TM 9 2320 272 23 1 Field Maintenance Manual 2012
User Manual: TM-9-2320-272-23-1-Field-Maintenance-Manual-2012 M939 Series Trucks
Open the PDF directly: View PDF 
.
Page Count: 1316
| Download | |
| Open PDF In Browser | View PDF |
ARMY *TM 9-2320-272-23-1 AIR FORCE *TO 36A12-1C-1155-2-1 TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR TRUCK, 5-TON, 6X6, M939, M939A1, AND M939A2 SERIES TRUCKS (DIESEL) TRUCK, CARGO: 5-TON, 6X6 DROPSIDE NSN NSN NSN NSN NSN NSN M923 2320-01-050-2084 M923A1 2320-01-206-4087 M923A2 2320-01-230-0307 M925 2320-01-047-8769 M925A1 2320-01-206-4088 M925A2 2320-01-230-0308 TRUCK, DUMP: 5-TON, 6X6 (EIC BRY) NSN (EIC BSS) NSN (EIC BS7) NSN (EIC BRT) NSN (EIC BST) NSN (EIC BS8) NSN TRUCK, CARGO: 5-TON, 6X6 XLWB M927 NSN 2320-01-047-8771 (EIC BRV) M927A1 NSN 2320-01-206-4089 (EIC BSW) M927A2 NSN 2320-01-230-0309 (EIC BS9) M928 NSN 2320-01-047-8770 (EIC BRU) M928A1 NSN 2320-01-206-4090 (EIC BSX) M928A2 NSN 2320-01-230-0310 (EIC BTM) M929 2320-01-047-8756 M929A1 2320-01-206-4079 M929A2 2320-01-230-0305 M930 2320-01-047-8755 M930A1 2320-01-206-4080 M930A2 2320-01-230-0306 (EIC BTN) M934 NSN 2320-01-047-8750 (EIC BTB) M934A1 NSN 2320-01-205-2682 (EIC BS4) M934A2 NSN 2320-01-230-0300 (EIC BTR) (EIC BTG) TRUCK, MEDIUM WRECKER: 5-TON, 6X6 (EIC BTH) (EIC BSY) (EIC BSZ) (EIC BT7) TRUCK, TRACTOR: 5-TON, 6X6 M931 NSN 2320-01-047-8753 M931A1 NSN 2320-01-206-4077 M931A2 NSN 2320-01-230-0302 M932 NSN 2320-01-047-8752 M932A1 NSN 2320-01-205-2684 M932A2 NSN 2320-01-230-0303 TRUCK, VAN, EXPANSIBLE: 5-TON, 6X6 M936 NSN 2320-01-047-8754 (EIC BTF) M936A1 NSN 2320-01-206-4078 (EIC BS6) M936A2 NSN 2320-01-230-0304 (EIC BTT) (EIC BTE) (EIC BS2) (EIC BTP) (EIC BTD) (EIC BSZ) (EIC BTQ) *SUPERSEDURE NOTICE - This manual supersedes TM 9-2320-272-24-1, TM 9-2320-272-24-2, TM 9-2320-272-24-3, TM 9-2320-272-24-4 and TO 36A12-1C-1155-2-1, TO 36A12-1C-1155-2-2, TO 36A12-1C-1155-2-3, & TO 36A12-1C-1155-2-4, dated 30 June 1998, including all changes. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENTS OF THE ARMY AND THE AIR FORCE 10 SEPTEMBER 2012 03/15/2011 Rel(1.8) root(frntcover) wpno(F00007) TM 9-2320-272-23-1 WARNING SUMMARY This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of the vehicle. Failure to observe these precautions or operating this vehicle without training or instruction may result in serious injury or death to personnel. FIRST AID DATA For information on first aid, refer to FM 4-25.11, First Aid. EXPLANATION OF SAFETY WARNING ICONS EAR PROTECTION - Headphones over ears show that noise level will harm ears. ELECTRICAL - Electrical wire to hand with electricity symbol running through hand shows that shock hazard is present. EYE PROTECTION - Person with goggles shows that the material will injure the eyes. FIRE - Flame shows that a material may ignite and cause burns. HEAVY OBJECT - Human figure stooping over heavy object shows physical injury potential from improper lifting technique. HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush and harm. HEAVY PARTS - Foot with heavy object on top shows that heavy parts can crush and harm. HEAVY PARTS - Heavy object pinning human figure against wall shows that heavy, moving parts present a danger to life or limb. a 03/15/2011 Rel(1.8) root(warnsum) wpno(F00008) TM 9-2320-272-23-1 WARNING SUMMARY - Continued EXPLANATION OF SAFETY WARNING ICONS - Continued HEAVY PARTS - Heavy object on human figure shows that heavy parts present a danger to life or limb. HOT AREA - Hand over object radiating heat shows that part is hot and can burn. MOVING PARTS - Hand with fingers caught between gears shows that the moving parts of the equipment present a danger to life or limb. RADIATION - Three circular wedges shows that the material emits radioactive energy and can injure human tissue. SLICK FLOOR - Wavy line on floor with legs prone shows that slick floor presents a danger for falling. VAPOR - Human figure in a cloud shows that material vapors present a danger to life or health. b 03/15/2011 Rel(1.8) root(warnsum) wpno(F00008) TM 9-2320-272-23-1 WARNING SUMMARY - Continued GENERAL SAFETY WARNINGS DESCRIPTION WARNING Ensure electrical power is off prior to working on all electrical connections. Prior to working on or around vehicle, remove all jewelry, such as rings, ID tags, bracelets, etc. Jewelry, and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. WARNING Personnel hearing can be permanently damaged if exposed to constant high noise levels of 85 dB or greater. Failure to comply may reslult in injury to personnel. WARNING Unless otherwise specified, perform all maintenance procedures with all attachments lowered to the ground, pilot shutoff lever in the up position, and engine shut off. Failure to comply may result in injury or death to personnel. c 03/15/2011 Rel(1.8) root(warnsum) wpno(F00008) TM 9-2320-272-23-1 WARNING SUMMARY - Continued EXPLANATION OF HAZARDOUS MATERIALS ICONS BIOLOGICAL - Abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health. CHEMICAL - Drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue. EXPLOSION - Rapidly expanding symbol shows that the material may explode if subjected to high temperatures, sources of ignition, or high pressure. POISON - Skull and crossbones symbol shows that dangerous gases, sprays, vapors, liquids, or materials contain compounds that present a danger to life or health. d 03/15/2011 Rel(1.8) root(warnsum) wpno(F00008) TM 9-2320-272-23-1 WARNING SUMMARY - Continued HAZARDOUS MATERIALS DESCRIPTIONS WARNING CARBON MONOXIDE • Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body of oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death to personnel can result from severe exposure. • Carbon monoxide occurs in exhaust fumes from internal combustion engines. It also occurs in exhaust fumes from engine coolant heater (arctic machine only). Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must observed to ensure safety of personnel when engine of vehicle is operated. 1. 2. 3. 4. DO NOT operate engine in enclosed area without adequate ventilation. DO NOT idle engine without adequate ventilation. DO NOT drive machine with inspection plates or cover plates removed. BE ALERT for exhaust poisoning symptoms. They are: • Headache • Dizziness • Sleepiness • Loss of muscular control 5. If you see another person with exhaust poisoning symptoms: • Remove person from area • Expose to fresh air • Keep person warm • DO NOT permit physical exercise • Administer cardiopulmonary resuscitation (CPR) if necessary • Notify a Medic 6. BE AWARE. The field protective mask for Nuclear-Biological-Chemical (NBC) protection will not protect you from carbon monoxide poisoning. e 03/15/2011 Rel(1.8) root(warnsum) wpno(F00008) TM 9-2320-272-23-1 WARNING SUMMARY - Continued HAZARDOUS MATERIALS DESCRIPTIONS - Continued WARNING CHEMICAL AGENT RESISTANT COATING (CARC) PAINT Chemical Agent Resistant Coating (CARC) paint contains isocyanate which is highly irritating to skin and respiratory system. High concentrations of isocyanate can produce symptoms of itching and reddening of skin, a burning sensation in the throat and nose, and watering of the eyes. In extreme concentrations, isocyanate can cause cough, shortness of breath, pain during respiration, increased sputum production, and chest tightness. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid fro skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. if symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Failure to comply may result in injury or death to personnel. f 03/15/2011 Rel(1.8) root(warnsum) wpno(F00008) TM 9-2320-272-23-1 WARNING SUMMARY - Continued HAZARDOUS MATERIALS DESCRIPTIONS - Continued WARNING SOLVENT CLEANING COMPOUND Solvent cleaning compound MIL-PRF-680 type II and III may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well ventilated areas. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and repository tract, and may cause lung and central nervous system damage. Can be fatal if swallowed. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated clothing, Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition. Failure to comply may result in injury or death to personnel. The flash point for type II solvent cleaning compound is 141°F to 198°F (61°C to 92°C) and type III is 200°F to 241°F (93°C to 116°C). Fire extinguishers should be placed nearby when using solvent cleaning compound. Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment. Cloths or rags saturated with solvent cleaning compound must be disposed of using authorized facilities procedures. Eye shields must be worn when cleaning with a wire brush. Flying rust and metal particles may cause injury. g 03/15/2011 Rel(1.8) root(warnsum) wpno(F00008) TM 9-2320-272-23-1 WARNING SUMMARY - Continued HAZARDOUS MATERIALS DESCRIPTIONS - Continued WARNING LUBRICATING OIL Prolonged contact with lubricating oil may cause skin rash. Remove saturated clothing immediately and wash skin thoroughly that comes in contact with lubricating oil. Failure to comply may result in injury or death to personnel. Spilled hydraulic oil is slippery and creates a hazardous condition. Clean up and properly dispose of hydraulic oil. Failure to comply may result in injury or death to personnel. WARNING NUCLEAR, BIOLOGICAL, OR CHEMICAL If Nuclear, Biological, or Chemical (NBC) exposure is suspected, all filter media should be handled by personnel wearing protective equipment. Consult your unit NBC Officer or NBC NCO for appropriate handling or disposal instructions. Failure to comply may result in injury or death to personnel. h 03/15/2011 Rel(1.8) root(warnsum) wpno(F00008) TM 9-2320-272-23-1 WARNING SUMMARY - Continued HAZARDOUS MATERIALS DESCRIPTIONS - Continued WARNING LEAD-ACID BATTERIES Avoid battery electrolyte contact with skin, eyes, and clothing. If battery electrolyte spills, take the following immediate action to stop burning effects: External - If battery electrolyte contacts skin, immediately flush affected area with cold running water. Failure to comply may result in injury or death to personnel. Eyes - If battery electrolyte contacts eyes, immediately flush eyes with cold water for 15 minutes and seek immediate medical attention. IMPORTANT - If only one eye is affected, ensure the affected eye is always kept lower then the unaffected eye, during both flushing and transport. This will keep the the affected eye from draining into and contaminating the unaffected eye. Failure to comply may result in injury or death to personnel. Internal - If battery electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, a beaten egg or vegetable oil and seek immediate medical attention. Failure to comply may result in injury or death to personnel. Clothing or vehicle - immediately flush area with cold water and neutralize battery electrolyte with baking soda or household ammonia solution. Failure to comply may result in injury or death to personnel. Batteries produce explosive gases. Do not smoke or use open flame near batteries. Do not allow hot, parking or glowing objects near batteries. If batteries are giving off gases, the presence of heat, flame, or spark may cause fire and/or explosion. Failure to comply may result in injury or death to personnel. Wear proper eye protection, gloves, and an apron when working near batteries. Failure to comply may result in injury or death to personnel. i 03/15/2011 Rel(1.8) root(warnsum) wpno(F00008) TM 9-2320-272-23-1 WARNING SUMMARY - Continued HAZARDOUS MATERIALS DESCRIPTIONS - Continued WARNING DIESEL FUEL • Diesel fuel is highly flammable and can be accidentally ignited. Do not smoke or allow open flame or sparks in the vicinity while working on any part of the fuel system. Keep fire extinguisher within easy reach when working with fuel. Failure to comply may result in injury or death to personnel. • Spilled fuel is slippery and creates a hazardous condition. Clean up and properly disposed of spilled fuel as soon as possible. Failure to comply may result in injury or death to personnel. • Do not work on fuel system when engine is hot. Failure to comply may result in injury or death to personnel. • Safety glassed must be worn when working on pressurized systems. Failure to comply may result in injury or death to personnel. WARNING ADHESIVES AND SEALANTS Adhesives and sealants are flammable, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in a well-ventilated area. If adhesive or sealant contacts eye, flush with large amounts of water, and seek medical attention. If adhesive or sealant get on skin or clothing, flush with large amounts of water. If irritation persists, seek medical attention. Failure to comply may result in serious injury or death to personnel. j 03/15/2011 Rel(1.8) root(warnsum) wpno(F00008) TM 9-2320-272-23-1 LIST OF EFFECTIVE PAGES/WORK PACKAGES NOTE: * Supersedes TM 9-2320-272-24-1, TM 9-2320-272-24-2, TM 9-2320-272-24-3, TM 9-2320-272-24-4 and TO 36A12-1C-1155-2-1, TO 36A12-1C-1155-2-2, TO 36A12-1C-1155-2-3, & TO 36A12-1C-1155-2-4, dated 30 June 1998. Zero in the Change No. Column indicates an original page or work package. Date of issue for the original manual is: Original 10 September 2012 TOTAL NUMBER OF VOLUMES IS 5, TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 510 AND TOTAL NUMBER OF WORK PACKAGES IS 828 CONSISTING OF THE FOLLOWING: Page/WP No. Change No. Page/WP No. Change No. VOLUME 1 Front Cover (2 pages) WARNING SUMMARY (10 pages) i-clii (152 pages) Chapter 1 Title Page (2 pages) WP 0001 (6 pages) WP 0002 (24 pages) WP 0003 (60 pages) Chapter 2 Title Page (2 pages) WP 0004 (2 pages) WP 0005 (8 pages) WP 0006 (8 pages) WP 0007 (22 pages) WP 0008 (4 pages) WP 0009 (10 pages) WP 0010 (4 pages) WP 0011 (4 pages) WP 0012 (8 pages) WP 0013 (4 pages) WP 0014 (16 pages) WP 0015 (6 pages) WP 0016 (4 pages) WP 0017 (6 pages) WP 0018 (6 pages) WP 0019 (2 pages) WP 0020 (4 pages) WP 0021 (16 pages) WP 0022 (2 pages) WP 0023 (4 pages) WP 0024 (6 pages) WP 0025 (6 pages) WP 0026 (6 pages) WP 0027 (6 pages) WP 0028 (16 pages) WP 0029 (8 pages) WP 0030 (4 pages) WP 0031 (6 pages) WP 0032 (4 pages) WP 0033 (4 pages) WP 0034 (4 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 WP 0035 (4 pages) WP 0036 (4 pages) WP 0037 (2 pages) WP 0038 (4 pages) WP 0039 (6 pages) WP 0040 (8 pages) WP 0041 (4 pages) WP 0042 (4 pages) WP 0043 (6 pages) WP 0044 (6 pages) WP 0045 (6 pages) WP 0046 (4 pages) WP 0047 (4 pages) WP 0048 (6 pages) WP 0049 (4 pages) WP 0050 (6 pages) WP 0051 (4 pages) WP 0052 (6 pages) WP 0053 (12 pages) WP 0054 (8 pages) WP 0055 (6 pages) WP 0056 (4 pages) WP 0057 (4 pages) WP 0058 (6 pages) WP 0059 (14 pages) WP 0060 (6 pages) WP 0061 (4 pages) WP 0062 (4 pages) WP 0063 (4 pages) WP 0064 (6 pages) WP 0065 (4 pages) WP 0066 (4 pages) WP 0067 (6 pages) WP 0068 (6 pages) WP 0069 (2 pages) WP 0070 (4 pages) WP 0071 (2 pages) WP 0072 (6 pages) WP 0073 (2 pages) WP 0074 (6 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 A 03/15/2011 Rel(1.8) root(loepwp) wpno(F 00009) USA TM 9-2320-272-23-1 LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued Page/WP No. Change No. Page/WP No. Change No. WP 0075 (4 pages) WP 0076 (4 pages) WP 0077 (2 pages) WP 0078 (4 pages) WP 0079 (4 pages) WP 0080 (4 pages) WP 0081 (6 pages) WP 0082 (4 pages) WP 0083 (4 pages) WP 0084 (8 pages) WP 0085 (8 pages) WP 0086 (4 pages) WP 0087 (10 pages) WP 0088 (16 pages) WP 0089 (10 pages) WP 0090 (14 pages) WP 0091 (8 pages) WP 0092 (4 pages) WP 0093 (6 pages) WP 0094 (8 pages) WP 0095 (12 pages) WP 0096 (8 pages) WP 0097 (6 pages) WP 0098 (8 pages) WP 0099 (6 pages) WP 0100 (12 pages) WP 0101 (4 pages) WP 0102 (4 pages) WP 0103 (8 pages) WP 0104 (6 pages) WP 0105 (6 pages) WP 0106 (6 pages) WP 0107 (8 pages) WP 0108 (4 pages) WP 0109 (10 pages) WP 0110 (12 pages) WP 0111 (4 pages) WP 0112 (6 pages) WP 0113 (8 pages) WP 0114 (6 pages) WP 0115 (6 pages) WP 0116 (6 pages) WP 0117 (4 pages) WP 0118 (6 pages) WP 0119 (6 pages) WP 0120 (56 pages) WP 0121 (8 pages) WP 0122 (8 pages) WP 0123 (4 pages) WP 0124 (4 pages) WP 0125 (2 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 WP 0126 (12 pages) WP 0127 (4 pages) WP 0128 (4 pages) WP 0129 (6 pages) WP 0130 (8 pages) WP 0131 (10 pages) WP 0132 (4 pages) WP 0133 (8 pages) WP 0134 (2 pages) WP 0135 (8 pages) WP 0136 (6 pages) WP 0137 (4 pages) WP 0138 (4 pages) WP 0139 (4 pages) WP 0140 (12 pages) WP 0141 (4 pages) Chapter 3 Title Page (2 pages) WP 0142 (2 pages) WP 0143 (2 pages) WP 0144 (24 pages) WP 0145 (12 pages) WP 0146 (20 pages) WP 0147 (6 pages) WP 0148 (14 pages) WP 0149 (12 pages) WP 0150 (6 pages) WP 0151 (4 pages) WP 0152 (10 pages) WP 0153 (10 pages) Index 1 - Index 5/6 blank (6 pages) Inside Back Cover Back Cover 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 VOLUME 2 Front Cover (2 pages) WARNING SUMMARY (10 pages) i-xxxvii/xxxviii blank (38 pages) Chapter 4 Title Page (2 pages) WP 0154 (6 pages) WP 0155 (2 pages) WP 0156 (16 pages) WP 0157 (4 pages) WP 0158 (4 pages) WP 0159 (6 pages) WP 0160 (8 pages) WP 0161 (8 pages) WP 0162 (8 pages) WP 0163 (8 pages) WP 0164 (4 pages) WP 0165 (4 pages) WP 0166 (6 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 B 03/15/2011 Rel(1.8) root(loepwp) wpno(F00009) USA TM 9-2320-272-23-1 LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued Page/WP No. Change No. Page/WP No. Change No. WP 0167 (6 pages) WP 0168 (4 pages) WP 0169 (6 pages) WP 0170 (6 pages) WP 0171 (6 pages) WP 0172 (6 pages) WP 0173 (6 pages) WP 0174 (4 pages) WP 0175 (6 pages) WP 0176 (6 pages) WP 0177 (6 pages) WP 0178 (6 pages) WP 0179 (6 pages) WP 0180 (6 pages) WP 0181 (6 pages) WP 0182 (4 pages) WP 0183 (2 pages) WP 0184 (4 pages) WP 0185 (6 pages) Chapter 5 Title Page (2 pages) WP 0186 (4 pages) WP 0187 (2 pages) WP 0188 (10 pages) WP 0189 (4 pages) WP 0190 (4 pages) WP 0191 (4 pages) WP 0192 (2 pages) WP 0193 (4 pages) WP 0194 (2 pages) WP 0195 (4 pages) WP 0196 (4 pages) WP 0197 (4 pages) WP 0198 (2 pages) WP 0199 (4 pages) WP 0200 (4 pages) WP 0201 (2 pages) WP 0202 (10 pages) WP 0203 (8 pages) WP 0204 (6 pages) WP 0205 (2 pages) Chapter 6 Title Page (2 pages) WP 0206 (2 pages) WP 0207 (44 pages) WP 0208 (12 pages) WP 0209 (2 pages) Chapter 7 Title Page (2 pages) WP 0210 (2 pages) WP 0211 (56 pages) WP 0212 (8 pages) WP 0213 (40 pages) WP 0214 (4 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 WP 0215 (2 pages) WP 0216 (10 pages) WP 0217 (4 pages) WP 0218 (6 pages) WP 0219 (6 pages) WP 0220 (4 pages) WP 0221 (6 pages) WP 0222 (16 pages) WP 0223 (10 pages) WP 0224 (4 pages) WP 0225 (4 pages) WP 0226 (6 pages) WP 0227 (4 pages) WP 0228 (6 pages) WP 0229 (10 pages) WP 0230 (6 pages) WP 0231 (10 pages) WP 0232 (10 pages) WP 0233 (8 pages) WP 0234 (10 pages) WP 0235 (6 pages) WP 0236 (2 pages) WP 0237 (14 pages) WP 0238 (6 pages) WP 0239 (4 pages) WP 0240 (12 pages) WP 0241 (6 pages) WP 0242 (18 pages) WP 0243 (6 pages) WP 0244 (4 pages) WP 0245 (8 pages) WP 0246 (6 pages) WP 0247 (6 pages) WP 0248 (6 pages) WP 0249 (10 pages) WP 0250 (8 pages) WP 0251 (12 pages) WP 0252 (6 pages) WP 0253 (8 pages) WP 0254 (12 pages) WP 0255 (6 pages) WP 0256 (10 pages) WP 0257 (4 pages) WP 0258 (12 pages) WP 0259 (6 pages) WP 0260 (6 pages) WP 0261 (4 pages) WP 0262 (4 pages) WP 0263 (6 pages) WP 0264 (4 pages) WP 0265 (4 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 C 03/15/2011 Rel(1.8) root(loepwp) wpno(F00009) USA TM 9-2320-272-23-1 LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued Page/WP No. Change No. Page/WP No. Change No. WP 0266 (6 pages) WP 0267 (6 pages) WP 0268 (8 pages) WP 0269 (12 pages) WP 0270 (6 pages) WP 0271 (6 pages) WP 0272 (4 pages) WP 0273 (4 pages) WP 0274 (6 pages) WP 0275 (6 pages) WP 0276 (6 pages) WP 0277 (6 pages) WP 0278 (10 pages) WP 0279 (6 pages) WP 0280 (14 pages) WP 0281 (8 pages) WP 0282 (6 pages) WP 0283 (6 pages) WP 0284 (6 pages) WP 0285 (10 pages) WP 0286 (6 pages) WP 0287 (6 pages) WP 0288 (6 pages) WP 0289 (10 pages) WP 0290 (8 pages) WP 0291 (4 pages) WP 0292 (4 pages) WP 0293 (6 pages) WP 0294 (8 pages) WP 0295 (4 pages) WP 0296 (6 pages) WP 0297 (6 pages) WP 0298 (6 pages) WP 0299 (6 pages) WP 0300 (10 pages) WP 0301 (12 pages) WP 0302 (6 pages) WP 0303 (6 pages) WP 0304 (4 pages) WP 0305 (6 pages) WP 0306 (4 pages) WP 0307 (10 pages) WP 0308 (6 pages) WP 0309 (6 pages) WP 0310 (14 pages) WP 0311 (6 pages) WP 0312 (6 pages) WP 0313 (6 pages) WP 0314 (6 pages) WP 0315 (6 pages) WP 0316 (2 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 WP 0317 (2 pages) WP 0318 (2 pages) WP 0319 (4 pages) WP 0320 (8 pages) WP 0321 (2 pages) WP 0322 (6 pages) WP 0323 (4 pages) WP 0324 (4 pages) WP 0325 (8 pages) WP 0326 (6 pages) WP 0327 (24 pages) WP 0328 (4 pages) WP 0329 (8 pages) WP 0330 (6 pages) WP 0331 (6 pages) WP 0332 (6 pages) WP 0333 (4 pages) WP 0334 (4 pages) WP 0335 (2 pages) WP 0336 (4 pages) WP 0337 (4 pages) WP 0338 (4 pages) WP 0339 (2 pages) WP 0340 (4 pages) WP 0341 (2 pages) WP 0342 (10 pages) WP 0343 (6 pages) WP 0344 (6 pages) WP 0345 (6 pages) WP 0346 (6 pages) WP 0347 (4 pages) WP 0348 (4 pages) WP 0349 (6 pages) WP 0350 (6 pages) Index 1 - Index 5/6 blank (6 pages) Inside Back Cover Back Cover 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 VOLUME 3 Front Cover (2 pages) WARNING SUMMARY (10 pages) i-xxxix/xl blank (40 pages) Chapter 8 Title Page (2 pages) WP 0351 (4 pages) WP 0352 (6 pages) WP 0353 (6 pages) WP 0354 (12 pages) WP 0355 (6 pages) WP 0356 (10 pages) WP 0357 (48 pages) WP 0358 (36 pages) 0 0 0 0 0 0 0 0 0 0 0 0 D 03/15/2011 Rel(1.8) root(loepwp) wpno(F00009) USA TM 9-2320-272-23-1 LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued Page/WP No. Change No. Page/WP No. Change No. WP 0359 (30 pages) WP 0360 (4 pages) WP 0361 (4 pages) WP 0362 (16 pages) WP 0363 (6 pages) WP 0364 (4 pages) WP 0365 (8 pages) WP 0366 (2 pages) WP 0367 (10 pages) WP 0368 (4 pages) WP 0369 (6 pages) WP 0370 (6 pages) WP 0371 (10 pages) WP 0372 (10 pages) WP 0373 (14 pages) WP 0374 (20 pages) WP 0375 (6 pages) WP 0376 (4 pages) WP 0377 (10 pages) WP 0378 (6 pages) WP 0379 (6 pages) WP 0380 (4 pages) WP 0381 (6 pages) WP 0382 (14 pages) WP 0383 (6 pages) WP 0384 (4 pages) WP 0385 (18 pages) WP 0386 (24 pages) WP 0387 (6 pages) WP 0388 (4 pages) WP 0389 (6 pages) WP 0390 (6 pages) WP 0391 (6 pages) WP 0392 (6 pages) WP 0393 (6 pages) WP 0394 (6 pages) WP 0395 (4 pages) WP 0396 (14 pages) WP 0397 (4 pages) WP 0398 (6 pages) WP 0399 (4 pages) WP 0400 (4 pages) WP 0401 (14 pages) WP 0402 (6 pages) WP 0403 (8 pages) WP 0404 (10 pages) WP 0405 (2 pages) WP 0406 (6 pages) WP 0407 (4 pages) WP 0408 (4 pages) WP 0409 (4 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 WP 0410 (4 pages) WP 0411 (8 pages) WP 0412 (12 pages) WP 0413 (2 pages) WP 0414 (14 pages) WP 0415 (4 pages) WP 0416 (2 pages) WP 0417 (2 pages) WP 0418 (4 pages) WP 0419 (8 pages) WP 0420 (6 pages) WP 0421 (6 pages) WP 0422 (6 pages) WP 0423 (4 pages) WP 0424 (6 pages) WP 0425 (6 pages) WP 0426 (4 pages) WP 0427 (12 pages) WP 0428 (10 pages) WP 0429 (10 pages) WP 0430 (10 pages) WP 0431 (6 pages) WP 0432 (6 pages) WP 0433 (4 pages) WP 0434 (6 pages) WP 0435 (8 pages) WP 0436 (8 pages) WP 0437 (4 pages) WP 0438 (6 pages) WP 0439 (4 pages) WP 0440 (6 pages) WP 0441 (6 pages) WP 0442 (10 pages) WP 0443 (8 pages) WP 0444 (6 pages) WP 0445 (6 pages) WP 0446 (6 pages) WP 0447 (6 pages) WP 0448 (6 pages) WP 0449 (6 pages) WP 0450 (14 pages) WP 0451 (4 pages) WP 0452 (4 pages) WP 0453 (4 pages) WP 0454 (4 pages) WP 0455 (6 pages) WP 0456 (6 pages) WP 0457 (6 pages) WP 0458 (6 pages) WP 0459 (6 pages) WP 0460 (4 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 E 03/15/2011 Rel(1.8) root(loepwp) wpno(F00009) USA TM 9-2320-272-23-1 LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued Page/WP No. Change No. Page/WP No. Change No. WP 0461 (6 pages) WP 0462 (6 pages) WP 0463 (4 pages) WP 0464 (4 pages) WP 0465 (4 pages) WP 0466 (4 pages) WP 0467 (10 pages) WP 0468 (6 pages) WP 0469 (4 pages) WP 0470 (8 pages) WP 0471 (6 pages) WP 0472 (4 pages) WP 0473 (4 pages) WP 0474 (6 pages) WP 0475 (6 pages) WP 0476 (6 pages) WP 0477 (6 pages) WP 0478 (6 pages) WP 0479 (6 pages) WP 0480 (8 pages) WP 0481 (10 pages) WP 0482 (12 pages) WP 0483 (6 pages) WP 0484 (8 pages) WP 0485 (6 pages) WP 0486 (6 pages) WP 0487 (6 pages) WP 0488 (6 pages) WP 0489 (6 pages) WP 0490 (6 pages) WP 0491 (6 pages) WP 0492 (4 pages) WP 0493 (6 pages) WP 0494 (10 pages) WP 0495 (4 pages) WP 0496 (2 pages) WP 0497 (4 pages) WP 0498 (2 pages) WP 0499 (10 pages) WP 0500 (10 pages) WP 0501 (4 pages) WP 0502 (6 pages) WP 0503 (10 pages) WP 0504 (6 pages) WP 0505 (6 pages) WP 0506 (6 pages) WP 0507 (4 pages) WP 0508 (6 pages) WP 0509 (6 pages) WP 0510 (8 pages) WP 0511 (4 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 WP 0512 (6 pages) WP 0513 (22 pages) WP 0514 (4 pages) WP 0515 (2 pages) WP 0516 (6 pages) WP 0517 (4 pages) WP 0518 (6 pages) WP 0519 (8 pages) WP 0520 (6 pages) WP 0521 (4 pages) WP 0522 (6 pages) WP 0523 (10 pages) WP 0524 (6 pages) WP 0525 (4 pages) WP 0526 (10 pages) WP 0527 (4 pages) WP 0528 (6 pages) WP 0529 (4 pages) WP 0530 (4 pages) WP 0531 (2 pages) WP 0532 (2 pages) WP 0533 (2 pages) WP 0534 (12 pages) WP 0535 (4 pages) WP 0536 (4 pages) WP 0537 (2 pages) WP 0538 (2 pages) WP 0539 (12 pages) WP 0540 (10 pages) WP 0541 (6 pages) WP 0542 (4 pages) WP 0543 (4 pages) WP 0544 (12 pages) WP 0545 (4 pages) WP 0546 (4 pages) WP 0547 (4 pages) WP 0548 (2 pages) WP 0549 (2 pages) WP 0550 (2 pages) WP 0551 (4 pages) WP 0552 (8 pages) WP 0553 (2 pages) Index 1 - Index 5/6 blank (6 pages) Inside Back Cover Back Cover 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 VOLUME 4 Front Cover (2 pages) WARNING SUMMARY (10 pages) i-xxxvii/xxxviii blank (38 pages) Chapter 9 Title Page (2 pages) 0 0 0 0 F 03/15/2011 Rel(1.8) root(loepwp) wpno(F00009) USA TM 9-2320-272-23-1 LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued Page/WP No. Change No. Page/WP No. Change No. WP 0554 (4 pages) WP 0555 (4 pages) WP 0556 (4 pages) WP 0557 (2 pages) WP 0558 (6 pages) WP 0559 (18 pages) WP 0560 (4 pages) WP 0561 (2 pages) WP 0562 (4 pages) WP 0563 (2 pages) WP 0564 (2 pages) WP 0565 (12 pages) WP 0566 (2 pages) WP 0567 (6 pages) WP 0568 (6 pages) WP 0569 (4 pages) WP 0570 (4 pages) WP 0571 (4 pages) WP 0572 (4 pages) WP 0573 (4 pages) WP 0574 (4 pages) WP 0575 (4 pages) WP 0576 (10 pages) WP 0577 (4 pages) WP 0578 (6 pages) WP 0579 (4 pages) WP 0580 (4 pages) WP 0581 (6 pages) WP 0582 (14 pages) WP 0583 (4 pages) WP 0584 (4 pages) WP 0585 (4 pages) WP 0586 (6 pages) WP 0587 (4 pages) WP 0588 (10 pages) WP 0589 (4 pages) WP 0590 (6 pages) WP 0591 (6 pages) WP 0592 (6 pages) WP 0593 (4 pages) WP 0594 (8 pages) WP 0595 (8 pages) WP 0596 (2 pages) WP 0597 (4 pages) WP 0598 (2 pages) WP 0599 (2 pages) WP 0600 (4 pages) WP 0601 (10 pages) WP 0602 (6 pages) WP 0603 (8 pages) WP 0604 (6 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 WP 0605 (8 pages) WP 0606 (2 pages) WP 0607 (4 pages) WP 0608 (4 pages) WP 0609 (4 pages) WP 0610 (2 pages) WP 0611 (4 pages) WP 0612 (4 pages) WP 0613 (4 pages) WP 0614 (6 pages) WP 0615 (4 pages) WP 0616 (4 pages) WP 0617 (4 pages) WP 0618 (2 pages) WP 0619 (2 pages) WP 0620 (4 pages) WP 0621 (6 pages) WP 0622 (2 pages) WP 0623 (4 pages) WP 0624 (2 pages) WP 0625 (4 pages) WP 0626 (4 pages) WP 0627 (6 pages) WP 0628 (4 pages) WP 0629 (6 pages) WP 0630 (16 pages) WP 0631 (6 pages) WP 0632 (10 pages) WP 0633 (6 pages) WP 0634 (4 pages) WP 0635 (6 pages) WP 0636 (6 pages) WP 0637 (6 pages) WP 0638 (4 pages) WP 0639 (32 pages) WP 0640 (4 pages) WP 0641 (6 pages) WP 0642 (4 pages) WP 0643 (4 pages) WP 0644 (2 pages) WP 0645 (6 pages) WP 0646 (4 pages) WP 0647 (6 pages) WP 0648 (4 pages) WP 0649 (2 pages) WP 0650 (10 pages) WP 0651 (10 pages) WP 0652 (10 pages) WP 0653 (6 pages) WP 0654 (6 pages) WP 0655 (8 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 G 03/15/2011 Rel(1.8) root(loepwp) wpno(F00009) USA TM 9-2320-272-23-1 LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued Page/WP No. Change No. Page/WP No. Change No. WP 0656 (6 pages) WP 0657 (6 pages) WP 0658 (12 pages) WP 0659 (6 pages) WP 0660 (10 pages) WP 0661 (6 pages) WP 0662 (4 pages) WP 0663 (6 pages) WP 0664 (4 pages) WP 0665 (4 pages) WP 0666 (6 pages) WP 0667 (6 pages) WP 0668 (6 pages) WP 0669 (2 pages) WP 0670 (10 pages) WP 0671 (6 pages) WP 0672 (4 pages) WP 0673 (4 pages) WP 0674 (2 pages) WP 0675 (8 pages) WP 0676 (8 pages) WP 0677 (8 pages) WP 0678 (16 pages) WP 0679 (10 pages) WP 0680 (6 pages) WP 0681 (6 pages) WP 0682 (10 pages) WP 0683 (4 pages) WP 0684 (6 pages) WP 0685 (14 pages) WP 0686 (6 pages) WP 0687 (6 pages) WP 0688 (6 pages) WP 0689 (14 pages) WP 0690 (6 pages) WP 0691 (4 pages) WP 0692 (8 pages) WP 0693 (6 pages) WP 0694 (6 pages) WP 0695 (6 pages) WP 0696 (22 pages) WP 0697 (4 pages) WP 0698 (18 pages) WP 0699 (6 pages) WP 0700 (6 pages) WP 0701 (6 pages) WP 0702 (12 pages) WP 0703 (10 pages) WP 0704 (6 pages) WP 0705 (4 pages) WP 0706 (6 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 WP 0707 (10 pages) WP 0708 (4 pages) WP 0709 (8 pages) WP 0710 (4 pages) WP 0711 (6 pages) WP 0712 (6 pages) WP 0713 (8 pages) WP 0714 (4 pages) WP 0715 (10 pages) WP 0716 (6 pages) WP 0717 (12 pages) WP 0718 (4 pages) WP 0719 (2 pages) WP 0720 (2 pages) WP 0721 (6 pages) WP 0722 (10 pages) WP 0723 (4 pages) WP 0724 (8 pages) WP 0725 (24 pages) WP 0726 (6 pages) WP 0727 (6 pages) WP 0728 (10 pages) WP 0729 (6 pages) WP 0730 (6 pages) WP 0731 (4 pages) WP 0732 (4 pages) WP 0733 (2 pages) WP 0734 (2 pages) WP 0735 (6 pages) WP 0736 (6 pages) WP 0737 (8 pages) WP 0738 (6 pages) WP 0739 (6 pages) WP 0740 (2 pages) WP 0741 (4 pages) WP 0742 (4 pages) WP 0743 (4 pages) WP 0744 (2 pages) WP 0745 (6 pages) WP 0746 (6 pages) WP 0747 (6 pages) WP 0748 (6 pages) WP 0749 (2 pages) WP 0750 (6 pages) WP 0751 (4 pages) WP 0752 (6 pages) WP 0753 (4 pages) WP 0754 (6 pages) WP 0755 (6 pages) WP 0756 (4 pages) WP 0757 (12 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 H 03/15/2011 Rel(1.8) root(loepwp) wpno(F00009) USA TM 9-2320-272-23-1 LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued Page/WP No. Change No. Page/WP No. Change No. WP 0758 (6 pages) WP 0759 (4 pages) WP 0760 (6 pages) WP 0761 (6 pages) WP 0762 (6 pages) WP 0763 (6 pages) WP 0764 (6 pages) WP 0765 (6 pages) WP 0766 (4 pages) WP 0767 (4 pages) WP 0768 (6 pages) WP 0769 (10 pages) WP 0770 (10 pages) Index-1 - Index-6 (6 pages) Inside Back Cover Back Cover 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 VOLUME 5 Front Cover (2 pages) WARNING SUMMARY (10 pages) i-xvii/xviii blank (18 pages) Chapter 10 Title Page (2 pages) WP 0771 (4 pages) WP 0772 (10 pages) WP 0773 (4 pages) WP 0774 (12 pages) WP 0775 (42 pages) WP 0776 (10 pages) WP 0777 (4 pages) WP 0778 (6 pages) WP 0779 (6 pages) WP 0780 (4 pages) WP 0781 (6 pages) WP 0782 (6 pages) WP 0783 (10 pages) WP 0784 (12 pages) WP 0785 (8 pages) WP 0786 (6 pages) WP 0787 (8 pages) WP 0788 (12 pages) WP 0789 (2 pages) WP 0790 (10 pages) WP 0791 (6 pages) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 WP 0792 (6 pages) WP 0793 (6 pages) WP 0794 (6 pages) WP 0795 (6 pages) WP 0796 (6 pages) WP 0797 (6 pages) WP 0798 (6 pages) WP 0799 (6 pages) WP 0800 (6 pages) WP 0801 (10 pages) WP 0802 (10 pages) WP 0803 (4 pages) WP 0804 (6 pages) WP 0805 (2 pages) WP 0806 (20 pages) WP 0807 (6 pages) WP 0808 (4 pages) WP 0809 (8 pages) WP 0810 (10 pages) WP 0811 (6 pages) WP 0812 (10 pages) WP 0813 (2 pages) WP 0814 (8 pages) WP 0815 (4 pages) WP 0816 (2 pages) WP 0817 (4 pages) WP 0818 (6 pages) WP 0819 (8 pages) WP 0820 (34 pages) WP 0821 (10 pages) Chapter 11 Title Page (2 pages) WP 0822 (4 pages) WP 0823 (4 pages) WP 0824 (78 pages) WP 0825 (8 pages) WP 0826 (4 pages) WP 0827 (26 pages) WP 0828 (2 pages) Index 1 - Index 20 (20 pages) FP-1 - FP-27/FP-28 blank (28 pages) Inside Back Cover Back Cover 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 I/J blank 03/15/2011 Rel(1.8) root(loepwp) wpno(F00009) 0 0 USA *TM 9-2320-272-23-1 *TO 36A12-1C-1155-2-1 HEADQUARTERS DEPARTMENTS OF THE ARMY AND THE AIR FORCE WASHINGTON, D.C., 10 SEPTEMBER 2012 TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR TRUCK, 5-TON, 6X6, M939, M939A1, AND M939A2 SERIES TRUCKS (DIESEL) TRUCK, DUMP: 5-TON, 6X6 TRUCK, CARGO: 5-TON, 6X6 DROPSIDE NSN NSN NSN NSN NSN NSN M923 2320-01-050-2084 M923A1 2320-01-206-4087 M923A2 2320-01-230-0307 M925 2320-01-047-8769 M925A1 2320-01-206-4088 M925A2 2320-01-230-0308 (EIC BRY) NSN (EIC BSS) NSN (EIC BS7) NSN (EIC BRT) NSN (EIC BST) NSN (EIC BS8) NSN M929 2320-01-047-8756 M929A1 2320-01-206-4079 M929A2 2320-01-230-0305 M930 2320-01-047-8755 M930A1 2320-01-206-4080 M930A2 2320-01-230-0306 TRUCK, VAN, EXPANSIBLE: 5-TON, 6X6 M934 NSN 2320-01-047-8750 (EIC BTB) M934A1 NSN 2320-01-205-2682 (EIC BS4) M934A2 NSN 2320-01-230-0300 (EIC BTR) (EIC BTH) (EIC BSY) (EIC BTN) (EIC BTG) TRUCK, MEDIUM WRECKER: 5-TON, 6X6 (EIC BSZ) (EIC BT7) TRUCK, CARGO: 5-TON, 6X6 XLWBTRUCK, TRACTOR: 5-TON, 6X6 M927 NSN 2320-01-047-8771 (EIC BRV) M927A1 NSN 2320-01-206-4089 (EIC BSW) M927A2 NSN 2320-01-230-0309 (EIC BS9) M928 NSN 2320-01-047-8770 (EIC BRU) M928A1 NSN 2320-01-206-4090 (EIC BSX) M928A2 NSN 2320-01-230-0310 (EIC BTM) M931 NSN 2320-01-047-8753 M931A1 NSN 2320-01-206-4077 M931A2 NSN 2320-01-230-0302 M932 NSN 2320-01-047-8752 M932A1 NSN 2320-01-205-2684 M932A2 NSN 2320-01-230-0303 M936 NSN 2320-01-047-8754 (EIC BTF) M936A1 NSN 2320-01-206-4078 (EIC BS6) M936A2 NSN 2320-01-230-0304 (EIC BTT) (EIC BTE) (EIC BS2) (EIC BTP) (EIC BTD) (EIC BSZ) (EIC BTQ) 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: Reports, as applicable by the requiring service, should be submitted as follows: (A) Army - Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms), located in the back of this manual directly to: U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/ TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. You may also send in your recommended changes via electronic mail or by fax. Our fax number is DSN 786-1856 or Commercial (586) 282-1856. Our email address is tacomlcmc.daform2028@us.army.mil. (F) Air Force - By Air Force AFTO Form 22 directly to WR/ALC/GRVEB, Robins GA. You may also send in your recommended changes electronically via email. Email AFTO form 22 to robins.ce.afto22@robins.af.mil. A reply will be furnished to you. * SUPERSEDURE NOTICE - This manual supersedes TM 9-2320-272-24-1, TM 9-2320-272-24-2, TM 9-2320-272-24-3, TM 9-2320-272-24-4 and TO 36A12-1C-1155-2-1, TO 36A12-1C-1155-2-2, TO 36A12-1C-1155-2-3, & TO 36A12-1C-1155-2-4, dated 30 June 1998, including all changes DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. i/ii blank 03/15/2011 Rel(1.8) root(titleblk) wpno(F00010) TM 9-2320-272-23-1 TABLE OF CONTENTS Page No. WP Sequence No. Volume 1 HOW TO USE THIS MANUAL ............................................................................................................................ cli Chapter 1 - GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION GENERAL INFORMATION.......................................................................................................................... WP 0001 Table 1. Hazardous Materials............................................................................................................ 0001-2 Table 2. List of Abbreviations/Acronyms............................................................................................ 0001-3 EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002 Figure 1. M923 Cargo Truck................................................................................................................ 0002-2 Figure 2. M925 Cargo Truck................................................................................................................ 0002-3 Figure 3. M927 Extra Long Wheelbase Cargo Truck.......................................................................... 0002-4 Figure 4. M928 Extra Long Wheelbase Cargo Truck.......................................................................... 0002-5 Figure 5. M929 Dump Truck................................................................................................................ 0002-6 Figure 6. M930 Dump Truck................................................................................................................ 0002-7 Figure 7. M931 Tractor Truck.............................................................................................................. 0002-8 Figure 8. M932 Tractor Truck.............................................................................................................. 0002-9 Figure 9. M934 Expansible Vans....................................................................................................... 0002-10 Figure 10. M936 Medium Wreckers.................................................................................................... 0002-11 Figure 11. Location Of Exterior Major Components............................................................................ 0002-12 Table 1. Description of Exterior Major Components......................................................................... 0002-13 Figure 12. Description of Interior Cab Components............................................................................ 0002-15 Table 2. Description of Interior Cab Components............................................................................ 0002-16 Table 3. Differences Between Models.............................................................................................. 0002-17 Table 4. Vehicle Performance Data................................................................................................. 0002-19 THEORY OF OPERATION.......................................................................................................................... WP 0003 Figure 1. Starting and Ether Starting Components.............................................................................. 0003-2 Figure 2. Starting and Ether Starting Components.............................................................................. 0003-3 Figure 3. Accelerator Controls System Components.......................................................................... 0003-4 iii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Parking Brake System Components.................................................................................... 0003-5 Figure 5. Steering System Components.............................................................................................. 0003-6 Figure 6. Transmission Control System Components......................................................................... 0003-7 Figure 7. Transfer Case Control System Components........................................................................ 0003-9 Figure 8. Transfer Case Control System Components...................................................................... 0003-10 Figure 9. Air Intake System Components.......................................................................................... 0003-13 Figure 10. Fuel System (Dual Tank) Components.............................................................................. 0003-15 Figure 11. Fuel System (Single Tank) Components............................................................................ 0003-16 Figure 12. Exhaust System Components............................................................................................ 0003-17 Figure 13. Cooling System Components............................................................................................. 0003-19 Figure 14. Engine Oil System Components........................................................................................ 0003-21 Figure 15. Engine Oil System Components........................................................................................ 0003-22 Figure 16. Powertrain System Components........................................................................................ 0003-23 Figure 17. Battery System Components.............................................................................................. 0003-25 Figure 18. Starting System Components............................................................................................. 0003-26 Figure 19. Ether Starting System Components................................................................................... 0003-27 Figure 20. Generating System Components....................................................................................... 0003-28 Figure 21. Directional Signal System Components............................................................................. 0003-29 Figure 22. Heating System Components............................................................................................. 0003-31 Figure 23. Indicator, Gauge, and Warning System Components........................................................ 0003-33 Figure 24. Trailer and Semitrailer Connection Components............................................................... 0003-34 Figure 25. Medium Wrecker Automatic Brake Lock System Components.......................................... 0003-35 Figure 26. Air Pressure Supply System Components......................................................................... 0003-37 Figure 27. Constant Air Pressure Supply System Components.......................................................... 0003-39 Figure 28. Secondary Service Airbrake System Components............................................................ 0003-41 Figure 29. Spring Airbrake System Components................................................................................ 0003-43 Figure 30. Primary Service Airbrake System Components................................................................. 0003-45 iv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 31. Auxiliary Air-Powered System Components....................................................................... 0003-47 Figure 32. Air Venting System Components....................................................................................... 0003-49 Figure 33. Central Tire Inflation System Components......................................................................... 0003-51 Figure 34. Front Winch Hydraulic System Components...................................................................... 0003-52 Figure 35. Rear Winch Hydraulic System Components...................................................................... 0003-53 Figure 36. Dump Body Hydraulic System Components...................................................................... 0003-55 Figure 37. Medium Wrecker Crane Hydraulic System Components................................................... 0003-57 Figure 38. Hoist Action Components................................................................................................... 0003-58 Figure 39. Crowd Action Components................................................................................................. 0003-59 Figure 40. Swing Action Components................................................................................................. 0003-60 Chapter 2 - GENERAL TROUBLESHOOTING PROCEDURES GENERAL TROUBLESHOOTING............................................................................................................... WP 0004 GENERAL TROUBLESHOOTING INDEX................................................................................................... WP 0005 ENGINE FAILS TO CRANK......................................................................................................................... WP 0006 Figure 1. Battery Cables...................................................................................................................... 0006-2 Figure 2. Battery Specific Gravity Test................................................................................................ 0006-3 Figure 3. Starter Cables...................................................................................................................... 0006-4 Figure 4. DCA Connection................................................................................................................... 0006-5 Figure 5. Starter Solenoid.................................................................................................................... 0006-6 Figure 6. Starter Motor........................................................................................................................ 0006-6 Figure 7. Starter Motor........................................................................................................................ 0006-7 Figure 8. Starter Motor........................................................................................................................ 0006-8 ENGINE CRANKS BUT DOES NOT START.............................................................................................. WP 0007 Figure 1. Engine Stop Control............................................................................................................. 0007-2 Figure 2. Air Cleaner Indicator............................................................................................................. 0007-2 Figure 3. Engine Exhaust.................................................................................................................... 0007-3 Figure 4. Engine Exhaust.................................................................................................................... 0007-4 v 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 5. Engine Dipstick..................................................................................................................... 0007-5 Figure 6. Engine Fuel Supply Line...................................................................................................... 0007-6 Figure 7. Fuel Transfer Pump.............................................................................................................. 0007-7 Figure 8. Fuel Pressure Transducer.................................................................................................... 0007-8 Figure 9. Fuel Injector Supply Lines.................................................................................................... 0007-9 Figure 10. Fuel Filter........................................................................................................................... 0007-10 Figure 11. Fuel System....................................................................................................................... 0007-11 Figure 12. Engine................................................................................................................................ 0007-12 Figure 13. Fuel Filter........................................................................................................................... 0007-13 Figure 14. Fuel Filter........................................................................................................................... 0007-14 Figure 15. Fuel Tank........................................................................................................................... 0007-15 Figure 16. Ether Start System............................................................................................................. 0007-16 Figure 17. Ether Start System............................................................................................................. 0007-17 Figure 18. Thermal Close Valve.......................................................................................................... 0007-18 Figure 19. Thermal Close Valve.......................................................................................................... 0007-19 Figure 20. Thermal Close Valve.......................................................................................................... 0007-20 Figure 21. Thermal Close Valve.......................................................................................................... 0007-21 STARTER CRANKS ENGINE SLOWLY, HARD TO START...................................................................... WP 0008 Figure 1. Engine.................................................................................................................................. 0008-2 Figure 2. Accelerator Pedal................................................................................................................. 0008-3 ENGINE STOPS DURING NORMAL OPERATION.................................................................................... WP 0009 Figure 1. Air Cleaner Indicator............................................................................................................. 0009-2 Figure 2. Fuel Tank............................................................................................................................. 0009-3 Figure 3. Emergency Shutoff Valve..................................................................................................... 0009-4 Figure 4. Fuel Filter............................................................................................................................. 0009-5 Figure 5. Fuel Tank............................................................................................................................. 0009-6 Figure 6. Fuel Line............................................................................................................................... 0009-7 vi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 7. Fuel System......................................................................................................................... 0009-8 Figure 8. Vent Lines............................................................................................................................ 0009-9 Figure 9. Exhaust System................................................................................................................. 0009-10 ENGINE STOPS WHEN ACCELERATOR IS RETURNED TO IDLE POSITION....................................... WP 0010 Figure 1. Accelerator Linkage.............................................................................................................. 0010-2 Figure 2. Tachometer.......................................................................................................................... 0010-3 ENGINE FAILS TO STOP........................................................................................................................... WP 0011 Figure 1. Emergency Stop Cable........................................................................................................ 0011-2 Figure 2. Throttle Control Solenoid...................................................................................................... 0011-3 ENGINE RUNS, BUT MISFIRES................................................................................................................. WP 0012 Figure 1. Fuel Filter............................................................................................................................. 0012-2 Figure 2. Fuel Tank............................................................................................................................. 0012-3 Figure 3. Air Cleaner Indicator............................................................................................................. 0012-4 Figure 4. Throttle Linkage.................................................................................................................... 0012-5 Figure 5. Fuel Lines............................................................................................................................. 0012-6 ENGINE IDLE ROUGH OR ERRATIC......................................................................................................... WP 0013 Figure 1. Injector Tubes....................................................................................................................... 0013-2 Figure 2. Injector Tubes....................................................................................................................... 0013-3 POOR ACCELERATION AND/OR LACK OF POWER............................................................................... WP 0014 Figure 1. Air Cleaner Indicator............................................................................................................. 0014-2 Figure 2. Fuel System......................................................................................................................... 0014-3 Figure 3. Exhaust System................................................................................................................... 0014-4 Figure 4. Accelerator Cable................................................................................................................. 0014-5 Figure 5. Accelerator Cable................................................................................................................. 0014-6 Figure 6. Modulator Cable................................................................................................................... 0014-7 Figure 7. Air Fuel Control Tube........................................................................................................... 0014-8 Figure 8. Exhaust System................................................................................................................... 0014-9 vii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 9. Fuel Transfer Pump............................................................................................................ 0014-10 Figure 10. Fuel Pressure Transducer.................................................................................................. 0014-11 Figure 11. Fuel Injector Supply Line.................................................................................................... 0014-12 Figure 12. Fuel Filter........................................................................................................................... 0014-13 Figure 13. Turbocharger...................................................................................................................... 0014-14 ENGINE SURGES....................................................................................................................................... WP 0015 Figure 1. Fuel Tank............................................................................................................................. 0015-2 Figure 2. Modulator Cable................................................................................................................... 0015-3 Figure 3. Throttle Linkage.................................................................................................................... 0015-4 EXCESSIVE OIL CONSUMPTION.............................................................................................................. WP 0016 Figure 1. Oil Dipstick........................................................................................................................... 0016-2 Figure 2. Engine.................................................................................................................................. 0016-3 Figure 3. Turbocharger........................................................................................................................ 0016-4 LOW OIL PRESSURE................................................................................................................................. WP 0017 Figure 1. Engine Oil Lines................................................................................................................... 0017-2 Figure 2. Oil Filter................................................................................................................................ 0017-3 Figure 3. Engine Oil Pressure Sending Unit........................................................................................ 0017-4 ENGINE OIL CONTAMINATED................................................................................................................... WP 0018 Figure 1. Oil Sample............................................................................................................................ 0018-2 Figure 2. Fuel Transfer Pump.............................................................................................................. 0018-3 Figure 3. Engine Oil Cooler and Aftercooler........................................................................................ 0018-4 EXCESSIVE VIBRATION OR CLUNKING.................................................................................................. WP 0019 EXCESSIVE FUEL CONSUMPTION.......................................................................................................... WP 0020 Figure 1. Air Cleaner Indicator............................................................................................................. 0020-1 Figure 2. Fuel System......................................................................................................................... 0020-2 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY)................................................................................................................................................ WP 0021 Figure 1. Ether Cylinder....................................................................................................................... 0021-2 viii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Ether Valve........................................................................................................................... 0021-3 Figure 3. Ether Valve Circuit 570 Wire................................................................................................ 0021-4 Figure 4. Fuel Pressure Switch Circuit 570 Wire................................................................................. 0021-6 Figure 5. Ether Start Switch Circuit 570 Wire...................................................................................... 0021-8 Figure 6. Ether Start Switch Circuit 5C Wire..................................................................................... 0021-10 Figure 7. Ether Valve......................................................................................................................... 0021-12 Figure 8. Thermal Close Valve.......................................................................................................... 0021-14 Figure 9. Atomizer............................................................................................................................. 0021-15 EXHAUST COLOR BLUE DURING NORMAL OPERATION...................................................................... WP 0022 EXHAUST COLOR WHITE DURING NORMAL OPERATION.................................................................... WP 0023 Figure 1. Fuel Filter............................................................................................................................. 0023-2 EXHAUST COLOR BLACK DURING NORMAL OPERATION AND IDLE.................................................. WP 0024 Figure 1. Fuel Filter............................................................................................................................. 0024-2 Figure 2. Fuel Filter............................................................................................................................. 0024-3 Figure 3. Fuel Tank............................................................................................................................. 0024-4 Figure 4. Air Cleaner Indicator............................................................................................................. 0024-5 EXCESSIVE EXHAUST NOISE.................................................................................................................. WP 0025 Figure 1. Muffler.................................................................................................................................. 0025-2 Figure 2. Exhaust System (M939/A1).................................................................................................. 0025-3 Figure 3. Exhaust System (M939A2)................................................................................................... 0025-4 EXHAUST FUMES IN CAB......................................................................................................................... WP 0026 Figure 1. Exhaust System (M939/A1).................................................................................................. 0026-2 Figure 2. Exhaust System (M939A2)................................................................................................... 0026-3 Figure 3. Exhaust System................................................................................................................... 0026-4 ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE................................................... WP 0027 Figure 1. Surge Tank........................................................................................................................... 0027-2 Figure 2. Fan Clutch............................................................................................................................ 0027-3 ix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Coolant Temperature Sending Unit...................................................................................... 0027-4 ENGINE OVERHEATS................................................................................................................................ WP 0028 Figure 1. Surge Tank........................................................................................................................... 0028-2 Figure 2. Engine Oil Dipstick............................................................................................................... 0028-3 Figure 3. Engine Drive Belt.................................................................................................................. 0028-4 Figure 4. Engine Cooling System (M939/A1)...................................................................................... 0028-6 Figure 5. Engine Cooling System (M939A2)....................................................................................... 0028-7 Figure 6. Engine Cooling System (M939/A1)...................................................................................... 0028-8 Figure 7. Engine Cooling System (M939A2)....................................................................................... 0028-9 Figure 8. Engine Cooling Fan............................................................................................................ 0028-10 Figure 9. Radiator.............................................................................................................................. 0028-11 Figure 10. Air Pressure Gauge............................................................................................................ 0028-12 Figure 11. Fan Clutch Actuator............................................................................................................ 0028-13 Figure 12. Water Pump....................................................................................................................... 0028-14 Figure 13. Test Lead Hookup.............................................................................................................. 0028-15 LOSS OF COOLANT................................................................................................................................... WP 0029 Figure 1. Engine Cooling System (M939/A1)...................................................................................... 0029-2 Figure 2. Engine Cooling System (M939A2)....................................................................................... 0029-3 Figure 3. Transmission Oil Cooler....................................................................................................... 0029-4 Figure 4. Surge Tank........................................................................................................................... 0029-6 CONTAMINATED COOLANT...................................................................................................................... WP 0030 Figure 1. Surge Tank........................................................................................................................... 0030-2 EXCESSIVE NOISE DURING SHIFTING................................................................................................... WP 0031 Figure 1. Transmission Dipstick.......................................................................................................... 0031-2 Figure 2. Transmission Dipstick.......................................................................................................... 0031-3 Figure 3. Transmission Yoke............................................................................................................... 0031-4 Figure 4. Transmission Universal Joints.............................................................................................. 0031-5 x 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. LOW TRANSMISSION OIL PRESSURE..................................................................................................... WP 0032 Figure 1. Transmission Dipstick.......................................................................................................... 0032-2 TRANSMISSION OIL LEAKING.................................................................................................................. WP 0033 Figure 1. Transmission Oil Pan........................................................................................................... 0033-2 Figure 2. Transmission Oil Cooling Lines............................................................................................ 0033-3 NO RESPONSE TO SHIFT LEVER MOVEMENT....................................................................................... WP 0034 Figure 1. Transmission Dipstick.......................................................................................................... 0034-2 Figure 2. Transmission Selector.......................................................................................................... 0034-3 ROUGH SHIFTING...................................................................................................................................... WP 0035 Figure 1. Transmission Dipstick.......................................................................................................... 0035-2 Figure 2. Transmission Selector.......................................................................................................... 0035-3 TRANSMISSION OVERHEATS AS INDICATED BY TRANSMISSION TEMPERATURE GAUGE........................................................................................................................................................ WP 0036 Figure 1. Transmission Dipstick.......................................................................................................... 0036-2 Figure 2. Test Lead Hookup................................................................................................................ 0036-3 DIRT OR METAL PARTICLES IN TRANSMISSION OIL............................................................................ WP 0037 Figure 1. Transmission Oil Sample Port.............................................................................................. 0037-2 OIL THROWN FROM TRANSMISSION DIPSTICK TUBE.......................................................................... WP 0038 Figure 1. Transmission Dipstick.......................................................................................................... 0038-2 Figure 2. Transmission Dipstick.......................................................................................................... 0038-3 TRANSMISSION OIL DIRTY, FOAMY, AND/OR MILKY............................................................................ WP 0039 Figure 1. Transmission Dipstick.......................................................................................................... 0039-2 Figure 2. Transmission Dipstick.......................................................................................................... 0039-3 Figure 3. Transmission Dipstick.......................................................................................................... 0039-4 Figure 4. Transmission Dipstick.......................................................................................................... 0039-5 HARD SHIFTING OF TRANSFER CASE.................................................................................................... WP 0040 Figure 1. Transfer Case....................................................................................................................... 0040-2 Figure 2. Transfer Case Linkage......................................................................................................... 0040-3 xi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Circuit 586 Wire.................................................................................................................... 0040-4 Figure 4. Circuit 585 Wire.................................................................................................................... 0040-5 Figure 5. Circuit 37 Breaker................................................................................................................. 0040-6 Figure 6. Circuit 10 Breaker................................................................................................................. 0040-7 TRANSFER CASE LEAKING OIL............................................................................................................... WP 0041 Figure 1. Transfer Case....................................................................................................................... 0041-2 EXCESSIVE NOISE.................................................................................................................................... WP 0042 Figure 1. Transfer Case....................................................................................................................... 0042-2 EXCESSIVE VIBRATION............................................................................................................................ WP 0043 Figure 1. Transfer Case....................................................................................................................... 0043-2 Figure 2. Propeller Shafts.................................................................................................................... 0043-3 EXCESSIVE PROPELLER AND DRIVE SHAFTS NOISE OR VIBRATION............................................... WP 0044 Figure 1. Universal Joints.................................................................................................................... 0044-2 Figure 2. Propeller Shaft...................................................................................................................... 0044-3 Figure 3. Center Bearing..................................................................................................................... 0044-4 CONTINUOUS AXLE OR WHEEL NOISE.................................................................................................. WP 0045 Figure 1. Front Wheel Drive Lock-In Switch........................................................................................ 0045-2 Figure 2. Wheel Lug Nuts.................................................................................................................... 0045-3 Figure 3. Differential Lubrication Level................................................................................................ 0045-4 Figure 4. Wheel Bearings.................................................................................................................... 0045-5 TOWING PINTLE DOES NOT LATCH OR LOCK....................................................................................... WP 0046 Figure 1. Pintle Hook Assembly.......................................................................................................... 0046-2 Figure 2. Pintle Hook Assembly.......................................................................................................... 0046-3 PINTLE HOOK DOES NOT TURN.............................................................................................................. WP 0047 Figure 1. Pintle Hook Assembly.......................................................................................................... 0047-2 Figure 2. Pintle Hook Mounting Housing Bracket................................................................................ 0047-3 Figure 3. Pintle Hook Shaft.................................................................................................................. 0047-4 xii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. EXCESSIVELY LOOSE LIFTING SHACKLE.............................................................................................. WP 0048 Figure 1. Front and Rear Shackle Pin Assembly................................................................................. 0048-2 Figure 2. Front and Rear Shackle Pin Assembly................................................................................. 0048-3 Figure 3. Front and Rear Shackle Pin Assembly................................................................................. 0048-4 Figure 4. Front and Rear Shackle Pin Assembly................................................................................. 0048-5 LOOSE SPARE TIRE CARRIER................................................................................................................. WP 0049 Figure 1. Spare Tire Carrier................................................................................................................. 0049-2 Figure 2. Spare Tire Carrier Assembly................................................................................................ 0049-3 UNEVEN TIRE WEAR................................................................................................................................. WP 0050 Figure 1. Lugnuts................................................................................................................................. 0050-2 Figure 2. Toe-In Adjustment................................................................................................................ 0050-3 Figure 3. Wheel Bearing Assembly..................................................................................................... 0050-4 WHEEL SHIMMY OR WOBBLE.................................................................................................................. WP 0051 Figure 1. Wheel................................................................................................................................... 0051-2 Figure 2. Wheel Bearing Assembly..................................................................................................... 0051-3 HARD STEERING....................................................................................................................................... WP 0052 Figure 1. Steering Hydraulic Lines...................................................................................................... 0052-2 Figure 2. Steering Assembly............................................................................................................... 0052-3 Figure 3. Pitman Arm........................................................................................................................... 0052-4 Figure 4. Spring U-Bolts...................................................................................................................... 0052-5 Figure 5. Toe-In Check........................................................................................................................ 0052-6 VEHICLE WANDERS OR PULLS TO ONE SIDE....................................................................................... WP 0053 Figure 1. Tire....................................................................................................................................... 0053-2 Figure 2. Front Wheel Assembly......................................................................................................... 0053-3 Figure 3. Truck Jack............................................................................................................................ 0053-4 Figure 4. Wheel Bearing Assembly..................................................................................................... 0053-5 Figure 5. Steering Assist Cylinder....................................................................................................... 0053-6 xiii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 6. Tie Rod................................................................................................................................. 0053-7 Figure 7. Steering Gear....................................................................................................................... 0053-8 Figure 8. Pitman Arm........................................................................................................................... 0053-9 Figure 9. Shackle Pins....................................................................................................................... 0053-10 Figure 10. Toe-In Check...................................................................................................................... 0053-11 EXCESSIVE PLAY IN STEERING WHEEL................................................................................................. WP 0054 Figure 1. Steering Wheel..................................................................................................................... 0054-2 Figure 2. Drag Link.............................................................................................................................. 0054-3 Figure 3. Tie Rod................................................................................................................................. 0054-4 Figure 4. Pitman Arm........................................................................................................................... 0054-5 Figure 5. Steering Assist Cylinder....................................................................................................... 0054-6 SHIMMY....................................................................................................................................................... WP 0055 Figure 1. Wheel Lugnuts..................................................................................................................... 0055-2 Figure 2. Wheels................................................................................................................................. 0055-3 Figure 3. Wheel Bearing Assembly..................................................................................................... 0055-4 Figure 4. Toe-In Check........................................................................................................................ 0055-5 Figure 5. Steering Knuckle.................................................................................................................. 0055-6 CONTINUOUS WANDERING OR SWAYING (POOR CONTROL)............................................................ WP 0056 Figure 1. Leaf Springs......................................................................................................................... 0056-2 Figure 2. Shock Absorber.................................................................................................................... 0056-3 Figure 3. U-Bolts.................................................................................................................................. 0056-4 HARSH OR HARD RIDE............................................................................................................................. WP 0057 Figure 1. Leaf Springs, Pivots, and Shackle Pins................................................................................ 0057-2 Figure 2. Spring Shackles................................................................................................................... 0057-3 Figure 3. Shock Absorbers.................................................................................................................. 0057-4 SPRING LEAF DEFECT.............................................................................................................................. WP 0058 Figure 1. Spring Shackles................................................................................................................... 0058-2 xiv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. U-Bolts.................................................................................................................................. 0058-3 Figure 3. Leaf Springs and Shackle Pins............................................................................................ 0058-4 WINCH DOES NOT OPERATE................................................................................................................... WP 0059 Figure 1. Hydraulic Oil Check.............................................................................................................. 0059-2 Figure 2. Power Takeoff Controls........................................................................................................ 0059-3 Figure 3. Power Takeoff Linkage......................................................................................................... 0059-4 Figure 4. Front Winch.......................................................................................................................... 0059-5 Figure 5. Front Winch Drum Lock........................................................................................................ 0059-6 Figure 6. Front Winch.......................................................................................................................... 0059-7 Figure 7. Oil Lines............................................................................................................................... 0059-8 Figure 8. Oil Return Line..................................................................................................................... 0059-9 Figure 9. Oil Filter.............................................................................................................................. 0059-10 Figure 10. Oil Pump............................................................................................................................. 0059-11 Figure 11. Winch Motor....................................................................................................................... 0059-12 WINCH OPERATES IN ONE DIRECTION ONLY....................................................................................... WP 0060 Figure 1. Front Winch.......................................................................................................................... 0060-2 Figure 2. Control Valve........................................................................................................................ 0060-3 Figure 3. Air Operator Tensioner......................................................................................................... 0060-4 Figure 4. Winch Torque Control Lever................................................................................................ 0060-5 DRAG BRAKE DOES NOT OPERATE....................................................................................................... WP 0061 Figure 1. Front Winch.......................................................................................................................... 0061-2 Figure 2. Front Winch.......................................................................................................................... 0061-3 WINCH WILL NOT HOLD LOAD................................................................................................................. WP 0062 Figure 1. Torque Control Lever........................................................................................................... 0062-2 Figure 2. Front And Rear Winches...................................................................................................... 0062-3 AUTOMATIC BRAKE OVERHEATS........................................................................................................... WP 0063 Figure 1. Front and Rear Winch.......................................................................................................... 0063-2 xv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Automatic Brake Setscrew................................................................................................... 0063-3 FRONT WINCH OPERATES AT ONE SPEED ONLY................................................................................ WP 0064 Figure 1. Winch Control Valve............................................................................................................. 0064-2 Figure 2. Front Winch.......................................................................................................................... 0064-3 Figure 3. Throttle Control Cable.......................................................................................................... 0064-4 REAR WINCH CABLE TENSIONER WILL NOT OPERATE....................................................................... WP 0065 Figure 1. Rear Winch Cable Tensioner............................................................................................... 0065-2 VEHICLE ROLLS WHILE OPERATING REAR WINCH.............................................................................. WP 0066 Figure 1. Spring Brake......................................................................................................................... 0066-2 Figure 2. Field Chocks......................................................................................................................... 0066-3 PTO EXCESSIVELY NOISY........................................................................................................................ WP 0067 Figure 1. PTO Universal Joint............................................................................................................. 0067-2 Figure 2. Transmission PTO to Hydraulic Pump Propeller Shaft........................................................ 0067-3 Figure 3. Transfer Case PTO to Hydraulic Pump Propeller Shaft....................................................... 0067-4 PTO SHIFTS HARD..................................................................................................................................... WP 0068 Figure 1. PTO Shift Linkage................................................................................................................ 0068-2 Figure 2. PTO Shift Linkage Condition................................................................................................ 0068-4 PTO LEAKING LUBRICANT........................................................................................................................ WP 0069 Figure 1. PTO Mounting Screws......................................................................................................... 0069-2 RADIO INTERFERENCE............................................................................................................................. WP 0070 Figure 1. Alternator Wiring................................................................................................................... 0070-2 Figure 2. Alternator.............................................................................................................................. 0070-3 TRAILER WILL NOT HITCH TO FIFTH WHEEL......................................................................................... WP 0071 Figure 1. Fifth Wheel........................................................................................................................... 0071-2 WRECKER HYDRAULIC SYSTEM DOES NOT OPERATE....................................................................... WP 0072 Figure 1. Hydraulic Oil Reservoir......................................................................................................... 0072-2 Figure 2. Power Takeoff Controls........................................................................................................ 0072-3 xvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Oil Lines............................................................................................................................... 0072-4 WRECKER HYDRAULIC PUMP NOISY..................................................................................................... WP 0073 Figure 1. Hydraulic Oil Level............................................................................................................... 0073-2 DUMP BODY WILL NOT RAISE................................................................................................................. WP 0074 Figure 1. Power Takeoff Controls........................................................................................................ 0074-2 Figure 2. Hydraulic Lines..................................................................................................................... 0074-3 Figure 3. Control Valve........................................................................................................................ 0074-4 Figure 4. Control Valve Movement...................................................................................................... 0074-4 Figure 5. Pump Housing...................................................................................................................... 0074-5 DUMP BODY WILL NOT LOWER............................................................................................................... WP 0075 Figure 1. Dump Body Brace................................................................................................................ 0075-2 Figure 2. Control Valve........................................................................................................................ 0075-3 DUMP BODY WILL NOT HOLD IN RAISED POSITION............................................................................. WP 0076 Figure 1. Hydraulic Lines..................................................................................................................... 0076-2 Figure 2. Control Valve........................................................................................................................ 0076-3 DUMP HYDRAULIC PUMP NOISY............................................................................................................. WP 0077 Figure 1. Hydraulic Oil Level............................................................................................................... 0077-2 TAILGATE WILL NOT OPEN ..................................................................................................................... WP 0078 Figure 1. Tailgate Linkage................................................................................................................... 0078-2 SIDE PANELS HARD TO RETRACT OR EXPAND.................................................................................... WP 0079 Figure 1. Sprocket Assembly............................................................................................................... 0079-2 Figure 2. Rollers.................................................................................................................................. 0079-3 SIDE PANEL CANNOT BE LOCKED IN RETRACT POSITION................................................................. WP 0080 Figure 1. Side Panel............................................................................................................................ 0080-2 Figure 2. Roof Edge............................................................................................................................ 0080-3 VAN BODY NOT WATERPROOF OR LIGHT TIGHT................................................................................. WP 0081 Figure 1. Side Panel............................................................................................................................ 0081-2 xvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. End Panel............................................................................................................................. 0081-3 Figure 3. Block Seal............................................................................................................................ 0081-4 Figure 4. Rear Door Seal..................................................................................................................... 0081-5 DOOR LOCK WILL NOT OPERATE........................................................................................................... WP 0082 Figure 1. Door Lock............................................................................................................................. 0082-2 Figure 2. Striker Plate.......................................................................................................................... 0082-3 ENGINE AND VEHICLE ELECTRICAL SYSTEMS MALFUNCTIONING................................................... WP 0083 Figure 1. Protective Control Box.......................................................................................................... 0083-2 ENGINE WILL NOT CRANK; SOME ELECTRICAL SYSTEMS INOPERATIVE OR WEAK...................... WP 0084 Figure 1. Batteries............................................................................................................................... 0084-2 Figure 2. Battery Terminals................................................................................................................. 0084-3 Figure 3. Specific Gravity Test............................................................................................................ 0084-4 Figure 4. Specific Gravity Test............................................................................................................ 0084-5 Figure 5. Battery/Solenoid Voltage Test.............................................................................................. 0084-6 ALL VEHICLE ELECTRICAL SYSTEMS INOPERATIVE............................................................................ WP 0085 Figure 1. Battery Terminals................................................................................................................. 0085-2 Figure 2. Battery Terminals................................................................................................................. 0085-3 Figure 3. Battery Terminals................................................................................................................. 0085-4 Figure 4. Specific Gravity Test............................................................................................................ 0085-5 Figure 5. Specific Gravity Test............................................................................................................ 0085-6 Figure 6. Protection Control Box Test................................................................................................. 0085-7 STARTER MOTOR INOPERATIVE............................................................................................................. WP 0086 Figure 1. Battery and Starter Switches................................................................................................ 0086-2 Figure 2. Battery/Solenoid Voltage Test.............................................................................................. 0086-3 SOLENOID OPERATES, STARTER OPERATES, BUT ENGINE CRANKS SLOWLY.............................. WP 0087 Figure 1. Engine Stop Control Switch.................................................................................................. 0087-2 Figure 2. Specific Gravity Test............................................................................................................ 0087-3 xviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Specific Gravity Test............................................................................................................ 0087-4 Figure 4. Battery/Solenoid Voltage Test.............................................................................................. 0087-5 Figure 5. Starter Motor To Solenoid Voltage Drop Test...................................................................... 0087-6 Figure 6. Starter Motor Solenoid Voltage Drop Test........................................................................... 0087-7 Figure 7. Starter Motor Ground Voltage Drop Test............................................................................. 0087-8 Figure 8. Starter Motor Cable Voltage Drop Test................................................................................ 0087-9 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP.................................................................... WP 0088 Figure 1. Light Switch.......................................................................................................................... 0088-2 Figure 2. Protective Control Box.......................................................................................................... 0088-3 Figure 3. Battery Switch Wire 81A....................................................................................................... 0088-4 Figure 4. Battery Switch Test.............................................................................................................. 0088-5 Figure 5. Protective Control Box Wire 459.......................................................................................... 0088-6 Figure 6. Protective Control Box Wire 81............................................................................................ 0088-7 Figure 7. Starter Solenoid Wire 74...................................................................................................... 0088-8 Figure 8. Start Switch Wire 5B............................................................................................................ 0088-9 Figure 9. Start Switch........................................................................................................................ 0088-10 Figure 10. Neutral Start Switch Wire 498............................................................................................ 0088-11 Figure 11. Neutral Start Switch............................................................................................................ 0088-12 Figure 12. Protective Control Box Wire 499........................................................................................ 0088-13 Figure 13. Alternator Wire 566............................................................................................................ 0088-14 Figure 14. Protective Control Box........................................................................................................ 0088-15 NO OR LOW ALTERNATOR OUTPUT....................................................................................................... WP 0089 Figure 1. Alternator Drive Belt............................................................................................................. 0089-2 Figure 2. DCA Connector.................................................................................................................... 0089-3 Figure 3. Alternator Electrical Wiring................................................................................................... 0089-4 Figure 4. Alternator Wire 568.............................................................................................................. 0089-5 Figure 5. Alternator Wiring................................................................................................................... 0089-6 xix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 6. Alternator Wire 5.................................................................................................................. 0089-7 Figure 7. Alternator Wire 5/568........................................................................................................... 0089-8 NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR)........................................................................... WP 0090 Figure 1. Alternator Drive Belt............................................................................................................. 0090-2 Figure 2. DCA Connector.................................................................................................................... 0090-3 Figure 3. Voltage Regulator Harness.................................................................................................. 0090-4 Figure 4. Voltage Regulator Harness.................................................................................................. 0090-5 Figure 5. Voltage Regulator Harness.................................................................................................. 0090-6 Figure 6. Voltage Regulator Harness.................................................................................................. 0090-7 Figure 7. Voltage Regulator Harness.................................................................................................. 0090-8 Figure 8. Voltage Regulator Harness.................................................................................................. 0090-9 Figure 9. Voltage Regulator Harness................................................................................................ 0090-10 Figure 10. Voltage Regulator Harness................................................................................................ 0090-11 Figure 11. Voltage Regulator Harness................................................................................................ 0090-12 ALTERNATOR OVERCHARGING, BATTERY INDICATOR GAUGE IN RED POSITION......................... WP 0091 Figure 1. DCA Connector.................................................................................................................... 0091-2 Figure 2. Alternator Electrical Wiring................................................................................................... 0091-3 Figure 3. Alternator.............................................................................................................................. 0091-4 Figure 4. Alternator Wire 568.............................................................................................................. 0091-5 Figure 5. Alternator Electrical Wiring................................................................................................... 0091-6 HEADLAMP (ONE SIDE) INOPERATIVE................................................................................................... WP 0092 Figure 1. Headlamp Bulb..................................................................................................................... 0092-2 Figure 2. Headlamp Connectors.......................................................................................................... 0092-3 HEADLAMP (BOTH SIDE) INOPERATIVE................................................................................................. WP 0093 Figure 1. Beam Select Switch............................................................................................................. 0093-2 Figure 2. Beam Select Switch............................................................................................................. 0093-3 Figure 3. Main Lighting Switch............................................................................................................ 0093-4 xx 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Main Lighting Switch Connector........................................................................................... 0093-5 Figure 5. Main Lighting Switch Connector........................................................................................... 0093-6 BLACKOUT DRIVE OR BLACKOUT MARKER LIGHT INOPERATIVE...................................................... WP 0094 Figure 1. Light Bulbs............................................................................................................................ 0094-2 Figure 2. Light Socket.......................................................................................................................... 0094-2 Figure 3. Lamp Holder......................................................................................................................... 0094-3 Figure 4. Blackout Light Assemblies................................................................................................... 0094-4 Figure 5. Main Lighting Switch Connector........................................................................................... 0094-5 Figure 6. Main Lighting Switch Connector........................................................................................... 0094-6 Figure 7. Main Lighting Switch Connector........................................................................................... 0094-7 STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT)......................................................................... WP 0095 Figure 1. Light Bulbs............................................................................................................................ 0095-2 Figure 2. Light Socket.......................................................................................................................... 0095-2 Figure 3. Lamp Holder......................................................................................................................... 0095-3 Figure 4. Stoplight Switch.................................................................................................................... 0095-4 Figure 5. Main Lighting Switch Connector........................................................................................... 0095-5 Figure 6. Main Lighting Switch Connector........................................................................................... 0095-6 Figure 7. Main Lighting Switch Connector........................................................................................... 0095-7 Figure 8. Stoplight Switch Test............................................................................................................ 0095-8 Figure 9. Main Lighting Switch Connector........................................................................................... 0095-9 Figure 10. Main Lighting Switch Connector......................................................................................... 0095-10 Figure 11. Main Lighting Switch Connector......................................................................................... 0095-11 TAIL AND MARKER LIGHTS INOPERATIVE............................................................................................. WP 0096 Figure 1. Light Bulbs............................................................................................................................ 0096-2 Figure 2. Light Socket.......................................................................................................................... 0096-2 Figure 3. Lamp Holder......................................................................................................................... 0096-3 Figure 4. Rear Composite Light........................................................................................................... 0096-4 xxi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 5. Main Lighting Switch Connector........................................................................................... 0096-5 Figure 6. Main Lighting Switch Connector........................................................................................... 0096-6 Figure 7. Main Lighting Switch Connector........................................................................................... 0096-6 INDIVIDUAL LIGHTS DO NOT LIGHT WITH DIRECTIONAL SIGNAL LEVER IN ANY POSITION.................................................................................................................................................... WP 0097 Figure 1. Light Bulbs............................................................................................................................ 0097-2 Figure 2. Directional Signal Circuit Test.............................................................................................. 0097-3 Figure 3. Directional Signal Circuit Test.............................................................................................. 0097-4 Figure 4. Directional Signal Circuit Test.............................................................................................. 0097-5 NO LIGHTS OPERATE WITH DIRECTIONAL SIGNAL CONTROL LEVER IN ANY POSITION.................................................................................................................................................... WP 0098 Figure 1. Control Unit Harness Connector.......................................................................................... 0098-2 Figure 2. Main Lighting Switch Connector........................................................................................... 0098-3 Figure 3. Main Lighting Switch Connector........................................................................................... 0098-3 Figure 4. Main Lighting Switch Connector........................................................................................... 0098-4 Figure 5. Flasher Wire Harness Test................................................................................................... 0098-5 Figure 6. Flasher Wire Harness Test................................................................................................... 0098-6 Figure 7. Flasher Wire Harness Test................................................................................................... 0098-7 SYSTEM OPERATES INCORRECTLY IN ONE OR MORE POSITIONS OF DIRECTIONAL SIGNAL CONTROL LEVER........................................................................................................................ WP 0099 Figure 1. Directional Signal Control Neutral Position.......................................................................... 0099-2 Figure 2. Directional Signal Control Right Turn Position..................................................................... 0099-3 Figure 3. Directional Signal Control Left Turn Position........................................................................ 0099-4 Figure 4. Directional Signal Control Hazzard Position......................................................................... 0099-5 PROTECTIVE CONTROL BOX ASSEMBLY TEST.................................................................................... WP 0100 Figure 1. Protective Control Box Connector........................................................................................ 0100-2 Figure 2. Protective Control Box Connector........................................................................................ 0100-3 Figure 3. Protective Control Box Connector........................................................................................ 0100-4 xxii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Protective Control Box Connector........................................................................................ 0100-5 Figure 5. Protective Control Box Connector........................................................................................ 0100-6 Figure 6. Protective Control Box Connector........................................................................................ 0100-7 Figure 7. Protective Control Box Connector........................................................................................ 0100-8 Figure 8. Protective Control Box Connector........................................................................................ 0100-9 Figure 9. Protective Control Box Connector...................................................................................... 0100-10 SPEEDOMETER OR TACHOMETER NOISY OR ERRATIC..................................................................... WP 0101 Figure 1. Speedometer and Tachometer Flexible Shafts.................................................................... 0101-2 Figure 2. Speedometer and Tachometer............................................................................................. 0101-3 AIR PRESSURE GAUGE INOPERATIVE................................................................................................... WP 0102 Figure 1. Air Pressure Gauge.............................................................................................................. 0102-2 Figure 2. Air Pressure Gauge.............................................................................................................. 0102-3 OIL PRESSURE GAUGE INOPERATIVE (OIL LEVEL IS CORRECT)....................................................... WP 0103 Figure 1. Oil Pressure Sending Unit.................................................................................................... 0103-2 Figure 2. Oil Pressure Gauge Test...................................................................................................... 0103-4 Figure 3. Oil Pressure Gauge Voltage Test......................................................................................... 0103-6 ALL GAUGES INOPERATIVE..................................................................................................................... WP 0104 Figure 1. Circuit Breaker...................................................................................................................... 0104-2 Figure 2. Circuit Breaker Test.............................................................................................................. 0104-3 Figure 3. Circuit 27 Wire Test.............................................................................................................. 0104-4 TRANSMISSION TEMPERATURE GAUGE INOPERATIVE...................................................................... WP 0105 Figure 1. Transmission Temperature Sending Unit............................................................................. 0105-2 Figure 2. Transmission Temperature Gauge Wire 324....................................................................... 0105-3 Figure 3. Transmission Temperature Gauge Wire 27......................................................................... 0105-4 TEMPERATURE GAUGE INOPERATIVE (COOLANT).............................................................................. WP 0106 Figure 1. Coolant Temperature Sending Unit...................................................................................... 0106-2 Figure 2. Coolant Temperature Gauge Test........................................................................................ 0106-4 xxiii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Coolant Temperature Gauge Voltage Test.......................................................................... 0106-5 FUEL GAUGE INOPERATIVE..................................................................................................................... WP 0107 Figure 1. Fuel Level Sending Unit....................................................................................................... 0107-2 Figure 2. Fuel Level Gauge Test......................................................................................................... 0107-4 Figure 3. Fuel Selector Switch............................................................................................................. 0107-5 Figure 4. Fuel Gauge Test................................................................................................................... 0107-6 Figure 5. Fuel Gauge Test................................................................................................................... 0107-7 BATTERY/ALTERNATOR GAUGE INOPERATIVE.................................................................................... WP 0108 Figure 1. Battery-Alternator Gauge..................................................................................................... 0108-2 Figure 2. Battery-Alternator Gauge Test............................................................................................. 0108-3 HORN INOPERATIVE................................................................................................................................. WP 0109 Figure 1. Horn Air Supply.................................................................................................................... 0109-2 Figure 2. Horn Circuit Breaker............................................................................................................. 0109-3 Figure 3. Horn Circuit Breaker Test..................................................................................................... 0109-4 Figure 4. Horn Solenoid Test............................................................................................................... 0109-5 Figure 5. Horn Solenoid Test............................................................................................................... 0109-6 Figure 6. Horn Switch Test.................................................................................................................. 0109-8 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE).......................................................................................................... WP 0110 Figure 1. Pressure Switch................................................................................................................... 0110-2 Figure 2. Pressure Switch................................................................................................................... 0110-4 Figure 3. Pressure Switch Wire 57...................................................................................................... 0110-6 Figure 4. Pressure Switch Wire 578A.................................................................................................. 0110-8 Figure 5. Failsafe Warning Control Module....................................................................................... 0110-10 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF AND PARKING BRAKE WARNING LIGHT FLASHES WITH HAND/PARKING BRAKE IN ANY POSITION (AIR PRESSURE NORMAL)................................................................................................................................ WP 0111 Figure 1. Pressure Switch................................................................................................................... 0111-2 xxiv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Pressure Switch................................................................................................................... 0111-3 SPRING BRAKE WARNING LIGHT INOPERATIVE WITH SPRING BRAKE OVERRIDE ENGAGED................................................................................................................................................... WP 0112 Figure 1. Spring Brake Override Light................................................................................................. 0112-2 Figure 2. Spring Brake Pressure Switch Wire 37................................................................................ 0112-3 Figure 3. Spring Brake Override Warning Circuit Breaker Wire 10..................................................... 0112-4 Figure 4. Spring Brake Override Warning Circuit Breaker Wire 37..................................................... 0112-5 ONE OR MORE TRAILER LIGHTS INOPERATIVE.................................................................................... WP 0113 Figure 1. Lighting System.................................................................................................................... 0113-2 Figure 2. Trailer Receptacle................................................................................................................ 0113-3 Figure 3. Trailer Receptacle................................................................................................................ 0113-4 Figure 4. Trailer Receptacle................................................................................................................ 0113-5 Figure 5. Trailer Lighting System Cable.............................................................................................. 0113-6 Figure 6. Trailer................................................................................................................................... 0113-7 HEATER WILL NOT OPERATE WITH SWITCH IN LOW POSITION (HIGH POSITION OPERATION NORMAL).............................................................................................................................. WP 0114 Figure 1. Heater Switch Wiring............................................................................................................ 0114-2 Figure 2. Circuit Breaker Wire 569A.................................................................................................... 0114-3 Figure 3. Circuit Breaker Wire 569A.................................................................................................... 0114-4 Figure 4. Battery Switch Wire 569A..................................................................................................... 0114-5 HEATER WILL NOT OPERATE WITH SWITCH IN HIGH POSITION (LOW POSITION OPERATION NORMAL).............................................................................................................................. WP 0115 Figure 1. Heater Switch Wiring............................................................................................................ 0115-2 Figure 2. Circuit Breaker Wire 27........................................................................................................ 0115-3 Figure 3. Circuit Breaker Wire 5A........................................................................................................ 0115-4 HEATER WILL NOT OPERATE IN LOW OR HIGH POSITION.................................................................. WP 0116 Figure 1. Heater Blower Motor Wiring................................................................................................. 0116-2 Figure 2. Heater Switch Wiring............................................................................................................ 0116-4 xxv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. NO CAB HEAT (COOLANT TEMPERATURE GAUGE READS NORMAL)................................................ WP 0117 Figure 1. Engine Coolant Shutoff Valve.............................................................................................. 0117-2 Figure 2. Coolant Level....................................................................................................................... 0117-3 PARKING BRAKE DOES NOT HOLD VEHICLE ON GRADE.................................................................... WP 0118 Figure 1. Brake Lever.......................................................................................................................... 0118-2 Figure 2. Parking Brake Cable Assembly............................................................................................ 0118-3 Figure 3. Parking Brake Assembly...................................................................................................... 0118-4 Figure 4. Parking Brake Actuating Mechanism................................................................................... 0118-5 PARKING BRAKE DRAGS, AS INDICATED BY SMOKING OR BURNING SMELL.................................. WP 0119 Figure 1. Brake Lever.......................................................................................................................... 0119-2 Figure 2. Brake Lever.......................................................................................................................... 0119-3 Figure 3. Parking Brake Cable Assembly............................................................................................ 0119-4 Figure 4. Parking Brake Actuating Mechanism................................................................................... 0119-5 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING)........................................................................................................................ WP 0120 Figure 1. Service Brake Chamber Vent Line....................................................................................... 0120-2 Figure 2. Front Service Brake Chamber.............................................................................................. 0120-4 Figure 3. Front Service Brake Chamber.............................................................................................. 0120-6 Figure 4. Rear Service Brake Chamber.............................................................................................. 0120-8 Figure 5. Rear Service Brake Chamber............................................................................................ 0120-10 Figure 6. Rear Service Brake Chamber............................................................................................ 0120-12 Figure 7. Rear Service Brake Chamber............................................................................................ 0120-14 Figure 8. Rear Service Brake Chamber............................................................................................ 0120-16 Figure 9. Rear Service Brake Chamber............................................................................................ 0120-18 Figure 10. Rear Service And Spring Brake Chamber.......................................................................... 0120-20 Figure 11. Rear Service And Spring Brake Chamber.......................................................................... 0120-22 Figure 12. Rear Service And Spring Brake Chamber.......................................................................... 0120-24 xxvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 13. Rear Service And Spring Brake Chamber.......................................................................... 0120-26 Figure 14. Rear Service And Spring Brake Chamber.......................................................................... 0120-28 Figure 15. Rear Service And Spring Brake Chamber.......................................................................... 0120-30 Figure 16. Limiting Valve..................................................................................................................... 0120-32 Figure 17. Limiting Valve..................................................................................................................... 0120-34 Figure 18. Limiting Valve..................................................................................................................... 0120-36 Figure 19. Limiting Valve..................................................................................................................... 0120-37 Figure 20. Double Check Valve #1...................................................................................................... 0120-38 Figure 21. Service Brake Pedal Valve................................................................................................. 0120-40 Figure 22. Primary Relay Valve Delivery Port..................................................................................... 0120-42 Figure 23. Primary Relay Valve Delivery Port..................................................................................... 0120-44 Figure 24. Primary Relay Valve Supply Port....................................................................................... 0120-46 Figure 25. Secondary Relay Valve Delivery Port................................................................................ 0120-48 Figure 26. Secondary Relay Valve Delivery Port................................................................................ 0120-50 Figure 27. Secondary Relay Valve Supply Port.................................................................................. 0120-52 Figure 28. Brake Assembly................................................................................................................. 0120-54 VEHICLE PULLS RIGHT OR LEFT WHEN APPLYING BRAKES.............................................................. WP 0121 Figure 1. Front Service Brake Chamber.............................................................................................. 0121-2 Figure 2. Brake Shoe Assembly.......................................................................................................... 0121-4 Figure 3. Brake Drum.......................................................................................................................... 0121-5 Figure 4. Left and Right Brake Assemblies......................................................................................... 0121-6 Figure 5. Service Brake Adjustment.................................................................................................... 0121-7 VEHICLE REAR BRAKES GRAB OR DRAG.............................................................................................. WP 0122 Figure 1. Brake Shoe Assembly.......................................................................................................... 0122-2 Figure 2. Brake Drum.......................................................................................................................... 0122-3 Figure 3. Left and Right Brake Assemblies......................................................................................... 0122-4 Figure 4. Service Brake Adjustment.................................................................................................... 0122-5 xxvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 5. Rear Service Brake Chamber.............................................................................................. 0122-6 Figure 6. Rear Service and Spring Brake Chamber............................................................................ 0122-6 VEHICLE VIBRATES, CHATTERS, OR BOUNCES WHEN BRAKES ARE APPLIED............................... WP 0123 Figure 1. Rear Service Brake Chamber.............................................................................................. 0123-2 Figure 2. Rear Service and Spring Brake Chamber............................................................................ 0123-3 BRAKES SQUEAL....................................................................................................................................... WP 0124 Figure 1. Brakeshoes.......................................................................................................................... 0124-2 Figure 2. Brakeshoes.......................................................................................................................... 0124-3 WARNING BUZZER SOUNDS WHEN BRAKES ARE APPLIED (PRIMARY & SECONDARY GAUGE PRESSURE DROPS BELOW 55-65 PSI [379-448 KPA])............................................................. WP 0125 NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES)................................................................ WP 0126 Figure 1. Air Supply System................................................................................................................ 0126-2 Figure 2. Air Compressor Governor Signal Line.................................................................................. 0126-4 Figure 3. Air Compressor Outlet Line.................................................................................................. 0126-5 Figure 4. Air Compressor Outlet Line.................................................................................................. 0126-6 Figure 5. Wet Supply Tank.................................................................................................................. 0126-8 Figure 6. Air Pressure Gauges............................................................................................................ 0126-9 Figure 7. Air Governor....................................................................................................................... 0126-10 AIR PRESSURE DOES NOT BUILD TO NORMAL OPERATING PRESSURE (ABOVE 80 PSI [552 KPA]) ACCORDING TO GAUGES...................................................................................................... WP 0127 Figure 1. Air Supply System................................................................................................................ 0127-2 Figure 2. Air Governor......................................................................................................................... 0127-3 AIR PRESSURE BUILDS SLOWLY (TAKES EXCESSIVE AMOUNT OF TIME TO BUILD TO 100 PSI (690KPA)........................................................................................................................................ WP 0128 Figure 1. Air Supply System................................................................................................................ 0128-2 Figure 2. Air Governor......................................................................................................................... 0128-3 AIR PRESSURE EXCEEDS MAXIMUM (GAUGES SHOW OVER 130 PSI [896 KPA]), SAFETY VALVE OPENS TO RELEASE PRESSURE............................................................................................... WP 0129 xxviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Auxiliary Air Power System.................................................................................................. 0129-2 Figure 2. Air Governor Signal Line...................................................................................................... 0129-3 Figure 3. Air Governor Signal Line...................................................................................................... 0129-4 PRIMARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. SECONDARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED).................................................................... WP 0130 Figure 1. Air Supply System................................................................................................................ 0130-2 Figure 2. Primary Air Pressure Gauge................................................................................................ 0130-3 Figure 3. Brake Pedal.......................................................................................................................... 0130-4 Figure 4. Primary Air Reservoir Drain Line.......................................................................................... 0130-5 Figure 5. Primary Air System Supply Line........................................................................................... 0130-6 Figure 6. One-Way Check Valve......................................................................................................... 0130-7 SECONDARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. PRIMARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED).................................................................... WP 0131 Figure 1. Air Supply System................................................................................................................ 0131-2 Figure 2. Secondary Air Pressure Gauge............................................................................................ 0131-3 Figure 3. Brake Pedal.......................................................................................................................... 0131-4 Figure 4. Secondary Air Reservoir Drain Line..................................................................................... 0131-6 Figure 5. Secondary Air System Supply Line...................................................................................... 0131-8 Figure 6. One-Way Check Valve......................................................................................................... 0131-9 PRIMARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED)........................................ WP 0132 Figure 1. Service Brake Chamber Vent Line....................................................................................... 0132-2 SECONDARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED)................................... WP 0133 Figure 1. Secondary Relay Valve Delivery Port.................................................................................. 0133-2 Figure 2. Secondary Relay Valve Delivery Port.................................................................................. 0133-4 Figure 3. Service Brake Pedal Valve................................................................................................... 0133-6 xxix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. WARNING BUZZER FAILS TO SOUND OR FAILS TO SHUT OFF ON LOW PRESSURE (BELOW 55-65 PSI [379-448 KPA]), AIR PRESSURE SYSTEM OPERATING NORMALLY..................... WP 0134 SPRING BRAKES DO NOT RELEASE (VEHICLE BRAKES GRAB OR DRAG)........................................ WP 0135 Figure 1. Spring Brake Release Control.............................................................................................. 0135-2 Figure 2. Parking Brake Control Lever................................................................................................ 0135-3 Figure 3. Parking Brake Control Lever................................................................................................ 0135-4 Figure 4. Parking Brake Valve............................................................................................................. 0135-5 Figure 5. Air Intake Stack.................................................................................................................... 0135-6 Figure 6. Parking Brake Valve............................................................................................................. 0135-7 Figure 7. Parking Brake Quick Release Valve Assembly.................................................................... 0135-8 SPRING BRAKES DO NOT SET (GAUGES AT NORMAL OPERATING PRESSURES, AIR EXHAUSTING NOT HEARD WHEN PARKING BRAKE APPLIED)............................................................ WP 0136 Figure 1. Spring Brake Control............................................................................................................ 0136-2 Figure 2. Spring Brake Assembly........................................................................................................ 0136-3 Figure 3. Quick Release Valve............................................................................................................ 0136-4 Figure 4. Parking Brake Valve............................................................................................................. 0136-5 ALL AIR-OPERATED ACCESSORIES DO NOT OPERATE (HORN, WINDSHIELD WIPERS, WINDSHIELD WASHERS, TRANSFER CASE CONTROLS), GAUGES AT NORMAL OPERATING PRESSURE........................................................................................................................... WP 0137 Figure 1. Air Pressure Gauges............................................................................................................ 0137-2 COOLING FAN DOES NOT OPERATE, ENGINE TEMPERATURE ABOVE 195°F (91°C) AS INDICATED BY TEMPERATURE GAUGE.................................................................................................. WP 0138 Figure 1. Secondary Air Pressure Gauge............................................................................................ 0138-2 Figure 2. Fan Clutch Actuator.............................................................................................................. 0138-3 COOLING FAN DOES NOT STOP RUNNING, ENGINE TEMPERATURE BELOW NORMAL OPERATING RANGE (OVERRIDE BOLT NOT INSTALLED).................................................................... WP 0139 Figure 1. Fan Clutch Actuator.............................................................................................................. 0139-2 FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION)................................................. WP 0140 Figure 1. Transfer Case Shift Lever.................................................................................................... 0140-2 xxx 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Transfer Case Shift Lever and Drive Lock In Switch............................................................ 0140-3 Figure 3. Transfer Case Shift Lever.................................................................................................... 0140-4 Figure 4. Air Line Between Actuator Valve and Transfer Case........................................................... 0140-5 Figure 5. Air Supply Line to Actuator Valve......................................................................................... 0140-6 Figure 6. Air Supply Line to Actuator Valve......................................................................................... 0140-7 Figure 7. Front Wheel Drive Lock-in Switch........................................................................................ 0140-8 Figure 8. Actuator Valve...................................................................................................................... 0140-9 Figure 9. Actuator Valve.................................................................................................................... 0140-10 HORN DOES NOT WORK (GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING)........................................................................................................................ WP 0141 Figure 1. Air Horn................................................................................................................................ 0141-2 Chapter 3 - CTIS TROUBLESHOOTING PROCEDURES CENTRAL TIRE INFLATION SYSTEM (CTIS) TROUBLESHOOTING....................................................... WP 0142 CTIS TROUBLESHOOTING INDEX............................................................................................................ WP 0143 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS.................................................. WP 0144 Figure 1. Air Lines............................................................................................................................... 0144-2 Figure 2. Air Lines............................................................................................................................... 0144-3 Figure 3. Air Lines............................................................................................................................... 0144-4 Figure 4. Air Dryer And Water Seperator............................................................................................ 0144-5 Figure 5. Quick Release Valves And Pneumatic Controller................................................................ 0144-6 Figure 6. Quick Release Valves And Pneumatic Controller................................................................ 0144-7 Figure 7. Quick Release Valves And Pneumatic Controller................................................................ 0144-8 Figure 8. Quick Release Valves And Wheel Valves............................................................................ 0144-9 Figure 9. Quick Release Valves And Wheel Valves.......................................................................... 0144-10 Figure 10. Quick Release Valves And Wheel Valves.......................................................................... 0144-11 Figure 11. Hub Air Seals..................................................................................................................... 0144-12 Figure 12. Pneumatic Controller.......................................................................................................... 0144-13 Figure 13. Quick Release Valves........................................................................................................ 0144-14 xxxi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 14. Relief Valve........................................................................................................................ 0144-15 Figure 15. CTIS Wiring Harness.......................................................................................................... 0144-16 Figure 16. Pressure Transducer.......................................................................................................... 0144-17 Figure 17. CTIS Wiring Harness.......................................................................................................... 0144-18 Figure 18. CTIS Wiring Harness.......................................................................................................... 0144-20 Figure 19. Pressure Transducer.......................................................................................................... 0144-22 Figure 20. Pneumatic Controller.......................................................................................................... 0144-23 FOUR PRESSURE MODE LIGHTS FLASHING......................................................................................... WP 0145 Figure 1. Wheel Valve......................................................................................................................... 0145-2 Figure 2. Wheel Valve......................................................................................................................... 0145-3 Figure 3. Wheel Valve......................................................................................................................... 0145-4 Figure 4. Wheel Valve......................................................................................................................... 0145-6 Figure 5. Quick Release Valves And Pneumatic Controller................................................................ 0145-7 Figure 6. Quick Release Valves And Pneumatic Controller................................................................ 0145-8 Figure 7. Quick Release Valves And Pneumatic Controller................................................................ 0145-9 Figure 8. Hub Air Seals..................................................................................................................... 0145-10 Figure 9. Pneumatic Controller.......................................................................................................... 0145-11 FIVE INDICATOR LIGHTS FLASHING....................................................................................................... WP 0146 Figure 1. Quick Release Valves And Pneumatic Controller................................................................ 0146-2 Figure 2. Quick Release Valves And Pneumatic Controller................................................................ 0146-3 Figure 3. Quick Release Valves and Pneumatic Controller................................................................. 0146-4 Figure 4. Quick Release Valves And Wheel Valves............................................................................ 0146-5 Figure 5. Quick Release Valves and Wheel Valves............................................................................ 0146-6 Figure 6. Quick Release Valves and Wheel Valves............................................................................ 0146-7 Figure 7. Pneumatic Controller............................................................................................................ 0146-8 Figure 8. Wet Tank.............................................................................................................................. 0146-9 Figure 9. CTIS Wiring Harness.......................................................................................................... 0146-10 xxxii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 10. Pressure Transducer.......................................................................................................... 0146-11 Figure 11. Pressure Transducer.......................................................................................................... 0146-12 Figure 12. Electronic Control Unit ....................................................................................................... 0146-13 Figure 13. CTIS Wiring Harness.......................................................................................................... 0146-14 Figure 14. CTIS Wiring Harness.......................................................................................................... 0146-16 Figure 15. Pressure Transducer.......................................................................................................... 0146-18 Figure 16. Pneumatic Controller.......................................................................................................... 0146-19 SYSTEM REPEATEDLY RESUMES CYCLING 30 SECONDS AFTER MODE LIGHT STOPS FLASHING................................................................................................................................................... WP 0147 Figure 1. Wheel Valve......................................................................................................................... 0147-2 Figure 2. Wheel Valve......................................................................................................................... 0147-3 Figure 3. Wheel Valve......................................................................................................................... 0147-4 SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED.............................................................................................................................................. WP 0148 Figure 1. Relief Valve.......................................................................................................................... 0148-2 Figure 2. Quick Release Valves.......................................................................................................... 0148-3 Figure 3. Pneumatic Controller............................................................................................................ 0148-4 Figure 4. Air Lines............................................................................................................................... 0148-5 Figure 5. Air Lines............................................................................................................................... 0148-6 Figure 6. Air Lines............................................................................................................................... 0148-7 Figure 7. Hub Air Seals....................................................................................................................... 0148-8 Figure 8. Relief Valve.......................................................................................................................... 0148-9 Figure 9. Tire..................................................................................................................................... 0148-10 Figure 10. Wheel Valve Filter.............................................................................................................. 0148-12 CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE................................... WP 0149 Figure 1. Air Lines............................................................................................................................... 0149-2 Figure 2. Air Lines............................................................................................................................... 0149-3 Figure 3. Air Lines............................................................................................................................... 0149-4 xxxiii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. CTIS Wiring Harness............................................................................................................ 0149-6 Figure 5. Pneumatic Controller............................................................................................................ 0149-7 Figure 6. Wet Tank.............................................................................................................................. 0149-8 Figure 7. CTIS Wiring Harness............................................................................................................ 0149-9 Figure 8. Pressure Switch................................................................................................................. 0149-10 Figure 9. Pressure Switch................................................................................................................. 0149-11 LOSS OF AMBER WARNING LIGHT AND/OR OVERSPEED LIGHT........................................................ WP 0150 Figure 1. CTIS Amber Warning Light.................................................................................................. 0150-2 Figure 2. CTIS Electronic Control Unit................................................................................................ 0150-3 Figure 3. CTIS Wiring Harness............................................................................................................ 0150-4 Figure 4. Speed Signal Generator and ECU....................................................................................... 0150-5 Figure 5. Speed Signal Generator....................................................................................................... 0150-6 SOLID OVERSPEED WARNING LIGHT..................................................................................................... WP 0151 Figure 1. Speed Signal Generator and ECU....................................................................................... 0151-2 Figure 2. Speed Signal Generator....................................................................................................... 0151-3 SYSTEM OVER-INFLATES TIRES............................................................................................................. WP 0152 Figure 1. Tire....................................................................................................................................... 0152-2 Figure 2. CTIS Wiring Harness............................................................................................................ 0152-4 Figure 3. CTIS Wiring Harness............................................................................................................ 0152-6 Figure 4. Pressure Transducer............................................................................................................ 0152-8 SLOW AIR RECOVERY OR OCCASIONAL LOW AIR WARNING DURING BRAKING............................ WP 0153 Figure 1. Pressure Switch................................................................................................................... 0153-2 Figure 2. CTIS Wiring Harness............................................................................................................ 0153-4 Figure 3. Pressure Switch................................................................................................................... 0153-6 Figure 4. Pressure Switch................................................................................................................... 0153-7 Figure 5. Pressure Switch................................................................................................................... 0153-8 Index Volume 2 xxxiv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Chapter 4 - ABS TROUBLESHOOTING PROCEDURES ANTILOCK BRAKE SYSTEM (ABS) ELECTRONIC DIAGNOSTIC TROUBLESHOOTING....................... WP 0154 Figure 1. ABS Wiring Harness ECU Connector.................................................................................. 0154-3 Table 1. Diagnostic Fault Codes........................................................................................................ 0154-4 ABS TROUBLESHOOTING INDEX............................................................................................................. WP 0155 TROUBLESHOOTING ABS WITHOUT DIAGNOSTIC TOOLS.................................................................. WP 0156 Figure 1. Wheel Speed Sensor Leads................................................................................................. 0156-2 Figure 2. ABS Solenoid Valve Connectors.......................................................................................... 0156-3 Figure 3. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0156-4 Figure 4. ABS Power Supply Connection............................................................................................ 0156-6 Figure 5. ABS Power Supply Connection............................................................................................ 0156-8 Figure 6. Battery Test Points............................................................................................................. 0156-10 Figure 7. ABS Power Supply Connection.......................................................................................... 0156-11 Figure 8. ABS Power Supply Connection.......................................................................................... 0156-12 ABS - CODE EO - E9, EA - EF (ECU FAULT)............................................................................................ WP 0157 Figure 1. ABS ECU.............................................................................................................................. 0157-2 ABS - CODE SOL 80, ECU 93, OR ECU 99 (ECU FAULT)........................................................................ WP 0158 Figure 1. ABS ECU.............................................................................................................................. 0158-2 ABS - CLEAR HISTORICAL CODES WITH THE HALDEX INFO CENTER (SCAN TOOL)....................... WP 0159 Figure 1. Info Centre Fault Code "OK 07" Display.............................................................................. 0159-2 Figure 2. Info Centre "BUSY" Display................................................................................................. 0159-3 Figure 3. Info Centre Fault Code Display............................................................................................ 0159-4 Figure 4. Info Centre "CLR CA" Display.............................................................................................. 0159-4 Figure 5. Info Centre Fault Code "OK 07" Display.............................................................................. 0159-5 WHEEL SPEED SENSOR OUTPUT TEST................................................................................................. WP 0160 Figure 1. Info Centre Fault Code "OK 07" Display.............................................................................. 0160-2 Figure 2. Info Centre "WHL" Display................................................................................................... 0160-3 xxxv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Info Centre "S2A" Display.................................................................................................... 0160-3 Figure 4. Wheel Speed Sensor........................................................................................................... 0160-4 Figure 5. Info Centre "S2B" Display.................................................................................................... 0160-5 Figure 6. Wheel Speed Sensor........................................................................................................... 0160-6 ABS - START - RETRIEVING FAULT CODES WITH THE HALDEX INFO CENTER (SCAN TOOL).......................................................................................................................................................... WP 0161 Figure 1. Info Centre Fault Code "OK 07" Display.............................................................................. 0161-2 Figure 2. Info Centre "BUSY" Display................................................................................................. 0161-3 Figure 3. Info Centre Fault Code Display............................................................................................ 0161-4 Figure 4. Info Centre "CLR CA" Display.............................................................................................. 0161-4 Figure 5. Info Centre Fault Code "OK 07" Display.............................................................................. 0161-6 ABS - CODE S2A 03 (LEFT SIDE - BLUE CHANNEL)............................................................................... WP 0162 Figure 1. Wheel Speed Sensor Connector.......................................................................................... 0162-2 Figure 2. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0162-4 Figure 3. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0162-6 ABS - CODE S2B 04 (RIGHT SIDE - YELLOW CHANNEL)....................................................................... WP 0163 Figure 1. Wheel Speed Sensor Connector.......................................................................................... 0163-2 Figure 2. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0163-4 Figure 3. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0163-6 ABS - CODE S2A 13 (LEFT SIDE - BLUE CHANNEL)............................................................................... WP 0164 Figure 1. Wheel Speed Sensor Connector.......................................................................................... 0164-2 ABS - CODE S2B 14 (RIGHT SIDE - YELLOW CHANNEL)....................................................................... WP 0165 Figure 1. Wheel Speed Sensor Connector.......................................................................................... 0165-2 ABS - CODE S2A 23 (LEFT SIDE - BLUE CHANNEL)............................................................................... WP 0166 Figure 1. Wheel Bearing...................................................................................................................... 0166-2 Figure 2. ABS Exciter Ring.................................................................................................................. 0166-3 Figure 3. ABS Wheel Speed Sensor................................................................................................... 0166-4 ABS - CODE S2A 24 (RIGHT SIDE - YELLOW CHANNEL)....................................................................... WP 0167 xxxvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Wheel Bearing...................................................................................................................... 0167-2 Figure 2. ABS Exciter Ring.................................................................................................................. 0167-3 Figure 3. ABS Wheel Speed Sensor................................................................................................... 0167-4 ABS - CODE SLW 42 (LEFT SIDE - BLUE CHANNEL).............................................................................. WP 0168 Figure 1. Front Relay Valve................................................................................................................. 0168-2 Figure 2. Front Modulator Valve.......................................................................................................... 0168-3 ABS - CODE SLW 43 (RIGHT SIDE - YELLOW CHANNEL)...................................................................... WP 0169 Figure 1. Rear Relay Valve................................................................................................................. 0169-2 Figure 2. Rear Modulator Valve........................................................................................................... 0169-3 ABS - CODE BUHd 62 (LEFT SIDE - BLUE CHANNEL)............................................................................ WP 0170 Figure 1. Front Relay Valve Solenoid Connector................................................................................ 0170-2 Figure 2. Front Relay Valve Solenoid Connector................................................................................ 0170-3 Figure 3. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0170-4 ABS - CODE YEHd 63 (RIGHT SIDE - YELLOW CHANNEL).................................................................... WP 0171 Figure 1. Rear Relay Valve Solenoid Connector................................................................................. 0171-2 Figure 2. Rear Relay Valve Solenoid Connector................................................................................. 0171-3 Figure 3. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0171-4 ABS - CODE BUDU 68 (LEFT SIDE - BLUE CHANNEL)............................................................................ WP 0172 Figure 1. Front Relay Valve Solenoid Connector................................................................................ 0172-2 Figure 2. Front Relay Valve Solenoid Connector................................................................................ 0172-3 Figure 3. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0172-4 ABS - CODE YEDU 69 (RIGHT SIDE - YELLOW CHANNEL).................................................................... WP 0173 Figure 1. Rear Relay Valve Solenoid Connector................................................................................. 0173-2 Figure 2. Rear Relay Valve Solenoid Connector................................................................................. 0173-3 Figure 3. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0173-4 ABS - CODE BUHd 72 (LEFT SIDE - BLUE CHANNEL)............................................................................ WP 0174 Figure 1. Front Relay Valve Solenoid Connector................................................................................ 0174-2 xxxvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0174-4 ABS - CODE YEHd 73 (RIGHT SIDE - YELLOW CHANNEL).................................................................... WP 0175 Figure 1. Rear Relay Valve Solenoid Connector................................................................................. 0175-2 Figure 2. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0175-4 ABS - CODE BUDU 78 (LEFT SIDE - BLUE CHANNEL)............................................................................ WP 0176 Figure 1. Front Relay Valve Solenoid Connector................................................................................ 0176-2 Figure 2. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0176-4 ABS - CODE YEDU 79 (RIGHT SIDE - YELLOW CHANNEL).................................................................... WP 0177 Figure 1. Rear Relay Valve Solenoid Connector................................................................................. 0177-2 Figure 2. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0177-4 ABS - CODE BUHd 82 (LEFT SIDE - BLUE CHANNEL)............................................................................ WP 0178 Figure 1. Front Relay Valve Solenoid Connector................................................................................ 0178-2 Figure 2. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0178-4 ABS - CODE YEHd 83 (RIGHT SIDE - YELLOW CHANNEL).................................................................... WP 0179 Figure 1. Rear Relay Valve Solenoid Connector................................................................................. 0179-2 Figure 2. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0179-4 ABS - CODE BUDU 88 (LEFT SIDE - BLUE CHANNEL)............................................................................ WP 0180 Figure 1. Front Relay Valve Solenoid Connector................................................................................ 0180-2 Figure 2. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0180-4 ABS - CODE YEDU 89 (RIGHT SIDE - YELLOW CHANNEL).................................................................... WP 0181 Figure 1. Rear Relay Valve Solenoid Connector................................................................................. 0181-2 Figure 2. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0181-4 ABS - CODE B+LO 90 (ABS VOLTAGE BELOW 21.0 VOLTS).................................................................. WP 0182 Figure 1. Battery Test Points............................................................................................................... 0182-2 ABS - CODE ISO1 91 (ABS VOLTAGE BELOW 8.0 VOLTS)..................................................................... WP 0183 ABS - CODE B+HI 92 (ABS VOLTAGE ABOVE 32.0 VOLTS)................................................................... WP 0184 Figure 1. Battery Test Points............................................................................................................... 0184-2 xxxviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. ABS - NO DATA (BLANK SCREEN ON HALDEX INFO-CENTER)............................................................ WP 0185 Figure 1. ABS Wiring Harness 28-pin ECU Connector....................................................................... 