Italeri M978A2R1, M985E1A2, M985E1A2R1 Technical Manual

TM 9-2320-279-34-1
TECHNICAL MANUAL
MAINTENANCE INSTRUCTIONS
DIRECT SUPPORT AND GENERAL SUPPORT
M977 SERIES 8 x 8 HEAVY
EXPANDED MOBILITY
TACTICAL TRUCKS (HEMTT)
MODEL
TRUCK, CARGO, WITH WINCH, M977
TRUCK, CARGO, WITH WINCH, M977A2
TRUCK, CARGO, WITH WINCH, M977A2R1
TRUCK, CARGO, WITHOUT WINCH, M977
TRUCK, CARGO, WITHOUT WINCH, M977A2
TRUCK, CARGO, WITHOUT WINCH, M977A2R1
TRUCK, TANK, FUEL, WITH WINCH, M978
TRUCK, TANK, FUEL, WITH WINCH, M978A2
TRUCK, TANK, FUEL, WITH WINCH, M978A2R1
TRUCK, TANK, FUEL, WITHOUT WINCH, M978
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2R1
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2R1
TRUCK, TRACTOR, WITH WINCH,
WITH CRANE, M983
TRUCK, WRECKER-RECOVERY, M984
TRUCK, WRECKER-RECOVERY, M984A1
TRUCK, WRECKER-RECOVERY, M984A2
TRUCK, WRECKER-RECOVERY, M984A2R1
TRUCK, CARGO, WITH WINCH, M985
TRUCK, CARGO, WITH WINCH, M985A2
TRUCK, CARGO, WITH WINCH, M985A2R1
TRUCK, CARGO, WITHOUT WINCH, M985
TRUCK, CARGO, WITHOUT WINCH, M985A2
TRUCK, CARGO, WITHOUT WINCH, M985A2R1
TRUCK, CARGO, WITH WINCH, M985E1
TRUCK, CARGO, WITH WINCH, M985E1A2
TRUCK, CARGO, WITH WINCH, M985E1A2R1
NSN
2320-01-097-0260
2320-01-493-3774
2320-01-493-3782
2320-01-099-6426
2320-01-493-3779
2320-01-493-3785
2320-01-097-0249
2320-01-492-8216
2320-01-492-8226
2320-01-100-7672
2320-01-492-8215
2320-01-492-8225
2320-01-097-0247
2320-01-492-8223
2320-01-492-8231
2320-01-099-6421
2320-01-097-0248
2320-01-195-7641
2320-01-492-8224
2320-01-492-8233
2320-01-097-0261
2320-01-492-8214
2320-01-493-3787
2320-01-100-7673
2320-01-492-8201
2320-01-493-3789
2320-01-194-7032
2320-01-493-3790
2320-01-493-3792
Approved for public release; distribution is unlimited.
TABLE OF CONTENTS
PAGE ii
INTRODUCTION
PAGE 1-1
MAINTENANCE
INSTRUCTIONS
PAGE 2-1
TROUBLESHOOTING
PAGE 2-2
MAINTENANCE PROCEDURES
PAGE 2-145
ENGINE MAINTENANCE
PAGE 3-1
FUEL SYSTEM
MAINTENANCE
PAGE 4-1
COOLING SYSTEM
MAINTENANCE
PAGE 5-1
ELECTRICAL SYSTEM
MAINTENANCE
PAGE 6-1
TRANSMISSION
MAINTENANCE
PAGE 7-1
TRANSFER CASE
MAINTENANCE
PAGE 8-1
AXLES NO. 1 AND NO. 2
MAINTENANCE
PAGE 9-1
ALPHABETICAL
INDEX
PAGE INDEX 1
HEADQUARTERS, DEPARTMENT OF THE ARMY
JUNE 1987
TM 9-2320-279-34-1
WARNING
CARBON MONOXIDE (EXHAUST GAS) CAN CAUSE DEATH.
Carbon monoxide is without color or smell, but can cause death. Breathing air
with carbon monoxide produces symptoms of headache, dizziness, loss of
muscular control, a sleepy feeling, and coma. Brain damage or death can result
from heavy exposure. Carbon monoxide occurs in the exhaust fumes of
fuel-burning heaters and internal combustion engines. Carbon monoxide can
become dangerously concentrated under conditions of no ventilation.
Precautions must be followed to ensure crew safety when the arctic engine
heater or engine of any vehicle is operated for any purpose.
1. DO NOT operate arctic engine heater or engine of vehicle in a closed place
without proper ventilation.
2. DO NOT drive any vehicle with inspection plates, cover plates, or engine
compartment covers removed unless necessary for maintenance purposes.
3. 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 crew to fresh
air and keep warm. DO NOT PERMIT PHYSICAL EXERCISE. If necessary, give
artificial respiration and get immediate medical attention. For artificial
respiration, refer to FM 21-11.
4. BE AWARE that the gas particulate filter unit or the field protection mask for
nuclear-biological-chemical protection WILL NOT offer safety from carbon
monoxide poisoning.
THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD
VENTILATION.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
WARNING
Never use the parking brake for normal braking or wheels will lock up causing
severe skid. Skidding vehicle could result in serious injury or death.
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of vehicle.
WARNING
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry before
working around vehicle. Jewelry can catch on equipment and cause injury, or
may short across an electrical circuit and cause severe burns or electrical shock.
a
TM 9-2320-279-34-1
WARNING
The radiator is very hot and pressurized during vehicle operation. Let radiator
cool before removing cap. Failure to do so can result in serious burns.
WARNING
The exhaust pipe and muffler can become very hot during vehicle operation. Be
careful not to touch these parts with bare hands, or allow body to come in
contact with pipe or muffler. Exhaust system parts can become hot enough to
cause serious burns.
WARNING
Do not use trailer brakes as parking brake. Trailer brakes may not hold a loaded
vehicle and trailer on a grade. A runaway vehicle may cause severe personal
injury or death.
WARNING
Always use seatbelts when operating vehicle. Failure to use seatbelt can result in
serious injury in case of accident.
WARNING
Avoid quick, jerking, winch operation. Keep other personnel well away from
vehicles involved in winching operations. A snapped cable or shifting load can
cause serious injury or death.
WARNING
Always wear heavy gloves when handling winch cables. Never let cable run
through hands; frayed cables can cut. Never operate winch with less than five
wraps of cable on winch drum.
WARNING
If operating crane under powerlines, do not allow vehicle to contact high-voltage
connections. Death on contact can result. If possible, keep one hand away from
equipment to reduce the hazard of current flowing through vital organs of the
body.
WARNING
When working inside the vehicle with power off, be sure to ground every
capacitor likely to hold a dangerous voltage potential.
WARNING
Never work on electronic equipment unless there is another person nearby who
is familiar with the operation and hazards of the equipment.
WARNING
Be careful when working on or with electrical equipment. Do not be misled by
the term “low voltage”. Voltages as low as 50 volts may cause death. For
artificial respiration, refer to FM 21-11.
b
TM 9-2320-279-34-1
WARNING
Be careful not to short out battery terminals. Do not smoke or use open flame
near batteries. Batteries may explode from a spark. Battery acid is harmful to
skin and eyes.
WARNING
Brake shoes may be coated with dust. Breathing this dust may be harmful to your health.
Do not use compressed air to clean brake shoes. Wear a filter mask approved for use
against brake dust. Failure to comply may result in injury or death to personnel.
WARNING
Starting fluid is toxic and flammable. Do not store in cab and do not breathe
fumes. Do not puncture or burn containers. Dispose of container following
manufacturer’s recommendations on the container.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment, goggles,
shield, and gloves.
WARNING
After Nuclear, Biological, or Chemical (NBC) exposure of vehicle, all air filters
shall be handled with extreme caution. Unprotected personnel can experience
injury or death if residual toxic agents or radioactive material are present. If
vehicle is exposed to chemical or biological agents, servicing personnel shall wear
protective mask, hood, protective overgarments, and chemical protective gloves
and boots in accordance with TM 10-277. All contaminated air filters shall be
placed in double-lined plastic bags and moved swiftly to a segregation area away
from the worksite. The same procedure applies for radioactive dust
contamination. The Company NBC team should measure the radiation prior to
filter removal to determine the extent of safety procedures required per the NBC
Annex to the unit Standard Operating Procedures (SOP). The segregation area in
which the contaminated air filters are temporarily stored shall be marked with
appropriate NBC placards. Final disposal of contaminated air filters shall be in
accordance with local SOP. Decontamination operation shall be in accordance
with FM 3-5 and local SOP.
WARNING
DO NOT grind or sand painted equipment without high-efficiency air purifying
respirators in use.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep
away from open fire and use in well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash immediately with soap and
water.
WARNING
Use extreme care when removing or installing spring retainers. Spring retainers
are under tension and can act as projectiles when released suddenly. Ensure
proper eye protection is worn to prevent injury to personnel.
WARNING
Use extreme care when removing or installing springs. Springs are under tension
and can act as projectiles when released. Ensure proper eye protection is worn to
prevent injury to personnel.
Change 7
c
TM 9-2320-279-34-1
WARNING
CARC paint contains isocyanate (HDI) which is highly irritating to skin and
respiratory system. High concentrations of HDI can produce symptoms of itching
and reddening of skin, a burning sensation in throat and nose, and watering of
the eyes. In extreme concentrations, HDI can cause cough, shortness of breath,
pain during respiration, increased sputum production, and chest tightness. The
following precautions must be taken whenever using CARC paint:
S ALWAYS use air-line respirators when using CARC paint unless air sampling
shows exposure to be below standards. Use chemical cartridge respirator if air
sampling is below standards.
S DO NOT let skin or eyes come in contact with CARC paint. Always wear
protective equipment (gloves, ventilation mask, safety goggles, etc.).
S DO NOT use CARC paint without adequate ventilation.
S NEVER weld or cut CARC coated materials.
S DO NOT grind or sand painted equipment without high-efficiency, air-purifying
respirators in use.
S BE AWARE of CARC paint exposure symptoms: symptoms can occur a few days
after initial exposure. Seek medical help immediately if symptoms are detected.
WARNING
S Eye protection is required during all grinding operations. Failure to comply
may result in serious injury to personnel.
S Take all necessary precautions to confine grinding sparks so they cannot
contact flammable or combustible materials or vapors. Failure to comply may
result in serious injury or death to personnel.
S When grinding, avoid creating excess heat on CARC painted surfaces near
grinding area. CARC paint can ignite if heated. Failure to comply may result
in serious injury or death to personnel.
WARNING
CHEMICAL AGENT RESISTANT COATING (CARC)
Unusable CARC mixtures are considered hazardous waste and will require
disposal in accordance with Federal, state, Department of Defense, Department of
the Army, and local installation hazardous waste regulations. Consult the
installation environmental office for proper disposal guidance. Mixed CARC is
extremely flammable. Use only in well-ventilated areas. Keep away from open
flames, sparks, and other ignition sources.
CARC paint contains isocyanate (HDI), which is highly irritating to skin and
respiratory system. High concentrations of HDI can produce symptoms of itching
and reddening of skin, a burning sensation in throat and nose, and watering of
the eyes. In extreme concentrations, HDI can cause cough, shortness of breath,
pain during respiration, increased sputum production, and chest tightness. The
following precautions must be taken whenever using CARC paint:
S ALWAYS use air-line respirators when using CARC paint unless air sampling
shows exposure to be below standards. Use chemical cartridge respirator if air
sampling is below standards.
S DO NOT use CARC paint without adequate ventilation.
S NEVER weld or cut CARC coated materials.
S DO NOT grind or sand painted equipment without high-efficiency, air-purifying
respirators in use.
S BE AWARE of CARC paint exposure symptoms: symptoms can occur a few days
after initial exposure. Seek medical help immediately if symptoms are detected.
d
Change 7
TM 9-2320-279-34-1
C7
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 1 July, 2005
NO. 7
TECHNICAL MANUAL
MAINTENANCE INSTRUCTIONS
DIRECT SUPPORT AND GENERAL SUPPORT
M977 SERIES, 8 X 8 HEAVY EXPANDED MOBILITY
TACTICAL TRUCKS (HEMTT)
MODEL
NSN
TRUCK, CARGO, WITH WINCH, M977
TRUCK, CARGO, WITH WINCH, M977A2
TRUCK, CARGO, WITH WINCH, M977A2R1
TRUCK, CARGO, WITHOUT WINCH, M977
TRUCK, CARGO, WITHOUT WINCH, M977A2
TRUCK, CARGO, WITHOUT WINCH, M977A2R1
TRUCK, TANK, FUEL, WITH WINCH, M978
TRUCK, TANK, FUEL, WITH WINCH, M978A2
TRUCK, TANK, FUEL, WITH WINCH, M978A2R1
TRUCK, TANK, FUEL, WITHOUT WINCH, M978
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2R1
TRUCK, TRACTOR, WITH WINCH, WITHOUT CRANE, M983
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2R1
TRUCK, TRACTOR, WITH WINCH, WITH CRANE, M983
TRUCK, WRECKER-RECOVERY, M984
TRUCK, WRECKER-RECOVERY, M984A1
TRUCK, WRECKER-RECOVERY, M984A2
TRUCK, WRECKER-RECOVERY, M984A2R1
TRUCK, CARGO, WITH WINCH, M985
TRUCK, CARGO, WITH WINCH, M985A2
TRUCK, CARGO, WITH WINCH, M985A2R1
TRUCK, CARGO, WITHOUT WINCH, M985
TRUCK, CARGO, WITHOUT WINCH, M985A2
TRUCK, CARGO, WITHOUT WINCH, M985A2R1
TRUCK, CARGO, WITH WINCH, M985E1
TRUCK, CARGO, WITH WINCH, M985E1A2
TRUCK, CARGO, WITH WINCH, M985E1A2R1
2320-01-097-0260
2320-01-493-3774
2320-01-493-3782
2320-01-099-6426
2320-01-493-3779
2320-01-493-3785
2320-01-097-0249
2320-01-492-8216
2320-01-492-8226
2320-01-100-7672
2320-01-492-8215
2320-01-492-8225
2320-01-097-0247
2320-01-492-8223
2320-01-492-8231
2320-01-099-6421
2320-01-097-0248
2320-01-195-7641
2320-01-492-8224
2320-01-492-8233
2320-01-097-0261
2320-01-492-8214
2320-01-493-3787
2320-01-100-7673
2320-01-492-8201
2320-01-493-3789
2320-01-194-7032
2320-01-493-3790
2320-01-493-3792
Approved for public release; distribution is unlimited.
1 of 2
TM 9-2320-279-34-2
C1
TM 9-2320-279-34-1, June 1987, is changed as follows:
1.
2.
3.
4.
Remove old pages and insert new pages as indicated below.
New or changed material is indicated by a vertical bar in the margin of the page.
Minor changes to illustrations are indicated by a miniature pointing hand.
Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the
illustration identification number.
Remove Pages
Insert Pages
A thru C/(D blank)
c/(d blank)
1-1 and 1-2
6-73 and 6-74
6-83 and 6-84
none
9-13 and 9-14
none
9-15 and 9-16
9-89 and 9-90
Cover
A thru C/(D blank)
c and d
1-1 and 1-2
6-73 and 6-74
6-83 and 6-84
6-84.1/(6-84.2 blank)
9-13 and 9-14
9-14.1/(9-14.2 blank)
9-15 and 9-16
9-89 and 9-90
Cover
File this change sheet in front of the publication for reference purposes.
By Order of the Secretary of the Army:
PETER J. SCHOOMAKER
General, United States Army
Chief of Staff
Official:
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
0422207
DISTRIBUTION: To be distributed in accordance with the Initial Distribution Number IDN: 380653, requirements
for TM 9-2320-279-34-1.
2 of 2
TM 9-2320-279-34-1
C6
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 15 December, 2003
NO. 6
TECHNICAL MANUAL
MAINTENANCE INSTRUCTIONS
DIRECT SUPPORT AND GENERAL SUPPORT
M977 SERIES, 8 X 8 HEAVY EXPANDED MOBILITY
TACTICAL TRUCKS (HEMTT)
MODEL
NSN
TRUCK, CARGO, WITH WINCH, M977
TRUCK, CARGO, WITH WINCH, M977A2
TRUCK, CARGO, WITH WINCH, M977A2R1
TRUCK, CARGO, WITHOUT WINCH, M977
TRUCK, CARGO, WITHOUT WINCH, M977A2
TRUCK, CARGO, WITHOUT WINCH, M977A2R1
TRUCK, TANK, FUEL, WITH WINCH, M978
TRUCK, TANK, FUEL, WITH WINCH, M978A2
TRUCK, TANK, FUEL, WITH WINCH, M978A2R1
TRUCK, TANK, FUEL, WITHOUT WINCH, M978
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2R1
TRUCK, TRACTOR, WITH WINCH, WITHOUT CRANE, M983
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2R1
TRUCK, TRACTOR, WITH WINCH, WITH CRANE, M983
TRUCK, WRECKER-RECOVERY, M984
TRUCK, WRECKER-RECOVERY, M984A1
TRUCK, WRECKER-RECOVERY, M984A2
TRUCK, WRECKER-RECOVERY, M984A2R1
TRUCK, CARGO, WITH WINCH, M985
TRUCK, CARGO, WITH WINCH, M985A2
TRUCK, CARGO, WITH WINCH, M985A2R1
TRUCK, CARGO, WITHOUT WINCH, M985
TRUCK, CARGO, WITHOUT WINCH, M985A2
TRUCK, CARGO, WITHOUT WINCH, M985A2R1
TRUCK, CARGO, WITH WINCH, M985E1
TRUCK, CARGO, WITH WINCH, M985E1A2
TRUCK, CARGO, WITH WINCH, M985E1A2R1
2320-01-097-0260
2320-01-493-3774
2320-01-493-3782
2320-01-099-6426
2320-01-493-3779
2320-01-493-3785
2320-01-097-0249
2320-01-492-8216
2320-01-492-8226
2320-01-100-7672
2320-01-492-8215
2320-01-492-8225
2320-01-097-0247
2320-01-492-8223
2320-01-492-8231
2320-01-099-6421
2320-01-097-0248
2320-01-195-7641
2320-01-492-8224
2320-01-492-8233
2320-01-097-0261
2320-01-492-8214
2320-01-493-3787
2320-01-100-7673
2320-01-492-8201
2320-01-493-3789
2320-01-194-7032
2320-01-493-3790
2320-01-493-3792
Approved for public release; distribution is unlimited.
1 of 2
TM 9-2320-279-34-2
C1
TM 9-2320-279-34-1, June 1987, is changed as follows:
1.
2.
3.
4.
Remove old pages and insert new pages as indicated below.
New or changed material is indicated by a vertical bar in the margin of the page.
Minor changes to illustrations are indicated by a miniature pointing hand.
Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the
illustration identification number.
Remove Pages
Insert Pages
A thru C/(D blank)
i and ii
none
2-5 thru 2-8
2-127 thru 2-136
none
Index 1 thru Index 4
Cover
A thru C/(D blank)
i and ii
ii.1/(ii.2 blank)
2-5 thru 2-8
2-127 thru 2-136
2-136.1 thru 2-136.8
Index 1 thru Index 4
Cover
File this change sheet in front of the publication for reference purposes.
By Order of the Secretary of the Army:
PETER
J. SCHOOMAKER
JOHN
M KEANE
General, United States Army
Chief of Staff
Official:
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
0318303
DISTRIBUTION: To be distributed in accordance with the Initial Distribution Number IDN: 380653, requirements
for TM 9-2320-279-34-1.
2 of 2
TM 9-2320-279-34-1
C5
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 15 F e b r u a r y , 2002
NO. 5
TECHNICAL MANUAL
MAINTENANCE INSTRUCTIONS
DIRECT SUPPORT AND GENERAL SUPPORT
M977 SERIES, 8 X 8 HEAVY EXPANDED MOBILITY
TACTICAL TRUCKS (HEMTT)
MODEL
TRUCK,
TRUCK,
TRUCK,
TRUCK,
TRUCK,
TRUCK,
TRUCK,
TRUCK,
TRUCK,
TRUCK,
TRUCK,
TRUCK,
NSN
CARGO, WITH WINCH, M977
CARGO, WITHOUT WINCH, M977
TANK, FUEL, WITH WINCH, M978
TANK, FUEL, WITHOUT WINCH, M978
TRACTOR, WITH WINCH, WITHOUT CRANE, M983
TRACTOR, WITH WINCH, WITH CRANE, M983
WRECKER-RECOVERY, M984
WRECKER-RECOVERY, M984E1
CARGO, WITH WINCH, M985
CARGO, WITHOUT WINCH, M985
CARGO, WITH WINCH, M985E1
CARGO, WITHOUT WINCH, M985E1
2320-01-097-0260
2320-01-099-6426
2320-01-097-0249
2320-01-100-7672
2320-01-097-0247
2320-01-099-6421
2320-01-097-0248
2320-01-195-7641
2320-01-097-0261
2320-01-100-7673
2320-01-194-7032
2320-01-194-7031
Approved for public release; distribution is unlimited.
TM 9-2320-279-34-1, June 1987, is changed as follows:
1.
2.
3.
4.
Remove old pages and insert new pages as indicated below.
New or changed material is indicated by a vertical bar in the margin of the page.
Minor changes to illustrations are indicated by a miniature pointing hand.
Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the
illustration identification number.
Remove Pages
Insert Pages
i -- ii
3-1 -- 3-2
3-13 -- 3-14
6-1 -- 6-2
none
6-15 -- 6--18
i -- ii
3-1 -- 3-2
3-13 -- 3-14
6-1 -- 6-2
6-14.1 -- 6-14.14
6-15 -- 6--18
1 of 2
TM 9-2320-279-34-2
C1
Remove Pages
Insert Pages
6-87 -- 6-88
6-95 -- 6-96
6-105 -- 6-106
6-111 -- 6-114
6-119 -- 6-120
6-122.13/(6-122.14 blank)
6-123 -- 6-124
6-131 -- 6-132
6-133/(6-134 blank)
7-67 -- 7-72
7-151 -- 7-152
7-152.1 -- 7-152.2
6-87 -- 6-88
6-95 -- 6-96
6-105 -- 6-106
6-111 -- 6-114
6-119 -- 6-120
6-122.13/(6-122.14 blank)
6-123 -- 6-124
6-131 -- 6-132
6-133/(6-134 blank)
7-67 -- 7-72
7-151 -- 7-152
7-152.1 -- 7-152.2
File this change sheet in front of the publication for reference purposes.
By Order of the Secretary of the Army:
ERIC K. SHINSEKI
General, United States Army
Chief of Staff
Official:
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
0115509
DISTRIBUTION: To be distributed in accordance with the Initial Distribution Number (IDN) 380653, requirements
for TM 9-2320-279-34-1.
2 of 2
TM 9-2320-279-34-1
C4
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 15 December, 2000
NO. 4
TECHNICAL MANUAL
MAINTENANCE INSTRUCTIONS
DIRECT SUPPORT AND GENERAL SUPPORT
M977 SERIES, 8 X 8 HEAVY EXPANDED MOBILITY
TACTICAL TRUCKS (HEMTT)
MODEL
NSN
TRUCK, CARGO, WITH WINCH, M977
TRUCK, CARGO, WITHOUT WINCH, M977
TRUCK, TANK, FUEL, WITH WINCH, M978
TRUCK, TANK, FUEL, WITHOUT WINCH, M978
TRUCK, TRACTOR, WITH WINCH, WITHOUT CRANE, M983
TRUCK, TRACTOR, WITH WINCH, WITH CRANE, M983
TRUCK, WRECKER-RECOVERY, M984
TRUCK, WRECKER-RECOVERY, M984E1
TRUCK, CARGO, WITH WINCH, M985
TRUCK, CARGO, WITHOUT WINCH, M985
TRUCK, CARGO, WITH WINCH, M985E1
TRUCK, CARGO, WITHOUT WINCH, M985E1
2320-01-097-0260
2320-01-099-6426
2320-01-097-0249
2320-01-100-7672
2320-01-097-0247
2320-01-099-6421
2320-01-097-0248
2320-01-195-7641
2320-01-097-0261
2320-01-100-7673
2320-01-194-7032
2320-01-194-7031
Approved for public release; distribution is unlimited.
TM 9-2320-279-34-1, December 1998, is changed as follows:
1.
2.
3.
4.
Remove old pages and insert new pages as indicated below.
New or changed material is indicated by a vertical bar in the margin of the page.
Minor changes to illustrations are indicated by a miniature pointing hand.
Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the
illustration identification number.
Remove Pages
Insert Pages
3-29 thru 3-32
3-29 thru 3-32
File this change sheet in front of the publication for reference purposes.
1 of 1
By Order of the Secretary of the Army:
ERIC K. SHINSEKI
General, United States Army
Chief of Staff
Official:
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
0026313
DISTRIBUTION: To be distributed in accordance with the Initial Distribution Number (IDN) 380653, requirements
for TM 9-2320-279-34-1.
TM 9-2320-279-34-1
C3
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 3
Washington, D. C., 15 December 1998
TECHNICAL MANUAL
MAINTENANCE INSTRUCTIONS
DIRECT SUPPORT AND GENERAL SUPPORT
M977 SERIES, 8 X 8 HEAVY EXPANDED MOBILITY
TACTICAL TRUCKS (HEMTT)
NSN
MODEL
TRUCK, CARGO, WITH WINCH, M977
TRUCK,-CARGO, WITHOUT WINCH, M977
TRUCK, TANK, FUEL, WITH WINCH, M978
TRUCK, TANK, FUEL, WITHOUT WINCH, M978
TRUCK, TRACTOR, WITH WINCH, WITHOUT CRANE, M983
TRUCK, TRACTOR, WITH WINCH, WITH CRANE, M983
TRUCK, WRECKER-RECOVERY, M984
TRUCK, WRECKER-RECOVERY, M984E1
TRUCK, CARGO, WITH WINCH, M985
TRUCK, CARGO, WITHOUT WINCH, M985
TRUCK, CARGO, WITH WINCH, M985E1
TRUCK, CARGO, WITHOUT WINCH, M985E1
2320-01-097-0260
2320-01-099-6426
2320-01-097-0249
2320-01-100-7672
2320-01-097-0247
2320-01-099-6421
2320-01-097-0248
2320-01-195-7641
2320-01-097-0261
2320-01-100-7673
2320-01-194-7032
2320-01-194-7031
Approved for public release; distribution is unlimited.
TM 9-2320-279-34-1, 3 June 1987, is changed as follows:
1.
2.
3.
4.
Remove old pages and insert new pages as indicated below.
New or changed material is indicated by a vertical bar in the margin of the page.
Minor changes to illustrations are indicated by a miniature pointing hand.
Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the
illustration identification number.
5.
Changes on cover are: Removed VOLUME NO. 1, deleted destruction notice, and changed distribution
statement.
Remove Pages
Insert Pages
c/cd blank)
i thru vi
2-5 and 2-8
2-25 and 2-26
c/(d blank)
i thru vi
2-5 and 2-8
2-25 and 2-26
1 of 4
Remove Pages
Insert Pages
2-81 and 2-82
2-81 and 2-82
2-101 and 2-102
2-101 and 2-102
none
2-102.1/(2-102.2 blank)
2-117 thru 2-122
2-117 thru 2-122
2-127 and 2-128
2-127 and 2-128/(2-129 through 2-136 deleted)
2-129 thru 2-136
none
2-137 and 2-138
2-137 and 2-138
none
2-138.1/(2-138.2 blank)
2-139 and 2-140
2-139 and 2-140
3-7 and 3-8
3-7 and 3-8
3-13 thru 3-16
3-13 thru 3-16
3-19 and 3-20
3-19 and 3-20
3-25 and 3-26
3-25 and 3-26
6-1 and 6-2
6-1 and 6-2
6-7 and 6-8
6-7 and 6-8
6-13 and 6-14
6-13 and 6-14
6-91 thru 6-94
6-91 thru 6-94
6-97 thru 6-100
6-97 thru 6-100
6-122.1 and 6-122.2
6-122.1 and 6-122.2
6-122.11 and 6-122.12
6-122.11 and 6-122.12
7-7 and 7-8
7-7 and 7-8
7-10.1/(7-10.2 blank)
7-10.1/(7-10.2 blank)
7-19 and 7-20
7-19 and 7-20
7-23 and 7-24
7-23 and 7-24
7-27 and 7-28
7-27 and 7-28
7-31 and 7-32
7-31 and 7-32
7-37 and 7-38
7-37 and 7-38
7-43 thru 7-50
7-43 thru 7-50
7-53 thru 7-56
7-53 thru 7-56
7-59 thru 7-64
7-59 thru 7-64
7-67 thru 7-78
7-67 thru 7-78
7-81 thru 7-84
7-81 thru 7-84
none
7-84.1/(7-84.2 blank)
7-85 thru 7-88
7-85 thru 7-88
7-91 and 7-92
7-91 and 7-92
7-95 thru 7-98
7-95 thru 7-98
7-99 and 7-100
7-99 and 7-100
7-103 thru 7-118
7-103 thru 7-118
none
7-118.1/(7-118.2 blank)
7-119 and 7-120
7-119 and 7-120
7-123 thru 7-134
7-123 thru 7-134
7-137 thru 7-157/(7-158 blank) 7-137 thru 7-157/(7-158 blank)
8-1 thru 8-4
8-1 thru 8-4
8-7 and 8-8
8-7 and 8-8
8-11 and 8-12
8-11 and 8-12
8-17 and 8-18
8-17 and 8-18
8-21 and 8-22
8-21 and 8-22
8-25 thru 8-30
8-25 thru 8-30
8-33 and 8-34
8-33 and 8-34
2 of 4
Remove Pages
Insert Pages
8-37 thru 8-44
8-47 thru 8-54
9-3 thru 9-6
9-11 and 9-12
9-15 and 9-16
9-19 and 9-20
none
9-21 and 9-22
9-25 and 9-26
9-35 and 9-36
none
9-37 and 9-38
9-65 and 9-66
9-81 thru 9-84
9-87 and 9-88
9-91 and 9-92
none
DA 2028 sample F & B
DA 2028 F & B
DA 2028 F & B
DA 2028 F & B
Cover
8-37 thru 8-44
8-47 thru 8-54
9-3 thru 9-6
9-11 and 9-12
9-15 and 9-16
9-19 and 9-20
9-20.1/(9-20.2 blank)
9-21 and 9-22
9-25 and 9-26
9-35 and 9-36
9-36.1/(9-36.2 blank)
9-37 and 9-38
9-65 and 9-66
9-81 thru 9-84
9-87 and 9-88
9-91 and 9-92
9-92.1/(9-91.2 blank)
DA 2028 sample F & B
DA 2028 F & B
DA 2028 F & B
DA 2028 F & B
Cover
File this change sheet in front of the publication for reference purposes.
3 of 4
By Order of the Secretary of the Army:
DENNIS J. REIMER
General, United States Army
Chief of Staff
Administrative Assistant to the
Secretary of the Army
05642
DISTRIBUTION: To be distributed in accordance with the Initial Distribution
Number (IDN) 380653, requirements for TM 9-2320-279-34-1.
TM
9-2320-279-34-1
C2
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington D.C., 12 November, 1989
NO. 2
TECHNICAL
MAINTENANCE
DIRECT
977
SUPPORT
SERIES,
8
x
MANUAL
INSTRUCTIONS
AND
8
GENERAL
HEAVY
EXPANDED
SUPPORT
MOBILITY
TACTICAL TRUCKS (HEMTT)
NSN
MODEL
TRUCK, CARGO, WITH WINCH, M977
TRUCK, CARGO, WITHOUT WINCH, M977
2320-01-097-0260
TRUCK, TANK, FUEL, WITH WINCH, M978
2320-01-099-6426
2320-01-097-0249
TRUCK, TANK, FUEL, WITHOUT WINCH, M978
TRUCK, TRACTOR, WITH WINCH, WITHOUT CRANE, M963
2320-01-097-0247
TRUCK, TRACTOR, WITH WINCH, WITH CRANE, M983
TRUCK, WRECKER-RECOVERY, M984
2320-01-099-6421
2320-01-097-0248
TRUCK,
2320-01-195-7641
2320-01-097-0261
WRECKER-RECOVERY,
M984E1
TRUCK, CARGO, WITH WINCH, M985
TRUCK, CARGO, WITHOUT WINCH, M985
2320-01-100-7672
2320-01-100-7673
TRUCK, CARGO, WITH WINCH, M985E1
2320-01-194-7032
TRUCK, CARGO, WITHOUT WINCH, M985E1
2320-01-194-7031
TM 9-2320-279-34-1, 3 June 1987, is changed as follows:
1. Remove old pages and insert new pages as indicated below.
2. New or changed material is indicated by a vertical bar in the margin of the page.
3. Minor changes to illustrations are indicated by a miniature pointing hand.
4. Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the
illustration identification number.
Remove Pages
Insert Pages
7-51 and 7-52
7-51 and 7-52
7-73 thru 7-76
7-73 thru 7-76
9-21 and 9-22
9-21 and 9-22
File this change sheet in front of the publication for reference purposes.
By Order of the Secretary of the Army:
CARL
General,
Official:
E.
United
VUONO
States
Army
Chief of Staff
R.
L.
DILWORTH
Brigadier General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-38, Direct Support and
General Support maintenance requirements for Truck, Cargo, 10-ton, 8x8, Heavy
Expanded Mobility Tactical Truck, HEMTT, M977, M978, M983, M984, M985.
TM 9-2320-279-34-1
INSERT LATEST UPDATED PAGES/WORK PACKAGES, DESTROY SUPERSEDED DATE
LIST OF EFFECTIVE PAGES/WORK PACKAGES
NOTE:
The portion of text affected by the updates is indicated by a vertical line in the outer
margins of the page. Updates to illustrations are indicated by miniature pointing
hands. Updates to wiring diagrams are indicated by shaded areas.
Dates of issue for original and updated pages/work packages are:
O r iginal. . . 0 . . . . . . .
Change . . . 1 . . . . . . .
Change . . . 2 . . . . . . .
Change . . . 3 . . . . . . .
3 June 1987
28 Sept 1989
12 November 1989
15 December 1998
Change
Change
Change
Change
...
...
...
...
4
5
6
7
. . . . . . . 15 December 2000
. . . . . .15
. February 2002
. . . . . . . 15 December 2003
. . . . . . . 1 July 2005
TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 780
CONSISTING OF THE FOLLOWING:
Page/WP
No.
*Change
No.
Page/WP
No.
*Change
No.
Page/WP
No.
*Change
No.
Cover
7
2-29 - 2-80
0
3-1
0
Blank
7
2-81
3
3-2
5
a-b
0
2-82 - 2-101
0
3-3 - 3-6
0
c-d
7
2-102
3
3-7
3
i - ii
6
2-102.1
3
3-8 - 3-12
0
ii.1
6
2-102.2 Blank
0
3-13
3
ii.2 blank
6
iii
0
2-103 - 2-116
0
3-14
5
iv - v
3
2-117
2
3-15
0
vi - viii
1
2-118 - 2-119
0
3-16
3
1-1
7
2-120
2
3-17 - 3-19
0
1-2 - 1-8
0
2-121
0
3-20
3
2-1
0
2-122
2
3-21 - 3-24
0
2-2
6
2-123 - 2-126
0
3-25
3
2-3 - 2-4
0
2-126.1 - 2-126.6
0
3-26 - 3-28
0
2-5 - 2-8
6
2-127
0
3-29
4
2-9 - 2-22
0
2-128 - 2-136
6
3-30 - 3-31
0
2-22.1 - 2-22.2
0
2-136.1 - 2-136.8
3
3-32
4
2-23 - 2-24
0
2-137
0
4-1 - 4-3
0
2-24.1
0
2-138
3
4-4 Blank
0
2-24.2 Blank
0
2-138.1
3
5-1 - 5-4
0
2-25
3
2-138.2 Blank
3
6-1
5
2-26 - 2-28
0
2-139
0
6-2
3
3
6-3 - 6-7
0
2-28.1 - 2-28.8
0
2-140
* Zero in this column indicates an original page.
A
TM 9-2320-279-34-1
INSERT LATEST UPDATED PAGES/WORK PACKAGES, DESTROY SUPERSEDED DATE
.
Page/WP
No.
*Change
No.
Page/WP
No.
*Change
No.
Page/WP
No.
*Change
No.
6-8
3
6-122.11
3
7-56
3
6-9 - 6-13
0
6-122.12
0
7-57 - 7-59
0
6-14
3
6-122.13
5
7-60 - 7-61
3
6-14.1 - 6-14.14
5
6-122.14 Blank
5
7-62
0
6-15
5
6-123
0
7-63 - 7-64
3
6-16
0
6-124
5
7-65 - 7-66
0
6-17
5
6-125 - 6-130
0
7-67
3
6-18 - 6-64
0
6-131 - 6-132
5
7-68 - 7-69
5
6-64.1 - 6-64.6
0
6-133
5
7-70
0
6-65 - 6-70
0
6-134 Blank
5
7-71
5
6-70.1 - 6-70.8
0
7-1 - 7-7
0
7-72
3
6-71 - 6-72
0
7-8
3
7-73
2
6-73
7
7-9 - 7-10
0
7-74 - 7-75
3
6-74 - 6-83
0
7-10.1
3
7-76
0
6-84
7
7-10.2 Blank
3
7-77 - 7-78
3
6-84.1
7
7-11 - 7-19
0
7-79 - 7-80
0
6-84.2 Blank
7
7-20
3
7-81 - 7-84
3
6-85 - 6-86
0
7-21 - 7-22
0
7-84.1
3
6-87
5
7-23
3
7-84.2 Blank
3
6-88 - 6-91
0
7-24 - 7-26
0
7-85
0
6-92 - 6-93
3
7-27
3
7-86
3
6-94 - 6-95
0
7-28 - 7-30
0
7-87
0
6-96
5
7-31
3
7-88
3
6-97
0
7-32
0
7-89 - 7-90
0
6-98 - 6-99
3
7-32.1
0
7-91 - 7-92
3
6-100 - 6-104
0
7-32.2 Blank
0
7-93 - 7-95
0
6-105
5
7-33 - 7-37
0
7-96 - 7-97
3
6-106 - 6-110
0
7-38
3
7-98 - 7-99
0
6-111
5
7-39 - 7-42
0
7-100
3
6-112 - 6-113
0
7-43 - 7-44
3
7-101 - 7-102
0
6-114
5
7-45
0
7-103 - 7-105
3
6-115 - 6-119
0
7-46 - 7-48
3
7-106
0
6-120
5
7-49
0
7-107 - 7-108
3
6-121 - 6-122
0
7-50
3
7-109
0
6-122.1
0
7-51
0
7-110 - 7-115
3
6-122.2
3
7-52
2
7-116 - 7-117
0
3
7-118
3
0
7-118.1
3
7-53
6-122.3 7-54 - 7-55
6-122.10
0
* Zero in this column indicates an original page.
B
TM 9-2320-279-34-1
INSERT LATEST UPDATED PAGES/WORK PACKAGES, DESTROY SUPERSEDED DATE
.
Page/WP
No.
*Change
No.
Page/WP
No.
*Change
No.
Page/WP
No.
*Change
No.
7-118.2 Blank
0
8-5 - 8-6
0
9-15
0
7-119 - 7-120
3
8-7
3
9-16
7
7-121 - 7-122
0
8-8
3
9-17 - 9-19
0
7-123
3
8-9 - 8-11
0
9-20
3
7-124
0
8-12
3
9-20.1
3
7-125
3
8-13 - 8-17
0
9-20.2 Blank
3
7-126
0
8-18
3
9-21 - 9-22
3
7-127
3
8-19 - 8-20
0
9-23 - 9-25
0
7-128
0
8-21 - 8-22
3
9-26
3
7-129
3
8-23 - 8-24
0
9-27 - 9-35
0
7-130
0
8-25 - 8-29
3
9-36
3
7-131 - 7-133
3
8-30 - 8-32
0
9-36.1
3
7-134 - 7-137
0
8-33 - 8-34
3
9-36.2 Blank
3
7-138 - 7-140
3
8-35 - 8-37
0
9-37 - 9-38
3
7-141
0
8-38
3
9-39 - 9-64
0
7-142 - 7-145
3
8-39 - 8-40
0
9-65
3
7-146
0
8-41 - 8-43
3
9-66 - 9-81
0
7-147
3
8-44 - 8-46
0
9-82
3
7-148 - 7-149
0
8-47
3
9-83
0
7-150 - 7-151
3
8-48
0
9-84
3
7-152
5
8-49 - 8-53
3
9-85 - 9-86
0
7-152.1 - 7-152.2
5
8-54 - 8-56
0
9-87
3
7-153
3
9-1 - 9-2
0
9-88 - 9-89
0
7-154 - 7-155
0
9-3
3
9-90
7
7-156 - 7-157
3
9-4
0
9-91 - 9-92
3
7-158 Blank
3
9-5
3
9-92.1
3
8-1
0
9-6 - 9-10
0
9-92.2 Blank
3
8-2
3
9-11 - 9-12
3
9-93 - 9-96
0
8-2.1
0
9-13
0
Index 1
6
8-2.2 Blank
0
9-14
7
Index 2
0
8-3
0
9-14.1
7
Index 3
6
8-4
3
9-14.2 Blank
7
Index 4 - Index 10
0
* Zero in this column indicates an original page.
C/(D blank)
C
TM 9-2320-279-34-1
TECHNICAL MANUAL
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington, DC, 3 June 1987
No. 9-2320-279-34-1
MAINTENANCE INSTRUCTIONS
DIRECT SUPPORT AND GENERAL SUPPORT
M977 SERIES, 8 X 8 HEAVY EXPANDED MOBILITY
TACTICAL TRUCKS (HEMTT)
MODEL
TRUCK, CARGO, WITH WINCH, M977
TRUCK, CARGO, WITH WINCH, M977A2
TRUCK, CARGO, WITH WINCH, M977A2R1
TRUCK, CARGO, WITHOUT WINCH, M977
TRUCK, CARGO, WITHOUT WINCH, M977A2
TRUCK, CARGO, WITHOUT WINCH, M977A2R1
TRUCK, TANK, FUEL, WITH WINCH, M978
TRUCK, TANK, FUEL, WITH WINCH, M978A2
TRUCK, TANK, FUEL, WITH WINCH, M978A2R1
TRUCK, TANK, FUEL, WITHOUT WINCH, M978
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2
TRUCK, TANK, FUEL, WITHOUT WINCH, M978A2R1
TRUCK, TRACTOR, WITH WINCH, WITHOUT CRANE, M983
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2
TRUCK, TRACTOR, WITH WINCH,
WITHOUT CRANE, M983A2R1
TRUCK, TRACTOR, WITH WINCH, WITH CRANE, M983
TRUCK, WRECKER-RECOVERY, M984
TRUCK, WRECKER-RECOVERY, M984A1
TRUCK, WRECKER-RECOVERY, M984A2
TRUCK, WRECKER-RECOVERY, M984A2R1
TRUCK, CARGO, WITH WINCH, M985
TRUCK, CARGO, WITH WINCH, M985A2
TRUCK, CARGO, WITH WINCH, M985A2R1
TRUCK, CARGO, WITHOUT WINCH, M985
TRUCK, CARGO, WITHOUT WINCH, M985A2
TRUCK, CARGO, WITHOUT WINCH, M985A2R1
TRUCK, CARGO, WITH WINCH, M985E1
TRUCK, CARGO, WITH WINCH, M985E1A2
TRUCK, CARGO, WITH WINCH, M985E1A2R1
NSN
2320-01-097-0260
2320-01-493-3774
2320-01-493-3782
2320-01-099-6426
2320-01-493-3779
2320-01-493-3785
2320-01-097-0249
2320-01-492-8216
2320-01-492-8226
2320-01-100-7672
2320-01-492-8215
2320-01-492-8225
2320-01-097-0247
2320-01-492-8223
2320-01-492-8231
2320-01-099-6421
2320-01-097-0248
2320-01-195-7641
2320-01-492-8224
2320-01-492-8233
2320-01-097-0261
2320-01-492-8214
2320-01-493-3787
2320-01-100-7673
2320-01-492-8201
2320-01-493-3789
2320-01-194-7032
2320-01-493-3790
2320-01-493-3792
Approved for public release; distribution is unlimited.
Change 6
i
TM 9-2320-279-34-1
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this publication. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment
Technical Publications), through the Internet, on the Army Electronic Product Support (AEPS) Web site.
The Internet address is http://aeps.ria.army.mil. If you need a password, scroll down and click on “ACCESS
REQUEST FORM.” The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the
AEPS. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond
quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax, or e-mail
your letter or DA Form 2028 direct to: AMSTA--LC--CI/TECH PUBS, TACOM--RI, 1 Rock Island Arsenal,
Rock Island, IL 61299-7630. The e-mail address is [email protected]. The fax number
is DSN 793-0726 or Commercial (309) 782-0726.
M983 with crane and M985E1 without winch are no longer in the fleet. Ignore all references to these
vehicles. The M984E1 and M984A1 are the same vehicle. All references to M984E1 shall be interpreted as
the M984A1 model. All references to M977 series vehicles shall be interpreted to include A2 and A2R1
models, unless otherwise noted.
TABLE OF CONTENTS
Page
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
CHAPTER 1
Section I
Section II
Section III
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-7
1-8
CHAPTER 2
Section I
Section II
2-1
2-1
Section III
Section IV
MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts, Special Tools, and Test, Measurement and Diagnostic Equipment
(TMDE) and Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-2
2-137
CHAPTER 3
Section I
Section II
Section III
ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1
3-1
3-2
CHAPTER 4
Section I
Section II
FUEL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Throttle Treadle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CHAPTER 5
Section I
Section II
COOLING SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ii
Change 6
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TABLE OF CONTENTS (CONT)
Page
CHAPTER 6
Section I
Section II
Section III
Section IV
ELECTRICAL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator and Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane System Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
6-2
6-36
6-70.8
CHAPTER 7
Section I
Section II
Section III
Section IV
Section V
Section VI
Section VII
Section VIII
TRANSMISSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan and Internal Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Unit and Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Bodies and Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-1
7-1
7-3
7-8
7-72
7-77
7-91
7-135
CHAPTER 8
Section I
Section II
Section III
Section IV
TRANSFER CASE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8-1
8-2
8-44
8-52
CHAPTER 9
Section I
Section II
Section III
Section IV
AXLES NO. 1. AND NO. 2 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-1
9-2
9-19
9-82
CHAPTER 10
Section I
Section II
Section III
AXLES NO. 3 AND NO. 4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1
10-1
10-1
10-15
Change 6Change
ii.1/(ii.2
blank)
6
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TABLE OF CONTENTS (CONT)
Page
CHAPTER 11 BRAKE SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section II Service Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section III Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section IV Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section V Trailer Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 12 STEERING SYSTEM MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . .
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section II Steering Linkage and Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section III Steering Gear and Slave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section IV Steering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section V Steering System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1
11-1
11-1
11-5
11-18
11-33
12-1
12-1
12-1
12-19
12-42
12-48.13
CHAPTER 13 FRAME MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section II Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section III Fifth Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1
..........................................
CHAPTER 14 SUSPENSION MAINTENANCE
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section II Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section III Lateral Torque Rod and Equalizer Beams.
14-1
CHAPTER 15 CAB AND BODY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section II Cab Assembly .....................................................................................................................
Section III Pump Module, Tank, and Cargo Bodies.
15-1
.........................................
CHAPTER 16 WINCH MAINTENANCE
...................................................
Section I Introduction
............................................
Section II Self-Recovery Winch
..............................................
Section III Heavy-Duty Winch
16-1
CHAPTER 17 M977 AND M985 CRANE MAINTENANCE
Section I Introduction
Section II Crane, Subframe, and Swing Drive.
Section III Boom, Mast, and Extensions
Section IV Cylinders
Section V Hoist
Section VI Crane Control Systems.
Section VII Outriggers
13-1
13-2
13-91
14-1
14-1
14-11
15-1
15-2
15-26
16-1
16-2
16-22
17-1
17-1
17-2
17-50.10
17-70
17-93
17-119
17-156
CHAPTER 18 Deleted
iii
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TABLE OF CONTENTS (CONT)
Page
CHAPTER 19 POWER TAKEOFF (PTO) AND HYDRAULIC PUMP MAINTENANCE . . . . . . . .
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section II Power Take off (PT0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section III Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19-1
19-1
19-1
19-12.10
CHAPTER 20 HYDRAULIC SYSTEM MAINTENANCE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Hand Pump . . . . . . . . . . . . . .
Hydraulic Control Valve . . . . . . . . . . . . . .
20-1
20-1
20-1
20-5
CHAPTER 21 ARCTIC HEATER KIT MAINTENANCE.
Section I Introduction . . . . . . . . . . . . . . . . . . . . . .
Section II Arctic Heater Kit . . . . . . . . . . . . . . . . . . . . .
21-1
21-1
21-1
CHAPTER 22 M978 TANKER MAINTENANCE . . . . . . .
22-1
22-1
22-2
22-10
22-31
22-44
22-47
22-105
Section I
Section II
Section III
Section I
Section IT
Section III
Section IV
Section V
Section VI
Section VII
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Inspection . . . . . . . . . . . . . . . . . . . .
Pump, Pump Motor, and Auxiliary Pump . . .
Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Eliminator . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Service Nozzle . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 23 SPECIAL PURPOSE KIT INSTALLATION.
Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section II Arctic Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section III Armament Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section IV Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section V Chemical, Biological, and Radiological (CBR) Equipment
23-1
23-1
23-1
23-25
23-33
23-40
APPENDIXES
A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . .
B ILLUSTRATED LIST OF MANUFACTURED ITEMS
C EXPENDABLE SUPPLIES AND MATERIALS LIST
D TORQUE LIMITS
A-1
B-1
C-1
D-1
INDEX
...................................................................
Index 1
LIST OF ILLUSTRATIONS
Figure
1-1
1-2
1-3
1-4
1-5
1-6
iv
Title
M977 Cargo Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M978 Fuel Tanker Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . .
M983 Tractor Vehicle with Material Handling Crane .
M983 Tractor Vehicle without Material Handling Crane
M984 Wrecker-Recovery Vehicle . . . . . . . . . . . . . . . . . . . .
M984A1 Wrecker-Recovery Vehicle . . . . . . . . . . . . . . . . .
Change 3
Page
1-2
1-2
1-3
1-3
1-4
1-4
TM 9-2320-279-34-1
Figure
1-7
1-8
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
17-1
17-2
17-3
17-4
17-5
17-6
17-7
17-8
17-9
17-10
17-11
17-12
17-13
17-14
17-15
17-16
17-17
17-18
17-19
17-20
17-21
17-22
17-23
17-24
17-25
18-1
18-2
18-3
18-4
18-5
18-6
18-7
18-8
18-9
18-10
18-11
18-12
18-13
18-14
18-15
22-1
22-2
22-3
22-4
22-5
LIST OF ILLUSTRATIONS (CONT)
Title
M985 Cargo Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M985E1 Cargo Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STE/ICE Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Control Valve (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outrigger Control Valve (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Back Pressure (No Load) (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Tester Setup (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Distribution Board Wiring Diagram (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12V Electric Motors Test Circuit Schematic (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12V Electric Motors Tester Circuit Wiring Diagram (M983) . . . . . . . . . . . . . . . . . . . . .
Arctic Coolant Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist Hoses and Tubes (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist Hoses and Tubes (Right Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Telescoping Cylinders, Hoses, and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Telescoping Cylinders, Hoses, and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Cylinders, Hoses, and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Cylinders, Hoses, and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mast Erection Cylinders, Hoses, and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Drive Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Hydraulic Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload Solenoid (M977 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist Hoses and Tubes (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist Hoses and Tubes (Right Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Cylinder.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown Valves.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown Valves.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Hand Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outrigger Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outrigger Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extensions No. 3 and No. 4 Hoses and Tubes (Hose Reel Side) . . . . . . . . . . . . . . . . . . .
Extensions No. 3 and No. 4 Hoses and Tubes (Hose Reel Side) . . . . . . . . . . . . . . . . . . .
Extensions No. 1 and No. 2 Hoses and Tubes (Hose Reel Side) . . . . . . . . . . . . . . . . . . .
Extensions No. 1 and No. 2 Hoses and Tubes (Hoist Cable Tiedown Block Side) . . .
Extensions No. 1 and No. 2 Hoses and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist Hoses and Tubes (Hose Reel Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist Hoses and Tubes (Hose Reel Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist Hoses and Tubes (Hoist Cable Tiedown Block Side) . . . . . . . . . . . . . . . . . . . . . . .
Inner Boom Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unfolding Cylinders Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Hydraulic Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slewing System Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outrigger Control Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outrigger Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Control Valve Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tanker External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tanker Filter and Manual Dispensing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tanker Dispensing Components-Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tanker Loading and Unloading Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tanker Gages, Air, and Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change
Page
1-5
1-5
2-1
2-29
2-30
2-31
2-33
2-62
2-64
2-65
2-128
17-5
17-6
17-7
17-8
17-9
17-10
17-11
17-12
17-13
17-15
17-16
17-16.4
17-16.5
17-16.6
17-16.7
17-16.8
17-16.9
17-16.10
17-16.11
17-16.12
17-16.13
17-16.14
17-16.15
17.16.16
17-16.17
18-79
18-80
18-81
18-82
18-83
18-84
18-85
18-87
18-88
18-89
18-91
18-93
18-94
18-95
18-96
22-5
22-6
22-7
22-8
22-9
3
v
TM 9-2320-279-34-1
LIST OF ILLUSTRATIONS (CONT)
Title
Page
Lifting Eyes (PN 2BH944). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Detent Ball Compression Tool (Heavy-Duty Winch) (PN IPP161) . . . . . . . . . . . . . . . . . . . .
Crane Hoist Drive Unit Pressure Plate Removal/Installation Tool (M983) . . . . . . . . . . . . .
Arctic Heater Test Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seat Tool (M983) (PN 2CS30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Retainer Tool (M983) (PN 2CS31) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V5 Air Actuated Valve Spring Compression Tool (M978) (PN 2SK886). . . . . . . . . . . . . . . .
Air Compressor Unloader Bore Bushing Removal Tool (PN 2BF829) . . . . . . . . . . . . . . . . .
Air Compressor Cylinder Head Removal Tool (PN 2AH762) . . . . . . . . . . . . . . . . . . . . . . . .
Spanner Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoses and Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locking Strips.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locking Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Harness Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
B-2
B-3
B-3
B-4
B-6
B-6
B-7
B-9
B-10
B-11
B-14
B-17
B-18
B-18
FP-1
FP-23
FP-29
Figure
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
B-11
B-12
B-13
B-14
B-15
FO-1
FO-2
FO-3
LIST OF TABLES
Title
Number
1-1
1-2
2-1
2-2
2-3
7-1
7-2
16-1
17-1
17-2
17-3
17-4
17-5
17-6
17-7
17-8
17-9
17-10
17-11
17-12
17-13
17-14
17-15
17-16
17-17
17-18
17-19
17-20
17-21
17-22
17-23
17-24
17-25
vi
Nomenclature Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Significant Hazards and Safety Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Fault Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Subject Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring Load-Height Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring Load-Length Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Spring, Poppet Spring, and Spool Spring Load-Height Specifications . . . . .
