20-3-2
FRAME 8
Soldier A 1.
2.
Step on and press clutch pedal (1) all the way down.
Place front WINCH CONTROL lever (2) in upper N (neutral)
position.
3. Slowly let up clutch pedal (1).
IF TRUCK (3) ROLLS DOWN GRADE, GO TO FRAME 9.
IF TRUCK (3) DOES NOT ROLL DOWN GRADE, GO TO FRAME 10
18-33
TM 9-2320-211-20-3-2
FRAME 9
Step on and pushdown brake pedal (1). Pull up handbrake (2)
to on position and let goof brake pedal. Tell soldier B when
ready.
Soldier B 2. Using 3/4-inch wrench, turn screw (3) one-half turn in direction
of arrow.
NOTE
When correctly adjusted, the brake will become warm but
should not be too hot to allow hand to be held on brake
cover.
Soldier C 3. Push handbrake (2) down to off position. If truck (4) rolls
down grade, do steps 1 through 3 again.
GO TO FRAME 10
Soldier C 1.
18-34
TM 9-2320-211-20-3-2
FRAME 10
Soldier C 1.
Soldier A 2.
3.
4.
5.
6.
7.
Soldier B 8.
Soldier A 9.
END OF TASK
Pull up handbrake (1) to on position. Tell soldier B when ready.
Step on and press clutch pedal (2) all the way down.
Place front WINCH CONTROL lever (3) in R (reverse) position.
Slowly let up clutch pedal (2) until there is enough slack in cable
to unhook it from truck (4).
Step on and press clutch pedal (2) all the way down.
Place front WINCH CONTROL lever (3) in N (neutral) position.
Let up clutch pedal (2).
Unhook winch cable (5) from truck (4).
Rewind winch cable (5). Refer to TM 9-2320-211-10.
18-35
TM 9-2320-211-20-3-2
18-8.
REAR WINCH DRIVE CHAIN REMOVAL, REPLACEMENT AND
ADJUSTMENT (TRUCK M543A2).
TOOLS: 3/4-inch box wrench
3/4-inch socket wrench
Pliers
6-inch steel ruler
3/4-inch torque wrench, 150 pound-feet capacity
SUPPLIES:
50-inch long cord
Shims (as needed)
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Set rear winch control lever to NEUTRAL position.
Refer to TM 9-2320-211-10.
b. Removal.
FRAME
1.
1
Using 3/4-inch box wrench, hold two nuts (1). Using 3/4-inch socket wrench,
unscrew two screws (2) three turns. Do not take off nuts.
2. Using 3/4-inch box wrench, unscrew two nuts (3) three turns. Do not take
off nuts.
GO TO FRAME 2
18-36
TM 9-2320-211-20-3-2
FRAME 2
Using pliers, take out and throw away two cotter pins (1). Take out link
(2). Take off chain (3).
END OF TASK
1.
18-37
TM 9-2320-211-20-3-2
c. Replacement.
FRAME 1
NOTE
If putting in new chain, do this frame. If putting back
chain that was taken off, start with frame 2.
1. Using pliers, take out two cotter pins (1). Take out link (2).
GO TO FRAME 2
18-38
TM 9-2320-211-20-3-2
FRAME 2
Put chain (1) on drive sprocket (2) and driven sprocket (3).
Put link (4) in place. Put two cotter pins (5) through holes in link. Using
pliers, bend open ends of cotter pins.
GO TO FRAME 3
1.
2.
18-39
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
Using 3/4-inch box wrench, hold two nuts (1). Using 3/4-inch torque
wrench, screw in and tighten two screws (2) to 50 pound-feet.
Using 3/4-inch torque wrench, screw on and tighten two nuts (3) to 50
pound-feet.
NOTE
Follow-on Maintenance Action Required:
Adjust chain. Refer to para 18-8c.
END OF TASK
18-40
TM 9-2320-211-20-3-2
c.
Adjustment.
FRAME 1
Put cord (1) over chain (2) and around drive sprocket (3) and driven
sprocket (4). Hold both ends of cord in same hand and pull to make cord
tight.
2. Using 6-inch ruler, measure distance between cord (1) and top of chain (2)
at middle of chain. Distance should be 7/16 to 9/16 inch. Take off cord.
IF ADJUSTMENT IS NOT WITHIN GIVEN LIMITS, GO TO FRAME 2.
IF ADJUSTMENT IS WITHIN GIVEN LIMITS, END OF TASK
1.
18-41
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
GO
18-42
NOTE
There are three different thicknesses of shims. Use the
sizes needed.
Using 3/4-inch box wrench, hold two nuts (1). Using 3/4-inch socket wrench,
unscrew and take out two screws (2). Take off two nuts.
Holding bearing housing (3) and using 3/4-inch socket wrench, unscrew and
take off two nuts (4). Move bearing housing with shims (5) away enough to
put on or take off shims (5).
If chain is too tight, add shims (5). If chain is too loose, take out shims.
TO FRAME 3
TM 9-2320-211-20-3-2
FRAME 3
Using 3/4-inch socket wrench, screw on, but do not tighten, two nuts (1).
Bearing housing (2) must be free to aline holes for two screws (3).
2. Using 3/4-inch box wrench, hold two nuts (4). Using 3/4-inch torque wrench,
tighten two screws (3) to 50 pound-feet.
3. Using 3/4-inch torque wrench, tighten two nuts (1) to 50 pound-feet.
GO TO FRAME 1
1.
18-43
TM 9-2320-211-20-3-2
18-9.
REAR WINCH CABLE TENSIONER ASSEMBLY CHECKOUT AND
ADJUSTMENT (TRUCK M543A2).
3/4-inch wrench
TOOLS:
11/16-inch wrench
Pliers
5/8-inch diameter rod
SUPPLIES:
13/16-inch diameter rod
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedures.
(1) Remove winch cable from winch. Refer to para 18-5.
(2) Start engine and run it to build up normal operating air pressure in
compressed air system. Refer to TM 9-2320-211-10.
18-44
TM 9-2320-211-20-3-2
b.
Checkout.
FRAME 1
1.
2.
Move cable tensioner control valve lever (1) to ON position.
Put 5/8-inch diameter rod between two tensioner sheaves (2). Rod should
fit snugly. Take out rod.
Move cable tensioner control valve lever (1) to OFF position.
3.
4. Put 13/16-inch diameter rod between tensioner sheaves (2). Rod should
fit easily. Take out rod.
5.
If rods did not fit properly in steps 2 and 4, adjust cable tensioner
assembly. Refer to para 18-9c.
NOTE
Follow-on Maintenance Action Required:
1. Stop engine. Refer to TM 9-2320-211-10.
2. Replace winch cable. Refer to para 18-5.
END OF TASK
18-45
TM 9-2320-211-20-3-2
c. Adjustment.
FRAME 1
1.
2.
Using 3/4-inch wrench, loosen nut (1).
Using pliers, take out and throw away cotter pin (2). Push out clevis pin
(3).
3.
Using 11/16-inch wrench, unscrew and take off two nuts with washers (4).
Pull tensioner brake chamber (5) back to turn yoke (6).
4.
If tensioner sheaves are too tight, turn yoke (6) toward nut (1). If
tensioner sheaves are too loose, turn yoke away from nut.
5.
Put tensioner brake chamber (5) in place on bracket (7). Aline holes in
yoke (6) with hole in lever (8). Put in clevis pin (3).
6.
Using pliers, put in and bend open ends of new cotter pin (2).
7.
Using 11/16-inch wrench, screw on and tighten two nuts with washers (4).
8.
Using 3/4-inch wrench, tighten nut (1) against yoke (6).
Do checkout procedure again. Refer to para 18-9b.
9.
END OF TASK
18-46
TM 9-2320-211-20-3-2
18-10.
REAR WINCH PROPELLER SHAFT PILLOW BLOCK REMOVAL AND
REPLACEMENT.
3/4-inch wrench (2)
TOOLS:
5/32-inch sockethead screw key (Allen wrench or equivalent)
2-inch extension
None
SUPPLIES:
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
Preliminary Procedures.
a.
(1) Remove rear propeller shaft slip yoke. Refer to Part 1, para 10-12.
(2) Remove front floor plate. Refer to Part 1, para 10-11.
Removal.
b.
FRAME 1
1.
2.
3.
4.
END
Using 3/4-inch wrenches, unscrew and take out capscrew (1).
Take out two spacers (2).
Using 5/32-inch allen wrench, unscrew setscrew (3).
Slide pillow block (4) off propeller shaft (5).
OF TASK
18-47
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
2.
3.
4.
Slide pillow block assembly (1) onto propeller shaft (2).
Using 5/32-inch allen wrench, screw in setscrew (3).
Put in two spacers (4).
Using 3/4-inch wrenches, screw in two capscrews (5).
1.
2.
END OF TASK
18-48
Follow-on
Replace rear
Part 1, para
Replace front
NOTE
Maintenance Action Required:
propeller shaft slip yoke. Refer to
10-12.
floor plate. Refer to Part 1, para 10-11.
TM 9-2320-211-20-3-2
18-11.
REAR WINCH TO POWER DIVIDER CONTROLS AND LINKAGE
ADJUSTMENT (TRUCK M543A2).
TOOLS:
3/4-inch open end wrench
Pliers
SUPPLIES: None
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set, wheels
chocked.
Soldier A 1.
Soldier B 2.
Soldier A 3.
GO TO FRAME 2
Take out lockpin (1). Move control lever (2) back and forth.
Working under truck, find moving control rod (3). Tell
soldier A when ready.
Put control lever (2) in NEUTRAL position. Put in lockpin (1).
18-49
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
GO
18-50
Working on control rod (1) and using pliers, take out and throw away
cotter pin (2). Take out clevis pin (3).
Take control rod (1) off shifter shaft (4). Using wrench, loosen nut (5).
Push shifter shaft (4) into power divider (6) as far as it will go.
Pull shifter shaft (4) out of power divider (6) until you feel its first stop.
TO FRAME 3
TM 9-2320-211-20-3-2
FRAME 3
1.
Check alinement of holes for clevis pin (1). Screw control rod (2) in or
out as needed to aline holes for clevis pin. Note number of turns.
NOTE
There must be three or more threads on control rod (2)
screwed into clevis (3).
2.
If control rod was unscrewed in step 1, unscrew it four more turns to
check it. Screw control rod back in four turns. Aline holes for clevis
pin (1).
IF HOLES ARE NOT ALINED, GO TO FRAME 4.
IF HOLES ARE ALINED, GO TO FRAME 5
18-51
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
3.
4.
5.
GO
18-52
Using wrench, loosen nut (1).
Using pliers, take out and throw away cotter pin (2). Take out clevis
pin (3). Take clevis (4) off control lever (5).
Screw clevis (4) onto control rod (6) the number of turns noted in frame 3.
Put clevis (4) onto control lever (5), alining hole for clevis pin (3). Put
clevis pin in place. Put new cotter pin (2) through hole in clevis pin and
using pliers, bend open ends of cotter pin.
Using wrench, tighten nut (1) against clevis (4).
TO FRAME 5
TM 9-2320-211-20-3-2
FRAME 5
1.
Put clevis (1) in place on shifter shaft (2). Put clevis pin (3) through
clevis. Put cotter pin (4) through hole in clevis pin and using pliers,
bend open ends of cotter pin.
2.
Using wrench, tighten nut (5) against clevis (6).
NOTE
Follow-on Maintenance Action Required:
Check rear winch operation. Refer to TM 9-2320-211-10.
END OF TASK
18-53
TM 9-2320-211-20-3-2
REAR WINCH ASSEMBLY REMOVAL AND REPLACEMENT (TRUCK M543A2).
18-12.
1 x 11-inch brass tip drift pin
1 1/2-inch socket wrench
TOOLS:
punch
1 1/2-inch wrench
Medium ballpeen hammer
1 5/16-inch wrench (2)
9/16-inch wrench
Hoist, 2 ton capacity
7/16-inch wrench
Pliers
Mallet
Torque wrench, 600-poundfeet capacity
SUPPLIES: Length of wood, 2 x 4 x 36 inches
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
Preliminary Procedures.
a.
(1) Remove drive chain. Refer to para 18-8.
(2) Remove driven sprocket shear pin. Refer to para TM 9-2320-211-10.
(3) Tell direct support to remove driven sprocket.
(4) Swing boom to side. Refer to TM 9-2320-211-10.
18-54
TM 9-2320-211-20-3-2
b.
Removal.
FRAME 1
1.
Using pliers, take out, and throw away cotter pin (1). Take out yoke pin
(2). Move yoke (3) away from adjusting frame lever (4).
GO TO FRAME 2
18-55
TM 9-2320-211-20-3-2
FRAME 2
WARNING
Always wear leather gloves when handling winch cable.
Never allow cable to run through hands. Broken or
rusty wires can cause serious injury to personnel.
1.
Using 1 5/16-inch wrenches, unscrew and take off nut (1). Take out
screw (2) and take off chain and hook assembly (3).
GO TO FRAME 3
18-56
TM 9-2320-211-20-3-2
FRAME 3
1.
Using 7/16-inch wrench, unscrew and take out grease fitting (1) on each
end of shaft (2).
2.
Using 9/16-inch wrench, unscrew and take out two screws (3) and lockwashers (4).
3.
Take off key (5).
GO TO FRAME 4
18-57
TM 9-2320-211-20-3-2
FRAME 4
WARNING
Always wear leather gloves when handling winch cable.
Never allow cable to run through hands. Rusty or
broken wires can cause serious injury to personnel.
Using length of wood as lever, pry up roller (1) to keep shaft
Soldier A 1.
(2) alined with holes in brackets (3).
Using drift pin punch and hammer on right side of roller (1),
Soldier B 2.
drive out shaft (2) as far as it will go. Pull shaft the rest
of the way out.
Using length of wood, pry up roller (1) enough for clevis (4)
Soldier A 3.
to pass under roller.
Push clevis (4) and end of winch cable (5) under roller (1)
Soldier B 4.
into winch housing (6).
Soldier A 5.
Using length of wood, lower roller (1) into place and aline
shaft (2) with holes in roller and brackets (3).
Using mallet, lightly drive shaft (2) into brackets (3) and
Soldier B 6.
roller (1).
Take out length of wood.
Soldier A 7.
GO TO FRAME 5
18-58
TM 9-2320-211-20-3-2
FRAME 5
WARNING
Rear winch assembly (1) is heavy. Rig hoist chain on
rear winch assembly so that it does not slide. Sliding of
rear winch assembly could cause serious injury to personnel
and damage to equipment.
1.
Put hoist chain on rear winch assembly (1) as shown. Using
hoist, take slack out of hoist chain.
Soldier A
2.
Using 1 1/2-inch wrench, hold four nuts with lockwashers (2),
two on each side of rear winch assembly (1). Tell soldier B
when ready.
Soldier B
3.
Working under truck using 1 1/2-inch wrench, unscrew and
take out four screws (3).
Soldier A
4.
Take off four nuts with lockwashers (2).
5. Using hoist, lift rear winch assembly (1) off truck.
END OF TASK
18-59
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
WARNING
Rear winch assembly (1) is heavy. Rig hoist chain on rear
winch assembly so that it does not slide. Sliding of rear
winch assembly could cause serious injury to personnel and
damage to equipment.
1.
Using hoist as shown, lift rear winch assembly (1) into place
and aline four mounting screw holes.
Soldier A
2.
Working under truck, put in four screws (2), two on each side
of rear winch assembly (1) as shown.
Soldier B
3.
Place four nuts and lockwashers (3) on four screws (2).
Using 1 1/2-inch wrench, hold four nuts and lockwashers (3).
Tell soldier A when ready.
Soldier A
4.
Using 1 1/2-inch socket wrench with torque wrench, tighten
four screws (2) to 200 to 235 pound-feet.
5.
Take hoist chains off rear winch assembly (1). Take away
hoist.
GO TO FRAME 2
18-60
TM 9-2320-211-20-3-2
FRAME 2
WARNING
Soldier
Soldier
Soldier
Soldier
Soldier
Soldier
Soldier
GO TO
Always wear leather gloves when handling winch cable.
Never allow cable to run through hands. Rusty or broken
wires can cause serious injury to personnel.
1.
Using length of wood as lever, pry up roller (1) to keep shaft
A
(2) alined with holes in brackets (3).
Using drift pin punch and hammer on right side of roller (1),
2.
B
drive out shaft (2) as far as it will go. Pull shaft the rest
of the way out.
Using length of wood, pry up roller (1) enough for clevis (4)
A
3.
to pass under roller.
4.
Push clevis (4) and end of winch cable (5) out from winch
B
housing (6) and under roller (1) as shown.
5.
A
Using length of wood, lower roller (1) into place and aline
shaft (2) with holes in roller and brackets (3).
6.
Using mallet, lightly drive shaft (2) into brackets (3) and
B
roller (1).
7.
Take out length of wood.
A
FRAME 3
18-61
TM 9-2320-211-20-3-2
FRAME 3
Using pipe wrench, turn shaft (1) so keyway (2) is as shown.
Place key (3) in keyway (2), alining holes in key with holes in bracket (4).
Using 9/16-inch wrench, screw in and tighten two screws (5) and lockwashers (6).
4.
Using 7/16-inch wrench, screw in and tighten two grease fittings (7).
GO TO FRAME 4
1.
2.
3.
18-62
TM 9-2320-211-20-3-2
FRAME 4
WARNING
Always wear leather gloves when handling winch cable.
Never allow cable to run through hands. Rusty or
broken wires can cause serious injury to personnel.
1.
Put chain link (1) into clevis (2) and put screw (3) in place.
2.
Using 1 5/16-inch wrenches, screw on and tighten nut (4).
GO TO FRAME 5
18-63
TM 9-2320-211-20-3-2
FRAME 5
1.
2.
3.
Put yoke (1) in place on adjusting frame lever (2) and aline holes.
Put in yoke pin (3).
Using pliers, put in and bend open ends of cotter pin (4).
NOTE
Follow-on Maintenance Action Required:
1. Replace drive chain. Refer to para 18-8.
2. Tell direct support to replace driven sprocket.
3. Replace driven sprocket shear pin. Refer to
TM 9-2320-211-10.
4. Swing boom to travel position. Refer to
TM 9-2320-211-10.
END OF TASK
18-64
TM 9-2320-211-20-3-2
DUMP TRUCK BODY HOIST PUMP ASSEMBLY REMOVAL AND
REPLACEMENT.
3/8-inch wrench
TOOLS:
3/4-inch wrench
Hydraulic pump gasket
SUPPLIES:
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, dump body in raised position, safety
braces locked, engine off, handbrake set.
a. Preliminary Procedure. Drain hydraulic reservoir. Refer to
LO 9-2320-211-12.
Removal.
b.
18-13.
Soldier A 1.
2.
Soldier B 3.
Soldier A 4.
Soldier B 5.
Using 3/8-inch wrench , unscrew and take out universal joint
yoke screw (1).
Slide universal joint yoke (2) off pump shaft (3).
Hold hydraulic pump (4).
Using 3/4-inch wrench, unscrew and take off six screws (5) and
lockwashers (6).
Take out hydraulic pump (4) with gasket (7). Throw gasket
away.
END OF TASK
18-65
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
Put pump gasket (1) in place as shown and hold hydraulic
pump (2) in place.
Using 3/4-inch wrench, screw in and tighten six screws (3) and
Soldier B 2.
lockwashers (4).
3.
Put universal joint yoke (5) on pump shaft (6) as shown.
4.
Using 3/8-inch wrench, screw in and tighten universal joint
yoke screw (7).
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic reservoir. Refer to LO 9-2320-211-12.
END OF TASK
Soldier A 1.
18-66
TM 9-2320-211-20-3-2
18-14. CONTROL VALVE ASSEMBLY REMOVAL AND REPLACEMENT (TRUCK M51A2).
TOOLS:
9/16-inch wrench (2)
1 1/4-inch open end wrench
1 3/8-inch open end wrench
SUPPLIES: Control valve assembly gasket (2)
Control valve adapter gasket
Caps
Tags
PERSONNEL: Two
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
WARNING
Never work under a raised dump body unless
safety hoist braces are in position. Dump body
could drop down, causing death or injury to
personnel working under it.
FRAME 1
1.
2.
Start engine and raise dump body (1). Refer to TM 9-2320-211-10.
Swing two hoist braces (2), one on each side, into upright position under
dump body (1).
3. Lower dump body (1) onto hoist braces (2) and stop engine. Refer to
TM 9-2320-211-10.
4. Remove hydraulic pump. Refer to para 18-13.
GO TO FRAME 2
18-67
TM 9-2320-211-20-3-2
FRAME 2
Soldier A
1.
2.
Soldier B
3.
4.
5.
GO TO FRAME
Soldier A
18-68
Working under truck using 9/16-inch wrench, unscrew and take
out four screws (1) with lockwashers (2).
Hold control valve adapter (3) while soldier B takes out four
screws (4).
Working on top, using 9/16-inch wrench, unscrew and take out
four screws (4) with lockwashers (5).
Take out control valve adapter (3).
Take off and throw away gasket (6).
3
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
Using 9/16-inch wrenches, unscrew and take off nut (1) and lockwasher (2).
Working under truck, pull out screw (3) and take right control valve lever
(4) off trunnion (5).
GO TO FRAME 4
18-69
TM 9-2320-211-20-3-2
FRAME 4
CAUTION
Soldier
Soldier
Soldier
END OF
18-70
Cap all open hoses and fittings to keep dirt out of hydraulic system.
NOTE
Tag all hoses and fittings before taking them off so
they are put back in the same place.
A 1. Using 1 3/8-inch wrench, hold four hose nuts (1). Using
1 1/4-inch wrench, unscrew four fittings (2) and take off four
hoses (3).
2. Hold control valve assembly (4) while soldier B takes out seven
screws (5).
B 3. Using 9/16-inch wrench, unscrew and take out seven screws (5)
with lockwashers (6).
A 4. Slide out control valve assembly (4) to right.
5. Take off and throw away two gaskets (7).
6. Take off control valve lever (8).
TASK
TM 9-2320-211-20-3-2
b.
Replacement.
WARNING
Never work under a raised dump body unless
safety hoist braces are in position. Dump body
could drop down, causing death or injury to
personnel working under it.
FRAME 1
Put gasket (1) on each side of control valve assembly (2).
Hold control valve assembly (2) in place, alining holes in control
valve assembly with holes in mounting bracket (3).
Soldier B 3. Push seven screws (4) with lockwashers (5) through holes in control valve assembly (2).
4. Put left control valve lever (6) on trunnion (7).
5. Using 9/16-inch wrench, screw in and tighten seven screws (4).
NOTE
Take caps off hoses and fittings before putting them
together.
Soldier A 6. Using 1 3/8-inch wrench hold four hose nuts (8). Using
1 1/4-inch wrench, screw on and tighten four hose fittings (9)
as tagged. Take off tags.
GO TO FRAME 2
Soldier A 1.
2.
18-71
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Working under truck, place right control valve lever (1) around trunnion (2).
Push screw (3) through control valve levers (1) and put lockwasher (4) on
screw.
3. Using 9/16-inch wrenches, screw on and tighten nut (5).
GO TO FRAME 3
18-72
TM 9-2320-211-20-3-2
FRAME 3
Soldier A
1.
Working under truck, place gasket (1) on control valve adapter
(2).
2. Hold control valve adapter (2) in place and aline holes in adapter
with holes in control valve assembly (3).
NOTE
Screws (4) are different lengths. Be sure to put screws
in proper place.
Soldier B 3. Working on top, push four screws (4) with lockwashers (5)
through holes in control valve adapter (2).
4. Using 9/16-inch wrench, screw in and tighten four screws (4).
Soldier A 5. Push four screws (6) with lockwashers (7) through holes in
control valve adapter (2).
6. Using 9/16-inch wrench, screw in and tighten four screws (6).
GO TO FRAME 4
18-73
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
Replace hydraulic pump. Refer to para 18-13.
Start engine and raise dump body (1) far enough to free two hoist braces (2).
Refer to TM 9-2320-211-10.
3. Swing two hoist braces (2), one on each side, down to stowed position.
4. Lower dump body (1) and stop engine. Refer to TM 9-2320-211-10.
NOTE
Follow-on Maintenance Action Required:
Check hydraulic system for leakage.
END OF TASK
18-74
TM 9-2320-211-20-3-2
18-15. DUMP BODY HYDRAULIC LINES REMOVAL AND REPLACEMENT
(TRUCK M51A2).
TOOLS:
1 5/16-inch wrench
1 3/8-inch wrench
Tags
SUPPLIES:
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Drain hydraulic system. Refer to
LO 9-2320-211-12.
b.
Removal.
FRAME 1
NOTE
Tag lines before taking them off so that they will be
put back in the same place.
1. Using 1 5/16-inch wrench, unscrew and take out four lines (1) at manifold
(2).
2. Using 1 3/8-inch wrench, unscrew four nuts (3). Take out four hydraulic
lines (4).
END OF TASK
18-75
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
CAUTION
Do not overtighten line fittings. Overtightened fittings
will break and leak.
Using 1 3/8-inch wrench, screw four lines (1) into four fittings (2) as
1.
tagged. Take off tags.
2.
Using 1 5/16-inch wrench, screw four lines (3) into manifolds (4) as
tagged. Take off tags.
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic system. Refer to LO 9-2320-211-12.
END OF TASK
18-76
TM 9-2320-211-20-3-2
18-16.
DUMP BODY HOIST BRACE LOCKING AND UNLOCKING (TRUCK M51A2).
TOOLS:
None
None
SUPPLIES:
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
Locking.
a.
FRAME 1
1.
2.
Start engine and raise dump body (1). Refer to TM 9-2320-211-10.
Swing two hoist braces (2), one on each side, into upright position under
dump body (1).
3.
Lower dump body (1) onto hoist braces (2), and stop engine. Refer to
TM 9-2320-211-10.
END OF TASK
18-77
TM 9-2320-211-20-3-2
b.
1.
Unlocking.
Start engine and raise dump body (1) enough to free two hoist braces (2).
Refer to TM 9-2320-211-10.
2.
Swing two hoist braces (2), one on each side, down to stowed position.
Lower dump body (1) and stop engine. Refer to TM 9-2320-211-10.
3.
END OF TASK
18-78
TM 9-2320-211-20-3-2
HOIST CONTROL LINKAGE CHECK AND ADJUSTMENT (TRUCK M51A2).
18-17.
6-inch pliers
TOOLS:
Hammer
3/4-inch wrench
3/8-inch punch
SUPPLIES: None
PERSONNEL: TWO
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
Check.
a.
(1)
Start engine and raise and lower dump body. Refer to
TM 9-2320-211-10.
If dump body works correctly, stop engine. Refer to
(2)
TM 9-2320-211-10.
If dump body does not work correctly, stop engine. Refer to
(3)
TM 9-2320-211-10. Do adjustment. Refer to para 18-17b.
18-79
TM 9-2320-211-20-3-2
b.
Adjustment.
(1) Clevis adjustment.
FRAME 1
NOTE
Turn clevis (1) to the right to shorten control rod
assembly (2). Turn clevis to the left to lengthen
control rod assembly.
1. Using pliers and 3/4-inch wrench, hold clevis (1) and turn nut (3) to right to
loosen it.
2. Using pliers, take out cotter pin (4) and pull out clevis pin (5). Throw away
cotter pin.
3. Turn clevis (1) to right or left to adjust length of control rod assembly (2).
4. Aline holes in clevis (1) with hole in lever (6) and put in clevis pin (5).
5. Using 3/4-inch wrench, turn nut (3) to left to tighten it.
6. Using pliers, put in new cotter pin (4) and bend open ends of cotter pin.
END OF TASK
18-80
TM 9-2320-211-20-3-2
(2)
Hand lever rod and transfer motion rod adjustment.
FRAME 1
Soldier A
1.
Soldier B
2.
Soldier A
3.
4.
5.
6.
7.
Soldier B
Soldier A
8.
9.
Using pliers, take out cotter pin (1) and clevis pin (2) on
power takeoff relay lever (3). Throw away cotter pin. Tell
soldier B when ready.
Unlock dump control hand lever lock (4) and put dump control
hand lever (5) in RAISE position.
Using pliers, take out cotter pin (6) and clevis pin (7). Throw
away cotter pin. Push relay lever (8) towards back of truck
as far as it can go.
Check that clevis pin holes in clevis (9) aline with clevis pin
hole in relay lever (8). If holes are alined, do step 6.
If holes are not alined, do clevis adjustment for clevises (9)
and (10). Refer to para 18-17b (1). Then do step 7.
Put clevis pin (7) through clevis (9) and relay lever (8).
Using pliers, put in cotter pin (6) and bend open ends of cotter
pin. Tell soldier B when ready.
Put clevis pin (2) through clevis (11) and power takeoff relay
lever (3). Put in new cotter pin (1) and bend open ends of
cotter pin.
Put dump control hand lever (5) in LOWER position.
Check that relay lever (8) moves toward front of truck without
binding.
END OF TASK
18-81
TM 9-2320-211-20-3-2
Power takeoff dump control rod and power takeoff connecting rod
(3)
shaft adjustment.
FRAME 1
Soldier B
1.
Soldier A
2.
3.
4.
5.
6.
Soldier B
7.
8.
9.
END OF TASK
Soldier A
18-82
Put dump control hand lever (1) in RAISE position and step
down on clutch pedal (2).
Using pliers, take out cotter pin (3) and pull out clevis pin
(4).
Pull power takeoff dump control rod (5) towards back of truck
as far as it will go.
Check that clevis pin holes in clevis (6) aline with hole in
power takeoff relay lever (7). If holes are alined, do step 6.
If holes are not alined, do clevis adjustment for clevises (6 and 8).
Refer to para 18-17b. Then do step 6.
Put clevis pin (4) through clevis (6) and power takeoff relay
lever (7). Put in cotter pin (3) and bend open ends of cotter
pin.
Put dump control hand lever (1) in LOWER position and let go
of clutch pedal.
Check that all levers and rods move freely.
Do adjustment check again. Refer to para 18-17a.
TM 9-2320-211-20-3-2
18-18.
HYDRAULIC HOSES REMOVAL AND REPLACEMENT (TRUCK M543A2).
1 3/8-inch wrench
2-inch wrench
TOOLS:
1 1/2-inch wrench (2)
2 1/8-inch wrench
1 7/8-inch wrench
2 5/8-inch wrench
1 11/16-inch wrench (2)
2 7/8-inch wrench
1 3/4-inch wrench
1 9/16-inch wrench (2)
9/16-inch wrench
Pipe wrench
24-inch adjustable wrench (2)
1/2-inch wrench
None
SUPPLIES:
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
CAUTION
When putting in hoses and tubes, do not overtighten
nuts. Damage to hoses, tubes or adapters will
cause oil leaks.
Preliminary Procedure. Drain hydraulic reservoir. Refer to
a.
LO 9-2320-211-12.
18-83
TM 9-2320-211-20-3-2
b.
Lift Cylinder-to-Boom Support Crossover Tube Hoses.
(1) Removal.
NOTE
This task is for the right side hose. The task
for the left side hose is the same.
FRAME 1
Using 1 1/2-inch wrenches, unscrew union coupling nut (1) from hose (2)
and take out end of hose.
2.
Using 1 11/16-inch wrenches, unscrew other end of hose (2) from bushing
(3) and take off hose.
END OF TASK
1.
18-84
TM 9-2320-211-20-3-2
(2)
Replacement.
FRAME 1
Using 1 11/16-inch wrenches, screw in and tighten hose (1) into tee bushing (2).
2.
Using 1 1/2-inch wrenches, screw on and tighten coupling nut (3) to other
end of hose (1).
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic reservoir. Refer to LO 9-2320-211-12.
END OF TASK
1.
18-85
TM 9-2320-211-20-3-2
c.
Boom Support Crossover-to–Snubber Valve Hose.
(1)
Removal.
FRAME 1
Using 1 1/2-inch wrench, unscrew coupling nut (1).
Using 1 11/16-inch wrench, unscrew fitting (2) with hose (3). Take off
hose.
END OF TASK
1.
2.
18-86
TM 9-2320-211-20-3-2
(2) Replacement.
FRAME 1
1.
Using 1 11/16-inch wrench, screw in and tighten hose fitting (1) to snubber
valve assembly (2).
2. Using 1 1/2-inch and 1 11/16-inch wrenches, screw on and tighten coupling
nut (3) to hose fitting (4).
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic reservoir. Refer to LO 9-2320-211-12.