0185-2 Chapter 5 - STE/ICE TROUBLESHOOTING PROCEDURES STE/ICE TROUBLESHOOTING.................................................................................................................. WP 0186 Table 1. Go-Chain Test Index, Combined Mode Chain..................................................................... 0186-2 Table 2. No-Go-Chain Test Index, Combined Mode Chain................................................................ 0186-3 STE/ICE TROUBLESHOOTING INDEX...................................................................................................... WP 0187 G01: VTM CONNECTION AND CHECKOUT (PART 1).............................................................................. WP 0188 Figure 1. STE/ICE Setup..................................................................................................................... 0188-2 Figure 2. VTM Display......................................................................................................................... 0188-3 Figure 3. VTM Display......................................................................................................................... 0188-4 Figure 4. VTM Display......................................................................................................................... 0188-5 Table 1. Confidence Test................................................................................................................... 0188-5 Figure 5. VTM Display......................................................................................................................... 0188-6 Figure 6. Test 99................................................................................................................................. 0188-7 Figure 7. PASS Prompt Message........................................................................................................ 0188-7 Figure 8. PASS Prompt Message........................................................................................................ 0188-8 Figure 9. VTM Display......................................................................................................................... 0188-9 Table 2. Vehicle Identification Number............................................................................................... 0188-9 Table 3. Offset Test.......................................................................................................................... 0188-10 Table 4. Fuel Pressure Test............................................................................................................. 0188-10 Figure 10. Calibration Prompt Message.............................................................................................. 0188-10 G02: FIRST PEAK TEST– STARTER CURRENT....................................................................................... WP 0189 Figure 1. CAL Prompt Message.......................................................................................................... 0189-2 Figure 2. GO Prompting Message....................................................................................................... 0189-3 G03: ENGINE START- LUBRICATION CHECK.......................................................................................... WP 0190 G04: CHARGING CIRCUIT AND BATTERY VOLTAGE TEST................................................................... WP 0191 xxxix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Table 1. Battery Voltage Test............................................................................................................. 0191-1 G05: ENGINE WARMUP/COOLANT CHECK/OIL PRESSURE TEST....................................................... WP 0192 Table 1. Engine RPM Test................................................................................................................. 0192-2 Table 2. Engine Oil Pressure Specification........................................................................................ 0192-2 G06: GOVERNOR CHECK/POWER TEST................................................................................................. WP 0193 Table 1. Maximum Governor Speed.................................................................................................. 0193-1 Table 2. Power Test........................................................................................................................... 0193-2 Figure 1. CIP Prompting Message...................................................................................................... 0193-2 Table 3. Power Minimum Test Limits................................................................................................. 0193-3 G07: IDLE SPEED/GOVERNOR CHECK................................................................................................... WP 0194 Table 1. Engine RPM Test................................................................................................................. 0194-1 G08: COMPRESSION UNBALANCE TEST................................................................................................ WP 0195 Table 1. Engine RPM Test................................................................................................................. 0195-2 Figure 1. GO Prompting Message....................................................................................................... 0195-2 Figure 2. CAL Prompting Message..................................................................................................... 0195-2 DC VOLTAGE TEST.................................................................................................................................... WP 0196 Figure 1. STE/ICE Test....................................................................................................................... 0196-2 Table 1. Voltage Test......................................................................................................................... 0196-2 Figure 2. CAL Prompt Message.......................................................................................................... 0196-3 NG05: LOW PRESSURE CHECK............................................................................................................... WP 0197 Figure 1. STE/ICE Setup..................................................................................................................... 0197-2 Figure 2. CAL Prompt Message.......................................................................................................... 0197-2 Figure 3. Pass Prompt Message......................................................................................................... 0197-3 Table 1. Oil Pressure Limits............................................................................................................... 0197-3 Figure 4. Pass Prompt Message......................................................................................................... 0197-4 Table 2. Oil Pressure Limits............................................................................................................... 0197-4 NG20: NO CRANK- NO START.................................................................................................................. WP 0198 xl 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. NG30: ENGINE CRANK - NO START......................................................................................................... WP 0199 Table 1. Engine RPM Test................................................................................................................. 0199-1 Figure 1. CAL Prompt Message.......................................................................................................... 0199-2 Table 2. Pressure Test....................................................................................................................... 0199-3 NG31: GAUGE TEST.................................................................................................................................. WP 0200 Table 1. Voltage Test......................................................................................................................... 0200-2 Figure 1. CAL Prompt Message.......................................................................................................... 0200-2 NG50: CHARGING CIRCUIT TESTS.......................................................................................................... WP 0201 Table 1. Voltage Test......................................................................................................................... 0201-2 NG80: STARTER CIRCUIT TESTS............................................................................................................. WP 0202 Table 1. Starter Circuit Resistance Test............................................................................................. 0202-2 Figure 1. CAL Message....................................................................................................................... 0202-2 Figure 2. Prompt Message.................................................................................................................. 0202-3 Table 2. Starter Circuit Resistance..................................................................................................... 0202-4 Table 3. Starter Circuit Tests.............................................................................................................. 0202-5 Table 4. Starter Motor Voltage Test................................................................................................... 0202-6 Table 5. Starter Voltage..................................................................................................................... 0202-6 Table 6. Starter Negative Cable Drop Tests...................................................................................... 0202-7 Table 7. Starter Solenoid Voltage Test.............................................................................................. 0202-8 Table 8. Starter Voltage..................................................................................................................... 0202-8 Table 9. Battery Voltage Test............................................................................................................. 0202-9 NG81: BATTERY TESTS............................................................................................................................ WP 0203 Figure 1. CAL Prompting Message..................................................................................................... 0203-1 Figure 2. Battery Tests........................................................................................................................ 0203-2 Figure 3. CAL Prompting Message..................................................................................................... 0203-3 Figure 4. GO Prompting Message....................................................................................................... 0203-4 Table 1. Battery Resistance Change Test.......................................................................................... 0203-4 xli 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 5. OFF Prompting Message..................................................................................................... 0203-4 Table 2. Maximum Resistance Change............................................................................................. 0203-5 Table 3. Battery Resistance Test....................................................................................................... 0203-6 Figure 6. Prompt Message.................................................................................................................. 0203-6 Table 4. Maximum Resistance........................................................................................................... 0203-6 NG90: GOVERNOR/POWER TEST FAULT ISOLATION........................................................................... WP 0204 Figure 1. CAL Prompting Message..................................................................................................... 0204-3 Table 1. Pressure Test....................................................................................................................... 0204-4 Table 2. Minimum Fuel Pressure....................................................................................................... 0204-4 Table 3. Engine RPM Test................................................................................................................. 0204-5 Figure 2. Prompt Message.................................................................................................................. 0204-5 Table 4. Compression Unbalance Test Limits.................................................................................... 0204-6 NG130: ENGINE TIGHTNESS TEST.......................................................................................................... WP 0205 Chapter 6 - PREVENTIVE MAINTENANCE INSTRUCTIONS PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION............................. WP 0206 PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR MODELS M939/A1/A2 (SEMIANNUAL)........................................................................................................................................... WP 0207 Table 1. Field Preventive Maintenance Checks and Services........................................................... 0207-2 Figure 1. Front Winch........................................................................................................................ 0207-11 Figure 2. Front Winch........................................................................................................................ 0207-13 Figure 3. Wheel Assembly................................................................................................................. 0207-17 Figure 4. Steering System................................................................................................................. 0207-21 Figure 5. Power Steering Pump........................................................................................................ 0207-23 Figure 6. Springs and Shackles......................................................................................................... 0207-24 Figure 7. Front Shackle..................................................................................................................... 0207-24 Figure 8. Differential.......................................................................................................................... 0207-26 Figure 9. Differential.......................................................................................................................... 0207-39 Table 2. PMCS Mandatory Replacement Parts List......................................................................... 0207-42 xlii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR MODELS M939/A1/A2 (ANNUAL).................................................................................................................................................... WP 0208 Table 1. Field Preventive Maintenance Checks and Services........................................................... 0208-2 Figure 1. Engine Mounts..................................................................................................................... 0208-3 Figure 2. Air System............................................................................................................................ 0208-5 Figure 3. Air System............................................................................................................................ 0208-6 Table 2. PMCS Mandatory Replacement Parts List......................................................................... 0208-11 PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR MODELS M939/A1/A2 (BIENNIAL).................................................................................................................................................. WP 0209 Table 1. Field Preventive Maintenance Checks and Services........................................................... 0209-2 Chapter 7 - MAINTENANCE INSTRUCTIONS SERVICE UPON RECEIPT......................................................................................................................... WP 0210 POWER PLANT REPLACEMENT (M939/A1)............................................................................................. WP 0211 Figure 1. Sending Unit Disconnect...................................................................................................... 0211-2 Figure 2. Alternator Removal............................................................................................................... 0211-3 Figure 3. Hose Disconnect.................................................................................................................. 0211-5 Figure 4. Power Plant Throttle Cable Removal................................................................................... 0211-7 Figure 5. Power Plant Engine Air Hoses Removal.............................................................................. 0211-9 Figure 6. Power Plant Tachometer Cables Removal........................................................................ 0211-11 Figure 7. Power Plant Ether Cylinder Lines Removal....................................................................... 0211-13 Figure 8. Power Plant Starter Wires Removal................................................................................... 0211-15 Figure 9. Power Plant Transmission Shifter Cable Removal............................................................. 0211-17 Figure 10. Power Plant Transmission Electrical Wires Removal......................................................... 0211-19 Figure 11. Power Plant Transmission Module Removal...................................................................... 0211-21 Figure 12. Power Plant Ground Wires Removal.................................................................................. 0211-23 Figure 13. Power Plant Engine Mounts Removal................................................................................ 0211-26 Figure 14. Power Plant Maintenance Stand........................................................................................ 0211-27 Figure 15. Power Plant Water Cooler Removal................................................................................... 0211-28 xliii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 16. Power Plant Air Lines Assembly........................................................................................ 0211-29 Figure 17. Power Plant Heater Shutoff Valves.................................................................................... 0211-30 Figure 18. Power Plant Lifting Points.................................................................................................. 0211-31 Figure 19. Power Plant Engine Mounts Installation............................................................................. 0211-33 Figure 20. Power Plant Transmission Wires Installation..................................................................... 0211-35 Figure 21. Power Plant Transmission Module Installation................................................................... 0211-37 Figure 22. Power Plant Transmission Shifter Cable Installation.......................................................... 0211-39 Figure 23. Power Plant Electrical Wire Installation.............................................................................. 0211-41 Figure 24. Power Plant Air Line Installation......................................................................................... 0211-43 Figure 25. Power Plant Ether Line Installation.................................................................................... 0211-45 Figure 26. Power Plant Throttle Cable Installation.............................................................................. 0211-47 Figure 27. Power Plant Power Steering Hoses Installation................................................................. 0211-49 Figure 28. Power Plant Alternator Wiring Installation.......................................................................... 0211-51 Figure 29. Power Plant Temperature Wiring Installation..................................................................... 0211-52 Figure 30. In-Chassis Run-In............................................................................................................... 0211-53 Figure 31. In-Chassis Run-In............................................................................................................... 0211-54 ENGINE AND CONTAINER REPLACEMENT............................................................................................ WP 0212 Figure 1. Engine and Container Removal........................................................................................... 0212-2 Figure 2. Engine and Container Removal........................................................................................... 0212-3 Figure 3. Engine and Container Installation........................................................................................ 0212-5 Figure 4. Engine and Container Installation........................................................................................ 0212-7 POWER PLANT REPLACEMENT (M939A2).............................................................................................. WP 0213 Figure 1. Tachometer Cable and Drive Removal................................................................................ 0213-2 Figure 2. Air Intake System Removal.................................................................................................. 0213-3 Figure 3. Fuel Supply and Electrical System Removal........................................................................ 0213-5 Figure 4. Power System and Linkage Removal.................................................................................. 0213-7 Figure 5. Air Compressor and Power Steering Line Removal............................................................. 0213-8 xliv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 6. Alternator and Engine Harness Removal............................................................................. 0213-9 Figure 7. Starter Cable and Oil Cooler Hose Removal...................................................................... 0213-10 Figure 8. Oil Cooler Return Hose Removal....................................................................................... 0213-11 Figure 9. Transmission Supply Hose Removal................................................................................. 0213-11 Figure 10. Coolant System Hose Removal......................................................................................... 0213-13 Figure 11. Vent Tube and Sending Unit Lead Removal...................................................................... 0213-14 Figure 12. Transmission Cables and Electrical Lead Removal........................................................... 0213-15 Figure 13. Transmission and Engine Mount Removal......................................................................... 0213-17 Figure 14. Power Plant Removal......................................................................................................... 0213-19 Figure 15. Power Plant Installation...................................................................................................... 0213-21 Figure 16. Transmission and Engine Mount Installation...................................................................... 0213-23 Figure 17. Transmission Shift Cable, Electrical Leads, Oil Cooler Return, and Supply Hose Installation.......................................................................................................................... 0213-25 Figure 18. Oil Cooler Return Hose Installation.................................................................................... 0213-26 Figure 19. Transmission Supply Hose Installation.............................................................................. 0213-26 Figure 20. Starter Lead And Water Heater Hoses Installation............................................................ 0213-27 Figure 21. Alternator Lead Installation................................................................................................. 0213-29 Figure 22. Air Line and Power Steering Hose Installation................................................................... 0213-30 Figure 23. Fuel Pump Lines and Linkage Installation.......................................................................... 0213-31 Figure 24. Fuel Supply and Electrical System Installation................................................................... 0213-32 Figure 25. Air Intake, Tachometer Cable, and Drive Installation......................................................... 0213-33 Figure 26. Priming Lube System......................................................................................................... 0213-34 Figure 27. Priming Lube System......................................................................................................... 0213-35 Figure 28. Priming Lube System......................................................................................................... 0213-37 Figure 29. Accelerator Linkage Adjustment......................................................................................... 0213-38 ENGINE LIFT EYES REPLACEMENT (M939/A1)...................................................................................... WP 0214 Figure 1. Engine Lift Eyes Removal.................................................................................................... 0214-2 Figure 2. Engine Lift Eyes Installation................................................................................................. 0214-3 xlv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. ENGINE LIFTING BRACKETS REPLACEMENT (M939A2)....................................................................... WP 0215 Figure 1. Engine Lifting Brackets Removal......................................................................................... 0215-1 Figure 2. Engine Lifting Brackets Installation...................................................................................... 0215-2 ENGINE MOUNTING BRACKETS AND ISOLATORS REPLACEMENT.................................................... WP 0216 Figure 1. Engine Mounting Bracket Removal...................................................................................... 0216-3 Figure 2. Engine Mounting Bracket Removal...................................................................................... 0216-4 Figure 3. Engine Mounting Bracket Removal...................................................................................... 0216-5 Figure 4. Engine Mounting Bracket Installation................................................................................... 0216-6 Figure 5. Engine Mounting Bracket Installation................................................................................... 0216-7 Figure 6. Engine Mounting Bracket Installation................................................................................... 0216-8 Figure 7. Engine Mounting Bracket Installation................................................................................... 0216-9 Figure 8. Engine Mounting Bracket Installation................................................................................. 0216-10 ENGINE ACCESS COVER REPLACEMENT (M939/A1)............................................................................ WP 0217 Figure 1. Engine Access Cover Removal............................................................................................ 0217-2 Figure 2. Engine Access Cover Installation......................................................................................... 0217-3 CRANKSHAFT VIBRATION DAMPENER REPLACEMENT (M939/A1)..................................................... WP 0218 Figure 1. Vibration Dampener Runout and Wobble Check................................................................. 0218-2 Figure 2. Vibration Dampener Removal.............................................................................................. 0218-3 Figure 3. Vibration Dampener Inspection............................................................................................ 0218-4 Figure 4. Vibration Dampener Installation........................................................................................... 0218-5 VIBRATION DAMPENER REPLACEMENT (M939A2)............................................................................... WP 0219 Figure 1. Vibration Dampener Removal.............................................................................................. 0219-3 Figure 2. Vibration Dampener Installation........................................................................................... 0219-5 FLYWHEEL ASSEMBLY REPLACEMENT (M939/A1)............................................................................... WP 0220 Figure 1. Flywheel Assembly Removal............................................................................................... 0220-2 Figure 2. Flywheel Assembly Installation............................................................................................ 0220-3 FLEXPLATE AND FLYWHEEL ASSEMBLY REPLACEMENT (M939A2).................................................. WP 0221 xlvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Flexplate and Flywheel Assembly Removal......................................................................... 0221-3 Figure 2. Flexplate and Flywheel Assembly Installation...................................................................... 0221-5 Figure 3. Flexplate and Flywheel Assembly Torque Sequence.......................................................... 0221-6 VALVE COVER REPLACEMENT (M939A2)............................................................................................... WP 0222 Figure 1. Breather Tube Removal....................................................................................................... 0222-3 Figure 2. Radiator Inlet Tube Removal................................................................................................ 0222-5 Figure 3. Surge Tank Assembly Removal........................................................................................... 0222-7 Figure 4. Valve Cover Removal........................................................................................................... 0222-8 Figure 5. Valve Cover Installation...................................................................................................... 0222-11 Figure 6. Surge Tank Assembly Installation...................................................................................... 0222-13 Figure 7. Radiator Inlet Tube Installation........................................................................................... 0222-14 Figure 8. Breather Tube Installation.................................................................................................. 0222-15 Figure 9. Air Lines Installation........................................................................................................... 0222-16 CRANKCASE BREATHER AND TUBE REPLACEMENT (M939/A1/A2).................................................... WP 0223 Figure 1. Crankcase Breather and Tube Removal.............................................................................. 0223-3 Figure 2. Crankcase Breather and Tube Removal.............................................................................. 0223-5 Figure 3. Crankcase Breather and Tube Installation........................................................................... 0223-7 Figure 4. Crankcase Breather and Tube Installation........................................................................... 0223-9 OIL PUMP PICKUP HOSE REPLACEMENT (M939/A1)............................................................................ WP 0224 Figure 1. Oil Pump Pickup Hose Removal.......................................................................................... 0224-2 Figure 2. Oil Pump Pickup Hose Installation....................................................................................... 0224-3 OIL PUMP RETURN HOSE REPLACEMENT (M939/A1)........................................................................... WP 0225 Figure 1. Oil Pump Return Hose Removal.......................................................................................... 0225-2 Figure 2. Oil Pump Return Hose Installation....................................................................................... 0225-3 FRONT SUMP TUBE REPLACEMENT (M939/A1)..................................................................................... WP 0226 Figure 1. Front Sump Tube Removal.................................................................................................. 0226-2 Figure 2. Front Sump Tube Installation............................................................................................... 0226-4 xlvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. ENGINE SAMPLING VALVE REPLACEMENT........................................................................................... WP 0227 Figure 1. Engine Sampling Valve Removal......................................................................................... 0227-2 Figure 2. Engine Sampling Valve Installation...................................................................................... 0227-3 OIL DIPSTICK TUBE REPLACEMENT....................................................................................................... WP 0228 Figure 1. Dipstick Tube Removal........................................................................................................ 0228-3 Figure 2. Dipstick Tube Installation..................................................................................................... 0228-5 ENGINE OIL COOLER MAINTENANCE (M939A2).................................................................................... WP 0229 Figure 1. Engine Oil Cooler Removal.................................................................................................. 0229-3 Figure 2. Engine Oil Cooler Disassembly............................................................................................ 0229-5 Figure 3. Engine Oil Cooler Assembly................................................................................................. 0229-7 Figure 4. Engine Oil Cooler Installation............................................................................................... 0229-9 OIL PAN AND OIL SUCTION TUBE (M939A2)........................................................................................... WP 0230 Figure 1. Oil Pan and Suction Tube Removal..................................................................................... 0230-3 Figure 2. Oil Pan and Suction Tube Installation.................................................................................. 0230-5 ENGINE OIL PAN REPLACEMENT (M939/A1).......................................................................................... WP 0231 Figure 1. Engine Oil Pan Removal...................................................................................................... 0231-2 Figure 2. Engine Oil Pan Removal...................................................................................................... 0231-3 Figure 3. Engine Oil Pan Disassembly................................................................................................ 0231-5 Figure 4. Engine Oil Pan Assembly..................................................................................................... 0231-7 Figure 5. Engine Oil Pan Installation................................................................................................... 0231-9 Figure 6. Engine Oil Pan Installation................................................................................................. 0231-10 ENGINE OIL FILTER REPLACEMENT....................................................................................................... WP 0232 Figure 1. Engine Oil Drain Plugs......................................................................................................... 0232-2 Figure 2. Engine Oil Drain Plugs......................................................................................................... 0232-3 Figure 3. Engine Oil Drain Plugs......................................................................................................... 0232-4 Figure 4. Oil Filter Removal................................................................................................................. 0232-5 Figure 5. Oil Filter Removal................................................................................................................. 0232-5 xlviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 6. Filter Shell and Bolt Disassembly......................................................................................... 0232-6 Figure 7. Engine Oil Filter Cleaning and Inspection............................................................................ 0232-7 Figure 8. Filter Shell and Bolt Assembly.............................................................................................. 0232-8 Figure 9. Engine Oil Filter Installation.................................................................................................. 0232-9 Figure 10. Engine Oil Filter Installation................................................................................................ 0232-10 ENGINE OIL COOLER REPAIR (M939/A1)................................................................................................ WP 0233 Figure 1. Engine Oil Cooler Removal.................................................................................................. 0233-3 Figure 2. Engine Oil Cooler Disassembly............................................................................................ 0233-4 Figure 3. Engine Oil Cooler Cleaning and Inspection.......................................................................... 0233-5 Figure 4. Engine Oil Cooler Assembly................................................................................................. 0233-6 Figure 5. Engine Oil Cooler Installation............................................................................................... 0233-7 ENGINE AIR INTAKE MANIFOLD REPLACEMENT (M939/A1)................................................................. WP 0234 Figure 1. Engine Air Intake Manifold Removal.................................................................................... 0234-3 Figure 2. Engine Air Intake Manifold Disassembly.............................................................................. 0234-5 Figure 3. Engine Air Intake Manifold Assembly................................................................................... 0234-7 Figure 4. Engine Air Intake Manifold Installation................................................................................. 0234-9 ENGINE EXHAUST MANIFOLD REPLACEMENT (M939/A1).................................................................... WP 0235 Figure 1. Engine Exhaust Manifold Removal...................................................................................... 0235-3 Figure 2. Engine Exhaust Manifold Installation................................................................................... 0235-5 EXHAUST MANIFOLD REPLACEMENT (M939A2).................................................................................... WP 0236 Figure 1. Exhaust Manifold Removal................................................................................................... 0236-1 Figure 2. Exhaust Manifold Installation................................................................................................ 0236-2 Figure 3. Torque Sequence................................................................................................................. 0236-2 ENGINE ACCESSORY DRIVE AND PULLEY REPLACEMENT (M939/A1).............................................. WP 0237 Figure 1. Drive Pulley Removal........................................................................................................... 0237-2 Figure 2. Engine Drive Pulley Removal............................................................................................... 0237-3 Figure 3. Drive Disassembly................................................................................................................ 0237-5 xlix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Engine Accessory Cleaning and Inspection......................................................................... 0237-7 Figure 5. Drive Assembly.................................................................................................................... 0237-9 Figure 6. Drive Installation................................................................................................................. 0237-10 Figure 7. Drive Installation................................................................................................................. 0237-11 Figure 8. Drive Installation................................................................................................................. 0237-12 Figure 9. Engine Accessory Drive and Pulley Installation................................................................. 0237-13 FUEL INJECTOR REPLACEMENT (M939A2)............................................................................................ WP 0238 Figure 1. Fuel Injector Removal.......................................................................................................... 0238-3 Figure 2. Fuel Injector Installation....................................................................................................... 0238-4 PRIMING FUEL SYSTEM SERVICING (M939A2)...................................................................................... WP 0239 Figure 1. Fuel System Priming............................................................................................................ 0239-3 FUEL PUMP REPLACEMENT (M939/A1)................................................................................................... WP 0240 Figure 1. Fuel Pump Removal............................................................................................................. 0240-1 Figure 2. Fuel Pump Removal............................................................................................................. 0240-2 Figure 3. Fuel Pump Removal............................................................................................................. 0240-3 Figure 4. Fuel Pump Removal............................................................................................................. 0240-4 Figure 5. Fuel Pump Removal............................................................................................................. 0240-5 Figure 6. Fuel Pump Installation.......................................................................................................... 0240-5 Figure 7. Fuel Pump Installation.......................................................................................................... 0240-6 Figure 8. Fuel Pump Installation.......................................................................................................... 0240-7 Figure 9. Fuel Pump Installation.......................................................................................................... 0240-7 Figure 10. Fuel Pump Installation.......................................................................................................... 0240-9 Figure 11. Fuel Pump Adjustments..................................................................................................... 0240-10 Figure 12. Fuel Pump Adjustments..................................................................................................... 0240-11 FUEL INJECTOR TUBES REPLACEMENT (M939A2)............................................................................... WP 0241 Figure 1. Fuel Injector Tubes Removal............................................................................................... 0241-3 Figure 2. Fuel Injector Tubes Installation............................................................................................ 0241-5 l 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. FUEL INJECTION PUMP REPLACEMENT (M939A2)................................................................................ WP 0242 Figure 1. Fuel Injection Pump Removal.............................................................................................. 0242-3 Figure 2. Fuel Injection Pump Removal.............................................................................................. 0242-5 Figure 3. Fuel Injection Pump Removal.............................................................................................. 0242-6 Figure 4. Fuel Injection Pump Removal.............................................................................................. 0242-7 Figure 5. Fuel Injection Pump Removal.............................................................................................. 0242-9 Figure 6. Fuel Injection Pump Installation......................................................................................... 0242-11 Figure 7. Fuel Injection Pump Installation......................................................................................... 0242-12 Figure 8. Fuel Injection Pump Installation......................................................................................... 0242-13 Figure 9. Fuel Injection Pump Installation......................................................................................... 0242-15 Figure 10. Fuel Injection Pump Adjustment......................................................................................... 0242-17 FUEL TRANSFER PUMP AND SUPPLY LINES REPLACEMENT (M939A2)............................................ WP 0243 Figure 1. Fuel Transfer Pump and Supply Lines Removal.................................................................. 0243-3 Figure 2. Fuel Transfer Pump and Supply Lines Installation............................................................... 0243-5 AIR FUEL CONTROL (AFC) TUBE REPLACEMENT (M939A2)................................................................ WP 0244 Figure 1. Air Fuel Control Tube Removal............................................................................................ 0244-2 Figure 2. Air Fuel Control Tube Installation......................................................................................... 0244-3 AIR CLEANER ASSEMBLY AND MOUNTING BRACKET REPLACEMENT............................................. WP 0245 Figure 1. Air Cleaner Removal............................................................................................................ 0245-3 Figure 2. Air Cleaner Disassembly...................................................................................................... 0245-4 Figure 3. Air Cleaner Assembly........................................................................................................... 0245-5 Figure 4. Air Cleaner Installation......................................................................................................... 0245-7 AIR CLEANER INTAKE PIPE REPLACEMENT (M939/A1)........................................................................ WP 0246 Figure 1. Air Cleaner Intake Pipe Removal......................................................................................... 0246-3 Figure 2. Air Cleaner Intake Pipe Installation...................................................................................... 0246-5 AIR CLEANER INDICATOR AND TUBE REPLACEMENT......................................................................... WP 0247 Figure 1. Air Cleaner Indicator and Tube Removal............................................................................. 0247-2 li 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Air Cleaner Indicator and Tube Removal............................................................................. 0247-3 Figure 3. Air Cleaner Indicator and Tube Installation.......................................................................... 0247-4 Figure 4. Air Cleaner Indicator and Tube Installation.......................................................................... 0247-5 AIR CLEANER HOSE MAINTENANCE (M939A2)...................................................................................... WP 0248 Figure 1. Air Cleaner Hose Removal................................................................................................... 0248-2 Figure 2. Air Cleaner Hose Disassembly............................................................................................. 0248-3 Figure 3. Air Cleaner Hose Assembly................................................................................................. 0248-4 Figure 4. Air Cleaner Hose Installation................................................................................................ 0248-5 Figure 5. Air Cleaner Hose Inspection................................................................................................. 0248-6 TURBOCHARGER HOSES AND CLAMPS REPLACEMENT (M939A2).................................................... WP 0249 Figure 1. Turbocharger Hoses and Clamps Removal......................................................................... 0249-2 Figure 2. Turbocharger Hoses and Clamps Removal......................................................................... 0249-3 Figure 3. Turbocharger Hoses and Clamps Removal......................................................................... 0249-5 Figure 4. Turbocharger Hoses and Clamps Installation...................................................................... 0249-7 Figure 5. Turbocharger Hoses and Clamps Installation...................................................................... 0249-8 Figure 6. Turbocharger Hoses and Clamps Installation...................................................................... 0249-9 FUEL TANK REPLACEMENT..................................................................................................................... WP 0250 Figure 1. Fuel Tank Removal.............................................................................................................. 0250-3 Figure 2. Fuel Tank Removal.............................................................................................................. 0250-3 Figure 3. Fuel Tank Fitting Removal................................................................................................... 0250-4 Figure 4. Fuel Tank Installation........................................................................................................... 0250-5 Figure 5. Fuel Tank Installation........................................................................................................... 0250-6 Figure 6. Personnel Heater Fuel Line Installation............................................................................... 0250-7 FUEL TANK REPLACEMENT (M936/A1/A2).............................................................................................. WP 0251 Figure 1. Fuel Tank Removal (M936/A1/A2)....................................................................................... 0251-3 Figure 2. Fuel Tank Components Removal/Installation....................................................................... 0251-5 Figure 3. Fuel Tank Components Installation...................................................................................... 0251-7 lii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Fuel Tank Assembly............................................................................................................. 0251-9 Figure 5. Fuel Tank Installation......................................................................................................... 0251-10 FUEL TANK FILLER CAP AND SPOUT REPLACEMENT.......................................................................... WP 0252 Figure 1. Fuel Tank Filler Cap and Spout Removal............................................................................ 0252-3 Figure 2. Fuel Tank Filler Cap and Spout Installation......................................................................... 0252-5 FUEL TANK HANGERS AND RETAINING STRAPS REPLACEMENT...................................................... WP 0253 Figure 1. Fuel Tank Hangers and Retaining Straps Removal............................................................. 0253-3 Figure 2. Fuel Tank Hangers and Retaining Straps Inspection........................................................... 0253-5 Figure 3. Fuel Tank Hangers and Retaining Straps Installation.......................................................... 0253-7 FUEL TANK LINES REPLACEMENT (M939A2)......................................................................................... WP 0254 Figure 1. Fuel Tank Lines Removal..................................................................................................... 0254-3 Figure 2. Fuel Return and Supply Lines Removal............................................................................... 0254-5 Figure 3. Fuel Return and Supply Lines Removal............................................................................... 0254-7 Figure 4. Fuel Return and Supply Lines Installation............................................................................ 0254-9 Figure 5. Fuel Return and Supply Lines Installation.......................................................................... 0254-10 Figure 6. Fuel Return and Supply Lines Installation.......................................................................... 0254-11 FUEL SELECTOR VALVE, MOUNTING BRACKET, AND INDICATOR PLATE REPLACEMENT.......................................................................................................................................... WP 0255 Figure 1. Fuel Selector Valve Removal............................................................................................... 0255-3 Figure 2. Fuel Selector Valve Installation............................................................................................ 0255-5 FUEL DRAIN AND BYPASS TUBING REPLACEMENT (M939/A1)........................................................... WP 0256 Figure 1. Fuel Bypass Tubing Removal.............................................................................................. 0256-3 Figure 2. Fuel Bypass Tubing Removal.............................................................................................. 0256-5 Figure 3. Fuel Bypass Tubing Installation........................................................................................... 0256-7 Figure 4. Fuel Bypass Tubing Installation........................................................................................... 0256-9 FUEL SELECTOR VALVE FLEX HOSE REPLACEMENT.......................................................................... WP 0257 Figure 1. Fuel Selector Valve Flex Hose Removal.............................................................................. 0257-3 Figure 2. Fuel Selector Valve Flex Hose Installation........................................................................... 0257-4 liii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. FUEL FILTER AND COVER REPLACEMENT............................................................................................ WP 0258 Figure 1. Fuel Filter Removal.............................................................................................................. 0258-3 Figure 2. Fuel Filter Removal.............................................................................................................. 0258-5 Figure 3. Fuel Filter Removal.............................................................................................................. 0258-6 Figure 4. Fuel Filter Removal.............................................................................................................. 0258-7 Figure 5. Fuel Filter Cleaning and Inspection...................................................................................... 0258-8 Figure 6. Fuel Filter Installation........................................................................................................... 0258-9 Figure 7. Fuel Filter Installation......................................................................................................... 0258-10 Figure 8. Fuel Filter Installation......................................................................................................... 0258-11 AFC FUEL PUMP FILTER REPLACEMENT (M939/A1)............................................................................. WP 0259 Figure 1. AFC Fuel Pump Filter Removal............................................................................................ 0259-3 Figure 2. AFC Fuel Pump Filter Installation......................................................................................... 0259-4 FUEL PUMP WITH VS GOVERNOR FILTER REPLACEMENT (M939/A1)............................................... WP 0260 Figure 1. Fuel Pump with VS Governor Filter Removal....................................................................... 0260-3 Figure 2. Fuel Pump with VS Governor Filter Installation.................................................................... 0260-4 FUEL PRIMER PUMP REPLACEMENT (M939/A1).................................................................................... WP 0261 Figure 1. Fuel Primer Pump Removal................................................................................................. 0261-2 Figure 2. Fuel Primer Pump Installation.............................................................................................. 0261-3 ETHER START SWITCH REPLACEMENT (M939/A1)............................................................................... WP 0262 Figure 1. Ether Start Switch Removal................................................................................................. 0262-2 Figure 2. Ether Start Switch Installation.............................................................................................. 0262-3 ETHER CYLINDER AND VALVE REPLACEMENT (M939/A1)................................................................... WP 0263 Figure 1. Ether Cylinder Removal....................................................................................................... 0263-3 Figure 2. Ether Valve Removal............................................................................................................ 0263-4 Figure 3. Ether Valve Installation......................................................................................................... 0263-5 Figure 4. Ether Cylinder Installation.................................................................................................... 0263-6 ETHER THERMAL CLOSE VALVE AND BUSHING REPLACEMENT (M939/A1)..................................... WP 0264 liv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Ether Thermal Close Valve and Bushing Removal.............................................................. 0264-2 Figure 2. Ether Thermal Close Valve and Bushing Installation........................................................... 0264-3 ETHER ATOMIZER REPLACEMENT (M939/A1)....................................................................................... WP 0265 Figure 1. Ether Atomizer Removal...................................................................................................... 0265-2 Figure 2. Ether Atomizer Installation................................................................................................... 0265-3 ETHER ATOMIZER AND TEMPERATURE SENSOR REPLACEMENT (M939A2)................................... WP 0266 Figure 1. Ether Atomizer and Temperature Sensor Removal............................................................. 0266-3 Figure 2. Ether Atomizer and Temperature Sensor Installation.......................................................... 0266-4 ETHER TUBING REPLACEMENT (M939/A1)............................................................................................ WP 0267 Figure 1. Ether Tubing Removal.......................................................................................................... 0267-3 Figure 2. Ether Tubing Installation....................................................................................................... 0267-5 ACCELERATOR LINKAGE REPLACEMENT (M939/A1)............................................................................ WP 0268 Figure 1. Accelerator Linkage Removal.............................................................................................. 0268-3 Figure 2. Accelerator Linkage Installation........................................................................................... 0268-5 Figure 3. Accelerator Linkage Adjustment........................................................................................... 0268-7 ACCELERATOR LINKAGE REPLACEMENT (M939A2)............................................................................. WP 0269 Figure 1. Accelerator Linkage Removal.............................................................................................. 0269-3 Figure 2. Accelerator Linkage Disassembly........................................................................................ 0269-5 Figure 3. Accelerator Linkage Assembly............................................................................................. 0269-7 Figure 4. Accelerator Linkage Installation........................................................................................... 0269-9 Figure 5. Accelerator Linkage Adjustment......................................................................................... 0269-11 THROTTLE CONTROL CABLE REPLACEMENT....................................................................................... WP 0270 Figure 1. Throttle Control Cable Removal........................................................................................... 0270-3 Figure 2. Throttle Control Cable Installation........................................................................................ 0270-5 EMERGENCY STOP CONTROL CABLE REPLACEMENT........................................................................ WP 0271 Figure 1. Emergency Stop Control Cable Removal............................................................................. 0271-3 Figure 2. Emergency Stop Control Cable Installation.......................................................................... 0271-5 lv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. ACCELERATOR PEDAL, BRACKET, ROD, AND STOPSCREW REPLACEMENT.................................. WP 0272 Figure 1. Accelerator Pedal Removal.................................................................................................. 0272-2 Figure 2. Accelerator Pedal Installation............................................................................................... 0272-3 EXHAUST STACK REPLACEMENT........................................................................................................... WP 0273 Figure 1. Exhaust Stack Removal....................................................................................................... 0273-2 Figure 2. Exhaust Stack Installation.................................................................................................... 0273-3 MUFFLER AND SHIELD REPLACEMENT................................................................................................. WP 0274 Figure 1. Muffler and Shield Removal................................................................................................. 0274-3 Figure 2. Muffler and Shield Installation.............................................................................................. 0274-5 REAR EXHAUST PIPE, SUPPORT BRACKET, AND CAB HEAT SHIELD REPLACEMENT.................... WP 0275 Figure 1. Rear Exhaust Pipe, Support Bracket, and Cab Heat Shield Removal................................. 0275-3 Figure 2. Rear Exhaust Pipe, Support Bracket, and Cab Heat Shield Installation.............................. 0275-5 FRONT EXHAUST PIPE REPLACEMENT................................................................................................. WP 0276 Figure 1. Front Exhaust Pipe Replacement......................................................................................... 0276-3 Figure 2. Front Exhaust Pipe Installation............................................................................................. 0276-5 RADIATOR AND MOUNTING HARDWARE REPLACEMENT (M939A2 ONLY)........................................ WP 0277 Figure 1. Radiator and Mounting Hardware Removal......................................................................... 0277-3 Figure 2. Radiator and Mounting Hardware Installation...................................................................... 0277-5 SURGE TANK, RADIATOR VENT HOSE, AND MANIFOLD RETURN HOSE REPLACEMENT (M939/A1).................................................................................................................................................... WP 0278 Figure 1. Radiator Vent and Manifold Return Hoses Removal............................................................ 0278-3 Figure 2. Surge Tank Removal............................................................................................................ 0278-5 Figure 3. Surge Tank Installation......................................................................................................... 0278-7 Figure 4. Radiator Vent and Manifold Return Hoses Installation......................................................... 0278-9 SURGE TANK AND BRACKET REPLACEMENT (M939A2)...................................................................... WP 0279 Figure 1. Surge Tank and Bracket Removal....................................................................................... 0279-3 Figure 2. Surge Tank and Bracket Installation.................................................................................... 0279-5 COOLANT HOSES AND TUBES REPLACEMENT (M939/A1)................................................................... WP 0280 lvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Radiator Inlet Hoses and Tube Removal............................................................................. 0280-2 Figure 2. Thermostat Housing Hose, Radiator Bypass Tube, and Hose Removal............................. 0280-3 Figure 3. Surge Tank Hose Removal.................................................................................................. 0280-4 Figure 4. Radiator Outlet Hoses and Tee Removal............................................................................. 0280-5 Figure 5. Transmission Oil Cooler Hoses and Tube Removal............................................................ 0280-7 Figure 6. Transmission Oil Cooler Hoses and Tubes Installation........................................................ 0280-9 Figure 7. Radiator Outlet Hoses and Tee Installation........................................................................ 0280-10 Figure 8. Surge Tank Hose Installation............................................................................................. 0280-11 Figure 9. Thermostat Housing Hose, Radiator Bypass Tube, and Hose Installation........................ 0280-12 Figure 10. Radiator Inlet Hoses and Tube Installation........................................................................ 0280-13 RADIATOR AND MOUNTING HARDWARE REPLACEMENT (M939/A1)................................................. WP 0281 Figure 1. Radiator (M939/A1) Removal............................................................................................... 0281-2 Figure 2. Radiator (M939/A1) Removal............................................................................................... 0281-3 Figure 3. Radiator (M939/A1) Removal............................................................................................... 0281-4 Figure 4. Radiator (M939/A1) Installation............................................................................................ 0281-5 Figure 5. Radiator (M939/A1) Installation............................................................................................ 0281-6 Figure 6. Radiator (M939/A1) Installation............................................................................................ 0281-7 RADIATOR FAN SHROUD REPLACEMENT (M939/A1)............................................................................ WP 0282 Figure 1. Radiator Fan Shroud Removal............................................................................................. 0282-3 Figure 2. Radiator Fan Shroud Installation.......................................................................................... 0282-5 FAN AND FAN SHROUD REPAIR (M939A2)............................................................................................. WP 0283 Figure 1. Fan and Shroud Removal.................................................................................................... 0283-3 Figure 2. Fan and Shroud Installation................................................................................................. 0283-5 AIR COMPRESSOR COOLANT SUPPLY AND RETURN TUBES REPLACEMENT (M939/ A1)............................................................................................................................................................... WP 0284 Figure 1. Supply Tube Removal.......................................................................................................... 0284-2 Figure 2. Return Tube Inspection........................................................................................................ 0284-3 Figure 3. Supply Tube Installation....................................................................................................... 0284-4 lvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Return Tube Installation....................................................................................................... 0284-5 COOLANT HOSES AND LINES REPLACEMENT (M939A2)..................................................................... WP 0285 Figure 1. Coolant Hoses and Lines Removal...................................................................................... 0285-2 Figure 2. Coolant Hoses and Lines Removal...................................................................................... 0285-3 Figure 3. Coolant Hoses and Lines Removal...................................................................................... 0285-4 Figure 4. Coolant Hoses and Lines Removal...................................................................................... 0285-5 Figure 5. Coolant Hoses and Lines Installation................................................................................... 0285-6 Figure 6. Coolant Hoses and Lines Installation................................................................................... 0285-7 Figure 7. Coolant Hoses and Lines Installation................................................................................... 0285-8 Figure 8. Coolant Hoses and Lines Installation................................................................................... 0285-9 UPPER RADIATOR HOSES AND BRACKETS REPLACEMENT (M939A2).............................................. WP 0286 Figure 1. Upper Radiator Hoses and Brackets Removal..................................................................... 0286-2 Figure 2. Upper Radiator Hoses and Brackets Removal..................................................................... 0286-3 Figure 3. Upper Radiator Hoses and Brackets Installation.................................................................. 0286-4 Figure 4. Upper Radiator Hoses and Brackets Installation.................................................................. 0286-5 COOLING SYSTEM SERVICE.................................................................................................................... WP 0287 Figure 1. Cooling System.................................................................................................................... 0287-3 Table 1. Guide for Preparation of Antifreeze Solutions...................................................................... 0287-4 Figure 2. Cooling System.................................................................................................................... 0287-5 THERMOSTAT AND HOUSING REPLACEMENT (M939/A1).................................................................... WP 0288 Figure 1. Thermostat and Housing Removal....................................................................................... 0288-3 Figure 2. Thermostat and Housing Installation.................................................................................... 0288-5 THERMOSTATS AND HOUSING REPLACEMENT (M939A2)................................................................... WP 0289 Figure 1. Thermostat and Housing Removal....................................................................................... 0289-3 Figure 2. Thermostat and Housing Installation.................................................................................... 0289-5 Figure 3. Thermostat and Housing Removal....................................................................................... 0289-7 Figure 4. Thermostat and Housing Installation.................................................................................... 0289-9 lviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. ENGINE WATER MANIFOLD REPLACEMENT (M939/A1)........................................................................ WP 0290 Figure 1. Engine Water Manifold Removal.......................................................................................... 0290-3 Figure 2. Engine Water Manifold Disassembly.................................................................................... 0290-4 Figure 3. Engine Water Manifold Assembly........................................................................................ 0290-5 Figure 4. Engine Water Manifold Installation....................................................................................... 0290-6 WATER HEADER PLATES REPLACEMENT (M939/A1)........................................................................... WP 0291 Figure 1. Water Header Plates Removal............................................................................................. 0291-2 Figure 2. Water Header Plates Installation.......................................................................................... 0291-3 WATER PUMP REPLACEMENT (M939A2)................................................................................................ WP 0292 Figure 1. Water Pump Removal.......................................................................................................... 0292-2 Figure 2. Water Pump Installation....................................................................................................... 0292-3 WATER PUMP REPLACEMENT (M939/A1)............................................................................................... WP 0293 Figure 1. Water Pump Removal.......................................................................................................... 0293-2 Figure 2. Water Pump Removal.......................................................................................................... 0293-3 Figure 3. Water Pump Installation....................................................................................................... 0293-4 Figure 4. Water Pump Installation....................................................................................................... 0293-5 WATER PUMP DRIVEBELT REPLACEMENT (M939/A1).......................................................................... WP 0294 Figure 1. Water Pump Drivebelt Adjustment....................................................................................... 0294-3 Figure 2. Water Pump Drivebelt Removal........................................................................................... 0294-5 Figure 3. Water Pump Drivebelt Installation........................................................................................ 0294-7 FAN DRIVE CLUTCH REPLACEMENT (M939/A1).................................................................................... WP 0295 Figure 1. Fan Drive Clutch Removal................................................................................................... 0295-1 Figure 2. Fan Drive Clutch Removal................................................................................................... 0295-2 Figure 3. Fan Drive Clutch Installation................................................................................................ 0295-3 Figure 4. Fan Drive Clutch Installation................................................................................................ 0295-4 FAN DRIVEBELT AND DRIVEBELT TENSIONER REPLACEMENT (M939A2)........................................ WP 0296 Figure 1. Fan Drivebelt and Drivebelt Tensioner Removal.................................................................. 0296-3 lix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Fan Drivebelt and Drivebelt Tensioner Installation............................................................... 0296-5 FAN DRIVEBELTS MAINTENANCE (M939/A1)......................................................................................... WP 0297 Figure 1. Fan Drivebelt Adjustment..................................................................................................... 0297-3 Figure 2. Fan Drivebelt Removal......................................................................................................... 0297-5 Figure 3. Fan Drivebelt Installation...................................................................................................... 0297-6 RADIATOR FAN BLADE REPLACEMENT (M939/A1)................................................................................ WP 0298 Figure 1. Radiator Fan Blade Removal............................................................................................... 0298-3 Figure 2. Radiator Fan Blade Installation............................................................................................ 0298-5 AFTERCOOLER AND TUBES REPLACEMENT (M939A2)........................................................................ WP 0299 Figure 1. Aftercooler and Tubes Removal........................................................................................... 0299-2 Figure 2. Aftercooler and Tubes Removal........................................................................................... 0299-3 Figure 3. Aftercooler and Tubes Installation........................................................................................ 0299-4 Figure 4. Aftercooler and Tubes Installation........................................................................................ 0299-5 ALTERNATOR, MOUNTING BRACKET, AND PULLEY REPLACEMENT (M939/A1)............................... WP 0300 Figure 1. Alternator and Mounting Bracket Removal........................................................................... 0300-2 Figure 2. Alternator and Mounting Bracket Removal........................................................................... 0300-3 Figure 3. Alternator Pulley Removal.................................................................................................... 0300-5 Figure 4. Alternator Pulley Installation................................................................................................. 0300-7 Figure 5. Alternator and Mounting Bracket Installation........................................................................ 0300-8 Figure 6. Alternator and Mounting Bracket Installation........................................................................ 0300-9 ALTERNATOR, MOUNTING BRACKET, AND PULLEY REPLACEMENT (M939A2)................................ WP 0301 Figure 1. Alternator and Mounting Bracket Removal........................................................................... 0301-3 Figure 2. Pulley Removal.................................................................................................................... 0301-5 Figure 3. Pulley Installation................................................................................................................. 0301-7 Figure 4. Alternator and Mounting Bracket Installation........................................................................ 0301-9 Figure 5. Alternator, Mounting Bracket, and Pulley Adjustment........................................................ 0301-11 ALTERNATOR DRIVEBELTS REPLACEMENT (M939/A1)........................................................................ WP 0302 lx 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Alternator Drivebelts Removal.............................................................................................. 0302-2 Figure 2. Alternator Drivebelts Installation........................................................................................... 0302-3 Figure 3. Alternator Drivebelts Installation........................................................................................... 0302-3 Figure 4. Alternator Drivebelts Installation........................................................................................... 0302-4 Figure 5. Alternator Drivebelts Installation........................................................................................... 0302-4 STARTER REPLACEMENT........................................................................................................................ WP 0303 Figure 1. Starter Replacement Removal............................................................................................. 0303-3 Figure 2. Starter Installation................................................................................................................ 0303-5 THROTTLE CONTROL SOLENOID REPLACEMENT (M939A2)............................................................... WP 0304 Figure 1. Throttle Control Solenoid Removal...................................................................................... 0304-2 Figure 2. Throttle Control Solenoid Installation................................................................................... 0304-3 FUEL PUMP METERING VALVE REPLACEMENT (M939/A1).................................................................. WP 0305 Figure 1. Manual Shutoff Valve Removal............................................................................................ 0305-2 Figure 2. Fuel Pump Metering Valve Removal.................................................................................... 0305-3 Figure 3. Fuel Pump Metering Valve Installation................................................................................. 0305-4 Figure 4. Manual Shutoff Valve Installation......................................................................................... 0305-5 FUEL PUMP METERING VALVE REPLACEMENT (M936 Wrecker)......................................................... WP 0306 Figure 1. Fuel Pump Metering Valve Removal.................................................................................... 0306-2 Figure 2. Fuel Pump Metering Valve Installation................................................................................. 0306-3 ELECTRICAL SWITCHES AND CIRCUIT BREAKER REPLACEMENT.................................................... WP 0307 Figure 1. Switch Removal.................................................................................................................... 0307-1 Figure 2. Wire Removal....................................................................................................................... 0307-2 Figure 3. Wire Connector Installation.................................................................................................. 0307-2 Figure 4. Blower Motor Switch Installation.......................................................................................... 0307-3 Figure 5. Battery and Switch Removal................................................................................................ 0307-3 Figure 6. Battery and Starter Switch Removal.................................................................................... 0307-4 Figure 7. Battery and Switch Installation............................................................................................. 0307-5 lxi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 8. Battery and Starter Switch Installation................................................................................. 0307-5 Figure 9. Circuit Breaker Removal...................................................................................................... 0307-7 Figure 10. Circuit Breaker Installation................................................................................................... 0307-9 SPRING BRAKE PRESSURE SWITCH REPLACEMENT.......................................................................... WP 0308 Figure 1. Spring Brake Pressure Switch Removal.............................................................................. 0308-3 Figure 2. Spring Brake Pressure Switch Installation........................................................................... 0308-5 INSTRUMENT PANEL REPLACEMENT..................................................................................................... WP 0309 Figure 1. Instrument Panel Removal................................................................................................... 0309-3 Figure 2. Instrument Panel Installation................................................................................................ 0309-4 INSTRUMENT CLUSTER REPLACEMENT................................................................................................ WP 0310 Figure 1. Cable Removal..................................................................................................................... 0310-2 Figure 2. Cable Removal..................................................................................................................... 0310-3 Figure 3. Instrument Cluster Removal................................................................................................. 0310-4 Figure 4. Instrument Cluster Removal................................................................................................. 0310-5 Figure 5. Instrument Cluster Disassembly........................................................................................... 0310-7 Figure 6. Instrument Cluster Assembly............................................................................................... 0310-9 Figure 7. Instrument Cluster Installation............................................................................................ 0310-10 Figure 8. Instrument Cluster Installation............................................................................................ 0310-11 Figure 9. Instrument Cluster Installation............................................................................................ 0310-12 Figure 10. Instrument Cluster Installation............................................................................................ 0310-13 INDICATOR PANEL LIGHT AND LAMP REPLACEMENT......................................................................... WP 0311 Figure 1. Indicator Panel Light Removal............................................................................................. 0311-2 Figure 2. Indicator Panel Light Installation.......................................................................................... 0311-3 Figure 3. Lamp Removal..................................................................................................................... 0311-4 Figure 4. Lamp Installation.................................................................................................................. 0311-5 ELECTRICAL GAUGES REPLACEMENT.................................................................................................. WP 0312 Figure 1. Gauges Removal.................................................................................................................. 0312-3 lxii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Gauges Installation............................................................................................................... 0312-4 AUXILIARY OUTLET SOCKET AND RECEPTACLE REPLACEMENT...................................................... WP 0313 Figure 1. Auxiliary Outlet Socket and Receptacle Removal................................................................ 0313-3 Figure 2. Auxiliary Outlet Installation................................................................................................... 0313-5 FUEL SELECTOR VALVE SWITCH REPLACEMENT................................................................................ WP 0314 Figure 1. Fuel Selector Valve Switch Removal................................................................................... 0314-3 Figure 2. Fuel Selector Valve Switch Installation................................................................................ 0314-5 MAIN LIGHT SWITCH REPLACEMENT..................................................................................................... WP 0315 Figure 1. Main Light Switch Removal.................................................................................................. 0315-3 Figure 2. Main Light Switch Installation............................................................................................... 0315-5 HIGH BEAM SELECTOR SWITCH REPLACEMENT................................................................................. WP 0316 Figure 1. High Beam Selector Switch Removal................................................................................... 0316-1 Figure 2. High Beam Selector Switch Installation................................................................................ 0316-2 TURN SIGNAL CONTROL AND INDICATOR LAMP REPLACEMENT...................................................... WP 0317 Figure 1. Turn Signal Removal............................................................................................................ 0317-1 Figure 2. Turn Signal Installation......................................................................................................... 0317-2 TURN SIGNAL FLASHER REPLACEMENT............................................................................................... WP 0318 Figure 1. Turn Signal Removal............................................................................................................ 0318-1 Figure 2. Turn Signal Installation......................................................................................................... 0318-2 PROTECTIVE CONTROL BOX REPLACEMENT....................................................................................... WP 0319 Figure 1. Protective Control Box Removal.......................................................................................... 0319-2 Figure 2. Protective Control Box Installation....................................................................................... 0319-3 FLOODLIGHT CONTROL SWITCH REPLACEMENT................................................................................ WP 0320 Figure 1. Floodlight Switch Installation Removal................................................................................. 0320-2 Figure 2. Floodlight Switch Disassembly............................................................................................. 0320-3 Figure 3. Floodlight Switch Inspection................................................................................................. 0320-4 Figure 4. Floodlight Switch Assembly.................................................................................................. 0320-5 lxiii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 5. Floodlight Switch Installation................................................................................................ 0320-6 AMBER WARNING LIGHT REPLACEMENT.............................................................................................. WP 0321 Figure 1. Amber Warning Light Removal............................................................................................ 0321-1 Figure 2. Amber Warning Light Installation......................................................................................... 0321-2 CTIS WIRING HARNESS REPLACEMENT................................................................................................ WP 0322 Figure 1. Wiring Harness Removal...................................................................................................... 0322-3 Figure 2. Wiring Harness Installation................................................................................................... 0322-5 SPEED SIGNAL GENERATOR REPLACEMENT....................................................................................... WP 0323 Figure 1. Speed Signal Generator Removal........................................................................................ 0323-2 Figure 2. Speed Signal Generator Installation..................................................................................... 0323-3 PRESSURE SWITCH REPLACEMENT...................................................................................................... WP 0324 Figure 1. Pressure Switch Removal.................................................................................................... 0324-2 Figure 2. Pressure Switch Installation................................................................................................. 0324-3 HEADLIGHT REPAIR.................................................................................................................................. WP 0325 Figure 1. Headlight Removal............................................................................................................... 0325-2 Figure 2. Headlight Removal............................................................................................................... 0325-3 Figure 3. Headlight Installation............................................................................................................ 0325-4 Figure 4. Headlight Installation............................................................................................................ 0325-5 Figure 5. Headlight Alignment............................................................................................................. 0325-6 BLACKOUT LIGHT REPAIR........................................................................................................................ WP 0326 Figure 1. Blackout Light Removal........................................................................................................ 0326-2 Figure 2. Blackout Light Disassembly................................................................................................. 0326-3 Figure 3. Blackout Light Assembly...................................................................................................... 0326-4 Figure 4. Blackout Light Installation..................................................................................................... 0326-5 FRONT AND REAR COMPOSITE LIGHT AND BRACKET REPLACEMENT............................................ WP 0327 Figure 1. Front Composite Light Removal........................................................................................... 0327-3 Figure 2. Front Composite Light Installation........................................................................................ 0327-4 lxiv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Rear Composite Light Removal........................................................................................... 0327-5 Figure 4. Rear Composite Light Installation........................................................................................ 0327-6 Figure 5. Rear Composite Light Removal........................................................................................... 0327-7 Figure 6. Rear Composite Light Installation........................................................................................ 0327-9 Figure 7. Rear Composite Light and Bracket Removal..................................................................... 0327-11 Figure 8. Rear Composite Light and Bracket Installation.................................................................. 0327-13 Figure 9. Rear Composite Light and Bracket Removal..................................................................... 0327-15 Figure 10. Rear Composite Light and Bracket Installation.................................................................. 0327-17 Figure 11. Rear Composite Light Removal......................................................................................... 0327-19 Figure 12. Rear Composite Light Installation...................................................................................... 0327-21 Figure 13. Rear Composite Bulb Removal.......................................................................................... 0327-22 Figure 14. Rear Composite Bulb Installation....................................................................................... 0327-23 FLOODLIGHT SEALED BEAM LAMP AND DOOR REPLACEMENT........................................................ WP 0328 Figure 1. Floodlight Removal............................................................................................................... 0328-3 Figure 2. Floodlight Installation............................................................................................................ 0328-4 FLOODLIGHT REPAIR................................................................................................................................ WP 0329 Figure 1. Floodlight Removal............................................................................................................... 0329-2 Figure 2. Floodlight Disassembly........................................................................................................ 0329-3 Figure 3. Floodlight Disassembly........................................................................................................ 0329-4 Figure 4. Floodlight Assembly............................................................................................................. 0329-5 Figure 5. Floodlight Assembly............................................................................................................. 0329-6 Figure 6. Floodlight Installation............................................................................................................ 0329-7 SIDE MARKER LIGHTS AND BRACKET REPLACEMENT........................................................................ WP 0330 Figure 1. Side Marker Lamp Removal................................................................................................. 0330-2 Figure 2. Side Marker Light Removal.................................................................................................. 0330-3 Figure 3. Side Marker Light Installation............................................................................................... 0330-4 Figure 4. Side Marker Lamp Installation.............................................................................................. 0330-5 lxv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. BOOM FLOODLIGHT WIRE REPLACEMENT............................................................................................ WP 0331 Figure 1. Boom Floodlight Wire Removal............................................................................................ 0331-3 Figure 2. Boom Floodlight Wire Installation......................................................................................... 0331-4 FUEL LEVEL SENDING UNIT REPLACEMENT......................................................................................... WP 0332 Figure 1. Fuel Level Sending Unit Removal........................................................................................ 0332-3 Figure 2. Fuel Level Sending Unit Installation..................................................................................... 0332-4 OIL PRESSURE SENDING UNIT REPLACEMENT.................................................................................... WP 0333 Figure 1. Oil Pressure Sending Unit Removal..................................................................................... 0333-2 Figure 2. Oil Pressure Sending Unit Installation.................................................................................. 0333-3 WATER TEMPERATURE SENDING UNIT REPLACEMENT..................................................................... WP 0334 Figure 1. Water Temperature Sending Unit Removal......................................................................... 0334-2 Figure 2. Water Temperature Sending Unit Installation...................................................................... 0334-3 STOPLIGHT SWITCH REPLACEMENT..................................................................................................... WP 0335 Figure 1. Stoplight Switch Removal..................................................................................................... 0335-1 Figure 2. Stoplight Switch Installation.................................................................................................. 0335-2 FAILSAFE WARNING MODULE REPLACEMENT..................................................................................... WP 0336 Figure 1. Failsafe Warning Module Removal...................................................................................... 0336-2 Figure 2. Failsafe Warning Module Installation................................................................................... 0336-3 ETHER START FUEL PRESSURE SWITCH REPLACEMENT.................................................................. WP 0337 Figure 1. Ether Start Fuel Pressure Switch Removal.......................................................................... 0337-2 Figure 2. Ether Start Fuel Pressure Switch Installation....................................................................... 0337-3 TACHOMETER PULSE SENSOR REPLACEMENT................................................................................... WP 0338 Figure 1. Tachometer Pulse Sender Removal.................................................................................... 0338-2 Figure 2. Tachometer Pulse Sender Installation................................................................................. 0338-3 TACHOMETER PULSE SENSOR REPLACEMENT (M939A2).................................................................. WP 0339 Figure 1. Tachometer Pulse Sender Removal.................................................................................... 0339-1 Figure 2. Tachometer Pulse Sender Installation................................................................................. 0339-2 lxvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. FUEL PRESSURE TRANSDUCER REPLACEMENT................................................................................. WP 0340 Figure 1. Fuel Pressure Transducer Removal..................................................................................... 0340-2 Figure 2. Fuel Pressure Transducer Installation.................................................................................. 0340-3 TRANSMISSION TEMPERATURE TRANSMITTER REPLACEMENT....................................................... WP 0341 Figure 1. Transmission Temperature Transmitter Removal................................................................ 0341-1 Figure 2. Transmission Temperature Transmitter Installation............................................................. 0341-2 PRIMARY AND SECONDARY LOW AIR PRESSURE SWITCH REPLACEMENT.................................... WP 0342 Figure 1. Primary and Secondary Air Pressure Removal.................................................................... 0342-3 Figure 2. Primary and Secondary Air Pressure Removal.................................................................... 0342-5 Figure 3. Primary and Secondary Air Pressure Removal.................................................................... 0342-7 Figure 4. Primary and Secondary Air Pressure Installation................................................................. 0342-9 HORN, SOLENOID, AND BRACKET REPLACEMENT.............................................................................. WP 0343 Figure 1. Horn, Solenoid, and Bracket Removal................................................................................. 0343-3 Figure 2. Horn, Solenoid, and Bracket Installation.............................................................................. 0343-5 HORN SWITCH REPLACEMENT............................................................................................................... WP 0344 Figure 1. Horn Switch Removal........................................................................................................... 0344-3 Figure 2. Horn Switch Installation........................................................................................................ 0344-5 HORN CONTACT BRUSH REPLACEMENT.............................................................................................. WP 0345 Figure 1. Horn Contact Removal......................................................................................................... 0345-1 Figure 2. Horn Contact Removal......................................................................................................... 0345-3 Figure 3. Horn Contact Installation...................................................................................................... 0345-5 Figure 4. Horn Contact Installation...................................................................................................... 0345-6 BATTERY REPLACEMENT........................................................................................................................ WP 0346 Figure 1. Battery Removal................................................................................................................... 0346-3 Figure 2. Battery Inspection and Cleaning.......................................................................................... 0346-4 Figure 3. Battery Installation................................................................................................................ 0346-5 BATTERY BOX REPLACEMENT................................................................................................................ WP 0347 lxvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Battery Box Removal............................................................................................................ 0347-2 Figure 2. Battery Box Installation......................................................................................................... 0347-3 BATTERY BOX COVER REPLACEMENT.................................................................................................. WP 0348 Figure 1. Battery Box Cover Removal................................................................................................. 0348-2 Figure 2. Battery Box Cover Installation.............................................................................................. 0348-3 BATTERY CABLE AND TERMINAL ADAPTER REPLACEMENT.............................................................. WP 0349 Figure 1. Battery Cable Removal........................................................................................................ 0349-3 Figure 2. Battery Cable Installation..................................................................................................... 0349-5 BATTERY GROUND CABLE REPLACEMENT........................................................................................... WP 0350 Figure 1. Battery Ground Cable Disconnection................................................................................... 0350-3 Figure 2. Battery Ground Cable Connection....................................................................................... 0350-4 Index Volume 3 Chapter 8 - MAINTENANCE INSTRUCTIONS INSTRUMENT CLUSTER HARNESS REPLACEMENT............................................................................. WP 0351 Figure 1. Cluster Harness Removal.................................................................................................... 0351-2 Figure 2. Cluster Harness Installation................................................................................................. 0351-3 WIRING HARNESS REPAIR....................................................................................................................... WP 0352 Figure 1. Terminal-Type Cable Connector.......................................................................................... 0352-2 Figure 2. Male Cable Connector.......................................................................................................... 0352-3 Figure 3. Female Cable Connector..................................................................................................... 0352-3 Figure 4. Plug Assembly...................................................................................................................... 0352-4 Figure 5. Receptacle Assembly........................................................................................................... 0352-5 SLAVE RECEPTACLE REPLACEMENT.................................................................................................... WP 0353 Figure 1. Slave Receptacle Removal.................................................................................................. 0353-3 Figure 2. Slave Receptacle Installation............................................................................................... 0353-5 GROUND STRAP REPLACEMENT............................................................................................................ WP 0354 lxviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Ground Strap Removal......................................................................................................... 0354-2 Figure 2. Ground Strap Removal......................................................................................................... 0354-3 Figure 3. Ground Strap Removal......................................................................................................... 0354-3 Figure 4. Ground Strap Installation...................................................................................................... 0354-4 Figure 5. Ground Strap Installation...................................................................................................... 0354-5 Figure 6. Ground Strap Installation...................................................................................................... 0354-6 Figure 7. Ground Strap Removal......................................................................................................... 0354-7 Figure 8. Ground Strap Removal......................................................................................................... 0354-8 Figure 9. Ground Strap Removal......................................................................................................... 0354-9 Figure 10. Ground Strap Installation.................................................................................................... 0354-10 Figure 11. Ground Strap Installation.................................................................................................... 0354-11 Figure 12. Ground Strap Installation.................................................................................................... 0354-12 CRANE WIRING HARNESS REPLACEMENT............................................................................................ WP 0355 Figure 1. Crane Wiring Harness Removal........................................................................................... 0355-3 Figure 2. Crane Wiring Harness Installation........................................................................................ 0355-5 FRONT LIGHTS CABLE ASSEMBLY REPLACEMENT (M939/A1)............................................................ WP 0356 Figure 1. Front Lights Cable Assembly Removal................................................................................ 0356-3 Figure 2. Front Lights Cable Assembly Removal................................................................................ 0356-5 Figure 3. Front Lights Cable Assembly Installation............................................................................. 0356-7 Figure 4. Front Lights Cable Assembly Installation............................................................................. 0356-9 FRONT WIRING HARNESS REPLACEMENT (M939/A1).......................................................................... WP 0357 Figure 1. Front Wiring Harness Replacement..................................................................................... 0357-3 Figure 2. Front Wiring Harness Replacement..................................................................................... 0357-5 Figure 3. Front Wiring Harness Replacement..................................................................................... 0357-7 Figure 4. Front Wiring Harness Replacement..................................................................................... 0357-9 Figure 5. Front Wiring Harness Replacement................................................................................... 0357-11 Figure 6. Front Wiring Harness Replacement................................................................................... 0357-13 lxix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 7. Front Wiring Harness Replacement................................................................................... 0357-15 Figure 8. Front Wiring Harness Replacement................................................................................... 0357-17 Figure 9. Front Wiring Harness Replacement................................................................................... 0357-19 Figure 10. Front Wiring Harness Replacement................................................................................... 0357-21 Figure 11. Front Wiring Harness Replacement................................................................................... 0357-23 Figure 12. Front Wiring Harness Replacement................................................................................... 0357-25 Figure 13. Front Wiring Harness Replacement................................................................................... 0357-27 Figure 14. Front Wiring Harness Replacement................................................................................... 0357-28 Figure 15. Front Wiring Harness Replacement................................................................................... 0357-29 Figure 16. Front Wiring Harness Replacement................................................................................... 0357-30 Figure 17. Front Wiring Harness Replacement................................................................................... 0357-31 Figure 18. Front Wiring Harness Replacement................................................................................... 0357-33 Figure 19. Front Wiring Harness Replacement................................................................................... 0357-35 Figure 20. Front Wiring Harness Replacement................................................................................... 0357-37 Figure 21. Front Wiring Harness Replacement................................................................................... 0357-39 Figure 22. Front Wiring Harness Replacement................................................................................... 0357-41 Figure 23. Front Wiring Harness Replacement................................................................................... 0357-43 Figure 24. Front Wiring Harness Replacement................................................................................... 0357-45 Figure 25. Front Wiring Harness Replacement................................................................................... 0357-46 FRONT WIRING HARNESS REPLACEMENT (M939/A2).......................................................................... WP 0358 Figure 1. Front Wiring Harness Replacement..................................................................................... 0358-3 Figure 2. Front Wiring Harness Replacement..................................................................................... 0358-4 Figure 3. Front Wiring Harness Replacement..................................................................................... 0358-5 Figure 4. Front Wiring Harness Replacement..................................................................................... 0358-7 Figure 5. Front Wiring Harness Replacement..................................................................................... 0358-9 Figure 6. Front Wiring Harness Replacement................................................................................... 0358-11 Figure 7. Front Wiring Harness Replacement................................................................................... 0358-13 lxx 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 8. Front Wiring Harness Replacement................................................................................... 0358-14 Figure 9. Front Wiring Harness Replacement................................................................................... 0358-15 Figure 10. Front Wiring Harness Replacement................................................................................... 0358-17 Figure 11. Front Wiring Harness Replacement................................................................................... 0358-19 Figure 12. Front Wiring Harness Replacement................................................................................... 0358-21 Figure 13. Front Wiring Harness Replacement................................................................................... 0358-23 Figure 14. Front Wiring Harness Replacement................................................................................... 0358-25 Figure 15. Front Wiring Harness Replacement................................................................................... 0358-27 Figure 16. Front Wiring Harness Replacement................................................................................... 0358-29 Figure 17. Front Wiring Harness Replacement................................................................................... 0358-30 Figure 18. Front Wiring Harness Replacement................................................................................... 0358-31 Figure 19. Front Wiring Harness Replacement................................................................................... 0358-33 Figure 20. Front Wiring Harness Replacement................................................................................... 0358-35 REAR WIRING HARNESS REPLACEMENT.............................................................................................. WP 0359 Figure 1. Rear Wiring Harness Replacement...................................................................................... 0359-3 Figure 2. Rear Wiring Harness Replacement...................................................................................... 0359-5 Figure 3. Rear Wiring Harness Replacement...................................................................................... 0359-7 Figure 4. Rear Wiring Harness Replacement...................................................................................... 0359-9 Figure 5. Rear Wiring Harness Replacement.................................................................................... 0359-11 Figure 6. Rear Wiring Harness Replacement.................................................................................... 0359-13 Table 1. Clamps Required for Rear Wiring Harness........................................................................ 0359-14 Figure 7. Rear Wiring Harness Replacement.................................................................................... 0359-15 Figure 8. Rear Wiring Harness Replacement.................................................................................... 0359-17 Figure 9. Rear Wiring Harness Replacement.................................................................................... 0359-19 Figure 10. Rear Wiring Harness Replacement.................................................................................... 0359-20 Figure 11. Rear Wiring Harness Replacement.................................................................................... 0359-21 Figure 12. Rear Wiring Harness Replacement.................................................................................... 0359-23 lxxi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 13. Rear Wiring Harness Replacement.................................................................................... 0359-24 Figure 14. Rear Wiring Harness Replacement.................................................................................... 0359-25 Figure 15. Rear Wiring Harness Replacement.................................................................................... 0359-27 Figure 16. Rear Wiring Harness Replacement.................................................................................... 0359-28 Figure 17. Rear Wiring Harness Replacement.................................................................................... 0359-29 SIDE MARKER LIGHTS WIRING HARNESS REPAIR............................................................................... WP 0360 Figure 1. Side Marker Light Wiring Removal....................................................................................... 0360-2 Figure 2. Side Marker Light Wiring Installation.................................................................................... 0360-3 TRANSMISSION MOUNT AND BUSHING REPLACEMENT..................................................................... WP 0361 Figure 1. Transmission Mount and Bushing Removal......................................................................... 0361-2 Figure 2. Transmission Mount and Bushing Installation...................................................................... 0361-3 TRANSMISSION OIL SERVICE INSTRUCTIONS...................................................................................... WP 0362 Figure 1. Oil Pan.................................................................................................................................. 0362-3 Figure 2. Oil Filter Removal................................................................................................................. 0362-5 Figure 3. Oil Filter Installation.............................................................................................................. 0362-7 Figure 4. Oil Filter Installation.............................................................................................................. 0362-9 Figure 5. Governor Filter Removal.................................................................................................... 0362-11 Figure 6. Governor Filter Installation................................................................................................. 0362-13 Figure 7. Replenishing Oil................................................................................................................. 0362-15 TRANSMISSION DIPSTICK TUBE AND DIPSTICK REPLACEMENT....................................................... WP 0363 Figure 1. Dipstick Removal.................................................................................................................. 0363-1 Figure 2. Dipstick Removal.................................................................................................................. 0363-2 Figure 3. Dipstick Removal.................................................................................................................. 0363-3 Figure 4. Dipstick Installation............................................................................................................... 0363-4 Figure 5. Dipstick Installation............................................................................................................... 0363-5 Figure 6. Dipstick Installation............................................................................................................... 0363-5 TRANSMISSION MOUNTING BRACKET AND ISOLATOR (M939A2) REPLACEMENT.......................... WP 0364 lxxii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Mounting Bracket Removal.................................................................................................. 0364-2 Figure 2. Mounting Bracket Installation............................................................................................... 0364-3 TRANSMISSION MODULATOR AND CABLE REPLACEMENT................................................................ WP 0365 Figure 1. Modulator and Cable Removal............................................................................................. 0365-3 Figure 2. Modulator and Cable Installation.......................................................................................... 0365-5 Figure 3. Modulator and Cable Adjustment......................................................................................... 0365-7 TRANSMISSION NEUTRAL START SWITCH REPLACEMENT................................................................ WP 0366 Figure 1. Transmission Neutral Start Switch Removal........................................................................ 0366-1 Figure 2. Transmission Neutral Start Switch Installation..................................................................... 0366-2 GOVERNOR PIPING AND CAPACITOR REPLACEMENT........................................................................ WP 0367 Figure 1. Governor Piping Removal.................................................................................................... 0367-3 Figure 2. Capacitor Removal............................................................................................................... 0367-4 Figure 3. Governor Piping Removal.................................................................................................... 0367-5 Figure 4. Governor Piping Installation................................................................................................. 0367-6 Figure 5. Capacitor Installation............................................................................................................ 0367-7 Figure 6. Governor Piping Installation................................................................................................. 0367-9 TRANSMISSION 5TH GEAR LOCK-UP PRESSURE SWITCH REPLACEMENT...................................... WP 0368 Figure 1. Pressure Switch Removal.................................................................................................... 0368-2 Figure 2. Pressure Switch Installation................................................................................................. 0368-3 TRANSMISSION SELECT LEVER REPLACEMENT.................................................................................. WP 0369 Figure 1. Transmission Select Lever Removal.................................................................................... 0369-3 Figure 2. Transmission Select Lever Installation................................................................................. 0369-5 TRANSMISSION SHIFT TOWER REPLACEMENT.................................................................................... WP 0370 Figure 1. Transmission Shift Tower Removal...................................................................................... 0370-3 Figure 2. Transmission Shift Tower Installation................................................................................... 0370-5 TRANSMISSION SHIFT CABLE REPLACEMENT..................................................................................... WP 0371 Figure 1. Transmission Shift Cable Removal...................................................................................... 0371-2 lxxiii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Shift Tower Removal............................................................................................................ 0371-3 Figure 3. Engine Cover Removal........................................................................................................ 0371-4 Figure 4. Engine Cover Installation..................................................................................................... 0371-5 Figure 5. Shift Tower Installation......................................................................................................... 0371-6 Figure 6. Shift Cable Installation.......................................................................................................... 0371-7 Figure 7. Shift Cable Installation.......................................................................................................... 0371-9 TRANSMISSION REPLACEMENT (OUT-OF-VEHICLE)............................................................................ WP 0372 Figure 1. Flywheel Housing and Transmission Removal.................................................................... 0372-3 Figure 2. Transmission and Torque Convert Removal........................................................................ 0372-5 Figure 3. Transmission and Torque Converter Installation.................................................................. 0372-7 Figure 4. Flywheel and Flywheel Housing Cover Plate Installation..................................................... 0372-8 TRANSMISSION REPLACEMENT (IN-VEHICLE)...................................................................................... WP 0373 Figure 1. Transmission Flange Clamp and Wire Removal.................................................................. 0373-2 Figure 2. Transmission Support Bracket Removal.............................................................................. 0373-3 Figure 3. Transmission and Torque Converter Removal..................................................................... 0373-5 Figure 4. Transmission and Torque Converter Removal..................................................................... 0373-7 Figure 5. Transmission and Torque Converter Installation.................................................................. 0373-9 Figure 6. Torque Converter Installation............................................................................................. 0373-10 Figure 7. Transmission Power Takeoff Installation............................................................................ 0373-11 Figure 8. Transmission Flange Clamp and Wire Installation............................................................. 0373-12 TRANSMISSION OIL PRESSURE TESTING............................................................................................. WP 0374 Figure 1. Oil Cooler Pressure Test...................................................................................................... 0374-3 Figure 2. Oil Cooler Pressure Test...................................................................................................... 0374-5 Figure 3. Oil Cooler Pressure Test...................................................................................................... 0374-7 Figure 4. Main Pressure and Governor Pressure Test........................................................................ 0374-9 Figure 5. Main Pressure and Governor Pressure Test...................................................................... 0374-10 Figure 6. Main Pressure and Governor Pressure Test...................................................................... 0374-11 lxxiv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 7. Main Pressure and Governor Pressure Test...................................................................... 0374-12 Figure 8. Main Pressure and Governor Pressure Test...................................................................... 0374-13 Figure 9. Main Pressure and Governor Pressure Test...................................................................... 0374-14 Table 1. Transmission Shift Point Check......................................................................................... 0374-15 Figure 10. Main Pressure and Governor Pressure Adjustment........................................................... 0374-17 Figure 11. Transmission Oil Pressure Adjustment.............................................................................. 0374-17 Figure 12. Transmission Module Testing and Adjustment.................................................................. 0374-18 TRANSMISSION SELECTOR SHAFT OIL SEAL REPLACEMENT........................................................... WP 0375 Figure 1. Manual Control Linkage Removal........................................................................................ 0375-2 Figure 2. Seal Remover Removal....................................................................................................... 0375-3 Figure 3. Manual Control Linkage Installation..................................................................................... 0375-5 TRANSMISSION OUTPUT SHAFT YOKE AND OIL SEAL REPLACEMENT............................................ WP 0376 Figure 1. Transmission Output Shaft Yoke and Oil Seal Removal...................................................... 0376-2 Figure 2. Transmission Output Shaft Yoke and Oil Seal Installation................................................... 0376-3 TRANSMISSION OIL PAN AND FILTER REPLACEMENT........................................................................ WP 0377 Figure 1. Transmission Oil Pan and Filter Removal............................................................................ 0377-3 Figure 2. Transmission Oil Pan and Filter Removal............................................................................ 0377-5 Figure 3. Transmission Oil Pan and Filter Installation......................................................................... 0377-7 Figure 4. Transmission Oil Pan and Filter Installation......................................................................... 0377-8 TRANSMISSION LUBRICATION VALVE REPLACEMENT........................................................................ WP 0378 Figure 1. Front Winch Hoses Removal................................................................................................ 0378-2 Figure 2. Transmission Lubrication Valve Removal............................................................................ 0378-3 Figure 3. Transmission Lubrication Valve Installation......................................................................... 0378-4 Figure 4. Transmission Lubrication Valve Installation......................................................................... 0378-5 Figure 5. Front Winch Hoses Installation............................................................................................. 0378-5 TRANSMISSION FIFTH GEAR LOCK-IN SOLENOID REPLACEMENT.................................................... WP 0379 Figure 1. Transmission Fifth Gear Lock-in Solenoid Removal............................................................ 0379-3 lxxv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Governor and Main Pressure Lines Installation................................................................... 0379-4 TRANSMISSION OIL COOLER AND MOUNT REPLACEMENT (M939/A1).............................................. WP 0380 Figure 1. Oil Cooler Removal.............................................................................................................. 0380-2 Figure 2. Oil Cooler Removal.............................................................................................................. 0380-3 Figure 3. Oil Cooler Removal.............................................................................................................. 0380-3 Figure 4. Oil Cooler Removal.............................................................................................................. 0380-4 TRANSMISSION OIL COOLER FILTER AND HEAD REPAIR................................................................... WP 0381 Figure 1. Oil Cooler Filter Removal..................................................................................................... 0381-2 Figure 2. Oil Filter Cooler Head Removal............................................................................................ 0381-3 Figure 3. Oil Cooler Filter Head Installation......................................................................................... 0381-4 Figure 4. Oil Cooler Filter Installation.................................................................................................. 0381-5 TRANSMISSION OIL COOLER HOSES REPLACEMENT......................................................................... WP 0382 Figure 1. Oil Cooler Hoses Removal................................................................................................... 0382-3 Figure 2. Oil Cooler Hoses Removal................................................................................................... 0382-4 Figure 3. Oil Cooler Hoses Removal................................................................................................... 0382-5 Figure 4. Oil Cooler Hoses Removal................................................................................................... 0382-7 Figure 5. Oil Cooler Hoses Installation................................................................................................ 0382-9 Figure 6. Oil Cooler Hoses Installation.............................................................................................. 0382-10 Figure 7. Oil Cooler Hoses Installation.............................................................................................. 0382-11 Figure 8. Oil Cooler Hoses Installation.............................................................................................. 0382-12 TRANSMISSION OIL COOLER AND MOUNT REPLACEMENT (M939A2)............................................... WP 0383 Figure 1. Oil Cooler and Mount Removal............................................................................................ 0383-3 Figure 2. Oil Cooler and Mount Installation......................................................................................... 0383-5 TRANSMISSION BREATHER REPLACEMENT......................................................................................... WP 0384 Figure 1. Transmission Breather Removal.......................................................................................... 0384-2 Figure 2. Transmission Breather Installation....................................................................................... 0384-3 TRANSFER CASE REPLACEMENT (ALL EXCEPT M936/A1/A2)............................................................. WP 0385 lxxvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Transfer Case Components Removal.................................................................................. 0385-2 Figure 2. Transfer Case Brackets and Fittings Removal..................................................................... 0385-3 Figure 3. Transfer Case Brackets and Fittings Removal..................................................................... 0385-4 Figure 4. Transfer Case Components Removal.................................................................................. 0385-5 Figure 5. Transfer Case Components Removal.................................................................................. 0385-6 Figure 6. Transfer Case Brackets and Fittings Removal..................................................................... 0385-7 Figure 7. Transfer Case Brackets and Fittings Removal..................................................................... 0385-9 Figure 8. Transfer Case Brackets and Fittings Installation................................................................ 0385-11 Figure 9. Transfer Case Components Installation............................................................................. 0385-12 Figure 10. Transfer Case Components Installation............................................................................. 0385-13 Figure 11. Transfer Case Components Installation............................................................................. 0385-14 Figure 12. Transfer Case Components Installation............................................................................. 0385-15 Figure 13. Transfer Case Components Installation............................................................................. 0385-16 Figure 14. Transfer Case Cables Installation...................................................................................... 0385-17 TRANSFER CASE REPLACEMENT (M936/A1/A2).................................................................................... WP 0386 Figure 1. Transfer Case Power Takeoff Removal............................................................................... 0386-2 Figure 2. Transfer Case Power Takeoff Removal............................................................................... 0386-3 Figure 3. Transfer Case Power Takeoff Removal............................................................................... 0386-5 Figure 4. Transfer Case Power Takeoff Removal............................................................................... 0386-6 Figure 5. Transfer Case Power Takeoff Removal............................................................................... 0386-7 Figure 6. Transfer Case Power Takeoff Removal............................................................................... 0386-8 Figure 7. Transfer Case Lines and Cables Removal........................................................................... 0386-9 Figure 8. Transfer Case Brackets Removal...................................................................................... 0386-11 Figure 9. Transfer Case Brackets Removal...................................................................................... 0386-13 Figure 10. Transfer Case Brackets Installation................................................................................... 0386-15 Figure 11. Transfer Case Brackets Installation................................................................................... 0386-16 Figure 12. Transfer Case Lines and Cables Installation...................................................................... 0386-17 lxxvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 13. Transfer Case Lines and Cables Installation...................................................................... 0386-18 Figure 14. Transfer Case Lines and Cables Installation...................................................................... 0386-19 Figure 15. Transfer Case Lines and Cables Installation...................................................................... 0386-20 Figure 16. Transfer Case Lines and Cables Installation...................................................................... 0386-21 Figure 17. Transfer Case Power Takeoff Installation.......................................................................... 0386-22 Figure 18. Transfer Case Power Takeoff Installation.......................................................................... 0386-23 Figure 19. Transfer Case Power Takeoff Installation.......................................................................... 0386-24 TRANSFER CASE SPEEDOMETER DRIVE GEAR AND DRIVEN SHAFT REPLACEMENT................... WP 0387 Figure 1. Transfer Case Speedometer Drive Gear and Driven Shaft Removal................................... 0387-3 Figure 2. Transfer Case Speedometer Drive Gear and Driven Shaft Installation................................ 0387-4 TRANSFER CASE FRONT AXLE ENGAGEMENT CONTROL VALVE REPLACEMENT......................... WP 0388 Figure 1. Transfer Case Front Axle Engagement Valve Removal....................................................... 0388-2 Figure 2. Transfer Case Front Axle Engagement Valve Installation.................................................... 0388-3 TRANSFER CASE FRONT AXLE LOCK-IN CONTROL VALVE REPLACEMENT.................................... WP 0389 Figure 1. Control Valve Removal......................................................................................................... 0389-3 Figure 2. Control Valve Installation...................................................................................................... 0389-4 TRANSFER CASE INTERLOCK AIR CYLINDER REPLACEMENT........................................................... WP 0390 Figure 1. Transfer Case Interlock Air Cylinder Removal..................................................................... 0390-3 Figure 2. Transfer Case Interlock Air Cylinder Installation.................................................................. 0390-4 TRANSFER CASE FRONT AXLE ENGAGEMENT AIR CYLINDER REPLACEMENT.............................. WP 0391 Figure 1. Transfer Case Front Axle Engagement Air Cylinder Removal............................................. 0391-3 Figure 2. Transfer Case Front Axle Engagement Air Cylinder Installation.......................................... 0391-5 FRONT-WHEEL DRIVE LOCK-IN SWITCH REPLACEMENT.................................................................... WP 0392 Figure 1. Front-Wheel Drive Lock-In Switch Removal......................................................................... 0392-3 Figure 2. Front-Wheel Drive Lock-In Switch Installation...................................................................... 0392-4 FRONT WHEEL VALVE REPLACEMENT (M939A2)................................................................................. WP 0393 Figure 1. Front Wheel Valve Removal................................................................................................. 0393-3 lxxviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Front Wheel Valve Installation.............................................................................................. 0393-5 TRANSFER CASE INTERLOCK VALVE REPLACEMENT (ALL EXCEPT M936/A1/A2)........................... WP 0394 Figure 1. Transfer Case Interlock Valve Removal (Except M936/A1/A2)............................................ 0394-3 Figure 2. Transfer Case Interlock Valve Installation (Except M936/A1/A2)......................................... 0394-5 TRANSFER CASE INTERLOCK VALVE REPLACEMENT (M936/A1/A2)................................................. WP 0395 Figure 1. Transfer Case Interlock Valve Removal (M936/A1/A2)........................................................ 0395-2 Figure 2. Transfer Case Interlock Valve Installation (M936/A1/A2)..................................................... 0395-3 TRANSFER CASE CONTROLS AND LINKAGE REPAIR.......................................................................... WP 0396 Figure 1. Transfer Case Shift Lever Removal..................................................................................... 0396-3 Figure 2. Transfer Case Shift Lever Installation.................................................................................. 0396-4 Figure 3. Transfer Case Shift Lever Shift Rod Removal..................................................................... 0396-5 Figure 4. Transfer Case Shift Lever Shift Rod Installation.................................................................. 0396-6 Figure 5. Transfer Case Cross Shaft Removal.................................................................................... 0396-7 Figure 6. Transfer Case Cross Shaft Installation................................................................................. 0396-9 Figure 7. Transfer Case Shift Rod Removal...................................................................................... 0396-11 Figure 8. Transfer Case Shift Rod Installation................................................................................... 0396-12 Figure 9. Transfer Case Switch Removal.......................................................................................... 0396-13 Figure 10. Transfer Case Switch Installation....................................................................................... 0396-14 TRANSFER CASE CAPACITOR REPLACEMENT..................................................................................... WP 0397 Figure 1. Transfer Case Capacitor Removal....................................................................................... 0397-2 Figure 2. Transfer Case Capacitor Installation.................................................................................... 0397-3 TRANSFER CASE TRANSORB DIODE REPLACEMENT......................................................................... WP 0398 Figure 1. Transfer Case Transorb Diode Removal.............................................................................. 0398-3 Figure 2. Transfer Case Transorb Diode Installation........................................................................... 0398-4 TRANSFER CASE OIL PUMP REPLACEMENT......................................................................................... WP 0399 Figure 1. Transfer Case Oil Pump Removal........................................................................................ 0399-2 Figure 2. Transfer Case Oil Pump Installation..................................................................................... 0399-3 lxxix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. FORWARD-REAR TO REAR-REAR PROPELLER SHAFT REPLACEMENT............................................ WP 0400 Figure 1. Rear Propeller Shaft Removal.............................................................................................. 0400-2 Figure 2. Rear Propeller Shaft Installation........................................................................................... 0400-3 TRANSFER CASE TO FORWARD-REAR AXLE PROPELLER SHAFT REPAIR...................................... WP 0401 Figure 1. Forward-Rear Propeller Shaft Removal............................................................................... 0401-3 Figure 2. Propeller Shaft and Bracket Removal.................................................................................. 0401-5 Figure 3. Propeller Shaft Disassembly................................................................................................ 0401-7 Figure 4. Propeller Shaft Assembly..................................................................................................... 0401-9 Figure 5. Propeller Shaft and Bracket Installation............................................................................. 0401-11 Figure 6. Propeller Shaft Installation................................................................................................. 0401-13 TRANSFER CASE TO FRONT AXLE PROPELLER SHAFT REPAIR....................................................... WP 0402 Figure 1. Propeller Shaft Removal...................................................................................................... 0402-3 Figure 2. Propeller Shaft Installation................................................................................................... 0402-5 TRANSMISSION TO TRANSFER CASE PROPELLER SHAFT REPAIR................................................... WP 0403 Figure 1. Transmission To Transfer Case Propeller Shaft Removal................................................... 0403-2 Figure 2. Propeller Shaft Removal...................................................................................................... 0403-3 Figure 3. Yoke Disassembly................................................................................................................ 0403-4 Figure 4. Yoke Disassembly................................................................................................................ 0403-4 Figure 5. Yoke Assembly..................................................................................................................... 0403-5 Figure 6. Yoke Assembly..................................................................................................................... 0403-5 Figure 7. Propellor Shaft Installation................................................................................................... 0403-6 Figure 8. Propellor Shaft Installation................................................................................................... 0403-7 FRONT AXLE REPLACEMENT.................................................................................................................. WP 0404 Figure 1. Front Axle Removal.............................................................................................................. 0404-3 Figure 2. Front Axle Removal.............................................................................................................. 0404-5 Figure 3. Front Axle Installation........................................................................................................... 0404-7 Figure 4. Front Axle Installation........................................................................................................... 0404-9 lxxx 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. FRONT AXLE BREATHER REPLACEMENT.............................................................................................. WP 0405 Figure 1. Front Axle Breather Removal............................................................................................... 0405-1 Figure 2. Front Axle Breather Installation............................................................................................ 0405-2 FRONT AND REAR AXLE CARRIER DIFFERENTIAL REPLACEMENT................................................... WP 0406 Figure 1. Front and Rear Axle Carrier Differential Removal................................................................ 0406-3 Figure 2. Front and Rear Axle Carrier Differential Installation............................................................. 0406-4 FRONT DIFFERENTIAL OIL SEAL REPLACEMENT................................................................................. WP 0407 Figure 1. Front Differential Oil Seal Removal...................................................................................... 0407-2 Figure 2. Front Differential Oil Seal Installation................................................................................... 0407-3 FRONT AXLE DRIVE COMPANION FLANGE REPLACEMENT................................................................ WP 0408 Figure 1. Front Axle Drive Companion Flange Removal..................................................................... 0408-1 Figure 2. Front Axle Drive Companion Flange Inspection................................................................... 0408-2 Figure 3. Front Axle Drive Companion Flange Installation.................................................................. 0408-3 STEERING KNUCKLE BOOT REPLACEMENT......................................................................................... WP 0409 Figure 1. Steering Knuckle Boot Removal........................................................................................... 0409-1 Figure 2. Steering Knuckle Boot Removal........................................................................................... 0409-2 Figure 3. Steering Knuckle Boot Installation........................................................................................ 0409-3 Figure 4. Steering Knuckle Boot Installation........................................................................................ 0409-4 FRONT AXLE SEAL REPLACEMENT........................................................................................................ WP 0410 Figure 1. Front Axle Seal Removal...................................................................................................... 0410-2 Figure 2. Front Axle Seal Installation................................................................................................... 0410-3 FRONT AXLE SHAFT AND UNIVERSAL JOINT REPLACEMENT............................................................ WP 0411 Figure 1. Front Axle Shaft Removal.................................................................................................... 0411-3 Figure 2. Front Axle Shaft Inspection.................................................................................................. 0411-4 Figure 3. Front Axle Shaft Inspection.................................................................................................. 0411-5 Figure 4. Front Axle Shaft Installation................................................................................................. 0411-7 STEERING KNUCKLE REPAIR.................................................................................................................. WP 0412 lxxxi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Steering Knuckle Removal................................................................................................... 0412-3 Figure 2. Steering Knuckle Cleaning/Inspection.................................................................................. 0412-5 Figure 3. Steering Knuckle Installation................................................................................................ 0412-7 Figure 4. Steering Knuckle Installation................................................................................................ 0412-9 Figure 5. End Play Test..................................................................................................................... 0412-11 SPINDLE BEARING SLEEVE REPLACEMENT......................................................................................... WP 0413 Figure 1. Spindle Bearing Sleeve Removal......................................................................................... 0413-1 Figure 2. Spindle Bearing Sleeve Installation...................................................................................... 0413-2 FORWARD-REAR AND REAR-REAR AXLE REPLACEMENT.................................................................. WP 0414 Figure 1. Forward-Rear and Rear-Rear Axle Removal....................................................................... 0414-3 Figure 2. Axle on Jack Stand Removal............................................................................................... 0414-5 Figure 3. Axle on Jack Stand Removal............................................................................................... 0414-7 Figure 4. Forward-Rear and Rear-Rear Brackets Installation............................................................. 0414-9 Figure 5. Forward-Rear and Rear-Rear Brackets Installation........................................................... 0414-11 Figure 6. Axle Lines and Fittings Installation..................................................................................... 0414-12 Figure 7. Axle Lines and Fittings Installation..................................................................................... 0414-13 FORWARD-REAR AND REAR-REAR AXLE LEAKAGE TEST.................................................................. WP 0415 Figure 1. Axle Leakage Test................................................................................................................ 0415-3 REAR AXLE BREATHER REPLACEMENT................................................................................................ WP 0416 Figure 1. Rear Axle Breather Removal................................................................................................ 0416-1 Figure 2. Rear Axle Breather Installation............................................................................................. 0416-2 REAR AXLE SHAFT REPLACEMENT........................................................................................................ WP 0417 Figure 1. Rear Axle Shaft Removal..................................................................................................... 0417-1 Figure 2. Rear Axle Shaft Installation.................................................................................................. 0417-2 REAR DIFFERENTIAL OIL SEAL REPLACEMENT................................................................................... WP 0418 Figure 1. Rear Differential Oil Seal Removal....................................................................................... 0418-2 Figure 2. Rear Differential Oil Seal Installation.................................................................................... 0418-3 lxxxii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. CARRIER DIFFERENTIAL TOP COVER GASKET AND SIDE COVER GASKET REPLACEMENT.......................................................................................................................................... WP 0419 Figure 1. Top Cover Gasket Removal................................................................................................. 0419-2 Figure 2. Top Cover Gasket Removal................................................................................................. 0419-3 Figure 3. Top Cover Gasket Installation.............................................................................................. 0419-4 Figure 4. Top Cover Gasket Installation.............................................................................................. 0419-5 Figure 5. Side Cover Gasket Removal................................................................................................ 0419-6 Figure 6. Side Cover Gasket Installation............................................................................................. 0419-7 PARKING BRAKE ADJUSTMENT.............................................................................................................. WP 0420 Figure 1. Parking Brake Test............................................................................................................... 0420-2 Figure 2. Parking Brake Minor Adjustment.......................................................................................... 0420-3 Figure 3. Parking Brake Major Adjustment.......................................................................................... 0420-4 Figure 4. Parking Brake Lever Arm Adjustment.................................................................................. 0420-5 PARKING BRAKE CABLE AND BRACKET REPLACEMENT.................................................................... WP 0421 Figure 1. Parking Brake Cable and Bracket Removal......................................................................... 0421-2 Figure 2. Parking Brake Cable and Bracket Removal......................................................................... 0421-3 Figure 3. Parking Brake Cable and Bracket Installation...................................................................... 0421-4 Figure 4. Parking Brake Cable and Bracket Installation...................................................................... 0421-5 PARKING BRAKE SHOES REPLACEMENT.............................................................................................. WP 0422 Figure 1. Parking Brake Shoe Removal.............................................................................................. 0422-2 Figure 2. Parking Brake Shoe Removal.............................................................................................. 0422-3 Figure 3. Parking Brake Shoe Cleaning and Inspection...................................................................... 0422-4 Figure 4. Parking Brake Shoe Installation........................................................................................... 0422-5 Figure 5. Parking Brake Shoe Installation........................................................................................... 0422-6 PARKING BRAKE DRUM DUST COVER REPLACEMENT....................................................................... WP 0423 Figure 1. Parking Brake Drum Dust Cover Removal........................................................................... 0423-2 Figure 2. Parking Brake Drum Dust Cover Installation........................................................................ 0423-3 WHEEL BRAKE DRUM DUST COVERS REPLACEMENT........................................................................ WP 0424 lxxxiii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Wheel Dust Covers Removal............................................................................................... 0424-2 Figure 2. Wheel Dust Covers Removal............................................................................................... 0424-3 Figure 3. Wheel Dust Covers Installation............................................................................................ 0424-4 Figure 4. Wheel Dust Covers Installation............................................................................................ 0424-5 PARKING BRAKE LEVER REPLACEMENT............................................................................................... WP 0425 Figure 1. Parking Brake Lever Removal.............................................................................................. 0425-3 Figure 2. Parking Brake Lever Installation........................................................................................... 0425-5 BRAKE SHOE REPLACEMENT.................................................................................................................. WP 0426 Figure 1. Brake Shoe Removal........................................................................................................... 0426-2 Figure 2. Brake Shoe Installation........................................................................................................ 0426-3 FRONT BRAKE SPIDER AND ACTUATOR REPAIR................................................................................. WP 0427 Figure 1. Front Brake Spider Removal................................................................................................ 0427-3 Figure 2. Actuators Disassembly......................................................................................................... 0427-5 Figure 3. Actuators Assembly.............................................................................................................. 0427-9 Figure 4. Front Brake Spider Installation........................................................................................... 0427-11 REAR BRAKE SPIDER AND ACTUATOR REPAIR.................................................................................... WP 0428 Figure 1. Rear Brake Spider Removal................................................................................................. 0428-2 Figure 2. Rear Brake Actuator Disassembly....................................................................................... 0428-3 Figure 3. Seal Assembly...................................................................................................................... 0428-5 Figure 4. Seal Assembly...................................................................................................................... 0428-6 Figure 5. Rear Brake Actuator Assembly............................................................................................ 0428-7 Figure 6. Rear Brake Spider Installation.............................................................................................. 0428-9 BRAKE PEDAL (TREADLE) VALVE REPLACEMENT (ALL EXCEPT M936/A1/A2)................................. WP 0429 Figure 1. Brake Pedal Removal........................................................................................................... 0429-2 Figure 2. Brake Pedal Removal........................................................................................................... 0429-3 Figure 3. Brake Pedal Removal........................................................................................................... 0429-4 Figure 4. Brake Pedal Removal........................................................................................................... 0429-5 lxxxiv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 5. Brake Pedal Installation........................................................................................................ 0429-6 Figure 6. Brake Pedal Installation........................................................................................................ 0429-7 Figure 7. Brake Pedal Installation........................................................................................................ 0429-8 Figure 8. Brake Pedal Installation........................................................................................................ 0429-9 BRAKE PEDAL (TREADLE) VALVE REPLACEMENT (M936/A1/A2)........................................................ WP 0430 Figure 1. Cab Air Lines Removal......................................................................................................... 