Hoist Hoses and Tubes (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist Hoses and Tubes (Right Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Telescoping Cylinders, Hoses, and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Telescoping Cylinders, Hoses, and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Cylinders, Hoses, and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Cylinders, Hoses, and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mast Erection Cylindes, Hoses, and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Drive Hoses and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Hydraulic Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload Solenoid (M977 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist Hoses and Tubes (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist Hoses and Tubes (Right Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Lines.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Hand Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outrigger Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outrigger Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change 1
Page
1-6
l-7
2-2
2-5
2-10
7-65
7-161
16-59
17-5
17-6
17-7
17-8
17-9
17-10
17-11
17-12
17-13
17-14
17-16
17-1.6.3
17-16.5
17-16.6
17-16.7
17-16.8
17-16.9
17-16.10
17-16.11
17-16.12
17-16.13
17-16.14
17-16.15
17-16.6
17-16.17
TM 9-2320-279-34-1
LIST OF TABLES (CONT)
Title
Number
18-1
18-2
18-3
18-4
18-5
18-6
18-7
18-8
18-9
18-10
18-11
18-12
18-13
18-14
18-15
B-1
B-2
B-3
B-4
D-1
D-2
D-3
Page
Extensions No. 3 and No. 4 Hoses and Tubes (Hose Reel Side) . . . . . . . . . . . . . . . . . . . . . . 18-79
Extensions No. 3 and No. 4 Hoses and Tubes (Hose Reel Side) . . . . . . . . . . . . . . . . . . . . . . 18-80
Extensions No. 1 and No. 2 Hoses and Tubes (Hose Reel Side) . . . . . . . . . . . . . . . . . . . . . . 18-81
Extensions No. 1 and No. 2 Hoses and Tubes (Hoist Cable Tiedown Block Side). . . . . . . . 18-82
Extensions No. 1 and No. 2 Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-83
Hoist Hoses and Tubes (Hose Reel Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-84
Hoist Hoses and Tubes (Hose Reel Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-85
Hoist Hoses and Tubes (Hoist Cable Tiedown Block Side) . . . . . . . . . . . . . . . . . . . . . . . . . . 18-86
Inner Boom Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-88
Unfolding Cylinders Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-89
Main Hydraulic Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-90
Slewing System Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-92
Outrigger Control Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-94
Outrigger Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-95
Main Control Valve Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-96
Hoses and Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-14
Locking Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-17
Locking Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-18
Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-18
Torque Limits for Dry Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Torque Limits for Wet Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Dry Torque Limits for M983 Crane (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
HOW TO USE THIS MANUAL
This manual is designed to help maintain the M977 series vehicles. In addition to this manual
TM 9-2320-354-24&P provides additional unique maintenance instructions for the M984 with HIAB 8109
crane and TM 9-2320-355-24&P provides additional unique maintenance instructions for the M985E1 with
HIAB 8108 crane. Listed below are some of the special features which have been put into help locate and
use needed information.
The front cover index provides a quick reference to chapters and sections that will be used often.
The appendixes are located at the end of the manual. They contain a reference guide to other
manuals, a manufactured items list, a list of expendable supplies and materials, and tables for torque
values.
Subject headings and certain other essential information are printed in bold type throughout the
manual to make them more visible.
The maintenance tasks describe what must be done to the vehicle before starting the task, and what
must be done to return the vehicle to operating condition after the task is finished.
The manual is divided into chapters containing direct support and general support maintenance
procedures. These procedures describe a number of things such as:
What will be needed to do the job.
If any assistance will be needed.
How long the job will take.
Important safety precautions.
In addition to the text, there will be an exploded-view illustration of most steps. This illustration is keyed
to the text and shows you how to take the part off and put it on. Cleaning and inspection procedures are
also included when required. The following problem will describe some of the features of this manual.
PROBLEM
The vehicle operator brings an M977 vehicle into the shop with a problem. Whenever the crane is
operated, the remote controller will not operate the crane. Organizational maintenance troubleshooting has
been completed and trouble has not been fixed.
vii
Change 1
TM 9-2320-279-34-1
1.
2 . What kind of problem is it?
Find it in the symptom index.
There are two symptom indexes in the Troubleshooting section. One is arranged alphabetically by
fault symptom and the other is arranged alphabetically by subject/symptom. The symptom causing
the problem might be in the Troubleshooting Fault Symptom Index under Material Handling Crane
or Hydraulic System. In the Subject/Symptom Index, it might be under Remote Controller, or Crane.
When the symptom to the problem is found, go to the troubleshooting procedure page listed for
that symptom. For example, look for “Remote Controller will not operate crane.”
3 . How can the cause of the problem be determined?
Go to page 2-83.
Troubleshooting for CRANE WILL NOT OPERATE MANUALLY OR WITH REMOTE CONTROLLER is
on that page. The troubleshooting procedures have columns with the headings: MALFUNCTION,
TEST OR INSPECTION, and CORRECTIVE ACTION. Starting at step 1, read the procedure. Each
step describes what to do and what to look for. Follow the steps, in order, to troubleshoot the
symptom until the problem is found. When the problem is found, the CORRECTIVE ACTION
column will describe how to fix it.
4 . Let’s assume it was determined that the two-way solenoid valve is bad. The
replacement is in paragraph 17-32.
The procedure contains all the information needed to replace the two-way solenoid valve. First,
check the introductory material. It tells what will be needed before starting the job. Following the
introductory material is an exploded-view illustration and step-by-step instructions which show
how to remove and install the two-way solenoid valve.
FOLLOW THESE GUIDELINES WHEN USING THIS MANUAL:
Become familiar with the entire maintenance procedure before beginning a maintenance task.
Read all WARNINGS and CAUTIONS before performing any procedures.
viii
Change 1
TM 9-2320-279-34-1
CHAPTER 1
INTRODUCTION
Contents
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Forms, Records, and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Destruction of Army Material to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nomenclature Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reporting Equipment Improvement Recommendations (EIR) . . . . . . . . . . . . . . . . . . . . . .
Equipment Improvement Report and Maintenance Digest (EIR MD) and Equipment
Improvement Report and Maintenance Summary (EIR MS) . . . . . . . . . . . . . . . . . . . . . . .
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location and Description of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differences Between Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety, Care, and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Para
1-1
1-2
1-3
1-4
1-5
1-6
Page
1-1
1-5
1-5
1-6
1-6
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
1-6
1-6
1-6
1-7
1-7
1-7
1-7
1-7
1-8
Section I. GENERAL INFORMATION
Vehicle Models
1-1. SCOPE.
This chapter provides general information, equipment description, and principles of
operation for the M977 series vehicles.
a.
Type of Manual: Direct Support and General Support Maintenance Instructions, TM9-2320-279-34.
b.
Model Numbers and Equipment Names. The different vehicle models are listed below:
M977:
M978:
M983:
M984:
M984A1:
M985:
M985E1:
Cargo vehicle, with self-recovery winch (fig. 1-1).
Cargo vehicle, without self-recovery winch.
Fuel tanker vehicle, with self-recovery winch (fig. 1-2).
Fuel tanker vehicle, without self-recovery winch.
Tractor vehicle, with self-recovery winch and material handling crane (fig. 1-3).
Tractor vehicle, with self-recovery winch, without material handling crane (fig 1-4).
Wrecker-recovery vehicle (fig. 1-5).
Wrecker-recovery vehicle (fig. 1-6).
Cargo vehicle, with self-recovery winch (fig. 1-7).
Cargo vehicle, without self-recovery winch.
Cargo vehicle, with self-recovery winch (fig. 1-8).
Cargo vehicle, without self-recovery winch.
c. Purpose of Equipment. The M977 series vehicles are a family of 8 x 8 vehicles for tactical use.
The purposes of the vehicles are as follows.
(1) The M977 cargo vehicle is used for ammunition and other resupply missions.
(2) The M978 tanker vehicle is used to refuel wheel and track vehicles and for other fuel resupply
missions.
(3) The M983 tractor is used to transport Patriot missiles.
(4) The M984 and M984A1 wrecker-recovery vehicles are the prime recovery vehicles of the M977
series.
(5) The M985 cargo vehicle is used to resupply the Multiple Launch Rocket System (MLRS).
(6) The M985E1 cargo vehicle is used to resupply the Patriot Missile System.
Change 7
1-1
TM
9-2320-279-34-1
1-1.
Figure 1-1.
Figure 1-2.
1-2
TM 9-2320-279-34-1
Figure 1-3.
Figure 1-4.
1-3
TM 9-2320-279-34-1
1-1.
Figure 1-5.
Figure 1-6.
1-4
TM 9-2320-279-34-1
Vehicle Models (Cont)
Figure 1-7.
Figure 1-8. M985E1 Cargo Vehicle.
Equipment and Maintenance Reports
1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS. Department of the Army forms and
procedures used for equipment maintenance will be as specified in the latest edition of DA PAM 738-750,
The Army Maintenance Management System (TAMMS).
1-3. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE. Command decision,
according to the tactical situation, will determine when the destruction of the M977 series vehicles will be
accomplished. A destruction plan will be prepared by the using organization unless one has been prepared
by a higher authority. For general destruction procedures for this equipment, refer to TM 750-244-6,
Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use (U.S. Army
Tank-Automotive Command).
1-5
TM
9-2320-279-34-1
Equipment and Maintenance Reports (Cont)
1-4. PREPARATION FOR STORAGE OR SHIPMENT. Instructions for preparation for storage or
shipment are provided in TM 9-2320-279-20.
1-5. NOMENCLATURE CROSS-REFERENCE. Table 1-1 lists the nomenclature cross-references used
in this manual.
Table 1-1.
Nomenclature Cross-Reference
Common Name
Official Nomenclature
O-ring
Snap ring
Engine coolant
Cold start system
Jake brake, Jacobs® brake
Cable
Glad hand
Preformed packing
Retaining ring
Antifreeze, ethylene glycol mixture
Ether quick-start system
Engine retarder
Wire rope
Quick disconnect coupling
1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR). If any vehicle
needs improvement, let us know. Send us an EIR. The user is the only one who can tell us how the
equipment might be improved. Let us know what isn’t liked about the design. Put it on an SF 368 (Quality
Deficiency Report). Mail it to us at: Commander, U.S. Army Tank-Automotive Command, ATTN:
AMSTA-QRT, Warren, MI 48397-5000. We’ll send a reply.
1-7. EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE DIGEST (EIR MD) AND
EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE SUMMARY (EIR MS).The quarterly Equipment Improvement Report and Maintenance Digest, TB 43-0001-39 series, contains
valuable field information on the equipment covered in this manual. The information in the TB 43-0001-39
series is compiled from some of the Quality Deficiency Reports that have been prepared on the vehicles
covered in this manual. Many of these articles result from comments, suggestions, and improvement
recommendations that were submitted to the EIR program. The TB 43-0001-39 series contains information
on equipment improvements, minor alterations, proposed Modification Work Orders (MWO’s), warranties (if
applicable), actions taken on some of the DA Form 2028’s (Recommended Changes to Publications), and
advance information on proposed changes that may affect this manual. In addition, the more maintenance
significant articles, including minor alterations, field-fixes, etc., that have a more permanent and
continuing need in the field are republished in the Equipment Improvement Report and Maintenance
Summary (EIR MS) for TACOM Equipment (TM 43-1043). Refer to both of these publications
(TB 43-0001-39 series and TM 43-1043) periodically, especially the TB 43-0001-39 series, for most current
and authoritative information on the equipment. The information will help to do a better job and will
advise of the latest changes to this manual. Also refer to DA Pam 310-1, Consolidated Index of Army
Publications and Blank Forms, and Appendix A, References, of this manual.
1-8. WARRANTY INFORMATION. The M977 series vehicles are warranted by Oshkosh Truck
Corporation for 12 months or 12,000 miles (19 308 km), whichever comes first. For complete information
covering this warranty, refer to Warranty Technical Bulletin, TB 9-2300-295-15/19. Warranty starts on the
date found in block 23, DA Form 2408-9, in the logbook. Report all defects in material or workmanship to
the supervisor, who will take appropriate action.
1-9. METRIC SYSTEM. The equipment described herein contains metric components and requires
metric common and special tools; therefore, metric units in addition to English units will be used
throughout this manual. An English-to-metric conversion table is included as the last page of this manual
inside the back cover.
1-6
TM
9-2320-279-34-1
Section Il. EQUIPMENT DESCRIPTION AND DATA
Features and Technical Data
1-10. VEHICLE DESCRIPTION. The M977 series vehicles are 8x8, on/off road vehicles produced in a
number of different configurations. For equipment operation data, refer to operator instructions,
TM 9-2320-279-10, TM 9-2320-354-10, and TM 9-2320-355-10.
1-11. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES. Refer to
TM 9-2320-279-10 for equipment characteristics, capabilities, and features.
1-12. LOCATION AND DESCRIPTION OF COMPONENTS. Refer to TM 9-2320-279-10 for location
and description of components.
1-13. DIFFERENCES BETWEEN MODELS. Refer to TM 9-2320-279-20 for major differences between
models.
1-14. SAFETY, CARE, AND HANDLING.
a. Significant Hazards and Safety Recommendations. Significant hazards and safety
recommendations are listed in Table 1-2.
Table 1-2. Significant Hazards and Safety Recommendations
Operating
Condition 1
Hazard
Safety Recommendation or Precaution
Low air pressure for
brakes.
Do not drive vehicle while low air pressure warning
buzzer is sounding or red light is on.
Abnormal
Vehicle instability with
crane use.
Ensure that outriggers are down on firm ground, side
slope does not exceed five degrees, and crane is not
overloaded.
Abnormal
Fire with M978 tanker.
No smoking, flames, or sparks within 50 feet (15 m).
Disconnect batteries for all electrical work.
Normal
Fuel spills with M978
tanker.
Test tank automatic shutoff before bottom loading
per procedure in instructions. Do not bypass
dead-man controls.
Do not go between vehicles until vehicles are
stopped and brakes are set.
Abnormal
Shut off engine and no smoking when filling tank.
Normal
Connecting towing devices.
Refueling vehicle.
Normal
1
Category of hazards as to whether or not they maybe expected under normal or abnormal operating
conditions.
b. Cranes. Material handling cranes for models M977, M983, M984, M984E1, M985, and M985E1 all
have overload shutdown and/or tilt warning (unstable) systems.
(1) On M983, M984, and M985E1 models a yellow caution light and an audible warning signal alert
the operator when an unstable crane condition occurs.
(2) On all models an overload shutdown system prevents overloading the crane. The system will shut
down the crane to prevent hoisting, swinging, or boom extension when an overload condition exists. Load
lowering and boom retraction functions will not be affected.
1-7
TM 9-2320-279-34-1
Features and Technical Data (Cont)
1-14. SAFETY, CARE, AND HANDLING (CONT).
c. Crane Operating Instruction Plate Locations:
(1) The crane operating instruction plates are located on the heater compartment cover in the cab,
and at each of the fixed operating stations.
(2) The outrigger leg signs are located on each of the outrigger cylinders.
(3) The load capacity signs are located at the main and auxiliary control panels.
Section Ill.
1-15. PRINCIPLES OF OPERATION.
1-8
PRINCIPLES OF OPERATION.
Refer to TM 9-2320-279-20.
TM 9-2320-279-34-1
CHAPTER 2
MAINTENANCE INSTRUCTIONS
Para Page
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Common Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Troubleshooting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Preparation for Storage and Shipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Pre-Embarkation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Section I.
2-1
2-1
2-1
2-1
2-2
2-2
2-2
2-137
2-139
2-140
2-140
INTRODUCTION
2-1. GENERAL. This chapter provides information on tools, general maintenance, and troubleshooting
at direct support and general support maintenance levels for M977 series vehicles. Preparation for storage
and pre-embarkation inspection are also covered.
Section Il.
REPAIR PARTS, SPECIAL TOOLS, AND TEST EQUIPMENT
Parts, Tools, and Test Equipment
2-2. COMMON TOOLS AND EQUIPMENT. There are common tools and general mechanics tool sets
required for maintenance of the vehicle. For authorized common tools and equipment, refer to the
Modified Table of Organization and Equipment (MTOE) applicable to your unit.
2-3. SPECIAL TOOLS. Special tools for direct support and general support maintenance are listed in
the Repair Parts and Special Tools List (RPSTL) in TM 9-2320-279-34P which is your authority for
requisitioning.
2-4. TEST EQUIPMENT. The M977 series vehicles are
equipped with a diagnostic connector for Simplified Test
Equipment/Internal Combustion Engine (STE/ICE). The
STE/ICE connector (fig. 2-1) is located on passenger side of
the cab. Refer to TM 9-2320-279-20 for STE/ICE tests.
Figure 2-1. STE/lCE Connector.
2-1
TM 9-2320-279-34-1
Parts, Tools, and Test Equipment (Cont)
2-5. REPAIR PARTS.
Repair parts authorized for use at the direct support and general support
maintenance level are listed and illustrated in Repair Parts and Special Tools Lists (RPSTL).
Section III.
TROUBLESHOOTING
2-6. TROUBLESHOOTING INTRODUCTION. This section contains step by step procedures for
identifying, locating, isolating, and repairing M977 series vehicle and component malfunctions. Refer to
TM 9-2320-354-24&P and TM 9-2320-355-24&P to troubleshoot crane problems on the M984 and M985E1
vehicles.
2-7. TROUBLESHOOTING INSTRUCTIONS. The Troubleshooting Fault Symptom Index (Table 2-1) lists
common malfunctions by vehicle system. The Troubleshooting Subject Index (Table 2-2) lists common
malfunctions alphabetically. The Troubleshooting Procedures (Table 2-3) lists each malfunction followed by
tests, inspections, and corrective actions.
a. This manual cannot list all malfunctions that may occur, nor all tests, inspections, or corrective
actions. If a malfunction is not listed or is not corrected by listed corrective actions, notify the supervisor.
b. Do the tests and inspections in the order listed, and try to return the vehicle or component to
operation after each test, inspection, and corrective action has been performed.
c. Refer to the figures and foldouts listed below while doing troubleshooting. They will help to isolate
and locate troubles and get the vehicle back in service as quickly as possible. Folds are found at the end of
this manual.
Figure 2-2
Figure 2-3
Figure 2-4
Figure 2-5
Figure 2-6
Figure 2-7
Figure 2-8
Figure 2-9
Figure 2-10
Foldout 1
Foldout 2
Foldout 3
Main Control Valve (M983)
Outrigger Control Valve (M983)
System Back Pressure (No Load) (M983)
Pressure Tester Setup (M983)
Power Distribution Board Wiring Diagram (M983)
12v Electric Motor Tester Circuit Schematic (M983)
12v Electric Motor Tester Circuit Wiring Diagram (M983)
Arctic Coolant Pump Test (Model A)
Arctic Heater Fault Codes (Model B)
Hydraulic Schematics
Crane Wiring Diagrams
Crane Electrical Schematics
Troubleshooting Index
Table 2-1. Troubleshooting Fault Symptom Index
Troubleshooting
Procedure
Page
ENGINE
1.
Engine high idle does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
TRANSMISSION
1.
2.
3.
4.
5.
2-2
Transmission oil temperature gage stays over 250_F (121_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission will not shift into gear, slips out of gear or operates erratically . . . . . . . . . . . . . . . . . .
Oil leaking at converter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Excessive creep in first and reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change 6
2-12
2-13
2-15
2-16
2-17
TM 9-2320-279-34-1
Troubleshooting Index (Cont)
Table 2-1. Troubleshooting Fault Symptom Index (Cont)
TRANSMISSION (CONT)
6. Automatic shifts occur at too high speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
7. Automatic shifts occur at too low speed or shifts rough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
8. Vehicle moves in neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
9. Transmission slips in all forward gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
10. High stall speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
11. Low stall speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
HYDRAULIC SYSTEM
1. One or more hydraulic circuits inoperative (retriever, crane, winches, tanker pump) . . . . . . . . . . 2-22
2. Winch or crane hoist jerks when operated or will not pull load . . . . . . . . . . . . 2-22
3. Retriever or cylinders do not operate smoothly or will not lift load . . . . . . . . . . . . . . . . . . . . . . . . 2-22
4. One or more hydraulic circuits inoperative (fair lead tensioner, steering). . . . . . . . . . . . . . . . . . . 2-22.2
5. Steering is not smooth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22.2
STEERING SYSTEM
1. Wheel turns restricted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2. Vehicle steers hard in one or both directions (all except M984E1) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
3. Steering is not smooth (seizing, binding) (all except M984E1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
4. Vehicle steers hard in one or both directions (M984E1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
5. Steering is not smooth (seizing, binding) (M984E1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
TANKER SYSTEM
1. Flow meter does not operate (not registering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2. No flow through meter or meter runs too slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
SELF-RECOVERY WINCH
1. Self-recovery winch does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
HEAVY-DUTY WINCH (M984)
1. Winch cable will not payout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2. Winch will not pull load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
3. Winch makes excessive or unusual noise, or operates slowly or jerks. . . . . . . . . . . . . . . . . . . . . . . 2-28
HEAVY-DUTY WINCH (M984E1)
1. Winch will not operate in remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2. Winch will not pull load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28.1
3. Winch makes excessive or unusual noise or operates slowly or jerks . . . . . . . . . . . . . . . . . . . . 2-28.2
4. Winch will not operate in either direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28.3
5. Winch operates in only one direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28.5
6. Winch high speed does not operate or winch does not shift to lower speed under heavy load . 2-28.6
7. Fairlead tensioner motor does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28.8
MATERIAL HANDLING CRANE (M983)
1. Crane chatters when nearing maximum travel in any function or when operating with near
maximum load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2. Hoist operates slowly or will not lift load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
3. Hoist will not hold load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
4. Hoist will not lower load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
5. Boom extensions no. 3 and no. 4 will not extend or will not fully extend . . . . . . . . . . . . . . . . . . . 2-37
6. Boom extensions no. 3 and no. 4 will not hold load extended or retracted or creeps . . . . . . . . . . 2-38
7. Boom extensions no. 3 and no. 4 will not retract or will not fully retract. . . . . . . . . . . . . . . . . . . . 2-38
2-3
TM 9-2320-279-34-1
Troubleshooting Index (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-1.
MATERIAL HANDLING CRANE (M983) (CONT)
8. Boom extension no. 1 or no. 2 will not extend or will not fully extend. . . . . . . . . . . . . . . . . . . . . 2-39
9. Boom extension no. 1 or no. 2 will not hold load extended or retracted, or creeps . . . . . . . . . . . 2-40
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Boom extensions no. 1 and no. 2 will not retract or will not fully retract . . . . . . . . . . . . . . . . . . 2-41
Boom will not lower or will not lower completely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Boom will not go to maximum height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Boom will not lift load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Boom lowers under load or will not hold load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Crane will not unfold or will not unfold completely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Crane will not fold completely or folds slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Crane folds too quickly (falls when folding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Boom moves slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Crane does not rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Crane rotates slowly in one direction, but rotates normally in other direction. . . . . . . . . . . . . . . 2-54
Crane creeps clockwise or counterclockwise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Outrigger will not extend or retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Outrigger will not support load or creeps upward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Crane operating levers not moving in remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Crane will not operate in one or more remote control functions . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
One function rod returns to neutral, but does not respond to controller . . . . . . . . . . . . . . . . . . . 2-64
Crane operation is not smooth in remote control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Control rods do not move completely in or out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Crane will not raise or extend in remote operation, but will lower and retract and swing works
in both directions (overload protection circuit malfunction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
No visual or audible tilt alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Crane outrigger extended light does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Remote controller operating, but crane will not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
Crane starts to move as soon as remote controller is connected and turned on . . . . . . . . . . . . . . 2-80
MATERIAL HANDLING CRANE (M977, M985, M984E1)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
2-4
Crane will not operate manually or with remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outrigger operation slow or erratic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outrigger beam will not extend or retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outrigger leg (left or right) will not support load or extend and retract . . . . . . . . . . . . . . . . . . . .
Mast raises or lowers erratically, slowly, or will not raise and lower . . . . . . . . . . . . . . . . . . . . . . .
Mast will not hold raised position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom operates abnormally, slowly, will not telescope in or out, or raise or lower . . . . . . . . . . . .
Boom operation erratic when telescoping in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom will not telescope out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom will not telescope in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom raises or lowers slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom will not raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom will not lower (M977, M984E1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom will not hold load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist will not raise load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist will not lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist operation slow when lowering or raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoist will not hold load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-81
2-85
2-85
2-86
2-87
2-89
2-90
2-99
2-100
2-101
2-103
2-103
2-106
2-107
2-108
2-112
2-114
2-115
TM 9-2320-279-34-1
Troubleshooting Index (Cont)
Table 2-1. Troubleshooting Fault Symptom Index (Cont)
Troubleshooting
Procedure
Page
MATERIAL HANDLING CRANE (M977, M985) (CONT)
19.
20.
21.
22.
23.
24.
25.
26.
27.
Hoist lowers load too quickly (load drives hoist motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing operation slow or erratic in both directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing operation erratic or slow in one direction only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing system will not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing motor continues to operate when swing control is in neutral position . . . . . . . . . . . . . . . . .
Swing motor noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane controls sticking or control will not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane bounces or jerks or does not operate smoothly when crane controls are operated or
returned to neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote controller will not operate crane in one function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-115
2-117
2-119
2-122
2-124
2-125
2-126
2-126.1
2-126.2
RETRIEVAL SYSTEM
1.
2.
3.
4.
Lift cylinder will not lift load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift cylinder will not extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tow cylinder will not extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tow cylinder will not retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-126.5
2-126.5
2-126.5
2-126.5
ARCTIC HEATER
1.
2.
Coolant pump fails to operate (indicator light comes on) (Model A) . . . . . . . . . . . . . . . . . . . . . . . . . 2-128
Arctic heater diagnostic troubleshooting (Direct Level) (Model B) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129
Table 2-2. Troubleshooting Subject Index
Subject
Arctic heater diagnostic troubleshooting (Direct Level) . . . . . . . . . . . . . . . .
Automatic shifts occur at too high speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic shifts occur at too low speed or shifts rough . . . . . . . . . . . . . . . .
Boom extension no. 1 or no. 2 will not extend or will not fully extend . . .
Vehicle System
Page
Arctic Heater (Model B) .
Transmission . . . . . . . . . . .
Transmission . . . . . . . . . . .
Material Handling
Crane (M983) . . . . . . . . .
2-129
2-18
2-19
Boom extension no. 1 or no. 2 will not hold load extended or
retracted, or creeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Boom extensions no. 1 and no. 2 will not retract or will not fully retract Material Handling
Crane (M983) . . . . . . . . .
Boom extensions no. 3 and no. 4 will not extend or will not fully extend Material Handling
Crane (M983) . . . . . . . . .
Boom extensions no. 3 and no. 4 will not hold load extended or
retracted, or creeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Boom extensions no. 3 and no. 4 will not retract or will not fully
retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Change 6
2-39
2-40
2-41
2-37
2-38
2-38
2-5
TM 9-2320-279-34-1
Troubleshooting Index (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-2.
Subject
Troubleshooting Subject Index (Cont)
Vehicle System
Boom lowers under load or will not hold load . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Boom moves slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Boom operation erratic when telescoping in . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Boom operates abnormally, slowly, will not telescope in or out, or raise
or lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Boom raises or lowers slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Boom will not telescope out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Boom will not go to maximum height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Boom will not hold load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Boom will not lift load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Boom will not lower (M977, M985) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Boom will not lower or will not lower completely . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Boom will not raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Boom will not raise load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Boom will not telescope in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Cable, winch will not pay out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy Duty Winch . . . . . .
Control rods do not move complete in or out . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Coolant pump fails to operate (indicator light comes on) . . . . . . . . . . . . . . . Arctic Heater Kit
(Model A) . . . . . . . . . . . . . .
Crane bounces, jerks, or does not operate smoothly . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Crane chatters when nearing maximum travel in any function or
when operating with near maximum load . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Crane controls sticking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Crane controls will not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Crane creeps clockwise or counterclockwise . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Crane does not rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Crane folds too quickly (falls when folding) . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
2-6
Change 6
Page
2-47
2-50
2-93
2-90
2-87
2-100
2-44
2-107
2-45
2-106
2-42
2-100
2-100
2-101
2-27
2-69
2-128
2-124
2-32
2-123
2-123
2-54
2-54
2-50
TM 9-2320-279-34-1
Troubleshooting Index (Cont)
Table 2-2.
Subject
Troubleshooting Subject Index (Cont)
Vehicle System
Crane jerks when operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic . . . . . . . . . . . . . .
Material Handling
Crane (M977, M985) . . .
Crane operating levers not moving in remote control . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Crane operation is not smooth in remote control mode . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Crane outrigger extended light does not work . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Crane overload protection circuit malfunction . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Crane rotates slowly in one direction, but rotates normally in other
direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Crane starts to move as soon as remote controller is connected and
turned on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Crane will not fold completely or folds slowly . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Crane will not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Crane will not operate in one or more remote control functions . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Crane will not unfold or will not unfold completely . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Engine high idle does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . .
Excessive creep in first and reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . .
Flowmeter does not operate (not registering) . . . . . . . . . . . . . . . . . . . . . . . . . Tanker . . . . . . . . . . . . . . . . .
High idle does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . .
High stall speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . .
Hoist lowers load too quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Hoist operates slowly or will not lift load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Hoist operation slow when lowering or raising . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Hoist will not hold load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Cranes
(M983) . . . . . . . . . . . . . . . . .
(M977, M985) . . . . . . . . . . .
Hoist will not lower load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Cranes
(M983) . . . . . . . . . . . . . . . . .
(M977, M985) . . . . . . . . . . .
Hydraulic circuits inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic . . . . . . . . . . . . . .
Hydraulic oil is foamy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic . . . . . . . . . . . . . .
Lift cylinder will not extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Retrieval System
(M984E1) . . . . . . . . . . . . .
Lift cylinder will not lift load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Retrieval System
(M984E1) . . . . . . . . . . . . .
Change 6
Page
2-22
2-124
2-54
2-69
2-77
2-73
2-54
2-82
2-48
2-83
2-61
2-47
2-10
2-17
2-24
2-10
2-21
2-113
2-34
2-114
2-35
2-113
2-36
2-112
2-22
2-22
2-126.5
2-126.5
2-7
TM 9-2320-279-34-1
Troubleshooting Index (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-2.
Subject
Troubleshooting Subject Index (Cont)
Vehicle System
Load drives hoist motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Low stall speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . .
Mast raises or lowers erratically or slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Mast will not hold raised position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Mast will not raise and lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Meter runs too slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tanker . . . . . . . . . . . . . . . . .
No flow through meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tanker . . . . . . . . . . . . . . . . .
No visual or audible tilt alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Oil in reservoir is foamy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic . . . . . . . . . . . . . .
Oil leaking at converter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . .
One or more hydraulic circuits inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic . . . . . . . . . . . . . .
Outrigger beam will not extend or retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Outrigger leg will not extend or retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Outrigger leg will not support load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, (M985) . .
Outrigger operation slow or erratic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Outrigger will not extend or retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Outrigger will not support load or creeps upward . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Overload protection circuit malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Remote control function rod does not respond to controller . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Remote controller operating, but crane will not move . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . .
Remote controller will not operate crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Remote controller will not operate in one function . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
Rough shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . .
Self-recovery winch does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Recovery Winch . . . .
Steering is not smooth (seizing, binding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . . . . .
Steering wheel turns restricted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . . . . .
Swing motor continues to operate when swing control is in neutral
position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . .
2-8
Change 6
Page
2-113
2-21
2-87
2-89
2-87
2-25
2-25
2-76
2-22
2-16
2-22
2-85
2-86
2-86
2-85
2-55
2-57
2-71
2-64
2-78
2-126.2
2-126.2
2-19
2-26
2-24
2-23
2-124
TM 9-2320-279-34-1
Troubleshooting Index (Cont)
Table 2-2. Troubleshooting Subject Index (Cont)
Subject
Vehicle System
Page
Swing motor noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . . 2-125
Swing operation slow or erratic in both directions . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . . 2-117
Swing operation erratic or slow in one direction only . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . . 2-119
Swing system will not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M977, M985) . . . 2-122
Tilt alarms do not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Handling
Crane (M983) . . . . . . . . . 2-76
Tow cylinder will not extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Retrieval System
(M984E1) . . . . . . . . . . . . 2-126.5
Tow cylinder will not retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Retrieval System
(M984E1) . . . . . . . . . . . . 2-126.5
Transmission oil temperature gage stays over 250°F (121 °C) . . . . . . . . . . Transmission. . . . . . . . . . . 2-12
Transmission oil leaks at converter housing . . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . . 2-16
Transmission . . . . . . . . . . . 2-15
Transmission operates erratically. . . . .
Transmission. . . . . . . . . . . 2-19
Transmission shifts at too low speed . .
Transmission. . . . . . . . . . . 2-18
Transmission shifts at too high speed .
Transmission. . . . . . . . . . . 2-20
Transmission slips in all forward gears
Transmission . . . . . . . . . . . 2-15
Transmission slips out of gear. . . . . . . .
Transmission . . . . . . . . . . . 2-15
Transmission will not shift into gear . .
Transmission . . . . . . . . . . . 2-19
Transmission shifts roughly . . . . . . . . .
Transmission . . . . . . . . . . . 2-13
Transmission noisy . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . 2-24
Vehicle wanders from side to side . . . .
Transmission. . . . . . . . . . . 2-20
Vehicle moves in Neutral . . . . . . . . . . .
Vehicle pulls to one side . . . . . . . . . . . .
Steering . . . . . . . . . . . . 2-24
Vehicle steers hard in one or both directions . . . . . . . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . 2-23
Wheel turns restricted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . 2-23
Winch cable will not payout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy-Duty Winch . . . . . 2-27
Winch does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Recovery Winch. . . . 2-26
Winch jerks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy-Duty Winch . . . . . . 2-28
Hydraulic . . . . . . . . . . 2-22
Winch makes excessive or unusual noise . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy-Duty Winch . . . . . 2-28
Winch operates slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy-Duty Winch . . . . . 2-28
Winch or crane jerks when operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic . . . . . . . . . . 2-22
Winch will not pull load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy-Duty Winch . . . . . 2-27
2-9
TM
9-2320-279-34-1
Troubleshooting Malfunctions
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting
Malfunction
Test or Inspection
Corrective Action
ENGINE
1.
ENGINE HIGH IDLE DOES NOT OPERATE.
NOTE
On M984, winch remote controller switch must be operated instead of LATCH switch.
Step 1. Check that throttle control solenoid operates when ENGINE, PTO ENGAGE, and LATCH
switches are set to ON.
Replace solenoid if solenoid does not click (TM 9-2815-224-34&P).
Step 2. Check engine governor adjustment (TM 9-2815-224-34&P).
Adjust engine governor.
2-10
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
TRANSMISSION
Perform transmission stall test when power package (engine and transmission) is not performing
satisfactorily. Purpose of test is to find out if transmission or engine is defective.
WARNING
Apply both parking and service brakes when performing transmission stall test. Block
wheels to prevent forward or reverse movement. In the event of brake failure and/or
improper blocking of wheels, vehicle can suddenly move forward or backward and
may cause personal injury or death.
Chock wheels to prevent forward or reverse movement.
Set parking brake (TM 9-2320-279-10).
Start engine and set service brakes.
Put transfer case in high position, and set transmission to 2 position.
CAUTION
Do not maintain stall condition longer than 30 seconds. Transmission oil can become
overheated and damage to transmission may occur. Do not allow temperature to
exceed 300 °F (140 °C). Keep close check to prevent engine cooling system from
overheating.
Accelerate engine to full throttle. Write down maximum rpm engine will run (torque converter stall
speed). Stall speed should be 2100 rpm ( ± 150 rpm).
If high engine speed is noted, go to MALFUNCTION 9.
If engine speed is low, go to MALFUNCTION 10.
2-11
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
TRANSMISSION (CONT)
1.
TRANSMISSION OIL TEMPERATURE GAGE STAYS OVER 250 °F (121 °C).
Step 1. Check for low lubrication oil pressure. Remove oil line from transmission lube port and
install tee and 0 to 100 psi (0 to 690 kPa) gage. Start engine and increase speed to
approximately 1900 rpm. Check for 25 to 30 psi (172 to 207 kPa) lube system pressure.
If pressure is 25 to 30 psi (172 to 207 kPa), disassemble transmission and check for
damaged torque converter (para 7-7, 7-8).
Step 2. Check for low main pressure. Remove oil line from main pressure port on transmission and
install tee and 0 to 300 psi (0 to 2 070 kPa) gage. Start engine and allow to run at idle speed.
With parking brake applied, shift transmission into DRIVE. Check for 105 to 140 psi (725 to
965 kPa) main system pressure.
If pressure is 105 to 140 psi (725 to 965 kPa), disassemble transmission and inspect
lubrication pressure regulator and converter bypass valve for damage (para 7-9,
7-20).
2-12
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
TRANSMISSION (CONT)
1.
TRANSMISSION OIL TEMPERATURE GAGE STAYS OVER 250 °F (121 °C) (CONT).
Step 3. Check for clogged internal filter element. Remove oil pan (para 7-11). Inspect filter element.
If internal filter element is clogged, replace internal filter element (para 7-12).
Step 4. Check for damaged or missing preformed packing on internal filter pickup tube.
If preformed packing is damaged or missing, replace preformed packing
(para 7-12).
If preformed packing is not damaged or missing, disassemble transmission and
inspect oil pump, main pressure regulator valve, and control valve body for loose
screws and sticking valves (paras 7-8, 7-9, 7-20).
2. TRANSMISSION NOISY.
Step 1. Check for low lubrication oil pressure. Remove and plug lubrication oil line from lube port.
Install 0 to 100 psi (0 to 690 kPa) gage at lube port. Start engine and increase speed to
approximately 1900 rpm. Check for 25 to 30 psi (172 to 207 kPa) lube system pressure.
If pressure is 25 to 30 psi (172 to 207 kPa), disassemble transmission and check
torque converter, planetary gear assemblies, and bearings for damage (paras 7-7,
7-8, 7-9, and 7-13).
2-13
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
TRANSMISSION (CONT)
2. TRANSMISSION NOISY (CONT).
Step 2. Check for low main pressure. Remove line from main pressure port on transmission and
install tee and 0 to 300 psi (0 to 2 070 kPa) gage. Start engine and allow to run at idle speed.
With parking brake applied, shift transmission into DRIVE. Check for 105 to 140 psi (725 to
965 kPa) main system pressure.
If pressure is 105 to 140 psi (725 to 965 kPa), disassemble transmission and inspect
lubrication pressure regulator and converter bypass valve for damage (paras 7-9,
7-20). Inspect all other moving parts for damage from lack of oil.
Step 3. Check for clogged internal filter element. Remove internal filter element (para 7-12).
If filter element is clogged, replace filter element (para 7-12).
If filter element is not clogged, check for damaged or missing preformed packing
on pick-up tube. Replace damaged or missing preformed packing (para 7-12).
If transmission is still noisy, disassemble transmission, inspect oil pump, main
pressure regulator valve, converter bypass valve, and lubrication pressure
regulator for damage (paras 7-8, 7-9, 7-20). Inspect all other parts for damage from
lack of oil.
2-14
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table
2-3.
Troubleshooting
(Cont)
Malfunction
Test or Inspection
Corrective Action
TRANSMISSION
3.
TRANSMISSION
WILL
NOT
SHIFT
INTO
GEAR,
(CONT)
SLIPS
OUT
OF
GEAR,
OR
OPERATES
ERRATICALLY.
Step 1. Check for low main pressure. Remove line from main pressure port on transmission and
install tee and 0 to 300 psi (0 to 2 070 kPa) gage. Start engine and allow to run at idle speed.
With parking brake applied, shift transmission into DRIVE. Check for 105 to 140 psi (725 to
965 kPa) main system pressure.
If pressure is 105 to 140 psi (725 to 965 kPa), go to step 4.
Step 2. Check for clogged internal filter element. Remove oil pan (para 7-11)
If internal filter element is clogged, replace internal filter element (para 7-12).
Step 3. Check for damaged or missing preformed packing on internal filter pickup tube.
If preformed packing is damaged or missing, replace preformed packing and gasket
(para 7-12).
If preformed packing is not damaged or missing, disassemble transmission and
inspect oil pump, main pressure regulator valve, control valve body for leakage or
sticking valves (para 7-8, 7-9, 7-20).
2-15
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
Table
2-3.
(CONT).
Troubleshooting
(Cont)
Malfunction
Test or Inspection
Corrective
Action
TRANSMISSION
(CONT)
3. TRANSMISSION WILL NOT SHIFT INTO GEAR, SLIPS OUT OF GEAR, OR OPERATES
ERRATICALLY (CONT).
Step 4. Remove oil pan (para 7-11). Manually shift transmission and see if manual shaft and detent
lever engage selector valve and that actuator pin is attached to detent lever.
If selector valve does not engage detent lever, repair or replace defective parts
(para 7-20).
If selector valve engages detent lever, disassemble transmission and valve body to
check for worn clutch packs in transmission, loose valve body screws, and sticking
valves in valve body (paras 7-10, 7-15, 7-17, 7-18, 7-19).
4.
2-16
OIL
LEAKING
AT
CONVERTER
HOUSING.
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table
2-3.
Troubleshooting
(Cont)
Malfunction
Test or Inspection
Corrective Action
TRANSMISSION
4. O I L
LEAKING
AT
CONVERTER
HOUSING
(CONT)
(CONT).
Step 1. Remove cover from top of converter housing. Check for signs of oil.
If engine oil is inside housing, replace rear engine crankshaft oil seal
(TM
9-2320-279-34&P).
If transmission oil is inside housing, inspect inner converter housing mounting
screws, converter pump to converter housing seal ring, converter housing gasket,
torque converter cover seal ring, oil pump seal, pitot attachment screws, pump
hub seal rings and converter pump hub (para 7-9).
5.
EXCESSIVE
CREEP
IN
FIRST
AND
REVERSE.
Step 1. Check for too high engine idle speed.
If idle speed is more than 750 rpm, adjust engine idle speed (TM 9-2320-279-34&P).
Step 2. Check for lock up pressure at idle speed. Remove pressure switch at transmission lock up
port and install 0 to 300 psi (0 to 2 070 kPa) gage. Start engine and allow to idle with
parking brake applied. Shift transmission into DRIVE. Check for 0 psi (0 kPa) lockup
pressure. There should be no lockup pressure.
If there is no lockup pressure, disassemble transmission and check for warped
clutch plates, stuck (applied) clutch pack pistons or a damaged torque converter to
turbine support bearing (paras 7-7, 7-15, 7-17, 7-18, 7-19).
If there is any lockup pressure, inspect lockup clutch valve for sticking pistons
(para 7-22).
2-17
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
Table
2-3.
(CONT).
Troubleshooting
(Cont)
Malfunction
Test or Inspection
Corrective
Action
TRANSMISSION
6.
AUTOMATIC
SHIFTS
OCUR
AT
TOO
HIGH
A
(CONT)
SPEED.
Step 1. Check rear governor pressure. Remove plug from rear governor test port. Install a 0 to
200 psi (0 to 1 380 kPa) gage at rear governor test port. Start engine and shift transmission
into DRIVE. Release parking brake and drive vehicle until engine tachometer reads
approximately 1650 rpm. Check for 83 to 91 psi (573 to 628 kPa) rear governor pressure.
If pressure is 83 to 91 psi (573 to 628 kPa), repair valve body (para 7-23).
Step 2. Check for clogged governor oil filter screen. Remove oil pan (para 7-11). Remove plug and
oil filter screen (para 7-20).
If oil filter screen is clogged or damaged, clean or replace oil filter screen as
required (para 7-20).
If oil filter screen is not clogged or damaged, go to Malfunction 3, Steps 1
through 3.
2-18
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
TRANSMISSION
(CONT)
7. AUTOMATIC SHIFTS OCCUR AT TOO LOW A SPEED OR SHIFTS ROUGH.
Step 1. Check for defective modulator valve. Remove modulator valve from transmission
(para 7-21). Apply 70 psi (483 kPa) air pressure at modulator valve hose fitting. Check that
modulator valve plunger moves as air is applied. Modulator valve must not leak air when
operated.
If modulator valve does not operate properly, or is damaged, replace modulator
valve (para 7-21).
Step 2. Check for defective control valve. Remove modulator valve (para 7-21). Check valve stop in
transmission for free movement in. Check that spring pushes valve stop out when released
and is not damaged.
If valve stop does not move freely or spring is damaged or does not push valve stop
out, repair control valve (para 7-20).
Step 3. Check for high rear governor pressure. Remove plug from rear governor test port. Install a
0 to 200 psi (0 to 1380 kPa) gage at rear governor test port. Start engine and shift
transmission into DRIVE. Release parking brake and drive vehicle until engine tachometer
reads approximately 1650 rpm. Check for 83 to 91 psi (573 to 628 kPa) rear governor
pressure.
If pressure is over 91 psi (628 kPa) replace governor valve (para 7-23).
If pressure is 83 to 91 psi (573 to 628 kPa) repair control valve body (para 7-20).
2-19
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
Table
2-3.
(CONT).
Troubleshooting
(Cont)
Malfunction
Test or Inspection
Corrective Action
TRANSMISSION (CONT)
8.
VEHICLE
MOVES
IN
NEUTRAL.
Step 1. Remove oil pan (para 7-11). Manually shift transmission and see if the manual shaft and
detent lever are engaging with selector valve and that actuator pin is attached to detent
lever.
If selector valve does not engage replace defective parts (para 7-20).
If selector valve engages, disassemble transmission and valve body to check for
applied clutch packs or leaking or sticking valves in valve body (paras 7-15, 7-16,
7-17, 7-18, 7-19, 7-20).
9.
TRANSMISSION
SLIPS
IN
ALL
FORWARD
GEARS.
Step 1. Check for low main pressure. Remove line from main pressure port on transmission and
install a tee and a 0 to 300 psi (0 to 2 068 kPa) gage. Start engine and allow to run at idle
speed. With parking brake applied, shift transmission into DRIVE. Check for 105 to 140 psi
(725 to 965 kPa) main system pressure.
If pressure is 105 to 140 psi (725 to 965 kPa), rebuild forward clutch (para 7-15).
If pressure is less than 105 to 140 psi (725 to 965 kPa), go to Malfunction 3, steps 1
through 3.
2-20
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
TRANSMISSION
10.
HIGH
STALL
(CONT)
SPEED.
Step 1. Check for low main pressure. Remove line from main pressure port. Install tee and 0 to
300 psi (0 to 2 070 kPa) gage. Start engine and allow to run at idle speed. With parking
brake applied, shift transmission into DRIVE and accelerate engine to approximately
1200 rpm. Check for 140 to 175 psi (965 to 1 206 kPa) main system pressure.
If pressure is 140 to 175 psi (965 to 1 206 kPa), disassemble transmission and
inspect forward and first clutches for damage (para 7-15, 7-16).
If pressure is not 140 to 175 psi (965 to 1 206 kPa), go to Malfunction 3, steps 1
through 3.
11.
LOW STALL SPEED.
NOTE
Do step 1, then run stall check. If problem remains, go to step 2.
Step 1. Go to TM 9-2815-224-34&P, ENGINE troubleshooting, ENGINE FAILS T0 DELIVER FULL
POWER.
Step 2. Check for damaged torque converter. Disassemble torque converter stator, pump, and
housing (paras 7-7, 7-8, and 7-9).
Replace damaged torque converter parts (paras 7-7, 7-8, and 7-9).
2-21
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
Table
2-3.
(CONT).
Troubleshooting
(Cont)
Malfunction
Test or Inspection
Corrective Action
HYDRAULIC
1.
ONE OR MORE HYDRAULIC
TANKER PUMP).
CIRCUITS
SYSTEM
INOPERATIVE
(RETRIEVER,
CRANE,
WINCHES,
2. WINCH OR CRANE JERKS WHEN OPERATED OR WILL NOT PULL LOAD.
3.
RETRIEVER
LOAD.
OR
CRANE
CYLINDERS
DO
NOT
OPERATE
SMOOTHLY
OR
WILL
NOT
LIFT
NOTE
Before performing hydraulic tests, the hydraulic oil reservoir must be at least warm
to the touch.
Step 1. Check for defective hydraulic PTO pump. Set up hydraulic flowtester on PTO pump output
line. For M984E1 check output at both ports P3 and P4. Start engine, engage PTO, set high
idle (TM 9-2320-279-10).
2-22
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table
2-3.
Troubleshooting
(Cont)
2-3
para 19-4
19-4
2-3
2-22.1
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-22.2
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-23
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-24
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-24.1/(2-24.2blank
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
TANKER SYSTEM
1.
FLOWMETER DOES NOT OPERATE (NOT REGISTERING).
(FLOWMETER REMOVED FROM TANKER FOR CLARITY)
Step 1.
Remove four screws from adjuster cover plate and meter housing.
Step 2.
Remove adjuster cover plate. Check if gear and shaft are damaged.
Replace defective adjuster drive gear or drive shaft (para 22-8).
Step 3.
Remove flowmeter (para 22-7). Remove front cover (para 22-8). Check for damaged
displacement and blocking rotor gears.
Replace defective displacement and blocking rotor gears (para 22-8).
Step 4.
Remove flowmeter (para 22-7). Remove rear cover and bearing plate from meter housing
(para 22-8). Check for damaged displacement and blocking rotors. Check for deposits on
rotors. Checking housing and all parts for damage.
If rotors are damaged, replace rotors, replace housing and all damaged parts. Clean
deposits from rotors (para 22-8).
2.
NO FLOW THROUGH METER OR METER RUNS TOO SLOWLY.
Step 1.
Remove flowmeter (para 22-7), but do not remove flowmeter register or adjuster. Remove
flowmeter front cover (para 22-8). Check for damaged blocking and displacement rotor
gears.
Replace defective blocking and displacement rotor gears (para 22-8).
Change 3
2-25
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (C0NT).
Table 2-3. Troubleshooting (Cont)
Malfunction
lest or Inspection
Corrective Action
TANKER SYSTEM (CONT)
2.
NO FLOW THROUGH METER OR METER RUNS TOO SLOWLY (CONT).
Step 2. Remove flowmeter (para 22-7). Remove rear cover and bearing plate from meter housing
(para 22-8). Check for frozen and damaged blocking and displacement rotors. Check rotors
for deposits and corrosion, check meter housing for damage.
Clean deposits and corrosion from rotors. If rotors are frozen or damaged, replace
rotors. Replace meter housing if damaged. Repair flowmeter (para 22-8).
SELF-RECOVERY WINCH
1.
SELF-RECOVERY WINCH DOES NOT WORK.
Step 1. Go to HYDRAULIC SYSTEM troubleshooting, Malfunction 3.
Step 2. Check for defective winch counterbalance valve. Disconnect and plug brake release line at
fitting. Install a 0 to 3000 psi (0 to 20 700 kPa) gage on fitting. Start engine and engage PTO.
Operate winch IN and winch OUT.
If pressure is not 200 psi (1 380 kPa) or above in both directions, replace defective
counterbalance valve (para 16-5).
NOTE
Do not disconnect any hydraulic hoses. Check for defective hydraulic motor.
Step 3. Remove hose mounting bracket screws. Remove hydraulic motor (para 16-3). Start engine,
engage PTO. Operate self-recovery winch IN and OUT.
If motor does not operate in both directions, replace self-recovery winch hydraulic
motor (para 16-3).
Step 4. Check for defective self-recovery winch drum or brake. Remove brake (para 16-7). Turn
winch drum.
If winch drum turns, replace self-recovery winch brake (para 16-7).
If winch drum does not turn, repair self-recovery winch drum (para 16-2).
2-26
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
2-27
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting (Cont)
2-28
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
2-28.1
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-28.2
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-28.3
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting (Cont)
2-28.4
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-28.5
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT)
Table 2-3. Troubleshooting (Cont)
2-28.6
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-28.7
TM
9-2320-279-34-1
Troubleshooting
2-7.
TROUBLESHOOTING
INSTRUCTIONS
Malfunctions
(Cont)
(CONT).
Table 2-3. Troubleshooting (Cont)
2-28.8
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
Figure 2-2. Main Control Valve (M983).
2-29
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
Figure 2-3. Outrigger Control Valve (M983).
2-30
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
Figure 2-4. System Back Pressure (No Load) (M983).
2-31
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-32
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
Figure 2-5. Pressure Tester Setup (M983).
Special
Tools:
Adapter 3091597
Box, measure 9968709
Gage, pressure 9968792
Equipment
Condition:
Rear catwalk mount removed (TM 9-2320-279-20).
a. Installation.
(1) Remove plug (1) from outrigger control valve port (2).
(2) Install adapter (3) in port (2).
(3) Install nipple (4) in adapter (3).
(4) Connect gage (5) to adapter (6).
(5) Connect quick connector (7) to nipple (4).
b. Removal.
(1) Disconnect connector (7) from nipple (4).
(2) Disconnect gage (5) from adapter (6).
(3) Remove nipple (4) from adpater (3).
(4) Remove adapter (3) from port (2).
(5) Install plug (1) in outrigger control valve port (2).
2-33
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-34
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-35
TM
9-2320-279-34-1
Troubleshooting
2-7.
TROUBLESHOOTING
INSTRUCTIONS
Malfunctions
(Cont)
(CONT).
Table 2-3. Troubleshooting (Cont)
2-36
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-37
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting (Cont)
2-38
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-39
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-40
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-41
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-42
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-43
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-44
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-45
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-46
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-47
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-48
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
2-49
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-50
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-51
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-52
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-53
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-54
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
2-55
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-56
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-57
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-58
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-59
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
Figure 2-6. Power Distribution Board Wiring Diagram (M983).
2-60
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-61
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
Figure 2-7. 12V Electric Motor Tester Circuit Schematic (M983).
2-62
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
Figure 2-8. 12V Electric Motor Tester Circuit Wiring Diagram (M983).
2-63
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-64
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-65
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-66
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-67
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-68
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-69
TM
9-2320-279-34-1
Troubleshooting
2-7.
TROUBLESHOOTING
INSTRUCTIONS
Malfunctions
(Cont)
(CONT).
Table 2-3. Troubleshooting (Cont)
2-70
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-71
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-72
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-73
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-74
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
2-75
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-76
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-77
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-78
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-79
TM
9-2320-279-34-1
Troubleshooting
2-7.
TROUBLESHOOTING
INSTRUCTIONS
Malfunctions
(Cont)
(CONT).
Table 2-3. Troubleshooting (Cont)
2-80
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
MATERIAL HANDLING CRANE (M977, M985, M984E1)
WARNING
Always support crane when disconnecting lines from cylinders when crane is not
in transport position. Check valves may be bad and allow crane to fall, causing
injury or death to personnel.
NOTE
A common cause of crane malfunction is contaminated oil. Seals and packings
frequently break down in very hard use, and the small pieces of seals and packings
can travel through hydraulic lines into control valves, slowing or completely
blocking oil flow.
When troubleshooting the M977, M985, and M984E1 material handling cranes, refer
to foldout sheets, 3, 4, and 5 of Hydraulic Schematics, Wiring Diagrams, and Crane
Electrical Schematics.
M977 material handling crane is usually illustrated in this section. Location of
valves on cylinders, swing and hoist systems is very similar on M977, M985, and
M984E1 material handling cranes. Only important differences are illustrated.
1.
CRANE WILL NOT OPERATE MANUALLY OR WITH REMOTE CONTROL.
Step 1.
(M984E1) Operate retrieval system (TM 9-2320-279-10).
If retrieval system works, (the pump, relief valve and oil filter are good), repair
crane controls (para 17-28.2 or 17-28.3).
If retrieval system does not work, go to Step 2.
Change 3
2-81
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
MATERIAL HANDLING CRANE (M977, M985, M984E1) (CONT)
1.
CRANE WILL NOT OPERATE MANUALLY OR WITH REMOTE CONTROL (CONT).
Step 2. Check that shut-down solenoid valve operates. Set ENGINE and PTO ENGAGE switches to
ON. Move crane POWER switch ON and OFF several times. Listen for clicking sound of
solenoid to tell if solenoid operates.
If solenoid clicks but crane will not operate, try to operate crane using emergency
procedures (TM 9-2320-279-10).
If crane operates, replace defective shut-down solenoid valve (para 17-32 for M977
and M985), (para 17-32.1 for 11984E1).
If crane does not operate (M977 and M985). refer to Hydraulic System
Troubleshooting.
If crane does not operate (M984E1). refer to Step 4.
2-82
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-83
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-84
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-85
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
WARNING
2-86
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
WARNING
2-87
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-88
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
WARNING
2-89
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting (Cont)
WARNING
2-90
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
2-91
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-92
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-93
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
Table 2 - 3 .
2-94
(CONT).
Troubleshooting
(Cont)
TM
Troubleshooting
Malfunctions
9-232-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-95
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-96
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
WARNING
2-97
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting (Cont)
2-98
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
warning
2-99
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-100
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table. 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
MATERIAL HANDLING CRANE (M977, M985, M984E1) (CONT)
10.
BOOM WILL NOT TELESCOPE IN.
Step 1. Check for damaged extension cylinder lines.