END OF TASK
18-87
TM 9-2320-211-20-3-2
d.
Valve Bank-to-Swing Motor Hoses.
(1) Removal.
NOTE
This task is the same for both hoses.
FRAME 1
1.
Using 1 1/2-inch and 1 9/16-inch wrenches, unscrew coupling nut (1) and take
out hose (2).
2. Using 9/16-inch wrench, unscrew and take off nut (3). Take clamp (4) off
stud (5).
GO TO FRAME 2
18-88
TM 9-2320-211-20-3-2
FRAME 2
1.
Using 1/2-inch wrench, unscrew and take out six screws (1). Take off
gondola cover plate (2).
2. Using 1 1/2-inch and 1 11/16-inch wrenches, unscrew coupling nut (3) and
take off hose (4).
GO TO FRAME 3
18-89
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
END
18-90
Using 9/16-inch wrench, unscrew and take off nut (1). Take off clamp (2).
Using 1 1/2-inch wrenches, unscrew fitting (3).
Take out valve bank-to-swing motor hose (4).
OF TASK
TM 9-2320-211-20-3-2
(2) Replacement.
NOTE
This task is the same for both hoses.
FRAME 1
1.
Using 1 1/2-inch wrenches, screw on and tighten coupling nut (1) to hose
(2).
2.
Place hose (3) up against block (4) and put clamp (5) over stud (6).
3.
Using 9/16-inch wrench, screw on but do not tighten nut (7).
GO TO FRAME 2
18-91
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
GO
18-92
Using 1 1/2-inch wrenches, screw on
elbow (2) to hose (3).
Line up holes in cover plate (4) with
Using 1/2-inch wrench, screw in and
Using 9/16-inch wrench, tighten nut
TO FRAME 3
and tighten coupling nut (1) at
holes in gondola (5).
tighten six screws (6).
(7).
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
4.
Place hose (1) up against block (2).
Put clamp (3) on stud (4).
Using 9/16-inch wrench, screw on and tighten nut (5).
Using 1 1/2-inch wrenches, screw on and tighten coupling nut (6) at
elbow (7).
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic reservoir. Refer to LO 9-2320-211-12.
END OF TASK
18-93
TM 9-2320-211-20-3-2
e.
Pump-to-Valve Bank Hose and Tube.
(1) Removal.
FRAME 1
1. Using 1 1/2-inch wrench, unscrew coupling nut (1) and take off hose (2).
GO TO FRAME 2
18-94
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Take off valve bank cover. Refer to para 18-22.
Using 1 1/2-inch and 1 11/16-inch wrenches, unscrew coupling nut (1)
from hose (2). Takeoff hose.
3. Using 1 1/2-inch wrench, unscrew coupling nut (3) and take off tube (4).
4. Push tube (4) down through hole in gondola panel (5). Take out tube (4)
and hose (2).
END OF TASK
18-95
TM 9-2320-211-20-3-2
(2) Replacement.
FRAME 1
Slide end of hose (1) through cutout in left side of support assembly (2)
and bottom hole in side of gondola (3).
2. Using 1 1/2-inch wrench, screw in and tighten coupling nut (4) on hose
assembly (5).
GO TO FRAME 2
1.
18-96
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Put tube (1) through hole in gondola panel (2).
Using 1 1/2-inch wrench, screw on and tighten coupling nut (3) on
connector (4).
3.
Using 1 1/2-inch wrench, screw in and tighten coupling nut (5) on
pump-to-valve bank hose (6) into other end of tube (1).
4.
Using 1 1/2-inch wrench, tighten coupling nuts (3 and 5).
5 . Replace valve bank cover. Refer to para 18-22.
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic reservoir. Refer to LO 9-2320-211-12.
END OF TASK
18-97
TM 9-2320-211-20-3-2
f.
Valve Bank-to-Hoist Motor Tubes.
(1) Removal.
NOTE
This task is the same for both tubes.
FRAME 1
1.
2.
3.
GO
18-98
Using 1 1/2-inch wrench, unscrew and slide back coupling nut (1) on tube (2).
Using 9/16-inch wrench, unscrew and take off locknut (3).
Holding tube (2), take off clamp (4) and clamp pad (5).
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME 2
Using 1 11/16-inch and 1 1/2-inch wrenches, hold fitting (1) and unscrew
and slide back coupling nut (2).
2. Using 9/16-inch wrench, unscrew and take off locknut (3), clamp (4),
and clamp pad (5).
GO TO FRAME 3
1.
18-99
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
Using 9/16-inch wrench, unscrew two locknuts (1).
Holding tubes (2 and 3), take off two locknuts (1) and two clamps (4).
Take off pads (5).
3. Slide tube (2) to the left and out from behind lift cylinder bracket (6).
END OF TASK
18-100
TM 9-2320-211-20-3-2
(2) Replacement.
NOTE
This task is the same for both tubes.
FRAME 1
1.
2.
3.
4.
5.
GO
Slide tube (1) to the right and through lift cylinder bracket (2).
Using 1 1/2-inch wrench, screw in and tighten coupling nut (3) into
hoist motor elbow (4).
Put clamp pad (5) over tube (1).
Put clamp (6) on stud (7).
Using 9/16-inch wrench, screw on and tighten locknut (8).
TO FRAME 2
18-101
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
GO
18-102
Push and hold tubes (1 and 2) on each side of stud (3).
Put pad (4) over tube (1).
Put clamp (5) on stud (3).
Using 9/16-inch wrench, screw on locknut (6).
TO FRAME 3
TM 9-2320-211-20-3-2
FRAME 3
Push and hold tubes (1 and 2) on each side of studs (3).
Push on two pads (4).
Put two clamps (5) on studs (3).
Using 9/16-inch wrench, screw on and tighten nuts (6).
Screw coupling nut (7) into nut (8). Using 1 11/16-inch wrench, hold
nut (8) and using 1 1/2-inch wrench, tighten coupling nut (7).
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic reservoir. Refer to LO 9-2320-211-12.
END OF TASK
1.
2.
3.
4.
5.
18-103
TM 9-2320-211-20-3-2
g. Valve Bank-to-Hoist Motor Hoses.
(1) Removal.
NOTE
This task is the same for both hoses.
1. Using 1 1/2-inch and 1 11/16-inch wrenches, unscrew coupling nut (1).
2. Holding hose (2), pull back coupling nut (1).
GO TO FRAME 2
18-104
TM 9-2320-211-20-3-2
FRAME 2
1.
Using 9/16-inch wrench, unscrew and take off locknut (1). Take off
clamp (2).
GO TO FRAME 3
18-105
TM 9-2320-211-20-3-2
FRAME 3
1. Using 9/16-inch wrench, unscrew and take off nut (1) and clamp (2).
GO TO FRAME 4
18-106
TM 9-2320-211-20-3-2
FRAME 4
1. Using 1 1/2-inch wrench, unscrew coupling nut (1) at elbow (2).
2. Take out hose (3).
END OF TASK
18-107
TM 9-2320-211-20-3-2
(2) Replacement.
NOTE
This task is the same for both hoses.
FRAME 1
Using 1 1/2-inch and 1 11/16-inch wrenches, screw in and tighten coupling nut
(1) to fitting (2).
GO TO FRAME 2
1.
18-108
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
GO
Place hose (1) up against block (2).
Put clamp (3) on stud (4).
Screw on but do not tighten nut (5).
TO FRAME 3
18-109
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
GO
18-110
Place hose (1) against block (2).
Put clamp (3) on stud (4).
Screw on but do not tighten nut (5).
TO FRAME 4
TM 9-2320-211-20-3-2
1.
Using 1 1/2-inch wrench, screw on and tighten coupling nut (1) to fitting
(2).
2.
Using 9/16-inch wrench, screw on and tighten nut (3).
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic reservoir. Refer to LO 9-2320-211-12.
END OF TASK
18-111
TM 9-2320-211-20-3-2
h.
Valve Bank-to-Extension Cylinder Hoses.
(1) Removal.
NOTE
This task is the same for both hoses.
FRAME 1
1. Using 1 1/2-inch and 1 11/16-inch wrenches, loosen coupling nut (1).
2. Hold hose (2) and unscrew coupling nut (1).
GO TO FRAME 2
18-112
TM 9-2320-211-20-3-2
FRAME 2
1. Using 9/16-inch wrench, unscrew and take off locknut (1) and clamp (2).
GO TO FRAME 3
18-113
TM 9-2320-211-20-3-2
1. Using 9/16-inch wrench, unscrew and take off nut (1) and clamp (2).
GO TO FRAME 4
18-114
TM 9-2320-211-20-3-2
FRAME 4
Using 1/2-inch wrench, unscrew and take out six screws (1). Take off
gondola cover plate (2).
2.
Using 1 1/2-inch wrench, unscrew coupling nut (3) and take off hose (4).
Take hose out of truck.
END OF TASK
1.
18-115
TM 9-2320-211-20-3-2
(2) Replacement.
NOTE
This task is the same for both hoses.
FRAME 1
1.
Using 1 1/2-inch wrench, screw on and tighten coupling nut (1) to
hose (2).
GO TO FRAME 2
18-116
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
GO
Place hose (1) on block (2).
Put clamp (3) on stud (4).
Screw on but do not tighten nut (5).
TO FRAME 3
18-117
TM 9-2320-211-20-3-2
FRAME 3
1.
Place hose (1) on block (2).
2.
Slide clamp (3) over stud (4).
3.
Screw on but do not tighten nut (5).
GO TO FRAME 4
18-118
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
3.
4.
Using 1 1/2-inch wrench, screw on and tighten coupling nut (1) on hose (2).
Aline holes in gondola cover plate (3) with holes in gondola (4).
Using 1/2-inch wrench, screw in and tighten six screws (5).
Using 9/16-inch wrench, tighten nuts (6 and 7).
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic reservoir. Refer to LO 9-2320-211-12.
END OF TASK
18-119
TM 9-2320-211-20-3-2
i.
Boom Support Crossover Tube-to-Valve Bank Tube.
(1) Removal.
FRAME 1
1. Using 2-inch wrench, unscrew and slide back coupling nut (1) on tube (2).
GO TO FRAME 2
18-120
TM 9-2320-211-20-3-2
FRAME 2
1.
Take off gondola guard. Refer to para 18-33.
2.
Using 2-inch wrench, unscrew and slide back coupling nut (1) on tube (2).
Take out boom support crossover tube (3) to valve bank tube (2).
END OF TASK
18-121
TM 9-2320-211-20-3-2
(2) Replacement.
FRAME 1
1.
Put tube (1) in place. Using 2-inch wrench, screw in and tighten
coupling nut (2).
GO TO FRAME 2
18-122
TM 9-2320-211-20-3-2
1.
2.
Using 2-inch wrench, screw on and tighten coupling nut (1) on elbow (2).
Replace gondola guard. Refer to para 18-33.
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic reservoir. Refer to LO 9-2320-211-12.
END OF TASK
18-123
TM 9-2320-211-20-3-2
j.
Flow Regulator.
(1) Removal.
FRAME 1
1.
2.
Take out valve bank-to-extension cylinder hose. Refer to para 18-18h.
Using 1 3/4-inch wrench, hold regulator (1) and using 1 11/16-inch wrench,
unscrew hose with nut (2) from regulator.
3. Using 1 11/16-inch wrench, hold nut on hose with nut (3) and using
1 3/4-inch wrench, unscrew regulator (1).
END OF TASK
18-124
TM 9-2320-211-20-3-2
(2) Replacement.
FRAME 1
CAUTION
Arrow marked-on flow regulator (3) must face toward
extension cylinder end of hose.
1.
Using 1 11/16-inch and 1 3/4-inch wrenches, screw in and tighten nut (1)
on hose (2) into flow regulator (3).
2.
Using 1 11/16-inch and 1 3/4-inch wrenches, screw in and tighten nut (4) on
hose (5) into flow regulator (3).
3.
Put in valve bank-to-extension cylinder hose. Refer to para 18-18h.
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic reservoir. Refer to LO 9-2320-211-12.
END OF TASK
18-125
TM 9-2320-211-20-3-2
k.
Crossover Tube Tee Fitting.
(1) Removal.
FRAME 1
Remove gondola guard. Refer to para 18-33.
Using 2-inch wrench, unscrew and slide back coupling nut (1) on tube (2).
Using 1 11/16-inch wrench, unscrew and take out adapter nut (3).
Using 1 11/16-inch wrench, hold fitting (4) and using 1 1/2-inch wrench,
unscrew coupling nut (5).
Using 1 11/16-inch wrench, unscrew fitting (6) and take out hose (7).
5.
6.
Using pipe wrench, unscrew and take out crossover tube tee fitting (8).
END OF TASK
1.
2.
3.
4.
18-126
TM 9-2320-211-20-3-2
(2) Replacement.
FRAME 1
1.
2.
3.
4.
5.
Using pipe wrench, screw in and tighten crossover tube tee fitting (1) into
crossover tube (2).
Using 1 11/16-inch wrench, screw in and tighten adapter nut (3) in tee
fitting (1).
Using 2-inch wrench, screw in and tighten coupling nut (4) on tube (5) onto
adapter nut (3).
Using 1 11/16-inch wrench, screw in and tighten fitting (6) on hose (7) into
elbow (8).
Replace gondola guard. Refer to para 18-33.
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic reservoir. Refer to LO 9-2320-211-12.
END OF TASK
18-127
TM 9-2320-211-20-3-2
1.
Boom Support Crossover-to-Reservoir Hose.
(1) Removal.
FRAME 1
1. Using 1 7/8-inch wrench, unscrew coupling nut (1).
2. Using 2 1/8-inch wrench, unscrew fitting (2) and take out hose (3).
END OF TASK
18-128
TM 9-2320-211-20-3-2
(2) Replacement.
FRAME 1
1.
Using 2 1/8-inch wrench, screw in and tighten fitting (1) on hose (2) into
elbow (3).
2. Using 1 7/8-inch wrench, screw in and tighten coupling nut (4) to hose (2).
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic reservoir. Refer to LO 9-2320-211-12.
END OF TASK
18-129
TM 9-2320-211-20-3-2
m. Oil Filter-to-Pump Hose.
(1) Removal.
FRAME 1
1. Using 24-inch adjustable wrenches, unscrew coupling nut (1) from hose (2).
GO TO FRAME 2
18-130
TM 9-2320-211-20-3-2
FRAME 2
1.
Using 24-inch adjustable wrenches, unscrew coupling nut (1) and take
out oil filter-to-pump hose (2).
END OF TASK
18-131
TM 9-2320-211-20-3-2
(2) Replacement.
NOTE
The end of hose with one nut goes to oil hydraulic
pump.
FRAME 1
Using 24-inch adjustable wrench, screw in and tighten nut (1) on hose (2)
at oil hydraulic pump (3).
GO TO FRAME 2
1.
18-132
TM 9-2320-211-20-3-2
FRAME 2
1.
Using 24-inch adjustable wrenches, screw on and tighten nut (1) to
hose (2) at oil filter elbow (3).
NOTE
Follow-on Maintenance Action Required:
Fill hydraulic reservoir. Refer to LO 9-2320-211-12.
END OF TASK
18-133
TM 9-2320-211-20-3-2
LIFT CYLINDER PACKING ASSEMBLY ADJUSTMENT (TRUCK M543A2).
NOTE
This task is the same for the two lift cylinders.
TOOLS: Spanner wrench, pn 11602326
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
18-19.
FRAME 1
Using spanner wrench (1), tighten packing nut (2) just a little by turning it
to right.
2. Raise and lower boom (3). Refer to TM 9-2320-211-10. Check for oil leaks.
3. If oil is still leaking, tighten nut (2) a little more and raise and lower boom (3)
again. Check for oil leak.
4. If nut (2) becomes tight and oil leak does not stop, tell direct support maintenance.
END OF TASK
1.
18-134
TM 9-2320-211-20-3-2
18-20. HYDRAULIC SYSTEM PRESSURE TEST AND ADJUSTMENT (TRUCK M54342).
TOOLS: Flat-tip screwdriver
1/2-inch wrench
3/8-inch socket head screw key (Allen wrench or equivalent)
Hydraulic pressure test gage
SUPPLIES: None
PERSONNEL: TWO
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set,
wheels chocked.
a. Preliminary Procedures.
(1) Lower hoist cable to ground. Refer to TM 9-2320-211-10.
(2) Fully extend boom. Refer to TM 9-2320-211-10.
b. Test and Adjustment.
FRAME 1
Soldier A 1.
2.
GO TO FRAME 2
Using 3/8-inch allen wrench, unscrew plug (1) from valve body (2).
Take out plug.
Screw in hydraulic pressure test gage (3).
18-135
TM 9-2320-211-20-3-2
FRAME 2
Soldier B 1. Start engine. Refer to TM 9-2320-211-10.
2. Put on power divider (1). Tell soldier A when ready.
GO TO FRAME 3
18-136
TM 9-2320-211-20-3-2
FRAME 3
Soldier A 1.
Push in handles (1 and 2) and hold them. Check that gage (3)
reads 1,350. If gage reads 1,350, let handles (1 and 2) go and
go to frame 4.
2. Using 1/2-inch wrench, unscrew locknut (4).
3. Using flat-tip screwdriver, turn screw (5) until gage (3) reads
1,350. Tighten locknut (4). Let handles (1 and 2) go.
GO TO FRAME 4
18-137
TM 9-2320-211-20-3-2
FRAME 4
Soldier B. 1. Shut off engine. Refer to TM 9-2320-211-10.
2. Let down power divider handle (1).
GO TO FRAME 5
18-138
TM 9-2320-211-20-3-2
FRAME 5
Soldier A 1.
2.
Take out hydraulic pressure test gage (1) from valve body (2).
Using 3/8-inch allen wrench, screw in plug (3).
NOTE
Follow-on Maintenance Action Required:
1. Retract boom. Refer to TM 9-2320-211-10.
2. Rewind hoist cable. Refer to TM 9-2320-211-10.
END OF TASK
18-139
TM 9-2320-211-20-3-2
18-21. VALVE BANK RELIEF VALVE TEST AND ADJUSTMENT (TRUCK M543A2).
TOOLS: 7/16-inch wrench
7/8-inch wrench
1 5/16-inch wrench
Flat-tip screwdriver
Pressure checking kit, pn 3005456
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove valve bank cover. Refer to para 18-22.
b. Test and Adjustment.
FRAME 1
Using 7/16-inch wrench, unscrew and take out pipe plug (1).
Using 7/16-inch wrench, screw in and tighten pressure gage (2) into valve
bank (3).
GO TO FRAME 2
1.
2.
18-140
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
IF
IF
Start engine and prepare crane for lifting load. Refer to TM 9-2320-211-10.
Put HOIST lever (1) in DOWN position until hook touches ground.
NOTE
Boom must be all the way out when reading is taken.
Hold CROWD lever (2) in EXTEND position and read pressure on gage (3).
Gage should read 1210 to 1215 psi.
Let go of CROWD lever (2).
GAGE DID NOT READ 1210 TO 1215 PSI, GO TO FRAME 3.
GAGE READ 1210 TO 1215 PSI, GO TO FRAME 4
18-141
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
Using 1 5/16-inch wrench, loosen locknut (1).
Hold CROWD lever (2) in EXTEND position and using screwdriver, turn adjusting screw (3) either way until pressure on gage (4) reads 1210 to 1215
psi. Let go of CROWD lever.
NOTE
Do not let adjusting screw (3) turn once gage (4) reads
1210 to 1215 psi.
3. Using screwdriver and 15/16-inch wrench, hold adjusting screw (3) and
tighten locknut (1).
GO TO FRAME 4
18-142
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
3.
4.
Raise hook and retract boom. Refer to TM 9-2320-211-10.
Stop engine and prepare crane for travel. Refer to TM 9-2320-211-10.
Using 7/16-inch wrench, unscrew and take out pressure gage (1).
Using 7/16-inch wrench, screw in and tighten pipe plug (2) into valve
bank (3).
NOTE
Follow-on Maintenance Action Required:
Replace valve bank cover. Refer to para 18-22.
END OF TASK
18-143
TM 9-2320-211-20-3-2
18-22.
CONTROL VALVE BANK COVER REMOVAL AND REPLACEMENT
(TRUCK M543A2).
TOOLS: Flat-tip screwdriver
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
Preliminary Procedure. Disconnect battery ground cable. Refer to
Part 1, para 7-44.
b. Removal.
FRAME 1
1. Using screwdriver, unscrew and take out five screws (1).
2. Take off control valve bank cover (2).
END OF TASK
18-144
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
2.
Put control valve bank cover (1) on console (2) and aline screw holes.
Start five screws (3) in cover (1), and using screwdriver, screw in and
tighten screws.
NOTE
Follow-on Maintenance Action Required:
Reconnect battery ground cable. Refer to Part 1, para 7-44.
END OF TASK
18-145
TM 9-2320-211-20-3-2
18-23. CONTROL VALVE BANK ASSEMBLY REMOVAL AND REPLACEMENT
(TRUCK M543A2).
1 1/2-inch wrench
TOOLS:
2-inch wrench
3/4-inch wrench
7/8-inch wrench
Flat-tip screwdriver
Five-gallon container
Clean rags
SUPPLIES:
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
Preliminary Procedures.
a.
(1) Disconnect battery ground cable. Refer to Part 1, para 7-44.
(2) Drain hydraulic reservoir. Refer to LO 9-2320-211-12.
Removal.
b.
FRAME 1
1.
Using screwdriver, unscrew and take out five screws (1).
Take off control valve bank cover assembly (2).
2.
GO TO FRAME 2
18-146
TM 9-2320-211-20-3-1
FRAME 2
1.
2.
3.
4.
5.
6.
7.
GO
NOTE
Be sure to tag valve bank hoses before taking them off
so that they will be put back in same place. Place con–
tainer under hoses to catch hydraulic fluid drainage.
Using 1 1/2-inch wrench, unscrew and take off seven hose fittings (1).
Let hoses (2) hang.
Using 7/8-inch wrench, unscrew and take off hose (3). Let hose hang.
Using 2-inch wrench, unscrew nut (4). Slide nut back on tube (5).
Using 2-inch wrench, unscrew and take off adapter (6).
Using 1 1/2-inch wrench, unscrew fitting (7). Slide fitting back on tube
(8).
Cap all open hoses (2 and 3), tubes (5 and 8), and fittings (1 and 7).
Using clean rags, wipe up all hydraulic fluid that may have leaked from
hoses (2 and 3).
TO FRAME 3
18-147
TM 9-2320-211-20-3-2
FRAME 3
Using 3/4-inch wrench, unscrew and take out four nuts (1) with washers
(2).
2.
Take out four capscrews (3).
Take out control valve bank assembly (4).
3.
END OF TASK
1.
18-148
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
2.
3.
Put control valve bank (1) on truck as shown.
Put in four capscrews (2).
Using 3/4-inch wrench, screw on and tighten four nuts (3) with washers
(4).
GO TO FRAME 2
18-149
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
GO
18-150
NOTE
Put hoses back as tagged. Wrong connections will cause
malfunctions of hydrualic system. Uncap all hoses and
fittings.
Using 1 1/2-inch wrench, screw on seven hoses (1) as tagged. Take off
tags.
Using 7/8-inch wrench, screw on hose (2) as tagged. Take off tag.
Using 1 1/2-inch wrench, screw on fitting (3).
Using 2-inch wrench, screw on fitting (4).
TO FRAME 3
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
4.
Put on control valve bank assembly cover assembly (1) as shown.
Using flat-tip screwdriver, screw in and tighten five screws (2).
Throw away rags in proper container.
Take out container and put hydraulic fluid into approved disposal area.
NOTE
Follow-on Maintenance Action Required:
1. Reconnect battery ground cable. Refer to Part 1,
para 7-44.
2. Service hydraulic hoist system. Refer to
END OF TASK LO 9-2320-211-12.
18-151
TM 9-2320-211-20-3-2
HYDRAULIC OIL FILTER ELEMENT REMOVAL AND REPLACEMENT
(TRUCK M543A2).
Ratchet handle, 3/8-inch drive
TOOLS:
1/2-inch socket wrench, 3/8-inch drive
Flat-tip screwdriver
Five-gallon container
SUPPLIES: Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
Compressed air source, 30 psi max
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Drain hydraulic oil tank. Refer to
LO 9-2320-211-12.
b.
Removal.
18-24.
WARNING
Do not work on hot hydraulic system.
oil can burn personnel.
Hot hydraulic
FRAME 1
1.
2.
Put container under hydraulic oil filter housing (1).
Using 1/2-inch socket wrench, unscrew and take out four capscrews (2).
NOTE
Cover (3) and filter element (4) must be taken out of
filter housing (1) quickly so that built-in shutoff valve
will stop reservoir from draining. One to three gallons
of hydraulic fluid will drain when taking out filter
element.
Without stopping, quickly pull cover (3) with filter element (4) out of
3.
housing (1). Let hydraulic oil drain from filter element into container.
END OF TASK
18-152
TM 9-2320-211-20-3-2
c.
Disassembly.
FRAME 1
1.
Put rear cover (1) and filter element assembly (2) on workbench with rear
cover down.
2. Take filter element assembly (2) out of rear cover (1). Turn filter element
assembly over so heads of three screws (3) face up.
3. Take preformed packing (4) off rear cover (1).
GO TO FRAME 2
18-153
TM 9-2320-211-20-3-2
FRAME 2
1. Using screwdriver, unscrew and take out three screws (1).
2. Take off rear cap (2) and lift out filter element (3) from front cap (4).
3. Unhook and take off seal ring (5) from front cap (4).
4. Take out two cork gaskets (6), one from cap (2) and one from cap (4).
END OF TASK
18-154
TM 9-2320-211-20-3-2
d.
Cleaning, Inspection and Repair.
WARNING
Dry cleaning solvent is flammable. Do not use near
an open flame. Keep a fire extinguisher nearby when
solvent is used. Use only in well-ventilated places.
Failure to do this may result in injury to personnel
and damage to equipment.
Eye shields must be worn when using compressed
air. Eye injury can occur if eye shields are not used.
(1) Wash all parts in solvent.
(2) Using compressed air, blow out filter element from inside, to be sure
filter element is clean.
(3) Check that all metal parts are not worn or damaged.
(4) Check that filter element has no tears or holes.
(5) Throw away all damaged parts and get new ones in their place.
18-155
TM 9-2320-211-20-3-2
e.
Assembly.
FRAME 1
1.
2.
3.
4.
5.
GO
18-156
Put cork gasket (1) into rear cap (2).
Put cork gasket (3) into front cap (4).
Put filter element (5) on front cap (4). Put rear cap (2) over filter element.
Using screwdriver, screw in and tighten three screws (6).
Put seal ring (7) on front cap (4) and hook ends together.
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Put preformed packing (1) on rear cover (2).
Aline slot in rear cap (3) with shaft (4) in rear cover (2). Put filter
element assembly (5) in rear cover.
END OF TASK
18-157
TM 9-2320-211-20-3-2
f.
Replacement.
FRAME 1
NOTE
Make sure five-gallon container is under hydraulic oil
filter housing (1). Cover (2) and filter element (3)
must be put into filter housing quickly. One to three
gallons of hydraulic fluid will drain out when filter
element is put in place.
Put filter element (3) with cover (2) partway into filter housing (1).
1.
Turn cover (2) so indicator (4) is toward rear of truck. Aline screw
2.
holes in cover with screw holes in filter housing (1).
Quickly push filter element (3) all the way into filter housing (1).
3.
Using 1/2-inch socket wrench, screw in and tighten four capscrews (5).
4.
Empty five-gallon container in approved disposal area.
5.
NOTE
Follow-on Maintenance Action Required:
Refill hydraulic oil reservoir. Refer to LO 9-2320-211-12.
END OF TASK
18-158
TM 9-2320-211-20-3-2
18-25. HYDRAULIC OIL TANK ASSEMBLY REMOVAL AND REPLACEMENT
(TRUCK M543A2).
TOOLS: 24-inch adjustable wrench
1/2-inch socket wrench
1/2-inch open end wrench
9/16-inch socket wrench
9/16-inch open end wrench
7/8-inch open end wrench
A-frame 1-gallon container
Anti-seize tape, MIL-T-27730A
1/2-inch rope, 10 feet (2)
PERSONNEL: TWO
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Drain hydraulic oil tank. Refer to LO 9-2320-211-12.
b. Removal.
SUPPLIES:
FRAME 1
1.
2.
3.
GO
NOTE
Use container to catch oil that may be in hoses when
hoses are taken off.
Using adjustable wrenches, unscrew nut (1) on union (2). Pull hose (3)
away from union (2).
Using adjustable wrench, unscrew fitting on hose (3) from elbow (4).
Take off hose.
Using 7/8-inch wrench, unscrew nut (5) and take off hose (6).
TO FRAME 2
18-159
TM 9-2320-211-20-3-2
FRAME 2
1. Using adjustable wrenches, hold hose fitting (1) and unscrew slip nut (2).
2. Take off hose (3).
GO TO FRAME 3
18-160
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
Using 9/16-inch socket wrench and 9/16-inch open end wrench, unscrew
and take off two nuts (1) and take out two screws (2), one from each side
of oil tank assembly (3).
Using 1/2-inch socket wrench and 1/2-inch open end wrench, unscrew and
take off two nuts (4). Take out two screws (5) and take off two lower
straps (6).
Lift up and push back two upper straps (7).
G O TO FRAME 4
18-161
TM 9-2320-211-20-3-2
FRAME 4
Soldier A 1.
2.
3.
Soldier B 4.
Soldier A 5.
END OF TASK
18-162
Using two pieces of 1/2-inch rope, tie two slings (1) around oil
tank assembly (2) as shown.
Hook up chain hoist (3) to ropes (1).
Using chain hoist (3), raise oil tank assembly (2) up off wrecker
body (4).
Guide oil tank assembly (2) to the ground as soldier A lowers it.
Using chain hoist (3), move oil tank assembly (2) off truck
onto ground.
TM 9-2320-211-20-3-2
c. Replacement.
FRAME 1
Soldier
Soldier
Soldier
Soldier
GO TO
1.
2.
3.
4.
5.
Tie two pieces of 1/2-inch rope (1) around oil tank assembly (2).
Hook up chain hoist (3) to ropes (1).
Using chain hoist (3), raise oil tank assembly (2) from ground.
A
Guide oil tank assembly (2) from ground as soldier A hoists it.
B
Using chain hoist (3), raise oil tank assembly (2) up onto
A
wrecker body (4).
B 6. Guide oil tank assembly (2) into place on wrecker body (4).
Take off hoist (3) and ropes (1).
FRAME 2
18-163
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Put two upper straps (1) in place on top of oil tank assembly (2).
Put two lower straps (3) in place on oil tank assembly (2) and put two
screws (4) through bottom ends of lower straps.
3. Using 1/2-inch socket wrench and 1/2-inch open end wrench, screw on
and tighten two nuts (5).
4. Put two screws (6) through upper straps (1) and lower straps (3). Using
9/16-inch socket wrench and 9/16-inch open end wrench, screw on and
tighten two nuts (7).
GO TO FRAME 3
18-164
TM 9-2320-211-20-3-2
FRAME 3
NOTE
Put anti-seize tape on male end of each hose assembly
connector before joining hose assembly to fitting.
1. Put inlet hose assembly (1) in place on oil filter assembly (2).
2. Using adjustable wrenches, hold hose fitting (3) and tighten slipnut (4).
GO TO FRAME 4
18-165
TM 9-2320-211-20-3-2
FRAME 4
1.
Put hose assembly fitting (1) on elbow (2). Using adjustable wrench, tighten
fitting (1).
2. Put hose assembly fitting (3) on union assembly (4). Using adjustable
wrenches, tighten slipnut (5) on union assembly.
3. Using 7/8-inch wrench, put hose assembly nut (6) in elbow (7) and tighten
it.
NOTE
Follow-on Maintenance Action Required:
Refill hydraulic oil tank. Refer to LO 9-2320-211-12.
END OF TASK
18-166
TM 9-2320-211-20-3-2
18-26. SLIPRING CONTACT BRUSHES REMOVAL AND REPLACEMENT
(TRUCK M543A2).
TOOLS: Pliers
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1. Using pliers, unscrew and takeoff three cap plugs (1).
2. Take out three contact brushes (2).
END OF TASK
18-167
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1. Put in three contact brushes (1).
2. Using pliers, screw in and tighten three cap plugs (2).
END OF TASK
18-168
TM 9-2320-211-20-3-2
18-27.