0430-2 Figure 2. Air Lines Removal................................................................................................................ 0430-3 Figure 3. Brake Valve Removal........................................................................................................... 0430-4 Figure 4. Valve Removal..................................................................................................................... 0430-5 Figure 5. Brake Valve Installation........................................................................................................ 0430-6 Figure 6. Brake Valve Installation........................................................................................................ 0430-7 Figure 7. Brake Valve Installation........................................................................................................ 0430-8 Figure 8. Brake Pedal Installation........................................................................................................ 0430-9 SPRING PARKING BRAKE VALVE REPAIR.............................................................................................. WP 0431 Figure 1. Spring Parking Brake Valve Removal.................................................................................. 0431-3 Figure 2. Spring Parking Brake Valve Adjustment.............................................................................. 0431-4 Figure 3. Spring Parking Brake Valve Installation............................................................................... 0431-5 BRAKE MECHANISM ADJUSTMENTS...................................................................................................... WP 0432 Figure 1. Front Brake Check and Adjustment..................................................................................... 0432-3 Figure 2. Rear Brake Check and Adjustment...................................................................................... 0432-4 Figure 3. Brake Shoe Check............................................................................................................... 0432-5 BRAKE PEDAL REPLACEMENT................................................................................................................ WP 0433 Figure 1. Brake Pedal Removal........................................................................................................... 0433-2 Figure 2. Brake Pedal Installation........................................................................................................ 0433-3 Figure 3. Brake Pedal Adjustment....................................................................................................... 0433-4 SERVICE BRAKE CHAMBER REPLACEMENT......................................................................................... WP 0434 Figure 1. Service Brake Chamber Removal........................................................................................ 0434-2 lxxxv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Service Brake Chamber Removal........................................................................................ 0434-3 Figure 3. Service Brake Chamber Removal........................................................................................ 0434-3 Figure 4. Service Brake Chamber Installation..................................................................................... 0434-4 Figure 5. Service Brake Chamber Installation..................................................................................... 0434-5 Figure 6. Service Brake Chamber Installation..................................................................................... 0434-6 COMBINATION SPRING (EMERGENCY) AND SERVICE BRAKE CHAMBER REPLACEMENT.......................................................................................................................................... WP 0435 Figure 1. Service Brake Chamber Removal........................................................................................ 0435-3 Figure 2. Brake Chamber Disassembly............................................................................................... 0435-4 Figure 3. Brake Chamber Assembly.................................................................................................... 0435-5 Figure 4. Service Brake Chamber Installation..................................................................................... 0435-6 AIR GOVERNOR REPLACEMENT............................................................................................................. WP 0436 Figure 1. Air Governor Removal.......................................................................................................... 0436-2 Figure 2. Air Governor Installation....................................................................................................... 0436-3 Figure 3. Air Governor Testing............................................................................................................ 0436-4 Figure 4. Air Governor Testing............................................................................................................ 0436-5 Figure 5. Air Governor Adjustment...................................................................................................... 0436-6 AIR RESERVOIR ONE-WAY CHECK VALVE REPLACEMENT................................................................ WP 0437 Figure 1. Air Reservoir One-Way Check Valve Removal.................................................................... 0437-2 Figure 2. Air Reservoir One-Way Check Valve Installation................................................................. 0437-3 BRAKE CHAMBER AIR MANIFOLD TEE REPLACEMENT....................................................................... WP 0438 Figure 1. Brake Chamber Air Manifold Tee Replacement Removal.................................................... 0438-3 Figure 2. Brake Chamber Air Manifold Tee Replacement Installation................................................. 0438-5 FRONT LIMITING VALVE REPLACEMENT............................................................................................... WP 0439 Figure 1. Front Limiting Valve Replacement Removal........................................................................ 0439-2 Figure 2. Front Limiting Valve Replacement Installation..................................................................... 0439-3 PRIMARY AIR RESERVOIR (SUPPLY TANK) REPLACEMENT............................................................... WP 0440 Figure 1. Air Reservoir Removal......................................................................................................... 0440-3 lxxxvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Air Reservoir Installation...................................................................................................... 0440-4 SECONDARY AIR RESERVOIR (SUPPLY TANK) REPLACEMENT......................................................... WP 0441 Figure 1. Secondary Air Reservoir Removal....................................................................................... 0441-3 Figure 2. Secondary Air Reservoir Installation.................................................................................... 0441-5 WET AIR RESERVOIR (SUPPLY TANK) AND BRACKET REPLACEMENT............................................. WP 0442 Figure 1. Air Tank Removal................................................................................................................. 0442-3 Figure 2. Air Tank Removal................................................................................................................. 0442-5 Figure 3. Air Tank Installation.............................................................................................................. 0442-7 Figure 4. Air Line Installation............................................................................................................... 0442-9 WET AIR RESERVOIR (SUPPLY TANK) AND MOUNTING PLATE REPLACEMENT (M936/A1/ A2)............................................................................................................................................................... WP 0443 Figure 1. Wet Air Reservoir Removal.................................................................................................. 0443-3 Figure 2. Wet Air Reservoir Removal.................................................................................................. 0443-5 Figure 3. Wet Air Reservoir Installation............................................................................................... 0443-7 Figure 4. Wet Air Reservoir Installation............................................................................................... 0443-8 EMERGENCY SPRING BRAKE (SUPPLY TANK) AIR RESERVOIR REPLACEMENT............................ WP 0444 Figure 1. Air Reservoir Removal......................................................................................................... 0444-3 Figure 2. Air Reservoir Installation...................................................................................................... 0444-4 BRAKE PROPORTIONING VALVE REPLACEMENT................................................................................. WP 0445 Figure 1. Brake Proportioning Valve Removal.................................................................................... 0445-3 Figure 2. Brake Proportioning Valve Installation................................................................................. 0445-5 AIR RESERVOIR DRAIN VALVES REPLACEMENT.................................................................................. WP 0446 Figure 1. Air Reservoir Drain Valves Removal.................................................................................... 0446-3 Figure 2. Air Reservoir Drain Valves Installation................................................................................. 0446-4 FAN DRIVE CLUTCH ACTUATOR REPLACEMENT (M939/A1)................................................................ WP 0447 Figure 1. Fan Drive Actuator Removal................................................................................................ 0447-3 Figure 2. Fan Drive Actuator Installation............................................................................................. 0447-5 FAN CLUTCH ACTUATOR REPLACEMENT............................................................................................. WP 0448 lxxxvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Fan Clutch Actuator Removal.............................................................................................. 0448-2 Figure 2. Fan Clutch Actuator Removal.............................................................................................. 0448-3 Figure 3. Fan Clutch Actuator Installation........................................................................................... 0448-4 Figure 4. Fan Clutch Actuator Installation........................................................................................... 0448-5 SPRING BRAKE DASH CONTROL VALVE REPLACEMENT.................................................................... WP 0449 Figure 1. Spring Brake Dash Control Valve Removal......................................................................... 0449-3 Figure 2. Spring Brake Dash Control Valve Installation...................................................................... 0449-4 AIR COUPLINGS REPLACEMENT............................................................................................................. WP 0450 Figure 1. Front Air Coupling Removal................................................................................................. 0450-3 Figure 2. Rear Air Couplings Removal (M923/A1/A2)......................................................................... 0450-5 Figure 3. Rear Air Couplings Removal (M929/A1/A2, M931/A1/A2, M934/A1/A2, M936/ A1/A2).................................................................................................................................. 0450-7 Figure 4. Front Air Coupling Installation.............................................................................................. 0450-9 Figure 5. Rear Air Couplings Installation (M923/A1/A2).................................................................... 0450-11 Figure 6. Rear Air Couplings Installation (M929/A1/A2, M931/A1,A2, M934/A1/A2, M936/A1/A2)...................................................................................................................... 0450-13 WET RESERVOIR (SUPPLY TANK) SAFETY VALVE REPLACEMENT................................................... WP 0451 Figure 1. Safety Valve Removal.......................................................................................................... 0451-2 Figure 2. Safety Valve Installation....................................................................................................... 0451-3 ABS ELECTRONIC CONTROL UNIT (ECU) REPLACEMENT................................................................... WP 0452 Figure 1. ABS Electronic Control Unit Removal.................................................................................. 0452-2 Figure 2. ABS Electronic Control Unit Installation............................................................................... 0452-3 ABS DOUBLE CHECK VALVE NO. 5 REPLACEMENT............................................................................. WP 0453 Figure 1. Double Check Valve No. 5 Removal.................................................................................... 0453-2 Figure 2. Double Check Valve No. 5 Installation................................................................................. 0453-3 ABS DOUBLE CHECK VALVE NO. 6 REPLACEMENT............................................................................. WP 0454 Figure 1. Double Check Valve No. 6 Removal.................................................................................... 0454-3 Figure 2. Double Check Valve No. 6 Installation................................................................................. 0454-4 lxxxviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. ABS DOUBLE CHECK VALVE NO. 7 REPLACEMENT............................................................................. WP 0455 Figure 1. Double Check Valve No. 7 Removal.................................................................................... 0455-3 Figure 2. Double Check Valve No. 7 Installation................................................................................. 0455-4 BRAKE LQ-2 VALVE REPLACEMENT....................................................................................................... WP 0456 Figure 1. Brake LQ-2 Valve Removal.................................................................................................. 0456-3 Figure 2. Brake LQ-2 Valve Installation............................................................................................... 0456-5 REAR ABS RELAY VALVE REPLACEMENT ............................................................................................ WP 0457 Figure 1. Rear ABS Relay Valve Removal.......................................................................................... 0457-3 Figure 2. Rear ABS Relay Valve Installation....................................................................................... 0457-4 FORWARD ABS RELAY VALVE WITH ECU REPLACEMENT.................................................................. WP 0458 Figure 1. Forward ABS Relay Valve Removal..................................................................................... 0458-3 Figure 2. Forward ABS Relay Valve Installation.................................................................................. 0458-5 INVERSION VALVE REPLACEMENT......................................................................................................... WP 0459 Figure 1. Immersion Valve Removal................................................................................................... 0459-3 Figure 2. Inversion Valve Installation................................................................................................... 0459-5 AIR SUPPLY LINE SAFETY VALVE REPLACEMENT............................................................................... WP 0460 Figure 1. Air Supply Line Safety Valve Removal................................................................................. 0460-2 Figure 2. Air Supply Line Safety Valve Installation.............................................................................. 0460-3 GOVERNOR CONTROL AIR LINE REPLACEMENT................................................................................. WP 0461 Figure 1. Governor Control Air Line Removal..................................................................................... 0461-2 Figure 2. Governor Control Air Line Removal..................................................................................... 0461-3 Figure 3. Governor Control Air Line Installation.................................................................................. 0461-4 Figure 4. Governor Control Air Line Installation.................................................................................. 0461-5 AIR LINE CROSS FITTING REPLACEMENT............................................................................................. WP 0462 Figure 1. Air Line Cross Fitting Removal............................................................................................. 0462-3 Figure 2. Air Line Cross Fitting Installation.......................................................................................... 0462-4 ABS 3-AMP FUSE AND Y LEAD CONNECTOR REPLACEMENT............................................................. WP 0463 lxxxix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. ABS 3-AMP Fuse and Y-Connector Lead Removal............................................................. 0463-2 Figure 2. ABS 3-AMP Fuse and Y-Connector Lead Installation.......................................................... 0463-3 ABS 15-AMP FUSE AND JUMPER LEAD REPLACEMENT...................................................................... WP 0464 Figure 1. 15-AMP Fuse and Jumper Lead Removal........................................................................... 0464-2 Figure 2. 15-AMP Fuse and Jumper Lead Installation........................................................................ 0464-3 ABS GROUND JUMPER LEAD REPLACEMENT....................................................................................... WP 0465 Figure 1. ABS Ground Jumper Lead Removal.................................................................................... 0465-2 Figure 2. ABS Ground Jumper Lead Installation................................................................................. 0465-3 ABS INDICATOR LAMP REPLACEMENT.................................................................................................. WP 0466 Figure 1. ABS Indicator Lamp Removal.............................................................................................. 0466-2 Figure 2. ABS Indicator Lamp Installation........................................................................................... 0466-3 ABS ECU MAIN WIRING HARNESS REPLACEMENT.............................................................................. WP 0467 Figure 1. ABS ECU Main Wiring Harness Removal............................................................................ 0467-3 Figure 2. ABS ECU Main Wiring Harness Removal............................................................................ 0467-4 Figure 3. ABS ECU Main Wiring Harness Removal............................................................................ 0467-5 Figure 4. ABS ECU Main Wiring Harness Installation......................................................................... 0467-6 Figure 5. ABS ECU Main Wiring Harness Installation......................................................................... 0467-7 Figure 6. ABS ECU Main Wiring Harness Installation......................................................................... 0467-9 ABS WHEEL SENSOR AND BRACKET REPLACEMENT......................................................................... WP 0468 Figure 1. ABS Wheel Sensor and Bracket Removal........................................................................... 0468-3 Figure 2. ABS Wheel Sensor and Bracket Installation........................................................................ 0468-5 REAR ABS RELAY EXCITER RING REPLACEMENT............................................................................... WP 0469 Figure 1. Rear ABS Exciter Ring Removal.......................................................................................... 0469-2 Figure 2. Rear ABS Exciter Ring Installation....................................................................................... 0469-3 AIR COMPRESSOR AND LINES REPLACEMENT (M939A2)................................................................... WP 0470 Figure 1. Power Steering Pump Removal........................................................................................... 0470-2 Figure 2. Power Steering Pump Removal........................................................................................... 0470-3 xc 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Power Steering Pump Removal........................................................................................... 0470-4 Figure 4. Air Compressor Installation.................................................................................................. 0470-5 Figure 5. Air Compressor Installation.................................................................................................. 0470-6 Figure 6. Air Compressor Installation.................................................................................................. 0470-7 AIR COMPRESSOR COOLANT LINES REPLACEMENT (M939A2)......................................................... WP 0471 Figure 1. Air Compressor Coolant Lines Removal.............................................................................. 0471-3 Figure 2. Air Compressor Coolant Lines Installation........................................................................... 0471-4 TRAILER AIRBRAKE HAND CONTROL VALVE REPLACEMENT (M931/A1/A2, M932/A1/ A2)............................................................................................................................................................... WP 0472 Figure 1. Trailer Airbrake Hand Control Valve Removal..................................................................... 0472-3 Figure 2. Trailer Airbrake Hand Control Valve Installation.................................................................. 0472-4 DOUBLE CHECK VALVE NO. 1 REPLACEMENT...................................................................................... WP 0473 Figure 1. Double Check Valve No. 1 Removal.................................................................................... 0473-2 Figure 2. Double Check Valve No. 1 Installation................................................................................. 0473-4 DOUBLE CHECK VALVE NO. 2 REPLACEMENT...................................................................................... WP 0474 Figure 1. Double Check Valve No. 2 Installation................................................................................. 0474-3 Figure 2. Double Check Valve No. 2 Installation................................................................................. 0474-5 DOUBLE CHECK VALVE NO. 2 REPLACEMENT (M931/A1/A2, AND M932/A1/A2)................................ WP 0475 Figure 1. Double Check Valve No. 2 Removal.................................................................................... 0475-3 Figure 2. Double Check Valve No. 2 Installation................................................................................. 0475-5 DOUBLE CHECK VALVE NO. 5 REPLACEMENT (M931/A1/A2, AND M932/A1/A2)................................ WP 0476 Figure 1. Double Check Valve No. 5 Removal.................................................................................... 0476-3 Figure 2. Double Check Valve No. 5 Installation................................................................................. 0476-5 DOUBLE CHECK VALVE NO. 3, NO. 4, AND QUICK-RELEASE VALVE REPLACEMENT...................... WP 0477 Figure 1. Double Check Valve Removal.............................................................................................. 0477-2 Figure 2. Double Check Valve Removal.............................................................................................. 0477-3 Figure 3. Double Check Valve Installation........................................................................................... 0477-4 Figure 4. Double Check Valve Installation........................................................................................... 0477-5 xci 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. EMERGENCY AND TRAILER COUPLING HOSES REPLACEMENT (M931/A1/A2, M932/A1/ A2)............................................................................................................................................................... WP 0478 Figure 1. Emergency and Trailer Coupling Hoses Removal............................................................... 0478-3 Figure 2. Emergency and Trailer Coupling Hoses Installation............................................................ 0478-5 FRONT HUB AND DRUM REPLACEMENT (M939/A1).............................................................................. WP 0479 Figure 1. Front Hub Drum Removal.................................................................................................... 0479-2 Figure 2. Front Hub and Drum Replacement...................................................................................... 0479-3 Figure 3. Front Hub and Drum Replacement...................................................................................... 0479-3 Figure 4. Front Hub Drum Installation................................................................................................. 0479-5 REAR HUB AND DRUM REPLACEMENT (M939/A1)................................................................................ WP 0480 Figure 1. Rear Hub and Drum Removal.............................................................................................. 0480-2 Figure 2. Rear Hub and Drum Removal.............................................................................................. 0480-3 Figure 3. Dust Shield Removal............................................................................................................ 0480-3 Figure 4. Dust Shield Installation......................................................................................................... 0480-5 Figure 5. Rear Hub and Drum Installation........................................................................................... 0480-6 Figure 6. Rear Hub and Drum Installation........................................................................................... 0480-7 FRONT HUBS REPLACEMENT.................................................................................................................. WP 0481 Figure 1. Front Hubs Removal............................................................................................................ 0481-3 Figure 2. Front Hubs Repair................................................................................................................ 0481-5 Figure 3. Front Hubs Repair................................................................................................................ 0481-7 Figure 4. Front Hub Installation........................................................................................................... 0481-9 REAR HUBS REPLACEMENT (M939A2)................................................................................................... WP 0482 Figure 1. Rear Hubs Removal............................................................................................................. 0482-3 Figure 2. Rear Hubs Cleaning and Inspection..................................................................................... 0482-5 Figure 3. Rear Hubs Cleaning and Inspection..................................................................................... 0482-7 Figure 4. Rear Hubs Repair................................................................................................................. 0482-9 Figure 5. Rear Hubs Installation........................................................................................................ 0482-11 WHEEL BEARING ADJUSTMENT.............................................................................................................. WP 0483 xcii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Front Wheel Bearing Adjustment......................................................................................... 0483-3 Figure 2. Rear Wheel Bearing Adjustment.......................................................................................... 0483-4 WHEEL AND TIRE ROTATION/REPLACEMENT (M939).......................................................................... WP 0484 Figure 1. Wheel and Tire Removal...................................................................................................... 0484-2 Figure 2. Wheel and Tire Inspection.................................................................................................... 0484-3 Figure 3. Wheel and Tire Rotation....................................................................................................... 0484-4 Figure 4. Wheel and Tire Installation................................................................................................... 0484-5 Figure 5. Wheel and Tire Installation................................................................................................... 0484-6 Figure 6. Wheel and Tire Installation................................................................................................... 0484-7 WHEEL AND TIRE ROTATION/REPLACEMENT (M939A1/A2)................................................................. WP 0485 Figure 1. Wheel and Tire Removal...................................................................................................... 0485-2 Figure 2. Wheel and Tire Rotation....................................................................................................... 0485-3 Figure 3. Rear Wheel Installation........................................................................................................ 0485-4 Figure 4. Front Wheel Installation........................................................................................................ 0485-5 WHEEL VALVE FILTER REPLACEMENT (M939A2)................................................................................. WP 0486 Figure 1. Wheel Valve Filter Removal................................................................................................. 0486-3 Figure 2. Wheel Valve Filter Installation.............................................................................................. 0486-4 HUB AIR SEAL LEAK TEST........................................................................................................................ WP 0487 Figure 1. Front Hub Air Seal Test........................................................................................................ 0487-3 Figure 2. Rear Hub Air Seal Test........................................................................................................ 0487-5 REAR AXLE AIR MANIFOLD REPLACEMENT.......................................................................................... WP 0488 Figure 1. Rear Axle Air Manifold Removal.......................................................................................... 0488-3 Figure 2. Rear Axle Air Manifold Installation....................................................................................... 0488-5 WHEEL VALVE REPAIR (70 PSI M939A2)................................................................................................. WP 0489 Figure 1. Wheel Valve Disassembly.................................................................................................... 0489-3 Figure 2. Wheel Valve Assembly......................................................................................................... 0489-5 FRONT WHEEL VALVE MAINTENANCE (M939A2).................................................................................. WP 0490 xciii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Front Wheel Valve Removal................................................................................................. 0490-3 Figure 2. Front Wheel Valve Installation.............................................................................................. 0490-5 REAR WHEEL VALVE REPAIR (M939A2)................................................................................................. WP 0491 Figure 1. Rear Wheel Valve Removal................................................................................................. 0491-3 Figure 2. Rear Wheel Valve Installation.............................................................................................. 0491-5 DRAG LINK REPLACEMENT...................................................................................................................... WP 0492 Figure 1. Drag Link Removal............................................................................................................... 0492-2 Figure 2. Drag Link Installation............................................................................................................ 0492-3 TIE ROD AND TOE-IN CHECK/REPAIR..................................................................................................... WP 0493 Figure 1. Toe-In Check........................................................................................................................ 0493-3 Figure 2. Toe-In Adjustment................................................................................................................ 0493-4 Figure 3. Tie Rod Removal.................................................................................................................. 0493-5 Figure 4. Tie Rod Installation............................................................................................................... 0493-6 UPPER AND LOWER STEERING COLUMN REPAIR............................................................................... WP 0494 Figure 1. Steering Column Removal................................................................................................... 0494-3 Figure 2. Upper and Lower Steering Column Repair.......................................................................... 0494-5 Figure 3. Upper and Lower Steering Column Reassembly................................................................. 0494-7 Figure 4. Steering Column Installation................................................................................................ 0494-9 STEERING WHEEL REPLACEMENT......................................................................................................... WP 0495 Figure 1. Steering Wheel Removal...................................................................................................... 0495-2 Figure 2. Steering Wheel Installation................................................................................................... 0495-3 PITMAN ARM REPLACEMENT (ROSS)..................................................................................................... WP 0496 Figure 1. Pitman Arm Removal........................................................................................................... 0496-1 Figure 2. Pitman Arm Installation........................................................................................................ 0496-2 STEERING STOP ADJUSTMENT............................................................................................................... WP 0497 Figure 1. Steering Stop Adjustment..................................................................................................... 0497-3 STEERING GEAR STONE SHIELD REPLACEMENT................................................................................ WP 0498 xciv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Steering Gear Stone Shield Removal.................................................................................. 0498-1 Figure 2. Steering Gear Stone Shield Installation............................................................................... 0498-2 STEERING GEAR AND MOUNTING BRACKET REPLACEMENT (ROSS)............................................... WP 0499 Figure 1. Steering Gear Input Shaft Removal..................................................................................... 0499-2 Figure 2. Pitman Arm Removal........................................................................................................... 0499-3 Figure 3. Power Steering Lines Removal............................................................................................ 0499-4 Figure 4. Steering Geer (Ross) and Mounting Bracket Removal........................................................ 0499-5 Figure 5. Steering Gear Installation..................................................................................................... 0499-6 Figure 6. Power Steering Lines Installation......................................................................................... 0499-7 Figure 7. Pitman Arm Installation........................................................................................................ 0499-8 Figure 8. Steering Geer (Ross) Installation......................................................................................... 0499-9 STEERING GEAR (SHEPPARD) AND MOUNTING BRACKET REPLACEMENT (M939A2 ONLY).......................................................................................................................................................... WP 0500 Figure 1. Steering Gear (Sheppard) Removal (M939A2).................................................................... 0500-3 Figure 2. Steering Gear (Sheppard) and Mounting Bracket Installation (M939A2)............................. 0500-5 Figure 3. Steering Gear (Sheppard) and Mounting Bracket Installation (M939A2)............................. 0500-7 Figure 4. Steering Gear (Sheppard) Assembly (M939A2)................................................................... 0500-8 Figure 5. Steering Gear Installation (M939A2).................................................................................... 0500-9 PITMAN ARM REPLACEMENT (SHEPPARD)........................................................................................... WP 0501 Figure 1. Pitman Arm Removal........................................................................................................... 0501-2 Figure 2. Pitman Arm Installation........................................................................................................ 0501-3 POWER STEERING PUMP FILTER AND RESERVOIR REPLACEMENT (M939A2)................................ WP 0502 Figure 1. Power Steering Pump Filter and Reservoir Removal........................................................... 0502-3 Figure 2. Power Steering Pump Filter and Reservoir Installation........................................................ 0502-5 POWER STEERING PUMP REPLACEMENT (M939/A1)........................................................................... WP 0503 Figure 1. Power Steering Pump Removal........................................................................................... 0503-3 Figure 2. Power Steering Pump Disassembly..................................................................................... 0503-4 Figure 3. Power Steering Pump Disassembly..................................................................................... 0503-5 xcv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Power Steering Pump Assembly.......................................................................................... 0503-6 Figure 5. Power Steering Pump Assembly.......................................................................................... 0503-7 Figure 6. Power Steering Pump Installation........................................................................................ 0503-8 STEERING PUMP DRIVEBELTS REPLACEMENT (M939/A1).................................................................. WP 0504 Figure 1. Steering Pump Drivebelts Removal..................................................................................... 0504-2 Figure 2. Steering Pump Drivebelts Installation.................................................................................. 0504-3 Figure 3. Steering Pump Drivebelts Adjustment.................................................................................. 0504-4 POWER STEERING PUMP PRESSURE AND RETURN HOSES REPLACEMENT (ROSS) (M939/A1).................................................................................................................................................... WP 0505 Figure 1. Power Steering Pump Removal........................................................................................... 0505-3 Figure 2. Power Steering Pump Installation........................................................................................ 0505-5 POWER STEERING PUMP PRESSURE AND RETURN HOSES REPLACEMENT (SHEPPARD) (M939/A1)............................................................................................................................. WP 0506 Figure 1. Power Steering Pump Pressure and Return Hose Removal................................................ 0506-3 Figure 2. Power Steering Pump Pressure and Return Hose Installation............................................. 0506-5 STEERING ASSIST CYLINDER HOSES REPLACEMENT........................................................................ WP 0507 Figure 1. Steering Assist Cylinder Hoses Replacement...................................................................... 0507-3 STEERING GEAR-TO-ASSIST CYLINDER PRESSURE LINES REPLACEMENT.................................... WP 0508 Figure 1. Pressure Lines Removal...................................................................................................... 0508-3 Figure 2. Pressure Lines Installation................................................................................................... 0508-5 POWER STEERING GEAR STOP ADJUSTMENT (ON-VEHICLE)........................................................... WP 0509 Figure 1. Steering Wheel..................................................................................................................... 0509-2 Figure 2. Sector Shaft Adjustment (On-Vehicle)................................................................................. 0509-3 Figure 3. Worm Shaft Adjustment (On-Vehicle).................................................................................. 0509-4 Figure 4. Steering Wheel..................................................................................................................... 0509-5 STEERING ASSIST CYLINDER REPLACEMENT...................................................................................... WP 0510 Figure 1. Steering Assist Cylinder Removal........................................................................................ 0510-3 Figure 2. Steering Assist Cylinder Disassembly.................................................................................. 0510-4 xcvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Steering Assist Cylinder Assembly....................................................................................... 0510-5 Figure 4. Steering Assist Cylinder Installation..................................................................................... 0510-6 Figure 5. Steering Assist Cylinder Travel Adjustment......................................................................... 0510-7 STEERING ASSIST CYLINDER STONE SHIELD REPLACEMENT.......................................................... WP 0511 Figure 1. Steering Assist Cylinder Stone Shield Removal................................................................... 0511-2 Figure 2. Steering Assist Cylinder Stone Shield Installation................................................................ 0511-3 FRONT AND REAR LIFTING SHACKLE AND BRACKET REPLACEMENT.............................................. WP 0512 Figure 1. Shackle and Bracket Removal............................................................................................. 0512-3 Figure 2. Shackle and Bracket Installation.......................................................................................... 0512-4 REAR CAB IMPROVED CROSSMEMBER REPLACEMENT..................................................................... WP 0513 Figure 1. Muffler and Spare Tire Carrier Removal.............................................................................. 0513-2 Figure 2. Spare Tire Carrier Removal................................................................................................. 0513-3 Figure 3. Air Lines and Fuel Tank Removal........................................................................................ 0513-4 Figure 4. Primary Air Tank Removal................................................................................................... 0513-5 Figure 5. Fuel Line Clamps Removal.................................................................................................. 0513-6 Figure 6. Fuel Lines and Clamps Removal......................................................................................... 0513-7 Figure 7. Bracket Removal.................................................................................................................. 0513-8 Figure 8. Crossmember and Exhaust Support Bracket Removal........................................................ 0513-9 Figure 9. Rear Mount Cab Removal.................................................................................................. 0513-10 Figure 10. Hole Location Removal...................................................................................................... 0513-11 Figure 11. Raising the Cab Removal................................................................................................... 0513-12 Figure 12. Crossmember Removal...................................................................................................... 0513-13 Figure 13. Cross Shaft Lever and Cross Shaft Removal..................................................................... 0513-14 Figure 14. Cross Shaft Lever and Cross Shaft Installation.................................................................. 0513-15 Figure 15. Crossmember Assembly and Plates Installation................................................................ 0513-16 Figure 16. Crossmember Installation................................................................................................... 0513-17 Figure 17. Rear Cab Mount (Side Profile) Installation......................................................................... 0513-18 xcvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 18. Bracket Installation............................................................................................................. 0513-19 Figure 19. Primary Air Tank Installation.............................................................................................. 0513-20 Figure 20. Spare Tire Carrier Installation............................................................................................ 0513-21 FRONT AND REAR FIELD CHOCK ANCHORS REPLACEMENT (M936/A1 Wrecker)............................. WP 0514 Figure 1. Front and Rear Field Chock Anchors Removal (M936/A1).................................................. 0514-2 Figure 2. Front and Rear Field Chock Anchors Installation (M936/A1)............................................... 0514-3 BUMPERETTE REPLACEMENT................................................................................................................ WP 0515 Figure 1. Bumperette Removal............................................................................................................ 0515-1 Figure 2. Bumperette Installation......................................................................................................... 0515-2 FRONT BUMPER AND PLATES REPLACEMENT..................................................................................... WP 0516 Figure 1. Front Bumper and Plates Removal...................................................................................... 0516-3 Figure 2. Front Bumper and Plates Installation................................................................................... 0516-5 VEHICLE TIEDOWN COMPONENT REPLACEMENT............................................................................... WP 0517 Figure 1. Vehicle Tiedown Component Removal................................................................................ 0517-2 Figure 2. Vehicle Tiedown Component Installation............................................................................. 0517-3 PINTLE HOOK REPAIR.............................................................................................................................. WP 0518 Figure 1. Pintle Hook Removal............................................................................................................ 0518-1 Figure 2. Pintle Hook Disassembly...................................................................................................... 0518-2 Figure 3. Pintle Hook Cleaning and Inspection................................................................................... 0518-3 Figure 4. Pintle Hook Assembly.......................................................................................................... 0518-4 Figure 5. Pintle Hook Installation......................................................................................................... 0518-5 VAN DAVIT CHAIN AND WIRE ROPE REPLACEMENT............................................................................ WP 0519 Figure 1. Van Davit Chain and Wire Rope Removal........................................................................... 0519-2 Figure 2. Van Davit Chain and Wire Rope Removal........................................................................... 0519-3 Figure 3. Van Davit Chain and Wire Rope Removal........................................................................... 0519-4 Figure 4. Van Davit Chain and Wire Rope Installation........................................................................ 0519-5 Figure 5. Van Davit Chain and Wire Rope Installation........................................................................ 0519-6 xcviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 6. Van Davit Chain and Wire Rope Installation........................................................................ 0519-7 VAN SWING DAVIT AND PULLEY REPLACEMENT................................................................................. WP 0520 Figure 1. Van Swing Davit and Pulley Removal.................................................................................. 0520-3 Figure 2. Van Swing Davit and Pulley Installation............................................................................... 0520-5 VAN DAVIT WINCH REPLACEMENT (M934A1/A2)................................................................................... WP 0521 Figure 1. Van Davit Winch Removal.................................................................................................... 0521-2 Figure 2. Van Davit Winch Installation................................................................................................. 0521-3 TRACTOR SPARE TIRE CARRIER REPLACEMENT (M931 AND M932)................................................. WP 0522 Figure 1. Tractor Spare Tire Carrier Removal (M931 and M932)........................................................ 0522-3 Figure 2. Tractor Spare Tire Carrier Installation (M931 and M932)..................................................... 0522-5 TRACTOR SPARE TIRE CARRIER AND TOOLBOX REPLACEMENT (M931A1/A2 and M932A1/A2)................................................................................................................................................. WP 0523 Figure 1. Spare Tire Carrier and Toolbox Removal............................................................................. 0523-3 Figure 2. Spare Tire Carrier and Toolbox Removal............................................................................. 0523-4 Figure 3. Spare Tire Carrier and Toolbox Removal............................................................................. 0523-5 Figure 4. Spare Tire Carrier and Toolbox Installation.......................................................................... 0523-6 Figure 5. Spare Tire Carrier and Toolbox Installation.......................................................................... 0523-7 Figure 6. Spare Tire Carrier and Toolbox Installation.......................................................................... 0523-9 DUMP AND TRACTOR SPARE TIRE CARRIER ACCESS STEP REPLACEMENT.................................. WP 0524 Figure 1. Dump and Tractor Spare Tire Carrier Access Step Removal.............................................. 0524-3 Figure 2. Dump and Tractor Spare Tire Carrier Access Step Installation........................................... 0524-5 DUMP AND VAN SPARE TIRE CARRIER REPLACEMENT (M929, M930, M934)................................... WP 0525 Figure 1. Spare Tire Carrier Removal................................................................................................. 0525-2 Figure 2. Spare Tire Carrier Installation.............................................................................................. 0525-3 DUMP AND VAN SPARE TIRE CARRIER REPLACEMENT (M929A1/A2, M930A1/A2, M934A1/ A2)............................................................................................................................................................... WP 0526 Figure 1. Dump Spare Tire Carrier Removal....................................................................................... 0526-2 Figure 2. Dump Spare Tire Carrier Removal....................................................................................... 0526-3 xcix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Dump Spare Tire Carrier Installation.................................................................................... 0526-4 Figure 4. Dump Spare Tire Carrier Installation.................................................................................... 0526-5 Figure 5. Van Spare Tire Carrier Removal.......................................................................................... 0526-7 Figure 6. Van Spare Tire Carrier Installation....................................................................................... 0526-9 CARGO SPARE TIRE CARRIER REPLACEMENT (M923, M925, M927, M928)....................................... WP 0527 Figure 1. Cargo Spare Tire Carrier Removal....................................................................................... 0527-2 Figure 2. Cargo Spare Tire Carrier Installation.................................................................................... 0527-3 CARGO SPARE TIRE CARRIER REPLACEMENT (M923A1/A2, M925A1/A2, M927A1/A2, M928A1/A2)................................................................................................................................................. WP 0528 Figure 1. Cargo Spare Tire Carrier Removal....................................................................................... 0528-3 Figure 2. Cargo Spare Tire Carrier Installation.................................................................................... 0528-5 CARGO SPARE TIRE CARRIER ACCESS STEP REPLACEMENT.......................................................... WP 0529 Figure 1. Cargo Spare Tire Carrier Access Step Removal.................................................................. 0529-2 Figure 2. Cargo Spare Tire Carrier Access Step Installation............................................................... 0529-3 TRACTOR FIFTH WHEEL (DAYTON/WALTER) REMOVAL...................................................................... WP 0530 Figure 1. Fifth Wheel Removal............................................................................................................ 0530-3 FIFTH WHEEL APPROACH PLATES REPLACEMENT............................................................................. WP 0531 Figure 1. Fifth Wheel Approach Plates Removal................................................................................. 0531-1 Figure 2. Fifth Wheel Approach Plates Installation.............................................................................. 0531-2 FIFTH WHEEL DECK PLATE REPLACEMENT.......................................................................................... WP 0532 Figure 1. Fifth Wheel Deck Plate Removal.......................................................................................... 0532-1 Figure 2. Fifth Wheel Deck Plate Installation....................................................................................... 0532-2 FIFTH WHEEL SPACERS REPLACEMENT............................................................................................... WP 0533 Figure 1. Fifth Wheel Spacers Removal.............................................................................................. 0533-1 Figure 2. Fifth Wheel Spacers Installation........................................................................................... 0533-2 FRONT SPRING AND MAIN LEAF REPAIR............................................................................................... WP 0534 Figure 1. Steering Cylinder Removal................................................................................................... 0534-3 Figure 2. Steering Cylinder Removal................................................................................................... 0534-4 c 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Spring Assembly Removal................................................................................................... 0534-5 Figure 4. Front Spring Main Leaf Removal.......................................................................................... 0534-6 Figure 5. Front Spring Main Leaf Installation....................................................................................... 0534-7 Figure 6. Front Spring Installation....................................................................................................... 0534-9 Figure 7. Steering Cylinder Installation.............................................................................................. 0534-10 FRONT SPRING SHACKLE AND SHACKLE HANGER REPLACEMENT................................................. WP 0535 Figure 1. Front Spring Shackle and Shackle Hanger Removal........................................................... 0535-2 Figure 2. Front Spring Shackle and Shackle Hanger Installation........................................................ 0535-3 FRONT SPRING BUSHING REPLACEMENT............................................................................................ WP 0536 Figure 1. Front Spring Bushing Inspection.......................................................................................... 0536-1 Figure 2. Front Spring Bushing Removal............................................................................................ 0536-2 Figure 3. Front Spring Bushing Installation......................................................................................... 0536-3 FRONT SPRING BUMPER REPLACEMENT............................................................................................. WP 0537 Figure 1. Front Spring Bumper Removal............................................................................................. 0537-1 Figure 2. Front Spring Bumper Installation.......................................................................................... 0537-2 REAR SPRING BUMPER REPLACEMENT................................................................................................ WP 0538 Figure 1. Rear Spring Bumper Removal............................................................................................. 0538-1 Figure 2. Rear Spring Bumper Installation.......................................................................................... 0538-2 REAR SPRING REPAIR.............................................................................................................................. WP 0539 Figure 1. Rear Spring Removal........................................................................................................... 0539-1 Figure 2. Rear Spring Removal........................................................................................................... 0539-3 Figure 3. Rear Spring Removal........................................................................................................... 0539-4 Figure 4. Rear Spring Removal........................................................................................................... 0539-5 Figure 5. Rear Spring Removal........................................................................................................... 0539-6 Figure 6. Rear Spring Removal........................................................................................................... 0539-7 Figure 7. Rear Spring Installation........................................................................................................ 0539-8 Figure 8. Rear Spring Installation........................................................................................................ 0539-8 ci 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 9. Rear Spring Installation........................................................................................................ 0539-9 Figure 10. Rear Spring Installation........................................................................................................ 0539-9 Figure 11. Rear Spring Installation...................................................................................................... 0539-10 Figure 12. Rear Spring Installation...................................................................................................... 0539-10 Figure 13. Rear Spring Installation...................................................................................................... 0539-11 REAR SPRING SEAT REPAIR................................................................................................................... WP 0540 Figure 1. Rear Spring Seat Removal................................................................................................... 0540-2 Figure 2. Rear Spring Seat Removal................................................................................................... 0540-3 Figure 3. Rear Spring Seat Lubrication............................................................................................... 0540-4 Figure 4. Rear Spring Seat Installation................................................................................................ 0540-5 Figure 5. Rear Spring Seat Installation................................................................................................ 0540-7 Figure 6. Rear Spring Seat Adjustment............................................................................................... 0540-8 REAR AXLES SPRING SEAT WEAR PADS AND UPPER BRACKET REPLACEMENT........................... WP 0541 Figure 1. Rear Axle Spring Seat Wear Pads and Upper Bracket Removal......................................... 0541-2 Figure 2. Rear Axle Spring Seat Wear Pads and Upper Bracket Removal......................................... 0541-3 Figure 3. Rear Axle Spring Seat Wear Pads and Upper Bracket Installation...................................... 0541-4 Figure 4. Rear Axle Spring Seat Wear Pads and Upper Bracket Installation...................................... 0541-5 CROSS TUBE REPLACEMENT.................................................................................................................. WP 0542 Figure 1. Cross Tube Removal............................................................................................................ 0542-2 Figure 2. Cross Tube Installation......................................................................................................... 0542-3 SHOCK ABSORBER AND MOUNTING PINS REPLACEMENT................................................................. WP 0543 Figure 1. Shock Absorber and Mounting Pins Removal...................................................................... 0543-1 Figure 2. Shock Absorber and Mounting Pins Removal...................................................................... 0543-2 Figure 3. Shock Absorber and Mounting Pins Installation................................................................... 0543-3 Figure 4. Shock Absorber and Mounting Pins Installation................................................................... 0543-4 UPPER AND LOWER TORQUE ROD REPLACEMENT............................................................................ WP 0544 Figure 1. Upper Torque Rod Removal................................................................................................ 0544-2 cii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Upper Torque Rod Removal................................................................................................ 0544-3 Figure 3. Upper Torque Rod Removal................................................................................................ 0544-4 Figure 4. Lower Torque Rod Removal................................................................................................ 0544-5 Figure 5. Preload for Upper Torque Rod............................................................................................. 0544-8 Figure 6. Upper Torque Rod Installation............................................................................................. 0544-9 Figure 7. Lower Torque Rod Installation........................................................................................... 0544-10 CAB DOOR REPLACEMENT...................................................................................................................... WP 0545 Figure 1. Cab Door Removal............................................................................................................... 0545-2 Figure 2. Cab Door Installation............................................................................................................ 0545-3 OUTSIDE DOOR HANDLE REPLACEMENT.............................................................................................. WP 0546 Figure 1. Outside Door Handles Removal........................................................................................... 0546-2 Figure 2. Outside Door Handles Installation........................................................................................ 0546-3 CAB DOOR DOVETAIL WEDGE REPLACEMENT.................................................................................... WP 0547 Figure 1. Cab Door Dovetail Wedge Removal.................................................................................... 0547-2 Figure 2. Cab Door Dovetail Wedge Installation................................................................................. 0547-3 CAB DOOR DOVETAIL REPLACEMENT................................................................................................... WP 0548 Figure 1. Cab Door Dovetail Removal................................................................................................. 0548-1 Figure 2. Cab Door Dovetail Installation.............................................................................................. 0548-2 CAB DOOR WEATHER SEAL REPLACEMENT......................................................................................... WP 0549 Figure 1. Cab Door Weather Seal Removal........................................................................................ 0549-1 Figure 2. Cab Door Weather Seal Installation..................................................................................... 0549-2 CAB DOOR INSPECTION HOLE COVER REPLACEMENT...................................................................... WP 0550 Figure 1. Cab Door Inspection Hole Cover Removal.......................................................................... 0550-1 Figure 2. Cab Door Inspection Hole Cover Installation....................................................................... 0550-2 CAB DOOR LOCK REPLACEMENT........................................................................................................... WP 0551 Figure 1. Cab Door Lock Removal...................................................................................................... 0551-2 Figure 2. Cab Door Lock Installation................................................................................................... 0551-3 ciii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. CAB DOOR GLASS REPLACEMENT......................................................................................................... WP 0552 Figure 1. Cab Door Glass Removal..................................................................................................... 0552-3 Figure 2. Cab Door Glass Disassembly.............................................................................................. 0552-5 Figure 3. Cab Door Glass Assembly................................................................................................... 0552-6 Figure 4. Cab Door Glass Installation.................................................................................................. 0552-7 WINDOW WEATHER STRIPPING (CAB DOOR) REPLACEMENT........................................................... WP 0553 Figure 1. Window Weather Stripping Removal.................................................................................... 0553-1 Figure 2. Window Weather Stripping Installation................................................................................. 0553-2 Index Volume 4 Chapter 9 - MAINTENANCE INSTRUCTIONS WINDOW BLACKOUT PANEL REPLACEMENT........................................................................................ WP 0554 Figure 1. Window Blackout Panel Removal........................................................................................ 0554-2 Figure 2. Window Blackout Panel Installation..................................................................................... 0554-3 CAB DOOR CHECK ROD REPLACEMENT............................................................................................... WP 0555 Figure 1. Cab Door Check Rod Removal............................................................................................ 0555-2 Figure 2. Cab Door Check Rod Installation......................................................................................... 0555-3 CAB DOOR HINGE REPLACEMENT......................................................................................................... WP 0556 Figure 1. Cab Door Hinge Removal.................................................................................................... 0556-2 Figure 2. Cab Door Hinge Installation................................................................................................. 0556-3 CAB DOOR CATCH REPLACEMENT........................................................................................................ WP 0557 Figure 1. Cab Door Catch Removal.................................................................................................... 0557-1 Figure 2. Cab Door Catch Installation................................................................................................. 0557-2 HOOD LATCH AND BRACKET REPLACEMENT....................................................................................... WP 0558 Figure 1. Hood Latch & Bracket Removal........................................................................................... 0558-3 Figure 2. Hood Latch & Bracket Installation........................................................................................ 0558-5 HOOD SUPPORT BAR BRACKET, CROSSMEMBER, HINGES, AND TORSION BARS REPLACEMENT.......................................................................................................................................... WP 0559 civ 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Hood Support Bar and Bracket Removal............................................................................. 0559-3 Figure 2. Hood Support Bar and Bracket Installation.......................................................................... 0559-4 Figure 3. Hood Retaining Bracket Replacement................................................................................. 0559-5 Figure 4. Hood Crossmember Bracket Removal................................................................................. 0559-6 Figure 5. Hood Crossmember Bracket Cleaning and Inspection........................................................ 0559-7 Figure 6. Hood Crossmember Bracket Installation.............................................................................. 0559-9 Figure 7. Hood Hinge Removal......................................................................................................... 0559-11 Figure 8. Hood Hinge Installation...................................................................................................... 0559-13 Figure 9. Torsion Bars and Crossmembers Removal....................................................................... 0559-15 Figure 10. Torsion Bars and Crossmembers Installation.................................................................... 0559-17 HOOD STOP CABLES REPLACEMENT.................................................................................................... WP 0560 Figure 1. Hood Stop Cables Removal................................................................................................. 0560-2 Figure 2. Hood Stop Cables Installation.............................................................................................. 0560-3 HOOD GRAB HANDLE REPLACEMENT................................................................................................... WP 0561 Figure 1. Hood Grab Handle Removal................................................................................................ 0561-1 Figure 2. Hood Grab Handle Installation............................................................................................. 0561-2 RADIATOR BAFFLES, SEALS, AND PLATES REPLACEMENT............................................................... WP 0562 Figure 1. Radiator Baffles, Seals, and Plates Removal....................................................................... 0562-2 Figure 2. Radiator Baffles, Seals, and Plates Installation.................................................................... 0562-3 CAB HOOD STOP BRACKET REPLACEMENT......................................................................................... WP 0563 Figure 1. Cab Hood Stop Bracket Removal........................................................................................ 0563-1 Figure 2. Cab Hood Stop Bracket Installation..................................................................................... 0563-2 HOOD BUMPER REPLACEMENT.............................................................................................................. WP 0564 Figure 1. Hood Bumper Removal........................................................................................................ 0564-1 Figure 2. Hood Bumper Installation..................................................................................................... 0564-2 ENGINE HOOD REPLACEMENT............................................................................................................... WP 0565 Figure 1. Engine Hood Removal......................................................................................................... 0565-3 cv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Engine Hood Removal......................................................................................................... 0565-5 Figure 3. Engine Hood Installation...................................................................................................... 0565-7 Figure 4. Engine Hood Installation...................................................................................................... 0565-9 Figure 5. Engine Hood Adjustment.................................................................................................... 0565-11 WINDSHIELD STOP BRACKET AND LATCH REPLACEMENT................................................................ WP 0566 Figure 1. Windshield Stop Bracket and Latch Removal...................................................................... 0566-1 Figure 2. Windshield Stop Bracket and Latch Installation................................................................... 0566-2 ENGINE ACCESS COVER (IN-CAB) REPLACEMENT.............................................................................. WP 0567 Figure 1. Engine Access Cover (In-Cab) Removal.............................................................................. 0567-3 Figure 2. Engine Access Cover (In-Cab) Installation........................................................................... 0567-5 FRONT CAB MOUNT REPLACEMENT...................................................................................................... WP 0568 Figure 1. Front Cab Mount Removal................................................................................................... 0568-3 Figure 2. Front Cab Mount Installation................................................................................................ 0568-5 REAR CAB MOUNT REPLACEMENT........................................................................................................ WP 0569 Figure 1. Rear Cab Mount Removal.................................................................................................... 0569-2 Figure 2. Rear Cab Mount Installation................................................................................................. 0569-3 CAB GRAB HANDLE REPLACEMENT....................................................................................................... WP 0570 Figure 1. Cab Grab Handle Removal.................................................................................................. 0570-2 Figure 2. Cab Grab Handle Installation............................................................................................... 0570-3 VENT DOOR WEATHER SEAL REPLACEMENT...................................................................................... WP 0571 Figure 1. Vent Door Weather Seal Removal....................................................................................... 0571-2 Figure 2. Vent Door Weather Seal Installation.................................................................................... 0571-3 CAB COWL VENT SCREEN AND DOOR REPLACEMENT....................................................................... WP 0572 Figure 1. Cab Cowl Vent Screen & Door Removal.............................................................................. 0572-2 Figure 2. Cab Cowl Vent Screen & Door Installation........................................................................... 0572-3 FRONT FENDERS REPLACEMENT.......................................................................................................... WP 0573 Figure 1. Front Fender Removal......................................................................................................... 0573-2 cvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Front Fender Installation...................................................................................................... 0573-3 FRONT FENDER EXTENSION REPLACEMENT....................................................................................... WP 0574 Figure 1. Front Fender Extension Removal......................................................................................... 0574-2 Figure 2. Front Fender Extension Installation...................................................................................... 0574-3 FENDER SPLASH SHIELD REPLACEMENT............................................................................................. WP 0575 Figure 1. Fender Splash Shield Removal............................................................................................ 0575-2 Figure 2. Fender Splash Shield Installation......................................................................................... 0575-3 RADIATOR BRUSHGUARD REPLACEMENT............................................................................................ WP 0576 Figure 1. Radiator Brushguard Removal............................................................................................. 0576-3 Figure 2. Radiator Brushguard Removal............................................................................................. 0576-4 Figure 3. Radiator Brushguard Removal............................................................................................. 0576-5 Figure 4. Radiator Brushguard Installation.......................................................................................... 0576-6 Figure 5. Radiator Brushguard Installation.......................................................................................... 0576-7 Figure 6. Radiator Brushguard Installation.......................................................................................... 0576-9 WINDSHIELD AND OUTER FRAME ASSEMBLY REPLACEMENT.......................................................... WP 0577 Figure 1. Windshield and Outer Frame Assembly Removal................................................................ 0577-2 Figure 2. Windshield and Outer Frame Assembly Installation............................................................. 0577-3 WINDSHIELD FRAME ASSEMBLY REPLACEMENT................................................................................ WP 0578 Figure 1. Windshield Frame Removal................................................................................................. 0578-2 Figure 2. Cab Windshield Disassembly............................................................................................... 0578-3 Figure 3. Cab Windshield Assembly.................................................................................................... 0578-4 Figure 4. Windshield Frame Installation.............................................................................................. 0578-5 CAB WINDSHIELD HINGE ASSEMBLY REPLACEMENT......................................................................... WP 0579 Figure 1. Cab Windshield Hinge Removal........................................................................................... 0579-2 Figure 2. Cab Windshield Hinge Installation........................................................................................ 0579-3 CAB INSULATION REPLACEMENT........................................................................................................... WP 0580 Figure 1. Cab Insulation Removal....................................................................................................... 0580-2 cvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Cab Insulation Installation.................................................................................................... 0580-3 COMPANION SEAT CUSHION, BACKREST CUSHION, AND FRAME REPLACEMENT......................... WP 0581 Figure 1. Companion Seat Cushion, Backrest Cushion, and Frame Removal.................................... 0581-1 Figure 2. Companion Seat Cushion, Backrest Cushion, and Frame Removal.................................... 0581-2 Figure 3. Companion Seat Cushion, Backrest Cushion, and Frame Removal.................................... 0581-3 Figure 4. Companion Seat Cushion, Backrest Cushion, and Frame Installation................................. 0581-4 Figure 5. Companion Seat Cushion, Backrest Cushion, and Frame Installation................................. 0581-5 Figure 6. Companion Seat Cushion, Backrest Cushion, and Frame Installation................................. 0581-6 DRIVER'S SEAT, FRAME, AND BASE REPLACEMENT........................................................................... WP 0582 Figure 1. Driver's Seat Removal.......................................................................................................... 0582-3 Figure 2. Driver's Seat Installation....................................................................................................... 0582-5 Figure 3. Driver's Seat Frame and Base Removal.............................................................................. 0582-7 Figure 4. Driver's Seat Frame and Base............................................................................................. 0582-9 Figure 5. Driver's Seat and Frame Installation.................................................................................. 0582-11 Figure 6. Driver's Seat Frame and Base Installation......................................................................... 0582-13 DRIVER'S SEAT CUSHION AND BACKREST CUSHION REPLACEMENT.............................................. WP 0583 Figure 1. Driver's Seat Cushion and Backrest Cushion Removal....................................................... 0583-1 Figure 2. Driver's Seat Cushion and Backrest Cushion Removal....................................................... 0583-2 Figure 3. Driver's Seat Cushion and Backrest Cushion Installation.................................................... 0583-3 Figure 4. Driver's Seat Cushion and Backrest Cushion Installation.................................................... 0583-4 MAP COMPARTMENT REPLACEMENT.................................................................................................... WP 0584 Figure 1. Map Compartment Removal................................................................................................ 0584-2 Figure 2. Map Compartment Installation............................................................................................. 0584-3 VAN POWER CABLE REEL REPLACEMENT (M934A1/A2)...................................................................... WP 0585 Figure 1. Van Power Cable Reel Removal.......................................................................................... 0585-2 Figure 2. Van Power Cable Reel Installation....................................................................................... 0585-3 TOOLBOX AND STEPS REPLACEMENT.................................................................................................. WP 0586 cviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Toolbox and Steps Removal................................................................................................ 0586-3 Figure 2. Toolbox and Steps Installation............................................................................................. 0586-5 CARGO STOWAGE BOX REPLACEMENT................................................................................................ WP 0587 Figure 1. Cargo Stowage Removal..................................................................................................... 0587-2 Figure 2. Cargo Stowage Installation.................................................................................................. 0587-3 CARGO BODY ASSEMBLY REPAIR.......................................................................................................... WP 0588 Figure 1. Front Holddown Brackets..................................................................................................... 0588-2 Figure 2. Intermediate Holddown Brackets......................................................................................... 0588-3 Figure 3. Cargo Body Removal........................................................................................................... 0588-5 Figure 4. Cargo Body.......................................................................................................................... 0588-7 Figure 5. Cargo Body.......................................................................................................................... 0588-9 CARGO TROOP SEAT REPAIR................................................................................................................. WP 0589 Figure 1. Cargo Troop Seat Removal.................................................................................................. 0589-2 Figure 2. Cargo Troop Seat Installation............................................................................................... 0589-3 CARGO TAILGATE AND BUMPER REPLACEMENT................................................................................ WP 0590 Figure 1. Cargo Tailgate and Bumper Removal.................................................................................. 0590-3 Figure 2. Cargo Tailgate and Bumper Installation............................................................................... 0590-5 DUMP TAILGATE CONTROL LINKAGE REPLACEMENT......................................................................... WP 0591 Figure 1. Dump Tailgate Control Linkage Removal............................................................................. 0591-3 Figure 2. Dump Tailgate Control Linkage Installation.......................................................................... 0591-5 DUMP TAILGATE ASSEMBLY REPLACEMENT........................................................................................ WP 0592 Figure 1. Dump Tailgate Assembly Removal...................................................................................... 0592-3 Figure 2. Dump Tailgate Assembly Installation................................................................................... 0592-5 CARGO BODY FRAME RAIL SILL REPLACEMENT.................................................................................. WP 0593 Figure 1. Frame Rail Sill Removal....................................................................................................... 0593-1 Figure 2. Cargo Frame Fabrication..................................................................................................... 0593-2 Figure 3. Cargo Frame Fabrication..................................................................................................... 0593-3 cix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Frame Rail Sill Installation.................................................................................................... 0593-4 DUMP BODY REPAIR................................................................................................................................. WP 0594 Figure 1. Dump Body Removal........................................................................................................... 0594-3 Figure 2. Dump Body Installation........................................................................................................ 0594-5 Figure 3. Dump Body Installation........................................................................................................ 0594-7 DUMP CAB PROTECTOR SHIELD REPAIR.............................................................................................. WP 0595 Figure 1. Dump Cab Protector Shield Removal.................................................................................. 0595-2 Figure 2. Dump Cab Protector Shield Removal.................................................................................. 0595-3 Figure 3. Dump Cab Protector Shield Removal.................................................................................. 0595-4 Figure 4. Dump Cab Protector Shield Installation............................................................................... 0595-5 Figure 5. Dump Cab Protector Shield Installation............................................................................... 0595-6 Figure 6. Dump Cab Protector Shield Installation............................................................................... 0595-7 CARGO UPPER WHEEL SPLASH GUARD REPLACEMENT................................................................... WP 0596 Figure 1. Upper Wheel Splash Guard Removal.................................................................................. 0596-1 Figure 2. Upper Wheel Splash Guard Installation............................................................................... 0596-2 SIDE LOCKING PIN RETAINING CLIP REPLACEMENT........................................................................... WP 0597 Figure 1. Side Locking Pin Retaining Clip Removal............................................................................ 0597-2 Figure 2. Side Locking Pin Retaining Clip Installation......................................................................... 0597-3 TAILGATE PERSONNEL STEP REPLACEMENT...................................................................................... WP 0598 Figure 1. Tailgate Personnel Step Replacement................................................................................. 0598-2 VAN REAR DOOR AND SIDE DOOR WINDOW REPLACEMENT............................................................ WP 0599 Figure 1. Van Rear Door and Side Door Window Replacement......................................................... 0599-1 WINDOW BRUSH GUARD REPLACEMENT.............................................................................................. WP 0600 Figure 1. Window Brush Guard Removal............................................................................................ 0600-2 Figure 2. Window Brush Guard Installation......................................................................................... 0600-3 REAR DOOR REPAIR................................................................................................................................. WP 0601 Figure 1. Rear Door Removal.............................................................................................................. 0601-2 cx 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Rear Door Disassembly....................................................................................................... 0601-3 Figure 3. Rear Door Disassembly....................................................................................................... 0601-4 Figure 4. Rear Door Disassembly....................................................................................................... 0601-5 Figure 5. Rear Door Assembly............................................................................................................ 0601-7 Figure 6. Rear Door Assembly............................................................................................................ 0601-8 Figure 7. Rear Door Assembly............................................................................................................ 0601-9 Figure 8. Rear Door Installation......................................................................................................... 0601-10 VAN SIDE DOORS MAINTENANCE........................................................................................................... WP 0602 Figure 1. Side Doors Removal............................................................................................................ 0602-3 Figure 2. Side Doors Installation......................................................................................................... 0602-4 VAN HINGED END PANEL REPAIR........................................................................................................... WP 0603 Figure 1. Hinged End Panel Removal................................................................................................. 0603-3 Figure 2. Hinged End Panel Disassembly........................................................................................... 0603-5 Figure 3. Hinged End Panel Assembly................................................................................................ 0603-7 Figure 4. Hinged End Panel Installation.............................................................................................. 0603-8 VAN HINGED ROOF AND FLOOR COUNTERBALANCE CABLE REPLACEMENT................................. WP 0604 Figure 1. Hinge Roof and Floor Counterbalance Cable Removal....................................................... 0604-2 Figure 2. Hinge Roof and Floor Counterbalance Cable Removal....................................................... 0604-3 Figure 3. Hinge Roof and Floor Counterbalance Cable Installation.................................................... 0604-5 Figure 4. Hinge Roof and Floor Counterbalance Cable Installation.................................................... 0604-6 VAN RETRACTABLE WINDOW REPLACEMENT...................................................................................... WP 0605 Figure 1. Retractable Window Removal.............................................................................................. 0605-2 Figure 2. Retractable Window Installation........................................................................................... 0605-3 Figure 3. Window Glass Removal....................................................................................................... 0605-5 Figure 4. Window Glass Installation.................................................................................................... 0605-7 VAN WINDOW SCREEN REPLACEMENT................................................................................................. WP 0606 Figure 1. Window Screen Replacement.............................................................................................. 0606-2 cxi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. VAN RETRACTABLE WINDOW REGULATOR REPLACEMENT.............................................................. WP 0607 Figure 1. Retractable Window Regulator Removal............................................................................. 0607-2 Figure 2. Retractable Window Regulator Installation.......................................................................... 0607-3 WINDOW REGULATOR AND INSIDE DOOR HANDLE REPLACEMENT................................................. WP 0608 Figure 1. Window Removal................................................................................................................. 0608-2 Figure 2. Window Installation.............................................................................................................. 0608-3 VAN SIDE PANEL-TO-ROOF TOGGLE CLAMP REPLACEMENT............................................................ WP 0609 Figure 1. Side Panel-to-Roof Toggle Clamp Removal........................................................................ 0609-2 Figure 2. Side Panel-to-Roof Toggle Clamp Installation..................................................................... 0609-3 VAN TOGGLE CLAMP ANCHOR POST REPLACEMENT......................................................................... WP 0610 Figure 1. Toggle Clamp Anchor Post Replacement............................................................................ 0610-2 VAN SIDE PANEL ROOF SWIVEL HOOK REPLACEMENT...................................................................... WP 0611 Figure 1. Side Panel Roof Swivel Hook Removal............................................................................... 0611-2 Figure 2. Side Panel Roof Swivel Hook Installation............................................................................ 0611-3 VAN LADDER LOCKING CLAMP REPLACEMENT................................................................................... WP 0612 Figure 1. Ladder Locking Clamp Removal.......................................................................................... 0612-2 Figure 2. Ladder Locking Clamp Installation....................................................................................... 0612-3 VAN BONNET HANDLE AND CONTROL ROD REPLACEMENT.............................................................. WP 0613 Figure 1. Bonnet Handle and Control Rod Removal........................................................................... 0613-2 Figure 2. Bonnet Handle and Control Rod Installation........................................................................ 0613-3 VAN DOOR HINGE AND SEAL REPLACEMENT....................................................................................... WP 0614 Figure 1. Door Hinge and Seal Removal............................................................................................. 0614-3 Figure 2. Door Hinge and Seal Installation.......................................................................................... 0614-5 VAN PANEL SEALS REPLACEMENT........................................................................................................ WP 0615 Figure 1. Panel Seals Removal........................................................................................................... 0615-2 Figure 2. Panel Seals Installation........................................................................................................ 0615-3 VAN DOOR HANDLE AND LOCK REPLACEMENT................................................................................... WP 0616 cxii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Door Handle and Lock Removal.......................................................................................... 0616-2 Figure 2. Door Handle and Lock Installation....................................................................................... 0616-3 VAN DOOR CHECKS REPLACEMENT...................................................................................................... WP 0617 Figure 1. Door Checks Removal......................................................................................................... 0617-2 Figure 2. Door Checks Installation...................................................................................................... 0617-3 VAN LADDER RACK BUMPERS REPLACEMENT.................................................................................... WP 0618 Figure 1. Ladder Rack Bumpers Replacement................................................................................... 0618-1 VAN SIDE PANEL RUBBER BUMPERS REPLACEMENT......................................................................... WP 0619 Figure 1. Side Panel Rubber Bumper Replacement........................................................................... 0619-1 VAN SIDE PANEL REAR LOCK REPLACEMENT...................................................................................... WP 0620 Figure 1. Side Panel Rear Lock Removal........................................................................................... 0620-2 Figure 2. Side Panel Rear Lock Installation........................................................................................ 0620-3 VAN SIDE PANEL FRONT LOCK AND HINGED-TYPE ROOF LOCK REPLACEMENT........................... WP 0621 Figure 1. Latch Assembly Removal..................................................................................................... 0621-3 Figure 2. Latch Assembly Installation.................................................................................................. 0621-5 VAN SIDE PANEL EXTERIOR LOCK REPLACEMENT............................................................................. WP 0622 Figure 1. Side Panel Exterior Lock Removal....................................................................................... 0622-1 Figure 2. Side Panel Exterior Lock Installation.................................................................................... 0622-2 VAN FLUORESCENT LIGHT TUBE REPLACEMENT................................................................................ WP 0623 Figure 1. Fluorescent Light Tube Removal......................................................................................... 0623-2 Figure 2. Fluorescent Light Tube Installation...................................................................................... 0623-3 VAN EMERGENCY/BLACKOUT LIGHT LAMP AND LENS REPLACEMENT............................................ WP 0624 Figure 1. Emergency/Blackout Light Lamp and Lens Removal........................................................... 0624-1 Figure 2. Emergency/Blackout Light Lamp and Lens Installation........................................................ 0624-2 VAN BLACKOUT LIGHT SWITCH AND 110-VOLT RECEPTACLE REPLACEMENT............................... WP 0625 Figure 1. Blackout Light Switch and 110-Volt Receptacle Removal.................................................... 0625-2 Figure 2. Blackout Light Switch and 110-Volt Receptacle Installation................................................. 0625-3 cxiii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. VAN INSIDE TELEPHONE JACK POST REPLACEMENT......................................................................... WP 0626 Figure 1. Inside Telephone Jack Post Removal.................................................................................. 0626-2 Figure 2. Inside Telephone Jack Post Installation............................................................................... 0626-3 VAN OUTSIDE TELEPHONE JACK POST REPLACEMENT..................................................................... WP 0627 Figure 1. Outside Telephone Jack Post Removal............................................................................... 0627-3 Figure 2. Outside Telephone Jack Post Installation............................................................................ 0627-5 VAN SIDE AND REAR DOOR BLACKOUT LIGHT SWITCH REPLACEMENT.......................................... WP 0628 Figure 1. Side and Rear Door Blackout Light Switch Removal........................................................... 0628-1 Figure 2. Side and Rear Door Blackout Light Switch Installation........................................................ 0628-2 Figure 3. Side and Rear Door Blackout Light Adjustment................................................................... 0628-3 VAN HINGED ROOF-OPERATED BLACKOUT CIRCUIT PLUNGERS REPLACEMENT......................... WP 0629 Figure 1. Hinged Roof-Operated Blackout Circuit Plungers Removal................................................. 0629-3 Figure 2. Hinged Roof-Operated Blackout Circuit Plungers Installation.............................................. 0629-4 VAN RETRACTABLE BEAM ASSEMBLY REPLACEMENT....................................................................... WP 0630 Figure 1. Retractable Beam Assembly Removal................................................................................. 0630-2 Figure 2. Retractable Beam Assembly Removal................................................................................. 0630-3 Figure 3. Retractable Beam Assembly Removal................................................................................. 0630-5 Figure 4. Retractable Beam Assembly Removal................................................................................. 0630-7 Figure 5. Retractable Beam Assembly Cleaning, Inspection, and Repair........................................... 0630-9 Figure 6. Retractable Beam Assembly Installation............................................................................ 0630-11 Figure 7. Retractable Beam Assembly Installation............................................................................ 0630-13 Figure 8. Retractable Beam Assembly Installation............................................................................ 0630-14 Figure 9. Retractable Beam Assembly Installation............................................................................ 0630-15 VAN HEATER AND EXHAUST REPLACEMENT....................................................................................... WP 0631 Figure 1. Van Heater and Exhaust Removal....................................................................................... 0631-3 Figure 2. Van Heater and Exhaust Installation.................................................................................... 0631-5 VAN HEATER FUEL PUMP REPLACEMENT (M934/A1/A2)..................................................................... WP 0632 cxiv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Van Heater Fuel Pump Removal (M934A1/A2)................................................................... 0632-3 Figure 2. Van Heater Fuel Pump Installation (M934A1/A2)................................................................ 0632-5 Figure 3. Van Heater Fuel Pump Removal (M934)............................................................................. 0632-7 Figure 4. Van Heater Fuel Pump Installation (M934).......................................................................... 0632-8 AIR CONDITIONER DRAIN TUBE REPLACEMENT.................................................................................. WP 0633 Figure 1. Air Conditioner Drain Tube Removal.................................................................................... 0633-3 Figure 2. Air Conditioner Drain Tube Installation................................................................................. 0633-5 HEATER FUEL PUMP WIRING HARNESS REPLACEMENT.................................................................... WP 0634 Figure 1. Heater Fuel Pump Wiring Harness Removal....................................................................... 0634-1 Figure 2. Heater Fuel Pump Wiring Harness Removal....................................................................... 0634-2 Figure 3. Heater Fuel Pump Wiring Harness Installation.................................................................... 0634-3 Figure 4. Heater Fuel Pump Wiring Harness Installation.................................................................... 0634-4 RIGHT AND LEFT SIDE BLACKOUT HARNESS REPAIR......................................................................... WP 0635 Figure 1. Blackout Harness................................................................................................................. 0635-3 Figure 2. Blackout Harness................................................................................................................. 0635-4 CIRCUIT BREAKER HARNESS AND CIRCUIT BREAKER REPLACEMENT........................................... WP 0636 Figure 1. Circuit Breaker Harness and Circuit Breaker Removal........................................................ 0636-3 Figure 2. Circuit Breaker Harness and Circuit Breaker Installation..................................................... 0636-5 ENTRANCE RECEPTACLE 220V 3-PHASE WIRING HARNESS REPLACEMENT.................................. WP 0637 Figure 1. Entrance Receptacle Removal............................................................................................. 0637-3 Figure 2. Entrance Receptacle Installation.......................................................................................... 0637-5 FLEXIBLE CONVERTER WIRING HARNESS REPLACEMENT................................................................ WP 0638 Figure 1. Flexible Converter Wiring Harness Removal....................................................................... 0638-2 Figure 2. Flexible Converter Wiring Harness Installation.................................................................... 0638-3 ELECTRICAL LOAD CENTER BOX REPLACEMENT................................................................................ WP 0639 Figure 1. Load Center Box.................................................................................................................. 0639-2 Figure 2. Load Center Box.................................................................................................................. 0639-3 cxv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Load Center Box.................................................................................................................. 0639-4 Figure 4. Load Center Box.................................................................................................................. 0639-5 Figure 5. Load Center Box.................................................................................................................. 0639-6 Figure 6. Load Center Box.................................................................................................................. 0639-7 Figure 7. Load Center Box.................................................................................................................. 0639-8 Figure 8. Load Center Box.................................................................................................................. 0639-9 Figure 9. Load Center Box................................................................................................................ 0639-10 Figure 10. Load Center Box................................................................................................................ 0639-11 Figure 11. Load Center Box................................................................................................................ 0639-12 Figure 12. Load Center Box................................................................................................................ 0639-13 Figure 13. Load Center Box................................................................................................................ 0639-15 Figure 14. Load Center Box................................................................................................................ 0639-17 Figure 15. Load Center Box................................................................................................................ 0639-19 Figure 16. Load Center Box................................................................................................................ 0639-20 Figure 17. Load Center Box................................................................................................................ 0639-21 Figure 18. Load Center Box................................................................................................................ 0639-22 Figure 19. Load Center Box................................................................................................................ 0639-23 Figure 20. Load Center Box................................................................................................................ 0639-24 Figure 21. Load Center Box................................................................................................................ 0639-25 Figure 22. Load Center Box................................................................................................................ 0639-26 Figure 23. Load Center Box................................................................................................................ 0639-27 Figure 24. Load Center Box................................................................................................................ 0639-28 Figure 25. Load Center Box................................................................................................................ 0639-29 Figure 26. Load Center Box................................................................................................................ 0639-30 Figure 27. Load Center Box................................................................................................................ 0639-31 Figure 28. Load Center Box................................................................................................................ 0639-32 ELECTRICAL BOX REPLACEMENT.......................................................................................................... WP 0640 cxvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Electrical Box Removal........................................................................................................ 0640-2 Figure 2. Electrical Box Installation..................................................................................................... 0640-3 ELECTRICAL JUNCTION BOX REPLACEMENT....................................................................................... WP 0641 Figure 1. Electrical Junction Box Removal.......................................................................................... 0641-2 Figure 2. Electrical Junction Box Removal.......................................................................................... 0641-3 Figure 3. Electrical Junction Box Installation....................................................................................... 0641-4 Figure 4. Electrical Junction Box Installation....................................................................................... 0641-5 400 HZ CONVERTER HARNESS CONDUIT REPLACEMENT.................................................................. WP 0642 Figure 1. Converter Harness Conduit Removal................................................................................... 0642-2 Figure 2. Converter Harness Conduit Installation................................................................................ 0642-3 HEATER THERMOSTAT AND 10 KW HEATER THERMOSTAT REPLACEMENT................................... WP 0643 Figure 1. Heater Thermostat and 10 KW Heater Thermostat and 10 KW Heater Thermostat Removal............................................................................................................ 0643-1 Figure 2. Heater Thermostat and 10 KW Heater Thermostat and 10 KW Heater Thermostat Removal............................................................................................................ 0643-2 Figure 3. Heater Thermostat and 10 KW Heater Thermostat.............................................................. 0643-3 Figure 4. Heater Thermostat and 10 KW Heater Thermostat Installation........................................... 0643-4 BLACKOUT AND EMERGENCY LIGHT FIXTURES REPLACEMENT...................................................... WP 0644 Figure 1. Blackout and Emergency Light Fixtures Removal................................................................ 0644-1 Figure 2. Blackout and Emergency Light Fixtures Installation............................................................. 0644-2 AIR CONDITIONER MANUAL STARTER SWITCHES REPLACEMENT................................................... WP 0645 Figure 1. Air Conditioner Replacement............................................................................................... 0645-2 Figure 2. Air Conditioner Switch.......................................................................................................... 0645-3 Figure 3. Air Conditioner Switch.......................................................................................................... 0645-4 Figure 4. Air Conditioner Switch.......................................................................................................... 0645-5 FLUORESCENT LIGHT FIXTURES REPLACEMENT................................................................................ WP 0646 Figure 1. Fluorescent Light.................................................................................................................. 0646-2 Figure 2. Fluorescent Light.................................................................................................................. 0646-3 cxvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. 400 HZ CONVERTER REPLACEMENT...................................................................................................... WP 0647 Figure 1. 400 Hz Converter Removal.................................................................................................. 0647-3 Figure 2. 400 Hz Converter Installation............................................................................................... 0647-5 ELECTRICAL LOAD CENTER CONDUIT REPLACEMENT....................................................................... WP 0648 Figure 1. Electrical Load Center Conduit Removal............................................................................. 0648-1 Figure 2. Electrical Load Center Conduit Removal............................................................................. 0648-2 Figure 3. Electrical Load Center Conduit Installation.......................................................................... 0648-3 Figure 4. Electrical Load Center Conduit Installation.......................................................................... 0648-4 FRONT WALL REGISTERS REPLACEMENT............................................................................................ WP 0649 Figure 1. Front Wall Registers Removal.............................................................................................. 0649-1 Figure 2. Front Wall Registers Installation........................................................................................... 0649-2 BONNET ACCESS DOOR MAINTENANCE............................................................................................... WP 0650 Figure 1. Bonnet Access Door Removal............................................................................................. 0650-3 Figure 2. Bonnet Access Door Disassembly....................................................................................... 0650-5 Figure 3. Bonnet Access Door Cleaning and Inspection..................................................................... 0650-7 Figure 4. Bonnet Access Door Assembly............................................................................................ 0650-9 Figure 5. Bonnet Access Door Installation........................................................................................ 0650-10 BONNET DOOR MAINTENANCE............................................................................................................... WP 0651 Figure 1. Bonnet Door Removal.......................................................................................................... 0651-3 Figure 2. Bonnet Door Disassembly.................................................................................................... 0651-5 Figure 3. Bonnet Door Cleaning and Inspection.................................................................................. 0651-7 Figure 4. Bonnet Door Assembly......................................................................................................... 0651-9 Figure 5. Bonnet Door Installation..................................................................................................... 0651-10 AIR CONDITIONER REPAIR...................................................................................................................... WP 0652 Figure 1. Air Conditioner Removal...................................................................................................... 0652-3 Figure 2. Air Conditioner Removal...................................................................................................... 0652-5 Figure 3. Air Conditioner Installation................................................................................................... 0652-7 cxviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Air Conditioner Installation................................................................................................... 0652-8 Figure 5. Air Conditioner Installation................................................................................................... 0652-9 MAIN WIRING HARNESS REPLACEMENT............................................................................................... WP 0653 Figure 1. Main Wiring Harness Removal............................................................................................. 0653-3 Figure 2. Main Wiring Harness Installation.......................................................................................... 0653-5 VAN AIR CONDITIONER WIRING HARNESS REPLACEMENT................................................................ WP 0654 Figure 1. Van Air Conditioner Wiring Harness Removal..................................................................... 0654-3 Figure 2. Van Air Conditioner Wiring Harness Installation.................................................................. 0654-5 VAN HEATER WIRING HARNESS REPLACEMENT................................................................................. WP 0655 Figure 1. Van Heater Wiring Harness Removal.................................................................................. 0655-3 Figure 2. Van Heater Wiring Harness Removal.................................................................................. 0655-5 Figure 3. Van Heater Wiring Harness Installation............................................................................... 0655-7 Figure 4. Van Heater Wiring Harness Installation............................................................................... 0655-8 ELECTRIC HEATER (10 KW) WIRING HARNESS REPLACEMENT......................................................... WP 0656 Figure 1. Electric Heater (10 Kw) Wiring Harness Removal................................................................ 0656-3 Figure 2. Electric Heater (10 Kw) Wiring Harness Installation............................................................. 0656-5 BLACKOUT BYPASS WIRING HARNESS REPAIR................................................................................... WP 0657 Figure 1. Blackout Bypass Wiring Harness Removal.......................................................................... 0657-3 Figure 2. Blackout Bypass Wiring Harness Installation....................................................................... 0657-5 EMERGENCY LAMP WIRING HARNESS REPLACEMENT...................................................................... WP 0658 Figure 1. Emergency Lamp Wiring Harness Removal........................................................................ 0658-3 Figure 2. Emergency Wiring Harness Removal.................................................................................. 0658-5 Figure 3. Emergency Lamp Wiring Harness Installation..................................................................... 0658-7 Figure 4. Emergency Lamp Wiring Harness Installation..................................................................... 0658-9 Figure 5. Emergency Lamp Wiring Harness Installation................................................................... 0658-11 BLACKOUT AND CLEARANCE LIGHTS WIRING HARNESS REPLACEMENT....................................... WP 0659 Figure 1. Blackout and Clearance Lights Wiring Harness Removal.................................................... 0659-3 cxix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Blackout and Clearance Lights Wiring Harness Installation................................................. 0659-5 400 HZ SUPPLY WIRING HARNESS REPLACEMENT............................................................................. WP 0660 Figure 1. 400 Hz Supply Wiring Harness Removal............................................................................. 0660-3 Figure 2. 400 Hz Wiring Harness Removal......................................................................................... 0660-5 Figure 3. 400 Hz Supply Wiring Harness Installation.......................................................................... 0660-7 Figure 4. 400 Hz Supply Wiring Harness Removal............................................................................. 0660-9 BRANCHED 400 HZ RECEPTACLE WIRING HARNESS REPLACEMENT.............................................. WP 0661 Figure 1. Branched 400 Hz Receptacle Wiring Harness Removal...................................................... 0661-2 Figure 2. Branched 400 Hz Receptacle Wiring Harness Removal...................................................... 0661-3 Figure 3. Branched 400 Hz Receptacle Wiring Harness Installation................................................... 0661-4 Figure 4. Branched 400 Hz Receptacle Wiring Harness Installation................................................... 0661-5 TELEPHONE POST WIRING HARNESS REPLACEMENT........................................................................ WP 0662 Figure 1. Telephone Post Wiring Harness Removal........................................................................... 0662-2 Figure 2. Telephone Post Wiring Harness Installation........................................................................ 0662-3 3 PHASE RECEPTACLE WIRING HARNESS REPLACEMENT................................................................ WP 0663 Figure 1. 3 Phase Receptacle Wiring Harness Removal.................................................................... 0663-3 Figure 2. 3 Phase Receptacle Wiring Harness Removal.................................................................... 0663-5 FORWARD DECK PLATE REPLACEMENT............................................................................................... WP 0664 Figure 1. Forward Deck Plate Removal............................................................................................... 0664-2 Figure 2. Forward Deck Plate Installation............................................................................................ 0664-3 CRANE BODY HOUSING ASSEMBLY COVER REPLACEMENT............................................................. WP 0665 Figure 1. Crane Body Housing Assembly Cover Removal.................................................................. 0665-2 Figure 2. Crane Body Housing Assembly Cover Installation............................................................... 0665-3 WRECKER BODY REPLACEMENT........................................................................................................... WP 0666 Figure 1. Wrecker Body Removal........................................................................................................ 0666-3 Figure 2. Wrecker Body Installation..................................................................................................... 0666-5 FUEL CAN BRACKET REPLACEMENT..................................................................................................... WP 0667 cxx 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Fuel Can Bracket Removal.................................................................................................. 0667-3 Figure 2. Fuel Can Bracket Installation............................................................................................... 0667-5 FRONT WINCH REPLACEMENT............................................................................................................... WP 0668 Figure 1. Front Winch Removal........................................................................................................... 0668-3 Figure 2. Front Winch Installation........................................................................................................ 0668-5 REAR WINCH ADJUSTMENT..................................................................................................................... WP 0669 Figure 1. Cable Tensioner Check........................................................................................................ 0669-1 Figure 2. Cable Tensioner Adjustment................................................................................................ 0669-2 REAR WINCH REPLACEMENT.................................................................................................................. WP 0670 Figure 1. Rear Winch Removal........................................................................................................... 0670-1 Figure 2. Rear Winch Removal........................................................................................................... 0670-2 Figure 3. Rear Winch Removal........................................................................................................... 0670-3 Figure 4. Rear Winch Removal........................................................................................................... 0670-4 Figure 5. Rear Winch Removal........................................................................................................... 0670-5 Figure 6. Rear Winch Installation........................................................................................................ 0670-6 Figure 7. Rear Winch Installation........................................................................................................ 0670-7 Figure 8. Rear Winch Installation........................................................................................................ 0670-8 Figure 9. Rear Winch Installation........................................................................................................ 0670-9 Figure 10. Rear Winch Installation...................................................................................................... 0670-10 WINCH FRAME EXTENSION REPLACEMENT......................................................................................... WP 0671 Figure 1. Winch Frame Extension Removal........................................................................................ 0671-3 Figure 2. Winch Frame Extension Installation..................................................................................... 0671-5 FRONT WINCH AUTOMATIC BRAKE ADJUSTMENT............................................................................... WP 0672 Figure 1. Front Winch Automatic Brake Testing.................................................................................. 0672-3 Figure 2. Front Winch Automatic Brake Adjustment............................................................................ 0672-4 FRONT WINCH DRAG BRAKE ADJUSTMENT.......................................................................................... WP 0673 Figure 1. Front Winch Drag Brake Testing.......................................................................................... 0673-1 cxxi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Front Winch Drag Brake Testing.......................................................................................... 0673-2 Figure 3. Front Winch Drag Brake Adjustment.................................................................................... 0673-3 FRONT WINCH CABLE CHAIN AND HOOK REPLACEMENT.................................................................. WP 0674 Figure 1. Front Winch Cable Chain and Hook Removal...................................................................... 0674-1 Figure 2. Front Winch Cable Chain and Hook Installation................................................................... 0674-2 FRONT WINCH CABLE CLEVIS REPLACEMENT..................................................................................... WP 0675 Figure 1. Front Winch Cable Clevis Removal...................................................................................... 0675-2 Figure 2. Front Winch Cable Clevis Removal...................................................................................... 0675-3 Figure 3. Front Winch Cable Clevis Installation................................................................................... 0675-4 Figure 4. Front Winch Cable Clevis Installation................................................................................... 0675-5 Figure 5. Front Winch Cable Clevis Installation................................................................................... 0675-5 Figure 6. Front Winch Cable Clevis Installation................................................................................... 0675-6 Figure 7. Front Winch Cable Clevis Installation................................................................................... 0675-6 Figure 8. Front Winch Cable Clevis Installation................................................................................... 0675-7 REAR WINCH ROLLER REPAIR................................................................................................................ WP 0676 Figure 1. Rear Winch Roller Repair - Side Roller Disassembly.......................................................... 0676-2 Figure 2. Rear Winch Roller Repair - Top and Bottom Roller Disassembly........................................ 0676-3 Figure 3. Rear Winch Roller Cleaning and Inspection......................................................................... 0676-5 Figure 4. Rear Winch Roller Repair - Top and Bottom Roller Assembly............................................. 0676-6 Figure 5. Rear Winch Roller Repair - Side Roller Assembly............................................................... 0676-7 FRONT WINCH CABLE TENSIONER REPAIR.......................................................................................... WP 0677 Figure 1. Cable Tensioner Removal.................................................................................................... 0677-2 Figure 2. Cable Tensioner Disassembly.............................................................................................. 0677-3 Figure 3. Cable Tensioner Cleaning and Inspection........................................................................... 0677-5 Figure 4. Cable Tensioner Assembly.................................................................................................. 0677-6 Figure 5. Cable Tensioner Assembly.................................................................................................. 0677-7 Figure 6. Cable Tensioner................................................................................................................... 0677-8 cxxii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. FRONT AND REAR WINCH LEVEL WIND REPAIR................................................................................... WP 0678 Figure 1. Level Wind Disassembly...................................................................................................... 0678-3 Figure 2. Level Wind Disassembly...................................................................................................... 0678-5 Figure 3. Level Wind Disassembly...................................................................................................... 0678-7 Figure 4. Level Wind Cleaning and Inspection.................................................................................... 0678-9 Figure 5. Level Wind Cleaning and Inspection.................................................................................. 0678-10 Figure 6. Level Wind Assembly......................................................................................................... 0678-11 Figure 7. Level Wind Assembly......................................................................................................... 0678-13 Figure 8. Level Wind Assembly......................................................................................................... 0678-15 FRONT WINCH ROLLER ASSEMBLY REPAIR......................................................................................... WP 0679 Figure 1. Front Winch Roller Assembly Removal................................................................................ 0679-2 Figure 2. Roller Assembly Disassembly.............................................................................................. 0679-3 Figure 3. Roller Assembly Cleaning and Inspection............................................................................ 0679-5 Figure 4. Roller Assembly................................................................................................................... 0679-7 Figure 5. Roller Assembly................................................................................................................... 0679-9 Figure 6. Roller Assembly Installation............................................................................................... 0679-10 FRONT WINCH CONTROL VALVE CABLE REPLACEMENT................................................................... WP 0680 Figure 1. Front Winch Control Valve Cable Removal.......................................................................... 0680-2 Figure 2. Winch Control Valve Cable.................................................................................................. 0680-3 Figure 3. Winch Control Valve Cable.................................................................................................. 0680-4 Figure 4. Winch Control Valve Cable Installation................................................................................ 0680-5 FRONT AND REAR WINCH CONTROL VALVE REPLACEMENT............................................................. WP 0681 Figure 1. Front and Rear Winch Control Valve Removal.................................................................... 0681-3 Figure 2. Front and Rear Winch Control Valve Installation................................................................. 0681-5 REAR WINCH HYDRAULIC MOTOR REPLACEMENT.............................................................................. WP 0682 Figure 1. Rear Winch Hydraulic Motor Removal................................................................................. 0682-3 Figure 2. Rear Winch Hydraulic Motor Hoses and Fittings Removal.................................................. 0682-5 cxxiii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Rear Winch Hydraulic Motor Hoses and Fittings Installation............................................... 0682-7 Figure 4. Rear Winch Hydraulic Motor Installation.............................................................................. 0682-9 FRONT WINCH HYDRAULIC PUMP REPLACEMENT.............................................................................. WP 0683 Figure 1. Front Winch Hydraulic Motor Removal................................................................................. 0683-2 Figure 2. Front Winch Hydraulic Motor Installation.............................................................................. 0683-3 FRONT WINCH CABLE REPLACEMENT................................................................................................... WP 0684 Figure 1. Front Winch Cable Removal................................................................................................ 0684-3 Figure 2. Front Winch Cable Installation............................................................................................. 0684-5 FRONT WINCH HYDRAULIC HOSE AND TUBE REPLACEMENT........................................................... WP 0685 Figure 1. Hydraulic Oil Reservoir Hoses Removal.............................................................................. 0685-3 Figure 2. Front Winch Hydraulic Hoses and Tubes Removal.............................................................. 0685-5 Figure 3. Hydraulic Oil Reservoir Hoses Removal.............................................................................. 0685-6 Figure 4. Hydraulic Oil Reservoir Hoses Removal.............................................................................. 0685-7 Figure 5. Hydraulic Oil Reservoir Hoses Installation........................................................................... 0685-8 Figure 6. Hydraulic Oil Reservoir Hoses Installation........................................................................... 0685-9 Figure 7. Front Winch Hydraulic Hoses and Tubes Installation......................................................... 0685-11 Figure 8. Hydraulic Tubes and Hoses Installation............................................................................. 0685-13 BOOM REPLACEMENT.............................................................................................................................. WP 0686 Figure 1. Boom Removal..................................................................................................................... 0686-3 Figure 2. Boom Installation.................................................................................................................. 0686-5 INNER BOOM REPLACEMENT.................................................................................................................. WP 0687 Figure 1. Inner Boom Removal............................................................................................................ 0687-3 Figure 2. Inner Boom Installation......................................................................................................... 0687-5 BOOM ROLLER REPAIR............................................................................................................................ WP 0688 Figure 1. Boom Roller Removal.......................................................................................................... 0688-3 Figure 2. Boom Roller Installation....................................................................................................... 0688-5 CRANE SWIVEL VALVE REPAIR............................................................................................................... WP 0689 cxxiv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Wiring Harness Removal...................................................................................................... 0689-3 Figure 2. Crane Swivel Valve Removal............................................................................................... 0689-5 Figure 3. Crane Swivel Valve Removal............................................................................................... 0689-7 Figure 4. Crane Swivel Valve Installation............................................................................................ 0689-9 Figure 5. Crane Swivel Valve Installation.......................................................................................... 0689-11 Figure 6. Wiring Harness Connections.............................................................................................. 0689-13 CRANE HYDRAULIC SWING MOTOR REPLACEMENT........................................................................... WP 0690 Figure 1. Crane Hydraulic Swing Motor Removal............................................................................... 0690-3 Figure 2. Crane Hydraulic Swing Motor Installation............................................................................ 0690-4 CRANE SWING GEARCASE REPLACEMENT.......................................................................................... WP 0691 Figure 1. Crane Swing Gearcase Removal......................................................................................... 0691-2 Figure 2. Crane Swing Gearcase Installation...................................................................................... 0691-3 TURNTABLE REPAIR................................................................................................................................. WP 0692 Figure 1. Turntable Removal............................................................................................................... 0692-2 Figure 2. Turntable Gear and Bearing Removal.................................................................................. 0692-3 Figure 3. Turntable Gear and Bearing Installation............................................................................... 0692-5 Figure 4. Turntable Installation............................................................................................................ 0692-7 BOOM ELEVATING CYLINDER REPLACEMENT...................................................................................... WP 0693 Figure 1. Boom Elevating Cylinder Removal....................................................................................... 0693-3 Figure 2. Boom Elevating Cylinder Installation.................................................................................... 0693-5 FRONT WINCH MOTOR REPLACEMENT................................................................................................. WP 0694 Figure 1. Front Winch Motor Removal................................................................................................. 0694-2 Figure 2. Front Winch Motor Removal................................................................................................. 0694-3 Figure 3. Front Winch Motor Removal................................................................................................. 0694-4 Figure 4. Front Winch Motor Installation.............................................................................................. 0694-5 Figure 5. Front Winch Motor Installation.............................................................................................. 0694-5 Figure 6. Front Winch Motor Installation.............................................................................................. 0694-6 cxxv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. BOOM EXTENSION CYLINDER REPLACEMENT..................................................................................... WP 0695 Figure 1. Boom Extension Cylinder Removal...................................................................................... 0695-3 Figure 2. Boom Extension Cylinder Installation................................................................................... 0695-5 HOIST WINCH REPLACEMENT................................................................................................................. WP 0696 Figure 1. Hoist Winch Removal........................................................................................................... 0696-3 Figure 2. Hoist Winch Disassembly..................................................................................................... 0696-5 Figure 3. Hoist Winch Disassembly..................................................................................................... 0696-7 Figure 4. Hoist Winch Disassembly..................................................................................................... 0696-9 Figure 5. Hoist Winch Disassembly................................................................................................... 0696-11 Table 1. Hoist Winch Wear Limits.................................................................................................... 0696-13 Figure 6. Hoist Winch Assembly........................................................................................................ 0696-15 Figure 7. Hoist Winch Assembly........................................................................................................ 0696-17 Figure 8. Hoist Winch Assembly........................................................................................................ 0696-19 Figure 9. Hoist Winch Installation...................................................................................................... 0696-20 HOIST LEVEL WIND REPLACEMENT....................................................................................................... WP 0697 Figure 1. Hoist Level Wind Removal................................................................................................... 0697-2 Figure 2. Hoist Level Wind Installation................................................................................................ 0697-3 CRANE GONDOLA CONTROL VALVE REPAIR........................................................................................ WP 0698 Figure 1. Control Valve Cover Removal.............................................................................................. 0698-2 Figure 2. Hose Removal...................................................................................................................... 0698-3 Figure 3. Crane Gondola Control Valve Disassembly......................................................................... 0698-4 Figure 4. Crane Gondola Control Valve Disassembly......................................................................... 0698-5 Figure 5. Crane Gondola Control Valve Disassembly......................................................................... 0698-6 Figure 6. Crane Gondola Control Valve Disassembly......................................................................... 0698-7 Figure 7. Crane Control Valve Disassembly........................................................................................ 0698-9 Figure 8. Crane Gondola Control Valve Assembly............................................................................ 0698-11 Figure 9. Crane Gondola Control Valve Assembly............................................................................ 0698-12 cxxvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 10. Crane Gondola Control Valve Assembly............................................................................ 0698-13 Figure 11. Crane Gondola Control Valve Assembly............................................................................ 0698-14 Figure 12. Crane Gondola Control Valve Installation.......................................................................... 0698-15 Figure 13. Crane Gondola Control Valve Installation.......................................................................... 0698-16 Figure 14. Crane Gondola Control Valve Installation.......................................................................... 0698-17 GONDOLA REPAIR..................................................................................................................................... WP 0699 Figure 1. Gondola Removal................................................................................................................. 0699-3 Figure 2. Gondola Removal................................................................................................................. 0699-4 Figure 3. Gondola Installation.............................................................................................................. 0699-5 Figure 4. Gondola Installation.............................................................................................................. 0699-6 HYDRAULIC HOIST WINCH MOTOR AND LINES REPLACEMENT......................................................... WP 0700 Figure 1. Hydraulic Hoist Winch Motor and Lines Removal................................................................ 0700-3 Figure 2. Hydraulic Hoist Winch Motor and Lines Installation............................................................. 0700-4 WINCH HYDRAULIC OIL RESERVOIR REPLACEMENT.......................................................................... WP 0701 Figure 1. Winch Hydraulic Oil Reservoir Removal.............................................................................. 0701-3 Figure 2. Winch Hydraulic Oil Reservoir Removal.............................................................................. 0701-4 Figure 3. Winch Hydraulic Oil Reservoir Installation........................................................................... 0701-5 Figure 4. Winch Hydraulic Oil Reservoir Installation........................................................................... 0701-6 TRACTOR WINCH HYDRAULIC OIL RESERVOIR REPLACEMENT (M932/A1/A2)................................ WP 0702 Figure 1. Tractor Winch Hydraulic Oil Reservoir Removal.................................................................. 0702-3 Figure 2. Tractor Winch Hydraulic Oil Reservoir Removal.................................................................. 0702-5 Figure 3. Tractor Winch Hydraulic Oil Reservoir Removal.................................................................. 0702-7 Figure 4. Tractor Winch Hydraulic Oil Reservoir Installation............................................................... 0702-9 Figure 5. Tractor Winch Hydraulic Oil Reservoir Installation............................................................. 0702-10 Figure 6. Tractor Winch Hydraulic Oil Reservoir Installation............................................................. 0702-11 WRECKER HYDRAULIC OIL RESERVOIR, BRACKETS AND STRAPS REPAIR.................................... WP 0703 Figure 1. Hydraulic Oil Reservoir Removal......................................................................................... 0703-3 cxxvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Hydraulic Oil Reservoir Brackets and Straps Removal........................................................ 0703-4 Figure 3. Hydraulic Oil Reservoir Disassembly................................................................................... 0703-5 Figure 4. Hydraulic Oil Reservoir, Brackets and Straps Assembly...................................................... 0703-7 Figure 5. Hydraulic Oil Reservoir Brackets and Straps Installation..................................................... 0703-8 Figure 6. Hydraulic Oil Reservoir Installation...................................................................................... 0703-9 WINCH HYDRAULIC OIL RESERVOIR FILTER REPLACEMENT............................................................. WP 0704 Figure 1. Winch Hydraulic Oil Reservoir Filter Removal..................................................................... 0704-3 Figure 2. Winch Hydraulic Oil Reservoir Filter Installation.................................................................. 0704-5 PRESSURE RELIEF VALVE ADJUSTMENT.............................................................................................. WP 0705 Figure 1. Pressure Relief Valve Testing.............................................................................................. 0705-2 Figure 2. Pressure Relief Valve Adjustment........................................................................................ 0705-3 SNUBBER VALVE ASSEMBLY REPLACEMENT....................................................................................... WP 0706 Figure 1. Snubber Valve Assembly Removal...................................................................................... 0706-3 Figure 2. Snubber Valve Assembly Installation................................................................................... 0706-5 CRANE HYDRAULIC FILTER AND HOUSING REPAIR............................................................................ WP 0707 Figure 1. Hydraulic Oil Filter Housing.................................................................................................. 0707-3 Figure 2. Hydraulic Crane Filter........................................................................................................... 0707-4 Figure 3. Hydraulic Crane Filter........................................................................................................... 0707-5 Figure 4. Crane Hydraulic Filter........................................................................................................... 0707-7 Figure 5. Crane Hydraulic Filter........................................................................................................... 0707-8 Figure 6. Hydraulic Oil Filter Housing.................................................................................................. 0707-9 AUTOMATIC BRAKE (HOIST WINCH) SERVICING.................................................................................. WP 0708 Figure 1. Automatic Brake (Hoist Winch) Adjustment......................................................................... 0708-2 HOIST WINCH CABLE REPLACEMENT.................................................................................................... WP 0709 Figure 1. Hoist Winch Cable Removal................................................................................................. 0709-3 Figure 2. Hoist Winch Cable Removal................................................................................................. 0709-4 Figure 3. Hoist Winch Cable Installation.............................................................................................. 0709-5 cxxviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Hoist Winch Cable Installation.............................................................................................. 0709-7 REAR WINCH CABLE REPLACEMENT..................................................................................................... WP 0710 Figure 1. Rear Winch Cable Removal................................................................................................. 0710-1 Figure 2. Rear Winch Cable Removal................................................................................................. 0710-2 Figure 3. Rear Winch Cable Installation.............................................................................................. 0710-3 Figure 4. Rear Winch Cable Installation.............................................................................................. 0710-3 WRECKER CRANE HYDRAULIC HOSE AND TUBE REPLACEMENT..................................................... WP 0711 Figure 1. Wrecker Crane Hydraulic Hose and Tube Removal............................................................ 0711-3 Figure 2. Wrecker Crane Hydraulic Hose and Tube Installation......................................................... 0711-5 WRECKER CRANE HYDRAULIC PUMP REPLACEMENT........................................................................ WP 0712 Figure 1. Wrecker Crane Hydraulic Pump Removal............................................................................ 0712-3 Figure 2. Wrecker Crane Hydraulic Pump Installation......................................................................... 0712-5 TRANSMISSION PTO-TO-HYDRAULIC PUMP PROPELLER SHAFT REPAIR........................................ WP 0713 Figure 1. Transmission PTO-To-Hydraulic Pump Propeller Shaft Removal........................................ 0713-1 Figure 2. Transmission PTO-To-Hydraulic Pump Propeller Shaft Removal........................................ 0713-2 Figure 3. Transmission PTO-To-Hydraulic Pump Propeller Shaft Removal........................................ 0713-3 Figure 4. Transmission PTO-To-Hydraulic Pump Propeller Shaft Removal........................................ 0713-3 Figure 5. Transmission PTO-To-Hydraulic Pump Propeller Shaft Assembly...................................... 0713-4 Figure 6. Transmission PTO-To-Hydraulic Pump Propeller Shaft Assembly...................................... 0713-5 Figure 7. Transmission PTO-To-Hydraulic Pump Propeller Shaft Assembly...................................... 0713-6 Figure 8. Transmission PTO-To-Hydraulic Pump Propeller Shaft Assembly...................................... 0713-7 Figure 9. Transmission PTO-To-Hydraulic Pump Propeller Shaft Installation..................................... 0713-8 TRANSFER PTO-TO-HYDRAULIC PUMP PROPELLER SHAFT REPAIR................................................ WP 0714 Figure 1. Transfer PTO-to-Hydraulic Pump Propeller Shaft Removal................................................. 0714-2 Figure 2. Transfer PTO-to-Hydraulic Pump Propeller Shaft Installation.............................................. 0714-3 DUMP BODY HYDRAULIC HOSE REPLACEMENT.................................................................................. WP 0715 Figure 1. Hydraulic Hoses................................................................................................................... 0715-3 cxxix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Hydraulic Hoses................................................................................................................... 0715-4 Figure 3. Hydraulic Hoses................................................................................................................... 0715-5 Figure 4. Hydraulic Hoses................................................................................................................... 0715-6 Figure 5. Hydraulic Hoses................................................................................................................... 0715-7 Figure 6. Hydraulic Hoses................................................................................................................... 0715-8 DUMP VALVE CABLE AND SHIFT LEVER REPLACEMENT.................................................................... WP 0716 Figure 1. Valve Cable and Shift Lever Removal.................................................................................. 0716-3 Figure 2. Valve Cable and Shift Lever Installation............................................................................... 0716-5 DUMP SUBFRAME REPLACEMENT......................................................................................................... WP 0717 Figure 1. Dump Subframe Removal.................................................................................................... 0717-3 Figure 2. Dump Subframe Removal.................................................................................................... 0717-5 Figure 3. Dump Subframe Removal.................................................................................................... 0717-7 Figure 4. Dump Subframe Installation................................................................................................. 0717-9 Figure 5. Dump Subframe Installation............................................................................................... 0717-10 DUMP SAFETY BRACE REPLACEMENT.................................................................................................. WP 0718 Figure 1. Dump Safety Brace Removal............................................................................................... 0718-2 Figure 2. Dump Safety Brace Installation............................................................................................ 0718-3 DUMP HYDRAULIC PUMP REPLACEMENT............................................................................................. WP 0719 DUMP CONTROL VALVE REPLACEMENT............................................................................................... WP 0720 FRONT AND REAR WINCH CONTROL VALVE REPLACEMENT (M930/A1/A2)..................................... WP 0721 Figure 1. Front and Rear Winch Control Valve Removal.................................................................... 0721-2 Figure 2. Front and Rear Winch Control Valve Removal.................................................................... 0721-3 Figure 3. Front and Rear Winch Control Valve Installation................................................................. 0721-4 Figure 4. Front and Rear Winch Control Valve Installation................................................................. 0721-5 REAR WINCH CABLE TENSIONER REPAIR............................................................................................. WP 0722 Figure 1. Rear Winch Cable Tensioner Disassembly.......................................................................... 0722-3 Figure 2. Rear Winch Cable Tensioner Disassembly.......................................................................... 0722-5 cxxx 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Rear Winch Cable Tensioner Assembly............................................................................... 0722-7 Figure 4. Rear Winch Assembly.......................................................................................................... 0722-8 DUMP ROLLER ARM REPLACEMENT...................................................................................................... WP 0723 Figure 1. Dump Roller Removal.......................................................................................................... 0723-2 Figure 2. Dump Roller Installation....................................................................................................... 0723-3 DUMP HOIST CYLINDER REPLACEMENT............................................................................................... WP 0724 Figure 1. Dump Hoist Cylinder Removal............................................................................................. 0724-2 Figure 2. Dump Hoist Cylinder Removal............................................................................................. 0724-3 Figure 3. Dump Hoist Cylinder Removal............................................................................................. 0724-4 Figure 4. Dump Hoist Cylinder Installation.......................................................................................... 0724-5 Figure 5. Dump Hoist Cylinder Installation.......................................................................................... 0724-6 Figure 6. Dump Hoist Cylinder Installation.......................................................................................... 0724-7 TRANSFER CASE POWER TAKEOFF (PTO) REPLACEMENT................................................................ WP 0725 Figure 1. Transfer Case PTO Removal............................................................................................... 0725-3 Figure 2. PTO Shaft Disassembly....................................................................................................... 0725-5 Figure 3. PTO Shift Lever Disassembly.............................................................................................. 0725-6 Figure 4. PTO Clutch Collar Disassembly........................................................................................... 0725-7 Figure 5. PTO Disassembly................................................................................................................. 0725-8 Figure 6. PTO Disassembly................................................................................................................. 