Replace damaged extension cylinder lines (para 17-2 for M977 and M985)
(para 17-2.1 for M984E1).
Step 2. Check for contaminated or damaged extension cylinder holding valve.
Remove, clean, inspect, and install extension cylinder holding valve (para 17-19
for M977 and M985) (para 17-19.2 for M984E1). Do not remove extension cylinder.
Step 3. Check for overload sensor switch adjustment (para 17-33 for M977 and M985) (para 17-33.1
for M984E1).
If switch(es) cannot be adjusted, replace (para 6-12 for M977 and M985)
(para 6-12.1 for M984E1).
Step 4. Check for contaminated or damaged telescope directional control valve spool.
Remove, clean, inspect, and install directional control valve spool (para 17-28 for
M977 and M985) (para 17-28.4 for M984E1).
Step 5. Check for damaged boom extension sections and cylinder.
Remove extension No. 1 (para 17-12 for M977 and M985) (para 17-12.1 for
M984E1), extension No. 2 (para 17-13 for M977 and M985) (para 17-13.1 for
M984E1), and extension cylinder (para 17-18 for M977 and M985) (para 17-18.1 for
M984E1).
2-101
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT.).
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
MATERIAL HANDLING CRANE (M977, M985, M984A1) (CONT)
11. BOOM RAISES OR LOWERS SLOWLY.
step 1.
Refer to HYDRAULIC SYSTEM troubleshooting.
If problem remains, go to step 2.
Step 2.
Check for damaged lift cylinder lines and damaged lift cylinder.
Replace damaged lift cylinder lines (para 17-2 for M977 and M985) (para 17-2.1 for
M984E1).
Refer to step 6 if lift cylinder appears damaged.
WARNING
Do not loosen both lift cylinder holding valves unless crane is in stowed position
or boom is blocked. Boom will drop and can cause injury or death.
Step 3.
Check for contaminated or damaged lift cylinder holding valve.
Remove, clean, inspect, and install lift cylinder holding valve (para 17-17). Do not
remove lift cylinder.
2-102
Change 3
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
MATERIAL HANDLING CRANE (M977, M985, M984E1) (CONT)
Step 4.
Check main hydraulic pressure adjustment (para 17-31 for M977 and M985) (para 17-31.1
for M984E1).
If main hydraulic pressure cannot be adjusted, repair crane control valve
(para 17-28 for M977 and M985) (para 17-28.4 for M984E1).
Step 4.1
Check for contaminated or damaged boom relief valve.
Remove, clean, inspect, and install boom relief valve (para 17-32.1).
Change 3
2-102.1/(2-102.2 blank)
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-103
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-104
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
WARNING
2-105
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting (Cont)
2-106
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
WARNING
2-107
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-108
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-109
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-110
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-111
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
Table
2-112
2-30
(CONT).
Troubleshooting
(Cont)
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
2-113
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-114
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-115
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-116
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
MATERIAL HANDLING CRANE (M977, M985, M984E1) (CONT)
20. SWING OPERATION SLOW OR ERRATIC IN BOTH DIRECTIONS (CONT).
Step 4.
Check for contaminated or damaged swing drive valves. Set up hydraulic pressure tester.
Operate crane (TM 9-2320-279-10). Operate SWING control in both directions. Hydraulic
pressure should be within the range shown when operated from turntable stop to turntable
stop.
M977
M985
M984E1
1600 psi (11 032 kPa) - 1800 psi (12 411 kPa)
1800 psi (12 411 kPa) - 2000 psi (13 790 kPa)
1400 psi (9 653 kPa)
- 1600 psi (11032 kPa)
If pressure is outside of the range shown while at full swing, replace CW or CCW
swing drive valve (para 17-6 for M977 and M985) (para 17-6.1 for M984E1).
Step 5.
Check for defective turntable. Operate crane (TM 9-2320-279-10). Operate SWING control
Watch for any binding and listen for grinding or rumbling noise of turntable when
swinging. Check for damage to swing drive gear or turntable bearing gear.
If binding or noisy, remove, clean, inspect, and install turntable and bearing
(para 17-5 for M977 and M985) (para 17-5.1 for M984E1). If swing drive is damaged
replace (para 17-9 for M977 and M985) (para 17-9.1 for M984E1).
Change 2
2-117
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or lnspection
Corrective Action
MATERIAL HANDLING CRANE (M977, M985, M984E1) (CONT)
SWING OPERATION SLOW OR ERRATlC IN BOTH DIRECTIONS (CONT).
20.
Step 6. Check for contaminated swing directional control valve.
Remove, clean, inspect, and install directional control valve (para 17-28 for M977
and M985) (para 17-28.4 for M984E1).
Step 7. Check for defective drive motor. Remove motor (para 17-7 for M977 and M985) (para 17-7.1
for M984E1), but do not remove swing drive valve body, swing drive valve hoses and tubes,
or swing drive motor hydraulic hoses and tubes. Operate crane (TM 9-2320-279-10). Operate
SWING control CW or CCW.
If motor binds or there are grinding or rumbling noises, dissemble, clean,
inspect, assemble, and install swing drive motor (para 17-7 for M977 and M985)
(para 17-7.1 for M984E1).
Step 8. Check for defective swing drive brake.
Remove, disassemble, clean, inspect, assemble, and install swing drive brake
(para 17-8 for M977 and M985) (para 17-8.1 for M984E1).
Step 9. Check for defective swing drive.
Remove swing drive (para 17-9 for M977 and M985) (para 17-9.1 for M964E1).
Turn swing drive pinion gear If there is binding, disassemble, clean, inspect,
assemble, and install swing drive (para 17-9 for M977 and M985) (para 17-9.1 for
M984E1).
2-118
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
MATERIAL HANDLING CRANE (M977, M985, M984E1) (CONT)
21.
SWING OPERATION ERRATIC OR SLOW IN ONE DIRECT ION ONLY.
Step 1. Check for defective turntable. Operate crane (TM 9-2320-279-10). Operate SWING control
CW or CCW. Watch for any binding and listen for grinding or rumbling noise of turntable
when swinging.
If binding or noisy, remove, clean, inspect, and install turntable and bearing
(para 17-5 for M977 and M985) (para 17-5.1 for M984E1).
2-119
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
MATERIAL HANDLING CRANE (M977, M985, M984E1) (CONT)
21. SWING OPERATION ERRATIC OR SLOW IN ONE DIRECTION ONLY (CONT).
Step 2.
Check for damaged swing drive lines.
Replace damaged swing drive lines (para 17-2 for M977 and M985) (para 17-2.1 for
M984E1).
Step 3.
Check for contamination or damaged swing drive valves. Set up hydraulic pressure tester.
Operate crane (TM 9-2320-279-10). Operate SWING control in both directions. Hydraulic
pressure should be within the range shown when operated from turntable stop to turntable
stop.
M977
M985
M984E1
1600 psi (11032 kPa) - 1800 psi (12 411 kPa)
1800 psi (12 411 kPa) - 2000 psi (13 790 kPa)
1400 psi (9 653 kPa) - 1600 psi (11 032 kPa)
If pressure is outside of the range shown while at full swing, replace CW or CCW
swing drive valve (para 17-6 for M977 and M985) (para 17-6.1 for M984E1).
Step 4.
Check for damaged swing drive.
Remove swing drive (para 17-9 for M977 and M985) (para 17-9.1 for M984E1). Turn
switch drive pinion gear. If there is binding, disassemble, clean, inspect, assemble,
and install swing drive (para 17-9 for M977 and M985) (para 17-9.1 for M984E1).
Change 2
2-120
TM 9-2320-279-34-1
Troubloshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
Malfunction
Test of lnspection
Corrective Action
MATERIAL HANDLING CRANE (M977, M985, M984E1) (CONT)
21.
SWING OPERATION ERRATIC OR SLOW IN ONE DIRECTION ONLY (CONT),
Step 5. Check for defective swing drive brake.
F&move, disassemble, clean, inspect, assemble, and install swing drive brake
(para 17-8 for M977 and M985) (para 17-8.1 for M984E1).
Step 6. Check for defective swing drive motor. Remove swing drive motor (para 17-7 for M977 and
M985) (para 17-7.1 for M984E1). Do not remove swing drive valve body, swing drive valve
hoses and tubes, or swing drive motor hydraulic hoses and tubes. Operate crane
(TM 9-2320-279-10). Operate SWING control CW or CCW.
If motor binds or there are grinding or rumbling noises, disassemble, clean,
inspect, assemble, and install swing drive motor (para 17-7 for M977 and M985)
(para 17-7.1 for M984E1).
Step 7. Check if swing operation is erratic or slow in one direction only.
Replace swing drive valves (para 17-6 for M977 and M985) (para 17-6.1 for
M984E1).
2-121
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
MATERIAL HANDLING CRANE (M977, M985, M984E1) (CONT)
22. SWING SYSTEM WILL NOT WORK.
Step 1.
Check for damaged swing drive brake lines.
Replace damaged swing drive brake line (para 17-2 for M977 and M985) (para 17-2.
for M984E1).
CAUTION
If crane rotates slowly or in one direction, slowly operate control lever to prevent
damage to crane when it contacts rotational stop.
Step 2.
Step 3.
Check for contamination or damaged swing drive valves. Set up hydraulic pressure tester
Operate crane (TM 9-2320-279-10). Operate SWING control in both directions. Hydraulic
pressure should be within the range shown when operated from turntable stop to turntable
stop.
M977
1600 psi (11032 kPa) - 1800 psi (12 411 kPa)
M985
1800 psi (12 411 kPa) - 2000 psi (13 790 kPa)
M984E1
1400 psi (9 653 kPa) - 1600 psi (11 032 kPa)
If pressure is outside of the range shown while at full swing, replace CW or CCW
swing drive valve (para 17-6 for M977 and M985) (para 17-6.1 for M984E1).
Check for damaged swing drive lines.
Replace damaged swing drive lines (para 17-2 for M977 and M985) (para 17-2.1 for
M984E1).
Change 2
2-122
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-123
TM
9-2320-279-34-1
Troubleshooting
2 - 7 .
T R O U B L E S H O O T I N G
Table
2-124
Malfunctions
I N S T R U C T I O N S
2-3.
(Cont)
( C O N T ) .
Troubleshooting
(Cont)
TM
Troubleshooting
Table
2-3.
Malfunctions
(Cont)
Troubleshooting
(Cont)
9-2320-279-34-1
2-125
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
Table
2-3.
(CONT).
Troubleshooting
(Cont)
Malfunction
Test or Inspection
Corrective
MATERIAL
25.
CRANE
CONTROLS
Action
HANDLING
STICKING
OR
CRANE
(M977,
CONTROL
M985,
WILL
NOT
M984E1)
(CONT)
MOVE.
Step 1. Check for excessively high pressure in system. Set up hydraulic pressure tester on crane
control valve. Operate crane (TM 9-2320-279-10).
If pressure is more than 3000 psi (20 685 kPa) when operating TELESCOPE OUT or
LIFT UP controls, adjust main hydraulic pressure (para 17-31 for M977 and M985)
(para 17-31.1 for M984E1).
Step 2. Check for contaminated or damaged directional control spool valve.
Remove, clean, inspect, and install malfunctioning system directional control spool
valve (para 17-28 for M977 and M985) (paras 17-28.3 and 17-28.4 for M984E1).
2-126
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3. Troubleshooting (Cont)
WARNING
2-126.1
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-126.2
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-126.3
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-126.4
TM
Troubleshooting
Malfunctions
9-2320-279-34-1
(Cont)
Table 2-3. Troubleshooting (Cont)
2-126.5
TM
9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
2-7.
TROUBLESHOOTING
INSTRUCTIONS
(CONT).
Table 2-3. Troubleshooting (Cont)
2-126.6
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
table 2-3. Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
Test procedures for all retrieval cylinders are the same.
Step 3. Check for defective cylinders or holding valves. Install pressure gauge on test port on eight
valve bank. Operate cylinder in direction it will not work until relief valve engages
(TM 9-2320-279-10).
If pressure is correct, remove holding valves from cylinder and check for damage
or clogging.
Lift cylinder - Extend - 400 psi (2 758 kPa) (para 13-30.2)
- Retract - 2500 psi (17 238 kPa)
Tow cylinders- Extend - 300 psi (2 069 kPa) (para 13-30.4)
- Retract - 300 psi (2 069 kPa)
If holding valves are good, repair hydraulic cylinder (para 13-30.3 and 13-30.5).
If pressure is not correct, replace relief valve for cylinder in the direction it does
not work correctly.
If cylinder is still inoperative, replace or repair control valve.
2-127
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT (CONT)
WARNING
Do not wear jewelry when working around the vehicle. Jewelry can catch on
equipment and cause injury, or may short across an electrical circuit and cause
severe burns or electrical shock.
1. COOLANT PUMP FAILS TO OPERATE (INDICATOR LIGHT COMES ON) (MODEL A).
Check for defective coolant pump.
Figure 2-9. Arctic Coolant Pump Test
Remove coolant pump assembly (TM 9-2320-279-20) and mount pump assembly on bench.
Set up coolant pump test (fig. 2-9). Apply 24 vdc power to input terminal and ground
negative (-) to terminal on pump body. Let motor run 15 minutes.
If coolant does not flow at a rate of 16.0 GPM (60.5 liters/min) or pump operation is
not smooth and there is more than one cc/hr leakage from seal, repair or replace
coolant pump (para 21-2).
2-128
Change 6
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B).
S
S
S
S
Step 1.
NOTE
If the Fault Code Retrieval Device (FCRD) is not installed, the arctic heater indicator light
displays the diagnostic flash codes for the arctic heater. These flash codes are eight
seconds long and repeat after eight seconds.
The Fault Code Retrieval Device (FCRD) displays the last five faults that occur. The
latest fault is displayed with either “AF” or “F1”. If more than one fault code is displayed,
troubleshoot the latest fault code first.
All organizational level troubleshooting must be completed before performing this
procedure.
Refer to arctic engine heater (Model B) troubleshooting (TM 9-2320-279-20) for Fault Code
Retrieval Device (FCRD) operations.
Using the Fault Code Retrieval Device (FCRD) or the arctic heater indicator light,
determine which fault code is active from the list shown on Figure 2-10.
If fault code 000 is displayed and arctic heater does not operate, replace arctic
heater control unit (para 21-3) and go to Step 50.
If a fault code other than 000 is displayed, go to the step indicated in the list
shown.
Change 6
2-129
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT (CONT)
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
Figure 2-10. Arctic Heater Fault Codes (Model B)
2-130
Change 6
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
NOTE
Steps (2) through (8) are for fault codes 012, 013, 014 or 015.
Step 2.
Remove arctic heater control unit (para 21-3).
Step 3.
Perform resistance check across arctic heater temperature sensor at room temperature
(--13_ to 77_F [--25_ to 25_C]). Connect probes across arctic heater internal harness
connector terminals No. 14 and 18.
If resistance reading is not between 650 and 1000 ohms, replace arctic heater
temperature sensor (para 21-3) and go Step 6.
Step 4.
Perform resistance check across arctic overheat sensor at room temperature (--13_ to 77_F
[--25_ to 25_C]). Connect probes across arctic heater internal harness connector terminals
No. 11 and 17.
If resistance reading is not between 10k and 150k ohms, replace arctic heater
overheat sensor (para 21-3) and go Step 6.
Change 6
2-131
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT (CONT)
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
Figure 2-11. Arctic Heater Kit Wiring Diagram (Model B)
2-132
Change 6
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
Step 5.
Perform resistance check across arctic heater flame sensor at room temperature (--13_ to
77_F [--25_ to 25_C]). Connect probes across arctic heater internal connector terminals No.
15 and 16.
If resistance reading is between 900 and 1100 ohms, replace arctic heater coolant
pump (para 21-3).
If resistance reading is not between 900 and 1100 ohms, replace arctic heater flame
sensor (para 21-3).
Step 6.
Check if arctic heater operates.
If arctic heater operates, go to Step 50.
Step 7.
If Fault Code Retrieval Device (FCRD) is available, clear fault code 015 and go to
Step 50.
Step 8.
If Fault Code Retrieval Device (FCRD) is not available, replace arctic heater control unit
(para 21-3) and go to Step 50.
Step 9.
NOTE
Steps (9) through (15) are for fault codes 020 or 021.
Arctic heater glow pin harness white and brown wires are connected with a seal. Do not
separate white and brown wire from seal at glow pin terminal.
Remove arctic heater control unit (para 21-3).
Step 10.
Disconnect arctic heater glow pin harness from arctic heater glow pin (para 21-3).
Step 11.
Perform continuity check on arctic heater glow pin harness white wire. Connect probes at
arctic heater internal harness connector, terminal No. 2 and glow pin harness white wire
terminal.
S
S
If continuity is not present, replace arctic heater glow pin harness (para 21-3) and
go to Step 50.
Change 6
2-133
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT (CONT)
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
Step 12.
Step 13.
Step 14.
Step 15.
2-134
Perform continuity check on arctic heater glow pin harness brown wire. Connect probes at
arctic heater internal harness connector, terminal No. 7 and glow pin harness brown wire
terminal.
If continuity is not present, replace arctic heater glow pin harness (para 21-3) and
go to Step 50.
Perform continuity check on arctic heater glow pin harness wires. Connect probes to arctic
heater internal harness connector terminals No. 2 and 7. Check for shorts between brown
and white wires.
If continuity is measured, replace arctic heater glow pin harness (para 21-3) and go
to Step 50.
Perform resistance check across arctic glow pin. Connect probes at arctic heater glow pin
top and bottom terminals. Resistance should be 2 ohms (nominal).
If resistance reading of 2 ohms (nominal) is present, replace arctic heater control
unit (para 21-3).
If resistance reading of 2 ohms (nominal) is not present, replace arctic heater glow
pin.
Go to Step 50.
Change 6
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
NOTE
Steps (16) through (21) are for fault code 033.
Step 16.
Remove arctic heater control unit (para 21-3).
Step 17.
Check operation of arctic heater blower by connecting an external 24 vdc power supply to
the arctic heater internal harness connector. Place positive (+) lead at terminal No. 4.
Place negative (--) lead at terminal No. 1.
If blower motor does not operate, replace arctic heater blower (para 21-3) and go to
Step 50.
Change 6
2-135
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT (CONT)
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
Step 18.
Connect arctic heater harness connector to arctic heater control unit (para 21-3).
Step 19.
Check voltage at arctic heater control unit internal connector. Place positive (+) probe at
terminal No. 10. Place negative (--) probe at terminal No. 5. Turn arctic heater switch on.
Voltage should be 5 vdc (nominal).
If voltage reading of 5 vdc (nominal) is not present, replace arctic heater control
unit (para 21-3) and go to Step 50.
2-136
Change 6
TM 9-2320-279-34-1
Troubleshooting Malfunctions (Cont)
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
Step 20.
Check voltage at internal harness connector when blower is turned on. Connect arctic
heater internal harness connector to arctic heater control unit. Back probe arctic heater
internal harness connector. Place positive (+) probe at terminal No. 13. Place negative (--)
probe at terminal No. 5. Turn arctic heater switch on. Voltage should be 2.2 to 2.8 vdc.
If voltage reading of 2.2 to 2.8 vdc is present, replace arctic heater control unit
(para 21-3).
If voltage reading of 2.2 to 2.8 is not present, replace arctic heater blower
(para 21-3).
Step 21.
Go to Step 50.
Change 6
2-136.1
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT (CONT)
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
NOTE
Steps (22) through (24) are for fault codes 037, 042 or 059.
Step 22.
Remove arctic heater control unit (para 21-3).
Step 23.
Perform resistance check across arctic heater temperature sensor at room temperature
(--13_ to 77_F [--25_ to 25_C]). Connect probes across arctic heater internal harness
connector terminals No. 14 and 18.
If resistance reading is between 650 and 1000 ohms, replace arctic heater coolant
pump (para 21-3).
If resistance reading is not between 650 and 1000 ohms, replace arctic heater
temperature sensor (para 21-3).
Step 24.
Go to Step 50.
2-136.2
Change 6
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
Step 25.
Step 26.
Step 27.
Step 28.
NOTE
Steps (25) through (38) are for fault codes 050 or 052.
Check if arctic heater operates.
If arctic heater operates, go to step 29.
If Fault Code Retrieval Device (FCRD) is available, clear fault code 050 and go to
Step 28.
Replace arctic heater control unit (para 21-3).
Perform fuel metering pump quantity test.
a. Disconnect fuel line from arctic heater and place in graduated 1 quart (950 ml)
measuring container.
b. Turn arctic heater switch on.
c. Observe fuel delivery. Fuel metering pump will start approximately 63 seconds after
arctic heater switch is turned on. Stop 105 seconds after the switch is turned on and
restart 180 seconds after the switch is turned on.
d. When fuel metering pump stops after the second restart, turn arctic heater switch off.
e. Reconnect fuel line to arctic heater.
f. Measure fuel delivered.
If arctic heater does not operate, go to Step 26.
If no fuel is delivered and audible clicking is heard from fuel metering pump, go to
Step 32.
If arctic heater fuel metering pump delivers less than 0.62 ounces (18.64 ml) of fuel,
replace arctic heater fuel metering pump (TM 9-2320-279-20-3) and go to Step 36.
Change 6
2-136.3
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT (CONT)
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
Step 29.
Remove arctic heater control unit (para 21-3).
Step 30.
Perform resistance check across arctic heater flame sensor at room temperature (--13_ to
77_F [--25_ to 25_C]). Connect probes across arctic heater internal harness connector
terminals No. 15 and 16.
If resistance reading is between 900 and 1100 ohms, replace arctic heater glow pin
(para 21-3).
If resistance reading is not between 900 and 1100 ohms, replace arctic heater flame
sensor (para 21-3).
Go to Step 36.
NOTE
Audible clicking and no or low fuel flow may indicate the arctic heater fuel system is not
primed.
Arctic heater may go into lockout (code 050), due to too many start attempts. If arctic
heater goes into lockout, go to Step 34.
Attempt to prime arctic heater fuel system. Turn arctic heater switch on and observe
system operation. If system shuts down after the second start attempt, turn arctic heater
switch off and on to repeat start cycle. Repeat start cycle four times (eight start attempts)
or until arctic heater starts.
If arctic heater does not operate, go to Step 34.
If arctic heater fuel metering pump fails to prime within ten start attempts, replace
arctic heater fuel metering pump (TM 9-2320-279-20-3).
Go to Step 36.
If Fault Code Retrieval Device (FCRD) is available, clear fault code 050 and go to Step 32.
If Fault Code Retrieval Device (FCRD) is not available, replace arctic heater control unit
(para 21-3) and go to Step 32.
Step 31.
S
S
Step 32.
Step 33.
Step 34.
Step 35.
2-136.4
Change 6
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
Step 36.
Check if arctic heater operates.
If arctic heater operates, go to Step 50.
Step 37.
Step 38.
If Fault Code Retrieval Device (FCRD) is available, clear fault code 050 and go to Step 50.
If Fault Code Retrieval Device (FCRD) is not available, replace arctic heater control unit
(para 21-3) and go to Step 50.
NOTE
Steps (39) through (41) are for fault codes 051, 064 or 065.
Step 39.
Step 40.
Step 41.
Remove arctic heater control unit (para 21-3).
Perform resistance check across arctic heater flame sensor at room temperature (--13_ to
77_F [--25_ to 25_C]). Connect probes across arctic heater internal harness connector
terminals No. 15 and 16.
If resistance reading is between 900 and 1100 ohms, replace arctic heater control
unit (para 21-3).
If resistance reading is not between 900 and 1100 ohms, replace arctic heater flame
sensor (para 21-3).
Go to Step 50.
Change 6
2-136.5
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT (CONT)
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
NOTE
Steps (42) through (44) are for fault codes 053, 054, 055 or 056.
Step 42.
Remove arctic heater control unit (para 21-3).
Step 43.
Perform resistance check across arctic heater flame sensor at room temperature (--13_ to
77_F [--25_ to 25_C]). Connect probes across arctic heater internal harness connector
terminals No. 15 and 16.
If resistance reading is between 900 and 1100 ohms, replace arctic heater blower
(para 21-3).
If resistance reading is not between 900 and 1100 ohms, replace arctic heater flame
sensor (para 21-3).
Step 44.
2-136.6
Go to Step 50.
Change 6
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
NOTE
Steps (45) through (48) are for fault codes 060, 061, 071 or 072.
Step 45.
Step 46.
Step 47.
Remove arctic heater control unit (para 21-3).
Perform resistance check across arctic heater temperature sensor at room temperature
(--13_ to 77_F [--25_ to 25_C]). Connect probes across arctic heater internal harness
connector terminals No. 14 and 18.
If resistance reading is not between 650 and 1000 ohms, replace arctic heater
temperature sensor (para 21-3) and go to Step 50.
Perform resistance check across arctic overheat sensor at room temperature (--13_ to 77_F
[--25_ to 25_C]). Connect probes across arctic heater internal harness connector terminals
No. 11 and 17.
If resistance reading is between 10k and 150k ohms, replace arctic heater control
unit (para 21-3).
If resistance reading is not between 10k and 150k ohms, replace arctic heater
overheat sensor (para 21-3).
Step 48.
Go to Step 50.
Change 6
2-136.7
TM 9-2320-279-34--1
Troubleshooting Malfunctions (Cont)
2-7. TROUBLESHOOTING INSTRUCTIONS (CONT).
Table 2-3.
Troubleshooting (Cont)
Malfunction
Test or Inspection
Corrective Action
ARCTIC HEATER KIT (CONT)
2. ARCTIC HEATER DIAGNOSTIC TROUBLESHOOTING (DIRECT LEVEL) (MODEL B) (CONT).
NOTE
Step (49) is for fault codes 001, 002, 010, 011, 043, 047, 048, 090, 093, 094 or
097.
Step 49.
Replace arctic heater control unit (para 21-3).
Step 50.
If same fault code is displayed, notify the supervisor.
Step 51.
If different fault code is displayed, go to organizational arctic heater diagnostic
troubleshooting (TM 9-2320-279-20-1).
2-136.8
Change 6
TM 9-2320-279-34-1
Section IV. MAINTENANCE PROCEDURES
2-8. GENERAL MAINTENANCE INSTRUCTIONS. General maintenance instructions for systems
and components of the vehicle, except engine and transmission, and cranes on M984 and M985E1, are
covered in this section. Refer to TM 9-2815-224-34&P for engine general maintenance procedures. Refer to
Chapter 7 for transmission general maintenance procedures. Read all CAUTIONS and WARNINGS that
apply to all maintenance procedures. Refer to TM 9-2320-279-20 for additional general maintenance
procedures that may also apply. Refer to TM 9-2320-354-24&P or TM 9-2320-355-24&P for maintenance
instructions that apply to cranes on M984 and M985E1 vehicles.
a . Follow these maintenance practices when working on vehicle.
CAUTION
Do not use paint scrapers, knives, or other metal tools on aluminum parts and
machined surfaces. Aluminum is easily gouged and machined surfaces easily
scratched by steel tools.
(1) Handle all parts and subassemblies carefully to prevent nicking, scratching, and denting.
(2) Handle parts carefully to protect from damage and contamination during removal, cleaning and
inspection, installation, and while stored in containers before installation.
(3) When unpacking new parts, remove all packing material, barrier paper, tape, plastic bags,
protective caps, and protective grease coating.
(4) Do not unwrap parts until ready for use to protect from contamination and damage.
CAUTION
Do not use tape to close off fuel or oil openings. Sticky surface of tape can mix
with fuel and oil and cause equipment malfunctions.
(5) As soon as parts are removed, cap or cover open tubes, hoses, fittings, and openings in
equipment to keep dust, dirt, and other objects out of internal parts. Use suitable containers to
catch coolant, oil, or fuel spills.
WARNING
Be careful when working on or with electrical equipment. Voltage as low as
50 volts can cause injury or death. Always disconnect batteries when working on
electrical equipment. For artificial respiration, refer to FM 21-11.
(6) When repairing wire harness, remove wrap tape from wire harness, exposing wires for
inspection. Lay new wires alongside wire harness and cut new wires 1-1/2 in. (38 mm) longer
than wires being replaced. Cutting wires longer will allow organizational maintenance to replace
damaged pins and sockets later without replacing wires.
(7) When removing parts, inspect for breaks, dents, cracks, surface defects, and other visible
damage.
(8) When fastener tightening requirements are not given in maintenance task, tighten screws and
nuts in accordance with Appendix D, TORQUE LIMITS.
(9) The M977 series vehicles have a self bleeding hydraulic system. When the following steps are
completed, air from the hydraulic system should be purged to the hydraulic reservoir.
(a) Operate crane (TM 9-2320-279-10) and hold each crane or winch control lever (except for hoist
motor lever) completely in and then completely out for 30 seconds. Do this five times for each
lever.
(b) Operate hoist motor control lever and run hoist cable out 10 ft (3 m) and then back on the
winding drum. Do this three times.
(10) Replace all gaskets, packings, and seals.
(11) Replace lockwire, lockwashers, cotter pins, and plastic cable ties.
(12) Lubricate packings with oil, Stretch packings and place in position, pressing packings evenly in
place.
2-137
TM 9-2320-279-34-1
Maintenance Procedures (Cont)
2-8. GENERAL MAINTENANCE INSTRUCTIONS (CONT).
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
b.
Replace broken, frayed, kinked, or soft flexible hydraulic hoses. If fittings are damaged, replace
entire hose. Fittings not damaged or corroded can be used on new hoses.
Replace broken, frayed, or kinked air lines. If fittings on nylon lines are damaged, replace
fittings. If fittings on flexible hoses are damaged, replace entire hose. Fittings not damaged or
corroded can be used on new hoses and lines.
To prevent leaks, use pipe thread sealing compound or antiseize tape on threads of air line and
hydraulic hose fittings.
Burring. Remove burrs from gear teeth with fine-cut tile and emery cloth. Remove burrs from
sealing and bearing surfaces with crocus cloth.
Damaged Threads. Replace screws and nuts if threads are damaged. If threads on fittings are
only slightly damaged, chase threads with chasing tool. Replace cross-threaded fittings. Inspect
tapped holes for thread damage. If threads are damaged, tap hole for next oversize screw or
stud. If retapping weakens part of cost of part makes retapping impractical, replace part.
Bearings. Refer to TM 9-214, Inspection, Care, and Maintenance of Antifriction Bearings.
Lubricate bearings before assembly with lubricant used in the related housing. When installing
bearings on shafts, apply pressure to inner race. When installing bearings in housing, apply
pressure to outer race.
Welding. Refer to TM 9-237, Welding Theory and Application. Welding can be used to repair
cracks and breaks in steel parts, such as brackets, panels, and light framework. Because of time
required and chance of later failure, weld only when replacement parts are not available.
Grounding. To ensure good ground connections, clean or grind metal surfaces at connections to
remove paint, oxides, corrosion, oils, and/or grease. After connections are completed, apply
corrosion preventive compound to connections.
Follow these general cleaning instructions and warnings,
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
Trichlorethylene is toxic to skin, eyes, and respiratory tract. Avoid all exposure. Skin
and eye protection, and exhaust hood on degreasing equipment are required.
Contact unit safety officer for local procedures concerning the use of trichlorethylene
before using.
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only
with effective chip guarding and personal protective equipment, goggles, shield, and
gloves.
(1)
(2)
(3)
(4)
2-138
Electrical parts such as coils, junction blocks, and switches must not be soaked or sprayed with
cleaning solvents. Clean only with cloth moistened in drycleaning solvent (Item 57,
Appendix C).
Soak nonelectrical parts in drycleaning solvent and brush off caked deposits with paintbrush.
Clean rubber parts with hot, soapy water and cloths. Do not clean with solvents.
A degreasing machine may be used to remove heavy grease and oil deposits from metal parts.
Trichlorethylene, MIL-T-27602B (Item 66, Appendix C) is used as degreasing agent.
Change 3
TM 9-2320-279-34-1
Maintenance Procedures (Cont)
CAUTION
To prevent corrosion, parts should be coated with rust preventive within 2 hours
of degreasing.
(5)
Remove parts from degreaser. Check that all oil passages and cavities are clean and clear.
Before coating with rust preventive (Item 53, Appendix C), run thin flexible wire through oil
passages to make sure they are not clogged. Use drycleaning solvent and compressed air to
clean dirty oil passages.
Change 3
2-138.1/(2-138.2 blank)
TM 9-2320-279-34-1
Maintenance Procedures (Cont)
CAUTION
Do not use paint scrapers, knives, or other metal tools on aluminum parts and
machined surfaces. Aluminum is easily gouged and machined surfaces easily
scratched by steel tools.
(6) Use reasonable care in cleaning machined surfaces with scrapers and wire brushes. Do not use
abrasive wheels or compounds on machined surfaces.
(7) Bearings. Refer to TM 9-214, Inspection, Care, and Maintenance of Antifriction Bearings. When
cleaning ball or roller bearings, place in basket and soak in dry cleaning solvent. Use paintbrush
to remove caked deposits. Never use compressed air to clean and dry caged bearings. Caged
bearings must drip and air dry. Do not spin bearings before thoroughly clean. Coat cleaned
bearings liberally with lubricating oil, then wrap in protective wrapper if not using right away.
C. Follow these general inspection instructions.
(1) Inspect hoses and lines for damage or frayed coverings. Check for breaks or worn spots caused
by kinking or contact with other parts of vehicle. Inspect fittings for damage. If fittings are
damaged, look for possible causes of damage.
(2) Inspect wiring harnesses for chafed or burned insulation. Look for causes of chafing or burns.
Inspect terminal connectors for loose connections and broken parts.
(3) Inspect all surfaces in contact with gaskets, packings, or seals for nicks, burrs, or scratches
which might damage new seals, Remove defects with crocus cloth.
(4) Inspect castings and weldments for cracks and breaks. If the following patterns appear, replace
parts.
(a) Bursts or scattered, short, sharp lines (indicates high temperature).
(b) Flakes or separate, short, wavy lines, usually in one general direction (indicates improper
cooling).
(c) Grinding cracks (fine, sharp lines, tightly packed). On some surfaces, cracks may be shallow and
hard to see. Grinding cracks are usually caused by a glazed grinding wheel rubbing (instead of
cutting) and overheating the part.
(5) Inspect bearings. Clean, then lubricate bearings. Check for roughness of rotation. If rough,
replace bearing. Check for cuts, grooves, pitting, scratched, cracked or chipped races, and for
loose rollers or balls in caged bearings. If defect is found, replace bearing. Check bearing housing
or shaft for grooves, burrs, or abrasions that would indicate bearing had been turned in housing
or on shaft. If damage cannot be repaired with crocus cloth, replace defective part.
(6) Inspect bushings for scoring, burrs, roundness, sharp edges, and discoloration (overheated oil).
Replace out-of-round and overheated bushings. Remove scoring with crocus cloth, and remove
burrs and sharp edges with scraper or knife. Replace deeply scored bushings.
(7) Inspect gears for pitting, wear, and scoring.
(a) Slight scoring or minor marring of surfaces showing slight tears and scratches in direction of
sliding is not a reason to replace gears. Heavy scoring may be reason to replace gear if
equipment is not performing satisfactorily.
(b) Initial pitting, which occurs when gears are first started in service, is not serious if pitting only
reduces high spots so there is still enough contact area to carry load without hurting
performance.
(c) Destructive pitting, which follows initial pitting, may be serious because gears can be rapidly
destroyed if load carrying area of gears is severely pitted.
(d) Abrasive wear is not normally serious unless gears are gouged or have worn deep grooves.
Abrasive wear is caused by contaminated oil or grease in gear housing.
2 - 9 . LUBRICATION INSTRUCTIONS.
Refer to LO 9-2320-279-12 for lubricating procedures.
2-139
TM 9-2320-279-34-1
Maintenance Procedures (Cont)
2-10. PREPARATION FOR STORAGE AND SHIPMENT.
a.
Refer to TM 9-2320-279-20 to prepare vehicle for storage or shipment.
b.
Refer to TB 9-2300-281-35 for overseas shipment instructions.
c.
Refer to TB 9-2300-281-35 for Basic Issue Items (BII) packing instructions.
2-11. PRE-EMBARKATION INSPECTION. Refer to TB 9-2300-281-35 for pre-embarkation
requirements.
2-140
Change 3
TM
CHAPTER
ENGINE
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . .
General Maintenance Instructions . . . . . . .
Engine Removal/Installation . . . . . . . . . .
Engine to Engine Stand Installation/Removal
3
MAINTENANCE
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
Section
I.
9-2320-279-34-1
.
.
.
.
Para
. . . . . . . . . . . . . . . . . . . . . 3-1
. . . . . . . . . . . . . . . . . . . 3-2
. . . . . . . . . . . . . . . . . . 3-3
. . . . . . . . . . . . . . . . . . 3-4
Page
3-1
3-1
3-2
3-28
INTRODUCTION
3 - 1 . G E N E R A L . This chapter contains maintenance instructions for removal, installation, and set-up
for repair of the engine at the direct support and general support maintenance level. The subassemblies
and parts which must be removed before the engine and components can be removed will be referenced to
other paragraphs of this manual, TM 9-2320-279-20, or TM 9-2815-224-34&P.
Section
Il.
SERVICE
AND
INSPECTION
Engine Maintenance Instructions
3-2.
GENERAL
MAINTENANCE
INSTRUCTIONS.
a. Follow these maintenance instructions when removing and installing engine:
(1) When unpacking items, remove packing material (for example: barrier paper, tape, plastic bags,
and protective caps).
(2) Cap or tape over engine inlets and exhaust ducts to prevent foreign objects from getting inside
the engine. Keep dust, dirt, and other objects out of internal parts of the engine.
CAUTION
Do not use tape to close off fuel or oil openings. Sticky surface of tape will mix
with fuel or oil and will get in the engine lines.
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Cap or tape over open tubes, hoses, fittings, and engine openings as soon as parts are taken off.
Use suitable container to catch oil and coolant when removing hoses, fittings, and plugs.
Handle and store removed engine components carefully.
Inspect parts as removed for breaks, dents, cracks, surface defects, or other obvious damage.
Turn in bad parts. Set aside good parts for later use.
When possible, replace gaskets, packings, and seals removed during repair work. Replace
lockwire, lockwashers, and cotter pins at time of reassembly.
Replace broken, worn, or burned electrical wiring.
Replace broken, frayed, crimped, or soft flexible hoses. Replace stripped or damaged fittings.
Replace entire connected flexible hose if fittings are damaged.
Tag and mark shims, connectors, wires, valves, fittings, and mating ends of lines before
disconnecting or removing. Identify similar parts to ensure correct assembly.
Use hoist, jacks, and other aids when lifting engine.
b. Follow these inspection instructions when removing and installing engine:
(1) Inspect mounting surfaces and surfaces in contact with gaskets, seals, or machined surfaces.
Look for burrs or scratches which might damage parts or seals upon installation. Remove any
defects found.
3-1
TM 9-2320-279-34-1
Engine Maintenance Instructions (Cont)
3-2. GENERAL MAINTENANCE INSTRUCTIONS (CONT).
(2)
(3)
Remove drainplugs from engine system components and inspect sediment sticking to plug. Grit
or fine metal particles may indicate actual or potential component failure. A few fine particles
are normal. This inspection will help to show defective parts before internal inspection of the
component.
Inspect hose surfaces for broken or frayed fabric. Check for breaks caused by sharp kinks or
contact with other parts of the vehicle. Inspect fitting threads for damage. Replace any defective
part. After assembly and during initial vehicle operation period, check for leaks. Inspect wiring
harnesses for chafed or burned insulation. Inspect terminal connectors for loose connections and
broken parts. Visually inspect castings and weldments for cracks.
Section III. ENGINE ASSEMBLY
3-3. ENGINE REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Compound, sealing, pipe thread, Item 29,
Appendix C
Tags, identification, Item 60, Appendix C
Sealant, RTV200 Electrical, Item 55.2,
Appendix C
Connector, electrical, butt, Item 31,
Appendix C
Oil, lubricating, Item 47, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (3)
References
None
3-2
Change 5
c. Follow-on Maintenance
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-10 Spare tire removed.
TM 9-2320-279-10 Transmission and transfer
case set to N.
TM 9-2320-279-10 Hoist end of tire davit
removed.
TM 9-2320-279-10 Rear engine cover frame
removed.
TM 9-2320-279-10 Batteries disconnected.
TM 9-2320-279-10 Radiator removed.
LO 9-2320-279-12 Hydraulic reservoir drained.
LO 9-2320-279-12 Engine oil drained.
Para 13-6
Slinging support assemblies
removed.
Special Environmental Conditions
None
General Safety Instructions
Wheels chocked.
Level of Maintenance
Direct Support
TM
Engine
Maintenance
Instructions
9-2320-279-34-1
(Cont)
a. Removal.
(1)
(2)
(3)
(4)
Remove two nuts (1) and washers (2). Remove clamp (3) from muffler (4).
Remove nut (5) and clamp (6) from turbocharger (7).
Pull exhaust pipe (8) from turbocharger (7).
Remove exhaust pipe (8) from muffler (4).
NOTE
Tag and mark hoses before removal.
(5) Loosen clamp (9) and remove hose (10).
(6) Remove hose (11).
(7) Loosen clamps (12 and 13) and remove air intake duct (14).
3-3
TM 9-2320-279-34-1
Engine
3-3.
ENGINE
Maintenance
REMOVAL/INSTALLATION
Instructions
(Cont)
(CONT).
(8) Remove four nuts (15) and
screws (16).
(9) Soldier A and Soldier B
remove muffler
assembly (17).
(10) Remove two nuts (18), lockwashers (19), and screws (20) from cross brace (21).
(11) Remove nut (22) and two lockwashers (23) from other end of cross brace (21).
(12) Remove cross brace (21).
3-4
TM
Engine
Maintenance
Instructions
9-2320-279-34-1
(Cont)
NOTE
Attach chain with lifting hooks facing
out and with front leg under exhaust
pipe.
(13) Soldier A attaches 39-in. (1 m) chain
to two side lifting brackets (24) and
37-in. (94 cm) chain to forward lifting
bracket (25) while Soldier B operates
lifting device.
(14) Remove plug (26) from access hole (27).
NOTE
There are 12 torque converter screws. Each must be centered in access hole for
removal.
(15) Soldier A looks in access hole (27) while Soldier B turns pulley nut (28) slowly clockwise.
(16) Soldier A tells Soldier B to stop turning pulley nut (28) when torque converter screw (29) is
centered in access hole (27).
(17) Remove torque converter screw (29).
NOTE
Repeat steps (15), (16), and (17) until all 12 torque converter screws are removed.
3-5
TM
9-2320-279-34-1
Engine
Maintenance
Instructions
(Cont)
(18) Remove 13 screws (30), lockwashers (31), and three clamps (32) from top of transmission torque
converter housing (33). Remove 11 screws, lockwashers, and one clamp from bottom of housing.
(19) Loosen clamps (34, 35, and 36)
and remove three hoses (37, 38,
and 39).
(20) Disconnect two fuel hoses (40
and 41).
(21) Disconnect airhose (42).
3-6
TM 9-2320-279-34-1
Engine Maintenance Instructions (Cont)
(22)
Remove nut (43) and lockwasher (44).
NOTE
Tag and mark wires before disconnecting.
(23)
(24)
(25)
Disconnect five wires (45) from solenoid (46).
Remove nut (47) and lockwasher (48).
Disconnect seven starter wires (49) from starter (50).
(26)
(27)
Remove two nuts (51) and wires (52) from relay (53).
Remove two nuts (54) and cables (55).
Change 3
3-7
TM 9-2320-279-34-1
Engine Maintenance Instructions (Cont)
3-3. ENGINE REMOVAL/lNSTALLATION (CONT).
(28) Remove ether starting aid tube (56) from air inlet housing (57).
(29) Disconnect plug (58) from wires (59) at ether starting aid (60).
3-8
TM
Engine
Maintenance
Instructions
9-2320-279-34-1
(Cont)
(30) Disconnect three hoses (61, 62, and 63) from steering pump (64).
(31)
(32)
(33)
(34)
(35)
Disconnect two hoses (65 and 66) from air compressor (67).
Disconnect two hoses (68 and 69) from governor (70).
Disconnect STE/ICE connector (71).
Remove nut (72) and lockwasher (73).
Disconnect wire (74) from temperature sending unit (75).
3-9
TM
9-2320-279-34-1
Engine
Maintenance
Instructions
(Cont)
(36) Remove nut (76), lockwasher (77), washer (78), and screw (79).
(37) Move clamp (80) and transmission dipstick tube (81) aside.
(38) Disconnect plug (82).
(39) Disconnect plug (83) from PTO pressure switch (84).
(40) Cut two wires (85 and 86) at electrical butt connectors.
3-10
TM
Engine
Maintenance
Instructions
9-2320-279-34-1
(Cont)
(41) Disconnect hose (87).
(42) D i s c o n n e c t c o n n e c t o r ( 8 8 ) .
(43) Disconnect two connectors (89).
3-11
TM
9-2320-279-34-1
Engine Maintenance Instructions (Cont)
(44) Remove nut (90), washer (91), spacer (92), and screw (93) from each of two engine supports (94).
(45) Soldier A and Soldier B remove three nuts (95) and screws (96) from each side of engine frame
support (97).
3-12
TM 9-2320-279-34-1
Engine Maintenance Instructions (Cont)
WARNING
Keep out from under engine when removing from
vehicle. If engine slips, sways, or falls, serious injury
or death may result.
CAUTION
Make sure loose hoses and wires are
secure and moved out of way so they
do not snag and cause damage when
engine is lifted.
Before lifting engine completely out
of vehicle, test by lifting slightly to
see if balanced. If engine starts to
tilt, lower and adjust chain lengths.
Unbalanced engine may swing
causing damage.
(46)
(47)
(48)
(49)
(50)
Soldier A and Soldier B slide engine
frame support (97) forward on vehicle
while Soldier C operates lifting device to
lift engine (98) slightly.
Soldier A and Soldier B guide engine (98) while Soldier C operates lifting device and removes
engine from vehicle.
Soldier A and Soldier B guide engine (98) to suitable work area while Soldier C operates lifting
device.
Disconnect lifting chains from
engine (98).
Remove four spacers (99) from biscuit
mounts (100).
Change 3
3-13
TM 9-2320-279-34-1
Engine Maintenance Instructions (Cont)
3-3. ENGINE REMOVAL/INSTALLATION (CONT).
b.
Installation.
WARNING
·
Adhesives, solvents, and sealing
compounds can burn easily, can give
off harmful vapors, and are harmful
to skin and clothing. To avoid injury
or death, keep away from open fire
and use in well-ventilated area. If
adhesive, solvent, or sealing
compound gets on skin or clothing,
wash immediately with soap and
water.
·
Keep out from under engine when
lifting into vehicle. If engine slips,
sways, or falls, serious injury or
death may result.
CAUTION
·
Install lifting hooks facing outward.
Before lifting engine completely off
supports, test by lifting slightly to see
if balanced. If engine starts to tilt,
lower and adjust chain lengths.
Unbalanced engine can swing
causing damage.
·
Make sure hoses and wires are
secured and moved out of the way
when installing engine so they do not
snag and cause damage.
NOTE
(1)
(2)
(3)
·
Apply electrical sealant to exposed wire connectors after installing connectors.
·
Attach chain with lifting hooks facing out and with front leg under exhaust pipe.
Install 39-in. (1 m) lifting chain on two side lifting brackets (1).
Install 37-in. (94 cm) chain on forward lifting bracket (2).
Soldier A operates lifting device and lifts engine (3) slightly, while Soldier B checks that engine is
balanced.
CAUTION
Make sure engine is centered to prevent damage to bell-housing.
(4)
3-14
Soldier A operates lifting device and positions engine (3) in vehicle, while Soldier B and Soldier C
guide engine.
Change 5
TM 9-2320-279-34-1
Engine Maintenance Instructions (Cont)
Position wiring harness (4) around rear of engine (3).
Soldier A installs three clamps (5), 13 lockwashers (6), and screws (7) in top of transmission
torque converter housing (8), while Soldier B installs one clamp, 11 lockwashers, and screws in
bottom of housing.
(7) Soldier A and Soldier B position engine frame support (9).
(8) Soldier A installs and holds three nuts (10) on each side of engine frame support (9) while
Soldier B installs three screws (11). Do not tighten nuts or screws.
3-15
TM 9-2320-27934-1
Engine Maintenance Instructions (Cont)
3-3. ENGINE REMOVAL/lNSTALLTlON (CONT).
(9)
(10)
(11)
(12)
(13)
Install four spacers (12) on biscuit mounts (13).
Aline holes in engine frame support (9) with holes in biscuit mounts (13) on front engine
support (14).
Soldier A lubricates and installs two screws (15), while Solider B installs two bottom
spacers (16), two washers (17), and nuts (18).
Solider A holds two screws (15) while Soldier B tightens two nuts (18) to 170 lb-ft (230.5 Nom).
Soldier A tightens three screws (11) on each side of engine frame support (9) while Soldier B
holds three nuts (10).
3-16 Change 3
TM
9-2320-279-34-1
Engine Maintenance Instructions (Cont)
3-17
TM
9-2320-279-34-1
Engine Maintenance Instructions (Cont)
3-3.
3-18
TM 9-2320-279-34-1
Engine Maintenance Instructions (Cont)
(18) Soldier A looks in access hole (22) and tells Soldier B to stop turning torque converter (25) when
screw hole (27) is centered in access hole.
(19) Install, but do not fully tighten, one torque converter screw (28).
(20) Install inspection cover (20) and gasket (21) with two screws (19).
3-19
TM 9-2320-279-34-1
Engine Maintenance Instructions (Cont)
3-3. ENGINE REMOVAL/INSTALLATION (CONT).
(21)
(22)
Soldier A looks in access hole (22) while Soldier B turns pulley nut (23) until screw hole is
centered in access hole.
Install, but do not fully tighten, torque converter screw (28).
NOTE
Repeat steps (21) and (22) until all 12 torque converter screws have been installed.
(23)
(24)
(25)
Soldier A looks in access hole (22) while Soldier B turns pulley nut (23) clockwise.
Soldier A tells Soldier B to stop turning pulley nut (23) when torque converter screw (28) is
centered in access hole (22).
Soldier A tightens torque converter screw (28) to 105 to 115 lb-ft (142 to 156 N•m).
NOTE
Repeat steps (23), (24), and (25) until all 12 torque converter screws have been
tightened.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(26)
Apply pipe thread sealing compound and install plug (29) in access hole (22).
3-20 Change 3
TM
9-2320-279-34-1
Engine Maintenance Instructions (Cont)
3-21
TM
9-2320-279-34-1
Engine Maintaince Instructions (Cont)
3-3.
3-22
TM
9-2320-279-34-1
Engine Maintenance Instructions (Cont)
3-23
TM
9-2320-279-34-1
Engine
Maintenance
3-3.
3-24
Instructions
(Cont)
TM 9-2320-279-34-1
Engine Maintenance Instructions (Cont)
(41)
(42)
(43)
(44)
Install two wires (66) with two nuts (67)
Install two cables (68) with two nuts (69).
Install seven starter wires (70) on stud (71) with washer (71.1) lockwasher (72) and nut (73).
Install five solenoid wires (74) on stud (75) with lockwasher (76) and nut (77).
Change 3
3-25
TM 9-2320-279-34-1
Engine Maintenance Instructions (Cont)
3-3. ENGINE REMOVAL/lNSTALLATlON (CONT).
(45) Connect airhose (78).
(46) Connect two fuel hoses (79
and 80).
(47) Install three hoses (81, 82,
and 83) and tighten
clamps (84, 85, and 86).
(48) Install one end of cross brace (87) with two lockwashers (88) and nut (89). Install other end of
cross brace with two screws (90), lockwashers (91), and nuts (92).
3-26
TM
9-2320-279-34-1
Engine Maintenance Instructions (Cont)
3-27
TM
9-2320-279-34-1
Engine
Maintenance
Instructions
3-3.
3-28
(Cont)
TM 9-2320-279-34-1
Engine Maintenance Instructions (Cont)
a.
Install Engine on Stand.
(1)
Remove draincock (1).
NOTE
(2)
·
Remove cushion clips and plastic cable ties as necessary.
·
Tag and mark hoses before disconnecting.
(3)
(4)
Disconnect hose (2) and remove reducer bushing (3), adapter (4), and elbow (5). Move oil return
hose (6) out of way.
Remove reducer bushing (7) and elbow (8).
Remove two screws (9), lockwasher (10), washers (11), and starter mounting bracket (12).
(5)
Disconnect oil return hose (6).
NOTE
Some engines have a copper washer. Other
engines do not have a copper washer.
(6)
Remove oil dipstick tube (13),
adapter (14), and copper washer (14.1).
Change 4
3-29
TM
9-2320-279-34-1
Engine
Maintenance
3-4.
3-30
Instructions
(Cont)
TM
Engine
Maintenance
Instructions
9-2320-279-34-1
(Cont)
3-31
TM 9-2320-279-34-1
Engine Maintenance Instructions (Cont)
3-4. ENGINE TO ENGINE STAND INSTALLATION/REMOVAL (CONT).
NOTE
Some engines have a copper washer. Other
engines do not have a copper washer.
(3)
(4)
(5)
(6)
(7)
Install copper washer (4.1), adapter (5),
and oil dipstick tube (6).
Connect oil return hose (7).
Install starter mounting bracket (8)
with two screws (9), lockwasher (10),
and washers (11).
Install reducer bushing (12) and
elbow (13).
Install reducer bushing (14),
adapter (15), and elbow (16).
NOTE
Install cushion clips and plastic cable ties as
necessary.
(8)
(9)
c.
Connect hose (17).
Install draincock (18).
Follow- on Maintenance.
(1)
(2)
(3)
(4)
(5)
Install exhaust manifold (TM 9-2815-224-34&P).
Install air box covers (TM 9-2815-224-34&P).
Install air box drain (TM 9-2815-224-34&P).
Install sender mounting bracket (TM 9-2320-279-20).
Install engine (para 3-3).
END OF TASK
3-32
Change 4
TM
CHAPTER
FUEL
SYSTEM
9-2320-279-34-1
4
MAINTENANCE
Para
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Throttle Treadle Valve Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Section I.
Page
4-1
4-1
INTRODUCTION
4 - 1 . G E N E R A L . This chapter contains maintenance instructions for repair of fuel system components
at the direct support maintenance level. The subassemblies and parts which must be removed before fuel
system components can be repaired are found in TM 9-2320-279-20.
Section Il.
THROTTLE TREADLE VAVLE
Fuel System Maintenance Instructions
4-1
TM
9-2320-279-34-1
Fuel Sustem Maintenance Instructions (Cont)
4-2.
4-2
TM
Fuel
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
4-3/(4-4 blank)
TM
CHAPTER
COOLING
SYSTEM
9-2320-279-34-1
5
MAINTENANCE
Contents
Para
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Radiator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Section
I.
Page
5-1
5-1
INTRODUCTION
5 - 1 . G E N E R A L . This chapter contains maintenance instructions for repair of the cooling system at the
direct support maintenance level. Subassemblies and parts which must be removed before cooling
components can be repaired are found in TM 9-2320-279-20. The radiator is tube and fin type. The upper
portion of the radiator assembly contains an expansion/fill tank.
Section
II.
RADIATOR
Cooling System Maintenance Instructions
5-1
TM 9-2320-279-34-1
Cooling System Maintenance Instructions (Cont)
5-2.
5-2
TM 9-2320-279-34-1
Cooling System Maintenance Instructions (Cont)
WARNING
5-3
TM
9-2320-279-34-1
Cooling System Maintenance Instructions (Cont)
5-2.
5-4
TM 9-2320-279-34-1
CHAPTER 6
ELECTRICAL SYSTEM MAINTENANCE
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24V Alternator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Solenoid Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Motor Repair and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual and Audible Level Warning Indicators Removal/Installation (M983) . . . . . . . . . .
Outrigger Extended Switch Removal/Installation (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tilt Warning Alarm Switch Removal/Installation (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane Control Distribution Board Removal/Installation (M983) . . . . . . . . . . . . . . . . . . . . .
Power Interconnecting Cables Removal/Installation (M983) . . . . . . . . . . . . . . . . . . . . . . . .