HOIST AUTOMATIC BRAKE BANK REMOVAL, REPLACEMENT,
AND ADJUSTMENT (TRUCK M543A2).
TOOLS: 1/2-inch open end wrench
9/16-inch open end wrench
6-inch ruler
SUPPLIES: Brake case cover gasket
Brake bank adjusting screw preformed packing
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
Raise boom (1) until hoist winch gearbox (2) is just above top of boom elevating
cylinder (3). Put boom supports in place. Refer to TM 9-2320-211-10.
GO TO FRAME 2
18-169
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
Using 1/2-inch wrench, unscrew and take out six locking screws (1).
Take off brake case end cover (2) and gasket (3). Throw away gasket.
Using 9/16-inch wrench, unscrew and take out screw (4), flat washer (5), and
preformed packing (6). Throw away preformed packing.
GO TO FRAME 3
18-170
TM 9-2320-211-20-3-2
FRAME 3
Take out brake band assembly (1) and spring (2).
1.
END OF TASK
18-171
TM 9-2320-211-20-3-2
b. Replacement and Adjustment.
FRAME 1
1.
2.
Put brake band assembly (1) on brake drum disk (2).
Put spring (3) between screw holes in brake band assembly (1) and brake housing
case (4).
3. Put flat washer (5) and preformed packing (6) on screw (7), and put screw through
brake housing case (4), spring (3), and brake band assembly (1).
4. Draw up brake band assembly (1) partway by turning in screw (7).
GO TO FRAME 2
18-172
TM 9-2320-211-20-3-2
FRAME 2
Using 9/16-inch wrench and ruler, turn in screw (1) until gap in brake band
assembly (2) is between 1 3/16 inches and 1 1/4 inches as shown.
GO TO FRAME 3
1.
18-173
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
Put gasket (1) and brake case end cover (2) on brake housing case (3),
dining holes.
Using 1/2-inch wrench, screw in and tighten six locking screws (4).
NOTE
Follow-on Maintenance Action Required:
Take out boom supports and lower and secure boom.
Refer to TM 9-2320-211-10.
END OF TASK
18-174
TM 9-2320- 211-20-3-2
18-28. ROTOCHAMBER ADJUSTMENT (TRUCK M543A2).
TOOLS:
9/16-inch wrench (2)
6-inch ruler
SUPPLIES:
PERSONNEL:
EQUIPMENT
None
One
CONDITION:
Truck parked, engine off, handbrake set.
1.
Using wrenches, hold capscrew (1) and loosen locknut ( 2).
2.
Using wrench and ruler, turn capscrew (1) left or right until there is
3/32 to 1/4 inch clearance at point A as shown.
3.
Using wrenches, hold capscrew (1) and tighten locknut ( 2).
END OF TASK
18-175
TM 9-2320-211-20-3-2
HOIST WINCH CABLE REMOVAL AND REPLACEMENT (TRUCK M543A2).
18-29.
1/4-inch sockethead screw key (Allen wrench or equivalent)
TOOLS:
9/16-inch wrench
Leather gloves (2 pair)
None
SUPPLIES:
PERSONNEL:
EQUIPMENT
TW o
CONDITION:
Truck parked, engine off, handbrake set.
a.
Preliminary Procedure. Remove snatch block. Refer to para 18-32.
b.
Removal.
1.
Using wrench, unscrew and take out two capscrews with washers (1) on
each side of cable guard (2).
2.
Take off cable guard (2).
GO TO FRAME 2
18-176
TM 9-2320-211-20-3-2
FRAME 2
Soldier A
1.
2.
Start engine. Put transmission in fifth gear position, then
put transfer in neutral position, and power divider lever in
DOWN position. Put hydraulic pump control lever in ENGAGE
position. Refer to TM 9-2320-211-10.
Push hoist control lever (1) forward to DOWN position and
hold it.
WARNING
Always wear leather gloves when handling winch cable.
Never let cable run through hands. Rusty or broken
wires can cause injury.
CAUTION
Keep tension on cable whenever winch drum is turning.
Failure to do so will cause cable to snarl.
3.
Soldier B
Pull cable (2) hand over hand from boom (3).
4.
Watch cable drum (4). Tell soldier A to stop hoist
when cable (2) is completely unwound off winch drum.
Soldier A
5.
Let go of hoist control lever (1) to stop winch drum
(4) from turning.
GO TO FRAME 3
18-177
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
END
18-178
Using allen wrench, unscrew and take out setscrew (1).
Pull cable (2) out of winch drum (3) and off truck.
Stop engine. Refer to TM 9-2320-211-10.
OF TASK
TM 9-2320-211-20-3-2
c.
FRAME
Replacement.
1
WARNING
Always wear leather gloves when handling winch
cable. Never let cable run through hands. Rusty
or broken wires can cause injury.
Soldier A 1.
Feed cable (1) to soldier B as he needs it. Do not let go of
cable until soldier B tells you.
Soldier B 2.
Thread cable (1) over pulley (2), along top of boom (3),
under boom roller (4), over pulley (5), and around pulley
(6).
3.
Pull cable (1) under boom (3), over top, and through hole
in winch drum (7).
4.
Using allen wrench, screw in and tighten setscrew (8)
against cable (1).
5.
Tell soldier A to let go of cable (1).
GO TO FRAME 2
18-179
TM 9-2320-211-20-3-2
FRAME 2
Soldier A 1.
Start engine. Put transmission in fifth gear position, then put
transfer in neutral position, and power divider lever in DOWN
position. Put hydraulic pump control lever in ENGAGE position.
Refer to TM 9-2320-211-10.
WARNING
Always wear leather gloves when handling winch cable.
Never let cable run through hands. Rusty or broken
wires can cause injury.
CAUTION
Keep tension on cable whenever winch drum is turning.
Failure to do so will cause cable to snarl.
Soldier B 2. Hold cable (1) so that there is no slack. Watch winch drum
(2) to see that cable is winding tightly and evenly.
Soldier A 3. Pull hoist control lever (3) to UP position and hold it.
Soldier B 4. Tell soldier A to stop winch drum (2) when you are 15 feet
from end of cable (1).
Soldier A 5. Let go of hoist control lever (3) to stop winch drum (2) from
turning.
6. Stop engine. Refer to TM 9-2320-211-10.
GO TO FRAME 3
18-180
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
Put cable guard (1) over rear pulley assembly (2).
Using wrench, screw in and tighten two capscrews with washers (3) on each
side of cable guard (1).
NOTE
Follow-on Maintenance Action Required:
Replace snatch block. Refer to para 18-32.
END OF TASK
18-181
TM 9-2320-211-20-3-2
18-30.
CRANE BOOM AND SHIPPER CABLE ROLLERS REMOVAL AND
REPLACEMENT (TRUCK M543A2).
15/16-inch open end wrench
TOOLS:
None
SUPPLIES:
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
Preliminary Procedures.
a.
(1) Start engine. Refer to TM 9-2320-211-10.
(2) Move boom to the 12 FOOT mark. Raise or lower boom as needed to
make it level. Refer to TM 9-2320-211-10.
(3) Stop engine. Refer to TM 9-2320-211-10.
18-182
TM 9-2320-211-20-3-2
b.
Removal.
FRAME 1
1.
2.
3.
Using 15/16-inch wrench, unscrew and take out three capscrews with lockwashers (1).
Do step 1 again on other side of boom.
Take off upper boom roller assembly (2).
WARNING
Hold lower boom roller assembly (3) when taking out
capscrews (4). Boom roller assembly is heavy.
Dropping it could result in injury to personnel and
damage to equipment.
4.
Using 15/16-inch wrench, unscrew and take out three capscrews with lock–
washers (4).
Do step 4 again on other side of boom.
5.
6.
Take off boom roller assembly (3).
END OF TASK
18-183
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
2.
Put lower boom roller (1) in place as shown and hold it in place.
Using 15/16-inch wrench, screw in and hand tighten three capscrews
with lockwashers (2).
Do step 2 again on other side of boom and using 15/16-inch wrench, tighten
3.
three capscrews with lockwashers (2) on both sides of boom.
Put boom roller (3) in place on top of boom.
4.
5.
Using 15/16-inch wrench, screw in and hand tighten three capscrews
with lockwashers (4).
Do step 5 again on other side of boom and using 15/16-inch wrench,
6.
tighten three capscrews with lockwashers (4) on both sides of boom.
NOTE
Follow-on Maintenance Action Required:
Start engine. Refer to TM 9-2320-211-10.
1.
2.
Retract inner boom into outer boom assembly.
Refer to TM 9-2320-211-10.
Attach chain to hold crane block assembly in
3.
safe position on truck. Refer to TM 9-2320-211-10.
4.
Stop engine. Refer to TM 9-2320-211-10.
END OF TASK
18-184
TM 9-2320-211-20-3-2
18-31. CRANE INNER BOOM ROLLER ASSEMBLY ADJUSTMENT (TRUCK M543A2).
TOOLS: 3/4-inch open end wrench
Spanner wrench
Hammer
Drift punch
Prybar
SUPPLIES: Shims
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedures.
(1) Start engine. Refer to TM 9-2320-211-10.
(2) Operate boom to the 12 FOOT mark. Raise or lower boom, as needed,
until it is about level. Refer to TM 9-2320-211-10.
b. Vertical Adjustment.
FRAME 1
1.
Using 3/4-inch wrench, unscrew and take out four screws with lockwashers
(1) from each roller assembly.
2. Go to other side of boom (2) and do step 1 again for eight screws with lockwashers on other side.
GO TO FRAME 2
18-185
TM 9-2320-211-20-3-2
FRAME 2
1.
Using spanner wrench, turn mounting cap (1) to the left or to the right,
as needed, until inner boom (2) is parallel with outer boom (3). If mounting cap (1) binds before inner and outer booms are parallel, go to step 2.
If they are parallel, go to frame 3.
2. Using spanner wrench, turn mounting cap (4) to the left until it binds.
Counting turns, turn mounting cap to the right until it binds. Set cap
midway between binding places.
3. Using spanner wrench, turn mounting cap (1) to the left or to the right,
as needed, until top of inner boom (2) is parallel with outer boom (3).
GO TO FRAME 3
18-186
TM 9-2320-211-20-3-2
FRAME 3
1.
Using spanner wrench, turn mounting cap (1) to aline nearest holes for
screws with lockwashers (2).
2. Using 3/4-inch wrench, screw in and tighten four screws with lockwashers
(2). Go to other side of boom (3). Screw in and tighten four screws with
lockwashers on other side of boom.
GO TO FRAME 4
18-187
TM 9-2320-211-20-3-2
FRAME 4
1.
Using spanner wrench, turn mounting cap (1) to the right until it binds.
Turn mounting cap to the left until it stops binding and holes for screws
with lockwashers (2) are alined.
2. Using 3/4-inch wrench, screw in and tighten four screws with lockwashers
(2). Go to other side of boom (3). Screw in and tighten four screws with
lockwashers.
GO TO FRAME 5
18-188
TM 9-2320-211-20-3-2
FRAME 5
1.
Operate inner boom (1) all the way out and then all the way in. Refer to
TM 9-2320-211-10. Watch inner boom for sticking or jamming.
IF INNER BOOM STICKS OR JAMS, GO TO FRAME 6.
IF INNER BOOM DOES NOT STICK OR JAM, END OF TASK
18-189
TM 9-2320-211-20-3-2
FRAME 6
1.
2.
3.
4.
5.
GO
Using 3/4-inch wrench, unscrew and take out four screws with lockwashers
(1).
Go to other side of boom (2). Unscrew and take out four screws with
lockwashers (1).
Using spanner wrench, turn mounting cap (3) to the left until hole (4)
is alined for screw with lockwasher (1).
Using 3/4-inch wrench, screw in and tighten four screws with lockwashers
(1).
Go to other side of boom (2). Screw in and tighten four screws with
lockwashers (1).
BACK TO FRAME 5
18-190
TM 9-2320-211-20-3-2
c.
Lateral Adjustment.
FRAME 1
1.
Operate inner boom (1) all the way out and then all the way in, checking
inner boom side play for tightness or looseness. Refer to TM 9-2320-211-10.
2. Using 3/4-inch wrench, unscrew and take out four screws with lockwashers
(2).
3. Go to other side of boom. Using hammer and punch, drive shaft (3) to
loosen mounting cap (4).
GO TO FRAME 2
18-191
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Using prybar, takeoff mounting cap (1) and shims (2).
If boom is too loose, take out one shim (2). If boom is too tight, add one
shim.
3. Put mounting cap (1) with shims (2) in place, alining keyway (3) with
key (4). Tap with hammer and brass drift.
4. Using 3/4-inch wrench, screw in and tighten four screws (5) with lockwashers (6).
GO TO FRAME 3
18-192
TM 9-2320-211-20-3-2
FRAME 3
1.
Using hoist, support inner boom(1)so wieght of inner boom is off outer
boom (2).
2. Using 3/4-inch wrench, unscrew and take out four screws with lockwashers
(3).
3. Go to other side of boom. Using hammer and punch, drive shaft (4) to
loosen mounting cap (5).
GO TO FRAME 4
18-193
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
Using prybar, take off mounting cap (1) and shims (2).
If boom is too loose, take out one shim (2). If boom is too tight, add one
more shim.
3. Put mounting cap (1) with shims (2) in place, alining keyway (3) with key
(4). Tap with hammer and brass drift.
4. Using 3/4-inch wrench, screw in and tighten four screws (5) with lockwashers (6).
GO TO FRAME 5
18-194
TM 9-2320-211-20-3-2
FRAME 5
1.
2.
Take hoist off inner boom (1).
Work inner boom (1) all the way out and then all the way in, checking inner
boom side play for tightness or looseness. If side play is tight or loose, go
to step 2 of frame 1.
NOTE
Follow-on Maintenance Action Required:
1. Secure boom for travel. Refer to TM 9-2320-211-10.
2. Stop engine. Refer to TM 9-2320-211-10.
END OF TASK
18-195
TM 9-2320-211-20-3-2
18-32. CRANE SNATCH BLOCK REMOVAL AND REPLACEMENT (TRUCK M543A2).
1 1/4-inch wrench
TOOLS: Drift pin punch
1 1/2-inch wrench
5-pound hammer
Leather gloves
1-inch wrench
1 1/16-inch wrench
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
WARNING
Always wear leather gloves when handling winch
cable. Never let cable run through hands. Broken
or rusty wires could cause serious injury to personnel.
CAUTION
Keep tension on cable whenever winch drum is
turning. Failure to do this will cause cable to
snarl.
a. Preliminary Procedures.
(1) Extend and lower boom. Refer to TM 9-2320-211-10.
(2) Lower cable until crane snatch block rests on ground. Refer to
TM 9-2320-211-10.
18-196
TM 9-2320-211-20-3-2
b.
Removal of One-Part Line.
FRAME 1
1. Using 1-inch and 1 1/4-inch wrenches, unscrew and take off nut (1).
2. Take out screw (2) and clevis (3) from snatch block (4).
END OF TASK
18-197
TM 9-2320-211-20-3-2
c. Removal of Two-Part Line.
FRAME 1
Using 1-inch and 1 1/4-inch wrenches, hold screw (1) and unscrew and take
off nut (2).
2. Take out screw (1) and clevis (3).
3. Pull cable (4) out of snatch block (5).
END OF TASK
1.
18-198
TM 9-2320-211-20-3-2
d.
Removal of Three-Part Line.
FRAME 1
1.
2.
Using 1 1/8-inch wrench, hold two screws (1).
Using 1 1/16-inch wrench, unscrew and take off two nuts (2). Take out two
screws (1) and two spacers (3).
3. Using l-inch and 1 1/4-inch wrenches, hold screw (4) and unscrew and take
off nut (5). Take out screw (4) and take off clevis (6).
4. Pull cable (7) off boom pulley (8) and out of snatch block (9).
END OF TASK
18-199
TM 9-2320-211-20-3-2
e.
Replacement of One-Part Line.
FRAME 1
1.
2.
3.
Place clevis (1) over snatch block (2), alining holes.
Put in screw (3) and using 1-inch wrench, hold it.
Using 1 1/4-inch wrench , screw on and tighten nut (4).
NOTE
Follow-on Maintenance Action Required:
1. Wind winch cable on cable drum. Refer to
TM 9-2320-211-10.
2. Prepare crane for travel. Refer to
TM 9-2320-211-10.
END OF TASK
18-200
TM 9-2320-211-20-3-2
f.
Replacement of Two-Part Line.
FRAME 1
1.
2.
3.
Put clevis end of cable (1) through snatch block (2).
Put clevis (3) on boom (4), alining holes.
Put screw (5) through boom (4) and clevis (3) and using 1-inch wrench,
hold screw.
4. Using 1 1/4-inch wrench, screw on and tighten nut (6).
NOTE
Follow-on Maintenance Action Required:
1. Wind winch cable on cable drum. Refer to
TM 9-2320-211-10.
2. Prepare crane for travel. Refer to
TM 9-2320-211-10.
END OF TASK
18-201
TM 9-2320-211-20-3-2
g.
Replacement of Three-Part Line.
FRAME 1
1.
Put clevis end of cable (1) through snatch block (2) and up over boom pulley
(3) as shown.
GO TO FRAME 2
18-202
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Place clevis (1) over snatch block (2), alining holes.
Put screw (3) through clevis (1) and snatch block (2) and using 1-inch
wrench, hold it.
3. Using 1 1/4-inch wrench, screw on and tighten nut (4).
4. Put two screws (5) through boom (6) and two spacers (7) and using 1 1/8-inch
wrench, hold them.
5. Using 1 1/8-inch wrench, screw on and tighten two nuts (8).
NOTE
Follow-on Maintenance Action Required:
1. Wind winch cable on cable drum. Refer to
TM 9-2320-211-10.
2. Prepare crane for travel. Refer to
TM 9-2320-211-10.
END OF TASK
18-203
TM 9-2320-211-20-3-2
OPERATOR GUARD REMOVAL AND REPLACEMENT (TRUCK M543A2).
18-33.
None
TOOLS:
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
Lift guard (1) up and out of two gondola brackets (2).
1.
END OF TASK
18-204
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1.
Place two guard supports (1) into gondola brackets (2) and push down
evenly until guard (3) is seated.
END OF TASK
18-205/(18-206 blank)
TM 9-2320-211-20-3-2
CHAPTER 19
BODY ACCESSORY ITEMS GROUP MAINTENANCE
Section I. SCOPE
19-1. EQUIPMENT ITEMS COVERED . This chapter gives equipment maintenance
procedures for canvas items and related parts, accessory ii ems, and data plates for
which there are authorized corrective maintenance tasks at the organizational main–
tenance level.
19-2. EQUIPMENT ITEMS NOT COVERED . All equipment items for which corrective
maintenance is authorized at the organizational maintenance level are covered in this
chapter.
Section II.
CANVAS ITEMS AND RELATED PARTS
19-3. END CURTAINS REMOVAL AND REPLACEMENT.
TOOLS:
SUPPLIES :
None
None
PERSONNEL: One
EQUIPMENT CONDITION :
a. Preliminary Procedure.
211-10.
Truck parked, engine off, handbrake set.
Remove cargo body top cover. Refer to TM 9-2320-
19-1
TM 9-2320-211-20-3-2
b.
Removal.
FRAME 1
1.
2.
3.
4.
END
19-2
Untie lashing rope (1) from two lashing hooks (2).
Take rope out of eyelets (3) and unwind it from bow (4).
Take off and stow back end curtain (5).
Do steps 1 through 3 again for front end curtain (6).
OF TASK
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
2.
3.
GO
If bow assemblies (1) have been taken off, replace them. Refer to TM 9-2320-211-10.
Line up top center eyelet (2) with top center of bow (1).
Push half of lashing rope (3) through center eyelet.
TO FRAME 2
19-3
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
Wind lashing rope (1) to the left and right around bow (2) and through all eyelets (3).
Tie ends of lashing rope (1) to lashing hooks (4).
Do steps 1 and 2 again for front end curtain (5).
NOTE
Follow-on Maintenance Action Required:
Replace cargo body top cover. Refer to TM 9-2320-211-10.
END OF TASK
19-4
TM 9-2320-211-20-3-2
19-4. LONG CARGO BODY TOP COVER REMOVAL AND REPLACEMENT.
TOOLS: None
SUPPLIES: 8-foot step ladder (2)
PERSONNEL: TWO
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1. Untie lashing ropes (1) from lashing hooks (2) on four sides of truck body (3).
GO TO FRAME 2
19-5
TM 9-2320-211-20-3-2
FRAME
2
CAUTION
Soldier A
Soldier B
Soldiers
A and B
1.
2.
3.
4.
5.
END OF TASK
19-6
Do not fold or stow cover when cover is wet.
Stand on step ladder at front of truck body (1).
Stand on step ladder at rear of truck body (1).
Fold up one side of cover (2), making each fold about two feet
wide. Stop folding when top center of bows (3) is reached.
Fold up other side of cover (2), making each fold about two feet
wide. Take off folded cover.
Stow cover (2).
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME
1
NOTE
If bow assemblies (1) have been taken off, replace them.
Refer to TM 9-2320-211-10. If end curtains (2) have been
taken off, replace them. Refer to para 19-3.
1. Put step ladder at front of truck body (3).
2. Put step ladder at rear of truck body (3).
3. Working on step ladders, lay folded top cover (4) across top
center of bow assemblies (1). Folds must face up.
4. Unfold top cover (4) down left and right sides of truck.
Soldier A
Soldier B
Soldiers
A and B
Soldiers
A and B
5.
Soldier
A and B
END OF TASK
Tie lashing ropes (5) to lashing hooks (6) on four sides of truck
body (3).
19-7
TM 9-2320-211-20-3-2
19-5. BOW ASSEMBLY REPAIR.
TOOLS: Cross-tip screwdriver (Phillips type)
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove bow assembly from truck. Refer to
TM 9-2320-211-10.
b. Disassembly.
FRAME 1
Using screwdriver, unscrew and take out
Using screwdriver, unscrew and take out
(4) out of bow corner (5).
Using screwdriver, unscrew and take out
3.
(5) off of bow top (7).
Do steps 1 through 3 again on other side
4.
END OF TASK
1.
2.
19-8
screw (1). Take off strap (2).
two screws (3). Pull bow stake
two screws (6). Pull bow corner
of bow assembly.
TM 9-2320-211-20-3-2
c.
Inspection and Repair.
(1) Check all metal parts. Throw away any bent, broken or damaged parts.
Get new parts in their place.
(2) Check all wooden parts. Throw away any cracked, splintered or warped
parts. Get new parts in their place.
d. Assembly.
FRAME 1
Push bow top (1) into bow corner (2) and aline holes. Using screwdriver,
screw in and tighten two screws (3).
Push bow stake (4) into bow corner (2) and aline holes. Using screwdriver,
2.
screw in and tighten two screws (5).
Put strap (6) against bow corner (2) as shown, aline holes, and hold it in
3.
place. Using screwdriver, screw in and tighten screw (7).
Do steps 1 through 3 again on other side of bow top (1).
4.
NOTE
Follow-on Maintenance Action Required:
Put bow assembly on truck. Refer to TM 9-2320-211-10.
END OF TASK
1.
19-9
TM 9-2320-211-20-3-2
19-6. CAB COVER REMOVAL AND REPLACEMENT.
TOOLS: None
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1. Untie lashing rope (1) from two side handles (2) and hooks (3).
2. Turn 12 button fastener studs (4) to up-and-down position.
GO TO FRAME 2
19-10
TM 9-2320-211-20-3-2
FRAME 2
1.
Lift cover (1) off two side roof rails (2) and slide it up and out of channel
in two pillar posts (3).
2. Fold cover (1) over windshield (4) and slide cover to the left out of windshield
channel (5).
GO TO FRAME 3
19-11
TM 9-2320-211-20-3-2
FRAME 3
Pull up two cabtop catches (1) to unhook two side roof rails (2) from windshield assembly (3).
2. Fold two side roof rails (2) in and down toward two pillar posts (4).
GO TO FRAME 4
1.
19-12
TM 9-2320-211-20-3-2
FRAME 4
1. Lift up and take out two pillar posts (1) from cab frame (2).
2. Slide crossbar bows (3) out of crossbars (4).
3. Strap crossbars (4) and pillar posts (1) together with straps on rear crossbar.
4. Stow cab cover, crossbars (4), and pillar posts (1) behind cab seats.
END OF TASK
19-13
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1.
2.
Take crossbars, pillar post, and cab cover out from behind cab seats.
Slide left and right crossbar bows (1) into crossbars (2). Crossbar with
straps (3) slides onto lower bows as shown.
GO TO FRAME 2
19-14
TM 9-2320-211-20-3-2
FRAME 2
1. Put pillar posts (1) into cab frame (2).
GO TO FRAME 3
19-15
TM 9-2320-211-20-3-2
FRAME 3
1.
Pull up two side roof rails (1) to meet windshield assembly (3).
2.
Push down two catches (3) and lock side roof rails (1) to windshield
assembly (2).
GO TO FRAME 4
19-16
TM 9-2320 -211-20-3-2
FRAME 4
1.
Slide cover (1) into windshield channel (2).
2.
Pull cover (1) over windshield (3) to meet crossbar (4).
3.
Place cover (1) into channels in pillar posts (5) and onto side rails (6).
GO TO FRAME 5
19-17
TM 9-2320-211-20-3-2
FRAME 5
1. Put cover (1) onto 12 fastener studs (2).
2. Turn 12 fastener studs (2) to side-to-side position.
3. Tie lashing rope (3) to side handles (4) and to hooks (5) at rear of cab (6).
END OF TASK
19-18
TM 9-2320-211-20-3-2
19-7. LASHING HOOK REMOVAL AND REPLACEMENT.
TOOLS: 1/2-inch wrench (2)
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
2.
3.
END
Untie and take off rope (1).
Using 1/2-inch wrenches, unscrew and take out 12 screws (2) and 12 nuts (3).
Take off 6 lashing hooks (4).
OF TASK
19-19
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1.
2.
Put 6 lashing hooks (1) in place on cab.
Put in 12 screws (2). Using 1/2-inch wrenches, screw on and tighten 12
nuts (3).
3. Put back and tie lashing rope (4) as shown.
END OF TASK
19-20
TM 9-2320-211-20-3-2
Section III. ACCESSORY ITEMS
WINDSHIELD WIPER MOTOR REMOVAL AND REPLACEMENT .
NOTE
This task is the same for both windshield wiper motors.
This task is shown for the right windshield wiper motor.
TOOLS: Cross-tip screwdriver (Phillips type)
Pliers
3/8-inch open end wrench
Nose clamp pliers
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
19-8.
FRAME
1
Unclip wiper blade (1) from wiper arm (2) and take off blade.
Using 3/8-inch wrench, unscrew capnut (3) and take off arm (2).
Using pliers, slide off washer (4).
Using screwdriver, unscrew two screws (5), letting wiper motor (6) hang on
shaft (7).
GO TO FRAME 2
1.
2.
3.
4.
19-21
TM 9-2320-211-20-3-2
FRAME 2
Using nose clamp pliers, spread clamp (1) and slide clamp back on hose (2).
Pull hose (2) off wiper motor (3) and lift wiper motor clear of windshield
frame (4).
END OF TASK
1.
2.
19-22
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1.
Put end of hose (1) on wiper motor (2). Using hose clamp pliers, spread clamp
(3) and slide clamp down hose to wiper motor.
2. Put wiper motor shaft (4) through hole in windshield frame (5) as shown and
aline two mounting holes.
3. Turn manual control lever (6) to full right position.
GO TO FRAME 2
19-23
TM 9-2320-211-20-3-2
FRAME 2
1.
Using screwdriver, screw in and tighten two screws (1) through windshield
frame (2) into wiper motor (3).
2. Clip wiper blade (4) to wiper arm (5).
3. Using pliers, slide washer (6) onto serrated shaft of wiper motor (3).
4. Put wiper arm (5) on serrated shaft of wiper motor (3). Set arm so that blade
clears windshield center post (7).
5. Using 3/8-inch wrench, screw on and tighten capnut (8).
NOTE
Follow-on Maintenance Action Required:
Start engine and check operation of wiper motor. Refer to
TM 9-2320-211-10.
END OF TASK
19-24
TM 9-2320-211-20-3-2
19-9. WINDSHIELD WIPER BLADE REMOVAL AND REPLACEMENT.
NOTE
This task is the same for both wiper blades.
TOOLS: None
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1. Unhook and take off wiper blade (1) from wiper arm (2).
END OF TASK
19-25
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1. Hook wiper blade hook (1) into wiper arm receptacle (2).
END OF TASK
19-26
TM 9-2320-211-20-3-2
19-10. WINDSHIELD WIPER ARMS REMOVAL AND REPLACEMENT.
NOTE
This task is the same for both wiper arms.
TOOLS: 3/8-inch open end wrench
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
Using wrench, unscrew and take off capnut (1).
1.
2.
Slide off wiper arm (2).
END OF TASK
19-27
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1.
Push wiper arm (1) onto motor shaft (2).
Using wrench, screw on and tighten capnut (3).
2.
END OF TASK
19-28
TM 9-2320-211-20-3-2
19-11. WINDSHIELD WASHER KIT REMOVAL, REPAIR, AND REPLACEMENT.
TOOLS:
7/16-inch wrench (2)
9/16-inch wrench (2)
6-foot tape measure
Flat-tip screwdriver
SUPPLIES: None
PERSONNEL: TWO
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Open hood. Refer to TM 9-2320-211-10.
b. Removal.
FRAME 1
1.
2.
3.
Take cap (1) off reservoir ( 2).
Take strainer (3) off hose (4) and pull hose off cap (1).
Using screwdriver, unscrew and take off two screws (5). Take off
reservoir (2).
GO TO FRAME 2
19-29
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
GO
Working behind instrument panel, pull two hoses (1) off pump (2) and pull
hose (3) off washer jet (4).
Pull hose (5) through grommet (6) and take hoses (1, 3, and 5) off tee fitting
(7) and valve (8).
Pull 3-inch hose (9) off tee fitting (7) and valve (8).
Using 7/16-inch wrenches, unscrew and take off capscrew, two washers, and
nut (10). Take off pump (2).
TO FRAME 3
.
19-30
TM 9-2320-211-20-3-2
FRAME 3
Soldier A 1.
Soldier B 2.
Using 9/16-inch wrench, hold jet washer (1). Tell soldier B
when ready.
Using 7/16-inch wrench, unscrew and take off nut (2) and two
rubber washers (3).
NOTE
Note the way jet washer is facing so it will be put
back the same way.
Soldier A 3. Take jet washer (1) off truck.
END OF TASK
19-31
TM 9-2320-211-20-3-2
c. Repair. Check that all parts are not clogged, cracked or broken. If
parts are damaged, get new ones.
d. Replacement.
FRAME 1
Soldier A 1.
Put jet washer (1) on cowl of truck as shown. Using 9/16-inch
wrench, hold jet washer and face it as noted in removal. Tell
soldier B when ready.
Soldier B 2. Put two rubber washers (2) and nut (3) on jet washer (1).
Using 7/16-inch wrench, tighten nut (3).
GO TO FRAME 2
19-32
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
GO
Working behind instrument panel (1), put pump (2) in place under instrument
panel. Using 7/16-inch wrenches, screw in and tighten capscrew (3), two
washers (4), and nut (5).
Put 7-inch hose (6) and 9-inch hose (7) on pump (2).
Put tee fitting (8) on hose (6) and valve (9) on hose (7) as shown.
Put 3-inch hose (10) between tee fitting (8) and valve (9).
TO FRAME 3
19-33
TM 9-2320-211-20-3-2
FRAME
1.
3
Put one end of 11-inch hose (1) on jet washer (2) and other end of hose
on valve (3).
2. Put 39-inch hose (4) through grommet (5) and put end of hose on tee
fitting (6).
GO TO FRAME 4
19-34
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
3.
Using screwdriver, screw in and tighten two screws (1) in reservoir (2).
Put long (39-inch) hose (3) through cap (4) and put strainer (5) into
hose (3).
Screw cap (4) into reservoir (2).
NOTE
Follow-on Maintenance Action Required:
Close hood. Refer to TM 9-2320-211-10.
END OF TASK
19-35
TM 9-2320-211-20-3-2
19-12. REAR VIEW MIRROR REMOVAL AND REPLACEMENT .