0725-9 Figure 7. PTO Disassembly................................................................................................................. 0725-9 Figure 8. PTO Disassembly............................................................................................................... 0725-10 Figure 9. PTO Cleaning and Inspection............................................................................................ 0725-11 Figure 10. PTO Cleaning and Inspection............................................................................................ 0725-11 Figure 11. PTO Cleaning and Inspection............................................................................................ 0725-12 Figure 12. PTO Cleaning and Inspection............................................................................................ 0725-12 Figure 13. Transfer Case PTO Assembly............................................................................................ 0725-13 Figure 14. Transfer Case PTO Assembly............................................................................................ 0725-14 cxxxi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 15. Transfer Case PTO Assembly............................................................................................ 0725-15 Figure 16. Transfer Case PTO Assembly............................................................................................ 0725-17 Figure 17. Transfer Case PTO Assembly............................................................................................ 0725-19 Figure 18. Transfer Case PTO Assembly............................................................................................ 0725-20 Figure 19. Transfer Case PTO Assembly............................................................................................ 0725-21 Figure 20. Transfer Case PTO Assembly............................................................................................ 0725-21 Figure 21. Transfer Case PTO Installation.......................................................................................... 0725-23 TRANSFER CASE POWER TAKEOFF (PTO) CONTROL CABLE REPLACEMENT................................ WP 0726 Figure 1. Transfer Case PTO Control Cable Removal........................................................................ 0726-2 Figure 2. Transfer Case PTO Control Cable Removal........................................................................ 0726-3 Figure 3. Transfer Case PTO Control Cable Installation..................................................................... 0726-4 Figure 4. Transfer Case PTO Control Cable Installation..................................................................... 0726-5 TRANSFER CASE POWER TAKEOFF (PTO) CROSS SHAFT (CONTROL LEVER) REPLACEMENT.......................................................................................................................................... WP 0727 Figure 1. Transfer Case PTO Cross Shaft (Control Lever) Removal.................................................. 0727-3 Figure 2. Transfer Case PTO Cross Shaft (Control Lever) Installation............................................... 0727-5 TRANSMISSION POWER TAKEOFF (PTO) REPLACEMENT................................................................... WP 0728 Figure 1. Transmission PTO Removal................................................................................................ 0728-3 Figure 2. Transmission PTO Removal................................................................................................ 0728-5 Figure 3. Transmission PTO Installation............................................................................................. 0728-7 Figure 4. Transmission PTO Installation............................................................................................. 0728-9 TRANSMISSION POWER TAKEOFF (PTO) CONTROL CABLE REPLACEMENT................................... WP 0729 Figure 1. Transmission Control Cable Removal.................................................................................. 0729-2 Figure 2. Transmission Control Cable Removal.................................................................................. 0729-3 Figure 3. Transmission Control Cable Installation............................................................................... 0729-4 Figure 4. Transmission Control Cable Installation............................................................................... 0729-5 TRANSMISSION POWER TAKEOFF (PTO) CONTROL CABLE REPLACEMENT (M939A2)..................................................................................................................................................... WP 0730 cxxxii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Transmission PTO Control Cable Removal (M939A2)......................................................... 0730-2 Figure 2. Transmission PTO Control Cable Removal (M939A2)......................................................... 0730-3 Figure 3. Transmission PTO Control Cable Installation (M939A2)...................................................... 0730-4 Figure 4. Transmission PTO Control Cable Installation (M939A2)...................................................... 0730-5 CARGO BODY COVER BOWS REPLACEMENT....................................................................................... WP 0731 Figure 1. Cargo Body Cover Bows Removal....................................................................................... 0731-2 Figure 2. Cargo Body Cover Bows Installation.................................................................................... 0731-3 CAB TURNBUTTONS AND LASHING HOOKS REPLACEMENT.............................................................. WP 0732 Figure 1. Cab Turnbuttons and Lashing Hooks Removal.................................................................... 0732-2 Figure 2. Cab Turnbuttons and Lashing Hooks Installation................................................................. 0732-3 CAB TOP SEAL AND RETAINER REPAIR................................................................................................. WP 0733 Figure 1. Cab Top Seal and Retainer Repair...................................................................................... 0733-1 Figure 2. Cab Top Seal and Retainer Installation................................................................................ 0733-2 CARGO LOWER WHEEL SPLASH GUARD REPLACEMENT................................................................... WP 0734 Figure 1. Lower Wheel Splash Guard Replacement........................................................................... 0734-1 Figure 2. Lower Wheel Splash Guard Installation............................................................................... 0734-2 WINDSHIELD WIPER CONTROL VALVE REPLACEMENT...................................................................... WP 0735 Figure 1. Windshield Wiper Control Valve Removal............................................................................ 0735-3 Figure 2. Windshield Wiper Control Valve Installation......................................................................... 0735-4 WINDSHIELD WIPER BLADE, WIPER ARM, AND WIPER MOTOR REPLACEMENT............................. WP 0736 Figure 1. Windshield Wiper Blade, Wiper Arm, and Wiper Motor Removal........................................ 0736-3 Figure 2. Windshield Wiper Blade, Wiper Arm, and Wiper Motor Removal........................................ 0736-4 WINDSHIELD WIPER RESERVOIR, JET, CONTROL, AND WASHER HOSES REPLACEMENT.......................................................................................................................................... WP 0737 Figure 1. Windshield Washer Hoses Removal.................................................................................... 0737-2 Figure 2. Windshield Washer Hoses Installation................................................................................. 0737-3 Figure 3. Windshield Wiper Reservoir Removal.................................................................................. 0737-5 Figure 4. Windshield Wiper Reservoir Installation............................................................................... 0737-7 cxxxiii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. REARVIEW MIRROR AND BRACE REPLACEMENT................................................................................ WP 0738 Figure 1. Rearview Mirror and Brace Removal................................................................................... 0738-3 Figure 2. Rearview Mirror and Brace Installation................................................................................ 0738-5 WASHER CONTROL VALVE REPLACEMENT.......................................................................................... WP 0739 Figure 1. Washer Control Valve Removal........................................................................................... 0739-3 Figure 2. Washer Control Valve Installation........................................................................................ 0739-4 REFLECTORS REPLACEMENT................................................................................................................. WP 0740 Figure 1. Reflectors Removal.............................................................................................................. 0740-1 Figure 2. Reflectors Installation........................................................................................................... 0740-2 FRESH AIR VENT CONTROL CABLE ASSEMBLY REPLACEMENT....................................................... WP 0741 Figure 1. Fresh Air Vent Control Assembly Removal.......................................................................... 0741-1 Figure 2. Fresh Air Vent Control Assembly Removal.......................................................................... 0741-2 Figure 3. Fresh Air Vent Control Assembly Installation....................................................................... 0741-3 Figure 4. Fresh Air Vent Control Assembly Installation....................................................................... 0741-4 DIVERTER ASSEMBLY REPLACEMENT.................................................................................................. WP 0742 Figure 1. Diverter Assembly Removal................................................................................................. 0742-1 Figure 2. Diverter Assembly Removal................................................................................................. 0742-2 Figure 3. Diverter Assembly Installation.............................................................................................. 0742-3 Figure 4. Diverter Assembly Installation.............................................................................................. 0742-4 FRESH AIR INLET DUCTING REPLACEMENT......................................................................................... WP 0743 Figure 1. Fresh Air Inlet Ducting Removal........................................................................................... 0743-2 Figure 2. Fresh Air Inlet Ducting Installation........................................................................................ 0743-3 CAB HEAT AND DEFROST AIR DUCTING REPLACEMENT.................................................................... WP 0744 Figure 1. Cab Heat and Defrost Air Ducting Removal......................................................................... 0744-1 Figure 2. Cab Heat and Defrost Air Ducting Installation...................................................................... 0744-2 DEFROST AND HEAT CONTROLS REPLACEMENT................................................................................ WP 0745 Figure 1. Defrost and Heat Controls Removal..................................................................................... 0745-2 cxxxiv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Defrost and Heat Controls Removal..................................................................................... 0745-3 Figure 3. Defrost and Heat Controls Installation.................................................................................. 0745-4 Figure 4. Defrost and Heat Controls Installation.................................................................................. 0745-5 PERSONNEL HEATER HOSES REPLACEMENT...................................................................................... WP 0746 Figure 1. Personnel Heater Hoses Removal....................................................................................... 0746-3 Figure 2. Personnel Heater Hoses Installation.................................................................................... 0746-4 PERSONNEL HOT WATER HEATER REPLACEMENT............................................................................. WP 0747 Figure 1. Personnel Hot Water Heater Removal................................................................................. 0747-3 Figure 2. Personnel Hot Water Heater Installation.............................................................................. 0747-5 ENGINE COOLANT HEATER REPLACEMENT......................................................................................... WP 0748 Figure 1. Engine Coolant Heater Removal.......................................................................................... 0748-3 Figure 2. Engine Coolant Heater Installation....................................................................................... 0748-5 RADIATOR COVER KIT REPLACEMENT.................................................................................................. WP 0749 Figure 1. Radiator Cover Kit Removal................................................................................................. 0749-1 Figure 2. Radiator Cover Kit Installation.............................................................................................. 0749-2 HARDTOP KIT REPLACEMENT................................................................................................................. WP 0750 Figure 1. Hardtop Kit Removal............................................................................................................ 0750-3 Figure 2. Hardtop Kit Installation......................................................................................................... 0750-5 PERSONNEL FUEL BURNING HEATER AND MOUNTING BRACKET REPLACEMENT (M939/ A1)............................................................................................................................................................... WP 0751 Figure 1. Personnel Fuel Burning Heater and Mounting Bracket Removal (M939/A1)....................... 0751-2 Figure 2. Personnel Fuel Burning Heater and Mounting Bracket Installation (M939/A1).................... 0751-3 ENGINE COOLANT HEATER PUMP REPLACEMENT.............................................................................. WP 0752 Figure 1. Engine Coolant Heater Pump Removal............................................................................... 0752-3 Figure 2. Engine Coolant Heater Pump Installation............................................................................ 0752-5 ENGINE COOLANT HEATER CONTROL BOX REPLACEMENT.............................................................. WP 0753 Figure 1. Engine Coolant Heater Control Box Removal...................................................................... 0753-2 Figure 2. Engine Coolant Heater Control Box Installation................................................................... 0753-3 cxxxv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. ENGINE COOLANT HEATER HARNESS REPLACEMENT (M939/A1)..................................................... WP 0754 Figure 1. Engine Coolant Heater Harness Removal........................................................................... 0754-3 Figure 2. Engine Coolant Heater Harness Installation........................................................................ 0754-5 ENGINE COOLANT HEATER HARNESS REPLACEMENT (M939/A2)..................................................... WP 0755 Figure 1. Engine Coolant Heater Harness Removal........................................................................... 0755-3 Figure 2. Engine Coolant Heater Harness Installation........................................................................ 0755-5 ENGINE COOLANT OIL PAN SHROUD AND EXHAUST TUBE REPLACEMENT.................................... WP 0756 Figure 1. Engine Coolant Oil Pan Shroud and Exhaust Tube Removal.............................................. 0756-2 Figure 2. Engine Coolant Oil Pan Shroud and Exhaust Tube Installation........................................... 0756-3 ENGINE COOLANT HEATER HOSE REPLACEMENT.............................................................................. WP 0757 Figure 1. Engine Coolant Heater Hose Removal................................................................................ 0757-3 Figure 2. Engine Coolant Heater Hose Removal................................................................................ 0757-5 Figure 3. Engine Coolant Heater Hose Removal................................................................................ 0757-6 Figure 4. Engine Coolant Heater Hose Installation............................................................................. 0757-7 Figure 5. Hoses and Electrical Harness Installation............................................................................ 0757-9 Figure 6. Engine Coolant Heater Hose Installation........................................................................... 0757-11 ENGINE COOLANT BATTERY BOX HEATER PAD REPLACEMENT....................................................... WP 0758 Figure 1. Engine Coolant Battery Box Heater Pad Removal............................................................... 0758-3 Figure 2. Engine Coolant Battery Box Heater Pad Installation............................................................ 0758-5 PERSONNEL FUEL BURNING HEATER CONTROL BOX REPLACEMENT............................................ WP 0759 Figure 1. Personnel Fuel Burning Heater Control Box Removal......................................................... 0759-2 Figure 2. Personnel Fuel Burning Heater Control Box Installation...................................................... 0759-3 PERSONNEL FUEL BURNING HEATER AND MOUNTING BRACKETS REPLACEMENT (M939A2)..................................................................................................................................................... WP 0760 Figure 1. Personnel Fuel Burning Heater and Mounting Brackets Removal....................................... 0760-3 Figure 2. Personnel Fuel Burning Heater and Mounting Brackets Installation.................................... 0760-4 PERSONNEL FUEL BURNING HEATER FUEL PUMP REPLACEMENT (M939/A1)................................ WP 0761 Figure 1. Personnel Fuel Burning Heater Fuel Pump Removal.......................................................... 0761-3 cxxxvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Personnel Fuel Burning Heater Fuel Pump Installation....................................................... 0761-5 PERSONNEL FUEL BURNING HEATER ELECTRIC FUEL PUMP REPLACEMENT (M939A2)..................................................................................................................................................... WP 0762 Figure 1. Personnel Fuel Burning Heater Electric Fuel Pump Removal.............................................. 0762-3 Figure 2. Personnel Fuel Burning Heater Electric Fuel Pump Installation........................................... 0762-4 PERSONNEL FUEL BURNING HEATER FUEL SHUTOFF VALVE REPLACEMENT............................... WP 0763 Figure 1. Fuel Burning Heater Fuel Shutoff Valve Removal................................................................ 0763-3 Figure 2. Fuel Burning Heater Fuel Shutoff Valve Installation............................................................. 0763-5 PERSONNEL FUEL BURNING HEATER WIRING HARNESS REPLACEMENT....................................... WP 0764 Figure 1. Personnel Fuel Burning Heater Wiring Harness Removal................................................... 0764-3 Figure 2. Personnel Fuel Burning Heater Wiring Harness Installation................................................ 0764-5 PERSONNEL FUEL BURNING HEATER EXHAUST TUBE REPLACEMENT (M939/A1)......................... WP 0765 Figure 1. Fuel Burning Heater Exhaust Tube Removal....................................................................... 0765-3 Figure 2. Fuel Burning Heater Exhaust Tube Installation.................................................................... 0765-5 PERSONNEL FUEL BURNING HEATER EXHAUST TUBE REPLACEMENT (M939A2).......................... WP 0766 Figure 1. Fuel Burning Heater Exhaust Tube Removal....................................................................... 0766-3 Figure 2. Fuel Burning Heater Exhaust Tube Installation.................................................................... 0766-4 PERSONNEL FUEL BURNING HEATER CIRCUIT BREAKER REPLACEMENT...................................... WP 0767 Figure 1. Personnel Fuel Burning Heater Circuit Breaker Removal.................................................... 0767-2 Figure 2. Personnel Fuel Burning Heater Circuit Breaker Installation................................................. 0767-3 DEEPWATER FORDING CONTROL CABLE REPLACEMENT................................................................. WP 0768 Figure 1. Deepwater Fording Control Removal................................................................................... 0768-3 Figure 2. Deepwater Fording Control Installation................................................................................ 0768-5 DEEPWATER FORDING PRESSURIZATION VALVE REPLACEMENT................................................... WP 0769 Figure 1. Deepwater Fording Pressurization Valve Removal (M939/A1)............................................ 0769-3 Figure 2. Deepwater Fording Pressurization Valve Removal (M939/A2)............................................ 0769-5 Figure 3. Deepwater Fording Pressurization Valve Installation (M939/A2)......................................... 0769-7 Figure 4. Deepwater Fording Pressurization Valve Installation (M939/A1)......................................... 0769-9 cxxxvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. DEEPWATER FORDING AIR PRESSURE HOSE REPLACEMENT.......................................................... WP 0770 Figure 1. Deepwater Fording Air Pressure Hose Removal (M939/A1)................................................ 0770-3 Figure 2. Deepwater Fording Air Pressure Hose Removal (M939A2)................................................. 0770-5 Figure 3. Deepwater Fording Air Pressure Hose Installation (M939A2).............................................. 0770-7 Figure 4. Deepwater Fording Air Pressure Hose Installation (M939/A1)............................................. 0770-9 Index Volume 5 Chapter 10 - MAINTENANCE INSTRUCTIONS DEEPWATER FORDING REGULATOR VALVE REPLACEMENT............................................................. WP 0771 Figure 1. Deepwater Fording Regulator Valve Removal..................................................................... 0771-2 Figure 2. Deepwater Fording Regulator Valve Installation.................................................................. 0771-3 A-FRAME COMPONENTS REPLACEMENT.............................................................................................. WP 0772 Figure 1. A-Frame Components Removal........................................................................................... 0772-3 Figure 2. A-Frame Components Removal........................................................................................... 0772-5 Figure 3. A-Frame Components Installation........................................................................................ 0772-7 Figure 4. A-Frame Components.......................................................................................................... 0772-9 FIRE EXTINGUISHER MOUNTING BRACKET REPLACEMENT.............................................................. WP 0773 Figure 1. Fire Extinguisher Mounting Bracket Removal...................................................................... 0773-2 Figure 2. Fire Extinguisher Mounting Bracket Installation................................................................... 0773-3 CHEMICAL AGENT ALARM MOUNTING BRACKET REPLACEMENT..................................................... WP 0774 Figure 1. Chemical Agent Alarm Wiring Harness Removal................................................................. 0774-3 Figure 2. Chemical Agent Alarm Wiring Harness Removal................................................................. 0774-5 Figure 3. Detector and Alarm Bracket Removal.................................................................................. 0774-7 Figure 4. Detector and Alarm Bracket Installation............................................................................... 0774-8 Figure 5. Chemical Agent Alarm Wiring Harness Installation.............................................................. 0774-9 Figure 6. Chemical Agent Alarm Wiring Harness Installation............................................................ 0774-10 LIGHTWEIGHT WEAPON STATION MODIFICATION COMPONENT REPLACEMENT........................... WP 0775 cxxxviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Weapon Station Removal..................................................................................................... 0775-2 Figure 2. Weapon Station Removal..................................................................................................... 0775-3 Figure 3. Weapon Station Removal..................................................................................................... 0775-4 Figure 4. Weapon Station Removal..................................................................................................... 0775-5 Figure 5. Weapon Station Removal..................................................................................................... 0775-7 Figure 6. Weapon Station Removal..................................................................................................... 0775-9 Figure 7. Weapon Station Removal................................................................................................... 0775-11 Figure 8. Weapon Station Removal................................................................................................... 0775-13 Figure 9. Weapon Station Disassembly............................................................................................ 0775-15 Figure 10. Weapon Station Disassembly............................................................................................ 0775-17 Figure 11. Weapon Station Disassembly............................................................................................ 0775-19 Figure 12. Weapon Station Disassembly............................................................................................ 0775-20 Figure 13. Lightweight Weapon Station Assembly.............................................................................. 0775-21 Figure 14. Lightweight Weapon Station Assembly.............................................................................. 0775-23 Figure 15. Lightweight Weapon Station Assembly.............................................................................. 0775-25 Figure 16. Lightweight Weapon Station Assembly.............................................................................. 0775-26 Figure 17. Lightweight Weapon Station Installation............................................................................ 0775-27 Figure 18. Lightweight Weapon Station Installation............................................................................ 0775-28 Figure 19. Lightweight Weapon Station Installation............................................................................ 0775-29 Figure 20. Lightweight Weapon Station Installation............................................................................ 0775-30 Figure 21. Lightweight Weapon Station Installation............................................................................ 0775-31 Figure 22. Lightweight Weapon Station Installation............................................................................ 0775-32 Figure 23. Lightweight Weapon Station Installation............................................................................ 0775-33 Figure 24. Lightweight Weapon Station Installation............................................................................ 0775-35 Figure 25. Lightweight Weapon Station Installation............................................................................ 0775-37 Figure 26. Light Weapon Station Installation....................................................................................... 0775-39 Figure 27. Lightweight Weapon Station Installation............................................................................ 0775-40 cxxxix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 28. Lightweight Weapon Station Installation............................................................................ 0775-41 DECONTAMINATION APPARATUS AND MOUNTING BRACKET REPLACEMENT (M13)..................... WP 0776 Figure 1. Decontamination Apparatus and Mounting Bracket Removal (M929/A1/A2, M930/A1/A2, M931/A1/A2, M932/A1/A2)............................................................................. 0776-2 Figure 2. Decontamination Apparatus and Mounting Bracket Installation (M929/A1/A2, M930/A1/A2, M931/A1/A2, M932/A1/A2)............................................................................. 0776-3 Figure 3. Decontamination Apparatus and Mounting Bracket Removal (M934/A1/A2)....................... 0776-4 Figure 4. Decontamination Apparatus and Mounting Bracket Installation (M934/A1/A2).................... 0776-5 Figure 5. Decontamination Apparatus Components Removal (M939/A1/A2)..................................... 0776-6 Figure 6. Decontamination Apparatus Components Installation (M939/A1/A2).................................. 0776-7 Figure 7. Decontamination Apparatus Components Removal (M923/A1/A2, M925/A1/ A2, M927/A1/A2, M928/A1/A2)............................................................................................ 0776-8 Figure 8. Decontamination Apparatus Components Installation (M923/A1/A2, M925/A1/ A2, M927/A1/A2, M928/A1/A2)............................................................................................ 0776-9 MUD GUARD KIT (M931/A1/A2, M932/A1/A2) REPAIR............................................................................. WP 0777 Figure 1. Mud Guard Removal............................................................................................................ 0777-2 Figure 2. Mud Guard Installation......................................................................................................... 0777-3 RIFLE MOUNTING COMPONENTS REPLACEMENT............................................................................... WP 0778 Figure 1. Left Door Rifle Mounting....................................................................................................... 0778-2 Figure 2. Dash and Floor Rifle Mounting............................................................................................. 0778-3 Figure 3. Left Door Rifle Mounting....................................................................................................... 0778-4 Figure 4. Dash and Floor Rifle Mounting............................................................................................. 0778-5 HAND AIRBRAKE AIR SUPPLY VALVE REPLACEMENT......................................................................... WP 0779 Figure 1. Hand Airbrake Air Supply Valve Removal............................................................................ 0779-3 Figure 2. Hand Airbrake Air Supply Valve Installation......................................................................... 0779-5 100-AMP ALTERNATOR REPLACEMENT................................................................................................. WP 0780 Figure 1. 100-Amp Alternator Removal............................................................................................... 0780-2 Figure 2. 100-Amp Alternator Installation............................................................................................ 0780-3 CONVOY WARNING LIGHT MOUNT REPLACEMENT............................................................................. WP 0781 cxl 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Convoy Warning Light Mount Removal................................................................................ 0781-3 Figure 2. Convoy Warning Light Mount Installation............................................................................. 0781-5 EUROPEAN MINI-LIGHTING COMPONENT REPLACEMENT.................................................................. WP 0782 Figure 1. European Mini-Lighting Component Removal...................................................................... 0782-3 Figure 2. European Mini-Lighting Component Installation................................................................... 0782-5 AUTOMATIC THROTTLE COMPONENT REPLACEMENT (M936/A1)...................................................... WP 0783 Figure 1. Automatic Throttle Component Removal............................................................................. 0783-3 Figure 2. Automatic Throttle Component Removal............................................................................. 0783-4 Figure 3. Automatic Throttle Component Removal............................................................................. 0783-5 Figure 4. Automatic Throttle Component Installation.......................................................................... 0783-6 Figure 5. Automatic Throttle Component Installation.......................................................................... 0783-7 Figure 6. Automatic Throttle Component Installation.......................................................................... 0783-8 Figure 7. Automatic Throttle Component Installation.......................................................................... 0783-9 ATMOSPHERIC FUEL TANK VENT SYSTEM REPLACEMENT............................................................... WP 0784 Figure 1. Atmospheric Fuel Tank Vent System Component Removal................................................ 0784-2 Figure 2. Atmospheric Fuel Tank Vent System Component Removal................................................ 0784-3 Figure 3. Atmospheric Fuel Tank Vent System Component Removal................................................ 0784-5 Figure 4. Atmospheric Fuel Tank Vent System Component Removal................................................ 0784-7 Figure 5. Atmospheric Fuel Tank Vent System Component Installation............................................. 0784-9 Figure 6. Atmospheric Fuel Tank Vent System Component Installation........................................... 0784-10 Figure 7. Atmospheric Fuel Tank Vent system component Installation............................................. 0784-11 Figure 8. Atmospheric Fuel Tank Vent System Component Installation........................................... 0784-12 HYDRAULIC HOSE CHAFE GUARD COMPONENT REPLACEMENT..................................................... WP 0785 Figure 1. Hydraulic Hose Chafe Guard Component Removal............................................................. 0785-3 Figure 2. Hydraulic Hose Chafe Guard Component Removal............................................................. 0785-4 Figure 3. Hydraulic Hose Chafe Guard Component Installation.......................................................... 0785-5 Figure 4. Hydraulic Hose Chafe Guard Component Installation.......................................................... 0785-7 cxli 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. HYDRAULIC RESERVOIR DRAIN REPLACEMENT.................................................................................. WP 0786 Figure 1. Hydraulic Reservoir Drain Removal..................................................................................... 0786-3 Figure 2. Hydraulic Reservoir Drain Removal..................................................................................... 0786-4 Figure 3. Hydraulic Reservoir Drain Installation.................................................................................. 0786-5 Figure 4. Reservoir Drain Installation.................................................................................................. 0786-6 HYDRAULIC RESERVOIR SHUTOFF MODIFICATION REPLACEMENT (M936/A1/A2).......................... WP 0787 Figure 1. Hydraulic Reservoir Shutoff Modification Component Removal (M936/A1/A2)................... 0787-2 Figure 2. Hydraulic Reservoir Shutoff Modification Component Removal (M936/A1/A2)................... 0787-3 Figure 3. Hydraulic Oil Reservoir Shutoff Modification Component Removal (M936/A1/A2).............. 0787-4 Figure 4. Hydraulic Oil Reservoir Shutoff Modification Component Installation (M936/A1/ A2)........................................................................................................................................ 0787-5 Figure 5. Hydraulic Reservoir Shutoff Modification Component Installation (M936/A1/A2)................ 0787-6 Figure 6. Hydraulic Reservoir Shutoff Modification Component Installation (M936/A1/A2)................ 0787-7 VAN HANDRAIL COMPONENT REPLACEMENT (M934/A1/A2)............................................................... WP 0788 Figure 1. Van Handrail Component Removal (M934/A1/A2)............................................................... 0788-1 Figure 2. Van Handrail Component Installation (M934/A1/A2)............................................................ 0788-2 Figure 3. Van Handrail Component Removal (M934/A1/A2)............................................................... 0788-3 Figure 4. Van Handrail Component Removal (M934/A1/A2)............................................................... 0788-4 Figure 5. Van Handrail Component Installation (M934/A1/A2)............................................................ 0788-5 Figure 6. Van Handrail Component Installation (M934/A1/A2)............................................................ 0788-6 Figure 7. Van Handrail Component Removal (M934/A1/A2)............................................................... 0788-7 Figure 8. Van Handrail Component Installation (M934/A1/A2)............................................................ 0788-8 Figure 9. Van Handrail Component Removal (M934/A1/A2)............................................................... 0788-9 Figure 10. Van Handrail Component Installation (M934/A1/A2).......................................................... 0788-10 EXHAUST HEAT SHIELD ACCESSORY KIT REPLACEMENT................................................................. WP 0789 Figure 1. Exhaust Heat Shield Accessory Kit Removal....................................................................... 0789-1 Figure 2. Exhaust Heat Shield Accessory Kit Installation.................................................................... 0789-2 SEATBELT REPLACEMENT....................................................................................................................... WP 0790 cxlii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Driver's Seatbelt Removal.................................................................................................... 0790-3 Figure 2. Driver's Seatbelt Installation................................................................................................. 0790-5 Figure 3. Companion Seatbelt Removal.............................................................................................. 0790-7 Figure 4. Companion Seatbelt Installation........................................................................................... 0790-9 HAND AIRBRAKE CONTROLLER VALVE REPLACEMENT..................................................................... WP 0791 Figure 1. Hand Airbrake Controller Valve Removal............................................................................. 0791-3 Figure 2. Hand Airbrake Controller Valve Installation.......................................................................... 0791-4 100-AMP ALTERNATOR HARNESS REPLACEMENT.............................................................................. WP 0792 Figure 1. 100-AMP Alternator Harness............................................................................................... 0792-2 Figure 2. 100-AMP Alternator Ground Strap Removal........................................................................ 0792-3 Figure 3. 100-AMP Alternator Ground Strap Installation..................................................................... 0792-4 Figure 4. 100-AMP Alternator Harness............................................................................................... 0792-5 100-AMP VOLTAGE REGULATOR REPLACEMENT................................................................................. WP 0793 Figure 1. 100-AMP Voltage Regulator Removal................................................................................. 0793-3 Figure 2. 100-AMP Voltage Regulator Installation.............................................................................. 0793-5 CONVOY WARNING LIGHT MOUNT REPLACEMENT (M934/A1/A2)...................................................... WP 0794 Figure 1. Convoy Warning Light (M934/A1/A2) Removal.................................................................... 0794-3 Figure 2. Convoy Warning Light (M934/A1/A2) Installation................................................................. 0794-5 CONVOY WARNING LIGHT MOUNT REPLACEMENT (M929/A1/A2, M930/A1/A2)................................ WP 0795 Figure 1. Convoy Warning Light Mount Removal................................................................................ 0795-3 Figure 2. Convoy Warning Light Mount Installation............................................................................. 0795-4 CONVOY WARNING LIGHT HARNESS REPLACEMENT......................................................................... WP 0796 Figure 1. Convoy Warning Light Harness Removal............................................................................ 0796-3 Figure 2. Convoy Warning Light Harness Installation......................................................................... 0796-5 CONVOY WARNING LIGHT HARNESS REPLACEMENT (M929/A1/A2, M930/A1/A2)............................ WP 0797 Figure 1. Convoy Warning Light Harness Removal............................................................................ 0797-2 Figure 2. Convoy Warning Light Harness Removal............................................................................ 0797-3 cxliii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Convoy Warning Light Harness Installation......................................................................... 0797-4 Figure 4. Convoy Warning Light Harness Installation......................................................................... 0797-5 CONVOY WARNING LIGHT HARNESS REPLACEMENT (M934/A1/A2).................................................. WP 0798 Figure 1. Convoy Warning Light Harness Removal............................................................................ 0798-3 Figure 2. Convoy Warning Light Harness Installation......................................................................... 0798-5 CONVOY WARNING LIGHT REPLACEMENT........................................................................................... WP 0799 Figure 1. Convoy Warning Light Removal........................................................................................... 0799-3 Figure 2. Convoy Warning Light Installation........................................................................................ 0799-5 CONVOY WARNING LIGHT SWITCH REPLACEMENT............................................................................ WP 0800 Figure 1. Convoy Warning Light Switch Removal............................................................................... 0800-3 Figure 2. Convoy Warning Light Switch Installation............................................................................ 0800-5 PIONEER TOOL KIT MOUNTING BRACKET REPLACEMENT................................................................. WP 0801 Figure 1. Pioneer Tool Kit Mounting Bracket Removal........................................................................ 0801-2 Figure 2. Pioneer Tool Kit Mounting Bracket Installation..................................................................... 0801-3 Figure 3. Pioneer Tool Kit Mounting Bracket Removal........................................................................ 0801-4 Figure 4. Pioneer Tool Kit Mounting Bracket Installation..................................................................... 0801-5 Figure 5. Pioneer Tool Kit Mounting Bracket Removal........................................................................ 0801-6 Figure 6. Pioneer Tool Kit Mounting Bracket Installation..................................................................... 0801-7 Figure 7. Pioneer Tool Kit Mounting Bracket Removal........................................................................ 0801-8 Figure 8. Pioneer Tool Kit Mounting Bracket Installation..................................................................... 0801-9 HAND AIRBRAKE DOUBLE CHECK VALVES REPLACEMENT............................................................... WP 0802 Figure 1. Forward-Rear Axle Double Check Valve Removal.............................................................. 0802-3 Figure 2. Forward-Rear Axle Double Check Valve Installation........................................................... 0802-5 Figure 3. Rear-Rear Axle Double Check Valve Removal.................................................................... 0802-7 Figure 4. Rear-Rear Axle Double Check Valve Installation................................................................. 0802-9 HAND AIRBRAKE TRACTOR PROTECTION VALVE REPLACEMENT.................................................... WP 0803 Figure 1. Hand Airbrake Tractor Protection Valve Removal................................................................ 0803-2 cxliv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2. Hand Airbrake Tractor Protection Valve Installation............................................................. 0803-3 CONVOY WARNING LIGHT RELAY AND LEADS REPLACEMENT......................................................... WP 0804 Figure 1. Convoy Warning Light Relay and Leads Removal............................................................... 0804-3 Figure 2. Convoy Warning Light Relay and Leads Installation............................................................ 0804-5 AIR LINES FABRICATION.......................................................................................................................... WP 0805 AIR DRYER FILTER REPLACEMENT........................................................................................................ WP 0806 Figure 1. Air Dryer Kit Removal........................................................................................................... 0806-2 Figure 2. Air Dryer Kit Removal........................................................................................................... 0806-3 Figure 3. Air Dryer Kit Removal........................................................................................................... 0806-4 Figure 4. Air Dryer Kit Removal........................................................................................................... 0806-4 Figure 5. Air Dryer Kit Removal........................................................................................................... 0806-5 Figure 6. Air Dryer Kit Removal........................................................................................................... 0806-6 Figure 7. Air Dryer Kit Removal........................................................................................................... 0806-7 Figure 8. Air Dryer Kit Removal........................................................................................................... 0806-9 Figure 9. Air Dryer Kit Installation...................................................................................................... 0806-11 Figure 10. Air Dryer Kit Installation...................................................................................................... 0806-12 Figure 11. Air Dryer Kit Installation...................................................................................................... 0806-13 Figure 12. Air Dryer Kit Installation...................................................................................................... 0806-14 Figure 13. Air Dryer Kit Installation...................................................................................................... 0806-15 Figure 14. Air Dryer Kit Installation...................................................................................................... 0806-16 Figure 15. Air Dryer Kit Installation...................................................................................................... 0806-17 Figure 16. Air Dryer Kit Installation...................................................................................................... 0806-18 Figure 17. Air Dryer Kit Installation...................................................................................................... 0806-19 AIR DRYER AND MOUNTING BRACKETS REPLACEMENT.................................................................... WP 0807 Figure 1. Air Dryer Removal................................................................................................................ 0807-3 Figure 2. Air Dryer and Mounting Brackets Installation....................................................................... 0807-5 AIR DRYER HEATER REPLACEMENT...................................................................................................... WP 0808 cxlv 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1. Air Dryer Heater Removal.................................................................................................... 0808-2 Figure 2. Air Dryer Heater Installation................................................................................................. 0808-3 RELIEF SAFETY VALVE REPLACEMENT................................................................................................. WP 0809 Figure 1. Relief Valve Removal........................................................................................................... 0809-3 Figure 2. Relief Valve Removal........................................................................................................... 0809-4 Figure 3. Relief Valve Installation........................................................................................................ 0809-5 Figure 4. Relief Valve Installation........................................................................................................ 0809-7 PNEUMATIC CONTROLLER AND RELIEF VALVE REPAIR..................................................................... WP 0810 Figure 1. Pneumatic Controller Removal............................................................................................. 0810-2 Figure 2. Pneumatic Controller Disassembly...................................................................................... 0810-3 Figure 3. Wiring Harness Inspection................................................................................................... 0810-5 Table 1. Electrical Connections.......................................................................................................... 0810-5 Figure 4. Pneumatic Controller Assembly........................................................................................... 0810-7 Figure 5. Pneumatic Controller Installation.......................................................................................... 0810-8 WATER SEPARATOR REPLACEMENT..................................................................................................... WP 0811 Figure 1. Water Separator Removal.................................................................................................... 0811-3 Figure 2. Water Separator Installation................................................................................................. 0811-5 PRESSURE TRANSDUCER REPLACEMENT........................................................................................... WP 0812 Figure 1. Pressure Transducer Removal............................................................................................. 0812-1 Figure 2. Pressure Transducer Removal............................................................................................. 0812-2 Figure 3. Pressure Transducer Removal............................................................................................. 0812-3 Figure 4. Pressure Transducer Removal............................................................................................. 0812-4 Figure 5. Pressure Transducer Installation.......................................................................................... 0812-5 Figure 6. Pneumatic Controller Installation.......................................................................................... 0812-6 Figure 7. Pneumatic Transducer Installation....................................................................................... 0812-7 Figure 8. Pneumatic Transducer Installation....................................................................................... 0812-8 Figure 9. Pressure Transducer Installation.......................................................................................... 0812-9 cxlvi 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. ELECTRONIC CONTROL UNIT (ECU) REPLACEMENT........................................................................... WP 0813 Figure 1. Electronic Control Unit Removal.......................................................................................... 0813-1 Figure 2. Electronic Control Unit Installation....................................................................................... 0813-2 SPEEDOMETER DRIVESHAFT MAINTENANCE...................................................................................... WP 0814 Figure 1. Speedometer Driveshaft Removal....................................................................................... 0814-1 Figure 2. Speedometer Driveshaft Removal....................................................................................... 0814-2 Figure 3. Speedometer Driveshaft Removal....................................................................................... 0814-3 Figure 4. Speedometer Driveshaft Removal....................................................................................... 0814-4 Figure 5. Speedometer Driveshaft Installation.................................................................................... 0814-5 Figure 6. Speedometer Driveshaft Installation.................................................................................... 0814-6 Figure 7. Speedometer Instrument Cluster Installation....................................................................... 0814-7 Figure 8. Speedometer Driveshaft Installation.................................................................................... 0814-8 SPEEDOMETER AND TACHOMETER REPLACEMENT........................................................................... WP 0815 Figure 1. Speedometer Removal......................................................................................................... 0815-2 Figure 2. Speedometer Installation...................................................................................................... 0815-3 TACHOMETER DRIVE REPLACEMENT.................................................................................................... WP 0816 Figure 1. Tachometer Drive Removal.................................................................................................. 0816-1 Figure 2. Tachometer Drive Installation............................................................................................... 0816-2 TACHOMETER DRIVESHAFT REPAIR...................................................................................................... WP 0817 Figure 1. Tachometer Removal........................................................................................................... 0817-2 Figure 2. Tachometer Installation........................................................................................................ 0817-3 AIR GAUGE REPLACEMENT..................................................................................................................... WP 0818 Figure 1. Air Gauge Removal.............................................................................................................. 0818-3 Figure 2. Air Gauge Installation........................................................................................................... 0818-4 GENERAL MAINTENANCE INSTRUCTIONS............................................................................................. WP 0819 LUBRICATION INSTRUCTIONS................................................................................................................. WP 0820 Table 1. -KEY- ................................................................................................................................... 0820-2 cxlvii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Table 2. Total Man-Hours. ................................................................................................................. 0820-6 Figure 1. Truck Chassis. ..................................................................................................................... 0820-7 Figure 2. Truck Chassis. ..................................................................................................................... 0820-8 Figure 3. Truck Chassis. ..................................................................................................................... 0820-9 Figure 4. Truck Chassis. ................................................................................................................... 0820-10 Figure 5. Fifth Wheel/Van Body. ....................................................................................................... 0820-11 Figure 6. Van Body. .......................................................................................................................... 0820-12 Figure 7. Wrecker/Dump Body. ........................................................................................................ 0820-13 Figure 8. Wrecker Crane. ................................................................................................................. 0820-14 Figure 9. Wrecker Crane. ................................................................................................................. 0820-15 Figure 10. Rear Winch. ....................................................................................................................... 0820-16 Figure 11. Front Winch. ...................................................................................................................... 0820-17 Figure 12. Propeller Shaft. .................................................................................................................. 0820-18 Figure 13. Localized Lubrication. ........................................................................................................ 0820-19 Figure 14. Localized Lubrication. ........................................................................................................ 0820-20 Figure 15. Localized Lubrication. ........................................................................................................ 0820-21 Figure 16. Localized Lubrication. ........................................................................................................ 0820-22 Figure 17. Localized Lubrication. ........................................................................................................ 0820-23 Figure 18. Localized Lubrication. ........................................................................................................ 0820-24 Figure 19. Localized Lubrication. ........................................................................................................ 0820-25 Figure 20. Localized Lubrication. ........................................................................................................ 0820-26 Figure 21. Localized Lubrication. ........................................................................................................ 0820-27 Figure 22. Localized Lubrication. ........................................................................................................ 0820-28 Figure 23. Localized Lubrication. ........................................................................................................ 0820-29 TORQUE LIMITS......................................................................................................................................... WP 0821 Figure 1. Screw Diameter.................................................................................................................... 0821-1 Figure 2. Threads Per Inch.................................................................................................................. 0821-1 cxlviii 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Torque Wrench Adapter Conversion Formula...................................................................... 0821-3 Table 1. Torque Limits for Dry Fasteners........................................................................................... 0821-4 Table 2. Torque Limits for Wet Fasteners.......................................................................................... 0821-6 Table 3. Torque Limits for Metric Fasteners....................................................................................... 0821-8 Figure 4. Mini-Barb.............................................................................................................................. 0821-8 Figure 5. Knurl-On............................................................................................................................... 0821-9 Figure 6. Self-Align-PTF...................................................................................................................... 0821-9 Figure 7. Nylon Tubing for Airbrake..................................................................................................... 0821-9 Figure 8. Copper Tubing for Hand Airbrake...................................................................................... 0821-10 Chapter 11 - SUPPORTING INFORMATION REFERENCES............................................................................................................................................ WP 0822 INTRODUCTION FOR STANDARD TWO-LEVEL MAC............................................................................. WP 0823 MAINTENANCE ALLOCATION CHART (MAC).......................................................................................... WP 0824 Table 1. MAINTENANCE ALLOCATION CHART (MAC)................................................................... 0824-1 Table 2. Tools and Test Equipment Requirements.......................................................................... 0824-76 Table 3. Remarks............................................................................................................................. 0824-77 EXPENDABLE/DURABLE ITEMS LIST...................................................................................................... WP 0825 Table 1. Expendable/Durable Supplies and Materials List................................................................. 0825-2 TOOL IDENTIFICATION LIST..................................................................................................................... WP 0826 Table 1. Tool Identification List........................................................................................................... 0826-1 MANDATORY REPLACEMENT PARTS LIST............................................................................................ WP 0827 Table 1. MANDATORY REPLACEMENT PARTS LIST..................................................................... 0827-1 SCHEMATICS............................................................................................................................................. WP 0828 Foldout Figures FO-1. M939/A1 Electrical System Wiring Diagram (1 of 2)......................................................................... FP-1 FO-2. M939/A1 Electrical System Wiring Diagram (2 of 2)......................................................................... FP-3 FO-3. M939A2 Electrical System Wiring Diagram (1 of 2).......................................................................... FP-5 cxlix 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 TABLE OF CONTENTS - Continued Page No. WP Sequence No. FO-4. M939A2 Electrical System Wiring Diagram (2 of 2).......................................................................... FP-7 FO-5. M934/A1/A2 Electrical Wiring Diagram for Expansible Van............................................................. FP-9 FO-6. M939/A1/A2 WO/ABS Air Supply Line Diagram............................................................................. FP-11 FO-7. M939/A1/A2 W/ABS Air Supply Line Diagram................................................................................ FP-13 FO-8. M939/A1/A2 WO/ABS Air Control Line Diagram............................................................................ FP-15 FO-9. M939/A1/A2 W/ABS Air Control Line Diagram............................................................................... FP-17 FO-10. M939/A1/A2 Air Vent Line Diagram.............................................................................................. FP-19 FO-11. M939A2 C.T.I.S. Electrical System Wiring Diagram..................................................................... FP-21 FO-12. M939A2 C.T.I.S. Air Supply Line Diagram................................................................................... FP-23 FO-13. M939/A1/A2 ABS Electrical System Wiring Diagram................................................................... FP-25 FO-14. ABS Air Tubing Installation Diagram............................................................................................ FP-27 Index cl 03/15/2011 Rel(1.8) root(contents) wpno(F00015) TM 9-2320-272-23-1 HOW TO USE THIS MANUAL WARNINGS, CAUTIONS, AND NOTES Read all WARNINGS, CAUTIONS, and NOTES before performing any procedure. Warnings, cautions, notes, subject headings, and other essential information is printed in BOLD type, making them easier for the user to see. GENERAL INFORMATION This manual is divided into CHAPTERS and WORK PACKAGES. For a specific Chapter or Work Package, refer to the TABLE OF CONTENTS. VOLUME 1 The TABLE OF CONTENTS lists the titles of each Chapter and Work Package. • CHAPTER 1 provides general information, equipment description, and theory of operation. • CHAPTER 2 provides general troubleshooting procedures. • CHAPTER 3 provides the CTIS troubleshooting procedures. • VOLUME 2 CHAPTER 4 provides the ABS troubleshooting procedures. • CHAPTER 5 provides the STE/ICE troubleshooting procedures. • CHAPTER 6 provides PMCS maintenance instructions. • CHAPTER 7 provides maintenance instructions. • VOLUME 3 CHAPTER 8 provides maintenance instructions. • VOLUME 4 CHAPTER 9 provides maintenance instructions. • VOLUME 5 CHAPTER 10 provides maintenance instructions. • CHAPTER 11 provides supporting information. The supporting information includes tables listing • References used in this manual, an Introduction to the Standard Two-level MAC, the Two-level MAC, a listing of Expendable and Durable Items, a Tool Identification list, and a Mandatory Replacement Parts list. The illustrations throughout this manual contain numerical callouts pointing to various components mentioned in the procedural steps. Mandatory replacement parts must be discarded after removal and replaced with a new part, which is listed in the Materials/Parts section located at the beginning of the task. Prior to performing any maintenance functions on the 5-ton, 6x6, M939, M939A1, and M939A2 Diesel Truck series, ALWAYS do the following: Read and follow all WARNINGS in all work packages. • Read the Safety Summary. • Read the Equipment Description and Data located in Chapter 1. • Read completely through the maintenance procedure to familiarize yourself with the procedure and the • affected parts before beginning work. Troubleshooting section is setup by either how a physical problem is occurring or how an active or stored trouble code is read from a diagnostic tool. By following a prescribed flow path through making decisions will lead you to a solution to remedy the problem. RPSTL manual, TM 9-2320-272-24P, is to be used in conjunction with this manual to help find needed parts for procurement. RPSTL manual lists and authorized spares and repair parts; special tools, special Test, Measurement, and Diagnostic Equipment (TMDE); and other special support equipment required for performance of Field Maintenance on the 5-ton, 6x6, M939, M939A1, and M939A2 Diesel Truck series. It authorizes cli 3/15/2011 Rel(1.8) root(howtouse) wpno(F00011) TM 9-2320-272-23-1 HOW TO USE THIS MANUAL - Continued GENERAL INFORMATION - Continued the requisitioning, issue, and disposition of spares, repair parts, and special tools as indicated by the Source, Maintenance, and Recoverability (SMR) codes. METRIC SYSTEM The equipment described herein contains metric components and requires metric, common, and special tools. Therefore, metric units and English units will be used throughout this publication. An English-to-Metric conversion table is included as the last page of this manual inside the back cover. clii 03/15/2011 Rel(1.8) root(howtouse) wpno(F00011) TM 9-2320-272-23-1 CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION TM 9-2320-272-23-1 0001 FIELD MAINTENANCE GENERAL INFORMATION SCOPE This manual contains field level instructions for maintenance and troubleshooting of the 5-ton, 6x6, M939, M939A1, and M939A2 Diesel Truck Series. The vehicle is used for general cargo and troop transport, hauling and dumping, hauling semitrailers, and base station for electronics, maintenance, supply, and power. MAINTENANCE FORMS, RECORDS, AND REPORTS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual; or AR 700-138, Army Logistics Readiness and Sustainability. Maintenance forms and records used by Air Force personnel are prescribed in AFI 21-101 and the applicable TO 00-20 Series Technical Orders. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) If your M939 needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you do not like about your equipment. Let us know why you do not like the design or performance. For ALL non-Aviation/Missile EIR and PQDRs must be submitted through the Product Data Reporting and Evaluation Program (PDREP) Web site. The PDREP site is: http://www.pdrep.csd.disa.mil/. If you do not have Internet access, you may submit your information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368 using email, regular mail, or fax using the addresses/fax numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. We will send you a reply. CORROSION PREVENTION AND CONTROL (CPC) Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8,The Army Maintenance Management System (TAMMS) Users Manual. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For procedures to destroy the vehicle to prevent its use by the enemy, refer to TM 750-244-6, Procedures for Destruction of Tank-Automotive Equipment To Prevent Enemy Use. 0001-1 03/15/2011 Rel(1.8) root(ginfowp) wpno(G00002) TM 9-2320-272-23-1 0001 PREPARATION FOR STORAGE OR SHIPMENT For shipment procedures for the vehicle, refer to TM 9-2320-272-10, Preparation for Shipment. Additional information can be found in TM 740-90-1, Marking, Packing, and Shipment of Supplies and Equipment: General Packing Instructions for Field Use. Special requirements for shipment of vehicle: • Temperature limits: None • Pressure limits: None • Power source required during shipment: None • Humidity control: None • Shock and vibration requirements: None • Any other shipping requirements: None Hazardous Materials: Table 1. Hazardous Materials. Shipping Name Explosive Weight Venting Requirement Grounding Requirement Other Requirement Diesel Fuel NA None None NA Lubricating Oil NA None None NA Engine Coolant NA None None NA Dry Chemical Fire Extinguisher NA None None NA Lead Acid Batteries NA None None NA Refrigerant R134A NA None None NA 0001-2 03/15/2011 Rel(1.8) root(ginfowp) wpno(G00002) TM 9-2320-272-23-1 LIST OF ABBREVIATIONS AND ACRONYMS Table 2. List of Abbreviations/Acronyms. Abbreviation Definition AOAP Army Oil Analysis Program CAGEC Commercial and Government Entity Code CARC Chemical Agent Resistant Coating cm Centimeter CPC Corrosion Prevention and Control CTIS Central Tire Inflation System cu-ft Cubic Feet cu-yd Cubic Yard cuM Cubic Meter EA Each EIR Equipment Improvement Recommendations ft Feet/Foot GAA Grease, Automotive and Artillery GMTK General Mechanic's Tool Kit GTW Gross Towed Weight gal Gallon I.D. Inside Diameter in. Inch kg Kilogram km Kilometer km/L Kilometer Per Liter kPa KiloPascal L Left l Liter 0001-3 03/15/2011 Rel(1.8) root(ginfowp) wpno(G00002) 0001 TM 9-2320-272-23-1 LIST OF ABBREVIATIONS AND ACRONYMS - Continued Table 2. List of Abbreviations/Acronyms - Continued. Abbreviation Definition lb Pound lb-ft Pound-Feet MAC Maintenance Allocation Chart mm Millimeter mi Mile mpg Miles Per Gallon mph Miles Per Hour MTOE Modified Table of Organization and Equipment N·m Newton meter NATO North Atlantic Treaty Organization NBC Nuclear, Biological, or Chemical NSN National Stock Number O.D. Outside Diameter OE/HDO Oil, Engine/Heavy Duty Oil PMCS Preventive Maintenance Checks and Services POL Petroleum, Oils, and Lubricants psi Pounds Per Square Inch pt Pint PTO Power Takeoff qt Quart R Right rpm Revolutions Per Minute RPSTL Repair Parts and Special Tools List SMR Source, Maintenance, and Recoverability 0001-4 03/15/2011 Rel(1.8) root(ginfowp) wpno(G00002) 0001 TM 9-2320-272-23-1 0001 LIST OF ABBREVIATIONS AND ACRONYMS - Continued Table 2. List of Abbreviations/Acronyms - Continued. Abbreviation Definition STE/ICE Simplified Test Equipment for Internal Combustion Engine TAMMS The Army Maintenance Management System TM Technical Manual TMDE Test, Measurement, and Diagnostic Equipment U/I Unit of Issue WP Work Package W/W With Winch WO/W Without Winch XLWB Extra Long Wheelbase QUALITY OF MATERIAL Material used for replacement, repair, or modification must meet the requirements of this manual (TM 9-2320-272-23). If quality of material requirements are not stated in this maintenance manual, the material must meet the requirements of the drawings, standards, specifications, or approved engineering change proposals applicable to the vehicle. COMMON TOOLS AND EQUIPMENT Common tools and equipment are issued to field level maintenance personnel for maintaining vehicles. The General Mechanic's Tool Kit (GMTK) is required for all maintenance tasks. Common tools and equipment should not be used for purposes other than those prescribed and should be properly stored when not in use. For authorized common tools and equipment, refer to Modified Table of Organization and Equipment (MTOE), CTA 50-970. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT The Maintenance Allocation Chart (MAC) identifies the authority and responsibility for maintenance tasks listed in this manual. Tool kits, test equipment, and diagnostic equipment required to perform maintenance tasks listed in the MAC. The Repair Parts and Special Tools List (RPSTL), TM 9-2320-272-24P, lists special tools and equipment required to perform maintenance procedures in this manual. END OF WORK PACKAGE 0001-5/6 blank 03/15/2011 Rel(1.8) root(ginfowp) wpno(G00002) TM 9-2320-272-23-1 0002 FIELD MAINTENANCE EQUIPMENT DESCRIPTION AND DATA EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES The M939, M939A1, and M939A2 (M939/A1/A2) series of vehicles are varied in design and capabilities. The M939 was a redesign and retrofit of the M809 series of vehicles, providing enhanced capabilities. The leading features of the M939 are: • Automatic transmission (Allison MT654) • Hydraulic-assisted power steering system • Complete airbrake system • Improved cooling system • Three-crewmember cab • Tilt hood Changes were incorporated into later production engines (after engine serial number 11246663) which provided for control of exhaust gas recirculation back to the air intake manifold and the use of top-stop injectors to make up a clean air configuration. The M939A1 improved on the M939 by adding 14:00xR20 super-sized tires, increasing the minimum road clearance and approach and departure angle. This necessitated a modification to the spare tire rack and lifting device used on all series vehicles. The M939A2 incorporated a new engine (Cummins 6CTA8.3) and the Central Tire Inflation System (CTIS). The M939/A1/A2 series vehicles can be distinguished from the M809 series by the following features: On the left side, the exhaust was moved behind the cab and tilted out so exhaust gases clear the side of the vehicle. Hood latches were installed on the sides of the hood near the mirrors. The battery box was incorporated into the companion seat to improve battery life in cold climates. A steering-assist cylinder was installed between the right front frame rail and the right axle hub. From the front, the hood and fenders are an assembly which tilt forward for access to the engine compartment. A tilt handle and locking device was installed to tilt and hold the hood in a secured open position. The air filter was moved under the driver's door and the intake stack was brought up behind the cab, even with the cab top. Cargo Trucks With Dropsides: M923/A1/A2 WO/W and M925/A1/A2 W/W. These vehicles are used to transport cargo and troops. The vehicles have a payload rating of 10,000 lbs (4,540 kg) and provide 550 cu-ft (15.4 cuM) of cargo space. Removable dropsides and tailgate permit hauling of extra wide loads and easy access for unloading cargo. Troop seats, bows, and canvas are also available. The M925/A1/A2 models have front winches and can be used for recovery operation. The bed of the M923A1/A2 and M925A1/A2 has been shifted back to facilitate a new lifting davit and spare tire mount. When the tire is mounted in its storage location on the M923A1/A2 and M925A1/A2, the top of the tire extends above the minimal reducible height and may need to be removed to obtain the necessary measurement. 0002-1 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - Continued M923 M923A1 M923A2 Figure 1. G0001DAA M923 Cargo Truck. 0002-2 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - Continued M925 M925A1 M925A2 Figure 2. M925 Cargo Truck. 0002-3 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) G0002DAA TM 9-2320-272-23-1 0002 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - Continued Cargo Truck With Extra Long Wheelbase (XLWB): M927/A1/A2 WO/W and M928/A1/A2 W/W. These vehicles are used to transport troops and longer cargo loads. They have the same characteristics as the M923/A1/A2 and M925/A1/A2, but have additional 76 in. (193 cm) of bed space that allows an extra 194 cu-ft (5.4 cuM) of cargo space. Troop seats, bow, and tarpaulin are available. This vehicle has permanent steel-welded sides. The M928A1/A2 model vehicles have winches and can be used for recovery operations. The bed of the M923A1/A2 and M925A1/A2 has been shifted back to facilitate a new lifting davit and spare tire mount. When the tire is mounted in its storage location on the M923A1/A2 and M925A1/A2, the top of the tire extends above the minimal reducible height and may need to be removed to obtain the necessary measurement. M927 M927A1 M927A2 G0003DAA Figure 3. M927 Extra Long Wheelbase Cargo Truck. 0002-4 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - Continued M928 M928A1 M928A2 Figure 4. M928 Extra Long Wheelbase Cargo Truck. 0002-5 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) G0004DAA TM 9-2320-272-23-1 0002 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - Continued Dump Truck: M929/A1/A2 WO/W and M930/A1/A2 W/W. These vehicles are for hauling and dumping cargo. They have a capacity of 5 cu-yd (3.84 cuM). The bodies have provisions for side racks and troop seats, and bow and tarpaulin for troop transport. The M930/A1/A2 have front winches and can be used for recovery operations. Additional support brackets have been designed on the M929A1/A2 and M930A1/A2 model vehicles and are available to support the bed in a slightly raised position for removal of the 14:00xR20 spare tire. M929 M929A1 M929A2 Figure 5. G0005DAA M929 Dump Truck. 0002-6 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - Continued M930 M930A1 M930A2 G0006DAA Figure 6. M930 Dump Truck. 0002-7 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - Continued Tractor Trucks: M931/A1/A2 WO/W and M932/A1/A2 W/W. These vehicles are equipped with a fifth wheel and are used for hauling semitrailers. The fifth wheel is capable of pivoting 21 degrees up, 15 degrees down, or 7 degrees sideways. The M932/A1/A2 model vehicles have front winches and can be used for recovery operations. M931 M931A1 M931A2 G0007DAA Figure 7. M931 Tractor Truck. 0002-8 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - Continued M932 M932A1 M932A2 Figure 8. G0008DAA M932 Tractor Truck. 0002-9 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - Continued Expansible Vans: M934/A1/A2. These vehicles are used for electronics, maintenance, supply, power, and base station operation. The van body can be expanded when set up in a stationary mode of operation; when mission requires more mobile-type operation, the body is left in the retracted position. M934 M934A1 M934A2 Figure 9. G0009DAA M934 Expansible Vans. 0002-10 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - Continued Medium Wrecker: M936/A1/A2. These vehicles are used for wrecker and salvage operations. They have a revolving hydraulic crane with a self-supported extendable boom. Boom-to-ground supports and outriggers are provided. Crane lifting capacity is 20,000 lb (9,080 kg). The vehicle has a front winch with a 20,000 lb (9,080 kg) capacity. M936/A1 models are equipped with front anchor brackets for heavy straight and side pulls using the front winch. All models are equipped with a 45,000 lb (20,250 kg) capacity rear winch, rear anchor brackets for heavy straight and side pulls, and spring brake override of the Power Takeoff (PTO) air switch for self-recovery operations. M936 M936A1 M936A2 Figure 10. G0010DAA M936 Medium Wreckers. 0002-11 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Exterior Components. The components described herein are common to most vehicles covered in this manual. Specific differences can be found in TM 9-2320-272-10 or in Table 3, Differences Between Models, of this manual. 1 1 2 3 16 4 15 5 14 6 9 7 8 13 9 11 10 13 11 9 9 1 Figure 11. 1 12 G0011DAA Location Of Exterior Major Components. 0002-12 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued Table 1. Description of Exterior Major Components. 1 LIFTING SHACKLE(S) - Permit vehicle to be towed by another vehicle or used for tiedown attachment when transporting vehicle. 2 ENGINE - There are two different Cummins model engines used, the NHC 250 (M939/A1 series vehicles) and 6CTA8.3 diesel (M939A2 series vehicles), which provide mechanical power to the vehicle and enginedriven subsystems. 3 TRANSMISSION - The Allison MT654CR automatic, used on all M939/A1/A2 series vehicles, adapts the engine's output for a varying range of operating speeds. 4 PRIMARY AND SECONDARY AIR RESERVOIRS - Provides storage of compressed air and isolation between air subsystems. 5 TRANSFER CASE - Directs the engine and transmission output to the specified axles and/or auxiliary equipment. 6 WET TANK RESERVOIR - Provides reserve storage of compressed air created by the air compressor or external source when demand is low and releases it when required. This lessens the cycling of the enginedriven air compressor. 7 REAR PROPELLER SHAFT(S) - Transmits power between transfer case and forward-rear axle assemblies, and between forward-rear and rear-rear axle assemblies. 8 UNIVERSAL JOINT(S) - Provides a flexible point between a component and the propeller shafts. This allows components that cannot maintain precision alignment to transfer power from one point to another, without undue stress or breakage. 9 SERVICE BRAKE CHAMBER - Mechanical brake actuator that is activated by applying air pressure to an expandable cylinder, causing it to apply braking force to the brake drum. 10 REAR BOGIE - The suspension system comprised of both rear axles, upper and lower torque rods, springs, and seats that support the rear vehicle weight. 11 SPRING BRAKE CHAMBER - Mechanical brake actuator that is spring-loaded to apply brakes when air is low or not present. During normal vehicle operation, air piston counteracts the spring tension and allows the brakes to release. Spring brakes can be bypassed by pushing in the spring brake OVERRIDE switch on the instrument panel, or released using procedures found in TM 9-2320-272-10. 12 TOWING PINTLE - Provides a secure quick-connect/disconnect for towing vehicles or equipment. 13 REAR DIFFERENTIAL(S) - Bi-directionally transfer power from the propeller shafts to the axles, and provide a straight-through connection to power additional propeller shafts. 14 FUEL TANK(S) - Provides storage of fuel. 0002-13 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued Table 1. Description of Exterior Major Components - Continued. 15 SPARE TIRE CARRIER - Stores spare tire. Davit - Used to load and unload spare tire on M923/A1/A2, M925/A1/A2, M927/A1/A2, • M928/A1/A2, M931/A1/A2, and M9321/A1/A2 model vehicles. Winch and Swinging Davit - Used to load and unload spare tire of M934/A1/A2 model vehicles. • Optional kit is available for M934 model vehicle. Hoist and Lifting Eye - Used to load and unload spare tire on M929/A1/A2, M930/A1/A2, and M943 • model vehicles. Optional kit is available to support dump bed in semi-raised position during tire removal. • Vehicle Crane - Used to load and unload spare tire on M936/A1/A2 model vehicles. NOTE: On M936/A1/A2 model vehicles, remove spare tire prior to changing tire, and install tire in spare tire carrier after tire change is complete. Operation of crane and/or vehicle engine while vehicle is on jacks may cause the vehicle to slip off jack. 16 AIR CLEANER - Filters air before it enters the intake manifold or turbocharger and collects dust in removable section of filter canister. 0002-14 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued Interior Cab Components. The components described herein are common to one or more vehicles covered in this manual. Components not found here can be found in TM 9-2320-272-10 or in Table 3, Differences Between Models, of this manual. 1 2 3 19 4 5 18 6 7 17 8 13 12 11 10 16 9 15 14 G0012DAA Figure 12. Description of Interior Cab Components. 0002-15 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued Table 2. Description of Interior Cab Components. 1 INSTRUMENT PANEL - Houses controls and indicators. 2 TRANSMISSION SELECTOR LEVER - Manual control to select driving gear. 3 SPRING BRAKE OVERRIDE SWITCH - Pressed in to release spring brakes independent of the mechanical parking brake for tests and adjustments. Can be used to release spring brakes in the event a leak or stoppage occurs in lines between primary and spring brake reservoirs, or primary system air shutoff valve is closed. 4 TRANSMISSION POWER TAKEOFF (PTO) LEVER - Used on M925/A1/A2, M928/A1/A2, M929/A1/A2, M930/A1/A2, M932/A1/A2, and M936/A1/A2 model vehicles only. Provides hydraulic power for front winch and/or dump body operation. 5 WINCH CONTROL LEVER - Provides control of winch unwinding and winding operations from inside the cab. 6 PASSENGER SEAT - Combination two-person crew seat, battery box, and storage box. Seats are equipped with two sets of seatbelts, the battery box houses four batteries, and the storage compartment stores technical manuals. NOTE: Ensure companion seatbelts are not caught inside battery box. 7 TRANSFER CASE SHIFT LEVER - Pushed down to shift transfer case into HIGH gear, center position for NEUTRAL, and up position for LOW gear. When transfer case is placed in LOW, it will automatically engage six-wheel drive. In HIGH, the instrument panel-mounted front-wheel drive lock-in switch must be used to achieve six-wheel drive operation. 8 SPRING BRAKE CONTROL SWITCH - Senses the position of the parking brake control lever and signals the spring brakes to engage when the lever is up and disengage when it is down. Spring brakes can be tested independently from parking brake by raising this switch without pulling up the parking brake control lever (TM 9-2320-272-10). 9 (a) DUMP BODY CONTROL LEVER - Used on M929/A1/A2 and M930/A1/A2 to control raising (pulled back) and lowering (pushed forward) of dump body. (b) TRANSFER CASE POWER TAKEOFF (PTO) - Used on M936/A1/A2 to control the hydraulic pump that delivers hydraulic pressure to the rear winch and crane. A spring brake air dump switch is installed on the lever when used on these vehicles, which engages the spring brakes. To override this feature during self-recovery operation with the rear winch, the driver must depress and hold the PTO spring brake override air switch on the instrument panel. 10 DUMP BODY CONTROL LEVER SAFETY LATCH - Secures dump body control lever or transfer case PTO in NEUTRAL when not in use. 11 PARKING BRAKE CONTROL LEVER - Pulled up to set mechanical brake on output of transfer case and to engage the spring brakes, and down to disengage the brakes. Knob on top of handle is turned clockwise to increase braking action on the output of transfer case, and counterclockwise to decrease braking action. Spring brakes engagement is controlled by the spring brake control switch located on the back of the lever. 0002-16 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued Table 2. Description of Interior Cab Components - Continued. 12 FUEL TANK SELECTOR LEVER - Used on dual tank model vehicles only. NOTE: Tanks must be switched periodically to lessen the buildup of contaminants and fungus. 13 TRANSFER CASE SHIFT LEVER SWITCH - Used in conjunction with transmission selector lever in NEUTRAL position to allow transfer case to be shifted between HIGH and LOW gears. 14 ACCELERATOR PEDAL - Foot control to vary the speed of the engine. 15 BRAKE PEDAL - Applies the service brakes. 16 DIMMER SWITCH - Depressed to change between HIGH and LOW beam setting on headlights. 17 FUEL GAUGE TANK SELECTOR SWITCH - Used to switch fuel gauge to read either left or right fuel tank. Installed only on dual tank model vehicles. 18 FRONT-WHEEL DRIVE LOCK-IN SWITCH - A pneumatic switch that permits front-wheel drive to be engaged when the transfer case is in HIGH position. Operation of switch is not required when transfer case is in LOW position; system will automatically switch into six-wheel drive. 19 POWER TAKEOFF (PTO) SPRING BRAKE OVERRIDE SWITCH - Used during rear winch self-recovery operations of M936/A1/A2 model vehicles only. This air control switch must be held in to override spring brake air dump switch on transfer case PTO lever. DIFFERENCES BETWEEN MODELS Table 3. Differences Between Models. EQUIPMENT/FUNCTION VEHICLE BODY TYPE Cargo Dropside M923, M923A1, M923A2, M925, M925A1, M925A2 Cargo Fixed Side (XLWB) M927, M927A1, M927A2, M928, M928A1, M928A2 Crane M936, M936A1, M936A2 Dump M929, M929A1, M929A2, M930, M930A1, M930A2 Tractor M931, M931A1, M931A2, M932, M932A1, M932A2 Van M934, M934A1, M934A2 CENTRAL TIRE INFLATION SYSTEM M923A2, M925A2, M927A2, M928A2, M929A2, M930A2, M931A2, M932A2, M934A2, M936A2 FIELD CHOCKS AND ANCHORS Front M936, M936A1 0002-17 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 DIFFERENCES BETWEEN MODELS - Continued Table 3. Differences Between Models - Continued. EQUIPMENT/FUNCTION VEHICLE Rear M936, M936A1, M936A2 FLOODLIGHTS M936, M936A1, M936A2 FUEL TANKS Dual Tanks 116 gal (439.1 l) M929, M929A1, M929A2, M930, M930A1, M930A2, M931, M931A1, M931A2, M932, M932A1, M932A2 Dual Tanks 139 gal (526.1 l) M936, M936A1, M936A2 Single Tank 81 gal (306.6 l) M923, M923A1, M923A2, M925, M925A1, M925A2, M927, M927A1, M927A2, M928, M928A1, M928A2, M934, M934A1, M934A2 HEAT/AIR CONDITIONED BODY OPERATIONS Cargo/Personnel M923, M923A1, M923A2, M925, M925A1, M925A2, M927, M927A1, M927A2, M928, M928A1, M928A2, M929, M929A1, M929A2, M930, M930A1, M930A2, M934, M934A1, M934A2 Communications/Electronic Repair M934, M934A1, M934A2 Dump M929, M929A1, M929A2, M930, M930A1, M930A2 OPERATIONS Fifth Wheel M931, M931A1, M931A2, M932, M932A1, M932A2 Wrecker M936, M936A1, M936A2 TIRES 11:00xR20 M923, M925, M927, M928, M929, M930, M931, M932, M934, M936 14:00xR20 M923A1, M923A2, M925A1, M925A2, M927A1, M927A2, M928A1, M928A2, M929A1, M929A2, M930A1, M930A2, M931A1, M931A2, M932A1, M932A2, M934A1, M934A2, M936A1, M936A2 0002-18 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0002 DIFFERENCES BETWEEN MODELS - Continued Table 3. Differences Between Models - Continued. EQUIPMENT/FUNCTION VEHICLE WHEELBASES 167 in. (424.2 cm) M929, M929A1, M929A2, M930, M930A1, M930A2, M931, M931A1, M931A2, M932, M932A1, M932A2 179 in. (454.7 cm) M923, M923A1, M923A2, M925, M925A1, M925A2, M936, M936A1, M936A2 215 in. (546.1 cm) M927, M927A1, M927A2, M928, M928A1, M928A2, M934, M934A1, M934A2 WINCH Front M925, M925A1, M925A2, M928, M928A1, M928A2, M930, M930A1, M930A2, M932, M932A1, M932A2, M936, M936A1, M936A2 Rear M936, M936A1, M936A2 EQUIPMENT DATA Vehicle performance data for the M939/A1/A2 series vehicles are listed in Table 4. Additional information and equipment service data are in TM 9-2320-272-10. Table 4. Vehicle Performance Data. PAYLOAD: Carried Weight: M923, M923A1, M923A2, M925, M925A1, M925A2, M927, M927A1, M927A2, M928, M928A1, M928A2, M929, M929A1, M929A2, M930, M930A1, M930A2 10,000 lb (4,540 kg) M934, M934A1, M934A2 5,000 lb (2,270 kg) M936, M936A1, M936A2 7,000 lb (3,178 kg) Towed Load on Pintle: All (except M936, M936A1, M936A2) 15,000 lb (6,810 kg) M936, M936A1, M936A2 20,000 lb (9,080 kg) On Fifth Wheel: M929, M929A1, M929A2, M930, M930A1, M930A2 15,000 lb (6,810 kg) Semitrailer GTW: M929, M929A1, M929A2, M930, M930A1, M930A2 37,500 lb (17,025 kg) 0002-19 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 EQUIPMENT DATA - Continued Table 4. Vehicle Performance Data - Continued. CAPACITIES: Cooling System: All Models 47 qt (44.5 l) Differentials (Each): All Models 12 qt (11.3 l) Engine Crankcase Only: M939/A1 Series 23 qt (21.8 l) M939A2 Series 18 qt (17.0 l) Engine Crankcase and Filter: M939/A1 Series 27 qt (25.5 l) M939A2 Series 20 qt (18.9 l) Fuel Tank: M923, M923A1, M923A2, M925, M925A1, M925A2, M927, M927A1, M927A2, M928, M928A1, M928A2, M934, M934A1, M934A2 (Single Tank) 0.81 gal (306.6 l) M936, M936A1, M936A2 Dual Tanks 139 gal (526.1 l) M929, M929A1, M929A2, M930, M930A1, M930A2, M931, M931A1, M931A2, M932, M932A1, M932A2 (Dual Tanks) 116 gal (439.1 l) Hydraulic Tank: M925, M925A1, M925A2, M928, M928A1, M928A2, M932, M932A1, M932A2 8 gal (30.3 l) M929, M929A1, M929A2 5 gal (18.9 l) M930, M930A1, M930A2 6.25 gal (23.7 l) M936, M936A1, M936A2 100 gal (378.5 l) Steering System: M939A1 Series (Ross) 5 qt (4.7 l) M939A2 Series (Sheppard) 3 qt (2.83 l) Transmission: All Models (w/o PTO) 17 qt (16.1 l) All Models (w/PTO) 19 qt (18.0 l) 0002-20 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) 0002 TM 9-2320-272-23-1 EQUIPMENT DATA - Continued Table 4. Vehicle Performance Data - Continued. All Models (w/o PTO and converter dry) 23 qt (22.1 l) All Models (w/PTO and converter dry) 25 qt (23.7 l) Transfer Case: All Models 6.25 gal (23.7 l) Winch Gear Case (Front): All Models (W/W) 2.6 pt (1.2 l) Winch Gear Case (Rear): M936, M936A1, M936A2 7 pt (3.3 l) ENGINE M939/A1 Series Vehicles: Brake Horsepower 250 horsepower @ 2,100 rpm Cylinders 6 (in-line) Fuel Consumption 3 to 4 mpg (1.3 to 1.7 km/L) Idle Speed (engine rpm) 600 to 650 rpm Model Cummins NHC 250 Mount (Front) Trunnion Mount (Rear) Rubber biscuit Oil Pressure at Idle 15 psi (103 kPa) Operating Speed (engine rpm) 1,500 to 2,100 rpm Type Diesel, normally-aspirated, liquid-cooled M939A2 Series Vehicles: Brake Horsepower 240 horsepower @ 2,100 rpm Cylinders 6 (in-line) Fuel Consumption 5.5 to 6.0 mpg (2.3 to 2.6 km/L) Idle Speed 565 to 635 rpm Model Cummins 6CTA8.3 Mount (Front) Trunnion 0002-21 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) 0002 TM 9-2320-272-23-1 EQUIPMENT DATA - Continued Table 4. Vehicle Performance Data - Continued. Mount (Rear) Rubber biscuit Oil Pressure at Idle 10 psi (69 kPa) Operating Speed (engine rpm) 2,100 rpm Type Diesel, liquid-cooled, turbocharged, after-cooled COOLING SYSTEM M939/A1 Series Vehicles: Coolant Operating Temperature 175°F to 195°F (79°C to 91°C) Fan, 6-blade 26 in. (660 mm) Thermostat: Starts to Open 175°F (79°C) Fully Open 185°F (85°C) M939A2 Series Vehicles: Coolant Operating Temperature 190°F to 200°F (88°C to 93°C) Fan, 7-blade 26.5 in. (673 mm) Thermostat: Starts to Open 181°F (83°C) Fully Open 203°F (95°C) Radiator Type Crossflow Surge Tank Cap Pressure 14 psi (97 kPa) ELECTRICAL SYSTEM Alternator: Ampere Output (maximum) 60 amp Model Voltage Output 28 volts Voltage Regulation Mounted internal Batteries: Model 6TN Number Required 4 0002-22 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) 0002 TM 9-2320-272-23-1 EQUIPMENT DATA - Continued Table 4. Vehicle Performance Data - Continued. Plates Per Cell 23 Specific Gravity Full Charge 0 70°F (@ 21°C) Voltage 12 volts Protective Control Box WSU-4001-UT Starter: Model MES6401-CUT Voltage 24 volts TRANSMISSION (MT654CR) Drive Sequence Reverse, Neutral, 1, 2, 3, 4, 5 Drive Range and Shift Control Manual Oil Pressure 26 psi (179.3 kPa) Oil Type OE/HDO-10 Oil Capacity: Drain and Refill 4.25 gal (16.1 l) w/o PTO (dry) 5.75 gal (21.8 l) w/PTO (dry) 6.25 gal (23.7 l) Oil Temperature: Maximum 300°F (149°C) Normal Operating Temperature 120°F to 220°F (49°C to 104°C) Power Takeoff: Type Converter-driven Mounting Flange One-opening, SAE, 6-bolt TRANSFER CASE Model T-1138 Type Two-speed synchronized 0002-23 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) 0002 TM 9-2320-272-23-1 0002 EQUIPMENT DATA - Continued The location and contents of caution, data, and warning plates are provided in TM 9-2320-272-10, and a complete list and location of all caution, data, warning, and identification plates is in TM 9-2320-272-24P. If any of these plates are worn, broken, painted over, missing, or unreadable, they must be replaced. Maintain, in a secure location, an up-to-date inventory of all product and component serial numbers. Regularly verify that identification plates have not been removed. Report any evidence of tampering to appropriate agencies and order duplicate plates. Mark your machine with your own numbering system and take color photographs from several angles of each plate. END OF WORK PACKAGE 0002-24 03/15/2011 Rel(1.8) root(descwp) wpno(G00004) TM 9-2320-272-23-1 0003 FIELD MAINTENANCE THEORY OF OPERATION GENERAL This work package explains how components of the 5-ton M939/A1/A2 series vehicles work together. A functional description of these components and their related parts will be covered in the following paragraphs. CONTROL SYSTEM OPERATION The control system includes those controls and their related parts essential to the operation of the vehicle. These controls are common to all vehicles with the exception of the transmission and transfer case Power Takeoff (PTO) controls. All originate from the cab. Each of these controls and related parts will be described as part of the following systems: 1. Starting and Ether Starting System Operation. 2. Accelerator Controls System Operation. 3. Parking Brake System Operation. 4. Steering System Operation. 5. Transmission Control System Operation. 6. Transfer Case Control System Operation. 0003-1 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 STARTING AND ETHER STARTING SYSTEM OPERATION The starting system is identical on all models covered in this manual. It will start the engine in all types of weather and has built-in protection that prevents starting components from reengaging once the engine has been started. Major components of the starting and ether starting system are: A. BATTERY SWITCH - Activates all electrical circuits except arctic heaters. B. IGNITION SWITCH - Has OFF, RUN, and START positions. Switch automatically returns from START to RUN when hand pressure is released. C. TACHOMETER - Indicates speed of engine. D. VOLTMETER - Indicates charging condition of the battery. E. EMERGENCY ENGINE STOP - Control used to shut down engine during emergencies (M934/A1 series vehicles must be reset by Field Maintenance). F. ETHER START SWITCH - Injects ether into engine for cold-weather starting. G. HAND THROTTLE CONTROL - Used to set engine speed without applying pressure to the accelerator (rotated to lock). G F A B C E D G0013DAA Figure 1. Starting and Ether Starting Components. 0003-2 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 STARTING AND ETHER STARTING SYSTEM OPERATION - Continued A. PROTECTIVE CONTROL BOX - Prevents reengagement of starter motor once engine is running. B. BATTERIES - Provide 24-volt electrical current for energizing electrical circuits. C. STARTER SOLENOID - Relays 24-volt battery power to energize starter motor. D. STARTER MOTOR - When energized, converts electrical energy to mechanical power as it engages flywheel to crank engine. E. ETHER START CYLINDER - Stores ether used for cold-weather starting. A E B D C G0014DAA Figure 2. Starting and Ether Starting Components. 0003-3 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 ACCELERATOR CONTROLS SYSTEM OPERATION The accelerator controls system permits the operator to control vehicle speed and engine power. It is identical on all models covered in this manual. Major components of the accelerator control system are: A. HAND THROTTLE CONTROL - Used to set engine speed without maintaining pressure to the accelerator (rotated to lock). B. EMERGENCY ENGINE STOP CONTROL - Is pulled out to cut off fuel to engine. Used only in an emergency. C. ACCELERATOR PEDAL - Controls engine speed. D. MODULATOR - With transmission selector lever in drive, modulator controls transmission upshifting and downshifting as engine rpm changes. E. CABLE - Connects modulator to fuel pump. F. ACCELERATOR LINKAGE - Links accelerator pedal and throttle control to fuel pump. A A B C B F E D G0015DAA Figure 3. Accelerator Controls System Components. 0003-4 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 PARKING BRAKE SYSTEM OPERATION A mechanical and air-actuated brake system performs the following for all vehicles covered in this manual: 1. Keeps vehicle from rolling once it has stopped. 2. Slows down or stops vehicle movement. 3. Provides emergency stopping if there is a complete air system failure. The mechanical brake system is covered below. The compressed air function of the brake system will be covered in a following paragraph. Major components of the parking brake system are: A. PARKING BRAKE CONTROL LEVER - Is positioned up to engage parking brake; down to disengage parking brake. B. PARKING BRAKE CONTROL LEVER ADJUSTING KNOB - Permits operator to make minor tension adjustment of parking brake. C. PARKING BRAKE CABLE - Links parking brake control lever to brake shoe lever. D. BRAKE SHOE LEVER - Lever turns cam which pushes brake shoe against drum. E. PARKING BRAKE ADJUSTING NUT - Permits major tension adjustment between parking brake lever and brake shoes. F. PARKING BRAKE WARNING LIGHT - Illuminates when parking brake is engaged. A B F E C D G0016DAA Figure 4. Parking Brake System Components. 0003-5 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 STEERING SYSTEM OPERATION The steering system is identical for all models covered in this manual. It is a hydraulically-assisted system that provides ease of turning and control for the operator. Major components of the steering system are: A. OIL RESERVOIR AND STEERING PUMP - Combined in one unit, the reservoir serves as an oil fill point and the pump creates pressure. B. ACCESSORY DRIVEBELTS - Transmit mechanical power from accessory drive pulley to steering pump pulley to drive the steering pump. C. STEERING WHEEL - Serves as manual steering control for operator. D. STEERING COLUMN UNIVERSAL JOINT - Connects, at an angle, the steering wheel column and input shaft of power steering gear. E. POWER STEERING ASSIST CYLINDER - Receives hydraulic pressure from steering gear to assist in turning front wheels. F. STEERING KNUCKLE - Serves as pivot point and link for front wheels from tie rod assembly. G. TIE ROD ASSEMBLY - Connects steering knuckles so both wheels turn at the same time. H. STEERING ARM - Connects drag link to steering knuckle. I. DRAG LINK - Transmits movement from steering arm to pitman arm. J. PITMAN ARM - Transfers torque from power steering gear to drag link. K. STEERING GEAR - Converts hydraulic pressure from steering pump to mechanical power at pitman arm. A C B K D E J F I G H Figure 5. G0017DAA Steering System Components. 0003-6 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 TRANSMISSION CONTROL SYSTEM OPERATION The transmission control system permits shifting of transmission, prevents starting of engine with transmission in gear, and prevents shifting of transfer case unless transmission is in neutral. This system also permits engagement of the transmission Power Takeoff (PTO) to provide hydraulic power for auxiliary equipment on M925/A1/A2, M928/A1/A2, M929/A1/A2, M930/A1/A2, M932/A1/A2, and M936/A1/A2 vehicles. Major components of the transmission control system are: A. TRANSMISSION 5TH-GEAR LOCKUP SOLENOID VALVE - Activated by transmission control switch and transfer case switch, the 5th-gear lockup solenoid valve directs main oil pressure of transmission to the transmission governor system. This puts transmission in 5th-gear, creating less drag on transfer case synchronizer which permits smoother shifting from one transfer case drive range to another. Refer to TRANSFER CASE CONTROL SYSTEM OPERATION, for further details. B. TRANSMISSION NEUTRAL START SWITCH - The neutral start switch, wired to the starter switch, prevents the engine from being started with transmission in gear. C. TRANSMISSION PTO - Driven by the transmission, the PTO drives the hydraulic pump which provides hydraulic pressure to power the front winch on M925/A1/A2, M928/A1/A2, M930/A1/A2, M932/A1/A2, and M936/A1/A2 vehicles, and to power the dump body on M929/A1/A2 and M930/A1/A2 vehicles. The PTO is mounted on the right front side of the transmission. D. TRANSMISSION CONTROL SWITCH - Actuates transmission lockup solenoid valve when transmission selector lever is placed in NEUTRAL and transfer case shift lever lockout switch is pressed. E. TRANSMISSION SELECTOR LEVER - Is used to select vehicle driving gear range. F. PTO CONTROL LEVER - Engages transmission power takeoff to provide power for auxiliary equipment. C F E A B D G0018DAA Figure 6. Transmission Control System Components. 0003-7 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 TRANSFER CASE CONTROL SYSTEM OPERATION The transfer case control system converts four-wheel driving power into six-wheel driving power, provides smooth shifting of transfer case into high or low driving ranges while vehicle is in motion, prevents transfer case from being shifted with transmission in gear, and provides hydraulic power for auxiliary equipment through PTO. 1. Six-wheel drive is achieved two different ways, depending on the drive range (high or low) desired. In low range, the transfer case shift linkage automatically moves a cam-actuated vale which dumps air into the front drive cylinder. This forces a piston against the transfer case clutch to engage front-wheel drive. In high range, front-wheel drive is engaged in the same manner except that the front-wheel drive valve is manually actuated by the front-wheel drive lock-in switch on the instrument panel. 2. In order to shift the transfer case from one driving range to another, an interlock system working in conjunction with the 5th-gear lockup solenoid is used. This system prevents the transfer case from being shifted unless the transmission is in neutral. 3. With the automatic transmission, several actions must occur in order to shift transfer case from one driving range to another. Because of the interlock system, the transmission must be placed in neutral. The transfer case shift lever switch must also be depressed. 4. The transfer case control system, through use of a PTO driven by the transfer case, also provides hydraulic power to operate the crane and rear winch on M936/A1/A2 wreckers. 5. Major components of this system are: A. TRANSFER CASE SHIFT LEVER SWITCH - When depressed with transmission in NEUTRAL, signals interlock solenoid valve to exhaust air pressure from interlock air cylinder and actuates lockup solenoid. B. TRANSFER CASE SHIFT LEVER - Is pushed down to HIGH for light load operations, and up to LOW for heavy load operations. Six-wheel drive is achieved automatically when transfer case shift lever is placed in LOW. C. TRANSFER CASE PTO CONTROL LEVER - Manual control for engaging PTO. D. TRANSFER CASE PTO - Mounted and mechanically driven at rear of transfer case, the PTO drives a pump to supply hydraulic pressure to power the rear winch and crane on the M936/A1/A2 wreckers. E. FRONT-WHEEL DRIVE LOCK-IN SWITCH - Manual control for activating front-wheel drive valve to provide front-wheel drive with transfer case in HIGH drive range. 0003-8 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 TRANSFER CASE CONTROL SYSTEM OPERATION - Continued B A C D E G0019DAA Figure 7. Transfer Case Control System Components. 0003-9 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 TRANSFER CASE CONTROL SYSTEM OPERATION - Continued A. INTERLOCK AIR CYLINDER - Under air pressure, a piston in the interlock air cylinder forces a shaft against one of three grooves in transfer case shift lever. This prevents transfer case from being shifted with transmission in gear. B. INTERLOCK SOLENOID VALVE - Releases air from interlock air cylinder when transmission is in NEUTRAL and transfer case shift lever switch is depressed. This permits the transfer case high/low shift shaft to move. C. FRONT-WHEEL DRIVE AIR CYLINDER - When under pressure, it moves transfer case clutch forward to engage front-wheel drive. D. FRONT-WHEEL DRIVE VALVE - When tripped by a cam on transfer case shift shaft, the front-wheel drive valve routes air to front-wheel drive air cylinder. A D B C G0020DAA Figure 8. Transfer Case Control System Components. 0003-10 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 POWER SYSTEM OPERATION The power system includes components that supply all vehicles covered in this manual the power to move. Each of these components will be described as part of the following subsystems: 1. Air Intake System Operation. 2. Fuel System (Dual Tank) Operation. 3. Fuel System (Single Tank) Operation. 4. Exhaust System Operation. 5. Cooling System Operation. 6. Engine Oil System Operation. 7. Powertrain System Operation. 0003-11 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 AIR INTAKE SYSTEM OPERATION The air intake system channels and cleans air going to the combustion chamber, where it mixes with fuel from the injectors to provide power for the engine. This system is identical on all models, except where indicated. Major components of the air intake system are: A. AIR CLEANER INDICATOR - Shows red when engine air filter needs servicing. B. RAIN CAP - Prevents rain and large objects from entering air intake system. C. AIR INTAKE EXTENSION TUBE - Routes air to air intake system. Can be removed for shipping. D. STACK-TO-AIR INTAKE EXTENSION TUBE - Routes air to air cleaner and is high enough to keep intake opening above fording level. E. STACK-TO-AIR CLEANER ELBOW - Flexible connection between air stack and air cleaner. F. AIR CLEANER - Filters dirt and dust from air. G. HOSE - Flexible connection between air cleaner and air cleaner outlet tube. H. AIR CLEANER OUTLET TUBE - Routes air from air cleaner to intake manifold. I. INTAKE MANIFOLD - Distributes air to combustion chambers in each cylinder head (M939/ A1 series only). J. TURBOCHARGER - Mounts on exhaust manifold and uses spent exhaust gases to drive impeller and pressurize air entering aftercooler (M939A2 series only). K. AFTERCOOLER - Distributes compressed air from turbocharger to combustion chambers while cooling air intake out of turbocharger (M939A2 series only). 0003-12 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 AIR INTAKE SYSTEM OPERATION - Continued A B K J C D I H G F E G0021DAA Figure 9. Air Intake System Components. 0003-13 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 FUEL SYSTEM (DUAL TANK) OPERATION 1. The fuel system stores, cleans, and supplies fuel to the fuel injectors, where it is mixed with air to initiate engine combustion. 2. The fuel system is not identical for all models. Vehicles covered in this manual have either one or two tanks. These tanks can also differ in capacity. See Table 4, Vehicle Performance Data, (WP 0002) for these differences. 3. A typical dual tank fuel system is described below. A single tank fuel system is described later. Both systems include fuel supply, return, and vent lines to provide fuel flow and release the fumes throughout the system. Major components of the dual tank fuel system are: A. RIGHT TANK (REAR) VENT LINE - Vents vapors from fuel tank to vent hole in air intake stack. B. RIGHT TANK FUEL SUPPLY LINE - Directs fuel from tank to fuel filter. C. RIGHT TANK FUEL LEVEL SENDING UNIT - Electrical signal registers fuel level in right tank at gauge on instrument panel. D. LEFT TANK FUEL LEVEL SENDING UNIT - Electrical signal registers fuel level in left tank at gauge on instrument panel. E. LEFT TANK FUEL SUPPLY LINE - Directs fuel from tank to fuel filter. F. LEFT FUEL TANK - Stores fuel for vehicle use. G. LEFT TANK (REAR) VENT LINE - Vents vapors from fuel tank to vent hole in air intake stack. H. LEFT TANK FILLER CAP - Covers fuel filler opening on left fuel tank. I. LEFT TANK FUEL RETURN LINE - Returns unused fuel back to fuel tank. J. LEFT TANK (FRONT) VENT LINE - Vents vapors from fuel tank to vent hole in air intake stack. K. FUEL SELECTOR VALVE - Manual control valve that opens fuel flow to engine from left or right fuel tank. L. FUEL FILTER/WATER SEPARATOR - Filters water and dirt from fuel. M. FUEL FILTER-TO-PUMP SUPPLY LINE - Directs fuel from fuel filter to fuel pump. N. FUEL RETURN LINE - Returns unused fuel back to fuel tanks. O. FUEL PRIMER PUMP - Purges air from fuel system. P. FUEL PUMP - Draws fuel from tank(s) and pumps it through supply line to fuel injectors. Q. FUEL SUPPLY LINE - Directs fuel from fuel pump to fuel injectors. R. RIGHT TANK (FRONT) VENT LINE - Vents vapors from fuel tank to vent hole in air intake stack. S. RIGHT TANK FILLER CAP - Covers fuel filler opening on right fuel tank. T. RIGHT FUEL TANK - Stores fuel for vehicle use. U. RIGHT TANK FUEL RETURN LINE - Returns unused fuel back to fuel tank. 0003-14 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 FUEL SYSTEM (DUAL TANK) OPERATION - Continued A B C D E F G H U I T S J R Q K P L O M N G0022DAA Figure 10. Fuel System (Dual Tank) Components. 0003-15 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 FUEL SYSTEM (SINGLE TANK) OPERATION Major components of the single tank fuel system are: A. TANK (REAR) VENT LINE - Vents vapors from fuel tank to vent hole-in air intake stack. B. TANK FILLER CAP - Covers fuel filler opening. C. FUEL TANK - Stores fuel for vehicle use. D. FUEL TANK LEVEL SENDING UNIT - Electrical signal registers fuel level in tank at gauge on instrument panel. E. TANK (FRONT) VENT LINE - Vents vapors from fuel tank to vent hole in air intake stack. F. FUEL FILTER/WATER SEPARATOR - Filters water and dirt from fuel. G. FUEL RETURN LINE - Returns unused fuel back to fuel tank. H. FUEL PRIMER PUMP - Purges air from fuel system. I. FUEL PUMP - Draws fuel from tank and pumps it through supply line to fuel injectors. J. FUEL SUPPLY LINE - Directs fuel from fuel pump to fuel injectors. A B C D J E I H G F G0023DAA Figure 11. Fuel System (Single Tank) Components. 0003-16 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 EXHAUST SYSTEM OPERATION The exhaust system directs exhaust gases away from the vehicle for all models covered in this manual. Major components of the exhaust system are: A. EXHAUST MANIFOLD - Collects exhaust from cylinder head ports and directs it to front exhaust pipe. B. FRONT EXHAUST PIPE - Directs exhaust to rear exhaust pipe. C. FLEX PIPE - Part of rear exhaust pipe; allows flexibility for vibration and expansion in system. D. REAR EXHAUST PIPE - Directs exhaust to muffler. E. MUFFLER - Quiets exhaust noises. F. MUFFLER SHIELD - Protects personnel from muffler heat. G. EXHAUST STACK - Directs exhaust from muffler away from vehicle. H. TURBOCHARGER - Compresses the intake air above atmospheric pressure. A G F E D C B H G0024DAA Figure 12. Exhaust System Components. 0003-17 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 COOLING SYSTEM OPERATION This system provides cooling of the engine and transmission. It differs slightly between the M939/A1 series and M939A2 series vehicles because different engines are used. Major components of the cooling system are: A. WATER MANIFOLD - Collects coolant from cylinder heads and directs it to thermostat housing (M939/A1 series only). B. SURGE TANK-TO-WATER MANIFOLD VENT - Vents air trapped in water manifold (M939/A1 series only). C. SURGE TANK-TO-RADIATOR VENT - Vents air in cooling system. D. THERMOSTAT - Shuts off coolant flow to radiator until temperature reaches 175°F (79°C) on M939/A1 series vehicles and 181°F (83°C) on M939A2 series vehicles. Coolant is then directed to the radiator through the radiator inlet hose. E. RADIATOR INLET HOSE - Directs coolant from water manifold to radiator after thermostat has opened. F. BYPASS TUBE - Directs coolant back to transmission oil cooler, where it is then recirculated through the engine block until the thermostat opens. G. RADIATOR SHROUD - Concentrates air flow through the radiator. H. RADIATOR - Directs coolant through a series of fins or baffles so outside air can remove excessive heat from coolant. I. FAN CLUTCH - Regulates use of fan to control engine temperature fan to belt-driven pulley when conditions require additional cooling. J. WATER PUMP - Provides force to move coolant through engine. K. FAN - Provides force to pull air through radiator. L. RADIATOR DRAIN VALVE - Permits coolant to be drained from radiator. M. TRANSMISSION OIL COOLER HOSE - Directs coolant to transmission oil cooler. N. ENGINE OIL COOLER - Reduces heat of engine oil (M939/A1 series only). O. TRANSMISSION OIL COOLER - Reduces heat of transmission oil. P. ENGINE OIL COOLER-TO-HEATER HOSE - Directs coolant to personnel water heater when shutoff valve is open (M939/A1 series only). Q. PERSONNEL WATER HEATER - Provides heat for cab and personnel (M939/A1 only). R. SURGE TANK - Filling point for cooling system. On M939A2 vehicles, a float sensor monitors water level and illuminates a light on instrument panel. S. COOLANT PRESSURE CAP - Designed to depressurize cooling system and to access cooling system for filling. 0003-18 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 COOLING SYSTEM OPERATION - Continued D C B A E F S G R H I J Q K P M939/A1 SERIES O S N M L E C R K G I D N H O J F M L M939A2 SERIES Figure 13. Cooling System Components. 0003-19 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) G0025DAA TM 9-2320-272-23-1 0003 ENGINE OIL SYSTEM OPERATION The engine oil system provides lubricating oil for internal moving parts. Major components of the engine oil system are: A. CRANKCASE BREATHER - Vents hot engine oil fumes from engine and allows fresh air to enter. B. ENGINE OIL COOLER - Removes heat from engine oil as coolant circulates through internal tubes of oil cooler. C. OIL DIPSTICK - Indicates engine oil level. D. OIL FILTER - Filters out foreign particles suspended in oil. E. OIL FILLER CAP - Located on rocker lever cover, cap covers engine oil fill opening. F. OIL PRESSURE TRANSMITTER - Sends an electrical signal that indicates engine oil pressure to gauge on instrument panel. G. OIL PAN DRAIN PLUG - Plugs engine oil drain opening. H. OIL PAN - Reservoir for engine oil. I. OIL SUPPLY LINE - Carries oil from oil pan to oil pump. J. OIL BYPASS RETURN LINE - Returns oil from oil pump to oil pan. K. OIL PUMP - Provides mechanical pressurization of oil to circulate it through oil system. 0003-20 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 ENGINE OIL SYSTEM OPERATION - Continued A C M939/A1 SERIES B A B D C M939A2 SERIES Figure 14. Engine Oil System Components. 0003-21 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) G0026DAA TM 9-2320-272-23-1 0003 ENGINE OIL SYSTEM OPERATION - Continued E E F F K D J I C M939/A1 SERIES H H G M939A2 SERIES G G0027DAA Figure 15. Engine Oil System Components. 0003-22 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 POWERTRAIN SYSTEM OPERATION The powertrain system is the same on all models in this manual except the extra-long wheelbase models, which have an additional propeller shaft and center bearing. This system transmits engine power to the axles to put the vehicle in motion. Major components of the powertrain system are: A. UNIVERSAL JOINTS - Connections between two propeller shafts that permit one to drive the other even though they may be at different angles. B. DIFFERENTIALS - Distribute power to left and right axle shafts. C. AXLES - Transmit power from differentials to rotate wheels. D. PROPELLER SHAFTS - Serve as driving shafts that connect transmission to transfer case and transfer case to differentials. E. ENGINE - Provides power needed for powertrain component operation. F. TRANSMISSION - Adapts engine power to meet different driving conditions. G. CENTER BEARING - Provides support for propeller shaft to decrease vibration and wear on universal joints (M927/A1/A2, M928/A1/A2, and M934/A1/A2 series only). H. TRANSFER CASE - Distributes power evenly to front and rear axles. E F G H B A C D G0028DAA Figure 16. Powertrain System Components. ELECTRICAL SYSTEM OPERATION Nearly every component of models covered in this manual is affected by the electrical system. These components and their electrical connections are described as part of the following electrical subsystems: 1. Battery System Operation. 2. Starting System Operation. 3. Ether Starting System Operation. 4. Generating System Operation. 5. Directional Signal System Operation. 6. Heating System Operation. 7. Indicator, Gauge, and Warning System Operation. 8. Trailer and Semitrailer Connection System Operation. 0003-23 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 ELECTRICAL TERMS AND DEFINITIONS The following electrical terms and definitions will be frequently referred to throughout this section and should be understood before proceeding: Alternating Current (AC signal) - Current in a circuit that flows in one direction first, then in the other direction. Circuit - A complete path for electric current flow between components. Circuit Breaker - An automatic switch that interrupts current flow in a circuit when the current limit is exceeded. Direct Current (DC signal) - Current in a circuit that flows in one direction. Female Connector - One-half of a connector which fits over the other half. Ground - A common return to complete a path for current flow in a circuit. Harness - A group of wires connected between devices that are bundled and routed together to prevent damage and make repair and replacement easier. Male Connector - One-half of a connector which fits the other half. Polarity - The direction current flows in a circuit (usually positive to negative). Relay - An electromagnetic device that operates like an automatic switch to control flow of current in the same or different circuit. Reverse Polarity - The condition that exists when circuit polarity is connected opposite of that which was intended. Sending Unit - A device that produces an electrical signal and sends this signal to the device which will make use of it. Sensor - An electrical sensor takes a physical condition (temperature, oil presence or absence) and converts it into an electrical signal. Splice - A permanent physical connection of two or more wires. Terminal - Fastener at end of wire used to connect the wire to an electrically-powered device. BATTERY SYSTEM OPERATION The battery system is identical for all models covered in this manual and consists of the following major components and circuits: A. BATTERIES - Four 6TN batteries are connected in series parallel to provide 24-volts DC for electrical starter system and 12-volts DC for the heater fan low speed. B. SLAVE RECEPTACLE - Links an external power source directly to the slaved vehicle's batteries to assist in cranking engine when batteries are not sufficiently charged. C. CIRCUIT 7 - Provides a ground between starter, battery, and chassis. D. PROTECTIVE CONTROL BOX - Protects the vehicle electrical system in the event battery system polarity is reversed. Connects battery power to vehicle electrical lead through circuit 81 and circuit 5. Connects positive ground through circuit 94 to the starter. E. BATTERY SWITCH - Controls a relay in protective control box through circuit 459 that connects batteries to vehicle electrical load. F. STARTER SOLENOID - Junction point for battery positive lead (circuit 6) and vehicle electrical feed wire (circuit 81). G. CIRCUIT 6 - Connects batteries to starting motor and to protective control box through circuit 81. 0003-24 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 BATTERY SYSTEM OPERATION - Continued F A G B 6 49 7 81 3 94 81A 5 50 7 459 E D C G0029DAA Figure 17. Battery System Components. 0003-25 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 STARTING SYSTEM OPERATION The starting system is identical for all models covered in this manual and consists of the following major components and circuitry: A. PROTECTIVE CONTROL BOX - Locks out starter circuit, which prevents starter from reengaging while engine is running. B. IGNITION SWITCH - Provides battery power to fuel solenoid through circuits 54 and the neutral start safety switch through circuit 498. C. NEUTRAL START SAFETY SWITCH - Prevents starter from energizing when vehicle is not in neutral, by deenergizing circuit 499 and a relay in the protective control box, which disconnects power from circuit 74 and the starter solenoid. D. STARTER SOLENOID - A magnetic relay that is powered by circuit 74 to transmit 24-volt battery power to the starter motor through circuit 6. E. STARTER MOTOR - Cranks engine for starting. Supplied with 24-volt battery power through circuit 6. F. BATTERY SWITCH - Completes circuit 459, closing a relay in the protective control box to supply power to ignition switch through circuits 5 and 5B. A F B 5B 5 459 54 94 498 569 FUEL SHUTOFF SOLENOID ON FUEL PUMP 499 74 C 6 D BATTERY E G0030DAA Figure 18. Starting System Components. 0003-26 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 ETHER STARTING SYSTEM OPERATION The ether starting system is identical for all models covered in this manual and consists of the following major components and circuitry: A. BATTERY SWITCH - Provides 24-volt battery to protective control box through circuits 459, 81A, and 81. B. PROTECTIVE CONTROL BOX - Energizes ether feed switch through circuits 5, 5A, 27, 5C, and 570. C. ETHER FEED SWITCH - Controls 24-volt power to ether pressure switch through circuit 570. D. ETHER PRESSURE SWITCH - Connects ether feed switch to ether tank valve through circuit 570. E. ETHER TANK VALVE - Is activated through circuit 570 when ether pressure switch is closed and ether feed switch is pressed. A BATTERY 569 B 81A 81 459 5 5A CB 27 C 570 570 E 5C 570 D G0031DAA Figure 19. Ether Starting System Components. 0003-27 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 GENERATING SYSTEM OPERATION The generating system is identical for all vehicles covered in this manual and consists of the following major components and circuitry: A. VOLTMETER - Indicates electrical system voltage. It is connected to the electrical system through circuit 27. B. ALTERNATOR - Rated at 26-30 volts, 60 amperes, the alternator assists and recharges batteries during operation. A 100-ampere model is available as a kit. C. CIRCUIT 3 - Provides a ground circuit to alternator. D. CIRCUIT 566 - Controls a relay in protective control box that prevents starter from reactivating while engine is running. E. CIRCUIT 568 - Senses system voltage and excites the alternator field. F. PROTECTIVE CONTROL BOX - Connects circuit 5 to 80 to power the electrical system and charge the batteries. G. CIRCUIT 5 - Conducts alternator output to charge batteries and maintain vehicle voltage. H. BATTERY SWITCH - Closes relay in protective control box that connects battery circuits. A B BATTERY 27 3 568 CB C 5A D 5 G 566 E 6 H 459 STATER SOLENOID BATTERY TERMINAL 81A F 81 G0032DAA Figure 20. Generating System Components. 0003-28 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 DIRECTIONAL SIGNAL SYSTEM OPERATION The directional signal system is identical on all models covered in this manual and consists of the following major components and circuitry: A. LIGHT SWITCH - Provides battery power to directional signal switch through circuits 460 and 461 and to stoplight switch through circuit 75. B. STOPLIGHT SWITCH - Closing this switch allows power to flow from light switch through circuit 75 to circuit 22 to directional signal switch. C. REAR COMPOSITE LAMPS - Receive power from turn signal control through circuit 22-460 and 22-461 to indicate turning direction. D. TURN SIGNAL FLASHER - Receives power through circuit 467A and sends intermittent current to the signal lamp through circuit 467B. E. DIRECTIONAL SIGNAL SWITCH - A four-position switch that directs power to composite and signal lamps through circuits 460, 461, 22-460, and 22-461 to indicate direction of turn. F. FRONT COMPOSITE LAMP - Receives power from turn signal control through circuits 460 and 461 to indicate turning direction. A 15 B 75 75 C 22 F 460 460-461 22-460 461 467A E 22-461 467B 57 C F D G0033DAA Figure 21. Directional Signal System Components. 0003-29 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 HEATING SYSTEM OPERATION The electrical portion of the heating system is identical for all models covered in this manual and consists of the following major components and circuitry: A. PROTECTIVE CONTROL BOX - Provides 24-volt power to circuit breaker through circuits 5 and 5A and to heater switch through circuits 27 and 5C. B. CIRCUIT BREAKER - Provides overload protection for 24-volt circuits 5, 5A, 27, and 5C leading to the heater switch. C. BATTERY SWITCH - Provides 12-volt battery power from circuit 569 through 569A to the heater. D. CIRCUIT BREAKER - Provides overload protection for 12-volt circuit 569A leading to heater switch. E. HEATER SWITCH - Controls low and high blower motor speed and has two sources of power: 12-volt power is supplied through circuit 569A from battery switch and is used to provide low speed; 24-volt power is supplied through circuit 5C from protective control box and is used to provide high speed. F. HEATER BLOWER MOWER - A direct current motor controlled by heater switch through circuit 400. 0003-30 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 HEATING SYSTEM OPERATION - Continued A BATTERY 5 B 5A F 27 569 C 5C 400 569A E D G0034DAA Figure 22. Heating System Components. 0003-31 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 INDICATOR, GAUGE, AND WARNING SYSTEM OPERATION The indicator, gauge, and warning system is comprised of several subsystems: A. ENGINE OIL PRESSURE INDICATOR - Indicates engine oil pressure and receives battery power through circuit 27A. Circuit 36 completes the circuit to ground through the oil pressure transmitter located on the engine block. B. FUEL INDICATOR - Indicates fuel level. Receives battery power through circuit 27A. Circuit 28 or 29, depending on which position fuel selector switch is in, completes the circuit to ground through the oil pressure transmitter located on the engine block. C. TRANSMISSION OIL TEMPERATURE INDICATOR - Indicates transmission oil temperature and receives battery power through circuit 27A. Circuit 324 completes circuit to ground through a temperature sensor located in transmission. D. FRONT-WHEEL DRIVE ENGAGEMENT LIGHT - Informs the operator that front-wheel drive is engaged. The system consists of a normally open pressure switch, which is powered through circuit 27A and an indicator lamp powered through circuit 27A. E. HORN SYSTEM - The horn system consists of an air-operated horn that is controlled by an electric solenoid. The solenoid is powered through circuit 26 and controlled by the horn switch through circuit 25. F. SPRING BRAKE WARNING SYSTEM - Warns the operator that spring brakes are applied. The system consists of normally open pressure switch powered through circuit 37 and an indicator lamp which is powered through circuit 37. G. FAILSAFE WARNING SYSTEM - Intended to give the operator an audible as well as visual signal of a malfunction in one of the primary systems. Power for the system is supplied from the ignition switch through circuit 564. The failsafe module causes an indicator lamp to illuminate and an alarm to sound when air pressure falls below 60 psi (414 kPa) or when parking brake is set. H. VOLTMETER - Indicates system voltage and is connected to batteries through circuit 27A and to chassis ground through instrument panel. I. ENGINE COOLANT TEMPERATURE INDICATOR - Indicates engine coolant temperature and receives battery power through circuit 27A. Circuit 33 completes the circuit to ground through a coolant temperature sensor that reacts to changes in engine coolant temperature by increasing or decreasing the resistance in ground circuit. 0003-32 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 INDICATOR, GAUGE, AND WARNING SYSTEM OPERATION - Continued PRESSURE TRANSMITTER A SENSOR COOLANT TEMPERATURE I FUEL LEVEL SENSOR B 36 TRANS. TEMP SENSOR 28 33 324 C H D 27A 564 26 25 G 37 E BATTERY SWITCH BATTERY F G0035DAA Figure 23. Indicator, Gauge, and Warning System Components. 0003-33 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 TRAILER AND SEMITRAILER CONNECTION SYSTEM OPERATION The trailer receptacle is identical on all models covered in this manual. The semitrailer receptacle is on the tractor body only. A. SEMITRAILER RECEPTACLE - M931/A1/A2 and M932/A1/A2 vehicles equipped with a fifth wheel are provided with a semitrailer receptacle. This receptacle provides vehicle lighting, auxiliary power, and a ground circuit for semitrailers. B. TRAILER RECEPTACLE - Provides vehicle lighting, auxiliary power, and a ground circuit for trailers. A B G0036DAA Figure 24. Trailer and Semitrailer Connection Components. 0003-34 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 COMPRESSED AIR AND BRAKE SYSTEM OPERATION The compressed air and brake system takes filtered air, compresses it, and supplies it to various components that enable the operator to slow down or stop the vehicle. This system also supplies compressed air to air-actuated accessories throughout the vehicle. These components and accessories will be described as part of the following systems: 1. Medium Wrecker Automatic Brake Lock System Operation. 2. Air Pressure Supply System Operation. 3. Secondary Service Airbrake System Operation. 4. Spring Airbrake System Operation. 5. Primary Service Airbrake System Operation. 6. Auxiliary Air-Powered System Operation. 7. Air Venting System Operation. 8. Central Tire Inflation System (CTIS) (M939A2 series vehicles). MEDIUM WRECKER AUTOMATIC BRAKE LOCK SYSTEM OPERATION The M936/A1/A2 Medium Wrecker Automatic Brake Lock System locks the service airbrakes when the transfer case PTO lever is engaged. Major components of the automatic brake lock system are: A. TRANSFER CASE PTO LEVER - Opens the brake lock control valve through mechanical linkage when engaged. B. BRAKE LOCK CONTROL - Allows air pressure to flow from secondary air reservoir to pressure regulator and activate variable speed governor. C. PRESSURE REGULATOR - Reduces and regulates system air pressure to 70 psi (483 kPa) for automatic brake lock application. D. TREADLE VALVE - Connects pressure regulator and service airbrakes. A AIR SUPPLY LINE AIR CONTROL LINE AIR SIGNAL LINE MECHANICAL LINKAGE B TO SECONDARY AIR RESERVOIR TO VARIABLE SPEED GOVERNOR FUEL PUMP D C TO FRONT AND REAR, AND REAR-REAR RELAY VALVE G0037DAA Figure 25. Medium Wrecker Automatic Brake Lock System Components. 0003-35 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 AIR PRESSURE SUPPLY SYSTEM OPERATION A constant air pressure supply is developed by the compressor which is regulated by the governor to maintain 90 to 120 psi (621 to 827 kPa) for the airbrake system. Moisture within the system is controlled through the use of either the alcohol evaporator or air dryer. The major components of the system are: A. AIR DRYER - Installed in supply line to wet tank and removes moisture from inlet air to wet tank (M939/A1 air dryer kit installed only). B. AIR COMPRESSOR - Draws in air from the intake manifold and forces it into brake system and wet tank reservoir. C. SAFETY VALVE - Located at inlet side of wet reservoir, it prevents pressure buildup by releasing air pressure exceeding 150 psi (1,034 kPa) when the governor fails to regulate air supplied by the compressor. D. WET TANK RESERVOIR - Performs two functions: Traps water in air reservoir to protect other air systems from freezing or corroding. • Stores reserve air supply enabling operator to make normal stops when engine stalls or • compressor fails. E. PRESSURE PROTECTION VALVE - Performs two functions: Allows air pressure to build to 60 to 65 psi (414 to 448 kPa) before supplying air to auxiliary air• powered equipment. Closes off auxiliary air system from other systems if an accessory fails and prevents loss of air from • secondary reservoir. F. WET TANK RESERVOIR DRAIN VALVE - Provides a drain for moisture and air from reservoir. G. AIR DRYER - Removes moisture from inlet air to wet tank (M939A2 only). H. GOVERNOR - Trips valve inside compressor to regulate flow of air to the system. When pressure builds to 120 to 127 psi (827 to 876 kPa), the governor will close valve. 0003-36 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 AIR PRESSURE SUPPLY SYSTEM OPERATION - Continued ABS EQUIPPED VEHICLES M939A2 ONLY A ABS B C BIDIRECTIONAL FEED (para. 2) D E F G MOISTURE VENT G0038DAA Figure 26. Air Pressure Supply System Components. 0003-37 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 AIR PRESSURE SUPPLY SYSTEM OPERATION - Continued The constant air pressure supply is distributed to the primary service airbrake system and secondary airbrake system through a shutoff and check valve. Air pressure can either be fed from or supplied to another vehicle through the emergency couplings. A. FRONT EMERGENCY COUPLING - When vehicle is being towed, coupling receives compressed air from towing vehicle's brake system to charge its own brake system. B. PRIMARY AIR RESERVOIR - Stores sufficient air pressure to allow operator to make normal brake applications if system pressure fails or engine stalls. C. PRIMARY FEED CUTOFF - Manually-operated valve used to isolate pressure leaks in primary air system from draining wet tank (TM 9-2320-272-10). D. PRIMARY AIR RESERVOIR CHECKVALVE - Prevents backflow of air from primary tank if wet system develops a leak. E. SECONDARY FEED CUTOFF - Manually-operated valve used to isolate pressure leaks in secondary air system from draining wet tank (TM 9-2320-272-10). F. SECONDARY AIR RESERVOIR CHECKVALVE - Prevents backflow of air from secondary tank if wet system develops a leak. G. REAR EMERGENCY COUPLING - When towing another vehicle, coupling allows pressurized air from wet tank to charge towed vehicle's wet tank. H. SECONDARY AIR RESERVOIR - Stores enough air pressure in case constant pressure system fails or engine stalls. The operator can make normal brake application before running out of air. I. PRESSURE PROTECTION VALVE - Performs two functions: Allows air pressure to build to 60 to 65 psi (414 to 444 kPa) before supplying air to auxiliary air• powered equipment. Closes off auxiliary air system from other systems if an accessory fails and prevents loss of air from • secondary reservoir. 0003-38 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 AIR PRESSURE SUPPLY SYSTEM OPERATION - Continued PRIMARY SERVICE A B SPRING BRAKE SYSTEM C D E F G H BIDIRECTIONAL FEED SECONDARY SERVICE I AUXILIARY AIR-POWERED SYSTEM FROM SECONDARY SERVICE AIRBRAKE SYSTEM G0039DAA Figure 27. Constant Air Pressure Supply System Components. 0003-39 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 SECONDARY SERVICE AIRBRAKE SYSTEM OPERATION 1. The secondary service airbrake system is made up of two subsystems: a. Secondary constant pressure system provides continuous air pressure to: • Pedal valve • Rear relay valve • Spring brake air reservoir • Spring parking brake valve b. Secondary signal system serves three functions: • Contains air pressure only when operator steps on brake pedal. • Is regulated by various valves to control amount of braking. • Provides pressure to apply rear two service brakes and intermediate and rear axles stamped with B. Service brakes on rear axle are piggybacked to spring brakes, but operate independently of them. 2. The secondary constant pressure system is made up of the following components: A. LOW AIR PRESSURE SWITCH - Activates warning buzzer and warning lights when air pressure goes below 60 psi (414 kPa). B. PEDAL VALVE - Allows air pressure from secondary constant pressure system to flow into secondary signal system when operator depresses brake pedal. C. SECONDARY AIR PRESSURE GAUGE - Indicates amount of air pressure in secondary system. D. ONE-WAY CHECKVALVE - Allows air pressure to flow into secondary reservoir, but prevents it from coming out if constant pressure system fails or engine stalls. E. SECONDARY AIR RESERVOIR - Stores enough air pressure so the operator can make five normal brake applications before running out of air if constant pressure fails or engine stalls. F. INTERMEDIATE REAR BRAKE CHAMBERS - Converts air pressure to mechanical force which applies intermediate rear service brake. G. DOUBLE CHECK VALVE NO. 1 - Serves two functions: Allows system to receive signal pressure from either pedal valve or, when towed, from brake system • of towing vehicle. Serves as a tee between front and rear primary signal lines. • H. SECONDARY AIR RESERVOIR DRAIN VALVE - Provides a drain for moisture and air from secondary air reservoir. I. FRONT RELAY VALVE - Boosts signal air to rear brake chambers; regulates air pressure to rear brake chambers so operator has control over amount of braking; and releases air pressure to rear brake chambers directly to vent when brake pedal is released. J. STOPLIGHT SWITCH - As the brake pedal is depressed, switch receives an air pressure signal at electrical contacts which close to activate circuits to taillights. K. DOUBLE CHECK VALVE NO. 2 - Allows either primary or secondary signal air pressure to activate stoplight switch while keeping the two systems separate. L. REAR-REAR BRAKE CHAMBERS - Converts air pressure to mechanical force which applies rearrear brakes. 0003-40 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 SECONDARY SERVICE AIRBRAKE SYSTEM OPERATION - Continued TO FAN CLUTCH ACTUATOR A B C FROM SUPPLY SYSTEM F D E G H I K SUPPLY SYSTEM J L SECONDARY CONSTANT PRESSURE SYSTEM SECONDARY SIGNAL SYSTEM G0040DAA Figure 28. Secondary Service Airbrake System Components. 0003-41 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 SPRING AIRBRAKE SYSTEM OPERATION The spring airbrake system applies rear brakes when vehicle parking brake is applied or in event of a major brake failure. The spring brake is located on one of the two service brake chambers at each rear wheel. Major components of the spring airbrake system are: A. SPRING BRAKE WARNING LIGHT SWITCH - Activates warning light when spring brakes are engaged. B. SPRING BRAKE RELEASE CONTROL VALVE - Pushed in to release spring brakes independently of mechanical parking brake. Control is also used to release spring brakes in order to test and adjust mechanical brake. C. DOUBLE CHECK VALVE NO. 4 - Allows spring brake air pressure to come from either release control valve or spring parking brake valve directly to double check valve No. 3. D. INTERMEDIATE FRONT SPRING BRAKE CHAMBER - Contains a large spring which applies rear brakes when spring brake air pressure is released. E. ONE-WAY CHECKVALVE - Allows air pressure to flow into spring brake reservoir, but prevents it from coming out if constant pressure system or primary system fails. F. SPRING BRAKE AIR RESERVOIR - Stores enough air pressure to release spring brakes for emergency operation in event of primary or secondary air system failure. G. QUICK-RELEASE VALVE - Releases spring brake air pressure directly to vent if parking brake has been set or brake system fails. H. SPRING BRAKE VALVE - Automatically sets spring brakes when parking brake is set. Valve can be released independently of parking brake when spring brake control valve is pushed in. I. SPRING BRAKE RESERVOIR DRAIN VALVE - Provides a drain for moisture and air from spring brake reservoir. J. DOUBLE CHECK VALVE NO. 3 - Allows spring brake air pressure to come from either release control valve or spring parking brake valve directly to double check valve No. 4. K. REAR-BEAR SPRING BRAKE CHAMBER - Contains a large spring which applies rear brakes when spring brake air pressure is released. 0003-42 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 SPRING AIRBRAKE SYSTEM OPERATION - Continued A D B FROM PRIMARY SUPPLY C E F G J I H K FROM PRIMARY SIGNAL SYSTEM PRIMARY SUPPLY SPRING AIRBRAKE SYSTEM PRIMARY SIGNAL SYSTEM G0041DAA Figure 29. Spring Airbrake System Components. 0003-43 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 PRIMARY SERVICE AIRBRAKE SYSTEM OPERATION 1. The primary service airbrake system is made up of two subsystems: a. Primary constant pressure system provides continuous air pressure to: • Pedal valve • Rear relay valve • Spring brake air reservoir • Spring parking brake valve b. Primary signal system serves three functions: • Contains pressure only when operator steps on brake pedal. • Is regulated by various valves to give operator control over amount of braking. • Provides pressure to apply front service brakes and the front two service brakes on intermediate and rear axles stamped with an A. Service brakes on the intermediate axle are piggybacked to spring brakes, but operate independently of them. 2. The primary constant pressure system is made up of the following components: A. PRIMARY AIR PRESSURE GAUGE - Indicates amount of air pressure in primary system. B. LIMITING VALVE - Serves three functions: Regulates signal air pressure going to front brake chambers so rear brakes are applied first. • Regulates signal air pressure to front brake chambers so operator has control over amount • of braking. Releases air pressure in front brake chambers directly to vent in the valve when brake pedal • is released. C. FRONT BRAKE CHAMBERS - Convert air pressure to mechanical force which applies front service brakes. D. PRIMARY RESERVOIR LOW AIR PRESSURE SWITCH - Activates warning buzzer and warning light when air pressure goes below 60 psi (414 kPa). E. PEDAL INTO VALVE - Allows air pressure from primary constant pressure system to flow into primary signal system when operator depresses brake pedal. F. DOUBLE CHECK VALVE NO. 1 - Serves two functions: Allows system to receive signal pressure from either pedal valve or, when towed, from brake system • of towing vehicle. Serves as a tee between front and rear primary signal lines. • G. FRONT SERVICE COUPLING - When vehicle is being towed, coupling is connected to towing vehicle so the brake systems of the two vehicles work together. H. ONE-WAY CHECKVALVE - Allows air pressure to flow into primary reservoir, but prevents it from coming out if constant pressure system fails or engine stalls. I. PRIMARY AIR RESERVOIR - Stores enough air pressure so the operator can make five normal brake applications before running out of air if constant pressure fails or engine stalls. J. DOUBLE CHECK VALVE NO. 2 - Allows either primary or secondary signal air pressure to activate stoplight switch while keeping the two systems separate. K. STOPLIGHT SWITCH - As brake pedal is depressed, switch receives an air pressure signal which closes electric contacts turning on stoplight. L. REAR SERVICE COUPLING - When towing another vehicle, coupling is connected to towed vehicle so the brake systems of the two vehicles work together. M. INTERMEDIATE FRONT BRAKE CHAMBERS - Converts air pressure to mechanical force which applies intermediate rear service brake. N. PRIMARY RESERVOIR DRAIN VALVE - Provides a drain for moisture and air from primary air reservoir. O. REAR RELAY VALVE - Serves three functions: Boosts signal air pressure to rear brake chambers. Air signal from brake pedal opens valve to route constant air pressure to rear brake chambers. Regulates signal air pressure from brake pedal to rear brake chambers so operator has control over amount of braking. Regulates amount of constant air pressure going to brake chambers as the operator depresses the pedal. Releases air pressure in rear brake chamber directly to vent system when brake pedal is released. 0003-44 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 PRIMARY SERVICE AIRBRAKE SYSTEM OPERATION - Continued P. REAR FRONT BRAKE CHAMBERS - Converts air pressure to mechanical force which applies rear service brakes. PRIMARY CONSTANT PRESSURE SYSTEM A PRIMARY SIGNAL SYSTEM C B SUPPLY SYSTEM D E F G J H K I TO SPRING BRAKE SYSTEM M L N O FROM SUPPLY SYSTEM P TO SPRING BRAKE SYSTEM G0042DAA Figure 30. Primary Service Airbrake System Components. 0003-45 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 AUXILIARY AIR-POWERED SYSTEM OPERATION The auxiliary air-powered system consists of air-actuated vehicle accessories. All of these accessories receive air pressure through the accessory manifold and off the pressure protection valve with the exception of the horns. Components of the auxiliary air-powered system are: A. WINDSHIELD WIPER CONTROL SWITCH - Opens air pressure valve in wiper motor to operate wipers. B. WINDWHIELD WIPER MOTOR - Air-actuated motor powers windshield wipers. C. WINDSHIELD WASHER CONTROL - Spring-loaded valve that allows air pressure to force washer fluid from washer reservoir to windshield. D. WINDSHIELD WASHER RESERVOIR - Container for windshield washer fluid. E. ACCESSORY MANIFOLD - Receives air pressure from the pressure protection valve and distributes it to the various accessories. F. FRONT-WHEEL DRIVE LOCK-IN SWITCH - Air-actuated switch that engages front-wheel drive when transfer case is in HIGH. G. WINDSHIELD WASHER NOZZLES - Direct washer fluid on windshield. H. GOVERNOR - Serves as a tee between accessory manifold and horn relay valve. It also signals the air compressor to stop compressing air for the supply system when operating pressure has been reached. I. TRANSFER CASE AIR SHIFT CYLINDER - Engages front-wheel drive when it receives air pressure from lock-in switch or engagement control valve. J. FRONT AXLE ENGAGEMENT CONTROL VALVE - Operates off cam, on transfer case shift linkage so front-wheel drive engages automatically when transfer case is put into LOW. K. HORN RELAY VALVE - Electrical signal from horn button on steering wheel opens valve in horn relay, allowing air pressure to sound horns. L. HORNS - Receive air pressure from horn relay valve to sound off. 0003-46 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 AUXILIARY AIR-POWERED SYSTEM OPERATION - Continued CONSTANT PRESSURE SUPPLY LINES WINDSHIELD WASHER SIGNAL LINE A B C D F G I J FRONT-WHEEL DRIVE LOCK-IN SIGNAL LINE FROM PRESSURE PROTECTION VALVE E H K L G0043DAA Figure 31. Auxiliary Air-Powered System Components. 0003-47 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 AIR VENTING SYSTEM OPERATION The air venting system vents air from brake system and powertrain and fuel vapors from fuel system into air intake stack where it is released into the atmosphere. The components of the air venting system are: A. SPRING BRAKE RELEASE CONTROL VALVE - This valve functions as an override when a failure in the air supply system (causing spring brakes to engage) occurs. When valve is manually pushed in, emergency air is supplied to the spring brake chambers. This releases the spring brakes, allowing vehicle movement. B. PEDAL VALVE - Vents primary or secondary signal air pressure when pedal is released. C. FRONT BRAKE CHAMBER VENT - Vents air pressure inside chambers when pedal valve is released. D. LIMITING VALVE - Vents signal air pressure going to front brake chambers so rear brakes apply first. E. STEP BOX QUICK-RELEASE VALVE - Vents air pressure from spring brake chambers when parking brake valve has been actuated. F. REAR BRAKE CHAMBERS - Vents ports on chambers to prevent air pressure buildup. G. RELAY VALVES - Vents air pressure in rear brake chambers directly to intake tube when brake pedal is released. Vents signal air pressure through upper port in valve. H. AIR INTAKE STACK - Venting point for the vent system. I. TRANSMISSION VENT - Vents internal air pressure buildup due to internal heat. J. SPRING PARKING BRAKE VALVE - Vents air pressure from air and double check valves No. 3 and No. 4. K. TRANSFER CASE VENT - Vents internal air pressure buildup due to internal heat. L. FUEL TANK VENTS - Vent fuel vapors to prevent partial vacuum from stopping fuel flow. 0003-48 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 AIR VENTING SYSTEM OPERATION - Continued B A C E D F G H I J K L G0044DAA Figure 32. Air Venting System Components. 0003-49 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 CENTRAL TIRE INFLATION SYSTEM (CTIS) (M939A2 SERIES VEHICLES) The M939A2 Central Tire Inflation System (CTIS) uses the vehicle's air compressor system, pneumatic valves, and a microprocessor to adjust tire pressure according to mission demands. The system needs clean, dry air to maintain itself. The turbocharger and aftercooler help supply more compressed air when the vehicle is loaded and operating at high rpm. Compressed air enters air dryer, which filters dirt and ejects moisture from air. System air then enters the wet tank and is available to airbrakes and CTIS. The brake system is protected by an 85 psi (138 kPa) pressure switch in CTIS air line. If wet tank air pressure measures below 85 psi (138 kPa), the CTIS shuts down until pressure switch measures 120 psi (827 kPa). Air is then routed to pneumatic controller, which consists of three valves and solenoids working in conjunction with the Electronic Control Unit (ECU). The ECU is a microprocessor programmed to issue commands based on information it receives from pressure switch, pressure transducer (which tests tires pressure), and speed signal generator (which monitors vehicle speed). The commands are electrically received by the pneumatic controller, which affects inflation or deflation of tires through quick-exhaust valves. Six wheel valves isolate tire pressure during normal operation. They also open to allow tire inflation or tire deflation through three quick-exhaust valves. The system is automatic. The operator only needs to select the mode that best accomplishes the mission. The CTIS is common to all M939A2 series vehicles. This system maintains tire air pressure depending on which road type is selected. If this setting is changed, tires will automatically inflate or deflate to the new setting. A. ELECTRONIC CONTROL UNIT (ECU) - Contains CTIS selector panel so that operator can change tire inflation during vehicle operation. B. AIR PRESSURE SWITCH - Protects air brake system for a minimum supply of 85 psi (586 kPa) of air. C. AIR DRYER AND FILTER - Separates moisture from compressed air system and filters impurities from compressed air before they enter CTIS. D. EXHAUST VALVES - Exhaust air from tires during deflation. E. WHEEL VALVES - Isolate air pressure in tires during normal operation and for tire removal. F. SPEED SIGNAL GENERATOR - Signals ECU to automatically inflate CTIS when vehicle speed exceeds the top speed setting for the selected mode by 10 mph (16 kmh). G. PNEUMATIC CONTROLLER - Directs air pressure according to ECU commands. H. PRESSURE TRANSDUCER - Mounted in pneumatic controller, it measures tire pressure and sends information to ECU. 0003-50 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 CENTRAL TIRE INFLATION SYSTEM (CTIS) (M939A2 SERIES VEHICLES) - Continued B A C D H G E F D E G0045DAA Figure 33. Central Tire Inflation System Components. HYDRAULIC SYSTEM OPERATION Oil pressure (hydraulics) is used to provide operating power for the auxiliary equipment on the vehicles covered in this manual. The components that provide hydraulic power are discussed in the following order: 1. Front Winch Hydraulic System Operation. 2. Rear Winch Hydraulic System Operation. 3. Dump Body Hydraulic System Operation. 4. Medium Wrecker Crane Hydraulic System Operation. 0003-51 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 FRONT WINCH HYDRAULIC SYSTEM OPERATION A front winch is installed on M925/A1/A2, M928/A1/A2, M930/A1/A2, M932/A1/A2, and M936/A1/A2 series vehicles. The front winch hydraulic system converts mechanical power at the winch drive motor. The basic operating principles are the same for each model. Major components of this system are: A. WINCH CONTROL LEVER - An operator control that determines the hydraulic oil pressure flow from the control valve to the winch motor. The flow of this oil determines the direction the winch drum will turn. B. TRANSMISSION PTO - Uses transmission driving power to provide mechanical driving power for the hydraulic pump. C. PTO DRIVESHAFT - Transmits mechanical power from PTO to the hydraulic pump. D. HYDRAULIC PUMP - Driven by PTO driveshaft, it draws oil from the oil reservoir through hydraulic hoses, then pressurizes and directs this oil to the control valve. E. OIL FILTER - Filters used or bypassed oil from the control valve before it returns to the hydraulic oil reservoir. F. HYDRAULIC OIL RESERVOIR - Storage tank for hydraulic oil. G. CONTROL VALVE - Four-port valve accepts pressurized oil from the hydraulic pump and directs this oil to the winch motor. It also directs oil returning from the winch back to the oil reservoir. The flow of this oil from the valve determines the directional drive of the winch motor. H. WINCH MOTOR - Converts hydraulic power into mechanical power as hydraulic oil is forced through the winch motor. I. CLUTCH LEVER - Manual control that engages winch drum gear to drive gear of winch motor. J. TRANSMISSION PTO CONTROL - A manually-operated control lever located inside the cab that permits engagement or disengagement of the transmission PTO. A B C D E F J I H G Figure 34. Front Winch Hydraulic System Components. 0003-52 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) G0046DAA TM 9-2320-272-23-1 0003 REAR WINCH HYDRAULIC SYSTEM OPERATION A rear winch is installed only on the M936/A1/A2 medium wrecker. It is used primarily to rescue vehicles that have become deeply mired. The rear winch hydraulic system converts mechanical power of the engine into fluid power through use of the hydraulic pump and back into mechanical power at the winch drive motor. The major components of the rear winch hydraulic system are: A. PTO DRIVESHAFT - Transmits mechanical driving power from PTO to the hydraulic pump. B. HYDRAULIC PUMP - Draws oil from hydraulic oil reservoir and directs it to the rear winch control valve and winch drive motor. C. OIL FILTER - Filters used or bypassed oil from the control valve before it returns to the hydraulic oil reservoir. D. HYDRAULIC OIL RESERVOIR - Storage tank for hydraulic oil. E. TORQUE CONTROL LEVER - Controls the operating gear ratio of the winch drive motor. Lever is pulled outward to HIGH for heavy loads or pushed inward to LOW for light loads. F. WINCH DIRECTIONAL CONTROL LEVER - Manually-operated lever that controls the wind and unwind direction of the rear winch drum. Lever does this by opening and closing the directional control valve to the winch motor, and reversing the direction of pressurized hydraulic fluid. Lever is pushed inward to wind and pulled outward to unwind winch cable. G. DIRECTIONAL CONTROL VALVE - Receives pressurized hydraulic oil from the hydraulic pump and directs it to the winch motor. The flow of hydraulic oil to and from this control valve provides forward or reverse driving power to the winch motor. Valve also returns used oil back to the hydraulic oil reservoir from the winch. H. TORQUE CONTROL VALVE - Hydraulically controls the hydraulic oil pressure to engage rear winch drum clutch in high or low gear range. I. WINCH MOTOR - Converts hydraulic power back into mechanical power needed to turn the rear winch drum. J. CONTROL LINKAGE - Connects transfer case PTO control to transfer case PTO. K. TRANSFER CASE PTO CONTROL - A manually-operated control lever located inside the cab that permits engagement or disengagement of the PTO. L. TRANSFER CASE PTO - Uses driving power of the transfer case to provide mechanical driving power for the hydraulic pump. L A B C E D F K J I H G G0047DAA Figure 35. Rear Winch Hydraulic System Components. 0003-53 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 DUMP BODY HYDRAULIC SYSTEM OPERATION The dump body is installed on M929/A1/A2 and M930/A1/A2 model vehicles. These models are used to transport and deposit cargo. The dump body hydraulic system converts mechanical power from the engine into fluid power through use of the hydraulic pump. The pump draws fluid from the oil reservoir and then forces it into the control valve. This hydraulic pressure raises and lowers the dump body. Major components of the dump body hydraulic system are: A. PTO DRIVESHAFT - Transmits mechanical driving power from the PTO to the hydraulic pump. B. HYDRAULIC PUMP - Driven by the PTO driveshaft, it draws oil from oil reservoir through hydraulic hoses, then pressurizes and directs it to the control valve. C. HYDRAULIC OIL RESERVOIR - Storage tank for hydraulic oil. D. DUMP BODY SAFETY LATCH - Hydraulically-operated in conjunction with the dump body control lever, the safety latch locks dump body in the lowered position and releases it when the control lever is pulled back to the raised position. E. DUMP BODY CYLINDER ASSEMBLY - Consists of two piston-type hydraulic cylinder hoists. Assembly raises and lowers dump body with hydraulic oil, forcing the cylinder upward or downward. F. OIL FILTER - Filters used or bypassed oil from the control valve before it returns to the hydraulic oil reservoir. G. CONTROL VALVE - Four-port valve accepts pressurized oil from the hydraulic pump and directs oil pressure flow from control valve to the hydraulic cylinders. It also directs oil returning from the hydraulic cylinders back to the hydraulic oil reservoir. H. DUMP BODY CONTROL LEVER - An operator control that determines the hydraulic oil pressure flow from control valve to the hydraulic cylinders. The route this oil takes will determine whether the dump will raise or lower. I. CONTROL LINKAGE - Connects dump body control lever inside cab to the control valve. J. TRANSMISSION PTO CONTROL - A manually-operated control lever located inside the vehicle cab that permits engagement or disengagement of the transmission PTO. K. TRANSMISSION PTO - Uses driving power of the transmission to provide mechanical driving power for the hydraulic pump. 0003-54 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 DUMP BODY HYDRAULIC SYSTEM OPERATION - Continued A B C D E K J I H F G G0048DAA Figure 36. Dump Body Hydraulic System Components. 0003-55 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 MEDIUM WRECKER CRANE HYDRAULIC SYSTEM OPERATION The M936/A1/A2 medium wrecker is equipped with a hydraulically-operated crane that extends a maximum 18 ft (5 m), elevates 45 degrees, and swings 360 degrees. It is capable of lifting loads up to 20,000 lbs (9,090 kg). A. HYDRAULIC PUMP - Draws oil from hydraulic oil reservoir and directs it to valves inside the crane control console. B. OIL FILTER - Filters used or bypassed oil from the control valve before it returns to the hydraulic oil reservoir. C. HYDRAULIC OIL RESERVOIR - Storage tank for hydraulic oil. D. SWIVEL VALVE - Permits oil to channel through pivot post while crane is swinging and eliminates twisting of the hydraulic lines connecting reservoir to the stationary pump. E. BOOM LIFT CYLINDER - A hydraulically-driven piston that extends upward when boom control lever is pulled back to UP position, raising the boom. A check valve located near hydraulic oil inlet hose prevents piston from lowering when control lever is in NEUTRAL. Oil returns through boom control valve back to hydraulic oil reservoir allowing piston to lower when control lever is pushed forward to DOWN position. F. BOOM CONTROL LEVER - Manual control attached to the control valve that determines hydraulic oil flow for raising and lowering action of the boom. Lever is pulled back to raise the boom and pushed forward to lower the boom. G. CRANE CONTROL CONSOLE - Houses BOOM, HOIST, CROWD, and SWING levers and their control valves. H. BOOM CONTROL VALVE - Located directly below boom control lever. Valve directs hydraulic oil from the hydraulic pump to the boom lift cylinder for lifting, or out of the lift cylinder and back to the hydraulic oil reservoir for lowering. I. BOOM HYDRAULIC LINES - Carry the hydraulic oil to and from boom lift cylinder. Oil pumped through the bottom lines pushes the lift cylinder piston upward. Oil pumped through the top lines pushes the lift cylinder piston downward. When this downward action occurs, the oil that originally pushes the cylinder upwards is returned to the hydraulic oil reservoir. J. TRANSFER CASE PTO CONTROL - A manually-operated control lever located inside the cab that engages and disengages the transfer case PTO. K. TRANSFER CASE PTO LINKAGE - Connects transfer case PTO control to transfer case PTO. L. TRANSFER CASE PTO - Receives driving power from vehicle's engine through the transfer case to provide mechanical driving power for the hydraulic pump. M. PTO DRIVESHAFT - Transmits mechanical driving power from the power takeoff to the hydraulic pump. 0003-56 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 MEDIUM WRECKER CRANE HYDRAULIC SYSTEM OPERATION - Continued J K L M A B C D E F H I G G0049DAA Figure 37. Medium Wrecker Crane Hydraulic System Components. 0003-57 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 MEDIUM WRECKER CRANE HYDRAULIC SYSTEM OPERATION - Continued A. HOIST MOTOR ASSEMBLY - Converts hydraulic power back into mechanical power needed to turn the hoist drum. B. SHEAVES - Grooved wheels that guide hoist cable through boom. C. UPPER ROLLER ASSEMBLY - Prevents cable from contacting inner boom during winding/unwinding. D. CRANE HOIST CABLE DRUM - Is turned by the worm gear in hoist motor assembly. Drum unwinds cable when turning toward front of vehicle. Drum winds cable when turning towards rear of vehicle. E. HOIST CONTROL LEVER - Manual control attached to the control valve that determines hydraulic oil flow for the raising and lowering action of the crane hoist cable and hook. Lever is pulled back to raise cable and hook and pushed forward to lower cable and hook. F. HOIST CONTROL VALVE - Two-way hydraulic valve located under the hoist control lever directs fluid from the hydraulic pump to the hoist motor assembly and back through the valve to the hydraulic oil reservoir. A B C C D E F G0050DAA Figure 38. Hoist Action Components. 0003-58 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 MEDIUM WRECKER CRANE HYDRAULIC SYSTEM OPERATION - Continued A. CROWD CONTROL LEVER - Manual control attached to the control valve that determines oil flow for extending and retracting the crane boom. Lever is pushed forward to extend the boom and pulled back to retract the boom. B. ROLLERS - Guide inner boom assembly and permit smooth extension and retraction of boom. C. INNER BOOM ASSEMBLY - Extends when crowd control lever is pushed forward and retracts when control lever is pulled back. D. CROWD CYLINDER - A hydraulically-driven piston that extends outward when crowd control lever is pushed forward to EXTEND position. Piston is hydraulically-driven back into the cylinder when crowd control lever is pulled back to RETRACT position. This cylinder is contained in the inner boom assembly. E. CROWD CONTROL VALVE - Two-way hydraulic valve located directly below crowd control lever. Valve directs hydraulic oil from the hydraulic pump to the crowd cylinder to extend and retract inner boom assembly. A C B E D G0051DAA Figure 39. Crowd Action Components. 