Tilt Alarm Box Removal/Installation (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Junction Box and Connector Removal/Repair/Installation (M977, M985) . . . . . . . . . . . . .
Junction Box and Connector Removal/Repair/Installation (M984E1) . . . . . . . . . . . . . . .
Crane Overload Sensor Switches Removal/Installation (M977, M985) . . . . . . . . . . . . . . .
Crane Overload Sensor Switches and Plate and Terminal Box Removal/Installation
(M984E1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Wiring Harness Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Wiring Harness Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Wiring Harness Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Wiring Harness Removal/Installation (M984E1) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis/Engine Wiring Harness Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STE/ICE Wiring Harness Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Mount Stop Lamp Harness Removal/Installation (M978) . . . . . . . . . . . . . . . . . . . . . .
Section I.
Para
6-1
6-2
6-2.1
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
6-11
6-11.1
6-12
Page
6-1
6-2
6-14.1
6-15
6-19
6-36
6-39
6-41
6-44
6-48
6-54
6-55
6-64
6-64.6
6-12.1
6-13
6-14
6-15
6-15.1
6-16
6-17
6-18
6-70
6-70.8
6-87
6-104
6-122
6-122.13
6-125
6-131
INTRODUCTION
6-1. GENERAL.
This chapter contains maintenance instructions for removal, installation, and repair of
the electrical system components at the direct support maintenance level. Subassemblies and parts which
must be removed before electrical system components and harnesses can be removed are referenced to
other paragraphs or chapters of this manual or in TM 9-2320-279-20.
Change 5
6-1
TM 9-2320-279-34-1
Section II. ALTERNATOR AND STARTER
Electrical System Maintenance Instructions (Cont)
6-2. ALTERNATOR REPAIR.
This task covers:
a. Disassembly
b. Testing
c. Cleaning/Inspection
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Solvent, drycleaning, Item 57, Appendix C
Compound, insulating, Item 20, Appendix C
Compound, sealing, lubricating, Item 25,
Appendix C
Tags, identification, Item 60, Appendix C
Grease, automotive and artillery, Item 34,
Appendix C
a.
d. Assembly
e. Follow-on Maintenance
Personnel Required
MOS 63G, Fuel and electrical system repairer
References
None
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-20 Alternator and pulley
removed.
TM 9-2320-279-20 Voltage regulator removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
Disassembly
NOTE
There are two types of pulley used with the alternator. Model A has no key; Model
B uses a key in the shaft keyway. Model A is shown.
(1)
(2)
(3)
(4)
6-2
Remove nut (1), fan (2), and fan spacer (3) from rotor shaft (4).
Remove four screws (5), cover (6), and preformed packing (7).
Remove four screws (8), lockwashers (9), guard washers (10), brush cover (11), and gasket (12).
Mark position of brush holder (13). Remove brush holder and preformed packing (14).
Change 3
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-3
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-2.
6-4
TM 9-2320-279-34-1
Electrical System Maintemance Instructions (Cont)
6-5
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-2.
6-6
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
CAUTION
Mark position of connector assembly before removing.
Damage to regulator may result if improperly installed.
(31) Remove two screws (59) and connector
assembly (60).
(32) Remove three nuts (61) and lockwashers (62).
(33) Remove three nuts (63), washers (64), and three
terminal studs (65) from regulator holder (54).
b . Testing.
(1) Set multimeter to 10K range on RX scale. Touch
negative ( - ) test lead to positive rectifier (1).
(2) Touch positive (+) test lead to each of three eyelet
terminals (2) in turn. If resistance is low, positive
rectifier (1) is defective.
(3) Connect positive (+) test lead to positive
rectifier (1).
(4) Touch negative ( -) test lead to each of three
eyelet terminals (2) in turn. If resistance is high,
positive rectifier is defective.
(5) Connect negative (-) test lead to negative
rectifier (3).
(6) Touch positive (+) test lead to each of three eyelet
terminals (2) in turn. If resistance is high, negative rectifier (3) is defective.
(7) Connect positive (+) test lead to negative rectifier (3).
(8) Touch negative (-) test lead to each of three eyelet terminals (2). If resistance is low, negative
rectifier (3) is defective.
NOTE
Perform step (9) only if positive or negative rectifier is bad.
When disconnecting rectifiers, cut wires from bad rectifier as close as possible
to ring terminals.
(9) Cut three wires (4) just below three eyelet terminals (2).
(10) Touch one test lead to bare metal surface on stator (5)
and other test lead to each of three stator ring
terminals (6, 7, and 8), in turn. Low resistance
indicates stator is grounded. Replace stator.
(11) Touch test leads to stator ring terminals (6 and 7), (7
and 8), and (6 and 8), and read resistance across each
set of terminals. If resistance is high, stator (5) is
defective.
6-7
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-2. ALTERNATOR REPAIR (CONT).
(12)
(13)
(14)
(15)
C.
Connect test leads between shaft (9) and each slipring (10) consecutively. Low resistance in
either test indicates rotor coil is grounded. Do not repair or further test alternator.
Connect test leads to each slipring (10). Resistance should be zero.
Measure diameter of sliprings (10). If less than 0.767 in. (19.48 mm), do not repair or further
test alternator.
Measure diameter of shaft (9). If less than 0.871 in. (22.12 mm) do not repair or further test
alternator.
Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
CAUTION
To prevent damage to insulation, do not soak stator or rotor in solvents.
(1)
Clean stator and rotor with drycleaning solvent and clean cloth.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment, goggles,
shield, and gloves.
(2)
(3)
(4)
(5)
(6)
6-8
Dry with compressed air or dry cloth.
Clean all other components, except bearings, in drycleaning solvent.
Inspect electrical assemblies for damage, frayed or bare wires, or loose connections.
Inspect mechanical assemblies for damage. Check for old or excess grease.
Clean rectifier assembly holes and terminal screws to ensure good electrical contact.
Change 3
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
CAUTION
6-9
TM
9-2320-279-34-1
Electrical System Maintenance Instructrions (Cont)
6-2.
6-10
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-11
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-2.
6-12
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(23) Install rotor assembly (44) in drive end
housing (40).
(24) Aline marks and install drive end housing (40) on stator (36).
(25) Install three washers (45), screws (46), and locknuts (47).
(26) Install two wires (15 and 16) into brush holder
adapter (48).
(27) Install brush holder adapter (48) and insulator (49)
with two screws (50).
6-13
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-2. ALTERNATOR REPAIR (CONT).
(28)
Install two brushes (51) in brush holder (52).
(29)
Install preformed packing (53) and brush
holder (52).
Install gasket (54), brush cover (55), four
guard washers (56), lockwashers (57), and
screws (58).
(30)
CAUTION
Wires can be shorted out if rubbing on shaft.
(31)
Install preformed packing (59) and cover (60)
with four screws (61).
NOTE
Spacer is installed with notch facing away
from housing.
(32)
Install fan spacer (62) and fan (63) on rotor
shaft (64) with nut (65).
e. Follow-on Maintenance.
(1)
(2)
(3)
Test on test stand (TM 9-2920-225-34).
Install voltage regulator (TM 9-2320-279-20).
Install alternator and pulley
(TM 9-2320-279-20).
END OF TASK
6-14 Change 3
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-2.1.
24V ALTERNATOR REPAIR.
This task covers:
a. Disassembly
b. Testing
c. Cleaning/Inspection
d. Assembly
e. Follow-on Maintenance
Personnel Required
INITIAL SETUP
MOS 63G, Fuel and electrical system repairer
Models
References
All
None
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-20 Alternator removed.
Test Equipment
None
Special Tools
None
Supplies
Solvent, drycleaning, Item 57, Appendix C
Compound, insulating, Item 20, Appendix C
Compound, sealing, lubricating, Item 25,
Appendix C
Tags, identification, Item 60, Appendix C
Grease, automotive and artillery, Item 34,
Appendix C
a.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
Disassembly.
(1) Remove nut (1) from ignition (IGN) stud
(2) on regulator holder (3).
CAUTION
Voltage regulator is still connected by two
wires. Regulator cannot be removed until
after step (5). Failure to comply may result in
damage to alternator.
(2)
(3)
(4)
(5)
(6)
(7)
Remove four screws (4) and voltage
regulator (5) from regulator holder (3).
Remove ignition (IGN) stud (2) and blue
wire (6) from regulator holder (3).
Remove nut (7), lockwasher (8), and
black wire (9) from negative (--) terminal
of voltage regulator (5).
Remove nut (10), lockwasher (11), and
red wire (12) from positive (+) terminal
of voltage regulator (5).
Remove voltage regulator (5) and gasket
(13) from alternator (14).
Remove two brushes (15) from regulator
holder (3).
Change 5
6-14.1
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-2.1. 24-VOLT ALTERNATOR REPAIR (CONT).
NOTE
Vise is used to securely hold pulley
for step (9).
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
6-14.2
Position alternator (14) in vise.
Remove locknut (16) from shaft (17).
Remove alternator (14) from vise.
Remove pulley (18) from shaft (17).
Remove cooling plate (19), key (20), and
spacer (21) from shaft (17).
Remove screw (22), lockwasher (23),
and clip (24) from slip ring end housing
(25).
Remove three nuts (26) and wires (27)
from terminals (28).
Remove two screws (29), lockwashers
(30), screws (31), lockwashers (32),
spacers (33), and capacitor (34) from
slip ring end housing (25).
Change 5
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(16)
Remove three locknuts (35), washers
(36), and screws (37) from drive end
housing (38) and slip ring end housing
(25).
CAUTION
When removing rotor, completely separate
rotor from stator. Stator will still be attached
to slip ring housing. Do not attempt to
separate stator from slip ring housing. Failure
to comply may result in damage to stator
wires.
NOTE
Rotor will remain attached to drive end
housing during removal.
(17)
(18)
(19)
(20)
(21)
Remove drive end housing (38) and
rotor assembly (39) from slip ring end
housing (25) and stator (40).
Remove three nuts (41) and stator (40)
from slip ring end housing (25).
Remove two screws (42) and capacitor
(43) from positive rectifier (44) and
negative rectifier (45).
Remove screw (46) and wire (47) from
positive rectifier (44).
Remove nut (48) and positive terminal
screw (49) from positive rectifier (44)
and slip ring end housing (25).
Change 5
6-14.3
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-2.1. 24-VOLT ALTERNATOR REPAIR (CONT).
NOTE
Tag and mark wires before removal.
(22)
Remove six rectifier wires (50) from
three terminals (28).
CAUTION
Do not remove lower bushing from positive
rectifier. Failure to comply may damage
bushing.
(23)
(24)
(25)
(26)
6-14.4
Remove lower mounting screw (51),
lockwasher (52), washer (53), plastic
washer (54), positive rectifier (44) with
bushing (55), and bushing (56) from slip
ring end housing (25).
Remove screw (57) and wire (58) from
negative rectifier (45).
Remove nut (59), negative terminal
screw (60), two insulation bushings (61),
regulator holder (3), gasket (62), wire
(47), and wire (58) from negative
rectifier (45) and slip ring end housing
(25).
Remove three nuts (63) and terminal
studs (64) from regulator holder (3).
Change 5
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
CAUTION
Do not remove lower bushing from negative
rectifier. Failure to comply may damage
bushing.
(27)
Remove lower mounting screw (65),
lockwasher (66), washer (67), plastic
washer (68), negative rectifier (45) with
bushing (69), and two washers (70) from
slip ring end housing (25).
(28)
Position slip ring end housing (25) in
press and remove bearing (71).
Remove bushing (72) from slip ring end
housing (25).
(29)
(30)
Position drive end housing (38) and
rotor assembly (39) in press with
threaded end of shaft (17) pointing
upward.
CAUTION
Protect rotor assembly from striking floor
while pressing from drive end housing.
Failure to comply may result in damage to
rotor assembly.
(31)
Press rotor assembly (39) out from drive
end housing (38).
Change 5
6-14.5
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-2.1. 24-VOLT ALTERNATOR REPAIR (CONT).
(32)
Remove four screws (73) and bearing
retainer (74) from drive end housing
(38).
(33)
Position drive end housing (38) in press
with bearing (75) side down.
Press bearing (75) out of drive end
housing (38).
(34)
b. Testing.
(1)
Touch negative (--) test lead of
multimeter to bare metal surface on
positive rectifier (1).
NOTE
If multimeter does not indicate low resistance
in step (2), positive rectifier is defective.
Replace rectifier.
(2)
Touch positive (+) test lead of multimeter
separately to each of three eyelet
terminals (2).
(3)
Touch positive (+) test lead to bare metal
surface on positive rectifier (1).
NOTE
If multimeter does not indicate infinity in step
(4), positive rectifier is defective. Replace
rectifier.
(4)
6-14.6
Touch negative (--) test lead separately to
each of three eyelet terminals (2).
Change 5
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(5)
Touch negative (--) test lead to bare
metal surface on negative rectifier (3).
NOTE
If multimeter does not indicate infinity in step
(6), positive rectifier is defective. Replace
rectifier.
(6)
(7)
Touch positive (+) test lead separately to
each of three eyelet terminals (2).
Touch positive (+) test lead to bare metal
surface on negative rectifier (3).
NOTE
If multimeter does not indicate low resistance
in step (8), positive rectifier is defective.
Replace rectifier.
(8)
Touch negative (--) test lead separately to
each of three eyelet terminals (2).
NOTE
If resistance reading in step (9) is low, stator is
grounded and requires replacement.
(9)
Touch one test lead to bare metal surface
of stator (4) and other test lead
separately to each pair of three stator
ring terminals (5, 6, and 7).
NOTE
If resistance is not 1.0 ohm or less, stator is
defective. Replace stator.
(10)
Touch test leads to pairs of stator ring
terminals (5 and 6), (6 and 7), and (5
and 7), and read resistance across each
set of terminals.
Change 5
6-14.7
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-2.1. 24-VOLT ALTERNATOR REPAIR (CONT).
NOTE
If multimeter does not indicate an open circuit
in either test, rotor coil is grounded. Replace
rotor.
(11)
Touch one test lead to bare metal
surface on shaft (8) and other test lead
separately to each slip ring (9).
NOTE
If resistance is not 10.0 ohms or less, replace
rotor.
(12)
Touch test leads to each slip ring (9).
NOTE
Minimum outside diameter (OD) of slip rings
is 1.057 in. (26.85 mm). If measurement is
less, replace rotor.
(13)
Measure outside diameter (OD) of slip
rings (9).
NOTE
Minimum outside diameter (OD) of shaft is
0.669 in. (17 mm). If measurement is less,
replace rotor.
(14)
Measure diameter of shaft (8).
c. Cleaning/Inspection.
WARNING
·
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles and
gloves and use only in well-ventilated area. Avoid contact with skin, eyes, and
clothing, and do not breathe vapors. DO NOT use near open flame or excessive heat.
The flash point is 100-138oF (38-59oC). If you become dizzy while using cleaning
solvent, get fresh air immediately and medical aid. If contact with eyes is made,
wash your eyes with water and get medical aid immediately.
·
Compressed air for cleaning purposes will not exceed 30 psi (207 kPa). Use only with
effective chip guarding and personal protective equipment (goggles/shield, gloves,
etc.).
CAUTION
Do not soak stator or rotor in solvents. Damage to insulation may result.
(1)
6-14.8
Clean stator and rotor with dry cleaning solvent and clean cloth.
Change 5
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Dry stator and rotor with compressed air or dry cloth.
Clean all other components, except bearings, in dry cleaning solvent.
Inspect electrical assemblies for damage, frayed or bare wires, or loose connections.
Inspect mechanical assemblies for damage. Check for old or excess grease.
Clean rectifier assembly holes and terminal screws to ensure good electrical contact.
Clean carbon coating off slip rings with crocus cloth
Inspect brushes for burnt appearance, cracks, broken edges.
Check brush wear and replace if length measures less than 0.19 in. (4.8 mm).
Check drive end housing bearing for
smooth rotation. If bearing binds,
replace bearing.
Check slip ring housing bearing for
missing rollers. If rollers are missing,
replace bearing.
d. Assembly.
(1)
Position drive end housing (1) in press.
CAUTION
Apply pressure only on outer portion of race
when pressing bearing into drive end housing.
Failure to comply may result in equipment
damage.
(2)
(3)
Press bearing (2) in drive end housing
(1).
Install bearing retainer (3) in drive end
housing (1) with four screws (4).
NOTE
Threaded end of shaft must point downward.
(4)
(5)
Install rotor assembly (5) in drive end
housing (1).
Remove rotor assembly (5) from press.
Change 5
6-14.9
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-2.1. 24-VOLT ALTERNATOR REPAIR (CONT).
(6)
Position slip ring end housing (6) in
press.
NOTE
When properly installed, bearing seats on lip
inside bearing bore.
(7)
(8)
(9)
(10)
(11)
(12)
(13)
6-14.10
Press bearing (7) in slip ring end
housing (6).
Press bushing (8) in slip ring end
housing (6).
Remove slip ring end housing (6) from
press.
Coat bearing (7) rollers with grease.
Install negative (--) rectifier (9) in slip
ring end housing (6) with bushing (10),
two washers (11), plastic washer (12),
washer (13), lockwasher (14), and
mounting screw (15).
Install black wire (16) on negative (--)
rectifier (9) with screw (17).
Install positive (+) rectifier (18) in slip
ring end housing (6) with bushing (19),
bushing (20), plastic washer (21),
washer (22), lockwasher (23), and
mounting screw (24).
Change 5
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(14)
Install red wire (25) on positive (+)
rectifier (18) with screw (26).
(15)
Install three terminal studs (27) on
regulator holder (28) with three nuts
(29).
CAUTION
Red and black rectifier wires should be
positioned in grooves between regulator holder
and slip ring end housing. Failure to comply
may result in damaged wiring.
(16)
Install positive (+) terminal screw (30),
negative (--) terminal screw (31), two
insulation bushings (32), regulator
holder (28), new gasket (33), and two
nuts (34) in slip ring end housing (6),
positive (+) rectifier (18), and negative
(--) rectifier (9).
NOTE
·
Rectifier leads should be firmly
seated in regulator holder.
·
Wires should be positioned in
locations marked during removal.
(17)
(18)
Install six rectifier leads (35) on three
regulator studs (36).
Install capacitor (37) on positive
rectifier (18) and negative rectifier (9)
with two screws (38).
Change 5
6-14.11
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-2.1. 24-VOLT ALTERNATOR REPAIR (CONT).
(19)
Install stator ring terminals (39) on slip
ring end housing (6) and regulator studs
(36) with three nuts (40).
(20)
Aline screw holes on slip ring end
housing (6), stator (41), and drive end
housing (1).
Install slip ring end housing (6) on drive
end housing (1) with three screws (42),
washers (43), and locknuts (44).
(21)
(22)
6-14.12
Install capacitor (45) on slip ring end
housing (6) with two screws (46),
lockwashers (47), screws (48),
lockwashers (49), and spacers (50).
Change 5
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
NOTE
Capacitor wires have three different lengths.
Wires should be routed accordingly.
(23)
(24)
(25)
Install three wires (51) on regulator
studs (36) with nuts (52).
Secure three wires (51) to slip ring end
housing (6) with screw (53), lockwasher
(54), and clip (55).
Position spacer (56), key (57), cooling
plate (58), pulley (59), and locknut (60)
on shaft (61). Do not tighten.
NOTE
Vise is used to hold pulley securely for step
(26).
(26)
(27)
(28)
Position alternator (62) in vise.
Tighten locknut (60) to 70-80 lb-ft
(95-108 N∙m).
Remove alternator (62) from vise.
Change 5
6-14.13
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-2.1. 24-VOLT ALTERNATOR REPAIR (CONT).
NOTE
If using original brushes, wear pattern must
match radius of slip rings.
(29)
Insert two brushes (63) into regulator
holder (28).
NOTE
Brush springs are held compressed with 1/16
in. sockethead screw key to aid installation of
voltage regulator.
(30)
Compress brush springs (63). Install
1/16 in. sockethead screw key through
pilot hole (64) in regulator holder (28),
over springs (63), and into pilot hole
(65) inside regulator holder (28).
CAUTION
Regulator can only be installed one way. Position regulator so regulator pins align
with brush openings. Failure to comply may result in damage to equipment.
NOTE
Regulator must be positioned close to housing to allow installation of wires.
(31)
(32)
(33)
(34)
Install red wire (25) on positive (+)
terminal of voltage regulator (66) with
lockwasher (67) and nut (68).
Install black wire (16) on negative (--)
terminal of voltage regulator (66) with
lockwasher (69) and nut (70).
Install blue wire (71) and ignition (IGN)
stud (72) in regulator holder (28).
Install nut (73) on ignition (IGN) stud
(72).
CAUTION
Brush retaining pin must be positioned in
grooves between regulator holder and slip ring
end housing. Failure to comply may result in
damaged wiring.
(35)
Position gasket (74) and voltage
regulator (66) on regulator holder (28)
with four screws (75). Do not tighten.
(36) Remove sockethead screw key from rear
of regulator holder (28).
(37) Tighten four screws (75) on voltage
regulator (66).
e. Follow-On Maintenance.
Install alternator (TM 9-2320-360-20).
END OF TASK
6-14.14
Change 5
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-3. STARTER SOLENOID REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
References
All
Test Equipment
None
None
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-20 Starter removed.
Special Tools
None
Supplies
Sealant, RTV200 Electrical, Item 55.2,
Appendix C
Personnel Required
MOS 63G, Fuel and electrical systems repairer
a.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
Removal.
(1)
(2)
(3)
(4)
Remove nut (1) and
lockwasher (2).
Disconnect ground lead (3)
from terminal (4).
Remove nut (5) from motor terminal (6).
Remove nut (7) from field terminal (8).
Change 5
6-15
TM
9-2320-279-34-1
Electrical Sustem Maintenance Instructions (Cont)
6-3.
6-16
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
b.
Installation.
WARNING
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors,
and are harmful to skin and clothing. To avoid
injury or death, keep away from open fire and
use in well-ventilated area. If adhesive,
solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and
water.
NOTE
Apply electrical sealant to exposed wire
connectors after installing connectors.
(1)
Install connector (1) on motor
terminal (2).
art
(2)
(3)
Position solenoid (3) on starter (4) and plunger (5).
Install connector (1) on field terminal (6).
(4)
Install clip (7) over seal (8) on plunger (5).
Change 5
6-17
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-3.
6-18
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-19
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-4.
6-20
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-21
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-4.
6-22
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-23
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-4.
6-24
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
WARNING
6-25
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-4.
6-26
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-27
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-4.
6-28
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-29
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-4.
6-30
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cent)
6-31
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-4.
6-32
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-33
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-4.
6-34
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cent)
6-35
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cent)
Section
Ill.
CRANE
SYSTEM
6-5.
6-36
ELECTRICAL
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-37
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-5.
6-38
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-6.
6-39
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-6.
6-40
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-7.
6-41
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-7.
6-42
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
WARNING
6-43
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-8.
6-44
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-45
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-8.
6-46
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-47
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-9.
6-48
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
WARNING
6-49
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-9.
6-50
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-51
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-9.
6-52
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-53
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-10.
6-54
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-11.
6-55
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-11.
6-56
TM9-2320-279-34-1
Electrical
System
Maintenance
Instructions
(Cont)
(7) Disconnect cable (11) from junction
box ( 1 2 ) .
(8) Remove two
lockwashers
(9) Remove four
lockwashers
box (12).
nuts
(14),
nuts
(17),
(13),
and guard (15).
(16),
and junction
NOTE
Tag and mark electrical connectors before disconnecting.
(10) Disconnect six electrical connectors (18).
6-57
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-11.
JUNCTION
(CONT).
BOX
AND
CONNECTOR
b. D i s a s s e m b l y .
(1) Remove cap (1).
(2) Remove four screws (2),
lockwashers (3), washers (4), and
cover (5) from box (6).
N O T E
Tag and mark wires
disconnecting.
before
removing
or
(3) Remove two screws (7) and three
wires (8).
(4) Remove sealnut (9), lockwasher (10),
switch (11), and nut (12).
NOTE
Connector must be removed
with cable module.
(5) Remove nut (13) and
lockwasher (14).
(6) Remove nut (15),
lockwasher (16), and
connector (17).
6-58
REMOVAL/REPAIR/INSTALLATION
(M977,
M985)
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
(7) Disconnect eight wires (18).
(8) Remove two screws (19),
lockwasher (20), washers (21),
and relay module (22).
(9) Remove two screws (23),
lockwashers (24), and
washers (25).
NOTE
Connector must be removed
with cable module.
(10) Remove cable module (26),
connector (17), and
cables (27).
(11) R e m o v e r u b b e r
grommet (28) and wire (29)
(12) Remove nut (30),
screw (31), and chain and
cap (32).
6-59
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-11.
JUNCTION
BOX
CONNECTOR
REMOVAL/REPAIR/INSTALLATION
(CONT)
(13) Remove pin (33) from
connector (17).
(14) Remove pin (33) from wire (34).
c. A s s e m b l y .
(1) Install pin (1) on wire (2).
(2) Install pin (1) in connector (3).
(3) Install wire (4) and grommet (5) in box (6).
(4) Install cap and chain (7), screw (8), and nut (9).
6-60
(M977,M985)
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(5) Install cables (10),
connector (3), and cable
module (11).
(6) Install two washers (12),
lockwashers (13), and
screws (14).
(7) Install relay module (15) with two
screws (16), lockwasher (17), ant
washer (18).
(8) Connect eight wires (19).
(9) Install connector (3),
lockwasher (20), and
nut (21).
(10) Install lockwasher (22) and
nut (23).
6-61
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-11.
JUNCTION
BOX
AND
CONNECTOR
(CONT).
(11) Install nut (24), switch (25),
lockwasher (26), and sealnut (27).
(12) Install three wires (28) with two
screws (29).
(13) Install cover (30) on box (6)
with four washers (31),
lockwashers (32), and
screws (33).
(14) Install cap (34).
d. Installation.
(1) Connect six electrical connectors (1).
6-62
REMOVAL/REPAIR/INSTALLATION
(M977,M985)
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
(2) Install junction box (2), four
lockwashers (3), and nuts (4).
(3) Install guard (5), two
lockwashers (6), and nuts (7).
(4) Connect cable (8) to junction box (2).
(5)
(6)
(7)
(8)
(9)
Install seal (9) and two wires (10) in connector (11).
Connect two wires (10) to socket (12) with two screws (13).
Install socket (12) in connector (11).
Install washer (14) and screw (15).
Install washer (16) and fitting (17) on connector (11).
6-63
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cent)
6-11.
JUNCTION
(CONT).
BOX
AND
CONNECTOR
REMOVAL/REPAIR/INSTALLATION
(M977,
M985)
N O T E
M977 crane has 13 connectors.
M985 crane has 12 connectors.
(10) Install 12 seals (18) and connectors (11)
on valves (19).
(11) Tighten 12 screws (15).
e. Follow-on Maintenance. Connect
overload sensor switches (para 6-12).
crane
END OF TASK
6-11.1.
JUNCTION
BOX
AND
CONNECTOR
REMOVAL/REPAIR/INSTALLATION
(M984E1).
This task covers:
a. Removal
b. Disassembly
c. Assembly
d. Installation
e. Follow-on Maintenance
INITIAL SETUP
Equipment
Models
M984E1
Test Equipment
None
Special
Tools
Condition
TM or Para
Condition
TM 9-2320-279-20
TM 9-2320-279-20
Batteries disconnected.
Left remote control hookup
connector removed.
Overload protection switch
disconnected.
Right hand front control
body removed (plugs only).
Para 6-12.1
None
Para
Supplies
17-28.4
None
Personnel
Required
MOS 63W, Heavy wheel vehicle mechanic
References
None
Special Environmental Conditions
None
General Safety Instructions
None
Level of
Maintenance
Direct Support
6-64
Description
TM
Electrical
a.
9-2320-279-34-1
System Maintenance Instructions (Cont)
Removal.
(1) Disconnect connector (1) from high idle box (2),
NOTE
Remove all wire ties as necessary.
(2) Remove two nuts (3),
lockwashers (4),
flatwashers (5), and
screws (6).
(3) Remove two nuts (7),
lockwashers (8),
flatwashers (9), screws (10),
and front brace (11).
(4) Remove box (12) from
bracket (13).
b.
Disassembly.
6-64.1
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-11.1.
JUNCTION
(CONT).
BOX
AND
CONNECTOR
REMOVAL/REPAIR/INSTALLATION
(M984E1)
(6) Remove two screws (11) and washers (12) from
connector (13).
NOTE
All three pins must be removed at the same time.
(7) Remove three pins (14) from connector (13).
(8) Remove three pins (14) from wires (15).
NOTE
Tag and mark all wires.
(9)
(10)
(11)
(12)
(13)
(14)
6-64.2
Remove
Remove
Remove
Remove
Remove
Remove
four screws (16), lockwashers (17), washers (18), and cover (19) from box (20).
seal nut (21), switch (22), lockwasher (23), and nut (24).
two screws (25) and wire (26) from switch (22).
cap (27) from connector (28).
screw (29), washer (30), and chain (31) from box (20).
nut (32) and lockwasher (33).
TM 9-2320-279-34-1
Electrical
System
Maintenance
Instructions
(Cont)
TA476386
TA476386
(15)
(16)
(17)
(18)
(19)
Remove four screws (34), lockwasher (35), and washers (36) from cable module (37).
Remove two screws (38), lockwashers (39), and washers (40) from relay module (41).
Remove cable module (37), relay module (41), and connector (28) from box (20).
Disconnect seven connectors (42).
Remove relay module (41), disconnect two connectors (42) and remove two wires (43).
NOTE
Tag and mark all wires.
(20)
(21)
(22)
(23)
Remove
Remove
Remove
Remove
11 pins (44) from connector (28).
11 pins (44) from wires (45).
three plugs (46).
four rivets (47) and tag (48).
6-64.3
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cent)
6-11.1.
c.
JUNCTION
(CONT).
BOX
AND
CONNECTOR
REMOVAL/REPAIR/INSTALLATION
(M984E1)
Assembly.
(1) Install tag (1) with four rivets (2).
(2) Install 11 pins (3) on wires (4).
(3) Install 11 pins (3) in connector (5) and three plugs (6).
(4) Connect seven wires (7) from relay module (8) to seven wires (9) from cable module (10) and two
wires (11) with nine connectors (12).
( 5 ) Position relay module (8), cable module (10), and connector (5) in box (13).
( 6 ) Install two washers (14), lockwashers (15), and screws (16) in relay module (8).
( 7 ) Install four washers (17), lockwashers (18), and screws (19) in cable module (10).
6-64.4
TM9-2320-279-34-1
Electrical
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
System
Maintenance
Instructions
(Cont)
Install chain (20) with washer (21) and screw (22).
Install connector (5) in box (13) with lockwasher (23) and nut (24).
Install cap (25) on connector (5).
Connect two wires (11) with screws (26) to switch (27).
Install nut (28) and lockwasher (29) on switch (27).
Install switch (27) in box (13) with seal nut (30).
Install cover (31) with four washers (32), lockwashers (33), and screws (34).
Install
Install
Install
Install
Install
Install
Install
three pins (35) on wires (36).
three pins (35) in connector (37).
two washers (38) and screws (39).
fitting (40), washer (41), seal (42), and plug (43) on harness (44).
two wires (45) with screws (46).
plug connector (47) in plug (43) with washer (48) and screw (49).
seal (42), washer (41), and fitting (40) in plug (43).
6-64.5
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-11.1. JUNCTION
(CONT).
d.
BOX AND CONNECTOR REMOVAL/REPAIR/INSTALLATION
(M984E1)
Installation.
(1) Install box (1) to bracket (2).
(2) Install brace (3) with two
screws (4), flatwashers (5),
lockwashers (6). and
nut (7). Do not tighten.
(3) Install two screws (8),
flatwashers (9), lockwashers (10), and nuts (11).
(4) Tighten nuts (7 and 11).
(5) Connect connector (3) to
high idle box (4).
e. Follow-on Maintenance.
(1) Right hand front control body
plugs installed (para 17-28.4).
(2) Overload protection switches
connected (para 6-12.1).
(3) Left hand remote control
connector installed
(TM 9-2320-279-20).
(4) B a t t e r i e s c o n n e c t e d
(TM 9-2320-279-20).
END OF TASK
6-12.
CRANE
OVERLOAD
SENSOR
SWITCHES
REMOVAl/INSTALLATION
(M977,M985).
This task covers:
a.
b.
c.
d.
Main Overload Switch Removal
e. Mast Overload Switch Removal (M977 only)
Main Overload Switch Installation
f. Mast Overload Switch Installation (M977 only)
g. Follow-on Maintenance
Reduced Overload Switch Removal (M977 only)
Reduced Overload Switch Installation (M977 only)
INITIAL SETUP
Models
Equipment
M977, M985
Test Equipment
None
Special
Tools
Tags, identification, Item 60, Appendix C
Ties, cable, plastic, Item 65, Appendix C
Required
MOS 63W, Wheel vehicle repairer
None
6-64.6
Condition Description
None
Supplies
References
TM or Para
TM 9-2320-279-10 Prepare crane for use.
TM 9-2320-279-10 Boom raised approximately
1 ft (30 cm).
Special Environmental Conditions
None
Personnel
Condition
General Safety Instructions
None
Level of Maintenance
Direct Support
TM
Electrical
a.
Main
Overload
Switch
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
Removal.
N O T E
● Main overload switch is the same for M977 and M985.
● ‘lag and mark wires before removal.
(1) Disconnect three wires (1) at connectors (2).
(2) Remove nut (3) and main overload switch (4) from mounting bracket (5).
b.
Main
Overload
Switch
Installation.
NOTE
Main overload switch is the same for M977 and M985.
(1) Install main overload switch (1) on mounting
bracket (2) with nut (3).
(2) Connect three wires (4) to connectors (5) (fig. 6-1).
6-65
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-12.
CRANE
(CONT).
OVERLOAD
SENSOR
SWITCHES
REMOVAL/INSTALLATION
Figure 6-1. Main Overload Switch Wiring.
(3) Tighten nut (6) and jamnut (7) until one screw
thread is below surface of nut (6).
(4) Adjust nut (8) and jamnut (9) until main
overload switch (1) is 1/4 in. (6 mm) from switch
sensing plate (10),
c. Reduced
(M977 only).
Overload
Switch
Removal
NOTE
Tag and mark wires before removal.
(1) Disconnect three wires (1) at
connectors (2).
NOTE
Remove clips and plastic cable ties.
(2) Remove nut (3) and overload switch (4)
from mounting bracket (5).
6-66
(M977,
M985)
TM 9-2320-279-34-1
Electrical
d.
Reduced
Overload
Switch
System
Maintenance
Installation
(M977
Instructions
(Cont)
only].
(1) Install reduced overload switch (1) on mounting bracket (2) with nut (3).
(2) Connect three wires (4) to connectors (5) (fig. 6-2).
Figure 6-2. Reduced Overload and Mast Overload Switch Wiring.
6-67
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cent)
6-12.
CRANE
OVERLOAD
.
SENSOR
SWITCHES
REMOVAL/INSTALLATION
(3) Tighten nut (6) and jamnut (7) until one screw
thread is below surface of nut (6).
(4) Adjust nut (8) and jamnut (9) until reduced
overload switch (1) is 1/4 in. (6 mm) from switch
sensing plate (10).
e. Mast Overload Switch
Removal (M977 only).
NOTE
Tag and mark wires before
removal.
(1) Disconnect three wires (1)
at connectors (2).
NOTE
Remove clips and plastic cable
ties.
(2) Remove four screws (3) and
mounting clamp (4) from
mast (5).
(3) R e m o v e m a s t o v e r l o a d
switch (6) from mounting
clamp (4).
6-68
(M977,
M985)
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
f. Mast Overload Switch Installation (M977
only).
(1) Install mast overload switch (1) in mounting
clamp (2).
(2) Install mounting clamp (2) on mast (3) with four
screws (4).
(3) Connect three wires (5) to connectors (6) (fig. 6-2).
(4) Loosen four screws (4) and adjust mounting clamp (2) so mast overload switch (1) is 1/8 in.
(3 mm) from edge of mast (3). Tighten screws.
g. follow-on Maintenance. Adjust
overload
sensor
switches
(para
17-33).
END OF TASK
6-69
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-12.1.
CRANE OVERLOAD SENSOR SWITCHES
REMOVAL/INSTALLATION
(M984E1).
AND
PLATE
AND
TERMINAL
BOX
This task covers:
c. Follow-on Maintenance
a. Removal
b. Installation
INITIAL SETUP
Equipment
Models
M984E1
TM or Para
Test Equipment
Condition
Special Environmental Conditions
Special Too1s
None
None
General Safety Instructions
Supplies
None
None
Level of Maintenance
Required
Direct Support
MOS 63W, Heavy wheel vehicle repairer
References
None
a.
Removal.
NOTE
Remove wire clips and ties as necessary. Tag and mark all wires.
(1) D i s c o n n e c t three connectors (l), (2), and (3).
6-70
Description
TM 9-2320-279-10 Crane in operating condition.
TM 9-2320-279-10 Position crane for access.
None
Personnel
Condition
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(2) Remove two nuts (4), lockwashers (5), screws (6), and bracket (7).
NOTE
All four overload switches are removed the same way.
‘Iag and mark overload switches before removing.
(3) Remove nut (8) and overload switch (9) from mounting bracket (10).
NOTE
The three overload switches are removed the same way.
Remove clamp, wire ties and clips as necessary.
‘Iag and mark overload switches before removing.
(4) Remove four screws (11) and mounting flange (12) from mast (13).
(5) Remove overload switch (14) from mounting flange (12).
(6) Remove two screws (15), lockwashers (16), and sensor plate (17).
6-70.1
TM 9-2320-279-34-1
(7) Remove four screws (18), lockwashers (19), washers (20), and cover (21) from box (22).
NOTE
● Wires for seven overload
switches are removed the
same way.
● Remove wire clips and ties as
necessary.
(8) R e m o v e c o n n e c t o r ( 2 3 ) ,
spacer (24), and grommet (25)
from fitting (26).
NOTE
Tag and mark wires before
removing.
(9) Loosen three screws (27) on
terminal board (28) and
remove wires (29).
(10) R e m o v e c o n n e c t o r ( 2 3 ) ,
spacer (24), and grommet (25)
from wire harness (30).
(11) Remove four nuts (31),
lockwashers (32), clamp (33),
and box (22).
6-70.2
TM
Electrical
(12)
(13)
(14)
(15)
(16)
b.
Loosen
Loosen
Remove
Remove
Remove
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
six screws (27) and remove four rectifiers (34).
six screws (27) and remove seven jumper wires (35).
eight nuts (36) and fittings (26).
four screws (37), nuts (38), and lockwashers (39).
two strips (40) from box (22).
Installation.
(1)
(2)
(3)
(4)
(5)
(6)
Install two strips (1) in box (2).
Install four screws (3), lockwashers (4), and nuts (5).
Install eight fittings (6) and nuts (7).
Install seven jumper wires (8).
Tighten six screws (9).
Install four rectifiers (10) and tighten six screws (11).
6-70.3
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-12.1.
(7)
(8)
(9)
(l0)
(11)
CRANE OVERLOAD SENSOR SWITCHES AND PLATE
REMOVAL/INSTALLATION (M984E1) (CONT).
AND
TERMINAL
BOX
Install box (2) with four lockwashers (12), clamp (13), and nuts (14) to boom (15).
Install eight connectors (16), spacers (17), and grommet (18) on harness (19).
Install eight connectors (16) to fittings (6).
Install 24 wires (20).
Tighten 22 screws (21).
(12) Install cover (22) on box (2) with four washers (23), lockwashers (24), and screws (25).
6-70.4
TM
9-2320-279-34-1
Electrical System M a i n t e n a n c e I n s t r u c t i o n s ( C o n t )
(13) Install sensor plate (26) with two
screws (27) and lockwashers (28).
NOTE
The three overload switches are installed
the same way.
(14) Install mast overload switch (29) in
mounting flange (30).
(15) Install mounting flange (30) on mast (31)
with four screws (32).
NOTE
The four overload switches are installed
the same way.
(16) Install overload switch (33) on mounting
bracket (34) with nut (35).
NOTE
Settings are made the same way for all
four overload switches.
(17) Tighten nut (36) and jamnut (37) until
one screw thread is below surface of
nut (36).
(18) Adjust nut (35) and jamnut (38) until
overload switch (33) is 1/16 in.
(1.59 mm) from switch sensing
plate (39).
6-70.5
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-12.1.
CRANE OVERLOAD SENSOR SWITCHES AND PLATE
REMOVAL/INSTALLATION (M984E1) (CONT).
(19) Install
bracket
(40)
with
two
screws
(41),
AND
lockwashers
TERMINAL
(42),
and
nuts
BOX
(43).
N O T E
Settings are made the same way for all three overload switches.
(20) Loosen four screws (32) and adjust mounting flange (30) so overload switch (29) is 3/16 in.
(4.76 mm) from sensor plate (26). Tighten screws (32).
6-70.6
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
(21) Connect three connectors (44).
c. Follow-on Maintenance. Adjust hoist overload protection switches (para 17-25.1).
END OF TASK
6-70.7
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
Section
6-13.
CAB
WIRING
HARNESS
IV.
WIRING
HARNESSES
REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
Equipment
All
TM or Para
Test Equipment
None
Special
Condition
Tools
Insert removal tool 114010
Supplies
Connector, electrical, butt, Item 31,
Appendix C
Tags, identification, Item 60, Appendix C
Tape, insulation, electrical, Item 62,
Appendix C
Ties, cable, plastic, Item 65, Appendix C
Condition
Special Environmental Conditions
None
Personnel
Required
MOS 63W, Wheel vehicle repairer
References
a.
Wheels
chocked.
Direct Support
Removal.
NOTE
• Tag and mark all wires,
• Remove all clamps and
plastic cable ties as
necessary.
(1) Disconnect connector (1)
from flasher relay (2).
Remove wire (3) from
connector (1).
(2) Disconnect six wires (4)
from turn signal
connectors (5).
6-70.8
General Safety Instructions
Level of Maintenance
None
Description
TM 9-2320-279-20 Batteries disconnected.
TM 9-2320-279-20 Instrument panel removed.
TM 9-2320-279-20 TRACTION CONTROL switch
removed.
TM 9-2320-279-20 Starter switch removed.
TM 9-2320-279-20 TRACTION CONTROL
indicator light removed.
TM 9-2320-279-20 ENGINE STOP switch
removed.
TM 9-2320-279-20 ETHER START switch
removed.
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
(3) Remove nut (6), lockwasher (7), clip (8), five ground wires (9), lockwasher (10), washer (11), and
screw (12) from panel (13).
(4) Remove two screws (14) and wires (15) from switch (16).
(5) Remove four screws (17) and headlight guard (18).
(6) Remove two screws (19) and lockwashers (20). Remove dimmer switch (21) from bracket (22).
(7) Remove six wires (23) from dimmer switch (21).
6-71
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-13.
CAB
WIRING
HARNESS
REMOVAL/INSTALLATION
(8) Disconnect two turn signal light
connectors (24 and 25).
(9) Disconnect three plugs (26) from left
headlight (27).
(10) Remove four nuts (28), washers (29),
and 10 wires (30) from each of two
brake stoplight switches (31).
(11) Disconnect two wires (32) from brake low air
switches (33) at right of brake treadle valve (34).
(12) Disconnect three wires (35) from left
composite light connectors (36).
6-72
(CONT).
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(13)
Using insert removal tool,
disconnect left step clearance
light wire (37) from plug (38).
(13.1) Remove two screws (38.1) and
left step clearance light housing
(38.2).
(13.2) Remove mounting screw (38.3),
left step clearance light-to-cab
ground wire (38.4), and pigtail
ground wire (38.5) from left step
clearance light base (38.6).
(14)
Using insert removal tool,
disconnect right step clearance
light wire (39) from plug (40).
(14.1) Remove two screws (40.1) and
right step clearance light
housing (40.2).
(14.2) Remove mounting screw (40.3),
right step clearance light-to-cab
ground wire (40.4), and pigtail
ground wire (40.5) from right
step clearance light base (40.6).
(15)
Disconnect connector (41) from
left and right front marker
lights (42).
(16)
Disconnect two wires (43) from
connectors (44) at electric horns
(45).
(17)
Disconnect plug (46) from
blackout light (47).
Change 7
6-73
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-13.
CAB
WIRING
HARNESS
REMOVAL/INSTALLATION
(CONT).
(18) Remove electrical tape from three neutral start switch wires (48) and disconnect wires at
connectors (49).
(19) Remove screw (50), clamp (51), and heater control cable (52).
(20) Disconnect three chassis wiring harness plugs (53) from under console (54).
(21) Remove two nuts (55), lockwashers (56), and two wires (57) from stoplight switch (58).
6-74
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
Remove 11 screws (59) and
(22) two heater compartment
covers (60).
(23) Remove eight screws (61) and
heater compartment
cover (62).
(24) Disconnect plug (63)
takeoff (PTO) harness
(25) Disconnect connector
(26) Disconnect connector
from power
(64).
(65).
(66).
(27) Disconnect plug (67) from main light
switch (68).
6-75
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-13.
CAB
WIRING
HARNESS
REMOVAL/INSTALLATION
(CONT).
(28) Remove eight screws (69) and console
side panel (70).
(29) Disconnect three wires (71) from
ON/OFF switch (72) and HIGH/LOW
switch (73).
NOTE
WORK LIGHT switch is on M983, M984, and
M984E1 only.
(30) Disconnect two wires (74 and 75) from
domelight switch (76) and WORK LIGHT
switch (77). Disconnect three wires (78) from
CLLPS switch (79).
(31) Disconnect wire (80) from center terminal of heater fan switch (81).
6-76
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
(32) Remove two screws (82) and domelight (83).
NOTE
Domelight wire will have to be pulled up through console.
(33) Disconnect domelight wire (84) at connector (85).
(34) Remove four screws (86) and
headlight guard (87).
(35) Disconnect three plugs (88) from right
headlight (89).
(36) Remove screw (90), washer (91),
lockwasher (92), nut (93), and
clip (94) holding cab wiring
harness (95).
(37) Disconnect three wire connectors (96)
from right composite light wires (97).
6-77
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-13. CAB WIRING HARNESS REMOVAL/INSTALLATION (CONT).
(38) Disconnect cab wiring harness (95) from circuit breaker rack (98) inside console (54).
(39) Disconnect one harness wire (99) from starter relay (100) and two harness wires (101) from horn
relay (102).
(40) Pull neutral start switch wires (48) out through grommet (103).
(41) Remove grommet (103) from console (54).
(42) Remove grommet (104) from console (54).
(43) Remove right composite light wires (105) from heater compartment (106).
6-78
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(44)
(45)
(46)
(47)
b.
Disconnect two connectors (107).
Remove three screws (108), washers (109), and clamps (11O) holding cab wiring harness (95).
Remove 12 screws (111) and three receptacles (112) from console (54).
Remove cab wiring harness (95).
Installation.
NOTE
All cab wiring harness connections need to be secure. Tie all excess wiring
together with plastic cable ties.
(1) Install cab wiring harness (1) in console (2).
(2) Push domelight wire (3), three neutral start switch wires (4), and left step clea rance light
wire (5) through grommet (6).
(3) Install grommet (6) in console (2).
6-79
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-13.
CAB
WIRING
(4) Install three
screws (8).
(5) Install three
and washers
(6) Connect two
(7) Connect two
starter relay
(8) Connect one
relay (16).
(9) Connect cab
breaker rack
HARNESS
REMOVAL/INSTALLATION
receptacles (7) with 12
clamps (9) with screws (10)
(11).
connectors (12).
harness wires (13) to
(14).
harness wire (15) to horn
wiring harness (1) to circuit
(17).
(10) Pull right composite light
wires (18) through hole in
heater compartment (19).
NOTE
Tie right composite light wires
with plastic cable ties.
(11) Route right composite light
wires (18) through clip (20)
and install clip to glove
box (21) with screw (22),
washer (23),
lockwasher (24), and
nut (25).
(12) Connect three right
composite light wires (18) to
wire connectors (26).
(13) Connect three plugs (27) to
right headlight (28),
(14) Install headlight guard (29)
with four screws (30).
6-80
(CONT).
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(15) Connect domelight wire (31) to connector (32).
(16) Install domelight (33) with two screws (34).
(17) Connect wire (35) to center terminal on
heater fan switch (36).
NOTE
WORK LIGHT switch is on M983, M984, and
M984E1 only.
(18) Connect two wires (37) to DOMELIGHT
switch (38) and WORK LIGHT switch (39).
Connect three wires (40) to CL LPS
switch (41).
6-81
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-13.
CAB
WIRING
HARNESS
REMOVAL/INSTALLATION
NOTE
ENGINE BRAKE switches are identical.
Install both switches so that up position is
ON-HIGH and down position is OFF-LOW.
(19) Connect three wires (42) to ON/OFF
switch (43).
(20) Connect three wires (44) to HIGH/LOW
switch (45).
(21) Install console side panel (46) with eight
screws (47).
(22) Connect plug (48) to main light
switch (49) inside console side
panel (46).
(23) Connect plug (50) to power takeoff (PTO) harness (51).
(24) C o n n e c t c o n n e c t o r ( 5 2 ) .
(25) C o n n e c t c o n n e c t o r ( 5 3 ) .
6-82
(CONT).
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
(26) Install grommet (54) in
console (2).
(27) Connect three chassis wiring
harness plugs (55) to cab
wiring harness connectors (56)
under cab console floor (57).
(28) Install heater control
cable (58) with clamp (59) and
screw (60).
(29) Connect two wires (61) to
stoplight switch (62) with two
lockwashers (63) and
nuts (64).
(30) Connect three neutral start switch wires (4) to connectors (65).
(31) Wrap electrical tape over three neutral start switch wires (4) and connectors (65).
6-83
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-13.
6-84
CAB WIRING HARNESS REMOVAL/INSTALLATION (CONT).
(32)
(33)
Connect plug (66) to blackout light (67).
Connect two wires (68) to connectors (69) at electric horns (70).
(34)
Connect connector (71) to right and left front marker lights (72).
Change 7
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(35)
Using insert removal tool, connect wire (73) at plug (74) to left step clearance light (75).
(35.1) Feed left step clearance light-to-cab ground wire (75.1) through left step clearance light base
(75.2) from behind.
(35.2) Attach left step clearance light-to-cab ground wire (75.1) and pigtail ground wire (75.3) to left
step clearance light base (75.2) with mounting screw (75.4).
(35.3) Install left step clearance light housing (75.5) on left step clearance light base (75.2) with two
screws (75.6).
(36)
Using insert removal tool, connect wire (76) at plug (77) to right step clearance light (78).
(36.1) Feed right step clearance light-to-cab ground wire (78.1) through right step clearance light
base (78.2) from behind.
(36.2) Attach right step clearance light-to-cab ground wire (78.1) and pigtail ground wire (78.3) to
right step clearance light base (78.2) with mounting screw (78.4).
(36.3) Install right step clearance light housing (78.5) on right step clearance light base (78.2) with
two screws (78.6).
Change 7
6-84.1/(6-84.2 blank)
TM
9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(37) Connect three wires (79) to left
composite light connectors (80).
(38) Connect three plugs (81) to left
headlight (82).
(39) Connect two side turn signal wires (83)
to connectors (84).
(40) Install 10 wires (85) to each of two brake
stoplight switches (86) with four
nuts (87) and washers (88).
(41) Connect two wires (89) to brake low air switches (90)
at right of brake treadle valve (91).
6-85
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-13.
CAB
WIRING
HARNESS
REMOVAL/INSTALLATION
(42) Connect six wires (92) to
dimmer switch (93).
(43) Install dimmer switch (93)
on bracket (94) with two
screws (95) and
lockwashers (96).
(44) Install headlight guard (97)
with four screws (98).
(45) Install clip (99) and five ground wires (100)
behind panel (101) with screw (102),
washer (103), lockwasher (104),
lockwasher (105), and nut (106).
(46) Install two wires (107) with screws (108) to
switch (109).
(47) Pull six wires (110) up into
instrument compartment.
(48) Connect six wires (110) to
turn signal connectors (111).
(49) Install wire (112) into
connector (113). Install
connector on flasher
relay (114).
6 - 8 6
(CONT).
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(50)
(51)
c.
Install two heater
compartment covers (115)
on console (2) with 11
screws (116).
Install heater compartment
cover (117) with eight
screws (118).
Follow-on Maintenance.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Install ETHER START
switch (TM 9-2320--279-20).
Install starter switch
(TM 9-2320--279-20).
Install TRACTION
CONTROL switch
(TM 9-2320--279-20).
Install ENGINE STOP switch
(TM 9-2320--279-20).
Install TRACTION
CONTROL indicator light (TM 9-2320--279-20).
Install instrument panel (TM 9-2320--279-20).
Connect batteries (TM 9-2320--279-20).
END OF TASK
6-14.
ENGINE WIRING HARNESS REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Connector, electrical butt, Item 31,
Appendix C
Sealant, RTV200 Electrical, Item 55.2,
Appendix C
Tags, identification, Item 60, Appendix C
Tape, insulation, electrical, Item 62,
Appendix C
Ties, cable, plastic, Item 65, Appendix C
c. Follow-on Maintenance
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-20 Batteries disconnected.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
Change 5
6-87
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-14.
a.
ENGINE
WIRING
HARNESS
REMOVAL/INSTALLATION
(CONT).
Removal.
NOTE
●
Tag and mark all connections and wires before disconnecting.
●
Cut plastic cable ties as necessary.
(1) Disconnect two connectors (1) from two receptacles (2).
(2) Disconnect two-pin connector (3).
NOTE
M984E1 has only two cushion clips.
(3) Remove screw (4), washer (5), and cushion clip (6) to free engine harness (7) from lower right
flange of transmission (8).
6-88
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
(4) Disconnect STE/ICE harness (9) from engine harness (7) at connector (10).
(5) Remove nut (11) and disconnect wire (12) from transmission temperaturre sending unit (13).
(6) Cut wire (14) to transmission lockup solenoid (15).
NOTE
On M984E1, power takeoff is turned around.
(7) Disconnect connector (16) from power takeoff solenoid (17).
6-89
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
16-14.
ENGINE
WIRING
HARNESS
REMOVAL/INSTALLATION
(CONT).
NOTE
Ž All cushion clips are removed the same
way.
• M984E1 does not, have cushion clip.
(8) Remove screw (18), washer (19), and
cushion clip (20) to free engine
harness (7) from upper flange of
transmission (8).
(9) Disconnect ether start plug (21) at harness socket (22).
(10) Disconnect two wires (23) from water temperature thermostat (24).
6-90
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(11) Disconnect wire from tachometer
sending unit (25) at harness
connector (26).
(12) Cut wire to disconnect high idle solenoid
wire at connector (27).
(13) Cut left engine brake wire (28) at electrical butt connector (29).
(14) Cut right engine brake wire (30) at electrical butt connector (31).
6-91
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-14. ENGINE WIRING HARNESS REMOVAL/INSTALLATION (CONT).
(15)
(16)
(17)
(18)
(19)
6-92
Disconnect two wires (32) from buffer
switch (33) by pulling wires off switch
terminals.
Remove two nuts (34) and disconnect
two wires (35) from engine shutdown
solenoid (36). Return nuts to shutdown
solenoid terminals (37).
Remove nut (38) and washer (39). Disconnect wires (40 and 41) from starter solenoid
terminal (42).
Remove nut (43), washer (44), and wire (45) from starter solenoid terminal (46).
Remove nut (47) and lockwasher (48). Disconnect harness wires (49 and 51) and wire (52) from
starter terminal (53).
Change 3
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(20)
(21)
(22)
Remove nut (54) and lockwasher (55). Remove wire (56) from oil pressure sending unit (57).
Pull two wires (58) from low oil pressure switch (59).
Remove screw (60). Disconnect wire (61) from low engine oil switch (62).
(23)
(24)
(25)
Remove screw (63) and disconnect wire (64).
Remove screw (65) and disconnect wire (66).
Remove screw (67) and disconnect ether start ground wire (68).
Change 3
6-93
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-14. ENGINE WIRING HARNESS REMOVAL/lNSTALLATION (CONT).