NOTE
The right rear view mirror mounting bracket has
the open slot at the top, and the left rear view
mirror mounting bracket has the open slot on the
bottom. This task is shown for the left rear view
mirror.
TOOLS: 9/16-inch wrench
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
2.
3.
4.
END
19-36
Using wrench, unscrew and take off nut (1) and flat washer (2).
Using wrench, loosen nut (3).
Slide rear view mirror (4) out of bracket (5).
Pull stud (6) out of hole in bracket (7).
OF TASK
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
Put upper stud (1) through hole in mounting bracket (2). Slide lower stud
(3) into bottom bracket (4).
2. Using wrench, screw on and tighten nut (5) with washer (6).
3. Using wrench, tighten nut (7).
END OF TASK
1.
19-37
TM 9-2320-211-20-3-2
19-13. REAR VIEW MIRROR ARM ASSEMBLY REMOVAL AND REPLACEMENT.
NOTE
This task is the same for both left and right mirror
arm assemblies. This task is shown for the left
mirror arm assembly.
TOOLS: 7/16-inch wrench (2)
1/2-inch wrench
Flat punch
Hammer
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove mirror assembly. Refer to para 19-12.
b. Removal.
FRAME 1
Using 7/16-inch wrenches, unscrew and take off two nuts (1). Take off two
lockwashers (2) and flat washers (3).
2. Lift out rod (4) and take off brace assembly (5) and mirror rod brace (6).
GO TO FRAME 2
1.
19-38
TM 9-2320-211-20-3-2
FRAME
2
1.
Using 7/16-inch wrenches, unscrew and take off nut (1) holding braces (2 and
3) to cowl bracket (4).
2.
Take off screw (5) and braces (2 and 3).
GO TO FRAME 3
19-39
TM 9-2320-211-20-3-2
FRAME 3
Using 1/2-inch wrench, hold head of pivot screw (1).
Using 7/16-inch wrenches, unscrew and take off nut (2) holding brace (3) to
hinge (4).
3. Using flat punch and hammer, tap out pivot screw (1) and take off brace (3).
4. Put pivot screw (1) back in place.
GO TO FRAME 4
1.
2.
19-40
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
Using 1/2-inch wrench, hold head of pivot screw (1).
Using 7/16-inch wrenches, unscrew and take off nut (2) holding braces (3 and
4) to hinge (5).
3. Using hammer and flat punch, take out pivot screw (1) and take off braces
(3 and 4).
4. Put pivot screw (1) back in place.
END OF TASK
19-41
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
2.
3.
4.
5.
GO
19-42
Take pivot screw (1) out of hinge (2).
Place braces (3 and 4) on hinge (2) as shown.
Put pivot screw (1) through holes in braces (3 and 4) and in hinge (2).
Using 1/2-inch wrench, hold head of pivot screw (1).
Using 7/16-inch wrench, screw on and tighten nut (5).
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
5.
GO
Take pivot screw (1) out of hinge (2).
Place brace (3) on hinge (2) as shown.
Put pivot screw (1) through hole in brace (3) and in hinge (2) .
Using 1/2-inch wrench, hold head of pivot screw (1).
Using 7/16-inch wrench, screw on and tighten nut (4).
TO FRAME 3
19-43
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
GO
19-44
Place braces (1 and 2) on cowl bracket (3) as shown.
Put screw (4) through holes in braces (1 and 2) and in cowl bracket (3).
Using 7/16-inch wrenches, screw on and tighten nut (5).
TO FRAME 4
TM 9-2320-211-20-3-2
1.
2.
Put brace assembly (1) and mirror rod brace (2) in place as shown.
Put rod (3) through mirror rod brace (2). Put flat washer (4), lockwasher
(5), and nut (6) on each end of rod (3). Using 7/16-inch wrenches, tighten
nuts.
NOTE
Follow-on Maintenance Action Required:
Replace mirror assembly. Refer to para 19-12.
END OF TASK
19-45
TM 9-2320-211-20-3-2
Section IV. DATA PLATES
19-14. VEHICLE DATA PLATES REMOVAL AND REPLACEMENT.
NOTE
Data plates are mounted with screws, rivets, or
adhesive. This task shows one of each type.
TOOLS: For screw mounted plates:
Cross-tip screwdriver (Phillips type)
For drive screw and solid rivet mounted plates:
1/2-inch cold cut chisel
8-ounce ballpeen hammer
4-inch center punch (for drive screws)
Drill, electric (for drive screws)
1/4-inch drill bit (for drive screws)
1/8-inch punch (for rivets)
Blind hand riveter (for rivets)
For adhesive mounted plates:
Flat-tip screwdriver
SUPPLIES: Rivets
Drive screws
Solvent, dry cleaning, type II (SD-2), Fed. Spec PD-680
(for adhesive--held plates)
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
19-46
TM 9-2320-211-20-3-2
a.
FRAME
Removal (Screw-on Type).
1
1. Using phillips screwdriver, unscrew and take out four screws (1).
2. Take off data plate (2).
END OF TASK
19-47
TM 9-2320-211-20-3-2
b.
Replacement (Screw-on Type).
FRAME 1
1. Aline holes in data plate (1) with holes in surface where plate is to be attached.
2. Using phillips screwdriver, screw in and tighten four screws (2).
END OF TASK
19-48
TM 9-2320-211-20-3-2
c.
Removal (Drive Screw Type).
FRAME 1
1.
Using 1/2-inch cold cut chisel and eight-ounce ballpeen hammer, cut off four
drive screw heads (1).
2. Using four-inch center punch, make starter hole in four screw studs (2).
3. Using 1/4-inch drill, drill out four drive screw studs (2). Take off data
plate (3).
END OF TASK
19-49
TM 9-2320-211-20-3-2
d. Replacement (Drive Screw Type).
FRAME 1
1. Aline four holes in data plate (1) with holes in surface where plate is to be attached.
2. Place four drive screws (2) in data plate holes.
3. Using eight-ounce ballpeen hammer, drive in four screws (2).
END OF TASK
19-50
TM 9-2320-211-20-3-2
e.
Removal (Solid Rivets Type).
FRAME 1
1.
Using eight-ounce ballpeen hammer and 1/2-inch cold cut chisel, cut off ends
of four rivets (1).
CAUTION
Make sure rivet end is taken out and thrown
away. Loose rivet ends could cause damage
to equipment.
2. Using ballpeen hammer and 1/8-inch punch, drive out rivets (1). Take
off data plate (2).
END OF TASK
19-51
TM 9-2320-211-20-3-2
f.
Replacement (Solid Rivets Type).
FRAME 1
1.
Aline four holes in data plate (1) with holes in surfaces where plate is to be
attached.
2. Put rivets in riveter and through data plate (1) and part data plate is being
riveted to.
3. Using riveter, rivet data plate (1) tightly in place.
END OF TASK
19-52
TM 9-2320-211-20-3-2
g.
Removal (Adhesive Type)
FRAME 1
1.
Using-flat tip screwdriver (1), pry up end of data plate (2) from surface
where it is mounted.
2. Take off data plate (2).
END OF TASK
19-53
TM 9-2320-211-20-3-2
h.
Replacement (Adhesive Type).
FRAME 1
WARNING
Dry cleaning solvent is flammable. Do not use near
an open flame. Keep a fire extinguisher nearby when
solvent is used. Used only in well-ventilated places.
Failure to do this may result in injury to personnel
and damage to equipment.
1. Using solvent, clean and dry spot where data plate (1) is to be attached.
2. Peel off adhesive protective paper (2) from back of data plate (1).
3. Press on data plate (1).
END OF TASK
19-54
TM 9-2320-211-20-3-2
CHAPTER 20
NONELECTRICAL GAGES GROUP MAINTENANCE
Section I. SCOPE
20-1. EQUIPMENT ITEMS COVERED. This chapter gives equipment maintenance
procedures for nonelectrical gages for which there are authorized corrective maintenance tasks at the organizational maintenance level.
20-2. EQUIPMENT ITEMS NOT COVERED . All equipment items for which corrective
maintenance is authorized at the organizational maintenance level are covered in this
chapter.
Section II.
20-3.
TACHOMETER
AND
NONELECTRICAL
SPEEDOMETER
REMOVAL
GAGES
AND
REPLACEMENT.
NOTE
TOOLS :
This task is the same for the speedometer and
tachometer. This task is shown for the tachometer.
Flat-tip screwdriver
3/4-inch wrench
3/8-inch wrench
SUPPLIES : None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a.
Preliminary Procedure. Disconnect battery ground. Refer to Part 1, para 7-44.
20-1
TM 9-2320-211-20-3-2
b.
Removal.
FRAME 1
1.
Using screwdriver, turn four lockscrews (1) 1/4 turn to left.
2.
Pull instrument cluster (2) down away from instrument panel (3).
GO TO FRAME 2
20-2
TM 9-2320-211-20-3-2
FRAME 2
1.
Using 3/4-inch wrench, unscrew coupling nut (1) and pull flexible shaft
assembly (2) away from tachometer (3).
2. Take off gasket (4).
3. Using 3/8-inch wrench, unscrew and take off two nuts and lockwashers (5).
Pull clamp (6) off tachometer (3) and take tachometer out from front of
instrument cluster (7).
4. Enter hours of operation shown on tachometer in vehicle equipment log if
another tachometer is to be put in.
END OF TASK
20-3
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
Put tachometer (1) through hole from front of instrument cluster (2).
Place clamp (3) over studs (4) and screw on two nuts (5) with lockwashers (6).
Look at front of instrument cluster (2) and make sure tachometer (1) is
straight.
4. Using 3/8-inch wrench, tighten two nuts (5).
GO TO FRAME 2
1.
2.
3.
20-4
TM 9-2320-211-20-3-2
FRAME 2
Put gasket (1) over end of flexible shaft assembly (2) and press it into
coupling nut (3).
Put flexible shaft assembly (2) into tachometer (4).
2.
3.
Using 3/4-inch wrench, screw on and tighten coupling nut (3).
GO TO FRAME 3
1.
20-5
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
Place instrument cluster (1) on instrument panel (2).
Using screwdriver, turn four lockscrews (3) 1/4 turn to right.
Enter hours of operation shown on tachometer in vehicle equipment log if new
tachometer was put in.
NOTE
Follow-on Maintenance Action Required:
1. Reconnect battery ground. Refer to Part 1, para 7-44.
2. Start engine and check tachometer operation. Refer
to TM 9-2320-211-10.
3. Stop engine. Refer to TM 9-2320-211-10.
END OF TASK
20-6
TM 9-2320-211-20-3-2
20-4.
TACHOMETER DRIVE UNIT REMOVAL AND REPLACEMENT.
1-inch wrench
TOOLS:
7/8-inch wrench
SUPPLIES:
Gear cover to drive adapter gasket
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
Preliminary Procedure. Open hood. Refer to TM 9-2320-211-10.
a.
b. Removal.
FRAME 1
1.
2.
3.
4.
Using 1-inch wrench, unscrew coupling nut (1).
Pull flexible shaft (2) from drive unit (3).
Using 1-inch wrench, unscrew and pull out drive unit (3).
Using 7/8-inch wrench, unscrew and take out adapter (4) and gasket (5)
from front cover (6). Throw away gasket.
END OF TASK
20-7
TM 9-2320-211-20-3-2
c.
FRAME
1.
Replacement.
1
Put gasket (1) on adapter (2) and using 7/8-inch wrench, screw in and
tighten adapter into front cover (3).
2.
Line up drive unit (4) with adapter (2).
3.
Using wrench, screw in and tighten drive unit (4).
4.
Push end of flexible shaft (5) into drive unit (4).
5.
Using wrench, screw on and tighten coupling nut (6).
END OF TASK
20-8
TM 9-2320-211-20-3-2
20-5.
TACHOMETER FLEXIBLE SHAFT ASSEMBLY REMOVAL AND
REPLACEMENT.
TOOLS:
3/4-inch wrench
7/16-inch wrench (2)
SUPPLIES:
Tachometer flexible shaft gasket
Tachometer gasket
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a.
Preliminary Procedures.
(1) Disconnect battery ground. Refer to Part 1, para 7-44.
(2) Open hood and left side panel. Refer to TM 9-2320-211-10.
(3) Lower instrument cluster. Refer to Part 1, para 7-15.
b.
Removal.
FRAME 1
1.
Using 3/4-inch wrench, unscrew coupling nut (1) and pull flexible shaft
assembly (2) away from tachometer (3). Take off gasket (4).
GO TO FRAME 2
20-9
TM 9-2320-211-20-3-2
FRAME 2
1.
Using 1-inch wrench, unscrew coupling nut (1). Pull flexible shaft
assembly (2) away from right angle adapter (3).
2.
Take off and throw away gasket (4).
GO TO FRAME 3
20-10
TM 9-2320-211-20-3-2
1.
Using 7/16-inch wrenches, unscrew and take off two locknuts (1) and
bolts (2).
2.
Take two clamps (3) off brackets (4). Open clamps and take clamps off
flexible shaft assembly (5).
GO TO FRAME 4
20-11
TM 9-2320-211-20-3-2
FRAME
1.
4
Pull end of flexible shaft assembly (1) out through grommet (2) in
firewall (3).
Take grommet (2) out of hole in firewall (3).
2.
END OF TASK
20-12
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
Place flexible shaft assembly (1) along top of engine as shown.
Put grommet (2) in hole in firewall (3).
NOTE
Tachometer end (4) of flexible shaft assembly (1) has
square shank.
Put tachometer end (4) of flexible shaft assembly (1) through grommet
3.
(2) as shown.
GO TO FRAME 2
1.
2.
20-13
TM 9-2320-211-20-3-2
FRAME 2
Place gasket (1) on angle drive adapter (2). Aline key (3) with keyway
in angle drive adapter and screw on coupling nut (4). Using 1-inch
wrench, tighten coupling nut.
2.
Put two clamps (5) on flexible shaft assembly (6). Aline holes in clamps
with holes in two brackets (7).
Screw in two bolts (8) and two locknuts (9). Using 7/16-inch wrenches,
3.
tighten locknuts.
GO TO FRAME 3
1.
20-14
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
Put gasket (1) over end of flexible shaft assembly (2) and press it into
coupling nut (3).
Put square end of flexible shaft assembly (2) into tachometer (4) and
screw on coupling nut (3). Using 3/4-inch wrench, tighten nut.
1.
2.
3.
NOTE
Follow-on Maintenance Action Required:
Raise instrument cluster. Refer to Part 1, para 7-15.
Reconnect battery ground. Refer to Part 1, para 7-44.
Close hood and left side panel. Refer to
TM 9-2320-211-10.
END OF TASK
20-15
TM 9-2320-211-20-3-2
20-6.
TACHOMETER DRIVE ADAPTER REMOVAL, REPAIR, AND REPLACEMENT.
1-inch wrench
TOOLS:
1 7/16-inch wrench
Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
SUPPLIES:
Tachometer drive adapter gasket
Clean dry rags
Crocus cloth
Taps
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
Preliminary Procedure. Open hood. Refer to TM 9-2320-211-10.
a.
b.
Removal.
FRAME 1
1.
2.
3.
Using 1-inch wrench, unscrew tachometer drive shaft (1) and lift it off.
Use 1-inch wrench, unscrew tachometer drive adapter (2) and take it out.
Using 1 7/16-inch wrench, unscrew tachometer takeoff adapter (3). Take
out adapter with gasket (4). Throw away gasket.
END OF TASK
20-16
TM 9-2320-211-20-3-2
c.
Cleaning, Inspection, and Repair.
FRAME 1
WARNING
Dry cleaning solvent is flammable. Do not use near an
open flame. Keep a fire extinguisher nearby at all times
when solvent is used. Use only in well-ventilated places.
Failure to do this may result in injury to personnel and
damage to equipment.
1. Clean tachometer drive and adapter in dry cleaning solvent. Dry with
clean rags.
2. Check that tachometer drive adapter (1) and takeoff adapter (2) have no
damaged threads. Repair damaged threads by retapping.
3. Check that tachometer drive adapter (1) and takeoff adapter (2) have no
cracks. If parts are cracked, get new ones.
4. Check that adapter shaft (3) has no burrs or nicks. Polish burrs and
nicks with crocus cloth.
5. Put tachometer drive adapter (1) into takeoff adapter (2) and check that
shaft (3) turns freely. Get a new adapter if shaft is bent.
END OF TASK
20-17
TM 9-2320-211-20-3-2
d.
Replacement.
FRAME 1
1.
2.
3.
Put gasket (1) on takeoff adapter (2).
Using 1 7/16-inch wrench, screw takeoff adapter (2) into housing (3).
Using 1-inch wrench, screw tachometer drive adapter (4) into takeoff
adapter (2).
4. Using 1-inch wrench, screw driveshaft (5) onto tachometer drive adapter (4).
NOTE
Follow-on Maintenance Action Required:
1. Check tachometer operation. Refer to
TM 9-2320-211-10.
2. Close hood. Refer to TM 9-2320-211-10.
END OF TASK
20-18
TM 9-2320-211-20-3-2
20-7. SPEEDOMETER FLEXIBLE SHAFT AND CORE ASSEMBLY
REMOVAL AND REPLACEMENT.
TOOLS: Flat-tip screwdriver
Slip-joint pliers
1/8-inch wrench (2)
3/4-inch wrench
9/16-inch wrench
1-inch wrench
SUPPLIES: None
PERSONNEL: TWO
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedures.
(1) Disconnect battery ground. Refer to Part 1, para 7-44.
(2) Open hood and left side panel. Refer to TM 9-2320-211-10.
(3) Remove front and intermediate tunnels. Refer to para 17-5.
b. Removal.
(1) Flexible shaft assembly.
FRAME 1
1. Using screwdriver, turn four screws (1) 1/4 turn to left.
2. Slide instrument cluster (2) down from instrument panel (3).
GO TO FRAME 2
20-19
TM 9-2320-211-20-3-2
FRAME 2
1.
Using 3/4-inch wrench, unscrew coupling nut (1) and pull flexible shaft
assembly (2) away from speedometer (3) or tachograph (4).
2. Take out gasket (5).
GO TO FRAME 3
20-20
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
GO
Using 1-inch wrench, unscrew coupling nut (1) from adapter assembly (2).
Pull flexible shaft assembly (3) away from adapter assembly (2).
Take gasket (4) out of coupling nut (1).
TO FRAME 4
20-21
TM 9-2320-211-20-3-2
FRAME 4
Soldier A 1.
Using 1/8-inch wrench, hold locknut (1). Tell soldier B
when ready.
Soldier B 2.
Using 7/16-inch wrench, unscrew and take off screw (2).
Take clamp (3) off flexible shaft assembly (4).
GO TO FRAME 5
20-22
TM 9-2320-211-20-3-2
FRAME 5
Using 9/16-inch wrenches, unscrew and take off screw (1) with locknut (2).
Using 9/16-inch wrenches, unscrew and take off screw (3) with locknut (4)
through access hole (5).
NOTE
Note the way flexible shaft assembly (6) is routed so it
may be put back the same way.
3. Pull out flexible shaft assembly (6) and take off two clamps (7).
END OF TASK
1.
2.
20-23
TM 9-2320-211-20-3-2
(2) Core assembly.
FRAME 1
NOTE
To takeout core assembly (1), flexible shaft assembly (2)
does not need to be taken out of truck.
1. Take out C-clip from adapter side of flexible shaft assembly (2).
2. Using pliers, pull core assembly (1) out of flexible shaft assembly (2)
from speedometer end (3).
3. If core assembly (1) is broken, using pliers, pull out other piece from
adapter assembly end (4).
END OF TASK
20-24
TM 9-2320-211-20-3-2
c.
Replacement.
(1) Core assembly.
NOTE
Before putting in core assembly, check flexible
shaft assembly for dents, sharp bends or other
damage. If flexible shaft assembly is damaged,
get new flexible shaft assembly and core
assembly.
FRAME 1
1.
Put keyed end (1) of core assembly (2) into speedometer end (3) of flexible
shaft assembly (4). Speedometer end has smaller coupling nut.
2. Slowly push core assembly (2) through flexible shaft assembly (4) until
squared end (5) seats in speedometer end (3) of flexible shaft assembly.
Keyed end (1) should stick out of adapter assembly end (6) of flexible
shaft assembly.
3. Put C-clip back on adapter side of flexible shaft assembly (4).
END OF TASK
20-25
TM 9-2320-211-20-3-2
(2) Flexible shaft assembly.
FRAME 1
NOTE
Flexible shaft assembly (1) routing under cab may be
slightly different on some trucks. Route flexible shaft
same way as noted in removal.
1.
2.
3.
4.
GO
20-26
Put flexible shaft assembly (1) back in truck with keyed end (2) at adapter
assembly (3) on transfer case (4).
Seat gasket (5) in coupling nut (6).
Aline keyed end (2) with keyway in adapter assembly (3).
Using 1-inch wrench, screw on and tighten coupling nut (6).
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
Put clamp (1) on flexible shaft assembly (2).
Aline hole in clamp (1) with hole in cab floor (3).
Push screw (4) through hole in clamp (1).
Using 9/16-inch wrenches, screw on and tighten locknut (5) through access
hole (6).
GO TO FRAME 3
20-27
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
4.
GO
20-28
Put clamp (1) on flexible shaft assembly (2).
Aline hole in clamp (1) with hole in floor (3).
Push screw (4) through hole in clamp (1).
Using 9/16-inch wrenches, screw on and tighten locknut (5).
TO FRAME 4
TM 9-2320-211-20-3-2
FRAME 4
CAUTION
Check that flexible shaft assembly (1) is clear of all
moving parts and free of sharp bends.
Soldier A 1.
Soldier B 2.
Put clamp (2) on flexible shaft assembly (1). Aline hole in clamp
with hole in firewall (3). Push screw (4) through hole in clamp.
Screw locknut (5) on screw (4). Using 7/16-inch wrench, hold nut.
Tell soldier A when ready.
Soldier A 3.
Using 7/16-inch wrench, tighten screw (4).
GO TO FRAME 5
20-29
TM 9-2320-211-20-3-2
FRAME 5
1.
Put gasket (1) in speedometer end (2) of flexible shaft assembly (3).
2.
Using 3/4-inch wrench, screw on and tighten coupling nut (4) to speedometer
(5) or tachograph (6).
GO TO FRAME 6
20-30
TM 9-2320-211-20-3-2
FRAME 6
1.
2.
Put instrument cluster (1) on instrument panel (2).
Using screwdriver, turn four mounting screws (3) 1/4 turn to right.
NOTE
Follow-on Maintenance Action Required:
1. Reconnect battery ground. Refer to Part 1, para 7-44.
2. Close hood and left-side panel. Refer to
TM 9-2320-211-10.
3. Replace intermediate and front tunnels. Refer to
para 17-5.
4. Check operation of speedometer and odometer.
Refer to TM 9-2320-211-10.
END OF TASK
20-31
TM 9-2320-211-20-3-2
20-8.
SPEEDOMETER SHAFT ADAPTER ASSEMBLY REMOVAL AND REPLACEMENT.
7/8-inch wrench
TOOLS:
1-inch wrench
1 1/6-inch wrench
None
SUPPLIES:
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a.
Removal.
FRAME 1
1.
2.
3.
4.
GO
20-32
Working under truck at transfer and using 1 1/16-inch wrench, hold
adapter (1).
Using 1-inch wrench, unscrew coupling nut (2) from drive (3) on transfer
case.
Pull flexible shaft assembly (4) away from drive (3).
Take off gasket (5).
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME 2
1.
Using 7/8-inch wrench, hold coupling (1). Using 1-inch wrench, take off
coupling nut (2).
2.
Take off assembly (3).
GO TO FRAME 3
20-33
TM 9-2320-211-20-3-2
FRAME 3
1.
Using 7/8-inch wrench, unscrew and take off coupling (1).
2.
Take off drive adapter shaft (2).
END OF TASK
20-34
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
NOTE
Different gear ratios are available. The part numbers
used must be for specific vehicles. Refer to
TM 9-2320-211-20P.
1.
Put drive adapter shaft (1) in slot (2) in transfer case.
2.
Using 7/8-inch wrench, screw in and tighten coupling (3).
GO TO FRAME 2
20-35
TM 9-2320-211-20-3-2
FRAME 2
1.
Put drive joint shaft (1) in drive (2).
2.
Screw on drive nut (3). Do not tighten at this time.
GO TO FRAME 3
20-36
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
4.
5.
END
Put gasket (1) in cable coupling nut (2).
Aline keyed end (3) of cable with keyway in drive (4).
Screw on nut (2). Do not tighten at this time.
Position drive (4) so no sharp bends are in speedometer drive cable.
Tighten nuts (2 and 5).
OF TASK
20-37
TM 9-2320-211-20-3-2
20-9.
SPEEDOMETER DRIVE JOINT ASSEMBLY REMOVAL AND REPLACEMENT.
1-inch wrench
TOOLS:
None
SUPPLIES:
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
Using 1-inch wrench, unscrew coupling nut (1). Pull flexible shaft (2)
from speedometer drive joint assembly unit (3).
2.
Using 1-inch wrench, unscrew nut (4) and pull out speedometer drive
joint assembly (3).
END OF TASK
20-38
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1.
2.
3.
Push end of flexible shaft (1) into speedometer drive joint assembly (2).
Using 1-inch wrench, screw on and tighten coupling nut (3).
Place speedometer drive joint assembly (2) into opening in transfer case
(4).
4.
Using 1-inch wrench, screw on and tighten nut (5).
END OF TASK
20-39
TM 9-2320-211-20-3-2
20-10. TACHOGRAPH (LATE MODEL TRUCKS).
a. Description. The tachograph is an instrument that has a speedometer,
tachometer, odometer, engine revolution counter, and a 24-hour clock all in one
unit. Inside the tachograph is a paper disk chart that is turned by the 24-hour
clock. Readings of the instruments in the tachograph are recorded on the chart.
The chart must be changed every 24 hours or whenever a truck driver is changed.
Charts must be taken out of the tachograph and a new chart replaced at the end
of each 24-hour period. If they are not, readings will be recorded over a second
time and will be unclear.
Inside the tachograph behind the chart are two lamps that light the scales so
the operator can see them during night operation. Location and function of the
tachograph components are given as follows:
FRAME 1
1.
2.
3.
4.
5.
6.
20-40
Lock. Fasten paper disk chart behind instrument face.
Warning indicator. Lights at 2,300 rpm to show engine overspeeding.
Clock. Marks time during 24-hour period recorded on paper disk chart.
Odometer. Shows total vehicle mileage recorded on disk chart during
24-hour period.
MPH. Scale shows vehicle speed recorded on disk chart during 24-hour
period.
RPM. Scale shows engine rpm recorded on disk chart during 24-hour
period.
TM 9-2320-211-20-3-2
Removal.
b.
3/4-inch open end wrench
Flat-tip screwdriver
TOOLS:
Tachograph key
9/16-inch open end wrench
7/16-inch open end wrench
Tags
SUPPLIES:
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
(1) Chart removal.
FRAME 1
Using tachograph key, turn lock (1) to left and using key as a handle,
pull open tachograph (2).
GO TO FRAME 2
1.
20-41
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Lift clamping lever (1).
Lift tachograph chart (2) straight up and over clamping lever (1) and out
of RPM coupling (3). Take chart away from tachograph.
NOTE
Handle and store tachograph charts carefully. Do not
fold, scratch or write on them. After chart is taken
out of the tachograph, all readings from the chart must
be written down on DA Form 2408-1. Charts that have
unusual readings or were on a truck that had an accident should be handled with special care. These charts
must be kept at the unit to back up actions on equipment
improvement recommendations, warranty claims, and
accidents.
END OF TASK
20-42
TM 9-2320-211-20-3-2
(2) Lamp removal.
NOTE
There are three lamps inside the tachograph.
The two red lamps are used to light the scales
for night operation. The white lamp is used for
the engine overspeeding indicator. Procedure
is given in the following steps for the white
lamp. The two red lamps are taken out the same
way.
para 20-10b
FRAME 1
20-43
TM 9-2320-211-20-3-2
(3) Tachograph removal.
(a) Preliminary procedure. Disconnect battery ground cable.
Refer to Part 1, para 7-44.
(b) Removal.
FRAME 1
1.
Working from behind instrument cluster (1) using 9/16-inch open end
wrench, unscrew and take off tube nut (2).
GO TO FRAME 2
20-44
TM 9-2320-211-20-3-2
Using screwdriver, turn four mounting screws (1) 1/4 turn to left.
Pull instrument cluster (2) away from instrument panel (3) about two
inches.
GO TO FRAME 3
1.
2.
20-45
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
GO
20-46
NOTE
Tag driveshaft assemblies (1 and 2) so they will be
put back in the right place.
Working from behind instrument cluster (3) and using 3/4-inch open end
wrench, unscrew coupling nut (4) and take off tachometer driveshaft (1).
Using 3/4-inch open end wrench, unscrew coupling nut (5) and take off
speedometer driveshaft (2).
Pull down instrument cluster (3).
TO FRAME 4
TM 9-2320-211-20-3-2
FRAME 4
NOTE
Tag all wires so they will be put back in the right place.
1.
Unplug two electrical leads (1).
2.
Using 7/16-inch wrench, unscrew and take off capscrew (2) and lockwasher
(3).
Take off tachograph ground lead (4) from firewall (5).
3.
GO TO FRAME 5
20-47
TM 9-2320-211-20-3-2
FRAME 5
1.
2.
3.
END
20-48
Hold tachograph (1) in place from front of instrument cluster (2).
Unscrew and take off two wing nuts (3). Take off two clamps (4).
Take tachograph (1) out from front of instrument cluster (2).
OF TASK
TM 9-2320-211-20-3-2
c.
Replacement.
3/4-inch open end wrench
TOOLS: Flat-tip screwdriver
Tachograph
key
9/16-inch open end wrench
7/16-inch open end wrench
New tachograph chart
SUPPLIES:
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
(1) Tachograph replacement.
FRAME 1
1.
Put tachograph (1) in instrument cluster (2) from front of instrument
cluster.
2.
Put two clamps (3) on two studs (4).
Turn tachograph (1) so wires (5) are in position shown.
3.
4.
Screw on and tighten two wing nuts (6).
GO TO FRAME 2
20-49
TM 9-2320-211-20-3-2
FRAME 2
Put capscrew (1) and lockwasher (2) on tachograph ground lead (3).
Using 7/16-inch wrench, screw in and tighten capscrew to firewall (4).
2.
Plug in two electrical leads (5) as tagged. Take off tags.
3. Using 3/4-inch wrench, screw on and tighten two driveshaft assemblies (6)
as tagged. Take off tags.
GO TO FRAME 3
1.
20-50
TM 9-2320-211-20-3-2
FRAME 3
1.
Push instrument cluster (1) up to instrument panel (2) just enough to
connect driveshaft assemblies (3 and 4).
2.
Using 3/4-inch open end wrench, put two driveshaft assemblies (3 and 4)
in place as tagged and screw on and tighten two coupling nuts (5).
3.
Take off tags.
GO TO FRAME 4
20-51
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
Push instrument cluster (1) all the way up to instrument panel (2).
Using screwdriver, turn four mounting studs (3) 1/4 turn to right.
Check to be sure instrument cluster (1) is held tightly in instrument
panel (2).
GO TO FRAME 5
20-52
TM 9-2320-211-20-3-2
FRAME 5
CAUTION
Do not overtighten tube nut (1) or oil may leak out.
1.
Working from behind instrument cluster (2) using 9/16-inch wrench, screw
on and tighten tube nut (1).
2.
Reconnect battery ground cable. Refer to Part 1, para 7-44.
3.
Start engine. Refer to TM 9-2320-211-10.
4.
Check tube nut (1) for oil leaks and tighten it if needed.
5.
Stop engine. Refer to TM 9-2320-211-10.
END OF TASK
20-53
TM 9-2320-211-20-3-2
(2) Lamp replacement.
NOTE
There are three lamps inside the tachograph. The
two red lamps are used to light the scales for night
operation. The white lamp is used for the overspending indicator. The procedure given in the
following is for the white lamp. This task is the
same for the two red lamps.
FRAME 1
1.
2.
3.
END
20-54
Put lamp (1) in socket on tachograph (2) as shown.
Push down brass strap (3) so it touches end of lamp (1).
Put back tachograph chart. Refer to para 20-10c.
OF TASK
TM 9-2320-211-20-3-2
(3) Chart replacement.
CAUTION
If you cannot get a new chart, put in a used one.
Truck can be used this way until you can get a
new chart. Do not drive truck without a chart
or tachograph will be damaged.