0003-59 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 0003 MEDIUM WRECKER CRANE HYDRAULIC SYSTEM OPERATION - Continued A. SWING MOTOR - Converts hydraulic power back into mechanical power needed to turn the crane turntable when hydraulic fluid is forced through its worm gear. This gear turns a large gear at the base of the turntable to swing the crane. B. TURNTABLE ASSEMBLY - Driven by the swing motor through a ring gear at the base of the assembly, permits the crane to swing 360 degrees. C. SWING CONTROL LEVER - Manual control attached to the control valve that determines hydraulic oil flow for swinging wrecker boom to the left and to the right. Lever is pushed inward for left boom movement, and pulled outward for right boom movement. D. SWING CONTROL VALVE - Two-way hydraulic valve located directly below swing control lever. Valve directs hydraulic oil from the hydraulic pump to the swing motor assembly and back through the valve to the hydraulic oil reservoir. A B C D G0052DAA Figure 40. Swing Action Components. END OF WORK PACKAGE 0003-60 03/15/2011 Rel(1.8) root(thrywp) wpno(G00006) TM 9-2320-272-23-1 CHAPTER 2 GENERAL TROUBLESHOOTING PROCEDURES TM 9-2320-272-23-1 0004 FIELD MAINTENANCE GENERAL TROUBLESHOOTING INTRODUCTION 1. This chapter provides information needed to diagnose and correct malfunctions of mechanical, electrical, and compressed air and brake system at the field level of maintenance. 2. The troubleshooting procedures in this section cannot give all the answers or correct all vehicle malfunctions encountered. However, these procedures are a step-by-step approach to a problem that directs tests and inspections toward the source of a problem and a successful solution. 3. Principles of operation showing wiring diagrams for each system can be found in Theory of Operation (WP 0003). The wiring schematic (Volume 5, WP 0828) and point to point schematics show the interrelationship of these systems. Both should be utilized as references when performing troubleshooting procedures. 4. The compressed air schematic (Volume 5, WP 0828) and point to point schematics show the interrelationship of the compressed air and brake system. Both should be used as a reference when performing troubleshooting procedures. 5. Each malfunction symptom given for an individual component or system is followed by step(s) to determine the cause and corrective action you must take to remedy the problem. 6. Before taking any corrective action for a possible malfunction, the following rules should be followed: a. Question operator to obtain any additional information that might help you to determine the cause of the problem. b. Never overlook the chance the problem could be of a simple origin. The problem could require only a minor adjustment. c. Use all senses to observe and locate troubles. d. Use test instruments and gauges to help you determine and isolate problems. e. Always isolate the system where the malfunction occurs and locate the defective component. f. Use standard automotive theories and principles when troubleshooting the vehicles covered in this manual. g. Operate the vehicle yourself to ensure the operator’s description of the problem is correct. 7. This section cannot list all malfunctions that may occur. If a malfunction occurs that is not listed in the index, notify supervisor. 8. If malfunction corrective action does not correct malfunction, notify supervisor. EXPLANATION OF TROUBLESHOOTING PROCEDURES Troubleshooting procedures are defined as follows: 1. STEP: An action or process taken to isolate cause of fault. 2. CONDITION/INDICATION: States possible fault that may cause the symptom. 3. DECISION: Action required to move forward with next step or correct the fault. END OF WORK PACKAGE 0004-1/2 blank 03/15/2011 Rel(1.8) root(tsintrowp) wpno(T00300) TM 9-2320-272-23-1 0005 FIELD MAINTENANCE GENERAL TROUBLESHOOTING INDEX GENERAL TROUBLESHOOTING INDEX Malfunction/Symptom Troubleshooting Procedure ENGINE 1. Engine Will Not Crank....................................................................................................................... WP 0006 2. Engine Cranks But Will Not Start...................................................................................................... WP 0007 3. Starter Cranks Engine Slowly, Hard To Start.................................................................................... WP 0008 4. Engine Stops During Normal Operation............................................................................................ WP 0009 5. Engine Stops When Accelerator Is Returned To Idle Position.......................................................... WP 0010 6. Engine Fails To Stop......................................................................................................................... WP 0011 7. Engine Runs, But Misfires................................................................................................................. WP 0012 8. Engine Idle Rough Or Erratic............................................................................................................ WP 0013 9. Poor Acceleration And/Or Lack Of Power......................................................................................... WP 0014 10. Engine Surges................................................................................................................................... WP 0015 11. Excessive Oil Consumption............................................................................................................... WP 0016 12. Low Oil Pressure............................................................................................................................... WP 0017 13. Engine Oil Contaminated.................................................................................................................. WP 0018 14. Excessive Vibrating Or Clunking....................................................................................................... WP 0019 15. Excessive Fuel Consumption............................................................................................................ WP 0020 16. Engine Cranks But Will Not Start In Cold Weather (Fuel System Operating Properly)........................................................................................................................... WP 0021 17. Exhaust Color Blue During Normal Operation................................................................................... WP 0022 18. Exhaust Color White During Normal Operation................................................................................. WP 0023 19. Exhaust Color Black During Normal Operation And Idle................................................................... WP 0024 20. Excessive Exhaust Noise.................................................................................................................. WP 0025 21. Exhaust Fumes In Cab...................................................................................................................... WP 0026 22. Engine Does Not Reach Normal Operating Temperature................................................................. WP 0027 23. Engine Overheats............................................................................................................................. WP 0028 24. Loss Of Coolant................................................................................................................................ WP 0029 25. Contaminated Coolant...................................................................................................................... WP 0030 TRANSMISSION 1. Excessive Noise During Shifting....................................................................................................... WP 0031 0005-1 03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00301) TM 9-2320-272-23-1 0005 GENERAL TROUBLESHOOTING INDEX - Continued Malfunction/Symptom Troubleshooting Procedure 2. Low Transmission Oil Pressure......................................................................................................... WP 0032 3. Transmission Oil Leaking.................................................................................................................. WP 0033 4. No Response To Shift Lever Movement........................................................................................... WP 0034 5. Rough Shifting................................................................................................................................... WP 0035 6. Transmission Overheats As Indicated By Transmission Temperature Gauge.......................................................................................................................... WP 0036 7. Dirt Or Metal Particles In Transmission Oil....................................................................................... WP 0037 8. Oil Thrown From Transmission Dipstick Tube.................................................................................. WP 0038 9. Transmission Oil Dirty, Foamy, And/Or Milky.................................................................................... WP 0039 TRANSFER CASE 1. Hard Shifting Of Transfer Case......................................................................................................... WP 0040 2. Transfer Case Leaking Oil................................................................................................................ WP 0041 3. Excessive Noise................................................................................................................................ WP 0042 4. Excessive Vibration........................................................................................................................... WP 0043 DRIVELINE 1. Excessive Propeller And Driveshaft Noise Or Vibration.................................................................... WP 0044 2. Continuous Axle Or Wheel Noise...................................................................................................... WP 0045 FRAME AND CHASSIS 1. Towing Pintle Does Not Latch or lock............................................................................................... WP 0046 2. Pintle Hook Does Not Turn............................................................................................................... WP 0047 3. Excessively Loose Lifting Shackle.................................................................................................... WP 0048 4. Loose Spare Tire Carrier................................................................................................................... WP 0049 STEERING/TIRE 1. Uneven Tire Wear............................................................................................................................. WP 0050 2. Wheel Shimmy Or Wobble................................................................................................................ WP 0051 3. Hard Steering.................................................................................................................................... WP 0052 4. Vehicle Wanders Or Pulls To One Side............................................................................................ WP 0053 5. Excessive Play In Steering Wheel.................................................................................................... WP 0054 6. Shimmy............................................................................................................................................. WP 0055 7. Continuous Wandering Or Swaying (Poor Control)........................................................................... WP 0056 0005-2 03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00301) TM 9-2320-272-23-1 0005 GENERAL TROUBLESHOOTING INDEX - Continued Malfunction/Symptom Troubleshooting Procedure 8. Harsh Or Hard Ride.......................................................................................................................... WP 0057 9. Spring Leaf Defect............................................................................................................................ WP 0058 WINCH 1. Winch Does Not Operate.................................................................................................................. WP 0059 2. Winch Operates In One Direction Only............................................................................................. WP 0060 3. Drag Brake Does Not Operate.......................................................................................................... WP 0061 4. Winch Will Not Hold Load................................................................................................................. WP 0062 5. Automatic Brake Overheats.............................................................................................................. WP 0063 6. Front Winch Operates At One Speed Only....................................................................................... WP 0064 7. Rear Winch Cable Tensioner Will Not Operate................................................................................. WP 0065 8. Vehicle Rolls While Operating Rear Inch.......................................................................................... WP 0066 PTO 1. PTO Excessively Noisy..................................................................................................................... WP 0067 2. PTO Shifts Hard................................................................................................................................ WP 0068 3. PTO Leaking Lubricant..................................................................................................................... WP 0069 RADIO INTERFERENCE 1. Radio Interference............................................................................................................................. WP 0070 FIFTH WHEEL 1. Trailer Will Not Hitch To Fifth Wheel................................................................................................. WP 0071 WRECKER 1. Wrecker Hydraulic System Does Not Operate.................................................................................. WP 0072 2. Wrecker Hydraulic Pump Noisy......................................................................................................... WP 0073 DUMP BODY 1. Dump Body Will Not Raise................................................................................................................ WP 0074 2. Dump Body Will Not Lower............................................................................................................... WP 0075 3. Dump Body Will Not Hold In Raised Position.................................................................................... WP 0076 4. Dump Hydraulic Pump Noisy............................................................................................................ WP 0077 5. Dump Tailgate Will Not Open............................................................................................................ WP 0078 0005-3 03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00301) TM 9-2320-272-23-1 0005 GENERAL TROUBLESHOOTING INDEX - Continued Malfunction/Symptom Troubleshooting Procedure EXPANSIBLE VAN 1. Side Panels Hard To Retract Or Expand.......................................................................................... WP 0079 2. Side Panel Cannot Be Locked In Retracted Position........................................................................ WP 0080 3. Van Body Not Waterproof Or Light Tight........................................................................................... WP 0081 4. Door Lock Will Not Operate............................................................................................................... WP 0082 ENGINE AND VEHICLE ELECTRICAL SYSTEM 1. Engine And Vehicle Electrical System Malfunctioning...................................................................... WP 0083 2. Engine Will Not Crank; Some Electrical Systems Inoperative Or Weak................................................................................................................................................. WP 0084 3. All Vehicle Electrical Systems Inoperative........................................................................................ WP 0085 4. Starter Motor Inoperative.................................................................................................................. WP 0086 5. Solenoid Operates, Starter Operates, But Engine Cranks Slowly..................................................... WP 0087 6. Starter Motor Inoperative; No Solenoid Thump................................................................................. WP 0088 7. No Or Low Alternator Output............................................................................................................. WP 0089 8. No Alternator Output (100 Amp Alternator)....................................................................................... WP 0090 9. Alternator Overcharging, Battery Indicator Gauge In Red Position............................................................................................................................................. WP 0091 10. Headlamp (One Side) Inoperative..................................................................................................... WP 0092 11. Headlamp (Both Sides) Inoperative.................................................................................................. WP 0093 12. Blackout Drive Or Blackout Marker Light Inoperative........................................................................ WP 0094 13. Stoplight Inoperative (Service Or Blackout)...................................................................................... WP 0095 14. Tail Or Marker Lights Inoperative...................................................................................................... WP 0096 15. Individual Lights Do Not Light With Directional Signal Lever In Any Position...................................................................................................................................... WP 0097 16. No Lights Operate With Directional Signal Control Lever In Any Position............................................................................................................................................. WP 0098 17. System Operates Incorrectly In One Or More Positions Of Directional Signal Control Lever........................................................................................................ WP 0099 18. Protective Control Box Assembly Test.............................................................................................. WP 0100 INDICATOR, GAUGE, AND WARNING SYSTEM 1. Speedometer Or Tachometer Noisy Or Erratic................................................................................. WP 0101 2. Air Pressure Gauge Inoperative........................................................................................................ WP 0102 3. Oil Pressure Gauge Inoperative (Oil Level Is Correct)...................................................................... WP 0103 0005-4 03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00301) TM 9-2320-272-23-1 0005 GENERAL TROUBLESHOOTING INDEX - Continued Malfunction/Symptom Troubleshooting Procedure 4. All Gauges Inoperative...................................................................................................................... WP 0104 5. Transmission Temperature Gauge Inoperative................................................................................. WP 0105 6. Temperature Gauge Inoperative (Coolant)....................................................................................... WP 0106 7. Fuel Gauge Inoperative..................................................................................................................... WP 0107 8. Battery/Alternator Gauge Inoperative................................................................................................ WP 0108 9. Horn Inoperative................................................................................................................................ WP 0109 10. Low Air Pressure Warning Buzzer Will Not Shut Off (Air Pressure Gauges At Normal System Pressure)................................................................................ WP 0110 11. Low Air Pressure Warning Buzzer Will Not Shut Off And Parking Brake Warning Light Flashes With Hand/Parking Brake In Any Position (Air Pressure Normal).......................................................................................................... WP 0111 12. Spring Brake Warning Light Inoperative With Spring Brake Override Engaged............................................................................................................................. WP 0112 TRAILER CONNECTION 1. One Or More Trailer Lights Inoperative............................................................................................. WP 0113 CAB HEATER 1. Heater Will Not Operate With Switch In LOW Position (HIGH Position Operation Normal)............................................................................................................... WP 0114 2. Heater will Not Operate With Switch In HIGH position (LOW Position Operation Normal)............................................................................................................... WP 0115 3. Heater Will Not Operate In LOW Or HIGH Position.......................................................................... WP 0116 4. No Cab Heat (Coolant Temperature Gauge Reads Normal)............................................................ WP 0117 COMPRESSED AIR AND BRAKE SYSTEM 1. Parking Brake Does Hot Hold Vehicle On Grade.............................................................................. WP 0118 2. Parking Brake Drags, As Indicated By Smoking Or Burning Smell................................................................................................................................................. WP 0119 3. Insufficient Brakes (Vehicle Stopping Distance Too Long, No Apparent Air System Failure With Gauges At Normal Operating Pressure, Warning Buzzer Not Sounding)........................................................................................ WP 0120 4. Vehicle Pulls Right Or Left When Applying Brakes........................................................................... WP 0121 5. Vehicle Rear Brakes Grab Or Drag................................................................................................... WP 0122 6. Vehicle Vibrates, Chatters, Or Bounces When Brakes Are Applied.............................................................................................................................................. WP 0123 7. Brakes Squeal................................................................................................................................... WP 0124 0005-5 03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00301) TM 9-2320-272-23-1 0005 GENERAL TROUBLESHOOTING INDEX - Continued Malfunction/Symptom Troubleshooting Procedure 8. Warning Buzzer Sounds When Brakes Are Applied (Primary And Secondary Gauge Pressure Drops Below 55-65 psi (379-448 kPa)).................................................................................................................................. WP 0125 9. No Air Pressure (Warning Buzzer Sounding, Air Pressure Not Building To Normal Operating Range As Indicated By Gauges)....................................................... WP 0126 10. Air Pressure Does Not Build To Normal Operating Pressure (Above 80 psi (552 kPa)) According To Gauges............................................................................... WP 0127 11. Air Pressure Builds Slowly (Takes Excessive Amount Of Time To Build To 100 psi (690kPa)).......................................................................................................... WP 0128 12. Air Pressure Exceeds Maximum (Gauges Show Over 130 psi (896 kPa)), Safety Valve Opens To Release Pressure..................................................................... WP 0129 13. Primary Pressure Gauge Reads No Pressure, Low Pressure, Or Builds To Normal Operating Pressure Slowly. Secondary Pressure Gauge Reads Normal (Engine Idling, Brake Pedal Not Applied)............................................................................................................................................. WP 0130 14. Secondary Pressure Gauge Reads No Pressure, Low Pressure, Or Builds To Normal Operating Pressure Slowly. Primary Pressure Gauge Reads Normal (Engine Idling, Brake Pedal Not Applied)............................................................................................................................ WP 0131 15. Primary Air System Fails To Maintain Pressure (No Major Leaks, Air Can Be Heard Escaping Into Air Intake Stack, Parking Brake Applied)..................................................................................................................... WP 0132 16. Secondary Air System Fails To Maintain Pressure (No Major Leaks, Air Can Be Heard Escaping Into Air Intake Stack, Parking Brake Applied)..................................................................................................................... WP 0133 17. Warning Buzzer Fails To Sound Or Fails To Shut Off On Low Pressure (below 55-65 psi (379-448 kPa)), Air Pressure System Operating Normally.............................................................................................................. WP 0134 18. Spring Brakes Do Not Release (Vehicle Brakes Grab Or Drag)....................................................... WP 0135 19. Spring Brakes Do Not Set (Gauges At Normal Operating Pressures, Air Exhausting Not Heard When Parking Brake Applied)............................................................................................................................................. WP 0136 20. All Air-Operated Accessories Do Not Operate (Horn, Windshield Wipers, Windshield Washers, Transfer Case Controls), Gauges At Normal Operating Pressure............................................................................ WP 0137 21. Cooling Fan Does Not Operate, Engine Temperature Above 200°F (93°C) As Indicated By Temperature Gauge.......................................................................... WP 0138 22. Cooling Fan Does Not Stop Running, Engine Temperature Below Normal Operating Range (Override Bolt Not Installed).......................................................... WP 0139 23. Front Wheel Drive Does Not Engage (Front Wheel Drive LockIn Switch Engaged And Transfer Case Shift Lever In HIGH Position)............................................................................................................................................ WP 0140 0005-6 03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00301) TM 9-2320-272-23-1 0005 GENERAL TROUBLESHOOTING INDEX - Continued Malfunction/Symptom 24. Troubleshooting Procedure Horn Does Not Work (Gauges At Normal Operating Pressure, Warning Buzzer Not Sounding)......................................................................................................... WP 0141 END OF WORK PACKAGE 0005-7/8 blank 03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00301) TM 9-2320-272-23-1 FIELD MAINTENANCE ENGINE FAILS TO CRANK INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics References (cont.) WP 0086 WP 0088 Volume 2, WP 0220 Volume 2, WP 0303 Volume 2, WP 0346 Volume 2, WP 0349 Volume 2, WP 0350 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE ENGINE FAILS TO CRANK NOTE Conduct these malfunction tests if engine fails to crank. This procedure will check battery cables, clamps, posts and cases, starter motor, flywheel ring gear, specific gravity levels for each battery, test battery voltage and check for a seized engine. 0006-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00056) 0006 TM 9-2320-272-23-1 0006 ENGINE FAILS TO CRANK - Continued STEP 1. ARE ALL THE BATTERY CABLES, CLAMPS, POSTS, AND CASES FREE OF CORROSION, DAMAGE, LOOSENESS AND CRACKS? a. Visually inspect battery cables, clamps, and posts for breaks, looseness, corrosion, and damage. T0031DAA Figure 1. b. Battery Cables. Inspect battery cases for cracks. CONDITION/INDICATION ARE ALL THE BATTERY CABLES, CLAMPS, POSTS, AND CASES FREE OF CORROSION, DAMAGE, LOOSENESS AND CRACKS? DECISION NO - Cable or clamp corroded or loose. Repair or replace corroded or damaged cable or clamp (Volume 2, WP 0349). Go to Step (9) to verify problem is solved. NO - Cable clamp loose. Tighten loose battery cable clamp (Volume 2, WP 0349). Go to Step (9) to verify problem is solved. NO - Battery case cracked or post damaged. Replace cracked battery case or damaged post (Volume 2, WP 0346). Go to Step (9) to verify problem is solved. YES - Go to Step (2). 0006-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00056) TM 9-2320-272-23-1 0006 ENGINE FAILS TO CRANK - Continued STEP 2. DO BATTERIES HAVE CORRECT SPECIFIC GRAVITY? a. Access batteries. T0033DAA Figure 2. Battery Specific Gravity Test. b. Check each battery for specific gravity. Correct level is 1.225 or greater, temperature corrected. Each cell must also test within 25 points of the others. c. If specific gravity is incorrect add distilled water or recharge batteries if necessary. d. Perform specific gravity test again. CONDITION/INDICATION DO BATTERIES HAVE CORRECT SPECIFIC GRAVITY? DECISION NO - Replace defective battery (Volume 2, WP 0346). Go to Step (9) to verify problem is solved. YES - Go to Step (3). 0006-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00056) TM 9-2320-272-23-1 0006 ENGINE FAILS TO CRANK - Continued STEP 3. IS BATTERY TO STARTER OR BATTERY TO FRAME CABLE, LOOSE, CORRODED, OR DAMAGED? a. Visually inspect starter and ground cables for looseness. T0032DAA Figure 3. b. Starter Cables. Visually inspect starter and ground cables for corrosion and damage. CONDITION/INDICATION IS BATTERY TO STARTER OR BATTERY TO FRAME CABLE, LOOSE, CORRODED, OR DAMAGED? DECISION YES - Battery to starter cable faulty. Repair or replace faulty battery to starter cable (Volume 2, WP 0349). Go to Step (9) to verify problem is solved. YES - Battery ground cable faulty. Repair or replace faulty battery ground cable (Volume 2, WP 0350). Go to Step (9) to verify problem is solved. NO - Go to Step (4). 0006-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00056) TM 9-2320-272-23-1 0006 ENGINE FAILS TO CRANK - Continued STEP 4. DO BATTERIES HAVE PROPER VOLTAGE? a. Set multimeter to measure voltage. VEHICLE DIAGNOSTIC CONNECTOR ABS DIAGNOSTIC CONNECTOR Figure 4. T0863DAA DCA Connection. b. Connect multimeter red lead to DCA connector, terminal V. Refer to point to point schematics. c. Connect multimeter black lead to DCA connector, terminal W. d. Meter should display a reading between 23.5 and 25.5 VDC. CONDITION/INDICATION DO BATTERIES HAVE PROPER VOLTAGE? DECISION NO - Replace defective batteries (Volume 2, WP 0346). Go to Step (9) to verify problem is solved. YES - Go to Step (5). 0006-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00056) TM 9-2320-272-23-1 ENGINE FAILS TO CRANK - Continued STEP 5. DOES THE STARTER MOTOR SOLENOID SOUND LIKE IT IS ENERGIZED? a. Set vehicle controls to crank engine. Starter Solenoid T0034DAA Figure 5. b. Starter Solenoid. Depress starter switch and listen to starter motor solenoid inside engine compartment. CONDITION/INDICATION DOES THE STARTER MOTOR SOLENOID SOUND LIKE IT IS ENERGIZED? DECISION NO - Perform Starter Motor Inoperative, No Solenoid Thump troubleshooting (WP 0088). YES - Go to Step (7). STEP 6. DOES THE STARTER MOTOR SOUND LIKE IT IS RUNNING OVERSPEED? a. Set vehicle controls to crank engine. Starter Motor T0035DAA Figure 6. b. Starter Motor. Depress starter switch and listen to starter motor. 0006-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00056) 0006 TM 9-2320-272-23-1 0006 ENGINE FAILS TO CRANK - Continued CONDITION/INDICATION DOES THE STARTER MOTOR SOUND LIKE IT IS RUNNING OVERSPEED? DECISION NO - Perform Starter Motor Inoperative troubleshooting (WP 0086). YES - Go to Step (7). STEP 7. DOES THE STARTER DRIVE OR RING GEAR HAVE ANY BROKEN OR MISSING TEETH? a. Remove starter motor (Volume 2, WP 0303). Starter Motor T0036DAA Figure 7. b. Starter Motor. Check starter drive and ring gear for missing and/or damaged teeth. CONDITION/INDICATION DOES THE STARTER DRIVE OR RING GEAR HAVE ANY BROKEN OR MISSING TEETH? DECISION YES - Starter damaged. Replace damaged starter motor (Volume 2, WP 0303). Go to Step (9) to verify problem is solved. YES - Ring gear damaged. Replace damaged ring gear (Volume 2, WP 0220). Go to Step (9) to verify problem is solved. NO - Go to Step (8). 0006-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00056) TM 9-2320-272-23-1 0006 ENGINE FAILS TO CRANK - Continued STEP 8. IS ENGINE SEIZED? a. Starter motor remove. b. Rotate engine at vibration damper bolt two full revolutions. Starter Motor T0036DAA Figure 8. Starter Motor. CONDITION/INDICATION IS ENGINE SEIZED? DECISION NO - Replace starter motor (Volume 2, WP 0303). Go to Step (9) to verify problem is solved. YES - Notify supervisor that engine is seized. Action may not be possible at this level of maintenance. STEP 9. IS YOUR ORIGINAL ENGINE CRANK PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original engine crank problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL ENGINE CRANK PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0006-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00056) TM 9-2320-272-23-1 FIELD MAINTENANCE ENGINE CRANKS BUT DOES NOT START INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics TM 9-2320-272-10 WP 0021 WP 0086 Volume 2, WP 0239 Volume 2, WP 0241 References (cont.) Volume 2, WP 0243 Volume 2, WP 0251 Volume 2, WP 0254 Volume 2, WP 0258 Volume 2, WP 0259 Volume 2, WP 0260 Volume 2, WP 0263 Volume 2, WP 0264 Volume 2, WP 0265 Volume 2, WP 0266 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE ENGINE CRANKS BUT DOES NOT START NOTE Conduct these malfunction tests if engine fails to start. This procedure will check for the emergency engine stop control not correctly set, air in fuel system, coolant in combustion chambers, loose fuel supply line connections or fuel supply line at fuel filter head, leaking or damaged primary fuel filter, contaminated fuel, low fuel supply or vacuum pressure, and an empty ether cylinder. It also checks for a faulty fuel transfer pump, fuel supply line, starter circuit, fuel filter, ether start system, thermal close valve, and ether atomizer. In addition, this procedure checks for a clogged or dirty air intake stack, air cleaner element, fuel injector supply line, fuel filter, fuel pump filter, thermal close valve tubing, and atomizer tubing. 0007-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) 0007 TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued STEP 1. DOES ENGINE START WITH EMERGENCY ENGINE STOP CONTROL ALL THE WAY IN? a. Verify emergency engine stop control is all the way in and emergency shutoff valve has been reset (TM 9-2320-272-10). Battery Switch Starter Switch Eng Stop Control Instrument Panel T0359DAA Figure 1. Engine Stop Control. b. Press accelerator pedal all the way down to floor and hold while trying to start engine. CONDITION/INDICATION DOES ENGINE START WITH EMERGENCY ENGINE STOP CONTROL ALL THE WAY IN? DECISION YES - Problem fixed. NO - Go to Step (2). STEP 2. IS AIR CLEANER INDICATOR IN RED ZONE? a. Check air cleaner indicator for air restriction indication. Air Cleaner Indicator T0038DAA Figure 2. Air Cleaner Indicator. 0007-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued b. Inspect air intake stack for restrictions. CONDITION/INDICATION IS AIR CLEANER INDICATOR IN RED ZONE? DECISION YES - Perform air cleaner servicing (TM 9-2320-272-10). Go to Step (22) to verify problem is solved. NO - Go to Step (3). STEP 3. IS THERE WHITE SMOKE DURING CRANKING? Try to start engine while checking for white smoke in exhaust. Exhaust T0360DAA Figure 3. Engine Exhaust. CONDITION/INDICATION IS THERE WHITE SMOKE DURING CRANKING? DECISION NO - Go to Step (6). YES - Go to Step (4). 0007-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued STEP 4. DOES ENGINE START AFTER PRIMING FUEL SYSTEM? WARNING Diesel fuel is highly flammable. Do not perform fuel system procedures near open flame. Failure to comply may result in injury or death to personnel. a. Prime the fuel system M939/A1 (TM 9-2320-272-10), M939A2 (Volume 2, WP 0239). Exhaust T0360DAA Figure 4. Engine Exhaust. NOTE If engine starts, there was air in fuel system. b. Try to start engine while checking for white smoke in exhaust. CONDITION/INDICATION DOES ENGINE START AFTER PRIMING FUEL SYSTEM? DECISION YES - Problem fixed. NO - Go to Step (5). 0007-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued STEP 5. IS THERE COOLANT IN THE COMBUSTION CHAMBERS? Remove the dipstick and look for evidence of coolant on the dipstick. Dipstick Dipstick M939A2 M939/A1 T0376DAA Figure 5. Engine Dipstick. CONDITION/INDICATION IS THERE COOLANT IN THE COMBUSTION CHAMBERS? DECISION NO - Notify supervisor. It is possible that another troubleshooting work package applies. YES - Notify supervisor that there is coolant in the combustion chambers. Action may not be possible at this level of maintenance. 0007-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued STEP 6. IS THE FUEL SUPPLY LINE LOOSE AT FUEL FILTER HEAD? Check for loose fuel supply line at fuel filter head. Supply Line Fuel Filter Head T0361DAA Figure 6. Engine Fuel Supply Line. CONDITION/INDICATION IS THE FUEL SUPPLY LINE LOOSE AT FUEL FILTER HEAD? DECISION NO - Go to Step (11) (M939/A1 vehicles). NO - Go to Step (7) (M939A2 vehicles). YES - Tighten fuel supply line (Volume 2, WP 0243). Go to Step (22) to verify problem is solved. 0007-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued STEP 7. IS FUEL TRANSFER PUMP OPERATING PROPERLY? a. Loosen plunger on fuel transfer pump until air is purged from fuel system. PLUNGER FUEL PRESSURE TRANSDUCER FUEL TRANSFER PUMP T0362DAA Figure 7. Fuel Transfer Pump. NOTE If fuel is present at fuel transfer pump when operating hand primer, fuel transfer pump is not operating properly. b. Check for fuel at fuel transfer pump while operating hand primer. CONDITION/INDICATION IS FUEL TRANSFER PUMP OPERATING PROPERLY? DECISION YES - Go to Step (8). NO - Replace fuel transfer pump (Volume 2, WP 0243). Go to Step (22) to verify problem is solved. 0007-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued STEP 8. IS FUEL LEAKING FROM FUEL PRESSURE TRANSDUCER? Check for fuel leaking from fuel pressure transducer. Fuel Pressure Transducer T0364DAA Figure 8. Fuel Pressure Transducer. CONDITION/INDICATION IS FUEL LEAKING FROM FUEL PRESSURE TRANSDUCER? DECISION NO - Go to Step (11). YES - Go to Step (9). STEP 9. IS THE FUEL INJECTOR SUPPLY LINE CLOGGED? WARNING • Eyeshields must be worn when cleaning with compressed air. Compressed air source will not exceed 30 psi (207 kPa). Failure to comply may result in injury or death to personnel. • Diesel fuel is highly flammable. Do not perform fuel system procedures near open flame. Failure to comply may result in injury or death to personnel. 0007-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued Disconnect fuel injector supply lines and check for clogs (Volume 2, WP 0241). Fuel Injector Supply Lines T0365DAA Figure 9. Fuel Injector Supply Lines. CONDITION/INDICATION IS THE FUEL INJECTOR SUPPLY LINE CLOGGED? DECISION YES - Clear all clogged fuel injector supply lines with compressed air or sturdy wire (Volume 2, WP 0241). Go to Step (22) to verify problem is solved. NO - Go to Step (10). 0007-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued STEP 10. IS THE FUEL FILTER DIRTY OR CLOGGED? Remove fuel filter and check for a dirty filter or clogs (Volume 2, WP 0258). Fuel Filter Head Adapter Seal Fuel Filter T0367DAA Figure 10. Fuel Filter. CONDITION/INDICATION IS THE FUEL FILTER DIRTY OR CLOGGED? DECISION YES - Replace fuel filter (Volume 2, WP 0258). Go to Step (22) to verify problem is solved. NO - Notify supervisor. It is possible that another troubleshooting work package applies. STEP 11. IS FUEL SYSTEM IN GOOD OPERATING CONDITION? WARNING Diesel fuel is highly flammable. Do not perform fuel system procedures near open flame. Failure to comply may result in injury or death to personnel. a. Verify that there is fuel in the tank. 0007-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued T0039DAA Figure 11. Fuel System. b. Check fuel shut off solenoid and circuitry, and emergency fuel shutoff. c. Visually inspect AFC standard pump filter for dirty or clogged condition (Volume 2, WP 0259). d. Visually inspect fuel pump with VS governor filter for dirty or clogged condition (Volume 2, WP 0260). (M936A1 and M928 models) e. Visually check primary fuel filter for leaks or damage (Volume 2, WP 0258). f. Check fuel lines and connections for leaks, obstructions, and damage. g. Tighten all connections where a leak is detected. CONDITION/INDICATION IS FUEL SYSTEM IN GOOD OPERATING CONDITION? DECISION NO - Fuel filter leaking or damaged. Replace fuel filter (Volume 2, WP 0258). Go to Step (22) to verify problem is solved. NO - Bad fuel lines. Replace fuel lines (Volume 2, WP 0254). Go to Step (22) to verify problem is solved. NO - Bad AFC standard pump filter. Replace AFC standard pump filter filter (Volume 2, WP 0259). Go to Step (22) to verify problem is solved. NO - Bad fuel pump with VS governor filter. Replace fuel pump with VS governor filter (Volume 2, WP 0260). Go to Step (22) to verify problem is solved. YES - Go to Step (12). 0007-11 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued STEP 12. DOES ENGINE CRANKING SPEED REACH 100 RPM? a. Pull out ENG STOP lever to shut off fuel. T0065DAA Figure 12. b. Engine. Crank the engine and check of engine cranks at normal speed. CONDITION/INDICATION DOES ENGINE CRANKING SPEED REACH 100 RPM? DECISION NO - Perform Starter Motor Inoperative troubleshooting (WP 0086). YES - Go to Step (13). 0007-12 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued STEP 13. IS FUEL CONTAMINATED? a. Open drain valves at fuel filter and drain approximately 1 pt (0.473 L) of fuel into glass container. Draincock Primary Fuel Filter Draincock T0368DAA Figure 13. b. Fuel Filter. Check if fuel is contaminated. CONDITION/INDICATION IS FUEL CONTAMINATED? DECISION YES - Go to Step (14). NO - Go to Step (16). 0007-13 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued STEP 14. IS FUEL CONTAMINATED? a. Open drain valves at fuel filter and continue to drain fuel up to 1 qt (0.946 L) of fuel into glass container. Draincock Primary Fuel Filter Draincock T0368DAA Figure 14. b. Fuel Filter. Check if fuel is contaminated. CONDITION/INDICATION IS FUEL CONTAMINATED? DECISION YES - Go to Step (15). NO - Go to Step (16). STEP 15. DOES ENGINE START AFTER CLEANING FUEL SYSTEM? 0007-14 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued WARNING • Eyeshields must be worn when cleaning with compressed air. Compressed air source will not exceed 30 psi (207 kPa). Failure to comply may result in injury or death to personnel. • Diesel fuel is highly flammable. Do not perform fuel system procedures near open flame. Failure to comply may result in injury or death to personnel. a. Drain fuel tank (Volume 2, WP 0250). Fuel Tank T0375DAA Figure 15. Fuel Tank. b. Clean and flush fuel system. Dry with compressed air. c. Replace fuel filter (Volume 2, WP 0258). d. Refill tank with fuel. e. Prime fuel system M939/A1 (TM 9-2320-272-10), M939A2 (Volume 2, WP 0239). f. Verify ENG STOP lever is pushed in and emergency shutoff valve is reset (TM 9-2320-272-10). g. Attempt to start engine. CONDITION/INDICATION DOES ENGINE START AFTER CLEANING FUEL SYSTEM? DECISION NO - Go to Step (16). YES - Problem fixed. 0007-15 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued STEP 16. IS ETHER CYLINDER EMPTY? a. Remove ether cylinder from valve (Volume 2, WP 0263). Ether Cylinder Clamp Bracket Ground Wire Ether Valve Ether Cylinder Relief Tube Ether Supply Tube Ether Valve Bracket Connector T0369DAA Figure 16. b. Ether Start System. Shake ether cylinder and listen for liquid splashing inside. CONDITION/INDICATION IS ETHER CYLINDER EMPTY? DECISION YES - Replace empty ether cylinder with a full cylinder (Volume 2, WP 0263). Go to Step (22) to verify problem is solved. NO - Go to Step (17). STEP 17. DOES ETHER VALVE OPERATE PROPERLY? 0007-16 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued WARNING Ether is extremely flammable. Do not perform ether start system testing procedures near fire. Failure to comply may result in injury or death to personnel. a. Disconnect tubing at ether valve (Volume 2, WP 0263). Ether Cylinder Clamp Bracket Ground Wire Ether Valve Ether Cylinder Relief Tube Ether Supply Tube Ether Valve Bracket Connector T0369DAA Figure 17. b. Ether Start System. Watch for a small amount of ether being released by ether valve while pressing ether start switch. CONDITION/INDICATION DOES ETHER VALVE OPERATE PROPERLY? DECISION YES - Go to Step (18). NO - Perform Engine Cranks But Will Not Start In Cold Weather troubleshooting (WP 0021). 0007-17 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued STEP 18. IS THE THERMAL CLOSE VALVE OR TUBING RESTRICTED? WARNING • Ether is extremely flammable. Do not perform ether start system testing procedures near fire. Failure to comply may result in injury or death to personnel. • Eyeshields must be worn when cleaning with compressed air. Compressed air source will not exceed 30 psi (207 kPa). Failure to comply may result in injury or death to personnel. a. Verify thermal close valve is cold. Atomizer Ether Supply Tube Adapter Fittings Thermal Close Ether Supply Tube Adapter Bushing Thermal Close Valve T0370DAA Figure 18. Thermal Close Valve. b. Disconnect ether valve to thermal close valve tubing at ether valve (Volume 2, WP 0263). c. Blow compressed air into tubing at ether valve end to determine if system is clear. 0007-18 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued CONDITION/INDICATION IS THE THERMAL CLOSE VALVE OR TUBING RESTRICTED? DECISION YES - Go to Step (19). NO - Go to Step (20). STEP 19. IS THE THERMAL CLOSE VALVE TUBING RESTRICTED? a. Disconnect tubing from thermal close valve (Volume 2, WP 0263). Atomizer Ether Supply Tube Adapter Fittings Thermal Close Ether Supply Tube Adapter Bushing Thermal Close Valve T0370DAA Figure 19. b. Thermal Close Valve. Check for restrictions in tubing. CONDITION/INDICATION IS THE THERMAL CLOSE VALVE TUBING RESTRICTED? DECISION YES - Replace tubing (Volume 2, WP 0263). Go to Step (22) to verify problem is solved. NO - Replace thermal close valve (Volume 2, WP 0264). Go to Step (22) to verify problem is solved. 0007-19 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued STEP 20. IS THE ATOMIZER OR ATOMIZER TUBING RESTRICTED? WARNING • Ether is extremely flammable. Do not perform ether start system testing procedures near fire. Failure to comply may result in injury or death to personnel. • Eyeshields must be worn when cleaning with compressed air. Compressed air source will not exceed 30 psi (207 kPa). Failure to comply may result in injury or death to personnel. a. Reconnect tubing at ether valve (Volume 2, WP 0263). Atomizer Ether Supply Tube Adapter Fittings Thermal Close Ether Supply Tube Adapter Bushing Thermal Close Valve T0370DAA Figure 20. Thermal Close Valve. b. Disconnect thermal close valve to atomizer tubing at thermal close valve (Volume 2, WP 0264). c. Blow compressed air into tubing at thermal close valve end to determine if system is clear. 0007-20 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 0007 ENGINE CRANKS BUT DOES NOT START - Continued CONDITION/INDICATION IS THE ATOMIZER OR ATOMIZER TUBING RESTRICTED? DECISION YES - Go to Step (21). NO - Notify supervisor. It is possible that another troubleshooting work package applies. STEP 21. IS THE ATOMIZER TUBING RESTRICTED? a. Disconnect tubing from atomizer (M939/A1 vehicles) (Volume 2, WP 0265). Atomizer Ether Supply Tube Adapter Fittings Thermal Close Ether Supply Tube Adapter Bushing Thermal Close Valve T0370DAA Figure 21. Thermal Close Valve. b. Disconnect tubing from atomizer (M939A2 vehicles) (Volume 2, WP 0266). c. Check for restrictions in tubing. CONDITION/INDICATION IS THE ATOMIZER TUBING RESTRICTED? DECISION YES - Replace tubing (Volume 2, WP 0263). Go to Step (22) to verify problem is solved. NO - Replace atomizer M939/A1 (Volume 2, WP 0265), M939A2 (Volume 2, WP 0266). Go to Step (22) to verify problem is solved. 0007-21 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) TM 9-2320-272-23-1 ENGINE CRANKS BUT DOES NOT START - Continued STEP 22. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL ENGINE CRANK PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0007-22 03/15/2011 Rel(1.8) root(tswp) wpno(T00057) 0007 TM 9-2320-272-23-1 FIELD MAINTENANCE STARTER CRANKS ENGINE SLOWLY, HARD TO START INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) WP 0087 Volume 2, WP 0232 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE STARTER CRANKS ENGINE SLOWLY, HARD TO START NOTE Conduct this malfunction test if engine cranks slowly and is hard to start. This procedure will check for incorrect cold weather oil and a faulty starting system. 0008-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00058) 0008 TM 9-2320-272-23-1 0008 STARTER CRANKS ENGINE SLOWLY, HARD TO START - Continued STEP 1. IS CORRECT OIL IN ENGINE? If engine is in cold weather, verify that proper engine oil is being used (Volume 5, WP 0820). T0374DAA Figure 1. Engine. CONDITION/INDICATION IS CORRECT OIL IN ENGINE? DECISION YES - Perform Solenoid Operates, Starter Operates, But Engine Cranks Slowly troubleshooting (WP 0087). NO - Go to Step (2). STEP 2. DOES ENGINE START AFTER OIL IS CHANGED? a. Add or replace oil (Volume 2, WP 0232). b. Press accelerator pedal down to floor and hold. 0008-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00058) TM 9-2320-272-23-1 0008 STARTER CRANKS ENGINE SLOWLY, HARD TO START - Continued ACCELERATOR PEDAL T0373DAA Figure 2. c. Accelerator Pedal. Try starting engine. CONDITION/INDICATION DOES ENGINE START AFTER OIL IS CHANGED? DECISION YES - Go to Step (3). NO - Perform Solenoid Operates, Starter Operates, But Engine Cranks Slowly troubleshooting (WP 0087). STEP 3. IS YOUR ORIGINAL ENGINE CRANK PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original engine problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL ENGINE CRANK PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0008-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00058) TM 9-2320-272-23-1 FIELD MAINTENANCE ENGINE STOPS DURING NORMAL OPERATION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics TM 9-2320-272-10 Volume 2, WP 0239 Volume 2, WP 0243 Volume 2, WP 0251 Volume 2, WP 0254 References (cont.) Volume 2, WP 0258 Volume 2, WP 0259 Volume 2, WP 0260 Volume 2, WP 0273 Volume 2, WP 0274 Volume 2, WP 0275 Volume 2, WP 0276 Volume 2, WP 0305 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE ENGINE STOPS DURING NORMAL OPERATION NOTE Conduct this malfunction test if engine starts but fails to keep running or engine stops during normal operation. This procedure will check for air intake stack or air cleaner element clogged, fuel level, fuel contamination, fuel transfer pump faulty, fuel pump filter clogged of dirty, primary fuel filter leaking or damaged, fuel supply line faulty, fuel supply line connections loose, fuel tank vent line obstruction, and faulty exhaust system. 0009-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00059) 0009 TM 9-2320-272-23-1 ENGINE STOPS DURING NORMAL OPERATION - Continued STEP 1. IS AIR CLEANER INDICATOR IN RED ZONE? a. Check air cleaner indicator for fresh air restriction indication. A A Air Cleaner Indicator T0876DAA Figure 1. Air Cleaner Indicator. b. Inspect air intake stack for restrictions. CONDITION/INDICATION IS AIR CLEANER INDICATOR IN RED ZONE? DECISION YES - Perform air cleaner servicing (TM 9-2320-272-10). Go to Step (10) to verify problem is solved. NO - Go to Step (2). 0009-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00059) 0009 TM 9-2320-272-23-1 0009 ENGINE STOPS DURING NORMAL OPERATION - Continued STEP 2. IS THERE FUEL IN VEHICLE TANK(S)? Check fuel level. T0048DAA Figure 2. Fuel Tank. CONDITION/INDICATION IS THERE FUEL IN VEHICLE TANK(S)? DECISION NO - Fill tank(s) with recommended fuel. Go to Step (10) to verify problem is solved. YES - Go to Step (3). 0009-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00059) TM 9-2320-272-23-1 0009 ENGINE STOPS DURING NORMAL OPERATION - Continued STEP 3. IS EMERGENCY FUEL SHUTOFF VALVE IN DISENGAGED POSITION? Visually check if emergency shutoff valve is in disengaged position. Emergency Fuel Shutoff Valve T0073DAA Figure 3. Emergency Shutoff Valve. CONDITION/INDICATION IS EMERGENCY FUEL SHUTOFF VALVE IN DISENGAGED POSITION? DECISION YES - Go to Step (4). NO - Return shutoff valve to disengaged position and reset the emergency shutoff valve (TM 9-2320-272-10). Go to Step (10) to verify problem is solved. 0009-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00059) TM 9-2320-272-23-1 0009 ENGINE STOPS DURING NORMAL OPERATION - Continued STEP 4. IS FUEL CONTAMINATED? NOTE Fuel is contaminated if container is 1/4 full of water or contains dirt. a. Open drain valves at fuel filters and drain approximately 1 pt (0.473 L) of fuel into glass container. T0378DAA Figure 4. b. Fuel Filter. Check fuel for water and/or dirt contamination. CONDITION/INDICATION IS FUEL CONTAMINATED? DECISION YES - Go to Step (5). NO - Go to Step (6) for M939A2. Go to Step (7) for M939/A1. 0009-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00059) TM 9-2320-272-23-1 0009 ENGINE STOPS DURING NORMAL OPERATION - Continued STEP 5. DOES ENGINE START AFTER CLEANING FUEL SYSTEM? a. Drain fuel tank (Volume 2, WP 0250). Fuel Tank T0890DAA Figure 5. Fuel Tank. b. Clean and flush fuel system. Dry with compressed air. c. Replace fuel filters (Volume 2, WP 0258). d. Refill tank with fuel. e. Prime fuel filter M939/A1 (TM 9-2320-272-10), M939A2 (Volume 2, WP 0239). f. Attempt to start engine. CONDITION/INDICATION DOES ENGINE START AFTER CLEANING FUEL SYSTEM? DECISION YES - Go to Step (10) to verify problem is solved. NO - Go to Step (6) for M939A2. Go to Step (7) for M939/A1. 0009-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00059) TM 9-2320-272-23-1 0009 ENGINE STOPS DURING NORMAL OPERATION - Continued STEP 6. IS FUEL TRANSFER PUMP OPERATING PROPERLY? a. Loosen fuel line fitting from filter head (Volume 2, WP 0243). Supply Line Fuel Filter Head T0398`DAA Figure 6. Fuel Line. b. Operate hand primer on fuel transfer pump. c. Check for fuel leaking out of loosened line at fuel filter head. CONDITION/INDICATION IS FUEL TRANSFER PUMP OPERATING PROPERLY? DECISION YES - Go to Step (8). NO - Replace fuel transfer pump (Volume 2, WP 0243). Go to Step (10) to verify problem is solved. 0009-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00059) TM 9-2320-272-23-1 0009 ENGINE STOPS DURING NORMAL OPERATION - Continued STEP 7. IS FUEL SYSTEM IN GOOD OPERATING CONDITION? WARNING Diesel fuel is highly flammable. Do not perform fuel system procedures near open flame. Failure to comply may result in injury or death to personnel. a. Check fuel shut off solenoid and circuitry. T0879DAA Figure 7. b. Fuel System. Visually inspect AFC standard pump filter for dirty or clogged condition. NOTE Perform this step for M936A1 and M928 models. c. Visually inspect fuel pump with VC governor filter for dirty or clogged condition. d. Visually check primary fuel filter for leaks or damage. e. Check fuel lines and connections for leaks, obstructions, and damage. 0009-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00059) TM 9-2320-272-23-1 0009 ENGINE STOPS DURING NORMAL OPERATION - Continued f. Tighten all connections where a leak is detected. CONDITION/INDICATION IS FUEL SYSTEM IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (8). NO - Fuel filter is leaking or damaged. Replace fuel filter (Volume 2, WP 0258). Go to Step (10) to verify problem is solved. NO - Fuel lines are bad. Replace tubing (Volume 2, WP 0254). Go to Step (10) to verify problem is solved. NO - AFC standard pump filter is bad. Replace AFC standard pump filter (Volume 2, WP 0259). Go to Step (10) to verify problem is solved. NO - VC governor fuel filter is bad (M936A1 and M928 models only). Replace VC governor fuel filter (Volume 2, WP 0260). Go to Step (10) to verify problem is solved. STEP 8. ARE FUEL TANK VENT LINES UNOBSTRUCTED? Remove air vent lines at both ends and clean with compressed air. T0074DAA Figure 8. Vent Lines. CONDITION/INDICATION ARE FUEL TANK VENT LINES UNOBSTRUCTED? DECISION YES - Go to Step (9). NO - Replace vent lines and elbow(s) (Volume 2, WP 0254). Go to Step (10) to verify problem is solved. 0009-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00059) TM 9-2320-272-23-1 0009 ENGINE STOPS DURING NORMAL OPERATION - Continued STEP 9. IS EXHAUST SYSTEM IN GOOD CONDITION? Check exhaust system for restriction. T0381DAA Figure 9. Exhaust System. CONDITION/INDICATION IS EXHAUST SYSTEM IN GOOD CONDITION? DECISION YES - Go to Step (10) to verify problem is solved. NO - Front exhaust pipe damaged. Replace front exhaust pipe (Volume 2, WP 0276). Go to Step (10) to verify problem is solved. NO - Rear exhaust pipe damaged. Replace rear exhaust pipe (Volume 2, WP 0275). Go to Step (10) to verify problem is solved. NO - Muffler damaged. Replace muffler (Volume 2, WP 0274). Go to Step (10) to verify problem is solved. NO - Exhaust stack damaged. Replace exhaust stack (Volume 2, WP 0273). Go to Step (10) to verify problem is solved. STEP 10. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0009-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00059) TM 9-2320-272-23-1 FIELD MAINTENANCE ENGINE STOPS WHEN ACCELERATOR IS RETURNED TO IDLE POSITION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 2, WP 0240 Volume 2, WP 0242 Volume 2, WP 0268 Volume 2, WP 0269 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE ENGINE STOPS WHEN ACCELERATOR IS RETURNED TO IDLE POSITION NOTE Conduct these malfunction tests if engine stops when accelerator is returned to idle position. This procedure will check for proper accelerator linkage adjustment and correct engine idle speed setting. 0010-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00060) 0010 TM 9-2320-272-23-1 0010 ENGINE STOPS WHEN ACCELERATOR IS RETURNED TO IDLE POSITION - Continued STEP 1. IS ACCELERATOR LINKAGE PROPERLY ADJUSTED AND IN GOOD CONDITION? Inspect accelerator linkage for damage and proper adjustment. T0390DAA Figure 1. Accelerator Linkage. CONDITION/INDICATION IS ACCELERATOR LINKAGE PROPERLY ADJUSTED AND IN GOOD CONDITION? DECISION YES - Go to Step (2). NO - Replace/adjust accelerator linkage M939/A1 (Volume 2, WP 0268), M939A2 (Volume 2, WP 0269). Go to Step (3) to verify problem is solved. 0010-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00060) TM 9-2320-272-23-1 0010 ENGINE STOPS WHEN ACCELERATOR IS RETURNED TO IDLE POSITION - Continued STEP 2. IS ENGINE IDLE SPEED SET BETWEEN 600-650 RPM? a. Start engine. b. Check if tachometer reads between 600 to 650 RPM at idle. T0054DAA Figure 2. Tachometer. CONDITION/INDICATION IS ENGINE IDLE SPEED SET BETWEEN 600-650 RPM? DECISION YES - Go to Step (3) to verify problem is solved. NO - Adjust engine idle RPM M939/A1 (Volume 2, WP 0240), M939A2 (Volume 2, WP 0242). Go to Step (3) to verify problem is solved. STEP 3. IS YOUR ORIGINAL ENGINE RUNNING PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL ENGINE RUNNING PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0010-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00060) TM 9-2320-272-23-1 FIELD MAINTENANCE ENGINE FAILS TO STOP INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References (cont.) Volume 2, WP 0271 Volume 2, WP 0304 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE ENGINE FAILS TO STOP NOTE Conduct these malfunction tests if engine fails to stop. This procedure will check the emergency stop control cable, and throttle control solenoid operation. 0011-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00061) 0011 TM 9-2320-272-23-1 0011 ENGINE FAILS TO STOP - Continued STEP 1. IS EMERGENCY STOP CONTROL CABLE IN GOOD WORKING CONDITION? Visually check emergency stop cable for breaks, binding, and proper adjustment. T0396DAA Figure 1. Emergency Stop Cable. CONDITION/INDICATION IS EMERGENCY STOP CONTROL CABLE IN GOOD WORKING CONDITION? DECISION YES - Go to Step (2). NO - Repair/replace emergency stop control cable (Volume 2, WP 0271). Go to Step (3) to verify problem is solved. 0011-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00061) TM 9-2320-272-23-1 0011 ENGINE FAILS TO STOP - Continued STEP 2. IS THROTTLE CONTROL SOLENOID AND MOUNTING HARDWARE IN GOOD CONDITION? a. Visually check throttle control solenoid mounting hardware for loose or broken components. T0397DAA Figure 2. b. Throttle Control Solenoid. Check operation of throttle control solenoid. CONDITION/INDICATION IS THROTTLE CONTROL SOLENOID AND MOUNTING HARDWARE IN GOOD CONDITION? DECISION YES - Go to Step (3) to verify problem is solved. NO - Repair mounting hardware or replace solenoid (Volume 2, WP 0304). Go to Step (3) to verify problem is solved. 0011-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00061) TM 9-2320-272-23-1 ENGINE FAILS TO STOP - Continued STEP 3. IS YOUR ORIGINAL ENGINE RUNNING PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original engine running problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL ENGINE RUNNING PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0011-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00061) 0011 TM 9-2320-272-23-1 FIELD MAINTENANCE ENGINE RUNS, BUT MISFIRES INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics TM 9-2320-272-10 Volume 2, WP 0225 References (cont.) Volume 2, WP 0239 Volume 2, WP 0251 Volume 2, WP 0254 Volume 2, WP 0258 Volume 2, WP 0268 Volume 2, WP 0269 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE ENGINE RUNS, BUT MISFIRES NOTE Conduct these malfunction tests if engine misfires while running. This procedure will check for fuel contamination, air intake system clogs or restrictions, proper working condition of throttle linkage, fuel line damage, proper fuel supply pressure and engine compression unbalance. 0012-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00062) 0012 TM 9-2320-272-23-1 0012 ENGINE RUNS, BUT MISFIRES - Continued STEP 1. IS FUEL CONTAMINATED? NOTE Fuel is contaminated if container is 1/4 full of water or contains dirt. a. Open drain valves at fuel filters and drain approximately 1 pt (0.473 L) of fuel into glass container. T0892DAA Figure 1. b. Fuel Filter. Check fuel for water and/or dirt contamination. CONDITION/INDICATION IS FUEL CONTAMINATED? DECISION YES - Go to Step (2). NO - Go to Step (3). 0012-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00062) TM 9-2320-272-23-1 0012 ENGINE RUNS, BUT MISFIRES - Continued STEP 2. DOES ENGINE RUN WITHOUT MISFIRING AFTER CLEANING FUEL SYSTEM? a. Drain fuel tank (Volume 2, WP 0250). Fuel Tank T0891DAA Figure 2. Fuel Tank. b. Clean and flush fuel system. Dry with compressed air. c. Replace fuel filters (Volume 2, WP 0258). d. Refill tank with fuel. e. Prime fuel filter M939/A1 (TM 9-2320-272-10), M939A2 (Volume 2, WP 0239). f. Attempt to start engine. CONDITION/INDICATION DOES ENGINE RUN WITHOUT MISFIRING AFTER CLEANING FUEL SYSTEM? DECISION YES - Go to Step (6) to verify problem is solved. NO - Go to Step (3). 0012-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00062) TM 9-2320-272-23-1 ENGINE RUNS, BUT MISFIRES - Continued STEP 3. IS AIR CLEANER INDICATOR IN RED ZONE? a. Check air cleaner indicator for fresh air restriction indication. A A Air Cleaner Indicator T0877DAA Figure 3. Air Cleaner Indicator. b. Inspect air intake stack for restrictions. CONDITION/INDICATION IS AIR CLEANER INDICATOR IN RED ZONE? DECISION YES - Perform air cleaner servicing (TM 9-2320-272-10). Go to Step (6) to verify problem is solved. NO - Go to Step (4). 0012-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00062) 0012 TM 9-2320-272-23-1 0012 ENGINE RUNS, BUT MISFIRES - Continued STEP 4. IS THROTTLE LINKAGE IN GOOD CONDITION? Inspect accelerator linkage for damage and proper adjustment. T0053DAA Figure 4. Throttle Linkage. CONDITION/INDICATION IS THROTTLE LINKAGE IN GOOD CONDITION? DECISION YES - Go to Step (5). NO - Replace/adjust accelerator linkage M939/A1 (Volume 2, WP 0268), M939A2 (Volume 2, WP 0269). Go to Step (6) to verify problem is solved. 0012-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00062) TM 9-2320-272-23-1 0012 ENGINE RUNS, BUT MISFIRES - Continued STEP 5. ARE FUEL LINES IN GOOD CONDITION? a. Visually inspect fuel lines. T0880DAA Figure 5. Fuel Lines. b. Check fuel lines and connections for leaks, obstructions and damage. c. Tighten connections where leaks are detected. CONDITION/INDICATION ARE FUEL LINES IN GOOD CONDITION? DECISION YES - Go to Step (6) to verify problem is solved. NO - Replace defective fuel lines (Volume 2, WP 0254). Go to Step (6) to verify problem is solved. 0012-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00062) TM 9-2320-272-23-1 ENGINE RUNS, BUT MISFIRES - Continued STEP 6. IS YOUR ORIGINAL ENGINE FIRING PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL ENGINE FIRING PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0012-7/8 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00062) 0012 TM 9-2320-272-23-1 FIELD MAINTENANCE ENGINE IDLE ROUGH OR ERRATIC INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics Volume 2, WP 0241 TROUBLESHOOTING PROCEDURE ENGINE IDLE ROUGH OR ERRATIC NOTE • Conduct these malfunction test if the engine idle is rough or erratic. This procedure will check for damaged, loose or plugged injector tubes. • This work package applies only to the M939A2 engine only. 0013-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00063) 0013 TM 9-2320-272-23-1 0013 ENGINE IDLE ROUGH OR ERRATIC - Continued STEP 1. ARE INJECTOR TUBES IN GOOD OPERATING CONDITION? Visually check injector tubes for loose, cracked, or pinched condition. Fuel Injector Supply Lines T0889DAA Figure 1. Injector Tubes. CONDITION/INDICATION ARE INJECTOR TUBES IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (2). NO - Tighten/replace injector tubes (Volume 2, WP 0241). Go to Step (3) to verify problem is solved. 0013-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00063) TM 9-2320-272-23-1 0013 ENGINE IDLE ROUGH OR ERRATIC - Continued STEP 2. ARE INJECTOR TUBES FREE OF PLUGS? a. Remove one injector tube. Fuel Injector Supply Lines T0889DAA Figure 2. Injector Tubes. b. Check injector tube for plugged condition. c. Repeat previous test for other injector tubes. CONDITION/INDICATION ARE INJECTOR TUBES FREE OF PLUGS? DECISION YES - Notify supervisor. It is possible that another troubleshooting work package applies. NO - Tighten/replace injector tubes (Volume 2, WP 0241). Go to Step (3) to verify problem is solved. 0013-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00063) TM 9-2320-272-23-1 ENGINE IDLE ROUGH OR ERRATIC - Continued STEP 3. IS YOUR ORIGINAL ENGINE IDLE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL ENGINE IDLE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0013-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00063) 0013 TM 9-2320-272-23-1 FIELD MAINTENANCE POOR ACCELERATION AND/OR LACK OF POWER INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References (cont.) Volume 2, WP 0260 Volume 2, WP 0268 Volume 2, WP 0269 Volume 2, WP 0273 Volume 2, WP 0274 Volume 2, WP 0275 Volume 2, WP 0276 Volume 2, WP 0299 Volume 2, WP 0305 Volume 3, WP 0365 Personnel Required (2) References Point to Point Schematics TM 9-2320-272-10 Volume 2, WP 0243 Volume 2, WP 0244 Volume 2, WP 0249 Volume 2, WP 0254 Volume 2, WP 0258 Volume 2, WP 0259 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE POOR ACCELERATION AND/OR LACK OF POWER NOTE Conduct this malfunction test if there is poor acceleration or lack of power. This procedure will check for air intake stack or air cleaner element clogged, fuel pump filter clogged or dirty, fuel filter leaking or damaged, fuel supply line faulty, fuel supply line connections loose, exhaust system faulty, throttle level travel out of adjustment , air fuel control (AFC) tube faulty, exhaust leaks, fuel transfer pump faulty, fuel injector supply line clogged, fuel filter clogged and/or dirty, and turbocharger faulty. 0014-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) 0014 TM 9-2320-272-23-1 POOR ACCELERATION AND/OR LACK OF POWER - Continued STEP 1. IS AIR CLEANER INDICATOR IN RED ZONE? a. Check air cleaner indicator for fresh air restriction indication. A A Air Cleaner Indicator T0878DAA Figure 1. Air Cleaner Indicator. b. Inspect air intake stack for restrictions. CONDITION/INDICATION IS AIR CLEANER INDICATOR IN RED ZONE? DECISION YES - Perform air cleaner servicing (TM 9-2320-272-10). Go to Step (14) to verify problem is solved. NO - Go to Step (3) for M939A2. Go to Step (2) for M939/A1. STEP 2. IS FUEL SYSTEM IN GOOD OPERATING CONDITION? WARNING Diesel fuel is highly flammable. Do not perform fuel system procedures near open flame. Failure to comply may result in injury or death to personnel. a. Check fuel shut off solenoid and circuitry. 0014-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) 0014 TM 9-2320-272-23-1 0014 POOR ACCELERATION AND/OR LACK OF POWER - Continued T0881DAA Figure 2. b. Fuel System. Visually inspect AFC standard pump filter for dirty or clogged condition. NOTE Perform this step for M936A1 and M928 models. c. Visually inspect fuel pump with VC governor filter for dirty or clogged condition. d. Visually check primary fuel filter for leaks or damage. e. Check fuel lines and connections for leaks, obstructions, and damage. f. Tighten all connections where a leak is detected. CONDITION/INDICATION IS FUEL SYSTEM IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (3). NO - Fuel filter is leaking or damaged. Replace fuel filter (Volume 2, WP 0258). Go to Step (14) to verify problem is solved. NO - Fuel lines are bad. Replace tubing (Volume 2, WP 0254). Go to Step (14) to verify problem is solved. NO - AFC standard pump filter is bad. Replace AFC standard pump filter (Volume 2, WP 0259). Go to Step (14) to verify problem is solved. NO - VC governor fuel filter is bad (M936A1 and M928 models only). Replace VC governor fuel filter (Volume 2, WP 0260). Go to Step (14) to verify problem is solved. 0014-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) TM 9-2320-272-23-1 0014 POOR ACCELERATION AND/OR LACK OF POWER - Continued STEP 3. IS EXHAUST SYSTEM IS IN GOOD CONDITION? Check exhaust system for restriction. T0893DAA Figure 3. Exhaust System. CONDITION/INDICATION IS EXHAUST SYSTEM IS IN GOOD CONDITION? DECISION YES - Go to Step (4) to verify problem is solved. NO - Front exhaust pipe damaged. Replace front exhaust pipe (Volume 2, WP 0276). Go to Step (14) to verify problem is solved. NO - Rear exhaust pipe damaged. Replace rear exhaust pipe (Volume 2, WP 0275). Go to Step (14) to verify problem is solved. NO - Muffler damaged. Replace muffler (Volume 2, WP 0274). Go to Step (14) to verify problem is solved. NO - Exhaust stack damaged. Replace exhaust stack (Volume 2, WP 0273). Go to Step (14) to verify problem is solved. 0014-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) TM 9-2320-272-23-1 0014 POOR ACCELERATION AND/OR LACK OF POWER - Continued STEP 4. IS ACCELERATOR PEDAL AND THROTTLE LEVER IN GOOD CONDITION? Check accelerator pedal and throttle lever for full travel. ACCELERATOR AND MODULATOR CABLES T0379DAA Figure 4. Accelerator Cable. CONDITION/INDICATION IS ACCELERATOR PEDAL AND THROTTLE LEVER IN GOOD CONDITION? DECISION YES - Go to Step (5). NO - Adjust throttle level travel M939/A1 (Volume 2, WP 0268), M939A2 (Volume 2, WP 0269). Go to Step (14) to verify problem is solved. 0014-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) TM 9-2320-272-23-1 0014 POOR ACCELERATION AND/OR LACK OF POWER - Continued STEP 5. IS ACCELERATOR LINKAGE OPERATING CORRECTLY? Check accelerator linkage for proper operation. ACCELERATOR AND MODULATOR CABLES T0379DAA Figure 5. Accelerator Cable. CONDITION/INDICATION IS ACCELERATOR LINKAGE OPERATING CORRECTLY? DECISION YES - Go to Step (6). NO - Adjust or replace accelerator linkage as necessary M939/A1 (Volume 2, WP 0268), M939A2 (Volume 2, WP 0269). Go to Step (14) to verify problem is solved. 0014-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) TM 9-2320-272-23-1 0014 POOR ACCELERATION AND/OR LACK OF POWER - Continued STEP 6. IS MODULATOR CABLE IN GOOD CONDITION? Check modulator cable for proper operation. ACCELERATOR AND MODULATOR CABLES T0379DAA Figure 6. Modulator Cable. CONDITION/INDICATION IS MODULATOR CABLE IN GOOD CONDITION? DECISION YES - Go to Step (7). NO - Replace modulator cable (Volume 3, WP 0365). Go to Step (14) to verify problem is solved. 0014-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) TM 9-2320-272-23-1 0014 POOR ACCELERATION AND/OR LACK OF POWER - Continued STEP 7. IS AIR FUEL CONTROL (AFC) TUBE IN GOOD CONDITION? Check air fuel control (AFC) tube for leaks and/or restriction. T0382DAA Figure 7. Air Fuel Control Tube. CONDITION/INDICATION IS AIR FUEL CONTROL (AFC) TUBE IN GOOD CONDITION? DECISION YES - Go to Step (8). NO - Replace air fuel control tube (Volume 2, WP 0244). Go to Step (14) to verify problem is solved. 0014-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) TM 9-2320-272-23-1 0014 POOR ACCELERATION AND/OR LACK OF POWER - Continued STEP 8. ARE THERE AIR LEAKS IN EXHAUST SYSTEM? a. Check cross over tube, aftercooler, turbocharger, and exhaust manifold for leaks. Turbocharger Exhaust Manifold Aftercooler T0380DAA Figure 8. b. Exhaust System. Tighten any loose hose clamps. CONDITION/INDICATION ARE THERE AIR LEAKS IN EXHAUST SYSTEM? DECISION YES - Aftercooler leaking through gasket. Replace after cooler gasket (Volume 2, WP 0299). Go to Step (14) to verify problem is solved. YES - Turbocharger leaking through gasket. Replace turbocharger gasket (Volume 2, WP 0249). Go to Step (14) to verify problem is solved. NO - Go to Step (9). 0014-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) TM 9-2320-272-23-1 0014 POOR ACCELERATION AND/OR LACK OF POWER - Continued STEP 9. IS FUEL LEAKING FROM FUEL TRANSFER PUMP? Check for fuel at fuel transfer pump while operating hand primer. FUEL INJECTOR SUPPLY LINES FUEL PRESSURE TRANSDUCER FUEL TRANSFER PUMP T0384DAA Figure 9. Fuel Transfer Pump. CONDITION/INDICATION IS FUEL LEAKING FROM FUEL TRANSFER PUMP? DECISION YES - Replace fuel transfer pump (Volume 2, WP 0243). Go to Step (14) to verify problem is solved. NO - Go to Step (10). 0014-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) TM 9-2320-272-23-1 0014 POOR ACCELERATION AND/OR LACK OF POWER - Continued STEP 10. IS FUEL LEAKING FROM FUEL PRESSURE TRANSDUCER? Check for fuel leaking from fuel pressure transducer. FUEL INJECTOR SUPPLY LINES FUEL PRESSURE TRANSDUCER FUEL TRANSFER PUMP T0384DAA Figure 10. Fuel Pressure Transducer. CONDITION/INDICATION IS FUEL LEAKING FROM FUEL PRESSURE TRANSDUCER? DECISION YES - Go to Step (11). NO - Go to Step (13). 0014-11 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) TM 9-2320-272-23-1 0014 POOR ACCELERATION AND/OR LACK OF POWER - Continued STEP 11. IS FUEL INJECTOR SUPPLY LINE CLOGGED? Disconnect fuel injector supply lines and check for clogs. FUEL INJECTOR SUPPLY LINES FUEL PRESSURE TRANSDUCER FUEL TRANSFER PUMP T0384DAA Figure 11. Fuel Injector Supply Line. CONDITION/INDICATION IS FUEL INJECTOR SUPPLY LINE CLOGGED? DECISION YES - Clear all clogged fuel injector supply lines with compressed air or sturdy wire. Go to Step (14) to verify problem is solved. NO - Go to Step (12). 0014-12 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) TM 9-2320-272-23-1 0014 POOR ACCELERATION AND/OR LACK OF POWER - Continued STEP 12. IS FUEL FILTER DIRTY OR CLOGGED? Remove fuel filter (Volume 2, WP 0258) and check for a dirty filter or clogged. Fuel Filter Head Adapter Seal Fuel Filter T0040DAA Figure 12. Fuel Filter. CONDITION/INDICATION IS FUEL FILTER DIRTY OR CLOGGED? DECISION YES - Replace fuel filter (Volume 2, WP 0258). Go to Step (14) to verify problem is solved. NO - Go to Step (13). 0014-13 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) TM 9-2320-272-23-1 0014 POOR ACCELERATION AND/OR LACK OF POWER - Continued STEP 13. DOES TURBOCHARGER OPERATE PROPERLY? a. Remove air intake tube from turbocharger inlet (Volume 2, WP 0249). Turbocharger Exhaust Manifold Aftercooler T0380DAA Figure 13. Turbocharger. WARNING Turbocharger intake fans are extremely sharp and turn at very high RPMs. Keep hands and loose items away from intake opening. Failure to do so may cause injury to personnel. b. Start engine (TM 9-2320-272-10). c. Check if turbo fan rotates freely. CONDITION/INDICATION DOES TURBOCHARGER OPERATE PROPERLY? DECISION YES - Notify supervisor. It is possible that another troubleshooting work package applies. NO - Replace turbocharger (Volume 2, WP 0249). Go to Step (14) to verify problem is solved. 0014-14 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) TM 9-2320-272-23-1 POOR ACCELERATION AND/OR LACK OF POWER - Continued STEP 14. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0014-15/16 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00064) 0014 TM 9-2320-272-23-1 FIELD MAINTENANCE ENGINE SURGES INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 2, WP 0254 Volume 2, WP 0268 Volume 2, WP 0269 Volume 3, WP 0365 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE ENGINE SURGES NOTE Conduct these malfunction tests if engine speed is unstable or engine surges at all speeds. This procedure will check fuel lines for leaks, obstructions, or damage and throttle linkage and modulator cable for proper operation and adjustment. 0015-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00065) 0015 TM 9-2320-272-23-1 0015 ENGINE SURGES - Continued STEP 1. ARE FUEL LINES IN GOOD OPERATING CONDITION? a. Visually inspect fuel lines. T1033DAA Figure 1. Fuel Tank. b. Check fuel lines and connections for leaks, obstruction, and damage. c. Tighten connections where leaks are detected. CONDITION/INDICATION ARE FUEL LINES IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (2). NO - Replace defective fuel lines (Volume 2, WP 0254). Go to Step (4) to verify problem is solved. 0015-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00065) TM 9-2320-272-23-1 0015 ENGINE SURGES - Continued STEP 2. IS MODULATOR CABLE IN GOOD CONDITION? a. Check modulator cable for proper operation. T0395DAA Figure 2. b. Modulator Cable. Check if modulator cable operates properly. CONDITION/INDICATION IS MODULATOR CABLE IN GOOD CONDITION? DECISION YES - Go to Step (3). NO - Replace modulator cable (Volume 3, WP 0365). Go to Step (4) to verify problem is solved. 0015-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00065) TM 9-2320-272-23-1 0015 ENGINE SURGES - Continued STEP 3. IS THROTTLE LINKAGE ADJUSTED AND OPERATING PROPERLY? Visually check throttle linkage for proper operation and adjustment. T1034DAA Figure 3. Throttle Linkage. CONDITION/INDICATION IS THROTTLE LINKAGE ADJUSTED AND OPERATING PROPERLY? DECISION YES - Notify supervisor. It possible that another troubleshooting work package applies. NO - Clean, adjust, or repair as necessary M939/A1 (Volume 2, WP 0268), M939A2 (Volume 2, WP 0269). Go to Step (4) to verify problem is solved. 0015-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00065) TM 9-2320-272-23-1 ENGINE SURGES - Continued STEP 4. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0015-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00065) 0015 TM 9-2320-272-23-1 FIELD MAINTENANCE EXCESSIVE OIL CONSUMPTION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 2, WP 0222 Volume 2, WP 0231 Volume 2, WP 0232 Volume 2, WP 0249 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE EXCESSIVE OIL CONSUMPTION NOTE Conduct this malfunction test if there is excessive engine oil consumption. This procedure will check for excessive oil in engine, and engine oil leaks. 0016-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00066) 0016 TM 9-2320-272-23-1 0016 EXCESSIVE OIL CONSUMPTION - Continued STEP 1. IS ENGINE OIL LEVEL TOO HIGH? a. Check dipstick for excessive oil (Volume 2, WP 0232). Dipstick Dipstick M939A2 M939/A1 T0976DAA Figure 1. b. Oil Dipstick. If there is excessive oil in engine, drain crankcase to safe operating level. CONDITION/INDICATION IS ENGINE OIL LEVEL TOO HIGH? DECISION YES - Go to Step (4) to verify problem is solved. NO - Go to Step (2). 0016-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00066) TM 9-2320-272-23-1 0016 EXCESSIVE OIL CONSUMPTION - Continued STEP 2. IS OIL LEAKING FROM ENGINE? a. Wipe off edges of rocker arm cover, oil pan, screws, oil filters and other external engine surfaces. Oil Filter T0385DAA Figure 2. Engine. b. Start engine and observe for leaks. c. If an oil leak is seen, tighten nuts, screws, and oil filters as needed, and again observe for leaks. CONDITION/INDICATION IS OIL LEAKING FROM ENGINE? DECISION YES - Rocker arm cover(s) leak. Replace leaking gasket(s) M939A2 (Volume 2, WP 0222). Go to Step (4) to verify problem is solved. YES - Oil pan is leaking. Replace oil pan gasket M939/A1 (Volume 2, WP 0231), M939A2 (Volume 2, WP 0230). Go to Step (4) to verify problem is solved. YES - Oil filter is leaking. Replace oil filter (Volume 2, WP 0232). Go to Step (4) to verify problem is solved. NO - Go to Step (3). 0016-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00066) TM 9-2320-272-23-1 0016 EXCESSIVE OIL CONSUMPTION - Continued STEP 3. IS TURBOCHARGER LEAKING OIL INTO AIR INTAKE OR EXHAUST? a. Remove air intake tube from turbocharger inlet (Volume 2, WP 0249). Turbocharger Exhaust Manifold Aftercooler T0984DAA Figure 3. b. Turbocharger. Check turbocharger for leaking oil into air intake or exhaust. CONDITION/INDICATION IS TURBOCHARGER LEAKING OIL INTO AIR INTAKE OR EXHAUST? DECISION YES - Replace turbocharger (Volume 2, WP 0249). Go to Step (4) to verify problem is solved. NO - Notify supervisor. It is possible that another troubleshooting work package applies. STEP 4. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0016-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00066) TM 9-2320-272-23-1 FIELD MAINTENANCE LOW OIL PRESSURE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics WP 0103 Volume 2, WP 0224 References (cont.) Volume 2, WP 0225 Volume 2, WP 0226 Volume 2, WP 0230 Volume 2, WP 0232 Volume 2, WP 0333 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE LOW OIL PRESSURE NOTE Conduct these malfunction tests if engine oil pressure is low. This procedure will check oil lines for good condition, oil filter for leaks and engine oil pressure. 0017-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00067) 0017 TM 9-2320-272-23-1 0017 LOW OIL PRESSURE - Continued STEP 1. ARE OIL SUPPLY LINES IN GOOD CONDITION? a. Visually inspect oil supply lines for cracks, splits, leaks, and damage. T0062DAA Figure 1. Engine Oil Lines. WARNING Eyeshields must be worn when cleaning with compressed air. Compressed air source will not exceed 30 psi (207 kPa). Failure to comply may result in injury or death to personnel. b. Clear clogged or obstructed lines with compressed air or sturdy wire. CONDITION/INDICATION ARE OIL SUPPLY LINES IN GOOD CONDITION? DECISION YES - Go to Step (2). NO - Oil pick up hose is damaged. Replace damaged hose (Volume 2, WP 0224). Go to Step (4) to verify problem is solved. NO - Oil pump return hose is damaged. Replace oil pump return hose (Volume 2, WP 0225). Go to Step (4) to verify problem is solved. NO - Front sump tube is damaged. Replace front sump tube M939/A1 (Volume 2, WP 0226), M939A2. (Volume 2, WP 0230) Go to Step (4) to verify problem is solved. 0017-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00067) TM 9-2320-272-23-1 0017 LOW OIL PRESSURE - Continued STEP 2. DOES OIL FILTER LEAK? Visually inspect oil filter for leaks. Oil Filter T0385DAA Figure 2. Oil Filter. CONDITION/INDICATION DOES OIL FILTER LEAK? DECISION YES - Perform oil filter maintenance (Volume 2, WP 0232). Go to Step (4) to verify problem is solved. NO - Go to Step (3). 0017-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00067) TM 9-2320-272-23-1 0017 LOW OIL PRESSURE - Continued STEP 3. IS OIL PRESSURE WITHIN LIMITS 55-75 psi (379-571 kPa)? a. Stop vehicle engine. b. Make sure engine oil level is correct. T0061DAA Figure 3. Engine Oil Pressure Sending Unit. c. Remove oil pressure sending unit (Volume 2, WP 0333). d. Install pressure gauge. e. Start engine and hold vehicle engine speed at 2100 RPM. f. Oil pressure gauge should read between 55-75 psi (379-571 kPa). g. Shut off engine. h. Remove pressure gauge. i. Install oil pressure sending unit. CONDITION/INDICATION IS OIL PRESSURE WITHIN LIMITS 55-75 psi (379-571 kPa)? DECISION NO - Notify supervisor. It is possible that another troubleshooting work package applies. YES - Perform Oil Pressure Gauge Inoperative troubleshooting (WP 0103). 0017-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00067) TM 9-2320-272-23-1 LOW OIL PRESSURE - Continued STEP 4. IS YOUR ORIGINAL OIL PRESSURE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original oil pressure problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL OIL PRESSURE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0017-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00067) 0017 TM 9-2320-272-23-1 FIELD MAINTENANCE ENGINE OIL CONTAMINATED INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics Volume 2, WP 0211 Volume 2, WP 0213 References (cont.) Volume 2, WP 0229 Volume 2, WP 0232 Volume 2, WP 0233 Volume 2, WP 0243 Volume 2, WP 0299 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE ENGINE OIL CONTAMINATED NOTE Conduct this malfunction test if engine oil is contaminated. This procedure will check for sludge and metal particle in oil. It also checks for leaking transfer pump seal, transfer pump gasket, oil cooler and aftercooler. 0018-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00068) 0018 TM 9-2320-272-23-1 0018 ENGINE OIL CONTAMINATED - Continued STEP 1. DOES OIL SAMPLE TEST INDICATE OIL IS CONTAMINATED? Take oil sample to determine type of contamination. T0387DAA Figure 1. Oil Sample. 0018-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00068) TM 9-2320-272-23-1 0018 ENGINE OIL CONTAMINATED - Continued CONDITION/INDICATION DOES OIL SAMPLE TEST INDICATE OIL IS CONTAMINATED? DECISION YES - Excessive sludge in oil. Go to Step (4) to verify problem is solved. YES - Oil is thin and black. Go to Step (2) (M939A2). Notify supervisor. It is possible that another troubleshooting work package applies (M939/A1). YES - Oil has a milky color, coolant is present in oil. Go to Step (3). YES - Metal particles present in oil. Notify Supervisor. Action may not be possible at this level of maintenance. NO - Notify Supervisor. It is possible that another troubleshooting work package applies. STEP 2. DOES THE TRANSFER PUMP LEAK OIL? Check transfer pump seal and transfer pump mounting gasket for leaks. FUEL TRANSFER PUMP T1111DAA Figure 2. Fuel Transfer Pump. CONDITION/INDICATION DOES THE TRANSFER PUMP LEAK OIL? DECISION YES - Replace transfer pump and/or gasket (Volume 2, WP 0243). Go to Step (4) to verify problem is solved. NO - Notify supervisor. It is possible that another troubleshooting work package applies. 0018-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00068) TM 9-2320-272-23-1 0018 ENGINE OIL CONTAMINATED - Continued STEP 3. DO OIL COOLER OR AFTERCOOLER LEAK? a. Inspect oil cooler for leaks M939/A1 (Volume 2, WP 0233), M939A2 (Volume 2, WP 0229). Aftercooler Oil Cooler M939/A1 Oil Cooler Figure 3. b. M939A2 T0388DAA Engine Oil Cooler and Aftercooler. Inspect aftercooler for leaks. NOTE During engine operation, oil pressure will be higher than coolant pressure. A leak in oil cooler will show oil in coolant. After engine is shut down, residual pressure in cooling system will cause coolant to leak into oil. c. After engine has cooled off, check oil dipstick for evidence of coolant and surge tank for evidence of oil. CONDITION/INDICATION DO OIL COOLER OR AFTERCOOLER LEAK? DECISION YES - Oil cooler leaks. Replace oil cooler M939/A1 (Volume 2, WP 0233), M939A2 (Volume 2, WP 0229). Go to Step (4) to verify problem is solved. YES - Aftercooler leaks. Replace aftercooler (M939A2 only) (Volume 2, WP 0299). Go to Step (4) to verify problem is solved. NO - Replace engine M939/A1 (Volume 2, WP 0211), M939A2 (Volume 2, WP 0213). Go to Step (4) to verify problem is solved. 0018-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00068) TM 9-2320-272-23-1 ENGINE OIL CONTAMINATED - Continued STEP 4. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Drain and refill engine oil (Volume 2, WP 0232). c. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0018-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00068) 0018 TM 9-2320-272-23-1 0019 FIELD MAINTENANCE EXCESSIVE VIBRATION OR CLUNKING INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 2, WP 0216 Volume 2, WP 0218 Volume 2, WP 0219 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE EXCESSIVE VIBRATION OR CLUNKING NOTE Conduct this malfunction test if engine excessive vibration or clunking. This procedure will check for loose or damaged motor mounts and loose vibration damper. STEP 1. ARE ENGINE MOUNTING BRACKETS AND PADS LOOSE OR DAMAGED? Check engine mounting brackets and pads for looseness or damage. CONDITION/INDICATION ARE ENGINE MOUNTING BRACKETS AND PADS LOOSE OR DAMAGED? DECISION YES - Replace or tighten loose or damaged mounting brackets and pads (Volume 2, WP 0216). Go to Step (3) to verify problem is solved. NO - Go to Step (2). 0019-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00069) TM 9-2320-272-23-1 0019 EXCESSIVE VIBRATION OR CLUNKING - Continued STEP 2. IS VIBRATION DAMPER LOOSE? Check if vibration damper is loose. CONDITION/INDICATION IS VIBRATION DAMPER LOOSE? DECISION YES - Replace loose vibration damper M939/A1 (Volume 2, WP 0218), M939A2 (Volume 2, WP 0219). Go to Step (3) to verify problem is solved. NO - Notify supervisor. It is possible that another troubleshooting work package applies. STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0019-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00069) TM 9-2320-272-23-1 FIELD MAINTENANCE EXCESSIVE FUEL CONSUMPTION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References (cont.) TM 9-2320-272-10 Volume 2, WP 0254 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE EXCESSIVE FUEL CONSUMPTION NOTE Conduct these malfunction tests if fuel consumption is excessive. This procedure will check air intake stack and air cleaner element for restrictions and fuel lines for leaks or damage. STEP 1. IS AIR RESTRICTION INDICATOR IN RED ZONE? a. Check air cleaner indicator for air restriction indication. Air Cleaner Indicator T0077DAA Figure 1. b. Air Cleaner Indicator. Inspect air intake stack for restriction. CONDITION/INDICATION IS AIR RESTRICTION INDICATOR IN RED ZONE? DECISION YES - Perform air cleaner servicing (TM 9-2320-272-10). Go to Step (3) to verify problem is solved. NO - Go to Step (2). 0020-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00070) 0020 TM 9-2320-272-23-1 0020 EXCESSIVE FUEL CONSUMPTION - Continued STEP 2. ARE FUEL LINES IN GOOD CONDITION? Visually inspect fuel lines, hoses, fuel return lines and connections for leaks, bends, kinks, and damage. T0078DAA Figure 2. Fuel System. CONDITION/INDICATION ARE FUEL LINES IN GOOD CONDITION? DECISION YES - Go to Step (3) to verify problem is solved. NO - Replace damaged fuel lines (Volume 2, WP 0254). Go to Step (3) to verify problem is solved. 0020-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00070) TM 9-2320-272-23-1 EXCESSIVE FUEL CONSUMPTION - Continued STEP 3. IS YOUR ORIGINAL FUEL CONSUMPTION PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original fuel consumption problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL FUEL CONSUMPTION PROBLEM STILL PRESENT? DECISION YES - Contact supervisor. NO - Problem fixed. END OF WORK PACKAGE 0020-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00070) 0020 TM 9-2320-272-23-1 0021 FIELD MAINTENANCE ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0263 Volume 2, WP 0264 Volume 2, WP 0265 Volume 2, WP 0307 Volume 2, WP 0337 Volume 3, WP 0352 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) NOTE Conduct these malfunction tests if engine cranks but will not start with fuel available. This procedure will check for ether cylinder, ether start system electrical power source, defective ether start valve, clogged tubing, defective atomizer, faulty wiring or defective ether start switch. 0021-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued STEP 1. IS ETHER CYLINDER EMPTY? a. Check ether cylinder for ether level. T0476DAA Figure 1. Ether Cylinder. b. Remove ether cylinder from ether valve (Volume 2, WP 0263). c. Shake cylinder and listen for liquid splashing inside cylinder. CONDITION/INDICATION IS ETHER CYLINDER EMPTY? DECISION YES - Replace empty ether cylinder (Volume 2, WP 0263). Go to Step (10) to verify problem is solved. NO - Reinstall ether cylinder, go to Step (2). STEP 2. DOES ETHER VALVE OPERATE PROPERLY? a. Check for battery voltage at ether valve. Refer to point to point schematics. b. Disconnect circuit 570 wire at ether valve. 0021-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued 570 570 T0477DAA Ether Valve. Figure 2. c. Set multimeter to VDC. d. Turn battery switch to ON position. e. Connect red lead to disconnected circuit 570 wire. f. Connect black lead to good ground. g. Multimeter will display volts DC. h. Crank engine and depress ether start switch. NOTE If battery voltage is present, ether valve is not operating properly. i. Meter reading should be greater than 18 VDC. CONDITION/INDICATION DOES ETHER VALVE OPERATE PROPERLY? DECISION YES - Go to Step (3). NO - Go to Step (7). 0021-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued STEP 3. DOES CIRCUIT 570 WIRE CONDUCT BATTERY VOLTAGE TO ETHER VALVE? a. Check for battery voltage at fuel pressure switch terminal. Refer to point to point schematics. b. Disconnect circuit 570 wire at ether cylinder valve from fuel pressure switch. 570 570 T0478DAA Figure 3. Ether Valve Circuit 570 Wire. 0021-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued c. Connect red lead to circuit 570 terminal on fuel pressure switch. d. Connect black lead to good ground. e. Multimeter will display volts DC. f. Crank engine and depress ether start switch. NOTE If battery voltage is present, circuit 570 wire is faulty. g. Meter reading should be greater than 18 VDC. CONDITION/INDICATION DOES CIRCUIT 570 WIRE CONDUCT BATTERY VOLTAGE TO ETHER VALVE? DECISION YES - Go to Step (4). NO - Repair circuit 570 wire to ether valve (Volume 3, WP 0352). Go to Step (10) to verify problem is solved. 0021-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued STEP 4. DOES FUEL PRESSURE SWITCH OPERATE PROPERLY? a. Check for voltage at circuit 570 wire to ether start switch from fuel pressure switch. Refer to point to point schematics. b. Disconnect circuit 570 wire to ether start switch. 570 570 T0479DAA Figure 4. Fuel Pressure Switch Circuit 570 Wire. 0021-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued c. Connect red lead to circuit 570 wire. d. Connect black lead to good ground. e. Multimeter will display volts DC. f. Crank engine and depress ether start switch. NOTE If battery voltage is present, fuel pressure switch is faulty. g. Meter reading should be greater than 18 VDC. CONDITION/INDICATION DOES FUEL PRESSURE SWITCH OPERATE PROPERLY? DECISION YES - Go to Step (5). NO - Replace fuel pressure switch (Volume 2, WP 0337). Go to Step (10) to verify problem is solved. 0021-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued STEP 5. DOES CIRCUIT 570 WIRE CONDUCT BATTERY VOLTAGE TO FUEL PRESSURE SWITCH? a. Check for battery voltage at ether start switch connector. Refer to point to point schematics. b. Disconnect circuit 570 wire to fuel pressure switch from ether start switch. 570 T0480DAA Figure 5. Ether Start Switch Circuit 570 Wire. 0021-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued c. Make sure battery switch is in ON position. d. Connect red lead to circuit 570 ether start switch connector. e. Connect black lead to good ground. f. Multimeter will display volts DC. g. Depress ether start switch. NOTE If battery voltage is present, circuit 570 wire is faulty. h. Meter reading should be greater than 18 VDC. CONDITION/INDICATION DOES CIRCUIT 570 WIRE CONDUCT BATTERY VOLTAGE TO FUEL PRESSURE SWITCH? DECISION YES - Go to Step (6). NO - Repair circuit 570 wire to fuel pressure switch (Volume 3, WP 0352). Go to Step (10) to verify problem is solved. 0021-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued STEP 6. DOES ETHER START SWITCH OPERATE PROPERLY? a. Check for battery voltage at circuit 570 wire to circuit 5C connector. Refer to point to point schematics. b. Disconnect circuit 570 wire to circuit 5C connector at ether start switch. 570 TO CIRCUIT 5C CONNECTOR T0481DAA Figure 6. Ether Start Switch Circuit 5C Wire. 0021-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued c. Make sure battery switch is in ON position. d. Connect red lead to circuit 570 wire. e. Connect black lead to good ground. NOTE If battery voltage is present, ether start switch is faulty. f. Meter reading should be greater than 18 VDC. CONDITION/INDICATION DOES ETHER START SWITCH OPERATE PROPERLY? DECISION YES - Repair circuit 570 wire to circuit 5C connector (Volume 3, WP 0352). Go to Step (10) to verify problem is solved. NO - Replace ether start switch (Volume 2, WP 0307). Go to Step (10) to verify problem is solved. 0021-11 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued STEP 7. DOES ETHER VALVE OPERATE PROPERLY? a. Disconnect tubing at ether valve (Volume 2, WP 0263). b. Place battery switch to ON position. c. Depress ether start switch. ETHER VALVE T0482DAA Figure 7. Ether Valve. 0021-12 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued d. Check if a small amount of ether is dispensed. CONDITION/INDICATION DOES ETHER VALVE OPERATE PROPERLY? DECISION YES - Go to Step (8). NO - Replace defective ether valve (Volume 2, WP 0263). Go to Step (10) to verify problem is solved. 0021-13 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued STEP 8. IS THERMAL CLOSE VALVE OR THERMAL CLOSE VALVE TUBING RESTRICTED? a. Disconnect ether valve to thermal close valve tubing at ether valve (Volume 2, WP 0263). b. Disconnect thermal close valve to atomizer tubing at thermal close valve (Volume 2, WP 0263). T0483DAA Figure 8. Thermal Close Valve. c. With thermal close valve cold , blow compressed air into tubing at ether valve end to determine if system is clear. d. If restricted, disconnect tubing from thermal close valve and check for restrictions in tubing. CONDITION/INDICATION IS THERMAL CLOSE VALVE OR THERMAL CLOSE VALVE TUBING RESTRICTED? DECISION YES - Tubing restricted, replace tubing (Volume 2, WP 0263). Go to Step (10) to verify problem is solved. YES - Tubing clear, replace thermal close valve (Volume 2, WP 0264). Go to Step (10) to verify problem is solved. NO - Go to Step (9). 0021-14 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued STEP 9. IS ATOMIZER OR ATOMIZER TUBING RESTRICTED? a. Disconnect tubing between thermal close valve and atomizer at thermal close valve (Volume 2, WP 0264). T0484DAA Figure 9. Atomizer. b. Blow compressed air into tubing at thermal close valve end to determine if system is clear. c. If restricted, disconnect tubing from atomizer and check for restrictions in tubing. CONDITION/INDICATION IS ATOMIZER OR ATOMIZER TUBING RESTRICTED? DECISION YES - Tubing restricted, replace tubing (Volume 2, WP 0263). Go to Step (10) to verify problem is solved. YES - Tubing clear, replace atomizer (Volume 2, WP 0265). Go to Step (10) to verify problem is solved. NO - Go to Step (10) to verify problem is solved. 0021-15 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0021 ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY) Continued STEP 10. IS YOUR ORIGINAL ETHER START PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original ether start problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL ETHER START PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0021-16 03/15/2011 Rel(1.8) root(tswp) wpno(T00071) TM 9-2320-272-23-1 0022 FIELD MAINTENANCE EXHAUST COLOR BLUE DURING NORMAL OPERATION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) TM 9-2320-272-10 Volume 2, WP 0232 Volume 2, WP 0250 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE EXHAUST COLOR BLUE DURING NORMAL OPERATION NOTE Conduct these malfunction tests if exhaust smoke is blue during normal operation. This procedure will check for the correct engine oil and fuel. STEP 1. IS CORRECT OIL IN ENGINE? Check that engine oil grade is correct for vehicle use and climatic conditions (Volume 5, WP 0820). CONDITION/INDICATION IS CORRECT OIL IN ENGINE? DECISION YES - Go to Step (2). NO - Replace engine oil and filter (Volume 2, WP 0232). Go to Step (3) to verify problem is solved. STEP 2. IS CORRECT FUEL BEING USED? Check that engine fuel grade is correct for vehicle use and climatic conditions (TM 9-2320-272-10). CONDITION/INDICATION IS CORRECT FUEL BEING USED? DECISION YES - Notify supervisor. It is possible that another troubleshooting work package applies. NO - Drain fuel system (Volume 2, WP 0250) and replace with correct grade of fuel (TM 9-2320-272-10). Go to Step (3) to verify problem is solved. 0022-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00072) TM 9-2320-272-23-1 EXHAUST COLOR BLUE DURING NORMAL OPERATION - Continued STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0022-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00072) 0022 TM 9-2320-272-23-1 FIELD MAINTENANCE EXHAUST COLOR WHITE DURING NORMAL OPERATION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) TM 9-2320-272-10 WP 0028 Volume 2, WP 0250 Volume 2, WP 0258 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE EXHAUST COLOR WHITE DURING NORMAL OPERATION NOTE Conduct these malfunction tests if exhaust smoke is white during normal operation. This procedure will check for engine overheating and water in fuel. STEP 1. IS ENGINE ABOVE NORMAL OPERATING TEMPERATURE? CAUTION Thick white smoke indicates coolant is present in engine combustion chambers during operation. When this condition is evident, shut down immediately and determine cause. Continued engine operations may result in permanent damage to engine. a. Check engine temperature. b. Ensure engine temperature is within normal operating range 175°F to 200°F (79°C to 93°C). CONDITION/INDICATION IS ENGINE ABOVE NORMAL OPERATING TEMPERATURE? DECISION YES - Perform Engine Overheats troubleshooting (WP 0028). NO - Go to Step (2). 0023-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00073) 0023 TM 9-2320-272-23-1 0023 EXHAUST COLOR WHITE DURING NORMAL OPERATION - Continued STEP 2. IS WATER PRESENT IN FUEL? a. Open drain valves at fuel filter and drain approximately 1 pt (0.473 L) of fuel into a glass container. T1039DAA Figure 1. Fuel Filter. NOTE Fuel is contaminated if container is 1/4 full of water. b. Check for presence of water in fuel. CONDITION/INDICATION IS WATER PRESENT IN FUEL? DECISION YES - Drain fuel system (Volume 2, WP 0250), replace fuel filter (Volume 2, WP 0258), and refill fuel tanks (TM 9-2320-272-10). Go to Step (3) to verify problem is solved. NO - Notify supervisor. Action may not be possible at this level of maintenance. 0023-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00073) TM 9-2320-272-23-1 EXHAUST COLOR WHITE DURING NORMAL OPERATION - Continued STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0023-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00073) 0023 TM 9-2320-272-23-1 FIELD MAINTENANCE EXHAUST COLOR BLACK DURING NORMAL OPERATION AND IDLE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) TM 9-2320-272-10 Volume 2, WP 0239 Volume 2, WP 0251 Volume 2, WP 0258 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE EXHAUST COLOR BLACK DURING NORMAL OPERATION AND IDLE NOTE Conduct these malfunction tests if there is black exhaust smoke at idle. This procedure will check for fuel contamination or a restricted air filter. 0024-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00074) 0024 TM 9-2320-272-23-1 0024 EXHAUST COLOR BLACK DURING NORMAL OPERATION AND IDLE - Continued STEP 1. IS FUEL CONTAMINATED? T1010DAA Figure 1. Fuel Filter. NOTE Fuel is contaminated if container is 1/4 full of water or contains dirt. Open drain valves at fuel filter and drain approximately 1 pt (0.473 L) of fuel into glass container. CONDITION/INDICATION IS FUEL CONTAMINATED? DECISION YES - Go to Step (2). NO - Go to Step (4). 0024-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00074) TM 9-2320-272-23-1 0024 EXHAUST COLOR BLACK DURING NORMAL OPERATION AND IDLE - Continued STEP 2. IS FUEL CONTAMINATED? Open drain valves at fuel filter and continue to drain fuel up to 1 qt (0.946 L) of fuel into glass container. T1010DAA Figure 2. Fuel Filter. CONDITION/INDICATION IF FUEL CONTAMINATED? DECISION YES - Go to Step (3). NO - Go to Step (4). 0024-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00074) TM 9-2320-272-23-1 0024 EXHAUST COLOR BLACK DURING NORMAL OPERATION AND IDLE - Continued STEP 3. DOES BLACK SMOKE GO AWAY AFTER CLEANING FUEL SYSTEM? a. Drain fuel tank (Volume 2, WP 0250). Fuel Tank T1009DAA Figure 3. Fuel Tank. WARNING Eyeshields must be worn when cleaning with compressed air. Compressed air source will not exceed 30 psi (207 kPa). Failure to comply may result in injury or death to personnel. b. Clean and flush fuel system. Dry with compressed air. c. Replace fuel filter (Volume 2, WP 0258). d. Refill tank with fuel. e. Prime fuel system M939/A1 (TM 9-2320-272-10), M939A2 (Volume 2, WP 0239). f. Start engine. CONDITION/INDICATION DOES BLACK SMOKE GO AWAY? START AFTER CLEANING FUEL SYSTEM. DECISION YES - Problem corrected. NO - Go to Step (4). 0024-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00074) TM 9-2320-272-23-1 0024 EXHAUST COLOR BLACK DURING NORMAL OPERATION AND IDLE - Continued STEP 4. IS AIR CLEANER INDICATOR IN RED ZONE? a. Check air cleaner indicator for air restriction indication. A A AIR CLEANER INDICATOR T0394DAA Figure 4. b. Air Cleaner Indicator. Clean air intake stack of any restrictions. CONDITION/INDICATION IS AIR CLEANER INDICATOR IN RED ZONE? DECISION YES - Perform air cleaner servicing (TM 9-2320-272-10). Go to Step (5) to verify problem is solved. NO - Notify supervisor. Action may not be possible at this level of maintenance. STEP 5. IS YOUR ORIGINAL SMOKE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original smoke problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL SMOKE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0024-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00074) TM 9-2320-272-23-1 FIELD MAINTENANCE EXCESSIVE EXHAUST NOISE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 2, WP 0273 Volume 2, WP 0274 Volume 2, WP 0275 Volume 2, WP 0276 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE EXCESSIVE EXHAUST NOISE NOTE Conduct these malfunction tests if there is excessive exhaust noise. This procedure will check for damage to the muffler and exhaust system pipes and gaskets. 0025-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00075) 0025 TM 9-2320-272-23-1 0025 EXCESSIVE EXHAUST NOISE - Continued STEP 1. IS MUFFLER IN GOOD OPERATING CONDITION? a. Make sure engine is turned OFF. T0486DAA Figure 1. Muffler. WARNING Do not touch hot exhaust system components with bare hands. Failure to comply may result in injury or death to personnel. b. Visually inspect muffler for wear and damage. CONDITION/INDICATION IS MUFFLER IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (2). NO - Replace muffler (Volume 2, WP 0274). Go to Step (3) to verify problem is solved. 0025-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00075) TM 9-2320-272-23-1 0025 EXCESSIVE EXHAUST NOISE - Continued STEP 2. ARE EXHAUST PIPES AND GASKETS IN GOOD OPERATING CONDITION? WARNING Do not touch hot exhaust system components with bare hands. Failure to comply may result in injury or death to personnel. Visually inspect gaskets and front and rear exhaust pipes for cracks and damage. T0487DAA Figure 2. Exhaust System (M939/A1). 0025-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00075) TM 9-2320-272-23-1 0025 EXCESSIVE EXHAUST NOISE - Continued T0488DAA Figure 3. Exhaust System (M939A2). 0025-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00075) TM 9-2320-272-23-1 0025 EXCESSIVE EXHAUST NOISE - Continued CONDITION/INDICATION ARE EXHAUST PIPES AND GASKETS IN GOOD OPERATING CONDITION? DECISION NO - Front exhaust pipe damaged. Replace front exhaust pipe (Volume 2, WP 0276). Go to Step (3) to verify problem is solved. NO - Front pipe gasket damaged. Replace gasket (Volume 2, WP 0276). Go to Step (3) to verify problem is solved. NO - Rear exhaust pipe damaged. Replace rear exhaust pipe (Volume 2, WP 0275). Go to Step (3) to verify problem is solved. NO - Rear pipe gasket damaged. Replace gasket (Volume 2, WP 0275). Go to Step (3) to verify problem is solved. NO - Exhaust stack damaged. Replace exhaust stack (Volume 2, WP 0273). Go to Step (3) to verify problem is solved. NO - Exhaust stack gasket damaged. Replace gasket (Volume 2, WP 0273). Go to Step (3) to verify problem is solved. YES - Go to Step (3) to verify problem is solved. STEP 3. IS YOUR ORIGINAL EXHAUST NOISE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original exhaust noise problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL EXHAUST NOISE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0025-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00075) TM 9-2320-272-23-1 FIELD MAINTENANCE EXHAUST FUMES IN CAB INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 2, WP 0273 Volume 2, WP 0275 Volume 2, WP 0276 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE EXHAUST FUMES IN CAB NOTE Conduct these malfunction tests if exhaust fumes are in cab. This procedure will check for leaks from exhaust system pipe connections or damaged exhaust pipes. 0026-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00076) 0026 TM 9-2320-272-23-1 0026 EXHAUST FUMES IN CAB - Continued STEP 1. ARE PIPE CONNECTIONS LEAKING? a. Start vehicle engine. T1017DAA Figure 1. Exhaust System (M939/A1). 0026-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00076) TM 9-2320-272-23-1 0026 EXHAUST FUMES IN CAB - Continued T1107DAA Figure 2. Exhaust System (M939A2). WARNING Do not touch hot exhaust system components with bare hands. Failure to comply may result in injury or death to personnel. b. Look for leaking fumes at connections. c. Determine location of leaking connection. 0026-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00076) TM 9-2320-272-23-1 0026 EXHAUST FUMES IN CAB - Continued CONDITION/INDICATION ARE PIPE CONNECTIONS LEAKING? DECISION YES - Exhaust stack leaking. Replace gasket (Volume 2, WP 0273). Go to Step (3) to verify problem is solved. YES - Rear pipe leaking. Replace gasket (Volume 2, WP 0275). Go to Step (3) to verify problem is solved. YES - Front pipe leaking. Replace gasket (Volume 2, WP 0276). Go to Step (3) to verify problem is solved. NO - Go to Step (2). STEP 2. ARE MANIFOLD OR EXHAUST PIPES LEAKING FUMES? WARNING Do not touch hot exhaust system components with bare hands. Failure to comply may result in injury or death to personnel. Visually inspect manifold and exhaust pipes for cracks or damage. T1016DAA Figure 3. Exhaust System. 0026-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00076) TM 9-2320-272-23-1 0026 EXHAUST FUMES IN CAB - Continued CONDITION/INDICATION ARE MANIFOLD OR EXHAUST PIPES LEAKING FUMES? DECISION YES - Exhaust stack pipe damaged. Replace exhaust stack (Volume 2, WP 0273). Go to Step (3) to verify problem is solved. YES - Rear pipe damaged. Replace rear exhaust pipe (Volume 2, WP 0275). Go to Step (3) to verify problem is solved. YES - Front pipe damaged. Replace front exhaust pipe (Volume 2, WP 0276). Go to Step (3) to verify problem is solved. NO - Go to Step (3) to verify problem is solved. STEP 3. IS YOUR ORIGINAL FUMES IN CAB PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original fumes in cab problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL FUMES IN CAB PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0026-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00076) TM 9-2320-272-23-1 FIELD MAINTENANCE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics TM 9-2320-272-10 Volume 2, WP 0288 References (cont.) Volume 2, WP 0289 Volume 2, WP 0295 Volume 2, WP 0296 Volume 2, WP 0298 Volume 2, WP 0334 Volume 3, WP 0447 Volume 3, WP 0448 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE NOTE Conduct these malfunction tests if engine does not reach normal operating temperature. This procedure will check for proper thermostat and fan clutch operation. 0027-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00077) 0027 TM 9-2320-272-23-1 0027 ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE - Continued STEP 1. DOES COOLANT CIRCULATE THROUGH SURGE TANK WHEN ENGINE TEMPERATURE IS BELOW 175°F (79°C)? WARNING Extreme care should be taken when removing surge tank filler cap if temperature gauge reads below 175°F (79°C). Steam or hot coolant under pressure may cause injury. a. Remove surge tank cap. Surge Tank T1056DAA Figure 1. b. Start engine (TM 9-2320-272-10). c. Visually inspect coolant for circulation. d. Stop engine. Surge Tank. CONDITION/INDICATION DOES COOLANT CIRCULATE THROUGH SURGE TANK WHEN ENGINE TEMPERATURE IS BELOW 175°F (79°C)? 0027-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00077) TM 9-2320-272-23-1 0027 ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE - Continued DECISION YES - Replace thermostat M939/A1 (Volume 2, WP 0288), M939A2 (Volume 2, WP 0289). Go to Step (4) to verify problem is solved. NO - Go to Step (2). STEP 2. DOES FAN DRIVE CLUTCH WORK PROPERLY? a. Inspect fan drive clutch for proper operation. T0071DAA Figure 2. b. Fan Clutch. Make sure override lockup bolts are removed from clutch housing and stored in clutch housing bracket (M939/A1 only) (TM 9-2320-272-10). CONDITION/INDICATION DOES FAN DRIVE CLUTCH WORK PROPERLY? DECISION YES - Go to Step (3). NO - Fan drive clutch actuator defective. Replace fan drive clutch actuator M939/A1 (Volume 3, WP 0447), M939A2 (Volume 3, WP 0448). Go to Step (4) to verify problem is solved. NO - Fan drive clutch defective. Replace fan drive clutch (Volume 2, WP 0295). Go to Step (4) to verify problem is solved. 0027-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00077) TM 9-2320-272-23-1 0027 ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE - Continued STEP 3. DOES COOLANT TEMPERATURE GAUGE OPERATE PROPERLY? a. Place battery switch in OFF position. b. Remove circuit 33 wire from coolant temperature sending unit. Refer to point to point schematics. Temperature Sending Unit Circuit 33 wire M939/A1 VEHICLES Circuit 33 Wire Temperature Sending Unit M939/A2 VEHICLES T1108DAA Figure 3. Coolant Temperature Sending Unit. 0027-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00077) TM 9-2320-272-23-1 0027 ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE - Continued c. Place battery switch to ON position. d. Have assistant momentarily ground disconnected circuit 33 wire. e. Observe coolant temperature gauge for movement. CONDITION/INDICATION DOES COOLANT TEMPERATURE GAUGE OPERATE PROPERLY? DECISION YES - Replace coolant temperature sending unit (Volume 2, WP 0334). Go to Step (4) to verify problem is solved. NO - Perform Temperature Gauge Inoperative (Coolant) troubleshooting (WP 0106). STEP 4. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0027-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00077) TM 9-2320-272-23-1 FIELD MAINTENANCE ENGINE OVERHEATS INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics TM 9-2320-272-10 WP 0106 WP 0131 Volume 2, WP 0229 Volume 2, WP 0233 Volume 2, WP 0249 Volume 2, WP 0278 Volume 2, WP 0280 Volume 2, WP 0281 References (cont.) Volume 2, WP 0283 Volume 2, WP 0284 Volume 2, WP 0285 Volume 2, WP 0286 Volume 2, WP 0287 Volume 2, WP 0293 Volume 2, WP 0294 Volume 2, WP 0296 Volume 2, WP 0297 Volume 2, WP 0298 Volume 2, WP 0299 Volume 2, WP 0334 Volume 3, WP 0447 Volume 3, WP 0448 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE ENGINE OVERHEATS NOTE Conduct these malfunction tests if engine overheats. This procedure will check for improper coolant level, oil level, faulty fan drivebelts, radiator and radiator hoses for leaks and damage, cooling system for clogging, radiator fan for cracked blades, fan clutch, water pump and temperature gauge for malfunctions. 0028-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) 0028 TM 9-2320-272-23-1 0028 ENGINE OVERHEATS - Continued STEP 1. IS ENGINE COOLANT AT PROPER LEVEL? WARNING Extreme care should be taken when removing surge tank filler cap if temperature gauge reads above 175°F (79°C). Steam or hot coolant under pressure may escape rapidly or cause burns. Failure to comply may result in injury or death to personnel. CAUTION Do not add coolant when engine is hot. Internal engine damage could result. Visually check engine coolant level. T1013DAA Figure 1. Surge Tank. 0028-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) TM 9-2320-272-23-1 0028 ENGINE OVERHEATS - Continued CONDITION/INDICATION IS ENGINE COOLANT AT PROPER LEVEL? DECISION NO - Fill coolant to proper level (Volume 2, WP 0287). Go to Step (12) to verify problem is solved. YES - Go to Step (2). STEP 2. IS ENGINE OIL AT PROPER LEVEL? Check dipstick for proper oil level (TM 9-2320-272-10). Dipstick Dipstick M939A2 M939/A1 T0402DAA Figure 2. Engine Oil Dipstick. CONDITION/INDICATION IS ENGINE OIL AT PROPER LEVEL? DECISION NO - Oil level is high. Drain crankcase to safe operating level (Volume 2, WP 0232). Go to Step (12) to verify problem is solved. NO - Oil level is low. Add to proper operating level (Volume 5, WP 0820). Go to Step (12) to verify problem is solved. YES - Go to Step (3). 0028-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) TM 9-2320-272-23-1 0028 ENGINE OVERHEATS - Continued STEP 3. IS DRIVE BELT AND TENSIONER IN GOOD CONDITION? Visually check drivebelt and tensioner for looseness, missing, or worn out condition. T0403DAA Figure 3. Engine Drive Belt. 0028-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) TM 9-2320-272-23-1 ENGINE OVERHEATS - Continued CONDITION/INDICATION IS DRIVE BELT AND TENSIONER IN GOOD CONDITION? DECISION NO - Tighten/replace drivebelt or tensioner as necessary M939/A1 (Volume 2, WP 0297), M939A2 (Volume 2, WP 0296). Go to Step (12) to verify problem is solved. YES - Go to Step (4). 0028-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) 0028 TM 9-2320-272-23-1 0028 ENGINE OVERHEATS - Continued STEP 4. ARE RADIATOR, HOSES, HOSE CONNECTIONS, AND DRAIN VALVES LEAKING? Visually inspect radiator, hoses, hose connections, and drain valves for leaks. T0068DAA Figure 4. Engine Cooling System (M939/A1). 0028-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) TM 9-2320-272-23-1 0028 ENGINE OVERHEATS - Continued T1015DAA Figure 5. Engine Cooling System (M939A2). CONDITION/INDICATION ARE RADIATOR, HOSES, HOSE CONNECTIONS, AND DRAIN VALVES LEAKING? DECISION YES - Turbocharger coolant lines leaking. Tighten or replace coolant lines (Volume 2, WP 0249). Go to Step (12) to verify problem is solved. YES - Coolant hoses or tubes leaking. Tighten or replace coolant hoses, clamps, or fittings M939/A1 (Volume 2, WP 0280), M939A2 (Volume 2, WP 0285). Go to Step (12) to verify problem is solved. YES - Aftercooler tubes leaking. Tighten or replace aftercooler tubes (Volume 2, WP 0299). Go to Step (12) to verify problem is solved. YES - Upper radiator hoses leaking. Tighten or replace upper radiator hoses (Volume 2, WP 0286). Go to Step (12) to verify problem is solved. YES - Radiator leaks. Replace radiator (Volume 2, WP 0281). Go to Step (12) to verify problem is solved. YES - Water pump leaks. Perform water pump maintenance M939/A1 (Volume 2, WP 0293), M939A2 (Volume 2, WP 0292). Go to Step (12) to verify problem is solved. YES - Vent or manifold hoses or fittings leaking. Tighten or replace radiator vent and manifold hoses or fittings (Volume 2, WP 0278). Go to Step (12) to verify problem is solved. YES - Air compressor coolant tube leaking - Tighten or replace coolant tube or fittings (Volume 2, WP 0284). Go to Step (12) to verify problem is solved. YES - Engine oil cooler coolant tube leaking - Tighten or replace coolant tubes or fittings M939/A1 (Volume 2, WP 0233), M939A2 (Volume 2, WP 0229). Go to Step (12) to verify problem is solved. NO - Go to Step (5). 0028-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) TM 9-2320-272-23-1 0028 ENGINE OVERHEATS - Continued STEP 5. IS COOLING SYSTEM CLOGGED? Check cooling system for clogging. T0068DAA Figure 6. Engine Cooling System (M939/A1). 0028-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) TM 9-2320-272-23-1 0028 ENGINE OVERHEATS - Continued T1015DAA Figure 7. Engine Cooling System (M939A2). CONDITION/INDICATION IS COOLING SYSTEM CLOGGED? DECISION YES - Flush and clean cooling system (Volume 2, WP 0287). Go to Step (12) to verify problem is solved. NO - Go to Step (6). 0028-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) TM 9-2320-272-23-1 0028 ENGINE OVERHEATS - Continued STEP 6. IS COOLING FAN IN GOOD CONDITION? a. Make sure engine is not running and is cool. T0405DAA Figure 8. Engine Cooling Fan. b. Check cooling fan for damage. CONDITION/INDICATION IS COOLING FAN IN GOOD CONDITION? DECISION NO - Replace fan M939/A1 (Volume 2, WP 0298), M939A2 (Volume 2, WP 0283). Go to Step (12) to verify problem is solved. YES - Go to Step (7). 0028-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) TM 9-2320-272-23-1 0028 ENGINE OVERHEATS - Continued STEP 7. IS RADIATOR FREE OF AIRFLOW OBSTRUCTIONS? Visually check radiator for airflow obstructions. T0406DAA Figure 9. Radiator. CONDITION/INDICATION IS RADIATOR FREE OF AIRFLOW OBSTRUCTIONS? DECISION NO - Remove airflow obstructions. Go to Step (12) to verify problem is solved. YES - Go to Step (8). 0028-11 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) TM 9-2320-272-23-1 0028 ENGINE OVERHEATS - Continued STEP 8. IS AIR AVAILABLE TO RUN THE COOLING FAN? a. Start engine. INSTRUMENT PANEL SECONDARY AIR PRESSURE GAGE T1007DAA Figure 10. b. Air Pressure Gauge. Monitor secondary air pressure gauge on instrument panel. Refer to point to point schematics. CONDITION/INDICATION IS AIR AVAILABLE TO RUN THE COOLING FAN? DECISION NO - Perform Secondary Pressure Gauge Reads No Pressure, Low Pressure, Or Builds To Normal Operating Pressure Slowly. Primary Pressure Gauge Reads Normal troubleshooting (WP 0131). YES - Go to Step (9). 0028-12 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) TM 9-2320-272-23-1 0028 ENGINE OVERHEATS - Continued STEP 9. DOES FAN DRIVE CLUTCH ACTUATOR OPERATE? a. Shut off engine. b. Allow engine to cool. c. Remove fan drive clutch actuator and temporarily replace with a known good actuator M939/A1 (Volume 3, WP 0447), M939A2 (Volume 3, WP 0448). Refer to point to point schematics. FAN DRIVE CLUTCH ACTUATOR COOLING FAN ENGINE T1008DAA Figure 11. d. Fan Clutch Actuator. Start engine and bring to normal operating temperature. NOTE If fan operates properly, fan clutch was faulty. e. Check if fan operates properly. CONDITION/INDICATION DOES FAN DRIVE CLUTCH ACTUATOR OPERATE? DECISION NO - Replace fan drive clutch actuator M939/A1 (Volume 3, WP 0447), M939A2 (Volume 3, WP 0448). Go to Step (12) to verify problem is solved. YES - Go to Step (10). 0028-13 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) TM 9-2320-272-23-1 0028 ENGINE OVERHEATS - Continued STEP 10. IS WATER PUMP WORKING PROPERLY AND NOT LEAKING? Visually check water pump for damage or leaks. T0408DAA Figure 12. Water Pump. CONDITION/INDICATION IS WATER PUMP WORKING PROPERLY AND NOT LEAKING? DECISION NO - Replace water pump M939/A1 (Volume 2, WP 0293), M939A2 (Volume 2, WP 0292). Go to Step (12) to verify problem is solved. YES - Go to Step (11). 0028-14 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) TM 9-2320-272-23-1 0028 ENGINE OVERHEATS - Continued STEP 11. IS TEMPERATURE GAUGE OPERATING PROPERLY? a. Shut off engine. b. Remove connector from temperature sending unit on the vehicle. c. Turn vehicle battery switch to ON position. d. Connect multimeter red lead to connector removed from the temperature sending unit. Refer to point to point schematic. e. Connect multimeter black lead to a good ground. Red Test Probe Cable W2 Black Connector Removed From Temperature Sending Unit Figure 13. T1006DAA Test Lead Hookup. NOTE If meter displays a reading between 5.5 and 7.5 VDC, temperature gauge is operating correctly. f. Meter should display a reading between 5.5 and 7.5 VDC. CONDITION/INDICATION IS TEMPERATURE GAUGE OPERATING PROPERLY? DECISION YES - Replace temperature sending unit (Volume 2, WP 0334). Go to Step (11) to verify problem is solved. NO - Perform Temperature Gauge Inoperative (Coolant) troubleshooting (WP 0106). 0028-15 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) TM 9-2320-272-23-1 ENGINE OVERHEATS - Continued STEP 12. IS YOUR ORIGINAL ENGINE OVERHEATS PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original engine overheats problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL ENGINE OVERHEATS PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0028-16 03/15/2011 Rel(1.8) root(tswp) wpno(T00078) 0028 TM 9-2320-272-23-1 FIELD MAINTENANCE LOSS OF COOLANT INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics Volume 2, WP 0229 Volume 2, WP 0233 Volume 2, WP 0249 Volume 2, WP 0280 Volume 2, WP 0281 Volume 2, WP 0284 Volume 2, WP 0285 References (cont.) Volume 2, WP 0286 Volume 2, WP 0287 Volume 2, WP 0293 Volume 2, WP 0294 Volume 2, WP 0299 Volume 3, WP 0380 Volume 3, WP 0382 Volume 3, WP 0383 Volume 3, WP 0447 Volume 3, WP 0448 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE LOSS OF COOLANT NOTE Conduct these malfunction tests if there is loss of coolant. This procedure will check for leaks from cooling system components, leaks or damage to transmission cooler, aftercooler leaks and leaks or damage to oil cooler. 0029-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00079) 0029 TM 9-2320-272-23-1 0029 LOSS OF COOLANT - Continued STEP 1. ARE RADIATOR, HOSES, HOSE CONNECTIONS, AND DRAIN VALVES LEAKING? Visually inspect radiator, hoses, hose connections, and drain valves for leaks. T1109DAA Figure 1. Engine Cooling System (M939/A1). 0029-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00079) TM 9-2320-272-23-1 0029 LOSS OF COOLANT - Continued T0404DAA Figure 2. Engine Cooling System (M939A2). CONDITION/INDICATION ARE RADIATOR, HOSES, HOSE CONNECTIONS, AND DRAIN VALVES LEAKING? DECISION YES - Turbocharger coolant lines leaking. Tighten or replace coolant lines (Volume 2, WP 0249). Go to Step (4) to verify problem is solved. YES - Coolant hoses or tubes leaking. Tighten or replace coolant hoses, clamps, or fittings M939/A1 (Volume 2, WP 0280), M939A2 (Volume 2, WP 0285). Go to Step (4) to verify problem is solved. YES - Aftercooler tubes leaking. Tighten or replace aftercool tube (Volume 2, WP 0299). Go to Step (4) to verify problem is solved. YES - Upper radiator hoses leaking. Tighten or replace upper radiator hoses (Volume 2, WP 0286). Go to Step (4) to verify problem is solved. YES - Radiator leaks. Replace radiator (Volume 2, WP 0281). Go to Step (4) to verify problem is solved. YES - Water pump leaks. Perform water pump maintenance M939/A1 (Volume 2, WP 0293), M939A2 (Volume 2, WP 0292). Go to Step (4) to verify problem is solved. YES - Transmission oil cooler assembly leaks. Repair or replace transmission oil cooler components (Volume 3, WP 0382). Go to Step (4) to verify problem is solved. YES - Air compressor coolant tube leaking. Tighten or replace coolant tube and fitting (Volume 2, WP 0284). Go to Step (4) to verify problem is solved. NO - Go to Step (2). 0029-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00079) TM 9-2320-272-23-1 LOSS OF COOLANT - Continued STEP 2. IS THERE EVIDENCE OF LEAKS OR DAMAGE TO TRANSMISSION OIL COOLER? a. Visually check for loose hose clamps and fittings. b. Remove transmission oil dipstick and look for presence of coolant in transmission oil. BY - PASS Figure 3. c. Transmission Oil Cooler. Check for damaged condition. 0029-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00079) 0029 TM 9-2320-272-23-1 0029 LOSS OF COOLANT - Continued CONDITION/INDICATION IS THERE EVIDENCE OF LEAKS OR DAMAGE TO TRANSMISSION OIL COOLER? DECISION YES - Loose hoses and/or clamps. Tighten or replace hoses and clamps (Volume 3, WP 0382). Go to Step (4) to verify problem is solved. YES - Coolant present in transmission oil. Notify supervisor. Action may not be possible at this level of maintenance. YES - Damaged and leaking transmission oil cooler. Replace transmission oil cooler M939/A1 (Volume 3, WP 0380), M939A2 (Volume 3, WP 0383). Go to Step (4) to verify problem is solved. NO - Go to Step (3). 0029-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00079) TM 9-2320-272-23-1 0029 LOSS OF COOLANT - Continued STEP 3. DO THE OIL COOLER OR AFTERCOOLER LEAK? a. Check the oil cooler and aftercooler for leaks. NOTE During engine operation, oil pressure will be higher than coolant pressure. A leak in oil cooler will show oil in coolant. After engine is shut down, residual pressure in cooling system will cause coolant to leak into oil. b. Operate vehicle to normal operating temperature. T0401DAA Figure 4. c. Surge Tank. Remove oil dipstick and look for coolant in engine oil. 0029-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00079) TM 9-2320-272-23-1 0029 LOSS OF COOLANT - Continued WARNING Extreme care should be taken when removing surge tank filler cap if temperature gauge reads above 175°F (79°C). Steam or hot coolant under pressure may escape rapidly or cause burns. Failure to comply may result in injury or death to personnel. d. Wait for engine to cool and remove surge tank filler cap, look for evidence of oil in coolant. CONDITION/INDICATION DO THE OIL COOLER OR AFTERCOOLER LEAK? DECISION YES - Coolant present in engine oil. Repair or replace aftercooler (Volume 2, WP 0299). Go to Step (4) to verify problem is solved. YES - Oil present in coolant. Repair or replace oil cooler M939/A1 (Volume 2, WP 0233), M939A2 (Volume 2, WP 0229). Go to Step (4) to verify problem is solved. NO - Notify supervisor. It is possible that another troubleshooting work package applies. STEP 4. IS YOUR ORIGINAL COOLANT LOSS PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original coolant loss problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL COOLANT LOSS PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0029-7/8 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00079) TM 9-2320-272-23-1 FIELD MAINTENANCE CONTAMINATED COOLANT INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics Volume 2, WP 0229 References (cont.) Volume 2, WP 0233 Volume 2, WP 0287 Volume 2, WP 0299 Volume 3, WP 0382 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE CONTAMINATED COOLANT NOTE Conduct these malfunction tests if there is evidence of contaminated coolant. This procedure will check for rust in coolant, transmission oil leaking into coolant and engine oil leaking into coolant. 0030-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00080) 0030 TM 9-2320-272-23-1 0030 CONTAMINATED COOLANT - Continued STEP 1. WHAT TYPE OF CONTAMINATION IS PRESENT? a. Check engine oil cooler, transmission oil cooler, and aftercooler for leaks. NOTE During engine operation, oil pressure will be higher than coolant pressure. A leak in oil cooler will show oil in coolant. After engine is shut down, residual pressure in cooling system will cause coolant to leak into oil. b. Operate vehicle to normal operating temperature. WARNING Extreme care should be taken when removing surge tank filler cap if temperature gauge reads above 175°F (79°C). Steam or hot coolant under pressure may escape rapidly or cause burns. Failure to comply may result in injury or death to personnel. c. Wait for engine to cool and remove surge tank filler cap. T1014DAA Figure 1. Surge Tank. 0030-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00080) TM 9-2320-272-23-1 0030 CONTAMINATED COOLANT - Continued d. Inspect coolant for evidence of rust, engine oil, or transmission oil in coolant. CONDITION/INDICATION WHAT TYPE OF CONTAMINATION IS PRESENT? DECISION YES - Engine oil present in coolant. Repair or replace engine oil cooler M939/A1 (Volume 2, WP 0233), M939A2 (Volume 2, WP 0229), or aftercooler (Volume 2, WP 0299). Go to Step (2) to verify problem is solved. YES - Transmission oil present in coolant. Repair or replace transmission oil cooler M939/A1 (Volume 3, WP 0380), M939A2 (Volume 3, WP 0383). Go to Step (2) to verify problem is solved. YES - Evidence of rust is present in coolant. Drain and flush cooling system (Volume 2, WP 0287). Go to Step (2) to verify problem is solved. NO - Go to Step (2) to verify problem is solved. STEP 2. IS YOUR ORIGINAL COOLANT CONTAMINATION PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original coolant contamination problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL COOLANT CONTAMINATION PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0030-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00080) TM 9-2320-272-23-1 FIELD MAINTENANCE EXCESSIVE NOISE DURING SHIFTING INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 3, WP 0362 Volume 3, WP 0376 Volume 3, WP 0403 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE EXCESSIVE NOISE DURING SHIFTING NOTE Conduct these malfunction tests if there is excessive noise during shifting. This procedure will check transmission fluid level, transmission fluid viscosity, and the condition of propeller shaft universal joints and propeller shaft flanges. 0031-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00081) 0031 TM 9-2320-272-23-1 0031 EXCESSIVE NOISE DURING SHIFTING - Continued STEP 1. IS TRANSMISSION FLUID LEVEL CORRECT? Visually check transmission fluid level (Volume 5, WP 0820). ACCESS DOOR DIPSTICK HANDLE T0497DAA Figure 1. Transmission Dipstick. CONDITION/INDICATION IS TRANSMISSION FLUID LEVEL CORRECT? DECISION YES - Go to Step (2). NO - Add fluid as necessary (Volume 3, WP 0362). Go to Step (5) to verify problem is solved. 0031-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00081) TM 9-2320-272-23-1 0031 EXCESSIVE NOISE DURING SHIFTING - Continued STEP 2. IS TRANSMISSION FLUID VISCOSITY CORRECT? Check transmission fluid viscosity (Volume 5, WP 0820). ACCESS DOOR DIPSTICK HANDLE T0497DAA Figure 2. Transmission Dipstick. CONDITION/INDICATION IS TRANSMISSION FLUID VISCOSITY CORRECT? DECISION YES - Go to Step (3). NO - Perform transmission oil service (Volume 3, WP 0362). Go to Step (5) to verify problem is solved. 0031-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00081) TM 9-2320-272-23-1 0031 EXCESSIVE NOISE DURING SHIFTING - Continued STEP 3. IS TRANSMISSION YOKE IN GOOD OPERATING CONDITION? Visually check transmission yoke for looseness, wear, and damage. T0498DAA Figure 3. Transmission Yoke. CONDITION/INDICATION IS TRANSMISSION YOKE IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (4). NO - Replace transmission yoke (Volume 3, WP 0376). Go to Step (5) to verify problem is solved. 0031-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00081) TM 9-2320-272-23-1 0031 EXCESSIVE NOISE DURING SHIFTING - Continued STEP 4. ARE PROPELLER SHAFT UNIVERSAL JOINTS IN GOOD OPERATING CONDITION? Visually check propeller shaft universal joints for looseness, wear, and damage. FLANGE MOUNTING SCREWS T0499DAA Figure 4. Transmission Universal Joints. CONDITION/INDICATION ARE PROPELLER SHAFT UNIVERSAL JOINTS IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (5) to verify problem is solved. NO - Replace universal joint (Volume 3, WP 0403). Go to Step (5) to verify problem is solved. STEP 5. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0031-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00081) TM 9-2320-272-23-1 FIELD MAINTENANCE LOW TRANSMISSION OIL PRESSURE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References (cont.) Volume 3, WP 0362 Volume 5, WP 0820 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE LOW TRANSMISSION OIL PRESSURE NOTE Conduct these malfunction tests if transmission oil pressure is low. This procedure will check transmission fluid level and the transmission oil filter. 0032-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00082) 0032 TM 9-2320-272-23-1 0032 LOW TRANSMISSION OIL PRESSURE - Continued STEP 1. IS TRANSMISSION FLUID LEVEL CORRECT? Visually check transmission fluid level (Volume 5, WP 0820) . ACCESS DOOR DIPSTICK HANDLE T0985DAA Figure 1. Transmission Dipstick. CONDITION/INDICATION IS TRANSMISSION FLUID LEVEL CORRECT? DECISION YES - Replace transmission oil filter (Volume 3, WP 0362). Go to Step (2) to verify problem is solved. NO - Add fluid as necessary (Volume 3, WP 0362). Go to Step (2) to verify problem is solved. 0032-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00082) TM 9-2320-272-23-1 LOW TRANSMISSION OIL PRESSURE - Continued STEP 2. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0032-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00082) 0032 TM 9-2320-272-23-1 FIELD MAINTENANCE TRANSMISSION OIL LEAKING INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics Volume 3, WP 0362 References (cont.) Volume 3, WP 0363 Volume 3, WP 0377 Volume 3, WP 0381 Volume 3, WP 0382 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE TRANSMISSION OIL LEAKING NOTE Conduct these malfunction tests if there is transmission oil leakage. This procedure will check the drain plug, oil pan gasket and mounting bolts, dipstick tube connection, transmission housing, oil cooler oil filter, and oil cooler hoses. 0033-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00083) 0033 TM 9-2320-272-23-1 0033 TRANSMISSION OIL LEAKING - Continued STEP 1. IS THE TRANSMISSION OIL PAN LEAKING OIL? Visually inspect for loose or damaged drain plug or mounting bolts, gasket damage, dipstick tube connection or transmission housing leaks. T0500DAA Figure 1. Transmission Oil Pan. CONDITION/INDICATION IS THE TRANSMISSION OIL PAN LEAKING OIL? DECISION YES - Oil pan drain plug leaking. Tighten oil pan drain plug (Volume 3, WP 0362). Go to Step (3) to verify problem is solved. YES - Leaks at oil pan mounting bolts. Tighten oil pan mounting bolts (Volume 3, WP 0377). Go to Step (3) to verify problem is solved. YES - Oil pan gasket leaking. Replace oil pan gasket (Volume 3, WP 0377). Go to Step (3) to verify problem is solved. YES - Oil dipstick tube leaking. Tighten dipstick tube connection (Volume 3, WP 0363). Go to Step (3) to verify problem is solved. YES - Transmission housing leaking. Notify supervisor. Action may not be possible at this level of maintenance. NO - Go to Step (2). 0033-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00083) TM 9-2320-272-23-1 0033 TRANSMISSION OIL LEAKING - Continued STEP 2. IS TRANSMISSION OIL LEAKING FROM TRANSMISSION OIL COOLER SYSTEM? Visually inspect for loose or damaged oil cooler, oil filter, and oil cooler hoses. T0501DAA Figure 2. Transmission Oil Cooling Lines. CONDITION/INDICATION IS TRANSMISSION OIL LEAKING FROM TRANSMISSION OIL COOLER SYSTEM? DECISION YES - Oil cooler filter leaking. Tighten or replace oil filter (Volume 3, WP 0381). Go to Step (3) to verify problem is solved. YES - Oil cooler hose(s) leaking. Tighten or replace hose(s) (Volume 3, WP 0382). Go to Step (3) to verify problem is solved. NO - Go to Step (3) to verify problem is solved. STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0033-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00083) TM 9-2320-272-23-1 FIELD MAINTENANCE NO RESPONSE TO SHIFT LEVER MOVEMENT INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 3, WP 0362 Volume 3, WP 0369 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE NO RESPONSE TO SHIFT LEVER MOVEMENT NOTE Conduct these malfunction tests if there is no response to shift lever movement. This procedure will check transmission fluid level and the selector lever assembly linkage. 0034-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00084) 0034 TM 9-2320-272-23-1 0034 NO RESPONSE TO SHIFT LEVER MOVEMENT - Continued STEP 1. IS TRANSMISSION FLUID LEVEL CORRECT? Visually check transmission fluid level (Volume 5, WP 0820). ACCESS DOOR DIPSTICK HANDLE T1040DAA Figure 1. Transmission Dipstick. CONDITION/INDICATION IS TRANSMISSION FLUID LEVEL CORRECT? DECISION NO - Add fluid as necessary (Volume 3, WP 0362). Go to Step (5) to verify problem is solved. YES - Go to Step (2). 0034-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00084) TM 9-2320-272-23-1 0034 NO RESPONSE TO SHIFT LEVER MOVEMENT - Continued STEP 2. IS TRANSMISSION SELECTOR LEVER LINKAGE ATTACHING HARDWARE LOOSE, DAMAGED, OR MISSING? Visually inspect transmission selector lever linkage for loose, damaged, or missing hardware. T1042DAA Figure 2. Transmission Selector. CONDITION/INDICATION IS TRANSMISSION SELECTOR LEVER LINKAGE ATTACHING HARDWARE LOOSE, DAMAGED, OR MISSING? DECISION YES - Repair transmission selector lever linkage (Volume 3, WP 0369). Go to Step (3) to verify problem is solved. NO - Go to Step (3) to verify problem is solved. 0034-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00084) TM 9-2320-272-23-1 NO RESPONSE TO SHIFT LEVER MOVEMENT - Continued STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0034-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00084) 0034 TM 9-2320-272-23-1 FIELD MAINTENANCE ROUGH SHIFTING INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 3, WP 0362 Volume 3, WP 0369 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE ROUGH SHIFTING NOTE Conduct these malfunction tests if shifting is rough. This procedure will check transmission fluid level and the selector lever assembly linkage. 0035-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00085) 0035 TM 9-2320-272-23-1 0035 ROUGH SHIFTING - Continued STEP 1. IS TRANSMISSION FLUID LEVEL CORRECT? Visually check transmission fluid level (Volume 5, WP 0820). ACCESS DOOR DIPSTICK HANDLE T1041DAA Figure 1. Transmission Dipstick. CONDITION/INDICATION IS TRANSMISSION FLUID LEVEL CORRECT? DECISION NO - Add fluid as necessary (Volume 3, WP 0362). Go to Step (5) to verify problem is solved. YES - Go to Step (2). 0035-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00085) TM 9-2320-272-23-1 0035 ROUGH SHIFTING - Continued STEP 2. IS TRANSMISSION SELECTOR LEVER LINKAGE ATTACHING HARDWARE LOOSE, DAMAGED, OR MISSING? Visually inspect transmission selector lever linkage for loose, damaged, or missing hardware. T0504DAA Figure 2. Transmission Selector. CONDITION/INDICATION IS TRANSMISSION SELECTOR LEVER LINKAGE ATTACHING HARDWARE LOOSE, DAMAGED, OR MISSING? DECISION YES - Repair transmission selector lever linkage (Volume 3, WP 0369). Go to Step (3) to verify problem is solved. NO - Go to Step (3) to verify problem is solved. 0035-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00085) TM 9-2320-272-23-1 ROUGH SHIFTING - Continued STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0035-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00085) 0035 TM 9-2320-272-23-1 FIELD MAINTENANCE TRANSMISSION OVERHEATS AS INDICATED BY TRANSMISSION TEMPERATURE GAUGE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0341 Volume 3, WP 0362 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE TRANSMISSION OVERHEATS AS INDICATED BY TRANSMISSION TEMPERATURE GAUGE NOTE Conduct these malfunction tests if transmission temperature gauge indicates the transmission is overheating. This procedure will check the transmission fluid level and transmission temperature gauge. 0036-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00086) 0036 TM 9-2320-272-23-1 0036 TRANSMISSION OVERHEATS AS INDICATED BY TRANSMISSION TEMPERATURE GAUGE - Continued STEP 1. IS TRANSMISSION FLUID LEVEL CORRECT? Visually check transmission fluid level (Volume 5, WP 0820). ACCESS DOOR DIPSTICK HANDLE T1004DAA Figure 1. Transmission Dipstick. CONDITION/INDICATION IS TRANSMISSION FLUID LEVEL CORRECT? DECISION YES - Go to Step (2). NO - Add fluid as necessary (Volume 3, WP 0362). Go to Step (3) to verify problem is solved. STEP 2. IS TRANSMISSION TEMPERATURE GAUGE OPERATING PROPERLY? a. Turn battery switch to OFF position. b. Remove connector from temperature sending unit on the vehicle. c. Turn battery switch to ON position. d. Turn start switch to RUN position. e. Set multimeter to measure VDC. 0036-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00086) TM 9-2320-272-23-1 0036 TRANSMISSION OVERHEATS AS INDICATED BY TRANSMISSION TEMPERATURE GAUGE - Continued Red Test Probe Cable W2 Black Connector Removed From Temperature Sending Unit T0072DAA Figure 2. Test Lead Hookup. f. Connect multimeter red lead to connector removed from the temperature sending unit. Refer to point to point schematics. g. Connect multimeter black lead to a good ground. NOTE If meter displays a reading between 22 and 26 VDC, temperature gauge is operating correctly. h. Meter reading should be between 22 and 26 VDC. CONDITION/INDICATION IS TRANSMISSION TEMPERATURE GAUGE OPERATING PROPERLY? DECISION YES - Replace temperature sending unit (Volume 2, WP 0341). Go to Step (3) to verify problem is solved. NO - Perform Transmission Temperature Gauge Inoperative troubleshooting (WP 0105). STEP 3. IS YOUR ORIGINAL TRANSMISSION OVERHEATING PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original transmission overheating problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL TRANSMISSION OVERHEATING PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0036-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00086) TM 9-2320-272-23-1 FIELD MAINTENANCE DIRT OR METAL PARTICLES IN TRANSMISSION OIL INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References (cont.) Volume 3, WP 0362 Volume 5, WP 0820 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE DIRT OR METAL PARTICLES IN TRANSMISSION OIL NOTE Conduct these malfunction tests if there is dirt or metal particles in the oil. This procedure will check transmission oil for contamination. 0037-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00087) 0037 TM 9-2320-272-23-1 0037 DIRT OR METAL PARTICLES IN TRANSMISSION OIL - Continued STEP 1. DOES OIL SAMPLE TEST INDICATE OIL IS CONTAMINATED? Submit oil sample for testing (Volume 5, WP 0820). T0507DAA Figure 1. Transmission Oil Sample Port. CONDITION/INDICATION DOES OIL SAMPLE TEST INDICATE OIL IS CONTAMINATED? DECISION YES - Dirt in oil. Service transmission (Volume 3, WP 0362). Go to Step (2) to verify problem is solved. YES - Metal in oil. Notify supervisor. Action may not be possible at this level of maintenance. NO - Go to Step (2) to verify problem is solved. STEP 2. IS YOUR ORIGINAL DIRT OR METAL PARTICLES IN OIL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original dirt or metal particles in oil problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL DIRT OR METAL PARTICLES IN OIL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0037-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00087) TM 9-2320-272-23-1 FIELD MAINTENANCE OIL THROWN FROM TRANSMISSION DIPSTICK TUBE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References (cont.) Volume 3, WP 0362 Volume 3, WP 0363 Volume 5, WP 0820 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE OIL THROWN FROM TRANSMISSION DIPSTICK TUBE NOTE Conduct these malfunction tests if oil is thrown from the filler tube. This procedure will check the transmission oil level and that the dipstick is tight in the filler tube. 0038-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00088) 0038 TM 9-2320-272-23-1 0038 OIL THROWN FROM TRANSMISSION DIPSTICK TUBE - Continued STEP 1. IS TRANSMISSION OIL LEVEL TOO HIGH? Visually check transmission fluid level (Volume 5, WP 0820). ACCESS DOOR DIPSTICK HANDLE T0986DAA Figure 1. Transmission Dipstick. CONDITION/INDICATION IS TRANSMISSION OIL LEVEL TOO HIGH? DECISION YES - Drain oil to correct level (Volume 3, WP 0362). Go to Step (2) to verify problem is solved. NO - Go to Step (2). 0038-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00088) TM 9-2320-272-23-1 0038 OIL THROWN FROM TRANSMISSION DIPSTICK TUBE - Continued STEP 2. IS DIPSTICK LOOSE? Check dipstick to ensure it is not loose. ACCESS DOOR DIPSTICK HANDLE T0986DAA Figure 2. Transmission Dipstick. CONDITION/INDICATION IS DIPSTICK LOOSE? DECISION YES - Tighten dipstick (Volume 3, WP 0363). Go to Step (3) to verify problem is solved. NO - Go to Step (3) to verify problem is solved. 0038-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00088) TM 9-2320-272-23-1 OIL THROWN FROM TRANSMISSION DIPSTICK TUBE - Continued STEP 3. IS YOUR ORIGINAL OIL THROWN FROM FILLER TUBE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original oil thrown from filler tube problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL OIL THROWN FROM FILLER TUBE PROBLEM STILL PRESENT? DECISION YES - Notify Supervisor. NO - Problem Fixed. END OF WORK PACKAGE 0038-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00088) 0038 TM 9-2320-272-23-1 FIELD MAINTENANCE TRANSMISSION OIL DIRTY, FOAMY, AND/OR MILKY INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References (cont.) WP 0037 Volume 3, WP 0362 Volume 3, WP 0363 Volume 5, WP 0820 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics WP 0029 TROUBLESHOOTING PROCEDURE TRANSMISSION OIL DIRTY, FOAMY, AND/OR MILKY NOTE Conduct these tests if transmission oil is dirty, foamy, and/or milky. Dirt/grit in oil indicates oil needs to be changed. Foaming indicates contamination by air or water. Milky oil indicates contamination by coolant. 0039-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00089) 0039 TM 9-2320-272-23-1 0039 TRANSMISSION OIL DIRTY, FOAMY, AND/OR MILKY - Continued STEP 1. IS TRANSMISSION DIPSTICK DAMAGED OR LEAKING? Check transmission dipstick for damage and leaks. ACCESS DOOR DIPSTICK HANDLE T1018DAA Figure 1. Transmission Dipstick. CONDITION/INDICATION IS TRANSMISSION DIPSTICK DAMAGED OR LEAKING? DECISION YES - Repair transmission dipstick (Volume 3, WP 0363). Go to Step (5) to verify problem is solved. NO - Go to Step (2). 0039-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00089) TM 9-2320-272-23-1 0039 TRANSMISSION OIL DIRTY, FOAMY, AND/OR MILKY - Continued STEP 2. IS TRANSMISSION OIL CONTAMINATED WITH DIRT OR METAL PARTICLES? Visually check transmission fluid for dirt or metal particles (Volume 5, WP 0820). ACCESS DOOR DIPSTICK HANDLE T1018DAA Figure 2. Transmission Dipstick. CONDITION/INDICATION IS TRANSMISSION OIL CONTAMINATED WITH DIRT OR METAL PARTICLES? DECISION YES - Perform Dirt Or Metal Particles In Transmission Oil troubleshooting (WP 0037). NO - Go to Step (3). 0039-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00089) TM 9-2320-272-23-1 0039 TRANSMISSION OIL DIRTY, FOAMY, AND/OR MILKY - Continued STEP 3. IS TRANSMISSION OIL LEVEL CORRECT? NOTE High or low oil levels may cause transmission oil to foam. Visually check transmission fluid level (Volume 5, WP 0820). ACCESS DOOR DIPSTICK HANDLE T1018DAA Figure 3. Transmission Dipstick. CONDITION/INDICATION IS TRANSMISSION OIL LEVEL CORRECT? DECISION YES - Add or subtract fluid as necessary (Volume 3, WP 0362). Go to Step (5) to verify problem is solved. NO - Go to Step (4). 0039-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00089) TM 9-2320-272-23-1 0039 TRANSMISSION OIL DIRTY, FOAMY, AND/OR MILKY - Continued STEP 4. IS TRANSMISSION OIL CONTAMINATED WITH COOLANT? Visually check transmission if fluid is milky (Volume 5, WP 0820). ACCESS DOOR DIPSTICK HANDLE T1018DAA Figure 4. Transmission Dipstick. CONDITION/INDICATION IS TRANSMISSION OIL CONTAMINATED WITH COOLANT? DECISION YES - Perform Loss Of Coolant troubleshooting (WP 0029). NO - Go to Step (5) to verify problem is solved. 0039-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00089) TM 9-2320-272-23-1 TRANSMISSION OIL DIRTY, FOAMY, AND/OR MILKY - Continued STEP 5. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Perform transmission oil service (Volume 3, WP 0362) if one has not been done. b. Ensure vehicle is returned to normal operating condition. c. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0039-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00089) 0039 TM 9-2320-272-23-1 FIELD MAINTENANCE HARD SHIFTING OF TRANSFER CASE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0307 Volume 3, WP 0352 Volume 3, WP 0396 Volume 5, WP 0820 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE HARD SHIFTING OF TRANSFER CASE NOTE Conduct these malfunction tests if transfer case is hard shifting or will not shift. This procedure will check transfer case for fluid level, transfer case shift linkage for damage or missing parts, proper lubrication, and defective linear valve transfer case shift lever switch and wiring. 0040-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00090) 0040 TM 9-2320-272-23-1 0040 HARD SHIFTING OF TRANSFER CASE - Continued STEP 1. IS TRANSFER CASE FLUID LEVEL CORRECT? a. Visually inspect transfer case fluid level. FILL PLUG T0509DAA Figure 1. Transfer Case. b. Access and remove transfer case fill plug. c. Check for fluid presence at fill plug opening. d. If fluid is not at fill plug opening, add fluid as necessary (Volume 5, WP 0820). e. Install fill plug. CONDITION/INDICATION IS TRANSFER CASE FLUID LEVEL CORRECT? DECISION YES - Go to Step (2). NO - Fluid added. Go to Step (7) to verify problem is solved. 0040-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00090) TM 9-2320-272-23-1 0040 HARD SHIFTING OF TRANSFER CASE - Continued STEP 2. IS TRANSFER CASE SHIFT LINKAGE IN GOOD OPERATING CONDITION? a. Visually inspect transfer case shift linkage for broken, bent, or missing parts. T0510DAA Figure 2. b. Transfer Case Linkage. Inspect and lubricate linkage as necessary (Volume 5, WP 0820). CONDITION/INDICATION IS TRANSFER CASE SHIFT LINKAGE IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (3). NO - Replace any bent, broken, or missing parts (Volume 3, WP 0396). Go to Step (7) to verify problem is solved. 0040-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00090) TM 9-2320-272-23-1 0040 HARD SHIFTING OF TRANSFER CASE - Continued STEP 3. IS THERE BATTERY VOLTAGE AT CIRCUIT 586 WIRE? a. Check for battery voltage at circuit 586 wire. Refer to point to point schematics. b. Place battery to OFF position. c. Disconnect circuit 586 wire from transfer case control switch. 585 586 586 T0118DAA Figure 3. Circuit 586 Wire. d. Place battery switch to ON position. e. Place transmission control lever to neutral. f. Set multimeter to VDC. g. Connect red multimeter lead to disconnected circuit 586 wire as shown. h. Connect black multimeter lead to vehicle chassis ground. i. Make sure transfer case control switch button is depressed. j. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT CIRCUIT 586 WIRE? DECISION YES - Notify supervisor. It is possible that another troubleshooting work package applies. NO - Go to Step (4). 0040-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00090) TM 9-2320-272-23-1 0040 HARD SHIFTING OF TRANSFER CASE - Continued STEP 4. DOES CIRCUIT 585 WIRE SUPPLY CONTROL SWITCH WITH BATTERY VOLTAGE? a. Check for battery voltage at circuit 585 wire. Refer to point to point schematics. b. Place battery to OFF position. c. Reconnect circuit 586 wire. d. Disconnect circuit 585 wire from transfer case control switch. 585 585 586 586 T0117DAA Figure 4. Circuit 585 Wire. e. Place battery switch to ON position. f. Connect red multimeter lead to disconnected circuit 585 wire as shown. g. Connect black multimeter lead to vehicle chassis ground. h. Meter reading should be greater than 18 VDC. CONDITION/INDICATION DOES CIRCUIT 585 WIRE SUPPLY CONTROL SWITCH WITH BATTERY VOLTAGE? DECISION YES - Replace transfer case control switch (Volume 3, WP 0396). Go to Step (7) to verify problem is solved. NO - Go to Step (5). 0040-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00090) TM 9-2320-272-23-1 0040 HARD SHIFTING OF TRANSFER CASE - Continued STEP 5. IS THERE BATTERY VOLTAGE AT CIRCUIT 37 TERMINAL OF CIRCUIT BREAKER? a. Check for battery voltage at circuit breaker 37 terminal. Refer to point to point schematics. b. Place battery to OFF position. c. Reconnect circuit 585 wire. d. Disconnect circuit 37 wire from circuit breaker. 37 10 T0116DAA Figure 5. Circuit 37 Breaker. e. Place battery switch to ON position. f. Connect red multimeter lead to circuit breaker 37 terminal. g. Connect black multimeter lead to vehicle chassis ground. NOTE If voltage is present, circuit wire 585 is faulty. h. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT CIRCUIT 37 TERMINAL OF CIRCUIT BREAKER? DECISION YES - Repair circuit 585 wire (Volume 3, WP 0352). Go to Step (7) to verify problem is solved. NO - Go to Step (6). 0040-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00090) TM 9-2320-272-23-1 0040 HARD SHIFTING OF TRANSFER CASE - Continued STEP 6. IS THERE BATTERY VOLTAGE AT TRANSFER CASE CONTROL CIRCUIT BREAKER? a. Place battery to OFF position. b. Reconnect circuit 37 wire. c. Disconnect circuit 10 wire from circuit breaker. Refer to point to point schematics. T0115DAA Figure 6. Circuit 10 Breaker. d. Place battery switch to ON position. e. Connect red multimeter lead to circuit 10 wire as shown. f. Connect black multimeter lead to vehicle chassis ground. g. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT TRANSFER CASE CONTROL CIRCUIT BREAKER? DECISION YES - Replace circuit breaker (Volume 2, WP 0307). Go to Step (7) to verify problem is solved. NO - Repair circuit 10 wire (Volume 3, WP 0352). Go to Step (7) to verify problem is solved. 0040-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00090) TM 9-2320-272-23-1 HARD SHIFTING OF TRANSFER CASE - Continued STEP 7. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0040-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00090) 0040 TM 9-2320-272-23-1 FIELD MAINTENANCE TRANSFER CASE LEAKING OIL INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References (cont.) Volume 3, WP 0385 Volume 3, WP 0386 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE TRANSFER CASE LEAKING OIL NOTE Conduct these malfunction tests is transfer case oil leaks are detected. This procedure will check for leaks or looseness from drain plugs and leaks from transfer case housing. 0041-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00091) 0041 TM 9-2320-272-23-1 0041 TRANSFER CASE LEAKING OIL - Continued STEP 1. ARE FILL AND DRAIN PLUGS OR TRANSFER CASE HOUSING LEAKING OIL? a. Visually check transfer case fill and drain plugs for leaks and looseness. FILL PLUG DRAIN PLUG T0869DAA Figure 1. b. Transfer Case. Visually inspect transfer case housing for leaks. CONDITION/INDICATION ARE FILL AND DRAIN PLUGS OR TRANSFER CASE HOUSING LEAKING OIL? DECISION YES - Fill and drain plugs leak or are loose. Tighten loose fill and drain plugs. Go to Step (2) to verify problem is solved. YES - Transfer case housing leaks. Replace transfer case (Volume 3, WP 0385), M936 (Volume 3, WP 0386). Go to Step (2) to verify problem is solved. NO - Go to Step (2) to verify problem is solved. 0041-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00091) TM 9-2320-272-23-1 TRANSFER CASE LEAKING OIL - Continued STEP 2. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0041-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00091) 0041 TM 9-2320-272-23-1 FIELD MAINTENANCE EXCESSIVE NOISE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics Volume 5, WP 0820 TROUBLESHOOTING PROCEDURE EXCESSIVE NOISE NOTE Conduct these malfunction test if excessive transfer case noise is detected. This procedure will check transfer case fluid level. 0042-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00092) 0042 TM 9-2320-272-23-1 0042 EXCESSIVE NOISE - Continued STEP 1. IS TRANSFER CASE FLUID LEVEL CORRECT? a. Visually inspect transfer case fluid level. FILL PLUG T1105DAA Figure 1. Transfer Case. b. Access and remove transfer case fill plug. c. Check for fluid presence at fill plug opening. d. If fluid is not at fill plug opening, add fluid as necessary (Volume 5, WP 0820). e. Install fill plug. CONDITION/INDICATION IS TRANSFER CASE FLUID LEVEL CORRECT? DECISION YES - Notify supervisor. It is possible that another troubleshooting work package applies. NO - Fluid added. Go to Step (2) to verify problem is solved. 0042-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00092) TM 9-2320-272-23-1 EXCESSIVE NOISE - Continued STEP 2. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0042-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00092) 0042 TM 9-2320-272-23-1 FIELD MAINTENANCE EXCESSIVE VIBRATION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Wrench, Torque, Click, Ratcheting, 3/8" Drive, 75 Ft-Lb (Volume 5, WP 0826, Table 1, Item 62) Personnel Required (2) References (cont.) Volume 3, WP 0401 Volume 3, WP 0402 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE EXCESSIVE VIBRATION NOTE Conduct these malfunction tests if there is excessive vibration from transfer case. This procedure will check for proper transfer case fluid level and proper torque of yoke and companion flange screws. 0043-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00093) 0043 TM 9-2320-272-23-1 0043 EXCESSIVE VIBRATION - Continued STEP 1. IS TRANSFER CASE FLUID LEVEL CORRECT? a. Visually inspect transfer case fluid level. FILL PLUG T0509DAA Figure 1. Transfer Case. 0043-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00093) TM 9-2320-272-23-1 EXCESSIVE VIBRATION - Continued b. Access and remove transfer case fill plug. c. Check for fluid presence at fill plug opening. d. If fluid is not at fill plug opening, add fluid as necessary (Volume 5, WP 0820). e. Install fill plug. CONDITION/INDICATION IS TRANSFER CASE FLUID LEVEL CORRECT? DECISION YES - Go to Step (2). NO - Fluid added. Go to Step (3) to verify problem is solved. 0043-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00093) 0043 TM 9-2320-272-23-1 0043 EXCESSIVE VIBRATION - Continued STEP 2. DO YOKE AND COMPANION FLANGE SCREWS HAVE PROPER TORQUE? a. Check all yoke and companion flange screws for looseness. TRANSFER CASE TO FRONT AXLE ASSEMBLY TRANSFER CASE TO FORWARD REAR AXLE ASSEMBLY T0518DAA Figure 2. b. Propeller Shafts. Flange lock nuts should be tightened to 30 to 40 ft-lb (43 to 54 N·m). 0043-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00093) TM 9-2320-272-23-1 0043 EXCESSIVE VIBRATION - Continued CONDITION/INDICATION DO YOKE AND COMPANION FLANGE SCREWS HAVE PROPER TORQUE? DECISION YES - Go to Step (3) to verify problem is solved. NO - Transfer to front axle flange screws loose. Tighten any loose screws (Volume 3, WP 0402). Go to Step (3) to verify problem is solved. NO - Transfer to forward rear axle flange screws loose. Tighten any loose screws (Volume 3, WP 0401). Go to Step (3) to verify problem is solved. STEP 3. IS YOUR ORIGINAL TRANSFER CASE VIBRATION PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original transfer case vibration problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL TRANSFER CASE VIBRATION PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0043-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00093) TM 9-2320-272-23-1 FIELD MAINTENANCE EXCESSIVE PROPELLER AND DRIVE SHAFTS NOISE OR VIBRATION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Wrench, Torque, Click, Ratcheting, 3/8" Drive, 75 Ft-Lb (Volume 5, WP 0826, Table 1, Item 62) Personnel Required (2) References (cont.) Volume 3, WP 0401 Volume 3, WP 0402 Volume 3, WP 0403 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE EXCESSIVE PROPELLER AND DRIVE SHAFTS NOISE OR VIBRATION NOTE Conduct these malfunction tests if excessive noise or vibration from propeller and drive shafts is detected. This procedure will check universal joint lubrication, torque of all propeller shaft yoke screws, propeller shaft for wear and damage and center bearing for looseness and damage. 0044-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00253) 0044 TM 9-2320-272-23-1 0044 EXCESSIVE PROPELLER AND DRIVE SHAFTS NOISE OR VIBRATION - Continued STEP 1. ARE UNIVERSAL JOINTS PROPERLY LUBRICATED? Visually check universal joints for proper lubrication. T0523DAA Figure 1. Universal Joints. CONDITION/INDICATION ARE UNIVERSAL JOINTS PROPERLY LUBRICATED? DECISION YES - Go to Step (2). NO - Lubricate universal joints (Volume 5, WP 0820). Go to Step (4) to verify problem is solved. STEP 2. ARE ALL PROPELLER SHAFT COMPONENTS IN GOOD OPERATING CONDITION? a. Check torque of all propeller shaft flange yoke screws. b. Tighten any loose propeller shaft flange yoke screws to 32-40 ft-lb (43-54 N·m). 0044-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00253) TM 9-2320-272-23-1 0044 EXCESSIVE PROPELLER AND DRIVE SHAFTS NOISE OR VIBRATION - Continued T0524DAA Figure 2. c. Propeller Shaft. Visually check all propeller shafts for wear and damage. CONDITION/INDICATION ARE ALL PROPELLER SHAFT COMPONENTS IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (3). NO - Transmission to transfer damaged. Replace damaged propeller shaft (Volume 3, WP 0403). Go to Step (4) to verify problem is solved. NO - Transfer to forward rear axle propeller shaft damaged. Replace damaged propeller shaft (Volume 3, WP 0401). Go to Step (4) to verify problem is solved. NO - Transfer to front axle propeller shaft damaged. Replace damaged propeller shaft (Volume 3, WP 0402). Go to Step (4) to verify problem is solved. 0044-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00253) TM 9-2320-272-23-1 0044 EXCESSIVE PROPELLER AND DRIVE SHAFTS NOISE OR VIBRATION - Continued STEP 3. IS CENTER BEARING ASSEMBLY IN GOOD OPERATING CONDITION? a. Visually inspect center bearing assembly for looseness and damage. T0525DAA Figure 3. b. Center Bearing. Tighten center bearing to forward rear axle propeller shaft yoke to transfer to center bearing rear flange screws to 32-40 ft-lb (43-54 N·m). CONDITION/INDICATION IS CENTER BEARING ASSEMBLY IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (4) to verify problem is solved. NO - Replace damaged center bearing assembly (Volume 3, WP 0401). Go to Step (4) to verify problem is solved. 0044-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00253) TM 9-2320-272-23-1 EXCESSIVE PROPELLER AND DRIVE SHAFTS NOISE OR VIBRATION - Continued STEP 4. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your propeller and drive shafts noise or vibration problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0044-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00253) 0044 TM 9-2320-272-23-1 FIELD MAINTENANCE CONTINUOUS AXLE OR WHEEL NOISE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) High Boy Jack Stands (Volume 5, WP 0826, Table 1, Item 24) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 3, WP 0404 Volume 3, WP 0411 Volume 3, WP 0484 Volume 3, WP 0485 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE CONTINUOUS AXLE OR WHEEL NOISE NOTE Conduct these malfunction tests if there is continuous axle or wheel noise. This procedure will check if the front wheel drive is engaged when traveling on hard surfaces, for missing wheel lug nuts, axle and differential lubrication and loose or damaged wheel bearings. 0045-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00254) 0045 TM 9-2320-272-23-1 0045 CONTINUOUS AXLE OR WHEEL NOISE - Continued STEP 1. WAS FRONT WHEEL DRIVE ENGAGED WHILE TRAVELING ON HARD FLAT SURFACE? a. Visually inspect if front wheel drive is engaged. A A FRONT WHEEL DRIVE LOCK - IN SWITCH T0528DAA Figure 1. Front Wheel Drive Lock-In Switch. b. Locate front wheel drive lock-in switch and check for engaged position. c. Disengaged front wheel drive when traveling on hard flat surfaces. CONDITION/INDICATION WAS FRONT WHEEL DRIVE ENGAGED WHILE TRAVELING ON HARD FLAT SURFACE? DECISION YES - Go to Step (6) to verify problem is solved. NO - Go to Step (2). 0045-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00254) TM 9-2320-272-23-1 0045 CONTINUOUS AXLE OR WHEEL NOISE - Continued STEP 2. ARE THERE ANY LOOSE OR MISSING WHEEL LUG NUTS? Visually check for loose or missing wheel lug nuts. T0529DAA Figure 2. Wheel Lug Nuts. CONDITION/INDICATION ARE THERE ANY LOOSE OR MISSING WHEEL LUG NUTS? DECISION YES - Tighten or replace wheel lug nuts M939 (Volume 3, WP 0484), M939A1/A2 (Volume 3, WP 0485). Go to Step (6) to verify problem is solved. NO - Go to Step (3). 0045-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00254) TM 9-2320-272-23-1 0045 CONTINUOUS AXLE OR WHEEL NOISE - Continued STEP 3. IS AXLE HOUSING AND DIFFERENTIAL PROPERLY LUBRICATED? a. Visually check front and rear axle housing and differential lubrication level. T0526DAA Figure 3. Differential Lubrication Level. b. Remove axle housing drain plug and check for fluid level at drain plug opening. CONDITION/INDICATION IS AXLE HOUSING AND DIFFERENTIAL PROPERLY LUBRICATED? DECISION YES - Go to Step (4). NO - Fill axle housing to proper level (Volume 5, WP 0820). Go to Step (6) to verify problem is solved. 0045-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00254) TM 9-2320-272-23-1 0045 CONTINUOUS AXLE OR WHEEL NOISE - Continued STEP 4. ARE WHEEL BEARINGS IN GOOD OPERATING CONDITION? a. Visually check wheel bearing for adjustment and damage. T0530DAA Figure 4. b. Wheel Bearings. Raise vehicle wheels until they are off the ground M939 (Volume 3, WP 0484), M939A1/A2 (Volume 3, WP 0485). NOTE Excessive play indicates improperly adjusted or damaged bearings. c. Lift up on bottom of tire using prybar to determine bearing play. CONDITION/INDICATION ARE WHEEL BEARINGS IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (5). NO - Moderate play. Adjust wheel bearing(s) (Volume 3, WP 0483). Go to Step (6) to verify problem is solved. NO - Excessive play front wheel bearing damaged. Replace damaged front wheel bearings M939/A1 (Volume 3, WP 0479), M939A2 (Volume 3, WP 0481). Go to Step (6) to verify problem is solved. NO - Excessive play rear wheel bearing damaged. Replace damaged rear wheel bearings M939/A1 (Volume 3, WP 0480), M939A2 (Volume 3, WP 0482). Go to Step (6) to verify problem is solved. 