(26) Remove nut (69) and disconnect wire (70) from starter solenoid (71).
(27) Remove three nuts (72) and washers (73). Disconnect two wires (74 and 75) from terminals at
alternator (76) and one wire (77) from alternator regulator (78).
6-94
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
6-95
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-14.
b.
ENGINE WIRING HARNESS REMOVAL/INSTALLATION (CONT).
Installation.
(1)
Wrap electrical tape around loose wires of harness (1) to make it easier to thread wires through
engine.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
NOTE
Apply electrical sealant to exposed wire connectors after installing connectors.
6-96
(2)
(3)
Install two connectors (2) to receptacles (3).
Connect two-pin connector (4).
(4)
Begin threading taped ends of harness (1) through vehicle from beneath right rear corner of
engine.
Change 5
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
Remove tape, as necessary, to connect harness ends to component or connector.
(5) Pull harness all the way to the left and connect lead (5) to water temperature sending unit (6)
with washer (7) lockwasher (8) and nut (9).
(6) Connect lead (10) to high water temperature switch (11) with washer (12), lockwasher (13), and
nut (14).
(7) Connect wire (15) to alternator regulator (16) and wires (17 and 18) to terminals of
alternator (19). Secure each wire with washer (20) and nut (21).
6-97
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-14. ENGINE WIRING HARNESS REMOVAL/INSTALLATION (CONT).
(8)
(9)
(10)
(11)
6-98
Connect wire (22) to starter solenoid (23) with nut (24).
Connect ether start ground wire (25) to bracket (26) with screw (27).
Connect wire (28) with screw (29).
Connect two wires (30) with screw (31).
Change 3
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(12) Connect lead (32) to low engine oil
switch (33) with screw (34).
(13) Connect two wires (35) to low oil
pressure switch (36).
(14) Connect wire (37) to oil pressure
sending unit (38) with lockwasher (39)
and nut (40).
(15)
Connect wire (41) and harness wires (42 and 44) to starter terminal (45) with lockwasher (46)
and nut (47).
(16)
(17)
Connect wire (48) to starter solenoid terminal (49) with washer (50) and nut (51).
Connect two wires (52 and 53) to starter solenoid terminal (54) with nut (55) and washer (56).
Change 3
6-99
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-14. ENGINE WIRING HARNESS REMOVAL/INSTALLATION (CONT).
(18) Thread two wires (57) to engine shutdown
solenoid (58) and connect to shutdown solenoid
terminal (59) with two nuts (60).
(19) Route three wires (61) under engine shutdown
solenoid (58) and push slip-on terminals onto
terminals of buffer switch (62).
(20) Pull together right engine brake wire (63) and its companion wire (64) from harness. Insert
stripped ends of each wire into electrical butt connector (65) and crimp connector to complete
splice.
(21) Pull together left engine brake wire (66) and its companion wire (67) from harness. Insert
stripped ends of each wire into electrical butt connector (68) and crimp connector to complete
splice.
6-100
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
(22) Connect high idle solenoid wire (69) to
connector (70).
(23) Push connector (71) of tachometer
sending unit (72) firmly into harness
connector (73).
(24) Connect push-on terminals (74) of two wires (75) to water temperature thermostat (76).
(25) Connect ether start plug (77) into harness socket (78).
6-101
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-14.
ENGINE
WIRING
HARNESS
REMOVAL/INSTALLATION
(CONT).
NOTE
M984E1 does not use this cushion clip.
(26) Install cushion clip (79) around engine
harness (1) and secure cushion clip to
flange of transmission (80) with
washer (81) and screw (82).
NOTE
On M984E1, power takeoff is turned around.
(27) Connect two wires (83) to power takeoff solenoid (84).
(28) Pull wire (85) from transmission lockup solenoid (86) and harness wire (87) together. Insert
stripped ends into electrical butt connector (88) and crimp connector to complete splice.
6-102
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
(29) Connect wire (89) to transmission temperature sending unit (90) with nut (91).
(30) Connect STE/ICE harness (92) and engine harness (93) at connector (94).
NOTE
M984E1 uses two cushion clips.
(31) Anchor engine harness (1) to lower right flange of transmission (80) with cushion clip (95),
washer (96), and screw (97).
c.
Follow-on Maintenance.
(1) Connect batteries (TM 9-2320-279-20).
(2) Start engine and check operation of engine components (TM 9-2320-279-20).
(3) Shut off engine (TM 9-2320-279-10).
END OF TASK
6-103
TM 9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-15.
CHASSIS
WIRING
HARNESS
REMOVAL/iNSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
References
All except M984E1
Test
None
Equipment
Equipment
None
Condition
TM or Para
Special Tools
None
Supplies
Connector, electrical, butt, Item 31,
Appendix C
Tags, identification, Item 60, Appendix C
Tape, insulation, electrical, Item 62,
Appendix C
Ties, cable, plastic, Item 65, Appendix C
Condition
Description
TM 9-2320-279-10 Shut off engine.
TM 9-2320-279-10 Air system drained.
TM 9-2320-279-20 Batteries disconnected.
TM 9-2320-279-20 Work lamps and bracket
removed (M984).
Special
Environmental
Conditions
None
General
Safety
Instructions
None
Personnel
Required
MOS 63W, Wheel vehicle repairer
Level of Maintenance
Direct
a.
Support
Removal.
NOTE
Tag and mark all wires and connectors.
(1) Remove four screws (1), lockwashers (2), nuts (3), and trailer electrical connector (4),
(2) Remove spring cover (5) from mounting bracket (6).
6-104
TM 9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
NOTE
·
Remove clamp, cushion
clips, and plastic cable ties
as necessary.
·
Cushion clips are returned
to same positions after
section of chassis harness is
removed.
(3)
Remove nut (7),
lockwasher (8), washer (9),
screw (10), and cushion
clip (11) from chassis wiring
harness (12).
NOTE
Do step (4) for wiring each
rear composite light.
(4)
Disconnect four
connectors (13).
NOTE
·
Do step (5) for M978 only.
·
Do step (5.1) for M978 only if equipped with high mount stop light.
(5) Disconnect tanker module power connector (14) at left rear of frame (15).
(5.1) Disconnect high mount stop lamp connector (15.1) from under left rear of vehicle.
Change 5
6-105
TM
9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-15.
CHASSIS
WIRING
HARNESS
NOTE
Do steps (6) through (11) for
M977 and M985 only.
(6) Disconnect 4-pin crane
power connector (16).
NOTE
Left and right clearance light
wiring harnesses are removed
the same.
(7) Pull clearance light wiring
harness (17) from under
subframe (18).
(8) Open loom (19) and cut
chassis wiring harness (12).
(9) Disconnect locking
device (20) from
connector (21).
(10) Disconnect connector (22)
from connector (21).
(11) Pull harness branch (23)
down under vehicle.
6-106
REMOVAL/INSTALLATION
(CONT).
TM
9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
NOTE
Do steps (12) through (16)
M 9 8 3 only.
(12) Disconnect clearance light
connector (24).
(13) Disconnect crane power
connector (25).
(14) Push back sleeving (26) and
loom (27). Remove
connector (28) from harness
work light branch (29) and
work light wires (30).
NOTE
Ground wire will come free when right-rear screw is removed.
(15) Remove four nuts (31), lockwashers (32), ground wire (33), and four screws (34).
(16) Remove spring cover (35) and inter-vehicular connector (36) from mounting bracket (37).
6-107
TM 9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-15.
CHASSIS
WIRING
HARNESS
REMOVAL/INSTALLATION
(CONT).
NOTE
Do steps (17) and (18) on each side of M984 only.
(17) Remove three nuts (38), lockwashers (39), screws (40), washers (41), three cushion clips (42),
and chassis wiring harness (12).
(18) Remove two screws (43), cushion clips (44), and chassis wiring harness (12).
NOTE
Ž
Ž
Chassis
wiring
harness
is
attached
to
crossmembers
on
frame.
Harness cable is removed from rear between frame and body toward engine.
(19) Remove two brake lines (45) and pull chassis wiring harness (12) between crossmember (46) and
frame (15).
6-108
TM
Electrical
System
Maintenance
Instruction
9-2320-279-34-1
(CONT)
(20) Remove nut (47), lockwasher (48), screw (49), and cushion clip (50).
NOTE
Trailer electrical connector on chassis wiring harness must be turned sideways to
fit through transfer case mount.
(21) Pull chassis wiring harness (12) through transfer case mount (51).
(22) Remove tape from speedometer cable plug (52) and disconnect wiring harness (12).
(23)
Remove nut (53), lockwasher (54), washer (55), chassis wiring harness (12) from stud (56) on
fuel level sending unit (57).
6-109
TM 9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-15.
CHASSIS
WIRING
HARNESS
REMOVAL/INSTALLATION
(CONT).
NOTE
Chassis wiring harness cable cannot move past transfer case front crossmember.
Trailer electrical connector at end of cable will not fit through clearance.
(24) Pull chassis wiring harness (12) up to crossmember (58) in front of transfer case (59).
NOTE
All cushion clips, plastic cable ties, and hardware from chassis harness must be
removed to pull chassis harness through frame.
(25) Disconnect chassis harness plug (60) from engine harness plug (61) at engine harness
connectors (62).
(26) Pull chassis wiring harness (12) through cab and frame up to engine harness connectors (62).
6-110
TM 9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
(27)
Remove two nuts (63) and chassis wiring harness (12) from towing brake pressure switch (64).
(28)
Pull back rubber boot (65) on air dryer (66).
NOTE
·
M983 with crane has three wires.
·
Do step (29.1) for M978 only if equipped with high mount stop light.
(29) Remove nut (67), two lockwashers (68), and two wires (69).
(29.1) Disconnect connector (69.1) from connector (69.2).
(30)
Remove chassis harness
connector (70) from
receptacle (71) under cab
floor (72).
Change 5
6-111
TM 9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-15.
CHASSIS
WIRING
HARNESS
REMOVAL/INSTALLATION
(CONT).
(31) Remove nut (73), lockwasher (74), screw (75), and two cushion clips (76).
(32) Pull chassis wiring harness (12) out from cab (77).
(33) Loosen lockring (78) and back shell (79) from chassis harness connector (70).
(34) Push back shell (79) and lockring (78) down chassis wiring harness (12) and pull harness from
vehicle.
6-112
TM
9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-113
TM 9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-15.
(3)
CHASSIS WIRING HARNESS REMOVAL/INSTALLATION (CONT).
Route chassis wiring harness (1) up under cab beside chassis/engine harness (7).
NOTE
Do step (4.1) for M978 only if equipped with high mount stop light.
(4) Connect chassis harness connector (6) to receptacle (8) under cab floor (9).
(4.1) Connect connector (9.1) to connector (9.2).
6-114 Change 5
TM
9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-115
TM 9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-116
TM
9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-117
TM 9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-118
TM
9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-119
TM 9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-15.
CHASSIS WIRING HARNESS REMOVAL/INSTALLATION (CONT).
NOTE
Left and right clearance light wiring
harnesses are installed the same.
(24)
(25)
(26)
Connect clearance light
wiring harness (65) with
electrical butt
connector (66).
Close loom (67) over
clearance light wiring
harness (65).
Connect 4-pin crane power
connector (68).
NOTE
·
Do step (27) for M978 only.
Do step (27.1) for M978 only if equipped with high mount stop light.
(27) Connect tanker module power connector (69) at left rear of frame (34).
(27.1) Connect high mount stop lamp connector (69.1) under left rear of vehicle.
·
6-120
Change 5
TM 9-2320-279-34-1
Electrical Systems Maintenance Instructions (Cont)
6-121
TM 9-2320-279-34-1
Electrical
System
Maintenance
(Cont)
6-15.1.
TM 9-2320-279-20
TM 9-2320-279-20
Appendix C
6-122
TM 9-2320-279-34-1
Electrical System Maintenance (Cont)
NOTE
Do steps (2) through (6) for
right and left rear clearance
light and taillight wires. Right
rear shown.
(2) Remove three screws (8),
nuts (9) lockwashers (10),
and cover (11).
(3) Disconnect clearance light
wire (12). Remove wire
from cover (11).
(4) Disconnect four taillight
wires (13).
(5) Remove clearance light
wire (12) taillight
wires (12) and
grommet (14) from
fender (15).
(6) Remove grommets (14) from wires (12 and 13).
(7) Disconnect connector (16) from high idle control box (17).
(8) Remove screws (18) and clamps (19) from rear fenders (15 and 20) and chassis wiring
harness (2 1).
(9) Pull chassis wiring harness (21) under vehicle.
6-122.1
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-15.1. CHASSIS WIRING HARNESS REMOVAL/INSTALLATION (M984E1) (CONT).
(10) Remove nut (22), two lockwashers (23), and three wires (24).
(10.1) Remove nut (24.1), lockwasher (24.21, wires (24.3 and 24.4), and screw (24.5) from right side axle
stop (24.6).
(11) Disconnect connector (25) from clearance light harness connector (26) and equipment body (27).
(12)
6-122.2
Remove tape from speedometer wire connector (28) and disconnect connector (29).
Change 3
TM
9-2320-279-34-1
Electrical System Maintenance (Cont)
6-122.3
TM 9-2320-279-34-1
Electrical
6-122.4
System
Maintenance
(Cont)
TM
Electrical
System
Maintenance
9-2320-279-34-1
(Cont)
6-122.5
TM 9-2320-279-34-1
Electrical
6-122.6
System
Maintenance
(Cont)
TM 9-2320-279-34-1
Electrical System Maintenance (Cont)
6-122.7
TM 9-2320-279-34-1
Electrical
6-122.8
System
Maintenance
(Cont)
TM
9-2320-279-34-1
Electrical System Maintenance (Cont)
6-122.9
TM 9-2320-279-34-1
Electrical
6-122.10
System
Maintenance
(Cont)
TM 9-2320-279-34-1
Electrical System Maintenance (Cont)
(18.1) Install Screw (52.1), two wires (52.2 and 52.3), lockwasher (52.4), and nut (52.5) on right side axle
(19)
(20)
(21)
(22)
(23)
(24)
stop (52.6).
Install three wires (53), two lockwashers (54), and nut (55).
Route chassis harness (1) and taillight and clearance light wires (56 and 57) up to high idle
control box (58) and rear fenders (59 and 60).
Connect connector (61) to high idle control box (58).
Install grommets (62) on taillight and clearance light wires (56 and 57).
Push taillight and clearance light wires (56 and 57) through holes in rear fenders (59 and 60).
Install grommets (62) in holes.
Install two clamps (63) and screws (64).
Change 3
6-122.11
TM 9-2320-279-34-1
Electrical System Maintenance (Cont)
6-15.1
CHASSIS WIRING HARNESS REMOVAL/INSTALLATION (M984E1) (CONT).
NOTE
Do steps (26, 27, and 28) for
both right and left rear
clearance light and taillight
wires. Right side shown.
(25) Install clearance light
connectors (65) through
grommet (66). Connect
connector (65) to wire (56).
(26) Connect four taillight
wires (57).
(27) Install cover (67)
screws (68),
lockwashers (69) and
nuts (70).
(28) Install trailer electrical
connector (71) trailer
electrical connector
cover (72) four screws (73)
three lockwashers (74), two
wires (75), two
lockwashers (76) and
four nuts (77).
c. Follow-on Maintenance.
(1) Install skid plate grille (TM 9-2320-279-20).
(2) Connect batteries (TM 9-2320-279-20).
END OF TASK
6-122.12
TM 9-2320-279-34-1
Electrical System Maintenance (Cont)
6-16.
CHASSIS/ENGINE WIRING HARNESS REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
References
All except M984E1
Test Equipment
None
Special Tools
None
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-20 Batteries disconnected.
TM 9-2320-279-20 Skid plate grille removed.
Special Environmental Conditions
None
Supplies
Tags, identification, Item 60, Appendix C
Ties, cable, plastic, Item 65, Appendix C
General Safety Instructions
Personnel Required
Level of Maintenance
MOS 63W, Wheel vehicle repairer
a.
None
None
Direct Support
Removal.
NOTE
·
Tag and mark all wires and connectors.
·
Remove clamps, cushion clips, and plastic ties as necessary.
·
Cushion clips are returned to same positions after section of chassis/engine wire
harness is removed.
·
Do step (1) for M978 only if equipped with high mount stop light.
(1) Disconnect connector (1) from connector (1.1).
(1.1) Remove two plug connectors (1.2 and 2) from receptacles (3 and 4) under cab floor (5).
Change 5
6-122.13/(6-122.14 blank)
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
6-123
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-16.
CHASSIS/ENGINE WIRING HARNESS REMOVAL/INSTALLATION (CONT).
NOTE
Three clips attach chassis/engine harness to
frame. All clips are installed to frame the
same way.
(3)
Attach chassis/engine harness (7) to frame (8)
with clip (9), screw (10), washer (11),
lockwasher (12), and nut (13).
(4)
Route chassis/engine harness (7) through
frame (8) and up under cab floor (14).
Bundle harness (15) to chassis/engine
harness with plastic cable ties along
length of harness.
NOTE
Connectors are keyed to fit proper receptacles
only.
(5)
Connect two plug connectors (16 and 17) to two
receptacles (18 and 19) under cab floor (14).
NOTE
c.
·
Install clamps, cushion clips, and
plastic ties as necessary.
·
Do step (6) for M978 only if equipped
with high mount stop light.
(6)
Connect connector (20) to connector (21).
Follow-on Maintenance.
(1)
(2)
(3)
Install skid plate grille (TM 9-2320-279-20).
Connect batteries (TM 9-2320-279-20).
Start engine, check vehicle operation
(TM 9-2320-279-10).
END OF TASK
6-124 Change 5
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
6-17.
TM 9-2320-279-20
TM 9-2320-279-20
Appendix C
Appendix C
6-125
TM 9-2320-279-34-1
Electrical
6-126
System
Maintenance
(Cont)
TM
Electrical
System
Maintenance
Instructions
9-2320-279-34-1
(Cont)
6-127
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-128
TM
9-2320-279-34-1
Electrical System Maintenance (Cont)
6-129
TM
9-2320-279-34-1
Electrical
6-130
System
Maintenance
(Cont)
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-18.
HIGH MOUNT STOP LAMP HARNESS REMOVAL/INSTALLATION (M978).
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
References
M978
None
Equipment Condition
TM or Para
Condition Description
Para 7-91
Batteries disconnected.
TM 9-2320-279-10 Pump module rear
doors opened.
Test Equipment
None
Special Tools
None
Supplies
Tags, identification, Item 48, Appendix C
Special Environmental Conditions
None
Personnel Required
General Safety Instructions
MOS 63S, Heavy wheel vehicle mechanic
a.
None
Removal.
NOTE
Tag and mark wires before disconnecting.
(1)
(2)
(3)
Remove four screws (1) and guard (2) from rear of right hand door (3).
Disconnect connector (4) from high mount stop lamp (5).
Repeat steps (1) and (2) for left hand door.
Change 5
6-131
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
6-18.
(4)
HIGH MOUNT STOP LAMP HARNESS REMOVAL/INSTALLATION
(M978) (CONT).
Disconnect high mount stop lamp wire
harness connector (6) from chassis wire
harness connector (7) under left rear of
vehicle.
NOTE
b.
·
Remove clamps, cushion clips, and
cable ties as necessary.
·
Cushion clips are returned to same
positions after section of high mount
stop lamp harness is removed.
·
Note routing of high mount stop lamp
harness to ensure proper installation.
(5)
Remove high mount stop lamp harness
(8) from vehicle.
Installation.
(1)
Position and route high mount stop lamp harness (1) as noted prior to removal.
NOTE
(2)
·
Install clamps, cushion clips, and cable ties as necessary.
·
Cushion clips are returned to same positions after section of high mount stop lamp
harness is installed.
Connect high mount stop lamp wire harness connector (2) to chassis wire harness connector (3)
under left rear of vehicle.
6-132 Change 5
TM 9-2320-279-34-1
Electrical System Maintenance Instructions (Cont)
(3)
(4)
(5)
c.
Connect connector (4) to high mount stop lamp (5) on right hand door (6).
Install guard (7) on door (6) with four screws (8).
Repeat steps (3) and (4) for left hand door.
Follow-on Maintenance.
(1)
(2)
(3)
Connect batteries (para 7-91).
Close pump module rear doors (TM 9-2320-279-10).
Check operation of high mount stop lamps.
Change 5
6-133/(6-134
blank)
Change
5
6-133
TM
9-2320-279-34-1
CHAPTER 7
TRANSMISSION MAINTENANCE
Contents
Para
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Transmission Shift Tower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Transmission Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Transmission Installation/Removal From Transmission Stand.... . . . . . . . . . . . . . . . . . . . . . 7-5
Flywheel AssemblyRemoval/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Torque Converter Stator Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Torque Converter Pump Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Torque ConverterHousingRemoval/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Transmission Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Oil Pan Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Internal Filter Element Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Gear Unit and Main Shaft Assembly Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . . . 7-13
Output Yoke, Dust Shield, and Oil Seal Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Forward Clutch AssemblyRemoval/Repair/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Rear Cover and First Clutch Assembly Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . 7-16
Fourth Clutch AssemblyRemoval/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Third Clutch and Center Support Housing Removal/Repair/Installation. . . . . . . . . . . . . . . . . 7-18
Second Clutch and Center Support Housing Removal/Repair/Installation . . . . . . . . . . . . . . . 7-19
Control Valve BodyRemoval/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Modulator Valve Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Lock up Cutoff ValveBodyRemoval/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Governor Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Section 1 .
Page
7-1
7-1
7-3
7-8
7-33
7-36
7-47
7-50
7-55
7-68
7-72
7-76
7-77
7-89
7-91
7-106
7-116
7-122
7-130
7-135
7-153
7-154
7-156
INTRODUCTION
7-1. G E N E R A L .
This chapter contains maintenance instructions for removal, installation, and repair of
the transmission at the direct support and general support maintenance levels. Subassemblies and parts
which must be removed before transmission components can be removed or repaired are referenced to
other paragraphs of this manual or TM 9-2320-279-20.
Section
Il.
SERVICE
AND
INSPECTION
Transmission Maintenance Instructions
7-2. GENERAL MAINTENANCE INSTRUCTIONS.
a. F o l l o w t h e s e m a i n t e n a n c e p r a c t i c e s w h e n w o r k i n g o n t h e t r a n s m i s s i o n .
( 1 ) Handle transmission parts and subassemblies carefully to prevent nicking, scratching, and
denting. Parts which fit together closely and must have proper operating clearance can bind if
damaged. This is very important concerning parts of the control valve body assembly (valves,
when dry, must move freely by their own weight). Parts which depend upon smooth surfaces for
sealing may leak if scratched.
( 2 ) Do not use metal tools on transmission housing when removing gaskets, packings, or seals to
avoid scratching sealing surfaces. Use pointed wooden dowel to remove packings from grooves.
Use wooden or plastic scrapers on gasket surfaces.
7-1
TM 9-2320-279-34-1
Transmission
Maintenance
Instructions
(Cont)
7-2. GENERAL MAINTENANCE INSTRUCTIONS (CONT).
b. Follow these cleaning instructions when working on the transmission.
(1) All parts must be-clean to permit effective inspection. During assembly no dirt or foreign
material can be allowed to enter the transmission. Even minute particles can cause malfunction
of close-fit parts, such as valves.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(2) All transmission metallic parts, except bearings and friction-faced clutch plates, should be
cleaned thoroughly with dry cleaning solvent or by steam cleaning method. Do not use caustic
soda solution for steam cleaning. Use only dry cleaning solvent to clean friction-faced clutch
plates.
WARNING
Compressed air used for cleaning and drying purposes will be reduced to 30 psi
(207 kPa) and used only with adequate chip guarding and personal protection
equipment, goggles, shield, and gloves.
(3) Bearings should drip and air dry, then be oiled. Other parts should be dried with compressed air.
Steam cleaned parts should be oiled immediately after drying to prevent rust.
(4) Clean oil passages by working a piece of soft wire back and forth through the passages and
flushing with dry cleaning solvent. Dry passages with compressed air.
(5) Examine parts, especially oil passages, after cleaning to make certain they are entirely clean.
Reclean parts if necessary.
c. Follow these inspection instructions when working on the transmission.
(1) Inspect surfaces in contact with gaskets, packings, or seals for nicks, burrs, or scratches. Remove
any defect before assembly.
(2) Before inspection, oil bearings lightly with same type of oil used in transmission to prevent
damage to bearings.
(3) Inspect bores for wear, scratches, grooves, burrs, and dirt. Remove scratches, grooves, and burrs
with crocus cloth. Remove foreign matter. Replace deeply scratched or grooved parts.
(4) Inspect housings and other cast parts for cracks.
(5) Inspect machined surfaces for damage that could cause oil leakage or other malfunction. Correct
damage with crocus cloth, if possible, or replace defective parts.
(6) Inspect gears for scuffed, nicked, burred, worn, or broken teeth. If defect cannot be removed
with soft stone, replace gear.
(7) Inspect thrust face of gears for scoring, scratches, and burrs. Remove defects with soft stone. If
scratches and scoring cannot be removed with soft stone, replace gear.
(8) Inspect splined parts for stripped, twisted, chipped, or burred splines. Remove burrs with soft
stone. Replace part if other defects are found. Spline wear is not considered defective except
where it affects tightness of an assembly such as driveline flanges.
(9) Inspect retaining rings for nicks, distortion, and looseness. Retaining ring must snap tight in
groove for proper functioning. Replace retaining ring if any defects are found.
(10) Inspect springs for signs of overheating, permanent set, or wear due to rubbing adjacent parts.
Replace spring if any of these defects are found.
(11) Inspect friction clutch plates (internal-splined plates) for burrs, embedded metal particles,
severely pitted faces, loose facings, excessive wear, cracks, distortion, and damaged spline teeth.
Remove burrs using soft stone. Replace clutch plates which have other defects.
(12) Inspect steel clutch plates (external-tanged plates) for burrs, scoring, excessive wear, distortion,
embedded metal, galling, cracks, breaks, and damaged tangs. Remove burrs and minor surface
defects using soft stone. Replace clutch plates which have other defects.
7-2
TM 9-2320-279-34-1
Transmission
Maintenance
Instructions
(Cont)
Section III.
7-3.
TM 9-2320-279-10
TM 9-2320-279-20
TM 9-2320-279-20
7-3
TM 9-2320-279-34-1
Transmission
7-4
Maintenance
Instructions
(Cont)
TM
Transmission
M a i n t e n a n c e Instructions
9-2320-279-34-1
(Cont)
7-5
TM 9-2320-279-34-1
Transmission
7-6
Maintenance
Instructions
(Cont)
TM 9-2320-279-34-1.
Transmission Maintenance Instructions (Cont)
(8) Install angle bracket (15) with two screws (16)
and nuts (17).
(9) Install switch (18) with screw (19),
washer (20), spacer (21), washer (22),
and nut (23).
(10) Install washer (24) and cotter pin (25).
d. Follow-on Maintenance.
(1) Install shift control (TM 9-2320-279-20).
(2) Install shift cable (TM 9-2320-279-20).
(3) Adjust neutral safety switch (TM 9-2320-27420).
END OF TASK
7-7
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
Section IV. TRANSMISSION ASSEMBLY
7-4. TRANSMISSION REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Antifreeze, permanent, glycol, inhibited,
Item 10, Appendix C.
Compound, sealing, thread locking,
Item 26, Appendix C.
Compound, sealing, pipe thread, Item 29,
Appendix C
Oil, lubricating, Item 47, Appendix C
Tags, identification, Item 60, Appendix C
Wood block, 4x6x40 in. (102x152x1016 mm),
Item 69, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
None
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-10 Transmission and transfer
case set to Neutral.
TM 9-2320-279-20 Batteries disconnected.
TM 9-2320-279-10 Spare tire removed.
TM 9-2320-279-10 Engine side panels
removed.
TM 9-2320-279-20 Engine cover removed.
7-8
Change 3
Equipment Condition (cont)
TM or Para
Condition Description
TM 9-2320-279-20 Cargo body front panel
removed (M977, M985).
Para 15-9
Cargo body floor panel
removed (M977, M985).
TM 9-2320-279-20 Fuel can stowage box
removed (M978).
TM 9-2320-279-20 30 KW generator removed
(M983).
TM 9-2320-279-20 Rear decking removed
(M983 without crane).
Para 15-6
Cargo body removed
(M984).
TM 9-2320-279-20 Right and left rear splash
guards removed.
TM 9-2320-279-20 Hydraulic reservoir drained.
TM 9-2320-279-20 Transmission fluid drained.
TM 9-2320-279-20 Air system drained.
TM 9-2320-279-20 Coolant system lowered.
Para 13-6
Lift bracket assemblies
removed.
Special Environmental Conditions
None
General Safety Instructions
Wheels chocked.
Level of Maintenance
Direct Support.
TM 9-2320-279-34-1
Transmission
Maintenance
Instructions
(Cont)
7-9
TM 9-2320-279-34-1
Transmission
7-10
Maintenance
Instructions
(Cont)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
NOTE
Go to step (22) when removing transmission on M984E1.
(18)
(19)
Disconnect hose (34) from fitting (35).
Remove four screws (36), lockwashers (37), and two clamp halves (38), and move fitting (39) with
preformed packing (39.1) aside.
NOTE
Trucks with guard, perform step (19.1). Trucks without guard, proceed to step (21).
(19.1) Loosen two screws (39.2) and remove guard (39.3).
(20) Deleted.
(21) Remove four screws (42), lockwashers (43), two clamp halves (44), hose (45), and preformed
packing (45.1).
Change 3
7-10.1/(7-10.2 blank)
TM
Transmission
Maintenance
Instructions
9-2320-279-34-1
(Cont)
7-11
TM 9-2320-279-34-1
Transmission
7-12
Maintenance
Instructions ( C o n t )
TM
9-2320-279-34-1
Transmission Maintenance Instructions ( C o n t )
7-13
TM 9-2320-279-34-1
Transmission
7-14
Maintenance
Instructions
(Cont)
TM
Transmission
Maintenance
Instructions
9-2320-279-34-1
(Cont)
7-15
TM 9-2320-279-34-1
Transmission
7-16
Maintenance
Instructions
(Cont)
TM
Transmission
Maintenance
Instructions
9-2320-279-34-1
(Cont)
7-17
TM 9-2320-279-34-1
Transmission
7-18
Maintenance
Instructions
(Cont)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
NOTE
Left and right side mounting
brackets are removed the same.
Left side is shown.
Tag and mark mounting brackets.
(59) Remove six screws (122),
lockwashers (123), and transmission
mount (109).
NOTE
Skip steps (61) through (64) for M984E1.
(60) Remove five nuts (124) and washers (125) from base of FY10 (126).
(61) Remove screw (127).
(62) Remove PTO (126) and hydraulic pump (128) from transmission (120).
CAUTlON
Access hole must be covered to prevent dust and dirt from entering transmission
and causing damage to equipment.
(63) Remove gasket (129) from transmission (120). Cover transmission access hole (130).
NOTE
All components removed in this procedure must be installed on replacement (new)
transmission.
Refer to paragraph 23-9 if transmission is to be prepared for storage.
7-19
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-4. TRANSMISSION REMOVAL/INSTALLATION (CONT).
b. Installation
(1)
(2)
(3)
NOTE
Refer to paragraph 23-9 if transmission
must be unpacked from container.
Install fittings, sending units, and plugs
from old transmission on new
transmission.
Skip steps (1) through (3) when
installing transmission on M984E1.
Uncover access hole before doing
step (1).
Install gasket (1) on transmission access
hole (2).
Install hydraulic pump (3) and PTO (4)
on transmission (5) with five nuts (6),
washers (7), and screw (8).
Tighten nuts (6) and screw (8) to 30 to 35 lb-ft (41 to 48 N•m).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(3.1) Apply thread locking sealing compound to
threads of six screws (11).
NOTE
Left and right mounting brackets are installed
the same. Left side is shown.
(4)
Install transmission mount (9) with six
lockwashers (10) and screws (11). Tighten
screws to 130 to 140 lb-ft (176 to 190 N•m).
WARNING
Keep out from under heavy parts. Falling parts may
cause serious injury or death.
(5)
7-20
Hook one chain of lifting device to
transmission yoke (12) and chains to left
and right transmission mounts (9 and
13).
Change 3
TM
Transmission
Maintenance
Instructions
9-2320-279-34-1
(Cont)
7-21
TM 9-2320-279-34-1
Transmission
7-22
Maintenance
Instructions
(Cont)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(12)
Install gasket (19) and access cover (18) with two screws (17).
NOTE
Do steps (13) and (14) until 12 screws are installed.
(13)
(14)
(15)
(16)
Soldier A looks in access hole (20) while Soldier B turns pulley nut (22) clockwise.
When screw hole is centered, Soldier A tells Soldier B to stop turning pulley nut (22) and Soldier
A instaIls remaining 11 converter screws (21). Do not tighten.
Tighten 12 screws (21) to 105 to 115 lb-ft (142 to 156 N•m).
Apply pipe thread sealing compound to plug (23) and install plug (23).
Change 3
7-23
TM 9-2320-279-34-1
Transmission Maintenonce Instructions (Cont)
7-4. TRANSMISSION REMOVAL/INSTALLATION (CONT).
(17) Connect hose (24) to elbow (25).
(18) Remove chains from
transmission (5) and attach
to engine lifting eyes (26).
(19) Soldier A installs three mounting
biscuits (27) between transmission
mount (9) and bracket (28) on each
side of transmission (5) while
Soldier B operates suitable lifting
device.
7-24
TM
Transmission
Maintenance
Instructions
9-2320-279-34-1
(Cont)
7-25
TM 9-2320-279-34-1
Transmission
7-26
Maintenance
Instructions
(Cont)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(28)
(29)
(30)
(31)
(32)
(33)
Position shift cable (40) on transmission oil pan (41).
Install shift lever (42) with nut (43).
Install clamp (44) with two screws (45) and nuts (46).
Install dipstick tube (47) with fitting (48). Tighten fitting to 90 to 100 lb-ft (122 to 136 N•m).
Connect plug (49).
Connect three hoses (50, 51, and 52).
Change 3
7-27
TM 9-2320-279-34-1
Transmission Mointenonce Instructions (Cont)
17-4. TRANSMISSION REMOVAL/INSTALLATION (CONT).
M984E1 has one hose on bracket.
(34) Connect bracket (53) with screw (54) and locknut (55).
(35) Connect hose (56) to modulator valve (57).
(36) Install insulating washer (58), washer (59), wire (60), and lockwasher (61) with nut (62) on
transmission temperature sending unit (63).
7-28
TM
Transmission
Maintenance
Instructions
9-2320-279-34-1
(Cont)
7-29
TM 9-2320-279-34-1
Transmission
7-30
Maintenance
Instructions
(Cont)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(47) Deleted.
(48) Install fitting (86), preformed packing (86.1), two clamp halves (87), four lockwashers (88), and
screws (89).
NOTE
Trucks with guard, perform step (48.1). Trucks without guard, proceed to step (50).
Ensure guard is fully seated under flat washers.
(48.1) Install guard (89.1) under two flat washers (89.2) with two lockwashers (89.3) and screws (89.4).
(49) Deleted:
NOTE
DO steps (50) through (59) for M984E1.
(50)
(51)
(52)
(53)
(54)
(55)
(56)
Connect hose (92) to fitting (93) on
heavy-duty winch manifold valve (94).
Connect two hoses (95) to fittings (96)
on heavy-duty winch manifold
valve (94).
Connect two hoses (97) to fittings (98)
on heavy-duty winch manifold
valve (94).
Connect hose (99) to fitting (100).
Remove valve (101).
Connect hose (102) to fitting (103) on
heavy-duty winch manifold valve (94).
Install valve (101).
Change 3
7-31
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-4. TRANSMISSION REMOVAL/lNSTALLATlON (CONT).
(57) Connect hose (104) to fitting (105).
(58) Connect hose (106) to fitting (107) on pump (108).
(59) Connect hose (109) to fitting (110).
(60) Install lockwasher (111) on cross brace (112).
(61) Install one end of cross brace (112) with two screws (113), lockwashers (114), and nuts (115).
(62) Install lockwasher (116) and nut (117).
7-32
TM
Transmission
Maintenance
Instructions
9-2320-279-34-1
(Cont)
7-32.1/(7-32.2 blank)
TM
Transmission
Maintenance
Instructions
9-2320-279-34-1
(Cont)
7-33
TM 9-2320-279-34-1
Transmission
7-34
Maintenance
Instructions
(Cont)
TM 9-2320-279-34-1
Transmission
Maintenance
Instructions
(Cont)
7-35
TM 9-2320-279-34-1
Transmission
Maintenance
Instructions
7-6.
Para 7-4
Appendix C
Appendix C
7-36
(Cont)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(3) Aline and install lifting bracket with two screws (4) and washers (5).
(4) Remove two screws (6) from access cover (7).
(5) Remove access cover (7) and gasket (8).
NOTE
Use flywheel lifting bracket to turn flywheel for access
to screws inside converter housing.
(6) Remove 29 of 30 screws (9) and washers (10). Leave
one screw in place behind lifting bracket.
(7) Install lifting device to lifting bracket.
(8) Raise lifting device until it supports
weight of flywheel (3).
7-37
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-6. FLYWHEEL ASSEMBLY REMOVAL/REPAlR/INSTALLATION (CONT).
(9)
Remove the remaining screw (9) and
washer (10) from flywheel (3).
CAUTION
When flywheel is removed from converter
housing, torque converter turbine may come
off with flywheel, stay with converter
housing, or be in a position to fall. Take care
to prevent torque converter turbine from
falling and becoming damaged.
(10)
(11)
(12)
7-38
Soldier A removes flywheel (3) with
torque converter turbine (11) from
converter pump (12) while Soldier B
operates lifting device.
Soldier A moves flywheel (3) with
torque converter turbine (11) to work
surface while Soldier B operates lifting
device. Soldier B removes lifting
device.
Remove converter seal ring (13) and
turbine shaft seal ring (14).
Change 3
TM
Transmission
Maintenance
Instructions
9-2320-279-34-1
(Cont)
7-39
TM
9-2320-279-34-1
Transmission
7-40
Maintenance
Instructions
(Cont)
TM
Transmission
Maintenance
Instructions
9-2320-279-34-1
(Cont)
7-41
TM
9-2320-279-34-1
Transmission
7-42
Maintenance
Instructions
(Cont)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(6)
(7)
(8)
(9)
(10)
Apply lubricating oil to outer groove of
piston (5).
Apply lubricating oil to seal ring (6) and
install.
Apply lubricating oil to inner hub (7) of
piston (5) and to piston seal surface (8)
of flywheel (9).
Aline six holes (10) with six pins (11).
Install piston (5) on hub (3). Make sure
piston is firmly seated on pins (11).
NOTE
Some transmissions will have two keys.
(11)
Install key (12) in slot (13).
Change 3
7-43
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-6. FLYWHEEL ASSEMBLY REMOVAL/REPAIR/INSTALLATION (CONT).
(12)
Soak lockup clutch plate (14) in
lubricating oil for 3 minutes and
install.
NOTE
On transmission prior to Serial No. 83229,
the old style flywheel and backplate were
used. If either flywheel or backplate are to be
replaced, they must be replaced with the new
two keyed flywheel and backplate.
(13)
Aline notch (15) with key (12) and
install backplate (16) flat side first in
flywheel (9).
NOTE
Gear on torque converter turbine must be
lined up with teeth of lockup clutch plate
before installation.
(14)
7-44
Install torque converter turbine (17) on
flywheel (9).
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
e.
Installation.
(1) Install lifting bracket with two screws (1)
and washers (2).
(2) Coat turbine shaft seal ring (3) and converter seal
ring (4) with lubricating oil.
(3) Install turbine shaft seal ring (3) in groove and snap
ends together.
(4) Install converter seal ring (4) on torque converter
pump (5).
(5) Coat torque converter thrust pads (6) with lubricating
oil.
(6) Soldier A alines and installs flywheel (7) so flywheel
fits flush against torque converter pump (5) while
Soldier B operates lifting device.
7-45
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-6. FLYWHEEL ASSEMBLY REMOVAL/REPAIR/INSTALLATION (CONT).
(7)
(8)
Install one screw (8) and washer (9)
through hole (10) in flywheel (7).
Tighten screw until snug.
Remove lifting device from lifting
bracket.
NOTE
Lifting bracket is used to turn flywheel for
access to screw holes inside converter
housing.
(9)
(10)
Install 29 screws (8) and washers (9)
through holes (10) in flywheel (7).
Tighten screws until snug.
Tighten 30 screws (8) to 41 to 49 lb-ft (56 to 66 N•m).
(11) Remove two screws (1) and washers (2).
(12) Remove lifting bracket.
(13) Install gasket (11) and access cover (12).
(14) Install two screws (13).
(15) Tighten two screws (13) to 26 to 32 lb-ft (35 to 43 N•m).
f.
Follow-on Maintenance. Remove transmission from transmission stand (para 7-5).
END OF TASK
7-46
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-7. TORQUE CONVERTER STATOR REMOVAL/REPAIR/INSTALLATION.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Conditions
Condition Description
TM or Para
Transmission installed
Para 7-5
on transmission stand.
Flywheel assembly
Para 7-6
removed.
Special TOOls
Stator roller holder J24218-2
Supplies
Oil, lubricating, Item 46, Appendix C
Solvent, drycleaning, Item 57, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
NOTE
Twist stator counterclockwise and
away from torque converter pump
when removing stator from shaft.
Bearings and springs may fall out
when stator is removed.
a.
Removal. Remove stator (1) from shaft (2).
b. Disassembly.
(1) Hold rim of stator (1) on work surface.
(2) Turning roller race (2) clockwise, slowly
remove roller race from stator (1).
(3) Remove roller bearing (3) and thrust
bearing race (4) from stator (1).
NOTE
Note orientation of springs prior to removal
from stator.
(4)
Remove 10 rollers (5) and 10 roller
springs (6) from stator (1).
Change 3
7-47
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-7. TORQUE CONVERTER STATOR REMOVAL/REPAlR/INSTALLATION (CONT).
C.
Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1)
Clean all parts in drycleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment, goggles,
shield, and gloves.
(2)
(3)
(4)
Use clean lint free cloth or compressed air to dry parts cleaned with drycleaning solvent.
Inspect parts for damage. Replace damaged parts.
Coat all parts with lubricating oil.
d. Assembly.
(1)
(2)
(3)
Position stator (1) on work surface, rear
side upward.
Install thrust bearing race (2) in
stator (1).
Install stator roller holder
against thrust bearing race
(2) so string of stator roller
holder hangs out bottom of
stator (1).
CAUTION
Roller springs must be installed as
shown in illustration. On later
models install the spring with bends
against stator thrust washers (Style
A). The ends of the spring can be up
or down against the roller. Earlier
models require the end of the spring
to be against the roller with bends
toward the freewheel roller race
(Style B).
(4)
7-48
Install 10 roller springs (3)
and rollers (4) in stator cam
pockets (5).
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(5) Install roller bearing (6) on roller race (7).
(6) Install roller race (7) in stator (1) until roller bearing (6) is near stator roller holder.
(7) Remove stator roller holder by pulling on attached string.
(8) Push roller race (7) inward while turning roller race clockwise until roller bearing (6) seats.
(9) Position stator (1) with roller race (7) up.
(10) Turn roller race (7) counterclockwise to lock in place.
e. Installation.
CAUTION
Keep outer face of stator down so bearings and springs
will not fall out.
(1) Hold stator (1) with thrust pads (2) away from
transmission (3).
CAUTION
Stator must turn freely in clockwise direction and lock up
in counterclockwise direction to operate properly and
prevent damage to equipment.
(2) Install stator (1) on shaft (4).
f. Follow-on Maintenance. Install flywheel assembly (para 7-6).
END OF TASK
7-49
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-8. TORQUE CONVERTER PUMP REMOVAL/REPAIR/INSTALLATION
This task covers:
a. Removal
b. Disassembly
c. Cleaniing/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
TM or Para
Condition Description
Pat-a 7-7
Torque converter stator
removed from torque
converter housing.
Special Tools
Rear bearing installer J24447
Driver handle J24202-4
Supplies
Oil. lubricating, Item 46, Appendix C
Solvent, drycleaning, Item 57, Appendix C
Personnel Required
MOS 63W. Wheel vehicle repairer
a.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
Removal.
(1)
Turn transmission so torque converter housing (1) faces up.
CAUTION
(2)
(3)
7-50
Do not scrape the ground sleeve during removal.
Remove retaining ring (2) from ground sleeve (3).
Remove Spacer (4).
Change 3
TM
9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-51
TM 9-2320-279-34-1
7 - 5 2
Change
2
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
NOTE
Check that three parts of bearing have same
serial number.
(2)
(3)
Install inner race (3) on hub (2).
Install pump (4) on hub (2).
CAUTION
Bearing must be kept clean during
installation. Keep bearing wrapped until
bearing is installed. Set bearing on clean,
lint-free paper and never on dirty surface.
(4)
(5)
(6)
Install bearing (5) in inner race (3).
Install outer race (6) over bearing (5).
Position bearing retainer (7) shoulder
side up on hub (2).
(7)
Install one screw (9) and lockstrip (8) at
12 o’clock position. Do not tighten bolt.
Install three more screws (9) and
lockstrips (8) at 3, 6, and 9 o’clock
positions.
Snug screws in sequence (12, 6, 3, and 9
o’clock).
(8)
(9)
CAUTION
Failure to tighten screws using sequential
tightening procedures may lead to premature
bearing failure.
(10)
(11)
(12)
e.
Tighten screws (9) to 33 to 40 lb-ft (45
to 54 N•m) in sequence (12, 6, 3, and 9
o’clock).
Install the remaining eight screws (9)
and two lockstrips (8). Tighten
screws (9) and lockstrips (8) to 33 to 40
lb-ft (45 to 54 N•m).
Bend corners of lockstrips (8) against
head of screws (9).
Installation.
NOTE
Keep seal ring sealed in package until ready
to use so seal ring does not change shape.
(1) Roll seal ring (1) to one-half length and
hold for at least 10 seconds.
(2) Install seal ring (1) in groove (2).
Change 3
7-53
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-8. TORQUE CONVERTER PUMP REMOVAL/REPAIR/INSTALLATION (CONT).
(3) Install pump (3) in torque converter
housing (4).
(4) Install bearing installer tool around
ground sleeve (5) and on bearing (6).
(5) Place bearing installer tool handle over bearing
installer tool.
(6) Drive bearing (6) down until seated.
(7) Remove bearing installer tool.
7-54
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(8) Install spacer (7) over ground sleeve (5) on pump (3).
(9) Install retaining ring (8) on ground sleeve (5).
(10) Coat pump hub (3) and hub area (9) with lubricating
oil.
f . follow-on Maintenance. Install torque converter stator into torque converter housing (para 7-7).
END OF TASK
7-9. TORQUE CONVERTER HOUSING REMOVAL/REPAlR/lNSTALLATION.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
Test Equipment
None
References
None
Special Tools
Pitot tube guide screws (2) J6889-1
Front support needle bearing installer J24197
Equipment Condition
TM or Para
Para 7-8
Fabricated Tools
Lifting eyes, Item 1, Appendix B
Supplies
Oil, lubricating, Item 46, Appendix C
Adhesive-sealant, silicone, Item 6, Appendix C
Solvent, dry cleaning, Item 57, Appendix C
Tags, identification, Item 60, Appendix C
Condition Description
Torque converter pump
removed from torque
converter housing.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
7-55
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-9. TORQUE CONVERTER HOUSING REMOVAL/REPAIR/INSTALLATlON (CONT).
a.
Removal.
(1)
(2)
Remove two screws (1) and washers (2)
from inside torque converter
housing (3).
Remove seven screws (4) and
lockwashers (5) from inside torque
converter housing (3).
NOTE
Two screws and lockwashers were removed
from torque converter housing during
installation of holding fixtures. Seven screws
and lockwashers remain to hold torque
converter housing on transmission housing.
(3)
(4)
(5)
(6)
(7)
(8)
7-56
Remove seven screws (6) and
lockwashers (7) holding torque
converter housing (3) to transmission
housing (8).
Install two lifting eyes on torque
converter housing (3).
Install lifting device to lifting eyes.
Soldier A removes torque
converter housing (3)
while Soldier B operates
lifting device.
Remove bearing race (9),
roller bearing (10), and
bearing race (11).
Remove pitot collector (12).
Change 3
TM
9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
CAUTION
7-57
TM
9-2320-279-34-1
Transmission
Maintenance
7-9.
7-58
Instructions
(Cont)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
WARNING
Parts are under spring tension. Release tension
slowly to prevent personal injury.
(11) Soldier A removes retaining ring (13) while
Soldier B pushes support assembly (14).
NOTE
Tag and mark all parts.
(12) Remove support assembly (14), valve seat (15),
converter bypass valve (16) and spring (17).
(13) Soldier A removes retaining ring (18) while
Soldier B pushes retainer washer (19).
NOTE
Tag and mark all parts.
(14) Remove retainer washer (19), valve stop (20),
valve spring (21), and lockup shift valve (22).
(15) Soldier A removes retaining ring (23) while
Soldier B pushes retainer washer (24).
NOTE
Tag and mark all parts.
(16) Remove retainer washer (24) valve stop (25), main
pressure regulator valve spring (26), and main
pressure regulator valve (27).
(17) Remove 15 screws (28) holding front support
assembly (3) to torque converter housing (1).
(18) Remove three screws (29).
(19) Remove screw (30).
7-59
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-9. TORQUE CONVERTER HOUSING REMOVAL/REPAlR/INSTALLATlON (CONT).
(20)
(21)
(22)
Soldier A and Soldier B position and
hold torque converter housing (1) on
rim.
Soldier A and Soldier B remove front
support assembly (3).
Remove gasket (31) from torque
converter housing (1).
Remove bearing (32) from ground
sleeve bore (33).
Cleaning/Inspection.
WARNING
(23)
c.
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors,
and are harmful to skin and clothing. To
avoid injury or death, keep away from open
fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets
on skin or clothing, wash immediately with
soap and water.
(1) Clean all metallic parts with
drycleaning solvent and inspect for
damage. If there is damage, replace
parts.
(2) Converter bypass valve spring, lockup
shift valve spring, and main pressure
regulator valve spring must be replaced
if load-height specifications, listed in
Table 7-1, are not met.
Table 7-1. Valve Spring Load-Height Specifications
7-60
Spring
Length Without Load
Length Under Load
Load
Converter
bypass valve
2.65 in.
(67.3 mm)
1.62 in.
(41.2 mm)
21.1 to 23.3 lb
(93.9 to 103.6 N•m)
Lockup shift
valve
3.22 in.
(81.8 mm)
1.8 in.
(45.7 mm)
22.10 to 23.50 lb
(98.3 to 104.5 N•m)
Main regulator
valve
3.94 in.
(100.1 mm)
2.64 in.
(67.1 mm)
82.4 to 86.6 lb
(366.5 to 385.2 N•m)
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
d. Assembly.
(1)
Install bearing (1) in ground sleeve
bore (2) using bearing installer.
(2)
Set torque converter housing (3) on
wooden blocks.
Install gasket (4) on torque converter
housing (3).
Aline holes and install front support
assembly (5).
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Install three screws (6) across front
support assembly (5).
Install 15 screws (7) around outer edge
of front support assembly (5).
Install screw (8).
Tighten three screws (6), 15 screws (7),
and screw (8) to 36 to 43 lb-ft (49 to
58 N•m).
Install main pressure regulator
valve (9) small end first.
Install main pressure regulator valve
spring (10) and valve stop (11).
Install retainer washer (12) on main
pressure regulator valve spring (10).
Soldier A installs retaining ring (13)
while Soldier B pushes retainer
washer (12).
Change 3
7-61
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-9. TORQUE CONVERTER HOUSING REMOVAL/REPAIR/INSTALlLATlON (CONT).
(13)
(14)
(15)
(16)
Install lockup shift valve (14) small end first.
Install valve spring (15) and valve stop (16).
Install retainer washer (17) on valve spring (15).
Soldier A installs retaining ring (18) while Soldier
pushes retainer washer (17).
(17) Install spring (19), converter bypass valve (20)
valve seat (21) and support assembly (22).
(18) Soldier A installs retaining ring (23) while Soldier
pushes against support assembly (22).
(19) Install bearing (24) in driven gear (25).
(20) Install driven gear (25) on shaft (26).
(21) Install drive gear (27) in oil pump (28).
7-62
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(22) Install backplate (29).
(23) Install screw (30). Tighten screw to 9 to 11 lb-ft (12 to 15 N•m).
(24)
(25)
(26)
Check clearance between backplate (29), drive gear (27), and driven gear (25). Maximum
clearance is 0.006 in. (0.15 mm).
Turn oil pump (28) over.
Apply lubricating oil to rubber lip of oil
seal (31) and install oil seal in oil
pump (28).
Change 3
7-63
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-9. TORQUE CONVERTER HOUSING REMOVAL/REPAIR/INSTALLATION (CONT).
7-64
(27)
Coat outer seal ring (32) with lubricating oil and install outer seal ring in groove (33) on oil
pump (28).
(28)
(29)
(30)
(31)
(32)
Turn torque converter housing (3) on side.
Aline screw holes in oil pump (28) with holes in torque converter housing (3).
Soldier A installs oil pump (28) while Soldier B holds torque converter housing (3).
Soldier A installs six screws (34) through front support (5) while Soldier B holds oil pump (28).
Tighten six screws (34) to 26 to 32 lb-ft (35 to 43 N•m).
Change 3
TM
9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
CAUTION
7-65
TM
9-2320-279-34-1
Transmission
Maintenance
7-9.
7-66
Instructions
(Cont)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(10)
Soldier A alines two pitot tube guide
screws with two small holes in torque
converter housing (11) while Soldier B
operates lifting device.
CAUTION
Take care not to damage pitot tube and
collector ring when installing converter
housing.
(11)
(12)
Install torque converter housing (11)
on transmission housing (12).
Remove lifting device and lifting eyes.
NOTE
Move pitot tube guide screws up and down to
check that pitot tube is free.
(13)
Install seven screws (13) and
lockwashers (14). Tighten screws to 67
to 80 lb-ft (90 to 108 N•m).
WARNING
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors,
and are harmful to skin and clothing. To
avoid injury or death, keep away from open
fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets
on skin or clothing, wash immediately with
soap and water.
(14)
(15)
(16)
(17)
Apply small amount of silicone
adhesive-sealant to two screws (15) and
washers (16).
Remove one pitot tube guide screw and
install screw (15) and washer (16).
Remove other pitot tube guide screw
and install screw (15) and washer (16).
Tighten screws (15) to 30 to 48 lb-in.
(266 to 425 N•m).
Change 3
7-67
TM 9-2320-279-34-1
Transmission Maintenance Instructions (cont)
7-9. TORQUE CONVERTER HOUSING REMOVAL/REPAIR/INSTALLATION (CONT).
NOTE
Nine screws and lockwashers are used to install
torque converter housing on transmission housing.
Two screws and lockwashers must be installed after
lifting eyes are removed.
(18)
Install seven screws (17) and lockwashers
(18) to hold torque converter housing (11) to
transmission housing (12). Tighten screws
to 67 to 80 lb-ft (91 to 108 NSm).
f. Follow- on Maintenance. Install torque converter
pump in torque converter housing (para 7-8).
END OF TASK
7-10.
TRANSMISSION HOUSING REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Manual shaft oil seal installer J26282
Manual shaft oil seal remover J26401
Supplies
Solvent, drycleaning, Item 57, Appendix C
Compound, sealing, lubricating,
Item 25, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
7-68
Change 5
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-20 Transmission breather
removed.
TM 9-2320-279-20 Neutral safety switch
removed.
Para 7-16
Rear cover and first
clutch assembly
removed.
Para 7-13
Gear unit and main
shaft assembly
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
a.
Disassembly.
(1)
(2)
Remove nut (1) from manual shaft (2).
Remove selector lever (3) from manual
shaft (2).
(3)
(4)
(5)
Remove cotter pin (4).
Remove locknut (5).
Hold detent lever (6) with one hand and
remove manual shaft (2) by pulling
shaft through oil seal (7).