NOTE
Only put in charts with a speed range the same
as the tachograph on the truck or the readings
on the chart will be wrong.
FRAME 1
1.
2.
Write in all information on both sides of new chart shown.
On green side, write driver’s name, date chart is put in, beginning
odometer reading, and engine revolution counter reading.
On blue side of chart, write truck serial number and starting time.
3.
GO TO FRAME 2
20-55
TM 9-2320-211-20-3-2
FRAME
2
NOTE
Clock should be wound each time a new chart is put
in tachograph.
1.
Wind clock by moving winding lever (1) back and forth until it hits the
stop (2).
2.
Set clock by turning chart support (3) to the left.
GO TO FRAME 3
20-56
TM 9-2320-211-20-3-2
FRAME 3
1.
Lift up clamping lever (1).
NOTE
Put chart (2) on tachograph (3) with green side facing
you.
2. Put edge of chart (2) under RPM coupling (4) and over clamping lever (1)
as shown.
3. Push down clamping lever (1).
GO TO FRAME 4
20-57
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
3.
END
20-58
Close tachograph (1) using tachograph key as a handle.
Using tachograph key, lock tachograph (1). Take out key.
Using lateral wheel (2), make final clock setting.
OF TASK
TM 9-2320-211-20-3-2
d.
Tachograph Adjustment.
NOTE
Personnel making tachograph adjustments must
know how to figure out chart recordings. Refer
to para 20-11 for these instructions.
TOOLS:
Flat-tip screwdriver
None
SUPPLIES:
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
(1) Preliminary procedure. Open tachograph. Refer to para 20-10b
(1), frame 1.
(2) Adjusting stop and go stylus.
FRAME
1
1.
2.
3.
4.
If base line reads too high on chart as shown, turn adjusting screw left.
If base line reads too low as shown, turn adjusting screw right.
Close tachograph. Refer to para 20-10c (3), frame 4.
Start engine, let it run for five minutes, then drive truck for at least
five minutes. Refer to TM 9-2320-211-10.
5.
Open tachograph. Refer to para 20-10b (1) frame 1.
Read stop and go field on chart for correct base line recording as shown.
6.
NOTE
Follow-on Maintenance Action Required:
Close tachograph. Refer to para 20-10c (3), frame 4.
END OF TASK
20-59
TM 9-2320-211-20-3-2
(3) Adjusting engine RPM contact.
(a) Preliminary procedure. Open tachograph. Refer to para 20-10b
(1), frame 1.
(b) Adjustment.
FRAME 1
1.
2.
NOTE
Warning indicator (1) should light at 2,300 rpm.
If during operation of truck, warning indicator (1) does not come on at
2,300 rpm, adjust as follows:
a. If warning indicator (1) comes on below 2,300 rpm, turn adjusting
screw (2) to the right.
b. If warning indicator (1) comes on above 2,300 rpm, turn adjusting
screw (2) to the left.
Close tachograph. Refer to para 20-10c (3), frame 4.
CAUTION
During road test, do not go faster or drive the truck
continuously at the maximum allowable speeds shown on
the truck instruction and caution data plate.
3.
Road test truck. Refer to TM 9-2320-211-10. While driving truck, bring
engine speed to 2,300 rpm for a short time. Warning indicator (1) should
light. If indicator does not come on at rpm noted, adjust as given in
step (a) or (b).
END OF TASK
20-60
TM 9-2320-211-20-3-2
(4) Adjusting clock movement.
(a) Preliminary procedure. Remove tachograph chart. Refer to
para 20-10b.
(b) Adjustment.
FRAME 1
1.
2.
If clock (1) is losing time, move adjusting lever (2) towards plus (+).
If clock (1) is gaining time, move adjusting lever (2) towards minus (-).
NOTE
Follow-on Maintenance Action Required:
Replace tachograph chart. Refer to para 20-10c.
END OF TASK
20-61
TM 9-2320-211-20-3-2
20-11. TACHOGRAPH CHART.
a. Description.
The chart is made of a strong red backing paper covered on both sides with a
thin wax coating. Each tachograph stylus cuts a groove in the wax coating so the red
backing paper shows. The red lines that show are the tachograph recordings.
The chart (fig. 20- 1) is divided into four recording fields by green and blue
markings so that the red lines that the stylus makes can be read. The recording
field printed on the front side is green; the field printed on the back side is blue.
Figure 20-1. Front and Back View of Tachograph Chart
20-62
TM 9-2320-211-20-3-2
Four separate readings (Fig. 20-2) are recorded on the chart: truck speed,
stop and go periods, distance traveled, and engine rpm (shown on blue side; green
side is shown here). When the chart is put into the tachograph and the tachograph
cover is closed, the styluses start to record on the chart. The time scales have five
minute markings so the recordings from the styluses can be read according to each
five minute mark.
Figure 20-2. Tachograph Chart Divisions
20-63
TM 9-2320-211-20-3-2
Purpose.
(1) General. The chart contains important information as to how the truck
is being driven. The recordings on the chart will give you the answers to questions,
such as:
(a) How much is the truck used?
(b) How many stops did the truck make and how long were the stops?
(c) Was the truck speeding?
(d) Was the engine left idling too long?
(e) Was the engine warmed up correctly and shut off correctly?
(f) Was the truck driven in the right rpm range?
(g) Was the engine being over speeded?
(h) Was the transmission shifted into the correct gears at all times?
(i) What is the total engine rpm compared to total miles driven?
Tachograph automatically records the answers to these questions on the chart.
Recordings on the chart just have to be read correctly.
(2) Time range for evaluation. The time needed to read the chart depends
on which recordings are being read. A complete daily reading of the chart is not
necessary to make an analysis for a year. Readings can be taken every day for one
month, then these readings can be spread out to give a year reading. For a complete
detailed reading, a time of one or two minutes a chart is all that is needed.
(3) Working times. A new chart is put into the tachograph at the start of
duty hours. The beginning and end of the recordings on the chart should be within
duty hours. By adding the parts of the times marked on the red band by the stop
and go stylus, you will get the exact amount of driving, that was done during duty
hours. The thin line recordings on the chart show pauses or breaks.
NOTE
Make sure trucks have not been used without
permission after duty hours.
(4) Traveling periods. Traveling time is read by the length of broad bands
on the stop and go field. These recordings show how much time the driver was at
the wheel. The total amount of time traveled can be figured by adding broad bands
in the stop and go field. It is also important in figuring average speed and how the
truck is being driven.
(5) Stopped time. Thin lines between broad bands on the stop and go fields
show the time the truck was stopped. The stopped time can be figured by adding the
thin lines in the time periods. When the truck is used locally, there may be a lot of
stopped time. Some reasons for a lot of stopped time periods are:
(a) Loading and unloading.
(b) Waiting at a loading space.
(c) Repairs, servicing or refueling.
(d) Pauses in work.
b.
20-64
TM 9-2320-211-20-3-2
(6) Amount of use. The amount of truck use is the traveling time as compared to the total operating time. Take the total traveling time and divide it by the
total clock time from the chart, then multiply the answer by 100. This answer will
give you the amount of time the truck was used during the 24-hour period.
Traveling time x 100
Amount of use =
Total time
NOTE
The size of the load will affect the traveling time.
(7) Average speed. Average speed can be figured from chart readings.
Take the miles traveled and divide them by the actual driving time in minutes from
the chart, then multiply the answer by 60.
Miles traveled
Average speed = Actual driving time in minutes x 60
MPH
(8) Legal speed limits. For certain types of trucks, the law limits how fast
they may travel on public roads. Check charts from time to time to make sure these
laws are obeyed.
(9) Distance traveled in miles. The amount of miles the truck has traveled
can be found by the odometer reading and the chart reading. The mileage counter
section of the distance recorder counts all miles traveled, even if the tachograph was
left open. The day’s journey or part journey can be read from the chart. At the
start and the end of a journey, distance recorder readings must be written in the
inner field of the chart. The distance traveled will be the reading on the odometer
at the beginning of the journey subtracted from the odometer reading at the end of
the journey. This reading must be the same as the distance recording field on the
chart, unless the readings written on the chart were false or the tachograph was
left open.
20-65
TM 9-2320-211-20-3-2
c.
Reading of Chart.
(1) Vehicle speed field.
The speed field of the chart (Fig. 20-3) is divided by five circles. Each
circle is equal to ten miles an hour. When the truck goes faster, the speed recording
stylus moves up to show how fast the truck was driven. When the truck is stopped,
a base line is recorded. The base line will record just above the time scale as shown.
This line must run even with and above the inside time scale or the chart will not
show the right truck speed. If the base line is below the position shown, it is possible the stylus was bent down to show the truck was driven more slowly than it really
was.
Figure 20-3. Vehicle Speed Recordings
20-66
TM 9-2320-211-20-3-2
(2) Stop and go field. The stop and go field (Fig. 20-4) is between the
inside time scale and the distance recording field. The stop and go stylus records
when the truck is moving or standing still. The recording mechanism is made up of
an oscillating pendulum balanced by a spring. When the truck is moving, the pendulum vibrates, which makes the stop and go stylus move up and down. This up and
down movement of the stylus makes a solid looking red bar about 1/16-inch wide.
When the truck is stopped, the stylus will not move up and down, so a thin red line
will be recorded. The vibrating pendulum records all vibrations of the truck without
any connections to the drive train. This recording will work even if the drive cables
are broken or taken off the tachograph.
Figure 20-4. Stop and Go Recordings
20-67
TM 9-2320-211-20-3-2
(3) Distance recording field. The distance recording field (Fig. 20-5) below
stop and go field is divided by five circles. The space between each circle is equal
to driving exactly one mile. The distance recording stylus records how many miles
were driven in how much time. One complete upward and downward line means the
truck was driven ten miles. Thin straight lines show truck was stopped and for how
long it was stopped.
Figure 20-5. Distance Traveled Recordings
20-68
TM 9-2320-211-20-3-2
(4) Engine RPM field. The engine rpm is recorded on the blue side of the
chart. The readings are recorded at the same time as the readings on the green side.
The engine rpm field (Fig. 20-6) is divided by seven circles. Each circle is equal to
500 rpm. The base line is recorded just above the inside time scale and the 3500 rpm
circle is just below the outside time scale. The base line is recorded as soon as the
chart is put into the tachograph and is only recorded with the engine off. The rpm
recording is made up of vertical arcs. The circle at the top of the arcs shows the
top rpm of the engine at the time shown on the time scale.
Figure 20-6. Engine RPM Recordings
20-69
TM 9-2320-211-20-3-2
d. Analyzing the Chart.
(1) General. After reading charts all the time, tests show that the driver
takes charge of the economical operation of his truck. Charts show if the driver is
driving the truck properly or if he needs some driving instructions. The chart can
be figured out by reading the speed and engine rpm fields daily. The charts shown
in this section show good and bad driving habits.
(2) Good driving speed chart. A good driving speed chart (Fig. 20-7) will
show uniform driving and average speeds. The closer the highest speed reading
comes to the average speed, the more uniform and economical the truck will be driven.
Figure 20-7. Good Driving Speed Chart
20-70
TM 9-2320-211-20-3-2
(3) Bad driving speed chart. High needle-shaped peaks in the vehicle
speed field (Fig. 20-8) show the truck was speeded up and then braked suddenly.
This is bad driving and is an important reason why the truck will not last long.
When reading charts, always think about road and traffic conditions.
Figure 20-8.
Bad Driving Speed Chart
20-71
TM 9-2320-211-20-3-2
(4) Good and bad driving over short distances. Reading the speed field
alone will not give true operation of the truck. Heavy trucks used for short hauls
in heavy traffic must also be covered. Even with law speed limits and heavy traffic,
the driver still has control of the economy of his truck. Two different drivers driving the same route can have the same chart readings and still have different driving
and economy readings. When the speed field is read with the engine rpm field, you
can then figure out the way the truck is being driven. The charts in Fig. 20-9 show
two trips on a scheduled route with good economy driving, and two trips with bad
economy driving. The Speed field recordings show very little difference between each
trip, but look at the rpm fields. In one case, the rpm recordings show good economy
driving. In the other case, the engine was run at the highest rpm in each gear.
There was only a very small difference in the time it took to finish the trips.
Figure 20-9.
20-72
Good and Bad Driving Over Short Distances
TM 9-2320-211-20-3-2
(5) Driving downhill without gears engaged. This can easily be read on the
speed field. Individual speed peaks (Fig. 20-10) will be seen above the maximum
speed stated in the operating instructions for the truck. This condition can also be
read on the rpm field by looking to see if the engine was idling during this time. If
the engine was connected to the wheels at that time on chart, the rpm field would
show an increase as the speed of the truck increased.
Figure 20-10. Driving Downhill without Gear Engaged
20-73
TM 9-2320-211-20-3-2
(6) Driving uphill in wrong gear. This speed field on the chart will not tell
you which gear the truck was driven during this time period. However, the rpm
field (fig. 20-11) will show that during this-time period, the engine was overloaded
at low rpm. This kind of driving will cause major engine damage, and the driver
of the truck must be told of this problem. Driving uphill in the correct gear will
show in the rpm field maximum torque area (fig. 20-12).
Figure 20-11. Driving Uphill in Wrong Gear
Figure 20-12. Driving Uphill in Correct Gear
20-74
TM 9-2320-211-20-3-2
(7) Driving downhill in wrong gear. The speed field (Fig. 20-13) will record
truck speed that changes constantly because the weight of the truck will try to make
the truck go faster. When the service brakes are put on, heavy stress is put on the
brakes and the transmission components. The rpm field will also show constant
change between high and low rpm. With this kind of driving the engine can easily
run at very high rpms.
Figure 20-13. Driving Downhill in Wrong Gear
20-75
TM 9-2320-211-20-3-2
(8) Engine run at excessively high RPM. High rpms can be read on the rpm
field. The rpm field (Fig. 20-14) will clearly show the allowable maximum rpm is constantly being exceeded.
Figure 20-14. Engine Run at Excessively High RPM
20-76
TM 9-2320-211-20-3-2
(9) Excessive engine idling. The rpm field (Fig. 20-15) will clearly show if
the engine has been idling for a period of several hours. Excessive engine idling
will show as low engine rpm for periods of several minutes or hours, while during the
same time period, the speed field will show the truck did not move.
Figure 20-15.
Excessive Engine Idling
20-77
TM 9-2320-211-20-3-2
(10) Cold starting and warming up the engine. The chart in Fig. 20-16
shows the engine was run at 2,300 rpm as soon as it was started. During the same
time period, the speed field shows the truck was driven at 60 mph. Reading the two
fields shows the engine was not warmed up before driving the truck. This kind of
driving can cause damage to pistons and other engine parts. Again, the driver of
the truck must be told to change this driving habit.
Figure 20-16. Poor Cold Starting Procedure
Recording of idling for several minutes on the rpm field (Fig. 20-17) shows good
engine warm up. The speed field will record a base line which shows the truck was
not driven during warm up, pointing out a good cold starting procedure.
Figure 20-17. Good Cold Starting Procedure
20-78
TM 9-2320-211-20-3-2
Falsification and Irregularities.
on the chart fields may not be able to be read
(1) General. Some recordings
from the examples given so far. The reasons could be the driver may have done
something to the tachograph to hide the true recordings or the tachograph may be
broken. The tachograph was built so any readings that record on the chart can be
read.
The tachograph has a lock and key and a knife-type pin on the door of the instrument. When the door is closed, a hole is punched in the chart. This arrangement
will let only authorized personnel see the chart.
Taking off the speedometer or tachometer drive shafts makes the styluses draw base
lines only, but the stop and go stylus still records and shows the truck was driven.
Putting a weight or a rubber band on the speed stylus will record and show something was done on it. Bending the stylus will make it record below zero when the
truck is stopped. The recordings cannot be taken off the chart. Grease can be
washed off the chart but the readings will still be able to be read. False recordings
are rare. The following examples show what to look for if any false readings show on
the chart.
(2) Lowered speed.
(a) Problem. The speed stylus records the base line lower than what
it should be.
(b) Cause. The speed stylus was bent down so the recording on the
chart will show the truck was going slower than it really was. (See fig. 20-18.) To
find the true speed of the truck, add the lower base line reading to the recorded
reading. The tachograph will have to be adjusted so it will read correctly.
e.
Figure 20-18. Speed Stylus Bent to Simulate Lower Speeds
20-79
TM 9-2320-211-20-3-2
(3) Deflection of speed and distance styluses.
(a) Problem. Only the stop and go field shows deflection, while the
speed and distance fields show base line recordings.
(b) Cause. Speedometer drive shaft is broken or the drive shaft was
taken out from the tachograph so the truck can be used without authorization.
Reading the stop and go field (fig. 20-19) will show if truck was used.
Figure 20-19.
20-80
No Deflection of Speed and Distance Styluses
TM 9-2320-211-20-3-2
(4) Interrupted recordings on front side of chart.
(a) Problem. All recordings on the front side of the chart are interrupted, leaving a blank space for part of a trip.
(b) Cause. Tachograph was opened. Blank spaces will show on the
chart because the recording styluses were not touching the chart (Fig. 20-20).
Figure 20-20. All Recordings on Front Side of Chart Interrupted
In addition, check final mileage figures on odometer with original mileage figures on
next chart. If the figures are not the same, trips have been made between chart
changes. Check the time used to take out one chart and put in another. This will
be clearly recorded on the chart. Normally, a new chart should be put into the
tachograph as soon as the used one is taken out. If distance does match, the chart
may have been turned backwards to show different working times (Fig. 20-21).
Figure 20-21. Trip Made Between Removal of Used Chart
and Insertion of New Chart
20-81
TM 9-2320-211-20-3-2
(5) Superimposed recordings.
(a) Problem. Distance and speed recordings show the truck was
stopped and moving at the same time.
(b) Cause:
1. The tachograph was opened and the chart was turned back so
long stops were not recorded (Fig. 20-22, detail A).
2. The chart was in the tachograph more than 24 hours and the
recordings of one day were made on top of the other recordings (Fig. 20-22, detail
B). Check time the chart was put into the tachograph.
3. Recordings have been made by hand (Fig. 20-22, detail C).
These recordings will not look like the recordings made by the tachograph.
Figure 20-22. Superimposed Recordings
20-82
TM 9-2320-211-20-3-2
(6) Long periods of constant speed.
(a) Problem. The speed field recording shows long periods of constant
speed. Constant speeds of this kind should not be used for long time periods.
(b) Cause. The speed stylus was stopped from moving up the scale by
something being stuck into the tachograph. This will show the truck was moving
slower than it really was. True speed may be found by figuring the average speed
on the chart for the time the tachograph recorded constant speed (Fig. 20-23). The
figure you get will usually be higher than the maximum speed allowed. The rpm field
should also show constant rpm in this time period, but it probably will not.
Figure 20-23. Speed Recording Runs for Unusually Long
Period at a Uniform Level
20-83
TM 9-2320-211-20-3-2
(7) All styluses give vertical recordings. The clock was not wound and did
not turn the chart, or the clock was stopped by something being stuck into it. The
chart will not turn, so the styluses will record in the same place on the fields
(Fig. 20-24).
Figure 20-24.
20-84
All Styluses Give Vertical Recordings Due to Stoppage
TM 9-2320-211-20-3-2
20-12. TACHOGRAPH DRIVE SHAFTS REMOVAL AND REPLACEMENT. For procedures to remove and replace the tachograph drive shafts, refer to speedometer
drive shaft removal and replacement, para 20-7, and tachometer drive shaft removal
and replacement, para 20-5.
20-85/(20-86 blank)
TM 9-2320-211-203-2
CHAPTER 21
MAINTENANCE OF MATERIAL USED IN CONJUNCTION
WITH MAJOR ITEMS
Section I. SCOPE
21-1. EQUIPMENT ITEMS COVERED. This chapter gives equipment maintenance
procedures for winterization kits, deep water fording kit, and special purpose kits
for which there are authorized corrective maintenance tasks at the organizational
maintenance level.
21-2. EQUIPMENT ITEMS NOT COVERED. All equipment items for which corrective
maintenance is authorized at the organizational maintenance level are covered in
this chapter.
Section II.
WINTERIZATION KITS
21-3. PERSONNEL HEATER ELECTRIC FUEL PUMP REMOVAL, REPLACEMENT,
AND TEST.
WARNING
Smoking, sparks, or open flame are not allowed
within 50 feet of work area during this task.
TOOLS:
General mechanic tool kit
Flat-tip screwdriver
6-inch pliers
1/2-gallon container
SUPPLIES:
PERSONNEL:
EQUIPMENT
a.
Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
Fuel pump cover gasket
Fuel pump cup gasket
Rags
Two
CONDITION: Truck parked, engine off, handbrake set.
Preliminary Procedures.
(1) Disconnect battery ground cable. Refer to Part 1, para 7-44.
(2) Turn off personnel heater, powerplant heater, and shutoff cocks. Refer
to TM 9-2320-211-10.
21-1
TM 9-2320-211-20-3-2
b.
Removal.
FRAME 1
1.
2.
3*
Using wrenches, hold tube fitting (1) and unscrew tube nut (2).
Pull tube (3) with tube nut (2) away from tube fitting (1).
Using rags, wipe up any fuel which drains from tube (3) and put rags in
approved disposal area.
GO TO FRAME 2
21-2
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
5.
6.
7.
NOTE
When taking off tubes, drain fuel into container and
put fuel in approved disposal area.
Open tool compartment door (1).
Unplug electrical lead (2).
Using wrenches, hold tube fitting (3) and unscrew and take off tube nut (4).
Using wrenches, hold tube fitting (5) and unscrew and take off tube nut (6).
Using wrench, unscrew and take off tube nut (7).
Using wrench, unscrew and take off two capscrews (8) and nuts (9).
Take out fuel pump (10).
21-3
TM 9-2320-211-20-3-2
c. Replacement.
1.
2.
3.
4.
5.
6.
GO
21-4
Aline screw hole in electrical lead clamp (1) with screw hole in fuel pump (2).
Put fuel pump in place as shown. Using wrench, screw in and tighten two
capscrews (3) and nut (4).
Plug in electrical lead (5).
Using wrenches, hold tube fitting (6) and screw in and tighten tube nut (7).
Using wrenches, hold tube fitting (8) and screw in and tighten tube nut (9).
Using wrench, screw on and tighten tube nut (10).
Close tool compartment door.
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME 2
1.
Using wrenches, hold tube fitting (1) and screw on and tighten tube nut (2)
with tube (3).
NOTE
Follow-on Maintenance Action Required:
Reconnect battery ground cable. Refer to Part 1, para 7-44.
END OF TASK
21-5
TM 9-2320-211-20-3-2
d.
Test.
FRAME 1
Soldier A 1.
Soldier B 2.
Soldier A 3.
4.
Soldier
Soldier
Soldier
END OF
21-6
B 5.
A 6.
B 7.
TASK
Check that emergency switch (1) is in ON position.
Open tool compartment door (2) and hold hand on fuel pump (3).
Set heater blower switch (4) to LO or HI position.
Hold RUN-OFF-START switch (5) to START position until indicatorlight comes on and tell soldier B.
Tell soldier A if fuel pump (3) is running.
Let go of RUN-OFF-START switch (5).
Close tool compartment door (2).
TM 9-2320-211-20-3-2
21-4. HOT WATER PERSONNEL HEATER INSPECTION AND FUNCTIONAL TEST.
TOOLS: None
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Inspection. Check all electrical wires for cracks, breaks, or worn or melted
insulation. Pull apart each connector and check for dirt, rust, or corrosion. Tell
direct support maintenance if any wire is damaged.
b. Preliminary Procedure. Start engine and bring it to operating temperature,
Refer to TM 9-2320-211-10.
c. Test.
FRAME 1
1. Pull out AIR knob (1) until it stops.
2. Set heater switch (2) to LO position.
GO TO FRAME 2
21-7
TM 9-2320-211-20-3-2
FRAME 2
Put hand in front of heat diverter opening (1). Slight warm air flow should
be felt.
2. If slight air flow is not felt, adjust cable. Refer to para 21-8.
GO TO FRAME 3
1.
21-8
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
Set heater switch (1) to HI position.
Put hand in front of diverter opening (2). Strong warm air flow must be
felt.
3. If strong air flow is not felt, adjust cable. Refer to para 21-8.
GO TO FRAME 4
21-9
TM 8-2320-211-20-3-2
FRAME 4
1.
2.
3.
Put hands over defroster deflectors (1). Little or no warm air flow will be
felt. If not, adjust cable. Refer to para 21-8.
Pull out DEFROSTER knob (2) until it stops.
Put hands over defroster deflectors (1). Strong warm air flow will be felt. If
not, adjust cable. Refer to para 21-8.
4. Set heater switch (3) to OFF position.
5. Push in DEFROSTER knob (2) and AIR knob (4).
NOTE
Follow-on Maintenance Action Required:
Stop engine. Refer to TM 9-2320-211-10.
END OF TASK
21-10
TM 9-2320-211-20-3-2
21-5. HEATER CIRCUIT BREAKER REMOVAL, REPLACEMENT, AND TEST.
TOOLS: 11/32-inch open end wrench
Flat-tip screwdriver
Multimeter
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedures.
(1) Remove heater control box. Refer to para 21-9.
(2) Remove heater motor control switch. Refer to para 21-10.
21-11
TM 9-2320-211-20-3-2
b.
Removal.
FRAME 1
1.
Using screwdriver and 11/32-inch open end wrench, unscrew and take off
two nuts (1), with ground wire (2). Take out two screws (3) and two
spacers (4).
2. Tag three wire leads (5) so they can be put back in the same place. Using
screwdriver, unscrew and take out screw (6).
3. Turn circuit breaker (7) to the right and tag wire lead (8).
4. Using screwdriver, unscrew and take out screw (9). Take out circuit
breaker (7).
END OF TASK
21-12
TM 9-2320-211-20-3-2
c.
1.
2.
3.
4.
5.
GO
Replacement.
Put circuit breaker (1) in control box (2).
Aline holes in three tagged wire leads (3) with hole in circuit breaker
terminal (4).
Using screwdriver, screw in and tighten screw (5). Take off tags.
Turn circuit breaker (1) to the right. Aline hole in wire lead (6) with hole in
circuit breaker terminal (7).
Using screwdriver, screw in and tighten screw (8). Take off tag.
TO FRAME 2
21-13
TM 9-2320-211-20-3-2
FRAME 2
Aline two mounting holes in circuit breaker (1) with two holes in control
box (2).
2. Push in two screws (3), with two spacers (4). Put on ground wire (5).
3. Using 7/16-inch wrench and screwdriver, screw on and tighten two nuts (6).
NOTE
Follow-on Maintenance Action Required:
Replace heater motor control switch. Refer to para 21-10.
END OF TASK
1.
21-14
TM 9-2320-211-20-3-2
d.
Test.
FRAME 1
1. Plug in and screw on control box harness (1) to control box receptacle (2).
2. Plug wire connector (3) into power lead (4).
GO TO FRAME 2
21-15
TM 9-2320-211-20-3-2
FRAME 2
WARNING
Rest control box on seat or nonmetallic object when battery switch is on to avoid electric shock and injury to
personnel.
1. Turn on battery switch. Refer to TM 9-2320-211-10.
2. Move heater motor control switch (1) to RUN position.
3. Using multimeter, check circuit breaker (2) for 24 volts.
4. Move switch (1) to OFF position.
5. Turn off battery switch. Refer to TM 9-2320-211-10.
NOTE
Follow-on Maintenance Action Required:
Replace heater control box. Refer to para 21-9.
END OF TASK
21-16
TM 9-2320-211-20-3-2
21-6. BLOWER MOTOR EMERGENCY SWITCH REMOVAL, TEST, AND REPLACEMENT.
TOOLS: 7/16-inch wrench (2)
Offset flat-tip screwdriver
Ohmmeter
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
2.
3.
GO
Reach behind emergency switch (1) and pull off two connectors (2).
Using wrenches, unscrew and take out two screws (3) with nuts (4).
Take off protective guard (5) with emergency switch (1).
TO FRAME 2
21-17
TM 9-2320-211-20-3-2
FRAME 2
1. Using screwdriver, unscrew and take out two screws (1) with lockwashers (2).
2. Take off emergency switch (3) from protective guard (4).
END OF TASK
21-18
TM 9-2320-211-20-3-2
b.
Test.
FRAME 1
Put emergency switch (1) in ON position (2).
Using ohmmeter on two connectors (3), check emergency switch (1) for closed
circuit. Refer to vol 2, chapter 26.
3. Put emergency switch (1) in OFF position (4).
4. Using ohmmeter on two connectors (3), check emergency switch for open
circuit. Refer to vol 2, chapter 26.
END OF TASK
1.
2.
21-19
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
Aline holes in emergency switch (1) with holes in protective guard (2).
NOTE
Be sure emergency switch is in OFF (up) position.
2. Using screwdriver, screw in and tighten two screws (3) with lockwashers (4).
GO TO FRAME 2
1.
21-20
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Aline holes in protective guard (1) with holes in underlip of instrument panel (2).
Push two screws (3) through holes in instrument panel (2) and protective guard
(1).
3. Using wrenches, screw on and tighten two nuts (4).
4. Push two connectors (5) into back of emergency switch (6).
END OF TASK
21-21
TM 9-2320-211-20-3-2
21-7. CONTROL VALVE RESISTOR ASSEMBLY (MODEL 8460-C24) REMOVAL, TEST,
AND REPLACEMENT.
WARNING
Smoking, sparks or open flame are not allowed
within 50 feet of work area during this task.
7/16-inch wrench
TOOLS: Flat-tip screwdriver
3/8-inch wrench
11/32-inch socket wrench,
Ohmmeter
1/4-inch drive
13/16-inch wrench
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedures.
(1) Open hood. Refer to TM 9-2320-211-10.
b.
(2) Disconnect battery ground. Refer to Part 1, para 7-44.
NOTE
Tag all wires before taking them off so they can
be put back in their right place.
Test.
FRAME 1
1. Using screwdriver, turn screw (1) 1/4 turn and take off guard (2).
GO TO FRAME 2
21-22
TM 9-2320-211-20-3-2
FRAME 2
1.
Using screwdriver, take off three wire leads (1) from terminal no. 4, 7, and
8 on terminal board (2).
2.
Check resistor (3) for cracks or other damage.
3.
Using ohmmeter, check resistor (3) for breaks in wire. Refer to vol. 2.
4.
If resistor (3) is damaged, take it out and put in a new one. Refer to para
21-7c. If resistor is not damaged, using screwdriver, put wire leads (1)
back on terminal board (2) as tagged. Take off tags.
END OF TASK
21-23
TM 9-2320-211-20-3-2
c.
Removal.
FRAME 1
1.
2.
3.
4.
Using 11/32-inch socket wrench, unscrew and takeoff nut (1).
Take copper strap (2) off igniter (3) and push strap to one side.
Using 13/16-inch wrench, unscrew and takeout igniter (3).
Using 3/8-inch wrench, loosen nut (4). Using 7/16-inch wrench, takeoff
nut (5) and take off primary fuel tube (6).
5. Slide control valve resistor assembly (7) off of primary standpipe (8).
END OF TASK
21-24
TM 9-2320-211-20-3-2
d.
Replacement.
FRAME 1
1.
2.
3.
4.
5.
6.
7.
GO
Slide control valve resistor assembly (1) on primary standpipe (2).
Using screwdriver, put three wire leads (3) on terminal nos. 4, 7, and 8 on
terminal board (4) as tagged. Take off tags.
Push primary fuel tube (5) into primary standpipe (2).
Using 7/16-inch wrench, tighten nut (6). Using 3/8-inch wrench, tighten
nut (7).
Slide igniter (8) into position and, using 13/16-inch wrench, screw in and
tighten igniter.
Place copper strap (9) on igniter (8).
Using 11/32-inch socket wrench, screw on and tighten nut (10).
TO FRAME 2
21-25
TM 9-2320-211-20-3-1
FRAME 2
Place guard (1) into position on personnel heater (2).
Using screwdriver, turn screw (3) 1/4 turn.
NOTE
Follow-on Maintenance Action Required:
1. Reconnect battery ground. Refer to Part 1, para
7-44.
2. Close hood. Refer to TM 9-2320-211-10.
END OF TASK
1.
2.
21-26
TM 9-2320-211-20-3-2
21-8. HOT WATER PERSONNEL HEATER CONTROL CABLES REMOVAL AND
REPLACEMENT.
NOTE
This task is the same for the right and left
heater control cables. This task is shown
for the left heater controllable.