0045-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00254) TM 9-2320-272-23-1 0045 CONTINUOUS AXLE OR WHEEL NOISE - Continued STEP 5. ARE FRONT AXLE SHAFTS AND UNIVERSAL JOINTS IN GOOD OPERATING CONDITION? Check front axle shafts and universal joints for defects (Volume 3, WP 0411). CONDITION/INDICATION ARE FRONT AXLE SHAFTS AND UNIVERSAL JOINTS IN GOOD OPERATING CONDITION? DECISION YES - Replace faulty axle (Volume 3, WP 0404). Go to Step (6) to verify problem is solved. NO - Repair or replace defective components (Volume 3, WP 0411). Go to Step (6) to verify problem is solved. STEP 6. IS YOUR ORIGINAL AXLE OR WHEEL NOISE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your axle or wheel noise problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL AXLE OR WHEEL NOISE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0045-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00254) TM 9-2320-272-23-1 FIELD MAINTENANCE TOWING PINTLE DOES NOT LATCH OR LOCK INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Volume 3, WP 0518 Volume 5, WP 0820 TROUBLESHOOTING PROCEDURE TOWING PINTLE DOES NOT LATCH OR LOCK NOTE Conduct these malfunction tests if the towing pintle does not latch or lock. This procedure will check the pintle hook for lubrication, damaged parts, and proper operation. 0046-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00107) 0046 TM 9-2320-272-23-1 0046 TOWING PINTLE DOES NOT LATCH OR LOCK - Continued STEP 1. IS PINTLE HOOK PROPERLY LUBRICATED? Visually check pintle hook for proper lubrication. T0987DAA Figure 1. Pintle Hook Assembly. CONDITION/INDICATION IS PINTLE HOOK PROPERLY LUBRICATED? DECISION YES - Go to Step (2). NO - Lubricate pintle (Volume 5, WP 0820). Go to Step (3) to verify problem is solved. 0046-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00107) TM 9-2320-272-23-1 0046 TOWING PINTLE DOES NOT LATCH OR LOCK - Continued STEP 2. IS PINTLE HOOK LOCK IN GOOD OPERATING CONDITION? Visually check pintle hook lock for bends, cracks, breaks and proper operation (Volume 3, WP 0518). T0987DAA Figure 2. Pintle Hook Assembly. CONDITION/INDICATION IS PINTLE HOOK LOCK IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (3) to verify problem is solved. NO - Replace defective pintle hook lock (Volume 3, WP 0518). Go to Step (3) to verify problem is solved. 0046-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00107) TM 9-2320-272-23-1 TOWING PINTLE DOES NOT LATCH OR LOCK - Continued STEP 3. IS YOUR ORIGINAL TOWING PINTLE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original towing pintle problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL TOWING PINTLE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0046-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00107) 0046 TM 9-2320-272-23-1 FIELD MAINTENANCE PINTLE HOOK DOES NOT TURN INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Volume 3, WP 0518 Volume 5, WP 0820 TROUBLESHOOTING PROCEDURE PINTLE HOOK DOES NOT TURN NOTE Conduct these malfunction tests if the pintle hook does not turn. This procedure will check the pintle hook for lubrication, proper adjustment, and a bent shaft. 0047-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00108) 0047 TM 9-2320-272-23-1 0047 PINTLE HOOK DOES NOT TURN - Continued STEP 1. IS PINTLE HOOK PROPERLY LUBRICATED? Visually check pintle hook for proper lubrication. T0566DAA Figure 1. Pintle Hook Assembly. CONDITION/INDICATION IS PINTLE HOOK PROPERLY LUBRICATED? DECISION YES - Go to Step (2). NO - Lubricate pintle (Volume 5, WP 0820). Go to Step (4) to verify problem is solved. 0047-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00108) TM 9-2320-272-23-1 0047 PINTLE HOOK DOES NOT TURN - Continued STEP 2. IS THERE PROPER CLEARANCE BETWEEN THRUST WASHER AND MOUNTING BRACKET HOUSING? a. Check clearance between thrust washer and mounting bracket housing using feeler gage. b. Check that clearance is the same all around and within .010 in +/- .007 in. (.25 mm +/- .18 mm). PINTLE HOOK THRUST WASHER MOUNTING BRACKET HOUSING T0567DAA Figure 2. Pintle Hook Mounting Housing Bracket. CONDITION/INDICATION IS THERE PROPER CLEARANCE BETWEEN THRUST WASHER AND MOUNTING BRACKET HOUSING? DECISION YES - Go to Step (3). NO - Adjust to proper clearance (Volume 3, WP 0518). Go to Step (4) to verify problem is solved. 0047-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00108) TM 9-2320-272-23-1 PINTLE HOOK DOES NOT TURN - Continued STEP 3. IS PINTLE HOOK SHAFT BENT? Visually check pintle hook shaft for bends. T0568DAA Figure 3. Pintle Hook Shaft. CONDITION/INDICATION IS PINTLE HOOK SHAFT BENT? DECISION YES - Replace bent pintle hook shaft (Volume 3, WP 0518). Go to Step (4) to verify problem is solved. NO - Go to Step (4) to verify problem is solved. STEP 4. IS YOUR ORIGINAL PINTLE HOOK PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original pintle hook problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PINTLE HOOK PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0047-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00108) 0047 TM 9-2320-272-23-1 FIELD MAINTENANCE EXCESSIVELY LOOSE LIFTING SHACKLE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Volume 3, WP 0512 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE EXCESSIVELY LOOSE LIFTING SHACKLE NOTE Conduct these malfunction tests if the lifting shackle is excessively loose. This procedure will check the shackle and shackle pin for wear and damage and the shackle mounting bracket for defective attaching hardware. 0048-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00109) 0048 TM 9-2320-272-23-1 0048 EXCESSIVELY LOOSE LIFTING SHACKLE - Continued STEP 1. IS SHACKLE PIN IN GOOD OPERATING CONDITION? Visually check shackle pin for wear and bends. SHACKLE SHACKLE PIN SHACKLE PIN REAR FRONT SHACKLE T0570DAA Figure 1. Front and Rear Shackle Pin Assembly. CONDITION/INDICATION IS SHACKLE PIN IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (2). NO - Replace worn or bent shackle pin (Volume 3, WP 0512). Go to Step (5) to verify problem is solved. 0048-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00109) TM 9-2320-272-23-1 0048 EXCESSIVELY LOOSE LIFTING SHACKLE - Continued STEP 2. IS SHACKLE PIN THE CORRECT SIZE? Visually inspect shackle pin for correct size. SHACKLE SHACKLE PIN SHACKLE PIN REAR FRONT SHACKLE T0570DAA Figure 2. Front and Rear Shackle Pin Assembly. CONDITION/INDICATION IS SHACKLE PIN THE CORRECT SIZE? DECISION YES - Go to Step (3). NO - Replace shackle pin (Volume 3, WP 0512). Go to Step (5) to verify problem is solved. 0048-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00109) TM 9-2320-272-23-1 0048 EXCESSIVELY LOOSE LIFTING SHACKLE - Continued STEP 3. IS SHACKLE IN GOOD OPERATING CONDITION? Visually inspect shackle for wear and bends. SHACKLE SHACKLE PIN SHACKLE PIN REAR FRONT SHACKLE T0570DAA Figure 3. Front and Rear Shackle Pin Assembly. CONDITION/INDICATION IS SHACKLE IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (4). NO - Replace bent or worn shackle (Volume 3, WP 0512). Go to Step (5) to verify problem is solved. 0048-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00109) TM 9-2320-272-23-1 0048 EXCESSIVELY LOOSE LIFTING SHACKLE - Continued STEP 4. IS SHACKLE MOUNTING BRACKET ATTACHING HARDWARE LOOSE, DAMAGED, OR MISSING? Visually inspect shackle mounting bracket for loose, damaged, or missing hardware. SHACKLE SHACKLE PIN SHACKLE PIN REAR FRONT SHACKLE T0570DAA Figure 4. Front and Rear Shackle Pin Assembly. CONDITION/INDICATION IS SHACKLE MOUNTING BRACKET ATTACHING HARDWARE LOOSE, DAMAGED, OR MISSING? DECISION YES - Replace defective mounting bracket hardware (Volume 3, WP 0512). Go to Step (5) to verify problem is solved. NO - Go to Step (5) to verify problem is solved. 0048-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00109) TM 9-2320-272-23-1 EXCESSIVELY LOOSE LIFTING SHACKLE - Continued STEP 5. IS YOUR ORIGINAL LOOSE LIFTING SHACKLE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original loose lifting shackle problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL LOOSE LIFTING SHACKLE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0048-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00109) 0048 TM 9-2320-272-23-1 FIELD MAINTENANCE LOOSE SPARE TIRE CARRIER INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Volume 3, WP 0522 Volume 3, WP 0523 References (cont.) Volume 3, WP 0525 Volume 3, WP 0526 Volume 3, WP 0527 Volume 3, WP 0528 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE LOOSE SPARE TIRE CARRIER NOTE Conduct these malfunction tests if the spare tire carrier is loose. This procedure will check for loose mounting hardware and damage to the carrier. 0049-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00110) 0049 TM 9-2320-272-23-1 0049 LOOSE SPARE TIRE CARRIER - Continued STEP 1. IS THE SPARE TIRE CARRIER IN GOOD OPERATING CONDITION? Check spare tire carrier for damage and loose, damaged, or missing hardware. T0572DAA Figure 1. Spare Tire Carrier. 0049-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00110) TM 9-2320-272-23-1 0049 LOOSE SPARE TIRE CARRIER - Continued T0573DAA Figure 2. Spare Tire Carrier Assembly. CONDITION/INDICATION IS THE SPARE TIRE CARRIER IN GOOD OPERATING CONDITION? DECISION NO - Repair or replace tractor spare tire carrier (M931 and M932) (Volume 3, WP 0522). Go to Step (2) to verify problem is solved. NO - Repair or replace tractor spare tire carrier (M931A1/A2 and M932A1/A2) (Volume 3, WP 0523). Go to Step (2) to verify problem is solved. NO - Repair or replace dump and van spare tire carrier (M929, M930, M934) (Volume 3, WP 0525). Go to Step (2) to verify problem is solved. NO - Repair or replace dump and van spare tire carrier (M929A1/A2, M930A1/A2, M934A1/A2) (Volume 3, WP 0526). Go to Step (2) to verify problem is solved. NO - Repair or replace cargo spare tire carrier (M923, M925, M927, M928) (Volume 3, WP 0527). Go to Step (2) to verify problem is solved. NO - Repair or replace cargo spare tire carrier (M923A1/A2, M925A1/A2, M927A1/A2, M928A1/A2) (Volume 3, WP 0528). Go to Step (2) to verify problem is solved. YES - Go to Step (2) to verify problem is solved. 0049-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00110) TM 9-2320-272-23-1 LOOSE SPARE TIRE CARRIER - Continued STEP 2. IS YOUR ORIGINAL SPARE TIRE CARRIER PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original spare tire carrier problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL SPARE TIRE CARRIER PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0049-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00110) 0049 TM 9-2320-272-23-1 FIELD MAINTENANCE UNEVEN TIRE WEAR INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) High Boy Jack Stands (Volume 5, WP 0826, Table 1, Item 24) Personnel Required (2) References Point to Point Schematics Volume 3, WP 0479 References (cont.) Volume 3, WP 0480 Volume 3, WP 0481 Volume 3, WP 0482 Volume 3, WP 0483 Volume 3, WP 0484 Volume 3, WP 0485 Volume 3, WP 0493 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE UNEVEN TIRE WEAR NOTE Conduct these malfunction tests if there is evidence of uneven tire wear. This procedure will check for loose or missing wheel lug nuts, improper toe-in adjustment and wheel bearing looseness or damage. 0050-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00101) 0050 TM 9-2320-272-23-1 0050 UNEVEN TIRE WEAR - Continued STEP 1. ARE THERE ANY LOOSE OR MISSING WHEEL LUG NUTS? Visually check for loose or missing wheel lug nuts. T0532DAA Figure 1. Lugnuts. CONDITION/INDICATION ARE THERE ANY LOOSE OR MISSING WHEEL LUG NUTS? DECISION YES - Tighten or replace wheel lug nuts M939 (Volume 3, WP 0484), M939A1/A2 (Volume 3, WP 0485). Go to Step (4) to verify problem is solved. NO - Go to Step (2). 0050-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00101) TM 9-2320-272-23-1 0050 UNEVEN TIRE WEAR - Continued STEP 2. IS FRONT TIRE TOE-IN ADJUSTMENT CORRECT? a. Check front tires for proper toe-in adjustment. b. Follow toe-in check procedure (Volume 3, WP 0493). T0533DAA Figure 2. Toe-In Adjustment. CONDITION/INDICATION IS FRONT TIRE TOE-IN ADJUSTMENT CORRECT? DECISION YES - Go to Step (3). NO - Adjust front tires toe-in (Volume 3, WP 0493). Go to Step (4) to verify problem is solved. 0050-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00101) TM 9-2320-272-23-1 0050 UNEVEN TIRE WEAR - Continued STEP 3. ARE WHEEL BEARINGS IN GOOD OPERATING CONDITION? a. Visually check wheel bearings for proper adjustment or damage. T0534DAA Figure 3. b. Wheel Bearing Assembly. Raise vehicle wheels until they are off the ground M939 (Volume 3, WP 0484), M939A1/A2 (Volume 3, WP 0485) . NOTE Excessive play indicates improperly adjusted or damaged bearings. c. Lift up on bottom of tire using a prybar to determine bearing play. 0050-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00101) TM 9-2320-272-23-1 0050 UNEVEN TIRE WEAR - Continued CONDITION/INDICATION ARE WHEEL BEARINGS IN GOOD OPERATING CONDITION? DECISION NO - Moderate play, adjustment required. Adjust wheel bearing(s) (Volume 3, WP 0483). Go to Step (4) to verify problem is solved. NO - Excessive play, front wheel bearing damage. Replace damaged wheel bearings M939/A1 (Volume 3, WP 0479), M939/A2 (Volume 3, WP 0481). Go to Step (4) to verify problem is solved. NO - Excessive play, rear wheel bearing damaged. Replace rear wheel bearings M939/A1 (Volume 3, WP 0480), M939/A2 (Volume 3, WP 0482). Go to Step (4) to verify problem is solved. YES - Go to Step (4) to verify problem is solved. STEP 4. IS YOUR ORIGINAL UNEVEN TIRE WEAR PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your uneven tire wear problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL UNEVEN TIRE WEAR PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0050-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00101) TM 9-2320-272-23-1 FIELD MAINTENANCE WHEEL SHIMMY OR WOBBLE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics Volume 3, WP 0479 Volume 3, WP 0480 References (cont.) Volume 3, WP 0481 Volume 3, WP 0482 Volume 3, WP 0483 Volume 3, WP 0484 Volume 3, WP 0485 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE WHEEL SHIMMY OR WOBBLE NOTE Conduct these malfunction tests if a wheel shimmy or wobble is detected. This procedure will check for damage to the wheels or wheel bearings. 0051-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00102) 0051 TM 9-2320-272-23-1 0051 WHEEL SHIMMY OR WOBBLE - Continued STEP 1. ARE VEHICLE WHEELS IN GOOD OPERATING CONDITION? Visually check wheels for bends or damage. T0536DAA Figure 1. Wheel. CONDITION/INDICATION ARE VEHICLE WHEELS IN GOOD OPERATING CONDITION? DECISION NO - Replace bent or damaged wheels M939 (Volume 3, WP 0484), M939A1/A2 (Volume 3, WP 0485). Go to Step (3) to verify problem is solved. YES - Go to Step (2). STEP 2. ARE WHEEL BEARINGS IN GOOD OPERATING CONDITION? 0051-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00102) TM 9-2320-272-23-1 0051 WHEEL SHIMMY OR WOBBLE - Continued a. Visually check front and rear wheel bearings for proper adjustment and damage. T1043DAA Figure 2. b. Wheel Bearing Assembly. Raise vehicle wheels until they are off the ground M939 (Volume 3, WP 0484), M939A1/A2 (Volume 3, WP 0485). NOTE Excessive play indicates improperly adjusted or damaged bearings. c. Use prybar to lift up on bottom of tire to determine bearing play. Excessive play indicates improperly adjusted or damaged bearings. CONDITION/INDICATION ARE WHEEL BEARINGS IN GOOD OPERATING CONDITION? DECISION NO - Moderate play, adjustment required. Adjust wheel bearing(s) (Volume 3, WP 0483). Go to Step (3) to verify problem is solved. NO - Excessive play, front wheel bearings damaged. Replace damaged wheel bearings M939/A1 (Volume 3, WP 0479), M939/A2 (Volume 3, WP 0481). Go to Step (3) to verify problem is solved. NO - Excessive play, rear wheel bearings damaged. Replace rear wheel bearings M939/A1 (Volume 3, WP 0480), M939/A2 (Volume 3, WP 0482). Go to Step (3) to verify problem is solved. YES - Go to Step (3) to verify problem is solved. 0051-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00102) TM 9-2320-272-23-1 WHEEL SHIMMY OR WOBBLE - Continued STEP 3. IS YOUR ORIGINAL WHEEL SHIMMY OR WOBBLE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your wheel shimmy or wobble problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL WHEEL SHIMMY OR WOBBLE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0051-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00102) 0051 TM 9-2320-272-23-1 FIELD MAINTENANCE HARD STEERING INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) High Boy Jack Stands (Volume 5, WP 0826, Table 1, Item 24) Personnel Required (2) References Point to Point Schematics Volume 3, WP 0484 Volume 3, WP 0485 Volume 3, WP 0492 References (cont.) Volume 3, WP 0493 Volume 3, WP 0496 Volume 3, WP 0501 Volume 3, WP 0505 Volume 3, WP 0506 Volume 3, WP 0507 Volume 3, WP 0508 Volume 3, WP 0534 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE HARD STEERING NOTE Conduct these malfunction tests if vehicle steering becomes hard. This procedure will check for loose or leaking hydraulic lines and hoses, steering linkage damage, binding steering knuckles, loose U-bolts and incorrect front wheel alignment. 0052-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00103) 0052 TM 9-2320-272-23-1 0052 HARD STEERING - Continued STEP 1. ARE ALL HYDRAULIC LINES AND HOSES IN GOOD CONDITION? Visually inspect all hydraulic lines and hoses for leaks. T1019DAA Figure 1. Steering Hydraulic Lines. CONDITION/INDICATION ARE ALL HYDRAULIC LINES AND HOSES IN GOOD CONDITION? DECISION NO - Steering assist cylinder hoses damaged. Replace damaged hoses (Volume 3, WP 0507). Go to Step (6) to verify problem is solved. NO - Steering pump pressure and return hoses damaged (Ross). Replace damaged hoses (Volume 3, WP 0505). Go to Step (6) to verify problem is solved. NO - Steering pump pressure and return hoses damaged (Sheppard). Replace damaged hoses (Volume 3, WP 0506). Go to Step (6) to verify problem is solved. NO - Steering gear to assist cylinder pressure lines damaged. Replace damaged pressure lines (Volume 3, WP 0508). Go to Step (6) to verify problem is solved. YES - Go to Step (2). 0052-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00103) TM 9-2320-272-23-1 0052 HARD STEERING - Continued STEP 2. IS STEERING LINKAGE IN GOOD OPERATING CONDITION? Visually inspect steering linkage for binding, damage, and improper lubrication. T1020DAA Figure 2. Steering Assembly. CONDITION/INDICATION IS STEERING LINKAGE IN GOOD OPERATING CONDITION? DECISION NO - Pitman arm damaged (Ross). Repair or replace as necessary (Volume 3, WP 0496). Go to Step (6) to verify problem is solved. NO - Pitman arm damaged (Sheppard). Repair or replace as necessary (Volume 3, WP 0501). Go to Step (6) to verify problem is solved. NO - Drag link damaged. Replace damaged drag link (Volume 3, WP 0492). Go to Step (6) to verify problem is solved. NO - Steering linkage improperly lubricated. Lubricate steering linkage (Volume 5, WP 0820). Go to Step (6) to verify problem is solved. YES - Go to Step (3). 0052-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00103) TM 9-2320-272-23-1 0052 HARD STEERING - Continued STEP 3. ARE STEERING KNUCKLES IN GOOD CONDITION? a. Raise front vehicle wheels until they are off the ground M939 (Volume 3, WP 0484), M939A1/A2 (Volume 3, WP 0485). T1021DAA Figure 3. b. Pitman Arm. Disconnect drag link at pitman arm (Volume 3, WP 0496). NOTE If binding occurs, steering knuckles may be faulty c. Turn wheels from side to side to determine if there is binding. CONDITION/INDICATION ARE STEERING KNUCKLES IN GOOD CONDITION? DECISION NO - Notify supervisor. Action may not be possible for this level of maintenance. YES - Go to Step (4). 0052-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00103) TM 9-2320-272-23-1 0052 HARD STEERING - Continued STEP 4. ARE SPRING U-BOLTS IN GOOD WORKING CONDITION? Visually check spring U-bolts for damage and looseness. T0540DAA Figure 4. Spring U-Bolts. CONDITION/INDICATION ARE SPRING U-BOLTS IN GOOD WORKING CONDITION? DECISION NO - Tighten or replace damaged U-bolts (Volume 3, WP 0534). Go to Step (6) to verify problem is solved. YES - Go to Step (5). 0052-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00103) TM 9-2320-272-23-1 0052 HARD STEERING - Continued STEP 5. IS FRONT WHEEL ALIGNMENT PROPERLY ADJUSTED? a. Make sure tires are evenly inflated to proper pressure. T1022DAA Figure 5. b. Toe-In Check. Check front wheel alignment settings (toe in check) (Volume 3, WP 0493). CONDITION/INDICATION IS FRONT WHEEL ALIGNMENT PROPERLY ADJUSTED? DECISION NO - Adjust alignment to proper setting (Volume 3, WP 0493). Go to Step (6) to verify problem is solved. YES - Go to Step (6) to verify problem is solved. STEP 6. IS YOUR ORIGINAL STEERING PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original steering problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL STEERING PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0052-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00103) TM 9-2320-272-23-1 FIELD MAINTENANCE VEHICLE WANDERS OR PULLS TO ONE SIDE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) High Boy Jack Stands (Volume 5, WP 0826, Table 1, Item 24) Wrench, Torque, Click, Ratcheting, 3/4" Drive, 600 Ft-Lb (Volume 5, WP 0826, Table 1, Item 61) Personnel Required (2) References Point to Point Schematics TM 9-2320-272-10 WP 0119 WP 0121 Volume 3, WP 0479 References (cont.) Volume 3, WP 0480 Volume 3, WP 0481 Volume 3, WP 0482 Volume 3, WP 0483 Volume 3, WP 0484 Volume 3, WP 0485 Volume 3, WP 0493 Volume 3, WP 0496 Volume 3, WP 0499 Volume 3, WP 0500 Volume 3, WP 0501 Volume 3, WP 0510 Volume 3, WP 0535 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE VEHICLE WANDERS OR PULLS TO ONE SIDE NOTE Conduct these malfunction tests if vehicle wanders or pulls to one side. This procedure will check front tires for uneven tire pressure and underinflation, uneven tire wear indicating alignment problem and dragging brakes. 0053-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00104) 0053 TM 9-2320-272-23-1 0053 VEHICLE WANDERS OR PULLS TO ONE SIDE - Continued STEP 1. ARE FRONT TIRES PROPERLY AND EVENLY INFLATED? T0543DAA Figure 1. Tire. Check front tires for underinflation and uneven tire pressure. CONDITION/INDICATION ARE FRONT TIRES PROPERLY AND EVENLY INFLATED? DECISION YES - Go to Step (2). NO - Inflate tires to proper pressure (TM 9-2320-272-10). Go to Step (11) to verify problem is solved. 0053-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00104) TM 9-2320-272-23-1 0053 VEHICLE WANDERS OR PULLS TO ONE SIDE - Continued STEP 2. IS THERE UNEVEN WEAR BETWEEN FRONT TIRES? Visually check front tires for uneven wear. T0544DAA Figure 2. Front Wheel Assembly. CONDITION/INDICATION IS THERE UNEVEN WEAR BETWEEN FRONT TIRES? DECISION YES - Adjust front wheel alignment (toe-in) (Volume 3, WP 0493). Go to Step (11) to verify problem is solved. NO - Go to Step (3). 0053-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00104) TM 9-2320-272-23-1 0053 VEHICLE WANDERS OR PULLS TO ONE SIDE - Continued STEP 3. ARE BRAKES DRAGGING? a. Check for dragging brakes. T0545DAA Figure 3. b. Truck Jack. Raise vehicle wheels until they are off the ground M939 (Volume 3, WP 0484), M939A1/A2 (Volume 3, WP 0485). NOTE Wheels should turn with slight drag when brakes are properly adjusted. c. Spin wheel by hand. CONDITION/INDICATION ARE BRAKES DRAGGING? DECISION NO - Go to Step (4). YES - Perform Vehicle Pulls Right or Left When Applying Brakes troubleshooting (WP 0121). STEP 4. ARE WHEEL BEARINGS IN GOOD OPERATING CONDITION? a. Visually check front and rear wheel bearing for adjustment and damage. 0053-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00104) TM 9-2320-272-23-1 0053 VEHICLE WANDERS OR PULLS TO ONE SIDE - Continued T0546DAA Figure 4. b. Wheel Bearing Assembly. Raise vehicle wheels until they are off the ground M939 (Volume 3, WP 0484), M939A1/A2 (Volume 3, WP 0485). NOTE Excessive play indicates improperly adjusted or damaged bearings. c. Lift up on bottom of tire using a prybar to determine bearing play. CONDITION/INDICATION ARE WHEEL BEARINGS IN GOOD OPERATING CONDITION? DECISION NO - Moderate play, adjustment required. Adjust wheel bearings (Volume 3, WP 0483). Go to Step (11) to verify problem is solved. NO - Excessive play at front wheel. Replace damaged wheel bearings M939/A1 (Volume 3, WP 0479), M939A2 (Volume 3, WP 0481). Go to Step (11) to verify problem is solved. NO - Excessive play at rear wheel. Replace rear wheel bearings M939/A1 (Volume 3, WP 0480), M939A2 (Volume 3, WP 0482). Go to Step (11) to verify problem is solved. YES - Little or no play, wheel bearings OK. Go to Step (5). 0053-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00104) TM 9-2320-272-23-1 0053 VEHICLE WANDERS OR PULLS TO ONE SIDE - Continued STEP 5. IS STEERING ASSIST CYLINDER IN GOOD OPERATING CONDITION? Check steering assist cylinder for damage and improper adjustment (Volume 3, WP 0510). T0547DAA Figure 5. Steering Assist Cylinder. CONDITION/INDICATION IS STEERING ASSIST CYLINDER IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (6). NO - Adjust or replace steering assist cylinder (Volume 3, WP 0510). Go to Step (11) to verify problem is solved. 0053-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00104) TM 9-2320-272-23-1 0053 VEHICLE WANDERS OR PULLS TO ONE SIDE - Continued STEP 6. IS TIE ROD IN GOOD OPERATING CONDITION? Visually check tie rod for looseness, bends, cracks and stripped threads (Volume 3, WP 0493). T1023DAA Figure 6. Tie Rod. CONDITION/INDICATION IS TIE ROD IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (7). NO - Tighten or replace tie rod (Volume 3, WP 0493). Go to Step (11) to verify problem is solved. 0053-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00104) TM 9-2320-272-23-1 0053 VEHICLE WANDERS OR PULLS TO ONE SIDE - Continued STEP 7. DOES VEHICLE STEER PROPERLY AFTER TIGHTENING STEERING GEAR MOUNTING BOLTS? a. Visually check for loose or missing steering gear mounting bolts. T0549DAA Figure 7. Steering Gear. b. Replace any missing mounting bolts (Ross) (Volume 3, WP 0499), (Sheppard) (Volume 3, WP 0500). c. Tighten mounting bolts to 260-280 ft-lb (353-380 N·m). d. Ensure vehicle is returned to normal operating condition. e. Check to see if your original vehicle wanders or pulls problem still exists. CONDITION/INDICATION DOES VEHICLE STEER PROPERLY AFTER TIGHTENING STEERING GEAR MOUNTING BOLTS? DECISION YES - Go to Step (11) to verify problem is solved. NO - Go to Step (8). 0053-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00104) TM 9-2320-272-23-1 0053 VEHICLE WANDERS OR PULLS TO ONE SIDE - Continued STEP 8. IS PITMAN ARM IN GOOD OPERATING CONDITION? Visually check pitman arm for wear and damage. T0550DAA Figure 8. Pitman Arm. CONDITION/INDICATION IS PITMAN ARM IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (9). NO - Replace worn pitman arm (Ross) (Volume 3, WP 0496), (Sheppard) (Volume 3, WP 0501). Go to Step (11) to verify problem is solved. 0053-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00104) TM 9-2320-272-23-1 0053 VEHICLE WANDERS OR PULLS TO ONE SIDE - Continued STEP 9. ARE FRONT SPRING SHACKLE PINS IN GOOD CONDITION? Visually check front spring shackle pins for wear or damage. T0551DAA Figure 9. Shackle Pins. CONDITION/INDICATION ARE FRONT SPRING SHACKLE PINS IN GOOD CONDITION? DECISION YES - Go to Step (10). NO - Replace worn or damaged shackle pins (Volume 3, WP 0535). Go to Step (11) to verify problem is solved. 0053-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00104) TM 9-2320-272-23-1 0053 VEHICLE WANDERS OR PULLS TO ONE SIDE - Continued STEP 10. IS FRONT TIRE TOE-IN ADJUSTMENT CORRECT? Check front tires for proper toe-in adjustment (Volume 3, WP 0493). T0541DAA Figure 10. Toe-In Check. CONDITION/INDICATION IS FRONT TIRE TOE-IN ADJUSTMENT CORRECT? DECISION YES - Go to Step (11) to verify problem is solved. NO - Adjust front tires toe-in (Volume 3, WP 0493). Go to Step (11) to verify problem is solved. STEP 11. IS YOUR ORIGINAL VEHICLE WANDERS OR PULLS PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original vehicle wanders or pulls problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL VEHICLE WANDERS OR PULLS PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0053-11/12 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00104) TM 9-2320-272-23-1 FIELD MAINTENANCE EXCESSIVE PLAY IN STEERING WHEEL INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics Volume 3, WP 0492 References (cont.) Volume 3, WP 0493 Volume 3, WP 0496 Volume 3, WP 0501 Volume 3, WP 0510 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE EXCESSIVE PLAY IN STEERING WHEEL NOTE Conduct these malfunction tests if there is excessive play in the steering wheel. This procedure will check steering wheel free play, drag link for looseness and damage, tie rod for damage and loose ends, pitman arm for damage, and steering assist cylinder for improper adjustment and damage. 0054-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00105) 0054 TM 9-2320-272-23-1 0054 EXCESSIVE PLAY IN STEERING WHEEL - Continued STEP 1. DOES STEERING WHEEL HAVE EXCESSIVE PLAY? a. Check steering wheel free play. T0554DAA Figure 1. Steering Wheel. b. With engine running, place stiff wire against dash that’s long enough to touch the steering wheel rim. c. Turn steering wheel left then right until there is resistance. d. Mark the points on the steering wheel where the travel ends. e. Measure the distance between these to points. Distance should be less than 2 1/2 in. (6.3 cm). CONDITION/INDICATION DOES STEERING WHEEL HAVE EXCESSIVE PLAY? DECISION YES - Go to Step (2). NO - Go to Step (6) to verify problem is solved. 0054-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00105) TM 9-2320-272-23-1 0054 EXCESSIVE PLAY IN STEERING WHEEL - Continued STEP 2. IS DRAG LINK IN GOOD OPERATING CONDITION? Visually check drag link for looseness and damage. T0555DAA Figure 2. Drag Link. CONDITION/INDICATION IS DRAG LINK IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (3). NO - Tighten or replace drag link (Volume 3, WP 0492). Go to Step (6) to verify problem is solved. 0054-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00105) TM 9-2320-272-23-1 0054 EXCESSIVE PLAY IN STEERING WHEEL - Continued STEP 3. IS TIE ROD IN GOOD OPERATING CONDITION? a. Visually inspect tie rod for damage and loose ends. T0556DAA Figure 3. Tie Rod. NOTE No free play is allowable. b. Check for any free play at tie rod connections. CONDITION/INDICATION IS TIE ROD IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (4). NO - Tighten or replace tie rod (Volume 3, WP 0493). Go to Step (6) to verify problem is solved. 0054-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00105) TM 9-2320-272-23-1 0054 EXCESSIVE PLAY IN STEERING WHEEL - Continued STEP 4. IS PITMAN ARM IN GOOD OPERATING CONDITION? Visually check pitman arm for damage. T0557DAA Figure 4. Pitman Arm. CONDITION/INDICATION IS PITMAN ARM IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (5). NO - Replace pitman arm (Ross) (Volume 3, WP 0496) (Sheppard) (Volume 3, WP 0501). Go to Step (6) to verify problem is solved. 0054-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00105) TM 9-2320-272-23-1 0054 EXCESSIVE PLAY IN STEERING WHEEL - Continued STEP 5. IS STEERING ASSIST CYLINDER IN GOOD OPERATING CONDITION? Check steering assist cylinder for damage and improper adjustment (Volume 3, WP 0510). T0558DAA Figure 5. Steering Assist Cylinder. CONDITION/INDICATION IS STEERING ASSIST CYLINDER IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (6) to verify problem is solved. NO - Adjust or replace steering assist cylinder (Volume 3, WP 0510). Go to Step (6) to verify problem is solved. 0054-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00105) TM 9-2320-272-23-1 0054 EXCESSIVE PLAY IN STEERING WHEEL - Continued STEP 6. IS YOUR ORIGINAL STEERING WHEEL PLAY PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original steering wheel play problem still exists. c. With engine running, place stiff wire against dash that’s long enough to touch the steering wheel rim. d. Turn steering wheel left then right until there is resistance. e. Mark the points on the steering wheel where the travel ends. f. Measure the distance between these points. Distance should be less than 2 1/2 in. (6.3 cm). CONDITION/INDICATION IS YOUR ORIGINAL STEERING WHEEL PLAY PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0054-7/8 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00105) TM 9-2320-272-23-1 FIELD MAINTENANCE SHIMMY INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) High Boy Jack Stand (Volume 5, WP 0826, Table 1, Item 24) Personnel Required (2) References Point to Point Schematics Volume 3, WP 0479 References (cont.) Volume 3, WP 0480 Volume 3, WP 0481 Volume 3, WP 0482 Volume 3, WP 0483 Volume 3, WP 0484 Volume 3, WP 0485 Volume 3, WP 0493 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE SHIMMY NOTE Conduct these malfunction tests if shimmy is detected. This procedure will check for loose or missing wheel lug nuts, damaged or bent wheels, improper wheel bearing adjustment, front wheel alignment, and loose front axle steering knuckles. 0055-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00106) 0055 TM 9-2320-272-23-1 0055 SHIMMY - Continued STEP 1. ARE THERE ANY LOOSE OR MISSING WHEEL LUG NUTS? Visually check front and rear wheels for any loose or missing wheel lug nuts. T0561DAA Figure 1. Wheel Lugnuts. CONDITION/INDICATION ARE THERE ANY LOOSE OR MISSING WHEEL LUG NUTS? DECISION YES - Replace or tighten lug nuts M939 (Volume 3, WP 0484), M939A1/A2 (Volume 3, WP 0485). Go to Step (6) to verify problem is solved. NO - Go to Step (2). 0055-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00106) TM 9-2320-272-23-1 0055 SHIMMY - Continued STEP 2. ARE VEHICLE WHEELS IN GOOD OPERATING CONDITION? Visually inspect wheels for bends and damage. T0560DAA Figure 2. Wheels. CONDITION/INDICATION ARE VEHICLE WHEELS IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (3). NO - Replace bent and damaged wheels M939 (Volume 3, WP 0484), M939A1/A2 (Volume 3, WP 0485). Go to Step (6) to verify problem is solved. 0055-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00106) TM 9-2320-272-23-1 0055 SHIMMY - Continued STEP 3. ARE WHEEL BEARINGS IN GOOD OPERATING CONDITION? a. Visually check front and rear wheels bearings for adjustment and damage. T0562DAA Figure 3. b. Wheel Bearing Assembly. Raise vehicle wheels until they are off the ground M939 (Volume 3, WP 0484), M939A1/A2 (Volume 3, WP 0485). NOTE Excessive play indicates improperly adjusted or damaged bearings. c. Lift up on bottom of tire using a prybar to determine bearing play. CONDITION/INDICATION ARE WHEEL BEARINGS IN GOOD OPERATING CONDITION? DECISION NO - Moderate play, adjustment required. Adjust wheel bearing(s) (Volume 3, WP 0483). NO - Excessive play, front wheel bearing damaged. Replace damaged wheel bearings M939/A1 (Volume 3, WP 0479), M939A2 (Volume 3, WP 0481). Go to Step (6) to verify problem is solved. NO - Excessive play, rear wheel bearing damaged. Replace rear wheel bearings M939/A1 (Volume 3, WP 0480), M939A2 (Volume 3, WP 0482). Go to Step (6) to verify problem is solved. YES - Go to Step (4). 0055-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00106) TM 9-2320-272-23-1 0055 SHIMMY - Continued STEP 4. IS FRONT WHEEL ALIGNMENT PROPERLY ADJUSTED? Check front wheels for proper alignment setting (toe in check) (Volume 3, WP 0493). T0548DAA Figure 4. Toe-In Check. CONDITION/INDICATION IS FRONT WHEEL ALIGNMENT PROPERLY ADJUSTED? DECISION YES - Go to Step (5). NO - Adjust front wheel toe-in (Volume 3, WP 0493). Go to Step (6) to verify problem is solved. 0055-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00106) TM 9-2320-272-23-1 0055 SHIMMY - Continued STEP 5. ARE FRONT AXLE STEERING KNUCKLES PROPERLY ADJUSTED? a. Check front axle steering knuckle(s) for proper adjustment. T0564DAA Figure 5. Steering Knuckle. b. Raise front vehicle wheels until they are off the ground M939 (Volume 3, WP 0484), M939A1/A2 (Volume 3, WP 0485). c. Turn wheels from side to side to check for loose steering knuckle. CONDITION/INDICATION ARE FRONT AXLE STEERING KNUCKLES PROPERLY ADJUSTED? DECISION YES - Go to Step (6) to verify problem is solved. NO - Notify supervisor. Action required may not be possible at this level of maintenance. STEP 6. IS YOUR ORIGINAL SHIMMY PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original shimmy problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL SHIMMY PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0055-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00106) TM 9-2320-272-23-1 FIELD MAINTENANCE CONTINUOUS WANDERING OR SWAYING (POOR CONTROL) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References (cont.) Volume 3, WP 0534 Volume 3, WP 0543 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE CONTINUOUS WANDERING OR SWAYING (POOR CONTROL) NOTE Conduct these malfunction tests if continuous wandering or swaying is evident. This procedure will check for breaks in front leaf springs, leaking or damaged shock absorbers and loose or damaged spring u-bolts. 0056-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00111) 0056 TM 9-2320-272-23-1 0056 CONTINUOUS WANDERING OR SWAYING (POOR CONTROL) - Continued STEP 1. ARE FRONT LEAF SPRINGS IN GOOD OPERATING CONDITION? Visually inspect front leaf springs for breaks. T0582DAA Figure 1. Leaf Springs. CONDITION/INDICATION ARE FRONT LEAF SPRINGS IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (2). NO - Replace broken main leaves (Volume 3, WP 0534). Go to Step (4) to verify problem is solved. 0056-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00111) TM 9-2320-272-23-1 0056 CONTINUOUS WANDERING OR SWAYING (POOR CONTROL) - Continued STEP 2. ARE SHOCK ABSORBERS IN GOOD OPERATING CONDITION? Visually check shock absorbers for leaks and damage. T0583DAA Figure 2. Shock Absorber. CONDITION/INDICATION ARE SHOCK ABSORBERS IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (3). NO - Replace leaking or damaged shock absorbers (Volume 3, WP 0543). Go to Step (4) to verify problem is solved. 0056-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00111) TM 9-2320-272-23-1 0056 CONTINUOUS WANDERING OR SWAYING (POOR CONTROL) - Continued STEP 3. ARE SPRING U-BOLTS PROPERLY TIGHT AND IN GOOD CONDITION? Visually check for loose and damaged spring U-bolts. T0584DAA Figure 3. U-Bolts. CONDITION/INDICATION ARE SPRING U-BOLTS PROPERLY TIGHT AND IN GOOD CONDITION? DECISION YES - Go to Step (4). NO - Tighten or replace U-bolts as necessary (Volume 3, WP 0534). Go to Step (4) to verify problem is solved. STEP 4. IS YOUR ORIGINAL VEHICLE CONTROL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original vehicle control problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL VEHICLE CONTROL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0056-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00111) TM 9-2320-272-23-1 FIELD MAINTENANCE HARSH OR HARD RIDE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 3, WP 0535 Volume 3, WP 0543 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE HARSH OR HARD RIDE NOTE Conduct these malfunction tests when a harsh or hard ride is evident. This procedure will check for improper lubrication of springs, pivots and shackle pins, frozen spring shackles and defective shock absorbers. 0057-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00112) 0057 TM 9-2320-272-23-1 0057 HARSH OR HARD RIDE - Continued STEP 1. ARE SPRINGS, PIVOTS, AND SHACKLE PINS PROPERLY LUBRICATED? Visually check springs, pivots, and shackle pins for proper lubrication. T0586DAA Figure 1. Leaf Springs, Pivots, and Shackle Pins. CONDITION/INDICATION ARE SPRINGS, PIVOTS, AND SHACKLE PINS PROPERLY LUBRICATED? DECISION YES - Go to Step (2). NO - Lubricate springs, pivots, and shackle pins (Volume 5, WP 0820). Go to Step (4) to verify problem is solved. 0057-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00112) TM 9-2320-272-23-1 0057 HARSH OR HARD RIDE - Continued STEP 2. ARE SPRING SHACKLES IN GOOD OPERATING CONDITION? Visually check spring shackles for frozen condition. T0587DAA Figure 2. Spring Shackles. CONDITION/INDICATION ARE SPRING SHACKLES IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (3). NO - Replace leaf spring shackles (Volume 3, WP 0535). Go to Step (4) to verify problem is solved. 0057-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00112) TM 9-2320-272-23-1 0057 HARSH OR HARD RIDE - Continued STEP 3. ARE SHOCK ABSORBERS IN GOOD OPERATING CONDITION? a. Test shock absorbers for resistance. b. Disconnect top end of shock absorber and pull up and down (Volume 3, WP 0543) . If there is little or no resistance, shock absorber is faulty. T0588DAA Figure 3. Shock Absorbers. CONDITION/INDICATION ARE SHOCK ABSORBERS IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (4). NO - Replace defective shock absorber (Volume 3, WP 0543). Go to Step (4) to verify problem is solved. STEP 4. IS YOUR ORIGINAL HARSH OR HARD RIDE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original harsh or hard ride problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL HARSH OR HARD RIDE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0057-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00112) TM 9-2320-272-23-1 FIELD MAINTENANCE SPRING LEAF DEFECT INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References (cont.) Volume 3, WP 0534 Volume 3, WP 0539 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE SPRING LEAF DEFECT NOTE Conduct these malfunction tests if vehicle leans to one side. This procedure will check for loose or damaged front spring shackles, loose or damaged U-bolts and nuts, and spring leaves for breaks. 0058-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00113) 0058 TM 9-2320-272-23-1 0058 SPRING LEAF DEFECT - Continued STEP 1. ARE FRONT SPRING SHACKLES IN GOOD OPERATING CONDITION? Visually inspect for loose or damaged front spring shackles. T0590DAA Figure 1. Spring Shackles. CONDITION/INDICATION ARE FRONT SPRING SHACKLES IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (2). NO - Tighten or replace as necessary (Volume 3, WP 0535). Go to Step (4) to verify problem is solved. 0058-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00113) TM 9-2320-272-23-1 0058 SPRING LEAF DEFECT - Continued STEP 2. ARE SPRING U-BOLTS PROPERLY TIGHTENED AND IN GOOD CONDITION? Visually check for damaged and loose spring U-bolts and nuts. T0591DAA Figure 2. U-Bolts. CONDITION/INDICATION ARE SPRING U-BOLTS PROPERLY TIGHTENED AND IN GOOD CONDITION? DECISION YES - Go to Step (3). NO - Tighten or replace U-bolts as necessary (Volume 3, WP 0534). Go to Step (4) to verify problem is solved. 0058-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00113) TM 9-2320-272-23-1 0058 SPRING LEAF DEFECT - Continued STEP 3. ARE SPRING LEAVES IN GOOD OPERATING CONDITION? Visually inspect front and rear spring leaves for breaks and damage. T0592DAA Figure 3. Leaf Springs and Shackle Pins. CONDITION/INDICATION ARE SPRING LEAVES IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (4) to verify problem is solved. NO - Front spring damaged. Replace damaged spring leaves (Volume 3, WP 0534). Go to Step (4) to verify problem is solved. NO - Rear spring leaves damaged. Replace damaged spring leaves (Volume 3, WP 0539). Go to Step (4) to verify problem is solved. 0058-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00113) TM 9-2320-272-23-1 SPRING LEAF DEFECT - Continued STEP 4. IS YOUR ORIGINAL VEHICLE LEANING PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original spring leaf problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL VEHICLE LEANING PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0058-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00113) 0058 TM 9-2320-272-23-1 FIELD MAINTENANCE WINCH DOES NOT OPERATE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics TM 9-2320-272-10 References (cont.) Volume 4, WP 0668 Volume 4, WP 0683 Volume 4, WP 0694 Volume 4, WP 0704 Volume 4, WP 0707 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE WINCH DOES NOT OPERATE NOTE Conduct these malfunction tests if front winch does not operate. This procedure will check for proper oil level, power takeoff linkage for breaks and adjustment, drum clutch engaged, drum lock pulled out, damaged winch control cable, oil lines for damage and leaks, return line oil filter for leaks, hydraulic oil tank filter, oil pump for leaks and overheating, and winch motor for leaks. 0059-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00114) 0059 TM 9-2320-272-23-1 0059 WINCH DOES NOT OPERATE - Continued STEP 1. IS HYDRAULIC OIL LEVEL AT PROPER LEVEL? Check reservoir for proper oil level (Volume 5, WP 0820). Wrecker only T0594DAA Figure 1. Hydraulic Oil Check. CONDITION/INDICATION IS HYDRAULIC OIL LEVEL AT PROPER LEVEL? DECISION YES - Go to Step (2). NO - Fill to proper level (Volume 5, WP 0820). Go to Step (12) to verify problem is solved. 0059-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00114) TM 9-2320-272-23-1 0059 WINCH DOES NOT OPERATE - Continued STEP 2. DOES POWER TAKEOFF ENGAGE? Engage power takeoff (TM 9-2320-272-10). T0595DAA Figure 2. Power Takeoff Controls. CONDITION/INDICATION DOES POWER TAKEOFF ENGAGE? DECISION YES - Go to Step (3). NO - Notify supervisor. Action may not be possible at this level of maintenance. 0059-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00114) TM 9-2320-272-23-1 0059 WINCH DOES NOT OPERATE - Continued STEP 3. IS POWER TAKEOFF LINKAGE IN GOOD OPERATING CONDITION? Visually inspect power takeoff linkage for breaks and proper adjustment. A B A POWER TAKEOFF CONTROL LEVER B TRANSMISSION POWER TAKEOFF T0867DAA Figure 3. Power Takeoff Linkage. CONDITION/INDICATION IS POWER TAKEOFF LINKAGE IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (4). NO - Notify supervisor. Action may not be possible at this level of maintenance. 0059-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00114) TM 9-2320-272-23-1 0059 WINCH DOES NOT OPERATE - Continued STEP 4. DOES FRONT DRUM CLUTCH ENGAGE (FRONT WINCH)? a. Engage front drum clutch (TM 9-2320-272-10). CLUTCH CONTROL LEVER T0596DAA Figure 4. b. Front Winch. Check if front drum clutch is engaged. CONDITION/INDICATION DOES FRONT DRUM CLUTCH ENGAGE (FRONT WINCH)? DECISION YES - Go to Step (5). NO - Replace front winch (Volume 4, WP 0668). Go to Step (12) to verify problem is solved. 0059-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00114) TM 9-2320-272-23-1 0059 WINCH DOES NOT OPERATE - Continued STEP 5. DOES DRUM LOCK PULL OUT? Pull out drum lock (TM 9-2320-272-10). WINCH DRUM LOCK T0597DAA Figure 5. Front Winch Drum Lock. CONDITION/INDICATION DOES DRUM LOCK PULL OUT? DECISION YES - Go to Step (6). NO - Replace front winch (Volume 4, WP 0668). Go to Step (12) to verify problem is solved. 0059-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00114) TM 9-2320-272-23-1 0059 WINCH DOES NOT OPERATE - Continued STEP 6. IS WINCH CONTROL CABLE IN GOOD OPERATING CONDITION? a. Locate winch control cable. b. Visually check winch control cable for damage. T0598DAA Figure 6. Front Winch. CONDITION/INDICATION IS WINCH CONTROL CABLE IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (7). NO - Notify supervisor. Action may not be possible at this level of maintenance. 0059-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00114) TM 9-2320-272-23-1 0059 WINCH DOES NOT OPERATE - Continued STEP 7. ARE ALL OIL LINES IN GOOD OPERATING CONDITION? a. Determine operating condition of all oil lines. Refer to point to point schematics. T0599DAA Figure 7. b. Oil Lines. Visually check all oil lines for damage and leaks. Refer to point to point schematics. CONDITION/INDICATION ARE ALL OIL LINES IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (8). NO - Replace damaged hoses (Volume 4, WP 0685). 0059-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00114) TM 9-2320-272-23-1 0059 WINCH DOES NOT OPERATE - Continued STEP 8. IS RETURN LINE OIL FILTER IN GOOD CONDITION? a. Locate oil return line filter housing. Refer to point to point schematics. b. Visually inspect oil return line filter housing for leaks. T0600DAA Figure 8. Oil Return Line. CONDITION/INDICATION IS RETURN LINE OIL FILTER IN GOOD CONDITION? DECISION YES - Go to Step (9). NO - Tighten filter housing nut (Volume 4, WP 0704). Go to Step (12) to verify problem is solved. 0059-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00114) TM 9-2320-272-23-1 0059 WINCH DOES NOT OPERATE - Continued STEP 9. IS HYDRAULIC OIL TANK FILTER IN GOOD CONDITION? NOTE If BYPASS is indicated, filter is faulty. Locate and visually inspect oil filter. T0601DAA Figure 9. Oil Filter. CONDITION/INDICATION IS HYDRAULIC OIL TANK FILTER IN GOOD CONDITION? DECISION YES - Go to Step (10). NO - Replace filter (Volume 4, WP 0704). Go to Step (12) to verify problem is solved. 0059-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00114) TM 9-2320-272-23-1 0059 WINCH DOES NOT OPERATE - Continued STEP 10. IS OIL PUMP IN GOOD OPERATING CONDITION? a. Visually check oil pump for leaks and overheating. T0602DAA Figure 10. Oil Pump. NOTE If leaks continue or overheating is detected, oil pump is faulty. b. Tighten loose fittings. CONDITION/INDICATION IS OIL PUMP IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (11). NO - Replace oil pump (Volume 4, WP 0683). Go to Step (12) to verify problem is solved. 0059-11 03/15/2011 Rel(1.8) root(tswp) wpno(T00114) TM 9-2320-272-23-1 0059 WINCH DOES NOT OPERATE - Continued STEP 11. IS WINCH MOTOR IN GOOD OPERATING CONDITION? Visually check winch motor for leaks. T0603DAA Figure 11. Winch Motor. CONDITION/INDICATION IS WINCH MOTOR IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (12) to verify problem is solved. NO - Replace winch motor (Volume 4, WP 0694). Go to Step (12) to verify problem is solved. 0059-12 03/15/2011 Rel(1.8) root(tswp) wpno(T00114) TM 9-2320-272-23-1 WINCH DOES NOT OPERATE - Continued STEP 12. IS YOUR ORIGINAL WINCH PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original winch problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL WINCH PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0059-13/14 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00114) 0059 TM 9-2320-272-23-1 FIELD MAINTENANCE WINCH OPERATES IN ONE DIRECTION ONLY INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) TM 9-2320-272-10 Volume 4, WP 0677 Volume 4, WP 0680 Volume 4, WP 0681 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE WINCH OPERATES IN ONE DIRECTION ONLY NOTE Conduct these malfunction tests if winch operates in one direction only. This procedure will check for damage to the winch control cable (front winch), in and out movement of winch check valve, damaged or leaking control valve, rear winch tensioner released and rear winch control lever engaged. 0060-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00115) 0060 TM 9-2320-272-23-1 0060 WINCH OPERATES IN ONE DIRECTION ONLY - Continued STEP 1. IS WINCH CONTROL CABLE IN GOOD OPERATING CONDITION? a. Locate winch control cable. b. Visually inspect winch control cable for signs of damage. T1047DAA Figure 1. Front Winch. CONDITION/INDICATION IS WINCH CONTROL CABLE IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (2). NO - Replace control cable (Volume 4, WP 0680). 0060-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00115) TM 9-2320-272-23-1 0060 WINCH OPERATES IN ONE DIRECTION ONLY - Continued STEP 2. IS VALVE SHAFT MOVING IN AND OUT? a. Visually check for in and out valve shaft movement. b. Check control valve for damage. CONTROL VALVE Figure 2. T0605DAA Control Valve. CONDITION/INDICATION IS VALVE SHAFT MOVING IN AND OUT? DECISION YES - M936 vehicles, go to Step (3). All other vehicles, go to Step (5) to verify problem is solved. NO - Replace control valve (Volume 4, WP 0681). 0060-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00115) TM 9-2320-272-23-1 0060 WINCH OPERATES IN ONE DIRECTION ONLY - Continued STEP 3. DOES AIR OPERATED TENSIONER RELEASE? a. Visually inspect if air operated tensioner is released. T0606DAA Figure 3. Air Operator Tensioner. b. Release tensioner (TM 9-2320-272-10). CONDITION/INDICATION DOES AIR OPERATED TENSIONER RELEASE? DECISION YES - Go to Step (4). NO - Repair cable tensioner (Volume 4, WP 0677). 0060-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00115) TM 9-2320-272-23-1 0060 WINCH OPERATES IN ONE DIRECTION ONLY - Continued STEP 4. DOES WINCH TORQUE CONTROL LEVER REMAIN ENGAGED? Attempt to engage winch torque control lever (TM 9-2320-272-10). T0607DAA Figure 4. Winch Torque Control Lever. CONDITION/INDICATION DOES WINCH TORQUE CONTROL LEVER REMAIN ENGAGED? DECISION YES - Go to Step (5) to verify problem is solved. NO - Repair cable tensioner (Volume 4, WP 0677). 0060-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00115) TM 9-2320-272-23-1 WINCH OPERATES IN ONE DIRECTION ONLY - Continued STEP 5. IS YOUR ORIGINAL WINCH PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original winch problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL WINCH PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0060-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00115) 0060 TM 9-2320-272-23-1 FIELD MAINTENANCE DRAG BRAKE DOES NOT OPERATE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 4, WP 0668 Volume 4, WP 0672 Volume 4, WP 0673 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE DRAG BRAKE DOES NOT OPERATE NOTE • Conduct these malfunction tests if winch drag brake does not operate. This procedure will check for drag brake adjustment. • M939 series vehicles utilize two types of winches depending on configuration, one type of winch uses level wind drag brake whereas the other does not. Ensure to determine the type prior to troubleshooting. 0061-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00116) 0061 TM 9-2320-272-23-1 0061 DRAG BRAKE DOES NOT OPERATE - Continued STEP 1. IS THE DRAG BRAKE PROPERLY ADJUSTED? T0609DAA Figure 1. Front Winch. a. Inspect automatic winch drag brake adjustment (Volume 4, WP 0672) on front winch. b. Inspect winch drag brake adjustment (Volume 4, WP 0673) on front and rear winch. CONDITION/INDICATION IS THE DRAG BRAKE PROPERLY ADJUSTED? DECISION NO - Automatic drag brake adjustment faulty. Adjust drag brake (Volume 4, WP 0672). Go to Step (2). NO - Drag brake adjustment faulty. Adjust drag brake (Volume 4, WP 0673). Go to Step (2). YES - Go to Step (3) to verify problem is solved. 0061-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00116) TM 9-2320-272-23-1 0061 DRAG BRAKE DOES NOT OPERATE - Continued STEP 2. WAS DRAG BRAKE SUCCESSFULLY ADJUSTED? T0609DAA Figure 2. Front Winch. NOTE If drag brake could not be adjusted, winch must be replaced. a. Inspect automatic winch drag brake adjustment (Volume 4, WP 0672) on front winch. b. Inspect winch drag brake adjustment (Volume 4, WP 0673) on front and rear winch. CONDITION/INDICATION WAS DRAG BRAKE SUCCESSFULLY ADJUSTED? DECISION YES - Go to Step (3) to verify problem is solved. NO - Front winch drag brake could not be adjusted. Replace front winch (Volume 4, WP 0668). Go to Step (3) to verify problem is solved. 0061-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00116) TM 9-2320-272-23-1 DRAG BRAKE DOES NOT OPERATE - Continued STEP 3. IS YOUR ORIGINAL WINCH PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original winch problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL WINCH PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0061-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00116) 0061 TM 9-2320-272-23-1 FIELD MAINTENANCE WINCH WILL NOT HOLD LOAD INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics Volume 4, WP 0668 References (cont.) Volume 4, WP 0669 Volume 4, WP 0672 Volume 4, WP 0673 Volume 4, WP 0722 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE WINCH WILL NOT HOLD LOAD NOTE Conduct these malfunction tests if the winch will not hold a load. This procedure will check for an improperly set torque control lever and if the automatic brake needs adjustment. 0062-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00117) 0062 TM 9-2320-272-23-1 0062 WINCH WILL NOT HOLD LOAD - Continued STEP 1. CAN TORQUE CONTROL LEVER BE SET TO HIGH OR LOW POSITION? a. Visually check torque control lever position. b. If level is not positioned in HIGH or LOW, reposition lever to HIGH or LOW. T1050DAA Figure 1. Torque Control Lever. CONDITION/INDICATION CAN TORQUE CONTROL LEVER BE SET TO HIGH OR LOW POSITION? DECISION YES - Go to Step (2). NO - Repair cable tensioner (Volume 4, WP 0677). STEP 2. CAN BRAKE SETSCREW AND WINCH CABLE TENSIONER BE ADJUSTED FOR FRONT AND REAR WINCH? a. Attempt to adjust automatic brake setscrew for front winch (Volume 4, WP 0672). b. Attempt to adjust drag brake for front winch (Volume 4, WP 0673). 0062-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00117) TM 9-2320-272-23-1 0062 WINCH WILL NOT HOLD LOAD - Continued T0610DAA Figure 2. c. Front And Rear Winches. Attempt to adjust winch cable tensioner for rear winch (Volume 4, WP 0669). CONDITION/INDICATION CAN BRAKE SETSCREW AND WINCH CABLE TENSIONER BE ADJUSTED FOR FRONT AND REAR WINCH? DECISION YES - Both front and rear winches can be adjusted. Go to Step (3) to verify problem has been solved. NO - Front winch brake cannot be adjusted. Replace front winch (Volume 4, WP 0668). Go to Step (3) to verify problem is solved. NO - Rear winch cable tensioner cannot be adjusted. Repair rear winch tensioner (Volume 4, WP 0722). Go to Step (3) to verify problem is solved. 0062-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00117) TM 9-2320-272-23-1 WINCH WILL NOT HOLD LOAD - Continued STEP 3. IS YOUR ORIGINAL WINCH HOLDING LOAD PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original winch holding load problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL WINCH HOLDING LOAD PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0062-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00117) 0062 TM 9-2320-272-23-1 FIELD MAINTENANCE AUTOMATIC BRAKE OVERHEATS INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 4, WP 0668 Volume 4, WP 0669 Volume 4, WP 0672 Volume 4, WP 0722 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE AUTOMATIC BRAKE OVERHEATS NOTE Conduct these malfunction tests if winch automatic brake overheats. This procedure will check for proper load size and automatic brake adjustment. 0063-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00118) 0063 TM 9-2320-272-23-1 0063 AUTOMATIC BRAKE OVERHEATS - Continued STEP 1. IS WINCH LOAD WITHIN WEIGHT LIMITS? NOTE • Front winch load is limited to 20,000 lb. • Rear winch load is limited to 45,000 lb. Check weight limits of winch. T0611DAA Figure 1. Front and Rear Winch. CONDITION/INDICATION IS WINCH LOAD WITHIN WEIGHT LIMITS? DECISION YES - Go to Step (2). NO - Adjust load. Go to Step (3) to verify problem is solved. 0063-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00118) TM 9-2320-272-23-1 0063 AUTOMATIC BRAKE OVERHEATS - Continued STEP 2. CAN AUTOMATIC BRAKE SETSCREW AND WINCH CABLE TENSIONER BE ADJUSTED FOR FRONT AND REAR WINCH? a. Attempt to adjust automatic brake setscrew for front winch (Volume 4, WP 0672). T0610DAA Figure 2. b. Automatic Brake Setscrew. Attempt to adjust winch cable tensioner for rear winch (Volume 4, WP 0669). CONDITION/INDICATION CAN AUTOMATIC BRAKE SETSCREW AND WINCH CABLE TENSIONER BE ADJUSTED FOR FRONT AND REAR WINCH? DECISION YES - Both front and rear winches can be adjusted. Go to Step (3) to verify problem has been solved. NO - Front winch brake cannot be adjusted. Replace front winch (Volume 4, WP 0668). Go to Step (3) to verify problem is solved. NO - Rear winch cable tensioner cannot be adjusted. Repair rear winch tensioner (Volume 4, WP 0722). Go to Step (3) to verify problem is solved. 0063-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00118) TM 9-2320-272-23-1 AUTOMATIC BRAKE OVERHEATS - Continued STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0063-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00118) 0063 TM 9-2320-272-23-1 FIELD MAINTENANCE FRONT WINCH OPERATES AT ONE SPEED ONLY INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0270 Volume 4, WP 0680 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE FRONT WINCH OPERATES AT ONE SPEED ONLY NOTE Conduct these malfunction tests if winch operates at one speed only. This procedure will check for a damaged or leaking winch control valve, winch control cable, and throttle control cable. 0064-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00119) 0064 TM 9-2320-272-23-1 0064 FRONT WINCH OPERATES AT ONE SPEED ONLY - Continued STEP 1. IS CONTROL VALVE IN GOOD CONDITION? Visually check front winch control valve for damage and leaks. CONTROL VALVE Figure 1. Winch Control Valve. CONDITION/INDICATION IS CONTROL VALVE IN GOOD CONDITION? DECISION YES - Go to Step (2). NO - Replace control valve (Volume 4, WP 0681). 0064-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00119) T1049DAA TM 9-2320-272-23-1 0064 FRONT WINCH OPERATES AT ONE SPEED ONLY - Continued STEP 2. IS WINCH CONTROL CABLE IN GOOD CONDITION? Visually inspect winch control cable for damage. T1048DAA Figure 2. Front Winch. CONDITION/INDICATION IS WINCH CONTROL CABLE IN GOOD CONDITION? DECISION YES - Go to Step (3). NO - Replace control cable (Volume 4, WP 0680). 0064-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00119) TM 9-2320-272-23-1 0064 FRONT WINCH OPERATES AT ONE SPEED ONLY - Continued STEP 3. IS THROTTLE CONTROL CABLE IN GOOD OPERATING CONDITION? Visually inspect throttle control cable for any sign of damage. HAND THROTTLE CONTROL T0608DAA Figure 3. Throttle Control Cable. CONDITION/INDICATION IS THROTTLE CONTROL CABLE IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (4) to verify problem is solved. NO - Replace throttle control cable (Volume 2, WP 0270). 0064-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00119) TM 9-2320-272-23-1 FRONT WINCH OPERATES AT ONE SPEED ONLY - Continued STEP 4. IS YOUR ORIGINAL WINCH PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original winch problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL WINCH PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0064-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00119) 0064 TM 9-2320-272-23-1 FIELD MAINTENANCE REAR WINCH CABLE TENSIONER WILL NOT OPERATE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE REAR WINCH CABLE TENSIONER WILL NOT OPERATE NOTE Conduct these malfunction tests if rear winch cable tensioner does not operate. This procedure will check for leaking air supply lines. 0065-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00120) 0065 TM 9-2320-272-23-1 0065 REAR WINCH CABLE TENSIONER WILL NOT OPERATE - Continued STEP 1. ARE AIR SUPPLY LINES IN GOOD CONDITION? a. Check air supply lines for leaks. T0613DAA Figure 1. Rear Winch Cable Tensioner. NOTE If air supply lines leaks after tightening fitting, Problem has not been solved. b. Tighten any loose fittings. CONDITION/INDICATION ARE AIR SUPPLY LINES IN GOOD CONDITION? DECISION YES - Go to Step (2) to verify problem is solved. NO - Replace damaged air lines (Volume 5, WP 0805). Go to Step (2) to verify problem is solved. STEP 2. IS YOUR ORIGINAL WINCH PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original winch problem still exists. 0065-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00120) TM 9-2320-272-23-1 REAR WINCH CABLE TENSIONER WILL NOT OPERATE - Continued CONDITION/INDICATION IS YOUR ORIGINAL WINCH PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0065-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00120) 0065 TM 9-2320-272-23-1 FIELD MAINTENANCE VEHICLE ROLLS WHILE OPERATING REAR WINCH INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References (cont.) TM 9-2320-272-10 Volume 3, WP 0420 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE VEHICLE ROLLS WHILE OPERATING REAR WINCH NOTE Conduct these malfunction tests if the vehicle rolls while operating the rear winch. This procedure will check the parking brake for proper adjustment, the spring brake for caging and the field chock positioning. 0066-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00121) 0066 TM 9-2320-272-23-1 0066 VEHICLE ROLLS WHILE OPERATING REAR WINCH - Continued STEP 1. IS PARKING BRAKE PROPERLY ADJUSTED? Test parking brake for proper adjustment (Volume 3, WP 0420). CONDITION/INDICATION IS PARKING BRAKE PROPERLY ADJUSTED? DECISION YES - Go to Step (2). NO - Adjust parking brake (Volume 3, WP 0420). Go to Step (4) to verify problem is solved. STEP 2. IS SPRING BRAKE CAGE RELEASED? Visually check if spring brake cage is released. T0617DAA Figure 1. Spring Brake. CONDITION/INDICATION IS SPRING BRAKE CAGE RELEASED? DECISION YES - Go to Step (3). NO - Release brakes (TM 9-2320-272-10). Go to Step (4) to verify problem is solved. 0066-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00121) TM 9-2320-272-23-1 0066 VEHICLE ROLLS WHILE OPERATING REAR WINCH - Continued STEP 3. IS FIELD CHOCK IN CORRECT POSITION? Visually check chock positioning. Field chocks should be facing load. T0615DAA Figure 2. Field Chocks. CONDITION/INDICATION IS FIELD CHOCK IN CORRECT POSITION? DECISION YES - Go to Step (4) to verify problem is solved. NO - Reposition chocks (TM 9-2320-272-10). Go to Step (4) to verify problem is solved. STEP 4. IS YOUR ORIGINAL VEHICLE ROLLING PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original vehicle rolling problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL VEHICLE ROLLING PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0066-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00121) TM 9-2320-272-23-1 FIELD MAINTENANCE PTO EXCESSIVELY NOISY INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 4, WP 0713 Volume 4, WP 0714 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE PTO EXCESSIVELY NOISY NOTE Conduct these malfunction tests if there is excessive noise at the transmission or transfer case power takeoff. This procedure will check universal joints for proper lubrication and propeller shafts for bends. 0067-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00122) 0067 TM 9-2320-272-23-1 0067 PTO EXCESSIVELY NOISY - Continued STEP 1. IS PTO UNIVERSAL JOINT PROPERLY LUBRICATED? Visually inspect PTO universal joint for proper lubrication. T0619DAA Figure 1. PTO Universal Joint. CONDITION/INDICATION IS PTO UNIVERSAL JOINT PROPERLY LUBRICATED? DECISION YES - Go to Step (2). NO - Lubricate PTO universal joints (Volume 5, WP 0820). Go to Step (4) to verify problem is solved. 0067-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00122) TM 9-2320-272-23-1 0067 PTO EXCESSIVELY NOISY - Continued STEP 2. IS TRANSMISSION PTO TO HYDRAULIC PUMP PROPELLER SHAFT BENT? Visually inspect propeller shaft for bend. T0620DAA Figure 2. Transmission PTO to Hydraulic Pump Propeller Shaft. CONDITION/INDICATION IS PTO UNIVERSAL JOINT PROPERLY LUBRICATED? DECISION YES - Go to Step (3). NO - Replace bent propeller shaft (Volume 4, WP 0713). Go to Step (4) to verify problem is solved. 0067-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00122) TM 9-2320-272-23-1 0067 PTO EXCESSIVELY NOISY - Continued STEP 3. IS TRANSFER CASE PTO TO HYDRAULIC PUMP PROPELLER SHAFT BENT? Visually inspect propeller shaft for bend. T0621DAA Figure 3. Transfer Case PTO to Hydraulic Pump Propeller Shaft. CONDITION/INDICATION IS TRANSFER CASE PTO TO HYDRAULIC PUMP PROPELLER SHAFT BENT? DECISION YES - Go to Step (4) to verify problem is solved. NO - Replace bent propeller shaft (Volume 4, WP 0714). Go to Step (4) to verify problem is solved. 0067-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00122) TM 9-2320-272-23-1 PTO EXCESSIVELY NOISY - Continued STEP 4. IS YOUR ORIGINAL NOISE AT POWER TAKEOFF PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original noise at power takeoff problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL NOISE AT POWER TAKEOFF PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0067-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00122) 0067 TM 9-2320-272-23-1 FIELD MAINTENANCE PTO SHIFTS HARD INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 4, WP 0729 Volume 4, WP 0730 Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE 0068-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00123) 0068 TM 9-2320-272-23-1 0068 PTO SHIFTS HARD STEP 1. IS PTO SHIFT LINKAGE PROPERLY LUBRICATED? Visually inspect PTO shift linkage for proper lubrication. T0623DAA Figure 1. PTO Shift Linkage. 0068-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00123) TM 9-2320-272-23-1 PTO SHIFTS HARD - Continued CONDITION/INDICATION IS PTO SHIFT LINKAGE PROPERLY LUBRICATED? DECISION YES - Go to Step (2). NO - Lubricate PTO shift linkage (Volume 5, WP 0820). Go to Step (3) to verify problem is solved. 0068-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00123) 0068 TM 9-2320-272-23-1 0068 PTO SHIFTS HARD - Continued STEP 2. IS PTO SHIFT LINKAGE IN GOOD OPERATING CONDITION? Visually inspect PTO shift linkage for bends, cracks, and loose, damaged or missing hardware. T0623DAA Figure 2. PTO Shift Linkage Condition. 0068-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00123) TM 9-2320-272-23-1 0068 PTO SHIFTS HARD - Continued CONDITION/INDICATION IS PTO SHIFT LINKAGE IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (3) to verify problem is solved. NO - Replace transmission PTO cable M939/A1 (Volume 4, WP 0729), M939A2 (Volume 4, WP 0730). Go to Step (3) to verify problem is solved. STEP 3. IS YOUR ORIGINAL HARD SHIFTING OF POWER TAKEOFF PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original hard shifting of power takeoff problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL HARD SHIFTING OF POWER TAKEOFF PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0068-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00123) TM 9-2320-272-23-1 FIELD MAINTENANCE PTO LEAKING LUBRICANT INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics Volume 4, WP 0728 TROUBLESHOOTING PROCEDURE PTO LEAKING LUBRICANT NOTE Conduct these malfunction tests if lubrication is leaking at PTO. This procedure will check PTO for loose mounting screws. 0069-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00124) 0069 TM 9-2320-272-23-1 PTO LEAKING LUBRICANT - Continued STEP 1. ARE MOUNTING SCREWS LOOSE? a. Inspect PTO mounting screws for looseness. b. Tighten any loose PTO mounting screws. T0624DAA Figure 1. PTO Mounting Screws. c. Visually inspect PTO for lubricant leaks. CONDITION/INDICATION ARE MOUNTING SCREWS LOOSE? DECISION YES - Tighten loose screws (Volume 4, WP 0728). Go to Step (2) to verify problem is solved. NO - Go to Step (2) to verify problem is solved. STEP 2. IS YOUR ORIGINAL LEAKING LUBRICANT AT POWER TAKEOFF PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original leaking at power takeoff problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL LEAKING LUBRICANT AT POWER TAKEOFF PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0069-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00124) 0069 TM 9-2320-272-23-1 FIELD MAINTENANCE RADIO INTERFERENCE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0300 Volume 2, WP 0301 Volume 3, WP 0352 Volume 5, WP 0780 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE RADIO INTERFERENCE NOTE Conduct these malfunction tests if there is radio interference. This track will check alternator and associated wiring. 0070-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00128) 0070 TM 9-2320-272-23-1 0070 RADIO INTERFERENCE - Continued STEP 1. IS ALTERNATOR WIRING IN GOOD CONDITION? a. Inspect alternator wiring for defects. ALTERNATOR/ ELECTRICAL WIRING T0640DAA Figure 1. Alternator Wiring. b. Inspect starter/battery wiring for frays, loose or broken connections, refer to point to point schematic. c. Inspect horn wiring for frays, loose or broken connections, refer to point to point schematic. d. Inspect transmission wiring for frays, loose or broken connections, refer to point to point schematic. e. Inspect wiring for cracked, worn, or missing insulation. CONDITION/INDICATION IS ALTERNATOR WIRING IN GOOD CONDITION? DECISION YES - Go to Step (2). NO - Repair wiring as needed (Volume 3, WP 0352). Go to Step (3) to verify problem is solved. 0070-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00128) TM 9-2320-272-23-1 0070 RADIO INTERFERENCE - Continued STEP 2. IS ALTERNATOR IN GOOD OPERATING CONDITION? NOTE Prevent open wires from touching each other, or any metal part. a. Disconnect harness connector from alternator. Refer to point to point schematics. (1) M939/A1 60 amp alternator (Volume 2, WP 0300). (2) M939A2 60 amp alternator (Volume 2, WP 0301). (3) 100 amp alternator (Volume 5, WP 0780). RADIO ALTERNATOR/ ELECTRICAL WIRING T0641DAA Figure 2. b. Alternator. Start engine. NOTE If no interference is heard, alternator is faulty. c. Listen to radio for interference. CONDITION/INDICATION IS ALTERNATOR IN GOOD OPERATING CONDITION? DECISION YES - Notify supervisor. Action may not be possible at this level of maintenance. NO - Replace faulty alternator M939/A1 60 amp (Volume 2, WP 0300), M939A2 60 amp (Volume 2, WP 0301), 100 amp (Volume 5, WP 0780). Go to Step (3) to verify problem is solved. 0070-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00128) TM 9-2320-272-23-1 RADIO INTERFERENCE - Continued STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0070-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00128) 0070 TM 9-2320-272-23-1 FIELD MAINTENANCE TRAILER WILL NOT HITCH TO FIFTH WHEEL INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Volume 3, WP 0530 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE TRAILER WILL NOT HITCH TO FIFTH WHEEL NOTE Conduct this malfunction test if trailer will not hitch to fifth wheel. This procedure will check coupling jaws for bends and breaks. 0071-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00130) 0071 TM 9-2320-272-23-1 0071 TRAILER WILL NOT HITCH TO FIFTH WHEEL - Continued STEP 1. ARE COUPLING JAWS IN GOOD OPERATING CONDITION? Visually inspect coupling jaws for bends and breaks. COUPLING JAWS T0643DAA Figure 1. Fifth Wheel. CONDITION/INDICATION ARE COUPLING JAWS IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (2) to verify problem is solved. NO - Replace damaged fifth wheel (Volume 3, WP 0530). Go to Step (2) to verify problem is solved. STEP 2. IS YOUR ORIGINAL FIFTH WHEEL HITCHING PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original fifth hitching problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL FIFTH WHEEL HITCHING PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0071-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00130) TM 9-2320-272-23-1 FIELD MAINTENANCE WRECKER HYDRAULIC SYSTEM DOES NOT OPERATE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) TM 9-2320-272-10 Volume 4, WP 0711 Volume 4, WP 0728 Volume 5, WP 0820 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE WRECKER HYDRAULIC SYSTEM DOES NOT OPERATE NOTE • Conduct these malfunction tests if hydraulic system does not operate. This procedure will check for improper oil level, power takeoff condition, hydraulic lines for leaks and oil leaks from reservoir drain plug and valves. • Rear winch controls must be in neutral for crane operation. 0072-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00131) 0072 TM 9-2320-272-23-1 0072 WRECKER HYDRAULIC SYSTEM DOES NOT OPERATE - Continued STEP 1. IS HYDRAULIC OIL LEVEL AT PROPER LEVEL? Check reservoir for proper level. T0871DAA Figure 1. Hydraulic Oil Reservoir. CONDITION/INDICATION IS HYDRAULIC OIL LEVEL AT PROPER LEVEL? DECISION YES - Go to Step (2). NO - Fill reservoir to proper level (Volume 5, WP 0820). Go to Step (5) verify problem is solved. 0072-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00131) TM 9-2320-272-23-1 0072 WRECKER HYDRAULIC SYSTEM DOES NOT OPERATE - Continued STEP 2. DOES POWER TAKEOFF ENGAGE? Engage power takeoff (TM 9-2320-272-10). T0872DAA Figure 2. Power Takeoff Controls. CONDITION/INDICATION DOES POWER TAKEOFF ENGAGE? DECISION YES - Go to Step (3). NO - Replace transmission power takeoff (Volume 4, WP 0728). Go to Step (5) to verify problem is solved. 0072-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00131) TM 9-2320-272-23-1 0072 WRECKER HYDRAULIC SYSTEM DOES NOT OPERATE - Continued STEP 3. ARE ALL OIL LINES IN GOOD OPERATING CONDITION? a. Determine operating condition of all oil lines. b. Visually check all oil lines for damage and leaks. Refer to point to point schematics. T0873DAA Figure 3. c. Oil Lines. Tighten any loose fittings. CONDITION/INDICATION ARE ALL OIL LINES IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (4). NO - Replace damaged hoses (Volume 4, WP 0711). Go to Step (5) to verify problem is solved. STEP 4. IS RESERVOIR LEAKING OIL? Visually inspect reservoir drain plug and valve for oil leaks. CONDITION/INDICATION IS RESERVOIR LEAKING OIL? DECISION YES - Reservoir valve is leaking, Close leaking valve. Go to Step (5) to verify problem is solved. YES - Reservoir drain plug is leaking. Tighten leaking drain plug. Go to Step (5) to verify problem is solved. NO - Go to Step (5) to verify problem is solved. 0072-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00131) TM 9-2320-272-23-1 WRECKER HYDRAULIC SYSTEM DOES NOT OPERATE - Continued STEP 5. IS YOUR ORIGINAL HYDRAULIC SYSTEM PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original hydraulic system problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL HYDRAULIC SYSTEM PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0072-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00131) 0072 TM 9-2320-272-23-1 FIELD MAINTENANCE WRECKER HYDRAULIC PUMP NOISY INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics Volume 5, WP 0820 TROUBLESHOOTING PROCEDURE WRECKER HYDRAULIC PUMP NOISY NOTE Conduct this malfunction test if hydraulic pump is noisy. This procedure will check for hydraulic oil level. 0073-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00132) 0073 TM 9-2320-272-23-1 0073 WRECKER HYDRAULIC PUMP NOISY - Continued STEP 1. IS HYDRAULIC OIL AT PROPER LEVEL? Check reservoir for proper level. T0875DAA Figure 1. Hydraulic Oil Level. CONDITION/INDICATION IS HYDRAULIC OIL AT PROPER LEVEL? DECISION YES - Go to Step (2) to verify problem is solved. NO - Fill reservoir to proper level (Volume 5, WP 0820). Go to Step (2) to verify problem is solved. STEP 2. IS YOUR ORIGINAL HYDRAULIC PUMP PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original hydraulic pump problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL HYDRAULIC PUMP PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0073-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00132) TM 9-2320-272-23-1 FIELD MAINTENANCE DUMP BODY WILL NOT RAISE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) TM 9-2320-272-10 Volume 4, WP 0715 Volume 4, WP 0719 Volume 4, WP 0720 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE DUMP BODY WILL NOT RAISE NOTE Conduct these malfunction tests if dump body will not raise. This procedure will check for power takeoff condition, oil leaks from hydraulic lines or control valve, condition of control valve and pump housing for leaks or overheating with power takeoff engaged. 0074-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00133) 0074 TM 9-2320-272-23-1 0074 DUMP BODY WILL NOT RAISE - Continued STEP 1. DOES POWER TAKEOFF ENGAGE? a. Check if power takeoff is engaged. b. Engage power takeoff (TM 9-2320-272-10). T0644DAA Figure 1. Power Takeoff Controls. CONDITION/INDICATION DOES POWER TAKEOFF ENGAGE? DECISION YES - Go to Step (2). NO - Notify supervisor. Action may not be possible at this level of maintenance. 0074-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00133) TM 9-2320-272-23-1 0074 DUMP BODY WILL NOT RAISE - Continued STEP 2. ARE ALL HYDRAULIC LINES IN GOOD CONDITION? a. Check all hydraulic lines for leaks and brakes. Refer to point to point schematics. T0645DAA Figure 2. b. Hydraulic Lines. Tighten loose fittings. CONDITION/INDICATION ARE ALL HYDRAULIC LINES IN GOOD CONDITION? DECISION YES - Go to Step (3). NO - Replace leaking or damaged hoses (Volume 4, WP 0715). Go to Step (6) to verify problem is solved. 0074-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00133) TM 9-2320-272-23-1 0074 DUMP BODY WILL NOT RAISE - Continued STEP 3. IS CONTROL VALVE IN GOOD CONDITION? a. Visually check control valve for leaks and damage. CONTROL VALVE Figure 3. b. T0646DAA Control Valve. Tighten loose fittings. CONDITION/INDICATION IS CONTROL VALVE IN GOOD CONDITION? DECISION YES - Go to Step (4). NO - Replace dump body control valve (Volume 4, WP 0720). Go to Step (6) to verify problem is solved. STEP 4. DOES CONTROL VALVE SHAFT MOVE IN AND OUT? a. Locate control valve. CONTROL VALVE Figure 4. b. Control Valve Movement. Check for in and out movement of control valve shaft. 0074-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00133) T0646DAA TM 9-2320-272-23-1 0074 DUMP BODY WILL NOT RAISE - Continued CONDITION/INDICATION DOES CONTROL VALVE SHAFT MOVE IN AND OUT? DECISION YES - Go to Step (5). NO - Replace dump body control valve (Volume 4, WP 0720). Go to Step (6) to verify problem is solved. STEP 5. ARE THERE LEAKS OR OVERHEATING OF PUMP HOUSING WITH POWER TAKEOFF ENGAGED? a. Visually inspect pump housing for leaks and overheating. T0647DAA Figure 5. b. Pump Housing. Tighten any loose fittings. CONDITION/INDICATION ARE THERE LEAKS OR OVERHEATING OF PUMP HOUSING WITH POWER TAKEOFF ENGAGED? DECISION YES - Replace dump hydraulic pump (Volume 4, WP 0719). Go to Step (6) to verify problem is solved. NO - Go to Step (6) to verify problem is solved. 0074-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00133) TM 9-2320-272-23-1 DUMP BODY WILL NOT RAISE - Continued STEP 6. IS YOUR ORIGINAL DUMP BODY PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original dump body problem exists. CONDITION/INDICATION IS YOUR ORIGINAL DUMP BODY PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0074-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00133) 0074 TM 9-2320-272-23-1 FIELD MAINTENANCE DUMP BODY WILL NOT LOWER INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) TM 9-2320-272-10 Volume 4, WP 0720 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE DUMP BODY WILL NOT LOWER NOTE Conducting these malfunction tests if dump body does not lower. This procedure will check for incorrect brace positioning and control valve shaft movement. 0075-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00134) 0075 TM 9-2320-272-23-1 0075 DUMP BODY WILL NOT LOWER - Continued STEP 1. ARE BRACES UNDER DUMP BODY IN RAISED POSITION? Check for braces in raised position under dump body. T0649DAA Figure 1. Dump Body Brace. CONDITION/INDICATION ARE BRACES UNDER DUMP BODY IN RAISED POSITION? DECISION YES - Lower and stow braces (TM 9-2320-272-10). Go to Step (3) to verify problem is solved. NO - Go to Step (2). STEP 2. DOES CONTROL VALVE SHAFT MOVE IN AND OUT? a. Locate valve. Refer to point to point schematics. 0075-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00134) TM 9-2320-272-23-1 0075 DUMP BODY WILL NOT LOWER - Continued CONTROL VALVE Figure 2. b. T0648DAA Control Valve. Check for control valve shaft in and out movement. CONDITION/INDICATION DOES CONTROL VALVE SHAFT MOVE IN AND OUT? DECISION YES - Go to Step (3) to verify problem is solved. NO - Replace dump control valve (Volume 4, WP 0720). Go to Step (3) to verify problem is solved. STEP 3. IS YOUR ORIGINAL DUMP BODY LOWERING PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original dump body lowering problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL DUMP BODY LOWERING PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0075-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00134) TM 9-2320-272-23-1 FIELD MAINTENANCE DUMP BODY WILL NOT HOLD IN RAISED POSITION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 4, WP 0719 Volume 4, WP 0720 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE DUMP BODY WILL NOT HOLD IN RAISED POSITION NOTE Conduct these malfunction tests if the dump body will not hold in raised position. This procedure will check for damaged hydraulic hoses and faulty control valve. 0076-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00135) 0076 TM 9-2320-272-23-1 0076 DUMP BODY WILL NOT HOLD IN RAISED POSITION - Continued STEP 1. ARE ALL HYDRAULIC LINES IN GOOD OPERATING CONDITION? a. Visually check all hydraulic lines for breaks and leaks. Refer to point to point schematics. T0650DAA Figure 1. b. Hydraulic Lines. Tighten loose fittings. CONDITION/INDICATION ARE ALL HYDRAULIC LINES IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (2). NO - Replace damaged hydraulic lines (Volume 4, WP 0715). Go to Step (3) to verify problem is solved. STEP 2. IS CONTROL VALVE IN GOOD OPERATING CONDITION? a. Visually inspect control valve for hydraulic oil leaks. 0076-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00135) TM 9-2320-272-23-1 0076 DUMP BODY WILL NOT HOLD IN RAISED POSITION - Continued CONTROL VALVE Figure 2. b. T0651DAA Control Valve. Tighten loose fitting. CONDITION/INDICATION IS CONTROL VALVE IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (3) to verify problem is solved. NO - Replace damaged or leaking valve (Volume 4, WP 0720). Go to Step (3) to verify problem is solved. STEP 3. IS YOUR ORIGINAL DUMP BODY PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original dump body problem exists. CONDITION/INDICATION IS YOUR ORIGINAL DUMP BODY PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0076-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00135) TM 9-2320-272-23-1 FIELD MAINTENANCE DUMP HYDRAULIC PUMP NOISY INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics Volume 5, WP 0820 TROUBLESHOOTING PROCEDURE DUMP HYDRAULIC PUMP NOISY NOTE Conduct this malfunction test if hydraulic pump is noisy. This procedure will check for hydraulic oil level. 0077-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00136) 0077 TM 9-2320-272-23-1 0077 DUMP HYDRAULIC PUMP NOISY - Continued STEP 1. IS HYDRAULIC OIL AT PROPER LEVEL? Check reservoir for proper level. T0652DAA Figure 1. Hydraulic Oil Level. CONDITION/INDICATION IS HYDRAULIC OIL AT PROPER LEVEL? DECISION YES - Go to Step (2) to verify problem is solved. NO - Fill reservoir to proper level (Volume 5, WP 0820). Go to Step (2) to verify problem is solved. STEP 2. IS YOUR ORIGINAL HYDRAULIC PUMP PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original hydraulic pump problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL HYDRAULIC PUMP PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0077-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00136) TM 9-2320-272-23-1 FIELD MAINTENANCE TAILGATE WILL NOT OPEN INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Volume 4, WP 0591 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE TAILGATE WILL NOT OPEN NOTE Conduct these malfunction tests if tailgate does not open. This procedure will check for bent or broken tailgate linkage. 0078-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00137) 0078 TM 9-2320-272-23-1 0078 TAILGATE WILL NOT OPEN - Continued STEP 1. ARE TAILGATE LINKAGE COMPONENT IN GOOD OPERATING CONDITION? Visually check tailgate for bent or broken components. T0654DAA Figure 1. Tailgate Linkage. CONDITION/INDICATION ARE TAILGATE LINKAGE COMPONENT IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (2) to verify problem is solved. NO - Replace bent or broken linkage (Volume 4, WP 0591). Go to Step (2) to verify problem is solved. 0078-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00137) TM 9-2320-272-23-1 TAILGATE WILL NOT OPEN - Continued STEP 2. IS YOUR ORIGINAL TAILGATE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original tailgate problem exists. CONDITION/INDICATION IS YOUR ORIGINAL TAILGATE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0078-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00137) 0078 TM 9-2320-272-23-1 FIELD MAINTENANCE SIDE PANELS HARD TO RETRACT OR EXPAND INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Volume 5, WP 0820 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE SIDE PANELS HARD TO RETRACT OR EXPAND NOTE Conduct these malfunction test if side panels are hard to retract. This procedure will check for improper lubrication of sprocket assembly and damage or dirt contamination of rollers. 0079-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00138) 0079 TM 9-2320-272-23-1 0079 SIDE PANELS HARD TO RETRACT OR EXPAND - Continued STEP 1. IS SPROCKET ASSEMBLY CLEAN AND PROPERLY LUBRICATED? Visually inspect sprocket assembly for dirt or foreign material contamination. T0662DAA Figure 1. Sprocket Assembly. CONDITION/INDICATION IS SPROCKET ASSEMBLY CLEAN AND PROPERLY LUBRICATED? DECISION YES - Go to Step (2). NO - Clean and lubricate sprocket assembly (Volume 5, WP 0820). Go to Step (3) to verify problem is solved. 0079-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00138) TM 9-2320-272-23-1 0079 SIDE PANELS HARD TO RETRACT OR EXPAND - Continued STEP 2. ARE ROLLERS IN GOOD OPERATING CONDITION? a. Visually check rollers for damage or dirt contamination. T0661DAA Figure 2. b. Rollers. If dirt contamination is detected, clean dirt from rollers. CONDITION/INDICATION ARE ROLLERS IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (3) to verify problem is solved. NO - Notify supervisor. Action may not be possible at this level of maintenance. 0079-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00138) TM 9-2320-272-23-1 SIDE PANELS HARD TO RETRACT OR EXPAND - Continued STEP 3. IS YOUR ORIGINAL SIDE PANEL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original side panel problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL SIDE PANEL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0079-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00138) 0079 TM 9-2320-272-23-1 FIELD MAINTENANCE SIDE PANEL CANNOT BE LOCKED IN RETRACT POSITION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) TROUBLESHOOTING PROCEDURE SIDE PANEL CANNOT BE LOCKED IN RETRACT POSITION NOTE Conduct these malfunction tests if side panels cannot be locked in retracted position. This procedure will check if panels align properly. 0080-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00139) 0080 TM 9-2320-272-23-1 0080 SIDE PANEL CANNOT BE LOCKED IN RETRACT POSITION - Continued STEP 1. IS SIDE PANEL FULLY RETRACTED? a. Visually check for front edge of panel to be fully retraced. T0658DAA Figure 1. Side Panel. b. If side panel front edge is not fully retracted, place heavy block of wood (2x4 or 4x4) against rub rail at front of panel. c. Strike block with heavy hammer. 0080-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00139) TM 9-2320-272-23-1 0080 SIDE PANEL CANNOT BE LOCKED IN RETRACT POSITION - Continued CONDITION/INDICATION IS SIDE PANEL FULLY RETRACTED? DECISION YES - Go to Step (2). NO - Notify supervisor. Action may not be possible at this level of maintenance. STEP 2. IS TOP OF SIDE PANEL CLOSE ENOUGH TO ROOF EDGE IN ORDER TO ENGAGE? a. Visually check if top of side panel is too far out to engage edge of roof. T0910DAA Figure 2. Roof Edge. b. If top of side panel is to far out to engage edge of roof, place heavy block of wood against flat surface of seal retainer opposite locking bar at top of side panel. c. Strike block with heavy hammer. CONDITION/INDICATION IS TOP OF SIDE PANEL CLOSE ENOUGH TO ROOF EDGE IN ORDER TO ENGAGE? DECISION YES - Go to Step (3) to verify problem is solved. NO - Notify supervisor. Action may not be possible at this level of maintenance. 0080-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00139) TM 9-2320-272-23-1 SIDE PANEL CANNOT BE LOCKED IN RETRACT POSITION - Continued STEP 3. IS YOUR ORIGINAL SIDE PANEL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original side panel problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL SIDE PANEL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0080-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00139) 0080 TM 9-2320-272-23-1 FIELD MAINTENANCE VAN BODY NOT WATERPROOF OR LIGHT TIGHT INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Volume 4, WP 0614 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE VAN BODY NOT WATERPROOF OR LIGHT TIGHT NOTE Conduct these malfunction tests if van body is not waterproof or light tight.This procedure will check for tight fit of side panels to van body, sagging end panel and seal for improper position or worn out condition. 0081-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00140) 0081 TM 9-2320-272-23-1 0081 VAN BODY NOT WATERPROOF OR LIGHT TIGHT - Continued STEP 1. IS LOWER PART OF SIDE PANEL PROPERLY POSITIONED? a. Visually inspect lower part of panel for tightness against van body. T0909DAA Figure 1. Side Panel. b. If leak is detected, place heavy block of wood against rub rail at end side of panel were leak occurs. c. Strike block with heavy hammer. CONDITION/INDICATION IS LOWER PART OF SIDE PANEL PROPERLY POSITIONED? DECISION YES - Go to Step (2). NO - Notify supervisor. Action may not be possible at this level of maintenance. 0081-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00140) TM 9-2320-272-23-1 0081 VAN BODY NOT WATERPROOF OR LIGHT TIGHT - Continued STEP 2. IS END PANEL PROPERLY POSITIONED? a. Visually check end panel for sagging. T0911DAA Figure 2. End Panel. b. If leak is detected, place heavy block of wood against rub rail at end side of panel were leak occurs. c. Strike block with heavy hammer. CONDITION/INDICATION IS END PANEL PROPERLY POSITIONED? DECISION YES - Go to Step (3). NO - Notify supervisor. Action may not be possible at this level of maintenance. 0081-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00140) TM 9-2320-272-23-1 0081 VAN BODY NOT WATERPROOF OR LIGHT TIGHT - Continued STEP 3. IS BLOCK SEAL OUT OF POSITION? a. Visually check if lip of block seal at inner rear corner of hinged roof is out of position. T0659DAA Figure 3. Block Seal. b. If seal is out of position, move side panel out to disengage corner block seal. c. Push seal lip up into correct position. d. Retract side panel and check if end panel door properly engages seal. CONDITION/INDICATION IS BLOCK SEAL OUT OF POSITION? 0081-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00140) TM 9-2320-272-23-1 0081 VAN BODY NOT WATERPROOF OR LIGHT TIGHT - Continued DECISION YES - Notify supervisor. Action may not be possible at this level of maintenance. NO - Go to Step (4). STEP 4. IS REAR DOOR SEAL IN GOOD CONDITION? Visually check for worn or loose seal at top of rear doors. T0660DAA Figure 4. Rear Door Seal. CONDITION/INDICATION IS REAR DOOR SEAL IN GOOD CONDITION? DECISION YES - Go to Step (5) to verify problem is solved. NO - Replace rear door seal (Volume 4, WP 0614). Go to Step (5) to verify problem is solved. 0081-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00140) TM 9-2320-272-23-1 VAN BODY NOT WATERPROOF OR LIGHT TIGHT - Continued STEP 5. IS YOUR ORIGINAL PANEL FIT PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original panel fit problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PANEL FIT PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0081-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00140) 0081 TM 9-2320-272-23-1 FIELD MAINTENANCE DOOR LOCK WILL NOT OPERATE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Volume 4, WP 0616 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE DOOR LOCK WILL NOT OPERATE NOTE Conduct these malfunction tests if door lock will not operate. This procedure will check for a jammed vertical bar, and alignment of vertical bar and striker plate. 0082-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00141) 0082 TM 9-2320-272-23-1 0082 DOOR LOCK WILL NOT OPERATE - Continued STEP 1. IS DOOR LOCK JAMMED? a. Open door with faulty door lock. VERTICAL BAR HANDLE DOOR LOCK T0665DAA Figure 1. b. Door Lock. Turn door handle to see if vertical bar move freely. CONDITION/INDICATION IS DOOR LOCK JAMMED? DECISION YES - Disassemble and repair lock assembly (Volume 4, WP 0616). Go to Step (3) to verify problem is solved. NO - Go to Step (2). 0082-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00141) TM 9-2320-272-23-1 0082 DOOR LOCK WILL NOT OPERATE - Continued STEP 2. ARE VERTICAL BAR AND STRIKER PLATE ALIGNED? Slowly pull faulty door closed while watching alignment of vertical bar and striker plate. DOOR FRAME STRIKER PLATE VERTICAL BAR T0666DAA Figure 2. Striker Plate. CONDITION/INDICATION ARE VERTICAL BAR AND STRIKER PLATE ALIGNED? DECISION YES - Add or remove shims behind lock until bolt properly engages striker plate (Volume 4, WP 0616). Go to Step (3) to verify problem is solved. NO - Go to Step (3) to verify problem is solved. 0082-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00141) TM 9-2320-272-23-1 DOOR LOCK WILL NOT OPERATE - Continued STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0082-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00141) 0082 TM 9-2320-272-23-1 FIELD MAINTENANCE ENGINE AND VEHICLE ELECTRICAL SYSTEMS MALFUNCTIONING INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) WP 0089 Volume 2, WP 0319 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE ENGINE AND VEHICLE ELECTRICAL SYSTEMS MALFUNCTIONING NOTE Conduct these malfunction tests if engine and vehicle electrical systems are malfunctioning. This procedure will check the protective control box function. STEP 1. ARE VEHICLE GROUND STRAPS SECURELY FASTENED? a. Ensure ground straps are securely fastened. b. Ensure no paint is under starwashers. CONDITION/INDICATION ARE VEHICLE GROUND STRAPS SECURELY FASTENED? DECISION NO - Remove paint and secure ground strap. Go to Step (3) to verify problem is solved. YES - Go to Step (2). 0083-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00143) 0083 TM 9-2320-272-23-1 0083 ENGINE AND VEHICLE ELECTRICAL SYSTEMS MALFUNCTIONING - Continued STEP 2. IS PROTECTIVE CONTROL BOX FAULTY? PROTECTIVE CONTROL BOX PROTECTIVE CONTROL CONNECTOR Figure 1. T1106DAA Protective Control Box. NOTE If thug is heard when connector is disconnected, protective control box is faulty. a. Unplug harness connector from protective control box. b. Listen for protective control box to reset. CONDITION/INDICATION IS PROTECTIVE CONTROL BOX FAULTY? DECISION YES - Replace protective control box (Volume 2, WP 0319). Go to Step (3) to verify problem is solved. NO - Perform No Or Low Alternator Output troubleshooting (WP 0089). 0083-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00143) TM 9-2320-272-23-1 ENGINE AND VEHICLE ELECTRICAL SYSTEMS MALFUNCTIONING - Continued STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0083-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00143) 0083 TM 9-2320-272-23-1 FIELD MAINTENANCE ENGINE WILL NOT CRANK; SOME ELECTRICAL SYSTEMS INOPERATIVE OR WEAK INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) TM 9-6140-200-14 Volume 2, WP 0346 Volume 2, WP 0349 Volume 2, WP 0350 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE ENGINE WILL NOT CRANK; SOME ELECTRICAL SYSTEMS INOPERATIVE OR WEAK NOTE Conduct these malfunction tests if some electrical systems are inoperative or weak. This procedure will check the battery terminals, posts, cases and cables as well as battery electrolyte levels, specific gravity and voltage. 0084-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00145) 0084 TM 9-2320-272-23-1 0084 ENGINE WILL NOT CRANK; SOME ELECTRICAL SYSTEMS INOPERATIVE OR WEAK - Continued STEP 1. ARE THE BATTERIES IN GOOD CONDITION? a. Visually check batteries for cracks or leaks. T0679DAA Figure 1. b. Batteries. Visually check batteries for loose or broken terminal posts. Clean corroded terminal posts to bright metal. CONDITION/INDICATION ARE THE BATTERIES IN GOOD CONDITION? DECISION NO - Replace faulty battery (Volume 2, WP 0346). Go to Step (6) to verify problem is solved. YES - Go to Step (2). 0084-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00145) TM 9-2320-272-23-1 0084 ENGINE WILL NOT CRANK; SOME ELECTRICAL SYSTEMS INOPERATIVE OR WEAK - Continued STEP 2. ARE BATTERY TERMINALS OR CABLES LOOSE, BROKEN, OR WORN? a. Visually check batteries for loose, broken, or worn terminals. Refer to point to point schematics. T0680DAA Figure 2. b. Battery Terminals. Visually check batteries for loose, broken, or worn cables. CONDITION/INDICATION ARE BATTERY TERMINALS OR CABLES LOOSE, BROKEN, OR WORN? DECISION YES - Battery terminals or cables loose, broken, or worn. Replace damaged terminals and cables (Volume 2, WP 0349). Go to Step (6) to verify problem is solved. YES - Battery ground cables loose, broken, or worn. Replace damaged cables (Volume 2, WP 0350). Go to Step (6) to verify problem is solved. NO - Go to Step (3). 0084-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00145) TM 9-2320-272-23-1 0084 ENGINE WILL NOT CRANK; SOME ELECTRICAL SYSTEMS INOPERATIVE OR WEAK - Continued STEP 3. IS THE ELECTROLYTE IN EACH BATTERY CELL AT THE PROPER LEVEL? Check electrolyte level in each battery cell (TM 9-6140-200-14). T0681DAA Figure 3. Specific Gravity Test. CONDITION/INDICATION IS THE ELECTROLYTE IN EACH BATTERY CELL AT THE PROPER LEVEL? DECISION NO - Fill each cell to the fill ring with distilled water (TM 9-6140-200-14). Go to Step (4). YES - Go to Step (4). 0084-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00145) TM 9-2320-272-23-1 0084 ENGINE WILL NOT CRANK; SOME ELECTRICAL SYSTEMS INOPERATIVE OR WEAK - Continued STEP 4. ARE BATTERIES SPECIFIC GRAVITY READINGS CORRECT? a. Perform a specific gravity test (TM 9-6140-200-14). T0681DAA Figure 4. Specific Gravity Test. b. Batteries must test 1.225 or greater, temperature corrected. c. Each cell in a battery must test within 25 points of the other cells. d. If any battery or batteries do not meet requirements, recharge as required (TM 9-6140-200-14). e. Perform specific gravity test again. CONDITION/INDICATION ARE BATTERIES SPECIFIC GRAVITY READINGS CORRECT? DECISION NO - Replace defective battery (Volume 2, WP 0346). Go to Step (6) to verify problem is solved. YES - Go to Step (5). 0084-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00145) TM 9-2320-272-23-1 0084 ENGINE WILL NOT CRANK; SOME ELECTRICAL SYSTEMS INOPERATIVE OR WEAK - Continued STEP 5. IS BATTERY VOLTAGE DROP 1 VOLT OR GREATER UNDER LOAD? a. Set up multimeter to measure VDC. STARTER SOLENOID STARTER MOTOR T0682DAA Figure 5. Battery/Solenoid Voltage Test. b. Connect multimeter red lead to starter, terminal 6. Refer to point to point schematics. c. Connect multimeter black lead to ground. d. Note meter reading. e. Turn headlight switch and battery switch to ON position for 15 seconds (headlights on bright). f. Voltage should not drop more than 1 volt. CONDITION/INDICATION IS BATTERY VOLTAGE DROP 1 VOLT OR GREATER UNDER LOAD? DECISION YES - Recharge batteries (Volume 2, WP 0346). Go to Step (6) to verify problem is solved. NO - Notify supervisor. It is possible another troubleshooting work package applies. 0084-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00145) TM 9-2320-272-23-1 0084 ENGINE WILL NOT CRANK; SOME ELECTRICAL SYSTEMS INOPERATIVE OR WEAK - Continued STEP 6. IS YOUR ORIGINAL ELECTRICAL SYSTEMS PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original electrical systems problem still exists. Refer to point to point schematics. CONDITION/INDICATION IS YOUR ORIGINAL ELECTRICAL SYSTEMS PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0084-7/8 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00145) TM 9-2320-272-23-1 FIELD MAINTENANCE ALL VEHICLE ELECTRICAL SYSTEMS INOPERATIVE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0319 Volume 2, WP 0346 Volume 2, WP 0349 Volume 2, WP 0350 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE ALL VEHICLE ELECTRICAL SYSTEMS INOPERATIVE NOTE Conduct these malfunction tests if all vehicle electrical systems are inoperative. This procedure will check the battery cable connections, batteries, and the protective control box. 0085-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00146) 0085 TM 9-2320-272-23-1 0085 ALL VEHICLE ELECTRICAL SYSTEMS INOPERATIVE - Continued STEP 1. ARE BATTERIES CONNECTED PROPERLY? a. Place battery switch to OFF position. b. Verify batteries are properly connected. Refer to point to point schematics. T1052DAA Figure 1. Battery Terminals. CONDITION/INDICATION ARE BATTERIES CONNECTED PROPERLY? DECISION YES - Go to Step (2). NO - Connect batteries properly (Volume 2, WP 0346). Go to Step (7) to verify problem is solved. 0085-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00146) TM 9-2320-272-23-1 0085 ALL VEHICLE ELECTRICAL SYSTEMS INOPERATIVE - Continued STEP 2. ARE THE BATTERIES IN GOOD CONDITION? Visually check batteries for cracks, leaks, and loose or broken terminal posts. Clean corroded terminal posts to bright metal (Volume 2, WP 0346). T1052DAA Figure 2. Battery Terminals. CONDITION/INDICATION ARE THE BATTERIES IN GOOD CONDITION? DECISION YES - Go to Step (3). NO - Replace faulty battery (Volume 2, WP 0346). Go to Step (7) to verify problem is solved. 0085-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00146) TM 9-2320-272-23-1 0085 ALL VEHICLE ELECTRICAL SYSTEMS INOPERATIVE - Continued STEP 3. ARE BATTERY TERMINALS OR CABLES LOOSE, BROKEN, OR WORN? Visually check batteries for loose, broken, or worn terminals and cables. Refer to point to point schematics. T1052DAA Figure 3. Battery Terminals. CONDITION/INDICATION ARE BATTERY TERMINALS OR CABLES LOOSE, BROKEN, OR WORN? DECISION YES - Battery terminals or cables loose, broken, or worn. Replace damaged terminals and cables (Volume 2, WP 0349). Go to Step (7) to verify problem is solved. YES - Battery ground cables loose, broken, or worn. Replace damaged cables (Volume 2, WP 0350). Go to Step (7) to verify problem is solved. NO - Go to Step (4). 0085-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00146) TM 9-2320-272-23-1 0085 ALL VEHICLE ELECTRICAL SYSTEMS INOPERATIVE - Continued STEP 4. IS THE ELECTROLYTE IN EACH BATTERY CELL AT THE PROPER LEVEL? a. Check electrolyte level in each battery cell (TM 9-6140-200-14). T1053DAA Figure 4. b. Specific Gravity Test. Fill each cell to the fill ring with distilled water (TM 9-6140-200-14). CONDITION/INDICATION IS THE ELECTROLYTE IN EACH BATTERY CELL AT THE PROPER LEVEL? DECISION YES - Go to Step (5). NO - Electrolyte was low. Go to Step (5). 0085-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00146) TM 9-2320-272-23-1 0085 ALL VEHICLE ELECTRICAL SYSTEMS INOPERATIVE - Continued STEP 5. ARE BATTERIES SPECIFIC GRAVITY READINGS CORRECT? a. Perform a specific gravity test (TM 9-6140-200-14). T1053DAA Figure 5. Specific Gravity Test. b. Batteries must test 1.225 or greater, temperature corrected. c. Each cell in a battery must test within 25 points of the other cells. d. If any battery or batteries do not meet requirements, recharge as required. e. Perform specific gravity test again. CONDITION/INDICATION ARE BATTERIES SPECIFIC GRAVITY READINGS CORRECT? DECISION YES - Go to Step (6). NO - Replace defective battery (Volume 2, WP 0346). Go to Step (7) to verify problem is solved. STEP 6. IS THERE CONTINUITY BETWEEN PIN C AND PIN D OF THE PROTECTIVE CONTROL BOX? a. Place battery switch to OFF position. b. Disconnect circuit 81 connector from protective control box. Refer to point to point schematics. c. Set up multimeter to read ohms. 0085-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00146) TM 9-2320-272-23-1 0085 ALL VEHICLE ELECTRICAL SYSTEMS INOPERATIVE - Continued PROTECTIVE CONTROL BOX PROTECTIVE CONTROL BOX F A G E B D C PROTECTIVE CONTROL CONNECTOR T1097DAA Figure 6. Protection Control Box Test. d. Connect jumper wire between circuit 81 connector, terminal A, and protective control box connector, terminal A. e. Connect multimeter red lead to protective control box pin D. f. Connect multimeter black lead to protective control box pin C. g. Place battery switch to ON position. h. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PIN C AND PIN D OF THE PROTECTIVE CONTROL BOX? DECISION YES - Notify supervisor. Action may not be possible at this level of maintenance. NO - Replace protective control box (Volume 2, WP 0319). Go to Step (7) to verify problem is solved. 0085-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00146) TM 9-2320-272-23-1 ALL VEHICLE ELECTRICAL SYSTEMS INOPERATIVE - Continued STEP 7. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0085-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00146) 0085 TM 9-2320-272-23-1 FIELD MAINTENANCE STARTER MOTOR INOPERATIVE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) WP 0087 WP 0088 Volume 2, WP 0303 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE STARTER MOTOR INOPERATIVE NOTE Conduct these malfunction tests if the starter motor is inoperative. This procedure will check for a faulty starter motor and solenoid. 0086-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00147) 0086 TM 9-2320-272-23-1 0086 STARTER MOTOR INOPERATIVE - Continued STEP 1. DOES THE STARTER MOTOR SOLENOID ENERGIZE? a. Place battery switch to ON position. BATTERY SWITCH STARTER SWITCH INSTRUMENT PANEL T0692DAA Figure 1. Battery and Starter Switches. NOTE If thump is heard when starter switch is position to START, solenoid is energized. b. Turn starter switch to START. CONDITION/INDICATION DOES THE STARTER MOTOR SOLENOID ENERGIZE? DECISION NO - Go to Step (2). YES - Perform Solenoid Operates, Starter Operates, But Engine Cranks Slowly troubleshooting (WP 0087). 0086-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00147) TM 9-2320-272-23-1 0086 STARTER MOTOR INOPERATIVE - Continued STEP 2. IS THERE BATTERY VOLTAGE AT THE STARTER? a. Verify battery switch is set to ON position. b. Set up multimeter to measure VDC. STARTER SOLENOID STARTER MOTOR T0924DAA Figure 2. Battery/Solenoid Voltage Test. c. Connect multimeter red lead to starter, terminal 6. Refer to point to point schematics. d. Connect multimeter black lead to ground. e. Turn starter switch to START. f. Meter reading should be between 22 and 26 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT THE STARTER? DECISION NO - Perform Starter Motor Inoperative, No Solenoid Thump troubleshooting (WP 0088). YES - Replace starter motor and solenoid (Volume 2, WP 0303). Go to Step (3) to verify problem is solved. 0086-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00147) TM 9-2320-272-23-1 STARTER MOTOR INOPERATIVE - Continued STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0086-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00147) 0086 TM 9-2320-272-23-1 FIELD MAINTENANCE SOLENOID OPERATES, STARTER OPERATES, BUT ENGINE CRANKS SLOWLY INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) TM 9-6140-200-14 Volume 2, WP 0303 Volume 2, WP 0349 Volume 2, WP 0350 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE SOLENOID OPERATES, STARTER OPERATES, BUT ENGINE CRANKS SLOWLY NOTE Conduct these malfunction tests if the starter motor and solenoid operate, but the engine cranks slowly. This procedure will check for faulty batteries, starter motor and solenoid. It will also check for bad cable connections at the batteries, starter, and ground. 0087-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00148) 0087 TM 9-2320-272-23-1 0087 SOLENOID OPERATES, STARTER OPERATES, BUT ENGINE CRANKS SLOWLY - Continued STEP 1. ARE THE BATTERIES OVERHEATING? a. Pull Engine Stop handle to prevent engine from starting. BATTERY SWITCH ENGINE STOP CONTROL STARTER SWITCH INSTRUMENT PANEL T0696DAA Figure 1. Engine Stop Control Switch. b. Crank engine for 15 seconds. c. Check batteries for overheating by feeling battery terminal connections. CONDITION/INDICATION ARE THE BATTERIES OVERHEATING? DECISION YES - Repair, clean, and tighten all hot battery terminal (Volume 2, WP 0349), starter (Volume 2, WP 0303), and ground (Volume 2, WP 0350) connections. Go to Step (9) to verify problem is solved. NO - Go to Step (2). 0087-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00148) TM 9-2320-272-23-1 0087 SOLENOID OPERATES, STARTER OPERATES, BUT ENGINE CRANKS SLOWLY - Continued STEP 2. IS THE SPECIFIC GRAVITY NORMAL FOR EACH BATTERY? a. Perform a specific gravity test on each battery (TM 9-6140-200-14). BATTERY TESTER BATTERIES T0697DAA Figure 2. Specific Gravity Test. b. Each battery must test 1.225 or greater, temperature corrected. c. Each cell in a battery must test within 25 points of the others. CONDITION/INDICATION IS THE SPECIFIC GRAVITY NORMAL FOR EACH BATTERY? DECISION NO - Go to Step (3). YES - Go to Step (4). 0087-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00148) TM 9-2320-272-23-1 0087 SOLENOID OPERATES, STARTER OPERATES, BUT ENGINE CRANKS SLOWLY - Continued STEP 3. IS THE SPECIFIC GRAVITY NORMAL FOR EACH BATTERY? a. Charge all batteries that failed the specific gravity test (TM 9-6140-200-14). T0920DAA Figure 3. Specific Gravity Test. b. Perform another specific gravity test on each newly charged battery. c. Each battery must test 1.225 or greater, temperature corrected. d. Each cell in a battery must test within 25 points of the others. CONDITION/INDICATION IS THE SPECIFIC GRAVITY NORMAL FOR EACH BATTERY? DECISION NO - Replace defective battery (Volume 2, WP 0346). Go to Step (9) to verify problem is solved. YES - Go to Step (4). 0087-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00148) TM 9-2320-272-23-1 0087 SOLENOID OPERATES, STARTER OPERATES, BUT ENGINE CRANKS SLOWLY - Continued STEP 4. IS STARTER MOTOR VOLTAGE NORMAL? a. Set up multimeter to measure VDC. STARTER SOLENOID STARTER MOTOR T0925DAA Figure 4. Battery/Solenoid Voltage Test. b. Connect multimeter red lead to starter, terminal 6. Refer to point to point schematics. c. Connect multimeter black lead to ground. d. Turn battery switch to ON position. e. Assistant cranks engine. f. Meter reading should be 22 VDC or greater while engine is cranked. CONDITION/INDICATION IS STARTER MOTOR VOLTAGE NORMAL? DECISION NO - Repair, clean, and tighten all battery terminal (Volume 2, WP 0349), starter (Volume 2, WP 0303), and ground (Volume 2, WP 0350) connections. Go to Step (9) to verify problem is solved. YES - Go to Step (5). 0087-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00148) TM 9-2320-272-23-1 0087 SOLENOID OPERATES, STARTER OPERATES, BUT ENGINE CRANKS SLOWLY - Continued STEP 5. IS STARTER MOTOR TO SOLENOID VOLTAGE DROP NORMAL? a. Connect multimeter red lead to motor terminal stud of solenoid. Refer to point to point schematics. RED BLACK 6 74 7 T0698DAA Figure 5. Starter Motor To Solenoid Voltage Drop Test. b. Connect multimeter black lead to positive terminal stud of starter motor. c. Assistant cranks engine. d. Meter reading should be less than or equal to 0.1 VDC while engine is cranked. CONDITION/INDICATION IS STARTER MOTOR TO SOLENOID VOLTAGE DROP NORMAL? DECISION NO - Repair, clean, and tighten motor to solenoid battery voltage strap terminal connections (Volume 2, WP 0303). Go to Step (9) to verify problem is solved. YES - Go to Step (6). 0087-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00148) TM 9-2320-272-23-1 0087 SOLENOID OPERATES, STARTER OPERATES, BUT ENGINE CRANKS SLOWLY - Continued STEP 6. IS VOLTAGE DROP ACROSS STARTER MOTOR SOLENOID CONTACTS NORMAL? a. Connect multimeter red lead to starter motor solenoid terminal as shown. Refer to point to point schematics. RED BLACK 6 74 7 T0699DAA Figure 6. Starter Motor Solenoid Voltage Drop Test. b. Connect multimeter black lead to starter motor solenoid terminal as shown. c. Assistant cranks engine. d. Meter reading should be less than or equal to 0.4 VDC while engine is cranked. CONDITION/INDICATION IS VOLTAGE DROP ACROSS STARTER MOTOR SOLENOID CONTACTS NORMAL? DECISION NO - Replace starter motor and solenoid assembly (Volume 2, WP 0303). Go to Step (9) to verify problem is solved. YES - Go to Step (7). 0087-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00148) TM 9-2320-272-23-1 0087 SOLENOID OPERATES, STARTER OPERATES, BUT ENGINE CRANKS SLOWLY - Continued STEP 7. IS NEGATIVE CABLE 7 VOLTAGE DROP NORMAL BETWEEN BATTERIES AND STARTER MOTOR? a. Connect multimeter red lead to terminal stud on end plate of starter motor. Refer to point to point schematics. 6 74 7 RED 68-6 BLACK 68 68 T0700DAA 68-6 Figure 7. Starter Motor Ground Voltage Drop Test. b. Connect multimeter black lead to grounding point at batteries. c. Assistant cranks engine. d. Meter reading should be less than or equal to 0.4 VDC while engine is cranked. CONDITION/INDICATION IS NEGATIVE CABLE 7 VOLTAGE DROP NORMAL BETWEEN BATTERIES AND STARTER MOTOR? DECISION NO - Repair, clean, and tighten all cable connections at batteries (Volume 2, WP 0350), starter (Volume 2, WP 0303), and chassis. Go to Step (9) to verify problem is solved. YES - Go to Step (8). 0087-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00148) TM 9-2320-272-23-1 0087 SOLENOID OPERATES, STARTER OPERATES, BUT ENGINE CRANKS SLOWLY - Continued STEP 8. IS POSITIVE CABLE 6 VOLTAGE DROP NORMAL BETWEEN BATTERIES AND STARTER MOTOR? a. Connect multimeter red lead to positive terminal point on batteries. Refer to point to point schematics. BLACK 6 74 7 68-6 RED 68 68-6 68 T0701DAA Figure 8. Starter Motor Cable Voltage Drop Test. b. Connect multimeter black lead to positive terminal on starter motor solenoid. c. Assistant cranks engine. d. Meter reading should be less than or equal to 0.4 VDC while engine is cranked. CONDITION/INDICATION IS POSITIVE CABLE 6 VOLTAGE DROP NORMAL BETWEEN BATTERIES AND STARTER MOTOR? DECISION NO - Repair, clean, and tighten all cable connections at batteries (Volume 2, WP 0349) and starter (Volume 2, WP 0303). Go to Step (9) to verify problem is solved. YES - Replace starter motor and solenoid assembly (Volume 2, WP 0303). Go to Step (9) to verify problem is solved. 0087-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00148) TM 9-2320-272-23-1 SOLENOID OPERATES, STARTER OPERATES, BUT ENGINE CRANKS SLOWLY - Continued STEP 9. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0087-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00148) 0087 TM 9-2320-272-23-1 FIELD MAINTENANCE STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics WP 0084 References (cont.) Volume 2, WP 0300 Volume 2, WP 0301 Volume 2, WP 0307 Volume 2, WP 0319 Volume 2, WP 0346 Volume 3, WP 0352 Volume 3, WP 0366 Volume 5, WP 0780 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP NOTE Conduct these malfunction tests if the starter motor is inoperative and there is no solenoid thump. This procedure will check for faulty wires 81A/81, 459, 81, 74, 5A/5B, 498, 499, and 566. It will also check for a faulty alternator, battery switch, start switch, neutral start switch, and protective control box. 0088-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) 0088 TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 1. ARE ELECTRICAL SYSTEMS OTHER THAN THE STARTING SYSTEM NOT WORKING? a. Place battery switch to ON position. INSTRUMENT PANEL LIGHT SWITCH T0706DAA Figure 1. Light Switch. b. Check operation of lights. c. If lights fail to function, or are very low in brilliance system fails test. CONDITION/INDICATION ARE ELECTRICAL SYSTEMS OTHER THAN THE STARTING SYSTEM NOT WORKING? DECISION YES - Perform Engine Will Not Crank, Some Electrical System Inoperative Or Weak troubleshooting (WP 0084). NO - Go to Step (2). 0088-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 2. DOES THE ENGINE START IF THE STARTER LOCKOUT IS RESET? a. Place battery switch to ON position. PROTECTIVE CONTROL BOX PROTECTIVE CONTROL CONNECTOR Figure 2. T0707DAA Protective Control Box. b. Disconnect harness connector from protective control box. c. Reconnect harness connector to protective control box to reset starter lockout switch. d. Start engine. CONDITION/INDICATION DOES THE ENGINE START IF THE STARTER LOCKOUT IS RESET? DECISION NO - Go to Step (3). YES - Replace alternator M939/A1 60 amp (Volume 2, WP 0300), M939A2 60 amp (Volume 2, WP 0301), 100 amp (Volume 5, WP 0780). Go to Step (15) to verify problem is solved. 0088-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 3. IS THERE BATTERY VOLTAGE TO PIN A OF THE BATTERY SWITCH? a. Disconnect lead 81A (pin A) from the battery switch. b. Set up multimeter to measure VDC. BATTERY SWITCH 459 569A 569 81A 81 B D C A VOM TO PROTECTIVE CONTROL BOX FROM STARTER T0708DAA Figure 3. Battery Switch Wire 81A. c. Connect multimeter red lead to disconnected lead 81A. Refer to point to point schematics. d. Connect multimeter black lead to a known good ground. e. Meter reading should be between 22 and 26 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE TO PIN A OF THE BATTERY SWITCH? DECISION NO - Repair wire 81A/81 (Volume 3, WP 0352). Go to Step (15) to verify problem is solved. YES - Go to Step (4). 0088-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 4. IS THERE BATTERY VOLTAGE TO PIN B OF THE BATTERY SWITCH? a. Reconnect lead 81A to battery switch pin A. b. Disconnect lead 459 (pin B) from the battery switch. BATTERY SWITCH 459 569A 569 81A VOM 81 B D C A TO PROTECTIVE CONTROL BOX FROM STARTER Figure 4. T0709DAA Battery Switch Test. c. Connect multimeter red lead to contact end of pin B. Refer to point to point schematics. d. Connect multimeter black lead to a known good ground. e. Turn battery switch to ON position. f. Meter reading should be between 22 and 26 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE TO PIN B OF THE BATTERY SWITCH? DECISION NO - Replace battery switch (Volume 2, WP 0307). Go to Step (15) to verify problem is solved. YES - Go to Step (5). 0088-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 5. IS THERE BATTERY VOLTAGE AT HARNESS CONNECTOR PIN A? a. Reconnect lead 459 to battery switch pin B. b. Disconnect harness connector at protective control box. VOM CONNECTOR HARNESS PROTECTIVE CONTROL BOX F A G E B D C T0710DAA Figure 5. Protective Control Box Wire 459. c. Connect multimeter red lead to harness connector, pin A (lead 459). Refer to point to point schematics. d. Connect multimeter black lead to a known good ground. e. Meter reading should be between 22 and 26 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT HARNESS CONNECTOR PIN A? DECISION NO - Repair wire 459 (Volume 3, WP 0352). Go to Step (15) to verify problem is solved. YES - Go to Step (6). 0088-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 6. IS THERE BATTERY VOLTAGE AT HARNESS CONNECTOR PIN C? a. Place battery switch to OFF. CONNECTOR HARNESS PROTECTIVE CONTROL BOX VOM F A G E B D C T0711DAA Figure 6. Protective Control Box Wire 81. b. Connect multimeter red lead to harness connector, pin C (lead 81). Refer to point to point schematics. c. Connect multimeter black lead to a known good ground. d. Meter reading should be between 22 and 26 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT HARNESS CONNECTOR PIN C? DECISION NO - Repair wire 81 (Volume 3, WP 0352). Go to Step (15) to verify problem is solved. YES - Go to Step (7). 0088-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 7. IS THERE CONTINUITY BETWEEN PIN B OF THE PROTECTIVE CONTROL BOX HARNESS CONNECTOR AND LEAD 74 AT THE STARTER SOLENOID? a. Disconnect battery ground cables (Volume 2, WP 0346). b. Disconnect harness connector at protective control box. c. Disconnect lead 74 at starter solenoid. d. Set up multimeter to measure resistance. STARTER SOLENOID HARNESS CONNECTOR 6 74 PROTECTIVE CONTROL BOX F A G E B D C 7 VOM STARTER MOTOR Figure 7. T0713DAA Starter Solenoid Wire 74. e. Connect multimeter red lead to harness connector, pin B (lead 74). Refer to point to point schematics. f. Connect multimeter black lead to lead 74 at the starter solenoid. g. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PIN B OF THE PROTECTIVE CONTROL BOX HARNESS CONNECTOR AND LEAD 74 AT THE STARTER SOLENOID? DECISION NO - Repair wire 74 (Volume 3, WP 0352). Go to Step (15) to verify problem is solved. YES - Go to Step (8). 0088-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 8. IS THERE CONTINUITY BETWEEN PIN D OF THE HARNESS CONNECTOR AND CONTACT END OF 5B AT START SWITCH? a. Connect lead 74 to starter solenoid. b. Disconnect lead 5B (pin B) at start switch. 54 5B R B 498 S TO PROTECTIVE CONTROL 5A BOX HARNESS CONNECTOR PROTECTIVE CONTROL BOX START SWITCH TO CIRCUIT BREAKER F A G E B D C VOM T0714DAA Figure 8. Start Switch Wire 5B. c. Connect multimeter red lead to harness connector, pin D (lead 5A/5B). Refer to point to point schematics. d. Connect multimeter black lead to contact end of 5B at start switch. e. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PIN D OF THE HARNESS CONNECTOR AND CONTACT END OF 5B AT START SWITCH? DECISION NO - Repair wire 5A/5B (Volume 3, WP 0352). Go to Step (15) to verify problem is solved. YES - Go to Step (9). 0088-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 9. IS THERE CONTINUITY BETWEEN PINS B AND S OF THE START SWITCH? a. Disconnect lead 5B (pin B) and lead 498 (pin S) at start switch. R 54 5B B 498 S VOM T0715DAA Figure 9. Start Switch. b. Connect multimeter red lead to pin B of the start switch. Refer to point to point schematics. c. Connect multimeter black lead to pin S of the start switch. d. Position and hold start switch in the START position. e. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PINS B AND S OF THE START SWITCH? DECISION NO - Replace start switch (Volume 2, WP 0307). Go to Step (15) to verify problem is solved. YES - Go to Step (10). STEP 10. IS THERE CONTINUITY BETWEEN CONTACT END OF LEAD 498 AT START SWITCH AND CONTACT END OF LEAD 498 AT NEUTRAL START SWITCH? a. Reconnect lead 5B to start switch (pin B). b. Set parking brake. c. Disconnect lead 498 at start switch. d. Disconnect lead 498 at neutral start switch. 0088-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued 54 R 5B B S 498 NEUTRAL START SWITCH VOM 498 Figure 10. T0716DAA Neutral Start Switch Wire 498. e. Connect multimeter red lead to contact end of lead 498 at start switch. Refer to point to point schematics. f. Connect multimeter black lead to contact end of lead 498 at neutral start switch. g. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN CONTACT END OF LEAD 498 AT START SWITCH AND CONTACT END OF LEAD 498 AT NEUTRAL START SWITCH? DECISION NO - Repair wire 498 (Volume 3, WP 0352). Go to Step (15) to verify problem is solved. YES - Go to Step (11). 0088-11 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 11. IS THERE CONTINUITY BETWEEN NEUTRAL START SWITCH CONTACT END OF LEAD 499 AND NEUTRAL START SWITCH CONTACT END OF LEAD 498? a. Reconnect lead 498 to start switch (pin S). b. Disconnect lead 499 at neutral start switch. c. Ensure transmission is in neutral. NEUTRAL START SWITCH 499 VOM 498 Figure 11. T0717DAA Neutral Start Switch. d. Connect multimeter red lead to neutral start switch contact end of lead 499. Refer to point to point schematics. e. Connect multimeter black lead to neutral start switch contact end of lead 498. f. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN NEUTRAL START SWITCH CONTACT END OF LEAD 499 AND NEUTRAL START SWITCH CONTACT END OF LEAD 498? DECISION NO - Replace neutral start switch (Volume 3, WP 0366). Go to Step (15) to verify problem is solved. YES - Go to Step (12). 0088-12 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 12. IS THERE CONTINUITY BETWEEN CONTACT END OF LEAD 498 AT START SWITCH AND CONTACT END OF LEAD 498 AT NEUTRAL START SWITCH? a. Reconnect lead 498 to neutral start switch. b. Disconnect harness connector at protective control box. HARNESS CONNECTOR VOM PROTECTIVE CONTROL BOX 499 498 NEUTRAL START SWITCH F A G E B D C T0718DAA Figure 12. Protective Control Box Wire 499. c. Connect multimeter red lead to contact end of lead 499. Refer to point to point schematics. d. Connect multimeter black lead to harness connector, pin E (lead 499). e. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN CONTACT END OF LEAD 498 AT START SWITCH AND CONTACT END OF LEAD 498 AT NEUTRAL START SWITCH? DECISION NO - Repair wire 499 (Volume 3, WP 0352). Go to Step (15) to verify problem is solved. YES - Go to Step (13). 0088-13 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 13. IS THERE CONTINUITY BETWEEN PIN F AT HARNESS CONNECTOR AND CONTACT END OF LEAD 566 AT ALTERNATOR? a. Reconnect lead 499 to neutral start switch. b. Disconnect lead 566 at alternator. c. Disconnect harness connector at protective control box. HARNESS CONNECTOR VOM PROTECTIVE CONTROL BOX 566 5 F A G E B D C 3 T0719DAA Figure 13. Alternator Wire 566. d. Connect multimeter red lead to harness connector, pin F (lead 566). Refer to point to point schematics. e. Connect multimeter black lead to contact end of lead 566 at alternator. f. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PIN F AT HARNESS CONNECTOR AND CONTACT END OF LEAD 566 AT ALTERNATOR? DECISION NO - Repair wire 566 (Volume 3, WP 0352). Go to Step (15) to verify problem is solved. YES - Go to Step (14). 0088-14 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 0088 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 14. DOES ENGINE START WITH LEAD 566 DISCONNECTED FROM ALTERNATOR? a. Reconnect harness connector to protective control box. PROTECTIVE CONTROL BOX PROTECTIVE CONTROL CONNECTOR Figure 14. T0707DAA Protective Control Box. b. Verify lead 566 disconnected from alternator. Refer to point to point schematics. c. Attempt to start engine. CONDITION/INDICATION DOES ENGINE START WITH LEAD 566 DISCONNECTED FROM ALTERNATOR? DECISION NO - Replace protective control box (Volume 2, WP 0319). Go to Step (15) to verify problem is solved. YES - Replace alternator M939/A1 60 amp (Volume 2, WP 0300), M939A2 60amp (Volume 2, WP 0301), 100 amp (Volume 5, WP 0780). Go to Step (15) to verify problem is solved. 0088-15 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) TM 9-2320-272-23-1 STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP - Continued STEP 15. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0088-16 03/15/2011 Rel(1.8) root(tswp) wpno(T00149) 0088 TM 9-2320-272-23-1 FIELD MAINTENANCE NO OR LOW ALTERNATOR OUTPUT INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 2, WP 0296 Volume 2, WP 0297 Volume 2, WP 0300 Volume 2, WP 0301 Volume 2, WP 0302 Volume 2, WP 0346 Volume 3, WP 0352 Volume 5, WP 0780 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE NO OR LOW ALTERNATOR OUTPUT NOTE Conduct these malfunction tests if there is no or low output from the alternator. This procedure will check the alternator belts, alternator, wire 568, and wire 5. 0089-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00153) 0089 TM 9-2320-272-23-1 0089 NO OR LOW ALTERNATOR OUTPUT - Continued STEP 1. DO THE ALTERNATOR DRIVE BELTS HAVE THE PROPER TENSION? a. Verify engine is stopped. ALTERNATOR DRIVE BELT T0932DAA Figure 1. b. Alternator Drive Belt. Inspect alternator belts for damage and proper tension M939/A1 (Volume 2, WP 0297), M939A2 (Volume 2, WP 0296). CONDITION/INDICATION DO THE ALTERNATOR DRIVE BELTS HAVE THE PROPER TENSION? DECISION NO - Adjust or replace alternator belt M939/A1 (Volume 2, WP 0297), M939A2 (Volume 2, WP 0296). Go to Step (8) to verify problem is solved. YES - Go to Step (2). STEP 2. IS THE ALTERNATOR OUTPUT VOLTAGE NORMAL? a. Verify engine is stopped. b. Set up multimeter to measure VDC. 0089-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00153) TM 9-2320-272-23-1 0089 NO OR LOW ALTERNATOR OUTPUT - Continued VEHICLE DIAGNOSTIC CONNECTOR ABS DIAGNOSTIC CONNECTOR Figure 2. T0055DAA DCA Connector. c. Connect multimeter red lead to vehicle DCA connector, terminal N. Refer to point to point schematics. d. Connect multimeter black lead to vehicle DCA connector, terminal P. e. Start engine and run at fast idle. f. Meter reading should be between 26.5 and 29.5 VDC. CONDITION/INDICATION IS THE ALTERNATOR OUTPUT VOLTAGE NORMAL? DECISION NO - Go to Step (3). YES - Go to Step (4). 0089-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00153) TM 9-2320-272-23-1 0089 NO OR LOW ALTERNATOR OUTPUT - Continued STEP 3. IS A 100 AMP ALTERNATOR INSTALLED? a. Stop engine. ALTERNATOR/ ELECTRICAL WIRING T0930DAA Figure 3. Alternator Electrical Wiring. NOTE 100 amp alternators are equipped with a quick disconnect connector. b. Determine which alternator is in your vehicle. CONDITION/INDICATION IS A 100 AMP ALTERNATOR INSTALLED? DECISION YES - Replace 100 amp alternator (Volume 5, WP 0780). Go to Step (8) to verify problem is solved. NO - Replace 60 amp alternator M939/A1 (Volume 2, WP 0300), M939A2 (Volume 2, WP 0301). Go to Step (8) to verify problem is solved. 0089-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00153) TM 9-2320-272-23-1 0089 NO OR LOW ALTERNATOR OUTPUT - Continued STEP 4. IS THERE BATTERY VOLTAGE AT WIRE 568 AT THE ALTERNATOR? a. Stop engine. b. Disconnect wire 568 from the alternator. RED BLACK 5 (POS) 568 3 (NEG) T0937DAA Figure 4. Alternator Wire 568. c. Place battery switch to ON position. d. Connect multimeter red lead to lead 568. Refer to point to point schematics. e. Connect multimeter black lead to vehicle ground. f. Meter reading should be between 22 and 26 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT WIRE 568 AT THE ALTERNATOR? DECISION NO - Go to Step (6). YES - Go to Step (5). 0089-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00153) TM 9-2320-272-23-1 0089 NO OR LOW ALTERNATOR OUTPUT - Continued STEP 5. IS A 100 AMP ALTERNATOR INSTALLED? a. Place battery switch to OFF position. ALTERNATOR/ ELECTRICAL WIRING T0930DAA Figure 5. Alternator Wiring. NOTE 100 amp alternators are equipped with a quick disconnect connector. b. Determine which alternator is in your vehicle. CONDITION/INDICATION IS A 100 AMP ALTERNATOR INSTALLED? DECISION YES - Replace 100 amp alternator (Volume 5, WP 0780). Go to Step (8) to verify problem is solved. NO - Replace 60 amp alternator M939/A1 (Volume 2, WP 0300), M939A2 (Volume 2, WP 0301). Go to Step (8) to verify problem is solved. 0089-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00153) TM 9-2320-272-23-1 0089 NO OR LOW ALTERNATOR OUTPUT - Continued STEP 6. IS THERE BATTERY VOLTAGE AT WIRE 5 AT THE ALTERNATOR TERMINAL? a. Connect multimeter red lead to circuit 5 at the alternator terminal. Refer to point to point schematics. RED BLACK 5 (POS) 3 (NEG) 568 T0936DAA Figure 6. Alternator Wire 5. b. Connect multimeter black lead to vehicle ground. c. Meter reading should be between 22 and 26 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT WIRE 5 AT THE ALTERNATOR TERMINAL? DECISION NO - Go to Step (7). YES - Repair wire 568 (Volume 3, WP 0352). Go to Step (8) to verify problem is solved. 0089-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00153) TM 9-2320-272-23-1 0089 NO OR LOW ALTERNATOR OUTPUT - Continued STEP 7. IS THERE CONTINUITY BETWEEN CIRCUIT 5 AND CIRCUIT 568? a. Disconnect battery negative cable (Volume 2, WP 0346). b. Set up multimeter to measure resistance. BLACK RED 5 (POS) 568 3 (NEG) T0938DAA Figure 7. Alternator Wire 5/568. c. Connect multimeter red lead to circuit 568. Refer to point to point schematics. d. Connect multimeter black lead to circuit 5 at the alternator terminal. e. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN CIRCUIT 5 AND CIRCUIT 568? DECISION NO - Repair wire 568 (Volume 3, WP 0352). Go to Step (8) to verify problem is solved. YES - Notify supervisor. Action may not be possible at this level of maintenance. 0089-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00153) TM 9-2320-272-23-1 NO OR LOW ALTERNATOR OUTPUT - Continued STEP 8. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0089-9/10 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00153) 0089 TM 9-2320-272-23-1 FIELD MAINTENANCE NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0296 Volume 2, WP 0297 Volume 2, WP 0302 Volume 3, WP 0352 Volume 5, WP 0780 Volume 5, WP 0792 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) NOTE Conduct these malfunction tests if there is no output from the alternator. This procedure will check the alternator belts, alternator, starter, and voltage regulator harness. 0090-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00184) 0090 TM 9-2320-272-23-1 0090 NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) - Continued STEP 1. DO THE ALTERNATOR DRIVE BELTS HAVE THE PROPER TENSION? a. Verify engine is stopped. ALTERNATOR DRIVE BELT T0164DAA Figure 1. b. Alternator Drive Belt. Inspect alternator belts for damage and proper tension M939/A1 (Volume 2, WP 0297), M939A2 (Volume 2, WP 0296). CONDITION/INDICATION DO THE ALTERNATOR DRIVE BELTS HAVE THE PROPER TENSION? DECISION NO - Adjust or replace alternator belt M939/A1 (Volume 2, WP 0297), M939A2 (Volume 2, WP 0296). Go to Step (12) to verify problem is solved. YES - Go to Step (2). 0090-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00184) TM 9-2320-272-23-1 0090 NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) - Continued STEP 2. IS THE ALTERNATOR OUTPUT VOLTAGE NORMAL? a. Verify engine is stopped. b. Set up multimeter to measure VDC. VEHICLE DIAGNOSTIC CONNECTOR ABS DIAGNOSTIC CONNECTOR Figure 2. T0994DAA DCA Connector. c. Connect multimeter red lead to vehicle DCA connector, terminal N. Refer to point to point schematics. d. Connect multimeter black lead to vehicle DCA connector, terminal P. e. Start engine and run at fast idle. f. Meter reading should be between 26.5 and 29.5 VDC. CONDITION/INDICATION IS THE ALTERNATOR OUTPUT VOLTAGE NORMAL? DECISION NO - Replace defective alternator (Volume 5, WP 0780). Go to Step (12) to verify problem is solved. YES - Go to Step (3). 0090-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00184) TM 9-2320-272-23-1 0090 NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) - Continued STEP 3. IS THERE CONTINUITY BETWEEN PIN F OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND LEAD 566 OF THE VOLTAGE REGULATOR HARNESS? a. Stop engine. b. Disconnect quick disconnect for lead 566. c. Disconnect voltage regulator harness connector at alternator and voltage regulator. d. Set up multimeter to measure resistance. VOLTAGE REGULATOR HARNESS CONNECTOR ALTERNATOR HARNESS CONNECTOR 566 568 566 568 VOM T0167DAA Figure 3. Voltage Regulator Harness. e. Connect multimeter red lead to contact end of lead 566. Refer to point to point schematics. f. Connect multimeter black lead to pin F of the voltage regulator harness connector. g. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PIN F OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND LEAD 566 OF THE VOLTAGE REGULATOR HARNESS? DECISION NO - Replace voltage regulator harness (Volume 5, WP 0792). Go to Step (12) to verify problem is solved. YES - Go to Step (4). 0090-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00184) TM 9-2320-272-23-1 0090 NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) - Continued STEP 4. IS THERE CONTINUITY BETWEEN PIN D OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND PIN B OF THE ALTERNATOR HARNESS CONNECTOR? a. Connect multimeter red lead to pin B of the alternator harness connector. Refer to point to point schematics. VOLTAGE REGULATOR HARNESS CONNECTOR ALTERNATOR HARNESS CONNECTOR 566 568 566 568 VOM T0168DAA Figure 4. Voltage Regulator Harness. b. Connect multimeter black lead to pin D of the voltage regulator harness connector. c. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PIN D OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND PIN B OF THE ALTERNATOR HARNESS CONNECTOR? DECISION NO - Replace voltage regulator harness (Volume 5, WP 0792). Go to Step (12) to verify problem is solved. YES - Go to Step (5). 0090-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00184) TM 9-2320-272-23-1 0090 NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) - Continued STEP 5. IS THERE CONTINUITY BETWEEN PIN E OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND PIN E OF THE ALTERNATOR HARNESS CONNECTOR? a. Connect multimeter red lead to pin E of the alternator harness connector. Refer to point to point schematics. VOLTAGE REGULATOR HARNESS CONNECTOR ALTERNATOR HARNESS CONNECTOR 566 568 566 568 VOM T0169DAA Figure 5. Voltage Regulator Harness. b. Connect multimeter black lead to pin E of the voltage regulator harness connector. c. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PIN E OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND PIN E OF THE ALTERNATOR HARNESS CONNECTOR? DECISION NO - Replace voltage regulator harness (Volume 5, WP 0792). Go to Step (12) to verify problem is solved. YES - Go to Step (6). 0090-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00184) TM 9-2320-272-23-1 0090 NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) - Continued STEP 6. IS THERE CONTINUITY BETWEEN PIN C OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND PIN C OF THE ALTERNATOR HARNESS CONNECTOR? a. Connect multimeter red lead to pin C of the alternator harness connector. Refer to point to point schematics. VOLTAGE REGULATOR HARNESS CONNECTOR ALTERNATOR HARNESS CONNECTOR 566 568 566 568 VOM T0170DAA Figure 6. Voltage Regulator Harness. b. Connect multimeter black lead to pin C of the voltage regulator harness connector. c. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PIN C OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND PIN C OF THE ALTERNATOR HARNESS CONNECTOR? DECISION NO - Replace voltage regulator harness (Volume 5, WP 0792). Go to Step (12) to verify problem is solved. YES - Go to Step (7). 0090-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00184) TM 9-2320-272-23-1 0090 NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) - Continued STEP 7. IS THERE CONTINUITY BETWEEN PIN B OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND PIN D OF THE ALTERNATOR HARNESS CONNECTOR? a. Connect multimeter red lead to pin D of the alternator harness connector. Refer to point to point schematics. VOLTAGE REGULATOR HARNESS CONNECTOR ALTERNATOR HARNESS CONNECTOR 566 568 566 568 VOM T0171DAA Figure 7. Voltage Regulator Harness. b. Connect multimeter black lead to pin B of the voltage regulator harness connector. c. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PIN B OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND PIN D OF THE ALTERNATOR HARNESS CONNECTOR? DECISION NO - Replace voltage regulator harness (Volume 5, WP 0792). Go to Step (12) to verify problem is solved. YES - Go to Step (8). 0090-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00184) TM 9-2320-272-23-1 0090 NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) - Continued STEP 8. IS THERE CONTINUITY BETWEEN PIN B OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND LEAD 81 AT STARTER SOLENOID? a. Disconnect quick disconnect for lead 568. b. Disconnect voltage regulator harness connector at voltage regulator. c. Disconnect voltage regulator harness at starter motor and starter solenoid. VOM 81 STARTER MOTOR VOLTAGE REGULATOR HARNESS CONNECTOR GND ALTERNATOR HARNESS CONNECTOR 566 568 566 568 T0172DAA Figure 8. Voltage Regulator Harness. d. Connect multimeter red lead to pin B at voltage regulator harness connector. Refer to point to point schematics. e. Connect multimeter black lead to end of lead 81 at starter solenoid. f. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PIN B OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND LEAD 81 AT STARTER SOLENOID? DECISION NO - Replace voltage regulator harness (Volume 5, WP 0792). Go to Step (12) to verify problem is solved. YES - Go to Step (9). 0090-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00184) TM 9-2320-272-23-1 0090 NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) - Continued STEP 9. IS THERE CONTINUITY BETWEEN PIN A OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND LEAD 81 AT STARTER SOLENOID? a. Connect multimeter red lead to pin A at voltage regulator harness connector. Refer to point to point schematics. VOM 81 STARTER MOTOR VOLTAGE REGULATOR HARNESS CONNECTOR GND ALTERNATOR HARNESS CONNECTOR 566 568 566 568 T0173DAA Figure 9. Voltage Regulator Harness. b. Connect multimeter black lead to end of lead 81 at starter solenoid. c. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PIN A OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND LEAD 81 AT STARTER SOLENOID? DECISION NO - Replace voltage regulator harness (Volume 5, WP 0792). Go to Step (12) to verify problem is solved. YES - Go to Step (10). 0090-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00184) TM 9-2320-272-23-1 0090 NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) - Continued STEP 10. IS THERE CONTINUITY BETWEEN PIN C OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND LEAD AT STARTER MOTOR? a. Connect multimeter red lead to pin C at voltage regulator harness connector. Refer to point to point schematics. 81 VOM STARTER MOTOR GND VOLTAGE REGULATOR HARNESS CONNECTOR ALTERNATOR HARNESS CONNECTOR 566 568 566 568 T0174DAA Figure 10. Voltage Regulator Harness. b. Connect multimeter black lead to end of lead to the ground connector at starter motor. c. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PIN C OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND LEAD AT STARTER MOTOR? DECISION NO - Replace voltage regulator harness (Volume 5, WP 0792). Go to Step (12) to verify problem is solved. YES - Go to Step (10). 0090-11 03/15/2011 Rel(1.8) root(tswp) wpno(T00184) TM 9-2320-272-23-1 0090 NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) - Continued STEP 11. IS THERE CONTINUITY BETWEEN PIN F OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND LEAD 568? a. Connect multimeter red lead to pin F at voltage regulator harness connector. Refer to point to point schematics. 81 STARTER MOTOR GND VOLTAGE REGULATOR HARNESS CONNECTOR ALTERNATOR HARNESS CONNECTOR VOM 566 568 566 568 T0175DAA Figure 11. Voltage Regulator Harness. b. Connect multimeter black lead to lead 568. c. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PIN F OF THE VOLTAGE REGULATOR HARNESS CONNECTOR AND LEAD 568? DECISION NO - Replace voltage regulator harness (Volume 5, WP 0792). Go to Step (12) to verify problem is solved. YES - Notify supervisor. Action may not be possible at this level of maintenance. 0090-12 03/15/2011 Rel(1.8) root(tswp) wpno(T00184) TM 9-2320-272-23-1 NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR) - Continued STEP 12. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0090-13/14 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00184) 0090 TM 9-2320-272-23-1 FIELD MAINTENANCE ALTERNATOR OVERCHARGING, BATTERY INDICATOR GAUGE IN RED POSITION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) WP 0108 Volume 2, WP 0300 Volume 2, WP 0301 Volume 5, WP 0780 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE ALTERNATOR OVERCHARGING, BATTERY INDICATOR GAUGE IN RED POSITION NOTE Conduct these malfunction tests if the battery indicator gauge is in red position. This procedure will check the alternator and the gauge circuitry. 0091-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00156) 0091 TM 9-2320-272-23-1 0091 ALTERNATOR OVERCHARGING, BATTERY INDICATOR GAUGE IN RED POSITION - Continued STEP 1. IS THE ALTERNATOR OUTPUT VOLTAGE EXCESSIVE? a. Verify engine is stopped. b. Set up multimeter to measure VDC. VEHICLE DIAGNOSTIC CONNECTOR ABS DIAGNOSTIC CONNECTOR Figure 1. T0994DAA DCA Connector. c. Connect multimeter red lead to vehicle DCA connector, terminal N. Refer to point to point schematics. d. Connect multimeter black lead to vehicle DCA connector, terminal P. e. Start engine and run at fast idle. f. Meter reading should be less than 29.5 VDC. CONDITION/INDICATION IS THE ALTERNATOR OUTPUT VOLTAGE EXCESSIVE? DECISION NO - Go to Step (3). YES - Go to Step (2). 0091-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00156) TM 9-2320-272-23-1 0091 ALTERNATOR OVERCHARGING, BATTERY INDICATOR GAUGE IN RED POSITION - Continued STEP 2. IS A 100 AMP ALTERNATOR INSTALLED? a. Stop engine. 568 568 568 Figure 2. T0739DAA Alternator Electrical Wiring. NOTE 100 amp alternators are equipped with a quick disconnect connector. b. Determine which alternator is in your vehicle. CONDITION/INDICATION IS A 100 AMP ALTERNATOR INSTALLED? DECISION YES - Replace 100 amp alternator (Volume 5, WP 0780). Go to Step (6) to verify problem is solved. NO - Replace 60 amp alternator M939/A1 (Volume 2, WP 0300), M939A2 (Volume 2, WP 0301). Go to Step (6) to verify problem is solved. 0091-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00156) TM 9-2320-272-23-1 ALTERNATOR OVERCHARGING, BATTERY INDICATOR GAUGE IN RED POSITION - Continued STEP 3. IS THE ALTERNATOR OVERHEATING? a. Start engine and run for approximately 10 minutes. b. Stop engine. ALTERNATOR T0738DAA Figure 3. c. Alternator. Check alternator for high temperature by holding hand NEAR alternator. CONDITION/INDICATION IS THE ALTERNATOR OVERHEATING? DECISION YES - Go to Step (4). NO - Perform Battery/Alternator Gauge Inoperative troubleshooting (WP 0108). 0091-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00156) 0091 TM 9-2320-272-23-1 0091 ALTERNATOR OVERCHARGING, BATTERY INDICATOR GAUGE IN RED POSITION - Continued STEP 4. DOES THE GAUGE READ HIGH AND THE ALTERNATOR OVERHEAT A SECOND TIME? a. Disconnect wire 568 at alternator. Refer to point to point schematics. 568 568 568 Figure 4. T0739DAA Alternator Wire 568. b. Allow alternator to cool. c. Reconnect wire 568. d. Start engine and run for approximately 10 minutes. e. Check indicator gauge. f. Check alternator for high temperature by holding hand NEAR alternator. CONDITION/INDICATION DOES THE GAUGE READ HIGH AND THE ALTERNATOR OVERHEAT A SECOND TIME? DECISION YES - Go to Step (5). NO - Notify supervisor. Action may not be possible at this level of maintenance. 0091-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00156) TM 9-2320-272-23-1 0091 ALTERNATOR OVERCHARGING, BATTERY INDICATOR GAUGE IN RED POSITION - Continued STEP 5. IS A 100 AMP ALTERNATOR INSTALLED? 568 568 568 T0739DAA Figure 5. Alternator Electrical Wiring. NOTE 100 amp alternators are equipped with a quick disconnect connector. Determine which alternator is in your vehicle. CONDITION/INDICATION IS A 100 AMP ALTERNATOR INSTALLED? DECISION YES - Replace 100 amp alternator (Volume 5, WP 0780). Go to Step (6) to verify problem is solved. NO - Replace 60 amp alternator M939/A1 (Volume 2, WP 0300), M939A2 (Volume 2, WP 0301). Go to Step (6) to verify problem is solved. 0091-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00156) TM 9-2320-272-23-1 ALTERNATOR OVERCHARGING, BATTERY INDICATOR GAUGE IN RED POSITION - Continued STEP 6. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0091-7/8 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00156) 0091 TM 9-2320-272-23-1 FIELD MAINTENANCE HEADLAMP (ONE SIDE) INOPERATIVE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0325 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE HEADLAMP (ONE SIDE) INOPERATIVE NOTE Conduct these malfunction tests if headlamp on one side is inoperative. This procedure will check for defective headlamp bulb, wiring harness, or headlamp assembly. 0092-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00158) 0092 TM 9-2320-272-23-1 HEADLAMP (ONE SIDE) INOPERATIVE - Continued STEP 1. ARE BULBS IN GOOD CONDITION? a. Replace non-operating bulb with one known to be operative (Volume 2, WP 0325). T0751DAA Figure 1. Headlamp Bulb. b. Place battery switch to ON position. c. Place lighting switch to SERVICE DRIVE position. d. Press beam select switch to HIGH BEAM and LOW BEAM position. NOTE If headlamp operates, bulb was faulty. e. Check if headlamp operates in low and high beam. CONDITION/INDICATION ARE BULBS IN GOOD CONDITION? DECISION NO - Go to Step (3) to verify problem is solved. YES - Go to Step (2). 0092-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00158) 0092 TM 9-2320-272-23-1 HEADLAMP (ONE SIDE) INOPERATIVE - Continued STEP 2. IS THERE BATTERY VOLTAGE AT HEADLAMP CONNECTOR? a. Place battery switch to OFF position. T0752DAA Figure 2. Headlamp Connectors. b. Disconnect circuit 18 and 17 wire at inoperative headlamp. c. Make sure wire connector contacts are clean. d. Place battery switch to ON position. e. Place lighting switch to SERVICE DRIVE position and press beam select switch to LOW BEAM. f. Set up multimeter to measure VDC. g. Connect multimeter red lead to circuit 18 wire. Refer to point to point schematics. h. Connect multimeter black lead to good ground. i. Meter reading should be greater than 18 VDC. Note reading. j. Press beam select switch to HIGH BEAM. k. Connect multimeter red lead to circuit 17 wire. l. Connect multimeter black lead to good ground. m. Meter reading should be greater than 18 VDC. Note reading. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT HEADLAMP CONNECTOR? DECISION NO - Repair or replace loose or corroded connections and wiring from headlamp to beam select switch (Volume 3, WP 0352). Go to Step (3) to verify problem is solved. YES - Replace defective headlamp (Volume 2, WP 0325). Go to Step (3) to verify problem is solved. 0092-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00158) 0092 TM 9-2320-272-23-1 HEADLAMP (ONE SIDE) INOPERATIVE - Continued STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0092-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00158) 0092 TM 9-2320-272-23-1 FIELD MAINTENANCE HEADLAMP (BOTH SIDE) INOPERATIVE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0315 Volume 2, WP 0316 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE HEADLAMP (BOTH SIDE) INOPERATIVE NOTE Conduct these malfunction tests if headlamps on both sides are inoperative. This procedure will check for defective wiring harness or connector, corroded parts or defective switch. 0093-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00159) 0093 TM 9-2320-272-23-1 0093 HEADLAMP (BOTH SIDE) INOPERATIVE - Continued STEP 1. IS HEADLAMP WIRING HARNESS IN GOOD CONDITION? a. Place battery switch to OFF position. T0755DAA Figure 1. Beam Select Switch. b. Disconnect circuit 18 and 17 wire at beam selector switch. c. Place battery switch to ON position. d. Place lighting switch to SERVICE DRIVE position and press beam select switch to LOW BEAM. e. Set up multimeter to measure VDC. f. Connect multimeter red lead to circuit 18 terminal on switch. Refer to point to point schematics. g. Connect multimeter black lead to good ground. NOTE If meter reading is greater than 18 VDC for both measurements, headlamp wiring harness is faulty. h. Meter reading should be greater than 18 VDC. Note reading. i. Press beam select switch to HIGH BEAM. j. Connect multimeter red lead to circuit 17 terminal on switch. k. Connect multimeter black lead to good ground. l. Meter reading should be greater than 18 VDC. Note reading. CONDITION/INDICATION IS HEADLAMP WIRING HARNESS IN GOOD CONDITION? 0093-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00159) TM 9-2320-272-23-1 0093 HEADLAMP (BOTH SIDE) INOPERATIVE - Continued DECISION NO - Repair or replace loose or corroded connections and wiring from headlamps to beam select switch (Volume 3, WP 0352). Go to Step (6) to verify problem is solved. YES - Go to Step (2). STEP 2. IS THERE BATTERY VOLTAGE AT CIRCUIT 16 WIRE? a. Place battery switch to OFF position. T0755DAA Figure 2. Beam Select Switch. b. Disconnect circuit 16 wire from beam selector switch. c. Inspect and make sure circuit wire 16 is in good condition. d. Place battery switch to ON position. e. Place lighting switch to SERVICE DRIVE position. f. Connect multimeter red lead to circuit 16 wire (not the switch terminal). Refer to point to point schematics. g. Connect multimeter black lead to good ground. h. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT CIRCUIT 16 WIRE? DECISION NO - Go to Step (3). YES - Replace beam selector switch (Volume 2, WP 0316). Go to Step (6) to verify problem is solved. 0093-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00159) TM 9-2320-272-23-1 0093 HEADLAMP (BOTH SIDE) INOPERATIVE - Continued STEP 3. IS THERE BATTERY VOLTAGE AT MAIN LIGHT SWITCH HARNESS CONNECTOR? a. Place battery switch to OFF position. T0756DAA Figure 3. Main Lighting Switch. b. Remove lighting switch from instrument panel and disconnect harness connector (Volume 2, WP 0315). c. Place battery switch to ON position. d. Connect multimeter red lead to connector socket pin F. Refer to point to point schematics. e. Connect multimeter black lead to good ground. f. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT MAIN LIGHT SWITCH HARNESS CONNECTOR? DECISION NO - Go to Step (4). YES - Go to Step (5). 0093-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00159) TM 9-2320-272-23-1 0093 HEADLAMP (BOTH SIDE) INOPERATIVE - Continued STEP 4. IS WIRING HARNESS IN GOOD CONDITION? a. Place battery switch to OFF position. T0756DAA Figure 4. b. Main Lighting Switch Connector. Visually check wiring harness for loose connections or broken wiring. Refer to point to point schematic. CONDITION/INDICATION IS WIRING HARNESS IN GOOD CONDITION? DECISION NO - Repair or replace broken wire (Volume 3, WP 0352). Go to Step (6) to verify problem is solved. YES - Notify supervisor. Action may not be possible at this level of maintenance. 0093-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00159) TM 9-2320-272-23-1 0093 HEADLAMP (BOTH SIDE) INOPERATIVE - Continued STEP 5. IS MAIN LIGHT SWITCH OPERATING PROPERLY? a. Place battery switch to OFF position. T0756DAA Figure 5. Main Lighting Switch Connector. b. Connect jumper cable from socket pin F to socket pin M. c. Place battery switch to ON position. NOTE If headlamps light, lighting switch is not operating properly. d. Look for lighted headlamps. CONDITION/INDICATION IS MAIN LIGHT SWITCH OPERATING PROPERLY? DECISION YES - Repair or replace circuit wire 16 (Volume 3, WP 0352). Go to Step (6) to verify problem is solved. NO - Replace defective main light switch (Volume 2, WP 0315). Go to Step (6) to verify problem is solved. STEP 6. IS YOUR ORIGINAL LIGHTING PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original lighting problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL LIGHTING PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0093-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00159) TM 9-2320-272-23-1 FIELD MAINTENANCE BLACKOUT DRIVE OR BLACKOUT MARKER LIGHT INOPERATIVE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 2, WP 0315 Volume 2, WP 0326 Volume 2, WP 0327 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE BLACKOUT DRIVE OR BLACKOUT MARKER LIGHT INOPERATIVE NOTE Conduct these malfunction tests if blackout drive or blackout marker light is inoperative. This procedure will check for defective bulbs, defective wiring harness or connector, corroded parts, or defective switch. 0094-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00160) 0094 TM 9-2320-272-23-1 BLACKOUT DRIVE OR BLACKOUT MARKER LIGHT INOPERATIVE - Continued STEP 1. ARE BULBS IN GOOD CONDITION? T0745DAA Figure 1. Light Bulbs. a. If blackout drive light is inoperative, replace blackout light bulb with one known to be operative (Volume 2, WP 0326). b. If front blackout light is inoperative, replace blackout light bulb with one known to be operative (Volume 2, WP 0327). c. If rear blackout light is inoperative, replace blackout light bulb with one known to be operative (Volume 2, WP 0327). NOTE If all blackout lights operates, bulb was faulty. d. Place battery switch to ON position. e. Place lighting switch to B.O. DRIVE position. f. Check if all blackout lights operates. CONDITION/INDICATION ARE BULBS IN GOOD CONDITION? DECISION NO - Go to Step (8) to verify problem is solved. YES - Go to Step (2). STEP 2. ARE SOCKETS AND TERMINALS CLEAN AND IN GOOD CONDITION? a. Place battery switch to OFF position. T0746DAA Figure 2. Light Socket. b. Visually check for corrosion or dirt in sockets or on terminals. Refer to point to point schematic. c. Clean corroded connections. 0094-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00160) 0094 TM 9-2320-272-23-1 0094 BLACKOUT DRIVE OR BLACKOUT MARKER LIGHT INOPERATIVE - Continued CONDITION/INDICATION ARE SOCKETS AND TERMINALS CLEAN AND IN GOOD CONDITION? DECISION NO - Blackout drive light defective. Replace defective blackout drive light (Volume 2, WP 0326). Go to Step (8) to verify problem is solved. NO - Composite light defective. Replace defective composite light (Volume 2, WP 0327). Go to Step (8) to verify problem is solved. YES - Go to Step (3). STEP 3. ARE LAMP HOLDERS IN GOOD OPERATING CONDITION? T0747DAA Figure 3. Lamp Holder. Visually check lamp holders for loose and broken wire terminals. Refer to point to point schematic. CONDITION/INDICATION ARE LAMP HOLDERS IN GOOD OPERATING CONDITION? DECISION NO - Repair or replace broken wire (Volume 3, WP 0352). Go to Step (8) to verify problem is solved. YES - Go to Step (4). 0094-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00160) TM 9-2320-272-23-1 0094 BLACKOUT DRIVE OR BLACKOUT MARKER LIGHT INOPERATIVE - Continued STEP 4. IS THERE BATTERY VOLTAGE AT NON-OPERATING BLACKOUT LAMP CONNECTOR? a. Place battery switch to OFF position. T0758DAA Figure 4. Blackout Light Assemblies. b. Disconnect circuit 19 wire from non-operating blackout drive light. c. Disconnect circuit 20 wire from non-operating left and right front composite lights. d. Disconnect circuit 24 wire from non-operating left and right rear composite lights. e. Place battery switch to ON position. f. Place lighting switch to B.O. DRIVE position. g. Set up multimeter to measure VDC. NOTE Perform the following Steps at non-operating blackout light. h. Connect multimeter red lead to disconnected wire. Refer to point to point schematics. i. Connect multimeter black lead to good ground. j. Meter reading should be greater than 18 VDC for each reading. Note reading. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT NON-OPERATING BLACKOUT LAMP CONNECTOR? 0094-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00160) TM 9-2320-272-23-1 0094 BLACKOUT DRIVE OR BLACKOUT MARKER LIGHT INOPERATIVE - Continued DECISION YES - Battery voltage at circuit 19 wire. Replace non-operating blackout drive light (Volume 2, WP 0326). Go to Step (8) to verify problem is solved. YES - Battery voltage at circuit 20 wire. Replace non-operating front composite light (Volume 2, WP 0327). Go to Step (8) to verify problem is solved. YES - Battery voltage at circuit 24 wire. Replace non-operating rear composite light (Volume 2, WP 0327). Go to Step (8) to verify problem is solved. NO - Go to Step (5). STEP 5. IS THERE BATTERY VOLTAGE AT MAIN LIGHT SWITCH HARNESS CONNECTOR? a. Place battery switch to OFF position. E F M C LK B A N H T0759DAA Figure 5. Main Lighting Switch Connector. b. Remove lighting switch from instrument panel and disconnect harness connector (Volume 2, WP 0315). c. Place battery switch to ON position. d. Connect multimeter red lead to connector socket pin F. Refer to point to point schematics. e. Connect multimeter black lead to good ground. f. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT MAIN LIGHT SWITCH HARNESS CONNECTOR? DECISION NO - Go to Step (6). YES - Go to Step (7). 0094-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00160) TM 9-2320-272-23-1 0094 BLACKOUT DRIVE OR BLACKOUT MARKER LIGHT INOPERATIVE - Continued STEP 6. IS WIRING HARNESS IN GOOD CONDITION? a. Place battery switch to OFF position. E F M C LK B A N H T0759DAA Figure 6. Main Lighting Switch Connector. b. Visually check wiring harness for loose connections or broken wiring. Refer to point to point schematic. CONDITION/INDICATION IS WIRING HARNESS IN GOOD CONDITION? DECISION NO - Repair or replace broken wire (Volume 3, WP 0352). Go to Step (8) to verify problem is solved. YES - Notify supervisor. Action may not be possible at this level of maintenance. 0094-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00160) TM 9-2320-272-23-1 0094 BLACKOUT DRIVE OR BLACKOUT MARKER LIGHT INOPERATIVE - Continued STEP 7. IS MAIN LIGHT SWITCH OPERATING PROPERLY? a. Place battery switch to OFF position. E F M C LK B A N H T0759DAA Figure 7. Main Lighting Switch Connector. b. Connect jumper cable from socket pin F to socket pin D. Refer to point to point schematics. c. Place battery switch to ON position. NOTE If non-operating blackout drive light illuminates, lighting switch is not operating properly. d. Look for lighted B.O. driving light. e. Connect jumper cable from socket pin F to socket pin E. NOTE If non-operating blackout lights illuminates, lighting switch is not operating properly. f. Look for lighted front and rear B.O. lights. CONDITION/INDICATION IS MAIN LIGHT SWITCH OPERATING PROPERLY? DECISION NO - Replace defective main light switch (Volume 2, WP 0315). Go to Step (8) to verify problem is solved. YES - Repair or replace wiring from main light switch to non-operating lamp (Volume 3, WP 0352). Go to Step (8) to verify problem is solved. 0094-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00160) TM 9-2320-272-23-1 BLACKOUT DRIVE OR BLACKOUT MARKER LIGHT INOPERATIVE - Continued STEP 8. IS YOUR ORIGINAL BLACKOUT DRIVE OR MARKER LIGHT PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original blackout drive or marker light problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL BLACKOUT DRIVE OR MARKER LIGHT PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0094-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00160) 0094 TM 9-2320-272-23-1 FIELD MAINTENANCE STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0315 Volume 2, WP 0327 Volume 2, WP 0335 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT) NOTE Conduct these malfunction tests if stoplight is inoperative. This procedure will check for battery voltage at stoplight switch, defective bulb, faulty wiring, damaged contacts, faulty stoplight switch, and faulty main lighting switch. 0095-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00161) 0095 TM 9-2320-272-23-1 STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT) - Continued STEP 1. ARE BULBS IN GOOD CONDITION? a. Replace non-operating stoplight bulb with one known to be operative (Volume 2, WP 0327). T1024DAA Figure 1. b. Light Bulbs. Start engine and run to build air supply to normal operating pressure. NOTE • For stoplight circuit test, air pressure must be maintained at operating pressure and brake pedal must be depressed. • If all stoplights operates, bulb was faulty. c. Press brake pedal. d. Check if all stoplights operates. CONDITION/INDICATION ARE BULBS IN GOOD CONDITION? DECISION NO - Go to Step (12) to verify problem is solved. YES - Go to Step (2). STEP 2. ARE SOCKETS AND TERMINALS CLEAN AND IN GOOD CONDITION? a. Place battery switch to OFF position. T1025DAA Figure 2. Light Socket. 0095-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00161) 0095 TM 9-2320-272-23-1 0095 STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT) - Continued b. Visually check for corrosion or dirt in sockets or on terminals. Refer to point to point schematic. c. Clean corroded connections. CONDITION/INDICATION ARE SOCKETS AND TERMINALS CLEAN AND IN GOOD CONDITION? DECISION NO - Replace defective composite light (Volume 2, WP 0327). Go to Step (12) to verify problem is solved. YES - Go to Step (3). STEP 3. ARE LAMP HOLDERS IN GOOD OPERATING CONDITION? T1026DAA Figure 3. Lamp Holder. Visually check lamp holders for loose and broken wire terminals. Refer to point to point schematic. CONDITION/INDICATION ARE LAMP HOLDERS IN GOOD OPERATING CONDITION? DECISION NO - Repair or replace broken wire (Volume 3, WP 0352). Go to Step (12) to verify problem is solved. YES - Go to Step (4). 0095-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00161) TM 9-2320-272-23-1 0095 STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT) - Continued STEP 4. IS THERE VOLTAGE AT STOPLIGHT SWITCH? a. Place battery switch to OFF position. T0762DAA Figure 4. Stoplight Switch. b. Disconnect both circuit 75 wires at stoplight switch. c. Place battery switch to ON position. d. Set up multimeter to measure VDC. e. Connect multimeter black lead to good ground. f. Connect multimeter red lead to both circuit 75 wires, one at a time. Refer to point to point schematics. g. Meter reading should be greater than 18 VDC for at one of the wires. Note reading. CONDITION/INDICATION IS THERE VOLTAGE AT STOPLIGHT SWITCH? DECISION NO - Go to Step (5). YES - Go to Step (8). 0095-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00161) TM 9-2320-272-23-1 STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT) - Continued STEP 5. IS THERE BATTERY VOLTAGE AT MAIN LIGHT SWITCH HARNESS CONNECTOR? a. Place battery switch to OFF position. E F M C LK B A N H T0763DAA Figure 5. Main Lighting Switch Connector. b. Remove lighting switch from instrument panel and disconnect harness connector (Volume 2, WP 0315). c. Place battery switch to ON position. d. Connect multimeter red lead to connector socket pin F. Refer to point to point schematics. e. Connect multimeter black lead to good ground. f. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT MAIN LIGHT SWITCH HARNESS CONNECTOR? DECISION NO - Go to Step (6). YES - Go to Step (7). 0095-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00161) 0095 TM 9-2320-272-23-1 0095 STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT) - Continued STEP 6. IS WIRING HARNESS IN GOOD CONDITION? a. Place battery switch to OFF position. E F M C LK B A N H T0763DAA Figure 6. Main Lighting Switch Connector. b. Visually check wiring harness for loose connections or broken wiring. Refer to point to point schematic. CONDITION/INDICATION IS WIRING HARNESS IN GOOD CONDITION? DECISION NO - Repair or replace broken wire (Volume 3, WP 0352). Go to Step (8) to verify problem is solved. YES - Notify supervisor. Action may not be possible at this level of maintenance. 0095-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00161) TM 9-2320-272-23-1 0095 STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT) - Continued STEP 7. IS THERE CONTINUITY ACROSS CIRCUIT WIRE 75? a. Place battery switch to OFF position. b. Setup multimeter to measure ohms. E F M C N H LK B A T0763DAA Figure 7. Main Lighting Switch Connector. c. Connect jumper cable between lighting system harness connector socket pins A and K. Refer to point to point schematic. d. Connect multimeter red lead to circuit wire 75 at stop switch. e. Connect multimeter black lead to other circuit wire 75 at stop switch. f. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY ACROSS CIRCUIT WIRE 75? DECISION NO - Repair or replace broken circuit wire 75 (Volume 3, WP 0352). Go to Step (12) to verify problem is solved. YES - Replace defective main light switch (Volume 2, WP 0315). Go to Step (12) to verify problem is solved. 0095-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00161) TM 9-2320-272-23-1 0095 STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT) - Continued STEP 8. IS STOPLIGHT SWITCH OPERATING PROPERLY? a. Connect circuit 75 wire where battery voltage was present to stoplight switch terminal. T0764DAA Figure 8. Stoplight Switch Test. b. Connect multimeter red lead to circuit wire 75 at stop switch. Refer to point to point schematic. c. Connect multimeter black lead to vehicle chassis ground. NOTE For stoplight circuit test, air pressure must be maintained atIS THERE CONTINUITY ACROSS CIRCUIT WIRE 75? operating pressure and brake pedal must be depressed. d. Start vehicle engine and depress brake pedal. e. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS STOPLIGHT SWITCH OPERATING PROPERLY? DECISION NO - Replace defective stoplight switch (Volume 2, WP 0335). Go to Step (12) to verify problem is solved. YES - Go to Step (9). 0095-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00161) TM 9-2320-272-23-1 0095 STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT) - Continued STEP 9. IS THERE CONTINUITY ACROSS CIRCUIT WIRE 75? a. Place battery switch to OFF position. b. Disconnect circuit 75 wire at stoplight switch. c. Remove lighting switch from instrument panel and disconnect harness connector (Volume 2, WP 0315). d. Setup multimeter to measure ohms. E F M C LK B A N H T0763DAA Figure 9. Main Lighting Switch Connector. e. Connect jumper cable between lighting system harness connector socket pins A and K. Refer to point to point schematic. f. Connect multimeter red lead to circuit wire 75 at stop switch. g. Connect multimeter black lead to other circuit wire 75 at stop switch. h. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY ACROSS CIRCUIT WIRE 75? DECISION NO - Repair or replace broken circuit wire 75 (Volume 3, WP 0352). Go to Step (12) to verify problem is solved. YES - Go to Step (10). 0095-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00161) TM 9-2320-272-23-1 0095 STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT) - Continued STEP 10. IS MAIN LIGHT SWITCH OPERATING PROPERLY? a. Place battery switch to OFF position. E F M C LK B A N H T0763DAA Figure 10. b. Main Lighting Switch Connector. Connect jumper cable from socket pin F to socket pin C. Refer to point to point schematics. NOTE • For stoplight circuit test, air pressure must be maintained at operating pressure and brake pedal must be depressed. • If all service and blackout stoplights operate, main light switch is faulty. c. Start vehicle engine and depress brake pedal. d. Look for lighted service stoplights. e. Connect jumper cable from socket pin F to socket pin N. f. Look for lighted B.O stoplights. CONDITION/INDICATION IS MAIN LIGHT SWITCH OPERATING PROPERLY? DECISION NO - Replace defective main light switch (Volume 2, WP 0315). Go to Step (12) to verify problem is solved. YES - Go to Step (11). 0095-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00161) TM 9-2320-272-23-1 0095 STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT) - Continued STEP 11. IS STOPLIGHT WIRING HARNESS IN GOOD CONDITION? a. Place battery switch to OFF position. E F M C LK B A N H T0763DAA Figure 11. b. Main Lighting Switch Connector. Visually check wiring to rear composite light for damaged or loose wiring and connections. Refer to point to point schematic. CONDITION/INDICATION IS STOPLIGHT WIRING HARNESS IN GOOD CONDITION? DECISION NO - Repair or replace broken wire (Volume 3, WP 0352). Go to Step (8) to verify problem is solved. YES - Notify supervisor. Action may not be possible at this level of maintenance. STEP 12. IS YOUR ORIGINAL STOPLIGHT PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original stoplight problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL STOPLIGHT PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0095-11/12 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00161) TM 9-2320-272-23-1 FIELD MAINTENANCE TAIL AND MARKER LIGHTS INOPERATIVE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 2, WP 0315 Volume 2, WP 0327 Volume 2, WP 0330 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE TAIL AND MARKER LIGHTS INOPERATIVE NOTE Conduct these malfunction tests if tail and marker lights are inoperative. This procedure will check for battery voltage at tail and marker light connector, lighting system harness connector and faulty wiring or connectors. 0096-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00162) 0096 TM 9-2320-272-23-1 0096 TAIL AND MARKER LIGHTS INOPERATIVE - Continued STEP 1. ARE BULBS IN GOOD CONDITION? T1028DAA Figure 1. Light Bulbs. a. If taillight is inoperative, replace taillight bulb with one known to be operative (Volume 2, WP 0327). b. If side marker light is inoperative, replace side marker light bulb with one known to be operative (Volume 2, WP 0330). NOTE If all tail and marker lights operates, bulb was faulty. c. Place battery switch to ON position. d. Place lighting switch to SERVICE DRIVE position. e. Check if all tail and marker lights operates. CONDITION/INDICATION ARE BULBS IN GOOD CONDITION? DECISION NO - Go to Step (8) to verify problem is solved. YES - Go to Step (2). STEP 2. ARE SOCKETS AND TERMINALS CLEAN AND IN GOOD CONDITION? a. Place battery switch to OFF position. T1029DAA Figure 2. Light Socket. 0096-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00162) TM 9-2320-272-23-1 0096 TAIL AND MARKER LIGHTS INOPERATIVE - Continued b. Visually check for corrosion or dirt in sockets or on terminals. Refer to point to point schematic. c. Clean corroded connections. CONDITION/INDICATION ARE SOCKETS AND TERMINALS CLEAN AND IN GOOD CONDITION? DECISION NO - Composite light defective. Replace defective composite light (Volume 2, WP 0327). Go to Step (8) to verify problem is solved. NO - Marker light defective. Replace defective marker light (Volume 2, WP 0330). Go to Step (8) to verify problem is solved. YES - Go to Step (3). STEP 3. ARE LAMP HOLDERS IN GOOD OPERATING CONDITION? T1030DAA Figure 3. Lamp Holder. Visually check lamp holders for loose and broken wire terminals. Refer to point to point schematic. CONDITION/INDICATION ARE LAMP HOLDERS IN GOOD OPERATING CONDITION? DECISION NO - Repair or replace broken wire (Volume 3, WP 0352). Go to Step (8) to verify problem is solved. YES - Go to Step (4). 0096-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00162) TM 9-2320-272-23-1 0096 TAIL AND MARKER LIGHTS INOPERATIVE - Continued STEP 4. IS THERE BATTERY VOLTAGE AT NON-OPERATING TAIL AND MARKER LAMP CONNECTOR? a. Place battery switch to OFF position. 22-460 24 23 21 24 RH 22-461 24 23 21 24 LH T0767DAA Figure 4. Rear Composite Light. b. Disconnect circuit 21 wire from inoperative rear composite lights (taillight). c. Disconnect circuit 489 wire from inoperative marker light. d. Place battery switch to ON position. e. Place lighting switch to SERVICE DRIVE position. f. Set up multimeter to measure VDC. 0096-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00162) TM 9-2320-272-23-1 0096 TAIL AND MARKER LIGHTS INOPERATIVE - Continued g. Connect multimeter red lead to disconnected wire. Refer to point to point schematics. h. Connect multimeter black lead to good ground. i. Meter reading should be greater than 18 VDC for each reading. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT NON-OPERATING TAIL AND MARKER LAMP CONNECTOR? DECISION YES - Voltage at wire 21. Replace defective composite light (Volume 2, WP 0327). Go to Step (8) to verify problem is solved. YES - Voltage at wire 489. Replace defective marker light (Volume 2, WP 0330). Go to Step (8) to verify problem is solved. NO - Go to Step (5). STEP 5. IS THERE BATTERY VOLTAGE AT MAIN LIGHT SWITCH HARNESS CONNECTOR? a. Place battery switch to OFF position. E F M C LK B A N H T0768DAA Figure 5. Main Lighting Switch Connector. b. Remove lighting switch from instrument panel and disconnect harness connector (Volume 2, WP 0315). c. Place battery switch to ON position. d. Connect multimeter red lead to connector socket pin F. Refer to point to point schematics. e. Connect multimeter black lead to good ground. f. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT MAIN LIGHT SWITCH HARNESS CONNECTOR? DECISION NO - Go to Step (6). YES - Go to Step (7). 0096-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00162) TM 9-2320-272-23-1 0096 TAIL AND MARKER LIGHTS INOPERATIVE - Continued STEP 6. IS WIRING HARNESS IN GOOD CONDITION? a. Place battery switch to OFF position. E F M C LK B A N H T0768DAA Figure 6. Main Lighting Switch Connector. b. Visually check wiring harness for loose connections or broken wiring. Refer to point to point schematic. CONDITION/INDICATION IS WIRING HARNESS IN GOOD CONDITION? DECISION NO - Repair or replace broken wire (Volume 3, WP 0352). Go to Step (8) to verify problem is solved. YES - Notify supervisor. Action may not be possible at this level of maintenance. STEP 7. IS MAIN LIGHT SWITCH OPERATING PROPERLY? a. Place battery switch to OFF position. E F M C LK B A N H T0768DAA Figure 7. Main Lighting Switch Connector. b. Connect jumper cable from socket pin F to socket pin H. Refer to point to point schematics. c. Place battery switch to ON position. NOTE If non-operating tail and marker lights illuminates, lighting switch is not operating properly. d. Look for lighted tail and marker lights. 0096-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00162) TM 9-2320-272-23-1 0096 TAIL AND MARKER LIGHTS INOPERATIVE - Continued CONDITION/INDICATION IS MAIN LIGHT SWITCH OPERATING PROPERLY? DECISION NO - Replace defective main light switch (Volume 2, WP 0315). Go to Step (8) to verify problem is solved. YES - Repair or replace wiring from main light switch to non-operating lamp (Volume 3, WP 0352). Go to Step (8) to verify problem is solved. STEP 8. IS YOUR ORIGINAL TAIL OR MARKER LIGHT PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original tail or marker light problem still exists. Refer to point to point schematics. CONDITION/INDICATION IS YOUR ORIGINAL TAIL OR MARKER LIGHT PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0096-7/8 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00162) TM 9-2320-272-23-1 FIELD MAINTENANCE INDIVIDUAL LIGHTS DO NOT LIGHT WITH DIRECTIONAL SIGNAL LEVER IN ANY POSITION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) WP 0098 Volume 2, WP 0327 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE INDIVIDUAL LIGHTS DO NOT LIGHT WITH DIRECTIONAL SIGNAL LEVER IN ANY POSITION NOTE Conduct these malfunction tests if signal lamps do not light with directional signal control lever in any ON position. This procedure will check for defective lamps, dirty lamp sockets, and frayed or pinched wires. 0097-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00164) 0097 TM 9-2320-272-23-1 0097 INDIVIDUAL LIGHTS DO NOT LIGHT WITH DIRECTIONAL SIGNAL LEVER IN ANY POSITION - Continued STEP 1. IS LAMP IN GOOD OPERATING CONDITION? T1031DAA Figure 1. Light Bulbs. a. Replace non-operating signal bulb with one known to be operative (Volume 2, WP 0327). b. Place battery switch to ON position. c. Place main lighting switch in STOP TURN position. d. Place directional signal control lever to HAZARD warning position. NOTE If all turn signal lights flash, bulb is faulty. e. Check if stop signal lamps flash. CONDITION/INDICATION IS LAMP IN GOOD OPERATING CONDITION? DECISION NO - Signal lamp bulb was faulty. Go to Step (5) to verify problem is solved. YES - Go to Step (2). STEP 2. DOES BATTERY VOLTAGE CYCLE ON AND OFF AT CONNECTOR OF LAMP THAT DOES NOT ILLUMINATE? a. Place battery switch to OFF position. b. If right front turn signal not illuminating, disconnect wire 461 at right front composite light. c. If left front turn signal not illuminating, disconnect wire 460 at left front composite light. d. If right rear turn signal not illuminating, disconnect wire 22-461 at right rear composite light. e. If left rear turn signal not illuminating, disconnect wire 21-460 at left rear composite light. f. Place battery switch to ON position. g. Place main lighting switch in STOP TURN position. h. Place directional signal control lever to HAZARD warning position. i. Set up multimeter to measure VDC. 0097-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00164) TM 9-2320-272-23-1 0097 INDIVIDUAL LIGHTS DO NOT LIGHT WITH DIRECTIONAL SIGNAL LEVER IN ANY POSITION - Continued HAZARD WARNING POSITION CONTROL UNIT FLASHER FRONT COMPOSITE LIGHT REAR COMPOSITE LIGHT STOP TURN POSITION FRONT COMPOSITE LIGHT REAR COMPOSITE LIGHT VOM LIGHT SWITCH T0777DAA Figure 2. Directional Signal Circuit Test. j. Connect multimeter red lead to disconnected wire. Refer to point to point schematics. k. Connect multimeter black lead to a known good ground. l. Meter reading should cycle from 0 to greater than 18 VDC at a rate of 1 to 2 cycles per second. CONDITION/INDICATION DOES BATTERY VOLTAGE CYCLE ON AND OFF AT CONNECTOR OF LAMP THAT DOES NOT ILLUMINATE? DECISION NO - Go to Step (3). YES - Clean light socket and install lamp. Go to Step (5) to verify problem is solved. 0097-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00164) TM 9-2320-272-23-1 0097 INDIVIDUAL LIGHTS DO NOT LIGHT WITH DIRECTIONAL SIGNAL LEVER IN ANY POSITION - Continued STEP 3. IS THERE CONTINUITY THROUGH WIRE THAT CONNECTS TO FAULTY LAMP? a. Place battery switch to OFF position. b. Jumper disconnected wire to a known good ground. CONTROL UNIT FRONT COMPOSITE LIGHT REAR COMPOSITE LIGHT A E BC OFF POSITION LH FRONT COMPOSITE LIGHT HARNESS CONNECTOR RH REAR COMPOSITE LIGHT VOM RH LH LIGHT SWITCH T0778DAA Figure 3. Directional Signal Circuit Test. c. Disconnect wire connector from control unit. d. Set up multimeter to measure resistance. e. Near control unit, connect multimeter black lead to good ground. f. If wire 461 is disconnected, connect multimeter red lead to circuit 461 wire at socket point B. Refer to point to point schematics. g. If wire 460 is disconnected, connect multimeter red lead to circuit 460 wire at socket point A. h. If wire 22-461 is disconnected, connect multimeter red lead to circuit 22-461 wire at socket point C. i. If wire 21-460 is disconnected, connect multimeter red lead to circuit 21-460 wire at socket point E. j. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY THROUGH WIRE THAT CONNECTS TO FAULTY LAMP? DECISION NO - Repair broken wire (Volume 3, WP 0352). Go to Step (5) to verify problem is solved. YES - Go to Step (4). 0097-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00164) TM 9-2320-272-23-1 0097 INDIVIDUAL LIGHTS DO NOT LIGHT WITH DIRECTIONAL SIGNAL LEVER IN ANY POSITION - Continued STEP 4. IS THERE A SHORT IN THE WIRING HARNESS? a. Remove jumper from disconnected wire and ground. CONTROL UNIT FRONT COMPOSITE LIGHT HARNESS CONNECTOR REAR COMPOSITE LIGHT A E BC OFF POSITION LH FRONT COMPOSITE LIGHT RH REAR COMPOSITE LIGHT VOM RH LH LIGHT SWITCH T0778DAA Figure 4. Directional Signal Circuit Test. b. Near control unit, connect multimeter black lead to good ground. c. If wire 461 is disconnected, connect multimeter red lead to circuit 461 wire at socket point B. Refer to point to point schematics. d. If wire 460 is disconnected, connect multimeter red lead to circuit 460 wire at socket point A. e. If wire 22-461 is disconnected, connect multimeter red lead to circuit 22-461 wire at socket point C. f. If wire 21-460 is disconnected, connect multimeter red lead to circuit 21-460 wire at socket point E. g. Meter reading should be greater than 10,000 ohms. CONDITION/INDICATION IS THERE A SHORT IN THE WIRING HARNESS? DECISION YES - Repair frayed, or pinched wire (Volume 3, WP 0352). Go to Step (5) to verify problem is solved. NO - Perform No Lights Operate With Directional Signal Lever In Any Position (WP 0098) troubleshooting. 0097-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00164) TM 9-2320-272-23-1 0097 INDIVIDUAL LIGHTS DO NOT LIGHT WITH DIRECTIONAL SIGNAL LEVER IN ANY POSITION - Continued STEP 5. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0097-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00164) TM 9-2320-272-23-1 FIELD MAINTENANCE NO LIGHTS OPERATE WITH DIRECTIONAL SIGNAL CONTROL LEVER IN ANY POSITION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) WP 0099 Volume 2, WP 0315 Volume 2, WP 0318 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE NO LIGHTS OPERATE WITH DIRECTIONAL SIGNAL CONTROL LEVER IN ANY POSITION NOTE Conduct these malfunction tests if no lights operate with directional signal control lever in any ON position. This procedure will check the control unit cable and flasher. 0098-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00165) 0098 TM 9-2320-272-23-1 0098 NO LIGHTS OPERATE WITH DIRECTIONAL SIGNAL CONTROL LEVER IN ANY POSITION - Continued STEP 1. IS THERE BATTERY VOLTAGE AT PIN G OF THE CONNECTOR CONTROL UNIT? a. Place battery switch to OFF position. CONNECTOR ON CONTROL UNIT HARNESS G STOP TURN POSITION VOM LIGHT SWITCH T0780DAA Figure 1. Control Unit Harness Connector. b. Disconnect control unit harness connector from directional signal control unit. c. Place battery switch to ON position. d. Place lighting switch to STOP TURN position. e. Set up multimeter to measure VDC. f. Connect multimeter red lead to connector terminal point G. Refer to point to point schematics. g. Connect multimeter black lead to a known good ground. h. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT PIN G OF THE CONNECTOR CONTROL UNIT? DECISION NO - Go to Step (2). YES - Go to Step (5). STEP 2. IS THERE BATTERY VOLTAGE AT MAIN LIGHT SWITCH HARNESS CONNECTOR? a. Place battery switch to OFF position. 0098-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00165) TM 9-2320-272-23-1 0098 NO LIGHTS OPERATE WITH DIRECTIONAL SIGNAL CONTROL LEVER IN ANY POSITION - Continued M C E F L K B A N H T1027DAA Figure 2. Main Lighting Switch Connector. b. Remove lighting switch from instrument panel and disconnect harness connector (Volume 2, WP 0315). c. Place battery switch to ON position. d. Connect multimeter red lead to connector socket pin F. Refer to point to point schematics. e. Connect multimeter black lead to good ground. f. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT MAIN LIGHT SWITCH HARNESS CONNECTOR? DECISION NO - Go to Step (3). YES - Go to Step (4). STEP 3. IS WIRING HARNESS IN GOOD CONDITION? a. Place battery switch to OFF position. M C E F L K B A N H T1027DAA Figure 3. b. Main Lighting Switch Connector. Visually check wiring harness for loose connections or broken wiring. Refer to point to point schematic. CONDITION/INDICATION IS WIRING HARNESS IN GOOD CONDITION? DECISION NO - Repair or replace broken wire (Volume 3, WP 0352). Go to Step (9) to verify problem is solved. YES - Notify supervisor. Action may not be possible at this level of maintenance. 0098-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00165) TM 9-2320-272-23-1 0098 NO LIGHTS OPERATE WITH DIRECTIONAL SIGNAL CONTROL LEVER IN ANY POSITION - Continued STEP 4. IS MAIN LIGHT SWITCH OPERATING PROPERLY? a. Place battery switch to OFF position. M C E F L K B A N H T1027DAA Figure 4. Main Lighting Switch Connector. b. Connect jumper cable from socket pin F to socket pin J. Refer to point to point schematics. c. Place battery switch to ON position. d. Connect multimeter red lead to control unit harness connector socket pin G. e. Connect multimeter black lead to good ground. NOTE If meter reading is greater than 18 VDC, main light switch is faulty. f. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS MAIN LIGHT SWITCH OPERATING PROPERLY? DECISION NO - Replace defective main light switch (Volume 2, WP 0315). Go to Step (9) to verify problem is solved. YES - Repair or replace wiring from main light switch to control unit (Volume 3, WP 0352). Go to Step (9) to verify problem is solved. 0098-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00165) TM 9-2320-272-23-1 0098 NO LIGHTS OPERATE WITH DIRECTIONAL SIGNAL CONTROL LEVER IN ANY POSITION - Continued STEP 5. IS THERE CONTINUITY BETWEEN TERMINAL A OF THE FLASHER UNIT AND TERMINAL H OF THE CONTROL UNIT CABLE? a. Set up multimeter to measure resistance. CONTROL UNIT CABLE FLASHER UNIT CABLE VOM 2 1 F A H C B 1 2 3 T1032DAA Figure 5. Flasher Wire Harness Test. b. Connect multimeter red lead to terminal H of the control unit cable. Refer to point to point schematics. c. Connect multimeter black lead to terminal A of the flasher units. d. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN TERMINAL A OF THE FLASHER UNIT AND TERMINAL H OF THE CONTROL UNIT CABLE? DECISION NO - Repair faulty wire (Volume 3, WP 0352). Go to Step (9) to verify problem is solved. YES - Go to Step (6). 0098-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00165) TM 9-2320-272-23-1 0098 NO LIGHTS OPERATE WITH DIRECTIONAL SIGNAL CONTROL LEVER IN ANY POSITION - Continued STEP 6. IS THERE CONTINUITY BETWEEN TERMINAL B OF THE FLASHER UNIT AND TERMINAL F OF THE CONTROL UNIT CABLE? a. Connect multimeter red lead to terminal F of the control unit cable. Refer to point to point schematics. CONTROL UNIT CABLE FLASHER UNIT CABLE VOM 2 1 F A H C B 1 2 3 T1032DAA Figure 6. Flasher Wire Harness Test. b. Connect multimeter black lead to terminal B of the flasher units. c. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN TERMINAL B OF THE FLASHER UNIT AND TERMINAL F OF THE CONTROL UNIT CABLE? DECISION NO - Repair faulty wire (Volume 3, WP 0352). Go to Step (9) to verify problem is solved. YES - Go to Step (7). 0098-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00165) TM 9-2320-272-23-1 0098 NO LIGHTS OPERATE WITH DIRECTIONAL SIGNAL CONTROL LEVER IN ANY POSITION - Continued STEP 7. IS THERE CONTINUITY BETWEEN TERMINAL C OF THE FLASHER UNIT AND GROUND? a. Connect multimeter red lead to terminal C of the flasher unit. Refer to point to point schematics. CONTROL UNIT CABLE FLASHER UNIT CABLE VOM 2 1 F A H C B 1 2 3 T1032DAA Figure 7. Flasher Wire Harness Test. b. Connect multimeter black lead to a known good ground. c. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN TERMINAL C OF THE FLASHER UNIT AND GROUND? DECISION NO - Repair faulty wire (Volume 3, WP 0352). Go to Step (9) to verify problem is solved. YES - Go to Step (8). STEP 8. IS YOUR ORIGINAL PROBLEM STILL PRESENT AFTER REPLACING FLASHER UNIT? a. Replace flasher unit (Volume 2, WP 0318). b. Ensure vehicle is returned to normal operating condition. c. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT AFTER REPLACING FLASHER UNIT? DECISION YES - Perform System Operates Incorrectly In One Or More Posiitions Of Directional Signal Control Lever troubleshooting (WP 0099). NO - Problem fixed. 0098-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00165) TM 9-2320-272-23-1 NO LIGHTS OPERATE WITH DIRECTIONAL SIGNAL CONTROL LEVER IN ANY POSITION - Continued STEP 9. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0098-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00165) 0098 TM 9-2320-272-23-1 0099 FIELD MAINTENANCE SYSTEM OPERATES INCORRECTLY IN ONE OR MORE POSITIONS OF DIRECTIONAL SIGNAL CONTROL LEVER INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References Point to Point Schematics Volume 2, WP 0317 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) TROUBLESHOOTING PROCEDURE SYSTEM OPERATES INCORRECTLY IN ONE OR MORE POSITIONS OF DIRECTIONAL SIGNAL CONTROL LEVER NOTE Conduct these malfunction tests if the system operates incorrectly in one or more positions of directional signal control lever. This procedure will check for a defective directional signal control unit. 0099-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00166) TM 9-2320-272-23-1 0099 SYSTEM OPERATES INCORRECTLY IN ONE OR MORE POSITIONS OF DIRECTIONAL SIGNAL CONTROL LEVER - Continued STEP 1. DO THE ELECTRICAL CONTACTS INSIDE THE DIRECTIONAL SIGNAL CONTROL UNIT WORK PROPERLY WHEN IN "NEUTRAL" POSITION? a. Set up multimeter to measure resistance. b. Disconnect control unit harness connector from directional signal control unit. c. Remove indicator lamp from directional signal control. d. Set control lever to "Neutral" position. DIRECTIONAL SIGNAL CONTROL LEVER IN “NEUTRAL” POSITION TEST PROBE LEADS BLACK (-) RED (+) H H H H D D F CONTINUITY INDICATION OPEN OPEN OPEN OPEN SHORTED SHORTED OPEN A B C E C E G T0782DAA Figure 1. Directional Signal Control Neutral Position. e. Connect multimeter black lead to first location listed in graphic. Refer to point to point schematics. f. Connect multimeter red lead to first location listed in graphic. g. Note reading and compare to the first location listed under "Continuity Indication". Meter reading should be greater than 10,000 ohms for open indication. h. Move black and red multimeter leads to each location listed in the graphic and compare the readings to those listed under "Continuity Indication". CONDITION/INDICATION DO THE ELECTRICAL CONTACTS INSIDE THE DIRECTIONAL SIGNAL CONTROL UNIT WORK PROPERLY WHEN IN "NEUTRAL" POSITION? DECISION NO - Replace directional signal control unit (Volume 2, WP 0317). Go to Step (5) to verify problem is solved. YES - Go to Step (2). 0099-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00166) TM 9-2320-272-23-1 0099 SYSTEM OPERATES INCORRECTLY IN ONE OR MORE POSITIONS OF DIRECTIONAL SIGNAL CONTROL LEVER - Continued STEP 2. DO THE ELECTRICAL CONTACTS INSIDE THE DIRECTIONAL SIGNAL CONTROL UNIT WORK PROPERLY WHEN IN "RIGHT TURN" POSITION? a. Set control lever to "Right Turn" position. DIRECTIONAL SIGNAL CONTROL LEVER IN “RIGHT TURN” POSITION TEST PROBE LEADS BLACK (-) RED (+) F H H H H D D CONTINUITY INDICATION SHORTED SHORTED SHORTED OPEN OPEN SHORTED OPEN G A E B C C E T0783DAA Figure 2. Directional Signal Control Right Turn Position. b. Connect multimeter black lead to first location listed in graphic. Refer to point to point schematics. c. Connect multimeter red lead to first location listed in graphic. d. Note reading and compare to the first location listed under "Continuity Indication". Meter reading should be greater than 10,000 ohms for open indication. e. Move black and red multimeter leads to each location listed in the graphic and compare the readings to those listed under "Continuity Indication". CONDITION/INDICATION DO THE ELECTRICAL CONTACTS INSIDE THE DIRECTIONAL SIGNAL CONTROL UNIT WORK PROPERLY WHEN IN "RIGHT TURN" POSITION? DECISION NO - Replace directional signal control unit (Volume 2, WP 0317). Go to Step (5) to verify problem is solved. YES - Go to Step (3). 0099-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00166) TM 9-2320-272-23-1 0099 SYSTEM OPERATES INCORRECTLY IN ONE OR MORE POSITIONS OF DIRECTIONAL SIGNAL CONTROL LEVER - Continued STEP 3. DO THE ELECTRICAL CONTACTS INSIDE THE DIRECTIONAL SIGNAL CONTROL UNIT WORK PROPERLY WHEN IN "LEFT TURN" POSITION? a. Set control lever to "Left Turn" position. DIRECTIONAL SIGNAL CONTROL LEVER IN “LEFT TURN” POSITION TEST PROBE LEADS BLACK (-) RED (+) H H H H F D D CONTINUITY INDICATION SHORTED SHORTED OPEN OPEN SHORTED SHORTED OPEN B C A E G E C T0784DAA Figure 3. Directional Signal Control Left Turn Position. b. Connect multimeter black lead to first location listed in graphic. Refer to point to point schematics. c. Connect multimeter red lead to first location listed in graphic. d. Note reading and compare to the first location listed under "Continuity Indication". Meter reading should be greater than 10,000 ohms for open indication. e. Move black and red multimeter leads to each location listed in the graphic and compare the readings to those listed under "Continuity Indication". CONDITION/INDICATION DO THE ELECTRICAL CONTACTS INSIDE THE DIRECTIONAL SIGNAL CONTROL UNIT WORK PROPERLY WHEN IN "LEFT TURN" POSITION? DECISION NO - Replace directional signal control unit (Volume 2, WP 0317). Go to Step (5) to verify problem is solved. YES - Go to Step (4). STEP 4. DO THE ELECTRICAL CONTACTS INSIDE THE DIRECTIONAL SIGNAL CONTROL UNIT WORK PROPERLY WHEN IN "HAZARD WARNING" POSITION? a. Set control lever to "Hazard Warning" position. 0099-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00166) TM 9-2320-272-23-1 0099 SYSTEM OPERATES INCORRECTLY IN ONE OR MORE POSITIONS OF DIRECTIONAL SIGNAL CONTROL LEVER - Continued DIRECTIONAL SIGNAL CONTROL LEVER IN “HAZARD WARNING” POSITION TEST PROBE LEADS BLACK (-) RED (+) H H H H D D F G A E B C C E CONTINUITY INDICATION SHORTED SHORTED SHORTED SHORTED OPEN OPEN SHORTED T0785DAA Figure 4. Directional Signal Control Hazzard Position. b. Connect multimeter black lead to first location listed in graphic. Refer to point to point schematics. c. Connect multimeter red lead to first location listed in graphic. d. Note reading and compare to the first location listed under "Continuity Indication". Meter reading should be greater than 10,000 ohms for open indication. e. Move black and red multimeter leads to each location listed in the graphic and compare the readings to those listed under "Continuity Indication". CONDITION/INDICATION DO THE ELECTRICAL CONTACTS INSIDE THE DIRECTIONAL SIGNAL CONTROL UNIT WORK PROPERLY WHEN IN "HAZARD WARNING" POSITION? DECISION NO - Replace directional signal control unit (Volume 2, WP 0317). Go to Step (5) to verify problem is solved. YES - Go to Step (5) to verify problem is solved. STEP 5. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0099-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00166) TM 9-2320-272-23-1 FIELD MAINTENANCE PROTECTIVE CONTROL BOX ASSEMBLY TEST INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References Point to Point Schematics Volume 2, WP 0319 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) TROUBLESHOOTING PROCEDURE PROTECTIVE CONTROL BOX ASSEMBLY TEST NOTE Conduct these malfunction tests is protective control box is not operating properly. This procedure will check for fault protection control box. 0100-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00187) 0100 TM 9-2320-272-23-1 0100 PROTECTIVE CONTROL BOX ASSEMBLY TEST - Continued STEP 1. IS PROTECTIVE CONTROL BOX PROPERLY GROUNDED? a. Disconnect connector from protective control box. b. Set up multimeter to measure ohms. PROTECTIVE CONTROL BOX PROTECTIVE CONTROL BOX F A G E B D C PROTECTIVE CONTROL CONNECTOR T1066DAA Figure 1. Protective Control Box Connector. c. Connect multimeter red lead to protective control box connector pin E. Refer to point to point schematics. d. Connect multimeter black lead to chassis ground. e. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS PROTECTIVE CONTROL BOX PROPERLY GROUNDED? DECISION NO - Replace protective control box (Volume 2, WP 0319). Go to Step (10) to verify problem is solved. YES - Go to Step (2). 0100-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00187) TM 9-2320-272-23-1 0100 PROTECTIVE CONTROL BOX ASSEMBLY TEST - Continued STEP 2. IS THERE NO CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR PINS B AND D? PROTECTIVE CONTROL BOX PROTECTIVE CONTROL BOX F A G E B D C PROTECTIVE CONTROL CONNECTOR T1066DAA Figure 2. Protective Control Box Connector. a. Connect multimeter red lead to protective control box connector pin B. Refer to point to point schematics. b. Connect multimeter black lead to protective control box connector pin D. c. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS THERE NO CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR PINS B AND D? DECISION NO - Replace protective control box (Volume 2, WP 0319). Go to Step (10) to verify problem is solved. YES - Go to Step (3). 0100-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00187) TM 9-2320-272-23-1 0100 PROTECTIVE CONTROL BOX ASSEMBLY TEST - Continued STEP 3. IS THERE NO CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR PINS C AND D? PROTECTIVE CONTROL BOX PROTECTIVE CONTROL BOX F A G E B D C PROTECTIVE CONTROL CONNECTOR T1066DAA Figure 3. Protective Control Box Connector. a. Connect multimeter red lead to protective control box connector pin C. Refer to point to point schematics. b. Connect multimeter black lead to protective control box connector pin D. c. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS THERE NO CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR PINS C AND D? DECISION NO - Replace protective control box (Volume 2, WP 0319). Go to Step (10) to verify problem is solved. YES - Go to Step (4). 0100-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00187) TM 9-2320-272-23-1 0100 PROTECTIVE CONTROL BOX ASSEMBLY TEST - Continued STEP 4. IS THERE NO CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR PINS A AND GROUND? PROTECTIVE CONTROL BOX PROTECTIVE CONTROL BOX F A G E B D C PROTECTIVE CONTROL CONNECTOR T1066DAA Figure 4. Protective Control Box Connector. a. Connect multimeter red lead to protective control box connector pin A. Refer to point to point schematics. b. Connect multimeter black lead to chassis ground. c. Meter reading should be about 1,000 ohms. CONDITION/INDICATION IS THERE NO CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR PINS A AND GROUND? DECISION NO - Replace protective control box (Volume 2, WP 0319). Go to Step (10) to verify problem is solved. YES - Go to Step (5). 0100-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00187) TM 9-2320-272-23-1 0100 PROTECTIVE CONTROL BOX ASSEMBLY TEST - Continued STEP 5. IS THERE NO CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR PINS B AND GROUND? PROTECTIVE CONTROL BOX PROTECTIVE CONTROL BOX F A G E B D C PROTECTIVE CONTROL CONNECTOR T1066DAA Figure 5. Protective Control Box Connector. a. Connect multimeter red lead to protective control box connector pin B. Refer to point to point schematics. b. Connect multimeter black lead to chassis ground. c. Meter reading should be greater than 10,000 ohms. CONDITION/INDICATION IS THERE NO CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR PINS B AND GROUND? DECISION NO - Replace protective control box (Volume 2, WP 0319). Go to Step (10) to verify problem is solved. YES - Go to Step (6). 0100-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00187) TM 9-2320-272-23-1 0100 PROTECTIVE CONTROL BOX ASSEMBLY TEST - Continued STEP 6. IS THERE NO CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR PINS C AND GROUND? PROTECTIVE CONTROL BOX PROTECTIVE CONTROL BOX F A G E B D C PROTECTIVE CONTROL CONNECTOR T1066DAA Figure 6. Protective Control Box Connector. a. Connect multimeter red lead to protective control box connector pin C. Refer to point to point schematics. b. Connect multimeter black lead to chassis ground. c. Meter reading should be greater than 10,000 ohms. CONDITION/INDICATION IS THERE NO CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR PINS C AND GROUND? DECISION NO - Replace protective control box (Volume 2, WP 0319). Go to Step (10) to verify problem is solved. YES - Go to Step (7). 0100-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00187) TM 9-2320-272-23-1 0100 PROTECTIVE CONTROL BOX ASSEMBLY TEST - Continued STEP 7. IS THERE NO CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR PINS D AND GROUND? PROTECTIVE CONTROL BOX PROTECTIVE CONTROL BOX F A G E B D C PROTECTIVE CONTROL CONNECTOR T1066DAA Figure 7. Protective Control Box Connector. a. Connect multimeter red lead to protective control box connector pin D. Refer to point to point schematics. b. Connect multimeter black lead to chassis ground. c. Meter reading should be about 1,000 ohms. CONDITION/INDICATION IS THERE NO CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR PINS D AND GROUND? DECISION NO - Replace protective control box (Volume 2, WP 0319). Go to Step (10) to verify problem is solved. YES - Go to Step (8). STEP 8. IS THERE CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR C AND D AND NO CONTINUITY BETWEEN B AND D, WHEN 24 VDC IS APPLIED TO PIN A? 0100-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00187) TM 9-2320-272-23-1 0100 PROTECTIVE CONTROL BOX ASSEMBLY TEST - Continued PROTECTIVE CONTROL BOX PROTECTIVE CONTROL BOX F A G E B D C PROTECTIVE CONTROL CONNECTOR T1066DAA Figure 8. Protective Control Box Connector. a. Apply 24 VDC to pin A. b. Connect multimeter red lead to protective control box connector pin C. Refer to point to point schematics. c. Connect multimeter black lead to protective control box connector pin D. d. Meter reading should be less than 200 ohms. Note reading. e. Connect multimeter red lead to protective control box connector pin B. f. Connect multimeter black lead to protective control box connector pin D. g. Meter reading should be greater than 10,000 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR C AND D AND NO CONTINUITY BETWEEN B AND D, WHEN 24 VDC IS APPLIED TO PIN A? DECISION NO - Replace protective control box (Volume 2, WP 0319). Go to Step (10) to verify problem is solved. YES - Go to Step (9). 0100-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00187) TM 9-2320-272-23-1 0100 PROTECTIVE CONTROL BOX ASSEMBLY TEST - Continued STEP 9. IS THERE CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR B AND D, WHEN 24 VDC IS APPLIED TO PIN E? PROTECTIVE CONTROL BOX PROTECTIVE CONTROL BOX F A G E B D C PROTECTIVE CONTROL CONNECTOR T1066DAA Figure 9. Protective Control Box Connector. a. Disconnect 24 VDC from pin A. b. Apply 24 VDC to pin E. c. Connect multimeter red lead to protective control box connector pin B. Refer to point to point schematics. d. Connect multimeter black lead to protective control box connector pin D. e. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PROTECTIVE CONTROL BOX CONNECTOR B AND D, WHEN 24 VDC IS APPLIED TO PIN E? DECISION NO - Replace protective control box (Volume 2, WP 0319). Go to Step (10) to verify problem is solved. YES - Go to Step (10) to verify problem is solved. 0100-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00187) TM 9-2320-272-23-1 PROTECTIVE CONTROL BOX ASSEMBLY TEST - Continued STEP 10. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0100-11/12 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00187) 0100 TM 9-2320-272-23-1 FIELD MAINTENANCE SPEEDOMETER OR TACHOMETER NOISY OR ERRATIC INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References (cont.) Volume 5, WP 0815 Volume 5, WP 0817 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Volume 5, WP 0814 TROUBLESHOOTING PROCEDURE SPEEDOMETER OR TACHOMETER NOISY OR ERRATIC NOTE Conduct these malfunction tests if the speedometer or tachometer is noisy or erratic. This procedure will check the speedometer/tachometer flexible shaft for binding, kinks, or loose connections, and the speedometer or tachometer for proper operation. 0101-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00125) 0101 TM 9-2320-272-23-1 0101 SPEEDOMETER OR TACHOMETER NOISY OR ERRATIC - Continued STEP 1. ARE THE SPEEDOMETER AND TACHOMETER FLEXIBLE SHAFTS IN GOOD OPERATING CONDITION? Visually check the speedometer and tachometer flexible shafts for binding, kinks, or loose connections. FLEXIBLE SHAFT T026DAA Figure 1. Speedometer and Tachometer Flexible Shafts CONDITION/INDICATION ARE THE SPEEDOMETER AND TACHOMETER FLEXIBLE SHAFTS IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (2). NO - Replace speedometer flexible shaft or tighten connections (Volume 5, WP 0814). Go to Step (3) to verify problem is solved. NO - Replace tachometer flexible shaft or tighten connections (Volume 5, WP 0817). Go to Step (3) to verify problem is solved. STEP 2. ARE SPEEDOMETER AND TACHOMETER IN GOOD OPERATING CONDITION? Test operation of tachometer and speedometer. 0101-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00125) TM 9-2320-272-23-1 0101 SPEEDOMETER OR TACHOMETER NOISY OR ERRATIC - Continued T0628DAA Figure 2. Speedometer and Tachometer. CONDITION/INDICATION ARE SPEEDOMETER AND TACHOMETER IN GOOD OPERATING CONDITION? DECISION NO - Replace defective speedometer or tachometer (Volume 5, WP 0815). Go to Step (3) to verify problem is solved. YES - Go to Step (3) to verify problem is solved. STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0101-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00125) TM 9-2320-272-23-1 FIELD MAINTENANCE AIR PRESSURE GAUGE INOPERATIVE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Remove instrument cluster panel. (Volume 2, WP 0310) Personnel Required (2) References Point to Point Schematics Volume 5, WP 0818 TROUBLESHOOTING PROCEDURE AIR PRESSURE GAUGE INOPERATIVE NOTE Conduct these malfunction tests if air pressure gauge is inoperative. This procedure will check the air pressure gauge for proper operation. 0102-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00126) 0102 TM 9-2320-272-23-1 0102 AIR PRESSURE GAUGE INOPERATIVE - Continued STEP 1. DOES AIR PRESSURE GAUGE HAVE AIR SUPPLY? a. Check air supply at air pressure gauge. b. Refer to point to point schematics. T0629DAA Figure 1. Air Pressure Gauge. c. Make sure air pressure is at normal operating pressure and warning buzzer is not sounding. d. Loosen air supply line from defective air pressure gauge very slowly and listen for air escaping. CONDITION/INDICATION DOES AIR PRESSURE GAUGE HAVE AIR SUPPLY? DECISION YES - Go to Step (2). NO - Notify supervisor. It is possible another troubleshooting work package applies. 0102-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00126) TM 9-2320-272-23-1 0102 AIR PRESSURE GAUGE INOPERATIVE - Continued STEP 2. IS AIR PRESSURE GAUGE OPERATING PROPERLY? a. Refer to point to point schematics. b. Replace air gauge with one known to be good (Volume 5, WP 0818). c. Start engine. T0629DAA Figure 2. Air Pressure Gauge. NOTE If air pressure reads 30 psi within 5 minutes, air pressure gauge was not operating correctly. d. Observe air pressure gauge and verify it reads at least 30 psi within five minutes. CONDITION/INDICATION IS AIR PRESSURE GAUGE OPERATING PROPERLY? DECISION NO - If test air pressure gauge operates properly, replace defective air pressure gauge (Volume 5, WP 0818). Go to Step (3) to verify problem is solved. YES - Notify supervisor. It is possible another troubleshooting work package applies. 0102-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00126) TM 9-2320-272-23-1 AIR PRESSURE GAUGE INOPERATIVE - Continued STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0102-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00126) 0102 TM 9-2320-272-23-1 FIELD MAINTENANCE OIL PRESSURE GAUGE INOPERATIVE (OIL LEVEL IS CORRECT) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 2, WP 0310 Volume 2, WP 0312 Volume 2, WP 0333 Volume 3, WP 0351 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE OIL PRESSURE GAUGE INOPERATIVE (OIL LEVEL IS CORRECT) NOTE Conduct these malfunction tests if oil pressure gauge is inoperative. This procedure will check for a faulty sending unit, wiring harness or gauge. 0103-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00127) 0103 TM 9-2320-272-23-1 OIL PRESSURE GAUGE INOPERATIVE (OIL LEVEL IS CORRECT) - Continued STEP 1. IS OIL PRESSURE SENDING UNIT OPERATIONAL? a. Place battery switch in the OFF position. b. Refer to point to point schematics. T0631DAA Figure 1. Oil Pressure Sending Unit. 0103-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00127) 0103 TM 9-2320-272-23-1 OIL PRESSURE GAUGE INOPERATIVE (OIL LEVEL IS CORRECT) - Continued c. Remove circuit 36 wire from oil pressure sending unit. d. Place battery switch to ON position. e. Have assistant momentarily ground disconnected circuit 36 wire. NOTE If oil pressure gauge deflects when grounded, oil pressure sending unit is faulty. f. Observe oil pressure gauge for movement. CONDITION/INDICATION IS OIL PRESSURE SENDING UNIT OPERATIONAL? DECISION YES - Go to Step (2). NO - Replace oil pressure sending unit (Volume 2, WP 0333). Go to Step (4) to verify problem is solved. 0103-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00127) 0103 TM 9-2320-272-23-1 0103 OIL PRESSURE GAUGE INOPERATIVE (OIL LEVEL IS CORRECT) - Continued STEP 2. IS CIRCUIT 36 WIRE IN GOOD CONDITION? a. Visually check circuit 36 wire for damage. b. Refer to point to point schematics. c. Remove instrument cluster panel (Volume 2, WP 0310). 27 27 27 27 27 JUMPER WIRE TO GROUND T0632DAA Figure 2. Oil Pressure Gauge Test. 0103-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00127) TM 9-2320-272-23-1 OIL PRESSURE GAUGE INOPERATIVE (OIL LEVEL IS CORRECT) - Continued d. Disconnect circuit 36 wire from oil pressure gauge. e. Connect jumper wire to open oil pressure gauge terminal. f. Place battery switch to ON position. g. Momentarily touch jumper wire to vehicle chassis ground. NOTE If oil pressure gauge deflects when grounded, circuit 36 wire is faulty. h. Observe oil pressure gauge for movement. CONDITION/INDICATION IS CIRCUIT 36 WIRE IN GOOD CONDITION? DECISION YES - Go to Step (3). NO - Repair circuit 36 wire (Volume 3, WP 0352). Go to Step (4) to verify problem is solved. 0103-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00127) 0103 TM 9-2320-272-23-1 0103 OIL PRESSURE GAUGE INOPERATIVE (OIL LEVEL IS CORRECT) - Continued STEP 3. IS THERE BATTERY VOLTAGE AT OIL PRESSURE GAUGE? a. Check for battery voltage at oil pressure gauge. b. Place battery switch to the OFF position. c. Refer to point to point schematics. TEST POINT 27 27 27 27 27 T0634DAA Figure 3. Oil Pressure Gauge Voltage Test. d. Disconnect circuit 27 wire from inoperative oil pressure gauge. e. Set multimeter to measure VDC. f. Place battery switch to ON position. g. Connect multimeter probe red lead to disconnected circuit 27 wire. h. Connect multimeter probe black lead to vehicle chassis ground. i. Meter reading should be greater than or equal to 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT OIL PRESSURE GAUGE? DECISION YES - Replace defective gauge (Volume 2, WP 0312). Go to Step (4) to verify problem is solved. NO - Replace instrument cluster wiring harness (Volume 3, WP 0351). Go to Step (4) to verify problem is solved. 0103-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00127) TM 9-2320-272-23-1 OIL PRESSURE GAUGE INOPERATIVE (OIL LEVEL IS CORRECT) - Continued STEP 4. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0103-7/8 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00127) 0103 TM 9-2320-272-23-1 FIELD MAINTENANCE ALL GAUGES INOPERATIVE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 2, WP 0307 Volume 2, WP 0310 Volume 3, WP 0352 Volume 3, WP 0357 Volume 3, WP 0358 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE ALL GAUGES INOPERATIVE NOTE Conduct these malfunction tests if all gauges are inoperative. This procedure will check for instrument panel voltage feed, defective circuit breaker, defective gauge and instrument cluster wire assembly. 0104-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00168) 0104 TM 9-2320-272-23-1 0104 ALL GAUGES INOPERATIVE - Continued STEP 1. IS INSTRUMENT CLUSTER CIRCUIT BREAKER BATTERY VOLTAGE FEED CORRECT? a. Place battery switch to the OFF position. b. Check instrument cluster voltage feed. c. Refer to point to point schematics. T0082DAA Figure 1. Circuit Breaker. d. Disconnect circuit 5A wire at circuit breaker. e. Set multimeter to measure VDC. f. Place battery switch to ON position. g. Connect multimeter red lead to disconnected circuit 5A wire. h. Connect multimeter black lead to vehicle chassis ground. i. Meter reading should be greater than or equal to 18 VDC. CONDITION/INDICATION IS INSTRUMENT CLUSTER CIRCUIT BREAKER BATTERY VOLTAGE FEED CORRECT? DECISION YES - Go to Step (2). NO - Repair or replace circuit 5A wire (Volume 3, WP 0352). Go to Step (4) to verify problem is solved. STEP 2. IS CIRCUIT BREAKER IN GOOD OPERATING CONDITION? a. Check for battery voltage at circuit breaker terminal. b. Place battery switch to the OFF position. 0104-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00168) TM 9-2320-272-23-1 0104 ALL GAUGES INOPERATIVE - Continued T0082DAA Figure 2. Circuit Breaker Test. c. Refer to point to point schematics. d. Reconnect circuit 5A wire and disconnect circuit 27 wire from circuit breaker. e. Place battery switch to ON position. f. Connect multimeter red lead to circuit 27 circuit breaker terminal. g. Connect multimeter black lead to vehicle chassis ground. h. Meter reading should be greater than or equal to 18 VDC. CONDITION/INDICATION IS CIRCUIT BREAKER IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (3). NO - Replace circuit breaker (Volume 2, WP 0307). Go to Step (4) to verify problem is solved. 0104-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00168) TM 9-2320-272-23-1 0104 ALL GAUGES INOPERATIVE - Continued STEP 3. IS THERE BATTERY VOLTAGE AT CIRCUIT 27 POWER WIRE? a. Check for battery voltage at instrument cluster circuit 27 power wire. b. Place battery switch to the OFF position. c. Remove instrument cluster panel (Volume 2, WP 0310). d. Refer to point to point schematics. To Circuit Breaker Circuit 27 Power Wire 27 27 27 27 27 T0083DAA Figure 3. Circuit 27 Wire Test. e. Disconnect instrument cluster wire assembly from circuit 27 power wire. f. Place battery switch to ON position. g. Connect multimeter red lead to disconnected circuit 27 wire. h. Connect multimeter black lead to vehicle chassis ground. i. Meter reading should be greater than or equal to 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT CIRCUIT 27 POWER WIRE? DECISION YES - Notify supervisor. Action may not be possible at this level of maintenance. NO - Replace front wiring harness M939/A1 (Volume 3, WP 0357), M939A2 (Volume 3, WP 0358). Go to Step (4) to verify problem is solved. 0104-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00168) TM 9-2320-272-23-1 ALL GAUGES INOPERATIVE - Continued STEP 4. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0104-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00168) 0104 TM 9-2320-272-23-1 FIELD MAINTENANCE TRANSMISSION TEMPERATURE GAUGE INOPERATIVE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 2, WP 0310 Volume 2, WP 0312 Volume 2, WP 0341 Volume 3, WP 0351 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE TRANSMISSION TEMPERATURE GAUGE INOPERATIVE NOTE Conduct these malfunction tests if transmission temperature gauge is inoperative. This procedure will check for a faulty sending unit, wiring harness or gauge. 0105-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00169) 0105 TM 9-2320-272-23-1 0105 TRANSMISSION TEMPERATURE GAUGE INOPERATIVE - Continued STEP 1. IS TRANSMISSION TEMPERATURE SENDING UNIT OPERATIONAL? a. Place battery switch in the OFF position. b. Refer to point to point schematics. CIRCUIT 324 WIRE TRANSMISSION TEMPERATURE SENDING UNIT T0993DAA Figure 1. Transmission Temperature Sending Unit. c. Remove circuit 324 wire from transmission temperature sending unit. d. Place battery switch to ON position. e. Have assistant momentarily ground disconnected circuit 324 wire. NOTE If transmission temperature gauge deflects when grounded, transmission temperature sending unit is faulty. f. Observe transmission temperature gauge for movement. CONDITION/INDICATION IS TRANSMISSION TEMPERATURE SENDING UNIT OPERATIONAL? DECISION YES - Go to Step (2). NO - Replace transmission temperature sending unit (Volume 2, WP 0341). Go to Step (4) to verify problem is solved. 0105-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00169) TM 9-2320-272-23-1 0105 TRANSMISSION TEMPERATURE GAUGE INOPERATIVE - Continued STEP 2. IS CIRCUIT 324 WIRE IN GOOD CONDITION? a. Visually check circuit 324 wire for damage. b. Refer to point to point schematics. c. Remove instrument cluster panel (Volume 2, WP 0310). TEST POINT T1104DAA Figure 2. Transmission Temperature Gauge Wire 324. d. Disconnect circuit 324 wire from transmission temperature gauge. e. Connect jumper wire to open transmission temperature gauge terminal. f. Place battery switch to ON position. g. Momentarily touch jumper wire to vehicle chassis ground. NOTE If transmission temperature gauge deflects when grounded, circuit 324 wire is faulty. h. Observe transmission temperature gauge for movement. CONDITION/INDICATION IS CIRCUIT 324 WIRE IN GOOD CONDITION? DECISION YES - Go to Step (3). NO - Repair circuit 324 wire (Volume 3, WP 0352). Go to Step (4) to verify problem is solved. 0105-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00169) TM 9-2320-272-23-1 0105 TRANSMISSION TEMPERATURE GAUGE INOPERATIVE - Continued STEP 3. IS THERE BATTERY VOLTAGE AT TRANSMISSION TEMPERATURE GAUGE? a. Check for battery voltage at transmission temperature gauge. b. Place battery switch to the OFF position. c. Refer to point to point schematics. TEST POINT T1103DAA Figure 3. Transmission Temperature Gauge Wire 27. d. Disconnect circuit 27 wire from inoperative transmission temperature gauge. e. Place battery switch to ON position. f. Set multimeter to measure VDC. g. Connect multimeter red lead to disconnected circuit 27 wire. h. Connect multimeter black lead to vehicle chassis ground. i. Meter reading should be greater than or equal to 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT TRANSMISSION TEMPERATURE GAUGE? DECISION YES - Replace defective gauge (Volume 2, WP 0312). Go to Step (4) to verify problem is solved. NO - Replace instrument cluster wiring harness (Volume 3, WP 0351). Go to Step (4) to verify problem is solved. 0105-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00169) TM 9-2320-272-23-1 TRANSMISSION TEMPERATURE GAUGE INOPERATIVE - Continued STEP 4. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0105-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00169) 0105 TM 9-2320-272-23-1 FIELD MAINTENANCE TEMPERATURE GAUGE INOPERATIVE (COOLANT) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0310 Volume 2, WP 0312 Volume 2, WP 0334 Volume 3, WP 0351 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE TEMPERATURE GAUGE INOPERATIVE (COOLANT) NOTE Conduct these malfunction tests if coolant temperature gauge is inoperative. This procedure will check for inoperative coolant temperature sending unit, faulty circuit 33 wire, defective gauge or instrument cluster wiring assembly. 0106-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00170) 0106 TM 9-2320-272-23-1 0106 TEMPERATURE GAUGE INOPERATIVE (COOLANT) - Continued STEP 1. IS COOLANT TEMPERATURE SENDING UNIT OPERATIONAL? a. Place battery switch in the OFF position. b. Refer to point to point schematics. Temperature Sending Unit Circuit 33 wire M939/A1 VEHICLES Circuit 33 Wire Temperature Sending Unit M939/A2 VEHICLES T0085DAA Figure 1. Coolant Temperature Sending Unit. c. Remove circuit 33 wire from coolant temperature sending unit. d. Place battery switch to ON position. 0106-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00170) TM 9-2320-272-23-1 0106 TEMPERATURE GAUGE INOPERATIVE (COOLANT) - Continued e. Have assistant momentarily ground disconnected circuit 33 wire. NOTE If coolant temperature gauge deflects when grounded, coolant temperature sending unit is faulty. f. Observe coolant temperature gauge for movement. CONDITION/INDICATION IS COOLANT TEMPERATURE SENDING UNIT OPERATIONAL? DECISION YES - Go to Step (2). NO - Replace coolant temperature sending unit (Volume 2, WP 0334). Go to Step (4) to verify problem is solved. 0106-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00170) TM 9-2320-272-23-1 0106 TEMPERATURE GAUGE INOPERATIVE (COOLANT) - Continued STEP 2. IS CIRCUIT 33 WIRE IN GOOD CONDITION? a. Visually check circuit 33 wire for damage. b. Refer to point to point schematics. c. Remove instrument cluster panel (Volume 2, WP 0310). 27 27 27 27 27 Jumper Wire To Ground T0086DAA Figure 2. Coolant Temperature Gauge Test. d. Disconnect circuit 33 wire from coolant temperature gauge. e. Connect jumper wire to open coolant temperature gauge terminal. f. Place battery switch to ON position. g. Momentarily touch jumper wire to vehicle chassis ground. NOTE If coolant temperature gauge deflects when grounded, circuit 33 wire is faulty. h. Observe coolant temperature gauge for movement. CONDITION/INDICATION IS CIRCUIT 33 WIRE IN GOOD CONDITION? DECISION YES - Go to Step (3). NO - Repair circuit 33 wire (Volume 3, WP 0352). Go to Step (4) to verify problem is solved. 0106-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00170) TM 9-2320-272-23-1 0106 TEMPERATURE GAUGE INOPERATIVE (COOLANT) - Continued STEP 3. IS THERE BATTERY VOLTAGE AT COOLANT TEMPERATURE GAUGE? a. Check for battery voltage at coolant temperature gauge. b. Place battery switch to the OFF position. c. Refer to point to point schematics. Test Point 27 27 27 27 27 T0087DAA Figure 3. Coolant Temperature Gauge Voltage Test. d. Disconnect circuit 27 wire from inoperative coolant temperature gauge. e. Place battery switch to ON position. f. Set multimeter to measure VDC. g. Connect multimeter red lead to disconnected circuit 27 wire. h. Connect multimeter black lead to vehicle chassis ground. i. Meter reading should be greater than or equal to 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT COOLANT TEMPERATURE GAUGE? DECISION YES - Replace defective gauge (Volume 2, WP 0312). Go to Step (4) to verify problem is solved. NO - Replace instrument cluster wiring harness (Volume 3, WP 0351). Go to Step (4) to verify problem is solved. 0106-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00170) TM 9-2320-272-23-1 TEMPERATURE GAUGE INOPERATIVE (COOLANT) - Continued STEP 4. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0106-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00170) 0106 TM 9-2320-272-23-1 FIELD MAINTENANCE FUEL GAUGE INOPERATIVE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0310 Volume 2, WP 0312 Volume 2, WP 0314 Volume 2, WP 0332 Volume 3, WP 0351 Volume 3, WP 0352 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE FUEL GAUGE INOPERATIVE WARNING Do not perform testing near fuel tank with fill cap or sending unit removed. Fuel may ignite. Failure to comply may result in injury or death to personnel. NOTE Conduct these malfunction tests if fuel gauge is inoperative. This procedure will check for a faulty sending unit, faulty circuit 28 or 29 wire, defective gauge or instrument cluster wiring assembly. 0107-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00171) 0107 TM 9-2320-272-23-1 0107 FUEL GAUGE INOPERATIVE - Continued STEP 1. IS FUEL LEVEL SENDING UNIT OPERATIONAL? a. Place battery switch in the OFF position. b. Refer to point to point schematics. T0089DAA Figure 1. Fuel Level Sending Unit. NOTE Make sure fuel selector switch is set to sending unit side being tested. c. Remove circuit wire from inoperative fuel sending unit (wire 28 for left hand tank, wire 29 for right hand tank). d. Place battery switch to ON position. e. Have assistant momentarily ground disconnected circuit 28 or 29 wire. NOTE If fuel gauge deflects when circuit 28 or 29 wire is grounded, fuel sending unit is faulty. f. Observe fuel gauge for movement. 0107-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00171) TM 9-2320-272-23-1 FUEL GAUGE INOPERATIVE - Continued CONDITION/INDICATION IS FUEL LEVEL SENDING UNIT OPERATIONAL? DECISION YES - Go to Step (2). NO - Replace fuel level sending unit (Volume 2, WP 0332). Go to Step (6) to verify problem is solved. 0107-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00171) 0107 TM 9-2320-272-23-1 0107 FUEL GAUGE INOPERATIVE - Continued STEP 2. ARE CIRCUIT WIRES 28 OR 29 FROM FUEL LEVEL SENDING UNIT TO FUEL SELECTOR SWITCH IN GOOD CONDITION? a. Check for 5 to 8 VDC at fuel selector switch terminal. b. Refer to point to point schematics. 28 28 29 T0090DAA Figure 2. Fuel Level Gauge Test. c. Place battery switch to the OFF position. NOTE Make sure fuel selector switch is set to side being tested. d. Disconnect circuit 28 or 29 wire from fuel selector switch (wire 28 for left hand tank, wire 29 for right hand tank). e. Place battery switch to ON position. f. Set multimeter to measure VDC. g. Connect multimeter red lead to open circuit 28 (pin B) or 29 (pin D) terminal at fuel selector switch. h. Connect multimeter black lead to vehicle chassis ground. NOTE If 5 to 8 VDC is present, circuit 28 or 29 wire is faulty. i. Meter reading should be between 5 and 8 VDC. CONDITION/INDICATION ARE CIRCUIT WIRES 28 OR 29 FROM FUEL LEVEL SENDING UNIT TO FUEL SELECTOR SWITCH IN GOOD CONDITION? DECISION YES - Go to Step (3). NO - Repair or replace circuit 28 or 29 wire (Volume 3, WP 0352). Go to Step (6) to verify problem is solved. 0107-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00171) TM 9-2320-272-23-1 0107 FUEL GAUGE INOPERATIVE - Continued STEP 3. IS FUEL SELECTOR SWITCH IN GOOD OPERATING CONDITION? a. Check for 5 to 8 VDC at circuit 28 wire pin A. b. Refer to point to point schematics. 28 28 29 T0090DAA Figure 3. Fuel Selector Switch. c. Place battery switch to the OFF position. d. Disconnect circuit 28 wire from fuel selector switch pin A. e. Place battery switch to ON position. f. Connect multimeter red lead to disconnected circuit 28 wire. g. Connect multimeter black lead to vehicle chassis ground. NOTE If 5 to 8 VDC is present, fuel selector switch is faulty. h. Meter reading should be between 5 and 8 VDC. CONDITION/INDICATION IS FUEL SELECTOR SWITCH IN GOOD OPERATING CONDITION? DECISION YES - Go to Step (4). NO - Replace fuel selector switch (Volume 2, WP 0314). Go to Step (6) to verify problem is solved. 0107-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00171) TM 9-2320-272-23-1 0107 FUEL GAUGE INOPERATIVE - Continued STEP 4. IS THERE BATTERY VOLTAGE AT CIRCUIT 27 WIRE? a. Check for battery voltage at circuit 27 wire. b. Place battery switch to the OFF position. c. Remove instrument cluster panel (Volume 2, WP 0310). d. Refer to point to point schematics. Test Point 27 27 27 27 27 T0092DAA Figure 4. Fuel Gauge Test. e. Disconnect circuit 27 wire from inoperative fuel gauge. f. Place battery switch to ON position. g. Connect multimeter red lead to disconnected circuit 27 wire. h. Connect multimeter black lead to vehicle chassis ground. i. Meter reading should be greater than or equal to 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT CIRCUIT 27 WIRE? DECISION YES - Go to Step (5). NO - Replace instrument cluster wiring harness (Volume 3, WP 0351). Go to Step (6) to verify problem is solved. STEP 5. IS THERE VOLTAGE AT FUEL GAUGE? a. Check for 5 to 8 VDC at fuel gauge. 0107-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00171) TM 9-2320-272-23-1 0107 FUEL GAUGE INOPERATIVE - Continued b. Place battery switch to the OFF position. c. Refer to point to point schematics. d. Reconnect circuit 27 wire to fuel gauge. 27 27 27 27 27 Test Point T0093DAA Figure 5. Fuel Gauge Test. NOTE Trucks with right hand only tanks will disconnect circuit 29 wire from fuel gauge. e. Disconnect circuit 28 wire from fuel gauge. f. Place battery switch to ON position. g. Connect multimeter red lead to open terminal on fuel gauge. h. Connect multimeter black lead to vehicle chassis ground. NOTE If 5 to 8 VDC is not present at fuel gauge, fuel gauge is faulty. i. Meter reading should be between 5 and 8 VDC. CONDITION/INDICATION IS THERE VOLTAGE AT FUEL GAUGE? DECISION NO - Replace defective gauge (Volume 2, WP 0312). Go to Step (6) to verify problem is solved. YES - Repair or replace circuit 28 wire from gauge to selector switch (Volume 3, WP 0352). Go to Step (6) to verify problem is solved. 0107-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00171) TM 9-2320-272-23-1 FUEL GAUGE INOPERATIVE - Continued STEP 6. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0107-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00171) 0107 TM 9-2320-272-23-1 FIELD MAINTENANCE BATTERY/ALTERNATOR GAUGE INOPERATIVE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0310 Volume 2, WP 0312 Volume 3, WP 0351 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE BATTERY/ALTERNATOR GAUGE INOPERATIVE NOTE Conduct these malfunction tests if battery-alternator gauge is inoperative. This procedure will check for faulty gauge or instrument cluster wiring harness. 0108-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00172) 0108 TM 9-2320-272-23-1 0108 BATTERY/ALTERNATOR GAUGE INOPERATIVE - Continued STEP 1. IS BATTERY-ALTERNATOR GAUGE PROPERLY GROUNDED? a. Remove instrument cluster panel (Volume 2, WP 0310). T0095DAA Figure 1. Battery-Alternator Gauge. b. Visually inspect battery-alternator gauge for proper ground. c. Clean and tighten indicator mounting point. CONDITION/INDICATION IS BATTERY-ALTERNATOR GAUGE PROPERLY GROUNDED? DECISION YES - Go to Step (2). NO - Mounting points are damaged. Replace defective gauge (Volume 2, WP 0312). Go to Step (3) to verify problem is solved. STEP 2. IS THERE BATTERY VOLTAGE AT CIRCUIT 27 WIRE? a. Check for battery voltage at circuit 27 wire. b. Place battery switch to the OFF position. c. Refer to point to point schematics. 0108-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00172) TM 9-2320-272-23-1 0108 BATTERY/ALTERNATOR GAUGE INOPERATIVE - Continued 40 40 27 33 40 40 27 T0096DAA Figure 2. Battery-Alternator Gauge Test. d. Disconnect circuit 27 wire from inoperative battery-alternator gauge. e. Place battery switch to ON position. f. Set multimeter to measure VDC. g. Connect multimeter red lead to disconnected circuit 27 wire. h. Connect multimeter black lead to vehicle chassis ground. i. Meter reading should be greater than or equal to 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT CIRCUIT 27 WIRE? DECISION YES - Replace defective gauge (Volume 2, WP 0312). Go to Step (3) to verify problem is solved. NO - Replace instrument cluster wiring harness (Volume 3, WP 0351). Go to Step (3) to verify problem is solved. 0108-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00172) TM 9-2320-272-23-1 BATTERY/ALTERNATOR GAUGE INOPERATIVE - Continued STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0108-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00172) 0108 TM 9-2320-272-23-1 FIELD MAINTENANCE HORN INOPERATIVE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 2, WP 0307 Volume 2, WP 0343 Volume 2, WP 0344 Volume 3, WP 0352 Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE HORN INOPERATIVE NOTE Conduct these malfunction tests if horn is inoperative. This procedure will check for correct air and voltage supply, faulty wiring, horn solenoid and switch. 0109-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00173) 0109 TM 9-2320-272-23-1 0109 HORN INOPERATIVE - Continued STEP 1. DOES HORN ELECTRIC VALVE HAVE AIR SUPPLY? a. Check air supply at air electric valve. T0098DAA Figure 1. Horn Air Supply. b. Make sure air gauges read normal operating pressure and warning buzzer is not sounding. c. Loosen air supply line from horn air electric valve very slowly and listen for air escaping. CONDITION/INDICATION DOES HORN ELECTRIC VALVE HAVE AIR SUPPLY? DECISION YES - Go to Step (2). NO - Replace damaged air supply line (Volume 5, WP 0805). Go to Step (7) to verify problem is solved. STEP 2. DOES HORN CIRCUIT BREAKER HAVE PROPER INPUT VOLTAGE? a. Measure voltage at horn circuit breaker wire 10. b. Refer to point to point schematics. 0109-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00173) TM 9-2320-272-23-1 0109 HORN INOPERATIVE - Continued 10 26 T0099DAA Figure 2. Horn Circuit Breaker. c. Place battery switch to the OFF position. d. Disconnect circuit 10 wire from circuit breaker. e. Place battery switch to ON position. f. Set multimeter to measure VDC. g. Connect multimeter red lead to disconnected circuit 10 wire. h. Connect multimeter black lead to vehicle chassis ground. i. Meter reading should be greater than or equal to 18 VDC. CONDITION/INDICATION DOES HORN CIRCUIT BREAKER HAVE PROPER INPUT VOLTAGE? DECISION YES - Go to Step (3). NO - Repair or replace circuit 10 wire (Volume 3, WP 0352). Go to Step (7) to verify problem is solved. 0109-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00173) TM 9-2320-272-23-1 0109 HORN INOPERATIVE - Continued STEP 3. DOES HORN CIRCUIT BREAKER HAVE PROPER OUTPUT VOLTAGE? a. Check for battery voltage at horn circuit breaker terminal. b. Place battery switch to the OFF position. 26 10 T0100DAA Figure 3. Horn Circuit Breaker Test. c. Refer to point to point schematics. d. Reconnect circuit 10 wire and disconnect circuit 26 wire from circuit breaker. e. Place battery switch to ON position. f. Connect multimeter red lead to open circuit 26 terminal on circuit breaker. g. Connect multimeter black lead to vehicle chassis ground. h. Metter reading should be greater than or equal to 18 VDC. CONDITION/INDICATION DOES HORN CIRCUIT BREAKER HAVE PROPER OUTPUT VOLTAGE? DECISION YES - Go to Step (4). NO - Replace circuit breaker (Volume 2, WP 0307). Go to Step (7) to verify problem is solved. 0109-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00173) TM 9-2320-272-23-1 0109 HORN INOPERATIVE - Continued STEP 4. DOES HORN SOLENOID HAVE BATTERY VOLTAGE? a. Check for battery voltage at horn solenoid. b. Place battery switch to the OFF position. c. Refer to point to point schematics. 25 26 T0101DAA Figure 4. Horn Solenoid Test. d. Reconnect circuit 26 wire to circuit breaker. e. Disconnect circuit 26 wire from horn solenoid. f. Place battery switch to ON position. g. Connect multimeter red lead to disconnected circuit 26 wire. h. Connect multimeter lack lead to vehicle chassis ground. i. Meter reading should be greater than or equal to 18 VDC. CONDITION/INDICATION DOES HORN SOLENOID HAVE BATTERY VOLTAGE? DECISION YES - Go to Step (5). NO - Repair or replace circuit 26 wire (Volume 3, WP 0352). Go to Step (7) to verify problem is solved. 0109-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00173) TM 9-2320-272-23-1 0109 HORN INOPERATIVE - Continued STEP 5. IS HORN SOLENOID OPERATING PROPERLY? a. Check operation of horn solenoid. b. Refer to point to point schematics. 26 25 T0102DAA Figure 5. Horn Solenoid Test. 0109-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00173) TM 9-2320-272-23-1 HORN INOPERATIVE - Continued c. Reconnect circuit 26 wire to horn solenoid. d. Disconnect circuit 25 wire from horn solenoid. e. Connect one end of jumper wire to vehicle chassis ground. NOTE If horn does not operate, horn solenoid is faulty. f. Touch other end of jumper wire to circuit 25 wire connection point on horn solenoid. CONDITION/INDICATION IS HORN SOLENOID OPERATING PROPERLY? DECISION YES - Go to Step (6). NO - Replace defective horn solenoid (Volume 2, WP 0343). Go to Step (7) to verify problem is solved. 0109-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00173) 0109 TM 9-2320-272-23-1 0109 HORN INOPERATIVE - Continued STEP 6. DOES HORN SWITCH WORK PROPERLY? a. Check operation of horn switch. b. Refer to point to point schematics. 25 T0103DAA Figure 6. Horn Switch Test. c. Reconnect circuit 25 wire to horn solenoid. d. Disconnect circuit 25 wire from horn switch. e. Connect one end of jumper wire to vehicle chassis ground. NOTE If horn operates, horn switch is faulty. f. Touch other end of jumper wire to disconnected end of circuit 25 wire. 0109-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00173) TM 9-2320-272-23-1 HORN INOPERATIVE - Continued CONDITION/INDICATION DOES HORN SWITCH WORK PROPERLY? DECISION YES - Notify supervisor. Action may not be possible at this level of maintenance. NO - Replace defective horn switch (Volume 2, WP 0344). Go to Step (7) to verify problem is solved. STEP 7. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0109-9/10 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00173) 0109 TM 9-2320-272-23-1 0110 FIELD MAINTENANCE LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0336 Volume 2, WP 0342 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE) NOTE Conduct these malfunction tests if low air pressure warning buzzer will not shut off. This procedure will check for low air pressure, defective pressure switch or faulty wiring. 0110-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00174) TM 9-2320-272-23-1 0110 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE) - Continued STEP 1. IS PRIMARY LOW AIR PRESSURE SWITCH WORKING PROPERLY? a. Check continuity for primary low air pressure switch. b. Make sure air gauges read at least 90 psi. Primary Switch 578 578A 57 Secondary Switch T0105DAA Figure 1. Pressure Switch. 0110-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00174) TM 9-2320-272-23-1 0110 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE) - Continued c. Disconnect wires 578 and 578A from primary low air pressure switch. d. Set up multimeter to measure resistance. e. Connect multimeter red lead to contact end of pressure switch. Refer to point to point schematics. f. Connect multimeter black lead to other contact end of pressure switch. g. Meter reading should be less than 300 ohms. CONDITION/INDICATION IS PRIMARY LOW AIR PRESSURE SWITCH WORKING PROPERLY? DECISION NO - Replace primary low air pressure switch (Volume 2, WP 0342). Go to Step (6) to verify problem is solved. YES - Go to Step (2). 0110-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00174) TM 9-2320-272-23-1 0110 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE) - Continued STEP 2. IS SECONDARY LOW AIR PRESSURE SWITCH WORKING PROPERLY? a. Check continuity for secondary low air pressure switch. b. Make sure air gauges read at least 90 psi. Primary Switch 578 578A 57 Secondary Switch T0105DAA Figure 2. Pressure Switch. 0110-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00174) TM 9-2320-272-23-1 0110 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE) - Continued c. Install wires 578 and 578A to primary low air pressure switch. d. Disconnect wires 57 and 578A from secondary low air pressure switch. e. Connect multimeter red lead to contact end of pressure switch. Refer to point to point schematics. f. Connect multimeter black lead to other contact end of pressure switch. g. Meter reading should be less than 300 ohms. CONDITION/INDICATION IS SECONDARY LOW AIR PRESSURE SWITCH WORKING PROPERLY? DECISION NO - Replace secondary low air pressure switch (Volume 2, WP 0342). Go to Step (6) to verify problem is solved. YES - Go to Step (3). 0110-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00174) TM 9-2320-272-23-1 0110 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE) - Continued STEP IS WIRE 57 IN GOOD CONDITION? a. Install wire 578A to secondary low air pressure switch. 8 57 578A 3. 57 T0106DAA Figure 3. Pressure Switch Wire 57. 0110-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00174) TM 9-2320-272-23-1 0110 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE) - Continued b. Visually inspect wire 57 for frayed or damaged condition. Refer to point to point schematic. c. Disconnect wire 57 from secondary low air pressure switch. d. Place battery switch to ON position. e. Place start switch to RUN position. f. Make sure air gauges read at least 90 psi. NOTE If alarm is silenced when jumper wire is installed, wire 57 is faulty. g. Connect jumper wire from open contact on secondary low air pressure switch to good ground. CONDITION/INDICATION IS WIRE 57 IN GOOD CONDITION? DECISION NO - Repair or replace wire 57 (Volume 3, WP 0352). Go to Step (6) to verify problem is solved. YES - Go to Step (4). 0110-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00174) TM 9-2320-272-23-1 0110 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE) - Continued STEP 4. IS WIRE 578A IN GOOD CONDITION? a. Place battery switch to OFF position. b. Install wire 57 to secondary low air pressure switch. 8 57 578A 57 T0107DAA Figure 4. Pressure Switch Wire 578A. 0110-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00174) TM 9-2320-272-23-1 0110 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE) - Continued c. Visually inspect wire 578A for frayed or damaged condition. Refer to point to point schematic. d. Disconnect wire 578A from primary and secondary low air pressure switch. e. Place battery switch to ON position. f. Place start switch to RUN position. g. Make sure air gauges read at least 90 psi. NOTE If alarm is silenced when jumper wire is installed, wire 578A is faulty. h. Connect jumper wire from open contact on primary low air pressure switch to open contact on secondary low air pressure switch. CONDITION/INDICATION IS WIRE 578A IN GOOD CONDITION? DECISION NO - Repair or replace wire 578A (Volume 3, WP 0352). Go to Step (6) to verify problem is solved. NO - Go to Step (5). 0110-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00174) TM 9-2320-272-23-1 0110 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE) - Continued STEP 5. IS WIRE 578 IN GOOD CONDITION? a. Place battery switch to OFF position. b. Install wire 578A to primary and secondary low air pressure switch. T0108DAA Figure 5. Failsafe Warning Control Module. c. Visually inspect wire 578 for frayed or damaged condition. d. Disconnect wiring harness at failsafe warning control module. e. Make sure air gauges read at least 90 psi. f. Connect multimeter red lead to pin F on wiring harness connector. Refer to point to point schematics. g. Connect multimeter black lead to good ground. h. Meter reading should be less than 600 ohms. 0110-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00174) TM 9-2320-272-23-1 0110 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE) - Continued CONDITION/INDICATION IS WIRE 578 IN GOOD CONDITION? DECISION NO - Repair or replace wire 578 (Volume 3, WP 0352). Go to Step (6) to verify problem is solved. YES - Replace failsafe warning control module (Volume 2, WP 0336). Go to Step (6) to verify problem is solved. STEP 6. IS YOUR ORIGINAL WARNING BUZZER PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original warning buzzer problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL WARNING BUZZER PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0110-11/12 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00174) TM 9-2320-272-23-1 0111 FIELD MAINTENANCE LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF AND PARKING BRAKE WARNING LIGHT FLASHES WITH HAND/PARKING BRAKE IN ANY POSITION (AIR PRESSURE NORMAL) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0336 Volume 3, WP 0431 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF AND PARKING BRAKE WARNING LIGHT FLASHES WITH HAND/PARKING BRAKE IN ANY POSITION (AIR PRESSURE NORMAL) NOTE Conduct these malfunction tests if low air pressure warning buzzer will not shut off and parking brake warning light flashes with hand/parking brake in any position. This procedure will check for low air pressure, defective pressure switch or faulty wiring. 0111-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00175) TM 9-2320-272-23-1 0111 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF AND PARKING BRAKE WARNING LIGHT FLASHES WITH HAND/PARKING BRAKE IN ANY POSITION (AIR PRESSURE NORMAL) - Continued STEP 1. IS PARKING BRAKE PRESSURE SWITCH WORKING PROPERLY? a. Check continuity for parking brake pressure switch. b. Release parking brake. PARKING BRAKE VALVE PARKING BRAKE SWITCH T1005DAA Figure 1. Pressure Switch. c. Disconnect wires 584 from parking brake pressure switch (under cab). d. Set up multimeter to measure resistance. e. Connect multimeter red lead to contact end of pressure switch. Refer to point to point schematics. f. Connect multimeter black lead to good ground. g. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS PARKING BRAKE SWITCH WORKING PROPERLY? DECISION NO - Replace parking brake switch (Volume 3, WP 0431). Go to Step (3) to verify problem is solved. YES - Go to Step (2). STEP 2. IS WIRE 584 IN GOOD CONDITION? a. Install wire 584 to parking brake pressure switch. 0111-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00175) TM 9-2320-272-23-1 0111 LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF AND PARKING BRAKE WARNING LIGHT FLASHES WITH HAND/PARKING BRAKE IN ANY POSITION (AIR PRESSURE NORMAL) - Continued PARKING BRAKE VALVE PARKING BRAKE SWITCH T1005DAA Figure 2. Pressure Switch. b. Visually inspect wire 584 for frayed or damaged condition. c. Disconnect wiring harness at failsafe warning control module. d. Make sure parking brakes are released. e. Connect multimeter red lead to pin I on wiring harness connector. Refer to point to point schematics. f. Connect multimeter black lead to good ground. g. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS WIRE 584 IN GOOD CONDITION? DECISION NO - Replace failsafe module (Volume 2, WP 0336). Go to Step (3) to verify problem is solved. YES - Notify supervisor. Action may not be possible at this level of maintenance. STEP 3. IS YOUR ORIGINAL WARNING BUZZER PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original warning buzzer problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL WARNING BUZZER PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0111-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00175) TM 9-2320-272-23-1 FIELD MAINTENANCE SPRING BRAKE WARNING LIGHT INOPERATIVE WITH SPRING BRAKE OVERRIDE ENGAGED INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 2, WP 0307 Volume 2, WP 0308 Volume 2, WP 0310 Volume 2, WP 0311 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE SPRING BRAKE WARNING LIGHT INOPERATIVE WITH SPRING BRAKE OVERRIDE ENGAGED NOTE Conduct these malfunction tests if spring brake warning light is inoperative with spring brake override engaged. This procedure will check for bad lamp, faulty spring brake pressure switch or faulty circuit breaker. 0112-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00176) 0112 TM 9-2320-272-23-1 0112 SPRING BRAKE WARNING LIGHT INOPERATIVE WITH SPRING BRAKE OVERRIDE ENGAGED - Continued STEP 1. IS SPRING BRAKE OVERRIDE WARNING LIGHT LAMP IN GOOD CONDITION? a. Visually inspect lamp and lamp holder for faulty condition. T0110DAA Figure 1. Spring Brake Override Light. b. Check lamp holder for corrosion and damage. c. Replace lamp with one known to be operational (Volume 2, WP 0311). NOTE If spring brake override lamp operates, bulb was faulty. d. Check if spring brake override lamp operates. CONDITION/INDICATION IS SPRING BRAKE OVERRIDE WARNING LIGHT LAMP IN GOOD CONDITION? DECISION NO - Go to Step (5) to verify problem is solved. YES - Go to Step (2). STEP 2. DOES SPRING BRAKE PRESSURE SWITCH OPERATE PROPERLY? a. Remove instrument cluster to access spring brake pressure switch (Volume 2, WP 0310). b. Disconnect both circuit 37 wires. 0112-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00176) TM 9-2320-272-23-1 0112 SPRING BRAKE WARNING LIGHT INOPERATIVE WITH SPRING BRAKE OVERRIDE ENGAGED - Continued T0111DAA Figure 2. Spring Brake Pressure Switch Wire 37. c. Connect a jumper wire from one circuit 37 wire to another. Refer to point to point schematic. d. Place battery switch to ON position. NOTE If spring brake override lamp operates, spring brake pressure switch is faulty. e. Check if spring brake override lamp operates. CONDITION/INDICATION DOES SPRING BRAKE PRESSURE SWITCH OPERATE PROPERLY? DECISION NO - Replace defective spring brake pressure switch (Volume 2, WP 0308). Go to Step (5) to verify problem is solved. YES - Go to Step (3). 0112-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00176) TM 9-2320-272-23-1 0112 SPRING BRAKE WARNING LIGHT INOPERATIVE WITH SPRING BRAKE OVERRIDE ENGAGED - Continued STEP 3. IS THERE BATTERY VOLTAGE AT SPRING BRAKE WARNING LIGHT CIRCUIT BREAKER? a. Place battery switch to OFF position. b. Disconnect circuit 10 wire at circuit breaker. 10 37 T0112DAA Figure 3. Spring Brake Override Warning Circuit Breaker Wire 10. c. Place battery switch to ON position. d. Set up multimeter to measure VDC. e. Connect multimeter red lead to circuit 10 wire as shown. Refer to point to point schematics. f. Connect multimeter black lead to vehicle chassis ground. g. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT SPRING BRAKE WARNING LIGHT CIRCUIT BREAKER? DECISION NO - Notify supervisor. Action may not be possible at this level of maintenance. YES - Go to Step (4). STEP 4. IS THERE BATTERY VOLTAGE AT CIRCUIT 37 TERMINAL OF CIRCUIT BREAKER? a. Place battery switch to OFF position. 0112-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00176) TM 9-2320-272-23-1 0112 SPRING BRAKE WARNING LIGHT INOPERATIVE WITH SPRING BRAKE OVERRIDE ENGAGED - Continued b. Reconnect circuit 10 wire. 37 10 T0113DAA Figure 4. Spring Brake Override Warning Circuit Breaker Wire 37. c. Disconnect circuit 37 wire from circuit breaker. d. Place battery switch to ON position. e. Connect multimeter red lead to circuit 37 terminal at circuit breaker as shown. Refer to point to point schematics. f. Connect multimeter black lead to vehicle chassis ground. g. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT CIRCUIT 37 TERMINAL OF CIRCUIT BREAKER? DECISION NO - Replace defective circuit breaker (Volume 2, WP 0307). Go to Step (5) to verify problem is solved. YES - Repair or replace circuit 37 wire from circuit breaker to brake pressure switch (Volume 3, WP 0352). Go to Step (5) to verify problem is solved. 0112-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00176) TM 9-2320-272-23-1 0112 SPRING BRAKE WARNING LIGHT INOPERATIVE WITH SPRING BRAKE OVERRIDE ENGAGED - Continued STEP 5. IS YOUR ORIGINAL WARNING LIGHT PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original warning light problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL WARNING LIGHT PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0112-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00176) TM 9-2320-272-23-1 FIELD MAINTENANCE ONE OR MORE TRAILER LIGHTS INOPERATIVE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) WP 0094 WP 0095 WP 0096 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE ONE OR MORE TRAILER LIGHTS INOPERATIVE NOTE Conduct these malfunction tests if one or more trailer lights are inoperative. This procedure will check for battery voltage at trailer receptacle, faulty wires or connections at trailer receptacle and faulty lamps. 0113-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00163) 0113 TM 9-2320-272-23-1 0113 ONE OR MORE TRAILER LIGHTS INOPERATIVE - Continued STEP 1. DOES CORRESPONDING LIGHTING SYSTEM ON TRUCK FUNCTION? a. Place battery switch to ON position. T0120DAA Figure 1. b. Lighting System. Place truck main light switch in position corresponding to inoperative system on trailer. NOTE For stoplight circuit test, air pressure must be maintained at operating pressure and brake pedal must be depressed. c. Check if corresponding lighting system on truck operates. CONDITION/INDICATION DOES CORRESPONDING LIGHTING SYSTEM ON TRUCK FUNCTION? DECISION NO - Blackout marker lights do not operate. Perform Blackout Drive Or Marker Light Inoperative troubleshooting (WP 0094). NO - Service or blackout stoplights do not operate. Perform Stoplights Inoperative (Service or Blackout) troubleshooting (WP 0095). NO - Tail and marker lights do not operate. Perform Tail and Marker Lights Inoperative troubleshooting (WP 0096). YES - Go to Step (2). 0113-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00163) TM 9-2320-272-23-1 0113 ONE OR MORE TRAILER LIGHTS INOPERATIVE - Continued STEP 2. IS THERE BATTERY VOLTAGE AT TRAILER RECEPTACLE? a. Place battery switch to ON position. b. Place truck main light switch in position corresponding to inoperative system on trailer. c. Set up multimeter to measure VDC. A J K L M N F C D E B T0121DAA Figure 2. Trailer Receptacle. d. Connect multimeter red lead to the trailer receptacle socket terminal pin that corresponds to circuit being tested. Refer to point to point schematics. e. Connect multimeter black lead to trailer receptacle socket terminal pin L. NOTE For stoplight circuit test, air pressure must be maintained at operating pressure and brake pedal must be depressed. f. Meter reading should be greater than 18 VDC for each reading. Note reading. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT TRAILER RECEPTACLE? DECISION NO - Go to Step (3). YES - Go to Step (5). 0113-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00163) TM 9-2320-272-23-1 0113 ONE OR MORE TRAILER LIGHTS INOPERATIVE - Continued STEP 3. IS TRAILER RECEPTACLE PROPERLY GROUNDED? a. Place battery switch to OFF position. A J K L M N F C D E B T0122DAA Figure 3. Trailer Receptacle. b. Set up multimeter to measure resistance. c. Connect multimeter red lead to circuit 90 wire at socket (receptacle terminal L and then D). Refer to point to point schematics. d. Connect multimeter black lead to good ground. e. Meter reading should be less than 200 ohms for both measurements. CONDITION/INDICATION IS TRAILER RECEPTACLE PROPERLY GROUNDED? DECISION NO - Repair broken circuit 90 wire (Volume 3, WP 0352). Go to Step (7) to verify problem is solved. YES - Go to Step (4). 0113-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00163) TM 9-2320-272-23-1 0113 ONE OR MORE TRAILER LIGHTS INOPERATIVE - Continued STEP 4. IS WIRING HARNESS IN GOOD CONDITION? A J K L M N F C D E B T0122DAA Figure 4. Trailer Receptacle. Visually check wiring harness for loose connections or broken wiring. Refer to point to point schematic. CONDITION/INDICATION IS WIRING HARNESS IN GOOD CONDITION? DECISION NO - Repair or replace broken wire (Volume 3, WP 0352). Go to Step (7) to verify problem is solved. YES - Notify supervisor. Action may not be possible at this level of maintenance. 0113-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00163) TM 9-2320-272-23-1 0113 ONE OR MORE TRAILER LIGHTS INOPERATIVE - Continued STEP 5. IS TRAILER LIGHTING SYSTEM CABLE IN GOOD CONDITION? a. Check trailer lighting system cable for continuity and for broken or frayed condition. b. Disconnect both ends of the trailer lighting system cable. T0123DAA Figure 5. Trailer Lighting System Cable. c. Open and lock hinged covers on trailer lighting system cable. d. Set up multimeter to measure resistance. e. Connect multimeter red lead to socket on one end of the cable. f. Connect multimeter red lead to corresponding socket on other end of the cable. g. Meter reading should be less than 200 ohms for each measurements. CONDITION/INDICATION IS TRAILER LIGHTING SYSTEM CABLE IN GOOD CONDITION? DECISION NO - Replace defective trailer connecting cable. Go to Step (7) to verify problem is solved. YES - Go to Step (6). STEP 6. IS WIRING FROM MAIN SWITCH TO LAMP IN GOOD CONDITION? NOTE Perform these steps if faulty trailer is available. a. Check for battery voltage at non-operating lamp holder. b. Connect trailer lighting system cable to vehicle trailer receptacle and trailer. c. Remove faulty circuit lamp. d. Place battery switch to ON position. 0113-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00163) TM 9-2320-272-23-1 0113 ONE OR MORE TRAILER LIGHTS INOPERATIVE - Continued e. Place truck main light switch in position corresponding to inoperative system on trailer. f. Set up multimeter to measure VDC. T0119DAA Figure 6. Trailer. g. Connect multimeter red lead to to center contact inside lamp holder or wire connector. h. Connect multimeter black lead to to good ground. NOTE • For stoplight circuit test, air pressure must be maintained at operating pressure and brake pedal must be depressed. • If voltage is present, wiring to the lamp is in good condition. i. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS WIRING FROM MAIN SWITCH TO LAMP IN GOOD CONDITION? DECISION NO - Notify supervisor. Perform trailer lighting troubleshooting. YES - Replace faulty lamp. 0113-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00163) TM 9-2320-272-23-1 ONE OR MORE TRAILER LIGHTS INOPERATIVE - Continued STEP 7. IS YOUR ORIGINAL LIGHTING PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original lighting problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL LIGHTING PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0113-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00163) 0113 TM 9-2320-272-23-1 0114 FIELD MAINTENANCE HEATER WILL NOT OPERATE WITH SWITCH IN LOW POSITION (HIGH POSITION OPERATION NORMAL) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0307 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE HEATER WILL NOT OPERATE WITH SWITCH IN LOW POSITION (HIGH POSITION OPERATION NORMAL) NOTE Conduct these malfunction tests if heater will not operate with switch in low position. This procedure will check for faulty heater switch, faulty circuit 569A wire, defective circuit breaker or battery switch. 0114-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00178) TM 9-2320-272-23-1 0114 HEATER WILL NOT OPERATE WITH SWITCH IN LOW POSITION (HIGH POSITION OPERATION NORMAL) Continued STEP 1. DOES CIRCUIT 569A WIRE SUPPLY PROPER VOLTAGE TO HEATER SWITCH? a. Check for 12 or 13 volts at circuit 569A wire. b. Place battery switch to OFF position. 400 5C 569A T0125DAA Figure 1. Heater Switch Wiring. c. Disconnect circuit 569A wire from heater switch. d. Place battery switch to ON position. e. Set up multimeter to measure VDC. f. Connect multimeter red lead to the disconnected end of circuit 569A wire. Refer to point to point schematics. g. Connect multimeter black lead to vehicle chassis ground. h. Meter reading should be 12 VDC or greater. CONDITION/INDICATION DOES CIRCUIT 569A WIRE SUPPLY PROPER VOLTAGE TO HEATER SWITCH? DECISION NO - Go to Step (2). YES - Replace heater switch (Volume 2, WP 0307). Go to Step (5) to verify problem is solved. 0114-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00178) TM 9-2320-272-23-1 0114 HEATER WILL NOT OPERATE WITH SWITCH IN LOW POSITION (HIGH POSITION OPERATION NORMAL) Continued STEP 2. IS THERE PROPER VOLTAGE AT CIRCUIT 569A TERMINAL OF CIRCUIT BREAKER? a. Place battery switch to OFF position. To Heater Switch 569A To Battery Switch 569A T0126DAA Figure 2. Circuit Breaker Wire 569A. b. Disconnect circuit 569A wire to heater switch from circuit breaker. c. Place battery switch to ON position. d. Connect multimeter red lead to the open circuit 568A terminal on circuit breaker. Refer to point to point schematics. e. Connect multimeter black lead to vehicle chassis ground. f. Meter reading should be 12 VDC or greater. CONDITION/INDICATION IS THERE PROPER VOLTAGE AT CIRCUIT 569A TERMINAL OF CIRCUIT BREAKER? DECISION YES - Repair or replace circuit 569A wire between circuit breaker and heater switch (Volume 3, WP 0352). Go to Step (5) to verify problem is solved. NO - Go to Step (3). 0114-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00178) TM 9-2320-272-23-1 0114 HEATER WILL NOT OPERATE WITH SWITCH IN LOW POSITION (HIGH POSITION OPERATION NORMAL) Continued STEP 3. IS CIRCUIT BREAKER IN GOOD CONDITION? a. Place battery switch to OFF position. To Battery Switch To Heater Switch 569A 569A T0127DAA Figure 3. Circuit Breaker Wire 569A. b. Disconnect circuit 569A wire to battery switch from circuit breaker. c. Place battery switch to ON position. d. Connect multimeter red lead to the disconnected end of circuit 569A wire. Refer to point to point schematics. e. Connect multimeter black lead to vehicle chassis ground. NOTE If voltage is present, circuit breaker is faulty. f. Meter reading should be 12 VDC or greater. CONDITION/INDICATION IS CIRCUIT BREAKER IN GOOD CONDITION? DECISION NO - Replace circuit breaker (Volume 2, WP 0307). Go to Step (5) to verify problem is solved. YES - Go to Step (4). 0114-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00178) TM 9-2320-272-23-1 0114 HEATER WILL NOT OPERATE WITH SWITCH IN LOW POSITION (HIGH POSITION OPERATION NORMAL) Continued STEP 4. IS THERE BATTERY VOLTAGE AT BATTERY SWITCH TERMINAL? a. Place battery switch to OFF position. 569A T0128DAA Figure 4. Battery Switch Wire 569A. b. Disconnect circuit 569A wire to circuit breaker from battery switch. c. Place battery switch to ON position. d. Connect multimeter red lead to the open circuit 569A wire contact (D) on battery switch. Refer to point to point schematics. e. Connect multimeter black lead to vehicle chassis ground. f. Meter reading should be 12 VDC or greater. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT BATTERY SWITCH TERMINAL? DECISION NO - Replace defective battery switch (Volume 2, WP 0307). Go to Step (5) to verify problem is solved. YES - Repair or replace circuit 569A wire from battery switch to circuit breaker (Volume 3, WP 0352). Go to Step (5) to verify problem is solved. 0114-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00178) TM 9-2320-272-23-1 0114 HEATER WILL NOT OPERATE WITH SWITCH IN LOW POSITION (HIGH POSITION OPERATION NORMAL) Continued STEP 5. IS YOUR ORIGINAL HEATER PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original heater problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL HEATER PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0114-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00178) TM 9-2320-272-23-1 0115 FIELD MAINTENANCE HEATER WILL NOT OPERATE WITH SWITCH IN HIGH POSITION (LOW POSITION OPERATION NORMAL) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0307 Volume 3, WP 0352 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE HEATER WILL NOT OPERATE WITH SWITCH IN HIGH POSITION (LOW POSITION OPERATION NORMAL) NOTE Conduct these malfunction tests if heater will not operate with switch in high position. This procedure will check for faulty heater switch, faulty circuit 5C/27 wire, and defective circuit breaker. 0115-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00179) TM 9-2320-272-23-1 0115 HEATER WILL NOT OPERATE WITH SWITCH IN HIGH POSITION (LOW POSITION OPERATION NORMAL) Continued STEP 1. DOES CIRCUIT 5C WIRE SUPPLY PROPER VOLTAGE TO HEATER SWITCH? a. Check for battery voltage at circuit 5C wire. b. Place battery switch to OFF position. 5C 400 569A T0130DAA Figure 1. Heater Switch Wiring. c. Disconnect circuit 5C wire from heater switch. d. Place battery switch to ON position. e. Set up multimeter to measure VDC. f. Connect multimeter red lead to the disconnected end of circuit 5C wire. Refer to point to point schematics. g. Connect multimeter black lead to vehicle chassis ground. h. Meter reading should be greater than 18 VDC. CONDITION/INDICATION DOES CIRCUIT 5C WIRE SUPPLY PROPER VOLTAGE TO HEATER SWITCH? DECISION NO - Go to Step (2). YES - Replace heater switch (Volume 2, WP 0307). Go to Step (4) to verify problem is solved. 0115-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00179) TM 9-2320-272-23-1 0115 HEATER WILL NOT OPERATE WITH SWITCH IN HIGH POSITION (LOW POSITION OPERATION NORMAL) Continued STEP 2. IS THERE BATTERY VOLTAGE AT CIRCUIT 27 TERMINAL OF CIRCUIT BREAKER? a. Check for battery voltage from circuit breaker. b. Place battery switch to OFF position. c. Visually inspect circuit 5C and 27 wires for damaged or frayed condition. 27 5A T0131DAA Figure 2. Circuit Breaker Wire 27. d. Disconnect circuit 27 wire from circuit breaker. e. Place battery switch to ON position. f. Connect multimeter red lead to the open circuit 27 terminal on circuit breaker. Refer to point to point schematics. g. Connect multimeter black lead to vehicle chassis ground. h. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE AT CIRCUIT 27 TERMINAL OF CIRCUIT BREAKER? DECISION YES - Repair or replace circuit 5C and 27 wire between circuit breaker and heater switch (Volume 3, WP 0352). Go to Step (4) to verify problem is solved. NO - Go to Step (3). 0115-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00179) TM 9-2320-272-23-1 0115 HEATER WILL NOT OPERATE WITH SWITCH IN HIGH POSITION (LOW POSITION OPERATION NORMAL) Continued STEP 3. IS CIRCUIT BREAKER IN GOOD CONDITION? a. Check for battery voltage at circuit 5A wire. b. Place battery switch to OFF position. 5A 27 T0132DAA Figure 3. Circuit Breaker Wire 5A. c. Disconnect circuit 5A wire to battery switch from circuit breaker. d. Place battery switch to ON position. e. Connect multimeter red lead to the disconnected end of circuit 5A wire. Refer to point to point schematics. f. Connect multimeter black lead to vehicle chassis ground. NOTE If voltage is present, circuit breaker is faulty. g. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS CIRCUIT BREAKER IN GOOD CONDITION? DECISION NO - Replace circuit breaker (Volume 2, WP 0307). Go to Step (4) to verify problem is solved. YES - Repair or replace circuit 5A wire (Volume 3, WP 0352). Go to Step (4) to verify problem is solved. 0115-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00179) TM 9-2320-272-23-1 0115 HEATER WILL NOT OPERATE WITH SWITCH IN HIGH POSITION (LOW POSITION OPERATION NORMAL) Continued STEP 4. IS YOUR ORIGINAL HEATER PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original heater problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL HEATER PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0115-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00179) TM 9-2320-272-23-1 FIELD MAINTENANCE HEATER WILL NOT OPERATE IN LOW OR HIGH POSITION INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0307 Volume 3, WP 0352 Volume 4, WP 0747 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE HEATER WILL NOT OPERATE IN LOW OR HIGH POSITION NOTE Conduct these malfunction tests if heater will not operate in low or high position. This procedure will check for faulty heater switch, faulty wiring, or faulty heater. 0116-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00180) 0116 TM 9-2320-272-23-1 0116 HEATER WILL NOT OPERATE IN LOW OR HIGH POSITION - Continued STEP 1. IS HEATER BLOWER MOTOR IN GOOD OPERATING CONDITION? a. Check for proper voltage supply from circuit 400 wire terminal at heater blower motor. b. Place battery switch to OFF position. BLOWER MOTOR VOM T0133DAA Figure 1. Heater Blower Motor Wiring. 0116-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00180) TM 9-2320-272-23-1 0116 HEATER WILL NOT OPERATE IN LOW OR HIGH POSITION - Continued c. Disconnect circuit 400 wire from heater blower motor. d. Place battery switch to ON position. e. Place heater switch to HIGH speed position. f. Set up multimeter to measure VDC. g. Connect multimeter red lead to the disconnected circuit 400 wire. Refer to point to point schematics. h. Connect multimeter black lead to vehicle chassis ground. NOTE If voltage is present, heater blower motor is faulty. i. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS HEATER BLOWER MOTOR IN GOOD OPERATING CONDITION? DECISION NO - Replace heater blower motor (Volume 4, WP 0747). Go to Step (3) to verify problem is solved. YES - Go to Step (2). 0116-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00180) TM 9-2320-272-23-1 0116 HEATER WILL NOT OPERATE IN LOW OR HIGH POSITION - Continued STEP 2. IS HEATER SWITCH IN GOOD OPERATING CONDITION? a. Check for proper voltage supply from circuit 400 wire terminal on heater switch. b. Place battery switch to OFF position. 400 569B 5C T0134DAA Figure 2. Heater Switch Wiring. c. Disconnect circuit 400 wire from heater switch. d. Place battery switch to ON position. e. Place heater switch to HIGH speed position. f. Connect multimeter red lead to the circuit 400 wire terminal at the heater switch. Refer to point to point schematics. g. Connect multimeter black lead to vehicle chassis ground. NOTE If voltage is not present, heater switch motor is faulty. h. Meter reading should be greater than 18 VDC. 0116-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00180) TM 9-2320-272-23-1 0116 HEATER WILL NOT OPERATE IN LOW OR HIGH POSITION - Continued CONDITION/INDICATION IS HEATER SWITCH IN GOOD OPERATING CONDITION? DECISION NO - Replace heater switch (Volume 2, WP 0307). Go to Step (3) to verify problem is solved. YES - Repair or replace circuit wire 400 (Volume 3, WP 0352). Go to Step (3) to verify problem is solved. STEP 3. IS YOUR ORIGINAL HEATER PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original heater problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL HEATER PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0116-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00180) TM 9-2320-272-23-1 FIELD MAINTENANCE NO CAB HEAT (COOLANT TEMPERATURE GAUGE READS NORMAL) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References TM 9-2320-272-10 Volume 2, WP 0287 TROUBLESHOOTING PROCEDURE NO CAB HEAT (COOLANT TEMPERATURE GAUGE READS NORMAL) NOTE Conduct these malfunction tests if there is no cab heat and coolant temperature gauge reads normal. This procedure will check for position of engine coolant shutoff valves, air in personnel heater system, engine coolant level. 0117-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00260) 0117 TM 9-2320-272-23-1 0117 NO CAB HEAT (COOLANT TEMPERATURE GAUGE READS NORMAL) - Continued STEP 1. ARE ENGINE COOLANT SHUTOFF VALVES IN OPEN POSITION? a. Visually check position of engine coolant shutoff valves. T0493DAA Figure 1. Engine Coolant Shutoff Valve. b. Check if valves are in the open position. CONDITION/INDICATION ARE ENGINE COOLANT SHUTOFF VALVES IN OPEN POSITION? DECISION YES - Go to Step (2). NO - Open engine coolant shutoff valves (TM 9-2320-272-10). Go to Step (3) to verify problem is solved. STEP 2. IS ENGINE COOLANT AT PROPER LEVEL? a. Bleed air from personnel heater. CAUTION Do not add coolant when engine is hot. Internal engine damage could result. b. Visually check engine coolant level. 0117-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00260) TM 9-2320-272-23-1 0117 NO CAB HEAT (COOLANT TEMPERATURE GAUGE READS NORMAL) - Continued Surge Tank T0066DAA Figure 2. Coolant Level. CONDITION/INDICATION IS ENGINE COOLANT AT PROPER LEVEL? DECISION YES - Go to Step (3) to verify problem is solved. NO - Fill coolant to proper level (Volume 2, WP 0287). Go to Step (3) to verify problem is solved. 0117-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00260) TM 9-2320-272-23-1 NO CAB HEAT (COOLANT TEMPERATURE GAUGE READS NORMAL) - Continued STEP 3. IS YOUR ORIGINAL NO CAB HEAT PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original no cab heat problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL NO CAB HEAT PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0117-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00260) 0117 TM 9-2320-272-23-1 FIELD MAINTENANCE PARKING BRAKE DOES NOT HOLD VEHICLE ON GRADE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References WP 0136 References (cont.) Volume 3, WP 0420 Volume 3, WP 0421 Volume 3, WP 0422 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE PARKING BRAKE DOES NOT HOLD VEHICLE ON GRADE NOTE Conduct these malfunction tests if parking brake does not hold vehicle on grade. This procedure will check for improper parking brake adjustment, damage to parking brake cable, worn or damaged brakeshoes and broken or faulty actuating plate. 0118-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00188) 0118 TM 9-2320-272-23-1 0118 PARKING BRAKE DOES NOT HOLD VEHICLE ON GRADE - Continued STEP 1. IS PARKING BRAKE PROPERLY ADJUSTED? a. Visually check for proper adjustment of parking brake. T0180DAA Figure 1. Brake Lever. b. Turn knob on top of parking brake lever clockwise to increase braking action (Volume 3, WP 0420). c. Check to see if parking brake holds vehicle. d. If problem is corrected, parking brake was not adjusted properly. CONDITION/INDICATION IS PARKING BRAKE PROPERLY ADJUSTED? DECISION NO - Go to Step (5) to verify problem is solved. YES - Go to Step (2). 0118-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00188) TM 9-2320-272-23-1 0118 PARKING BRAKE DOES NOT HOLD VEHICLE ON GRADE - Continued STEP 2. IS PARKING BRAKE CABLE IN GOOD OPERATING CONDITION? Visually check parking brake cable for binding or breaks. T0181DAA Figure 2. Parking Brake Cable Assembly. CONDITION/INDICATION IS PARKING BRAKE CABLE IN GOOD OPERATING CONDITION? DECISION NO - Repair or replace parking brake cable (Volume 3, WP 0421). Go to Step (5) to verify problem is solved. YES - Go to Step (3). 0118-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00188) TM 9-2320-272-23-1 0118 PARKING BRAKE DOES NOT HOLD VEHICLE ON GRADE - Continued STEP 3. ARE PARKING BRAKE SHOES IN GOOD CONDITION? a. Check for worn parking brakeshoes. T0182DAA Figure 3. Parking Brake Assembly. b. Push parking brake lever clockwise by hand and measure brake lever travel. c. If parking brake lever travels less than 2 in., parking brakeshoes are OK. CONDITION/INDICATION ARE PARKING BRAKE SHOES IN GOOD CONDITION? DECISION NO - Replace parking brakeshoes (Volume 3, WP 0422). Go to Step (5) to verify problem is solved. YES - Go to Step (4). STEP 4. IS PARKING BRAKE ACTUATING MECHANISM WORKING PROPERLY? Visually check for broken or faulty actuating plate, lever, and spring. 0118-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00188) TM 9-2320-272-23-1 0118 PARKING BRAKE DOES NOT HOLD VEHICLE ON GRADE - Continued T0183DAA Figure 4. Parking Brake Actuating Mechanism. CONDITION/INDICATION IS PARKING BRAKE ACTUATING MECHANISM WORKING PROPERLY? DECISION NO - Notify supervision that parking brake is faulty. Action may not be possible at this level of maintenance. YES - Perform Spring Brake troubleshooting (WP 0136). STEP 5. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original parking brake problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0118-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00188) TM 9-2320-272-23-1 FIELD MAINTENANCE PARKING BRAKE DRAGS, AS INDICATED BY SMOKING OR BURNING SMELL INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) References (cont.) Volume 3, WP 0420 Volume 3, WP 0421 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References WP 0135 TROUBLESHOOTING PROCEDURE PARKING BRAKE DRAGS, AS INDICATED BY SMOKING OR BURNING SMELL NOTE Conduct these malfunction tests if parking brake drags. This procedure will check for partially engaged parking brake lever, improper parking brake adjustment, damaged or binding parking brake cable and for faulty actuating mechanism. 0119-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00189) 0119 TM 9-2320-272-23-1 0119 PARKING BRAKE DRAGS, AS INDICATED BY SMOKING OR BURNING SMELL - Continued STEP 1. IS PARKING BRAKE FULLY RELEASED? a. Visually check for partially engaged parking brake lever. T0185DAA Figure 1. Brake Lever. b. Fully release partially engaged parking brake. c. Check to see if parking brake drags. d. If problem is corrected, parking brake was not fully released. CONDITION/INDICATION IS PARKING BRAKE FULLY RELEASED? DECISION NO - Go to Step (5) to verify problem is solved. YES - Go to Step (2). 0119-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00189) TM 9-2320-272-23-1 0119 PARKING BRAKE DRAGS, AS INDICATED BY SMOKING OR BURNING SMELL - Continued STEP 2. IS PARKING BRAKE PROPERLY ADJUSTED? a. Visually check for proper adjustment of parking brake. T0185DAA Figure 2. Brake Lever. b. Turn knob on top of parking brake lever clockwise to increase, counter clockwise to decrease braking action (Volume 3, WP 0420). c. Check to see if parking brake drags. d. If problem is corrected, parking brake was not adjusted properly. CONDITION/INDICATION IS PARKING BRAKE PROPERLY ADJUSTED? DECISION NO - Go to Step (5) to verify problem is solved. YES - Go to Step (3). 0119-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00189) TM 9-2320-272-23-1 0119 PARKING BRAKE DRAGS, AS INDICATED BY SMOKING OR BURNING SMELL - Continued STEP 3. IS PARKING BRAKE CABLE IN GOOD OPERATING CONDITION? Visually check parking brake cable for binding or breaks. T0186DAA Figure 3. Parking Brake Cable Assembly. CONDITION/INDICATION IS PARKING BRAKE CABLE IN GOOD OPERATING CONDITION? DECISION NO - Repair or replace parking brake cable (Volume 3, WP 0421). Go to Step (5) to verify problem is solved. YES - Go to Step (4). STEP 4. IS PARKING BRAKE ACTUATING MECHANISM WORKING PROPERLY? Visually check for broken or faulty actuating plate, lever, and spring. 0119-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00189) TM 9-2320-272-23-1 0119 PARKING BRAKE DRAGS, AS INDICATED BY SMOKING OR BURNING SMELL - Continued T0187DAA Figure 4. Parking Brake Actuating Mechanism. CONDITION/INDICATION IS PARKING BRAKE ACTUATING MECHANISM WORKING PROPERLY? DECISION NO - Notify supervision that parking brake is faulty. Action may not be possible at this level of maintenance. YES - Perform Spring Brakes Do Not Release troubleshooting (WP 0135). STEP 5. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original parking brake problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0119-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00189) TM 9-2320-272-23-1 0120 FIELD MAINTENANCE INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Gauge, Pressure (Volume 5, WP 0826, Table 1, Item 19) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics Volume 3, WP 0424 References (cont.) Volume 3, WP 0426 Volume 3, WP 0429 Volume 3, WP 0430 Volume 3, WP 0434 Volume 3, WP 0435 Volume 3, WP 0439 Volume 3, WP 0457 Volume 3, WP 0458 Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) NOTE Conduct these malfunction tests if the vehicle appears to have insufficient brakes and there is no apparent air system failure. This procedure will check for air leaks in lines, hoses, and service brake chamber vent lines. Front service brake chamber pressure, service brake chamber pressure, spring and service brake chamber pressure, limiting valve venting, limiting valve air delivery pressure, limiting valve air supply pressure, double check valve #1 air supply pressure, service brake pedal valve primary air system delivery port pressure, primary air system relay valve pressure, primary air tank to relay valve supply line pressure, secondary air system relay valve pressure, secondary air tank to relay valve supply line pressure, and the brake mechanism will also be checked. 0120-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 1. DO ANY AIR LINES OR HOSES LEAK? a. Start engine and run to build air supply to normal operating pressure. b. Assistant fully applies service brakes. c. Listen for leaking air lines or fittings. Refer to point to point schematics. CONDITION/INDICATION DO ANY AIR LINES OR HOSES LEAK? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (30) to verify problem is solved. NO - Go to Step (2). STEP 2. DOES AIR LEAK THROUGH SERVICE BRAKE CHAMBER VENT LINES? a. Disconnect vent line from right front service brake chamber (Volume 3, WP 0434). Refer to point to point schematics. Vent Line Service Brake Chamber Vent Port T0201DAA Figure 1. Service Brake Chamber Vent Line. 0120-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. b. Assistant applies service brakes and feels for evidence of escaping air at vent port. c. Connect vent line to service brake chamber. d. Check vent lines on all service brake chambers. Note any chambers that leak air. CONDITION/INDICATION DOES AIR LEAK THROUGH SERVICE BRAKE CHAMBER VENT LINES? DECISION YES - Service brake chamber leaks. Replace leaking brake chamber (Volume 3, WP 0434). Go to Step (30) to verify problem is solved. YES - Service and spring brake chamber leaks. Replace leaking brake chamber (Volume 3, WP 0435). Go to Step (30) to verify problem is solved. NO - Go to Step (3). 0120-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 3. IS THERE PROPER AIR PRESSURE AT THE RIGHT FRONT SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting Service Brake Chamber T0203DAA Figure 2. Front Service Brake Chamber. c. Disconnect delivery line from right service brake chamber adapter fitting (Volume 3, WP 0434). Refer to point to point schematics. d. Connect tee between disconnected service brake chamber and delivery line. e. Connect pressure gauge to tee. f. Assistant starts engine and runs to build air supply to normal operating pressure. 0120-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. g. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel primary air pressure gauge reading. h. Pressure gauge should read 90 to 130 psi. i. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE RIGHT FRONT SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (17). YES - Go to Step (4). 0120-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 4. IS THERE PROPER AIR PRESSURE AT THE LEFT FRONT SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting Service Brake Chamber T0203DAA Figure 3. Front Service Brake Chamber. c. Disconnect delivery line from left service brake chamber adapter fitting (Volume 3, WP 0434). Refer to point to point schematics. d. Disconnect pressure gauge and tee from vehicle and return air line to original condition. e. Move tee to between disconnected service brake chamber and delivery line. f. Verify pressure gauge is connected to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. 0120-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel primary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE LEFT FRONT SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (17). YES - Go to Step (5). 0120-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 5. IS THERE PROPER AIR PRESSURE AT THE RIGHT FORWARD-REAR REAR SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting Service Brake Chamber T0203DAA Figure 4. Rear Service Brake Chamber. c. Disconnect delivery line from right forward-rear rear service brake chamber adapter fitting (Volume 3, WP 0434). Refer to point to point schematics. d. Disconnect pressure gauge and tee from vehicle and return air line to original condition. e. Move tee to between disconnected service brake chamber and delivery line. f. Verify pressure gauge is connected to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. 0120-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel primary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE RIGHT FORWARD-REAR REAR SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (9). YES - Go to Step (6). 0120-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 6. IS THERE PROPER AIR PRESSURE AT THE LEFT FORWARD-REAR REAR SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting Service Brake Chamber T0203DAA Figure 5. Rear Service Brake Chamber. c. Disconnect delivery line from left forward-rear rear service brake chamber adapter fitting (Volume 3, WP 0434). Refer to point to point schematics. d. Disconnect pressure gauge and tee from vehicle and return air line to original condition. e. Move tee to between disconnected service brake chamber and delivery line. f. Verify pressure gauge is connected to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. 0120-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel primary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE LEFT FORWARD-REAR REAR SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (9). YES - Go to Step (7). 0120-11 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 7. IS THERE PROPER AIR PRESSURE AT THE RIGHT REAR-FORWARD REAR SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting Service Brake Chamber T0203DAA Figure 6. Rear Service Brake Chamber. c. Disconnect delivery line from right rear-forward rear service brake chamber adapter fitting (Volume 3, WP 0434). Refer to point to point schematics. d. Disconnect pressure gauge and tee from vehicle and return air line to original condition. e. Move tee to between disconnected service brake chamber and delivery line. f. Verify pressure gauge is connected to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. 0120-12 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel primary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE RIGHT REAR-REAR FORWARD SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (24). YES - Go to Step (8). 0120-13 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 8. IS THERE PROPER AIR PRESSURE AT THE LEFT REAR-FORWARD REAR SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting Service Brake Chamber T0203DAA Figure 7. Rear Service Brake Chamber. c. Disconnect delivery line from left rear-forward rear service brake chamber adapter fitting (Volume 3, WP 0434). Refer to point to point schematics. d. Disconnect pressure gauge and tee from vehicle and return air line to original condition. e. Move tee to between disconnected service brake chamber and delivery line. f. Verify pressure gauge is connected to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. 0120-14 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel primary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE LEFT REAR-REAR FORWARD SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (24). YES - Go to Step (11). 0120-15 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 9. IS THERE PROPER AIR PRESSURE AT THE RIGHT REAR-REAR FORWARD SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting Service Brake Chamber T0203DAA Figure 8. Rear Service Brake Chamber. c. Disconnect delivery line from right rear-rear forward service brake chamber adapter fitting (Volume 3, WP 0434). Refer to point to point schematics. d. Disconnect pressure gauge and tee from vehicle and return air line to original condition. e. Move tee to between disconnected service brake chamber and delivery line. f. Verify pressure gauge is connected to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. 0120-16 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel primary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE RIGHT REAR-REAR FORWARD SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (25). YES - Go to Step (10). 0120-17 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 10. IS THERE PROPER AIR PRESSURE AT THE LEFT REAR-REAR FORWARD SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting Service Brake Chamber T0203DAA Figure 9. Rear Service Brake Chamber. c. Disconnect delivery line from left rear-rear forward service brake chamber adapter fitting (Volume 3, WP 0434). Refer to point to point schematics. d. Disconnect pressure gauge and tee from vehicle and return air line to original condition. e. Move tee to between disconnected service brake chamber and delivery line. f. Verify pressure gauge is connected to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. 0120-18 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel primary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE LEFT REAR-REAR FORWARD SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (25). YES - Go to Step (23). 0120-19 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 11. IS THERE PROPER AIR PRESSURE AT THE RIGHT FORWARD-REAR FORWARD SPRING AND SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting T0215DAA Figure 10. Rear Service And Spring Brake Chamber. 0120-20 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued c. Disconnect delivery line from right forward-rear forward spring and service brake chamber adapter fitting (Volume 3, WP 0435). Refer to point to point schematics. d. Disconnect pressure gauge and tee from vehicle and return air line to original condition. e. Move tee to between disconnected service brake chamber and delivery line. f. Verify pressure gauge is connected to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel secondary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE RIGHT FORWARD-REAR FORWARD SPRING AND SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (15). YES - Go to Step (12). 0120-21 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 12. IS THERE PROPER AIR PRESSURE AT THE LEFT FORWARD-REAR FORWARD SPRING AND SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting T0215DAA Figure 11. Rear Service And Spring Brake Chamber. 0120-22 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued c. Disconnect delivery line from left forward-rear forward spring and service brake chamber adapter fitting (Volume 3, WP 0435). Refer to point to point schematics. d. Disconnect pressure gauge and tee from vehicle and return air line to original condition. e. Move tee to between disconnected service brake chamber and delivery line. f. Verify pressure gauge is connected to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel secondary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE LEFT FORWARD-REAR FORWARD SPRING AND SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (15). YES - Go to Step (13). 0120-23 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 13. IS THERE PROPER AIR PRESSURE AT THE RIGHT REAR-REAR REAR SPRING AND SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting T0215DAA Figure 12. Rear Service And Spring Brake Chamber. 0120-24 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued c. Disconnect delivery line from right rear-rear rear spring and service brake chamber adapter fitting (Volume 3, WP 0435). Refer to point to point schematics. d. Disconnect pressure gauge and tee from vehicle and return air line to original condition. e. Move tee to between disconnected service brake chamber and delivery line. f. Verify pressure gauge is connected to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel secondary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE RIGHT REAR-REAR REAR SPRING AND SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (27). YES - Go to Step (14). 0120-25 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 14. IS THERE PROPER AIR PRESSURE AT THE LEFT REAR-REAR REAR SPRING AND SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting T0215DAA Figure 13. Rear Service And Spring Brake Chamber. 0120-26 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued c. Disconnect delivery line from left rear-rear rear spring and service brake chamber adapter fitting (Volume 3, WP 0435). Refer to point to point schematics. d. Disconnect pressure gauge and tee from vehicle and return air line to original condition. e. Move tee to between disconnected service brake chamber and delivery line. f. Verify pressure gauge is connected to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel secondary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE LEFT REAR-REAR REAR SPRING AND SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (27). YES - Go to Step (29). 0120-27 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 15. IS THERE PROPER AIR PRESSURE AT THE RIGHT REAR-REAR REAR SPRING AND SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting T0215DAA Figure 14. Rear Service And Spring Brake Chamber. 0120-28 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued c. Disconnect delivery line from right rear-rear rear spring and service brake chamber adapter fitting (Volume 3, WP 0435). Refer to point to point schematics. d. Disconnect pressure gauge and tee from vehicle and return air line to original condition. e. Move tee to between disconnected service brake chamber and delivery line. f. Verify pressure gauge is connected to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel secondary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE RIGHT REAR-REAR REAR SPRING AND SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (28). YES - Go to Step (16). 0120-29 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 16. IS THERE PROPER AIR PRESSURE AT THE LEFT REAR-REAR REAR SPRING AND SERVICE BRAKE CHAMBER? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Delivery Line Transducer Tee Adapter Fitting T0215DAA Figure 15. Rear Service And Spring Brake Chamber. 0120-30 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued c. Disconnect delivery line from left rear-rear rear spring and service brake chamber adapter fitting (Volume 3, WP 0435). Refer to point to point schematics. d. Disconnect pressure gauge and tee from vehicle and return air line to original condition. e. Move tee to between disconnected service brake chamber and delivery line. f. Verify pressure gauge is connected to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. NOTE Air pressure to service brake chambers must compare with reading on primary air pressure gauge. Air pressure to spring and service brake chambers must compare with reading on secondary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel secondary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT THE LEFT REAR-REAR REAR SPRING AND SERVICE BRAKE CHAMBER? DECISION NO - Go to Step (28). YES - Go to Step (26). 0120-31 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 17. DOES THE LIMITING VALVE OPERATE PROPERLY? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. c. Disconnect pressure gauge and tee from vehicle and return air line to original condition. d. Assistant starts engine and runs to build air supply to normal operating pressure. Vent Line Limiting Valve Vent Port Limiting Valve T0216DAA Figure 16. e. Limiting Valve. Disconnect vent line from limiting valve vent port (Volume 3, WP 0439). Refer to point to point schematics. 0120-32 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued WARNING Do not look in service chamber vent port when performing test. Failure to comply may result in injury or death to personnel. f. Assistant fully applies and holds service brake pedel. g. Feel for escaping air pressure at limiting valve vent port. h. If air is felt escaping, limiting valve vent is not operating properly. CONDITION/INDICATION DOES THE LIMITING VALVE OPERATE PROPERLY? DECISION NO - Replace defective limiting valve (Volume 3, WP 0439). Go to Step (30) to verify problem is solved. YES - Go to Step (18). 0120-33 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 18. IS LIMITING VALVE DELIVERING PROPER AIR PRESSURE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. c. Return vent line to original condition. Limiting Valve Transducer Limiting Valve Delivery Port Air Delivery Line Tee Fitting Air Delivery Line T0218DAA Figure 17. Limiting Valve. 0120-34 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued d. Disconnect delivery lines from tee fitting at limiting valve (Volume 3, WP 0439). Refer to point to point schematics. e. Disconnect tee fitting from limiting valve. f. Connect pressure gauge to disconnected limiting valve delivery port. g. Assistant starts engine and runs to build air supply to normal operating pressure. h. Assistant fully applies and holds service brakes. i. Monitor air pressure on pressure gauge. j. Measurement can be taken after pressure reaches 90 psi, or after 5 minutes, whichever occurs first. k. Pressure gauge should read 90 to 130 psi. CONDITION/INDICATION IS LIMITING VALVE DELIVERING PROPER AIR PRESSURE? DECISION NO - Go to Step (19). YES - Replace damaged air lines from limiting valve to front brake chambers (Volume 5, WP 0805). Go to Step (30) to verify problem is solved. 0120-35 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 19. IS THERE PROPER AIR SUPPLY PRESSURE AT LIMITING VALVE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. c. Disconnect pressure gauge from vehicle and return tee fitting and air lines to original condition. Limiting Valve Transducer Air Supply Line T0219DAA Figure 18. Limiting Valve. d. Disconnect air supply line from limiting valve (Volume 3, WP 0439). Refer to point to point schematics. e. Connect pressure gauge to o disconnected limiting valve air supply line. f. Assistant starts engine and runs to build air supply to normal operating pressure. g. Assistant fully applies and holds service brakes. h. Monitor air pressure on pressure gauge. i. Pressure gauge should read 90 to 130 psi. CONDITION/INDICATION IS THERE PROPER AIR SUPPLY PRESSURE AT LIMITING VALVE? DECISION NO - Go to Step (20). YES - Replace defective limiting valve (Volume 3, WP 0439). Go to Step (30) to verify problem is solved. 0120-36 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 20. IS THERE A BLOCKAGE IN THE LIMITING VALVE AIR SUPPLY LINE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. c. Disconnect pressure gauge from air supply line. Limiting Valve Transducer Air Supply Line T0219DAA Figure 19. d. Limiting Valve. Check air supply line for blockage. CONDITION/INDICATION IS THERE A BLOCKAGE IN THE LIMITING VALVE AIR SUPPLY LINE? DECISION NO - Go to Step (21). YES - Repair or replace blocked air line (Volume 5, WP 0805). Go to Step (30) to verify problem is solved. 0120-37 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 21. IS PROPER AIR SUPPLY PRESSURE AT DOUBLE CHECK VALVE #1? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. c. Disconnect pressure gauge from vehicle and return air line to original condition. d. Direct assistant to keep foot off service brake pedal. DOUBLECHECK VALVE #1 AIR SUPPLY LINE TRANSDUCER DELIVERY LINE T0220DAA Figure 20. Double Check Valve #1. 0120-38 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued e. Disconnect double check #1 valve air supply line (Volume 3, WP 0473). Refer to point to point schematics. f. Connect pressure gauge to disconnected air supply line. g. Assistant starts engine and runs to build air supply to normal operating pressure. h. Assistant fully applies and holds service brakes. i. Monitor air pressure on pressure gauge. j. Pressure gauge should read 90 to 130 psi. CONDITION/INDICATION IS PROPER AIR SUPPLY PRESSURE AT DOUBLE CHECK VALVE #1? DECISION NO - Go to Step (22). YES - Replace double check valve #1 (Volume 3, WP 0473). Go to Step (30) to verify problem is solved. 0120-39 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 22. IS PROPER AIR PRESSURE AT SERVICE BRAKE PEDAL VALVE PRIMARY AIR SYSTEM DELIVERY PORT? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. WARNING • Do not depress service brake pedal during removal of plug and/or installation of test gauge. Failure to comply may result in injury or death to personnel. • Remove correct plug only. Failure to comply may result in injury or death to personnel. c. Direct assistant to keep foot off service brake pedal. d. Disconnect pressure gauge from vehicle and return air line to original condition. SERVICE BRAKE PEDAL VALVE TRANSDUCER PRIMARY AIR SYSTEM DELIVERY POINT SERVICE BRAKE PEDAL PLUG T0222DAA Figure 21. Service Brake Pedal Valve. 0120-40 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued e. Remove plug from service brake pedal valve primary air system delivery port. Refer to point to point schematics. f. Connect pressure gauge to primary air system delivery port. g. Assistant starts engine and runs to build air supply to normal operating pressure. h. Assistant fully applies and holds service brakes. i. Monitor air pressure on pressure gauge. j. Pressure gauge should read 90 to 130 psi. CONDITION/INDICATION IS PROPER AIR PRESSURE AT SERVICE BRAKE PEDAL VALVE PRIMARY AIR SYSTEM DELIVERY PORT? DECISION NO - Replace defective service brake pedal valve (Volume 3, WP 0429), M936 (Volume 3, WP 0430). Go to Step (30) to verify problem is solved. YES - Repair or replace blocked air line to double check valve #1 (Volume 5, WP 0805). Go to Step (30) to verify problem is solved. 0120-41 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 23. IS PROPER AIR PRESSURE AT PRIMARY RELAY VALVE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. c. Disconnect pressure gauge from vehicle and return air line to original condition. PRIMARY AIR SYSTEM RELAY VALVE TRANSDUCER DELIVERY LINE DELIVERY PORT ELBOW T0223DAA Figure 22. Primary Relay Valve Delivery Port. 0120-42 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued d. Disconnect air line from elbow at primary relay valve delivery port (Volume 3, WP 0458). Refer to point to point schematics. e. Remove elbow from primary relay valve delivery port. f. Connect pressure gauge to disconnected relay valve delivery port. g. Assistant starts engine and runs to build air supply to normal operating pressure. h. Assistant fully applies and holds service brakes. i. Monitor air pressure on pressure gauge. j. Pressure gauge should read 90 to 130 psi. CONDITION/INDICATION IS PROPER AIR PRESSURE AT PRIMARY RELAY VALVE? DECISION NO - Go to Step (25). YES - Replace damaged air lines from primary relay valve to rear brake chambers (Volume 5, WP 0805). Go to Step (30) to verify problem is solved. 0120-43 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 24. IS PROPER AIR PRESSURE AT PRIMARY RELAY VALVE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. c. Disconnect pressure gauge from vehicle and return air line to original condition. DELIVERY PORT ELBOW DELIVERY LINE TRANSDUCER T0225DAA Figure 23. Primary Relay Valve Delivery Port. 0120-44 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued d. Disconnect air line from elbow at primary relay valve delivery port (Volume 3, WP 0458). Refer to point to point schematics. e. Remove elbow from primary relay valve delivery port. f. Connect pressure gauge to disconnected relay valve delivery port. g. Assistant starts engine and runs to build air supply to normal operating pressure. h. Assistant fully applies and holds service brakes. i. Monitor air pressure on pressure gauge. j. Pressure gauge should read 90 to 130 psi. CONDITION/INDICATION IS PROPER AIR PRESSURE AT PRIMARY RELAY VALVE? DECISION NO - Go to Step (25). YES - Replace damaged air lines from primary relay valve to rear brake chambers (Volume 5, WP 0805). Go to Step (30) to verify problem is solved. 0120-45 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 25. IS THERE PROPER AIR PRESSURE IN SUPPLY LINE FROM PRIMARY AIR TANK TO RELAY VALVE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. c. Disconnect pressure gauge from vehicle and return air line and elbow to original condition. Coupling Transducer Primary Air System Relay Valve Supply Line T0193DAA Figure 24. Primary Relay Valve Supply Port. 0120-46 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued d. Disconnect air line from primary relay valve supply port (Volume 3, WP 0458). Refer to point to point schematics. e. Connect pressure gauge to disconnected air supply line. f. Assistant starts engine and runs to build air supply to normal operating pressure. g. Assistant fully applies and holds service brakes. h. Monitor air pressure on pressure gauge. i. Pressure gauge should read 90 to 130 psi. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE IN SUPPLY LINE FROM PRIMARY AIR TANK TO RELAY VALVE? DECISION NO - Replace damaged air line from primary air tank to primary relay valve (Volume 5, WP 0805). Go to Step (30) to verify problem is solved. YES - Replace primary relay valve (Volume 3, WP 0458). Go to Step (30) to verify problem is solved. 0120-47 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 26. IS PROPER AIR PRESSURE AT SECONDARY RELAY VALVE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. c. Disconnect pressure gauge from vehicle and return air line to original condition. Transducer Relay Valve Elbow Delivery Port Delivery Line T0194DAA Figure 25. Secondary Relay Valve Delivery Port. 0120-48 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued d. Disconnect air line from elbow at secondary relay valve delivery port (Volume 3, WP 0457). Refer to point to point schematics. e. Remove elbow from secondary relay valve delivery port. f. Connect pressure gauge to disconnected relay valve delivery port. g. Assistant starts engine and runs to build air supply to normal operating pressure. h. Assistant fully applies and holds service brakes. i. Monitor air pressure on pressure gauge. j. Pressure gauge should read 90 to 130 psi. CONDITION/INDICATION IS PROPER AIR PRESSURE AT SECONDARY RELAY VALVE? DECISION NO - Go to Step (28). YES - Replace damaged air lines from secondary relay valve to rear brake chambers (Volume 5, WP 0805). Go to Step (30) to verify problem is solved. 0120-49 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 27. IS PROPER AIR PRESSURE AT SECONDARY RELAY VALVE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. c. Disconnect pressure gauge from vehicle and return air line to original condition. Relay Valve Delivery Line Elbow Transducer Delivery Port T0196DAA Figure 26. Secondary Relay Valve Delivery Port. 0120-50 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued d. Disconnect air line from elbow at secondary relay valve delivery port (Volume 3, WP 0457). Refer to point to point schematics. e. Remove elbow from secondary relay valve delivery port. f. Connect pressure gauge to disconnected relay valve delivery port. g. Assistant starts engine and runs to build air supply to normal operating pressure. h. Assistant fully applies and holds service brakes. i. Monitor air pressure on pressure gauge. j. Pressure gauge should read 90 to 130 psi. CONDITION/INDICATION IS PROPER AIR PRESSURE AT SECONDARY RELAY VALVE? DECISION NO - Go to Step (28). YES - Replace damaged air lines from secondary relay valve to rear brake chambers (Volume 5, WP 0805). Go to Step (30) to verify problem is solved. 0120-51 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 28. IS THERE PROPER AIR PRESSURE IN SUPPLY LINE FROM SECONDARY AIR TANK TO RELAY VALVE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. c. Disconnect pressure gauge from vehicle and return air line and elbow to original condition. Transducer Secondary Air System Relay Valve Supply Line T0198DAA Figure 27. Secondary Relay Valve Supply Port. 0120-52 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued d. Disconnect air line from secondary relay valve supply port (Volume 3, WP 0457). Refer to point to point schematics. e. Connect pressure gauge to disconnected air supply line. f. Assistant starts engine and runs to build air supply to normal operating pressure. g. Assistant fully applies and holds service brakes. h. Monitor air pressure on pressure gauge. i. Pressure gauge should read 90 to 130 psi. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE IN SUPPLY LINE FROM SECONDARY AIR TANK TO RELAY VALVE? DECISION NO - Replace damaged air line from primary air tank to secondary relay valve (Volume 5, WP 0805). Go to Step (30) to verify problem is solved. YES - Replace secondary relay valve (Volume 3, WP 0457). Go to Step (30) to verify problem is solved. 0120-53 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued STEP 29. ARE BRAKE MECHANISMS IN GOOD CONDITION? a. Remove brake dust covers (Volume 3, WP 0424). BRAKESHOE LINING BRAKESHOE LINING CHAMFER ACTUATOR SEALS T0199DAA Figure 28. Brake Assembly. b. Inspect chamfer on brakeshoe lining for wear. c. Inspect for oil on shoes or drum. d. Inspect actuator seals for rotted, torn, or worn condition. 0120-54 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 0120 INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) Continued CONDITION/INDICATION ARE BRAKE MECHANISMS IN GOOD CONDITION? DECISION NO - Brakeshoe lining worn. Replace worn brakeshoe linings (Volume 3, WP 0426). Go to Step (30) to verify problem is solved. NO - Oil on brakeshoes or drum. Notify supervisor. Action may not be possible at this level of maintenance. NO - Actuator seals are faulty. Notify supervisor. Action may not be possible at this level of maintenance. YES - Go to Step (30) to verify problem is solved. STEP 30. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0120-55/56 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00190) TM 9-2320-272-23-1 FIELD MAINTENANCE VEHICLE PULLS RIGHT OR LEFT WHEN APPLYING BRAKES INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Gauge, Pressure (Volume 5, WP 0826, Table 1, Item 19) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics References (cont.) WP 0053 WP 0120 Volume 3, WP 0424 Volume 3, WP 0426 Volume 3, WP 0432 Volume 3, WP 0434 Volume 3, WP 0479 Volume 3, WP 0481 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE VEHICLE PULLS RIGHT OR LEFT WHEN APPLYING BRAKES NOTE • Conduct these malfunction tests if vehicle pulls right or left when applying brakes. This procedure will check for front service brakes grabbing, front service brake chambers for proper air pressure, brakeshoe lining for wear, oil on brakeshoe lining or drum, actuator seals for rotted, torn or worn conditions and proper clearance between brakeshoe lining and drum. • Vehicle pulling to right or left indicates malfunction in one of the two front wheel service brakes. 0121-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00191) 0121 TM 9-2320-272-23-1 0121 VEHICLE PULLS RIGHT OR LEFT WHEN APPLYING BRAKES - Continued STEP 1. ARE FRONT SERVICE BRAKES GRABBING? a. Determine which brake is grabbing. b. Start engine and drive vehicle under normal conditions. c. In a safe test area, bring vehicle to a hard, sudden stop. d. Inspect front wheels for excessive heat on wheel and drum. e. Inspect for smoke or skid marks. CONDITION/INDICATION ARE FRONT SERVICE BRAKES GRABBING? DECISION YES - Go to Step (3). NO - Go to Step (2). STEP 2. DO FRONT BRAKE CHAMBERS HAVE PROPER AIR PRESSURE? a. Check front service brakes for proper air pressure. b. Stop engine and open all draincocks until brake system air pressure is vented. c. Close all draincocks. T0228DAA Figure 1. Front Service Brake Chamber. 0121-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00191) TM 9-2320-272-23-1 0121 VEHICLE PULLS RIGHT OR LEFT WHEN APPLYING BRAKES - Continued d. Disconnect delivery line from service brake chamber adapter fitting (Volume 3, WP 0434). Refer to point to point schematics. e. Connect tee between disconnected service brake chamber and delivery line. f. Connect pressure gauge to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel primary air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION DO FRONT BRAKE CHAMBERS HAVE PROPER AIR PRESSURE? DECISION YES - Go to Step (3). NO - Perform Insufficient Brakes troubleshooting (WP 0120). 0121-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00191) TM 9-2320-272-23-1 0121 VEHICLE PULLS RIGHT OR LEFT WHEN APPLYING BRAKES - Continued STEP 3. ARE FRONT BRAKESHOES IN GOOD CONDITION? a. Remove brake dust covers (Volume 3, WP 0424). CHAMFER CHAMFER T0229DAA Figure 2. b. Brake Shoe Assembly. Inspect chamfer on brakeshoe lining for wear. CONDITION/INDICATION ARE FRONT BRAKESHOES IN GOOD CONDITION? DECISION NO - Replace worn brakeshoe linings (Volume 3, WP 0426). Go to Step (7) to verify problem is solved. YES - Go to Step (4). 0121-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00191) TM 9-2320-272-23-1 0121 VEHICLE PULLS RIGHT OR LEFT WHEN APPLYING BRAKES - Continued STEP 4. IS THERE OIL CONTAMINATION ON FRONT SERVICE BRAKES? Visually check brakeshoe lining and drum for oil contamination. BRAKE DRUM BRAKE SHOE T0230DAA Figure 3. Brake Drum. CONDITION/INDICATION IS THERE OIL CONTAMINATION ON FRONT SERVICE BRAKES? DECISION YES - Replace brakeshoe linings (Volume 3, WP 0426) and axle seals M939/A1 (Volume 3, WP 0479), M939A2 (Volume 3, WP 0481), and clean drum M939/A1 (Volume 3, WP 0479), M939A2 (Volume 3, WP 0481). Go to Step (7) to verify problem is solved. NO - Go to Step (5). 0121-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00191) TM 9-2320-272-23-1 0121 VEHICLE PULLS RIGHT OR LEFT WHEN APPLYING BRAKES - Continued STEP 5. ARE PLUNGER SEALS IN GOOD OPERATING CONDITION? Visually check plunger seals for rotted, torn or worn conditions. PLUNGERS PLUNGERS Right Front Left Front T0231DAA Figure 4. Left and Right Brake Assemblies. CONDITION/INDICATION ARE PLUNGER SEALS IN GOOD OPERATING CONDITION? DECISION NO - Notify supervisor that brake plunger seals are faulty. Action may not be possible at this level of maintenance. YES - Go to Step (6). 0121-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00191) TM 9-2320-272-23-1 0121 VEHICLE PULLS RIGHT OR LEFT WHEN APPLYING BRAKES - Continued STEP 6. ARE FRONT SERVICE BRAKES PROPERLY ADJUSTED? NOTE Clearance should be between 0.020 to 0.040 in. (0.508 to 1.016 mm). Check front service brake clearance between brakeshoe lining and drum (Volume 3, WP 0432). ADJUSTING STAR WHEEL ADJUSTING HOLE ADJUSTING HOLE COVER T0864DAA Figure 5. Service Brake Adjustment. CONDITION/INDICATION ARE FRONT SERVICE BRAKES PROPERLY ADJUSTED? DECISION NO - Adjust front service brakes as necessary (Volume 3, WP 0432). Go to Step (7) to verify problem is solved. YES - Perform Vehicle Wanders Or Pulls To One Side troubleshooting (WP 0053). 0121-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00191) TM 9-2320-272-23-1 VEHICLE PULLS RIGHT OR LEFT WHEN APPLYING BRAKES - Continued STEP 7. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0121-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00191) 0121 TM 9-2320-272-23-1 FIELD MAINTENANCE VEHICLE REAR BRAKES GRAB OR DRAG INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Gauge, Pressure (Volume 5, WP 0826, Table 1, Item 19) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics References (cont.) WP 0120 Volume 3, WP 0424 Volume 3, WP 0426 Volume 3, WP 0432 Volume 3, WP 0434 Volume 3, WP 0480 Volume 3, WP 0482 Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE VEHICLE REAR BRAKES GRAB OR DRAG NOTE Conduct these malfunction tests if vehicle rear brakes grab or drag. This procedure will check for brake mechanism damage or malfunctions, brake system air leaks and proper pressure supply to rear brake chambers. 0122-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00192) 0122 TM 9-2320-272-23-1 0122 VEHICLE REAR BRAKES GRAB OR DRAG - Continued STEP 1. ARE REAR BRAKESHOES IN GOOD CONDITION? a. Look for evidence of locking, smoke, skid marks and excessive heat on wheel and drum to isolate faulty service brake. b. Remove rear brake dust covers (Volume 3, WP 0424). CHAMFER CHAMFER T0234DAA Figure 1. Brake Shoe Assembly. NOTE Brake shoe lining depth should be more than 5/16 (7.94mm). c. Inspect chamfer on brakeshoe lining for wear. CONDITION/INDICATION ARE REAR BRAKESHOES IN GOOD CONDITION? DECISION NO - Replace worn brakeshoe linings (Volume 3, WP 0426). Go to Step (7) to verify problem is solved. YES - Go to Step (2). 0122-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00192) TM 9-2320-272-23-1 0122 VEHICLE REAR BRAKES GRAB OR DRAG - Continued STEP 2. IS THERE OIL CONTAMINATION ON REAR SERVICE BRAKES? Visually check brakeshoe lining and drum for oil contamination. BRAKE DRUM BRAKE SHOE T0235DAA Figure 2. Brake Drum. CONDITION/INDICATION IS THERE OIL CONTAMINATION ON REAR SERVICE BRAKES? DECISION YES - Replace brakeshoe linings (Volume 3, WP 0426) and axle seals M939/A1 (Volume 3, WP 0480), M939A2 (Volume 3, WP 0482), and clean drum M939/A1 (Volume 3, WP 0480), M939A2 (Volume 3, WP 0482). Go to Step (7) to verify problem is solved. NO - Go to Step (3). 0122-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00192) TM 9-2320-272-23-1 0122 VEHICLE REAR BRAKES GRAB OR DRAG - Continued STEP 3. ARE PLUNGER SEALS IN GOOD OPERATING CONDITION? Visually check plunger seals for rotted, torn or worn conditions. PLUNGERS PLUNGERS PLUNGERS Left Rear Right Rear T0236DAA Figure 3. Left and Right Brake Assemblies. CONDITION/INDICATION ARE PLUNGER SEALS IN GOOD OPERATING CONDITION? DECISION NO - Notify supervisor that brake plunger seals are faulty. Action may not be possible at this level of maintenance. YES - Go to Step (4). 0122-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00192) TM 9-2320-272-23-1 0122 VEHICLE REAR BRAKES GRAB OR DRAG - Continued STEP 4. ARE REAR SERVICE BRAKES PROPERLY ADJUSTED? NOTE Clearance should be between 0.020 to 0.040 in. (0.508 to 1.016 mm). Check rear service brake clearance between brakeshoe lining and drum (Volume 3, WP 0432). ADJUSTING STAR WHEEL ADJUSTING HOLE ADJUSTING HOLE COVER T0237DAA Figure 4. Service Brake Adjustment. CONDITION/INDICATION ARE REAR SERVICE BRAKES PROPERLY ADJUSTED? DECISION NO - Adjust rear service brakes as necessary (Volume 3, WP 0432). Go to Step (7) to verify problem is solved. YES - Go to Step (5). STEP 5. IS THERE EVIDENCE OF BRAKE SYSTEM AIR LEAKS? a. Start engine and run to build air supply to normal operating pressure. b. Assistant fully applies service brakes. c. Listen for leaking air lines or fittings. Refer to point to point schematics. CONDITION/INDICATION IS THERE EVIDENCE OF BRAKE SYSTEM AIR LEAKS? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (7) to verify problem is solved. NO - Go to Step (6). 0122-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00192) TM 9-2320-272-23-1 0122 VEHICLE REAR BRAKES GRAB OR DRAG - Continued STEP 6. DO REAR BRAKE CHAMBERS HAVE PROPER AIR PRESSURE? a. Check rear service brakes chambers for proper air pressure. b. Stop engine and open all draincocks until brake system air pressure is vented. c. Close all draincocks. T0238DAA Figure 5. Rear Service Brake Chamber. T0238DAA Figure 6. Rear Service and Spring Brake Chamber. 0122-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00192) TM 9-2320-272-23-1 0122 VEHICLE REAR BRAKES GRAB OR DRAG - Continued d. Disconnect delivery line from service brake chamber adapter fitting (Volume 3, WP 0435). Refer to point to point schematics. e. Connect tee between disconnected service brake chamber and delivery line. f. Connect pressure gauge to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. NOTE Air pressure to front service brake chambers must compare with reading on secondary air pressure gauge. Air pressure to rear spring and service brake chambers must compare with reading on primary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION DO REAR BRAKE CHAMBERS HAVE PROPER AIR PRESSURE? DECISION YES - Go to Step (7) to verify problem is solved. NO - Perform Insufficient Brakes troubleshooting (WP 0120). 0122-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00192) TM 9-2320-272-23-1 VEHICLE REAR BRAKES GRAB OR DRAG - Continued STEP 7. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0122-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00192) 0122 TM 9-2320-272-23-1 FIELD MAINTENANCE VEHICLE VIBRATES, CHATTERS, OR BOUNCES WHEN BRAKES ARE APPLIED INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Gauge, Pressure (Volume 5, WP 0826, Table 1, Item 19) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) WP 0120 WP 0122 Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE VEHICLE VIBRATES, CHATTERS, OR BOUNCES WHEN BRAKES ARE APPLIED NOTE Conduct these malfunction tests if vehicle vibrates, chatters or bounces when brakes are applied. This procedure will check for faulty or damaged rear brake system mechanism or improper air supply pressure to rear brake chambers. STEP 1. ARE REAR SERVICE BRAKES LOCKING? a. Visually inspect rear service brakes for evidence of locking. b. Start engine and drive vehicle under normal conditions. c. In a safe test area, bring vehicle to a hard, sudden stop. d. Inspect rear wheels for excessive heat on wheel and drum. e. Inspect for smoke or skid marks. CONDITION/INDICATION ARE REAR SERVICE BRAKES LOCKING? DECISION YES - Perform Vehicle Rear Brakes Grab Or Drag troubleshooting (WP 0122). NO - Go to Step (2). 0123-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00193) 0123 TM 9-2320-272-23-1 0123 VEHICLE VIBRATES, CHATTERS, OR BOUNCES WHEN BRAKES ARE APPLIED - Continued STEP 2. IS THERE EVIDENCE OF BRAKE SYSTEM AIR LEAKS? a. Check for brake system air leaks. b. Start engine and run to build air supply to normal operating pressure. c. Assistant fully applies service brakes. d. Listen for leaking air lines or fittings. Refer to point to point schematics. CONDITION/INDICATION IS THERE EVIDENCE OF BRAKE SYSTEM AIR LEAKS? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (4) to verify problem is solved. NO - Go to Step (2). STEP 3. DO REAR BRAKE CHAMBERS HAVE PROPER AIR PRESSURE? a. Check rear service brakes for proper air pressure. b. Stop engine and open all draincocks until brake system air pressure is vented. c. Close all draincocks. T0241DAA Figure 1. Rear Service Brake Chamber. 0123-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00193) TM 9-2320-272-23-1 0123 VEHICLE VIBRATES, CHATTERS, OR BOUNCES WHEN BRAKES ARE APPLIED - Continued T0241DAA Figure 2. Rear Service and Spring Brake Chamber. d. Disconnect delivery line from service brake chamber adapter fitting (Volume 3, WP 0434). Refer to point to point schematics. e. Connect tee between disconnected service brake chamber and delivery line. f. Connect pressure gauge to tee. g. Assistant starts engine and runs to build air supply to normal operating pressure. NOTE Air pressure to front service brake chambers must compare with reading on secondary air pressure gauge. Air pressure to rear spring and service brake chambers must compare with reading on primary air pressure gauge. h. Assistant fully applies and holds service brakes while comparing pressure gauge reading to instrument panel air pressure gauge reading. i. Pressure gauge should read 90 to 130 psi. j. Both readings should be similar. CONDITION/INDICATION DO REAR BRAKE CHAMBERS HAVE PROPER AIR PRESSURE? DECISION YES - Go to Step (4) to verify problem is solved. NO - Perform Insufficient Brakes troubleshooting (WP 0120). 0123-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00193) TM 9-2320-272-23-1 VEHICLE VIBRATES, CHATTERS, OR BOUNCES WHEN BRAKES ARE APPLIED - Continued STEP 4. IS YOUR ORIGINAL VIBRATION OR BOUNCE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original vibration or bounce problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL VIBRATION OR BOUNCE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0123-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00193) 0123 TM 9-2320-272-23-1 FIELD MAINTENANCE BRAKES SQUEAL INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Personnel Required (2) References Volume 3, WP 0426 References (cont.) Volume 3, WP 0479 Volume 3, WP 0480 Volume 3, WP 0481 Volume 3, WP 0482 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE BRAKES SQUEAL NOTE Conduct these malfunction tests if brakes squeal. This procedure will check for worn or glazed brakeshoe lining and for dirt or metal trapped in brakeshoes. 0124-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00194) 0124 TM 9-2320-272-23-1 0124 BRAKES SQUEAL - Continued STEP 1. ARE BRAKESHOES IN GLAZED OR WORN OUT CONDITION? a. Remove front brakedrums M939/A1 (Volume 3, WP 0479), M939A2 (Volume 3, WP 0481). b. Remove rear brakedrums M939/A1 (Volume 3, WP 0480), M939A2 (Volume 3, WP 0482). T0243DAA Figure 1. Brakeshoes. NOTE Brakeshoe lining should appear dull. c. Visually inspect brakeshoes for glazed lining. d. If brakeshoe lining is shiny, remove glaze with wire brush. NOTE Brake shoe lining should be greater than 5/16 in (7.94 mm). e. Inspect chamfer on brakeshoe lining for wear. CONDITION/INDICATION ARE BRAKESHOES IN GLAZED OR WORN OUT CONDITION? DECISION YES - Replace worn out brakeshoes (Volume 3, WP 0426). Go to Step (3) to verify problem is solved. NO - Go to Step (2). 0124-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00194) TM 9-2320-272-23-1 0124 BRAKES SQUEAL - Continued STEP 2. IS THERE DIRT OR METAL TRAPPED IN BRAKESHOES? a. Visually inspect brakeshoes for trapped dirt or metal contamination. T0243DAA Figure 2. b. Brakeshoes. Clean out dirt or metal contamination with wire brush. CONDITION/INDICATION IS THERE DIRT OR METAL TRAPPED IN BRAKESHOES? DECISION YES - Replace contaminated brakeshoes (Volume 3, WP 0426). Go to Step (3) to verify problem is solved. NO - Go to Step (3) to verify problem is solved. 0124-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00194) TM 9-2320-272-23-1 BRAKES SQUEAL - Continued STEP 3. IS YOUR ORIGINAL BRAKE SQUEAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original vibration or bounce problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL BRAKE SQUEAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0124-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00194) 0124 TM 9-2320-272-23-1 0125 FIELD MAINTENANCE WARNING BUZZER SOUNDS WHEN BRAKES ARE APPLIED (PRIMARY & SECONDARY GAUGE PRESSURE DROPS BELOW 55-65 PSI [379-448 KPA]) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE WARNING BUZZER SOUNDS WHEN BRAKES ARE APPLIED (PRIMARY & SECONDARY GAUGE PRESSURE DROPS BELOW 55-65 PSI [379-448 KPA]) NOTE Conduct these malfunction tests if warning buzzer sounds when brakes are applied and primary and secondary gauge pressure drops below 55-65 psi. This procedure will check for air leaks in air delivery components. STEP 1. IS THERE EVIDENCE OF AN AIR LEAK FROM A BRAKE SYSTEM COMPONENT? a. Start engine and run to build air supply to normal operating pressure. b. Assistant fully applies service brakes. c. Listen for and locate any air leaks. Refer to point to point schematics. CONDITION/INDICATION IS THERE EVIDENCE OF AN AIR LEAK FROM A BRAKE SYSTEM COMPONENT? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (2) to verify problem is solved. NO - Go to Step (2) to verify problem is solved. 0125-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00195) TM 9-2320-272-23-1 0125 WARNING BUZZER SOUNDS WHEN BRAKES ARE APPLIED (PRIMARY & SECONDARY GAUGE PRESSURE DROPS BELOW 55-65 PSI [379-448 KPA]) - Continued STEP 2. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0125-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00195) TM 9-2320-272-23-1 0126 FIELD MAINTENANCE NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Gauge, Pressure (Volume 5, WP 0826, Table 1, Item 19) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) WP 0130 WP 0131 Volume 3, WP 0436 Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES) NOTE Conduct these malfunction tests if there is no air pressure, warning buzzer is sounding and air pressure is not building to normal operating range as indicated by gauges. This procedure will check for air leaks, faulty air compressor, blocked or clogged air lines, faulty air governor or air gauges. 0126-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00196) TM 9-2320-272-23-1 0126 NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES) - Continued STEP 1. ARE AIR LINES OR FITTINGS LEAKING? a. Start engine. Secondary - Lower Tank Primary - Upper Tank Wet Tank Treadle Valve Spring Brake Air Reservoir Primary (lower) Air Gauge Port Sec. Gage Primary Gage T0254DAA Figure 1. Air Supply System. 0126-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00196) TM 9-2320-272-23-1 0126 NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES) - Continued b. Listen for and locate any air leaks. Refer to point to point schematics. CONDITION/INDICATION ARE AIR LINES OR FITTINGS LEAKING? DECISION YES - Tighten fittings or replace damaged air lines (Volume 5, WP 0805). Go to Step (6) to verify problem is solved. NO - Go to Step (2). 0126-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00196) TM 9-2320-272-23-1 0126 NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES) - Continued STEP 2. IS AIR COMPRESSOR OPERATING NORMALLY? a. Check air compressor operation with engine running. Air Governor Signal Line T0868DAA Figure 2. Air Compressor Governor Signal Line. b. Loosen and bled air from governor signal line to air compressor. Refer to point to point schematics. 0126-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00196) TM 9-2320-272-23-1 0126 NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES) - Continued Outlet Line T0256DAA Figure 3. Air Compressor Outlet Line. c. Feel compressor outlet line for heat. d. If compressor outlet line is hot (under great pressure), compressor is operating normally. e. If compressor outlet line is not hot, carefully loosen fitting until air is heard escaping. f. If air is escaping, compressor is operating normally. CONDITION/INDICATION IS AIR COMPRESSOR OPERATING NORMALLY? DECISION NO - Notify supervisor that air compressor is faulty. Action may not be possible at this level of maintenance. YES - Go to Step (3). 0126-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00196) TM 9-2320-272-23-1 0126 NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES) - Continued STEP 3. IS AIR OUTLET LINE IN GOOD CONDITION? a. Visually inspect compressor outlet line for damage that could restrict airflow. Refer to point to point schematics. Outlet Line T0257DAA Figure 4. Air Compressor Outlet Line. b. Inspect outlet line for blockage. 0126-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00196) TM 9-2320-272-23-1 NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES) - Continued CONDITION/INDICATION IS AIR OUTLET LINE IN GOOD CONDITION? DECISION NO - Replace damaged air line (Volume 5, WP 0805). Go to Step (6) to verify problem is solved. YES - Go to Step (4). 0126-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00196) 0126 TM 9-2320-272-23-1 0126 NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES) - Continued STEP 4. ARE AIR GAUGES WORKING PROPERLY? a. Check air gauges reading accuracy. b. Stop engine and open all draincocks until brake system air pressure is vented. c. Close draincocks. T0258DAA Figure 5. Wet Supply Tank. d. Disconnect outlet line at wet supply tank and install tee between tank and line. Refer to point to point schematics. e. Install pressure gauge on tee. f. Start engine and allow sufficient time for air to build to normal operating pressure. 0126-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00196) TM 9-2320-272-23-1 0126 NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES) - Continued Primary Air Pressure Gage Secondary Air Pressure Gage T0253DAA Figure 6. Air Pressure Gauges. g. Compare pressure gauge reading with reading on instrument panel air pressure gauges. h. If instrument panel air pressure gauge reading is different than pressure gauge reading, instrument panel air pressure gauge is not working properly. CONDITION/INDICATION ARE AIR GAUGES WORKING PROPERLY? DECISION NO - Primary air system pressure gauge not reading properly. Perform Primary Pressure Gauge Reads No Pressure, Low Pressure, or Builds To Normal Pressure Slowly troubleshooting (WP 0130). NO - Secondary air system pressure gauge not reading properly. Perform Secondary Pressure Gauge Reads No Pressure, Low Pressure, or Builds To Normal Pressure Slowly troubleshooting (WP 0131). YES - Go to Step (5). 0126-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00196) TM 9-2320-272-23-1 0126 NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES) - Continued STEP 5. IS AIR GOVERNOR OPERATING PROPERLY? a. Replace air governor with a known good governor (Volume 3, WP 0436). T0259DAA Figure 7. Air Governor. b. Start engine and allow sufficient time for air to build to normal operating pressure. c. If air pressure gauges read 90 to 130 psi, air governor was not operating properly. CONDITION/INDICATION IS AIR GOVERNOR OPERATING PROPERLY? DECISION NO - Replace defective air governor (Volume 3, WP 0436). Go to Step (6) to verify problem is solved. YES - Notify supervisor. Action may not be possible at this level of maintenance. 0126-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00196) TM 9-2320-272-23-1 NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES) - Continued STEP 6. IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0126-11/12 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00196) 0126 TM 9-2320-272-23-1 0127 FIELD MAINTENANCE AIR PRESSURE DOES NOT BUILD TO NORMAL OPERATING PRESSURE (ABOVE 80 PSI [552 KPA]) ACCORDING TO GAUGES INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) WP 0126 Volume 3, WP 0436 Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE AIR PRESSURE DOES NOT BUILD TO NORMAL OPERATING PRESSURE (ABOVE 80 PSI [552 KPA]) ACCORDING TO GAUGES NOTE Conduct these malfunction tests if air pressures do not build to normal operating pressure (above 80 psi [552 kPa]) according to gauges. This procedure will check for air leaks from lines or fittings, adjust air governor and check for faulty compressor. 0127-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00197) TM 9-2320-272-23-1 0127 AIR PRESSURE DOES NOT BUILD TO NORMAL OPERATING PRESSURE (ABOVE 80 PSI [552 KPA]) ACCORDING TO GAUGES - Continued STEP 1. ARE AIR LINES OR FITTINGS LEAKING? a. Start engine. Secondary - Lower Tank Primary - Upper Tank Wet Tank Treadle Valve Spring Brake Air Reservoir Primary (lower) Air Gauge Port Sec. Gage Primary Gage T0261DAA Figure 1. b. Air Supply System. Listen and locate air leaks. Refer to point to point schematics. CONDITION/INDICATION ARE AIR LINES OR FITTINGS LEAKING? DECISION YES - Tighten fittings or replace damaged air lines (Volume 5, WP 0805). Go to Step (3) to verify problem is solved. NO - Go to Step (2). STEP 2. CAN AIR GOVERNOR BE PROPERLY ADJUSTED? a. Check if air governor is properly adjusted. Refer to point to point schematics. 0127-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00197) TM 9-2320-272-23-1 0127 AIR PRESSURE DOES NOT BUILD TO NORMAL OPERATING PRESSURE (ABOVE 80 PSI [552 KPA]) ACCORDING TO GAUGES - Continued T0262DAA Figure 2. b. Air Governor. Adjust governor to proper settings (Volume 3, WP 0436). CONDITION/INDICATION CAN AIR GOVERNOR BE PROPERLY ADJUSTED? DECISION NO - Perform No Air Pressure troubleshooting (WP 0126). YES - Go to Step (3) to verify problem is solved. STEP 3. IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0127-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00197) TM 9-2320-272-23-1 0128 FIELD MAINTENANCE AIR PRESSURE BUILDS SLOWLY (TAKES EXCESSIVE AMOUNT OF TIME TO BUILD TO 100 PSI (690KPA) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) WP 0126 Volume 3, WP 0436 Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE AIR PRESSURE BUILDS SLOWLY (TAKES EXCESSIVE AMOUNT OF TIME TO BUILD TO 100 PSI (690KPA) NOTE Conduct these malfunction tests if air pressure builds slowly (takes excessive amount of time to build to 100 psi [690kPa]). This procedure will check for air leaks form lines or fittings, improperly adjusted air governor or faulty compressor. 0128-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00198) TM 9-2320-272-23-1 0128 AIR PRESSURE BUILDS SLOWLY (TAKES EXCESSIVE AMOUNT OF TIME TO BUILD TO 100 PSI (690KPA) - Continued STEP 1. ARE AIR LINES OR FITTINGS LEAKING? a. Start engine. Secondary - Lower Tank Primary - Upper Tank Wet Tank Treadle Valve Spring Brake Air Reservoir Primary (lower) Air Gauge Port Sec. Gage Primary Gage T0886DAA Figure 1. b. Air Supply System. Listen and locate air leaks. Refer to point to point schematics. CONDITION/INDICATION ARE AIR LINES OR FITTINGS LEAKING? DECISION YES - Tighten fittings or replace damaged air lines (Volume 5, WP 0805). Go to Step (3) to verify problem is solved. NO - Go to Step (2). STEP 2. CAN AIR GOVERNOR BE PROPERLY ADJUSTED? a. Check if air governor is properly adjusted. Refer to point to point schematics. 0128-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00198) TM 9-2320-272-23-1 0128 AIR PRESSURE BUILDS SLOWLY (TAKES EXCESSIVE AMOUNT OF TIME TO BUILD TO 100 PSI (690KPA) - Continued T0887DAA Figure 2. b. Air Governor. Adjust governor to proper settings (Volume 3, WP 0436). CONDITION/INDICATION CAN AIR GOVERNOR BE PROPERLY ADJUSTED? DECISION NO - Perform No Air Pressure troubleshooting (WP 0126). YES - Go to Step (3) to verify problem is solved. STEP 3. IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0128-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00198) TM 9-2320-272-23-1 0129 FIELD MAINTENANCE AIR PRESSURE EXCEEDS MAXIMUM (GAUGES SHOW OVER 130 PSI [896 KPA]), SAFETY VALVE OPENS TO RELEASE PRESSURE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Gauge, Pressure (Volume 5, WP 0826, Table 1, Item 19) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 3, WP 0436 Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE AIR PRESSURE EXCEEDS MAXIMUM (GAUGES SHOW OVER 130 PSI [896 KPA]), SAFETY VALVE OPENS TO RELEASE PRESSURE NOTE Conduct these malfunction tests if air pressure exceeds maximum (gauges show over 130 psi), safety valve opens to release pressure. 