Remove detent lever (6) from
transmission housing (8).
(6)
(7)
(8)
Remove oil seal (7) using manual shaft
oil seal remover.
Remove governor pressure tap plug (9).
Change 5
7-69
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-10. TRANSMISSION HOUSING REPAIR (CONT).
(9) Remove fourth clutch pressure tap plug (10).
(10) Remove reverse signal switch plug (11).
(11) Remove five studs (12).
b. Cleaning/Inspection.
WARNlNG
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. ‘lb avoid injury or
death, keep away from open fire and use in
well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash
immediately with soap and water.
(1) Clean transmission housing and all metal parts with dry cleaning solvent.
(2) Inspect parts for damage. Replace damaged parts.
(3) If signs of damage to transmission housing are noted, replace transmission housing.
c. Assembly.
(1) Install five studs (1).
7-70
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(2)
(3)
Install reverse signal switch plug (2).
Install fourth clutch pressure tap
plug (3).
(4)
Install governor pressure tap plug (4).
WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. To avoid injury or
death, keep away from open fire and use in
well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash
immediately with soap and water.
(5)
Coat outside of oil seal (5) with sealing
and lubricating compound and install
oil seal in transmission housing (6)
using manual shaft oil seal installer.
(6)
Position detent lever (7) in transmission
housing (6) with selector pin pointing to
inside of housing.
Install manual shaft (8) by pushing
shaft through oil seal (5) in
transmission housing (6) and slot in
detent lever (7).
Install locknut (9) on manual shaft (8).
Tighten locknut (9) to 15 to 20 lb-ft (20
to 27 NSm).
Install cotter pin (10).
(7)
(8)
(9)
(10)
Change 5
7-71
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-10. TRANSMISSION HOUSING REPAIR (CONT.).
(11)
(12)
Install selector lever (11) on manual shaft (7).
Install nut (12) on manual shaft (7).
d. Follow-on Maintenance.
(1)
Install gear unit and main shaft
assembly (para 7-13).
(2) Install rear cover and first clutch
assembly (para 7-16).
(3) Install transmission breather
(TM 9-2320-279-20).
(4) Install neutral safety switch
(TM 9-2320-279-20).
END OF TASK
Section V. OIL PAN AND INTERNAL FILTER
7-11. OIL PAN REMOVAL/INSTALLATION.
This task covers:
a. Disassembly
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
TM or Para
Condition Description
LO 9-2320-279-12 Transmission oil
drained.
Para 7-4
Transmission dipstick
tube removed.
TM 9-2320-279-20 Transmission shift cable
removed.
Special Tools
None
Supplies
Compound, sealing, pipe thread,
Item 29, Appendix C
Grease, automotive and artillery,
Item 34, Appendix C
Special Environmental Conditions
None
Personnel Required
MOS 63W, Wheel vehicle repairer
General Safety Instructions
None
Level of Maintenance
Direct Support
7-72
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
a. Removal.
(1) Remove two screws (1), lockwashers (1.1), bracket (2), and two spacers (3).
NOTE
Support oil pan while removing screws.
(2) Remove remaining 21 screws (4) holding oil pan (5) to transmission (6).
(3) Remove oil pan (5) from transmission (6).
(4) Remove gasket (7) from oil pan (5).
Change 2
7-73
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-11. OIL PAN REMOVAL/INSTALLATION (CONT).
(5) Remove plug (8).
(6) Remove plug (9).
(7) Remove plug (10) and washer (11).
b. Installation.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep
away from open fire and use in well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash immediately with soap and
water.
(1)
(2)
(3)
(4)
(5)
7-74
Lightly coat threads of plugs (1, 2, and 3) with pipe thread sealing compound.
Install plug (1) in oil pan (4).
Install plug (2).
Install plug (3) and washer (5). Torque plug (3) to 15 to 20 lb-ft (20 to 27 N•m).
Apply grease to lip of oil pan (4) and install gasket (6).
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(6)
(7)
Install oil pan (4) on transmission (7) with 21 screws (8). Do not tighten screws.
Install two spacers (9), bracket (10), two lockwashers (10.1), and two screws (11) on oil pan (4)
Do not tighten screws.
NOTE
Oil pan has to be drawn evenly to transmission.
(8)
(9)
C.
Alternately tighten each screw (8 and 11), 180° apart in a crisscross pattern, to 10 lb-ft (14 N•m).
Tighten each screw (8 and 11) again, using same pattern, to 17 to 20 lb-ft (23 to 27 N•m).
Follow-on Maintenance.
(1)
(2)
(3)
(4)
Install transmission dipstick (para 7-4).
Install shift cable (TM 9-2320-279-20).
Fill transmission with oil (LO 9-2320-279-12).
Check for leaks.
END OF TASK
Change 3
7-75
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-12. INTERNAL FILTER ELEMENT REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
None
Supplies
Oil, lubricating, Item 46, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
TM or Para
Para 7-11
Condition Description
Oil pan removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
(1) Remove screw (1), washer (2), and filter element (3) from transmission (4).
(2) Remove two spacers (5).
(3) Remove preformed packing (6) from filter element (3).
7-76
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
b. Installation.
(1) Coat preformed packing (6) with lubricating oil and install preformed packing on filter
element (3).
(2) Install screw (1) with washer (2) through filter element (3) and two spacers (5).
(3) Install filter element (3) in transmission (4).
(4) Tighten screw (1) to 17 to 20 lb-ft (23 to 27 N•m).
C. Follow-on Maintenance. Install oil pan (para 7-11).
END OF TASK
Section VI. GEAR UNIT AND MAIN SHAFT
7-13. GEAR UNIT AND MAIN SHAFT ASSEMBLY REMOVAL/REPAIR/INSTALLATION
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
Test Equipment
None
References
None
Special Tools
Sun gear bushing reamer set J28489
Bushing installer J24201
Main shaft lifting bracket J24196
Bushing swaging tool J26997-A
Bushing installer J25458-3
Pilot tool J28489
Supplies
Solvent, drycleaning, Item 57, Appendix C
Compound, sealing, lubricating,
Item 25, Appendix C
Oil, lubricating, Item 46, Appendix C
Tag, identification, Item 60, Appendix C
Equipment Condition
Condition Description
TM or Para
Second clutch and
Para 7-19
center support
housing removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
Change 3
7-77
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-13. GEAR UNIT AND MAIN SHAFT ASSEMBLY REMOVAL/REPAIR/
INSTALLATION (CONT).
a.
Removal.
(1)
(2)
(3)
Install lifting bracket to main shaft (1)
of gear unit assembly (2) and secure
lifting device to bracket.
Soldier A removes gear unit
assembly (2) from transmission
housing (3) while Soldier B operates
lifting device.
Remove lifting bracket.
NOTE
Tag retaining ring and backing plate.
(4)
(5)
7-78
Remove retaining ring (4).
Remove 12 second clutch plates (5 and 6) from transmission housing (3).
Change 3
TM
Transmission
Maintenance
Instructions
9-2320-279-34-1
(Cont)
7-79
TM
9-2320-279-34-1
Transmission
Maintenance
7-13.
7-80
Instructions
(Cent)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(15)
(16)
(17)
(18)
Remove retaining ring (19),
internal gear (12), and spur
gear shaft (13).
Position transmission
drum (9) so rear carrier
assembly (20) is up.
Remove retaining ring (21)
and separate rear carrier
assembly (20) from
transmission drum (9).
Remove bearing (22) from
rear carrier assembly (20).
Check end play between pinion gears (23, 24, and 25) and carriers (1, 5, and 20). End play must
be between 0.008 and 0.031 in. (0.203 and 0.787 mm).
CAUTION
Do not drill into the carrier assemblies.
NOTE
If end play between piston gears and carriers is other than 0.008 and 0.031 in.
(0.203 and 0.787 mm), perform steps (20) through (25).
(20)
(21)
(22)
Drill away staked rear ends of front carrier assembly (1) pinion pins (26) using a 15/16 in. (23.8
mm) bit.
Drill away staked front ends of center carrier assembly (5) pinion pins (27) using a 15/16 in.
(23.8 mm) bit.
Drill away staked ends of rear carrier assembly (20) pinion pins (28) using a 1-3/16 in. (30.2
mm) bit.
Change 3
7-81
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-13. GEAR UNIT AND MAIN SHAFT ASSEMBLY REMOVAL/REPAIR/
INSTALLATION (CONT).
NOTE
Front, center, and rear carrier assemblies are disassembled the
same way. Disassembly of center carrier is shown.
(23)
(24)
(25)
C.
Position center carrier assembly (5) with drilled ends
of pinion pins (27) upward in press.
Press pinion pins (27) from center carrier
assembly (5).
Remove pinions (24), roller bearings (29), steel thrust
washers (30), and bronze thrust washers (31) from
center carrier assembly (5).
Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily,
can give off harmful vapors, and are harmful to skin and
clothing. To avoid injury or death, keep away from open tire
and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap
and water.
(1) Clean all metal parts with drycleaning
solvent.
NOTE
All planetary gears in a carrier assembly are replaced as a set.
(2)
(3)
Inspect parts for damage. Replace damaged parts.
Measure thickness of thrust washers. Thickness must be no less than 0.091 in. (2.31 mm)
NOTE
Bearing surface measurement will be used in
paragraph 7-16 to find output shaft bushing
clearance.
(4) Measure and note diameter of bearing
surface (1) of main shaft (2).
(5) Measure diameter of front carrier bearing
surface (3).
(6) Measure inside diameter of bushing (4).
(7) If bushing (4) to front carrier bearing
surface (3) clearance is greater than
0.0072 in. (0.15 mm), replace bushing.
(8) Measure diameter of bearing surfaces (2
and 5) on main shaft.
19) Measure inside diameter of bushings (6 and 7) in sun gear shaft (8).
(10) If clearance between bushings (6 and 7) and bearing surfaces (2 and 5) is more than 0.0064 in.
(0.16 mm), remove bushings.
7-82
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
d. Assembly.
NOTE
Front, center, and rear carrier assemblies are
assembled the same way. Assembly of center
carrier is shown.
(1)
Lubricate roller bearings (1), bronze
thrust washers (2), and steel thrust
washers (3) with lubricating oil.
NOTE
Front and rear carrier assemblies are
positioned in press for assembly with rear end
up and center assembly is positioned with
front end up.
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Position center carrier assembly (4) in
press with front end up.
Position roller bearings (1) in pinion (5).
Position steel thrust washer (3) at each end of pinion (5).
Position bronze thrust washer (2) on each steel thrust washer (3).
Position pinion (5) in center carrier assembly (4).
Using press, install pinion pin (6) in
carrier until both ends of pinion pin are
equal.
Remove center carrier assembly (4)
from press.
NOTE
Pinion must rotate freely and have 0.008 in.
(0.203 mm) minimum end play after staking
the pins.
(9)
Stake both ends of pinion pins (6) in
four places.
Change 3
7-83
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-13. GEAR UNIT AND MAIN SHAFT ASSEMBLY REMOVAL/REPAIR/
INSTALLATION (CONT).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
NOTE
Teflon impregnated bushings are fully interchangeable and replace previous
bushings. Teflon impregnated bushings are identified by a grey color on the
inside diameter. Previous bushings were bronze in color.
(10)
Apply lubricating sealing compound to bushings (7 and 8).
CAUTION
When installing Teflon impregnated bushings, use care not to damage coating on
inside diameter.
(11)
Position bushing (7) at bore of small
end of sun gear shaft (9). Aline bushing
so interlock split is more than 45
degrees from swaging hole in sun gear
shaft.
NOTE
When installing Teflon impregnated
bushings, do step (11.1) and continue with
step (12).
(11.1) Using bushing installer tool (J25458-3),
press in bushing (7) until flush with
sun gear shaft (9).
(12) Using end of bushing installer tool
(J24201), marked 0.360, press in
bushing (7) to 0.360 in. (9.14 mm)
below end surface into small outside
diameter of shaft (9).
(13) Position bushing (8) at bore of large end of sun gear shaft (9). Aline bushing so interlock split is
more than 45 degrees from swaging hole in sun gear shaft.
NOTE
When installing Teflon impregnated bushings, do step (13.1) and continue with
step (13.2).
(13.1) Using bushing installer tool (J25458-3), press in bushing (8) until flush with sun gear shaft (9).
(13.2) Using end of bushing installer tool (J24201), marked 0.260, press in bushing (8) to 0.260 in.
(6.60 mm) below end surface into the large outside diameter end of shaft.
7-84
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
CAUTION
When swaging bushing at small
end of sun gear shaft, the collar
supplied with swaging tool, must be
used or damage to shaft may result.
Collar is not required to swage
bushing at larger end.
(14)
Using swaging tool, push
both bushings in swaging
holes of sun gear shaft
assembly (9).
NOTE
Teflon impregnated bushings do not
require machining after
installation. Skip steps (15)
through (21) for Teflon
impregnated bushings.
(15)
Clamp holding fixture in
vise. Set sun gear shaft (9)
in holding fixture with
small end up. Position sun
gear bushing reamer and
pilot tool (J28489-1).
CAUTION
Keep reamer rotating at full drill
speed when pulling back through
bushing. If reamer is not rotating
at full drill speed, bushing could be
damaged.
(16) Using 1/2-in. (13 mm)
electric drill, machine
bushing at approximately
75 to 150 rpm while
adding oil through either
hole on top of pilot tool.
(17) Clamp pilot tool in vise.
Insert bushing pilot tool in
small end of sun gear
shaft (9) and hold with
locking pin. Position
bushing pilot tool in pilot
tool, and position reamer
and shaft assembly in sun
gear shaft.
Change 3
7-84.1/(7-84.2 blank)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(18) Engage shaft of reamer and shaft assembly with pilot
tool.
CAUTION
Keep reamer rotating at full drill speed when pulling
back through bushing. If reamer is not rotating at full
drill speed, bushing could be damaged.
(19) Using 1/2-in. (13 mm) electric drill, machine bushing
at approximately 75 to 150 rpm while adding
lubricating oil in bore at sides of sun gear shaft (9).
Check
inner diameter of bushings for runout. Runout
(20)
must not exceed 0.002 in. (0.05 mm) total indicator
reading. Surface finish should be 30-microinch
(0.762 micrometer).
(21) Thoroughly clean sun gear shaft (9) of chips and
debris.
(22) Install bearing (10) on rear carrier assembly (11).
(23) Position rear carrier assembly (11) on transmission drum (12).
(24) Install retaining ring (13).
7-85
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-13. GEAR UNIT AND MAIN SHAFT ASSEMBLY REMOVAL/REPAIR/
INSTALLATION (CONT).
(25)
(26)
(27)
(28)
(29)
Install internal gear (14) on spur gear
shaft (15).
Install retaining ring (16).
Install lube orifice plug (17) on large
end of main shaft (18).
Position main shaft (18) through
internal gear (14) and spur gear
shaft (15).
Install spiral locking ring (19).
(29.1) Apply lubrication to race (20), bearing (21), and race (22) prior to installation.
(30) Install larger bearing race (20), bearing (21), and smaller bearing race (22) in transmission
drum (12).
(31) Install main shaft (18) in transmission drum (12).
7-86
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(32) Install thrust washer (23) on base of main shaft (18).
(33) install center carrier assembly (4) in transmission drum (12).
(34) Install spur gear (24) in transmission drum (12).
(35) Install retaining ring (25) in transmission drum (12).
(36) Install sun gear shaft (9) on main shaft (18).
7-87
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-13. GEAR UNIT AND MAIN SHAFT ASSEMBLY REMOVAL/REPAIR/
INSTALLATION (CONT).
l
(36.1)
(37)
(38)
(39)
(40)
Lubricate thrust washer (26).
Install thrust washer (26) on center carrier assembly (4).
Install front carrier assembly (27) on center carrier assembly (4).
Install thrust washer (28) on front carrier assembly (27).
Install driven gear (29) in front carrier assembly (27).
e. Installation.
NOTE
External-tanged clutch plates (2) have two
thicknesses. Insure thicker external-tanged
clutch plate is next to piston. Thinner
external-tanged clutch plates should be
installed toward the rear of the transmission
housing.
(1)
(2)
7-88
Install 12 second clutch plates (1 and 2)
in transmission housing (3).
Install retaining ring (4).
Change 3
TM
9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-14.
7-89
TM
9-2320-279-34-1
Transmission
Maintenance
7-14.
7-90
Instructions
(Cont)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
c.
d.
Installation.
(1) Using oil seal installer, install oil seal (6) with seal lip facing rear cover (5).
(2) Install dust shield (4) in rear cover (5), flat side first, so rear edge of shield is flush with surface
of rear cover.
(3) Install output yoke (3) on output shaft (2).
(4) Coat threads of output shaft (2) and retainer nut (1) with lubricating oil.
(5) Install retainer nut (1) on output shaft (2). Tighten nut to 600 to 800 lb-ft (813 to 1085 N•m)
with lock socket.
Follow-on Maintenance. Install propeller shaft (TM 9-2320-279-20).
END OF TASK
Section VII. CLUTCH ASSEMBLIES
7-15. FORWARD CLUTCH ASSEMBLY REMOVAL/REPAIR/INSTALLATION
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
Clutch spring compressor J24204-3
Collector ring installer and staking set
J24200
Forward clutch piston inner seal protector
J24216-01
PTO gear removal fixture J26899
Fourth clutch alinement fixture J24221
Forward clutch lifting bracket J33079-1
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
None
Equipment Condition
Condition Description
TM or Para
Control valve body
Para 7-20
removed.
Torque converter housing
Para 7-9
removed.
Special Environmental Conditions
None
Fabricated Tools
Shim stock, Item 2, Appendix B
General Safety Instructions
None
Supplies
Oil, lubricating, Item 45, Appendix C
Oil, lubricating, Item 46, Appendix C
Solvent, drycleaning, Item 57, Appendix C
Compound, retaining, Item 24, Appendix C
Level of Maintenance
General Support
Change 3
7-91
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-15. FORWARD CLUTCH ASSEMBLY REMOVAL/REPAlR/INSTALLATION (CONT).
a.
Removal.
(1)
(2)
Install lifting bracket to turbine shaft (1) and secure lifting device to lifting bracket.
Soldier A removes forward clutch assembly (2) from transmission housing (6) while Soldier B
operates lifting device.
(3) Hold turbine shaft (1) and remove forward clutch assembly (2), outer race (3), roller bearing (4),
and inner race (5).
(4) Place forward clutch assembly (2) in clean area,
(5) Remove lifting bracket.
b. Disassembly.
(1)
(2)
(3)
7-92
Remove seal rings (1 and 2) from
turbine shaft (3).
Place collector ring installer on bed of
press.
Turn forward clutch assembly (4) over
and install through collector ring
installer and in bed of press.
Change 3
TM
9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-93
TM
9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-15.
7-94
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(10) Remove spring retainer (13) from forward clutch piston (15).
(11) Remove 20 piston return springs (16) from forward clutch piston (15).
NOTE
Not all clutch assemblies will have a seal ring. If seal ring is removed, discard and
do not replace during installation.
(12)
(13)
(14)
(15)
Remove
Remove
Remove
Remove
forward clutch piston (15) from forward clutch assembly (4).
inner seal ring (17) and outer seal ring (18) from forward clutch piston (15).
seal ring (19) from inner hub in forward clutch assembly (4).
forward clutch assembly (4) and collector ring installer from press.
7-95
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-15. FORWARD CLUTCH ASSEMBLY REMOVAL/REPAlR/INSTALLATION (CONT).
CAUTION
Do not damage pitot collector ring during removal.
(16)
Pry pitot collector ring (20) loose from forward clutch assembly (4).
(17)
Place PTO gear removal fixture in
press.
Install forward clutch assembly (4) on
PTO gear removal fixture.
Install PTO removal tool in forward
clutch assembly (4).
(18)
(19)
7-96
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
Find gap in retaining ring (21).
Install shim stock between retaining
ring (21) and teeth of PTO gear (22).
Push retaining ring in forward clutch
assembly (4). Put shim stock every 3 in.
(76 mm) around forward clutch
assembly.
(22) Press forward clutch assembly (4) out
of PTO gear (22).
(23) Remove PTO gear (22), forward clutch
assembly (4), PTO gear removal tool,
and PTO gear removal fixture from
press.
c. Cleaning/Inspection.
(20)
(21)
WARNING
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors, and are harmful to
skin and clothing. lb avoid injury or death, keep away
from open fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and water.
(1)
(2)
(3)
(4)
Clean all metal parts with drycleaning solvent and
inspect for damage. Replace damaged parts.
Turbine shaft is pressed in forward clutch housing and should be tight. Replace forward clutch
housing if there is any up and down movement.
Replace all 20 piston release springs if any three springs do not meet the following load-height
requirements:
(a) Length without load: 1.25 in. (31.8 mm)
(b) Length under load: 0.88 in. (22.4 mm) with load of 17.9 to 18.9 lb (79.6 to 84.1 N).
Clean ball pockets (1) with drycleaning solvent if there is leakage at bottom side of housing or if
balls do not move freely of their own weight.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment, goggles,
shield, and gloves.
(5)
(6)
Dry pockets with compressed air.
Apply lubricating oil around area of ball pockets (1).
Change 3
7-97
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-15. FORWARD CLUTCH ASSEMBLY REMOVAL/REPAlR/lNSTALLATlON (CONT).
d. Assembly.
NOTE
Coat all parts with lubricating oil before installation.
(1) Place collector ring installer in press.
(2) Install forward clutch assembly (1) on collector ring installer.
(3) Install retaining ring (2) in groove (3) on outside of forward
clutch assembly (1).
Wear heat-resistant gloves to prevent burning hands when
handling hot PTO gear.
(4) Heat PTO gear (4) in oven or oil bath to 350° to 375° F
(1770 to 191%).
NOTE
Install PTO gear with beveled side of inner teeth down.
(5) Carefully place PTO gear (4) on forward clutch assembly (1).
(6) Install PTO gear removal fixture on forward clutch assembly (1).
(7) Press PTO gear (4) on forward clutch assembly (1) until retaining ring (2) expands in groove (5)
inside PTO gear.
7-98
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(8) Remove forward clutch assembly (1) and collector ring
installer from press.
(9) Coat collar of oil collector ring (6) with retaining compound
and place on forward clutch assembly (1).
(10) Install collector ring installer on oil collector ring (6) and
install oil collector ring.
(11) Remove collector ring installer.
(12) Using staking tool, Soldier A bends edge of oil collector
ring (6) in groove in forward clutch assembly (1) while
Soldier B supports forward clutch assembly on edge,
making sure oil collector ring does not touch work
surface.
STAKING TOOL
(13) Look at bottom of forward clutch piston (7)
and note whether forward clutch piston is
labeled A, B, or C.
7-99
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-15. FORWARD CLUTCH ASSEMBLY REMOVAL/REPAIR/INSTALLATION (CONT).
(14)
(15)
Stack 10 clutch plates (8 and 9) on flat surface of press starting with steel plate (8) and
alternating with friction plate (9).
Place fourth clutch driving hub (10) on clutch plates (8 and 9).
NOTE
Pressure is applied to clutch pack to steady clutch pack.
(16)
(17)
(18)
(19)
7-100
Press evenly on fourth clutch driving hub (10) with 980 to 1020 lb load.
Measure distance from base of clutch pack (11) to machined surface (12) of hub (10) to get clutch
pack thickness.
If forward clutch piston (7) is an A piston, clutch pack thickness must be 1.415 to 1.442 in.
(35.94 to 36.63 mm). If forward clutch piston is a B piston, clutch pack thickness must be 1.388
to 1.414 in. (35.26 to 35.92 mm). If forward clutch piston is a C piston, clutch pack thickness
must be 1.361 to 1.387 in. (34.57 to 35.23 mm). Replace clutch plates (8 and 9) as needed to
ensure proper clutch pack thickness.
Remove clutch pack (11) and fourth clutch driving hub (10) from press.
Change 3
TM 9-2320-279-34-1
Transmission
Maintenance
Instructions
(Cont)
CAUTION
7-101
TM
9-2320-279-34-1
Transmission
Maintenance
7-15.
7-102
Instructions
(Cont)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
NOTE
Install bearing race with cupped side down.
(30)
(31)
(32)
(33)
(34)
(35)
Lubricate and install thrust bearing
race (19) on small hub of forward
clutch assembly (1).
Lubricate and install thrust bearing
(20) on thrust bearing race (19).
Coat bearing race (21) with lubricating
oil and install.
Install forward clutch drive hub (22) on
forward clutch assembly (1).
Soak five friction plates (9) in clean lubricating oil for 2 minutes.
Install 10 clutch plates (8 and 9), starting with external-tanged steel plate and alternating with
internally tanged friction plate.
Change 3
7-103
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-15. FORWARD CLUTCH ASSEMBLY REMOVAL/REPAIR/INSTALLATlON (CONT).
(36) Install fourth clutch driving hub (10) on forward clutch assembly (1).
(37) Install large inner retaining ring (23) on fourth clutch driving hub (10).
(38) Lubricate and install two seal rings (24) on turbine shaft (13).
e. Installation.
WARNING
Be sure forward clutch hub and fourth clutch driving hub are installed in the
forward clutch assembly. If these two hubs are installed into the fourth clutch
housing, the transmission will operate in reverse when the driver selects any
forward range.
(1)
7-104
Install outer race (1), roller bearing (2), and inner race (3) on fourth clutch assembly (4) in
transmission housing (5).
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(1.1) Install lifting bracket on turbine shaft (7).
(2) Install fourth clutch alinement fixture on fourth clutch assembly (4).
WARNING
Compressed air can cause injury. Compressed air in shop will not exceed 30 psi
(207 kPa). Use only with effective chip guarding and personal protective
equipment, goggles, shield, and gloves.
(3)
(4)
(5)
(6)
f.
Apply air pressure to port (6) to lock up fourth clutch plates.
Soldier A holds air pressure in fourth clutch assembly (4) while Soldier B removes fourth clutch
alinement fixture.
Soldier A continues to apply air pressure in fourth clutch assembly (4) while Soldier B lifts and
installs forward clutch assembly (8) by turbine shaft (7) into transmission housing (5).
Soldier A stops applying air pressure when Soldier B says forward clutch assembly (8) is fully
seated in transmission housing (5).
Follow-on Maintenance.
(1)
(2)
Install torque converter housing (para 7-9).
Install control valve body (para 7-20).
END OF TASK
Change 3
7-105
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-16. REAR COVER AND FIRST CLUTCH ASSEMBLY REMOVAL/REPAlR/lNSTALLATlON.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
Test Equipment
None
Reference
None
Special Tools
Clutch spring compressor J24204
Output shaft bushing installer J24203
Equipment Condition
Supplies
Oil, lubricating, Item 46, Appendix C
Solvent, dry cleaning, Item 57, Appendix C
Compound, retaining, Item 24, Appendix C
Compound, sealing, pipe thread, Item 29,
Appendix C
Grease, general purpose, lithium base,
Item 36, Appendix C
TM or Para
Para 7-14
Para 7-23
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
a. Removal.
(1) Position transmission (1) so output
shaft (2) is pointing up.
(2) Install yoke (3) and nut (4).
(3) Remove three screws (5) and
lockwashers (6).
(4) Remove 21 screws (7) and
lockwashers (8).
7-106
Condition Description
Output yoke, dust shield,
and oil seal removed.
Governor removed.
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(5)
(6)
(7)
Install suiting lifting device to rear
cover (9).
Soldier A guides rear cover (9) off and away
from transmission (1) while Soldier B operates
lifting device. Soldier B removes lifting device.
Remove gasket (10) from transmission (1).
NOTE
Some clutch assemblies contain paper
friction plates. Discard all paper friction
plates. They are replaced by graphite
friction plates.
(8)
(9)
b.
Remove two steel plates (11),
one friction plate (12), and rear
planetary ring gear (13) from
transmission housing (1).
Remove five friction plates (12)
and five steel plates (11) from
transmission housing (1).
Disassembly.
(1) Set rear cover (1) on wooden blocks.
(2) Remove nut (2), yoke (3), and output
shaft bearing retaining ring (4).
(3) Remove plug (5), plug (6), plug (7),
and bushing (8) from rear cover (1).
Change 3
7-107
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-16.
(4)
(5)
Position rear cover (1) on side. Use
wooden block for support.
Remove output shaft (7) from rear
cover (1).
(6)
Press output shaft (7) from bearing (8),
spacer (9), and speedometer drive
gear (10).
(7)
Screw long screw (11) into small orifice
plug (12). Pry up on screw to remove
plug.
Remove bushing (13) from output
shaft (7).
(8)
7-108
REAR COVER AND FIRST CLUTCH ASSEMBLY REMOVAL/REPAIR/
INSTALLATION. (CONT).
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(9)
(10)
(11)
(12)
Position rear cover (1) flange side up.
Install clutch spring compressor inside rear cover (1).
Compress clutch spring compressor and remove large external retaining ring (14).
Remove clutch spring compressor.
(13) Remove piston spring retainer (15) from first
clutch piston (16).
(14) Remove 30 piston release springs (17) from
first clutch piston (16).
(15) Remove first clutch piston (16) from rear
cover (1).
(16) Remove dowel pins (18 and 19) from rear
cover (1).
7-109
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-16. REAR COVER AND FIRST CLUTCH ASSEMBLY REMOVAL/REPAIR/
INSTALLATION (CONT).
(17)
Remove inner seal ring (20) and
outer seal ring (21) from first clutch
piston (16).
(18)
(19)
Position rear cover (1) flange side down. Use wooden blocks for support.
Remove governor support pin (22) from rear cover (1).
C.
Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1)
(2)
7-110
Clean all metal parts with drycleaning solvent and inspect for damage. Replace damaged parts.
Inspect and replace piston release springs if any five springs do not meet the following
load-height requirements:
(a) Length without load must be at least: 1.31 in. (33.3 mm).
(b) Length under load must be at least: 0.90 in. (22.9 mm) with load of 26.05 to 27.85 lb (115.9
to 123.9 N).
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(3)
(4)
(5)
Measure inside diameter of bushing (1).
Check clearance between diameter of
main shaft bearing surface, measured in
paragraph 7-13, and bushing diameter
measured in step (3). Clearance must
not be greater than 0.004 in. (0.10 mm).
Inspect ends and outside diameter of the
governor support pin (2) for wear. If
worn, replace pin.
d. Assembly.
NOTE
Some clutch assemblies contain paper friction plates.
When servicing clutch assembly, replace all paper
friction plates with graphite friction plates. Paper
friction plates and graphite friction plates cannot be
intermixed within the same clutch assembly. Refer to
TM 9-2320-279-24P for identification of parts.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Stack 13 clutch plates (1 and 2) on flat surface
of press, starting with steel plate (1) and
alternating with friction plate (2).
Place first clutch piston (3) on top of clutch
plates (1 and 2).
Press evenly on first clutch piston (3)
with 980 to 1020 lb load (4359 to
4536.9 N).
Measure distance from base of clutch
pack (4) to thrust pad (5).
Clutch pack thickness must be 2.521 to
2.553 in. (64.03 to 64.55 mm). Replace
clutch plates (1 and 2) as needed to
ensure proper clutch pack thickness.
Measure thickness of one tang (6) on
each of seven steel plates (1).
(a) If steel plate measures 0.116 to
0.123 in. (2.95 to 3.12 mm), steel
plate is thick.
(b) If steel plate measures 0.099 to 0.106 in. (2.51 to 2.70 mm), steel plate is thin.
Repeat steps (1) to (5) to recheck clutch pack thickness.
Remove first clutch piston (3) and clutch pack (4) from press.
Change 3
7-111
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-16. REAR COVER AND FIRST CLUTCH ASSEMBLY REMOVAL/REPAlR/
INSTALLATION (CONT).
CAUTION
Accuracy of location and alinement with the governor bore is critical when
installing pin.
(9)
(10)
(11)
(12)
(13)
7-112
Install governor support pin (7) in rear
cover (8) to a depth of 5.886 to 5.896 in. (149.50
to 149.76 mm).
Coat inner seal ring (9) and outer seal
ring (10) with lubricating oil.
Install inner seal ring (9) and outer seal
ring (10) on first clutch piston (3) with lips
facing down.
Install first clutch piston (3) in rear
cover (8).
Install two dowel pins (11 and 12) and
set pins height to 0.36 to 0.40 in. (9.14
to 10.16 mm) above the face of the
cover.
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(14)
(15)
(16)
(17)
Install 30 piston release springs (13) in
first clutch piston (3).
Install piston spring retainer (14) on
piston release springs (13).
Using clutch spring compressor, push
down on piston spring retainer (14) and
piston release springs (13) until
retaining ring groove in rear cover (8)
is cleared.
Install retaining ring (15). Remove
clutch spring compressor.
NOTE
The orifice plug must clear the chamfer at the
front of the plug bore in the output shaft.
(18)
Install small orifice plug (16) in output
shaft (17).
NOTE
Bushing must be 0.145 to 0.165 in. (3.68 to 4.19 mm) from front end of output
shaft.
(19)
(20)
(21)
(22)
Coat output shaft bushing (18) with
retaining compound.
Install output shaft bushing (18) in
output shaft (17) using output shaft
bushing installer.
Install speedometer drive gear (19),
spacer (20), and bearing (21) on output
shaft (17).
Install output shaft (17) in rear
cover (8).
Change 3
7-113
TM 9-2320-279-34-1
Transmission Maintenance instructions (Cont)
7-16. REAR COVER AND FIRST CLUTCH ASSEMBLY REMOVAL/REPAIR/
INSTALLATION (CONT).
(23)
Install retaining ring (22), yoke (23),
and nut (24).
WARNING
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors, and are harmful
to skin and clothing. To avoid injury or death, keep
away from open fire and use in well-ventilated area.
If adhesive, solvent, or sealing compound gets on skin
or clothing, wash immediately with soap and water.
(24)
(25)
(26)
e.
Lightly coat threads of plug (25) and plug
(25.1) with pipe thread sealing compound
and install in rear cover (8).
Install bushing (25.2) and plug (26) in rear
cover (8).
Torque plug (25), plug (25.11, and plug (26)
to 4 to 5 lb-ft (5 to 7 N•m).
Installation.
(1)
Soak six friction plates (1) in clean lubricating
oil for at least 2 minutes.
NOTE
If thick steel clutch plates are included in clutch plate
stack, install thick steel clutch plates on top of stack for
proper pressure distribution.
(2)
(3)
(4)
7-114
Install 10 clutch plates (1 and 2) in
transmission housing (3), starting with steel
plate (2) and alternating with friction plate (1).
Install rear planetary ring gear (4) in
transmission housing (3).
Install three clutch plates (1 and 2) in
transmission housing (3), starting with steel
plate (2) and alternating with friction plate (1).
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(5)
(6)
(7)
(8)
Lightly coat one side of gasket (5) with grease.
Set gasket (5) on transmission (3) with greased side
of gasket down.
Aline holes in gasket (5) with holes in transmission (3).
Install sling lifting device on rear cover (6).
NOTE
There are two different size dowel pins on screw flange
face of rear cover to help aline cover with transmission.
(9)
(10)
(11)
(12)
(13)
f.
Soldier A alines screw holes and installs rear
cover (6) on transmission (3) while Soldier B
operates lifting device. Soldier B removes lifting
device.
Install 21 screws (7) with lockwashers (8).
Install three screws (9) with lockwashers (10).
Tighten screws (7 and 9) alternately to 67 to
80 lb-ft (91 to 108 N•m).
Remove nut (11) and yoke (12).
Follow-on Maintenance.
(1) Install governor (para 7-23).
(2) Install output yoke, dust shield, and oil seal (para 7-14).
END OF TASK
Change 3
7-115
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-17. FOURTH CLUTCH ASSEMBLY REMOVAL/REPAlR/lNSTALLATlON.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
Clutch spring compressor J24204
Supplies
Oil, lubricating, Item 46, Appendix C
Ties, cable, plastic, Item 65, Appendix C
Solvent, dry cleaning, Item 57, Appendix C
Grease, general purpose, lithium base,
Item 36, Appendix C
Personnel Required
MOS 63W. Wheel vehicle repairer
TM or Para
Para 7-15
Condition Description
Forward clutch assembly
removed.
Special Environmental Conditions
None
General Safety Instructions
None
level of Maintenance
General Support
a. Removed.
(1) Remove fourth clutch assembly (1).
(2) Remove race (2), bearing (3), and race (4) from center support (5) and fourth clutch assembly (1).
(3) Remove two seal rings (6) from center support (5).
7-116
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
b. Disassembly.
(1) Position fourth clutch housing (1)
with front hub (2) up and remove
large retaining ring (3) and
backplate (4).
(2) Remove five steel plates (5) and
five friction plates (6) from fourth
clutch housing (1).
(3) Install fourth clutch housing (1) in hydraulic press.
(4) Compress spring retainer (7) with clutch spring
compressor. Remove retaining ring (8).
(5) Release pressure from spring retainer (7) and remove
clutch spring compressor.
(6) Remove fourth clutch housing (1) from press.
(7) Remove spring retainer (7) from fourth
clutch piston (9).
(8) Remove 20 piston release springs (10)
from fourth clutch piston (9).
7-117
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-17. FOURTH CLUTCH ASSEMBLY REMOVAL/REPAIR/INSTALLATION (CONT).
(9)
(10)
Remove fourth clutch piston (9) from fourth clutch housing (1).
Remove outer seal ring (11) from fourth clutch piston (9).
NOTE
There are two kinds of fourth clutch piston/fourth clutch housing assemblies.
Model A has a large seal ring on the piston and a medium seal ring in the
housing. Model B has a large seal ring and a small seal ring, both rings located on
piston. The Model B housing does not have a seal ring. If a Model A housing must
be replaced by a Model B housing, both the piston and seal rings must be
replaced.
(11)
c.
Remove inner seal ring (12) from fourth clutch
housing (1) or fourth clutch piston (9).
Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily,
can give off harmful vapors, and are harmful to skin and
clothing. To avoid injury or death, keep away from open fire
and use in well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash immediately
with soap and water.
(1)
(2)
7-118
Clean all metal parts with drycleaning solvent and inspect for damage. Replace damaged parts.
Replace all piston release springs if any three do not meet the following load-height
requirements:
(a) Length without load: Must be at least 1.25 in. (31.8 mm).
(b) Length under load: Must be at least 0.88 in. (22.4 mm) with load of 17.9 to 18.9 lb (79.6 to
84.1 N).
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(3)
Clean eight ball pockets (1) with dry
cleaning solvent.
WARNING
Compressed air used for cleaning purposes
will not exceed 30 psi (207 kPa). Use only
with effective chip guarding and personal
protective equipment, goggles, shield, and
gloves.
(4)
(5)
(6)
Dry ball pockets (1) with compressed
air.
Apply lubricating oil around area of ball
pockets (1).
Insure steel balls are staked and move
freely.
Change 3
7-118.1/7-118.2 blank)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
d. Assembly.
NOTE
There are two kinds of fourth clutch piston/fourth clutch housing assemblies.
Model A has a large seal ring on the piston and a medium seal ring in the
housing. Model B has a large seal ring and a small seal ring, both rings located on
the piston. The Model B housing does not have a seal ring. If a Model A housing
must be replaced by a Model B housing, both the piston and seal rings must be
replaced.
(1)
Check bottom of fourth clutch piston (1)
and note whether labeled T, S, or M.
(2)
Stack 10 clutch plates (2 and 3) on flat
surface of press starting with steel
plate (2) and alternating with friction
plate (3).
Place backplate (4) on clutch plates (2
and 3).
(3)
(4)
(5)
(6)
(7)
Press evenly on backplate (4) with 980
to 1020 lb load (4359 to 4536.9 N).
Measure distance from base of clutch
pack (5) to machined surface (6) of
backplate (4). This is clutch pack
thickness.
If fourth clutch piston (1) is a T-piston,
clutch pack thickness must be 1.361 to
1.387 in. (34.59 to 35.23 mm). If fourth
clutch piston is an S-piston, clutch pack
thickness must be 1.388 to 1.414 in.
(35.26 to 35.92 mm). If fourth clutch
piston is an M-piston, clutch pack
thickness must be 1.415 to 1.441 in.
(35.94 to 36.60 mm). If measurement of
clutch pack thickness is other than
stated above, replace clutch plates (2
and 3) as needed.
Remove clutch pack (5) and
backplate (4) from press.
Change 3
7-119
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-17. FOURTH CLUTCH ASSEMBLY REMOVAL/REPAIR/INSTALLATION (CONT).
(8)
(9)
(10)
Coat seal ring (7) and outer rim of
fourth clutch piston (1) with lubricating
oil.
Install seal ring (7) on outer rim of
fourth clutch piston (1) with seal ring
lip (8) facing down.
Coat seal ring (9) and hub (10) of
fourth clutch housing (11) with
lubricating oil.
NOTE
For Model A, do step (11); for Model B do step
(11.1).
(11)
Install seal ring (9) on hub (10) with
seal ring lip (12) pointing down.
(11.1) Install seal ring (9) on inner bore of
fourth clutch piston (1) with seal ring
lip pointing up.
(12) Install fourth clutch piston (1) in
fourth clutch housing (11).
(13)
(14)
7-120
Install 20 piston release springs (12) on fourth clutch piston (1).
Install piston release spring retainer (13) on piston release springs (12).
Change 3
TM
Transmission
Maintenance
Instructions
9-2320-279-34-1
(Cont)
CAUTION
7-121
TM
9-2320-279-34-1
Transmission
Maintenance
7-17.
7-18.
7-122
Instructions
(Cont)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
a.
Removal.
(1) Remove retaining ring (1).
(2) Remove backplate (2).
(3) Remove four friction plates (3) and four
steel plates (4).
NOTE
Some clutch assemblies contain paper friction
plates. Discard all paper friction plates.
They are replaced by graphite friction plates.
(4) Remove support housing
anchor screw (5) and
washer (6).
(5) Remove retaining ring (7)
holding center support
housing (8).
NOTE
Center support housing is fitted to
transmission housing with very little
clearance and may bind if
transmission housing is cold. Heat
transmission housing with heat
lamp or warm current of air.
If support housing starts upward
and then binds, tap center support
housing downward and lift again.
(6)
Lifting straight up, remove center
support housing (8) and thrust
washer (9) from transmission
housing (10).
Change 3
7-123
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-18. THIRD CLUTCH AND CENTER SUPPORT HOUSING REMOVAL/REPAlR/lNSTALLATlON
(CONT).
b. Disassembly.
(1) Remove third clutch piston (1) from center support housing (2).
(2) Remove outer seal ring (3) and inner seal ring (4) from third clutch piston (1).
(3) Cut and remove four retaining rings (5).
(4) Remove clutch ring (6) from third clutch piston (1).
(5) Remove 20 springs (7) from third clutch piston (1).
7-124
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(6)
(7)
(8)
c.
Measure diameter of main shaft bearing
surfaces (8) inside transmission
housing (9).
Measure inside diameter of
bushing (10).
If bushing (10) to main shaft bearing
surface (8) clearance is greater than
0.009 in. (0.229 mm), remove bushing.
Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open tire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1)
(2)
(3)
Clean all metallic parts with drycleaning solvent and inspect for damage. Replace damaged
parts.
Replace piston release springs if any three of each set of 20 do not meet the following
load-height requirements:
(a) Length without load must be at least 1.29 in. (32.8 mm).
(b) Length under load must be at least 0.82 in. (20.8 mm) with load of 4.3 to 5.7 lb (19.1 to
25.4 N).
Measure thrust washer thickness. Thickness must be no less than 0.091 in. (2.31 mm>.
d. Assembly.
(1)
(2)
Place center support housing (1) on
press, hub side up.
Install prebored bushing (2). Make sure
oil hole in prebored bushing is alined
with oil hole in center support
housing (1).
Change 3
7-125
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-18. THIRD CLUTCH AND CENTER SUPPORT HOUSING REMOVAL/REPAlR/lNSTALLATlON
(CONT).
(3) Use swaging tool to swage bushing (2) by staking
edges of oilhole (3).
(4) Set third clutch piston (4) in front cavity of center support housing (1).
(5) Install 20 piston release springs (5) in pockets on third clutch piston (4).
(6) Install clutch ring (6) on third clutch piston (4).
Clutch ring must be pushed completely down in center support housing while
installing retaining rings or clutch clearance will be wrong and transmission will
not shift properly.
(7) Install four retaining rings (7). Remove third clutch piston (4) from support housing (1).
7-126
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(8)
Place backplate (8) on flat surface of
press.
NOTE
Some clutch assemblies contain paper friction
plates. When servicing clutch assembly,
replace all paper friction plates with graphite
friction plates. Paper friction plates and
graphite friction plates cannot be intermixed
within the same clutch assembly. Refer to
TM 9-2320-279-24P for identification of parts.
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Stack eight clutch plates (9 and 10) on
backplate (8), starting with friction
plate (9) and alternating with steel
plate (10).
Place third clutch piston (4) on top of
clutch plates (9 and 10).
Press evenly on third clutch piston (4)
with 980 to 1020 lb load (4359 to
4536.9 N).
Measure distance from base of clutch
pack (11) to thrust pad (12).
Clutch pack thickness must be 3.010 to
3.042 in. (76.45 to 77.26 mm). Replace
clutch plates (9 and 10) as needed to
ensure proper clutch pack thickness.
Measure thickness of one tang (13) on
each of four steel plates (10).
(a) If steel plate measures 0.116 to
0.123 in. (2.95 to 3.12 mm) steel
plate is thick.
(b) If steel plate measures 0.099 to
0.106 in.(2.51 to 2.69 mm) steel
plate is thin.
Repeat steps (8) through (13) to
recheck clutch pack thickness.
Remove clutch pack (11) from press.
Apply lubricating oil to inner seal
ring (14) and outer seal ring (15).
Install inner seal ring (14) and seal
ring (15) on third clutch piston (4) with
lips facing down.
Change 3
7-127
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-18. THIRD CLUTCH AND CENTER SUPPORT HOUSING REMOVAL/REPAlR/lNSTALLATlON
(CONT).
e. Installation.
(1) Install third clutch piston (1) in center support housing (2).
(2) Install thrust washer (3).
NOTE
Center support housing is fitted to
transmission housing with very little
clearance and may bind if transmission
housing is cold. Heat transmission housing
with heat lamp or warm current of air.
(3) Lower center support housing (2) in
transmission housing (4). Make sure
tapped hole (5) in support housing is
alined with screw hole (6) in
transmission housing.
(4) Install support housing anchor screw (7)
and washer (8). Tighten support housing
anchor screw finger-tight.
7-128
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(5)
(6)
(7)
(8)
(9)
(10)
Install compressor sleeve on hub of center support housing (2) and place compressor bar across
transmission housing (4) with two screws (9).
Tighten compressor center screw to 5 lb-ft (6.8 N•m) to compress center support housing (2).
P l a c e snapring in retaining ring opening (10). Measure retaining ring opening with each of four
colored lugs on gage to determine lug with tightest fit.
(a) Blue color coded retaining ring is 0.148 to 0.150 in. (3.76 to 3.81 mm) thick.
(b) Yellow color coded retaining ring is 0.152 to 0.154 in. (3.86 to 3.91 mm) thick.
(c)
White color coded retaining ring is 0.155 to 0.157 in. (3.94 to 3.99 mm) thick.
(d) Red color coded retaining ring is 0.158 to 0.160 in. (4.01 to 4.06 mm) thick.
Install retaining ring (11) that has same color code as lug of gage. Retaining ring gap must be
opposite oil pan side (12) of transmission housing (4).
Remove compressor bar and compressor sleeve.
Tighten support housing screw (7) to 39
to 46 lb-ft (53 to 62 N•m).
Change 3
7-129
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-18. THIRD CLUTCH AND CENTER SUPPORT HOUSING REMOVAL/INSTALLATION
(CONT).
(11) Soak four friction
plates (13) in oil for
2 minutes.
NOTE
Thick steel plates must be
installed on bottom of stack.
(12) Install steel plate (14) with
gap (15) facing as shown.
(13) Install seven clutch
plates (13 and 14), starting
with friction plate (13) and
alternating with steel
plate (14).
(14) Install backplate (16).
(15) Install retaining ring (17)
with gap opposite oil pan
side (12) of transmission
housing (4).
f . Follow-on Maintenance. Install fourth clutch assembly (para 7-17).
END OF TASK
7-19. SECOND CLUTCH AND CENTER SUPPORT HOUSING REMOVAL/REPAIR/
INSTALLATION.
This
a.
b.
c.
task covers:
Removal
Disassembly
Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
None
Supplies
Oil, lubricating, Item 46, Appendix C
Solvent, dry cleaning, Item 57, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
7-130
TM or Para
Para 7-18
Condition Description
Third clutch and center
support housing removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
a.
Removal.
(1)
(2)
Remove retaining ring (1).
Remove seven steel plates (2) and six
friction plates (3) from transmission
housing (4).
NOTE
Some clutch assemblies contain paper
friction plates. Discard all paper friction
plates. They are replaced by graphite
friction plates.
b. Disassembly.
(1)
(2)
Remove second clutch piston (1) from
bottom of center support housing (2).
Remove outer seal ring (3) and inner
seal ring (4) from second clutch
piston (1).
Change 3
7-131
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-19. SECOND CLUTCH AND CENTER SUPPORT HOUSING REMOVAL/REPAIR/
INSTALLATION (CONT).
(3)
(4)
(5)
c.
Cut and remove four retaining rings (5).
Remove clutch ring (6) from second
clutch piston (1).
Remove 20 springs (7) from second
clutch piston (1).
Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are
harmful to skin and clothing. To avoid injury or death, keep away from open fire and use in
well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash
immediately with soap and water.
(1)
(2)
Clean all metallic parts with drycleaning solvent and inspect for damage. Replace damaged
parts.
Replace piston release springs if any three in each set of 20 do not meet the following
load-height requirements:
(a) Length without load must be at least 1.29 in. (32.8 mm).
(b) Length under load must be at least 0.82 in. (20.8 mm) with load of 4.3 to 5.7 lb-ft (19.1 to
25.4N).
d. Assembly.
(1) Set second clutch piston (1) in rear
cavity of center support housing (2).
(2) Install 20 piston release springs (3) in
second clutch piston (1).
(3) Install clutch ring (4) on second clutch
piston (1).
CAUTION
Clutch ring must be pushed completely
down in center support housing while
installing retaining rings or clutch
clearance will be wrong.
(4)
7-132
Install four retaining rings (5). Remove
second clutch piston (1) from center
support housing (2).
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
NOTE
Some clutch assemblies contain paper
friction plates. When servicing clutch
assembly, replace all paper friction plates
with graphite friction plates. Paper friction
plates and graphite friction plates cannot
be intermixed within the same clutch
assembly. Refer to TM 9-2320-279-24P for
identification of parts.
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Stack 13 clutch plates (6 and 7) on flat
surface of press, starting with steel
plate (6) and alternating with friction
plate (7).
Place second clutch piston (1) on top of
clutch plates (6 and 7).
Press evenly on second clutch piston (1)
with 980 to 1020 lb load (4359 to
4536.9 N).
Measure distance from base of clutch
pack (8) to top of thrust pad (9).
Clutch pack thickness must be 3.136 to
3.168 in. (79.66 to 80.48 mm). Replace
clutch plates (6 and 7) as needed to
ensure proper clutch pack thickness.
Measure thickness of one tang (10) on
each of seven steel plates (6).
(a) If steel plate measures 0.116 to
0.123 in. (2.95 to 3.12 mm), steel
plate is thick.
(b) If steel plate measures 0.099 to
0.106 in. (2.51 to 2.69 mm), steel
plate is thin.
Repeat steps (5) through (9) to recheck
clutch pack thickness.
Remove clutch pack (8) from press.
Apply lubricating oil to inner seal
ring (11) and outer seal ring (12) and
install inner seal ring and outer seal
ring on second clutch piston (1) with
lips facing down.
Change 3
7-133
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-19. SECOND CLUTCH AND CENTER SUPPORT HOUSING
REMOVAL/REPAIR/INSTALLATION (CONT).
(14) Install second clutch piston (1) in bottom of center support housing (2).
e. Installation.
(1) Soak six friction plates (1)
in oil for 2 minutes.
NOTE
Thick steel plates must be
installed on top of stack.
(2) install steel plates (2) with
gap (3) facing as shown.
(3) lnstall 12 clutch plates (1
and 2), starting with
friction plate (1) and
alternating with steel
Plate (2).
(4) install retaining ring (4)
with gap opposite oil pan
side (5) of transmission
housing (6).
f . Follow-on Maintenance. lnstall third clutch and center support housing (para 7-18).
END OF TASK
7-134
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-20 CONTROL VALVE BODY REMOVAL/REPAIR/INSTALLATION.
7-135
TM 9-2320-279-34-1
Transmission
Maintenance
7-20
7-136
Instructions
(Cont)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
NOTE
Record and identify check
balls by size and location.
(5) Remove check balls (6, 7, 8,
9, and 10).
(6) Soldier A removes retaining
pin (11) from check valve
pin (12) while Soldier B
presses down on cup
washer (13).
(7) Remove cup washer (13),
spring (14), lubrication
check valve (15) and check
valve pin (12) from oil
transfer plate (3).
WARNING
All valves are under spring
tension. Release springs
slowly to avoid personal
injury.
CAUTION
Do not use magnets to remove
valve bodies. Magnetized
valve bodies may not work
properly.
NOTE
Tag and mark all parts before removing.
Record each notch on adjusting ring that touches retaining pin.
(8) Press adjusting ring (16) inward and remove retaining pin (17) from
modulator valve body (2).
(9) Remove adjusting ring (16), washer (18), spring (19), valve stop (20)
and valve (21) from modulator valve body (2).
7-137
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-20. CONTROL VALVE BODY REMOVAL/REPAlR/INSTALLATION (CONT).
(10)
(11)
(12)
(13)
Remove priority valve (22), spring (23),
and valve stop (24) from control valve
body (5).
Remove six screws (25).
Remove last two screws (25) evenly
while holding down trimmer valve
cover (26). Remove trimmer valve
cover.
Remove plug (27) and governor screen
assembly (28) from control valve
body (5).
(14)
Remove two springs (29 and 30), valve stop (31), trimmer plug (32), and third clutch trimmer
valve (33) from control valve body (5).
(15)
Remove two springs (34 and 35), valve stop (36), plug (37), and first clutch trimmer valve (38)
from control valve body (5).
7-138
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(16)
Remove two springs (39 and 40), valve stop (41), plug (42), and second clutch trimmer valve (43)
from control valve body (5).
(17)
(18)
Remove accumulator valve (44), spring (45), and valve stop (46).
Remove two springs (47 and 48), valve stop (49), plug (50), and fourth clutch trimmer valve (51)
from control valve body (5).
Remove retaining pin (52), valve stop
(53), spring (54), and two-three relay
valve (55) from control valve body (5).
(19)
Change 3
7-139
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-20. CONTROL VALVE BODY REMOVAL/REPAIR/INSTALLATION (CONT).
(20)
(21)
Remove retainer pin (56), spring
spacer (57), spring (58), and one-two
relay valve (59).
Remove retaining pin (60), spring (61
valve stop (62), and accumulator
valve (63).
NOTE
Record each notch on adjusting rings that touch retaining pins.
(22)
7-140
Remove retaining pin (64), adjusting ring (65), washer (66), valve stop (67), valve spring (68),
and regulator valve (69) from control valve body (5).
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(23) Remove retaining pin (70) and selector valve (71).
(24) Remove retaining pin (72), adjusting ring (73) valve spring (74) valve stop (75) one-two
modulator valve (76), and one-two shift valve (77) from control valve body (5).
(25) Remove retaining pin (78) adjusting ring (79), valve spring (80) valve stop (81), two-three
modulator valve (82), and two-three shift valve (83) from control valve body (5).
7-141
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-20. CONTROL VALVE BODY REMOVAL/REPAIR/INSTALLATION (CONT).
(26)
Remove retaining pin (84), adjusting ring (85), valve spring (86), valve stop (87), three-four
modulator valve (88), and three-four shift valve (89) from control valve body (5).
(27)
Remove retaining pin (90), valve stop (91), valve spring (92), and three-four relay valve (93)
from control valve body (5).
7-142
Change
3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(28)
c.