TOOLS: General mechanic’s tool kit
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1. Using flat-tip screwdriver, unscrew and take out screw (1) and clamp (2).
2. Slide cable wire (3) up and off control arm (4).
GO TO FRAME 2
21-27
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
END
21-28
Using open end wrench, unscrew nut (1).
Slide nut (1) and washer (2) offend of cable (3).
Pull control assembly (4) with cable (3) out from front of bracket (5).
Take off identification plate (6).
OF TASK
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1. Hold identification plate (1) in place on bracket (2).
2. Push control cable (3) through hole in identification plate (1) and bracket (2).
GO TO FRAME 2
21-29
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
GO
21-30
Slide washer (1) and nut(2) on cable (3).
Hold control assembly (4) and identification plate (5) in place against bracket (6).
Using wrench, screw on and tighten nut (2) and washer (1).
TO FRAME 3
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
GO
Slide clamp (1) on control cable housing (2).
Push looped end of control wire (3) onto control arm (4).
Put screw (5) through clamp (1) and into hole in control cable bracket (6).
TO FRAME 4
21-31
TM 9-2320-211-20-3-2
FRAME 4
Push control knob (1) all the way in.
Push control arm (2) away from control cable bracket (3) until it stops.
Slide cable (4) in clamp (5) so knob (1) and arm (2) stay in place.
Using flat-tip screwdriver, screw in and tighten screw (6).
Pull out and push in control knob (1) and check that control arm (2) moves
back and forth without binding.
END OF TASK
1.
2.
3.
4.
5.
21-32
TM 9-2320-211-20-3-2
21-9. HEATER CONTROL BOX ASSEMBLY REMOVAL AND REPLACEMENT.
NOTE
This task is the same for personnel heater control box and engine heater control box. Engine
heater control box is under right side of instrument panel and personnel heater control box is
under left side of instrument panel.
TOOLS: Flat-tip screwdriver
7/16-inch wrench (2)
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1.
2.
3.
4.
5.
Unplug electrical sockets (1).
Unscrew and unplug electrical connector (2).
Using screwdriver, unscrew and take out two screws (3).
Slide out control box panel (4).
Using 7/16-inch wrenches, unscrew and take out two cap screws (5) with
lockwashers (6) and nuts (7) with washers (8).
6. Take out control box case assembly (9).
END OF TASK
21-33
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1.
Line up holes in control box case assembly (1) with holes in instrument panel
(2).
2. Using 7/16-inch wrenches, screw in and tighten two capscrews (3) with
lockwashers (4) and two nuts (5) with washers (6).
3. Slide in control box panel (7).
4. Using screwdriver, screw in and tighten two screws (8).
5. Plug in electrical sockets (9).
6. Line up pins on electrical plug (10) and plug into socket on control box
assembly (1).
7. Screw in and tighten nut on plug (10).
END OF TASK
21-34
TM 9-2320-211-20-3-2
21-10. HEATER CONTROL BOX ASSEMBLY REPAIR AND TEST.
TOOLS: Flat-tip screwdriver
11/32-inch open end wrench
9/16-inch open end wrench
3/4-inch open end wrench
SUPPLIES: Tags
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure, Remove heater control box assembly. Refer to para
21-9.
b. Disassembly.
NOTE
Tag all wires before taking them off so they
will be put back in the right place.
FRAME 1
1.
2.
3.
4.
5.
6.
GO
Using 9/16-inch wrench, unscrew and take off two nuts (1) with washers (2).
Take out heater motor switch (3) and blower switch (4).
Using screwdriver, unscrew and take off six screws (5) from back of heater
motor switch (3).
Take off connector jumper (6), connector (7), and six wires (8).
Using screwdriver, unscrew and take off two screws (9) from back of blower
switch (4).
Take off two wires (10).
TO FRAME 2
21-35
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
4.
5.
Using screwdriver, unscrew and take out two screws (1).
Takeoff wires (2 and 3) and push out grommet (4).
Using screwdriver, unscrew and take out two screws (5).
Take off electrical plug assembly (6) with angle bracket (7).
Using screwdriver, unscrew four screws (8) and take electrical plug assembly (6) off angle bracket (7).
GO TO FRAME 3
21-36
TM 9-2320-211-20-3-2
FRAME 3
1.
Using screwdriver and 11/32-inch wrench, unscrew and take off two screws
(1) and two nuts (2).
2. Take off circuit breaker (3) and two spacers (4).
3. Unscrew and take off lens cap (5).
4. Push in lamp (6), turn it to left, and pull it out.
5. Using 3/4-inch wrench, unscrew and take off nut (7).
6. Take out indicator lamp assembly (8) and washer (9).
END OF TASK
21-37
TM 9-2320-211-20-3-2
c.
Repair.
(1) Check all threaded parts for stripped or damaged threads.
(2) Check all wires for cracked, burned or worn insulation.
(3) Check switches for damaged, burned or cracked terminals.
(4) Check to see if lamp is burned out.
(5) Replace any damaged parts with new parts.
Assembly.
d.
FRAME
1.
2.
3.
4.
5.
6.
GO
1
Put indicator lamp assembly (1) with washer (2) into hole in center of
control box panel (3).
Using 3/4-inch wrench, screw on and tighten nut (4).
Push in lamp (5) and turn it to right.
Screw on lens cap (6).
Line up holes in circuit breaker (7), two spacers (8), and lug (9) with holes
in control box panel (3).
Using screwdriver and 11/32-inch wrench, screw in and tighten two screws
(10) and two nuts (11).
TO FRAME 2
21-38
TM 9-2320-211 -20-3-2
FRAME 2
1.
2.
3.
4.
5.
6.
7.
Put electrical plug assembly (1) into angle bracket (2) and line up holes.
Using screwdriver, screw in and tighten four screws (3).
Put angle bracket (2) in place as shown, and line up holes.
Using screwdriver, screw in and tighten four screws (4).
Put grommet (5) in hole as shown and put wire (6) through grommet.
Using screwdriver, screw in and tighten screw (7) with lug (8).
Using screwdriver, screw in and tighten screw (9) with three wires (10) as
tagged. Take off tags.
GO TO FRAME 3
21-39
TM 9-2320-211-20-3-2
FRAME 3
1.
Using screwdriver, screw in and tighten two screws (1) with two wires (2)
as tagged.
2. Put connector jumper (3) and connector (4) on back of heater motor switch (5)
as shown.
3. Using screwdriver, screw in and tighten six screws (6) with six wires as
tagged. Takeoff tags.
4. Put blower switch (7) through hole in control box panel (8) marked HI-LOW.
5. Put heater motor switch (5) through hole in control box panel (8) marked
RUN-OFF-START.
6. Using 9/16-inch wrench, screw on and tighten two nuts (9) with washers (10).
NOTE
Follow-on Maintenance Action Required:
Replace heater control box assembly. Refer to para 21-9.
END OF TASK
21-40
TM 9-2320-211-20-3-2
e.
Functional Test.
FRAME
1
Make sure emergency switch (1) is in ON position.
Pull AIR control knob (2) all the way out.
Set heater motor switch (3) to START position. Hold switch in this position
for at least 10 seconds or until indicator lamp (4) lights.
4. Set heater motor switch (3) to RUN position.
NOTE
If heater motor switch (3) is moved to RUN position
before indicator lamp (4) lights, heater will not work.
5. Set blower switch (5) to LO position, then set switch to HI position.
6. A change in blower speed should be noted. Air coming from heater should be
very warm.
7. Set heater motor switch (3) to OFF position.
8. Push in AIR control knob (2).
END OF TASK
1.
2.
3.
21-41
TM 9-2320-211-20-3-2
21-11. HOT WATER PERSONNEL HEATER HOSES REMOVAL AND REPLACEMENT.
NOTE
This task is the same for heater inlet and outlet
hoses, except outlet hose shutoff cock is at
water pump end of hose. This task is shown for
heater inlet hose.
TOOLS: Flat-tip screwdriver
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off and cool, handbrake set.
a. Preliminary Procedure. Open hood and left side panel. Refer to
TM 9-2320-211-10.
b. Removal.
FRAME 1
1.
2.
3*
Turn shutoff cock (1) to right to close.
Using screwdriver, loosen two screws (2) on two clamps (3).
Slide back two clamps (3) from ends of inlet hose (4).
NOTE
Some coolant will drain from heater unit (5) and hose (4)
when hose is pulled off.
4. Twist and pull off both ends of heater hose (4).
END OF TASK
21-42
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME
1.
2.
3.
4.
1
Put two clamps (1) on ends of inlet hose (2).
Put inlet hose (2) in place on shutoff cock (3) and heater inlet fitting (4).
Slide two clamps (1) to ends of inlet hose (2) and using screwdriver, screw in
and tighten two screws (5).
Turn shutoff cock (3) left to open.
1.
2.
NOTE
Follow-on Maintenance Action Required:
Close hood and left side panel. Refer to
TM 9-2320-211-10.
Add coolant to radiator as needed. Refer to
Part 1, para 6-13.
END OF TASK
21-43
TM 9-2320-211-20-3-2
21-12. POWERPLANT HEATER FUEL FILTER REMOVAL AND REPLACEMENT.
NOTE
There are two fuel filters in the winterization
kit. This task can be used for either one.
Some trucks may have only one filter.
TOOLS: 1/2-gallon container
Fuel filter gasket
SUPPLIES: Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedures.
(1) Disconnect battery ground. Refer to Part 1, para 7-44.
(2) Turnoff powerplant heater. Refer to TM 9-2320-211-10.
b. Removal.
FRAME 1
WARNING
Smoking, sparks or open flame are not allowed within
50 feet of work area during fuel filter service.
1. Put container under fuel filter bowl (1). Unscrew filter bowl and take off
helical compression spring (2), filter element (3), and gasket (4). Empty
fuel in filter bowl into container and put fuel in approved disposal area.
2. Throw away gasket (4).
END OF TASK
21-44
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
2.
Put gasket (1) over threaded relief flange on filter bowl (2).
Put helical compression spring (3) and fuel filter element (4) into filter bowl (2).
CAUTION
Do not overtighten filter bowl (2) as gasket (1) may
be damaged.
3. Screw in and hand tighten filter bowl (2) into head (5).
4. Reconnect battery ground. Refer to Part 1, para 7-44.
5. Start powerplant heater. Refer to TM 9-2320-211-10. Check filter bowl (2)
for leaks.
6. Turn off powerplant heater. Refer to TM 9-2320-211-10.
END OF TASK
21-45
TM 9-2320-211-20-3-2
21-13. POWERPLANT HEATER FUEL LINES AND FITTINGS REMOVAL AND REPLACEMENT. For procedures to remove and replace the powerplant heater fuel lines and
fittings, refer to fuel lines and fittings removal and replacement, Part 1, para 4-11.
21-14. POWERPLANT HEATER CONTROL BOX REMOVAL, REPAIR AND REPLACEMENT. For procedures to remove and replace the powerplant heater control box,
refer to heater control box assembly removal and replacement, para 21-9. For procedures to repair and test the powerplant heater control box, refer to heater control
box assembly repair and test, para 21-10.
21-46
TM 9-2320-211-20-3-2
21-15. BATTERY BOX HEATER KIT REMOVAL AND REPLACEMENT.
TOOLS: General mechanic’s tool kit
5-quart container
Storage battery carrier
SUPPLIES: Tags
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedures.
(1) Remove companion seat. Refer to para 17-8.
(2) Open hood. Refer to TM 9-2320-211-10.
(3) Disconnect battery ground. Refer to Part 1, para 7-44.
b. Removal.
FRAME
1
1.
Turn powerplant heater kit inlet coolant shutoff cock (1) and outlet coolant
shutoff cock (2) all the way to the right to close them.
GO TO FRAME 2
21-47
TM 9-2320-211-20-3-2
FRAME
1.
2.
3.
4.
5.
6.
7.
GO
21-48
2
Place container under truck and under battery box heater coolant outlet
connector (1).
From under truck and using flat-tip screwdriver, loosen screw (2) in
clamp (3).
Push clamp (3) back on hose (4).
Pull hose (4) from connector (1) and put end in container.
After coolant has drained into container, using flat-tip screwdriver, loosen
screw (5) on clamp (6).
Push clamp (6) back on hose (7) and pull hose from battery box heater
coolant inlet connection (8).
Take container from under truck.
TO FRAME 3
TM 9-2320-211-20-3-2
FRAME 3
WARNING
1.
2.
3.
GO
Do not let tool touch battery and truck. This will cause
a direct short, arcing, tool will heat to red hot, and
battery may explode. This can cause serious injury to
personnel and damage to equipment.
NOTE
Tag all cables before taking them off so they are put
back in the right place.
Open latches (1) and take off battery box cover (2).
Using wrenches, loosen screws (3) and take off jumper cable (4).
Using wrenches, loosen screws (5) and take off two battery cable lugs (6).
TO FRAME 4
21-49
TM 9-2320-211-20-3-2
FRAME 4
1.
Using 5/8-inch wrench, unscrew and take off four nuts (1) with washers (2)
and lockwashers (3).
2. Lift out hold down frame (4).
3. Using battery carrier, lift out two batteries (5).
GO TO FRAME 5
21-50
TM 9-2320-211-20-3-2
FRAME
1.
2.
3.
GO
5
Pull battery cables (1) down through holes in floor (2) and bottom of battery box (3).
Unhook and take out four J-bolts (4).
Take out battery heat pad (5).
TO FRAME 6
21-51
TM 9-2320-211-20-3-2
FRAME 6
1. Lift out five pieces of insulation (1).
2. Using 5/8-inch wrench, unscrew and take out four bolts (2) with washers (3).
3. Lift out battery box (4).
END OF TASK
21-52
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
2.
3.
Place battery box (1) on floor
Aline holes in battery box (1)
Using 5/8-inch wrench, screw
(4).
4. Place five pieces of insulation
GO TO FRAME 2
(2).
with holes in floor (2).
in and tighten four bolts (3) with lockwashers
(5) in battery box (1).
21-53
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
Slide battery heat pad (1) into bottom of battery box (2).
Pass inlet connection (3) through opening in left end of battery box (2).
Pass outlet connection (4) through hole in bottom of battery box (2) and cab
floor.
GO TO FRAME 3
21-54
TM 9-2320-211-20-3-2
FRAME
3
1.
2.
Hook four J-bolts (1) on straps (2).
Push battery cables (3) up through holes in floor (4) and bottom of battery
box (5).
GO TO FRAME 4
21-55
TM 9-2320-211-20-3-2
FRAME 4
WARNING
1.
2.
Do not let tool touch battery and truck. This will cause
a direct short, arcing, tool will heat to red hot, and
battery may explode. This can cause serious injury to
personnel and damage to equipment.
Using battery carrier, place two batteries (1) into battery box (2) with
positive (+) terminals toward front of truck.
Place four J-bolts (3) through holes in hold down frame (4).
CAUTION
Do not tighten nuts on J-bolts too much or battery case
may crack.
3. Using 5/8-inch wrench, screw on and tighten four nuts (5) with washers
(6) and lockwashers (7).
GO TO FRAME 5
21-56
TM 9-2320-211-20-3-2
FRAME 5
CAUTION
1.
2.
3.
4.
GO
Be sure battery cable lugs do not touch any part of battery
box or hold down frame.
Slide battery cable lugs (1) on battery posts (2).
Using wrenches, tighten two screws (3).
Slide one end of jumper cable (4) on positive (+) terminal of one battery (5).
Using wrenches, tighten lug screw (6).
TO FRAME 6
21-57
TM 9-2320-211-20-3-2
FRAME
6
Slide other end of jumper cable (1) on negative (-) terminal of second
battery (2).
2. Using wrenches, tighten screw (3).
3. Put cover (4) on battery box (5) and close latches (6).
GO TO FRAME 7
1.
21-58
TM 9-2320-211-20-3-2
FRAME 7
Push hose (1) with clamp (2) on coolant inlet
Place clamp (2) in position and using flat-tip
From under truck, push hose (5) with clamp
(7).
4. Place clamp (6) in position and using flat-tip
GO TO FRAME 8
1.
2.
3.
connection (3).
screwdriver, tighten screw (4).
(6) on coolant outlet connection
screwdriver, tighten screw (8).
21-59
TM 9-2320-211-20-3-2
FRAME 8
1.
Turn Powerplant heater kit inlet coolant shut off cock (1) and outlet coolant
shut off cock (2) all the way to the left to open them.
1.
2.
3.
4.
END OF TASK
21-60
NOTE
Follow-on Maintenance Action Required:
Replace companion seat. Refer to para 17-8.
Replace coolant drained during removal. Add
coolant if needed. Refer to Part 1, para 6-13.
Reconnect battery ground. Refer to Part 1, para 7-44.
Close hood. Refer to TM 9-2320-211-10.
TM 9-2320-211-20-3-2
21-16. HOOD COVER ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS: None
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove radiator assembly. Refer to para 21-17.
b. Removal.
(1) Hood cover.
FRAME 1
1.
2.
3.
4.
END
Open buckle on strap (1) and pull strap out of loops (2).
Open buckle on strap (3) and pull strap out of loops (4).
Do steps 1 and 2 again on other side of hood cover (5).
Take off hood cover (5).
OF TASK
21-61
TM 9-2320-211-20-3-2
(2) Side panel covers.
FRAME 1
1.
2.
3.
4,
END
21-62
Open buckle on strap (1) and pull strap out of loops (2).
Open buckle on strap (3) and pull strap out of loops (4).
Take off side panel cover (5).
Do steps 1 through 3 again for side panel cover on other side of truck.
OF TASK
TM 9-2320-211-20-3-2
c.
Replacement.
(1) Side panel covers.
FRAME
1.
2.
3.
4.
END
1
Put side panel cover (1) in place on truck as shown.
Lace strap (2) through loops (3) and close buckle (4).
Lace strap (5) through loops (6) and close buckle (7).
Do steps 1 through 3 again for side panel cover on other side of truck.
OF TASK
21-63
TM 9-2320-211-20-3-2
(2) Hood cover.
FRAME
1.
2.
3.
4.
1
Put hood cover
Lace strap (2)
Lace strap (5)
Do steps 2 and
END OF TASK
21-64
(1) in place on truck as shown.
through loops (3) and close buckle (4).
through loops (6) and close buckle (7).
3 again on other side of hood cover (1).
NOTE
Follow-on Maintenance Action Required:
Replace radiator cover assembly. Refer to para 21-17.
TM 9-2320-211-20-3-2
21-17. RADIATOR COVER ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS: None
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1. Take off four retaining springs (1).
2. Slide off buckles (2) and unlace tie strips (3).
3. Take off radiator cover (4).
END OF TASK
21-65
TM 9-2320-211-20-3-2
b. Replacement.
FRAME 1
1. Fit radiator cover (1) over mounting loops (2).
2. Lace tie strips (3) through mounting loops (2).
3. Slide buckles (4) over ends of tie strips (3) and pull tie strips tight.
4. Hook four retaining springs (5) into holes inside panel (6).
END OF TASK
21-66
TM 9-2320-211-20-3-2
21-18. GEARSHIFT LEVER COVER ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS: Flat-tip screwdriver
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
1. Using screwdriver, unscrew and take out four screws (1).
2. Unscrew and take off gearshift lever knob (2).
3. Lift out cover (3) over gearshift lever (4).
END OF TASK
21-67
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1. Drop cover (1) over gearshift lever (2) with curved seam toward front of truck.
2. Aline holes in cover (1) with holes in transmission tunnel (3).
3. Using screwdriver, screw in and tighten four screws (4).
4. Screw on gearshift lever knob (5).
END OF TASK
21-68
TM 9-2320-211-20-3-2
21-19. TRANSFER CASE LEVER COVER ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS: Flat-tip screwdriver
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set, TRANSFER
CASE lever in high range.
a. Removal.
FRAME
1.
2.
3.
END
1
Tilt back companion seat cushion (1).
Using screwdriver , unscrew and take out four screws (2).
Lift out cover (3) over TRANSFER CASE lever (4).
OF TASK
21-69
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
Drop cover (1) over TRANSFER CASE lever (2) with seam toward front of
truck.
2. Aline holes in cover (1) with holes in transmission tunnel (3).
3. Using screwdriver, screw in and tighten four screws (4).
4. Push companion seat cushion (5) down.
END OF TASK
1.
21-70
TM 9-2320-211-20-3-2
21-20. ALCOHOL EVAPORATOR KIT REMOVAL, INSPECTION, AND REPLACEMENT.
TOOLS: 7/16-inch wrench (2)
1/2-gallon container
SUPPLIES: Gasket
Solvent, dry cleaning, type II (SD-2), Fed. Spec P-D-680
Alcohol, grade 3
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Open hood. Refer to TM 9-2320-211-10.
b. Removal.
FRAME 1
1.
2.
Using wrenches, unscrew fitting (1) and takeoff tubing (2).
Using wrenches, unscrew and take off three bolts (3) with lockwashers (4)
and nuts (5).
3. Takeout alcohol evaporator assembly (6).
END OF TASK
21-71
TM 9-2320-211-20-3-2
c.
Disassembly.
FRAME 1
Unscrew glass jar (1) from strainer body (2) and take off and throw away
gasket (3).
2. Empty alcohol from glass jar (1) into container. Put alcohol in approved disposal area.
3. Using wrench, unscrew and take out elbow (4).
4* Unscrew and take out filler cap (5).
5. Unscrew and take out plastic tube (6).
END OF TASK
1.
21-72
TM 9-2320-211-20-3-2
WARNING
Dry cleaning solvent is flammable. Do not use
near an open flame. Keep a fire extinguisher
nearby when solvent is used. Use only in wellventilated places. Failure to do this may result
in injury to personnel and damage to equipment.
Eye shields must be worn when using compressed
air. Eye injury can occur if eye shields are not
used.
d. Cleaning and Inspection.
(1) Wash all parts in solvent. Let parts dry.
(2) Blow out tube and ports with compressed air.
(3) Check all parts for cracks, stripped threads, or other damage. If parts
are damaged, tell direct support maintenance.
e. Assembly.
FRAME 1
1.
2.
3.
4.
END
Screw in filler cap (1).
Using wrench, screw in and tighten elbow (2).
Screw in and tighten plastic tube (3) into strainer body (4).
Put gasket (5) into strainer body (4) and screw in and tighten glass jar (6).
OF TASK
21-73
TM 9-2320-211-20-3-2
f.
Replacement.
FRAME 1
1.
2.
3.
4.
Line up holes in strainer body (1) with holes in bracket (2).
Push three bolts (3) through holes in strainer body (1) and bracket (2).
Using wrenches, screw on and tighten three nuts (4) with lockwashers (5).
Using wrench, turn elbow (6) to position shown and screw on and tighten
fitting (7).
5. Unscrew filler cap (8) and fill glass jar (9) with alcohol. Screw on and
tighten filler cap.
NOTE
Follow-on Maintenance Action Required:
Close hood. Refer to TM 9-2320-211-10.
END OF TASK
21-74
TM 9-2320-211-20-3-2
21-21. EVAPORATOR TUBE ASSEMBLY REMOVAL AND REPLACEMENT.
TOOLS: 7/16-inch wrench (2)
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Open hood. Refer to TM 9-2320-211-10.
b. Removal.
FRAME
1
1. Using wrenches, unscrew two fittings (1 and 2).
2. Take off evaporator tube assembly (3).
END OF TASK
21-75
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
Put evaporator tube assembly (1) in place as shown.
Using wrenches, screw on and tighten two fittings (2 and 3).
NOTE
Follow-on Maintenance Action Required:
Close hood. Refer to TM 9-2320-211-10.
END OF TASK
1.
2.
21-76
TM 9-2320-211-20-3-2
21-22. BATTERY SLAVE RECEPTACLE ASSEMBLY REMOVAL, REPAIR, TEST,
AND REPLACEMENT.
TOOLS: 9/16-inch wrench
7/16-inch wrench (2)
Multimeter
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Disconnect battery ground. Refer to Part 1, para 7-44.
b. Removal.
(1) Trucks without powerplant coolant heater.
FRAME 1
1. Using 9/16-inch wrench, loosen nut (1) and take off cable lug (2).
2. Using 9/16-inch wrench, loosen nut (3) and take off cable lug (4).
GO TO FRAME 2
21-77
TM 9-2320-211-20-3-2
FRAME 2
From inside cab, pull cables (1) through grommets (2) into cab.
Using 7/16-inch wrench, hold four nuts (3).
Using 7/16-inch wrench, unscrew and take off four capscrews (4) and
nuts (3).
4. Pull receptacle (5) with cables (1) out of hole in cab (6).
END OF TASK
1.
2.
3.
21-78
TM 9-2320-211-20-3-2
(2) Truck with powerplant coolant heater.
FRAME 1
1.
2.
3.
Using 7/16-inch wrench, loosen nut (1) and take off cable lug (2).
Using 7/16-inch wrench, loosen nut (3) and take off cable lug (4).
Push cable lug (2) and end of cable (5) down through grommet (6) in cab
floor.
GO TO FRAME 2
21-79
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
From inside cab, pull two cables (1) up through grommets (2) into cab.
Using 7/16-inch wrench, hold four nuts (3).
Using 7/16-inch wrench, unscrew and take off four capscrews (4) and
nuts (3).
4. Pull receptacle (5) with cables (1) out of hole in cab (6).
END OF TASK
21-80
TM 9-2320-211-20-3-2
c.
broken
d.
to vol.
Repair. Check to see if receptacle is broken or cracked. If receptacle is
or cracked, get a new slave receptacle kit.
Test. Using multimeter, check receptacle and wiring for contintity. Refer
2 for procedures for using smultimeter.
21-81
TM 9-2320-211-20-3-2
e.
Replacement.
(1) Truck without powerplant coolant heater.
FRAME 1
1.
2.
3.
4.
5.
6.
7.
GO
21-82
Push cables (1) into hole in cab (2).
Aline mounting holes in receptacle (3) with holes in cab (2).
Push four capscrews (4) through holes in receptacle (3) and cab (2).
Screw on four nuts (5) onto four capscrews (4).
Using 7/16-inch wrench, hold four nuts (5).
Using 7/16-inch wrench, tighten four capscrews (4).
Push cables (1) down through grommets (6).
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME 2
1.
Place cable lug (1) of longer cable (2) behind nut (3). Using 9/16-inch
wrench, tighten nut.
2. Place cable lug (4) behind nut (5). Using 9/16-inch wrench, tighten nut.
NOTE
Follow-on Maintenance Action Required:
Reconnect battery ground. Refer to Part 1, para 7-44.
END OF TASK
21-83
TM 9-2320-211-20-3-2
(2) Trucks with powerplant coolant heater.
FRAME 1
1.
2.
3.
4.
5.
6.
7.
GO
21-84
Push two cables (1) into hole in cab (2).
Aline mounting holes in receptacle (3) with holes in cab (2).
Push four capscrews (4) through holes in receptacle (3) and cab (2).
Screw on four nuts (5) onto four capscrews (4).
Using 7/16-inch wrench, hold four nuts (5).
Using 7/16-inch wrench, tighten four capscrews (4).
Push cables (1) down through two grommets (6).
TO FRAME 2
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
3.
Push end of longer cable (1) up through grommet (2) into cab.
Place cable lug (3) behind nut (4). Using 7/16-inch wrench, tighten nut.
Place cable lug (5) behind nut (6). Using 7/16-inch wrench, tighten nut.
NOTE
Follow-on Maintenance Action Required:
Reconnect battery ground. Refer to Part 1, para 7-44.
END OF TASK
21-85
TM 9-2320-211-20-3-2
Section III. DEEP WATER FORDING KIT
21-23. DEEP WATER FORDING RELIEF VALVE REMOVAL AND REPLACEMENT.
NOTE
This task is the same for both relief valves.
TOOLS: Open end wrench set
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
Removal.
FRAME 1
1. Using wrench, hold nut (1).
2. Using wrench, unscrew and take off nut (2) and valve (3).
END OF TASK
21-86
TM 9-2320-211-20-3-2
b.
Replacement.
FRAME 1
1. Using wrench, hold nut (1).
2. Using wrench, screw on and tighten nut (2) and valve (3).
END OF TASK
21-87
TM 9-2320-211-20-3-2
Section IV. SPECIAL PURPOSE KITS
21-24. DECONTAMINATION APPARATUS MOUNTING BRACKET REMOVAL AND
REPLACEMENT.
TOOLS: 7/16-inch wrench
SUPPLIES: None
PERSONNEL: One
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Preliminary Procedure. Remove decontamination apparatus. Refer to
TM 3-4230-204-12&P.
b. Removal.
FRAME 1
Raise companion seat (1).
Using 7/16-inch wrench, unscrew and takeout 12 screws (2) with washers
(3). Lift up tunnel (4).
3. Using 7/16-inch wrench, unscrew and take out three screws (5) with
lockwashers (6) and nuts (7).
4. Takeout bracket (8).
END OF TASK
1.
2.
21-88
TM 9-2320-211-20-3-2
c.
Replacement.
FRAME 1
1.
Put on bracket (1). Put in three screws (2) with lockwashers (3). Using
7/16-inch wrench, put on three nuts (4).
2.
Set tunnel cover (5) in place. Using 7/16-inch wrench, screw in and tighten
12 screws (6) with lockwashers (7).
3. Lower companion seat (8).
NOTE
Follow-on Maintenance Action Required:
Replace decontamination apparatus. Refer to
TM 3-4230-204-12&P
END OF TASK
21-89
TM 9-2320-211-20-3-2
21-25. TROOP SEAT KIT REMOVAL, REPAIR, AND REPLACEMENT.
TOOLS: Cross-tip screwdriver (Phillips type)
General mechanic’s tool kit
3/8-inch drive socket wrench set
Mallet
SUPPLIES: None
PERSONNEL: TWO
EQUIPMENT CONDITION: Truck parked, engine off, handbrake set.
a. Removal.
FRAME 1
Soldiers
A and B
Soldier A
Soldier B
Soldiers
A and B
1.
Untie six lashing ropes (1) on both sides of truck.
2.
3.
4.
5.
Stand at front right side of cover (2).
Stand at rear right side of cover (2).
Fold cover (2) up, making each fold about two feet wide. Stop
folding at top center of cover.
Do steps 2 through 4 again for left side of cover ( 2).
6.
Lift cover (2) up and take it off truck.
GO TO FRAME 2
21-90
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Untie lashing rope (1) on both sides of rear curtain (2).
Pull lashing rope (1) from eyelets (3) and bow (4) on right side of rear curtain
(2).
3. Do step 2 again for left side of rear curtain (2).
4. Take rear curtain (2) off truck and fold it up.
GO TO FRAME 3
21-91
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
4.
GO
21-92
Unhook safety strap assembly (1) from rack stake (2) on both sides of truck
and take safety strap assembly from truck.
Working inside dump body, pull up on left side of bow assembly (3) and take it
out of rack stake (2).
Do step 2 again for right side of bow assembly (3).
Do steps 2 and 3 again for other four bow assemblies (3).
TO FRAME 4
TM 9-2320-211-20-3-2
FRAME 4
Pull up front edge of left seat assembly (1) and swing five legs (2) out from
under seat.
2. Lift up back edge of seat assembly (1) and take hook ends (3) out of slots in
body (4).
3. Take left seat assembly (1) out of truck.
4. Do steps 1 through 3 again for right seat assembly (5).
5. Push up on left rack assembly (6) and take it off truck.
6. Push up on right rack assembly (7) and take it off truck.
END OF TASK
1.
21-93
TM 9-2320-211-20-3-2
b.
Disassembly.
(1) Bow assembly.
FRAME 1
1.
2.
Using screwdriver
Using screwdriver
out of bow corner
3. Using screwdriver
off of bow top (7).
4. Do steps 1 through
END OF TASK
21-94
unscrew and take off screw (1). Take off strap (2).
unscrew and take off two screws (3). Pull bow stake (4)
(5).
unscrew and take off two screws (6). Pull bow corner (5)
3 again on other side of bow top (7).
TM 9-2320-211-20-3-2
(2) Rack assembly.
FRAME 1
1.
Using screwdriver and wrench, unscrew and take off two screws (1),
washers (2), clamps (3), and nuts (4).
2. Using wrenches, unscrew and take off eight bolts (5) and nuts (6). Take
off back board (7).
END OF TASK
21-95
TM 9-2320-211-20-3-2
(3) Seat assembly.