0129-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00199) TM 9-2320-272-23-1 0129 AIR PRESSURE EXCEEDS MAXIMUM (GAUGES SHOW OVER 130 PSI [896 KPA]), SAFETY VALVE OPENS TO RELEASE PRESSURE - Continued STEP 1. IS THERE EVIDENCE OF AIR LOSS THROUGH ACCESSORIES? a. Visually inspect air accessories for air leaks. b. Start engine. AUXILIARY AIR-POWER SYSTEM Windshield Wiper Switch CONSTANT PRESSURE SUPPLY LINES WINDSHIELD WASHER SIGNAL LINE FRONT WHEEL DRIVE LOCK-IN SIGNAL LINE FROM PRESSURE PROTECTION VALVE Windshield Washer Reservoir Windshield Wiper Motor Windshield Washer Control Windshield Washer Nozzles Front Wheel Drive Lock-in Switch Accessory Manifold Horns Transfer Case Air Shift Cylinder Horn Relay Valve Governor Front Axle Engagement Control Valve T0266DAA Figure 1. Auxiliary Air Power System. c. Listen and locate air leaks. Refer to point to point schematics. CONDITION/INDICATION IS THERE EVIDENCE OF AIR LOSS THROUGH ACCESSORIES? DECISION YES - Replace leaking accessory. Go to Step (4) to verify problem is solved. NO - Go to Step (2). 0129-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00199) TM 9-2320-272-23-1 0129 AIR PRESSURE EXCEEDS MAXIMUM (GAUGES SHOW OVER 130 PSI [896 KPA]), SAFETY VALVE OPENS TO RELEASE PRESSURE - Continued STEP 2. IS GOVERNOR SIGNAL LINE IN GOOD CONDITION? a. Visually check governor signal line for leaks and crimping. Refer to point to point schematics. Air Governor Signal Line T0267DAA Figure 2. b. Air Governor Signal Line. Remove governor signal line and inspect for clogging. CONDITION/INDICATION IS GOVERNOR SIGNAL LINE IN GOOD CONDITION? DECISION NO - Clear or replace damaged air line (Volume 5, WP 0805). Go to Step (4) to verify problem is solved. YES - Go to Step (3) to verify problem is solved. 0129-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00199) TM 9-2320-272-23-1 0129 AIR PRESSURE EXCEEDS MAXIMUM (GAUGES SHOW OVER 130 PSI [896 KPA]), SAFETY VALVE OPENS TO RELEASE PRESSURE - Continued STEP 3. DOES GOVERNOR SIGNAL LINE HAVE PROPER AIR PRESSURE? a. Check governor line for proper air pressure. b. Stop engine and open all draincocks until brake system air pressure is vented. c. Close draincocks. Transducer T0268DAA Figure 3. Air Governor Signal Line. d. Disconnect governor signal line from air governor. Refer to point to point schematics. e. Connect adapter fitting to air governor and tee to fitting. f. Install pressure gauge on tee. g. Start engine and allow sufficient time for air to build to normal operating pressure. h. Pressure gauge reading should be above 80 psi. i. Compare pressure gauge reading with reading on instrument panel air pressure gauges. CONDITION/INDICATION DOES GOVERNOR SIGNAL LINE HAVE PROPER AIR PRESSURE? DECISION NO - Notify supervisor. Action may not be possible at this level of maintenance. 0129-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00199) TM 9-2320-272-23-1 0129 AIR PRESSURE EXCEEDS MAXIMUM (GAUGES SHOW OVER 130 PSI [896 KPA]), SAFETY VALVE OPENS TO RELEASE PRESSURE - Continued YES - Replace defective air governor (Volume 3, WP 0436). Go to Step (4) to verify problem is solved. STEP 4. IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0129-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00199) TM 9-2320-272-23-1 0130 FIELD MAINTENANCE PRIMARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. SECONDARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Gauge, Pressure (Volume 5, WP 0826, Table 1, Item 19) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 3, WP 0428 Volume 3, WP 0429 Volume 3, WP 0430 Volume 5, WP 0805 Volume 5, WP 0818 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE PRIMARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. SECONDARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) NOTE Conduct these malfunction tests if primary air pressure gauge reads no pressure, low pressure or builds slowly to normal operating pressure, secondary air pressure gauge reads normal. This procedure will check for air leaks from lines or fittings, faulty primary air pressure gauge, clogged air supply lines, faulty brake pedal valve or one-way check valve. 0130-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00200) TM 9-2320-272-23-1 0130 PRIMARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. SECONDARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued STEP 1. ARE AIR LINES OR FITTINGS LEAKING? a. Start engine. Secondary - Lower Tank Primary - Upper Tank Wet Tank Treadle Valve Spring Brake Air Reservoir Primary (lower) Air Gauge Port Sec. Gage Primary Gage T0270DAA Figure 1. b. Air Supply System. Listen for leaking air lines or fittings. Refer to point to point schematics. CONDITION/INDICATION ARE AIR LINES OR FITTINGS LEAKING? DECISION YES - Tighten fittings or replace damaged air lines (Volume 5, WP 0805). Go to Step (7) to verify problem is solved. NO - Go to Step (2). 0130-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00200) TM 9-2320-272-23-1 0130 PRIMARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. SECONDARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued STEP 2. IS PRIMARY AIR PRESSURE GAUGE OPERATING PROPERLY? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close draincocks. Primary Air Pressure Gage Line Primary Air Pressure Gage T0888DAA Figure 2. Primary Air Pressure Gauge. c. Disconnect air line from primary air pressure gauge. Refer to point to point schematics. d. Connect pressure gauge to disconnected air line. e. Start engine. f. Monitor air pressure on pressure gauge. g. If pressure gauge reads 90 psi after 5 minutes, primary air pressure gauge is not operating properly. CONDITION/INDICATION IS PRIMARY AIR PRESSURE GAUGE OPERATING PROPERLY? DECISION NO - Replace defective primary air pressure gauge (Volume 5, WP 0818). Go to Step (7) to verify problem is solved. YES - Go to Step (3). 0130-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00200) TM 9-2320-272-23-1 0130 PRIMARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. SECONDARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued STEP 3. IS THERE PROPER AIR PRESSURE AT BRAKE PEDAL VALVE SUPPLY PORT? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close draincocks. T0272DAA Figure 3. Brake Pedal. c. Disconnect primary pressure gauge air line from pedal valve. Refer to point to point schematics. d. Connect adapter fitting to pedal valve and move pressure gauge from disconnected air line to adapter fitting. e. Start engine. f. Monitor air pressure on pressure gauge. g. After 5 minutes pressure gauge should be read 90 psi. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT BRAKE PEDAL VALVE SUPPLY PORT? DECISION NO - Go to Step (4). YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (7) to verify problem is solved. 0130-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00200) TM 9-2320-272-23-1 0130 PRIMARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. SECONDARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued STEP 4. DOES PRIMARY AIR RESERVOIR HAVE CORRECT AIR PRESSURE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close draincocks. c. Disconnect pressure gauge from vehicle. d. Reconnect both ends of primary air pressure gauge air line. T0273DAA Figure 4. Primary Air Reservoir Drain Line. e. Disconnect draincock from drain line. Refer to point to point schematics. f. Connect adapter fitting to drain line and pressure gauge to fitting. g. Start engine. h. Monitor air pressure on pressure gauge. i. After 5 minutes pressure gauge should be read 90 psi. CONDITION/INDICATION DOES PRIMARY AIR RESERVOIR HAVE CORRECT AIR PRESSURE? DECISION NO - Go to Step (6). YES - Go to Step (5). 0130-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00200) TM 9-2320-272-23-1 0130 PRIMARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. SECONDARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued STEP 5. IS THERE PROPER AIR PRESSURE AT BRAKE PEDAL VALVE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close draincocks. Primary Air Ssystem Supply Line T0274DAA Figure 5. Primary Air System Supply Line. c. Disconnect pressure gauge from vehicle return air line to original condition. d. Disconnect primary air system supply line from brake pedal valve fitting. Refer to point to point schematics. e. Connect pressure gauge to primary supply line. f. Start engine. g. Monitor air pressure on pressure gauge. h. After 5 minutes pressure gauge should be read 90 psi. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT BRAKE PEDAL VALVE? DECISION NO - Go to Step (6). 0130-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00200) TM 9-2320-272-23-1 0130 PRIMARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. SECONDARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued YES - Replace defective brake pedal valve (Volume 3, WP 0428), M936 (Volume 3, WP 0429). Go to Step (7) to verify problem is solved. STEP 6. IS ONE-WAY CHECK VALVE IN GOOD OPERATING CONDITION? a. Stop engine and open all draincocks until brake system is vented. b. Disconnect pressure gauge from vehicle return air line to original condition. Check Valve T0275DAA Figure 6. One-Way Check Valve. c. Remove one-way check valve. d. Inspect check valve for clogging and damage. CONDITION/INDICATION IS ONE-WAY CHECK VALVE IN GOOD OPERATING CONDITION? DECISION NO - Replace defective one-way check valve (Volume 3, WP 0437). Go to Step (7) to verify problem is solved. YES - Notify supervisor. Action may not be possible at this level of maintenance. 0130-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00200) TM 9-2320-272-23-1 0130 PRIMARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. SECONDARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued STEP 7. IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0130-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00200) TM 9-2320-272-23-1 0131 FIELD MAINTENANCE SECONDARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. PRIMARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Gauge, Pressure (Volume 5, WP 0826, Table 1, Item 19) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 3, WP 0428 Volume 3, WP 0429 Volume 3, WP 0430 Volume 5, WP 0805 Volume 5, WP 0818 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE SECONDARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. PRIMARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) NOTE Conduct these malfunction tests if secondary air pressure gauge reads no pressure, low pressure or builds slowly to normal operating pressure, primary air pressure gauge reads normal. This procedure will check for air leaks from lines or fittings, faulty secondary air pressure gauge, clogged air supply lines, faulty brake pedal valve, and one-way check valve. 0131-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00201) TM 9-2320-272-23-1 0131 SECONDARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. PRIMARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued STEP 1. ARE AIR LINES OR FITTINGS LEAKING? a. Start engine. Secondary - Lower Tank Primary - Upper Tank Wet Tank Treadle Valve Spring Brake Air Reservoir Primary (lower) Air Gauge Port Sec. Gage Primary Gage T0278DAA Figure 1. b. Air Supply System. Listen for leaking air lines or fittings. Refer to point to point schematics. CONDITION/INDICATION ARE AIR LINES OR FITTINGS LEAKING? DECISION YES - Tighten fittings or replace damaged air lines (Volume 5, WP 0805). Go to Step (7) to verify problem is solved. NO - Go to Step (2). 0131-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00201) TM 9-2320-272-23-1 0131 SECONDARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. PRIMARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued STEP 2. IS SECONDARY AIR PRESSURE GAUGE OPERATING PROPERLY? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close draincocks. Secondary Air Pressure Gage Line Secondary Air Pressure Gage T0279DAA Figure 2. Secondary Air Pressure Gauge. c. Disconnect air line from secondary air pressure gauge. Refer to point to point schematics. d. Connect pressure gauge to disconnected air line. e. Start engine. f. Monitor air pressure on pressure gauge. g. If pressure gauge reads 90 psi after 5 minutes, secondary air pressure gauge is not operating properly. CONDITION/INDICATION IS SECONDARY AIR PRESSURE GAUGE OPERATING PROPERLY? DECISION NO - Replace defective secondary air pressure gauge (Volume 5, WP 0818). Go to Step (7) to verify problem is solved. YES - Go to Step (3). 0131-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00201) TM 9-2320-272-23-1 0131 SECONDARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. PRIMARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued STEP 3. IS THERE PROPER AIR PRESSURE AT BRAKE PEDAL VALVE SUPPLY PORT? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close draincocks. T0280DAA Figure 3. Brake Pedal. 0131-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00201) TM 9-2320-272-23-1 0131 SECONDARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. PRIMARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued c. Disconnect secondary pressure gauge air line from pedal valve. Refer to point to point schematics. d. Connect adapter fitting to pedal valve and move pressure gauge from disconnected air line to adapter fitting. e. Start engine. f. Monitor air pressure on pressure gauge. g. After 5 minutes pressure gauge should be read 90 psi. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT BRAKE PEDAL VALVE SUPPLY PORT? DECISION NO - Go to Step (4). YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (7) to verify problem is solved. 0131-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00201) TM 9-2320-272-23-1 0131 SECONDARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. PRIMARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued STEP 4. DOES SECONDARY AIR RESERVOIR HAVE CORRECT AIR PRESSURE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close draincocks. T0281DAA Figure 4. Secondary Air Reservoir Drain Line. 0131-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00201) TM 9-2320-272-23-1 0131 SECONDARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. PRIMARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued c. Disconnect pressure gauge from vehicle. d. Reconnect both ends of secondary air pressure gauge air line. e. Disconnect draincock from drain line. Refer to point to point schematics. f. Connect adapter fitting to drain line and pressure gauge to fitting. g. Start engine. h. Monitor air pressure on pressure gauge. i. After 5 minutes pressure gauge should be read 90 psi. CONDITION/INDICATION DOES SECONDARY AIR RESERVOIR HAVE CORRECT AIR PRESSURE? DECISION NO - Go to Step (6). YES - Go to Step (5). 0131-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00201) TM 9-2320-272-23-1 0131 SECONDARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. PRIMARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued STEP 5. IS THERE PROPER AIR PRESSURE AT BRAKE PEDAL VALVE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close draincocks. Secondary Air System Supply Line T0282DAA Figure 5. Secondary Air System Supply Line. c. Disconnect pressure gauge from vehicle return air line to original condition. d. Disconnect secondary air system supply line from brake pedal valve fitting. Refer to point to point schematics. e. Connect pressure gauge to secondary supply line. f. Start engine. g. Monitor air pressure on pressure gauge. h. After 5 minutes pressure gauge should be read 90 psi. CONDITION/INDICATION IS THERE PROPER AIR PRESSURE AT BRAKE PEDAL VALVE? DECISION NO - Go to Step (6). 0131-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00201) TM 9-2320-272-23-1 0131 SECONDARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. PRIMARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued YES - Replace defective brake pedal valve (Volume 3, WP 0429), M936 (Volume 3, WP 0430). Go to Step (7) to verify problem is solved. STEP 6. IS ONE-WAY CHECK VALVE IN GOOD OPERATING CONDITION? a. Stop engine and open all draincocks until brake system is vented. b. Disconnect pressure gauge from vehicle return air line to original condition. Check Valve T0283DAA Figure 6. One-Way Check Valve. c. Remove one-way check valve. d. Inspect check valve for clogging and damage. CONDITION/INDICATION IS ONE-WAY CHECK VALVE IN GOOD OPERATING CONDITION? DECISION NO - Replace defective one-way check valve (Volume 3, WP 0437). Go to Step (7) to verify problem is solved. YES - Notify supervisor. Action may not be possible at this level of maintenance. 0131-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00201) TM 9-2320-272-23-1 0131 SECONDARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. PRIMARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED) - Continued STEP 7. IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0131-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00201) TM 9-2320-272-23-1 0132 FIELD MAINTENANCE PRIMARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics Volume 3, WP 0434 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE PRIMARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED) NOTE Conduct these malfunction tests if primary air pressure system fails to hold pressure. No major leaks, air can be heard escaping into air intake stack, parking brake applied. This procedure will check for air leaks through vent lines. 0132-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00202) TM 9-2320-272-23-1 0132 PRIMARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED) - Continued STEP 1. DOES AIR LEAK THROUGH SERVICE BRAKE CHAMBER VENT LINES? a. Disconnect vent line from right front service brake chamber (Volume 3, WP 0434). Refer to point to point schematics. Vent Line Vent Port Service Brake Chamber T0884DAA Figure 1. Service Brake Chamber Vent Line. WARNING Do not look in service chamber vent port when performing test. Failure to comply may result in injury or death to personnel. b. Assistant applies service brakes and feels for evidence of escaping air at vent port. c. Connect vent line to service brake chamber. d. Check vent lines on all service brake chambers. Note any chambers that leak air. CONDITION/INDICATION DOES AIR LEAK THROUGH SERVICE BRAKE CHAMBER VENT LINES? 0132-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00202) TM 9-2320-272-23-1 PRIMARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED) - Continued DECISION YES - Replace faulty brake chamber (Volume 3, WP 0434). Go to Step (2) to verify problem is solved. NO - Go to Step (2) to verify problem is solved. STEP 2. IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original air pressure problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0132-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00202) 0132 TM 9-2320-272-23-1 0133 FIELD MAINTENANCE SECONDARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Gauge, Pressure (Volume 5, WP 0826, Table 1, Item 19) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 3, WP 0429 Volume 3, WP 0430 Volume 3, WP 0457 Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE SECONDARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED) NOTE Conduct these malfunction tests if secondary air pressure system fails to hold pressure. No major leaks, air can be heard escaping into air intake stack, parking brake applied. This procedure will check for blocked secondary air system relay valve and secondary air pressure gauge delivery lines. 0133-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00203) TM 9-2320-272-23-1 0133 SECONDARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED) - Continued STEP 1. IS PROPER AIR PRESSURE AT SECONDARY RELAY VALVE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. Transducer Relay Valve Elbow Delivery Port Delivery Line T0286DAA Figure 1. Secondary Relay Valve Delivery Port. c. Disconnect air line from elbow at secondary relay valve delivery port (Volume 3, WP 0457). Refer to point to point schematics. d. Remove elbow from secondary relay valve delivery port. e. Connect pressure gauge to disconnected relay valve delivery port. f. Assistant starts engine and runs to build air supply to normal operating pressure. g. Assistant fully applies and holds service brakes. h. Monitor air pressure on pressure gauge. i. After 5 minutes, pressure gauge should read 90 to 130 psi. 0133-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00203) TM 9-2320-272-23-1 0133 SECONDARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED) - Continued CONDITION/INDICATION IS PROPER AIR PRESSURE AT SECONDARY RELAY VALVE? DECISION NO - Go to Step (2). YES - Replace damaged air lines from secondary relay valve to rear brake chambers (Volume 5, WP 0805). Go to Step (4) to verify problem is solved. 0133-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00203) TM 9-2320-272-23-1 0133 SECONDARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED) - Continued STEP 2. IS PROPER AIR PRESSURE AT SECONDARY RELAY VALVE? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. c. Disconnect pressure gauge from vehicle and return air line to original condition. Relay Valve Delivery Line Elbow Delivery Port Transducer T0289DAA Figure 2. Secondary Relay Valve Delivery Port. d. Disconnect air line from elbow at secondary relay valve delivery port (Volume 3, WP 0457). Refer to point to point schematics. e. Remove elbow from secondary relay valve delivery port. f. Connect pressure gauge to disconnected relay valve delivery port. g. Assistant starts engine and runs to build air supply to normal operating pressure. h. Assistant fully applies and holds service brakes. i. Monitor air pressure on pressure gauge. j. After 5 minutes, pressure gauge should read 90 to 130 psi. 0133-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00203) TM 9-2320-272-23-1 0133 SECONDARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED) - Continued CONDITION/INDICATION IS PROPER AIR PRESSURE AT SECONDARY RELAY VALVE? DECISION NO - Go to Step (3). YES - Replace damaged air lines from secondary relay valve to rear brake chambers (Volume 5, WP 0805). Go to Step (4) to verify problem is solved. 0133-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00203) TM 9-2320-272-23-1 0133 SECONDARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED) - Continued STEP 3. IS PROPER AIR PRESSURE AT SERVICE BRAKE PEDAL VALVE SECONDARY AIR SYSTEM DELIVERY PORT? a. Stop engine and open all draincocks until brake system air pressure is vented. b. Close all draincocks. c. Disconnect pressure gauge from vehicle and return air line to original condition. Adapter Fitting Transducer T0291DAA Figure 3. Service Brake Pedal Valve. d. Disconnect secondary pressure gauge air line from pedal valve. e. Connect adapter fitting to pedal valve. f. Connect pressure gauge to adapter fitting. g. Starts engine. h. Monitor air pressure on pressure gauge. i. After 5 minutes, pressure gauge should read 90 to 130 psi. 0133-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00203) TM 9-2320-272-23-1 0133 SECONDARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED) - Continued CONDITION/INDICATION IS PROPER AIR PRESSURE AT SERVICE BRAKE PEDAL VALVE SECONDARY AIR SYSTEM DELIVERY PORT? DECISION NO - Go to Step (4) to verify problem is solved. YES - Replace service brake pedal valve (Volume 3, WP 0429), M936 (Volume 3, WP 0430). Go to Step (4) to verify problem is solved. STEP 4. IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original air pressure problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0133-7/8 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00203) TM 9-2320-272-23-1 0134 FIELD MAINTENANCE WARNING BUZZER FAILS TO SOUND OR FAILS TO SHUT OFF ON LOW PRESSURE (BELOW 55-65 PSI [379-448 KPA]), AIR PRESSURE SYSTEM OPERATING NORMALLY INITIAL SETUP: References WP 0110 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE WARNING BUZZER FAILS TO SOUND OR FAILS TO SHUT OFF ON LOW PRESSURE (BELOW 55-65 PSI [379-448 KPA]), AIR PRESSURE SYSTEM OPERATING NORMALLY STEP NOTE This procedure is located in the electrical troubleshooting section. 1. Perform Warning Buzzer Fails To Sound or Fails To Shut Off on Low Pressure troubleshooting (WP 0110). CONDITION/INDICATION DECISION END OF WORK PACKAGE 0134-1/2 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00204) TM 9-2320-272-23-1 FIELD MAINTENANCE SPRING BRAKES DO NOT RELEASE (VEHICLE BRAKES GRAB OR DRAG) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) WP 0122 Volume 3, WP 0431 Volume 3, WP 0477 Volume 5, WP 0805 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE SPRING BRAKES DO NOT RELEASE (VEHICLE BRAKES GRAB OR DRAG) NOTE Conduct these malfunction tests if the spring brakes do not release. This procedure will check for oil needed at mechanical actuator, defective quick release valve, defective double-check valve, clogged or faulty air line between quick-release valve and double-check valve, defective parking brake valve, and defective spring brake diaphragms. 0135-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00205) 0135 TM 9-2320-272-23-1 0135 SPRING BRAKES DO NOT RELEASE (VEHICLE BRAKES GRAB OR DRAG) - Continued STEP 1. CAN SPRING BRAKES BE RELEASED? a. Assistant starts engine and builds air supply to normal operating pressure. SPRING BRAKE RELEASE CONTROL AIR PRESSURE GAGE T0295DAA Figure 1. Spring Brake Release Control. b. Assistant pulls out emergency spring brake release control and moves vehicle forward. c. Watch to see if any wheels with spring brakes do not turn. CONDITION/INDICATION CAN SPRING BRAKES BE RELEASED? DECISION NO - Only one wheel is not turning. Perform Vehicle Rear Brakes Grab Or Drag troubleshooting (WP 0122). NO - No wheels with spring brakes turn. Go to Step (5). YES - All wheels turn. Go to Step (2). 0135-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00205) TM 9-2320-272-23-1 0135 SPRING BRAKES DO NOT RELEASE (VEHICLE BRAKES GRAB OR DRAG) - Continued STEP 2. IS PARKING BRAKE VALVE MECHANICAL ACTUATOR STUCK IN ENGAGED POSITION? a. Turn off engine. b. Verify parking brake is released, then move mechanical actuator by hand to check for sticking. ACTUATOR BRAKE LEVER T0297DAA Figure 2. Parking Brake Control Lever. CONDITION/INDICATION IS PARKING BRAKE VALVE MECHANICAL ACTUATOR STUCK IN ENGAGED POSITION? DECISION NO - Go to Step (4). YES - Go to Step (3). 0135-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00205) TM 9-2320-272-23-1 0135 SPRING BRAKES DO NOT RELEASE (VEHICLE BRAKES GRAB OR DRAG) - Continued STEP 3. DOES OIL ON PARKING BRAKE VALVE MECHANICAL ACTUATOR CAUSE IT TO MOVE FREELY? a. Pull back rubber boot. ACTUATOR BRAKE LEVER T0297DAA Figure 3. Parking Brake Control Lever. b. Apply a few drops of light machine oil to the parking brake valve mechanical actuator. c. Move mechanical actuator by hand to check for sticking. CONDITION/INDICATION DOES OIL ON PARKING BRAKE VALVE MECHANICAL ACTUATOR CAUSE IT TO MOVE FREELY? DECISION NO - Go to Step (4). YES - Go to Step (8) to verify problem is solved. 0135-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00205) TM 9-2320-272-23-1 0135 SPRING BRAKES DO NOT RELEASE (VEHICLE BRAKES GRAB OR DRAG) - Continued STEP 4. IS AIR PRESSURE AT PARKING BRAKE SUPPLY LINE? a. Verify engine is running. SUPPLY LINE T0299DAA Figure 4. Parking Brake Valve. WARNING Loosen supply line at valve very slowly. Stop procedure and tighten fitting of supply line the moment air begins to escape. Failure to comply may result in injury or death to personnel. b. Slowly loosen valve supply line until any air escapes, then immediately tighten the line. Refer to point to point schematics. CONDITION/INDICATION IS AIR PRESSURE AT PARKING BRAKE SUPPLY LINE? DECISION NO - Go to Step (5). YES - Go to Step (6). 0135-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00205) TM 9-2320-272-23-1 0135 SPRING BRAKES DO NOT RELEASE (VEHICLE BRAKES GRAB OR DRAG) - Continued STEP 5. IS AIR ESCAPING FROM QUICK RELEASE VALVE? a. Verify engine is running. AIR INTAKE STACK T0300DAA Figure 5. Air Intake Stack. b. Release parking brake. c. Listen at air intake stack for the sound of air escaping. Refer to point to point schematics. CONDITION/INDICATION IS AIR ESCAPING FROM QUICK RELEASE VALVE? DECISION NO - Go to Step (7). YES - Replace defective quick release valve (Volume 3, WP 0477). Go to Step (8) to verify problem is solved. 0135-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00205) TM 9-2320-272-23-1 0135 SPRING BRAKES DO NOT RELEASE (VEHICLE BRAKES GRAB OR DRAG) - Continued STEP 6. IS AIR PRESSURE AT PARKING BRAKE DELIVERY LINE? a. Verify engine is running. PARKING BRAKE VALVE DELIVERY LINE T0302DAA Figure 6. Parking Brake Valve. WARNING Loosen supply line at valve very slowly. Stop procedure and tighten fitting of supply line the moment air begins to escape. Failure to comply may result in injury or death to personnel. b. Release parking brake. c. Slowly loosen valve supply line until any air escapes, then immediately tighten the line. Refer to point to point schematics. CONDITION/INDICATION IS AIR PRESSURE AT PARKING BRAKE DELIVERY LINE? DECISION NO - Replace parking brake valve (Volume 3, WP 0431). Go to Step (8) to verify problem is solved. YES - Notify supervisor that brake diaphragms are defective. Action is not possible at this level of maintenance. 0135-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00205) TM 9-2320-272-23-1 0135 SPRING BRAKES DO NOT RELEASE (VEHICLE BRAKES GRAB OR DRAG) - Continued STEP 7. IS THE AIR LINE BETWEEN THE QUICK-RELEASE AND DOUBLE-CHECK VALVES CLOGGED? Inspect for a clogged line between the quick-release and double-check valves. Refer to point to point schematics. DOUBLE CHECK VALVE AIR SUPPLY LINE QUICK RELEASE VALVE T0303DAA Figure 7. Parking Brake Quick Release Valve Assembly. CONDITION/INDICATION IS THE AIR LINE BETWEEN THE QUICK-RELEASE AND DOUBLE-CHECK VALVES CLOGGED? DECISION YES - Clear or replace line (Volume 5, WP 0805). Go to Step (8) to verify problem is solved. NO - Replace defective double-check valve (Volume 3, WP 0477). Go to Step (8) to verify problem is solved. STEP 8. IS YOUR ORIGINAL BRAKE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original brake problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL BRAKE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0135-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00205) TM 9-2320-272-23-1 0136 FIELD MAINTENANCE SPRING BRAKES DO NOT SET (GAUGES AT NORMAL OPERATING PRESSURES, AIR EXHAUSTING NOT HEARD WHEN PARKING BRAKE APPLIED) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 3, WP 0431 Volume 3, WP 0477 Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE SPRING BRAKES DO NOT SET (GAUGES AT NORMAL OPERATING PRESSURES, AIR EXHAUSTING NOT HEARD WHEN PARKING BRAKE APPLIED) NOTE Conduct these malfunction tests if spring brakes do not set. This procedure will check for spring brake release control out, parking brake not fully applied, quick release valve air lines crimped, faulty parking brake valve, and faulty quick release valve. 0136-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00206) TM 9-2320-272-23-1 0136 SPRING BRAKES DO NOT SET (GAUGES AT NORMAL OPERATING PRESSURES, AIR EXHAUSTING NOT HEARD WHEN PARKING BRAKE APPLIED) - Continued STEP 1. IS THE SPRING BRAKE RELEASE CONTROL OUT? Verify that spring brake release control is not out. SPRING BRAKE RELEASE CONTROL T0307DAA Figure 1. Spring Brake Control. CONDITION/INDICATION IS THE SPRING BRAKE RELEASE CONTROL OUT? DECISION YES - Push spring control in. Go to Step (5) to verify problem is solved. NO - Go to Step (2). 0136-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00206) TM 9-2320-272-23-1 0136 SPRING BRAKES DO NOT SET (GAUGES AT NORMAL OPERATING PRESSURES, AIR EXHAUSTING NOT HEARD WHEN PARKING BRAKE APPLIED) - Continued STEP 2. IS THE PARKING BRAKE FULLY APPLIED? Verify that the parking brake is fully applied. SPRING BRAKE ASSEMBLY PARKING BRAKE LEVER T0309DAA Figure 2. Spring Brake Assembly. CONDITION/INDICATION IS THE PARKING BRAKE FULLY APPLIED? DECISION NO - Fully apply parking brakes. Go to Step (5) to verify problem is solved. YES - Go to Step (3). 0136-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00206) TM 9-2320-272-23-1 0136 SPRING BRAKES DO NOT SET (GAUGES AT NORMAL OPERATING PRESSURES, AIR EXHAUSTING NOT HEARD WHEN PARKING BRAKE APPLIED) - Continued STEP 3. ARE ANY QUICK RELEASE VALVE AIR LINES CRIMPED? Check all air lines attached to the quick release valve. Refer to point to point schematics. AIR LINES QUICK RELEASE VALVE T0310DAA Figure 3. Quick Release Valve. CONDITION/INDICATION ARE ANY QUICK RELEASE VALVE AIR LINES CRIMPED? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (5) to verify problem is solved. NO - Go to Step (4). 0136-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00206) TM 9-2320-272-23-1 0136 SPRING BRAKES DO NOT SET (GAUGES AT NORMAL OPERATING PRESSURES, AIR EXHAUSTING NOT HEARD WHEN PARKING BRAKE APPLIED) - Continued STEP 4. DOES AIR VENT THROUGH THE PARKING BRAKE VALVE VENT PORT? a. Disconnect vent line from parking brake valve vent port. Refer to point to point schematics. PARKING BRAKE VALVE VENT PORT T0312DAA Figure 4. Parking Brake Valve. b. Assistant starts engine and runs to build air supply to normal operating pressure. c. Apply spring brake. d. Feel for air venting through parking brake valve vent port. CONDITION/INDICATION DOES AIR VENT THROUGH THE PARKING BRAKE VALVE VENT PORT? DECISION NO - Replace quick release valve (Volume 3, WP 0477). Go to Step (5) to verify problem is solved. YES - Replace parking brake valve (Volume 3, WP 0431). Go to Step (5) to verify problem is solved. 0136-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00206) TM 9-2320-272-23-1 0136 SPRING BRAKES DO NOT SET (GAUGES AT NORMAL OPERATING PRESSURES, AIR EXHAUSTING NOT HEARD WHEN PARKING BRAKE APPLIED) - Continued STEP 5. IS YOUR ORIGINAL BRAKE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original brake problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL BRAKE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0136-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00206) TM 9-2320-272-23-1 0137 FIELD MAINTENANCE ALL AIR-OPERATED ACCESSORIES DO NOT OPERATE (HORN, WINDSHIELD WIPERS, WINDSHIELD WASHERS, TRANSFER CASE CONTROLS), GAUGES AT NORMAL OPERATING PRESSURE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 3, WP 0442 Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE ALL AIR-OPERATED ACCESSORIES DO NOT OPERATE (HORN, WINDSHIELD WIPERS, WINDSHIELD WASHERS, TRANSFER CASE CONTROLS), GAUGES AT NORMAL OPERATING PRESSURE NOTE Conduct these malfunction tests if all air operated accessories do not work. This procedure will check for defective air lines between the governor and accessories, and the pressure protection valve. 0137-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00207) TM 9-2320-272-23-1 0137 ALL AIR-OPERATED ACCESSORIES DO NOT OPERATE (HORN, WINDSHIELD WIPERS, WINDSHIELD WASHERS, TRANSFER CASE CONTROLS), GAUGES AT NORMAL OPERATING PRESSURE - Continued STEP 1. DO THE INSTRUMENT PANEL GAUGES INDICATE NORMAL AIR PRESSURE? a. Start engine. PRIMARY AIR PRESSURE GAGE SECONDARY AIR PRESSURE GAGE T0324DAA Figure 1. Air Pressure Gauges. b. Monitor air pressure gauges on instrument panel. c. Pressure gauge should read 90 to 130 psi. CONDITION/INDICATION DO THE INSTRUMENT PANEL GAUGES INDICATE NORMAL AIR PRESSURE? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (2) to verify problem is solved. NO - Replace pressure protection valve (Volume 3, WP 0442). Go to Step (2) to verify problem is solved. 0137-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00207) TM 9-2320-272-23-1 0137 ALL AIR-OPERATED ACCESSORIES DO NOT OPERATE (HORN, WINDSHIELD WIPERS, WINDSHIELD WASHERS, TRANSFER CASE CONTROLS), GAUGES AT NORMAL OPERATING PRESSURE - Continued STEP 2. IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL AIR PRESSURE PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0137-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00207) TM 9-2320-272-23-1 0138 FIELD MAINTENANCE COOLING FAN DOES NOT OPERATE, ENGINE TEMPERATURE ABOVE 195°F (91°C) AS INDICATED BY TEMPERATURE GAUGE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) WP 0106 WP 0131 Volume 3, WP 0447 Volume 3, WP 0448 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE COOLING FAN DOES NOT OPERATE, ENGINE TEMPERATURE ABOVE 195°F (91°C) AS INDICATED BY TEMPERATURE GAUGE NOTE Conduct these malfunction tests if the cooling fan does not operate and the engine temperature is above 195 °F (91°C). This procedure will check for air availability, faulty temperature gauge, and faulty fan drive clutch actuator. 0138-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00208) TM 9-2320-272-23-1 0138 COOLING FAN DOES NOT OPERATE, ENGINE TEMPERATURE ABOVE 195°F (91°C) AS INDICATED BY TEMPERATURE GAUGE - Continued STEP 1. IS AIR AVAILABLE TO RUN THE COOLING FAN? a. Start engine. b. Monitor secondary air pressure gauge on instrument panel. Refer to point to point schematics. INSTRUMENT PANEL SECONDARY AIR PRESSURE GAGE T0328DAA Figure 1. Secondary Air Pressure Gauge. CONDITION/INDICATION IS AIR AVAILABLE TO RUN THE COOLING FAN? DECISION YES - Go to Step (2). NO - Perform Secondary Pressure Gauge Reads No Pressure, Low Pressure, Or Builds Too Slowly troubleshooting (WP 0131). STEP 2. IS FAN DRIVE CLUTCH ACTUATOR FAULTY? a. Shut off and allow engine to cool. Refer to point to point schematics. 0138-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00208) TM 9-2320-272-23-1 0138 COOLING FAN DOES NOT OPERATE, ENGINE TEMPERATURE ABOVE 195°F (91°C) AS INDICATED BY TEMPERATURE GAUGE - Continued FAN DRIVE CLUTCH ACTUATOR ENGINE COOLING FAN T0330DAA Figure 2. Fan Clutch Actuator. b. Replace fan drive clutch actuator with a known good actuator M939/A1 (Volume 3, WP 0447), M939A2 (Volume 3, WP 0448). c. Start engine and bring to normal operating temperature. NOTE If cooling fan operates, fan drive clutch actuator was faulty. d. Check if cooling fan operates. e. Shut off and allow engine to cool. f. If cooling fan does not operate, replace fan drive clutch actuator with original actuator. CONDITION/INDICATION IS FAN DRIVE CLUTCH ACTUATOR FAULTY? DECISION YES - Go to Step (3) to verify problem is solved. NO - Perform Temperature Gauge Inoperative (Coolant) troubleshooting (WP 0106). 0138-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00208) TM 9-2320-272-23-1 0138 COOLING FAN DOES NOT OPERATE, ENGINE TEMPERATURE ABOVE 195°F (91°C) AS INDICATED BY TEMPERATURE GAUGE - Continued STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0138-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00208) TM 9-2320-272-23-1 0139 FIELD MAINTENANCE COOLING FAN DOES NOT STOP RUNNING, ENGINE TEMPERATURE BELOW NORMAL OPERATING RANGE (OVERRIDE BOLT NOT INSTALLED) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 3, WP 0447 Volume 3, WP 0448 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE COOLING FAN DOES NOT STOP RUNNING, ENGINE TEMPERATURE BELOW NORMAL OPERATING RANGE (OVERRIDE BOLT NOT INSTALLED) NOTE Conduct these malfunction tests if the cooling fan does not stop running and the engine temperature is below the normal operating range. This procedure will check for a faulty fan drive clutch actuator. 0139-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00209) TM 9-2320-272-23-1 0139 COOLING FAN DOES NOT STOP RUNNING, ENGINE TEMPERATURE BELOW NORMAL OPERATING RANGE (OVERRIDE BOLT NOT INSTALLED) - Continued STEP 1. IS THE FAN DRIVE CLUTCH ACTUATOR FAULTY? a. Allow engine to cool. Refer to point to point schematics. FAN DRIVE CLUTCH ACTUATOR ENGINE COOLING FAN T0334DAA Figure 1. Fan Clutch Actuator. b. Replace fan drive clutch actuator M939/A1 (Volume 3, WP 0447), M939A2 (Volume 3, WP 0448). c. Start engine and bring to normal operating temperature. d. If cooling fan operates only when needed, fan drive clutch actuator was faulty. CONDITION/INDICATION IS THE FAN DRIVE CLUTCH ACTUATOR FAULTY? DECISION YES - Go to Step (2) to verify problem is solved. NO - Notify supervisor. It is possible another troubleshooting work package applies. 0139-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00209) TM 9-2320-272-23-1 COOLING FAN DOES NOT STOP RUNNING, ENGINE TEMPERATURE BELOW NORMAL OPERATING RANGE (OVERRIDE BOLT NOT INSTALLED) - Continued STEP 2. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0139-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00209) 0139 TM 9-2320-272-23-1 0140 FIELD MAINTENANCE FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Gauge, Pressure (Volume 5, WP 0826, Table 1, Item 19) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) WP 0131 Volume 3, WP 0389 Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION) NOTE Conduct these malfunction tests if front wheel drive does not engage. This procedure will check for leaking air lines from the actuator valve to transfer case and the supply line from the actuator valve to transfer case. It also checks for faulty actuator valve, front wheel drive lock-in switch, and air line from actuator valve to front wheel drive lock-in switch. Finally, it checks for transfer case not engaging front wheel drive, and air not being delivered to the actuator valve. 0140-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00210) TM 9-2320-272-23-1 0140 FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION) - Continued STEP 1. DOES FRONT WHEEL DRIVE FUNCTION WITH TRANSFER CASE SHIFT LEVER IN LOW POSITION? a. Start engine. TRANSFER CASE SHIFT LEVER T0338DAA Figure 1. Transfer Case Shift Lever. b. Place transfer case shift lever in low position. c. Check front wheel drive operation. CONDITION/INDICATION DOES FRONT WHEEL DRIVE FUNCTION WITH TRANSFER CASE SHIFT LEVER IN LOW POSITION? DECISION NO - Go to Step (2). YES - Go to Step (6). 0140-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00210) TM 9-2320-272-23-1 0140 FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION) - Continued STEP 2. DOES AIR SYSTEM LEAK WITH SHIFT LEVER IN HIGH POSITION? a. Place transfer case shift lever into high position. Refer to point to point schematics. FRONT WHEEL DRIVE LOCK - IN SWITCH TRANSFER CASE SHIFT LEVER T0340DAA Figure 2. Transfer Case Shift Lever and Drive Lock In Switch. b. Engage front wheel drive lock-in switch. c. Start engine and allow air pressure to build to normal operating pressure. d. Stop engine and observe secondary air pressure gauge. e. If pressure gauge indicates a steady loss of pressure, system is leaking. CONDITION/INDICATION DOES AIR SYSTEM LEAK WITH SHIFT LEVER IN HIGH POSITION? DECISION YES - Perform Secondary Pressure Gauge Reads No Pressure, Low Pressure, Or Builds To Normal Operating Pressure Slowly troubleshooting (WP 0131). NO - Go to Step (3). 0140-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00210) TM 9-2320-272-23-1 0140 FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION) - Continued STEP 3. DOES AIR SYSTEM LEAK WITH SHIFT LEVER IN LOW POSITION? a. Place transfer case shift lever into low position. Refer to point to point schematics. SECONDARY AIR PRESSURE GAGE INSTRUMENT PANEL SPRING BRAKE ASSEMBLY TRANSFER CASE SHIFT LEVER T0342DAA Figure 3. Transfer Case Shift Lever. b. Observe secondary air pressure gauge. c. If pressure gauge indicates a steady loss of pressure, system is leaking. CONDITION/INDICATION DOES AIR SYSTEM LEAK WITH SHIFT LEVER IN LOW POSITION? DECISION YES - Go to Step (4). NO - Go to Step (8). 0140-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00210) TM 9-2320-272-23-1 0140 FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION) - Continued STEP 4. IS THERE A LEAK FROM THE AIR LINE BETWEEN THE ACTUATOR VALVE AND THE TRANSFER CASE? Inspect the air line between the actuator valve and the transfer case for an air leak. Refer to point to point schematics. ACTUATOR VALVE DELIVERY LINE (TO TRANSFER CASE) T0343DAA Figure 4. Air Line Between Actuator Valve and Transfer Case. CONDITION/INDICATION IS THERE A LEAK FROM THE AIR LINE BETWEEN THE ACTUATOR VALVE AND THE TRANSFER CASE? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (10) to verify problem is solved. NO - Go to Step (5). 0140-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00210) TM 9-2320-272-23-1 0140 FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION) - Continued STEP 5. IS THERE AN AIR LEAK FROM THE SUPPLY LINE AT THE ACTUATOR VALVE? Inspect the supply line attached to the actuator valve for an air leak. Refer to point to point schematics. ACTUATOR VALVE SUPPLY LINE T0345DAA Figure 5. Air Supply Line to Actuator Valve. CONDITION/INDICATION IS THERE AN AIR LEAK FROM THE SUPPLY LINE AT THE ACTUATOR VALVE? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (10) to verify problem is solved. NO - Notify supervisor. Action may not be possible at this level of maintenance. 0140-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00210) TM 9-2320-272-23-1 0140 FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION) - Continued STEP 6. IS THERE AIR PRESSURE IN THE AIR LINE BETWEEN THE ACTUATOR VALVE AND THE FRONT WHEEL DRIVE LOCK-IN SWITCH? a. Disconnect air line from actuator valve. Refer to point to point schematics. AIR LINE (TO FRONT WHEEL DRIVE LOCK - IN SWITCH) ACTUATOR VALVE TRANSDUCER SUPPLY LINE DELIVERY LINE T0320DAA Figure 6. Air Supply Line to Actuator Valve. b. Connect pressure gauge to disconnected air line. c. Start engine and run at idle. d. Place transfer case shift lever into high position. e. Engage front wheel drive lock-in switch. f. Monitor air pressure on pressure gauge. g. After 5 minutes air pressure should read 90 to 130 psi. CONDITION/INDICATION IS THERE AIR PRESSURE IN THE AIR LINE BETWEEN THE ACTUATOR VALVE AND THE FRONT WHEEL DRIVE LOCK-IN SWITCH? DECISION YES - Notify supervisor. Action may not be possible at this level of maintenance. NO - Go to Step (7). 0140-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00210) TM 9-2320-272-23-1 0140 FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION) - Continued STEP 7. IS THERE AIR PRESSURE IN THE AIR LINE CONNECTED TO THE FRONT WHEEL DRIVE LOCK-IN SWITCH? a. Stop engine. b. Disconnect pressure gauge from vehicle and return air line to original condition. c. Disconnect air line from front wheel drive lock-in switch. Refer to point to point schematics. AIR LINE (TO ACTUATOR VALVE) TRANSDUCER FRONT WHEEL DRIVE LOCK - IN SWITCH T0348DAA Figure 7. Front Wheel Drive Lock-in Switch. d. Connect pressure gauge to front wheel drive lock-in switch. e. Start engine and run at idle. f. Place transfer case shift lever into high position. g. Engage front wheel drive lock-in switch. h. Monitor air pressure on pressure gauge. i. After 5 minutes air pressure should read 90 to 130 psi. CONDITION/INDICATION IS THERE AIR PRESSURE IN THE AIR LINE CONNECTED TO THE FRONT WHEEL DRIVE LOCK-IN SWITCH? DECISION YES - Replace defective air line at the front wheel drive lock-in valve (Volume 5, WP 0805). Go to Step (10) to verify problem is solved. NO - Replace defective front wheel drive lock-in switch (Volume 3, WP 0389). Go to Step (10) to verify problem is solved. 0140-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00210) TM 9-2320-272-23-1 0140 FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION) - Continued STEP 8. IS THERE AIR PRESSURE IN THE AIR LINE BETWEEN THE ACTUATOR VALVE AND THE TRANSFER CASE? a. Verify engine is stopped. b. Disconnect delivery air line from transfer case. Refer to point to point schematics. ACTUATOR VALVE DELIVERY LINE SUPPLY LINE TRANSDUCER T0351DAA Figure 8. Actuator Valve. c. Connect pressure gauge to disconnected air line. d. Start engine and run at idle. e. Place transfer case shift lever into low position. f. Monitor air pressure on pressure gauge. g. After 5 minutes air pressure should read 90 to 130 psi. CONDITION/INDICATION IS THERE AIR PRESSURE IN THE AIR LINE BETWEEN THE ACTUATOR VALVE AND THE TRANSFER CASE? DECISION YES - Notify supervision that transfer case is faulty. Action may not be possible at this level of maintenance. NO - Go to Step (9). 0140-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00210) TM 9-2320-272-23-1 0140 FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION) - Continued STEP 9. IS THERE AIR PRESSURE IN THE IR LINE AT THE ACTUATOR VALVE DELIVERY PORT? a. Stop engine. b. Disconnect pressure gauge from vehicle and return air line to original condition. c. Disconnect delivery air line from actuator valve delivery port. Refer to point to point schematics. ACTUATOR VALVE DELIVERY PORT TRANSDUCER SUPPLY LINE DELIVERY LINE T0353DAA Figure 9. Actuator Valve. d. Connect pressure gauge to actuator valve delivery port. e. Start engine and run at idle. f. Place transfer case shift lever into low position. g. Monitor air pressure on pressure gauge. h. After 5 minutes air pressure should read 90 to 130 psi. CONDITION/INDICATION IS THERE AIR PRESSURE IN THE AIR LINE AT THE ACTUATOR VALVE DELIVERY PORT? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (10) to verify problem is solved. NO - Notify supervisor. Action may not be possible at this level of maintenance. 0140-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00210) TM 9-2320-272-23-1 0140 FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION) - Continued STEP 10. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0140-11/12 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00210) TM 9-2320-272-23-1 0141 FIELD MAINTENANCE HORN DOES NOT WORK (GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) WP 0109 Volume 5, WP 0805 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE HORN DOES NOT WORK (GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) NOTE Conduct these malfunction tests if the horn does not work. This procedure will check for a defective air supply line. 0141-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00211) TM 9-2320-272-23-1 0141 HORN DOES NOT WORK (GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) - Continued STEP 1. IS THERE AIR AT THE AIR ELECTRIC VALVE? a. Start engine and allow air pressure to build to normal operating pressure. b. Stop engine. SUPPLY LINE AIR ELECTRIC VALVE T0357DAA Figure 1. Air Horn. WARNING Loosen supply line at valve very slowly. Stop procedure and tighten fitting of supply line the moment air begins to escape. Failure to comply may result in injury or death to personnel. c. Loosen air supply line very slowly. Refer to point to point schematics. CONDITION/INDICATION IS THERE AIR AT THE AIR ELECTRIC VALVE? DECISION NO - Replace damaged supply air line (Volume 5, WP 0805). Go to Step (2) to verify problem is solved. YES - Perform Horn Inoperative electrical circuit troubleshooting (WP 0109). 0141-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00211) TM 9-2320-272-23-1 HORN DOES NOT WORK (GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING) - Continued STEP 2. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0141-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00211) 0141 TM 9-2320-272-23-1 CHAPTER 3 CTIS TROUBLESHOOTING PROCEDURES TM 9-2320-272-23-1 0142 FIELD MAINTENANCE CENTRAL TIRE INFLATION SYSTEM (CTIS) TROUBLESHOOTING INTRODUCTION 1. This chapter provides information needed to diagnose and correct malfunctions of the Central Tire Inflation System (CTIS) at the field level of maintenance. 2. The troubleshooting procedures in this section cannot give all the answers or correct all vehicle malfunctions encountered. However, these procedures are a step-by-step approach to a problem that directs tests and inspections toward the source of a problem and a successful solution. 3. For most system components connected by wiring or pneumatic tubing, intermittent malfunctions are the most difficult to correct. In many instances, erratic operation can be traced to faulty electrical or pneumatic connections. 4. The wiring schematic (Volume 5, WP 0828) and point to point schematics show the interrelationship of these systems. Both should be utilized as references when performing troubleshooting procedures. 5. The compressed air schematic (Volume 5, WP 0828) and point to point schematics show the interrelationship of the compressed air and brake system. Both should be used as a reference when performing troubleshooting procedures. 6. Each malfunction symptom given for an individual component or system is followed by step(s) to determine the cause and corrective action you must take to remedy the problem. 7. Before taking any corrective action for a possible malfunction, the following rules should be followed: a. Question operator to obtain any additional information that might help you to determine the cause of the problem. b. Never overlook the chance the problem could be of a simple origin. The problem could require only a minor adjustment. c. Use all senses to observe and locate troubles. d. Use test instruments and gauges to help you determine and isolate problems. e. Always isolate the system where the malfunction occurs and locate the defective component. f. Use standard automotive theories and principles when troubleshooting the vehicles covered in this manual. g. Operate the vehicle yourself to ensure the operator’s description of the problem is correct. 8. This section cannot list all malfunctions that may occur. If a malfunction occurs that is not listed in the index, notify supervisor. 9. If malfunction corrective action does not correct malfunction, notify supervisor. EXPLANATION OF TROUBLESHOOTING PROCEDURES Troubleshooting procedures are defined as follows: 1. STEP: An action or process taken to isolate cause of fault. 2. CONDITION/INDICATION: States possible fault that may cause the symptom. 3. DECISION: Action required to move forward with next step or correct the fault. END OF WORK PACKAGE 0142-1/2 blank 03/15/2011 Rel(1.8) root(tsintrowp) wpno(T00302) TM 9-2320-272-23-1 0143 FIELD MAINTENANCE CTIS TROUBLESHOOTING INDEX CTIS TROUBLESHOOTING INDEX Malfunction/Symptom Troubleshooting Procedure CENTRAL TIRE INFLATION SYSTEM 1. TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS................................................................................................................................. WP 0144 2. FOUR PRESSURE MODE LIGHTS FLASHING............................................................................... WP 0145 3. FIVE INDICATOR LIGHTS FLASHING............................................................................................. WP 0146 4. SYSTEM REPEATEDLY RESUMES CYCLING 30 SECONDS AFTER MODE LIGHT STOPS FLASHING....................................................................................... WP 0147 5. SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED.......................................................................................... WP 0148 6. CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE.................................................................................................................... WP 0149 7. LOSS OF AMBER WARNING LIGHT AND/OR OVERSPEED LIGHT................................................................................................................................................ WP 0150 8. SOLID OVERSPEED WARNING LIGHT.......................................................................................... WP 0151 9. SYSTEM OVER-INFLATES TIRES.................................................................................................. WP 0152 10. SLOW AIR RECOVERY OR OCCASIONAL LOW AIR WARNING DURING BRAKING......................................................................................................... WP 0153 END OF WORK PACKAGE 0143-1/2 blank 03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00303) TM 9-2320-272-23-1 FIELD MAINTENANCE TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Goggles, Industrial (Volume 5, WP 0826, Table 1, Item 20) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Soap Solution Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics WP 0006 WP 0128 References (cont.) Volume 2, WP 0322 Volume 3, WP 0352 Volume 3, WP 0481 Volume 3, WP 0482 Volume 3, WP 0487 Volume 5, WP 0805 Volume 5, WP 0806 Volume 5, WP 0809 Volume 5, WP 0810 Volume 5, WP 0811 Volume 5, WP 0812 Volume 5, WP 0813 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS NOTE • Conduct these malfunction tests if two pressure modes are indicated with steady mode lights. This procedure will check for a problem with air lines between pneumatic controller and wet tank, between quick release valves and pneumatic controller, and between quick release valves and wheels. It will also check for a faulty filter element, water separator, hub air seal, pneumatic controller, quick release valve, and CTIS wiring harness. • The Electronic Control Unit (ECU) has five pressure mode settings, with each setting having a mode light. If, during programmed operation or after manually selecting a pressure mode setting, two mode lights remain on, the CTIS will discontinue operation. Two steady mode lights indicate that a particular inflate or deflate sequence has taken longer than the programmed limits allow, and has shut the system off with air pressure between the modes, indicated by lights. Use test box and follow the procedures below to diagnose the system. 0144-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) 0144 TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 1. WAS THE SYSTEM INFLATING WHEN IT STOPPED BETWEEN MODES? CONDITION/INDICATION WAS THE SYSTEM INFLATING WHEN IT STOPPED BETWEEN MODES? DECISION YES - Inflating. Go to Step (2). NO - Deflating. Go to Step (15). STEP 2. DO AIR LINES BETWEEN WET TANK AND PNEUMATIC CONTROLLER HAVE CRACKS OR OTHER DAMAGE? a. Refer to point to point schematics. WET TANK PNEUMATIC CONTROLLER (CAB) T0866DAA Figure 1. Air Lines. WARNING Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Failure to comply may result in injury or death to personnel. b. Inspect air lines between wet tank and pneumatic controller for cracks and damage. CONDITION/INDICATION DO AIR LINES BETWEEN WET TANK AND PNEUMATIC CONTROLLER HAVE CRACKS OR OTHER DAMAGE? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (23) to verify problem is solved. NO - Go to Step (3). 0144-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 3. DO AIR LINES BETWEEN WET TANK AND PNEUMATIC CONTROLLER HAVE ANY AIR LEAKS? a. Refer to point to point schematics. WET TANK PNEUMATIC CONTROLLER (CAB) T0866DAA Figure 2. b. Air Lines. Use soapy water at connections to check for air leaks. CONDITION/INDICATION DO AIR LINES BETWEEN WET TANK AND PNEUMATIC CONTROLLER HAVE ANY AIR LEAKS? DECISION YES - Tighten loose tubing connections (Volume 5, WP 0805). Go to Step (23) to verify problem is solved. NO - Go to Step (4). 0144-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 4. ARE AIR LINES BETWEEN WET TANK AND PNEUMATIC CONTROLLER RESTRICTED? a. Refer to point to point schematics. WET TANK PNEUMATIC CONTROLLER (CAB) T0866DAA Figure 3. Air Lines. WARNING • Release all air pressure before loosening or removing air system component(s). Failure to comply may result in injury or death to personnel. • Eyeshields must be worn when releasing compressed air. Failure to comply may result in injury or death to personnel. b. Disconnect air line at both ends. c. Check air line for restrictions. CONDITION/INDICATION ARE AIR LINES BETWEEN WET TANK AND PNEUMATIC CONTROLLER RESTRICTED? DECISION YES - Clear restriction, then reconnect air line (Volume 5, WP 0805). Go to Step (23) to verify problem is solved. NO - Go to Step (5). 0144-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 5. IS THE AIR SUPPLY FROM THE VEHICLE AIR COMPRESSOR NORMAL? a. Start engine. NOTE If steady mode lights extinguish, air supply is normal. b. Repeat inflation sequence with engine running at 1000 rpm for three to five minutes. CONDITION/INDICATION IS THE AIR SUPPLY FROM THE VEHICLE AIR COMPRESSOR NORMAL? DECISION YES - Two steady mode lights are extinguished. Go to Step (6). NO - Two steady mode lights persist. Perform Air Pressure Builds Slowly troubleshooting (WP 0128). STEP 6. ARE THE AIR DRYER OR WATER SEPARATOR CLOGGED OR DAMAGED? Check air dryer and water separator for clogs or damage. AIR DRYER WATER SEPARATOR T0414DAA Figure 4. Air Dryer And Water Seperator. CONDITION/INDICATION ARE THE AIR DRYER OR WATER SEPARATOR CLOGGED OR DAMAGED? DECISION YES - If air dryer is clogged or damaged, go to Air Dryer Kit Replacement (Volume 5, WP 0806). YES - If water separator is clogged or damaged, go to Water Separator Replacement (Volume 5, WP 0811). NO - Go to Step (7). 0144-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 7. DO AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER HAVE CRACKS OR OTHER DAMAGE? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE RELIEF VALVE PNEUMATIC CONTROLLER (CAB) T0978DAA Figure 5. Quick Release Valves And Pneumatic Controller. WARNING Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Failure to comply may result in injury or death to personnel. b. Inspect air lines between quick release valves and pneumatic controller for cracks and damage. CONDITION/INDICATION DO AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER HAVE CRACKS OR OTHER DAMAGE? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (23) to verify problem is solved. NO - Go to Step (8). 0144-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 8. DO AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER HAVE ANY AIR LEAKS? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE RELIEF VALVE PNEUMATIC CONTROLLER (CAB) T0978DAA Figure 6. Quick Release Valves And Pneumatic Controller. b. Use soapy water at connections to check for air leaks. CONDITION/INDICATION DO AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER HAVE ANY AIR LEAKS? DECISION YES - Tighten loose tubing connections (Volume 5, WP 0805). Go to Step (23) to verify problem is solved. NO - Go to Step (9). 0144-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 9. ARE AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER RESTRICTED? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE RELIEF VALVE PNEUMATIC CONTROLLER (CAB) T0978DAA Figure 7. Quick Release Valves And Pneumatic Controller. WARNING • Release all air pressure before loosening or removing air system component(s). Failure to comply may result in injury or death to personnel. • Eyeshields must be worn when releasing compressed air. Failure to comply may result in injury or death to personnel. b. Disconnect air line at both ends. c. Check air line for restrictions. CONDITION/INDICATION ARE AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER RESTRICTED? DECISION YES - Clear restriction, then reconnect air line (Volume 5, WP 0805). Go to Step (23) to verify problem is solved. NO - Go to Step (10). 0144-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 10. DO AIR LINES BETWEEN QUICK RELEASE VALVES AND WHEEL VALVES HAVE CRACKS OR OTHER DAMAGE? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE WHEEL VALVE T0979DAA Figure 8. Quick Release Valves And Wheel Valves. WARNING Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Failure to comply may result in injury or death to personnel. b. Inspect air lines between quick release valves and pneumatic controller for cracks and damage. CONDITION/INDICATION DO AIR LINES BETWEEN QUICK RELEASE VALVES AND WHEEL VALVES HAVE CRACKS OR OTHER DAMAGE? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (23) to verify problem is solved. NO - Go to Step (11). 0144-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 11. DO AIR LINES BETWEEN QUICK RELEASE VALVES AND WHEEL VALVES HAVE ANY AIR LEAKS? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE WHEEL VALVE T0979DAA Figure 9. b. Quick Release Valves And Wheel Valves. Use soapy water at connections to check for air leaks. CONDITION/INDICATION DO AIR LINES BETWEEN QUICK RELEASE VALVES AND WHEEL VALVES HAVE ANY AIR LEAKS? DECISION YES - Tighten loose tubing connections (Volume 5, WP 0805). Go to Step (23) to verify problem is solved. NO - Go to Step (12). 0144-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 12. ARE AIR LINES BETWEEN QUICK RELEASE VALVES AND WHEEL VALVES RESTRICTED? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE WHEEL VALVE T0979DAA Figure 10. Quick Release Valves And Wheel Valves. WARNING • Release all air pressure before loosening or removing air system component(s). Failure to comply may result in injury or death to personnel. • Eyeshields must be worn when releasing compressed air. Failure to comply may result in injury or death to personnel. b. Disconnect air line at both ends. c. Check air line for restrictions. CONDITION/INDICATION ARE AIR LINES BETWEEN QUICK RELEASE VALVES AND WHEEL VALVES RESTRICTED? DECISION YES - Clear restriction, then reconnect air line (Volume 5, WP 0805). Go to Step (23) to verify problem is solved. NO - Go to Step (13). 0144-11 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 13. DO HUB AIR SEALS LEAK? Perform leak test (Volume 3, WP 0487) on hub air seals. AIR SEALS WHEEL VALVE T0980DAA Figure 11. Hub Air Seals. CONDITION/INDICATION DO HUB AIR SEALS LEAK? DECISION YES - Front air seals leak. Replace faulty seals (Volume 3, WP 0481). Go to Step (23) to verify problem is solved. YES - Rear air seals leak. Replace faulty seals (Volume 3, WP 0482). Go to Step (23) to verify problem is solved. NO - Go to Step (14). 0144-12 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 14. IS THE PNEUMATIC CONTROLLER IN GOOD CONDITION? Listen for clicking noise while changing CTIS mode. PNEUMATIC CONTROLLER (CAB) T0981DAA Figure 12. Pneumatic Controller. CONDITION/INDICATION IS THE PNEUMATIC CONTROLLER IN GOOD CONDITION? DECISION YES - Clicking. Notify supervisor. Action may not be possible at this level of maintenance. NO - Not clicking. Replace pneumatic controller (Volume 5, WP 0810). Go to Step (23) to verify problem is solved. 0144-13 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 15. ARE THERE ANY CLOGGED QUICK RELEASE VALVES? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE WHEEL VALVE T0979DAA Figure 13. Quick Release Valves. WARNING • Release all air pressure before loosening or removing air system component(s). Failure to comply may result in injury or death to personnel. • Eyeshields must be worn when releasing compressed air. Failure to comply may result in injury or death to personnel. b. Check quick release valves for obstructions. CONDITION/INDICATION ARE THERE ANY CLOGGED QUICK RELEASE VALVES? DECISION YES - Clear valves (Volume 5, WP 0809). Go to Step (23) to verify problem is solved. NO - Go to Step (16). 0144-14 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 16. IS THERE AUDIBLE AIR FLOW FROM RELIEF VALVE ON PNEUMATIC CONTROLLER DURING DEFLATION? a. Refer to point to point schematics. RELIEF VALVE T1099DAA Figure 14. Relief Valve b. If air pressure is low, run engine at 1000 rpm for three to five minutes to build air supply to normal operating pressure. c. Stop engine. d. Check for continuous and audible air flow from relief valve on pneumatic controller during deflation. CONDITION/INDICATION IS THERE AUDIBLE AIR FLOW FROM RELIEF VALVE ON PNEUMATIC CONTROLLER DURING DEFLATION? DECISION YES - Go to Step (17). NO - Replace faulty relief safety valve (Volume 5, WP 0810). Go to Step (23) to verify problem is solved. 0144-15 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 17. IS THERE BATTERY VOLTAGE BETWEEN PINS X AND V ON CTIS WIRING HARNESS CANNON PLUG AT ECU? a. Turn battery switch to OFF position. T0983DAA Figure 15. CTIS Wiring Harness. CAUTION Turn battery switch to OFF position before disconnecting or connecting ECU wiring harness. Failure to do so may result in damage to ECU. b. Set multimeter to measure VDC. c. Disconnect CTIS wiring harness cannon plug at ECU. d. Turn battery switch to ON position. 0144-16 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued e. Connect multimeter red lead to CTIS wiring harness cannon plug pin X. f. Connect multimeter black lead to CTIS wiring harness cannon plug pin V. g. Meter reading should be between 18 and 26 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE BETWEEN PINS X AND V ON CTIS WIRING HARNESS CANNON PLUG AT ECU? DECISION YES - Go to Step (18). NO - Perform Engine Fails To Crank troubleshooting (WP 0006). STEP 18. DOES CTIS SYSTEM OPERATE CORRECTLY AFTER THE ELECTRICAL LEAD IS PROPERLY CONNECTED TO PRESSURE TRANSDUCER? a. Turn battery switch to OFF position. PRESSURE TRANSDUCER T0982DAA Figure 16. Pressure Transducer. b. Remove electrical lead from pressure transducer at pneumatic controller. c. Clean the connectors, then reconnect the lead. d. Check CTIS operation. CONDITION/INDICATION DOES CTIS SYSTEM OPERATE CORRECTLY AFTER THE ELECTRICAL LEAD IS PROPERLY CONNECTED TO PRESSURE TRANSDUCER? DECISION YES - Go to Step (23) to verify problem is solved. NO - Go to Step (19). 0144-17 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 19. IS THERE CONTINUITY BETWEEN PRESSURE TRANSDUCER AND ECU CANNON PLUG? a. Refer to point to point schematics. T0983DAA Figure 17. CTIS Wiring Harness. b. Connect CTIS wiring harness electrical lead to pressure transducer. c. Check connection of electrical lead at pressure transducer on pneumatic controller. Clean and tighten as needed. CAUTION Turn battery switch to OFF position before disconnecting or connecting ECU wiring harness. Failure to do so may result in damage to ECU. 0144-18 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued d. Turn battery switch to OFF position. e. Disconnect CTIS wiring harness cannon plug at ECU. f. Disconnect electrical lead at pressure transducer. g. Set multimeter to measure resistance. h. Connect multimeter red lead to pressure transducer. i. Connect multimeter black lead to pressure transducer lead at ECU cannon plug. j. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PRESSURE TRANSDUCER AND ECU CANNON PLUG? DECISION YES - Go to Step (20). NO - Replace faulty CTIS wiring harness (Volume 2, WP 0322). Go to Step (23) to verify problem is solved. 0144-19 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 20. IS THERE BATTERY VOLTAGE PRESENT AT PINS X AND V ON CTIS WIRING HARNESS CANNON PLUG AT ECU? a. Refer to point to point schematics. T0983DAA Figure 18. CTIS Wiring Harness. CAUTION Turn battery switch to OFF position before disconnecting or connecting ECU wiring harness. Failure to do so may result in damage to ECU. b. Turn battery switch to OFF position. c. Disconnect CTIS wiring harness cannon plug at ECU. d. Set multimeter to measure VDC. 0144-20 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued e. Turn battery switch to ON position. f. Connect multimeter red lead to CTIS wiring harness cannon plug pin V. g. Connect multimeter black lead to CTIS wiring harness cannon plug pin X. h. Meter reading should be between 18 and 26 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE PRESENT AT PINS X AND V ON CTIS WIRING HARNESS CANNON PLUG AT ECU? DECISION YES - Go to Step (21). NO - Perform Engine Fails To Crank troubleshooting (WP 0006). 0144-21 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 21. IS THERE 4.75 to 5.25 VDC PRESENT AT PRESSURE TRANSDUCER? a. Refer to point to point schematics. CAUTION Turn battery switch to OFF position before disconnecting or connecting ECU wiring harness. Failure to do so may result in damage to ECU. b. Turn battery switch to OFF position. c. Connect CTIS wiring harness cannon plug at ECU. PRESSURE TRANSDUCER T0982DAA Figure 19. Pressure Transducer. d. Disconnect CTIS wiring harness electrical lead from pressure transducer. e. Turn battery switch to ON position. f. Connect multimeter red lead to wire at pressure transducer. g. Connect multimeter black lead to a known good ground. h. Meter reading should be between 4.75 and 5.25 VDC. CONDITION/INDICATION IS THERE 4.75 to 5.25 VDC PRESENT AT PRESSURE TRANSDUCER? DECISION YES - Replace pressure transducer (Volume 5, WP 0812). Go to Step (23) to verify problem is solved. NO - Go to Step (22). 0144-22 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 0144 TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS - Continued STEP 22. IS THE PNEUMATIC CONTROLLER IN GOOD CONDITION? Listen for clicking noise while changing CTIS mode. PNEUMATIC CONTROLLER (CAB) T0981DAA Figure 20. Pneumatic Controller. CONDITION/INDICATION IS THE PNEUMATIC CONTROLLER IN GOOD CONDITION? DECISION YES - Replace electronic control unit (Volume 5, WP 0813). Go to Step (23) to verify problem is solved. NO - Replace or repair pneumatic controller (Volume 5, WP 0810). Go to Step (23) to verify problem is solved. STEP 23. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0144-23/24 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00230) TM 9-2320-272-23-1 FIELD MAINTENANCE FOUR PRESSURE MODE LIGHTS FLASHING INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Goggles, Industrial (Volume 5, WP 0826, Table 1, Item 20) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Soap Solution Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) TM 9-2320-272-10 Volume 3, WP 0481 Volume 3, WP 0482 Volume 3, WP 0487 Volume 3, WP 0490 Volume 3, WP 0491 Volume 5, WP 0805 Volume 5, WP 0810 Volume 5, WP 0813 Personnel Required (2) Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE FOUR PRESSURE MODE LIGHTS FLASHING NOTE Conduct these malfunction tests if four pressure mode lights flash. This procedure will check for a problem with air lines between wheel valves and wheel rims, and between quick release valves and pneumatic controller. It will also check for a faulty wheel valve, hub air seal, and pneumatic controller. 0145-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00231) 0145 TM 9-2320-272-23-1 0145 FOUR PRESSURE MODE LIGHTS FLASHING - Continued STEP 1. DO AIR LINES BETWEEN WHEEL VALVE AND WHEEL RIM HAVE CRACKS OR OTHER DAMAGE? a. Measure and record pressure of each tire (TM 9-2320-272-10). AIR SEALS WHEEL VALVE T0419DAA Figure 1. b. Wheel Valve. Refer to point to point schematics. WARNING Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Failure to comply may result in injury or death to personnel. c. For all tires significantly outside pressure limits, inspect air lines between wheel valve and wheel rim for cracks and damage. CONDITION/INDICATION DO AIR LINES BETWEEN WHEEL VALVE AND WHEEL RIM HAVE CRACKS OR OTHER DAMAGE? DECISION YES - Front air lines damaged. Replace damaged air line (Volume 3, WP 0490). Go to Step (10) to verify problem is solved. YES - Rear air lines are damaged. Replace damaged air line (Volume 3, WP 0491). Go to Step (10) to verify problem is solved. NO - Go to Step (2). 0145-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00231) TM 9-2320-272-23-1 0145 FOUR PRESSURE MODE LIGHTS FLASHING - Continued STEP 2. DO AIR LINES BETWEEN WHEEL VALVE AND WHEEL RIM HAVE ANY AIR LEAKS? a. Refer to point to point schematics. AIR SEALS WHEEL VALVE T0419DAA Figure 2. b. Wheel Valve. For all tires previously found to be significantly outside pressure limits, use soapy water at air line wheel valve and wheel rim connections to check for leaks. CONDITION/INDICATION DO AIR LINES BETWEEN WHEEL VALVE AND WHEEL RIM HAVE ANY AIR LEAKS? DECISION YES - Front air lines leak. Replace damaged air line (Volume 3, WP 0490). Go to Step (10) to verify problem is solved. YES - Rear air lines leak. Replace damaged air line (Volume 3, WP 0491). Go to Step (10) to verify problem is solved. NO - Go to Step (3). 0145-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00231) TM 9-2320-272-23-1 0145 FOUR PRESSURE MODE LIGHTS FLASHING - Continued STEP 3. ARE AIR LINES BETWEEN WHEEL VALVE AND WHEEL RIM RESTRICTED? a. Refer to point to point schematics. AIR SEALS WHEEL VALVE T0419DAA Figure 3. Wheel Valve. WARNING • Release all air pressure before loosening or removing air system component(s). Failure to comply may result in injury or death to personnel. • Eyeshields must be worn when releasing compressed air. Failure to comply may result in injury or death to personnel. b. For all tires significantly outside pressure limits, inspect front wheel air lines and rear wheel air lines between wheel valve and wheel rim for restrictions. 0145-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00231) TM 9-2320-272-23-1 0145 FOUR PRESSURE MODE LIGHTS FLASHING - Continued CONDITION/INDICATION ARE AIR LINES BETWEEN WHEEL VALVE AND WHEEL RIM RESTRICTED? DECISION YES - Front air lines restricted. Clear restrictions or replace damaged air line (Volume 3, WP 0490). Go to Step (10) to verify problem is solved. YES - Rear air lines restricted. Clear restrictions or replace damaged air line (Volume 3, WP 0491). Go to Step (10) to verify problem is solved. NO - Go to Step (4). 0145-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00231) TM 9-2320-272-23-1 0145 FOUR PRESSURE MODE LIGHTS FLASHING - Continued STEP 4. DOES WHEEL VALVE LEAK AIR? a. Refer to point to point schematics. AIR SEALS WHEEL VALVE T0419DAA Figure 4. Wheel Valve. WARNING Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Failure to comply may result in injury or death to personnel. NOTE To determine a wheel valve air leak, with wheel valve still connected to tire, check for air leak at quick release valves. Determine which valve is leaking, by disconnecting air line at quick release valve to either feel or listen for air escaping. b. Check for air leak at the quick release valves. CONDITION/INDICATION DOES WHEEL VALVE LEAK AIR? DECISION YES - Front wheel valve leaks. Replace wheel valve (Volume 3, WP 0490). Go to Step (10) to verify problem is solved. YES - Rear wheel valve leaks. Replace wheel valve (Volume 3, WP 0491). Go to Step (10) to verify problem is solved. NO - Go to Step (5). 0145-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00231) TM 9-2320-272-23-1 0145 FOUR PRESSURE MODE LIGHTS FLASHING - Continued STEP 5. DO AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER HAVE CRACKS OR OTHER DAMAGE? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE RELIEF VALVE PNEUMATIC CONTROLLER (CAB) T0416DAA Figure 5. Quick Release Valves And Pneumatic Controller. WARNING Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Failure to comply may result in injury or death to personnel. b. Inspect air lines between quick release valves and pneumatic controller for cracks and damage. CONDITION/INDICATION DO AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER HAVE CRACKS OR OTHER DAMAGE? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (10) to verify problem is solved. NO - Go to Step (6). 0145-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00231) TM 9-2320-272-23-1 0145 FOUR PRESSURE MODE LIGHTS FLASHING - Continued STEP 6. DO AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER HAVE ANY AIR LEAKS? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE RELIEF VALVE PNEUMATIC CONTROLLER (CAB) T0416DAA Figure 6. Quick Release Valves And Pneumatic Controller. b. Use soapy water at connections to check for air leaks. CONDITION/INDICATION DO AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER HAVE ANY AIR LEAKS? DECISION YES - Tighten loose tubing connections (Volume 5, WP 0805). Go to Step (10) to verify problem is solved. NO - Go to Step (7). 0145-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00231) TM 9-2320-272-23-1 0145 FOUR PRESSURE MODE LIGHTS FLASHING - Continued STEP 7. ARE AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER RESTRICTED? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE RELIEF VALVE PNEUMATIC CONTROLLER (CAB) T0416DAA Figure 7. Quick Release Valves And Pneumatic Controller. WARNING • Release all air pressure before loosening or removing air system component(s). Failure to comply may result in injury or death to personnel. • Eyeshields must be worn when releasing compressed air. Failure to comply may result in injury or death to personnel. b. Disconnect air line at both ends. c. Check air line for restrictions. CONDITION/INDICATION ARE AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER RESTRICTED? DECISION YES - Clear restriction, then reconnect air line (Volume 5, WP 0805). Go to Step (10) to verify problem is solved. NO - Go to Step (8). 0145-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00231) TM 9-2320-272-23-1 0145 FOUR PRESSURE MODE LIGHTS FLASHING - Continued STEP 8. DO HUB AIR SEALS LEAK? NOTE In extreme cold temperature hub seals may leak. Drive vehicle to ensure hub seals are at operating temperature. Perform leak test (Volume 3, WP 0487) on hub air seals. AIR SEALS WHEEL VALVE T0419DAA Figure 8. Hub Air Seals. CONDITION/INDICATION DO HUB AIR SEALS LEAK? DECISION YES - Front air seals leak. Replace faulty air seals (Volume 3, WP 0481). Go to Step (10) to verify problem is solved. YES - Rear air seals leak. Replace faulty air seals (Volume 3, WP 0482). Go to Step (10) to verify problem is solved. NO - Go to Step (9). 0145-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00231) TM 9-2320-272-23-1 0145 FOUR PRESSURE MODE LIGHTS FLASHING - Continued STEP 9. IS THE PNEUMATIC CONTROLLER IN GOOD CONDITION? Listen for clicking noise while changing CTIS mode. PNEUMATIC CONTROLLER (CAB) T0420DAA Figure 9. Pneumatic Controller. CONDITION/INDICATION IS THE PNEUMATIC CONTROLLER IN GOOD CONDITION? DECISION YES - Replace electronic control unit (Volume 5, WP 0813). Go to Step (10) to verify problem is solved. NO - Replace pneumatic controller (Volume 5, WP 0810). Go to Step (10) to verify problem is solved. STEP 10. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0145-11/12 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00231) TM 9-2320-272-23-1 FIELD MAINTENANCE FIVE INDICATOR LIGHTS FLASHING INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Goggles, Industrial (Volume 5, WP 0826, Table 1, Item 20) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Soap Solution Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) WP 0006 Volume 2, WP 0322 Volume 2, WP 0324 Volume 5, WP 0813 Volume 5, WP 0810 Volume 5, WP 0812 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE FIVE INDICATOR LIGHTS FLASHING NOTE • Conduct these malfunction tests if five indicator lights flash. This procedure will check for a problem with air lines between quick release valves and pneumatic controller, and between wheel and quick release valves. It will also check for a faulty hub air seal, pneumatic controller, electrical lead on pressure switch at wet tank, CTIS wiring harness, pressure switch, ECU and pressure transducer. • The ECU has a self-diagnostic capability which prevents operation of the CTIS when key elements or components of the system malfunction. When the ECU shuts down due to such system malfunction, the condition will be indicated by the flashing of all five mode lights on ECU selector panel. Since it is unlikely that the CTIS would operate properly, there is no option to override the ECU until the problem is corrected. An indication of five flashing lights can be caused by any of four conditions: 1) Faulty air line to tires; 2) Faulty pneumatic controller; 3) Faulty pressure switch circuit; 4) Faulty pressure transducer circuit. 0146-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) 0146 TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 1. DO AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER HAVE CRACKS OR OTHER DAMAGE? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE RELIEF VALVE PNEUMATIC CONTROLLER (CAB) T0894DAA Figure 1. Quick Release Valves And Pneumatic Controller. WARNING Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Failure to comply may result in injury or death to personnel. b. Inspect air lines between quick release valves and pneumatic controller for cracks and damage. CONDITION/INDICATION DO AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER HAVE CRACKS OR OTHER DAMAGE? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (17) to verify problem is solved. NO - Go to Step (2). 0146-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 2. DO AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER HAVE ANY AIR LEAKS? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE RELIEF VALVE PNEUMATIC CONTROLLER (CAB) T0894DAA Figure 2. Quick Release Valves And Pneumatic Controller. b. Use soapy water at connections to check for air leaks. CONDITION/INDICATION DO AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER HAVE ANY AIR LEAKS? DECISION YES - Tighten loose tubing connections (Volume 5, WP 0805). Go to Step (17) to verify problem is solved. NO - Go to Step (3). 0146-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 3. ARE AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER RESTRICTED? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE RELIEF VALVE PNEUMATIC CONTROLLER (CAB) T0894DAA Figure 3. Quick Release Valves and Pneumatic Controller. WARNING • Release all air pressure before loosening or removing air system component(s). Failure to comply may result in injury or death to personnel. • Eyeshields must be worn when releasing compressed air. Failure to comply may result in injury or death to personnel. b. Disconnect air line at both ends. c. Check air line for restrictions. CONDITION/INDICATION ARE AIR LINES BETWEEN QUICK RELEASE VALVES AND PNEUMATIC CONTROLLER RESTRICTED? DECISION YES - Clear restriction, then reconnect air line (Volume 5, WP 0805). Go to Step (17) to verify problem is solved. NO - Go to Step (4). 0146-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 4. DO AIR LINES BETWEEN QUICK RELEASE VALVES AND WHEEL VALVES HAVE CRACKS OR OTHER DAMAGE? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE T0895DAA Figure 4. Quick Release Valves And Wheel Valves. WARNING Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Failure to comply may result in injury or death to personnel. b. Inspect air lines between quick release valves and pneumatic controller for cracks and damage. CONDITION/INDICATION DO AIR LINES BETWEEN QUICK RELEASE VALVES AND WHEEL VALVES HAVE CRACKS OR OTHER DAMAGE? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (17) to verify problem is solved. NO - Go to Step (5). 0146-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 5. DO AIR LINES BETWEEN QUICK RELEASE VALVES AND WHEEL VALVES HAVE ANY AIR LEAKS? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE T0895DAA Figure 5. b. Quick Release Valves and Wheel Valves. Use soapy water at connections to check for air leaks. CONDITION/INDICATION DO AIR LINES BETWEEN QUICK RELEASE VALVES AND WHEEL VALVES HAVE ANY AIR LEAKS? DECISION YES - Tighten loose tubing connections (Volume 5, WP 0805). Go to Step (17) to verify problem is solved. NO - Go to Step (6). 0146-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 6. ARE AIR LINES BETWEEN QUICK RELEASE VALVES AND WHEEL VALVES RESTRICTED? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE T0895DAA Figure 6. Quick Release Valves and Wheel Valves. WARNING • Release all air pressure before loosening or removing air system component(s). Failure to comply may result in injury or death to personnel. • Eyeshields must be worn when releasing compressed air. Failure to comply may result in injury or death to personnel. b. Disconnect air line at both ends. c. Check air line for restrictions. CONDITION/INDICATION ARE AIR LINES BETWEEN QUICK RELEASE VALVES AND WHEEL VALVES RESTRICTED? DECISION YES - Clear restriction, then reconnect air line (Volume 5, WP 0805). Go to Step (17) to verify problem is solved. NO - Go to Step (7). 0146-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 7. IS THE PNEUMATIC CONTROLLER IN GOOD CONDITION? Listen for clicking noise while changing CTIS mode. PNEUMATIC CONTROLLER (CAB) T0899DAA Figure 7. Pneumatic Controller. CONDITION/INDICATION IS THE PNEUMATIC CONTROLLER IN GOOD CONDITION? DECISION YES - Go to Step (8). NO - Replace pneumatic controller (Volume 5, WP 0810). Go to Step (17) to verify problem is solved. 0146-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 8. DOES CTIS SYSTEM OPERATE CORRECTLY AFTER THE ELECTRICAL LEAD IS PROPERLY CONNECTED TO PRESSURE TRANSDUCER ON WET TANK? a. Turn battery switch to OFF position. b. Refer to point to point schematics. WET TANK T0423DAA Figure 8. Wet Tank. c. Remove electrical lead from pressure switch at wet tank. d. Clean the connectors, then reconnect electrical lead to pressure switch. e. Check CTIS operation. CONDITION/INDICATION DOES CTIS SYSTEM OPERATE CORRECTLY AFTER THE ELECTRICAL LEAD IS PROPERLY CONNECTED TO PRESSURE TRANSDUCER ON WET TANK? DECISION YES - Go to Step (17) to verify problem is solved. NO - Go to Step (9). 0146-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 9. IS THERE CONTINUITY BETWEEN PRESSURE SWITCH AND CTIS WIRING HARNESS CANNON PLUG AT ECU? a. Refer to point to point schematics. T0432DAA Figure 9. CTIS Wiring Harness. b. Set multimeter to measure resistance. c. Connect multimeter red lead to CTIS wiring harness cannon plug. d. Connect multimeter black lead to electrical lead at pressure switch. e. Meter reading should be less than 200 ohms. 0146-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PRESSURE SWITCH AND CTIS WIRING HARNESS CANNON PLUG AT ECU? DECISION YES - Go to Step (10). NO - Replace CTIS wiring harness (Volume 2, WP 0322). Go to Step (17) to verify problem is solved. STEP 10. IS THERE CONTINUITY BETWEEN PRESSURE SWITCH PINS A AND B WHEN AIR SYSTEM IS AT NORMAL OPERATING PRESSURE? a. Refer to point to point schematics. PRESSURE TRANSDUCER T0422DAA Figure 10. Pressure Transducer. b. Connect multimeter red lead to to pressure switch at pin A. c. Connect multimeter black lead to pressure switch at pin B. d. Use shop air pressure or start and run engine until air pressure reaches 112-120 psi while monitoring the instrument cluster air pressure gauge. e. Pressure switch should be closed. f. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PRESSURE SWITCH PINS A AND B WHEN AIR SYSTEM IS AT NORMAL OPERATING PRESSURE? DECISION YES - Go to Step (11). NO - Replace pressure switch (Volume 2, WP 0324). Go to Step (17) to verify problem is solved. 0146-11 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 11. IS THERE NO CONTINUITY BETWEEN PRESSURE SWITCH PINS A AND B WHEN AIR SYSTEM IS BELOW OPERATING PRESSURE? a. Refer to point to point schematics. PRESSURE TRANSDUCER T0422DAA Figure 11. Pressure Transducer. b. Connect multimeter red lead to to pressure switch at pin A. c. Connect multimeter black lead to pressure switch at pin B. d. Shut off air supply or engine. e. Drain secondary tank until air pressure gauge indicates less than 80 psi.. f. Pressure switch should open. g. Meter reading should be greater than 90 ohms. CONDITION/INDICATION IS THERE NO CONTINUITY BETWEEN PRESSURE SWITCH PINS A AND B WHEN AIR SYSTEM IS BELOW OPERATING PRESSURE? DECISION YES - Go to Step (12). NO - Replace pressure switch (Volume 2, WP 0324). Go to Step (17) to verify problem is solved. 0146-12 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 12. IS THE VOLTAGE FROM THE ECU TO THE PRESSURE SWITCH NORMAL? a. Start engine and run while monitoring the instrument cluster air pressure gauge. ELECTRONIC CONTROL UNIT (ECU) (INSIDE CAB) PRESSURE TRANSDUCER T0424DAA Figure 12. Electronic Control Unit . b. Operate until air pressure gauge indicates 112-120 psi. If gauge does not reach 112-120 psi or greater, adjust air governor. c. With engine running, drain secondary air tank until air pressure gauge indicates less than 80 psi. d. Set multimeter to measure VDC. e. Connect CTIS wiring harness cannon plug to ECU. f. Place battery switch to ON position. g. Connect multimeter red lead to pressure switch connector. h. Connect multimeter black lead to a known good ground. i. Meter reading should be greater than 18 VDC. CONDITION/INDICATION IS THE VOLTAGE FROM THE ECU TO THE PRESSURE SWITCH NORMAL? DECISION YES - Go to Step (13). NO - Replace ECU (Volume 5, WP 0813). Go to Step (17) to verify problem is solved. 0146-13 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 13. IS THERE CONTINUITY BETWEEN PRESSURE TRANSDUCER AND ECU CANNON PLUG? a. Refer to point to point schematics. b. Connect CTIS wiring harness electrical lead to pressure switch. c. Check connection of electrical lead at pressure transducer on pneumatic controller. Clean and tighten as needed. T0432DAA Figure 13. CTIS Wiring Harness. CAUTION Turn battery switch to OFF position before disconnecting or connecting ECU wiring harness. Failure to do so may result in damage to ECU. d. Turn battery switch to OFF position. 0146-14 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 FIVE INDICATOR LIGHTS FLASHING - Continued e. Disconnect CTIS wiring harness cannon plug at ECU. f. Disconnect electrical lead at pressure transducer. g. Set multimeter to measure resistance. h. Connect multimeter red lead to pressure transducer. i. Connect multimeter black lead to pressure transducer lead at ECU cannon plug. j. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PRESSURE TRANSDUCER AND ECU CANNON PLUG? DECISION YES - Go to Step (14). NO - Replace CTIS Wiring Harness (Volume 2, WP 0322). Go to Step (17) to verify problem is solved. 0146-15 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) 0146 TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 14. IS THERE BATTERY VOLTAGE PRESENT AT PINS X AND V ON CTIS WIRING HARNESS CANNON PLUG AT ECU? a. Refer to point to point schematics. T0432DAA Figure 14. CTIS Wiring Harness. CAUTION Turn battery switch to OFF position before disconnecting or connecting ECU wiring harness. Failure to do so may result in damage to ECU. b. Turn battery switch to OFF position. c. Disconnect CTIS wiring harness cannon plug at ECU. d. Set multimeter to measure VDC. 0146-16 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued e. Turn battery switch to ON position. f. Connect multimeter red lead to CTIS wiring harness cannon plug pin V. g. Connect multimeter black lead to CTIS wiring harness cannon plug pin X. h. Meter reading should be between 18 and 26 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE PRESENT AT PINS X AND V ON CTIS WIRING HARNESS CANNON PLUG AT ECU? DECISION YES - Go to Step (15). NO - Perform Engine Fails To Crank troubleshooting (WP 0006). 0146-17 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 15. IS THERE 4.75 to 5.25 VDC PRESENT AT PRESSURE TRANSDUCER? a. Refer to point to point schematics. CAUTION Turn battery switch to OFF position before disconnecting or connecting ECU wiring harness. Failure to do so may result in damage to ECU. b. Turn battery switch to OFF position. c. Connect CTIS wiring harness cannon plug at ECU. PRESSURE TRANSDUCER T0422DAA Figure 15. Pressure Transducer. d. Disconnect CTIS wiring harness electrical lead from pressure transducer. e. Turn battery switch to ON position. f. Connect multimeter red lead to wire at pressure transducer. g. Connect multimeter black lead to a known good ground. h. Meter reading should be between 4.75 and 5.25 VDC. CONDITION/INDICATION IS THERE 4.75-5.25 VDC PRESENT AT PRESSURE TRANSDUCER? DECISION YES - Replace pressure transducer (Volume 5, WP 0812). Go to Step (17) to verify problem is solved. NO - Go to Step (16). 0146-18 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0146 FIVE INDICATOR LIGHTS FLASHING - Continued STEP 16. IS THE PNEUMATIC CONTROLLER IN GOOD CONDITION? Listen for clicking noise while changing CTIS mode. PNEUMATIC CONTROLLER (CAB) T0899DAA Figure 16. Pneumatic Controller. CONDITION/INDICATION IS THE PNEUMATIC CONTROLLER IN GOOD CONDITION? DECISION YES - Replace electronic control unit (Volume 5, WP 0813) . Go to Step (17) to verify problem is solved. NO - Replace pneumatic controller (Volume 5, WP 0810). Go to Step (17) to verify problem is solved. STEP 17. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0146-19/20 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00232) TM 9-2320-272-23-1 0147 FIELD MAINTENANCE SYSTEM REPEATEDLY RESUMES CYCLING 30 SECONDS AFTER MODE LIGHT STOPS FLASHING INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Soap Solution Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) TM 9-2320-272-10 Volume 3, WP 0490 Volume 3, WP 0491 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE SYSTEM REPEATEDLY RESUMES CYCLING 30 SECONDS AFTER MODE LIGHT STOPS FLASHING NOTE • Conduct these malfunction tests if the system repeatedly resumes cycling 30 seconds after mode light stops flashing. This procedure will check for leaking air lines between wheel valves and wheels. It will also check for a faulty wheel valve. • The ECU is programmed to check tire pressures 30 seconds after completing a pressure changing sequence. The ECU does this to verify that all wheel valves are properly closed before making pressure checks at fifteen minute intervals. If the ECU repeatedly checks pressure 30 seconds after a mode light stops flashing, it is indicative of one or more tires losing air. 0147-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00233) TM 9-2320-272-23-1 0147 SYSTEM REPEATEDLY RESUMES CYCLING 30 SECONDS AFTER MODE LIGHT STOPS FLASHING Continued STEP 1. DO AIR LINES BETWEEN WHEEL VALVE AND WHEEL RIM HAVE CRACKS OR OTHER DAMAGE? a. Measure and record pressure of each tire (TM 9-2320-272-10). AIR SEALS WHEEL VALVE T0897DAA Figure 1. b. Wheel Valve. Refer to point to point schematics. WARNING Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Failure to comply may result in injury or death to personnel. c. For all tires significantly outside pressure limits, inspect front wheel air lines and inspect rear wheel air lines between wheel valve and wheel rim for cracks and damage. CONDITION/INDICATION DO AIR LINES BETWEEN WHEEL VALVE AND WHEEL RIM HAVE CRACKS OR OTHER DAMAGE? DECISION YES - Front air lines damaged M939A2. Replace damaged air line (Volume 3, WP 0490). Go to Step (4) to verify problem is solved. YES - Rear air lines are damaged M939A2. Replace damaged air line (Volume 3, WP 0491). Go to Step (4) to verify problem is solved. NO - Go to Step (2). 0147-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00233) TM 9-2320-272-23-1 0147 SYSTEM REPEATEDLY RESUMES CYCLING 30 SECONDS AFTER MODE LIGHT STOPS FLASHING Continued STEP 2. DO AIR LINES BETWEEN WHEEL VALVE AND WHEEL RIM HAVE ANY AIR LEAKS? a. Refer to point to point schematics. AIR SEALS WHEEL VALVE T0897DAA Figure 2. b. Wheel Valve. For all tires previously found to be significantly outside pressure limits, use soapy water at air line wheel valve and wheel rim connections to check for leaks. CONDITION/INDICATION DO AIR LINES BETWEEN WHEEL VALVE AND WHEEL RIM HAVE ANY AIR LEAKS? DECISION YES - Front air lines leak M939A2. Replace damaged air line (Volume 3, WP 0490). Go to Step (4) to verify problem is solved. YES - Rear air lines leak M939A2. Replace damaged air line (Volume 3, WP 0491). Go to Step (4) to verify problem is solved. NO - Go to Step (3). 0147-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00233) TM 9-2320-272-23-1 0147 SYSTEM REPEATEDLY RESUMES CYCLING 30 SECONDS AFTER MODE LIGHT STOPS FLASHING Continued STEP 3. DOES WHEEL VALVE LEAK AIR? a. Refer to point to point schematics. AIR SEALS WHEEL VALVE T0897DAA Figure 3. Wheel Valve. WARNING Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Failure to comply may result in injury or death to personnel. NOTE To determine a wheel valve air leak, with wheel valve still connected to tire, check for air leak at quick release valves. Determine which valve is leaking, by disconnecting air line at quick release valve to either feel or listen for air escaping. b. Check for air leak at the quick release valves. 0147-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00233) TM 9-2320-272-23-1 0147 SYSTEM REPEATEDLY RESUMES CYCLING 30 SECONDS AFTER MODE LIGHT STOPS FLASHING Continued CONDITION/INDICATION DOES WHEEL VALVE LEAK AIR? DECISION YES - Front wheel valve leaks M939A2. Replace wheel valve (Volume 3, WP 0490). Go to Step (4) to verify problem is solved. YES - Rear wheel valve leaks M939A2. Replace wheel valve (Volume 3, WP 0491). Go to Step (4) to verify problem is solved. NO - Go to Step (4) to verify problem is solved. STEP 4. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0147-5/6 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00233) TM 9-2320-272-23-1 0148 FIELD MAINTENANCE SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Goggles, Industrial (Volume 5, WP 0826, Table 1, Item 20) Soap Solution Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References Point to Point Schematics References (cont.) Volume 3, WP 0481 Volume 3, WP 0482 Volume 3, WP 0487 Volume 3, WP 0490 Volume 3, WP 0491 Volume 5, WP 0805 Volume 5, WP 0806 Volume 5, WP 0809 Volume 5, WP 0810 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) TROUBLESHOOTING PROCEDURE SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED NOTE • Conduct these malfunction tests if the system fails to deflate, partially deflates, or tire pressures are imbalanced. This procedure will check for excessive water in tire and faulty relief valve on pneumatic controller, quick release valves, pneumatic controller, air lines, hub air seals, wheel valve, and wheel valve filter. • During deflation, all tires respond independently. Generally, failure of the entire system to deflate indicates a control problem. Failure of an individual tire to deflate indicates a problem at the wheel. 0148-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00235) TM 9-2320-272-23-1 0148 SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED Continued STEP 1. WHAT IS THE CONDITION OF THE PNEUMATIC CONTROLLER RELIEF VALVE POPPET? a. Refer to point to point schematics. RELIEF VALVE T1068DAA Figure 1. b. Relief Valve. Inspect relief valve poppet on pneumatic controller. CONDITION/INDICATION WHAT IS THE CONDITION OF THE PNEUMATIC CONTROLLER RELIEF VALVE POPPET? DECISION YES - Poppet in. Go to Step (2). NO - Poppet out. Replace relief valve (Volume 5, WP 0810). Go to Step (11) to verify problem is solved. 0148-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00235) TM 9-2320-272-23-1 0148 SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED Continued STEP 2. ARE THERE ANY CLOGGED QUICK RELEASE VALVES? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE T0417DAA Figure 2. Quick Release Valves. WARNING • Release all air pressure before loosening or removing air system component(s). Failure to comply may result in injury or death to personnel. • Eyeshields must be worn when releasing compressed air. Failure to comply may result in injury or death to personnel. b. Check quick release valves for obstructions. CONDITION/INDICATION ARE THERE ANY CLOGGED QUICK RELEASE VALVES? DECISION YES - Clear valves (Volume 5, WP 0809). Go to Step (11) to verify problem is solved. NO - Go to Step (3). 0148-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00235) TM 9-2320-272-23-1 0148 SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED Continued STEP 3. ARE THERE AIR LEAKS FROM PNEUMATIC CONTROLLER? a. Set CTIS switch to HWY and run engine at 1000 rpm for three to five minutes to build air supply to normal operating pressure. b. Stop engine. c. Turn battery switch to OFF position. d. Refer to point to point schematics. PNEUMATIC CONTROLLER (CAB) T0900DAA Figure 3. Pneumatic Controller. e. Check for air leaks from pneumatic controller. f. Use soapy water at connectors to check for leaks. CONDITION/INDICATION ARE THERE AIR LEAKS FROM PNEUMATIC CONTROLLER? DECISION YES - Repair or replace pneumatic controller (Volume 5, WP 0810). Go to Step (11) to verify problem is solved. NO - Go to Step (4). 0148-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00235) TM 9-2320-272-23-1 0148 SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED Continued STEP 4. DO AIR LINES BETWEEN PNEUMATIC CONTROLLER, QUICK RELEASE VALVES, AND WHEELS HAVE CRACKS OR OTHER DAMAGE? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE PNEUMATIC CONTROLLER (CAB) RELIEF VALVE Figure 4. T0429DAA Air Lines. WARNING Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Failure to comply may result in injury or death to personnel. b. Inspect air lines between quick release valves and pneumatic controller for cracks and damage. CONDITION/INDICATION DO AIR LINES BETWEEN PNEUMATIC CONTROLLER, QUICK RELEASE VALVES, AND WHEELS HAVE CRACKS OR OTHER DAMAGE? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (11) to verify problem is solved. NO - Go to Step (5). 0148-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00235) TM 9-2320-272-23-1 0148 SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED Continued STEP 5. DO AIR LINES BETWEEN PNEUMATIC CONTROLLER, QUICK RELEASE VALVES, AND WHEELS HAVE ANY AIR LEAKS? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE PNEUMATIC CONTROLLER (CAB) RELIEF VALVE Figure 5. b. T0429DAA Air Lines. Use soapy water at connections to check for air leaks. CONDITION/INDICATION DO AIR LINES BETWEEN PNEUMATIC CONTROLLER, QUICK RELEASE VALVES, AND WHEELS HAVE ANY AIR LEAKS? DECISION YES - Tighten loose tubing connections (Volume 5, WP 0805). Go to Step (11) to verify problem is solved. NO - Go to Step (6). 0148-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00235) TM 9-2320-272-23-1 0148 SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED Continued STEP 6. ARE AIR LINES BETWEEN PNEUMATIC CONTROLLER, QUICK RELEASE VALVES, AND WHEELS RESTRICTED? a. Refer to point to point schematics. QUICK RELEASE VALVES QUICK RELEASE VALVE PNEUMATIC CONTROLLER (CAB) RELIEF VALVE Figure 6. T0429DAA Air Lines. WARNING • Release all air pressure before loosening or removing air system component(s). Failure to comply may result in injury or death to personnel. • Eyeshields must be worn when releasing compressed air. Failure to comply may result in injury or death to personnel. b. Disconnect air line at both ends. c. Check air line for restrictions. CONDITION/INDICATION ARE AIR LINES BETWEEN PNEUMATIC CONTROLLER, QUICK RELEASE VALVES, AND WHEELS RESTRICTED? DECISION YES - Clear restriction, then reconnect air line (Volume 5, WP 0805). Go to Step (11) to verify problem is solved. NO - Go to Step (7). 0148-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00235) TM 9-2320-272-23-1 0148 SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED Continued STEP 7. DO HUB AIR SEALS LEAK? a. Refer to point to point schematics. AIR SEALS WHEEL VALVE T0898DAA Figure 7. b. Hub Air Seals. Perform leak test (Volume 3, WP 0487) on hub air seals. CONDITION/INDICATION DO HUB AIR SEALS LEAK? DECISION YES - Front air seals leak. Replace faulty seals (Volume 3, WP 0481). Go to Step (11) to verify problem is solved. YES - Rear air seals leak. Replace faulty seals (Volume 3, WP 0482). Go to Step (11) to verify problem is solved. NO - Go to Step (8). 0148-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00235) TM 9-2320-272-23-1 0148 SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED Continued STEP 8. IS THERE AUDIBLE AIR FLOW FROM RELIEF VALVE ON PNEUMATIC CONTROLLER DURING DEFLATION? a. Refer to point to point schematics. RELIEF VALVE T1068DAA Figure 8. Relief Valve b. If air pressure is low, run engine at 1000 rpm for three to five minutes to build air supply to normal operating pressure. c. Stop engine. d. With the battery switch in the ON position, select a mode that will cause deflation. e. Check for continuous and audible air flow from relief valve on pneumatic controller during deflation. CONDITION/INDICATION IS THERE AUDIBLE AIR FLOW FROM RELIEF VALVE ON PNEUMATIC CONTROLLER DURING DEFLATION? DECISION YES - Go to Step (9). NO - Replace faulty relief safety valve (Volume 5, WP 0810). Go to Step (11) to verify problem is solved. 0148-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00235) TM 9-2320-272-23-1 0148 SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED Continued STEP 9. DOES AIR FLOW STEADILY FROM TIRE DURING DEFLATION? a. Refer to point to point schematics. TIRE T0430DAA Figure 9. Tire WARNING Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Failure to comply may result in injury or death to personnel. CAUTION Ensure that external air source is as clean and dry as air supplied by vehicle. If in doubt, use the vehicle's air supply. Contamination may cause damage to CTIS. NOTE Varying or intermittent air flow identifies a tire as having collected sufficient water to cause icing of the air passage, even at temperatures above freezing. 0148-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00235) TM 9-2320-272-23-1 SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED Continued b. Identify any tire that does not deflate properly. c. Manually inflate tires identified in the previous step to 80 psi (552 kPa). d. For each tire inflated in the previous step, disconnect hose assembly from wheel valve and note consistency of air escaping from wheel. e. Repeatedly fill tire with dry air and deflate until air flow from hose connected to wheel is steady. CONDITION/INDICATION DOES AIR FLOW STEADILY FROM TIRE DURING DEFLATION? DECISION YES - Go to Step (11) to verify problem is solved. NO - Go to Step (10). 0148-11 03/15/2011 Rel(1.8) root(tswp) wpno(T00235) 0148 TM 9-2320-272-23-1 0148 SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED Continued STEP 10. IS WHEEL VALVE FILTER OBSTRUCTED? a. Remove filter from wheel valve and inspect. WHEEL VALVE FILTER T1110DAA Figure 10. b. Wheel Valve Filter. Connect hose assembly to wheel valve. 0148-12 03/15/2011 Rel(1.8) root(tswp) wpno(T00235) TM 9-2320-272-23-1 0148 SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED Continued CONDITION/INDICATION IS WHEEL VALVE FILTER OBSTRUCTED? DECISION YES - Replace wheel valve filter (Volume 3, WP 0486). Go to Step (11) to verify problem is solved. NO - Perform wheel valve maintenance front (Volume 3, WP 0490), rear (Volume 3, WP 0491). Go to Step (11) to verify problem is solved. STEP 11. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0148-13/14 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00235) TM 9-2320-272-23-1 FIELD MAINTENANCE CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Goggles, Industrial (Volume 5, WP 0826, Table 1, Item 20) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Soap Solution Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) WP 0128 Volume 2, WP 0322 Volume 2, WP 0324 Volume 5, WP 0805 Volume 5, WP 0810 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE NOTE Conduct these malfunction tests if control panel lights work, but the system fails to inflate or deflate. This procedure will check for a problem with air lines between pneumatic controller and wet tank. It will also check for a faulty air supply from the vehicle air compressor, CTIS wiring harness, pneumatic controller, electrical lead at wet tank pressure switch, and pressure switch. 0149-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00236) 0149 TM 9-2320-272-23-1 0149 CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE - Continued STEP 1. DO AIR LINES BETWEEN WET TANK AND PNEUMATIC CONTROLLER HAVE CRACKS OR OTHER DAMAGE? a. Refer to point to point schematics. Wet Tank Pneumatic Controller (Cali) Figure 1. T1069DAA Air Lines. WARNING Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Failure to comply may result in injury or death to personnel. b. Inspect air lines between wet tank and pneumatic controller for cracks and damage. CONDITION/INDICATION DO AIR LINES BETWEEN WET TANK AND PNEUMATIC CONTROLLER HAVE CRACKS OR OTHER DAMAGE? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (11) to verify problem is solved. NO - Go to Step (2). 0149-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00236) TM 9-2320-272-23-1 0149 CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE - Continued STEP 2. DO AIR LINES BETWEEN WET TANK AND PNEUMATIC CONTROLLER HAVE ANY AIR LEAKS? a. Refer to point to point schematics. Wet Tank Pneumatic Controller (Cali) Figure 2. b. T1069DAA Air Lines. Use soapy water at connections to check for air leaks. CONDITION/INDICATION DO AIR LINES BETWEEN WET TANK AND PNEUMATIC CONTROLLER HAVE ANY AIR LEAKS? DECISION YES - Replace damaged air lines (Volume 5, WP 0805). Go to Step (11) to verify problem is solved. NO - Go to Step (3). 0149-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00236) TM 9-2320-272-23-1 0149 CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE - Continued STEP 3. ARE AIR LINES BETWEEN WET TANK AND PNEUMATIC CONTROLLER RESTRICTED? a. Refer to point to point schematics. Wet Tank Pneumatic Controller (Cali) Figure 3. T1069DAA Air Lines. WARNING • Release all air pressure before loosening or removing air system component(s). Failure to comply may result in injury or death to personnel. • Eyeshields must be worn when releasing compressed air. Failure to comply may result in injury or death to personnel. b. Disconnect air line at both ends. c. Check air line for restrictions. CONDITION/INDICATION ARE AIR LINES BETWEEN WET TANK AND PNEUMATIC CONTROLLER RESTRICTED? DECISION YES - Clear restriction, then reconnect air line (Volume 5, WP 0805). Go to Step (11) to verify problem is solved. NO - Go to Step (4). 0149-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00236) TM 9-2320-272-23-1 CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE - Continued STEP 4. IS THE AIR SUPPLY FROM THE VEHICLE AIR COMPRESSOR NORMAL? a. Start engine. NOTE If steady mode lights extinguish, air supply is normal. b. Repeat inflation sequence with engine running at 1000 rpm for three to five minutes. CONDITION/INDICATION IS THE AIR SUPPLY FROM THE VEHICLE AIR COMPRESSOR NORMAL? DECISION YES - Two steady mode lights are extinguished, go to Step (5). NO - Two steady mode lights persist. Perform Air Pressure Builds Slowly troubleshooting (WP 0128). 0149-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00236) 0149 TM 9-2320-272-23-1 0149 CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE - Continued STEP 5. IS THERE CONTINUITY BETWEEN PNEUMATIC CONTROLLER SOLENOIDS AND CTIS WIRING HARNESS CANNON PLUG AT ECU? a. Refer to point to point schematics. b. Turn battery switch to OFF position. T0906DAA Figure 4. CTIS Wiring Harness. CAUTION Turn battery switch to OFF position before disconnecting ECU wiring harness. Failure to do so may result in damage to ECU c. Disconnect CTIS wiring harness cannon plug at ECU. d. Disconnect connector from pneumatic controller. 0149-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00236) TM 9-2320-272-23-1 0149 CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE - Continued e. Set multimeter to measure resistance. f. Connect multimeter red lead to connector from pneumatic controller. g. Connect multimeter black lead to CTIS wiring harness cannon plug. h. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PNEUMATIC CONTROLLER SOLENOIDS AND CTIS WIRING HARNESS CANNON PLUG AT ECU? DECISION YES - Go to Step (6). NO - Replace CTIS wiring harness (Volume 2, WP 0322). Go to Step (11) to verify problem is solved. STEP 6. IS THE PNEUMATIC CONTROLLER IN GOOD CONDITION? Listen for clicking noise while changing CTIS mode. PNEUMATIC CONTROLLER (CAB) T0901DAA Figure 5. Pneumatic Controller. CONDITION/INDICATION IS THE PNEUMATIC CONTROLLER IN GOOD CONDITION? DECISION YES - Go to Step (7). NO - Replace pneumatic controller (Volume 5, WP 0810). Go to Step (11) to verify problem is solved. 0149-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00236) TM 9-2320-272-23-1 0149 CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE - Continued STEP 7. DOES CTIS SYSTEM OPERATE CORRECTLY AFTER THE ELECTRICAL LEAD IS PROPERLY CONNECTED TO PRESSURE SWITCH ON WET TANK? a. Turn battery switch to OFF position. b. Refer to point to point schematics. WET TANK T0903DAA Figure 6. Wet Tank. c. Remove electrical lead from pressure switch at wet tank. d. Clean the connectors, then reconnect the lead. e. Check CTIS operation. CONDITION/INDICATION DOES CTIS SYSTEM OPERATE CORRECTLY AFTER THE ELECTRICAL LEAD IS PROPERLY CONNECTED TO PRESSURE SWITCH ON WET TANK? DECISION YES - Go to Step (11) to verify problem is solved. NO - Go to Step (8). STEP 8. IS THERE CONTINUITY BETWEEN PRESSURE SWITCH AND CTIS WIRING HARNESS CANNON PLUG AT ECU? a. Refer to point to point schematics. b. Turn battery switch to OFF position. 0149-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00236) TM 9-2320-272-23-1 0149 CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE - Continued T0906DAA Figure 7. CTIS Wiring Harness. c. Connect multimeter red lead to CTIS wiring harness cannon plug. d. Connect multimeter black lead to electrical lead at pressure switch. e. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PRESSURE SWITCH AND CTIS WIRING HARNESS CANNON PLUG AT ECU? DECISION YES - Go to Step (9). NO - Replace faulty CTIS wiring harness (Volume 2, WP 0322). Go to Step (11) to verify problem is solved. 0149-9 03/15/2011 Rel(1.8) root(tswp) wpno(T00236) TM 9-2320-272-23-1 0149 CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE - Continued STEP 9. IS THERE CONTINUITY BETWEEN PRESSURE SWITCH PINS A AND B WHEN AIR SYSTEM IS AT NORMAL OPERATING PRESSURE? a. Refer to point to point schematics. PRESSURE SWITCH T0426DAA Figure 8. Pressure Switch. b. Connect multimeter red lead to pressure switch pin A. c. Connect multimeter black lead to pressure switch at pin B. d. Use shop air pressure or start and run engine until air pressure reaches 112-120 psi while monitoring the instrument cluster air pressure gauge. e. Pressure switch should close. f. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PRESSURE SWITCH PINS A AND B WHEN AIR SYSTEM IS AT NORMAL OPERATING PRESSURE? DECISION YES - Go to Step (10). NO - Replace pressure switch (Volume 2, WP 0324). Go to Step (11) to verify problem is solved. 0149-10 03/15/2011 Rel(1.8) root(tswp) wpno(T00236) TM 9-2320-272-23-1 0149 CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE - Continued STEP 10. IS THERE NO CONTINUITY BETWEEN PRESSURE SWITCH PINS A AND B WHEN AIR SYSTEM IS BELOW NORMAL OPERATING PRESSURE? a. Refer to point to point schematics. PRESSURE SWITCH T0426DAA Figure 9. Pressure Switch. b. Connect multimeter red lead to pressure switch at pin A. c. Connect multimeter black lead to pressure switch at pin B. d. Shut off air supply or engine. e. Drain secondary tank until air pressure gauge indicates less than 80 psi. f. Pressure switch should open. g. Meter reading should be greater than 90 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PRESSURE SWITCH PINS A AND B WHEN AIR SYSTEM IS BELOW NORMAL OPERATING PRESSURE? DECISION YES - Go to Step (11) to verify problem is solved. NO - Replace pressure switch (Volume 2, WP 0324). Go to Step (11) to verify problem is solved. 0149-11 03/15/2011 Rel(1.8) root(tswp) wpno(T00236) TM 9-2320-272-23-1 CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE - Continued STEP 11. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0149-12 03/15/2011 Rel(1.8) root(tswp) wpno(T00236) 0149 TM 9-2320-272-23-1 FIELD MAINTENANCE LOSS OF AMBER WARNING LIGHT AND/OR OVERSPEED LIGHT INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) Volume 2, WP 0321 Volume 2, WP 0322 Volume 2, WP 0323 Volume 5, WP 0813 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE LOSS OF AMBER WARNING LIGHT AND/OR OVERSPEED LIGHT NOTE • Conduct these malfunction tests if there is a loss of amber warning light or overspeed light. This procedure will check for a faulty light bulb, Electronic Control Unit (ECU), CTIS wiring harness, vehicle wiring harness connections, and speed signal generator. • The CTIS incorporates an over speed warning and an automatic pressure increase to prevent operation of the vehicle with insufficient tire pressure. This system incorporates a sensor to measure vehicle speed, a panel mounted flashing light, and a connection to the vehicle blackout lights to prevent flashing of the amber warning light when the vehicle is operating under blackout conditions. The ECU periodically measures the speed of the vehicle and compares the speed to programmed limits. If these limits are exceeded, the warning light and automatic pressure increase functions are actuated. STEP 1. IS THE AMBER WARNING LIGHT OUT WHEN THERE IS AN OVERSPEED PRESSURE CHANGE? Verify there was an overspeed pressure change. CONDITION/INDICATION IS THE AMBER WARNING LIGHT OUT WHEN THERE IS AN OVERSPEED PRESSURE CHANGE? DECISION YES - Amber light problem. Go to Step (2). NO - Overspeed light problem. Go to Step (5). 0150-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00237) 0150 TM 9-2320-272-23-1 0150 LOSS OF AMBER WARNING LIGHT AND/OR OVERSPEED LIGHT - Continued STEP 2. DOES WARNING LIGHT FLASH WITH BLACKOUT LIGHT SWITCH OFF? a. Ensure vehicle blackout light switch is OFF. CTIS AMBER WARNING LIGHT ECU T0461DAA Figure 1. CTIS Amber Warning Light. b. Check condition of warning light. CONDITION/INDICATION DOES WARNING LIGHT FLASH WITH BLACKOUT LIGHT SWITCH OFF? DECISION YES - Go to Step (3). NO - Replace amber warning light bulb (Volume 2, WP 0321). Go to Step (7) to verify problem is solved. 0150-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00237) TM 9-2320-272-23-1 0150 LOSS OF AMBER WARNING LIGHT AND/OR OVERSPEED LIGHT - Continued STEP 3. DOES WARNING LIGHT FLASH CORRECTLY? a. Select EMERGENCY on ECU to deflate CTIS. CTIS AMBER WARNING LIGHT EMER (EMGERENCY) ECU T0462DAA Figure 2. CTIS Electronic Control Unit. NOTE The ECU limits time spent in the EMERGENCY mode to ten minutes. Emergency mode must be re-selected to maintain correct test conditions. b. Monitor amber warning light as air pressure is reduced. Verify warning light flashes when emergency pressure is obtained (steady emergency mode light). c. Turn on blackout light switch. Verify amber warning light goes out. CONDITION/INDICATION DOES WARNING LIGHT FLASH CORRECTLY? DECISION YES - Go to Step (7) to verify problem is solved. NO - Go to Step (4). 0150-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00237) TM 9-2320-272-23-1 0150 LOSS OF AMBER WARNING LIGHT AND/OR OVERSPEED LIGHT - Continued STEP 4. DOES WARNING LIGHT FLASH? a. Refer to point to point schematics. CTIS AMBER WARNING LIGHT CTIS WIRING HARNESS ECU HARNESS CONNECTOR BLACKOUT WIRE #463 T0463DAA Figure 3. CTIS Wiring Harness. CAUTION Turn battery switch to OFF position before disconnecting or connecting ECU wiring harness. Failure to do so may result in damage to ECU. b. Turn battery switch OFF. c. Disconnect blackout wire #463 from CTIS wiring harness. CONDITION/INDICATION DOES WARNING LIGHT FLASH? DECISION YES - Go to Step (5). NO - Replace faulty CTIS wiring harness (Volume 2, WP 0322). Go to Step (7) to verify problem is solved. 0150-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00237) TM 9-2320-272-23-1 0150 LOSS OF AMBER WARNING LIGHT AND/OR OVERSPEED LIGHT - Continued STEP 5. IS THERE CONTINUITY BETWEEN SPEED SIGNAL GENERATOR AND ECU CANNON PLUG? a. Refer to point to point schematics. CTIS AMBER WARNING LIGHT SPEED SIGNAL GENERATOR TRANSFER CASE HWY (HIGHWAY) X-C SAND EMER (EMERGENCY) ECU RUN FLAT T0457DAA Figure 4. b. Speed Signal Generator and ECU. Check connection of electrical lead at speed signal generator on pneumatic controller. Clean and tighten as needed. CAUTION Turn battery switch to OFF position before disconnecting or connecting ECU wiring harness. Failure to do so may result in damage to ECU. c. Turn battery switch to OFF position. d. Disconnect CTIS wiring harness cannon plug at ECU. e. Disconnect electrical lead at signal generator. f. Set multimeter to measure resistance. g. Connect multimeter red lead to signal generator lead of wiring harness. h. Connect multimeter black lead to harness connector at ECU cannon plug. i. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN SPEED SIGNAL GENERATOR AND ECU CANNON PLUG? DECISION YES - Go to Step (6). NO - Replace faulty CTIS wiring harness (Volume 2, WP 0322). Go to Step (7) to verify problem is solved. 0150-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00237) TM 9-2320-272-23-1 0150 LOSS OF AMBER WARNING LIGHT AND/OR OVERSPEED LIGHT - Continued STEP 6. IS THE SPEED SIGNAL GENERATOR WORKING PROPERLY? a. Refer to point to point schematics. TRANSFER CASE SPEED SIGNAL GENERATOR T0455DAA Figure 5. Speed Signal Generator. b. Replace the speed signal generator with a known good unit and retest CTIS operation. (Volume 2, WP 0323) c. Drive vehicle above 5 mph. d. Check CTIS operation. CONDITION/INDICATION IS THE SPEED SIGNAL GENERATOR WORKING PROPERLY? DECISION YES - Go to Step (7) to verify problem is solved. NO - Replace the Electronic Control Unit (ECU) (Volume 5, WP 0813). Go to Step (7) to verify problem is solved. STEP 7. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0150-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00237) TM 9-2320-272-23-1 FIELD MAINTENANCE SOLID OVERSPEED WARNING LIGHT INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0322 Volume 2, WP 0323 Volume 5, WP 0813 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE SOLID OVERSPEED WARNING LIGHT NOTE Conduct these malfunction tests if the system gives a solid overspeed warning light. This fault is set because the ECU has seen 25 to 50 ignition cycles without sensing any speed input. Move vehicle at greater than 5 MPH. If light does not go out, perform the following tests. This procedure will check for a faulty Speed Signal Generator, Electronic Control Unit (ECU), and CTIS wiring harness. 0151-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00263) 0151 TM 9-2320-272-23-1 0151 SOLID OVERSPEED WARNING LIGHT - Continued STEP 1. IS THERE CONTINUITY BETWEEN SPEED SIGNAL GENERATOR AND ECU CANNON PLUG? a. Refer to point to point schematics. CTIS AMBER WARNING LIGHT SPEED SIGNAL GENERATOR TRANSFER CASE HWY (HIGHWAY) X-C SAND EMER (EMERGENCY) RUN FLAT ECU T0457DAA Figure 1. Speed Signal Generator and ECU. b. Check connection of electrical lead at speed signal generator on pneumatic controller. Clean and tighten as needed. CAUTION Turn battery switch to OFF position before disconnecting or connecting ECU wiring harness. Failure to do so may result in damage to ECU. c. Turn battery switch to OFF position. d. Disconnect CTIS wiring harness cannon plug at ECU. e. Disconnect electrical lead at signal generator. f. Set multimeter to measure resistance. g. Connect multimeter red lead to signal generator lead of wiring harness. h. Connect multimeter black lead to harness connector at ECU cannon plug. i. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN SPEED SIGNAL GENERATOR AND ECU CANNON PLUG? DECISION YES - Go to Step (2). NO - Replace faulty CTIS wiring harness (Volume 2, WP 0322). Go to Step (3) to verify problem is solved. 0151-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00263) TM 9-2320-272-23-1 0151 SOLID OVERSPEED WARNING LIGHT - Continued STEP 2. IS THE SPEED SIGNAL GENERATOR WORKING PROPERLY? a. Refer to point to point schematics. TRANSFER CASE SPEED SIGNAL GENERATOR T0455DAA Figure 2. Speed Signal Generator. b. Replace the speed signal generator with a known good unit and retest CTIS operation. (Volume 2, WP 0323) c. Drive vehicle above 5 mph. d. Check CTIS operation. CONDITION/INDICATION IS THE SPEED SIGNAL GENERATOR WORKING PROPERLY? DECISION YES - Go to Step (3) to verify problem is solved. NO - Replace the electronic control unit (ECU) (Volume 5, WP 0813). Go to Step (3) to verify problem is solved. STEP 3. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0151-3/4 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00263) TM 9-2320-272-23-1 FIELD MAINTENANCE SYSTEM OVER-INFLATES TIRES INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) Personnel Required (2) References (cont.) WP 0006 Volume 2, WP 0322 Volume 5, WP 0812 Volume 5, WP 0813 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) References Point to Point Schematics TROUBLESHOOTING PROCEDURE SYSTEM OVER-INFLATES TIRES NOTE • Conduct these malfunction tests if the system over-inflates tires. This procedure will check for a faulty CTIS wiring harness, Electronic Control Unit (ECU), and pressure transducer. • The ECU is programmed in conjunction with vehicle air compressor output. This procedure requires air source supplied by vehicle for accurate diagnosis. 0152-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00238) 0152 TM 9-2320-272-23-1 0152 SYSTEM OVER-INFLATES TIRES - Continued STEP 1. DO TIRE PRESSURES REMAIN THE SAME AFTER MANUALLY BALANCING TIRE PRESSURE? a. Manually measure the pressure in each tire with a pressure gauge to locate all over-inflated tires and to determine the accuracy of system pressure reading. TIRE T0905DAA Figure 1. Tire. CAUTION When vehicle is connected to an external air source, ensure that air is clean and dry. Dirty and wet air may result in CTIS malfunctions. b. Manually balance tire pressures with external air source. 0152-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00238) TM 9-2320-272-23-1 0152 SYSTEM OVER-INFLATES TIRES - Continued CAUTION Do not operate CTIS while vehicle is connected to an external air source. This may result in over-inflation or damage to tires. c. Remove external air source and run CTIS. d. Manually measure the pressure in each tire with a pressure gauge to locate all over-inflated tires and to determine the accuracy of system pressure reading. CONDITION/INDICATION DO TIRE PRESSURES REMAIN THE SAME AFTER MANUALLY BALANCING TIRE PRESSURE? DECISION YES - Go to Step (5) to verify problem is solved. NO - Go to Step (2). 0152-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00238) TM 9-2320-272-23-1 0152 SYSTEM OVER-INFLATES TIRES - Continued STEP 2. IS THERE CONTINUITY BETWEEN PRESSURE TRANSDUCER AND ECU CANNON PLUG? a. Refer to point to point schematics. T0907DAA Figure 2. CTIS Wiring Harness. b. Check connection of electrical lead at pressure transducer on pneumatic controller. Clean and tighten as needed. 0152-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00238) TM 9-2320-272-23-1 0152 SYSTEM OVER-INFLATES TIRES - Continued CAUTION Turn battery switch to OFF position before disconnecting or connecting ECU wiring harness. Failure to do so may result in damage to ECU. c. Turn battery switch to OFF position. d. Disconnect CTIS wiring harness cannon plug at ECU. e. Disconnect electrical lead at pressure transducer. f. Set multimeter to measure resistance. g. Connect multimeter red lead to pressure transducer. h. Connect multimeter black lead to pressure transducer lead at ECU cannon plug. i. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PRESSURE TRANSDUCER AND ECU CANNON PLUG? DECISION YES - Go to Step (3). NO - Replace faulty CTIS wiring harness (Volume 2, WP 0322). Go to Step (5) to verify problem is solved. 0152-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00238) TM 9-2320-272-23-1 0152 SYSTEM OVER-INFLATES TIRES - Continued STEP 3. IS THERE BATTERY VOLTAGE PRESENT AT PINS X AND V ON CTIS WIRING HARNESS CANNON PLUG AT ECU? a. Refer to point to point schematics. T0907DAA Figure 3. CTIS Wiring Harness. 0152-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00238) TM 9-2320-272-23-1 0152 SYSTEM OVER-INFLATES TIRES - Continued CAUTION Turn battery switch to OFF position before disconnecting or connecting ECU wiring harness. Failure to do so may result in damage to ECU. b. Turn battery switch to OFF position. c. Disconnect CTIS wiring harness cannon plug at ECU. d. Turn battery switch to ON position. e. Set multimeter to measure VDC. f. Connect multimeter red lead to CTIS wiring harness cannon plug pin V. g. Connect multimeter black lead to CTIS wiring harness cannon plug pin X. h. Meter reading should be between 18 and 26 VDC. CONDITION/INDICATION IS THERE BATTERY VOLTAGE PRESENT AT PINS X AND V ON CTIS WIRING HARNESS CANNON PLUG AT ECU? DECISION YES - Go to Step (4). NO - Perform Engine Fails To Crank troubleshooting (WP 0006). 0152-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00238) TM 9-2320-272-23-1 0152 SYSTEM OVER-INFLATES TIRES - Continued STEP 4. IS THERE 4.75 to 5.25 VDC PRESENT AT PRESSURE TRANSDUCER? a. Refer to point to point schematics. CAUTION Turn battery switch to OFF position before disconnecting or connecting ECU wiring harness. Failure to do so may result in damage to ECU. b. Turn battery switch to OFF position. c. Connect CTIS wiring harness cannon plug at ECU. PRESSURE TRANSDUCER T0902DAA Figure 4. Pressure Transducer. d. Disconnect CTIS wiring harness electrical lead from pressure transducer. e. Turn battery switch to ON position. f. Connect multimeter red lead to wire at pressure transducer. g. Connect multimeter black lead to a known good ground. h. Meter reading should be between 4.75 and 5.25 VDC. 0152-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00238) TM 9-2320-272-23-1 SYSTEM OVER-INFLATES TIRES - Continued CONDITION/INDICATION IS THERE 4.75 to 5.25 VDC PRESENT AT PRESSURE TRANSDUCER? DECISION NO - Replace electronic control unit (Volume 5, WP 0813). Go to Step (5) to verify problem is solved. YES - Replace pressure transducer (Volume 5, WP 0812). Go to Step (5) to verify problem is solved. STEP 5. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0152-9/10 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00238) 0152 TM 9-2320-272-23-1 FIELD MAINTENANCE SLOW AIR RECOVERY OR OCCASIONAL LOW AIR WARNING DURING BRAKING INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (Volume 5, WP 0826, Table 1, Item 56) Multimeter (Volume 5, WP 0826, Table 1, Item 34) Test Set, Electronic Systems (Volume 5, WP 0826, Table 1, Item 51) References (cont.) Volume 2, WP 0322 Volume 2, WP 0324 Volume 5, WP 0813 Equipment Condition Vehicle parked and engine shut down. (TM 9-2320-272-10) Personnel Required (2) References Point to Point Schematics TROUBLESHOOTING PROCEDURE SLOW AIR RECOVERY OR OCCASIONAL LOW AIR WARNING DURING BRAKING NOTE Conduct these malfunction tests if air recovery is slow, or there is an occasional low air warning during braking. This procedure will check for the pressure switch lead not making contact, and no continuity between pressure switch and CTIS wiring harness cannon plug at the Electronic Control Unit (ECU). It will also check for a faulty CTIS wiring harness, pressure switch, and ECU. 0153-1 03/15/2011 Rel(1.8) root(tswp) wpno(T00239) 0153 TM 9-2320-272-23-1 0153 SLOW AIR RECOVERY OR OCCASIONAL LOW AIR WARNING DURING BRAKING - Continued STEP 1. DOES CTIS SYSTEM OPERATE CORRECTLY AFTER THE ELECTRICAL LEAD IS PROPERLY CONNECTED TO PRESSURE SWITCH ON WET TANK? a. Refer to point to point schematics. WIRE HARNESS PRESSURE SWITCH PRESSURE SWITCH LEAD T0469DAA Figure 1. Pressure Switch. 0153-2 03/15/2011 Rel(1.8) root(tswp) wpno(T00239) TM 9-2320-272-23-1 0153 SLOW AIR RECOVERY OR OCCASIONAL LOW AIR WARNING DURING BRAKING - Continued b. Turn battery switch to "OFF" position. c. Remove electrical lead from pressure switch at wet tank. d. Clean the connectors, then reconnect the lead. e. Check CTIS operation. CONDITION/INDICATION DOES CTIS SYSTEM OPERATE CORRECTLY AFTER THE ELECTRICAL LEAD IS PROPERLY CONNECTED TO PRESSURE SWITCH ON WET TANK? DECISION YES - Go to Step (6) to verify problem is solved. NO - Go to Step (2). 0153-3 03/15/2011 Rel(1.8) root(tswp) wpno(T00239) TM 9-2320-272-23-1 0153 SLOW AIR RECOVERY OR OCCASIONAL LOW AIR WARNING DURING BRAKING - Continued STEP 2. IS THERE CONTINUITY BETWEEN PRESSURE SWITCH AND CTIS WIRING HARNESS CANNON PLUG AT ECU? a. Refer to point to point schematics. T0908DAA Figure 2. CTIS Wiring Harness. 0153-4 03/15/2011 Rel(1.8) root(tswp) wpno(T00239) TM 9-2320-272-23-1 0153 SLOW AIR RECOVERY OR OCCASIONAL LOW AIR WARNING DURING BRAKING - Continued b. Disconnect harness lead at the pressure switch. c. Set multimeter to measure resistance. d. Connect multimeter red lead to CTIS wiring harness cannon plug. e. Connect multimeter black lead to electrical lead at pressure switch. f. Meter reading should be less than 200 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PRESSURE SWITCH AND CTIS WIRING HARNESS CANNON PLUG AT ECU? DECISION YES - Go to Step (3). NO - Replace faulty CTIS wiring harness (Volume 2, WP 0322). Go to Step (6) to verify problem is solved. 0153-5 03/15/2011 Rel(1.8) root(tswp) wpno(T00239) TM 9-2320-272-23-1 0153 SLOW AIR RECOVERY OR OCCASIONAL LOW AIR WARNING DURING BRAKING - Continued STEP 3. IS THERE CONTINUITY BETWEEN PRESSURE SWITCH PINS A AND B WHEN AIR SYSTEM IS AT NORMAL OPERATING PRESSURE? a. Refer to point to point schematics. WIRE HARNESS PRESSURE SWITCH A B PRESSURE SWITCH LEAD T0473DAA Figure 3. Pressure Switch. b. Connect multimeter red lead to pressure switch at pin A. c. Connect multimeter black lead to pressure switch at pin B. d. Use shop air pressure or start and run engine until air pressure reaches 112-120 psi while monitoring the instrument cluster air pressure gauge. e. Pressure switch should be closed. f. Meter reading should be less than 20 ohms. CONDITION/INDICATION IS THERE CONTINUITY BETWEEN PRESSURE SWITCH PINS A AND B WHEN AIR SYSTEM IS AT NORMAL OPERATING PRESSURE? DECISION YES - Go to Step (10). NO - Replace pressure switch (Volume 2, WP 0324). Go to Step (11) to verify problem is solved. 0153-6 03/15/2011 Rel(1.8) root(tswp) wpno(T00239) TM 9-2320-272-23-1 0153 SLOW AIR RECOVERY OR OCCASIONAL LOW AIR WARNING DURING BRAKING - Continued STEP 4. IS THERE NO CONTINUITY BETWEEN PRESSURE SWITCH PINS A AND B WHEN AIR SYSTEM IS BELOW NORMAL OPERATING PRESSURE? a. Refer to point to point schematics. WIRE HARNESS PRESSURE SWITCH A B PRESSURE SWITCH LEAD T0473DAA Figure 4. Pressure Switch. b. Connect multimeter red lead to pressure switch at pin A. c. Connect multimeter black lead to pressure switch at pin B. d. Shut off air supply or engine. e. Drain secondary tank until air pressure gauge indicates less than 80 psi. f. Pressure switch should read open (no continuity). g. Meter reading should be greater than 90 ohms. CONDITION/INDICATION IS THERE NO CONTINUITY BETWEEN PRESSURE SWITCH PINS A AND B WHEN AIR SYSTEM IS BELOW NORMAL OPERATING PRESSURE? DECISION YES - Go to Step (5). NO - Replace pressure switch (Volume 2, WP 0324). Go to Step (6) to verify problem is solved. 0153-7 03/15/2011 Rel(1.8) root(tswp) wpno(T00239) TM 9-2320-272-23-1 SLOW AIR RECOVERY OR OCCASIONAL LOW AIR WARNING DURING BRAKING - Continued STEP 5. IS THE VOLTAGE FROM THE ECU TO THE PRESSURE SWITCH NORMAL? a. Refer to point to point schematics. WIRE HARNESS PRESSURE SWITCH A B PRESSURE SWITCH LEAD T0474DAA Figure 5. Pressure Switch. b. Connect CTIS wiring harness cannon plug to ECU. c. Place battery switch to ON position. d. Place CTIS switch to ON position. e. Set multimeter to measure VDC. f. Connect multimeter red lead to pressure switch connector. g. Connect multimeter black lead to a known good ground. h. Meter reading should be greater than 23 VDC. CONDITION/INDICATION IS THE VOLTAGE FROM THE ECU TO THE PRESSURE SWITCH NORMAL? DECISION YES - Notify supervisor. It is possible that another troubleshooting work package applies. NO - Replace ECU (Volume 5, WP 0813). Go to Step (6) to verify problem is solved. 0153-8 03/15/2011 Rel(1.8) root(tswp) wpno(T00239) 0153 TM 9-2320-272-23-1 SLOW AIR RECOVERY OR OCCASIONAL LOW AIR WARNING DURING BRAKING - Continued STEP 6. IS YOUR ORIGINAL PROBLEM STILL PRESENT? a. Ensure vehicle is returned to normal operating condition. b. Check to see if your original problem still exists. CONDITION/INDICATION IS YOUR ORIGINAL PROBLEM STILL PRESENT? DECISION YES - Notify supervisor. NO - Problem fixed. END OF WORK PACKAGE 0153-9/10 blank 03/15/2011 Rel(1.8) root(tswp) wpno(T00239) 0153 TM 9-2320-272-23-1 INDEX Subject WP Sequence No.-Page No. A AIR PRESSURE BUILDS SLOWLY (TAKES EXCESSIVE AMOUNT OF TIME TO BUILD TO 100 PSI (690KPA)....................................................................................................... AIR PRESSURE DOES NOT BUILD TO NORMAL OPERATING PRESSURE (ABOVE 80 PSI [552 KPA]) ACCORDING TO GAUGES................................................................ AIR PRESSURE EXCEEDS MAXIMUM (GAUGES SHOW OVER 130 PSI [896 KPA]), SAFETY VALVE OPENS TO RELEASE PRESSURE...................................................... AIR PRESSURE GAUGE INOPERATIVE........................................................................ ALL AIR-OPERATED ACCESSORIES DO NOT OPERATE (HORN, WINDSHIELD WIPERS, WINDSHIELD WASHERS, TRANSFER CASE CONTROLS), GAUGES AT NORMAL OPERATING PRESSURE................................................................................ ALL GAUGES INOPERATIVE.......................................................................................... ALL VEHICLE ELECTRICAL SYSTEMS INOPERATIVE................................................. ALTERNATOR OVERCHARGING, BATTERY INDICATOR GAUGE IN RED POSITION......................................................................................................................... AUTOMATIC BRAKE OVERHEATS................................................................................. WP 0128-1 WP 0127-1 WP 0129-1 WP 0102-1 WP 0137-1 WP 0104-1 WP 0085-1 WP 0091-1 WP 0063-1 B BATTERY/ALTERNATOR GAUGE INOPERATIVE......................................................... BLACKOUT DRIVE OR BLACKOUT MARKER LIGHT INOPERATIVE........................... BRAKES SQUEAL............................................................................................................ WP 0108-1 WP 0094-1 WP 0124-1 C CENTRAL TIRE INFLATION SYSTEM (CTIS) TROUBLESHOOTING............................ CONTAMINATED COOLANT........................................................................................... CONTINUOUS AXLE OR WHEEL NOISE....................................................................... CONTINUOUS WANDERING OR SWAYING (POOR CONTROL).................................. CONTROL PANEL LIGHTS WORK, SYSTEM FAILS TO INFLATE OR DEFLATE........ COOLING FAN DOES NOT OPERATE, ENGINE TEMPERATURE ABOVE 195°F (91°C) AS INDICATED BY TEMPERATURE GAUGE..................................................... COOLING FAN DOES NOT STOP RUNNING, ENGINE TEMPERATURE BELOW NORMAL OPERATING RANGE (OVERRIDE BOLT NOT INSTALLED)......................... CTIS TROUBLESHOOTING INDEX................................................................................. WP 0142-1 WP 0030-1 WP 0045-1 WP 0056-1 WP 0149-1 WP 0138-1 WP 0139-1 WP 0143-1 D DIRT OR METAL PARTICLES IN TRANSMISSION OIL.................................................. DOOR LOCK WILL NOT OPERATE................................................................................ DRAG BRAKE DOES NOT OPERATE............................................................................. DUMP BODY WILL NOT HOLD IN RAISED POSITION.................................................. DUMP BODY WILL NOT LOWER.................................................................................... DUMP BODY WILL NOT RAISE....................................................................................... DUMP HYDRAULIC PUMP NOISY.................................................................................. WP 0037-1 WP 0082-1 WP 0061-1 WP 0076-1 WP 0075-1 WP 0074-1 WP 0077-1 E ENGINE AND VEHICLE ELECTRICAL SYSTEMS MALFUNCTIONING......................... ENGINE CRANKS BUT DOES NOT START.................................................................... ENGINE CRANKS BUT WILL NOT START IN COLD WEATHER (FUEL SYSTEM OPERATING PROPERLY)............................................................................................... ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE........................ Index-1 03/15/2011 Rel(1.8) root(aindx) wpno(B00009) WP 0083-1 WP 0007-1 WP 0021-1 WP 0027-1 TM 9-2320-272-23-1 Subject WP Sequence No.-Page No. ENGINE FAILS TO CRANK.............................................................................................. ENGINE FAILS TO STOP................................................................................................ ENGINE IDLE ROUGH OR ERRATIC.............................................................................. ENGINE OIL CONTAMINATED........................................................................................ ENGINE OVERHEATS..................................................................................................... ENGINE RUNS, BUT MISFIRES...................................................................................... ENGINE STOPS DURING NORMAL OPERATION......................................................... ENGINE STOPS WHEN ACCELERATOR IS RETURNED TO IDLE POSITION............. ENGINE SURGES............................................................................................................ ENGINE WILL NOT CRANK; SOME ELECTRICAL SYSTEMS INOPERATIVE OR WEAK............................................................................................................................... EQUIPMENT DESCRIPTION AND DATA........................................................................ EXCESSIVE EXHAUST NOISE....................................................................................... EXCESSIVE FUEL CONSUMPTION................................................................................ EXCESSIVE NOISE......................................................................................................... EXCESSIVE NOISE DURING SHIFTING......................................................................... EXCESSIVE OIL CONSUMPTION................................................................................... EXCESSIVE PLAY IN STEERING WHEEL...................................................................... EXCESSIVE PROPELLER AND DRIVE SHAFTS NOISE OR VIBRATION.................... EXCESSIVE VIBRATION................................................................................................. EXCESSIVE VIBRATION OR CLUNKING....................................................................... EXCESSIVELY LOOSE LIFTING SHACKLE................................................................... EXHAUST COLOR BLACK DURING NORMAL OPERATION AND IDLE....................... EXHAUST COLOR BLUE DURING NORMAL OPERATION........................................... EXHAUST COLOR WHITE DURING NORMAL OPERATION......................................... EXHAUST FUMES IN CAB.............................................................................................. WP 0006-1 WP 0011-1 WP 0013-1 WP 0018-1 WP 0028-1 WP 0012-1 WP 0009-1 WP 0010-1 WP 0015-1 WP 0084-1 WP 0002-1 WP 0025-1 WP 0020-1 WP 0042-1 WP 0031-1 WP 0016-1 WP 0054-1 WP 0044-1 WP 0043-1 WP 0019-1 WP 0048-1 WP 0024-1 WP 0022-1 WP 0023-1 WP 0026-1 F FIVE INDICATOR LIGHTS FLASHING............................................................................ FOUR PRESSURE MODE LIGHTS FLASHING.............................................................. FRONT WHEEL DRIVE DOES NOT ENGAGE (FRONT WHEEL DRIVE LOCK-IN SWITCH ENGAGED AND TRANSFER CASE SHIFT LEVER IN HIGH POSITION)....... FRONT WINCH OPERATES AT ONE SPEED ONLY...................................................... FUEL GAUGE INOPERATIVE.......................................................................................... WP 0146-1 WP 0145-1 WP 0140-1 WP 0064-1 WP 0107-1 G GENERAL INFORMATION............................................................................................... GENERAL TROUBLESHOOTING.................................................................................... GENERAL TROUBLESHOOTING INDEX........................................................................ WP 0001-1 WP 0004-1 WP 0005-1 H HARD SHIFTING OF TRANSFER CASE......................................................................... HARD STEERING............................................................................................................ HARSH OR HARD RIDE.................................................................................................. HEADLAMP (BOTH SIDE) INOPERATIVE...................................................................... HEADLAMP (ONE SIDE) INOPERATIVE......................................................................... HEATER WILL NOT OPERATE IN LOW OR HIGH POSITION....................................... HEATER WILL NOT OPERATE WITH SWITCH IN HIGH POSITION (LOW POSITION OPERATION NORMAL)................................................................................................... HEATER WILL NOT OPERATE WITH SWITCH IN LOW POSITION (HIGH POSITION OPERATION NORMAL)................................................................................................... HORN DOES NOT WORK (GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING)........................................................................... Index-2 03/15/2011 Rel(1.8) root(aindx) wpno(B00009) WP 0040-1 WP 0052-1 WP 0057-1 WP 0093-1 WP 0092-1 WP 0116-1 WP 0115-1 WP 0114-1 WP 0141-1 TM 9-2320-272-23-1 Subject WP Sequence No.-Page No. HORN INOPERATIVE...................................................................................................... WP 0109-1 I INDIVIDUAL LIGHTS DO NOT LIGHT WITH DIRECTIONAL SIGNAL LEVER IN ANY POSITION......................................................................................................................... INSUFFICIENT BRAKES (VEHICLE STOPPING DISTANCE TOO LONG, NO APPARENT AIR SYSTEM FAILURE WITH GAUGES AT NORMAL OPERATING PRESSURE, WARNING BUZZER NOT SOUNDING)..................................................... WP 0097-1 WP 0120-1 L LOOSE SPARE TIRE CARRIER...................................................................................... LOSS OF AMBER WARNING LIGHT AND/OR OVERSPEED LIGHT............................. LOSS OF COOLANT........................................................................................................ LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF (AIR PRESSURE GAUGES AT NORMAL SYSTEM PRESSURE)............................................................... LOW AIR PRESSURE WARNING BUZZER WILL NOT SHUT OFF AND PARKING BRAKE WARNING LIGHT FLASHES WITH HAND/PARKING BRAKE IN ANY POSITION (AIR PRESSURE NORMAL).......................................................................... LOW OIL PRESSURE...................................................................................................... LOW TRANSMISSION OIL PRESSURE.......................................................................... WP 0049-1 WP 0150-1 WP 0029-1 WP 0110-1 WP 0111-1 WP 0017-1 WP 0032-1 N NO AIR PRESSURE (WARNING BUZZER SOUNDING, AIR PRESSURE NOT BUILDING TO NORMAL OPERATING RANGE AS INDICATED BY GAUGES)............. NO ALTERNATOR OUTPUT (100 AMP ALTERNATOR)................................................ NO CAB HEAT (COOLANT TEMPERATURE GAUGE READS NORMAL)..................... NO LIGHTS OPERATE WITH DIRECTIONAL SIGNAL CONTROL LEVER IN ANY POSITION......................................................................................................................... NO OR LOW ALTERNATOR OUTPUT............................................................................ NO RESPONSE TO SHIFT LEVER MOVEMENT............................................................ WP 0126-1 WP 0090-1 WP 0117-1 WP 0098-1 WP 0089-1 WP 0034-1 O OIL PRESSURE GAUGE INOPERATIVE (OIL LEVEL IS CORRECT)............................ OIL THROWN FROM TRANSMISSION DIPSTICK TUBE............................................... ONE OR MORE TRAILER LIGHTS INOPERATIVE......................................................... WP 0103-1 WP 0038-1 WP 0113-1 P PARKING BRAKE DOES NOT HOLD VEHICLE ON GRADE......................................... PARKING BRAKE DRAGS, AS INDICATED BY SMOKING OR BURNING SMELL....... PINTLE HOOK DOES NOT TURN................................................................................... POOR ACCELERATION AND/OR LACK OF POWER..................................................... PRIMARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED).......................................................................................................................... PRIMARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. SECONDARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED)............. PROTECTIVE CONTROL BOX ASSEMBLY TEST......................................................... PTO EXCESSIVELY NOISY............................................................................................. PTO LEAKING LUBRICANT............................................................................................. PTO SHIFTS HARD.......................................................................................................... Index-3 03/15/2011 Rel(1.8) root(aindx) wpno(B00009) WP 0118-1 WP 0119-1 WP 0047-1 WP 0014-1 WP 0132-1 WP 0130-1 WP 0100-1 WP 0067-1 WP 0069-1 WP 0068-1 TM 9-2320-272-23-1 Subject WP Sequence No.-Page No. R RADIO INTERFERENCE.................................................................................................. REAR WINCH CABLE TENSIONER WILL NOT OPERATE............................................ ROUGH SHIFTING........................................................................................................... WP 0070-1 WP 0065-1 WP 0035-1 S SECONDARY AIR SYSTEM FAILS TO MAINTAIN PRESSURE (NO MAJOR LEAKS, AIR CAN BE HEARD ESCAPING INTO AIR INTAKE STACK, PARKING BRAKE APPLIED).......................................................................................................................... SECONDARY PRESSURE GAUGE READS NO PRESSURE, LOW PRESSURE, OR BUILDS TO NORMAL OPERATING PRESSURE SLOWLY. PRIMARY PRESSURE GAUGE READS NORMAL (ENGINE IDLING, BRAKE PEDAL NOT APPLIED)............. SHIMMY............................................................................................................................ SIDE PANEL CANNOT BE LOCKED IN RETRACT POSITION...................................... SIDE PANELS HARD TO RETRACT OR EXPAND......................................................... SLOW AIR RECOVERY OR OCCASIONAL LOW AIR WARNING DURING BRAKING.......................................................................................................................... SOLENOID OPERATES, STARTER OPERATES, BUT ENGINE CRANKS SLOWLY........................................................................................................................... SOLID OVERSPEED WARNING LIGHT.......................................................................... SPEEDOMETER OR TACHOMETER NOISY OR ERRATIC........................................... SPRING BRAKE WARNING LIGHT INOPERATIVE WITH SPRING BRAKE OVERRIDE ENGAGED........................................................................................................................ SPRING BRAKES DO NOT RELEASE (VEHICLE BRAKES GRAB OR DRAG)............. SPRING BRAKES DO NOT SET (GAUGES AT NORMAL OPERATING PRESSURES, AIR EXHAUSTING NOT HEARD WHEN PARKING BRAKE APPLIED).......................... SPRING LEAF DEFECT................................................................................................... STARTER CRANKS ENGINE SLOWLY, HARD TO START............................................ STARTER MOTOR INOPERATIVE.................................................................................. STARTER MOTOR INOPERATIVE; NO SOLENOID THUMP......................................... STOPLIGHT INOPERATIVE (SERVICE OR BLACKOUT)............................................... SYSTEM FAILS TO DEFLATE, PARTIALLY DEFLATES, OR TIRE PRESSURES ARE IMBALANCED................................................................................................................... SYSTEM OPERATES INCORRECTLY IN ONE OR MORE POSITIONS OF DIRECTIONAL SIGNAL CONTROL LEVER.................................................................... SYSTEM OVER-INFLATES TIRES.................................................................................. SYSTEM REPEATEDLY RESUMES CYCLING 30 SECONDS AFTER MODE LIGHT STOPS FLASHING........................................................................................................... WP 0133-1 WP 0131-1 WP 0055-1 WP 0080-1 WP 0079-1 WP 0153-1 WP 0087-1 WP 0151-1 WP 0101-1 WP 0112-1 WP 0135-1 WP 0136-1 WP 0058-1 WP 0008-1 WP 0086-1 WP 0088-1 WP 0095-1 WP 0148-1 WP 0099-1 WP 0152-1 WP 0147-1 T TAIL AND MARKER LIGHTS INOPERATIVE.................................................................. TAILGATE WILL NOT OPEN .......................................................................................... TEMPERATURE GAUGE INOPERATIVE (COOLANT)................................................... THEORY OF OPERATION............................................................................................... TOWING PINTLE DOES NOT LATCH OR LOCK............................................................ TRAILER WILL NOT HITCH TO FIFTH WHEEL.............................................................. TRANSFER CASE LEAKING OIL.................................................................................... TRANSMISSION OIL DIRTY, FOAMY, AND/OR MILKY.................................................. TRANSMISSION OIL LEAKING....................................................................................... TRANSMISSION OVERHEATS AS INDICATED BY TRANSMISSION TEMPERATURE GAUGE............................................................................................................................. TRANSMISSION TEMPERATURE GAUGE INOPERATIVE........................................... Index-4 03/15/2011 Rel(1.8) root(aindx) wpno(B00009) WP 0096-1 WP 0078-1 WP 0106-1 WP 0003-1 WP 0046-1 WP 0071-1 WP 0041-1 WP 0039-1 WP 0033-1 WP 0036-1 WP 0105-1 TM 9-2320-272-23-1 Subject WP Sequence No.-Page No. TWO PRESSURE MODES INDICATED WITH STEADY MODE LIGHTS....................... WP 0144-1 U UNEVEN TIRE WEAR...................................................................................................... WP 0050-1 V VAN BODY NOT WATERPROOF OR LIGHT TIGHT...................................................... VEHICLE PULLS RIGHT OR LEFT WHEN APPLYING BRAKES................................... VEHICLE REAR BRAKES GRAB OR DRAG................................................................... VEHICLE ROLLS WHILE OPERATING REAR WINCH................................................... VEHICLE VIBRATES, CHATTERS, OR BOUNCES WHEN BRAKES ARE APPLIED.... VEHICLE WANDERS OR PULLS TO ONE SIDE............................................................ WP 0081-1 WP 0121-1 WP 0122-1 WP 0066-1 WP 0123-1 WP 0053-1 W WARNING BUZZER FAILS TO SOUND OR FAILS TO SHUT OFF ON LOW PRESSURE (BELOW 55-65 PSI [379-448 KPA]), AIR PRESSURE SYSTEM OPERATING NORMALLY...................................................................................................................... WARNING BUZZER SOUNDS WHEN BRAKES ARE APPLIED (PRIMARY & SECONDARY GAUGE PRESSURE DROPS BELOW 55-65 PSI [379-448 KPA]).......... WHEEL SHIMMY OR WOBBLE....................................................................................... WINCH DOES NOT OPERATE........................................................................................ WINCH OPERATES IN ONE DIRECTION ONLY............................................................ WINCH WILL NOT HOLD LOAD...................................................................................... WRECKER HYDRAULIC PUMP NOISY.......................................................................... WRECKER HYDRAULIC SYSTEM DOES NOT OPERATE............................................ Index-5/ 0 blank 03/15/2011 Rel(1.8) root(aindx) wpno(B00009) WP 0134-1 WP 0125-1 WP 0051-1 WP 0059-1 WP 0060-1 WP 0062-1 WP 0073-1 WP 0072-1 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA. Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). DATE Date you filled out this form. TO (Forward to proponent of publication or form) (Include ZIP Code) FROM (Activity and location) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command Your mailing address ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER TM Number ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO. DATE TITLE Date of the TM Title of the TM RECOMMENDED CHANGES AND REASON (Exact wording of recommended change must be given) 0007-3 Figure 2, Item 9 should show a lockwasher. Currently shows a flat washer. 0018-2 Cleaning and inspection, Step 6, reference to governor support pin (14) is wrong reference. Reference should be change to (12). SAMPLE TYPED NAME, GRADE OR TITLE Your Name DA FORM 2028, FEB 74 TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION Your Phone Number SIGNATURE Your Signature REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. APD V4.00 TO (Forward direct to addressee listed in publication) FROM (Activity and location) (Include ZIP Code) DATE U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS Date you filled out Your Address this form 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE Date of the TM TM Number PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER TITLE Title of the TM TOTAL NO. REFERENCE FIGURE ITEM OF MAJOR NO. NO. NO. ITEMS SUPPORTED RECOMMENDED ACTION SAMPLE PART III – REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.) TYPED NAME, GRADE OR TITLE Your Name TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION Your Phone Number Your Signature APD V4.00 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA TO (Forward to proponent of publication or form) (Include ZIP Code) Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). DATE FROM (Activity and location) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Truck, 5-Ton, 6X6, M939A1, And M939A2 Series Trucks 10 September 2012 TM 9-2320-272-1 (Diesel), Field Maintenance Manual PAGE PARAGRAPH TYPED NAME, GRADE OR TITLE DA FORM 2028, FEB 74 LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. APD V4.00 TO (Forward direct to addressee listed in publication) FROM (Activity and location) (Include ZIP Code) DATE U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Truck, 5-Ton, 6X6, M939A1, And M939A2 Series Trucks 10 September 2012 TM 9-2320-272-1 (Diesel), Field Maintenance Manual PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION PART III – REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.) TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION APD V4.00 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA TO (Forward to proponent of publication or form) (Include ZIP Code) Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). DATE FROM (Activity and location) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Truck, 5-Ton, 6X6, M939A1, And M939A2 Series Trucks 10 September 2012 TM 9-2320-272-1 (Diesel), Field Maintenance Manual ITEM PAGE PARAGRAPH TYPED NAME, GRADE OR TITLE DA FORM 2028, FEB 74 LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. APD V4.00 TO (Forward direct to addressee listed in publication) FROM (Activity and location) (Include ZIP Code) DATE U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Truck, 5-Ton, 6X6, M939A1, And M939A2 Series Trucks 10 September 2012 TM 9-2320-272-1 (Diesel), Field Maintenance Manual PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION PART III – REMARKS (Any general remark, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.) TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION APD V4.00 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA TO (Forward to proponent of publication or form) (Include ZIP Code) Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). DATE FROM (Activity and location) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Truck, 5-Ton, 6X6, M939A1, And M939A2 Series Trucks 10 September 2012 TM 9-2320-272-1 (Diesel), Field Maintenance Manual ITEM PAGE PARAGRAPH TYPED NAME, GRADE OR TITLE DA FORM 2028, FEB 74 LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. APD V4.00 TO (Forward direct to addressee listed in publication) FROM (Activity and location) (Include ZIP Code) DATE U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Truck, 5-Ton, 6X6, M939A1, And M939A2 Series Trucks 10 September 2012 TM 9-2320-272-1 (Diesel), Field Maintenance Manual PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION PART III – REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.) TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION APD V4.00 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA TO (Forward to proponent of publication or form) (Include ZIP Code) Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). DATE FROM (Activity and location) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Truck, 5-Ton, 6X6, M939A1, And M939A2 Series Trucks 10 September 2012 TM 9-2320-272-1 (Diesel), Field Maintenance Manual ITEM PAGE PARAGRAPH TYPED NAME, GRADE OR TITLE DA FORM 2028, FEB 74 LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. APD V4.00 TO (Forward direct to addressee listed in publication) FROM (Activity and location) (Include ZIP Code) DATE U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Truck, 5-Ton, 6X6, M939A1, And M939A2 Series Trucks 10 September 2012 TM 9-2320-272-1 (Diesel), Field Maintenance Manual PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION PART III – REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.) TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION APD V4.00 By Order of the Secretary of the Army: RAYMOND T. ODIERNO General, United States Army Chief of Staff Official: JOYCE E. MORROW Administrative Assistant to the Secretary of the Army 1220207 By Order of the Secretary of the Air Force: DONALD J. HOFFMAN General, United States Air Force Commander, AFMC NORTON A. SCHWARTZ General, United States Air Force Chief of Staff Distribution: To be distributed in accordance with the initial distribution number (IDN) 386968 requirements for TM 9-2320-272-23-1 . THE METRIC SYSTEM AND EQUIVALENTS LINEAR MEASURE SQUARE MEASURE 1 Centimeter=10 Millimeters=0.01 Meters=0.3937 Inches 1 Meter=100 Centimeters=1000 Millimeters=39.37 Inches 1 Kilometer=1000 Meters=0.621 Miles 1 Sq Centimeter=100 Sq Millimeters=0.155 Sq Inches 1 Sq Meter=10,000 Sq Centimeters=10.76 Sq Feet 1 Sq Kilometer=1,000,000 Sq Meters=0.386 Sq Miles WEIGHTS CUBIC MEASURE 1 Gram=0.001 Kilograms=1000 Milligrams=0.035 Ounces 1 Kilogram=1000 Grams=2.2 Lb 1 Metric Ton=1000 Kilograms=1 Megagram=1.1 Short Tons 1 Cu Centimeter=1000 Cu Millimeters=0.06 Cu Inches 1 Cu Meter=1,000,000 Cu Centimeters=35.31 Cu Feet LIQUID MEASURE 1 Milliliter=0.001 Liters=0.0338 Fluid Ounces 1 Liter=1000 Milliliters=33.82 Fluid Ounces TEMPERATURE 5/9 (°F – 32) = °C 212°Fahrenheit is equivalent to 100°Celsius 90°Fahrenheit is equivalent to 32.2°Celsius 32°Fahrenheit is equivalent to 0°Celsius 9/5 (°C + 32) = °F 6 14 5 13 12 4 11 10 3 2 1 INCHES 0 0.394 3.280 1.094 0.621 0.155 10.764 1.196 0.386 2.471 35.315 1.308 0.034 2.113 1.057 0.264 0.035 2.205 1.102 0.738 0.145 2.354 0.621 9 Inches . . . . . . . . . . . . . . . . . . . . . Feet . . . . . . . . . . . . . . . . . . . . . . . Yards . . . . . . . . . . . . . . . . . . . . . . Miles . . . . . . . . . . . . . . . . . . . . . . Square Inches . . . . . . . . . . . . . . . Square Feet. . . . . . . . . . . . . . . . . Square Yards . . . . . . . . . . . . . . . . Square Miles . . . . . . . . . . . . . . . . Acres . . . . . . . . . . . . . . . . . . . . . . Cubic Feet . . . . . . . . . . . . . . . . . . Cubic Yards . . . . . . . . . . . . . . . . . Fluid Ounces . . . . . . . . . . . . . . . . Pints . . . . . . . . . . . . . . . . . . . . . . Quarts . . . . . . . . . . . . . . . . . . . . . Gallons . . . . . . . . . . . . . . . . . . . . Ounces . . . . . . . . . . . . . . . . . . . . Pounds . . . . . . . . . . . . . . . . . . . . Short Tons . . . . . . . . . . . . . . . . . . Pound-Feet . . . . . . . . . . . . . . . . . Pounds per Sq Inch . . . . . . . . . . . Miles per Gallon . . . . . . . . . . . . . Miles per Hour . . . . . . . . . . . . . . . 8 Centimeters . . . . . . . Meters . . . . . . . . . . . Meters . . . . . . . . . . . Kilometers . . . . . . . . Sq Centimeters . . . . Square Meters . . . . . Square Meters . . . . . Square Kilometers . . Sq Hectometers . . . . Cubic Meters . . . . . . Cubic Meters . . . . . . Milliliters . . . . . . . . . . Liters . . . . . . . . . . . . Liters . . . . . . . . . . . . Liters . . . . . . . . . . . . Grams . . . . . . . . . . . Kilograms . . . . . . . . . Metric Tons . . . . . . . Newton-Meters. . . . . Kilopascals. . . . . . . . Km per Liter . . . . . . . Km per Hour . . . . . . MULTIPLY BY 7 TO 6 TO CHANGE 2.540 0.305 0.914 1.609 6.451 0.093 0.836 2.590 0.405 0.028 0.765 29.573 0.473 0.946 3.785 28.349 0.454 0.907 1.356 6.895 0.425 1.609 5 Centimeters . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . . . . . . . . . . Square Centimeters . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . Square Kilometers. . . . . . . . . . . . Square Hectometers . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . Milliliters. . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . . . . . . . . . . Kilograms. . . . . . . . . . . . . . . . . . . Metric Tons . . . . . . . . . . . . . . . . . Newton-Meters . . . . . . . . . . . . . . Kilopascals . . . . . . . . . . . . . . . . . Kilometers per Liter . . . . . . . . . . . Kilometers per Hour . . . . . . . . . . 4 Inches . . . . . . . . . . . Feet . . . . . . . . . . . . . Yards . . . . . . . . . . . . Miles . . . . . . . . . . . . Square Inches . . . . Square Feet . . . . . . . Square Yards . . . . . . Square Miles . . . . . . Acres . . . . . . . . . . . . Cubic Feet . . . . . . . . Cubic Yards . . . . . . . Fluid Ounces . . . . . . Pints. . . . . . . . . . . . . Quarts . . . . . . . . . . . Gallons. . . . . . . . . . . Ounces . . . . . . . . . . Pounds . . . . . . . . . . . Short Tons . . . . . . . . Pound-Feet . . . . . . . Pounds/Sq Inch . . . . Miles per Gallon . . . . Miles per Hour . . . . . 3 MULTIPLY BY 1 CM. 2 TO 0 TO CHANGE 15 APPROXIMATE CONVERSION FACTORS PIN: 087175-000
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.7 Linearized : Yes Page Mode : UseOutlines XMP Toolkit : Adobe XMP Core 4.0-c316 44.253921, Sun Oct 01 2006 17:14:39 Modify Date : 2012:12:16 10:57:15-08:00 Create Date : 2012:03:12 07:18:06-04:00 Metadata Date : 2012:12:16 10:57:15-08:00 Creator Tool : XSL Formatter V4.3 R1 (4,3,2008,0424) for Windows Format : application/pdf Document ID : uuid:51795413-4f38-480a-b7d6-aa4df8d22c70 Instance ID : uuid:7df7b656-77f2-4499-a680-4959c24afeab Producer : Antenna House PDF Output Library 2.6.0 (Windows) Has XFA : No Page Count : 1316 Page Layout : SinglePage Creator : XSL Formatter V4.3 R1 (4,3,2008,0424) for WindowsEXIF Metadata provided by EXIF.tools