Remove retaining pin (94), valve stop (95), valve spring (96), and trimmer regulator valve (97)
from control valve body (5).
Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1)
(2)
(3)
(4)
Clean all metallic parts with drycleaning solvent.
Inspect all valves, valve stops, and plugs for damage. Replace damaged parts.
Inspect bores and surfaces of control valve body for damage.
Replace springs which do not meet load-length specifications listed in Table 7-2.
Table 7-2. Spring Load-Length Specifications
Spring
Lubrication
check valve
Modulator
valve
Priority
valve
Third clutch
trimmer valve (primary)
Third clutch
trimmer valve (secondary)
First clutch
trimmer valve (secondary)
First clutch
trimmer valve (primary)
Second clutch
trimmer valve (secondary)
Length
Without Load
in. (mm)
2.56
(65.0)
1.47
(37.3)
1.17
(29.7)
2.27
(57.7)
1.45
(36.8)
1.69
(42.9)
2.96
(75.2)
1.95
(49.5)
Length
Under Load
in. (mm)
1.97
(50.0)
0.80
(20.3)
0.94
(23.9)
1.94
(49.3)
1.10
(27.9)
1.10
(27.9)
1.10
(27.9)
1.10
(27.9)
Load
lb (N)
35.72 to 39.48
(158.9 to 175.6)
11.9 to 13.1
(52.9 to 58.3)
8.15 to 9.25
(36.3 to 41.2)
9.4 to 11.4
(41.8 to 50.7)
20.7 to 25.3
(92.52 to 112.5)
32.6 to 39.8
(145.0 to 177.0)
15.95 to 17.65
(70.9 to 78.5)
29.0 to 35.4
(128.9 to 157.5)
Text Reference
Callout
Step
No.
No.
(14)
(7)
(9)
(19)
(10)
(23)
(14)
(29)
(14)
(30)
(15)
(34)
(15)
(35)
(16)
(40)
Change 3
7-143
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-20. CONTROL VALVE BODY REMOVAL/REPAIR/INSTALLATION (CONT).
Table 7-2. Spring Load-Length Specifications (Cont)
Spring
Second clutch
trimmer valve (primary)
Accumulator
valve
Fourth clutch
trimmer valve (secondary)
Fourth clutch
trimmer valve (primary)
2-3 Relay
valve
1-2 Relay
valve
Governor
accumulator valve
Regulator
valve
1-2 Shift
valve
2-3 Shift
valve
3-4 Shift
valve
3-4 Relay
valve
Trimmer
regulator valve
7-144
Change 3
Length
Without Load
in. (mm)
2.56
(65.0)
2.77
(70.4)
1.45
(36.8)
2.27
(57.7)
2.18
(55.4)
1.52
(38.6)
1.84
(46.7)
1.68
(42.7)
2.65
(67.3)
2.51
(63.8)
2.69
(68.3)
2.18
(55.4)
1.33
(33.78)
Length
Under Load
in. (mm)
1.94
(49.3)
1.49
(37.9)
1.10
(27.9)
1.94
(49.3)
1.20
(30.5)
1.10
(28.0)
(17.8)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.20
(30.5)
0.86
(21.84)
Load
lb (N)
20 to 22
(89.0 to 97.9)
11.6 to 12.8
(51.6 to 56.9)
21.7 to 25.3
(96.6 to 112.6)
9.4 to 11.4
(41.8 to 50.7)
16.2 to 19.8
(72.1 to 88.1)
7.2 to 6.8
(32.0 to 39.1)
9.6 to 10.6
(42.7 to 47.2)
5.14 to 5.36
(22.9 to 23.8)
8.65 to 9.35
(38.5 to 41.6)
10.75 to 11.25
(14.6 to 15.3)
8.9 to 9.6
(12.1 to 13.0)
16.2 to 19.8
(72.1 to 88.1)
2.3 to 2.54
(10.2 to 11.3)
Text Reference
Step
Callout
No.
No.
(16)
(39)
(17)
(45)
(18)
(48)
(18)
(47)
(19)
(58)
(20)
(54)
(21)
(61)
(22)
(68)
(24)
(74)
(25)
(80)
(26)
(86)
(27)
(92)
(28)
(96)
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
d.
Assembly.
(1)
(2)
(3)
(4)
(5)
Place control valve body (1) with flat
side up.
Install one-two relay valve (2),
spring (3), and spring spacer (4) in
bore of control valve body (1).
Press spring spacer (4) and install
retaining pin (5) in control valve
body (1).
Install two-three relay valve (6),
spring (7), and valve stop (8) in
control valve body (1).
Press valve stop (8) and install
retainer pin (9) in control valve
body (1).
NOTE
Install four clutch trimmer
valves with small end first.
(6)
(7)
Install fourth clutch
trimmer valve (10),
plug (11), spring (12)
spring (13), and valve
stop (14).
Install second clutch
trimmer valve (15),
plug (161, spring (17),
spring (18), and valve
stop (19) in control
valve body (1).
Change 3
7-145
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-20. CONTROL VALVE BODY REMOVAL/REPAIR/INSTALLATION (CONT).
(8) Install third clutch trimmer valve (20), plug (21), spring (22), spring (23), and valve stop (24) in
control valve body (1).
(9) Install first clutch trimmer valve (25), plug (26), secondary spring (27), primary spring (28), and
valve stop (29) in control valve body (1).
(10) Install valve stop (30), spring (31),
and accumulator valve (32) in
control valve body (1).
7-146
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(11)
(12)
(13)
(14)
(15)
Install trimmer valve cover (33) and
eight screws (34) while pressing on
springs. Tighten screws to 8 to
12 lb-ft (11 to 16 N•m).
Install trimmer regulator valve (35), valve spring (36), and valve stop (37) in control valve
body (1).
Press valve stop (37) and install retaining pin (38) in control valve body (1).
Install three-four relay valve (39), valve spring (40), and valve stop (41).
Press valve stop (41) and install retaining pin (42) in control valve body (1).
Change 3
7-147
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
17-20. CONTROL VALVE BODY REMOVAL/REPAlR/lNSTALLATlON (CONT).
(16) Install three-four shift valve (43), modulator valve (44), valve spring (45), valve stop (46), and
adjusting ring (47).
(17) Aline pinhole in valve stop (46) with pinholes in control valve body (1).
(18) Press adjusting ring (47) and install retaining pin (48) in control valve body (1).
(19) Install two-three shift valve (49), two-three modulator valve (50), valve spring (51), valve
stop (52), and adjusting ring (53).
(20) Aline pinhole in valve stop (52) with pinholes in control valve body (1).
(21) Press adjusting ring (53) and install retaining pin (54) in control valve body (1).
7-148
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(22) Install one-two shift valve (55), one-two modulator valve (56), spring (57), valve stop (58), and
adjusting ring (59).
(23) Aline pinhole in valve stop (58) with pinholes in control valve body (1).
(24) Press adjusting ring (59) and install retaining pin (60) in control valve body (1).
(25) Install selector valve (61).
(26) Aline pinhole in selector valve (61) with pinhole in control valve body (1).
(27) Install retaining pin (62) in control valve body (1).
(28) Install regulator valve (63), valve spring (64), valve stop (65), washer (66) and adjusting
(29) Aline pinhole in valve stop (65) with pinholes in control valve body (1).
(30) Press adjusting ring (67) and install retaining pin (68) in control valve body (1).
7-149
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-20. CONTROL VALVE BODY REMOVAL/REPAlR/INSTALLATION (CONT).
(31)
Install governor screen assembly (69)
and plug (70) in control valve body (1).
Tighten plug to 4 to 5 lb-ft (5 to 7 N•m).
(32)
Install accumulator valve (71),
spring (72), and valve stop (73) in
control valve body (1).
Aline pinhole in valve stop (73) with
pinholes in control valve body (1).
Press valve stop (73) and install
retaining pin (74) in control valve
body (1).
Install valve stop (75), spring (76), and
priority valve (77) in control valve
body (1).
(33)
(34)
(35)
(36)
(37)
Install modulator valve (78),
valve stop (79), spring (80),
washer (81), and adjusting
ring (82) in modulator valve
body (83).
Aline pinhole in valve stop (79)
with pinholes in modulator
valve body (83).
NOTE
Ensure adjusting ring (82) is in same
position as before removal.
(38)
7-150
Press adjusting ring (82) and
install retaining pin (84) in
modulator valve body (83).
Change 3
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
Install check valve
pin (85) through top side
of oil transfer plate (89).
(39.1) Install lubrication check
valve (86), spring (87), and
spring cup washer (88) on
oil transfer plate (89)
bottom side.
(40) Soldier A installs
retaining pin (90) while
Soldier B presses down on
spring cup washer (88).
(41) Install four 0.25 in. (6.4
mm) check balls (91, 93,
94, and 95) and 0.3125 in.
(7.94 mm) check ball (92).
(39)
(42)
Slide separator plate (96) on oil
transfer plate (89).
(43)
Hold separator plate (96) and oil
transfer plate (89) together, turn plates
over, and place on control valve
body (1).
Change 3
7-151
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-20. CONTROL VALVE BODY REMOVAL/REPAIR/INSTALLATION (CONT).
(44)
(45)
(46)
(47)
e.
Insert six screws (97) through oil
transfer plate (89), separator plate (96),
and control valve body (1) to aline
screw holes.
Place modulator valve body (83) on oil
transfer plate (89) and install three
screws (98).
Tighten screws (98) to 8 to
12 lb-ft (11 to 16 NSm).
Remove six screws (97).
Installation.
WARNING
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors,
and are harmful to skin and clothing. To
avoid injury or death, keep away from open
fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets
on skin or clothing, wash immediately with
soap and water.
CAUTION
Care must be exercised when grinding the
locator boss. The transmission must remain
clean and free of contamination. Failure to
comply may result in damage to equipment.
NOTE
7-152
·
If replacing modulator valve body
with the manufacturer logo M
I,
transmission housings manufactured
prior to 1986 may need to be altered.
·
Identify transmission housing
casting date located on the right or
left hand side of the transmission
housing.
·
If date in casting indicates casting
prior to 1986, go to step (1).
·
If date in casting indicates casting
after 1986, go to step (1.3).
·
Transmission housing described
above are altered by removing
material from the locator boss.
Change 5
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
(1)
(1.1)
(1.2)
Locator boss should be measured from
the transmission oil track surface to the
top of the locator boss prior to grinding.
Removing material from the housing
locator boss to a dimension of 1.500
inches (38 mm) as measured from the
transmission housing oil track face will
be sufficient to clear the modulator valve
body.
Clean all debris from transmission
housing oil track with dry cleaning
solvent.
Change 5
7-152.1
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-20. CONTROL VALVE BODY REMOVAL/REPAIR/INSTALLATION (CONT).
(1.3) Install control valve body
(1) and transfer plate (2), making
sure shift rack pin (3) engages
slot on selector valve (4).
(2) Install three screws (5).
(3) Install seven screws (6).
(4) Install two screws (7) and
washers (8).
(5) Install 15 screws (9) in control
valve body (1).
(6) Install manual detent lever (10)
and screw (11) in control valve
body (1).
(7) Install oil baffle (12) and two
screws (13).
(8) Tighten screws (5, 6, 7, 9, 11,
and 13) to 8 to 12 lb-ft (11 to
16 NSm).
f.
Follow-on Maintenance.
(1)
(2)
Install lockup cutoff valve body (para 7-22).
Install modulator valve (para 7-21).
END OF TASK
7-152.2
Change 5
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-21. MODULATOR VALVE REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Condition Description
TM or Para
TM 9-2320-279-10 Shut off engine.
Special Tools
None
Supplies
Tags, identification, Item 60, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
a.
b.
c.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
Removal.
NOTE
Tag and mark hose before disconnecting.
(1) Disconnect hose (1) from modulator valve (2).
(2) Remove screw (3), bracket (41, modulator valve (2), preformed packing (5), and pin (6).
Installation.
(1) Install pin (6), preformed packing (5), modulator valve (2), bracket (4), and screw (3).
(2) Tighten screw (3) to 10 to 13 lb-ft (14 to 18 N•m).
(3) Connect hose (1) to modulator valve (2).
Follow-on Maintenance. None.
END OF TASK
Change 3
7-153
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-22. LOCKUP CUTOFF VALVE BODY REMOVAL/REPAlR/lNSTALLATlON.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
None
TM or Para
Para 7-12
Condition Description
Internal filter element
removed.
Supplies
Solvent, dry cleaning, Item 57, Appendix C
Oil, lubricating, Item 46, Appendix C
Tags, identification, Item 60, Appendx C
Cloth, crocus, Item 16, Appendix C
Special Environmental Conditions
None
Personnel Required
MOS 63W, Wheel vehicle repairer
Level of Maintenance
General Support
General Safety Instructions
None
a . Removal. Remove eight screws (1) and valve (2) from transmission (3).
7-154
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
b. Disassembly.
NOTE
When assembled, each valve should be installed in same bore from which valve
was removed. Tag and mark all parts.
(1)
(2)
(3)
(4)
(5)
(6)
Remove
Remove
Remove
Remove
Remove
Remove
retainer pin (1) from valve body (2).
valve plug (3) and second and third clutch lockup cutoff valve (4) from bore (5).
retainer pin (6) from valve body (2).
valve plug (7) and first and second clutch lockup cutoff valve (8) from bore (9).
retainer pin (10) from valve body (2).
valve plug (11) and third and fourth clutch lockup cutoff valve (12) from bore (13).
c. Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Clean valve body and valves with dry cleaning solvent.
(2) Inspect valve body and valves for nicks, burrs, and scratches. Remove defects with crocus cloth.
If scratches are deep or part is cracked, replace part.
d. Assembly.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
NOTE
Each valve should be installed in same bore from which valve was removed.
When dry, check that all lockup cutoff valves move freely in their bores.
Apply lubricating oil to all parts.
Apply lubricating oil to valve body (2).
Install valve (12) and valve plug (11) in bore (13).
Install retainer pin (10) in valve body (2).
Install valve (8) and valve plug (7) in bore (9).
Install retainer pin (6) in valve body (2).
Install valve (4) and valve plug (3) in bore (5).
Install retainer pin (1) in valve body (2).
7-155
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
7-22. LOCKUP CUTOFF VALVE BODY REMOVAL/REPAIR/INSTALLATION (CONT).
e. Installation. Install valve (1) with eight screws (2) in transmission (3). Tighten screws to 8 to
12 lb-ft (11 to 16 N•m).
Follow-on Maintenance. Install internal filter element. (para 7-12).
f.
END OF TASK
7-23. GOVERNOR REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Condition Description
TM or Para
TM 9-2320-279-20 Batteries disconnected.
Special Tools
None
Supplies
None
General Safety Instructions
None
Personnel Required
MOS 63W, Wheel vehicle repairer
7-156
Special Environmental Conditions
None
Change 3
Level of Maintenance
Direct Support
TM 9-2320-279-34-1
Transmission Maintenance Instructions (Cont)
a.
Removal.
(1)
(2)
Remove four screws (1), cover (2), and gasket (3) from transmission (4).
Turn governor (5) clockwise and remove from transmission (4).
b.
Installation.
(1) Turn governor (5) counterclockwise in port (6) to install.
(2) Aline holes in gasket (3) and cover (2) with holes in port (6).
(3) Install four screws (1), cover (2), and gasket (3) in transmission (4). Tighten screws to 10 to
13 lb-ft (14 to 18 N•m).
c.
Follow-on Maintenance. Connect batteries (TM 9-2320-279-20).
END OF TASK
Change 3
7-157/(7-158 blank)
TM 9-2320-279-34-1
CHAPTER 8
TRANSFER CASE MAINTENANCE
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Mounting Brackets Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Seal Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top Input Shaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CenterShaftRepair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Rear Output Shaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Front Output Shaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Shift Rod Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Shift Rod Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HI-LO Range Transfer Case Lock-up Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction Control Valve Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockout Shift Chamber Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Pump Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Para
8-1
8-2
8-3
8-4
8-5
8-6
8-7
8-8
8-9
8-10
8-11
8-12
8-13
8-14
8-15
8-16
Page
8-1
8-2
8-11
8-12
8-28
8-29
8-34
8-36
8-38
8-41
8-42
8-44
8-45
8-47
8-52
8-54
Section I. INTRODUCTION
This chapter contains maintenance instructions for removal, installation, and repair of
8-1. GENERAL.
the transfer case and components at the direct support and general support maintenance level.
Subassemblies and parts which must be removed before the transfer case can be removed are referenced
to other paragraphs of this manual or in TM 9-2320-279-20. The HEMTT transfer is supplied as a dressed
assembly including output yoke half. All HEMTTS except the M984E1 use the output yoke half supplied
with the transfer. When replacing the transfer case on the M984E1 the output yoke on the new dressed
transfer will have to be replaced with an M984E1 yoke end. Exchange the yoke end on the old transfer
with that on the new, if the old yoke is still serviceable. If the old yoke end is not serviceable a new yoke
end will have to be ordered.
8-1
TM 9-2320-279-34-1
Section II.
TRANSFER CASE ASSEMBLY
Transfer Case Maintenance Instructions
8-2. TRANSFER CASE REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Adhesive-sealant, silicone, Item 6, Appendix C
Compound, sealing, Item 25, Appendix C
Ties, cable, plastic, Item 65, Appendix C
Oil, lubricating, Item 48, Appendix C
Tags, identification, Item 60, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
None
a.
Disassembly.
8-2
Change 3
c. Follow-on Maintenance
Equipment Condition
Condition Description
TM or Para
TM 9-2320-279-10 Transmission in neutral.
TM 9-2320-279-10 Transfer case in neutral.
LO 9-2320-279-12 Transfer case drained.
TM 9-2320-279-10 Air system drained.
TM 9-2320-279-20 Propeller shafts removed.
TM 9-2320-279-20 Speedometer sending unit
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-2.1/(8-2.2
blank)
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-2. TRANSFER CASE REMOVAL/lNSTALLATION (CONT).
NOTE
Cut plastic cable ties as needed.
(8) Disconnect airhoses (12 and 13).
(9) Loosen two nuts (14) and slide shift cable (7) out of shift cable bracket (15).
8-3
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-2. TRANSFER CASE REMOVAL/INSTALLATION (CONT).
NOTE
Push valve will remain with shift cable bracket when bracket is removed.
(10)
(11)
Remove two screws (16), lockwashers (17). and shift cable bracket (15).
Remove two screws (18) and retainer washer (19).
NOTE
Some models of vehicles have a washer under head of screw.
(12)
(13)
8-4
Remove nut (20), lockwasher (21), screw (22), washer (22.1), if installed, support bracket (23),
and hydraulic hoses (24) from right side of transfer case (25).
Support transfer case (25) with suitable lifting device.
Change 3
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-5
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-2.
8-6
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
(6)
(7)
(8)
Install three screws (8) and lockwashers (9) in right front of mounting bracket (3).
Install three screws (10) and lockwashers (11) in left front of mounting bracket (2).
Lower lifting device and move lifting device aside.
NOTE
Some models of vehicles have a washer under head of screw.
(9)
Install hydraulic hoses (12) and support bracket (13) on transfer case (1) with screw (14),
washer (14.1), if removed, lockwasher (15), and nut (16).
Change
3
8-7
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-2. TRANSFER CASE REMOVAL/INSTALLATION (CONT).
(10)
Install shift cable bracket (17) with two
screws (18) and lockwashers (19).
WARNING
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors,
and are harmful to skin and clothing. To avoid
injury or death, keep away from open fire and
use in well-ventilated area. If adhesive,
solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and
water.
(11)
Apply silicone adhesive-sealant to end
and splined surface of output shaft (20).
Apply sealing compound to threads of
two screws (21).
NOTE
Retaining screws may be either grade 5 or
grade 8. Torque screws accordingly,
8-8
(12)
Install retainer washer (22) and two
screws (21). Tighten grade 8 screws to
88 lb-ft (119 N•m). Tighten grade 5
screws to 60 lb-ft (81 N•m).
(13)
Slide shift cable (23) in slot in shift cable bracket (17). Tighten two nuts (24), one on each side of
shift cable bracket slot.
Change 3
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-9
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-2.
8-10
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-3. TRANSFER CASE MOUNTING BRACKETS REMOVAL/lNSTALLATlON.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
None
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-20 Fuel tank removed.
Para 13-8
Transfer case support
assembly removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
NOTE
Left and right brackets are removed
and installed the same way. Right
bracket does not have hose clamp.
(1) Remove six screws (1) and
washers (2) from transfer case (3)
(2) Remove screw (4), nut (5),
washer (6) and clamp (7).
(3) Remove bracket (8).
b. Installation.
(1) Install bracket (8) on transfer
case (3) with six screws (1) and
washers (2).
(2) Install clamp (7), screw (4),
washer (6), and nut (5).
c. Follow-on Maintenance.
(1) Install transfer case support
assembly (para 13-8).
(2) Install fuel tank (TM 9-2320-279-20).
END OF TASK
8-11
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-4. TRANSFER CASE REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
Dial indicator
Equipment Condition
Condition Description
TM or Para
Transfer case mounted in
transfer case stand.
TM 9-2320-279-20 Breather removed.
Oil seals removed.
Para 8-5
Lockout shift chamber
Para 8-14
removed.
Lubrication pump removed.
Para 8-15
Special Tools
None
Supplies
Solvent, drycleaning, Item 57, Appendix C
Oil, lubricating, Item 46, Appendix C
Oil, lubricating, Item 48, Appendix C
Adhesive-sealant, silicone, Item 6, Appendix C
Adhesive, Item 8, Appendix C
Grease, automotive and artillery, Item 34,
Appendix C
Compound, sealing, Item 26, Appendix C
Compound, sealing, pipe thread, Item 28.1,
Appendix C
Tags, identification, Item 60, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
a.
Disassembly.
8-12 Change 3
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
TM
Transfer
Case
Maintenance
Instructions
9-2320-279-34-1
(Cont)
8-13
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-4.
8-14
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-15
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-4.
8-16
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
(25) Remove three bearing cups (54) from transfer case rear half (25) and two bearing cups from
transfer case front half (10).
(26) Remove six screws (55), lockwashers (56), and upper end cap (57).
b. CIeaning/lnspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1)
(2)
(3)
(4)
(5)
(6)
Clean all metal parts with dry cleaning solvent.
Clean all sealing surfaces.
Inspect all machined surfaces for damage.
Inspect both case halves for cracks or damage.
Inspect all threads for peeled or crossed condition.
Replace all oil seals and damaged parts.
8-17
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-4. TRANSFER CASE REPAIR (CONT).
a.
Assembly.
WARNING
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors, and are harmful to
skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and water.
(1)
Apply light bead of adhesive to inside flange
of end cap (1). Apply sealing compound to
threads of six screws (2). Install six
screws (2), lockwashers (3), and end cap in
transfer case front half (4).
(2)
Support transfer case front and rear halves (4 and 5), open side up, on clean work surface.
NOTE
Use hammer and brass drift to seat taper bearing cups against shoulders.
(3)
(4)
Install three bearing cups (6) in transfer case rear half (5) and two bearing cups in transfer case
front half (4).
Install bearing cup (7) in bearing support (8).
8-18 Change 3
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-19
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-4.
8-20
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
(11)
(12)
(13)
(14)
(15)
Check the eight spring disks (15) and spacer (16) are assembled on lower shift rod assembly (17)
as shown.
Install lower shift rod assembly (17) in front case half (4) with spring disk end down and
spacer (16) against front case half.
Install spacers (18 and 19) on lower rear
output shaft assembly (20).
Install lockwasher (21) and locknut (22).
Tighten locknut to 180 to 220 lb-ft (244
to 298 N•m).
Using hammer and punch, bend up
tangs (23) of lockwasher (21).
Change 3
8-21
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-4. TRANSFER CASE REPAIR (CONT).
(16)
(17)
(18)
Coat bearing cone (24) with lubricating oil
(Item 48).
Using suitable sling and lifting device, install
lower rear output shaft assembly (20) in
transfer case rear half (5).
Install bearing support (8) with softhead
hammer to seat on dowels (25).
WARNING
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors, and are harmful to
skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and water.
Coat threads of six screws (26) with sealing
compound and install screws and
lockwashers (27). Tighten screws to 40 lb-ft
(54 N•m).
(20) Turn transfer case rear half (5) over.
(21) Remove six screws (28), lockwashers (29),
shims (31), and end cap (30). Clean off old
sealant.
Add
any combination of three available
(22)
shims (31) to equal 0.060 in. (1.5 mm).
(22.1) Apply sealing compound between shims (31)
and install shims.
(19)
NOTE
After checking end play (steps (23) through (26)),
remove screws, lockwashers, and end cap. Apply
sealing compound to threads of six screws. Repeat
step (23), then go to step (27).
(23)
Install end cap (30) with six lockwashers (29)
and screws (28). Tighten screws to 60 lb-ft
(81 N•m).
8-22 Change 3
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
WARNING
8-23
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-4.
8-24
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
(34.1) Apply pipe thread sealing compound to
threads of plug (42).
(35) Install outer ball (40), outer spring (41),
and plug (42).
Remove six screws (43),
lockwashers (44), shims (46), and end
cap (45). Clean off old sealant.
(37) Add any combination of shims (46) to
equal 0.060 in. (1.5 mm).
(37.1) Apply sealing compound between
shims (46) and install shims.
(36)
NOTE
After checking end play (steps (38) through
(43)), remove screws, lockwashers, and end
cap. Apply sealing compound to threads of six
screws. Repeat step (38), then go to step (44).
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Install end cap (45) with six
lockwashers (44) and screws (43).
Tighten screws to 60 lb-ft (81 N•m).
Remove plug (47) from end cap (45).
Clean off old sealant.
Thread a 3/8 in. x 4 in. (9.5 mm x 102 mm) long coarse-thread screw (48) through hole in end
cap (45).
Mount dial indicator on machined surface with indicator shaft resting on screw (48).
Pry or lift up on screw (48) to check end play.
Add or remove any combination of three available shims (46) as needed to provide 0.003 to
0.006 in. (0.08 to 0.15 mm) end play. Refer to steps (36) through (42) to add or remove shims.
Remove screw (48).
Apply sealing compound to plug (47) and install.
Change 3
8-25
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-4. TRANSFER CASE REPAIR (CONT).
WARNING
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors,
and are harmful to skin and clothing. To
avoid injury or death, keep away from open
fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets
on skin or clothing, wash immediately with
soap and water.
(45.1) Apply adhesive to mounting
surface of cover (49).
(46) Install cover (49) with two
screws (50) and lockwashers (51).
Tighten screws to 14 lb-ft (19 N•m).
(47) Coat threads of adapter and strainer (52)
with pipe thread sealing compound and
install adapter and strainer.
(48) Coat threads of elbow (53) with pipe thread
sealing compound and install elbow and
hose (54).
(49) Turn workstand to place transfer case front
half (4) up.
NOTE
Remove oil pump mounting from rear case half
for access to shims.
(50)
To set end play of top front input shaft (13)
repeat steps (40) through (43).
(51)
Install speedometer drive
shaft (55), spring (56),
thrust washer (57), and
thrust bearing (58) in
center shaft assembly (10).
Apply light bead of
adhesive around inside
flange of end cap (59) and
sealing compound to
threads of six screws (60).
Install six screws (60),
lockwashers (61), and end
cap.
Apply pipe thread sealing
compound to underside of
nut on sleeve (62) and
install in end cap (59).
(52)
(53)
8-26 Change 3
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
(54)
(55)
(56)
(57)
Turn workstand to place transfer case front half (4) in vertical position.
Coat groove in clutch collar (63) with grease.
Engage clutch collar (63) with lower shift rod assembly (17) so groove is in same location as noted
at removal.
Install input shaft yoke spacer (64).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open tire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(58)
Coat end of lower front output shaft assembly (65) with grease. Coat inside flange of bearing
cap (66) with adhesive and install.
(59) Coat threads of six screws (67) with sealing compound and install lockwashers (68) and screws.
Tighten screws to 60 lb-ft (81 N•m).
(60) Coat thread of elbows (69 and 70) with pipe thread sealing compound and install elbows.
(61) Install hose (71).
d.
Folllow-on
Maintenance.
(1)
(2)
(3)
(4)
lubrication pump (para 8-15).
lockout shift chamber (para 8-14).
oil seals (para 8-5).
breather (TM 9-2320-279-20).
Install
Install
Install
Install
END OF TASK
Change 3
8-27
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-5. OIL SEAL REMOVAL/INSTALLATION
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Grease, automotive and artillery, Item 34,
Appendix C
Adhesive-sealant, silicone, Item 6, Appendix C
Compound, sealing, Item 25, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
a.
Removal.
8-28 Change 3
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-10 Shut off engine.
LO 9-2320-279-12 Transfer case oil drained.
TM 9-2320-279-20 Propeller shafts removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
(1)
(2)
(3)
b.
NOTE
All three oil seals are removed and installed the same way.
Remove two screws (1) and retaining washer (2).
Remove yoke (3) from shaft (4).
Remove oil seal (5) from housing (6).
Installation.
(1) Coat lip of oil seal (5) with grease.
(2) Install oil seal (5) in housing (6).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(3)
(4)
Coat end and splined surface of shaft (4) with silicone adhesive-sealant.
Install yoke (3) and set yoke against shaft (4).
NOTE
Retaining screws may be either grade 5 or grade 8. Torque screws accordingly.
(4.1) Apply sealing compound to threads of two screws (1).
(5) Install retaining washer (2) and two screws (1). Tighten grade 8 screws to 88 lb-ft (119 N•m).
Tighten grade 5 screws to 60 lb-ft (81 N•m).
c.
Follow-on Maintenance.
(1)
(2)
Install propeller shafts (TM 9-2320-279-20).
Fill transfer case with oil (LO 9-2320-279-12).
END OF TASK
8-6. TOP INPUT SHAFT REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Solvent, drycleaning, Item 57, Appendix C
Oil, lubricating, Item 47, Appendix C
Grease, automotive and artillery, Item 34,
Appendix C.
Compound, seaIing, Item 25, Appendix C
Personnel Required
MOS 63W, wheel vehicle repairer
c. Assembly
d. Follow-on Maintenance
References
None
Equipment Condition
Condition Description
TM or Para
Top input shaft on clean
work surface.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
Change 3
8-29
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-6. TOP INPUT SHAFT REPAIR (CONT).
a. Disassembly.
(1)
(2)
(3)
(4)
Remove two screws (1) and pump drive plate (2).
Remove spacer (3) and piston ring (4).
Place top input shaft assembly (5) in suitable press with large gear (6) up.
Press top input shaft (5) out of bearing (7), spacer (8), and large gear (6).
(5) Remove two needle bearings (9), spacer (10),
spacer (11), and shift collar (12).
8-30
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-31
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-6.
8-32
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Turn top input shaft (1) over and install
shaft collar (8) so larger taper is down.
Install gear spacer (9), needle
bearing (10), spacer (11), and second
needle bearing.
Coat two needle bearings (10) with
grease.
Install large gear (12) over top input
shaft (1).
Install spacer (13).
Press bearing (14) to seat against
spacer (13).
Install spacer (15) and piston ring (16).
Install pump drive plate (17).
NOTE
Retaining screws may be either grade 5 or grade 8.
Torque screws accordingly.
(15)
Coat threads of two screws (18) with sealing
compound and install. Tighten grade 8
screws to 88 lb-ft (119 N•m). Tighten grade 5
screws to 60 lb-ft (81 N•m).
d. Follow-on Maintenance. None.
END OF TASK
Change 3
8-33
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-7. CENTER SHAFT REPAIR
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
TM or Para
Condition Description
Center shaft on clean
work surface.
Special Tools
None
Supplies
Compound, sealing, Item 26,
Appendix C
Solvent, drycleaning, Item 57, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
a.
Disassembly.
(1)
Remove two screws (1) and retainer
washer (2) from end of center shaft (3).
(2)
Place center shaft assembly in suitable press
with large gear (4) up.
Press center shaft (3) out of bearing cone (5),
spacer (6), and large gear (4).
Remove spacer (7) from center shaft (3).
(3)
(4)
8-34 Change 3
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-35
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-7.
8-36
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
a. Disassembly.
(1) Place lower rear output shaft assembly (1) in
press with supports under gear (2).
(2) Press lower rear output shaft (1) out of
bearing cone (3), spacer (4), and gear (2).
(3) Turn lower rear output shaft (1) over and press out of
bearing cone (6).
b. CIeaning/lnspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily,
can give off harmful vapors, and are harmful to skin and
clothing. lb avoid injury or death, keep away from open fire
and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap
and water.
(1)
(2)
(3)
(4)
Clean all metal parts in dry cleaning solvent.
Inspect all parts for wear or damage.
Remove all nicks and burrs from machined surfaces.
Replace all worn or damaged parts.
TA189163
c. Assembly.
(1) Place lower rear output shaft (1) on clean work surface and
install spacer (2).
(2) Press bearing cone (3) on lower rear output shaft (1) and seat
against spacer (2).
(3) Coat bearing cone (3) with grease.
TA189162
8-37
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-8. LOWER REAR OUTPUT SHAFT REPAIR (CONT).
(4)
(5)
(6)
Turn lower rear output shaft (1) over and
press gear (4) on lower rear output shaft.
Press bearing (5) on lower rear output
shaft (1) and set on gear (4).
Coat bearing (5) with grease.
d. Follow-on Maintenance. None
END OF TASK
8-9. LOWER FRONT OUTPUT SHAFT REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Solvent, drycleaning, Item 57, Appendix C
Compound, sealing, pipe thread, Item 28.1,
Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
8-38 Change 3
c. Assembly
d. Follow-on Maintenance
References
None
Equipment Condition
TM or Para
Condition Description
Lower front output shaft on
clean work surface.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-39
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-9.
8-40
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
UPPER SHIFT ROD ASSEMBLY REPAIR.
8-10.
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Condition Description
TM or Para
Upper shift rod assembly
on clean work surface.
Special Tools
None
Supplies
Solvent, drycleaning, Item 57, Appendix C
Oil, lubricating, Item 46, Appendix C
Lockwire, Item 39, Appendix C
Compound, sealing, Item 26, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
a.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
Disassembly.
NOTE
Spacers are different in length. Mark for
proper assembly.
(1)
(2)
(3)
(4)
Remove two spacers (1 and 2) from
shift rod (3).
Cut lockwire (4) holding two screws (5).
Remove two screws (5) from fork (6).
Remove shift rod (3) from fork (6).
b. Cleaning/inspection.
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1)
(2)
(3)
Clean all metal parts in drycleaning solvent.
Inspect all parts for wear or damage.
Replace all worn or damaged parts.
Change 3 8-41
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8.10. UPPER SHIFT ROD ASSEMBLY REPAIR (CONT).
c.
Assembly.
(1)
Slide shift rod (1) in fork (2).
WARNING
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors,
and are harmful to skin and clothing. To avoid
injury or death, keep away from open fire and
use in well-ventilated area. If adhesive,
solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and
water.
(2)
(3)
(4)
(5)
Coat threads of two screws (3) with sealing compound,
Install two screws (3). Tighten screws to 40 lb-ft (54 N•m).
Secure two screws (3) together with lockwire (4).
Install two spacers (5 and 6) on shift rod (1).
d. Follow-on Maintenance. None.
END OF TASK
8-11.
LOWER SHIFT ROD ASSEMBLY REPAIR.
‘This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
Equipment Condition
TM or Para
Condition Description
Upper shift rod assembly
on clean work surface,
None
Special Tools
None
Supplies
Solvent, drycleaning, Item 57, Appendix C
Oil, lubricating, Item 46, Appendix C
Lockwire, Item 39, Appendix C
Compound, sealing, Item 26, Appendix C
Grease, lithium, Item 36, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
8-42 Change 3
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
a.
Disassembly.
(1)
(2)
(3)
(4)
(5)
Remove spacer (1) and eight spring disks (2).
Cut lockwire (3) holding screw (4).
Remove screw (4) from fork (5).
Slide shift rod (6) from fork (5).
Remove stud (7) from shift rod (6).
b. Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. lb avoid injury or death, keep away
from open tire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1)
(2)
(3)
c.
Clean all metal parts in drycleaning solvent.
Inspect all parts for wear or damage.
Replace all worn or damaged parts.
Assembly.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Apply lithium grease to threads of stud (7) and install stud in shift rod (6). Tighten stud
to 15 lb-ft (20 N•m).
Slide shift rod (6) in fork (5).
Coat threads of screw (4) with sealing compound.
Aline holes (8) and install screw (4). Tighten screw to 40 lb-ft (54 N•m).
Secure screw (4) with lockwire (3).
Install eight spring disks (2), alternating concaved surfaces, in pairs.
Install spacer (1).
d. Follow-on Maintenance. None.
END OF TASK
Change 3
8-43
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
Section III. TRANSFER CASE CONTROLS
8 - 1 2 . HI-LO RANGE TRANSFER CASE LOCK-UP VALVE REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
Models
All
Equipment Condition
TM or Para
Test Equipment
None
Special Tools
None
Supplies
Oil, lubricating, Item 48, Appendix C
Solvent, dry cleaning, Item 57, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
Condition Description
HI-LO range transfer case
lock-up valve on clean work
surface.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
References
None
a. Disassembly.
(1) Remove boot (1) and two nuts (2).
(2) Remove adapter (3), plunger (4), valve stem (5), and two preformed packings (6 and 7).
(3) Remove capnut (8), spring (9), seat (10), and inlet valve (11) from body (12).
8-44
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-13.
Appendix C
Appendix C
8-45
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-46
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-14.
LOCKOUT SHIFT CHAMBER REMOVAL/REPAIR/INSTALLATlON
This task covers:
d. Assembly
e. Installation
f. Follow-on Maintenance
a. Removal
b. Disassembly
c. Cleaning/Inspection
INITIAL SETUP
Models
All
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
Test Equipment
None
References
None
Special Tools
None
Supplies
Compound, sealing, pipe thread, Item 28.1,
Appendix C
Tags, identification, Item 60, Appendix C
Solvent, drycleaning, Item 57, Appendix C
Oil, lubricating, Item 46, Appendix C
Compound, sealing, Item 26, Appendix C
Adhesive, Item 8, Appendix C
Equipment Condition
Condition Description
TM or Para
TM 9-2320-279-10 Shut off engine.
Special Environmental Conditions
None
General Safety Instructions
Wheels chocked.
Level of Maintenance
Direct Support
a.
Removal.
NOTE
Tag and mark airhoses before disconnecting.
(1)
(2)
Disconnect two airhoses (1 and 2).
Remove elbow (3) and connector (4) from chamber body (5).
Change 3
8-47
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-14.
LOCKOUT SHIFT CHAMBER REMOVAL/REPAlR/lNSTALLATlON (CONT).
(3) Remove plug (6) and preformed packing (7).
(4) Remove locknut (8) and copper washer (9).
(5) Remove two screws (10), lockwashers (11), lockout shift chamber (12), and copper washer (13).
8-48
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
b. Disassembly.
WARNING
Spring inside chamber is under load. Remove ring clamp carefully to
avoid personal injury.
NOTE
A vise may be used to relieve spring pressure when disassembling
chamber.
(1)
(2)
(3)
Remove two nuts (1) and screws (2).
Remove ring clamp (3) and open vise.
Remove front cover (4).
Remove diaphragm (5) and spring (6).
Remove pilot ring (7) and seal (8) from
rear of chamber body (9).
(6) Deleted.
(4)
(5)
(7)
Remove nut (11), guide (12), and
diaphragm (13) from air pressure
plate (14).
Change 3
8-49
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-14.
c.
LOCKOUT SHIFT CHAMBER REMOVAl/REPAIR/INSTALLATlON (CONT).
Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. lb avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Clean all metal parts in drycleaning solvent.
(2) Inspect all metal parts for damage.
(3) Replace damaged parts.
d. Assembly.
(1)
Install diaphragm (1), guide (2), and
nut (3) on air pressure plate (4).
(2)
Install seal (5) and pilot ring (6) in rear of chamber body (7).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give
off harmful vapors, and are harmful to skin and clothing. To avoid
injury or death, keep away from open fire and use in well-ventilated
area. If adhesive, solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and water.
(3)
Coat rear of chamber body (7) with adhesive.
8-50 Change 3
TM 9-2320-279-34-1
Transfer Case Instructions (Cont)
(4)
Place ring clamp (9) on rear part of chamber body (7).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(5)
Coat threads of two screws (10) with sealing compound and install screws, lockwashers (11), and
rear part of chamber body (7).
NOTE
Check that shifter shaft is completely out.
(6)
e.
Soldier A installs copper washer (12), spring (13), and pushes diaphragm assembly (14) towards
chamber body (7) while Soldier B installs copper washer (15) and locknut (16).
Installation.
(1)
(2)
Press cover (1) in ring clamp (2) and
install two screws (3) and nuts (4).
Install preformed packing (5) and
plug (6).
Change 3
8-51
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-14.
LOCKOUT SHIFT CHAMBER REMOVAL/REPAIR/INSTALLATION (CONT).
WARNING
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors,
and are harmful to skin and clothing. To avoid
injury or death, keep away from open fire and
use in well-ventilated area. If adhesive,
solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and
water.
Coat threads of elbow (7) and
connector (8) with pipe thread sealing
compound.
(4) Install elbow (7).
(5) Install connector (8).
Connect two airhoses (9 and 10).
(6)
(3)
f.
Follow-on Maintenance. Start engine, build up air pressure, check for leaks (TM 9-2320-279-10).
END OF TASK
LUBRICATION PUMP REMOVAL/INSTALLATION.
8-15.
This task covers:
a. Removal
b. Installation
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Compound, sealing, Item 26, Appendix C
Compound, sealing, pipe thread, Item 28.1,
Appendix C
Adhesive, Item 8, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
8-52 Change 3
c. Follow-on Maintenance
References
None
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-10 Shut off engine.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
a.
Removal.
(1)
(2)
(3)
(4)
(5)
Disconnect lubrication hose (1) from fitting (2).
Remove four screws (3) and lockwashers (4).
Remove lubrication pump (5) from bearing cover (6).
Remove fitting (2) from lubrication pump (5).
Remove plug (7).
b. Installation.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1)
Coat pipe threads of fitting (2) with pipe thread sealing compound and install fitting in
lubrication pump (5).
(2) Coat pump mounting surface of bearing cover (6) with adhesive.
(2.1) Apply sealing compound to threads of four screws (3).
(3) Mount lubrication pump (5) on bearing cover (6) with four screws (3) and lockwashers (4).
Tighten screws to 15 lb-ft (20 N•m).
(4) Connect lubrication hose (1) to fitting (2).
(5) Coat threads of plug (7) with pipe thread sealing compound and install plug.
c.
Follow-on Maintenance. None.
END OF TASK
Change 3 8-53
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-16. LUBRlCATlON PUMP REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
TM or Para
Special Tools
None
Supplies
Grease, automotive and artillery, Item 34,
Appendix C
Solvent, dry cleaning, Item 57, Appendix C
Paper, abrasive, garnet, (emery cloth),
Item 51, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
a. Disassembly.
(1) Remove two screws (1),
head (2) and gasket (3)
from casing (4).
(2) Remove two needle
bearings (5) from head (2).
(3) Remove gear (6) and
shaft (7).
(4) Remove shaft (8) with
gear (9).
8-54
Condition Description
Lubrication pump on clean
work surface.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
TM
9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-55
TM 9-2320-279-34-1
Transfer Case Maintenance Instructions (Cont)
8-56
TM 9-2320-279-34-1
CHAPTER 9
AXLES NO. 1 A N D N O . 2 M A I N T E N A N C E
Para
Contents
9-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Shaft Assembly Removal/Repair/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Axle No. l Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Axle No. 2 Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Axle Housing Cover Assembly, Axle No. 2 Removal/Repair/Installation . . . . . . . . . . . . . . . . 9-5
Axles No. land No. 2 Yoke and Oil Seal Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Differential Carrier, Axle No. l Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Differential Carrier Cover, Axle No. 2 Removal/Installation.. . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Differential Carrier Cover, Axle No. 2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Differential Carrier, Axle No. 2 Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Differential Carrier, Axle No. l Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Differential Carrier, Axle No. 2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Ball Socket Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Axles No. land No. 2 Ball, Bushing, and Oil Seal Removal/Installation . . . . . . . . . . . . . . . . 9-14
Section I.
Page
9-1
9-2
9-6
9-10
9-14
9-17
9-19
9-22
9-26
9-35
9-38
9-56
9-82
9-94
INTRODUCTION
9-1. GENERAL.
This chapter contains maintenance instructions for removal, installation, and repair of
No. 1 and No. 2 axles at the direct support and general support maintenance level. The subassemblies and
parts which must be removed before the axles and their components can be removed are referenced to
other paragraphs or chapters of this manual or TM 9-2320-279-20.
9-1
TM 9-2320-279-34-1
Section Il. AXLE ASSEMBLIES
9-2. AXLE SHAFT ASSEMBLY REMOVAL/REPAIR/INSTALLATION.
9-2
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
(2)
Matchmark axle skein (2), brake
spider (3), and ball socket (4).
NOTE
.
It may be necessary to adjust brake
camshaft to remove axle skein,
.
Pin should not be removed unless
necessary
(3)
Remove axle skein (2), brake spider (3),
and pin (4.1) from axle shaft
assembly (5).
Remove brake spider (3) from axle
skein (2).
Remove axle shaft assembly (5) from ball
socket (4).
(4)
(5)
MATCHMARK
b. Dissssembly.
CAUTION
ONE MATCHMARK
Before splitting cage ring, axle shafts and cage
ring halves must be marked to insure correct
assembly. Cage ring halves sometimes have
dowel pins to insure proper assembly, but
shafts can be assembled improperly into cage
ring itself. Axle shaft yoke trunnion must be
replaced into same cage ring holes in order to
insure proper operation.
TWO MATCHMARKS
(1)
Matchmark both halves of cage ring (1).
Change
3
9-3
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-2. AXLE SHAFT ASSEMBLY REMOVAL/REPAlR/lNSTALLATlON (CONT).
(2) Remove eight screws (2)
from cage ring halves (1).
(3) Remove cage ring halves (1)
from shafts (3 and 4).
(4) Assemble cage ring
halves (1) with eight
screws (2). Tighten screws
to 30 lb-ft (41 N•m).
(5) Measure inside diameter of
cage ring halves (1) and
outside diameter of yokes
on shafts (3 and 4). If
difference is more than
0.200 in. (5.08 mm), replace
cage ring halves (1) and
shafts (3 and 4).
(6) Remove eight screws (2)
from cage ring halves (1).
c. Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can bum easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(1) Clean parts in dry cleaning solvent.
(2) Inspect parts for damage.
(3) Replace damaged parts.
d. Assembly.
(1) Apply light film of grease to
four trunnions (1) and two
halves of cage ring (2).
(2) Aline matchmarks and
install two halves of cage
ring (2) on two shafts (3
and 4).
(3) Install eight screws (5). Do
not tighten.
(4) Move two shafts (3 and 4)
to check for free
side-to-side movement
inside cage ring (2).
(5) Tighten eight screws (5) to
95 lb-ft (129 N•m).
9-4
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
e.
Installation.
(1)
(2)
(3)
Turn ball socket (1) to straight ahead
position.
Apply thin coat of oil to polished surfaces
of axle shaft assembly (2).
Pack cage ring (3) with grease.
CAUTION
Use care when installing axle shaft. Axle
housing oil seal could be damaged.
(4)
(5)
Install axle shaft assembly (2) in ball
socket (1) long end first.
Fill ball socket (1) and cage ring (3) with
7.5 to 8.5 lbs (3.40 to 3.86 kg) of grease.
WARNING
Adhesives, solvents, and sealing compounds
can burn easily, can give off harmful vapors,
and are harmful to skin and clothing. To avoid
injury or death, keep away from open tire and
use in well-ventilated area. If adhesive,
solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and
water.
(6)
Apply thin coat of silicone
adhesive-sealant to both sides of brake
spider (4) and axle skein (5).
NOTE
If pin was removed, perform step (6.1). If pin
was not removed, proceed to step (7).
(6.1) Install pin (5.1) in ball socket (1).
(7) Aline matchmarks on brake spider (4)
with marks on axle skein (5).
(8) Install brake spider (4) and axle skein (5)
over axle shaft assembly (2).
(9) Aline matchmarks on brake spider (4)
and axle skein (5) with matchmarks on
ball socket (1).
Change
3
9-5
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-2. AXLE SHAFT ASSEMBLY REMOVAL/REPAIR/INSTALLATION (CONT).
(10) Apply silicone adhesive-sealant to underside of heads
of 10 screws (6).
(11) Install 10 screws (6). Tighten screws to 185 to
190 lb-ft (251 to 257 N•m).
(12) Apply thin coat of grease to bearing and seal surfaces
of axle skein (6).
f. Follow-on Maintenance.
(1) Install front brakeshoes (TM 9-2320-279-20).
(2) Fill axle (LO 9-2320-279-12).
END OF TASK
9-3. AXLE NO. 1 REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Preventive, rust, Item 53, Appendix C
oil, lubricating, Item 46, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
None
Equipment Condition
TM or Para
TM 9-2320-279-20
Condition Description
Propeller shaft removed
from No. 1 axle.
Ball and bushing removed
Para 9-14
from No. 1 axle.
TM 9-2320-279-20 Shocks removed from No. 1
axle.
Para 14-4
Lateral torque rod removed
(front only).
Special Environmental Conditions
None
General Safety Instructions
Wheels chocked.
Level of Maintenance
Direct Support
9-6
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-7
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-8
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-9
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-4. AXLE NO. 2 REMOVAL/ INSTALLATION
9-10
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
NOTE
Tag and mark air lines before disconnecting.
(1)
(2)
(3)
(4)
Disconnect two air lines (1 and 2) from
lockout air chamber (3).
Remove three screws (4), washers (5),
nuts (6), lockwashers (7), and clamps (8)
from three brackets (9). Move two
hoses (10 and 11) aside.
Remove fitting (12) from lockout air
chamber (3).
Position suitable lifting device and
secure to axle (13).
NOTE
.
Do not disconnect frame end of
torque rod.
.
Some models of vehicles contain
washers between torque rod and axle.
Perform step (5.1) for these models.
Remove two locknuts (14), screws (15),
and four washers (16), and disconnect
axle end of torque rod (17).
(5.1) Remove two locknuts (14), screws (15),
four washers (16), two washers (16.1),
and disconnect axle end of torque
rod (17).
(5)
NOTE
Screw on left side can only be removed
with inner beam end adapter.
Remove two locknuts (18), four
washers (19), two screws (20),
and four beam end adapters (21)
from two equalizer beams (22).
(7) Soldier A and Soldier B remove
axle (13).
(6)
Change 3
9-11
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-4. AXLE NO. 2 REMOVAL/INSTALLATION (CONT).
b. Installation.
(1)
(2)
Secure axle (1) to suitable lifting device.
Soldier A and Soldier B install axle (1)
and aline holes in two axle beam hanger
brackets (2) with holes in two equalizer
beams (3).
(3)
Lubricate threads of two screws (4)
with oil and four beam end
adapters (5) with rust preventive.
NOTE
Screw on left side can only be installed with
inner beam end adapter.
(4)
Install two screws (4), four
washers (5), four beam end
adapters (6) and two nuts (7)
loosely.
NOTE
Some models of vehicles require washers
between torque rod and axle. Perform
step (5.1) for these models.
Lower torque rod (8) onto axle (1).
Lubricate two screws (9) with oil and
install screws, four washers (10), and
two locknuts (11).
(5.1) Lower torque rod (8) onto axle (1) with
two washers (8.1) positioned between
torque rod and axle. Lubricate two
screws (9) with oil and install screws,
four washers (10), and two locknuts (11).
(6) Tighten two locknuts (11) to 95 to
130 lb-ft (129 to 176 N•m).
(5)
9-12 Change 3
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance lnstructions (Cont)
9-13
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-5. AXLE HOUSING COVER ASSEMBLY, AXLE NO. 2 REMOVAL/REPAIR/
INSTALLATION.
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Grease, automotive and artillery, GAA,
Item 34, Appendix C
Solvent, dry cleaning, Item 57, Appendix C
Adhesive-sealant, silicone, Item 6, Appendix C
Oil, lubricating, gear, Item 47, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
9-14
Change 7
d. Assembly
e. Installation
f. Follow-on Maintenance
References
None
Equipment Condition
TM or Para
Condition Description
LO 9-2320-279-12 Axle lubrication drained.
Para 9-6
Yoke and oil seal removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
a.
Removal.
(1)
Remove screw (1) and lockwasher (2).
NOTE
•
Perform step (2) for Non-A2 and
A2R1 model vehicles.
•
Perform step (2.1) for A2 and A2R1
model vehicles.
(2)
Remove 11 nuts (3), lockwashers (4), and
four tapered locks (5).
(2.1)
(3)
Remove 11 screws (3.1), lockwashers (4)
and four tapered locks (5).
Remove cover (6).
Change 7
9-14.1/(9-14.2 blank)
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
(4) Remove bearing sleeve (7).
b. Disassembly.
(1) Remove pipe plug (1) and magnetic plug (2) from
cover (3).
(2) Remove retaining ring (4).
(3) Remove roller bearing (5).
c. Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors, and are harmful to
skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets on skin or
clothing, wash immediately with soap and water.
(1) Clean all metal parts with dry cleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment, goggles,
shield, and gloves.
(2) Dry metal parts, except bearings, with compressed air.
(3) Allow bearings to air dry.
(4) Inspect metal parts for breaks, cracks, and sharp edges.
(5) Inspect machined parts for nicks and burrs.
(6) Inspect bearings for loose rollers and cracked or broken races.
(7) Coat bearing with lubricating oil.
(8) Inspect dowel pins and mounting studs for cracks, breaks, and damaged threads.
(9) Replace all damaged parts.
d. Assembly.
(1) Pack roller bearing (5) with grease and install in cover (3).
(2) Install retaining ring (4).
(3) Install magnetic plug (2) and pipe plug (1).
9-15
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-5. AXLE HOUSING COVER ASSEMBLY, AXLE NO. 2 REMOVAL/REPAIR/
INSTALLATION (CONT).
e.
Installation.
(1)
Install bearing sleeve (1).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
NOTE
(2)
(2.1)
(3)
f.
9-16
•
Perform step (2) for Non-A2 and A2R1 model vehicles.
•
Perform step (2.1) for A2 and A2R1 model vehicles.
Apply silicone adhesive-sealant and install cover (2) with four tapered locks (3),
11 lockwashers (4), and nuts (5). Tighten nuts to 55 lb-ft (75 NSm).
Apply silicone adhesive-sealant and install cover (2) with four tapered locks (3), 11 lockwashers
(4), and screws (5). Tighten screws to 55 lb-ft (75 NSm).
Install lockwasher (6) and screw (7). Tighten screw to 40 lb-ft (54 NSm).
Follow-on Maintenance.
(1)
Install yoke and oil seal (para 9-6).
(2)
Fill axle (LO 9-2320-279-12).
Change 7
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-17
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-6.
9-18
TM 9-2320-279-34-1
Axles No. 7 and No. 2 Maintenance Instructions (Cont)
(3) Lubricate oil seal (7) with oil. Install oil seal on shaft (8).
(4) Install yoke (9) with flanged nut (10). Soldier A and Soldier B tighten nut to 840 to 1020 lb-ft
(1139 to 1383 N•m).
(5) Set TRACTION CONTROL lever to OFF position (TM 9-2320-279-10).
d . Follow-on Maintenance. Install propeller shaft (TM 9-2320-279-20).
END OF TASK
Section III. DIFFERENTIAL CARRIERS
9-7. DIFFERENTIAL CARRIER, AXLE NO. 1 REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Cleaning/Inspection
c. Installation
d. Follow-on Maintenance
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
Special Tools
None
Supplies
Solvent, dry cleaning, Item 57, Appendix C
Adhesive-sealant, silicone, Item 6, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
TM or Para
Para 9-3
Condition Description
Axle No. 1 removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
9-19
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance instructions (Cont)
9-7. DIFFERENTIAL CARRIER, AXLE NO. 1 REMOVAL/INSTALLATION (CONT).
a. Removal.