FRAME
1
Using wrench, hold machine screw (1) at each of five channels (2). Using
wrench, unscrew and take off five nuts (3). Take out screws and five
legs (4).
GO TO FRAME 2
1.
21-96
TM 9-2320-211-20-3-2
FRAME 2
1.
Using socket wrench, unscrew and take off four nuts (1) from each of five
channels (2).
2. Take off four hook hinges (3).
3. Take off five channels (2).
4. Using mallet, hammer five screws (4) out of each outside board (5).
5. Using mallet, hammer five screws (6) out of each inside board (7).
END OF TASK
21-97
TM 9-2320-211-20-3-2
c.
Inspection.
(1) Check that all metal parts are not bent, broken or damaged. Get new
parts in place of damaged ones.
(2) Check that all wood parts are not cracked, splintered or warped. Get
new parts in place of damaged ones.
(3) Check that all cloth and rope parts are not torn, cut or frayed. Get new
parts in place of damaged ones.
21-98
TM 9-2320-211-20-3-2
d.
Assembly.
(1) Seat assembly.
FRAME 1
1.
2.
3.
4.
5.
GO
NOTE
The top part of boards (1 and 6) has clearance around
the screw holes to sink the screw head. The bottom
part of boards does not have clearance around the screw
holes.
Find top part of outside board (1). Put five screws (2) through holes in
outside board so screw heads are on top side. Put channels (3) onto screws
with holes (4) to outside board.
Using socket wrench, screw on and tighten nuts (5) onto five screws (2). If
screws do not come through enough to screw on nuts, using mallet, hammer
screws in.
Find top part of outside board (6). Put five screws (7) through holes in
outside board so screw heads are on top side. Put screws through screw holes
in channels (3).
Put hook hinges (8) onto four rear screws (7) with hook part of hinge to top
of outside board (6).
Using wrench, screw on and tighten nuts (9) onto screws (7). If screws do
not come through enough to screw on nuts, using mallet, hammer screws in.
TO FRAME 2
21-99
TM 9-2320-211-20-3-2
FRAME 2
NOTE
The top part of boards (1) has clearance around the
screw holes to sink the screw head. The bottom part
of boards does not have clearance around the screw
holes.
1. Find top part of inside boards (1). Put ten screws (2) through holes in each
inside board so screw heads are on top side.
2. Put screws (2) through holes in channels (3). Using socket wrench, screw
on and tighten ten nuts (4) on screws. If screws do not come through enough
to screw on nuts, using mallet, hammer screws in.
GO TO FRAME 3
21-100
TM 9-2320-211-20-3-2
FRAME 3
1.
Put legs (1) onto channels (2) alining holes for five machine screws (3). Put
machine screws through holes in channels and legs and using wrench, hold
them.
2. Using wrench, screw on five nuts (4), until they are just snug and do not
keep legs (1) from moving easily.
END OF TASK
21-101
TM 9-2320-211-20-3-2
(2) Rack assembly.
FRAME
1.
2.
1
Layout five rack stakes (1) as shown and put in eight screws (2).
Put back board (3) on five rack stakes (1) and fit eight screws (2) into
holes in back board.
3. Using wrenches, screw in and tighten eight nuts (4) and screws (2).
4. Using screwdriver and wrench, screw in and tighten two screws (5),
washers (6), clamps (7), and nuts (8).
END OF TASK
21-102
TM 9-2320-211-20-3-2
(3) Bow assembly.
FRAME 1
Push bow top (1) into bow corner (2) as shown and aline holes. Using screwdriver, screw in and tighten two screws (3).
2. Push bow stake (4) into bow corner (2) as shown and aline holes. Using
screwdriver, screw in and tighten two screws (5).
3. Put strap (6) against bow corner (2). Aline holes and hold in place. Using
screwdriver, screw in and tighten screws (7).
4. Do steps 1 through 3 again for other side of bow top (1).
END OF TASK
1.
21-103
TM 9-2320-211-20-3-2
e.
Replacement.
FRAME 1
1.
Put left rack assembly (1) in place over stake holes (2) as shown. Push down
on rack assembly so stakes (3) are seated.
2. Do step 1 again on other side of truck.
GO TO FRAME 2
21-104
TM 9-2320-211-20-3-2
FRAME 2
1.
2.
Lay right seat assembly (1) on floor of truck with five legs (2) out as shown.
Lift rear edge of seat assembly (1) and put four hook hinges (3) into slots in
body (4).
3. Lift front edge of seat assembly (1) and fold five legs (2) under seat assembly
(1). Move bottom of legs to corner where side meets floor of body.
4. Do steps 1 through 3 again on other side of truck.
GO TO FRAME 3
21-105
TM 9-2320-211-20-3-2
FRAME 3
1.
2.
3.
4.
GO
21-106
Put left bow stake (1) into pocket of rack stake (2). Push bow stake down until
it is seated.
Do step 1 again for right side of bow assembly (3).
Do steps land 2 again for other four bow assemblies (3).
Hook safety strap assembly (4) into place on rack stakes (2) on both sides of truck.
TO FRAME 4
TM 9-2320-211-20-3-2
FRAME 4
1.
2.
Put rear curtain (1) up against end bow assembly (2) as shown.
Thread end of lashing rope (3) through top center eyelet (4), then wind
rope around end bow assembly (2). Keep threading and winding until last
eyelet (5) is reached. Tie rope to lashing hook (6).
3. Do step 2 again with lashing rope (7) on other side of rear curtain (1).
GO TO FRAME 5
21-107
TM 9-2320-211-20-3-2
FRAME 5
Soldiers
A and B
Soldier A
Soldier B
Soldiers
A and B
1.
2.
3.
4.
5.
6.
END OF TASK
21-108
Lay folded cover (1) overtop center of five bow assemblies (2)
with folds up. Front of cover must face front of truck.
Stand at right front of cover (1).
Stand at right rear of cover (1).
Unfold cover (1) down right side of bow assemblies (2) as
shown.
Do steps 2 through 4 again for left side of cover (1).
Tie six lashing ropes (3) to six lashing hooks (4) on both sides of
truck.
TM 9-2320-211-20-3-2
APPENDIX A
REFERENCES
A-1. PUBLICATION INDEXES AND GENERAL REFERENCE.
Indexes should be checked often for the latest changes or revisions of references
given in this appendix and for new publications on materiel covered in this technical
manual.
a.
Military Publications Indexes.
Index of Army Motion Pictures
and Related Audio-Visual Aids . . . . . . . . . DA Pam 108-1
Index of Administrative Publications . . . . . . . DA Pam 310-1
Index of Blank Forms .... . . . . . . . . . . . DA Pam 310-2
Index of Doctrinal Training and
Organizational Publications . . . . . . . . . . . DA Pam 310-3
Military Publications:
Index of Technical Manuals, Technical
Bulletins, Supply Bulletins, and,
Lubrications Orders . . . . . . . . . . . . . . . DA Pam 310-4
Index of Supply Catalogs and
Supply Manuals (excluding types
7, 8, and 9) . . . . . . . . . . . . . . . . . . . DA Pam 310-6
Index of Modification Work Orders . . . . . . . DA Pam 310-7
Common Tools and Equipment . . . . . . . . . .
Supply Manuals . . . . . . . . . . . . . . . . . DA Supply Manuals
SC-4910-95-CL-A01, A02,
A50, A63, A64, A65, A67,
A68, A72, A73, and A74.
SC-4910-950CL-A31 and
-A32
b.
General Reference.
Authorization Abbreviations and Brevity
Codes . . . . . . . . . . . . . . . . . . . . . . AR 310-50
Dictionary of United States Army Terms . . . . AR 310-25
A-1
TM 9-2320-211-20-3-2
A-2. FORMS.
The following forms are for this materiel (refer to DA pamphlet 310-2 for index
of blank forms and to TM 38-750 for explanation of their use).
DA Form 2028
Recommended Changes to Publications . . . . . . . .
DA Form 2407-1
Maintenance Request - Continuation Sheet . . .
DA Form 2408
Equipment Log Assembly (Records) . . . . . . . . .
Processing and Reprocessing Records for
Shipment, Storage, and Issue of
DD Form 1397
Vehicles and Spare Engines . . . . . . . . . . . . . . . .
A-3. OTHER PUBLICATIONS.
a. Vehicle.
LO 9-2320-211-12
Lubrication Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM 9-2320-211-10-1
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Support and General Support
TM 9-2320-211-34
Maintenance Manual (Multifuel Engine) . . . . . .
Organizational Maintenance Repair Parts
TM 9-2320-211-20P
and Special Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Support and General Support
Maintenance Repair Parts and Special
TM 9-2320-211-34P
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . .
TB 43-0123
Rustproofing for Tactical Vehicles. . . . . . . . . . . . . . . .
b. General.
Chemical, Biological, and Radiological
TM 3-220
(CBR) Decontamination . . . . . . . . . . . . . . . . . . .
Chemical, Biological, Radiological, and
FM 21-40
Nuclear Defense . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Inspection and Testing of Lifting
TB 43-0142
Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM 5-725
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AR 385-40
Accident Reporting and Records . . . .. . . . . . .
FM 31-70
Basic Cold Weather Manual . . . . . . . . . . . . . . . . . . . .
TM 750-254
Cooling Systems: Tactical Vehicles . . . . . . . . . . . . . .
TM 21-305
Manual for the Wheeled Vehicle Driver . . . . . .
Driver Selection and Training (Wheeled
TM 21-300
Vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM 9-238
Deepwater Fording of Ordnance Materiel . . . . . . . . . .
Color, Marking and Camouflage Painting
of Military Vehicles, Construction EquipTB 43-0209
ment, and Materials Handling Equipment . . . . .
TM 9-2300-422-20
Security of Tactical Wheeled Vehicles . . . . . . . . . . . .
A-2
TM 9-2320-211-20-3-2
Fording Kits for Combat and Transport
Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-F-3201
Maintenance Assistance and Instruction
Team (MAIT) Program . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 750-51
Transportability Guidance, Trucks, 5 ton,
6 x 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 55-2320-211-15-1
Army Motor Transport Operations . . . . . . . . . . . . . . . . . . FM 55-30
Mountain Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-72
Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-71
Operation and Maintenance of Ordnance
Materiel in Cold Weather (0°F to -65°F) . . . . . . . . . . . . TM 9-207
Painting Instruction for Field Use . . . . . . . . . . . . . . . . . TM 43-0139
Petroleum Handling Equipment and
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 10-1101
Preservation-Packaging, Methods of . . . . . . . . . . . . . . . MIL-P-116
Principles of Automotive Vehicles . . . . . . . . . . . . . . . . . . TM 9-8000
Prevention of Motor Vehicle Accidents . . . . . . . . . . . . . AR 385-55
Organizational Maintenance: Spark Plugs
Used on Ordnance Materiel . . . . . . . . . . . . . . . . . . . . . . . TM 9-8638
Functional Grouping Codes - Combat, Tactical,
and Support Vehicles and Special Purpose
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-93-1
The Army Management System . . . . . . . . . . . . . . . . . . . . . TM 38-750
Administrative Storage of Equipment . . . . . . . . . . . . . . . TM 740-90-1
c. Maintenance and Repair.
Use of Antifreeze Solutions and Cleaning
Compounds in Engine Cooling Systems . . . . . . . . . . . TB 750-651
Organizational Care, Maintenance and Repair of Pneumatic Tires and Inner Tubes. . . . . . . . . TM 9-2610-200-20
Combat Vehicles and Tactical Transport
Vehicles: Procedure for Starting Engines
With Slave Cable . . . . . . . . . . . . . . . . . . . . . . . . . TB ORD 537
Description, Use, Bonding Techniques,
and Properties of Adhesives . . . . . . . . . . . . . . . . . . . . . TB ORD 1032
General Supply: Winterization Kits for
Army Tank-Automotive Materiel . . . . . . . . . . . . . . . . SB 9-16
Inspection, Care and Maintenance of
Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-214
Purging, Cleaning and Coating Interior
Ferrous and Terne Sheet Vehicle
Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . TB 43-0212
A-3
TM 9-2320-211-20-3-2
Operator and Organizational Maintenance
Manual for Lead-Acid Storage Batteries . . . . . . . . . . . TM 9-6140-200-12
Army Materiel Maintenance Concepts and
Policies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 750-1
Operator’s Manual: Welding Theory and
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-237
A-4
TM 9-2320-211-20-3-2
INDEX
Paragraph
Subject
Page
A
Accelerator controls and linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air brake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air brake reservoir assembly . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air brake system valves and fittings (typical) . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air cleaner lines and fittings . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air compressor drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . ....... . . . . . . . . . . . . . .
Replacement and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air compressor leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air compressor service . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air filter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . .
Air filter indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-34
4-34e
4-34a
4-34b
4-34c
4-34d
12-32
12-32a
12-32b
12-32c
12-32d
12-23
12-23a
12-23b
12-23c
12-21
12-21a
12-21b
12-21c
4-6
4-6a
4-6b
4-6c
12-28
12-28a
12-28b
12-28c
12-27
12-27a
12-27b
12-26
12-26d
12-26c
12-26a
12-26b
12-26e
4-5
4-5a
4-5b
4-7
4-7a
4-7b
4-168
4-175
4-168
4-168
4-171
4-171
12-184
12-184
12-185
12-186
12-191
12-144
12-144
12-144
12-150
12-136
12-136
12-136
12-138
4-12
4-12
4-12
4-16
12-168
12-168
12-168
12-169
12-167
12-167
12-167
12-163
12-165
12-164
12-163
12-163
12-166
4-10
4-10
4-11
4-20
4-20
4-21
Index 1
TM 9-2320-211-20-3-2
INDEX - CONT
Paragraph
Subject
Page
A - Cont
Air horn, electric
Preliminary procedure
Removal
Replacement
Air hydraulic cylinder
Preliminary procedure
Removal
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Air pressure relief valve, front and rear axle . . . . . . . . . . . .
Cleaning
Removal
Replacement
Air pressure sending unit, low
Removal
Replacement
Air pressure warning buzzer, low
Preliminary procedure
Removal
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Air shift lines and connections . . . . . . . . . . . . . . . . . .
Inspection and repair
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . .
Removal
Replacement
Air supply valve assembly
Preliminary procedure
Removal
Replacement
Air system leakage test
Air tank safety valve assembly
Removal
Replacement . . . . . . . . . . . . . . . . . . . . . .
Alcohol evaporator kit
Assembly
Cleaning and inspection
Disassembly
Preliminary procedure
Removal
Replacement
Auxiliary power socket assembly
Preliminary procedure . . . . . . . . . . . . . . . . . . . .
Removal
Replacement . . . . .. . . . . . . . . . . . . . . . . . . . . . . .
Index 2
.
.
.
.
.
.
.
.
7-41
7-41a
7- 41b
7- 41c
12-13
12-13a
12-13b
12-13c
11-3
11- 3b
11- 3a
11- 3C
7-39
7-39a
7-39b
7-36
7-36a
7-36b
7-36c
9-4
9-4c
9-4a
9-4b
9-4d
12-20
12-20a
12-20b
12-20c
1-5
12-24
12-24a
12-24b
21-20
21-20e
21-20d
21-20c
21-20a
21-20b
21-20f
7-20
7-20a
7-20b
7-20c
7-212
7-212
7-212
7-213
12-77
12-77
12-77
12-82
11-1
11-3
11-2
11-4
7-203
7-203
7-204
7-201
7-201
7-201
7-202
9-5
9-7
9-5
9-5
9-7
12-133
12-133
12-134
12-135
12-156
12-156
12-156
21-71
21-73
21-73
21-72
21-71
21-71
21-74
7-109
7-109
7-109
7-110
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
10-3
10-3a
10-3b
10-3d
10-3c
16-3
16-3a
16-3b
16-3c
16-4
16-4a
16-4b
16-4c
11-5
11-5a
11-5b
10-1
10-2
10-3
10-5
10-4
16-1
16-1
16-2
16-6
16-11
16-11
16-11
16-14
11-12
11-12
11-13
7-42
7-42c
7-42a
7-42b
21-15
21-15a
21-15b
21-15c
7-44
7-44a
7-44b
21-22
21-22a
21-22b
21-22c
21-22e
21-22d
10-9
10-9a
10-9b
12-15
12-15b
12-15a
12-15c
7-214
7-217
7-214
7-214
21-47
21-47
21-47
21-53
7-233
7-233
7-235
21-77
21-77
21-77
21-81
21-82
21-81
10-34
10-34
10-37
12-100
12-104
12-100
12-108
A - Cont
Axle housing, jacking and supporting . . . . . . . . . . .
Jacking and supporting front axle housing . . . . . .
Jacking and supporting rear axle housing . . . . . . . . .
Removal of front axle housing supports. . . . . . . .
Removal of rear axle housing supports . . . . . . .
Axle spring assembly, front . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle leaf spring assembly, rear . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . .
Axle shaft, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B
Batteries, servicing the . . . . . . . . . . . . . . .
Cleaning the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . .
Specific gravity check . . . . . . . . . . . . . . . .
Battery box heater kit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . .
Battery ground cable, disconnect and reconnect . . . . .
Disconnection . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnection . . . . . . . . . . . . . . . . . .
Battery slave receptacle assembly . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair. . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing assembly, drive shaft center . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . .
Bleeding service air brake system without using bleeder tank . . . .
Bleading air-hydraulic cylinder . . . . . . . . . . . . .
Bleeding master cylinder . . . . . . . . . . . . . . . . . . . . . . .
Bleeding wheel cylinders . . . . . . . . . . . . . . . . . . . . . . .
Index 3
TM 9-2320-211-20-3-2
INDEX-CONT
Paragraph
Subject
Page
B - Cont
Bleeding service brake system using bleeder tank . . . . .
Bleeding air-hydraulic cylinder . . . . . . . . . . . . .
Bleeding master cylinder . . . . . . . . . . . . . . . . .
Bleeding wheel cylinders . . . . . . . . . . . . . . . .
Connecting bleeder tank . . . . . . . . . .
Disconnecting bleeder tank . . . . . . . . . . .
Bow assembly . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . .
Inspection and repair . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . .
Bracket, decontamination apparatur mounting . . . . . . . ..
Preliminary procedure . . . . . . . . . . . . . . . . . . . . .
Removal .. . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Brake band, hoist, automatic, truck M543A2 . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement and adjustment . . . . . . . . . . . . . . . .
Brake hub and drum assembly, front . . . . . . . . . . . . . . .
Preliminary procedure .... . . . . . . ..
Removal
. . . . . . . . . . . . . . . . . .
Cleaning and inspection . . . . . . . .
Replacement . . . . . . . . . . . . .
Brake hub and drum assembly, rear . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . .
Replacement
. . . . . . . . . . . . . . .
Brake hydraulic lines, fittings and hoses . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . .
Replacement
...............................
Brake pedal assembly . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake pedal pad . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . .
Replacement
. . . . . . . . . . . . .
Brakeshoe assembly . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . . .
Removal ... . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . .
Brake valve assembly, hand control . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . ... . . . . . . . . . . . . . . . . . . .
Index 4
12-14
12-14c
12-14b
12-14d
12-14a
12-14e
19-5
19-5d
19-5b
19-5c
19-5a
21-24
21-24a
21-24b
21-24c
18-27
18-27a
18-27b
13-4
13-4a
13-4b
13-4c
13-4d
13-10
13-10a
13-10b
13-10c
12-12
12-12a
12-12b
12-16
12-16a
12-16b
12-16c
12-17
12-17a
12-17b
12-7
12-7a
12-7b
12-7c
12-31
12-31a
12-31b
12-87
12-92
12-90
12-95
12-87
12-97
19-8
19-9
19-8
19-9
19-8
21-88
21-88
21-88
21-89
18-169
18-169
18-172
13-10
13-10
13-10
13-12
13-12
13-53
13-53
13-53
13-56
12-60
12-61
12-69
12-111
12-111
12-111
12-113
12-115
12-115
12-116
12-28
12-18
12-29
12-32
12-178
12-178
12-181
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
17-3
17-3a
17-3b
17-3c
15-3
15-3a
15-3b
17-1
17-1
17-2
17-3
15-1
15-2
15-5
19-6
19-6a
19-6b
17-4
17-4a
17-4b
17-4c
17-5
17-5a
17-5b
17-6
17-6a
17-6b
17-6c
21-5
21-5a
21-5b
21-5c
21-5d
7-12
7-12a
7-12b
1-3
3-4
3-4a
3-4b
3-4c
3-3
3-3b
3-3a
17-8
17-8a
17-8b
19-10
19-10
19-14
17-4
17-4
17-4
17-7
17-10
17-10
17-11
17-12
17-12
17-12
17-13
21-11
21-11
21-12
21-13
21-15
7-62
7-62
7-63
1-1
3-8
3-8
3-8
3-11
3-1
3-3
3-2
17-18
17-18
17-19
B - Cont
Brush guard assembly . . .. . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c
Cab cover . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab door assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab tunnel . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab windshield assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit breaker, heater . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit breaker, instrument panel . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch pedal linkage . . . . .. . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . .. . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . .. . . .. . .
Clutch pedal linkage adjustment . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . .
Check . . . . . . . . . . . . . . . . .
Companion seat assembly . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . .
Index 5
TM 9-2320-211-20-3-2
INDEX-CONT
Paragraph
Subject
Page
C - Cont
Compressed air lines and fittings . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . .
Removal . . . ....... . . . . . . . . . . . . . . .
Replacement . .......... . . . . . . . . . . . . .
Compressor assembly, power driver reciprocating . . . .
Preliminary procedures . . ......... . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . ..... . .
Control box, powerplant heater . . . . . . . . . . . . . .
Replacement . . . . . . . . . . .... . . . . . . . . . . . . . . . .
Control valve assembly, truck M51A2 . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Cotrol valve bank cover, truck M543A2 . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . ... . . . . . . . . . . . . . . . . . . .... . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control valve bank assembly, truck M543A2 . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . .. . .. . .. .
Removal . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .
Replacement .. . . . . . . . . . . . . . . . . . . . . . . . .
Control valve resistor assembly . . . . . . . .. . . . . . .. .
Preliminary procedures . . . . . . . . . . . .. . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Test . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling fan, engine . . . . . . . . . . . . . . . . . .. ......... . . . .
Preliminary procedure .... . . . . . . . .. ... . .. . . . . . .
Removal . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling radiator assembly, engine . . . ... . . . . .. . .. . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . .
Removal . . . ... .... . . . . .. . .. . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system service . . . . . . . . . ... . . . . . . . . .
Cleaning ... . . . . . . . . . . . . . . ... . . .... . . . .
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling . . . . . . . . . . . . .. . . . . . ... . . . . . . . . . .
Flushing . . . . . . . . . . . . . ... . . . . . . . . . . . .
Neutralization . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . .
Crane Boom and shipper cable rollers, truck M543A2 . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 6
12-19
12-19a
12-19b
12-19c
12-25
12-25a
12-25b
12-25c
21-14
21-14c
18-14
18-14a
18-14b
18-22
18-22a
18-22b
18-22c
18-23
18-23a
18-23b
18-23c
21-7
21-7a
21-7c
21-7d
21-7b
6-11
6-11a
6-11b
6-11c
6-3
6-3a
6-3b
6-3c
6-13
6-13c
6-13b
6-13f
6-13e
6-13d
6-13a
18-30
18-30a
18-30b
18-30c
12-118
12-118
12-119
12-126
12-158
12-158
12-158
12-160
21-46
21-46
18-67
18-67
18-71
18-144
18-144
18-144
18-145
18-146
18-146
18-146
18-149
21-22
21-22
21-24
21-25
21-22
6-48
6-48
6-48
6-51
6-1
6-1
6-2
6-6
6-59
6-61
6-60
6-81
6-75
6-64
6-59
18-182
18-182
18-183
18-184
TM 9-2320-211-20-3-2
INDEX-CONT
Paragraph
Subject
Page
C - Cont
Crane inner boom roller assembly, truck M543A2 . . . . . . . . .
Lateral adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . .
Vertical adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane operators back rest, truck M543A2 . . . . ....... .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . .... . . . . . . . . . . . . . . . . . . . . . .
Crane operator’s seat, truck M543A2 . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . .
Replacement ... . . ....... . . . . . . . . . . .
Crane snatch block, truck M543A2 . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of one-part line . . . . . . . . . . . . . . . . . . . . . . . .
Removal of three-part line . . . . . . . . . . . . . . . . . . . . .
Removal of two-part line . . . . . . . . . . . . . . . . . . . . . . .
Replacement of one-part line . . . . . ........ . . . .
Replacement of three-part line . . . . . . . . . . . . . . . .
Replacement of two-part line . . . . . . . . . . . . . . . . . . . . .
Crankcase breather tube, engine . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . ..... . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . .
18-31
18-31c
18-31a
18-31b
17-10
17-10a
17-10b
17-9
17-9a
17-9b
18-32
18-32a
18-32b
18-32d
18-32c
18-32e
18-32g
18-32f
2-5
2-5a
2-5b
2-5c
18-185
18-191
18-185
18-185
17-22
17-22
17-23
17-20
17-20
17-21
18-196
18-196
18-197
18-199
18-198
18-200
18-202
18-201
2-18
2-18
2-18
2-19
21-23
21-23a
21-23b
1-15
1-14
7-49
7-49a
7-49b
14-7
14-7a
14-7b
14-6
14-6e
14-6d
14-6a
14-6b
14-6c
21-86
21-86
21-87
1-5
1-5
7-253
7-253
7-255
14-22
14-22
14-23
14-15
14-21
14-20
14-15
14-15
14-18
D
Deep water fording relief valve . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . ......... . . . . . . . . . . . . . . . . .
Destruction to prevent enemy use . . . . . . . . . . . . . . . . . . . . . .
Directional signal control indicator lamps . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . ......... . . . . ...... . . . . . . . . . . .
Replacement . . . . . ....... . . . . . . . . . . . ......
Drag link relay lever . . . . ..... . . . . . . .... . . . . . ..... .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drag links, upper and lower . . . . . . . . . . . . . . . . . . . . . . .
Draglink adjustment . . . . ...... . . . . . . . . . . . . . . . . . . . . .
Draglink check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 7
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
18-8
18-8d
18-8a
18-8b
18-8c
17-7
17-7a
17-7b
18-16
18-16a
18-16b
18-13
18-13a
18-13b
18-13c
11-4
11-4b
11-4a
11-4c
18-36
18-41
18-36
18-36
18-38
17-14
17-14
17-16
18-77
18-77
18-78
18-65
18-65
18-65
18-66
11-5
11-8
11-5
11-8
7-18
7-18a
7-18b
7-18c
19-3
19-3a
19-3b
19-3c
7-3
7-3a
7-3b
7-3c
7-4
7-4a
7-4b
7-4c
7-103
7-103
7-103
7-105
19-1
19-1
19-2
19-3
7-1
7-1
7-2
7-9
7-20
7-20
7-20
7-21
1-11
21-21
21-21a
21-21b
21-21c
1-2
21-75
21-75
21-75
21-76
D - Cont
Drive chain, gear winch, truck M543A2 . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .
Replacement . . . . . . . . . . . . . .. . . . . . . . . . . . . . .
Driver's seat assembly . . . .. . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dump body hoist brace, truck M51A2 . . . . . . . . . . . . . . .
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dump truck body hoist pump assembly . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . .... . . ... . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dust and moisture seal boot . . . . . . . . . ... . . . . . . . .
Cleaning, inspection, and repair . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .
Replacement . . . . . . . . . . . . . .. . . . . . . . . . . . .
E
Electric brake lock switch, truck M543A2 . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . ... . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
End curtains . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . ... . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine generator . . . . . . . . . . . . . . . .... . . . .
Preliminary procedures . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . ...... . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . ..... .
Engine generator regulator . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . ... . . ... . .. .
Removal . . . .. . .. . . . . . . . . . . .. . . . . . . ..... . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment improvement report and maintenance digest
(EIR MD) and equipment improvement report and maintenance
summary (EIR MS) . . . . . . . . . . . . . . . . . . . . .
Evaporator tube assembly . .. . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . ..... . .. . . . . . . . . . . . . . . .. .. .
Replacement . . ...... . . . . . . . . . . . . . . . ... .
Index 8
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
5-3
5-3c
5-3a
5-3b
5-3d
5-4
5-4c
5-4a
5-4b
5-4d
5-1
5-8
5-1
5-2
5-8
5-17
5-19
5-17
5-17
5-19
6-12
6-12a
6-12b
6-12c
7-31
7-31c
7-31a
7-31d
7-31b
1-10
13-6
13-6c
13-6d
13-6e
13-6a
13-6b
13-6f
4-12
4-12a
4-12b
4-12c
4-16
4-16a
4-16b
4-16c
4-15
4-15a
4-15b
4-13
4-13a
4-13b
4-13c
6-54
6-54
6-54
6-56
7-186
7-190
7-186
7-191
7-188
1-2
13-31
13-32
13-33
13-34
13-31
13-31
13-35
4-59
4-59
4-59
4-63
4-78
4-78
4-79
4-80
4-74
4-74
4-74
4-68
4-68
4-69
4-70
E - Cont
Exhaust pipe, horizontal . . . . . . . . . . . . ....... . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . ..... . . . . . . . . . . . . .......
Exhaust pipe, vertical . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
F
Fan drive belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement and adjustment . . . . . . . . . . . . . . . . . . . .
Floodlight, electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of electric floodlight assembly . . . . . .
Removal of lamp . . . . . . ... . . ........ . . . . . . . . . .
Replacement of electrical floodlight assembly . . . . . . . . . . . . . . .
Replacement of lamp . . . . . . . . . . . . . ..... . . . . . . . .
Forms and records . . . . ......... . . . . . . . . . . . . . . . . . . . .
Front wheel bearing cones and seal for service . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel filter assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel filter element, final, early model trucks . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel filter element, final, late model trucks. . . . . . . . . . . . . . .
Removal . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel filter element, primary . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . .. . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 9
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
4-14
4-14a
4-14b
4-20
4-20a
4-20b
4-20c
21-12
21-12a
21-12b
21-12c
7-35
7-35a
7-35b
21-13
4-3
4-3a
4-3b
4-3c
4-17
4-17b
4-17a
4-9
4-9a
4-9b
4-9c
4-10
4-10a
4-10b
4-4
4-4a
4-4b
4-4c
4-71
4-72
4-73
4-93
4-93
4-93
4-94
21-44
21-44
21-44
21-45
7-199
7-199
7-200
21-46
4-1
4-1
4-2
4-4
4-81
4-81
4-81
4-26
4-26
4-27
4-32
4-36
4-36
4-36
4-7
4-7
4-8
4-9
21-18
21-18a
21-18b
12-29
12-29a
12-29b
12-29c
21-67
21-67
21-68
12-170
12-170
12-170
12-172
F - Cont
Fuel filter element, secondary . ......... . .............. . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel filter, manifold heater (top-mounted, covered) . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel filter, power plant heater . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . .. .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel gage sending unit . . . . . . . . . . ... . . . . . . . .. . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .
Replacement . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel lines and fittings, power plant heater . . . . . . . .
Fuel supply pump . . . . . . . . . . . . . . .... . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .. . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system, low pressure, air bleed . . . . . . . . . . . . .
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . ... . . . . . . . . . . . . . . . . . .
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .
Fuel tank mounting straps . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel transfer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G
Gear shift lever cover assembly . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . .. . .. . . . . . . . . . . .
Governor assembly, air compressor . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . .. . . . . . . .. . . . . . . . . . . . . .
Index 10
TM 9-2320-211-20-3-2
INDEX-CONT
Paragraph
Subject
Page
G - Cont
Governor valve, air compressor, early model trucks . . . . . .
Cleaning filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-30
12-30c
12-30a
12-30b
12-30d
12-174
12-176
12-174
12-175
12-177
12-3
12-3a
12-3b
12-3c
12-4
12-4a
12-4b
12-6
12-6b
12-6a
12-5
12-5a
12-5b
7-22
7-22a
7-22b
7-24
7-23
7-23c
7-23a
7-23b
7-23d
7-25
7-25a
7-25b
7-25d
7-25c
7-25e
21-10
21-10d
21-10b
21-10e
21-10a
21-10c
21-9
21-9a
21-9b
12-1
12-1
12-2
12-4
12-6
12-6
12-6
12-23
12-24
12-23
12-14
12-14
12-18
7-131
7-131
7-131
7-146
7-139
7-143
7-139
7-140
7-144
7-155
7-155
7-155
H
Handbrake lever assembly . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . ......... . . . . . . . . . . . . . . . .