NOTE
(1)
(2)
(2.1)
(2.2)
(2.3)
.
There are two models of axle housings: Model A and Model B. The differential carrier
is mounted on Model A housing by studs, lockwashers, and nuts. The differential
carrier is mounted on Model B housing by a combination of studs, lockwashers, and
nuts, and screws and lockwashers.
.
Do steps (1), (2), and (3) through (5) for Model A housing.
.
Do steps (1) and (2.1) through (5) for Model B housing.
Mark location of air line brackets (1) on differential carrier (2).
Remove 12 nuts (3), lockwashers (4), and three air line brackets (1) from differential carrier (2).
Remove four nuts (3) and lockwashers (4) from differential carrier (2).
Tag and mark placement of 2 1/4 inch screws and 1 3/4 inch screws during removal.
Remove eight screws (4.1), lockwashers (4.2), and three air line brackets (1).
WARNING
Keep out from under differential carrier. Serious injury may result if differential
carrier falls from lifting device.
CAUTION
Do not strike differential carrier to loosen if stuck. Tap around edge of flange to
avoid damage.
(3)
(4)
(5)
Attach lifting device to differential carrier (2).
Soldier A removes differential carrier (2) while Soldier B operates lifting device.
Mount differential carrier (2) on stand. Remove lifting device.
9-20 Change 3
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
b. Cleaning/Inspection.
(1)
Scrape dirt and old sealant from mounting
surface (1) on axle housing (2).
WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. To avoid injury or
death, keep away from open fire and use in
well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash
immediately with soap and water.
(2)
(3)
(4)
(5)
c.
Use drycleaning solvent to clean axle
housing (2).
Use clean cloth to wipe dry.
Inspect mounting studs (3) for cracks, breaks, and damaged threads. Replace if damaged.
Inspect axle housing (2) for cracks or damage. Replace if damaged.
Installation.
WARNING
Keep out from under differential carrier. Serious injury may result if differential
carrier falls from lifting device.
(1)
(2)
(3)
Attach suitable lifting device to differential carrier (1).
Soldier A removes differential carrier (1) from stand while Soldier
B operates lifting device.
Apply silicone adhesive-sealant in
pattern illustrated on mounting
surface (2) of axle housing (3).
Change 3
9-20.1/(9-20.2 blank)
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
(4)
Install differential carrier (1) on axle housing (3).
NOTE
.
There are two models of axle housings: Model A and Model B. The
differential carrier is mounted on housing A by studs,
lockwashers, and nuts. The differential carrier is mounted on
housing B by a combination of studs, lockwashers, and nuts, and
screws and lockwashers.
.
Do steps (5) and (6) for housing A.
.
Do steps (5.1), (5.2), and (6) for housing B.
(5)
Install three air line brackets (4), 12 lockwashers (5), and nuts (6). Tighten nuts to
180 lb-ft (244 N•m).
NOTE
Ensure 2 1/4 inch and 1 3/4 inch screws are positioned as tagged and marked
during removal.
(5.1) Install three air line brackets (4), eight lockwashers (5), and screws (6).
(5.2) Install four lockwashers (6.1) and nuts (6.2) on differential carrier. Tighten nuts to
180 lb-ft (244 N•m).
(6) Remove lifting device from differential carrier (1).
d. Follow-on Maintenance.
(1)
(2)
Install No. 1 axle (para 9-3).
Fill axle (LO 9-2320-279-12).
END OF TASK
Change 3
9-21
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenances Instructions (Cont)
9-8. DIFFERENTIAL CARRIER COVER, AXLE NO. 2 REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Installation
INITIAL SETUP
Models
All
References
None
Test Equipment
Indicator, dial J7872
Equipment Condition
TM or Para
Condition Description
LO 9-2320-279-12 Axle drained.
TM 9-2320-279-20 Propeller shafts removed.
Special Tools
Socket, 2 7/8-in. IM 923
Special Environmental Conditions
None
Supplies
Solvent, drycleaning, Item 57, Appendix C
Adhesive-sealant, silicone, Item 6, Appendix C
Oil, lubricating, Item 46, Appendix C
Tags, identification, Item 60, Appendix C
Compound, sealing and thread locking,
Item 25, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
a.
c. Follow-on Maintenance
Removal
9-22 Change 3
General Safely Instructions
None
Level of Maintenance
Direct Support
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance lnstructions (Cont)
9-23
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-24
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
NOTE
To tighten yoke nut, use torque multiplier
and 250 lb-ft capacity ratchet end torque
wrench.
(8) Tighten locknut (8) to 840 to 1020 lb-ft
(1 139 to 1 383 N•m).
(9) Attach dial indicator to yoke (9).
(10) Push yoke (9) in, then pry yoke away
from bearing cover (10) and read amount
of end play on dial indicator. Allowable
end play is 0.003 to 0.007-in. (0.08 to
0.18 mm).
(11) Remove dial indicator from yoke (9).
NOTE
• Steps (12) through (18) are performed only if end play adjustment is required.
• If measured end play is more than allowable amount, shims must be removed.
If measured end play is less than allowable amount, shims must be added.
( 1 2 ) To correct amount of end play, remove locknut (8), washer (11), and yoke (9).
(13) Remove five screws (12) and lockwasher (13) from bearing cover (10).
(14) Remove bearing cover (10).
(15) Add or remove shims (14) as necessary.
(16) Install bearing cover (10) over shims (14).
(17) Apply thread locking compound to five screws (12) and install lockwashers (13) and screws.
Tighten screws to 75 to 86 lb-ft (102 to 115 N•m).
(18) Install yoke (9), washer (11), and locknut (8). Using 2 7/8-in. socket, tighten nut to 840 to
1020 lb-ft (1 139 to 1 383 N-m).
9-25
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-8. DIFFERENTIAL CARRIER COVER, AXLE NO. 2 REMOVAL/lNSTALLATlON (CONT).
(19)
(20)
c.
Install fitting (15) in lockout air
chamber (16).
Connect two air lines (17 and 18) to
lockout air chamber (16).
Follow-on Maintenance.
(1)
(2)
Install propeller shafts (TM 9-2320-279-20).
Fill axle (LO 9-2320-279-12).
END OF TASK
9-9. DIFFERENTIAL CARRIER COVER, AXLE NO. 2 REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
INITIAL SETUP
ModeIs
All
Test Equipment
None
Special Tools
Socket, 2 7/8-in. IM 923
Supplies
Solvent, drycleaning, Item 57, Appendix C
Adhesive-sealant, silicone, Item 6, Appendix C
Oil, lubricating, gear, Item 43, Appendix C
Compound, sealing, Item 28, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
9-26 Change 3
c. Assembly
d. Follow-on Maintenance
References
None
Equipment Condition
TM or Para
Condition Description
Differential carrier cover on
clean work surface.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-27
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-9.
9-28
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance lnstructions (Cont)
9-29
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-9.
9-30
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-31
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-32
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-33
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-34
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
(28) Tighten locknut (16) to 35 to
45 lb-ft (47 to 61 N•m).
(29) install D-washer (46) and thrust
washer (47) on input shaft (33).
WARNING
Wear safety glasses while installing
retaining rings to protect eyes from
possible injury or blindness.
(30) Install helical side gear (35) and
retaining ring (48) on input
shaft (33).
d. Follow-on Maintanance. None.
END OF TASK
9-10. DIFFERENTIAL CARRIER, AXLE NO. 2 REMOVAL/lNSTALLATlON.
This task covers:
a. Removal
b. Cleaning/Inspection
c. Installation
d. Follow-on Maintenance
INITIAL SETUP
Models
All
Test Equipment
None
Special Tools
None
Supplies
Solvent, dry cleaning, Item 57, Appendix C
Adhesive-sealant, silicone, Item 6, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
References
None
Equipment Condition
TM or Para
Para 9-4
Para 9-5
Para 9-8
Condition Description
Axle No. 2 removed.
Axle housing cover assembly,
No. 2 removed.
Differential carrier cover
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
9-35
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-10.
a.
DIFFERENTIAL CARRIER, AXLE NO. 2 REMOVAL/INSTALLATION (CONT.).
Removal.
NOTE
.
There are two models of axle
housings: Model A and Model B. The
differential carrier is mounted on
Model A housing by two screws and
10 studs and nuts. The differential
carrier is mounted on Model B
housing by eight screws and four
studs and nuts.
.
Do steps (1) through (3) and (4)
through (6) for Model A housing. Do
steps (1) and (3.1) through (6) for
Model B housing.
Remove two screws (1), lockwashers (2),
and bracket (3) from differential
carrier (4).
(2) Remove 10 nuts (5), lockwashers (6), and
two brackets (7).
(3) Mark location and remove four tapered dowels (8).
(3.1) Remove four nuts (5), lockwashers (6), and tapered dowels (8) from differential carrier.
(3.2) Remove six screws (1), lockwashers (2), and two brackets (7).
(1)
WARNING
Keep out from under differential carrier. Serious injury may result if differential
carrier falls from lifting device.
CAUTION
(4)
(5)
(6)
Do not strike differential carrier to loosen. Tap around edge of flange to avoid
damage.
Attach lifting device to differential carrier (4).
Soldier A removes differential carrier (4) while Soldier B operates lifting device.
Mount differential carrier (4) on stand
and fasten in place. Remove lifting
device.
9-36 Change 3
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
b. Cleaning/Inspection.
(1)
Scrape dirt and old sealant from mounting surface (1) on axle housing (2).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(2)
(3)
(4)
(5)
c.
Use drycleaning solvent to clean axle housing (2).
Use clean cloth to wipe dry.
Inspect mounting studs (3) for cracks, breaks, and damaged threads. Replace if damaged.
Inspect axle housing (2) for cracks or damage. Replace if damaged.
Installation.
WARNING
Keep out from under differential carrier. Serious injury may result if differential
carrier falls from lifting device.
NOTE
There are two models of axle housings: Model A and Model B. The
differential carrier is mounted on Model A housing by two screws
and 10 studs and nuts. The differential carrier is mounted on Model
B housing by eight screws and four studs and nuts.
Do steps (1) through (7), (8), and (9) for Model A housing. Do
steps (1) through (6), (7.1) through (7.4), (8) and (9) for Model B
housing.
(1)
(2)
Attach lifting device to differential carrier (1).
Soldier A removes differential carrier (1) from stand while Soldier B
operates lifting device.
Change 3
9-36.1/(9-36.2 blank)
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance instructions (Cont)
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off
harmful vapors, and are harmful to skin and clothing. lb avoid injury or
death, keep away from open fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets on skin or clothing, wash
immediately with soap and water.
(3)
Apply silicone adhesive-sealant on inside edge of axle
housing (2) mounting surface.
(4)
Soldier A installs differential carrier (1) in
axle (2) while Soldier B operates lifting
device.
Install bracket (3), two lockwashers (4),
and screws (5).
Install four tapered dowels (6).
Install two brackets (7), 10
lockwashers (8), and nuts (9).
Install two brackets (7) and six
lockwashers (4) and screws (5).
Install four tapered dowels (6),
lockwashers (8), and nut (9).
Install bracket (3), two lockwashers (4),
and screws (5).
Tighten all screws to 180 lb-ft (244 N•m).
Tighten screws (5) to 210 to 230 lb-ft (285
to 312 N•m).
Tighten nuts (9) to 150 to 170 lb-ft (203
to 231 N•m).
(5)
(6)
(7)
(7.1)
(7.2)
(7.3)
(7.4)
(8)
(9)
d.
Follow-on Maintenance.
(1)
(2)
(3)
Install differential carrier cover (para 9-8).
Install axle housing cover assembly, No. 2 (para 9-5).
Install axle No. 2 (para 9-4).
END OF TASK
Change 3
9-37
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-11.
DIFFERENTIAL CARRIER. AXLE NO. 1 REPAIR.
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
d. Follow-on Maintenance
INITIAL SETUP
ModeIs
All
Personnel Required
MOS 63W, Wheel vehicle repairer (2)
Test Equipment
Indicator, dial
Scale, spring, with attaching soft wire
References
None
Special Tools
Socket, 2 1/4-in. lM723
Supplies
Oil, lubricating, gear, Item 44, Appendix C
Solvent, drycleaning, Item 57, Appendix C
Dye, prussian blue, Item 32, Appendix C
Lockwire, Item 39, Appendix C
Adhesive-sealant, silicone, Item 6,
Appendix C
Compound, sealing, and thread locking, Item
25, Appendix C
Compound, sealing, Item 28, Appendix C
9-38 Change 3
Equipment Condition
Condition Description
TM or Para
Differential carrier, axle
No. 1 on clean work
surface.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
General Support
TM
9-2320-279-34-1
Axles No. land No. 2 Maintenance lnstructions (Cont)
9-39
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-40
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-41
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-42
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-43
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-11.
9-44
TM
9-2320-279-34-1
Axles No. 1 and No.2 Maintenance lnstructions (Cont)
9-45
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-46
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-47
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-48
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance lnstructions (Cont)
9-49
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-11.
9-50
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-51
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-52
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-53
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance lnstructions (Cont)
9-11.
9-54
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance lnstructions (Cont)
9-55
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-12. DIFFERENTIAL CARRIER, AXLE NO. 2 REPAIR.
9-56
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-57
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-58
T M
9 - 2 3 2 0 - 2 7 9 - 3 4 - 1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-59
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-12. DIFFERENTIAL CARRIER, AXLE NO. 2REPAIR (Cont)
9-60
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cent)
9-61
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-62
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-63
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-64
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
(48)
(49)
(50)
Remove filler plug (65) from
differential carrier (3).
Remove two screws (66),
lockwashers (67), and cover (66).
Remove two expansion plugs (69).
b. Cleaning/Inspection.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep
away from open fire and use in well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash immediately with soap and
water.
NOTE
If differential carrier housing must be replaced, the new housing will come as
part of a kit. This kit will contain parts not required in this application. Refer to
TM 9-2320-279-24P for proper identification of parts.
(1)
Clean all metal parts with drycleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment, goggles,
shield, and gloves.
(2)
(3)
(4)
(5)
(6)
Use clean, lint-free cloth or compressed air to dry all metal parts, except bearings.
Allow bearings to air dry.
Scrape old sealant from carrier.
Inspect all metal parts for breaks, cracks, and sharp edges.
Inspect machined parts for nicks and burrs.
NOTE
If support bearing is bad, replace support bearing race (para 9-9).
(7)
(8)
(9)
(10)
(11)
Inspect bearings for loose rollers and cracked or broken races.
Coat bearings with lubricating oil.
Replace differential and output shaft bushings.
If pinion or ring gear is bad, replace both as a matched set.
Inspect dowel pins for breaks or cracks. Replace if damaged.
Change 3
9-65
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-12. DIFFERENTIAL CARRIER, AXLE NO. 2 REPAIR (CONT).
c. Assembly.
(1) Install bearing cone (1) on differential case flanged
half (2).
(2) Install bearing cone (3) on differential case plain half (4).
(3) Install thrust washer (5) and side gear (6) in differential
case flanged half (2).
(4) Lubricate spider (7) and install four side pinions (8)
and thrust washers (9) on spider.
9-66
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-67
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-12
9-68
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-69
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-70
TM
9-2320-279-34-1
Axles No. land No.2 Maintenance lnstructions (Cont)
9-71
TM 9-2320-279-34-1
9-72
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
(50) Install same number and size of
shims (32) recorded in disassembly
step (42).
WARNING
Adhesives, solvents, and sealing
compounds can burn easily, can give off
harmful vapors, and are harmful to skin
and clothing. To avoid injury or death,
keep away from open fire and use in
well-ventilated area. If adhesive, solvent,
or sealing compound gets on skin or
clothing, wash immediately with soap and
water.
(51) Apply sealing compound to flange of
bearing cage (23).
(52) Install bearing cage (23) on differential
carrier (17).
(53) Apply thread locking compound to threads of six
screws (33) and install screws and six lockwashers (34).
Tighten screws to 155 to 175 lb-ft (210 to 237 N·m).
(54) Coat outside diameter of bearing cage (23) with sealing
compound.
(55) Install bearing cup (35) in bearing adjuster (36).
9-73
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-12. DIFFERENTIAL CARRIER, AXLE NO. 2 REPAIR (CONT).
(56) Install two bushings (37) in differential carrier (17).
(57) Attach suitable lifting device to assembled
ring gear and differential (38).
(58) Lubricate bearing cones (1 and 3) with oil and
position bearing cup (39) on bearing cone (3).
NOTE
Ring gear must be tilted to clear casting inside
carrier.
(59) Soldier A installs assembled ring gear and
differential (38) into differential carrier (17)
while Soldier B operates lifting device.
CAUTION
Threads on bearing adjusters can be damaged if
bearing adjusters are not installed carefully.
(60) Install bearing cap (40) with two screws (41)
and washers (42). Tighten screws finger-tight.
(61) Install bearing cap (43) with two screws (44)
and washers (45). Tighten screws finger-tight.
(62) Install bearing adjusters (36 and 46)
finger-tight.
(63) Remove lifting device.
(64) Tighten four screws (41 and 44) to 40 to
50 lb-ft (54 to 68 N·m).
9-74
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance lnstructions (Cont)
(65) Install pinion gear (31) on pinion (30).
NOTE
Support bearing and bearing race are provided as a set,
Replace support bearing race (para 9-9) whenever
support bearing is replaced.
(66) Install support bearing (47) and locknut (48). Tighten
locknut to 980 lb-ft (1 329 N·m).
NOTE
Aline notch in bearing adjusters with mark on bearing
cap.
(67) Tighten bearing adjuster (46) until one thread shows.
(68) Tighten bearing adjuster (36) until ring gear (13)
cannot be rocked back and forth toward two bearing
adjusters and there is no backlash.
(69) Rotate ring gear (13) and check for bind. If ring gear
binds, loosen bearing adjuster (36) then tighten until
ring gear does not bind.
(70) Tighten bearing adjuster (46) until it contacts bearing
cup or resists turning.
(71) Tighten bearing adjuster (46) two or three more
notches until ring gear (13) has backlash.
TA355977
NOTE
If old pinion and ring gear are used, backlash
should be the same as recorded in disassembly
step (11). If new pinion and ring gear are used,
backlash should be 0.008 to 0.018 in. (0.203 to
0.457 mm).
(72) Move ring gear (13) back and forth to measure
backlash with dial indicator If backlash is
correct, go to step (81). If there is too much
backlash, go to step (77). If there is not enough
backlash, continue with step 3).
9-75
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-12. DIFFERENTIAL CARRIER, AXLE NO. 2 REPAIR (CONT).
(73) To add backlash, loosen bearing adjuster (46) five or six notches.
(74) Loosen bearing adjuster (36) one notch.
(75) Tighten bearing adjuster (46) until bearing adjuster resists movement, then tighten two or three
more notches.
(76) Repeat step (72).
(77) To remove backlash, loosen bearing adjuster (46) five or six notches.
(78) Tighten bearing adjuster (36) one notch.
(79) Tighten bearing adjuster (46) until bearing adjuster resists movement, then tighten two or three
more notches.
(80) Repeat step (72).
(81) Paint one-third of teeth on ring gear (13) with prussian blue dye.
(82) Roll ring gear (13) one-third turn, then rock ring gear forward and backward to set pattern in
.dye.
9-76
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance lnstructions (Cont)
CORRECT PATTERN (NEW GEARING)
NOTE
●
A correct gear pattern for a used pinion and ring gear is clear of the toe and
centers evenly along the face of gear tooth, but can be any length and shape
and is acceptable as long as pattern does not run off gear tooth at any point.
●
If gear pattern was correct at disassembly, then gear pattern after assembly
should be the same.
●
If pattern is not the same, review steps (84) through (87) and adjust backlash as
required until pattern that was recorded at disassembly is reached.
●
If pattern was incorrect (pattern runs off gear tooth) at disassembly then, after
assembly, review steps (84) through (87) and adjust backlash as required until
correct gear pattern (pattern does not run off gear teeth) is reached.
●
Remember, a correct gear pattern for a used pinion and ring gear does not have
to match PATTERN A (correct pattern for new gearing).
If new pinion and ring gear are used, tooth pattern should be like correct
pattern A above. If tooth pattern does not look like A, check patterns B
through E to find one that looks close to ring gear tooth pattern, then do step
that follows incorrect pattern.
(83) If tooth contact is like pattern A, do not adjust. Go to step (88).
9-77
TM 9-2320-279-34-1
Axles No. 1 and
No. 2 Maintenance Instructions (Cont)
19-12. DIFFERENTIAL CARRIER, AXLE NO. 2 REPAIR (CONT).
(84) If tooth contact is like pattern B, add backlash,
steps (73) through (76). Repeat steps (81) through
(83).
(85) If tooth contact pattern is like pattern C,
remove backlash, steps (77) through (80).
Repeat steps (81) through (83).
NOTE
To add or remove shims in steps (86) and (87)
remove ring gear and differential assembly
(steps (15) through (23) in Disassembly) and
pinion (steps (39) through (42) in Disassembly).
Add or remove shims, then install pinion, ring
gear, and differential assembly (steps (51)
through (66)).
(86) If tooth contact is like pattern D, move pinion
closer to ring gear (13) by removing shims.
Repeat steps (72) through (83).
9-78
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
(87) If tooth contact is like pattern E, move pinion away
from ring gear (13) by adding shims. Repeat steps (72)
through (83).
(88) Tighten four screws (41 and 44) to
370 to 430 lb-ft (502 to 583
).
NOTE
Bearing adjuster may be turned slightly
to aline adjuster locks.
(89) Install adjuster lock (49) and cotter
pin (50) on bearing cap (43).
(90) Install lockwire on four screws (41
and 44).
(91) Install adjuster lock (51) with two
screws (52).
(92) Install lockwire on two screws (52).
9-79
TM
9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
19-12. DIFFERENTIAL CARRIER, AXLE NO. 2 REPAIR (CONT).
NOTE
To install roll pin do not loosen locknut. Always tighten locknut to aline holes.
(93) Install roll pin (53) through locknut (48) and pinion (30).
(94) Install bearing cup (54) in differential carrier (17).
(95)
(96)
(97)
(98)
Install bearing (55) on side gear (56).
Install bushing (57) in end of output shaft (58).
Apply lubricating oil to two preformed packings (59) and install on output shaft (58).
Install side gear (56) and assembled parts on output shaft (58).
WARNING
Wear safety glasses while installing retaining rings to protect eyes from possible
injury or blindness.
(99) Install retaining ring (60) on end of output shaft (58).
9-80
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
(100) Install output shaft (58) and assembled parts in differential carrier (17).
(101) Lubricate spider (61), four bushings (62), and side pinions (63) and install bushings, side pinions,
and thrust washers (64) on spider.
(102) Aline matchmarks and install inter-axle differential case halves (65 and 66) on spider (61) with
assembled parts.
(103) Install eight screws (67) and locknuts (68) in two inter-axle differential case halves (65 and 66).
Tighten locknuts to 17 to 23 lb-ft (23 to 31 N•m).
9-81
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-12.
DIFFERENTIAL CARRIER, AXLE NO. 2 REPAIR (CONT).
CAUTION
Inter-axle differential and output shaft are not
secured in carrier and can fall out and be
damaged if differential carrier is tipped over.
(104) Install assembled inter-axle
differential (69) on side gear (56) so
eight locknuts (68) face outward.
d.
Follow-on Maintenance. None
END OF TASK
Section IV.
BALL SOCKET
9-13.
BALL SOCKET REMOVAL/INSTALLATION.
This task covers:
a. Removal
b. Cleaning/Inspection
INITIAL SETUP
ModeIs
All
Test Equipment
Scale, spring
Special Tools
None
Supplies
Grease, automotive and artillery, Item 34,
Appendix C
Adhesive, Item 2.1, Appendix C
Adhesive-sealant, silicone, Item 6, Appendix C
Tags, identification, Item 60, Appendix C
Solvent, drycleaning, Item 57, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
References
None
9-82 Change 3
c. Installation
d. Follow-on Maintenance
Equipment Condition
TM or Para
Condition Description
TM 9-2320-279-10 Wheel and tire assembly
removed.
LO 9-2320-279-12 Axle drained.
TM 9-2320-279-20 Brake chamber removed.
TM 9-2320-279-20 Slack adjuster and
camshaft removed.
TM 9-2320-279-20 Steering arm removed.
TM 9-2320-279-20 Tie rod removed.
Axle shaft assembly
Para 9-2
removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
a . Removal.
(1) Record number and
thickness of shims (1) and
remove shims from studs (2)
on left-hand ball socket (3).
TA191142
NOTE
Steps (2) and (3) are for both left and right sides.
(2) Remove pipe plug (4).
(3) Remove four screws (5), lockwashers (6), bottom
cover (7), and shims (8) from ball socket (3).
Record number and thickness of shims.
TA191143
NOTE
Steps (4) through (6) are for
right side only.
(4) Remove grease fitting (9).
(5) Remove four screws (10),
lockwashers (11), and top
cover (12).
(6) Record number and
thickness of shims (13) and
remove shims.
9-83
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-13.
BALL SOCKET REMOVAL/INSTALLATION (CONT).
NOTE
Steps (7) through (13) are for both left and right sides.
(7)
(8)
(9)
(10)
(11)
(12)
Remove grease fitting (14).
Remove four screws (15) and lockwashers (16).
Remove brake chamber mounting bracket (17).
Measure and record length from top of stop bolt (18) to top of nut (19).
Remove nut (19) and stop bolt (18) from ball socket (3).
Remove six screws (20) and lockwashers (21).
NOTE
Seal halves are glued together and may be one piece on Model A or two pieces on
Model B.
(13)
Remove seal retainer (22) and seal (23).
9-84 Change 3
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
NOTE
Step (14) is for left side only.
(14) Remove two screws (24) and end plate (25).
NOTE
Steps (15) through (21) are for both left and right sides.
(15) Remove lower axle ball trunnion (26) by driving
lower axle ball trunnion upward into ball and bushing
assembly (27).
(16) Remove two screws (28) and end plate (29) from upper
axle ball trunnion (30).
(17) Remove upper axle ball trunnion (30) by driving upper
axle ball trunnion downward into ball and bushing
assembly (27).
9-85
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-13. BALL SOCKET REMOVAL/INSTALLATION (CONT).
CAUTION
Use sledge hammer carefully. Hammering too hard can
crack ball socket or damage trunnion bearings if they are
not seated while hammering.
(18) Hammer around top of ball socket (3) until upper and
lower bearing cups (31 and 32) are 1/8 in. (3.18 mm)
above and below ball socket surface.
(19) Tip ball socket (3) out and up
from bottom and remove from
ball and bushing assembly (27).
NOTE
Upper and lower bearings and bearing cups are matched
sets. Tag and mark bearings and bearing cups.
(20) Remove bearings (33 and 34).
9-86
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
(21)
(22)
(23)
Remove upper and lower bearing cups (31
and 32) from ball socket (3).
Remove four studs (35) from ball socket (3)
on left side only.
Remove two seals (36) and bushings (37) on
right and left side.
b. Cleaning/Inspection.
Adhesives, solvents, and sealing
compounds can burn easily, can give off
harmful vapors, and are harmful to skin
and clothing. To avoid injury or death,
keep away from open fire and use in
well-ventilated area. If adhesive, solvent,
or sealing compound gets on skin or
clothing, wash immediately with soap and
water.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
c.
Clean all metal parts with drycleaning solvent.
Inspect ball socket for cracks and breaks. Replace if damaged.
Inspect bearing cups for gouges. If gouged, replace bearing cups and bearings.
Inspect bearings for loose rollers and cracked or broken races. Replace if damaged.
Inspect seals for tears. Replace torn seals.
Inspect bushings for gouges and out-of-round condition. If bushing is gouged or more than
0.050 in. (1.270 mm) out-of-round, replace.
Inspect axle ball trunnions for breaks or gouges. Replace if damaged.
Inspect studs for damaged threads and cracks or breaks. Replace if damaged.
Installation
.
.
(1)
NOTE
Steps (1) through (16) are for both left
and right ball sockets. Left ball socket
is shown.
Top bearing cup has small opening up
and bottom bearing cup has small
opening down.
Install bearing cups (1 and 2) in ball
socket (3). Tap bearing cups down until
bearing cups are not more than 1/8 in.
(3.18 mm) above ball socket.
CAUTION
Lip of seal (hub side) must face toward bushing
to prevent grease from entering brake area.
Lip of seal (axle side) must face away from
bushing to allow grease to exit socket.
(2)
(3)
Install two bushings (4) and seals (5)
in ball socket (3).
Install four studs (6) in left ball socket (3).
Change 3
9-87
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-13. BALL SOCKET REMOVAL/INSTALLATION (CONT).
NOTE
Pack bearings with grease.
(4) Install lower bearing (7) in bearing cup (2).
(5) Install upper bearing (8) in bearing cup (1).
TA191158
(6) With brake air chamber mounting
surface (9) facing to the rear and mounting
holes (10) facing outward, install ball
socket (3) over ball and bushing
assembly (11).
TA191159
(7) Aline ball socket (3) with trunnion holes in ball
and bushing assembly (11). Install axle ball
trunnions (12 and 13).
(8) Drive bearing cups (1 and 2) flush with surface
of ball and bushing assembly (11).
9-88
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance lnstructions (Cont)
NOTE
Steps (9) and (10) are for left side only.
(9) Apply light coat of grease to threads of two
screws (14).
(10) Install end plate (15) and two screws (14) on lower
axle ball trunnion (13). Tighten screws to 40 lb-ft
(54 N·m).
NOTE
Install same number and thickness of shims as removed.
(11) Install shims (16), bottom cover (17), four
lockwashers (18), and screws (19).
(12) Tighten screws (19) to 185 lb-ft (251 N·m).
(13) Install grease fitting (20) in bottom cover (17).
(14) Lubricate lower bearing at grease fitting (20) with grease.
(15) Remove grease fitting (20).
(16) Install pipe plug (21).
(17) Apply grease to ball and bushing assembly (11) at rear of
ball socket (3).
9-89
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-13.
(18)
BALL SOCKET REMOVAL/INSTALLATION (CONT).
Install end plate (22) and two screws
(23) on upper axle ball trunnion (12).
Tighten screws to 40 lb-ft (54 NSm).
NOTE
•
Steps (19) through (25) are for left
ball socket only.
•
Install same number and thickness
of shims as removed.
(19)
Install shims (24) on four studs (6).
NOTE
Install steering arm with flange side down.
(20)
(21)
Install steering arm (25) on studs (6).
Install four dowel pins (26) in studs (6).
(22)
Secure steering arm (25) with four
lockwashers (27) and nuts (28).
Tighten nuts (28) to 320 lb-ft (434
NSm).
Install grease fitting (29).
Lubricate upper bearing at grease
fitting (29).
(23)
(24)
(25)
9-90
Change 7
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
NOTE
.
Steps (26) through (28) are for right
ball socket only.
.
Install same number and thickness
of shims as removed.
(26)
(27)
(28)
(29)
(30)
(31)
(32)
Install shims (30), top cover (31), four
lockwashers (32), and screws (33).
Tighten screws to 185 to 190 lb-ft (251
to 258 N•m).
Install grease fitting (34).
Apply grease to upper axle ball
trunnion through lubrication
fitting (34).
Hook spring scale on end of ball
socket (3).
Pull spring scale and check
that ball socket (3) will move
with pull of 35 to 45 lb
(16 to 20 kg). If it does, go to
step (33). If less than 35 lb
(16 kg) is required, go to step
(31). If more than 45 lb (20 kg)
is required, go to step (32).
Record number and thickness
of shims and remove one shim,
same thickness, from top and
bottom of ball socket. Repeat
step (30).
Record number and thickness
of shims and add one shim,
same thickness, to top and
bottom of ball socket. Repeat
step (30).
Change 3
9-91
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-13.
BALL SOCKET REMOVAL/INSTALLATION (CONT).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep
away from open fire and use in well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash immediately with soap and
water.
CAUTION
Apply only one drop of adhesive to each seal joint. Excess adhesive can cause seal
to become brittle and damaged.
NOTE
Cut seal ends square before installation. Be certain grooved side of seal faces
upward. Seals may be one piece on Model A or two pieces glued together on
Model B. Overall length should be approximately 27 in. (686 mm) long. The one
piece seal should be used whenever possible. If two pieces must be used, do step
(32.1). If a one piece seal is used, go to Step (33).
(32.1) Apply one drop of adhesive to each end of one seal half (34.1) and join to second seal half (34.1).
(33) Install seal (34.1) so it overlaps joint of seal retainer halves (35). Apply one drop of adhesive to
one end of seal.
9-92
Change 3
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
(34) Open second joint of seal retainer
halves (35) and slide seal retainer
halves over ball and bushing
assembly (11).
MODEL A
NOTE
If assembling Model A retainer, perform step (35). If assembling Model B, perform
step (35.1).
(35)
Install seal retainer halves (35) and other half of seal (34.1) so it overlaps second joint and butts
up against other half of seal on both ends.
(35.1) Install seal retainer halves (35) and remainder of seal (34.1) so it overlaps second joint and
butts up against other half of seal on both ends.
*U.S. GOVERNMENT PRINTING OFFlCE:1999-746-025/80164
Change 3
9-92.1/(9-92.2 blank)
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and clothing. To avoid injury or death, keep away
from open fire and use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap and water.
(36)
(37)
(38)
(39)
(40)
Apply silicone adhesive-sealant to inner sides of seal retainer halves (35) and six screws (36).
Apply silicone adhesive-sealant between seal retainer halves (35).
Aline seal retainer halves (35) and install six lockwashers (37) and screws (36).
Tighten six screws (36) to 25 lb-ft (34 N·m).
Install steering stop bolt (38) and nut (39) to same measurement as recorded during removal.
d. Follow-on Maintenance.
(1) Install axle shaft assembly (para 9-2).
(2) Install slack adjuster and camshaft (TM 9-2320-279-20).
(3) Install brake chamber (TM 9-2320-279-20).
(4) Install tie rod (TM 9-2320-279-20).
(5) Install steering arm (TM 9-2320-279-20).
(6) Install wheel and tire assembly (TM 9-2320-279-10).
(7) Lubricate axle (LO 9-2320-279-12).
END OF TASK
9-93
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-14. AXLES NO. 1 AND NO. 2 BALL, BUSHING, AND OIL SEAL REMOVAL/INSTALLATION.
This task covers:
c. Follow-on Maintenance
a. Removal
b. Installation
INITIAL SETUP
Models
All
References
None
Test Equipment
None
Equipment Condition
TM or Para
Para 9-13
Special Tools
None
Supplies
Adhesive-sealant, silicone, Item 6, Appendix C
Solvent, dry cleaning, Item 57, Appendix C
Personnel Required
MOS 63W, Wheel vehicle repairer
Condition Description
Ball socket removed.
Special Environmental Conditions
None
General Safety Instructions
None
Level of Maintenance
Direct Support
a. Removal.
NOTE
Ball, bushing, and oil seal removal is the same for both sides of axles No. 1 and
No. 2. Left side of axle No. 1 is shown.
(1) Remove four screws (1) and lockwashers (2) from bottom holes of ball and bushing assembly (3).
9-94
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
WARNING
Ball and bushing assembly is heavy. Support ball and bushing assembly to keep it
from falling and causing personal injury.
(2) Remove six screws (4), lockwashers (5), and airhose mounting bracket (6).
(3) Remove ball and bushing assembly (3) from axle housing assembly (7).
(4) Remove old sealant from mounting face of axle housing assembly (7) and ball and bushing
assembly (3).
(5) Pry oil seal (8) from ball and bushing assembly (3).
(6) Measure front axle outer diameter and inner diameter of axle
ball bushing (9). If difference in measurement is less than
0.008 in. (0.203 mm) or more than 0.020 in. (0.508 mm),
remove bushing from axle ball (10).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can
give off harmful vapors, and are harmful to skin and clothing. To
avoid injury or death, keep away from open fire and use in
well-ventilated area. If adhesive, solvent, or sealing compound
gets on skin or clothing, wash immediately with soap and water.
(7) Clean axle ball (10) with soft, lint-free cloth and dry cleaning
solvent.
(8) Inspect axle ball (10) for scratches and grooves. Replace axle
ball if damaged.
b. Installation.
NOTE
Installation of ball, bushing, and oil seal is the same for both sides of axles No. 1
and No. 2.
(1) Install oil seal (1) in axle ball (2).
9-95
TM 9-2320-279-34-1
Axles No. 1 and No. 2 Maintenance Instructions (Cont)
9-14. AXLES NO. 1 AND NO. 2 BALL, BUSHING, AND OIL SEAL REMOVAL/INSTALLATION
(CONT).
(2) Support axle ball (2) on blocks to protect seal end of assembly.
(3) Install axle ball bushing (3) in axle ball (2) so grease slots (4) are
alined with trunnion holes (5) and open ends of grease slots
face up.
WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. To avoid injury or
death, keep away from open fire and use in
well-ventilated area. If adhesive, solvent, or
sealing compound gets on skin or clothing, wash
immediately with soap and water.
(4) Coat mounting face of axle housing
assembly (6) with silicone adhesive-sealant.
(5) Install ball and bushing assembly (7) and
airhose mounting bracket (8) on axle housing
assembly (6) with six screws (9),
lockwashers (10), four screws (11), and
lockwashers (12).
c. Follow-on Maintenance. Install ball socket
(para 9-13).
END OF TASK
9-96
TM 9-2320-279-34-1
INDEX
Subject
Paragraph
Figure, Table
Number
A
Adhesive and solvent warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Alarm box, tilt (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Alarm, tilt warning, switch (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Alternator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Army materiel, destruction of, to prevent enemy use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Arctic coolant pump test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-9
Arctic heater fault codes (Model B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-10
Asbestos warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c
Assembly, axle shaft removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Assembly, axle housing cover, axle No. 2 removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Attaching engine to engine stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Attaching transmission to transmission stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Audible and visual level warning indicators (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . 6-5
Axle housing cover assembly, axle No. 2 removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Axle No. 1 removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Axle No. 1, differential carrier
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Axle No. 2 removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Axle No. 2, axle housing cover assembly removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Axle No. 2, differential carrier
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Axle No. 2, differential carrier cover
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Axle shaft assembly removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Axles No. 1 and No. 2, axle shaft assembly removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Axles No. 1 and No. 2 ball, bushing, and oil seal removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Axles No. 1 and No. 2 ball socket removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Axles No. 1 and No. 2 yoke and oil seal removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
B
Ball, bushing, and oil seal, axles No. 1 and No. 2 removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Ball socket removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Batteries, terminals, and cables warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c
Board, crane control distribution (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Body, control valve removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Body, lockup cutoff valve removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Box, junction and connector (M977, M985) removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Box, junction and connector (M984E1) removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11.1
Box, tilt alarm (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Brackets, mounting, transfer case removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Bushing, ball, and oil seal, axles No. 1 and No. 2 removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
C
Cab wiring harness removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Cables, power interconnecting (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Capabilities, features, and characteristics, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Carbon monoxide (exhaust gas) warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Care, handling, and safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Carrier cover, differential, axle No. 2
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Change 6
Index 1
TM 9-2320-279-34-1
INDEX (CONT)
Subject
Carrier, differential, axle No. 1
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carrier, differential, axle No. 2
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Case, transfer, lock-up valve, HI-LO range repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Case, transfer
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Case, transfer, mounting brackets removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Center shaft repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Center support housing and second clutch removal/repair/installation . . . . . . . . . . . . . . . . . . .
Center support housing and third clutch removal/repair/installation . . . . . . . . . . . . . . . . . . . . .
Chamber, lockout shift removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Characteristics, capabilities, and features, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis/Engine wiring harness removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis wiring harness removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis wiring harness (M984E1) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning instructions and warnings, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch assembly, first, and rear cover removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . .
Clutch assembly, forward removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch assembly, fourth removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch, second, and center support housing removal/installation . . . . . . . . . . . . . . . . . . . . . . . .
Clutch, third, and center support housing removal/repair/installation . . . . . . . . . . . . . . . . . . . .
Common tools and equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Components, major, location and description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressed air warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector and junction box (M977, M985) removal/repair/installation . . . . . . . . . . . . . . . . . . .
Connector and junction box (M984E1) removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . .
Control distribution board, crane (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Control valve body removal/repair/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control valve, traction repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converter, torque, housing removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converter, torque, pump removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converter, torque, stator removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover assembly, axle No. 2, axle housing removal/repair/installation . . . . . . . . . . . . . . . . . . . . .
Cover, differential carrier, axle No. 2
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, rear, and first clutch assembly removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . .
Crane (M977, M985) troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane (M983) troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane control distribution board (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane, material handling, shutdown system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane operating instruction plate locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crane overload sensor switches removal/installation (M977, M985) . . . . . . . . . . . . . . . . . . . . . .
Crane overload sensor switches, plate, and terminal box (M984E1) removal/installation . . . .
Cross-Reference, nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutoff valve body, lockup removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 2
Paragraph,
Figure, Table
Number
9-7
9-11
9-10
9-12
8-12
8-2
8-4
8-3
8-7
7-19
7-18
8-14
1-11
6-16
6-15
6-15.1
2-8
7-16
7-15
7-17
7-19
7-18
2-2
1-12
c
6-11
6-11.1
6-8
7-20
8-13
7-9
7-8
7-7
5-1
9-5
9-8
9-9
7-16
2-7
2-7
6-8
1-14
1-14
6-12
6-12.1
1-5
7-22
TM 9-2320-279-34-1
INDEX
Subject
Paragraph
Figure, Table
Number
D
Description and data, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Description and location of major components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Destruction of Army materiel to prevent enemy use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Differences between models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Differential carrier, axle No. 1
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Differential carrier, axle No. 2
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Differential carrier cover, axle No. 2
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Distribution board, crane control (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Dust shield, oil seal, and output yoke removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
E
Electric motors tester circuit schematic (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-7
Electric motors tester circuit wiring diagram (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-8
Electrical system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Element, filter, internal removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Engine removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Engine arctic heater-troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Engine/Chassis wiring harness removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Engine, general maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine to engine stand removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Engine troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Engine wiring harness removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Equipment characteristics, capabilities, and features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Equipment description and data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Equipment improvement recommendations (EIR), reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Equipment improvement report and maintenance digest (EIR MD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Equipment improvement report and maintenance summary (EIR MS) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Equipment names and models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Equipment, common . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Equipment, purpose of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Equipment, test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Extended switch, outrigger (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
F
Features, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Filter element, internal removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
First clutch assembly and rear cover removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Flywheel assembly removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Forms, records, and reports, maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Forward clutch assembly removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Fourth clutch assembly removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Front output shaft, lower repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Fuel system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fuel warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Change 6
Index 3
TM 9-2320-279-34-1
INDEX (CONT)
Paragraph,
Figure, Table
Number
Subject
G
Gear unit and main shaft assembly removal/repair/installation . . . . . . .
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning instructions and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . .
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..................
..................
..................
..................
.................
..................
7-13
1-1
2-8
1-1
2-8
7-23
H
Harness, cab wiring removal/installation . . . . . . . . . . . . . . . . . . . . . . . . .
Harness, chassis wiring removal/installation . . . . . . . . . . . . . . . . . . . . . . .
Harness, chassis wiring (M984E1) removal/installation . . . . . . . . . . . . . .
Harness, chassis/engine wiring removal/installation . . . . . . . . . . . . . . . . .
Harness, engine wiring removal/installation . . . . . . . . . . . . . . . . . . . . . . .
Harness, STE/ICE wiring removal/installation. . . . . . . . . . . . . . . . . . . . . .
Hazards, significant, and safety recommendations . . . . . . . . . . . . . . . . . .
Heavy-duty winch (M984) troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .
High voltage warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HI-LO range transfer case lock-up valve repair . . . . . . . . . . . . . . . . . . . . .
Hot exhaust pipe/muffler warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot radiator warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing cover assembly, axle, axle No. 2 removal/repair/installation . . .
Housing, second clutch and center support removal/repair/installation.
Housing, third clutch and center support removal/repair/installation . .
Housing, torque converter removal/repair/installation . . . . . . . . . . . . . .
Housing, transmission repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic system-troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-13
6-15
6-15.1
6-16
6-14
6-17
1-14
2-7
b
8-12
b
b
9-5
7-19
7-18
7-9
7-10
vi
2-7
I
ICE/STE wiring harness removal/installation . . . . . . . . . . . . . . . . . . . . . .
Identification, tanker component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Illustrated list of manufactured items, Appendix B . . . . . . . . . . . . . . . . .
Illustrations, list of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicator, visual and audible level warning (M983) removal/installation
Information, warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input shaft, top repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection, pre-embarkation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-embarkation inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparation for storage or shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interconnecting cables, power (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal filter element removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction, troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-17
2-8
B-1
iv
6-5
1-8
8-6
2-11
2-9
2-8
2-11
2-10
2-7
6-9
7-12
1-1
2-6
J
Jewelry, wearing, warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Junction box and connector (M977, M985) removal/repair/installation . . . . . . . . . . . . . . . . . . .
Junction box and connector (M984E1) removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . .
a
6-11
6-11.1
L
Level warning indicators, visual and audible (M983) removal/installation . . . . . . . . . . . . . . . . .
List of illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 4
6-5
iv
TM 9-2320-279-34-1
INDEX (CONT)
Paragraph,
Figure, Table
Number
vi
1-12
8-14
8-12
7-22
8-9
8-8
8-11
2-9
8-15
8-16
Main shaft assembly and gear unit removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine, general instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forms, records, and reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions, transmission, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance digest (EIR MD), equipment improvement report . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance summary (EIR MS), equipment improvement report . . . . . . . . . . . . . . . . . . . . . . .
Major components, location and description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual
How to use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Material handling crane - troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model numbers and equipment names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models, difference between . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modulator valve removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor, starter, repair and testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting brackets, transfer case removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F 2-2
7-13
6-1
3-2
1-2
4-1
2-8
2-8
1-7
1-7
1-12
vi
1-1
2-7
1-9
1-1
1-13
7-21
6-4
8-3
N
Names, equipment, and model numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 1 axle removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 1 axle, differential carrier
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 2 axle removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 2 axle, axle housing cover assembly removal/repair/installation . . . . . . . . . . . . . . . . . . . . .
No. 2 axle, differential carrier
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 2 axle, differential carrier cover
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 1 and No. 2 axles ball, bushing, and oil seal removal/installation. . . . . . . . . . . . . . . . . . . . .
No. 1 and No. 2 axles, ball socket removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 1 and No. 2 axle shaft assembly removal/repair/installation . . . . . . . . . . . . . . . . . . . . . .
No. 1 and No. 2 axles, yoke and oil seal removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-10
9-3
9-7
9-11
9-4
9-5
9-10
9-12
9-8
9-9
9-14
9-13
9-2
9-6
Index 5
TM
9-2320-279-34-1
INDEX (CONT)
Paragraph,
Figure, Table
Number
Subject
Nomenclature cross-reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nuclear, biological, or chemical exposure warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Numbers, model, and equipment names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5
a
1-1
O
Oil cooler (see radiator) repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pan, transmission removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil seal removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil seal and yoke, axles No. 1 and No. 2 removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil seal, ball, and bushing, axles No. 1 and No. 2 removal/installation . . . . . . . . . . . . . . . . . . .
Oil seal, output yoke, and dust shield (transmission) removal/installation . . . . . . . . . . . . . . . . .
Operation, principles of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output shaft, lower front repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output shaft, lower rear repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output yoke, dust shield, and oil seal removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outrigger control valve (M983). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F
Outrigger extended switch (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload sensor switch (M977, M985), crane removal/installation . . . . . . . . . . . . . . . . . . . . . . .
Overload sensor switches, plate, and terminal box (M984E1), crane removal/installation . . . .
5-2
7-11
8-5
9-6
9-14
7-14
1-15
8-9
8-8
7-14
2-3
6-6
6-12
6-12.1
P
7-11
Pan, oil, transmission removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a
Parking brake, incorrect use of, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12.1
Plate and terminal box, overload sensor switches (M984E1), crane removal/installation . . . . .
1-14
Plate locations, crane operating instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power distribution board wiring diagram (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-6
6-9
Power interconnecting cables (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11
Pre-embarkation inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10
Preparation for storage or shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure tester setup (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-5
1-3
Prevent enemy use, destruction of army equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-15
Principles of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump, lubrication, transfer case
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
7-8
Pump, torque converter removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
R
Radiator repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Range, HI-LO, transfer case lock-up valve repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear cover and first clutch assembly removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . .
Rear output shaft, lower repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommendations (EIR), reporting equipment improvement . . . . . . . . . . . . . . . . . . . . . . . . . . .
Records, reports, and forms, maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reporting equipment improvement recommendations (EIR) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reports, forms, and records, maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rod assembly, transfer case, lower shift repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rod assembly, transfer case, upper shift repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2
8-12
7-16
8-8
1-6
1-2
2-5
1-6
1-2
8-11
8-10
S
Safety, care, and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety recommendations and significant hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal, oil, transfer case removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal, oil, and yoke, axles No. 1 and 2 removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 6
1-14
1-14
. 1-1
8-5
9-6
TM 9-2320-279-34-1
INDEX (CONT)
Paragraph,
Figure, Table
Number
Subject
9-14
Seal, oil, axles No. 1 and No. 2 ball and bushing removal/installation . . . . . . . . . . . . . . . . . . . .
7-14
Seal, oil, transmission output yoke, and dust shield removal/installation . . . . . . . . . . . . . . . . .
b
Seatbelts use warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-19
Second clutch and center support housing removal/repair/installation . . . . . . . . . . . . . . . . . . .
6-12
Sensor switch, overload (M977, M985), crane removal/installation . . . . . . . . . . . . . . . . . . . .
6-12.1
Sensor switches, overload and plate and terminal box (M984E1), crane removal/installation .
7-13
Shaft assembly, main and gear unit removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . .
9-2
Shaft assembly, No. 1 and No. 2 axles removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . .
8-7
Shaft, center repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9
Shaft, lower front output repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8
Shaft, lower rear output repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6
Shaft, top input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-14
Shield, dust, oil seal, and output yoke removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-14
Shift chamber, lockout removal/repair/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11
Shift rod assembly, lower repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10
Shift rod assembly, upper repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3
Shift tower, transmission repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10
Shipment or storage, preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-14
Significant hazards and safety recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-13
Socket, ball removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
Solenoid, starter removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
Stand, engine to engine removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4
Starter motor repair and testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
Starter solenoid removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c
Starting fluid warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7
Stator, torque converter removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7
Steering system - troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-17
STE/ICE wiring harness removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10
Storage or shipment, preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Subject index, troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 2-2
7-19
Support housing, center, and second clutch removal/repair/installation . . . . . . . . . . . . . . . . . .
7-18
Support housing, center, and third clutch removal/repair/installation . . . . . . . . . . . . . . . . . . . .
6-6
Switch, outrigger extended (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7
Switch, tilt warning alarm (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12
Switch, overload sensor (M977, M985), crane removal/installation . . . . . . . . . . . . . . . . . . . . . .
6-12.1
Switches, overload sensor and plate and terminal box (M984E1), crane removal/installation .
Symptom index, troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 2-1
System
5-1
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-9
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System back pressure (M983 crane) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-4
System symptom index (troubleshooting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 2-1
T
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Tables, list of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
6-12.1
Terminal box and plate, overload sensor switches (M984E1), crane removal/installation . . .
2-4
Test equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4
Testing, motor starter repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-18
Third clutch and center support housing removal/repair/installation . . . . . . . . . . . . . . . . . . . . .
4-2
Throttle treadle valve repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10
Tilt alarm box (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 7
TM
9-2320-279-34-1
INDEX (CONT)
Subject
Paragraph,
Figure, Table
Number
Tilt warning alarm switch (M983) removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools, common . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools, special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top input shaft repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque converter
Housing removal/repair/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tower, shift, transmission repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction control valve repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailer brake warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer case
HI-LO range, lock-up valve repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockout shift chamber removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower front output shaft repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower rear output shaft repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower shift rod assembly repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication pump removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication pump repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting brackets removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil seal removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift rod assembly, lower repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift rod assembly, upper repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top input shaft repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission
Control valve body removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward clutch assembly removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fourth clutch assembly removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal filter element removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockup cutoff valve body removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main shaft assembly and gear unit removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modulator valve removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pan removal/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil seal, output yoke, and dust shield removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation on stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft assembly, main and gear unit removal/repair/installation . . . . . . . . . . . . . . . . . . . . . .
Shift tower repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Third clutch and center support housing removal/repair/installation . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Treadle valve, throttle repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 8
6-7
2-2
2-3
8-6
7-9
7-8
7-7
7-3
8-13
b
8-12
8-14
8-9
8-8
8-11
8-15
8-16
8-1
8-3
8-5
8-2
8-4
8-11
8-10
8-6
7-20
7-15
7-17
7-2
7-10
7-12
7-22
7-13
7-1
7-21
7-11
7-14
7-4
7-5
7-13
7-3
7-18
2-7
4-2
2-6
2-7
TM 9-2320-279-34-1
INDEX (CONT)
Paragraph,
Figure, Table
Number
Subject
Troubleshooting (Cont)
2-7
. . . . . . .. . . . . . . . .
Engine arctic heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
2-7
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Hydraulic system . . . . .
2-7
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . .
2-7
Material handling crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . T 2-3
2-7
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .
Subject index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 2-2
Symptom index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 2-1
2-7
Tanker system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
Type of manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
u
Unit, gear, and main shaft assembly removal/repair/installation. . . . . . . . . . . . . . . . . . . . . . . . .
Upper shift rod assembly repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-13
8-10
Valve body, control removal/repair/installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve body, lockup cutoff removal/repair/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, modulator removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, throttle treadle repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, traction control repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, transfer case lock-up, HI-LO range repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual and audible level warning indicators (M983) removal/installation. . . . . . . . . . . . . . . . . .
7-20
7-22
7-21
4-2
8-13
8-12
1-10
6-5
v
w
6-7
Warning alarm switch, tilt removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5
Warning indicators, visual and audible level (M983) removal/installation . . . . . . . . . . . . . . . . .
Warnings
a
Adhesives and solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c
Asbestos in brake linings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c
Batteries, terminals, and cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a
Carbon monoxide (exhaust gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c
Compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b
Crane operation under powerlines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b
High voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b
Hot exhaust pipe/muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b
Hot radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a
Jewelry, wearing of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b
“Low’’ voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c
Nuclear, biological, or chemical (NBC) exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a
Parking brake, incorrect use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b
Seatbelts, use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c
Starting fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b
Trailer brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b
Winch cable, handling of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b
Winch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8
Warranty information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring diagrams
Electric motor tester circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-8
Engine arctic heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-9
Power distribution board (M983) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-6
Wiring harness removal/installation
6-13
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 9
TM 9-2320-279-34-1
INDEX (CONT)
Paragraph,
Figure, Table
Number
Subject
Wiring harness removal/installation (Cont)
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis (M984E1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis/Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STE/ICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-15
6-15.1
6-16
6-14
6-17
Y
Yoke and oil seal, axles No. 1 and No. 2 removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yoke, output, dust shield, and oil seal removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 10
9-6
7-14
By Order of the Secretary of the Army:
Official:
JOHN A.. WICKHAM, JR.
General United States Army
Chief of Staff
R.L. DILWORTH
Brigadier General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-38, Direct and General Support Maintenance
requirements for Truck, Cargo, 10-Ton, 8x8, Heavy Expanded Mobility, Tactical Truck, HEMTT, M977,
M978, M983, M984, and M985.
U. S. GOVERNMENT PRINTING OFFICE : 1993 - 311-831 (62450)
TM 9-2320-279-34-1
TM 9-2320-279-34-1
TM 9-2320-279-34-1
PIN: 062143-- 000
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