Handbrake linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . ...... . . . . . . . . . . . . ....
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Handbrake shoe adjustment . . . . . ........ . . . . . . . .
Major adjustment . . . . . . . . . . . . . . . . . . . . . . . . .
Minor adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .
Handbrake shoe assembly . . . . . . . . ......... . . . . . . .
Removal ..... . . ........ . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . .........
Headlamp assembly . . . . . . . . . . . ....... . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight assembly . . . . . . . . . . . . . . . . . . . . . . .
Cleaning, inspection, and repair . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight assembly, shielded blackout . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . .. . . . .. . . . . . .
Removal of sealed beam . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of shielded blackout headlight assembly . . . .
Replacement of sealed beam . . . . . . . . . . . . . . . . .
Replacement of shielded blackout headlight assembly . . . . .
Heater control box assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .
Disassembly . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . .
Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater control box assembly . . . . . . . . . . . . . ... . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . .
Replacement . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-158
7-164
21-35
21-38
21-35
21-41
21-35
21-38
21-33
21-33
21-34
Index 11
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
H - Cont
Hoist control linkage, truck M51A2 . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist winch cable, truck M543A2 . . ....... . ........ . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood cover assembly . . . . . . ..... . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn contact button . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn solenoid, with mounting brackets . . . . . . . . . . . . . . . . .
Preliminary procedure . ........ . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn solenoid, without mounting brackets . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoses and clamps . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system hoses and clamps . . . . . . . . . . . . . . . . . . .
Crankcase breather tube hose and clamps . . . . . . . . . .
Turbocharger oil drain tube hose and clamps . . . . . . . . . . . . . .
Hot water heater inspection and functional test . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .
Hub and drum assembly, front and rear . . . . . . . . . . . . . . . .
Front hub and drum . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear hub and drum . . . .. . . . ... . . . . . . . .
Hydraulic brake master cylinder assembly . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic lines, dump body, truck M51A2 . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . .. . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . . .
Index 12
18-17
18-17b
18-17a
18-29
18-29a
18-29b
18-29c
21-16
21-16a
21-16b
21-16c
7-38
7-38a
7-38a
7-38c
7-39
7-39a
7-39b
7-39c
7-40
7-40a
7-40b
7-40c
6-7
6-7a
6-7b
6-7c
21-4
21-4a
21-4b
21-4c
13-5
13-5b
13-5a
13-5c
12-11
12-11a
12-11b
18-15
18-15a
18-15b
18-15c
18-79
18-80
18-79
18-176
18-176
18-176
18-179
21-61
21-61
21-61
21-63
7-205
7-205
7-205
7-206
7-207
7-207
7-207
7-208
7-210
7-210
7-210
7-211
6-24
6-24
6-26
6-28
21-7
21-7
21-7
21-7
13-15
13-15
13-15
13-23
12-52
12-52
12-56
18-75
18-75
18-75
18-76
TM 9-2320-211-20-3-2
INDEX-CONT
Paragraph
Subject
Hydraulic hoses, truck M543A2 . . . . . . . . . . . . . . . . . . . . . .
Boom support crossover-to-reservoir hose . . . . . . . . . .
Boom support crossover-to-snubber valve hose . . . . . .
Boom support crossover tube-to-valve bank tube . . . . .
Crossover tube tee fitting . . . . . . . . . . . . . . . . . . . . .
Flow regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift cylinder-to-boom support crossover tube hoses . . . . .
Oil filter-to-pump hose . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . .
Pump-to-valve bank hose and tube . . . . . . . . . . . . . . .
Valve bank-to-extension cylinder hoses . . . . . . . . . . . . . .
Valve bank-to-hoist motor hoses . . . . . . . . . . . . . . . . . . . . .
Valve bank-to-hoist motor tubes . . . . . . . . . . . . . . . . . .
Valve bank-to-swing motor hoses . . . . . . . . . . . . . . . .
Hydraulic oil filter element, truck M543A2 . . . . . . . . . . .. . .
Assembly . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .
Cleaning, inspection, and repair . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic oil tank assembly, truck M543A2 . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .
Hydraulic steering oil reservoir . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic system pressure . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . .
Test and adjustment . . . . . . . . . . . . . . . . . . . . . . . . .
Page
18-18
18-181
18-18c
18-18i
18-18h
18-18j
18-18b
18-18m
18-18a
18-18e
18-18k
18-18g
18-18f
18-18d
18-24
18-24e
18-24d
18-24c
18-24a
18-24b
18-24f
18-25
18-25a
18-25b
18-25c
14-12
14-12a
14-12b
14-12c
18-20
18-20a
18-20b
18-83
18-128
18-86
18-120
18-112
18-124
18-84
18-130
18-83
18-94
18-112
18-104
18-98
18-88
18-152
18-156
18-155
18-153
18-152
18-152
18-158
18-159
18-159
18-159
18-163
14-47
14-47
14-48
14-51
18-135
18-135
18-135
1-16
7-46
7-46a
7-46b
7-46c
7-15
7-15a
7-15b
7-15c
1-5
7-241
7-241
7-243
7-243
7-74
7-74
7-74
7-80
I
Identification and tabulated data . . . . . . . . . . . . . . . . . . . . .
Intervehicular electrical receptacle connector, M52A2 truck . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. .
Instrument cluster, with speedometer and tachometer . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 13
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
7-16
7-16a
7-16b
7-16c
7-21
7-21a
7-21b
7-21c
7-14
7-14d
7-14a
7-14b
7-14c
7-86
7-86
7-86
7-93
7-111
7-111
7-112
7-121
7-71
7-73
7-71
7-71
7-72
7-13
7-13a
7-13b
7-13c
19-7
19-7a
19-7b
7-64
7-64
7-64
7-67
19-19
19-19
19-20
18-19
7-27
7-27c
7-27a
7-27d
7-27b
7-51
7-51a
7-51b
7-26
7-26a
7-26b
4-11
4-11a
4-11b
19-4
19-4a
19-4b
1-20
18-134
7-169
7-171
7-169
7-172
7-170
7-259
7-259
7-260
7-167
7-167
7-168
4-38
4-39
4-49
19-5
19-5
19-7
1-13
I - Cont
Instrument cluster, with tachgraph . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . .
Instrument panel . . . . . . . . . . . . . . . . . . . .......
Preliminary procedures . . . . . . . . . .... . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruments and gages . . . . . . . . . . . . . . . . . . . . .
Functional test . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . .... . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . .. . . .... . . . . . . . . . . . . ...
L
Lamp assemblies, instrument cluster . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . ......... . . . . . . . . . . . ..
Replacement ..... . ........ . . . . . . . . . .
Lashing hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift cylinder packing assembly, adjustment, trucks M543,
M543A1, and M543A2 . . . . . . . . . . . . . . . . . . . . . . . .
Light assembly, composite front and lamp (late models) . . . . . . .
Removal of front composite light assembly . . . . . . . . . . .
Removal of lamp . . . . . . . . . . . . . . . . . . . . . .
Replacement of front composite light assembly . . . . .
Replacement of lamp . . . . . . . . . . . . . . . . . . . .. . . . .
Light flasher, warning . . . . .. . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . .. ..... . . . . . . . . . . . . . . . . . . . ...
Light, special lighting marker . . . . . . . . . .... . . . .. . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lines and fittings, fuel tank . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . ... . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Long cargo body top cover ... . ..... . . . . . .. . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . .
Lubrication instructions, general . . . . . . . . . . . . . . .
Index 14
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
1-2
4-18
4-18a
4-18b
4-18c
4-31
4-31a
4-31b
4-31c
4-29
4-29a
4-29b
4-29c
4-30
4-30a
4-30b
4-30c
4-25
4-25a
4-25b
4-25c
4-21
4-21a
4-21b
4-21c
4-19
4-19a
4-19b
4-19c
4-27
4-27a
4-27b
4-27c
1-1
4-85
4-85
4-85
4-87
4-158
4-158
4-158
4-159
4-152
4-152
4-152
4-153
4-154
4-154
4-154
4-156
4-142
4-142
4-142
4-143
4-95
4-95
4-95
4-97
4-89
4-89
4-89
4-91
4-146
4-146
4-146
4-147
4-28
4-28a
4-28b
4-28c
1-13
4-148
4-148
4-148
4-150
1-5
M
Maintenance, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold heater electrical fuel supply pump . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold heater wiring harness . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Manifold heater ignition unit, coil ...... . . . . . . . . .
Preliminary procedures . . . . . . ..... . . . . ...
Removal . . . . . . . . . . ........ . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold heater ignition unit, side mounted . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . ....
Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold heater nozzle and valve assembly . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . .
Removal . ........ . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Manifold heater side mounted fuel fitter. .. . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . .
Manifold heater side mounted fuel pump. . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . .... . . . . . . . . . . . . . . . .
Manifold heater spark plug . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . ..... . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold heater (top-mounted, covered) ignition coil
and fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures ...... . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . ..... . . . . . . . . . .
Replacement ......... . ......... . . . . . .
Metric system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 15
TM 9-2320-211-20-3-2
INDEX-CONT
Paragraph
Subject
Page
O
Oil cooler water inlet tube . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . ......... . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Oil filter element . . . . . . . . . . . . . . . . . ..... . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pressure gage sending unit . . . . . . . . . . . . . . .
Removal . . . . . . . . . .. . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . .
Operator guard, truck M543A2 . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10
6-10a
6-10b
6-10c
2-4
2-4a
2-4b
7-34
7-34a
7-34b
18-33
18-33a
18-33b
6-46
6-46
6-46
6-47
2-13
2-13
2-15
7-197
7-197
7-198
18-204
18-204
18-205
1-4
7-47
7-47a
7-47b
21-3
21-3a
21-3b
21-3c
21-3d
21-8
21-8a
21-8b
21-11
21-11a
21-11b
21-11c
18-10
18-10a
18-10b
18-10c
15-5
15-5a
15-5b
15-4
15-4a
15-4b
1-2
7-245
7-245
7-245
21-1
21-1
21-2
21-4
21-6
21-27
21-27
21-29
21-42
21-42
21-42
21-43
18-47
18-47
18-47
18-48
15-19
15-19
15-20
15-9
15-9
15-14
P
Painting . . . . . . . . . ... .... . . . . . . . . . . . . . . . . . . . . . . .
Park and warning light socket and wiring, truck M543A2 . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . .. . . . . . . . ..
Personnel heater electric fuel pump . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . .. . . . . . . . . . . ... . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personnel hot water heater control cables. . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personnel hot water heater hoses . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . .
Pillow block, rear winch propeller shaft . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . .. . . . . . . . . . . . . . . . . . .
Pintle assembly, towing . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . .... . . . . . .. . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Pintle assembly, towing . . . . . . . . . . . . . . . . . . . .. .. . . .
Removal . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 16
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
17-12
17-12a
17-12b
17-12c
14-4
14-4a
14-4b
14-4c
14-11
14-11a
14-11b
14-11c
10-10
10-10a
10-10b
17-27
17-27
17-28
17-29
14-8
14-8
14-8
14-10
14-41
14-41
14-43
14-45
10-40
10-40
10-40
10-13
10-13a
10-13b
10-67
10-67
10-74
10-12
10-12a
10-12b
10-49
10-49
10-58
10-11
10-11a
10-11b
10-44
10-44
10-46
10-15
10-15a
10-15b
10-87
10-87
10-90
10-8
10-8a
10-8b
10-24
10-24
10-24
10-7
10-7a
10-7b
10-20
10-20
10-22
P - Cont
Pioneer stowage tool box assembly, truck M52A2 without
winch and truck M543A2 with winch . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Pitman arm . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . .
Removal . . . . . . . . . ...... . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power steering hoses, lines and fittings . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller shaft, forward rear axle-to-rear axle . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller shaft, power divider-to-bevel gearcase,
truck M543A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller shaft, power divider-to-rear winch,
truck M543A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller shaft, power takeoff-to-front winch,
trucks with front winch. . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller shaft, power takeoff-to-hydraulic hoist pump,
truck M51A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . .. ....... . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller shaft, transfer case-to-forward rear axle,
with center wearing, truck M55A2 . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Propeller shaft, transfer case-to-forward rear axle,
without center bearing, trucks M51A2, M52A2, M54A2,
M54A2C, and M543A2 . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 17
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
10-6
10-6a
10-6b
10-5
10-5a
10-5b
4-24
4-24a
4-24b
4-24c
10-16
10-16
10-18
10-12
10-12
10-14
4-124
4-124
4-124
4-133
4-23
4-23c
4-23d
4-23a
4-23b
4-23e
4-109
4-116
4-116
4-109
4-110
4-117
4-22
4-22c
4-22a
4-22b
4-22d
4-99
4-104
4-99
4-99
4-104
6-4
6-4c
6-4a
6-4b
6-4d
21-17
21-17a
21-17b
6-6
6-6a
6-6b
6-6c
6-5
6-5a
6-5b
6-5c
16-5
16-5a
16-5b
16-5c
6-11
6-12
6-11
6-11
6-12
21-65
21-65
21-66
6-15
6-15
6-16
6-20
6-13
6-13
6-13
6-14
16-18
16-18
16-19
16-24
P - Cont
Propeller shaft, transfer case-to-front axle . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . ...... . . .
Propeller shaft, transmission-to-transfer case . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump lines and fittings, manifold heater (side-mounted) . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Pump lines and fittings, manifold heater (top-mounted,
uncovered) . . . . . . . . . . . . . . . . . . ... . . . . . . . . .
Cleaning . . . . . . ... . . . . . . . . . . . . . ..
Inspection . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump lines and fittings, manifold heater (top-mounted,
covered) . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . .. . . .. ..
Preliminary procedures . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . .. . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . .. . . . .
R
Radiator cap with chain . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . .. . . .
Replacement . . . . . . . . . . . . . . . . . . .
Radiator cover assembly. . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . .
Radiator hose, preformed, lower outlet . . . . . . . . . . ... .
Preliminary procedures . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Radiator hose, preformed, upper inlet . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear spring seat ... . . . . . . . . . . . . . . . . . . .. . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement and adjustment . . . . . ... . .. . . . . . .
Index 18
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
R - Cont
Rear view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear view mirror arm assembly . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . ....... . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear winch to power divider controls and linkage
adjustment, truck M543A2 . . . . . . . . . . . . . . . . . .
Relay assembly, starter . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . .
Removal . ......... . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . .
Repair parts, maintenance . . . . . . . . . . . . . . . . . . . . . . . .
Reporting improvement recommendations . . . . . . . . . . . . .
Rotochamber adjustment, truck M543A2 . . . . . . . . . . .
Paragraph
Page
19-12
19-12a
19-12b
19-13
19-13a
19-13b
19-13c
19-36
19-36
19-37
19-38
19-38
19-38
19-42
18-11
7-6
7-6a
7-6b
7-6c
1-19
1-12
18-28
18-49
7-34
7-34
7-35
7-36
1-13
1-3
18-125
1-9
12-9
12-8
1-17
15-6
15-6a
15-6b
15-7
15-7c
15-7a
15-7b
15-7d
16-6
16-6a
16-6b
18-26
18-26a
18-26b
15-8
15-8a
15-8b
15-8
15-11
15-11c
15-11a
15-11b
15-11d
1-2
12-40
12-38
1-11
15-21
15-21
15-23
15-25
15-27
15-25
15-26
15-28
16-32
16-32
16-33
18-167
18-167
18-168
15-29
15-29
15-33
15-33
15-48
15-51
15-48
15-49
15-52
S
Safety inspection and testing of lifting devices . . . . . .
Service brakes major adjustment . . . . . . . . . . ..... .
Service brakes, minor adjustment . ...... . . . . . . . . . .
Service upon receipt of material . . . . . . . . . . . . . . . .... .
Shackle bracket, front lifting . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . ....... . .........
Replacement . . . . . . . . . . . . . . . . . . . . . . .
Shackle bracket, rear lifting . . . . . . . . . . . . . . ...... . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . ..... .. ....
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shock absorber, front axle . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . ...... . . . . . . ....
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slipring contact brushes, truck M543A2 . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . ... . . . . . . . . . . . . . . . ..... . .....
Spare wheel carrier, truck M51A2 . . . ...... . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . ......... . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Spare wheel carrier, truck M52A2 without winch . . . . . . . . . .
Cleaing, inspection, and repair. . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . .... . . . . . . . . . .
Index 19
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
15-10
15-10a
15-10b
15-9
15-9e
15-9a
15-9b
15-9c
15-9d
4-26
4-26a
4-26b
4-26c
20-9
20-9a
20-9b
20-7
20-7a
20-7b
20-7c
20-8
20-8a
20-8b
7-5
7-5d
7-5a
7-5b
7-5c
14-9
14-10
14-10a
14-10b
14-10c
14-5
14-5a
14-5b
14-5d
14-5c
14-8
14-8a
14-8b
14-8c
15-46
15-46
15-47
15-39
15-43
15-39
15-41
15-42
15-42
4-144
4-144
4-144
4-145
20-38
20-38
20-39
20-19
20-19
20-19
20-25
20-32
20-32
20-35
7-24
7-33
7-24
7-25
7-26
14-27
14-28
14-28
14-29
14-35
14-11
14-11
14-12
14-14
14-13
14-24
14-24
14-24
14-26
S - Cont
Spare wheel carrier, trucks M54A2 and M54A2C without
winch and truck M54A2C with winch . . . . . . .. . . ...
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . .... . . . . . . . . . . . . .
Spare wheel carrier, trucks M54A2 and M55A2 with winch . . . . .
Assembly
. . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . ......... . .
Removal . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning, inspection, and repair . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark plug and nozzle, manifold heater (side-mounted) . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . .... . . .
Speedometer drive joint assembly . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer flexible shaft and core assembly . . . . . . . . . . .
Preliminary procedure . .. . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . .. . . . . . . . . . .
Speedometer shaft adapter assembly . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter assembly, engine, electric . . . . . . . . . . . . . . .
Functional test . . . . . . . . . .. . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . .. . . . . . . . . . ... . . . . . . . . . . .
Steering knuckle arm check and adjustment . . . . . . . . . . . . . . . . . . . .
Steering mechanism . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . .. . . . . . . . . . . . . . . .. . . .
Steering tie rod assembly and tie rod end . . . . . . . . . . . . . . .
Removal of tie rod assembly . . .... . . . . . . . . . . . . . .
Removal of tie rod end . . . . . . . . . . . . . . . . . . . . .
Replacement of tie rod assembly . . . . . . . . . . .
Replacement of tie rod end . . . . . . . . . . . . . . . . . . .
Steering wheel assembly . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . ..
Replacement . . . . . . . . . ... . . . . . . . . . . . .
Index 20
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
4-32
4-32d
4-32a
4-32b
4-32c
7-28
7-28a
7-28b
7-7
7-7a
7-7b
1-21
4-160
4-164
4-160
4-160
4-162
7-173
7-173
7-173
7-37
7-37
7-39
1-13
7-43
7-43a
7-43b
7-52
7-52a
7-52b
7-52c
21-6
21-6a
21-6c
21-6b
7-32
7-32c
7-32a
7-32b
7-32d
7-10
7-10a
7-10b
7-10c
7-8
7-8a
7-8b
7-8c
7-19
7-19a
7-19b
7-19c
7-9
7-9a
7-9b
7-9c
7-219
7-219
7-225
7-261
7-261
7-261
7-262
21-17
21-17
21-20
21-19
7-192
7-193
7-192
7-192
7-194
7-51
7-51
7-52
7-55
7-41
7-41
7-41
7-43
7-107
7-107
7-107
7-108
7-45
7-45
7-45
7-48
S - Cont
Stop cable, engine . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stoplight and taillight . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of lamp . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .
Replacement of lamp . . . . . . . . . . . . . . . . . . . . . . . . .
Stoplight switch assembly . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Storage, administrative . . . . . . . . . . . . . . .. . . . . .
Storage batteries, battery retainer, hook and volt assembly,
battery box, and battery cables . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, electrical, headlight dimmer . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . .. . . . .... . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, emergency, blower motor . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .
Switch, floodlight housing (truck M543A2) . . . . . . . . . .
Cleaning, inspection, and repair . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switches, fuel transfer pump and fuel tank . . . . . . . . . . . . . .
Preliminary procedure . . .... . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, manifold heater . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, rotary . . . . . . . . . . . . . . .. . . . . . . . . .
Preliminary procedure . . . . . . . . . .. . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .
Index 21
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
7-17
7-17a
7-17b
7-17c
7-101
7-101
7-101
7-102
20-11
20-11d
20-11a
20-11e
20-11b
20-11c
20-12
20-12a
20-12b
20-10
20-10a
20-10b
20-10c
20-10d
20-3
20-3a
20-3b
20-3c
20-4
20-4a
20-4b
20-4c
20-6
20-6c
20-6a
20-6b
20-6d
20-5
20-5a
20-5b
20-5c
17-14
7-29
7-29c
7-29a
7-29b
7-29d
20-62
20-70
20-62
20-79
20-64
20-66
20-85
S - Cont
Switch, starter, engine . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . .
Removal . . . . . . ... . ... . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T
Tachograph chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analyzing the chart . . . . . . ... . . . . . .. . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Falsification and Irregularities . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading of chart . . . . . . . . . . . . . . . . . . .
Tachograph drive shaft . . . . . . . . . . . . . . . . ... . . . . .
Removal . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . .
Tachograph, late model trucks . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . .. . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . .
Tachograph adjustments . . . . . . . . . . . . . . . . . . . . .
Tachometer and speedometer . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . .. . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . ........ . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Tachometer drive unit . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . .. . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tachometer drive adapter . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning, inspection, and repair . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . .. . . . . . . . . . . . . ... . . . . . . . .
Tachometer flexible shaft assembly . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . .. . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate control linkage adjustment, truck M51A2 . . . . . . . .
Taillight assembly, composite . . . . . . . . . . . . . .
Removal of composite taillight assembly . . . . . . . . . . . .
Removal . . . . . . . . ... . . . . . . . . . . ... . . .
Replacement of lamp . . . . . . . . .. . . . . .
Replacement of taillight assembly . . . . . . . . . . . . . . .
Index 22
20-40
20-40
20-41
20-49
20-59
20-1
20-1
20-2
20-4
20-7
20-7
20-7
20-8
20-16
20-17
20-16
20-16
20-18
20-9
20-9
20-9
20-13
17-39
7-175
7-177
7-175
7-176
7-178
TM 9-2320-211-20-3-2
INDEX-CONT
Paragraph
Subject
Page
T - Cont
Tension sheave assembly, front winch, truck M543A2 . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire and tube, pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tool box assembly, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools and equipment, special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools common . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailer connector harness repair . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer case lever cover assembly . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission breather vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission transfer case air pressure relief valve . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troop seat kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18-6
18-6a
18-6b
6-8
6-8a
6-8b
6-8c
13-13
13-13a
13-13b
13-13c
17-11
17-11a
17-11b
1-18
1-7
1-8
7-45
7-45c
7-45a
7-45b
21-19
21-19a
21-19b
8-3
8-3a
8-3b
8-3c
9-3
9-3b
9-3a
9-3c
21-25
21-25d
21-25b
21-25c
21-25a
21-25e
18-18
18-18
18-20
6-30
6-30
6-30
6-32
13-73
13-73
13-73
13-78
17-24
17-24
17-25
1-13
1-2
1-2
7-237
7-239
7-237
7-239
21-69
21-69
21-70
8-1
8-1
8-2
8-3
9-1
9-3
9-2
9-4
21-90
21-99
21-94
21-98
21-90
21-104
Index 23
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
17-15
17-15h
17-15i
17-15g
17-15e
17-15c
17-15b
17-15d
17-15f
17-15a
10-4
10-4b
10-4f
10-4d
10-4a
10-4c
10-4c
15-12
15-12a
15-12b
4-8
4-8a
4-8b
4-8c
7-30
7-30a
7-30c
7-30b
7-30d
7-48
7-48a
7-48b
7-48c
7-50
7-50a
7-50b
17-40
17-48
17-50
17-45
17-44
17-41
17-40
17-42
17-44
17-40
10-6
10-7
10-11
10-9
10-6
10-10
10-8
15-54
15-54
15-55
4-22
4-22
4-22
4-24
7-179
7-179
7-181
7-180
7-183
7-249
7-249
7-250
7-252
7-257
7-257
7-258
10-14
10-14a
10-14b
10-81
10-81
10-82
T - Cont
Troop seat rack assembly, repair . . . . . . . . . . . . .
Assembly of rack assembly . . . . . . . . . . . . . . . . .
Assembly of rack and seat assembly . . . . . . . . .
Assembly of seat assembly . . . . . . . . . . . . . . . ..
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly of rack assembly . . . . . . . . . . . . . . . .
Disassembly of rack and seat assembly . . . . . . . . . . . . .
Disassembly of seat assembly .. . . . . . . . . . . . . . .
Inspection and repair .. . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . .. .
Truck chassis, jacking and supporting . . . . . . . . . . . . . . . .
Lowering front chassis . . . . . . . . . . . . . . . . . . . . . .
Lowering rear of chassis, both sides . . . . . . . . . . . . . .
Lowering rear of chassis, one side . . . . . . . . . . . . . . .
Raising front chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raising rear of chassis, both sides . . . . . . . . . . . . .
Raising rear of chassis, one side . . . . . . . . . . . . . .
Truck fifth wheel assembly . . . . . . . . . . . . . . .. . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger oil inlet and oil drain tubes . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . .
Turn signal and blackout marker lamp and light assembly . . . . .
Removal of lamp . . . . . . . ... . . . . . . . . . . . . . . . . .
Removal of light assembly . . . . . . . . . . .. . . . .
Replacement of lamp . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of light assembly . . . . . . . . . . . . . .
Turn signal control . .. . . . . .... . . . . . . . .. . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . .. . . . ... . . . . . . .
Turn signal flasher assembly . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
U
Universal joint assembly . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 24
TM 9-2320-211-20-3-2
INDEX-CONT
Paragraph
Subject
Page
V
Values, torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve adjustment, intake and exhaust . . . . . . . . . . . . . .
Crankcase breather adapter removal . . . . . . . . . .
Crankcase breather adapter replacement . . . . .
Cylinder head covers removal . . . . . . . . . . . . . . . . .
Cylinder head covers replacement . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . .
Valve adjustment . . . . . . . . . . . . . . . . . . . . .
Valve, air brake hand control, truck M52A2 . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . .
Valve bank relief valve, truck M543A2 . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . .
Test and adjustment . . . . . . . . . . . . . . . . . . . .
Vehicle data plates . . . . . . . . . . . . . . . . . . ... . . .
Removal, adhesive type . . . . . . .. . . . . . . . . . .
Removal, drive screw type . . . . . . . . . . . . . . .
Removal, screw-on type . . . . . . . . . . . . . . . . . . . . . .
Removal, solid rivets type . . . . . . . . . . . . . . . . . . .
Replacement, adhesive type . . . . . . . . . . . . . .
Replacement, drive screw type . . . . . . .. . . . .
Replacement, screw-on type . . . . . . . . . . . . . . . . . . . . . .
Replacement, solid rivets type . . . . . . . . . . . . . .
Venting air system pressure . . . . . . . . . . . . . . . . . . . .
1-6
2-3
2-3b
2-3f
2-3c
2-3e
2-3a
2-3d
12-22
12-22a
12-22b
12-22c
18-21
18-21a
18-21b
19-14
19-14g
19-14c
19-14a
19-14e
19-14h
19-14d
19-14b
19-14f
12-18
1-2
2-1
2-2
2-12
2-3
2-11
2-1
2-4
12-140
12-140
12-140
12-142
18-140
18-140
18-140
19-46
19-53
19-49
19-47
19-51
19-54
19-50
19-48
19-52
12-117
6-9
6-9a
6-9b
6-9c
7-33
7-33a
7-33b
7-33c
14-3
14-3a
14-3b
13-3
13-3a
13-3b
13-3c
6-36
6-36
6-36
6-41
7-195
7-195
7-195
7-196
14-1
14-1
14-2
13-1
13-1
13-2
13-5
W
Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . .. . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . .
Water temperature gage sending unit . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel alinement, front . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . .
Toe-in check and adjustment . . . . . . . . . . . . . . . . . . . . .
Wheel and brake drum assembly, front . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . .. . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . ....
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 25
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
13-9
13-9a
13-9b
13-9c
13-11
13-11c
13-11d
13-11e
13-11a
13-11b
13-11f
13-7
13-7c
13-7d
13-7e
13-7a
13-7b
13-7f
13-12
13-12c
13-12d
13-12e
13-12a
13-12b
13-12f
12-10
12-10a
12-10b
12-10c
13-8
13-8a
13-8b
13-8c
18-7
18-7a
18-7b
18-7c
18-12
18-12a
18-12b
18-12c
18-3
18-3c
18-3b
18-3a
13-45
13-45
13-45
13-48
13-60
13-61
13-62
13-63
13-60
13-60
13-64
13-36
13-38
13-39
13-40
13-36
13-36
13-41
13-65
13-67
13-68
13-69
13-65
13-65
13-71
12-50
12-50
12-50
12-51
13-43
13-43
13-43
13-44
18-22
18-22
18-23
18-24
18-54
18-54
18-55
18-60
18-1
18-4
18-2
18-1
W - Cont
Wheels and brake drum assembly, rear . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel bearing cones and seals, rear . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .
Inspection . . . . . . . . . . . .. . . . . . . . . . . . . ..
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . .. . . . . . . . . . . .
Wheel bearings and seals, front inner and outer . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . .. . .
Wheel bearings and seals, rear inner and outer . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . .. . . . . . . . . . . . .. . .
Wheel cylinder, front and rear . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel studs . . . . . .. . . . . . . . . . .. . . . . . . . . .
Preliminary procedure . .. . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement .. . . . . . . . . . . . . . . .. . . . . . . . . . . . .
Winch and roller assembly, front . . . . . .. . . . . . . .. .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . .. . . . . . .
Test and adjustment . . . . . . . . .. . . . . . . .
Winch assembly, rear, truck M543A2 . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . .
Replacement . . .. . . .. . . . . .. . . . . . . . . .
Winch automatic brake, rear, truck M543A2 . . . . . . . .
Automatic brake test and adjustment . . . . . . . . . . . . .
Drag brake test and adjustment .
. . .
. . . .
Preliminary procedures . . . . . . . . . . . . . . .
Index 26
TM 9-2320-211-20-3-2
INDEX-CONT
Subject
Paragraph
Page
18-4
18-4a
18-4b
18-4c
18-5
18-5a
18-5b
18-5c
18-9
18-9c
18-9b
18-9a
19-11
19-11a
19-11b
19-11c
19-11d
19-10
19-10a
19-10b
19-9
19-9a
19-9b
19-8
19-8a
19-8b
7-11
7-11a
7-11b
18-14
18-14
18-14
18-15
18-16
18-16
18-16
18-17
18-44
18-46
18-45
18-44
19-29
19-29
19-29
19-32
19-32
19-27
19-27
19-28
19-25
19-25
19-26
19-21
19-21
19-23
7-58
7-58
7-60
W - Cont
Winch cable, front, all trucks except M543A2 . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Winch cable, front and rear, truck M543A2 . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
Winch cable tensioner assembly, rear, truck M543A2 . . . . .
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checkout . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedures . . . . . . . . . . . . . . . . . . . . . .
Windshield washer kit . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary procedure . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windshield wiper arms . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . .. . . . .
Windshield wiper blade . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Windshield wiper motor . . . . . . . .. . . . . . . .. . .
Removal . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windshield wiper pressure regulating valve assembly . . .
Removal . . . . . . . . . . . . . . . . . . . . . .. . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 27/(Index 28 blank)
TM 9-2320-211-20-3-2
By Order of the Secretaries of the Army and the Air Force:
E. C. MEYER
General, United States Army
Chief of Staff
Official:
J. C. PENNINGTON
Major General, United States Army
The Adjutant General
LEW ALLEN, JR., General, USAF
Chief of Staff
Official:
VAN L. CRAWFORD, JR., Colonel, USAF
Director of Administration
Distribution:
To be distributed in accordance with DA Form 12-38, Organizational Maintenance requirements
for 5-Ton Truck Chassis: 5-Ton, 6x6, M39A2.
✰ U.
S.
GOVERNMENT
PRINTING
OFFICE
:
1992
O
-
311-831
(44353)
PIN: 048320-000
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